Agricultural Machines – Service Training
CROSS-FLOW CF 80
1
General Issues
2
Engine
3
Fuel System
4
Electrical System
5
Steering and Machine Frame
6
Ground Drive
7
Brakes
8
Hydraulics
9A Header and Feeder 9B Threshing Unit 9C Cleaning Unit 9D Elevators and Belt Drives 9E Grain Tank 9F
Chaff-Cuttern and Chaff Distributer
9G Cab 10
Accesory Equipment
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 1 General Issues
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
1 GENERAL ISSUES Table of Contents Page Functional Elements
1–3
Equipment and Accessory Equipment
1–6
Dimensions
1–8
Documentation and Accessories
1 – 10
Delivery Inspection
1 – 11
1st Check
1 – 17
Winterizing
1 – 18
Preparation for the New Season
1 – 20
Starting Process
1 – 21
Adjustment Table
1 – 22
Basic Rules of Threshing Unit Adjustment
1 – 24
Adjusting the Threshing Unit
1 – 25
Loss Determination
1 – 30
Lubrication, Filters and Fluids
1 – 40
Overview of the Maintenance Parts
1 – 43
Lubrication Schedule
1 – 44
Filters
1 – 56
Fluids
1 – 57
Centralized Lubrication
1 – 58
Dimensions when Ready for Transport
1 – 59
Technical Data
1 – 61
Cab Filters
1 – 63
Cooling Box
1 – 65
Handling by Crane
1 – 66
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1-1
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Cross-Flow CF 80
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1-2
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Functional Elements The combine harvester is outstandingly suited as a self-propelled combine harvester for harvesting cereals and seeds ("usage as intended"). It distinguishes itself by a high level of work comfort, enormous performance capacity and extraordinary reliability. It has proven itself many times over in practice under the most difficult conditions. It effortlessly handles even moist grain, crops with undergrowth, lodged crops and locations on a slope, for example. Headers of various widths are available to choose from. The dismantling of the header for road transport only requires short takedown times. A special trailer serves in the transport of the header.
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Reel Dividing device Cutter bar Auger Sloped belt conveyor Stone trap Threshing drum Concave Guide drum Separating drum Separating concave Straw drum Hillside leveling auger Auger casing with grain and tailing augers Grain elevator Tailings elevator Unloader auger Cross grain auger Discharging auger, grain tank Grain pan Axial fan Grain return pan Grain pan rake Grain tank Ear sieve Upper sieve, 2nd sieve level Cascade sieve, 1st sieve level Lower sieve, 3rd sieve level 6-hurdle straw-walker Trap sheet
TRAINING CENTER NEUSTADT
1-3
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Functional Elements and their Method of Operation The Header Dividing devices are attached to both side walls of the header. The reel guides the threshed crops to the auger, which has a multiple-finger auger starting at 6.6 m. The knife cuts the crop with the heads attached. Guide plates, as an option, increase the flow of goods when there are crops with short stalks. The auger brings the crops to the center of the trough after the cutting. Forced-control prongs take over the transport of the threshed crops to the sloped belt conveyor there at the center portion of the auger; the sloped belt conveyor delivers it to the threshing drum. The header can be shut off, independently of the threshing unit, with a quick stop key. The header is available in two different designs of the field tracker. In the case of Design P (electrical - mechanical), the header is guided with adjustable slip heels. The pan pressure of the header is set by means of two adjustable pre-loaded springs. It tracks cross-wise and lengthwise to the direction of the work. An automatic system takes over the readjustment of the shaft if an end position of the longitudinal tracking is reached. An automatic cutting-height control is available for lodged grain. In the case of Design Q (electrical - hydraulic), the ground profile is sampled by means of 4 probe skids and a pressure sensor in the hydraulic line of the shaft. An electronic subassembly then controls the guidance of the header in a cross-wise direction and the readjustment of the shaft. Many setting variations are possible because of the electronic control unit (see Chapter 4). Threshing Unit The threshing drum threshes out the grain in collaboration with the concaves. You can quickly adapt the rotary speed of the threshing drum to the respective threshing conditions in a continuous fashion by means of an electrical adjustment from the driver's seat. A threshing drum step-down gear is available as an option. An awner sheet removes the awns of the grain if necessary. It is attached so as to be able to swivel below the inlet on the threshing basket and can be externally adjusted. The stone trap in front of the threshing equipment prevents damage to the concaves and the threshing drum. It can be emptied from the outside by means of a lever. After leaving the concaves, the residual grain-straw mixture goes into the separating equipment. It can be adjusted to 3 levels of intensity. The mixture is pre-separated there in a 2nd phase before it is conveyed to the 6-hurdle straw walker in a loosened condition. The trap sheet prevents the spraying of the grain in the direction of the end of the straw walker, brought about by the threshing action, and consequently brings about a reduction in the grain loss. The 6-hurdle straw walker provides for intensive separation of the residual grain contained in the straw mat. 3 straw walker covers are available to choose from for the most diverse usage conditions. The straw goes out of the machine because of the straw walker movement; the shaken-out grain-chaff mixture goes from the straw walker pan to the grain pan.
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Cleaning Unit The grain-chaff mixture that is separated from the threshing unit and separating basket and that is shaken out by the straw walker falls onto the grain pan. The 6 elements can be taken out towards the front for better cleaning. Grain and chaff or short straw separate out because of the oscillations of the grain pan. These components get to the cascade sieve through the 1st drop stage and to the upper sieve with a connecting ear sieve for preliminary filtering through the 2nd drop stage. From there, the pre-filtered material falls through the 3rd drop stage onto the lower sieve lying below for the main cleaning. The distributing auger located at the end of the grain pan evenly distributes the crops, which are oriented down the slope in the contour line, over the cascade sieve. The grain that has been cleaned falls through the lower sieve onto the grain return pan and slides on it into the grain auger. A flap sieve is available as a standard feature; various perforated sieves can be used as an option. From the grain auger, the grain goes through the grain elevator and the cross grain auger into the grain tank. Stems that have not yet been threshed out, or incompletely threshed out, are separated out at an ear sieve that can be separately adjusted. They fall to the tailing return pan, which delivers them to the tailing auger. From there, they get through the tailings elevator to the tailing auger and back to the threshing drum. The axial fan guides the air flow that is necessary for the cleaning process into the three drop stages between the grain pan, cascade sieve, upper sieve and lower sieve. The light chaff and straw parts are blown out of the machine in this way. The air flow can be adapted to the harvesting conditions with an adjustable guide blade. Grain Tank The grain tank is emptied through the closed unloader system, which is engaged and disengaged from the driver's stand. It can be emptied in any arbitrary position of the unloader pipe, except in the transport position. The swiveling into the highest operating position (90°) and into the transport position can be controlled by an automatic system. The tank emptying speed can be correspondingly adjusted to the harvesting conditions in the hopper with 2 plates having variable settings, which are also mounted at 4 different heights.
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Equipment and Accessory Equipment A comprehensive program of equipment and accessory equipment is available for all of the conditions of grain harvesting, as well as for the threshing of oil seeds and legumes, and in the harvesting of corn: Headers with an operating width of 6.0m, 6.6m and 7.8m are available. 1 Rape attachment for headers KPAB chaff cutter with mech. chaff shield Sunflower equipment for headers KPAB chaff cutter with elec. chaff shield 2 Header vehicle KPAB corn equipment 3 Individual wheel brake Set of chopping cutters 5 mm (corn) 5 Cereal threshing basket, 7.5 mm; 9.7 mm KPAP chaff distributor (fan) and 12.5 mm Heuling chaff distributor (plate) 6 Corn equipment Rape separator, right 7 Set for legumes Unloader auger 5225 mm 8 Straw chopper Unloader auger 4575 mm 9 Hillside ridges Drum rod 10 Special sieve for harvesting special cultures Nut wrench (Diameter in mm: 2.5; 3.0; 4.5; 12.0; Tire equipment, see page 1 - 8 16.0; 20.0) Windrower Double-nose sieve, corn Test equipment Double-nose sieve, corn-cob mix Flap sieve 1-5/8 11 Clover huller pan 12 Divider tips, foldable 13 Dividing device, tracking 14 Grain lifter Centralized lubrication with lubrication strip Centralized lubrication with a lubricator nipple Centralize lubrication with elec. pump Threshing drum step-down gear Corn picker
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Dimensions when Ready for Transport
1 2 3 4 5
6
7 8 9
Engine system Trailer hitch, perm. support load 250 kp Wheel chocks, left and right on the basic machine 2 batteries, 12V Tires 650/75R32 (24.5R32 167 A8) Disk Wheel DW21x32 G-60 Or Tires 800/65R32 (30.5LR32 167A8) Disk Wheel DW 27x32 G-150 Tires 14.9780-24 Disk Wheel W 113x24 ET 0 Or Tires 480/70R24 138A8 Disk Wheel W13x24 ET50 Rearview mirror 10 Tires 185-R 14 8PR, disk wheel K14 H 004 Nameplate 11 Wheel chock, header Drawbar eye 12 Product identification number (machine number)
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Dimensions A, C and R for various header widths Chopping width
6.00 m
6.60 m
7.80 m
A
Overall length with header vehicle
17.720 m
17.950 m
19.265 m
C
Overall length of the header vehicle
10.950 m
11.180 m
12.500 m
R
Axle spacing of the header vehicle
5.740 m
5.740 m
6.450 m
Tire Equipment 3920
3000
A B
Track width A Width B
650/75R32 2775 3390
Track width C Width D
460/70R24 2920 3385
C D Drive Axle 680/85R32 2775 3460 Steering Axle 480/70R24 2920 3405
710/75R34 2835 3575
800/65R32 2895 3720
All dimensions are in mm
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1-8
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
The Following Documentation and Accessories are Included with the CF 80 Combine Harvester and the Header (As of 10/2000): OK
Not OK
a) Declaration of conformity
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b) Operating permit
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c) Expert report (according to §70 of the STVZO exception authorization when the combine harvester has excess width due to wide tires)
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d) Operating instructions, combine harvester
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e) Catalog of replacement parts, combine harvester
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f) Catalog of replacement parts, header
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g) Catalog of replacement parts / operating instructions KPAB chopper Catalog of replacement parts / operating instructions KPAB chaff distributor Catalog of replacement parts / operating instructions Heuling chaff distributor h) Documentation, radio h) Accessories, combine harvester (see packing list) Key for cab Key for the tool box Radio with operating element Antenna Cooling box 2 pieces, underlay blocks Tool box with tools Fire extinguisher Drum rod Flap sieve adjustment lever Nut wrench Adjustment gauge (plastic wedge for sieve adjustment) Replacement lamp assortment Contained in the header 1 Replacement blade Divider tip, foldable / outer divider, left Divider tip, foldable / outer divider, right i) Header accessories 1 set, grain lifter – Hdr. 6.00 m 19 pieces 6.60 m 21 pieces 7.80 m 25 pieces 4 pieces, rocker shovels [10/2000]
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1-9
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Delivery Check Inspection before Delivery to Check the Traffic and Operational Safety. The following testing, adjustment and inspection work has to be carried out by you before the combine harvester and header are delivered. The work time required for the delivery inspection does not fall under our warranty conditions. The actual condition that is determined in each case is to be marked in the OK / Not □ OK column with an X. When defects are noted ( - Not OK -), the corresponding explanations are to be added to the form. Corrections have to be carried out, if necessary, before delivery to the customer. L = Left R = Right OK Not OK 1. Check engine oil level ► Full marking on the oil dipstick
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2. Check cooling fluid level ► Lower edge, filling level pipe
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3. Check hydraulic oil level ► Maximum oil level with a lowered sloped conveyor
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4. Check signal and illumination equipment ► Driving headlights, brake light, flasher, work illumination, warning signal normal and reverse movement, flashing beacon,
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5. Steering ► From the stop limit on the left to the right 3 + 0.5 revolutions
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8. Function of the electrical control equipment, ► Acoustic warning equipment ► Loading control lamp, cooling water temperature ► Engine oil pressure, hand brake, flasher
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9. Inspection of the on-board computer and selection of the language
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6. Check foot brake ► Brake fluid level up to the sieve of the brake fluid container and tightness of the brake lines ► Function of the individual wheel brake ► Even skid marks on the left and right when there is a braking test 7.
Check hand brake ► Standstill of the CF 80 when the hand brake lever is pulled
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
10. Set header width in the on-board computer (see training documents, Chapter 4)
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11. Function of the hydrostatic drive ► Zeroing of the throttle and achieving the maximum ► Driving speed of 20 km/h in 3rd gear
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12. Function of engine shutoff / engine stop ► Via the ignition lock □ □ ► Via the fuel cut off lever □ □ 13. Drive wheels - tightening torque of the wheel nuts and air pressure in the tires 650 / 75 – R 32 800 / 65 – R 32
L □ □ □ □
650 Nm 2.4 bar 650 Nm 1.6 bar
R □ □ □ □
L □ □ □ □
R □ □ □ □
14. Steering wheels - tightening torque of the wheel nuts and air pressure in the tires 14.9 / 80 – 24
275 Nm 2.8 bar
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480 / 70 – R 24
275 Nm 2.0 bar
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15. Header trailer - tightening torque of the wheel nuts and air pressure in the tires 185 R 14 C – 8 PR
150 Nm 4.5 bar
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16. Oil level in the gear box ► Inspection at the hexagon socket screw 17. Oil level of the spur gear ► Inspection at the hexagon socket screw
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□ L □
R □
□ L □
R □
18. Oil level of the threshing drum gearing - if existing ► Inspection at the inspection screw
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19. Check of the upper no-load speed of the diesel engine ► 2340 rpm.
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19. Inspection of the straw walkers ► Free running of the straw walkers with a V-belt that has been removed
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20. Function of the rubber seals ► Grain pan (preparation pan), catch box, ► grain tank, elevators
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21. Function of the stone trap and its seal
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22. Inspection of all V-belt protectors and check the play between the protector and V-belt disks of 10 mm □
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
23. Inspection of the tension of all of the V-belts and of the chains, except for hydraulically-controlled V-belt couplings
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24. Completeness of the protective equipment ► Sloped conveyor ► Chaff cutter ► Chaff distributor
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25. Notices and safety stickers exist
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26. Air-conditioning system, fully functional
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27. Mounting of the ladder to the driver's platform ► With 800 / 65 – R 32 driving wheels, external attachment
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Inspection with Regard to Functional Dependability Before the combine harvester is delivered, a functional test is to be carried out with a header included and the basic factory settings are to be checked - observe the safety rules. Header – AB and AC, General (electrical-mechanical and electrical-hydraulic field tracker)
OK
Not OK
1. Check the parallel position of the reel ► (Reel tines may only come into light contact the auger spiral runs)
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2. Height of the reel tines over the blade fingers ► In the lowered position of the reel, 20 mm +/- 5 mm
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3. Spacing of the tines of the cross-wise auger ► To the trough floor, 15 mm +/- 5 mm
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4. Height of the auger spiral of the cross-wise auger ► To the trough floor, 20 mm +/- 5 mm
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1. Remove latching equipment of the pendulum bar
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2. Adjust the eccentric rollers on the pendulum frame to the header
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3. Set the parallelism of the mass equalizer to the header
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Header – Design P (Electrical-Mechanical Field tracker)
4. Set the ground pressure of the header (approx. 20 kg) □ ► (depending on the ground conditions or approx. 20 kg pre-adjustment)
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Header – Design Q (Electrical-Hydraulic Field tracker) 1. System alignment through the TEACH-IN program ► Adjustment of the probe skids ► Determination of the horizontal position of the header ► Determination of the header mass with a pressure sensor ► Determination of the upper end positions of the feeder housing
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(In the process, follow Chapter 4 starting on page 4 - 19)
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Combine harvester 10
Awner folded out ► (Lever is forward in the direction of motion)
11
Concave basic setting – Notch 2 of the setting scale ► Inlet at the 3rd threshing basket strip 15 mm +/- 2 mm – left / right ► Outlet at the 10th threshing basket strip 9 mm + 1 mm – left / right
12
Check adjustability of the separating concave ► Set separating basket to Setting 1 - Folded
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13
Sloped auger upwards setting ► Upwards setting
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14
Folding lower sieve pre-setting ► 6 mm (no usage conditions)
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15
Cascade sieve pre-setting ► 14 mm (no usage conditions)
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16. Upper sieve pre-setting ► 12 mm (no usage conditions)
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17. Ear sieve pre-setting ► 16mm (no usage conditions)
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18. Set auger cover in the grain hopper to the lower position
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19. Start engine at 1200 r.p.m.
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20. Switch on working hydraulics ► Switch is in the front area of the cab roof
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21
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22. Switch on the header
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23. Automatically swivel out the grain tank loading pipe
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24. Switch on the grain tank emptying system
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25. Check the engine for the rated load speed
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26. Check the threshing drum speed setting ► 386 – 1250 r.p.m. ► (Basic setting 1000 r.p.m.)
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27. Check the fan speed setting ► 400 – 2500 r.p.m. ► (Basic setting 1500 r.p.m.)
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Items 14, 15, 16 and 17 are factory settings. Test Run
Switch on the threshing unit
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
28. Check the reel speed setting ►5 – 48 r.p.m.
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29. Actuate the reel hydraulic function
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30. Switch off header
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31. Switch on header reversing equipment
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32. Set lowering speed (7 sec.) of the feeder housing ► At Throttle Valve AB, header ► At the operating and display element
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33. Switch off grain tank emptying system
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34. Switch on automatic swiveling-in of the grain tank loading pipe ► Control lamp has to go out
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35. Set engine to no-load speed, 1200 r.p.m.
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36. Switch off threshing unit
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37. Switch off engine
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Because there is still a great deal of paint on the V-belt disks when the combine harvesters are new, it is recommended that the engine should first be shut off and then the threshing unit. (Exchange Items 36 and 37)
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1-15
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
First Check after 20 Threshing Hours or 50 Hectares The most important check is the 1st one after an operating period of 20 hours or 50 hectares. All of the operating elements have now been run in and settled. A conscientious check has a very heavy influence on the availability.
Work Steps: 1. 2. 3. 4. 5. 6.
7. 8. 9. 10.
11.
12.
Inspect the parallelism of the header and readjust it if necessary. Readjust the ground pressure of the header and adapt it to the harvesting conditions. Inspect the basic settings of the concaves and readjust them if necessary. Change the oil in the travel gearbox and final drive. Inspect the starting torque of the drive wheels and steering wheels. Tighten all chains Drive chain of the cross-wise auger at the header. Drive chain of the reel drive unit. Feeder chain of the shaft. Grain elevator. Tailings elevator. Drive chains at the grain and tailings elevators. Drive chains of the unloader auger. Tighten all belts (see the belt and chain operation plans in Chapter 9D). Inspect the straw walker bearings for a firm seating. Check all belt protectors. Functional test Engagement of the straw chopper, threshing unit and header. Check of the full adjustment range of the reel drive unit. Disengagement of the header through the button on the drive lever. Actuation of header reverse mechanism. Swiveling the unloader pipe out, inspection of the limit stop switch. Engagement and disengagement of the unloader equipment. Automatic swiveling in of the unloader pipe, inspection of the limit stop switch. Check of the full adjustment range of the threshing drum variable speed gear and fan drive unit. Inspection of all of the display and monitoring functions of the on-board computer and the display unit. Inspection of the operational safety Brakes Ground drive Illumination system Air conditioning Steering Hydraulic oil sample
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Winterizing / Preservation of the Combine harvester 1. Thoroughly clean off adhesive, aggressive and corrosive residues from the combine harvester and the header. Threshing drum, concaves Separating concave Stone trap Grain pan Straw walker (straw walker return pan) Sieves Augers and elevators Grain tank
By opening the sealing cover on the right and left side wall, as well as over the shaft Over the straw walker Oil or grease hinges after cleaning After removing the sieves Open the sealing cover at the bottom and in the back By removing; oil the adjustment shafts of the flap sieves Open all of the sealing covers Open the cleaning flap on the discharge auger
It is recommended that the components be cleaned with cleaning tools (broom, wire brush) and compressed air. Don't use water (promotes corrosion). 2. Grease all of the lubrication points on the combine harvester according to the lubrication plan and let the combine harvester run for a short period after the lubrication. 3. Remove delete rust and grease bare areas. 4. Loosen all of the V-belts and chains (The V-belt for the hydrostatic drive pump unit is loosened after the final shutoff of the combine harvester!) 5. Oil all of the chains with a spray pistol and acid-free oil. 6. Take the load off all of the springs and the friction clutches on the cross-wise auger of the header. 7. Store the combine harvester and the header under cover (garage/hangar). 8. Jack up the combine harvester and the header vehicle and let out the tire pressure down to 50 kPa (0.5 kp/cm²). 9. Remove the condensation water – Water trap next to the fuel tank – Motor oil drain hose – Hydraulic oil drain hose 10. Fill the hydraulic tank and fuel tank up to the brim with hydraulic oil or diesel fuel respectively. 11. Tighten the screws of the drive shaft attachment of the spur gear (straddle gear) with 110 Nm. 12. Run in all of the hydraulic operating drums or grease the visible piston rods. 13. Remove the batteries and store them in a frost-free, dry room.
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
14. It is recommended that the diesel engine be started every 4 weeks and run for approx. 15 minutes. 15. Remove the electrical starter of the header reverse mechanism. It will be mounted again after cleaning and preservation. 16. Open the cab roof and clean it. Remove and clean the cab filters. 17. Close up the air filter and exhaust pipe. 18. Open the cover on the feed auger and oil the feed pins. 19. Preserve the cutter bar on the header. 20. Check the anti-freeze protection of the cooling water. Refill anti-freeze agent if necessary. 21. Thoroughly flush out all of the radiators and the generator. 22. Seal up the generator so that it's waterproof. 23. Inspect the interior of the discharge pipe for dirt and clean it if necessary.
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1-18
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Preparation of the Combine Harvester for the New Season 1.
Drain the excess hydraulic oil and condensation water from the hydraulic oil tank.
2.
Carry out a hydraulic oil test.
3.
Drain off the condensation water at the fuel tank.
4.
Change the engine oil.
5.
Change filters in the engine (fuel, oil, air and water filters).
6.
Change the ventilation filter at the hydraulic tank.
7.
Install the inspected and charged batteries.
8.
Loosen the springs on the friction clutch of the feed auger. Block the auger and let it slip. Set the springs to the old dimensions again.
9.
Tighten all of the chains and belts to the prescribed tension.
10.
Oil all of the chains with chain oil.
11.
Oil the header blade, feed fingers and reel rollers.
12.
Check the rubber-metal connections for cleanliness and the grain pan for play and change these if necessary.
10.
Inspect the basic setting of the concaves.
11.
Inspect all of the seals.
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1-19
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Starting Process The combine harvester has an electronic starting safety circuit that is visible for the driver in the display unit.
The engine can only be started when all of the red indicator panels have been extinguished. The individual indicator panels mean the following here: 6 7 5 4 3 2 1
The engine stop solenoid is not ready for operation. This indicator panel is only extinguished after approx. 5 seconds, when none of the other indicator panels are illuminated. Driver's seat monitoring (prepared) Switch for emptying pipe is not in the neutral position. Throttle is not in a neutral position. Not used. Horn signal lacking. Speed adjustment lever of the diesel engine is in the position "Engine Off".
Work Steps for Starting
Switch on the master switch. Turn the ignition switch to the first position in a clockwise direction (ignition on). Bring about the safety conditions for the starting process so that the control lamps 4 and 5 are not illuminated. Set the manual throttle of the diesel engine into the position "half gas" (Control Lamp 1 will go out) Actuate the horn (Control Lamp 2 will go out) After Control Lamp 6 goes out (approx. 5 seconds), turn the ignition switch into the second position in a clockwise direction.
After the combine harvester is shut down, the electrical system is to be switched into a no-current state with the master switch.
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1-20
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Adjustment Table
1 2 3 4
Basic threshing unit concave setting, corn Special concave (no grain threshing basket) When there are moist harvesting conditions or undergrowth Install clover grating pan
[10/2000]
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1-21
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Basic Rules of Threshing Unit Adjustment The foundation of all adjustment is the adjustment table. It has been created based on values that have come from experience. But because the harvesting conditions are dependent upon a number of factors, it is not possible to include everything in this table. A optimum setting will always be obtained by the targeted change in base values.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
The 4-drum threshing unit will get the highest throughputs with sharp threshing (a high threshing drum speed and close concave spacing). First optimize the threshing yield with the concave setting. When no improvement is achieved, increase the speed of the threshing drum (this is only applicable to normal straw). When there is green straw, adjust the speed of the threshing drum to the upper limit value (before grain breakage). The threshing unit has to be preset in such a way that losses are visible. Then optimize these losses in a targeted way. Only carry out one adjustment step, never several of them at the same time. The straw moisture and the threshing-yield behavior are always the basis for the adjustment. The minimum amount of tailings is to be adjusted via the lower sieve and ear sieve. Totally clean hopper goods always have increased losses as a consequence. When adjusting the sieves, the sieve is always opened to set the correct dimension. The adjustment values in the adjustment table refer to an engine speed of 2200 r.p.m.. This means that the engine speed has to be lowered to 2200 r.p.m. when adjustment is done.
A harvest without losses is not possible. The smallest losses come at the expense of the throughput. It is economical to adjust losses and throughput in a reasonable way.
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1-22
1 – GENERAL ISSUES
CROSS - FLOW CF 80 COMBINE HARVESTER
Adjusting the Threshing unit The adjustment of the combine harvester is primarily oriented towards the yield to be expected and the nature of the straw. A distinction is therefore made here between the setting in normal straw with a yield of 40 - 80 tenths of a ton / ha, and in green hay with a yield of more than 60 tenths of a ton / ha. The values in the adjustment table refer to average yields, in wheat for example, of 40 to 80 tenths of a ton / ha with normal, dry straw. The adjustment values can be interpolated when there are other yields. The adjustment is made here from the right to the left in the adjustment table. The small number in the sieve adjustment is the standard figure for a yield of approx. 40 tenths of a ton / ha; the large one is for approx. 80 tenths of a ton / ha. If the yield is greater than 80 tenths of a ton / ha., every ton / ha. of difference in yield from 80 tenths of a ton is an increase in the sieve opening of approx. 1 mm. In the case of the cascade sieve, the maximum opening of the sieve is 16 mm. When there are yields less than 40 tenths of a ton / ha., the process is the same, only a deduction is made here from the smaller number. A pre-adjustment is first done that creates visible losses. These losses are then optimized in the order of threshing yield, cleaning and hopper unit. All of the values refer to the adjustment table in the process. When there are moist hay and high yields, work is done with a higher threshing drum speed. Every sieve adjustment has mechanical leeway. When adjusting the sieves, the sieve is to first be closed and then opened to the correct value because of this. If the sieve is only closed, the adjustment value will be reduced by the amount of mechanical leeway due to the harvested grain. This can lead to a distortion of the adjustment value and to increased losses!
Harvest grain
Wheat
Cascade sieve Spacing in mm
Upper sieve Spacing in mm
12..16
10..14
Ear sieve Spacing in mm
Lower sieve Diameter in mm
Lower flap sieve Spacing in mm
12..18
12.5; 9
6 8
Fan Speed in r.p.m.
1400.... 1650
Threshing Concave Separatdrum adjust- ing conspeed cave ment in r.p.m. Notches/ value spacing
900..... .1150
2...4
1/28
Value is not spacing in mm ! Standard equipment Option in place of the flap sieve Adjustment value for a yield of approx. 80 tenths of a ton / ha. Adjustment value for a yield of approx. 40 tenths of a ton / ha. Example:
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
The maximum opening of the cascade sieve is 16 mm. This means that starting with a yield of 80 tenths of a ton/ha. (and over), the cascade sieve remains set at 16 mm.
General Notes Grain pan
Cascade sieve Upper sieve Ear sieve
Lower sieve Pre-Adjustment of the Sieves Adjustment of the sieves according to the grain yield (see page 1-25). The cascade and ear sieves should be opened 2 mm wider than the upper sieve for the pre-adjustment. In the process, the maximum opening of 16 mm of the cascade sieve is to be observed. The opening of the lower sieve is approximately half of the upper sieve. The sieve is always to be opened to the adjustment value in order to take the mechanical leeway of the sieve adjustment into account. Adjustment of the Tailings A share of grain in the tailings that is too high can be noted from the visibly higher losses on the right side of the windrow. 1. Open the upper sieve and ear sieve by a notch 2. Open the lower sieve by a notch Adjustment of the Threshing Drum Speed The threshing drum speed is always set at an engine speed of 2200 r.p.m., which corresponds to the threshing unit speed. The value to be set corresponds to the harvesting conditions (see pages starting with 1-22 and 1-24). Adjustment of the Fan Speed The fan speed is always set at an engine speed of 2200 r.p.m., which corresponds to the threshing unit speed. The first adjustment starts with the smallest table value, which is then increased in steps of 50 r.p.m. if necessary.
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Awner Flap The awner flap is to only be folded in when satisfactory awn removal of the grain was not able to be achieved with an increase of the threshing drum speed and reduction of the basket spacing. Separating Concave The separating concave is adjusted as stated in the adjustment table. Normal Straw with a Grain Yield of Approx. 40 to 80 Tenths of a Ton/Ha. Pre-Adjustment 1. 2. 3. 4. 5.
Separating concave in the uppermost position Average concave gap Average threshing drum speed Lowest fan speed Adjustment of the sieves according to the yield to be expected (small figure 40 tenths of a ton/ha. – large figure 80 tenths of a ton/ha.)
Optimization of the Pre-Adjustment 1 Reduce the threshing drum gap by 0.5 step-by-step until the threshing yield is set in an optimum way. No more than 3 grains should be found in 50 threshedout stems. If no grain is found in 50 stems in the first sample, the concave gap is to be increased. 1.1 If the threshing yield cannot be set with the concave adjustment, the drum speed is increased. 2. Slowly increase the fan speed step-by-step until the cleaning losses are visible. The fan speed is now reduced by 50 r.p.m., and the cleaning losses are checked once again. 3. Check the total losses and make a correction to the sieve adjustment if necessary. 4. Check the grain tank smple for purity. If necessary, correct the lower-sieve or fan speed. Adaptation for Wet, Normal Straw and Average Yield Reduce the concave gap Increase the threshing drum speed Absolutely leave the separating concave in the uppermost position Adjust the sieves for the minimum tailings Increase the fan speed if necessary Check the basket inlet for impurities Adaptation for Extremely Dry Straw Increase the concave spacing Reduce the threshing drum speed (above all in the case of a low yield less than 40 tenths of a ton/ha.) Reduce the cross-wise auger speed to 180 r.p.m. Fold out the separating concave in the center position Adjust the fan speed to the harvesting conditions
[10/2000]
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1-25
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Adaptation for Normal, Dry Straw and a Very High Yield Increase the threshing drum speed by 50 to 100 r.p.m. Increase the fan speed Open the sieves further. In so doing, one should see to it that the cascade sieve is opened to a maximum of 16 mm. Minimize the tailings The adjustment values always refer to the adjustment table (see page 1-21) Green, Moist Straw with a Grain Yield of More than 60 Tenths of a Ton/Ha. Pre-Adjustment 1. 2. 3. 4. 5. 6.
The separating concave is in the uppermost position The concave is set to the smallest value from the adjustment table Upper threshing drum speed Preset the fan speed to the minimum value Set the cascade sieve to a maximum of 16 mm Accordingly adjust the upper sieve and ear sieve to the yield (spacing is larger than in the adjustment table) 7. The lower sieve is 2 mm larger than half of the spacing of the upper sieve (unthreshed stems are found in the grain tank)
Optimization of the Pre-Adjustment 1. Increase the threshing drum speed until grain breakage arises. Then reduce the speed again slightly until the grain breakage is normal. 2. Optimize the threshing yield with the concave setting. 3. Increase the fan speed until increased cleaning losses arise, then reduce it until the losses are normal. 3.1 The wind guide plates can be set in the case of the CF 80. The lowering of the upper wind guide plate causes more air to get into the first drop stage and consequently greater separation to be achieved in the case of very high yields.
4. Optimize the cleaning losses if necessary with the upper sieve and ear sieve. 5. Check the amount of stems in the grain tank smple that have not been threshed out and optimize this by closing the lower / ear sieve tailings. 6. Check the tailings (right side of the windrow). See page 1-26 for the adjustment.
[10/2000]
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
A combine harvester that has been optimized for high throughput threshes sharply, which has destroyed straw as a consequence.
The adjustment values always refer to the adjustment table (see page 1-22) Normal Straw with a Grain Yield of Less than 40 Tenths of a Ton/Ha. Pre-Adjustment 1 2. 3. 4. 5.
The separating concave is in the uppermost position Large concave gap Average threshing drum speed Smallest fan speed Adjustment of the sieves according to the yield to be expected (small figure 40 tenths of a ton/ha. – large figure 80 tenths of a ton/ha.) Optimization of the Pre-Adjustment
1
2 3 4 5 6 7
Reduce the threshing drum gap by 0.5 step-by-step until the threshing yield is set in an optimum way. No more than 3 grains should be found in 50 threshed-out stems. If no grain is found in 50 stems in the first sample, the concave gap is to be increased. Optimize the grain breakage proportion by possibly lowering the threshing drum speed. The separating concave can be folded out in the case of very dry straw. After this, a check of the losses and clogging danger of the last drums is to be carried out by means of the speed display in the on-board computer. Slowly increase the fan speed step-by-step until the cleaning losses are visible. The fan speed is now reduced by 50 r.p.m., and the cleaning losses are checked once again. Check the total losses and if necessary make a correction to the sieve adjustment. Check the tailings (right side of the windrow). See page 1-26 for the adjustment. Check the grain tank sample for purity. Correct the lower sieve or the fan speed if necessary. Adaptation for Wet, Normal Straw and Undergrowth Reduce the concave gap Increase the threshing drum speed Absolutely leave the separating concave in the uppermost position Open the lower sieve Adjustment of the sieve to the minimum tailings If no grain is in the tailings (same losses over the entire windrow width, but the left sieve side is dirtier), the ear sieve is to be closed by one notch Increase the fan speed if necessary Check the concave inlet for impurities
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1-27
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Adaptation for Extremely Dry Straw Increase the threshing concave spacing Reduce the threshing drum speed Reduce the cross-wise auger speed to 180 r.p.m. Fold out the separating concave in the center position Adjust the fan speed to the harvesting conditions The adjustment values always refer to the adjustment table (see page 1-22) Loss Determination The most diverse methods and testing instruments exist for loss determination. The precise assignment of the losses is important. The chaff cutter and the chaff distributor are to always be shut off in the process. Losses are determined
Total losses:
when the threshing system is closed. So after 50 to 100 m of threshing with an amount stock that remains constant when work was done with a constant driving speed
Put a test tray between the two axles. Header and pre-harvest losses are found under the test tray The cleaning and straw walker losses are in the test tray
Straw walker losses: Put a test tray in front of the straw falling down. A check has to be done here that the cleaning unit is not overblown (above all small grain is blown directly in to the falling straw above the chaff). Cleaning losses: Total losses minus straw walker losses. Threshing yield losses: Counting out the grain in the stems in the windrow. Determination of the cleaning losses: Catch the chaff with a container. The area above the chaff (overblowing of the cleaning unit) is to also be checked in the process.
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Loss Types and their Elimination 1.
Threshing Yield Losses (more than 3 grains in 50 stems)
2.1
High Straw Walker Losses with Normal, Dry Straw
2.2
Increase the threshing drum speed Check the straw walker hurdles for cleanliness Check the straw walker speed
High Straw Walker Losses with Green, Wet Straw
3.
When straw has been beaten to pieces, increase the concave gap (but note 1.) Increase the threshing drum speed Check the cleanliness of the straw walker hurdles
High Straw Walker Losses with Normal, Wet Straw
2.3
Reduce the concave gap Increase the threshing drum speed (watch out for grain breakage) Increase the driving speed when there is a low yield Check the concave with regard to basic settings and deformation Possibly switch on the awner
Check the threshing drum speed at an engine speed of 2200 r.p.m. Increase the threshing drum speed (check grain breakage) Reduce the concave gap Check the straw walker speed Optimize the tailings Change the straw walker linings of the 4th drop stage Alternately disassemble the conveyor rail at the 2nd and 3rd drop stage
High Cleaning Loss
[10/2000]
Lower the fan speed Check the cleanliness of the sieves Check the tailings and open the upper and/or lower sieve if necessary Open the cascade sieve (maximum opening width 16 mm) Open the upper sieve When there is a very high yield, lower the driving speed
TRAINING CENTER NEUSTADT
1-29
CROSS - FLOW CF 80 COMBINE HARVESTER 4.
Grain Breakage
5.
Reduce the threshing drum speed Check the tailings and open the lower and/or upper sieve if necessary
Unclean Hopper Goods
6.
1 – GENERAL ISSUES
Increase the fan speed The lower sieve is to be closed when there are half-stems Check the opening of the cascade sieve (depending on the yield, but a maximum of 16 mm) Close the upper sieve Close the ear sieve When there is cracking, dry straw, reduce the threshing drum speed and fold out the separating basket Attention! Do not lower the separating concave when there is Moist straw Flax Very low proportion of straw
Grain in the Cleaning Unit Housing
[10/2000]
Increase the fan speed Open the lower sieve The grain in the fan housing has to be removed, because the wind is not in a position to do this.
TRAINING CENTER NEUSTADT
1-30
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Loss Determination There are several methods to determine losses. The most precise, practical method is the use of a standardized test tray that is put in front of the rear axis of the combine harvester. After this, the straw is shaken out over the test tray and the grain is counted out. Then the actual losses can be determined. The most simple method for determining losses is to count the grain in the windrow. In the process, approx. 50 meters of the straw is shaken by hand and then put aside. The chaff is now carefully blown away, and the grain is counted out on a surface of 15 x 15 cm (hand area). This is repeated several times, and the average value is found. Constant losses that are created by a continuous threshing speed in an even and constant amount. Throughput performance of combine harvesters is indicated with 1% loss. In practice, losses of 1% are already too high and the orientation is at 0.5%. There is no set upper limit on loss. The following table shows the number of lost grains on a surface of 15 cm x 15 cm (hand area) in dependence on the header size and the yield with an average grain size. The number (printed in boldface). Double this number therefore corresponds to 1% and is consequently to be viewed as being a very high loss. .
BARLEY / WHEAT Hdr. width 4.2 m 4.8 m 5.4 m 6.0 m 6.6 m 7.2 m 7.8 m
Hdr. width 4.2 m 4.8 m 5.4 m 6.0 m 6.6 m 7.2 m 7.8 m
20 2 3 3 3 4 4 5
20 2 2 3 3 4 5 6
40 3 4 4 4 5 5 6
Yield in tenths of a ton/ha 60 80 4 6 5 7 6 7 6 8 8 10 8 11 9 12
100 7 8 9 10 12 13 15
120 9 10 11 12 14 16 18
40 3 4 5 6 6 7 8
OATS / RYE Yield in tenths of a ton/ha 60 80 5 7 6 8 7 9 8 10 9 12 10 14 12 16
100 8 10 12 13 15 17 19
120 10 12 14 16 18 20 22
These tables illustrate what 0.5% in losses are. The losses that are strived for could be more or less.
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Lubrication - Filters - Fluids Engine Lubrication Check oil level .......................................................................................................Daily CF80 oil and filter change . ..................................................Every 240 operating hours, or once a year Oil type....................................................................................CASE IH NO.1, 15 W-40 Oil filling amount with filter change....................................................................21 liters
Cooling System Check the filling level in the compensation reservoir.............................................Daily Coolant change................................................................ Every 2000 operating hours .............................................................................................(or every two years) Coolant additive change...............................................Always with the coolant change Coolant filter change............................................................ Every 250 operating hours Coolant filling amount...................................................................................... 65 liters
Fuel System Fuel filter in the engine.........................................................Every 500 operating hours ................................................or change it when there is a drop in performance Water separation filter....................................Drain the water every 50 operating hours .................................................or change it when there is a drop in performance CF80 fuel tank capacity.............................................................................520/650 liters
Air Filter Air filter maintenance period ........................................................... Clean the filter when the clogging display lights up in the A panel Main filter element change..............................................................................Once a year or after three cleanings th Safety filter change................................................At every 5 change of the main filter or once a year. Never clean it.
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Lubrication - Filters - Fluids
Gearbox Check the oil level....................................................................Every 120 operating hours Oil change...............................................................After 60 operating hours the first time, after that every 240 operating hours or once a year Filling amount CF80.......................................................................................7.0 liters Oil type.............................................................................................................API-GL-5-90
Spur Gear (Straddle Gear) Check oil level.......................................................................... Every 120 operating hours Oil change............................................................... After 60 operating hours the first time, after that every 240 operating hours or once a year Filling amount...............................................,..........................................................4.5 liters Oil type..............................................................................................................API-GL-5-90
Threshing Drum Gear (Accessory Equipment) Check oil level............................................................................ Every 120 operating hours Oil change................................................................. After 60 operating hours the first time, after that every 240 operating hours or once a year Filling amount............................................................................................................1.4 liters Oil type..............................................................................................................GLP 220/GL4
Brake System Check the level of brake fluid.....................................................................On a weekly basis
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Hydraulic System Check the oil level............................................................Every 10 operating hours or daily !!! check it with a lowered header (center of filling sieve) and observe the warning display in the cabin !!! Check the clogging display of the filter...........................................................Every 2 weeks Check oil sample............................................................................................Every 2 weeks Drain condensation water.................................................................................Once a week ........................................2-3 times per week when there are large temperature differences Oil change.............................................Every 600 operating hours or before the 3rd season Oil filter change..........................................................Annually or every 600 operating hours Filter on the hydrostatic drive pump and ventilation filter of the hydraulic tank Oil filter change......................................Every 600 operating hours or before the 3rd season Return filter on the hydraulic tank Filling amount Hydraulic tank..........................................................................................Approx. 60 liters Complete system.....................................................................................Approx. 80 liters Oil type...........................................................HLP 46 according to DIN 51524 (yellow color)
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Overview of the Maintenance Parts/Replacement Part Numbers Oils/Greases: Engine........................................................................................... CASE IH NO.1, 15 W-40 Gearbox, straddle gear......................................................................................API-GL-5-90 Threshing drum gear (accessory equipment).................................GLP220/GL4 DIN 51517 Bevel gearing, unloading pipe, lower..............................................................GPO F-20/NA Bevel gearing, unloading pipe, upper..............................................................GPO F-20/NA Bevel gearing, cross grain auger.....................................................................GPO F-20/NA Hydraulic system................................................................ HLP 46 according to DIN 51524 Filters: Engine oil filter........................................................................................................J 919 562 Fuel filter (on the engine)........................................................................................J 903 640 Fuel water separation filter (right side of the machine, under the fuel tank)...............................................................................060533204 Engine coolant filter..................................................................................................A 77 544 Engine air filter Main filter element.................................................................................................060503834 Safety cartridge.....................................................................................................060533124 Hydraulic oil filters Hydraulic filter, hydrostatic drive pump.....................................................................................................................060525294 Hydraulic filter, tank return......................................................................................03105372 Ventilation filter, hydraulic tank.............................................................................072051780 Cabin air filter (required 4 times).............................................................................31336727 This is only an excerpt of the most important and most frequently needed parts.
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Lubrication Schedule 1 Left Side Daily or after 10 operating hours (recommended) Header: - (5) sickle drive head bearings, 1 stroke After 60 operating hours - (5) sickle drive unit gear housing, 5 strokes Header: - (4) universal-joint shaft header drive (8) Profile sleeve, ground drive shaft (25) Steering knuckle, 2 nipples (62) Wheel bearings, steering axle (80) Chopper belt coupling, guiding idler arm (81) Chopper transmission gear shaft bearings, 2 nipples (only for standard lubrication system) (82) Chopper drive unit, guiding idler arm (83) Chopper shaft bearings (only for standard lubrication system) After 120 operating hours - (10) Reel suspension bearings Header: - (12) Drive shaft Central lubrication block, left-hand side: (19) Fan shaft bearings (20) Cleaning unit drive shaft bearings (35) Straw walker crankshaft bearings, front (36) Straw walker crankshaft bearings, back (41) Separating guide drum bearings (42) Threshing drum shaft bearings (46) Slope distributing auger bearings (70) Separating drum bearings (72) Straw guide drum bearings (73) Intermediate shaft bearings (26) Center axle bolts, steering axle (28) Engine power take-off, front side take-off shaft (29) Threshing unit clutch, guiding idler arm (30) Header clutch, guiding idler arm (34) Pendulum frame, shaft (electrical-mechanical field tracking) (37) Working cylinder, unloader auger, 2 nipples (38) Unloader auger, auger end bearings (39) Unloader auger, rim bearing, 3 nipples (40) Grain and tailing auger bearings, 2 nipples (43) Lower shaft spindle bearings (77) Unloader clutch, guiding idler arm (starting with Machine No.:61) (84) Shaft lift cylinder, 2 nipples (85) Hydrostatic drive pump pedestal (86) Concave adjustment device, 2 nipples (87) Attachment drive belt, guiding idler arm 360 operating hours or annually (34) Pendulum frame, shaft (electrical-hydraulic field tracking) (48) Trailer hitch, rear axle [10/2000]
TRAINING CENTER NEUSTADT
1-44
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Lubrication Schedule 1 Right Side After 60 operating hours (8) Profile sleeve, ground drive shaft (25) Steering knuckle, 2 nipples (62) Wheel bearings, steering axle (83) Chopper shaft bearings (only for standard lubrication system) After 120 operating hours Central lubrication block, right-hand side: (19) Fan shaft bearings (20) Cleaning unit drive shaft bearings (35) Straw walker crankshaft bearings, front (36) Straw walker crankshaft bearings, back (41) Separating guide drum bearings (42) Threshing drum shaft bearings (45) Cross grain auger, upper bearings (46) Slope distributing auger bearings (47) Grain elevator bearings, 2 nipples (70) Separating drum bearings (72) Straw guide drum bearings (73) Intermediate shaft bearings (31) Pre-loaded spring joints, shaft, 5 nipples (only for electromechanical field tracking) (34) Pendulum frame, shaft (electrical-mechanical field tracking) (40) Grain and tailing auger bearings, 2 nipples (43) Lower shaft spindle bearings (74) Spring-controlled variator, external nipple !!!Only grease with an open variator!!! (76) Engine fan drive, transmission gear shaft, 2 nipples (78) Grain elevator, transmission gear (79) Grain elevator, guiding idler rocker (88) Head plate pivot, shaft (electrical-hydraulic field tracking) (89) Intermediate shaft bearings, shaft (90) Rod-linkage, shifter, ground drive 360 operating hours or annually (34) Pendulum frame, shaft (electrical-hydraulic field tracking) (74) Spring-controlled variator, interior nipple !!!Only grease with an open variator!!! (75) Electrically-adjustable variator, intermediate shaft, 2 nipples (91) Adjustment prong, electrically-adjustable variator
1
Numbers in parentheses indicate the illustration number in the following sketches
[10/2000]
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1-45
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Oil Level Check After 10 operating hours or daily
(1) Engine oil level (2) Coolant compensation reservoir (3) Hydraulic oil tank (4) Filling level of the cooling box under the passenger seat
After 120 operating hours
(5) Gearbox (6) Straddle gear, right and left (7) Threshing drum reduction gear (accessory equipment) (8) Angular gear Bevel gearing, unloading pipe, lower Bevel gearing, unloading pipe, upper Bevel gearing, cross grain auger
Filter Overview
(1) Engine oil filter (2) Fuel filter on the engine (3) Water separation filter, fuel (4) Hydraulic oil filter, return line (5) Hydraulic filter, hydrostatic drive pump with inspection glass (6) Ventilation filter, hydraulic tank (7) Coolant filter (8) Air filter with safety cartridge (9) External air filter, cab, left and right
[10/2000]
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1-46
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Header Lubrication Points Daily Oil the bearing surfaces of the reel rollers (2) and grease the head bearings of the sickle drive (5). Every 60 operating hours 4 Universal-joint shaft, header drive (4 nipples) 5 Universal-joint shaft, header drive (4 nipples) Every 120 operating hours 10 Reel suspension bearings (2 nipples) 12 Drive shaft 20 & 21 Drive chains 22 & 23 Oil bearing surfaces
[10/2000]
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1-47
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Lubrication Schedule 60 h, Left Side
(8) Profile sleeve, ground drive shaft (25) Steering knuckle, 2 nipples (62) Wheel bearings, steering axle (80) Chopper belt coupling, guiding idler arm (81) Chopper transmission gear shaft bearings, 2 nipples (82) Chopper drive unit, guiding idler arm (83) Chopper shaft bearings (only for standard lubrication system)
[10/2000]
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1-48
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Central Lubrication Block, Left Side 120 operating hours
(19) Fan shaft (20) Cleaning unit drive shaft (35) Straw walker crankshaft, front (36) Straw walker crankshaft, back (41) Separating guide drum (42) Threshing drum shaft (46) Slope distributing auger (70) Separating drum (72) Straw guide drum (73) Intermediate shaft
The lubrication interval is shortened to daily 10 strokes with the grease press in the case of the equipment variation with a central lubrication point and chopper.
(70) Separating drum (72) Straw guide drum (73) Intermediate shaft
As an option, the central lubrication block can be fed by a central lubrication point or by an automatic centralized lubrication system via a distribution valve. If one of these variations are used, the chopper shaft bearings (83) are also supplied by a supplemental lubrication line.
[10/2000]
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Individual Lubrication Nipples, Left Side, for Electrical-Mechanical Field Tracking 120 operating hours (26) Center axle bolts, steering axle (28) Engine power take-off, front side take-off shaft (29) Threshing unit clutch, guiding idler arm (30) Header clutch, guiding idler arm (37) Working cylinder, unloader auger, 2 nipples (if existing) (38) Unloader auger, auger end (39) Unloader auger, rim bearing, 3 nipples (40) Grain and tailing auger bearings, 2 nipples (43) Lower shaft spindle bearings (84) Shaft lift cylinder, 2 nipples (85) Hydrostatic drive pump pedestal (86) Concave adjustment device, 2 nipples (87) Attachment drive belt, guiding idler arm (77) Unloader clutch, guiding idler arm 360 operating hours (48) Trailer hitch, rear axle
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1-50
CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Individual Lubrication Nipples, Left Side, for Electrical-Hydraulic Field Tracking 120 operating hours (26) Center axle bolts, steering axle (28) Engine power take-off, front side take-off shaft (29) Threshing unit clutch, guiding idler arm (30) Header clutch, guiding idler arm (34) Pendulum frame, shaft (37) Working cylinder, unloader auger, 2 nipples (if existing) (38) Unloader auger, auger end (39) Unloader auger, rim bearing, 3 nipples (40) Grain and tailing auger bearings, 2 nipples (43) Lower shaft spindle bearings (77) Unloader clutch, guiding idler arm (84) Shaft lift cylinder, 2 nipples (85) Hydrostatic drive pump pedestal (86) Concave adjustment device, 2 nipples (87) Attachment drive belt, guiding idler arm 360 operating hours or annually (48) Trailer hitch, rear axle (34) Pendulum frame, shaft
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1 – GENERAL ISSUES
Lubrication Schedule 60 h, Right Side
(19) Profile sleeve, ground drive shaft (25) Steering knuckle, 2 nipples (62) Wheel bearings, steering axle (83) Chopper shaft bearings (only for standard lubrication system)
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Central Lubrication Block, Right Side
120 operating hours (19) (20) (35) (36) (41) (42) (45) (46) (47) (70) (72) (73)
Fan shaft Cleaning unit drive shaft Straw walker crankshaft, front Straw walker crankshaft, back Separating guide drum
The lubrication interval is shortened to daily 10 strokes with the grease press in the case of the equipment variation with a central lubrication point and chopper.
Threshing drum shaft Cross grain auger, upper bearings Slope distributing auger Grain elevator, 2 nipples Separating drum Straw guide drum Intermediate shaft
As an option, the central lubrication block can be fed by a central lubrication point or by an automatic centralized lubrication system via a distribution valve. If one of these variations are used, the chopper shaft bearings (83) are also supplied by a supplemental lubrication line.
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Individual Lubrication Nipples, Right Side, for Electrical-Mechanical Field Tracking 120 operating hours (31) Pre-loaded spring joints, shaft, 5 nipples (34) Pendulum frame, shaft (40) Grain and tailing auger, 2 nipples (43) Lower shaft spindle bearings (74) Spring-controlled variator, external nipple (76) Engine fan drive, transmission gear shaft, 2 nipples (78) Grain elevator, transmission gear (79) Grain elevator, guiding idler rocker (89) Intermediate shaft bearings, shaft (90) Rod-linkage, shifter, ground drive 360 operating hours or annually (75) Electrically-adjustable variator, intermediate shaft, 2 nipples (74) Spring-controlled variator, interior nipple (91) Adjustment prong, electrically-adjustable variator Only grease the variator when it's open!!!
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Individual Lubrication Nipples, Right Side, for Electrical-Hydraulic Field Tracking 120 operating hours (40) Grain and tailing auger bearings, 2 nipples (43) Lower shaft spindle bearings (74) Spring-controlled variator, external nipple (76) Engine fan drive, transmission gear shaft, 2 nipples (78) Grain elevator, transmission gear (79) Grain elevator, guiding idler rocker (88) Head plate pivot, shaft (89) Intermediate shaft bearings, shaft (90) Rod-linkage, shifter, ground drive 360 operating hours or annually (75) Electrically-adjustable variator, intermediate shaft, 2 nipples (74) Spring-controlled variator, interior nipple (91) Adjustment prong, electrically-adjustable variator (34) Pendulum frame, shaft Only grease the variator when it's open!!!
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1 – GENERAL ISSUES
Filters
(1) (2) (3) (4) (5) (6) (7) (8) (9)
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Engine oil filter Fuel filter on the engine Water separation filter, fuel Hydraulic oil filter, return line Hydraulic filter, hydrostatic drive pump with inspection glass Ventilation filter, hydraulic tank Coolant filter Air filter Safety cartridge of the air filter External air filter, cabin, left and right
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J 919 562 J 903 640 060533204 03105372 03105372 072051780 A 77 544 060503834 060533124
1-56
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1 – GENERAL ISSUES
Fluids After 10 operating hours or daily (1) Engine oil level (2) Coolant compensation reservoir (3) Hydraulic oil tank (4) Filling level of cooling box under the passenger's seat After 120 operating hours (5) Gearbox (6) Straddle gear, left and right (7) Threshing drum reduction gear (accessory equipment) Service life (8) Angular gear * Bevel gearing, unloading pipe, lower * Bevel gearing, unloading pipe, upper * Bevel gearing, cross grain auger
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Centralized Lubrication The combine harvester is equipped with one central lubricating strip each on the right and left-hand side as a standard feature. The following bearing points can be separately lubricated from there: Threshing drum, threshing guide drum, separating drum, straw drum, cleaning unit drive shaft, fan shaft, intermediate shaft, both straw walking crankshafts, slope auger, cross upper cross grain auger, grain elevator drive shaft. The assignment of the lines and the lubrication intervals are included in the following lubrication schedules. Specified grease types: Greases in Grease Class 2 In warm countries, such as in southern Europe, Grease Class 3 Accessory equipment with a single-nipple system or an automatic system If you have purchased one of these variations, the bearing points of the chopper and of the chopper transmission gear are additionally greased when equipped with a chaff cutter. Single-nipple system: One central distributor each is connected in front of the lubrication strips described above. These distributors separately control the assigned amount of grease for each bearing set per lubrication cycle. The individual lubrication points are worked through one after the other; after this, the lubrication cycle is started again from the beginning with the first lubrication point. When there are blockages in the distributor or in a particular line, greasing is no longer possible after the blockage is reached, i.e. no more grease can be pressed in. A leak in the line can only be recognized through a visual inspection; the greasing of all of the remaining lines will not be impacted by this. Automatic system: A pump is connected in front of the distributors. The warranty documents of the manufacturer, a description and the list of possible malfunctions are a part of the combine harvester documents. A lubrication interval of 3 h has been set in the factory; the pump runs through 10 lubrication cycles in the process. Depending on the model, the automatic system is equipped with a malfunction display in the cabin. The control lamp on the control panel lights up when there are blockages after a cycle run; this can also be noted from the escape of grease at the excess pressure valve of the pump. The control lamp goes out when the intermediate lubrication is actuated (see the operating instructions for the automatic central lubrication system). It lights up again when the error has not been remedied. [01/2001]
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Dimensions when Ready for Transport
1 2 3 4 5 Or 6 Or 7 8 9 10 12
Engine system Trailer hitch, permissible support load 250 kp Wheel chocks, left and right on the basic machine 2 batteries 12V Tires 650/75R32(24.5R32 167 A8) Disk Wheel DW21x32 G-60 Tires 800/65R32(30.5LR32 167A8) Disk Wheel DW 27x32 G-150 Tires 14.9780-24 Disk Wheel W 113x24 ET 0 Tires 480/70R24 138A8 Disk Wheel W13x24 ET50 Rearview mirror Nameplate Drawbar eye Tires 185-R 14 8PR, Disk Wheel K14 H 004 Product identification number (machine number)
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CROSS - FLOW CF 80 COMBINE HARVESTER
11
1 – GENERAL ISSUES
Wheel chock, header
Dimensions A, C and R for various header widths
Chopping width
6.00 m
6.60 m
7.80 m
A
Overall length with header vehicle
17.720 m
17.950 m
19.265 m
C
Overall length of the header vehicle
10.950 m
11.180 m
12.500 m
R
Axle spacing of the header vehicle
5.740 m
5.740 m
6.450 m
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
Technical Data Header Chopping widths..................................................................................... 6.0 m; 6.6 m; 7.8 m Cutting system................................................................................................... Schumacher Number of double fingers....................................................................................... 40; 43; 52 Sickle drive............................................................................. Drive through planetary gears Sickle speed............................................................................................................. 1.71 m/s Field guidance.............................................. Automatic cross-wise and longitudinal tracking Accident protection system...................,.................. Quick stop and shaft and header return Reel................................................................................... 6-part with plastic or steel prongs Reel drive................................................................................................................ hydraulic Reel adjustment................................................................ hydraulic (horizontal and vertical) Reel speed......................................................................................................... 5 – 48 r.p.m. Feed auger diameter................................................................................................ 610 mm
Threshing unit Threshing principle...................................................4 – drum threshing / separating system Threshing channel width......................................................................................... 1630 mm Threshing drum diameter.......................................................................................... 600 mm Guide drum diameter................................................................................................ 395 mm Separating drum diameter......................................................................................... 570mm Threshing drum speed.................................................. 386 – 1250 (without reduction gear) Number of straw walker hurdles.......................................................................................... 6 Number of drop stages........................................................................................................ 5 Straw walker area........................................................................................................ 7.4 m² Concave area..................................................................... ......................... 1.02 m² Separating concave area........................................................................................... 1.45 m² Outflow rake............................................................................................................... 0.34 m² Overall separation area........................................................................................... 10.21 m²
Cleaning unit Lower / upper sieve............................................................................................... Flap sieve Operating principle.....................................................................................3 – stage cleaning Cleaning fan............................................................................................................. Axial fan Speed of the fan........................................................................................ 400 – 2500 r.p.m. Overall sieve area........................................................................................................ 6.8 m²
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1 – GENERAL ISSUES
Traction mechanism Ground drive.................................................. Hydrostatically-driven front axle with gearbox Turning circle ............................................................................................................. 18.9 m Driving machinery Engine............................................................................................................6TAA-830 CDC Engine output................................................................................................. kW / HP r.p.m. .................................................................................................................... 224 /300 at 2200 Fuel tank.......................................................................................................... Plastic design Fuel tank capacity up to DCF880060...................................................................... 520 liters starting with DCF 880061 650 liters Grain tank Grain tank capacity................................................................................................ 9000 liters Unloading time................................................................................................ Approx. 2 min. Swivel angle of the unloader auger........................................ ....................................... 107° Cab / driver's stand Equipment......................................................................................... According to Euronorm Belt couplings....................................................................... Low-pressure hydraulic system ................................................................................................................. (electrically-driven) Cab................................................................................................................... CASE design Noise level................................................................................................... Less than 78 dB On-board computer............................................................................................... LH AGRO Dimensions / weights Transport width................................................................................ Tires 24.5.32 3485 mm ......................................................................................................... Tires 30.5-32 3780 mm Height.............................................................................................................. 3980 mm Length without header.................................................................................... 8765 mm Length without header with straw chopper ..............................9200 mm Weight without header with straw chopper ..............................13250 kg Weight with header.................................................................... With 6.0 m hdr. 14915 kg ................................................................................................... With 6.6 m hdr. 15010 kg Measured values of noise and vibration at the driver's seat Noise.............................................................................................................. SPL: 81.5 dBA ....................................................................................................................... Laq: 81.3 dBA ....................................................................................................................... Lt5: 81.8 dBA Accelerations.................................................................................................. In X: 0.12 m/s² ........................................................................................................................ In Y: 0.10 m/s² ........................................................................................................................ In Z: 0.50 m/s²
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CROSS - FLOW CF 80 COMBINE HARVESTER
1 – GENERAL ISSUES
External Air Filter The external air filter has to be cleaned in accordance with the operating conditions, in order to ensure the proper supply of fresh air. When there are high humidity and high levels of dust, the filter has to be cleaned more frequently. The filters are located behind the maintenance flaps on the left and right at the top of the cab. They are hidden with a removable metal cover. To take out the filters, remove these covers by pushing the latches, Pos. 1, down and pulling out the cover on the left or on the right. After this, pull the air filters out of their housings to clean them.
