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SAME DEUTZ-FAHR DEUTSCHLAND GmbH

WORKSHOP MANUAL

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

Service
Training

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

Copyright 2006 by

SAME DEUTZ-FAHR DEUTSCHLAND GmbH


Deutz-Fahr-Str. 1
D-89415 Lauingen/Donau

Contents
Layout
Order

DF-EZ (Technical Documentation)


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

All rights reserved.


1. Edition, 10.2006

Part No.: 307.1133.3.6


Printed in the Federal Republic of Germany

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307.1133.3.6 englisch (en) 10.2006

Service
Training

Summary 5650H 5690HTS

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


General

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

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

....

Front axle, gearbox, Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B


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

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Service
Training

General Safety Instructions


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

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

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307.1133.3.6 englisch (en) 10.2006

Service
Training

Safety instructions for maintenance and repair


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

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Service
Training

Safety instructions for maintenance and repair


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

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307.1133.3.6 englisch (en) 10.2006

Service
Training

Safety instructions for maintenance and repair


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

307.1133.3.6 englisch (en) 10.2006

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Service
Training

Notes

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307.1133.3.6 englisch (en) 10.2006

Service
Training

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

5650H
5680H
5660HTS 5690HTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

307.1133.3.6 englisch (en) 10.2006

Service
Training

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

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

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

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

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

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

0,00328
0,08333
1,0

ft
ft
ft

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

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

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

USgall
USgall
USgall
USgall
USgall
Ibs
Ibs
Ibs
Ibs

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

daNm
daNm
daNm
daNm

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

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

Conversion from mm to inches


mm
0
1
2
3
4
5
6
7
8
9
10

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

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

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

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

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

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

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

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

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

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

307.1133.5.6 englisch (en) 10.2006

Service
Training

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

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

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

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

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

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

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

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

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

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

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

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

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

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


C

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

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

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

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

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

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

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

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

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

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

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

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

Temp. C = 5 (t F 32)
9

307.1133.3.6 englisch (en) 10.2006

Temp. F = 5 (t C + 32)
9

Service
Training

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

Bolting class II
Tightening torques M A nenn
Nm

Shoulder stud with metric fine thread


Friction factor ges. = 0,12
Bolting class II
Tightening torques M A nenn
Nm

d
mm

Strengh
class

M4

8,8
10,9
12,9

2,5
3,5
4,5

M8 x1

8,8
10,9
12,9

22
34
38

M5

8,8
10,9
12,9

5,0
7,5
8,5

M10 x 1,

8,8
10,9
12,9

46
70
80

M6

8,8
10,9
12,9

8,5
13
13

M10 x 1,25

8,8
10,9
12,9

44
65
75

M7

8,8
10,9
12,9

14
20
24

M12 x 1,25

8,8
10,9
12,9

80
110
140

M8

8,8
10,9
12,9

20
30
36

M12 x 1,5

8,8
10,9
12,9

75
110
130

M10

8,8
10,9
12,9

42
60
70

M14 x 1,5

8,8
10,9
12,9

120
180
210

M12

8,8
10,9
12,9

70
110
120

M16 x 1,5

8,8
10,9
12,9

190
280
320

M14

8,8
10,9
12,9

110
170
200

M18 x 1,5

8,8
10,9
12,9

280
400
480

M16

8,8
10,9
12,9

180
260
300

M18 x 2

8,8
10,9
12,9

260
380
440

M18

8,8
10,9
12,9

260
360
420

M20 x 1,5

8,8
10,9
12,9

400
550
650

M20

8,8
10,9
12,9

360
500
600

M20 x 2

8,8
10,9
12,9

360
550
600

M22

8,8
10,9
12,9

480
700
800

M22 x 1,5

8,8
10,9
12,9

550
750
850

M24

8,8
10,9
12,9

600
850
1000

M22 x 2

8,8
10,9
12,9

500
700
850

M27

8,8
10,9
12,9

900
1300
1500

M24 x 1,5

8,8
10,9
12,9

700
1000
1200

M30

8,8
10,9
12,9

1200
1700
2000

M24 x 2

8,8
10,9
12,9

650
950
1100

M27 x 2

8,8
10,9
12,9

650
950
1100

M30 x 2

8,8
10,9
12,9

1400
1900
2300

d
mm

Strengh
class

307.1133.3.6 englisch (en) 10.2006

Service
Training

Lubricants
Solid lubricants
Material
specification

Part No.

Operating temperature
range in C

Equivalent manufacturer's

DEUTZ S 1

0134 0198

180 bis +1400

Never Seize

DEUTZ S 2
DEUTZ S 5

0100 5149
0101 6126

125 bis +1450


130 bis +1130

Molykote Paste G-n Rapid


Molykote BR 2

0100 9454

20 bis +140

Emteka NU 15

Grease
DEUTZ F 15

Cooling System Protection

5l Container

0101 1490

20l Container

0101 6416

210l Container

1221 1500

307.1133.5.6 englisch (en) 10.2006

Service
Training

Sealants
Material
specification

KHD Part-No.

Operating temperature
range in C

Equivalent manufacturer's
designation

DEUTZ DW 25
DEUTZ DW 30
DEUTZ DW 40

0100 1306

190 to + 250
190 to + 700
190 to + 350

DEUTZ
DEUTZ
DEUTZ
DEUTZ
DEUTZ

0100
0100
0100
0134
0100

9463
8379
8383
0088
1286

135
130
165
173
190

to
to
to
to
to

+ 100
+ 150
+ 230
+ 230
+ 110

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

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

190
155
155
155
155
155

to
to
to
to
to
to

+ 150
+ 150
+ 150
+ 150
+ 150
+ 150

155
155
155
155
155

to
to
to
to
to

+ 200
+ 150
+ 150
+ 120
+ 150

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

DW
DW
DW
DW
DW

43
44
47
48
50

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

Adhesives

Material
specification

KHD Part No.

Operating temperature
range in C

Equivalent manufacturer's
designation

DEUTZ
DEUTZ
DEUTZ
DEUTZ
DEUTZ
DEUTZ
DEUTZ
DEUTZ

0100
0292
0100
0100
0100
0131
0100
0100

30 to + 200

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

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

1300
5947
8365
9331
9332
9914
4131
9506

60
60
60
30
30
30

to
to
to
to
to
to

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

307.1133.3.6 englisch (en) 10.2006

Service
Training

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

KHD
Designation

KHD
Part No.

Loctite
Type

Omnifit
Type

Conloc
Type

Guidelines for use

DEUTZ DW 55

0100 1251

601

M 150

CL 202

for play of 0.020.03, makes threads harder to loosen,


secures screws up to M16

DEUTZ DW 56

0109 8072

586 (AVX)

M 80
red

CL 103

for play of 0.020.02, makes threads harder to loosen,


secures screws up to M20

DEUTZ DW 57

0100 1256

221

L 150
green

CL 051

Improved press-fit 00.03, easily loosened,


screws up to M14

DEUTZ DW 59

0100 1252

270

M 250
violet

CL 301

for play of 0.0203, very firm connection,


only for large-size threads

DEUTZ DW 60

0100 1254

582 (CVX)

H 150
green

CL 303

for play of 0.030.5, extra-firm connection for temperatures


up to 100, only for large-size threads

DEUTZ DW 61

0109 8073

747
Activator
(Activator T) RS
US

CL
Activator

for faster hardening

0114 5546

648

307.1133.3.6 englisch (en) 10.2006

high-strength connection for joints shafts hubs

Service
Training

Maintenance and Inspection Schedule for Combine Harvesters


for the first time after
operating hours

after every
operating hours

Maintenance and Inspection Schedule


for DEUTZ-FAHR Combine Harvesters
To be carried out by authorised DEUTZ-FAHR workshops only

Engine Maintenance and inspection according to engine operating instructions


1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24

Check oil level (twice per day during running in phase)


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

X
X

X
X

every two years


X
X

2 hours after engine shutdown)


X

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

X
X

Change fuel filter cartridge


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

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

X
X

X
X

at least every two years


X
X

X
X

X
X
X

X
X

X
X

X
X
X

X
X
X

*Deutz lube oil TLX-10W 40FE


Alternatively it is possible to use oils in compliance with the DEUTZ lube oil quality
classes DQC III-05, CEA E4-99/E6-04

Drives
2.1
2.2
2.3
2.4
2.5
2.6
2.7

3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12

Check hydraulic oil level


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

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


X

X
X

X
X

X
X

X
X

X
X

X
X
X

X
X

X
Hydraulic oil HLP 46 DIN 51524 Part 2

X
X
X

X
X

X
X
X

X
X

X
X

Check tension of V-belt and feeding chain


Check, adjust friction clutch

X
X
X

X
X

Check function of electrical reversing device


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

X
X
X
X

Threshing Mechanism, Cleaning System, Grain Tank


5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8

Oil level checking


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

Feed passage
4.1
4.2
4.3
4.4
4.5
4.6
4.7

Check gear shift and adjust if necessary


Final drive oil change (at least once a year)
Oil level checking
Threshing drum reduction gear oil change (at least once a year)

Hydraulic system
3.1
3.2
3.3

Check for oil leakage

Shift gear oil change (at least once a year)


Oil level checking

Check concave basic setting, threshing drum


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

X
X
X

X
X
X

X
X
X
X
X

X
X
X
X

X
X

307.1133.3.6 englisch (en) 10.2006

Service
Training

Maintenance and Inspection Schedule for Combine Harvesters


for the first time after
operating hours

after every
operating hours

Maintenance and Inspection Schedule


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

Check grain pan sections for firm fit

Check fan variator


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

X
X
X
X
X
X

X
X
X
X

6 Wheels and Brakes


6.1
6.2
6.3
6.4
6.5

X
X

6.6

Check service brake, free movement of brake pads


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

6.7
6.8
6.9
6.10

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

X
X
X
X

X
X
every two years
X
X

X
X
X

X
X
X

X
X
X

X
X

7 Lubrication (see Lubrication Schedule)

Thoroughly clean points of lubrication prior to greasing


7.1
7.2

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

X
X

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

Check lighting equipment


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

X
X
X

X
X
X
X

X
X
X
X
X

X
X
X
X

X
X

X
X

9 Cabin, Compressor Cooling System, Cabin Heating


9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8

Check sealing of fresh air filters


Clean fresh air filter and recirculating air filter (replace if required)

Check correct functioning of compressor cooling system


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

X
X
X

10 Cutting Mechanism, Trailer, Front Attachment for Rape


10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
10.10

Check tension of V-belt and chains


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

X
X
X
X
X

X
X
X

X
X

X
X
X

X
X

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

X
X

All maintenance and inspection operations must comply


with the individual operating instructions

12 Accident Prevention Regulations


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

307.1133.5.6 englisch (en) 10.2006

X
X

X
every two years

Service
Training

5650H, 5660HTS, 5680H, 5690HTS


Operating fluids, filling levels1) and oil grades
Designation

5650H
5660HTS

5680H
5690HTS

Level
Change
Inspection2) Interval3)

operating media
Specifications

Fuel tank

ca.555 l

ca.555 l

daily

Diesel fuel, sulphur content below 0,5 %

DEUTZ-engine

20,0 l

20,0 l

10 h

incl. filter change

21,0 l

21,0 l

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

Cooling System

55.0 l

55.0 l

daily

2000 h or
every two years

Shift gear

17,0 l

17,0 l

250 h

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

Final drive

10,0 l

10,0 l

250 h

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

65 l

65 l

daily

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

Front attachment for rape

6l

6l

50 h

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

Hydraulic brake system

0,3 l

0,3 l

100 h

every two
years

Threshing drumReduction gear

1.0 l

1.0 l

250 h

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

2,0 kg
3
207 cm

2,0 kg
3
207 cm

annualy

Lower angular gear


at grain tank tube

0,75 l

0,75 l

250 h

Gear chaff spreader

0,4

0,4 l

Chains, joints

as required as required

Hydraulic System

4)

Air conditioning system


Compressor

5)

Deutz Cooling System Protection Agent


Ordering no. 01011490 (5l)

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

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

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

10

307.1133.3.6 englisch (en) 10.2006

Service
Training

Release list DEUTZ lube oil quality stage DQC III-05


Manufacturer
DEUTZ
ADDINOL
AGIP
Akros
ARAL
AVIA
BAYWA
BP OIL International

Castrol

CEPSA
CHEVRON
DEA

ESSO
FUCHS EUROPE
MOBIL OIL

OMV AG
Ravensberger
Schmierlvertrieb
Lube oil refinery
Salzbergen
Shell International

Texaco
TOTAL

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

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

Castrol Enduron

10W-40

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

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

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

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

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

Wintershall TFG

10W-40

Europe

Shell Myrina TX/Shell Rimula Ultra

5W-30

Europe, designation
varies nationally

Shell Myrina TX/Shell Rimula Ul-tra

10W-40

Ursa Super TDX10W-40


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

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

Europe, designation
varies nationally
Europe
Europe
worldwide
worldwide

307.1133.5.6 englisch (en) 10.2006

11

Service
Training

5650H 5690HTS
Speeds
5670

Combine Harvester

5680
5690 -12225

5650, 5660
5680, 5690 + 12226

Engine
with threshing mechanism disengaged

1/min

2610 2655

2425

15

2390

15

Engine
with threshing mechanism engaged

1/min

2590 2635

2415

15

2385

15

Straw stripper drum 1)

1/min

930

Threshing drum

1/min

400 1250

Grain tank discharge

1/min

560

Fan

1/min

400 900

Sieve box

1/min

285

Returns elevator grain


Returns elevator maize

1/min
1/min

1110 30
795 20

Straw walkers grain


Straw walkers rice

1/min
1/min

201
210

+5

206
213

2
2

206
213

+5/ 6

Feed passage shaft, top

1/min

425

+/ 2

430

20

430

20

10

Turbo Separator Grain


Turbo Separator Maize

1/min
1/min

790 20
380 30

805
390

+30/ 20

805
390

+30/ 20

+25/40

945
50

40

+15

945

405 1265
530

+50/30

+25/40

40

410 950
301

50

405 1265
530

+50/30

50

40

410 950
301

1170 30
850 20

+25/40

+50/30

1170 30
850 20

30

30

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

12

307.1133.3.6 englisch (en) 10.2006

Service
Training

A00005

A00006

307.1133.3.6 englisch (en) 10.2006

13

Service
Training

5650H 5690HTS
Tightening values of adapter bearings
Bearing point

Bearing

Tightening torque

Threshing drum/turbo separator

Grooved ball bearing

140 Nm

Straw stripper drum left side

Grooved ball bearing

140 Nm

Straw stripper drum right side

Ball joint bearing

180 Nm

Straw walker bearing

Grooved ball bearing

Pretensioning torque 50 Nm
+ Swivelling angle 180

Shaft of sieve box drive

Swivel-joint roller bearing

100

Countershaft inside of feed passage

Swivel-joint roller bearing

56 Nm

14

+20

Nm

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Notes

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Service
Training

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

10

11

Check spring tension L


Caption

Tensioning piece

Length

Comment

Block tightener reel drive chain

fixed

Block tightener angular gear drive chain

fixed

Idler pulley, turbo separator drive

Idler pulley, straw walker countershaft

Tensioning pulley knife gear drive

fixed

Tensioning wheel intake auger drive chain

fixed

Idler pulley, cutting table

Tensioning pulley impeller synchronous drive

Idler pulley, sieve box drive

10

Idler pulley, grain auger drive chain

11

Tensioning pulley returns elevator drive belt

fixed

L = Length according to adjustment gauge

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

16

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2
1
L
34940-1

35371

35036

35035

32983

32983

L
L

35355

33815
K0036-2

11

30969
90009

10

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

12

14

16

19

17

15

24

23

22

20

21

34939-2

Check spring tension L


Caption
12
13
14
15
16
17
18
19
20
21
22
23
24

Tension spring
Length
Dust extractor fan

Idler pulley, cooler drive


L
Fuel pump, generator V-belt

Air-conditioning compressor V-belt

Idler pulley, grain tank discharge drive


L
Block tightener grain tank filler auger drive chain

Tension device elevator chain

Idler pulley, threshing drum drive


L
Chain variator adjustment

Idler pulley, fan drive


L
Idler pulley, straw walker drive
L
Idler pulley, straw chopper drive
L
Chaff spreader: Check belt alignment, correct if necessary

Comment

Visual inspection

L = Length according to adjustment gauge

18

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12

14

35366

35455

12

13

00-2

14

15

17
L

30509

15

35367

16

31658

17

20
18
L
31656

18

34944

19

35362

20

L
35353

21

34945

22

34942

23

00-3

24
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5650H 5690HTS
Maintenance and repair
General instructions
Observe the general accident prevention regulations with all repair and maintenance works.
Make sure that the engine cannot be started by a second person while working at the combine harvester: Remove
start key and battery master switch!
Operating media must be disposed environmental fairly.
Retighten highly stressed screwed connections subsequent to reassembly after a few operating hours, e.g. wheel nuts,
bolts on axles.
Perform a functional test and check the oil level after carrying out repair works at the hydraulic system. Check hydraulic
system for leaks.
Replace porous or damaged hydraulic or fuel hoses in due time.
Check cable harnesses for pinched spots or damages.
Observe fire protection requirements while carrying out welding works at the combine harvester. Thoroughly remove
dust and crop residuals. Protect cable harnesses, hydraulic hoses and sealing elements against impact of heat. Remove
connectors from electronic control units.
Tighten the circlip to rotational direction of shaft while assembling circlip bearings.
Mount adapter bearing according to factory specification.
Causes for vibration must be remedied immediately. E.g. imbalance caused by foulings on beating arms of the threshing
drum or by broken chopper knives, by v-belts with grinding marks or by imbalance of tensioning pulleys by dust deposit.

20

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Servicing and Maintenance


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

A00160

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

A00161

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

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

22

Part No

Sieve box drive shaft bearing, countershaft inside of feed passage

0043 6070

Straw walker bearing d 40

0041 6050

Threshing drum bearing, straw stripper, turbo separator

0041 6055

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

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

Remark

0625 7346

Bolt M16x140 to draw out the adjusting


device of the threshing drum variator

0041 6070

3 pole test adapter for position transmitter EMR-D, balance


55 pole test adapter for EMR-D control device
Programming cable for Balance and Commander Control

1603 1484
1601 7182
1605 0267

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Service
Training

5650H 5690HTS
Engine
Table of Contents
Combine Harvester Type

5650H

5680H

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Further technical documentation for the engine of Deutz AG:


Operating instructions engine 1012/1013
Workshop manual BFM 1012/1013 de, en, fr, es
System description EMR de, en
Manual SERDIA, LEVEL III
Fault diagnosis, main focus on fuel injection system

A2

0297
0297
0297
0297
0297

7379
7438
7432
7482
7509

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5650H 5690HTS Maintenance and


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

3. Only fill up fuel with the engine stopped No


smoking!
4. Caution while draining hot lube oil danger of
burning!
5. Observe the specified quality of oil and fuel and store
both only in approved containers!
6. Provide for collection of leakage fuel and waste oil in
accordance with anti-pollution regulations!
7. Dispose of properly oils, fuels and filters!
8. After maintenance and repair works: Check whether
all safety devices have been remounted and all tools
have been removed from the engine!
9. Only carry out cleaning jobs with the engine stopped!
10. Battery gases are explosive! Avoid sparking and open
fire near the batteries! Do not spill acid on skin or
clothes! Wear safety goggles! Do not put tools on the
batteries!
11. Also observe the additional safety instructions in this
chapter!

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Technical Data DEUTZ Engine
Type BFM 1013 E
Four-Stroke Diesel Engine with Direct Injection

BF6M 1013 E
Number of cylinders / configuration

6 in tandem

Bore [mm]

108

Stroke [mm]

130

Total cylinder capacity [ltr.]

7,1

Method of operation / method of combustion

Four-stroke diesel with direct injection


and exhaust-driven supercharger.

Firing order

1-5-3-6-2-4

Rotational direction

when facing flywheel: left

Rated speed [rpm]

see engine name plate

Power [kW]

see engine name plate

Valve clearance inlet / exhaust [mm]


Commencement of delivery
Injector opening pressure [bar]
Min. oil pressure [bar], at lower idle speed and

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

warmed-up engine (120 C operating temperature)


Method of cooling

Liquid cooled with integrated lube oil cooler

Coolant quantity [approx. ltr.]


Engine and cooling system

55

Thermostat starts opening at [C]

83

Thermostat fully open from [C]

95

A4

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

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

26 332_3

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

26 231_1

The engine serial number is stamped on the crankcase itself


(arrow) as well as on the rating plate.

26 232_1

The cylinders are numbered consecutively, beginning at flywheel


end.

26 233_0

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5650H 5690HTS
Technical data DEUTZ engine
Rating Plate

2013-0008

Pos.

Description

Remark

Type of engine

e.g. BF6M 1013 EC

Code

with engines according to specifications of


commission 88/195/EWG

engine number

kW (G)

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

kW (S)

"nominal power (S-power), cooling fan is running at


full speed.

1/min

Nominal speed of the engine.

Commencement of delivery and

Commencement of delivery in degrees.

type of camshaft
8

kW (W)

Letter stands for type of camshaft


"Active vent (fan/blower) as a part of the specified
power.

9,10

For free disposal.

11

Statement of standard and/or regulation

12

kW (G) red.

Reduced "overall power, conditions on site


pos. 14, 15.

13

kW (S) red.

Reduced "nominal power, conditions on site pos.


14, 15.

14

Air temperature in C

For environmental conditons on site.

15

Altitude above sealevel in m

For environmental conditons on site.

16

Injection pump code

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

A6

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

Initial tightening value:


Bolts 30 45 mm long

20-30 Nm

Bolts 50 85 mm long

30-40 Nm

1. retightening angle
Bolts 30 85 mm long

60

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

30
60
212 Nm

Initial tightening value:

40-50 Nm

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

Bolts 60 mm long

60

Bolts 80 mm long

60

2. retightening angle
Bolts 60 mm long

30

Bolts 80 mm long

60

Note: Use Torx socket wrench E20


Front covers

212 Nm

Vibration damper with clutch flange


(bolts fixed with glue)
Cylinder head bolts
(Observe sequential order)

70 Nm
Initial tightening value:
1. step

50 Nm

2. step

130 Nm

Retightening
Rocker arm support

90
21 Nm

Rocker arm locknut

202 Nm

Crank case vent

8,51 Nm

Cylinder head cover

91 Nm

Connection nut fuel injection valve

40-50 Nm

Grip holder for fuel injection valve


Injection pipe

16 + 5 Nm
Initial tightening
Retightening

Pressure control valve

5 Nm
25 + 3,5 Nm
30 Nm

Charging air pipe at cylinder head

111 Nm

Coolant tube at cylinder head

212 Nm

Coolant pump

212 Nm

Exhaust manifold

252 Nm

Exhaust-driven supercharger

- Bolts M8
- Bolts M10

212 Nm
40,54 Nm

Pressure oil pipe at turbocharger

212 Nm

Pressure oil pipe at crank case

393 Nm

Oil return pipe

212 Nm

Lube oil cooler

212 Nm

Connection piece at fuel filter casing

505 Nm

Oil pan - sheet metal oil pan

212 Nm

Connection case at flywheel


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

307.1133.3.6 englisch (en) 10.2006

M12

9910 Nm

M16

24325 Nm
70 Nm
21 Nm
171,5 Nm
182 Nm

A7

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

A8

Oil filling tube


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

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26336-3

26337-0

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5650H 5690HTS
EMR Electronic engine controller
System description

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

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

Equipment pertaining to the engine


charging air pressure
sensor

adjusting rod position


transmitter/ actuator

temperature sensor
coolant

speed sensor
camshaft

EMR
control unit

Equipment pertaining to the vehicle


power supply

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

Droop switchover
K11

key switch
start/stop
indicator lamp
malfunction
EMR

Fuel temperature
EMR 2

A 10

oil pressure
lifting magnet
sensor (optional)
(optional)

diagnosis plug-socket

307.1133.3.6 englisch (en) 10.2006

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Service
Training

5650H 5690HTS
EMR Electronic engine controller
System description

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

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

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

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5650H 5690HTS
EMR Electronic engine controller
System description

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

sensor inputs for:


displacement of
adjusting rod speed
coolant temperature
charging air pressure
oil pressure
Fuel temperature
EMR 2

setpoint

microprocessor

pedal position
transmitter
manual gas
switch for
changeover
gas control unit

interfaces

underlined =
basic configuration
program
memory

power supply
diagnosis interfaces
CAN bus

display functions

actuator functions
actuating magnet
lifting magnet

parameters
characteristic
characteristic
diagram

speed
torque
warning signals
error lamp

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

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

number of engine
complete part number

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

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5650H 5690HTS
EMR Electronic engine controller
Diagnosis

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

Diagnosis options with software SERDIA


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

Error location (e.g. "pedal value transmitter,* "coolant temperature sensor).


