CASE IH Forage Harvester CHX320, CHX420, CHX520 and CHX620 Service Manual

Forage Harvester
CHX320, CHX420, CHX520

and CHX620
Repair Manual
6--71020EN
CNH BELGIUM N.V., Leon Claeystraat 3A, B-8210 ZEDELGEM -- Belgium
AFTER SALES -- Technical Information
Print No. 6--71020EN -- 1st Edition -- 08 -- 2003
PRINTED IN BELGIUM
COPYRIGHT BY CNH BELGIUM N.V.
All rights reserved. No part of the text or illustrations of

this publication may be reproduced.
Case IH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your Case IH Dealer.
-- 1--4 --
CHX320-CHX420-CHX520-CHX620
FORAGE HARVESTERS
REPAIR MANUAL
SECTIONS
CONTENT
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LIVE P.T.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4WD LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT MECHANICAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKES AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CAB CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ATTACHMENTS/HEADERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
PRODUCT FEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CHOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
EJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
S E R V I C E
CONTENTS 1
GENERAL INFORMATION
Section Description Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rotating shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
O--ring seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealing compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cotter pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Protecting the electronic / electrical systems during charging or welding . . . . . . . . . . . 4
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical sustem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wheels and Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal and Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Explanation of machine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conversion chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hardware tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drive line and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubricants to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 10 -- ENGINE
Chapter 1 -- IVECO Engine F3A -- General
Walk around the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
The Iveco engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine block and cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Timing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6- 71020EN - 08 - 2003
2 CONTENTS
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Auxiliary drivebelt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electronically controlled injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pump injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 2 -- IVECO Engine -- F3A

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Plan of tightening sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Mechanical troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Preliminary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine -- Disassembly – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pistons, Pistons rings and Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Oil pump and , timing system intermediate gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Injectors pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Completing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Assembly diagram for Fan drive belt -- Water pump -- Alternator . . . . . . . . . . . . . . . . . . . . 63
Crankcase, Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Crankshaft, Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Selecting main and big end bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Preliminary appraisal of data to make the selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Piston and Connecting rod -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Tappets and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Valve springs, Rocker arm shaft and Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Checks, Measurements and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Fitting valves and oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6- 71020EN - 08 - 2003
CONTENTS 3
Rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Main data of the rocker arm shaft (Dimensions in mm) . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Replacing the valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Injector case -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cranckshaft front cover seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Adjusting clearance of rocker arms to valves and pre--load of pump injector rocker arms 121
Pump injector -- Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Bleeding the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Water pump -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Thermostat -- Removel -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Chapter 3 -- IVECO Engine F3B -- General

Engine description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cranckshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankcase gas ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Injector--pump control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Camshaft driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Auxiliary component control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Main components of the ms6.2 edc system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MS6.2 electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control unit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Supercharging air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Supercharging pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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4 CONTENTS
Flywheel sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Distribution sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pre -- After heating resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 4 -- IVECO Engine F3B

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine -- Disassembly – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pistons and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil pump and intermediate timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Engine flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Injectors pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Crankcase and cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Crankshaft and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Piston -- Connecting rod assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Valve springs, Rocker arm shaft and rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Main data for checking the valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Fitting valves and oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Valve guides -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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CONTENTS 5
Crankshaft front cover seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Clearance of valves to rocker arms and pre--load of pump injector rocker arms . . . . . . . 111
Pump injector -- Removal, Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Water pump -- Removal, Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Thermostat -- Removal, Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Chapter 5 -- CATERPILLAR Engine

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Case IH -- Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Caterpillar engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service / Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 21 -- TRANSMISSION
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening torques and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shifting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of selector forks and shifter shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of transmission main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal of the half--shaft from the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal of the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of the half--shafts of the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of transmission main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of selector shafts and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calculation of shims to be installed on the shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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6 CONTENTS
SECTION 23 -- 4WD LINES
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self--made tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4WD gearbox -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4WD gearbox -- Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4WD gearbox -- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Output shaft and clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clutch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4WD gearbox -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clutch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Output shaft and clutch -- pre assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input shaft -- pre assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Intermediate shaft -- installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Input shaft -- installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cover -- installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Clutch pre--assembly -- installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4WD gearbox -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 25 - FRONT MECHANICAL DRIVE
Chapter 1 -- Final drives CHX320

Final drives -- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Final drives -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
End play adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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CONTENTS 7
SECTION 25 - FRONT MECHANICAL DRIVE
Chapter 2 -- Final drives CHX420--520--620

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel bolt - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Final drive - R./ I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Final drive D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 29 -- HYDROSTATIC SYSTEM
Hydrostatic circuit and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic Pump and motor Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Multifunction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Servo Solenoid Valve Energized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fixed Displacement Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Motor Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil Cooler bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Filling and bleeding the hydrostatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Starting the hydrostatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 33 -- BRAKES AND CONTROL
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Road Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement of the brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bleeding the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleeding the left--hand side circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleeding the connection pipe between the two main cylinders . . . . . . . . . . . . . . . . . . . 6
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Bleeding the right--hand side circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly and assembly of brake shoes and discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly of brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly of brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 35 -- HYDRAULIC SYSTEM
Chapter 1 -- General
Torque tables for hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Union nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Ferrules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Metric fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swivel nut with ball-type nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump group -- Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of the pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of the triple pump from the hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Splitting of the triple pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly of the pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation of the pump group to the hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2 -- Work hydraulics -- Attachment height control

Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Work Hydraulics -- Attachment height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
High pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Non--return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Work hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
High pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Attachment height control valve (EMR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Neutral position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Attachment lifting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Attachment lowering position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure relief valve h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Emergency hand buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Attachment compensation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transport mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Compensation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Stubble height mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydropneumatic accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Attachment lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 3 -- Work hydraulics -- Base unit
Circuit diagrams -- Base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stack valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Repair of control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Load sensing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cutterhead reverse drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spout rotation pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spout rotation motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Quick--release couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spout lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cylinder disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reinstallation of spout lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chapter 4 -- Steering hydraulics
Circuit diagrams -- Steering hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Steering hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Steering valve - D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Toe--in adjustment, steering ball joints, steering wheel stops . . . . . . . . . . . . . . . . . . . . . 19
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Chapter 5 -- Low pressure hydraulics

Circuit diagrams -- Low pressure hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Low pressure hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil and Filter change procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil pressure check procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filling the system when (re)installing the low pressure pump . . . . . . . . . . . . . . . . . . . . . 5
Filling the system after (re)installing the main drive transfer gearbox . . . . . . . . . . . . . . . 5
Low pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main drive belt tensioning cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spout deflector cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 6 -- High--flow hydraulics

Circuit diagrams -- High--Flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 50 -- CAB CLIMATE CONTROL
Correct use of the airconditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Storage maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Air conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Circuit parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filter--drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Compressor clutch replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ventilation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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SECTION 55 -- ELECTRICAL SYSTEM
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Color code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wire identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 2 -- Wiring Diagrams CHX Europe

Wiring diagrams CHX Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Chapter 3 -- Wiring Diagrams CHX NA

Wiring diagrams CHX NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used
Chapter 4 -- Can network basics

Can network basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General layout electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electronic system layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Analog signals (from input or to output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Digital Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional info: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Can spy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Decimal and hexadecimal counting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Decimal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Hexadecimal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How to use the CAN Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How to Enter CAN--SPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CAN--SPY in practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Error codes messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiring checking procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fault finding routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 5 -- Calibration
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Machine calibration with EST tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Configuration Item Selection screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maximum Handle position calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Minimum forward pump current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Minimum reverse pump current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Vehicle Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 6 -- Software update

Software Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Software update with EST tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 7 -- Troubleshooting
Machine error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Attachment height control error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Error reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Caterpillar error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
List of CAN identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Detailed analisys per function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1. Electric conditions, engine running or not running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2. Engine protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3. Harvest mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5. Cutterhead engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6. Feed rolls forward engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7. Feed rolls reverse engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8. Power reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9. Four--wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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10. Spout rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
11. Raise / lower spout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
12. Spout deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
13. Reverse cutterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
14. Auxiliary front hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
15. Auxiliary rear hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
16. Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
17. Silage additives application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
18. Knife sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
19. Adjust--O--Matic routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
20. Crop processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
21. Metal detector operation and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
22. Attachment height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
23. Ground speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
24. High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
25. Rotary screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
26. Rotary screen brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
27. Caterpillar engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
28. CAN network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
SECTION 60 -- PRODUCT FEEDING
Chapter 1 -- Feed rolls

Metal detector roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Metal detector components -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Smooth roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Upper feed rolls -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Before removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal of the upper feed rolls as a complete assembly. . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal of the upper feed rolls as separate components. . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing wear plates on the upper feed rolls frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Chapter 2 -- Length of Control gearbox

Length of Control gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Length of Control gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. Alternative drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2. Transfer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Upper feed rolls drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4. Selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. Smooth roll drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. Metal detector roll drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7. Reinstall the alternative drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8. Install seals and covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 3 -- Attachments drive gearbox

Attachments drive gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Attachments drive gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transfer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Attachment drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Idler shaft -- Re--installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Chapter 4 -- Upper feed rolls drive gearbox

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Upper feed rolls drive gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Upper feed rolls drive gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Upper feed rolls drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front upper feed roll drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rear upper feed roll drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Re--install the upper feed rolls drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Seals and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 64 -- CHOPPING
Chapter 1 -- Cutterhead
Splitting of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rotor and bearings -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shearbar -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shearbar support -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Chapter 2 -- Cutterhead gearbox

Cutterhead gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cutterhead gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil cooler -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gearbox -- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gearbox -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 70 -- EJECTION
Chapter 1 -- Blower gearbox

Inspection between cutterhead and blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Blower -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Blower gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Blower gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjusting the shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6- 71020EN - 08 - 2003
GENERAL INFORMATION 1
GENERAL INFORMATION
CONTENT
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rotating shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
O--ring seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealing compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cotter pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Protecting the electronic / electrical systems during charging or welding . . . . . . . . . . . 4
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical sustem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wheels and Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal and Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Explanation of machine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conversion chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hardware tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drive line and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubricants to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6- 71020EN - 08 - 2003
2 GENERAL INFORMATION
INTRODUCTION
This manual is subdivided in sections marked by two-digit numbers, with independent page numbering within
each section. For a quick reference, these sections have the same identification number and the same descrip-
tion of the relevant Flat Time Rate Manual.
The dealt matters and the information can be easily detected by index on the previous pages.
At the bottom of each page there is the manual print number and the relevant publication/up-dating date.
The information of this manual are up-dated at the date of the publication. As Case IH continuously improves
its product range, some information could be not up-dated due to modifications of technical or commercial type,
as well as for suiting the law regulations of the different countries.
In case of disagreement, refer to Case IH Sales and Service networks.
IMPORTANT INFORMATION
All repair and maintenance works listed in this manual must be carried out only by staff belonging to the Case
IH Service network, strictly complying with the instructions given and using, whenever required, the special tools.
Anyone who carries out the above operations without complying with the prescriptions shall be responsible for
the subsequent damages.
The manufacturer and all the organizations of its distribution chain, including -- without limitation -- national, re-
gional or local dealers, reject any responsibility for damages due to the anomalous behaviour of parts and/or
components not approved by the manufacturer himself, including those used for the servicing or repair of the
product manufactured or marketed by the Manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the Manufacturer
in case of damages due to an anomalous behaviour of parts and/or components not approved by the Manufac-
turer.
No reproduction, though partial of text and illustrations allowed
6- 71020EN - 08 - 2003
GENERAL INSTRUCTIONS O--ring seals
Shimming
Lubricate the O--RING seals before inserting them in
the seats, this will prevent them from overturning and
For each adjustment operation, select adjusting twisting, which would jeopardise sealing efficiency.
shims and measure individually using a micrometer,
then add up the recorded values. Do not rely on
measuring the entire shimming set, which may be in-
correct, or the rated value indicated on each shim. Sealing compounds
Apply one of the following sealing compounds on the

mating surfaces marked with an X: RTV SILMATE,
Rotating shaft seals
RHODORSIL CAF 1 or LOCTITE PLASTIC
GASKET.
Before applying the sealing compound, prepare the
For correct rotating shaft seal installation, proceed
as follows: surfaces as follows:
-- before assembly, allow the seal to soak in the oil -- remove any incrustations using a metal brush;
it will be sealing for at least thirty minutes
-- thoroughly de--grease the surfaces using one of
-- thoroughly clean the shaft and check that the the following cleaning agents: trichlorethylene,
working surface on the shaft is not damaged petrol or a water and soda solution.
-- position the sealing lip facing the fluid; with

hydrodynamic lips, take into consideration the
shaft rotation direction and position the grooves Bearings
so that they will deviate the fluid towards the
inner side of the seal When installing bearings it is advised to:
-- coat the sealing lip with a thin layer of lubricant -- heat the bearings to 80 to 90 0C before fitting on
(use oil rather than grease) and fill the gap the shafts;
between the sealing lip and the dust lip on double
lip seals with grease -- allow the bearings to cool before installing them
from the outside.
-- insert the seal in its seat and press down using
a flat punch, do not tap the seal with a hammer Cotter pins
or mallet
-- whilst inserting the seal, check that it is When fitting split cotter pins, ensure that the pin
perpendicular to the seat; once settled, make notch is positioned in the direction of the force re-
sure that it makes contact with the thrust quired to stress the pin.
element, if required Spiral cotter pins do not require special positioning.
-- to prevent damaging the seal lip on the shaft,

position a protective guard during installation
operations
6- 71020EN - 08 - 2003
Protecting the electronic / electrical systems

during charging or welding
To avoid damage to the electronic/electrical

systems, always observe the following:
1. Never make or break any of the charging circuit

connections, including the battery connections,
when the engine is running.
2. Never short any of the charging components to

ground.
3. Always disconnect the ground cable from the

battery before arc welding on the machine or on
any attachment attached to the machine.
• Position the welder ground clamp as close to

the welding area as possible.
• If welding in close proximity to a computer

module, then the module should be
removed.
• Never allow welding cables to lay on, near or

across any electrical wiring or electronic
component while welding is in progress.
IMPORTANT: If welding must be performed on the

unit or the attachment (if it is attached), the battery
ground cable must be disconnected from the battery.
The electronic monitoring system and charging
system will be damaged if this is not done.
Remove the battery ground cable.

Reconnect the cable when welding is
completed.
4. Always disconnect the negative cable from the

battery when charging the battery with a battery
charger.
WARNING
Batteries contain sulfuric acid. In case of contact
with skin, flush the affected area with water for
five minutes. Seek medical attention
immediately. Avoid contact with the skin, eyes or
clothing. Wear eye protection when working
near batteries.
6- 71020EN - 08 - 2003
SPARE PARTS ABBREVIATIONS
Below some often used abreviations used in this

Only genuine spare parts guarantee the same qual- manual:
ity, duration and safety as original parts, as they are
the same parts that are assembled during standard
AKS: Automatic Knife Sharpening
production.
Only Case IH genuine spare parts can offer this guar-
antee. ASBA: Automatic Shear Bar Adjustment
When ordering spare parts, always provide the fol-
lowing information: CP: Crop Processor
-- Machine model (commercial name) and serial CPU: Central Processing Unit
number
EST: Electronic Service Tool
-- part number of the ordered part, which can be
found in the ”Microfiches” or the ”Spare Parts
Catalogue”, used for order processing LCD: Liquid Christal Display
MD: Metal Detector
TOOLS
The tools that CASE IH suggests and illustrate in this

manual have been:
-- specifically researched and designed for use

with Case IH machines
-- essential for reliable repair operations
-- accurately built and rigorously tested so as to

offer efficient and long--lasting operation
By using these tools, Repair Personnel will benefit

from:
-- operating in optimal technical conditions
-- obtaining the best results
-- saving time and effort
-- working in safe conditions
NOTE:
Wear limit values indicated for certain parts should

be considered to be recommended, but not binding.
The terms ”front”, ”rear”, ”right-hand” and ”left-hand”
(when referred to different parts) are determined
from the rear, facing in the direction of travel of the
machine during operation.
6- 71020EN - 08 - 2003
SAFETY REGULATIONS
WARNING AND DANGER SYMBOL
This warning symbol points out important personal safety messages.

Carefully read the following safety regulations and observe advised precautions in
order to avoid potential hazards and safeguard your health and safety.
In this manual the symbol is accompanied by the following key-words:
WARNING -- Warnings concerning unsuitable repair operations that may jeopardise
the safety of Repair personnel.
DANGER -- Specific warnings concerning potential hazards for operator safety or for
other persons directly or indirectly involved.
ACCIDENT PREVENTION • Do not carry out repair operations with someone

sitting in the driver’s seat, unless the person is a
trained technician who is assisting with the
Most accidents or injuries that occur in workshops operation in question.
are the result of non--observance of simple and fun-
damental safety regulations. For this reason, IN • Do not operate the machine or use any of the
MOST CASES THESE ACCIDENTS CAN BE implements from different positions, other than
AVOIDED by foreseeing possible causes and conse- the driver’s seat.
quently acting with the necessary caution and care.
• Do not carry out operations on the machine with
Accidents may occur with all types of machine, re- the engine running, unless specifically indicated.
gardless of how well the machine in question was de-
signed and built. • Stop the engine and check that the hydraulic
circuits are pressure--free before removing caps,
covers, valves, etc.
A careful and judicious service technician is the best
guarantee against accidents.
• All repair and maintenance operations must be
carried out using extreme care and attention.
Precise observance of the most basic safety rule is
normally sufficient to avoid many serious accident
• Service steps and platforms used in the
DANGER workshop or elsewhere should be built according
Never carry out any cleaning, lubrication or to standard accident prevention regulations.
maintenance operations when the engine is running.
• Disconnect the batteries and label all controls to
indicate that the machine is being serviced. Any
SAFETY RULES parts that are to be raises must be locked in
position.
General guidelines
• Do not check or fill fuel tanks, accumulator
batteries, nor use starting liquid when smoking or
• Carefully follow specified repair and near naked flames, as these fluids are
maintenance procedures. inflammable.
• Do not wear rings, wristwatches, jewellery, • Brakes are inoperative when manually released
unbuttoned or loose articles of clothing such as: for repair or maintenance purposes. Use blocks
ties, torn clothing, scarves, open jackets or shirts or similar devices to control the machine in these
with open zips that may remain entangled in conditions.
moving parts. It is advised to wear approved
safety clothing, e.g.: non-slip footwear, gloves,
safety goggles, helmets, etc.
6- 71020EN - 08 - 2003
• The fuel nozzle should always be in contact with • Never use naked flames for lighting when
the filling aperture. Maintain this position until working on the machine or checking for leaks.
filling operations are completed in order to avoid
possible sparks caused by the accumulation of • All movements must be carried out carefully
static electricity. when working under, on or near the machine.
Wear protective equipment: helmets, goggles
• Only use specified towing points for towing the and special footwear.
machine. Connect parts carefully. Make sure
that all pins and/or locks are secured in position • When carrying out checks with the engine
before applying traction. Never remain near the running, request the assistance of an operator in
towing bars, cables or chains that are operating the driver’s seat. The operator must maintain
under load. visual contact with the service technician at all
times.
• Transport machines that cannot be driven using
a trailer or a low--loading platform trolley, if • If operating outside the workshop, position the
available. machine on a flat surface and lock in position. If
working on a slope, lock the machine in position.
• When loading or unloading the machine from the Move to a flat area as soon as is safely possible.
trailer (or other means of transport), select a flat
area capable of sustaining the trailer or truck • Damaged or bent chains or cables are unreliable.
wheels. Firmly secure the machine to the truck Do not use them for lifting or towing. Always use
or trailer and lock the wheels in the position used suitable protective gloves when handling chains
by the carrier. or cables.
• Electric heaters, battery-chargers and similar • Chains should always be safely secured. Make
equipment must only be powered by auxiliary sure that the hitch--up point is capable of
power supplies with efficient ground insulation to sustaining the load in question. Keep the area
avoid electrical shock hazards. near the hitch--up point, chains or cables free of
all bystanders.
• Always use suitable hoisting or lifting devices
when raising or moving heavy parts. • Maintenance and repair operations must be
carried out in a CLEAN and DRY area. Eliminate
• Take extra care if bystanders are present. any water or oil spillage immediately.
• Never pour gasoline or diesel oil into open, wide • Do not create piles of oil or grease--soaked rags
or low containers. as they represent a serious fire hazard. Always
store rags in a closed metal container.
• Never use gasoline, diesel oil or other Before engaging the machine, make sure that
inflammable liquids as cleaning agents. Use there are no persons within the machine or
non-inflammable, non toxic commercially implement range of action.
available solvents.
• Empty your pockets of all objects that may fall
• Wear safety goggles with side guards when accidentally unobserved into the machine inner
cleaning parts with compressed air. compartments.
• Reduce the air pressure according to the local • In the presence of protruding metal parts, use
regulations in force.. protective goggles or goggles with side guards,
helmets, special footwear and gloves.
• Do not run the engine in confined spaces without
suitable ventilation. • When welding, use protective safety devices:
tinted safety goggles, helmets, special overalls,
gloves and footwear. All persons present in the
• Do not smoke, use naked flames, or cause
sparks in the area when fuel filling or handling area where welding is taking place must wear
tinted goggles. NEVER LOOK DIRECTLY AT
highly inflammable liquids.
THE WELDING ARC WITHOUT SUITABLE
EYE PROTECTION.
6- 71020EN - 08 - 2003
• Metal cables tend to fray with repeated use. Electrical sustem

Always use suitable protective devices (gloves,
goggles, etc.) when handling cables. • If it is necessary to use auxiliary batteries,
remember that both ends of the cables must be
• Handle all parts carefully. Do not put your hands connected as follows: (+) with (+) and (--) with (--).
or fingers between moving parts. Wear suitable Avoid short--circuiting the terminals. GAS
safety clothing -- safety goggles, gloves and RELEASED FROM BATTERIES IS HIGHLY
shoes. INFLAMMABLE. During charging, leave the
battery compartment uncovered to improve
Start-up ventilation. Never check the battery charge using
”jumpers” (metal objects placed on the
terminals). Avoid sparks or flames near the
• Never run the engine in confined spaces that are
battery zone. Do not smoke to prevent explosion
not equipped with adequate ventilation for
exhaust gas extraction. hazards.
• Before servicing operations, check for fuel or

• Never place the head, body, limbs, feet, hands or
current leaks.Eliminate any eventual leaks
fingers near rotating and moving parts.
before proceeding with work.
Engine
• Never charge batteries in confined spaces.Make
sure that there is adequate ventilation in order to
• Always loosen the radiator cap slowly before prevent accidental explosion hazards as a result
removing it to allow any remaining pressure in of the accumulation of gases released during
the system to be discharged. Filling up with charging operations.
coolant should only be carried out with the engine
stopped or idling (if hot)..
• Always disconnect the batteries before
performing any kind of servicing on the electrical
• Never fill up with fuel when the engine is running, system.
especially if hot, in order to prevent the outbreak
of fire as a result of fuel spillage.
Hydraulic systems
• Never check or adjust fan belt tension when the
• A liquid leaking from a tiny hole may be almost
engine is running.
invisible but, at the same time, be powerful
Never adjust the fuel injection pump when the
enough to penetrate the skin. Therefore,
Forage Harvester is moving.
NEVER USE HANDS TO CHECK FOR LEAKS
but use a piece of cardboard or wood for this
• Never lubricate the Forage Harvester when the purpose. If any liquid penetrates skin tissue, call
engine is running. for medical aid immediately. Failure to treat this
condition with correct medical procedure may
result in serious infection or dermatosis.
• In order to check the pressure in the system use

suitable instruments.
6- 71020EN - 08 - 2003
Wheels and Tyres Removal and Re-fitting
• Make sure that the tyres are correctly inflated at • Lift and handle all heavy parts using suitable
the pressure specified by the manufacturer. hoisting equipment. Make sure that parts are
Periodically check the rims and tyres for sustained by appropriate hooks and slings. Use
damage. the hoisting eyebolts for lifting operations. Extra
care should be taken if persons are present near
• Stand away from (at the side of) the tyre when the load to be lifted.
checking inflation pressure.
• Handle all parts carefully. Do not put your hands
• Do not use parts of recovered wheels as or fingers between parts. Wear suitable safety
incorrect welding brazing or heating may weaken clothing -- safety goggles, gloves and shoes.
and eventually cause damage to the wheel.
• Avoid twisting chains or metal cables. Always
• Never cut or weld a rim mounted with an inflated wear safety gloves when handling cables or
tyre. chains.
• To remove the wheels, lock all wheels. After

having raised the machine, position supports
underneath, according to regulations in force.
• Deflate the tyre before removing any objects that

may be jammed in the tyre tread.
• Never inflate tyres using inflammable gases, as

this may result in explosions and injury to
bystanders.
6- 71020EN - 08 - 2003
EXPLANATION OF MACHINE SERIAL

NUMBER
Example : n° 285266001
285266001: The first two digits identify the model

within a product line:
CHX320 = 19
CHX420 = 20
CHX520 = 28
CHX620 = 17
285266001 : The third digit indicates the product line.

The code for the forage harvester product line is (5).
285266001 : These 3 digits indicate the batch in

which the machine was made.
285266001 : Product line number (5) and batch

(266) together form the series number (5266).
285266001 : The last 3 digits are a sequential

number for each model within a batch.
Summarizing we can say that this machine is the first

CHX520 of serie 5266.
6- 71020EN - 08 - 2003
CONVERSION CHART
Linear
1 mm = 0.03937 in 1 in = 25.4 mm
1 Km = 0.6214 miles 1 mile = 1.6093 km
1m = 3.281 ft 1 ft = 0.3048 m
Area
1 ha = 2.471 acre 1 acre = 0.4047 ha
Volume
1 litre = 0.0063 barrel 1 barrel = 158.987 litre

1 litre = 0.028 US bushel 1 US bushel = 35.2391 litre
1 litre = 0.2642 US gal 1 US gal = 3.7853 litre
1 litre = 1.057 US quart 1 US quart = 0.9464 litre
1 mm3 = 0.061 in3 1 in3 = 16387 mm3
Weight
1 kg = 2.204 pound 1 pound = 0.4536 kg
Torque
1 Nm = 0.7376 lbf.ft 1 lbf ft = 1.3558 Nm
Power
1 kW = 1.358 hp 1 hp = 0.746 kW
Pressure
1 bar = 14.505 lbf/in2(psi) 1 lbf/in2(psi) = 0.06894 bar

1 kPa = 0.145 lbf/in2(psi) 1 lbf/in2(psi) = 6.894 kPa
1 pa = 10 --5 bar 1 bar = 100 kPa
Temparature
1 °C = ((1.8 x ° C) + 32) ° F 1 °F = (0.56 x (° F -- 32))°C
6- 71020EN - 08 - 2003
HARDWARE TIGHTENING TORQUES
MINIMUM HARDWARE TIGHTENING TORQUES

IN NEWTON-METRES -- Nm (FOOT POUNDS -- LBF. FT)
FOR NORMAL ASSEMBLY APPLICATIONS
METRIC 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*) 1.8 (16*)
M6 5.8 (51*) 7.6 (67*) 8.9 (79*) 12 (102*) 13 (115*) 17 (150*) 6.3 (56*)
M8 14 (124*) 18 (159*) 22 (195*) 28 (248*) 31 (274*) 40 (354*) 15 (133*)
M10 28 (21) 36 (27) 43 (32) 56 (41) 61 (45) 79 (58) 30 (22)
M12 49 (36) 63 (46) 75 (55) 97 (72) 107 (79) 138 (102) 53 (39)
M16 121 (89) 158 (117) 186 (137) 240 (177) 266 (196) 344 (254) 131 (97)
M20 237 (175) 307 (226) 375 (277) 485 (358) 519 (383) 671 (495) 265 (195)
M24 411 (303) 531 (392) 648 (478) 839 (619) 897 (662) 1160 (855) 458 (338)
NOTE: Torque values shown with * are inch pounds.

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

CLASSES 05 AND UP
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS CLOCK MARKING
6- 71020EN - 08 - 2003
MINIMUM HARDWARE TIGHTENING TORQUES

IN NEWTON-METRES -- Nm (FOOT POUNDS -- LBF. FT)
FOR NORMAL ASSEMBLY APPLICATIONS
INCH 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*) 6.9 (61*) 9.8 (86*) 1/4
5/16 13 (115*) 17 (149*) 20 (178*) 26 (229*) 28 (250*) 37 (324* ) 14 (125* ) 20 (176*) 5/16
3/8 23 (17) 30 ( 22) 35 (26) 46 (34) 50 (37) 65 (48) 26 (19) 35 (26) 3/8
7/16 37( 27) 47 (35) 57 (42) 73 (54) 80 (59) 104 (77) 41 (30) 57 (42) 7/16
1/2 57 (42) 73 (54) 87 (64) 113 (83) 123 (91) 159 (117) 61 (45) 88 (64) 1/2
9/16 81 (60) 104 (77) 125 (92) 163 (120) 176 (130) 229 (169) 88 (65) 125 (92) 9/16
5/8 112 (83) 145 (107) 174 (128) 224 (165) 244 (180 ) 316 (233) 122 (90) 172 (127) 5/8
3/4 198 (146) 256 (189) 306 (226) 397 (293) 432 (319) 560 (413) 217 (160) 306 (226) 3/4
7/8 193 (142) 248 (183) 495 (365) 641 (473) 698 (515) 904 (667) 350 (258) 494 (364) 7/8
1 289 ((213) 373 (275) 742 (547) 960 ( 708) 1048 (773) 1356 (1000) 523 (386) 739 (545) 1
NOTE: Torque values shown with * are inch pounds.

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

HEX NUTS HEX NUTS
LOCKNUTS
GRADE A NO MARK
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION
GRADE IDENTIFICATION GRADE IDENTIFICATION
GRADE A NO MARKS
GRADE A NO NOTCHES
GRADE B THREE MARKS
GRADE B ONE CIRCUMFERENTIAL NOTCH
GRADE C SIX MARKS
GRADE C TWO CIRCUMFERENTIAL NOTCHES
MARKS NEED NOT BE LOCATED
AT CORNERS
6- 71020EN - 08 - 2003
DRIVE LINE AND COMPONENTS
Listed below and in the figure on the opposite page are all the forage harvester functional components and their
drives.
The speeds and torques mentioned apply to the nominal engine speed of 2100 rpm. At this speed the engine
will deliver its maximum power.
Speed (rpm)
1. Length of cut control gearbox
2. Transfer shaft
3. Lower front feed roll (or metal detector roll) 68 -- 171 / 138 -- 345
4. Smooth roll 131 -- 327 / 264 -- 660
5. Upper feed rolls drive pto
6. Upper feed rolls gearbox
7. Cutterhead 1229
8. Cutterhead gearbox
9. Cutterhead drive shaft 2765
10. Blower 663 (735)
11. Blower drive shaft 2100
12. High speed blower gearbox
13. Blower drive shaft 2100
14. Main drive belt
15. Cutterhead reverse drive hydraulic motor 800 - 860
16. Engine 2100
17. Main drive transfer gearbox
18. Hydrostatic pump (Feed rolls) 3006
19. Hydrostatic pump (Groundspeed) 3006
20. Work hydraulics pump 3006
21. Steering hydraulics pump 3006
22. Low pressure hydraulics pump 3006
23. Lower crop processor roll 4070
24. Upper crop processor roll 3620
25. Upper rear feed roll 121 -- 303 / 244 -- 611
26. Upper front feed roll 68 -- 171 / 138 -- 344
27. Hydrostatic motor feed rolls drive 1200 -- 3000
28. Attachment drive gearbox
29. Attachment drive shaft 300 -- 750
30. Transfer drive shaft 505 -- 1263
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
LUBRICANTS TO BE USED
16
A new line of specially formulated AKCELA Lubricants, based on own engineering specifications, is available from your CASE IH dealer.
Item Servicing interval Amount/unit [litres] CASE--IH Lubricant grade International
6- 71020EN - 08 - 2003
Specification specification
Grease fittings 10h -- AKCELA NLGI 2

50h -- Multi--purpose grease
100h -- 251H EP
or
AKCELA
Moly grease
251H EP--M
Cutterhead Change: 4.3 AKCELA SAE 80W-90 API GL5

gearbox -- after first 100 h Gear 135H EP LS
-- every 600 h or MIL-L-2105 D
annually
Blower gearbox Change: 1.4 AKCELA SAE 80W-90 API GL5

-- after first 100 h Gear 135H EP LS
annually
GENERAL INFORMATION
High speed blower Change: 0.7 AKCELA SAE 80W-90 API GL5
gearbox [if instal- -- after first 100 h Gear 135H EP LS
led] -- every 600 h or MIL-L-2105 D
annually
Attachment drive Change: 1.8 AKCELA SAE 80W-90 API GL5

annually
Length of Control Change: 7.25 AKCELA SAE 80W-90 API GL5

annually
Upper feed roll Change: 1.4 AKCELA SAE 80W-90 API GL5
drive gearbox -- after first 100 h Gear 135H EP LS
annually
Traction gearbox Change: 15 AKCELA SAE 80W-90 API GL5

-- after first 100 h Gear 135H EP LS
annually
Final drive Change: 5 AKCELA SAE 80W-90 API GL5

annually
Four-wheel drive Change: 1.4 AKCELA SAE 80W-90 API GL5

gearbox [if instal- -- after first 100 h Gear 135H EP LS
led] -- every 300 h or MIL-L-2105 D
annually
Four wheel drive Change: 10 AKCELA SAE 80W-90 API GL5

steering axle [if -- after first 100 h Gear 135H EP LS
GENERAL INFORMATION
installed] -- every 600 h or MIL-L-2105 D

annually
4WD steering axle Change: 1 AKCELA SAE 80W-90 API GL5

planetary final -- after first 100 h Gear 135H EP LS
drives -- every 600 h or MIL-L-2105 D
[if installed] annually
6- 71020EN - 08 - 2003
17
18

Engine Check daily CHX320: AKCELA SAE 10W-30 API CH--4

(oil + filters) Change: 29 No.1 Engine oil ACEA E3/E5
6- 71020EN - 08 - 2003
-- after first 100 h
CHX420--520:
CHX320--420--520: 35
-- every 600 h
CHX620:
CHX620: 34
-- every 500 h
Brake system Change every 0.5 (reservoir) AKCELA SAE J1703 ISO 4925
two years 2 (system) Dot 4 Fluid
Hydraulic and hy- Check daily 38 (reservoir) AKCELA ISO VG 46 DIN 51524 Part 2 HV
drostatic Change: 93 (system) Hydraulic Excavator
system -- after first 100 h fluid BIO
(oil + filters) -- every 600 h or
annually
Main hydraulic Check daily 7 (reservoir) AKCELA ISO VG 46 DIN 51524 Part 2 HV
clutch Change: 10 (system) Hydraulic Excavator
-- after first 100 h fluid BIO
GENERAL INFORMATION
-- every 600 h or
annually
High capacity rear Check daily 70 (reservoir) AKCELA ISO VG 46 DIN 51524 Part 2 HV
hydraulics Change: 77 (system) Hydraulic Excavator
(oil + filter) -- after first 100 h fluid BIO
[if installed] -- every 600 h or
annually
Chains Weekly Sparingly AKCELA SAE 80W-90 API GL5

Threaded rods -- every 200 h Gear 135H EP LS
Pivot points -- every 200 h MIL-L-2105 D
SECTION 10 -- ENGINE -- CHAPTER 1 1
Chapter 1 -- IVECO Engine F3A -- General

Model IVECO Engine
CHX320 F3AE0684D*B001
CONTENTS
Walk around the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Right Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
The iveco engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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 drivebelt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
External Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Upstream Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Filter Septum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Downstream Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Structural Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electronically controlled injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pump injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Filling Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Injection Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flow-back Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6- 71020EN -- 08 -- 2003
2 SECTION 10 -- ENGINE -- CHAPTER 1
WALK AROUND THE ENGINE
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
6- 71020EN -- 08 -- 2003
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
6- 71020EN -- 08 -- 2003
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
6- 71020EN -- 08 -- 2003
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
6- 71020EN -- 08 -- 2003
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
6- 71020EN -- 08 -- 2003
20015801
THE IVECO ENGINE
The IVECO engine is a six cylinder tubocharged and

aftercooled diesel engine. The engine uses
electronically 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.
6- 71020EN -- 08 -- 2003
20015802
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.
6- 71020EN -- 08 -- 2003
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
20015803
together. The inner finish of the cylinder liners and the
liner and engine block structure are so well 8
engineered that part deformation is not possible and
engine oil consumption is therefore exceptionally low.
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 IVECO 6
cylinder in line engines. The firing order of the IVECO
engine is 1-4-2-6-3-5. The crankpins and
half-bearings are sorted into three thickness
20015804
categories, with a difference of .01 mm between one
category and the next. When servicing, carefully 10
select the category of half-bearing to be fitted to each
main journal and crankpin in order to ensure radial
clearance is maintained within specified limits.
6- 71020EN -- 08 -- 2003
CRANKSHAFT SEALING RINGS

1
The front and rear sealing rings are Rotostat sliding
type. The rings take the form of a washer, 1, fitted 4
directly onto the crankshaft, a sealing lip, 2, and a 2
case, 4, fitted into a seat on the front cover or flywheel
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 1
ring.
Pistons are sorted into two categories, 1 and 2,

according to diameter. They are elliptical in shape 2
and made out of aluminum alloy. The piston crown
includes a high-turbulence combustion chamber.
20015807
13
6- 71020EN -- 08 -- 2003
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 1

a cascade unit located to the rear of the engine. Upper
intermediate gear, 2, is fitted on an adjustable mount.
This maintains the correct clearance between this
2
gear and gear, 1, whose position is affected by head
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
6- 71020EN -- 08 -- 2003
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).
1 3
The electronic system does not require the holes to
be specially marked, but some (1, 2, 3, 4, lower figure)
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 4
notches.
The angular position of the flywheel at every instant 2

is detected by the EDC control unit by means of an
20015810
induction sensor (positioned at 1, upper figure). The
holes marked with notches should be aligned 16
alternatively with the inspection hole (2, upper figure)
in the flywheel cover casing during adjustment and
timing setting.
6- 71020EN -- 08 -- 2003
AUXILIARY DRIVEBELT
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
6- 71020EN -- 08 -- 2003
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
6- 71020EN -- 08 -- 2003
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
20015814
Consists of inert inorganic fibers bonded with resin of
exclusive manufacture to a structure with graduated 19
pores. The septum is manufactured in accordance
with precise requirements and is subject to strict
quality control checks.
Downstream Mount
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
throughout 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.
6- 71020EN -- 08 -- 2003
These high filtration devices have so far only adopted

for industrial processes. When used on vehicles, they
enable us to:
31. Reduce wear on engine components with time
32. 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.
6- 71020EN -- 08 -- 2003
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
interference, 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

20015816
improves injection system management.
22
The control unit is equipped with a highly advanced
self diagnostic system. It is able to take
environmental factors into consideration in order to
detect and store anomalies (even if intermittent)
occurring within the system during vehicle operation
to ensure more 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.
6- 71020EN -- 08 -- 2003
PUMP INJECTOR
1
The pump injector consists mainly of three parts:
solenoid, 1, pumping element, 2, and nozzle, 3.
These three parts cannot be individually replaced and
cannot be serviced. 2
The pumping element is operated mechanically upon

each cycle by a rocker. It compresses the fuel in the
delivery chamber. 3
Nozzle configuration and operation are similar to 20015817

those of conventional injector nozzles. It is opened by
fuel under pressure to inject a fine spray of fuel into 23
the combustion chamber.
The solenoid is controlled directly by the electronic

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
1
During the filling stage, pumping element, 2, moves
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 2
injector from the cylinder head lower channel, 4.
Filling continues until the pumping element reaches 3
the top end of its travel.
4
20015818
24
Injection Stage
1
The injection stage begins when the solenoid is
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 2
electronic control unit and varies according to engine
3
service conditions. The cam continues to push
pumping element, 2, via the rocker and the injection 4
stage continues until fuel valve, 1, remains closed.
20015819
25
6- 71020EN -- 08 -- 2003
Flow-back Stage
1
Injection finishes when fuel valve, 1, opens at a
certain point on the pumping element descending
stroke following solenoid de-activation. Fuel flows
through open valve, 1, the injector holes and channel, 2
4, in the cylinder head. The time for which the
solenoid is excited is processed by the electronic 3
control unit and represents the duration of injection
4
(output). It varies according to engine service
conditions.
20015820
The electronic control unit is able to monitor current
uptake by the solenoid in order to establish whether 26
injection has taken place correctly or if mechanical
problems have occurred, e.g. binding. The control
unit can detect injector errors only when the engine is
running or during start up.
6- 71020EN -- 08 -- 2003
6- 71020EN -- 08 -- 2003
Chapter 2 -- IVECO Engine -- F3A
Model IVECO Engine
CHX320 F3AE0684D*B001
CONTENTS
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Sub--Cranckcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rocker arm cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Preliminary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine -- Disassembly – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cranckshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pistons, Pistons rings and Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Oil pump and , timing system intermediate gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Injectors pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assembly diagram for Fan drive belt -- Water pump -- Alternator . . . . . . . . . . . . . . . . . . . . 63
Crankcase, Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Crankshaft, Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6- 71020EN - 08 - 2003

Main journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Crankpins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Selecting small end bearings (pins with nominal diameter) . . . . . . . . . . . . . . . . . . . . . . 72
Selecting the main bearing shells (pins with nominal diameter) . . . . . . . . . . . . . . . . . . . 74
Selecting the main bearing shells (ground pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Selecting the big end bearing shells (pins with nominal diameter) . . . . . . . . . . . . . . . . 80
Selecting the big end bearing shells (ground pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Checking main journal assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Tightening sequence of the screws fixing the sub--crankcase under the crankcase. . 85
Remove the sub--crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Checking crankshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Piston and Connecting rod -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Valve springs, Rocker arm shaft and Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Replacing the valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Adjusting clearance of rocker arms to valves and pre--load of pump injector rocker arms 121
Pump injector -- Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Water pump -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Thermostat -- Removel -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6- 71020EN - 08 - 2003
GENERAL SPECIFICATIONS
Engine, technical 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 mm (4.9″)
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5.5″)
Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10300 cm3 (629 in3)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ± 0.8
Maximum power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 kW (428 HP)
Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
Maximum power speed for Mod. CHX320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1380 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel
6- 71020EN - 08 - 2003
Engine, technical type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 mm (4.9″)
Piston stroke: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5.5″)
Total displacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10300 cm3

(629 in3)
Compression ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ± 0.8
Maximum power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 kW (428 HP)
Maximum speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
Maximum power speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1380 rpm
Number of main bearings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(cont.)
6- 71020EN - 08 - 2003
(cont.)
GENERAL SPECIFICATIONS F3A
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 105
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . 1.83

start of opening = 80 oC (176°F)
max = 95 oC (203°F)
For further cooling system technical data . . . . . . . . . . . . . . . . . . See page 110
Rev counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . incorporated in control panel
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from gear on camshaft

(cont.)
6- 71020EN - 08 - 2003
(cont.)
GENERAL SPECIFICATIONS F3A
Timing system 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16o
-- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32o
Exhaust:
-- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11o
Valve--rocker arm clearance for timing check: . 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 98
Fuel system
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
6- 71020EN - 08 - 2003
FUEL SYSTEM DATA
F3A
Turbocharger:
-- HOLSET type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HX50W
9861 B A/P 22PC3
Injectors: pump electro--injectors governed by the
camshaft and controlled by the electronic
control unit
BOSCH type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PDE 31 12 Volt
Nozzle: BOSCH type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA 140
Number of nozzle holes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Nozzle hole diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.21 mm
(0.0083″)
Pressure setting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 ± 6 bar
(4292 ± 87 psi)
Injection pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 bar (21,750 psi)
Injection sequence: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4--2--6--3--5
6- 71020EN - 08 - 2003
MAIN DATA
F3A
CRANK GEAR AND CYLINDER DATA
mm (in)
Diameter of cylinder liner bores on block:
-- upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.000 ÷ 142.025
(5.5906″ ÷ 5.5915″)
-- lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140.000 ÷ 140.025
(5.5118″ ÷ 5.5128″)
Cylinder liners – external diameter:
-- upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.961 ÷ 141.986
(5.5890″ ÷ 5.5900″)
-- lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139.890 ÷ 139.915
(5.5075″ ÷ 5.5085″)
Cylinder liner interference – bores on block:
-- upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.014 ÷ 0.064
(0.0006″ ÷ 0.0025″)
-- lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.085 ÷ 0.135
(0.0033″ ÷ 0.0053″)
Cylinder liner external diameter oversizes . . . . . . . . . . . . . . . . --
Cylinder liners – internal diameter driven in and machined:
-- class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.000 ÷ 125.013
(4.9213″ ÷ 4.9218″)
-- class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.011 ÷ 125.024
(4.9217″ ÷ 4.9222″)
-- protrusion of cylinder liner from crankcase . . . . . . . . . . . . 0.045 ÷ 0.075
(0.0018″ ÷ 0.0030″)
Pistons:
Standard piston diameter measured from skirt base: 19
-- class A* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.881 ÷ 124.890
(4.9166″ ÷ 4.9168″)
-- class B** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.890 ÷ 124.899
(4.9168″ ÷ 4.9137″)
Pin seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.010 ÷ 50.018
(1.9689″ ÷ 1.9692″)
0.110 ÷ 0.134
Piston assembly clearance – cylinder liners . . . . . . . . . . . . . .
(0.0043″ ÷ 0.0053″)
Piston diameter oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --
49.994 ÷ 50.000
Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(1.9683″ ÷ 1.9685″)
0.010 ÷ 0.024
Piston pin – pin seat clearance . . . . . . . . . . . . . . . . . . . . . . . . .
(0.0004″ ÷ 0.0009″)
(cont.)
* Pistons supplied as spare parts.
** Class B pistons are assembled solely in production and are not supplied as spares.
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3A
mm (in)
1st seat* . . . . . . . 2.94 (0.116″)
Piston ring seat depth: 2nd seat . . . . . . . 3.05 ÷ 3.07

(0.120″ ÷ 0.121″)
3rd seat . . . . . . . . 4.02 ÷ 4.04

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

(0.1101″ ÷ 0.1114″)
Piston ring thickness: 2nd ring . . . . . . . . 2.970 ÷ 3.000

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

(0.1563″ ÷ 0.1571″)
* measured on ∅ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 (4.724″)
1.............. 0.110 ÷ 0.144

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

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

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

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

(0.0024″ ÷ 0.0295″)
3rd ring . . . . . . . . 0.35 ÷ 0.65

(0.0138″ ÷ 0.0256″)
Small end bushing seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . 54.000 ÷ 54.030

(2.1260″ ÷ 2.1272″)
(cont.)
6- 71020EN - 08 - 2003
MAIN DATA
F3A
mm (in)
Small end bearing seat diameter:

-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.000 ÷ 87.030
(3.4252″ ÷ 3.4264″)
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.000 ÷ 87.010
(3.4252″ ÷ 3.4256″)
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.011 ÷ 87.020
(3.4256″ ÷ 3.4260″)
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.021 ÷ 87.030
(3.4260″ ÷ 3.4264″)
Small end bushing diameter:

-- external diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.085 ÷ 54.110
(2.1293″ ÷ 2.1303″)
-- internal diameter (with bushings fitted) . . . . . . . . . . . . . . 50.019 ÷ 50.035
(1.9693″ ÷ 1.9699″)
Small end bushing – seat interference . . . . . . . . . . . . . . . . . . . . . 0.055 ÷ 0.110

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

(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″)
(cont.)
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3A
mm (in)
Main journal diameter:

-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.970 ÷ 93.000
(3.6602″ ÷ 3.6614″)
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.970 ÷ 92.979
(3.6602″ ÷ 3.6606″)
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.980 ÷ 92.989
(3.6606″ ÷ 3.6610″)
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.990 ÷ 93.000
(3.6610″ ÷ 3.6614″)
Connecting rod journal diameter:
-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.970 ÷ 83.000
(3.2665″ ÷ 3.2677″)
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.970 ÷ 82.979
(3.2665″ ÷ 3.2669″)
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.980 ÷ 82.989
(3.2669″ ÷ 3.2673″)
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.990 ÷ 83.000
(3.2673″ ÷ 3.2677″)
Standard main journal half bearing thickness:
-- red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.965 ÷ 2.974
(0.1167″ ÷ 0.1171″)
-- green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.975 ÷ 2.984
(0.1171″ ÷ 0.1175″)
-- yellow* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.985 ÷ 2.995
(0.1175″ ÷ 0.1179″)
-- red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.970 ÷ 1.980
(0.0776″ ÷ 0.0780″)
-- green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.981 ÷ 1.990
(0.0780″ ÷ 0.0783″)
-- yellow* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.991 ÷ 2.000
(0.0784″ ÷ 0.0787″)
Main bearing diameter:
-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.000 ÷ 99.030
(3.8976″ ÷ 3.8988″)
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.000 ÷ 99.009
(3.8976″ ÷ 3.8980″)
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.010 ÷ 99.019
(3.8980″ ÷ 3.8984″)
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.020 ÷ 99.030
(3.8984″ ÷ 3.8988″)
(cont.)
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3A
mm (in)
Half bearing – main journal clearance . . . . . . . . . . . . . . . . . . . . . 0.050 ÷ 0.090

(0.0020″ ÷ 0.0035″)
Connecting rod half bearing clearance . . . . . . . . . . . . . . . . . . . . . 0.040 ÷ 0.080
(0.0016″ ÷ 0.0031″)
Main bearing undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.127 -- 0.254 -- 0.508
(0.0050″ -- 0.0100″ -- 0.0200″)
Main journal length per thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.95 ÷ 46.00
(1.8091″ ÷ 1.8110″)
Main journal width per thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.94 ÷ 38.99
(1.5331″ ÷ 1.5350″)
Thrust ring thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 ÷ 3.43
(0.1331″ ÷ 0.1350″)
Crankshaft thrust clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 ÷ 0.30
(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″)
* Assembled solely in production and not supplied as a spare. (cont.)
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3A
CYLINDER HEAD – TIMING SYSTEM
mm (in)
Diameter of valve guide bores in the cylinder head . . . . . . . . . . 14.980 ÷ 14.997

(0.5898″ ÷ 0.5904″)
Valve guide external diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.012 ÷ 15.025
(0.5910″ ÷ 0.5915″)
Valve guide internal diameter
(after fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.015 ÷ 9.030
(0.3549″ ÷ 0.3555″)
Valve guide and bore interference in head . . . . . . . . . . . . . . . . . 0.015 ÷ 0.045
(0.0006″ ÷ 0.0018″)
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 ÷ 0.4 (0.0079″ ÷ 0.0157″)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.960 ÷ 8.975
(0.3528″ ÷ 0.3533″)
Valve seat angle: intake . . . . . . . . . . . . . 60o 30’ ± 7’ 30”
exhaust . . . . . . . . . . . 45o 30’ ± 7’ 30”
Valve stem and relative guide assembly clearance . . . . . . . . . . 0.040 ÷ 0.070
(0.0016″ ÷ 0.0028″)
Internal diameter of bore on head for valve seat:
intake . . . . . . . . . . . . . 44.185 ÷ 44.220
(1.7396″ ÷ 1.7409″)
exhaust . . . . . . . . . . . 42.985 ÷ 43.020
(1.6923″ ÷ 1.6937″)
Valve seat external diameter: intake . . . . . . . . . . . . 44.260 ÷ 44.275
(1.7425″ ÷ 1.7431″)
exhaust . . . . . . . . . . . 43.060 ÷ 43.075
(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 . . . . . . . . . . . . 0.65 ÷ 0.95
(0.0256″ ÷ 0.0374″)
exhaust . . . . . . . . . . . 1.8 ÷ 2.1
(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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.985 ÷ 43.015
(1.6923″ ÷ 1.6935″)
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.985 ÷ 42.015
(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″)
(cont.)
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3A
mm (in)
Valve spring height:

free spring height . . . . . . . . . --
under a load of N – (kg) [lbs.]

454 ± 22 5 (46.3 ± 2.2) [102 ± 5 lbs.] height . . . . . . . . . --
840 ± 42 9.5 (85.7 ± 2.2) [189 ± 5 lbs.] height . . . . . . . . . --
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 ÷ 1.4
(0.0449″ ÷ 0.0551″)
(cont.)
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3A
mm (in)
Camshaft bushing seat diameter in cylinder head . . . . . . . . . . . 88.000 ÷ 88.030

(3.4646″ ÷ 3.4657″)
Camshaft support journal diameter . . . . . . . . . . . . . . . . . . . . . . . . 82.950 ÷ 82.968

(3.2657″ ÷ 3.2665″)
Camshaft bushing external diameter . . . . . . . . . . . . . . . . . . . . . . 88.153 ÷ 88.183

(3.4706″ ÷ 3.4718″)
Internal diameter of finished bushings in seats . . . . . . . . . . . . . . 83.018 ÷ 83.085

(3.2684″ ÷ 3.2711″)
Bush and seat interference in block . . . . . . . . . . . . . . . . . . . . . . . 0.123 ÷ 0.183

(0.0048″ ÷ 0.0072″)
Coupling between bushings and support journals

of the camshaft (assembly clearance) . . . . . . . . . . . . . . . . . . . . . 0.050 ÷ 0.135
(0.0020″ ÷ 0.0053″)
Cam lift: intake . . . . . . . . . . . . . . . . . . 9.30 (0.3661″)

exhaust . . . . . . . . . . . . . . . . 9.45 (0.3720″)
injector--pump . . . . . . . . . . . 11.21 (0.4413″)
Rocker arm support shaft diameter . . . . . . . . . . . . . . . . . . . . . . . 41.984 ÷ 42.000

(1.6529″ ÷ 1.6535″)
Seat diameter for rocker arm support shaft bushings in rocker

arms:
-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.000 ÷ 45.016
(1.7717″ ÷ 1.7723″)
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.000 ÷ 59.019
(2.3228″ ÷ 2.3236″)
-- injectors--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.000 ÷ 46.016
(1.8110″ ÷ 1.8117″)
Bushing external diameter for rocker arms:

-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.090 ÷ 45.130
(1.7752″ ÷ 1.7768″)
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.100 ÷ 59.140
(2.3268″ ÷ 2.3283″)
-- injectors--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.066 ÷ 46.091
(1.8136″ ÷ 1.8146″)
(cont.)
6- 71020EN - 08 - 2003
MAIN DATA
F3A
mm (in)
Bushing internal diameter for rocker arms with bushing fitted:

-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.025 ÷ 42.041
(1.6545″ ÷ 1.6552″)
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.030 ÷ 56.049
(2.2059″ ÷ 2.2067″)
-- injectors--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.015 ÷ 42.071
(1.6541″ ÷ 1.6563″)
Clearance between bushings and rocker arm support shaft:

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

-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.074 ÷ 0.130
(0.0029″ ÷ 0.0051″)
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.081 ÷ 0.140
(0.0032″ ÷ 0.0055″)
-- injectors--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 ÷ 0.091
(0.0020″ ÷ 0.0036″)
6- 71020EN - 08 - 2003
TORQUE SETTINGS
TORQUE
PART Thread
N⋅m (ft. lbs.) 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. lbs.) 3
Internal screws Second phase: pre--torque . . . . . . . . . . M 17x2 120 (88 ft. lbs.) 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. lbs.)
Screws securing heat exchanger to crankcase
(see Fig. 9) ♦ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25
-- pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 (8 ft. lbs.) 1.15
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 (14 ft. lbs.) 1.9

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

Screws securing gearbox to crankcase . . . . . . . . . . . . . . M 12x1.25 63±7 6.3±0.7
(46±5 ft. lbs.)
Screw securing cylinder head (see Fig. 6) ♦ . . . . . . . . . M 17x2
First phase: pre--torque . . . . . . . . . . . . . . . . . . . . . . . . 60 (44 ft. lbs.) 6
Second phase: pre--torque . . . . . . . . . . . . . . . . . . . . . . . . 120 (88 ft. lbs.) 12
Third phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . 120°
Fourth phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . 60°
Screw securing rocker arm shaft ♦ . . . . . . . . . . . . . . . . . M 16x1.5
Second phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . 60°
Lock nut for rocker arm adjustment screw . . . . . . . . . . . M 10x1.25 39±5 3.9±0.5
(28±3 ft. lbs.)
Screw for injector fixing brackets ♦ . . . . . . . . . . . . . . . . . M 8x1.25 26 (19 ft. lbs.) 2.6
Screw securing thrust plates to the head . . . . . . . . . . . . M 8x1.25 19 (14 ft. lbs.) 1.9
Screw securing engine bracket to cylinder head M 18x2
(cont.)
♦ Before assembly, lubricate with engine oil
• Before assembly, lubricate with graphitized oil
6- 71020EN - 08 - 2003
TORQUE SETTINGS
(cont.)
TORQUE
PART Thread
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.)
(cont.)
6- 71020EN - 08 - 2003
TORQUE SETTINGS
(cont.)
TORQUE
PART Thread
Screws securing exhaust manifold • (see Fig. 7) . . . . . . M 10x1.5
-- pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5±7.5 3.2±0.7
(24±5 ft. lbs.)
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45±5 4.5±0.5
(33±3 ft. lbs.)
Screw securing connecting rod cap ♦ . . . . . . . . . . . . . . . M 14x2
Screws securing engine flywheel ♦ . . . . . . . . . . . . . . . . . M 18x1.5
Third phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . 30°
Screws securing pulley to crankshaft ♦ . . . . . . . . . . . . . . M 14x2
-- pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 (51 ft. lbs.) 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. lbs.)
Screw securing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
(18±1 ft. lbs.)
Screw securing oil pump suction hose and pipe to M 8x1.25 25±2 2.5±0.2
crankcase . . . . (18±1 ft. lbs.)
Screw securing fuel filter to cylinder head . . . . . . . . . . . . M 10x1.5 37±3 3.7±0.3
(27±2 ft. lbs.)
Screw securing crankshaft gasket cover . . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
(25±1 ft. lbs.)
Screw securing control unit mount to crankcase . . . . . . M 8x1.25 19±3 1.9±0.3
(14±2 ft. lbs.)
Screw securing fuel pump to flywheel cover box . . . . . . M 8x1.25 19±3 1.9±0.3
(14±2 ft. lbs.)
Screw securing thermostat box to cylinder head . . . . . . M 8x1.25 19±3 1.9±0.3
(14±2 ft. lbs.)
Screw securing rocker arm cover (see Fig. 13) . . . . . . . M 6x1 8.5±1.5 0.8±0.1
(75±13 in. lbs.)
(cont.)
6- 71020EN - 08 - 2003
TORQUE SETTINGS
(cont.)
TORQUE
PART Thread
Screws and nuts securing turbocharger • (see Fig. 8) . M 10x1.5
-- pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.5±7.5 3.3±0.7
(24±5 ft. lbs.)
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46±2 4.6±0.2
(34±1 ft. lbs.)
Screw securing water pump to crankcase . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
(18±1 ft. lbs.)
Screw securing spacer/pulley to fan . . . . . . . . . . . . . . . . . M 8x1.25 30±3 3±0.3
(22±2 ft. lbs.)
Screw securing automatic tightener to crankcase . . . . . M 10x1.5 50±5 5±0.5
(37±3 ft. lbs.)
Screw securing fixed tightener to crankcase . . . . . . . . . . M 12x1.75 105±5 10.5±0.5
(77±3 ft. lbs.)
Screw securing fan mount to crankcase . . . . . . . . . . . . . M 12x1.75 100±5 10±0.5
(73±3 ft. lbs.)
Screw securing starter motor . . . . . . . . . . . . . . . . . . . . . . . M 12x1.75 74±8 7.4±0.8
(54±6 ft. lbs.)
Screw securing air heater to the cylinder head . . . . . . . . M 10x1.5 37±3 3.7±0.3
(27±2 ft. lbs.)
(cont.)
6- 71020EN - 08 - 2003
TORQUE SETTINGS
(cont.)
TORQUE
PART Thread
Screw securing air--conditioner compressor drive belt
automatic tightener to crankcase . . . . . . . . . . . . . . . . . . . . . M 8x1.25 26±2 2.6±0.2
(19±1 ft. lbs.)
Screw securing alternator bracket to crankcaseL = 35mm M 10x1.5 30±3 3±0.3
(22±2 ft. lbs.)
L = 60mm M 10x1.5 44±4 4.4±0.4
(32±3 ft. lbs.)
L = 30mm M 8x1.25 24.5±2.5 2.4±0.2
(18±2 ft. lbs.)
Screw securing air--conditioner compressor mount . . . . . . M 8x1.25 24.5±2.5 2.5
(18±2 ft. lbs.)
Screw securing guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 24.5±2.5 2.5
(18±2 ft. lbs.)
Filter clogging sensor fixing . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4--16 UNF 55±5 5.5
(40±3 ft. lbs.)
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. lbs.)
Temperature switch/transmitter fixing . . . . . . . . . . . . . . . . . M 16x1.5 23±2.5 2.3±0.2
(17±2 ft. lbs.)
Air temperature transmitter fixing . . . . . . . . . . . . . . . . . . . . . M 16x1.5 32.5±2.5 3.2±0.2
(24±2 ft. lbs.)
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.)
6- 71020EN - 08 - 2003
PLAN OF TIGHTENING SEQUENCE
Sub--Cranckcase
First phase A
external screw pre--torque:
-- F3A 30 N⋅m (22 ft. lbs.)
MID1001A
Second phase
internal screw pre--torque:
-- F3A 120 N⋅m (88 ft. lbs.)
MID1002A
Third phase
internal screw angle closed:
-- F3A 90°
MID1003A
Fourth phase
-- F3A 45°
MID1004A
6- 71020EN - 08 - 2003
Fifth phase
external screw angle closed:
-- F3A 60°
A = front side
A
MID1005A
Cylinder head
MID1006A
Exhaust manifold
MID1007A
Turbocharger
Sequence:
pre--torque 4--3--1--2
torque 1--4--2--3
MID1008A
6- 71020EN - 08 - 2003
Heat exchanger
MID1009A
Engine oil sump
First phase: from 1 to 16

Second phase: from 17 to 32
MID1010A
10
Rocker arm cover
MID1011A
11
6- 71020EN - 08 - 2003
TOOLS
CAUTION
The operations described in this section can only be
carried out with the ESSENTIAL tools indicated by an
(X).
To work safely and efficiently and obtain the best
results, it is also necessary to use the recommended
specific tools listed below and certain other tools,
which are to be made according to the drawings
included in this manual.
PART DESCRIPTION
380000120 Tool to remove crankshaft front gasket
380000121 Tool to remove crankshaft rear gasket
380000126 Key for fitting crankshaft front gasket
380000127 Key for fitting crankshaft rear gasket
380000128 Tools (12+6) to retain rocker arm adjustment screw sliding blocks when
disassembling and reassembling the rocker arm shaft
380000130 Caps (6) protecting injector seats
380000131 Tool to disassemble and reassemble engine valves (use with specific plates)
380000132 Plate to disassemble and reassemble engine valves (use with 380000131)
380000136 Drift to reassemble valve guide (use with 380000365)
380000137 Tool for engine flywheel rotation (use with 380000138)
380000138 Spacer (use with 380000137)
380000139 Key to fit gasket on valve guide
380000140 Tool for compression to measure cylinder liner protrusion (use with 380000364
and specific plates)
380000142 Spacers (use with 380000140)
380000143 Plate for cylinder liner compression (use with 380000140 -- 380000142)
380000144 Tool to retain engine flywheel
380000146 Drift to disassemble and reassemble camshaft bushings
380000147 Bracket to disassemble and reassemble engine flywheel
380000148 Tool to assemble and install rocker arm shaft (use with 380000128)
380000150 Tool for engine T.D.C. positioning
380000151 Tool for phonic wheel timing on camshaft
380000153 Ring (115 mm) (use with 380000366)
380000155 Brackets fixing engine to rotary stand 380000361

6- 71020EN - 08 - 2003
PART DESCRIPTION
380000157 Tool for upsetting injector sheath
380000159 Tool for threading injector sheaths to remove (use with 380000160)
380000160 Guide bushing (use with 380000159)
380000162 Guide bushing (use with 380000163 or 380000164)
380000163 Milling cutter to rebore injector seat (use with: 380000162 for F3A engine)
380000164 Reamer to rebore bottom of injector sheaths (use with: 380000162 for F3A engine)
380000165 Extractor for injector sheath
380000167 Gauge to determine centre distance between camshaft and transmission gear
380000169 Crankshaft front gasket cover centring ring
380000220 Clamp to insert piston in cylinder liner (60--125 mm)
380000221 Tool to install piston rings
380000304 Pair of gauges for angular torque with 1/2” and 3/4” square connection
380000324 Pliers for piston ring disassembly and reassembly (105--160 mm)
380000360 Engine removal and installation tool
380000361 Revolving telescopic service stand (capacity 2000 daN, torque 375 daN/m)
380000362 Crankshaft lifting tool
380000363 Tool to retain cylinder liners
380000364 Tool for measuring cylinder liner protrusion (use with 380000167)
380000365 Drift to remove valve guide
380000366 Tool to remove cylinder liners (use with specific rings)
380000368 Valve guide reamer
380000370 Tool to remove remains of injector sheath
380000549 Percussion extractor
6- 71020EN - 08 - 2003
Oil by gravity
Oil under pressure
MID1012A
12
Lubrication diagram
6- 71020EN - 08 - 2003
MID1013A
13
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
6- 71020EN - 08 - 2003
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

efficient terminals or replace them
1.b Starter motor: -- Not efficient -- Check or replace
1.c Heater: -- Not efficient -- Check supply and earth
connection.
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
6- 71020EN - 08 - 2003
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
6- 71020EN - 08 - 2003
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

couplings when hot)
-- Valve 0.8 bars on fuel return
from cylinder head:
a) Jammed open -- Replace
(low pressure)
b) Jammed shut
(high temperature) -- Replace
-- Bad fuel leakage

-- Check, repair
-- Supply pump broken (seized,
broken coupling, pressure -- Check pressure on filter inlet
adjustment valve, etc.) Replace
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
(constriction clogged filter) indicator.
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
6- 71020EN - 08 - 2003
4 GREY--WHITE SMOKE FROM ENGINE
DEFECT CAUSE REMEDY

4.a Water in cylinders -- Leakage from head gasket -- Check water circuit
pressurization liquid level
-- Leakage from injector sheaths
-- Check tank cleaning
-- Incoming water from intake
system
-- Water in diesel
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
6- 71020EN - 08 - 2003
Engine -- Disassembly – 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.
Before securing the engine on the rotary stand,
remove: 1
1. the electric cable of the engine, disconnecting it

from the control unit and from all the
sensors/transmitters to which it is connected.
3
2. With an appropriate tool, 3, act in the direction of
the arrow on the tightener, 5, and remove the
compressor drive belt, 1.
2 5
3. Remove the compressor, 2, together with the
engine mount. MID1014A
14
4. Remove the oil pressure adjustment valve, 1.
MID1015A
15
5. Remove the engine mounts.
6. Remove the drive, 1.
MID1016A
16
6- 71020EN - 08 - 2003
7. Secure the engine to the rotary stand with the

brackets (1) 380000155.
MID1017A
17
8. Drain the lubricating oil from the sump.
MID1018A
18
9. Using a suitable tool, 3, act in the direction of the
arrow on the tightener, 2, and remove the belt, 1.
MID1019A
19
6- 71020EN - 08 - 2003
Remove:
10. the alternator, 2;
11. the mounts, 2 and 5.
MID1020A
20
Remove:
12. thermostat assembly, 8;
13. pipes together with coolant, 6;
14. pulley, 4;
15. water pump, 7;
16. automatic tightener mount, 1;
17. fixed tightener, 5;
18. damper flywheel, 3, and pulley beneath;
19. automatic tightener, 2.

MID1021A
21
20. With the extractor, 2 380000120, applied as
illustrated in the Fig., remove the gasket, 4.
Unscrew the screws, 1, and take off the cover, 3.
Disconnect all the electric connections and
sensors. 1
4
MID1022A
22
6- 71020EN - 08 - 2003
From the engine exhaust side, remove the following

parts:
21. oil delivery pipe, 1;
22. air pipe for actuator, 5;
23. oil return pipe, 4;
24. turbocharger, 3;
25. exhaust manifold, 2.

MID1023A
23
26. disconnect the oil pipes, 3 and 4, and disengage
them from the clamps (←).
27. remove the fixing screws, 1, and the heat

exchanger, 2;
MID1024A
24
28. disconnect the fuel pipes, 1, from the supply
pump, 2. 3
Remove:
4
29. the supply pump, 2;
30. the mount, 3, together with the fuel filter, 4, and 1

pipes, 1.
2
MID1025A
25
31. unscrew the oil filters, 1.
MID1026A
26
6- 71020EN - 08 - 2003
32. Disconnect the pipes, 2 and 3, from the mounts,

1 or 4, disengaging them from the clamps, and 4
remove them.
33. Take out the screws, 5, and remove the mounts,

1 or 4.
5
MID1027A
27
34. Remove the screws, 2, and intake manifolds, 1.
MID1028A
28
Remove:
35. the starter motor, 1;
36. the control unit, 2, and the relevant mount;
37. the oil dipstick, 3, from the crankcase.
MID1029A
29
38. Remove the rocker arm cover, 1.
39. Remove the timing system cover, 2. 1

2
MID1030A
30
6- 71020EN - 08 - 2003
40. Unscrew the screws, 2, and take out the gear, 1,

together with the phonic wheel.
MID1031A
31
41. Unscrew the five screws, 1.
42. Take out the thrust plate, 2, together with the ring
seal as follows:
1
-- screw three screws 10x1.5 in the holes (A, B,
C) to extract the thrust plate, 2. Remove the
sheet metal gasket beneath.
2
MID1032A
32
43. Unscrew the screws, 1, and remove the
transmission gear, 2.
2
MID1033A
33
44. With an appropriate wrench, unscrew the screw
(2) and remove the transmission gear, 1.
2
MID1034A
34
6- 71020EN - 08 - 2003
45. Block rotation of the engine flywheel, 3, with tool

380000144, 1. Unscrew the fixing screws, 2, and
remove the engine flywheel.
1
2
3
MID1035A
35
46. With the extractor (2) 380000121, applied as
illustrated in the Fig., remove the ring seal, 1,
from the timing box.
1
2
MID1036A
36
47. Unscrew the screws, 1, and remove the timing
gear box, 2.
2
1
MID1037A
37
48. Unhook the springs, 3, lever check, 2.
49. Unscrew the rocker arm shaft fixing screws, 1.
MID1038A
38
6- 71020EN - 08 - 2003
50. With tool 380000170, 2, constrain the sliding

blocks, 3, to the rocker arms, 1.
MID1039A
39
51. With the tool, 1 380000148, applied as in the Fig.,
remove the rocker arm shaft assembly. 1
MID1040A
40
52. Remove the crosspieces from the valves.
53. Unscrew the screws and remove the electric

connections, 1, from the solenoid valves.
54. Unscrew the screws, 3, fixing the brackets, 4,

retaining the pump injectors, 2.
55. Remove the pump injectors, 2.
MID1041A
41
56. Fit the caps, 1 380000130, in place of the
injectors:
57. Remove the camshaft, 2.
58. Remove the screws, 3, fixing the cylinder head. 2 1
MID1042A
42
6- 71020EN - 08 - 2003
59. With specific ropes and lift, take off the cylinder
head, 1.
60. Remove the gasket, 2.

1
2
MID1043A
43
61. Unscrew the screws, 2, and remove the engine oil
sump, 1, together with the spacer, 3, and the
gasket.
MID1044A
44
62. Unscrew the screws and remove the suction
hose, 1.
MID1045A
45
63. Turn the crankcase, 1, upright.
MID1046A
46
6- 71020EN - 08 - 2003
64. Unscrew the screws, 2, fixing the connecting rod

cap, 3, and remove it.
2
65. From the top, take out the piston connecting rod
assembly, 1. Repeat the same operations for the 1
other pistons.
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 3
the same position found in disassembly.
MID1047A
47
66. 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 2
bottom main bearing shells since, if they are to be
reused, they will need to be fitted in the same position
found in disassembly. 3
MID1048A
48
67. Using tool 380000362, 1, remove the crankshaft,
2.
MID1049A
49
68. Take out the main bearing shells, 1.
Unscrew the screws and remove the oil nozzles,
2.
69. Remove the cylinder liners as described in the

relevant paragraph on page 68.
1
MID1050A
50
6- 71020EN - 08 - 2003
General notes
-- After taking down the engine, clean the parts

carefully.
-- The following pages illustrate the assembly

operations that must be read extremely carefully
to be able to assemble the parts correctly.
-- The torques of the parts and the instructions that

must be followed meticulously are given
beginning on pages 14 through 27.
IN ADDITION IT IS NECESSARY TO BEAR IN

MIND THAT:
-- When totally or partially stripping the engine, all

the gaskets need to be replaced.
-- Before inserting the rotary parts and gaskets in

the coupling, it is necessary to lubricate the parts
with engine oil.
-- When fitting the oil filter, lubricate the seal with

engine oil.
CAUTION
The following pages give the instructions for the main
checks and measurements to make to determine
whether the parts are sound enough to be reused
after reassembly.
CAUTION
Handle all parts carefully. Do not put your hands
between parts and use the most suitable tools to align
holes.
Wear the required safety clothing – safety goggles,
gloves and shoes.
6- 71020EN - 08 - 2003
CRANCKSHAFT
Fitting the crankshaft bearings
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.
If dismantled, refit the oil nozzles, 2, tightening the

union, 3, to the required torque.
2
Put the half bearings, 1, on the crankshaft mounts of 1
3
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. MID1051A
51
Using a hoist and hook 380000362, 1, mount the
crankshaft, 2.
MID1052A
52
6- 71020EN - 08 - 2003
Put the half bearings, 1, on the main bearings in the

sub--crankcase, 2.
1
MID1053A
53
Apply LOCTITE 5699 sealant on the crankcase with
an appropriate tool, 1, as shown in the Fig.
1
The box contains a diagram for applying LOCTITE
5699 sealant.
CAUTION
Fit the sub--crankcase within 10 min. of applying the
sealant.
MID1054A
54
Fit the sub--crankcase, 1, using a hoist and
appropriate hooks.
1
2
MID1055A
55
CAUTION
The sub--crankcase fixing screws must, before 2 3 4
assembly, be lubricated with engine oil.
Screw down the screws, 1, and tighten them

according to the torques and phases shown in the
following Figs.
1
1
MID1056A
56
6- 71020EN - 08 - 2003
First phase
-- 30 N⋅m (22 ft. lbs.) A
MID1057A
57
Second phase
-- 120 N⋅m (88 ft. lbs.)
MID1058A
58
Third phase
-- 90°
MID1059A
59
Fourth phase
-- 45°
MID1060A
60
6- 71020EN - 08 - 2003
Fifth phase
-- 60°
A = front side
MID1061A
61
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 Fig.
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
MID1062A
62
With the centring ring, 2 380000169, position the front
cover, 1, on the crankcase, screws down the screws,
3, and tighten them to the required torque.
MID1063A
63
Key the ring seal, 1, onto the crankshaft, on which you
should apply the tool, 3 380000126.
Screw down the nut, 4, to mount the ring seal, 1, 1

completely in the cover, 2.
2
MID1064A
64
6- 71020EN - 08 - 2003
PISTONS, PISTONS RINGS AND

CONNECTING RODS
Fit the rings, 1, on the pistons, 2, with the pliers 1

380000221, 3. The rings have to be fitted with the
word ”TOP”, 4, facing upwards, also arrange the 2
openings of the piston rings so they are out of step 3
with each other by 120°.
MID1065A
4
65
CAUTION
On finding there is no need to replace the connecting 1
rod bearings, it is necessary to fit them back on in the
disassembly. 2
If you need to replace them, select the connecting rod
pages 75 -- 79 -- 81 -- 82. 1
Lubricate the half bearings, 1 and 2, and fit them on

the connecting rod, 2, and on the cap, 4. 4
MID1066A
CAUTION 66
Do not make any adjustments to the half bearings.
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 Fig. 68, checking
that: 1
-- The number of each connecting rod corresponds

to the cap coupling number.
2
-- The symbol, 2, (Fig. 68), punched on the top of
the pistons faces towards the engine flywheel; or
MID1067A
the cavity in the shell of the pistons corresponds
to the position of the oil nozzles. 67
CAUTION
Class A pistons are supplied as spares and they can
also be fitted in a class B cylinder liner.
6- 71020EN - 08 - 2003
Outline for fitting the

connecting rod--piston
assembly in the cylinder liner 2
1. Connecting rod--piston
assembly.
2. Punched zone on the top of

the piston with symbol for the
assembly position and class
of selection.
3. Connecting rod punching 1

zone.
MID1068A
68
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 1

two stages to the torques given in the following table:
1
F3A
1st phase 60 N⋅m (6 kgm [44 ft. lbs.])
2
2
2nd phase, angle 60°
MID1069A
CAUTION 69
The connecting rod cap fixing screws of the F3A
engine must, before assembly, be lubricated with
engine oil.
Angle closing is performed with tool 380000304, 3.
CAUTION
Lubricate the relevant parts before final assembly.
Before reusing the connecting rod cap fixing screws,
measure the thread diameter is no lower than 13,4
mm (.528″).
Replace the screw if its diameter is any lower.
6- 71020EN - 08 - 2003
CYLINDER HEAD
Check that the pistons 1--6 are exactly at the T.D.C.

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 Fig. 71 and in four successive stages as
shown in the Figs. 2
MID1070A
70
CAUTION
The cylinder head fixing screws of the F3A engine
must, before assembly, be lubricated with engine oil.
Tightening sequence of the cylinder head fixing

screws.
MID1071A
71
Pre--tightening with torque wrench, 1.
1
F3A
60 N⋅m
1st phase
(6 kgm [44 ft. lbs.])
120 N⋅m
2nd phase
(12 kgm [88 ft. lbs.])
MID1072A
72
Angle closing with tool 380000304, 1.
F3A
1a fase 120°
2a fase 60°
MID1073A
73
6- 71020EN - 08 - 2003
OIL PUMP AND , TIMING SYSTEM

INTERMEDIATE GEARS
Fit the oil pump, 4, intermediate gears, 2, together 1

with connecting rod, 1, and tighten the screws, 3, in
two stages:
2
3
-- pre--torque 30 N⋅m (22 ft. lbs.) 4
-- closed angle 90°
CAUTION MID1074A
The screws, 3 fixing the intermediate gear of the F3A 74

engine must, before assembly, be lubricated with
engine oil.
Apply LOCTITE 5699 silicone on the gear box, 2, with

an appropriate tool, 1, as shown in the Fig.
1
CAUTION
Fit the gear box within 10 min. of applying the sealant. 2
MID1075A
75
Tighten the fixing screws of the timing system box
to the torques indicated here and according to the
given sequence.
10 screws M12 x 1.75 x 100; 63 N⋅m (46 ft. lbs.)

1 screw M12 x 1.75 x 120; 63 N⋅m (46 ft. lbs.)
: 2 screws M12 x 1.75 x 193; 63 N⋅m (46 ft. lbs.)
MID1076A
76
6- 71020EN - 08 - 2003
Key the ring seal, 1, onto the crankshaft, on which

you should apply the tool, 2 380000127. 1
Screw down the nut, 3, to mount the ring seal, 1, 2

completely in the gear box, 4.
3
MID1077A
77
6- 71020EN - 08 - 2003
ENGINE FLYWHEEL
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 D
corresponding to 54°.
CAUTION View of holes: A – B – C B View of holes: D

If the teeth of the rim mounted on the engine flywheel,
for starting the engine, are badly damaged, replace MID1078A
the rim. Assembly must be done after heating the rim

to a temperature of 200°C (392°F). 78
Fit the engine flywheel without locking the fixing

screws, 2, and insert the pin 380000150, 1.
CAUTION
The engine flywheel fixing screws of the F3A engine
1
must, before assembly, be lubricated with engine oil. 2
MID1079A
79
Lock rotation with tool 380000144, 1; tighten the
screws, 2, in the following phases: 1
4
F3A 2
1st phase 120 N⋅m (12 kgm [88 ft. lbs.])
MID1080A
80
Second phase: closed angle with tool 380000304, 1.
F3A
2nd phase 60°
1
3rd phase 30°
MID1081A
81
6- 71020EN - 08 - 2003
CAMSHAFT
Mount the camshaft, 4, arranging it with the holes (→)

positioned as in Fig. 82.
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.
MID1082A
82
Apply the gauge, 1 380000167.
Check and adjust the position of the connecting rod,

3, for the transmission gear, lock the screw, 2, to the
required torque.
1
2
3
MID1083A
83
Fit the transmission gear, 1, back on and lock the
screws, 2, with an appropriate hex wrench to the
required torque.
MID1084A
2
84
Fit the gear, 2, back on the camshaft, without fully
locking the screws, 5, positioning it so that the 4 slots
are centred 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
0.073 – 0.195 mm (.0029 -- .0077″).
2
5
If this is not so, adjust the clearance as follows:
loosen the screws, 4, fixing the transmission gear, 3, 3
loosen the screw, 2, (Fig. 83), fixing the lever, move
the connecting rod, 3, (Fig. 83), to obtain the required
clearance; lock the screw, 2, (Fig. 83), fixing the con- 4
necting rod and the screws, 4, (Fig. 85), fixing the MID1085A
transmission gear to the required torque.

85
6- 71020EN - 08 - 2003
INJECTORS PUMP
Mount the ring seals, 1, 2 and 3, on the injectors.
MID1086A
86
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 3

crosspieces.
CAUTION 4
Position the crosspieces on the valve stem, all with
the largest hole on the same side.
1
MID1087A
87
ROCKER ARM SHAFT
CAUTION 1 5
Before refitting the rocker arm shaft assembly, make
sure that all the adjustment screws have been fully
unscrewed.
With tool 296170, 3, constrain the sliding blocks, 4, to

the rocker arms, 3. 2
Apply tool, 1, to the rocker arm shaft, 5 380000148, 4

and position it on the cylinder head.
3
MID1088A
88
6- 71020EN - 08 - 2003
CAUTION
The screws, 2, of the F3A engine must, before 2
1
Tighten the screws, 2, fixing the rocker arm shaft in
two phases: 3
1st phase: tightening with torque wrench, 1, to a

torque of 100 N⋅m (10 kgm [73 ft. lbs.]).
2nd phase: closing, with tool 380000304, 3, with an

angle of 60°.
MID1089A
89
Constrain the levers, 1, to the spacer, 3, with the
springs, 2.
1
2
MID1090A 3
90
Camshaft timing
Apply the tool for flywheel rotation to the gear box, 2:
-- 380000137, 7, and spacer 380000138, 6.

1
CAUTION 2 6
The arrow indicates the direction of rotation of the
working engine.
With the above--mentioned tool, turn the engine
7
flywheel, 1, in the direction of rotation of the engine
3
so as to take the piston of cylinder no.1 to
approximately the T.D.C. in the phase of combustion.
This condition is accomplished 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.
5
MID1091A
91
6- 71020EN - 08 - 2003
The exact position of the piston of cylinder no.1 at the

T.D.C. is obtained when, in the above--described
conditions, 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, ap-
propriately.
Remove the tool 380000150, 1.
MID1092A
92
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 1

until the pointer of the dial gauge reaches the
minimum value under which it cannot go.
Zero the dial gauge.
Turn the engine flywheel anticlockwise until on the

dial gauge you read the cam lift value of the camshaft 2
of:
-- 4.44 – 0.05 mm (0.175 -- 0.002″), for the F3A

engine. MID1093A
93
The camshaft timing is correct if the above cam lift
values correspond to the following conditions:
1. The hole with a double 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
engine flywheel, 4.
MID1094A
94
6- 71020EN - 08 - 2003
If the conditions described in Fig. 94 and indicated in

points 1 and 2 were not obtained, proceed as follows.
Loosen the screws, 2, fixing the gear, 1, to the cam-

shaft, 3.
1
Take appropriate action on the engine flywheel to
bring about the conditions indicated in points 1 and 2,
but the cam lift must not be affected. 2
Lock the screws, 2, and repeat the check as de-
scribed above.
Tighten the screws, 2, to the required torque.
MID1095A
95
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, (Fig. 95), are locked.
Turn the engine flywheel clockwise by approx. 1/2
turn.
1
Turn the engine flywheel anticlockwise until the dial
gauge shows a camshaft cam lift value of 4.44 ± 0.05
mm (0.175 -- 0.002″).
2
Take out the screws, 2, (Fig. 95) and remove the
gear, 2, from the camshaft.
Repeat the steps described in Fig. 94.
MID1096A
Mount the gear, 2, (Fig. 95) on the camshaft and
tighten the fixing screws to the required torque. 96
Phonic wheel timing
In the conditions described in Fig. 100, check that the

pin 380000151, 2, is positioned on the marked tooth 1
of the phonic wheel, 1. If this is not so, loosen the
screws, 3, and orient the phonic wheel, 1, appropri-
ately.
2
Then tighten the screws, 3, to the required torque.
MID1097A
97
6- 71020EN - 08 - 2003
COMPLETING THE ENGINE

1
Mount the rocker arm cover, 1, and the timing system
cover, 2, with new gaskets, tightening the fixing
screws to the required torque.
2
CAUTION
The fixing screws of the rocker arm cover, 1, must be
tightened in the sequence shown in the diagrams on
page 26.
MID1098A
98
Mount the suction hose, 1, and tighten the fixing
MID1099A
99
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.
MID1100A
100
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 control
unit mount and replace them if they are deteriorated. MID1101A
101
6- 71020EN - 08 - 2003
Fit the intake manifolds, 1, and tighten the fixing

screws, 2, to the required torque.
MID1102A
102
Fit the mount, 4, and tighten the fixing screws to the
required torque.
Connect the oil pipes (3) to the mounts (4) tightening

the fittings to the required torque.
MID1103A
103
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.).
MID1104A
104
Mount the following with their gaskets and tightening
the screws to the required torque:
-- fuel pump, 2;
3
4
-- mount, 3, with fuel filter, 4, and pipes, 1;
-- connect the pipes, 1, to the fuel pump, 2. 1
MID1105A
105
6- 71020EN - 08 - 2003
Fit the heat exchanger, 2, with its gasket and tighten

the fixing screws, 1, to the required torque.
1
Tighten the screws, 4, fixing the pipe clamps, 3 and
5, to the spacer.
2
3 4
5
MID1106A
106
Mount the following with new gaskets:
-- exhaust manifold, 2;
-- turbocharger, 3;
-- oil pipe, 1 and 4;
-- pipe to actuator, 5.
MID1107A
107
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; MID1108A
108
-- pulley, 4;
-- pipes with coolant, 6;
-- thermostat assembly, 8.
6- 71020EN - 08 - 2003
Mount the following, tightening the screws to the

required torque:
-- mounts, 1;
-- alternator, 2;
MID1109A
109
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
adjustments are required after assembly.
MID1110A
110
6- 71020EN - 08 - 2003
ASSEMBLY DIAGRAM FOR FAN DRIVE

BELT -- WATER PUMP -- ALTERNATOR
1. Alternator
2. Water pump
3. Crankshaft
4. Supercharger.
MID1111A
111
Put the tool 380000360 on the engine lifting hooks,
fasten this on the hoist.
Remove the screws fixing the brackets 380000155 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 re-
quired torque:
-- fit the drive, 1; MID1112A
112
-- fit the engine mounts;
-- fit the oil pressure adjustment valve, 1.
MID1113A
113
Fit the engine mount together with the air--conditioner
compressor, 2. 1
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 engine with the required amount and
grade of lubricating oil.
3
2
MID1114A
114
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CRANKCASE, CYLINDER LINERS

Checks, Measurements and Repairs
CAUTION 1
gloves and shoes.
2
CAUTION 3
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,
previously zeroed on the ring gauge, 3, 380000153 of
diameter 125 mm (4.921″).
If the ring gauge is not available, use a micrometer. MID1115A
115
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 Fig. 116.
MID1116A
116
Selection X
F3A
class
A 125 -- 125.013 (4.9213 -- 4.9218″)
B 125.011 -- 125.024 (4.9217 -- 4.9222″)
(Dimensions in mm [inches]) A-
B
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 Fig., it is necessary to replace the
cylinder liner as grinding, lapping and dressing are
not permitted.
CAUTION MID1117A
The cylinder liners are supplied as spares with
selection class ”A”. Class B is mounted solely in 117
production.
X = Selection class marking area.