Clean the filters in the cab roof on a regular basis every 2 to 3 days by blowing them out or beating them.
Two methods for cleaning the filter: Compressed air: Blow compressed air with a maximum pressure of 241 kPa (35 psi) through the filter. Washing them with water: The filter can also be washed by dipping it in water and washing it with a mild, nonfoaming cleaning agent.External air filter, access on the left Rinse the filter with water until it is clean. The water pressure may not exceed 241 kPa (35 psi).
When the filter is changed and reinstalled, the arrow in the labeling has to absolutely point in the direction one drives in.
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1 – GENERAL ISSUES
Circulating-Air Filter The circulating-air filter 1 of the cab is located behind the driver's seat. Clean the filter in accordance with the requirements of the operating conditions. Use mild soap and water for this. Rinse it with clean water and press out excess water. Reinstall the filter.
Circulating-Air Filter
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1 – GENERAL ISSUES
Cooling Box The transportable cooling box is located under the passenger's seat. To operate it, connect it by means of the connection cable that is provided to the to the socket in the housing under the passenger's seat. ( Pos. 1)
Cooling Bag
Socket
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1 – GENERAL ISSUES
Handling by Crane When handling by crane, note the overall weight of the combine harvester and only use suitable lifting and hook-up equipment. When handling by crane, only the attachment points shown in the illustrations are to be used to attach the hook-up equipment.
Attachment Point on the Front Left Side
Attachment Point on the Back Left Side
Attachment Point on the Front Right Side
Attachment Point on the Back Right Side
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Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 2 Engine
CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
2 ENGINE Table of Contents Page Lubrication
2–2
Tappet Clearance
2–5
Air Filter System
2–6
Cooling System
2–7
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2 – ENGINE
Lubrication of engine Make sure to observe the following intervals for engine maintenance and oil change: Check oil level Change oil Oil capacity Oil capacity
every day every 240 hours of operation 19 litres (20 US quarts) without filter change 21 litres (22 US quarts) with filter change
Engine oil filter Filter change interval every 240 hours of operation (or once per year) For changing the engine oil filter proceed as follows: 1. Drain the oil from the engine. 2. Turn the oil filter counter-clockwise and remove it. Use a filter spanner if required. 3. Apply clean oil to the gasket of the new filter. 4. Install the filter and turn until the gasket Drain hose for engine oil makes contact with the filter head. Tighten the filter by another half a turn 1 drain hose by hand. 5. Loosen the filter by approx. one turn and tighten again until the gasket makes contact with the filter head. Tighten the filter by another half to three- quarters of a turn by hand. IMPORTANT: For installing the filter DO NOT make use of a filter spanner. Excessive tightening might damage the gasket and the filter. 6. Close the screw plug on the drain hose (Item 1). 7. Re-fill engine with new oil to marks on Engine oil filter dipstick.
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CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
Engine oil level For checking the engine oil level, park the combine harvester on even ground and stop the engine. Turn the handle of the gauge rod counter-clockwise and pull it out. If the oil level is found to be below the hatched mark this should be topped up to the required level. Take care to fill in oil up to the "FULL" mark only Install the gauge rod again and turn the handle clockwise to lock the gauge stick in its tube.
1 gauge rod 2 oil filler neck
The oil used for the diesel engine must of a grade as specified by the engine manufacturer. After the oil has been changed, the engine must be rotated by means of the starter (throttle lever in its "0" position) to build up oil pressure. As soon as this has been achieved, the engine may be started for operation.
Engine oil change For changing the engine oil, park the combine harvester on even ground and stop the engine. Change the engine oil according to the procedure described below: NOTE: Change the oil when the engine is still warm. 1. Allow the engine oil drain hose (Item 1) to discharge into a container. For ventilating the engine, remove the cover of the oil filler neck. 2. Open the screw plug (Item 2) and allow Engine oil drain hose the oil to drain from the engine. 3. Close the screw plug. 4. Refer to the section entitled "Engine oil filter" if the oil filter needs to be replaced. 5. Take care to fill the correct grade and quantity of fresh oil into the engine. Pull out the gauge rod and check the oil level in the engine. 6. Start the engine and watch the oil pressure indicator lamp. 7. Check the engine for absence of leaks. [10/2000]
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CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
Engine oil The engine oil recommended for the Case engine is of ICH No. 1 grade because Case ICH engine oil provides for the proper lubrication of the engine under any conditions of operation. Should oil of grade Case ICH No. 1 not be available, use must be made of an oil of grade CF according to the API specification.
Oil viscosity/outside temperature ranges * At temperatures within this range it will be necessary to use an engine oil or cooling agent heating system.
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CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
Tappet clearance check Tappet clearance adjustment Maintenance interval – every 1,000 hours of operation
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2-5
CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
Air filter assembly Air filter Air filter maintenance interval - clean filter as soon as dirt indicator lights up. Air filter cartridge replacement interval - once per year or after third clean-up. Safety replacement interval - after every 5th change of the air filter cartridge; DO NOT clean. The air filter assembly consists of the intake head AK for the separation of coarse dirt particles, the combined filter (dry air filter and safety cartridge) KF, the air intake pipe and the ejector exhaust EA. Any coarse dirt particles entering the air filter assembly are withdrawn by an ejector. Periodically check that the perforated plate of the intake head does not get clogged. The time at which it is necessary to change or clean the filter cartridge will be indicated by a signal lamp in the indicator unit.
Ejector exhaust of the air filter assembly KF combined filter VS screw plug D cover AK intake head EA ejector exhaust
If air is taken in from the exhaust gas system through the ejector hose due to a defect in the air filter assembly or as a result of a clogged intake head, a sensor will cause the air filter control lamp to come on without delay and an audible signal to be given in addition. The air filter is equipped with a safety cartridge to prevent dirt from entering the clean-air side of the air filter assembly when changing the air filter cartridge. The safety cartridge may NOT be cleaned. The air filter cartridge is cleaned by means of a blast of compressed air from inside to outside or by gentle tapping.
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CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
Cooling system Overpressure cooling system When the radiator cap is removed with the cooling system still in hot condition, there is the danger that hot cooling agent can escape. Therefore, the system should be allowed to cool down before the radiator cap is removed. For removing the cap, turn it to the first stop and wait for the pressure to escape. Do not open the cap in one go because this might involve the danger of scalding. . 1. In overpressure cooling systems the pressure cap is fitted with a pressure limiting valve with SAFETY VALVE function. This will keep the pressure in the system in its operating range all the time. If the engine is run without a pressure cap or with a pressure cap whose pressure limiting valve is not set to the correct pressure, this may lead to engine damage. 2. An overpressure cooling system minimises the loss of cooling agent due to evaporation or boiling. For the operation of the cooling system it should be ensured that the radiator cap gasket, the hoses and hose connections are in proper working order. Make sure that ALL LEAKS OF ANY SIZE are repaired immediately on detection. A small leak may lead to a high loss of fluid as pressure is built up in the cooling system.
Cooling agent compensating tank AB compensating tank D pressure cap E filler neck
During the operation of the combine harvester there is the danger that a porous hose might break and cause injuries to man and damage to equipment. It is imperative therefore to keep hoses, hose connections and pressure cap is proper working order all the time.
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CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
Cooling agent level Make a check for the level of the cooling agent in the compensating tank once a day. Check the cooling agent level when cold and with the engine at rest. If the cooling agent level is found to be below the bottom edge of the level tube, it will be necessary to top it up to the required level. Use the cooling agent of the specifications mentioned in this manual. Cooling agent IMPORTANT: Change the cooling agent at an interval of two years. The heat produced by the diesel engine will cause the inhibitors contained in the cooling agent to be changed which may lead to the loss of the corrosion protection property. The loss of the inhibitors may result in cavitation of the water pumps and erosion of the cylinder block. The anti-freezing agent used in the cooling system should be of ethylene glycol or propylene glycol type only. It should be of top quality, have a high boiling point and be free of sealing additives. The silicate content should not exceed 0.1 %. IMPORTANT: Make use of high-quality anti-freezing agent with low silicate content only. Commercial anti-freezing agents for road vehicles normally have a high silicate content and are not allowed to be used in Case engines. The corrosion inhibitors used should be of a type approved by Case. The corrosion inhibitors and anti-freezing agent might be incompatible with each other so that they cancel each other's effect. This will lead to a situation in which the corrosion protection function is no longer guaranteed and deposits will develop in the cooling system with resultant damage to the cooling system and radiator. Do not use anti-freezing agent on alcohol base or with a low boiling point. As the boiling point of alcohol is below the minimum operating temperature of the combine harvester, this might lead to an excessive loss of cooling agent due to evaporation. IMPORTANT: Keep the content of anti-freezing agent in the cooling system at a minimum of 50 % all the time. A content lower than 50 % will reduce the heat dissipation effect and lead to an excessively high temperature of the engine. Take care to observe the following for the preparation of the cooling agent: 1. Use water of good quality and make sure it has been treated with Case water additive (see "Cooling agent filter"). 2. Mix the anti-freezing agent with the treated water at a ratio of 50:50. 3. Fill the radiator and cooling agent compensating tank according to the data given in this manual (see "Cooling system filling").
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CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
Cooling system maintenance intervals Check the cooling agent level in the tank - daily Check and retighten the cooling agent hose clamps – every 250 hours of operation Change the cooling agent filter – every 250 hours of operation Change the cooling agent – every 2,000 hours of operation (or every 2 years) Change the cooling agent additive – every 2,000 hours of operation (or each time the cooling agent is changed) Cooling agent capacity – 65 litres Thermostat - 83-95 °C (181-203 °F) Cooling agent filter The cooling agent filter 1 comprises an element for filtering the cooling agent and feeding the chemicals for water treatment. Change the cooling agent filter at an interval of 250 hours of operation to protect the cooling system against corrosion, accumulation of dirt, the impact of chemicals and erosion of cylinder bushes due to cavitation. Each time the cooling agent is changed make sure to treat it with Case cooling agent additive (Part No. 331-509). Make sure to change the cooling agent filter as well to ensure the chemical concentration returns to the level that prevailed before the cooling agent was drained. If the filter is changed only, the amount of chemicals admixed would be too low. The cooling agent stop valve must be closed before the cooling agent filter is changed.
Cooling agent filter
Hot cooling agent may splash out of the cooling system when under pressure. Shut the valves before removing the filter.
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CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
Filter installation: 1. Lubricate the gasket of the new filter. 2. Screw the filter into the adapter until the gasket makes contact. 3. After the gasket has made contact proceed with turning the filter with the adapter by another half to three-quarters of a turn. Take care not to over-tighten the filter and DO NOT use a filter spanner. 4. Open the stop valve. NOTE: The admixture of sealing additives such as StopLeak, for example, to the cooling agent will cause an early clogging of the filter. Cooling agent drainage Engine block drain valve Clean the cooling system as described below each time the cooling agent is changed: 1. With the cooling agent still in hot condition, open the radiator drain hose 1 and the engine block drain valve 1. After the cooling agent has been drained make sure to close the radiator drain hose and engine block drain valve. 2. Fill in a high-grade radiator detergent and the cooling system with pure water. Take care to observe the instructions supplied with the radiator detergent. 3. Drain the radiator cleaning solution and rinse the cooling system with pure water.
Radiator drain hose
IMPORTANT: Never fill cooling agent into a hot engine because this may lead to cracking due to the temperature difference between the metal and the cooling agent.
Radiator cover AB compensating tank D pressure cap E cap (filler neck)
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CROSS - FLOW CF 80 COMBINE HARVESTER
2 – ENGINE
Cooling system filling After the cooling agent has been drained or if the cooling agent level in the compensating tank is found to be below the filler pipe, proceed with cooling agent filling as described below. IMPORTANT: Never fill cooling agent into a hot engine because this may lead to cracking of the engine block or cylinder heads due to the temperature difference between the metal and the cooling agent. Make sure before filling the cooling system that all drain valves are closed.
Radiator cover AB compensating tank D pressure cap E cap (filler neck)
1. Fill the radiator to capacity using the specified cooling agent. Fill the radiator at a slow rate until the cooling agent comes up to the bottom edge of the level tube. 2. Check the hoses, radiator, pump and the water distributor for absence of leaks. 3. Fill in cooling agent through the filler neck E up to the bottom edge of the level tube. 4. Start the engine and allow to run at no-load speed for one minute. Top up cooling agent level to the bottom edge of the level tube if required. 5. Run the engine until the cooling agent has reached its normal operating temperature. 6. Stop the engine and allow the cooling agent to cool down. Check the cooling agent level after the engine has cooled down. Top up the cooling agent level in the compensating tank (to the bottom edge of the filler tube) if required.
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Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 3 Fuel System
CROSS - FLOW CF 80 COMBINE HARVESTER
3 – FUEL SYSTEM
3 FUEL SYSTEM Table of Contents Page Fuel Tank
3–2
Fuel Filter
3–3
Injection System
3–4
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3 – FUEL SYSTEM
The fuel system comprises a 650-litre fuel tank, a water separator filter, a fuel filter and a fuel injection pump. Use clean fuel only, remove any matter accumulated in the water separator filter at regular intervals and attend to the fuel filters to avoid that dirt and water can enter the fuel system and cause loss of output. Diesel specification Use diesel fuel of No. 2 grade only. The use of other types and grades may lead to loss of engine power and increase of fuel consumption. NOTE: At very low outside temperatures it is allowed to use a mixture of No. 1 and No. 2 diesel fuel grades for a short time. Diesel fuel additive: 1. cleans the injection nozzles, valves and the distributor and thus increases the service life; 2. dissolves indissoluble sticky accumulations that might develop in the fuel system; 3. removes humidity from the fuel; 4. stabilises the fuel during storage.
Schematic sketch of fuel system 1. fuel filter 2. nozzle holder 3. overflow valve 4. fuel tank 5. feed pump 6. injection pump 7. water separator 8. electric fuel pump
Fuel system maintenance intervals Water separator filter Drain water at an interval of 50 hours of operation. Replace filter by new one if output is found to drop. Replace the primary engine filter after every 500 hours of operation or when output is found to drop. Water separator filter replacement Close the fuel stop valve. Unscrew the water separator filter (Item 1) by means of a filter spanner. Lubricate the gasket of the new filter with some oil or grease. Install the filter and open the fuel stop valve again.
Water separator filter
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CROSS - FLOW CF 80 COMBINE HARVESTER
3 – FUEL SYSTEM
IMPORTANT: Turn the filter clockwise until the filter gasket makes contact with the filter head. Apply another half a turn by hand. Unscrew the filter re-tighten and continue to turn by one half to three quarters of a turn after the gasket has made contact with the filter head so as to provide an optimum sealing effect. Do not overtighten the filter to prevent damage to the gasket and filter. Fuel filter replacement 1. Turn the fuel stop valve clockwise to close it. 2. Clean the filter 1 and the filter area on the engine. 3. Turn the filter 1 counter-clockwise to remove it. Use a filter spanner if required. 4. Remove the gasket from the adapter and discard. Mount a new gasket to the adapter. 5. Lubricate the gasket of the new filter 1 with clean oil or grease. 6. Install the new filter 1.
Fuel filter
IMPORTANT: Turn the filter clockwise until the filter gasket makes contact with the filter head. Apply another half a turn by hand. Unscrew the filter re-tighten and continue to turn by one half to three-quarters of a turn after the gasket has made contact with the filter head so as to provide an optimum sealing effect. 7. Fill the fuel tank and bleed the fuel system. Fuel system bleeding Make sure to bleed the fuel system. Air may enter the fuel system if: 1. the fuel tank has been fully emptied; 2. parts of the fuel system had been removed for the purpose of maintenance and repair; 3. the combine harvester has been at a standstill for a longer period of time. NOTE: If no fuel is in the fuel tank, proceed with filling the tank and starting the engine without having to bleed the fuel system. But there might be some air in the filters and injection pump. Air contained in the system will lead to loss of power and stalling of the engine as soon as load is applied.
[10/2000]
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CROSS - FLOW CF 80 COMBINE HARVESTER
3 – FUEL SYSTEM
For bleeding the fuel system proceed as follows: 1. Unscrew the vent plug 1 situated on the outlet side of the fuel filter housing. 2. Operate the manual fuel pump 1 to fill the fuel filter with fuel. Tighten the vent plug if clean fuel is found to flow from the plug without air bubble development. Then operate the manual pump for another 20 times. 3. Set the speed lever to maximum speed in the no-load position and start the engine.
Vent plug on fuel filter
NOTE: If the engine fails to start, repeat the steps 1 to 3 and bleed the fuel injection line. See steps 5 to 7. 4. Unscrew three of the injection line nuts 1 on the injection nozzles. 5. Crank the engine for ten seconds. The engine must not start with the lines opened. If it should start, set the speed lever to its "ENGINE STOP" position right away. TURN OFF the ignition. 6. Tighten the injection line nuts, start the engine and check the lines and connections for possible fuel leaks. Manual fuel pump
Injection line nuts
[10/2000]
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CROSS - FLOW CF 80 COMBINE HARVESTER
3 – FUEL SYSTEM
Injection nozzles The maintenance interval (replacement or overhaul) for the injection nozzles is 2000 hours of operation. Apply to the authorised workshop.
[10/2000]
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3-5
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 4 Electrical System
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
4 ELECTRICAL SYSTEM Table of Contents Page Overhead Console
4–3
Joystick
4–5
Starting Process
4–6
Control Panel Design P (Electrical-Mech. Field Tracking)
4–7
Control Panel Design Q (Electrical-Hydr. Field Tracking)
4 – 10
Header Return
4 – 13
Field Tracking Design P (Electrical-Mechanical)
4 – 14
Manual Program
4 – 14
High-Cut Program
4 – 14
Field Tracking Program
4 – 15
Setting the Angle Transmitter
4 – 16
Field Tracking Design Q (Electrical-Hydraulic)
4 – 17
TEACH IN Program
4 – 19
MANUAL Program
4 – 26
HIGH-CUT (RTC) Program
4 – 29
SUPPORT PRESSURE CONTROL Program
4 – 32
FIELD TRACKING (HT) Program
4 – 34
Transmitter and Signal Function
4 – 42
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Display Unit, Model 2000
4 – 51
LH AGRO 965 On-Board Computer
4 – 60
Setting the Headlights
4 – 100
Central Processing Unit
4 – 101
Electronic Components
4 – 101
Relay and Diode Equipment
4 – 110
Fuses
4 – 120
Plug-Type Connectors
4 – 130
Graphical Symbols
4 – 190
Circuit Diagrams CF 80
4 – 197
Circuit Diagrams CF 70
4 – 297
Circuit Diagrams CF 60
4 – 397
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Overhead console
Fan speed (Item 1) - Switch for fan speed selection Heater valve (Item 2) red - permits hot water to flow to the heat exchanger Temperature preselection (Item 3) blue - permits a constant cab temperature to be set (in cooling operation)
Working light for field work - Switch in outermost front position The cab lights, travelling lights, rear lights, front marker lights, discharge pipe lights (if pipe is swivelled out), grain tank lights and rear floodlights are on. The floodlights will go out if – in this switch position – the warning beacons are turned on with switch Item 4 (glare protection when travelling on the road).
Warning beacon switch (Item 4) This switch must be turned on when the Wiper switch (Item 7) combine is on the road. Field/road switch (Item 8) - Switch is in lower position Hazard warning light switch (Item 5) If the engine is running, the FIELD working functions can be activated in this position. Light switch (Item 6) This switch has three positions. It is used Air conditioner switch (Item 9) as follows: Road travelling light – DAYTIME Radio receiver (Item 10) - Light switch is set to lowermost posi- A radio set is incorporated in the overhead tion. console. Instructions for use are provided for Use this switch position for daytime the radio; they are kept together with the travelling. operating instructions for the machine in the Road travelling light – NIGHT TIME cab. - Light switch is set to front position. 2 headlights, front marker lights, rear Recess for radio equipment (Item 11) lights and internal lights are on. Use this switch position for night time travelling. To turn off the lights, push If the warning beacon is switched with the the switch downward. working lights on, the lights for road travelling are automatically changed over too.
[01/2001]
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Radio equipment At present, the radio equipment must be installed by the customer. The manufacturer has provided for the operating voltage connection and aerial connection in the recess. It may be necessary to adapt the radio connecting facilities to the inbuilt connections. We recommend to rely on the services of a shop specialising in electrical and electronic motor car equipment. NOTE: The connection of an aerial has been factory-prepared so that a mobile phone can be connected on the left side of the driver seat. Make sure to fix an aerial to the receptacle (receptacle is located on the left mirror holder) that is suitable for the mobile phone network you use. To connect a radio phone, screw an aerial rod suitable for the radio network concerned into the receptacle. Then connect the radio set to the aerial in the recess. Heating/ ventilation / air conditioning Condition: - Items 1, 2 and 3 are ready for operation only if the switch (Item 9) has been turned on. Heating: - Set the rotary button of the heating valve (Item 2) to mid-position (12 o'clock). Use the fan speed selector (Item 1) to adjust the desired quantity of warm air. Ventilation: - Close the heating valve (Item 2). To do so, turn the button counterclockwise as far as it will go. Adjust the desired fresh air supply by turning the fan speed selector (Item 1).
If the system is out of operation for an extended period, for example in winter, and the temperature is higher than 6°C, the engine must be started once a month, and the air conditioner must be operated for a few minutes to lubricate the compressor sealings.
Air conditioning (cooling): - Close the heating valve (Item 2). Turn on switch "Air conditioner" (Item 11). Adjust the desired cooling air supply by means of the fan speed selector (Item 1). Set the cab temperature to be maintained on the rotary button for temperature preselection.
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Switches on the joy stick Reel control switch (Item 1) The switch has four positions
-
Lift – press the switch downward to lift the reel Lower – press the switch upward to lower the reel Forward – push the switch to the left to move the reel forward Reverse – push the switch to the right to reverse the reel
Header lift switch (Item 2) This switch has four positions; it works as follows: - Lift – press the switch downward to lift the header - Lower – press the switch upward to lower the header - Left and right movements of the switch have no function Grain tank discharge pipe switch (Item 3) - Push the switch upward to move out the discharge pipe - Push the switch downward to move in the discharge pipe The mid-position of the switch is the NEUTRAL position. Set the switch to its NEUTRAL position to start the engine. Grain tank unloading auger switch (Item 4) (function can only be used when grain tank unloading auger is swung out and grain tank slats are closed. - Press the switch and let go to start the unloading auger - (Press the switch again to stop the unloading auger.) Switch for turning off the feed elevator and header (Item 5) This switch immediately stops the header and feed elevator. - Press the switch and let go to stop the feeder elevator and header drives. - To restart the header and feed elevator, operate the header switch on the control console. Differences in the Joystick in Design Q (Electrical - Hydraulic Field Tracking) 1.
In the case of the electrical-hydraulic field tracking, the key for turning on the type of automatic system that has been chosen is located on the back side of the joystick. Tilting the switch (Pos. 2) to the left or to the right overrides the parallelism of the header and swivels it in the respective direction.
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
The combine is equipped with an electronic start safety system the functions of which are displayed to the driver.
The engine cannot be started until all red tell-tale lamps are out. These tell-tale lamps indicate the following: 6 7 5 4 3 2 1
engine stop solenoid not ready for operation. This lamp will go out approx. 5 seconds after all the other tell-tale lamps have extinguished. driver's seat monitoring (in preparation) discharge pipe switch not in neutral position joy stick not in neutral position not used no hooter signal speed setting lever of Diesel engine is in position „engine off“
Starting procedure
Turn on master switch. Turn the ignition key clockwise to the first position (ignition on). Observing the safety aspects, prepare the machine for starting so that tell-tale lamps 4 and 7 do not come on. Shift the throttle lever of the Diesel engine to „half throttle“ (tell-tale lamp 1 will go out). Actuate the hooter (tell-tale lamp 2 goes out). After lamp 6 has gone out (after some 5 seconds), turn the ignition key clockwise to the second position.
After cutting off the combine engine, operate the master switch to turn off the electrical system.
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Control Panel Design P (Electrical-Mechanical Field Tracking) Switching elements and control lamps are arranged on the control panel. Control panel for electro-mechanical adjustment to soil contour
1 Switch for adjustment to soil contour Upper position: high cut „ON“ Mid-position: adjustment „OFF“ Lower position: adjustment „ON“ To use the functions of switch 2, the machine must run at low travelling speed!
[01/2001]
2 Switch for laid grain (is only operable when switch 1 is in position „ON“) In connection with switch 3, the swing range of the header can be narrowed down when working in laid grain so that the header seems to be guided with hanging blade fingers.
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
3 Rotary switch for setting the swing range of the header (located behind header stop) 6 not used
7 Mode selector switch for reel speed Condition: header must be coupled Switch position OFF – manual speed setting (with Item 8) Switch position ON – reel speed setting dependent on travelling speed (automatic) (overload factor adjustable with Item 8). 8 Rotary switch for reel speed Mode „0“ for Item 7 – direct speed setting Mode „I“ for Item 7 –“overload factor” setting the reel speed as a percentage of ground speed (reel rotates only if header is coupled) 10 Switch for thresher coupling Condition: field/road switch (Item 8, p. 2-16) must be in position „FELDBETRIEB“ (field use).
11 Header coupling switch Condition: thresher must have been turned on (if necessary, activate switch from OFF position) 12 Rape separator left and right Condition: header must have been turned on (if necessary, activate switch from the "OFF" position)
Note! For the protection of the reversing motor, a safety circuit is used that automatically implements a min. 20 second pause after every operation of the reversing equipment.
[01/2001]
14 Switch for feed elevator locking (hold or release swing frame of slope conveyor at/from rear stop) 15 Fan speed switch Increase and decrease of fan speed Condition: - fan speed indication has been selected on on-board computer - thresher is coupled 16 Switch for threshing cylinder speed increase and decrease of threshing cylinder speed Condition: threshing cylinder speed indication has been selected on onboard computer, thresher is coupled green
17 Switch for changeover of onboard computer display If this switch is operated, the grain quantity of the tailings is displayed in the loss diagram rather than the walker losses. Note! Be aware that you may have to vary the display sensitivity of the bar diagram (depends on switch position; see also Section "Onboard computer). 18 Switch for diffuser screen adjustment By operating this switch, the diffuser screen of the straw chopper is moved to the right or left (option). 21 Switch for mirror adjustment (main mirror left and right) 22 12 V socket (telephone/ cigarette lighter – left side of driver seat)
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4-8
CROSS - FLOW CF 80 COMBINE HARVESTER 13 Header reverse switch: serves to clear minor obstructions in the header and the feeder zone of the feed elevator. Condition: - thresher must be on - header must be off - keep pushbutton pressed for 5 seconds
[01/2001]
4 – ELECTRICAL SYSTEM
23 Pilot lamp indicating mid-position of straw chopper diffuser screen (option for Item 18) 24 Straw chopper pilot lamp (orange) on: straw chopper is operated by the slats on the chopper.
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Control Panel Design Q (Electrical-Hydraulic Field Tracking)
6
Not used
26
Control lamp for the malfunction display for the central lubrication system (pump) accessory equipment
25
Control lamp for operational readiness of the central lubrication system (pump) accessory equipment
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Operating and Display Device for the Field Tracking
7
8 MAN
RTC
10 HT
HEADER CONTROL
FLOAT
** MODUS HT ** MIN MAX NIEDRIGER HOEHER TASTE AB TASTE AUF TEACHIN
MANUAL
RTC
1
2
3
HT
4
12 16
FLOAT
5
OPTION
14
STOP
6
KEY Teach-In mode KEY Manual Operation mode KEY High-Cut mode KEY Field Tracking mode KEY Support Pressure Control mode KEY Stop LED Display Manual Operation mode LED Display High-Cut mode LED Display Field Tracking with Cutting Height Guide mode LED Display Support Pressure Control mode KEY Up KEY Down DISPLAY Key OPTION for the display of supplementary functions Key Increase / Reduce Sensitivity Mode HT Key Sensitivity Right / Left Mode HT
7 Mode selector switch for reel speed Condition: header must be coupled Switch position OFF – manual speed setting (with Item 8) Switch position ON – reel speed setting dependent on travelling speed (automatic) (overload factor adjustable with Item 8).
[01/2001]
15
11
13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
9
15 Fan speed switch Increase and decrease of fan speed Condition: - fan speed indication has been selected on on-board computer - thresher is coupled
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4-11
CROSS - FLOW CF 80 COMBINE HARVESTER 8 Rotary switch for reel speed Mode „0“ for Item 7 – direct speed setting Mode „I“ for Item 7 –“overload factor” setting the reel speed as a percentage of ground speed (reel rotates only if header is coupled) 10 Switch for thresher coupling Condition: field/road switch (Item 8, p. 2-16) must be in position „FELDBETRIEB“ (field use).
11 Header coupling switch Condition: thresher must have been turned on (if necessary, activate switch from OFF position) 12 Rape separator left and right Condition: header must have been turned on (if necessary, activate switch from the "OFF" position)
Note! For the protection of the reversing motor, a safety circuit is used that automatically implements a min. 20 second pause after every operation of the reversing equipment. 13 Header reverse switch: serves to clear minor obstructions in the header and the feeder zone of the feed elevator. Condition: - thresher must be on - header must be off - keep pushbutton pressed for 5 seconds
[01/2001]
4 – ELECTRICAL SYSTEM
16 Switch for threshing cylinder speed increase and decrease of threshing cylinder speed Condition: threshing cylinder speed indication has been selected on onboard computer, thresher is coupled green
17 Switch for changeover of on-board computer display If this switch is operated, the grain quantity of the tailings is displayed in the loss diagram rather than the walker losses. Note! Be aware that you may have to vary the display sensitivity of the bar diagram (depends on switch position; see also Section "Onboard computer). 18 Switch for diffuser screen adjustment By operating this switch, the diffuser screen of the straw chopper is moved to the right or left (option). 21 Switch for mirror adjustment (main mirror left and right) 22 12 V socket (telephone/ cigarette lighter – left side of driver seat) 23 Pilot lamp indicating mid-position of straw chopper diffuser screen (option for Item 18) 24 Straw chopper pilot lamp (orange) on: straw chopper is operated by the slats on the chopper.
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Header and Feeder Reverser The combine harvester is delivered with a header and feeder reverser. You can remedy a clogging of the header and the shaft with this. When the switch is actuated, there is a reversal of the direction of rotation of the working elements of the header and the shaft. If the electrical motor of the header and feeder reverser does not start up 5 seconds after actuation of the switch (very heavy dirt), then stop the process and clear the clogging manually. The following prerequisites have to be met for the header and feeder reverser to function: -
The working hydraulics are activated The threshing unit is engaged The header is disengaged The drive spindle of the shaft (upper shaft spindle) has to have come to a standstill.
This process is electronically monitored. When these prerequisites are met, the electrical motor for driving the return equipment turns on 5 seconds after actuation of the switch. Keep continually pressing down on the switch in the process. The return process is automatically shut off after 10 seconds to avoid overheating of the electrical motor. If this period of time is not sufficient to clear the header, the return can be put into operation again for a further 10 seconds by pressing the switch again after a waiting period of approx. 1 minute.
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Field Tracking Design P (Electrical-Mechanical Field Tracking) The field tracking serves to ensure proper and automatic following (tracking) of the ground profile or a preset high cut. Operating Modes The can select the following operating with the switch (Pos. 1): 1. 2.
Manual High-Cut
Center position Switch pushed upwards
3.
Field Tracking
Switch pushed downwards
1.
Manual
3
The switch is in the center position. The automatic system is not activated, which is displayed by the switching symbol illuminating. The manual operating mode is mainly used for attaching and removing the header. The use of this operating mode is also recommended for lodged grain and for grounds with unevenness not occurring naturally. 1 2 3 2. High-Cut
Operating mode switch Lodged grain switch Turning angle potentiometer
The switch is pushed upwards. When the threshing unit and header are switch in, the automatic system is activated, which is displayed by the switching symbol illuminating. The pendulum frame is fixed into its end position with the clamp (A) and the cable of the hydraulic header latch (see the illustration). When the "Lower header" key on the joystick is briefly actuated, the shaft lowers itself down to the value preselected on the potentiometer of the display unit. There is no contact between the ground and the header. The number shown in the display is not the cutting height. The upper end position of the shaft is shown in the display with "HI". If the setting is changed, the shaft has to first be moved into the upper A Clamp end position. The value for the high-cut is then changed by turning the potentiometer. After this, the lowering process is started and the desired cutting height is checked.
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4-14
CROSS - FLOW CF 80 COMBINE HARVESTER 3.
4 – ELECTRICAL SYSTEM
Field Tracking The switch is pushed downwards. When the threshing unit and header are switched in, the automatic system is activated, which is displayed by the switch symbol illuminating. The pendulum frame can be swiveled. The header was adapted to the combine harvester (Chapter 9A). The desired cutting height was set on the slip heels. When the "Lower header" key on the joystick is briefly actuated, the header lowers itself down to the ground. The header is continually adapted to the cross-wise and longitudinal direction of the ground profile through its own weight. The load of the header on the ground is taken off by two spring packets. In the longitudinal tracking, the angle of tilt of the header is measured with a transmitter on the pendulum frame. The shaft is automatically readjusted in both end positions, so that the header is fully capable of movement again. The front switching point (pendulum frame fully swiveled out) brings about a lowering of the shaft. The back switching point (pendulum frame is adjacent to the shaft) brings about a lifting of the shaft. The sickle spacing to the ground is smallest when the pendulum frame is fully swiveled out. If the pendulum frame is adjacent to the shaft, the spacing is the greatest and takes the load off the springs, which has the consequence of high ground pressure of the header. You override the automatic system by actuating the "Lift header" key on the joystick (e.g. when obstacles suddenly arise and when turning is done).
Harvesting layed crop When the lodged grain switch (Pos. 2) is actuated, the back switching point is changed over to a value preselected with the potentiometer (Pos. 3). The swivel range of the header is thereby limited, and the sickle spacing to the ground is small. Adjustment of the Back Switching Point with the Potentiometer 1. 2. 3. 4. 5. 6.
Start the engine Activate the working hydraulics Switch in the threshing unit and header Turn the potentiometer (Pos. 3) in a counterclockwise direction into the end position Press the operating mode switch (Pos. 1) downwards (field tracking is switched on) The header lowers itself because of a lowering pulse at the "Lower header" key. The pendulum frame falls into the front end position before reaching the ground. After this, the header sets down on the ground and the sloped conveyor lifts up for a short period of time, so that the pendulum frame swivels back somewhat from the front end limit stop. 7. Switch on the lodged grain switch (Pos. 2) 8. Slowly turn the potentiometer (Pos. 3) in a clockwise direction until the sloped conveyor lifts up. Turning in a counterclockwise direction ⇒ The back switching point is repositioned in the direction of the front one ⇒ Butt height is reduced Turning in a clockwise direction ⇒ The back switching point is repositioned in the direction of the back end limit stop. ⇒ Butt height increases
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4-15
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Setting the Angle Transmitter The angle transmitters are set by adjustment in the oblong holes. In the process, the connector is pulled at the angle transmitter and a 3-contact measurement cable is connected between them. The voltage between the two external cables can now be measured with a voltmeter. Angle Transmitter Shaft Height There is a voltage of less than 5.0 volts in the deepest position of the shaft. In the uppermost, there is a voltage of more than 1.0 volts. The arm of the angle transmitter has to point forward (see the illustration). Adjustment Specifications 1. 2. 3. 4. 5. 6.
Lift the shaft to the maximum Put in a bridge between F1.2 and F 4.1 Switch in the threshing unit and header clutch Unscrew the fastening screws of the angle transmitter Turn the angle transmitter in a counterclockwise direction up to the end limit stop Turn the angle transmitter in the clockwise direction until a voltage of more than 1.0 volt exists (e.g. 1.2 volts). If this is not possible, a rough adjustment with the rod linkage should be made. 7. Screw down the fastening screws 8. Lower the shaft to 11 cm over the ground and check the voltage (less than 5.0 volts, e.g. 4.8 volts)
Angle Transmitter Pendulum Frame There is a voltage of 1.0 volt in the back end position. If the pendulum frame is swiveled out completely forward, the voltage is 5.0 volts. Adjustment Specifications 1 Lift the shaft so that the pendulum is completely next to the shaft (see the illustration) 2 Put in a bridge between F1.2 and F 4.1 3 Switch in the threshing unit and header clutch 4 Unscrew the fastening screws of the angle transmitter 5 Turn the angle transmitter in a counterclockwise direction up to the end limit stop 6 Turn the angle transmitter in the clockwise direction until a voltage of more than 1.0 volt exists. If this is not possible, a rough adjustment with the rod linkage should be made. 7 Screw down the fastening screws
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Field Tracking Design Q (Electrical-Hydraulic Field Tracking) The field tracking is based on a sensor-bound probing of the ground profile, combined with hydraulic control elements on the header. The design variation realizes a choice of spacing control or ground-bound pressure control. The spacing control (HT) records the spacing of the header to the ground as a control variable. It realizes a tracking of vertical and horizontal ground undulations; the lifting cylinder of the sloped conveyor and the cross pendulum cylinder are driven on the right-hand side of the sloped conveyor. Furthermore, it makes a defined cutting height possible that is dependent upon the driving speed and the setting of the cutting angle. The support pressure control (FLOAT) records the difference between the load taken on by the lifting cylinder and the set residual support on the ground as a control variable. It only realizes a maximum force on the ground, independent from the support area. This means that the header is controlled in accordance with the selected cross-wise tilt on the ground and is not adjusted in the horizontal direction. Furthermore it makes the shortest cut possible by direct ground support of the header, combined with a corresponding cutting angle adjustment. The functions of the HEADER CONTROL also include the "High-Cut (RTC)" mode for a regulated position relative to the combine harvester. In the process, the lowest cutting height is when the slip skids come in contact with the ground and thereby impact the angle transmitter. The "MANUAL" operating mode is a pure manual control of the functions of lifting / lowering / swinging right / swinging left of the header. All of the adjustment and operating functions are carried out from an operating and display device. This device communicates via a CAN node with the central 16-bit electronics, which contains the entire "HEADER CONTROL" program package. The electronics also contain a serial interface of the type RS232, in addition to a central connection cable, for reprogramming and for troubleshooting.
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Operating and Display Device
7
8 MAN
RTC
10 HT
15 FLOAT
HEADER CONTROL
11
13
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
9
** MODUS HT ** MIN MAX NIEDRIGER HOEHER TASTE AB TASTE AUF TEACHIN
MANUAL
RTC
1
2
3
HT
4
FLOAT
5
12 16 OPTION
14
STOP
6
KEY Teach-In mode KEY Manual Operation mode KEY High-Cut mode KEY Field Tracking with Cutting Height Guide mode KEY Support Pressure Control mode KEY Stop LED Display Manual Operation mode LED Display High-Cut mode LED Display Field Tracking with Cutting Height Guide mode LED Display Support Pressure Control mode KEY Up KEY Down DISPLAY 4 x 20 Key OPTION for the display of supplementary functions Key Increase / Reduce Sensitivity Mode HT Key Sensitivity Right / Left Mode HT
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CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
TEACH-IN Program The Teach-In program is for the equalization of the probe skid sensors the determination of the horizontal position of the header the determination of the header weight by means of a pressure sensor the determination of the upper end position of the sloped conveyor The Teach-In program represents a conscious system adjustment to the components added at this point in time. Any changes that my arise that are implemented after the TeachIn do not change the values of the Teach-In (a cutting angle change because of mechanical adjustment to the sloped conveyor; changing the probe skid potentiometer; change of the header and adding accessory equipment such as a rape sickle). A renewed Teach-In is to be carried out after the parameters mentioned above have been changed to update the system parameters. As a general principle, the Teach-In can be run any arbitrary number of times. In the process, the combine harvester with a mounted header is to be driven on ground that is as level as possible. When the header is lowered, all 4 probe skids have to be moved in as a maximum to the limit stop on the header bottom. Prerequisites for Running the Teach-In: 1. Header is mounted 2. Diesel engine is running 3. Working hydraulics flip switch is on "field operation" 4. The threshing unit and header clutch is switched out Program Sequence: 1. 2.
The "TEACH-IN" key on the operating and display device is pressed for ď‚ł 5 sec. The display output in accordance with the illustration is provided after 5 sec.
3.
Readiness for the Teach-In is signalized.
4.
The "AUTOMATIC" key on the joystick is pressed, in order to consciously start TEACH-IN. The display output is switched over.
5. 6. 7. 8.
** MODUS TEACH-IN ** STARTEN MIT TASTE AUTOMATIK !
** MODUS TEACH-IN ** TEACH-IN LAEUFT ABBRECHEN MIT STOP!
The "Lift" valve is driven for 15 sec. and the sloped conveyor is lifted up to the upper mechanical limit stop. The header "Right" valve is driven for t = 10 sec. The header "Left" valve is driven for t = 10 sec. The header is positioned horizontally. An error in the header-cross angle transmitter or in the cross pendulum valve can arise at this point that will lead to an immediate cancellation of the program due to its seriousness. If the transmitter is not recognized or if the voltage change from limit stop to limit stop is not large enough, the adjustment of the horizontal position is not possible.
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CROSS - FLOW CF 80 COMBINE HARVESTER The following display output is provided immediately:
4 – ELECTRICAL SYSTEM
** MODUS TEACH-IN ** PROGRAMMABBRUCH FEHLER QUERNEIGUNG TASTE AB
The 2 possible hardware causes for this error can be shown in the display as display outputs with the "AB" key.
1.FEHLERVARIANTE WINKELGEBER AM TRAGRAHMEN PRUEFEN ! TASTE AUF TASTE AB 9
2.FEHLERVARIANTE WEGEVENTIL MIT HANDNOT BETAETIGEN ! TASTE AUF
The sloped conveyor is brought to the ground support for 20 sec. via the "Lower" valve. All of the sensors are probed, normalized and checked for plausibility during the lowering process. This normalization forms the basis for all of the HEADER CONTROL functions.
10. The header is lifted again, and the characteristic curve of the lifting and lowering valves is input (slow lifting and lowering movement). A Teach-In is to be run as a general principle when the header is changed, when the transmitter is changed and after updates to the software. All of the parameters that are determined are stored on an EEPROM and are therefore always available, independently of an interruption in the voltage supply. 11. If the TEACH-IN is complete and has run without errors, the following is shown in the display.
12
** MODUS TEACH-IN ** TEACH-IN OHNE FEHLER AUSGEFUEHRT. BETRIEBSBEREIT !
If the Teach-In was not able to be successfully carried out for various reasons, the following output is provided on the display; X stands for the number of errors recorded in the process, and the number of errors is inserted in place of the generic variable X. The listing of errors that have arisen can now be scrolled through in the submenu with the AB KEY. In so doing, one error will correspondingly be output per display page.
** MODUS TEACH-IN ** TEACH-IN FEHLER X FEHLER ERFASST TASTE AB
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4 – ELECTRICAL SYSTEM
The Teach-In that was run with errors is written into the memory (EEPROM), and the display can be seen on the display for 15 sec. when there is any further activation of the working hydraulics, even after shutting off the battery voltage, in order to show that errors that more or less limit the functioning of the individual operating **TEACH-IN FEHLER** modes arose during the last Teach-In LETZTES TEACH-IN (see the following table). FEHLERHAFT !!! The errors are output in the following order in the display: Error 1 Error 2 Error 3 Error 4 Error 5 Error 6 Error 7
Analog Transmitter Probe Skid 1 Analog Transmitter Probe Skid 2 Analog Transmitter Probe Skid 3 Analog Transmitter Probe Skid 4 Analog Transmitter Shaft Height Analog Transmitter Cross Pendulum Analog Pressure Transmitter
**FEHLER TEACH-IN** FEHLER XYZ GEBER TASTKUFE 1 TASTE AUF TASTE AB Error 1
**FEHLER TEACH-IN** FEHLER XYZ GEBER TASTKUFE 2 TASTE AUF TASTE AB Error 2
**FEHLER TEACH-IN** FEHLER XYZ GEBER TASTKUFE 3 TASTE AUF TASTE AB Error 3
**FEHLER TEACH-IN** FEHLER XYZ GEBER TASTKUFE 4 TASTE AUF TASTE AB Error 4
**FEHLER TEACH-IN** FEHLER XYZ SCHACHTHOEHE TASTE AUF TASTE AB Error 5
**FEHLER TEACH-IN** FEHLER XYZ QUERPENDEL TASTE AUF TASTE AB Error 6
**FEHLER TEACH-IN** FEHLER XYZ DRUCKSENSOR TASTE AUF TASTE AB Error 7
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4 – ELECTRICAL SYSTEM
Selection of Various Transmitter Errors in the Teach-In and Their Significance for Running the Operating Modes Error
Manual Mode
Probe Skid 1
No influence Key does not react as a switch when there is a ground obstacle; Illustration 28
Signal of the symmetrical probe skid TK4 is shut off; no mean value formation of the pair-by-pair probe skids is possible; values of the Probe Skids TK2 and TK3 are directly processed; Illustration 11
Probe Skid 2
No influence Key does not react as a switch when there is a ground obstacle; Illustration 28 No influence Key does not react as a switch when there is a ground obstacle; Illustration 28
No influence Signal of the symmetrical probe skid TK4 is shut off; no mean value formation of the pair-by-pair probe skids is possible; values of the Probe Skids TK1 and TK4 are directly processed; Illustration 12
Probe Skid 4
No influence Key does not react as a switch when there is a ground obstacle; Illustration 28
No influence Signal of the symmetrical probe skid TK1 is shut off; no mean value formation of the pair-by-pair probe skids is possible; values of the Probe Skids TK2 and TK3 are directly processed; Illustration14
Probe Skid 1 and Probe Skid 2
No influence Key does not react as a switch when there is a ground obstacle; Illustration 28
No symmetrical signal recording is No influence possible; the operating mode cannot be run, when the "field tracking" operating mode is selected, the display Illustration 15 is output.
Probe Skid 3
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High-Cut
Spacing Regulation for Field Tracking
Support Pressure Control No influence
Signal of the symmetrical probe No influence skid TK2 is shut off; no mean value formation of the pair-by-pair probe skids is possible; values of the Probe Skids TK1 and TK4 are directly processed; Illustration 13
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Manual Mode
High-Cut
4 – ELECTRICAL SYSTEM
Spacing Regulation for Field Tracking
Support Pressure Control No symmetrical signal recording is No influence No influence Key does not possible; the operating mode canreact as a not be run, when the "field trackswitch when ing" operating mode is selected, there is a the display Illustration 16 is outground obstacle; Illustration put. 28
3 or 4 probe skid without function
No influence Key does not react as a switch when there is a ground obstacle; Illustration 28
No symmetrical signal recording is No influence possible; the operating mode cannot be run, when the "field tracking" operating mode is selected, the display Illustration 17 is output.
Transmitter shaft height
An automatic horizontal positioning when a certain windrow height is reached is not carried out; Illustration 29
The automatic drive unit does not recognize any actual value through the cutting-height preselector; no reaction when there is pressure on the automatic key; when the "highcut" operating mode is selected, the display in Illustration 18 is output. Automatic horiAutomatic zontal positionhorizontal positioning of ing of the the header is header is done done errone- erroneously; Illustration 21 ously; Illustration 20
Automatic driving of the preselected butt height is possible as long as the sensors on TK1 to TK4 supply the actual values; No driving or end-position dampening is possible behind the butt height (Keys TK1 to 4 are completely folded down); Illustration 19
Cross pendulum angle transmitter
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An automatic horizontal positioning when a certain windrow height is reached is not carried out; Illustration 30
Automatic horizontal positioning of Automatic horizontal posithe header is done erroneously; tioning of the Illustration 22 header; Illustration 23
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4 – ELECTRICAL SYSTEM
Error
Manual Mode
High-Cut
Spacing Regulation for Field Tracking
Pressure sensor
The protective function is not effective when there is support set-down that is stronger than preselected; output is Illustration 24
The protective function is not effective when there is support set-down that is stronger than preselected; output is Illustration 25
The protective function is not effective when there is support setdown that is stronger than preselected; output is Illustration 26
Support Pressure Control The control variable for regulation is not available; the operating mode cannot be run; when the "support pressure control" operating mode is chosen, the display of Illustration 27 is output.
Error Display
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER TASTKUFE 1 Illustration 11
Illustration 12
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER TASTKUFE 3 Illustration 13
Illustration 15
** MODUS HT ** MODUS NICHT BEREIT ! FEHLER TASTKUFE 3 FEHLER TASTKUFE 4 Illustration 16
** MODUS HT ** MODUS NICHT BEREIT ! FEHLER TASTKUFEN: 1 2 3 4
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** MODUS HT ** MODUS EINGESCHRAENKT FEHLER TASTKUFE 4 Illustration 14
** MODUS HT ** MODUS NICHT BEREIT ! FEHLER TASTKUFE 1 FEHLER TASTKUFE 2
Illustration 17
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER TASTKUFE 2
** MODUS RTC ** MODUS NICHT AUSFUEHRBAR ! FEHLER HOEHENGEBER Illustration 18
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** MODUS HT ** MODUS EINGESCHRAENKT FEHLER HOEHENGEBER Illustration 19
Illustration 21
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER QUERPENDEL KEINE MITTELLAGE Illustration 22
** MODUS FLOAT ** MODUS EINGESCHRAENKT FEHLER QUERPENDEL KEINE MITTELLAGE Illustration 23
** MODUS MANUAL ** MODUS EINGESCHRAENKT FEHLER DRUCKSENSOR Illustration 24
** MODUS RTC ** MODUS EINGESCHRAENKT FEHLER DRUCKSENSOR Illustration 25
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER DRUCKSENSOR Illustration 26
** MODUS FLOAT ** MODUS NICHT AUSFUEHRBAR ! FEHLER DRUCKSENSOR Illustration 27
** MODUS RTC ** MODUS EINGESCHRAENKT FEHLER TASTKUFEN 1 2 3 4 Illustration 28
** MODUS MANUAL ** MODUS EINGESCHRAENKT FEHLER HOEHENGEBER
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** MODUS MANUAL ** MODUS EINGESCHRAENKT FEHLER QUERPENDEL KEINE MITTELLAGE Illustration 20
** MODUS RTC ** MODUS EINGESCHRAENKT FEHLER QUERPENDEL KEINE MITTELLAGE
Illustration 29
4 – ELECTRICAL SYSTEM
** MODUS FLOAT ** MODUS EINGESCHRAENKT FEHLER HOEHENGEBER Illustration 30
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4 – ELECTRICAL SYSTEM
Manual Program The MANUAL operating mode is switched in as a general principle when the "working hydraulics" is activated or when the threshing unit is shut off. In addition, the operating mode can also be switched in as a general principle via the operating and display device when there is a running threshing unit. But this is not necessary, because each of the other operating modes is manually overridden by actuating the joystick key. This means that the automatic operating mode is manually overridden until the "Automatic" key is actuated. In this operating mode, it is possible to do the following to the header via the joystick key: 1) 2) 3) 4)
Lift it Lower it Swing it right Swing it left
When the MANUAL operating mode is active, this display output is provided and, in addition, the "MAN" LED is switched to constantly illuminate.
** MODUS MANUAL ** EINSTELLUNG HUBZEIT SENKZEIT TASTE AUF TASTE AB Basic Manual Display
Functional Description: 1.
The valves are controlled via the "Lift", "Lower", "Right" and "Left" keys.
2.
The lifting process of the sloped conveyor is electronically dampened in front of the upper limit stop. The "Lift" valve is closed over a time ramp within a small angle before the upper limit stop in such a way that the mechanical limit stop is only reached at a very low speed.
3.
Depending on the function, ramps that are switched on and off are used for gentler acceleration or a delay of the header. This means in practice that after-running comes about when the "Lower" and "Lift" keys are released. The magnitude of this after-running is dependent upon the lifting or lowering speed that is set in each case.
4.
The lifting and lowering speeds of the shaft can be set within a window of between 2.5 to 20 seconds with the "UP" and "DOWN" keys of the operating and display device in the "MANUAL" operating mode.
Adjustment of Lifting Speed The adjustment is made by pressing the "UP" key. This display output results: The lifting speed can be changed in increments of 5% with the "UP" and "DOWN" keys. The number of vertical bars that are shown corresponds to the speed setting:
*HUBGESCHWINDIGKEIT low|||||||||||||high TASTE AB TASTE AUF
1 bar = 20 %; 2 bars = 25 % ,13 bars = 80 %
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4 – ELECTRICAL SYSTEM
The increment per press of the key therefore comes to 5 %. Pushing on the keys for a longer period of time does not result in a change in the increment. The "lifting speed" display is ended by pushing on the "MANUAL" key. The value that is set is stored, and the basic display appears again. Adjustment of Lowering Speed The adjustment is made by pressing the "DOWN" key. This display output results:
*SENKGESCHWINDIGKEIT low|||||||||||||high TASTE AB TASTE AUF ENDE ďƒ” TASTE MANUAL
The lifting speed can be changed in increments of 5% with the "UP" and "DOWN" keys. The number of vertical bars that are shown corresponds to the speed setting: 1 bar = 20 %; 2 bars = 25 %, 13 bars = 80 % The increment per press of the key therefore comes to 5 %. Pushing on the keys for a longer period of time does not result in a change in the increment. The "lowering speed" display is ended by pushing on Key 2, "MANUAL". The value that is set is stored, and the basic display appears again. 5.
The probe skids are ineffectual.
6.
The key for automatic mode is ineffectual.
9.
If the voltage on the angle transmitter for the sloped conveyor reaches a certain value during "lifting", the header is positioned horizontally, independently of whether "Lift" is pushed further.
The header is not positioned horizontally in the "MANUAL" operating mode in the case of "lowering". 10.
The "MANUAL" operating mode is ended by one of the 3 other operating modes being chosen.
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4 – ELECTRICAL SYSTEM
The output of transmitter errors in the "MANUAL" mode is done with the appearance of the display outputs of Illustrations 20, 24, and 29. The output of the errors is done in an alternating way with the basic display output in such a way that the basic display output is provided for 10 seconds and the respective error output of Illustrations 20, 24 or 29 is provided in each case for 5 sec.
** MODUS MANUAL ** EINSTELLUNG HUBZEIT SENKZEIT TASTE AUF TASTE AB Basic Display, Manual
** MODUS MANUAL ** MODUS EINGESCHRAENKT FEHLER QUERPENDEL KEINE MITTELLAGE Illustration 20
** MODUS MANUAL ** MODUS EINGESCHRAENKT FEHLER DRUCKSENSOR
** MODUS MANUAL ** MODUS EINGESCHRAENKT FEHLER HOEHENGEBER
Illustration 24
Illustration 29
The error output is interrupted when the "UP" and "DOWN" keys are actuated. The basic output follows and the "lifting speed" and "lowering speed" submenus can be reached with the "UP" and "DOWN" keys. The adjustment of the lifting and lowering speed can be done through "UP" and "DOWN". The error output loop is activated again 5 sec. after the last actuation of a key.