Type of error (e.g. "lower limit exceeded, "sporadic error)
Environmental data (e.g. speed at the moment of error occurrence)
Number of error locations
Frequency
Error status ("1 for active, "0 for passive).

Error messages of non-current/recovered errors can be erased with SERDIA.


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

* With the combine harvester, the pedal value transmitter corresponds to the gas control unit.
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5650H 5690HTS
EMR Electronic engine controller
Diagnosis
error lamp

error messages (only readable with SERDIA)


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

(2) measuring point


defective

(3) reduced power

continuous light
(engine off)
flashing
(reduced power)

(5) shut down limit


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

(0) cable break or


short circuit existing

(2) measuring point


defective

(5) shut down limit


fallen below/exceeded

(engine cannot
be started)
flashing

(0) cable break or


short circuit existing

flashing or
continuous light
off

A 14

coolant temperature too high for


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

speed control unit

o.k.

(M9) coolant temperature sensor (8140)

plug contacts polluted


or corroded
o.k.
sensor defective
o.k.
wire interrupted

(M24) boost pressure sensor (8150)


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

speed monitoring (8305)


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

(M13) speed 1, camshaft (8170)


(only, if speed transducer 2 is not existing
or defective)

(M17) position sensor (8112)

speed monitoring (8305)


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

0) cable break or
short circuit existing

(M13) speed 1, camshaft (8170)


(only, if speed transducer 2 is not available)

(5) shut down limit


fallen below/exceeded

failure actuating magnet (8405)

remedy
n.o.k.

engine speed switch

(M11) speed 2, terminal w (8180)


(only, if speed transducer 1 is defective)

flashing
(engine off)

possible causes

restore plug-in connection

clean plug, replace


if necessary

replace sensor

check cable harness, replace

check data in SERDIA menu


"configuration, change if necessary

restore plug-in connection

clean plug, replace if necessary

replace the sensor

check cable harness, replace if necessary

problems with evaluation


of external PWM signal

temperature alert limit exceeded


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

plug-in connection interrupted

o.k.
plug contacts polluted

or corroded
o.k.
actuator defective

o.k.
wire interrupted

limits were fallen below resp.

exceeded for too long. Incorrect


configuration (e.g. push operation off).
actuator defective

data loss, software defective

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

actuator defective

restore plug-in connection


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

replace control unit

replace actuator

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5650H 5690HTS
Engine - Sensors

Sensor
Charge Air Pressure
Oil Pressure

Temperature Sensor Coolant


Temperature Switch/Sensor

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Connector X 107
at Engine

Connector X 107
at Engine

A 15

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Training

F19

50a

30

75

K0

15

F39

G3

F34
D+

te
Nulls

B46

H34

0
1
2
S5

A
H
S

A30
B7

S40

Commander
Control
2000

15a

A13

B48

30

15
F7

F42

K11 K12

K48

K22

15b

A1

M1

EEC

A2

56-104--1

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

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

Control unit EEC (electronic controller Diesel engine)


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

1
2
3
4
5

Low-pressure switch air filter


Temperature switch coolant
Temperature switch engine oil
Oil pressure switch
Coolant level switch

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

A1 control unit EMR


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

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

A2 pin assignment
Pin
1
2
3

A 18

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

Cable colour
gr/rt
gr/bl
br

Pot. throttle slider

ws/bl

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

Pot. throttle supply


Input droop changeover from K11
Output droop changeover to A1
Ground droop changeover
Supply 12V from control cabinet X8
Supply A1

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

Supply for diagnosis connector


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

sw
br
br
br
br

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

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X8

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

SOLARI 1.she

Engine

Vehicle

A1

A2
3

16

9
1

56-116

56-055

10

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

25

13

25

14

13

14

Pin-No. Designation

Description

Pin-No. Designation

Description

Reserve

Reserve

1 x U Batt -

Negative pole at battery (clamp 31)

Output: digital 3

Digital output for solenoid

2 x GND

Reference potential for signal

Output: DIGITAL/PWM 3

PWM or digital output

NC

Not occupied

PWM or digital output,


various functions

NC

Not occupied

4 x Output: Digital 1

Fault lamp

Output: digital / PWM 1

PWM or digital output, various


functions

Reserve

Reserve

NC

Not occupied

NC

Not occupied

NC

Not occupied

NC

Not occupied

NC

Not occupied

GND

Reference potential for analog signal


at pin 9

Input: Analog 3

Analog input for coolant temperature


transmitter (NTC)

Output: digital / PWM2

10

GND

Reference potential for signal at pin 11

10

11

Input: Drehzahl 2

Digital input second engine speed


(crankshaft)

11 x K-Line
12 x CAN high

Interface for CAN-Bus

12

GND

Reference potential for signal at pin 13

13 x CAN low

Interface for CAN-Bus

13

Input: Drehzahl 1

Digital input first engine speed


(camshaft)

14 x U Batt +

Positive pole for battery (clamp 15)

L-Line

Serial ISO 9141 interface


Serial ISO 9141 interface

15

Output: digital 2

Digital output, various functions.

16

Output: digital / PWM/


Frequency

Frequency ., PWM or Digital output


various functions

14

STG -

PWM ouitput, signal for control coil

15

STG +

PWM ouitput, signal for control coil

16

Screen

Shielding for position encoder


(for lines 17,18,19)

17 x Ground

Reference potential for signal at


pins 18, 19 and 21.

17

RF -

General connection for reference and


measuring coil

18

PWM or digital input, various


functions

18

RF REF

Analog input, reference signal of the


reference coil

19

RF MESS

Analog input, measuring signal of the


measuring coil

20

GND

Reference potential for signal at pin 24

21

Input: Analog 4

22

Input: Digital / PWM 1

19

Input: digital

Digital input, various functions

20

Input: digital / Analog

Digital or analog input,


various functions

21 x Input: digital / PWM 2

PWM oder digital input,


various functions

Analog input 2 sensor signal charge air

22

+5V REF

+5 V Reference voltage for signal at


pin 21 (max. 15 mA)

Screening (e.g. for lines 9 hand


throttle or PWG)

23 x GND

23

GND

Reference potential for signal at pin 24

Reference potential for signal at


pin 24

24

Input: Analog 2

Analog input sensor signal charge air

24 x Input: Analog 1

25

+5V LDA

+5 V Reference voltage for signal at


pin 24 (max. 15 mA)

Analog input pedal value sensor,


(PWG)

25 x +5V REF

+5 V Reference voltage for signal


at Pin 24

Screen

x) Pin used for combines

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

25

13

25

14

13

14

Pin No. Designation


1

Reserve Reserve

Output: digital 3

Description

Digital output for solenoid 1)

Pin-No Designation
1 x U Batt -

Description
Negative pole at battery (clamp 31)

2 x GND

Reference potential for signal

PWM or digital output,


various functions

Output: digital 2

Output: digital 4

For heating flange (optional)/


glow plug (optional)

Input (optional) Temp 1

Fuel temperature 2)

4 x Input / output: DigInOut

Fault lamp and diagnostic button

Input (optional) Temp 2

Charge air temperature

Output: PWM 1/Dig 1

Input (optional) DigIn 5

Coolant level / oil level

PWM or digital output, various


functions

Output: PWM2/digital 6

Multi-function input:
Digin 3

Genset applications/gear shift/motor


brake

GND

Reference potential for analog signal at pin 9

Input: digital 10/velocity

Speed signal (tacho input)

Input: analog 7

Analog input for Coolant temperature


sensor (NTC)

NC

Not occupied

10

GND

Reference potential for signal at pin 11

11

Multi-function input:
speed 2/DigIn 2

Digital input second engine speed


(crankshaft) (optional) and speed signal
(optional)

12

GND

Reference potential for signal at pin 13

13

Input: speed 1

Digital input first engine speed


(camshaft)

14

STG -

PWM output, signal for actuator coil

15

STG +

PWM output, signal for actuator coil

16

Screen

Screening regulating rod travel sensor


(for lines 17, 18, 19)

17

RF -

General connection for

18

RF REF

Analog input, reference signal

19

RF MESS

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

Interface for CAN-Bus

15

Output: digital 5

Digital output, various functions

16

Output: digital 7/Frequency

Frequency, PWM or digital output,


various functions

20

GND

Reference potential for signal at pin 21

21

Input: analog 4/digital 9

Analog input 4 (sensor signal oil


pressure sensor) or digital input 9

22

+5 V REF

+5 V Reference voltage for signal at pin


21 (max. 15 mA)

23

GND

Reference potential for signal at pin 24

24

Input: analog 2/digital 7

Analog input 2 (sensor signal charge


air) or digital input 7

25

+5 V LDA

+5 V Reference potential for signal at


pin 24 (max. 15 mA)

1) For continuous power: < 4 A


2) Corresponds to special functionfuel temperature compensation at the
EMR (0211 2571)

307.1133.3.6 englisch (en) 10.2006

Interface for CAN-Bus

Positive pole for battery (clamp 15)

17 x Ground

Reference potential for signal at


pins 18, 19 and 21.

18

Input: digital 1 / PWM 1

PWM 1 or digital input 1, various


functions

19

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


applications

20

Multi-function input:
digital 8 / analog 3

Analog input, measuring signal


of the measuring coil

Serial ISO 9141 interface


Serial ISO 9141 interface

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

reference and measuring coil

of the reference coil

Not occupied

Hand hand throttle/genset applications,


Digital (8) or analog input (3)

21 x Input: digital 2 / PWM 2

PWM 2 or digital input 2,


various functions

22

Screening (e.g. for lines 9 hand


throttle or PWG)

Screen

23 x GND

Reference potential for signal at


pin 24

24 x Input: analog 1 / digital 6 Analog input 1 (pedal value


sensor, PWG) digital input 6
25 x +5V REF
+5 V Reference voltage for signal
at Pin 24
x) Pin used for combines

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Training

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

Transmitter/switch coolant temperature display


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

2.1
56-117

1.1
4

2
19,39

20,9

8
18,57

19,63

5
9
19,41
A 22

56-118
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1
2

3
4

26337-2

2.1

9
6

7
26336-2
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34926

5
6
7

11

10

8
9

14

12
13

17

18
15
19
16
A007

A 24

56-069

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5650H 5690HTS
Fuel system, overview

Injection pipe

Shut-off solenoid (until year of manufacture 2002)

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

Pressure control valve 5 bar

Plug-in injection pump

Line to plug-in injection pumps

Line to fuel filter

Fuel pump

Fuel filter

10

Fuel suction line to fuel pump

11

Return line to fuel cooler

12

Fuel Cooler

13

Fuel suction line to pump

14

Tank stopcock

15

Vent pump

16

Fuel tank

17

Fuel pre-filter

18

Drain plug at pre-filter

19

Drain plug at fuel tank sump

Check for proper connection of fuel lines at the pre-filter:


Line from bleed pump (16) to connection EIN / IN
Line to engine at connection AUS / OUT

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5650H 5690HTS
Fuel pump

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

2013 - 0043

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Service
Training

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

Changing interval filter element: 1000 op. hrs

2
Clean/replace filter element (8)

3
34923

Close tank stopcock (1).

Open the venting screw (7).

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

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

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

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

Tighten drain plug (3).

Open tank stopcock (1).

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

Actuate vent pump (2) until fuel flows hereable without


air into the tank.

3
25 801_0

Venting the fuel system.

Open the venting screw (7).

Open tank stopcock (1).

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

Close the venting screw (7).

Actuate vent pump (2) repeatedly.

Start the engine.


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

30 084_0

5670-90 englisch (en) 02.2001

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

A 27

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5650H 5690HTS
Change fuel filter

Close tank stopcock.

Loosen and unsrew fuel filter cartridge (1).

Collect leaking fuel

Remove possible dirt from the sealing surface of the filter


support.

Slightly lubricate the rubber seal of the new fuel filter


cartridge resp. moisten with fuel oil.
Fill filter cartridge with fuel.

Screw on cartridge by hand until the seal properly fits.

Tighten fuel filter cartridge with another half turn.

Open tank stopcock.

Actuate vent pump repeatedly.

Check filter for leakage.

1
26336-2

25880/0

25881/0

25882/0

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5650H 5690HTS
Change fuel oil leakage pipe

Changing interval: 1000 operating hours, at least every


second year.
Mounting tool: Hose clamp pliers TN8020

Close tank stopcock.

Take down the rocker assembly cover hood.

Loosen hose clamps (6) by means of hose clamp pliers


TN 8020.

Disconnect rubber hoses (3) and hose clamps (6) from


the fuel injection valves.

Loosen the pressure control valve (9).

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

30034_1

Observe at assembly that the hose clamp lock is


pointing to the fuel injection valves and the hose
clamp cannot fall into the engine compartment.

Attaching new oil leakage pipe:


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

30901_0

Assembly of pressure control valve (9):


Tighten new collar piece with socket pin / threaded pin (5).

Remount the rocker assembly cover hood.

Open tank stopcock.

Actuate vent pump repeatedly.

Check for leakage after commissioning.

30 084_0

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

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

28-4-44

Put on the grip holder. Screw in bolt slightly.

38-4-192

Attach new injection pipe with rubber seal. Screw on


connection nut slightly by hand.
Note: At assembly of the fuel injection pipes the sealing
cones must match exactly.
Subsequent bending is not permissible. The fuel
injection pipes may not be used twice.

38-4-193

Tighten the bolt of the gripholders with a tightening torque


of 16 + 5 Nm.

38-4-194

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

38-4-145

Attach oil leakage pipe and introduce through rubber


seals.
Note: It is mandatory to replace used oil leakage pipes.

38-4-146

Attach pressure control valve with new copper seals and


oil leakage pipe.
Tighten pressure control valve with a tightening torque of
30 Nm.

38-4-164

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

Mount injector to nozzle tester.


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

1.3

Slowly press down lever of the nozzle tester with


connected pressure gauge.The pressure at which
the pointer stops or suddenly drops is the opening
pressure.
Opening pressure: 275 + 8 bar

Reference: After having operated the hand lever of the


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

If the measured values of 3 tests are identical, they


can be considered valid.

Chattering and spray pattern test


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

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2. Setting the injector
2.1

If the opening pressure must be corrected,dismantle


injector from nozzle tester. Unscrew tensioning nut,
dismantle all parts.
Special tools for taking the injector depending of
engine type.

2.2

Sequence of dismantling and mounting of parts


1. Tensioning nut
2. Injector comprising nozzle body with nozzle needle
3. Adapter
4. Pressure bolt
5. Pressure spring
6. Spacer disk

2.3

Set the opening pressure by selecting the suitable


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

3. Check for tightness


3.1

Dry injector blow dry with air. Slowly press down


hand lever of the nozzle tester, until approx. 20 bar
below the previously read opening pressure are
reached.

3.2

Injector is tight, when no drop falls down within 10


seconds.

3.3

If a drop should fall, the injector must be


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

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Cooling circuit, overview

1.2

1.1

11

12

18,7

5
A 34

10
56-107

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Cooling circuit, overview

Expansion tank

1.1 Sight glass


1.2 Relief valve in the cap opens at 95 kPa
2

Vent hose from cylinder head

Inlet from radiator to coolant pump

Return line from thermostat housing to radiator

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

Vent hose from radiator

Radiator

Coolant pump

Heat exchanger coolant/engine oil

10

Drain cock

11

Thermostat housing

12

Connection vent hose (2) at cylinder head

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

1
18,7

Place drip tray under drain plug.

Open the cap (2) at the expansion tank.

Attach hose to drain cock.

Drain coolant via drain cock (1).

Drain coolant which remains in the engine at the


drain plug (6) of the heat exchanger.

2
3

Filling:

Close drain cock (1).

Fill up coolant at cap opening (2) until the sight glass


(3) is covered.

Attach the cap (2).

Start the engine and warm up until the thermostat


opens.

Turn off the engine.

Check coolant level when the engine is cold and refill


if necessary.

Venting is done automatically through the vent


hoses.

19,1

Note: Open the heating valve entirely if the heating


circuit for the cabin is connected.

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

(4) Connection for heating hose from the cabin.

56-112

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Mounting of the coolant temperature
transmitter

Tighten coolant temperature transmitter (1) with new


seal with a tightening torque of 18 2 Nm.

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

1
39-40

Assembly of coolant level sensor


3
4
5

Coolant level sensor


Floater
Marking

The marking (5) at the hexagonal bolt must point


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

exceeds 2 km/h.

4
3

56-120

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Replacement of thermostat
Mounting tool: 170 090

Dismantle the thermostat housing (1).

Push down thermostat and remove from thermostat


housing.

Visually inspect all parts, replace if necessary.

Push down thermostat and screw into the thermostat


housing.

54

10-3.130

10-3.131

Note: The retainer must engage in the thermostat


housing.

Remove the seal ring for the thermostat housing if


necessary.

10-3.132

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Mounting of coolant pump

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

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

Push plug-in piece into the coolant pump.

Insert new o-ring seal in connecting piece.

10-4.184-1

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

38-4-112-1

Attach the assembled coolant pump with a new seal.

Tighten the bolts mutually with a tightening torque of


21 2 Nm.

38-4-244

38-4-245

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

Commissioning
Check engine oil level prior to commissioning.

10-3.130

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Maintenance Schedule Engine 1013
Job

Check oil level

once
at/after (op. hrs)

regularly
every (op. hrs)

upon delivery

daily1)

Clean engine compartment

daily

Visual inspection of engine for leaks

upon delivery

5 / 50-150

Check battery and battery cable connections

upon delivery

100

Check cooling system


Change engine oil 2) 3)

125/250/500/1000/2000
50

250 at least annualy

Change oil filter cartridge

50

250

Clean air filter cartridge

only when indicator light is on

Change air filter cartridge

after cleaning 5 times resp.

at least annually

after choking with rust


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

when replacing air filter cartridge


50

1000

upon delivery

if required

50-150

---

---

10004)

upon delivery

at least annually

50

500

50-150

500

Vibration damper, check condition


Check V-belt tensions, retension if necessary at:

at least every 2 years

500
upon delivery / 50-150

250

upon delivery / 50-150

annually

generator, coolant pump, fan, suction blower


Alarm system, check/clean
Attachments

50-150

Coolant, check concentration of additives


Check coolant level

upon delivery

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

--500
daily
2000/or every 2 years

upon delivery / 50

250

upon delivery

annually

Check hose sleeves between air filter and turbocharger

upon delivery / 50

250

Check sealing brush at sieve pan, replace if necessary

upon delivery / 50

250

upon delivery

250

upon delivery / 50

annually

Check condition of oil drain hose, fuel hoses


Check cable harnesses, connectors for damage and
proper laying

1) During the running-in period twice a day.


2) For approved engine oils see Deutz engine oils approval list (page 46)
3) These intervals only apply for a Diesel fuel with maximum 0,5% by weight of sulfur and for central-european or
comparable climate conditions.
In the case of aggravating conditions for oil stress, e.g.
intensified climate conditions (temperatures exceeding permanently 30 C)
usage of fuels containing more than 0,5% of sulfur
the oil change intervals shown in the table must be halved for each aggravating condition.
4) Replace however every 2 years.
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Air filter
Cleaning of dry-type air filter
Indication at combined instrument gauge.
Lighting of indicator light (1), flashing of central warning
light (2) and sounding of an alarm signal.
The low-pressure switch (3) initiating the alarm is mounted
in the filter housing (4).

Never wipe the air filter cover or the filter


cartridge by using oily rags.
31663

Replacement of fine filter cartridge

11
10

Verify that the gasket between the fine filter


cartridge and the filter housing is clean and
undamaged.

5
6
11

34927

When equipped with exhaust ejector (10)


unscrew butterfly nut (5) and remove cover (6).

Remove dirty fine filter cartridge (8), either clean or


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

Replacement of the safety cartridge


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

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

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Coolant

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

6,5

Chloride ion content [mg/dm3]

100

Sulfate ion content [mg/dm3]

100

Total hardness [dKH]

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

8,5

12

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

Cooling system protective agent


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

Water
55%
65%

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

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

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

Cooling System Protection


Protective Agent
[% by vol.]

Protection against freezing to


[C]

35

-22

40

-28

45

-35

50

-45

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

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

ACEA-Classification

E2-96

or API-Classification

CF/CF-4

or worldwide specification

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

E4-99/
E6-04

E4-99/
E6-04

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

Fuel
Viscosity classes in relation to the ambient temperature

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

Figure legend:
I
II
A
B

Summer diesel fuel


Winter diesel fuel
Ambient temperature
Percentage of kerosene
added

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

Mix in tank only! Fill in the


appropriate amount of
kerosene first, then add the
diesel fuel.

307.1133.3.6 englisch (en) 10.2006

At temperatures below 15 C or 20 , kerosene should be added


to the diesel fuel. The relevant percentages are given in the diagram
opposite.
If summer-grade diesel fuel has to be used at temperatures below 0
C, up to 60% kerosene may be added (see diagram opposite).
In most cases, adequate resistance to cold is also attained by adding
a flow improver (fuel additive). Ask your service representative for
further information.
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Release list DEUTZ lube oil quality stage DQC III-05


Manufacturer
DEUTZ
ADDINOL
AGIP
Akros
ARAL
AVIA
BAYWA
BP OIL International

Castrol

CEPSA
CHEVRON
DEA

ESSO
FUCHS EUROPE
MOBIL OIL

OMV AG
Ravensberger
Schmierlvertrieb
Lube oil refinery
Salzbergen
Shell International

Texaco
TOTAL

A 46

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

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

Castrol Enduron

10W-40

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

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

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

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

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

Wintershall TFG

10W-40

Europe

Shell Myrina TX/Shell Rimula Ultra

5W-30

Europe, designation
varies nationally

Shell Myrina TX/Shell Rimula Ultra

10W-40

Ursa Super TDX10W-40


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

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

Europe, designation
varies nationally
Europe
Europe
worldwide
worldwide

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

A00023

Ensure that the combine harvester is on a level surface.


Allow the engine to warm up lube oil temperature
approx. 80 C.
Switch off the engine

A00024

Unscrew oil drain plug (1).


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

1
33975

Start the engine and operate at low idle speed.


Observe oil pressure indicator light.
Switch off the engine.
Check oil level with the machine placed on a level
surface.
If necessary, fill up oil to the max marking.

A00026

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V-Belt generator
Tensioning/Replacement
Tensioning:

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

Push generator (5) to direction of arrow (A) until correct


v-belt tension is attained.

Replacement:

Loosen screws (1) and (2).

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


is strainfree.

Remove v-belt and apply new v-belt and tension (see


above).

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

91 107

V-Belt coolant pump/fuel pump


Tensioning:

Loosen screws (1) and (2).

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

Retighten screws (1) and (2).

A-008

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

Slackening/tensioning of v-belt for cooling compressor


and ventilating wheel:

Disassemble half-flange (7) from driven shaft of


engine.

Remove v-belt and apply new v-belt.


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

A-009

7
A00175-2

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Checking valve clearances, adjusting
valve clearances if necessary

Loosen venting valve and slew to the side.

Remove cylinder-head cover.

Position of crankshaft as per schematic.

Before adjusting valve clearance, allow engine to cool


down for at least 30 minutes: The oil temperature
should be below 80 C.

Check valve clearance 1 between rocker arm tappet


contact face 2 and valve stem 3 with feeler gauge 6
(there should only be a slight resistance when feeler
blade is inserted).

Permissible valve clearances:


Inlet IN
= 0,3+0,1 mm
Outlet EX
= 0,5+0,1 mm

If necessary, adjust valve clearances as follows:

19 961_2

- Loosen counter nut 4.


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

Check the valve clearances at each of the cylinders


and adjust if necessary.

Remount the cylinder-head cover (use new seal if


necessary).

Slew venting valve back into position and attach.

Note: Increase the valve clearance by 0,1 mm upon each


replacement of the cylinder-head gasket.
Adjust the standard valve clearance after 50 150
operating hours.

26262_1

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Valve clearance adjustment schematic

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

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

26263_2_1

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Determination of cylinder-head gasket

The thickness of the cylinder-head gasket is responsible


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

Measuring the piston projection


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

Dial gauge

Bridge 100750

2 Distance plates (1)

Put the distance plates on the sealing surface of the


crankcase and set dial gauge to "0.

38-4-188

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

95
90

Place the dial gauge on the piston at the measuring


points and determine the biggest piston projection.

Note: All pistons must be measured.

Observe measuring points:


BFM 1013 95 mm

Axe de Piston
Eje de bul de piston

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5650H 5690HTS
Determination of cylinder-head gasket

Compare highest value with the table and determine


the corresponding cylinder-head gasket.