6- 71020EN - 08 - 2003
Ø F3A
142.000 -- 142.025
A
(5.5906 -- 5.5915″)
140.000 -- 140.025
B
(5.5118 -- 5.5128″)
141.961 -- 141.986
C
(5.5890 -- 5.5900″)
139.890 -- 139.915
D
(5.5075 -- 5.5085″)
(Dimensions in mm [inches])
MID1118A
The diagram illustrated in Fig. 118 gives the outside
diameters of the cylinder liner and the inside diam- 118
eters of their seats.If necessary, the cylinder liners
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 2
the plate, 4, rests correctly on the cylinder liner.
Screw down the nut of screw, 1, and extract the cylin-
der liner, 3, from the crankcase. 3
4
MID1119A
119
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 1
assembly with an appropriate tool.
CAUTION 2 4
The adjustment ring (1) is supplied as a spare in the
following thicknesses: 0.08 mm – 0.10 mm – 0.12 mm 3
(0.003 -- 0.004 -- 0.005″). 5
MID1120A
120
6- 71020EN - 08 - 2003
Checking protrusion
1
Check the protrusion of the cylinder liners with tool
380000140, 2, and tightening the screw, 1, to the 2
torque of 220 N⋅m (162 ft. lbs.).
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
Fig. 122. If this is not so, replace the adjustment ring,
1, (Fig. 120), supplied as a spare in several
thicknesses.
MID1121A
121
Cylinder liner protrusion
X
Protrusi
F3A
on
0.045 – 0.075
X
(0.0018 -- 0.0030″)
(Dimensions in mm [inches])
MID1122A
122
On completing assembly, lock the cylinder liners, 1,
to the crankcase, 2, with the pins 380000363, 3.
1
2
MID1123A
123
6- 71020EN - 08 - 2003
CRANKSHAFT, BEARINGS
CAUTION
fingers between parts. 1
gloves and shoes. 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 always be
ground to the same class of undersizing so as not to MID1124A
alter the balance of the crankshaft.
124
It is advisable to note down the measurements in a

table Fig. 62.
6- 71020EN - 08 - 2003
.
.
.
.
. .
.
. .
. Top main bearing shells .
.
. .
.
. .
. .
.
.
.
.
.
.
. .
MID1125A . Bottom main bearing shells .
125
Engine F3A -- Main data of crankshaft and main bearing shells
6- 71020EN - 08 - 2003
X. Detail of the fittings of the main journals

(dimensions in mm)
POL- .
ISHED
. . -
GROUND
GROUND
. .
MID1126A
126
Y. Detail of the fittings of the main journals
(dimensions in mm)
POL- .
ISHED
. . -- .
GROUND
. .
MID1127A
127
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.
1
When fitting the gear, 1, on the crankshaft, 2, heat it
for approx. 15 minutes in an oven at a temperature of 2
180°C.
After driving it home, leave it to cool.
CAUTION
After heating the gear, 1, fit it on the shaft by applying
a load of 6000 N (1350 lbf.) to the gear, positioning the
load at the distance shown in Fig. 128. After cooling,
the gear must have no axial movement under a load
of 29100 N (6547.5 lbf.). MID1128A
128
6- 71020EN - 08 - 2003
SELECTING MAIN AND BIG END BEARING SHELLS
To obtain the required assembly clearances, the main

and big end bearing shells need to be selected as de-
scribed below.
This operation makes it possible to identify the most
suitable half bearings for each of the pins of the shaft
(the half bearings may even be of a different class
from one pin to another).
Depending on the thickness, the half bearings are se-

lected in classes of tolerance, marked by a colour
(red--green – red/black – green/black).
The following tables give the characteristics of the
main and big end bearing shells available as spares
in the standard (STD) sizes and in the permissible
oversizes (+0.127, +0.254, +0.508 [0.0050, 0.0100,
0.0200″]).
6- 71020EN - 08 - 2003
STD +0.127 +0.254 +0.508
red 1.970 -- 1.980 2.097 -- 2.107 2.224 -- 2.234
red
black 2.033 -- 2.043
green 1.981 -- 1.990 2.108 -- 2.117 2.235 -- 2.244
green
black 2.044 -- 2.053
yellow
* 1.991 -- 2.000
yellow * 2.054 -- 2.063

black
STD +0.127 +0.254 +0.508
red 2.965 -- 2.974 3.092 -- 3.102 3.219 -- 3.229
red
black 3.028 -- 3.037
green 2.975 -- 2.984
green
black 3.038 -- 3.047
yellow
* 2.985 -- 2.995
yellow * * Mounted in production only and not supplied as

3.048 -- 3.058
black spares.
MID0389A
129
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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
-- determine the class of diameter of the seat in the

crankcase;
-- determine the class of diameter of the main

journal;
-- choose the class of half bearings to fit.
Crankpins

connecting rod;
-- determine the class of diameter of the crankpin;
Selecting small end bearings (pins with nominal

diameter)
Two sets of Figs. are marked on the front of the

crankcase, in the position shown, (Fig. 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, (Fig. 142 at bottom);
-- each of these digits may be 1, 2 or 3.
6- 71020EN - 08 - 2003
CLASS MAIN BEARING NOMINAL DIAMETER
1 99.000 -- 99.009
2 99.010 -- 99.019
3 99.020 -- 99.030
MID0390A
130
6- 71020EN - 08 - 2003
Selecting the main bearing shells (pins with

nominal diameter)
Main journals and crankpins: determining the class of

diameter of the pins.
Three sets of Figs. are marked on the crankshaft, in

the position shown by the arrow (Fig. 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, represent the class of
diameter of each of the crankshafts to which they
refer (Fig. 134 at top).
-- the set of seven digits, on the right, refers to the

main journals and is preceded by a single digit,
which indicates 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
(Fig. 134 at bottom).
6- 71020EN - 08 - 2003
CLASS CRANKPIN NOMINAL DIAMETER
1 82.970 -- 82.979
2 82.980 -- 82.989
3 82.990 -- 83.000
40019
CLASSE MAIN JOURNAL NOMINAL DIAMETER
1 92.970 -- 92.979
2 92.980 -- 92.989
3 92.990 -- 93.000
MID0391A
131
6- 71020EN - 08 - 2003
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:
6- 71020EN - 08 - 2003
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
MID0392A
132
6- 71020EN - 08 - 2003
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.
6- 71020EN - 08 - 2003
F3A
red/black 3.028 -- 3.037

green/black 3.038 -- 3.047
--0.127 Class 1 2 3
green/black green/black green/black

F3A 92.843
92.852
1
red/black green/black green/black

F3A 92.853
92.862 2
red/black red/black green/black

F3A 92.863
92.873 3
F3A
red 3.092 -- 3.102
--0.254
1 2 3
red red red

F3A 93.224
93.234
red red red
F3A
red 3.219 -- 3.229
--0.508 1 2 3
93.468
red red red
F3A 93.508
red red red
MID0393A
133
6- 71020EN - 08 - 2003
Selecting the big end bearing shells

(pins with nominal diameter)
On the body of the connecting rod, in position “A”,

there are three markings:
VIEW FROM ”A”
3. Letter specifying the weight classes:
F3A
A = 3973 -- 4003 g. (8.76 -- 8.83 lbs.) 3
2
B = 4004 -- 4034 g. (8.8 -- 8.89 lbs.)
1
C = 4035 -- 4065 g. (8.9 -- 8.96 lbs.)
4. Number specifying the selection of the diameter

of the big end bearing seat:
A
F3A
MID0394A
1 = 87.000 -- 87.010 mm (3.4252 -- 3.4256″)
134
2 = 87.011 -- 87.020 mm (3.4256 -- 3.4260″)
3 = 87.021 -- 87.030 mm (3.4260 -- 3.4264″)
5. Numbers identifying the cap--connecting rod

coupling.
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 (Fig. 135).
6- 71020EN - 08 - 2003
green green green
green green green
red green green
red green green
red red red
red red red

MID0395A
135
6- 71020EN - 08 - 2003
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.
6- 71020EN - 08 - 2003
F3A
red/black 2.044 -- 2.053

green/black 2.033 -- 2.043
--0.127 Class 1 2 3
F3A 82.843
82.852 1
82.853
F3A 82.862 2
F3A 82.863 red/black red/black green/black

82.873 3
F3A
red 2.097 -- 2.107

green 2.108 -- 2.117
--0.254
1 2 3
red green green
82.726
F3A 82.735
red green green
red red green

F3A 82.736
82.746
red red green
F3A
red 2.224 -- 2.234

green 2.235 -- 2.244
--0.508
1 2 3
red green green
F3A 82.472
82.481
red green green
red red green

F3A 82.482
82.492
red red green
MID0396A
136
6- 71020EN - 08 - 2003
Checking main journal assembly clearance

1
3
If dismantled, mount the oil nozzles, 3, making the
grub screw coincide with the hole, 2, on the 2
crankcase.
CAUTION
Clean the parts carefully and remove every trace
of oil.
Put the half bearings, 1, on the main bearings. MID0397A
137
With a hoist and hook 380000362, 1, fit on the
crankshaft, 2.
MID0398A
138
Place the half bearings, 1, on the main bearings in the
sub--crankcase, 2.
Check the assembly clearance between the main 1
journals of the crankshaft and the respective
bearings, proceeding as follows:
MID0399A
139
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
MID0400A
140
6- 71020EN - 08 - 2003
CAUTION
The screws, 1, must, before assembly, be
lubricated with engine oil.
Screw down the internal screws, 1, and tighten them 2

in the sequence given in the diagram of Fig. 142 and
to the torques given on page 24.
1
The closed angle is done with tool 380000304, 2.
MID0401A
141
Tightening sequence of
the screws fixing the
sub--crankcase under the
crankcase.
FRONT SIDE
MID0402A
142
Remove the sub--crankcase
The clearance between the crankshaft bearings and 1

the relevant pins is measured by comparing the width
taken on by the calibrated wire, 2, at the point of
greatest crushing, with the graduated scale on the 2
case, 1, containing the calibrated wire.
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.
MID0403A
143
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 Fig. 156. If you find the clearance is higher than as
and repeat the clearance check.
2
1
MID0404A
144
6- 71020EN - 08 - 2003
PISTONS
CAUTION
or fingers between parts.
gloves and shoes.
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. 2
3
Piston
1
Remove the piston rings, 2, from the piston, 3, with
the pliers 380000211, 1.
MID0405A
145
Remove the split rings, 2, holding the piston pin with
round--nose pliers, 1. 1
MID0406A
146
Remove the piston pin, 1.
If disassembly is difficult, use an appropriate drift.
MID0407A
147
6- 71020EN - 08 - 2003
Measuring piston diameter

1
Using a micrometer, 2, measure the diameter of the
piston, 1, to determine the assembly clearance. 2
X
CAUTION
The diameter has to be measured at the distance
X = 19 mm (0.748″″) from the base of the piston
skirt:
The pistons are selected in two classes A and B ac- MID0408A

cording to the diameter.
148
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
MID0409A
149
Piston pin
The pins are mounted with clearance both on the 2

small end and on the piston.
Measure the diameter of the pin, 1, with a micrometer,

2.
MID0410A
150
Conditions for correct pin--piston coupling
When fitting new pins, 1, check they couple correctly 1

with the seat on the piston in the following manner:
-- 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.
MID0411A
-- The pin must not slip out of the bosses on its own.
151
6- 71020EN - 08 - 2003
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
MID0412A 50.018 50.000
152
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
MID0413A
153
Check the clearance between the ring seals, 2, and
their seats on the piston, 1, with a feeler gauge, 3. 3
1
2
MID0414A
154
6- 71020EN - 08 - 2003
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
MID0415A
155
Using a feeler gauge, 2, check the opening between
the ends of the ring seals, 1, inserted in the cylinder
liner, 3. 1
On finding a higher or lower distance between the
ends than as required, replace the piston rings.
2
MID0416A
156
CONNECTING RODS
CAUTION
gloves and shoes.
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 MID0417A
all of the same class.
157
6- 71020EN - 08 - 2003
Outline of connecting--rod punch--marks
1. Letter specifying class of weight:

VIEW FROM ”A”
F3A 1
A = 3973 -- 4003 g. (8.759 -- 8.825 lbs.)
2
B = 4004 -- 4034 g. (8.827 -- 8.893 lbs.)
C = 4035 -- 4065 g. (8.896 -- 8.962 lbs.)

3
MID0418A
2. Number indicating the selection of the big--end
bearing seat diameter: 158
F3A
1 = 87.000 -- 87.010 mm (3.4252 -- 3.4256″)
2 = 87.011 -- 87.020 mm (3.4256 -- 3.4260″)
3 = 87.021 -- 87.030 mm (3.4260 -- 3.4264″)

coupling.
Bushings
The bushing, 2, is disassembled and assembled with 1 2

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
order to obtain the required diameter.
MID0419A
159
6- 71020EN - 08 - 2003
Rebore the small--end bushing with a boring

machine.
MID0420A
160
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 1

follows:
2
-- Fit the connecting rod, 1, on the spindle of the 3
tool, 5, and lock it with the screw, 4.
5
-- Place the spindle, 3, on the V--prisms resting the 4
connecting rod, 1, on the stop bar, 2.
MID0421A
161
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
2
the pin, 3, at point A and zero the dial gauge, 2. Move
the spindle, 4, with the connecting rod, 5, and on the 3
opposite side (B) of the pin, 3, compare any deviation:
the difference between A and B must be no greater 5
than 0.08 mm (0.003″).
MID0422A
162
6- 71020EN - 08 - 2003
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 1
mount, 1, of the dial gauge, 2, so that the latter rests 2
on the pin, 3, at point C.
Swing the connecting rod forwards and backwards, C D
searching for the highest position of the pin and zero
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
3
the highest point. The difference between points C
and D must be no greater than 0.08 mm (0.003″). 4
MID0423A
163
PISTON AND CONNECTING ROD --
ASSEMBLY
1 10
Piston--connecting rod assembly
2 5
1. Connecting rod body
2. Half bearings 3 8
3. Connecting rod cap
4. Cap fixing screws
5. Split ring
6. Oil scraper ring with slots with spiral spring 7
7. Ring seal
9
8. Trapezoidal ring seal 4
9. Piston pin 6
10. Piston 5
MID0424A
164
Connecting rod--piston coupling
CAUTION
The piston, 1, has to be fitted on the connecting
rod, 2, so that the symbol, 4, showing the
assembly position in the cylinder liner and the
punch mark, 3, of the connecting rod are
observed as shown in the Fig.
MID0425A
165
6- 71020EN - 08 - 2003
Mount the pin, 2, and constrain it to the piston, 1, with

the split rings, 3.
1
2
3
MID0426A
166
Fitting the piston rings
To fit the piston rings, 1, on the piston, 2, use the pliers

380000324, 3. 1
The rings need to be fitted with the word ”TOP”, 4,
facing upwards, also direct the openings of the rings
so they are staggered 120° apart. 2 3
MID0427A 4
167
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.
MID0428A
168
6- 71020EN - 08 - 2003
MID0429A
169
1. Connecting rod--piston assembly – 2. Punch mark area on the top of the piston with symbols for assembly
position and selection class – 3. Connecting rod punch mark area.
With the aid of the clamp 380000220, 1, (Fig. 184),

mount the connecting rod--piston assemblies, 2, in
the cylinder liners, checking that:
1
-- The openings of the piston rings are staggered
120° apart.
-- The pistons are all of the same class, A or B.

2
-- 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 MID0430A
the oil nozzles.
170
6- 71020EN - 08 - 2003
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
2
F3A
MID0431A
60 N⋅m (6 kgm [44 ft.
1st phase
lbs.]) 171
CAUTION
The screws, 2, of the F3A engine must, before
The closed angle is performed with the tool

380000304, 3.
Remove the caps and determine the existing

clearance, comparing the width of the calibrated wire
with the graduated scale on the bag containing the
wire.
CAUTION
Lubricate the relevant parts prior to final
assembly.
Before reusing the screws fixing the connecting
rod caps, measure to check the diameter of the
thread is no less than 13.4 mm (0.528″″).
For lower values, replace the screw.
6- 71020EN - 08 - 2003
CYLINDER HEAD
CAUTION
gloves and shoes.
Checking the hydraulic seal

Before removing the cylinder head, check the hy-
draulic seal with appropriate equipment: replace the 3
cylinder head if there is any leakage.
1
2 5
Removing the valves
6
With the bracket, 4, secure the tool, 2 3
380000131--380000132, to the cylinder head. 7
Screw down with the lever, 1, until it is possible to 8

remove the cotters, 3. Remove the tool, 2, and extract 4
the top plate, 5, spring, 6, and bottom plate, 7. MID0432A
Repeat this process for all the valves.
Turn the cylinder head over and extract the valves, 8. 172
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 1 2 3
After this process you need to check the valve
cavity and injector protrusion. MID0433A
173
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 Fig 175); if it does not, replace
the valves.
MID0434A
174
6- 71020EN - 08 - 2003
Main data of the valves and valve guides

(Dimensions in mm)
Check with a micrometer that the diameter of the 8.960

valve stems is as specified in the Fig.: 8.975
15.012
-- 8.960 – 8.975 (0.3528 -- 0.3533″) 15.025
1 2
9.015
* Measurement to make after driving in the valve
9.030
guides.
45°30’±7’30”
1. Intake
2. Exhaust. 60°30’±7’30”
45.85--43.15 41.85--42.15
Valve grinding
If necessary, grind the seats on the valves with a MID0435A
grinding machine, scalping as little material as 175

possible.
Checking clearance between stem--valve and

relevant valve guide
Using a dial gauge with a magnetic base, check the

clearance between the valve stem and the relevant
guide. If the clearance is too great, replace the valve
and, if necessary, the valve guide.
6- 71020EN - 08 - 2003
Valv seats
Main data on the intake and

exhaust valve seats 1 2
(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. Intake valve seat MID0436A

2. Exhaust valve seat
176
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 Fig 176. If you need to replace them, 1
with the same tool and taking care not to damage the
cylinder head, scalp as much material as possible 2
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 Fig 176.
MID0437A
After reboring the valve seats, use tool 380000364

177
and the dial gauge to check that the position of the
valves in relation to the face of the cylinder head is:
-- --0.65 -- --0.95 mm (--0.0256 -- --0.0374″) (cavity)

intake valves;
-- --1.8 -- --2.1 mm (--0.0709 -- --0.0827″) (cavity)

exhaust valves.
6- 71020EN - 08 - 2003
TAPPETS AND CAMSHAFT
CAUTION
gloves and shoes.
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.
.
.
. . .
. . .
.
. . . . .
.
. . .
. .
. . .
. . .
.
MID0438A .
. . .
178
Main data of the camshaft and tolerances (Dimensions in mm)
TOLERANCES SUBJECT OF TOLERANCE GRAPHIC SYMBOL

ORIENTATION Perpendicularity ⊥
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation ↗
CLASSES OF IMPORTANCE ATTRIBUTED TO THE CHARACTERISTICS OF THE GRAPHIC SYMBOL
PRODUCT
CRITICAL 
IMPORTANT ⊕
SECONDARY ⊝
6- 71020EN - 08 - 2003
Checking cam lift and pin alignment

1 2 1
Place the camshaft, 4, on the tailstock centres, 1,
and, using a dial gauge, 2, check that the lift of the
cams, 3, corresponds to the values given in the
following table:
F3A 3 4
intake cam mm 9.30
(0.3661″)
exhaust cam mm 9.45 MID0439A
(0.3720″)
pump injector 179
operating cam mm 11.21
(0.4413″)
Again with the camshaft, 4, on the tailstock centres,

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
MID0440A
180
To check the assembly clearance, measure the in-
side diameter of the bushings (Figs. 185 and 182)
and the diameter of the pins (Figs. 181 and 178) of 1
the 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.
MID0441A
181
6- 71020EN - 08 - 2003
Bushings
. -- .
. -- .
. -- .
MID0442A
182
F3A Engine – Main data for the camshaft bushings and seats on the cylinder head
(Dimensions in mm)
* Inside diameter of bushings after driving them in
Replacing camshaft bushings
A B C D E F D N G H D I
MID0443A
183
The surfaces of the bushings must have no sign of A. Drift – B. Bushing positioning grub screw – C.
seizing or scoring, replace them if they do. Reference for fitting the 7th bushing – D. Reference
Using a bore gauge, measure the inside diameter of for fitting bushings: 1 – 2 – 3 – 4 – 5 – 6, reference
the bushings. If it is above the tolerance value, mark for the F2B engine, red mark for the F3A engine
replace the bushings. – E. Guide bushing – G. Guide bushing to secure to
the 7th bushing mount – H. Plate for securing bushing
To disassemble and reassemble the bushings of the G to cylinder head – I. Grip – L. Extension coupling.
camshaft, use the drift 380000146.
6- 71020EN - 08 - 2003
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 380000146
coincide with the bushing.
MID0444A N
184
Assembly
Assemble the drift with the extension.

To fit the bushings 1 – 2 – 3 – 4 – 5 – 6, proceed as
follows:
1. Position the bushing to mount on the drift A

making its grub screw coincide with the seat on
the bushing.
2. Position the guide bushing E and secure the

guide bushing G on the seat of the 7th bushing
with the plate H.
3. When driving in the bushing, make the reference

mark F coincide with the mark M. In this way, after
driving it home, the hole in the bushing for
lubrication coincides with the oil duct in its seat.
The bushing is completely driven home when the
first yellow reference mark D is flush with the
guide bushing G.
6- 71020EN - 08 - 2003
To mount the bushing 6:

N E A G I
-- Unscrew the grip 1 and the 6
extension N.
-- Position the extension N

and the guide bushing E
as shown in the Fig.
-- Repeat steps 1, 2, 3
performed for driving in
the bushings 1, 2, 3, 4, 5.
MID0445A D
185
To mount the 7th bushing:
-- Remove the grip and the

guide bushing G secured N E G A I
7
to the cylinder head (Fig.
185).
-- 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. MID0446A
C
186
CAUTION
The bushing is driven in correctly when the
reference C is flush with the bushing seat.
6- 71020EN - 08 - 2003
VALVE SPRINGS, ROCKER ARM SHAFT

AND ROCKER ARMS
CAUTION
gloves and shoes.
Before assembly, the flexibility of the valve springs

needs to be checked with an appropriate tool. Com-
pare the load and elastic deformation data with the
data of the new springs given in the following Fig.
MID0447A
187
Main data for checking the valve springs
(Dimensions in mm [pounds feet])
1. Load of 500 ± 25 N (112.5 ± 5.6 lbf.).

2. Load of 972 ± 25 N (218.7 ± 5.6 lbf.). 1
75 2
61
47,8
MID0448A
188
6- 71020EN - 08 - 2003
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 380000139.
Fit the oil seal, 1, on the valve guide, 2, then mount

the valves as follows.
2
3
MID0449A
189
Mount the springs, 6, and top plate, 5.
1 3
On the cylinder head, fit the tool, 2 380000131 and 2
380000132, and secure it with the bracket, 4. Screw 5
down the lever, 1, until it is possible to mount the
cotters, 3, remove the tool, 2. 6
3 7
MID0450A 4
190
6- 71020EN - 08 - 2003
Rocker arm shaft
Check that the mating surfaces have no scoring or

signs of seizing. If they do, replace the damaged
parts.
Check the clearance between the bushings of the

rocker arms and the shaft. If you find the bushings
worn, replace the entire rocker arm.
1
2 3 2 3 2 3 2 3 2 3 2 3
1 1 1 1 1 1
MID0451A
191
1. Intake valve rocker arm – 2. Injector rocker arm – 3. Exhaust valve rocker arm.
F2B F3A
37.984 41.984
38.000 42.000
MID0452A
192
Main data of the rocker arm shaft (Dimensions in mm)
6- 71020EN - 08 - 2003
Rocker arms
SECTION SECTION
Intake valve rocker arms A--A B--B
(Dimensions in mm)
42.025
MID0453A
42.041
193
Exhaust valve rocker arm SECTION SECTION
A--A B--B
Main data for rocker arms
(Dimensions in mm)
56.030
56.049
MID0454A
194
Injector pump rocker arms
SECTION SECTION
(Dimensions in mm) A--A B--B
LUBRICATION SYSTEM 42.015

MID0455A 42.071
195
CAUTION
gloves and shoes.
Lubrication is by forced circulation, obtained with a

gear pump, 1. 1
The pump is governed, via gearing, by the crank- 2
shaft, 2.
Check that the gears have no sign of wear or seizure;
if they do, replace the entire pump.
To replace the gear, 2, see under the relevant heading MID0456A
on page 73.
196
6- 71020EN - 08 - 2003
Oil pump section

B
SECT. B-B
1. Overpressure valve
A SECT. A-A
Pressure of starting
opening 10.1 ± 0.7 bars
(146 ± 10 psi). B
MID0457A
197
Main data for checking the overpressure valve
spring
1. Load of 334 ± 22 N (75.1 ± 5 lbf.)

2. Load of 526 ± 24 N (118.4 ± 5.4 lbf.). 1
2
.
MID0458A
198
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.
MID0459A
199
6- 71020EN - 08 - 2003
Main data for checking the oil pressure control

valve spring
1
F3A
2
1. Load N 194.5 ± 5 (43.8 ± 1.1 lbf.)
2. Load N 450.5 ± 20 (101.4 ± 4.5 lbf.)
A mm 68.1 (15.3 lbf.)
B mm 56 (12.6 lbf.)
C mm 40 (9.0 lbf.)
MID0460A
200
Bypass valve
The valve quickly opens at a pressure of:
-- 3 bars (43.5 psi)
MID0461A
201
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).
MID0462A
202
6- 71020EN - 08 - 2003
Heat exchanger
SECT. A-A
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: 9

SECT. B-B
MID0463A
203
A B
A
B
MID0464A
D A B
204
6- 71020EN - 08 - 2003
Oil filter
High--filtration oil filter.
CAUTION
Always replace the ring seals every time after
removing 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

contact with the bases.
-- Tighten the filter to a torque of 35--40 N⋅m

(25 -- 29 ft. lbs.).
MID0465A
205
6- 71020EN - 08 - 2003
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
”AKCELA Premium Anti--Freeze” fluid (50% in
volume) that cannot freeze down to:
oC --8 --15 --25 --35

(oF) (17.6) (5) (--13) (--31)
% in volume of
”AKCELA
20 30 40 50
Premium
Anti--Freeze”
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 centrifugal vane pump. The

pump bearing forms a single piece with the impeller
shaft, the drive pulley is keyed onto this shaft.
MID0466A
206
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 TAN-
K
FROM TO THE-
THE BYPASS
ENGINE
MID0467A
207
6- 71020EN - 08 - 2003
Water leaving the thermostat
TO THE
RADIATOR
TO THE
EXPANSION
TANK
TO THE
BYPASS
FROM
THE
ENGINE
MID0468A
208
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 MID0469A
D. Fuel return from the pump--injectors
E. Pressure relief valve 209
Opening pressure: 5--8 bars (72.5--116 psi)
Section of the fuel pump
1. Oil or fuel leakage gauge
MID0470A
1
210
6- 71020EN - 08 - 2003
Pump injector
The pump--injector is composed of a pumping el-

ement, nozzle and solenoid valve.
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
delivery pressure. Its return stroke is activated by a
spring. 1
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 be-
tween errors of an electrical origin from those of a
mechanical/hydraulic origin.
It indicates broken pump--injectors. MID0471A
It is therefore necessary to interpret all the control
unit’s error messages correctly. 211
Any defects in the injectors require them to be re- 1. Diesel/oil ring seal – 2. Diesel/diesel ring seal
placed as no repairs are permitted. 3. Diesel/exhaust gas ring seal.
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.]).
6- 71020EN - 08 - 2003
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
0 411 700 002
XXXXXX XXXX X
off the fuel contained in the pipes in the cylinder 868 USA /
head by unscrewing the delivery and return
fittings on the cylinder head.
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
MID0472A
injector (Fig. 212) to reprogram the control unit.
212
CAUTION
If the electronic diagnosis instrument is not
available, it is exceptionally possible to replace
an injector without control unit identification.
CAUTION
When checking the rocker arm clearance, you
need to check the pump--injector pre--load.
6- 71020EN - 08 - 2003
REPLACING THE VALVE GUIDES F3A
CAUTION
gloves and shoes.
The valve guides are removed with drift 380000365.
Assembly is performed with drift 380000365

equipped with part 380000136.
CAUTION
Part 380000136 determine the exact position of
assembly of the valve guides in the cylinder MID0473A
head. If they are not available, it is necessary to 213

drive the valve guides into the cylinder head so
they protrude from it by:
-- 31.3 – 31.7 mm (1.232 -- 1.248″″) (Fig. 213).
After driving in the valve guides, rebore their hole with

the reamer 380000368.
* Dimension to be obtained after driving in the valve

guides.
6- 71020EN - 08 - 2003
INJECTOR CASE -- REPLACEMENT
CAUTION
gloves and shoes. A
To replace the injector case, 2, proceed as follows:
-- Thread the case, 2, with tool 380000159, 1.

1
The steps described in Figs. 214, 215, 216, 217
must be performed by securing the tools with bracket
A to the cylinder head.
MID0474A
214
-- Screw the extractor 380000165, 2, into the case,
3. Screw down the nut, 1, and extract the case
from the cylinder head.
1
MID0475A
215
6- 71020EN - 08 - 2003
-- With tool 380000370, 2, remove any residues, 1,

left in the groove of the cylinder head.
MID0476A
216
-- Lubricate the ring seals, 3, and fit them on the
case, 4 with tool, 2, 380000157 secured to the 1
cylinder head with bracket A, drive in the new
case, screw down the screw, 1, pressing the
2
bottom of the case.
4
MID0477A
217
Rebore the hole in the case, 3, with the reamer
380000164, 1.
3
MID0478A
218
6- 71020EN - 08 - 2003
Rebore the seat of the injector in the case, 3, with the

milling cutter 380000164, 1 and 2, equipped with
guide bushing 380000162.
MID0479A
219
Checking injector protrusion
Check injector protrusion, 2, with a dial gauge, 1. The

protrusion needs to be 1.14 – 1.4 mm (0.045 --
0.055″). 1
MID0480A
220
6- 71020EN - 08 - 2003
CRANCKSHAFT FRONT COVER SEAL --

REPLACEMENT
Removal--Refitting
CAUTION
gloves and shoes.
Drain off the coolant from the engine cooling system.

Disconnect the pipes from the thermostat box. 7
Disconnect the engine cooling fan.
1
Using a suitable tool, 6, turn in the direction of the
arrow on the tightener, 5, and remove the belt, 4. 2
3 5
arrow on the tightener, 2, and remove the belt, 1.
4 6
Take out the fixing screws and remove the damper
flywheel, 7, and the pulley beneath.
MID0481A
221
With the extractor, 2, 380000120, applied as shown
in the figure, extract the seal, 4. Unscrew the
screws, 3, and take off the cover, 1. 1
4
Disconnect all the electrical connections and
sensors. 2
MID0482A
222
Key the ring seal, 1, onto the crankshaft and onto this
apply tool, 2, 380000126.
Screw the nut, 3, down to mount the ring seal, 1, 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.
MID0483A
223
6- 71020EN - 08 - 2003
ADJUSTING CLEARANCE OF ROCKER

ARMS TO VALVES AND PRE--LOAD OF
PUMP INJECTOR ROCKER ARMS
CAUTION
gloves and shoes.
Adjusting the clearance between the rocker arms and

the intake and exhaust valve crosspieces and adjust-
ing 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 crosspieces
-- 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 1

the adjustment screw. 4
2
-- Check that the blade of the feeler gauge, 3, can 5
slide with a slight amount of friction. 3
-- Lock the nut, 1, holding the adjustment screw still.

6
MID0484A
224
6- 71020EN - 08 - 2003
Pre--loading pump injector rocker arms

the rocker arm adjustment screw, 5, pump
injector rocker arm screw, 6.
-- With an appropriate wrench, 4, screw the

adjustment screw to take the pumping element to
the end of its travel.
1 4
-- Using a torque wrench, tighten the adjustment 2
screw to a torque of 5 N⋅m (0.5 kgm [44 in lbs.]). 5
3
-- Unscrew the adjustment screw by 1/2 – 3/4 of a
turn. 6
-- Tighten the lock nut. MID0485A
225
Ignition sequence: 1--4--2--6--3--5
Start and Balance Adjust Adjust

clockwise valves of clearance pre--load
rotation cylinder of valves of injectors
no. of cylinder of cylinder
no. no.
1 and 6 at T.D.C. 6 1 5
120° 3 4 1
120° 5 2 4
120° 1 6 2
120° 4 3 6
120° 2 5 3
CAUTION
To make the above--mentioned adjustments
correctly, you must follow the sequence given in
the table, checking correct positioning at each
phase of rotation with pin 380000150 to be
inserted in the 11th hole of each of the three
sectors of 18 holes each.
6- 71020EN - 08 - 2003
PUMP INJECTOR. REMOVAL --

REFITTING
Removal
CAUTION
gloves and shoes.
From underneath the vehicle, take the inspection 1

cover off the timing system gearbox.
2 6
Fit the flywheel rotation tool on the gearbox, 2
380000137, 7, and spacer 380000138, 6.
7
CAUTION 3
The arrow shows in which direction the engine
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 T.D.C. in the phase of 5
combustion.
one reference mark, 4, after the hole with two 4
reference marks, 5, on the engine flywheel, 1, can
be seen through the inspection window, 3.
MID0486A
226
The exact position of the piston of cylinder no. 1 at the
conditions, the tool 380000150, 1, enters the hole, 3,
in the engine flywheel, 4, through the seat, 2, of the
If this is not the case, turn the engine flywheel, 4, ap-
propriately.
Remove the tool 380000150, 1.
MID0487A
227
6- 71020EN - 08 - 2003
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.
Unscrew the rocker arm shaft fixing screws, 1.

MID0488A
228
With tool 380000128, 2, constrain the sliding blocks,
3, to the rocker arms, 1.
MID0489A
229
With the tool, 1 380000148, applied as in the Fig.,
remove the rocker arm shaft assembly. 1
MID0490A
230
Remove the crosspieces 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.
MID0491A
231
6- 71020EN - 08 - 2003
Refitting
Thoroughly clean the pump--injector seat and the

pump--injectors.
Fit the ring seals, 1, 2 and 3, onto the injectors.

1
MID0492A
232
Mount the injectors and, using a torque wrench, 2,
lock the screws fixing the injector brackets, 1, to the
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 3

crosspieces.
CAUTION 4
Position the crosspieces on the valve stem, all
with the largest hole on the same side.
1
MID0493A
233
CAUTION
Before reassembling the rocker arm shaft
assembly, make sure all the adjustment screws 1 5
are fully unscrewed.
Using tool 380000128, 3, constrain the sliding blocks,

4, to the rocker arms, 3.
2
Apply tool, 1, to the rocker arm shaft, 5 380000148,
and position it on the cylinder head.
4
3
MID0494A
234
6- 71020EN - 08 - 2003
Tighten the screws, 2, fixing the rocker arm shaft in

two stages:
Stage 1: tightening with a torque wrench, 1, to a

torque of 100 N⋅m (10 kgm [73 ft. lbs.]). 2
Stage 2: closing, with tool 380000304, 3, with an 1

angle of 60°.
3
MID0495A
235
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. 1
With a new gasket, tightening the fixing screws to the

required torque and in the tightening sequence given
on page 26.
2
3
MID0496A
236
BLEEDING THE FUEL SUPPLY SYSTEM
CAUTION 3
1
gloves and shoes.
Before starting the engine, bleed the fuel system as

follows:
MID0497A
237
6- 71020EN - 08 - 2003
For the bled fuel to run off into a container, fit tubes
to the bleed screws:
2
-- 1, (Fig. 237), on the pre--filter mount;
-- 2, (Fig. 238), situata sul supporto filtro;
-- 4, (Fig. 239), on the front of the cylinder head.
-- Operate the pump, 3, Fig. 237, on the pre--filter

mount until fuel flows out through the screw, 1,
without any bubbles of air in it. Tighten the screw, MID0498A
1.
238
-- Repeat these steps for screw, 2, Fig. 238.
-- Repeat these steps for screw, 4, Fig. 239.
CAUTION
Never let fuel foul the drive belts of the alternator,
water pump, etc.
MID0499A
239
WATER PUMP -- REMOVAL--REFITTING
CAUTION
gloves and shoes.

arrow on the tightener, 2, and remove the drive belt,
1.
Take out the fixing screws and remove the water

pump, 5. MID0500A
240
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,
fill the cooling system with the required type and
amount of coolant.
6- 71020EN - 08 - 2003
THERMOSTAT -- REMOVAL -- REFITTING
CAUTION
gloves and shoes.
Disconnect the coolant pipes from the thermostat

box, 4, (Fig. 241).
Take out the fixing screws and disconnect the ther-

mostat box, 4, (Fig. 241).
MID0501A
Replace the thermostat and fit the box back on by 241

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.
6- 71020EN - 08 - 2003
Chapter 3 -- IVECO Engine F3B -- General
Model IVECO Engine
CHX420 F3BE0684A*B001
CHX520 F3BE0684D*B001
CONTENTS
Engine description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cranckshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankcase gas ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Injector--pump control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Camshaft driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Auxiliary component control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Main components of the ms6.2 edc system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pump injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Filling phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Injection phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure reduction phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6- 71020EN - 08 - 2003
MS6.2 electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Control unit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel batching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flow--rate correction depending on water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flow--rate correction to avoid noises, fumes or overloads . . . . . . . . . . . . . . . . . . . . . . . 14
De--rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electronic injection spark advance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Speed regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cold start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hot start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Run Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
After Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cylinder Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Synchronisation search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Supercharging air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Supercharging pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flywheel sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Distribution sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pre -- After heating resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6- 71020EN - 08 - 2003
ENGINE DESCRIPTION
Due to their innovative contents, F3B engines, as

compared with “traditional” engines are more sturdy,
efficient, reliable and have a longer life. There are
qualities enabling better power and consumption
performance.
They not only comply with current laws concerning
gaseous and acoustic emissions, but they are
designed to comply with future more restrictive laws
without required substantial amendments.
ENGINE MAIN COMPONENTS
The cylinder unit consists of a crankcase and of an

engine block from where seven main bearings are
obtained. Thin wall castings assuring uniform
stresses and cooling are achieved by innovative
forming and core assembling methods.
Interchangeable and removable cylinder liners are

wet assembled onto crankcase.
Water tightness is achieved by three rubber rings MID1242A

fitted on the lower part of the cylinder liners.
242
Cylinder liner protrusions can be adjusted by means
of special shims supplied as spares.
The special technology used to finish the inside of the

cylinder liner, together with the liner structure and the
crankcase does not allow any warping and enables
an exceptionally low engine oil consumption.
Cylinder liner inside diameter is selected at the origin

into two classes of tolerance: class A, and class B.
Each cylinder liner is matched at the factory to a MID1243A

piston of the corresponding class.
243
Cylinder liner cooling is optimised by the coolant
circulating at different speeds.
A High speed cooling for the hotter areas
B Low speed cooling for the colder areas
MID1244A
244
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CRANCKSHAFT
The crankshaft is made of steel with integral

counterweights.
Main journals and crankpins are induction hardened.

B
It is supported by half bearings, the half bearings on B
the engine flywheel side have integral side shoulders.
Crank layout in this crankshaft achieves a

combustion order which is different from the typical MID1245A
one of the traditional 6--cylinder in--line IVECO

engines. 245
Combustion order of Cursor engines
1–4–2–6–3–5
Journals and half bearings are selected into 3 classes

of tolerance on thickness, with a difference of 1
hundredth of mm between one class and the other.
This enables to match half bearings with journals to

achieve a minimum and more even radial float, with
a consequent reduction in oil consumption and in
vibrations to improve life time.
A Front shank
B Timing control gear (rear side)
CRANKCASE GAS RING
Front and rear gas rings belong to the drawer

“Rotostat” type. D
They consist of a sheet (3) directly keyed on the

crankcase, of a seal lip (2) and of an outer body (1)
keyed onto the special seat of the front cover or onto
the engine flywheel housing.
The advantage of this type of gasket is to achieve

tightness at the sheet (at point D), which is not hence
influenced by crankshaft radial oscillations.
MID1246A
246
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CONNECTING RODS
They belong to the skew cut type, they are in pressed

steel and broached on the coupling surfaces between
the stem and the cap.
VIEW FROM “A”
Data referring to weight class, half--bearing seat
diameter selection class, and matching numbers for 1
rod and cap are marked on the connecting rod.
2. Letter showing class of weight. 2
3. Number showing class of selection for the half

bearing seat.
3
4. Connecting rod – cap coupling number.
A
MID1247A
247
PISTONS
Pistons are fitted with three elastic piston rings: the

first one is for sealing, with a trapezoidal cross
section; the second one is for sealing, chamfer cut;
the third one is a scraper ring.
They are made of aluminium alloy and shaped as an

ellipsoid; the high swirl combustion chamber is
achieved on the crown of the piston.
Piston crown cooling is obtained by running MID1248A

lubricating oil through the annular chamber achieved
by a casting inside the piston. 248
A new combustion chamber has been adopted to

reduce oil contamination on the engines. The new
piston moreover also enables to share loads better,
gives a longer life and reliability and a reduction of
maintenance operations.
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CYLINDER HEAD
The cylinder head is fitted with four valves per

cylinder to improve cylinder air filling and exhaust gas
disposal two intake valves and two exhaust valves
are directly driven by the camshaft.
CAMSHAFT
Camshaft turns on 7 integral supports (without a

removable cap) obtained from the cylinder heads and
provided with bushes. MID1249A
249
There are 3 control cams per cylinder.
INTAKE VALVE CONTROL
MID1250A
250
EXHAUST VALVE CONTROL
MID1251A
251
INJECTOR--PUMP CONTROL
MID1252A
252
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CAMSHAFT DRIVE
Camshaft is driven by a set of helical gears in

cascade, set in the rear part of the engine.
The upper intermediate gear (B) is mounted on an

adjustable support to assure a correct backlash with
gear (A) the layout of which is influenced by thickness
tolerances on head gasket.
For all the other ones, rotation centre is fixed and it is

set by mechanical machining. MID1253A
Camshaft gears are not marked by notches or figures 253

as for traditional engines because traditional timing
for all gears is not required, since only timing between
camshaft and crankshaft is required.
A Camshaft gear
B Upper intermediate gear
C Lower intermediate gear
D Crankshaft gear
E Oil pump gear
CAMSHAFT DRIVING
1. Adjustable small connecting rod
2. Intermediate gear
3. Fixing screws
4. Oil pump
MID1254A
254
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ENGINE FLYWHEEL
A centring dowel enables assembling the flywheel on

the crankshaft on a unique setting.
Besides its traditional functions (balancing mass,

support for the starting ring gear, and friction surface),
it operates also as a phonic wheel for the sensor
connected to the control unit.
To this purpose 54 holes have been drilled, divided

into 3 different sectors of 18 holes each.
Each of these sectors is matched to a couple of

crankpins (1 – 6, 2 – 5, 3 – 4). MID1255A
255
The electronics does not require any special marks
on the holes, however on some of them (A, B, C, D
figure to the right) there are notches to enable the
repair operator to perform certain adjustments and
timings.
The hole in each sector (A, B, C, in the right hand

figure) is marked by one notch, while only one hole of
the sectors (D, on the right hand figure) is marked by
two notches.
The flywheel angular position is “read” at each

instant, by the EDC control unit by means of the
induction sensor (1) while the holes marked by
notches must be made to coincide alternatively,
during mechanical adjustment and timing operations,
with the inspection hole (2) on the flywheel housing.
MID1256A
256
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AUXILIARY COMPONENT CONTROL
Two Poly--V belts transmit motion respectively to the

water pump, to the alternator, to the fan pulley and to
the air conditioner unit compressor.
Belt tension is automatically adjusted by belt

tighteners thanks to the gauged spring they contain.
Two fixed pulleys on the run of the larger belt enable

increasing belt contact surface on the pulley.
Belt assembly diagram for driving fan – water

pump – alternator and conditioner compressor
drive
1. Alternator pulley – 2. Belt – 3. Automatic belt

tightener – 4. Belt – 5. Conditioner compressor – 6.
Automatic belt tightener – 7. Fixed pulley – 8. Water MID1257A
pump pulley – 9. Fixed pulley – 10. Crankshaft pulley.

257
OIL SUMP
The oil sump is fixed in a new way to the crankcase,

i.e. it is suspended in an elastic way.
(Particular)
The edge of the sump (1) remains enclosed inside a

thick “C” shaped rubber seal (4) and the contents is
all supported by an aluminium component (3) fixed to
the crankcase by screws (2).
This solution enables avoiding noisiness and

provides a better tightness although it requires less MID1258A
screws than the traditional system.
258
Another advantage is that it is not necessary to
replace the seal at each disassembly.
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OIL FILTER
This is a new generation of filters enabling a very

accurate filtration since it can hold a larger quantity of
particles, with smaller dimensions as compared with
those held by traditional filters with paper filtering
elements.
External spiral winding
Filtering elements are tightly wound up around a
spiral so that each fold is strongly anchored to the
spiral as compared to the other ones. This means a
uniform use of the septum even under the heaviest
duty conditions such as it could be at cold starts with
high viscosity fluids and at flow peaks. This moreover
assures an even flow distribution throughout the
whole length of the filtering element, optimising
thereby load losses and life time in operation. MID1259A
Upstream support 259

To optimise flow distribution and filtering element
stiffness, this is provided with an exclusive support
consisting of a sturdy nylon net and of high resistance
synthetic material.
Filtering septum
It consists of inorganic inert fibres bonded by an
exclusively manufactured resin and by scalar
structured pores, and it is manufactured exclusively
in compliance with precise procedures and strict
quality controls.
Downstream support
A support to the filtering element and a sturdy nylon
net confer to the septum a further resistance, which
specially convenient during cold starts and in long
periods of use. Filter performance remain constant
and reliable throughout its working life and from
element to element, independently of changes in
operating conditions.
Structural parts
The O--rings the filtering element is provided with
assure a perfect tightness between themselves and
the container, eliminating any bypass risk and
keeping filter performance constant. The structure of
the filtering element is completed by a corrosion
resistant bottom plate and by a sturdy metal core.
The adoption of these high level filtering devices, so
far used only in industrial processes, enables:
-- reducing engine component wear in the course

of time;
-- keeping oil performance / characteristics and

increasing therefore time intervals between their
replacement.
6- 71020EN - 08 - 2003
FUEL SUPPLY
Engine fuel supply is obtained by an EDC MS6,2 type

electronic management high pressure system.
Injection pressure values reaches the 1500 bar.
EDC system can control flow rate through its control
unit, FLOW RATE and ADVANCE, enabling to
improve the different vehicle running conditions,
performance and consumption and drastically reduce
polluting emissions. It mainly consists of a
mechanical fuel supply pump (in cases of vehicles
where the engine is in a high position with respect to
the tank, it is helped by an electric pump), a fuel filter,
a fuel pre--filter with a support provided with a priming
pump, by six pump injectors, driven by the camshaft,
by an electronic unit managing fuel injection into
engine by processing signals sent by temperature
and pressure sensors in the engine as well as by the
position sensor of the pedal accelerator.
MAIN COMPONENTS OF THE MS6.2 EDC

SYSTEM
Pump injector
The pump injector consists of:
• pumping element (2);
• nozzle (3);
• solenoid valve (1)
The pumping element mechanically operated at each

cycle by a rocker arm, compresses the fuel contained
in the delivery chamber. The nozzle, built and
operating same as for traditional injectors, is opened
by the fuel under pressure and injects it finely sprayed
into the combustion chamber. A solenoid valve,
directly controlled by the electronic unit, sets the
delivery procedure in accordance with the control
signal. An injector casing houses the lower part of the
pump injector into the cylinder head.
MID1260A
260
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Operation
Filling phase
During the filling phase, the pumping element (2)

moves to its upper position.
The highest cam position is passed and the rocker

roller gets closer to the cam basic circle.
The fuel valve (1) is open and the fuel can flow into
the injector from the lower channel (4) of the cylinder
head.
The filling head continues until the pumping element

has reached its upper end – of – stroke position.
1. Fuel valve – 2. Pumping element. 3. Fuel discharge

– 4. Filling and flowing back channel.
MID1261A
261
Injection phase
The injection phase starts when, during the pumping

element descending phase, the solenoid valve is
energised and the fuel valve (1) closes. Delivery start
time, properly processed by the electronic control
unit, depends on engine operating conditions.
Through the rocker, the cam continues to activate the
pumping element (2) and the injection phase
continues as long as the fuel valve is closed (1).
1. Fuel valve – 2. Pumping element – 3. Fuel

discharge – 4. Fuel and flowing back channel.
MID1262A
262
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Pressure reduction phase
Injection stops when the fuel valve (1) opens, during

the pumping element descending phase, following
the solenoid valve de--energising.
The fuel flows back, through the open valve (1), the
injector holes and the channel (4), into the cylinder
head.
The solenoid valve energising period, properly

processed by the electronic control unit, is the
injection duration (capacity) and depends on the
engine operating conditions.
1. Fuel valve – 2. Pumping element – 3. Fuel

discharge – 4. Filling and flowing back channel.
MS6.2 ELECTRONIC CONTROL UNIT MID1263A
263
The electronic control unit belongs to the “flash
e.p.r.o.m.” type, i.e. it can be externally programmed
again without operating on the hardware.
In order to reduce the number of connections, length

of connection cables with injectors, and hence to
reduce transmitted signal noises, the electronic
control unit is assembled directly on the engine with
a heat exchanger to cool it, using elastic small blocks
to damp the vibrations transmitted by the engine.
It is connected to the wiring harness by means of two

35--pole connectors:
connector “A” for components on engine
connector “B” for components in the cab
Internally it has an environment pressure sensor
used to further improve the injection system
management.
The electronic control unit is provided with a very
advanced self--diagnosis system able to
acknowledge and store, depending on environment
conditions, any defect, even if intermittent, taking
place to system during vehicle operation, thus
assuring a more correct and reliable repair operation.
Besides managing system operations described in
the relevant chapter, the electronic control unit is
interfaced with other on board electronic systems of
vehicle edges.
6- 71020EN - 08 - 2003
CONTROL UNIT OPERATION Flow--rate correction depending on water

temperature
The MS6.2 electronic unit manages the following
main functions: When cold, the engine meets higher resistances to its
Fuel injection operation: mechanical frictions are high, oil is still very
Auxiliary functions (cruise control, speed limiter, viscous, the various clearances have not yet been
power takeoff, etc) optimised.
Self--diagnosis Moreover, the injected fuel tends to condense on still
Recovery cold metallic surfaces.
With a cold engine, fuel batching is therefore greater
than with hot engine.
It further allows:
Interfacing with other on--board electronic systems
Programming EOL and Service Flow--rate correction to avoid noises, fumes or
Diagnosis. overloads
Fuel batching The behaviours that could make the interested

inconveniences occur are known.
Fuel batching is computed depending on:
The designer therefore has suitable instructions
-- accelerator pedal position inserted into the unit in order to avoid them.
-- engine revolutions
De--rating
-- amount of inserted air.
In case of engine overheating, the injection is
The result can be corrected as function: modified, by decreasing the flow--rate differently,
proportionally to the temperature reached by the
-- of water temperature cooling liquid.
or to avoid: Electronic injection spark advance check
-- noises The spark advance (delivery start moment,

expressed in degrees) can be different from an
-- fumes injection to the following one, even in a different way
-- overloads from one cylinder to another, and is computed,
similarly to the flow--rate, as function of engine load
-- overheating (accelerator position, engine revolutions and inserted
air).
Delivery can be modified in case of:
-- intervention of external devices The spark advance is adequately corrected
-- serious inconveniences implying a load reduction -- in acceleration phases

or engine stop.
The unit, after having determined the mass of -- depending on water temperature
inserted air by measuring its volume and
temperature, computes the corresponding fuel mass and in order to obtain:
to be injected into the affected cylinder (mg per
delivery) taking also into account the fuel -- reduction of emissions, noises and overloads
temperature.
The thereby computed fuel mass is first converted -- better vehicle accelerations
into volume (mm# per delivery) and then into crank
degrees, that is into injection length.
Upon start--up a very high spark advance is set,
depending on water temperature.
The delivery start moment feed--back is supplied by
the impedance variation of the injector solenoid
valve.
6- 71020EN - 08 - 2003
Speed regulator Hot start--up
The electronic speed regulator has both regulators If reference temperatures all exceed 10 °C, upon
characteristics: key--contact insertion the warning light is on for about
2 sec. for a brief test, then it turns off. Now it is
-- minimum and maximum possible to start the engine.
-- all speeds Run Up
It remains stable in ranges where traditional When inserting the key--contact, the units takes care
mechanical regulators become inaccurate. of transferring into the main memory all stored
information during the previous engine stop (see:
After run), and performs a system diagnosis.
Engine start--up
After Run
In the first engine dragging revolutions,
synchronisation of phase and cylinder 1
acknowledgement signals occurs (flywheel sensor Upon every engine turning--off through a key, the unit
and distribution shaft sensor). remains still supplied for some seconds by the main
Upon start--up the accelerator pedal signal is ignored. relay.
The start--up flow--rate is set only depending on water
temperature, through a suitable map. This allows the microprocessor memory to transfer
When the unit measures such a number of some data from main memory (of the volatile type) to
revolutions and a flywheel acceleration as to be able a non--volatile, erasable and rewritable memory
to consider the engine as started--up and not dragged (EEPROM), in order to make them available for the
any more by the starter, it enables again the following start--up (see: Run up).
accelerator pedal.
These data essentially comprise:
Cold start--up
-- various settings (engine minimum, etc.)
Should even only one of the three temperature
sensors (water, air or fuel) measure a temperature -- calibrations of some components
that is less than 10 °C, the pre--post heating is
activated.
-- failure memory.
Upon key--contact insertion, the pre--heating warning

The process goes on for some seconds, typically
light is turned on and it remains on for a period that
from 2 to 7 (depending on the amount of data to be
changes depending on the temperature (while the
saved), and after that the ECU sends a command to
suction manifold input resistance heats the air), then
the main relay and makes it disconnect from the
it blinks. battery.
Now it is possible to start the engine.

CAUTION
It is very important that this procedure is not stopped,
With running engine, the warning light blinks, while for example by turning off the engine from the
the resistance continues to be supplied for a certain battery--disconnecting device, or by disconnecting
(variable) time, performing the post--heating. the battery--disconnecting device before at least 10
seconds have elapsed from engine turning--off.
If with the blinking warning light the engine is not If this happens, the system functionality remains
started up within 20 ÷ 25 seconds (carelessness ensured, till the fifth incorrect turning--off (also not
time), the operation is cancelled in order not to consecutive), and after that a failure is stored in the
uselessly discharge the batteries. failure memory, and at the next start--up the engine
runs with degraded performance while the EDC
The pre--heating curve is variable also depending on warning light remains turned on.
battery voltage. Repeated procedure stops can as a matter of fact
lead to damaging the control unit.
6- 71020EN - 08 - 2003
Cylinder Balancing Synchronisation search
The individual cylinder balancing helps increasing If the camshaft sensor signal is missing, the unit
comfort and driveability. manages anyway to recognise the cylinders on which
fuel must be injected.
This function allows an individual and customised
check of fuel flow--rate and delivery start for every If this occurs then the engine is already running, the
cylinder, even in a different way from one cylinder to combustion succession is thereby acquired, so that
the other, to compensate for hydraulic injector the unit goes on with the sequence on which it is
tolerances. already synchronised.
The flowing (flow--rate characteristic) differences If this occurs when the engine is stopped, the unit
among the various injectors cannot be directly energises a single solenoid valve. Within 2 drive shaft
evaluated by the unit, but the provided bar code revolutions maximum, an injection will occur in that
reading operation for every injector, upon assembly, cylinder, so that the unit must do nothing more than
through Modus, takes care of providing such synchronising itself on the combustion order and start
information. the engine up.
ENGINE COOLANT TEMPERATURE

SENSOR
This is an N.T.C. type sensor and it is located on the

output water manifold from the left side head of the
engine.
It detects coolant temperature values for the different

engine running logic with a hot or a cold engine
identifying the requirement to enrich injection with a
cold engine or to reduce the quantity of fuel with a hot
engine. MID1264A
264
FUEL TEMPERATURE SENSOR
This is an N.T.C. type sensor and it is located on the

fuel filter on the left side of the engine.
It detects fuel temperature values enabling the

electronic control unit to set the fuel density and
volume thus correcting delivery.
MID1265A
265
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SUPERCHARGING AIR TEMPERATURE

SENSOR
This is an N.T.C. type sensor and it is located at the

entrance of the intake manifold downstream the
intercooler, on the right side of the engine.
Together with the supercharging pressure sensor it

provides the electronic control unit with the
necessary parameters to set the exact value of air
flow rate.
MID1266A
266
SUPERCHARGING PRESSURE SENSOR
This is a strainmeter pressure transducer and it is

located at the entrance of the intake manifold
downstream the intercooler on the right side of the
engine.
It detects pressure value of the supercharging air

entering into the intake manifold.
This value together with that of the air temperature

sensor, enables the electronic control unit to set with MID1267A
precision the quantity of air entering the cylinders so
as to pilot injectors adjusting fuel delivery, limiting 267
harmful issues, improving consumption and
performance. Internally the sensor is provided with a
temperature correction electronic circuit to optimise
pressure detection depending on intake air
temperature.
FLYWHEEL SENSOR
This is an inductive type sensor and it is located on

the flywheel.
It issues signals obtained from magnetic flow lines

which are closed through the holes in the flywheel
itself. Number of holes is 54 (three sectors of 18 holes
each).
The electronic control unit uses this signal to detect

the different engine rpm and to drive the electronic
revolution counter.
MID1268A
Should this signal fail the revolution counter will not

operate. 268
This sensor air gap IS NOT ADJUSTABLE.
6- 71020EN - 08 - 2003
DISTRIBUTION SENSOR
This is an inductive type sensor and it is located on

the camshaft. It issues signals obtained from
magnetic flow lines which close through the teeth of
a phonic wheel assembled on the camshaft itself.
Number of teeth is 6 plus one for the phase. The
signal issued by this sensor is used by the electronic
control unit as an injection phase signal. Although it
electrically equal to the rpm sensor (assembled on
the flywheel), IT IS NOT interchangeable with the
latter since it has a shorter cable and a larger
diameter projection. This sensor air gap IS NOT
ADJUSTABLE.
MID1269A
269
PRE -- AFTER HEATING RESISTANCE
The resistance is ∼ 0.7 Ohm.
When a key switch is entered, if only one of the

water--temperature, air, fuel sensors -- records a
value lower than 10 °C, the electronic control unit
actuates the pre / post heating and turns on the pilot
lamp on the dashboard for a length of time depending
on temperature.
After this time the pilot lamp starts blinking thus

informing the driver that at this point the engine can
be started up. MID1270A
When the engine is running the pilot light is turned off 270
while the resistance continues to be powered for a
certain time, varying, to perform post heating.
If the engine is not started within 20/25 seconds with

the blinking pilot lamp (oversight time) the operation
is cancelled to avoid uselessly discharging the
battery.
Is however reference temperatures exceed 10 °C,

when the key is entered the pilot lamp is turned on for
about 2 seconds to perform the test and it is then
turned off showing that the engine can be started up.
6- 71020EN - 08 - 2003
Chapter 4 -- IVECO Engine F3B
Model IVECO Engine
CHX420 F3BE0684A*B001
CHX520 F3BE0684D*B001
CONTENTS
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine -- Disassembly – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pistons and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil pump and intermediate timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Engine flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Injectors pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Crankcase and cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Crankshaft and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6- 71020EN - 08 - 2003

Main journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Crankpins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Selecting small end bearings (pins with nominal diameter) . . . . . . . . . . . . . . . . . . . . . . 67
Selection of main half-bearings (rectified pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Selecting the big end bearing shells (pins with nominal diameter) . . . . . . . . . . . . . . . . 73
Selection of connecting rod half-bearings (rectified pins) . . . . . . . . . . . . . . . . . . . . . . . . 75
Checking main journal assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Remove the sub--crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Checking crankshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Piston -- Connecting rod assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Valve springs, Rocker arm shaft and rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Valve guides -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Clearance of valves to rocker arms and pre--load of pump injector rocker arms . . . . . . . 111
Pump injector -- Removal, Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Water pump -- Removal, Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Thermostat -- Removal, Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6- 71020EN - 08 - 2003
GENERAL SPECIFICATION
Engine, technical type: F3B
-- Mod. CHX420 -- type F3B E0684A*B001 . . . . . . . . . . . . . . . . . . . . . . . . . . see data pages 3--5
-- Mod. CHX520 -- type F3B E0684E*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. CHX420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
-- Mod. CHX520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Piston stroke
-- Mod. CHX420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 mm
-- Mod. CHX520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 mm
Total displacement
-- Mod. CHX420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12880 cm3
-- Mod. CHX520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12880 cm3
Compression ratio mod. CHX420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5 ± 0.8
Compression ratio mod. CHX520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5 ± 0.8
Maximum power:
-- Mod. CHX420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 kW (428 HP)
-- Mod. CHX520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 kW (481 HP)
Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
Maximum power speed for Mod. CHX420 . . . . . . . . . . . . 1340 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel
6- 71020EN - 08 - 2003
Engine, technical type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3B
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 mm
Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12880 cm3
Compression ratio mod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5 ± 0.8
Maximum power for:
-- Mod. CHX420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 kW (428 HP)
-- Mod. CHX520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 kW (481 HP)
Maximum power speed for Mod.: . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(cont.)
6- 71020EN - 08 - 2003
(cont.)
GENERAL SPECIFICATIONS F3B
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with gear pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from crankshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . 1:1.633
Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh filter on oil intake and high--filtration

cartridge on delivery line
Oil filter quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Normal oil pressure with engine warm (100°C ± 5°C) and at

top speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 bar (5 kg/cm2)
Normal oil pressure with engine warm (100°C ± 5°C) and at

idling speed of 1300 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . 4 bar (4 kg/cm2)
Minimum permissible pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 bar
Adjustment valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in the oil pump body
Valve initial opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 bar (5 kg/cm2)
For further lubrication technical data . . . . . . . . . . . . . . . . . . . . . . See page 95
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . 2

start of opening = 80 oC
max = 95 oC
For further cooling system technical data . . . . . . . . . . . . . . . . . . See page 100
Rev counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . incorporated in control panel
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from gear on camshaft
(cont.)
6- 71020EN - 08 - 2003
(cont.)
GENERAL SPECIFICATIONS F3B
Timing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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:
-- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30o
Exhaust:
-- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11o
Valve--rocker arm clearance for timing check: . . . . . . . . . . . . . . --
Valve--rocker arm clearance (with engine cold):
-- intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 ± 0.05 mm
-- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 ± 0.05 mm
For further timing system technical data . . . . . . . . . . . . . . . . . . . See page 81
Fuel system
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
6- 71020EN - 08 - 2003
FUEL SYSTEM DATA
F3B
Turbocharger:
-- HOLSET type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HX60W -- 0988 O/AX 27Z
Injectors: pump electro--injectors governed by the
camshaft and controlled by the electronic
control unit
BOSCH type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PDE 31 12 Volt
Nozzle: BOSCH type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA 140 PV3
Number of nozzle holes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Nozzle hole diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.21
Pressure setting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 ± 6
Injection pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 bar
Injection sequence: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4--2--6--3--5
6- 71020EN - 08 - 2003
MAIN DATA
F3B
mm
1st seat* . . . 3.445 ÷ 3.475
Piston ring seat depth: 2nd seat . . . 3.05 ÷ 3.07
3rd seat . . . 5.02 ÷ 5.04

* measured on ∅ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1st ring* . . . 3.296 ÷ 3.364
Piston ring thickness: 2nd ring . . . 2.970 ÷ 2.990
3rd ring . . . . 4.970 ÷ 4.990

* measured on ∅ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1 ......... 0.081 ÷ 0.179
Piston ring – seat clearance 2 ......... 0.060 ÷ 0.100
3 ......... 0.030 ÷ 0.070

Piston ring end gap in cylinder liner:
1st ring . . . . . . . . 0.40 ÷ 0.55
2nd ring . . . . . . . . 0.65 ÷ 0.80
3rd ring . . . . . . . . 0.40 ÷ 0.75
Small end bushing seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . 59.000 ÷ 59.030
Small end bearing seat diameter:

-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.000 ÷ 94.030
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.000 ÷ 94.010
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.011 ÷ 94.020
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.021 ÷ 94.030
Small end bushing diameter:

-- external diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.085 ÷ 59.110
-- internal diameter (with bushings fitted) . . . . . . . . . . . . . . 54.019 ÷ 54.035
Small end bushing – seat interference . . . . . . . . . . . . . . . . . . . . . 0.055 ÷ 0.110
Piston pin – bushing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.019 ÷ 0.041
Connecting rod half bearing undersizes . . . . . . . . . . . . . . . . . . . . 0.127 ÷ 0.254 -- 0.508

Tolerance for parallelism between the two connecting rod
axes:
measured 125 mm from the connecting rod stem . . . . . . . . . . . 0.08
(cont.)
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3B
mm
Diameter of cylinder liner bores on block:

-- upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.000 ÷ 153.525
-- lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.000 ÷ 152.025
Cylinder liners – external diameter:

-- upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.461 ÷ 153.486
-- lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.890 ÷ 151.915
Cylinder liner interference – bores on block:

-- upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.014 ÷ 0.039
-- lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.085 ÷ 0.135
Cylinder liner external diameter oversizes . . . . . . . . . . . . . . . . . . --
Cylinder liners – internal diameter driven in and machined:

-- class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.000 ÷ 135.013
-- class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.011 ÷ 135.024
-- Cylinder liner protrusion from engine block under a load of
8,000 kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 ÷ 0.075
Pistons:
Standard piston diameter measured from skirt base: 20
-- class A* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.881 ÷ 134.893
-- class B** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.892 ÷ 124.894
Pin seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.010 ÷ 54.018
Piston assembly clearance – cylinder liners . . . . . . . . . . . . . . . . 0.107 ÷ 0.132
Piston diameter oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --
Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.994 ÷ 54.000
Piston pin – pin seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 ÷ 0.024

(cont.)
* Pistons supplied as spare parts.
** Class B pistons are assembled solely in production and are not supplied as spares.
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3B
mm
Main journal diameter:
-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.970 ÷ 100.000
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.970 ÷ 99.979
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.980 ÷ 99.989
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.990 ÷ 100.000
Connecting rod journal diameter:
-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.970 ÷ 99.000
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.970 ÷ 89.979
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.980 ÷ 89.989
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.990 ÷ 90.000
-- red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.110 ÷ 3.120
-- green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121 ÷ 3.130
-- yellow* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.131 ÷ 3.140
Standard connecting rod half bearing thickness:
-- red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.965 ÷ 1.975
-- green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.976 ÷ 1.985
-- yellow* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.986 ÷ 1.995
Main bearing diameter:
-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.300 ÷ 106.330
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.300 ÷ 106.309
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.310 ÷ 106.319
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.320 ÷ 106.330
Half bearing – main journal clearance . . . . . . . . . . . . . . . . . . . . . 0.060 ÷ 0.100
Connecting rod half bearing clearance . . . . . . . . . . . . . . . . . . . . . 0.050 ÷ 0.090
Main bearing undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.127 -- 0.254 -- 0.508
Main journal length per thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.95 ÷ 48.00
Main journal width per thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.94 ÷ 40.99
Thrust ring thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 ÷ 3.43
Crankshaft thrust clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 ÷ 0.30
Thrust ring oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 -- 0.508
Maximum tolerance for alignment of main journals
(total dial gauge reading) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  0.025
Maximum tolerance for alignment of connecting rod journals
in relation to main journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ÷ 0.025
Maximum ovality of main journals and the connecting rod
after grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010
Maximum taper of main journals and the connecting rod after
grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010
* Assembled solely in production and not supplied as a spare. (cont.)
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3B
mm
Diameter of valve guide bores in the cylinder head . . . . . . . . . . 15.980 ÷ 15.997

Valve guide external diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.015 ÷ 10.030
Valve guide internal diameter
(after fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.012 ÷ 16.025
Valve guide and bore interference in head . . . . . . . . . . . . . . . . . 0.015 ÷ 0.045
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.960 ÷ 9.975
Valve seat angle: intake . . . . . . . . . . . . . 60o 30’ ± 7’ 30”
exhaust . . . . . . . . . . . 45o 30’ ± 7’ 30”
Valve stem and relative guide assembly clearance . . . . . . . . . . 0.040 ÷ 0.070
Internal diameter of bore on head for valve seat:
intake . . . . . . . . . . . . . 49.185 ÷ 49.220
exhaust . . . . . . . . . . . 46.985 ÷ 47.020
Valve seat external diameter: intake . . . . . . . . . . . . 49.260 ÷ 49.275
exhaust . . . . . . . . . . . 47.060 ÷ 47.075
Valve seat angle in cylinder head:
intake . . . . . . . . . . . . 60° -- 30’
exhaust . . . . . . . . . . . 45° -- 30’
Valve depth in relation to cylinder

head surface: intake . . . . . . . . . . . . 0.54 ÷ 0.85
exhaust . . . . . . . . . . . 1.75 ÷ 2.05
Valve seat and bore fit on cylinder head
(interference) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 ÷ 0.090
Valve mushroom--head diameter:
intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.985 ÷ 47.015
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.985 ÷ 46.015
Maximum off--centring of the valve with the indicator resting in
the centre of the contact surface . . . . . . . . . . . . . . . . . . . . . . . . . 0.03
Valve spring height:
free spring height . . . . . . . . . 72.40

under a load of N – (kg)
575 ± 28 (58.67 ± 2.85) height . . . . . . . . . 58
1095 ± 54 (111.73 ± 5.5) height . . . . . . . . . 45
Injector protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.52 ÷ 1.34
(cont.)
6- 71020EN - 08 - 2003
MAIN DATA
(cont.)
F3B
mm
Camshaft bushing seat diameter in cylinder head . . . . . . . . . . . 88.000 ÷ 88.030
Camshaft support journal diameter . . . . . . . . . . . . . . . . . . . . . . . . 82.950 ÷ 82.968
Camshaft bushing external diameter . . . . . . . . . . . . . . . . . . . . . . 88.153 ÷ 88.183
Internal diameter of finished bushings in seats . . . . . . . . . . . . . . 83.018 ÷ 83.085
Bush and seat interference in block . . . . . . . . . . . . . . . . . . . . . . . 0.123 ÷ 0.183
Coupling between bushings and support journals

of the camshaft (assembly clearance) . . . . . . . . . . . . . . . . . . . . . 0.050 ÷ 0.135
Cam lift: intake . . . . . . . . . . . . . . . . . . 9.231

exhaust . . . . . . . . . . . . . . . . 9.5607
injector--pump . . . . . . . . . . . 11.216
Rocker arm support shaft diameter . . . . . . . . . . . . . . . . . . . . . . . 41.984 ÷ 42.000
Seat diameter for rocker arm support shaft bushings in rocker

arms:
-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.000 ÷ 45.016
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.000 ÷ 59.019
-- injectors--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.000 ÷ 46.016
Bushing external diameter for rocker arms:

-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.090 ÷ 45.130
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.100 ÷ 59.140
-- injectors--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.066 ÷ 46.091
Bushing internal diameter for rocker arms with bushing fitted:

-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.025 ÷ 42.041
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.030 ÷ 56.049
-- injectors--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.015 ÷ 42.071
Clearance between bushings and rocker arm support shaft:

-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 ÷ 0.057
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 ÷ 0.057
-- injectors--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 ÷ 0.087
Coupling between bushings and seats in rocker arms:

-- intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.074 ÷ 0.130
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.081 ÷ 0.140
-- injectors--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 ÷ 0.091
6- 71020EN - 08 - 2003
TORQUE SETTINGS
TORQUE
PART Thread
Nm kgm
Screws securing sub--crankcase to crankcase
(see figures 1--2--3--4--5) ♦ . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External screws First phase: pre--torque . . . . . . . . . . . . M 12x1.75 30 3
Internal screws Second phase: pre--torque . . . . . . . . . M 18x2 120 12
Internal screws Third phase: angle closed . . . . . . . . . . M 18x2 60°
Internal screws Fourth phase: angle closed . . . . . . . . . M 18x2 55°
External screws Fifth phase: angle closed . . . . . . . . . . M 12x1.75 60°
Piston cooling oil nozzle union . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12x15 35±2 3.5±0.2
Screws securing heat exchanger to crankcase
(see figure 9) ♦ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25
-- pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 1.15
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1.9
Screws securing spacer and oil sump (see fig. 11) ♦ . . . . . . . M 10x1.5
-- pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 3.8
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.5
Screws securing gearbox to crankcase . . . . . . . . . . . . . . . . . . . . M 12x1.75 63±7 6.3±0.7
Screw securing cylinder head (see figure 6) ♦ . . . . . . . . . . . . . M 18x2
First phase: pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 6
Second phase: pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 12
Third phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120°
Fourth stage: angle locking screws No. 4 – 5 – 12 – 20 -- 21 45°
Fifth stage: angle locking screws No. 1 -- 2 -- 3 -- 6 -- 7 --
8 -- 9 -- 10 -- 11 -- 14 -- 15 -- 16 -- 17 -- 18 --
19 -- 22 -- 23 -- 24 -- 25 -- 26 . . . . . . . . . . . . . . . . 65°
Screw securing rocker arm shaft ♦ . . . . . . . . . . . . . . . . . . . . . . . M 16x1.5
First phase: pre--torque . . . . . . . . . . . . . . . . . . . . . . . 100 10
Second phase: angle closed . . . . . . . . . . . . . . . . . . . . . 60°
Lock nut for rocker arm adjustment screw . . . . . . . . . . . . . . . . . M 10x1.25 39±5 3.9±0.5
Screw for injector fixing brackets ♦ . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 26 2.6
Screw securing thrust plates to the head . . . . . . . . . . . . . . . . . . M 8x1.25 19 1.9
Screw securing engine bracket to cylinder head . . . . . . . . . . . . M 18x2
Screw securing engine bracket to timing system gearbox . . . . M 16x2
(cont.)
6- 71020EN - 08 - 2003
TORQUE SETTINGS
(cont.)
TORQUE
PART Thread
Nm kgm
Screw securing camshaft gear ♦ . . . . . . . . . . . . . . . . . . . . . . . . M 14x2
First phase: pre--torque . . . . . . . . . . . . . . . . . . . . . . 60 6
Second phase: angle closed . . . . . . . . . . . . . . . . . . . . 60°
Screw securing phonic wheel to timing system gear . . . . . . . . M 6x1 8.5±1.5 0.8±0.1
Screws securing exhaust manifold • (see fig. 7) . . . . . . . . . . . M 10x1.5
-- pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5±7.5 3.2±0.7
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45±5 4.5±0.5
Screw securing connecting rod cap ♦ . . . . . . . . . . . . . . . . . . . . M 14x2
First phase: pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 6
Second phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
Screws securing engine flywheel ♦ . . . . . . . . . . . . . . . . . . . . . . M 18x1.5
First phase: pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 12
Second phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
Third phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Screws securing pulley to crankshaft ♦ . . . . . . . . . . . . . . . . . . . M 14x2
-- pre--torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 7
-- angle closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50°
Screws securing middle gear pins ♦ . . . . . . . . . . . . . . . . . . . . . M 12x1.75
First phase: pre--torque . . . . . . . . . . . . . . . . . . . . . . 30 3
Second phase: angle closed . . . . . . . . . . . . . . . . . . . . 90°
Screw securing connecting rod for transmission gear
adjustment ♦ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 25±2.5 2.5±0.2
Screw securing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
Screw securing oil pump suction hose and pipe to
crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
Fuel filter support fixing screw to cylinder head . . . . . . . . . . . . M 10x1.5 19±3 1.9±0.3
Screw securing crankshaft gasket cover . . . . . . . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
Screw securing control unit mount to crankcase . . . . . . . . . . . M 8x1.25 19±3 1.9±0.3
Screw securing fuel pump to flywheel cover box . . . . . . . . . . . M 8x1.25 19±3 1.9±0.3
Screw securing thermostat box to cylinder head . . . . . . . . . . . M 8x1.25 19±3 1.9±0.3
Screw securing rocker arm cover (see fig. 13) . . . . . . . . . . . . . M 6x1 8.5±1.5 0.8±0.1
Screws and nuts securing turbocharger • (see fig. 8) . . . . . . . M 12x1.75 74±8 7.4±0.8
(cont.)
6- 71020EN - 08 - 2003
TORQUE SETTINGS
(cont.)
TORQUE
PART Thread
Nm kgm
Screw securing water pump to crankcase . . . . . . . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
Screw securing spacer/pulley to fan . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 30±3 3±0.3
Screw securing automatic tightener to crankcase . . . . . . . . . . . M 10x1.5 50±5 5±0.5
Screw securing fixed tightener to crankcase . . . . . . . . . . . . . . . . M 12x1.75 105±5 10.5±0.5
Screw securing fan mount to crankcase . . . . . . . . . . . . . . . . . . . M 12x1.75 100±5 10±0.5
Screw securing starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12x1.75 74±8 7.4±0.8
Screw securing air heater to the cylinder head . . . . . . . . . . . . . . M 10x1.5 30±3 3±0.3
Screw securing air--conditioner compressor drive belt
automatic tightener to crankcase . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 26±2 2.6±0.2
Screw securing alternator bracket to crankcaseL = 35mm . . . M 10x1.5 30±3 3±0.3
L = 60mm . . . M 10x1.5 44±4 4.4±0.4
L = 30mm . . . M 8x1.25 24.5±2.5 2.4±0.2
Screw securing air--conditioner compressor mount . . . . . . . . . . M 8x1.25 24.5±2.5 2.5
Screw securing guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 24.5±2.5 2.5
Filter clogging sensor fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4--16 UNF 55±5 5.5
Pressure transmitter fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 5x0.8 8±2 0.8±0.2
Coolant/fuel temperature sensor fixing . . . . . . . . . . . . . . . . . . . . M 16x1.5 32.5±2.5 3.2±0.2
Temperature switch/transmitter fixing . . . . . . . . . . . . . . . . . . . . . M 16x1.5 23±2.5 2.3±0.2
Air temperature transmitter fixing . . . . . . . . . . . . . . . . . . . . . . . . . M 16x1.5 32.5±2.5 3.2±0.2
Pulse transmitter fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 6x1 8±2 0.8±0.2
Connections to injector--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 3x0.5 1.36±1.92 0.13±0.19
Screw securing electric cables . . . . . . . . . . . . . . . . . . . . . . . . . . . M 6x1 8±2 0.8±0.2
6- 71020EN - 08 - 2003
PLAN OF TIGHTENING SEQUENCE
Sub -- cranckcase
First phase A
-- 30 Nm
MID1271A
Second phase
-- 120 Nm
MID1272A
Third phase
-- 60°
MID1273A
Fourth phase
-- 55°
MID1274A
6- 71020EN - 08 - 2003
Fifth phase
external screw angle closed:
-- 60°
A = front side
A
MID1275A
Cylinder head
MID1276A
Exhaust manifold
8 1 4 5 8 1 2 5 8 1 4 5
6 3 2 7 6 3 4 7 6 3 2 7
MID1277A
Turbocharger
1 4
Sequence:
pre--torque 4--3--1--2
torque 1--4--2--3
MID1278A
3 2
8
6- 71020EN - 08 - 2003
Heat exchanger
2 3 4 5 6 7
1 8
19 9
18 11
17 16 15 14 13 12 10
MID1279A
Engine oil sump 12/28 13/29 1/30 14/31 15/32
11/27 16/17
First phase: from 1 to 16
Second phase: from 17 to 32
3/26 4/18
10/25 5/19
MID1280A
9/24 8/23 2/22 7/21 6/20
10
Rocker arm cover
MID1281A
11
6- 71020EN - 08 - 2003
TOOLS
CAUTION
The operations described in this section can only be
carried out with the ESSENTIAL tools indicated by an
(X).
To work safely and efficiently and obtain the best
results, it is also necessary to use the recommended
specific tools listed below and certain other tools,
which are to be made according to the drawings
included in this manual.
PART DESCRIPTION
380000112 Plate to disassemble and reassemble engine valves (use with 380000131)
380000113 Drift to reassemble valve guide (use with 380000367)
380000115 Plate for cylinder liner compression (use with 380000140--380000142)
380000116 Ring (135 mm) (use with 380000366)
380000120 Tool to remove crankshaft front gasket
380000121 Tool to remove crankshaft rear gasket
380000123 Extractor for injector sheath
380000126 Key for fitting crankshaft front gasket
380000127 Key for fitting crankshaft rear gasket
380000128 Tools (12+6) to retain rocker arm adjustment screw sliding blocks when
disassembling and reassembling the rocker arm shaft
380000130 Caps (6) protecting injector seats
380000131 Tool to disassemble and reassemble engine valves (use with specific plates)
380000132 Plate to disassemble and reassemble engine valves (used with 380000131)
380000137 Tool for engine flywheel rotation (use with 380000138)
380000138 Spacer (use with 380000137)
6- 71020EN - 08 - 2003
PART DESCRIPTION
380000140 Tool for compression to measure cylinder liner protrusion (use with 380000364
and specific plates)
380000142 Spacers (use with 380000140)
380000144 Tool to retain engine flywheel
380000146 Drift to disassemble and reassemble camshaft bushings
380000147 Bracket to disassemble and reassemble engine flywheel
380000148 Tool to assemble and install rocker arm shaft (use with 380000128)
380000150 Tool for engine T.D.C. positioning
380000151 Tool for phonic wheel timing on camshaft
380000155 Brackets fixing engine to rotary stand 380000361
380000157 Tool for upsetting injector sheath
380000158 Torque screwdriver for tightening stop nut of pump injector solenoid valve
connectors
380000159 Tool for threading injector sheaths to remove (use with 380000160)
380000160 Guide bushing (use with 380000159)
380000162 Guide bushing (use with 380000163 or 380000164)
380000163 Milling cutter to rebore injector seat (use with 380000162)
380000164 Reamer to rebore bottom of injector sheaths (use with 380000162)
380000169 Crankshaft front gasket cover centring ring
380000220 Clamp to insert piston in cylinder liner (60--125 mm)
380000221 Tool to remove and install piston rings
380000304 Pair of gauges for angular torque with 1/2” and 3/4” square connection
380000324 Pliers for piston ring disassembly and reassembly (105--160 mm)
380000360 Engine removal and installation tool
380000361 Revolving telescopic service stand (capacity 2000 daN, torque 375 daN/m)
6- 71020EN - 08 - 2003
PART DESCRIPTION
380000362 Crankshaft lifting tool
380000363 Tool to retain cylinder liners
380000364 Tool for measuring cylinder liner protrusion
380000366 Tool to remove cylinder liners (use with specific rings)
380000370 Tool to remove remains of injector sheath
380000549 Percussion extractor
6- 71020EN - 08 - 2003
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 -- Re--load
-- Connections to terminals not -- Clean, check and tighten

efficient terminals or replace them
-- Pre--heating resistance always -- Perform checks or replace

on
1.b Starter motor: -- Not efficient -- Check or replace
1.c Heater: -- Not efficient -- Check supply and earth
connection.
Replace.
-- Check heater relay perform

active diagnosis
1.d Main Relay -- Not efficient -- Check for fuse efficiency
-- Fuse -- Check remote switch by active

diagnosis
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
1.h 0.8 bar valve on fuel return -- Not efficient -- Check for its efficiency: if
blocked open, replace it
6- 71020EN - 08 - 2003
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
-- With losses -- Replace

2.f Air filter -- Clogged -- Check for filter clogging
warning device
-- Sleeves clogged
-- 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
6- 71020EN - 08 - 2003
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

couplings when hot)
-- Valve 0.8 bars on fuel return
from cylinder head:
a) Jammed open -- Replace
(low pressure)
b) Jammed shut
(high temperature) -- Replace
-- Bad fuel leakage

-- Check, repair
-- Supply pump broken (seized,
broken coupling, pressure -- Check pressure on filter inlet
adjustment valve, etc.) Replace
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
(constriction clogged filter) indicator.
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
3.h Engine running temperatures -- Not corresponding -- Check for cooling system
6- 71020EN - 08 - 2003
4 GREY--WHITE SMOKE FROM ENGINE
DEFECT CAUSE REMEDY

4.a Presence of water in cylinders -- Leakage from cylinder head -- Check for level of liquid in
gasket water circuit pressurisation
-- Leakage from injector casings -- Replace injector casings
-- Water entering from intake -- Check for tank cleaning

system
-- Replace gaskets
-- Water in Diesel fuel
-- Grind cylinder heads
5 BLUE SMOKE FROM ENGINE
DEFECT CAUSE REMEDY

5.a Presence of oil in cylinders -- Excessive oil consumption -- Replace turbocharger
-- Oil blow--by from turbocharger -- Overhaul cylinder head
-- Blow--by from valve guides -- Overhaul engine
-- Blow--by from piston snap rings
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
7 EXCESSIVE FUEL CONSUMPTION
DEFECT CAUSE REMEDY

7.a Air cleaner -- Clogged -- Replace
7.b Fuel tank piping -- Losses -- Check and replace
6- 71020EN - 08 - 2003
8 OIL PRESSURE INSUFFICIENT OR EXCESSIVE
DEFECT CAUSE REMEDY

8.a Pressure control valve -- Out of calibration -- Check – replace
8.b Oil pump, -- Worn out -- Replace
oil ducts and pipes
-- Clogged or broken -- Clean or replace
8.c Main bearings and/or big end -- Worn out -- Replace bearings and if
bearings necessary grind crankshaft
8.d Engine oil -- Oil viscosity not proper -- Replace engine oil with specific
oil
6- 71020EN - 08 - 2003
MID1282A
12
Engine longitudinal section
6- 71020EN - 08 - 2003
LUBRICATION CIRCUIT
Oil in fall
Oil in pressure
B -- to cylinders
C -- to cylinders
D -- to cylinders
MID1283A
13
Lubrication diagram
Oil in fall
Oil in pressure
6- 71020EN - 08 - 2003
MID1284A
14
Fuel supply system diagram

1. Temperature sensor – 2. Bleeder – 3. Secondary fuel filter – 4. Bypass valve (0.3--0.4 bars) – 5. Fuel
supply pump – 6. Integrated valve (3.5 bars) – 7. Pressure relief valve (5 bars) – 8. Fuel tank – 9. Priming
pump – 10. Primary fuel filter – 11. Check valve (opening 0.1 bars) – 12. Heater – 13. Electronic control unit
– 14. Fuel return fitting with incorporated valve (0.2 bars) – 15. Injectors--pump
6- 71020EN - 08 - 2003
ENGINE -- DISASSEMBLY – ASSEMBLY
CAUTION
gloves and shoes.
Protect the electric parts before any washing with

high--pressure jets.
Before fixing the engine on the turning stand

380000361, remove from the engine right hand side: 1
1. The engine electric cable by disconnecting it from

the processing unit and from all the
sensors/transmitters to which it is connected.
2. The fuel filter (1).
3. Disassemble the drive (2). 2
MID1285A
15
4. Use the proper tool (3) to operate in the direction
of the arrow on belt tightener (5) and remove the 1
compressor drive belt (1);
5. Disassemble compressor (2) including engine

support.
3
2
MID1286A
16
From engine left hand side
6. engine support (1)
MID1287A
17
6- 71020EN - 08 - 2003
7. disassemble oil pressure valve (1);
MID1288A
18
8. Fix engine to turning stand 380000361 by means
of brackets 380000155 (1, figure 19):
MID1289A
19
9. Use tool (1) 380000144 to block engine flywheel;
MID1290A
20
6- 71020EN - 08 - 2003
10. Remove the screws (3), disassemble the pulley

(2) and the damper flywheel (1).
MID1291A
21
11. Use a proper tool (1) to operate in the direction of
the arrow to remove the auxiliary drive control belt
(2)
MID1292A
22
Disassemble the following components:
12. Alternator (1)
13. fixed pulley (2)
14. automatic belt tightener (3)
15. crankshaft pulley (4)
16. water pump (6)
17. fixed pulley (7) MID1293A
18. air conditioner drive belt automatic tightener 23
6- 71020EN - 08 - 2003
19. Remove the screws (1) and disassemble the

thermostat unit (1) including the VGT control
solenoid valve (2).
MID1294A
24
20. Use puller 380000120 (2) applied as shown in

figure to remove seal gasket (1). Unscrew screws
(4) and remove cover (3)
MID1295A
25
21. oil delivery piping (1);
22. oil return piping (4);
23. turbocharger unit (2);
24. exhaust manifold (3).
MID1296A
26
25. Unscrew oil filters (1).
MID1297A
27
6- 71020EN - 08 - 2003
26. Unscrew screws (1) and disassemble heat

exchanger (4).
27. Unscrew screws (2) and disassemble water

piping (3).
MID1298A
28
28. Fuel filter support (1);
29. fuel pump (2) and relevant piping;
30. starter motor (3);
31. intake manifold (4) comprising engine preheating

resistance;
32. engine control unit (6).