The appearance of the error illustrations 20, 24 and 29 does not result in the "MANUAL" operating mode no longer being capable of running. The transmitter errors of Illustrations 20 and 24 have the consequence that no return message about the position of the header is available. The electronic end-position dampening and the horizontal positioning can therefore not be carried out. In this case, the shutoff of the outputs does not come about and the position of the header can be corrected via the keys on the joystick.
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4 – ELECTRICAL SYSTEM
High-Cut (RTC) The RTC operating mode can be selected via the RTC key of the operating and display device with an activation of the "working hydraulics" switch and a switched-in threshing unit. The position of the header can be overridden ** MODUS RTC ** with the keys on the joystick in this operating SCHNITTHOEHE XXX % mode. NIEDRIGER HOEHER This display output is provided when the TASTE AB TASTE AUF RTC operating mode is activated and the "RTC" LED is illuminated in a flashing manner. Basic RTC Functional Description: 1.
If this operating mode is chosen by pressing the "RTC" key, the above display is shown and the desired cutting height can be set via the "UP" and "DOWN" keys. The display is shown from 0 to 100% in 5% increments in the place of the generic variable XXX. The display XXX is continually updated with a press of the "UP" and "DOWN" keys. The value 0% is made equal to the header height at which the first probe skid has just made contact with the ground here. The value 100 % corresponds to the upper limit stop of the sloped conveyor.
2.
The preset height is first moved to when the "Automatic" key on the back ** MODUS RTC ** side of the joystick is pressed. In addiRUECKKEHR AUF tion, the header is positioned horizonSCHNITTHOEHE tally. MIT TASTER AUTOMATIK If the preset height is reached, the "RTC" LED is illuminated in a constant fashion in order to display the activation of the mode.
3.
If the preset height is overridden by manually pressing the "Lift" or "Lower" keys, the "RTC" LED is illuminated in a flashing manner and the display output (Item 2) is provided in order to signalize that the mode was overridden. In addition, the probe skids are shut off when there is a manual override and they do not bring about a lifting of the header when the probe skids set down.
4.
If the horizontal position of the header is overridden by pressing the "Swivel right" key or PIN 16 "Swivel left", the "RTC" LED 8 is illuminated in a flashing manner and the display output (Item 2) is provided.
5.
The approach to the preset cutting height and the horizontal positioning of the header are achieved by pressing the "Automatic" key; the "RTC" LED 8 is illuminated in a constant manner again when the target height is reached and the above illustration is output in order to display the activation of the mode.
6.
If the setting of the cutting height is changed with an activated "RTC" mode (the mode was activated with the "Automatic" key), the header follows in the range of 0% to 100% while the corresponding entries via the "UP" and "DOWN" keys are made.
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4 – ELECTRICAL SYSTEM
7.
If the voltage reaches a certain threshold value during the lifting of the shaft, the header is positioned horizontally, independently of whether the "RTC" mode is active or has been manually overridden. The header is also positioned horizontally during lowering.
8.
If at least one probe skid is lifted by the ground profile by more than 60% in the "RTC" operating mode, the header is lifted until the 60% is undershot and the lowering to the target height is done without actuating the "Automatic" key.
9.
The "RTC" operating mode is ended by choosing one of the 3 other operating modes or when the threshing unit is shut off.
10. The output of transmitter errors in the "RTC" mode is done via the appearance of the display outputs of Illustrations 18, 21, 25 and 28. If shaft angle transmitter error appears, the display output of Illustration 18 is shown and the LED is illuminated in a flashing manner as soon as the "RTC" mode is chosen. The mode cannot run with this error.
** MODUS RTC ** SCHNITTHOEHE XXX % NIEDRIGER HOEHER TASTE AB TASTE AUF
** MODUS RTC ** MODUS NICHT AUSFUEHRBAR ! FEHLER HOEHENGEBER
Basic Display, RTC
Illustration 18
** MODUS RTC ** MODUS EINGESCHRAENKT FEHLER QUERPENDEL KEINE MITTELLAGE Illustration 21
** MODUS RTC ** MODUS EINGESCHRAENKT FEHLER DRUCKSENSOR Illustration 25
** MODUS RTC ** MODUS EINGESCHRAENKT FEHLER TASTKUFEN 1 2 3 4 Illustration 28
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4 – ELECTRICAL SYSTEM
The output of the errors of the cross-wise angle transmitter, Illustration 21; pressure sensor, Illustration 25; and Probe Skid 1 to Probe Skid 4, Illustration 28; is only provided with an activated "RTC" (the "Automatic" key was pressed), alternating with the basic RTC in such a way that the display output is provided for 10 sec. and the respective error output of Illustrations 21, 25, and 28 is each provided for 5 seconds. The error output is interrupted if the "UP" and "DOWN" keys are actuated. The constant display output is provided and the adjustment of the cutting height via "UP" and "DOWN" can be done. The error output loop is activated again 5 sec. after the last actuation of a key. The support pressure control is overridden in the "RTC" mode when the set support pressure is exceeded until the support pressure reaches the set value again. The basic RTC display remains for this period of time.
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4 – ELECTRICAL SYSTEM
Support Pressure Control Operating Mode, FLOAT The FLOAT operating mode can be selected via the FLOAT key of the operating and display device with an activation of the "working hydraulics" switch and a switched in threshing unit. The cross-wise tilt of the header can be controlled in the operating mode without switching the mode into inactive status. Actuation of the "Lift" and "Lower" keys brings about an inactive setting of the ** MODUS FLOAT ** automatic system. AUFLAGEDRUCK XX % NIEDRIGER HOEHER When the FLOAT operating mode is TASTE AB TASTE AUF activated, this display output is provided and the "FLOAT" LED is switched on in a flashing manner. Basic Display, FLOAT Functional Description: 1. If the operating mode is activated through the "FLOAT" key, the header support pressure can be set with the "UP" and "DOWN" keys. The display is shown from 5% to 50% in 5% increments in place of the generic variable XX. 5% means here that the header is supported by the ground with 5% of its own weight, and 50% means that the header is supported by the ground with half of its own weight. It is independent of the size of the support area of the header here. A small support area (header positioned at a tilt; no ground unevenness) has just the same set residual load on it as the area with complete contact of the header bottom. The display XX is continually updated with a push of the "UP" and "DOWN" keys. Pushing on the keys for a longer period of time does not result in a change of the increment. 2. The calculation value for the support pressure is determined in the Teach-In. An equalization function is formed from the pressure values that are determined in dependence on the shaft angle, which is used as an absolute value of the header mass. It is also extremely important for this reason to repeat the Teach-In when the header has been changed or the rape attachment was mounted. 3. If the set support pressure is to be activated, the "AUTOMATIK" key is to be pressed and the header is lowered until the set pressure is reached. The display continues to show the illustration above, and the "FLOAT" LED is illuminated in a constant manner. 4. If the preset support pressure is overridden by actuating the "Lift" or "Lower" keys, the "FLOAT" LED is illuminated in a flashing manner and the display output is provid** MODUS FLOAT ** ed in order to signalize that the mode RUECKKEHR ZU AUFwas overridden: LAGEDRUCK
MIT TASTER AUTOMATIK
5. If the horizontal position of the header is overridden by pressing the "Swivel right" or the "Swivel left" keys, the mode remains active and the support pressure control also continues to run with a header that is situated at an angle!
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4 – ELECTRICAL SYSTEM ** MODUS FLOAT ** AUFLAGEDRUCK XX % NIEDRIGER HOEHER TASTE AB TASTE AUF
7. If the setting of the support pressure is changed via the "UP" and "DOWN" keys with an activated "FLOAT" mode (mode was activated through the "Automatic" key), the cylinder pressure is also accordingly changed in parallel. 8. If the voltage reaches a certain threshold value during the lifting of the shaft, the header is positioned horizontally, independently of whether "Lift" is pressed. The header is likewise positioned horizontally during lowering. 9. The "FLOAT" operating mode is ended by choosing one of the 3 other operating modes or when the threshing unit is shut off. 10. The output of transmitter errors in the "FLOAT" mode is done with the appearance of the display outputs ILLUSTRATIONS 23, 27 and 30. If the pressure sensor error arises, the display output Illustration 27 is shown and the "FLOAT" LED is illuminated in a flashing manner as soon as the "FLOAT" mode is also selected. The mode cannot be run with this error! The output of the shaft angle transmitter, Illustration 30, and the cross-wise pendulum transmitter, Illustration 23; only takes place in the activated "FLOAT" ("Automatic" key was pressed), alternating with the basic FLOAT display in such a way that the basic display output is provided for 10 sec. and the error outputs Illustration 23 or 30 are each provided for 5 sec. The error output is interrupted if the "UP" and "DOWN" keys are actuated. The basic display output image is provided and the support pressure can be adjusted via "UP" and "DOWN". The error output loop is activated again 5 sec. after the last actuation of a key.
** MODUS FLOAT ** AUFLAGEDRUCK XX % NIEDRIGER HOEHER TASTE AB TASTE AUF Basic Display, FLOAT
** MODUS FLOAT ** MODUS NICHT AUSFUEHRBAR ! FEHLER DRUCKSENSOR Illustration 27
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** MODUS FLOAT ** MODUS EINGESCHRAENKT FEHLER QUERPENDEL KEINE MITTELLAGE Illustration 23
** MODUS FLOAT ** MODUS EINGESCHRAENKT FEHLER HOEHENGEBER Illustration 30
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4 – ELECTRICAL SYSTEM
Field Tracking HT Operating Mode The "field tracking" operating mode permits the header to be controlled with a preselected cutting height in the area close to the ground by having the four probe skids record the spacing to the ground under the header. When there are deviations from the target value, corrections of the position of the header are made via the functions "Swing left", "Swing right", "Lift" and "Lower". The HT operating mode can be chosen via the "HT" key of the operating and display device with an activation of the "working hydraulics" switch and a switched in threshing unit. The basic display output is provided and the "HT" LED is illuminated in a flashing manner.
** MODUS HT ** low ||||||||||| high NIEDRIGER HOEHER TASTE AB TASTE AUF Basic Display, HT
Functional Description: 1. If the operating mode is chosen by pressing the "HT" key, the basic display is shown and the "HT" LED is illuminated in a flashing manner. 2. The desired cutting height can be set via the "UP" and "DOWN" keys. The number of the bars shown in the display corresponds to the cutting height setting. The cutting height increases with an increasing number of bars, with an increment of 10% per press of the key. Pressing on the keys for a longer period of time does not result in a change in the increment. 3. The "HT" operating mode is activated when the "Automatic" key is actuated. The basic display continues to be shown, and the "HT" LED is illuminated in a constant manner in order to display the activation of the mode. When the "Automatic" key is pressed, the header is raised or lowered to the target height and guided in parallel to the ground surface. The control variable (actual value) is the mean value of the probe skids. 4. If the preset height is overridden by the actuation of the "Lift" or "Lower" keys, the "HT" LED is illuminated in a flashing manner, and this display is output in order to signalize that the mode was overridden. 5. If the "Swivel right" or "Swivel left" key is pressed, there is no adjustment movement with an activated "HT" mode. This display output is provided.
** MODUS HT ** RUECKKEHR AUF SCHNITTHOEHE MIT TASTER AUTOMATIK
** MODUS HT ** FUNKTION QUERVERVERSTELLUNG IM MODUS HT GESPERRT
6 The approach to the preset cutting height is reached by pressing the "Automatic" key; the "RTC" LED 8 is illuminated in a constant fashion again, and the basic display is output again in order to display the activation of the mode.
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4 – ELECTRICAL SYSTEM
7 if the setting of the cutting height is changed when the "HT" mode is activated (the mode was activated by the "Automatic" key), the header follows in the range of 0% to 100% while the corresponding entries are made via the "UP" and "DOWN" keys. 8 If the voltage reaches a certain threshold value during the lifting of the shaft, the header is positioned horizontally, independently of whether the "HT" mode is active or has been manually overridden. The header is also positioned horizontally during lowering. 9 The "HT" operating mode is ended by choosing one of the 3 other operating modes or by shutting off the threshing unit. 10 The output of transmitter errors in the "HT" mode is provided with the appearance of Illustrations 11, 12, 13, 14, 15, 16, 17, 19, 22 and 26 in the display. If the Probe Skid 1 and Probe Skid 2 errors arise, Illustration 15 is shown in the display and the "HT" LED is illuminated in a flashing manner as soon as the "HT" mode is chosen by the key. In the case of Probe Skid 3 and Probe Skid 4 errors, Illustration 16 appears. The mode cannot run with these errors.
** MODUS HT ** MODUS NICHT BEREIT ! FEHLER TASTKUFE 1 FEHLER TASTKUFE 2 Illustration 15
** MODUS HT ** MODUS NICHT BEREIT ! FEHLER TASTKUFE 3 FEHLER TASTKUFE 4 Illustration 16
If the Probe Skid 1, Probe Skid 2, Probe Skid 3 and Probe Skid 4 errors arise, Illustration 17 is shown in the display and the "HT" LED is illuminated in a flashing manner as soon as the "HT" mode is chosen by the key. The mode cannot run with this error.
** MODUS HT ** MODUS NICHT BEREIT ! FEHLER TASTKUFEN: 1 2 3 4 Illustration 17
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4 – ELECTRICAL SYSTEM
The output of the errors Illustrations 11, 12, 13, 14, 19, 22 and 26 is only provided in the activated "HT" mode ("Automatic" key was pressed), alternating with the basic display in such a way that the display is provided for 10 sec. and the respective error output Illustration 11, 12, 13, 14, 19, 22 and 26 is provided for 5 sec. each. The error output is interrupted when the "UP" and "DOWN" keys are actuated. The basic display is provided and the cutting height is adjusted via "UP" and " DOWN". The error output loop is activated again 5 sec. after the last actuation of a key.
** MODUS HT ** low ||||||||||| high NIEDRIGER HOEHER TASTE AB TASTE AUF Basic Display, HT
Illustration 11
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER TASTKUFE 2 Illustration 12
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER TASTKUFE 3 Illustration 13
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER TASTKUFE 4 Illustration 14
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER HOEHENGEBER Illustration 19
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER QUERPENDEL KEINE MITTELLAGE Illustration 22
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER TASTKUFE 1
** MODUS HT ** MODUS EINGESCHRAENKT FEHLER DRUCKSENSOR Illustration 26
The support pressure control is overridden when the set support pressure is exceeded in "HT" mode until the support pressure reaches the set value again. The basic HT display remains for this period of time.
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Functions of "OPTION" Key The "OPTION" key that has been additionally introduced is backed with the following three functions: a) Display of the Teach-In values (Illustration 75)
* ANZEIGE TEACH-IN * ** ANALOGWERTE ** ANZEIGEN TASTE AB
b) Menu for setting mode changeover HT, RTC to FLOAT (Illustration 76)
c) Menu for setting the cross pendulum speed (Illustration 77)
d) Menu for carrying out a program reset (Illustration 78)
e) Language selection German / English / French / Russian (Illustration 79)
*MODUS-UMSCHALTUNG * *HT,RTC ZU FLOAT ** Status: XXX AENDERN TASTE AB
**GESCHWINDIGKEIT** **QUERPENDEL ** MAX MIN TASTE AB TASTE AUF ** PROGRAMM-RESET ** TASTE AUF 5 SEKUNDEN DRUECKEN RESET AUSGEFUEHRT
*SPRACHE***LANGUAGE* *LANGUE****ЯЗЫК * DEUTSCH FRANCAIS ENGLISH РУССКЙ
Functional Method: The "OPTION" key is only active when the threshing unit and header clutch is shut off. The display has to be at "MANUAL MODE" (the lifting and lowering speed menu may not be selected). The displays of Illustration 75 to Illustration 79 can now be called up one after the other with the Option key. One gets to the next menu, or back to the starting display (with "STOP" as well) "MANUAL MODE", each time the "OPTION" key is pressed a further time.
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Display of Teach-In Values The first function backed for "OPTION" is the output of the following non-normalized Teach-In values in the display: 1) Shaft angle transmitter voltage value, upper limit stop 2) Shaft angle transmitter voltage value, lower rest 3) Cross pendulum transmitter voltage value, right limit stop 4) Cross pendulum transmitter voltage value, left limit stop 5) Pressure sensor voltage value, 1st measurement point 6) Pressure sensor voltage value, 2nd measurement point 7) Left skid probe, upper voltage value 8) Left skid probe, lower voltage value 9) Left_center skid probe, upper voltage value 10) Left_center skid probe, lower voltage value 11) Right_center skid probe, upper voltage value 12) Right_center skid probe, lower voltage value 13) Right skid probe, upper voltage value 14) Right skid probe, lower voltage value 15) Initial current, lift valve 16) Initial current, lower valve 17) Initial current, right valve 18) Initial current, left valve
[V] [V] [V] [V] [bar] [bar] [V] [V] [V] [V] [V] [V] [V] [V] [mA] [mA] [mA] [mA]
In order to call in the analog value determined in the Teach-In independently of DLWWIN, a page-by-page output of the respective end values is provided. One gets to display output 80 when the "DOWN" key is actuated. Every further actuation of DOWN and UP leads to the next (DOWN key) or previous (UP key) display ** ANALOGWERTE ** output (Illustrations 80 to 88). Schachtwinkel:
oben: U = X.X Volt unten: U = X.X Volt Illustration 80 If the "OPTION" key is pressed during the scrolling with UP / DOWN, the display output Illustration 4.75 is displayed. Scrolling can now be done from the beginning or the "OPTION" key is pressed once again to get back to the "MANUAL MODE" display output.
** ANALOGWERTE ** Querpendel: rechts: U = X.X Volt links: U = X.X Volt Illustration 81
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** ANALOGWERTE ** Drucksensor: Wert1: p = XXX.X bar Wert2: p = XXX.X bar Illustration 82
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** ANALOGWERTE ** Tastkufe 1 (Li): oben: U = X.X Volt unten: U = X.X Volt Illustration 83
Illustration 85
** ANALOGWERTE ** Tastkufe 4 (Re): oben: U = X.X Volt unten: U = X.X Volt Illustration 86
** ANALOGWERTE ** Anfangsstroeme 1: Heben: I = XXXX mA Senken: I = XXXX mA
[01/2001]
** ANALOGWERTE ** Tastkufe 2 (LiMi): oben: U = X.X Volt unten: U = X.X Volt Illustration 84
** ANALOGWERTE ** Tastkufe 3 (ReMi): oben: U = X.X Volt unten: U = X.X Volt
Illustration 87
4 – ELECTRICAL SYSTEM
** ANALOGWERTE ** Anfangsstroeme 2: Rechts: I = XXXX mA Links: I = XXXX mA Illustration 88
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Setting the Switching for "RTC" and "HT" Modes If the "OPTION" key is pressed twice, the display output Illustration 76 appears and the additional changeover to "FLOAT" in the modes "RTC" and "HT" is switched in or out. The mode can be set with the "DOWN" key. Every change is immediately stored and activated when the "OPTION" key is actuated.
*MODUS-UMSCHALTUNG * *HT,RTC ZU FLOAT ** Status: XXX AENDERN TASTE AB
Change of the Swivel Speed Right / Left If the "OPTION" key is pressed twice, the display output Illustration 77 appears and the speed of the header cross pendulum move**GESCHWINDIGKEIT** ment can be changed. The current value **QUERPENDEL ** determined in the Teach-In in each case is MAX MIN used as the starting value for the adjustment TASTE AB TASTE AUF of the speed. This current value corresponds to a time period of 4.5 to 5.5 sec. from stop limit to stop limit. The current values with which the valves are driven in manual mode can be changed with the swivel speed menu item. The current determined from the Teach-In is output with 5 bars. The number of bars and thereby the swivel speed can be changed with the "UP" and "DOWN" keys. One bar corresponds to the current value from the Teach-In minus 20%. Nine bars correspond to the current value from the Teach-In plus 20%. Every change is immediately stored and activated when the "OPTION" key is actuated. Resetting the Variables to the Basic Programming If the "OPTION" key is pressed four times, the display output Illustration 78 appears ** PROGRAMM-RESET ** and the variables of the program brought TASTE AUF up can be reset. 5 SEKUNDEN DRUECKEN An automatic reset of all of the quantities is RESET AUSGEFUEHRT introduced for the major part of the variables used. The RESET is carried out by actuating the "UP" key for 5 sec. If the RESET has been carried out, the line "RESET CARRIED OUT" appears in the 4th line, which was previously without an output. The reset of the values previously took place by bringing up a new program version.
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Language Selection The language is selected by pressing the "OPTION" key five times. The display output Illustration 79 appears, and the desired language can be selected with the "UP" and "DOWN" keys.
*SPRACHE***LANGUAGE* *LANGUE****ЯЗЫК * DEUTSCH FRANCAIS ENGLISH РУССКЙ
An arrow appears for this in front of the language specified as the standard one or that was last selected. The language can be changed with actuation of the key. Every change is immediately stored and activated when the "OPTION" key is actuated.
Software Programming and Evaluation Program The CCU electronics used are programmed with the most current program of "HEADER CONTROL" functions when delivered. Furthermore, the electronics are set up in such a way that the FLASH EPROM used permits external programming or an RS232 serial interface. It is therefore possible to also equip older machines up to the most recent status in the update service. The MEMTOOL1 program package is available for programming, and the DLWWIN2 program is available for diagnosis. Both programs together make simple programming via a PC and the diagnosis of all of the inputs and outputs possible.
1 2
Memtool is a registered trademark of Siemens/ Infineon AG DLWWIN is a registered trademark of Kirstein Technische Systeme GmbH
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Transmitter and Signal Definition Probe Skid Transmitter Two probe skid pairs are arranged in a symmetrical fashion on the header bottom. Probe Skids 1 and 2 are located on the left-hand side, and Probe Skids 3 and 4 are located on the right-hand side there. The pair-by-pair arrangement results in greater dependability in probing the ground when there are processing tracks running in the direction of travel. The probe skids are supported so as to be able to turn. On the back side of the trough, the probe skids are connected to turning-angle transmitters that transform the mechanical signal into a proportional voltage. The voltage range that forms the basis for the transmitter path is 0.5 V to 4.5 V. The resolution of the spacing to the ground from 5 cm to 25 cm is provided over the entire range of 4 V. The cutting height cannot be indicated concretely, because the position of the cutter bar is additionally determined by the upper link on the sloped conveyor. It is to be noted with regard to the voltage signal that is output that the voltage change always refers to a concrete angle that the turning angle transmitter scans through. The transmitters on the header have an 80° signal range. If the values of 0° or 80° are undershot or exceeded, as the case may be, there is no longer a change in voltage. It is important for this reason for the inspection of the transmitters that the voltage in the two end positions is checked during a change. The voltages will ideally be at 0.5 and 4.5 V (corresponding to the 80°) in order to register a voltage change over the entire path. But because exceeding or undershooting the transmitter limit leads to values that are wrong, the voltage has to be measured over the entire transmitter path! A proportional change in voltage has to be capable of being registered even for the smallest change in path for the measurement at the end positions. The turning angle transmitters are set in such a way that the voltage in the folded-out state is 4.5 V and is 0.5 V in the folded-in state. The adjustment of the turning angle transmitter directly influences the precision of the ground spacing control!
2 1
Probe Skids Model 2000 Position 1 = Header raised, probe skid free V = 4.5 V Position 2 = Header set down, probe skid applied V = 0.5 V All of the transmitters are normalized in the Teach-In (page 4-18), in order to compensate for the deviations of the transmitters. The angle transmitters are to be set in such a way that they are already in their working range in the two end limit stops. This means that the voltage changes with the slightest movement towards the other end limit stop! [01/2001]
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CROSS - FLOW CF 80 COMBINE HARVESTER Designation of the Probe Skids TK
1
2
3
4
Adjustment Specifications 1 Lift the header so that none of the 4 probe skids have contact with the ground. 2 Put a bridge between F1.2 and F 4.1. 3 Switch in the threshing unit and header clutch. 4 Connect the measurement cable between the angle transmitter and cable. 5 Unscrew the fastening screws of the angle transmitter. 6 Turn Angle Transmitters 1 and 3 in a counterclockwise direction up to the end limit stop. Angle Transmitters 2 and 4 are turned in a clockwise direction because of the different installation position. 7 Turn the angle transmitters in the other direction until there is a voltage of 4.5 volts. 8 Lift the probe skid. The voltage has to be reduced over the entire adjustment path and only be 1.0 volt at the upper limit stop. If this is not possible a rough adjustment with the rod linkage is to be done. 9 Screw down the fastening screws. Probe Skids on the Model 2001 Header
A
A
B C A B C
B C
Probe skid folded in the maximum amount, 0.5 volts Probe skid in the center position Probe skid folded out in the maximum amount, 4.5 volts
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Cross-Angle Transmitter The header cross-angle transmitter is attached to the right side of the sloped conveyor.
Header Angle Transmitter on the Sloped Conveyor It is to be noted with regard to the voltage signal that is output that the change in voltage always refers to a concrete angle that the turning angle transmitter scans through. The transmitter for the pendulum frame has an 80° signal range. If the values undershoot or exceed 0° or 80°, as the case may be, there is no longer a change in voltage. It is important for this reason for the inspection of the transmitters that the voltage in the two end positions is checked during a change. The voltages will ideally be at 0.5 and 4.5 V (corresponding to the 80°) in order to register a voltage change over the entire path. But because exceeding or undershooting the transmitter limit leads to values that are wrong, the voltage has to be measured over the entire transmitter path! A proportional change in voltage has to be capable of being registered even for the smallest change in path for the measurement at the end positions. The turning angle transmitter is set in such a way that the voltage with a header swung out to the right will be 4.5 V and the voltage with a header swung out to the left will be 0.5 V.
The adjustment of the turning angle transmitter directly influences the precision of the horizontal positioning of the header!
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Header Position at the Limit Stop, "Swing Right" Function
Voltage at the angle transmitter V = 4.5 V
Header Position at the Limit Stop, "Swing Left" Function
Voltage at the angle transmitter V = 0.5 V Adjustment Specifications 1 2 3 4 5 6 7 8 9
Swivel the header hydraulically to the left up to the end limit stop (check by the fully moved-in piston of the hydraulic cylinder). Put a bridge between F1.2 and F 4.1. Switch in the threshing unit and header clutch. Connect the measurement cable between the angle transmitter and cable. Unscrew the fastening screws of the angle transmitter. Turn the angle transmitter in a counterclockwise direction up to the end limit stop. Turn the angle transmitter in the other direction until there is a voltage of 0.5 volts. In so doing, the angle transmitter has to be in its working range. Screw down the fastening screws. Swivel the header hydraulically to the right up to the end limit stop. The voltage has to then increase over the full swivel range and be 4.5 volts at the right end limit stop.
The angle transmitters are to be set in such a way that they are already in their working range in the two end limit stops. This means that the voltage changes with the slightest movement towards the other end limit stop!
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Sloped Conveyor Angle Transmitter The sloped conveyor angle transmitter is attached to the right side on the side plate of the sloped conveyor. It is to be noted with regard to the voltage signal that is output that the change in voltage always refers to a concrete angle that the turning angle transmitter scans through. The transmitter for the sloped conveyor has an 60° signal range. If the values undershoot or exceed 0° or 60°, as the case may be, there is no longer a change in voltage. It is important for this reason for the inspection of the transmitters that the voltage in the two end positions is checked during a change. The voltages will ideally be at 0.5 and 4.5 V (corresponding to the 60°) in order to register a voltage change over the entire path. But because exceeding or undershooting the transmitter limit leads to values that are wrong, the voltage has to be measured over the entire transmitter path! A proportional change in voltage has to be capable of being registered even for the smallest change in path for the measurement at the end positions. The turning angle transmitter is set in such a way that the voltage with a raised sloped conveyor will be 4.5 V and the voltage with a lowered sloped conveyor will be 0.5 V. The adjustment of the turning angle transmitter directly influences the precision of the height setting (high-cut, upper limit stop) and the automatic horizontal positioning of the header! If, for example, the voltage 4.5 V is already reached before the upper end position is reached, the "Lift" valve shuts off when the 4.5 V is reached although the sloped conveyor could be raised even higher mechanically! If the turning angle transmitter is installed so that it's turned around by 180°, no lifting or lowering movement will be possible under certain circumstances! Shaft (Sloped Conveyor) Position at the Limit Stop, "Lift" Function
Voltage at the angle transmitter V = 4.5 V
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Shaft (Sloped Conveyor) Position at the Limit Stop, "Lower" Function
Voltage at the angle transmitter V = 0.5 V
There is a voltage of 0.5 volts in the deepest position of the shaft, and a voltage of 0.5 volts in the uppermost position. The arm of the angle transmitter has to point forwards (see the illustration).
Adjustment Specifications 1 2 3 4 5 6 7. 8
Lower the shaft to 11 cm over the ground (measured at the deepest point). Put a bridge between F1.2 and F 4.1. Switch in the threshing unit and header clutch. Unscrew the fastening screws of the angle transmitter. Turn the angle transmitter in a clockwise direction up to the end limit stop. Turn the angle transmitter in a counterclockwise direction until there is a voltage of 0.5 volts. The angle transmitter has to be in its working range in the process. If this is not possible, a rough adjustment with the rod linkage is to be made. Screw down the fastening screws. Lift the shaft up to the upper limit stop. The voltage has to increase over the entire lifting range in the process and be at 4.5 volts at the end limit stop.
The angle transmitters are to be set in such a way that they are already in their working range in the two end limit stops. This means that the voltage changes with the slightest movement towards the other end limit stop!
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Indicator unit Cooling water temperature (excessive cooling water temperature is signalled acoustically and optically) Tank filling level Pilot lamp array for optical and acoustic signalling: The signal is given by the lighting up of the associated symbol. Charge control (red) - extinguishes when engine is running Engine oil pressure is below minimum (red) - warning sound when engine is running STOP symbol is illuminated switch off engine Parking brake (red) applied = acoustic signal is turned off Operation of the joy stick with parking brake applied sounds off the alarm when the engine is running Maximum cooling water temp. exceeded (red) - warning sound and STOP symbol is illuminated when engine is running Minimum cooling water level underrun (red) - warning sound and STOP symbol is illuminated Maximum hydraulic oil temperature exceeded (red) Minimum hydraulic oil level below minimum (red) - warning sound and STOP symbol is illuminated Grain tank full (red) - warning sound limited to 3 seconds Grain tank level: three quarters full (orange) - warning beacon on Air filter or suction head contaminated (red)
Straw zone clogged (red) Main fuse F6 blown (red) Find cause!
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Discharge pipe swung out Unloading coupling engaged Control array The nominal height of the header guidance and adjustment to the ground are set and performed, respectively, by means of the potentiometer. When the header guidance is set for "high cut", the actual cutting height is displayed above the symbol (height of cutter bar – with header pulled up above ground, measured in cm). When the header guidance is set for „adjustment to soil contour“,„LO“ (LOW) is displayed when the header has been lowered. If the header is higher than 90 cm above the ground, „HI“ (HIGH) will be displayed. Adjustment of threshing gap between concave and threshing cylinder. The gap can be adjusted (when the thresher is running) by means of the pushbuttons. The distance is displayed above the symbol in the form of a value that ranges between step (notch) 0 (minimum) and step 8 (maximum permissible setting range). Steps 0 to 8 correspond to the steps specified in the setting table.
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CROSS - FLOW CF 80 COMBINE HARVESTER On-board computer LH AGRO 968 The data are displayed on the LCD screen (A1). The dialogue between the combine driver and the on-board computer is performed via the various menus. In principle, the menu system is built up like a book the sheets of which you can "leaf through" using the function keys (A2). The basic menu is broken down into the function sets OPERATION INPUT DATA/DELETE TEST. All function sets comprise several individual functions that are activated from the function keys (A2). See the description of the individual functions on the screen (left side of function key). A 3 = Return key - Going back to previous menu, different frames are shown on the screen (2.31.1 to 2.31.11) - Turning off speed alarm A 4 = Speed key - Pressing this key causes shaft speeds to be displayed of: threshing cylinder grain elevator tailings elevator straw walker drive separating cylinder upper feeder housing shaft Pressing this key again causes shaft speeds to be displayed of: engine fan straw breaker A 5 = Zoom frame Loss bar diagram is enlarged (full frame display) A 6 = Image contrast - contrast is adjustable by means of A2 - Pressing key A7 sets the contrast to mid-range value A 7 = Delete key The delete key is used together with [10/2000]
4 – ELECTRICAL SYSTEM
A 8 = Change of function key (ring connection) - If this key is actuated with frame OPERATION or ZOOM on the screen, the display changes from the travelling speed to the fan and threshing cylinder speed. In connection with the speed adjustment keys on the control console, only that speed can be adjusted which is displayed; if the travelling speed is displayed, only the reel speed can be adjusted.
A 9 = Screen light - Is used for turning on and off the screen light A 10 = Numerical key pad The numerical keys are used exclusively with the INPUT menu.
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the numerical keys for inputs. OPERATION When voltage is applied to the on-board systems (battery master switch and ignition/starter switch) of the combine, the first computer frame will always be the OPERATION main menu (frame 2.31.2).
B1 = Straw walker losses B2 = Cleaning losses B3 = Hectare and harvesting time counter (see also DATA/DELETE) B4 = Losses too high (see also INPUT) B5 = Reduced cutting width Change using function key TEILBREITE/SUBWIDTH Automatic reset to full cutting width when symbol lights up. HA/H = Display of area worked at current travelling speed.
[10/2000]
HA = Display of area worked since last reset HA REST = Display of residual area if, under INPUT, the initial field size (HA REST) is entered. ST.UHR = Display of harvesting time elapsed since last reset (see also DATA /DELETE). ENDZEIT = Display of expected end of work if field size was entered (HA REST). UHR = Display of time. The clock is set in function set INPUT. DATUM = Display of date.
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4 – ELECTRICAL SYSTEM The date is set in function set
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INPUT
If you choose the ENCODE function set, the input options shown in frames 2.31.5 and 2.31.6 will appear. If you want to enter function parameters, use the arrow keys to move the black field to the respective function (e.g. C4), and strike key „WÄHLE/SELECT“ (C2). Press key „NÄCHSTE SEITE/NEXT PAGE“ (C3) to g to the next screen frame (e.g. from frame 2.31.5 to frame 2.31.6). Input of wheel perimeter and working width Both functions are protected from unauthorised use by a code. Proceed as follows to set new parameters. 1. Use the arrow keys to move the black field to the parameter to be changed. 2. Select the parameter with „Wähle/Select“. 3. Enter code. Code: ................ 4. Actuate key „C“ to delete the old parameter value. 5. Enter new parameter value. 6. Actuate the backspace key to return to the standard menu. [10/2000]
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Loss adjustment The loss display on the computer is a trend display. It is properly set if the loss bars vary between one quarter and one half of the bar height. A loss alarm will be given at three quarters of the bar height. Two setting options are available. The first option is based on the determination of the actual losses. If this calibration option is made use of, losses of 0.25 % to 0.5 % or 0.5 % to 1.0% can be worked with in the desired working ranges. Half the bar height is here equivalent to a loss of 0.5% and 1.0%, respectively. Thus, an optical and acoustic loss signal is given at 0,75 % (1,5 %). The second calibration option is independent of the determination of the actual losses. The combine is optimally prepared for operation, and the travelling speed is chosen so that the losses are optimal, too. Any desired value can here be set (i.e. also values below 0.5 %). Proceed as follows.: 1. 2. 3. 4. 5.
Prepare (adjust) the combine for operation (see Chapter 1). With the combine properly adjusted, test-thresh a uniformly grown crop strip at a constant travelling speed which is adapted to the harvesting conditions, until the loss bars don't change anymore (some 50 m to 100 m): Determine the actual losses by applying one of the conventional methods. Select the loss frame under the INPUT menu. Make a second threshing test at exactly the same speed. When the loss bars don't change anymore (after about 50 m to 100m), use the + or – keys to set the loss bars to the actual loss value (to one quarter of the bar height if the second calibration option is used).
The following table shows the number of lost grains in a 15 cm x 15 cm square versus the header size and yield for a medium grain size. The bold figures correspond to a loss of 0.5 %. Doubling these figures would give a loss of 1 % which would clearly be too high a loss. BARLEY / WHEAT Header width 4.2 m 4.8 m 5.4 m 6.0 m 6.6 m 7.2 m 7.8 m
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20 2 3 3 3 4 4 5
40 3 4 4 4 5 5 6
Yield in dt/ha 60 80 4 6 5 7 6 7 6 8 8 10 8 11 9 12
100 7 8 9 10 12 13 15
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120 9 10 11 12 14 16 18
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Header width 4.2 m 4.8 m 5.4 m 6.0 m 6.6 m 7.2 m 7.8 m
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20 2 2 3 3 4 5 6
40 3 4 5 6 6 7 8
4 – ELECTRICAL SYSTEM
OATS / RYE Yield in dt/ha 60 80 5 7 6 8 7 9 8 10 9 12 10 14 12 16
100 8 10 12 13 15 17 19
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120 10 12 14 16 18 20 22
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Loss alarm Choose whether an alarm shall be given or not when the loss is excessive (ON; OFF). If set to ON, the alarm will be activated when the loss indicator reaches 75 % fullscale. The alarm will be given in the form of a pulsating light on the display screen and an acoustic signal. It is possible to delay the acoustic signal by up to 10 seconds so that a short-time exceeding of the loss limit does not sound off the alarm.
Setting the transmitter for walker losses and cleaning Speed alarm During threshing, the speeds of the following drives are monitored: Grain elevator Tailings elevator Walker drive Engine Fan Feeder housing Separator drum Straw chopper Straw cylinder
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In the INPUT menu, the speed monitor can be turned ON or OFF. If the speed of a monitored drive is too low, the alarm frame will appear (e.g. 2.31.10 – straw breaker), irrespective of which frame was previously selected. In addition, brief acoustic signals are given. The alarm frame will not disappear until the speed has exceeded the alarm limit. The alarm can be turned off by actuating the backspace key. The alarm may be turned off only for the period required to find the cause of the alarm and remedy the defect. The speed monitor is activated by the on-board computer when the threshing cylinder speed exceeds 250 rpm.
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Function set DATA/DELETE In this function set, the harvesting time and harvested area displayed as daily values without any identifier, campaign values with the identifier , and life data with the identifier . All daily values can be deleted at a time by pressing function key D2. All values can be deleted individually by means of D1 if the "black field" has previously been set with D3 to the respective value. Note! Life data HA and time cannot be deleted.
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Function set TEST In the first three frames of this function set, the sensors can be statically tested. LO means there is an input signal (metal at sensors) at the respective measuring point. HI means there is no signal present (no metal at sensors). The figure below the measuring point is the number of signals given during the measurement. It can be reset to zero by „Delete“. No functions have been assigned to the two lower measuring points of the second frame. The last frame serves the testing of the threshing cylinder variator setting facility (see circuit diagram "Threshing cylinder speed adjustment", page 4 – 34.
Speed transmitter
Transmitter for tailings
Loss transmitter
IS GE
[10/2000]
Pulse disk Transmitter
TRAINING CENTER NEUSTADT
4-69
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Setting the headlights The headlights are factory-set so that they comply with the applicable traffic rules. For this reason, readjust the headlights only in case of damage or after a replacement of internal headlight components. Ensure that the headlights are set in compliance with § 50 Par. 6 STVZO/Motor Vehicle Construction and Use Regulation. Reset the headlights as follows: -
For proper headlight setting, you need a completely plane and vertical setting surface. Concentrate on the low beam only since the combine is equipped with asymmetric headlights. Place the combine on even, horizontal ground at a distance of 10 m away from the setting surface. Make sure the centre line of the setting surface is at right angles to the centre line of the combine. For setting the headlights, inflate the tires to the required pressure. Measure distance H (headlight centre - ground). Measure distance h = H - H/3 mm as the bright-dark boundary for the low beam. Set the low beam so that the bright-dark boundary is exactly at height h and horizontal. Ensure that the point where the horizontal part turns into the rising part of the brightdark boundary coincides with the marking. A deviation to the left is not permissible, but the point may deviate toward the right side by up to 200 mm.
Headlight adjustment
[10/2000]
TRAINING CENTER NEUSTADT
4-100
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Central Processing Unit Field Tracking Design Q Electrical-Hydraulic
Field Tracking Design P Electrical-Mechanical
A
A
B
B
C
D
C
D
E
A B C D E
Proportional amplifier (different) Card subassembly Start Stop (same) Card subassembly Field Tracking / Threshing Basket Adjustment (different) Card subassembly Header Return (same) Control unit Electrical Field Tracking
[10/2000]
TRAINING CENTER NEUSTADT
4-101
CROSS - FLOW CF 80 COMBINE HARVESTER
[10/2000]
4 – ELECTRICAL SYSTEM
TRAINING CENTER NEUSTADT
4-102
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Proportional Amplifier The adjustment of the speeds of the reel and the fan is realized by the proportional amplifier. The cables are directly connected to the amplifier. Because there are two different hydraulic-port valves, the proportional amplifiers are also different. But they are mounted at the same location and are externally identical. Mistakes can therefore come about. Replacement part numbers Design P 060522195 (mechanical field tracking) from DCF 880001 to DCF 880300 Design P 31340877 (mechanical field tracking) starting with DCF 880301 Design Q 07091177 (electrical field tracking) from DCF 880001 to DCF 880300 Design Q 31340885 (electrical field tracking) starting with DCF 880301 Card Subassembly Start Stop This card subassembly is structurally identical for the two designs. The connection to the harness is created with the X 44 connector. There is only one possibility for mounting the plug. The replacement part number is 060509382
[10/2000]
TRAINING CENTER NEUSTADT
4-103
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Card Subassembly Mechanical Field Tracking / Threshing Basket Adjustment The card subassembly is different starting with DCF 880061. Just the basket adjustment exists in this card subassembly in the case of the electrical-hydraulic field tracking starting with DCF 880061, which can be seen from the number of connectors. There are 2 connectors for the electricalhydraulic field tracking, and there are 3 connectors for the electrical-mechanical field tracking. Replacement part numbers Design P (mechanical field tracking) Design Q electrical field tracking up to DCF 880060 starting with DCF 880061
07078862
07078862 07090352
Plug assignments Design P (mechanical field tracking)
3 1
2
Plug assignments Design Q starting with DCF 880061 (electrical field tracking) only the basket adjustment
1
[10/2000]
TRAINING CENTER NEUSTADT
2
4-104
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Card Subassembly Header Return The card subassembly is identical for both field tracking types and has the replacement part number 060510800. The connection to the harness is created by the X 45 connector. There is also only one connection possibility here.
Control Unit The control unit is only available in the electrical-hydraulic field tracking. It has the replacement part number 07090215.
[10/2000]
TRAINING CENTER NEUSTADT
4-105
4 – ELECTRICAL SYSTEM
CROSS - FLOW CF 80 COMBINE HARVESTER Relay and Diode Equipment
12V
[03/2001]
4-110
K19
K35 K61P
K18
K34 K61M
D5
K54
K4 D4
K17
K33
K59
D3
K30
K16
K15
K29
K44
K31
K28 K43
TRAINING CENTER NEUSTADT
K58
K14
K27
K42
K13
K11
K26
K41
D2
D1
K10
K25
K40
K60
K9
K24
K39
K12
K8
K23
K38
K5
K7
K22 K37
K6
K21 K32
K20
KKWS
K3
K2
K1
The following relays (designated with K) exist in the central processing unit: K1 Working lights F6 K2 Flasher unit K3 Dipper relay K4 Incremental relay, unloader clutch Sicherungen K5 Relay field / road K6 Safety relay, rape separator K7 Rape separator, right K8 Rape separator, left K9 Starting safety, neutral position K10 Starting safety electronics subassembly start - stop K11 Protective relay for starter motor K12 Relay for 12 V loads with connected ignition switch K13 Relay for starting safety Unloader pipe K14 Brake light relay K15 Safety circuit Chaff-cutter clutch K16 Chaff-cutter clutch K17 Relay for speed adjustment Threshing drum variator K18 Relay for speed adjustment Fan control K19 Relay for rotaflare lights K20 Lower shaft (only Design P) K37 Switch in permanent low beam with K21 Lift shaft (only Design P) attached corn adapter K22 Lift reel K38 Changeover low beam, left K23 Lower reel headlight (corn) K24 Reel forwards K39 Changeover low beam, right K25 Reel backwards headlight (corn) K26 Not used K41 Safety circuit, threshing unit K27 Relay for 24V loads with connected clutch ignition switch K42 Safety circuit, header K28 Not used clutch K29 Not used K43 Header emergency stop K30 Swivel out unloader pipe K44 Speed monitoring, header K31 Swivel in unloader pipe K54 Shut-off delay, fan K32 Relay for honking, starting safety K58 Switch-on conditions, electrical K33 Safety circuit, unloader clutch central lubrication pump K34 Not used K 59 Relay starting safety K35 Voltage supply sensors of the K61P Relay starting safety field tracking K61M Relay starting safety KKWSSignal from cooling water status sensor (only starting with DCF 880301)
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Relays Outside of the Central Processing Unit Cab The relays K A1 to K A5 are located in the cab. The front ceiling cover is removed after unscrewing the 4 fastening screws and taking off the fan sprayers. The relays K A1 to K A5 are located in the right corner over the computer panel. They are responsible for the air conditioning.
The relays K A6 and K A7 are located on the left machine side behind the master battery switch. Relay K A7 is in front in the direction of travel starting with Machine Numbers 01 to 60. Relay K A6 is located in front in the direction of travel starting with Machine Number 61. K A6 header return K A7 12 volt on-board voltage K A6
K A7
Relay K A8 is located between the two dynamos. It is still designated K 53 in older circuit diagrams. K A8
[03/2001]
TRAINING CENTER NEUSTADT
4-111
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Replacement Part Numbers of the Various Relays 12V
K1
F6 Fuse Block
K 20 K 21 K 35 K 58
Only Design P Only Design P Starting with DCF 880061 Starting with DCF 880061 (option) K KWS Starting with DCF 880301
K3
K5
K12 K60 D1
K K K K K K K K 6 7 8 9 10 11 W
K K K K K K 20 21 22 23 24 25
D2
K2
K4
K54
D3
D4
D5
K K K K K K K 13 14 15 16 17 18 19
K 27
K K K 30 31 33
K K K K K K K K K 32 37 38 39 40 41 42 43 44
Relay number
Designation
Remark
Flasher unit Dipper relay Incremental relay Drop-off delay
T = 5 seconds
K1 K2 K3 K4 K 54 K 5 ; 12 ; 60 K 7 ; 8 ; 11
24 volt mini-relay
Remaining relays
24 volt mini-relay
K 32 ; 37 ; 38 ; 39
12 volt mini-relay
[03/2001]
Change in the reconstruction program in 2001 Changeover to new relay in I / 2001
TRAINING CENTER NEUSTADT
K 35
K K K K 58 59 61 61 M P
Replacement part number 07080994 98032739 98032740 060518496 07090545 31346987 072079260 replaced by 31346987 07077033
4-112
CROSS - FLOW CF 80 COMBINE HARVESTER K A1 ; A2 ; A3 ; A4 ; A5 12 volt relay K A6 ; A7 ; A8 24 volt power relay
[03/2001]
4 – ELECTRICAL SYSTEM
In cab roof
TRAINING CENTER NEUSTADT
07074850 9019059245
4-113
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Fuses From Machine Numbers DCF 880001 to DCF 880060
F1:1 (25 A) Load through heater starter switch F1:2 (15 A) Water level transmitter and reversing horn F1:3 (15 A) Cooling bag socket F1:4 (25 A) Air conditioner and fan F1:5 (7,5 A)Windscreen wiper F1:6 (25 A) Lighting system F1:7 (15 ) Socket and seat adjustment F1:8 (7,5 A)Radio
F4:1 (7,5 A) Working hydraulics (without discharge pipe) F4:2 (7,5 A) Hydraulics, discharge pipe F4:3 (7,5 A) Unloader clutch F4:4 (4 A) Fan and reel speed adjustment F4:5 (10 A) Threshing unit and header clutch F4:6 (10 A) Chaff-cutter, complete F4:7 (25 A) Rape separator, right F4:8 (25 A) Rape separator, left
F2:1 ( 4 A) High beam, right F2:2 ( 4 A) High beam, left F2:3 ( 4 A) Low beam, right F2:4 ( 4 A) Low beam, left F2:5 ( 4 A) Parking light, right, rear and trailer F2:6 ( 4 A) Parking light, left, rear and trailer F2:7 ( 4 A) Parking light, right, front and grain tank F2:8 ( 4 A) Parking light, left, front and grain tank
F5:1 (10 A) Reel, fan and threshing drum speed adjustment F5:2 (10 A) Field tracking and threshing basket adjustment F5:3 (7,5 A) Header return F5:4 Free F5:5 (4 A) Grain tank filling display F5:6 (4 A) On-board computer, 12V F5:7 (2 A) Speed initiators, right, 12 V F5:8 (2 A) Speed initiators, left, 12 V
F3:1 (15 A) Working lights, roof, right, and backup lights F3:2 (15 A) Working lights, roof, left F3:3 (15 A) Working lights, platform and unloader F6: Main fuse lighting 24 volt F3:4 (10 A) Rotaflare light, horn, headlight flasher F3:5 (7,5 A) Brake light F3:6 (7,5 A) Direction indicator F3:7 (4 A) Mirror adjustment
[03/2001]
TRAINING CENTER NEUSTADT
4-120
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
F3:8 (4 A) Electrical central lubrication system
Fuses Starting with DCF 880061
F1:1 (25 A) Load through heater starter switch F1:2 (15 A) Water level transmitter and horn F1:3 (15 A) Cooling bag socket F1:4 (25 A) Air conditioner and fan F1:5 (7,5 A) Windscreen wiper F1:6 (25 A) Lighting system F1:7 (15 ) Socket and seat adjustment F1:8 (7,5 A)Radio F2:1 ( 4 A) High beam, right F2:2 ( 4 A) High beam, left F2:3 ( 4 A) Low beam, right F2:4 ( 4 A) Low beam, left F2:5 ( 4 A) Parking light, right, rear and trailer F2:6 ( 4 A) Parking light, left, rear and trailer F2:7 ( 4 A) Parking light, right, front and grain tank F2:8 ( 4 A) Parking light, left, front and grain tank
F4:1 (7,5 A) Working hydraulics (without discharge pipe) F4:2 (7,5 A) Hydraulics, discharge pipe F4:3 (7,5 A) Unloader clutch F4:4 (4 A) Fan and reel speed adjustment F4:5 (10 A) Threshing unit and header clutch F4:6 ( 10 A) Chaff-cutter, complete F4:7 (25 A) Rape separator, right F4:8 (25 A) Rape separator, left F5:1 (10 A) Reel, fan and threshing drum speed adjustment F5:2 (10 A) Field tracking and threshing basket adjustment F5:3 (7,5 A) Header return F5:4 (4 A) Grain tank filling display F5:5 (7,5 A) Yield recording / all-wheel drive F5:6 (4 A) On-board computer, 12V F5:7 (2 A) Speed initiators, right, 12 V F5:8 (2 A) Speed initiators, left, 12 V
F3:1 (15 A) Working lights, roof, right, and backup lights F3:2 (15 A) Working lights, roof, left F3:3 (15 A) Working lights, platform and unloader F6: (50 A) lighting
Main fuse (circuit breaker) 24 volt
F3:4 (10 A) Rotaflare light, horn, headlight flasher F3:5 (7,5 A) Brake light F3:6 (7,5 A) Direction indicator
[03/2001]
TRAINING CENTER NEUSTADT
4-121
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
F3:7 (4 A) Mirror adjustment F3:8 (4 A) Electrical central lubrication system
[03/2001]
TRAINING CENTER NEUSTADT
4-122
CROSS - FLOW CF 80 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Position of the Connectors, CF80 X2 X5 X 5.1 X6 X 6.1 X7 X 7.3 X 7.4 X8 X9 X 10 X 11 X 12 X 13 X 13.1 X 14 X 14.1 X 14.2 X 15 X 16 X 17 X 24 X 25 X 26 X 27 X 28 X 30 X 31 X 32 X 33 X 34 X 44 X 45 X 101
Position in the combine harvester Input into the central processing unit Input into the central processing unit Between engine and grain tank Input into the central processing unit Left side wall, under the power engine take-off Input into the central processing unit In the steering axle support, right In the steering axle support, left Input into the central processing unit Input into the central processing unit Input into the central processing unit Platform, right, on distributing valve In the control panel Input into the central processing unit In the control panel Input into the central processing unit Cab roof over the display unit Cab roof over the display unit Input into the central processing unit Input into the central processing unit Input into the central processing unit Platform, lamp unit, left Platform, lamp unit, right Under the driver's platform; for the steering column On the drive axle, right, for the shaft Platform, left, for threshing basket adjustment In the steering axle support, right Straw area hood at ascent stage in the back At the grain tank, right, behind the central processing unit In the steering axle support, right In the steering axle support, left In the central processing unit; electronics subassembly, start stop In the central processing unit; electronics subassembly, header return Right cab capping piece; front; top
[03/2001]
Number of the circuit diagram 00;01;02;03;05;17;19;20;23;31;40;41 00;05;09 00 00;01;05;21;22;23;24;27;31 00;01;31 00;01;02;15;16;19;23;25;26;28;29;30 03 03 00;01;02;03;09;19;24;25;26;29;30;31 00;02;04;08;09;19;20;21;22;23;24; 25;26;29;30;31;40;41 04;08;09;19;20;21;22;24;27;28;41 19;23;25;26;29;30 00;23;25;29;30 00;22;23;24;26;29;30;40;41 25 00;03;05;15;16;23;25 03;05 05;09;15;16;25 00;01;03;04;05;08;17;23 09;19;20;21;22;24;26;27;30;31;40 26;30 00;01 00;01;03 00;01;02;03 24;25;26;31 03;15;16 01;02;03 01;02;17 01;17;23 02 01;02 22;24 19;20;21;22;24;31
TRAINING CENTER NEUSTADT
4-130
CROSS - FLOW CF 80 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Sockets Voltage XA XB
12 volt 12 volt
X Br XC XD XE XF XH XL XR XS X Sw
12 volt 12 volt 12 volt 12 volt 12 volt 12 volt 24 volt 24 volt 12/24 volt 12 volt
[03/2001]
Function
Position in the combine harvester Hand lamp In the central processing unit Cigarette lighter On the left next to the driver's seat Radio loudspeaker Cab roof; behind the radio Hand lamp Right front lamp unit Hand lamp Left front lamp unit Cooling box Under the passenger seat Hand lamp In front of the battery box Header vehicle On the trailer equipment Left rape separator Left side wall of the header Right rape separator Right side wall of the header Header Back left wall of the header Radio power supply
TRAINING CENTER NEUSTADT
Circuit diagrams 00 00 08 00 00 00;08 00 01;03 28 28 01;03;19;26;28 08
4-131
CROSS - FLOW CF 80 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Plugs on the Central Processing Unit The plugs are numbered on the central processing unit and the accompanying harness.
X2
X5
X6
X7
X8
X 17
X9
X 10
X 13
X 14
X 15
X 16
The following plugs are located in the central processing unit: X 44 X 45
Card subassembly Start-Stop Card subassembly Header Return
The connectors for the card subassembly of field tracking / threshing basket adjustment are labeled with 1; 2; 3 for Design P or 1; 2 for Design Q. Also see page 4-104
[03/2001]
TRAINING CENTER NEUSTADT
4-132
CROSS - FLOW CF 80 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Combine Harvester, Right The following connectors are presented on this page : X2 X5 X6 X7 X8 X9
X 10 X 11 X 13 X 14 X 14.1 X 14.2
X 15 X 16 X 17 X 26 X 44 X 45
X 101
The following sockets are presented on this page : XA XC
X 14.1 X 14.2 X 101
XA XA X 44 X 45 26 X XC X 11 X 2 X 5 X 6 X 7 X 8 X 9 X 10 x 13 X 14 X 15 X 16 X 17
[03/2001]
TRAINING CENTER NEUSTADT
4-133
CROSS - FLOW CF 80 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Combine Harvester, Left The following connectors are presented on this page : X 6.1 X 28 The following sockets are presented on this page : XD XE XF XS
X 28
X 6.1
XE
XD XS
[03/2001]
XF
TRAINING CENTER NEUSTADT
4-134
CROSS - FLOW CF 80 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Combine Harvester from Above The following connectors are presented on this page : X 5.1 X 31 X 32 The following sockets are presented on this page : xA XB X Br XC XD XE XF
X 32
X 5.1
X 31
XA XC
XB X Br X Sw XD
XE
[03/2001]
XF
TRAINING CENTER NEUSTADT
4-135
CROSS - FLOW CF 80 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Combine Harvester from the Front The following connectors are presented on this page : X 13.1 X 14.1 X 14.2 X 24 X 25 X 26
X 27 X 38 X 101
X 14.1 X 14.2 X 101
X 13.1
X 38
X 25
X 24
X 26 X 27
[03/2001]
TRAINING CENTER NEUSTADT
4-136
CROSS - FLOW CF 80 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Combine Harvester from the Back The following connectors are presented on this page : X 30 X 33 X 34 The following sockets are presented on this page : XH
X 34
X 30 X 33 XH
[03/2001]
TRAINING CENTER NEUSTADT
4-137
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Graphical Symbols There are currently two different presentation variations of the circuit diagrams. Both will be pointed out for purposes of completeness. New circuit diagrams will only be developed in accordance with the newest form of presentation. Cable There are two different possibilities for identifying the individual cables. One way is with the cable number, which is printed at a constant spacing on the cable jacket, or with the cable color. In the old form of presentation, the cable color is printed with or without the cable crosssection and the cable number is printed in a box on the respective cable. 1,5 rtws
382 Cable number Cable color Cable cross-section Cable
Cable colors Single-color cables: rt br sw ws ge Two-color cables
– – – – –
red brown black white yellow
gn gr bl or vio
– – – – -
green gray blue orange violet
rt ws Marking color Base color For example rt ws: Red cable with white marking line
Cable cross-section : ● A number in front of the cable color indicates the cable crosssection in mm². The number given there is greater then 1.0 mm². For example 1,5 swws: Black cable with a white marking line and a cross-section of 1.5 mm² ● No number in front of the cable color indicates a cable crosssection of equal to or less than 1.0 mm². In the new form of presentation, the cable colors, cable cross-section and the cable number are integrated into the cable representation. brws -1,5 - 421 Cable number Cable cross-section in mm² Cable color The voltage supply is presented in horizontal lines above (plus) and below (minus) in the respective switching states. [01/2001]
TRAINING CENTER NEUSTADT
4-190
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Cable Connections Ground point of the machine frame Detachable cable connection (screw-type) Non-detachable cable connection Inserted cable connection Jack Plug Plug-Type Connectors The connectors are labeled with the letter X and a serial number. If the harness is subdivided once again with a connector, it will be labeled with the same number and a second number will additionally be added (for example X 14.1). Sockets are labeled with a letter (for example X A) instead of a number. Number of the connector Assignment of the plugs
Plug side of the connector Jack side of the connector The assignment (number) is stamped on both sides of the connector. The outer two pin numbers for each series are always stamped. Mounting is only possible in one position.