BFM 1013
Piston projection

10-4.152

0,28 - < 0,54 mm


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

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

28-4.36

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Mounting of the cylinder head

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

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Tightening of the cylinder head screws
Sequential order

Manifold side

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Special Tools
V-belt tension gauge
Order no. 91107

All special tools can be ordered from:


WILBR
PO-box 14 05 80
D 42826 Remscheid

91 107

Adapter for compression gauge


Order no. 100 110

100 110

Extractor for fuel injection valve, to be used with 150800


Order no. 110 030

110 030

Extractor for fuel injection valve, to be used with drawing


device
Order no. 150 800

150 800

A 56

307.1133.3.6 englisch (en) 10.2006

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

170 090

Pliers for hose-clamps


Order no. 8011

8011

Torx tool set


Order no. 8189

8189

307.1133.3.6 englisch (en) 10.2006

A 57

A
Service
Training

19,59

5650H 5690HTS
Charge cooling

1
2
3
4
5
6
7
8

Pipe from charging air cooler to cylinder head


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

3
4

19,55

6
5
7
2004514-2

A-010

A 58

307.1133.3.6 englisch (en) 10.2006

A
Service
Training

5650H 5690HTS
Cooling fan drive, radiator

1
2

Hydraulic oil cooler

Condenser for cooling system

Fuel Cooler

V-belt pulley on driven shaft of engine

Tensioning pulley

5.1 Tension spring with adjusting plate (5.2)

35510

11

12

Charging air cooler

Cooler for engine coolant

Ventilating wheel

V-belt pulley

10

V-belt exhauster drive

11

Sieve pan covering

12

Locking device of sieve pan covering

19,13

6
7

5.2
5.1
4

5
8
9
10

307.1133.3.6 englisch (en) 10.2006

A 59

A
Service
Training

5650H 5690HTS
Exhauster drive

Charging air cooler

Radiator

V-belt pulleys

V-belt exhauster drive

Exhauster drive

Flexible suction tube to cooling air duct

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

Rotating sieve pan

A 60

307.1133.3.6 englisch (en) 10.2006

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Service
Training

1,2

8
3

4
6
5

307.1133.3.6 englisch (en) 10.2006

13_mot.tif

A 61

A
Service
Training

5650H 5690HTS
Rotating sieve pan drive

Rotating sieve pan

Driving belt

2.1 Guide pulley


3

Tensioning pulley, spring-loaded

Driven shaft of engine

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

Bedding of sieve pan and air intake louver

Connecting branch exhauster hose

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

Fume hood

10

Stripping brush

11

Headless screw

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

A 62

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A
Service
Training

2.1

2
3
3

19,59

2004514-2

9
5

1
1

6
8

10
11
9

9
2004514-1

16053690

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A 63

A
Service
Training

5670
Driven shaft of engine
1

Vibration damper: Check for cracks in the rubber coating.

Screws

3
4

Set collar (threaded pin unsrewed from the groove)


Gap 1+1 mm to seal ring

Grease outlet

Screw

Screw

Nut

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

5650H 5690HTS
Driven shaft of engine
1

Vibration damper

Screws M10x110, 10.9

Assembly dimension [mm] of V-belt pulleys

2.1 Distance ring


3

V-belt pulley cooling compressor drive

V-belt pulley cooling fan drive

5
6

Set collar (threaded pin unscrewed from the groove)


Gap 1+1 mm to seal ring

Bearing cover: Remove before mounting

Bearing housing: Center while mounting

Grease outlet

Type

5650/60

36

174

227

5680/90

136

201

378

Lock screws with screw retention agent Loctite 243


Apply grease before mounting.

5650H 5690HTS
Observe proper sequential order when mounting:

Flange driven shaft to engine.

Align bearing housing (8) to bearing shell.

Mount bearing cover (7).

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

A 64

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Service
Training

5670
6

A00158-1

5650H 5690HTS
Mta =

Mta =

70 Nm

Mta =

Mta =

25 Nm

250 Nm

50 Nm

2,1
3

+1

22310 CC/C3

A
B
C
1

Mta =

210 Nm

8
56-110

307.1133.3.6 englisch (en) 10.2006

A 65

A
Service
Training

A00174-1

7
3
4

2
A00175

A 66

307.1133.3.6 englisch (en) 10.2006

A
Service
Training

5650H 5690HTS
Driven shaft of engine
Bedding

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

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

Compensating cams

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

Mount with strong washer

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

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

Half-flange (not 5670)


Dismantle in order to replace the v-belt.

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

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A 67

A
Service
Training

5650H 5690HTS
Mounting of hydraulic pumps

Apply new o-ring seal (1).

Place new gasket (2) with mounting flange on


hydraulic pump.

Mount gearwheel (3).

28-3.51

3
Note: Observe whether the feather key is existing.

28-3.52

Tighten self-locking nut with a tightening torque of


80 Nm.

Note: Always use new self-locking nut.

28-3.53

Attaching the hydraulic pumps:


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

For standard hydraulics: 2x tie rod (4), M10x275 10.9


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

A 68

Clean tie rod threads and screw in with sealing


compound (sealing of thread hole in the flange to the
engine).
307.1133.3.6 englisch (en) 10.2006

B
Service
Training

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

5650H
5680H
5660HTS 5690HTS

Maintenance and inspection


Safety instructions, tyres, screwed fixings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02

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

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

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

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

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

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

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

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

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

5670

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

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

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

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

307.1133.3.6 englisch (en) 10.2006

B1

B
Service
Training

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

When working on the wheels, make sure that the


combine harvester is safely parked and secured
against rolling (wheel chocks).

2.

When working underneath the jacked combine


harvester, make sure that nobody is allowed on the
combine.

3.

Make sure that the jack or lifting device has sufficient


load-bearing capacity.

4.

Tyre removal and fitting require specialised


knowledge and regulatory fitting tools.

5.

Check the tyre pressures at regular intervals.


If the pressure is too high, the tyre(s) may burst.

6.

Tighten all fixing screws and nuts of the front and


rear wheels and the track adjusting components in
conformity with the manufacturer's specifications.

B-8

Brakes, brake fluid:

B2

1.

Always check the brakes before setting out.

2.

The brake systems must be thoroughly tested at


regular intervals.

3.

Brake system settings and repairs may only be


carried out by specialised workshops or recognised
brake services.

4.

When driving on public roads, the independent wheel


braking system must be disabled (engage the pedal
interlock).

5.

Check the brake fluid level at regular intervals. Only


use authorised brake fluid and replace it as specified.

6.

Take care when handling brake fluid (toxic and


corrosive). Do not spill or pour brake fluid into the
environment.

7.

Dispose of brake fluid in conformity with


environmental regulations.

8.

During all repairs to the brakes, make sure that no


impurities enter the system.

9.

After all servicing, maintenance or repairs of the


brake system, carry out a final test of leakproofing,
operation and efficiency.

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

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

Service interval

Oil change
Manual gearbox

After 50 operating hours, and then every 500 operating hours


but at least once a year

Oil change
Side gears

After 50 operating hours, and then every 500 operating hours


but at least once a year

Check oil level


Manual gearbox / side gears

On handover, every 250 operating hours,

Check the gearshift


and reset if necessary

On handover, after 50 operating hours,


and then every 500 operating hours

Capacities and oil grades


For filling quantities and oil qualities see section "General"

Drive axle / steering axle


Maintenance / Inspection

Service interval

Inspect
brake system

On handover, after 50 operating hours,


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

Check brake fluid level,

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

Change brake fluid

At least every 2 years

Check parking brake, readjust if necessary

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

Retighten
screw fixings

After 20 operating hours, after 50 operating hours,


and then every 500 operating hours

Retighten
wheel nuts as specified

On handover, after 5, 20, 50 operating hours,


and then every after 250 operating hours

Check toe-in of the guide wheels

On handover, and then every after 500 operating hours

Check or set the wheel bearing play


of the steered wheels

On handover, after 20 operating hours,


and then every 250 operating hours

Check tyre pressure

On handover, daily

Visual inspection for oil leaks at gears and


Brake system

307.1133.3.6 englisch (en) 10.2006

daily

B3

B
Service
Training

5650H 5690HTS
Maintenance and inspection
Manual gearbox

Checking the oil level


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

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

35486

For the oil change intervals please refer to


the lubrication plan, but in all cases the oil
must be changed at least after the harvest
season in the course of the winter storage
preparations.

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

33802

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

Pour fresh oil into (5), up to the bottom edge of the


threaded hole at (3).
Screw in the oil inspection screw (3).

33820

B4

For the oil change intervals please refer to


the lubrication plan, but in all cases the oil
must be changed at least after the harvest
season in the course of the winter storage
preparations.

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

5650H 5690HTS
Maintenance and inspection

Final drive Balance

The gear case is vented through the venting valve (1).


Oil level checking
Place the machine in neutral position (the front gear
cover must be perpendicular 90 to the ground).
Oil level shall be checked at the control screw (2).

3
35626

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

307.1133.3.6 englisch (en) 10.2006

B5

B
Service
Training

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

Checking the brake fluid / brake pads


Important!
B-1

For reasons of traffic safety, it is indispensable that the


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

When the brake pad has worn down to a thickness


of 2 mm
If the brake pads are unevenly worn.

Always replace the brake pads on all callipers of an axle


at the same time.
Only use brake pad sets approved by the vehicle
manufacturer or brake manufacturer.

B-7

B6

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

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

Fixed calliper

Repair set

Brake pad assembly

Fit bolt

Hexagon-head bolt

Bleeder valve

307.1133.3.6 englisch (en) 10.2006

B7

B
Service
Training

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

B-13

Using piston-rotating pliers, rotate the piston to the correct


position against the gauge.

Direction of rotation of the disc brake during


forward travel

2b Lower contact surface in the calliper slot


3

Piston gauge with 20 measuring edge

Piston face recess angle

Hole for applying the piston-rotating pliers

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

B-17

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

For mounting the retaining pins

Brake pin punch:


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

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

B-15

B8

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

5650H 5690HTS
Maintenance and inspection:
Brake system

Changing the brake pads


Special tools
1 Brake pad remover
Part No. 03.93141400.2/011)

B-22

2 Piston retracting tool


Part No. 03.93144950.3/01

B-18

Piston-rotating pliers for setting the


20 piston face recess angle
Part No. 03.93145700.3/01

20 piston gauge for checking the setting of the


20 piston face recess angle
for piston- 42 48 mm
Part No. 03.93140900.1/02
for piston- 5257 mm
Part No. 03.93140600.1/02
for combine harvester types
4030, 4035, 4040, 4045H

B-20

5 Gauge for measuring brake pad wear


Part No. 03.93146170.3/01

B-21

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

B-19

B9

B
Service
Training

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

Always change both brake discs on an axle at the same


time.

Reworking dimensions

5650H 5690HTS

Disc thickness
original

Minimum thickness
reworked

22 mm

21 mm

Condition:
a)

Brake disc can be reworked if necessary.

b)

Severe scoring and ridging of the outer


circumference. The possibility of reworking depends
on the depth of wear. The wear depth must not
exceed the maximum reworking dimension.

c)

Wedge-shaped wear of the brake disc. The brake


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

B-.23

B-24

B 10

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

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

307.1133.3.6 englisch (en) 10.2006

B 11

B
Service
Training

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

B 12

Brake lever

O ring

Brake plate

Shaft

Brake shoe with brake pad

19

Thrust washer

17

Flange

18

Brake drum

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

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

Generally common configuration:


Positive offset
E

Offset

Rim centre line

Inner attachment face

Pitch circle

Hub bore

B-40

Special design:
Negative offset
E

Offset

Rim centre line

Inner attachment face

Pitch circle

Hub bore

B-37

307.1133.3.6 englisch (en) 10.2006

B 13

B
Service
Training

M20x1.5 300 Nm

740 Nm
M24

750 Nm

210 Nm

1
A

4.1

A
5
210 Nm

B-38

B 14

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

5650H 5690HTS
Drive axle
1

End play of the side shafts, max. 3 mm

Parking brake

Brake calliper

Profilmuffe

4.1 Bolt M10x85


5

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

Hydrostatic motor

HMF 105: 5650 - 5660


HMF 135:

5650 - 5660 Balance


5680 - 5690

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

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

307.1133.3.6 englisch (en) 10.2006

B 15

B
Service
Training

5650H 5690HTS
Balance
Drive axle
1

Axle

Final drive

Drive plate

Bolt M20, 10.9 secured with Loctite 243

Washer Disc

Thrust ring

Spacer discs

Retaining plate

Bearing sleeve, cemented in place with Loctite 648

10 Spacing sleeve between profile sleeves


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

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

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

B 16

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

3
4

300 Nm

5, 7, 8

17

1
9
B-50

16
18

10

12

11

210 Nm

6
2

15

14

13
20 Nm

B-49

307.1133.3.6 englisch (en) 10.2006

B 17

B
Service
Training

5670
Shift Gear SBK 419 (1604 0899)
1

Drive Shaft

Countershaft

Slotted nut, caulked on the drive shaft

Shifter collar, 1st and 2nd gear

Shifter collar, 3rd and 4th gear

Hand Brake

Differential Gear

Output Shaft with Brake Disc

Disc

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

B 18

307.1133.3.6 englisch (en) 10.2006

307.1133.3.6 englisch (en) 10.2006

200-250 Nm 3

46-54 Nm

46-54 Nm

0-0,6

64 Nm

25-28 Nm

25-28 Nm

80-94 Nm

46-54 Nm

Service
Training

B005

B 19

B
Service
Training
1
13

13

200-250 Nm

B006

30-35 Nm

BB

3
35-41 Nm

54-69 Nm
69-83 Nm

10
4
10

9
B007

B 20

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

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

Housing cover

Shifter rail for shift finger

Shift finger

Shift lock

Guide pin for shift lock

Ball, pressure spring for locking of the shifter rails

Shifter rails for shift-forks

Shift-fork, 1st and 2nd gear

Shift-fork, 3rd and 4th gear

10

Threaded pin with counter nut, secured with Loctite 262

Adjustment of the shift-forks (8, 9):


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

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

307.1133.3.6 englisch (en) 10.2006

B 21

B
Service
Training

5680, 5690
Shift Gear (1604 0895)
1

Drive Shaft

Countershaft

Shifter collar, 1st and 2nd gear

Shifter collar, 3rd and 4th gear

Hand Brake

Output Shaft with Brake Disc

Differential lock, actuation not coupled

Differential Gear

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

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

B 22

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307.1133.3.6 englisch (en) 10.2006

90-106 Nm

46-54 Nm

46-54 Nm

80-94 Nm

0,3-0,8

80-94 Nm

46-54 Nm

24-28 Nm

116 Nm

80-94 Nm

25-28 Nm

80-94 Nm

25-28 Nm

90-106 Nm

Service
Training

B001

B 23

B
Service
Training
1
9

2
5

10

11

B002

4
1

CC

AA

55-65 Nm

30-40 Nm

4
B004

12
7

EE

30-40 Nm
55-65 Nm

8
9

FF
9
10

11

10, 11

B010

FF

B003

9
B 24

B011

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

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

Gear Shift Cover

Housing cover

Shaft for shift finger

Shift finger

Dowel Pin, two pieces

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

Ball, pressure spring for locking of the shifter rails

Balls for shift lock

Shifter rails for shift-forks

10

Shift-fork, 1st and 2nd gear

11

Shift-fork, 3rd and 4th gear

12

Threaded pin with counter nut, secured with Loctite 262

Adjustment of the shift-forks (10, 11):


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

307.1133.3.6 englisch (en) 10.2006

B 25

B
Service
Training

5650H 5690HTS
Gear Shift

Gearshift Lever

Gear shift bracket (Selection of gear shift gate)

Star wheel with guide finger (engaging of gears)

Steering rod star wheel bellcrank

Bellcrank gears

Shifting Gate

Feed rods gear shift gate

Feed rods Gears

Bellcrank for shift gate at gear box

10

Gear Shift Head

11

Shifter rail in gear cover

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

Star wheel fulcrum (3) - Engaging of gears

Position of shift gates


A
5670

3 and 4

1 and 2

5650, 5660 1 and 2

3 and 4

5680, 5690

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

B 26

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

4
6

5
7
8

11

10
A
B

9
8
1,3

2,4
307.1133.3.6 englisch (en) 10.2006

56-116

B 27

B
Service
Training

4
6

8
2
6

6
1

2
3

4
1

B 28

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

5650H 5690HTS
Final Drive (1604 0897)
1

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

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

Gear Wheel Shaft

Shrunk-on intermediate ring

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

Shim Rings

Thrust Washer

Shaft Seal Ring

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

X Detail Final Drive (1604 1806) for Balance Axle


1

Drive Shaft

Shaft Seal Ring

Retaining Ring

Shim Rings

Washer Disc

Gear Box Housing with Bearing Tube

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

307.1133.3.6 englisch (en) 10.2006

B 29

B
Service
Training

5650H 5690HTS
Steering Axle
1

Steering Axle Support

Hinged Stop

Steering knuckle

Steering tie rod

Steering cylinder

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

Stop Screw

Steering Stop Limit

Hub of the Wheel

10

Seal Washer

11

Supporting Disc

12

Castle nut, secured with cotter pin

13

Washer Disc

14

Thrust Washer

15

Cover disc with spring dowel (anti-rotation pin)

16

Washer disc, shim ring

Adjustments at the steering axle:


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

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

B 30

307.1133.3.6 englisch (en) 10.2006

B
Service
Training

1
1,1

6
3

15

16

8
14
10
12

11
13
b

307.1133.3.6 englisch (en) 10.2006

B 31

B
Service
Training

Notes

B 32

307.1133.3.6 englisch (en) 10.2006

C
Service
Training

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

5650H
5680H
5660HTS 5690HTS

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

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

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

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

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

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

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

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

307.1133.3.6 englisch (en) 10.2006

C1

C
Service
Training
B40
15

S22

S23

15

30

31

F34
F39

30506-1

H35

X505

X515

S40

A30
X510

X507
2

A8

26

13

14

H1b H2b
H3b H4b

F2

F1

35402

X5
X1
H1a

X505
X508
X509

X508

X2
H2a

4
F3

F4

R1 R2

X4
H4a

X3
H3a

G3

D+

X1
X3
X4

+12V
X6
GND-

R3 R4

C0105

K50 K71

G
W

X16

M5
X142
X143

B39

M4

M6

B38
B19

C2

M7

307.1133.3.6 englisch (en) 10.2006

C
Service
Training

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

Clutch Control Power Unit

A30

Commander Control

B19

Speed sensor chopper

B38

Sensor for chopper flap position

B39

Sensor grain tank tube

B40

Central Indicator

Fuses

G3

Generator

H35

Indicator light chopper flap

K50, K71

Relay swivel grain tank tube

M4

Servomotor threshing mechanism clutch

M5

Servomotor for feed passage clutch

M6

Servo motor grain tank clutch

M7

Servomotor chopper clutch

S22

Foot switch cutting mechanism stop

S23

Foot switch grain tank clutch

S40

Working master switch

X....

Connector

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

Engaging belt couplings at engine stop:


Press key

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

Working master switch must be ON.

307.1133.3.6 englisch (en) 10.2006

C3

C
Service
Training

34939-4

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

SOLARI 1.she

56-000

A8

26

13

14

H1b H2b
H3b H4b

F2

F1

X5
X1
H1a

3
4
F3

X2
H2a
+12V
X6
GND-

F4

X3
H3a

30
31

R1 R2

X4
H4a

R3 R4

C0105

C4

307.1133.3.6 englisch (en) 10.2006

C
Service
Training

5650H 5690HTS
Electric actuation of the belt couplings
Integrated clutch control power unit (CCP2)
14

Load relay
1

Threshing mechanism

Feed passage

Grain tank discharging

Straw chopper

F1 F4

Fuses 30 A

F1 F5

Fuse 60 A

X1 X6

Plug-in connectors

H1b H4b

LEDs, control input

H1a H4a

LEDs, load output

R1 R4

Potentiometers

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

LEDs for indicating the switch status at the control input


(signals from the control unit) for belt clutches 1 4

H1a H4a:

LEDs for indicating the switch status at the load output


(connectors X1 X4) for belt clutches 1 4

Setting the load switching point:


R1 R4:

Potentiometer for adjustment of the cut-off current of the servo motors


(spring-loading of the relevant belt clutch)
Turn clockwise:
increase load current (spring-loading)
Turn counter-clockwise:
reduce load current (spring-loading)
1 turn = approx. 2.8 A change in load current

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

Pin

A8
A8
A8
A8
A8
A8
A8
A8

X5
X5
X5
X5
X5
X5
X5
X5

Pin No. Function


6
2
9
8
19
18
22
21

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

307.1133.3.6 englisch (en) 10.2006

Cable colour

Pin

Pin No.

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

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

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

Com.
Control

Pin

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

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

C5

C
Service
Training

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

Grain tank discharging clutch


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

C6

307.1133.3.6 englisch (en) 10.2006

C
Service
Training

C0110

C0111

307.1133.3.6 englisch (en) 10.2006

C7

C
Service
Training

C0112

C0113

C8

307.1133.3.6 englisch (en) 10.2006

C
Service
Training

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

Feed passage clutch


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

307.1133.3.6 englisch (en) 10.2006

C9

C
Service
Training

Lubrication distributor
left side
Installation Diagram

Bent pipe discharge pipe

Slewing rim bent tube

Slewing rim bent tube

Angular gear grain tank discharge

Turbo separator

Impeller

Threshing drum

Shaft of sieve pitman arm

Bearing feed passage

11 Bearing feed passage shaft

C 10

For more information about lubrication


distributor blocks refer to section "lubrication
distributor right side.

307.1133.3.6 englisch (en) 10.2006

C
Service
Training

Lubrication distributor
right side

10h

1. Bearing feed passage


2. Bearing feed passage shaft

35618

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

Installation diagrams of lubrication distributor


blocks

Instructions for trouble shooting


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

In the installation diagrams, the allocation and


assignment of the points of lubrication to the
corresponding distributor block is shown.

If lines are replaced, they must be


connected according to the installation
diagram as the amount of grease for each
point of lubrication is metered individually by
the corresponding distributor block valve!

307.1133.3.6 englisch (en) 10.2006

If the distributor block cannot be lubricated, identify the


clogging point of lubrication and clear.

Call on a specialised workshop if necessary.

C 11

C
Service
Training

Lubrication distributor
Balance

1+2

Journal bearing

3+4

Journal bearing

5+6

Hydraulic cylinder rear

7+8

Hydraulic cylinder front

35618

For more information about lubrication


divider blocks refer to section
"lubrication distributor right side.

Installation Diagram Central lubrication system


Block
No

Designation

Pump unit of centralised lubrication system

Distributor block right

Distributor block

Distributor block

Distributor block

Distributor block

Distributor block above front axle

Instructions for trouble shooting


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

(only with Balance)


8
10

C 12

Distributor block left


Distributor block feed passage

If the distributer block cannot be lubricated, identify


the clogging point of lubrication and clear.

Call on a specialised workshop if necessary.

307.1133.3.6 englisch (en) 10.2006

307.1133.3.6 englisch (en) 10.2006

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

Chopper

Right side

VPKM-4-520
Lubrication aid

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

VPBM-4-209
Lubrication aid

Feeder front right

Pivoting cutting
mechanism

Feed passage

Sieve pitman arm


Sieve pitman arm
Sieve pitman arm
Tensioning pulley

Left side

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

Tensioning pulley
Tensioning pulley
Tensioning pulley
Tensioning pulley

Speed setting

Pivoting cutting
mechanism
Tensioning pulley
Feeder front left

Revolvingg turret
Tensioning pulley
Tensioning pulley
Tensioning pulley
Chopper

VPKM-5-404
Lubrication aid

Service
Training

C 13

C
Service
Training

Notes

C 14

307.1133.3.6 englisch (en) 10.2006

D
Service
Training

5650H 5690HTS
Hydraulic
Table of contents
Combine Harvester Types

5650H
5680H
5660HTS 5690HTS

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

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

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

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

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

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

Subplate for control valve block:


Flow control valve with integral pressure-limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 19

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

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

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

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

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

X
X
X
X
X
X

X
X
X
X
X
X

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

X
X
X

X
X
X

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

X
X
X
X

X
X
X
X

X
X

X
X

X
X
X
x
X
x
X

X
X
X
X
X
X
X

.
.
.
.

.
.
.
.

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

Hydrostatic ground drive


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

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D1

D
Service
Training

5650H 5690HTS
Hydraulic
Table of contents
Combine Harvester Types

5650H
5680H
5660HTS 5690HTS

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

D2

X
X
X
X
X
X
X
X
X
X

X
X
X
X
X
X
X
X
X
X

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D
Service
Training

Hydraulic system
General
Safety instructions
1.
2.
3.

4.
5.