MID1299A
29
33. Disassemble rocker cover (1) and timing gear
cover (2) fitted with blow--by filter. 1
MID1300A
30
34. Unscrew screws (2) and disassemble gear (1)
comprising phonic wheel.
MID1301A
31
6- 71020EN - 08 - 2003
35. Unscrew screws (1); screw one of them into a

reaction hole to remove shoulder plate (2),
remove plate gasket.
MID1302A
32
36. Unscrew screws (1) and disassemble
transmission gear (2).
2
MID1303A
33
37. Use tool 380000144 (1) to block engine flywheel.
38. Unscrew fixing screws (2) and disassemble

engine flywheel.
1
2
3
MID1304A
34
39. Use puller 380000121 (2) applied as shown in
figure, to disassemble seal ring (1) from timing
chest (3).
1
2
MID1305A
35
6- 71020EN - 08 - 2003
40. With an appropriate wrench, unscrew the screw

(2) and remove the transmission gear (1).
2
1
MID1306A
36
41. Unscrew screws (3) and disassemble oil pump
(4).
42. Unscrew screws (1) and disassemble

transmission gear (2).
43. Unscrew screws (5) and disassemble link rod (6).
MID1307A
37
44. Unhook the springs (3) from the levers (2).
45. Unscrew the rocker arm shaft fixing screws (1).
MID1308A
38
46. With tool 380000128 (2) constrain the sliding
blocks (3) to the rocker arms (1).
MID1309A
39
6- 71020EN - 08 - 2003
47. Use tool 380000148 (1) applied as shown in

figure to disassemble rocker arm shaft assembly. 1
MID1310A
40
48. Disassemble valve cross beam.
49. Unscrew screws and remove electric

connections (1) from solenoid valves.
50. Unscrew screws (3) fixing brackets (4) retaining

pump injectors (2).
51. Disassemble pump injectors (2).
52. Unscrew screws fixing injector cable retaining

clamp – pump to cylinder head, and remove
cabling from the front side. MID1311A
41
53. Assemble plugs (1) 380000130 instead of
injectors.
54. Disassemble camshaft (3).
55. Remove screws (2) fixing cylinder head. 2 1
MID1312A
42
56. Use special ropes and hoist to detach cylinder
head (1).
57. Remove gasket (2).

1
2
MID1313A
43
6- 71020EN - 08 - 2003
58. Unscrew screws (2) and remove engine oil sump

(1) comprising spacer (3) and seal gasket.
1
2
3
MID1314A
44
59. Unscrew screws and remove suction rose (1)
MID1315A
45
60. Turn crankcase (1) to a vertical position.
MID1316A
46
61. Unscrew the screws (2) fixing the connecting rod
cap (3) and remove it.
2
62. From the top, take out the piston connecting rod
assembly (1). Repeat the same operations for the 1
other pistons.
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 3
the same position found in disassembly.
MID1317A
47
6- 71020EN - 08 - 2003
63. 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 2
bottom main bearing shells since, if they are to be
reused, they will need to be fitted in the same position
found in disassembly. 3
MID1318A
48
64. Using tool 380000362 (1), remove the crankshaft
(2).
MID1319A
49
65. Take out the main bearing shells (1).
Unscrew the screws and remove the oil nozzles
(2).
66. Remove the cylinder liners as described in the

relevant paragraph on page 57.
1
MID1320A
50
GENERAL NOTES
-- After taking down the engine, clean the parts

carefully.
-- The following pages illustrate the assembly

operations that must be read extremely carefully
to be able to assemble the parts correctly.
-- The torques of the parts and the instructions that

must be followed meticulously are given on pages
12 -- 13 -- 14 -- 15 -- 16 -- 17.
6- 71020EN - 08 - 2003
IN ADDITION IT IS NECESSARY TO BEAR IN

MIND THAT:
-- When totally or partially stripping the engine, all

the gaskets need to be replaced.
-- Before inserting the rotary parts and gaskets in

the coupling, it is necessary to lubricate the parts
with engine oil.
-- When fitting the oil filter, lubricate the seal with

engine oil.
CAUTION
The following pages give the instructions for the main
checks and measurements to make to determine
whether the parts are sound enough to be reused
after reassembly.
CAUTION
between parts and use the most suitable tools to align
holes.
Wear the required safety clothing – safety goggles,
gloves and shoes.
6- 71020EN - 08 - 2003
CRANKSHAFT
Fitting the crankshaft bearings
CAUTION
On finding there is no need to replace the crankshaft
bearings, it is necessary to fit them back on in the
disassembly.
If you need to replace them, select the crankshaft
pages 61 -- 62 -- 63 -- 64.
If dismantled, refit the oil nozzles (2), tightening the

union (3) to the required torque.
2
Put the half bearings (1) on the crankshaft mounts of 1
3
the crankcase.
The crankshaft bearings are supplied as spare parts

with an undersized internal diameter of 0.127 – 0.254
– 0.508 mm.
CAUTION
Do not make any adjustments to the bearings. MID1321A
51
Using a hoist and hook 380000362 (1) mount the
crankshaft (2).
MID1322A
52
6- 71020EN - 08 - 2003
Put the half bearings (1) on the main bearings in the

sub--crankcase (2).
1
MID1323A
53
Apply LOCTITE 5699 sealant on the crankcase with
an appropriate tool (1) as shown in the figure.
1
The box contains a diagram for applying LOCTITE
5699 sealant.
CAUTION
Fit the sub--crankcase within 10 min. of applying the
sealant.
MID1324A
54
Fit the sub--crankcase (1) using a hoist and
appropriate hooks.
1
2
MID1325A
55
CAUTION
The sub--crankcase fixing screws (1) must, before 2 3 4
Tighten the screws (1) using the torque wrench (3)

according to the tightening torque values and stages
shown in the following figures.
1
Tightening to angle shall be performed using tool
1
380000304.
MID1326A
56
6- 71020EN - 08 - 2003
First phase
-- 30 Nm A
MID1327A
57
Second phase
-- 120 Nm
MID1328A
58
Third phase
-- 60°
MID1329A
59
Fourth phase
-- 55°
MID1330A
60
6- 71020EN - 08 - 2003
Fifth phase
-- 60°
A = front side
MID1331A
61
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
and check the clearance again. 2
1
MID1332A
62
With the centring ring 380000169 (2):
-- position the front cover (1) on the crankcase,

screws down the screws (3) and tighten them to
the required torque.
1
MID1333A
63
Key the ring seal 380000126 (1) onto the crankshaft,
on which you should apply the tool (3):
Screw down the nut (4) to mount the ring seal (1) 1
completely in the cover (2).
2
4
MID1334A
64
6- 71020EN - 08 - 2003
PISTONS AND CONNECTING RODS
Fit the rings (1) on the pistons (2) with the pliers
380000221 (3). The rings have to be fitted with the
1
word “TOP” (4) facing upwards, also arrange the
openings of the piston rings so they are out of step
2
with each other by 120°. 3
MID1335A
4
65
CAUTION
On finding there is no need to replace the connecting
rod bearings, it is necessary to fit them back on in the 1
disassembly.
If you need to replace them, select the connecting rod
pages 63 -- 66 -- 67.
Lubricate the half bearings (1 and 2) and fit them on

the connecting rod (2) and on the cap (4). 1
MID1336A
CAUTION 66
Do not make any adjustments to the half bearings.
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 68, checking
that: 1
-- The number of each connecting rod corresponds

to the cap coupling number.
2
-- The symbol (2, figure 68) punched on the top of
the pistons faces towards the engine flywheel; or
MID1337A
the cavity in the shell of the pistons corresponds
to the position of the oil nozzles. 67
CAUTION
Class A pistons are supplied as spares and they can
also be fitted in a class B cylinder liner.
6- 71020EN - 08 - 2003
1. Connecting rod--piston
assembly.
2
2. Punched zone on the top of
the piston with symbol for the
assembly position and class
of selection.
3. Connecting rod punching

zone.
MID1338A
68
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 1

two stages to the torques given in the following table:
1
1st phase 60 Nm (6 kgm)
2
2
MID1339A
CAUTION
The connecting rod cap fixing screws must, before 69
Angle closing is performed with tool 380000304 (3).
CAUTION
Lubricate the relevant parts before final assembly.
Before reusing the connecting rod cap fixing screws,
measure the thread diameter is no lower than 13,4
mm.
Replace the screw if its diameter is any lower.
6- 71020EN - 08 - 2003
CYLINDER HEAD
Check that the pistons 1--6 are exactly at the T.D.C.

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 71 and in four successive stages
as shown in the figures. 2
MID1340A
70
CAUTION
The cylinder head fixing screws must, before
Tightening sequence of the cylinder head fixing

screws.
MID1341A
71
Pre--tightening with torque wrench (1).
1
2nd phase 120 Nm (12 kgm)
MID1342A
72
Angle closing with tool 380000304 (1).
1st phase 120°
2nd phase 60°

-- 4th phase: angle of 45° for the screws 4, 5, 12, 13,
20, 21 (Figure 71);
-- 5th phase: angle of 65° for the screws 1, 2, 3, 6, 1

7, 8, 9, 10, 11, 14, 15, 16, 17, 18, 19, 22, 23, 24,
25, 26 (Figure 71). MID1343A
73
6- 71020EN - 08 - 2003
OIL PUMP AND INTERMEDIATE TIMING

GEARS
Assemble oil pump (4) and tighten screws (3) to the

set torque.
Refit the articulated connecting rod (6) without
tightening the fastening screw (5).
Assemble intermediate gears (2), lubricate screw
threads (1) with engine oil and tighten them in two
stages. to:
-- preliminary tightening 30 Nm MID1344A
-- angle closing 90° 74
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 sealant.
MID1345A
75
10 screws M12 x 1.75 x 100; 63 ± Nm
2 screws M12 x 1.75 x 70; 63 ± Nm
4 screws M12 x 1.75 x 35; 63 ± Nm
1 screw M12 x 1.75 x 120; 63 ± Nm
: 2 screws M12 x 1.75 x 193; 63 ± Nm
MID1346A
76
6- 71020EN - 08 - 2003
Key the ring seal 380000127 (1) onto the

crankshaft, on which you should apply the tool (2): 1
Screw down the nut (3) to mount the ring seal (1) 2
completely in the gear box (4).
4
3
MID1347A
77
ENGINE FLYWHEEL
Detail of punching on engine flywheel of piston

position: A C
A Hole on flywheel with 1 notch, corresponding to
B Hole on flywheel with 1 notch, corresponding to

C Hole on flywheel with 1 notch, corresponding to

the TDC of pistons 2--5. D
D Hole on flywheel with 2 notches, position

corresponding to 54°.
View of holes: A – B – C
B View of holes: D
MID1348A
The flywheel shows a reference slot hole which must
be coupled to a centring dowel on the crankshaft. 78
CAUTION
If the teeth of the rim mounted on the engine flywheel,
for starting the engine, are badly damaged, replace
the rim. Assembly must be done after heating the rim
to a temperature of –200°C.
Assemble engine flywheel (1) on crankshaft.

Lubricate screw threads (2) with engine oil and screw
them on.
1
4
Use tool 380000144 (3) applied as shown in figure to
block engine flywheel rotation (1) 2
Tighten screws (2) as follows:
1st stage use torque wrench (4) to tighten to a torque 3

of 120 Nm (120 kgm)
MID1349A
79
6- 71020EN - 08 - 2003
2nd stage closure to an angle of 60°
3rd stage closure to an angle of 30°
Use tool 380000304 (1) to close to angle disassemble

tool (3).
1
MID1350A
80
CAMSHAFT
Position crankshaft with pistons 1 and 6 to TDC

This condition is implemented when;
1. hole showing notch (5) of engine flywheel (4) is

visible through the inspection window
2. Tool 380000150 (1) through rpm sensors seat (2)

enters hole (3) on engine flywheel (4)
Otherwise turn engine flywheel (4) in a convenient

way.
Remove tool 380000150 (1).
MID1351A
81
Assemble camshaft (4) and orient it with holes (→)
positioned as shown in figure 82.
Lubricate seal ring (3) and assemble it on shoulder
plate (2).
Assemble shoulder plate (2) with iron sheet gasket
(1) and tighten screws (5) to the set torque.
MID1352A
82
6- 71020EN - 08 - 2003
Apply calipers 380000167 as shown in figure.
Check and adjust link rod (3) for transmission gear

and lock screw (2) to the set torque.
2
3
MID1353A
83
Assemble again the transmission gear (1) and tighten
fixing screws (2) in two stages:
-- 1st stage locking to a torque of 30 ± 3 Nm
-- 2nd stage, use tool 380000304 to close to an

angle of 90°
1
MID1354A
84
Assemble again gear (2) without fully tightening
screws (5) on camshaft and position it so that the 4 1
slotted holes are centred with respect to the fixing
holes on camshaft. With a magnetic based
comparator (1) check for backlash between gears (2
and 3) which must be 0.073 to 0.195 mm otherwise 2
adjust backlash as follows:
-- loosen screws (4) fixing transmission gears (3);

5
-- loosen screw (2, figure 83) fixing the link rod, shift 3
the link rod (3, figure 83) so as to obtain the set
backlash; MID1355A 4
-- lock screw (2, figure 83) fixing the link rod and 85
screws (4, figure 85); use screws (5) to fix
camshaft gear to the set torque.
6- 71020EN - 08 - 2003
INJECTORS PUMP
Mount the ring seals (1) (2) (3) on the injectors.

1
3
MID1356A
86
Fit the injectors and, with a torque wrench (2), lock the
screws fixing the brackets (1) for the injectors to the
required torque.
MID1357A
87
Position cross members (1) on valve stems
CAUTION
Holes that are larger than cross member must be
positioned on the same side.
MID1358A
88
ROCKER ARM SHAFT
CAUTION
Before refitting the rocker arm shaft assembly, make
sure that all the adjustment screws have been fully
unscrewed.
With tool 380000128 (3) constrain the sliding blocks

(4) to the rocker arms (2).
Apply tool 380000148 (1) to the rocker arm shaft and MID1359A
position it on the cylinder head.
89
6- 71020EN - 08 - 2003
Use engine oil to lubricate threads of screw (2) fixing

rocker shaft and tighten them in two stages:
1st stage: use a torque wrench (1) to tighten to a 2

torque of 100 Nm (10 kgm).
2nd stage: use tool 380000304 to tighten to an angle 1

of 60°.
3
MID1360A
90
Use springs (2) to link levers (1) to spacer (3).
2
MID1361A 3
91
Assemble electric wiring on pump--injectors and
tighten.
Tighten fixing nuts to a torque of 1.36 to 1.92 Nm

(0.13 to 0.19 kgm).
Tighten screws fixing cabling retaining clamps to

cylinder heads to the set torque.
MID1362A
92
6- 71020EN - 08 - 2003
Camshaft timing
Apply the tool for flywheel rotation to the gear box (2):
380000137 (7) and spacer 380000138 (6).
CAUTION
The arrow indicates the direction of rotation of 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 of cylinder no.1 to
approximately the T.D.C. in the phase of combustion.
one notch (4), after the hole with two notches (5) on
the engine flywheel (1), can be seen through the
inspection window (3).
MID1363A
93
The exact position of the piston of cylinder no.1 at the
conditions, the tool 380000150 (1) enters the hole (3)
on the engine flywheel (4) through the seat (2) of the
If this is not the case, orient the engine flywheel (4)
appropriately.
Remove the tool 380000150 (1).
MID1364A
94
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.
1
6 mm
Using tool 380000137, turn the crankshaft clockwise

until the pointer of the dial gauge reaches the
minimum value under which it cannot go.
Zero the dial gauge. 2

Turn the engine flywheel anticlockwise until on the MID1365A
dial gauge you read the cam lift value of the camshaft
of: 5.31 ± 0.05 mm. 95
6- 71020EN - 08 - 2003
The camshaft timing is correct if the above cam lift

values 5.31 ± 0.05 correspond to the following
conditions:
1. The hole with a double 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 engine flywheel (4).
MID1366A
96
If the conditions described in figure 96 and indicated
in points 1 and 2 were not obtained, proceed as
follows.
Loosen the screws (2) fixing the gear (1) to the 1

camshaft (3).
3
2
Take appropriate action on the engine flywheel to
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- MID1367A
scribed above.
97
Tighten the screws (2) to the required torque.
When the slots (1) are not sufficient to recover the

timing, 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 97) are locked.

Turn the engine flywheel clockwise by approx. 1/2
turn. 1
Turn the engine flywheel anticlockwise until the dial
gauge shows a camshaft cam lift value of: di 5.31 ±
0.05 mm. 2
Take out the screws (2, figure 97) and remove the
gear (2) from the camshaft.
MID1368A
Repeat the steps described in figure 96.
98
Mount the gear (2, figure 97) on the camshaft and
tighten the fixing screws to the required torque.
6- 71020EN - 08 - 2003
Phonic wheel timing
In the conditions described in figure 96, check that the 1

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. 2
Then tighten the screws (3) to the required torque.
MID1369A 3
99
COMPLETING THE ENGINE
1
Adjust intake/exhaust valve rocker arm backlash and
pump injector control rocker arm pre--load (operation
10 106 12), as shown on page 99.
2
Mount the rocker arm cover (1) and the timing system
cover (2) with new gaskets, tightening the fixing
CAUTION
The fixing screws of the rocker arm cover (1) must be MID1370A
tightened in the sequence shown in the diagrams on

page 17. 100
Mount the suction rose (1) and tighten the fixing

screws to the required torque. 1
MID1371A
101
Arrange seal (4) on oil sump (1) position spacer (3)
and assemble sump on crankcase, screw on screws
(2) and tighten them to set torque. 1
4
3
MID1372A
102
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CAUTION
Check conditions of control unit support elastic
components, and replace them if found deteriorated.
Assemble the following components and tighten

screws to the set torque:
-- engine control unit (5)
-- intake manifold (4) with new seals, comprising
pre heating resistance
-- starter motor (3)
-- fuel pump (2) and relevant piping
MID1373A
-- fuel filter support (1)
103
Assemble new gaskets:
-- heat exchanger (4) and tighten fixing screws (1)

to set torque according to tightening orders
shown in fig. 9 on page 16;
-- water piping (3) and tighten fixing screws (2) to

set torque
MID1374A
104
Assemble oil filter (1) on support as follows:
-- oil seals;
-- screw on filters until they get in contact with

gaskets on support base;
-- tighten filter to a torque of 35 ÷ 40 Nm.
MID1375A
105
Assemble the following components with new
gaskets and tighten screws/joints to set torque:
-- Exhaust manifold (3);
-- turbo charger (2);
-- oil delivery piping (1);
-- oil return piping (4).
MID1376A
106
6- 71020EN - 08 - 2003
Assemble thermostat unit (2) and tighten fixing

screws (1) to required torque.
MID1377A
107
Use tool (1) 380000144 to block engine flywheel.
MID1378A
108
Assemble the following components together with
relevant gaskets and tighten screws to the set torque:
-- automatic belt tightener (3) for air conditioner
compressor control belt;
-- fixed pulley (7);
-- water pump (6);
-- pulley (4);
-- automatic belt tightener (3);
-- fixed pulley (2);
-- alternator (1).
MID1379A
109
CAUTION
Belt tighteners (3, fig. 109 and 1, fig. 110) are of the
automatic type and do not require adjustments after
assembling.
Using the proper tool (2) fitted into belt tightener (1),
operate in the direction shown by the arrow and refit
the auxiliary component control belt (3).
MID1380A
110
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Assembly diagram for fan -- water pump --

alternator control belt
1. Alternator – 2. Fixed pulley – 3. Water pump – 4.
Fixed pulley – 5. Output shaft.
MID1381A
111
Assemble damper flywheel (1) and tighten screws (2)
to set torque
MID1382A
112
Apply rocker arm 380000360 to engine lifting hooks,
and hook it to hoist.
Remove bracket 380000155 fixing screws to turning
stand, lift engine and detach brackets from it.
Complete engine assembly of the following compo- 1

nents and tighten fixing screws to set torque:
-- engine support (1);
MID1383A
113
6- 71020EN - 08 - 2003
-- assemble drive (1);

1
-- assemble engine supports;
MID1384A
114
-- assemble oil pressure valve (1).
MID1385A
115
Fit the engine mount together with the air--
conditioner compressor (2). 1
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 engine with the required amount and
grade of lubricating oil.
3
2
MID1386A
116
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CRANKCASE AND CYLINDER LINERS
CAUTION
gloves and shoes.
2
CAUTION
Cylinder barrel bore is checked for ovalization,
excessive taper and wear using a 1/100 bore dial (1) 3
gauge (2), previously reset on 135 mm diameter ring
gauge (3).
If the ring gauge is not available, use a micrometer.
MID1387A
117
Outline for checking the diameter of the cylinder
liners
(dimensions in mm)
1
1. 1st measurement
2. 2nd measurement 2 B
3. 3rd measurement. A
The measurements have to be made on each single
cylinder liner at three different heights and on two 3
planes (A--B) at right angles to each other, as shown
in figure 118.
MID1388A
118
Selection class
A 135.000 -- 135.013
B 135.011 -- 135.024
A--B
(Dimensions in mm)
On finding greater wear than 0.150 mm or maximum
ovalization of 0.100 mm over the values given in the
figure, it is necessary to replace the cylinder liner as
grinding, lapping and dressing are not permitted.
CAUTION
The cylinder liners are supplied as spares with
selection class ”A”. Class B is mounted solely in
production.
X = Selection class marking area.

MID1389A
119
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Ø
C
A 153.500 -- 153.525 A
B 152.000 -- 152.025
C 153.461 -- 153.486
D 151.890 -- 151.915
D
(Dimensions in mm)
B
The diagram illustrated in figure 120 gives the outside
diameters of the cylinder liner and the inside diam-
eters of their seats.If necessary, the cylinder liners
can be taken out and fitted in different seats a number MID1390A
of times.
120
Check the state of the plugs of the cylinder assembly:
if rusty or there is any doubt at all about their seal, re-
place them. 1
Replacing the cylinder liners

2
Disassembly
Position the parts of tool 380000366 (2) and the plate 3

380000116 (4) 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 cylin- 4
MID1391A
der liner (3) from the crankcase.
121
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 1
assembly with an appropriate tool.
2 4
CAUTION
The adjustment ring (1) is supplied as a spare in the 3
following thicknesses: 0.08 mm – 0.10 mm – 5
0.12 mm.
MID1392A
122
Cylinder liner protrusion
1
Check the protrusion of the cylinder liners with tool
380000140 (2) and tightening the screw (1) to the 2
torque of: 225 Nm.
Measure, with the dial gauge (3), that the protrusion 3

of the cylinder liner from the supporting surface of the
cylinder head is the value X indicated in the table of
figure 124. If this is not so, replace the adjustment
ring (1, figure 122), supplied as a spare in several
thicknesses. MID1393A
123
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Protrusion X
X 0.045 -- 0.075
(Dimensions in mm)
MID1394A
124
On completing assembly, lock the cylinder liners (1)
to the crankcase (2) with the pins 380000363 (3).
1
2
CRANKSHAFT AND BEARINGS MID1395A
125
CAUTION
gloves and shoes.
1
Measuring main journals and crankpins
2
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.
Measuring main journals
CAUTION
All the main journals and crankpins should always be
ground to the same class of undersizing so as not to
alter the balance of the crankshaft.
MID1396A
It is advisable to note down the measurements in a
table (Figure 127). 126
6- 71020EN - 08 - 2003
MAIN JOURNALS
MINIMUM Ø
MAXIMUM Ø
CRANKPINS
MINIMUM ∅
MAXIMUM ∅
MID1397A
127
Top main bearing shells
.
.
.
.
.
.
. .
. .
.
. .
.
. .
. .
.
.
.
.
.
.
. .
. .
Bottom main bearing shells
MID1398A
128
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.
6- 71020EN - 08 - 2003
Detail of the fittings of the main journals

(X, figure 128)
(dimensions in mm)
POL- .
ISHED
. . +
GROUND
GROUND
. .
MID1399A
129
Detail of the fittings of the main journals
(Y, figure 128)
(dimensions in mm)
POL- .
ISHED
. . -- .
GROUND
. .
MID1400A
130
Replacing timing and oil pump control gear
Check whether gear toothing is not damaged or worn

out, otherwise use a proper puller to extract it. 5 ± 0.5
When assembling, heat gear (1) to 180 °C for 15’ 1

(max temperature 200 °C) and assemble it at the
height shown in figure. 2
3+ 5
-- 0
MID1401A
131
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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 colour
scribed below. (red--green – red/black – green/black).
This operation makes it possible to identify the most The following tables give the characteristics of the
suitable half bearings for each of the pins of the shaft main and big end bearing shells available as spares
(the half bearings may even be of a different class in the standard (STD) sizes and in the permissible
from one pin to another). oversizes (+0.127, +0.254, +0.508).
Big end half-bearings STD +0.127 +0.254 +0.508
red 1.965 to 1.975 2.092 to 2.102 2.219 to 2.229
red/black 2.028 to 2.038
green 1.976 to 1.985 2.103 to 2.112 2.230 to 2.239
green/black 2.039 to 2.048
Main half-bearings
STD + 0,127 + 0,254 + 0,508
red 3.110 to 3.120 3.237 to 3.247 3.364 to 3.374
red/black 3.173 to 3.183
green 3.121 to 3.130
green/black 3.184 to 3.193
MID1402A
132
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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

crankcase;
-- determine the class of diameter of the main

journal;
Crankpins

connecting rod;
-- determine the class of diameter of the crankpin;
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 133 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 133 at bottom);
-- each of these digits may be 1, 2 or 3.
6- 71020EN - 08 - 2003
CLASS MAIN BEARING NOMINAL DIAMETER
1 106.300 -- 106.309
2 106.310 -- 106.319
3 106.320 -- 106.330
MID1403A
133
6- 71020EN - 08 - 2003
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 136 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), the other six digits,
taken singly, represent the class of diameter of
each of the crankshafts to which they refer
(figure 134 at top).
-- the set of seven digits, on the right, refers to the

main journals and is preceded by a single digit,
which indicates the status of the pins (1 = STD,
2 = --0.127), the other seven digits, taken singly,
represent the class of diameter of each of the
main journals to which they refer (figure 134 at
bottom).
6- 71020EN - 08 - 2003
CLASS CRANKPIN NOMINAL DIAMETER
1 89.970 -- 89.979
2 89.980 -- 89.989
3 89.990 -- 90.000
40019
CLASS MAIN JOURNAL NOMINAL DIAMETER
1 99.970 -- 99.979
2 99.980 -- 99.989
MID1404A
3 99.990 -- 100.000
134
6- 71020EN - 08 - 2003
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
MID1405A
135
6- 71020EN - 08 - 2003
Selection of main half-bearings (rectified pins)

If the journals have been rectified, the procedure described cannot be applied.
In this case, make sure that the new diameter of the journals is as specified on the table and install the only
half-bearing type required for this undersizing.
red/black = --0.127
mm 3.173 to 3.183
green/black =
mm 3.184 to 3.193
Class 1 2 3
99.843 green/black green/black green/black
99.852 1
99.853 red/black green/black green/black

99.862 2
99.863 red/black red/black green/black

99.873 3
--0.254
red =
mm 3.237 to 3.247
1 2 3
99.726 red red red

99.746
red red red
--0.508
red =
mm 3.364 to 3.374
1 2 3
99.472 red red red

99.492
red red red
MID1406A
136
6- 71020EN - 08 - 2003
Selecting the big end bearing shells (pins with

nominal diameter)
On the body of the connecting rod, in position ”A”,

there are three markings:
1. Letter specifying the weight classes:

VIEW FROM “A”
A = 4661 -- 4694 g.
B = 4695 -- 4728 g.
3
C = 4729 -- 4762 g. 2
2. Number specifying the selection of the diameter
of the big end bearing seat: 1
1 = 94.000 -- 94.010 mm
2 = 94.011 -- 94.020 mm A
3 = 94.021 -- 94.030 mm
MID1407A
coupling. 137
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
(fig. 138).
6- 71020EN - 08 - 2003
green green green
green green green
red green green
red green green
red red red
red red red

MID1408A
138
6- 71020EN - 08 - 2003
Selection of connecting rod half-bearings (rectified pins)

If pins have been rectified, the procedure described must be applied.
In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the
half-bearings identified according to the relative table.
red/black = --0.127
mm 2.028 to 2.038
green/black =
mm 2.039 to 2.048
Class 1 2 3
1
89.853 red/black green/black green/black

2
89.862
89.863 red/black red/black green/black

89.873 3
--0.254
red =
mm 2.092 to 2.102
green =
1 2 3
mm 2.103 to 2.112
89.726 red green green

89.736 red red green

89.746
red red green
--0.508
red =
mm 2.219 to 2.229
1 2 3
green =
mm 2.230 to 2.239

89.481
red green green
89.482 red red green

89.492
red red green
MID1409A
139
6- 71020EN - 08 - 2003
Checking main journal assembly clearance

1
3
If dismantled, mount the oil nozzles (3) making the
grub screw coincide with the hole (2) on the 2
crankcase.
CAUTION
Clean the parts carefully and remove every trace of
oil.
Put the half bearings (1) on the main bearings. MID1410A
140
With a hoist and hook 380000362 (1) fit on the
crankshaft (2).
MID1411A
141
Place the half bearings (1) on the main bearings in the
sub--crankcase (2).
Check the assembly clearance between the main 1
journals of the crankshaft and the respective
bearings, proceeding as follows:
MID1412A
142
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
MID1413A
143
6- 71020EN - 08 - 2003
Use engine oil to lubricate internal screws (1) and use

a torque wrench to tighten them to a torque of 120 Nm
and then close them to an angle of 605 following the
diagram shown in figure 145.
Use tool 380000304 (2) to perform angular closure. 2

1
MID1414A
144
Diagram of the tightening
sequence of the screws
fixing the sub--crankcase
under the crankcase.
FRONT SIDE
MID1415A
145
Remove the sub--crankcase
The clearance between the crankshaft bearings and 1

the relevant pins is measured by comparing the width
taken on by the calibrated wire (2) at the point of
greatest crushing, with the graduated scale on the 2
case (1) containing the calibrated wire.
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
repeat the check.
MID1416A
146
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 147. If you find the clearance is higher than
as required, replace the rear main thrust bearing
shells and repeat the clearance check.
2
1
MID1417A
147
6- 71020EN - 08 - 2003
PISTONS
CAUTION
gloves and shoes.
Check the pistons, they must have no sign of seizure,

scoring, cracking or excessive wear; if this is not so,
replace them.
2
3
Remove the piston rings (2) from the piston (3) with
the pliers 380000221 (1). 1
MID1418A
148
Remove the split rings (2) holding the piston pin with
round--nose pliers (1). 1
MID1419A
149
Remove the piston pin (1).
If disassembly is difficult, use an appropriate drift.
MID1420A
150
6- 71020EN - 08 - 2003
Measuring piston diameter

1
Using a micrometer (2), measure the diameter of the
piston (1) to determine the assembly clearance. 2
X
CAUTION
Diameter shall be measured at 20 mm from piston
skirt base.
The pistons are selected in two classes A and B

according to the diameter.
As spares they are supplied in class A and can also MID1421A
be mounted in the cylinder liners with inside diameter
class B. 151
The clearance between piston and cylinder liner can
also be measured with a feeler gauge (1).
MID1422A
152
Piston pin
The pins are mounted with clearance both on the 2

small end and on the piston.
Measure the diameter of the pin (1) with a micrometer

(2).
MID1423A
153
Conditions for correct pin--piston coupling
When fitting new pins (1), check they couple correctly 1

with the seat on the piston in the following manner:
-- 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. MID1424A
154
6- 71020EN - 08 - 2003
3.445 3.050 5.020 3.296 2.970 4.970 A=134.881--134.893

* 3.475 3.070 5.040 * 3.364 2.990 4.990 B=134.892--134.904
20
54.010 53.994
MID1425A
54.018 54.000
155
Main data on pistons, and pistons rings

* Values are determined on Ø of 130 mm.
Piston rings
Check the thickness of the piston ring (2) with a

micrometer (1).
1
MID1426A
156
Check the clearance between the ring seals (2) and
their seats on the piston (1) with a feeler gauge (3). 3
1
2
MID1427A
157
6- 71020EN - 08 - 2003
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
MID1428A
158
Using a feeler gauge (2), check the opening between
the ends of the ring seals (1) inserted in the cylinder
liner (3). 1
On finding a higher or lower distance between the
ends than as required, replace the piston rings.
2
MID1429A
159
CONNECTING RODS
CAUTION
Handle all parts carefully. Do not put your hands or 59.00
Wear suitable safety clothing – safety goggles, 59.03
gloves and shoes. 0 59.08 54.01 * 53.99
5 9 4
59.11 54.03 54.00
Clean the parts thoroughly before doing any work. 0 5 0
1.965
1.995
Main data for the connecting rod, bushing, pin
and half bearings (Dimensions in mm) 94.00
0
* Dimension to be obtained after driving home the 94.03
bushing. 0
MID1430A
160
The data for the classes of selection for the big--end CAUTION
bearing seat and weights are punched on the big end When fitting the connecting rods, check they are all
of the connecting rod. of the same class.
6- 71020EN - 08 - 2003
Outline of connecting--rod punch--marks
1. Letter specifying class of weight:
A = 4661 -- 4694 g.
VIEW FROM “A”
B = 4695 -- 4728 g.
1
C = 4729 -- 4762 g.
2. Number indicating the selection of the big--end 2
bearing seat diameter:
1 = 94.000 -- 94.010 mm 3
2 = 94.011 -- 94.020 mm
A
3 = 94.021 -- 94.030 mm MID1431A

coupling. 161
Bushings
The bushing (2) is disassembled and assembled with 1 2

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 order to obtain the
required diameter.
MID1432A
162
Rebore the small--end bushing with a boring
machine.
MID1433A
163
6- 71020EN - 08 - 2003
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 1

follows:
2
-- Fit the connecting rod (1) on the spindle of the tool 3
(5) and lock it with the screw (4).
5
-- Place the spindle (3) on the V--prisms resting the 4
connecting rod (1) on the stop bar (2).
MID1434A
164
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 on the pin (3)
2
at point A and zero the dial gauge (2). Move the
spindle (4) with the connecting rod (5) and on the op- 3
posite side (B) of the pin (3) compare any deviation:
the difference between A and B must be no greater 5
than 0.08 mm.
MID1435A
165
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 1
mount (1) of the dial gauge (2) so that the latter rests 2
on the pin (3) at point C.
Swing the connecting rod forwards and backwards, C D
searching for the highest position of the pin and zero
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
3
the highest point. The difference between points C
and D must be no greater than 0.08 mm. 4
MID1436A
166
6- 71020EN - 08 - 2003
PISTON -- CONNECTING ROD

ASSEMBLY
1 10
1. Connecting rod body – 2. Half bearings – 3.
Connecting rod cap – 4. Cap fixing screws – 5. Split 2 5
ring – 6. Oil scraper ring with slots with spiral spring –
7. Ring seal – 8. Trapezoidal ring seal – 9. Piston pin – 3 8
10. Piston.
7
9
4
6
5
MID1437A
167
CAUTION
The piston (1) has to be fitted on the connecting
rod (2) so that the symbol (4) showing the assembly
position in the cylinder liner and the punch mark (3)
of the connecting rod are observed as shown in the
figure.
MID1438A
168
Mount the pin (2) and constrain it to the piston (1) with
the split rings (3).
1
2
3
MID1439A
169
6- 71020EN - 08 - 2003
Fitting the piston rings
To fit the piston rings (1) on the piston (2) use the
pliers 380000324 (3). 1
The rings need to be fitted with the word ”TOP” (4)
facing upwards, also direct the openings of the rings
so they are staggered 120° apart. 2 3
MID1440A 4
170
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.
MID1441A
171
MID1442A
172
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
position and selection class – 3. Connecting rod punch mark area.
6- 71020EN - 08 - 2003
With the aid of the clamp 380000220 (1, fig. 173),

mount the connecting rod--piston assemblies (2) in
the cylinder liners, checking that:
1
-- The openings of the piston rings are staggered
120° apart.
-- The pistons are all of the same class, A or B.

2
-- 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 MID1443A
the oil nozzles.
173
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
2
MID1444A
174
CAUTION CYLINDER HEAD
The screws (2) must, before assembly, be lubricated
with engine oil. CAUTION
The closed angle is performed with the tool Wear suitable safety clothing – safety goggles,
380000304 (3). gloves and shoes.
Remove the caps and determine the existing

clearance, comparing the width of the calibrated wire Checking the hydraulic seal
with the graduated scale on the bag containing the
wire. Before removing the cylinder head, check the hy-
draulic seal with appropriate equipment: replace the
cylinder head if there is any leakage.
CAUTION
Lubricate the relevant parts prior to final assembly.
Before reusing the screws fixing the connecting rod
caps, measure to check the diameter of the thread is
no less than:13.4 mm.
For lower values, replace the screw.
6- 71020EN - 08 - 2003
Removing the valves

1 3
With the bracket (4), secure the tool (2):
380000131--380000132, engine to the cylinder head. 5
2
Screw down with the lever (1) until it is possible to 6
remove the cotters (3). Remove the tool (2) and 3
extract the top plate (5), spring (6) and bottom plate 7
(7).
Repeat this process for all the valves.
8
Turn the cylinder head over and extract the valves (8). 4
MID1445A
175
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,
replace the cylinder head.
CAUTION 1 2 3
After this process you need to check the valve cavity
and injector protrusion. MID1446A
176
VALVES
Decarbonizing and checking the valves
Remove carbon deposits from valves using the

proper metal brush.
Check that valves show no signs of seizing, scoring

or cracking. Use a micrometer to check also that the
diameter of the valve stem is falling within the
specified limits (see figure 178), otherwise replace.
MID1447A
177
6- 71020EN - 08 - 2003
Check with a micrometer that the diameter of the 9.960

valve stems is as specified in the figure: 9.975
16.012
Main data of the valves and valve guides 10.025
(Dimensions in mm) 10.015

* 10.030
* Measurement to make after driving in the valve
45°30’±7’30’’
guides.
60°30’±7’30’’
1. Intake – 2. Exhaust.
46.850--47.150 45.850--46.150
MID1448A
Valve grinding
178
If necessary, grind the seats on the valves with a
grinding machine, scalping as little material as
possible.
Checking clearance between stem--valve and

relevant valve guide
Using a dial gauge with a magnetic base, check the

clearance between the valve stem and the relevant
guide. If the clearance is too great, replace the valve
and, if necessary, the valve guide.
Main data on the intake and

exhaust valve seats 1 2
(Dimensions in mm)
4.75±0.06
5.3±0.06
CAUTION .
The valve seats on the cylinder
head are ground every time the
valves or valve guides are ground
or replaced. Ø 43.00 Ø 43.20
1.84÷2.06
0.34÷0.86
1. Intake valve seat MID1449A

2. Exhaust valve seat
179
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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 178 and 179. 1
If you need to replace them, with the same tool and
taking care not to damage the cylinder head, scalp as 2
much material 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 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 178 and 179. MID1450A
180
After reboring the valve seats, use tool 380000364
and the dial gauge to check that the position of the
valves in relation to the face of the cylinder head is:
-- --0.54 -- --0.85 mm (cavity) intake valves;
-- --1.75 -- --2.05 mm (cavity) exhaust valves.
6- 71020EN - 08 - 2003
TAPPETS AND CAMSHAFT
CAUTION
gloves and shoes.
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.
.
.
. .
. .
. .
.
. . . .
.
. .
.
. .
. . .
. .
.
.
.
MID1451A . . .
181
Main data of the camshaft and tolerances (Dimensions in mm)
TOLERANCES SUBJECT OF TOLERANCE GRAPHIC SYMBOL

ORIENTATION Perpendicularity ⊥
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation ↗
CLASSES OF IMPORTANCE ATTRIBUTED TO THE CHARACTERISTICS OF THE GRAPHIC SYMBOL
PRODUCT
CRITICAL 
IMPORTANT ⊕
SECONDARY ⊝
6- 71020EN - 08 - 2003
Checking cam lift and pin alignment

1 2 1
Place the camshaft (4) on the tailstock centres (1)
and, using a dial gauge (2), check that the lift of the
cams (3) corresponds to the values given in the
following table:
intake cam mm 9.231 3 4

exhaust cam mm 9.56
pump injector operating cam mm 11.216
MID1452A
182
Again with the camshaft (4) on the tailstock centres
(1), using a dial gauge (2), check the alignment of the 1
supporting pins (3): it must be no greater than 0.030
1 2
mm. If there is any greater misalignment, replace the
shaft.
3 4
MID1453A
183
To check assembly clearance, measure bush internal
diameter (figure 185) and camshaft pin diameter (fig-
ure 181), the difference will give the actual existing 1
clearance.
If the clearance is greater than 0.135 mm, replace the
bushings and, if necessary, the camshaft as well.
MID1454A
184
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Bushings
Ø 88.000 - 88.030
* Ø 83.018 - 83.085
Ø 88.153 - 88.183
MID1455A
185
Main data for the camshaft bushings and seats on the cylinder head
(Dimensions in mm)
* Inside diameter of bushings after driving them in
A B C D E F D N G H D I
MID1456A
186
Replacing camshaft bushings A. Drift – B. Bushing positioning grub screw – C.

Reference for fitting the 7th bushing – D. Reference
The surfaces of the bushings must have no sign of for fitting bushings: 1 – 2 – 3 – 4 – 5 – 6, reference
seizing or scoring, replace them if they do. mark for the F2B engine, red mark for the F3A engine
Using a bore gauge, measure the inside diameter of – E. Guide bushing – G. Guide bushing to secure to
the bushings. If it is above the tolerance value, the 7th bushing mount – H. Plate for securing bushing
replace the bushings. G to cylinder head – I. Grip – L. Extension coupling.
To disassemble and reassemble the bushings of the

camshaft, use the drift: 380000146.
6- 71020EN - 08 - 2003
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 380000155,
380000146 coincide with the
bushing.
MID1457A N
187
Assembly 2. Position the guide bushing E and secure the

guide bushing G on the seat of the 7th bushing
Assemble the drift with the extension. with the plate H.
To fit the bushings 1 – 2 – 3 – 4 – 5 – 6, proceed as
follows: 3. When driving in the bushing, make the reference
mark F coincide with the mark M. In this way, after
driving it home, the hole in the bushing for
1. Position the bushing to mount on the drift A
lubrication coincides with the oil duct in its seat.
making its grub screw coincide with the seat on
The bushing is completely driven home when the
the bushing.
first yellow reference mark D is flush with the
guide bushing G.
To mount the bushing 6:
N E A G I
-- Unscrew the grip 1 and the 6
extension N.
-- Position the extension N

and the guide bushing E
as shown in the figure.
-- Repeat steps 1, 2, 3
performed for driving in
the bushings 1, 2, 3, 4, 5.
MID1458A D
188
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To mount the 7th bushing:
-- Remove the grip and the

guide bushing G secured N E G A I
7
to the cylinder head (figure
188).
-- 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. MID1459A
C
189
CAUTION
The bushing is driven in correctly when the reference
C is flush with the bushing seat.
VALVE SPRINGS, ROCKER ARM SHAFT

AND ROCKER ARMS
CAUTION
gloves and shoes.
Before assembly, the flexibility of the valve springs

needs to be checked with an appropriate tool. Com-
pare the load and elastic deformation data with the
data of the new springs given in the following figure.
MID1460A
190
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Main data for checking the valve springs

Spring release
(Dimensions in mm)
1. Load of 575 ± 28 N
2. Load of 1095 ± 54 N. 1
.
2
.
.
MID1461A
191
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: 380000139.
Fit the oil seal (1) on the valve guide (2), then mount
the valves as follows.
2
3
MID1462A
192
Mount the springs (6) and top plate (5).
1 3
On the cylinder head, fit the tool (2) 380000131 and 2
380000132. 5
And secure it with the bracket (4). Screw down the 6

lever (1) until it is possible to mount the cotters (3), re- 3
move the tool (2).
7
MID1463A 4
193
6- 71020EN - 08 - 2003
Rocker arm shaft
Check that the mating surfaces have no scoring or

signs of seizing. If they do, replace the damaged parts.
Check the clearance between the bushings of the

rocker arms and the shaft. If you find the bushings
worn, replace the entire rocker arm.
2 3 2 3 2 3 2 3 2 3 1 2 3
1 1 1 1 1
MID1464A
194
1. Intake valve rocker arm – 2. Injector rocker arm – 3. Exhaust valve rocker arm.
41.984
42.000
MID1465A
195
Main data of the rocker arm shaft (Dimensions in mm)
6- 71020EN - 08 - 2003
Rocker arms
Check surfaces of bushes which must not show any

A
signs of scoring or excessive wear; otherwise replace
B
the whole rocker arm. SECTION A--A
SECTION B--B
Intake valve rocker arms
(Dimensions in mm)
42.0
42.0
A B
25
41
MID1466A
196
Exhaust valve rocker arm
Main data for rocker arms A
(Dimensions in mm) SECTION A--A

B
SECTION B--B
56.0
56.0
A
30
49
MID1467A
197
Injector pump rocker arms
(Dimensions in mm) A
SECTION A--A
B
SECTION B--B
B
42.0
42.0
A
15
71
MID1468A
198
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LUBRICATION SYSTEM
CAUTION
gloves and shoes.
Lubrication is by forced circulation, obtained with a

1
gear pump (1).
The pump is governed, via gearing, by the crankshaft MID1469A

2
(2).
199
Check that the gears have no sign of wear or seizure;
if they do, replace the entire pump.
To replace the gear (2), see under the relevant head-

ing on page 60.
Oil pump section

B
SEC. B-B
1. Overpressure valve
A SEC. A-A
Pressure of starting
opening 10.1 ± 0.7 bars.
B
MID1470A
200
6- 71020EN - 08 - 2003
Main data for checking the overpressure valve

spring
1. Load of 334 ± 22 N
2. Load of 526 ± 24 N. 1
2
.
MID1471A
201
Oil pressure control valve
Pressure of starting opening 5 bars.
The oil pressure control valve is located on the left

side of the crankcase.
MID1472A
202
Main data for checking the oil pressure control
valve spring
1
1. Load N 194.5 ± 5
2
2. Load N 450.5 ± 20
A mm 68.1
B mm 56
C mm 40
MID1473A
203
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Heat exchanger SECTION A--A
The heat exchanger is fitted with:
F. Oil filter clogging indicator.

G. Oil temperature transmitter.
H. Oil pressure transmitter.
I. Low oil pressure switch.
J. Filter bypass valve.
K. Thermostat
L. Oil filters
Number of heat exchanger elements: 14
MID1474A
204
SECTION B--B
MID1475A
205
MID1476A
206
6- 71020EN - 08 - 2003
Bypass valve
The valve quickly opens at a pressure of: 3 bar
MID1477A
207
Thermostat valve
Start of opening
-- travel 0.1 mm at a temperature of 82 ± 2°C
End of opening
-- travel 8 mm at a temperature of 97°C.
MID1478A
208
Oil filter
High filtering oil filters
CAUTION
Always replace seal rings whenever assembled
components are disassembled on heat exchanger oil
filter support
MID1479A
Comply with the following norm when filters (1) are
assembled: 209
-- oil seals;
-- screw on filters until they get in touch with gaskets

on the support base;
-- tighten filter to a torque of 35 -- 40 Nm.
6- 71020EN - 08 - 2003
COOLING SYSTEM
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
“AKCELA Premium Anti--Freeze” fluid (50% in
volume) that cannot freeze down to:
oC --8 --15 --25 --35

% in volume of
”AKCELA Premium 20 30 40 50
Anti--Freeze”
This mixture, moreover, has antioxidant,

anticorrosive, 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 centrifugal vane pump. The

pump bearing forms a single piece with the impeller
shaft, the drive pulley is keyed onto this shaft.
MID1480A
210
6- 71020EN - 08 - 2003
Engine thermostat
Start of travel at 84 °C ± .
Travel 15 mm at 94 °C ± 2 °C.
Water circulating in the engine TO

EXPANSION
TANK
BY TO THE
THE ENGINE BY-PASS
MID1481A
211
Water leaving the thermostat TO THE
RADIATOR
TO
EXPANSION
TANK
TO THE
BY-PASS
BY
MID1482A
THE ENGINE
212
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 MID1483A
D. Fuel return from the pump--injectors
E. Pressure relief valve 213
Opening pressure: 5--8 bars
6- 71020EN - 08 - 2003
Section of the fuel pump
1. Oil or fuel leakage gauge
MID1484A
1
214
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

1
that, in its turn, is directly governed by the cam of the
camshaft. The pumping element can ensure a high 2
delivery pressure. Its return stroke is activated by a
spring. 3
Nozzle
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 be- MID1485A
tween errors of an electrical origin from those of a

215
mechanical/hydraulic origin.
It indicates broken pump--injectors.
It is therefore necessary to interpret all the control
unit’s error messages correctly.
Any defects in the injectors require them to be re-
placed as no repairs are permitted.
6- 71020EN - 08 - 2003
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 Nm
(0.136 – 0.192 kgm).
Replacing the pump--injectors
The injectors have to be replaced with great care (see

the description on pages 50--54 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
0 411 700 002
XXXXXX XXXX X
unscrewing the delivery and return fittings on the 868 USA /
cylinder head.
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 216) to reprogram the control unit.
MID1486A
CAUTION 216
If the electronic diagnosis instrument is not available,
it is exceptionally possible to replace an injector
without control unit identification.
CAUTION
When checking the rocker arm clearance, you need
to check the pump--injector pre--load.
6- 71020EN - 08 - 2003
VALVE GUIDES -- REPLACEMENT
CAUTION
31 ± 0.20
Handle all parts carefully. Do not put your hands or * Ø 10.015 -- 10.030
gloves and shoes.
The valve guides are removed with drift: 380000365.
For refitting use beater 380000365 fitted with tool

380000136.
CAUTION
Parts 380000136 determine the exact position of MID1487A
assembly of the valve guides in the cylinder head. If 217

they are not available, it is necessary to drive the
valve guides into the cylinder head so they protrude
from it by: 30.8 -- 31.2 mm (figure 217).
After driving in the valve guides, rebore their hole with

the reamer: 380000368.
* Dimension to be obtained after driving in the valve

guides.
6- 71020EN - 08 - 2003
INJECTOR CASE -- REPLACEMENT
CAUTION
gloves and shoes.
To replace the injector case (2), proceed as follows:
-- Thread the case (2) with tool 380000159 (1).

1
The steps described in figures 218, 219, 220, 221
must be performed by securing the tools with bracket
A to the cylinder head.
MID1488A
218
-- Screw the extractor 380000123 (2) into the case
(3). Screw down the nut (1) and extract the case
from the cylinder head.
1
MID1489A
219
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-- With tool 380000370 (2) remove any residues (1)

left in the groove of the cylinder head.
MID1490A
220
-- Lubricate the ring seals (3) and fit them on the
case (4). 1
With tool 380000157 (2) secured to the cylinder head 2

with bracket A, drive in the new case, screw down the
screw (1), pressing the bottom of the case.
A
4
MID1491A
221
Rebore the hole in the case (3) with the reamer
380000164 (1).
3
MID1492A
222
6- 71020EN - 08 - 2003
Rebore the seat of the injector in the case (3) with the
milling cutter 380000164 (1 and 2), equipped with
guide bushing 380000162.
MID1493A
223
Checking injector protrusion
Check injector protrusion (2) with a dial gauge (1).

The protrusion needs to be: 0.5 -- 0.134 mm.
1
MID1494A
224
6- 71020EN - 08 - 2003
CRANKSHAFT FRONT COVER SEAL --

REPLACEMENT
CAUTION
gloves and shoes.

Disconnect the pipes from the thermostat box.
Disconnect the engine cooling fan.
Using a suitable tool (8), turn in the direction of the

arrow on the tightener (7) and remove the belt (4).

arrow on the tightener (2) and remove the belt (1).
MID1495A
Remove the fastening screws and disassemble the

pulley (6) and the damper flywheel (5). 225
With the extractor 380000120 (2); applied as shown

in the figure, extract the seal (4). Unscrew the
screws (3) and take off the cover (1). 1
4
Disconnect all the electrical connections and
sensors. 2
MID1496A
226
Key the ring seal (1) onto the crankshaft and onto this
apply tool 380000126 (3):
Screw the nut (4) down to mount the ring seal (1) 1
completely in the cover (2).
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. 4
MID1497A
227
6- 71020EN - 08 - 2003
CLEARANCE OF VALVES TO ROCKER

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

the intake and exhaust valve crosspieces and adjust-
ing 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 crosspieces

the adjustment screw (1).
-- Insert the blade of the feeler gauge (3).
-- With an appropriate wrench, screw or unscrew
the adjustment screw.
1 4
-- Check that the blade of the feeler gauge (3) can
slide with a slight amount of friction. 2
5
-- Lock the nut (1) holding the adjustment screw 3
still.
6
Pre--loading pump injector rocker arms
MID1498A
the rocker arm adjustment screw (5) pump 228
injector rocker arm screw (6).
-- With an appropriate wrench (4), screw the
adjustment screw to take the pumping element to
the end of its travel.
-- Using a torque wrench, tighten the adjustment
screw to a torque of 5 Nm (0.5 kgm).
-- Unscrew the adjustment screw by 1/2 – 3/4 of a
turn.
-- Tighten the lock nut.
6- 71020EN - 08 - 2003
Ignition sequence: 1--4--2--6--3--5
Start and Balance Adjust Adjust

clockwise valves of clearance pre--load of
rotation cylinder of valves injectors of
no. of cylinder cylinder
no. no.
1 and 6 at T.D.C. 6 1 5
120° 3 4 1
120° 5 2 4
120° 1 6 2
120° 4 3 6
120° 2 5 3
CAUTION
To make the above--mentioned adjustments
correctly, you must follow the sequence given in the
table, checking correct positioning at each phase of
rotation with pin 380000150 to be inserted in the 11th
hole of each of the three sectors of 18 holes each.
6- 71020EN - 08 - 2003
PUMP INJECTOR -- REMOVAL,

REFITTING
Removal
CAUTION
gloves and shoes.
From underneath the vehicle, remove the inspection

window (3). Fit the flywheel rotation tool on the
gearbox (2) 380000137 (7) and spacer
380000138 (6)
CAUTION
The arrow shows in which direction the engine 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 T.D.C. in the phase of
combustion.
one reference mark (4), after the hole with two
reference marks (5) on the engine flywheel (1), can
be seen through the inspection window (3).
MID1499A
229
The exact position of the piston of cylinder no. 1 at the
conditions, the tool 380000150 (1) enters the hole (3)
in the engine flywheel (4) through the seat (2) of the
If this is not the case, turn the engine flywheel (4) ap-
propriately.
Remove the tool 380000150 (1).
MID1500A
230
6- 71020EN - 08 - 2003
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).
Unscrew the rocker arm shaft fixing screws (1).

MID1501A
231
With tool 380000128 (2) constrain the sliding blocks
MID1502A
232
With the tool (1) 380000148 (1) applied as in the
figure, remove the rocker arm shaft assembly. 1
MID1503A
233
Remove the crosspieces 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).
MID1504A
234
6- 71020EN - 08 - 2003
Refitting
Thoroughly clean the pump--injector seat and the

pump--injectors.
Fit the ring seals (1), (2) and (3) onto the injectors.
1
MID1505A
235
Mount the injectors and, using a torque wrench (2),
lock the screws fixing the injector brackets (1) to the
trical connections (4) locking them with a torque
screwdriver (3) to a torque of 1.36 – 1.92 Nm (0.136 2
– 0.192 kgm).
-- Position the intake and exhaust valve 3

crosspieces.
4
CAUTION
Position the crosspieces on the valve stem, all with
the largest hole on the same side. 1
MID1506A
236
CAUTION
Before reassembling the rocker arm shaft assembly,
make sure all the adjustment screws are fully
unscrewed.
Using tool 380000128 (3), constrain the sliding blocks

Apply tool (1) to the rocker arm shaft 380000148 and

position it on the cylinder head.
MID1507A
237
6- 71020EN - 08 - 2003
Tighten the screws (2) fixing the rocker arm shaft in

two stages:
Stage 1: tightening with a torque wrench (1) to a

torque of: 100 Nm (10 kgm). 2
Stage 2: closing, with tool 380000304 (3), with an 1

angle of 60°.
3
MID1508A
238
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. 1
With a new gasket, tightening the fixing screws to the

required torque and in the tightening sequence given
on page 17.
2
3
MID1509A
239
6- 71020EN - 08 - 2003
BLEEDING THE FUEL SUPPLY SYSTEM
CAUTION 3
1
gloves and shoes.
Before starting the engine, bleed the fuel system as

follows:
MID1510A
240
for the bled fuel to run off into a container, fit tubes to
the bleed screws:
2
-- (1, fig. 240), on the pre--filter mount;
-- (2, fig, 241), located on the filter support;
-- (4, fig. 242), on the front of the cylinder head.
-- Operate the pump (3) on the pre--filter mount until

fuel flows out through the screw (1) without any
bubbles of air in it. Tighten the screw (1). MID1511A
-- Repeat these steps for screw (2). 241

-- Repeat these steps for screw (4).
CAUTION
Never let fuel foul the drive belts of the alternator,
water pump, etc.
MID1512A
242
6- 71020EN - 08 - 2003
WATER PUMP -- REMOVAL, REFITTING
CAUTION
gloves and shoes.

arrow on the tightener (2) and remove the drive
belt (1).
Take out the fixing screws and remove the water

pump (5). MID1513A
243
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,
fill the cooling system with the required type and
amount of coolant.
THERMOSTAT -- REMOVAL, REFITTING
CAUTION
gloves and shoes.
Disconnect the coolant pipes from the thermostat box

(4, fig. 243).
Take out the fixing screws and disconnect the ther-

mostat box (4, fig. 243).
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.
6- 71020EN - 08 - 2003
Chapter 5 -- CATERPILLAR Engine
Model CATERPILLAR Engine
CHX620 C--15
CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Case IH -- Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Caterpillar engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service / Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6- 71020EN - 08 - 2003
GENERAL CASE -- CATERPILLAR
In effect Case IH has purchased the Caterpillar For each CHX built with a Caterpillar engine, Case will
engine with a Catarpillar waranty. This means that collate and provide on a regular basis the following
engines repairs should be performed and claimed by information to Caterpillar:
Caterpillar Dealers. The Warranty period is 24
months from the date of delivery. • CHX base unit serial number
To identify the “delivery date”, the local Caterpillar • Engine serial number
dealer has to be invited, prior to putting the machine
into service by the customer, to carry out an • Shipment date
inspection of the engine. He will complete an “Engine
Delivery Service Report” form, delivered with each
unit. The Caterpillar dealer is responsible for • Country
completing this form by entering the engine and
custumer related details, as well as entering the • Case IH dealer / importer (if known)
delivery date into the Caterpillar Product Information
System (PIS). This completed form will be sent to • Customer name and address (if known)
Caterpillar Overseas S.A. and it will confirm both the
location and the good condition of the engine at the Caterpillar will inform the local Caterpillar dealer that
“delivery date”. this Caterpillar engine will enter / has entered his
territory. This advice will assist the local Caterpillar
At the same time the Caterpillar dealer will train the dealer in assuring that spare parts are available and
customer to familiarise with the engine and its warranty documentation is prepared.
maintenance.
CATERPILLAR ENGINE
This can happen:
The Caterpillar engine specifications are calibrated
• at the Case IH dealership, after the Case IH from the factory and protected.
dealer has completed the PDI (Pre Delivery
Inspection).
The fuel injection system is an integral part of the
Caterpillar engine.
• during the operator training.
The starter motor is a Caterpillar part.
Caterpillar has limitations in the costs that are to be
covered by the Delivery Inspection. It is
The alternator is a Delco Remy component. Delco
recommended that the Case IH dealer makes
Remy is responsible for Service and Warranty.
arrangements for the Delivery Inspection with the
Warranty period is 12 months.
local Caterpillar dealer before the machine is to be
delivere to the customer.
The cooling, induction and exhaust systems are
Case IH components and are part of the base unit.
The CHX Operator’s Manual will contain all
information required to check and maintain the
engine.
The CHX Repair Manual, however, will not include
repair instructions for the Caterpillar engine.
6- 71020EN - 08 - 2003
SERVICE / PARTS
In the case of a failure of an engine component, the

customer should always call his Case IH dealer first.
The Case IH dealer will take following actions:
• The Case IH dealer will investigate the failure and

identify whether the failure is related to Case IH
parts or to the Caterpillar engine itself.
• Case IH parts should be treated as parts of the

base unit.
• If there is any doubt, the Caterpillar dealer should

be informed.
Where the failure is related to the Caterpillar engine,

the Case IH dealer has to make arrangements with
the Caterpillar dealer in his area, as required, to
intervene to perform appropriate engine repairs.
The Caterpillar dealer will effect the repair, in order

not to effect the warranty of the engine, and submit a
warranty claim to Caterpillar. The Caterpillar dealer
will receive compensation for any failures directly
from Caterpillar.
The Case IH dealer should continue to monitor the

repair process and ensure that the customer receives
a service that meet his expectations.
Caterpillar service during weekends, nights, holidays

will depend on the local Caterpillar dealer and on local
arrangements with the Case IH dealer.
In many countries, Caterpillar has a “parts and

service program” available that would allow the Case
IH dealer to perform some work on behalf of the
Caterpillar dealer. If the Case IH dealer meets the
requirements for the “parts and service program”, this
would allow him to receive training, as well as to
procure parts to perform repairs, from the local
Caterpillar dealer.
The Case IH dealer or the customer can perform

regular planned maintenance, as outlined in the
Operation and Maintenance Guide documentation
supplied with the engine, by Caterpillar for the
following: replacement of fuel filters, oil filters, coolant
conditioning filters.
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
SECTION 21 -- TRANSMISSION 1
SECTION 21 -- TRANSMISSION
CONTENT
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening torques and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shifting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of selector forks and shifter shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of transmission main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal of the half--shaft from the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal of the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of the half--shafts of the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of transmission main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of selector shafts and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calculation of shims to be installed on the shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6- 71020EN - 08 - 2003
2 SECTION 21 -- TRANSMISSION
SPECIFICATIONS
Gears 4
Differential ratio 11/50
Differential lock Yes
TIGHTENING TORQUES AND ADJUSTMENTS
Description Torque
Slotted nut on transmission main shaft 130 Nm
Axial clearance on input shaft 0.2 -- 0.6 mm
Axial clearance on drive shaft 0.2 -- 0.6 mm
Axial clearance on countershaft 0.2 -- 0.6 mm
Axial clearance on transmission main shaft 0.5 -- 0.8 mm
6- 71020EN - 08 - 2003
SPECIAL TOOLS
Number Description
380000337 Bushing to install ball and spring in selector fork
380000340 Retainer to remove the countershaft
380000341 Retainer to install the transmission main shaft and the counter shaft
380000342 Retainer to install the transmission main shaft
380000351 Puller to remove transmission main shaft bearing
NOTE: To remove bearing R (Fig. 13), a special

puller S (part n° 380000351) has to be used.
Refer to Fig. 1 and to Fig. 2 for the bore diameter.

To have good results, make the finger out of
42CrMoS4V+S material.
51146
51145
6- 71020EN - 08 - 2003
GEARBOX SHAFTS
Shaft A: half--shafts from differential
Shaft B: transmission main shaft
Shaft C: countershaft
Shaft D: drive shaft
51140
3
SHIFTING DIAGRAM
First gear: 1 -- 2 -- 3 -- 4 differential
Second gear: 1 -- 2 -- 5 -- 6 differential
Third gear: 1 -- 2 -- 7 -- 8 differential
Fourth gear: 1 -- 2 -- 9 differential
6- 71020EN - 08 - 2003
DISASSEMBLY OF TRACTION
GEARBOX
General
1. Remove the chopper body from the base unit.
2. Remove the blower from the base unit.
3. Remove the hydrostatic motor with the housing

from the gearbox.
4. Loosen or remove the items fastened to the

upper part of the gearbox: 5
-- Shifter shaft
-- Differential cable
-- Handbrake cable
-- Electric wires
5. Note the position of the differential lock lever and

shaft.
6. Remove the cover by removing bolts A.
Removal of selector forks and shifter shafts
1. Drive out roll pins B.
2. Move shifter shafts C to the right--hand side and

remove selector forks D. Ensure balls and
springs do not fall into the gearbox.
6
Removal of drive shaft
1. Remove the selector fork and shifter shafts.
2. Remove cover E.
3. Remove circlip F and slide it halfway the shaft G.
4. Drive shaft G to the left--hand side.
6- 71020EN - 08 - 2003
5. Remove ball bearing H and slide circlip F and

gear I from shaft G.
6. Remove shaft G from the left--hand side.
8
Removal of the countershaft
NOTE: This shaft can be removed without removing

shifter shafts C (Fig. 4) or input shaft G (Fig. 7).
1. Remove the four--wheel drive (refer to paragraph

headed “Four--wheel drive angle gearbox”)
(right--hand side).
2. Remove the handbrake shoe and disc (refer to

paragraph headed “Disassembly of brake shoe
and discs”).
9
3. Remove the five nuts J (Fig. 9) and drive out
bearing housing K (Fig. 10) from the inside using
a plastic hammer.
4. Install special tool L (part n° 380000340) and

install bearing housing K the other way around
(Fig. 11).
5. Drive the shaft out to the right until the left--hand

part of the shaft is detached from the left--hand
bearing.
6. Remove bearing housing K and special tool L

(Fig. 11).
10
7. Remove the shaft together with gears M and N.
Finally remove gear O.
11
6- 71020EN - 08 - 2003
Removal of transmission main shaft
NOTE: This shaft can be removed without removing

the input shaft or the countershaft.
1. Remove the four--wheel drive on the right--hand

side (refer to paragraph headed “Four--wheel
drive angle gearbox”).
2. Remove the brake shoes and discs on both sides

(refer to paragraph headed “Disassembly of
brake shoes and discs”).
3. Remove the selector forks and shifter shafts 12

(refer to paragraph headed “Removal of selector
forks and shifter shafts”).
4. Remove bearing housing P by removing the six

nuts Q and by screwing two bolts into the bearing
housing P.
5. Pull bearing R from the shaft using special puller

S (part n° 380000351) on the right--hand side.
13
6. Drive the shaft to the left--hand side and remove

slotted nut 1, lock washer 2 and bearing R1.
14
6- 71020EN - 08 - 2003
7. Remove ring 3, gear 5, needle bearing 6 and

circlip 7 through the aperture in the left--hand side
of the gearbox (Fig. 13).
8. Remove the shaft with the remaining gears from

the gearbox.
51141
15
Removal of the half--shaft from the differential

2. Remove the brake shoes and discs on both sides

(refer to paragraph headed “Disassembly of
brake shoes and discs”).
3. Carefully remove oil seal ring T, O--ring X and

circlip U on both sides.
16
6- 71020EN - 08 - 2003
4. Pull out both shafts V together with bearings W.
17
Removal of the differential
NOTE: For a possible disassembly of the differential

control lever, refer to Fig. 18.
1. Remove both half--shafts (Fig. 17).
2. Remove six nuts 8 (Fig. 19).
3. Remove bearing housing 9 by screwing in two

bolts 10 (M8x60) instead of two M8x16 bolts
(Fig. 19).
51144
4. Proceed in the same way on the other side and 18

remove differential 11 (Fig. 19).
NOTE: Remove the differential lock jaws and spring

together with the left--hand bearing housing 9.
51143
19
6- 71020EN - 08 - 2003
ASSEMBLY OF TRACTION GEARBOX
Assembly of the differential
1. Install the bearing housing 12 with six nuts 8 on

the right--hand side (Fig. 19).
2. Position the differential between bearing housing

12 and bearing housing 9, and drive bearing
housing 9 to the right--hand side (Fig. 19).
NOTE: Before driving bearing housing 9 to the

right--hand side, install the differential lock jaws and
spring between the differential and bearing housing
9 (Fig. 19).
3. Install the six nuts 8 on the left--hand side

securing bearing housing 9 (Fig. 19).
Assembly of the half--shafts of the differential
1. Install bearing W on shaft V (Fig. 20).
2. Install shaft V, circlip U, O--ring X and oil seal ring

T. Ensure that oil seal ring T is installed as deep
as possible (Fig. 21).
3. Proceed in the same way on both sides.
NOTE: An alternative way to disassemble the

left--hand half--shaft V with the differential lock is:
-- Before installation of housing 9 on the gearbox,

pre--assemble housing 9 together with shaft V,
bearing W, O--ring X, oil seal T and circlip U as
one unit.
-- Slide the differential lock jaws and spring onto

half--shaft V.
20
-- Slide the whole unit into the gearbox and secure
with nuts 8.
21
6- 71020EN - 08 - 2003
Assembly of transmission main shaft
1. Position shaft 36 in its aperture in the gearbox

and install from the left--hand side in following
sequence:
-- Sleeve 34, needle bearing 32, gear 33,

shifting gear 30, shifter ring 31 (Fig. 22).
-- Needle bearing 28, gear 29, sleeve 27, ring

26, ring 25, needle bearing 23, gear 24,
shifting gear 21, shifter ring 22 and circlip 20
(Fig. 22).
22
-- Ring 19, needle bearing 17, gear 18 and ring
16 (Fig. 22).
2. Install special tool Z (part n° 380000341)

(Fig. 23).
3. Install bearing R1 on the left--hand side of the

shaft and drive it further with the shaft in the
gearbox (Fig. 23).
4. Install special tool Y (part n° 380000342)

(Fig. 23).
5. Install bearing R on the right--hand side (Fig. 23)

and bearing housing P (Fig. 24). Drive bearing
housing P to the left--hand side and tighten it with 23
nuts Q (Fig. 24).
6. Remove special tools Z and Y.
7. Drive the shaft and bearing R1 to the right--hand

side.
8. Install lock washer 2 and slotted nut 1 (Fig. 14).

Tighten nut 1 with a torque of 130 Nm.
24
6- 71020EN - 08 - 2003
Assembly of the countershaft
Install following parts on the shaft outside the

gearbox.
1. Bearing 44 on the right--hand side (the small gear

on the right--hand side is part of the shaft).
2. Narrow ring 42.
3. Gear 41, with the wider part of the hub to the

left--hand side.
4. Wide ring 40. 25

lefthand side (Fig. 25).
Introduce the reassembled shaft in the gearbox and

install:

right--hand side (Fig. 25).
7. Gasket together with bearing housing K using

special tool Z (part n° 380000341) (Fig. 26).
Tighten bearing housing K with nuts J (Fig. 9).
8. Left--hand bearing 37, maintaining a minimum

axial clearance between the gears (Fig. 25).
26
Assembly of the drive shaft
1. Install input shaft G with the pre--assembled

left--hand bearing in the gearbox and slide gear
I with circlip F on the shaft.
2. Install the right--hand bearing and cover E.
3. Slide gear I and circlip F to the left--hand side in

the right place.
4. Install the left--hand bearing against gear I

keeping a minimum clearance and ensuring that
the filler opening in the bearing outer ring is
located at ±25° before the vertical axial line. 27
6- 71020EN - 08 - 2003
Assembly of selector shafts and forks
1. Install ball and spring in selector forks A using

special tool B (part n° 380000337) (Fig. 26).
28
2. Slide selector shafts C in forks D (the notch
pointing upwards) and secure the latter with pins
B which are themselves secured with a piece of
wire (Fig. 27).
29
Calculation of shims to be installed on the shafts
ON INPUT, DRIVE OR CLUTCH SHAFT AND THE

COUNTERSHAFT
The permissible axial clearance of these shafts is 0.2

to 0.6 mm.
1. Depth of bearing in gearbox. 2 mm

2. Raised part on the clutch hous- 1.2 mm
ing:
51142
Difference: 0.8 mm
30
3. Thickness of gasket: 0.15 mm
Total: 0.95 mm
Shims to be installed: 0.75 to 0.35 mm.
ON TRANSMISSION MAIN SHAFT
The permissible axial clearance of this shaft is 0.5 to

0.8 mm.
To calculate the shims, proceed in the same way as

explained above.
6- 71020EN - 08 - 2003
Assembly of the cover
Install the cover and adjust pawl 45 (Fig. 30) as

follows:
1. Position the shifter shaft in third or fourth gear.
2. Turn in adjusting bolt 46 until it is tight and

unscrew one turn. Tighten the lock nut.
3. Position the shifter shaft in first or second gear.

Turn in adjusting bolt 47 until it is tight and
unscrew one turn. Tighten the lock nut. 51144
31
NOTE: Make sure the differential lock control is
correctly assembled, and that the fork goes into its
slot.
6- 71020EN - 08 - 2003
SECTION 23 -- 4WD LINES 1
SECTION 23 -- 4WD LINES
CONTENT
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self--made tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4WD gearbox -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4WD gearbox -- Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4WD gearbox -- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Output shaft and clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clutch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4WD gearbox -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clutch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Output shaft and clutch -- pre assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input shaft -- pre assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Intermediate shaft -- installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Input shaft -- installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cover -- installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Clutch pre--assembly -- installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4WD gearbox -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6/71020EN - 08 - 2003
2 SECTION 23 - 4WD LINES
SPECIFICATIONS
Hydraulic engagement pressure 24 bar
Gear ratio 23/34
TIGHTENING TORQUES AND

ADJUSTMENTS
Description Description
Cylinder head bolts (item 52) 25 Nm
Allen screws which fits clutch disc plate on toothed shaft (item 31) 10 Nm
Slotted nut on output shaft (item 30) 150 Nm -- 1/4 turn
Slotted nut on input shaft (item 16) 150 Nm -- 1/4 turn
Slotted nut on intermediate shaft (item 21) 150 Nm -- 1/4 turn
Bolts on input shaft casting (item 6) 26 Nm
Backlash input gear / intermediate gear 0.2 -- 0.3 mm
6- 71020EN - 08 - 2003
SPECIAL TOOLS
Number Description
84038243 Nut ring wrench to remove/tighten the slotted nut on the output shaft
84038244 Nut ring wrench to remove/tighten the slotted nut on the intermediate shaft
84038245 Nut ring wrench to remove/tighten the slotted nut on the input shaft
84038246 Centering flange to install 4WD gearbox to the base unit
Self--made tools
Tool T1
32
33
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Tool T2
34
35
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GEARBOX SHAFTS
1. Input shaft
2. Intermediate shaft
3. Output shaft with hydraulic clutch
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4WD GEARBOX -- REMOVAL
1. Drain the oil from the gearbox.
2. Remove the drive shaft to the rear axle by

removing bolts A.
3. Disconnect and plug the hydraulic pipe coming to

the clutch at B.
30642
2
4. Remove bolts A and B, remove rubber
coupling C.
5. Remove gearbox fastening bolts at D. Note the

location and number of shims, if installed.
Remove the gearbox from the machine.
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4WD GEARBOX -- COMPONENTS
6/71020EN - 08 - 2003
1. Input shaft 28. Dowel pin
2. Intermediate shaft 29. Allen screws
3. Output shaft 30. Slotted nut
4. Gearbox casting 31. Allen screws
5. Input shaft -- housing 32. Plate
6. Bolts and washers 33. Clutch disc with outer tabs
7. Shimpac 34. Clutch disc with inner tabs
8. O--ring 35. Toothed shaft
9. Bolts and washers 36. Pressure plate
10. Cover 37. Springs
11. Bolts and washers 38. Bearing
12. O--ring 39. Bearing
13. O--ring 40. Circlip
14. Seal 41. Bearing
15. Internal retaining ring 42. Seal
16. Nut 43. Clutch cylinder outer housing
17. Ring 44. Piston guide ring
18. Bearing 45. Piston guide ring
19. Bearing 46. O--ring
20. Input gear 47. Seal ring
21. Slotted nut 48. Piston
22. Lock washer 49. O--ring
23. Spacer 50. Clutch cylinder inner housing
24. Bearing 51. Dowel pin
25. Bearing 52. Bolts
26. Intermediate gear 53. O--ring
27. Clutch casing 54. Seal ring
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4WD GEARBOX -- DISASSEMBLY
To disassemble the 4wd gearbox, proceed as

follows:
1. Drain the oil from the gearbox (refer to the 4. Remove the input shaft assembly (5). Do not
Operator’s manual). damage the shimpac (7) and the O--ring (8).
2. Remove the bolts (9) and take away the cover 5. Remove the bolts and washers (11).
(10). The cover (10) was sealed with a liquid
sealant. 6. Pull out the output shaft with the hydraulic clutch
(43). Do not damage the O--ring (12).
3. Remove the bolts and washers (6).
6/71020EN - 08 - 2003
Intermediate shaft
7. In the gearbox casting (4), unlock the slotted NOTE: The clutch housing (27), the intermediate
nut (21). gear (26) and the bearing inner ring (25) will stay on
the intermediate shaft (2).
8. Remove the slotted nut (21), the lock washer (22)
and the spacer (23). 10. Remove the Allen screws (29) to remove the
clutch casing (27) from the intermediate
NOTE: To remove the slotted nut use special tool shaft (2).
84038244.
11. Press out the intermediate shaft (2) from the
9. Press out the intermediate shaft (2). intermediate gear (26) and the bearing inner
ring (25).
6- 71020EN - 08 - 2003
Input shaft
12. Press out the input shaft (1). Do not damage the
O--rings 13.
13. Remove the seal (14).
NOTE: The seal (14) will be damaged when it is

removed.
14. Remove the internal retaining ring (15).
15. Unlock the slotted nut (16).
NOTE: To remove the slotted nut use special tool

84038245.
16. Remove the slotted nut (16) and the lock

washer (17).
17. Press out the input gear (20) and remove the
bearings (18) and (19).
6/71020EN - 08 - 2003
Output shaft and clutch
18. Remove the slotted nut (30). 20. Remove the seal (42), the bearing outer ring
(41), the circlip (40) and the bearing (39).
IMPORTANT: Place the complete clutch assembly
under a press before removing the slotted nut 21. Remove the bearing inner ring (41) from the
completely, the clutch disc assy is springloaded. output shaft (3).
19. Press the output shaft (3) out of the clutch

cylinder (43).
6- 71020EN - 08 - 2003
Clutch cylinder
22. Apply some air pressure to the cylinder to 25. In the outer housing (43), replace the piston
remove the piston (48) from its housing. guide rings (44) and (45).
23. Remove the bolts (51). 26. Replace the O--ring (46) and the seal ring (47).
24. Take apart the clutch cylinder inner housing (50) 27. On the inner housing (50), replace the O--ring
and the clutch cylinder outer housing (43). (53) and the seal ring (54).
6/71020EN - 08 - 2003
4WD GEARBOX -- ASSEMBLY
Clutch cylinder
1. Install the dowel pins (51) in the cylinder (48).
9
2. Install the O--ring (53) and the seal ring (54).
10
3. Install the cylinder (48). Rotate the cylinder so
the dowel pins (51) fits the holes (A).
11
4. Install the O--ring (49).
12
6- 71020EN - 08 - 2003
5. Install the two piston guide rings (44) and (45).
6. Install the O--ring (46) (not visible on this picture)

and the seal ring (47).
13
7. Install the outer housing (43).
IMPORTANT: Take care the oil return line (R) in the

inner housing is positioned to the breather opening
(B) and the oil pressure opening (P) in the outer
housing as shown.
With the breather opening (B) at the top, the oil return
line (R) should be at the bottom.
8. Apply loctite to the bolts (52) and tighten them to

a torque of 25 Nm.
14
Output shaft and clutch -- pre assembly
9. Install the bearing (41).
10. Install the seal (42) and set it parallel to its

housing.
IMPORTANT: The bearing (41) can not be installed

after installation of the seal.
15
11. Support the clutch cylinder and install the output
shaft (3).
16
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12. Rotate the pre--assembly, install the circlip (40).
17
18
14. Install the bearing ring (38).
19
15. If disassembled, install plate (32) on toothed
shaft (35). Apply loctite to bolts (31) and tighten
them to 10 Nm.
20
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16. Install the clutch discs (33) and (34).
17. Install the springs (37).
21
18. Install the bearing ring (38) on the pressure plate
(36).
22
19. Place the pressure plate (36) on top of the
springs.
23
20. Install the pre--assy on the special tool (T1) as
shown.
21. Place the ring with the rollers of bearing (38).
24
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22. Take the cylinder assy and place it on top of the

disc assy.
23. Install the threaded rods. Do not tighten the nuts

(T1) yet.
24. Align the teeth of the pressure plate (36) with

teeth on the shaft (35) (Fig. 24).
25. Press the clutch disc assy on the output shaft by

tightening the nuts (T1) simultaneously until they
block.
25
26. Turn the complete assembly upside down.
27. Degrease the thread on the output shaft (3) and

the slotted nut (30).
26
28. Install the slotted nut (30) with loctite 270.
NOTE: Install the slotted nut (30) with the chamfer on

top.
29. Tighten the slotted nut (30) to a torque of 150

Nm. Then loosen the slotted nut (30) 1/4 turn.
NOTE: Use special tool 84038243.
27
30. Lock the slotted nut (30) with an extra 4 punch
marks as shown.
31. Remove the special tool (T1).
28
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29
Input shaft -- pre assembly
33. Install the bearing outer rings (18) and (19) into
the housing (5).
30
34. Heat the bearing inner ring (19) to 80°C and
install it on the input gear (20).
31
35. Install the bearing housing (5) on the input gear
(20).
36. Install the bearing inner ring (18).
32
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37. Install the lock washer (17) with its internal notch
aligned with the notch in the input gear (20).
33
38. Install the slotted nut (16).

the down side.
39. Tighten the slotted nut (16) to 150 Nm. Then

loosen the slotted nut 1/4 turn.
40. Lock the slotted nut with the lock washer.
34
NOTE: Use the input shaft (1) to prevent the input
gear from rotating while tightening the slotted nut.
35
41. Install the internal retaining ring (15).
36
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Intermediate shaft -- installation
42. Heat the intermediate gear (26) to 185°C and

install it on the intermediate shaft (2).
NOTE: Take care the gear is against the flange at the

end of the intermediate shaft.
37
43. Heat the bearing inner ring (25) to 80°C and
install it on the intermediate shaft (2).
44. Install the clutch casing (27).
45. Apply thread locking compound on the thread of

the six bolts (29) and install them.
38
NOTE: Tighten the bolts after installing the dowel
pins.
46. Install the two dowel pins (28).
NOTE: The dowel pins must be flat with the surface

of the clutch casing.
47. Tighten the six bolts (29).
48. Lock the dowel pins in place with two punch

marks.
39
49. Install the bearing outer rings (24) and (25) in the
gearbox casting (4).
40
6/71020EN - 08 - 2003
50. Install the intermediate shaft (2).
51. Install the special tool (T2).
NOTE: The special tool prevents the intermediate

shaft from falling out and also prevents the
intermediate from rotating while tightening the
slotted nut (see further).
41
42
53. Install the spacer (23), the lock washer (22) and
the slotted nut (21).

the down side.
54. Tighten the slotted nut (21) to 150 Nm. Then

loosen the slotted nut 1/4 turn.
55. Lock the slotted nut with the lock washer.
56. Remove the special tool (T2). 43

Input shaft -- installation
57. Install the input shaft pre--assembly.
NOTE: Be sure the grease opening (G) is at the

same side as the oil fill opening (F).
44
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58. With the castings parallel, measure the distance

(M) between the two castings.
59. Calculate the thickness (T) of the shimpac (7) to

be used as follows:
T = M + 0.3 mm
NOTE: Shim thickness 0.3 -- 0.2 -- 0.15mm are

available.
45
60. Install the shimpac (7).
61. Install the input shaft and tighten the housing with
two bolts (6).
62. Install a dial gauge (D) to measure the backlash.
46
63. Set the probe perpendicular to the teeth.
64. Block the intermediate shaft and measure the

backlash. The backlash should be between 0.2
-- 0.3 mm.
65. If required, adjust the thickness of the

shimpac (7). To decrease the backlash,
decrease the thickness of the shimpac.
47
66. Install O--ring (8).
48
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67. Install the input shaft pre--assembly (5).
NOTE: Be sure the grease opening (G) is at the

same side as the oil fill opening (F) (see Fig. 44) .
68. Tighten the bolts (6) to a torque of 26 Nm.
49
69. Install the seal (14).
50
70. Install the two O--rings (13).
51
71. Install the input shaft (1).
52
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Cover -- installation
72. Apply sealing compound on the casting cover

surface.
53
73. Install the cover (10).
74. Install the bolts and washers (9).
54
Clutch pre--assembly -- installation
75. Align the clutch discs.
55
76. Install the clutch pre--assembly.
NOTE: The breather (B) and the oil pressure

opening (P) must point towards the oil filler
opening (F).
77. Install the bolts and washers (11).
56
6/71020EN - 08 - 2003
4WD GEARBOX -- INSTALLATION
1. Install the drive flange on the handbrake shaft.
2. Install the centering flange shown in Figure 57

(special tool) on the drive flange on the
handbrake shaft.
3. Install the 4WD gearbox on the flange.
4. Install bolts D with sufficient shims between the

gearbox and the base unit frame, and fasten the
gearbox with bolts D (Fig. 58). 30643
57
5. Remove the special tool and install the rubber
coupler.
6. Install drive shaft F with bolts A.
7. Connect the hydraulic pipe to the clutch housing

at B.
8. Fill the gearbox housing with hydraulic oil (refer

to the Operator’s Manual).
30642
58
9. Bleed the system:
a) Put the gearbox in neutral.

b) Apply the handbrake and make sure the ma-
chine cannot move.
c) Start the forage harvester engine.
d) Engage the four--wheel drive.
e) Open bleed screw A (Fig. 59) until the oil es-
caping is free from air bubbles, then close the
bleed screw.
30644
59
6- 71020EN - 08 - 2003
SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 1
SECTION 25 -- FRONT MECHANICAL DRIVE
Chapter 1 -- Final drives CHX320
CONTENT
Final drives -- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Final drives -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
End play adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6- 71020EN - 08 - 2003
2 SECTION 25 - FRONT MECHANICAL DRIVE -- CHAPTER 1
FINAL DRIVES -- DISASSEMBLY
Output shaft
1. After draining the oil, remove cover P, three bolts

G, washer F, shims H and the cover on top of the
housing.
2. Press output shaft B out of the housing, keeping

bearing C and seal D installed on the shaft.
3. Remove the rings of bearings C and E out of the

housing.
4. Remove sealing D from the output shaft.
Input shaft
1. Remove bearing covers R and S and shims I.
2. Push the shaft out of the housing.
3. Remove the bearing rings out of the housing and

remove the bearings from the shaft.
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50361
6- 71020EN - 08 - 2003
FINAL DRIVES -- ASSEMBLY Output shaft
Input shaft 1. Install the rings of bearings C and E in the

housing.
1. Install both bearings on the shaft and oil the
2. Grease seal D (with multipurpose grease NLGI2)
bearings.
and install the seal and bearing C on shaft B.
2. Introduce the preassembled shaft in the housing.
3. Introduce the gear in the housing.
3. Install the bearing rings of bearings L and M.
4. Push shaft B in the housing until the seal is
completely inside.
4. Install bearing cover R using sealing paste.
5. Lay the housing flat on the wheel flange.
5. Install a new seal in bearing cover S and install
the cover.
6. Install circlips N, bearing E and washer F.
End play adjustment
7. Press the bearing on the shaft by tightening bolts
G to 90 Nm (66 lbf.ft) torque.
1. Tighten the bolts of cover S to 34 Nm (25 lbf.ft)
torque. Preload adjustment
2. Loosen the bolts.
1. Loosen the three bolts G until a small end play is
obtained on the output shaft.
3. Tighten the bolts again and at the same time
check with a dial gauge on the top of shaft K
2. Install a dial gauge on washer F and tighten the
whether the end play is still 0.1 mm (0,004’’).
three bolts G uniformly until an end play = O is
obtained.
4. Measure the end play between the housing and
bearing cover S and install shims I for the same
3. Remove the three bolts G and washer F.
value. Tighten the bolts again to 34 Nm (25 lbf.ft)
torque. Check the end play again which should
4. Measure distance X between the shaft end and
now be 0.05 to 0.1 mm (0,002’’ -- 0,004’’). If not
the bearing edge.
so, shims should be removed or added.
5. Install shims to the same value as the measured
5. Apply sealing paste between bearing cover S
value X -- 0.3 mm (X -- 0,012’’).
and the housing, and between the separate
shims.
6. Install washer F and bolts G and tighten the bolts
to 235 Nm (173 lbf.ft) torque.
6. Tighten the bolts of bearing cover S to 34 Nm
(25 lbf.ft) torque.
7. Apply sealing paste to cover P and install the
cover. Install the housing cover with a new
gasket.
8. Fill the final drive housings with 5 litres oil each

(Refer to the Operator’s Manual).
6- 71020EN - 08 - 2003
50361
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SECTION 25 -- FRONT MECHANICAL DRIVE --CHAPTER 2 1
SECTION 25 -- FRONT MECHANICAL DRIVE
Chapter 2 -- Final drives CHX420--520--620
CONTENT
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel bolt - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Final drive - R./ I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Final drive D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6- 71020EN - 08 - 2003
2 SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2
SPECIFICATIONS
Gear ratio 10/75
Max. input rpm (30 km/h -- 18.6 miles/h) 998 rpm
Max. output rpm (30 km/h -- 18.6 miles/h) 132
Nom. input torque 1560 Nm (1150 ft.lbs) 1630 Nm (1200 ft. lbs)
Nom. output torque 15750 Nm (11620 ft.lbs) 16500 Nm (12170 ft. lbs)
Input shaft axial end play 0.05 -- 0.1 mm (0.00197” -- 0.00394” )
Approx. total weight 245 kg (540 lbs)
Oil capacity 5 litres (1.3 US gal)
TIGHTENING TORQUES
Description Torque
Bolt final drive cover 28 -- 45 Nm ( 21 -- 33 ft.lbs)
Bolt input shaft cover 34 Nm (25 ft.lbs)
Bolt in output shaft 235 Nm (175 ft.lbs)
Level plug 70 -- 90 Nm (50 -- 65 ft.lbs)
Magnetic plug 90 -- 110 Nm (65 -- 80 ft.lbs)
Filler / Breather plug 90 -- 110 Nm (65 -- 80 ft.lbs)
Bolt final drive to traction beam 440 Nm (325 ft.lbs)
Wheel nuts torque 610 -- 732 Nm (450 -- 540 ft.lbs)
6- 71020EN - 08 - 2003
GEARBOX SHAFTS
1. Input shaft
2. Output gear
3. Wheel hub
6- 71020EN - 08 - 2003
WHEEL BOLT - REPLACEMENT
To replace a wheel bolt, proceed as follows:
1. Remove the traction wheel.
CAUTION
Install a suitable and safe support underneath the
combine traction axle to support the combine.
2. Remove the sleeve (1) at the final drive.
2
3. Turn the output shaft of the final drive until wheel
bolt (2) (the bolt to be replaced) is aligned with
notch 3 in the final drive housing.
4. Drive out the wheel bolt (2).
5. Insert a new wheel bolt and pull it on its place

with a wheel nut.
NOTE: Make sure the notch on the wheel bolt is in

line with the step on the output shaft.
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FINAL DRIVE - R./ I.
To remove a final drive, proceed as follows:
1. Remove the traction tyre from the combine.
CAUTION
Install a suitable and safe support underneath the
combine traction axle to support the combine.
2. Disconnect the sleeve (1) at the final drive.
4
3. Support the final drive.
CAUTION
A final drive is heavy. Take extreme caution when
removing the final drive! Use a supporting device
which can handle this weight!
4. Loosen the bolts (2) and remove

the final drive (3).
NOTE: If the 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”).
6- 71020EN - 08 - 2003
To install the final drive, proceed as follows:
1. Insert the two dowel pins (4) in the final drive

housing.
2. Install the final drive onto the traction axle of the

combine.
CAUTION
A final drive is heavy. Take extreme caution when
handling the final drive! Use a supporting device
which can handle this weight!
6
3. Apply thread locking compound type 1
(Loctite 242) to the bolts (2) and install them.
4. Tighten the bolts (2) to a torque of 440 Nm

(325 ft.lbs)
5. Fill the final drive with oil (Refer to the

Operator’s Manual, section 4 -
“Lubrication and Maintenance”).
6. Install the traction wheel and tighten the wheel

nuts to a torque between 610 and 732 Nm
(450 and 540 ft.lbs).
6- 71020EN - 08 - 2003
FINAL DRIVE D./A.
Disassembly
Output shaft
1. After draining the oil, remove the covers (5)

and (10).
2. Remove the nut (11), the lock plate (12) and the
nut (13).
3. Remove the inner ring of the bearing (8) from the

output shaft (18).
4. Remove the circlip (6).
5. Press the wheel hub (18) out of the final drive

housing.
NOTE: The inner ring of the bearing (2) and the

spacer (3) will remain on the shaft. The seal (1) will
remain in the housing.
IMPORTANT: In case mud seals are installed, only

a part of the mud seal will remain on the shaft. The
other part will remain in the housing. The surface
between the two parts of the mud seal should be
oiled before touching them.
6. Remove the spacer (3) and the inner ring of the

bearing (2) from the output shaft (18).
7. Remove the output gear (4).
8. Use a soft punch to remove the outer rings of

bearings (8) and (2) out of the final drive housing.
9. If necessary, remove the seal (1) from the final

drive housing.
NOTE: The seal (1) will be damaged when it is

removed.
Input shaft
1. Remove the bolts (9) and the cover (13).
NOTE: Shims (15) behind the housing. The seal (14)

and the O-ring (16) will remain in the cover.
2. Remove the input shaft (17) with the bearings

(19) and (20).
3. If necessary, remove the inner rings of the

bearings (19) and (20) from the input shaft.
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
9
1. Seal 6. Circlip 11. Nut 16. O--ring
2. Bearing 7. Seal 12. Lock plate 17. Input shaft
3. Spacer 8. Bearing 13. Nut 18. Output shaft
4. Output gear 9. Bolts 14. Seal 19. Bearing
5. Cover 10. Cover 15. Shims 20. Bearing
6- 71020EN - 08 - 2003
Assembly
Input shaft
1. Install the bearings (19) and (20) on the input

shaft (17).
2. Insert the input shaft (17) assembly into the final
drive housing.(as shown)
NOTE: Fill up the seal (14) with grease NLGI-2.
3. Install a new O-ring (16). (see fig. 9)
4. Measure the distance between the final drive

housing and the bearing (19) to determine the
number of shims to be installed to have an end
play between 0.05 and 0.1 mm. Install or remove
as much the shims (15) as necessary to obtain
that value.
10
5. Install and tighten the four bolts (9) of the final
drive housing (13).
11
6- 71020EN - 08 - 2003
Output shaft
1. Install the both outer rings of the bearings (2) and

(8) in the final drive housing.
2. Install the seal (1) as shown and apply grease to

the lip of the seal.
12
3. Install the inner ring of the bearing (2) and the
spacer (3) on the output shaft (18).
13
4. Slide the output gear (4) into the final drive
housing.
5. Bring the output shaft assembly into the final

drive housing, through the output gear.
14
6- 71020EN - 08 - 2003
6. Install the circlip (6) (see fig. 9) and the
bearing (8).
7. Install the first nut (13) and tighten it to a torque

of 250 Nm. (184.4 ft.lbs)
8. Rotate the output shaft (18) three to four times in

the housing.
9. Repeat the last two sequences until the nut (13)

does not turn when tightening to a torque of
250 Nm. (184.4 ft.lbs)
10. Loosen the nut (13) and retighten until there is no

free play (20 to 40 Nm) (14.8 to 29.5 ft.lbs) 15
+72° further, to give preload.
11. Install the lock plate (12) and the second nut (11)
and tighten it to a torque between
1950 and 2050 Nm (1438 and 1512 ft.lbs), while
holding the first nut in the same position.
12. Bend the lips of the lock plate (12) to secure the
both nuts (11) and (13).
16
13. Install the cover (10), using sealant.
17
14. Install the cover (5) with a new seal (7) and
tighten the bolts with a torque between 28 and
45 Nm. (21 and 33 ft.lbs)
15. Fill up the final drive gearbox with 5 litres

(1.3 US gal) of oil as described in the
Operator’s manual, section 4 -
“Lubrication and Maintenance”.
6- 71020EN - 08 - 2003
SECTION 29 -- HYDROSTATIC SYSTEM 1
SECTION 29 -- HYDROSTATIC SYSTEM
CONTENT
Hydrostatic circuit and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic Pump and motor Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Multifunction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Servo Solenoid Valve Energized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fixed Displacement Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Motor Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil Cooler bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Filling and bleeding the hydrostatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Starting the hydrostatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6- 71020EN - 08 - 2003
2 SECTION 29 -- HYDROSTATIC SYSTEM
HYDROSTATIC CIRCUIT AND

COMPONENTS
Circuit
A Engine
B Main drive transfer gearbox
C1 Hydrostatic pump -- Feed rolls drive
C2 Hydrostatic pump -- Traction
D Work hydraulics pump
E Steering hydraulics pump
F Low pressure pump
OC Oil cooler
P Filler opening with filter
PF Pressure filter
Q Drain hose
R Hydraulic/Hydrostatic oil reservoir
S Breather with filter and non--return valve
SF Suction filter
SV Stop valve
TV Thermovalve
Z Collector block
17 Low pressure system
18 Hydrostatic motor -- Traction
19 Hydrostatic motor -- Feed rolls drive
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
HYDROSTATIC PUMP AND MOTOR

IDENTIFICATION PLATE
Each hydrostatic pump and motor has an
identification plate attached to the housing. The
identification plate will include the model number, the
model code and the serial number.
BSC1349A
Model Code A Serial Number C

The Sauer Danfoss model code defines the specific The Sauer Danfoss serial number identifies the
build configuration of each unit and must be used location and date of manufacture and the unit
when ordering spare parts or a new pump or motor. sequence in the build.
The letter coding indicates the location of original

Model Number B assembly “A” indicates assembly in Ames, Iowa,
The Sauer Danfoss model number is used by the USA “N” indicates assembly in Neumunster,
factory in manufacturing. A new unit can be ordered Germany.
by the model number.
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.
6- 71020EN - 08 - 2003
HYDROSTATIC PUMP
Pump operation
NEUTRAL
The hydropump swash plate is perpendicular to the

axis of rotation. There is no axial movement of the
pistons so there is no displacement in the high
pressure lines. The charge pump turns and serves oil
to the check valves which are open and to the charge
pump relief valve. If the pressure exceeds 24 bar, the
charge pump relief valve 3 will open and oil will flow
through this valve to the pump case.
RIGHT--HAND ROTATION
The operator moves the control handle of control

valve 4, thereby actuating the servocylinders.
The swash plate is now positioned at a certain angle.