[01/2001]
TRAINING CENTER NEUSTADT
4-191
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Fuses The fuses are labeled with the letter F. The number behind it indicates the respective fuse block and the position in the block. The number under the symbol is the rating of the fuse in amperes. All of the fuses except for F 7 (hand lamp socket next to the master battery switch) are located in the central processing unit. They are housed in 5 fuse blocks, each with 8 individual fuses. Number of the fuse block Position in the fuse block F4:3 7,5 A Rating of the fuse in amperes - Fuses with a number (e.g. F7) are individual fuses Contact Mechanism Relays All of the relays are labeled with the letter K. The number behind the letter is the number of the respective relay. all of the relays with K and a number are located in the central processing unit. The are inserted into relay sockets that are labeled on both sides. There is only one possibility for mounting. If the letter A (e.g. K A1) is located in front of the relay number, the relay is located outside of the central processing unit. K 11
Relay number Working relay
Power relay
A designation of the connections is indicated with the same numbers on the symbol of the relay, just as it is also indicated on its original.
[01/2001]
TRAINING CENTER NEUSTADT
4-192
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Lamps The lamps are labeled with the letter H. The number behind the letter is the respective number of the lamp. If two more letters are behind this number, they mean the following: re. Right li. Left A designation for the respective lamp is below the symbol. The lamps are 12-volt lamps with the exception of the grain tank lights. The two working lights in the grain tank have been designed to be 24-volt lamps. Motors The motors are labeled with the letter M and a serial number. The voltage of the motor is found in the symbol.
Solenoid Valves The solenoid valves are designated with the letter Y. The first number behind the letter indicates the respective hydraulic element (e.g. unloader pipe). The second number that is located behind the decimal is the number of the solenoid valve. A maximum of two solenoid valves that are labeled with .1 or .2 can belong to a hydraulic element. All of the solenoid valves are driven with 24 volts. The difference in the presentation of the solenoid valves only involves the plug. The solenoid valve depicted on the left-hand side is equipped with a single plug that contains a diode. The solenoid valve on the right has an additional light-emitting diode in the plug, in addition to the diode. Solenoid valve with single plug and diode
[01/2001]
Solenoid valve with plug with diode and light-emitting diode
TRAINING CENTER NEUSTADT
4-193
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Switches The switches are labeled with the letter S and a number. In the circuit diagram for the Display Unit 4-205, some of the numbers are replaced by three letters. The functional symbol is beside each switch symbol. The assignment of the switches can consequently be determined unambiguously. The numbers of the switches of the control panel are identical to the item numbers on 4 - 7 or page 4 – 10. The switches are labeled in the "off" position, corresponding to 0. The function of the switch can be determined from the switch symbol. Plug contact with numbering
Switching possibilities 0 "Off" 1 "On" Connection between the switching rocker and the lighting signifies a functiondependent brightness of the switch illumination Off → No current in the switch → Glowing→ Current applied, switch is in Position 0 Lit up Current applied, switch is in Position 1 Switch lighting in 3 brightness levels Shut-off switch: -
[01/2001]
Switches a circuit on or off It remains in each switching position Mechanical actuation
-
Actuation with a certain temperature
-
Actuation with a certain pressure
TRAINING CENTER NEUSTADT
4-194
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Three-way switch: -
Changes when switched from one output to the other Single-pole
-
Independent of the switching position of illuminated switches
-
Independent of the switching position of illuminated switches with an additional search lighting (weakly illuminating)
-
Double-pole switch with switching-dependent illumination and search lighting
-
Single-pole key with full illumination Key always automatically resets into the 0 position
-
Double-pole three-way switch that is only illuminated in the search lighting independently of the function
Keys:
[01/2001]
TRAINING CENTER NEUSTADT
4-195
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
CF 80 Circuit Diagram Index The circuit diagrams are numbered according to the machine type. The individual numbers (corresponds to the page number) signify the following here:
4-2 00 two-digit number of the circuit diagram (same for all types) Machine type 2 CF 80 3 CF 70 4 CF 60 Number of the chapter (4- Electrics) The circuit diagrams that act independently of the field position are presented from circuit diagram number 00 to 14. All of the circuit diagrams that are first activated during the threshing by the field position are presented from circuit diagram number 15 to 49. The circuit diagrams for combines equipped with touch screen monitor starting with circuit diagram number 50. Individual page numbers are reserved for the future and are therefore not assigned. Every circuit diagram is additionally labeled with a letter. These letters indicate the machine number that the circuit diagram starts with. The validity of the circuit diagram is only canceled when a new circuit diagram with the same number and a different letter is substituted for it. In the process, individual letters in the alphabet can be jumped over (e.g. Circuit Diagram 4-208 A is first substituted with 4-208 D). The letters start according to the alphabet with A. The individual letters signify the following here: A
B
C
D
Starting with Machine Number DCF 88 0001 until a subsequent letter is substituted Starting with Machine Number DCF 88 0031 until a subsequent letter is substituted Starting with Machine Number DCF 88 0061 until a subsequent letter is substituted Starting with Machine Number DCF 88 0301 until a subsequent letter is substituted
Combine harvesters with Design Q (electrical-hydraulic field tracking) are first manufactured starting with Machine Number DCF880031. There is a legend for every circuit diagram. The legend is labeled with the same circuit diagram number, but without letters. If the legend goes on over several pages, they are provided with an additional number (for example 4-200.1) Notes are labeled with a serial number in the circuit diagram, and are then explained in the legend. The circuit diagrams are closed within themselves as a rule, so troubleshooting only has to be carried out on this circuit diagram. Every circuit diagram starts with the respective fuse. The wiring in front of the fuse is drawn in the circuit diagram Operating Voltage 4-200. If there are links to another circuit diagram, for instance if the same fuse is used or if the witch-on conditions are on a different circuit diagram, this is indicated with an arrow and the circuit diagram number.
[01/2001]
TRAINING CENTER NEUSTADT
4-197
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Index of the circuit diagrams CF 80 A
B
C
D
Starting with Machine Number DCF 88 0001 until a subsequent letter is substituted Starting with Machine Number DCF 88 0031 until a subsequent letter is substituted Starting with Machine Number DCF 88 0061 until a subsequent letter is substituted Starting with Machine Number DCF 88 0301 until a subsequent letter is substituted
General Circuit Diagrams (Independent of the Field Position) 4-200 A 4-200 C 4-201 A 4-201 B 4-201 C 4-202 A 4-203 A 4-203 B 4-204 A 4-205 A 4-208 A 4-208 D 4-209 A 4-209 C 4-214 A
[01/2001]
Operating Voltage Starting with DCF 88 0001 Operating Voltage Starting with DCF 88 0061 Lighting System Starting with DCF 88 0001 Lighting System Starting with DCF 88 0031 Lighting System Starting with DCF 88 0061 Warning Device Starting with DCF 88 0001 Direction Indicator Starting with DCF 88 0001 Direction Indicator Starting with DCF 88 0031 Mirror Adjustment Starting with DCF 88 0001 Display Unit Starting with DCF 88 0001 Cab Starting with DCF 88 0001 Cab Starting with DCF 88 0301 Air Conditioner Starting with DCF 88 0001 Air Conditioner Starting with DCF 88 0061 Header Vehicle Starting with DCF 88 0001
TRAINING CENTER NEUSTADT
4-198
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Circuit Diagrams Activated by the Field Position 4-215 A 4-216 B 4-216 C 4-217 A 4-217 C 4-219 A 4-219 B 4-219 D 4-220 A 4-221 A 4-221 D 4-222 A 4-222 C 4-223 A 4-223 C 4-224 A 4-224 C 4-225 A 4-225 C 4-226 B 4-226 C 4-227 A 4-228 A 4-228 B 4-229 A 4-229 C 4-230 B 4-230 C 4-231 A 4-231 C 4-240 C 4-241 D
[01/2001]
Threshing Basket Adjustment Design P Starting with DCF 88 0001 Threshing Basket Adjustment Design Q Starting with DCF 88 0031 Threshing Basket Adjustment Design Q Starting with DCF 88 0061 Grain Tank Filling Display Starting with DCF 88 0001 Grain Tank Filling Display Starting with DCF 88 0061 Reel Speed Adjustment Starting with DCF 88 0001 Reel Speed Adjustment Starting with DCF 88 0031 Reel Speed Adjustment Starting with DCF 88 0301 Threshing Drum Speed Adjustment Starting with DCF 88 0001 Fan Adjustment Starting with DCF 88 0001 Fan Adjustment Starting with DCF 88 0301 Threshing Unit and Header Clutch Starting with DCF 88 0001 Threshing Unit and Header Clutch Starting with DCF 88 0061 Unloader Clutch with Unloader Pipe Control Starting with DCF 88 0001 Unloader Clutch with Unloader Pipe Control Starting with DCF 88 0061 Header Return Starting with DCF 88 0001 Header Return Starting with DCF 88 0061 Field Tracking Design P Starting with DCF 88 0001 Field Tracking Design P Starting with DCF 88 0061 Field Tracking Design Q Starting with DCF 88 0031 Field Tracking Design Q Starting with DCF 88 0061 Chaff-Cutter Starting with DCF 88 0001 Rape Electrical System Starting with DCF 88 0001 Rape Electrical System Starting with DCF 88 0031 Working Hydraulics Design P Starting with DCF 88 0001 Working Hydraulics Design P Starting with DCF 88 0061 Working Hydraulics Design Q Starting with DCF 88 0031 Working Hydraulics Design Q Starting with DCF 88 0061 LH AGRO 965 Control System Starting with DCF 88 0001 LH AGRO 965 Control System Starting with DCF 88 0061 Electrical Central Lubrication System Starting with DCF 88 0061 All-Wheel Drive Starting with DCF 88 0301
TRAINING CENTER NEUSTADT
4-199
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Operating Voltage Circuit diagrams: 4-200 A from Machine Number DCF 880001 to 60 4-200 C starting with Machine Number DCF 880061 Circuit Diagram Legend Number Function H 33 Central processing unit interior light Magnets Y 30 Stop magnet Motors M 12 Compressor seat M 13 Starter M 14 Motor time counter M 15 Auxiliary fuel pump DLM12V Dynamo DLM24V Dynamo Relays K5 Field / road K9 Starting safety K10 Starting safety Lamps
Switches
Plugs
K11 K 12 K 13 K 27 K 58 K 59 K 60 K 61 M K 61 P K A7
Starting safety Starting safety Starting safety 12-volt on-board voltage
KA8 S0 S 21 S 29 S 35 S 42 S 50
Starter relay Emergency stop Swivel discharge pipe Seat switch Field / road Steering column switch Neutral position
S 80
Master battery switch
X2 X5 X 5.1 X6 X 6.1 X7 X8
[01/2001]
Starter protection On-board computer Starting safety Display Unit 2 Fan delay
Remark Location Can be switched off Central processing unit For fuel 12 volt 24 volt 24 volt 24 volt 12 volt 24 volt
On the injection pump In the driver's seat On the diesel engine On the diesel engine On the fuel tank Exterior on the engine Interior on the engine
Neutral joystick Electronics subassembly, Start Stop Display Unit 2 Safety circuit
Minus controlled Plus controlled Note page 4-94
Horn 4-pole
In front of the battery box Between both dynamos On the gas lever In the joystick In the driver's seat Cab roof In the steering column Large hydrostatic drive pump In front of the battery box Central processing unit Central processing unit Central processing unit Under the engine power take-off Central processing unit Central processing unit
TRAINING CENTER NEUSTADT
4-200
CROSS - FLOW CF 80 COMBINE HARVESTER
Plugs
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
X9 X 12 X 13 X 14 X 15 X 24 X 25 X 26 X 90
Plug connection
XA
12-volt socket
XB
12-volt socket
XC XD XE
12-volt socket 12-volt socket 12-volt socket
XF
12-volt socket
4 – ELECTRICAL SYSTEM Central processing unit Central processing unit Central processing unit Central processing unit
Grain yield measurement For the hand lamp
Under the seat console
In the central processing unit Cigarette lighter On the left next to the driver's seat For the hand lamp Right lamp unit For the hand lamp Left lamp unit For the cooling box Under the passenger's seat For the hand lamp In front of the battery box
Not used (free) Also see the circuit diagrams Lighting System 4-201 Also see the circuit diagrams Cab 4-208 Also see the circuit diagrams Air Conditioner 4-209 Also see the circuit diagrams Field Tracking 4-225 or 4-226 and the circuit diagrams Threshing Basket Adjustment 4-215 or 4-216 Also see the circuit diagrams Reel Speed Adjustment 4-219 and Fan Speed Adjustment 4-221 Also see the circuit diagrams Working Hydraulics 4-229 or 4-230 Electronically-controlled central lubrication pump (option) Also see the circuit diagram 4-240 Also see the circuit diagram Grain Tank Filling Display 4-217 Radio, also see the circuit diagram Cab 4-208 See the circuit diagrams Warning Device 4-202 and Display Unit 4-205 See Presentation F 1 (presented twice) on the right next to F 6 Alternative connection possibility (close to K 43) Subassembly for motor starting in Display Unit 2 Grounded on Pin 15 when ready to start Grounded on Pin 10 when there is a dynamo at a standstill and positive when there is a rotating dynamo Switch position presented: Emergency stop switch in ready position 24 volts applied when the threshing unit clutch is switched in Also see the circuit diagrams Threshing Unit and Header Clutch 4-223
[01/2001]
TRAINING CENTER NEUSTADT
4-201
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Lighting System Circuit diagrams: 4-201 A from Machine Number DCF 880001 to 30 4-201 B from Machine Number DCF 880031 to 60 4-201 C starting with Machine Number DCF 880061 Circuit Diagram Legend Lamps
Relays
Switches
Number H 9 li H 9 re H 10 H 10 H 11 li H 11 re H 12 li H 12 re H 15 li H 15 re H 16 H 17 H 19 H 22 li H 22 re K1
Function Side lamp Side lamp Working light Working light Driving light, left Driving light, right Parking light, left Parking light, right Low beam Low beam Unloader lighting Working light Back-up light Back light, left Back light, right Light relay
K3
Low beam relay
K 37 K 38 K 39 S 34 S 36 S 42 S 72
Plugs
X2 X6 X 6.1 X7 X8 X 15
Rotaflare lights Light switch Steering column switch Discharge pipe transport
Remark On the left On the right
Interior left Interior right Switch-on conditions
12 volt 12 volt
Location Corn adapter Corn adapter In cab roof In cab roof Left lamp unit Right lamp unit Left lamp unit Right lamp unit Cab roof Cab roof Over cab door On the rail On the outflow hood Central processing unit Central processing unit
Headlamp flasher
In the cab roof In the cab roof In the steering column
Limit stop switch
Discharge pipe, center Central processing unit Central processing unit Under the engine power take-off Central processing unit Central processing unit Central processing unit
X 24 X 25 [01/2001]
TRAINING CENTER NEUSTADT
4-201
CROSS - FLOW CF 80 COMBINE HARVESTER
1 2 3 4 5 6
X 26 X 30 X 31 X 32 x 34 XH
Trailer socket
xS
Header socket
4 – ELECTRICAL SYSTEM
On the steering axle support Next to the multiclutch of the hydraulic system
Switching position: Discharge pipe moved out (open when discharge pipe is moved in) 12 volt on Fuse F 1:E Switch lighting (it is only one of all that are drawn in) Display unit on the steering column For use as a low beam light during road travel with a mounted corn adapter 13-pole connector for corn adapter
[01/2001]
TRAINING CENTER NEUSTADT
4-202
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Warning Device Circuit diagrams : 4-202 A starting with Machine Number DCF 880001 Transmitters Switches Lamps Plugs
Number Function G 20 Signal transmitter, backwards G 21 Horn S 40 Switch, backwards H 23 re Brake light H 23 li Brake light X2 X7 X8 X9 X 26 X 30 X 31 X 33 X 34 X 35
1 2 3 4 5 6 7
Remark
Right Left
Location On the outflow hood Under the cab On the joystick On the outflow hood On the outflow hood Central processing unit Central processing unit Central processing unit Central processing unit Steering column
On Relay K 32:85 horn signal for starting release; see Circuit Diagram 200A,C Horn Brake light Signal backwards 24 volt when ignition on Required equipment for towing switch on the joystick (brake light actuation when there is a reduction in speed) On Relay K 32:30
[01/2001]
TRAINING CENTER NEUSTADT
4-202
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Direction Indicator Circuit diagrams: 4-203 A from Machine Number DCF 880001 to 30 4-203 B starting with Machine Number DCF 880031 Circuit Diagram Legend
Relays
Number H 13 re H 13 li H 21 re H 21 li K3
Function Indicator lights Indicator lights Indicator light Indicator light Flasher unit
Switches
S 42
Plugs
S 43 X2
Steering column flasher switch Warning light switch
Lamps
Remark Right front Left front Right back Left back
X 7.3 X 7.4 X8
X 14.1 X 15
1 2 3 4 5 6
Cab roof Central processing unit Central processing unit Central processing unit
X 14
X 25 X 26 X 28 X 30 XH XS
Location Driver platform, right Driver platform, left On the outflow hood On the outflow hood Central processing unit Steering column
Central processing unit
Trailer socket Header socket
Rear axle support Left lamp unit
Not used (free) Control sound in the display unit Control lamps in the steering column R Right flasher L Left flasher 13-pole header socket for connecting a corn adapter
[01/2001]
TRAINING CENTER NEUSTADT
4-203
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Mirror Adjustment Circuit diagrams: 4-204 A starting with Machine Number DCF 880001 Circuit Diagram Legend Motors Switches Plugs
Number M1 M2 S 58 X9
Function Mirror adjustment Mirror adjustment Mirror adjustment
X 10 X 15 3
Remark Right Left
Location In the right mirror In the left mirror Control panel Central processing unit Central processing unit Central processing unit
Mirror heating is not connected
[01/2001]
TRAINING CENTER NEUSTADT
4-204
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Display Unit Circuit diagrams: 4-205 A from Machine Number DCF 880001 to 300 4-205 D starting with Machine Number DCF 880301 Circuit Diagram Legend Number Function G-KWT Cooling water temperature G-TFS Fuel display G-MÖD Engine oil pressure Relays K KWS Cooling water level Switches S 52 Hand brake S 70 Filling level transmitter 3/4 S 71 Filling level transmitter 4/4 S 75-1 Straw area clogging S 75-2 Straw area clogging Transmitter
S Luf/EJ Ejector control S LUF S HÖT S HÖS S KWT S KWS S MÖD X2 X5 X6 X 14 X 14.1 X 14.2 X 15
Plugs
1 2 3 4 5 6 7
Air filter control Hydraulic oil temperature Hydraulic oil level Cooling water temperature Cooling water level Engine oil pressure
Remark Analog transmitter
Location On the engine
Analog transmitter Analog transmitter Grain tank
On the fuel tank On the engine Central processing unit Under the platform Grain tank, lower
Grain tank
Grain tank, upper
In the outflow hood Only for chaff cutter At the end of the straw area hood Switching point On the ejector of the air 55°C filter Vacuum switch On the air filter Switching point On the hydraulic tank 85°C On the hydraulic tank Switching point On the engine 103°C On the water cooler On the engine Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit
For the display field starting conditions see the circuit diagrams Operating Voltage 4-200A or 4-200C For the threshing gap and cutting height display, see the circuit diagram Threshing Basket Adjustment Design P 4-215A and Field Tracking Design P 4-225A or 4225C For the speed monitoring, see the circuit diagrams Control System 4-231A or 4231C For the display in the steering column, see the circuit diagrams Lighting System 4201A , 4-201B or 4-201C Display unit Voltage supply for the display unit Not used (free)
[01/2001]
TRAINING CENTER NEUSTADT
4-205
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
8
There are 24 volts applied to K27;87 when the ignition is switched on. See the circuit diagrams Operating Voltage 4-200A or 4-200C
9 10 11 12 13 14
On F6 battery side On switched F6 side See the circuit diagrams Unloader Clutch and Discharge Pipe 4-223A or 4-223C Connection 61 from the 24 volt dynamo On F 1;4 Connection 61 from the 12 volt dynamo
[01/2001]
TRAINING CENTER NEUSTADT
4-206
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Cab Circuit diagrams : 4-208 A from Machine Number DCF 880001 to 300 4-208 D starting with Machine Number DCF 880301 Circuit Diagram Legend Lamps Motors
Number H 30 H 31re H 31li M4 M 16
Switches Plugs
S 30 S 44 XE X Br X Sw X9
Function Control panel lighting Cab lighting Cab lighting Windscreen wiper motor Windscreen wash pump Door contact switch Windscreen wiper Cooling box socket
Remark Night (yellow) Right (white) Left (white)
Loudspeaker on the radio Radio power supply
Brown
X 10 X 15
Black
Location Cab ceiling Cab ceiling Cab ceiling Cab roof
Hinge side, top Cab roof Under the passenger seat hinter Radio Behind the radio Central processing unit Central processing unit Central processing unit
Air Conditioner 4-209A or 4-209C Lighting System 4-201A, 4-201B or 4- 201C Operating Voltage 4-200A or 4-200C Mirror Adjustment 4-204A Grain Tank Filling Display 4-217A or 4-217C
1
Also see the circuit diagrams
2 3 4 5 6 7
12 volt from Switch S Lighting Interior lighting To Switch S Lighting Loudspeaker, left Loudspeaker, right Connection for mobile radio (located behind the right cover of the radio next to the radio in the cab roof) Radio and mobile radio (pre-equipped) Antenna Windscreen wiper On parking light
8 9 10 11
[01/2001]
TRAINING CENTER NEUSTADT
4-208
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Air Conditioner Circuit diagrams : 4-209 A from Machine Number DCF 880001 to 60 4-209 C starting with Machine Number DCF 880061 Circuit Diagram Legend Transmitters Lamps Motors Relays
Switches
Plugs
1
2 3 4 5 6
Number Function NT C1 Temperature sensor NT C2 Temperature sensor H 32 Indicator panel M5 Evaporator fan M6 Evaporator fan MK Compressor K A1 K A2 K A3 K A4 K A5 S 45 Cab fan S 31 Under / overpressure S 32 Air conditioner switch S 33 Potentiometer X5 X8 X9 X 10 X 14.2 X 16
Remark Room air temperature Icing protection
Location Between the center of the back wall and the cab roof In the cab roof Cab roof
Safety switch
On the engine Cab roof, front right Cab roof, front right Cab roof, front right Cab roof, front right Cab roof, front right Cab roof On the dry filter Cab roof
Temperature
Cab roof Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit
Electronic thermostat Target value range: Icing protection:
14....26°C ± 1°C ν off = 3°C ν on = 7°C Under or overpressure switch combination attached to the dry filter. Not used (free) Harness connector to air conditioner Control lamp in the display unit On the parking light and ground of the cab harness
[01/2001]
TRAINING CENTER NEUSTADT
4-209
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Header Vehicle Circuit diagrams: 4-214 A starting with Machine Number DCF 880001 Circuit Diagram Legend Number Function
Remark
Location
Diodes Transmitters Lamps Magnets Motors Relays Switches Plugs
[01/2001]
TRAINING CENTER NEUSTADT
4-214
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Threshing Basket Adjustment Design P (Electrical-Mechanical Field Tracking) Circuit diagrams: 4-215 A starting with Machine Number DCF 880001 Circuit Diagram Legend Transmitters
Number G 30 Analog transmitter, basket gap G 31 Initiator "narrow" G 32
Initiator "wide"
Motors
M7
Actuator motor
Plugs
X7 X 14
Remark
Location On the basket adjustment Like the speed initiator On the basket adjustment On the basket adjustment On the basket adjustment Central processing unit Central processing unit
X 14.2 X 28 1 2 3 4 6
Card subassembly Basket Adjustment / Field Tracking (with 3 plugs) Down High Data bus Display unit (6; 7; 8; 9 display )
[01/2001]
TRAINING CENTER NEUSTADT
4-215
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Threshing Basket Adjustment Design Q (Electrical-Hydraulic Field Tracking) Circuit diagrams: 4-216 B from Machine Number DCF 880031 to 60 4-216 C starting with Machine Number DCF 880061 Circuit Diagram Legend Transmitters
Number Function G 30 Analog transmitter, basket gap G 31 Initiator "narrow" G 32
Initiator "wide"
Motors
M7
Actuator motor
Plugs
X7 X 14
Remark Like the speed initiator
Location On the basket adjustment On the basket adjustment On the basket adjustment On the basket adjustment Central processing unit Central processing unit
X 14.2 X 28 1 2 3 4 5 6
Card subassembly Basket Adjustment / Field Tracking (with 3 plugs) Down High Data bus Card subassembly Basket Adjustment / Field Tracking Design Q (with 2 plugs) Display unit (6; 7; 8; 9 display )
[01/2001]
TRAINING CENTER NEUSTADT
4-216
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Grain Tank Filling Display Circuit diagrams: 4-217 A from Machine Number DCF 880001 to 60 4-217 C starting with Machine Number DCF 880061 Circuit Diagram Legend Number Function H 25.re Grain tank lighting
Remark 24 volt !
H 25.li
Grain tank lighting
24 volt !
Relays
K 19
Rotaflare light
Switches
S 34 S 70 S 71 X2
Rotaflare light For both Filling level transmitter 3/4 Filling level transmitter 4/4
Lamps
Plugs
X 15
Location In the grain tank, on the right In the grain tank, on the left Central processing unit Cab roof, front In the grain tank In the grain tank Central processing unit Central processing unit
X 31 X 32 1 2 3 4 5
Control lamps in the display unit Current only with the position "Field" Rotaflare light on the straw area hood Rotaflare light on the cab roof Also see the circuit diagrams Lighting 4-201A; 4-201B or 4-201C
[01/2001]
TRAINING CENTER NEUSTADT
4-217
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Reel Speed Adjustment Circuit diagrams: 4-219 A from Machine Number DCF 880001 to 30 4-219 B from Machine Number DCF 880031 to 300 4-219 D starting with Machine Number DCF 880301 Circuit Diagram Legend Function
Diodes
Number D4
Transmitters
G5 G 17
Driving speed Reel speed
Solenoid Y 1 valve Switches S 7 S8 X2
Plugs
Remark Diode block D 4
Proportional valve, reel speed Reel speed, automatic system Potentiometer, reel speed
X7 X8 X9 X 10 X 11 X 16
1 2 3 4 5 6 7 8 9 10 11
Location
XS
Plug to the header
X 101
Plug of the computer
Central processing unit Initiator Left rear wheel Initiator Reel drive unit on the header Battery Under the driver's distributing valve platform, right Control panel Control panel Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Under the driver's Other plug starting with DCF platform, left 880031 Cab; right, top
24 volts are applied when the threshing unit clutch has been switched in 24 volts are applied when the field position has been activated Other functions when the threshing unit clutch has been switched in FCT = off; starting with Program Version 1.05 for replacement parts Input speed at the LH AGRO 965 on-board computer On F5:7 12 volt (voltage supply initiators, right side) In Diode Block D 4 Proportional amplifier, reel and fan speed Also see the circuit diagram Fan Speed 4-221A Pin 1 is presented several times There are even more branch-offs on this dashed line On Switch S (24 Volt) when the header clutch has been switched in Also see the circuit diagrams Threshing Unit and Header Clutches 4-222A or 4222C
[01/2001]
TRAINING CENTER NEUSTADT
4-219
CROSS - FLOW CF 80 COMBINE HARVESTER 12 13
4 – ELECTRICAL SYSTEM
O Manual reel speed (independent of the driving speed) 1 Automatic reel speed (dependent on the driving speed) Adjustment values of the proportional amplifier for "Design P" (mech. field tracking) "Design Q" (electr. field tracking)
1
[01/2001]
TRAINING CENTER NEUSTADT
4-220
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Threshing Drum Speed Adjustment Circuit diagrams: 4-220 A starting with Machine Number DCF 880001 Circuit Diagram Legend Motors
Number Function M8 Speed adjustment for threshing drum
Relays
K 17
Switches
S 16
Plugs
X2
Speed adjustment for threshing drum Speed adjustment for threshing drum
X9 X 10 X 16 X 101 1 2 3 18
Computer plug
Remark Motor with friction clutch
2-pole key
Location On the lower threshing drum variator Central processing unit Control panel Central processing unit Central processing unit Central processing unit Central processing unit Cab, top right
On Relay K 18 (fan speed adjustment) On the proportional amplifier for fan and reel speed adjustment 24 volts are applied when the threshing unit clutch S is switched in Also see the circuit diagrams Threshing Unit and Header Clutch 4- 222A or 4-222C Activation of the speed adjustment by selection of the speed display "Threshing Drum" in the on-board computer at more than 250 r.p.m. threshing drum speed or switching over in the on-board computer into the chapter Test. The on-board computer switches ground to the relay K 17.
[01/2001]
TRAINING CENTER NEUSTADT
4-220
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Fan Speed Adjustment Circuit diagrams: 4-221 A from Machine Number DCF 880001 to 300 4-221 D starting with Machine Number DCF 880301 Circuit Diagram Legend Solenoid valve Relays
Number Function Remark Y 10 Change in the volume flow K 18 Speed adjustment for fan K 54 Drop-off delay T = 5 seconds
Switches
S 15
Plugs
X6
Speed adjustment for fan
X9 X 10 X 16 X 101 1 2 3 4 5 6
7
Computer plug
Location Fan adjustment pump Central processing unit Central processing unit Control panel Central processing unit Central processing unit Central processing unit Central processing unit Cab, top right
Proportional amplifier for reel and fan speed adjustment Also see the circuit diagrams 4-219 A; 4-219 B or 4-219 D On K 17 (speed adjustment of the threshing drum) 24 volts when the field position is activated 24 volts when the threshing unit clutch is switched in S 10 Activation of the speed adjustment by selection of the speed display "Fan" in the onboard computer at more than 250 r.p.m. threshing drum speed or switching over in the on-board computer into the chapter Test. The on-board computer switches ground to the relay K 17. The connector for the harness is in the center on harness, on the left-hand side
[01/2001]
TRAINING CENTER NEUSTADT
4-221
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Threshing Unit and Header Clutches Circuit diagrams: 4-222 A from Machine Number DCF 880001 to 60 4-222 C starting with Machine Number DCF 880061 Circuit Diagram Legend Diodes
Number Function D3
Solenoid valve Relays
Y 11 Y 12 K 41
Threshing unit clutch Header clutch Safety circuit
Threshing unit
K 42
Safety circuit
Header
K 43
Header rapid stop
K 44
Activation of speed monitoring, header Threshing unit clutch Header clutch Rapid stop key Seat switch
Switches
Plugs
S 10 S 11 S 20 S 29 X6
Remark
X9 X 10 X 13 X 16
1 2 3 4
X 45
Card subassembly
X 101
Computer plug for LH Agro 965
Header Pre-equipped
Location Central processing unit On the left side wall, beneath engine Central processing unit Central processing unit Central processing unit Central processing unit Control panel Control panel In the joystick In the driver's seat Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit In the central processing unit In the front right cab capping piece
Switch-on condition "Threshing Unit ON" for header return. Also see the circuit diagram 4-224 A Switch-on condition "Header OFF" for header return Also see the circuit diagram 4-224 A Activation of the speed monitoring "Upper Shaft Spindle" Also see the circuit diagrams Control System 4-231 A or 4-231 C 24 volts with a switched-in threshing unit S for a)chaff cutter, also see the circuit diagrams Chaff Cutter 4-227 A or 4-227 C b) speed adjustment of the threshing drum, see the circuit diagram 4-220 A
[01/2001]
TRAINING CENTER NEUSTADT
4-222
CROSS - FLOW CF 80 COMBINE HARVESTER 5
6 7 8 9
10
4 – ELECTRICAL SYSTEM
24 volts with a switched-in header S for a) reel speed adjustment, also see the circuit diagrams 4-219 A, 4-219 B or 4-219 D b) electric rape, also see with regard to this the circuit diagrams 4-228 A or 4228 B c) field tracking Design P, also see the circuit diagrams 4-225 A or 4-225 C field tracking Design Q, also see the circuit diagrams 4-226 B or 4-226 C 24 volts with activated "Field Position" See the unloader clutch circuit diagrams 4-223 A or 4-223 C See the chaff cutter circuit diagrams 4-227 A or 4-227 C Alternative connection possibility (Line 279 ends directly at K 43). If Line 279 is connected directly to K 43:87a instead of the ground currently existing, the corresponding safety requirements can be realized by shutting off the header, with a free driver's seat. The connector for the harness is in the center on harness, on the left-hand side
[01/2001]
TRAINING CENTER NEUSTADT
4-223
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Unloader Clutch with Discharge Pipe Control Circuit diagrams: 4-223 A from Machine Number DCF 880001 to 60 4-223 C starting with Machine Number DCF 880061 Circuit Diagram Legend Diodes Transmitters Lamps Relays
Number D1 D2 G 40 G 41 H 29
K4 K 30 K 31 Switches S 21 S 22 S 73 Plugs X2 X6 X7 X9 X 11 X 12 X 13 X 14 X 15 X 32 1 2 3 4 6 7 8
Function
Remark
Safety circuit Safety circuit Unloading lighting
For unloading For unloading
Unloader clutch Unloader pipe out Unloader pipe in Swivel discharge pipe Unloader clutch Unloader pipe moved out
Incremental relay Key
Location Central processing unit Central processing unit Grain tank flap Grain tank flap Cab roof under driver's door Central processing unit Central processing unit Central processing unit In the joystick In the joystick On the swivel device
Switching position is discharge pipe moved out; the end position has not yet been reached (opens in the end position of discharge pipe out) The connector for the harness is in the center on harness, on the left-hand side 24 volts with activated field position Control lamps in the display unit Switching position is discharge pipe moved out (opens when discharge pipe is moved in) Connector at K 33 is currently not used (free) On 12 volts of the working lighting Also see the circuit diagrams Lighting 4-201 A; 4-201 B or 4-201 C
[01/2001]
TRAINING CENTER NEUSTADT
4-223
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Header Return Circuit diagrams: 4-224 A from Machine Number DCF 880001 to 60 4-224 C starting with Machine Number DCF 880061 Circuit Diagram Legend Diodes
Number Function D3 Diode D6
Transmitters Motors Relays
Switches
Plugs
1 2 3 4
5 6 7
Remark
K 43
Spark extinguishing diode Speed, upper shaft spindle Header return Speed control, upper shaft spindle Header rapid stop
K A6
Header return
Power relay
S 13
Header return
Press for at least 5 seconds
S 10 S 11 S 20 S 80
Threshing unit clutch Header clutch Rapid stop Master battery switch
G 15 M9 K 44
X6 X8 X9 X 10 X 13 X 16 X 27 X 45
Plug, electronics subassembly, header return
Initiator Starter motor
Header 2-pole
Location Central processing unit In front of the battery box Upper shaft spindle, right Shaft, front left Central processing unit Central processing unit In front of the battery box Control panel Control panel Control panel On the joystick In front of the battery box
On the electronics subassembly in the central processing unit
X 101 See the circuit diagrams Control System LH AGRO 4-231 A or 4-231 C Pin 8 → N upper shaft spindle (speed pulses of the upper shaft spindle) Pin 18→ E upper shaft spindle (switch-in control of the upper shaft spindle) Card subassembly Header Return Switch-in conditions for the header return ● Field position is activated ● Threshing Unit Switch S10 is activated (threshing unit is switched in) ● Header Switch S11 is not activated (header is switched off) ● Standstill of the upper shaft spindle (speed control through G15) ● Hold down Header Return Switch S 13 for about 5 seconds 24 volts with activated field position The connector for the harness is in the center on harness, on the left-hand side On Relay K 42
[01/2001]
TRAINING CENTER NEUSTADT
4-224
CROSS - FLOW CF 80 COMBINE HARVESTER 8 9
4 – ELECTRICAL SYSTEM
Also see the circuit diagrams Threshing Unit and Header Clutch 4-222A or C When threshing unit is switched in
[01/2001]
TRAINING CENTER NEUSTADT
4-225
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Field Tracking Design P (Electrical-Mechanical Field Tracking) Circuit diagrams: 4-225 A from Machine Number DCF 880001 to 60 4-225 C starting with Machine Number DCF 880061 Circuit Diagram Legend Number G 22 G 23 Y 7.1 Y 7.2 K 20 K 21 Switches S 1 Transmitters Solenoid valves Relays
S2 S3 S 24 S 38 Plugs
1
2 3 4 5 6 7
Function Shaft height Longitudinal pendulum Lift shaft Lower shaft
Remark
Location On the shaft, right On the shaft, front right
Operating modes of field tracking Lodged grain Target value pendulum Potentiometer range, longitudinal tracking Lift / lower shaft Target value cutting Potentiometer height
X7 X8 X9 X 11 X 12 X 13.1 X 14 X 14.2 X 27 24 volts are applied with a switched-in header clutch Also see the circuit diagrams Threshing Unit and Header Clutch 4-222 The shaft can only be adjusted manually with the keys in the joystick when the header clutch is switched off. Joystick 24 volts with field position Display of the cutting height in the display unit Electronic unit for field tracking The PINs St2:3; St1:14 and St2:7 are presented several times Reserve line laid up to the control unit
[01/2001]
TRAINING CENTER NEUSTADT
4-225
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Field Tracking Design Q (Electrical-Hydraulic Field Tracking) Circuit diagrams: 4-226 B from Machine Number DCF 880031 to 60 4-226 C starting with Machine Number DCF 880061 Circuit Diagram Legend Transmitters
Solenoid valves
Relays Switches Plugs
1 2 3 4 5 6 7 8 9 10 11 12
Number G 22 G 24 G 25 G 26 G 27 G 28 G 29 Y 7.1 Y 7.2 Y 8.1 Y 8.2 Y9 K 35
Function Remark Shaft height Cross pendulum Pressure sensor Header probe skid Outer right Header probe skid Inner right Header probe skid Inner left Header probe skid Outer left Lift shaft Lower shaft Cross-tracking, left Cross-tracking, right Supplemental valve Voltage supply transmitter
S 24 S 26 S 37 X7 X8 X9 X 11 X 13 X 16 X 17 X 27 XS
Lift / lower shaft Automatic field tracking. Boot switch
Location
Central processing unit In the joystick, back In the joystick, front
Header plug
24 volts with field position "ON" 12 volts with ignition "ON" 24 volts with threshing unit clutch "ON" Ground, central processing unit Ground, machine frame CCU control unit DIL Switches 1 and 6 in "On" position Operating and display device Supplemental equipment Joystick Shaft Lift Lower Left Right Further to reel switch in the joystick Also see the circuit diagrams Working Hydraulics 4-230
[01/2001]
TRAINING CENTER NEUSTADT
4-226
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Straw Cutter Circuit diagram: 4-227 A starting with Machine Number DCF 880001 Circuit Diagram Legend Transmitters Lamps
Number Function G6 Chopper speed H SRA
Chopper control lamp
H SRA1
Control lamp black
Solenoid valve Motors
Y 14
Chopper clutch
M 17
Diffusing screen adjustment
Relays
K 15 K 16 S 76 X6 X 10 X 16
Switches Plugs
1 2 3 4 5 6
Straw guide plate
Remark Speed initiator
Not visible ( 5 )
Limit stop switch
Location Chopper shaft, left In the operating device In the operating device
Straw flap, left
Connector harness left Connector harness center Computer LH AGRO 965 24 volts with field position Covered control lamp next to On threshing unit clutch switch 24 volts are applied when the threshing unit clutch is switched in
[01/2001]
TRAINING CENTER NEUSTADT
4-227
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Rape Electrical System Circuit diagrams: 4-228 A from Machine Number DCF 880001 to 30 4-228 B starting with Machine Number DCF 880031 Circuit Diagram Legend Motors
Relays
Number Function M 10 Vertical sickle
Remark 24 volt; right
M 11
Vertical sickle
24 volt; left
K6
Safety relay
Rape separator
K7 K8
Rape separator, right Rape separator, left
Switches S 12 Plugs
X7 X 10 X 80 X 81 XS XL XR
1
Location Right header side wall Left header side wall Central processing unit Central processing unit
Rape separator
Switching Position l: M7 Switching Position ll:M7 and M8
Plug of the rape separator Plug of the rape separator Header plug Socket of the rape separator Socket of the rape separator
Right Left Left Right
Right header side wall Left header side wall On the header Left header side wall Right header side wall
24 volts when the header clutch is switched in Also see the circuit diagrams Threshing Unit and Header Clutches 4-222 A or 4-222 C
[01/2001]
TRAINING CENTER NEUSTADT
4-228
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Working Hydraulics Design P (Electrical-Mechanical Field Tracking) Circuit diagrams: 4-229 A from Machine Number DCF 880001 to 60 4-229 C starting with Machine Number DCF 880061 Circuit Diagram Legend Number Solenoid Y 1 valve Y 2.1 Y 2.2 Y3 Y 4.1 Y 4.2 Y 5.1 Y 5.2 Y 6.1 Y 6.2 Y 7.1 Y 7.2 Relays K 20 K 21
Lift shaft
K 22
Lift reel
K 23
Lower reel
K 24
Reel forwards
K 25
Reel backwards
K 30
Swivel out unloader pipe
K 31
Swivel in unloader pipe
Switches S 14 S 21 S 24.1 S 24.2 S 25.1 S 25.2 Plugs
[01/2001]
Function Reel speed Unloader pipe in Unloader pipe out Pressure relief Header latch Header latch Reel adjustment Reel adjustment Reel adjustment Reel adjustment Lower shaft Lift shaft Lower shaft
S 51 X7 X8 X9 X 11 X 12 X 13
Header latch Swivel discharge pipe Shaft cross pendulum Lift / lower shaft Reel vertical adjustment Reel horizontal adjustment Pressure relief
Remark Location Proportional valve
Rigid Swinging Back Forward Lift Lower
Out / in Left right Lift / lower Forwards / backwards
Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit In the control panel In the joystick In the joystick In the joystick In the joystick In the joystick
TRAINING CENTER NEUSTADT
4-229
CROSS - FLOW CF 80 COMBINE HARVESTER 1
Proportional amplifier, reel and fan speed
2 3
24 volts with field position Shaft Left Right Lift Lower Joystick Free; not used
4 5
[01/2001]
4 – ELECTRICAL SYSTEM
TRAINING CENTER NEUSTADT
4-230
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Working Hydraulics Design Q (Electrical-Hydraulic Field Tracking) Circuit diagrams: 4-230 B from Machine Number DCF 880031 to 60 4-230 C starting with Machine Number DCF 880061 Circuit Diagram Legend Number Solenoid Y 1 valves Y 2.1 Y 2.2 Y 5.1 Y 5.2 Y 6.1 Y 6.2 Y 7.1 Y 7.2 Y 8.1 Y 8.2 Y9 Relays K 20 K 21
Lift shaft
K 22
Lift reel
K 23
Lower reel
K 24
Reel forwards
K 25
Reel backwards
K 30
Swivel out unloader pipe
K 31
Swivel in unloader pipe
Switches S 14 S 21 S 24.1 S 24.2 S 25.1 S 25.2 S 26 Plugs
[01/2001]
Function Reel speed Unloader pipe in Unloader pipe out Reel adjustment Reel adjustment Reel adjustment Reel adjustment Lower shaft Lift shaft Cross-tracking Cross-tracking Supplemental valve Lower shaft
S 51 X7 X8 X9 X 11 X 12
Remark Location Proportional valve Back Forward Lift Lower Left Right Not connected
Header latch Swivel discharge pipe Out / in Shaft cross pendulum Left right Lift / lower shaft Reel vertical adjustment Lift / lower Reel horizontal Forwards / adjustment backwards Switching in the automatic system of field tracking Pressure relief
Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit In the control panel In the joystick In the joystick In the joystick In the joystick In the joystick In the joystick; front
TRAINING CENTER NEUSTADT
4-230
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
X 13
1 2 3 4 5 6
X 16 X 17 Proportional amplifier, reel and fan speed 24 volts with field position Shaft Left Right Lift Lower Joystick Free; not used Control unit, shaft and basket adjustment (shaft function not used)
[01/2001]
TRAINING CENTER NEUSTADT
4-231
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
LH AGRO 968 Control System Circuit diagrams: 4-231 A from Machine Number DCF 880001 to 60 4-231 C starting with Machine Number DCF 880061 Circuit Diagram Legend Transmitters
Relays Plugs
1 2 3 4 5 6 7 8
Number G1 G2 G3 G4 G5 G6 G7 G8 G9 G 10 G 11
Function Threshing drum speed Fan speed Straw walker speed Engine speed Driving speed Chaff cutter Loss transmitter (plate) Loss transmitter (plate) Loss transmitter (plate) Loss transmitter (plate) Loss transmitter (pipe)
Remark Speed initiator Speed initiator Speed initiator Speed initiator Speed initiator Speed initiator Straw walker Cleaning unit Cleaning unit Straw walker For tailings
G 12 G 13 G 14 G 15 G 16 K 17 K 18
Speed, 4th drum Grain elevator speed Tailings elevator speed Shaft speed Harvested grain switch Adjustment, fan speed Adjustment, threshing drum speed
Speed initiator Speed initiator Speed initiator Speed initiator Speed initiator
X2 X6 X 6.1 X8 X9 X 16 X 27 X 101
Computer plug
Location Threshing drum, left Fan shaft, left Straw walker shaft, left Left rear wheel Chopper shaft, left Left straw walker Cleaning unit, left Cleaning unit, right Right straw walker Under tailings auger in front of the threshing drum Shaft, 4th drum, right Grain elevator, right Tailings elevator, right Upper shaft spindle, right Shaft inlet, right Central processing unit Central processing unit
Cab roof, right front
Free; not used Computer LH AGRO 965 Signal decoupling for fan and reel speed 12 volts with ignition "On" Switching-in conditions, chaff cutter; also see the circuit diagrams 4-227 Chaff cutter connector near the battery box Connection for extension cable, harness on the right White connection housing of the loss measurement in the straw area hood, right
[01/2001]
TRAINING CENTER NEUSTADT
4-231
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Electrical Central Lubrication System Circuit diagrams: 4-240 C starting with Machine Number DCF 880061 Circuit Diagram Legend Motors Relays Plugs
1 2 3 4 5 6 7
Number Function Remark M 18 Pump, centralized lubrication K 58 Switching-on conditions, centralized lubrication X2 X9 X 13 X 16
Location Right side wall Central processing unit
12 volts with ignition on Also see the circuit diagrams Operating Voltage System 4-200 24 volts with threshing unit clutch "On" Ground, central processing unit Ground, machine frame Free, not used Control lamps (Positions 25 and 26 ) in the operating device Contacts (2) for displaying an operational malfunction
[01/2001]
TRAINING CENTER NEUSTADT
4-240
CROSS - FLOW CF 80 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
All-Wheel Axle Circuit diagrams: 4-241 D starting with Machine Number DCF 880301 Circuit Diagram Legend Solenoid valves Switches Plugs
1. 2. 3. 4.
Number Function Y 15 All-wheel S 27 X2 X9 X10 X 13 X 30
Remark 12 volt
All-wheel
Location Operating device
12 volts when ignition "On" Ground, central processing unit Ground, machine frame Connection in cable, steering axle support
[01/2001]
TRAINING CENTER NEUSTADT
4-241
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
CF 60 Circuit Diagram Index The circuit diagrams are numbered according to the machine type. The individual numbers (corresponds to the page number) signify the following here:
4-4 00 two-digit number of the circuit diagram (same for all types) Machine type 2 CF 80 3 CF 70 4 CF 60 Number of the chapter (4- Electric’s) The circuit diagrams that act independently of the field position are presented from circuit diagram number 00 to 14. All of the circuit diagrams that are first activated during the threshing by the field position are presented from circuit diagram number 15 to 49. The circuit diagrams for combines equipped with touch screen monitor starting with circuit diagram number 50. Individual page numbers are reserved for the future and are therefore not assigned. Every circuit diagram is additionally labeled with a letter. These letters indicate the machine number that the circuit diagram starts with. The validity of the circuit diagram is only canceled when a new circuit diagram with the same number and a different letter is substituted for it. In the process, individual letters in the alphabet can be jumped over (e.g. Circuit Diagram 4-408 A is first substituted with 4-408 D). The letters start according to the alphabet with A. The individual letters signify the following here: A
Starting with Machine Number DCF 86 0103 until a subsequent letter is substituted Combine harvesters with Design Q (electrical-hydraulic field tracking) are first manufactured starting with Machine Number DCF880031. There is a legend for every circuit diagram. The legend is labeled with the same circuit diagram number, but without letters. If the legend goes on over several pages, they are provided with an additional number (for example 4-300.1) Notes are labeled with a serial number in the circuit diagram, and are then explained in the legend. The circuit diagrams are closed within themselves as a rule, so troubleshooting only has to be carried out on this circuit diagram. Every circuit diagram starts with the respective fuse. The wiring in front of the fuse is drawn in the circuit diagram Operating Voltage 4-400. If there are links to another circuit diagram, for instance if the same fuse is used or if the witch-on conditions are on a different circuit diagram, this is indicated with an arrow and the circuit diagram number.
[01/2001]
TRAINING CENTER NEUSTADT
4-397
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
General Circuit Diagrams (Independent of the Field Position) 4-400 A 4-401 A 4-402 A 4-403 A 4-404 A 4-405 A 4-408 A 4-409 A
Operating Voltage Starting with DCF 86 0103 Lighting System Starting with DCF 86 0103 Warning Device Starting with DCF 86 0103 Direction Indicator Starting with DCF 86 0103 Mirror Adjustment Starting with DCF 86 0103 Display Unit Starting with DCF 86 0103 Cab Starting with DCF 86 0103 Air Conditioner Starting with DCF 86 0103
Circuit Diagrams Activated by the Field Position 4-416 A 4-417 A 4-419 A 4-420 A 4-421 A 4-422 A 4-423 A 4-424 A 4-426 A 4-427 A 4-428 A 4-428 B 4-430 A 4-431 A 4-440 A 4-441 A
[01/2001]
Threshing Basket Adjustment Design Q Starting with DCF 86 0103 Grain Tank Filling Display Starting with DCF 86 0103 Reel Speed Adjustment Starting with DCF 86 0103 Threshing Drum Speed Adjustment Starting with DCF 86 0103 Fan Adjustment Starting with DCF 86 0103 Threshing Unit and Header Clutch Starting with DCF 86 0103 Unloader Clutch with Unloader Pipe Control Starting with DCF 86 0103 Header Return Starting with DCF 86 0103 Field Tracking Design Q Starting with DCF 86 0103 Chaff-Cutter Starting with DCF 86 0103 Rape Electrical System Starting with DCF 86 0103 Rape Electrical System Starting with DCF 86 0103 Working Hydraulics Design Q Starting with DCF 86 0103 LH AGRO 968 Control System Starting with DCF 86 0103 Electrical Central Lubrication System Starting with DCF 86 0103 All-Wheel Drive Starting with DCF 86 0103
TRAINING CENTER NEUSTADT
4-398
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Operating Voltage Circuit diagrams: 4-400 A from Machine Number DCF 860103 Circuit Diagram Legend Number Function H 33 Central processing unit interior light Magnets Y 30 Stop magnet Motors M 12 Compressor seat M 13 Starter M 14 Motor time counter M 15 Auxiliary fuel pump DLM12V Dynamo DLM24V Dynamo Relays K5 Field / road K9 Starting safety K10 Starting safety Lamps
Switches
Plugs
K11 K 12 K 13 K 27 K 58 K 59 K 60 K 61 M K 61 P K A7
Starting safety Starting safety Starting safety 12-volt on-board voltage
KA8 S0 S 21 S 29 S 35 S 42 S 50
Starter relay Emergency stop Swivel discharge pipe Seat switch Field / road Steering column switch Neutral position
S 80
Master battery switch
X2 X5 X 5.1 X6 X 6.1 X7 X8 X9
[01/2001]
Starter protection On-board computer Starting safety Display Unit 2 Fan delay
Remark Location Can be switched off Central processing unit For fuel 12 volt 24 volt 24 volt 24 volt 12 volt 24 volt
On the injection pump In the driver's seat On the diesel engine On the diesel engine On the fuel tank Exterior on the engine Interior on the engine
Neutral joystick Electronics subassembly, Start Stop Display Unit 2 Safety circuit
Minus controlled Plus controlled Note page 4-94
Horn 4-pole
In front of the battery box Between both dynamos On the gas lever In the joystick In the driver's seat Cab roof In the steering column Large hydrostatic drive pump In front of the battery box Central processing unit Central processing unit Central processing unit Under the engine power take-off Central processing unit Central processing unit Central processing unit
TRAINING CENTER NEUSTADT
4-400
CROSS - FLOW CF 60 COMBINE HARVESTER
Plugs
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
X 12 X 13 X 14 X 15 X 24 X 25 X 26 X 90
Plug connection
XA
12-volt socket
XB
12-volt socket
XC XD XE
12-volt socket 12-volt socket 12-volt socket
XF
12-volt socket
4 – ELECTRICAL SYSTEM Central processing unit Central processing unit Central processing unit
Grain yield measurement For the hand lamp
Under the seat console
In the central processing unit Cigarette lighter On the left next to the driver's seat For the hand lamp Right lamp unit For the hand lamp Left lamp unit For the cooling box Under the passenger's seat For the hand lamp In front of the battery box
Not used (free) Also see the circuit diagrams Lighting System 4-401 Also see the circuit diagrams Cab 4-408 Also see the circuit diagrams Air Conditioner 4-409 Also see the circuit diagrams Field Tracking 4-426 and the circuit diagrams Threshing Basket Adjustment 4-416 Also see the circuit diagrams Reel Speed Adjustment 4-419 and Fan Speed Adjustment 4-421 Also see the circuit diagrams Working Hydraulics 4-430 Electronically-controlled central lubrication pump (option) Also see the circuit diagram 4-440 Also see the circuit diagram Grain Tank Filling Display 4-417 Radio, also see the circuit diagram Cab 4-408 See the circuit diagrams Warning Device 4-402 and Display Unit 4-405 See Presentation F 1 (presented twice) on the right next to F 6 Alternative connection possibility (close to K 43) Subassembly for motor starting in Display Unit 2 Grounded on Pin 15 when ready to start Grounded on Pin 10 when there is a dynamo at a standstill and positive when there is a rotating dynamo Switch position presented: Emergency stop switch in ready position 24 volts applied when the threshing unit clutch is switched in Also see the circuit diagrams Threshing Unit and Header Clutch 4-423
[01/2001]
TRAINING CENTER NEUSTADT
4-400
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Lighting System Circuit diagrams: 4-401 A from Machine Number DCF 860103 Circuit Diagram Legend Lamps
Relays
Switches
Number H 9 li H 9 re H 10 H 10 H 11 li H 11 re H 12 li H 12 re H 15 li H 15 re H 16 H 17 H 19 H 22 li H 22 re K1
Function Side lamp Side lamp Working light Working light Driving light, left Driving light, right Parking light, left Parking light, right Low beam Low beam Unloader lighting Working light Back-up light Back light, left Back light, right Light relay
12 volt
K3
Low beam relay
12 volt
K 37 K 38 K 39 S 34 S 36 S 42 S 72
Plugs
X2 X6 X 6.1 X7 X8 X 15
Rotaflare lights Light switch Steering column switch Discharge pipe transport
Remark On the left On the right
Interior left Interior right Switch-on conditions
Location Corn adapter Corn adapter In cab roof In cab roof Left lamp unit Right lamp unit Left lamp unit Right lamp unit Cab roof Cab roof Over cab door On the rail On the outflow hood Central processing unit Central processing unit
Headlamp flasher
In the cab roof In the cab roof In the steering column
Limit stop switch
Discharge pipe, center Central processing unit Central processing unit Under the engine power take-off Central processing unit Central processing unit Central processing unit
X 24 X 25 X 26 X 30 [01/2001]
TRAINING CENTER NEUSTADT
4-301.1
CROSS - FLOW CF 60 COMBINE HARVESTER
1 2 3 4 5 6
X 31 X 32 x 34 XH
Trailer socket
xS
Header socket
4 – ELECTRICAL SYSTEM
On the steering axle support Next to the multiclutch of the hydraulic system
Switching position: Discharge pipe moved out (open when discharge pipe is moved in) 12 volt on Fuse F 1:E Switch lighting (it is only one of all that are drawn in) Display unit on the steering column For use as a low beam light during road travel with a mounted corn adapter 13-pole connector for corn adapter
[01/2001]
TRAINING CENTER NEUSTADT
4-301.1
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Warning Device Circuit diagrams : 4-402 A starting with Machine Number DCF 860103 Transmitters Switches Lamps Plugs
Number Function G 20 Signal transmitter, backwards G 21 Horn S 40 Switch, reverse H 23 re Brake light H 23 li Brake light X2 X7 X8 X9 X 26 X 30 X 31 X 33 X 34 X 35
1 2 3 4 5 6 7
Remark
Right Left
Location On the outflow hood Under the cab On the joystick On the outflow hood On the outflow hood Central processing unit Central processing unit Central processing unit Central processing unit Steering column
On Relay K 32:85 horn signal for starting release; see Circuit Diagram 400A Horn Brake light Signal reverse 24 volt when ignition on Required equipment for towing switch on the joystick (brake light actuation when there is a reduction in speed) On Relay K 32:30
[01/2001]
TRAINING CENTER NEUSTADT
4-302
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Direction Indicator Circuit diagrams: 4-403 A from Machine Number DCF 860103 Circuit Diagram Legend
Relays
Number H 13 re H 13 li H 21 re H 21 li K3
Function Indicator lights Indicator lights Indicator light Indicator light Flasher unit
Switches
S 42
Plugs
S 43 X2
Steering column flasher switch Warning light switch
Lamps
Remark Right front Left front Right back Left back
X 7.3 X 7.4 X8
X 14.1 X 15
1 2 3 4 5 6
Cab roof Central processing unit Central processing unit Central processing unit
X 14
X 25 X 26 X 28 X 30 XH XS
Location Driver platform, right Driver platform, left On the outflow hood On the outflow hood Central processing unit Steering column
Central processing unit
Trailer socket Header socket
Rear axle support Left lamp unit
Not used (free) Control sound in the display unit Control lamps in the steering column R Right flasher L Left flasher 13-pole header socket for connecting a corn adapter
[01/2001]
TRAINING CENTER NEUSTADT
4-303
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Mirror Adjustment Circuit diagrams: 4-404 A starting with Machine Number DCF 860103 Circuit Diagram Legend Motors Switches Plugs
Number M1 M2 S 58 X9
Function Mirror adjustment Mirror adjustment Mirror adjustment
X 10 X 15 3
Remark Right Left
Location In the right mirror In the left mirror Control panel Central processing unit Central processing unit Central processing unit
Mirror heating is not connected
[01/2001]
TRAINING CENTER NEUSTADT
4-304
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Display Unit Circuit diagrams: 4-405 A from Machine Number DCF 860103 Circuit Diagram Legend Number Function G-KWT Cooling water temperature G-TFS Fuel display G-MÖD Engine oil pressure Relays K KWS Cooling water level Switches S 52 Hand brake S 70 Filling level transmitter 3/4 S 71 Filling level transmitter 4/4 S 75-1 Straw area clogging S 75-2 Straw area clogging Transmitter
S Luf/EJ Ejector control S LUF S HÖT S HÖS S KWT S KWS S MÖD X2 X5 X6 X 14 X 14.1 X 14.2 X 15
Plugs
1 2 3 4 5 6 7 8 9 10
Air filter control Hydraulic oil temperature Hydraulic oil level Cooling water temperature Cooling water level Engine oil pressure
Remark Analog transmitter
Location On the engine
Analog transmitter Analog transmitter Grain tank
On the fuel tank On the engine Central processing unit Under the platform Grain tank, lower
Grain tank
Grain tank, upper
In the outflow hood Only for chaff cutter At the end of the straw area hood Switching point On the ejector of the air 55°C filter Vacuum switch On the air filter Switching point On the hydraulic tank 85°C On the hydraulic tank Switching point On the engine 103°C On the water cooler On the engine Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit
For the display field starting conditions see the circuit diagrams Operating Voltage 4-400A For the threshing gap and cutting height display, see the circuit diagram Threshing Basket Adjustment Design P For the speed monitoring, see the circuit diagrams Control System 4-431A For the display in the steering column, see the circuit diagrams Lighting System 4-401A Display unit Voltage supply for the display unit Not used (free) There are 24 volts applied to K27;87 when the ignition is switched on. See the circuit diagrams Operating Voltage 4-400A On F6 battery side On switched F6 side
[01/2001]
TRAINING CENTER NEUSTADT
4-305
CROSS - FLOW CF 60 COMBINE HARVESTER 11 12 13 14
4 – ELECTRICAL SYSTEM
See the circuit diagrams Unloader Clutch and Discharge Pipe 4-423A Connection 61 from the 24 volt dynamo On F 1;4 Connection 61 from the 12 volt dynamo
[01/2001]
TRAINING CENTER NEUSTADT
4-306
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Cab Circuit diagrams : 4-408 A from Machine Number DCF 860103 Circuit Diagram Legend Lamps Motors
Number H 30 H 31re H 31li M4 M 16
Switches Plugs
S 30 S 44 XE X Br X Sw X9
Function Control panel lighting Cab lighting Cab lighting Windscreen wiper motor Windscreen wash pump Door contact switch Windscreen wiper Cooling box socket
Remark Night (yellow) Right (white) Left (white)
Loudspeaker on the radio Radio power supply
Brown
X 10 X 15
Black
Location Cab ceiling Cab ceiling Cab ceiling Cab roof
Hinge side, top Cab roof Under the passenger seat hinter Radio Behind the radio Central processing unit Central processing unit Central processing unit
Air Conditioner 4-409A Lighting System 4-401A Operating Voltage 4-400A Mirror Adjustment 4-404A Grain Tank Filling Display 4-417A
1
Also see the circuit diagrams
2 3 4 5 6 7
12 volt from Switch S Lighting Interior lighting To Switch S Lighting Loudspeaker, left Loudspeaker, right Connection for mobile radio (located behind the right cover of the radio next to the radio in the cab roof) Radio and mobile radio (pre-equipped) Antenna Windscreen wiper On parking light
8 9 10 11
[01/2001]
TRAINING CENTER NEUSTADT
4-308
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Air Conditioner Circuit diagrams : 4-409 A from Machine Number DCF 860103 Circuit Diagram Legend Transmitters Lamps Motors Relays
Switches
Plugs
1
2 3 4 5 6
Number Function NT C1 Temperature sensor NT C2 Temperature sensor H 32 Indicator panel M5 Evaporator fan M6 Evaporator fan MK Compressor K A1 K A2 K A3 K A4 K A5 S 45 Cab fan S 31 Under / overpressure S 32 Air conditioner switch S 33 Potentiometer X5 X8 X9 X 10 X 14.2 X 16
Remark Room air temperature Icing protection
Location Between the center of the back wall and the cab roof In the cab roof Cab roof
Safety switch
On the engine Cab roof, front right Cab roof, front right Cab roof, front right Cab roof, front right Cab roof, front right Cab roof On the dry filter Cab roof
Temperature
Cab roof Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit
Electronic thermostat Target value range: Icing protection:
14....26°C ± 1°C ν off = 3°C ν on = 7°C Under or overpressure switch combination attached to the dry filter. Not used (free) Harness connector to air conditioner Control lamp in the display unit On the parking light and ground of the cab harness
[01/2001]
TRAINING CENTER NEUSTADT
4-309
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Threshing Basket Adjustment Design Q (Electrical-Hydraulic Field Tracking) Circuit diagrams: 4-416 A from Machine Number DCF 860103 Circuit Diagram Legend Transmitters
Number Function G 30 Analog transmitter, basket gap G 31 Initiator "narrow" G 32
Initiator "wide"
Motors
M7
Actuator motor
Plugs
X7 X 14
Remark Like the speed initiator
Location On the basket adjustment On the basket adjustment On the basket adjustment On the basket adjustment Central processing unit Central processing unit
X 14.2 X 28 1 2 3 4 5 6
Card subassembly Basket Adjustment / Field Tracking (with 3 plugs) Down High Data bus Card subassembly Basket Adjustment / Field Tracking Design Q (with 2 plugs) Display unit (6; 7; 8; 9 display )
[01/2001]
TRAINING CENTER NEUSTADT
4-316
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Grain Tank Filling Display Circuit diagrams: 4-417 A from Machine Number DCF 860103 Circuit Diagram Legend Number Function H 25.re Grain tank lighting
Remark 24 volt !