The hydraulic system is under high pressure.


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

Maintenance
1.
2.
3.
4.

5.
6.

When connecting hydraulic equipment, make sure


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

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D3

D
Service
Training

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

Meaning

Lines

Working line

Energy conversion
Symbol

Designation

Meaning

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

Control line
Leak line
Double line

Shaft, lever, rod

with 1 delivery direction

Circle

Differentiated by
size of symbol:
Pump, compressor,
motor

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

Measuring device
Check valve,
rotary connection

with 1 direction of flow

Joint, contact roller

with 2 directions of flow

Square,
Rectangle

Example: valves,
cylinders, actuators

Square
on tip

Filter, lubricator,
heat exchanger

Various
symbols

Spring

Symbol

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

Restrictor
with 2 directions of flow
Measuring orifice
Function symbols
Designation

Meaning

Function
symbols
Delta

Direction of flow
with indication
of pressure medium
hydraulic
pneumatic

Arrow

Direction of flow
Rotatability

Oblique
arrow

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

Thin dotted
border

Frame around parts


belonging to a single
block or subassembly

D4

Symbol

Pump
motors

Hydraulic devices that


can operate as both
pump and motor

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

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D
Service
Training

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

Pressure valves

Designation

Meaning

Singleacting
cylinders

The force applied by the


pressure medium moves
the piston in only
1 direction

Symbol

Designation

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

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

Telescopic
cylinders

Cylinder with a number


of telescoping pistons
adding their strokes
together

singleacting

Return movement
only by external force

doubleacting

Forward and return


movement by hydraulic
liquid or compressed air

Symbol

Valves that mainly


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

Return movement
by external force

Doubleacting
cylinders

Meaning

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

Valve with a remote


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

Cylinder with Double-acting cylinder,


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

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D5

D
Service
Training

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

Meaning

Check valves
Symbol

Designation

Valves that mainly


influence the flow rate

Orifice valve

2-way
flow control
valve

Flow valve with


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

2-way
adjustable
flow control
valve

Flow valve that


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

3-way
flow control
valve

Flow valve that


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

3-way
adjustable
flow control
valve

Non-return
valve

Flow valve with


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

Flow valve that


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

Symbol

Valves that block the


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

Flow control
valves with
constant
restriction
Restrictor
valve

Meaning

Check valve that closes


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

Remotecontrolled
non-return
valve

Non-return valve with


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

Switch
positions
Circulating
position

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

Floating
position

All ports are connected.

Blocking
position

All ports are closed.

D6

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D
Service
Training

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

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

Symbol

Actuators
Designation
Actuators
with
operatorsupplied
control force

Forward
position

Reverse
position

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

307.1133.3.6 englisch (en) 10.2006

by pushbutton

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

Channel shut-offs are


indicated by transverse
dashes inside the boxes.

Flow
positions

General

by pedal

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

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

Symbol

by lever

Inside the boxes, the


lines represent the
channels and the arrows
the directions of flow.

Abbreviated
designation

Meaning

Electrically
operated
actuators

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

Directly
operated
actuators

by applied pressure

Filters
Designation

Meaning

Filter

Device for separating


dirt particles

Symbol

D7

D
Service
Training

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

Pipes/Lines

Designation

Meaning

Cooler

Device for cooling the


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

Symbol

Meaning

Hydraulic
accumulator

Device for storing


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

Symbol

Meaning

Containers

Ventilated, with pipes


above the level of the
liquid

Symbol

Control
line

Line for transmitting


the control energy,
including settings and
adjustments

Leakage
line

Line for draining


any leaking liquid
or for venting

Flexible
line

Line that can flex


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

Connection
between
lines

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

Pressurised connections
Designation

Meaning

Pressurised
connections

Ventilated, with supply


to pump

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

Pressurised

with stopper

Ventilated, with pipes


below the level of the
liquid

Meaning

Electric
motor

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

Combustion
motor

Symbol

with connecting line

Energy sources
Designation

Symbol

Electric
line

Containers/Tanks
Designation

Meaning

Working line, Line for transferring


return line
energy
and supply
(feed) line

Accumulators
Designation

Designation

Symbol
Quick-release coupling
M

Designation

Meaning

Quickrelease
coupling

Line connector that


can be joined and
separated without tools

Symbol

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

D8

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D
Service
Training

Hydraulic system
General

Pressure
regulating

Pressure-limiting valve
Pressure-reducing valve

Pressure
switching

Pressure
valves

Pressure control

Circuit symbols in the hydraulic circuit diagram conforming to ISO 1219

Connecting valve

with fixed switching


positions
without fixed
switching positions
pressuredependent
pressureindependent

Flow control
valves

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

Shut-off
valves

Check
valves

Flow control

Directional
control valves

VALVE FUNCTIONS

2/2-way valve

307.1133.3.6 englisch (en) 10.2006

Plunger valve
Servovalve

Restrictor

Orifice

2-way flow control valve


3-way flow control valve

Non-return valve
Releasable
non-return valve

Shut-off valve

D9

D
Service
Training

5650H 5690HTS
Circuit diagram working hydraulics

Circuit logic working hydraulics:


Adjustment function

Magnet

Cutting table

Raise
Lower

Reel, vertical adjustment

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

Raise
Lower

Grain tank discharge tube

Slew outboard

Slew inboard
Reel, horizontal adjustment

Forward
Back

Grain tank extension

Extend

Retract
Cutting angle

Forward
Back

Cutting table tilting

Left down
Right down

Hydraulic pumps

1.1

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

1.2

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

1.3

Geared pump for steering gear (8 ccm/rev)

Pressure-control valve for cutting mechanism, 180 bar

Control valve for cutting mechanism

Sequence valve for accumulator, with pressure sensor

Two accumulators, filling pressure 45 bar and 70 bar

Control block for small consumers

Steering hydraulics

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

D 10

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Service
Training

1.1
1.2
1.3

2
4
5
3
A00242-1

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Service
Training

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

Hydraulic pumps:

1.1
1.2

Lift/lower cutting table (14 cm3/rev)


Small consumers (8 cm3/rev)

1.3

Steering (8 cm3/rev)

Pressure relief valve 200 bar

Flow divider

Control block

4.1

Reel vertical

4.2

Grain tank tube

4.3

Reel horizontal

4.4

Grain tank extension

4.5

Cutting angle adjustment

Control block for automatic pitch compensation of cutting table

5.1

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

5.2

Pressure control valve

Pressure relief valve 150 bar for banking cylinder of cutting table

Control valve for cutting table

7.1

Sequence valve for accumulator, with pressure sensor

7.2

Two accumulators, filling pressure 45 bar and 70 bar

Pressure relief valve 180 bar for control valve of cutting table

Oil cooler

10

Oil reservoir with return filter

Hydraulic system of Balance

Steering

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1.2

1.3

1.1

7.1

7.2

10

4.1

4.2

4.3

4.4

5.2

4.5

5.1

Service
Training

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D55
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Service
Training

D56-1

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Service
Training

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

Hydraulic pumps:

1.1 Lift/lower cutting table (14 cm3/rev)


1.2 Small consumers (8 cm3/rev)
1.3 Steering (8 cm3/rev)
2

Pressure relief valve 200 bar

Flow divider

Control block

Control block for automatic pitch compensation of cutting table

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


5.2 Pressure control valve
5.3 Baseplate with pressure-control valve 170 + 5 bar
5.4 End plate
5.5 Orifice 2,5 mm in the pipe for oil under pressure
5.6 Changeover valve
6

Pressure relief valve 150 bar for banking cylinder of cutting table

Control valve for cutting table

Pressure relief valve 180 bar for control valve of cutting table

Oil cooler

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

Hydraulic system of Balance

Steering

Banking cylinder of cutting table

Tightening torque values for nuts and adjustable bolts


a =
b =
c =

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

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

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

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

Function

1 525 503 524

Connection subplate (flow control valve) with pressure-limiting valve


Control valve single-acting, reel vertical adjustment

0 521 608 851


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

Control valve (proportional valve), double-acting, field tracker control


(located in a separate valve block in case of balance)

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

Control valve block


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

307.1133.3.6 englisch (en) 10.2006

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

=
=
=
=
=
=
=
=
=
=
=

blue/red
brown
brown/yellow
yellow/red
green
green/yellow
green/red
orange
red
black
white
D 17

D
Service
Training

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

+5

bar

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

Port

Port

Pump (Supply)

Return

Pressure balancing piston

Pressure limiting valve

P 3 bar spring

Load-dependent control port

LS Load-dependent control system

D 18

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Training

A00234

A00238

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A00232

A00236

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

Reel, vertical adjustment

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

Port

Port

Pump (supply)

Return

Control spool

1.1

Solenoid coil

1.2

Solenoid coil

Check valve

2.3

Copper washers

Change-over valve

Load-dependent control port

Floating piston

LS

load-dependent control system

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Training

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

Grain tank discharge tube, slew inboard/outboard


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

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

Port

Port

Pump (supply)

Return

Control spool

1.1

Solenoid coil

1.2

Solenoid coil

2.1

Check valve

2.2

Check valve

2.3

Copper washers

Change-over valve

Load-dependent control port

Floating piston

LS

load-dependent control system

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A00231

A00237

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Training

A00233

A00212

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

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

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

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

Control spool

1.1

Solenoid coil

1.2

Restrictor port

1.3

Control edge

Pressure sensor

Pressure accumulator

Cutting table cylinders

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

Working cylinder

Neutral circulation

Pump

Return

Flow control valve (pressure balancing valve)

Control spool (proportional valve)

Adjusting restrictor, lowering

Pressure limiting valve (200 bar, cylinder safety valve)

Lowering valve with load compensation

Check valve

Proportional solenoid lower

Proportional solenoid raise

Neutral circulation or return


Control oil flow
Lowering or raising oil flow
Flow direction
Residual oil flow

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A00216

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Training

A00213

A00216

A00214

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Training

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

Lower cutting table


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

A
N
P
R

Working cylinder
Neutral circulation
Pump
Return

1
2
3
4
5
6
7
8

Flow control valve (pressure balancing valve)


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

Neutral circulation or return


Control oil flow
Lowering or raising oil flow
Flow direction
Residual oil flow

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

Oil tank for working hydraulics and ground drive hydraulics

Hydraulic pump: capacity 19 cm3 / Udr.

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

Pilot control unit:


Neutral circuit check valve M0 with pressure limiting valve (175 bar)

Control valve block "Balance left

Control valve block Balance right

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

External flow control valves + SR2.


Observe the mounting position

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

Arrow points in forward direction.

Circuit logic for self-levelling control:


Adjustment function

M0

M1

Extend left and right actuators


Raise front of machine

Retract left and right actuators


Lower front of machine

Extend left / Retract right actuator


Tilt machine from mid-position to right

Extend right / Retract left actuator


Tilt machine from mid-position to left

D 30

M2

M3

M4

M5

M6

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Service
Training

M1

A1.1

A2.2

A1.2

A1.2
ERV

RV2

M3

M6

M4

M1

A1.1

A2.2

ERV

RV2

M2

A2.1

A2.1

M2

M1
M2

M5

RV1

RV1

SR1

-SR1

7
+SR2

+SR2

max. 29 l/min

max. 29 l/min

M
P1

M0

175 bar

T
T

T1

A1.2
5
A2.2
6

7
1
6
A2.1
4
2
A1.1
3
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Service
Training

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

Valve block pilot control

Pilot control valve (M0)

2.1 Solenoid coil


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

Pressure limiting valve 175 bar

3.1 Pressure adjusting device


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

O-ring seal

G1/8" measuring port for pressure measurement

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

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M2 / M5

M3 / M6

M1 / M4

25+5 Nm

3
7

25+5 Nm

30 Nm

25+5 Nm

RV2

A1.1

T
A2.1

6
SR1

40 Nm

30 Nm

RV1

A1.2 A2.2

10
M1

40 Nm

10
M2

30 Nm

8
ERV

M1

A1.1

A2.2

A1.2

M4

A1.2
ERV

M6

M1

A1.1

A2.2

ERV

RV2

M2

A2.1

A2.1

M2

RV2

M3

M1
M2

M5

RV1

RV1

SR1

-SR1

11

D 34

11

+SR2

+SR2

max. 29 l/min

max. 29 l/min

307.1133.3.6 englisch (en) 10.2006

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

Balance valve block

Solenoid coils

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

3/2-way valves (M3, M6)

O-ring seal

Flow control valve (SR1, +SR2)

Non-return valve (RV1, RV2)

Hydraulically releasable non-return valve (ERV)

Machined hole (no function)

10 Measurement port M1, M2, (M14 x 1,5)


11 Flow control valve + SR2 externally in return line

Observe the mounting position

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

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

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

Piston rod

Pipe break safety valve

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Service
Training

1
2

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S62

b
a

1,0 mm

A
1

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

Pressure retaining valve (35 bar)

Shock valves 150 bar

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

Balance
Hydraulic cutting angle adjustment
Description

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

515 mm, stroke approx. 200 mm


The swivel frame must not rest on the feed passage connection.

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

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

Snap ring

Scraper ring

Grooved ring

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

Guide bushing

Locking wire

Cap nut

Scraper ring

Sealing ring

A Version: Hengstler
B Version: Pacoma

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

Scraper ring

Sealing ring

Locking wire

O-Ring

Piston seal

B Reel horizontal left


1

Scraper ring

Grooved ring

Locking wire

O-Ring
Piston seal

Leakage oil compensation

C Grain tank discharge tube


1

Scraper ring

Sealing ring

Locking wire

O-Ring
Piston seal

D Grain tank discharge tube-locking


1

Snap ring

Grooved ring

Scraper ring

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

Port P or R

Bleeder

A1 A2 Reel horizontal
A1 B

Reel vertical

Hydraulic actuator for grain tank extension


A

0.6 mm baffle plate. Dismantle to bleed.

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

Steering column

Neutral position springs

Housing

Non-return valve (short-circuit valve)

Inner spool

Outer spool

Universally jointed shaft

Toothed ring (rotor ring)

Gear wheel (rotor)

10

Shock valves

11

Refill valves

12

Non-return valve (TV valve)

13

Pressure limiting valve

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A00221

A00225

A00227

A00224

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Training

A00210

A00227

A00220

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A00222

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Service
Training

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

Shock valves (205 bar)

Pressure limiting valve (150 bar)

Housing

Non-return valve (short-circuit valve)

Inner spool

Outer spool

Universally jointed shaft

Toothed ring (rotor ring)

Gear wheel (rotor)

10

Refill valve

11

Non-return valve (TV valve)

12

O-rings

13

Axial needle bearing

14

Ring

15

Neutral position springs

16

Distributor plate

17

Cover

18

Washers

19

Screws (tighten in diagonally opposite sequence)

20

Nameplate

21

Pressure setting screw

Repairs / General overhaul of the Lenkorbitrol


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

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

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

Possible cause

Remedy

The steering wheel is hard to turn.

1. No or insufficient oil pressure.


a) Pump not running.
b) Pump faulty.
c) Pump rotating the wrong way.

1.

d) Pump worn.

Constant steering corrections are


required with the steering wheel
(cornering).

The steering wheel does not return to


the neutral position.

The steering wheel continues turning


after it is turned.

Steering wheel play.

307.1133.3.6 englisch (en) 10.2006

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

2. The pressure limiting valve sticks


in the open position, or the set
pressure is too low.

2. Repair or clean the pressure


limiting valve. Adjust the valve to
the correct pressure.

3. Excessive friction of the


mechanical parts of the steering
system.

3. Lubricate the bearings and links


of the steering system, and repair
if necessary. Check the steering
column assembly.

1. Leaf springs lacking tensional


force or broken.

1. Change the leaf springs.

2. Spring in double shock valve


broken.

2. Replace the shock valve.

3. Gear set worn.

3. Replace the gear set.

4. Cylinder cracked or piston seals


worn.

4. Replace the defective parts.

1. Steering column and steering unit


not centred.

1. Centre the steering column in


alignment with the steering unit.

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

2. Adjust the clearance. If necessary,


shorten the multiple-spline shaft.

3. Seizing between the inner and


outer spool.

3. Contact your nearest Danfoss


service agent.

1. Leaf springs lacking tensional


force or broken.

1. Replace the leaf springs.

2. Inner and outer spools seizing,


possibly due to dirt.

2. Clean the steering unit or contact


your nearest Danfoss service
agent.

1. Yoke of universally jointed shaft


worn or broken.

1. Replace the universally jointed


shaft.

2. Leaf springs lacking tensional


force or broken.

2. Replace the leaf springs.

3. Splines of steering column worn.

3. Replace the steering column.

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

Possible cause

Remedy

Steered wheels vibrate.


(coarse tyre tread causes vibrations).

1. Air in the steering cylinder.

1. Bleed the cylinder. Identify and


remedy the cause of the air
build-up.

2. Piston seal of the steering


cylinder faulty.

2. Replace or repair the cylinder.

3. Gear set worn.

3. Replace the gear set.

4. Spacer missing above the


universally jointed shaft.

4. Fit the spacer.

The steering wheel can be turned


slowly in one direction, and possibly
both directions, without turning the
steered wheels.

1. One refill valve, or possibly both,


leaky or missing.

1. Replace the defective valves.

2. One shock valve, or possibly


both, leaky or missing.

2. Clean/replace defective valves or


fit missing valves.

The steering responds too slowly and


is too hard to turn when you try to
steer rapidly.

1. Steering unit is not receiving


enough oil; pump defective or
running too slowly.

1. Replace pump or increase its


speed.

2. Pressure limiting valve "sticking"


due to dirt.

2. Clean the valve and adjust to the


correct pressure.

"Kick-back" from the system to the


steering wheel.

1. Fault in system.

1. Contact Danfoss service.

Jolts from the wheels.

1. Incorrect setting of universally


jointed shaft and gear set.

1. Correct the setting or contact


Danfoss service.

Steering wheel jerks forcefully to both


sides.
When the steering wheel is turned,
the steered wheels turn the wrong
way.

1. Mismatched connection between


the steering unit and the steering
cylinder.

1. Replace the hoses.

Insufficient steering force


(possibly on one side only).

1. Pump pressure too low.

1. Correct the pump pressure.

2. Steering cylinder too small.

2. Fit a larger cylinder.

3. Area of the piston rod in the


differential cylinder too large in
relation to the piston diameter.

3. Install a cylinder with a thinner


piston rod, or fit 2 differential
cylinders.

1. Seal faulty.

1. Replace seal, or contact Danfoss


service.

2. Screws loose.

2. Tighten screws.
Torque 3 5 daNm.

3. Washers or O-rings faulty.

3. Replace washers or O-ring.

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

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5650H 5690HTS
Hydrostatic ground drive
General

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

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

Regularly clean the oil cooler.

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

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

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

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

Strictly follow the safety instructions!

Combine harvesters equipped with hydrostatic units


Combine Harvester Type

Hydrostatic pump

Hydrostatic motor

5650, 5660 HTS

HPV 105-02

HMF 105-02

5650, 5660 HTS - Balance

HPV 135-02

HMF 135-02

HPV 135-02

HMF 135-02

5680, 5690 HTS


Standard and Balance

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5650H 5690HTS
Hydrostatic ground drive
Basic construction:

Wiring diagram
Circuit diagram

Hydrostatic pump (swashplate pump)

Bypass valve integrated in the change-over filter

Feed pump

Block-type oil cooler in the air duct

Replaceable filter

High-pressure valve

High-pressure valve

Axial piston pump

Supply pressure valve opening pressure:

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

Observe mounting position

Function description of the hydrostatic system


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

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13

14

kor22/18-l

11
1

19

16
15

15
HY003-1

14

L2

19

L1

10

10
2

15

11
P

18

420

16

10

17

Ma

M
420

A
L

10

7
Ms

S
U
L

12
B

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HPV7-2

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2.1
1

210

49

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

Flange for mounting of hydrostatic pump

2.

Clutch disc

2.1

Bolt M10 x 35, cemented in place

3.

Clamping hub with retaining ring

4.

Diesel engine flywheel

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

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5650H 5690HTS
Hydrostatic ground drive
Drive control
1

Adjusting nut

Holder

Drive lever

Rack mechanism

Ball joint

Neutral detent

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

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

Release the handbrake.

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

Set the drive lever to reverse and back to neutral.


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

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

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

Backlash in the rack mechanism (4)

Play in the ball joint (5)

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

Rack mechanism
1

Engaging fork

Rack

Guide sleeve

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

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

Cam adjustment

Replaceable filter

Pressure limiting valve (cold-starting valve)

Gear pump (feed pump)

Pressure limiting valve (Boost pressure)

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

Pressure outlet, gear pump (A)

Shaft

Cradle (hydrostatic swashplate bearing)

10 Working piston (quantity: 9)


11 Cylinder block
12 Control head
13 Intake strainer for feed pump

Tightening torques for valves


Valve

HPV 105

HPV 135

Cold start valve 3

30 Nm

40 Nm

Boost pressure valve 5

30 Nm

40 Nm

High pressure valves 6

140 Nm

170 Nm

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1
2

HPV1-1

6
HPV4

4
7
1

10 11

12

13
HPV3

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

Adjustment

Cam

Operating lever

Stop screws

Nozzles

Pilot housing (hollow screw)

Marking

Pilot

Feed pump

10

Adjusting piston

11

Adjusting piston

12

Compression spring (mechanical neutral position)

13

Retaining plate

14

Cradle

Drive direction: right, (view X)


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

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3
2

1
1

8
9
4
10

11

12

12

14

13

6
6

4
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4
F

1
3

L2

L1

10
10
2

2
1
P

Ma
420

M
420

10

Ms

U
L

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5650H 5690HTS
Hydrostatic ground drive
Swashplate pump HPV 105, HPV 135
Measuring and testing
Overview of connections and measuring points
Circuit diagram
P, S

High-pressure port

Pressure port, feed pump

Intake port, feed pump

Control pressure supply,


Pressure supply, filter inlet

Measuring port, supply pressure, M14x1,5

Ms, Mp

Measuring ports, high pressure, M14x1,5

L, U

Leakage oil connections


Oil drain, optional leakage oil and
purge oil return from hydrostatic motor

L1, L2

Bleed connections

Pos Part
1

Setting:
2

19 bar

20 bar

25 bar

25 bar

420 bar

420 bar

Combined supply/high-pressure limiting valves


Setting:

HPV 135

Cold-starting pressure limiting valve


Setting:

HPV 105

Supply pressure limiting valve

Change filter

Arrow points in forward direction.

General instructions for pressure measurement:

Check hydraulic oil level.

Warming up hydostatic system, oil temperatures approx. 60 C.

Even under load the boost pressure must not fall below 10 bar.

In case of uncertainty whether a too low boost pressure is caused by the pump or by the hydro motor, obturate the
high pressure connections at the pump and measure again.

High pressure measurements must only be performed for a short time; danger of valve overheating.

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5650H 5690HTS
Hydrostatic motor, type HMF
Hydrostatic motor HMF 105, HMF 135
HMF-type hydrostatic motors are swashplate axial-piston motors.
1

Drive shaft

Bearing

Working piston with sho

Cylinder block

High-pressure ports

Discharge

6.1 Purge valve (10 bar)


6.2 Switchover valve
7

Leakage oil / purge oil, max. housing pressure: 1.5 bar

Control head

Swashplate

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HMF

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4
5
10

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5650H 5690HTS
Hydrostatic ground drive
Hydrostatic motor HMF

Circuit diagram
Radial shaft seal
Discharge device

Retaining ring

Radial shaft seal

Shaft seal holder

Switchover valve

4.1 Plug screw M 22 x 1.5 V80


4.2 O-ring 23.52 x 1.8 V80
4.3 Compression spring
4.4 Washer
4.5 Valve piston
4.6 Valve sleeve
5

Purge valve 10 bar

5.1 Plug screw


5.2 Spacing washer
5.3 Compression spring
5.4 Ball
5.5 Valve sleeve (adhesive-mounted)
5.6 O-ring 11 x 2 V80
6

Purge oil / leakage oil port

Dismantling/Assembly of radial sealing ring (2)

Release the retaining ring (1)


Force out the shaft sealing ring holder (3), including the shaft sealing ring (2) by blowing compressed air through the
leakage oil port (6).
Note:
Fix the washer and screw to the shaft end, in order to prevent the cover (3) being blown off.

The discharge system is used for purging the circuit and the housing.
Discharge flow rate: 12 l/min.
Purge valve opening pressure: 10 bar
Note:
The valve sleeve (4.6) of the switchover valve (4) is secured with adhesive.
Assemble/dismantle accordingly (dismantling: heat to approx. 200 C).

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5650H 5690HTS
Hydrostatic ground drive
New refilling and bleeding
1

Drain screw

Plug screw

Measuring port supply pressure

Measuring port high pressure

1.

Fill the system from the oil tank

2.