The hydropump pushes oil under pressure to the
hydromotor. The charge check valve on the high
pressure side is closed. The hydromotor runs. The
shuttle valve is actuated. Oil flows from the low
pressure side through the charge pressure relief
valve (24 bar) to the motor case. This oil serves as
a coolant for the hydromotor and will be added to the
lubrication oil. Via a case drain line the oil will flow to
the pump case, through the pump case and over the
heat exchanger back to the reservoir.
LEFT--HAND ROTATION
With the handle in the rearward position, the

servocylinders are actuated in the opposite direction
and the swash plate is moved to the opposite angle.
The hydropump pushes the oil under high pressure
to the other side of the hydromotor causing the
output shaft to turn in the opposite direction.
6- 71020EN - 08 - 2003
Circuit 1 Pump with variable displacement

2 Charge pump (gerotor--type pump)
A Engine 3 Pump charge pressure relief valve (24 bar)
B Main drive transfer gearbox 4 Displacement control valve (electrical)
C1 Hydrostatic pump -- Feed rolls drive 5 Servo pressure relief valves
C2 Hydrostatic pump -- Traction 6 Multifunction valves
D Work hydraulics pump 6a Set at 420 bar
E Steering hydraulics 6b Set at 450 bar
F Low pressure pump 6c By--pass
OC Oil cooler 6d Charge check valves
P Filler opening with filter 7 Motor charge pressure relief valve (24 bar)
PF Pressure filter 8 Shuttle valve (spring--centred to a closed posi-
R Hydraulic/Hydrostatic oil reservoir tion)
The shuttle valve establishes a circuit between
TV Thermovalve
the main line that is at the low pressure side and
Z Collector block the charge pressure relief valve 7.
9 Motor with fixed displacement
14 Servocylinder
15 Orifice check valves
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6- 71020EN - 08 - 2003
Variable Displacement Pump

The variable displacement pump is designed to The swashplate angle can be varied by the control
convert an output power from the engine into piston, altering the swashplate 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 (swashplate), 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
4
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
6- 71020EN - 08 - 2003
Pump characteristics
The hydrostatic pump model code can be found on

the pump identification plate. The model code is
containing all pump characteristics.
(Feed rolls drive)
90 R 100 KA 5 CK 80 S 3 C7 E 00 GBA 42 42 24
90 Series 90, closed circuit

R Right hand rotation pump (clockwise rotation)
100 Maximum displacement 100 cc/rev (6.1 in3/rev)
KA Electrical displacement control - standard linear -- with MS connector
5 Pressure limiter function in ports A and B, with smaller orifice in HD poppet
CK Endcap with SAE--C adapter -- sealed cover -- 25 teeth coupling (20/40 pitch)
80 Twin ports
L Integrated pressure filtering (long)
3 No mechanical displacement limitation
C7 Splined shaft - 23 teeth - pitch 16/32
E Charge pump displacement 20 cc/rev
00 No control orifice
GBA Brake manifold installed
42 420 bar high pressure setting port A
42 420 bar high pressure setting port B
24 24 bar charge pump pressure setting
(Traction)
90 R 100 KA 5 AB 80 L 3 G1 E 03 GBA 42 42 28

R Right hand (clockwise rotation)
KA Electrical displacement control - standard linear -- with MS connector
5 Pressure limiter function in ports A and B
AB Endcap with SAE--A adapter -- sealed cover -- 9 teeth coupling
80 Twin ports
L Integrated pressure filtering (long)
3 No mechanical displacement limitation
G1 Splined shaft - 25 teeth - pitch 20/40
E Charge pump displacement 20 cc/rev
03 Control orifices for electr displ control P=0.81 mm -- A, B = 0.8mm -- TA, TB =1.3 mm
GBA Brake manifold installed
42 420 bar high pressure setting port A
42 420 bar high pressure setting port B
28 28 bar charge pump pressure setting
6- 71020EN - 08 - 2003
Multifunction valve
Two multifunction valves (G) are incorporated in the

hydrostatic pump.
The multifunction valve contains four different

valves.
• A Charge Pressure Check Valve to keep the

system full of oil.
• A Pressure Limiter Valve to make the work

pressure (delta p) does not exceed 420 bar (6090 42567
psi). 5
• A High Pressure Relief Valve to protect the

system from shock loads above 450 bar (6525
psi) (delta p).
• The multi function valve also includes a 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.
A. Bypass Actuator J. Valve Seat

B. Pressure Limiter Adjustment Screw K. Spring
C. Pressure Limiter Lock Nut L. Pressure Limiter Poppet Seat
D. Pressure Limiter Housing M. Pressure Limiter Valve Poppet
E. Pressure Limiter Spring 6a. Charge Check Valve
F. Spring Seat 6b. Pressure Limiter (420 bar) (6090 psi)
G. Check Valve Carriage 6c. High Pressure Relief Valve (450 bar) (6525 psi)
H. High Pressure Relief/check Valve Poppet 6d. Bypass Valve
6- 71020EN - 08 - 2003
6
Multi Function Valve Cross Section
Multi Function Valve Schematic
6- 71020EN - 08 - 2003
1. Charge Check Valve 6a
When the pressure on carrier (A) is greater than the

pressure of spring (B), carrier (A) moves to the left
taking piston (C) with it.
Oil will flow from (Y) to (X) to fill up the system.
8
2. Pressure Limiter 6b
When the high pressure exceeds 420 bar (6090 psi),

poppet (D) will move to the left, compressing spring
(E).
Oil will flow from (X) to (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.
9
3. High Pressure Relief Valve 6c
When the pressure limiter opens at 420 bar (6090

psi) a certain oil flow will escape through (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 (X) to (Y). In this phase, the
pressure limiter function remains active as well (oil
keeps flowing from (X) to (Z).
10
6- 71020EN - 08 - 2003
4. Bypass Valve 6d
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
and oil flows from (X) through opening (G) to (Z).
The plunger (C) will also move easily to the left

allowing the pressurized oil from (X) to flow to (Y). As
pressure increases to the valve which equals spring
(B), the plunger (C) will move to the left and allowing
oil to flow directly from (X) to (Y) (oil keeps flowing 11
from (X) to (Z).
NOTE: When the machine has to be towed, shift the

gearbox to neutral.
6- 71020EN - 08 - 2003
Servo Valve As the oil flow increases to the servo cylinder through
port, 31, the displaced oil on the opposite servo
System in Neutral cylinder will flow back through port, 32, and orifice,
33, past the spool, 28, through to the case drain
through orifice, 34, and port, 35.
Charge pump oil flows to both cavities, 20, from port,
21, oil also flows from port, 21, through the check
valve orifice, 22, to the central land of servo spool NOTE: When the opposite direction of travel is
valve, 28. selected spools, 26, and 28, will move to the left. The
feed pressure to the servo cylinder will be through
orifice, 33, and port, 32. Displaced oil from the
Charge pressure oil flows equally from cavity, 21,
opposite cylinder will flow to case drain through port,
through the orifices, A and B, to cavity, 23, to the case
36, and orifice, 37.
drain. As the electric solenoid, 24, is not energized
oil flow from cavities, 20, into cavity, 23, is the same,
so the pressure in cavities, 25 and 27, will be equal As the swash plate moves the mechanical feed back
and the spool assembly will remain in neutral. linkage will move to the right compressing its internal
spring when the spring force is equal to the pressure
in cavity, 25, spool, 28, will move back to neutral
Servo Solenoid Valve Energized
holding the swash plate in its new position.
Anchor, 29, of the servo solenoid valve 10a moves
Any movement of the swash plate or hydrostatic
to the left when the solenoid is energized. The
control lever will affect the balance of spring force
movement of anchor, 29, is proportional to the
current through the solenoid dependant on the and cavity pressure. The spool, 28, will then move to
a position where the balance is restored
position of the hydrostatic lever.
If a shock load occurs in the system it will be felt by

Oil flow from the left hand cavity, 20, to case drain
the pump swash plate and will create an increase in
cavity, 23, will decrease and the flow from the right
pressure in the servo cylinder lines and servo valve.
hand cavity, 20, to cavity, 23, will increase. The
To protect the servo valve from the increased
pressure in cavity, 25, on the left side of the servo
spool, 26, is higher than the pressure in cavity, 27, on pressure in the system the check valve 10c will open
the right hand side of the spool, 28, causing the connecting the servo cylinder lined directly to the
charge pressure circuit. In this circuit the pressure is
spools, 26 and 28, to move to the right.
limited by the charge pressure relief valve.
The charge pump oil can now flow from the center of
spool, 28, through the check valve orifice, 22, to the
hydrostatic pump servo cylinder through orifice, 30,
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
6- 71020EN - 08 - 2003
A B
12
Servo Valve Cross Section
13
Servo Valve Schematic
6- 71020EN - 08 - 2003
HYDROSTATIC 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 swashplate (path of least
resistance). As the piston rides up the swashplate
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 or
attachments/feed rolls drive.
5
3 2
DS00N035
14
1. Swashplate 4. Cylinder Block
2. Piston 5. Shuttle Spool
3. Flushing Valve
6- 71020EN - 08 - 2003
Drive Motor Characteristics
The hydrostatic motor model code can be found on

the motor identification plate. The model code is
containing all motor characteristics.
(Feed rolls drive)
90 M 100 NC 0 N V N 0 C7 W 00 NNN 00 00 H0

M Fixed displacement bi-directional rotation
NC Standard
0 Standard
V Endcap with integrated feeder drive stop function
U Axial ports (SAE J518C code 62) (special end cap with FOI and increased flushing)
N Standard
0 Standard
W Standard loop flushing function
00 Standard
NNN Standard Hardware
00 Standard
00 Standard
H0 Loop flushing orifice diameter 2.4 mm (0.094″) -- 16 bar opening pressure
(Traction)
90 M 100 NC 0 N 8 N 0 C7 W 00 NNN 00 00 F3

M Left hand (counterclockwise rotation)
NC Standard
0 Standard
N Standard
8 Twin ports (SAE J518C code 62)
N Standard
0 Standard
W Standard loop flushing funstion
00 Standard
NNN Standard hardware
00 Standard
00 Standard
F3
6- 71020EN - 08 - 2003
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 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.
15
1. Thermostat Assembly
2. Sleeve
3. Seal
4. Spring
A. Inlet Port
B. Reservoir Port
C. Oil Cooler Port
6- 71020EN - 08 - 2003
FILLING AND BLEEDING THE

HYDROSTATIC SYSTEM
After repair or replacement of a hydrostatic element

a complete refill is required.
NOTE: Before mounting a new motor or a new pump,

shipment oil should be drained from the new pump
or motor case.
1. Place the machine on level ground.
2. Place the wheel chocks in front and behind the

traction wheels to keep the machine stationary.
3. Place the ground speed control lever and the

gearshift lever in the cab in neutral position.
4. Disconnect the sleeves (1) on both sides of the

traction gearbox.
CAUTION
Before disconnecting the sleeves, secure the
machine safely in place by placing adequate wheel
chocks against the front and the rear of both traction
wheels and steering wheels.
16
5. Fill the hydraulic/hydrostatic oil reservoir with
hydrostatic oil.
6. Loosen the traction hydrostatic motor drain

plug (1) and bleed the charge line and motor
housing until oil comes through the drain plug.
7. Tighten the drain plug (1).
17
6- 71020EN - 08 - 2003
8. Loosen the feed rolls hydrostatic motor drain

plug (2) and bleed the charge line and motor
housing until oil comes through the drain plug.
9. Tighten the drain plug (2).
18
10. Open the gauge connection (3) on the feed rolls
hydrostatic pump and bleed until oil escapes
at (3).
11. Tighten the gauge connection (3).
19
12. Open the gauge connection (4) on the traction
hydrostatic pump and bleed until oil escapes
at (4).
13. Tighten the gauge connection (4).
20
14. Disconnect the connector (1) in the engine
compartment.
• CHX320--420--520 (Iveco Engine)
21
6- 71020EN - 08 - 2003
• CHX620 (Caterpillar engine)
NOTE: Disconnecting the connector (1) allows to

crank the engine without starting it.
22
15. Connect a manometer, preferably a damped
one, with a 500 bar range in gauge connection (1)
(high pressure forward).
16. Crank the engine with the starter motor for 30

seconds, wait for one minute to cool the starter
motor, crank again for 30 seconds or until a
minimum pressure of 20 bar has been reached.
17. Reinstall the electric connector (1) in the engine

compartment (Fig. 21 and 22).
18. Top--up the hydraulic/hydrostatic oil reservoir

with hydrostatic oil as explained in the Operator’s
Manual. 23
STARTING THE HYDROSTATIC SYSTEM
1. Start the engine.
IMPORTANT: Immediately after starting the

recorded pressure should be minimum 28 bar. If not
stop the engine and bleed again the complete
hydrostatic system.
2. Switch the harvest switch to its harvest position

(field mode ).
3. Let the engine run at low idle, shift to fourth gear

and apply the parking brake.
4. Gently push the hydrostatic control lever forward

a short stroke, so a pressure of 200 bar is
recorded. Keep the pressure on for one minute.
5. Return the hydrostatic control lever to neutral.
6. Gently push the hydrostatic control lever to

reverse until the hydrostatic pump makes the
same noise as in step 3. Keep the pressure on for
one minute.
7. Return the hydrostatic control lever to neutral.
6- 71020EN - 08 - 2003
8. Shift the gearbox to neutral and release the

parking brake.
9. Position the hydrostatic control lever at half

stroke for one minute, both forward and in
reverse.
10. Engage the cutterhead.
11. Engage the feed rolls for one minute both in

reverse and in forward.
12. Increase the engine speed to high idle
13. Position the hydrostatic control lever at

maximum forward and maximum rearward for
two minutes each.
At the same time, forward and reverse the feed

rolls. Change the feed roll speed from maximum
to minimum and vice versa and verify the feed
rolls rpm on the operator’s monitor.
14. Measure and write down the gauge pressure at

full stroke in reverse position. This pressure
should be 25 +/--4 bar (flush pressure).
15. With the hydrostatic control lever in neutral

position and the engine at high idle, measure and
write down the pressure reading. This pressure
(charge pressure) should be 4 +/--2 bar higher
than the value measured in step 14.
16. With the engine at high idle, shift to fourth gear,

press down both brake pedals firmly and apply
the handbrake. Move the hydrostatic control
lever fully forward for a maximum of 10 seconds.
The measured pressure should be between 420
and 450 bar (high pressure forward).
17. Stop the engine, remove the manometer, check

the oil level and check for possible leaks and
correct, if necessary.
18. Connect the sleeves (1) on both sides of the

traction gearbox.
6- 71020EN - 08 - 2003
SECTION 33 -- BRAKES AND CONTROL 1
SECTION 33 -- BRAKES AND CONTROL
CONTENT
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Road Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement of the brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bleeding the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleeding the left--hand side circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleeding the connection pipe between the two main cylinders . . . . . . . . . . . . . . . . . . . 6
Bleeding the right--hand side circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly and assembly of brake shoes and discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly of brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly of brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6- 71020EN - 08 - 2003
2 SECTION 33 -- BRAKES AND CONTROL
BRAKE SYSTEM
General
The two main cylinders 1 and 2 are mutually

connected with the pipes P/P1 and T/T1, further with
the pipe T2 to the fluid reservoir 3 and with the pipes
4 to the brake cylinders (refer to Fig. 2 for internal
connections in the brake pressure limiter valve 10).
Fluid from the fluid reservoir 3 enters the brake main When only one brake pedal is engaged, the port T or
cylinders through the pipes T and T1 (pedals not T1 is also shut off by seal 5 and fluid is pressed
engaged). through one pipe 4 to the brake cylinder (LH or RH).
When both brake pedals are engaged, the pipes T In the other main cylinder, the seat 8 is pressed down
and T1 are shut off by the seal 5. Fluid is pressed by the fluid pressure coming from the first cylinder.
through the pipes 4 to the brake cylinder. The balls The fluid flow is stopped by the seal 9.
6 are lifted up in both main cylinders 1 and 2 by the
plunger 7. The seat 8 and seal 9 are lifted by the ball
6. The pipes 4, P and P1 are now connected with
each other which ensures the brake pressure in the
pipes 4 to the brake cylinders is equal.
6- 71020EN - 08 - 2003
Road Mode
With the harvest switch in road mode position, the

solenoid 11 in the brake pressure limiter valve 10 is
engaged.
The brake pressure in the pipes 4, P and P1 is limited

to the set value of the pressure release valve 12
which is 40 bar which avoids tipping of the forage
harvester when excecuting an emergency stop.
CAUTION
For safety reasons, always couple the brake pedals
by means of the pedal coupler when driving on public 2
roads. This ensures the brakes are actuated
together.
6- 71020EN - 08 - 2003
PARKING BRAKE ADJUSTMENT
1. Disengage the handbrake in the cab.
2. Check if the dimension is 219 mm as shown in

Fig. 4.
NOTE: When measuring the above dimension, en-

sure that cable A is tensioned by pulling lever B.
3. Loosen lock nuts C and thereafter bolts D.

52001
4. If necessary (see step 2), adjust the dimension

to 219 mm with nuts E. Make sure that cable A
is straight. Tighten nuts E.
5. Tighten bolts D simultaneously by hand until they

touch the brake blocks (Fig. 4).
6. Engage and disengage the handbrake in the cab

a few times.
7. Check the tightness of bolts D. If possible,

tighten them simultaneously by hand. Turn them
an extra quarter of a turn with a spanner (Fig. 4).
30225
8. Engage and disengage the handbrake in the cab 5

a few times.
9. Loosen bolts D and tighten them simultaneously

by hand, if possible (Fig. 4).
10. The adjustment is correct when, while engaging

the handbrake in the cab, the tension begins at
the 6th or 7th tooth of the locking ratchet. If not,
repeat steps 8 and 9 until the adjustment is
correct.
11. Tighten lock nuts C (ensure that bolts D are not

turning with nuts C (Fig. 4).
12. Check again that the dimension still is 219 mm.

If not, repeat the adjustment from step 2
onwards.
6- 71020EN - 08 - 2003
REPLACEMENT OF THE BRAKE

LININGS
Removal
1. Bring the brake fluid level to a minimum.
2. Remove cover B.
3. Disconnect the electric wires on connectors C.
30254
4. Remove pins D out of the bracket housings.
5. Take out the brake linings.
CAUTION
If the seals (VITON type), protecting the cylinders,
have been exposed to temperatures in excess of
315°C, the material will not burn, but will decompose
and one of the products formed is hydrofluoric acid.
This is an extremely corrosive acid which is almost
impossible to remove once it has contaminated the
skin.
30253
7
Installation
1. Press the cylinders in the brake lining housings

to the outside.
2. Install the new brake linings.
3. Secure the brake linings with pins D (Fig. 7).
4. Connect the electric wires.
5. Check the brakes.
6- 71020EN - 08 - 2003
BLEEDING THE BRAKES
Bleeding the left--hand side circuit
1. Slide one end of a transparent hose over bleed

screw F1 and insert the other end of the hose in
a can partially filled with brake fluid.
2. Open the brake cylinder bleed screw F1.
3. Depress the left--hand side brake pedal several

times until fluid flows into the can.
50587
4. Close bleed screw F1. 8
5. Depress the left--hand side brake pedal several

times to build up a pressure.
6. Keep the pedal depressed.
7. Open the bleed screw F1 slightly to allow air and

fluid to escape through the transparent hose.
8. Close bleed screw F1.
9. Release the brake pedal.
10. Remove the transparent hose from bleed screw

F1 and repeat steps 1 to 10 for bleed screws F2
and F3.
Bleeding the connection pipe between the two

main cylinders
1. Slide the transparent hose over the right--hand

side bleed screw F1.
2. Open the right--hand side bleed screw F1.
3. Depress and hold the right--hand side brake

pedal depressed.
4. Depress the left--hand side brake pedal once and

keep it depressed.
5. Release the right--hand side pedal and then the

left--hand side pedal
6. Repeat steps 3, 4 and 5.
6- 71020EN - 08 - 2003
Bleeding the right--hand side circuit
1. With the transparent hose slide over the

right--hand side bleed screw F1 depress the
right--hand side brake pedal several times until
brake fluid flows into the can.
2. Close the right--hand side bleed screw F1.
3. Depress the right--hand side brake pedal several

times to build up a pressure.
4. Keep the pedal depressed.
5. Open slightly the right--hand side bleed screw F1

to allow air to escape through the transparent
hose.
6. Close bleed screw F1.
7. Release the brake pedal.
8. Repeat steps 3 to 7 until fluid free of air bubbles

flows through the transparent hose.
9. Remove the transparent hose from bleed screw

F1 and repeat steps 1 to 9 for bleed screws F2
and F3.
6- 71020EN - 08 - 2003
DISASSEMBLY AND ASSEMBLY OF

BRAKE SHOES AND DISCS
Disassembly of brake shoes

2. Remove handbrake shoe A by loosening two

bolts.
30298
3. Remove brake line B by loosening bolts C on
both sides. 9
4. Loosen brake line D from the bleed nipple holder

E on both sides.
5. Remove brake shoes F by loosening bolts G

through the holes of the disc on both sides.
30296
10
Disassembly of brake discs
1. Remove circlip H and hand brake disc J on the

right--hand side.
2. Remove slotted nut K, lock washer L and brake

disc M on both sides.
Assembly of brake discs
1. Install brake disc M, lock washer L and slotted

nut K. Tighten nut K with a torque of 180 Nm on
both sides. 30299
11
2. Install circlip N on the transmission main shaft.
3. Install handbrake disc J and circlip H.
6- 71020EN - 08 - 2003
Assembly of brake shoes
1. Install bleed nipple P in bleed nipple holder E on

both sides.
2. Install brake line D on the lower brake shoes F

and ensure that there is a washer between the
nipple and the brake shoe.
3. Install brake shoe F and fasten with bolts G on

both sides. Tighten bolts G with a torque of 266
Nm.
30296
12
4. Install brake line B with nipples R on both sides

and ensure there is a washer between the nipple
and the brake shoe and between the nipple and
the bolt.
5. Install brake shoe A and fasten it with two bolts.
6. Install the four--wheel drive on the right--hand

30298
13
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 1
CONTENT
Torque tables for hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Union nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Ferrules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Metric fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swivel nut with ball-type nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump group -- Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of the pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of the triple pump from the hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Splitting of the triple pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly of the pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation of the pump group to the hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6- 71020EN - 08 - 2003
2 SECTION 35 - HYDRAULIC SYSTEM -- CHAPTER 1
TORQUE TABLES FOR HYDRAULIC

COMPONENTS
Union nuts
55009
1
Ferrules
The ferrule must be pre-assembled on the tube.

Tighten the union nut as specified in the table below.
The ferrule and screw thread are greased.
Tube outer Torque Nm (lbf.ft)

diameter
mm (in) Min. Max.
8 (0.32) 15 (11) 20 (15)

10 (0.4) 25 (18) 30 (22)
12 (0.47) 35 (26) 40 (29)
16 (0.63) 50 (37) 55 (40)
18 (0.71) 60 (44) 70 (51)
22 (0.87) 100 (74) 110 (81)
28 (1.10) 110 (81) 120 (88)
Metric fittings
Unions
Are suitable for use with union nuts and ferrules and
ball-type nipples.
55011
2
6- 71020EN - 08 - 2003
Connections
Are screwed in ISO metric thread - tolerance class

6H - with a tightening torque as specified in the table
below.
Tube outer Torque Nm (lbf.ft)

diameter
mm (in) Min. Max.
8 (0,32) 40 (29) 45 (33)
10 (0,40) 65 (48) 70 (51) 55012
12 (0,47) 80 (59) 85 (63) 3
16 (0,63) 100 (74) 120 (88)
18 (0,71) 120 (88) 140 (103)
22 (0,87) 200 (147) 220 (164)
28 (1,10) 350 (257) 380 (280)
Swivel nut with ball-type nipple
Are suitable for use with female unions
D1 Torque Nm (lbf.ft.)
6H Min. Max.
M14 x 1.5 -- --
M16 x 1.5 15 (11) 20 (15)
M18 x 1.5 20 (15) 25 (18) 55013
M24 x 1.5 30 (22) 35 (26) 4
M26 x 1.5 -- --
M30 x 2 -- --
M36 x 2 -- --
6- 71020EN - 08 - 2003
PUMP GROUP -- DISASSEMBLY AND

ASSEMBLY
The pump group consists of five pumps driven by the

engine via the main drive transfer gearbox.
C1: Hydrostatic pump: see Section 29.
-- Feed roll drive
-- Spout flipper movement
-- 4WD clutch (if installed)
C2: Hydrostatic pump: see Section 29.
-- Traction 5
D: Work hydraulics pump:
-- Attachment height control
-- Reverse drive of the cutterhead / Hydraulic

crop processor drive (if installed)
-- Spout rotation and vertical movement
-- Auxiliary rear hydraulics (if installed)
-- Auxiliary front hydraulics
-- Crop processor open -- close (if installed)
E: Steering hydraulics pump:
-- Steering
-- Auto-Pilot (if installed)
F: Low pressure pump:
-- Main drive clutch
-- Main drive belts stretching cylinder
6- 71020EN - 08 - 2003
DISASSEMBLY OF THE PUMP GROUP
WARNING
Before starting a service job, always:
- Shut off the engine.
- Remove the ignition key.
- Switch off the battery switch.
- Wait until all parts have completely stopped
rotating.
In this paragraph, the following will be explained:
-- Removal of the three hydraulic pumps from the

hydrostatic pump.
-- Separation of the three hydraulic pumps.
6- 71020EN - 08 - 2003
Removal of the triple pump from the hydrostatic

pump
1. Drain the hydraulic oil reservoir.
6
2. Remove the left-hand side shielding.
43138
7
3. Remove hoses 5 and 6 from the low pressure
pump F.
4. Remove hose 3 and hose 4 from the steering

hydraulic pump E.
5. Remove hose 1 and hose 2 from the work

hydraulic pump D.
6. Unscrew cap screws 7.
7. Remove the triple pump from the hydrostatic

pumps.
6- 71020EN - 08 - 2003
Splitting of the triple pump
The triple pump consists of four main components:
D: Work hydraulics pump
E: Steering hydraulics pump
1: Connecting piece
F: Low pressure pump
The low pressure pump F is connected to the 9

connecting piece 1 with two cap screws 2.
The connecting piece is connected to the steering

hydraulic pump E with four cap screws 3.
10
6- 71020EN - 08 - 2003
11
6- 71020EN - 08 - 2003
12
1. Intermediate piece
2. Two cap screws (M10)
3. Four cap screws (M8)
4. Four washers (M8)
5. Four nuts (M8)
6. Two washers (M10)
7. O-ring seal (towards the low pressure pump)
8. O-ring seal (towards the steering hydraulics pump)
9. Fitting sleeve (connection between drive shafts)
The steering hydraulics pump E is connected to the

work hydraulics pump D with 4 long stud bolts 10
(M10 x 185.5 mm).
These bolts are screwed into the part that connects

the triple pump to the hydrostatic pump.
The steering and the work hydraulics pumps are

tightened to each other with special M10 nuts 11 on
these stud bolts.
The drive shafts of the latter pumps are connected

to each other with coupling 12.
6- 71020EN - 08 - 2003
Assembly of the pump group
Assemble in the reverse order of the disassembly

sequence.
IMPORTANT: Below is a list of recommended

torques. Ignoring these torques may lead to severe
damage to the pumps.
Verify the seals for wear or damage. Replace when
necessary. Also verify that the seals are properly
seated before attaching the pumps to each other.
Cap screw 2: 44 - 54 Nm (32--40 lbf.ft)
Cap screw 3: 26 - 31 Nm (19--23 lbf.ft)
Stud bolt 10 in the connecting piece (to the

hydrostatic pump): 5 - 10 Nm (4--7 lbf.ft)
Nut 11 (on stud bolt k): 44 - 54 Nm (32--40 lbf.ft)
Hose 6: 110 - 120 Nm (81--88 lbf.ft)
Torque tables for ferrules, connections and ball-type

nipples can be found in paragraph headed ‘‘Torque
tables for hydraulic components” at the beginning of 13
this section.
Installation of the pump group to the hydrostatic

pump
Cap screws 7: 27 - 37 Nm (20--27 lbf.ft)
14
6- 71020EN - 08 - 2003
Chapter 2 -- Work hydraulics -- Attachment height control

CONTENT
Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Work Hydraulics -- Attachment height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
High pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Non--return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Work hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
High pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Attachment height control valve (EMR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Neutral position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Attachment lifting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Attachment lowering position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure relief valve h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Emergency hand buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Attachment compensation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transport mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Compensation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Stubble height mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydropneumatic accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Attachment lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6- 71020EN - 08 - 2003
CIRCUIT DIAGRAMS
Work Hydraulics -- Attachment height control

1A CHX320--420--520--620 Series 5262 > ............
A Engine 1 From cutterhead reverse drive motor

B Main drive transfer gearbox 2 From spout rotation motor
C1 Hydrostatic pump -- Feed roll drive 10 Attachment lift cylinders
C2 Hydrostatic pump -- Traction 17 From low pressure system
D Work hydraulics pump 18 From hydrostatic motor -- traction
E Steering hydraulics pump 19 From hydrostatic motor -- feed roll drive
F Low pressure pump
G High pressure relief valve
H Attachment height control valve (E.M.R.)
J Pressure sensor
K Compensation valve
L1 Accumulators CHX520--620
L2 Accumulators CHX320--420 (100 bar is optional)
M Non-return valve
N Low pressure filter (Return filter)
NN High pressure filter
OC Oil cooler
PF Pressure filter
Q Drain hose
R Oil reservoir
R1 = R2 Hydraulic oil reservoir

R3 Low pressure hydraulic oil reser-
voir
S Breather with filter and non-return valve

SF Suction filter
T To/from steering valve (without Auto-Pilot)
TV Thermovalve
V Stack valve
X To steering valve (with Auto-Pilot)
Y From steering valve (with Auto-Pilot)
Z Collector block
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
HYDRAULIC OIL RESERVOIR
The hydraulic system, work hydraulics and steering

hydraulics, and the hydrostatic system, feed rolls
drive and ground speed, uses oil from one hydraulic
oil reservoir.
2
Several lines are located on the oil reservoir. Below
an overview:
R Oil reservoir
SF Suction filter -- Oil flow to the hydrostatic pump
C1 -- Feed roll drive
C2 Oil flow to the hydrostatic pump C2 -- Traction
Q Oil flow to the drain hose Q
1 Oil flow to the cutterhead reverse drive motor 1
R Oil reservoir
D Oil flow to the work hydraulics pump D
E Oil flow to the steering hydraulics pump E
OC Oil returning from the oil cooler OC
R Oil reservoir
V Oil returning from the stack valve V
1 Oil flow from the cutterhead reverse drive motor 1
5
6- 71020EN - 08 - 2003
LOW PRESSURE FILTER
The low pressure filter N is installed on top of the

hydraulic reservoir and has a by-pass (non-return)
valve set to 1.15 bar (17 psi).
The return oil from the work hydraulics and the

steering hydraulics system is flowing through the low
pressure filter before entering the hydraulic oil
reservoir.
6
BREATHER
The breather S allows the air in the reservoir to

escape whenever a considerable oil flow arrives at
the reservoir (e.g. when lowering the attachment).
HIGH PRESSURE FILTER
The high pressure filter NN is installed between the

electronic box and the spout base and has a by-pass
(non-return) valve set to 3.5 bar (51 psi).
Oil from the work hydraulics pump D is flowing

through the high pressure filter NN to the attachment
height control valve (E.M.R.) H.
7
NON--RETURN VALVE
Function
This non--return valve M is set to 2 bar (29 psi). The

valve is meant to ensure an oil pressure in the return
line from the stack valves V. This is to prevent the
cutterhead reverse drive motor from running dry
while the cutterhead is running in forward direction.
The non-return valve M is situated between the stack

valves V and the low pressure filter N.
NOTE: Ensure to install non-return valve M 8

according to the symbol mark. The oil flow is from
stack valves V towards the hydraulic oil reservoir R.
6- 71020EN - 08 - 2003
WORK HYDRAULICS PUMP 1. Set of two bushings

2. Pump housing
Specifications 3. Cover plate (to the hydrostatic pump)
4. Cover plate (to the steering hydraulics pump)
Gear pump
5. Driving gear
Output per revolution: 19.2 cc (1,17 cu.in.) 6. Driven gear
7. Anti-extrusion seal (2 off)
Direction of rotation: clockwise
8. Seal (2 off)
Pression on suction side: 0.3 - 1 bar (absolute) 9. Plug

(4,3--14,5 psi) 10. Plug
11. M5 cap screw (torque 2.5 - 3.4 Nm) (1.8 - 2.5 lbf.ft)
Maximum pressure: 210 bar (3045 psi) (2 off)
12. Circlip
Maximum peak pressure: 230 bar (3335 psi)
13. Dowel pin (4 off)
Maximum speed: 3000 rpm 14. O-ring (2 off)
15. Lip seal (2 off)
Minimum speed with maximum pressure: 1000 rpm 16. O-ring
55124
9
6- 71020EN - 08 - 2003
HIGH PRESSURE RELIEF VALVE
The high pressure relief valve G is situated on the

right-hand side of the hydraulic reservoir.
This valve is set at 180 bar (2610 psi) and protects

the work hydraulics circuit.
10
51726
11
6- 71020EN - 08 - 2003
ATTACHMENT HEIGHT CONTROL

VALVE (EMR)
This attachment height control valve H is situated on

the right-hand side of the forage harvester, under the
stack valve.
12
10 Oil flow from or to attachment lift cylinders a Load sensing valve
D Oil flow from work hydraulics pump b Attachment height control spool
H Attachment height control valve (E.M.R.) c Pilot line
N Low pressure filter d Pilot line
NN High pressure filter e Restriction
R2 Oil flow to hydraulic reservoir f Flow limiter valve
V Oil flow to stack valve g Non-return valve
h Pressure relief valve (200 bar)
i Adjustable restriction
j Restriction
k Restriction
l Spring
m Restricting pilot line
n Chamber
p Restriction grooves
q Pressure line
s Restriction
t Chamber
v Chamber
w Restriction grooves
z Chamber
6- 71020EN - 08 - 2003
This figure shows both a schematic drawing and a

section of the attachment height control valve.
52596
13
6- 71020EN - 08 - 2003
Neutral position Attachment lifting position
The attachment height control spool b is not The attachment height control spool b is moved to
activated and thus remains in neutral position. the left (according to the cross-section in
Figure 13).
The work hydraulics pump D pumps oil to port P:
The distance of movement of spool b depends on the
• Maximum pressure (due to pressure relief valve average voltage that is put on the pushing solenoid.
G): 180 bar (2610 psi) This average voltage depends on the input signal
which the electronic attachment height control
module receives. This input signal can come from
• 52 l/min (55 qts/min) (engine speed: 1900 rpm).
either the attachment height control switch on the
multifunction lever or from the pressure sensor on
The load sensing valve a divides this oil flow first in compensation valve K (see further).
two flows:
The signal from the attachment height control switch
1. A small oil flow (± 4 litres/min) (4,2 qts/min) goes is always the same, which results in a definite
through restriction e to stack valve V. position of the attachment height control spool b and,
as a result, in a definite lifting (or lowering) speed of
2. The second flow (about the same amount) goes the attachment.
through restriction k.
Control spool b does not permit any oil flow via line The signal from the pressure sensor on the
q. On the contrary, some oil can flow through pilot line compensation valve depends on the difference
d, via restrictions j, s and i to reservoir R2. between the calibrated and the measured pressure.
The inlet pressure (port P) is also seated at the As a result, in this case the position of the attachment
bottom of the load sensing valve a through pilot line height control spool b varies with the measured
c. difference in pressure.
When the inlet pressure is high enough to overcome In lifting position, oil can flow via restriction k through
the force of spring l and the pressure on this side of line q, to chamber n.
the load sensing valve a, valve a will move against
spring l. Another oil flow reaches chamber n through pilot
lines d and m.
This movement will open restriction e and close
restriction k. Both oil flows result in a drop of pressure in the
neighbourhood of valve a. This means that load
Closing restriction k causes the pressure in the pilot sensing valve a will now find an equilibrium that
line c to drop. This will move valve a over a certain closes restriction e and that opens restriction k.
distance back again, which closes restriction e and
opens restriction k.
NOTE: The oil flow to the stack valve V, via restriction
According to the level of the inlet pressure, the load e, is at least 3.8 l/min.
sensing valve a will find an equilibrium position. Most
of the oil flow will now go through the more opened Depending on the distance spool b was moved,
restriction p will be more or less open. The grooves
restriction e to stack valve V.
on spool b provide a more sensitive control of the
small oil flows through p. The grooves also result in
a smoother transition when spool b starts moving.
Pressure now builds up in chamber v. Check valve g

is forced to the left and the pressure D flows to port
A and the lift cylinders.
6- 71020EN - 08 - 2003
Attachment lowering position Pressure relief valve h
The attachment height control spool b is moved to This valve is set to 200 bar (2900 psi). It protects the
the right (according to the cross-section in Figure 13) non-return valve g against overpressure in chamber
over a certain distance, depending on the average z.
voltage put on the left-hand side solenoid.
Overpressure can originate when driving over
Restriction p is closed. So, there is no oil flow through bumpy surfaces.
line q.
Emergency hand buttons
Restriction w is more or less opened to the return
circuit and allows the oil pressure in chambers v and With these buttons, situated on both sides of the
t to drop to oil return pressure. attachment height control valve H, the attachment
height control spool b can be activated manually.
The high oil pressure in chamber z, due to the weight
of the attachment, and the low pressure in chamber This is meant to be used in emergency cases.
v cause the non-return valve g to close.
It may also be a useful instrument to check whether
Similar to the neutral position, load sensing valve a an error is situated in the electric wiring to the
moves to the right (according to the cross-section in solenoids or in the attachment height control valve H
Figure 13). itself.
The inlet oil flow is now divided into two flows. Push the rear button (closest to the door) to lower the
attachment. Use the front button (closest to the cab)
The major flow goes via restriction e to stack valve to lift the attachment.
V.
Specifications
The minor flow goes via restriction k and pilot line d
towards the rear side of valve f. The pressure on this Solenoid: 0-12 V
side is in between inlet pressure and return pressure
due to restriction i. This means that this pressure is
higher than the pressure in chamber t. ATTENTION
Never put 12V continuously to a solenoid as this will
This difference in pressure moves valve f to open the cause the solenoid to burn.
non-return valve g, which results in a lowering of the It is allowed to put 12V on a solenoid as a pulse or
attachment. maximum 7V continuously!
The oil flow from port A to control spool b results in

Maximum permitted pressures:
a rise of pressure in chamber t. This moves valve f
back again and tries to close the non-return valve g.
The heavier the attachment, the more valve g will be
closed to reduce the lowering speed. -- port P: 250 bar (3625 psi)
-- port R 5 bar (72,5 psi)
The lowering speed of the attachment is adjustable -- port N 200 bar (2900 psi)
with the adjustable restriction i. Permitting more oil
Maximum oil flow:
flow from pilot line d through restruction i to the return
circuit, decreases the pressure on the rear side of
valve f. This will reduce the lowering speed. Less oil
-- lifting attachment: 45 l/min (12 gpm)
flow through restriction i will increase the lowering
speed. -- lowering attachment: 63 l/min (17 gpm)
6- 71020EN - 08 - 2003
ATTACHMENT COMPENSATION VALVE
The compensation valve K is situated behind the

blower above the traction axle.
14
Specifications
Solenoid: 0-12 V
ATTENTION
cause the solenoid to burn.
It is allowed to put 12V on a solenoid as a pulse or
maximum 7V continuously!
Switching only happens when the oil flow is about

0 l/min.
Nominal oil flow: 100 l/min (26 gpm).
Max. permitted pressure: 200 bar (2900 psi).
6- 71020EN - 08 - 2003
55140
15
In position 0, when the solenoid a is not activated, the

attachment cylinders 10 are not directly connected
with the accumulator(s). The oil flows between ports
s and z via pilot line g, through valve h and orifice j.
This is to increase the reaction time when lifting or
lowering the attachment.
In position 1, the solenoid is activated and pushes

valve h against the spring. In this position oil can flow
freely between ports S and Z via the outside of valve
h. The attachment cylinders are directly connected
with the accumulators, which absorb pressure
shocks.
6- 71020EN - 08 - 2003
The attachment height control can be achieved in Stubble height mode

three modes.
a. When pressing the automatic attachment height
These modes can be chosen with the attachment control button:
height control selector switch on the arm rest module Compensation valve is closed.
(refer to the Operator’s Manual). Compensation valve opens 3.5 seconds after the
button was released.
The electric circuit pilots the attachment height
control valve H in these three modes: b. While working in stubble height mode:
always open.
-- Transport mode:
Manual operation of the attachment. c. While lifting or lowering the attachment with the
attachment height control switch (leaving stubble
-- Stubble height mode: height mode):
Attachment operates at a preset height. Compensation valve is closed.
Compensation valve opens 2 seconds after the
switch was released.
-- Compensation mode:
Attachment remains on the ground with a preset
pressure. Pressure sensor J measures the pressure in the
attachment cylinders to give input for the attachment
compensation system.
The compensation valve K functions as follows:
Transport mode
Always open (Solenoid a activated)
Compensation mode
a. When pressing the automatic attachment height

control button:
The compensation valve is closed until the at-
tachment touches the ground. At that moment
the compensation valve is opened.
b. While working in compensation mode:

always open.
c. While lifting or lowering the attachment with the

attachment height control switch (leaving com-
pensation mode):
Compensation valve is closed.
Compensation valve opens 2 seconds after the
switch was released.
6- 71020EN - 08 - 2003
PRESSURE SENSOR
The pressure sensor J measures the pressure in the

attachment lift cylinders.
16
The electronic attachment height control module
compares this measured pressure with the pressure
choosen with the ground pressure potentiometer on
the arm rest module (refer to the Operator’s Manual).
The electronic attachment height control module

translates this difference in pressure in a voltage
signal to one of the solenoids on the attachment
height control valve H.
For instance, when the attachment (in compensation

mode) is lifted by a stone, the pressure in the
attachment cylinders drops below the chosen
pressure. The electronic attachment height control
module activates the front (lifting) solenoid of the
attachment height control valve to compensate for
the drop of pressure with an oil flow towards the
attachment lift cylinders.
The magnitude of the oil flow (i.e. the distance the

attachment height control spool b moves) depends
on the average voltage put on the solenoid of the
attachment height control valve, which depends on
the measured difference in pressure.
Specifications
Pressure: 0-160 bar (0--2320 psi)
Supply: 8-12V
Signal: Supply voltage + [0.25 to 0.75V]
6- 71020EN - 08 - 2003
HYDROPNEUMATIC ACCUMULATORS
When the attachment has to be changed from maize

attachment to pick-up attachment, or vice versa, the
pressure in the lift cylinders changes because of the
difference in weight.
This difference affects the required ground pressure

level and, consequently, the hydropneumatic
accumulators L required.
17
Attachment CHX320--420 CHX520--620

HDX30P Two accumulators: Three accumulators:
HDX51D -- 70 bar -- 85 bar
-- 35 bar -- 55 bar
-- 30 bar
HDX45R Add a 100 bar accumulator.
HDX60R
Kemper 345
Kemper 360
ATTENTION It may even be necessary to check the potentiometer

To improve the stability of the forage harvester when adjustment (measuring the height of the
equipped with heavy attachment, counterweight attachment). Refer to the Operator’s Manual section
must be installed. Refer to the Operator’s Manual 4 “Lubrication and Maintenance”, paragraph headed
section 4 “Lubrication and Maintenance”, paragraph “Attachment height sensor”.
headed “Counterweights” to know the recommended
amount and combination of counter weights used. One side of a hydropneumatic accumulator is filled
with nitrogen.
Furthermore, changing the attachment implies a The other side is connected to the hydraulic lines to
recalibration of the ground level, the stubble height the attachment lift cylinders.
level and the ground pressure. The calibration
procedure is explained in the Operator’s Manual
section 3 “Field and Site operation”, paragraph
headed “Attachment height control”.
Apart from this, the operator’s monitor must also be

recalibrated for a new attachment width and
attachment height.
Refer to the Operator’s Manual section 3 “Field and
Site operation”, paragraph headed “Calibration
mode”.
6- 71020EN - 08 - 2003
Filling
Required tools:
-- Bottled nitrogen
-- Special tool (valve + pressure gauge)

(Bosch ref. No. 0538103012)
Procedure
1. First loosen the Allen screw on the accumulator.
2. Connect the special tool to the accumulator and

to the bottle of nitrogen.
3. Open valve m and read the pressure registered

on the pressure gauge. If necessary, add
nitrogen by opening valve l. When the correct
pressure is obtained, close valves m and l, bleed
excess pressure through valve n and disconnect
the special tool. 40573
4. Tighten the Allen screw. 18
6- 71020EN - 08 - 2003
ATTACHMENT LIFT CYLINDERS
a Piston rod e Seal ring

b Cylinder f Seal ring
c Locking wire g Scraper ring
d Piston guide ring (2x) h (Dis)assembly groove
j Locking groove
55141
19
55142 55143
a b
20
6- 71020EN - 08 - 2003
To disassemble piston rod a (and the seal rings

thereafter), move piston rod a until locking wire c is
visible through the hydraulic line connection on
cylinder b. Through this opening, locking wire c can
be pushed (Fig. 20a) into groove h. In this position,
locking wire c allows piston rod a to be pulled out.
To reassemble, replace seals e and f installing them

with their grooves (Fig. 18) facing inward using the
special tool, as shown in Figure 21. Then install
scraper ring g.
After assembly of piston rod a, reinstall locking wire

c in its original groove j (Fig. 20b).
30238 30239
a b
21
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6- 71020EN - 08 - 2003
Chapter 3 -- Work hydraulics -- Base unit

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

Stack valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Repair of control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Load sensing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cutterhead reverse drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spout rotation pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spout rotation motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Quick--release couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spout lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cylinder disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reinstallation of spout lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6- 71020EN - 08 - 2003
CIRCUIT DIAGRAMS -- BASE UNIT

2a Work Hydraulics -- Base unit
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A Engine V Stack valve

VA Load sensing valve
C1 Hydrostatic pump -- Feed roll drive
VB Cutterhead reverse drive engaging valve
VC Spout rotation control
CV Check valve
VD Auxiliary front hydraulics control valve
VE Auxiliary rear hydraulics control valve[ac-
E Steering hydraulics pump cessory]
F Low pressure pump VG Spout height control valve
G High pressure relief valve VH Top plate
H Attachment height control valve (E.M.R.) X To steering valve (with Auto-Pilot)

K Compensation valve Y From steering valve (with Auto-Pilot)
M Non-return valve Z Collector block
N Low pressure filter
NN High pressure filter 1 Cutterhead reverse drive motor
OC Oil cooler 2 Pressure relief valve
P Filler opening with filter 3 Spout rotation motor
PF Pressure filter 4 Front hydraulics quick-release couplings
Q Drain hose 5 External front hydraulics
R Oil reservoir 6 Rear hydraulics quick-release couplings (if

installed)
R1 = R2 Hydraulic oil reservoir 7 External rear hydraulics
R3 Low pressure hydraulic oil reservoir 8 Orifice
S Breather with filter and non-return valve 9 Spout lift cylinder
SF Suction filter 17 From low pressure valve
T To/from steering valve (without Auto-Pilot) 18 Hydrostatic motor -- Traction
TV Thermovalve 19 Hydrostatic motor -- Feed roll drive
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
Refer to chapter 2 ‘‘Work hydraulics - Attachment

height control’’ for additional information on:
-- Hydraulic reservoir R2
-- Low pressure filter N
-- High pressure filter NN
-- Non--return valve M
-- Breather S
-- Work hydraulic pump D
-- High pressure relief valve G
-- Attachment height control valve H (EMR)
6- 71020EN - 08 - 2003
STACK VALVE
The stack valve V is a modular system. This means

that control valves can be added or removed quickly.
When (re)assembling the stack valve, pay attention
to the sequence (1 - 2 - 3) and the tightening torques
of the bolts.
Also adhere to the original sequence of installation of
the valves and orifices.
43165
2
51139
3
6- 71020EN - 08 - 2003
Repair of control valves
If a control valve does not respond to a switch

command, either an electrical or a hydraulic problem
may be the cause.
• Electrical cause: No power supply to the solenoid

spool or failure of solenoid spool.
Result: The solenoid does not operate the valve
spool.
In this case, the valve spool can be manually

activated by pushing on the rubber cap of the
solenoid and moving the valve spool into an
operating position.
DANGER
Before activating a solenoid manually, ensure that
everybody stands clear of the machine. Activate it
just long enough to notice that the valve works.
Front button Rear button

(closest to the (closest to the
cab) door)
VG Spout height control valve DOWN UP
VF Crop processor opening control valve DOWN UP
VE Auxiliary rear hydraulics control valve Pressure RIGHT Pressure LEFT
VD Auxiliary front hydraulics control valve Pressure RIGHT Pressure LEFT
VC Spout rotation control valve RIGHT LEFT
VB Cutterhead reverse drive -- ON
As a provisional solution, if there is no power

available on a solenoid, the electrical wires of
another valve (which is not needed at that
moment) may be connected to the failed
solenoid.
ATTENTION
It is allowed to put 12V on a solenoid as a pulse or
• Hydraulic cause: Repair of an individual valve is

not possible. Only replacement of the seal rings
is possible.
6- 71020EN - 08 - 2003
LOAD SENSING VALVE
System in neutral
The work hydraulics pump D pumps oil via the

attachment height control valve H (EMR) to the load
sensing valve VA.
As no control valve (VB ... VF) is activated yet,

pressure builds up between ports P and a.
At the spring side c of the load sensing spool d, the

pressure is approximately identical to the return oil
pressure.
When the pressure between ports P becomes high

enough to surpass spring c (6 bar) and the return oil
pressure, the load sensing spool d moves to the left
(position 1). This connects inlet port P directly to
return port R. The oil flows straight to hydraulic
reservoir R2.
48103
4
6- 71020EN - 08 - 2003
CUTTERHEAD REVERSE DRIVE MOTOR
The cutterhead reverse drive motor 1 is situated on

the right-hand side of the forage harvester at the front
side of the engine.
Specifications
-- Gear motor
-- Output per revolution: 26.5 cc (1,62 cu.in)
-- Max. pressure: 210 bar (3045 psi) 5
-- Max. peak pressure: 230 bar (3335 psi)
-- Max. speed: 3,000 rpm
-- Min. speed at max. pressure: 800 rpm
-- Build--in non--return valve
When the motor (i.e. valve solenoid VB) is not

activated and the cutterhead is engaged (in forward
drive), the motor works as an idling pump.
The hydraulic line to the return circuit adds oil to the

pump (motor) circuit or returns oil from that circuit.
Another hydraulic line (dotted line in Figure 1)

returns the motor leak oil straight to the reservoir R2.
The purpose of this valve is to avoid underpressure

at the pressure side VB when the engine speed
drops while driving the cutterhead in reverse.
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43158
6
1. Dowel pin (4 off) 12. Cover plate

2. Plastic plugs (2 off) 13. Cover plate
3. Bolt (M10) (16 off) 14. Pump gear
4. Washer (M10) (16 off) 15. Pump gear
5. Circlip 16. Anti-extrusion seal (2 off)
6. O-ring (4 off) 17. --
7. O-ring (2 off) 18. --
8. O-ring (2 off) 19. Joint (2 off)
9. Seal 20. --
10. Bushing (2 off) 21. Gear pump chamber plate (2 off)
11. Pump house 22. Draining plug
6- 71020EN - 08 - 2003
SPOUT ROTATION PRESSURE RELIEF

VALVE
This pressure relief valve 2 is mounted on top of the

spout rotation motor. It protects motor 3 and its
support from excessive tension when the spout
reaches its mechanical stops.
This pressure relief valve 2 protects both directions

of rotation.
The valve 1 opens when the difference in pressure

is 65 bar (950 psi) at 50 l/min (13,2 gpm).
The valve 1 is factory--set and sealed.
SPOUT ROTATION MOTOR
The spout rotation motor 3 is an Orbit-type motor.
Specifications
-- Geometric displacement: 200 cc/rev (12,2

cu.in./rev)
-- Max. speed continuous/intermitting: 300/375

rpm
-- Max. oil flow cont./int.: 60/75 l/min (16/20 gpm) 7
-- Max. differential pressure cont./int: 100/140 bar

(1450/2030 psi)
-- Max. inlet or outlet pressure: 140/175 bar

(2030/2540 psi)
-- Max. torque cont./int.: 24.3/33.5 Nm (18/24,5

lbf.ft)
-- Max. performance: 6.4/8.4 kW
When installing the motor or the worm wheel, special

attention has to be paid to the adjustment of motor
and worm wheel in relation to each other and to their
supports (Fig. 8).
Adjust the worm wheel as close as possible to the

crown gear and eliminate possible axial play of the
worm.
6- 71020EN - 08 - 2003
To adjust, proceed as follows:
1. Check worm gear a for axial play.

Maximum allowed axial play: 0.25 mm (0,01”).
2. To remove possible play, loosen bolts b and

install shims between worm bracket g and
bearing block d at e. Retighten bolts b.
3. The worm gear assembly pivots around the bolt

and bushing connection j.
4. Loosen the three worm gear bracket bolts f and 30584

adjust bracket g with bolts h so that there is no
rotational play on the spout. 8
5. Rotate the spout a full cycle both left and right to

ensure it moves freely. Readjust, if necessary.
6. Retighten all hardware and install all grease lines

and covers.
Tighten bolts f to 95 Nm (70 lbf.ft) torque and
retighten them after the first 50 operating hours.
NOTE: Covers and grease lines are removed for

clarity
QUICK--RELEASE COUPLINGS
Items 4 and 6
Specifications
Maximum oil flow: 15 l/min (4 gpm)

Maximum pressure: 160 (180) bar
(2320/2610 psi)
(pressure relief valve G)
10
6- 71020EN - 08 - 2003
SPOUT LIFT CYLINDER
Item 9 -- Fig. 1
Cylinder disassembly and assembly
43168
11
a Piston j Hole
b Cylinder k Seal ring
c Piston guide l O-ring
d Piston guide m Seal ring
e Bolt n O-ring
f Washer p Scraper ring
g Guide ring q Rod
h Seal ring
1. Unscrew piston guide c using a hook spanner 5. Remove all seals (be careful not to scratch the
(hole j). grooves).
2. Pull out the ‘‘rod q - piston a - piston guide d’’ 6. Replace the seals, taking into account the
assembly. direction of the seal grooves.
3. Unscrew bolt e attaching piston a to piston guide 7. When reassembling the cylinder, tighten bolt e
d. with a torque of 142 Nm (105 lbf.ft).
4. Remove piston a from piston guide d.
6- 71020EN - 08 - 2003
Reinstallation of spout lift cylinder
Pay attention to following remarks:
-- Clean the ball joints r before reinstalling them.
-- Adjust the ball joints in such a way that, when the

cylinder is fully retracted, the rubber cushion
underneath the spout lies on the spout support.
-- The depth to which the ball joints are screwed in,

must at least be equal to the diameter width of
their threaded rod (M20 or M30).
-- Tighten the ball joints r to a torque of 170 to 180

Nm (125--132 lbf.ft).
-- Tighten nuts s to a torque of 190 Nm (140 lbf.ft)
43169
12
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
Chapter 4 -- Steering hydraulics

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

Steering hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Steering valve - D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Toe--in adjustment, steering ball joints, steering wheel stops . . . . . . . . . . . . . . . . . . . . . 19
6- 71020EN - 08 - 2003
CIRCUIT DIAGRAMS -- STEERING

HYDRAULICS
3a Steering Hydraulics -- without Auto--Pilot
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A Engine
F Low pressure pump
H From/ to header height control valve (EMR)
M Non-return valve
Q Drain hose
R Oil reservoir

R3 Low pressure hydraulic oil reservoir

T Steering valve (without Auto-Pilot)
V From stack valve
1 From cutterhead reverse drive motor
11 Steering cylinders -- 2WD
1
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
3b Steering Hydraulics -- with Auto--Pilot

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A Engine
F Low pressure pump
H From/ to attachment height control valve (EMR)
M Non-return valve
Q Drain hose
R Oil reservoir
R1 = R2 Hydrostatic oil reservoir


V From stack valve
W Pressure relief valve
X Steering valve (with Auto-Pilot)
Y Selector valve
Z Auto-Pilot valve
1 From cutterhead reverse drive motor
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
Refer to chapter 2 ‘‘Work hydraulics - Attachment

height control’’ for additional information on:
-- Hydraulic reservoir R2
-- Low pressure filter N
-- Non--return valve M
-- Breather S
6- 71020EN - 08 - 2003
STEERING HYDRAULICS PUMP
55123
3
1. Bushing 9. Shaft coupling

2. Pump housing 10. Plug (2 off)
3. Cover plate 11. --
4. Cover plate 12. M5 bolt (torque: 2.45 to 3.43 Nm!) (1,8 -- 2,5 lbf.ft)
5. Driving pump gear 13. Dowel pin (4 off)
6. Driven pump gear 14. O-ring
7. Anti-extrusion seal (2 off) 15. O-ring (2 off)
8. Seal
Specifications -- Maximum pressure: 250 bar (3625 psi)
-- Gear pump -- Maximum peak pressure: 280 bar (4060 psi)
-- Output per revolution: 6 cc (0,37 cu.in.) -- Maximum speed: 4,000 rpm
-- Direction of rotation: clockwise -- Minimum speed at maximum pressure: 1,400

rpm
-- Pressure on suction side: 0.3 -- 1 bar (absolute)
(4,35 -- 14,5 psi)
6- 71020EN - 08 - 2003
STEERING VALVE
The steering valve X is situated at the front under the

cab.
• without Auto--Pilot
The Danfoss steering valve OSPC 100 ON consists

of a selector valve and an orbit pump.
The purpose of having an orbit pump built in the valve

is to have a perfect ratio between the steering wheel 50482
and the steering cylinder, and to guarantee a manual
operation in case of breakdown. 4
The steering wheel controls the selector valve and

the orbit pump. The valve sleeve is held in neutral by
leaf springs.
These leaf springs only allow a minor shifting

between the valve sleeve and the spool when turning
the steering wheel.
Four ports discharge into the valve body.
P: Pressure inlet
T: Return to reservoir
L and R: Left and right cylinder connection
to steering.
A ball is fitted between the ports P and T. During
normal operation the ball is pushed on its seat,
closing the connection between P and T.
When no oil under pressure (e.g. failure of hydraulic

pump) flows from the pump into port P, steering will
still be possible as the return oil pushes the ball from
its seat and flows into suction line P.
The pressure relief valve, situated between inlet P

and return T, is set to 140 bar (2030 psi).
The double-acting shock-valve situated between

ports L and R is set to 200 bar (2900 psi).
6- 71020EN - 08 - 2003
• with Auto--Pilot
This steering valve X (type OSPB 100 ON) does not

contain a selector valve nor a pressure relief valve.
This steering valve only consists of an orbit pump.
The selector valve Y is integrated in the Auto-Pilot

valve Z.
The pressure relief valve W is a separate component

on the forage harvester.
Special tools
Number Description
380000305 to fit new seals in the steering valve body.
6- 71020EN - 08 - 2003
Steering valve - D./A.
CAUTION
This valve has an important safety function. Do not
try to repair this valve unless you received training on
it and are totally familiar with it. Only use genuine
CASE IH parts.
Preceding remarks:
• Make sure that the special tool (no. 380000305)

is available before disassembling the steering
valve.
This special tool is used to fit new seals in the
valve body.
• Place the shaft in the rotor so that the drive slot

forms a straight line with the rotors hollows [see
arrows].
• Make sure that the ball between ports “P” and “T”
is correctly seated when the special screw, with
the roll pin, is fitted.
5
To disassemble the steering valve, proceed as fol-
lows:
1. Clamp the steering valve in a vice (as shown)
2. Remove the end plate (1) by loosening the bolts
(2).
6
3. Remove the end plate (1), together with the rotor
housing (3) and the rotor, as well as the O-rings
from both sides of the rotor housing.
6- 71020EN - 08 - 2003
4. Remove the spacer (4), if fitted and the drive

shaft (5).
8
5. Remove the intermediate plate (6) and the O-
ring (7).
9
6. Unscrew the stop (8).
10
7. Remove the ball (9) out of the rotor housing and
the two suction valves at (10) (2 pins and 2 balls)
11
6- 71020EN - 08 - 2003
8. Press the valve spool out of the valve housing.

The valve housing should be held in a vertical
position as shown.
12
9. Subsequently remove the washer (1), the needle
bearing (2), the bearing race (3) and the ring (4).
10. Press out the cross pin (5) and remove the leaf
springs (6).
11. Remove the valve spool from the valve sleeve.
13
12. The ring (7) and the O-ring (8) can now be re-
moved from the steering valve body. These seals
are located in the neck of the steering valve body.
14
13. Clean all the parts carefully.
Prior to assembly it is recommended to replace
all O-rings (1), the washers (2), and the plate
springs (3) with new parts.
14. Before assembly, lubricate all parts with hy-
draulic oil.
15
6- 71020EN - 08 - 2003
16
1. Dust seal ring
2. Housing spool/sleeve
3. Ball
4. Thread bushing
5. O-ring
6. Check valve
7. Bearing assembly
8. Bushing with pin
9. Ball
10. Ring
11. Cross pin
12. Set of springs
13. Shaft
14. Complete shock valve
15. O-ring
16. Distributor plate
17. Gear wheel set
18. O-ring
19. End cover
20. Washer
21. Spring for relief valve
22. Screw with pin
23. Screw
24. Identification plate
25. Pressure relief valve
6- 71020EN - 08 - 2003
To assemble the steering valve, proceed as follows:

1. Install the leaf springs (1) symmetrically in the
spool (2) so that the spring ends open when in-
stalled correctly.
17
2. Assemble the spool (2) and the sleeve (3), and
secure it with the cross pin (1).
18
3. Install the ring (5), the bearing race (6), the
needle bearing (7) and the washer (8) on the
valve spool in the above-mentioned order.
19
4. Grease the ring (1) and the O-ring (2).
5. Place the subassembly of the rings (1) and (2)
around the spindle of special tool.
(nr. 380000305).
20
6- 71020EN - 08 - 2003
6. Push the sleeve of the special tool over the seal

rings on the spindle until there is some resis-
tance.
21
7. Lead the special tool, with the seal rings, into the
bore in the valve housing until the tool sleeve
touches the bottom.
22
8. Hold the sleeve in position and push the spindle
downwards, turning it at the same time so that
the subassembly of the rings (1) and (2)
(see fig. 20) seats in the groove.
9. First remove the spindle of the special tool and
then the sleeve.
23
10. Install the spool with all its parts in the valve
housing, turning it slowly at the same time.
24
6- 71020EN - 08 - 2003
11. Place the ball (1) in the correct hole and retain
with the stop (2). Place the two suction valves
(two pins and two balls) 180 degrees turned
away from the position of the ball (1).
25
12. Install the O-ring (7) and the intermediate plate
(6).
26
13. Now refit the rotor housing (3) (see also fig. 7)
with rotor and drive shaft with the coupling (4), to-
gether with the new seal rings.
14. Place the coupling (4), so that the drive slot (5)
forms a straight line with the rotor hollows. Turn
the rotor housing until the drive slot (5) engages
with the cross pin (1) (fig. 18) in the spool.
15. Install the spacer (4).(fig. 8)
27
16. Reinstall the end cap (2) and turn the rotor hous-
ing until all the holes are correctly aligned.
Check whether the ball (1) is in its proper posi-
tion.
17. Install the bolt and the pin assembly together with
a new washer to ensure the ball (1) remains cor-
rectly seated.
28
6- 71020EN - 08 - 2003
18. Install the remaining bolts with new washers and

tighten the bolts diagonally to a torque of 30 Nm.
19. Install the adapter with new O-rings.
29
6- 71020EN - 08 - 2003
STEERING CYLINDERS
Disassembly and assembly
WARNING
This cylinder has an important safety function. Do not
attempt to repair it unless you are totally familiar with
it.
Only use new genuine CASE IH parts.
1. Unscrew piston guide c using a hook spanner

(hole j).
2. Pull out the ‘‘rod q - piston a - piston guide d’’

assembly.
3. Unscrew bolt e attaching piston a to piston guide

d.
4. Remove piston a from piston guide d.
5. Remove all seals (be careful not to scratch the

grooves).
6. Replace the seals, taking into account the

direction of the seal grooves.
7. When reassembling the cylinder, tighten bolt e

with a torque of:
-- 108 Nm (79 lbf.ft) for 2WD steering cylinders
-- 164 Nm (120 lbf.ft) for 4WD steering cylinder
6- 71020EN - 08 - 2003
43157
30
a Piston j Hole
b Cylinder k Seal ring
c Piston guide l O-ring
d Piston guide m Seal ring
e Bolt n O-ring
f Washer p Scraper ring
g Guide ring q Rod
h Seal ring
Toe--in adjustment, steering ball joints, steering

wheel stops
Refer to the Operator’s Manual, section 4

“Lubrication and Maintenance” paragraph headed
“Steering axle”.
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
Chapter 5 -- Low pressure hydraulics

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

Low pressure hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil and Filter change procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil pressure check procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filling the system when (re)installing the low pressure pump . . . . . . . . . . . . . . . . . . . . 5
Filling the system after (re)installing the main drive transfer gearbox . . . . . . . . . . . . . . 5
Low pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main drive belt tensioning cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spout deflector cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6- 71020EN - 08 - 2003
CIRCUIT DIAGRAMS -- LOW PRESSURE

HYDRAULICS
4a Low Pressure Hydraulics
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A Engine
F Low pressure pump
G Low pressure valve
H Main hydraulic clutch (is part of B).
K Filter
OC Oil Cooler
P Pressure contacts
PF Pressure filter
Q Drain hose
R Oil reservoir

SF Suction filter
TV Thermo valve
Z Collector block
12 Main drive belts tensioning cylinder
13 Hydraulic spout deflector cylinder
14 4WD clutch (if installed)
19 Hydrostatic motor -- Feed roll drive
6- 71020EN - 08 - 2003
4a Low Pressure Hydraulics

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 08 - 2003
LOW PRESSURE HYDRAULIC

RESERVOIR
This reservoir R3 contains the oil used by the low

pressure pump.
The low pressure pump provides oil pressure for:
-- Main drive clutch
-- Main drive belts streching cylinder
Oil and Filter change procedure
1. Drain the oil reservoir.
2. Thoroughly clean the surrounding area of filter 3.
3. Remove the filter 3.
4. Fill the reservoir to the dipstick mark through

opening 1.
58209
2
5. Fill the new filter with new hydraulic oil.
6. Apply a film of oil to the gasket of the new filter.
58210
3
7. Screw on the new filter by hand. Tighten firmly

but DO NOT USE TOOLS.
8. Carry out the oil pressure check procedure

below.
6- 71020EN - 08 - 2003
Oil pressure check procedure Filling the system when (re)installing the low
pressure pump
1. First check the oil level in the reservoir.
1. Fill the suction line before connecting it to the
2. Start the engine and let it run at low idle for two pump.
minutes.
2. Carry out the oil pressure check procedure.
3. Switch ON the Harvest switch.
Filling the system after (re)installing the main
Check if the main drive belts are tensioned by the drive transfer gearbox
cylinder.
1. First fill the main drive transfer gearbox from the
If not, shutt off the engine and check whether the top until the oil level in the reservoir rises (i.e. 4
suction line to the low pressure pump is filled with to 5 litres of oil).
oil.
2. Fill the oil reservoir through the filler cap to the
4. If the belts are tensioned, engage the dipstick mark.
cutterhead.
3. Unscrew the suction line from the low pressure
5. Increase the engine speed to at least 1700 rpm. pump.
6. Watch the ‘‘Main drive clutch oil pressure’’ 4. Fill the suction line with oil.
warning light on the instrument panel.
5. Screw the suction line back to the pump.
7. This warning light should not be illuminated or at
least disappear within 15 seconds. 6. Carry out the oil pressure check procedure.
CAUTION
If the warning light remains illuminated, stop the
engine and search for the cause.
NOTE: With the engine running at 1900 rpm and the

cutterhead engaged, the pressure measured at
pressure check point W should be:
• 31-33 bar (450--480 psi) at an oil temperature

of 30-40_C (86--104_F)
• 30 bar (435 psi) at an oil temperature of

75-85_C (170--190_F)
6- 71020EN - 08 - 2003
LOW PRESSURE PUMP
55121
55121
4
1. Bushing 12. Plastic plug

2. Bushing 13. Plastic plug
3. Pump house 14. --
4. Cover plate 15. --
5. Cover 16. Circlip
6. Driven pump gear 17. Circlip
7. Driven pump gear 18. Dowel pin
8. Anti-extrusion seal 19. O-ring
9. Inner seal 20. --
10. Outer seal (2 off) 21. Oil baffle
11. Bolt (4 off)
Specifications -- Pressure on suction side: 0.3 to 1 bar (absolute)

(4,5 to 14,5 psi)
-- Gear pump
-- Maximum pressure: 210 bar (3045 psi)
-- Output per revolution: 6 cc (0,37 cu.in.)
-- Maximum peak pressure: 230 bar (3335 psi)
(0,1 cu.in.)
-- Maximum speed: 5,000 rpm
-- Direction of rotation: clockwise
-- Minimum speed at max. pressure: 1,200 rpm
6- 71020EN - 08 - 2003
LOW PRESSURE VALVE
The low pressure valve G (fig. 1) is situated above

the hydrostatic pump.
A To main hydraulic clutch

B To/from hydraulic cylinder (main drive belts)
A1 To/from hydraulic spout deflector cylinder
A2 To/from hydraulic spout deflector cylinder
A3 To 4-WD clutch (option)
A4 Not used
MP Pressure contact 24 bar (350 psi) (main drive
clutch)
MP1 Pressure contact 5 bar (70 psi) (hydrostatic
charge pump)
P From low pressure pump 5
P1 From hydrostatic charge pump
T To return circuit (hydraulic reservoir)
To the main drive transfer gear-box gears
T1 To return circuit (low pressure hydraulic reser-
voir)
W Pressure check point
6- 71020EN - 08 - 2003
Valve a -- main drive clutch and main drive belts This is to protect the main clutch from slipping.
cylinder
CAUTION
• Start the forage harvester Never put 12V continuously to a solenoid as this will
The valve a is automatically activated into position 1. It is allowed to put 12V on a solenoid as a pulse or
The low pressure pump F pumps oil via port P.
This oil flow is divided in an oil flow straight to the oil The warning will only be activated in following
reservoir R3 (hydraulic line n) and an oil flow to the conditions:
main drive transfer gearbox (hydraulic line q).
-- When the cutterhead is engaged
NOTE: The main drive clutch H is part of the main
drive transfer gearbox. -- When the engine speed is at least 1700 rpm
This oil flow is meant to cool and lubricate the rotating Valve b -- 4WD clutch
parts inside the main drive transfer gearbox and
flows via the overflow line r to the oil reservoir R3. The valve b is activated when:
The pressure at port B (the hydraulic cylinder) is not -- The Harvest switch is switched ON
high enough to stretch the main drive belts.
-- The 4-wheel drive switch is switched ON
• Switch ON the Harvest switch,
The pressure contact at port MP 1 switches off when
The valve a is not activated. the pressure, delivered by the charge pump of the
hydrostatic pump C, drops below 5 bar (73 psi).
The valve moves back to neutral position. The In that case, the feed rolls will stop immediately.
pressure is now completely on the hydraulic cylinder,
which stretches the main drive belts. After 5 seconds the main clutch will be disengaged
giving the cutterhead, blower and spout time to clear.
• Switch ON the cutterhead drive switch,
The engine slows down to low idle.
The valve a is activated into position 2.
Another 5 seconds later the engine will stop.
NOTE: To achieve this step, the Harvest switch must
be switched ON. Check the hydrostatic system.
The low pressure pump will pump oil via port A to the Valve c
main hydraulic clutch H (hydraulic line s).
Valve C controls the hydraulic spout deflector
The flow resistance of the clutch is such that the cylinder.
pressure on port B is still high enough to keep the
main drive belts tensioned. The valve is activated when:
The oil flow through the main hydraulic clutch H -- The harvest switch is switched on.
arrives at reservoir R3 via hydraulic line r.
-- Spout deflector rocker switch is activated (up or
The pressure in this system is maximum 30 bar (435 down).
psi), due to the pressure relief valve k.
Valve d
The pressure contact at port MP warns the operator
through the ‘‘main drive clutch oil pressure’’ warning
Valve d is not used.
light that the pressure has dropped below 24 bar (348
psi).
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
MAIN DRIVE BELT TENSIONING

CYLINDER
43160
2
a Piston
b Cylinder
c Locking wire
d Piston guide ring (2x)
f Seal ring
g Guide ring
h Seal ring
The disassembly and assembly instructions are

similar to those for the attachment lift cylinders.
6- 71020EN - 08 - 2003
SPOUT DEFLECTOR CYLINDER
1. Bolt 8. Piston
2. Washer 9. Piston guide
3. Piston guide 10. O--ring
4. Guide ring 11. Seal ring
5. Seal ring 12. O--ring
6. Seal ring 13. Cavity
7. Cylinder 14. Scraper ring
1. Unscrew piston guide 9 using a hook spanner

(cavity 13).
2. Pull out the “piston 8 -- piston guide 3” assembly.
3. Unscrew bolt 1 attaching piston 8 to piston guide

3.
4. Remove piston 8 from piston guide 3.
5. Remove all seals (be careful not to scratch the

grooves).
6. Replace the seals taking into account the

direction of the seal grooves.
7. When reassembling the cylinder, tighten bolt 1

with a torque of 34 Nm (25 lbf.ft).
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
Chapter 6 -- High--flow hydraulics

CONTENT
Circuit diagrams -- High--Flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6- 71020EN - 08 - 2003
CIRCUIT DIAGRAMS -- HIGH--FLOW

HYDRAULICS
5a High--Flow Hydraulics
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A Engine
B Supporting bearing
C Pump (38cc CHX320--420--520
33.5cc -- CHX620)
87 l/min CHX320--420--520
77 l/min CHX620
D Control valve
E Quick--release couplings
F Pressure relief valve
G Low pressure valve
Q Drain plug
R Oil reservoir
6- 71020EN - 08 - 2003
SECTION 50 -- CAB CLIMATE CONTROL 1
SECTION 50 -- CAB CLIMATE CONTROL

CONTENT
Correct use of the airconditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Storage maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Air conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Circuit parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filter--drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Compressor clutch replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ventilation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6- 71020EN - 08 - 2003
2 SECTION 50 - CAB CLIMATE CONTROL
CORRECT USE OF THE

AIRCONDITIONING SYSTEM
-- Keep door and window closed.
-- Use the airconditioning as much as possible.
-- Use the airconditioning only with the ventilator in

position I or II.
-- Control the desired temperature with the

airconditioning knob (thermostat).
Regularly pay attention to the following:
-- The status of the sight glass and the moisture

indicator (Fig. 2).
-- The cleanliness of the condenser and

evaporator.
-- The cleanliness of the air intake filters.
-- The cleanliness of the air recycling filter 4

(Fig. 19).
-- The water dropping at the drain tubes.
STORAGE MAINTENANCE
Operate the airconditioning unit with the engine on

idle speed and the ventilator on position II for at least
five minutes once a month during the storage period
(i.e. to oil all compressor seals and to avoid
leakages).
NOTE: The airconditioning system must only be op-

erated if the cab temperature is 21°C or more.
The airconditioning system must only be operated if
the ambient temperature is higher than 10°C.
ATTENTION: It is fully recommended to have the air-

conditioning system checked yearly by a specialist
(before the start of the harvest season).
ATTENTION: After recharging of the system by a

specialist, ensure the engine speed is set at low idle,
then engage and run the airconditioning system for
two (2) minutes to allow the system gas and lubrica-
tion to normalise.
After this initial run--up the system can be used
normally.
6- 71020EN - 08 - 2003
AIR CONDITIONING CIRCUIT
Components
1. Compressor
2. High pressure switch
3. High pressure charge port
4. Condenser
5. Filter--drier
6. Expansion valve
7. Evaporator
8. Low pressure charge port
9. Low pressure switch
51125
6- 71020EN - 08 - 2003
SPECIFICATIONS NOTE: The use of R134a in an automotive aircondi-

tioning compressor requires special attention to lu-
brication.
Refrigerant
A specific PAG--type oil, Sanden SP--20, has been
developed to suit the SD7H15. Care must be taken
Specification: R134 a to avoid incorrect oils being used as SP--20 is the
only lubricant approved for use with the SD7H15.
Amount: 2100 gr
Compressor clutch
Compressor
Rated voltage: DC 12V
Type: SANDEN SD7H15KG7862
Break--away torque: 34 Nm (3.5 kgf.m)
Displacement per revolution: 154.9 cc
Minimum engagement voltage: 7.5 V
Oil capacity: 360 cc (Sanden SP--20) (135 cc in
compressor + 225 cc in circuit) Power consumption: 49 W
Belt type: A type
Circuit parameters
Airconditioning Ambient temperature °C Low pressure bar High pressure bar

Not in operation 20 4.5 4.5
Not in operation 30 6.5 6.5
In operation 20 0.5 to 1 11
In operation 30 1 14
Low pressure switch High pressure switch
Switch normally open: non adjustable Switch normally closed: non adjustable
Cut--in set point: 2.5 bar ± 0.3 bar Cut--out set point: 28 bar ± 1.5 bar
Cut--out set point: 0.3 bar ± 0.15 bar Cut--in set point: 19 bar ± 1.5 bar
Switch body colour: bronze Switch body colour: green
6- 71020EN - 08 - 2003
Filter--drier
A sight glass and a ring--shaped moisture indicator

serve for determining the condition of the R134 a.
IF:
-- The glass shows a milky refrigerant without air

bubbles, then the refrigerant is OK.
-- The glass shows air bubbles: lack of refrigerant.
-- The moisture indicator is blue: filter and

refrigerant are OK.
-- The moisture indicator is red: too much moisture:

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

much contamination: filter--drier has to be
replaced.
NOTE: The filter--drier must be replaced when the

airconditioning circuit has been opened.
1. Outlet
51126
2. Sight glass and moisture indicator
2
3. Inlet
6- 71020EN - 08 - 2003
COMPRESSOR CLUTCH
REPLACEMENT
Clutch removal
Insert the two pins of the front plate spanner into any
two threaded holes of the clutch front plate. Hold the
clutch plate stationary. Remove the hex nut with a
19 mm socket.
30288
3
Remove the clutch plate using a puller. Align the
puller centre bolt to the compressor shaft. Thumb
tighten the 3 puller bolts into the threaded holes.
Turn the centre bolt clockwise until the front plate is

loosened.
30287
4
Remove the shaft key by lightly tapping it loose with
a slot screw driver and hammer.
30291
5
Remove the internal bearing snap ring.
30290
6
6- 71020EN - 08 - 2003
Remove the front housing external snap ring.
30292
7
Remove the rotor pulley assembly:
-- Insert the lips of the jaws into the internal bearing

snap ring groove.
-- Place the rotor puller shaft protector over the

exposed shaft.
30295
30289
9
Align the thumb head bolts to the puller jaws and
finger--tighten.
30286
10
6- 71020EN - 08 - 2003
Turn the puller centre bolt clockwise until the rotor

pulley is free.
30280
11
Remove the field coil
Loosen the coil lead wire from the clip on top of the
compressor front housing.
30281
12
Remove the snap ring and the field coil.
30294
13
Clutch installation
Install the field coil: the coil flange protrusion must

match the hole in the front housing to prevent coil
movement and the lead wire must be correctly
located.
Replace the rotor pulley.
30293
14
6- 71020EN - 08 - 2003
Support the compressor on the 4 mounting ears at

the compressor rear side. If using a vise, clamp only
the mounting ears, never the compressor body itself.
Align the rotor assy squarely on the front housing

hub.
Using a hammer and a special tool, tap until the rotor

bottoms to the compressor front housing hub.
30283
15
Reinstall the internal bearing snap ring.
Reinstall the front housing external snap ring.
30284
16
Replace the front plate assy.
Check that the original clutch shims are in place on

the compressor shaft.
Replace the compressor shaft key.
Align the front plate keyway to the compressor shaft

key.
Using a shaft protector, tap the front plate to the shaft

until it has bottomed to the clutch shims.
30282
17
Replace the shaft hex nut and torque to 35 to 40 Nm
(3.5 to 4 kgf.m).
Check the air gap with a feeler gauge (0.4 to 0.8 mm).
If the air gap is not consistent around the
circumference, lightly pry up at the minimum
variations. Lightly tap down at points of maximum
variation.
30285
18
6- 71020EN - 08 - 2003
VENTILATION UNIT IMPORTANT:
The ventilation unit is situated underneath the seat. -- If the drink storage door is open, the ventilator
and airconditioning system are switched off.
1. Ventilator -- Flipping up the operator’s seat to get access to
2. Thermostat the ventilation unit does NOT switch off the venti-
lator and airconditioning system!
3. Evaporator • Take care not to injure your fingers.
4. Air recycling filter
• The ventilator will now have very low
5. Drink storage place resistance, which can cause the fuse (F3) to
be blown.
51124
19
6- 71020EN - 08 - 2003
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 1
CONTENT
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Color code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wire identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6- 71020EN -- 08 -- 2003
2 SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1
GENERAL INFORMATION
Wires
The wiring diagram is drawn following the DIN 40719

standards.
Each page contains a part of the complete wiring

diagram, not necessarily a complete group.
Color code
Ten colours of wires are used on the combine, each

color having its specific signification.
-- Red (rd):+ 12 V without passing the ignition

switch
-- Black (zw): directly earthed to the frame
-- White (wt): connected with the pin of a switch

which engages a system that increases
something (e.g. increase of drum rpm)
-- Grey (gr): connected with the pin of a switch

which disengages a system that decreases
something
-- Brown (br): signal wire from the rpm monitor to a

sensor
-- Blue (bl): earth of sensors through the monitor
-- Green (gn): wire to non rpm sensors (e.g. engine

oil pressure, temperature, etc)
-- Orange (or): lighting
-- Yellow (ge): lighting
-- Purple (pu): to rear direction indicator lights.
On the upper part of the page, the + 12 V lines are

drawn.
6- 71020EN -- 08 -- 2003
The line at the top (first line) always is at + 12 V (when

the main battery switch is engaged).
Lines 2 and 3 have + 12 V when relays K6 and K9 are

820
energized. This happens when the ignition switch is E.g.
engaged.
60 70 80 90 100 110 120 130

52865
1
Wire identification
The wiring diagram is marked as follows:
-- X16p01:
Connector X16, position 01
-- 893:
Wire number
-- 6:
Wire section is 6 mm2
52866
-- wt: 2
Wire color (white)
-- X108p02:
Connector X108, position 02
This information is printed at regular distances on the

wire itself, e.g.
X16/01 < - 893 - > X108/02
Thick drawn lines in the wiring diagrams do not

exist as a wire but are lines in the printed circuit.
51844
3
6- 71020EN -- 08 -- 2003
Fuses
A fuse can protect one or more electrical circuits.
When more circuits are protected, the first time the

fuse is mentioned, the drawing is as follows (really
connected):
51845
4
The other circuits that are protected by the same fuse

are drawn as follows:
(*): The line reference indicates the line on which

all connections (lines) with that particular fuse
are mentioned.
51846
5
Symbols
All symbols used in the wiring diagram are drawn

according to the DIN 40719 standard and are marked
with a letter and a number.
Each letter represents a group of similar

components.
6- 71020EN -- 08 -- 2003
The letters used can be found in following list:
Letter Component Example
A Monitors, prints Radio, CB, displays
B Commutator from non-electrical Sensor, horn, sender elements of water, air, oil tem-
into electrical signals, and vice perature and pressure, buzzer
versa
C Condensers
D Accumulator equipment Accumulators
E Lighting All lamps, except warning lights, dashboard lights
F Safety components All fuses
G Generators Battery, alternator
H Control components All control lamps
K Relays All relays, flasher unit, 12/24 V transformer
L Inductive components Coils in relays Motors
M Motors Varistor motors, ventilator, actuators
N Amplifier, controller Voltage controller
P Measuring instrument Clock, fuel and water temperature gauge
R Resistances Potentiometer, preheating
S Switch All switches
T Transformer Ignition coils
U Commutator from electrical sig- Frequence commutator, converter

nals into other electrical signals
V Semi-conductors Diodes, transistors, thyristors
W Wiring looms, antennas CB and radio antenna, coax wires
X Connectors All connectors, plugs
Y Mechanical components electri- Hydraulic valve, electromagnetic clutches, electrical

cally energized valve on injection pump.
Z Electrical filter Suppressor
6- 71020EN -- 08 -- 2003
The letters used can be found in following list:
Symbol Description
Electrical motor, actuator
Lamp
Double-acting lamp
Diode
Led (light emitting diode)
Fuse
Socket (female)
Plug in (male)
Automatic fuse
Buzzer
Inductive sensor
6- 71020EN -- 08 -- 2003
Symbol Description
Horn
Ignition switch
Solenoid for control valves
Flashing unit
Battery
Gauge
Electromagnetic clutch
Adjustable resistance
Bipolar switch
Loudspeaker
Alternator
6- 71020EN -- 08 -- 2003
Symbol Description
Wiper motor
Electric starter motor
Normally closed switch, manually controlled
Normally open switch, mechanical control by pedal
Normally open switch, mechanically controlled
Normally open switch, mechanically controlled
Normally closed switch, mechanically controlled
Normally open switch, controlled by a pressure sender
Normally open switch, controlled by under-pressure
6- 71020EN -- 08 -- 2003
Symbol Description
Normally closed switch, controlled by over-pressure
Normally open switch, controlled by a temperature sender
Normally closed switch, controlled by a level indicator
Normally open switch, controlled by the grain level indicator
Relay
Airconditioning ventilation motor
Mirror motor
The switches are drawn in the position as they are removed from the forage harvester.
6- 71020EN -- 08 -- 2003
Relays
A fuse can protect one or more electrical circuits.
NOTE: Never use relays with a diode parallel with the

coil or without a suppressor.
Relays with terminal references 1 - 2 - 3 - 4 - 5 (see
diagrams) have no suppressor and are soldered
to the printed circuit.
The relays can be recognized by the drawing on the
relay housing (Figures 6 to 8).
52867
Use relays with drawing as shown in Figure 6.
6
Do not use relays with drawings as shown in Figures
7 and 8.
52868
7
52869
8
6- 71020EN -- 08 -- 2003
CONNECTORS
X168 X199 X500 X625 X630 X653
ZDA0428A
9
X194 X195 X196
1 3
2 4
ZDA0429A
10
X193 X198
A10 A11
11
X92 X604 X625
S38 S40 S125 S126 S127 S128 S130 S143
12
6- 71020EN - 08 - 2003
X401 X402 X403 X404 X405 X406

X407 X408 X409 X410 X411 X412
X413 X414 X416 X417 X421 X422
X423 X424 X431 X433 X480
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
ZDA0436A
13
6- 71020EN - 08 - 2003
X303 X415 X432 X434
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
ZDA0437A 13
14
X57
53 52 51 50 49 48 47 46 45 44 43 42 41 40
35 34 33 25 24 23 22
17 16 15 14 6 5 4 3
ZDA0438A
15
6- 71020EN - 08 - 2003
X605
16
X91 X121 X131 X132 X169 X170 X257 X608
X620 X621 X638 X644 X645
2 3
ZDA0425A
17
X105 X106 X131 X134 X171 X191 X331 X600
X601 X606 X607 X610 X612 X615 X616 X635
X636 X637 X639 X641 X670 X674 X676
2 3
ZDA0427A
18
X329
19
6- 71020EN - 08 - 2003
X21 X184 X323 X604 X609 X614 X621 X649 X675
2 1
ZDA0447A
20
X318 X319 X613
21
X192 X617 X618 X640 X648
3 1
5 4
8 6
ZDA0446A
22
6- 71020EN - 08 - 2003
X26 X302 X306 X503 X505 X512 X513
3 2
6 4
10 7
13 11
16 14
15
ZDA0444A
23
X332 X511 X646
2 1
ZDA0439A
24
6- 71020EN - 08 - 2003
X06 X500 X502 X507
4 1
9 5
15 10
20 16
24 21
ZDA0441A
25
X509
3 1
6 4
9 7
ZDA0440A
26
6- 71020EN - 08 - 2003
X501
4 1
9 5
15 10
22 16
28 23
33 29
37 34
ZDA0442A
27
X06 X10 X305 X504 X506 X508
1
3 2
8 4
14 9
19 15
21 20
22
ZDA0443A
28
X627
6- 71020EN - 08 - 2003
29
X260
30
6- 71020EN - 08 - 2003
X155 X673
31
X626 X642
32
6- 71020EN - 08 - 2003
X629
33
M12
34
6- 71020EN - 08 - 2003
B13 B50 B106
R4
35
Y19 Y20 Y25 Y31 Y32 Y33 Y34 Y35 Y36 Y37
Y38 Y39
36
X130 X628 X647
37
Y22 Y40 Y42 Y44 Y45 Y46 Y49 Y50 Y51 Y52
38
6- 71020EN - 08 - 2003
X678
39
S125
40
K52 K53 K54 K55 K66 K67 K69
41
S59
42
6- 71020EN - 08 - 2003
X652
43
X330
44
X677
45
6- 71020EN - 08 - 2003
X672
46
E16
47
X328
48
6- 71020EN - 08 - 2003
B41
49
X189
50
X619
51
6- 71020EN - 08 - 2003
Chapter 2 -- Wiring Diagrams CHX
CONTENT
Wiring diagrams CHX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6- 71020EN - 09 - 2002
ELECTRICAL DIAGRAMS CHX
Ref. Line Group / Series
1a 10 STARTER CIRCUIT 24V IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
1b 10 STARTER CIRCUIT 24V CATERPILLAR

CHX620 5262 > ....
2a 520 ENGINE THROTTLE CONTROL IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
2b 520 ENGINE THROTTLE CONTROL CATERPILLAR

CHX620 5262 > ....
3a 690 HYDROSTATIC CONTROL IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
3b 690 HYDROSTATIC CONTROL CATERPILLAR

CHX620 5262 > ....
4a 860 FOUR--WHEEL DRIVE

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
5a 1030 ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6a 1540 ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6b 1540 ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1

CHX620 5262 > ....
7a 2050 ELECTRONIC SYSTEM: ELECTRONIC BOX 2

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
8a 2390 CPU INPUTS AND DISPLAY

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
9a 2900 ENGINE PROTECTION IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
9b 2900 ENGINE PROTECTION CATERPILLAR

CHX620 5262 > ....
10a 3410 SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY

HYDRAULICS
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
11a 3920 METAL DETECTOR IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
11b 3920 METAL DETECTOR CATERPILLAR

CHX620 5262 > ....
12a 4260 CROP PROCESSOR

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
13a 4430 SPOUT CONTROL

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
14a 4770 ROTARY DUST SCREENS AND CENTRAL GREASING SYSTEM

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
15a 4940 REVERSE DRIVE CUTTERHEAD AND SHARPENING

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
16a 5450 AUTOMATIC GREASING SYSTEM

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
17a 5790 SHEARBAR ADJUSTMENT

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
18a 6300 SILAGE ADDITIVE APPLICATION

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
19a 6470 AUTO--PILOT

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
20a 6810 HEADER HEIGHT CONTROL (HHC)

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
21a 7320 COOLANT TEMPERATURE AND FUEL GAUGE IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
21b 7320 COOLANT TEMPERATURE AND FUEL GAUGE CATERPILLAR

CHX620 5262 > ....
22a 7830 PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
23a 8340 DIRECTION INDICATOR AND HAZARD WARNING LIGHTS

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
24a 8680 OPERATING LIGHTS AND BEACONS IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
24b 8680 OPERATING LIGHTS AND BEACONS CATERPILLAR

CHX620 5262 > ....
25a 9190 AIR CONDITIONING

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
26a 9700 CAB

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
27a 10210 MIRROR CONTROL AND WINDSHIELD HEATING

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
28a 10720 FEED ROLLS

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
29a 10890 HIGH FLOW REAR HYDRAULICS

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
30a 11040 ADDITIONAL LIGHTS FOR FLIP--UP ATTACHMENTS

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
31a 11560 ELECTRONIC ENGINE CONTROL CATERPILLAR

CHX620 5262 > ....
32a 11900 ELECTRONIC ENGINE CONTROL IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
LIST OF SYMBOLS AND WHERE TO FIND THEM
A. Prints and Monitors
Code Description Location Line
A1. Radio Cab roof 9900
A2. CB Cab roof 9910
A3. Drive print (CAN) 1540
A4. AKS & ASBA print (feed rolls drive) 3500
A5. Drive print (feed rolls drive) 3500
A6. Module 4390
A7. Module 4700
A8. Performance monitor display (print) Performance monitor 2780
A9. Header height indicator Instrument panel 2840
A10. CPU print Central electronic box 1810
A11. Engine surveillance CPU print 2970
A12. RH–side door sensor interface CPU print 3640
A13. Crop processor roll clearance measur- CPU print 4320

ing
A14. Bosch interface CPU print 7280
A15. Sensor interface CPU–print 2610
A16. Meter input CPU print 7410
A17. AC–compressor surveillance CPU print 9400
A18. Engine rpm control CPU print 620
A20. AKS & ASBA print Central electronic box 1690
A21. Ground speed control AKS & ASBA print 710
A23. Sharpening control AKS & ASBA print 5260
A24. Shearbar adjustment control AKS & ASBA print 5930
A25. Metal detector control AKS & ASBA print 4000
A26. Brake control Drive print 8240
A28. Cutterhead rpm Drive print 10810
A30. Lights print Central electronic box 1960
A31. Reverse buzzer control Lights print 820

6- 71020EN - 09 - 2002
A32. 12 V Auto–Pilot Lights print 6480
A34. Silage additive control Lights print 6390
A35. Brake lights control Lights print 8300
A36. Operating lights and beacons control Lights print 8870
A37. AC–compressor control Lights print 9350
A40. Actuator print Central electronic box 2110
A42. Engine protection Actuator print 3040
A43. Spout deflector control (electrically) Actuator print 4610
A44. Crop processor roll clearance control Actuator print 4270
A45. Bosch interface Actuator print 7100
A46. Auto–Pilot amplifier Actuator print 6680
A47. Rotary dust screen control Actuator print 4790
A50. Valve print Central electronic box 2250
A51. 4WD control Valve print 900
A52. Switch–on control Valve print 3440
A53. Auxiliary hydraulics control Valve print 3870
A54. Spout rotation control (hydraulically) Valve print 4530
A55. Cutterhead reverse drive control Valve print 4970
A56. High flow rear hydraulics control Valve print 10910
A60. Bosch HHC module Central electronic box 7220
A70. Auto–Pilot module Central electronic box 6650
A81. Electronic control box Engine 11720
A82. Electronic injection box Engine 11790
A84. Engine electronic control box Engine 11960
A116. High flow rear hydraulics switch–on Dashboard print 11020
A150. Dashboard LED’s Dashboard print 1370
A151. Alarm LED print Instrument panel 2980
A152. LED control Instrument panel 3540
A153. Metal detector LED control Dashboard print 4040
A154. LED control Dashboard print 5060
6- 71020EN - 09 - 2002
A156. Compressor LED’s control Dashboard print 9470
A160. 3 switch print Instrument panel 1620
A163. Switch–on input 3 switch print in dashboard 3630
A171. Sharpening control print AKS & ASBA panel 5140
A172. Shearbar adjustment output AKS & ASBA panel 5890
A180. Multifunctional lever print Underneath multifunctional lever 1100
A181. Ground speed control Multifunctional lever print 750
A182. Switch–on control Multifunctional lever print 3720
A183. Spout control Multifunctional lever print 4670
A184. Header height operation Multifunctional lever print 6950
A185. Auto–Pilot control Multifunctional lever print 6720
A190. Arm rest module print Arm rest module 6900
A300. Dashboard print Instrument panel 1240
A301. Engagement switch print Instrument panel 3470
A302. AKS & ASBA control Dashboard print 5000
A303. Switch on operating lights and beacons Dashboard print 8740
A304. Silage additive application operation Dashboard print 6330
A305. Auto–Pilot operation Dashboard print 6760
A306. Crop processor roll clearance operation Dashboard print 4350
A307. Metal detector switch–on Dashboard print 3980
A320. CAN–Dashboard print Instrument panel 1240
A321. Start input Instrument panel 280
A322. Auxiliary hydraulics control Dashboard print 3800
Spout height control Cab floor 4450
A323. Brake contact input Dashboard print 8270
A324. Air conditioning operation Dashboard print 9200
A325. Meter control Dashboard print 7330
A326. Brake alarm input Instrument panel 2660
A327. Operator’s seat control print in dashboard 3800
6- 71020EN - 09 - 2002
B. Sensors, limit switches, buzzers, speakers

B1. Engine oil pressure contact 2910
B3. Engine oil temperature contact Engine 11680
B4. Hydrostatic oil pressure contact 2970
B5. Hydrostatic oil temperature contact 2410
B7. Air filter underpressure contact Air filter 2440
B12. Fuel level sender In fuel tank 7420
B13. Attachment pressure sensor Behind blower 7130
B16. Ground speed sensor Traction gearbox 2570
B29. Horn Underneath steering platform 7840
B30. Direction indicator lights buzzer Dashboard 8520
B31. Loudspeaker 1 Cab roof 9850
B40. Reverse buzzer Left–hand side of the machine at the 810

rear
B41. Wheel sensor On steering axle, left–hand side 6630
B42. Air temperature sensor Engine 11570
B43. Engine rpm sensor 1 Engine 11610
B45. Turbo pressure sensor Engine 11720
B46. Air pressure sensor Engine 11760
B47. Oil pressure sensor Engine 11800
B48. Fuel temperature sensor Engine 11830
B50. Knock sensor left Shearbar left 6060
B51. Oil temperature sender Engine 7380
B52. Feed rolls hydrostatic pressure sensor 3600
B54. Blower speed sensor 3600
B61. Thermostat switch Dashboard print 9230
B100. Main clutch oil pressure contact Low pressure valve 2460
B101. Cutterhead speed sensor Rear right–hand cutterhead drive 2600

pulley
6- 71020EN - 09 - 2002

B102. Right–hand side door sensor Right–hand side door 3660
B103. Spout end of travel sensor -- RH side Spout base 4690
B104. Crop processor roll speed sensor 4360
B105. Coolant temperature contact Cutterhead gearbox 2470
B106. Knock sensor RH side Shearbar RH side 6030
B107. Sharpening stone cover sensor On top of the chopper body 5220
B108. Adjust sharpening stone sensor Left–hand side of chopper body 5370
B109. Sharpening stone home position Left–hand side of chopper body 5340
B110. Metal detector Lower front feed roll 3950
B111. Maize header sensor – RH side At front of maize header 6560
B112. Maize header sensor – LH side At front of maize header 6510
B116. Feed rolls speed sensor 10790
B117. Spout end of travel sensor -- LH side Spout base 4720
6- 71020EN - 09 - 2002
E. Lighting
E1. Beacon 1 Behind cab 8960
E3. Brake light -- LH side Rear of machine 8300
Direction indicator -- LH side, rear Dashboard 8630
Parking light -- LH side, rear Rear of machine 8010
E5. Brake light -- RH side Rear of machine 8320
Direction indicator -- RH side, rear Dashboard 8570
Parking light -- RH side, rear Rear of machine 8150
E7. Direction indicator -- LH side, front Dashboard 8610
Parking light -- LH side, front Front of machine 7970
E8. Additional direction indicator -- LH side, Steering platform railing 11390

front
Additional parking light -- LH side, front Front of machine 7990
Additional parking light -- LH side, front Steering platform railing 11330
Additional direction indicator -- LH side, Dashboard 8630

front
E9. Direction indicator on attachment -- LH 11370

side
Parking light on attachment -- LH side 11290
E10. Direction indicator on attachment -- RH 11410

side
Parking light on attachment -- RH side 11310
E11. Direction indicator -- RH side, front 8590
Parking light -- RH side, front Front of machine 8110
E12. Additional direction indicator -- RH side, Steering platform railing 11430

front
Additional parking light -- RH side, front Front of machine 8130
Additional parking light -- RH side, front Steering platform railing 11350
Additional direction indicator -- RH side, Dashboard 8560

front
E15. Dimmed head lights -- LH side Front of machine 8190
Headlight -- LH side Steering platform railing 11120
E16. Dimmed head lights -- RH side Front of machine 8240
6- 71020EN - 09 - 2002
Headlight -- RH side Steering platform railing 11210
E17. Additional brake light (Germany) Rear of machine 8290
Additional parking light (Germany) 8170
E19. Headlight on attachment -- LH side Attachment 11060
E20. Headlight on attachment -- RH side Attachment 11150
E21. Headlight -- LH side high Steering platform railing 11090
E22. Headlight -- RH side high Steering platform railing 11180
E27. Operating light -- LH side 1 Railing platform 8730
Operating light -- LH side 2 8760
E28. Operating light -- RH side 1 Railing platform 8780
Operating light -- RH side 2 8810
E29. Spot light -- LH side Cab roof 8850
E30. Spot light -- RH side Cab roof 8870
E34. Stubble light -- LH side Cab roof 8820
E35. Stubble light -- RH side Cab roof 8840
E37. Cab spot light Cab roof 9970
E38. Cab interior light Cab roof 10010
E41. Licence plate lights Rear of machine 8030
E45. Reverse drive operating light Rear of engine hood 9000
E100. Spout operating light Spout 8930
6- 71020EN - 09 - 2002
F. Fuses
F1. 15A Additional fuse 330
F2. 15A Horn lights Fuse print 7840
F3. 25A Operator’s seat fan + gauges Fuse print 7330
Air conditioning fan 9230
F4. 15 A Printed circuits fuse after contact Fuse print 1650
CPU print 2060
Metal detector 3920
HHC contact 6990
F5. 10A Direction indicators Fuse print 8350
F6. 25A Windshield wiper + mirrors Fuse print 9760
10190
F7. 10A Automatic greasing after contact Fuse print 5460
F8. 40A Silage application Bottom of central electronic box 6440
F9. 15A Parking lights -- RH side Fuse print 8080
11350
F10. 15A Parking lights -- LH side Fuse print 7950
11290
F11. 25A Contact Fuse print 250
F12. 10A Dashboard 12 V sockets Fuse print 9710
F13. 10A Clock, radio, CB, cab lights 9870
F14. 25A Road lights Fuse print 7850
F15. 10A CPU print Fuse print 1760
F16. 15A Hazard warning lights Fuse print 8360
F17. 25A Valve print Fuse print 2200
HHC print 6980
F18. 30A AKS & ASBA print Fuse print 1630
F19. 25A Actuator print Fuse print 2050
F20. 30A Operating lights print Fuse print 1890
F23. 15A Main beam head lights Fuse print 8180
6- 71020EN - 09 - 2002
11060
11150
F24. 15A Dimmed head lights Fuse print 8220
11090
11180
F42. Rear windshield heating Cab roof 10530
F43. Fan Central electronic box 9330
G. Generators, batteries
G1. Battery In battery box 20
G2. Battery In battery box 40
G3. Alternator Left–hand side of engine 180
6- 71020EN - 09 - 2002
H. Control lights (mostly LED’s)
H1. Engine oil pressure LED Instrument panel 2910
H2. Engine oil and coolant temp. LED Instrument panel 2930
H3. Battery charge/voltage LED Instrument panel 2400
H4. Hydrostatic oil temperature LED Instrument panel 2410
H5. Hydrostatic oil pressure LED Instrument panel 2970
H6. Air filter obstruction LED Instrument panel 2440
H7. Brake linings/brake fluid level LED Instrument panel 2490
H8. Parking brake LED Instrument panel 2500
H13. Compressor overpressure LED Instrument panel 9460
H14. Compressor underpressure LED Instrument panel 9470
H15. Main beam head lights indicator light Steering column 7880
H16. Direction indicators control light Steering column 8440
H17. Trailer direction indicators control light Steering column 8370
H18. HHC red control LED Arm rest module 6820
H19. HHC green control LED Arm rest module 6840
H20. Auto–Pilot ON control light Steering column 6640
H21. Field mode LED Instrument panel 3550
H22. Metal detector LED Instrument panel 4030
H24. Main drive clutch oil pressure LED Instrument panel 2460
H25. Sharpening stone cover LED Instrument panel 5050
H26. Cutterhead gearbox oil temp. LED Instrument panel 2470
H120. Shearbar adjustment routine LED LED # 2 in AKS & ASBA panel 5860
H121. 1 minute sharpening LED LED # 3 in AKS & ASBA panel 5100
H122. 2 minutes sharpening LED LED # 4 in AKS & ASBA panel 5120
H124. Interrupt sharpening routine LED LED # 6 in AKS & ASBA panel 5160
H125. Shearbar adjustment rpm fault LED LED # 7 in AKS & ASBA panel 5780
H126. Shearbar adjustment motor fault LED LED # 8 in AKS & ASBA panel 5800
H127. Shearbar adjustment sensor fault LED LED # 9 in AKS & ASBA panel 5820
H128. Adjust cutterhead knives LED LED # 10 in AKS & ASBA panel 5840
H129. AKS & ASBA ready to use LED LED # 1 in AKS & ASBA panel 5860
6- 71020EN - 09 - 2002
K. Relays
K1. 12 V after contact relay 1 Fuse print in central electronic box 300
K2. Silage additive relay Fuse print in central electronic box 6430
K3. Parking lights relay Fuse print in central electronic box 7930
K4. Direction indicators relay Fuse print in central electronic box 8370
K11. 12 V after contact relay 2 Fuse print in central electronic box 310
K51. 12/24 V start relay In battery box 120
K52. Start relay In battery box 160
K53. Mirror control relay, right–hand side Cab roof 10310
K54. Mirror control relay, left–hand side Cab roof 10350
K55. Rear windshield heating relay Cab roof 10460
K56. Fan relay Console module in cab 9280
K57. Fan ground relay Console module in cab 9310
K58. Grease pressure switches relay 5540
K68. Pre--heating 12040
K69. Electronic motor control 160
6- 71020EN - 09 - 2002
M. Motors
M1. Starter motor Engine 110
M11. Fan motor Underneath operator’s seat 9310
M12. Front windshield wiper motor Cab roof 9810
M13. Mirror -- RH side Right–hand side of cab 10410
M14. Mirror -- LH side Left–hand side of cab 10360
M15. Additional mirror -- RH side (Germany Right–hand side of cab 10490

only)
M19. Additional fan 9290
M21. Crop processor roll clearance motor On top of chopper body 4280
M22. Sharpening stone cover motor Right–hand side of chopper body 5290
M23. Sharpening stone motor Left–hand side of chopper body 5410
M24. Shearbar adjuster motor -- LH side Left–hand side of chopper body 5970
M25. Shearbar adjuster motor -- RH side Right–hand side of chopper body 6000
M26. Rotary dust screen motor -- LH side Left–hand door 4780
M27. Rotary dust screen motor -- RH side Right–hand door 4800
M28. Rotary screen brush actuator -- LH side Left 4820
M29. Rotary screen brush actuator -- RH Right 4850

side
M31. Rear windshield wiper motor Rear windshield 10140
M32. Front windshield washer pump Cab roof 9830
M33. Side windows washer pump Side windows 10150
M34. Rear windshield washer pump Rear windshield 10150
M35. Window wiper motor -- RH side Right–hand side window 10140
M36. Window wiper motor -- LH side Left–hand side window 10140
6- 71020EN - 09 - 2002
P. Measuring equipment
P1. Engine temperature gauge Console module in cab 7330
P2. Fuel gauge Console module in cab 7350
P4. Clock Cab roof 9850
R. Resistances
R1. Engine heating Engine 12040
R4. Header height sensor Chopper body, left–hand side 7160
R5. Multifunctional lever position potentio- Underneath multifunctional lever 750

meter
R6. Stubble height control potentiometer Arm rest module 6820
R7. Ground pressure control potentiometer Arm rest module 6850
R14. Auto–Pilot centering potentiometer Steering column 6610
R15. Rear windshield heating Rear windshield 10480
R30. Crop processor roll clearance potentio- Left–hand side of chopper body 4300
meter
R31. CAN resistance Engine 11740
6- 71020EN - 09 - 2002
S. Switches
S17. Contact switch Instrument panel 240
S18. Attachment manual control switch 7290
S20. Attachment down switch Multifunctional lever 6920
S22. Attachment up switch Multifunctional lever 6940
S28. Emergency stop switch Button # 4 in multifunctional lever 3710
S29. Reverse feed rolls switch Switch # 1 in multifunctional lever 3720
S30. Automatic header height control switch Switch # 6 in multifunctional lever 3740
(former override switch) 6930
S31. Multifunctional lever neutral position Underneath multifunctional lever 710

switch
S35. HHC selector switch Arm rest module 6870
S36. Handbrake contact Handbrake 2650
S37. Fan + air conditioning switch Console module in cab 9250
S38. Front windshield wiper switch Cab roof 9760
S39. Mirror control switch Cab roof 10260
S40. Mirror selection + heating switch Cab roof 10510
S41. Auxiliary hydraulics up Cab floor 3800
Spout up foot switch 4440
S42. Auxiliary hydraulics down Cab floor 3820
Spout down foot switch 4460
S45. Brake fluid level contact Brake fluid 2670
S58. Brake contact Underneath steering platform 8280
S59. Combined light switch Steering column 7850
8450
S60. Air conditioning safety switch Console module in cab 9230
S62. Compressor overpressure contact Compressor 9380
S63. Compressor underpressure contact Compressor 9420
S64. Main battery switch At the front of the battery box 20
S65. Hazard warning lights switch Steering column 8420
S66. Brake linings sensor Disc brakes 2500
6- 71020EN - 09 - 2002
Greasing pump 5490
S77. Auto–Pilot engagement switch 6580
S82. Sharpening stone cover closed micro- Inside sharpening stone cover motor 5260
switch
S83. Seat switch Operator’s seat 3740
S84. Cab door switch Cab door 9980
S85. Switch for spout rotation to the right– Switch # 2 in multifunctional lever 4670
slow
S86. Switch for spout rotation to the left – Switch # 2 in multifunctional lever 4650
fast
slow
S88. Spout deflector down switch Switch # 2 in multifunctional lever 4730
S89. Spout deflector up switch Switch # 2 in multifunctional lever 4710
S90. Feed rolls forward switch Switch # 1 in multifunctional lever 3680
S91. Auto–Pilot button Multifunctional lever 6720
Auto–Pilot switch Switch # 5 in multifunctional lever 3760
S92. Stop feed rolls switch Switch # 1 in multifunctional lever 3700
S93. Switch for spout rotation to the right – Switch # 2 in multifunctional lever 4690
fast
S101. Cutterhead switch Switch # 14 in instrument panel 3630
S102. 4WD tumbler switch Switch no. 15 in instrument panel 890
S103. Engine throttle control switch Switch in instrument panel 550
S105. Road/Field mode switch Switch # 2 in instrument panel 3440
S106. Metal detector switch Switch # 3 in instrument panel 3970
S108. Auto–Pilot main switch Switch # 5 in instrument panel 6750
S109. Silage additive application switch Switch # 6 in instrument panel 6320
S110. Operating lights switch Switch # 7 in dashboard 8710
S111. Beacons switch Switch # 8 in dashboard 8790
S112. Automatic reversing aid system switch Switch # 9 in instrument panel 3520
S113. AKS & ASBA switch Switch # 10 in instrument panel 5050
S114. Cutterhead reverse drive switch Switch # 11 in instrument panel 4970
S115. Crop processor roll clearance switch Switch # 12 in instrument panel 4340
6- 71020EN - 09 - 2002
S120. Shearbar adjustment switch Switch # 2 in AKS & ASBA panel 5820
S121. 1 minute sharpening switch Switch # 3 in AKS & ASBA panel 5100
S122. 2 minutes sharpening switch Switch # 4 in AKS & ASBA panel 5120
S124. Interrupt sharpening routine switch Switch # 6 in AKS & ASBA panel 5160
S125. Additional mirror switch, right–hand Cab roof 10480

side (Germany only)
S126. Front windshield washer switch Cab roof 9810
S127. Side windows wiper/washer switch Cab roof 10080
S128. Rear windshield wiper/washer switch Cab roof 10070
S130. Engine electronic control box diagnos- 12000

tics switch
S137. High flow rear hydraulics switch Dashboard 11010
S138. Grease pressure switch 8R or 6R 5560
S139 Grease pressure switch cutterhead 5570
S140 Automatic greasing switch 5530
6- 71020EN - 09 - 2002
V. Semi--conductors (diodes)
V21. Direction indicators diode, left Lights print in central electronic box 8550
V22. Direction indicators diode, right Lights print in central electronic box 8550
X. Connectors
X130. Direction indicator socket, rear right Rear of machine 8550
X130. Trailer 12 V socket Rear of machine 8050
X147. 12 V socket, right–hand side Right–hand side, underneath head 7950

light
X148. 12 V socket, left–hand side Left–hand side, underneath head 8090

light
X150. 12 V socket Console module 9710
X189. Engine electronic control box connector 12020
X456. CAN/RS232 connector Instrument panel 2800
X510. Silage additive application socket Bottom of central electronic box 6440
6- 71020EN - 09 - 2002
Y. Valves
Y19. Header down valve Stack valve 7020
Y20. Header up valve Stack valve 7040
Y22. 4WD valve Low pressure hydraulic valves 870
Y25. Compensation valve 7060
Y27. Compressor Left–hand side of engine 9340
Y28. Hydrostatic pump Mounted on LH side of main drive 700

gearbox
Y31. Cutterhead reverse drive valve Stack valve 4950
Y32. Spout rotation left Stack valve 4540
Y33. Spout rotation right Stack valve 4570
Y34. Front auxiliary hydraulics up valve Stack valve 3830
Y35. Front auxiliary hydraulics down Stack valve 3860
Y36. Rear auxiliary hydraulics up valve Stack valve 3870
Y37. Rear auxiliary hydraulics down valve Stack valve 3900
Y38. Spout height up Stack valve 4500
Y39. Spout height down Stack valve 4530
Y40. Main drive clutch neutral position valve Low pressure valve 3450
Y42. Stop valve solenoid Feed rolls hydrostatic motor 4020
Y44. Valve for main drive clutch + Low pressure valve 3420
main drive belt idler
Y45. Spout deflector up Stack valve 4580
Y46 Spout deflector down Stack valve 4610
Y49. Tip trailer up valve Right–hand side of engine 10890
Y50. Tip trailer down valve Right–hand side of engine 10920
Y51. Valve for Auto–Pilot left Underneath steering platform 6550
Y52. Valve for Auto–Pilot right Underneath steering platform 6580
Y73. Hydrostatic feed rolls 3600
Y75. Cropprocessor open valve 4380
Y76. Cropprocessor closed valve 4400
Y77. Brake control valve 8240
6- 71020EN - 09 - 2002
6- 71020EN - 09 - 2002
1a STARTER CIRCUIT 24V IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
F1. 15A Additional fuse Fuse print 330
F11. 15A contact Fuse print 250
G1. Battery In battery box at right–hand side of 20

machine

machine
K1. 12 V after contact relay 1 Fuse print 300
K69. Electronic motor control 160
Line: 10 -- 340
6- 71020EN - 09 - 2002
1A STARTER CIRCUIT 24V IVECO
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
1b STARTER CIRCUIT 24V CATERPILLAR
CHX620 5262 > ....
F1. 15A Additional fuse Fuse print 330
F11. 15A contact Fuse print 260

machine

machine
Line: 10 -- 340
6- 71020EN - 09 - 2002
1B STARTER CIRCUIT 24V CATERPILLAR
CHX620 5262 > ....
6- 71020EN - 09 - 2002
2a ENGINE THROTTLE CONTROL IVECO
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
Line: 520 -- 680
6- 71020EN - 09 - 2002
2A ENGINE THROTTLE CONTROL IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
2b ENGINE THROTTLE CONTROL CATERPILLAR

CHX620 5262 > ....
A18. Engine rpm control CPU print 620
Line: 520 -- 680
6- 71020EN - 09 - 2002
2B ENGINE THROTTLE CONTROL CATERPILLAR

CHX620 5262 > ....
6- 71020EN - 09 - 2002
3a HYDROSTATIC CONTROL IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
A21. Ground speed control AKS & ASBA print 710

rear

meter

switch
Y28. Hydrostatic pump Mounted on left–hand side of main 700

drive gearbox
Line: 690 -- 850
6- 71020EN - 09 - 2002
3A HYDROSTATIC CONTROL IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
3b HYDROSTATIC CONTROL CATERPILLAR

CHX620 5262 > ....
A21. Ground speed control Adjust–o–Matic print 710

rear

meter

switch
Y28. Hydrostatic pump Mounted on left–hand side of main 700

drive gearbox
Line: 690 -- 850
6- 71020EN - 09 - 2002
3B HYDROSTATIC CONTROL CATERPILLAR

CHX620 5262 > ....
6- 71020EN - 09 - 2002
4a FOUR--WHEEL DRIVE
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A51. 4WD control Valve print 900
S102. 4WD tumbler switch Switch no. 15 in instrument panel 890
Y22. 4WD valve Low pressure hydraulic valves 870
Line: 860 -- 1020
6- 71020EN - 09 - 2002
4A FOUR--WHEEL DRIVE
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
5a ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A150. Dashboard LED’s Dashboard print 1370
A180. Multifunctional lever print Underneath multifunctional lever 1100
A300. Dashboard print Instrument panel 1240
A320. CAN–Dashboard print Instrument panel 1240
Line: 1030 -- 1530
6- 71020EN - 09 - 2002
5A ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
6a ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
A20. AKS & ASBA print Central electronic box 1690
F4. 15A -- Printed circuits Fuse print 1650
F15. 10A -- CPU print Fuse print 1760
F18. 30A -- AKS & ASBA print Fuse print 1630
F20. 30A -- Operating lights Fuse print 1890
Line: 1540 -- 2040
6- 71020EN - 09 - 2002
6A ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
6b ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1
CHX620 5262 > ....
A20. Adjust–o–Matic print Central electronic box 1690
F4. 15A -- Printed circuits Fuse print 1650
F18. 30A -- Adjust–o–Matic print Fuse print 1630
Line: 1540 -- 2040
6- 71020EN - 09 - 2002
6B ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1
CHX620 5262 > ....
6- 71020EN - 09 - 2002
7a ELECTRONIC SYSTEM: ELECTRONIC BOX 2
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A40. Actuator print Central electronic box 2110
A50. Valve print Central electronic box 2250
F17. 25A -- Valve print Fuse print 2200
F19. 25A -- Actuator print Fuse print 2050
Line: 2050 -- 2380
6- 71020EN - 09 - 2002
7A ELECTRONIC SYSTEM: ELECTRONIC BOX 2
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
8a CPU INPUTS AND DISPLAY
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A8. Performance monitor display (print) Performance monitor 2780
A9. Header height indicator Instrument panel 2840
A15. Sensor interface CPU–print 2610
A326. Brake alarm input Instrument panel 2660
B5. Hydrostatic oil temperature contact 2410
B7. Air filter underpressure contact Air filter 2440
B16. Ground speed sensor Traction gearbox 2570
B100. Main clutch oil pressure contact Low pressure valve 2460
B101. Cutterhead speed sensor Cutterhead drive pulley 2600
B105. Coolant temperature contact Cutterhead gearbox 2470
H3. Battery charge/voltage LED Instrument panel 2400
H4. Hydrostatic oil temperature LED Instrument panel 2410
H6. Air filter obstruction LED Instrument panel 2440
H7. Brake linings/brake fluid level LED Instrument panel 2490
H8. Parking brake LED Instrument panel 2500
H24. Main drive clutch oil pressure LED Instrument panel 2460
H26. Cutterhead gearbox oil temp. LED Instrument panel 2470
S36 Handbrake contact Handbrake 2650
S45. Brake fluid level contact Brake fluid 2670
X456. CAN/RS232 connector Instrument panel 2800
Line: 2390 -- 2890
6- 71020EN - 09 - 2002
8A CPU INPUTS AND DISPLAY
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
9a ENGINE PROTECTION IVECO
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
B1. Engine oil pressure contact 2910
Line: 2900 -- 3060
6- 71020EN - 09 - 2002
9A ENGINE PROTECTION IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
9b ENGINE PROTECTION CATERPILLAR

CHX620 5262 > ....
Line: 2900 -- 3060
6- 71020EN - 09 - 2002
9B ENGINE PROTECTION CATERPILLAR

CHX620 5262 > ....
6- 71020EN - 09 - 2002
10a SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY

HYDRAULICS
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A4. AKS & ASBA print (feed rolls drive) 3500
A5. Drive print (feed rolls drive) 3500
A12. RH–side door sensor interface CPU print 3640
A52. Switch–on control Valve print 3440
A53. Auxiliary hydraulics control Valve print 3870
A152. LED control Instrument panel 3540
A163. Switch–on input 3 switch print in dashboard 3630
A182. Switch–on control Multifunctional lever print 3720
A301. Engagement switch print Instrument panel 3470
A322. Auxiliary hydraulics control Dashboard print 3800
A327. Operator’s seat control print in dashboard 3800
B52. Feed rolls hydrostatic pressure sensor 3600
B54. Blower speed sensor 3600
B102. Right–hand side door sensor Right–hand side door 3660
H21. Field mode LED Instrument panel 3550
S28. Emergency stop switch Button # 4 in multifunctional lever 3710
S29. Reverse feed rolls switch Switch # 1 in multifunctional lever 3720
S30. Automatic header height control switch Switch # 6 in multifunctional lever 3740
(former override switch)
S41. Auxiliary hydraulics up Cab floor 3800
S42. Auxiliary hydraulics down Cab floor 3820
S83. Seat switch Operator’s seat 3740
S90. Feed rolls forward switch Switch # 1 in multifunctional lever 3680
S91. Auto–Pilot switch Switch # 5 in multifunctional lever 3760
S92. Stop feed rolls switch Switch # 1 in multifunctional lever 3700
S101. Cutterhead switch Switch # 14 in instrument panel 3630
S105. Road/Field mode switch Switch # 2 in instrument panel 3440
S112. Automatic reversing aid system switch Switch # 9 in instrument panel 3520
Y34. Front auxiliary hydraulics up valve Stack valve 3830

6- 71020EN - 09 - 2002
Y35. Front auxiliary hydraulics down valve Stack valve 3860
Y36. Rear auxiliary hydraulics up valve Stack valve 3870
Y37. Rear auxiliary hydraulics down valve Stack valve 3900
Y40. Main drive clutch neutral position valve Low pressure valve 3450
Y44. Valve for main drive clutch + main drive Low pressure valve 3420
belt idler
Y73. Hydrostatic feed rolls valve 3600
Line: 3410 -- 3910
6- 71020EN - 09 - 2002
6- 71020EN - 09 - 2002
10A SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
11a METAL DETECTOR IVECO
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
A25. Metal detector control Adjust–o–Matic print 4000
F4. 15A -- Metal detector Fuse print 3920
Y42. Stop valve solenoid Feed rolls hydrostatic motor 4020
Line: 3920 -- 4250
6- 71020EN - 09 - 2002
11A METAL DETECTOR IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
11b METAL DETECTOR CATERPILLAR

CHX620 5262 > ....
A25. Metal detector control Adjust–o–Matic print 4000
F4. 15 A -- Metal detector 3920
Y42. Stop pawl solenoid Above pawl wheel 4020
Line: 4260 -- 4420
6- 71020EN - 09 - 2002
11B METAL DETECTOR CATERPILLAR

CHX620 5262 > ....
6- 71020EN - 09 - 2002
12a CROP PROCESSOR

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A6. Module 4390
A13. Crop processor roll clearance measur- CPU print 4320

ing
A44. Crop processor roll clearance control Actuator print 4270
A306. Crop processor roll clearance operation Dashboard print 4350
B104. Crop processor roll speed sensor 4360
M21. Crop processor roll clearance motor On top of chopper body 4280
R30. Crop processor roll clearance potentio- Left–hand side of chopper body 4300
meter
S115. Crop processor roll clearance switch Switch # 12 in instrument panel 4340
Y75. Cropprocessor open valve 4380
Y76. Cropprocessor closed valve 4400
Line: 4260 -- 4420
6- 71020EN - 09 - 2002
12A CROP PROCESSOR

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
13a SPOUT CONTROL

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A7. Module 4700
A43. Spout deflector control (electrically) Actuator print 4610
A54. Spout rotation control (hydraulically) Valve print 4530
A183. Spout control Multifunctional lever print 4670
A322. Spout height control Cab floor 4450
B103. Spout end of travel sensor Spout base 4690
B117. Spout end of travel sensor -- LH side Spout base 4720
S41. Spout up foot switch Switch in cab floor 4440
S42. Spout down foot switch Switch in cab floor 4460
S85. Switch for spout rotation to the right– Switch # 2 in multifunctional lever 4670
slow
fast
slow
S88. Spout deflector down switch Switch # 2 in multifunctional lever 4730
S89. Spout deflector up switch Switch # 2 in multifunctional lever 4710
S93. Switch for spout rotation to the right – Switch # 2 in multifunctional lever 4690
fast
Y32. Spout rotation left Stack valve 4540
Y33. Spout rotation right Stack valve 4570
Y38. Spout height up Stack valve 4500
Y39. Spout height down Stack valve 4530
Y45. Spout deflector up Stack valve 4580
Y46 Spout deflector down Stack valve 4610
Line: 4430 -- 4760
6- 71020EN - 09 - 2002
13A SPOUT CONTROL
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
3930
6- 71020EN - 09 - 2002
14a ROTARY DUST SCREENS AND CENTRAL GREASING SYSTEM
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A47. Rotary dust screen control Actuator print 4790
M26. Rotary dust screen motor -- LH side Left–hand door 4780
M27. Rotary dust screen motor -- RH side Right–hand door 4800
M28. Rotary screen brush actuator -- LH side Left 4820
M29. Rotary screen brush actuator -- RH Right 4850

side
Line: 4770 -- 4930
6- 71020EN - 09 - 2002
14A ROTARY DUST SCREENS

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
15a REVERSE DRIVE CUTTERHEAD AND SHARPENING

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A23. Sharpening control AKS & ASBA print 5260
A55. Cutterhead reverse drive control Valve print 4970
A171. Sharpening control print AKS & ASBA panel 5140
A302. AKS & ASBA control Dashboard print 5000
B107. Sharpening stone cover sensor On top of the chopper body 5220
B108. Adjust sharpening stone sensor Left–hand side of chopper body 5370
B109. Sharpening stone home position sen- Left–hand side of chopper body 5340
sor
H25. Sharpening stone cover LED Instrument panel 5050
H121. 1 minute sharpening LED LED # 3 in AKS & ASBA panel 5100
H124. Interrupt sharpening routine LED LED # 6 in AKS & ASBA panel 5160
M22. Sharpening stone cover motor Right–hand side of chopper body 5290
M23. Sharpening stone motor Left–hand side of chopper body 5410
S82. Sharpening stone cover closed micro- Inside sharpening stone cover motor 5260
switch
S113. AKS & ASBA switch Switch # 10 in instrument panel 5050
S114. Cutterhead reverse drive switch Switch # 11 in instrument panel 4970
S121. 1 minute sharpening switch Switch # 3 in AKS & ASBA panel 5100
S124. Interrupt sharpening routine switch Switch # 6 in AKS & ASBA panel 5160
Y31. Cutterhead reverse drive valve Stack valve 4950
Line: 4940 -- 5440
6- 71020EN - 09 - 2002
15A REVERSE DRIVE CUTTERHEAD AND SHARPENING
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
16a AUTOMATIC GREASING SYSTEM
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
F7. 10A -- Automatic greasing after contact Fuse print 5460
K58. Grease pressure switches relay 5540
S67. Greasing pump 5490
S138. Grease pressure switch 8R or 6R 5560
S139. Grease pressure switch cutterhead 5570
S140. Automatic greasing switch 5530
Line: 5450 -- 5610
6- 71020EN - 09 - 2002
16A AUTOMATIC GREASING SYSTEM

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
17a SHEARBAR ADJUSTMENT

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A24. Shearbar adjustment control AKS & ASBA print 5930
A172. Shearbar adjustment output AKS & ASBA panel 5890
B50. Knock sensor -- LH side Shearbar -- LH side 6060
B106. Knock sensor -- RH side Shearbar -- RH side 6030
H120. Shearbar adjustment routine LED LED # 2 in AKS & ASBA panel 5860
H125. Shearbar adjustment rpm fault LED LED # 7 in AKS & ASBA panel 5780
H126. Shearbar adjustment motor fault LED LED # 8 in AKS & ASBA panel 5800
H127. Shearbar adjustment sensor fault LED LED # 9 in AKS & ASBA panel 5820
H128. Adjust cutterhead knives LED LED # 10 in AKS & ASBA panel 5840
H129. AKS & ASBA ready to use LED LED # 1 in AKS & ASBA panel 5860
M24. Shearbar left–hand adjuster motor Left–hand side of chopper body 5970
M25. Shearbar right–hand adjuster motor Right–hand side of chopper body 6000
S120. Shearbar adjustment switch Switch # 2 in AKS & ASBA panel 5820
Line: 5780 -- 6110
6- 71020EN - 09 - 2002
17A SHEARBAR ADJUSTMENT
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
18a SILAGE ADDITIVE APPLICATION
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A34. Silage additive control Lights print 6390
A304. Silage additive application operation Dashboard print 6330
F8. 40A -- Silage application Bottom of central electronic box 6440
K2. Silage additive relay Fuse print 6430
S109. Silage additive application switch Switch # 6 in instrument panel 6320
X510. Silage additive application socket Bottom of central electronic box 6440
Line: 6300 -- 6460
6- 71020EN - 09 - 2002
18A SILAGE ADDITIVE APPLICATION

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
19a AUTO--PILOT
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A32. 12 V Auto–Pilot Lights print 6480
A46. Auto–Pilot amplifier Actuator print 6680
A70. Auto–Pilot module Central electronic box 6650
A185. Auto–Pilot control Multifunctional lever print 6720
A305. Auto–Pilot operation Dashboard print 6760
B41. Wheel sensor On steering axle, left–hand side 6630
B111. Maize header sensor – RH side At front of maize header 6560
B112. Maize header sensor – LH side At front of maize header 6510
H20. Auto–Pilot ON control light Steering column 6640
R14. Auto–Pilot centering potentiometer Steering column 6610
S77. Auto–Pilot engagement switch 6580
S91. Auto–Pilot button Multifunctional lever 6720
S108. Auto–Pilot main switch Switch # 5 in instrument panel 6750
Y51. Valve for Auto–Pilot left Underneath steering platform 6550
Y52. Valve for Auto–Pilot right Underneath steering platform 6580
Line: 6470 -- 6800
6- 71020EN - 09 - 2002
19A AUTO--PILOT
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
20a HEADER HEIGHT CONTROL (HHC)
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A14. Bosch interface CPU print 7280
A45. Bosch interface Actuator print 7100
A60. Bosch HHC module Central electronic box 7220
A184. Header height operation Multifunctional lever print 6950
A190. Arm rest module print Arm rest module 6900
B13. Header pressure sensor Behind blower 7130
F4. 15A -- HHC contact Fuse print 6990
F17. 25A -- HHC print Fuse print 6980
H18. HHC red control LED Arm rest module 6820
H19. HHC green control LED Arm rest module 6840
R4. Header height sensor Chopper body, left–hand side 7160
R6. Stubble height control potentiometer Arm rest module 6820
R7. Ground pressure control potentiometer Arm rest module 6850
S18. Attachment manual control switch 7290
S20. Header down switch Multifunctional lever 6920
S22. Header up switch Multifunctional lever 6940
S30. Automatic HHC button Multifunctional lever 6930
S35. HHC selector switch Arm rest module 6870
Y19. Header down valve Stack valve 7020
Y20. Header up valve Stack valve 7040
Y25. Compensation valve 7060
Line: 6810 -- 7310
6- 71020EN - 09 - 2002
20A HEADER HEIGHT CONTROL (HHC)
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
21a COOLANT TEMPERATURE AND FUEL GAUGE IVECO
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
F3. 25A -- Operator’s seat fan + gauges Fuse print 7330
P1. Engine temperature meter Console module in cab 7330
Line: 7320 -- 7480
6- 71020EN - 09 - 2002
21A COOLANT TEMPERATURE AND FUEL GAUGE IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
21b COOLANT TEMPERATURE AND FUEL GAUGE CATERPILLAR

CHX620 5262 > ....
F3. 25A -- Operator’s seat fan + gauges Fuse print 7330
P1. Engine temperature meter Console module in cab 7330
Line: 7320 -- 7480
6- 71020EN - 09 - 2002
21B COOLANT TEMPERATURE AND FUEL GAUGE CATERPILLAR

CHX620 5262 > ....
6- 71020EN - 09 - 2002
22a PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....

A26. Brake control Drive print 8240
A35. Brake lights control Lights print 8300
A323. Brake contact input Dashboard print 8270
B29. Horn Underneath steering platform 7840
E3. Brake light, left Rear of machine 8300
E3. Parking light, left Rear of machine 8010
E5. Brake light, right Rear of machine 8320
E5. Parking light, right Rear of machine 8150
E7. Parking light, front left Front of machine 7970
E8. Additional parking light, front left Front of machine 7990
E11. Parking light, front right Front of machine 8110
E12. Additional parking light, front right Front of machine 8130
E15. Head lights, left Front of machine 8190
E16. Head lights, right Front of machine 8230
E17. Additional brake light (Germany) Rear of machine 8290
E17. Additional parking light (Germany) 8170
E41. Licence plate lights Rear of machine 8030
F2. 15A -- Horn lights Fuse print 7840
F9. 15A -- Parking light, right Fuse print 8080
F10. 15A -- Parking light, left Fuse print 7950
F14. 25A -- Road lights Fuse print 7850
F23. 15A -- Main beam head lights Fuse print 8190
F24. 15A -- Fuse dipped head lights Fuse print 8220
H15. Main beam head lights indicator light Steering column 7880
K3. Parking lights relay Fuse print 7930
S58. Brake contact Underneath steering platform 8280
S59. Combined light switch Steering column 7850
X130. Trailer 12 V socket Rear of machine 8050
8170
8300
X147. 12 V socket, right–hand side RH – side, underneath head light 7950
X148. 12 V socket, left–hand side LH – side, underneath head light 8090
Y77. Brake control valve 8240
Line: 7830 -- 8330
6- 71020EN - 09 - 2002
22A PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
23a DIRECTION INDICATOR AND HAZARD WARNING LIGHTS
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
B30. Direction indicator lights buzzer Dashboard 8520
E3. Direction indicator, left rear Dashboard 8630
E5. Direction indicator, right rear Dashboard 8570
E7. Direction indicator, left front Dashboard 8610
E8. Direction indicator, left front additional Dashboard 8630
E11. Direction indicator, right front Dashboard 8590
E12. Direction indicator, right front additional Dashboard 8560
F5. 10A -- Direction indicator Fuse print 8350
F16. 15A -- Hazard warning lights Fuse print 8360
H16. Direction indicators control light Steering column 8440
H17. Trailer direction indicators control light Steering column 8370
K4. Direction indicators relay Fuse print 8370
S59. Combined switch Steering column 8450
S65. Hazard warning lights switch Steering column 8420
V21. Direction indicators diode, left Lights print 8550
V22. Direction indicators diode, right Lights print 8550
X130. Direction indicator socket, rear right Rear of machine 8550
X130. Direction indicator socket, rear left Rear of machine 8640
Line: 8340 -- 8670
6- 71020EN - 09 - 2002
23A DIRECTION INDICATOR AND HAZARD WARNING LIGHTS
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
24a OPERATING LIGHTS AND BEACONS IVECO
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
E27. Operating light, left 1 Railing platform 8730
E28. Operating light, right 1 Railing platform 8780
E29. Spot light, left Cab roof 8850
E30. Spot light, right Cab roof 8870
E34. Stubble light, left Cab roof 8820
E35. Stubble light, right Cab roof 8840
Line: 8680 -- 9010
6- 71020EN - 09 - 2002
24A OPERATING LIGHTS AND BEACONS IVECO
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
24b OPERATING LIGHTS AND BEACONS CATERPILLAR
CHX620 5262 > ....
E29. Spot light, left Cab roof 8850
E30. Spot light, right Cab roof 8870
E34. Stubble light, left Cab roof 8820
E35. Stubble light, right Cab roof 8840
Line: 8680 -- 9010
6- 71020EN - 09 - 2002
24B OPERATING LIGHTS AND BEACONS CATERPILLAR
CHX620 5262 > ....
6- 71020EN - 09 - 2002
25a AIR CONDITIONING
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A17. AC–compressor surveillance CPU print 9400
A37. AC–compressor control Lights print 9350
A156. Compressor LED’s control Dashboard print 9470
A324. Air conditioning operation Dashboard print 9200
B61. Thermostat switch Dashboard print 9230
F3. 25A -- Air conditioning fan Fuse print 9230
F43. Fan Central elctronic box 9330
H13. Compressor overpressure LED Instrument panel 9460
H14. Compressor underpressure LED Instrument panel 9470
K56. Fan relay Console module in cab 9280
K57. Fan ground relay Console module in cab 9310
M11. Fan motor Underneath operator’s seat 9310
M19. Additional fan 9290
S37. Fan + air conditioning switch Console module in cab 9250
S60. Air conditioning safety switch Console module in cab 9230
S62. Compressor overpressure contact Compressor 9380
S63. Compressor underpressure contact Compressor 9420
Y27. Compressor Left–hand side of engine 9340
Line: 9190 -- 9520
6- 71020EN - 09 - 2002
25A AIR CONDITIONING
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
26a CAB
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A1. Radio Cab roof 9900
A2. CB Cab roof 9910
E37. Cab spot light Cab roof 9970
E38. Cab interior light Cab roof 10010
F6. 25A -- Windshield wiper + mirrors Fuse print 9760

10190
F12. 10A -- Dashboard 12 V sockets Fuse print 9710
F13. 10A -- Clock, radio, CB, cab lights Fuse print 9870
M12. Windshield wiper motor Cab roof 9810
M31. Rear windshield wiper motor Rear windshield 10140
M32. Front windshield washer pump Cab roof 9830
M33. Side windows washer pump Side windows 10150
M34. Rear windshield washer pump Rear windshield 10150
M35. Right–hand side window wiper motor Right–hand side window 10140
M36. Left–hand side window wiper motor Left–hand side window 10140
P4. Clock Cab roof 9850
S38. Windshield wiper switch Cab roof 9760
S84. Cab door switch Cab door 9980
S126. Front windshield washer switch Cab roof 9810
S127. Side windows wiper/washer switch Cab roof 10080
S128. Rear windshield wiper/washer switch Cab roof 10070
Line: 9700 -- 10200
6- 71020EN - 09 - 2002
26A CAB
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
27a MIRROR CONTROL AND WINDSHIELD HEATING
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
F42. Rear windshield heating circuit breaker Cab roof 10530
K53. Mirror control relay, right–hand side Cab roof 10310
K54. Mirror control relay, left–hand side Cab roof 10350
K55. Rear windshield heating relay Cab roof 10460
M13. Right–hand side mirror Right–hand side of cab 10410
M14. Left–hand side mirror Left–hand side of cab 10360
M15. Additional mirror, right–hand side Right–hand side of cab 10490

(Germany only)
R15. Rear windshield heating Rear windshield 10480
S39. Mirror control switch Cab roof 10260
S40. Mirror selection + heating switch Cab roof 10510
S125. Additional mirror switch, right–hand Cab roof 10480

side (Germany only)
Line: 10210 -- 10540
6- 71020EN - 09 - 2002
27A MIRROR CONTROL AND WINDSHIELD HEATING
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
28a FEED ROLLS
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A28. Cutterhead rpm Drive print 10810
B116. Feed rolls speed sensor 10790
Line: 10720 -- 10880
6- 71020EN - 09 - 2002
28A FEED ROLLS

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
29a HIGH FLOW REAR HYDRAULICS

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
A56. High flow rear hydraulics control Valve print 10910
A116. High flow rear hydraulics switch–on Dashboard print 11020
S137. High flow rear hydraulics switch Dashboard 11010
Y49. Tip trailer up valve Right–hand side of engine 10890
Y50. Tip trailer down valve Right–hand side of engine 10920
Line: 10890 -- 11050
6- 71020EN - 09 - 2002
29A HIGH FLOW REAR HYDRAULICS

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
30a ADDITIONAL LIGHTS FOR FLIP--UP ATTACHMENTS

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
E8. Additional direction indicator, LH side Steering platform railing 11390
E8. Additional parking light, LH side Steering platform railing 11330
E9. Direction indicator on attachment, Attachment 11370

LH side
E9. Parking light on attachment, LH side Attachment 11290
E10. Direction indicator on attachment, Attachment 11410

RH side
E10. Parking light on attachment, RH side Attachment 11310
E12. Additional direction indicator, RH side Steering platform railing 11430
E12. Additional parking light, RH side Steering platform railing 11350
E15. Headlight, LH side Steering platform railing 11120
E16. Headlight, RH side Steering platform railing 11210
E19. Headlight on attachment, LH side Attachment 11060
E20. Headlight on attachment, RH side Attachment 11150
E21. Headlight, LH side high Steering platform railing 11090
E22. Headlight, RH side high Steering platform railing 11180
F9. 15A -- Parking lights, RH side Fuse print 11350
F10. 15A -- Parking lights, LH side Fuse print 11290
F23. 15A -- Main beam headlights Fuse print 11060
F23. 15A -- Main beam headlights Fuse print 11150
F24. 15A -- Dimmed headlights Fuse print 11090
F24. 15A -- Dimmed headlights Fuse print 11180
Line: 11040 -- 11550
6- 71020EN - 09 - 2002
30A ADDITIONAL LIGHTS FOR FLIP--UP ATTACHMENTS
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
CHX620 5262 > ....
6- 71020EN - 09 - 2002
31a ELECTRONIC ENGINE CONTROL CATERPILLAR
CHX620 5262 > ....
A81. Electronic cintrol box Engine 11720
A82. Electronic injection box Engine 11790
B3. Oil temperature sensor Engine 11680
B42. Air temperature sensor Engine 11570
B45. Turbo pressure sensor Engine 11720
B46. Air pressure sensor Engine 11760
B47. Oil pressure sensor Engine 11800
B48. Fuel temperature sensor Engine 11830
R31. CAN resistance Engine 11740
Line: 11560 -- 11890
6- 71020EN - 09 - 2002
31A ELECTRONIC ENGINE CONTROL CATERPILLAR
CHX620 5262 > ....
6- 71020EN - 09 - 2002
32a ELECTRONIC ENGINE CONTROL IVECO
CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
A84. Engine electronic control box Engine 11960
K68. Pre--heating 12040
R1. Engine heating Engine 12040
S130. Engine electronic control box diagnos- 12000

tics switch
X189. Engine electronic control box connector 12020
Line: 11900 -- 12060
6- 71020EN - 09 - 2002
32A ELECTRONIC ENGINE CONTROL IVECO

CHX320 5262 > .... CHX420 5262 > .... CHX520 5262 > ....
6- 71020EN - 09 - 2002
6- 71020EN - 09 - 2002
Chapter 3 -- Wiring Diagrams CHX North America
CONTENT
Wiring diagrams CHX NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
Chapter 4 -- Can network basics

CONTENT
Can network basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General layout electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electronic system layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Analog signals (from input or to output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Digital Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional info: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Can spy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Decimal and hexadecimal counting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Decimal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hexadecimal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How to use the CAN Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How to Enter CAN--SPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CAN--SPY in practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Error codes messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiring checking procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fault finding routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6- 71020EN - 08 - 2003
CAN NETWORK BASICS
The main reason for building an integrated electrical / electronic system is the increasing demand for more func-
tions and ease of operation!
The CAN (Controller Area Network) is a communication system that links several microprocessors, using two
leads to send information between them. These two leads are known as the bus.
Instead of leading wiring harnesses all over the machine, functions are grouped and collected into Input and Out-
put stations (on electronic printed circuits). These I/O stations are linked by only a small number of wires with
a serial data transmission network. The network connects all stations. As such it is merely a way of transporting
information/messages from one place to another in the machine.
GENERAL LAYOUT ELECTRONIC

SYSTEM
Electronic components c Metal Detector
Contains node W.
a Cab area
Cab sections connected to the network: d Caterpillar Engine (Only for CHX620)
• Performance monitor: contains nodes A and S A communication link is established between the
controller of the Caterpillar engine and the Electronic
Box to exchange information between both systems.
Node A: performance monitor/dashboard
operation
The electronic control unit can only be updated and
configured by an official Caterpillar representative.
Node S: Symbols and languages
Conclusion
• Instrument Panel
The electronics on the Forage Harvester contain four

• Multifunction lever and armrest module
memories, located on several electronic printed
circuits, which are responsible for the functional
• Floor console module operation of the machine.
They are all flash memories that can be updated by

b Electronic Box means of PC laptop or EST tool. This means that
when a new software revision is released, no
Printed circuits located in the electronic box and hardware changes have to be carried out and no
connected to the network: EPROM’s have to be changed.
• CPU printed circuit: contains node B Only a new installation disk (for PC laptop) is
necessary to install the new software revision. This
• AKS & ASBA printed circuit: contains node T happens via a DIN connector underneath the
dashboard.
• Lights printed circuit
REMARK:
• Electric motor and actuator printed circuit Module: used to indicate the hardware and printed
circuit boards all over the machine.
• Valve printed circuit Node: used to indicate the software that translates all
input messages to output messages.
• Bosch module
• Auto–Pilot module [accessory]

6- 71020EN - 08 - 2003
CAN NETWORK
EST Tool A+S B T E W

Engine
perform- CPU AKS & ASBA Drive Metal
Module
ance moni- print print print Detector
tor
6- 71020EN - 08 - 2003
ELECTRONIC SYSTEM LAYOUT
3
Input Analog signals (from input or to output)
Switches Examples:
Sensors: • 0 or 12V constant voltage (from switches;

most end users)
Pressure / Temperature sensors • 0 or 12V variable voltage (potentiometer)
Header height sensors
• PWM variable voltage (to proportional
RPM sensors
signal electro valves)
Proximity sensors
PWM: pulse width modulation.
Potentiometers
Digital Information
Output
(see also picture 2)
To end users:
All information that passes through the CAN
Electromagnetic valves Network.
Electromagnetic clutches The medium can be:

Fibre optics
Actuators
Flat cable
Solenoids
Standard cable
Electric motors Interfaces
Lights (located on the printed circuit boards)

Translates an analog signal to a digital signal, or
Translates a digital signal to an analog signal.
6- 71020EN - 08 - 2003
Software
A sequential decision making process, where the

presence of particular input signals result in a
desired task (output) being achieved. If all the
necessary input signals are not present, or are
introduced in the wrong sequence, then the
desired task or action will not be achieved. The
software program determines the function of the
machine, where all inputs and requisites for a
particular task or action are specified.
Changing the software program can effect the

machine function as a result of the input requirement
specifications for a particular output being changed.
Calibrations
Calibration effect machine function and error code

reporting.
Calibrations are achieved through the performance

monitor and by using the EST tool.
The calibration procedure dictated a choice to the

software program. This change in the software
decision making process enables us to adapt the
mode of operation of the machine to respect any
additional equipment that is installed, or refine the
operation of a particular function to suit the working
environment.
Additional info:
1. Each Node contains a particular software

program that is unique to that location. Therefore
the Software cannot be transferred from one
Node to another.
2. The calibrations preferences are held on Three

Nodes, when the engine is started these
preferred choice or setting on each Node are
compared. If the choices or settings on one Node
are different from the others the Nodes in the
majority will influence and change choices or
settings of the Node that is in the minority.
3. With an integrated system, the functionality of

the system can NOT be deduced from the wiring
diagram (in comparison with a classical wired
system).
6- 71020EN - 08 - 2003
CAN SPY
Decimal and hexadecimal counting
To enable us to count up to Sixteen and only use One

digit position (to enable the large volume of
information to be displayed) the Hexadecimal
counting system has been introduced.
Decimal
Number 0 1 2 3 4 5 6 7 8 9
NOTE: Zero is a number in the decimal counting sys- If only One digit position is available on the display,
tem and can be considered as the first option in the then 0 -- 9 (Ten options) can be expressed.
sequence of Ten numbers.
If Two digit positions are available on the display,
then 0 -- 99 (One Hundred options) can be
Thousands Hundreds Tens Units expressed.
0 0 0 0
In simple terms:
1 1 1 1
2 2 2 2 28 is formed of Eight Units and Two groups of Ten
(= 2 x 10 + 8).
3 3 3 3
4 4 4 4 6789 is formed of Nine Units, Eight groups of
Ten, Seven groups of One Hundred and Six
5 5 5 5 groups of One Thousand (= 6 x 1000 + 7 x 100
+ 8 x 10 + 9).
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
Hexadecimal
Decimal number 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Hexadecimal number 0 1 2 3 4 5 6 7 8 9 A B C D E F
NOTE: Zero is a number in the hexadecimal count- Units are expressed in one digit from 0 -- F. Then
ing system and can be considered as the first option groups of Sixteen are expressed in the first digit
in the sequence of Sixteen numbers. position and the Units shown in the Second giving 00
-- FF.
To enable us to express the Eleventh option and
beyond, letters of the Alphabet are used (A, B, C, D,
Some calculators have an automatic hexadecimal --
E, F).
decimal conversion option.
The same counting principals apply in hexadecimal
counting as in decimal counting.
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Sixteen X Sixteen X Sixteens Units

Sixteen X Sixteen
Sixteen
0 0 0 0
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
A A A A
B B B B
C C C C
D D D D
E E E E
F F F F
Example:
Hexade- Decimal
cimal
20 (2 x 16) + 0 = 32
2FA3 (2 x 163)+(F x 162)+(A x 161)+3
2FA3 (2 x 4096)+(15 x 256)+(10 x 16)+3
2FA3 8192+3840+160+3 = 12195
A clear example of hexadecimal counting can be

observed when recalling identifier 1327 of the
CAN--SPY mode. This is the CAN identifier for date
and time. The counting of the seconds gives a fair
idea of what hexadecimal counting is.
6- 71020EN - 08 - 2003
How to use the CAN Identifiers
The CAN--system provides the ability to obtain

”inside information” for component or continuity fault
diagnosis. This system is called the ”CAN--SPY
troubleshooting”.
The CAN--SPY system enables us to check the

presence and status of input and output signals
within the electronic system for each component or
function. This information can be recalled on the
performance monitor and used in conjunction with
the Can Spy notes.
Once the CAN--SPY mode and the right identifier are

selected, you are able to compare the expected
values given in the CAN--SPY notes with the values
provided by the electronic system. Any difference
between these two values, for any given situation
can be of help to isolate the location of a fault in the
electronic system. A logical process of elimination
should be used, where each expected value from the
inputs, prerequisites or outputs for a particular
function are checked in sequence.
When checking Output and Status values it is often

necessary to follow normal operating procedures
during testing. Some individual Output or Status
values will not be available unless all preceding
inputs or functions are present.
6- 71020EN - 08 - 2003
How to Enter CAN--SPY
Simultaneously press MEM and ESC on the

performance monitor panel. The Can Spy screen will
appear and shows the following information:
• The identifier number or ”Page number” (e.g.

1280). This can be changed with the scroll
buttons.
• Four words in the bottom text line (shown as xxxx

xxxx xxxx xxxx). Each word contains four digits.
The four words in the bottom text line contain the

information of the CAN system in hexadecimal
numbers.
ZDA482A
CAN--SPY in practice
The CAN identifier values are shown in four columns

known as ’Words’. In each word there are four digit
positions.
There are four basic rules that must be used to

calculate the appropriate value from the notes:
1. Only add values together. Never subtract.
2. Identify the function status statements that

match the current machine situation (’true
statements’) and add the relevant values
together.
3. Only add values in the same word and the same

digit position.
4. Calculate the ’expected value’ on paper and then

check that it corresponds to the value given on
the performance monitor screen.
NOTE: Values in the same Word that are not relevant

to the function description are shown in the notes as =.
6- 71020EN - 08 - 2003
CAN ID Data description word1 word2 word3 word4

1282 Header down switch pressed 8===
1282 Header down switch not pressed 4===
1282 Feed rolls reverse switch pressed 2===
1282 Feed rolls reverse switch not pressed 1===
Word One, Digit Position One

Function Description + Function Status Statement
Can Identifier (Page) Number
The function descriptions are found in group of four

(A group is defined by the digit position within a
particular word), where each individual status is
given by a value of 8, 4, 2 or 1. No matter how these
values or combination (using each value only once)
of values are added together a unique value will
result.
Word 1 2 3 4
DB 0 1 2 3 4 5 6 7
Digit 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Bit 7654 3210 7654 3210 7654 3210 7654 3210 7654 3210 7654 3210 7654 3210 7654 3210
Hex 8421 8421 8421 8421 8421 8421 8421 8421 8421 8421 8421 8421 8421 8421 8421 8421
Digit Values
0
1 1
2 2
3 1 2
4 4
5 1 4
6 2 4
7 1 2 4
8 8
9 1 8
A 2 8
B 1 2 8
C 4 8
D 1 4 8
E 2 4 8
F 1 2 4 8
6- 71020EN - 08 - 2003
Example 1

1282 Header down switch pressed 8===
1282 Header down switch not pressed 4===
1. Enter the CAN--SPY on page 1282, It is likely that 3. Press and hold both the header down switch and
no switches on the multifunction lever are the feed roll reverse switch simultaneously. The
pressed. machine status has now changed again, so we
must add the corresponding values shown in the
Therefore the ’true statements’ are: notes that are relevant to this new situation.
These are:
• Header down switch not pressed. Which has
a value of 4. • Header down switch pressed. Which has a
value of 8.
• Feed rolls reverse switch not pressed. Which
has a value of 1. • Feed rolls reverse switch not pressed. Which
has a value of 2.
If these two values are added together the ’expected
value’ on the performance monitor in word one, digit If these two values are added together the ’expected
position one is 5. Look at the performance monitor in value’ on the performance monitor in word one, digit
identifier (’page’) number 1282 and confirm that a position one is 10 (expressed in decimal terms). The
value of 5 is shown in word one, digit position one. If performance monitor must express this value using
there is a value of 5 is shown continue in a logical only one digit position and uses the hexadecimal
sequence. expression for a decimal 10 which is A. Look at the
performance monitor at identifier number 1282 and
2. Press and hold the header down switch. The confirm that a value of A is shown in word one, digit
position one. If there is a value of A the following
machine status has now changed, so we must
conclusions can be made.
add the corresponding values shown in the notes
that are relevant to the new situation. These are:
Conclusion:
• Header down switch pressed. Which has a
value of 8. By pressing and holding the switches (to change the
machine status) and checking that the values shown
• Feed rolls reverse switch not pressed. Which on the performance monitor against the relevant
has a value of 1. value in the notes. We not only confirm the correct
function of the switch but also the connections
If these two values are added together the ’expected through classical wiring, PCB tracks and in some
value’ on the performance monitor in word one, digit case the Optical Fibre communications.
position one is 9. Look at the performance monitor in
identifier (’page’) number 1282 and confirm that a Having checked the function of these two switches
value of 9 is shown in word one, digit position one. If and found a satisfactory result the CAN--SPY system
there is a value of 9 shown continue in a logical can be used to check each individual input or status
sequence. that the Software requires to implement an output
signal or change in status. These other functions
may be found on other pages. Knowledge of the
function of the machine is a benefit when diagnosing
complex failures.
6- 71020EN - 08 - 2003
Example 2
CAN ID Data description word1 word2 word3 word4 Comments

1282 MFH switch Out of Neutral =2==
1282 MFH switch In Neutral =1==
1282 Ground Speed Potentiometer ==XX In Neutral XX=5C±30
or3E <XX<7A
Limit 00 <XX<D0±10
In the CAN--SPY notes the value XX is shown in word

3, digit position 3 & 4. XX refers to a variable input
received from a sensor, in this case the ground speed
control potentiometer located below the
multifunction lever.
The values in word 3, digit position 2 refer to the

status of the neutral switch, which is also located
below the multifunction lever. In neutral the switch
has an added value of 1, out of neutral it has an
added value of 2.
The comment column gives the parameters within

which the XX value must be set and the overall range
of the potentiometer. If the multifunction lever is
moved from the position where the neutral switch
value changes from 2 to 1(either from FWD to
neutral, or from REV to neutral), the XX value should
be in a range of 5C (Hexadecimal) plus or minus a
decimal value of thirty, or a range (in hexadecimal
terms) of 3E -- 7A. The acceptable range over the
total travel of the potentiometer is from 00 to D0 ± 10
(decimal).
6- 71020EN - 08 - 2003
Example 3

1283 AKS & ASBA switch switched ON 8===
1283 Cutterhead Reversing switch switched OFF 4===
1283 Automatic reversing aid system switch switched ON 2===
1283 Crop Processor roll clearance close switch pressed 1===
1. When the ignition switched on, enter CAN--SPY NOTE: The other functions relevant to this word and
on page 1283. Ensure that none of the relevant digit position are either not pressed or are off. There-
switches are switched on or pressed, the only fore these statements can be considered as not true
true statement is: and the relevant values do not need to be con-
sidered. In addition the comment column tells that
• Cutterhead reversing switch, switched off. when the switch is open then the value is 0.
Which has a value of 4.
3. Switch on the AKS & ASBA switch (Automatic
Knife Sharpening & Automatic Shear Bar
In this situation the value shown in word two, digit
Adjustment). Leaving the cutterhead reverse
position one should be 4.
switch off and the automatic reversing aid
system switch off. The machine status has now
changed again, so we must add the
NOTE: The other functions relevant to this word and corresponding values shown in the notes that are
digit position are either not pressed or are off. There- relevant to the new situation. These are:
fore these statements can be considered as not true
and the relevant values do not need to be con- • Cutterhead reversing switch, switched off.
sidered. In addition the comment column tells that Which has a value of 4.
when the switch is open then the value is 0.
• Automatic reversing aid system switch on.
2. Switch on the automatic reversing aid system
Which has a value of 2.
switch. The machine status has now changed,
so we must add the corresponding values shown
in the notes that are relevant to the new situation. • AKS & ASBA switch on. Which has a value
These are: of 8.
• Cutterhead reversing switch, switched off. If these three values are added together the
Which has a value of 4. ’expected value’ on the performance monitor in word
two, digit position one is 14 (decimal). The
• Automatic reversing aid system switch, performance monitor must express this value using
switched on. Which has a value of 2. only one digit position and uses the hexadecimal
expression for a decimal 14 which is E. Look at the
If these two values are added together the ’expected performance monitor at identifier (’page’) number
value’ on the performance monitor in word two, digit 1283 and confirm that a value of E is shown in word
position one is 6. Look at the performance monitor at two, digit position one. If there is a value of E,
identifier (’page’) number 1283 and confirm that a continue in a logical sequence.
value of 6 is shown in word two, digit position one. If
a value of 6 is shown, continue in a logical sequence.
NOTE: The other functions relevant to this word and
digit position are either not pressed or are off. There-
fore these statements can be considered as not true
and the relevant values do not need to be con-
sidered. In addition the comment column tells that
when the switch is open then the value is 0.
6- 71020EN - 08 - 2003
4. Press and hold the crop processor clearance 5. Switch the cutterhead reversing switch, and hold
close switch. Leaving the AKS & ASBA switch on the crop processor clearance close switch.
(Automatic Knife Sharpening & Automatic Shear Leaving the AKS & ASBA switch on (Automatic
Bar Adjustment), the cutterhead reverse switch Knife Sharpening & Automatic Shear Bar
off and the automatic reversing aid system Adjustment), and the automatic reversing aid
switch on. The machine status has now changed system switch on. The machine status has now
again, so we must add the corresponding values changed again, so we must add the
shown in the notes that are relevant to the new corresponding values shown in the notes that are
situation. These are: relevant to the new situation. These are:
• Crop processor clearance close switch, • Crop processor clearance close switch,
pressed. Which has a value of 1. pressed. Which has a value of 1.
• Cutterhead reversing switch, switched off. • Automatic reversing aid system switch on.
Which has a value of 4. Which has a value of 2.
• Automatic reversing aid system switch, • AKS & ASBA switch on. Which has a value
switched on. Which has a value of 2. of 8.
• AKS & ASBA switch, switched on. Which has If these three values are added together the
a value of 8. ’expected value’ on the performance monitor in word
two, digit position one is 11 (decimal). The
If these four values are added together the ’expected performance monitor must express this value using
value’ on the performance monitor in word two, digit only one digit position and uses the hexadecimal
position one is 15 (decimal). The performance expression for a decimal 11 which is B. Look at the
monitor must express this value using only one digit performance monitor at identifier (’page’) number
position and uses the hexadecimal expression for a 1283 and confirm that a value of B is shown in word
decimal 15 which is F. Look at the performance two, digit position one. If there is a value of B, the
monitor at identifier (’page’) number 1283 and following conclusions can be made.
confirm that a value of F is shown in word two, digit
position one. If there is a value of F, continue in a
logical sequence.
6- 71020EN - 08 - 2003
ERROR CODES MESSAGES
All interfaces are built in such a way that they can

deduce an interruption in the signal. This interruption
can be a short circuit or an open circuit from the
sensor / switch or to an end user (motor, valve).
The interface will send a message on the CAN

system, which will be translated into an error
message on the performance monitor.
Also refer to chapter 9/4b ’’Error messages
overview’’.
Once an interruption in the signal for an end user is

detected, the electronic system will automatically
stop to power the output line.
Possible causes:
-- Open or short circuit in wiring loom or

connectors.
-- Sensor or end user shorted or damaged.
-- Interface defect.
Action:
1. Check wiring and connections.
2. Check switch/sensor or end user (motor, valve).
3. Check interface visually (located on printed

circuit boards).
6- 71020EN - 08 - 2003
Wiring checking procedure
1. Is there an open circuit in the wiring?

Check each cable separately for infinity
resistance.
And
2. Is there a shorted circuit in the wiring loom?

Check each pair of cables for 0 resistance.
And
EL--003
3. Is there a shorted circuit with the ground?

Check each cable separately with ground for 0
resistance.
REMARK: If a problem only occurs now and then,

the problem will most likely be related to bad contacts
in connectors or bad connections in switches.
In this case, it is recommended to test with a new
(self--made) wiring loom directly connected between
the output on the electronic printed circuit and the
end user. Make sure you never contact the original
wiring loom and disconnect all original cables at the 9
beginning and at the end.
6- 71020EN - 08 - 2003
ATTENTION
• Never put 12 V (battery voltage) to an end
user (electric motor, actuator or electro
valve) when the wiring loom is still
connected to the printed circuit, as this will
burn the electronic components on the
printed circuit.
• Always disconnect the end user from the

central electronic box before testing it.
• When doing this test, be sure the end user

can stand 12 V power supply. Some valves
have a supply voltage of 7V. 10
FAULT FINDING ROUTINE 7. If there is no error code related to the problem,

check the output of the Bus CAN with the CAN
1. After listening to the customer, try to check the identifiers and the functional classification. If the
faulty function to make sure the malfunction is output of the Bus CAN is OK, check the
not due to a user mistake or to the calibration. Try connections on the printed circuit, the wiring and
the final element (as described in point 5).
related functions to reduce scope of diagnosis.
Consult the Operator’s Manual or the Repair
8. If the wiring and the final element are OK, the
Manual.
failure is probably due to the output interface.
2. Make sure it is not a mechanical, hydraulic or Check the electrical diagrams to locate the
corresponding printed circuit and replace it.
fuse failure.
3. Check the performance monitor memory in the 9. In case the outputs of the Bus CAN are incorrect,
Service Mode for errors related to this problem. check the inputs one by one with the identifier list
If so, delete all the errors, switch on the engine and the detailed analysis per function (refer to
and perform the failed function. Then check if the section 55 chapter 7).
error has reappeared in the memory.
10. If an input identifier is incorrect, check the
4. If the error has reappeared, the problem is element relating to this identifier.
probably electrical. Consult the error code list
11. If the input (switch or sensor) is correct, the
and the electrical diagrams to locate the
failure is probably related to the printed circuit.
problem.
5. If there is a network error code, solve this first

before checking anything else. A printed circuit
or connections between printed circuits can
cause a network error.
6. If the error code concerns an output, a quick way

to check is to power the element directly from the
central box. Disconnect the connection at the
printed circuit and power the pins related to the
problem from the fuse, which powers the printed
circuit. In this way a simultaneous check of the
wiring and of the final element is performed. If the
wiring or the final element is not OK, use the
electrical diagrams.
6- 71020EN - 08 - 2003
Listen to the customer. Check

faulty function yourself.
Try related oper-

ations to reduce
scope of diagnosis
Malfunction
Yes
due to user Explain how to use
mistake or the function correctly
calibration
No
Hydraulic Yes Perform repair of

or mechanic or hy-
Mechanical draulic circuit.
Fault Use Repair Manual
No
Yes
Fuse Replace fuse.
burned?
No
Error Codes on Yes Solve this first before

the performance Yes Network checking anything else.
monitor related Error Code Consult Error Code List
to the problem stored? and Electrical Diagrams
No
No
Perform output and wiring
Yes test by powering the end
Yes Error Code
user, disconnected at the
Is the problem CAN--ID for concerns an
printed circuit.
related to the end user is output Consult Error Code List
end user? correct? and Electrical Diagrams.
Yes No
Perform output and wiring test
Consult Error Code
by powering the end user. Dis- Check CAN--ID for inputs list and Electrical
connect at printed circuit one by one Diagrams
A
Yes Test CAN--ID Yes
successfull? for Input
is correct Check next Input
No No
Interface can be de- Repair elec- Check input switch/sensor

fective. trics or replace
Replace printed circuit end user
Yes Repair electrics or re-

Input switch/
place input switch/
sensor
sensor
defect
Interface can be defective.