H 25.li
Grain tank lighting
24 volt !
Relays
K 19
Rotaflare light
Switches
S 34 S 70 S 71 X2
Rotaflare light For both Filling level transmitter 3/4 Filling level transmitter 4/4
Lamps
Plugs
X 15
Location In the grain tank, on the right In the grain tank, on the left Central processing unit Cab roof, front In the grain tank In the grain tank Central processing unit Central processing unit
X 31 X 32 1 2 3 4 5
Control lamps in the display unit Current only with the position "Field" Rotaflare light on the straw area hood Rotaflare light on the cab roof Also see the circuit diagrams Lighting 4-401A
[01/2001]
TRAINING CENTER NEUSTADT
4-317
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Reel Speed Adjustment Circuit diagrams: 4-419 A from Machine Number DCF 860103 Circuit Diagram Legend Diodes
Number Function D4
Transmitters
G5 G 17
Solenoid Y 1 valve Switches S 7 S8 X2
Plugs
Remark Diode block D 4
Driving speed Reel speed Proportional valve, reel speed Reel speed, automatic system Potentiometer, reel speed
X7 X8 X9 X 10 X 11 X 16
1 2 3 4 5 6 7 8 9 10 11 12 13
XS
Plug to the header
X 101
Plug of the computer
Location Central processing unit Initiator Left rear wheel Initiator Reel drive unit on the header Battery Under the driver's distributing valve platform, right Control panel Control panel Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Under the driver's platform, left Cab; right, top
24 volts are applied when the threshing unit clutch has been switched in 24 volts are applied when the field position has been activated Other functions when the threshing unit clutch has been switched in FCT = off; starting with Program Version 1.05 for replacement parts Input speed at the LH AGRO 968 on-board computer On F5:7 12 volt (voltage supply initiators, right side) In Diode Block D 4 Proportional amplifier, reel and fan speed Also see the circuit diagram Fan Speed 4-421A Pin 1 is presented several times There are even more branch-offs on this dashed line On Switch S (24 Volt) when the header clutch has been switched in Also see the circuit diagrams Threshing Unit and Header Clutches 4-422A O Manual reel speed (independent of the driving speed) 1 Automatic reel speed (dependent on the driving speed) Adjustment values of the proportional amplifier for "Design P" (mech. field tracking) "Design Q" (electr. field tracking)
[01/2001]
TRAINING CENTER NEUSTADT
4-319
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Threshing Drum Speed Adjustment Circuit diagrams: 4-420 A starting with Machine Number DCF 860103 Circuit Diagram Legend Motors
Number Function M8 Speed adjustment for threshing drum
Relays
K 17
Switches
S 16
Plugs
X2
Speed adjustment for threshing drum Speed adjustment for threshing drum
X9 X 10 X 16 X 101 1 2 3 18
Computer plug
Remark Motor with friction clutch
2-pole key
Location On the lower threshing drum variator Central processing unit Control panel Central processing unit Central processing unit Central processing unit Central processing unit Cab, top right
On Relay K 18 (fan speed adjustment) On the proportional amplifier for fan and reel speed adjustment 24 volts are applied when the threshing unit clutch S is switched in Also see the circuit diagrams Threshing Unit and Header Clutch 4- 422 A Activation of the speed adjustment by selection of the speed display "Threshing Drum" in the on-board computer at more than 250 r.p.m. threshing drum speed or switching over in the on-board computer into the chapter Test. The on-board computer switches ground to the relay K 17.
[01/2001]
TRAINING CENTER NEUSTADT
4-320
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Fan Speed Adjustment Circuit diagrams: 4-421 A from Machine Number DCF 860103 Circuit Diagram Legend Solenoid valve Relays
Number Function Remark Y 10 Change in the volume flow K 18 Speed adjustment for fan K 54 Drop-off delay T = 5 seconds
Switches
S 15
Plugs
X6
Speed adjustment for fan
X9 X 10 X 16 X 101 1 2 3 4 5 6
7
Computer plug
Location Fan adjustment pump Central processing unit Central processing unit Control panel Central processing unit Central processing unit Central processing unit Central processing unit Cab, top right
Proportional amplifier for reel and fan speed adjustment Also see the circuit diagrams 4-419 A On K 17 (speed adjustment of the threshing drum) 24 volts when the field position is activated 24 volts when the threshing unit clutch is switched in S 10 Activation of the speed adjustment by selection of the speed display "Fan" in the onboard computer at more than 250 r.p.m. threshing drum speed or switching over in the on-board computer into the chapter Test. The on-board computer switches ground to the relay K 17. The connector for the harness is in the center on harness, on the left-hand side
[01/2001]
TRAINING CENTER NEUSTADT
4-321
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Threshing Unit and Header Clutches Circuit diagrams: 4-422 A from Machine Number DCF 860103 Circuit Diagram Legend Diodes
Number Function D3
Solenoid valve Relays
Y 11 Y 12 K 41
Threshing unit clutch Header clutch Safety circuit
Threshing unit
K 42
Safety circuit
Header
K 43
Header rapid stop
K 44
Activation of speed monitoring, header Threshing unit clutch Header clutch Rapid stop key Seat switch
Switches
Plugs
S 10 S 11 S 20 S 29 X6 X9 X 10 X 13 X 16 X 45 X 101
1 2 3 4 5
6 7 8
Remark
Header Pre-equipped
Location Central processing unit On the left side wall, beneath engine Central processing unit Central processing unit Central processing unit Central processing unit Control panel Control panel In the joystick In the driver's seat Central processing unit
Card subassembly Computer plug for LH Agro 965
In the central processing unit In the front right cab capping piece
Switch-on condition "Threshing Unit ON" for header return. Also see the circuit diagram 4-424 A Switch-on condition "Header OFF" for header return Also see the circuit diagram 4-424 A Activation of the speed monitoring "Upper Shaft Spindle" Also see the circuit diagrams Control System 4-431 A 24 volts with a switched-in threshing unit S for a)chaff cutter, also see the circuit diagrams Chaff Cutter 4-427 A b) speed adjustment of the threshing drum, see the circuit diagram 4-420 A 24 volts with a switched-in header S for a) reel speed adjustment, also see the circuit diagrams 4-419 A b) electric rape, also see with regard to this the circuit diagrams 4-428 A c) field tracking Design P, also see the circuit diagrams 4-425 A field tracking Design Q, also see the circuit diagrams 4-426 A 24 volts with activated "Field Position" See the unloader clutch circuit diagrams 4-423 A See the chaff cutter circuit diagrams 4-427 A
[01/2001]
TRAINING CENTER NEUSTADT
4-322
CROSS - FLOW CF 60 COMBINE HARVESTER 9
10
4 – ELECTRICAL SYSTEM
Alternative connection possibility (Line 279 ends directly at K 43). If Line 279 is connected directly to K 43:87a instead of the ground currently existing, the corresponding safety requirements can be realized by shutting off the header, with a free driver's seat. The connector for the harness is in the center on harness, on the left-hand side
[01/2001]
TRAINING CENTER NEUSTADT
4-3221
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Unloader Clutch with Discharge Pipe Control Circuit diagrams: 4-423 A from Machine Number DCF 860103 Circuit Diagram Legend Diodes Transmitters Lamps Relays
Number D1 D2 G 40 G 41 H 29
K4 K 30 K 31 Switches S 21 S 22 S 73 Plugs X2 X6 X7 X9 X 11 X 12 X 13 X 14 X 15 X 32 1 2 3 4 6 7 8
Function
Remark
Safety circuit Safety circuit Unloading lighting
For unloading For unloading
Unloader clutch Unloader pipe out Unloader pipe in Swivel discharge pipe Unloader clutch Unloader pipe moved out
Incremental relay Key
Location Central processing unit Central processing unit Grain tank flap Grain tank flap Cab roof under driver's door Central processing unit Central processing unit Central processing unit In the joystick In the joystick On the swivel device
Switching position is discharge pipe moved out; the end position has not yet been reached (opens in the end position of discharge pipe out) The connector for the harness is in the center on harness, on the left-hand side 24 volts with activated field position Control lamps in the display unit Switching position is discharge pipe moved out (opens when discharge pipe is moved in) Connector at K 33 is currently not used (free) On 12 volts of the working lighting Also see the circuit diagrams Lighting 4-401 A
[01/2001]
TRAINING CENTER NEUSTADT
4-323
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Header Return Circuit diagrams: 4-424 A from Machine Number DCF 860103 Circuit Diagram Legend Number Function D3 Diode D6 Spark extinguishing diode TransG 15 Speed, upper shaft mitters spindle Motors M9 Header return Relays K 44 Speed control, upper shaft spindle K 43 Header rapid stop K A6 Header return Switches S 13 Header return
Remark
Location Central processing unit In front of the battery box
Initiator
Upper shaft spindle, right
Starter motor
Shaft, front left Central processing unit
Diodes
S 10 S 11 S 20 S 80 X6 X8 X9 X 10 X 13 X 16 X 27 X 45
Plugs
Threshing unit clutch Header clutch Rapid stop Master battery switch
Plug, electronics subassembly, header return
Power relay Press for at least 5 seconds Header 2-pole
Central processing unit In front of the battery box Control panel Control panel Control panel On the joystick In front of the battery box
On the electronics subassembly in the central processing unit
X 101 1 2 3 4
5 6 7 8 9
See the circuit diagrams Control System LH AGRO 4-431 A Pin 8 → N upper shaft spindle (speed pulses of the upper shaft spindle) Pin 18→ E upper shaft spindle (switch-in control of the upper shaft spindle) Card subassembly Header Return Switch-in conditions for the header return ● Field position is activated ● Threshing Unit Switch S10 is activated (threshing unit is switched in) ● Header Switch S11 is not activated (header is switched off) ● Standstill of the upper shaft spindle (speed control through G15) ● Hold down Header Return Switch S 13 for about 5 seconds 24 volts with activated field position The connector for the harness is in the center on harness, on the left-hand side On Relay K 42 Also see the circuit diagrams Threshing Unit and Header Clutch 4-422A When threshing unit is switched in
[01/2001]
TRAINING CENTER NEUSTADT
4-324
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Field Tracking Design Q (Electrical-Hydraulic Field Tracking) Circuit diagrams: 4-426 B from Machine Number DCF 860103 Circuit Diagram Legend Transmitters
Solenoid valves
Relays Switches Plugs
1 2 3 4 5 6 7 8 9 10 11 12
Number G 22 G 24 G 25 G 26 G 27 G 28 G 29 Y 7.1 Y 7.2 Y 8.1 Y 8.2 Y9 K 35
Function Remark Shaft height Cross pendulum Pressure sensor Header probe skid Outer right Header probe skid Inner right Header probe skid Inner left Header probe skid Outer left Lift shaft Lower shaft Cross-tracking, left Cross-tracking, right Supplemental valve Voltage supply transmitter
S 24 S 26 S 37 X7 X8 X9 X 11 X 13 X 16 X 17 X 27 XS
Lift / lower shaft Automatic field tracking. Boot switch
Location
Central processing unit In the joystick, back In the joystick, front
Header plug
24 volts with field position "ON" 12 volts with ignition "ON" 24 volts with threshing unit clutch "ON" Ground, central processing unit Ground, machine frame CCU control unit DIL Switches 1 and 6 in "On" position Operating and display device Supplemental equipment Joystick Shaft Lift Lower Left Right Further to reel switch in the joystick Also see the circuit diagrams Working Hydraulics 4-430
[01/2001]
TRAINING CENTER NEUSTADT
4-326
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Straw Cutter Circuit diagram: 4-427 A starting with Machine Number DCF 860103 Circuit Diagram Legend Transmitters Lamps
Number Function G6 Chopper speed H SRA
Chopper control lamp
H SRA1
Control lamp black
Solenoid valve Motors
Y 14
Chopper clutch
M 17
Diffusing screen adjustment
Relays
K 15 K 16 S 76 X6 X 10 X 16
Switches Plugs
1 2 3 4 5 6
Straw guide plate
Remark Speed initiator
Not visible ( 5 )
Limit stop switch
Location Chopper shaft, left In the operating device In the operating device
Straw flap, left
Connector harness left Connector harness center Computer LH AGRO 968 24 volts with field position Covered control lamp next to On threshing unit clutch switch 24 volts are applied when the threshing unit clutch is switched in
[01/2001]
TRAINING CENTER NEUSTADT
4-327
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Rape Electrical System Circuit diagrams: 4-428 A from Machine Number DCF 860103 Circuit Diagram Legend Motors
Relays
Number Function M 10 Vertical sickle
Remark 24 volt; right
M 11
Vertical sickle
24 volt; left
K6
Safety relay
Rape separator
K7 K8
Rape separator, right Rape separator, left
Switches S 12 Plugs
X7 X 10 X 80 X 81 XS XL XR
1
Location Right header side wall Left header side wall Central processing unit Central processing unit
Rape separator
Switching Position l: M7 Switching Position ll:M7 and M8
Plug of the rape separator Plug of the rape separator Header plug Socket of the rape separator Socket of the rape separator
Right Left Left Right
Right header side wall Left header side wall On the header Left header side wall Right header side wall
24 volts when the header clutch is switched in Also see the circuit diagrams Threshing Unit and Header Clutches 4-422 A
[01/2001]
TRAINING CENTER NEUSTADT
4-328
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Working Hydraulics Design Q (Electrical-Hydraulic Field Tracking) Circuit diagrams: 4-430 A from Machine Number DCF 860103 Circuit Diagram Legend Number Solenoid Y 1 valves Y 2.1 Y 2.2 Y 5.1 Y 5.2 Y 6.1 Y 6.2 Y 7.1 Y 7.2 Y 8.1 Y 8.2 Y9 Relays K 20 K 21 K 22 K 23 K 24 K 25 K 30 K 31 Switches S 14 S 21 S 24.1 S 24.2 S 25.1 S 25.2 S 26 S 51 X7 X8 X9 X 11 X 12 X 13
Plugs
1 2 3 4
Function Remark Reel speed Proportional valve Unloader pipe in Unloader pipe out Reel adjustment Back Reel adjustment Forward Reel adjustment Lift Reel adjustment Lower Lower shaft Lift shaft Cross-tracking Left Cross-tracking Right Supplemental valve Lower shaft Not connected Lift shaft Lift reel Lower reel Reel forwards Reel backwards Swivel out unloader pipe Swivel in unloader pipe Header latch Swivel discharge pipe Out / in Shaft cross pendulum Left right Lift / lower shaft Reel vertical adjustment Lift / lower Reel horizontal Forwards / adjustment backwards Switching in the automatic system of field tracking Pressure relief
Location
Central processing unit
In the control panel In the joystick
In the joystick; front
X 16 X 17 Proportional amplifier, reel and fan speed 24 volts with field position Shaft Left Right Lift Lower Joystick
[01/2001]
TRAINING CENTER NEUSTADT
4-330
CROSS - FLOW CF 60 COMBINE HARVESTER 4 5
4 – ELECTRICAL SYSTEM
Free; not used Control unit, shaft and basket adjustment (shaft function not used)
[01/2001]
TRAINING CENTER NEUSTADT
4-330.1
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
LH AGRO 968 Control System Circuit diagrams: 4-431 A from Machine Number DCF 860103 Circuit Diagram Legend Transmitters
Relays Plugs
1 2 3 4 5 6 7 8
Number G1 G2 G3 G4 G5 G6 G7 G8 G9 G 10 G 11
Function Threshing drum speed Fan speed Straw walker speed Engine speed Driving speed Chaff cutter Loss transmitter (plate) Loss transmitter (plate) Loss transmitter (plate) Loss transmitter (plate) Loss transmitter (pipe)
Remark Speed initiator Speed initiator Speed initiator Speed initiator Speed initiator Speed initiator Straw walker Cleaning unit Cleaning unit Straw walker For tailings
G 12 G 13 G 14 G 15 G 16 K 17 K 18
Speed, 4th drum Grain elevator speed Tailings elevator speed Shaft speed Harvested grain switch Adjustment, fan speed Adjustment, threshing drum speed
Speed initiator Speed initiator Speed initiator Speed initiator Speed initiator
X2 X6 X 6.1 X8 X9 X 16 X 27 X 101
Computer plug
Location Threshing drum, left Fan shaft, left Straw walker shaft, left Left rear wheel Chopper shaft, left Left straw walker Cleaning unit, left Cleaning unit, right Right straw walker Under tailings auger in front of the threshing drum Shaft, 4th drum, right Grain elevator, right Tailings elevator, right Upper shaft spindle, right Shaft inlet, right Central processing unit Central processing unit
Cab roof, right front
Free; not used Computer LH AGRO 968 Signal decoupling for fan and reel speed 12 volts with ignition "On" Switching-in conditions, chaff cutter; also see the circuit diagrams 4-427 Chaff cutter connector near the battery box Connection for extension cable, harness on the right White connection housing of the loss measurement in the straw area hood, right
[01/2001]
TRAINING CENTER NEUSTADT
4-331
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
Electrical Central Lubrication System Circuit diagrams: 4-440 A starting with Machine Number DCF 860103 Circuit Diagram Legend Motors Relays Plugs
1 2 3 4 5 6 7
Number Function Remark M 18 Pump, centralized lubrication K 58 Switching-on conditions, centralized lubrication X2 X9 X 13 X 16
Location Right side wall Central processing unit
12 volts with ignition on Also see the circuit diagrams Operating Voltage System 4-400 24 volts with threshing unit clutch "On" Ground, central processing unit Ground, machine frame Free, not used Control lamps (Positions 25 and 26 ) in the operating device Contacts (2) for displaying an operational malfunction
[01/2001]
TRAINING CENTER NEUSTADT
4-340
CROSS - FLOW CF 60 COMBINE HARVESTER
4 – ELECTRICAL SYSTEM
All-Wheel Axle Circuit diagrams: 4-441 A starting with Machine Number DCF 860103 Circuit Diagram Legend Solenoid valves Switches Plugs
1. 2. 3. 4.
Number Function Y 15 All-wheel S 27 X2 X9 X10 X 13 X 30
Remark 12 volt
All-wheel
Location Operating device
12 volts when ignition "On" Ground, central processing unit Ground, machine frame Connection in cable, steering axle support
[01/2001]
TRAINING CENTER NEUSTADT
4-341
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
CF 60 Circuit Diagram Index The circuit diagrams are numbered according to the machine type. The individual numbers (corresponds to the page number) signify the following here:
4-4 00 two-digit number of the circuit diagram (same for all types) Machine type 2 ⇒ CF 80 3 ⇒ CF 70 4 ⇒ CF 60 Number of the chapter (4- Electrics) The circuit diagrams that act independently of the field position are presented from circuit diagram number 00 to 14. All of the circuit diagrams that are first activated during the threshing by the field position are presented from circuit diagram number 15 to 49. The circuit diagrams for combines equipped with touch screen monitor starting with circuit diagram number 50. Individual page numbers are reserved for the future and are therefore not assigned. Every circuit diagram is additionally labeled with a letter. These letters indicate the machine number that the circuit diagram starts with. The validity of the circuit diagram is only canceled when a new circuit diagram with the same number and a different letter is substituted for it. In the process, individual letters in the alphabet can be jumped over (e.g. Circuit Diagram 4-408 A is first substituted with 4-408 D). The letters start according to the alphabet with A. The individual letters signify the following here: A
⇒
Starting with Machine Number DCF 86 0103 until a subsequent letter is substituted Combine harvesters with Design Q (electrical-hydraulic field tracking) are first manufactured starting with Machine Number DCF880031. There is a legend for every circuit diagram. The legend is labeled with the same circuit diagram number, but without letters. If the legend goes on over several pages, they are provided with an additional number (for example 4-300.1) Notes are labeled with a serial number in the circuit diagram, and are then explained in the legend. The circuit diagrams are closed within themselves as a rule, so troubleshooting only has to be carried out on this circuit diagram. Every circuit diagram starts with the respective fuse. The wiring in front of the fuse is drawn in the circuit diagram Operating Voltage 4-400. If there are links to another circuit diagram, for instance if the same fuse is used or if the witch-on conditions are on a different circuit diagram, this is indicated with an arrow and the circuit diagram number.
[01/2001]
TRAINING CENTER NEUSTADT
4-397
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
General Circuit Diagrams (Independent of the Field Position) 4-400 A 4-401 A 4-402 A 4-403 A 4-404 A 4-405 A 4-408 A 4-409 A
Operating Voltage Starting with DCF 86 0103 Lighting System Starting with DCF 86 0103 Warning Device Starting with DCF 86 0103 Direction Indicator Starting with DCF 86 0103 Mirror Adjustment Starting with DCF 86 0103 Display Unit Starting with DCF 86 0103 Cab Starting with DCF 86 0103 Air Conditioner Starting with DCF 86 0103
Circuit Diagrams Activated by the Field Position 4-416 A 4-417 A 4-419 A 4-420 A 4-421 A 4-422 A 4-423 A 4-424 A 4-426 A 4-427 A 4-428 A 4-428 B 4-430 A 4-431 A 4-440 A 4-441 A
[01/2001]
Threshing Basket Adjustment Design Q Starting with DCF 86 0103 Grain Tank Filling Display Starting with DCF 86 0103 Reel Speed Adjustment Starting with DCF 86 0103 Threshing Drum Speed Adjustment Starting with DCF 86 0103 Fan Adjustment Starting with DCF 86 0103 Threshing Unit and Header Clutch Starting with DCF 86 0103 Unloader Clutch with Unloader Pipe Control Starting with DCF 86 0103 Header Return Starting with DCF 86 0103 Field Tracking Design Q Starting with DCF 86 0103 Chaff-Cutter Starting with DCF 86 0103 Rape Electrical System Starting with DCF 86 0103 Rape Electrical System Starting with DCF 86 0103 Working Hydraulics Design Q Starting with DCF 86 0103 LH AGRO 968 Control System Starting with DCF 86 0103 Electrical Central Lubrication System Starting with DCF 86 0103 All-Wheel Drive Starting with DCF 86 0103
TRAINING CENTER NEUSTADT
4-398
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Operating Voltage Circuit diagrams: 4-400 A from Machine Number DCF 860103 Circuit Diagram Legend Lamps Magnets Motors
Relays
Number Function H 33 Central processing unit interior light Y 30 Stop magnet M 12 Compressor seat M 13 Starter M 14 Motor time counter M 15 Auxiliary fuel pump DLM12V Dynamo DLM24V Dynamo K5 Field / road K9 Starting safety K10 Starting safety
K11 K 12 K 13 K 27 K 58 K 59 K 60 K 61 M K 61 P K A7 KA8 Switches S 0 S 21 S 29 S 35 S 42 S 50 S 80
[01/2001]
Starter protection On-board computer Starting safety Display Unit 2 Fan delay Starting safety Starting safety Starting safety 12-volt on-board voltage Starter relay Emergency stop Swivel discharge pipe Seat switch Field / road Steering column switch Neutral position Master battery switch
Remark Location Can be switched off Central processing unit For fuel 12 volt 24 volt 24 volt 24 volt 12 volt 24 volt
On the injection pump In the driver's seat On the diesel engine On the diesel engine On the fuel tank Exterior on the engine Interior on the engine
Neutral joystick Electronics subassembly, Start Stop
Display Unit 2 Safety circuit
Minus controlled Plus controlled Note page 4-94
Horn
4-pole
In front of the battery box Between both dynamos On the gas lever In the joystick In the driver's seat Cab roof In the steering column Large hydrostatic drive pump In front of the battery box
TRAINING CENTER NEUSTADT
4-400
CROSS - FLOW CF 60 COMBINE HARVESTER Plugs
4 - ELECTRICAL SYSTEM
X2 X5 X 5.1 X6 X 6.1
Central processing unit Central processing unit Central processing unit Under the engine power takeoff Central processing unit Central processing unit Central processing unit
X7 X8 X9
Plugs
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17
X 12 X 13 X 14 X 15 X 24 X 25 X 26 X 90 XA XB
Central processing unit Central processing unit Central processing unit
Plug connection 12-volt socket 12-volt socket
Grain yield measurement For the hand lamp Cigarette lighter
Under the seat console In the central processing unit On the left next to the driver's seat Right lamp unit Left lamp unit Under the passenger's seat In front of the battery box
XC 12-volt socket For the hand lamp XD 12-volt socket For the hand lamp XE 12-volt socket For the cooling box XF 12-volt socket For the hand lamp Not used (free) Also see the circuit diagrams Lighting System 4-401 Also see the circuit diagrams Cab 4-408 Also see the circuit diagrams Air Conditioner 4-409 Also see the circuit diagrams Field Tracking 4-426 and the circuit diagrams Threshing Basket Adjustment 4-416 Also see the circuit diagrams Reel Speed Adjustment 4-419 and Fan Speed Adjustment 4-421 Also see the circuit diagrams Working Hydraulics 4-430 Electronically-controlled central lubrication pump (option) Also see the circuit diagram 4-440 Also see the circuit diagram Grain Tank Filling Display 4-417 Radio, also see the circuit diagram Cab 4-408 See the circuit diagrams Warning Device 4-402 and Display Unit 4-405 See Presentation F 1 (presented twice) on the right next to F 6 Alternative connection possibility (close to K 43) Subassembly for motor starting in Display Unit 2 Grounded on Pin 15 when ready to start Grounded on Pin 10 when there is a dynamo at a standstill and positive when there is a rotating dynamo Switch position presented: Emergency stop switch in ready position 24 volts applied when the threshing unit clutch is switched in Also see the circuit diagrams Threshing Unit and Header Clutch 4-423
[01/2001]
TRAINING CENTER NEUSTADT
4-400.1
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Lighting System Circuit diagrams: 4-401 A from Machine Number DCF 860103 Circuit Diagram Legend Number Function Lamps H 9 li Side lamp H 9 re Side lamp H 10 Working light H 10 Working light H 11 li Driving light, left H 11 re Driving light, right H 12 li Parking light, left H 12 re Parking light, right H 15 li Low beam H 15 re Low beam H 16 Unloader lighting H 17 Working light H 19 Back-up light H 22 li Back light, left H 22 re Back light, right Relays K1 Light relay K3 Low beam relay K 37 K 38 K 39 Switches S 34 Rotaflare lights S 36 Light switch S 42 Steering column switch S 72 Discharge pipe transport Plugs X2 X6 X 6.1
[01/2001]
X7 X8 X 15 X 24 X 25 X 26 X 30 X 31 X 32 x 34 XH
Trailer socket
xS
Header socket
Remark On the left On the right
Location Corn adapter Corn adapter In cab roof In cab roof Left lamp unit Right lamp unit Left lamp unit Right lamp unit Interior left Cab roof Interior right Cab roof Switch-on conditions Over cab door On the rail On the outflow hood
12 volt 12 volt
Central processing unit Central processing unit
Headlamp flasher
In the cab roof In the cab roof In the steering column
Limit stop switch
Discharge pipe, center Central processing unit Central processing unit Under the engine power take-off Central processing unit Central processing unit Central processing unit
On the steering axle support Next to the multi-clutch of the hydraulic system
TRAINING CENTER NEUSTADT
4-401
CROSS - FLOW CF 60 COMBINE HARVESTER
1 2 3 4 5 6
4 - ELECTRICAL SYSTEM
Switching position: Discharge pipe moved out (open when discharge pipe is moved in) 12 volt on Fuse F 1:E Switch lighting (it is only one of all that are drawn in) Display unit on the steering column For use as a low beam light during road travel with a mounted corn adapter 13-pole connector for corn adapter
[01/2001]
TRAINING CENTER NEUSTADT
4-401.1
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Warning Device Circuit diagrams : 4-402 A starting with Machine Number DCF 860103 Transmitters Switches Lamps Plugs
Number Function G 20 Signal transmitter, backwards G 21 Horn S 40 Switch, backwards H 23 re Brake light H 23 li Brake light X2 X7 X8 X9 X 26 X 30 X 31 X 33 X 34 X 35
1 2 3 4 5 6 7
Remark
Right Left
Location On the outflow hood Under the cab On the joystick On the outflow hood On the outflow hood Central processing unit Central processing unit Central processing unit Central processing unit Steering column
On Relay K 32:85 horn signal for starting release; see Circuit Diagram 400A Horn Brake light Signal backwards 24 volt when ignition on Required equipment for towing switch on the joystick (brake light actuation when there is a reduction in speed) On Relay K 32:30
[01/2001]
TRAINING CENTER NEUSTADT
4-402
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Direction Indicator Circuit diagrams: 4-403 A from Machine Number DCF 860103 Circuit Diagram Legend
Relays
Number H 13 re H 13 li H 21 re H 21 li K3
Function Indicator lights Indicator lights Indicator light Indicator light Flasher unit
Switches
S 42
Plugs
S 43 X2
Steering column flasher switch Warning light switch
Lamps
Remark Right front Left front Right back Left back
X 7.3 X 7.4 X8
X 14.1 X 15
1 2 3 4 5 6
Cab roof Central processing unit
Central processing unit Central processing unit
X 14
X 25 X 26 X 28 X 30 XH XS
Location Driver platform, right Driver platform, left On the outflow hood On the outflow hood Central processing unit Steering column
Central processing unit
Trailer socket Header socket
Rear axle support Left lamp unit
Not used (free) Control sound in the display unit Control lamps in the steering column R Right flasher L Left flasher 13-pole header socket for connecting a corn adapter
[01/2001]
TRAINING CENTER NEUSTADT
4-403
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Mirror Adjustment Circuit diagrams: 4-404 A starting with Machine Number DCF 860103 Circuit Diagram Legend Motors Switches Plugs
Number M1 M2 S 58 X9
Function Mirror adjustment Mirror adjustment Mirror adjustment
X 10 X 15
3
Remark Right Left
Location In the right mirror In the left mirror Control panel Central processing unit Central processing unit Central processing unit
Mirror heating is not connected
[01/2001]
TRAINING CENTER NEUSTADT
4-404
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Display Unit Circuit diagrams: 4-405 A from Machine Number DCF 860103 Circuit Diagram Legend Number Function G-KWT Cooling water temperature G-TFS Fuel display G-MÖD Engine oil pressure Relays K KWS Cooling water level Switches S 52 Hand brake S 70 Filling level transmitter 3/4 S 71 Filling level transmitter 4/4 S 75-1 Straw area clogging S 75-2 Straw area clogging Transmitter
S Luf/EJ Ejector control S LUF S HÖT S HÖS S KWT S KWS S MÖD X2 X5 X6 X 14 X 14.1 X 14.2 X 15
Plugs
1 2 3 4 5 6 7 8 9
Air filter control Hydraulic oil temperature Hydraulic oil level Cooling water temperature Cooling water level Engine oil pressure
Remark Analog transmitter
Location On the engine
Analog transmitter Analog transmitter
Grain tank
On the fuel tank On the engine Central processing unit Under the platform Grain tank, lower
Grain tank
Grain tank, upper
In the outflow hood Only for chaff cutter At the end of the straw area hood Switching point On the ejector of the air 55°C filter Vacuum switch On the air filter Switching point On the hydraulic tank 85°C On the hydraulic tank Switching point On the engine 103°C On the water cooler On the engine Central processing unit Central processing unit Central processing unit Central processing unit
Central processing unit
For the display field starting conditions see the circuit diagrams Operating Voltage 4-400A For the threshing gap and cutting height display, see the circuit diagram Threshing Basket Adjustment Design P For the speed monitoring, see the circuit diagrams Control System 4-431A For the display in the steering column, see the circuit diagrams Lighting System 4-401A Display unit Voltage supply for the display unit Not used (free) There are 24 volts applied to K27;87 when the ignition is switched on. See the circuit diagrams Operating Voltage 4-400A On F6 battery side
[01/2001]
TRAINING CENTER NEUSTADT
4-405
CROSS - FLOW CF 60 COMBINE HARVESTER 10 11 12 13 14
4 - ELECTRICAL SYSTEM
On switched F6 side See the circuit diagrams Unloader Clutch and Discharge Pipe 4-423A Connection 61 from the 24 volt dynamo On F 1;4 Connection 61 from the 12 volt dynamo
[01/2001]
TRAINING CENTER NEUSTADT
4-405.1
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Cab Circuit diagrams : 4-408 A from Machine Number DCF 860103 Circuit Diagram Legend Lamps
Motors
Number H 30 H 31re H 31li M4 M 16
Switches Plugs
S 30 S 44 XE X Br X Sw X9
Function Control panel lighting Cab lighting Cab lighting Windscreen wiper motor Windscreen wash pump Door contact switch Windscreen wiper Cooling box socket
Remark Night (yellow) Right (white) Left (white)
Loudspeaker on the radio Radio power supply
Brown
X 10 X 15
Black
Location Cab ceiling Cab ceiling Cab ceiling Cab roof
Hinge side, top Cab roof Under the passenger seat hinter Radio Behind the radio Central processing unit Central processing unit Central processing unit
• Air Conditioner 4-409A • Lighting System 4-401A • Operating Voltage 4-400A • Mirror Adjustment 4-404A • Grain Tank Filling Display 4-417A
1
Also see the circuit diagrams
2 3 4 5 6 7
12 volt from Switch S Lighting Interior lighting To Switch S Lighting Loudspeaker, left Loudspeaker, right Connection for mobile radio (located behind the right cover of the radio next to the radio in the cab roof) Radio and mobile radio (pre-equipped) Antenna Windscreen wiper On parking light
8 9 10 11
[01/2001]
TRAINING CENTER NEUSTADT
4-408
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Air Conditioner Circuit diagrams : 4-409 A from Machine Number DCF 860103 Circuit Diagram Legend Transmitters
Lamps Motors
Relays
Switches
Plugs
1
2 3 4 5 6
Number Function NT C1 Temperature sensor NT C2 Temperature sensor H 32 Indicator panel M5 Evaporator fan M6 Evaporator fan MK Compressor K A1 K A2 K A3 K A4 K A5 S 45 Cab fan S 31 Under / overpressure S 32 Air conditioner switch S 33 Potentiometer X5 X8 X9 X 10 X 14.2 X 16
Remark Room air temperature Icing protection
Location Between the center of the back wall and the cab roof In the cab roof
Cab roof
Safety switch
On the engine Cab roof, front right Cab roof, front right Cab roof, front right Cab roof, front right Cab roof, front right Cab roof On the dry filter Cab roof
Temperature
Cab roof Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit
Electronic thermostat Target value range: Icing protection:
14....26°C ± 1°C ν off = 3°C ν on = 7°C Under or overpressure switch combination attached to the dry filter. Not used (free) Harness connector to air conditioner Control lamp in the display unit On the parking light and ground of the cab harness
[01/2001]
TRAINING CENTER NEUSTADT
4-409
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Threshing Basket Adjustment Design Q (Electrical-Hydraulic Field Tracking) Circuit diagrams: 4-416 A from Machine Number DCF 860103 Circuit Diagram Legend Transmitters
Number Function G 30 Analog transmitter, basket gap G 31 Initiator "narrow" G 32
Initiator "wide"
Motors
M7
Actuator motor
Plugs
X7 X 14
Remark
Like the speed initiator
Location On the basket adjustment On the basket adjustment On the basket adjustment On the basket adjustment Central processing unit Central processing unit
X 14.2 X 28 1 2 3 4 5 6
Card subassembly Basket Adjustment / Field Tracking (with 3 plugs) Down High Data bus Card subassembly Basket Adjustment / Field Tracking Design Q (with 2 plugs) Display unit (6; 7; 8; 9 display )
[01/2001]
TRAINING CENTER NEUSTADT
4-416
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Grain Tank Filling Display Circuit diagrams: 4-417 A from Machine Number DCF 860103 Circuit Diagram Legend Number Function H 25.re Grain tank lighting
Remark 24 volt !
H 25.li
Grain tank lighting
24 volt !
Relays
K 19
Rotaflare light
Switches
S 34 S 70 S 71 X2
Rotaflare light For both Filling level transmitter 3/4 Filling level transmitter 4/4
Lamps
Plugs
X 15
Location In the grain tank, on the right In the grain tank, on the left Central processing unit Cab roof, front In the grain tank In the grain tank Central processing unit Central processing unit
X 31 X 32 1 2 3 4 5
Control lamps in the display unit Current only with the position "Field" Rotaflare light on the straw area hood Rotaflare light on the cab roof Also see the circuit diagrams Lighting 4-401A
[01/2001]
TRAINING CENTER NEUSTADT
4-417
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Reel Speed Adjustment Circuit diagrams: 4-419 A from Machine Number DCF 860103 Circuit Diagram Legend Diodes
Number Function D4
Transmitters
G5 G 17
Solenoid Y 1 valve Switches S 7 S8 X2
Plugs
Remark Diode block D 4
Driving speed Reel speed Proportional valve, reel speed Reel speed, automatic system Potentiometer, reel speed
X7 X8 X9 X 10 X 11 X 16
1 2 3 4 5 6 7 8 9 10 11 12 13
XS
Plug to the header
X 101
Plug of the computer
Location Central processing unit Initiator Left rear wheel Initiator Reel drive unit on the header Battery Under the driver's distributing valve platform, right Control panel Control panel Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Central processing unit Under the driver's platform, left Cab; right, top
24 volts are applied when the threshing unit clutch has been switched in 24 volts are applied when the field position has been activated Other functions when the threshing unit clutch has been switched in FCT = off; starting with Program Version 1.05 for replacement parts Input speed at the LH AGRO 968 on-board computer On F5:7 12 volt (voltage supply initiators, right side) In Diode Block D 4 Proportional amplifier, reel and fan speed Also see the circuit diagram Fan Speed 4-421A Pin 1 is presented several times There are even more branch-offs on this dashed line On Switch S (24 Volt) when the header clutch has been switched in Also see the circuit diagrams Threshing Unit and Header Clutches 4-422A O Manual reel speed (independent of the driving speed) 1 Automatic reel speed (dependent on the driving speed) Adjustment values of the proportional amplifier for "Design P" (mech. field tracking) "Design Q" (electr. field tracking)
[01/2001]
TRAINING CENTER NEUSTADT
4-419
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Threshing Drum Speed Adjustment Circuit diagrams: 4-420 A starting with Machine Number DCF 860103 Circuit Diagram Legend Motors
Number Function M8 Speed adjustment for threshing drum
Relays
K 17
Switches
S 16
Plugs
X2
Speed adjustment for threshing drum Speed adjustment for threshing drum
X9 X 10 X 16 X 101 1 2 3 18
Computer plug
Remark Motor with friction clutch
2-pole key
Location On the lower threshing drum variator Central processing unit Control panel Central processing unit Central processing unit Central processing unit Central processing unit Cab, top right
On Relay K 18 (fan speed adjustment) On the proportional amplifier for fan and reel speed adjustment 24 volts are applied when the threshing unit clutch S is switched in Also see the circuit diagrams Threshing Unit and Header Clutch 4- 422 A Activation of the speed adjustment by selection of the speed display "Threshing Drum" in the on-board computer at more than 250 r.p.m. threshing drum speed or switching over in the on-board computer into the chapter Test. The on-board computer switches ground to the relay K 17.
[01/2001]
TRAINING CENTER NEUSTADT
4-420
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Fan Speed Adjustment Circuit diagrams: 4-421 A from Machine Number DCF 860103 Circuit Diagram Legend Solenoid valve Relays
Number Function Remark Y 10 Change in the volume flow K 18 Speed adjustment for fan K 54 Drop-off delay T = 5 seconds
Switches
S 15
Plugs
X6
Speed adjustment for fan
X9 X 10 X 16 X 101 1 2 3 4 5 6
7
Computer plug
Location Fan adjustment pump Central processing unit Central processing unit Control panel Central processing unit Central processing unit Central processing unit Central processing unit Cab, top right
Proportional amplifier for reel and fan speed adjustment Also see the circuit diagrams 4-419 A On K 17 (speed adjustment of the threshing drum) 24 volts when the field position is activated 24 volts when the threshing unit clutch is switched in S 10 Activation of the speed adjustment by selection of the speed display "Fan" in the onboard computer at more than 250 r.p.m. threshing drum speed or switching over in the on-board computer into the chapter Test. The on-board computer switches ground to the relay K 17. The connector for the harness is in the center on harness, on the left-hand side
[01/2001]
TRAINING CENTER NEUSTADT
4-421
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Threshing Unit and Header Clutches Circuit diagrams: 4-422 A from Machine Number DCF 860103 Circuit Diagram Legend Diodes
Number Function D3
Solenoid valve Relays
Y 11 Y 12 K 41
Threshing unit clutch Header clutch Safety circuit
Threshing unit
K 42
Safety circuit
Header
K 43
Header rapid stop
K 44
Activation of speed monitoring, header Threshing unit clutch Header clutch Rapid stop key Seat switch
Switches
Plugs
S 10 S 11 S 20 S 29 X6 X9 X 10 X 13 X 16 X 45 X 101
1 2 3 4
5
6 7 8
Remark
Header Pre-equipped
Location Central processing unit On the left side wall, beneath engine Central processing unit Central processing unit Central processing unit Central processing unit Control panel Control panel In the joystick In the driver's seat Central processing unit
Card subassembly Computer plug for LH Agro 965
In the central processing unit In the front right cab capping piece
Switch-on condition "Threshing Unit ON" for header return. Also see the circuit diagram 4-424 A Switch-on condition "Header OFF" for header return Also see the circuit diagram 4-424 A Activation of the speed monitoring "Upper Shaft Spindle" Also see the circuit diagrams Control System 4-431 A 24 volts with a switched-in threshing unit S for a)chaff cutter, also see the circuit diagrams Chaff Cutter 4-427 A b) speed adjustment of the threshing drum, see the circuit diagram 4-420 A 24 volts with a switched-in header S for a) reel speed adjustment, also see the circuit diagrams 4-419 A b) electric rape, also see with regard to this the circuit diagrams 4-428 A c) field tracking Design P, also see the circuit diagrams 4-425 A field tracking Design Q, also see the circuit diagrams 4-426 A 24 volts with activated "Field Position" See the unloader clutch circuit diagrams 4-423 A See the chaff cutter circuit diagrams 4-427 A
[01/2001]
TRAINING CENTER NEUSTADT
4-422
CROSS - FLOW CF 60 COMBINE HARVESTER 9
10
4 - ELECTRICAL SYSTEM
Alternative connection possibility (Line 279 ends directly at K 43). If Line 279 is connected directly to K 43:87a instead of the ground currently existing, the corresponding safety requirements can be realized by shutting off the header, with a free driver's seat. The connector for the harness is in the center on harness, on the left-hand side
[01/2001]
TRAINING CENTER NEUSTADT
4-422.1
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Unloader Clutch with Discharge Pipe Control Circuit diagrams: 4-423 A from Machine Number DCF 860103 Circuit Diagram Legend Diodes Transmitters Lamps Relays
Number D1 D2 G 40 G 41 H 29
K4 K 30 K 31 Switches S 21 S 22 S 73 Plugs X2 X6 X7 X9 X 11 X 12 X 13 X 14 X 15 X 32 1
2 3 4 6 7 8
Function
Remark
Safety circuit Safety circuit Unloading lighting
For unloading For unloading
Unloader clutch Unloader pipe out Unloader pipe in Swivel discharge pipe Unloader clutch Unloader pipe moved out
Incremental relay
Key
Location Central processing unit Central processing unit Grain tank flap Grain tank flap Cab roof under driver's door Central processing unit Central processing unit Central processing unit In the joystick In the joystick On the swivel device
Switching position is discharge pipe moved out; the end position has not yet been reached (opens in the end position of discharge pipe out) The connector for the harness is in the center on harness, on the left-hand side 24 volts with activated field position Control lamps in the display unit Switching position is discharge pipe moved out (opens when discharge pipe is moved in) Connector at K 33 is currently not used (free) On 12 volts of the working lighting Also see the circuit diagrams Lighting 4-401 A
[01/2001]
TRAINING CENTER NEUSTADT
4-423
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Header Return Circuit diagrams: 4-424 A from Machine Number DCF 860103 Circuit Diagram Legend Number Function D3 Diode D6 Spark extinguishing diode TransG 15 Speed, upper shaft mitters spindle Motors M9 Header return Relays K 44 Speed control, upper shaft spindle K 43 Header rapid stop K A6 Header return Switches S 13 Header return
Remark
Location Central processing unit In front of the battery box
Initiator
Upper shaft spindle, right
Starter motor
Shaft, front left Central processing unit
Diodes
S 10 S 11 S 20 S 80 X6 X8 X9 X 10 X 13 X 16 X 27 X 45
Plugs
Threshing unit clutch Header clutch Rapid stop Master battery switch
Plug, electronics subassembly, header return
Power relay Press for at least 5 seconds
Header 2-pole
Central processing unit In front of the battery box Control panel Control panel Control panel On the joystick In front of the battery box
On the electronics subassembly in the central processing unit
X 101 1 2 3 4
5 6 7 8 9
See the circuit diagrams Control System LH AGRO 4-431 A Pin 8 → N upper shaft spindle (speed pulses of the upper shaft spindle) Pin 18→ E upper shaft spindle (switch-in control of the upper shaft spindle) Card subassembly Header Return Switch-in conditions for the header return ● Field position is activated ● Threshing Unit Switch S10 is activated (threshing unit is switched in) ● Header Switch S11 is not activated (header is switched off) ● Standstill of the upper shaft spindle (speed control through G15) ● Hold down Header Return Switch S 13 for about 5 seconds 24 volts with activated field position The connector for the harness is in the center on harness, on the left-hand side On Relay K 42 Also see the circuit diagrams Threshing Unit and Header Clutch 4-422A When threshing unit is switched in
[01/2001]
TRAINING CENTER NEUSTADT
4-424
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Field Tracking Design Q (Electrical-Hydraulic Field Tracking) Circuit diagrams: 4-426 B from Machine Number DCF 860103 Circuit Diagram Legend Transmitters
Solenoid valves
Relays Switches
Plugs
1 2 3 4 5 6 7 8 9 10 11 12
Number G 22 G 24 G 25 G 26 G 27 G 28 G 29 Y 7.1 Y 7.2 Y 8.1 Y 8.2 Y9 K 35
Function Remark Shaft height Cross pendulum Pressure sensor Header probe skid Outer right Header probe skid Inner right Header probe skid Inner left Header probe skid Outer left Lift shaft Lower shaft Cross-tracking, left Cross-tracking, right Supplemental valve Voltage supply transmitter
S 24 S 26 S 37 X7 X8 X9 X 11 X 13 X 16 X 17 X 27 XS
Lift / lower shaft Automatic field tracking. Boot switch
Location
Central processing unit In the joystick, back In the joystick, front
Header plug
24 volts with field position "ON" 12 volts with ignition "ON" 24 volts with threshing unit clutch "ON" Ground, central processing unit Ground, machine frame CCU control unit DIL Switches 1 and 6 in "On" position Operating and display device Supplemental equipment Joystick Shaft Lift Lower Left Right Further to reel switch in the joystick Also see the circuit diagrams Working Hydraulics 4-430
[01/2001]
TRAINING CENTER NEUSTADT
4-426
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Straw Cutter Circuit diagram: 4-427 A starting with Machine Number DCF 860103 Circuit Diagram Legend Transmitters Lamps
Number Function G6 Chopper speed H SRA
Chopper control lamp
H SRA1
Control lamp black
Solenoid valve Motors
Y 14
Chopper clutch
M 17
Diffusing screen adjustment
Relays
K 15 K 16 S 76 X6 X 10 X 16
Switches Plugs
1 2 3 4 5 6
Straw guide plate
Remark Speed initiator
Not visible ( 5 )
Limit stop switch
Location Chopper shaft, left In the operating device In the operating device
Straw flap, left
Connector harness left Connector harness center Computer LH AGRO 968 24 volts with field position Covered control lamp next to On threshing unit clutch switch 24 volts are applied when the threshing unit clutch is switched in
[01/2001]
TRAINING CENTER NEUSTADT
4-427
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Rape Electrical System Circuit diagrams: 4-428 A from Machine Number DCF 860103 Circuit Diagram Legend Motors
Relays
Number Function M 10 Vertical sickle
Remark 24 volt; right
M 11
Vertical sickle
24 volt; left
K6
Safety relay
Rape separator
K7 K8
Rape separator, right Rape separator, left
Switches S 12
Plugs
X7 X 10 X 80 X 81 XS XL XR
1
Location Right header side wall Left header side wall Central processing unit Central processing unit
Rape separator
Switching Position l: M7 Switching Position ll:M7 and M8
Plug of the rape separator Plug of the rape separator Header plug Socket of the rape separator Socket of the rape separator
Right Left
Left Right
Right header side wall Left header side wall On the header Left header side wall Right header side wall
24 volts when the header clutch is switched in Also see the circuit diagrams Threshing Unit and Header Clutches 4-422 A
[01/2001]
TRAINING CENTER NEUSTADT
4-428
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Working Hydraulics Design Q (Electrical-Hydraulic Field Tracking) Circuit diagrams: 4-430 A from Machine Number DCF 860103 Circuit Diagram Legend Number Solenoid Y 1 valves Y 2.1 Y 2.2 Y 5.1 Y 5.2 Y 6.1 Y 6.2 Y 7.1 Y 7.2 Y 8.1 Y 8.2 Y9 Relays K 20 K 21 K 22 K 23 K 24 K 25 K 30 K 31 Switches S 14 S 21 S 24.1 S 24.2 S 25.1 S 25.2 S 26 S 51 X7 X8 X9 X 11 X 12 X 13
Plugs
1 2 3 4
Function Remark Reel speed Proportional valve Unloader pipe in Unloader pipe out Reel adjustment Back Reel adjustment Forward Reel adjustment Lift Reel adjustment Lower Lower shaft Lift shaft Cross-tracking Left Cross-tracking Right Supplemental valve Lower shaft Not connected Lift shaft Lift reel Lower reel Reel forwards Reel backwards Swivel out unloader pipe Swivel in unloader pipe Header latch Swivel discharge pipe Out / in Shaft cross pendulum Left right Lift / lower shaft Reel vertical adjustment Lift / lower Reel horizontal Forwards / adjustment backwards Switching in the automatic system of field tracking Pressure relief
Location
Central processing unit
In the control panel
In the joystick
In the joystick; front
X 16 X 17 Proportional amplifier, reel and fan speed 24 volts with field position Shaft Left Right Lift Lower Joystick
[01/2001]
TRAINING CENTER NEUSTADT
4-430
CROSS - FLOW CF 60 COMBINE HARVESTER 4 5
4 - ELECTRICAL SYSTEM
Free; not used Control unit, shaft and basket adjustment (shaft function not used)
[01/2001]
TRAINING CENTER NEUSTADT
4-430.1
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
LH AGRO 968 Control System Circuit diagrams: 4-431 A from Machine Number DCF 860103 Circuit Diagram Legend Transmitters
Relays
Plugs
1 2 3 4 5 6 7 8
Number G1 G2 G3 G4 G5 G6 G7 G8 G9 G 10 G 11
Function Threshing drum speed Fan speed Straw walker speed Engine speed Driving speed Chaff cutter Loss transmitter (plate) Loss transmitter (plate) Loss transmitter (plate) Loss transmitter (plate) Loss transmitter (pipe)
Remark Speed initiator Speed initiator Speed initiator Speed initiator Speed initiator Speed initiator Straw walker Cleaning unit Cleaning unit Straw walker For tailings
G 12 G 13 G 14 G 15 G 16 K 17 K 18
Speed, 4th drum Grain elevator speed Tailings elevator speed Shaft speed Harvested grain switch Adjustment, fan speed Adjustment, threshing drum speed
Speed initiator Speed initiator Speed initiator Speed initiator Speed initiator
X2 X6 X 6.1 X8 X9 X 16 X 27 X 101
Computer plug
Location Threshing drum, left Fan shaft, left Straw walker shaft, left Left rear wheel Chopper shaft, left Left straw walker Cleaning unit, left Cleaning unit, right Right straw walker Under tailings auger in front of the threshing drum Shaft, 4th drum, right Grain elevator, right Tailings elevator, right Upper shaft spindle, right Shaft inlet, right Central processing unit Central processing unit
Cab roof, right front
Free; not used Computer LH AGRO 968 Signal decoupling for fan and reel speed 12 volts with ignition "On" Switching-in conditions, chaff cutter; also see the circuit diagrams 4-427 Chaff cutter connector near the battery box Connection for extension cable, harness on the right White connection housing of the loss measurement in the straw area hood, right
[01/2001]
TRAINING CENTER NEUSTADT
4-431
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
Electrical Central Lubrication System Circuit diagrams: 4-440 A starting with Machine Number DCF 860103 Circuit Diagram Legend Motors Relays
Plugs
1 2 3 4 5 6 7
Number Function Remark M 18 Pump, centralized lubrication K 58 Switching-on conditions, centralized lubrication X2 X9 X 13 X 16
Location Right side wall Central processing unit
12 volts with ignition on Also see the circuit diagrams Operating Voltage System 4-400 24 volts with threshing unit clutch "On" Ground, central processing unit Ground, machine frame Free, not used Control lamps (Positions 25 and 26 ) in the operating device Contacts (2) for displaying an operational malfunction
[01/2001]
TRAINING CENTER NEUSTADT
4-440
CROSS - FLOW CF 60 COMBINE HARVESTER
4 - ELECTRICAL SYSTEM
All-Wheel Axle Circuit diagrams: 4-441 A starting with Machine Number DCF 860103 Circuit Diagram Legend Solenoid valves Switches Plugs
1. 2. 3. 4.