Remove the drain screw (1) from the hydrostatic motor.


If oil escapes from the drain hole when filling the system, refit the drain screw.
Note: If the high-pressure circuit is opened, check that the high-pressure hoses are filled with oil.
Keep all parts scrupulously clean.

3.

Unscrew the plug screw (2) to allow air to escape.


When oil starts escaping at the plug screw, retighten the plug screw.
Now fill the oil tank up to the "MAX" mark.

4.

Screw a transparent hose to the measuring point (3), and place the other end of the hose in the tank.
Turn the pump with the starter motor until oil is discharged without air bubbles (drive lever in neutral position).
un the engine at low idling speed (approx. 2 to 3 minutes), and monitor the transparent hose to the oil tank to make
sure that the return oil is free of bubbles.
Caution:
The drive lever must be in neutral position.
Check the oil level in the oil tank.
Repeat this procedure several times.
Remove the transparent hose.
Plug the measuring point (3).
Check the oil level in the oil tank and top up if necessary.

5.

Fit a transparent hose to the high-pressure measuring port (4), and place the other end of the hose in the tank.
Set the manual gearbox to idling mode (neutral).
Start the engine and run at low idling speed.
Move the drive lever gently forward and back until bubble-free oil is discharged from the transparent hose.
Repeat this procedure several times.
Monitor the oil level constantly, and top up if necessary.

Additionally: for machines with steering axle drive (all-wheel drive)


Secure the vehicle, i.e. apply the handbrake and block the drive axle wheels with safety chocks.
Jack up the steering axle, so that the wheels can turn freely.
Select 1st gear.
Repeat the bleeding procedure described in Step 5 (high pressure).

Tools required for bleeding:


Screw nipple x GE 8 SM M14x1.5
0110 1368
Cap nut M8 S
0111 6660
Cutting ring M8 L
0111 6635
Steel pipe 8x1 St 35.4 NBK Zn approx. 50 mm long
Hose clip S 12 8 Zy
Plastic hose, transparent, approx. 1500 mm long

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Mp

Ms

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5650H 5690HTS
Hydrostatic ground drive
Troubleshooting
1. Loud cavitation noises on starting up the system
The flow delivered by the feed pump is not sufficient to replace the leakage. The supply pressure collapses.
Check the supply pressure with the system under load.
Lines between pump and hydrostatic motor leaky

yes

Seal the lines, top up with oil,


bleed system

yes

Replace the feed pump,


clean the filter

yes

Replace the cold-starting valve

yes

Repair or replace the hydrostatic motor

no
Delivery capacity of pump too low
no
Cold-starting valve set too low
no
Excessive oil leakage in hydrostatic motor

Linde Repair Manual


no
Excessive oil leakage in pump

yes

If leakage identified, replace or repair


the pump.

2. Insufficient system traction with normal supply pressure and without cavitation noise
Slipping (internal connection) from the high-pressure side to the low-pressure side
High-pressure valve is leaky at the cutting edge
and valve seat

yes

Tighten high-pressure valve


as specified

yes

Replace high-pressure valve

yes

Replace pump and hydrostatic motor

no
High-pressure valve is set too low
no
Running surfaces of cylinder block and
control head worn

General
You can determine whether the control head of the pump or hydrostatic motor is worn (scored) by dismantling the feed
pump from the main pump and checking the filter behind it for metal shavings.

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5650H 5690HTS
Hydrostatic ground drive
Troubleshooting
3. System seized
Motor piston seized

yes

Replace motor

yes

Adjust the linkage or Bowden cable


to the pump so that the end-stop
of the drive lever matches the end-stop
in the pump

4. Machine fails to reach top speed


Linkage or Bowden cable
incorrectly set
Check whether the adjusting lever
on the pump is moved to its end position
by link-rods or Bowden cable.

5. Machine does not move forward or back when the drive lever is actuated
Not enough oil in tank

yes

Top up with oil

yes

Repair or replace

yes

Replace Centaflex coupling

yes

Check the supply circuit


(feed pump, supply pressure valve,
cold-starting valve)

yes

Clean nozzles
Linde Repair Manual

no
Linkage or Bowden cable sticking
no
Centaflex coupling between engine and
pump worn.
no
No supply pressure
no
Nozzles of servo adjusting system dirty

Testing
Remove the pump cover and adjusting lever

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5650H 5690HTS
Hydrostatic ground drive
Troubleshooting
6. Excessive oil temperature Max. 95 C
Oil cooler fouled

yes

Clean oil cooler. Seal the leak


in the air shaft or cyclone
(prevent dirt ingress)

yes

Make sure of correct air supply

yes

Replace temperature sensor

yes

Select a lower gear

yes

Replace cooler and pipes

yes

Replace cold-starting valve

yes

Replace high-pressure valve

yes

Replace pump and motor

yes

Set the linkage or Bowden cable so that


the drive lever and pump adjusting lever
reach the neutral position (0 position)
simultaneously

no
Insufficient cooling supply
no
Temperature sensor defective
no
Selected gear too high for working
at high load
no
Cooler back-pressure too high.
Cooler and pipes crushed.
no
Cold-starting valve set too low
no
High-pressure valve set too low
no
Excessive leakage oil from hydrostatic motor and pump

7. Neutral position unattainable


Linkage or Bowden cable incorrectly set.

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Training

5650H 5690HTS
Hydrostatic ground drive
Troubleshooting
8. No supply pressure
Not enough oil in tank

yes

Top up with oil

yes

Replace the feed pump

yes

Replace the cold-starting valve

yes

Replace the supply pressure valve

yes

Repair or replace the hydrostatic motor

yes

If leakage is detected, repair or replace


the pump

yes

Repair or replace

yes

Replace high-pressure valve

yes

Clean nozzle

yes

Repair or replace pump

no
Feed pump capacity too low
no
Cold-starting valve set too low
no
Feed pump set too low
no
Excessive leakage in hydrostatic motor
no
Excessive leakage from pump to outside

9. Machine only runs in one direction


Linkage or Bowden cable seized
no
Check high-pressure valve
(seized, fouled or faulty)
no
Nozzle of servo adjusting system clogged
no
Piston of servo adjusting system damaged
or leaky

10. In one direction, the speed fluctuates irregularly or traction is reduced

A spring in the switchover valve of the


hydrostatic motor is broken, or the valve piston
does not close fully

307.1133.3.6 englisch (en) 10.2006

yes

Repair the switchover valve

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5650H 5690HTS
Drive Hydraulics
Steering axle drive
1. Description / Function
The hydrostatic drive for the steering axle supports the ground drive under difficult working conditions.
2 slow-running wheel hub motors of the radial piston type are built into the steering axle to transmit the drive torque.
These motors are switched into the hydrostatic oil circuit by an electrohydraulic valve.
An electronic traction control system (ASR) prevents single-sided wheel spin when the traction conditions are different
on the two sides ("differential lock" effect).
2. Operation
The steering axle drive is engaged by the electric switch for 4-wheel drive in the driver's cab.
The integral warning lamp in the switch comes on to indicate that 4-wheel drive is activated.
Warning:
The steering axle drive can only be engaged when the machine is stationary (hydrostatic drive lever in neutral position).
The steering axle drive can only be disengaged when the machine is stationary, since otherwise the vehicle would
suddenly accelerate.
The steering axle drive cannot be activated in 4th gear.
On very steep downhill slopes with low load on the steering axle drive, the vehicle may accelerate due to loss of traction
on the driven steering axle.
Under these conditions, it is advisable to switch off the all-wheel drive.
The driver is informed that the steering axle drive is engaged by the green warning lamp with the 4-wheel drive symbol.

Traction control
If one of the drive wheels on the steering axle starts to spin, the traction control can be activated by pressing the
foot-switch. The red warning lamp confirms to the driver that traction control is activated.
When cornering with a steering angle of more than 10, the ASR control function is automatically suspended until the
steering angle is again less than 10 C.

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5650H 5690HTS
Drive Hydraulics
Steering axle drive Operation

Operating instructions
Activating 4-wheel drive
1.

Start the engine, or stop the combine harvester and


leave the engine running.

2.

Make sure that the Commander Stick is in neutral


position.

3.

Select the desired gear (not 4th).

4.

Press the "4-wheel drive" push-button.

5.

The "4-wheel drive" indicator lamp comes on.

If you select 4th gear in this mode, the steering axle


drive will be switched off, and will be immediately
switched on again when you select another gear.

5
31395-1

ASR Traction Control


1.

4-wheel drive is on.


The "4-wheel drive on" indicator lamp is lit.

2.

The steering angle to the left or right is no more


than 10.

3.

Press the ASR foot-switch.

4.

The "ASR on" indicator lamp comes on.

ASR traction control only remains activated while the


foot-switch is depressed.

2
10

31396

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5650H 5690HTS
Drive Hydraulics
Steering axle drive Hydraulic block diagram
1

High-torque radial piston motors

Pressure maintaining valve (1.5 bar)

Leakage oil return

Double valve (ASR)

Oil reservoir

Forwards high pressure

Hydrostatic pump.

Switching valve, steering axle drive

Arrow shows direction of travel

10 High pressure when driving forwards


11 Hydrostatic motor. Type: HMF
12 Forwards high pressure

Steering axle drive Hydraulic circuit diagram


1

High-torque radial piston motors

Pressure maintaining valve (1.5 bar)

Leakage oil return

Double valve (ASR)

Oil reservoir

Forwards high pressure

Hydrostatic pump.

Switching valve, steering axle drive

Arrow shows direction of travel

10 High pressure when driving forwards


11 Hydrostatic motor. Type: HMF
12 Forwards high pressure

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Training

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Service
Training

5650H 5690HTS
Drive Hydraulics
Steering wheel drive, double valve (ASR Traction Control)

Steering wheel drive, hydraulic switching valve (without pilot control valve)
1 Tightening torque 65

+/ 6,5

Nm

2 Tightening torque 65

+/ 6,5

Nm

3 Tightening torque 25

+/ 2

Nm

4 Tightening torque 30

+/ 3

Nm

5 Tightening torque 10

+/ 1

Nm

Steering wheel drive, pressure maintaining valve (1.5 bar)


1 Tightening torque 60

+/ 6

Nm

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5650H 5690HTS
Drive Hydraulics
Steering axle drive
Operating principle of the radial piston motors
Movement stages of the piston in relation to the cams:
Piston position 1
The oil is channelled under pressure to the distributor, passes through the distributor and presses against the piston.
This stage is the start of the oil supply stroke.
The pressure of the piston causes the roller to roll along the cam, thereby turning the cylinder block.
Piston position 2
The oil supply is opened to its maximum and now starts closing again as the piston continues its travel.
Piston position 3
When the piston reaches the bottom of the cam, oil supply is stopped. There is no further driving force. This point is the
bottom dead centre. Another piston must drive, so that the next cam brings the first piston back.
Piston position 4
The dead centre is overcome by the drive from another piston. The oil can return to the tank.
This stage is the start of the oil return stroke.
Piston position 5
The oil return reaches its maximum, and then the outlet port gradually starts reclosing. When the piston reaches the top
point of the cam (top dead centre), a new working cycle can start.
The direction of rotation of the motor depends on the setting of the distributor. If the direction of oil flow is reversed,
the direction of rotation is automatically changed.

Piston position 1

Piston position 2

Piston position 3

Piston position 4

Piston position 5

Steering wheel drive


Traction control (ASR)
The traction control system operates on the principle of rotary speed compensation, i.e. the speeds of the individual
wheels are measured and compared in the central electronic control unit.
If a faster speed (wheelslip, spinning) is measured on one or both wheels of the steering axle, a corresponding control
signal is sent to the control valve to reduce the oil flow to this wheel or wheels.

Double valve (proportional control valve)

Wheel drive

Speed (rotary speed tolerance range1)

Wheelslip

1)

Permissible speed difference without requiring control adjustment

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Training

5650H 5690HTS
Drive Hydraulics
Steering axle drive
Installation position of sensors and
valves
Switching valve (Fig. 31329)
The steering axle drive is engaged by the solenoid valve
mounted on the left-hand side of the machine.

31329

Inductive sensor for hydrostatic pump


The inductive pickup (1) at the hand throttle prevents
engaging of the steering drive axle while driving. To
activate the steering axle drive, the commander stick
must be in neutral position.

0
V
R

1+

0,

1
,5

Nulls

tellu

ng

1+

56-072de

4th gear switch


The switch (2) on the shift linkage prevents the steering
axle drive from being activated. When 4th gear is
engaged, the steering axle drive is switched off.

D-65

Pressure maintaining valve, 1.5 bar


The pressure maintaining valve (3) under the hydraulic
fluid tank maintains the pressure (1.5 bar) in the leakage
collecting line of the radial piston motors.

31332

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Service
Training

5650H 5690HTS
Drive Hydraulics
Steering axle drive
Installation position of sensors and
valves
Speed sensor for wheel hub motors (Fig. 31333 /
Fig. 31334)
Traction control (ASR)
The two sensors on the rear wheels, Fig. 31333 (1) and
the wheel sensor on the front right wheel, Fig. 31334 (1),
record the number of wheel revolutions. The ASR
electronic control unit calculates the distances each wheel
has travelled, taking into account the tyre size, and
compares these distances.

31333

Front axle speed sensor (Fig. 31334)

31334

Double valve (Fig. 31335)


If the values deviate from one another, the electronic
control unit actuates the double valve (1) under the
steering drive axle in order to adjust the volumetric flow in
the two radial piston motors accordingly, thereby
preventing the rear wheels from spinning.

31335

Steering angle sensor (Fig. 31382)


The steering angle sensor (1), mounted on the right
of the driven steering axle, monitors the steering angle.
When cornering with a steering angle of more than
10 to the left or right, the ASR traction control function is
suspended until the steering angle is again reduced to
less than 10.
The "ASR on" warning lamp goes out while the ASR
control function is suspended.

31382

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5650H 5690HTS
Drive Hydraulics
Steering axle drive
Setting Inspection
1. Before inspecting, make sure that the hydrostatic system,
including the steering axle drive (wheel motors) is properly bled.
Jack up the combine harvester (all 4 wheels).
Set the steered wheels to the "straight ahead" position.
2. Test the supply pressure of the BPV hydrostatic pump.
The pressure at nominal speed is 21 bar (system at operating temperature).
When the ASR traction control is activated, the pressure must not drop below 19 bar.
3. Inspecting the wheel speed sensors and steering angle sensor
Ignition on (engine off).
Engage the steering axle drive (green lamp comes on in the instrument panel).
Rotate the front wheel:
Sensor flashes ready for operation
Sensor constantly lit gap too small
Sensor unlit gap too wide
Follow the same procedure for inspecting the rear wheels.
Air gap of wheel sensors and steering angle sensor: 1

+0,5/0,3

mm

Test the steering angle sensor:


Sensor constantly lit ready for operation.
Caution: observe gap setting!
Sensor unlit sensor gap too wide
or steering angle > 10
Steering angle coverage: +10 / 10
Check the gap of the inductive sensor on the hydrostatic pump:
Gap size: 4 +/2 mm (hydrostatic drive lever in neutral position).
Check the switching function of the electrical 4th gear switch:
Engage 4th gear switch open (normally closed) no pass
4th gear not engaged switch closed pass
After successful inspection / setting, the machine can be let down again.

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Training

5650H 5690HTS
Drive Hydraulics
Troubleshooting Traction control (ASR)
Problem

Possible cause

Remedy

One or both steered drive


wheels spinning very
excessively

Double valve sticking/blocked

Replace the valve if the blockage


cannot be cleared
Check the electrical connections

Electrical connections of double valve broken

One or both steered drive


wheels tending to brake

Speed sensor defective or wiring broken

Replace the sensor


Check the wiring

Traction control (ASR)


not working

Electrical supply
Steering angle sensor faulty or air
gap too wide
Fuse in central electronic control box defective
Programming error in central electronic
control bo

Check the supply voltage


Check the wiring

Supply pressure too low

Measure the supply pressure


(> 19 bar)
Check/replace double valve
Check the supply voltage

Traction control (ASR)


working with considerable
delay

Wheels "chatter"
when driving in one direction

307.1133.3.6 englisch (en) 10.2006

Double valve blocked


Supply voltage too low or too high
Control spool of double valve sticking
Restrictor hole fouled

Check/replace fuse
Replace electronic control box

Dismantle the valve


Clean the restrictor hole
Test the control spool

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Notes

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Service
Training

5650H 5690HTS
Feed passage
Table of Contents
Combine Harvester Type

5650H
5680H
5660HTS 5690HTS

Feed passage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 03

Feed passage, Feed passage slip clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 05

Feed passage, Stabilising shaft for intake chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 07

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

Anti-wrapping device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 11

Anti-wrapping device between the chain sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 11

Reversing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 13

Feed passage floating frame, tilt adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 15

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Service
Training

5650H 5690HTS
Feed passage

The cutting table can be positioned parallel to the ground by tensioning or loosening the diagonal struts (1) with the nuts (2).
Before retightening a diagonal strut, loosen the screws (3) on the left and right and loosen the opposite diagonal strut.
1

Diagonal struts

Nuts

Screws

Floating bearing

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E3

E
Service
Training

E0002

E0003

E4

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Service
Training

5650H 5690HTS
Feed passage

M10 screws

Spacer washer

Lubricate the sliding surface of the bearing housing and the bearing half shell on the left and on the right side.

5650H 5690HTS
Feed passage
Feed passage slip clutch

Before each harvest season, air the slip clutch and make it slide through its complete adjustment range.
1
2
3

Metal surfaces must be degreased and coated with anti-corrosion agent "i RC 123 V" (Fuchs),
part No. 0 9097 123 400 40, before assembly (drying time: approx. 4 hours at 20 C).
Greased with Molykote BR2 0 9097 127 544 50
Slipping torque 450 Nm

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Service
Training

5650H 5690HTS
Feed passage
Feed passage

1
2
3
4
5

Tightening torque: 400 Nm (M24x1.5)


Upper end-stop for rocker arm
Lower end-stop for rocker arm (for maize threshing: turn 180)
Tightening torque for grooved nut: 56 Nm
Intake chain tensioner

5650H 5690HTS
Feed passage

Stabilising shaft (2) for intake chain


For threshing maize or sunflowers, lock the stabilising shaft (2) in the upper position or remove it.
1

Limit tube

Stabilising shaft

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Training

E0004

E0005

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Service
Training

5650H 5690HTS
Feed passage
Feed passage clutch
1

Reference dimension for the servomotor stroke (60 mm) during the clutch engaging process.

Spring-loading dimension for the engaged clutch


(set by means of the load relay potentiometer: see Chapter C ).

The servomotor stroke is set by adjusting the position of the spring assembly on the threaded rod (3).

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Service
Training

5650H 5690HTS
Feed passage
Anti-wrapping device
Item

Designation

Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Anti-wrapping device left


Anti-wrapping device right
U-piece
Screw M10x80
Screw M10x85
Stud bolt M10x90
Screw M10x100
Spring washer A10
Mushroom head screw M8x30
Washer 8.4x18x2
Spring washer A8
Nut M8
Washer 10.5x30x3
Lock nut M10

1
1
2
6
6
1
1
10
4
4
4
4
4
2

5650H 5690HTS
Anti-wrapping device between the chain sprockets
(Extra attachment for linseed threshing)
1

Plastic slider

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Training

E0018

E0020

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Service
Training

5650H 5690HTS
Feed passage
Reversing device

Plate

Relay for magnet-operated switch

Insulators

Connector for thermal protection switch (see wiring diagram)

Plate

Self-tapping screws M10x35

Detail Z1:
5.5 mm clearance between the ring gear and the armature spindle.
This clearance is set by adjusting the plate (1) in the oblong hole.
Detail Z2:
3 mm axial clearance between the ring gear and the pinion.
This clearance is set by adjusting the position of the flywheel on the transmission shaft.

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Training

E0023

E0024

E0025

307.1133.3.6 englisch (en) 10.2006

E0026

E 13

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Service
Training

5650H 5690HTS
Feed passage
Floating frame
Tilt adapter for cutting table (without hydraulic cutting angle adjustment)
The cutting angle of the cutting table must be adapted to the tyre size by adjusting the turnbuckles (1).
1

Turnbuckles

Sealing plate

5650H 5690HTS
Feed passage
Floating frame
Tilt adapter for cutting table with hydraulic cutting angle adjustment
When the piston rods of the hydraulic cylinders are fully retracted, the tilt adapter must not strike the feed passage.
If necessary, adjust the piston rods in the rod-end swivel joints.
The piston rod (1) must be screwed at least 24 mm into the swivel joint (2). The reference dimension between the
piston rod and the lock nut is max. 26 mm.

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Training

E0028

E0029

E0030-1

307.1133.3.6 englisch (en) 10.2006

E 15

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Service
Training

Notes

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Training

5650H - 5690HTS
Cabin, Driver's stand
Table of Contents
Combine Harvester Type

5650H
5680H
5660HTS 5690HTS

Drivers Stand, Control consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 03

Commander Control 2000, EMR-D control panel . . . . . . . . . . . . . . . . . . . . . . . . . . .04 05

Drivers Stand, Commander Stick, Control consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . .06

Drivers Stand, Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07

Cabin, Foot-operated controls, Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08

Cabin, Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .09

Cabin, Operating Controls, Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 11

Cabin Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Cabin, Operating Controls, Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Cabin, Rear-view mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

On-board computer (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 - 17

Cabin suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 - 19

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1.1

1.2

1.3

6
33892

14

15

16

17

18

19

20
13
12
11

21

10
9

22

7
30

29

28

27

26

25

24

23
33899

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5650H - 5690HTS
Driver's stand
Control consoles

25

Instrument panel

Indicator lights, spreader plates left

1.1 Central instrument cluster

25.1 Indicator light, spreader plates half-left

1.2 Hydraulic temperature display

25.2 Indicator light, spreader plates full left

1.3 Coolant temperature gauge

26

Indicator light, differential lock, on/off

Shift lever

27

Switch, 4-wheel drive on/off

Commander Control 2000

28

Indicator light, automatic fan inclination control on/off

EMR-D control panel

29

Fault indicator light, engine management (EMR)

Control console

30

Engine speed switch with three positions:

Commander Stick

lower idling

Starter switch

increased idling speed

Hazard warning lights on/off switch

nominal engine speed

Indicator light, straw chopper on/off

10

Indicator light, one-point lubrication system

11

Automatic cutting angle control

12

Grain tank extension extend/retract

13

Grain tank lamp on/off switch

14

Indicator light, 4-wheel drive on/off

15

Rocker switch, reversing system on

16

Rocker switch, side cutting table on/off

17

Width segment switch (TCS only)

18

Switch, spreader plate adjustment left/right

18.1 Key: spreader plates to right


18.2 Key: spreader plates to left
19

Indicator lights, spreader plates right

19.1 Indicator light, spreader plates half-right


19.2 Indicator light, spreader plates full right
20

Operating hour counter

21

Socket, 12 Volt

22

Cigar lighter

23

Switch, straw guide plate, short/long straw

24

Work master switch

25.1

18.1
19.1

19.2

25.2

18.2

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33898

1.4

1.3

1.2

1.1

1
6
5
2

G4

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5650H - 5690HTS

Commander Control 2000


General
The Commander Control is operated by a membrane keypad with 14 keys.

1
2
3
4
5
6
7
8
9

Screen
Swing grain tank discharge pipe inboard/outboard
Threshing section on/off
Cutting table on/off
Adjust concave clearances
Adjust speeds alarm
Fan speed adjustment/Setup menu*
Threshing drum speed adjustment/Diagnosis menu*
Pick-up reel speed adjustment/Calibration menu*
* Press + and keys at the same time

For detailed information and instructions on the function and operation, see section H.

5650H 5690HTS
EMR-D control panel

1
1.1
1.2
1.3
1.4
2
3
4
5
6

Mode selector switch


Transport mode, calibration
Cutting height preselection mode
Ground pressure mode
Cutting height control mode
Overstroke button
Ground pressure preselection
Cutting height preselection
Diagnosis indicator (red LED)
Status indicator (green LED)

For detailed information and instructions on the function and operation, see section H.

307.1133.3.6 englisch (en) 10.2006

G5

G
Service
Training

5650H - 5690HTS
Driver's stand
Commander Stick
Control Consoles

2
1

Shift lever
Gearshift positions

33900

33901-1
All gears must only be shifted during standstill!