Replace printed circuit.
6- 71020EN - 08 - 2003
Chapter 5 -- Calibration
CONTENT

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Machine calibration with EST tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Configuration Item Selection screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maximum Handle position calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Minimum forward pump current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Minimum reverse pump current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Vehicle Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6- 71020EN - 08 - 2003
GENERAL
Apart from the calibrations and settings carried out

on the performance monitor like e.g. the Attachment
Height Control calibration, an initial machine (re)
calibration can be carried out with the EST -- Tool,
e.g. after a rework or after installing different tyres.
The latter is normally carried out in the plant before

shipment, but there may be circumstances in which
the calibration has to be repeated.
SPECIAL TOOLS
Number Description
Electronic Service Tool (PC, EST software)
......... Machine software update (Info and partnumber distributed via Service Bulletin)
380000817 Connector adapter cable
6- 71020EN - 08 - 2003
MACHINE CALIBRATION WITH EST

TOOL
The following calibrations can be done with the EST

tool:
Calibration
Maximum handle position
Minimum forward current to hydrostatic pump
Minimum reverse current to hydrostatic pump
Four wheel drive
Engine throttle control
High flow rear hydraulics
Rear auxiliary hydraulics
Sharpen on the move (NA only)
To re--calibrate the machine, proceed as follows:
1. Connect Laptop to machine.
2. Start the Electronic Service Tool program.
1
3. Click on the Tool pull down menu in the tool bar
area of the screen.
6- 71020EN - 08 - 2003
4. Select the desired application using the cursor

arrow.
5. Click on “CHX Self--Propelled Forage

Harvester”.
NOTE: A check “V” symbol will be displayed next to

the current product selection.
A message will appear on the screen to confirm

to reconfigure the EST for operation on the CHX
Self--Propelled Forage Harvester.
6. Click the “OK” button.
The EST will reconfigure to the application

selected.
3
As the EST is started or reconfigured to the CHX
Self--Propelled Forage Harvester application, a
“Vehicle Connector Selection” screen will display.
7. Select the “Dashboard Diagnostic Connector” to

re--calibrate the machine.
6- 71020EN - 08 - 2003
Now the programming screen is appearing.
9. Activate the configuration window by pressing

the Configuration button in the tool bar area of
the screen.
The Configuration Item Selection screen will

appear (Fig. 6) .
6- 71020EN - 08 - 2003
Configuration Item Selection screen
Following calibrations/configurations can be done:
• Calibration -- Maximum Handle Position
• Calibration -- Minimum forward pump current
• Calibration -- Minimum Reverse pump current
• Vehicle Configuration
6- 71020EN - 08 - 2003
Maximum Handle position calibration
The maximum handle position is calibrated at the

factory. You may wish to recalibrate whenever the
customer is not satisfied with the current
performance, when any involved component has
been replaced, or when more than 1 electronic
control unit is replaced at the same time. Please
observe safety practices while performing this
calibration.
NOTE: The Service Tool screen can only report that

this electronic controller has passed calibration even
if the calibration fails in the controller. Check the
machine performance or the corresponding CAN
identifier to confirm that the calibration is successfull.
1. Select “Calibration -- Maximum Handle Position”

(Fig. 6) .
NOTE: The selection becomes highlighted.
2. Click on “Configure selected item” (Fig. 6) .
NOTE: Pop--up screen Fig. 7 appears on the screen.
3. Click on “Start Calibration”.
NOTE: Pop--up screen Fig. 8 appears on the screen.
6- 71020EN - 08 - 2003
4. Move handle to maximum forward position and CALIBRATION -- MAXIMUM HANDLE POSITION
click on “enter”.
Move handle to maximum forward position
and press “enter”.
NOTE: “Calibration finshed” will appear on the

screen.
ENTER
5. Click on “Exit” to return to the Configuration Item

Selection screen (Fig. 6).
6- 71020EN - 08 - 2003
Minimum forward pump current calibration
The minimum forward pump current is calibrated at

the factory. You may wish to recalibrate whenever
the customer is not satisfied with the current
control unit is replaced at the same time. The vehicle
will move during this calibration! Please observe
safety practices while performing this calibration.

1. Select “Calibration -- Minimum Forward pump

current”
2. Click on “Configure selected item”.
NOTE: Pop--up screen Fig. 10 appears on the

screen.
10

screen.
6- 71020EN - 08 - 2003
4. Choose 2nd or 3rd gear with engine at low idle. CALIBRATION -- MINIMUM FORWARD PUMP CURRENT
Move handle slowly forward until vehicle starts to
crawl. Do not move handle any further forward
Choose 2nd or 3rd gear with engine at low
after vehicle has begun to move. Move handle
idle. Move handle slowly forward until
slowly backward until vehicle stops and press
vehicle starts to crawl. Do not move handle
“ENTER”.
any further forward after vehicle has begun
to move. Move handle slowly backward
until vehicle stops and press
“ENTER”.
NOTE: “Calibration finshed” will appear on the ENTER

screen.
11
12
5. Click on “Exit” to return to the Configuration Item

Selection screen (Fig. 6).
6- 71020EN - 08 - 2003
Minimum reverse pump current calibration
The minimum reverse pump current is calibrated at

the factory. You may wish to recalibrate whenever
the customer is not satisfied with the current
control unit is replaced at the same time. The vehicle
will move during this calibration! Please observe
safety practices while performing this calibration.

1. Select “Calibration -- Minimum Reverse pump

current” (Fig. 6).
2. Click on “Configure selected item” (Fig. 6).

screen.
13

screen.
6- 71020EN - 08 - 2003
4. Choose 2nd or 3rd gear with engine at low idle. CALIBRATION -- MINIMUM REVERSE PUMP CURRENT
Move handle slowly backward until vehicle starts
to crawl. Do not move handle any further
Choose 2nd or 3rd gear with engine at low
backward after vehicle has begun to move. Move
idle. Move handle slowly backward until
handle slowly forward until vehicle stops and
vehicle starts to crawl. Do not move handle
press “ENTER”.
any further backward after vehicle has
begun to move. Move handle slowly
forward until vehicle stops and press
“ENTER”.
NOTE: “Calibration finshed” will appear on the ENTER

screen.
14
15
5. Click on “Exit” to return to the “Configuration Item

Selection” screen (Fig. 6).
6- 71020EN - 08 - 2003
Vehicle Configuration
The Vehicle Configuration screen contains following

items to configure:
• 4 Wheel drive: Installed / Not installed
• Engine throttle control: Manual / Automatic
Manual: The engine rpm will increase or

decrease as long as the upper or lower part of the
engine throttle control rocker switch is pressed.
Engine rpm increase/decrease will stop as soon
as the switch is released. Engine rpm
increase/decrease will also stop when maximum
or minimum rpm is reached.
Automatic: The engine rpm will automatically

increase to maximum rpm or decrease to
minimum rpm with one single pulse on the upper
or lower part of the engine throttle control rocker
switch. Press the opposite part of the switch to
stop the automatic engine rpm
increase/decrease.
• High flow hydraulics: Not installed / Installed
• Rear auxiliary hydraulics: Not installed / Installed
• Sharpen on the move: Yes / No (NA only)
6- 71020EN - 08 - 2003
To re--configure the items mentioned above, proceed

as follows.
1. Select “Vehicle Configuration” (Fig. 6).
2. Click on “Configure selected item” (Fig. 6).

screen.
16
3. Click the pull--down arrow next to the item to

re--configure.
A pull--down menu appears with the selections

available.
NOTE: If an item does not require re--configuration,

leaf the “Modified values” window blank.
17
4. Select the correct setting using the cursor arrow
and click on it. This setting will appear in the
“Modified values” window.
5. Proceed the same for the other items to

re--configure.
6. Click on “Send values to controller”.
7. Click on “Exit”.
6- 71020EN - 08 - 2003
Chapter 6 -- Software update

CONTENT
Software Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Software update with EST tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6- 71020EN - 08 - 2003
SOFTWARE REVISION
The software revision installed on the different nodes

can be found on the Can ID pages:
CAN DATA DESCRIPTION word1 word2 word3 word4 COMMENTS

ID
1275 Soft revision node W ==XX
1294 Soft revision node E ==XX
1303 Soft revision node B ==XX
1304 Soft revision node T ==XX
1326 Soft revision node A ==XX
1326 Soft revision node S ==XX
The revisions released until now are listed below.

When a new software revision is released, add the
information to this table.
Revision
03D0 03E0
Soft revision node W 2B 2B
Soft revision node E 03 03
Soft revision node B 2C 2D
Soft revision node T 01 01
Soft revision node A 2F 30
Soft revision node S 2C 2C
To view the actual installed sofware revision, select

the service mode by pressing “6 service”.
The software revision installed is shown in the

right--hand upper corner.
18
6- 71020EN - 08 - 2003
SOFTWARE UPDATE WITH EST TOOL
To download software to the different nodes,

proceed as follows:
1. Connect Laptop to machine.
2. Start the Electronic Service Tool program.
19
3. Click on the Tool pull down menu in the tool bar
area of the screen.
20
6- 71020EN - 08 - 2003
4. Select the desired application using the cursor

arrow.
5. Click on “CHX Self--Propelled Forage

Harvester”.
NOTE: A check “V” symbol will be displayed next to

the current product selection.
A message will appear on the screen to confirm

to reconfigure the EST for operation on the CHX
Self--Propelled Forage Harvester.
The EST will reconfigure to the application

selected.
21
As the EST is started or reconfigured to the CHX
Self--Propelled Forage Harvester application, a
“Vehicle Connector Selection” screen will display.
22
7. Select the “Dashboard Diagnostic Connector” to

re--calibrate the machine.
6- 71020EN - 08 - 2003
The programming screen is appearing.
23
9. Select the node to download software to and

press the “Browse” button.
NOTE: Only one node at the time can be

downloaded.
6- 71020EN - 08 - 2003
The “Choose program file name” pop--up screen is

appearing.
24
10. Select the HEX file and press “OPEN”.
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A “Download file information” pop--up screen is

appearing with information of the selected file.
25
11. Press the “OK” button.
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A confirmation screen is appearing.
26
12. Press the “OK” button to continue or press the

“Cancel” button to NOT replace the program on
the controller.
6- 71020EN - 08 - 2003
When “OK” was pressed, the validation process

will start and the “Validating” screen is appearing.
27
13. Turn the contact switch OFF and then back ON

to start the download process.
NOTE: While downloading, the alarm led’s on the

dashboard will run from left to right.
6- 71020EN - 08 - 2003
The download process is started. The complete

download is happening in three steps:
• Preparation of the controller (Fig. 28)
• Programming the controller (Fig. 29)
• Verifying application download (Fig. 30)
The “Programming” pop--up screen is appearing.
A progress bar is showing the actual status of each

step during the download process.
28
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29
30
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Finally the message “Programming completed

succesfully” will appear.
The program file which was selected has been

succesfully downloaded to the selected controller.
31
14. Press the “OK” button.
6- 71020EN - 08 - 2003
The programming screen is appearing.
In the Download status field is appearing

“Succesfull”.
32
15. Select another node to download software to and

proceed with steps 9 to 15.
In the table below are the approximate times required

to download software to the nodes.
Node Time (Min.)

A&S 27
B 8
E 7
T 9
W 4
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
Chapter 7 -- Troubleshooting
CONTENT
Machine error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Attachment height control error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Error reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Caterpillar error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
List of CAN identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Detailed analisys per function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1. Electric conditions, engine running or not running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2. Engine protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3. Harvest mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5. Cutterhead engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6. Feed rolls forward engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7. Feed rolls reverse engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8. Automatic reversing aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9. Four--wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10. Spout rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
11. Raise / lower spout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
12. Spout deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
13. Reverse cutterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
14. Auxiliary front hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
15. Auxiliary rear hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
16. Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
17. Silage additives application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
18. Knife sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
19. Automatic Shear Bar Adjustment routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
20. Crop processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
21. Metal detector operation and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
22. Attachment height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
23. Ground speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
24. High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
25. Rotary screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
26. Rotary screen brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
27. Caterpillar engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
28. CAN network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6- 71020EN - 08 - 2003
MACHINE ERROR MESSAGES

Error Code Description Importance
001 LCD NETWORK ERROR High
Explanation : General CAN network failure.
Information sent out by the different nodes, through the optical fibres and the flat cable, is
not arriving.
If the outgoing communication from the performance monitor to dashboard can node, from
the dashboard can node to the AKS & ASBA node and from the AKS & ASBA node to the
CPU node is interrupted.
All the nodes react as if there is no network, as if they are not connected to the network.
This failure can be caused by any node on the network or by a network path that generates
so many errors that all the nodes can not communicate any more.
Action :
Check software revision
on service page.
Is x.x displayed?
Yes
Check software rev. of

each node on CANSPY.
Press “Mem“ and “ESC“
button before switching on
ignition
Communication from AKS

& ASBA white connector
Restart the machine. If
Is only CAN. Id of Node B Yes to CPU black connector is
Yes problem persists, restart
incorrect? Value “00“ dis- incorrect.
Possible to download check routine from begin-
played? ning?
Software Node B?
No No
Is CAN--ID of Node B, Disconnect fiber optic

Node D 2 Node M incor- cable at CPU black con- Yes Try new CPU printed cir-
rect? nector. Red light is visible cuit of known performan-
Value “00” displayed for at end of fiber optic? ce.
these Nodes?
Yes
No
Replace the flat Check flat cable connec- Disconnect fiber optic
cable between tion between dashboard cable arriving from dash-
No Install new small fiber
dashboard and CAN Node and perform- board at AKS & ASBA optic cable and try new
performance ance monitor. Connection black connector? Red light AKS & ASBA printed cir-
monitor and flat cable correct is visible at end of fiber cuit of known performance
optic?
Yes No
Try new Dashboard CAN Try new Dashboard CAN

printed circuit of known printed circuit of known
performance Problem performance
Solved?
No
Try new AKS & ASBA

printed circuit of known
performance
6- 71020EN - 08 - 2003

002 OTHER NETWORK ERROR High
Explanation : General CAN network failure.
Information sent out by the different nodes, through the optical fibres and the flat cable, is
not arriving.
This error is caused by a lot of erroneous message transmissions and indicates a low quality
communication combined with a lot of network traffic.
Action : See ERROR 001.

003 NETWORK OVERLOAD High
Explanation : Too much or unclear data information on the CAN Bus. This error report will be always ac-
companied by error 001 and/or 002.
Too busy traffic on the local network. Software revision necessary.
Action : Load the latest software revision.

010 AOM DASHBOARD NETW. High
Explanation : The dashboard CAN node, closest to the LCD, is not transmitting CAN messages on a reg-
ular basis (at least 1 message / 2 seconds).
It is possible that all communication between the LCD and the other nodes is correct al-
though this dashboard CAN node is not transmitting messages to the performance monitor
node on a regular basis.
Action : Check the flat cable connection between the dashboard CAN node and LCD node.
If not correct, replace the flat cable between dashboard and performance monitor.
If correct, replace the dashboard CAN node for latest type of dashboards or replace old type
of dashboard by new type.
If the problem persists, try a new performance monitor of known performance (Do not forget
to download software when changing performance monitor).
6- 71020EN - 08 - 2003

011 DASHBOARD NETW. ERROR High
Explanation : The dashboard CAN node is not transmitting messages on a regular basis (at least 1 mess-
age / 2 seconds).
This error is only valid for machines with an old dashboard where two microprocessors are
located. This error code is related to the dashboard printed circuit, mounted in the centre
of the dashboard. This dashboard node serves the dashboard switches and the warning
lights above the switches.
On new type of dashboards, this error message should not appear as the function of both
microprocessors is grouped in one microprocessor.
Action : Replace the old type of dashboard by new type.

012 HANDLE NETWORK ERROR High
Explanation : The multifunction handle node is not transmitting CAN messages on a regular basis (at
least 1 message / 2 seconds).
though this handle node is not transmitting messages to the performance monitor node on
a regular basis.
Action : Refer to wiring diagram: line 1050.
Check the connection between the instrument panel and the multifunction lever.
Check for open and shorted circuits at power wire 1001--wt, at ground wires 1002--br
and 1074--bl and at CAN communication wires 1003--gn and 1004--ge.
If wiring is not correct, locate and repair open or shorted circuit.
If wiring is correct, replace the multifunction handle printed circuit.
If the problem persists, try a new dashboard with known performance.
6- 71020EN - 08 - 2003

013 CENTRAL NETW. ERROR High
Explanation : The CPU node in the central box is not transmitting CAN messages on a regular basis (at
least 1 message / 2 seconds).
though this CPU node is not transmitting CAN messages to the AKS & ASBA node on a
regular basis.
Action : Communication from CPU

white connecter to AKS &
ASBA black connector is Yes Restart the machine and
incorrect? check software revision.
Possible to download Soft-
ware Node B
No
Disconnect fiber optic

cable at the AKS & ASBA Yes Try New AKS & ASBA
black connector arriving printed circuit of known
from the CPU printed cir- performance
cuit. Red light is visible at
end of fiber optic?
No
Install new small fiber

optic cable and try new
CPU printed circuit of
known performance.
6- 71020EN - 08 - 2003

015 AOM NETWORK ERROR High
Explanation : The AKS & ASBA node in the central box is not transmitting CAN messages on a regular
basis (at least 1 message / 2 seconds).
though this AKS & ASBA node is not transmitting CAN messages to the dashboard node
on a regular basis.
Mostly error messages 15 and 13 appear together.
Action :
Communication from AKS
& ASBA white connector to
Dashboard black con- Yes Restart the machine and
nector is incorrect? Poss- check software revision
ible to download software
node D
No
Disconnect fiber optic

cable at the dashboard Yes Try new Dashboard CAN
black connector arriving printed circuit of known
from the AKS & ASBA performance
printed circuit
Red light is visible at end of
fiber optic
No
Clean fiber optic cables

between dashboard and
AKS & ASBA printed cir-
cuit.
Problem persists?
Yes
Try new AKS & ASBA

printed circuit of known
performance
6- 71020EN - 08 - 2003

100 TOTAL ENGINE HOURS = Medium
Explanation : There is more than 10 hours difference between the total amount of engine hours stored
in the CPU Memory and the total engine hours in the performance monitor memory.
Remark: Switching off the battery key before turning off the ignition may result in memoris-
ing an incorrect engine hour value in the performance monitor or in the CPU.
Different total hours are detected in the nodes on the network.
REMARK: This error is displayed in a special error page format.
REMARK: The error counter is automatically cleared when the selection of the right total
engine hours is made. So the error will not be displayed any more showing the right total
engine hours or showing engine hours differences of < 10h while looking up the errors
through the error overview.
Action : The total amount of engine hours, stored in the CPU and performance monitor, can only
be equalised when the error report automatically appeared after starting the engine.
On the special error 100 layout, the two different engine hours are indicated.
One of the values has an arrow in front of it.
Move the arrow in front of the selected hour value with the help of the ”ARROW” keys.
Confirm your choice by pressing the “Enter” key.
The selected engine hours are now stored in both memories, together with the related
threshing hours and hectares (or acres).
Press the “ESC” button to return to work screen. This error will not be stored in the error
overview list.
6- 71020EN - 08 - 2003

113 CROP. PROC. SENSOR O Medium
Explanation : The crop processor RPM sensor is disconnected from the CPU printed circuit.
Action : If no crop processor is installed, check in the performance monitor calibration for “CROP
PROCESSOR : NO”.
If the crop processor is installed, refer to the wiring diagram: sensor B104, line 4350.
Open the connector at the crop processor rpm sensor.
Turn on ignition and check for 8 Volts at the end of wire 2047--BR.
If not correct, locate and repair the open circuit in the brown wire.
If correct, check for ground at the end of wire 2048--BL.
If not correct, locate and repair the open circuit in the blue wire.
If correct, replace the sensor.
No Check performance moni-

Crop Processor installed? tor calibration for “Crop
Processor: No”
Yes
Open connector at the Crop

Processor RPM Sensor. No Locate and repair the open
Check for 8V at the end of circuit in the brown wire.
the brown wire
Yes
Check for ground at end of No Locate and repair the open

wire 2048 -- bl circuit in the blue wire.
Yes
Replace CP RPM Sensor

(B104).

114 CROP. PROC. SENSOR -- Medium
Explanation : The power wire (brown) of the crop processor RPM sensor is shorted to ground (blue wire
or frame ground).
PROCESSOR : NO”.
Locate and repair shorted circuit to ground in the wire 2047--BR.
After repair, check if 8 Volts arrives on the brown wire at the RPM sensor.
6- 71020EN - 08 - 2003

115 CROP. PROC. SENSOR + Medium
Explanation : The power wire (brown) of the crop processor RPM sensor is shorted to an external 12 Volts
power supply.
Action : If no crop processor is installed, check in the performance monitor calibration for ”CROP
PROCESSOR : NO”.
Locate and repair shorted circuit to 12 Volts in the wire 2047--BR.

117 EMD NETWORK ERROR Medium
Explanation : This Error Code is related to the function of the network connections between the metal
detector itself and the AKS & ASBA--print (A20). Physically these connections consist of
the wires 2097 and 2098 and their connections to the printed circuit boards.
When there is no CAN--info available on the network for more than 60 seconds, while the
EMD--output signal is 12V, this Error Code will appear.
Error Code 117 overrides all Error Codes that are generated by the metal detector
(270--277).
Action : Refer to wiring diagram: line 3980 and 3990.
Check network connections. Locate and repair open circuit, shorted circuit, shorted circuit
to frame ground or to an external 12 V power supply in wires 2097 and 2098.
Disconnect wire 2097 and 2098

in central box and at metal de-
tector (see wiring diagram: line
3980 and 3990)
Check for:
Open and short circuit,
Frame short circuit,
Short circuit to 12V.
Open or short Yes

circuit?
No Repair open or short circuit.

Reconnect wires 2097 and 2098
correctly.
Download the correct software.

Reconnect wires 2097 and
2098 correctly.
Problem solved?
No
Try with new electronic board

(A20) or a new metal detector.
Electronic Module
6- 71020EN - 08 - 2003

120 GROUND SPEED SENS. O Medium
Explanation : The ground speed RPM sensor is disconnected.
Action : Refer to wiring diagram: sensor B16, line 2570.
Open the connector at the ground speed rpm sensor.

121 GROUND SPEED SENS. -- Medium
Explanation : The power wire (brown) of the ground speed RPM sensor is shorted to ground (blue wire
or frame ground).
Action : Refer to the wiring diagram: sensor B16, line 2570.

122 GROUND SPEED SENS. + Medium
Explanation : The power wire (brown) of the ground speed RPM sensor is shorted to an external 12 Volts
power supply.

129 WRONG ENGINE CCM Medium
Explanation : The electronic system detected a wrong engine CCM (Iveco engine).
When engine CCM of higher power rating is installed, the error code will appear and the
engine will not start.
When engine CCM with lower power rating is installed, the error code will appear and the
engine will start.
Action : Install correct engine CCM.
6- 71020EN - 08 - 2003

130 CUTTERHEAD SENSOR O Medium
Explanation : The cutterhead RPM sensor is disconnected.
Open the connector at the cutterhead rpm sensor.
If correct, replace the cutterhead rpm sensor.

131 CUTTERHEAD SENSOR -- Medium
Explanation : The power wire (brown) of the cutterhead RPM sensor is shorted to ground (blue wire or
frame ground).

132 CUTTERHEAD SENSOR + Medium
Explanation : The power wire (brown) of the cutterhead RPM sensor is shorted to an external 12 Volts
power supply.
6- 71020EN - 08 - 2003

136 FEED ROLLS SENSOR O Medium
Explanation : The feed rolls sensor is disconnected.
Open the connector at the feed rolls rpm sensor.
Turn on ignition and check for 8 Volts at the end of wire 2226--GN.
If not correct, locate and repair the open circuit in the green wire.

137 FEED ROLLS SENSOR -- Medium
Explanation : The power wire (green) of the feed rolls sensor is shorted to ground (blue wire or frame
ground).
Locate and repair shorted circuit to ground in the wire 2226--GN.
After repair, check if 8 Volts arrives on the green wire at the RPM sensor.

138 FEED ROLLS SENSOR + Medium
Explanation : The power wire (green) of the feed rolls sensor is shorted to an external 12 Volts power
supply.
Locate and repair shorted circuit to 12 Volts in the wire 2226--GN.
After repair, check if 8 Volts arrives on the green wire at the RPM sensor.
6- 71020EN - 08 - 2003

142 SPOUT ROTATION SENSOR O Medium
Explanation : The spout rotation sensor is disconnected.
Open the connector at the sensor.
Turn on ignition and check for 8 Volts at the end of wire 2041--br.
If correct, check for ground at the end of wire 2042--bl.

143 SPOUT ROTATION SENSOR -- Medium
Explanation : The power wire (brown) of the spout rotation sensor is shorted to ground (blue wire or frame
ground).
Locate and repair shorted circuit to ground in the wire 2041--br.
After repair, check if 8 Volts arrives on the brown wire at the sensor.

144 SPOUT ROTATION SENSOR + Medium
Explanation : The power wire (brown) of the spout rotation sensor is shorted to an external 12 Volts power
supply.
Locate and repair shorted circuit to 12 Volts in the wire 2041--br.
6- 71020EN - 08 - 2003

145 ATTACHM HEIGHT S. O/-- Medium
Explanation : The attachment height sensor is disconnected or shorted to ground.
Action : Refer to wiring diagram: sensor R4, line 7150.
Locate and repair open circuit or shorted circuit to ground in the wire 229--GN, starting from
X415 p12 at the CPU printed circuit.
If the performance monitor error message is accompanied by a header self--diagnostic
message, refer to the attachment control trouble--shooting section to check the attachment
height sensor circuit.

146 ATTACHM HEIGHT S. + Medium
Explanation : The attachment height sensor is shorted to an external 12V--power supply.
Action : Refer to wiring diagram: sensor R4, line 7150.
Locate and repair shorted circuit to 12 Volts in the wire 229--GN, starting from X415 p12
at the CPU printed circuit.
If the performance monitor error message is accompanied by a header self--diagnostic
message, refer to the attachment control trouble--shooting section to check the attachment
height sensor circuit.

147 ATTACHM HEIGHT RANGE Medium
Explanation : The attachment height bargraph is not calibrated correctly. The same attachment height
is calibrated for ground and raised position.
Action : Restart the header height calibration routine and calibrate different attachment heights. if
error code returns, the sensor voltage does not change.
Check pivot arm and sensor.
6- 71020EN - 08 - 2003

150 CROP PROCESSOR SENS. Medium
Explanation : There is no voltage change of the crop processor distance sensor while the CP electric
motor is powered.
PROCESSOR : NO”.
If the crop processor is installed, check crop processor sensor linkage.
If correct, check potentiometer voltage with different sensor angle.
If same voltage, change potentiometer.
If different voltages, try other CPU printed circuit.
Check for correct CP No Repair Crop Processor

sensor linkage Sensor Linkage
Yes
Is the electric Motor rotating No Check CP Mechanical No Repair, grease or clear CP

while it is powered? Components mechanical Components
Turn Manually
Yes
Test CP Electric Motor No Try new electric motor of

Yes Function Correct? known performance.
Measure sensor voltage

with different angle posi-
tions.
Same voltage readings No Try other CPU printed cir-

with different angles? cuit.
Yes
Replace Sensor
6- 71020EN - 08 - 2003

151 LEFT KNOCK SENSOR Medium
Explanation : During chopping, the AKS & ASBA noise level is monitored on a frequent and regular basis
(after 15 minutes every 30 sec.). Where a “noise “ is identified, a flag is “raised”. Any fault
found during operation will result in the flag being “dropped”. This dropped flag will result
in the creation of an error code which is recorded but suppressed until the AKS & ASBA
panel is switched on. This error code will be repeated each time the AKS & ASBA system
is switched on until the fault is rectified.
During the sharpening procedure, the AKS & ASBA noise level is monitored on a frequent
and re--gular basis. if no “noise” is heard, the flag will “drop” and the error code will be dis-
played immediatly.
Open the connector at the LH knock sensor.
Locate and repair the open/shorted circuit in wires 2058--gn and 2059--bl.
If no open/shorted circuit, replace the sensor.

152 RIGHT KNOCK SENSOR Medium
Explanation : During chopping, the AKS & ASBA noise level is monitored on a frequent and regular basis
(after 15 minutes every 30 sec.). Where a “noise “ is identified, a flag is “raised”. Any fault
found during operation will result in the flag being “dropped”. This dropped flag will result
in the creation of an error code which is recorded but suppressed until the AKS & ASBA
panel is switched on. This error code will be repeated each time the AKS & ASBA system
is switched on until the fault is rectified.
During the sharpening procedure, the AKS & ASBA noise level is monitored on a frequent
and re--gular basis. if no “noise” is heard, the flag will “drop” and the error code will be dis-
played immediatly.
Open the connector at the LH knock sensor.
Locate and repair the open/shorted circuit in wires 2198--gn and 2197--bl.
If no open/shorted circuit, replace the sensor.
6- 71020EN - 08 - 2003

170 DISPLAYTEMP TOO HIGH Medium
Explanation : The performance monitor temperature is too high.
If the monitor temperature is above 70 °C, the display will become blank and the contrast
light intensity will decrease. If the temperature decreases below 70 °C., then the display
will be reactivated again. At this time, the error report 170 will appear on the screen.
Action : Decrease the monitor ambient temperature by switching on the cab air conditioning system
or by driving the machine in the shadow.

171 SUPPLY VOLT = XX.X V Medium
Explanation : The battery voltage is lower than 10 Volts.
The actual voltage is shown at the bottom of the screen and will always be available through
the service page error overview.
Action : Recharge the battery or check the alternator for proper functioning.

180 CPU PRINT ERROR Medium
Explanation : Poor communication arriving at CPU printed circuit through the flat cable, that connects
CPU, light, actuator and valve printed circuits.
Action : Disconnect the flat cable at the rear of the CPU. Clear all error reports in the service over-
view. If the error 180 appears again, replace the CPU printed circuit. If this is not the case,
replace the flat cable.

181 LIGHTS PRINT DISCONN Medium
Explanation : Poor communication from light printed circuit through the flat cable, that connects CPU,
light, actuator and valve printed circuits.
Action : Check the flat cable male--female connections. If no visible damage, replace first the flat
cable. If the problem still persists, replace the light printed circuit.

182 ACTUATOR PRINT DISC Medium
Explanation : Poor communication from actuator printed circuit through the flat cable, that connects CPU,
cable. If the problem still persists, replace the actuator printed circuit.

183 HYDRO PRINT DISCONN Medium
Explanation : Poor communication from valve printed circuit through the flat cable, that connects CPU,
cable. If the problem still persists, replace the valve printed circuit.
6- 71020EN - 08 - 2003

220 ENGINE DOOR SENSOR O Medium
Explanation : The right hand side door sensor is disconnected.
Open the connector at the right hand side door sensor.

221 ENGINE DOOR SENSOR -- Medium
Explanation : The power wire (brown) of the right hand side door sensor is shorted to ground (blue wire
or frame ground).

222 ENGINE DOOR SENSOR + Medium
Explanation : The power wire (brown) of the right hand side door sensor is shorted to an external 12 Volts
power supply.
6- 71020EN - 08 - 2003

226 COVER CUTTERH. SENS. O Medium
Explanation : The sharpening stone cover sensor is disconnected.
Open the connector at the sharpening stone cover sensor.

227 COVER CUTTERH. SENS. -- Medium
Explanation : The power wire (brown) of the sharpening stone cover sensor is shorted to ground (blue
wire or frame ground).

228 COVER CUTTERH. SENS. + Medium
Explanation : The power wire (brown) of the sharpening stone cover sensor is shorted to an external 12
Volts power supply.
6- 71020EN - 08 - 2003

232 SPOUT LIMIT SWITCH Medium
Explanation : The spout rotation valve is activated for more than 5 seconds while the spout end of travel
sensor is still detecting metal.
Is spout rotating when pres- No Try Manual override on hy- No Check and repair hy-
sing the spout left/right draulic valve spout rotat- draulic circuit
FAST buttons ing?
Yes Yes
No Check spout end of travel Consult spout rotation

Readjust spout end of
sensor adjustment. fault finding routine
travel sensor
Adjustment correct?
Yes
Check for 8 Volt at end of

Locate and repair open or No wire 2041 -- br check for
shorted circuit ground at end of wire 2042
-- bl
Yes
Replace spout end of

travel sensor.
Problem solved?
No
Try new actuator printed

circuit of known perform-
ance.
6- 71020EN - 08 - 2003

270 EMD NOISE LEVEL LOW Medium
Explanation : When there is a low signal from one ore both channels during working operation (cutterhead
and feed rolls engaged), this error code is generated. This message can only appear 12
seconds after the feed rolls are engaged.
It indicates a bad contact between the sensor and the electronics of the metal detector or
inside the electronics.
Action : Remove the metal detector and check the connections between the sensor and the elec-
tronics.
Try temporary with higher feed

roll speed.
Yes
Problem solved?
No
Too low magnetic noise from
Check on which channel (left or feed rolls.
right) the peak noise reading is
lower than 03, whatever the
feed roll speed is.
See CAN Identifier page 1276, If possible, continue working in
word 3 and 4. a higher feed roll speed. But do
not charge any electronic com-
ponent.
Remove metal detector and dis-

connect wiring loom from sensor
to electronic Module.
Check coil resistance of both

channels
Yes Open or short Yes

Open or short
circuit in wiring
circuit?
loom to coils?
No No
Replace EMD Replace upper part If possible, repair open or short

electronic module: (coils and magnets). circuit in wiring loom.
6- 71020EN - 08 - 2003

271 EMD OUTPUT LINE -- Medium
Explanation : This Error Code is related to the (classical) output line (wire 2096).
When there is no detection, this output signal is 12 Volt; if a metal detection takes place,
the voltage will drop to 0 Volt for 1 second.
In case the metal detector determines an output voltage that is < 7.5V, while it expects the
signal to be high (=12V), this error code is generated.
It is likely that the wire is short--circuited to earth.
This message can only appear after the feed rolls have been activated for the first time.
Thereafter this test is executed until the ignition is switched off.
Check continuity of wire 2096.
Locate and repair the frame short circuit in wire 2096.
If no frame short circuit can be found in the wire 2096, replace the EMD electronic mod-
ule.

272 EMD OUTPUT LINE + Medium
Explanation : This Error Code is related to the (classical) output line (wire 2096).
In case the metal detector determines an output voltage that is > 1.0V, while it expects the
signal to be low (=0V) during a metal detection, this error code is generated.
It is likely the wire is shorted to 12V.
This message can only appear after the feed rolls have been activated for the first time.
Thereafter this test is executed until the ignition is switched off.
Check continuity of wire 2096.
Locate and repair the short circuit to 12 V in the wire 2096.
If no short circuit to 12 V can be found in the wire 2096, replace the EMD electronic mod-
ule.
6- 71020EN - 08 - 2003

273 EMD CHANNEL FAULT Medium
Explanation : In case the coil and amplifier test fails during the run time test, this error code will be dis-
played.
The expected signal is a peak noise reading of 16 (hex). The allowed tolerance on the signal
ranges from OD to 1F (hex).
Action : Remove the detector and check the connections between the sensor and the electronic
module.
Check on which channel (left or

right) the peak noise reading is
not between OD and 1F during
the run time test.
See CAN Identifier page 1276,
word 3 and 4.
Remove metal detector and dis-

connect wiring loom from sensor
to electronic module.
Check coil resistance of both

channels
Yes Open or short Yes

Open or short
circuit in wiring
circuit?
loom?
No No
Replace EMD Replace upper part If possible, repair open or short

electronic module: (coils and magnets). circuit in wiring loom.
6- 71020EN - 08 - 2003

274 EMD NOISE LEVEL HIGH Medium
Explanation : This Error Code is related to the setting of the adaptive threshold.
This error message can be generated when during working operation the system becomes
so noisy that one of the adaptive thresholds is beyond the adaptive limits. Consequently,
there is a risk that small ferrous objects will not be detected.
Action : Work temporary in fixed mode.
Replace the metal detector feed roll and execute a quick adapt routine. If the problem per-
sists check if other feed rolls are creating excessive magnetic noise. At last, try new metal
detector of known performance.

275 EMD NETWORK ERROR Medium
Explanation : Suppressed in software Rev99 or later.
Remark: the metal detector can only report this error code after the CAN communication
problem has been repaired. By that time the problem has already been reported by the Ad-
just--O--Matic printed circuit by means of error code 117.
Action :

276 EMD PROCESSOR FAULT Medium
Explanation : There are 2 situations during which this Error Code will appear:
1. Flash Code “checksum” does not correspond with stored value. This error code can
only appear shortly after the ignition is switched ON.
2. There is a problem with the reading or writing of values to EEprom, e.g. the storing of
threshold settings.
Action : Load new software.
If this does not solve the problem, replace metal detector electronics.
6- 71020EN - 08 - 2003

278 EMD OUTPUT FAILURE Medium
Explanation : This error code is generated when the (classical) output signal is low (0V) for more than
60 seconds, while the CAN--messages appear normal.
Check continuity in wire 2096. Locate and repair the open circuit in the wire 2096. If no open
circuit can be found in the wire 2096, check for voltage drop to 0 volt when a metal detection
is simulated while the wire 2096 is disconnected. If correct, try with new AKS & ASBA
printed circuit of known performance. If not correct, try new EMD electronic module of
known performance.

279 EMD POWER FAILURE Medium
Explanation : This error code is generated when the (classical) output signal is low (0V) for more than
60 seconds, while at the same time there are no CAN--messages for more than 60 seconds
either.
Possibly there is no power to the metal detector at all, or the power was interrupted.
Action : Check fuse F4.
Check continuity in wire 2094 (power supply).
Check continuity in wire 2096 (classic output line) and the continuity in wires 2097 and 2098
(CAN network lines).
(See flow chart)
6- 71020EN - 08 - 2003
Fuse F4 Yes
burned?
No
Replace fuse F4.
Disconnect wire 2094 and 2095
in central box and at metal de-
tector.
Check for:
Frame short circuit,
Short circuit to 12 V.
Open or short Yes

circuit?
No
Reconnect wires 2094 and 2095 Repair open or short circuit.

correctly.
Reconnect wires 2094 and

Disconnect wires 2096, 2097 2095 correctly.
and 2098 in central box and at
metal detector.
Check for:
Frame short circuit.
Open or short Yes

circuit?
No
Repair open or short circuit.
Reconnect wires 2096, 2097
and 2098 correctly.
Reconnect wires 2096,

Download the correct software. 2097 and 2098 correctly.
Problem solved?
No
Try with new electronic board

(A20) or a new metal detector
electronic Module.
6- 71020EN - 08 - 2003

301 DASHBOARD SWITCH Medium
Explanation : Malfunction of one or more dashboard switch(es).
Action : Replace switch. If problem persists, replace complete dashboard.
In case of several dashboard switch error reports, check all flat cables inside dash-
board.

330 HANDLE SWITCH Medium
Explanation : Malfunction of one or more switch(es) on the multi function handle.
Action : Check connections on the vertical handle print.
If correct, try another handle with known performance.
If not correct, replace handle.

350 GROUND SPEED POT--M. Medium
Explanation : Malfunction of the ground speed potentiometer of the multi--function lever.
Action :
Check connectors at po-
tentiometer and vertical No Repair connections.
handle printed circuit.
Connections correct?
Yes
Check potentiometer fix- No Fix potentiometer with

ation with small gear
gear.
Fixation correct?
Yes
Check potentiometer
value on CANSPY page
1282 word 3 digit 3 & 4.
Is value between range of No Readjust Neutral potentio-
48--71 (5C ± 20) at the mo- meter value
ment the neutral position
switch leaves the neutral
position (from 1 to 2)
Yes
Check potentiometer
value on CANSPY for full No Check potentiometer No Try with new potentio-
forward and reverse posi- manually. Does resistance meter
tion. Is value between 00 -- change correct?
DO ± 10?
Yes
Replace vertical handle

printed circuit
6- 71020EN - 08 - 2003

351 STOP GROUND SPEED SW Medium
Explanation : Malfunction of the neutral position switch of the multi--function lever.
Action :
Check connections at
neutral position switch and No Repair connections.
Handle printed circuit
Connections correct?
Yes
Check neutral position No Improve adjustment of

switch adjustment the neutral position
Adjustment correct? switch
Yes
Check neutral position on

CANSPY page 1282, word
3 digit 2.
When moving the handle
Does the value “0“ ap-
pears?
Yes
Test out the switch man-

ually. No Replace neutral position
(Test normal open and 2 switch.
normal closed positions in
switch are correct?
Yes
Replace vertical handle

printed circuit.
6- 71020EN - 08 - 2003

360 NO ENGINE OIL PRESS. Medium
Explanation : The engine oil pressure contact stays closed for more than 5 seconds after the engine is
started, as if the engine oil pressure stays low.
Check for shorted circuit to ground in wire 56--GN.
If shorted circuit is found, repair first.
If no shorted circuit can be found, replace the engine oil pressure switch.

361 OIL PRESS SENS FAULT Medium
Explanation : The engine oil pressure contact is open, as if high engine oil pressure is detected, before
the engine is started.
Check for open circuit in wire 56--GN.
If open circuit is found, repair first.
If no open circuit can be found, replace the engine oil pressure switch.

362 NO HYDROST. PRESSURE Medium
Explanation : The hydrostatic oil pressure contact stays closed for more than 5 seconds, after the engine
is started, as if the hydrostatic oil pressure stays low.
Check for shorted circuit to ground in wire 58--GN.
If shorted circuit is found, repair first.
If no shorted circuit can be found, replace the hydrostatic oil pressure switch.

363 HYDROST. SENSOR FAULT Medium
Explanation : The hydrostatic oil pressure contact is open, as if high hydrostatic oil pressure is detected,
before the engine is started.
Check for open circuit in wire 58--GN or wire 041--ZW.
If no open circuit can be found, replace the hydrostatic oil pressure switch.
6- 71020EN - 08 - 2003

364 CAT OIL TEMP. SENSOR Medium
Explanation : The CAT engine oil temperature sensor is open for app. 5 minutes after the engine is
started, as if high engine oil temperature is detected.
Only valid for CHX620.
Check for open circuit in wire 2183--GN.
If no open circuit can be found, replace the CAT engine oil temperature sensor.

370 COVER CUTTERHEAD EOT Medium
Explanation : Power was supplied to the sharpening cover electric motor but the sharpening cover did
not arrive to its home (closed) position.
Action : Refer to wiring diagram: sharpening cover closed limit switch S82, line 5260
Readjust sharpening cover limit switch.
Make sure the limit switch S82 (wires 2092--gn and 2093--bl) in the sharpening cover elec-
tric motor is open when the sharpening cover is closed.
If error messages 370 and 483 appears together, repair first error message 483.

371 AOM POWER FAILURE Medium
Explanation : No power arriving at AKS & ASBA printed circuit.
Action : Refer to wiring diagram: Fuse 18 (30A), line 1650
Check Fuse F18 in central box.
If correct, check connections of fuse holder with the fuse printed circuit.
If correct, locate and repair open circuit in the wire 2110--RD
If correct, try with other AKS & ASBA printed circuit of known performance.
6- 71020EN - 08 - 2003

400 CROP PROC.DIST. ACT. Medium
Explanation : Crop processor distance electric motor is open or shorted.
Action : If no crop processor is installed,
check in the performance monitor calibration for “CROP PROCESSOR : NO”.
If the crop processor is installed, refer to the wiring diagram: Motor M21, line 4270.
Check CP mechanical
components. Can CP No Repair, grease or clean
CP mechanical compo-
been turned manually by
key? nents.
Yes
Open connector at the CP Check for open or

electric motor check for shorted circuit in wires Try new actuator printed
No No
battery voltage at the con- 2052--gn and 2053--wt circuit with known per-
nector arriving from cen- open or shorted circuit? formance (A40)
tral box when the CP
switch is pressed.
(Select Harvest Mode
first) 12V measured
Locate and repair open or
shorted circuit
Yes
Power electric motor from

separate battery (Insert No
fuse in power cables.) Replace CP electric motor
Motor functioning?
Yes
Reconnect everything and

try again.

401 SPOUT DEFLECTOR ACT. Medium
Explanation : Spout deflector solenoid is open or shorted.
Action : Refer to the wiring diagram: Y45 and Y46, line 4600
Open both connectors at Check for open or shorted

electro valves on low pres- circuit in wiring loom where
sure valve. Check for bat- there was no battery volt- Try new actuator printed
tery voltage at both con- No age measured. No
circuit with known perform-
nectors when the correct 1. 2039--wt and 2030--zw
ance
spout deflector switch is 2. 2040--gr and 2030--zw
pressed. 12V measured Open or shorted circuit
on both connectors? found?
Yes Yes
Check Hydraulic circuit Locate and repair open or

shorted circuit
6- 71020EN - 08 - 2003

420 HYDROSTATIC PUMP O Medium
Explanation : The traction hydrostatic pump is not functioning due to open circuit.
Action : Refer to wiring diagram: electro valve Y28, line 700.
Disconnect electro valve on hydrostatic pump and check for coil resistance of 24 Ohm.
If not correct, replace electro valve on hydrostatic pump.
If correct, check for open circuit in wires 394--wt and 395--gr.
If open circuit is found, repair open circuit.
If no open circuit, try with new AKS & ASBA printed circuit of known performance.

421 HYDROSTATIC PUMP -- Medium
Explanation : The traction hydrostatic pump is not functioning due to shorted circuit.
If correct, check for shorted circuit or shorted circuit to ground in wires 394--wt and 395--gr.
If shorted circuit is found, repair shorted circuit.
If no shorted circuit, try with new AKS & ASBA printed circuit of known performance.

422 HYDROSTATIC PUMP + Medium
Explanation : The traction hydrostatic pump is not functioning due to shorted circuit to external 12 V
power supply.
If correct, check for shorted circuit to 12 V in wires 394--wt and 395--gr.
If no shorted circuit, try with new AKS & ASBA printed circuit of known performance.
6- 71020EN - 08 - 2003

423 FEED ROLLS PUMP O Medium
Explanation : The feed rolls hydrostatic pump is not functioning due to open circuit.
If correct, check for open circuit in wires 2179 and 2178.
If open circuit is found, repair open circuit.
If no open circuit, try with new Drive printed circuit of known performance.

424 FEED ROLLS PUMP -- Medium
Explanation : The feed rolls hydrostatic pump is not functioning due to shorted circuit.
If correct, check for shorted circuit or shorted circuit to ground in wires 2179 and 2178.
If no shorted circuit, try with new Drive printed circuit of known performance.

425 FEED ROLLS PUMP + Medium
Explanation : The feed rolls hydrostatic pump is not functioning due to shorted circuit to external 12 V
power supply.
If correct, check for shorted circuit to 12 V in wires 2179 and 2178.
If no shorted circuit, try with new Drive printed circuit of known performance.
6- 71020EN - 08 - 2003

440 AIRCONDITION. CLUTCH Medium
Explanation : The air conditioning electric clutch is open or shorted.
Action : Refer to wiring diagram: electric clutch Y27, line 9340.
Disconnect the air conditioning clutch Y27.
Check for battery voltage at Y27 while the air conditioning is activated.
If no battery voltage:
Locate and repair the open or shorted circuit in wire 401--wt.
If no open or shorted circuit can be found, try new lights printed circuit of known
performance.
If battery voltage is measured:
Power the electric clutch with separate battery (insert fuse in power cable).
If the clutch is not functioning, try new electric clutch Y27 of known performance.
If the clutch can be activated with separate battery, connect everything and try
again.

445 ROTARY SCREEN BRUSH Medium
Explanation : The rotary screen brush actuators are open or shorted.
Action : Refer to wiring diagram: rotary screen brush actuators M28 and M29, line 4820.
Disconnect the rotary screen brush actuators M28 and M29.
Check for battery voltage at M28 and M29 while the engine is running.
Locate and repair the open or shorted circuit in wire 2159--WT and wire 2160--GR.
If no open or shorted circuit can be found, try new actuator printed circuit of known
performance.
Power the actuators with separate battery (insert fuse in power cable).
If one or more actuators is not functioning, try new rotary screen brush actuator of
known performance.
If both actuators can be activated with separate battery, connect everything and try
again.
6- 71020EN - 08 - 2003

446 ROTARY SCREEN MOTOR Medium
Explanation : The rotary screen electric motors are open or shorted.
Action : Refer to wiring diagram: electric motors M26 and M27, line 4780.
Disconnect both connectors at rotary screen motors.
Check for battery voltage at M26 and M27 while the engine is running.
Locate and repair the open or shorted circuit in wire 2147--WT and 2148--ZW and/or
2149--WT and 2150--ZW.
If no open or shorted circuit can be found, try new actuator printed circuit of known
performance.
Power the electric motors with separate battery (insert fuse in power cable).
If one or more rotary screen motor is not functioning, try new electric motor of
known performance.
If both electric motors can be activated with separate battery, connect everything
and try again.
6- 71020EN - 08 - 2003

453 SPOUT RIGHT HYDR.SOL Medium
Explanation : The solenoid of the spout right rotation hydraulic valve is open or shorted.
Action : Refer to wiring diagram : hydraulic valve Y33, line 4570.
Disconnect the solenoid Y33 on the stack valve.
Check for battery voltage at Y33 while the spout right fast rotation switch is pressed.
Locate and repair the open or shorted circuit in wire 2005--GR and/or wire 2006--ZW.
If no open or shorted circuit can be found, try new hydraulic printed circuit of known
performance.
If battery voltage:
Check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured)
or eventually power the solenoid with separate battery (insert fuse in power cable).
If the valve is not functioning, try new hydraulic valve Y33 of known performance.
If the coil resistance is correct and the hydraulic valve is functioning, connect
everything and try again.

454 SPOUT LEFT HYDR.SOL Medium
Explanation : The solenoid of the spout left rotation hydraulic valve is open or shorted.
Action : Refer to wiring diagram : hydraulic valve Y32, line 4550.
Check for battery voltage at Y32 while the spout left fast rotation switch is pressed.
Locate and repair the open or shorted circuit in wire 2003--WT and/or wire 2004--ZW.
performance.
If battery voltage:
6- 71020EN - 08 - 2003

455 REAR HYDR. DOWN SOL. Medium
Explanation : The solenoid of the rear hydraulics down valve is open or shorted.
Action : Refer to wiring diagram : solenoid Y37, line 3900.
If no rear auxiliary hydraulics is installed on the machine, recalibrate the rear auxiliary hy-
draulics option by means of the EST.
If rear auxiliary hydraulics is installed, disconnect the solenoid Y37 on the stack valve.
Check for battery voltage at Y37 while the rear hydraulics down valve is activated.
Locate and repair the open or shorted circuit in wire 2013--GR and/or wire 2014--ZW.
performance.
If battery voltage:

456 REAR HYDR. UP SOL. Medium
Explanation : The solenoid of the rear hydraulics up valve is open or shorted.
If no rear auxiliary hydraulics is installed on the machine, recalibrate the rear auxiliary hy-
If rear auxiliary hydraulics is installed, disconnect the solenoid Y36 on the stack valve.
Check for battery voltage at Y36 while the rear hydraulics up valve is activated.
performance.
If battery voltage:
6- 71020EN - 08 - 2003

457 MAIN DRIVE HYDR.SOL. Medium
Explanation : The solenoid of the main drive hydraulic valve is open or shorted.
Disconnect the solenoid Y40 on the low pressure valve.
Check for battery voltage at Y40 while the engine is running and the cutterhead is engaged.
performance.
If battery voltage:
Check coil resistance of the solenoid (a resistance of app. 3--10 ohm should be
measured) or eventually power the solenoid with separate battery (insert fuse in power
cable).

458 4 WHEEL DRIVE SOLEN. Medium
Explanation : The 4 wheel drive solenoid is open or shorted.
If no 4 wheel drive is installed on the machine, recalibrate the 4 wheel drive option by means
of the EST.
If 4 wheel drive is installed, disconnect the solenoid Y22 on the low pressure valve.
Check for battery voltage at Y22 while the 4 wheel drive is activated.
Locate and repair the open or shorted circuit in wire 40--wt and/or wire 41--zw.
performance.
If battery voltage:
Check coil resistance of the solenoid (a resistance of app. 3--10 ohm should be
measured) or eventually power the solenoid with separate battery (insert fuse in power
cable).
6- 71020EN - 08 - 2003

459 SPOUT DOWN HYDR.SOL. Medium
Explanation : The solenoid of the spout down hydraulic valve is open or shorted.
Check for battery voltage at Y39 while the spout down switch is pressed.
Locate and repair the open or shorted circuit in wire 2017--gr and/or wire 2018--zw.
performance.
If battery voltage:

460 SPOUT UP HYDR.SOL. Medium
Explanation : The solenoid of the spout up hydraulic valve is open or shorted.
Check for battery voltage at Y38 while the spout up switch is pressed.
performance.
If battery voltage:
6- 71020EN - 08 - 2003

461 CUTTERHEAD REVERSE Medium
Explanation : The solenoid of the reverse cutterhead hydraulic valve is open or shorted.
Check for battery voltage at Y31 while the cutterhead reverse switch is switched on
(harvest function activated).
performance.
If battery voltage:

462 MAIN CLUTCH IDLER Medium
Explanation : The solenoid of the main clutch idler valve is open or shorted.
Action : Refer to wiring diagram: Y44, line 3420
Disconnect the solenoid Y44 on the low pressure valve.
Check for battery voltage at Y44 while the harvest function is activated.
performance.
If battery voltage:
6- 71020EN - 08 - 2003

464 FRONT HYDR. UP SOL. Medium
Explanation : The solenoid of the front hydraulics up valve is open or shorted.
Check for battery voltage at Y34 while the front hydraulics up valve is activated.
performance.
If battery voltage:

465 FRONT HYDR. DOWN SOL Medium
Explanation : The solenoid of the front hydraulics down valve is open or shorted.
Check for battery voltage at Y35 while the front hydraulics down valve is activated.
performance.
If battery voltage:
6- 71020EN - 08 - 2003

467 HIGH CAP.HYDR.UP SOL Medium
Explanation : The solenoid of the high capacity up hydraulic valve is open or shorted.
If no high capacity hydraulics is installed on the machine, recalibrate the high capacity hy-
If high capacity hydraulics is installed, disconnect the solenoid Y49 on the hydraulic valve.
Check for battery voltage at Y49 while the high capacity up hydraulic valve is activated.
performance.
If battery voltage:
Check coil resistance of the solenoid (for open or shorted circuit) or eventually power
the solenoid with separate battery (insert fuse in power cable).
If the hydraulic valve is functioning, connect everything and try again.

468 HIGH CAP.HYDR.DO SOL Medium
Explanation : The solenoid of the high capacity down hydraulic valve is open or shorted.
If no high capacity hydraulics is installed on the machine, recalibrate the high capacity hy-
If high capacity hydraulics is installed, disconnect the solenoid Y50 on the hydraulic valve.
Check for battery voltage at Y50 while the high capacity down hydraulic valve is activated.
performance.
If battery voltage:
6- 71020EN - 08 - 2003

479 CROP PROC CLOSE ERR Medium
Explanation :
Action : Refer to wiring diagram: solenoid Y75, line 4390.
If no crop pro plus is installed on the machine,
check in the performance monitor calibration for “CROP PRO PLUS: NO”.
If crop pro plus is installed, disconnect the solenoid Y75 on the hydraulic valve.
Check for battery voltage at Y75 while the crop pro plus close valve is activated.
performance.
If battery voltage:

480 CROP PROC OPEN ERR Medium
Explanation :
If no crop pro plus is installed on the machine,
check in the performance monitor calibration for “CROP PRO PLUS: NO”.
If crop pro plus is installed, disconnect the solenoid Y76 on the hydraulic valve.
Check for battery voltage at Y76 while the crop pro plus close valve is activated.
performance.
If battery voltage:
6- 71020EN - 08 - 2003

481 BRAKE ERROR Medium
Explanation : The solenoid of the brake valve is open.
Open the connector at the brake valve solenoid.
Turn ignition on and with road mode selected, check for battery voltage at Y77.
Check for battery voltage at the end of wire 2223--wt.
If not correct, locate and repair the open circuit in wire 2223--wt.
If correct, check for ground at the end of wire 22--zw.
If not correct, locate and repair the open circuit in wire 22--zw.
If correct, try with new drive print of known performance.
If battery voltage:
If the valve is not functioning, try new brake valve Y77 of known performance.
If the coil resistance is correct and the brake valve is functioning, connect everyth-
ing and try again.
6- 71020EN - 08 - 2003

483 COVER CUTTERH. MOTOR Medium
Explanation : Sharpening stone cover electric motor is open or shorted.
Action : Refer to wiring diagram : electric motor M22, line 5300.
Disconnect the electric motor M22.
Check for battery voltage at M22 while the cover motor is activated (e.g. open cover for
inspection).
Locate and repair the open or shorted circuit in wire 2062--wt and/or wire 2063--gr.
If no open or shorted circuit can be found, try new AKS & ASBA printed circuit with
known performance.
If battery voltage:
Check coil resistance of the electric motor (a resistance of app. 0.4--1 ohm should be
measured) or eventually power the electric clutch with separate battery (insert fuse in
power cable).
If the motor is not functioning, try new electric motor M22 of known performance.
If the coil resistance is correct and the electric motor is functioning, connect

484 STOP VALVE Medium
Explanation : The solenoid of the stop valve is open.
Open the connector at the stop valve solenoid.
Turn ignition on and check for battery voltage at Y73.
Locate and repair the open circuit in wire 2179 and/or 2178.
If no open circuit can be found, try with new drive print of known performance.
If battery voltage:
If the valve is not functioning, try new brake valve Y73 of known performance.
If the coil resistance is correct and the brake valve is functioning, connect everyth-
ing and try again.
6- 71020EN - 08 - 2003

485 AOM MOTOR L FAILURE Medium
Explanation : The shearbar left--hand adjuster electric motor is open or shorted.
Check for battery voltage at M24 while the left AKS & ASBA electric motor is activated (e.g.
during full pull).
known performance.
If battery voltage:
power cable).

486 AOM MOTOR R FAILURE Medium
Explanation : The shearbar right--hand adjuster electric motor is open or shorted.
Check for battery voltage at M25 while the right AKS & ASBA electric motor is activated
(e.g. during full pull).
known performance.
If battery voltage:
power cable).
6- 71020EN - 08 - 2003

487 SHARP MOTOR FAILURE Medium
Explanation : Sharpening stone electric motor is open or shorted.
Check for battery voltage at M23 while the sharpening stone motor is activated.
known performance.
If battery voltage:
power cable).

489 CUT.KNIVES WORN DOWN Medium
Explanation : The electronic system detected one or more worn knives.
Action : 1. The shearbar has travelled to its rearmost position and needs readjusting. Clean space
between shearbar and scraper, and adjust shearbar forward by means of the full pull
procedure. Subsequently adjust the cutterhead knives.
Or
2. The space between the shearbar and the cutterhead frame is filled with dirt and crop.
Move the shearbar away from the cutterhead (full pull) and remove the dirt/crop be-
tween shearbar and cutterhead frame.

490 AOM NOISE TOO HIGH Medium
Explanation : The electronic system detected a too high AKS & ASBA noise at the beginning or during
the shearbar procedure.
Action : Reduce or increase the engine speed. If this does not help, search machine for loose parts
generating a hammering noise. If problem remains unsolved, check and replace if necess-
ary cutterhead bearings.
Refer to wiring diagram : AKS & ASBA sensors B106 and B50, line 6030.
Check for open or shorted circuit in wiring loom to AKS & ASBA sensors, wires 2058--gn
and/or 2059--bl, and wires 2198--gn and/or 2197--bl.
If problem remains unsolved, try first with new AKS & ASBA sensor(s) and later with new
AKS & ASBA printed circuit of known performance.
6- 71020EN - 08 - 2003

525 BLOWER RPM SENSOR O Low
Explanation : The blower rpm sensor is disconnected.
Open the connector at the blower rpm sensor.
Turn ignition on and check for 8 Volts at the end of wire 2208--gn.
If not correct, locate and repair the open circuit in the wire 2208--gn.
If correct, check for ground at the end of wire 2209--bl.
If not correct, locate and repair the open circuit in the wire 2209--bl.
If correct, replace the blower speed sensor.

526 BLOWER RPM SENSOR -- Low
Explanation : The power wire (green) of the blower rpm sensor is shorted to ground (blue wire or frame
ground).
Locate and repair shorted circuit to ground in the wire 2208--gn.
After repair, check if 8V arrives on the wire 2208--gn at the rpm sensor.

527 BLOWER RPM SENSOR + Low
Explanation : The power wire (brown) of the blower rpm sensor is shorted to an external 12 Volts power
supply.
Locate and repair shorted circuit to 12V in the wire 2208--gn.
After repair, check if 8V arrives on the wire 2208--gn at the rpm sensor.
6- 71020EN - 08 - 2003

545 FUEL LEVEL SENS -- Low
Explanation : Fuel level potentiometer is shorted to ground.
Action : Refer to wiring diagram : sensor B12, line 7420.
Disconnect fuel level sensor and check resistance range of sensor between 3 and 350
Ohm.
If not correct, try with new sensor of known performance.
If correct, locate and repair shorted circuit to ground in the wire 291--gn.
If problem remains unsolved, try with new CPU printed circuit of known performance.

546 FUEL LEVEL SENS O/+ Low
Explanation : Fuel level potentiometer disconnected or shorted to external power supply.
Action : Refer to wiring diagram : sensor B12, line 7420.
Disconnect fuel level sensor and check resistance range of sensor between 3 and 350
Ohm.
If not correct, try with new sensor of known performance.
If correct, locate and repair open circuit or shorted circuit to 12 Volt in wires 291--gn and/
or 292--zw.
If problem remains unsolved, try with new CPU printed circuit of known performance.
6- 71020EN - 08 - 2003

552 BLOWER SPEED Low
Explanation : The electronic system does not detect a blower speed rpm after cutterhead engagement.
Action : Check the quality of the blower speed sensor B54 as described in the Operator’s Manual
section 4 “Adjustment and Maintenance”, paragraph headed “Sensors”.
If not correct, replace the blower speed sensor B54.
Install the sensor as described in the Operator’s Manual section 4 “Adjustment and Main-
tenance”, paragraph headed “Sensors”.
If problem remains unsolved, try with new drive printed circuit of known performance.

553 KNIFE SPEED TOO HIGH Low
Explanation : The electronic system detected a too high knife speed when working with the DC510 at-
tachment.
Action : Reduce the knife speed as decribed in the attachment Operator’s Manual.
6- 71020EN - 08 - 2003
ATTACHMENT HEIGHT CONTROL

ERROR MESSAGES
The blinking sequence of the red self--diagnostic

control light identifies an error report.
The blinking sequence always consists of 2 periods

separated by a short interval. Then, after a longer
interval, the blinking sequence will repeat again.
The first period indicates the first digit of the error

report, the second period indicates the second digit.
Example
Error report 23
52002
33
General Information:
After repair, most of the attachment height control
error reports must be cleared by switching off the
ignition.
6- 71020EN - 08 - 2003
Error reports
Code 11 Connector X57 Pin 37 -- (35)

Explanation
Open circuit of the power line to the attachment height control module A60 (fuse F17).
Or output failure of the attachment height control module A60.
Remarks: If the open circuit occurs before the attachment lift solenoid was activated, then error 14
appears.
Action
Refer to the wiring diagram: line 6980.
Check for 12 Volts at X57/29 of the attachment height control module A60. If not correct, locate and
repair open circuit at fuse F17 or wiring 1030 rd.
If the previous step was correct, replace the attachment height control module A60.
Code 12 Connector X57 Pin 19 -- (35)

Explanation
Open circuit of the power line to the attachment height control module A60 (fuse F17).
Or output failure of the attachment height control module A60.
Remarks: If the open circuit occurs after the attachment lowering solenoid was activated, then error
14 appears.
Action
Check for 12 Volts at X57/29 of the header height control module A60. If not correct, locate and re-
pair open circuit in fuse F17 or wire 1030 rd.
If the previous step was correct, replace the header height control module A60.
Code 13 ... Pin 35 -- (37) -- (19)

Explanation
Shorted circuit of the wires from the attachment height control module A60 to the attachment lift
and/or lowering solenoid. This shorted circuit may blow fuse F17.
Remarks: A shorted circuit to the common ground wire will create error 13 and cuts off the power
automatically. A shorted circuit to the frame creates no error and will blow up the fuse
F17.
Action
Locate and repair the shorted circuit in the wires 226 gr and/or 227 Wt, or at the lowering (Y19) and/
or lift solenoid (Y20).
6- 71020EN - 08 - 2003
Code 14 ... Pin 35 -- (37) -- (19) -- (29)

Explanation
No current coming back from the attachment lift or lowering solenoids at the attachment height con-
trol connector X57/35. This can be due to:
-- Open circuit at the solenoid wires
-- Solenoid failure.
-- No input power at the attachment height control module connector X57/29 (fuse F17).
-- Attachment height control module A60 failure.
Action
Refer to the wiring diagram: line 7030. Locate and repair open circuit in the wires 225 zw, 226 gn,
227 Wt or at the lowering (Y19) and lift solenoid. (Y20).
Check for 12 Volts at X57/29 of the attachment height control module A60. If not correct, locate and
repair open circuit in fuse F19 or wire 235 Rd.
If all previous steps were correct, replace the attachment height control module A60.
Code 15 ... Pin 9

Explanation
The common power wire to the attachment height control switches is shorted to the ground or to an
external 12 Volts power supply.
Remark: The Attachment height control switches are simulated by the actuator printed circuit on
wires 209 wt, 210 wt, 211 wt and 212 wt.
Common power wire: 209 -- wt
fast speed wire: 212 -- wt
Header down wire: 210 -- wt
Header up wire: 211 -- wt
Action
Locate and repair shorted circuit in the wire 209 Wt of the attachment height control switches.
Code 16 ... Pin 2 -- 20

Explanation
Open or shorted to ground wires of the attachment control selector switch (S35).
Remark: The attachment control selector switch S35 is simulated by the actuator printed circuit on
wires 214--bl, 221--br, 222--gn.
common power wire: 214--bl
selector switch wires: 221--br and 222--gn
Action
Refer to the wiring diagram: line 7160. Locate and repair open circuit or shorted circuit in the wires
214 Bl, 221 Br and/or 222 Gn (together with error 18).
Remark: Shorted circuit in wire 221 Br will lock the attachment height control without error messages.
6- 71020EN - 08 - 2003
Code 17 ... Pin 29

Explanation
Battery voltage higher than 18 Volts.
Action
Check and repair the alternator regulator.
Code 18 ... Pin 21

Explanation
Incorrect signal from the attachment control selector switch S35 due to open wire or shorted to an
unacceptable external power supply.
Action
If error 18 is accompanied of error 16, locate and repair open circuit in wire 222 Gn.
If not, locate and repair shorted circuit to 12 Volt at wire 222 -- Gn.
Refer to the header lift trouble shooting section for correct voltages at the header control module
connector X57/21.
Code 21 ... Pin 6
Explanation
Incorrect signal from the attachment height sensor R4.
Action
Check attachment height sensor R4 adjustment and recalibrate the attachment height control (per-
formance monitor).
Locate and repair open circuit in wires 228 Bl or 238 Br.
Remark: open circuit in sensor information wire 229 Gn will not create an error report.
Or locate and repair shorted circuit to ground in the sensor information wire 229 Gn.
Remark: shorted circuit to ground of the wire 238 Br will lock to attachment height control
without creating a error report. Each time the shorted circuit is interrupted, both
control lights (green and red) will blink to start up the attachment height control.
Or replace the header height sensor R4.
Code 22 ... Pin 22

Explanation
Incorrect signal from the stubble height potentiometer R6.
Remark: The stubble height potentiometer R6 Voltage is simulated by the actuator printed circuit
on wire 216 gn.
Action
Locate and repair open circuit in wire 216 Gn.
Remark: shorted circuit to ground of the wire 216 Gn will not create an error report but will unable
the stubble height control.
6- 71020EN - 08 - 2003
Code 23 ... Pin 8

Explanation
Incorrect signal from the attachment lift cylinder oil pressure sensor B13.
Action
Locate and repair open circuit in wires 236 Bl or 238 Br.
Remark: open circuit in sensor information wire 229 Gn will not create an error report.
Or locate and repair shorted circuit to ground in the sensor information wire 237 Gn.
Remark: shorted circuit to ground of the wire 238 Br will lock to attachment height control
without creating a error report. Each time the shorted circuit is interrupted, both
control lights (greeen and red) will blink to start up the attachment height control.
Or replace the oil pressure sensor B13.
Code 24 ... Pin 5
Explanation
Incorrect signal from the compensation potentiometer R7.
Remark: the compensation potentiometer R7 Voltage is simulated by the actuator printed circuit on
wire 2176 zw (X57/05).
Action
Locate and repair open circuit in wire 217 Gn.
Remark: shorted circuit to ground of the wire 217 Gn will not create an error report but will unable
the compensation control.
Code 25 ... Pin 3 -- 36
Explanation
The attachment fast moving switch was activated before the lift or lowering switch was activated.
Remark: The attachment height control switches are simulated by the actuator printed circuit on wires
209 -- wt, 210 --wt, 211 -- wt and 212 -- wt. This means Voltage on wire 212 -- wt arrives be-
fore voltage on wire 210 -- wt or 211-- wt at attachment height control module A60.
Action
Refer to the wiring diagram: line 7090. Locate and repair open circuit in wire 210 Wt or 211 Wt.
Or replace the header lift/lowering switches.
Code 33 ... Pin 27
Explanation
Shorted to ground circuit at the automatic switch S30.
Action
If the error 33 appears after ignition and activating the automatic switch S30, locate and repair
shorted circuit to ground in wire 208 Wt (from the header height module A3 connector X57/13).
6- 71020EN - 08 - 2003
Code 35 ... Pin 29

Explanation
Battery voltage lower than 10 Volts.
Action
Recharge battery or check alternator and repair if necessary.
Code 36
Explanation
Failure of the hydraulic header lift control valve. Electrical components are correct.
Action
Clean the hydraulic spools or replace the hydraulic control valve.
6- 71020EN - 08 - 2003
CATERPILLAR ERROR MESSAGES
Error Description CID--FMI Flash CAN--ID

Nr Code Page 1353
Cylinder 1 Fault 1--11 72 Word 2 : 8===
Cylinder 5 Fault 5--11 74 Word 2 : =8==
Cylinder 6 Fault 6--11 74 Word 2 : =4==
Check Timing Sensor Calibration 22--13 42 Word 2 : =2==
8 Volt Supply Above Normal 41--03 21 Word 2 : =1==
8 Volt Supply Below Normal 41--04 21 Word 2 : ==8=
Invalid Throttle Signal 91--08 32 Word 2 : ==4=
Throttle Sensor Calibration 91--13 28 Word 2 : ==2=
Low Fuel Pressure Warning 94--01 -- Word 2 : ==1=
Fuel Pressure Sensor Open Circuit 94--03 37 Word 2 : ===8
Fuel Pressure Sensor Short Circuit 94--04 37 Word 2 : ===4
Low Oil Pressure Warning 100--01 -- Word 2 : ===2
Oil Pressure Sensor Open Circuit 100--03 24 Word 2 : ===1
Oil Pressure Sensor Short Circuit 1100--04 24 Word 3 : 8===
Very Low Oil Pressure 100--11 -- Word 3 : 4===
Boost Pressure Reading Stuck High 102--00 25 Word 3 : 2===
Boost Pressure Sensor Open Circuit 102--03 25 Word 3 : 1===
Boost Pressure Sensor Short Circuit 102--04 25 Word 3 : =8==
High Inlet Manifold Temperature Warning 105--00 -- Word 3 : =4==
Inlet Manifold Temp Sensor Open Circuit 105--03 38 Word 3 : =2==
Inlet Manifold Temp Sensor Short Circuit 105--04 38 Word 3 : =1==
Very High Inlet Manifold Temperature 105--11 -- Word 3 : ==8=
Atmospheric Pressure Sensor Open Circ 108--03 26 Word 3 : ==4=
Atmospheric Pressure Sensor Short Circ 108--04 26 Word 3 : ==2=
High Coolant Temperature Warning 110--00 -- Word 3 : ==1=
Coolant Temperature Sensor Open 110--03 27 Word 3 : ===8
Coolant Temperature Sensor Short 110--04 27 Word 3 : ===4
6- 71020EN - 08 - 2003
Error Description CID--FMI Flash CAN--ID

Nr Code Page 1353
Very High Coolant Temperature 110--11 -- Word 3 : ===2
Low Coolant Level Warning 111--01 -- Word 3 : ===1
Intermittent Battery 168--02 51 Word 4 : 8===
High Fuel Temperature Warning 174--00 -- Word 4 : 4===
Fuel Temperature Sensor Open Circuit 174--03 13 Word 4 : 2===
Fuel Temperature Sensor Short Circuit 174--04 13 Word 4 : 1===
Engine Overspeed Warning 190--00 35 Word 4 : =8==
Loss of Engine RPM Signal 190--02 34 Word 4 : =4==
5 Volt Supply Above Normal 232--03 21 Word 4 : =2==
5 Volt Supply Below Normal 232--04 21 Word 4 : =1==
Incorrect Engine Software 252--11 59 Word 4 : ==8=
Personality Module Fault 252--12 -- Word 4 : ==4=
Check Customer or System Parameters 253--02 56 Word 4 : ==2=
6- 71020EN - 08 - 2003
LIST OF CAN IDENTIFIERS
CAN ID Data Description Comments
1275 Data from metal detector (NODE M)
1278 Data used by metal detector
1279 Not used
1280 Not available for user Used during PC -- calibrations
1281 Not available for user Used for supplier testing
1282 Multi Function Handle inputs
1283 Dashboard switches inputs
1284 Not used
1285 Not used
1286 AKS & ASBA panel inputs
1287 Armrest module inputs (BOSCH CONSOLE)
1288 Ground speed
1289 Engine rpm
1290 Crop processor rpm
1291 Not used
1292 Not used
1293 Cutterhead rpm
1294 Drive Print E
1295 Not used
1296 Not used
1297 Not used
1298 Not used
1299 Not used
1300 Not used
1301 Not used
1302 Not used
1303 Data from CPU print
1304 Data from AKS & ASBA print
6- 71020EN - 08 - 2003
1305 Total hours
1306 Total Ha
1307 Not used
1308 Not used
1309 Not used
1310 Not used
1311 Not used
1312 Not used
1313 Header Height, Ground Pressure, CP rolls Distance
1314 Dashboard leds
1315 Automatic knife sharpening leds
1316 Not used
1317 Header height control leds (BOSCH)
1318 Fuel level and Engine temperature
1319 Limb home and AKS & ASBA
1320 Calibration data
1321 Not available for user Used for internal communication
1325 Not used
1326 Software revision display, node A and S
1327 Date & Time
1328 Not available for user Used for sofw download to EMD
1329 Not available for user Used for sofw download to EMD
1330 Not used
1331 Calibration data in node T
1332 Calibration data in node B
1333 Not used
6- 71020EN - 08 - 2003
1334 Calibration data in node E
1335 Not available for user Used for plant testing
1339 Not used
1340 Not used
1341 Not used
1342 Calibrated values 2 T
1343 Calibrated values 3 E
1344 Not used
1345 Calibrated values 3 T
1346 Not used
1347 Not used
1348 Not used
1349 AKS & ASBA Print T
1351 Drive Print E
1352 Engine
1353 Engine
1354 Engine
1355 Engine
1356 Engine + AKS & ASBA
1357 Not used
1358 Not used
1359 Feedrolls
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 63 63
CAN ID Data Description word1 word2 word3 word4 Comments
1275 Data from METAL DETECTOR (NODE W)
1275 MD A/D value channel 0 right ==XX 0<=X<=f;
1275 MD error flag 7: adaptive treshold level fault =1==
1275 MD A/D value channel 1 LEFT XX== 0<=X<=f;
1275 MD adaptive treshold setting channel 1-- ==XX ?<=X<=?;
1275 MD adaptive treshold setting channel 1+ XX== ?<=X<=?;
1275 MD adaptive treshold setting channel 0+ XX== ?<=X<=?;
1275 MD adaptive treshold setting channel 0-- ==XX ?<=X<=?;
1275 MD metal detected =1== set 1 sec period after detection
1275 MD object detected =2== set 1 sec period after detection
1275 Soft revision node W ==XX hex => Dec
1278 Data used BY METAL DETECTOR (every 10 ms)
1278 MD sensitivity setting ch 1 ===X 0 <= X < 11; 0 = most sensitive
1278 MD sensitivity setting ch 0 ==X= 0 <= X < 11; 0 = most sensitive
1278 MD A/F thresholds mode =1== adaptive threshold mode;0 fixed mode
1278 MD feedrolls forward status =2== 0=false;
1278 MD feedrolls reverse status =4== 0=false;
1278 MD initialize thresholds ===1 quick (1’) adaptive threshold setting
6- 71020EN - 08 - 2003
1280 CALIBRATION BY PC
1280 Calibration passive stop (quick feed rolls stop) 1144
1280 Calibration groundspeed tuning 2242 XXXX this value realy affects the current to
the pump, dependant on the mounted
tyres
1280 Calibration low pressure valves installed 3342
1280 Calibration speed pot 3544
1280 Calibration rear hydraulics not installed 3741
1280 Calibration disable max speed old 3a44
1280 Calibration disable max speed 3b44
1280 Calibration serial number 3c00 XXXX XXXX XXXXXXXX = serial number
1280 Calibration rotary screens old print location (< 4442

1996)
1280 Calibration shearbar gap 5144 XX== XX = shearbar gap in mm
1280 Calibration max speed and current old 5344
1280 Calibration max speed and current 5444
1280 Calibration auto flipper on 5542
1280 Calibration disable min pwm forward 5c44
1280 Calibration reduced engine 6642
1280 Calibration rear hydraulics installed 7341
1280 Calibration active stop pal (quick feed rolls stop) 7744
1280 Calibration rotary screens new print location 8842
1280 Calibration no reduced engine 9942
1280 Calibration disable min pwm reverse a344

6- 71020EN - 08 - 2003
1280 Calibration auto deflector off aa42
1280 Calibration minimum pwm forward ac44
1280 Calibration latch header / limited height c342
1280 Calibration minimum pwm reverse c544

1280 Calibration no latch header / limited height ca42
1280 Calibration low pressure valves not installed cc42
1282 Multi Function Handle inputs
1282 Feed rolls stop not pressed S92 ===1

1282 Feed rolls stop pressed S92 ===2
1282 Automatic height control button not pressed S30 ===4
1282 Automatic height control button pressed S30 ===8
1282 Attachment up not pressed S22 ==4=
1282 Attachment up pressed S22 ==8=
1282 Spout R fast not pressed S93 =1==
1282 Spout R fast pressed S93 =2==
1282 Feed rolls reverse not pressed S29 1===
1282 Feed rolls reverse pressed S29 2===
1282 Attachment down not pressed S20 4===
1282 Attachment down pressed S20 8===
1282 Feed rolls forward not pressed S90 ===1
6- 71020EN - 08 - 2003
1282 Feed rolls forward pressed S90 ===2
1282 Emergency stop not pressed S28 ===4
1282 Emergency stop pressed S28 ===8
1282 Spout slow right not pressed S85 ==1=
1282 Spout slow right pressed S85 ==2=
1282 Start autopilot / shift rear hydr not pressed S91 ==4=
1282 Start autopilot /shift rear hydr pressed S91 ==8=
1282 Spout deflector down not pressed S88 =1==
1282 Spout deflector down pressed S88 =2==
1282 Spout deflector up not pressed S89 =4==
1282 Spout deflector up pressed S89 =8==
1282 Spout fast left not pressed S86 1===
1282 Spout fast left pressed S86 2===
1282 Spout slow left not pressed S87 4===
1282 Spout slow left pressed S87 8===
1282 Groundspeed potentiometer R5 ==XX in neutral XX = 5C ± 30 or 3E < XX <

7A
1282 MF handle in neutral S31 =1==
1282 MF handle out of neutral S31 =2==
6- 71020EN - 08 - 2003
1283 Dashboard switches inputs
1283 Parking brake S36 ===1 ===0: open; ===1: closed
1283 Crop processor roll clearance close switch S115 ===2 ===0: not pressed; ===2: pressed
pressed
1283 Airco thermoswitch in cab B61 ==1= ==0=: open; ==1=: closed
1283 Brakes fluid level switch S45 =4== =0==: open; =4==: closed
1283 Brakes pressure switch S58 =8== =0==: open; =8==: closed
used for rear brake lights (and 4 wheel
drive)
1283 Seat switch (person on seat) S83 2=== 0===: open; 2===: closed
1283 Spout down / front hydr down / rear hydr down S42 4=== 0===: not pressed; 4===: pressed
1283 Spout up / front hydr up / rear hydr up S41 8=== 0===: not pressed; 8===: pressed
1283 Revolving flashlight switch on S111 ===1
1283 Auto--Pilot main switch on S108 ===2 ===0: switch off
1283 Revolving flashlight switch off S111 ===4 ===0: switch on
1283 Silage additive applicator switch off S109 ===8 ===0: switch on
1283 Operating lights switch on (pos B) S110 ==1= ==0=: switch off
1283 Auto--Pilot main switch off S108 ==2= ==0=: switch on
1283 Operating lights switch off (pos A) S110 ==4= ==0=: switch on
1283 Silage additive applicator switch on S109 ==8= ==0=: switch off
1283 Auto reversing aid system switch off S112 =2== =0==: switch on
1283 Cutterhead reverse switch on S114 =4== =0==: switch off
1283 AKS & ASBA switch off / sharpener door closed S113 =8== =0==: switch on
6- 71020EN - 08 - 2003
1283 Crop processor roll clearance open switch S115 1=== 0===: not pressed
pressed
1283 Auto reversing aid system switch on S112 2=== 0===: switch off
1283 Cutterhead reverse switch off S114 4=== 0===: switch on
1283 AKS & ASBA switch on / sharpener door open S113 8=== 0===: switch off
1283 Harvest mode switch off (Road mode) S105 =8== =0==: switch on
1283 Harvest mode switch on (Field mode) S105 8=== 0===: switch off
1283 Metal detector off switch pressed S106 =4== =0==: not pressed
1283 Metal detector on switch pressed S106 4=== 0===: not pressed
1283 High flow hydraulics close switch pressed S137 =2== =0==: not pressed
1283 High flow hydraulics open switch pressed S137 2=== 0===: not pressed
1286 AKS & ASBA panel inputs
1286 Engine speed switch down pressed S103 ===1 ===0: not pressed
1286 Cutterhead drive switch on S101 ===2 ===0: switch off
1286 Four--wheel drive switch on S102 ===4 ===0: switch off
1286 Engine speed switch up pressed S103 ===8 ===0: not pressed
1286 Four--wheel drive switch off S102 ==1= ==0=: switch on
1286 Cutterhead drive switch off S101 ==2= ==0=: switch on
1286 Automatic shear bar adjustment key pressed S120 =2== =0==: not pressed
1286 Sharpening routine 1 min key pressed S121 =4== =0==: not pressed
1286 Sharpening routine 2 min key pressed S122 =8== =0==: not pressed
6- 71020EN - 08 - 2003
1286 Sharpening routine 3 min key pressed S123 1=== 0===: not pressed
1286 Stop sharpening / shearbar adjust key pressed S124 2=== 0===: not pressed
1287 ARMREST module inputs (BOSCH CON-

SOLE)
1287 HHC ground pressure potentiometer R7 ==XX Limits: ????????
1287 HHC stubble height potentiometer R6 XX== Limits: ????????
1287 HHC stubble height / no lateral float selected S35 =4==
1287 HHC stubble height / lateral float selected S35 =8==
1287 HHC compensation mode selected S35 1===
1288 GROUND SPEED
1288 Ground speed based on PC calibration XXXX Groundspeed in mm/s based on PC

calibration
1288 Ground speed reference B16 XXXX XXXX is always zero except when
rpm’s are read in by machine (=>
FFFF) word 3 = analog voltage
1288 Ground speed shown on display XXXX Groundspeed in mm/s based on dis-
play calibration
1289 ENGINE RPM
1289 Engine rpm B43 XXXX rpm -- hexadecimal code

B44
1289 Calibrated maximum engine speed XXXX rpm -- hexadecimal code
6- 71020EN - 08 - 2003
1290 CROP PROCESSOR RPM
1290 Crop processor rpm B104 XXXX rpm -- hexadecimal code
1290 Crop processor rpm reference XXXX rpm -- hexadecimal code
1293 CUTTERHEAD RPM
1293 Cutterhead rpm B101 XXXX rpm -- hexadecimal code
1293 Cutterhead rpm reference XXXX rpm -- hexadecimal code
1294 Drive Print E
1294 Feedrolls rpm B116 XXXX
1294 Number of knives XXXX between 2 and 12 (2 and C hex)
1294 Software revision drive print E ==XX
1294 PWM hydropump feedrols XXXX
1303 Data FROM CPU print
1303 Main drive clutch engaged active (output status) ===1 ===0: not engaged
1303 Buzzer continous ===2
1303 Buzzer interrupted ===4
1303 Feed rolls reverse engaged (output status) ===8 ===0: not engaged
1303 Field mode active (status) ==1= ==0=: not active
1303 Engine airfilter pressure switch closed B7 ==2= ==0=: switch open
6- 71020EN - 08 - 2003
1303 Hydrostatic / hydraulic oil temp switch closed B5 ==4= ==0=: switch open
1303 Hydrostatic oil pressure switch closed B4 ==8= ==0=: switch open
1303 Main drive oil pressure switch closed B100 =1== =0==: switch open
1303 Cutterhead gearbox oil temperature switch B105 =2== =0==: switch open
closed
1303 Engine oil pressure switch closed B1 =4== =0==: switch open
1303 Main drive oil filter pressure switch closed =8== =0==: switch open
1303 Airco H pressure switch closed S62 1=== 0===: open
1303 Airco L pressure switch closed S63 2=== 0===: open
1303 Brakes worn out S66 4=== 0===: contacts open

S67
S70
S71
1303 Parking lights on ===1 ===0: lights off
1303 Engine coolant temperature switch closed ===8 ===0: open
1303 Engine oil temperature switch closed B3 ==1= ==0=: open
1303 RH screen door sensor activated B102 ==2= ==0=not activated
1303 Spout rotation limit sensor activated (LH) B103 ==4= ==0=not activated
1303 Alternator loading ==8= ==0=: not loading
1303 Cutterhead reverse active (output status) Y31 =1== =0==: not active
1303 Engine emergency stop activated (status) =2== =0==: not active
1303 4 wheel drive engaged (output status) Y22 =4== =0==: notengaged
1303 Engine shut off disabled (status) =8== Engine started after quick stop
1303 Header height latched (status) 1===
6- 71020EN - 08 - 2003
1303 HHC automatic resume given (status) 2===
1303 Software version display node B ==XX
1304 Data FROM AKS & ASBA PRINT
1304 Metal detector off ===1 ===0: metal detector on
1304 Groundspeed > 90 % Vmax PC calibrated ===2 ===0: groundspeed < 90% Vmax
1304 Sharpener stone at home position B109 ===4 ===0: sharpener stone not at home
position
1304 Sharpener stone worn out B108 ===8 ===0: sharpener stone not worn out
1304 Shearbar backwards L or R end of stroke ==1=

switches
1304 Shearbar forward L end of stroke switch ==2=
1304 Shearbar forward R end of stroke switch ==4=
1304 Request buzzer continous =1==
1304 Feed rolls forward active (output status) =2== =0==: feed rolls forward not engaged
1304 Metal detected B110 =4== =0==: no metal detected
1304 Request buzzer interrupted =8==
1304 Sharpener door closed S82 1=== 0===: sharpener door between open
and closed
1304 Sharpener door open B107 2=== 0===: sharpener door between open
and closed
1304 Hydrostatic pump forward 4=== 0===: not driving
1304 Hydrostatic pump backwards 8=== 0===: not driving
6- 71020EN - 08 - 2003
1304 Knock sensor hit value XXXX last measured real knives hit peak val-
ue during adjust operation
1304 Hydrostatic pump current pwm duty cycle XXXX
1304 Software version display node T ==XX
1305 TOTAL HOURS
1305 Total cutterhead hours XXXX XXXX word 1 = msb & word 2 = lsb
1305 Total engine hours XXXX XXXX word 3 = msb & word 4 = lsb
1306 TOTAL HA
1306 Total ha XXXX XXXX word 1 = msb & word 2 = lsb
1313 HEADER HEIGHT / Ground PRESSURE / CP Rolls DISTANCE
1313 Header height XXXX
1313 Ground pressure XXXX
1313 Crop processor rolls distance XXXX Limits: 3b < XX < 79
1314 Dashboard LEDS
1314 Park brakes led H8 ===1 ===0: extinguished
1314 Road/field mode status led H21 ===2 ===0: extinguished = field mode
1314 Metal detector led H22 ===4 ===0: extinguished
1314 Main drive oil filter under pressure led ===8 ===0: extinguished
1314 Main drive oil pressure led H24 ==1= ==1=: extinguished
6- 71020EN - 08 - 2003
1314 Engine oil pressure led H1 =1== =0==: extinguished
1314 Engine temperature led H2 =2== =0==: extinguished
1314 Battery--alternator led H3 =4== =0==: extinguished
1314 Hydrostatic / hydraulic oil temperature led H4 =8== =0==: extinguished
1314 Brake linings / brake fluid level led H7 1=== 0===: extinguished
1314 Airfilter under pressure led H6 2=== 0===: extinguished
1314 Hydrostatic oil pressure led H5 4=== 0===: extinguished
1314 AKS & sharpener door status led H25 =8== =0==: extinguished
1314 Chopper gearbox oil temperature led H26 1=== 0===: extinguished
1314 Airco Low pressure led H14 2=== 0===: extinguished
1314 Airco High pressure led H13 4=== 0===: extinguished
1314 Header height indication led bar ==X= XX== yellow: upper = 8 00, lower 0 04 and
lowest 0 02; red: 0 08 all leds: F FE
1315 Automatic Knife Sharpening LEDS
1315 AKS 3 min led H123 ===1 ===0: extinguished
1315 AKS stop led H124 ===2 ===0: extinguished
1315 AKS rpm fault led H125 =1== =0==: extinguished
1315 AKS motor fault led H126 =2== =0==: extinguished
1315 AKS sensor fault led H127 =4== =0==: extinguished
1315 AKS service led H128 =8== =0==: extinguished
6- 71020EN - 08 - 2003
1315 AKS OK led H129 1=== 0===: extinguished
1315 AKS adjust led H120 2=== 0===: extinguished
1315 AKS 1min led H121 4=== 0===: extinguished
1315 AKS 2 min led H122 8=== 0===: extinguished
1315 Noise left knock sensor B50 XXXX
1315 Noise right knock sensor B106 XXXX
1317 Header Height control LEDS (BOSCH)
1317 HHC red led H18 2=== 0===: extinguished
1317 HHC green led H19 4=== 0===: extinguished
1318 Fuel level and Engine temperature
1318 Fuel level analog B12 XXXX
1318 Engine coolant temperature analog XXXX
1319 Limb home and AKS & ASBA
1319 Activate Limb home request (Urgent drive proce- XXXX 53CA to rise the request else 0000
dure)
1319 Answer on limb home request XXXX 0000 not answered yet;
55CC: ’yes’ is answered;
1111 ’ no’ is answered
1319 Stop AKS & ASBA adjustmment during forward ===2 ===2: set; ===0: not set
drive
1319 Continue AKS & ASBA adjustment during for- ===1 ===1: set; ===0: not set
ward drive
6- 71020EN - 08 - 2003
1320 Calibration data
1320 Calibrate knives ===4 ===0: not calibrate