Number Function Y 15 All-wheel S 27 X2 X9 X10 X 13 X 30
Remark 12 volt
All-wheel
Location
Operating device
12 volts when ignition "On" Ground, central processing unit Ground, machine frame Connection in cable, steering axle support
[01/2001]
TRAINING CENTER NEUSTADT
4-441
01/2001 TC Neustadt
from DCF 880001 to DCF 880060
4-200 A
Operating Voltage
01/2001 TC Neustadt
st. w/ DCF 880061
4-200 C
Operating Voltage
12/2000 TC Neustadt
from DCF 880001 to DCF 880030
4-201 A
Lighting System
12/2000 TC Neustadt
from DCF 880031 to DCF 880060
4-201 B
Lighting System
12/2000 TC Neustadt
starting w/ DCF 880061
4-201 C
Lighting System
Warning Device 12/2000 TC Neustadt
4-202 A strt. w/ DCF 880001
1272000 TC Neustadt
strt. w/ DCF 880001
4-202 A
Warning Device
12/2000 TC Neustadt
from DCF 880001 to DCF 880030
4-203 A
Direction Indicator
12/2000 TC Neustadt
starting w/ DCF 880031
4-203 B
Direction Indicator
Mirror Adjustment 12/2000 TC Neustadt
4-204 A str. w/ DCF 880001
12/2000 TC Neustadt
from DCF 880001 to DCF 880300
4-205 A
Display Unit
12/2000 TC Neustadt
str. w/ DCF 880301
4-205 D
Display Unit
12/2000 TC Neustadt
Cab s. w/ DCF 880301
4-208 D
12/2000 TC Neustadt
from DCF 880001 to DCF 880060
4-209 A
Air Conditioner
12/2000 TC Neustadt
srt. w/ DCF 880061
4-209 C
Air Conditioner
Thresh. Basket Adjstmt. Des. P
4-215 A 12/2000 TC Neustadt
starting w/ DCF 880001
Thresh. Basket Adjstmt. Des. Q
4-216 B 12/2000 TC Neustadt
from DCF 880031 to DCF 880060
Thresh. Basket Adjstmt. Des. Q
4-216 C 12/2000 TC Neustadt
starting w/ DCF 880061
Grain Tank Fill. Dspl.
4-217 A 12/2000 TC Neustadt
from DCF 880001 to DCF 880060
Grain Tank Filling Display
4-217 C 12/2000 TC Neustadt
starting w/ DCF 880061
Reel Speed Adjustment
4-219 A 12/2000 TC Neustadt
from DCF 880001 to DCF 880030
12/2000 TC Neustadt
from DCF 880031 to DCF 880300
4-219 B
Reel Speed Adjustment
12/2000 TC Neustadt
DCF starting w/ 880301
4-219 D
Reel Speed Adjustment
12/2000 TC Neustadt
strt. w/ DCF 880001
4-220 A
Threshing Drum Speed Adjustment
Fan Adjustment
4-221 A 12/2000 TC Neustadt
from DCF 880001 to DCF 880300
Fan Speed Adjustment 12/2000 TC Neustadt
4-221 D starting w/ DCF 880301
Threshing Unit and Header Clutch
4-222 A 12/2000 TC Neustadt
from DCF 880001 to DCF 880061
Threshing Unit and Header Clutch
4-222 C 12/2000 TC Neustadt
starting w/ DCF 880061
12/2000 TC Neustadt
from DCF 880001 to DCF 880060
4-223 A
Unloader Clutch with Unloader Pipe Control
12/2000 TC Neustadt
strg. w/ DCF 880061
4-223 C
Unloader Clutch with Unloader Pipe Control
12/2000 TC
from DCF 880001 to DCF 880060
4-224 A
Header Return
12/2000 TC Neustadt
starting w/ DCF 880061
4-224 C
Header Return
12/2000 TC Neustadt
from DCF 880001 to DCF 880060
4-225 A
Field Tracking Des. P (Electrical-Mechanical)
12/2000 TC Neustadt
starting w/ DCF 880061
4-225 C
Field Tracking Des. P (Electrical-Mechanical)
12/2000 TC Neustadt
from DCF 880031 to DCF 880060
4-226 B
Field Tracking Des. Q (Electrical-Hydraulic)
12/2000 TC Neustadt
strt. w/ DCF 880061
4-226 C
Field Tracking Des. Q (Electrical-Hydraulic)
12/2000 TC Neustadt
fm. DCF 880001 to DCF 880060
4-227 A
Chaff-Cutter
12/2000 TC Neustadt
from DCF 880001 to DCF 880030
4-228 A
Rape Electrical System
12/2000 TC Neustadt
st. w/ DCF 880031
4-228 B
Rape Elect. Sys.
Working Hydraulics Design P (Electr.-Mech Field Tracking)
4-229 A 01/2001 TC Neustadt
from DCF 880001 to DCF 880060
Working Hydraulics Des. P (Electr.-Mech. Field Track.)
4-229 C 01/2001 TC Neustadt
starting with DCF 880061
Working Hydr. Des. P (Electr.-Hyd. Fld. Trck.)
4-230 A 01/2001 TC Neustadt
from DCF 880001 to DCF 880060
Working Hydr. Des. Q (Electr.-Hyd. Fld. Track.)
4-230 C 01/2001 TC Neustadt
starting with DCF 880061
12/2000 TC Neustadt
from DCF 880001 to DCF 880060
4-231 A
LH AGRO 965 Control System
12/2000 TC Neustadt
starting w/ DCF 880061
4-231 C
LH AGRO 965 Control System
Electrical grease pump 12/2000 TC Neustadt
4-240 C from DCF 880061
4 weel drive
4-241 D 12/2000 TC Neustadt
from DCF 880301
03/2001 TC Neustadt
from DCF 87 0103
4-300 A
Operating voltage
03/2001 TC Neustadt
from DCF 87 0103
4-301 A
Lighting system
03/2001 TC Neustadt
Warn
Warning system 4-302 A from DCF 87 0103
03/2001 TC Neustadt
from DCF 87 0103
4-303 A
Direction indication
Mirror adjustment
4-304 A 03/2001 TC Neustadt
from DCF 87 0103
03/2001 TC Neustadt
from DCF 87 0103
4-305
Display unit
03/2001 TC Neustadt
from DCF 87 0103
4-308 A
Cab
03/2001 TC Neustadt
from DCF 87 0103
4-309 A
Air condition
Concave adjustment
4-316 A 03/2001 TC Neustadt
from DCF 87 0103
Grain tank filling level indication
4-317 A 03/2001 TC Neustadt
from DCF 87 0103
03/2001 TC Neustadt
from DCF 87 0103
4-319 A
Reel speed adjustment
03/2001 TC Neustadt
from DCF 87 0103
4-320 A
Threshing drum speed adjustment
Fan speed adjustment
4-321 A 03/2001 TC Neustadt
from DCF 87 0103
Clutch threshing mechanism and header
4-322 A 03/2001 TC Neustadt
from DCF 87 0103
03/2001 TC Neustadt
from DCF 87 0103
4-323 A
Unloading clutch and unloading auger control
03/2001 TC Neustadt
from DCF 87 0103
4-324 A
Header reverse
03/2001 TC Neustadt
from DCF 87 0103
4- 326 A
Feld tracker version Q (electro-mechanical)
03/2001 TC Neustadt
from DCF 87 0103
4-327 A
Straw chopper
03/2001 TC Neustadt
from DCF 87 0103
4-328 A
Electrical schematics rape equipment
Hydraulicsystem version Q (electro-hydraulic feld tracker)
4-330 A 03/2001 TC Neustadt
from DCF 87 0103
03/2001 TC Neustadt
from DCF 87 0103
4-331 A
Control system LH Agro 968
Electrical grease pump 03/2001 TC Neustadt
4-340 A from DCF 87 0103
4 weel drive
4-341 A 03/2001 TC Neustadt
from DCF 87 0103
03/2001 TC Neustadt
from DCF 86 0103
4-400 A
Operating voltage
03/2001 TC Neustadt
from DCF 86 0103
4-401 A
Lighting system
03/2001 TC Neustadt
from DCF 86 0103
4-402 A
Warning system
03/2001 TC Neustadt
from DCF 86 0103
4-403 A
Direction indication
Mirror adjustment
4-404 A 03/2001 TC Neustadt
from DCF 86 0103
03/2001 TC Neustadt
from DCF 86 0103
4-405 A
Display unit
03/2001 TC Neustadt
from DCF 86 0103
4-408 A
cab
03/2001 TC Neustadt
from DCF 86
4-409 A
Air condition
Concave adjustment variant Q
4-416 A 03/2001 TC Neustadt
from DCF 86 0103
Grain tank filling level indication
4-417 A 03/2001 TC Neustadt
from DCF 86 0103
03/2001 TC Neustadt
from DCF 86 0103
4-419 A
Reel speed adjustment
03/2001 TC Neustadt
from DCF 86 0103
4-420 A
Threshing drum speed adjustment
Fan speed adjustment 03/2001 TC Neustadt
4-421 A from DCF 86 0103
Clutch threshing mechanism and header 03/2001 TC Neustadt
4-422 A from DCF 86 0103
03/2001 TC Neustadt
from DCF 86 0103
4-423 A
Unloading clutch and unloading auger control
03/2001 TC Neustadt
from DCF 86 0103
4-424 A
Header reverse
03/2001 TC Neustadt
ab DCF 86 0103
4-426 A
Feld tracker version Q (electro-hydraulic)
03/2001 TC Neustadt
from DCF 86 0103
4-427 A
Straw chopper
03/2001 TC Neustadt
from DCF 86 0103
4-428 A
Electrical schematics rape equipment
Hydraulicsystem variant Q (electro-hydraulic feld tracker)
4-430 A 03/2001 TC Neustadt
from DCF 86 0103
03/2001 TC Neustadt
from DCF 86 0103
4-431 A
Control system LH Agro 968
Electrical grease pump
4-440 A 03/2001 TC Neustadt
from DCF 86 0103
4 weel drive
4-441 A 03/2001 TC Neustadt
from DCF 86
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 5 Steering and Machine Frame
CROSS - FLOW CF 80 COMBINE HARVESTER
5 – STEERING
5 STEERING AND MACHINE FRAME Table of Contents Page Front Axle Support Tightening Torques
5–2
Crosshead Tightening Torque
5–3
Rear Axle Support Tightening Torques
5–3
Tightening Torques of the Straddle Gear
5–4
Tightening Torques of the Gearbox
5–4
[05/2001]
5-1
TRAINING CENTER NEUSTADT
CROSS - FLOW CF 80 COMBINE HARVESTER
5 – STEERING
Tightening Torques of the Machine Frame Front Axle Support The front axle support is screwed down to the machine frame with a torque of 240 Nm on both sides. When changing the front axle support, one must see to it that no displacement in the longitudinal and cross-wise direction arises. Only one screw connection of a group is shown in the illustration at all times for a better overview.
240 Nm
.
240 Nm 240 Nm
[05/2001]
TRAINING CENTER NEUSTADT
5-2
5 – STEERING
CROSS - FLOW CF 80 COMBINE HARVESTER Crosshead
The crosshead connects the lower part of the side walls between the axle supports. It is tightened with a torque of 91 Nm. Only one screw connection of a group is shown in the illustration at all times for a better overview.
91 Nm
91 Nm
91 Nm Rear Axle Support The rear axle support is attached with a torque of 135 Nm and 91 Nm. When changing the rear axle support, one must see to it that no displacement in the longitudinal and crosswise direction arises. Only one screw connection of a group is shown in the illustration at all times for a better overview.
135 Nm
91 Nm
[05/2001]
TRAINING CENTER NEUSTADT
5-3
5 – STEERING
CROSS - FLOW CF 80 COMBINE HARVESTER Straddle Gear
The tightening torque for both straddle gears on the front axle support 370 Nm. Only one screw connection of a group is shown in the illustration at all times for a better overview.
370 Nm Tightening Torques on the Gearbox The fastening screws of the gearbox on the front axle support are tightened with a torque of 78 Nm. Only one screw connection of a group is shown in the illustration at all times for a better overview.
78 Nm
[05/2001]
TRAINING CENTER NEUSTADT
5-4
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 6 Ground Drive
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
6 GROUND DRIVE Table of Contents Page Speeds
6–2
Wheels and Tightening Torques
6–3
Transmission
6–4
V-Belt Drive
6–7
Pump Adjustment
6–7
Service Intervals
6–9
Connection Diagram, Driving Hydraulics
6 – 10
Variable Displacement Pump A4VG 125
6 – 12
Measurement Points
6 – 15
Individual Subassemblies, Pump
6 – 18
Individual Subassemblies, Engine
6 – 24
Troubleshooting, Hydrostatic Ground Drive
6 – 28
[01/2001]
6-1
TRAINING CENTER NEUSTADT
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Speeds The hydrostatic ground drive consists of an axial reciprocating tilted-disk pump and an axial-piston tilted-axle motor. Three gearing levels with the corresponding graduated speed ranges are available for forward and backward travel. 25 km/h grounds variation (only front-axle drive) 1st gear 2nd gear 3rd gear
0 - 7 km/h 0 - 11 km/h 0 - 24 km/h
25 km/h grounds variation (added all-wheel drive) See values above for switched-off all-wheel drive. 1st gear 5.5 km/h 2nd gear 8 km/h 3rd gear 14 km/h _____________________________________________________________ 20 km/h grounds variation (only front-axle drive): There is a speed limitation in action that is in effect in all gearing ranges. 1st gear 2nd gear 3rd gear
6 km/h 9.5 km/h 21 km/h
20 km/h grounds variation (added all-wheel drive) There is no speed limitation in action, see values above for switched-off all-wheel drive. 1st gear 2nd gear 3rd gear
4.8 km/h 7 km/h 12 km/h
The speed of the ground drive is reduced when 3rd gear is used for grounds variations up to 20 km/h. The maximum speed for reverse gear is around 50% of the indicated values. The mechanically-adjustable pump is driven via the joystick with a push-pull Bowden cable. The joystick is to be moved in the desired direction of travel for this.
[01/2001]
TRAINING CENTER NEUSTADT
6-2
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
TIGHTENING TORQUES OF THE WHEELS AND AIR PRESSURES
Wheel Variations Drive wheel Drive wheel Drive wheel Drive wheel
650/ 75-R 32 (Goodyear) 650/ 75-R 32 (Michelin) 800/ 65-R 32 (Goodyear) 800/ 65-R 32 (Michelin)
Article Number Article Number Article Number Article Number
31286226 31302992 31286234 31303003
Steering wheel Steering wheel
14.9/80-24 460/70-R24
Article Number Article Number
31286250 31286242
[01/2001]
TRAINING CENTER NEUSTADT
6-3
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Transmission Gear shifting The gears are shifted with this lever (Pos. 1). -
NEUTRAL - The neutral position is the center position. The gearshift grip can only be lifted when the gearshift lever is at NEUTRAL.
-
Shift the gearshift lever to NEUTRAL and pull up the gearshift grip to shift the combine harvester gearing into first gear.
-
Shift the gearshift lever to NEUTRAL again, press it downwards and shift it forward to shift the combine harvester gearing into second gear. Gearshift Lever
-
Pull the gearshift lever out of the NEUTRAL POSITION or second gear all the way back to shift the combine harvester gearing into third gear.
..
The gearshift grip (Pos. 2) -
The gearshift grip is ONLY used for shifting into first gear.
[01/2001]
The cause of sluggishness in the shifting process lies in the fact that two gears put pressure on each other in the transmission. Lining up the joystick will solve the problem.
TRAINING CENTER NEUSTADT
6-4
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Transmission Care -
Drain the oil in a warm state at the drain screw AS. - After this, rinse the transmission out well with rinsing oil. - Clean the drain screw and screw it in. - Fill it up with new transmission oil and check the oil level at the inspection screw KS. Check the oil level every 120 operating hours or after every harvesting period at the oil inspection screw KS of the spur gear and the gearbox. Oil used Oil amount Gearbox API-GL-5-90 7.0 l Drive axle Spur gear API-GL-5-90 4.5 l Drive axle Threshing drum CLP 1.4 l gearing 220/GL4 DIN 51 517 Instead of the specified transmission oil, you can use a different oil corresponding to SAE 90 in the performance class TM3 (corresponding to 125 mm²/s (cST) at 50 °C).
Oil level inspection at the spur gear and gearbox, drive axle KS Oil level inspection screw AS Oil drain screw ES Oil filling screw EES ventilation and oil filling screw
Gearbox Check oil level.............................................................................Every 120 operating hours Oil change.....................,,,,,,.................................For the first time after 60 operating hours, after that, every 240 operating hours or once a year Filling amount CF80.........................................................................................7.0 liters Oil type...............................................................................................................API-GL-5-90 Spur Gear (Straddle Gear) Check oil level.............................................................................Every 120 operating hours Oil change.....................,,,,,,.................................For the first time after 60 operating hours, after that, every 240 operating hours or once a year Filling amount............................................................................................................4.5 liters Oil type...............................................................................................................API-GL-5-90
[01/2001]
TRAINING CENTER NEUSTADT
6-5
6 – GROUND DRIVE
CROSS - FLOW CF 80 COMBINE HARVESTER Tightening Torques on the Gearbox
All of the screws with which the gearbox is attached to the front axle support have a tightening torque of 78 Nm (see Chapter 5). The hydraulic fixed displacement motor is screwed onto the transmission with a tightening torque of 195 Nm. The brake is screwed onto the transmission flange with a torque of 110 Nm.
195 Nm
110 Nm
Shifting Paths The following illustrations show the shifting paths. The respective selector shaft almost connects with the transmission housing in 1st or 2nd gear.
0 1st gear 32 mm 1st gear 2nd gear 25 mm 2nd and 3rd gears Selector Shafts
[01/2001]
3rd gear 20 mm 0
Shifting Paths
TRAINING CENTER NEUSTADT
6-6
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Ground Drive V-Belt Drive The variable displacement pump drive is realized with a V-belt drive. The required pretension is held via a tension spring F while a tension path is kept. The V-belt tension is to be checked every 50 operating hours at the adjustment plate EB, above all in the first 50 operating hours. The upper edge of the adjustment plate EB should correspond to the upper edge of the tension spring F. The most important this is that the tension spring has a spacing of 1 to 2 mm between the individual spring coils. V-belt tension that is too low leads to increased belt wear and tear, and the full driving and braking output cannot be transferred. The correct spring tension is to be checked at eye level on a daily basis in the run-in period (2 weeks). Mechanical Pump Adjustment The mechanical adjustment of the pump is done via a push-pull Bowden cable from the joystick. The adjustment mechanism acts on a zeroposition switch that prevents starting of the engine when the pump is not in neutral. The adjustment mechanism is set in the following steps: 1. Joystick in neutral position 2. Release the Bowden cable BZ at the adjustment lever VH 3. Unscrew the binding screw KS a the adjustment lever VH 4. Clamp down the adjustment lever VH again in a horizontal position 5. Set the adjustment nut JM1 in such a way that the hole in the fork head GK is exactly lined up with the hole in the adjustment lever 6. Tighten the adjustment nut and fix it in place with a locknut 7. Functional test without a running engine 8. Functional test with a running engine with an engaged 1st gear
[01/2001]
Adjusting the pump setting BZ Bowden cable VH Adjustment lever KS Binding screw JM1 Adjustment nut JM2 Adjustment nut
TRAINING CENTER NEUSTADT
6-7
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
The other end of the Bowden cable is attached in a ball joint on the pump. Easy-running action is thereby achieved in the entire adjustment range. Deformation of the ball or corrosion can influence the easy-running action of the adjustment.
Adjustment at the Joystick The operating forces at the joystick can be set. The control panel cover has to be removed for this. The adjustment is made on the adjustment nut of the brake (see arrow).
[01/2001]
TRAINING CENTER NEUSTADT
6-8
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Filter Change to the Ground Drive -
Change the filter cartridge FP on the pump of the driving hydraulics every 600 operating hours, but at least before every harvesting season.
-
The optical dirt indicator on the filter head is the be checked on a 14-day basis during the harvesting season with oil that is warm from operating. The diesel engine is to be brought to the nominal speed for this, and a second person checks whether the pointer is in the green range of the display field. If the pointer reaches the red range, the filter element is to be changed regardless of the number of operating Change the filter cartridge on the driving hours. hydraulics pump FP Filter cartridge VA Dirt indicator
Oil Change
See page 8-2
Service Intervals, Driving Hydraulics Daily
∗
Check of the oil level at the minimum marking of the oil tank (externally visible)
Weekly
∗
Remove condensation water at the drain hose
Every 2 weeks
∗
Check the dirt indicator of the return filter on the hydraulic oil tank. Check the dirt indicator of the pressure filter on the driving hydraulics pump Oil test
∗ ∗ 600 engines hours ∗ or annually
Filter change on the hydrostatic drive pump ∗ Ventilation filter of the hydraulic tank
600 engines hours ∗ Hydraulic oil change (approx. 80 liters) rd or before the 3 season
[01/2001]
TRAINING CENTER NEUSTADT
6-9
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Connection Diagram
[01/2001]
TRAINING CENTER NEUSTADT
6-10
CROSS - FLOW CF 80 COMBINE HARVESTER Legend for the Connection Diagram 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 35 36 37 38 39 40 41
[01/2001]
6 – GROUND DRIVE
Axial reciprocating, variable displacement pump 125 cm³/R Feed pump 28.3 cm³/R Mechanical pump adjustment Regulating piston Pressure relief valve 465 bar Feed pressure relief valve 25 bar High-pressure shuttle valve Pressure cut-off 440 bar Mechanical stroke limiter Electrical zero-position switch Easy-change filter 20 µm Optical dirt indicator Nozzle 1.0 mm High-pressure connector B 1 ¼“ High-pressure connector A 1 ¼“ Suction connector S M 48x2 Measurement connector MH M 12x1.5 Measurement connector MA M 12x1.5 Measurement connector MB M 12x1.5 Connector Fa M 33x1.5 Connector Ps M 18x1.5 Connector T1 M 33x1.5 Connector R M 16x1.5 Connector T2 M 33x2 Adjustment chamber connector X1 M 16x1.5 Adjustment chamber connector X2 M 16x1.5 Outside pressure supply G M 22x1.5 Axial-piston motor 125cm³/R Purge valve 8 l/min Feed pressure valve 16 bar High-pressure connector A1 ¼“ High-pressure connector B1 ¼“ Connector L1 M 18x1.5 Connector L2 M 18x1.5
TRAINING CENTER NEUSTADT
6-11
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Variable Displacement Pump A4VG 125 With Mechanical Adjustment
1 2 3 4 5 6 7 8 9 10 11 12
Variable displacement pump REXROTH A4VG 125 HW Pressure filter 20 Âľm Cold-start valve with optical display Pressure relief valve, forwards Pressure relief valve, backwards Measurement connector MH Regulating pressure connector Ps Connector T1 Mechanical zero adjustment control Suction connector S High-pressure connector B (forwards) Mechanical stroke limiter, forwards
[01/2001]
13 14 15 16 17 18 19 20 21 22 23
Mech. stroke limiter, backwards Measurement connector X1 Measurement connector X2 Measurement connector R Electrical zero-position switch Adjustment lever Measurement connector MA Measurement connector MB Outside pressure supply Feed pressure relief valve Pressure cut-off valve
TRAINING CENTER NEUSTADT
6-12
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Technical Data, Hydrostatic Drive Pump: REXROTH-HYDROMATIK A4VG 125 HWDL Direction of rotation TO THE LEFT Speed range: Pump No-load operation 1150 r.p.m. Nominal speed 2650 r.p.m. Feed pump: Internal gear pump with D g = 28.3 cm³/R Q max at n max = 75 l/min Q min at n min = 30 l/min p max = 40 bar Axial reciprocating pump: Q max at n max n max perm. ∆p max p max
= = = =
315 l/min 2850 r.p.m. 420 bar 500 bar
Pressure Settings in the CF 80:
High-pressure relief valve p abs = 465±10 bar Pressure cut-off p abs = 440 bar Feed pressure p abs = 25 + 3 bar (dependent on the pump speed and oil temperature). Turning the hexagon adjustment screw in a clockwise direction increases the pressure setting, in a counterclockwise direction lowers the pressure setting.
[01/2001]
TRAINING CENTER NEUSTADT
6-13
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Hydromotor A2FM125 with Purge Valve
1 2
Driving mechanism Purge and feed pressure valve
[01/2001]
TRAINING CENTER NEUSTADT
6-14
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Measurement Points
High Pressure (Pressure Cut-Off) The machine is to be secured with chocks, 3rd gear is to be engaged, and the parking brake is to be pulled to check the high pressure. Measurement Point M-HDSecure the combine harvester forwards and backwards with wheel chocks. Select 3rd gear Pull the hand brake Slowly extend the joystick forwards with a raised no-load speed Read the pressure value on the manometer (0-600 bar) Repeat the measurement for the backwards direction Set motor to nominal speed Repeat measurements Target value:
440 +15 bar
Control Oil Pressure The oil pressure of the feed pump circulation system of the axial reciprocating pump is responsible for the adjustment of the tilted disks and the low-pressure hydraulics. The measurement point is located on the valve block of the low-pressure hydraulics. Measurement Point M-ND The pressure value with the joystick in the O position is 25 + 3 bar. When the joystick is extended, the pressure drops by a max. of 3 bar. Measure the control oil pressure in no-load state (1100-50 r.p.m.) and at nominal speed (2200 r.p.m.). All of the measurement values refer to a motor speed of 2200 r.p.m. and an oil temperature of 50°C.
[01/2001]
TRAINING CENTER NEUSTADT
6-15
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Pressure Cut-Off:
The pressure cut-off corresponds to pressure regulation that reregulates the displacement volume to D g0 = 0 after the set target pressure value of 440 +15 bar is reached. This valve prevents the response of the high-pressure relief valves when there are acceleration and deceleration events. The adjustment value is to be chosen to be approx. 20 bar less than the high-pressure valve setting.
High-Pressure Relief:
The high-pressure relief valves protect against the pressure peaks that arise when there are very rapid swiveling processes and the maximum pressure in the system. High-pressure test (HD valves): Measurements are not possible on a static basis, because the pressure is limited through the pressure cut-off that is set lower - 465Âą10 bar. The pressure cut-off has to be blocked to test the valves. The adjustment screw of the pressure cut-off is screwed in to the limit stop in a nopressure state for this. With a blocked pressure cut-off, and to check the adjustment values of the high-pressure relief valve, the engine has to run at the nominal speed because the hydraulic output is over that of the engine! If high pressure that is too low only arises in the case of one driving direction, the two high-pressure vales forwards / backwards are to be exchanged. If the cause cannot be specified by this (the high-pressure valve opens below the adjustment value of the pressure cut-off), the portioned high pressure (shuttle valve) of the pressure cut-off is to be measured for the change forwards / backwards. The feed pressure relief valve protects the low-pressure side of the closed circulation system. Feeding takes place into the circulation system up to a maximum, set pressure value. The excess oil is pumped through the valve into the pump housing, where it gets to the oil cooler.
Feed Pressure Relief:
[01/2001]
TRAINING CENTER NEUSTADT
6-16
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Ground Drive Filter System: The filtering of the oil sucked out of the reservoir is done via the attached medium-pressure filter with 20 µm nominal filtering precision. The filtered oil is fed into the closed circulation system, or flushed out through the filling pressure relief valve and the pump housing. The coldstart valve connected in front of the filter element protects the ground drive against an impermissible load at low temperatures because the pressure differential valve in front of the filter starts to open when there is a pressure drop through the filter element of 6 bar and leads the sucked in oil flow back to the suction connector. The oil amount fed into the circulation system always drops further with an increasing pressure differential, and the combine harvester can only be moved in its full speed range with an increasing oil temperature. The same function sets in with increasing filter dirt. Filter design: Without bypass Flow resistance: At ν = 30mm²/s___∆p ≤ 1 bar At cold start_____ ∆p ≤ 3 bar Dirt indicator: Switching point at ∆p ≤ 5 bar Cold-start valve opens at: ∆p ≥ 6 bar
2 6 11 12 13
Filling pump Fee pressure relief valve Shuttle valve 20 µm Optical dirt indicator Cold-start valve
[01/2001]
TRAINING CENTER NEUSTADT
6-17
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Individual Subassemblies, Pump (Rexroth)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
[01/2001]
Regulating piston cover Screw plug M12x1.5 Screw plug M16x1.5 Nozzle M10 – 1.0 Screw plug M16x1.5 Washer Control spool Dowel pin 3x12 Driving mechanism Screw plug M12x1.5 Screw plug M33x2 Connection plate, complete Internal gear pump set Screw plug M42x2 Screw plug M12x1.5 Seal Double pull-off stopper M10 Regulating piston, complete Screw plug M12x1.5 Housing Dowel pin 3x12 Screw plug M12x1, O-ring 39.34x2.62-NBR
TRAINING CENTER NEUSTADT
6-18
CROSS - FLOW CF 80 COMBINE HARVESTER Pressure Relief Valves
Pressure Cut-Off
1 O-ring 23.47 x 2.62-NBR90 2 Valve seat 3 Valve seat 4 Valve piston 5 Helical compression spring 6 O-ring 6.07 x 1.78-NBR90 7 Spring plate 8 Screw plug 9 Control piston 10 Adjustment screw 11 Seal, lock collar nut M10x1
[01/2001]
6 – GROUND DRIVE
1 2 3 4 5 6 7 8 9 10 11 12
Valve seat Valve piston Valve bushing Piston Control piston Spring plate Helical compression spring Spring plate O-ring 17.12 x 2.62-NBR90 O-ring 17.12 x 2.62-NBR90 O-ring 17.12 x 2.62-NBR90 Adjustment screw
TRAINING CENTER NEUSTADT
6-19
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Variable Displacement Pump A4VG with Mechanical Pump Adjustment
Connection Plate with High-Pressure Relief Valves, Pressure Cut-Off and Feed Pressure Relief Valve
[01/2001]
TRAINING CENTER NEUSTADT
6-20
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Regulating Piston Unit with HW Adjustment
Feed Pump
[01/2001]
TRAINING CENTER NEUSTADT
6-21
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Hydromotor A2FM125 with Purge Valve
[01/2001]
TRAINING CENTER NEUSTADT
6-24
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Purge and Feed Pressure Valve
1 2 3 4 5 6 8 9 15 16 18 19 20 21 22 24 24 24 30
[01/2001]
Housing Purge Piston Valve piston Screw plug Screw plug Washer Helical compression spring 50312.0200 Helical compression spring 50312.0100 Pan head screw M6x30-8.8 DIN912 Screw plug M10x1-FPM O-ring 17.12 x 2.62-FKM90 O-ring 15.54 x 2.62-FKM90 O-ring 10.77 x 2.62-FKM90 O-ring 9.19 x 2.62-FKM90 Locking ring 8x0.8 DIN472 Adjusting washer 7x13x0.5 DIN988 Adjusting washer 7x13x0.3 DIN988 Adjusting washer 7x13x1.0 DIN988 Screen 09447591
TRAINING CENTER NEUSTADT
6-25
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Motor A2FM with Flange-Connected Purge Valve
Connection Plate with Purge Valve
[01/2001]
TRAINING CENTER NEUSTADT
6-26
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
TROUBLESHOOTING, HYDROSTATIC GROUND DRIVE Problems with the ground drive could be due to mechanical or hydraulic reasons. Mechanical Sources of Malfunction: 1.
Control of the hydrostatic drive pump through the Bowden cable • Joystick moves over the entire adjustment range with too much difficulty or too easily Set the parking brake on the joystick
The joystick moves into the neutral position with difficulty and is then easy to operate The ball joint of the Bowden cable on the pump is too stiff
2.
Pump Drive • The ground drive doesn't provide any traction power or the full driving speed Readjust the pretension of the drive belt Check the joined belt for wear and tear and change it if necessary
3.
Gearbox • No high pressure is generated Gear is not engaged The transfer of power to a drive wheel is interrupted • The full high pressure is immediately generated (This could be possible after a gear change under pressure) 2 gears are simultaneously engaged in the gearbox
[01/2001]
TRAINING CENTER NEUSTADT
6-28
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
The troubleshooting is listed according to the deviations from normal driving operation. The individual diagnostic plans are support for a logical approach in the troubleshooting. The troubleshooting is divided up into the following possible phenomena: •
Only drives in one direction
•
Doesn't drive in either direction
•
No full driving speed
•
Oil temperature is too high
•
No traction power
•
No zero position
[01/2001]
TRAINING CENTER NEUSTADT
6-29
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Combine Harvester Only Drives in One Direction The combine harvester only drives either forwards or backwards. The full adjustment range of the Bowden cable was checked.
Manometer at measurement point M ND
Extend the joystick in the direction where the combine harvester doesn't drive
Control oil pressure drops to around 0 bar
Scouring valve is defective
Control oil pressure remains constant Exchange highpressure valves
Change control valve
Change pump
[01/2001]
TRAINING CENTER NEUSTADT
6-30
6 – GROUND DRIVE
CROSS - FLOW CF 80 COMBINE HARVESTER Combine Harvester Doesn't Drive in Either Direction
The combine harvester drives neither forward nor backward. The pump drive, adjustment range of the Bowden cable, switching state of the transmission and the power flow from the transmission up to the straddle gears were checked. Normal filling level in the hydraulic oil tank, no foam formation due to leaks and no rubbed-off metal in the oil. Check the dirt indicator on the pressure filter
Check the pressure cut-off valve
Manometer at measurement point M-ND
Control oil pressure drops sharply when there is actuation at 0 bar
Control oil pressure is too low
Control oil pressure constant 25 bar
Check filling pressure relief valve
Manometer at measurement point M-HD
Check both highpressure valves
Change pump
Check purge pressure valve
Check coldstart valve
Change pump
[01/2001]
Check scouring valve
TRAINING CENTER NEUSTADT
6-31
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Combine Harvester Doesn't Reach the Full Driving Speed The oil temperature is at over 40° C. The combine harvester does not reach the full driving speed on a level road, as can be read about on page 6-2. The joined belt of the pump drive is not damaged and has the correct tension (1-2 mm play between the individual spring coils). The mechanical adjustment of the drive device is fully ensured. Check the oil level in the oil tank
Check the dirt indicator on the pressure filter
Manometer at measurement point M-ND
Control oil pressure is too low
Check filling pressure relief valve
Check coldstart valve
[01/2001]
Control oil pressure constant 25 bar
Manometer at measurement point M-HD
High-pressure is too low forwards and backwards and different
High-pressure is too low forwards and backwards and equal
Adjust or change the high-pressure valve
Adjust or change the pressure cut-off valve
TRAINING CENTER NEUSTADT
6-32
CROSS - FLOW CF 80 COMBINE HARVESTER
6 – GROUND DRIVE
Oil Temperature is Too High The control lamp for an oil temperature that is too high is illuminated. There were supplemental measurements indicating that the switching point of the transmitter in the oil tank of 85° C has been exceeded. Check the oil level in the oil tank
Check the oil cooler for contaminants
Manometer at measurement point M-HD
High-pressure is too low forwards and backwards and different
Adjust or change the highpressure valve
[01/2001]
High pressure is 440 bar forwards and backwards
Clean or change the cooler bypass valve in the oil tank
TRAINING CENTER NEUSTADT
6-33
6 – GROUND DRIVE
CROSS - FLOW CF 80 COMBINE HARVESTER No Traction Power Measure control oil pressure at M ND
Control oil pressure too low
Control oil pressure 24+4 bar
Check the dirt indicator on the pressure filter
Measure highpressure at M-HD forwards and backwards
[01/2001]
Check cold-start valve
High-pressure is different
High pressure is equal and too low
Change pump
Change or adjust high pressure valve
Change or adjust pressure cut-off valve
TRAINING CENTER NEUSTADT
6-34
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 7 Brakes
CROSS - FLOW CF 80 COMBINE HARVESTER
7 – BRAKES
7 BRAKES Table of Contents Page Parking Brake
7–2
Brake Care
7–3
Bleeding the Brake
7–3
Adjustment of the Brakes of the Drive Axle
7–5
Adjustment of the Brakes on the Transport Vehicle
7–6
[01/2001]
7-1
TRAINING CENTER NEUSTADT
CROSS - FLOW CF 80 COMBINE HARVESTER
7 – BRAKES
Parking Brake The parking brake operates independently of the foot brake. The brake should take effect after the first 3 to 4 teeth. See to it that the catch piece still securely engages in the tooth segment even after a longer period of use. The symbol (ďƒ¨) appears on the display unit when there is a switchedon ignition and engaged parking brake. An alarm is triggered as soon as the machine is moved with an engaged hand brake. The alarm generates a horn sound. Engaging the parking brake Push the pedal "down" with the foot as far as possible and let it click into place. Make sure that the parking brake is engaged with adequate firmness.
Pedals
Releasing the parking brake Push the pedal "up" somewhat with the foot until the catch piece disengages. Then let the pedal loose. Entirely release the parking brake before starting every trip! Pedal for steering column adjustment - Press the pedal and move the steering column to adjust the steering column. - Release the pedal, and the steering column is fixed in the desired position.. Brake pedals (Pos. 3) - The left brake pedal brakes the left wheel, and the right brake pedal brakes the right drive wheel. - Operate the brake pedals separately to support the change in direction. The The brake pedal latch connects the two pedals have to be connected with the brake pedal latch (Pos. 4) for safe trav- brake pedals! The brake pedals have to be locked together when roads are travel on roads. eled upon. Equal braking and the maxBrake pedal latch (Pos. 4) imum braking performance is ensured - The brake pedal latch locks the two brake in this way. pedals to each other so that they can be jointly operated. Make sure that the bar completely engages in the slot intended for this in the latched position.
[01/2001]
TRAINING CENTER NEUSTADT
7-2
CROSS - FLOW CF 80 COMBINE HARVESTER
7 – BRAKES
Brake Care -
-
-
-
-
The braking system is filled with brake fluid according to SAE J 1703 (DOT-3 ISO 4925). When correctly set and when the wheel brakes have been bled, the foot brake has to already show a braking effect over a short pedal distance. If the braking effect only appears with a larger pedal distance or after pumping the brakes several times, or after pumping the connected pedals when there is a single-wheel brake, bleed the braking system. Replace the brake fluid every 2 years or after the boiling point of 180°C is undershot (determine this with brake fluid testing equipment) Change the disk brake linings when the minimum thickness of the pad of 4 mm is reached at the latest. A pair-by-pair change is specified
Bleeding the Two-Pedal Braking System The play in the plunger rod in the singleline main brake cylinders is a maximum of 1.0 mm and can be set at the plunger rods DS. Secure this setting with the locking nut. The maximum stroke path of 28 to 29 mm is limited by the pedal mechanism. . Single-line main brake cylinders under the driver's platform. DS Plunger rods AS Stop screws
[01/2001]
TRAINING CENTER NEUSTADT
7-3
CROSS - FLOW CF 80 COMBINE HARVESTER
7 – BRAKES
Bleed the Disk Brake -
Fill the brake fluid tank 1 behind the door on the left next to the cab up to the rim with brake fluid. - Put the bleeding hose S onto the drive axle bleeding screw ES of one brake caliper. Put the end of the hose into a container filled with brake fluid. - Unscrew the bleeding screw ES around half a revolution. - Slowly actuate the accompanying brake pedal up to the limit stop, leave it there Brake Fluid Tank and close the bleeding screw ES. - Now let the pedal go back into the starting position. - Repeat this process until no more air escapes from the system. The fluid level in the tank may not drop under the marking "min". - If air bubbles no longer rise in the bottle, close the bleeding screw ES before pulling away the bleeding hose S. Bleed the second disk brake in the same way. The foot brake has to already show a braking effect with a short pedal distance. The plunger rod path in the case of latched brake pedals is around 12 mm after the bleeding of the system (unlatched around17 mm). Bleeding disk brakes on the drive axle ES Bleeding screw S Bleeding hose
[01/2001]
TRAINING CENTER NEUSTADT
7-4
CROSS - FLOW CF 80 COMBINE HARVESTER
7 – BRAKES
Adjustment of the Brakes of the Drive Axle Disk Brakes The disk brakes of the drive axle are maintenance-free and don't need to be adjusted.
Parking Brake The parking brake is designed to be a separated drum brake for the drive axle. When necessary, set the parking brake to be free of play with the aid of the adjustment nut (4) located on the fork head (3).
Adjusting the hand brake 1 Brake drum 2 Brake lever 3 Fork head 4 Adjustment nut 5 Cable mechanism
[01/2001]
TRAINING CENTER NEUSTADT
7-5
CROSS - FLOW CF 80 COMBINE HARVESTER
7 – BRAKES
Adjustment of the Brakes on the Transport Vehicle The brakes of the transport vehicle are readjusted manually. Jack up the rear axle of the transport vehicle for this. Turn every wheel in the forward direction; reposition the adjustment nut (1) on the inner side of the brake shield in the process by screwing it to the right until the brake shoes start to grind on the brake drum and the wheel is difficult to turn. After this, unscrew the adjustment nut NM by approx. ½ revolution, until the wheel runs freely.
Readjustment of the Brake Shoes
After adjusting the wheel brakes, put the nut (1) up against the cable scales SW. Now pull the hand brake 3-4 times in a forceful manner and release it again. Compensate for any play that may arise between the nut M and the cable scales SW by readjusting the nut (1). Don't forget to secure with lock nuts! Readjustment of the Brake Cables on the Transport Vehicle Have the wear and tear of the brake linings inspected every two years. The wear and tear depends on the running operation, so it is not possible to provide mileage information. Repair work on the wheel brakes is to only be carried out by specialist workshops.
[01/2001]
TRAINING CENTER NEUSTADT
7-6
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 8 Hydraulics
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
8 HYDRAULICS Table of Contents Page Oils, Oil Filters, Oil Change
8–2
Oil Tank
8–5
Axial Reciprocating Pump A10V045
8 – 10
Steering System
8 – 19
Priority Valve
8 – 20
Steering Unit
8 – 22
Distributing Valve Design P (Electrical-Mech. Field Tracking)
8 – 23
Distributing Valve Design Q (Electrical-Hydr. Field Tracking)
8 – 30
Lowering Brake Valve
8 – 44
Low - Pressure Hydraulics
8 – 50
Low - Pressure Valve
8 – 52
Header Hydraulics
8 – 60
Fan Drive
8 – 70
Overall Connection Diagram Design P Electrical-Mechanical Field Tracking
8 – 90
Overall Connection Diagram Design Q Electrical-Hydraulic Field Tracking
8 – 91
[01/2001]
8-1
TRAINING CENTER NEUSTADT
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Oils, Oil Filters and Oil Change HLP 46 according to DIN 51524 is filled from the factory as hydraulic oil for the combine harvester. When the hydraulic system is put into operation, approx. 75 to 80 liters of hydraulic oil are put into the system of the combine harvester (without header). The hydraulic oils based on mineral oil according to ISO-VG46 and 68 meet the viscosity requirements for climactic conditions up to an outside temperature of 35 °C. Different oil types may not be mixed when the hydraulic oil is refilled. A changeover of oil types with Hydran Plus is possible. One must see to it that the filling piece is clean when filling is done! Biologically degradable hydraulic fluids (esterified or non-esterified) may not be put in. Hydraulic Oil Change Check the optical status of the hydraulic oil by taking a sample from the tank before the initial operation at the start of a harvesting season and on a 14-day basis during the harvesting season. 1. Open the lock on the oil drain hose 1, let around 0.5 l. run into a oil collection pan, and after this another 0.5 l. into a clean glass. 2. If the separation of water is found in the glass on the bottom, oil is to be drained out until no more water can be noted in the sample. 3. If sediment is found on the bottom of the oil sample after it stands for several hours, or if the oil has a very dark color and has a burnt smell, then carry out an oil change. If the hydraulic oil that has been drained is opaque and milky white, the dissolved water portion is more than 0.1%. Only a small portion of the water that has been absorbed can evaporate during the operation of the system. A complete oil change is to likewise be carried out in this case, because the valves, motors and pumps will tend to corrode especially in the case of a longer period of time being laid up.
When there are oil samples free of complaints, change the hydraulic oil every 600 operating hours, but after every second harvesting season at the latest.
[01/2001]
TRAINING CENTER NEUSTADT
8-2
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Condensation water is to be drained at the drain hose on a weekly basis. Condensation is drained 2 to 3 times per week in climate areas where there is a large difference in temperature between the day and the night. -
-
-
∗Run in all of the working cylinders before the oil change. Unscrew the screw plug of the oil drain hose and drain out the oil that is warm from the operations. ∗Screw out the reflux valve RV on the hydromotor of the ground drive. Collect the draining oil (approx. 5 l.) with a suitable container. After this, the RV is screwed in again. ∗Thoroughly clean the top side of the oil tank. ∗Fill up the new hydraulic oil to the marking "Maximum oil level". Approx. 62 liters of hydraulic oil are filled up.
Reflux valve on the hydromotor of the ground drive RV Reflux valve Initial Operation 1. Connect the manometer to the measurement point of the low-pressure hydraulics. 2. Undo the plug of the stop magnets on the injection pump. 3. Only turn over the diesel engine with the starter in several cycles until a constant pressure on the manometer of approx. 15 bar is built up. 4. Check the oil level and fill up if necessary. 5. Put in the plug of the stop magnets and start the diesel engine (approx. 5 min. at 1100 r.p.m.). 6. Oil level check. 7. Test run of the diesel engine at full speed (approx. 5 min.). 8. Check the oil level and do a test drive. When a filter filling station is available, please fill the system through the reflux valve on the hydrometer of the ground drive with a connector 15-L. This type of filling provides for the greatest operating dependability with regard to oil purity and low levels of air inclusion.
[01/2001]
TRAINING CENTER NEUSTADT
8-3
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Service Intervals, Drive and Working Hydraulics Daily
∗
Inspection of the oil level at the minimum marking of the oil tank (visible from the outside).
Weekly
∗
Remove condensation water at the drain hose.
Every 3 weeks
∗
∗
Check the dirt indicator of the reflux filter on the hydraulic oil tank. Check the dirt indicator of the pressure filter on the drive hydraulics pump. Oil sample.
600 engine hours or annually
∗ ∗
Filter change on the hydrostatic drive pump. Ventilation filter of the hydraulic tank.
600 engine hours or before the 3rd season
∗
Hydraulic oil change (approx. 65 liters). A changeover of the oil type to Hydran Plus is possible.
∗
[01/2001]
TRAINING CENTER NEUSTADT
8-4
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Oil Tank The gross volume of the hydraulic tank is approx. 65 liters. Approx. 57 liters are required for a filling up to the maximum marking.
Oil tank unit:
1 2 3 4 5 6 7 8 9 10 11 12
[01/2001]
Oil tank Aeration filter 3 µm fiberglass web Reflux filter 10 µm fiberglass web Suction connection 42-L ground drive (feed pump) Suction connection 42-L working hydraulics, steering Return 18-L ; steering and leak oil A10VO Reflux valve, cooler bypass 28-L 2.0 bar Filling level switch Temperature switch 85°C Oil drain 18-L Return, working hydraulics, low-pressure hydraulics and Cooler return TRAINING CENTER NEUSTADT
8-5
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Oil and Aeration Filter -
-
-
-
⇒Change the filter cartridge FP on the pump of the working hydraulics every 600 operating hours, but at least before every harvesting season. ⇒Change the filter element FE of the oil tank reflux filter after 600 operating hours or before the 3rd season. ⇒The optical dirt indicator on the filter head is to be checked on a 14-day basis during the harvesting season with oil that is warm from operations. The diesel engine is to be brought up to the nominal speed for this, and the second person checks whether the pointer is in the green range of the display field. If the pointer reaches the red range, the filter element is to be changed regardless of the number of operating hours. ⇒Change the aeration filter BF on the hydraulic oil tank on an annual basis, because the filter element has great exposure to the influences of weather. The sealing ring DR is to be mounted on the threaded connector when installing the new filter.
Changing the filter element of the tank reflux filter FE Filter element BF Aeration filter DR Sealing ring
Only use original filter elements from the CASE replacement part service! Do not operate the combine harvester under any circumstances without the reflux filter element or without an aeration filter.
The aeration filter is to be changed annually; otherwise air containing oil will escape from the filter.
[01/2001]
TRAINING CENTER NEUSTADT
8-6
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Reflux Filter with Bypass Valve and Dirt Indicator 1 Filter element with bypass 2 Upper filter part (aluminum cast) 3 Filter pot (polyamide, fiberglassreinforced) 4 Screw plug M90x2 5 O-ring 82x3 6 O-ring 75x3 7 O-ring 40x3 8 O-ring 88x3 9 Spring = 52 mm
Nominal filter fineness 10 µm; fiberglass web. Filter element change after 2 years or when there is a display in the optical dirt indicator. Dirt indicator with a changing time limit display at an absolute pressure of 2.5 bar in front of the filter element. The opening pressure of the bypass valve in the filter element is 3.5 bar. No filtering of the hydraulic oil that flows back takes place starting at this point in time. Temperature range: Max. operating pressure: Opening pressure, bypass:
[01/2001]
-10°C to 80°C (100°C for a short period) 10 bar absolute 3.5 bar absolute
TRAINING CENTER NEUSTADT
8-7
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Optical Dirt Indicator
Aeration Filter for Tank Installation
Nominal filter fineness 3 µm; fiberglass web The aeration filter is to be changed annually. Otherwise an escape of air containing oil will come about.
[01/2001]
TRAINING CENTER NEUSTADT
8-8
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Easy-Change Filter on the Ground Drive Variable Displacement Pump
FP Va
Filter cartridge Dirt indicator
Nominal filter fineness 20 µm, fiberglass web;
[01/2001]
TRAINING CENTER NEUSTADT
8-9
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER
Axial Reciprocating, Variable Displacement Pump A10VO45 The axial reciprocating, variable displacement pump A10VO45 supplies the circulation systems of the working hydraulics and steering system. 6
4
5
1
2
3
Symbol
1. 2. 3.
Pressure regulator Pump flow regulator LS connection M14x1.5
[01/2001]
4. 5. 6.
Pressure connection 1“ SAE 3000 Psi Suction connection 1 ½“ SAE 3000 Psi Leakage oil connection M22x1.5
TRAINING CENTER NEUSTADT
8-10
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER
Technical Data: Brueninghaus-HYDROMATIK A10VO45 DFR1 Direction of rotation TO THE LEFT Speed range: At lower no-load speed: 1150 r.p.m. At nominal speed: 2400 r.p.m. At upper no-load speed: 2650 r.p.m. Volume flow:
Q max (n max ) Q min (n min )
= =
117 l./min. 52 l./min.
Operating pressures:
p max p nom
= =
350 bar 315 bar
9
10
11
5
12
6 1. 2. 3. 4. 5. 6.
[01/2001]
4
3
Piston, complete Cylinder Swivel mount Release plate Pressure contact spring Return ball
7
8
1 2 7. 8. 9. 10. 11. 12.
Regulating piston Piston guide Counterpressure spring Counter piston Piston guide Pressure, pump flow regulator
TRAINING CENTER NEUSTADT
8-11
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Pressure Settings: Pressure control valve Stand-by pressure
p abs = p abs =
210 Âą 10 bar 18 bar
Pressure and pump flow regulators have a cap nut for covering the control equipment. The cap nut is sealed to the regulator with a metal/plastic compound seal. The setting of the maximum system pressure takes place on the pressure regulator. The setting of the stand-by pressure takes place on the pump flow regulator (indirectly thereby the regulation pressure difference). Checking the Maximum System Pressure on the Pressure Regulator: Connect the manometer (0-250 bar) to the measurement point M-AH above the fuel tank. The adjustment value can be changed with a hexagon socket screw key, Size 4, after the cap nut (Wrench Size 17) is removed and the lock nut (Wrench Size 17) is unscrewed. In the process a load (preferably one of the reel adjustment devices) has to be moved against the mechanical end limit stop and held there. The pressure that is actually reached with a zero stroke of the pump is displayed on the manometer. If this value lies below the 210-10 bar, a readjustment is to be carried out. In so doing, the value is always adjusted from the "bottom" to the "top", i.e. the load is first taken off the spring and the spring is subsequently set to the 210 bar while watching the manometer. Turning the hexagon adjustment screw in the clockwise direction increases the pressure setting, turning it counterclockwise lowers the pressure setting. Checking the Stand-By Pressure on the Pump Flow Regulator: Connect the manometer (0-40 bar) to the measurement point M-AH above the fuel tank. The adjustment value can be changed with a hexagon socket screw key, Size 4, after the cap nut (Wrench Size 17) is removed and the lock nut (Wrench Size 17) is unscrewed. In the process, no function may be actuated when there is a running diesel engine. The pump is at zero stroke, and the stand-by pressure can be read from the manometer. If this value lies below the 18-2 bar, a readjustment is to be carried out. In so doing, the value is always adjusted from the "bottom" to the "top", i.e. the load is first taken off the spring and the spring is subsequently set to the 18 bar while watching the manometer. Turning the hexagon adjustment screw in the clockwise direction increases the pressure setting, turning it counterclockwise lowers the pressure setting. The adjustment value may not exceed 25 bar, because fatigue phenomena of the regulating spring appear in this case and the oil flows of the individual valve spools are too high. The regulating pressure difference is derived from the stand-by pressure. The regulating pressure difference controls the stroke of the variable displacement pump. The pump volume flow that is provided is oriented towards the opening ratio (prop. valve) and the number of loads, because the regulating pressure difference that is set is kept constant via a hydraulic load (throttle cross section).
[01/2001]
TRAINING CENTER NEUSTADT
8-12
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Steering System The hydrostatic steering system and the working hydraulics are jointly supplied by an axial reciprocating, variable displacement pump A10VO 45 with a pressure and pump flow regulator. To ensure the priority supply of the steering system, a steering priority valve is used, the piston position of which is determined by the working pressure in the steering system. It is thereby ensured that the steering unit always has an adequate oil flow available that is adapted to the steering speed if the pump has an adequate oil amount available. The oil flow that is not required for steering is available for the ancillary loads (functions of the working hydraulics). The signal line has to be protected with a pressure relief valve in the LS system in order to protect the steering system from overload. The steering unit distinguishes itself by its particularly low-noise manner of operating. It is supplied by the priority valve with an amount of oil that is adapted to the steering speed. The load sensing (LS) signal line between the priority valve and the steering unit is there for this. The LS line is open towards the tank in the neutral position of the steering unit. The dynamic oil flow that flows to the steering unit through the LS line from the priority valve is throttled proportionally to the level control of the rotary valve. The LS connection is only closed towards the tank when there is a full opening of the rotary valve. The dynamic oil flow continually runs through the steering unit and is at around 1 to 1.5 l./min. The hydrostatic steering system consists of a Danfoss steering unit and two differential cylinders in a cross mounting. Testing the steering unit: Number of steering wheel revolutions: 3 + 0.5 from one limit stop to the other. Maximum steering pressure on M-LS with a steering system actuation against the limit stop: The pressure has to be 175 + 10 bar. Measurement point on the high-pressure pump M-LS Measurement point
[01/2001]
TRAINING CENTER NEUSTADT
8-19
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER
Priority Valve The task of the priority valve is the priority supply of the steering system with oil under pressure. Impurities in the oil can lead to sticking of the piston in the valve. This results in the breakdown of the working hydraulics. The screw plug (see arrow) and the screw connection are disassembled vis-a-vis one another for cleaning the priority valve. The piston can now be taken out for cleaning.
SYMBOL
[01/2001]
TRAINING CENTER NEUSTADT
8-20
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER Sectional View, Priority Valve
1 6
7
8
4
5
1. 2. 3. 4. 5. 6. 7. 8. 9.