7
5

Commander Stick

Cutting angle adjustment forward/back

Pick up reel, raise/lower

Front attachment, tilt right down/left down

Front attachment, raise/lower

Pick-up reel forward/back

EMR-D automatic mode button

32504/1
9

10

12

11

17

15

16

14

13

33895

Air conditioner control panel

10

Rotary control knob for heater

11

Blower control knob

12

Cab cooling system control knob

13

Cab cooling system on/off switch

14

Fault indicator light, cab cooling

15

Unused

16

Digital clock

17

Loudspeaker

18

Warning beacon

19

Windscreen wiper

20

Control panel

21

Work lights:

Off
4 front work lights
All work lights

19

18

G6

22

Headlights top/bottom

23

Headlights:

Off
Parking lights

20

23

22

Driving lights

21
33894

307.1133.3.6 englisch (en) 10.2006

G
Service
Training

2
1

5650H - 5690HTS
Driver's stand
Steering wheel

Spindle-shaped button for steering wheel adjuster

Drop-arm switch
comprising the following switch functions:

Position
33708

3
2
2
1

4
5
6

33748

Function

Press

Horn

Push forward

Indicator, right

Raise

Main beam (only at engine running)

Pull back

Indicator, left

Down

Dipped beam (only at engine running)

Fully down

Headlight flasher

Grain loss monitor

Ignition switch
with following switching functions:

4
0

0
I

II

Zero position
Operating position (the warning lights for
the battery charge and oil pressure are lit
if the engine is off).
Start

II
The servomotors of the belt clutches may
move on switching on the ignition and
starting the engine. The clutches will be
driven to the disengaged position.
33946

After switching off the engine, always


remove the key from the ignition on leaving the cab.

307.1133.3.6 englisch (en) 10.2006

The engine can and may only be started when


the Commander Stick is in the Neutral position.

G7

G
Service
Training

5650H - 5690HTS
Cabin
Foot-operated controls

Parking brake (Handbrake)

Cover for switch (3)

Cutting table emergency stop, red

Grain tank discharge, yellow

Pedal for braking the right wheel

Interlock plate

Pedal for braking the left wheel

Locking button

Handbrake lever

33910

32567

8
7

33911

G8

307.1133.3.6 englisch (en) 10.2006

G
Service
Training

5650H - 5690HTS
Cabin
Operating Controls

Lamp for interior lighting

Switch for interior lighting

Spotlight

Spotlight switch

Flap for access to air conditioning system evaporator

Recirculating air filters

Fresh air filters

33902

33948

6
33903

33925

307.1133.3.6 englisch (en) 10.2006

G9

G
Service
Training

5650H - 5690HTS
Cabin
Operating Controls
Seats

Drawer

Pocket

Crank handle

2
33909

- Height adjust of seat (seat unloaded)


- Weight adaption mechanism (seat unloaded)

Weight display

Seat forward/back

Backrest inclination adjustment

Armrest angle adjustment

Foldable armrest

Passenger seat

6
4

33907

33908

G 10

307.1133.3.6 englisch (en) 10.2006

G
Service
Training

1
8

2
7
10

3
6

4
1

5
Aero Fit seat (air sprung) (optional)

32863-1
5

Combined weight/height adjuster (infinitely variable)


Weight setting:

Never adjust the seat while driving.

Raise or push the handle slightly until the green


marking on the weight and height display is visible.

Headrest, height adjustable and removable

Height setting:

Lumbar support

Fully raise or press the handle until the desired position is obtained (the green marking must be visible).

Backrest inclination = backrest adjustment

Weight and height display

The weight and height adjuster can only


be operated when the ignition is on.
The adjuster should not be operated continuously for longer than 1 minute.
6

Longitudinal adjustment

Safety belt fixing

Armrest, folding

Height adjustment, armrest

10 Armrest inclination

307.1133.3.6 englisch (en) 10.2006

G 11

G
Service
Training

5650H - 5690HTS
Cabin
Operating Controls

1
1

Defroster/demister nozzles

Fresh air nozzles

Fresh air nozzles

Inspection window

Beverage holder

33904

2
3

33905

33906

G 12

307.1133.3.6 englisch (en) 10.2006

G
Service
Training

A
1

5650H - 5690HTS
Cabin
Operating Controls
Emergency exit
1

Lever:
- Opening of knockout window

33912
- Emergency exit. For this purpose lift lever and

unhinge from interlock (2), push open window.

Interlock

Door handle

Knob (opening of drivers cabin door from outside)

2
33913

3
33914

33915

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G 13

G
Service
Training

5650H - 5690HTS
Cabin
Rear-view mirrors

1
1

Hexagon bolts:
- Basic adjustment

Tighten the screws


- only sufficiently to hold the mirrors in position, but

allowing them to fold in without damage if they hit

33887

an obstacle

35607
Electrical adjustment of the right rear-view mirror

Switch

Press the edges of the knob to adjust the mirrors to the


desired position.
up
down
right
left
35608
The mirrors must be adjusted to the seat position and
driver's height.

G 14

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G
Service
Training

Notes

307.1133.3.6 englisch (en) 10.2006

G 15

G
Service
Training

4
7

30672

10

8
30768

G 16

307.1133.3.6 englisch (en) 10.2006

G
Service
Training

5650H - 5690HTS
On-board computer (optional)
System description
The hectaremeter comprises the following units:
1. Control instrument:

For display and operation

2. Wheel sensor:

Transmits one impulse per wheel revolution to the control instrument to enable the
various functions to be controlled and calculated.

3. Solenoid switch:

Starts and stops the hectaremeter. If the hectaremeter is stopped, the letter "r" ("raised") is displayed on the left-hand side of the display next to the speed indicator.

The solenoid switch is located on the right-hand side of the feed channel bearing. The hectaremeter is started or stopped by raising or lowering the cutting table. The switching threshold is set to a cutting table height of about 40 50 cm
above the ground. The operation of this solenoid switch can be monitored by switching over from hectaremeter to speed
indicator.

Description of the function keys


1

Working time (hours and minutes)

Hectaremeter (partial count)

Hectaremeter (total count)

Speed (km/h)

Working width input

Wheel circumference input

Zero reset for all functions:

working time, partial area and total area


This key is also used to enter the figure 0.

Description of system connections


8

Connection to 12 V power supply

Connection for wheel sensor

10

Connection for solenoid switch

307.1133.3.6 englisch (en) 10.2006

G 17

G
Service
Training

1, (2)

G 18

307.1133.3.6 englisch (en) 10.2006

G
Service
Training

5650H - 5690HTS
Cabin suspension
1

front rubber suspension, marking 510 5 N S

rear rubber suspension, marking 510 3 N S, colour coding green - white

Marking at rubber suspension

Distance plate

Disc

Bolt M12x80

Observe upon assembly:


Do not interchange front and rear rubber suspensions, observe marking.
Observe mounting position of rubber suspensions.

307.1133.3.6 englisch (en) 10.2006

G 19

G
Service
Training

Notes

G 20

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Electrical System
Table of contents
Combine Harvester Types

5650H
5680H
5660HTS 5690HTS

General, Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03

Index of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04

Cable colours and colour coding for connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05

Electrical system, wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 09

System overview of electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 11

Control console, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 13

Operating elements in cabin roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 13

Control console, switches and lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 15

Control elements Commander Control 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 15

Overview wiring diagram electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 17

Fuse assignment in control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 19

Relay assignment in control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 21

Funktion Diode arrays D1, D2, D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 23

Cable harnesses, connector assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 27

Multiple contact strips in control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 43

Multiple contact strips under the control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 45

Connector plug configuration foot switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 45

Distributing connector engine frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 49

Pin configuration actuator connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Schematic diagram CAN bus Commander Control 2000 with combined


instrument gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 53

Schematic diagram CAN bus Commander Control 2000 with TERIS/TCS . . . . . . . . . . .54 55

Schematic diagram electrical deflector adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 57

Schematic diagram electrical straw guide plate adjustment . . . . . . . . . . . . . . . . . . . . . .58 59

Schematic diagram electrical sieve adjustment control . . . . . . . . . . . . . . . . . . . . . . . . .60 61

Wiring diagram CAN bus system with combined instrument gauge . . . . . . . . . . . . . . . .62 63

Wiring diagram CAN bus system with Commander Control und TERIS/TCS . . . . . . . . .64 65

Function and programming of CAN modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 73

Connector pin assignment at job computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 79

Connector pin assignment CAN modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 81

Combined instrument gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 83

Combined instrument gauge and Commander Control 2000, overview monitoring


and control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 85

Diagram inputs/outputs Commander Control 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 87

307.1133.3.6 englisch (en) 10.2006

H1

H
Service
Training

5650H 5690HTS
Electrical System
Table of contents
Combine Harvester Types

5650H
5680H
5660HTS 5690HTS

Connector pin assignment A30, Commander Control 2000 . . . . . . . . . . . . . . . . . . . . . .88 89

Functional monitoring by the Commander Control 2000 . . . . . . . . . . . . . . . . . . . . . . . .90 91

Switches and sensors for monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 95

Functional description inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 97

Sensors, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 101

Multifunction lever, gear rack device/sensor adjustment . . . . . . . . . . . . . . . . . . . . . . . .102 103

Multifunction lever, connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 105

A13 logic module, connector pin assignment, function . . . . . . . . . . . . . . . . . . . . . . . . . .106 107

Control unit EEC, gas control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 109

Electronic cutting table control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 119

Control unit EMR-D, connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Throughput Monitor (Grain Loss Monitor) / On-board Computer . . . . . . . . . . . . . . . . . .146

Appendix A: Wiring diagrams


Appendix B: Commander Control 2000, Operating Instructions
Appendix C: Commander Control 2000, Setup and Diagnosis

H2

307.1133.3.6 englisch (en) 10.2006

5650H 5690HTS
Electrical System
General
Safety instructions
1.

When working on the electrical system, always


disconnect the cable from the negative terminal of the
battery.

2.

Always observe the correct connection procedure


first connect the positive terminal, then the negative.

3.

Beware of battery gases they are highly explosive!


Avoid generating any sparks or naked flame near the
battery!

4.

Only use original fuses. The electrical system will be


destroyed if fuses with too high ratings are used!

5.

Disconnect the cable from the generator and battery


when carrying out electric welding work on the
combine harvester!

6.

Take care when handling battery acid (toxic and


corrosive)!

7.

Only operate the starter for a limited time, since


otherwise the winding will overheat. Allow the starter
engine to cool!

8.

Do not place any tools on the battery!

A0009

Remark
The electrical system is described with full equipment,
which means that the combine harvester maintained by
you may not be equipped with particular components (e.g.
printer, PC keyboard, etc.), depending on the respective
equipment.

307.1133.3.6 englisch (en) 10.2006

H3

H
Service
Training

5650H 5690HTS
Index of Abbreviations
AHS

Working master switch

CCP

Clutch Control Power Unit (shift gear control device)

EEC

Engine control unit (electronic engine control)

EMR-D Electronic control of cutting mechanism


GPS

Global Positioning System

KT

Grain tank

KTS

Grain tank unloading auger

MF

Multifunction control lever (Commander Stick)

MV

Solenoid valve

MW

Cutting mechanism

TS

Turbo-separator

TCS

Terminal Control System (job computer)

SMPS

Constant voltage power supply 5V/12V

H4

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Cable colours and colour coding for connectors

Basic colours applied for cables:

Colour codes for connectors

Abbreviation

Colour

Abbreviation Colour

bl

blue

DBL

dark blue

br

brown

DBR

dark brown

ge

yellow

DGR

dark grey

gn

green

DGN

dark green

gr

grey

DRT

dark red

nat

nature

ELB

ivory

or

orange

GEL

yellow

pk

pink

HBL

light blue

rs

pink

HBR

light brown

rt

red

HGN

light green

sw

black

HGR

light grey

tr

transparent

HRT

light red

vi

violet

NAT

nature

ws

white

OR
SW
WS

orange
black
white

Fundamentally, the basic colour is always indicated first, followed by the indication colours. Therefore, rt/ws/bl is a cable
with red as basic colour and white/blue as indication colours.
Markings in the circuit diagram
A30.5
pin number
device number

X512.14
pin number
connector X512

307.1133.3.6 englisch (en) 10.2006

H5

H
Service
Training

5650H 5690HTS
Electrical System
Wiring diagram
Layout of the wiring diagrams
The wiring diagrams are clearly broken down and their structure is easy to understand at a glance. The positive lines are
shown at the top edge:
30 = Permanent positive
15 = Switched positive
The negative lines are shown at the bottom:
31 = Vehicle earth
These three lines extend along the full length of the wiring diagram and are marked with 30, 15 and 31.
The individual circuits are all located between positive and negative and can therefore be clearly and comprehensibly
represented in "current paths" next to one another.
Each circuit contains:

Wire colour and cross-section,


Colour and number of the plug-in connector,
Serial number and current rating of the fuse.

The "inner life" of the individual components is also shown for better comprehension. Please note that, in conformity with
the DIN standard, all switches and relays have been drawn in the rest position, i.e. without the effect of voltage, pressure
or temperature etc.. You therefore have to imagine the working position when voltage, pressure or temperature is applied.
All components are identified by a circle containing a number (item number). You can then find the corresponding part
name in the parts list. In the course of the wiring diagram, the same components may have different numbers when used
in different sections.
Cable cross-sections used in the combine harvester:
Starter motor cable
Main cables
Load cables:

50 mm2 / 70 mm2
4 mm2 / 6 mm2
4 mm2 / 2.5 mm2 / 1.5 mm2 / 1 mm2 / 0.75 mm2.

Basic cable colours used:


Colour:

Abbreviation:

Use:

red
black
brown
grey
white
yellow
blue
green
mauve
orange
natural

rd
bk
br
gr
wt
yl
bu
gn
mv
or
nat

B + /30
15
31
58
56a
56b
monitoring

As a rule, the basic colour is specified first, followed by the identification colours. Therefore "rd/wt/bu" designates a cable
with the basic colour red and with white/blue as identification colours.

H6

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Electrical System
Wiring diagram
Terminal Designations
Terminal

Designation

30
31
31b
30a
31a
50
50a
15
19
17
61
D+
D
DF
54
54f
56
56a
56b
58
58L
58R
53a
53
31b
52
54g
49
49a
C
C2
L
R
LB
RB
54f
86
85
88
88a
87
87a
87
87a
88a

Battery + (unswitched positive)


Battery (earth)
Switched negative to earth
Battery switchover relay, battery II input
Battery switchover relay, battery II return
Starter motor control (direct)
Starter motor control (indirect)
Switched positive
Preheating (upstream resistor input)
Preheating when starting (bridging over the resistor)
Battery charge warning lamp (D+)
Dynamo +
Dynamo
Dynamo field
Brake light
Output from brake light switch to dual circuit flasher switch
Supply cable to headlight dipper switch
Main beam, main beam indicator
Dipped beam
Parking light, sidelights, contour lights and instrument panel lamps
Rear light, left, number plate light
Rear light, right, number plate light
Windscreen wiper +
Windscreen wiper actuation (switched positive)
Switched negative for final switch-off
Tyre monitor or other signal from the trailer
Magnetventil fr Dauerbremse im Anhnger
Flasher + (input)
Flasher pulse (output)
Flasher warning light for tractor vehicle
Flasher warning light for trailer
Turn signal lights, left
Turn signal lights, right
Dual-circuit flasher switch, left
Dual-circuit flasher switch, right
Input from brake light switch (dual circuit system)
Relay coil (+)
Relay coil ()
Relay input contact for make relay
Relay output contact for make relay
Relay input contact for break relay
Relay output contact for break relay
Relay input contact for change-over relay
Relay output contact for break side
Relay output contact for make side

The terminal designations are not cable designations and are therefore not marked on the cables.

307.1133.3.6 englisch (en) 10.2006

H7

H
Service
Training

Electrical System
Wiring diagram
Key to Wiring Diagram

Permanent positive
from the battery, always energised
Switched positive
behind the battery, switched by the ignition switch
From the alternator
only energised when the engine is running
Fuse
specifying the fuse strip (GN = green) and
number (3, input), C: output to load,
current rating (7.5 A)

Cable colour
Connector
with receptacle assignments and connector colour
Component positioning
Description and designation in the key
Cross-reference
To the section (module/group) to which the cable leads

Terminal designation
on the component
Switch symbol
here diode
Vehicle earth
Section designation (group)
for delimiting the section in the wiring diagram

H8

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Electrical System
Terminal designations of the 8-pin
connectors
Coloured connectors with anti-torsion protection are used.
The position of the terminals is shown in the sketch
below. The simplified diagram shows which pins the cable
cores are connected to at the inlet and outlet of the
connector.

Example:
If a cable core enters the connector at pin 8, the cable
core on the other side leaves from pin 5.

307.1133.3.6 englisch (en) 10.2006

H9

H
Service
Training

5650H 5690HTS
System Overview of Electrical System
The electrical system consists of the following main components:

Connector X140 X147, AMP connector grain loss sensory system

A1, A2 electronic engine controller EEC

Control cabinet

A4 control unit EMR-D

A30 Commander Control 2000

A24 control unit balance II

A31 or A22, LH 1000 area meter or printer (with TERIS/TCS)

Control unit air condition/heating/ventilation

A32 grain loss monitor LH 865 or display unit A21 (with TERIS/TCS)

9.1

Distribution box grain loss sensory system

10

B40 or A17, combined instrument gauge or terminal (with TERIS/TCS)

11

Control console

12

A19 control unit balance II

13

G1 battery, S1 battery main switch

14

K101 hazard flasher relay

15

A8 powershift device for actuators of belt couplings

16

A10 control unit all-wheel drive (optional)

17

Fuses

18

Relays

18.1 Diode array D1, D2, D3


19

A3 control unit EMR-D

20

A11 job computer (TERIS/TCS)

21

A12 control unit autocontrol

22

A13 logic module: starter blocking/reversing horn/all-wheel drive/differential lock

23

A25 CAN module deflector adjustment

24

A26 CAN module straw guide plate adjustment

25

A16 inclinometer (fan control TERIS/TCS)

26

A27 CAN module sieve adjustment

27

A14 constant voltage power supply 5V, 12V (only TERIS/TCS) for:

Observe the proper mounting position!

Job computer
Inclinometer
Field data printer
PC keyboard
28 Insulated ground connector strip for potentiometer ground of servo motors for chopper deflectors, chopper flap and
sieve adjustment.

H 10

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

9
10

11

34939-2

13

9.1

12
28

14

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

15

16

23

24

25

26

27

SOLARI 1.she

18.1

22
21

20

19

H001

17

H002

18

307.1133.3.6 englisch (en) 10.2006

H 11

H
Service
Training

1.2
1.1

1.3

6
33892

6
33923
H 12

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Control console, overview
Standard design
1
1.1
1.2
1.3
2
3
4
5
6

Instrument panel
Combined Instrument Gauge
Indication hydraulic system temperature
Indication coolant temperature
Gear-shift lever
Commander Control 2000
EMR-D operating device
Control console
Commander stick

TERIS/TCS design
7
8

TERIS/TCS terminal (optional)


Keyboard (only TCS)

Operating elements in cabin roof


Control panel air condition

10

13

14

12

15

11

Control button for heating (type 5680/5690 only)

Rotary switch for ventilation

10

Control button for cooling system

11

Switch cooling system on/off

12

Indicator light cooling system malfunction

13

Empty field

14

digital clock

15

Loudspeaker

33895

Control panel lighting

17

16

18

16

Revolving lights

17

Windscreen wipers

18

Control panel

19

Work light:

off
4 front projectors
all projectors

21

20

307.1133.3.6 englisch (en) 10.2006

19

20

Projectors on top/ at the bottom

21

Projector:

off
parking light

33894

dipped beam

H 13

H
Service
Training

5650H 5690HTS
Control console, switches and lamps
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

25

Ignition start switch


Switch hazard warning signal flasher on/off
Indicator light straw guide plate in position chopper operation
Indicator light central lubrication system
Indicator light Automatic cutting angle control
Retract/extend grain tank extension
Switch grain tank illumination on/off
Indicator light all-wheel drive on/off
Rocker button reversing on
Switch side cutter bar on/off
Partial width activation (only TCS/TERIS)
Switch deflector adjustment left right
Indicator lights deflector position
Operating-hours counter
Plug-socket 12 Volt
Cigarette lighter
Switch straw guide plate, chopping or long straw shedding
Working master switch
not applicable
Indicator light slip control active
Switch all-wheel drive on/off
Indicator light automatic slope blower control on/off (only TCS/TERIS)
Indicator light engine controller (EEC) malfunction (only 5680/90)
Switch engine speed (only 5680/90) with three positions:
lower idle speed
increased idle speed
nominal speed
Buzzer

Control elements Commander Control 2000


The Commander Control 2000 is operated by means of a touch key board with 14 keys.
1
2
3
4
5
6

7
8
9

Display
Retract/extend grain tank tube
Threshing mechanism on/off (chopper)
Cutting mechanism on/off
Menu key for adjustment of concave clearance and TS clearance resp. concave quick opening
Menu key for adjustment of speed warning thresholds
Special function of menu key:
Hold key pressed down while turning start switch into pos. I. When buzzer resounds, belt couplings can be
activated while the engine is stopped. Working master switch (18) must be switched on.
Adjustment of blower speed
setup menu*
Adjustment of threshing drum speed
diagnosis menu*
Adjustment of reel speed resp. activation of automatic speed control*
calibration menu*

* Plus and minus key pressed simultaneously (see instructions)

H 14

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

10

11

12

13

14
7
6
15

5
4
3

16

2
25
1
24

23

22

21

13

20

18

17
33898

33898

307.1133.3.6 englisch (en) 10.2006

H 15

H
Service
Training

II
III

H 16

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Overview wiring diagram electrical system
A1
A2
A3
A8
A13
A19
A23
A30
B7
B40
B45
B46
B48
F..
G3
K0
K11
K12
K13
K22
K48
K34
K51
K55
K98
M1
M19
S2
S5
S40
S42
S43
S44
S49
S55
S66
S67
Y11, Y12

Control unit EEC (electronic controller Diesel engine)


Gas control unit for control unit EEC (A1)
Control unit EMR-D
Clutch control power unit couplings CCP II
Logic module
Control unit Balance II
Distribution box grain loss sensory system (supply from F44 with TERIS/TCS)
Commander Control 2000
Buzzer
Combined instrument gauge
sensor multifunction handle neutral (start interlock)
sensor multifunction handle reverse (reversing horn)
Reverse gear horn
Fuses
Generator
70 Relay for terminal 15
Relay release threshing mechanism on, terminal 15b
Relay release EMR automatic system
Relay multifunction handle release reel (relay was dropped as of year of construction 2001)
Relay starter
Relay power supply EEC
Relay multifunction handle release channel
Relay rape ripping knife
Relay multifunction handle release EMR
Relay reversing motor (attached at feed passage)
Starter
Reversing motor
Ignition start switch
Switch engine speed
Working master switch
Switch rape ripping knife
Switch reversing device
Switch grain tank interior light
Switch deflector adjustment, chopper
Hand break switch
Switch straw guide plate adjustment
Switch grain tank extension lift/lower
Solenoid valves cutting angle

Relay sets:
K8, K29 Extend/retract grain tank extension
K7, K28, K49, K70
Relay reel hydraulics
K50, K71 Swing out/swing in grain tank tube
K59, K80 Relay cutting angle up/down

Must not be inserted with balance model!

Speed adjustment KX, KY:


K14, K35 Relay set reel variator
K15, K36 Relay set blower variator
K56, K77 Relay set threshing drum variator
Concave clearances KV, KW:
K18, K39 Relay set concave front
K19, K40 Relay set turbo separator up/down
K60, K81 Relay set concave rear

307.1133.3.6 englisch (en) 10.2006

H 17

H
Service
Training

5650H 5690HTS
Fuse assignment in control cabinet
Left row

Middle row

Right row

revolving lights
right

grain tank tube

flasher system

cooling system, heating


blower
control cooling syst.,
heating
treshing drum variator

controls
AHS term. 15 a

controls
threshing on term. 15b

cabin roof

H 18

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

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

SOLARI 1.she

56-000

307.1133.3.6 englisch (en) 10.2006

H 19

H
Service
Training

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

SOLARI 1.she

D1-D3

K64
K0

K1
K73
K74
K10
K11
K83

K20

56-000

H 20

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Relay assignment in control cabinet

S55

display steering column

Multifunction handle
release reel

chopper flap

307.1133.3.6 englisch (en) 10.2006

H 21

H
Service
Training

D+
K44, Kl.2
K45, Kl.2
K65, Kl.2
K66, Kl.2
K2, Kl.2
K25, Kl.2

D1
87
30
86

87a

K64, Kl.2

85
K43, Kl.2

K67

D2
87

30
K75, Kl.2

86

87a

85

D3
87
30
Comm.Control PIN 48 X509.1

86
P

87a

X503.4

85

S55

K76, Kl.2

Handbremschalter
hand brake switch

H57

86
87a
30

87
85

56-073

H 22

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Function diode arrays D1, D2, D3
D1
D2
D3

Connection to ground of the relays for lighting via relay K67 (ground at D+)
Connection to ground of relay K75 (power supply Balance) via relay K67
Connection to ground via hand brake switch S55 for:
Relay K76 (Balance)
Hand brake switch monitoring of Commander Control
Indicator light hand brake H57 with TERIS/TCS
K67 Ground at D+
S55 Switch hand brake

Function:
Prevention of return current between the relays which are connected in series with K67 or with the hand brake switch.
Current load max. 1A per diode.