1320 Calibrate max header height 0008
1320 Calibrate min header height 0010
1320 Calibrate groundspeed tuning 0200 XXXX XXX = groundspeed tuning to be cali-
brated (on monitor display)
1320 Calibrate min speed spout L 1000 00XX spout rotation L typical setting = 200
1320 Calibrate min speed spout R 2000 00XX spout rotation R typical setting = 195
1320 Calibration shearbar gap value 4000 00XX 2<=XX<=8; if not calibrated or XX<2 or
XX>8 then as if XX=4
1320 Calibration crop processor presence 8000 000X 0001 if present: X = 1; if not present: X = 0;
1320 Calibration crop processor distance 8000 000X 0002 if at maximum: X = 1; if at minimumt: X
= 0;
1320 Calibration airco presence 8000 000X 0010 if present: X = 1; if not present: X = 0;
1320 Calibration language 8000 000X 0020 X=0: English, X=1: French, X=2: Ger-
man, X=3: Italian, X=4: Spanish, X=5:
Danish, X=6: Dutch
1320 Calibration user messages 8000 000X 0040 X=1: YES, X=0: NO
1320 Calibration displayed units 8000 000X 0100 X=1: metric, X=0: imperial
1320 Calibration LCD contrast 8000 00XX 0080 XX contrast value
1320 Calibration header width 8000 XXXX 0400 XXXX<2000: header width in cm, else:
(XXX--2000)/100 rows and XXXX%100
cm/row
1320 Calibration year 8000 XXXX 4000 XXXX: year
1320 Calibration date & time 8000 XXYY ZZUU 8000 XX: hour (bcd); YY: minute (bcd);
ZZ: month (bcd); UU:day (bcd)
1320 Knive speed protection ===8 ===0 not engaged
6- 71020EN - 08 - 2003
1326 Software revision display, node A and S
1326 Software version display node A ( functional ) ==XX
1326 Software version display node S ( symbols ) ==XX
1327 DATE & TIME
1327 Minutes ==XX Hexadecimal code
1327 Hours XX== Hexadecimal code
1327 Month ==XX Hexadecimal code
1327 Day XX== Hexadecimal code
1327 Year XXXX Hexadecimal code
1327 Year of construction XXXX Hexadecimal code
1331 calibration data in node T (AKS & ASBA)
1331 max calibrated speed stored in node T XXXX mm/s (Hexadecimal code)
1331 max cal current to pump pwm stored in node T XXXX 1199 = +/-- 105 mA
1331 serial nr stored in node T OXXX XXXX 0<=X<10 (Hexadecimal code)
6- 71020EN - 08 - 2003
1332 CALIBRATION DATA IN NODE B
1332 Max calibrated speed stored in node B XXXX mm/s (Hexadecimal code)
1332 Max cal current to pump pwm stored in node B XXXX 1199 = +/-- 105 mA
1332 Serial nr stored in node B OXXX XXXX 0<=X<10 (Hexadecimal code)
1334 CALIBRATION DATA IN NODE E (Drive print)
1334 Max calibrated speed stored in node E XXXX mm/s (Hexadecimal code)
1334 Max cal current to pump pwm stored in node E XXXX 1199 = +/-- 105 mA
1334 Serial nr stored in node E OXXX XXXX 0<=X<10 (Hexadecimal code)
1342 CALIBRATED VALUES 2 T
1342 Calibrated rear valves X000 X=8: yes; X=0: no
1342 Calibrated low pressure stack valves X000 X=4: yes; (X=0: no)
1342 Calibrated values initialised X000 X=2: yes; X=0: no
1342 Calibrated ground speed cte XYYY 0<=X<=1, 0<=Y<=f
1342 Calibrated min forward hydrostatic current XXXX 0<=X<=f
1342 Calibrated min backward hydrostatic current XXXX 0<=X<=f
1342 Calibrated max ground speed handle pot meter XX== 0<=X<=f
1342 Calibrated header height latch value ==XX 0<=X<=f
6- 71020EN - 08 - 2003
1343 CALIBRATED VALUES 3 E should be identical to 1345, by

voting
1343 Hydro--acceleration for It.,Germ.,Swi.,Oost. =8==
1345 CALIBRATED VALUES 3 T
1345 Calibrated rotary screens new location ===1 1:yes, if 0:no
1345 Calibrated active stop (quick feedrolls stop) ===2 2:yes, if 0:no
1345 Calibrated fixed deflector position ===4 ===0 not calibrated ===4 calibrated
1345 Calibrated full engine speed road mode ===8 ===0 not calibrated ===8 calibrated
1345 Calibrated four wheel drive ==1= ==0= yes; ==1= no
1345 Sharpening on the move ==2= ==0= yes; ==2= no
1345 Calibrated air conditioning ==4= ==0= no; ==4 yes
1345 Calibrated high flow hydraulics ==8= ==0= no; ==8 yes
1345 Calibrated rotary brush screen =1== =0== no; =1== yes
1345 Reverse feedrolls on active =2== =0== not; =2== active
1345 Electronic controlled engine =4== is standard =4==
1345 Low activation hydropump =8== =0== no; =8== yes
1345 Manual engine speed 1=== 0=== automatic engine speed accel-
eration
1=== manual
1345 Calibrated shearbar gap ===X 0<=X<=f
6- 71020EN - 08 - 2003
1347 Output Identifiers from CPU print
1347 Spout deflector up Y45 =8== =8== : activated ; =0== : not activated
1347 Spout deflector down Y46 =2== =2== : activated ; =0== : not activated
1347 Engine speed down ==2= ==2= : activated ; ==0= : not activated
1347 Engine speed up ==1= ==1= : activated ; ==0= : not activated
1347 Close crop processor Y76 ===2 ===2 : activated ; ===0 : not activated
1347 Open crop processor Y75 ===1 ===1 : activated ; ===0 : not activated
1347 Rotary screens M26 4=== 4=== : activated ; 0=== : not activated
M27
1347 Bosch header down switch simulation 2=== 2=== : activated ; 0=== : not activated
1347 Bosch header up/down fast switch simulation =8== =8== : activated ; =0== : not activated
1347 Auto--Pilot resume switch simulation =2== =2== : activated ; =0== : not activated
1347 Engine stop solenoid -- hold =1== =1== : activated ; =0== : not activated
1347 Bosch automatic resume switch simulation ==4= ==4= : activated ; ==0= : not activated
1347 Bosch ground press mode switch simulation ==2= ==2= : activated ; ==0= : not activated
1347 Bosch stubble height mode switch simulation ==1= ==1= : activated ; ==0= : not activated
1347 Bosch header up switch simulation ===2 ===2 : activated ; ===0 : not activated
1347 Bosch transport mode off switch simulation ===1 ===1 : activated ; ===0 : not activated
1347 Bosch stubble height pot simulation XX== Limits : OA < XX < E5 +/-- 10
1347 Bosch ground pressure pot simulation ==XX Limits : OA < XX < E5 +/-- 10
6- 71020EN - 08 - 2003
1348 Output Identifiers from CPU print
1348 Work lights (operating lights) 8=== 8=== : activated ; 0=== : not activated
1348 Work lights (operating and spot lights) 4=== 4=== : activated ; 0=== : not activated
1348 Work lights (rear) 2=== 2=== : activated ; 0=== : not activated
1348 Operating lights =4== =4== : activated ; =0== : not activated
1348 Spots lights =2== =2== : activated ; =0== : not activated
1348 Spout light =1== =1== : activated ; =0== : not activated
1348 Rear drive buzzer ==4= ==4= : activated ; ==0= : not activated
1348 Brake lights ==2= ==2= : activated ; ==0= : not activated
1348 Revolving flashlights E1 ==1= ==1= : activated ; ==0= : not activated

E2
1348 Power to Auto--Pilot ===8 ===8 : activated ; ===0 : not activated
1348 Airco compressor clutch Y27 ===4 ===4 : activated ; ===0 : not activated
1348 Power to silage additive applicator K2 ===2 ===2 : activated ; ===0 : not activated
1348 Main drive clutch engaged Y44 4=== 4=== : engaged ; 0=== : not engaged
1348 Rear hydraulics up Y36 2=== 2=== : activated ; 0=== : not activated
1348 Rear hydraulics down Y37 1=== 1=== : activated ; 0=== : not activated
1348 Spout rotation Left Y32 =2== =2== : activated ; =0== : not activated
1348 Spout rotation Right Y33 =1== =1== : activated ; =0== : not activated
1348 Feed rolls reverse engaged ==2= ==2= : engaged ; ==0= : not engaged
1348 Main drive belt not tensioned Y40 ==1= ==1= : not tensioned ; ==0= : ten-
sioned
1348 Cutterhead reverse engaged Y31 ===8 ===8 : engaged ; ===0 : not engaged
6- 71020EN - 08 - 2003
1348 Spout up Y38 ===4 ===4 : activated ; ===0 : not activated
1348 Spout down Y39 ===2 ===2 : activated ; ===0 : not activated
1348 Four--wheel drive engaged Y22 ===1 ===1 : engaged ; ===0 : not engaged
1348 Front hydraulics down Y35 =4== =4== : activated ; =0== : not activated
1348 Front hydraulics up Y34 =1== =1== : activated ; =0== : not activated
1348 Spout rotation L & R pwm ==XX Hexadecimal code
1349 Sharpening routine engaged ===1 ===1 activated: ===0 not activated
1349 Stopvalve activated Y42 ===2 ===2 activated; ===0 not activated
1349 Right ASBA motor to the knives ===4 ===4 activated; ===0 not activated
1349 Right ASBA motor forward ===8 ===8 activated; ===0 not activated
1349 Left ASBA motor to the knives ==1= ==1= activated; ===0 not activated
1349 Left ASBA motor forward ==2= ==2= activated; ==0= not activated
1349 Sharpener door close ==4= ==4= activated; ==0= not activated
1349 Sharpener door open ==8= ==8= activated; ==0= not activated
1349 Chopperbody not fitted =2== =2== not fitted; =0== fitted
1349 Hydraulic cprol open Y75 =4== =4== opening hydraulic cp;
=0== not activated
1349 Hydraulic cprol close Y76 =8== =8== closing hydraulic cp;
=0== not activated
1349 Brake pressure limiter valve Y77 4=== 4=== brake pressure limiter activated ;
0=== not activated
6- 71020EN - 08 - 2003
1349 Spout rotation limit sensor detected (RH) B117 =4== =4== spout left sensor detect the spout
;
=0== no spout detection
1349 Cutterlength out of range =8== =8== cutterlength is out of range ;

=0== not
1349 No feed rolls rpm 1=== 1=== no feed rolls speed ;

0=== feed rolls speed detected
1350 Knock2 sensor level XXXX
1350 Sharpening stone home B109 =1== =1== sharpening stone in home posi-
tion ;
=0== sharpening stone not in home
position
1350 Sharpening door closed B107 =2== =2== sharpening door closed;
=0== sharpening door moving
1350 Sharpening door open B107 =4== =4== sharpening door open ;
=0== sharpening door moving
1350 Sharpening 1=== 1=== sharpening ;

0=== not sharpening
1350 Value sensor sharpening stone home =XXX value between =000 and =3FF
1350 Analogue value sharpening stone thickness XX== YY== value= XX bit 3 to 7 + Y Y bit 3 to 7 ;
1350 Analogue value
1351 Drive Print E
1351 Lenght of cut XX==
1351 Header RPM XXXX not available
6- 71020EN - 08 - 2003
1352 Engine
1352 Fuel temp B48 ==XX Range: --40˚C to +210˚C (1˚C/bit)
1352 Engine coolant temperature XX== Range: --40˚C to +210˚C (1˚C/bit)
1352 Procent engine load ==XX range from 0% to 125 % ( 1%bit)
1352 Boost air temp XX== Range: --40˚C to +210˚C (1˚C/bit)
1352 Calibrated max. engine rpm XXXX Range: 0 to 8031.875 rpm (0.125 rpm/
bit)
1352 Engine oil pressure B47 ==XX Range: 0Kpa to +500Kpa ( 2Kpa/bit)
1352 Engine inlet manifold pressure XX== Range: 0Kpa to +1000Kpa ( 4Kpa/bit)
1353 Engine
1353 Engine rpm XXXX Range: 0 to 8031.875 rpm (0.125 rpm/

bit)
1353 Actual engine speed XXXX
1353 Throttle sensor calibration ==4=
1353 Invalid throttle signal ==8=
1353 8 Volt supply above normal =1==
1353 Check timing sensor calibration =2==
1353 Cylinder 6 fault =4==
1353 Cylinder 5 fault =8==
1353 Cylinder 4 fault 1===
6- 71020EN - 08 - 2003
1353 Error codes XXXX XXXX XXXX ERROR CODES
1353 5 Volt supply above normal =2==
1353 5Volt supply below normal =1==
1353 Incorrect engine software ==8=
1353 Personality module fault ==4=
1353 Check Customer or system Parameters ==2=
1354 Engine
1354 DTC warning lamp ==XX =
1354 DTC number iveco =X==
1354 Number of DTC X===
1354 Occurrence counter ==XX 00=<XX<4F
1354 DTC storage Lamp =X== 0=<X<=2
1354 Failor mode Id XX== 4=<X<=4F
1354 SPN_LSB+ MSB XX=2
1355 engine
1355 Intermediate speed point XXXX
1355 Actual torque limit XXXX
1355 Controls Bits XX==
6- 71020EN - 08 - 2003
1356 Engine + AKS & ASBA
1356 copy of EDC_ECM XXXX XXXX XXXX copy of J1939
1356 ALL_ENGINE_OFF =1==
1356 Close sharpening door =2== =0== no action ;

=2== close command
1356 Open sharpening door =4== =0== no action ;

=4== open command
1356 Start full pull =8== =0== no action ;

=8== starts full pull
1356 Stop full pull 1=== 0=== no action;

1=== stop full pull
1356 Start sharpening 2=== 0=== no action;

2=== starts sharpening
1356 Cutterlength out of range 4=== 0=== all normal;

4=== out of range
1356 Spout left detected B103 8=== 0=== not spout;

B117 8=== spout detected by sensor
1356 EDC_EMC_ value ok ===1 ===0 not ok;

===1 ok
1356 Drive control off ===8 ===0 on;

===8 off
1356 Feedrolls active forward ==1= ==0= not active;

==1= active
1359 Feedrolls
1359 Configuration2 XXXX
6- 71020EN - 08 - 2003
1359 Max speed forward XXXX
1359 Pc_90_forward speed XXXX
1359 Current pwm 100 pc XXXX
1361 Blow up ===1 ===0 no blow up; ===1 blow up
1361 AKS & ASBA off S113 ==8= ==0= AKS & ASBA on ;
==8= AKS & ASBA off
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
DETAILED ANALYSIS PER FUNCTION
1. Electric conditions, engine running or not running
2. Engine quick stop system
3. Harvest mode
4. Engine acceleration
5. Cutterhead engagement
6. Feed rolls forward engagement
7. Feed rolls reverse engagement
8. Automatic reversing aid system
9. Four--wheel drive
10. Spout rotation
11. Raise/lower spout
12. Spout deflector
13. Reverse cutterhead
14. Auxiliary front hydraulics
15. Auxiliary rear hydraulics
16. Air conditioning
17. Silage additives application
18. Knife sharpening
19. Automatic Shear Bar Adjustment routine
20. Crop processor
21. Metal detector operation and trouble shooting
22. Attachment Height Control
23. Ground speed
24. High flow Hydraulics
25. Rotary Screens
26. Rotary Screen Brushes
27. Caterpillar engine
28. CAN netwerk
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
1. ELECTRIC CONDITIONS, ENGINE REMARK: If the engine is running, but there is no ro-
RUNNING OR NOT RUNNING tary screen rotation, possible consequences are:
• No engagement of the cutterhead and feed rolls.

Reason
• No stop system.
The system must know if the engine is running or not.
A lot of functions can only be activated when the • Engine rpm not displayed on the screen.
engine is physically running.
Indication • Engine oil pressure led, battery alternator led
and hydrostatic oil pressure led remain
An indication for the engine running or not running illuminated.
are the rotary screens.
As soon as one of the three conditions for “engine is Alternator charging
running” is valid, also the rotary screens will rotate.
Or, if the rotary screens rotate (engine running or The alternator (wire 007 -- gn) is connected to an
not), this means that for the electronics the engine is internal resistor (fictive bulb) in the electronic system
started. (actuator printed circuit). With contact on, the
electronic system puts 12V on the resistor:
Conditions for “engine is running”
1. Indication that the alternator is charging • when the engine is not running, the alternator
connects the wire 007--gn to ground. A current is
or
flowing through the resistor (fictive bulb
2. Sufficient engine oil pressure and sufficient illuminates), and the electronic system causes
hydrostatic oil pressure the charging led in the cab to be illuminated.
or
• When the engine is running, the alternator puts
3. Information from engine rpm sensor 12V on the wire 007--gn. Over the internal
Conditions for “engine is not running” resistor is now 0V, no current is flowing any
longer (fictive bulb extinguishes) and the
1. Insufficient charge of the alternator electronic system causes the charging led to
extinguish.
and
REMARK: When contact is on and the wire 007--gn
Insufficient engine oil pressure
is disconnected from the alternator: no current can
flow through the internal resitor. For the electronic
and
system, the engine is running now and the rotary
screens will rotate.
No information from engine rpm sensor
or
2. Insufficient charge of the alternator
and
Insufficient hydrostatic oil pressure
and
No information from engine rpm sensor
6- 71020EN - 08 - 2003
Can Spy

ID
1289 Engine rpm XXXX Rotation per minute --
Hexadecimal code
1303 Alternator charging ==8= ==0=: Alternator not charging
1303 Engine oil pressure switch =4== =0==: Switch open;
=4==: Switch closed
1303 Hydrostatic oil pressure switch ==8= ==0=: Switch open;
==8=: Switch closed
Error messages
Error Code Key words

360 No engine oil press.
361 Oil press sens fault
362 No hydrost. pressure
363 Hydrost. sensor fault
Electrical diagrams
Group 1: Starter circuit, line 10 -- 340
Group 7: Electronic system, line 2050 -- 2380
Group 9: Engine protection, line 2900 -- 3060
6- 71020EN - 08 - 2003
2. ENGINE PROTECTION
Engine oil Engine oil Engine coolant Hydrostatic oil

pressure temperature temperature pressure
switch switch switch switch
Engine oil Engine oil Hydrostatic Engine quick--

pressure temperature oil pressure stop procedure
Led Led Led activated
When: Engine oil pressure < 1.3 bar

or Engine oil temperature > 126°C (Iveco Cursor) or 188°C (Caterpillar)
or Engine coolant temperature > 105°C
or Hydrostatic oil pressure < 5 bar
the “engine quick--stop status” becomes high, the corresponding led starts to blink and the buzzer will sound.
When the feed rolls are engaged, they will be disengaged immediately. 5 seconds later, the main drive clutch
will be disengaged and the engine speed will drop, giving the cutterhead and the blower time to clear. After 10
seconds, the engine will stop automatically.
problems occurs 5 sec 10 secs
Led starts to blink, alarm sounds Main drive disengaged Engine stops
and feed rolls disengage Engine speed to low idle automatically
To restart, start the engine twice without switching off the ignition.
6- 71020EN - 08 - 2003
REMARK: 3. When a temperature sensor has a shorted

1. When a problem occurs and it only lasts for 5 circuit, an indication of the problem is shown on
seconds, work can be continued. However, the the dashboard when switching on the ignition.
system will keep these 5 seconds in memory. Once the engine is started, the quick--stop
When later on the problem starts again, the system is activated and the engine will stop after
system will stop the engine after 5 seconds. 15 seconds.
2. When a pressure sensor has an open circuit, an

indication of the problem is shown on the
dashboard when switching on the ignition (the
corresponding led will start to flash).
Once the engine is started, everything will
function normally.
Can Spy

ID
1303 Engine oil pressure switch =4== =0==: Switch open;
=4==: Switch closed
1303 Engine oil temperature switch ==1= ==0=: Switch open;
==1=: Switch closed
1303 Engine coolant temperature switch ===8 ===0: Switch open;
===8: Switch closed
1303 Hydrostatic oil pressure switch ==8= ==0=: Switch open;
==8=: Switch closed
1303 Engine emergency stop activated =2== =0==: Engine emergency
stop not activated
1303 Engine shut--off disabled =8== Engine started after engine
quick--stop
1314 Engine oil pressure led =1== =0==: Extinguished
1314 Engine temperature led =2== =0==: Extinguished
1314 Hydrostatic / hydraulic oil temperature led =8== =0==: Extinguished
6- 71020EN - 08 - 2003
Error messages

360 No engine oil press.
361 Oil press sens fault
Electrical diagrams
Group 9 : Engine protection, line 2900 -- 3060
Group 21: Coolant temp and fuel gauge, line 7320 -- 7480
6- 71020EN - 08 - 2003
3. HARVEST MODE
Harvest Quick--stop Right--hand Ground speed

switch switch screen door sensor
sensor
Harvest Mode Harvest/

activate Road Mode
(Status) Led
When switching on the contact, the machine is always in Road Mode.
For switching to Harvest mode, four conditions must be met:
1. The quick--stop switch may not be pressed

and 2. The right--hand screen door must be closed
and 3. The ground speed must be slower than 90% of the calibrated maximum ground speed
and 4. The Harvest switch must be switched into Harvest Mode after previous conditions are done.
When all these conditions are met, the Harvest/Road Mode led on the dashboard is not longer illuminated.
The machine switches immediately into ROAD Mode (with ignition on) when:
1. The Harvest switch is switched into ROAD mode

or 2. The quick--stop switch is pressed
or 3. The ground speed has reached 90% of the calibrated maximum ground speed
or 4. The right--hand screen door has been opened.
The Harvest/Road mode led illuminates again.
6- 71020EN - 08 - 2003
The Harvest tumbler switch must be switched to its HARVEST position in order to be able to harvest. When
switched to ROAD position, the following functions will not be operational:
• Spout rotation
• Spout height control
• Auto--Pilot (accessory)
• Automatic shear bar adjustment and automatic knife sharpening
• Cutterhead engagement and, therefore, feed roll and attachment engagement
• 4--wheel drive (optional)
• Metal detector
• Auxiliary hydraulics
• Silage applicator
Can Spy

ID
1282 Quick--stop switch pressed ===8
1282 Quick--stop switch not pressed ===4
1283 Harvest mode switch ON (Field mode) 8=== = Harvest Mode,
0===: Switched off
1283 Harvest mode switch OFF (Road mode) =8== = Road Mode,
=0==: Switched on
1288 Ground speed based on PC calibration XXXX Ground speed in mm/s based
on PC calibration
1303 Field mode activated ==1= ==0=: Road Mode
1303 Right--hand screen door sensor activated ==2= ==0=: Screen door open
Door closed
1304 Ground speed > 90% Vmax calibrated ===2 ===0: Ground speed < 90% V
max
1314 Road/Field mode led ===2 ===0: Extinguished = Field
Mode
6- 71020EN - 08 - 2003
Error messages

120 Ground speed sens. O
121 Ground speed sens. --
122 Ground speed sens. +
220 Engine door sensor O
221 Engine door sensor --
222 Engine door sensor +
Electrical diagrams
Group 8: CPU inputs and display, line 2390 -- 2890
B16: Ground speed sensor
Group10: Switches, instrument panel, multi--function handle and auxiliary hydraulics, line 3410 -- 3910
B102: Engine door sensor
S28: Quick stop switch
S105: Road/Field mode switch
6- 71020EN - 08 - 2003
4. ENGINE ACCELERATION
Field Mode Throttle Throttle control Engine Full engine speed in

control up down switch CCM Road Mode (NA)
See paragraph 3 switch (EST Calibration)
Engine Throttle
Seat switch Control
Manual or Automatic
(EST Calibration)
A selection between Manual and Automatic Engine throttle control is available by means of the EST calibration.
When Manual Throttle control is selected, the engine speed will rise or lower as long as the engine throttle switch
is pressed. Once the engine speed reaches 1850 rpm in Field mode, the engine speed will automatically rise
to full engine speed.
When Automatic Throttle Control is selected, the engine speed rises automatically to 1750 rpm (1650 rpm for
Caterpillar engines) in ROAD mode and 2100 rpm in Field mode with one single pulse on the engine speed up
bottom. Pushing once on the engine speed down button, the engine speed will automatically drop to low idle.
An intermediate engine speed can be selected by giving a counter pulse on the engine speed button.
Scheme
Road mode 900 rpm IVECO Field mode

850 rpm CAT
"
Low Idle
Throttle up A Throttle up
engine engine
speed speed
Throttle down Throttle down
engine speed engine speed
B B
1750 rpm IVECO Switch to Road Mode Full engine speed

A
1650 rpm CAT (2100 rpm)
"
Switch to Harvest Mode and throttle up engine speed
6- 71020EN - 08 - 2003
REMARK: In case engine speed is higher than low idle speed, the engine speed automatically drops to low idle
in the following cases:
1. Driver leaves seat (seat switch)
2. The cutterhead is engaged
3. The cutterhead is reversed
4. The automatic shear bar adjustment is started
The engine speed can only be increased 5 seconds after starting the engine.
Can Spy

ID
1283 Seat switch (person on seat) 2=== 0===:open
2===: closed
1286 Throttle down switch pressed ===1 ===0: Not pressed
1286 Throttle up switch pressed ===8 ===0: Not pressed
Hexadecimal code
1345 Calibrated full engine speed in road mode ===8 ===0: not calibrated (no)
NA only ==8=: calibrated (yes)
1345 Calibrated engine speed control 1=== 0===: manual

1===:automatic
6- 71020EN - 08 - 2003
Error messages

129 Wrong engine CCM
Electrical diagrams
Group 2: Engine throttle control, line 520 -- 880
S103: Engine throttle control switch
Group10: Switches, instrument panel, multi--function handle and auxiliary hydraulics, line 3410 -- 3910
S83: Seat switch
6- 71020EN - 08 - 2003
5. CUTTERHEAD ENGAGEMENT
Field Mode Cutterhead Engine Cutterhead Chopper Attachment

See engaging RPM RPM body height over-
paragraph 3 switch sensor not present ride switch
Main drive
clutch oil
pressure switch
Main drive Main drive Main drive

belt clutch clutch oil
tensioned engaged pressure led
Road mode Harvest mode Cutterhead

engaged
Y40 12V 0V 0V
(Main drive clutch neutral position valve)
Y44 (Main drive belt + Main drive clutch) 0V 0V 12V
Main drive belt Not tensioned Tensioned
See electrical diagrams
To engage the cutterhead:
1. Switch ON the ignition and start the engine.
2. Switch the Harvest switch to Field mode.
3. Switch ON the cutterhead switch.
4. REVERSE the feed rolls.
6- 71020EN - 08 - 2003
REMARK:
1. To engage the cutterhead, the system must

know whether the engine is running.
(See paragraph 1 -- Engine Running/Not
Running).
2. The cutterhead can be engaged only 5 sec after

starting the engine.
3. After cutterhead engagement, the engine rpm

will drop automatically to low idle. The engine
speed must be throttled up again.
4. When the direction of rotation of the cutterhead

is changed while the cutterhead is running (from
forward to reverse, or vice versa), the drive will
be disengaged first and the machine will wait until
the cutterhead speed has dropped to less than
10 rpm. If you try to engage in the other direction
of rotation, the user message “CUTTERHEAD
RPM IS STILL > 10” will appear on the
performance monitor display. As soon as the
cutterhead has stopped, the next user message
“REENGAGE CUTTERHEAD” is displayed.
Only then the cutterhead can be reengaged in

the other direction of rotation. Switch the
respective cutterhead engagement switch OFF
and ON again.
5. In case the cutterhead speed sensor has failed,

and you want to engage the cutterhead in the
opposite direction, the system is not able to
check whether the cutterhead speed has actually
dropped or not. In order to prevent damage to
mechanical or hydraulic components, a 100
seconds count--down is started as soon as the
cutterhead is disengaged.
The following message appears on the screen:
“WAIT UNTIL ENGAGE TIMER = 100”.
When 0 has been reached, the cutterhead drive
can be switched ON. The message “Reengage
cutterhead” will appear.
6. Once the oil pressure switch on the low pressure

valve has detected a pressure lower than 24 bar,
the led on the instrument panel will flash. This is
only when the engine is running at full speed to
avoid slipping of the main drive belt.
7. When the chopper body is not present, it is no

longer possible to engage the cutterhead in
forward or reverse in the normal way.
For test reasons, the output shaft can be
engaged (forward direction) by simultaneously
pressing the attachment height override
switch and the cutterhead engagement
switch.
6- 71020EN - 08 - 2003
Can Spy

ID
1282 Automatic height control button not ===4
pressed
1282 Automatic height control button pressed ===8
1286 Cutterhead drive switch ON ===2 ===0: Switched off
1286 Cutterhead drive switch OFF ==2= ==0=: Switched on
1289 Engine rpm XXXX rpm -- Hexadecimal code
1293 Cutterhead rpm XXXX rpm -- Hexadecimal code
1303 Main drive clutch engaged ===1 ===0: not engaged
1303 Field mode active ==1= ==0=: Road Mode
1303 Main drive oil pressure switch closed =1== =0==: Switch open;
(Insufficient pressure) =1==: Switch closed
1314 Main drive clutch oil pressure led ==1= ==0=: Extinguished
1342 Calibrated low pressure valve X=== 0===: Not calibrated (no)
4===: Calibrated (yes)
1349 Chopper body not present =2== =2==: Not present
=0==: Present
Error messages

130 Cutterhead sensor O
131 Cutterhead sensor --
132 Cutterhead sensor +
457 Main drive hydr. sol.
462 Main clutch idler
Electrical diagrams
Group 8: CPU inputs and display, line 2390 -- 2890

B100: Main clutch oil pressure contact
B101: Cutterhead speed sensor
H24: Main drive clutch oil pressure LED
Group 10: Switches, instrument panel, multifunctional lever and auxiliary hydraulics, line 3410 -- 3910
S101: Cutterhead switch
Y40: Main drive clutch neutral position valve
Y44: Valve for main drive clutch + main drive belt
idler
6- 71020EN - 08 - 2003
6. FEED ROLLS FORWARD ENGAGEMENT
Field Mode Cutterhead Feed rolls Feed rolls

See engaged forward stop switch Seat switch
paragraph 3 See paragraph 5 switch
Feed rolls Metal detector

forward stop
engaged system
To engage the feed rolls forward drive:
1. Switch ON ignition and start the engine.
NOTE: A few seconds after the cutterhead is engaged, the metal detector alarm will sound.
4. Reverse the feed rolls by pressing the lower part of the feedroll drive button in order to activate the metal
detector stop system.
5. Engage the feed rolls forward drive by pressing twice the upper side of the feedroll drive button.
The feed rolls will stop automatically in the following cases:
1. The feed rolls stop button is pressed (lower side of feedroll drive button).
2. The seat switch is opened for at least 5 seconds.
3. The cutterhead is disengaged (see Cutterhead Engagement).
4. The Harvest mode is no longer active (see Harvest Mode).
5. When a metal detection takes place.
REMARK:
1. When pressing the quick--stop button, the stop system will be powered so that crop feeding is stopped
immediately.
2. When the classical output line of the metal detector is open, it is not longer possible to engage the feedrolls
forward (see group 21).
6- 71020EN - 08 - 2003
Can Spy

ID
1282 Feed rolls stop switch not pressed ===1
1282 Feed rolls stop switch pressed ===2
1282 Feed rolls forward switch not pressed ===1
1282 Feed rolls forward switch pressed ===2
1283 Seat switch (person on seat) 2=== 0===: Switch open;
2===: Switch closed
1303 Main drive clutch engaged ===1 ===0: Main drive not engaged
1303 Field mode active ==1= ==0=: Road Mode
1304 Feed rolls forward engaged =2== =0==: Feed rolls forward not
engaged
Error messages

330 Handle switch
(Feed rolls forward switch)
423 Feedrolls pump O
424 Feedrolls pump --
425 Feedrolls pump +
484 Stop valve
Electrical diagrams
S29: Feed rolls reverse switch
S83: Seat switch
S90: Feed rolls forward switch
S92: Feed rolls stop switch
Y73: Hydrostatic feed rolls
Group 11: Metal detector, line 3920 -- 4080
Y42: Stop valve solenoid
6- 71020EN - 08 - 2003
7. FEED ROLLS REVERSE ENGAGEMENT
Harvest Mode Cutterhead engaged Feed rolls Feed rolls

See See reverse reverse
paragraph 3 paragraph 5 switch engaged
To reverse the feed rolls:
3. Engage the cutterhead
4. Reverse the feed rolls by pressing the lower part of the feed rolls drive button to its second stop.
NOTE: The feed rolls will reverse until the switch is is released.
The feed rolls will stop in the following cases:
1. When releasing the feed rolls reverse button.
2. When disengaging the cutterhead (see Cutterhead engagement).
3. When the Harvest mode is no longer active (see Harvest mode).
REMARK:
1. When the feed rolls rotate forward, first press the feed rolls stop switch (lower part of the feed roll drive button
to first stop).
6- 71020EN - 08 - 2003
Can Spy

ID
1282 Feed rolls stop switch not pressed ===1
1282 Feed rolls stop switch pressed ===2
1303 Feed rolls reverse engaged ===8 =0==: Feed rolls reverse not
engaged
Error messages

330 Handle switch
(Feed rolls reverse switch)
Electrical diagrams
S29: Feed rolls reverse switch
S92: Feed rolls stop switch
Y73: Hydrostatic feed rolls
6- 71020EN - 08 - 2003
8. AUTOMATIC REVERSING AID SYSTEM
Harvest Mode Feed rolls Feed rolls Automatic reversing

forward reverse aid system
See group 3 switch switch switch
Front
Front
Hydraulics
Hydraulics UP
DOWN
When the automatic reversing aid system is

installed:
• The pick--up windguard can be lifted hydraulically.
• The eccentric position of the retractable pick--up fingers can be inversed hydraulically.
The windguard flips up when the feed rolls are reversed.

It will only flip down again when the feed rolls are reengaged.
Operation
3. Switch ON the automatic reversing aid system switch.
Front hydraulics Up is activated (12 V to electrovalve Y34) during 5 seconds when the feed rolls reverse switch
is pressed.
Front hydraulics Down is activated (12 V to electrovalve Y35) during 5 seconds when the feed rolls are reen-
gaged.
6- 71020EN - 08 - 2003
Can Spy

ID
1282 Feed rolls forward switch not pressed ===1
1282 Feed rolls forward switch pressed ===2
1283 Auto reversing aid system switch OFF =2== 0===: Switched on
1283 Auto reversing aid system switch ON 2=== 0===: Switched off
1348 Front hydraulics up =1== =1==: Activated
=0==: Not activated
1348 Front hydraulics down =4== =4==: Activated
=0==: Not activated
Error messages

330 Handle switch 1
(Feed rolls forward switch)
464 Front hydr. up sol.
465 Front hydr. down sol.
Electrical diagrams
Group 10: Switches, instrument panel, multifunction lever and auxiliary hydraulics, line 3410 -- 3910
S112:Automatic reversing aid system switch
Y34: Front auxiliary hydraulics up valve
Y35: Front auxiliary hydraulics down
6- 71020EN - 08 - 2003
9. FOUR--WHEEL DRIVE
Harvest Mode Four--wheel Four--wheel

See drive switch drive calibrated
paragraph 3 (EST--Calibration)
Four--wheel
drive
engaged
To engage the four--wheel drive:
3. Switch ON the four--wheel drive switch.
The four--wheel drive will be disengaged when:
1. The four--wheel drive switch is switched OFF.
2. The Harvest mode is no longer active (see Harvest mode)
6- 71020EN - 08 - 2003
Can Spy

ID
1286 Four--wheel drive switch OFF ==1= ==0=: Switched on
1286 Four--wheel drive switch ON ===4 ===0: Switched off
1303 Harvest mode activated ==1= ==0=: Road Mode
1303 Four--wheel drive engaged =4== =0==: Four--wheel drive not
engaged
1345 Calibrated four--wheel drive ==1= ==0=: Calibration (yes);
==1=: Not calibrated (no)
1348 Four--wheel drive engaged =4== =0==: 4WDnot engaged
Error messages

458 4 wheel drive solenoid
Electrical diagrams
Group 4: Four--wheel drive, line 860--1020.
S102: 4WD tumbler switch
Y22: 4WD valve
6- 71020EN - 08 - 2003
10. SPOUT ROTATION
Harvest Mode Spout fast Spout slow Spout fast Spout slow
See right switch right switch left switch left switch
paragraph 3
Spout rotation Spout rotation Spout rotation Spout rotation

Right engaged Left engaged end--of travel end--of travel
sensor -- Left sensor -- Right
To rotate the spout:
3. Raise the spout using the spout UP switch.
4. Rotate the spout using the spout operating switch.
REMARKS:
1. Depending on the selection in the performance monitor calibration (Type), it is possible to activate the spout
deflector and the spout rotation at the same time.
2. The spout rotation speed depends on the value calibrated in the performance monitor (Type).
Values are 80 minimum to 245 maximum.
A good average slow speed is 150.
3. Once the spout has reached its end--of--travel sensor (B103), the electrovalves Y32 or Y33 are no longer
powered, and the rotation will stop.
Release the rotation switch. It is possible to continue the rotation to the mechanical stop by pressing the
released switch again.
6- 71020EN - 08 - 2003
Can Spy

ID
1282 Spout fast right switch not pressed =1==
1282 Spout fast right switch pressed =2==
1282 Spout slow right switch not pressed ==1=
1282 Spout slow right switch pressed ==2=
1282 Spout fast left switch not pressed 1===
1282 Spout fast left switch pressed 2===
1282 Spout slow left switch not pressed 4===
1282 Spout slow left switch pressed 8===
1303 Harvest mode activated ==1= ==0=: Road Mode
1303 Spout rotation end of travel sensor acti- ==4= ==0=: Spout not end--of--
vated travel
1348 Spout rotation right =1== =1==: Activated
=0==: Not activated
1348 Spout rotation left =2== =2==: Activated
=0==: Not activated
1348 Spout rotation L & R pwm ==XX XX: Hexadecimal code
1349 Spout left detected =4== =4==spout detected
=0==: No spout detection
1356 Spout left detected 8=== 8===spout detected
0===: No spout detection
NOTE: For the spout left switch and the spout right switch:
When the fast switch is pressed, also the slow switch is pressed (internal structure of the MF Lever).
Error messages

330 Handle switch
142 Spout rot sensor O
143 Spout rot sensor --
144 Spout rot sensor +
232 Spout limit switch
453 Spout right hydr. sol.
454 Spout left hydr. sol.
6- 71020EN - 08 - 2003
Electrical diagrams
Group 13: Spout control, line 4430 -- 4760.
B103: Spout end of travel sensor -- RH side
B117: Spout end of travel sensor -- LH side
S85: Switch for spout rotation to the right–slow
S86: Switch for spout rotation to the left – fast
S87: Switch for spout rotation to the left – slow
S93: Switch for spout rotation to the right – fast
Y32: Spout rotation left
Y33: Spout rotation right
6- 71020EN - 08 - 2003
11. RAISE / LOWER SPOUT
Harvest Mode Spout Up Spout Down

See switch switch
paragraph 3
Spout Up Spout Down

engaged engaged
To raise or lower the spout:
3. To raise the spout, press the spout UP switch.
4. To lower the spout, press the spout DOWN switch.
6- 71020EN - 08 - 2003
Can Spy

ID
1283 Spout down switch pressed 4=== 0===: Switch not pressed;
4===: Pressed
1283 Spout up switch pressed 8=== 0===: Switch not pressed;
8===: Pressed
1348 Spout down activated ===2 ===2: Activated;
===0: Not activated
1348 Spout up activated ===4 ===4: Activated;
===0: Not activated
Error messages

459 Spout down hydr. sol.
460 Spout up hydr. sol.
Electrical diagrams
S41: Spout up switch
S42: Spout down switch
Y38: Spout height up
Y39: Spout height down
6- 71020EN - 08 - 2003
12. SPOUT DEFLECTOR
Spout Spout Fixed deflector Simultaneous movement of spout

deflector up deflector position and deflector
switch down switch (NA only) (performance monitor calibration)
Spout deflector
Spout deflector
down
up engaged
engaged
To raise or lower the spout deflector:
2. To raise the spout deflector, press the spout deflector UP switch.
3. To lower the spout deflector, press the spout deflector DOWN switch.
NOTE: To move the spout deflector, it is not required to switch to field mode.
REMARKS:
1. Depending on the selection in the performance monitor calibration (Type), it is possible to activate the spout
deflector and the spout rotation at the same time.
2. Fixed deflector position (PC Calibration): NA machines only

So: for Eur machines: answer No
for NA machines: answer Yes
On European machines, when switching on the Field mode switch, the spout deflector will automatically open
up to halfway. When switching OFF the Harvest switch, the spout deflector will close automatically.
On North American machines, switching between Field and Road Mode does not affect the deflector position.
6- 71020EN - 08 - 2003
Can Spy

ID
1282 Spout deflector up switch pressed =8==
1282 Spout deflector up switch not pressed =4==
1282 Spout deflector down switch pressed =2==
1282 Spout deflector down switch not pressed =1==
1345 Calibration fixed deflector position ===4 ===0: Not calibrated (no);
(NA only) ===4: Calibrated (yes)
1347 Spout deflector down activated =2== =2==: Activated

=0==: Not activated
1347 Spout deflector up activated =8== =8==: Activated
=0==: Not activated
Error messages

330 Handle switch
401 Spout deflector act.
Electrical diagrams
S88: Spout deflector down switch
S89 : Spout deflector up switch
Y45: Spout deflector up solenoid
Y46: Spout deflector down solenoid
6- 71020EN - 08 - 2003
13. REVERSE CUTTERHEAD
Field Mode Cutterhead Cutterhead Chopper

Engine
See reversing RPM body
RPM
paragraph 3 switch sensor not present
Main drive Main drive Cutterhead

belt not clutch reverse
tensioned not engaged engaged
To reverse the cutterhead:
3. Switch ON the cutterhead reversing switch.
NOTE: Switching on the cutterhead reversing switch will cause the main drive belt and clutch neutral position
solenoid to be activated. The main drive belt is not tensioned.
The output status is: Voltage

Main clutch is not engaged Y44 0V
Main drive belt is not tensioned Y40 12 V
Cutterhead reverse valve is engaged Y31 12 V
6- 71020EN - 08 - 2003
REMARKS: 5. In case the cutterhead speed sensor has failed,

(see cutterhead engagement: paragraph 5) and you want to engage the cutterhead in the
opposite direction, the system is not able to
1. To reverse the cutterhead, the system must check whether the cutterhead speed has actually
know whether the engine is running. dropped or not. In order to prevent damage to
(See paragraph 1 -- Engine Running/Not mechanical or hydraulic components, a 100
Running). seconds count--down is started as soon as the
cutterhead is disengaged.
2. The cutterhead can be reversed only 5 sec after The following message appears on the screen:
starting the engine. “WAIT UNTIL ENGAGE TIMER = 100”.
When 0 has been reached, the cutterhead drive
3. After cutterhead engagement, the engine rpm can be switched ON. The message
will automatically drop to low idle. Throttle up “REENGAGE CUTTERHEAD” will appear.
engine speed again.
4. When the direction of rotation of the cutterhead

is changed while the cutterhead is running (from
forward to reverse, or vice versa), the drive will
be disengaged first and the machine will wait until
the cutterhead speed has dropped to less than
10 rpm. If you try to engage in the other direction
of rotation, the user message “CUTTERHEAD
RPM IS STILL > 10” will appear on the
performance monitor display. As soon as the
cutterhead has stopped, the next user message
“REENGAGE CUTTERHEAD” is displayed.
Only then the cutterhead can be reengaged in
the other direction of rotation. Switch the
respective cutterhead engagement switch OFF
and ON again.
Can Spy

ID
1283 Cutterhead reversing switch ON =4== =0==: Switched off
1283 Cutterhead reversing switch OFF 4=== 0===: Switched on
Hexadecimal code
1293 Cutterhead rpm XXXX Rotation per minute --
Hexadecimal code
1303 Main drive clutch engaged ===1 Must be ===0
1303 Cutterhead reverse engaged =1== =0==: Cutterhead reverse not
engaged
1348 Main drive belt not tensioned ==1= ==1=: Not tensioned
==0=: Tensioned
1348 Cutterhead reverse engaged ===8 ===8:Engaged
===0:Not engaged
1349 Chopper body not fitted =2== =2==: Not fitted
=0==: Fitted
6- 71020EN - 08 - 2003
Error messages

130 Cutterhead rpm sensor O
131 Cutterhead rpm sensor --
132 Cutterhead rpm sensor +
457 Main drive hydr. sol.
461 Cutterhead reverse
462 Main clutch idler
Electrical diagrams
Group 8: CPU inputs and Display, line 2390 -- 2890.
B101: Cutterhead speed sensor
Group 10: Switched, instrument panel, multi--function lever and auxiliary hydraulics, line 3410 -- 3910.
Y40: Main drive belt + clutch neutral position solenoid
Y44: Main drive clutch + belt solenoid
Group 15: Cutterhead reverse drive and sharpening, line 4940 -- 5440.
S114: Cutterhead reverse drive switch
Y31: Cutterhead reverse drive solenoid
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14. AUXILIARY FRONT HYDRAULICS
Field Mode Spout Up Spout Down Attachment

See switch switch height override
paragraph 3 switch
Front Front
Hydraulics Hydraulics
UP DOWN
To use the auxiliary front hydraulics:
The front auxiliary hydraulic valves are powered (12 V on output) with the spout up/down switches in the cab
floor, in combination with the attachment height override switch.
6- 71020EN - 08 - 2003
Can Spy

ID
1282 Attachment height override switch not ===4
pressed
1282 Attachment height override switch pressed ===8
4===: Pressed
8===: Pressed
1348 Front hydraulics up =1== =1==: Activated
=0==: Not activated
1348 Front hydraulics down =4== =4==: Activated
=0==: Not activated
Error messages

330 Handle switch
464 Front hydr. up sol.
465 Front hydr. down sol.
Electrical diagrams
S30: Automatic header height control switch
S41: Spout up foot switch
S42: Spout down foot switch
Y34: Front auxiliary hydraulics up solenoid
Y35: Front auxiliary hydraulics down solenoid
6- 71020EN - 08 - 2003
15. AUXILIARY REAR HYDRAULICS
Field Mode Spout Up Spout Down Auto--Pilot Rear Hydraulics

See switch switch switch installed
paragraph 3 (EST--Calibration
Rear Rear
Hydraulics Hydraulics
UP DOWN
To use the auxiliary rear hydraulics:
The rear auxiliary hydraulic valves are powered (12 V on output) with the spout up/down switches in the cab
floor, in combination with the Auto--Pilot switch.
REMARKS:
Auxiliary rear hydraulics are an accessory.
Machines without auxiliary rear hydraulics are delivered without electrovalve.
An additional calibration has to be carried out to avoid error messages.
Refer to the EST calibration instructions.
6- 71020EN - 08 - 2003
Can Spy

ID
1282 Auto--Pilot switch not pressed ==4=
1282 Auto--Pilot switch pressed ==8=
4===: Pressed
8===: Pressed
1342 Calibrated rear hydraulics 8=== 0===: not calibrated (no);
8===: calibrated (yes)
1348 Rear hydraulics down 1=== 1===: Activated
0===: Not activated
1348 Rear hydraulics up 2=== 2===: Activated
0===: Not activated
Error messages

330 Handle switch
456 Rear hydr. down sol.
456 Rear hydr. up sol.
Electrical diagrams
S41: Spout up foot switch
S42: Spout down foot switch
S91: Auto–Pilot switch
Y36: Rear auxiliary hydraulics up solenoid
Y37: Rear auxiliary hydraulics down solenoid
6- 71020EN - 08 - 2003
16. AIR CONDITIONING
Fan + Airco Airco high Airco low Airco

switch in cab pressure pressure safety
switch switch switch
Airco Airco high Airco low

pressure Thermostat
compressor pressure
led switch
clutch led
Switch on the air conditioning with the airco switch in the cab. This causes the electromagnetic clutch of the airco
compressor to be powered (12V on output: see electrical diagrams).
The airco switch in the cab is in fact a combination of three conditions:
Airco Switch ON = Fan speed switch (S37) in position 1, 2 or 3

and
Airco thermo switch (B61) closed
and
Air conditioning safety switch (S60) closed
Airco Switch OFF = Fan speed switch in position O
or
Airco thermo switch (B61) open
or
Air conditioning safety switch (S60) open
6- 71020EN - 08 - 2003
REMARKS:
1. When the compressor pressure is too low or too

high, the power to the electromagnetic clutch will
automatically drop to 0 volt to avoid damage of
the compressor.
(When the pressure is too low, there is no noise,
only the led starts to blink).
2. The system must only be operated when the

engine is warm and the interior temperature of
the cab is 15°C minimum.
ATTENTION
Ignoring this precaution may cause damage to the
system.
Can Spy

ID
1283 Airco switch in cab closed ==1= ==0=: Switch open;
==1=: Switch closed
1303 Airco high pressure switch 1=== 0===: Switch open;
1===: Switch closed
1303 Airco low pressure switch 2=== 0===: Switch open;
2===: Switch closed
1314 Airco low pressure led 2=== 0===: Extinguished
1314 Airco high pressure led 4=== 0===: Extinguished
1348 Airco compressor clutch ===4 ===4: Activated
===0: Not activated
Error messages

440 Airconditioning clutch
Electrical diagrams
Group 25: Air conditioning, line 9190 -- 9520.

B61: Thermostat switch
S37: Fan + air conditioning switch
S60: Air conditioning safety switch
S62: Compressor overpressure contact
S63: Compressor underpressure contact
Y27: Airco compressor clutch
6- 71020EN - 08 - 2003
17. SILAGE ADDITIVES APPLICATION
Field Mode Cutterhead Feed rolls Drive Forward Silage additive

See Engaged Engaged See applicator
paragraph 3 See See paragraph 23 main switch
paragraph 5 paragraph 6
Power to
silage additive
applicator
Conditions:
3. Switch ON the silage additive applicator switch.
4. Engage cutterhead.
5. Engage feed rolls forward drive.
6. Drive forward.
REMARKS:
The 12 V silage additives application socket output can be checked (silage additives applicator installed):
1. Switch the Harvest switch to Road mode.
2. Switch ON the silage additive applicator switch.
6- 71020EN - 08 - 2003
Can Spy

ID
1283 Silage additive applicator main switch ===8 ==0=: Switched on
OFF
1283 Silage additive applicator main switch ON ==8= ==0=: Switched off
engaged
1304 Driving forward 4=== 0===: Not driving
1348 Power to silage additive applicator ===2 ===2: Activated
===0: Not activated
Error messages
Electrical diagrams
Group 18: Silage additive applicator, line 6300 -- 6460
S109: Silage additive application switch
K2: Silage additive relay
X510: Silage additive application socket
6- 71020EN - 08 - 2003
18. KNIFE SHARPENING
Reverse Throttle AKS & ASBA sharpening Home grinding reset sharpening
Cutterhead switch dashboard door open position 1’,2’ or 3’ button on the
See group switch sensor sharpening AKS & move (NA)
13 stone ASBA pc
sensor panel calibration
Sharpening motor motor “ok” 1’ 2’ 3’ Reset

Door sharpening sharpening LED sharpening sharpening sharpening button
Open LED door stone LED LED LED LED
“cutterhead speed “Failure of “Sharpening

too low” LED sharpening stone stone worn out”
drive motor” LED LED
Conditions:
1. Start the engine and set speed at low idle
2. Disengage the feed rolls by pushing the feed roll drive switch (MF lever)
3. Disengage the cutterhead by switching off the cutterhead drive switch. Wait until the cutterhead has stopped
rotating.
4. Ensure the harvest switch is switched to field mode
5. Switch on the reverse drive cutterhead switch
6. Throttle up the engine speed until the cutterhead speed is at least 750 rpm. This will ensure a good
sharpening quality. The higher the speed, the better the sharpening.
6- 71020EN - 08 - 2003
7. Switch ON the AKS & ASBA switch (instrument panel). The OK--light on the AKS & ASBA panel is
illuminated.
Press one of the automatic knife sharpening routine keys (1, 2 or 3 minutes). As a guide--line, the shortest
time (one minute) is recommended, unless the knives are really worn. The light on the chosen key will
illuminate during the sharpening operation.
8. The sharpener door warning light will start flashing, meaning the sharpener door is opening.
9. The AKS & ASBA system will now start sharpening the knives during 1, 2 or 3 minutes, depending on the
selection that was made. During sharpening the sharpener door warning light will be illuminated.
10. The sharpener routine will stop after 1, 2 or 3 minutes, unless the routine is interrupted with the interrupt key.
At the end of the sharpening cycle, the stone will travel across the cutterhead knives slowly for at least half
a cycle. This is done to make sure the knives are properly sharpened and burrs are removed.
11. When sharpening is finished, the sharpener door closes automatically and the OK--light (AKS & ASBA panel)
will illuminate.
REMARK: You can also sharpen the knifes with the cutterhead turning forward, however it is recommended to
sharpen in reverse. The routine stays the same.
6- 71020EN - 08 - 2003
Can Spy

ID
1283 AKS & ASBA main switch ON 8=== 0=== : switched off
1283 Cutterhead reversing switch OFF 4=== 0=== : switched on
1283 AKS & ASBA main switch OFF =8== =0== : switched on
1283 Cutterhead reversing switch ON =4== =0== : switched off
1286 Stop sharp./adj. switch pressed 2=== 0=== : not pressed
1286 Sharpening routine 3’ pressed 1=== 0=== : not pressed
1286 Sharpening routine 2’ pressed =8== =0== : not pressed
1286 Sharpening routine 1’ pressed =4== =0== : not pressed
hexadecimal code
1303 Cutterhead reverse engaged =1== =0== : cutterhead reverse not
engaged
1304 Sharpener door open 2=== 0=== : sharpener door between
open and closed
1304 Sharpener door closed 1=== 0=== : sharpener door between
open and closed
1304 Sharpener stone worn out ===8 ===0 : sharpener stone not
worn out
1304 Sharpener stone at home position ===4 ===0 : sharpener stone not at
home position
1314 Sharpener door LED =8== =0== : extinguished
1315 AKS 2’ LED 8=== 0=== : extinguished
1315 AKS 1’ LED 4=== 0=== : extinguished
1315 AKS adjust LED 2=== 0=== : extinguished
1315 AKS OK LED 1=== 0=== : extinguished
1315 AKS Service LED =8== =0== : extinguished
1315 AKS Motor fault LED =2== =0== : extinguished
1315 AKS rpm fault LED =1== =0== : extinguished
1315 AKS stop sharp. LED ===2 ===0 : extinguished
1315 AKS sharp routine 3’ LED ===1 ===0 : extinguished
1349 Sharpener door open ==8= ==8= : activated
==0= : not activated
1349 Sharpener door close ==4= ==4= : activated
1349 Sharpener routine engaged ===1 ===1 : activated
===0 : not activated
1350 Sharpening stone home =1== =1== :stone in home position
=0==:stone not in home posi-
tion
1350 Sharpening door closed =2== =2== :door closed
=0==:door moving
1350 Sharpening door open =4== =4== :dooropen
=0==:door moving
1350 Sharpening 1=== 1=== :sharpening
0===:not sharpening
1361 AKS & ASBA Mode off ==8= ==8= : off
==0= :on
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Error messages
Error Code Description

226 Cover cutterh. sensor O
227 Cover cutterh. sensor --
228 Cover cutterh. sensor +
370 Cover cutterhead EOT
371 AOM Power failure
483 Cover cutterh. Motor
487 Sharp motor failure
489 Cut. knives worn down
Electrical scheme
Group 15: Reverse drive cutterhead and sharpening, line 4940 -- 5440.
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19. AUTOMATIC SHEARBAR ADJUSTMENT ROUTINE
There are two possibilities to start an automatic shearbar adjustment: With cutterhead turning forward and cutter-
head turning backward.
Reverse AKS & ASBA Knocksensor(s) interrupt button pc calibr

Shearbar
cutterhead group AKS routine shearbar
Adj. switch on
13 or engage Dashboard on gap
AKS & ASBA
cutterhead forward switch AKS & ASBA
panel
group 5 panel
ASBA ASBA shearbar adj. OK LED cutter head Shearbar adj. Knives worn
motor motor LED on on speed too motor failure Led
AKS & ASBA AKS & ASBA low LED on LED on AKS & ASBA
Left Right panel panel AKS & ASBA AKS & ASBA panel
panel Panel
Rear
Interrupt LED
drive
AKS & ASBA
Panel Buzzer
34
Primarily checks:
1. Lock the stone pawl first to avoid the stone can lower during a sharpening cycle.
Sharpen for at least three minutes to obtain a complete parallel cutterhead.
2. Check for play at the electric motors fixation points.
3. Verify the noise sensor installation.

Max. 20 Nm
Place sensor connector as high as possible.
4. Check all frame ground on knock sensors.
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5. Check the knock sensors:
To start up the knock sensors check procedure, the engine has to be shut down, the contact must be ON; push
the AKS & ASBA reset button while switching on the AKS & ASBA dashboard switch.
The ’sharpening stone’ warning led on the AKS & ASBA display panel lights up to confirm you are in sensor test
mode.
To do the actual testing you have to hit the shearbar or somewhere close with a piece of iron (keys, screw-
driver,...). If the sensor(s) is ok the reverse buzzer and LCD buzzer will sound, simultaneously the knock sensor
led on the AKS & ASBA display lights up for a few seconds. After the buzzing stopped you can try again as long
as you stay in the test mode.
6. Clean the area between shearbar and scraper.
7. Execute a full pull : Switch on ignition and AKS & ASBA

Press ’Stop’ and ’Shearbar adjust’ button on AKS & ASBA--Panel.
8. If necessary adjust all knives. (See procedure described in Operator’s Manual).
9. Clean the area between shearbar and cutterhead properly.
10. Check shearbar for scratches. If necessary turn or replace.
11. Verify messing plate under the shearbar.
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Conditions and description of Shearbar adjustment Procedure.
Start the engine

Switch the harvest switch to Field mode
Switch on reverse cutterhead button
Switch on AKS & ASBA dashboard button (ok LED on AKS & ASBA display illuminates)
When the shearbar adjustment button is pressed, the shearbar adjustment led illuminates during the whole ad-
justomatic procedure and
1°) First the engine rpm drops to low idle.
2°) Then the shearbar turns backwards (towards feed rolls). This includes :
the LHS electric motor is powered first for 1 rotation &
the RHS electric motor is powered also for 1 rotation.
Check the output of the electric motors on CAN SPY Page :
1349 word 1 : ==2= (Left motor)
1349 word 2 : ===8 (Right motor)
3°) error check during ASBA procedure

From time to time the knock sensors are being checked on optimum working condition. When at the
beginning of an ASBA procedure one or two sensors seem to work less, an error question message
”check sensors continue? Yes/no?” is displayed.
As soon as this message appears you are in the sensor check procedure as described under primarily
checks 5°. This way you can check the sensors even while the cutterhead is turning.
* When ”yes” has been confirmed two situations may occur
Or during testing now or later in the test procedure described under primarily checks 5°, whether
the sensors needed repair or not, the sensor check was successful (equal to buzzer went off), the
ASBA procedure will continue its cycle.
Or if there was no check, bad repair or no repair (equal to buzzer did not go off), the message
”adjust manually” will appear on the screen for a few seconds and the ASBA procedure is
terminated.
* When ”No” has been confirmed, the ASBA procedure stops.
The measured machine background noise is displayed on:

Page 1304, Word 2 : XX==.
4°) The limit for background noise has been brought to 170 (= AAhex) Maximum and 60 (= 3Chex) average.
If the first background noise measurement is too high, error 490 “AOM NOISE TOO HIGH” (= new)
comes up the screen while sensor error led lights up on the AKS & ASBA panel. The background noise
level is measured again.
When the shearbar threshold is calculated, this value is displayed on
Page 1304, Word 2 : XX==
The last measured information from the sensor is displayed on :
Page 1304, word 2, ==XX and is always a few digits higher than page 1304, Word 2 : XX==
6- 71020EN - 08 - 2003
5°) Then the Shearbar adjustment is started and the shearbar turns forward (towards knives). First the LHS
electric motor is powered for maximum 1 2/8 rotations.
When the impact of the shearbar with the knives (measured noise) becomes higher than the Shearbar
threshold, the forward rotation is stopped and the motor starts to back off the shearbar from the knives
in parts of 1/18 rotation as long as the measured noise stays higher than the shearbar threshold. Then
the LHS motor backs off for an extra 5/9 rotation.
1349 word 1 : ==2= (Left motor, back off)
1349 word 1 : ==1= (Left motor, towards knives)
1349 word 2 : ===8 (Right motor, back off)
1349 word 1 : ===4 (Right motor, towards knives)
6°) The same procedure is repeated for the RHS electric motor.
7°) Steps 6 and 7 are again repeated for the LHS and RHS electric motor. Only instead of 5/9 rotation extra
back off, the system backs off the calibrated shearbar gap (default setting is 4/8).
At the end of the ASBA procedure the RHS motor is turned 1/8th turn extra in order to establish a parallel
shearbar.
REMARK I: When one adjustment step is finished (step 6--8) the system will wait one second before the next
adjustment step (at the other side) will start, this to allow the Shearbar can stretch itself.
REMARK II: ASBA procedure, cutterhead turning forward.

When executing the ASBA procedure with the cutterhead turning forward, the ASBA stops
at each phase until the sensors heard a hit, from then on everything happens automati-
cally.
When nothing is heard, the operator has to acknowledge at each phase if he wants to con-
tinue or not. This way the operator has the time to react when the shearbar should hit the
drum.
There is no acknowledging procedure when turning the cutterhead backward.
REMARK III: Once the shearbar has touched the knives, the system has to detect four knife approaches after
each other (2 left and 2 right) without interruption. When during the shearbar adjustment the shear-
bar does not touch the knives, the counter for 4 knife approaches is reset.
This happens when the shearbar goes direction knives but the shearbar does not touch the knives.
This results in the powering of the electric motor at the other side.
This symptom will create a constant shearbar adjustment.
Possible causes :
--) Round shape of the cutterhead.
--) Play in the electric motor fixation points
--) Shearbar pivoting around midpoint
6- 71020EN - 08 - 2003
Can Spy

ID
1283 AKS & ASBA main Switched ON 8=== 0=== : switched off
switch
1283 Cutterhead reversing Switched ON 4=== 0=== : switched on
switch
1283 AKS & ASBA main Switched OFF =8== =0== : switched on
switch
1283 Cutterhead reversing Switched ON =4== =0== : switched off
switch
1286 Stop sharpening/ad- Pressed 2=== 0=== : not pressed
justment switch
1286 ASBA switch Pressed =2== =0== : not pressed
1286 Cutterhead engage Switched OFF ==2= ==0= : switched on
switch
1286 Cutterhead engage Switched ON ===2 ===0 : switched off
switch
hexadecimal code
1304 AKS & ASBA mode Status ==8= ==8= : set ; ==0= : not set
1304 Continue ASBA adjust- Status ==4= ==4= : set ; ==0= : not set
ment request
1304 Check ASBA sensors Status ==2= ==2= : set ; ==0= : not set
request
1304 Activate Reverse Buz- Status ==1= ==1= : set ; ==0= : not set
zer
1304 Measured background XX== Normal value : +/-- 60 ;
noise and measured max value for still good oper-
threshold limit during ation : AA
adjust operation
1304 Last measured knives ==XX Always some digits higher
hit peak value than the measured back-
during adjust operation ground noise.
1315 AKS OK LED Lights up 1=== 0=== : extinguished
1315 AKS Service LED Lights up =8== =0== : extinguished
1315 AKS Sensor fault LED Lights up =4== =0== : extinguished
1315 AKS Motor fault LED Lights up =2== =0== : extinguished
1315 AKS rpm fault LED Lights up =1== =0== : extinguished
1315 AKS shearbar adjust- Lights up ===2 ===0 : extinguished
ment led
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ID
1345 Calibrated shearbar ===X Possible values : 2 to 8
gap
1348 Rear drive buzzer Output status ==4= ==4= : activated ;
1349 Left ASBA electric Output status ==2= ==2= : activated ;
motor forward ==0= : not activated
1349 Left ASBA electric Output status ==1= ==1= : activated ;
motor to knives ==0= : not activated
1349 Right ASBA electric Output status ===8 ===8 : activated ;
motor forward ===0 : not activated
1349 Right ASBA electric Output status ===4 ===4 : activated ;
motor to knives ===0 : not activated
Error codes

310 Dashboard switch 10
371 Power failure AOM
485 AOM Motor left failure
486 AOM Motor right failure
489 Cut. knives worn down
490 AOM Noise too high
Electrical scheme
See group 17: Shearbar adjustment, line 5780 -- 6110.
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20. CROP PROCESSOR
Harvest CP CP CP CP Calibration
Mode dashboard Potentiometer Rpm sensor (Performance
See group 3 switch 12 Monitor)
CP LCD
Electric Motor CP clearance
Readout
To open and close the crop processor rolls:
1. Switch on the ignition.
2. Switch the harvest switch to Field mode.
3. Push the crop processor switch up to open the crop processor gap ( up to 20 mm max) and down to make
the gap smaller (up to 2 mm min).
REMARK:
1. To view the cp rpm on can spy, the engine has to be running and the cutterhead has to be engaged.
2. The users message “crop processor slippage” comes up when the speed of the crop processor rolls drop
below 2.5 times the cutterhead speed. With 0% slippage the cp roll speed is 3.2 times higher than cutterhead
speed. When the cutterhead speed for instance is 1000 rpm, then the cp speed is 3200. When cp speed
drops below 2500 (or 09C4Hex on can id page 1290) the user message comes up.
3. The electronic system should be informed if the crop processor is installed to avoid error reports. See
performance monitor calibration.
6- 71020EN - 08 - 2003
Can Spy

ID
1283 CP roll clearance close switch pressed ===2 ===0 : switch not pressed ;
===2 : pressed
1283 CP roll clearance open switch pressed 1=== 0=== : switch not pressed ;
1=== : pressed
1290 CP Rpm XXXX Rotation per minute --
hexadecimal code
1313 CP distance ==XX Limits : 3B < XX < 79
1347 Close CP ===2 ===2 : activated
1347 Open CP ===1 ===1 : activated
Error codes
Error Code Error code description

113 Crop. proc. sensor O
114 Crop. proc. sensor --
115 Crop. proc. sensor +
150 Crop Processor Sens.
400 Crop. proc. dist. act.
Electrical scheme
See group 12: Crop processor, line 4260 -- 4420.
B104: Crop processor roll speed sensor
R30: Crop processor roll clearance potentiometer
S115: Crop processor roll clearance switch
Y75: Cropprocessor open valve
Y76: Cropprocessor closed valve
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21. METAL DETECTOR OPERATION AND TROUBLESHOOTING
Introduction
The model CHX forage harvester is equipped with an electronic metal detector (EMD).
The metal detector has the following advantages:
-- Modular construction: individual components can be replaced
-- Adaptive threshold adjustment
-- Manual threshold adjustment (fixed mode)
-- On--board diagnostics (= Run time test)
-- Display of important information on the performance monitor (noise readings, thresholds)
-- Error codes
-- CAN Identifiers
The general function of the metal detector is explained in the Operator’s Manual.
METAL DETECTOR HARDWARE
The metal detector consists of two parts:
1. The sensor (upper part)
2. The electronic module (lower part)
6- 71020EN - 08 - 2003
The sensor
The heart of the metal detector is the sensor that contains the magnets and the coils.
Left Channel
Right Channel
It consists of 2 rows of permanent magnets. The magnets in one row are arranged offset to the other row. One
row of magnets starts at the far left--hand side of the sensor. The other row starts at the far right--hand side.
Between the two rows of magnets a permanent magnetic field exists. This magnetic field crosses the boundaries
of the feed roll shell and ‘fills’ the space between the upper and lower front feed rolls. Since the magnetic field
must not be disturbed by the feed roll, the feed roll is made of low magnetic stainless steel and demagnetised
steel.
Above the rows of magnets the coils are placed next to each other. Those coils are wired in two series. One row
of coils starts at the far left--hand side of the sensor: this row is called the left channel. The other row starts at
the far right--hand side and is called the right channel.
NOTE: On the metal detector diagnostic page of the performance monitor, the left and right channel are referred
to as channel A and channel B in order to avoid confusion as to where metal has entered the machine.
When metal passes over the sensor, the magnetic field between the magnets is disturbed. A disturbance of the
magnetic field will generate a current through the coils (channels). Depending on where the metal enters, the
current may be generated in the coils of the left or right channel, or both.
6- 71020EN - 08 - 2003
The electronic module
The current through the coils which is generated by a disturbance in the magnetic field is a relatively weak signal.
If this signal would be sent directly to the electronic box on the base unit, it would be subjected to electromagnetic
influences. Therefore, this signal is amplified first.
Since the CAN system can only use digital information, the analog signal (magnetic noise) is converted to a digital
signal by means of an A/D converter.
Then the control unit compares the (digital) magnetic noise to the threshold level (available from adaptive or fixed
mode).
This depends on 2 parameters
-- The extent to which the noise levels increase
-- The setting of the thresholds (or trip levels).
So, the thresholds determine at which noise level a detection will take place.
Since there are 2 channels, and positive and negative values for each channel, there are 4 thresholds in total.
As soon as one of the thresholds is exceeded, the metal detector will trip.
This will result in the following:
-- The output voltage will drop from 12 Volt to 0 Volt for 1 second
-- A CAN message will be transmitted informing that a metal detection has taken place.
These signals will have the following consequences:
-- The stop valve solenoid will be activated, which will stop the feed rolls
-- The feed rolls hydrostatic pump will be sent to neutral
-- The metal detector diagnostic page will appear on the performance monitor screen.
The classic signal and the CAN message work completely independent from each other. This means that when
the classic signal is not functioning for whatever reason, the CAN message will make sure the detection message
is passed on, and vice versa.
X619
Amplifier 12 V
1Ground
ADC
Control Output 0 V : Detection
Unit
12 V : No Detection
ADC
CAN Network
Amplifier
Coils Electronic Processor Connector and wiring

loom to central box
6- 71020EN - 08 - 2003
PERFORMANCE MONITOR
6 52706
35
The metal detector page can be displayed on the performance monitor after key 10 is pressed.
Since there are 2 channels, left and right, there are 2 bargraphs, CHAN A and CHAN B, as shown on the perform-
ance monitor display (Fig. 35).
The black segments (A) on both bargraphs represent the peak magnetic noise readings in the two channels
(measured during a period of 6 1/4 seconds).
In case the machine would be perfectly quiet (which in reality is rare), the bargraphs would be empty. As soon
as magnetic noise is detected, part of the histogram will be filled around the midpoint with black sections.
The resolution of the noise readings is half a bargraph segment.
NOTE: In case the background magnetic noise is high and the size or speed of the ferrous object is small, the
magnetic disturbance caused by the object may not be able to exceed the magnetic noise. It will not be detected
in that case, regardless, of the position of the threshold.
The 4 lines B above the black sections represent the actual (fixed or adptative) threshold levels (or trip levels).
When the magnetic noise readings exceed a threshold level, a metal detection will take place.
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FIXED AND ADAPTIVE MODE
There are 2 ways for setting the thresholds:

-- Fixed: Manual setting of the thresholds
-- Adaptive: Automatic setting in function of the average peak noise level.
At the top of the performance monitor screen the thresholds will either be marked “A” or “F” (see Figure 1).
-- “A” stands for Adaptive Mode.
-- “F” stands for Fixed Mode.
To switch between adaptive and fixed mode, press the scroll down and scroll up buttons simultaneously when
the metal detector page is displayed. The “A” will change to “F”, or vice versa.
The range within which the thresholds can be set is the same, both for the adaptive and the fixed mode. It ranges
from 1 1/2 to 5 1/2 blocks above or below the midpoint.
Fixed mode
The fixed thresholds are set manually between 1 1/2 to 5 1/2 blocks from the midpoint. It is generally recom-
mended to set the fixed thresholds at 1 1/2 blocks removed from the noisiest reading (feed rolls engaged at full
speed). These fixed thresholds are set symmetrically (same setting for all 4 thresholds).
NOTE: The arrows to the left--hand side of the bargraph indicate the adaptive threshold levels. In the fixed mode,
these are purely informative.
These thresholds have to be adjusted manually by moving the lines B above and below the black sections. To
do so, use the scroll up and down buttons and confirm the new settings by pressing the Enter key. After confirma-
tion, the right--hand side arrows will jump to the same level as the lines B.
Adaptive mode
The adaptive thresholds are set automatically in function of the average peak noise readings, regardless of differ-
ences between the 4 noise levels. This means the thresholds are not necessarily set symmetrically, but can in
fact differ significantly.
To prevent the adaptive thresholds from changing too quickly, they represent a slow moving average of the peak
noise readings of the last couple of minutes.
During each 6.25 seconds, the 4 peak noise values are stored. These peak readings are averaged with the peak
readings of the last 31 samples.
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When the background noise level of the feed rolls increases with time, the adaptive thresholds are automatically
adjusted.
When, however, the threshold limit of 5 1/2 blocks is crossed, the system will notify the operator by means of
an error code.
The figure below shows how the metal detector compare, in the fixed mode and the adaptive mode, regarding
the reaction of increased magnetic noise in function of time.
CEILING MAXIMUM LIMITATION
II III
FIXED DETECTION LEVEL

AVERAGE DETECTION
LEVEL
VOLTS
1 2 3 4 1 2 3 4
5 5
YEARS YEARS
TIME TIME 36
⇒ ⇒
Quick adjustment of the adaptive mode
Although the adaptive thresholds are set relatively fast, there may be circumstances that letting them adjust auto-
matically in the field is not fast enough, e.g.
-- When the metal detector was replaced
-- When the feed roll shell was replaced or demagnetized
-- When a dent in the feed roll shell has increased the magnetic noise.
In these cases the following can be done:
-- Switch to fixed mode, or
-- Carry out the quick--adjust routine of the adaptive mode.
The quick--adjust routine will allow the adaptive thresholds to be set within a minute.
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Proceed as follows:
1. Switch on ignition and start the engine.
2. Switch the harvest switch to Field mode.
4. Engage the feed rolls.
5. Throttle up to full engine speed.
6. Recall the metal detector page of the performance monitor by pressing key 10 (refer to Figure 35).
7. Press key 6 on the performance monitor to start the quick adjustment procedure (refer to Figure 35).
Run time test (On--board diagnostics)
The run time test is on--board diagnostic routine, initiated each 90 seconds when the cutterhead is not engaged,
However, the first run time test after disengaging the cutterhead starts after 120 seconds.
This on--board diagnostic routine runs a test on the metal detector hardware to check if the left and right channel
hardware components (coils, amplifiers, A/D converter and frame ground) are still working properly.
The run time test consists of two parts:

1. The microprocessor checks the continuity of the coils in the EMD.
(This is done by injecting a small current into the coils to simulate a disturbance in the magnetic field. This
current is again measured by the microprocessor and verified if it corresponds with the injected current or
within a small deviation).
If this test fails, the run time test will be interrupted and an error code 273 will be communicated by the EMD
microprocessor to the performance monitor.
2. The microprocessor checks the continuity of the metal detector frame ground. Flat earth cables can be found
between the electronic module and the metal detector shaft, between the metal detector shaft and
right--hand side of the chopper body unit. A good frame ground between chopper body unit and base unit
is also necessary.
If this test does not succeed, an error code 277 will be generated.
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TROUBLESHOOTING
527
15 37
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Conditions
When ignition is switched on, all information, such as threshold settings in performance monitor, cutterhead and
feed rolls status and machine driving status, is provided to the EMD microprocessor through the CAN network.
(See CAN--Identifier 1278), who decides which actions need to be executed.
When the cutterhead is engaged (even if feed rolls are not running yet), the EMD microprocessor monitors if
metal is passing through the feed rolls. In other words, the EMD microprocessor continuously compares the
measured magnetic noise with the calculated adaptive thresholds or the selected fixed thresholds.
However, the adaptative thresholds calculation routine works only when the cutterhead and the feed rolls forward
drive is engaged and the machine is driving forward.
-- When the cutterhead is disengaged, every 90 seconds a “run time” test routine will be initiated to check all
EMD components.
However, the first “run time” test after disengaging the cutterhead starts after 120 seconds.
-- When a metal detection takes place during working operation (cutterhead engaged), it will always be com-
municated by the metal detector to the AKS & ASBA printed circuit (the classic output line drops to 0 Volts
and a CAN message is transmitted: see CAN Identifier 1304 first word: “Metal Detected”).
The decision to stop the feedrolls is made by the AKS & ASBA system based on the “metal detector status”
(see CAN Identifier 1304, first word: ===1).
The “metal detector status” is enabled when the engine is started, harvest mode is switched ON and the cutter-
head is engaged (see CAN Identifier 1304, first word: ===1).
The “metal detector status” is disabled by means of the metal detector rocker switch on the instrument panel.
The metal detector can be enabled by pressing the other side of the metal detector rocker switch or by restarting
the machine.
When the “Metal detector status” is enabled and a metal detection takes place, the following will happen:
-- The stop valve solenoid will be activated, which will stop the feed rolls
-- The feed rolls hydrostatic pump will be sent to neutral
-- The metal detector diagnostic page will appear on the performance monitor screen.
However, when “metal detector status” is disabled and a metal detection then takes places:
-- The stop valve solenoid will not be activated, which will not stop the feed rolls.
-- The feed rolls hydrostatic pump will not be sent to neutral
-- The metal detector diagnostic page will not appear on the performance monitor screen.
but:
-- A user message “Metal Detector OFF” will appear on the performance monitor every 30 seconds together
with one single beep.
-- The date and hour of the metal detection will be stored in the “Missed Metal Detection Date” (See CAN Ident-
ifier page 1301).
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When the classic output line (wire 2096) suddenly has an open circuit or is short--circuited to earth, the pawl stop
system will be activated, although the signal is not generated by the metal detector.
Also, it is not possible to reactivate the metal detector by pressing the feed rolls reverse switch as long as the
problem is not solved.
The following table explains whether the pawl stop system will be activated or not when a metal detection takes
place.
Classic output
Wire 2096 not damaged Wire 2096 shorted to 12 V
CAN Network
EMO no network error Feed rolls will stop Feed rolls will stop (NEW)
EMO network error (117) Feed rolls will stop Feed rolls will not stop
ATTENTION: When diode V24 (located in the central box on X432) is defective or incorrectly installed, the AKS
& ASBA printed circuit can be damaged and the metal detector stop system will no longer work.
During working operation, several test routines are watching the EMD functionality. If one test is unsuccessful,
it will be announced by means of an Error message.
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CAN Identifiers

ID
1276 RUN time test procedure running =1== =0==: Not running
1276 EMD hardware version ==XX
1276 EMD software version: XX== See software revisions
Node M
1276 Error code 277 set ==8= ==0=: Not set
1276 Error code 273 set ===8 ==0=: Not set
1276 Peak noise level left channel, + values XX== Limits: 00 < XX < 7F
1276 Peak noise level left channel, -- values ==XX Limits: 00 < XX < 7F
1276 Peak noise level right channel, + values XX== Limits: 00 < XX < 7F
1276 Peak noise level right channel, -- values ==XX Limits: 00 < XX < 7F
1278 Cutterhead disengaged 8=== 0===: Cutterhead engaged
1278 Feed rolls stopped pressed 6===
1278 Feed rolls reverse pressed 4===
1278 Feed rolls forward pressed 2===
1278 Adaptive mode selected 1=== 0===: Fixed mode selected
1278 EMD threshold setting in fixed mode =X== = 0 when adaptive mode is
selected.
= 0 < X < 8 when fixed mode

is selected
1278 Forage Harvester stopped ===6
1278 Forage Harvester driving backwards ===4
1278 Forage Harvester driving forwards ===2
1278 Quick Adapt routine activated ===1 ===1: Quick adapt routine
started
1283 Metal detector ON switch pressed 4=== 0===: Not pressed
1283 Metal detector OFF switch pressed =4== =0==: Not pressed
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ID
1301 Missed metal detection date XXXX XXXX XXXX Hours: Minutes Day Month
Year (decimal code)
1303 Harvest mode activated ==1= ==0=: Road mode
1303 Feed rolls reverse engaged ===8 ===0: Feed rolls reverse not
engaged
1304 Metal detected =4== =0==: No metal detected
engaged
1304 Metal detector status ===1 ===0: Enabled
===1: Disabled
1314 Metal detector led lights up ===4 ===0: Extinguished
1349 Stop valve activated ===2 ===2: Activated
===0: Not activated
Error Messages
Error codes related to the electronic metal detector:
Error Code Key Words

117 EMD Network error
270 EMD Noise level low
271 EMD Output line --
272 EMD Output line +
273 EMD Channel fault
274 EMD Noise level high
275 EMD Network error
276 EMD Processor fault
278 EMD Output failure
279 EMD Power failure
REMARK: Error 275 is suppressed by software.
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22. ATTACHMENT HEIGHT CONTROL
1°°) Calibration
To avoid error messages during the attachment height calibration, first check the voltages for the minimum and
maximum attachment height positions on the display, before starting the calibration procedure.
The voltage when the attachment is raised must be higher than : 6,2 V. Preferably not higher than 6.7 V.
The voltage when the attachment is lowered must be lower than : 5,0 V.
To start the attachment height calibration :
1. Start the engine.
2. Press the “CAL” button on the performance monitor.
3. Select and Enter “2--Attachment calibration”.
4. Go to “Semi Automatic HHC Calibration” and Enter “Yes”.
Calibration procedure :
1. Calibration of the attachment height range: ground level.
The attachment is lowered to ground level, which for the Bosch module corresponds with a pressure in the
cylinders of 0 bar.
-- start from a level above ground.

-- push “attachment down” for 2 seconds.
-- the attachment will automatically lower to ground level.
-- green LED: 5 blinks.
-- beep tone.
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2. Calibration of the attachment height range: upper position.
Smax has to be higher than 6,2 V.
-- push “attachment up” for 2 seconds.

-- the attachment will automatically raise to its upper position.
-- beep tone
If Smax is lower than 6,2 V, the calibration procedure will interrupt and the following message will be displayed.
Stop the machine and adjust first the attachment height sensor before restarting the attachment calibration pro-
cedure.
CALIBRATION
SEMI AUTOMATIC HHC

CALIBRATION
INTERRUPTED
ATTACHM HEIGHT SENS.

OUT OF RANGE
READJUST SENSOR
06,0 V
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3. Calibration of oil the pressure range: lower position.
The attachment will lower to to S1 = Smin + 0,9 V.

S1 has to be lower than 6,4 V.
-- push “attachment down” for 2 seconds.

-- the attachment will automatically lower to just above ground level
-- green LED: 8 blinks
-- beep tone
When the attachment is lowered for a second time, the system calculates the expected
S1 = Smin + 0,9 V. has to be lower than 6,4 V.
If this value is higher than 6,4 V, the system interrupts the calibration procedure with the following message:
CALIBRATION
SEMI AUTOMATIC HHC

CALIBRATION
INTERRUPTED
ATTACHM HEIGHT SENS.

OUT OF RANGE
MIN > 5,5 V
READJUST SENSOR
06,5 V
NOTE: If wait messages remains on screen at this point for more than 2 minutes, check performance at pressure
sensor B13.
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4. Calibration of the oil pressure range: upper position.
The attachment is raised completely, and then lowered to level S2 = Smax -- 0,1 V.
And S2 has to be higher than S1 + 0,8 V.
-- push ”attachment up” for 2 seconds.

-- the attachment will automatically raise just under upper position
-- green LED: 12 blinks
-- beep tone
After reaching the last point S2, the system verifies the difference between S2 and S1.
If the result is lower than 0,8 V, a build--in standard curve will be applied.
This is indicated by the following message:
CALIBRATION
SEMI AUTOMATIC HHC

CALIBRATION
DEFAULT CALIBRATION
APPLIED
06,5 V
When the difference between S2 and S1 is higher than 0,8 V, the calibration procedure will finish and the follow-
ing message will be displayed.
CALIBRATION
SEMI AUTOMATIC HHC

CALIBRATION
SUCCESSFUL
05,0 V
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Conclusion:
Allowed voltage range for Smin, Smax, S1 and S2.
An example is worked out for a machine on which Smax = 6.8 V.
Conditions for Smin
Calibration successful Default Calibration not possible

calibration
Smax = 6,8 V
S2 = 6,7 V (Smax -- 0,1 V)
S1 < 5,9 V (S2 -- 0,8 V)
Smin < 5,0 V (S1 -- 0,9 V)
If the attachment lowest position was lower than 5,0 V, the calibration would have been successful.
In case the lowest position would have been between 5,0 V and 5,5 V, which does not agree with condition S2
-- S1 > 0,8 V, the default calibration will be applied (a standard height--pressure line foreseen by Bosch).
In case the lower position would be higher than 5,5 V, the calibration procedure cannot be carried out as the
attachment is positioned too close to ground level in raised position.
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2°°) Functional Operation
a) Compensation mode
1) True compensation or floatation ( compensation mode selected).
1. Attachment bumps: attachment raises -- pressure drops

2. Compensation reaction: attachment raises -- pressure raises
3. Attachment drops: attachment drops -- pressure raises
4. Compensation reaction: attachment drops -- pressure drops
This mode is recommended when using a pick--up attachment.

Start the engine and engage the cutterhead.
Turn the attachment height control selector switch into ”pressure” position.
Give a pulse on the automatic attachment height button.
The attachment will automatically lower to the pre--selected pressure.
Adjust the required ground pressure during harvesting by means of the ground pressure potentiometer.
In this mode, the working pressure Pwork is adjusted with the potentiometer between 80% and 108% of the cali-
brated pressure P1 (= pressure calibrated in the low position, at sensor position S1). A line is drawn parallel to
the line between P1 and P2 that runs through Pwork. The system will always try to maintain a position on this curve
in function of sensor position S, for as long as the potentiometer remains in that position.
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2) Compensation in stubble height mode.
1. Attachment bumps: attachment raises -- pressure drops

2. Compensation reaction: attachment raises -- pressure raises
3. Obstruction passed: returns to preset stubble height
In the stubble height mode, the compensation will start working when the pressure drops below P1 -- 4 bar (P1
is the pressure at the calibration point just above ground level) at any stubble height. If for example P1 = 45 bar,
then the compensation will always start working at 45 -- 4 bar = 41 bar, also if the pressure at the selected stubble
height actually is 50 bar. So P1 determines the pressure at which the compensation will start working in stubble
height control.
b) Stubble height mode

This mode is recommended when harvesting standing crops (e.g. maize) or when operating in stony conditions.
Start the engine and engage the cutterhead.
Turn the attachment height control selector switch into ”Stubble height” position.
Give a pulse on the automatic attachment height button.
The attachment will automatically lower to the pre--selected height.
Adjust the required attachment height during harvesting by means of the stubble height potentiometer.
It is possible to adjust the attachment in the following stubble height range :

Bottom level : Ground level determined during calibration (Smin)
--5% of the attachment height sensor operating range.
Top level : Ground level determined during calibration (Smin)
+ 45% of the attachment height sensor operating range.
See following picture.
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38
3) Additional information :
a) All signals from switches are communicated over the CAN network, but the attachment height control module
(A60) does not communicate to the CAN network. For this reason all signals are again simulated by the
actuator printed circuit.
Simulated functions:
Attachment up and down switches :
Common wire : 209--wt to X57/P09 ; 5 Volts.
Switch up : 210--wt to X57/P36.
Switch down : 211--wt to X57/17.
Fast up or down (when field mode is selected) : 212--wt to X57/P03.
Automatic Attachment height control button S30.