9
2 Connector CF (steering system) Connector P (pump) Connector EF (ancillary s.) Connector LS (steering system) Screen PP 0.8 mm Screen, dynamic 0.8 mm Spring 7 bar Screen LS 0.8 mm Regulating piston
[01/2001]
3 G1/2“ G3/4“ G3/4“ G1/4“
TRAINING CENTER NEUSTADT
8-21
CROSS - FLOW CF 80 COMBINE HARVESTER Steering Unit 4
3
8 – HYDRAULICS
2
1
5
6
1 2 3
Connector, pressure Connector, right Connector, return
[01/2001]
G1/2“ G1/2“ G1/2“
4 5 6
Connector, left Connector, LS Reflux valve in P
TRAINING CENTER NEUSTADT
G1/2“ G1/4“
8-22
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER Distributing Valves
The working hydraulics are provided with pressure / pump flow regulation by a variable displacement pump (center pump). A priority valve for the priority supply of the hydrostatic steering unit is located between the pump and the working hydraulics. The working hydraulics are different depending on the design of the field tracking on the distributing valve.
Valve Block of the Working Hydraulics of the Electrical-Mechanical Field Tracking The functions of the working hydraulics are put together in a valve block: 4 1. 2. 3. 4. 5. 6. 7. 8. 9.
Input element Spool, hydraulic reel drive Spool, sloped conveyor stroke Spool, swivel unloader pipe Spool, vertical reel adjustment Spool, pressure relief, header functions Spool, horizontal reel adjustment Spool, header latch End plate
The maximum operating pressure of the working hydraulics can be checked at the measurement point M-AH above the fuel tank. The sloped conveyor is moved against the upper limit stop for this, and the steering system is not actuated.
1
5
6
7
8
3
2 9 Valve block of the working hydraulics of the electrical-mechanical field tracking
The pressure has to be 220 ± 10 bar. The stand-by pressure of the variable displacement pump can likewise be checked at the measurement point M-AH. The pressure has to be 18 ± 2 bar.
Pipeline measurement point M-AH Measurement point, working hydraulics and steering hydraulics
[01/2001]
TRAINING CENTER NEUSTADT
8-23
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
The electromagnets of the distributing valve battery have an additional manual adjustment. A quick check can be done by actuating them. In so doing, one will discover whether the malfunction is of an electrical or of a hydraulic nature.
Manual adjustment of the electromagnets When several elements break down, up to the complete distributing valve battery, the reason is usually due to oil impurities that have been deposited on the pressure relief valve. In this case, the pressure relief valve is to merely be taken out and cleaned. After this, it is installed again, and the pressure of 220Âą10 bar is set on the valve.
Pressure relief valve Flow regulation valve for setting the lowering speed of the sloped conveyor
[01/2001]
TRAINING CENTER NEUSTADT
8-24
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER
Valve Block of the Working Hydraulics of the Electrical-Hydraulic Field Tracking 31 32
11
10 14 2
16
20
18
1 34
33
3
4
5
6
7
30 13
15
17
19
21
12
Valve Block, Working Hydraulics 1 Input element / hydr. reel drive 2 Lift / lower module 3 Distributing valve, disch. pipe on/off 4 Distr. valve, cross pendulum right/left 5 Distr. valve, lift/lower reel 6 Distr. valve, reel forward/backward 7 End plate 10 Prop. magnet, hydr. reel drive 11 Prop. magnet, lift sloped conveyor 12 Prop. magnet, lower sloped conveyor 13 Switching magnet, shut-off valve NG 2 14 Switching magnet, discharge pipe on 15 Switching magnet, discharge pipe off [01/2001]
16 17 18 19 20 21 30 31 32 33 34
Prop. magnet, cross pendulum right Prop. magnet, cross pendulum left Switching magnet, lower reel Switching magnet, lift reel Switching magnet, reel backward Switching magnet, reel forward P connector M27x2 T connector M22x1.5 LS connector M12x1.5 S connector M18x1.5 H connector M18x1.5
TRAINING CENTER NEUSTADT
8-30
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Input Element / Hydr. Reel Drive The valve block unites all of the functions of the working hydraulics. It is characterized by the segment-by-segment structure of the individual functions. The individual segments are secured together with 3 tie rods. The customary O- ring seals between the individual segments are replaced by Kant seal rings, which are distinguished by the square cross-section and exercise a support function in addition to the sealing function. All of the pole pipes are equipped with manual emergency actuation pins for mechanical checking of the valve switching functions. The functions "hydraulic reel drive" and "lower reel" have screw-type (latching) manual emergency actuation equipment. The function "hydraulic reel drive" has a "pushing" magnet. The manual emergency actuation equipment is to be screwed in when necessary with a screwdriver. The function "lower reel" has a "pulling" magnet. The manual emergency actuation equipment is to be screwed out when necessary (no tool is necessary).
1
2 3 4 5 6 7 8
[01/2001]
Flow regulator with prop. magnet "lift" Flow regulator with prop. magnet "reel" Valve axle, discharge pipe on / off Valve axle, cross pendulum right / left Valve axle, lift / lower reel Valve axle, reel forward / backward Valve axle, special equipment Screw-in housing, reflux valve
TRAINING CENTER NEUSTADT
8-31
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
If this screw-type, manual emergency actuation equipment is used, one must see to it that the actuation equipment is also completely brought into the starting position because otherwise the valve will not close! Manual emergency actuation equipment is to only be used for use in checks over a short period of time. The usage involves a substantial danger of creating an accident!
1 2 3 4 5 6 7 8 9 10 11 12 13
[01/2001]
Lift flow regulator Lower flow regulator Lift / lower shut-off valve Flow regulator, reel drive Magnet, move out discharge pipe Magnet, move in discharge pipe Prop. magnet, cross pendulum right Prop. magnet, cross pendulum left Magnet, lower reel Magnet, lift reel Magnet, reel forward Magnet, reel backward Accessory valve, special equipment
TRAINING CENTER NEUSTADT
8-32
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Lift / Lower Sloped Conveyor Segment
13
14 15
10 11 16
12
6 5 4 3 2 1 1 2 3 4 5 6 7 8
7 8 9
Valve housing Valve core NG2 Pole pipe (frame) Coil 24V DC switching O-ring 22x2 Union nut M18x1 Locking tappet Spring
[01/2001]
9 10 11 12 13 14 15 16
Reflux valve Expander Locking tappet Expander Locking tappet Inset, reflux valve, flow regulator Flow regulator Expander
TRAINING CENTER NEUSTADT
8-33
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
The segment takes on the functions / valves Lift flow regulator Lower flow regulator Lift / lower shut-off valve Shut-off valve free of leakage oil Purge valve Reflux valve for LS tap Measurement point for P input The functions of lift / lower are realized with two proportional flow regulators. Both functions can be run independently of each other because of the division into 2 spools, and this makes advantages in regulation possible because of this. The flow regulators can be run in a volume flow range of 1 l./min. to 68 l./min. The range actually used is at 20 l./min. to 60 l./min. Lifting and lowering speeds of a minimum of 2.5 sec. to a maximum of 7 sec. can be realized with these values. The adjustment is done with the operating and display device. A hydraulic, pilot-controlled screw-in logic element is used for sealing free of leakage oil. The regenerating DELRIN plastic valve seat ensures a permanent sealing function, even with flow-through dirt particles. The logic element is driven by a 2/2-port seat valve. This seat valve is also electrically driven in parallel during lifting and lowering.
[01/2001]
TRAINING CENTER NEUSTADT
8-34
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER Hydraulic Reel Drive Segment
3 2
6 5
1
4
9 10 11 7
8
12 13
1 2 3 4 5 6 7
Screw plug Shuttle valve Expander O-ring 11x2 Housing, flow regulation plate Kant seal 14x1.68 Kant seal 6.07x1.68
[01/2001]
8 9 10 11 12 13
Flow regulator Kant seal 14x1.68 Screen 0.6 Seal Expander Expander
TRAINING CENTER NEUSTADT
8-35
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
The segment takes on the functions / valves 1. 2. 3. 4.
Flow regulator, reel drive Central pressure input Central reflux connector Load Sensing connector, working hydraulics
The function Hydraulic Reel Drive is realized with a proportional flow regulator. The flow regulator can be run in a volume flow range of 1 l./min. to 40 l./min. The range actually used lies at 1 l./min. to 35 l./min. Reel speeds of a minimum of 4 r.p.m. up to a maximum of 80 r.p.m. can be realized with this value. The adjustment is made with the potentiometer in the operating console.
[01/2001]
TRAINING CENTER NEUSTADT
8-36
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Move Discharge Pipe and Reel In and Out Segment
11 14
13
12
15 2 4
5
3 6
1 10 9
1 2 3 4 5 6 7 8
Reflux valve, complete Piston Housing Pop piston Pressure balance regulator 2.0mm Spring Adjustment screw Buffer block
[01/2001]
9 10 11 12 13 14 15
8
7
Spring Magnet 24V DC, switching Ball Ball seat Kant seal 6.07 x 1.68 Kant seal 14.0 x 1.68 Kant seal 12.41 x 1.68
TRAINING CENTER NEUSTADT
8-37
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
4/3-port electromagnet switching valve with hydraulic, pilot-controlled reflux valves. The reflux valves are equipped with a plastic seat for the lowest amount of leakage and regeneration. An input flow regulator added in the sectional pressure channel provides for oil flow dimensioning of 6 l./min., independent of the load pressure, on both of the connectors when there is parallel operation with other sections. The volume flow through the connectors can be changed via the pretension on the spring of the input flow regulator by Âą 20 %. Screwing it in brings about an increase, screwing it out brings about a decrease in the volume flow. In the process, one must see to it that the adjustment screw does not stick out beyond the housing. The adjustment is around 6 l./min. on a standard basis and should only be changed in exceptional cases.
[01/2001]
TRAINING CENTER NEUSTADT
8-38
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Header Cross Pendulum Segment
9 12
11
10
13
2
3
1 4
8 7
1 2 3 4 5 6
Housing Piston (proportional) Pressure balance regulator Spring Closing piece Buffer block
[01/2001]
6 5
9 10 11 12 13
Ball Ball seat Kant seal 6.07 x 1.68 Kant seal 14.0 x 1.68 Kant seal 12.41 x 1.68
TRAINING CENTER NEUSTADT
8-39
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
4/3-port electromagnetic, proportional valve without hydraulic reflux valves. The segment has a partial pressure balance regulator with a regulating pressure difference of 5 to 6 bar. The proportional piston is designed with regard to the adjustment slots in such a way that only around 10 l./min. flow to the load, even with a maximum current flow in the proportional magnets. The partial pressure balance regulator sees to it that the volume flow through the adjustment slots of the proportional piston remains constant even when there is a fairly high system pressure (another load with a higher burden is actuated in parallel). The partial pressure balance regulator is screwed into the valve core. The setting on the pressure balance regulator is not to be changed under any circumstances. The magnets have a manual emergency actuation pin.
[01/2001]
TRAINING CENTER NEUSTADT
8-40
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER Lift / Lower Reel Segment
10 13
12
11
16 15 14 2
4
1 5
3 9
1 2 3 4 5 6 7 8
Housing Piston Shut-off valve 24V DC Pressure balance regulator 2.0mm Spring Adjustment screw Buffer block Spring
[01/2001]
9 10 11 12 13 14 15 16
8
7
6
Screw plug Ball Ball seat Kant seal 6.07x1.68 Kant seal 14.0x1.68 Kant seal 12.41x1.68 Screw plug Magnet 24V DC, switching
TRAINING CENTER NEUSTADT
8-41
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
4/2-port electromagnetic valve with an electrical, pilot-controlled 2/2-port valve. The 2/2port valve fulfills the sealing function and ensures a lowering of the reel through the existing load pressure in the cylinders. An inlet flow regulator that is added in the sectional pressure channel provides for oil flow dimensioning of 6 l./min. independent of the load pressure when there is parallel operation with other sections. The volume flow through the connectors can be changed via the pretension on the spring of the inlet flow regulator by Âą 20 %. Screwing it in brings about an increase, screwing it out brings about a decrease in the volume flow. In the process, one must see to it that the adjustment screw does not stick out beyond the housing. The adjustment is around 6 l./min. on a standard basis and should only be changed in exceptional cases.
Reel Forward / Backward Segment (same structure)
[01/2001]
Also see the Discharge Pipe Segment
TRAINING CENTER NEUSTADT
8-42
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER CL-08 Disk
10
13
14 15 2 12
3 1 4
9
1 2 3 4 5 6 7 8
Housing 9 Piston 10 Pressure balance regulator 12 Spring, pressure balance regulator13 Screw plug 14 Buffer block 15 Centering spring (both sides) Screw plug
[01/2001]
13
8
7
6
5
Reflux valve, complete Magnet P channel T channels Tie rod, M8 threaded rods Load-sensing channel
TRAINING CENTER NEUSTADT
8-43
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Installation Position, Positive Pressure Maintenance Valve and Differential Cylinder
Cylinder on the Sloped Conveyor 40/25 x 250 The cylinder for carrying out the cross-wise header movement and the double lowering brake valve with all of the lines are attached to the sloped conveyor. The differential cylinder 40/25 x 250, Illustration 3.17, ensures a swinging range of the header of 7.5° in both directions. The piston side is driven when the header is swung right; the rod side is driven to swing the header to the left. The cylinder is driven via the 4/3-port proportional valve, Pos. 4. A double positive pressure maintenance valve is built into the load lines.
[01/2001]
TRAINING CENTER NEUSTADT
8-44
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Double Lowering Brake Valve
5 6 7
2
1
4
3
1 2 3 4 5 6 7
Connector V1 G3/8“ Connector V2 G3/8“ Connector C1 G3/8“ Connector C2 G3/8“ Adjustment screw with hexagon socket Lock nut Screw-in cartridge, lowering brake valve
Lowering Brake Valve (Section) 1 2 3 4 5 6 7 8
Adjustment screw Counter brace Adjustment nut Pressure spring (adjustment pressure) Sealing cone Regulating slider Pressure spring (RÜV function, 1.03 bar) Pilot pressure channels
[01/2001]
TRAINING CENTER NEUSTADT
8-45
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER Cylinder 50/25 x 480 Discharge pipe
1 2 3 4 5 6 7
Cleaning ring Groove ring O-ring (2X) O-ring Cleaning ring Wynseal compact seal Guide band
[01/2001]
Cylinder 60 x 505 Sloped conveyor
1 2 3 4 5 6 7 8 9 10
Piston rod Cylinder pipe Cylinder floor Guide nut Guide sleeve Floor eye Piston rod eye Flange Connection tappet Cleaning ring
11 12 13 14 15 16
Groove ring O-ring Round wire snap ring Cone lubrication nipple Cu sealing ring Hexagon head screw
TRAINING CENTER NEUSTADT
8-46
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Low-Pressure Hydraulics The low-pressure hydraulics are supplied by the feed pump circulation system of the hydrostatic ground drive. The distributing valve includes the following functions: 1. 2. 3. 4.
Threshing unit coupling Header coupling Unloader coupling Chopper coupling
If no coupling is switched in, there is pressure on the piston rod side and the working cylinders are moved in. 4 3 2 1 When the corresponding unit coupling is switched in, the valve is switched and the pressure is on the piston side. Distributing valve for couplings The cylinder moves out in accordance with M-ND Measurement point; control oil the belt force. pressure, ground drive and low-pressure hydraulics The cube plugs are equipped with lightemitting diodes for displaying the switching state for the function. Mechanical actuation for diagnosis can take place via the manual emergency actuation on the magnet. Low-Pressure Valve Block
1 2 3 4 5 6
3/2-port seat valve, threshing unit coupling 3/2-port seat valve, header coupling 3/2-port seat valve, unloader coupling 3/2-port seat valve, chopper coupling Connector P1 M12x1.5 Connector P2 M12x1.5
[01/2001]
7 8 9
Connector T M12x1.5 Connector A M12x1.5 Latching manual emergency actuation
TRAINING CENTER NEUSTADT
8-50
CROSS - FLOW CF 80 COMBINE HARVESTER Technical Information:
8 – HYDRAULICS
Design type: Magnet-actuated seat valve Installation position is arbitrary Ambient temperature –30°C...45°C Fluid temperature –20°C...100°C Magnet voltage 24 V DC Maximal current 0.9 A Maximum pressure p = 50 bar Electrical connection Z4, cube plug
Manner of Functioning: There is no current in the distributing valves 1, 2, 3, 4 when the combine harvester is started. The rod side of the coupling cylinders is directly connected to the ground drive feed pump there via the pressure continuation line. The 3/2-port seat valves link the connector A to T. The couplings are thereby moved in. If current is provided in the electromagnet of the 3/2-port seat valve, Connector P is linked to Connector A of the respective valve and pressure fluid flows to the piston side of the cylinder; the coupling process takes place because of this. Only the differential force that results from the piston surface ratio is available because the rod side of the cylinder also continues to be provided with feed pressure. Screens with a hole diameter of 2 mm are put into the respective connector A of the 3/2port seat valves so that the feed pressure does not break down and a certain amount of volume flow to the coupling cylinder is not exceeded.
The seat valves have a manual emergency actuation (see the arrow) on the magnet side. This can be used for bypassing the electrical system when the industrial safety regulations are taken into consideration.
If an electromagnet has broken down, the respective valve is not permitted to be continually latched because a rapid coupling disengagement cannot be realized !
[01/2001]
TRAINING CENTER NEUSTADT
8-51
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Low-Pressure Valve (Section) No Current in the Magnet
The ball is pressed against the sealing edge by the spring and the system pressure in the feed system. The sealing cone on the pilot slider is free, and the connection A (foot side of the respective coupling cylinder) is open to T (return). Magnet Engaged with Current
The ball is pushed against the spring by the pilot slider. The connection P to A is opened. The sealing cone on the pilot slider simultaneously closes the connection A to T. The foot side of the respective cylinder is connected with the connector A in this state. The cylinder moves out. [01/2001]
TRAINING CENTER NEUSTADT
8-52
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Connection Diagram, Low-Pressure Hydraulics
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
[01/2001]
Low-pressure valve 3/2-port seat valve Screen, hole diameter 2 mm P1 connection P2 connection T1 connection T2 connection A connection Measurement connection, feed pressure Feed pump, ground drive Medium pressure filter, ground drive, 20 µm Pressure relief valve, feed system, 28 bar Reflux filter, oil tank, 10 µm Cylinder 55/45x160, threshing unit coupling Cylinder 55/45x160, header coupling Cylinder 40/30x125, unloader coupling Cylinder 40/30x125, chopper coupling
TRAINING CENTER NEUSTADT
8-53
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Cylinder 55/45x160 (Threshing Unit - Header Coupling)
1. 2. 3. 4.
O-ring Piston seal O-ring Groove ring
5. 6. 7. 8.
O-ring Piston seal O-ring Groove ring
Cylinder 40/30x125 (Unloader - Chopper Coupling)
The hydraulic cylinders that are used are special low-pressure cylinders that are designed for a maximum pressure of 50 bar. The sealing system only consists of 4 individual elements that are only distinguished by the size: The positions 1 and 5 cannot be exchanged because the cylinder pipe is rolled together with the foot. The positions 2-4 and 6-8 can be exchanged after disassembly of the rod guide nut. Malfunctions:
The hydraulic cylinder of the coupling actuation equipment does not move out or only moves out very slowly: Bypass the electric system with the manual emergency actuation Measure the feed pressure on the low-pressure valve Connector P and on the respective cylinder on the piston side; if the piston rod side builds up a pressure that is > 10 bar, the screen with a hole diameter of 2.0 mm in the distributing valve is to be checked for dirt. If the screen is free, the cylinder on the rod side is released from the coupler (possibly with sluggishness in the slide sleeve of the coupler) and the actuation is carried out again. If the maximum feed pressure of 25 bar is applied on the piston rod side and floor side, the complete cylinder or the groove rings have to be changed. Check the easy of mechanical action of the coupling.
[01/2001]
TRAINING CENTER NEUSTADT
8-54
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Header Hydraulics
5
5
6 4 1
3
2
1
Multi-coupling, 5-fold
2 3 4 5 6
Hydraulic motor 200 cm³/r. Lift reel cylinder 24.5x250 Lift reel cylinder 35/25x250 Reel forward/backward cylinder 32/20x240 One-way restrictor valve
[01/2001]
TRAINING CENTER NEUSTADT
8-60
CROSS - FLOW CF 80 COMBINE HARVESTER The header hydraulics consist of a hydromotor for the reel drive, the vertical reel adjustment and the horizontal reel adjustment. The header hydraulics are supplied by the main valve. The multi-coupling is to be engaged for this. The loose half LH is to be put into the fixed half FH here. Separate pressure relief of the header hydraulics can be brought about by actuating the black pushbutton next to the coupling. After this, the operating forces for latching the coupling are smaller. Subsequent to this, the latch strap VB is pressed backwards until it catches into place. To release the connection, the latch head VK is pressed and the latch strap is pulled forward. After the separation of the coupling, the cover of the fixed half FH is to be closed and the loose half is to be put into the receptacle intended for it.
8 – HYDRAULICS
Multi-coupling, header hydraulics FH Fixed half LH Loose half VB Latch strap VK Latch head
The coupling elements make uncomplicated and quick cleaning possible. The coupling of cleaned elements reduces the entry of dirt into the hydraulic system and increases the service life for many coupling processes. 1 2 3 4 5
Coupling element M22x1.5-3/8“ (P connection, reel drive) Coupling element M22x1,5-3/8“ (reel cylinder connections) Coupling element M22x1.5-1/2“ (T connection, reel drive) Mounting plate Guide pins
[01/2001]
TRAINING CENTER NEUSTADT
8-61
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Multi-coupling receptacle on the header
Setting the Lowering Speed of the Header Design P The setting of the lowering speed of the electrical-mechanical field tracking is done via the flow regulation valve on the valve block. The lowering speed of the sloped conveyor can be set down to a minimum of 2 seconds by turning the adjustment knob. An adjustment is necessary when there are changes in weight of the header (corn adapter, sunflower equipment or rape table).
[01/2001]
TRAINING CENTER NEUSTADT
8-62
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Setting the Reel Lowering Speed
One-Way Restrictor Valve The one-way restrictor valve (arrow) is used for setting the reel lowering speed. The lowering speed set at the factory is around 5 seconds for the entire stroke. The adjustment wheel of the one-way restrictor valve is latched in this position. The hexagon head screw is to be unscrewed before the adjustment and screwed down again after it ends, which prevents independent adjustment under pressure, in order to prevent damage to the adjustment wheel and the lifting spindle.
[01/2001]
TRAINING CENTER NEUSTADT
8-63
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Connection of pick-up and corn adapter with hydraulically-operated adjustment and working elements. The hydraulic functions of the header hydraulics can be used for attaching these harvesting adapters. The following are available for this: 1) The electrically-adjustable proportional valve with Q = 0...35 l./min. 2) A double-action 4/3-port valve with Q = 6 l./min. and 3) A single-action 4/3-port valve with Q = 6 l./min. Illustrations 7.10 to 7.14 show various connection possibilities. The unused connections of the loose half are to be closed, or the elements are to be completely screwed out, because the hydraulic lines are connected through the multicoupling.
[01/2001]
TRAINING CENTER NEUSTADT
8-64
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
3 4
3 4
Illustration 7.10
Connection Diagram, Pick-Up Equipment
1
2
3 4 5
3 4 12 5
Illustration 7.11 -
[01/2001]
Connection Diagram, Corn Adapter Equipment With silage corn auger drive With picking rail adjustment (spring reset) Foldable
TRAINING CENTER NEUSTADT
8-65
8 – HYDRAULICS
CROSS - FLOW CF 80 COMBINE HARVESTER
1
2
5
12 5
Illustration 7.12 -
Connection Diagram, Corn Adapter With picking rail adjustment (spring reset) Foldable
1
1
Illustration 7.13
[01/2001]
Connection Diagram, Corn Adapter - With picking rail adjustment (spring reset)
TRAINING CENTER NEUSTADT
8-66
CROSS - FLOW CF 80 COMBINE HARVESTER
2
8 – HYDRAULICS
5
25
Illustration 7.14
[01/2001]
Connection Diagram, Corn Adapter - With double-action picking rail adjustment
TRAINING CENTER NEUSTADT
8-67
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Hydraulic Fan Drive The hydraulic fan drive is in a closed circulation system with a tilted-disk axial reciprocating pump (pump furthest to the rear) and a tiltedaxle reciprocating motor. The hydraulic check of the fan drive is limited to the measurement of the speed and the check of the pressure values. The speed check is done by having a second person actuate the manual emergency actuation HN of the magnets lying in the direction of travel at a nominal speed of the diesel engine up to the limit stop. A speed of 2500 + 100 r.p.m. has to be reached with an empty cleaning unit. In the process, the speed is read on the on-board computer. The measurement point M-HD2 can be used for pressure checking. The feed pressure of the circulation system is also measured at this point. When the drive is not actuated the target value is 25 + 3 bar. Checking the fan speed with manual emergency actuation HN Manual emergency actuation The cube plug for actuating the solenoid valve for threshing unit coupling is to be pulled out to check the fan! During the testing process, work is to only be carried out while maintaining an appropriate safety distance from the rotating parts!
Measurement point on the pump, fan speed M-HD 2 Measurement point
[01/2001]
TRAINING CENTER NEUSTADT
8-70
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Connection Diagram, Hydraulic Fan Drive
1
Axial reciprocating pump V g = 18 cm³/r. 20
2 3 4 5 6 7 8 9 10 11 12 13 14 16 17
Electrical, proportional adjustment 21 Regulating piston 22 High-pressure relief valve, B-side 23 High-pressure relief valve, A-side 24 Feed press. scav. throttle, diam. 1.4 mm 25 Suction connector S 30 Pressure connector A 31 Pressure connector B 32 Feed pressure connector G 33 Measurement connector M B Regulating pressure supply P S Leakage oil connector T 1 Leakage oil connector T 2 Regulating pressure connector X 2 Measurement connector M A
[01/2001]
Axial recip., fixed-displacement motor V g = 23 cm³/r. Pressure connector A Pressure connector B Leakage oil connector T 1 Leakage oil connector T 2 Purge nozzle, diameter 1.6 mm Oil cooler Air filter Reflux filter Oil tank
TRAINING CENTER NEUSTADT
8-71
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Axial Reciprocating, Variable Displacement Pump A10VG18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Pressure connector B M27x2 Pressure connector A M27x2 Leakage oil connector T1 M18x1.5 (closed) Leakage oil connector T2 M18x1.5 Measurement connector MB M12x1.5 Measurement connector MA M12x1.5 (closed) Filling connector R M12x1.5 (closed) Suction connector S M26x1.5 Regulating pressure connector X1 M12x1.5 (closed) Regulating pressure connector X2 M12x1.5 (closed) Regulating pressure supply M12x1.5 (closed) Feed pressure connector G M14x1.5 (closed) High-pressure relief valve B-side High-pressure relief valve A-side Feed pressure lock with purge nozzle Proportional magnet B-side Proportional magnet A-side Manual emergency actuation (both sides) Zero-position adjustment
[01/2001]
TRAINING CENTER NEUSTADT
8-72
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Technical Data Variable Displacement Pump: REXROTH-HYDROMATIK A10VG 18 EP2 Direction of rotation TO THE LEFT Speed range: Pump (diesel engine) No-load operation 1050 r.p.m. Nominal speed 2615 r.p.m. Feed pump:
Without one, outside feed from feed pump of the drive hydraulics p max = 28 bar
Axial reciprocating pump: Q max at n max = 50 l./min. n max,Dauer = 5000 r.p.m. ∆p max = 330 bar p max = 350 bar Measurement Connections:
M B (0-350 bar) High-pressure fan motor LEFT; M12x1.5 minimeasurement system M A (0-350 bar) High-pressure fan motor RIGHT ; M12x1.5 minimeasurement system R (0-10 bar) Housing pressure / ventilation; M12x1.5 minimeasurement system
Pressure Settings:
[01/2001]
High-pressure relief valve p abs = 340 ± 10 bar Feed pressure p abs = 25 + 2 bar (dependent on the speed); because the outside feed cannot be adjusted !
TRAINING CENTER NEUSTADT
8-73
CROSS - FLOW CF 80 COMBINE HARVESTER High-Pressure Relief:
8 – HYDRAULICS
The high-pressure relief valves protect against the pressure peaks that arise when there are very rapid swivel processes and the maximum pressure in the system.
Pressure Check: Carry it out with oil that is warm from operations (50°C). Measure the feed pressure in a no-load state and at the nominal speed. High-Pressure Check The maximum system pressure of 340 bar does not arise in normal operation of the fan up to the maximum speed of 2500 r.p.m. The pressure value at a certain speed is directly connected to the load on the cleaning unit, the oil temperature and the total operating period of the hydromotors. Thus, for example, the hydraulic output with an empty cleaning unit increases by 100% with reference to a completely loaded cleaning unit. The speed / pressure values are documented in the check of the machine before delivery. The pressure or functional testing of the fan drive merely covers the check of the maximum speed with a full pump excursion. If the value of 2500 r.p.m. is reached here on the upper fan, full functional capability of the hydraulic fan drive components can be assumed. If the maximum speed is not reached, the pressure measurement on M B of the fan pump (Measurement Point HD2) will be made. If the maximum system pressure of 340 bar already comes about under 2000 r.p.m., the bearings of the fan shaft are to be checked. The manual emergency actuation HN on the front side of the valves can be made here to bypass the electrical pump adjustment. EP Adjustment The pump swing angle is realized through the EP (electrical-proportional) adjustment. The on-board computer serves as an input device for the fan speed. The digital electronics MC-8 are driven via the on-board computer; the digital electronics then output a current value between 200 and 600 mA in accordance with the specifications. The respective regulating chamber is provided with a regulating pressure through the EP driving device in dependence upon the preselected current intensity I [mA] on the two proportional magnets (a or b). The tilted disk, and thereby the displacement volume, can be continuously adjusted because of this. A flow direction is assigned to every proportional magnet. The start of adjustment is at around 200 mA (pump 0°), and the adjustment end is at 525 mA (pump 17°). The adjustment and values are equal for forwards / backwards.
[01/2001]
TRAINING CENTER NEUSTADT
8-74
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
A speed regulation unit of the fan drive (only when equipped with the on-board computer system) is integrated into the digital electronics for interpreting the changes in the diesel speed and viscosity changes. In the process, the specified target speed is compared with the actual speed of the fan shaft and corresponding flow corrections are made on the proportional magnets of the pump adjustment equipment. Axial Reciprocating, Fixed Displacement Motor
1 2 3 4
Pressure connector B ; M22 x 1.5 Pressure connector A ; M22 x 1.5 Leakage oil connector T 1 ; M14 x 1.5 Leakage oil connector T 2 ; M14 x 1.5
1.Technical Data, Fixed Displacement Motor: REXROTH-HYDROMATIK A2FM 16 Direction of rotation ALTERNATING Feed capacity: V g = 16 cm³/r. Nominal pressure p Nom = 400 bar Max. pressure: p max = 450 bar Max. speed: n max = 6300 r.p.m.
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8-75
CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Subassemblies and Sectional Views A10VG18
1 2 3 4 5 10 13 14 18 22 24 28 31 41
Driving mechanism Adjustment, hydr. Connection plate Pump support Drive device Housing Joint pin Straight pin M6x12 DIN6325 Slide block Screw plug M12x1.5-NBR Screw plug M10x1-NBR Nozzle M6-1.0 Dowel pin 3x8 O-ring 101.27 x 2.62-NBR70
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CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Connection Plate
1 2 5 7 8 11 12 22 35
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Pressure relief valve 02000663 Lock set ND‘1.6‘A10VG1855912.1012 Connection plate Pan head screw M10x50-8.8 DIN912 Straight pin M6x16 DIN7-ST Double detaching stopper M6 Screw pin M8x1-NBR Cylinder roller bearing RNU 17.759x30x17 Screw plug M12x1.5-NBR
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CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Pressure Relief Valve
1 2 3 4 5 6 7 9
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Screw plug Valve disk Valve spindle Spring spanner Pressure spring .52113.0515 Pressure spring, conical 52113.0515 Threaded pin O-ring 19.3 x 2.2-NBR90
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CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Control Device
1 2 3 4 5 6 7 8 9 10 11 12
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Control device Proportional magnet 09441692 Socket GDM2009-931965-106 Socket GDM2009-931965-100 O-ring 18.77 x 1.78-NBR90 Pan head screw M6x70-8.8 DIN6912 O-ring 7.59 x 2.62-NBR90 Pan head screw M6x45-8.8 DIN6912 Seal 42622.0111 Connector cover Tension spring 42622.0111 Seal 42722.0120
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CROSS - FLOW CF 80 COMBINE HARVESTER
8 – HYDRAULICS
Hydraulics Connection Diagram, Complete
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Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 9A
Header and Shaft
CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
9A HEADER AND SHAFT Table of Contents Page Dividing Devices
9A - 2
Grain Lifter
9A - 3
Sickle Drive
9A - 4
Reel
9A - 6
Halm Auger
9A - 8
Shaft
9A - 12
Header Return
9A - 16
Shaft Design P (Electrical-Mechanical)
9A - 20
Field Tracking Design P (Electrical-Mechanical)
9A - 30
Shaft Design Q (Electrical-Hydraulic)
9A - 40
Field Tracking Design Q (Electrical-Hydraulic)
9A - 42
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9A-1
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CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
PLATFORM HEADER Dividers Two different dividing mechanisms are available for grain headers to meet the sometimes very different crop conditions: Folding divider toe Divider Folding divider toe Attach the folding divider toes to the bottom and to the side frame of the header as shown in the picture. Fold down the divider toes before transporting the header on the header trailer. To do so, pull out the spring connector F and move the locking bar R.
How to attach the folding divider top S = Fixing screws R = Locking bar F = Spring connector Fold up the divider toes before lifting the header from the header trailer –risk of deformation! Divider The picture shows how to mount the divider. The divider is moveable and self-adjusting to the soil contour. The upper divider can be adjusted in height after the screw KS is loosened and rotated after loosening the screw S. The height of the divider is adjusted at the stop (see lower picture). For road transport, unplug the rear bolt BZ and place it in another hole of the upper coupler. So the divider will swivel upward. Dividing is very important for ensuring a smooth grain flow. So make sure you always choose the best setting in accordance with the actual crop conditions.
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CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Crop lifters Use the crop lifters in case of difficult harvest conditions, especially for highly lodging crops. Attach the crop lifters as shown in the picture: Slide the crop lifter into the holder ( K ). Then move it upwards over the double finger and fix it in any of the three positions with the stop bar.
-
-
-
-
-
How to attach the crop lifter L = Stop bar released R = Stop bar engaged O = Upper stop position M = Middle stop position U = Lower stop position S = Washer K = Holder Place the combine harvester on even ground to be able to find the correct position for fixing the crop lifters. Mount one of the crop lifters somewhere in the middle of the cutter bar. Lower the header until the crop lifter gently touches down. But make sure you never put pressure from the header onto the crop lifter by lowering it too far down. Check whether the sliding zone is touching the ground in parallel. If that is not the case, select another stop position according to the illustration given in the picture. Additional fine adjustment is possible by placing washers between the holder and the mowing fingers. The holder is pre-assembled. For headers with plastic reel, also check the lifter for contact points where it is rubbing against any tine of the reel. Then relocate the appropriate holder to the next screw.
Crop lifters will not work properly unless adjusted correctly as shown in the picture. A holding device for non-mounted crop lifters is located in the header tray in the back on the right-hand side.
How to adjust the crop lifter properly A correct setting B wrong – the crop lifter is “climbing”. C wrong – the crop lifter is “digging”.
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9A-3
CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Knife – knife drive The cutting knife is driven by an angular gear. The input speed is 540 rpm. The output speed is 605 rpm. When changing an angle drive box, make sure the knife will not contact the fingers. Adjust by shimming. Lubricate the lube point at the knife head daily (10 h). Lubricate the lube point on the angle drive box weekly (60 h) with five grease strokes.
60 h
10 h The essential feature of the two-way cutting system is that the blades are fixed on the knife back with the cutting edges alternately pointing upward and downward. No over-cut adjustment is required (85 mm travel). But it should be noted that the distance between the first finger on the gear side is set to 10 mm from the inner edge (by shifting the finger bar).
First finger distance
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CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
New knives are fastened with rivets. Blades are replaced by bolting.
Description Toothed bolt Bolt for knife head Bolt for knife head Nut Press-in nut Knife blade
Spare parts number 35 36 37 38 39 47
catalogue Spare part number 4260 71641.6 00 379407 1 00 379408 8 00 379409 6 4260 71640 8 4260 7142 6
How to replace a knife Turn the gear such that the two socket head cap screws Z at the head bearing holder can be loosened from the front side.
How to replace knives Z = Socket head cap screw PG = Planetary gear SK = Hexagon head bolt Then pull out the knives. Proceed in the reverse order to reinstall the knives. Make sure you loosen the hexagon head bolt SK at the knife head. -
Turn the gear manually to check whether it is running well. Make sure there is no pressure from the knife head onto the fingers. Check whether the screwed connection of the clamping seat at the knife head is tight. If required, retighten the connection.
A spare knife is provided in the lower crossbeam of the header.
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CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Reel The reel is a laid grain design. The reel setting is crucial for the cutting process and the feed flow of the crop into the pan of the header. Therefore, adjust the reel setting to the actual crop conditions. The reel allows for hydraulic vertical and horizontal adjustment. The lowering speed can be adjusted by means of a variable throttle provided on the right-hand side frame of the header. The reel setting should be so as to allow for smooth and gentle crop feed to the knife. The reel is to engage the stalks below the ears. Adapt the reel speed to the ground speed in a way to help the cutting process and ensure a uniform grain flow towards the knife on the one hand, but to prevent grains from being beaten or raked off the ears and to avoid crimped ears on the other. Reel speed can be set in two ways (as a function of ground speed or independent). Tine engagement can be adjusted by an eccentric control with the help of the hand lever HH and the hexagon head bolt SK. Headers of 7.2 meters and more are provided with a second control located on the right-hand side of the reel.
First loosen the hexagon head bolt SK and then set the tines to the desired position using the hand lever HH. Re-tighten the hexagon head bolt SK. The reel tines must be vertical for standing crop. For lodged grain, set the tines to “catch”, i.e. the tines must be inclined towards the header
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CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
To prevent the reel tines from being accidentally cut off by the knives, the mounting length of the hydraulic cylinders for the vertical reel adjustment can be adjusted via the eye bolts AS. The setting must be such that the parallel and lowest position is not within the reach of the knife. For mounting a rapeseed attachment, the reel can be raised by plugging the piston rod in two optional positions (as marked by the arrows).
Adjust a clearance of 1 mm between the reel guide and the reel arm on the lefthand side using shims (spare part number 06 104391 0).
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CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Tined auger The tined auger is adjustable in height for best operation. The works pre-setting for its clearance above auger bed level in normal harvest conditions is 20±5 mm. When correcting this clearance, take care your adjustment is parallel. Select a wider clearance for coarse crop and a smaller clearance for finer crop. You can adjust the height of the auger using the bearing plates LP at the outside of the pan. Prior to the adjustment, loosen the fixing bolts BS and readjust the bearing plate LP using the spindle SP. After the adjustment, How to adjust the auger and tines re-tighten the fixing screws BS firmly. LP Bearing plate BS Fixing screw The auger includes eccentrically controlled H Lever tines. The position of the tines can be VH Bolt adjusted by means of the lever provided on SP Spindle the right-hand side of the header pan (picture). The correct adjustment is when the tines are retracted to the maximum for crop delivery (arrow in the picture about 4 o’clock). Before changing the tine positions, loosen the bolt VH of the lever H. After the adjustment is made, refasten the bolt and check the tine position to make sure the tines do not hit the pan bottom. You are recommended to oil the tines after harvesting and before the new harvest. When making the auger adjustment, adapt the clearance between the rails A and the auger to the prevailing harvesting conditions. For wet crop with undergrowth, Tined auger A Rail set the rails to the smallest clearance SW Auger spiral possible. TB Pan bottom FZ Tine
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9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER Accessory Equipment of the Auger
An auger extension (A), conveyor scoops (B) and carriers (C) are available as accessory equipment.
B C A A
The auger extension (A) is mounted for use in the CF 60 and CF 50. The auger is thereby adapted to the channel width of 1300 mm. The conveyor scoops (B) are contained without mounting in the basic equipment of the header. They are mounted for better transfer to the sloped conveyor when there is shortstemmed harvest grain (e.g. barley) and low quantities. They can interfere when there is long-stem harvest grain (e.g. rye) and have to be removed. The carriers (C) are mounted when there are flax and sunflowers. All of the pins of the auger are removed here. Speed Adjustment 2 speeds are available for the auger (180 r.p.m. or 200 r.p.m.). A change in the speed is achieved by moving the double pinion and displacing the drive chain. The double pinion is axially secured by a screw. Both positions are specified there by holes in the shaft.
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9A-9
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER If the adjustment path on Lever H is not sufficient, Screw S is to be unscrewed and Lever H is to be put up, moved by a hexagon level. After this, the lever is to be axially secured with Screw S.
S
H Control Shaft The control shafts are distinguished by the design and length of the auger. They were only clamped up to Model Year 2000. Starting in Model Year 2001, they will be additionally protected against twisting with an adjustment key.
Drive Side of the Multi-Finger Auger
Slip clutch The torque setting of the slip clutch is 700 Nm. This corresponds to a spring length of about 45+2 mm. Full torque will be reached after a slipping time of 30 seconds only. Prior to each harvest, unload the springs, turn the slip clutch and then re-establish the previous setting of the springs. This is necessary to prevent corrosioninduced jamming of the clutch facings.
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9A-10
CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Slip Heel (Electrical-Mechanical Field Tracking) The basic equipment of each header includes 2 slip heels. They are used to adjust the cutting height or stubble height. Three optional heights are possible: 70 mm, 100 mm und 130 mm.
How to adjust the slip heel SB = Socket pin FS = Spring connector For cutting height adjustment, first lift the header a bit above ground and then remove the spring connector FS and the socket pin SB to set the slip heel to the desired height. Then lock the slip heel in its new position. Increased wear of the slip heels indicates too high a ground pressure from the header (for adjustment refer to page 9B-10).
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CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Shaft Feed Chain The feed chain takes on the transport from the cross auger to the threshing drum. The feed chain is partitioned. See to the correct tension of the feed chain. Insufficient tension can lead to jumping out of the chain tracks and wear and tear on the feed chain that is too high. The chain is correctly tightened when about the 3rd to 5th tooth angle piece ZW is slightly supported on the shaft floor SB in the central shaft area. HL
Tightening the conveyor chain SB = Shaft floor ZW = Tooth angle US = Lower shaft spindle A = Limit stop HL = Wooden strip
The shaft chain is tightened as follows: 1. 2.
3.
Tighten the lower shaft spindle until it remains in the upper position on both sides. Slowly take the load off the shaft spindle until the shaft spindle drops into the lower position on its own. Check by lifting it again that the shaft spindle drops down on its own. Readjust it if necessary.
In addition, see to it that the lower shaft spindle US can be lifted up by hand and that it slowly returns to the limit stop A again of its own accord. Provide for an even spacing between the front shaft edge and the projection of the lower shaft spindle. Wooden strips HL (top illustration) are attached below the upper shaft chain area for the return of the feed chain. The two lubrication nipples on the lower feed roller are to be lubricated every 60 operating hours. Bent tooth angle pieces are to be changed immediately, because they will otherwise lead to the destruction of the shaft chain. -
Check the wooden and plastic strips for wear and tear before every harvesting season. Change the strips when necessary.
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9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER Changing the Shaft Chain
The simplest way is to change the shaft chain with the old chain. This takes place by connecting the old chain to the new chain. After this, the upper shaft spindle is simply spun around and the new chain is thereby pulled on. If this is no longer possible, the cover on the shaft can be removed and the new shaft chain can be pulled on with cords. The push-on elements (chain joints) are to be mounted in such a way that the securing elements point inwards.
Direction of Mounting of the Push-On Elements (Chain Joints) If transfer problems arise between the auger and the shaft chain, the installation of an additional offset element K-213B is recommended besides the mounting of the discharge blades on the auger. The distance between the shaft chain and the auger is thereby reduced. A check has to then be done when tightening the shaft chain, though, that the shaft chain does not bump up against the auger in the header.
A
B
A....Offset element K- 213B B Push-on element E 213B
Offset element K-213B
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9A-13
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER V-Belt Drive on the Shaft
The drive belt has been provided with a spring-loaded guiding idler starting with Machine Number 31. The net spring measurement is 110 mm. The diameter of the V-belt disks has been increased starting with Machine Number 61.
110
Lower Output Shaft The cardan shaft for the header drive is mounted on the left on the lower output shaft, and the cardan shaft for a corn adapter is mounted on the right if necessary.
A
The drive disk is additionally clamped in place to the profile with a flange on the shaft. The tightening torque of the two hexagon head screws is (C) 54 Nm.
C B
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9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER Upper Shaft Spindle
B
A
C
D
The upper shaft spindle has a grease filling on the left between the two ball bearings A. The ball bearing B is only used for reversing. The double ball bearing C is to be greased every 1000 operating hours. The spindle is first mounted on the left; the securing ring D has to be applied without play on the double ball bearing C in the process. After this, the right side is mounted. Friction Clutch of the Shaft The shaft drive is protected from overload by a friction clutch. It is located on the V-belt drive disk of the shaft, on the left-hand side. A free-wheel blocks this clutch when the shaft is reversing. Mounting and Adjustment of the Clutch 1. Manually screw the slotted nut N onto the disk spring T so that there is no play. 2. Tighten down the slotted nut 450° with the sickle wrench (corresponds to 1¼ revolutions). This corresponds to a torque with bedded friction linings of 330 Nm.
N
T [04/2001]
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9A-15
CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Greasing the Upper Shaft Spindle The upper shaft spindle is to only be regreased on the right-hand side. Regreasing of the left bearing is not necessary, because it only turns when the friction clutch responds. Remove the initiator disk (1) on the right-hand side of the upper shaft spindle. Remove the securing ring (2) and the sealing disk (3) in front of the bearing. Refill with grease. Reassemble this in the reverse order. Upper shaft spindle, right-hand side 1 Impulse disk of the initiator 2 Securing ring 3 Sealing disk
Header Return The combine harvester is delivered with a header return. You can remedy a clogging of the header and the shaft with this. When the switch is actuated, there is a reversal of the direction of rotation of the working elements of the header and the shaft. If the electrical motor of the header return does not start up 5 seconds after actuation of the switch (very heavy dirt), then stop the process and clear the clogging manually. The following prerequisites have to be met for the header return to function: -
The working hydraulics are activated The threshing unit is engaged The header is disengaged The drive spindle of the shaft (upper shaft spindle) has to have come to a standstill.
This process is electronically monitored. When these prerequisites are met, the electrical motor for driving the return equipment turns on 5 seconds after actuation of the switch. Keep continually pressing down on the switch in the process. The return process is automatically shut off after 10 seconds to avoid overheating of the electrical motor. If this period of time is not sufficient to clear the header, the return can be put into operation again for a further 10 seconds by pressing the switch again after a waiting period of approx. 1 minute.
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9A-16
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER
Disassembling the Shaft The shaft has to be disassembled when the upper shaft spindle, the threshing concave or the threshing drum is changed. The shaft is coupled to the header, which is latched to the header vehicle. The pendulum frame here is locked into place by the 2 supports A. The drive belt of the upper shaft spindle, lifting cylinder, header return cable, initiator cable, ground cable and the 2 hydraulic hoses for the pendulum frame locking device are disassembled from the shaft. The shaft is supported by a connecting piece close to the upper shaft spindle. Support A for Locking the Pendulum Frame into Place
The 2 supports, No. 8, and the holders, No. 7, can now be disassembled.
Support
The shaft is now released from the combine harvester by running the combine harvester in reverse.
It is quite a bit simpler when a fork-lift truck is used. The shaft is then taken off from the front.
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9A-17
CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Shaft Design P (Mechanical-Electrical Field Tracking) The shaft of the combine harvester is locked into place mechanically when it is delivered (see the illustration). If field-tracking work is done with the header, the locking devices have to be removed.
Mechanical locking of the pendulum bar into place A Locking device 1 Hexagon head screw M 12x20 2 Disk A 13 This equipment arrangement is absolutely necessary for all of the high-cut harvesting procedures (no contact of the slip heel with the ground), for example corn pickers, a header with a rape attachment and header with sunflower equipment. Mounting Work on the Shaft The pendulum bar of the shaft has to be mechanically and hydraulically locked into place by the working cylinders for all high-cut work.
A – 1 piece, brace 4260 70279 8 with 1.--.2 pieces, hexagon head screw M 12x20-8.8 2.—2 pieces, disk A 13 .
Mounting of the Brace A on the Pendulum Frame The Following is in Effect for a Mounted Rape Table: -
Mount the profiled support section 06 018353 7 and the shim 06 018352 0, in accordance with the illustration, onto the left and right-hand side of the console of the header suspension for this.
-
Carry out this work when the header is on the header vehicle. Attach the header to the combine harvester.
-
Mount the brace 4260 70279 8 and firmly tighten down all of the screws.
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9A-20
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER
The profiled support sections have to run up to the support pipe of the shaft, and thereby block the lateral swinging of the header, when the pendulum frame and header are pulled out. When necessary, the height of the support pieces is to be varied with the aid of the shims 06 018352 0.
Laying the Profiled Support Section on the Support Pipe Hydraulic Header Locking Device The pendulum frame with the attached header is to be locked into place by the working cylinder on the shaft when the following occur: Attachment and removal of the header Any transport trips with an attached header High-cut harvesting procedure Non-compliance will lead to increased wear and tear on the mechanical parts of the field tracking.
1
2
The tension of the cable is to be checked with the pendulum frame is locked into place. The pendulum bar has to be pulled into its end position without play. The cable is tautly tightened here and the working cylinder (2) is fully moved in (max. 5 mm before the end position). The cable tension is to be set on the fork (1). A cable that has been too tautly tightened (the working cylinder cannot be fully moved in) will lead to a deformation of the pendulum bar.
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9A-21
CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Setting the Header / Pendulum Frame Spacing The front part of the shaft is called the pendulum frame. The spacing between this pendulum frame and the contact surface of the header should be 0.5 ... 1 mm. You can adjust this dimension on the left and right-hand side of the shaft with the aid of the eccentric pulley ER. Loosen the screw connections of the eccentric bolt EB for this and turn it in the gear mechanism. Firmly screw down the screw connections again after the adjustment procedure. Leeway that is correctly set is recognized when there is still paint on the lower part of the pendulum frame. One-sided wearing of the eccentric pulley is the effect of leeway that is too large.
Adjustment of the eccentric pulley AS = Contact surface, header PR = Pendulum frame ER = Eccentric pulley EB = Eccentric bolt Pre-Loaded Spring Adjust the floor pressure of the header on the adjusting spindle SS.
B
Pre-loaded spring SS = Adjusting spindle B = Bolt
Check that the two bolts B are not screwed down too tightly and thereby influence the possibilities for movement of the pre-loaded spring. In the case of a new combine harvester, paint still inhibits the movement. Grease the sliding surfaces when it is initially put into operation because of this. The pre-loaded spring will have been run in after the first 1 or 2 work days. The optimum ground pressure is reached when the header can be moved on the peaks of the outer divider with a low amount of manual force (approx. 20 kg) in the entire swivel range of the pendulum frame. In so doing, the reel has to be in its operating position. If necessary, readjust the settings. It is necessary that the header (reel in the operating position) tips forwards by itself during lowering (a minimum of 30 cm over the ground) for the proper functioning of the field tracking.
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9A-22
CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
Weight Equalization You can align the header so as to be parallel to the ground via the threaded spindle GS by weight equalization. This has to be set for each new combine harvester. This setting is to be checked again after 1 to 2 work days and readjusted if necessary.
Weight equalization on the shaft GS = Threaded spindle ZF = Tension springs
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9A-23
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER Field Tracking Design P (Electrical-Mechanical)
1 1 2 3
2
3
Switch, operating modes Switch, lodged grain Potentiometer, swivel angle
Operating Modes You can select the following operating modes with the switch (1): 1. 2. 3.
Manual High-cut Field tracking
Center position Switch pushed up Switch pushed down
If an automatic function (high-cut or field tracking) has been selected, this is displayed by the switch lighting that has been turned on. The pendulum frame is located between the shaft and the header in the case of field tracking Design P (electrical-mechanical). The longitudinal tracking is realized between the pendulum frame and the shaft. The soil pressure of the header is reduced by the upper spring assembly. Longitudinal tracking can only take place when the pendulum frame is not in one end position (fully folded to the front or to the back). If the pendulum frame is at its front end limit stop (max. swivel angle), the shaft has to be lowered to get to the operating range. If the pendulum frame is located at its back end limit stop (swivel angle 0°), the shaft has to be lifted to get to its operating range again. This shaft regulation is taken over by the automatic system when the operating switch (1) is pushed down (field tracking). The cross-wise tracking is done by the header's own weight. The lateral spring assembly creates the parallelism of the raised header.
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9A-30
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER 1.
Manual
The switch is in the center position. The automatic system is not active. The switch is not illuminated. If the manual header operation is selected, one must absolutely see to it that the pendulum frame with the attached header is always folded out forwards. The angle is not important in the process, it has to only be greater than 0°. If the pendulum frame is adjacent to the shaft (angle 0°), it is automatically locked into place in the cross-wise direction. No tracking takes place, therefore, in this direction. this can lead to an overload on the shaft with possible consequential damage. The lowest stubble height is achieved with the maximum swivel angle of the pendulum frame. A maximum swivel angle is achieved by lifting the shaft Maximum swivel angle
Swivel angle 0° 7°
Lower shaft
0°
Lift shaft
If the header is controlled manually (e.g. when there is a high filling of stones), the shaft has to always be readjusted. It is recommended that the pendulum frame limiter DRB be mounted when there are extremely uneven fields or combine harvester drivers who do not have experience with this field tracking. Pendulum Frame Limiter DRB The pendulum frame limiter DRB prevents the locking up of the pendulum frame in its rear end position. The header is therefore always tracking in a longitudinal and cross-wise direction. Mounting 1. 2. 3.
Attach the header Lower the shaft until the pendulum frame folds forward Mount the pendulum frame limiter
The pendulum frame limiter is to absolutely be disassembled before the disassembly of the header.
Mounted Pendulum Frame Limiter
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9A-31
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER 2.
High-Cut The switch is pushed up. The automatic system is activated when the threshing unit and header are switched in, which is indicated by the illumination of the switch symbol. The pendulum frame is fixed in its end position with the clamp (A) and the cable of the hydraulic header latch (see the illustration).
A The shaft drops down to the value preselected on the potentiometer (1) of the display unit when the "Lower header" key on the joystick is pressed for a short time. There is no contact between the ground and the header. The number shown in the display is not the cutting height. The upper end position of the shaft is shown in the display with "HI". If the setting is to be changed, the shaft has to first be moved into the upper end position. The value for the high-cut is then changed by turning the potentiometer (1).
Clamp
1
Lower part of the operating and display device
The lowering process is started after this, and the desired cutting height is checked.
[04/2001]
TRAINING CENTER NEUSTADT
9A-32
CROSS - FLOW CF 80 COMBINE HARVESTER 3.
9A – HEADER
Field Tracking The switch (1) is pushed down. The automatic system is activated when the threshing unit and header are switched in, which is indicated by the illumination of the switch symbol. The pendulum frame can be swiveled. The header was adjusted to the combine harvester (starting on page 9A-18). The desired cutting height was set on the 1 2 3 slip heels. The header is lowered to the ground by pressing the "Lower header" key on the joystick. The header is continually adjusted to the ground profile in the cross-wise and longitudinal direction through the slip heels by its own weight. The load on the ground is taken off the header by spring assemblies. The tilt angle of the longitudinal tracking of the header is measured by a transmitter on the pendulum frame. The shaft is automatically readjusted in both end positions so that the header is fully capable of movement again. The front switching point (the pendulum frame is fully swiveled out) brings about a lowering of the shaft. The rear switching point (the pendulum frame is almost up against the shaft) brings about a lifting of the shaft. The sickle spacing to the ground is smallest if the pendulum frame is fully swiveled out. If the pendulum frame is up against the shaft, the spacing is the greatest and the load is taken off the springs, which results in high pressure on the ground by the header. The cross-wise tracking is also blocked in this position. You can bypass the automatic system by actuating the "Lift header" key on the joystick (e.g. when obstacles suddenly appear and when turning around).
[04/2001]
TRAINING CENTER NEUSTADT
9A-33
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER Harvest Grain Lying About
1
2
3
When there is harvest grain that is lying about or in the case of hilly fields, the lodged grain switch ( 2 ) is also switched in, in addition to the operating mode switch ( 1 ). The switching status is also indicated by the switch lighting here. The rear switching point (the swivel angle of the pendulum frame is 0°) is changed over to a preselected value with the potentiometer ( 3 ) in this function. The front switching point (the pendulum frame is swiveled fully forward at 7°) remains unchanged. The swivel range of the header is thereby limited, and the sickle spacing to the ground is small. Adjustment of the Rear Switching Point with the Potentiometer 1. 2. 3. 4. 5. 6.
Start the engine Activate the working hydraulics Switch in the threshing unit and header Turn the potentiometer (3) counterclockwise into the end position Push the operating mode switch (1) down (the field tracking is switched on) The header is lowered through a lowering impulse on the "Lower header" key. The pendulum frame falls into the front end position before reaching the ground. After this, the header touches down on the ground and the sloped conveyor is raised up for a short period of time so that the pendulum frame swivels back a bit from the front end position. 7. Turn on the lodged grain switch (2) 8. Slowly turn the potentiometer (3) clockwise until the sloped conveyor is raised. Turning counterclockwise ⇒ The rear switching point is reposition in the direction of the front one. ⇒ The stubble height is reduced. Turning clockwise
⇒ The rear switching point is repositioned in the direction of the rear end limit stop. ⇒ The stubble height is increased.