1
2

View on male connectors, position of terminals.


Backside view, marking with yellow label.

307.1133.3.6 englisch (en) 10.2006

H 23

H
Service
Training

5650H 5690HTS
Cable harnesses, plug-in connections between
cabin and control cabinet
control cabinet and tail
1
1.1

Control console
Connector inside of control console:
- X170, X171 for combined instrument gauge
- connector for terminal TERIS/TCS
- X308 for keyboard
- X514 programming plug for Commander Control 2000

2
2.1

Multifunction handle
sensors for start interlock and reverse gear horn

Electric system steering column

Foot switch cutting mechanism stop

Foot switch grain tank clutch

Foot switch all-wheel slip control

Switch hand brake

Drivers cabin

8.1
9

Distributing connector in cabin roof right


Control cabinet

9.1

Multiple contact strip, 8-pole connector below in control cabinet

9.2

Multiple contact strip, 21-pole connector in control cabinet

10

Distribution box grain loss sensory system

11

Electronic control system engine controller

12

Distributing connector engine frame

13

Ground - collecting terminal

H 24

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

8.1

X135
X136

X134
X115
X182

1.1
1
8
6
2.1
7
X1
X1 90
91
92

ge

X515
X190
X191
X192

X5

15

X1

hebl
hegn
hert

9
E
40

21

20

9.2

9.1
D

X513

X512

X510

X509

X508

X507

X511

X506

X505

X504

X503

B
A
C

X502

X501

11

EEC

10
F

X146
X145
X144
X147
X143
X142

12
G

13

X141
X140

56-018

307.1133.3.6 englisch (en) 10.2006

H 25

H
Service
Training

X135
X136

X134
X115
X182

X515
X190
X191
X192

X5

X1
X1 90
91
92

15

X1

ge
hebl
hegn
hert

E
40

21

20

X513

X512

X510

X509

X508

X507

X511

X506

X505

X504

X503

B
A
C

X502

X501

EEC

X146
X145
X144
X147
X143
X142

X141
X140

56-018

H 26

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Cable harnesses, plug-in connections between
cabin and control cabinet
control cabinet and tail
21-pole connector in control cabinet

X504
X505
X506
X512

Connector in control console


switches, indicator lights in control console
control unit cutting mechanism control
X190
X191
X192
X515

multifunction handle
sensor start interlock
sensor reverse gear horn
foot switch grain tank clutch
foot switch cutting mechanism stop
footswitch all-wheel
hand brake switch

X507
X508
X509
X510
X511

Commander-Control
X514 programming plug
X170 ZI I ws
X171 ZI II sw
monitor TERIS/TCS
X308 keyboard

X503

steering column
Connectors in cabin roof

X501

X502
X513

X115 dark brown sensor brightness, power supply data printer


X182 dark green
LH 1000
switch illumination
control unit balance
data line for printer

8-pole connectors below at control cabinet


X34 yellow

X134 yellow, term. 30 cabin roof, air condition


X135 light green, working lights

X14 light red

X136 ivory, dipped beam projector at the top


ground cabin roof, interior light, revolving light

Connectors in engine compartment


AMP connectors 5-pole for supply distribution box grain loss sensory system

X140-X147

307.1133.3.6 englisch (en) 10.2006

Power supply for consumers and sensors at engine and combine


harvester tail

Junction box grain loss sensor

H 27

H
Service
Training

5650H 5690HTS
Multiple contact strips in control cabinet
Upper multiple contact strip (A), 21-pole connector

front
Note: Push the unlock pin (2) in order to separate the connector housing. Pull the brown interlocking strip (1) out of the
connector housing and unlock the snap-in pin of the contacts in order to remove the plug contacts.

Connector 21-pole, view from cable side connector housing (fixed in control cabinet)

A1

Connector 21-pole, view from cable side female connector housing (plugged in from below)

A2

2
H 28

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

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

SOLARI 1.she

A1

A2

56-003

A1

1
A2

2
1,19

307.1133.3.6 englisch (en) 10.2006

H 29

H
Service
Training

5650H 5690HTS
Pin Assignment Connector X501 - X505

A1

56-020

H20

H 30

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Pin Assignment Connector X506 - X509

A1

H20

307.1133.3.6 englisch (en) 10.2006

H 31

H
Service
Training

5650H 5690HTS
Pin Assignment Connector X510 - X513

A1

56-020

H20

Note: At Connector X513 the colours of the lines change


from A1 to A2.

H 32

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Notes

307.1133.3.6 englisch (en) 10.2006

H 33

H
Service
Training

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

SOLARI 1.she

1
20
B
C

21

40
56-003

Only 5650 - 5690 with


combined instrument gauge:
Resistor 68 Ohm at
connector X1, pin 8 (input
temperature transducer
engine oil).

H 34

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

colour

32

33

34

30

31

function allocation

35

X20

GE

SW

NAT

GE

X40

SW

X19

NAT

20

X39

ELB

19

X18

X17

X13

X12

X16

X11

X14

X25

HBL HRT DBR

DRT DGN

OR

HBR HGN

38

39 40

36

37

B
connector connector
no.
design
1
X1

HRT HGN HBR

18

X38

29

HBL

17

X37

28

OR

16

X36

27

HGN DBL

15

X34

26

14

X33

25

24

13

X32

SW

12

X35

GE

11

X31

HGN

X30

X28

OR

X29

X27

HBL DRT HGR NAT DGR ELB

NAT DGR

23

10

X10

X9

X8

X7

X6

X15

X23

22

X26

X4
SW

X24

X3
DGN

HGR DBL

21

X2

GE

WS

X22

front

X1

X21

X5

5650H 5690HTS
Lower multistrip connector, rear (B) and front (C), pneutron connector

connector connector
no.
design
21
X21

colour
HGR

function allocation
Speed sensor elevator; rear outline marker
lamp; switch straw chamber; lighting sieve
pan, - tail
Grain loss sensors; wheel sensor LH 1000;
CAN bus

WS

Engine: Terminal W, D+; Starter;


sensors motor monitoring
Engine: Temperature transmitter hydraulic
oil, switch cooling fan, air filter

22

X22

DBL

Drum variator, sensor straw walker speed,


grain tank tube; switch air filter; cooling
compressor; rear working light
Flasher lamps; sensor, chopper flap,
chopper speed, fuel tank; reverse gear horn;
sensors returns elevator
Servo-motor chopper flap; key switch lower
sieve open - close

23

X23

NAT

not allocated

24

X24

DGR

not allocated

25

X26

OR

X2

GE

X3

DGN

X4

SW

X5

HBL

X6

DRT

EMR: Solenoid valve accumulator; pressure


sensor; transmitter feed passage

26

X15

HGN

X7

HGR

Cutting mechanism: reel variator;


potentiometer for touching skids

27

X27

GE

Cutting mechanism: Speed sensor reel;


solenoid valve colza cutter left

X8

NAT

Engine control EEC; CAN -BUS SAEJ1939

28

X28

SW

Electric system balance: Connection to EMR

X9

DGR

Solenoid valves working hydraulics

29

X29

HBL

Electric system balance

10

X10

ELB

Solenoid valves working hydraulics

30

X30

HRT

Electric system balance

11

X25

HGN

EMR: Regulating valve cutting mechanism,


solenoid valve Autocontrol

31

X31

DBR

Electric system balance

12

X11

DBL

Grain tank: Interior light, sensors, working


light

32

X35

ELB

Servo-motors concave open - close

13

X12

OR

Front lighting: flasher light, position lights

33

X32

NAT

Cabin: bugle, flasher-, position lights,


projectors, brake light switch

14

X17

HBL

Speed sensors: Threshing drum, blower,


sieve pan, ground sensors feed passage

34

X33

SW

Central lubrication; auxiliary heating

15

X14

HRT

Cabin roof - lighting

35

X34

GE

Cabin roof: Cooling system, wind screen


wipers, working lights

16

X16

HGN

Belt clutches

36

X36

DRT

Turbo separator: Servo-motor, speed sensor

17

X13

HBR

Adjustment rear-view mirror

37

X37

DGN

18

X18

SW

not allocated

38

X38

OR

Feed passage: sensor LH 1000, speed


sensor, relay K98; servo-motor wind variator;
inductive sensor gear-shift mechanism
Allwheel electric system

19

X19

NAT

not allocated

39

X39

HBR

Allwheel steering angle sensor

20

X20

GE

not allocated

40

X40

HGN

Allwheel speed sensor, -solenoid valve

307.1133.3.6 englisch (en) 10.2006

Servo-motor straw spreader; key switch


upper sieve open - close
Servo-motor upper-, lower sieve

H 35

H
Service
Training

5650H 5690HTS
Lower rear multiple contact strip (B)

pin configuration connector 1 to 10


Inside of control cabinet

push-button

push-button

left rear and trailer

br ,

bl

switch
coolant level _

switch
coolant level +

5670: cylinderhead temperature

H 36

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

pin configuration connector 1 to 10


Outside of control cabinet

5650H 5690HTS
Lower rear multiple contact strip (B)

extend/retract grain tank tube

push-button

push-button

reverse gear horn


left rear and trailer

sw

br
switch
coolant level _

switch
coolant level +

5670: cylinderhead temperature

307.1133.3.6 englisch (en) 10.2006

H 37

H
Service
Training

5650H 5690HTS
Lower rear multiple contact strip (B)

H 38

pin configuration connector 11 to 20


Inside of control cabinet

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

pin configuration connector 11 to 20


Outside of control cabinet

307.1133.3.6 englisch (en) 10.2006

5650H 5690HTS
Lower rear multiple contact strip (B)

H 39

H
Service
Training

5650H 5690HTS
Lower front multiple contact strip (C)

H 40

pin configuration connector 21 to 30


Inside of control cabinet

push-button switch

push-button switch

push-button switch

push-button switch

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

pin configuration connector 21 to 30


Outside of control cabinet

push-button switch

5650H 5690HTS
Lower front multiple contact strip (C)

push-button switch

supply
push-button switch

push-button switch

307.1133.3.6 englisch (en) 10.2006

H 41

H
Service
Training

5650H 5690HTS
Lower front multiple contact strip (C)

pin configuration connector 31 to 40


Inside of control cabinet

gn-ge 1,0

to push-button switch

H 42

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

pin configuration connector 31 to 40


Outside of control cabinet

5650H 5690HTS
Lower front multiple contact strip (C)

sw-ge 2,5

to push-button switch

307.1133.3.6 englisch (en) 10.2006

H 43

H
Service
Training

5650H 5690HTS
Multiple contact strip under the control console
Connector plug configuration X190, X191, X192

multi-function handle

reverse gear sensor

neutral position sensor

Control cabinet

56-029

Connector plug configuration X515


Foot switch
pin configuration X515, from switches

GE
X515

bl

1 sw/rt

switch S55
hand brake

foot switch S28


foot switch S23
all-wheel anti-slip control grain tank clutch

5 br

sw

vio/ge

or/gn

foot switch S22


cutting mechanism stop

ground

ground

pin configuration X515, to control cabinet


or/gn

bl

sw/rt

GE

X515

foot switch S22


cutting mechanism stop

foot switch S23


grain tank clutch

switch S55
foot switch S28
all-wheel anti-slip control hand brake

br

ground

vio/ge

br

ground

56-070
H 44

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

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

SOLARI 1.she

X192 HRT
X191 HGN
X190 HBL
X515 GE

H003

307.1133.3.6 englisch (en) 10.2006

H 45

H
Service
Training

34939-2

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

SOLARI 1.she

56-114

A
B

56-018-1

H 46

56-062

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Distributing connector engine frame
A Pneutron connector
Connector no. Connector id.
1

X140

Colour
WS

function allocation
Rear flasher light, tail- /brake lights
Returns elevator

X141

GE

Flasher, tail / brake lights trailer

X142

SW

Cooling system, Straw chamber warning flap,

X143

HRT

sensors grain tank tube / straw guide plate,

X147

HBR

push-button switch sieve operation

X144

HGN

sieve actuators

X145

OR

potentiometer / deflector drive, chopper

X146

HBL

potentiometer / straw guide plate drive

Speed sensor chopper, Lighting


hydraulic oil temperature sensor, Lighting sieve pan

B AMP grain loss sensory system connector


PIN

colour

rt

grain loss sensor sieve pan

function allocation

Cable harness junction box


gn/ge

ge

wheel sensor for LH 865 and LH 1000

sw 4

bl

grain loss sensor straw walker

sw 3

ws

power supply grain loss sensory system

sw 2

br

ground grain loss sensors

sw 1

returns sensor with TERIS/TCS

C trailer plug socket


PIN

colour

function allocation

1/L

sw/ws

flasher light left

2/54g

not used

3/31

br

ground

4/R

sw/gn

5/58R

gr/rt

tail light right

6/54

sw/rt

brake lights left/right

7/58L

gr/sw

tail light left

307.1133.3.6 englisch (en) 10.2006

flasher light right

H 47

H
Service
Training

5650H 5690HTS
multiple contact strip at engine frame
engine cable harness side (coming from control cabinet)

left rear

H 48

push-button switch

push-button switch

push-button switch

push-button switch

right rear

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
multiple contact strip at engineframe
hood cable harness side

push-button

push-button

push-button

push-button

right rear

307.1133.3.6 englisch (en) 10.2006

left rear

H 49

H
Service
Training

5650H 5690HTS
pin configuration actuator connectors

H 50

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Notes

307.1133.3.6 englisch (en) 10.2006

H 51

H
Service
Training

56-030

H 52

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Schematic diagram CAN bus Commander Control 2000 with combined instrument gauge

A25

CAN module deflector adjustment

A26

CAN module straw guide plate adjustment

A30

Commander Control 2000

B40

combined instrument gauge

K16

relay chopping

K17

relay deflectors left

K37

relay long straw

K38

relay deflectors right

M12 deflector servo-motor


M13 straw guide plate servo-motor
1

120 load resistor: terminal connector (pin 7, 8) in control console

120 load resistor: connector X22 (pin 5, 6) at outside of control cabinet

The Commander Control 2000 is responsible for the following functions:


Operation
Monitoring (speeds)
Display (Commander Control 2000 and combined instrument gauge)
The display functions of the combined instrument gauge are controlled by the Commander Control 2000.

307.1133.3.6 englisch (en) 10.2006

H 53

H
Service
Training

5650H 5690HTS
Schematic diagram CAN bus Commander Control 2000 with TERIS/TCS

A11

TCS job computer

A14

stabilized power supply unit (SMPS)

A15

keyboard

A16

inclinometer (fan control TERIS/TCS)

A17

terminal with load resistor 120 Ohm

A21

display unit steering column

A22

printer

A25

CAN module deflectors

A26

CAN module straw guide plate

A27

CAN module sieve adjustment

A30

Commander Control 2000

X22

load resistor 120 in connector X22, outside of control cabinet

Observe proper mounting position!

connector pin assignment inclinometer A16


connection

cable colour
to SMPS

cable colour at
inclinometer

PIN

from A14.6

rt/sw

br

to job computer connector B.17


from A 14.2

signification
inclinometer power supply 5V

bl

bl

inclinometer signal

br/ws

sw

inclinometer ground

connector pin assignment SMPS A14 (stabilized power supply unit)


colour

PIN

signification

br/ws

ground stabilized for printer

br/ws

ground stabilized for PC-keyboard and inclinometer

br/ws

ground stabilized for job computer connector A.12

br

ground SMPS

rt/gr

5 V stabilized printer

rt/sw

power supply 5V for PC-keyboard and inclinometer

rt/ws

12 V stabilized job computer connector A.11

sw

power supply SMPS

pin configuration A14

fuse 10 AP

H 54

LEDs for output


Stabilised voltage
1 x 12 V, 2 x 5 V

LED for supply 12 V

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A25

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switch operation
deflectors left

CAN module
deflectors
A25
relay
K17
deflectors left

M12

light deflectors
left outside

light deflectors
left centre

actuator
deflectors with
potentiometer
light deflectors
right centre

relay
K38
deflectors right

light deflectors
right outside

switch operation
deflectors right

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Schematic diagram electrical deflector adjustment chopper

A25

CAN module deflector adjustment

A30

Commander Control 2000

K17

relay deflectors left

K38

relay deflectors right

M12 actuator deflectors with potentiometer

pin configuration:
DI
DO
AI
AO

digital IN
digital OUT
analog IN
analog OUT

designation:
D O / 1 ( 11 )
pin no.
channel
digital OUT

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Schematic diagram electrical straw guide plate adjustment

A26

CAN module straw guide plate

A30

Commander Control 2000

K16

relay chopping

K37

relay long straw

M13

actuator

pin configuration:
DI
DO
AI
AO

digital IN
digital OUT
analog IN
analog OUT

designation:
D O / 1 ( 11 )
pin no.
channel
digital OUT

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operation of deflector
switch (S66) in position
"chopping

CAN Module
deflector

relay
K16
chopping

actuator M13
deflector
with
potentiometer

operation of deflector switch


(S66) in position "long
straw deposit

relay
K37
long straw

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keyswitch upper sieve


open
S70

S70

CAN
module
CAN-Modul
sieve
adjustment
Siebverstellung

relay upper sieve


open
K41

K41

A27
A27
keyswitch upper sieve
close S69

S69

keyswitch lower sieve


open
S72

S72

keyswitch lower sieve


close
S71
S71

actuator
upper sieve with
potentiometer
M17
M17

relay upper sieve


close
K20

K20

relay lower sieve


open
K83

K83

actuator
lower sieve with
potentiometer
M18

M18

relay lower sieve


close K62
K62

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5650H 5690HTS
Schematic diagram electrical sieve adjustment control

A27

CAN module sieve adjustment

A30

Commander Control 2000

K20

relay upper sieve close

K41

relay upper sieve open

K62

relay lower sieve close

K83

relay lower sieve open

M17 actuator upper sieve with potentiometer


M18 actuator lower sieve with potentiometer
S69

key switch upper sieve close (behind at the toolbox)

S70

key switch upper sieve open (behind at the toolbox)

S71

key switch lower sieve close (behind at the toolbox)

S72

key switch lower sieve open (behind at the toolbox)

pin configuration:
DI
DO
AI
AO

digital IN
digital OUT
analog IN
analog OUT

designation:
D O / 1 ( 11 )
pin no.
channel
digital OUT

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Wiring diagram CAN bus system Com. Contr. with combined instrument gauge

A25

CAN module deflector adjustment

UNIT 19

A26

CAN module straw guide plate adjustment

UNIT 19

A27

CAN module sieve adjustment

UNIT 19

A30

Commander Control 2000

UNIT 18

Terminating resistor 120 at terminal connector in the control console

Terminating resistor 120 at connector X22 control cabinet outside

Resistance CAN bus line with 2 terminating resistors 120 Ohm


CAN bus participant
Without A30, without CAN-Module

Measuring value
60 Ohm

With A30, without CAN modules

44 Ohm

With A30 and 1 CAN module

35 Ohm

With A30 and 2 CAN modules

29 Ohm

Internal resistance of CAN bus participants


Com. Control A30, pin 94 - 95
163 Ohm
CAN module, pin 4 - 12

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163 Ohm

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95

94

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95

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Wiring diagram CAN bus system with Commander Control 2000 and TERIS/TCS
A11

job computer

UNIT 8-13

A17

terminal

UNIT 0-3

A21

throughput display steering column

UNIT 26

A25

CAN module deflector adjustment

UNIT 19

A26

CAN module straw guide plate adjustment

UNIT 19

A27

CAN module sieve adjustment

UNIT 19

A30

Commander Control 2000

UNIT 18

Terminating resistor 120 at connector X22 control cabinet outside

Resistance CAN bus line with 1 terminating resistor 120 Ohm


CAN bus participant

Measuring value

Without A17, without A30, without CAN modules

120 Ohm

With A17, without A30, without CAN modules

60 Ohm

With A17, A30, without CAN modules

44 Ohm

With A17, A30 and 1 CAN module

35 Ohm

With A17, A30 and 2 CAN modules

29 Ohm

With A17, A30 and 3 CAN modules

24 Ohm

Internal resitance of CAN-Bus partcipans


Terminal A17, pin 7 - 8

120 Ohm

Com. Control A30, pin 94 - 95

163 Ohm

CAN module, pin 4 - 12

163 Ohm

The internal resistance of job computer A11 and display unit A21
is in the kOhm range.

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Function and programming of CAN modules
The CAN modules (part number: 16057402) for controlling of the deflectors, the straw guide plate and the sieves serve
for supporting of the Commander Control 2000. The modules are working in remote control mode, i.e. they cannot
perform any controlling actions without the master computer, which in this case means without the Commander Control
2000. The Software of the modules is only able to execute commands which are transmitted via CAN bus.

Example
The illustration opposite shows a flow chart as an example. The Commander Control 2000 (A30) is supposed to further
open the upper sieve (open 5 mm). The actuator is connected to CAN module A27. For this purpose the following
command sequence is necessary:
1.
2.
3.
4.

A30:
A27:
A30:
A27:

"A27,
"A30,
"A27,
"A30,

switch on connection DO/1 (relay upper sieve open).


connection DO/1 (relay upper sieve open) is switched on.
send voltage from connection AI/1 (potentiometer upper sieve).
voltage at connection AI/1 (potentiometer upper sieve) amounts to 3,6V.

A30 now performs the control and compares the actual voltage of A27.AI/1 with the nominal voltage. For this purpose
several requests for voltage measuring are sent to A27, and A27 continually communicates the actual voltage to A30. If
actual voltage and nominal voltage are identical the report is as follows:
5.
6.

A30: "A27, disconnect connection DO/1 (relay upper sieve open).


A27: "A30, connection DO/1 (relay upper sieve open) is disconnected.

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Upper sieve open


5mm

A30: A27, activate


DO/1! (relay upper
sieve open)

A27: A30, DO/1 (relay


upper sieve open) is
activated.

A30: A27, send


voltage AI/1!

A27: A30, voltage


AI/1 = ... V

A30
U AI/1 = Usetp
?

no

yes
A30: A27, deactivate
DO/1! (relay upper
sieve open)

A27: A30, DO/1 (relay


upper sieve open) is
deactivated.

Upper sieve is open


5mm

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Function and programming of CAN modules

All modules are physically identical and mutually exchangeable. All modules are equipped with the same software The
only difference is the CAN bus address the modules and thus also the functions can be accessed with. This operational
address is assigned from Commander Control 2000 by setup. For this purpose the Commander Control 2000 transmits
the future operational address with a special message to the programming address of the module. The programming
address is identical with all modules, for this reason observe that only one module is connected during this process. The
operational address can be reassigned anytime via the Commander Control 2000, it is therefore possible to mutually
exchange the modules of a machine.

Programming procedure (upon upgrading or exchange of a module):


1.
2.
3.