Wire 206--wt to X57/P27 and wire 208--wt.
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Attachment height control selector switch S35;

Wire 221--br to X57/P02, wire 214--bl to X57/P20 and wire 222--gn to X57/P21.
Measured voltage at X57/P21 with selector switch S35 in following positions :
Transport : between 63% and 80% of voltage at X57/P02.
Compensation : between 21% and 42% of voltage at X57/P02.
Stubble height : between 57% and 62% of voltage at X57/P02.
Compensation potentiometer R7.

Wire 2176--zw at X57/P05 ; between 0 and 10 Volts.
Stubble height potentiometer R6.

Wire 216--zw at X57/P22 ; between 0 and 10 Volts.
Green led :
Wire 215--gn at X57/P12.
Red led :
Wire 213--gn at X57/P31.
b) The attachment height sensor R4:
Disconnect sensor : measured voltages with ground.

X57/P39 : 9,5 Volts
X57/P06 : 7,2 Volts
Reconnect sensor.
Sensor fully in : 7,2 Volts (app. 75% of voltage at X57/P39).
Sensor fully out : 2,2 Volts (app. 25% of voltage at X57/P39).

c) Oil pressure sensor B13.
Disconnect sensor : measured voltages with ground.

X57/P39 : 9,5 Volts
X57/P08 : 7,2 Volts
Reconnect sensor.
Oil pressure sensor on Max pressure (160 bar) : 7,2 Volts (app. 75% of voltage at X57/P39).
Oil pressure sensor on Min pressure (0 bar) : 2,2 Volts (app. 25% of voltage at X57/P39).
4) Error messages :
Refer to Attachment height control error messages list
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23. GROUND SPEED
Hydrostatic Hydrostatic Limb

oil oil home
pressure temp. procedure
switch switch
Engine MF MF Ground speed Mechanical PC

running handle forward handle Rpm sensor conditions: Calibrations
See group 1 = Drive backward = * No handbrake
forward Reverse * Machine in
drive gear
Speed Servo valve Reverse Hydrostatic oil Hydrostatic

indication on hydrostatic buzzer pressure led temperature
LCD pump led
Conditions
1. Engine is running.
2. Hydrostatic oil pressure is ok.
3. Hydrostatic oil temperature is ok.
4. Machine is not in limb home procedure.
5. Machine is in gear and handbrake is off.
6. To drive forward, the MF handle has to be moved to the front.

To drive in reverse the MF handle has to be moved to the back. The reverse buzzer will sound as soon as
the handle is out of neutral when moved to the back.
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What causes the machine to move?

In short:
A switch inside the handle monitors if the handle is in neutral. When moving the MF handle to the front or the
rear the switch detects an out of neutral position. At the same time a potentiometer moves along with the move-
ment of the handle. An electronic circuit inside the handle assembly makes sure that this movement is translated
into a current which is transported to the hydrostatic servo valve in the hydrostatic pump. This valve again trans-
lates the current into a mechanical movement which controls the oil flow to the hydrostatic motor. This motor
is responsible for the movement of the machine.
Important things to know
I: * In Road mode, the ground speed sensor is used to determine and regulate the maximum allowed
speed.
* In field mode, the ground speed sensor is NOT used to regulate the forward speed.
A linear hydrostatic current curve is used to increase the forward speed. A maximum current of app. 105
mA (ID1304 word 4 = 1199) related to a maximum forward speed of app. 20 km/h in 3th gear.
* When driving in harvest mode and exceeding a speed that is higher than 90% of the maximum
calibrated forward speed, the machine will automatically go to ROAD mode, which means the engine
rpm will drop back to 1650 rpm (Caterpillar engine) or 1750 rpm (Iveco engine).
* If the ground speed sensor information is not available, the forward speed in ROAD mode will be set
to a maximum of 90% of its maximum calibrated speed.
* North America machines have the ability to select full engine speed in ROAD mode.
II: It is not advisable but possible to move the machine with the handbrake on, however you will hear a
warning signal from the LCD buzzer and the hand brake warning led on the dashboard will start blinking.
III: The ’limb home’ procedure ( can id 1319):
If a fault in the CAN communication between Multi--function Lever and dashboard occurs or if a
Multi--function Lever errors code (error 12 or a combination of errors 350 & 351 together) occurs,
resulting operator being unable to move the machine. The message ”urgent drive procedure continue
yes/no” appears on the performance monitor.
1. When choosing ”yes”, machine can be driven forward and rearwards at a speed of approximately
3 km /hour (depending of maximum speed calibration) using the crop processor gap adjustment
switch on the dashboard (up = forward, down = rearward, spring loaded to centre = neutral). To
escape from this mode switch off the contact.
2. When choosing ”no” the procedure is terminated. The fault must be repaired before the machine
will move.
IV: PC Calibration settings and LCD calibration settings are very important for ground speed
troubleshooting. Before starting troubleshooting see that all calibrations are correctly done by following
the instructions on the EST tool.
They are for EST: * Maximum handle position

* Minimum forward current to hydrostatic pump
* Minimum backward current to hydrostatic pump
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All these calibrations can be checked through can id.
And for LCD: ground speed tuning in calibration mode on the performance monitor; its only purpose is
displaying the correct speed on the performance monitor, you cannot manipulate the real
speed of the machine by changing the numbers.
To make the meaning of the calibration values more clear, a potentiometervalue/speed diagram is given.
As we can see here, when moving the handle forward, at first there is no movement of the machine until
potentiometer value of 71Hex is reached. From then on we have a linear function until 90% of the
maximum speed calibration has been reached. At this point the curve is no longer linear to prevent the
machine from going above the calibrated speed.
As for the reverse drive it is possible to drive up to about 15 kph, depending of the calibrated maximum
speed, from there on the current to the pump stays the same.
The hexadecimal numbers on the diagram are a reference, they don’t have to be exactly the same when
checking a machine through can spy 1282, word 3.
SPEED (V)
Vmax Max. calibrated speed (¦ 30 km/h)
90% of max. calibrated speed (CANSPY page 1304)
FOR-
WARD
DRIVE
Vmin, FW
CANSPY
Page 1283 -- word
3=
Vmin, BW
potentiometer
RE- value
VERSE- in HEX.
DRIVE
Vmax, BW
(¦ 15km/h)
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CAN SPY
CAN DESCRIPTION word1 word2 word3 word4 COMMENTS

ID
1282 Multifunction lever =2==
Out of neutral
1282 Multifunction lever =1==
In neutral
1282 Ground speed potentiometer ==XX In neutral XX = 5C +/-- 30 or
3E<XX<7A
limits : 00 < XX < D0 +/-- 10
1288 Ground speed based on PC calibration XXXX Ground speed in mm/s based
on PC calibration
1288 Ground speed displayed XXXX Ground speed in mm/s based
on display calibration
1303 Hydrost. oil press. switch closed ==8= ==0= : switch open
Insufficient press ==8= : switch closed
1303 Hydrost. oil temp. switch closed ==4= ==0= : switch open
Temp too high ==4= : switch closed
1304 Drive backwards 8=== 0=== : not driving

1304 Drive forwards 4=== 0=== : not driving
1304 Ground speed > 90% ===2 ===0 : ground speed < 90 %
V max. calibr. by pc Vmax
1304 Current to hydrostatic pump XXXX Limits: 0000 < XXXX < +/--1199
(= +/-- 105 mA)
1314 Hydrostatic oil pressure LED 4=== 0=== : extinguished
1314 Hydrostatic oil temp. LED =8== =0== : extinguished
1319 Activate Limb Home Request XXXX 53CA : to raise the request ;
else 0000
1319 Answer Limb Home Request XXXX 0000 : not answered yet ;
55CC : ’yes’ is answered ;
1111 : ’no’ is answered
1331 Calibrated max speed XXXX mm/s (hexadecimal code)
1331 Calibrated max current to hydrost. pump XXXX Maximal value : 1199 (= +/--
105 mA)
1342 Calibrated ground speed constant =XXX Hexadecimal code
1342 Calibrated min forward current XXXX Hexadecimal code
1342 Calibrated min backward current XXXX Hexadecimal code
1342 Calibrated max handle pos. XX== Hexadecimal code
1345 Calibrated low acceleration hydr. pump =8== =0==: not calibrated (no);
=8==:calibrated (yes)
1345 Calibrated full engine speed road mode ===8 ===0: not calibrated (no);
===8: calibrated (yes)
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Error codes
Error Codes Description

120 Ground speed sensor O
121 Ground speed sensor --
122 Ground speed sensor +
350 Ground speed POT--M
351 Stop ground speed SW
420 Hydrostatic pump O
421 Hydrostatic pump --
422 Hydrostatic pump +
Electrical scheme
See group 3: Hydrostatic control, line 690 -- 850
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24. HIGH FLOW HYDRAULICS
Field Mode High capacity High capacity PC Calibration

See hydraulics hydraulics High Flow
paragraph 3 switch UP switch down Hydraulics
High capacity
High capacity
Hydraulics
Hydraulics UP
down
To use the high capacity hydraulics.
3. Press the high capacity hydraulics UP switch to power the high capacity UP valve.
Press the high capacity hydraulics DOWN switch to power the high capacity DOWN valve.
REMARKS: High capacity hydraulics are an accessory.

To use the high capacity hydraulics, first the switch needs to be installed in the dashboard and the EST calibration
“High Flow Hydraulics” needs to be set (check on CAN SPY page 1345).
Afterwards the output lines can be powered.
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Can Spy

ID
1283 High Flow Hydraulics open switch 2=== 0=== : not pressed
Pressed
1283 High Flow Hydraulics close switch =2== =0== : not pressed
Pressed
1345 Calibrated High Flow Hydraulics ==8= ==0=: not calibrated (no);
==8=:calibrated (yes)
Error Codes

301 Dashboard switch 1
467 High cap. hydr. up sol.
468 High cap. hydr. down sol.
Electrical diagram
Group 29: High flow rear hydraulics, line 10890 -- 11050.
S137: High flow rear hydraulics switch
Y49: Tip trailer up valve
Y50: Tip trailer down valve
6- 71020EN - 08 - 2003
25. ROTARY SCREENS
Engine
running
See paragraph 1
Rotary Rotary
screen screen
motor left motor right
Conditions:
As soon as the engine starts running, the rotary screens start rotating.
Can Spy

ID
1345 Calibrated rotary screens ===1 ===0: not calibrated (no);
===1: calibrated (yes)
1347 Rotary screens 4=== 4=== : activated ;
0=== : not activated
Error codes

446 Rotary screen motor
Electrical diagram
Group 14: Rotary dust screens, line 4770 -- 4930.
M26: Rotary dust screen motor -- LH side
M27: Rotary dust screen motor -- RH side
6- 71020EN - 08 - 2003
26. ROTARY SCREEN BRUSHES
Field mode LCD

See calibration
paragraph 3
Dust screen
brush
actuator
Conditions:
In the calibration/type menu of the LCD there are two options out of which you can choose to determine the fre-
quency of the brush cleaning. There is a ’frequent’ option for heavy conditions (= every 8 minutes the brush en-
gages 2 minutes) and there is a ’standard’ option (= brush engages 1 minute every 15 minutes).
Can Spy
CAN DATA DESCRIPTION word1 word2 word3 word4 Comments

ID
1345 Calibrated rotary screen brushes =1== =0==: not calibrated (no);
=1==:calibrated (yes)
Error codes

445 Rotary screen brush
REMARK: Error 405 is suppressed by software.

The actuator contains end of stroke switches which will create an error code every time the actuator is extracted
or retracted. For this reason the error code is suppressed.
Electrical diagram
Group 14: Rotary dust screens, line 4770 -- 4930.
M28: Rotary screen brush actuator -- LH side
M29: Rotary screen brush actuator -- RH side
6- 71020EN - 08 - 2003
27. CATERPILLAR ENGINE
39
6- 71020EN - 08 - 2003
General Information
1°°) Power Supply

Power (12 V) is supplied from the fuse printed circuit X404 p14 (line 1760) to the Caterpillar electronic Control
Module. See electrical drawing group 6 and 31.
Conclusion:
-- 12 V after ignition, to be able to start the engine.
-- Engine will stop immediately or can not be started when output line becomes low (0V).
REMARK: Output current is approximately 3 Amp.
2°°) Engine Throttle control

Special PWM output line only used for CHX 620 on X415 p04.
Frequency: 500 Hz Nominal (between 300 and 700 Hz)
Pulse width minimum engine rpm (850 rpm): 20%
Pulse width maximum engine rpm (2100 rpm): 80%
The engine rpm in road mode for the Caterpillar engine is 1650 rpm, on Aifo machines it is 1750 rpm.
See electrical diagram group 2.
3°°) CAN Network
The CAN communication wires to the Caterpillar engine are parallel on the CAN wires of the metal detector.
See electrical diagram group 11.
AKS & ASBA printed circuit involved, only for CHX 620.
Can not be used on other CHX forage Harvesters.
A CAN resistor R31 (line 11730) of app. 120 Ω is installed close to the Caterpillar electronic control Module to
obtain a correct CAN communication.
6- 71020EN - 08 - 2003
CAN IDENTIFIER LIST

See complete CAN Identifier List
CAN Identifier 1352 & 1353

ID
1352 Coolant temperature XX== Range : --40°C to +210°C
(1C/bit)
1352 Fuel temperature ==XX ==XX Range : --40°C to +210°C
(1C/bit)
1352 Inlet air temperature XX== Range : --40°C to +210°C
(1C/bit)
1352 Load percentage at current engine speed ==XX Range : 0% to 125% (1%/bit)
1352 Inlet manifold pressure XX== Range : 0kPa to +500 kPa
(2kPa/bit)
1352 Engine oil pressure ==XX Range : 0kPa to +1000kPa
(4kPa/bit)
1352 Calibrated maximum engine rpm XXXX Range : 0 to 8031.875 rpm
(0.125 rpm/bit)
1353 Engine rpm XXXX Range : 0 to 8031.875 rpm
(0.125 rpm/bit)
1353 Error codes report XXXX XXXX XXXX See detailed list
4°°) Error codes reporting
Two wires from Caterpillar electronic control module towards the CPU printed circuit are used for error code re-
porting (lines 2174 and 2175).
When the Caterpillar electronic control module detects an error, the corresponding CAT error code number is
shown on the performance monitor below the engine rpm bargraph.
Detailed list of Caterpillar error codes: see section 55--7B.
Error codes

118 Caterpillar Network Error
360 No Engine oil press.
361 Oil press. sens. fault
364 Cat. oil temp. sensor
6- 71020EN - 08 - 2003
5°°) Engine protection
-- From an engine coolant temperature of 103° C the Caterpillar software reduces the available engine power
in steps of 25% per ° C.
-- The engine is shut down by the NH electronic system (see point 1: power supply) when the engine coolant
temperature reaches 105° C or when the engine oil pressure is less than 1 Bar.
-- An additional engine oil temperature sensor located in the oil sump will stop the engine at a temperature of
app. 118° C.
This sensor is connected to the NH electronic system (see electrical wiring diagram: group 20) and is used as
a back--up sensor to protect the Caterpillar engine when a CAN network fault occurs.
This engine protection device is programmed to wait 10 minutes with engine below 1500 rpm or 3 minutes with
the engine above 1500 rpm. This is to allow the oil temperature to rise above the minimum operating limit of the
sensor.
If the sensor or wiring to this sensor becomes defective, the engine shuts down.
REMARK: Both protection devices work parallel to each other.

The first who indicates an excessive temperature or pressure will activate the engine shut down procedure.
So the engine will stop after 10 seconds.
If the engine has been shut down, restart the engine by leaving the contact on and restart. Afterwards the mess-
age “AUTOMATIC ENGINE SHUT OFF DISABLED” will appear on the performance monitor.
6°°) Caterpillar operation
-- The engine load bargraph at the right--hand side of the screen represents the engine power consumption.
The top (narrow) segment represents the engine power range from 95% to 100%.
The lower (wide) segment represents the engine power range from 100% to 110%.
-- When the engine rpm drops below 1850 rpm and the power consumption is above 98%, a buzzer will warn
the driver to slow down. Also the engine symbol will blink.
6- 71020EN - 08 - 2003
28. CAN NETWORK
B B B B B B
Performance CPU
Drive print AKS & ASBA
Monitor Node B
Node E Node T
Nodes A + S
Y
B B
EMD Engine
Node W module
General procedure to diagnose CAN--NETWORK
-- Verify Software Revision on Service page.

• If Rev99 or later is displayed, correct software is installed and no network fault is present.
• If Rev X.X is displayed, incorrect software revision is installed or a network fault is present.
-- Check software revision CAN--identifiers in CAN SPY
Node Location CAN--Identifier Word 1 Word 2 Word 3 Word 4

A Performance Monitor 1326 ==XX
S Performance Monitor 1326 ==XX
E Drive print 1294 ==XX
T AKS & ASBA printed 1304 ==XX
circuit
B CPU printed circuit 1303 ==XX
W Metal Detector 1275 ==XX
-- If one or more nodes contain a “00” --value or not the correct value, try to download the correct software re-
vision in the corresponding nodes.
REMARK: If the AOM printed circuit is defective and a “OO” value is displayed on the CAN--Identifiers 1304,
most probably a “00” will also be displayed for the node B and W, as all communication goes over the AOM printed
circuit.
6- 71020EN - 08 - 2003
Conclusion:
-- If B, T and W node indicate a “00” value, start to focus on the T--Node.
• If the software download is finished correctly, check if the problem persists by starting the engine and
clearing all error codes in the error overview.
• If the software download procedure will not start, or is not finished correctly, a hardware problem is
causing the problem.
-- First check all power supplies to all printed circuits.
• Check fuses F4 and F11.
• Check for battery voltage when ignition is switched on:

at X303 p07 in Dashboard (line 280, diagram 1)
at X417 p15 on CPU printed circuit (line 1790, diagram 6))
at X656 p09 on AOM printed circuit (line 1680, diagram 6)
at X657 p1 on Drive printed circuit (line 1570, diagram 6)
at X413 p08 on Actuater printed circuit (line 2090, diagram 7)
at X619 p01 at Metal detector (line 3930, diagram 11)
at X57 p24 at Bosch Module (line 7000, diagram 20)
• Check for ground

at X303 p10 in Dashboard (line 1500, diagram 5)
at X417 p06 on CPU printed circuit (line 1860, diagram 6)
at X656 p07/08 on AOM printed circuit (line 1740, diagram 6)
at X657 p2 on Drive printed circuit (line 1570, diagram 6)
at X424 p04 on Valve print (line 2300, diagram 7)
at X411 p05/06 on Actuator printed circuit (line 2090, diagram 7)
at X619 p03 at Metal detector (line 3960, diagram 11)
at X57 p28/07 at Bosch Module (line 7000, diagram 20)
If necessary, locate and repair open or shorted circuit in Electronic box. Replace fuses.
Start engine again to verify if problem persists.
-- Check fiber optics and flat cables and their connections.

Refer also to error code list: errors 1 to 15.
To understand better the function of the network error codes imagine you are in the performance monitor.
• Information sent out from the performance monitor towards the CPU Node through the flat cable and optical
fibers is not arriving in one node.
However the communication lines towards the performance monitor are still correct.
These nodes will lose synchronisation in communicating to each other and the performance monitor can not
understand any longer the messages. For this reason, the performance monitor will display an Error 1
(and 2).
• If information sent out from the CPU--Node towards the performance monitor is interrupted somewhere, the
closest node can still communicate in a correct way and indicate it does not receive good information from
the other node.
6- 71020EN - 08 - 2003
In this way:
an error 10 will be displayed in case of incorrect communication from dashboard to performance monitor
an error 13 will be displayed in case of incorrect communication from CPU--Node to AOM--node
an error 15 will be displayed in case of incorrect communication from AOM--Node to dashboard.
REMARK:
An error 117 will be displayed in case of incorrect communication with the Metal detector.
An error 118 will be displayed in case of incorrect communication with the Engine electronic Module.
Additional Information
Difficulties to download software:
1. Software download does not start.
2. Software download interrupts after a few seconds.
We recommend to proceed as follows in case of a problem:
1. Make sure the batteries are fully charged.
2. When the software download does not start, try to switch the ignition key off and on again several times.
3. When the software download interrupts, it is possible to download an individual software node by connecting
the fibre optics from the dashboard directly to the printed circuit you want to update.
REMARK: Always write down the position of the optical wires before disconnecting so that you can reinstall them
in the original position after software download.
For CHX Forage Harvesters proceed as follows:
a) Download of node A and S (in performance monitor)

Disconnect optical wires (from dashboard) in central box on the AKS & ASBA printed circuit. Only the
performance monitor can receive the CAN messages.
After software download, (re)connect all optical wires to the original positions.
b) Download of node B (in CPU printed circuit)
Disconnect the small optical wires (from AKS & ASBA print) in the central box on the CPU printed circuit.
Remove the optical wire (from the dashboard) located in the white sender of the AOM print and connect to
the white sender of the CPU print. Proceed in the same way with the other optical wire in the black receiver.
Only the performance monitor and the CPU print can receive the CAN messages.
After software download, (re)connect all optical wires to the original positions.
6- 71020EN - 08 - 2003
c) Download of node T (in AOM printed circuit)
Disconnect the small optical fibres in the central box on the CPU printed circuit.
Disconnect the CAN communication line to the metal detector. Disconnect for example X431 on AOM printed
circuit or X627 above RHS traction wheel.
Only the performance monitor and the AOM print can receive the CAN messages.
After software download, (re)connect all optical fibres to the original positions.
How to recognize a network error code:
If a AOM network failure occurred, all AOM Leds on the dashboard will illuminate, the led of the sharpening cover
will start to flash and the work lights will illuminate.
If a CPU network failure occurred, the engine oil pressure led, the engine coolant led, the battery led, the airco
leds will illuminate or will start to flash, also the work lights will illuminate.
REMARK: The errors 1 to 15 will only appear on the performance monitor when the problem occurred while the
engine was running.
In all other cases, the errors will not appear, but the above described symptoms will indicate the presence of a
Network failure.
The Auto Voting PC--calibrations exchange

The calibration preferences are stored on three nodes, e.g. performance monitor, CPU and AKS & ASBA printed
circuits.
When the engine is started these calibration settings are compared.
If the choices or settings on one Node is different from the others, the Nodes in majority will influence and change
the choices or settings of the node that is in the minority.
For this reason never exchange two printed circuits at the same time.
Software download
The Auto--Voting PC--calibrations exchange does not apply to the software itself, so always check new printed
circuit boards if the correct software is installed (by means of the CAN--Identifiers),
If not correct, always download the correct software first.
12 V battery voltage after ignition

Engine hours cutterhead hours, hectare information and calibrations settings need to be stored after the engine
has been stopped.
Therefore permanent battery voltage need to arrive on performance monitor, CPU and AKS & ASBA printed
circuit to store this information.
REMARK: 12 V battery voltage can be found on flat cable, position 15 and 16 in performance monitor.
When no battery voltage arrives in performance monitor you will not hear a relay click after 3 to 5 seconds after
ignition has been switched off.
This can result in an Error Code 100 after some time.
6- 71020EN - 08 - 2003
SECTION 60 -- PRODUCT FEEDING -- CHAPTER 1 1
Chapter 1 -- Feed rolls
CONTENT
Metal detector roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Metal detector components -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Smooth roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Upper feed rolls -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Before removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal of the upper feed rolls as a complete assembly. . . . . . . . . . . . . . . . . . . . . . . . 12
Removal of the upper feed rolls as separate components. . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing wear plates on the upper feed rolls frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6- 71020EN - 08 - 2003
2 SECTION 60 - PRODUCT FEEDING -- CHAPTER 1
METAL DETECTOR ROLL
Removal
1. Remove the upper feed roll module from the

chopper body. (Refer to the operators manual
Section 4 -- Lubrication and maintenance).
1
2. Tie up the lower front roll to a suitable lifting
device and support the roll 1.
2
3. Loosen the screw 2 and push the sleeve 3 in the
direction of the arrow.
3
4. Cut the plastic straps at 1.
5. Disconnect the grease line 4 to the lower front

feed roll.
6. Open up the connector box 5 and disconnect the

connector to the metal detector.
NOTE: Seal the connector ends from dirt.
4
6- 71020EN - 08 - 2003
7. Remove the two screws and lock washers 6 and

the plate 7.
8. Remove the two screws and lock washers 8.
NOTE: Keep the parts for later use.
WARNING
The bearing housing 9 will turn due to the weight of
the metal detector inside the lower front feed roll
when the screws 8 are removed. Be careful not to
hurt your hands.
5
9. Slide the metal detector roll 1 in the direction of
the arrow and lift it out of the chopper body.
6
10. Remove the bolts and washers 10 and remove
the cover 11. Keep the parts for later use.
11. Remove the grease line 12 and remove the

silicone from the end of the metal detector shaft.
6- 71020EN - 08 - 2003
Disassembly
12. Remove all bolts 14 and keep for later use.
NOTE: The bolts 14 are installed with a thread

retainer.
13. Remove the circlip 13 and keep for later use.
14. Pull the bearing housing 9 together with flange 27

away from the metal detector shaft. Do not loose
the key that is installed on the metal detector
shaft.
8
NOTE: The metal detector may come out together
with the bearing housing 9 and flange assembly 27.
NOTE: Do not damage the O--ring when removing

the flange 27 from the metal detector roll.
15. Pull out the metal detector from the lower front
feed roll.
16. Remove the sleeve 15 from the hub 16.
17. Remove all bolts 14.
NOTE: The bolts 14 are installed with a thread

retainer.
18. Pull the hub 16 from the metal detector roll 1 and
the metal detector shaft if the metal detector still
is in the roll.
NOTE: Do not damage the O--ring 17 (Fig.10)
19. Remove the metal detector from the inside of the 9

metal detector roll 1.
20. If necessary replace O--ring 17, circlip 20, special

bearing 19, rubber seal 18 and hub 16.
21. Remove the bearing 33 from the end of the metal

detector shaft or from the bearing housing of
flange 16. Install a new bearing 33 in the bearing
housing of the flange 16.
10
6- 71020EN - 08 - 2003
22. Remove the circlip 21, seal 22, Circlip 23, circlip
24, bearing 25 and circlip 26.
23. Remove the flange 27 from the bearing housing

9.
24. Replace the grease line connector 29, the screw

assembly 30 and the grease line assembly 31.
NOTE: Use a thread retainer when installing 30.
25. Replace the seal 28. The lips of the seal should
be turned towards the bearing 25.
26. Install the flange 27 together with the seal 28 11

onto the bearing housing 9.
27. Install the circlip 26, bearing 25, circlip 24, circlip
23.
28. Install a seal 22. The lips of the seal should be

turned towards the bearing 25.
29. Install the circlip 21.
Metal detector components -- D./A.
Disassembly
1. Cut the plastic strap 1 and free the metal detector

cable 2 from the shaft 3.
NOTE: Note the position of the cable cut out in the

shaft 3 in comparison to the metal detector 4.
2. Remove the bolts and washers 5, lift the shaft 3

away from the metal detector 4 and remove the
bushings 6.
Assembly
1. Install the bushings 6 and the shaft 3 onto the

metal detector 4.
2. Secure the assembly in place with bolts and

washers 5.
3. Tie the metal detector cable 2 into the groove in

the shaft 3 with a plastic strap 1.
12
6- 71020EN - 08 - 2003
Assembly
1. Push the metal detector assembly 4 into the

metal detector roll as shown.
NOTE: The direction of rotation.
13
2. Install the bearing 33 into the flange 16.
NOTE: Fill the bearing cavity with grease.
3. Install the metal detector shaft 3 into the bearing

33.
4. Install the O--ring 17 and install the hub 16 onto

the metal detector roll and secure in place with
bolts 14. Use a thread retainer (Loctite 270 or
similar).
5. Tighten the bolts 14 to a torque of 45 Nm.

14
6. Install the key 32 on the metal detector shaft 3.
7. Install the bearing housing 9 together with flange

27 (Fig. 16) onto the metal detector shaft 3.
NOTE: Note the position of the metal detector 4 in

relation to the bearing housing 9. Make sure you
make a correct installation.
15
8. Install an O--ring 17 between the flange 27 and
the metal detector roll 1.
9. Install all bolts 14 and tighten to a torque of 45

Nm.
NOTE: Use a thread retainer (Loctite 270 or similar).
11. Seal off the openings round the shaft with

silicone.
16
6- 71020EN - 08 - 2003
12. Install the grease line 12.
13. Install the cover 11 with the bolts and washers

10.
17
Installation
14. Lift the lower front feed roll assembly into the
chopper body.
15. Install the sleeve 3 on to the hub as shown.
16. Push the bearing into the cavity of the gearbox

shaft at in the direction of the arrow.
18
WARNING
The bearing housing 9 will turn due to the weight of
the metal detector inside the lower front feed roll. Be
careful not to hurt your hands.
17. Lower the lower front feed roll in place and install
the two screws and lock washers 8 and tighten
them.
18. Install the plate 7 with screws and lock washers

6.
19
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19. Route the grease line 4 and the metal detector

wiring loom in such a way that they do not touch
sharp edges or rotating parts.
20. Connect the grease line 4.
21. Open up the connector box 5 and connect the

metal detector wiring loom to the forage
harvester.
22. Fix the grease line and the wiring loom in place
with plastic straps at 1.
23. Install the upper feed roll module to the chopper

body. (Refer to the operators manual Section 4 20
-- Lubrication and maintenance).
6- 71020EN - 08 - 2003
SMOOTH ROLL
Removal
1. Remove the left--hand side shieldings of the

chopperbody.
2. Remove or tilt down the upper feed roll assembly.
3. Remove the scraper. Keep all removed parts for

later use.
4. Remove the bolts and washers 1 and remove the

cover 2. 21
5. Disconnect the grease line 3.
6. Remove the circlip 4 and eventual shims behind

it and keep them for later use.
7. Remove the collar 5.
8. Remove the four Allen screws and lock washers

6 and keep for later use.
22
9. Loosen the locking screw 9 and push the sleeve
10 in the direction of the arrow.
10. Push the smooth roll assembly in the direction of

the arrow.
11. Remove the bearing housing 7 (Fig. 22) from the

end of the smooth roll 8. Note down the number
of shims between the smooth roll bearing and the
smooth roll and keep them for later use.
12. Lift the smooth roll 8 out of the chopperbody.
23
13. Remove sleeve 10 from shaft 8.
14. If necessary, replace circlip 11, special bearing

12 and O--ring 13 on the shaft 8.
24
6- 71020EN - 08 - 2003
15. Remove the grease line connector 14 from the

bearing assembly 7.
16. If damaged, replace the bearing assembly 7 and

install the grease line connector 14.
25
Installation
1. Lift the smooth roll 8 into the chopper body so

that the left--hand shaft end goes through the
hole in the attachment gearbox.
2. Push the sleeve 10 on to the shaft of the smooth

roll 8.
3. Push the smooth roll assembly in the direction of

the arrow and insert the bearing 2 into the hole
in the shaft 15 of the length of cut control
gearbox.
26
4. Install the same amount of shims 15 onto the
smooth roll shaft 8 as you removed at
disassembly.
NOTE: The normal quantity is 4 shims.
27
5. Install the bearing housing 7 onto the shaft of the
smooth roll 8.
6. Install the four Allen screws and lock washers 6

and tighten the bearing housing in place. Do not
tighten completely.
7. Use a ruler and adjust the smooth roll to be in the

centre of the cutterhead by removing or adding
shims 15 at 16 (see also Fig. 27).
8. Tighten the Allen screws 6 securely.
28
6- 71020EN - 08 - 2003
9. Install the collar 5 and tighten in place
10. Install eventual shims between the collar 6 and

the circlip 4 to take away any horizontal play.
12. Reconnect the grease line 3.
13. Tighten the locking screw 9 (Fig. 23).
14. Install the cover 2 (Fig. 21).
15. Install and adjust the scraper. (Refer to the

operators manual Section 4 -- Lunrication and
maintenance).
16. Install the upper feed roll module in place.
17. Install the left--hand shieldings to the

chopperbody.
UPPER FEED ROLLS -- R./I.
Before removal
1. Drain the oil from the upper feed rolls drive

gearbox.
2. Tilt down, or remove the upper feed roll module

from the machine (Refer to the Section 4 --
Lubrication and maintenance).
3. Remove the spring assemblies for the upper

feed rolls. (Refer to the section 4 -- Lubrication
and maintenance).
4. Make sure that the upper feed rolls are well

supported at all times before you continue
working.
5. Remove the crop guides from the upper feed

rolls frame. (Refer to the section 4 -- Lubrication
and maintenance).
6- 71020EN - 08 - 2003
Removal of the upper feed rolls as a complete

assembly.
1. Disconnect all grease lines and the electric wiring

loom from the upper feed roll drive gearbox.
2. Remove the nut, washer and bolt 2 and remove

the plate 1. Note how the plate 1 is installed.
3. Remove the bolt and the bushing at 3.
29
4. Disconnect all grease lines from the upper feed
roll drive bearing housing assembly.
5. Remove the nut, washer and bolt 1 and remove

the plate 2. Note how the plate is installed.
6. Remove the bolt and the bushing at 3.
30
7. Install eye bolts, or bolts at 1.
8. Attach a suitable lifting tool to the eye bolts 1 and

lift the upper feed roll assembly to a suitable
table.
9. Continue the disassembly as described

hereafter.
31
6- 71020EN - 08 - 2003
Removal of the upper feed rolls as separate

components.
1. Remove the feed roll drive gearbox. (Refer to the

chapter 2 gearboxes in this section).
2. Disconnect the grease lines 1 and 2 from the

bearing housing assembly 9. ( if not done earlier).
3. Remove the bolt and washer 4, the special

washer 3.
4. Remove the nut and washer 6, install a washer

and nut at 7 and screw out the rod 5.
5. Remove the four bolts and washers 8.
32
6. Install M16 x 30 bolts at 10.
7. Use two pullers as shown and pull out the bearing

housing assembly 9.
8. Slide the upper front feed roll out from the upper
feed roll frame.
33
9. Pull out the bar 11 from the upper front feed roll.
34
6- 71020EN - 08 - 2003
10. Remove the circlip 12, bearing 13, the bearing

housing 14 and the cut off plate 15. See also
(Fig. 36).
NOTE: Note how the cut off plate is installed.
35
11. Replace the seal 16 in the bearing housing 14.
NOTE: When installing a new seal 16 into the

bearing housing 14, the seal lips must point towards
the upper front feed roll.
12. Replace the seal 17 in the bearing housing

assembly 9.
NOTE: When installing a new seal 17 into the

bearing housing assembly 9, the seal lips must point
towards the upper front feed roll.
36
13. Remove the circlip 1 and replace spacer 2, ring
3, bearing 4, ring 5 and spacer 6 in the bearing
housing assembly 9.
37
14. Remove the nut and washer 1.
15. Install a washer and nut M12 at 2 and screw out

the special rod 2.
16. Use a puller and pull off the arm 4. Do not loose
the spacer.
17. Repeat the steps 18 to 20 on the other side of the

feed roll 5 and remove the bar 3.
38
6- 71020EN - 08 - 2003
18. Remove the Allen screws 9 and remove the

flange 2.
19. Replace Cut off plate 1, seal 3, bearing 6, arm 4,

ring 7 and bushing 8.
NOTE: Tighten the Allen screws 9 to a torque of 24

Nm.
39
20. Remove the Allen screws 7 and remove the
flange 8.
21. Replace Cut off plate 6, seal 5, bearing 4, arm 3,

ring 2 and spacer 1.
NOTE: Tighten the Allen screws 7 to a torque of 24

Nm.
40
Replacing wear plates on the upper feed rolls
frame
1. Replace worn wear--plates.
2. Remove the plough bolts 1 for the inside wear

plates 2,3,4 and 5 on both sides of the upper feed
roll frame and replace the plates. Do not tighten
bolts completely.
3. Replace at the same time the outside wear plates

6, 7 and 9. Do not tighten bolts completely.
4. Tighten first the wear plates 2 and 9 in place.

41
5. Use a cut off plate 8 as template and tighten the
rest of the plates in place.
6- 71020EN - 08 - 2003
Installation
NOTE: Note the direction of rotation of the upper

feed rolls 1 and 2.
NOTE: Note the way the cut off plates 3 and 4 are
installed. There are plates for the left--hand side and
the right--hand side.
NOTE: Note how the arm assembly 5 is installed.
42
1. Install the cut off plates 4 (Fig. 42) onto the upper
rear feed roll 5.
2. Press arms 4 onto the upper rear feed roll shaft

on both sides. See figure 42 for correct
installation.
3. Install the bar 3 to the arms 4.
4. Install the special rods 2 as shown on both sides.

Tighten the rod 2 in place on the right hand side
with nut and washer 1. Do not tighten the
left--hand side completely at this time.
NOTE: Make sure that the arms 4 are turned the 43

same way.
5. Install the spacer 1 (Fig. 40) onto the shaft of the

upper front feed roll.
6. Install the upper feed rolls drive gearbox. (Refer

to chapter 2 Gearboxes) in this section.
7. Install the bar 11.
44
6- 71020EN - 08 - 2003
8. Install the cut off plate 15, the bearing housing

14, the bearing 13 and circlip 12.
9. Install on the rear upper feed roll shaft the

bushing 6 (Fig. 43).
45
10. Install the bearing housing assembly 9 onto the
shafts of the upper feed rolls as shown.
11. Use two long M12 bolts or threaded rods and

nuts 1 and big washers 2 and 3 and pull the
bearing housing assembly 9 in place.
46
12. Install the four bolts and washers 8.
13. Install the rod 5 and the nut and washer 6. Do not
tighten completely.
14. Install the special washer 3 and the bolt and

washer 4 and tighten in place.
15. Lift the upper feed roll assembly in place (Fig.

31).
16. Install the bolt and bushing at 7 on both sides.
17. Install the plate 11 with bolt, washer and nut 10

on both sides.
18. Adjust the upper feed roll assembly to move

freely in its support frame. Tighten the rod 5 in
place.
19. Check that all other bolt connections are tight.
47
6- 71020EN - 08 - 2003
20. Connect the grease lines 1 and 2 to the bearing

housing assembly 9 and to the gearbox.
21. Install the crop guides to the upper feed rolls

frame. (Refer to the section 4 -- Lubrication and
maintenance in the operator’s manual).
22. Install the spring assemblies for the upper feed

rolls. (Refer to the section 4 -- Lubrication and
23. Install the upper feed rolls module onto the

chopper body. (Refer to the section 4 --
Lubrication and maintenance in the operator’s
manual).
24. Fill the upper feed rolls drive gearbox with oil.
(Refer to the section 4 -- Lubrication and
6- 71020EN - 08 - 2003
Chapter 2 -- Length of cut control gearbox
CONTENT
Length of cut control gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Length of cut control gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. Alternative drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2. Transfer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Upper feed rolls drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4. Selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. Smooth roll drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. Metal detector roll drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7. Reinstall the alternative drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8. Install seals and covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6- 71020EN - 08 - 2003
LENGTH OF CUT CONTROL

GEARBOX -- R./I.
Removal
1. Drain the oil from the length of cut control

gearbox

chopper body.
NOTE: It is not necessary to remove the feed rolls

from the chopper body when the length of cut control
gearbox is removed.
3. Remove the upper feed roll drive safety guard.
4. Remove the upper feed roll drive yoke 2.
1
5. Remove the smooth roll scraper.
6. Remove the intermediate shaft 1 from the

chopper body.
7. Support the right--hand ends of the lower front

feed roll 3 and the smooth roll 4 well.
8. Move the sleeves 5 and 6 onto the shafts of the

rolls 3 and 4.
2
9. Tie the length of cut control gearbox 7 to a
suitable lifting device and support it as shown.
6- 71020EN - 08 - 2003
10. Remove the bolts and washers 8.
11. Remove the bushings 9. Keep parts for later use.
4
12. Lift the length of cut control gearbox away from
the chopper body.
Installation
1. Install a bushing 9 into the front hole as indicated.
NOTE: The bushing is a tight fit.
2. Lift the attachment gearbox in place (Fig. 3).
5
3. Install the bolt and washer 8 through the bushing
9. Fix the length of cut control gearbox into
position. Do not tighten the bolt yet.
4. Install the remaining bushings 9 and bolts and

washers 8. Make sure that the length of cut
control gearbox is well seated.
5. Tighten all bolts 8 to a torque of 240 Nm.
6- 71020EN - 08 - 2003
6. Line up the shafts of the smooth roll 4, the lower

front feed roll 3 and slide the sleeves 6, 5 in place
and secure in place.
7. Install the intermediate shaft 1.
8. Install and adjust the smooth roll scraper.
7
9. Install the upper feed roll module to the chopper
body.
10. Install the yoke 2.
11. Fill the gearbox with oil.
12. Install all removed guards.
6- 71020EN - 08 - 2003
GEARBOX SHAFTS
1. Alternative drive shaft 4. Selector shaft

2. Transfer shaft 5. Smooth roll drive shaft
3. Upper feed rolls drive shaft 6. Metal detector roll drive shaft
6- 71020EN - 08 - 2003
1. Alternative drive shaft 4. Selector shaft

2. Transfer shaft 5. Smooth roll drive shaft
3. Upper feed rolls drive shaft 6. Metal detector roll drive shaft
6- 71020EN - 08 - 2003
SPECIFICATIONS
Shaft adjustment:
Alternative drive shaft Adjust to 0.5 -- 3 Kg*cm, then remove 0.1 mm
Transfer shaft Adjust to 0.5 -- 3 Kg*cm, then remove 0.1 mm
Upper feed roll drive shaft Adjust to 0 -- 0.2 mm clearance
Selector shaft Adjust to 0.5 -- 3 Kg*cm, then remove 0.1 mm
Smooth roll drive shaft Adjust to 0.1 -- 0.3 mm clearance
Metal detector roll drive shaft Adjust to 0.1 -- 0.3 mm clearance
Alternative drive shaft rpm 1200 -- 3000
Transfer drive shaft rpm 500 -- 1260
Upper feed roll drive shaft rpm 220 -- 540 / 440 -- 1100
Selector shaft rpm 280 -- 700 / 570 -- 1420
Smooth roll drive shaft rpm 130 -- 320 / 260 -- 650
Metal detector drive shaft rpm 70 -- 170 / 140 -- 440
Approx. weight kg
6- 71020EN - 08 - 2003
LENGTH OF CUT CONTROL

GEARBOX -- D./A.
1. Alternative drive shaft 34. Seal

2. Transfer shaft 35. Seal
3. Upper feed rolls drive shaft 36. Circlip
4. Selector shaft 37. Shimpac
5. Smooth roll drive shaft 38. Circlip
6. Metal detector roll drive shaft 39. Bearing
7. 40. Gear
8. 41. Bushing
9. 42. Gear
10. Circlip 43. Bushing
11. Bearing 44. Circlip
12. Gear 45. Bearing
13. Disc 46. Ring
14. Circlip 47. Selector ring
15. Bearing 48. Gear
16. Shimpac 49. Seal
17. Circlip 50. Bearing
18. Seal 51. Gear
19. 52. Ring
22. Gear 55. Seal
23. Circlip 56.
24. Bearing 57.
25. Circlip 58.
28. Seal 61. Gear
29. 62.
30. Bearing 63. Bearing
31. Gear 64. Circlip
32. Bearing 65. Seal
33. Circlip
6- 71020EN - 08 - 2003
10
6- 71020EN - 08 - 2003
1. Alternative drive shaft 34. Seal
2. Transfer shaft 35. Seal
3. Upper feed rolls drive shaft 36. Circlip
4. Selector shaft 37. Shimpac
5. Smooth roll drive shaft 38. Circlip
6. Metal detector roll drive shaft 39. Bearing
7. 40. Gear
8. 41. Bushing
9. 42. Gear
10. Circlip 43. Bushing
12. Gear 45. Bearing
13. Disc 46. Ring
14. Circlip 47. Selector ring
15. Bearing 48. Gear
18. Seal 51. Gear
19. 52. Ring
22. Gear 55. Seal
23. Circlip 56.
24. Bearing 57.
25. Circlip 58.
28. Seal 61. Gear
29. 62.
30. Bearing 63. Bearing
31. Gear 64. Circlip
32. Bearing 65. Seal
33. Circlip
6- 71020EN - 08 - 2003
11
6- 71020EN - 08 - 2003
To assemble the length of cut control gearbox,

proceed as follows:
1. Install the alternative drive shaft and remove it

after the shimming procedure.
2. Install the transfer shaft.
3. Install the upper feed rolls drive shaft.
4. Install the selector shaft.
5. Install the smooth roll drive shaft.
6. Install the metal detector roll drive shaft.
7. Reinstall the alternative drive shaft.
8. Install seals and covers.
1. Alternative drive shaft.
1. Insert the circlip (10).
1
2. Support the extended part of the casting to avoid
damage during the installation of bearings and
the alternative drive shaft (see further).
3. Install the bearing (11) and oil it.
6- 71020EN - 08 - 2003
4. Place the gear (12) on top of the bearing (11).
3
5. Place the disc (13) on top of the gear (12).
4
6. Install the circlip (14) and the bearing inner ring
(15) on the alternative drive shaft (1).
5
7. Install the alternative drive shaft (1) until the
circlip (14) rests against disc (13).
8. Install the bearing outer ring (15).
9. Oil the bearing (15).
6
6- 71020EN - 08 - 2003
10. Install the shimpac (16) and the circlip (17).
7
11. Measure the running torque and adjust the shim
pac (16) until the running torque is 0.5 -- 3.0
kg.cm.
12. Remove 0.1 mm of the shimpac (16).
13. The running torque should now be less then 0.5

kg.cm.
8
14. Remove the support.
9
15. Remove the circlip (17) and the shimpac (16).
16. Remove the alternative drive shaft (1), the disc,

the gear and the bearings.
17. Keep these parts together and put them aside for
later reinstallation.
10
6- 71020EN - 08 - 2003
2. Transfer shaft
1. Install the circlip (20).
2. Insert the bearing (21).
11
3. Insert the gear (22) and place it on top of the
bearing (21).
12
4. Install the circlip (23) and the bearing inner ring
(24) on the transfer shaft (2).
5. Install the transfer shaft (2) into the gearbox.
13
8. Turn over the gearbox.
9. Carry out the shimming procedure in the same

way as with the alternative drive shaft 1.
6- 71020EN - 08 - 2003
3. Upper feed rolls drive shaft

bearing (30).
14
3. Insert the upper feed rolls drive shaft (3).
15
NOTE: Install the upper feed rolls drive shaft (3) with
the threaded end pointing toward the side as shown.
16
4. Install the second bearing (32) and the
circlip (33). (no adjustment).
17
6- 71020EN - 08 - 2003
4. Selector shaft
1. Install the bushing (41) into the smal gear (40) to

a depth D = 0.5 mm from the thrust face as
shown in the picture.
2. Install the bushing (43) into the big gear (42) to

a depth D = 1.5 mm from the thrust face as
shown in the picture.
18
3. Install the circlip (44) onto the selector shaft (4).
19
4. Apply antifriction grease to the selector shaft (4)
(2x) and to the inside of the bushings (43) and
(41).
20
21
6- 71020EN - 08 - 2003
6. Insert the selector shaft (4) through the housing

as far as possible.
NOTE: The selector shaft will block with the circlip

against the casting.
7. Slide the ring (46) over the selector shaft.
22
8. Place the gear (40) and the gear (42).
9. Separate the two gears (40) and (42) to enable

the installation of the selector ring (47) between
them.
10. Place the gear (48).
11. Push the selector shaft (4) through the gear (40),
the selector ring (47), the gear (42) and the gear
(48). Support the selector shaft.
23
12. Install the bearing (39) and the circlip (38).
24
13. Turn the gearbox upside down.
25
6- 71020EN - 08 - 2003
15. Measure the actual running torque A (without

shims installed).
17. Adjust the shim pack until the running torque is

between (A+0.5) and (A+3.0) kg.cm. Then
remove 0.1 mm of the shim pack.
18. The running torque should now be less then

(A+0.5) kg.cm
26
5. Smooth roll drive shaft
27
bearing (50).
28
NOTE: The gear (51) should be with its machined
side against the bearing (50).
29
6- 71020EN - 08 - 2003
3. Install the smooth roll drive shaft (5).
4. Slide the ring (52) over the smooth roll drive shaft
(5).
6. Install bearing outer ring (53).
NOTE: Do not install the complete bearing in one go.
7. Install the circlip (54) (no adjustment).
30
6. Metal detector roll drive shaft
31
2. Install the gear (61).
32
NOTE: The gear (61) should be with its machined
side against the bearing (60).
33
6- 71020EN - 08 - 2003
3. Install the metal detector roll drive shaft (6).
34
NOTE: Do not install the bearing (63) , inner and

outer ring, in one go.
35
6. Install the circlip (64). (no adjustment).
36
6- 71020EN - 08 - 2003
7. Reinstall the alternative drive shaft
1. Reinstall the bearing (11).
37
2. Reinsert the gear (12).
38
3. Reinsert the disc (13).
39
4. Reinstall the alternative drive shaft (1).
40
6- 71020EN - 08 - 2003
5. Reinstall the bearing outer ring (15).
41
6. Reinstall the shim pack (16) (thickness as
established previously).
42
7. Reinstall the circlip (17).
43
6- 71020EN - 08 - 2003
8. Install seals and covers.
1. Install the cover with selector arm.
NOTE: Ensure that the selector is correctly aligned

with the selector ring.
2. Install the covers.
3. Install the seals.
NOTE: The seals should sit [0--1.5 mm] into the

casting.
6- 71020EN - 08 - 2003
Chapter 3 -- Attachments drive gearbox
CONTENT
Attachments drive gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Attachments drive gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transfer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Attachment drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Idler shaft -- Re--installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6- 71020EN - 08 - 2003
ATTACHMENTS DRIVE GEARBOX -- R./I.
Removal
1. Drain the oil from the gearbox.
2. Tilt down or remove the upper feed roll module

from the chopper body.
3. Remove the lower front feed roll from the

chopper body.
4. Remove the smooth roll from the chopper body.
5. Remove the hydrostatic motor from the

Attachment drive gearbox.
6. Remove the bolt and lock nut 1.
7. Push the sleeve 2 onto the intermediate shaft 3.
1
8. Tie the attachment drive gearbox 4 to a suitable
lifting device and support it.
2
9. Remove the bolts and washers 5 and 6.
10. Remove the bushings 7 and 8. Keep parts for

later use.
11. Lift the attachment drive gearbox away from the

chopper body.
3
6- 71020EN - 08 - 2003
Installation
1. Insert the long bushing 8 in the upper hole of the

chopper body frame.
NOTE: The bushing is a tight fit.
2. Lift the attachment drive gearbox in place (Fig.

2).
4
3. Install first the bolt and washer 6 through the
bushing 8 and fix the attachment--drive gearbox
into position. Do not tighten the bolt yet.
4. Install the bushings 7 and the bolts and washers

5. Make sure that the attachment drive gearbox
is well seated.
5. Tighten all bolts 5 and 6 to a torque of 240 Nm.
5
6. Install the smooth roll into the chopper body.
7. Install the lower front feed roll into the chopper

body
8. Connect the intermediate shaft 3 to the

attachment drive gearbox with sleeve 2 and fix in
place bolt, washers and lock nut 1.
9. Install the hydrostatic motor to the attachment

drive gearbox.
6
10. Fill the gearbox with oil.
11. Re install the upper feed roll module to the

chopper body.
6- 71020EN - 08 - 2003
GEARBOX SHAFTS
1. Idler shaft
2. Input shaft
3. Transfer shaft
4. Attachment drive shaft
6- 71020EN - 08 - 2003
SPECIFICATIONS
Shaft adjustment:
Input shaft Adjust to 0.5 -- 2 Kg*cm, then remove 0.1 mm
Idler shaft Adjust to 0.5 -- 2 Kg*cm, then remove 0.1 mm
Transfer shaft Adjust to 0.5 -- 2 Kg*cm
Attachment drive shaft Adjust to 0.5 -- 3.5 Kg*cm
Input shaft rpm 1200 -- 3000
Idler shaft rpm 662 -- 1655
Transfer shaft rpm 505 -- 1263
Attachment drive shaft rpm 300 -- 750
Approx. weight kg
6- 71020EN - 08 - 2003
ATTACHMENTS DRIVE GEARBOX --

D./A.
1. Idler shaft 13. Shimpac

2. Input shaft 14. Idler gear
7. Seal 20. Bearing
8. Seal cap 21. Bearing
12. Circlip 24. Shimpac
6- 71020EN - 08 - 2003
3. Shimpac 35. Transfer gear

4. Attachment drive shaft 40. Bearing
7. Seal 41. Bearing
32. Circlip 44. Shimpac
33. Circlip 45. Attachment drive gear
34. Shimpac
6- 71020EN - 08 - 2003
10
6- 71020EN - 08 - 2003
1. Idler shaft 23. Circlip

2. Input shaft 24. Shimpac
3. Shimpac 30. Bearing
4. Attachment drive shaft 31. Bearing
7. Seal 32. Circlip
8. Seal cap 33. Circlip
10. Bearing 34. Shimpac
11. Bearing 35. Transfer gear
13. Shimpac 41. Bearing
14. Idler gear 42. Circlip
22. Circlip 45. Attachment drive gear
6- 71020EN - 08 - 2003
Assembly
To assemble the attachment drive gearbox, proceed

as follows:
1. Install the idler shaft (1), proceed with the

shimming procedure and then disassemble the
idler shaft.
2. Install the drive shaft (2).
3. Install the transfer shaft (3).
4. Install the attachment drive shaft (4).
5. Re--install the idler shaft (1) with the shimpac

determined in step 1.
6. Install the seals and the covers.
Idler shaft
1. Oil and install the bearing (10) into the casting.
2. Insert the idler gear (14) into the casting and

place it on top of the bearing (10).
11
3. Install the idler shaft (1) with the threaded hole on
the upper side.
6. Adjust the shimpac (13) until the running torque

is 0.5 -- 2.0 kg.cm. Then remove 0.1 mm of the
shimpac. The running torque should be less than
0.5 kg.cm.
7. Remove the idler shaft from the casting.
NOTE: Keep all parts together for later

re--installation.
6- 71020EN - 08 - 2003
Input shaft
9. Install the circlip (22) and the outer ring of bearing

(21) into the casting.
11. Install the inner ring of bearings (20) and (21)

onto the input shaft (2).
12. Install the input shaft (2) with the bearing inner
rings.
12
13. Install the outer ring of bearing (20).
13
15. Adjust the shimpac (24) until the running torque
is 0.5 -- 2.0 kg.cm. Then remove 0.1 mm of the
shimpac. The running torque should be less than
0.5 kg.cm.
14
6- 71020EN - 08 - 2003
Transfer shaft
16. Intall the circlip (32) and the complete bearing

(31).
15
17. Insert the transfer drive gear (35) on top of the
bearing (31).
16
18. Install the inner ring of the bearing (30) on the
transfer shaft (3)
19. Install the transfer shaft (3).
NOTE: Take care the splined shaft end and the

notched shaft end are positioned correctly.
IMPORTANT: Be sure the idler drive gear is inserted

the casting, ortherwise it will not be possible to intall
this gear.
17
22. Hit the transfer shaft on both sides to garantee

that the bearing outer rings fully contact the
circlip (32) and the shimpac (34).
18
6- 71020EN - 08 - 2003
23. Measure the rolling torque. The rolling torque

should be 0.5 -- 2.0 kg.cm.
NOTE: Be sure the idler shaft gear is free from the

tranfer drive gear.
24. If necessary, remove the circlip (33) and adjust

the shimpac (34).
25. Repeat this procedure until an acceptable rolling

torque is achieved.
19
Attachment drive shaft
26. Install the circlip (43) and the bearing (40).
27. Insert the attachment drive gear (45).
28. Install the inner ring of the bearing (41) on the

attachment drive shaft (4).
29. Install the attachment drive shaft (4).
20
NOTE: Be sure the shimpac installed results in an

end play of the attachment drive shaft.
32. Hit the attachment drive shaft on both sides to

garantee that the bearing outer rings fully contact
the circlip (43) and the shimpac (44).
21
33. Measure the rolling torque A on the attachment
drive shaft (4).
34. Remove the circlip (42) and adjust the shimpac

(44).
35. Measure the rolling torque and repeat the

procedure until the rolling torque is
(A + 0.5) -- (A + 3.5) kg.cm.
22
6- 71020EN - 08 - 2003
Idler shaft -- Re--installation
37. Bring the idler gear (14) in the correct place and
re--install the idler drive shaft (1) with the
shimpac determined in the first step.
23
38. Install the sealing rings (7) in the casting and set
them 1 mm inside their housing outer taking care
not to damage its sealing lip (fig. 24 and 25).
24
39. Install the sealing caps (8) in the casting and set
them 1 mm inside its housing outer.
25
40. Apply sealing compound on the casting cover
surface and install the cover (6).
41. Fill the gearbox with oil (refer to the Operator’s

Manual section 4 ”Lubrication and
Maintenance”.
26
6- 71020EN - 08 - 2003
Chapter 4 -- Upper feed rolls drive gearbox
CONTENT
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Upper feed rolls drive gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gearbox shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Upper feed rolls drive gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Upper feed rolls drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front upper feed roll drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rear upper feed roll drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Re--install the upper feed rolls drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Seals and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6- 71020EN - 08 - 2003
SPECIAL TOOLS
Number Description
84452544 Flange to remove the upper feed roll drive gearbox
Special tool 1: 84452544
1
UPPER FEED ROLLS DRIVE GEARBOX
-- R./I.
Removal
NOTE: For the removal of the gearbox you need the

special tool 1, two bolts M12x50, one bolt M10x100
and suitable washers.
1. Drain the oil from the upper feed rolls drive

gearbox.

machine. (Refer to the Section 4 --Lubrication
and maintenance).
3. Remove the spring assemblies for the upper

feed rolls. (Refer to the Section 4 --Lubrication
and maintenance).
4. Remove all the bolts and washers 1 and remove

the PTO shaft 2 from the gearbox. Keep the parts
for later use.
5. Disconnect the grease line 3 from the gearbox 4.
6. Disconnect the electric wire 5 to the sensor 6.
2
6- 71020EN - 08 - 2003
7. Turn the shaft 7 as shown and remove the

special bolt 8.
3
8. Install the special tool 1 as shown.
9. Remove the nut and washer 9 from the special

rod 10.
10. Install a M12 washer and nut at 1 and pull out the
special rod 10.
WARNING
The gearbox is heavy. Support it well before you
remove it from the feed rolls shafts.
Support the feed rolls well before you remove the
gearbox.
4
11. Pull out the gearbox with the special tool 1.
NOTE: Note down how the cut off plate 13 is installed

before removing it from the feed rolls.
5
12. Remove the bolts and washers 11 and remove
the guard 12.
6
6- 71020EN - 08 - 2003
Installation
1. Install the guard 12 with bolts and washers 11

(Fig. 6).
2. Install the cut off plate 13 onto the feed roll shaft
if removed (Fig. 5).
3. Lift the gearbox onto the upper feed roll shafts.

See also (Fig. 5). Make sure the splines fit.
4. Turn the shaft 7 as shown and install the special

bolt 8.
7
5. Pull the gearbox onto the feed roll shafts with the
special bolt 8 and tighten it to a torque of 220 Nm.
6. Install a M12 nut and a 50--55 diameter washer

on a M12 x 100 bolt 14 and install the assembly
onto the gearbox as shown.
NOTE: Adjust the gearbox and feed roll assembly to

be parallel with the bolt and nut assembly 14.
NOTE: Make sure the feed rolls assembly can move

freely up and down in the upper feed rolls frame.
8
7. Install the special rod 10 and tighten in place with
washer and nut 9.
8. Install the sensor 6 if removed and connect the

electric wire 5.
9. Route and install the grease line 3.
10. Install the PTO shaft 2 with bolts and lock

washers 1.
6- 71020EN - 08 - 2003
GEARBOX SHAFTS
1. Upper feed rolls drive shaft

2. Front upper feed roll drive shaft
3. Rear upper feed roll drive shaft
SPECIFICATIONS
Shaft adjustment:
Upper feed rolls drive shaft Adjust to 0.5 -- 3 Kg*cm
Front upper feed roll drive shaft Adjust to 0.5 -- 3 Kg*cm
Rear upper feed roll drive shaft Adjust to 0.5 -- 3 Kg*cm
Upper feed rolls drive shaft rpm 220 -- 540 / 440 -- 1100
Front upper feed roll drive shaft rpm 70 -- 170 / 140 -- 340
Rear upper feed roll drive shaft rpm 120 -- 300 / 240 -- 600
Approx. weight kg
6- 71020EN - 08 - 2003
UPPER FEED ROLLS DRIVE GEARBOX -- D./A.
1. Upper feed rolls drive shaft 24. Shimpac

2. Front upper feed rolls drive shaft 25.
3. Rear upper feed rolls drive shaft 26. Front upper feed rolls gear
4. Seal 27.
5. Seal cap 28.
6. 29.
7. Seal 30. Bearing
8. Casting 31. Bearing
9. 32. Circlip
12. Circlip 35. Ring
13. Circlip 36. Rear upper feed rolls gear
14. Shimpac 37.
15. 38.
16. 39.
17. 40. Seal
18. 41. Disc
19. 42. O--ring
20. Bearing 43. Washer
21. Bearing 44. Lockwasher
22. Circlip 45. Bolt
23.
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
1. Upper feed rolls drive shaft 24. Shimpac
2. Front upper feed rolls drive shaft 25.
3. Rear upper feed rolls drive shaft 26. Front upper feed rolls gear
4. Seal 27.
5. Seal cap 28.
6. 29.
7. Seal 30. Bearing
8. Casting 31. Bearing
9. 32. Circlip
12. Circlip 35. Ring
13. Circlip 36. Rear upper feed rolls gear
14. Shimpac 37.
15. 38.
16. 39.
17. 40. Seal
18. 41. Disc
19. 42. O--ring
20. Bearing 43. Washer
21. Bearing 44. Lockwasher
22. Circlip 45. Bolt
23.
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
Assembly
To assemble the upper feed rolls drive gearbox,

proceed as follows:
1. Install the upper feed rolls drive shaft and

determine the shimpac to install.
2. Remove the upper feed rolls drive shaft.
3. Install the front upper feed rolls drive shaft.
4. Install the rear upper feed rolls drive shaft.
5. Re--install the upper feed rolls drive shaft.
6. Install the seals and the cover.
Upper feed rolls drive shaft
1. Install the bearing outer ring (10), the shimpac

(14) and the circlip (12).
2. Install the bearing inner rings (10) and (11) on the

upper feed rolls drive shaft (1).
4
4. Install the upper feed rolls drive shaft (1).
6- 71020EN - 08 - 2003
6
7. Hit the upper feed rolls drive shaft on both sides

to garantee that the the bearing outer rings fully
contact the circlip (12) and the shimpac (14).
7
8. Measure the rolling torque on the upper feed rolls
drive shaft and adjust the shimpac (14) untill the
rolling torque is 0.5 -- 3 kg.cm.
NOTE: Make sure the upper feed rolls drive shaft is

rotating smoothly every time the shimpac (14) is
adjusted.
9. Remove the upper feed rolls drive shaft (1) from

the casting.
NOTE: Keep all parts together for later

re--installation.
Front upper feed roll drive shaft
10. Install the seal (7).
NOTE: Install the seal (7) with a shaft with the same
diameter as the seal.
6- 71020EN - 08 - 2003
9
13. Insert the front upper feed roll drive gear (26).
10
14. Place the front upper feed roll drive gear (26) on
top of the bearing (20).
11
15. Install the bearing inner ring (21) on the front
upper feed roll drive shaft (2).
NOTE: The bearing inner ring (21) is mounted on the

shortest side of the front upper feed rolls drive
shaft (2).
12
6- 71020EN - 08 - 2003
16. Install the front upper feed roll drive shaft (2).
13
17. Install the bearing outer ring (21) and the
circlip (22).
NOTE: Make sure the front upper feed roll drive shaft
is rotating smoothly.
14
18. Measure the rolling torque A (without shims
installed) on the front upper feed roll drive shaft.
15
19. Remove the circlip (22), install the shimpac (24)
and reinstall the circlip (22).
NOTE: Make sure the front upper feed roll drive shaft
is rotating smoothly.
20. Measure the rolling torque and repeat the

procedure until the rolling torque is (A+0.5) --
(A+3) kg.cm (Preload of 0.5 -- 3 kg.cm).
16
6- 71020EN - 08 - 2003
Rear upper feed roll drive shaft

circlip (33).
NOTE: Do not install the circlip in its groove, just

install it in the opening to avoid the bearing outer ring
to fall out. If the circlip is installed in its groove, it is
not possible to insert the gear (see following steps).
17
24. Insert the ring (35) and place it on top of the

bearing.
18
NOTE: Before to insert the rear upper feed roll drive
gear, be sure the bearing outer ring (10) is installed.
19
25. Insert the rear upper feed roll drive gear (36).
20
6- 71020EN - 08 - 2003
26. Place the gear (36) as shown.
21
27. Install the bearing inner ring (30) on the shortest
side of the rear upper feed roll drive shaft (3).
22
28. Insert the rear upper feed roll drive shaft (3)
through the gear (36) and the ring (35) until it is
against the bearing inner ring (31).
23
29. Turn the gearbox as shown and install the
circlip (33) in its groove.
24
6- 71020EN - 08 - 2003
30. Turn back the gearbox and install the rear upper
feed roll drive shaft completely.

circlip (32).
32. Remove the circlip (33), install the shimpac (34)

and reinstall the circlip (33).
33. Hit the rear upper feed rolls drive shaft on both
sides to guarantee smooth rolling of the rear
upper feed roll drive shaft.
25
34. Measure the rolling torque on the upper feed rolls
drive shaft and adjust the shimpac (34) untill the
rolling torque is 0.5 -- 3 kg.cm.
NOTE: Make sure the rear upper feed roll drive shaft
is rotating smoothly every time the shimpac (34) is
adjusted.
26
Re--install the upper feed rolls drive shaft
35. Install the bearing inner ring (10) and re--install

the upper feed rolls drive shaft (1).
27
6- 71020EN - 08 - 2003
Seals and cover
36. Install the three seals (4) and the seal (40).
37. Install the seal cap (5).
38. Install the disc (41).
40. Apply loctite to the bolts (45).
41. Install the washer (43), the lockwasher (44) and

the bolts (45).
42. Tighten the bolts (45) to a torque of 55 -- 64 Nm.
43. Lock the bolts with the lockwasher (44).
44. Install the cover.
6- 71020EN - 08 - 2003
6- 71020EN - 08 - 2003
SECTION 64 -- CHOPPING -- CHAPTER 1 1
Chapter 1 -- Cutterhead
CONTENT
Splitting of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rotor and bearings -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shearbar -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shearbar support -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6- 71020EN -- 08 -- 2003
2 SECTION 64 - CHOPPING -- CHAPTER 1
SPLITTING OF COMPONENTS
Refer to the Operator’s Manual, Section 4 --

Lubrication and Maintenance.
ROTOR AND BEARINGS -- R./I.
Removal
1. Remove the chopper body from the machine.
2. Swing down or remove the upper feed roll

assembly.
3. Remove the sharpener stone guard on the

right--hand side of the chopper body.
4. Remove the cutterhead gearbox as described in

chapter 2 of this section. 1
NOTE: If a crop processor is installed it should also

be removed (Refer to the Operator’s Manual Section
4 -- Lubrication and Maintenance).
5. Remove bolt and washer 1 and remove the

pulley 2 together with the overrun clutch.
6. Remove spacer bushing 3, shims 4 and the lip

seal 5.
7. Store these items together with the bolt and

washer 1 and pulley 2.
2
8. On a chopper body without a crop processor,
remove bolt 1, washer 2, spacer washer 3 and
the spacer tube 4 with a circlip, shims and a seal.
Store these for later use.
3
6- 71020EN -- 08 -- 2003
9. Remove shaft 1.
NOTE: The shaft 1 has conical splines and may be

very hard to remove.
4
10. Support the triangular frame 3.
11. Remove electrical wires and plastic straps from

the triangular frame 3 and the top part 4.
12. Remove the bolts 2 (Fig. 4) and lift away the

triangular frame.
5
13. Remove the front plate 1 from the chopper body.
6
14. Remove the bolts 5 holding the chopper body top
assembly 4.
15. Remove the sharpener stone cover 6.
7
6- 71020EN -- 08 -- 2003
16. Remove the nuts and lock washers 7 on both

sides see also (Fig. 8), remove the bearing
housings 8 and 9.
NOTE: Note the location and the quantity of shims

installed between the bearing housings 8 and 9 and
the chopper body frame at 10 on both sides of the
machine.
8
17. Lift away the cutterhead assembly 11.
9
18. Remove the bolts and lock washers 12 and the
bearing protection 13.
19. On both sides of the cutterhead, replace the ring

14 and the v--seal 15 inside the bearing
protection 13. See also (Fig. 9).
10
Assembly
1. Press bearing cups 16 into both ends of the

cutterhead assembly.
2. Press bearing cones 17 in bearing housings 8
and 9.
3. Install the cutterhead assembly 11 into the
chopper body. (Fig. 10).
4. Lubricate seals at 18 before installing the bearing
housings 8 and 9.
5. Install the bearing housings loosely in the
chopper body.
11
6- 71020EN -- 08 -- 2003
6. Install the top of chopper body 4 with bolts,

washers and nuts 5.
7. Install the sharpener stone cover 6.
12
8. Install the front plate 1.
13
9. Install the shaft 1 as shown.
14
10. Install the measuring gauge as shown in Figures
16 and 17.
11. The run--out should be measured on the outer

edge of the bearing housing at 1, on both sides
of the chopper body. The allowed run--out is +0.2
mm (0.008”).
15
6- 71020EN -- 08 -- 2003
12. Adjust the bearing pre load to between 4.5 and

6.75 Nm (3.3 -- 5 lbf.ft) by adding or removing the
same quantity of shims at 10 (Fig. 8 ). Tighten the
bearing housing bolts to a torque of 240 Nm (175
lbf.ft).
13. Before installing the cutterhead gearbox, check

the axial run--out at the inner end of the splines
of shaft 1 (Fig. 14 ). The run out must not exceed
0.2 mm (0.0083”). To reduce the run--out, turn the
shaft splines 40° at a time until the run--out is
acceptable.
16
14. Install the tube 4 with the longer end from the
circlip groove towards the chopper body.
15. Lubricate and install the lip seal 22 with the lip
towards the chopper body, install the shims 16
and circlip 11.
16. Press the assembly towards the chopper body

and check that the seal fits as intended. If
adjustment is needed then remove the required
quantity of shims 16.
17
17. Install at the end of the tube 4, spacer washer
3,washer 2 and bolt 1. Tighten the bolt 1 to a
torque of 500 Nm (370 lbf.ft). The thread must be
clean and dry.
NOTE: Check the bolt torque after the first week of

operation, then every 300 hrs of operation (at engine
oil replacement).
18
18. On a chopper body with a crop processor,
lubricate and install lip seal 5, shims 4 and tube 3.
19
6- 71020EN -- 08 -- 2003
19. Install the pulley 2 and tighten in place with

washer and bolt 1. Tighten the bolt 1 to a torque
of 500 Nm (370 lbf.ft). The thread must be dry
and clean.
NOTE: Check the bolt torque after the first week of

operation, then every 300 hrs of operation (at engine
oil replacement).
20
20. Install the cutterhead gearbox (Refer to the next
paragraph).
21. If necessary, readjust the cutterhead knives

(Refer to the operators manual Section 4 --
Lubrication and Maintenance).
22. Swing up the upper feed roll assembly.
23. Install the crop processor if it was removed.
24. Install the chopper body on the machine.
25. Sharpen the knives.
26. Adjust the shearbar.
IMPORTANT: Ensure all guards and covers are

reinstalled and all hardware is securely tightened.
6- 71020EN -- 08 -- 2003
SHEARBAR -- R./I.
Refer to the Operator’s Manual Section 4 --

Lubrication and maintenance.
SHEARBAR SUPPORT -- R./I.
Removal
1. Swing down the upper feed roll assembly.
2. Remove the scraper from the machine. (Refer to

the operator’s manual Section 4 -- Lubrication
and maintenance).
3. Remove the shearbar from the machine. (Refer

to the operator’s manual Section 4 -- Lubrication
and maintenance).
21
4. Remove the bolts 1 and remove the pin 2 and the
bushing 3 from both sides of the chopper body.
5. On both sides of the chopper body, remove bolts

and washers 1 and 2.
6. On both sides of the chopper body, remove nut

and lock washer 3 and the bolt 4.
7. On both sides of the chopper body, remove the

support 5 and the spacer 6.
NOTE: Keep the parts for later use.
22
8. From under the chopper body, remove the lock
washers and bolts 1.
23
6- 71020EN -- 08 -- 2003
WARNING
Block the rotation of the cutterhead before continuing
the work. You have to put your hands inside the
cutterhead to hold or to remove parts.
9. Support the wear plate 1 inside the cutterhead

and remove the bolts and flat washers 2.
NOTE: You may have to remove one knife on a

cutterhead equipped with 12 knives.
10. Remove the shearbar support 3 and the wear

plate 1. 24
Installation
1. Install the wear plate 1 and the shearbar support

3 and secure in place with bolts and washers 2
(Fig. 24). Do not tighten the bolts 2 completely.
2. Install the bolts and lock washers 1 (Fig. 23). Do

not tighten the bolts completely.
3. On both sides of the chopper body, install the

spacer 6, the support 5and secure in place with
bolt 4, nut and washer 3, bolt and washer 2 and
bolt and washer 1. Do not tighten completely.
4. On both sides of the chopper body tighten the 25

bolts in the following order: Bolts 1 (Fig. 23).
Bolts 2 (Fig. 24). Bolts 1, 2 and nut 3.
5. On both sides of the chopper body, install the

bushing 3, the pin 2 with bolts 1. Tighten the bolts
1 to a torque of 140 Nm.
6. Install the shearbar onto the chopper body (Refer

to the operator’s manual Section 4 -- Lubrication
and Maintenance).
7. Install the scraper (Refer to the operator’s

manual Section 4 -- Lubrication and
Maintenance).
8. Install the knife if removed.
26
9. Sharpen the knives and adjust the shearbar
(Refer to the operators manual Section 3 -- field
and site operation).
10. Swing up the upper feed roll assembly.
6- 71020EN -- 08 -- 2003
6- 71020EN -- 08 -- 2003
Chapter 2 -- Cutterhead gearbox
CONTENT
Cutterhead gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cutterhead gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil cooler -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gearbox -- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gearbox -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6- 71020EN -- 08 -- 2003
CUTTERHEAD GEARBOX -- R./I.
Removal
1. Remove the chopper body from the machine.
2. Swing down the upper feed roll assembly.
3. Remove the guards on the right--hand side of the

chopper body.
4. Remove the supports 1 and 2 from the gearbox.
5. Loosen or remove plastic straps and wires from 1

the cutterhead gearbox.
6. Remove the temperature sensor from the

gearbox and at the same time, drain the oil from
the gearbox.
7. Remove the cover 3.
8. Bend open the locking washer 4 and remove the

nut 5, and the nut 8 behind the washer 4.
2
9. Free the gearbox from the rubber clamping at 7.
Mark the shaft to gearbox position before
removing the gearbox. This is important to avoid
vibrations when reinstalling the gearbox.
10. Install two M 12 x 100 bolts in holes 6 and press

the gearbox from the conical splines of the shaft.
11. Do not loose the shim or the V--seal installed on

the cutterhead shaft.
6- 71020EN -- 08 -- 2003
Installation
1. Install a V--seal and a shim onto the cutterhead

shaft.
2. Lift the cutterhead gearbox onto the shaft and

push it onto the splines.
3. Install the nut 8 (Fig. 2) and pull the gearbox in

place. Tighten the nut to a torque of 500 Nm.
4. Install the locking washer 4 and the nut 5. Tighten

the nut 5 and lock the assembly in place with
washer 4. (Fig. 2).
5. Lock the gearbox in position by reinstalling the

rubber clamping at 7 (Fig. 3).
6. Install the cover 3 (Fig. 2).
7. Install the temperature sensor, the supports 2

and 3.
8. Tie up the loose wires and hoses with plastic

straps.
9. Swing up the upper feed roll assembly and install

all guards.
10. Install the chopper body on the machine.
11. Fill the cutterhead gearbox with oil.
6- 71020EN -- 08 -- 2003
CUTTERHEAD GEARBOX -- D./A.
6- 71020EN -- 08 -- 2003
5
1. Identification plate 12. Shimpac 23. Bolt
2. Shimpac 13. Shimpac 24. Bolt
3. Shimpac 14. Plate 25. Drain plug
4. Casting 15. Input shaft with pinion 26. Lip seal
5. Bearing housing 16. Bracket 27. Lip seal
6. Bearing housing 17. Bearing 28. Oil cooler
7. Cover 18. Bearing 29. O--ring
8. Output shaft 19. Bearing 30. O--ring
9. Special nut 20. Bearing 31. O--ring
10. Tube 21. Bolt 32. Dowel pin
11. Oil level indicator 22. Bolt 33. Bolt
6- 71020EN -- 08 -- 2003
6- 71020EN -- 08 -- 2003

Oil cooler -- D./A.
The oil cooler can be pulled out of the gearbox NOTE: The two O-rings (29) and (31) are not
housing. identical.
1. Remove the bolts (21) and the plate (14). 3. To re--install the oil cooler, apply liquid sealant in
the O-ring grooves before installing the O-rings
2. Carefully pull out the oil cooler (28). and push in the cooler.
6- 71020EN -- 08 -- 2003
Gearbox -- Disassembly
Input shaft Output shaft
1. Remove the bolts (22). 1. Remove the bolts (24), the bearing housing (6)
and the shimpac (2).
2. Remove the bearing housing (5) and the input
shaft (15). NOTE: Mark the position of bearing housing (6) in the
gearbox casting before removing it.
NOTE: Mark the position of the bearing housing (5)
in the gearbox casting before removing it. NOTE: A liquid sealant has been used at assembly
of the bearing housing (6).
NOTE: A liquid sealant has been used at assembly
of the bearing housing (5). 2. Remove the lip seal (27) from the bearing
housing (6).
3. Remove the bearings (18) and (19) from the input
shaft (15). Remove the shimpac (3). NOTE: It is not possible to remove the lip seal (27)
without damaging it.
4. Remove the lip seal (26), the bearing cup (18)
and the shimpac (13) from the bearing housing NOTE: Be extremely careful not to damage the oil
(5). cooler if it has been left inside the gearbox when
removing the output shaft assembly.
5. Remove the bearing cup (19) from the gearbox
casting.
3. Mark the position of the bracket (16) and the
cover (7).
4. Remove the bolts (24), the bracket (16) and the

cover (7).
5. Remove the lip seal (27), the bearing cup (20)

and the shimpac (12) from the cover (7).
6. Take out the output shaft (8) together with the

gear (15). Take care not to damage the oil cooler.
NOTE: The bearing (17) may interfere with the input

shaft support inside the gearbox.
7. Remove the bearings (17) and (20) from the

output shaft (8).
NOTE: Replace all the bearings if the other gearbox

components are being replaced.
8. Remove the bolts (23) and the bevel gear (15)

from the output shaft (8).
NOTE: The input shaft (15) and the bevel gear (15)
are only available as a matched set.
6- 71020EN -- 08 -- 2003

6- 71020EN -- 08 -- 2003
Gearbox -- Assembly
Input shaft NOTE: The seal (27) should not be installed.
1. Install the shimpac (3) of 1.3mm and the bearing 5. Install the output shaft assembly (8) into the
((19). On the other side, install the bearing (18). gearbox housing. Install the covers (6) and (7).
2. Install the bearing cup (19) in the casting (4). NOTE: Do not damage the oil cooler, if installed.
3. Install the shimpac (13) of 1.4 mm and the

6. Check the rolling torque. It should be 4 -- 12
bearing cup (18) in the bearing housing (5).
kg*cm. If not in range, remove or add shims at
(2).
4. Install the preassembled input shaft (15) in the
gearbox housing and install bearing housing (5).
7. Re--install the input shaft (15).
5. Check the rolling torque. It should be 4 --
12 Kg*cm. If not in range, remove or add shims Backlash
at (13).
1. Measure the backlash on the crown (15). On a
6. Remove the input shaft (15). radial distance of 140 mm, the backlash should
be 0.20 -- 0.28 mm.
NOTE: Keep all parts together and put them aside for
later re--installation. 2. If not in range, adjust the backlash by only
translating the output shaft. Remove (add) shims
Output shaft at (2) and add (remove) shims at (12).
NOTE: The sum of the shimpac installed at (2) and

1. If the gear (15) was replaced, install the new gear
(12) should not change. The preload on the output
on the output shaft (8).
shaft must remain.
NOTE: Make sure the gear is properly seated and
install the bolts (23). 3. Remove the cover (6), install the lip seal (27) and
reinstall the cover.
2. Install the shimpac (12) of 0.9 mm and the
4. Install the seals at (27) and (26).
bearing cup (20) into the bearing housing (7).
5. Install the oil cooler.
NOTE: The seal (27) should not be installed.
6. Reinstall the gearbox on the chopper body.
3. Install the bearing (20) and (17) onto the output
shaft (8). 7. Fill up the gearbox with oil (refer to the Operator’s
Manual).
4. Install the shimpac (2) of 1.6 mm and the bearing
cup (17) into the bearing housing (6).
6- 71020EN -- 08 -- 2003
SECTION 70 -- EJECTION 1
SECTION 70 -- EJECTION
Chapter 1 -- Blower gearbox
CONTENT
Inspection between cutterhead and blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Blower -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Blower gearbox -- R./I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Blower gearbox -- D./A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjusting the shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6- 71020EN - 08 - 2003
2 SECTION 70 - EJECTION
INSPECTION BETWEEN CUTTERHEAD

AND BLOWER

BLOWER -- R./I.

BLOWER GEARBOX -- R./I.

6- 71020EN - 08 - 2003
BLOWER GEARBOX -- D./A.
Disassembly
1. Remove bolts GG and cover EE.
2. Remove bolts M and lift out shaft K and bearing

housing L.
3. Remove shaft K from bearing housing L.
4. Remove seal J, circlip H, shims G and bearing

cup F from the bearing housing L.
NOTE: Measure the thickness of shim pack G and

note it down.
5. Remove bearing E from shaft K.
6. Remove bearing C from shaft K and shims D.
NOTE: Do not damage the shims D. Keep the shims

for later use. Measure and note down the thickness
of shimpack D.
7. If necessary, remove bearing cup B from

gearbox housing CC.
8. Remove bolts AA, cover T and shims Q from the

gearbox housing CC. Keep the shims for later
use.
9. Remove cotter pin V, castle nut W and spacer

washer BB.
10. Reinstall castle nut W and drive out shaft LL, or

use two M12 x 70 bolts and pull out shaft LL.
31081
11. Carefully remove gear DD, shims FF, spacer HH 1

and bearing A and S. If necessary, remove
bearing cup JJ and S from the gearbox housing
CC. Measure the thicknes of shimpack FF and
note it down and keep the shims for later use.
NOTE: Do not damage seal KK. If the seal has to be

removed, it will be damaged and must be replaced.
6- 71020EN - 08 - 2003
Assembly
Input shaft
1. Install bearing E onto shaft K.
2. Install the same quantity of shims at D as you

removed during disassembly. If you need to
restart shimming from scratch then install a 1.00
mm (0.04”) shim pack.
NOTE: No shimming codes are provided.

3. Install bearing C onto shaft K.
4. Install bearing cup B into the gearbox housing

CC.
5. Install the preassembled shaft K and bearings C

and E into the gearbox housing CC.
6. Install bearing housing L with bolts M.
7. Install bearing cup F into housing L and press it

as far down as possible.
8. Install as many shims as possible between the

bearing cup F and the circlip cavity H. Install
circlip H.
31082
9. The rotating torque on shaft K should be 5 to 30 2

Nm (3.6 -- 22 lbf.ft) without oil seal J.
Output shaft
10. Check the condition of seal KK and replace, if

damaged. Lubricate the seal cavity.
11. Install bearing cup JJ if it was removed.
12. Carefully introduce shaft LL into the gearbox

housing CC.
13. While installing shaft LL, install simultaneously

bearing A, spacer HH, shims FF, gear DD. Drive
or press them in place.
14. Install the same quantity of shims at FF as you

removed during disassembly. If you need to
restart shimming from scratch then install a 1.50
mm (0.06”) shim pack.
NOTE: No shimming codes are provided.

Install gear DD on the splines.
6- 71020EN - 08 - 2003
15. Install bearing S onto shaft LL and drive it fully in,

install spacer washer BB and castle nut W onto
shaft LL.
16. Tighten up the assembly and install cotter pin V.
17. Install bearing cup R into the bearing housing

and push it as far down as you can get it.
18. Measure the distance Y from the upper end of the

bearing to the surface of the casting CC, and
note down the value (Fig. 4).
19. Measure the distance Z on the cover T (Fig. 4).
20. The quantity of shims needed at Q can be

calculated with the following formula:
Y -- Z + 0.25 = shim pack in mm.
Y -- Z + 0.01 = shim pack in Inch.
21. The quantity of shims needed at Q (Fig. 3) Install

bearing cap T with with the calculated shim pack
at Q ensuring an axial play of 0.01 -- 0.05 mm
(0.0004” -- 0.002”) for shaft LL.
22. Recheck the axial play and readjust, if

necessary.
31082
Adjusting the shimming
23. Block gear DD and measure the backlash on the

splines of shaft K. The backlash should be 0.1 to
0.2 mm (0.004” -- 0.008”).
24. If the backlash need to be adjusted it should be

done by removing shims at FF (reduces the
backlash) or by adding shims at FF (increases
the backlash).
6- 71020EN - 08 - 2003
25. When the backlash is within the permissible

tolerance then check the tooth flank contact
area.
26. The tooth contact area should be as shown.
27. If not then adjust by removing or adding shims

at D.
28. When the shimming is correct then install oilseal

J and cover EE. Tighten bolts GG to 26 Nm (19
lbf.ft), bolts AA to 52 Nm (38 lbf.ft) and bolts M to
26 Nm (19 lbf.ft). 31084
6- 71020EN - 08 - 2003

CASE IH Forage Harvester CHX320, CHX420, CHX520 and CHX620 Service Manual

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Forage Harvester

CHX320, CHX420, CHX520

COPYRIGHT BY CNH BELGIUM N.V.

All rights reserved. No part of the text or illustrations of

Section Description Page

Chapter 2 -- IVECO Engine -- F3A

Chapter 3 -- IVECO Engine F3B -- General

Chapter 4 -- IVECO Engine F3B

Chapter 5 -- CATERPILLAR Engine

SECTION 25 - FRONT MECHANICAL DRIVE

Chapter 1 -- Final drives CHX320

Chapter 2 -- Final drives CHX420--520--620

SECTION 29 -- HYDROSTATIC SYSTEM

Hydrostatic circuit and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 33 -- BRAKES AND CONTROL

SECTION 35 -- HYDRAULIC SYSTEM

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 2 -- Work hydraulics -- Attachment height control

SECTION 35 -- HYDRAULIC SYSTEM

SECTION 35 -- HYDRAULIC SYSTEM

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 5 -- Low pressure hydraulics

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 6 -- High--flow hydraulics

SECTION 50 -- CAB CLIMATE CONTROL

Correct use of the airconditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 55 -- ELECTRICAL SYSTEM

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 2 -- Wiring Diagrams CHX Europe

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 3 -- Wiring Diagrams CHX NA

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 4 -- Can network basics

SECTION 55 -- ELECTRICAL SYSTEM

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 6 -- Software update

SECTION 55 -- ELECTRICAL SYSTEM

SECTION 60 -- PRODUCT FEEDING

Chapter 1 -- Feed rolls

SECTION 60 -- PRODUCT FEEDING

Chapter 2 -- Length of Control gearbox

SECTION 60 -- PRODUCT FEEDING

Chapter 3 -- Attachments drive gearbox

SECTION 60 -- PRODUCT FEEDING

Chapter 4 -- Upper feed rolls drive gearbox

Chapter 2 -- Cutterhead gearbox

Chapter 1 -- Blower gearbox

Section Description Page

No reproduction, though partial of text and illustrations allowed

GENERAL INSTRUCTIONS O--ring seals

Apply one of the following sealing compounds on the

-- position the sealing lip facing the fluid; with

-- to prevent damaging the seal lip on the shaft,

Protecting the electronic / electrical systems

To avoid damage to the electronic/electrical

1. Never make or break any of the charging circuit

2. Never short any of the charging components to

3. Always disconnect the ground cable from the

• Position the welder ground clamp as close to

• If welding in close proximity to a computer