Good functioning of the field tracking is obtained in this operating mode if the potentiometer is set in the position of 9 to 10 o'clock (see the illustration).
[04/2001]
TRAINING CENTER NEUSTADT
9A-34
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER Shaft Design Q (Electrical-Hydraulic Field Tracking)
The tilt of the pendulum frame can be adjusted with an adjustment spindle. The gap between the pendulum frame and the shaft can be set between 10 mm and 120 mm. The minimum has to be at least 10 mm, other wise the cross-wise tracking is interfered with. The maximum tilt of the header is achieved with a gap of 120 mm. A no-problem attachment of the header and setting down on the header delete.
Minimum 10 mm
The most favorable cutting angle of the sickle is at 60 mm. The automatic field tracking also works the best here.
60 mm The attachment and removal of the header on the header vehicle has to take place with a maximum extension of 80 mm. If the header is set down on the ground, one must always see to it that the grounds are even or, more favorable, rising (the header is tilted towards the combine harvester). A maximum extension of 120 mm is beneficial here.
[04/2001]
TRAINING CENTER NEUSTADT
9A-40
CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
The tilt angle of the header is set on the spindle.
[04/2001]
TRAINING CENTER NEUSTADT
9A-41
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER Field Tracking Design Q (Electrical-Hydraulic)
Operating and Display Device
7
8 MAN
Automatic Key on the Joystick
9 RTC
10 HT
15 FLOAT
HEADER CONTROL
11 ** MODUS HT ** MIN MAX NIEDRIGER HOEHER TASTE AB TASTE AUF
13
12 16
TEACHIN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
MANUAL
RTC
HT
FLOAT
OPTION
STOP
1 2 3 4 5 14 6 KEY Teach-In mode KEY Manual Operation mode KEY High-Cut mode KEY Field Tracking mode KEY Support Pressure Control mode KEY Stop LED display Manual Operation mode LED display High-Cut mode LED display Field Tracking and Cutting Height Guide mode LED display Support Pressure Control mode KEY Up KEY Down DISPLAY Key OPTION for displaying accessory functions Key Sensitivity Lift / Lower Mode HT (field tracking) Key Sensitivity Right / Left Mode HT (field tracking)
[04/2001]
TRAINING CENTER NEUSTADT
9A-42
CROSS - FLOW CF 80 COMBINE HARVESTER
9A – HEADER
If the field position is activated, the field tracking is in the MANUAL mode. LED MAN is constantly illuminated. Each automatic function (Keys 1; 3; 4; and 5) is first preselected by pressing the respective key. LED RTC, HT or FLOAT flashes. This function is then activated by pressing the automatic key on the joystick. The LED is constantly illuminated. Manual bypass is always ensured; the field tracking automatically switches back into the MANUAL mode. TEACH-IN The control unit recognizes the weight and regulation ** MODUS TEACH-IN ** data of the attached header and coordinates these TEACH-IN LAEUFT values with the program. The TEACH IN can be carried out regardless of the field position. ABBRECHEN MIT STOP! The program runs automatically up to the entry of the parallelism. The TEACH IN is to be carried out when there is a change in the weight of the header or a transmitter change. MANUAL The header is exclusively moved via the key for moving the header on the joystick (lifting, lowering, ** MODUS MANUAL ** swiveling). The probe skids and support pressure EINSTELLUNG control (all of the transmitters) are not in operation; HUBZEIT SENKZEIT the header orients itself horizontally starting at TASTE AUF TASTE AB around 2/3 of the lifting height. Note: The lifting and lowering speed can be set here in accordance with the individual wishes of the driver by means of the UP and Down keys for all of the operating modes. RTC High-Cut The header is only regulated through the transmitter on the shaft. There is an automatic changeover ** MODUS RTC ** to the value set in the support pressure control when there is contact with the ground. There is no SCHNITTHOEHE XXX % NIEDRIGER HOEHER cross-wise tracking. The adjustment of the cutting TASTE AB TASTE AUF height is set via the UP and DOWN keys to between 0% (approx. 15 cm over ground level) and 100% (uppermost position of the sloped conveyor, approx. 115 cm). HT Field Tracking The header is guided via 4 probe skids on the header in a field-tracking way (cross-wise and longitudinally). ** MODUS HT ** The header orients itself horizontally during lifting, starting at approx. 2/3 of the lifting height. The cutting MIN MAX NIEDRIGER HOEHER height adjustment is set via the UP and DOWN keys. TASTE AB TASTE AUF The stubble height comes to approx. 5 cm to 30 cm. If the header is tilted forwards by the maximum amount with the adjustment spindle, the stubble height is approx. 2 cm. FLOAT can be additionally selected after pressing the Option key twice. The field tracking now switches from HT to FLOAT and back after the automatic key is actuated. The probe skid pairs are connected when there are deep marks of travel lanes.
[04/2001]
TRAINING CENTER NEUSTADT
9A-43
9A – HEADER
CROSS - FLOW CF 80 COMBINE HARVESTER FLOAT SUPPORT PRESSURE CONTROL The header is supported on the ground with a certain portion of its weight. The support pressure control can be set by means of the UP and DOWN keys between 5 and 50%.
** MODUS FLOAT ** AUFLAGEDRUCK XX % NIEDRIGER HOEHER TASTE AB TASTE AUF
OPTION Functions Key The following 5 functions can be selected by pressing this key several times. One pages on further with the UP or DOWN keys in the respective function. The "OPTION" key is only active when the threshing unit and header clutch is shut off. The display has to be at "MANUAL MODE" (the lifting and lowering speeds menu is not permitted to be selected). 1. Display of the Teach-In values (Press once)
* ANZEIGE TEACH-IN * ** ANALOGWERTE ** ANZEIGEN
2. Menu for setting the mode changeover HT, RTC to FLOAT (Press twice)
TASTE AB
*MODUS-UMSCHALTUNG * *HT,RTC ZU FLOAT ** Status: XXX AENDERN TASTE AB
3. Menu for setting the cross pendulum speed (Press 3 times)
4. Menu for carrying out a program reset (Press 4 times)
**GESCHWINDIGKEIT** **QUERPENDEL ** MAX MIN TASTE AB TASTE AUF ** PROGRAMM-RESET ** TASTE AUF 5 SEKUNDEN DRUECKEN RESET AUSGEFUEHRT
5. Language selection German / English / French / Russian (Press 5 times)
*SPRACHE***LANGUAGE* *LANGUE**** ЯЗЫК* DEUTSCH FRANCAIS ENGLISH РУССКЙ
One goes into the next menu, or back to the starting display (even with "STOP") of the "MANUAL MODE: with every further push of the "OPTION" key.
[04/2001]
TRAINING CENTER NEUSTADT
9A-44
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 9B Threshing Unit
CROSS - FLOW CF 80 COMBINE HARVESTER
9B
9B – THRESHING UNIT
THRESHING UNIT Table of Contents Page
Stone Trap
9B - 2
Threshing Basket
9B - 3
Awner
9B – 6
Threshing Drum
9B – 7
Threshing Drum Shaft
9B - 8
Threshing Drum Variator
9B – 10
2nd Drum
9B - 21
3rd Drum
9B – 25
4th Drum
9B – 30
[04/2001]
TRAINING CENTER NEUSTADT
9B-1
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Stone trap The stone trap is an enclosed space before of the concave. Incoming stones are forced by the threshing drum into this chamber and displace the crop from the stone trap. Take care to remove trapped stones early enough. The actuating lever BT for opening the stone trap guard is located between the right-hand driving gear and the side frame.
How to empty the stone trap BT = Actuating lever AR = Locking mechanism
Move the actuating lever briefly to the top and to the left hand side. Then you can swing it some 90° to the front. This causes the hinged guard to open with the trap contents being discharged. Empty the stone trap every day, for which purpose the diesel engine must always be shut off.
The prestress of the rubber seal of the stone trap guard can be adjusted at the slot (arrow) of the actuating lever. After each harvest season, the guard hinge must be preserved from corrosion after the final cleaning.
Rubber seal
[04/2001]
TRAINING CENTER NEUSTADT
9B-2
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Threshing unit The threshing unit is composed of a concave with mounted awner, separating basket, preparation bottom with spread auger, threshing drum, preseparator, separator and stripper drum. The speed of the threshing drum is adjusted via an electrically operated variator. A step-down gear is available for special crops. The threshing drum adjusts the speeds of the 2nd, 3rd and 4th drums. The separating basket beneath the 2nd and 3rd drums can be lowered in three positions by means of a lever (optional: 4 positions for very dry harvesting conditions with an increased chaff percentage). A variable three-height spread auger is located at the end of the preparation bottom. An additional unventilated gravity stage is provided at the end of the grain pan.
Concave with awner Clear opening CF 80 spare part number Grain concave 7.5 mm 061000603 Grain concave 9.7 mm 061001364 Grain concave 12.5 mm 31303792 Corn concave 15.8 mm 060127298 The closely-braced grain-threshing basket (7.5 mm) is recommended for very dry harvesting conditions. The broadly-braced grain threshing basket (12.5 mm) is advantageous for high yields and very moist usage conditions´ Concave wear becomes visible at the bars. If the concave bars are worn, the concave can be turned round by 180°. This is only true for grain concaves. Also check the concave does not bulge. Single concave wires can be obtained as spare parts. When changing over to corn or sunflowers, take care to cover the stone trap, demount the awner flaps and close the threshing drum. A clover huller is available for threshing clover, alfalfa etc. Mount it onto the concave (see Chapter 10) [04/2001]
TRAINING CENTER NEUSTADT
9B-3
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Checkup and adjustment of the concave -
-
-
-
-
Let the machine idle for 2 to 3 minutes. Lift and lower the concave electrically 2 to 3 times to its limit positions and check the concave setting mechanism for easy movement. KL Lower the concave down to largest gap and then lift EL it again until the pointer of the mechanical indicator exactly shows the scale value 2 for grain, or the scale value 5 for corn. D2 Open the two inspection covers (beneath the drum D1) on both side frames. Turn the threshing drum by hand until you see the D1 D2 beater bar marked with x on its front face. Measure the clearance between the threshing drum and the concave bars always from this beater bar. Check the adjustment at the 3rd concave bar (EL) and at the 10th (KL) concave bar on the left and on the right. Check the concave especially for proper parallelism. The reference dimensions are stated in the table below.
Crop type
EL (mm) 3rd bar
KL (mm) 10th bar
Grain 9+1 15±2 Corn 32-1 35±2 Sunflowers 32-1 35±2 Corn cob mix (CCM) 14+1 25±2 , If the concave adjustment needs to be corrected proceed as follows: ∗ Loosen the idler for the 2nd drum and shift it to the top. ∗ Open the inspection cover D2 (both sides). ∗ Adjust the concave in parallel with the threshing drum according to the table, using the adjusting nuts (SM) of the concave rod. The run-in clearance is to be measured at the 3rd concave bar (EL) and the run-out clearance at the final concave bar (AL). ∗ Turn the beater bar, which is marked with x, over the 3rd concave bar. ∗ Make the adjustment for the run-in first on the right and then on the left. ∗ Then turn the beater bar, which is marked with x, over the final (14th) concave bar. ∗ After that, make the run-out adjustment on the right and then on the left. ∗ Repeat the adjusting process until the concave is fully parallel and meets all dimensions. [04/2001]
AL (mm) 14th bar
Scale value
Concave
7+1 22-1 22-1 6+1
2 5 5 2
Grain Corn Corn CCM
SM
AL
EL
TRAINING CENTER NEUSTADT
SM
9B-4
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Adjustments at the concave setting mechanism If the concave setting mechanism is in need of repair, it must be readjusted afterwards. When the pointer of the concave gap indicates the scale value 2, a spindle travel of 30 mm is visible. If the in-cab indicator shows another value, loosen the angle sensor module and turn it until the in-cab indicator points to the number 2.0. The two sensors operate as limit switches and must be adjusted in accordance with the drawing.
[04/2001]
TRAINING CENTER NEUSTADT
9B-5
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Awner The awner is for the additional removal of awns. In working position the awner flap closes the concave run-in section down to the 4th concave bar. So a crop pad will build up in this section causing a rubbing effect and the breaking of the awns.
Lever H for adjusting the awner flap Awner flap (Lever H set to de-awning)
Adjustment of the awner flaps H = Lever E = Awner flap F = Thumb screw Position I = Awner flapped back Position II = Awner flapped in Whenever you should have to demount the concave or the awner flap, make sure during remounting that the awner flaps are properly positioned for lever position II. Don’t install the awner with the corn concave. The separating surface of the concave is reduced during awner operation thereby reducing the threshing output.
[04/2001]
TRAINING CENTER NEUSTADT
9B-6
CROSS - FLOW CF 80 COMBINE HARVESTER 1st drum
9B – THRESHING UNIT
threshing drum
The threshing drum is for threshing the crop. It has a diameter of 600 mm and 8 beater bars. It is dynamically balanced. The drum speed is adjusted in steps between 386 rpm and 1240 rpm by electrical operation of a variator located on the intermediate shaft. Optionally, a threshing drum gearing can be mounted onto the drum shaft. The gearing has two switching positions. Position 1 is the direct gear ratio for the speed range of 386 rpm to 1240 rpm. Position 2 is a speed reduction from 216 rpm to 680 rpm. Beater bars Should any or several beater bars have become obsolete due to wear or foreign body impact, then note the following: -
-
Change the opposite beater bar as well. Only install beater bars having no or just minute weight differences (maximum: 50 grams). Clean the threshing drum by remove dirt deposits. Tighten the fixing bolts for the beater bars with a stud torque of 110 Nm and lock the connections with counternuts.
There are left-hand and right-hand beater bars, which are positioned alternately.
Left-hand beater bar
Right-hand beater bar
Left beater bar Right beater bar
[04/2001]
CF 80 Spare Part Number 4270718947 4270718930
TRAINING CENTER NEUSTADT
9B-7
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Threshing drum shaft The threshing drum shaft drive is along the right-hand side by means of a V-belt pulley or, optionally, a threshing drum step-down gear. The left-hand side drives the drums 2 to 4. The threshing drum is keyed to the shaft. The featherkey and shaft groove are matched and numbered. The right bearing is the locating bearing. The left bearing is the guide bearing and fixed with a clamp sleeve. The clearance between the right-hand machine frame and the drive V-belt pulley is 67 mm. The clamp sleeve is tightened with a stud torque of 150 +30 Nm. Right bearing – standard gear
Right bearing with step – down
67 20
Left-hand side The clearance between the shaft end and the machine frame is 101 mm. The stud torque of the clamping sleeve is 150 +30 Nm. The Vbelt pulley is mounted with zero play down to the shaft collar.
150 +30 Nm [04/2001]
TRAINING CENTER NEUSTADT
9B-8
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Mounting the threshing drum shaft 1.
2.
3. 4.
5.
Preassemble the shaft by mounting to it the right-hand locating bearing of the threshing drum. To do so, drive the self-aligning ball bearing down to the shaft collar and then mount the bearing housing. Insert the preassembled drum shaft from the right-hand side (variator side) through the threshing drum. The clearance between the left shaft end and the machine frame is 101 mm. Bolt the right bearing housing to the machine frame. Bolt the left bearing housing. Then mount the clamp sleeve with the self-aligning ball bearing and tighten the counternut with a stud torque of 150 +30 Nm. The clearance between the self-aligning bearing and the bearing housing cover is 5 mm. Centre the threshing drum in the machine frame. The featherkeys are matched and marked with the appropriated grooves.
Drum Rod The threshing and separating drum can be turned when necessary with the drum rod (5) on the left-hand side of the machine. The adapter (1) is screwed to the V-belt disk (2) with the screws (3) (M10x50) to turn the threshing drum. After this, the drum rod (5) is pushed up and locked into place with the screw (4) (M16x50) and the hexagon nut.
The adapter (1) is to be removed before the initial operation of the combine harvester to avoid damage to the drives. Push up the drum rod (5) onto the shaft end on the left-hand side of the separating drum and lock it into place as previously described to turn the separating drum.
[02/2001]
Drum rod 1 Adapter 2 V-belt disk 3 Screw M 10 x 50 4 Screw M 16 x 50 5 Drum rod
TRAINING CENTER NEUSTADT
9B-9
9B – THRESHING UNIT
CROSS - FLOW CF 80 COMBINE HARVESTER Threshing Drum Variator
The threshing drum variator regulates the threshing drum speed on a continuous basis from 1250 r.p.m. to 386 r.p.m. The full threshing drum speed of 1250 r.p.m. is only reached when there is a stretching of the belt by 2%. A speed range of 660 r.p.m. to 216 r.p.m. is additionally available when a threshing drum gear is used. The drive variator is adjusted with a lifting spindle motor (linear motor). The output variator is spring-controlled. It has an automatic torque amplifier. Adjustment Specifications The openings (A and B) of the variators are measured with a setting of the maximum speed of the threshing drum (new belt, 1200 r.p.m. to 1250 r.p.m. with a 2% stretching of the belt) and 1150 r.p.m. with a vertical motor. The dimensions A and B are to be measured from outer edge to outer edge of the variator disks. The difference per variator has to be the same. This means that the output variator regulates the same path together with the drive variator. One can draw the conclusion that the servomotor is correctly set and that the variator belt is not worn when the regulation path of both variators is the same.
A
Drive Variator
B
Output Variator
If the maximum threshing drum speed is no longer reached, the variator disk openings (A and B) are to be measured with a drive variator with maximum joint regulation. The following conclusions can be drawn with the aid of these measurements. Measurement A Measurement B (mm) of the (mm) of the outdrive variator put variator
84 Greater than 84
84 Greater than 84
[02/2001]
Smaller than 140 Smaller than 140 140 140
Cause
REMEDY
The belt is stretched more than 2.5 %
Change the belt
The servomotor is set wrong
Move the servomotor out
The variator belt has excessive tension Increased belt wear !!!
Move the servomotor in
TRAINING CENTER NEUSTADT
9B-10
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Adjustment of the Servomotor The servomotor of the variator is correctly set when the regulation paths (Measurement A/B with a threshing drum speed of 1200 r.p.m. and 1150 r.p.m.) are the same for both variators. If the regulating distance is greater at the drive variator, the lifting spindle motor is to be moved to the machine frame. The direction of the movement of the lifting spindle motor can also be found through the dimensions (A and B) in the table on page 9B-10. If adjustment of the lifting spindle motor is necessary, find out as the first thing the dimensions A and B for a threshing drum speed of 1200 r.p.m. and next for 1150 r.p.m. Regulating distance, drive variator = A 1200 – A 1150 Regulating distance, output variator = B 1200 – B 1150 The measurement for the movement of the servomotor is obtained by multiplying the difference between the regulating distance of the drive variator and that of the output variator by 2.6. The setting of both variators is to be checked when the maximum threshing drum speed is not reached and after a belt change and newly adjusted when necessary.
Mounting Work on the Spring-Controlled Output Variator Take-Off Equipment for Variators You can carry out the work steps below with the take-off equipment (Replacement Part Number 31288148): • Pull apart the variator disks to make it possible to put on the V-belt. • Pull the variators off the shaft. Completely disassemble the variator.
[02/2001]
TRAINING CENTER NEUSTADT
9B-11
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Changing the Variator Belt The threshing drum is to be regulated with a running motor at the maximum speed. The spring-controlled variator is now separately regulated, and the electricallyactuated variator is jointly regulated. Shut down the motor. After removal of the torque amplifier (wedge-shaped segments, fastened with 3 hexagon socket screws each), the springloaded variator is to be blocked in this position with the 2 screws M 12 x 120. The electrically-adjustable variator is to be regulated with the servomotor (LM) when the machine is at a standstill (page 4-68). The variator can also be regulated manually after the bolt (B) is undone. You can now change the variator belt. The settings of the variators are to be checked after the change.
Threshing Drum Regulation Mechanism
Screws M12 x 120 8.8 The tip of the screws has to be turned so as to be round.
Mounted screw on the variator. The segment has to be disassembled beforehand so that it fits into the threaded hole. 2 screws are to always be screwed in equally to prevent a tipping of the variator disk.
[02/2001]
TRAINING CENTER NEUSTADT
9B-12
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Demounting the drive variator
Protect the variator from falling down!
Pull-off device for variators
-
Remove the belt. Detach the linear motor (LM) by loosening the 2 bolts (B) Demount the U-clamp (BG) Loosen the bolt (S) M 16 x 1 x 35 – 10.9 (torque 200 Nm) Screw the ejector screw (DS) M 20 x 75 into the tapped bore, which has become vacant, to force the variator off the shaft.
[02/2001]
TRAINING CENTER NEUSTADT
9B-13
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Demount the drive variator (spring-loaded)
-
-
-
-
Remove the belt Loosen 2 opposite hexagon head bolts (SS) M 10 x 1 x 35 – 10.9 (torque 60 Nm secured with “mediumstrength” locking paste) at the cover of the variator. Loosen the hexagon head bolt (M) M 12 – 8 and demount the support bracket (SW). Screw the extracting disc (A) on the axle thread down to the variator Connect the extracting disc (A) with the variator using stud bolts (AS) M 10 x 1 x 45 – 10.9 Pull off the variator by turning the variator or extracting disc
Loosening more than 2 bolts (SS) is highly dangerous and shall be done only by people with appropriate experience using the appropriate mounting tools : spindle and back holder.
Pull-off device for variators
Pull-Off Disk A with Screws M 10 x 1 x 45 – 10.9 The pull-off disk is mounted after the angled support piece is removed.
[02/2001]
TRAINING CENTER NEUSTADT
9B-14
9B – THRESHING UNIT
CROSS - FLOW CF 80 COMBINE HARVESTER Disassembling the Output Variator (Spring-Loaded) The output variator can only be disassembled when it is removed. When the take-off equipment (31288148) is used, the inner ball bearings have to be mounted in the variator. • • •
• • • • •
C
B
A
Push Bushing A onto Spindle B Guide the spindle in through the bore hole of the variator until the bushing is up against the ball bearing Screw the holder C onto the spindle until it is up against the screw heads. The 2 threaded holes of the screws that have already been removed have to be visible here. Take-Off Equipment of the Output Variator Remove the 2 visible screws A = Bushing Turn the holder so that 4 screw heads B = Spindle that have not yet been taken out are C = Holder accessible in the bore holes of the holder Turn the spindle until the holder C is firmly against the cover and the spring is put under light tension Remove the remaining 4 screws Release the tension on the spring by turning the spindle
Removing the screws on the cover after bracing with the take-off equipment Unscrewing more than 2 screws (SS) is life-threatening and may only be done by persons with the appropriate experience and with the assembly tools of spindle and holder that are suitable for this !
[02/2001]
TRAINING CENTER NEUSTADT
9B-15
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Drive Variator from DCF 880001 to DCF 88 0300 Lube points on the electrically actuated variator The rear disc of the variator has 3 lube points. Regulate the variator such that the belt in the spring-loaded variator runs inside. Lock this position with two bolts M12X120. The lube points are located at the rear variator disc (see picture). Lubricate there every 360 operating hours or annually. ^
A
A
A B The 2 lube points A are located on the inner variator disc and offset by 180°. The lube point B is at the rear adjusting module of the variator.
Weekly adjustment of the variator over the entire speed range ensures easy movement of the adjusting
[02/2001]
TRAINING CENTER NEUSTADT
9B-16
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
Spring-actuated variator The electrically-adjustable variator has to be set after a belt change takes place. The minimum variator opening is 84 mm for the spring-operated variator. The maximum opening is 140 mm. The arrow indicates the lube point in the rear variator discs. The lubricating interval is 360 operating hours or annual.
[02/2001]
TRAINING CENTER NEUSTADT
9B-17
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
2nd drum – preseparator drum The 2nd drum conveys the crop from the threshing drum to the separating drum. It is serrated circumferentially and makes a first separation of the crop. The 2nd drum is clamped in centre position to the shaft with 130 Nm at the ends. Power transmission between the shaft and the drum body is by featherkeys. The right bearing is designed as the locating bearing. The left bearing is the guide bearing and tightened with 150 +30 Nm. Mounting 1. Insert the shaft from the left to the right through the 2nd drum. Take care to turn the shaft such that the featherkeys fit the groove of the drum. 2. Then mount the right bearing housing. Mount the duplex ball bearing without play and secure it with a retaining ring on the shaft. The bearing cover fixes the duplex ball bearing in axial direction.
Right bearing 3. Mount the left-hand self-aligning ball bearing and make sure the self-aligning bearing has a clearance of 5 mm to the outer edge of the bearing housing. Tighten the clamp sleeve with 150 +30 Nm. Screw down the bearing cover.
64
4. Mount the double V-belt pulley with a distance of about 64 mm between the machine frame and the inner edge of the big V-belt pulley. Proper alignment with the drive V-belt pulley on the threshing drum has priority over the 64 mm clearance. 5. Finally, centre the 2nd drum within the machine frame and tighten the 2 clamped connections with a torque of 130 Nm.
M=150+30 Nm M=130
The 2nd drum is accessible after the grain tank bottom is removed.
[02/2001]
TRAINING CENTER NEUSTADT
9B-21
CROSS - FLOW CF 80 COMBINE HARVESTER
9B – THRESHING UNIT
3rd drum – separating drum
12 ± 2
The separating drum is the 3rd drum. It is a welded design thus forming a complete subassembly. Again, the locating bearing is arranged on the right and the guide bearing on the left. And again, the stud torque is 150 +30 Nm. The separating drum is keyed to the shaft and secured in axial direction with a stud torque of 70 Nm.
6
Mounting 1.
2.
3.
Mount the right bearing housing with the duplex ball bearing with no play onto the shaft Insert the shaft from the right to the left through the separating drum. Take care to turn it such that the featherkeys fit the groove of the drum. The right bearing housing is at the machine frame. Then mount the left bearing housing with clamp sleeve and self-aligning ball bearing. The clearance between the outer edge of the bearing housing and the self-aligning ball bearing must be 5 mm. Then tighten the sleeve with 150 +30 Nm
4.
Then shift the separating drum on the shaft such that the clearance between the right side frame and the separating drum is 16 mm (centre position within the machine frame). Tighten the two clamping screws at the drum body with a torque of 70 Nm.
5.
Finally, mount the V-belt pulley with a clearance of approximately 123 mm from the side frame (see picture). Again, the proper alignment with the drive on the 2nd shaft has priority over the 123 mm clearance.
Right bearing
70 Nm
The 3rd drum is accessible from the top after the bottom of the grain tank is removed.
[02/2001]
TRAINING CENTER NEUSTADT
9B-25
9B – THRESHING UNIT
CROSS - FLOW CF 80 COMBINE HARVESTER
4th drum – stripper drum The task of the 4th drum is to pass the straw onto the feed of the straw walker. It has no separating function. The mounting position is defined by a groove in the shaft. Left bearing
116
Right bearing
60 Nm
30 Nm Mounting 1. 2. 3.
4.
Insert the shaft from the left to the right through the 4th drum. Then slide the clamp bearing on the right onto the shaft. After mounting the retaining ring on the right-hand side of the shaft, mount the shaft with no play and tighten the clamp connection at the ball bearing. After mounting the left ball bearing, attach the V-belt pulley with a clearance of about 116 mm (measured between the machine frame and the outer edge of the hub of the V-belt pulley). Again, alignment has priority, like for the other V-belt pulleys. Then tighten the stripper drum on the shaft each time with 2 bolts and a stud torque of 60 Nm or 30 Nm (see picture on the left). The position of the drum is defined by 2 grooves in the shaft with the bolts pressing the grooves.
The 4th drum is accessible from the top after the bottom of the grain tank is removed.
[02/2001]
TRAINING CENTER NEUSTADT
9B-30
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 9C
Cleaning Unit
CROSS - FLOW CF 80 COMBINE HARVESTER
9C – CLEANING UNIT
9C CLEANING UNIT Table of Contents Page Distributing Auger, Slope
9C – 2
Cleaning Unit Drive
9C - 3
Grain Pan
9C - 4
Sieves
[10/2000]
^
TRAINING CENTER NEUSTADT
9C - 6
9C-1
CROSS - FLOW CF 80 COMBINE HARVESTER
9C – CLEANING UNIT
Cleaning The three-stage cleaning consists of the cascade sieve (D), top sieve (E), ear sieve (F) and bottom sieve (G). The sieves are adjustable. There is the possibility to use a roundhole sieve as bottom sieve. For proper adjustment refer to the adjustments chart. A preparation bottom (A) is located upstream with an unventilated additional gravity stage. A variable-height spreader auger (B) ensures uniform distribution of the crop in hillside operation.
A
B D
E
F
G
Hillside spreader auger A spreader auger is standard. It is located at the end of the preparation bottom, ensuring uniform distribution in hillside operation. The crop tends to flow downhill and is conveyed uphill by the welded contra-rotating auger spirals. The auger screw always turns in the same direction and can be adjusted in height by means of the end shields (left and right). High position
Level land operation (crop will not reach the rotating auger) Works setting for delivery
Middle position
Hillside operation for much crop
Low position
Hillside operation for normal or little crop
The spread auger must be adjusted to the same height both sides. Never set the auger to a lower level than actually necessary. Lowest position in level land operation will increase loss.
[10/2000]
TRAINING CENTER NEUSTADT
9C-2
CROSS - FLOW CF 80 COMBINE HARVESTER
9C – CLEANING UNIT
Cleaning drive The cleaning drive operates the preparation bottom and the cleaning shoe by eccentric movement. Silent sleeve bearings are used. Silent sleeves are wear parts. Problems with individual sieves at the preparation bottom or cleaning shoe are mainly due to defective silent sleeves. Silent sleeve bearings are rubberised units.
Driving shaft
36
90
90
125
The inner eccentric bearings for the grain pan drive are mounted with a clearance of 90 mm between the bearing and the shaft collar. The outer eccentric bearings are for the cleaning drive. The right bearing is mounted with a clearance of 36 mm between shaft end and bearing. The driving pulley is located on the left-hand side. That is why the clearance between the bearing and the shaft end is 125 mm. The basic condition for trouble-free operation is that the driving shaft is installed at an exact right angle. To do so, mount the shaft with the V-belt pulley. Put a rule horizontally on the face the V-belt pulley and measure the distances of the ends with regard to the machine frame. If the distances are not the same, the shaft has no right angle.
[10/2000]
TRAINING CENTER NEUSTADT
9C-3
CROSS - FLOW CF 80 COMBINE HARVESTER
9C – CLEANING UNIT
Mounting the grain pan shims
260 Nm
Use shims to parallel the preparation bottom with the front fixation. Mount all rockers and push rods with no play and tighten them in drive centre position (featherkey on the driving shaft is either in top or in bottom position).
Rocker arms Mount the rockers with no play. The 24 mm dimension has no first priority.
[10/2000]
TRAINING CENTER NEUSTADT
9C-4
CROSS - FLOW CF 80 COMBINE HARVESTER
9C – CLEANING UNIT
Sieve shoe The sieve shoe is driven by the cleaning drive via a push bar. The shoe houses the 3 sieves (cascade sieve, top sieve with ear sieve, and bottom sieve). They are divided across the width for ease of replacement. All sieves are fixed with bolts. Changing the bottom sieve To be able to replace the bottom sieve, demount the cleaning rear panel and, if required, the top sieve. When mounting the sieve, clean thoroughly the guide rails and limit stops. Residues in these zones will cause the sieves to work loose and lead to consequential damage. Using a round-hole sieve as bottom sieve is required only in very special conditions. The clear width of slat openings can be adjusted to the actual crop type and to various harvesting conditions. Use the levers SH for adjusting the slat openings of the chaffer and ear sieves. The levers are located at the end of the cleaning shoe. The adjusting gauge is the black wedge in the toolbox.
Sieve arrangement and fixation KKS = cascade sieve KS = top sieve ÄS = ear sieve V = connection
Adjust the slatted bottom sieve using the adjusting lever (ST) with the scale (in mm) on it.
When adjusting the sieves, take care to ensure that “opening” is the last motion of the sieve. So the sieves have no play and will not “shut“ automatically. When installing sieves, make sure the guide rails and limit stops are free from debris.
[10/2000]
TRAINING CENTER NEUSTADT
9C-5
CROSS - FLOW CF 80 COMBINE HARVESTER
9C – CLEANING UNIT
The following additional sieves are available as optional equipment: Bottom sieves Description Round-hole sieve 2.5 Round-hole sieve 3.0 Round-hole sieve 4.5 Round-hole sieve 12 Round-hole sieve 16 Round-hole sieve 20
[10/2000]
D
Top sieves Article number Description 31302951 Graepel sieve – corn
Article number 31291947
D
31302968 Chaffer sieve 1-5/8
31291102
D
31290608 Top sieve – corn D 16
31320086
D
31290624 Top sieve – corn D 20
31320094
D
31302976 Graepel sieve – CCM
31320100
D
061078086
TRAINING CENTER NEUSTADT
9C-6
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 9D
Elevators and Belt Drives
CROSS - FLOW CF 80 COMBINE HARVESTER
9D – ELEVATORS
9D ELEVATORS AND BELT DRIVES Table of Contents Page Elevators
9D – 2
Belt Drives
9D - 4
Belt Couplings
9D - 4
Belt and Chain Diagrams
9D - 6
[10/2000]
TRAINING CENTER NEUSTADT
9D-1
CROSS - FLOW CF 80 COMBINE HARVESTER
9D – ELEVATORS
Elevators The elevator chains are accessible through covers located in the elevator. Check the elevator chains for easy movement of rollers and for defective pushers. Whenever pushers have to be changed, it is necessary to use new hexagon head bolts and nuts. Check the conveyor chains of the grain elevator and of the tailings elevator for correct tension. Never tension the chains of the grain and tailings elevators too tightly. Access to the elevator chains R Rollers Pushers Chains tend to expand especially during M SKS Hexagon head bolt the first days of operation. Therefore, SKM Hexagon head nut readjust the tension of the chains after the first 50 operating hours. Verify the chain tension at regular intervals of 200 operating hours.
It must be possible to lift the chain. The pusher can be tipped over (16 mm)
How to tension elevator chains
[10/2000]
TRAINING CENTER NEUSTADT
9D-2
CROSS - FLOW CF 80 COMBINE HARVESTER
9D – ELEVATORS
Check the conveyor chains of the grain and tailings elevators for correct tension. Never tension the chains of the grain and tailings elevators too tightly. Tension the conveyor chains using the tensioning screws SS at the elevator heads EK (tailings elevator – grain elevator). To do so, loosen the counternut KM or lock nut FS.
Always release the tension of the driving belt before tensioning the tailings elevator. After the adjustment of the elevator chain tension, tighten the driving belt again.
If it is necessary to replace the elevator chain, move the chain until the joint is at the lower cover. Then open the joint, remove the upper cover from the elevator head and take out the chain to the top.
How to tension the chain of the tailings elevator EK Elevator head KM Counternut (2x) SS Tensioning screw (2x)
For mounting the chain, proceed in reverse order.
How to tension the chain of the grain elevator EK Elevator head KM Counternut SS Tensioning screw (1x) FS Lock nut (2x)
[10/2000]
TRAINING CENTER NEUSTADT
9D-3
CROSS - FLOW CF 80 COMBINE HARVESTER
9D – ELEVATORS
V-belt drives In drives using V-belt sets always replace full sets of V-belts. Just changing single belts would have no effect. Centre the belt guide and belt mount to the belt run. The distance between the belt and the belt guide or belt mount should be some 6...8 mm when engaged (or with mechanical load on the idler pulleys). All Vbelt pulleys and idlers within the particular V-belt drive must be in alignment. The Vbelt strands of the straw walker drive (cross band) shall not be in touch. Clearance between belt and belt guide Checking the belt tension The belts must be exactly tightened to allow for full power transmission. The belt tester (Ordering No. 4221 65923 6) allows the belt tension to be determined in the following way: - Place the tester at a right angle onto the middle of the belt to be tested and load the tester with the hand force F. The belt tension is correct if the belt, when loaded, adopts the angle determined by the guide 3 and maintains the same angle outside the guide region, i.e. there shall be no bend at the end of guide. - In this condition, the spring must be compressed such that the pin with the corresponding ring groove of the setting scale 1 is in accordance with the values specified in the belt run drawing. - (1 scale division = 10 N). - In case of deviations, readjust the idler pulley. How to check belt tension using the belt tester F Hand force 1. Setting scale 2. V-belt to be tested 3. Guide
[10/2000]
TRAINING CENTER NEUSTADT
9D-4
CROSS - FLOW CF 80 COMBINE HARVESTER
9D – ELEVATORS
Adjustment of the belt coupling Adjust the belt guides and stops as shown in the pictures. The clearance between the outer edge of the V-belt pulley and the guard is 10 mm. After coupling, that would be a gap of about 5 mm between the V-belt and the guard. If the regulating travel is limited by the final stop and a drop in speed occurs during threshing (slipping belt), then the belt has reached its authorised maximum elongation and needs to be replaced. In case of V-belt oscillations, the belt has reached the Reference dimensions at the thresher coupling end of its service life and needs to be replaced.
Never use spare belts other than genuine CASE belts!
The dimensional data indicated in the belt coupling refer to the clearance between the outer diameter of the V-belt pulley and the inner edge of the belt guide.
Reference dimensions at the header coupling
Engage and disengage the thresher and straw chopper couplings only during no-load operation of the diesel engine!
Reference dimensions at the tank unloading coupling
[10/2000]
TRAINING CENTER NEUSTADT
9D-5
9D – ELEVATORS
CROSS - FLOW CF 80 COMBINE HARVESTER
Belt and chain run drawings – SEE LEGEND ON PAGE 9D-8 Belt and chain run drawing – right-hand side of combine harvester
srl. Drive No. 1 Intermediate shaft Transmission gear 2 Transmission gear Threshing drum 3 Intermediate shaft Grain elevator 4 Intermediate shaft Tailings elevator transmission 5 Tailings elevator transmission Tailings elevator auger 6 Motor Transmission gear 7 Transmission gear Fan 8 Motor Generator - A/C system 9 Transmission gear Separating drum 10 Grain elevator Tank feed auger gear
Z1 Z2/Z3 dw1 dw2/ n1 dw3 300- 540- 1000 540 300 356 512 1800555 173 375 1000 318
366
14 27/27
868
19
V-belt
1800555 1220400 460
Wide V-belt 71x30x2595 Joined V-belt 5 HB 2830 Narrow V-belt set 2 SPB 3750 868 Narrow V-belt SPB 2500
450/ Roller chain
450 12 B-01-73 2200 2066 Narrow V-belt set 2 SPA 1600 154 174 2066 1828 Narrow V-belt set 2 SPA 1600 173 85/128 2200 4555/ V-belt 3025 8 PK 2161 64 768 2066 172 V-belt 10x2600 460 460 Roller chain 12 B-01-70 LLBE 154
19
1000
n2/n3
164
For the V-belt drives of the diesel engine, please refer to the separate operating manual. b) recommended values for re-tightening the V-belts c) both V-belts tested together; d) only for corn, sunflowers etc. [10/2000]
TRAINING CENTER NEUSTADT
9D-6
9D – ELEVATORS
CROSS - FLOW CF 80 COMBINE HARVESTER
11
12 Belt and chain run drawing – left-hand side of combine harvester srl. Drive Z1 Z2 dw1 dw2 n1 n2 V-belt / chain No. 1 Motor 210 462 2200 1000 Joined V-belt Intermediate shaft 6 HB 4985 2 Motor 210 767 2200 602 Joined V-belt Tank unload. system 2 HB 5500 3 Motor 276 253 2200 2400 Joined V-belt Hydro 5 HB 2150 4 Intermediate shaft 130 480 1000 270 V-belt Cleaning 17x2110 5 Intermediate shaft 263 576 1000 456 Joined V-belt Upper duct shaft 3 HB 3300 6 Cleaning 224 275 270 220 Narrow V-belt Straw walker SPB 3750 7 Threshing drum 352 336 386- 360- Joined V-belt Stripper drum 1250 1160 2 HB 2120 8 Stripper drum 309 429 360- 248- Narrow V-belt set Separating drum 1160 800 2 XPB 2150 9 Separating drum 310 326 248- 235- Narrow V-belt set Straw drum 800 760 2 SPB 1900 10 Upper duct shaft 296 251 456 540 Joined V-belt Header transmission 4 HB 4400 K 11 Motor 2200 2675 Joined V-belt Chopper transmission 2 HC 3270 12 Chopper transmission 2675 3120 Joined V-belt Chopper 2 HB 6745 Chaff spreader KP2000 B 2800 (La) Chopper transmission B 1945 Spreader transmission
[10/2000]
TRAINING CENTER NEUSTADT
Belt tension b)
9D-7
CROSS - FLOW CF 80 COMBINE HARVESTER
9D – ELEVATORS
Header
Belt and chain run drawing – header srl. Drive Z1 Z2 dw1 dw2 n1 n2 No. 1 Hydromotor 15 32 0-102 0-45 Reel shaft 2 Driving shaft 15 41 540 200 Auger 3 Driving shaft 256 213 540 672 Knife drive
V-belt / chain Roller chain 10 B 1x66E Roller chain 16 B 1x74E Joined V-Belt 2 HB 3050 La
LEGEND Z1 = Z2 = dw1 = dw2 = n1 = n2 =
DRIVER – NO OF TEETH ON SPROCKET DRIVER – NO OF TEETH ON SPROCKET DRIVER – DIAMETER OF PULLEY DRIVER – DIAMETER OF PULLEY DRIVER – SPEED OF ROTATION DRIVER – SPEED OF ROTATION
[10/2000]
TRAINING CENTER NEUSTADT
9D-8
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 9E
Grain Tank
CROSS - FLOW CF 80 COMBINE HARVESTER
9E – GRAIN TANK
9E GRAIN TANK Table of Contents Page Grain Tank Extension
[10/2000]
9E - 2
TRAINING CENTER NEUSTADT
9E-1
CROSS - FLOW CF 80 COMBINE HARVESTER Grain tank top unit The diesel engine of the combine harvester can be started only with closed grain tank flaps.
9E – GRAIN TANK
The grain tank unloading system can be actuated only with the tank flaps shut (safety circuit).
For using the entire capacity of the grain tank, open the top unit by pulling it upwards as shown in the picture. The transport position (top unit folded down) is locked with a pawl, which has to be thrown over before the top unit can be unfolded.
Unfolding the top unit Checking the threshing quality The amount of grain contained in the returns is measured by a sensor in a casing between the upper ear auger and the threshing drum. This allows the operator to recognise poor machine settings. Grain sampler The device for taking grain samples from the tank is located behind the door of the left front panel. Swinging out the flap causes the bin of the grain sampler to be filled with grains last conveyed. A chute connects the feeding auger with the sampler flap. Once the sampler is flapped back, the grains will continue falling into the grain tank. Whenever the sampler is opened, the grains will for a short time fall into a small bin. This ensures that the sampler always collects grains from the last flow.
[10/2000]
Tank sampler
TRAINING CENTER NEUSTADT
9E-2
CROSS - FLOW CF 80 COMBINE HARVESTER
9E – GRAIN TANK
Auger cover in the grain tank The unloading auger is covered with roofshaped elements. The covering for the unloading auger is adjustable in height and can be set at four levels to adapt the system to the different flow characteristics of the crops in the tank. The works setting for the unloading auger cover is position 2. This setting is meant for unloading all types of grain in normal harvesting conditions and for corn harvest. Unloading auger cover Position 1: For grain with high moisture (lowest position) Position 2: For grain and corn from normal Height adjustment for the coverings of the harvesting conditions feed and unloading augers (works setting) Position 3: For very dry grain Position 4: Only for crops with very poor flow characteristics (top position) Safety clutch of the tank unloading system – only for systems built in 1999
The tank unloading system is secured with a shear bolt lock. Spare bolts are available in the bolt hopper in front of the clutch. The design of the clutch is such that only one bolt can be mounted at a time. There are two lube points (see arrows in the picture) for greasing the clutch.
[10/2000]
TRAINING CENTER NEUSTADT
9E-3
CROSS - FLOW CF 80 COMBINE HARVESTER
9E – GRAIN TANK
Prior to starting the harvest season, remove the shear bolt and check the clutch for easy movement. Grease the two lube points at the flange every 120 operating hours.
Tank unloading auger In case of downtimes exceeding 6 days, open the cover in the lower part of the vertical section of the tank unloading auger (riser auger). Clean the interior in the bottom plate zone by removing crop residues to prevent corrosion damage.
Tank feed auger Respect the following to prevent corrosion damage on the gears of the tank feed auger: -
-
In case of combine down-times exceeding 6 days, open the cover located at the lower end of the feed auger to allow any accumulated water to drain from the inside. Also remove residual moisture and crop residues. Shut the grain tank cover every day when parking the combine after work.
[10/2000]
TRAINING CENTER NEUSTADT
9E-4
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 9F Straw- Chopper and Chaff- Distributor
CROSS - FLOW CF 80 COMBINE HARVESTER
9F
9F – STRAW CHOPPER
STRAW- CHOPPER AND CHAFF DISTRIBUTOR Table of Contents Page
[10/2000]
TRAINING CENTER NEUSTADT
9F-1
CROSS - FLOW CF 80 COMBINE HARVESTER
9F – STRAW CHOPPER
Straw chopper Starting up the straw chopper Replace missing or defective cutting and counter blades. Never operate the unit with defective or missing cutting blades, because this will cause unbalance and malfunction of the rotor. In addition, rotor unbalance will cause damage to the chopper and in the region of the combine hood. Swivel the deflector to the top. Check the warning system in the straw chamber and the speed monitoring, check the clutch for proper functioning, respect the lubrication chart, make a test run for the straw chopper.
Deflector in upper position When starting the straw chopper, always run the diesel engine at low speed!
Straw screen adjustment There are two ways to adjust the spreading process for this chopper: 1. Manual adjustment The control at the straw screen offers several spreading patterns and ensures the uniform distribution of the chopped straw across the entire chopping width. A = Wide spread pattern B = Narrow spread pattern Manual adjustment of the straw screen 2. Electrical adjustment by servomotor. Adjust the windrowing width with this switch.
A pilot lamp indicates when you reach the mid-position of the guide plates during the adjustment of the windrowing width.
[10/2000]
Electrical screen adjustment
TRAINING CENTER NEUSTADT
9F-2
CROSS - FLOW CF 80 COMBINE HARVESTER
9F – STRAW CHOPPER
3. Simple screen height adjustment (three positions) with gas pressure spring suspension: High (B) – wide spread pattern Low (A) – narrow spread pattern
Height adjustment of straw screen 4. Every spreading van can be adjusted separately at the top and at the bottom (can be shifted to the left and to the right). The positions indicated by the arrows in the picture show the basic setting of the vanes.
Marking for basic setting of spreading vanes Adjustment of the counter blades Stationary chopper blades
Setting A: Only for dry and brittle straw Setting B: For moist straw with high green percentage Setting C: Only for very wet straw as well as for rapeseed and pea straw Counter blade adjustment
[10/2000]
TRAINING CENTER NEUSTADT
9F-3
CROSS - FLOW CF 80 COMBINE HARVESTER
9F – STRAW CHOPPER
V-belt tension The lengths of the spring F and of the bushing must correspond to the length of the reference plate B.
V-belt tightener
[10/2000]
TRAINING CENTER NEUSTADT
9F-4
CROSS - FLOW CF 80 COMBINE HARVESTER
9F – STRAW CHOPPER
Chopping of corn and sunflowers Please always respect the following for chopping corn and sunflowers - Demount the counter blade box - Demount the friction bars - Demount every second cutting blade - Mount the stepping-down gear Every second cutting blade shall be dismounted. Demounting cutting blades Mounting the stepping-down gear The stepping-down gear is optional.
Stepping-down gear Changed position of the idler pulley for chopping corn and sunflowers. Check the V-belt.
Position of idler pulley A 5 mm knife set is available for corn operation (Article number 31303366). It is not necessary to demount this set of blades for changing over from grain to corn. The standard blade thickness is 4 mm.
[10/2000]
TRAINING CENTER NEUSTADT
9F-5
CROSS - FLOW CF 80 COMBINE HARVESTER
9F – STRAW CHOPPER
Replacing defective cutting blades To avoid unbalance, it is necessary to change defective cutting blades immediately. As an interim solution, you can demount the defective cutting blade together with opposite cutting blade. You must immediately obtain new blades for replacement. Always use genuine curved cutting blades! Without curved cutting blades, there will be no blower effect inside the chopper, and that will have an adverse effect on spread width and spread uniformity. Also, your right of warranty will be affected by any modifications. How to demount the damaged cutting blade and to mount a new cutting blade Before starting the mounting work, clean and grease all bearing points (the stud torque of the fixing bolt is 75 Nm ). Mount the cutting blades as shown in the picture. When looking from the top onto the blades, you should see an X pattern ( )( ). Replacement of cutting blades Replacing defective counter blades Demounting: A – Remove the R-clip B – Pull out the holding bar C – Take out the defective blade Mounting: D – Insert the new blade B – Introduce the holding bar A – Replace the R-clip
Adjust the blade D such that the cutting blades can move easily. Replacement of counter blades
[10/2000]
TRAINING CENTER NEUSTADT
9F-6
CROSS - FLOW CF 80 COMBINE HARVESTER
9F – STRAW CHOPPER
Straw chopper troubleshooting Trouble
Remedy
Chopper is working unsteadily: (unbalance)
⇒Missing or damaged cutting blades – change or replace them ⇒The mounted cutting blades have different thicknesses. Only use genuine 4 mm curved cutting blades. ⇒Cutting blades are seized – make them move ⇒Chopper shaft bearing is defective – change the bearing ⇒Hood bracings are defective or not in place ⇒(The flail rotor may require balancing but this is a specialist task requiring machinery that can balance at up to 3600 rpm.) There is also the possibility to purchase a replacement rotor. ⇒Cutting blade or counter blade damaged or blunt – replace. ⇒Check the chopper speed, check the V-belt tension. ⇒Check the counter blade adjustment ⇒Correct the adjustment of the spreading shoe and/or vanes.
Chopped straw too long:
Chopper spread is not uniform, too wide or not wide enough: Blocking flow in the chopper:
Chopper will not start: Bearings are heating up: Driving V-belt is flailing:
[10/2000]
⇒Blunt cutting blade or counter blade – replace ⇒Check V-belt tension. Only use genuine V-belts. ⇒Straw guide plate wrongly mounted or not in proper position. ⇒Make sure the alarm or speed monitoring systems work properly ⇒Clutch not engaged (in case of motor drive) ⇒V-belt not tight – Check V-belt tension. ⇒Too little or too much lubrication ⇒Respect lubrication chart. ⇒Guide or idler pulleys are missing. ⇒Guide or idler pulleys are not in alignment – Correct the holder. ⇒Guide hoop for idler pulley has not been mounted. ⇒V-belt improperly tightened – Check V-belt tension.
TRAINING CENTER NEUSTADT
9F-7
CROSS - FLOW CF 80 COMBINE HARVESTER
9F – STRAW CHOPPER
Lubrication chart Refill the grease packing in the shown lube points every 50 operating hours, using grease K2K-30/Li according to DIN 51825. V-belt tension lube point
V-belt tightener Lube points on the V-belt coupling
Belt coupling Lube points at the straw chopper shaft on the left and on the right
Chopper shaft
[10/2000]
TRAINING CENTER NEUSTADT
9F-8
Agricultural Machines – Service Training
CROSS-FLOW CF 80
Chapter 10 Accessory Equipment
CROSS - FLOW CF 80 COMBINE HARVESTER
10
10 – ACCESSORYS
ACCESSORY EQUIPMENT Table of Contents
Page Threshing Drum Reduction Gear
10 - 2
Guide Rails
10 - 4
Clover Huller
10 - 5
Specially Cultivated Crops
10 - 6
Rape Knife
10 – 7
[10/2000]
TRAINING CENTER NEUSTADT
10-1
CROSS - FLOW CF 80 COMBINE HARVESTER Threshing cylinder reduction gear This gear can be mounted on the right-hand end of the threshing cylinder shaft instead of the one-way V-belt pulley. It is used for selecting either of two stages of the threshing cylinder speed range which can be steplessly controlled via a variator. The bottom half of the figure (II) shows the direct drive with a threshing cylinder speed range of 386-1,250 rpm. The arm (A) of the driving tongue (M) and the V-belt pulley (E) of the gear are connected to one another by means of a fillister-head bolt (C). The upper half of the figure (II) shows the gear for the additional reduction of the threshing cylinder speed in the range 216-660 rpm as desired. This speed range will only be required for harvesting the seeds of some special crops. For adjustment, the arm (B) of the driving tongue (M) is connected with the machine frame wall (D) using the fillister-head bolt (C) so that arm (A) and arm (B) are positioned directly opposite to each other. This will prevent the driving tongue from rotating with the V-belt pulley and causes the planetary gearing situated in the gear box to become effective.
10 – ACCESSORYS
Threshing cylinder gear
Mounting the threshing cylinder gear For mounting the threshing cylinder gear proceed with removing the four-way V-belt pulley (by loosening the hexagon-head bolt (SE), removing the end plate (EE) and the back-up ring (SG)). The spacer bush (BE) having a tapered inner bore will remain in its position on the shaft. For replacing the V-belt pulley by the threshing cylinder reduction gear it will be necessary to remove the right-hand driving wheel. Stop the engine and lock the combine against rolling. The weight of the threshing cylinder reduction gear is approx. 35 kg so that a hoisting unit should be used for lifting it in place.
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TRAINING CENTER NEUSTADT
10-2
CROSS - FLOW CF 80 COMBINE HARVESTER
10 – ACCESSORYS
For further mounting work proceed as follows: Apply a layer of anti-corrosive paste to the exposed shaft profile. Move the threshing cylinder gear in place. Bolt up the gear axially by means of the end plate (EE) and hexagon-head bolt (SE). The back-up ring (SG) is not mounted in this case. Lock the hexagon-head bolt by means of a locking plate. Mount the driving arm with the fillister-head bolt through (C) on the machine frame side wall (speed reduction) or on the driving bolt (E) (direct drive). Removing the gear For removing the gear proceed in reverse order of mounting. Checking the oil level The gear is filled with 1.0 litre gear oil (AP-GL590 DIN 51517). For checking the oil level, turn the gear until the two axles are in a horizontal position one beside the other and the M 26x1.5 gauge plug is at the bottom left. Axial gear bolt BE spacer bush EE end plate SE hexagon-head bolt SG back-up ring
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TRAINING CENTER NEUSTADT
10-3
CROSS - FLOW CF 80 COMBINE HARVESTER
10 – ACCESSORYS
Guide vanes The guide vanes will improve the distribution of the material to be threshed when working on sloped ground. For mounting the guide vanes proceed as follows: On the cascade sieve KKS, mount 4 guide vanes LS 1 – Spare Parts Order No.4247 05553 1 - as shown in the figure using 8 M4x10 hexagon-head bolts and 8 M4 hexagon nuts. For installing the vanes make use of the existing holes in the longitudinal ribs.
Guide vanes on slatted sieve and cascade sieve LS 1, LS 2 guide vanes On the slatted sieve KS, mount 4 guide vanes KKS cascade sieve LS 2 – Spare Parts Order No. 06 101187 2 - as KS slatted sieve shown in the figure using 32 M4x10 hexagonhead bolts and 32 M4 hexagon nuts. For installing the vanes make use of the existing holes in the longitudinal ribs. On the lower sieve US (applicable to roundhole sieves only), mount 4 guide vanes – Spare Parts Order No.4247 05556 4 - as shown in the figure using 12 M6 hexagon nuts, 12 A7 washers and 12 A6 toothed washers. For installing the vanes you will have to drill the required 8 mm dia. holes in the sieve.
Guide vanes on lower sieve US
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TRAINING CENTER NEUSTADT
10-4
CROSS - FLOW CF 80 COMBINE HARVESTER
10 – ACCESSORYS
Clover huller deck For threshing clover and lucerne it will be necessary to install a clover huller deck. For this, proceed as follows: For mounting the clover huller deck proceed with removing the stone trap. For this, it will be necessary to move the concave into its working position. It is possible in this position to remove the stone trap after its bolts have been loosened. Lower the concave into its lowermost position. Place the clover huller deck into contact with the threshing cylinder with its angle pointing up. Rotate the threshing cylinder until the clover huller deck is in its proper mounting position as shown in the figure. Lift the threshing cylinder into its working position again. Fasten the clover huller deck with the bolts from the direction of the demounted stone trap. .
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TRAINING CENTER NEUSTADT
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CROSS - FLOW CF 80 COMBINE HARVESTER
10 – ACCESSORYS
Harvest of special crops Special attachments will have to be mounted to the harvester-thresher for the harvest of rape, corn and sunflower. Special mounting and operating instructions are available for this equipment. Legumes harvesting attachment For harvesting special crops such as beans, peas, etc., use should be made of the covers for the grain and head elevator made of sieve plate and the grain board of sieve plate with a view to the separation of dust. These elements are available under the CASE Order No. 06 103818 3.
Legumes harvesting attachment 20 grain elevator sieve board 30 ear elevator sieve board 1 grain board of sieve plate
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TRAINING CENTER NEUSTADT
10-6
CROSS - FLOW CF 80 COMBINE HARVESTER
10 – ACCESSORYS
Rape stanchion, rape knife The rape knife is used for the vertical separation of the material to be harvested along the outer edge of the header. The rape knife is mounted to the right-hand side of the header and makes it possible to thresh rape also without a complete rape harvesting attachment. -
Mount the right-hand rape stanchion RB (CASE Order No. 31282263) to the header by means of • 4 M12x30 – 8.8 hexagon-head bolts, • 5 VSF B12 edged lock washers, • 1 M12 – 8 hexagon nut,
and then mount the right-hand rape knife RT (CASE Order No. 061045496) to the rape stanchion by means of • 4 M12x20 – 8.8 hexagon-head bolts, • 4 VSF B12 edged lock washers. Rape stanchion, rape divider RT rape knife RB rape stanchion -
Remove the covering of the electric motor and connect the cable to the motor. Check the motor for the direction of rotation as indicated (note direction arrow on covering).
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Feed the cable along the side wall of the header and fasten by means of selfsticking cable clips. Install the plug into the socket.
With the header running, the rape divider may be turned on by means of switch S 27 (for turning on, always go through the "OFF" position of the switch).
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