4.
5.

only 5670: Switch off Diesel engine


Switch off ignition
Unplug the modules which are not to be programmed, only one remaining module is allowed to be connected to the
CAN bus (the slot position however does not matter for programming, as only the CAN bus and the power supply are
used)
Switch on ignition (Do not start Diesel engine!!)
Press the right push button <+> and the right push button <-> at Commander Control 2000 simultaneously, the
program enters the "setup

By means of these
push buttons:

By means of these
push buttons:

Both push buttons


pressed
simultaneously:

--> Select page

--> Select line

--> Call setup

--> Quit menu

By means of the
push buttons:
--> Confirm selection

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Function and programming of CAN modules
The LC display now shows the following screen:
number of pages
in this menu

current page

Setup

1/3

Language:: english
Language

Front tires:
R adial 650/75R32
Turbo separator:
yes
LCD View angle;

screen 2
--> Switch over to page 3 by means of one of the left push buttons <+> or <->:

Setup

3/3

El.sieve adj.:

yes

El.straw guid:

yes

El.spre
a.
dp
.l
p.l:.:
El.spre
ad

no

Eng.sp.
factor:

3.32

Selected
line

screen 3
--> Change to the corresponding line by means of one of the centre push buttons <+> or <-> and confirm by means of
one of the right push buttons <+> or <->:

Setup

3/3

El.sieve adj.:
New address
Et
lraw
.sieve
adj.:
El.s
guid:

yes

El.spread.pl.:
Eng.sp.
factor:

yes
no
yesno
3.32

screen 4

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Function and programming of CAN modules
For programming change over to "yes by means of one of the centre push buttons <+> or <-> and confirm by means of
one of the right push buttons <+> or <-> besttigen:

Setup

3/3

El.sieve adj.:
New address
Et
lraw
.sieve
adj.:
El.s
guid:

yes

El.spread.pl.:
Search
module
Eng.
sp.
factor:

yes
no
yesno
3.32

screen 5
--> If no module could be found the highlighted bar remains on "no as shown in screen 4. If the module logs in correctly
to the CAN bus the highlighted bar changes to "yes:

Setup

3/3

El.sieve adj.:
New address
Et
lraw
.sieve
adj.:
El.s
guid:

yes

El.spread.pl.:
Search
module
Eng.
sp.
factor:

yes
no
yesno
3.32

screen 6
--> Confirm with one of the right push buttons <+> or <->. The operational address is transmitted from the Commander
Control to the module and stored into a nonvolatile memory (EEPROM) of the module:

Setup

3/3

El.sieve adj.:
New address
Et
lraw
.sieve
adj.:
El.s
guid:

yes

El.spread.pl.:

yes
no
yesno

Send
Adresse
Eng.
sp.
factor:

3.32

screen 7

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Function and programming of CAN modules
The setup can be quit by means of simultaneously pressing the left push buttons <+> and <>.
--> Switch off ignition
--> Reconnect all devices
The module is now logged on to the Commander Control and all the related functions and
diagnostic pages are ready to operate:

CAN diagnosis

1/4

El. adjustment:
Top sieve
Potentiomet.
Cal. min
Cal. max
Actual value
Extend button
R etract button
R el.:Extend "
R el.:Retract
screen 8
In case of a module failure a corresponding error message will be displayed by the
Commander Control 2000:

Error
Sieve adjusting
is not
addressable

screen 9

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Function and programming of CAN modules
Deactivation of a function with CAN module
If for some reason one of the modules cannot be accessed any more and no spare parts are available (or the machine
must be downgraded), the affected module must be logged out from the Commander Control. As a result, unsubstantial
error messages will be avoided.
Logging out of a CAN module:
--> Switch on ignition
--> Press the right push button <+> and the right push button <-> at the Commander Control 2000 simultaneously, the
program enters the "setup

Setup

1/3

Language: english
Front tires:
R adial 650/75R32
Turbo separator:
yes
LCD View angle;

screen 10
--> Switch over to page 3 with one of the left push buttons <+> or <->:

Setup

3/3

El.sieve adj.:

yes

El.straw guid:

yes

El.spreaadd..ppll..::

no

Eng.sp.
factor:

3.32

screen 11

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Function and programming of CAN modules
Change to the corresponding line by means of one of the centre push buttons <+> or <-> and confirm with one of the right
push buttons <+> or <->:

Setup

3/3

El.sieve adj.:
New address
Et
lraw
.sieve
adj.:
El.s
guid:

yes

El.spread.pl.:
Eng.sp.
factor:

yes
no
yesno
3.32

screen 12
--> Confirm by means of one of the right push buttons <+> or <-> in order to log out. Now the corresponding module is
not known any more by the Commander Control 2000 and the functions and diagnostic pages are not ready any
more, error monitoring is not activated any more for this module.

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Connector pin assignment at job computer
signal

Connector Asignification

colour

signification

colour

signal

spreader drum speed*

gr-rt

inductive

12

ground stabilized

br-ws

0V

11

ignition stabilized

rt-ws

12V

CAN-GND

sw

0V

CAN-H

bl

data

GPS/printer TxD

gr

data

yield logger TxD

gn

data

screen power supply

ws

12V

Pin No.
18

35
17
34
16
12V/4V

br-ws

elevator speed

33
15
32
14
31
13
30

0V

br-ws

ground stabilized

29
28
10
27
9
26
8
25
7
24
6
23

data
data
data
0V

rt
ro
ge

CAN-L
GPS/printer RxD
yield logger RxD

br

screen ground

22
21
20
19

* only for 8XL

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Connector pin assignment at job computer
Connector B
signal

colour

signification

signification

colour

signal

17

fan inclinometer

bl

0V...5V

16

engine oil temperature

sw-vi

0V...12V

15

ground drive hydr. temp. bl-vi

0V...12V

14

fuel tank level

vi-ws

0V...12V

turbo separator speed

ws-vi

12V/4V

conveyor auger speed* bl

12V/4V

sieve pan speed

ws-rt

12V/4V

partial width +

gn-vi

12V/0V

returns load

vi-sw

impulses

straw walker loss sensor bl

Pin No.
18
35

2,4-7,1V
0V.12V
2V...6V

sw-bl angle sensor feed passage


bl-gn
gn-ge

coolant temp. transmitter


cutting angle transmitter

34
33
32
31
13
30
12
29
11
28
10
27
26
25
7
24

12V/0V

gn-ge

partial width -

23
22

impulses

rt

sieve pan loss sensor

21
impulses

20
2
19
1
* only for 8XL

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5650H 5690HTS
Connector pin assignment at job computer
signal

colour

signification

Connector C
Pin No.

signification

colour

signal

18

signal MW skid centre or

2,4.7,1V

17

processing hydraulics temp.

bl-vi

35
0V.12V

gn-vi cutting mechanism hydr. temp.*

34

0V..12V

(Sensor not mounted)


16

33
15
32
14

impeller speed**

ws-rt

12V/4V

feed passage speed

ws-ge

inductive

31
13
30
12
29
11
28
10
27
9
12V/0V

rt-ws

indicator light fan control

26
8
25
7
24
6
23
5
22
4
21
3
20
2
19
1

* only for 8XL


** only with synchronous drive of impeller

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1
2
3
4
5
6
7
8

CAN-Modul

9
10
11
12
13
14
15
16

A25

CAN module deflector adjustment

A26

CAN module straw guide plate adjustment

A27

CAN module sieve adjustment


relay lower sieve close (K62)
relay upper sieve close (K20)

key switch upper sieve open


key switch upper sieve close

key switch lower sieve open


key switch lower sieve close

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Connector pin assignment CAN modules
1

CAN module

Connector

Technical data CAN modules:


Power supply:

10...16V (computer works down to approx. 7Volt), approx. 90mA/13,8V (without loads). Reverse
battery protection, transient protection, optional 24-V operation.

Sensor supply:

8 Volt, 100mA

Internal diagnosis:

BV sensor supply can be read back

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Combined instrument gauge
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Straw chopper speed


Grain tank unloading tube
Straw chamber (straw walker)
Returns elevator
Grain tank level display
Air filter engine
Cylinder head temperature engine, resp. engine oil temperature
Central warning light
Parking brake
Cooling fan belt engine 5670
Oil pressure engine
Main beam
Charge control
Direction-indicator transport trailer
direction-indicator combine harvester
Fuel tank level Diesel
Oil temperature engine (continually)
Ground speed

When switching on the ignition lock to pos. I all indicator lights (position 1-11 and 13) are lit for approx. 3 sec.,
simultaneously the acoustic warning signal (buzzer) is sounding.
During the operation a failure is indicated by activating the individual lights in the combined instrument gauge,
simultaneously the buzzer is sounding in conjunction with flashing of the central warning light (pos. 8). Additionally, a
warning message will appear in the Commander Control display.
Except for the temperature switches for cylinder head and engine oil, all transmitters (sensors) are equipped with normally
closed contacts to ground. In this way also a damage in the wire system (cable connections) will be indicated as a failure.

Connection diagram
connector pin assignment
Connector X171 (sw)

Connector X170 (ws)


pin

cable colour function

pin

cable colour function

ws

vi/ws

Fuel tank level Diesel (16)

Main beam (12)

bl

Charge control (13)

sw/vi

Oil temperature engine (17)

bl/ws

Direction-indicator

gn/sw

Straw chopper speed (1)

transport trailer (14)

ws/bl

Control grain tank unloading tube (2)

bl

Direction-indicator

ge/rt

Straw chamber (3)

combine harvester (15)

bl/gr

Returns elevator (4)

sw

Plus 12V

or

Grain tank level display (5)

ws/rt

Ground speed

gn

Air filter engine (6)

sw/ge

Central warning light (8)

bl/sw

Cylinder head temperature engine (7)

sw/rt

Parking brake (9)

10

br

Ground

bl/rt

Cooling fan engine (10)

11

br/rt

Terminal G

10

not used

12

gr

Lighting combined instrument gauge

11

bl/ge

Oil pressure engine (11)

12

not used

equipped with TERIS/TCS a cable


* When
jumper must be connected from pin 10 to
pin 11 at the connector X171 (connector II,
black) of the combined instrument gauge.

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Transmitters
sensors

Combined instrument
gauge

Commander Control
2000

engine oil temperature

Limit transmitters
(switches)

position
straw guide plate

buzzer
fuel tank level

straw chamber straw walker

AHS Page Working master switch


B40

B7
individual
light

central
warning light

A30

returns elevator
left/right
grain tank level
engine fan
v-belt
engine air filter
engine cylinder headtemperature, oil temp.
engine oil pressure
terminal D+, W

ground speed

parking brake
grain tank tube
coolant level

Threshing drum
Fan
Reel

56-068

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Combined instrument gauge and Commander Control 2000
Overview monitoring and operation functions
A8

Clutch control power unit CCP II for clutches

A30

Commander Control 2000

AHS Working master switch S40


B7

Buzzer

B40

Combined instrument gauge

K98

Relay reversing motor

M19 Reversing motor


S43

Switch reversing device

relay sets:
K50, K71 Grain tank tube swing out/swing in
Speed adjustment:
K14, K35 Relay set reel variator
K15, K36 Relay set fan variator
K56, K77 Relay set threshing drum variator
Concave clearances:
K18, K39 Relay set concave front
K19, K40 Relay set turbo separator up/down
K60, K81 Relay set concave rear

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Diagram inputs/outputs Commander Control 2000

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inductive sensors speed acquisition:


reel, threashing drum, blower

inductive sensor (speed monitoring):


straw walker, returns, filter auger, chopper

switch (condition monitoring):


cylinder head- /coolant temperature, -level, engine oil
excess temperature, engine oil pressure, cooling fan, air
filter, hand brake, straw chamber, returns

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Connector pin assignment A30, Commander Control 2000

34

45

51

56

46

52

63

67

72

64

68

466204

60
57

61

466203

40
35

41

466205

27

16

26
17

10
1

11

Connector view
seen from cable side

93

100

86

94

466206

80

85

73

81

IFM sensor filter auger speed

56-065-1

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Connector pin assignment A30, Commander Control 2000

34

45

51

56

46

52

63

67
64

68

93

100

466204

72

60
57

61

80

85

466203

40
35

41

466205

27

16

26
17

10
1

11

Connector view
seen from cable side

94

86

73

81

466206

Coolant level

Revolving light upon grain tank full

supply potentiometerservo motor turbo separator up/down

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LED

LED

D
E

56-053

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Function monitoring with the Commander Control 2000
The Commander Control 2000 (4) monitors and acquires speeds and operating conditions of the combine harvester by
means of switches and sensors.
Speed monitoring: Evaluation of switching frequencies which are induced by a turning shaft inside of inductive sensor (B).
Operating conditions: Monitoring is done with closed circuit systems. Upon normal operation the circuit between
Commander Control 2000 and switch/sensor is closed. Upon interruption of this circuit either when the sensor has
responded or wire break is existing or a switch/sensor is defective, the Commander Control 2000 indicates a warning
message: Display (5), combined instrument gauge (1) or buzzer (3).
Exception: The temperature switch (E) for cylinderhead resp. for coolant and engine oil: Switch contacts close against
ground when exceeding the limit temperaturight

Function of terminal D+ und W of the generator:


terminal D+:

- Function monitoring of generator (charge control).


- Release of the belt clutches in connection with the working master switch (upon voltage drop at
terminal D+ all belt clutches will be disengaged).

terminal W:

- Monitoring, acquisition of engine speed.


- Release of the threshing mechanism clutch if engine speed is less than approx. 1500 min-1.

Legend:
1

Combined instrument gauge or monitor TERIS/TCS

Generator

Buzzer

Commander Control 2000

Display

Pulse transmitter (mounted on shaft)

Inductive transmitter shift gear

Inductive sensor as speed sensor

Inductive sensor as monitoring switch

Mechanical monitoring switch

Temperature switch at engine

Capacitive transmitter for grain tank level

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Switches and sensors for monitoring
A

Inductive transmitter in the gear box cover for acquisition of the ground speed.
Control dimension upon mounting: air gap 10,5 mm between sensor and toothed wheel.
Internal impedance of the sensor: R = 1,05 k 100
Insulation against housing > 500k
In the case of TERIS/TCS the cutting mechanism drive is monitored with an inductive transmitter at the gear rim of the
reversing device.

Inductive sensor for monitoring and acquisition of speeds.


Control dimension upon mounting: air gap 4 mm between pulse transmitter (6) and head of sensor.
The LED is lit, when the pulse transmitter (6) covers the sensor head.

Speed sensors:
- Straw walker
- Elevator head
- Returns elevator
- Chopper
- Threshing drum
- Blower
- Reel drive
- sieve pan oscillating arm
- turbo separator

speed monitoring
by means of Commander Control 2000

speed display and control of speed adjustment


by means of Commander Control 2000
only with TERIS/TCS

Inductive sensor as monitoring switch


Control dimension upon mounting: air gap min. 4 mm between head of sensor and lever, grain tank tube etc.
Sensor grain tank tube:

LED is lit when grain tank tube is swung in.


- As long as the grain tank tube is not completely swung in, the indicator light no. 2 in the
combined instrument gauge is lighting.
- The grain tank clutch is automatically disengaged when the grain tank tube is swung in
(indicator light no. 2 is extinguishing).
Upon defective sensor or wire break the grain tank clutch function is blocked.

Sensor grain tank top:

LED is lit when the grain tank extension is lowered and the grain tank cover is closed.
- Warning message in display if: - grain tank top open
- Threshing mechanism and working master switch off
- Ground speed > 2 km/h

Sensor straw guide plate: LED is lit when the straw guide plate is adjusted to long straw.
In chop position the sensor is activating the following functions:
- Indicator light (3) at the control console is lit (see fig. control console).
- Actuation of the chopper clutch upon engaging and disengaging of the threshing
mechanism.
- Speed monitoring for the chopper.

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LED

LED

D
E

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LED

LED

D
E

56-053

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Switches and sensors for monitoring
D

Mechanical monitoring switches

Monitored function

type of switch*

Straw chamber straw walker 2 x


Cover returns elevator 2 x
Hand brake
cooling fan belt (engine BF6L.913 C)
Oil pressure switch engine
Low-pressure switch air filter

normally
normally
normally
normally
normally
normally

closed
opened
opened
closed
opened
closed

* Switching status of the switch when operated away from its neutral position.
Normally closed:
switch contacts are opening upon operation
Normally opened: switch contacts are closing upon operation

Temperature switch for cylinder head/coolant and engine oil (5650 - 5690)
Switch contacts are closing when temperature limits are exceeded (exception from closed circuit concept).

Capacitive transmitter for grain tank level


The capacitive transmitter is opening against ground (pin 2 to 3), when it is covered by the cone of grains.
Simultaneously the red LED on top of the transmitter is extinguishing and the Commander Control 2000 is initiating the
alarm message.
One or two transmitters may be mounted in the grain tank.
Design with one transmitter:

When the grain tank is full indicator light no. 5 in the combined instrument gauge is lit,
the buzzer and the revolving lights are activated.

Design with two transmitters:

1. transmitter: Warns if grain tank is 3/4 full, indicator light no. 5 is flashing, revolving
lights are operated in interval.
2. transmitter: Warns if grain tank is completely full, indicator light no. 5 is lit, buzzer
and revolving lights are activated.

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Functional description inductive sensor
The inductive sensor (1) is an electronic switch which changes its switching status
when the distance Ds (switching distance) between a metal body (2) and the sensor head exceeds or falls below approx.
8mm. In this way the position of levers or flaps or speeds can be monitored.
Depending on the electrical pin assignment the inductive sensor is working as a normally opened or as a normally closed
contact against ground.
Normally opened:

when the sensor clearance falls below 8mm the sensor current rises to approx. 10mA;
LED (3) is lit.
(with a clearance >8mm the sensor current decreases to 0,5mA, LED (3) is extinguished)

Normally closed:

when the sensor clearance falls below 8mm the sensor current decreases to approx. 0,5mA;
LED (3) is extinguished.

The LED (3) is always lit when the switching status is closed, independant from the the pin assignment.
At the combine harvester all inductive sensors are connected as normally opened contacts.
A minimum distance Dmin of at least 4 mm must be observed between the sensor head and the monitored functional
element in order to prevent possible damage.
The inductive sensor must not be connected to a 12V power supply without protection resistance (approx. 70
Ohm) as otherwise it will be destroyed.
Maximum current load 400mA.

1
2
3
4

H 96

Inductive sensor
Metal body
LED
AMP-connector 282 104-1

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1
Ds 8mm

Dmin > 4mm

SW

WS

NPN
NPN

NPN
NPN

switching
against minus
minusschaltend

switching
against minus
minusschaltend

normally opened function

normally closed function

Schliesserfunktion

Oeffnerfunktion

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Sensors, overview
Sensors right side of the machine
1

Low-pressure switch air filter

Grain sensor straw walker (left and right)

Switch straw chamber warning flaps

Potentiometer in servo motor for deflectors

Speed sensor chopper

Sensor for straw guide plate position

Potentiometer in servo motor for straw guide plate

Grain sensor sieve pan

Wheel sensor for grain loss monitor and job computer LH 1000 (not applicable with TERIS/TCS)

10

Switch returns elevator cover

11

Speed sensor returns elevator

12

Throughput sensor returns elevator (only with TERIS/TCS)

13

Potentiometer in the servo motors upper-/lower sieve open/close (only TERIS/TCS)

14

Sensor sieve pan oscillating arm (only TERIS/TCS)

15

Speed sensor turbo separator (only TERIS/TCS)

16

Sensor ground speed in gear box

17

Angle transmitter balance axis

18

Pressure sensor for cutting mechanism control

19

Speed sensor intermediate shaft in feed passage (only TERIS/TCS)

20

Angle transmitter cutting angle of cutting mechanism (only with balance)

21

Position sensor feed passage for LH-1000 job computer (not applicable with TERIS/TCS)

22

Position transmitter feed passage for cutting mechanism control

23

Potentiometer in servo motor concave clearance rear

24

Brake light switch

25

Switch hand brake

26

Sensors for start interlock and reverse gear horn multifunction handle

27

Brightness sensor for grain loss monitor

28

Speed sensor grains elevator

29

Throughput sensor in elevator head (only with TCS)

30

Humidity sensor in grain tank filling tube (only with TCS)

31

Potentiometer in servo motor turbo separator up/down

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31

29,30

28

27

26
25
24
23
22
21

10

11 12

13

14 15 16 17 18 19 20

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15

13

14

12

11

10

34940-1

13, 14, 15

21
16
19
17,18
20
17

56-017

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Sensors, overview
Sensors left side of the machine
1

Potentiometer for touching skid

Speed sensor reel

Potentiometer in servo motor concave clearance front

Angle transmitter balance axis

Speed sensor threshing drum

Speed sensor blower

Switch returns elevator cover

Throughput sensor returns elevator (only with TERIS/TCS)

Speed sensor straw walker

10

Level transmitter fuel tank

11

Temperature sensor hydraulic oil (in hydraulic pump)

12

Sensor grain tank tube

13

Sensor grain tank top

14

Level transmitter grain tank completely full

15

Level transmitter grain tank 3/4 full

Sensors at the engine (sensors for EEC see chapter A)


16

Transmitter/switch cylinder head temperature


- 5670: transmitter mounted in 1. cylinder head, switch mounted in 2. cylinder head.
- 5650 - 5690: transmitter and switch one component.

17

Transmitter/switch engine oil temperature (with 5670 only temperature transmitter)

18

Oil pressure switch at the 5670

19

Oil pressure switch

20

Switch at tensioning pulley cooling fan belt (only engine BF6L 913C)

21

Coolant level sensor

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Multifunction lever
Gear rack device / sensor adjustment
1

Wedge action socket

LED, lighting when in reverse motion

B46 inductive sensor for reverse gear horn

B45 inductive sensor for start interlock neutral position sensor (release all-wheel drive)

LED (functional check, not lighting in neutral position)

Gear rack device

Control disk

Bowden pull wire

= forward motion

= reverse motion

Adjustments at gear rack device and Bowden pull wire


1 - Mechanical zero position
2 - Electrical zero position
3 - Zero position at the hydraulic pump (see chapter D)
These three adjustments must be consistent!

mounting advice:
- Move the multifunction lever out of zero position to reverse motion position.
- Screw in the inductive sensors via the wedge action sockets into the gear rack device until reaching the mechanical stop
at the connecting member.
- Turn back one whole revolution (thread M12x1) and secure with flat nut.
- Move multifunction lever into forward as well as reverse motion.
Minimum distance of active sensor surface to control disk: 1 + 0,5 mm.
In neutral position of the multifunction lever the LEDs (2) and (5) must not be lit!

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0
V
R

8
1+

0,

5
2
4

Ze
N
ulrlo
stepllos
unigtio
n

,
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to control cabinet

to control cabinet

Service
Training

56-067

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5650H 5690HTS
Multifunction lever
Connector pin assignment
B45 Neutral position sensor
B46 Reverse motion sensor
X190 - X192
Pneutron connector under control console
X506, X512
21-pole connector in control cabinet

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H 105

A10

H 106

0VP

WS

K22

WS

VOY

S41

M/A

S28

24VP

WS

12VP

B47

B46

B45

A
B
B

86

SW

85 2

5
C

S40
S2

NC

output starter

output starter

reversing horn

output allwheel drive

output all-wheel
drive on

output all-wheel drive M/A

input working master


switch terminal 15a

input all-wheel drive

input differential lock

input sensor for 4th gear

input reverse motion sensor

input neutral position sensor

GND

terminal 15 12V

logic module start interlock reversing horn all-wheel

16

15

14

13

12

11

10

A13

Service
Training

30
15
D+
15a
15b

logic module start interlock reversing horn all-wheel

F19

50a

B48

SW

F22

SW

3
30

87

87a

starter

control unit all-wheel drive

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A13 logic module, connector pin assignment, function
A13

Logic module

A10

Control unit all-wheel

B45

Sensor neutral at hand throttle

B46

Sensor reverse at hand throttle

B47

Sensor 4th gear

B48

Reverse gear horn

F..

Fuses

K22

Start relay

H39

Indicator light all-wheel on

S2

Start switch

S28

Foot switch slip control (diff. lock)

S40

Working master switch

S41

Switch all-wheel on

Pin

Designation

Cable colour

Measuring value

Input from A10 M/A

bl

11V/0V

Input 12V for control unit A10

rt

12V

---

Output A10 12VPA

bl/ws

2V/12V

Output relay K22, starter

sw/vi

0V/12V

sw/vi

0V/12V

---

NC, input start switch S2

Output reverse gear horn B48

vi

1,5V/12V

Terminal 15

sw

12V

10

Ground GND

br

0V

11

Sensor neutral B 45

sw

11V/4V

12

Sensor reverse B46

ws

11V/4V

13

Sensor 4th gear B47

vi/gr

11V/4V

14

Input switch S28, diff. lock

15
16

bl

11V/0V

Input switch S41, all-wheel on

sw/ws

10V/0V

Input working master switch S40, terminal 15a

sw/gn

12V

When foot switch S28 is actuated the logic module is connecting pin 1 to ground.

Function of logic module:


1.

Start interlock:
Release of relay K22 upon neutral position of the multifunction lever by means of sensor B45

2.

Activation of the reverse gear horn B48 by means of sensor B46 upon position reverse of the multifunction lever

3a

Release of activating the all-wheel drive by means of switch S41 if:


- Working master switch S40 is on (terminal 15a)
- Multifunction lever is in neutral position, B45
- the 4. gear is not engaged, B47

3b

Activation of slip control (differential lock) upon activated foot switch S28 and activated all-wheel drive S41.

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Control unit EEC
Gas control unit
1

A1 control unit EEC

Connector at engine side

Connector at vehicle side

Gas control unit

Diagnosis plug-socket

LED UB, power supply voltage

LED VCC, power supply from EEC

LED TH/2, half throttle

LED TH/1, full throttle

10

LED SDW, threshing mechanism on = 15b, (LED on = threshing operation)

Notice: With full throttle and switched-on threshing mechanism all LEDs are lit.

A2 pin assignment
Pin
1
2
3

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

Cable colour
gr/rt
gr/bl
br

Pot. throttle slider

ws/bl

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

Pot. throttle supply


Input droop changeover from K11
Output droop changeover to A1
Ground droop changeover
Supply 12V from control cabinet X8
Supply A1

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

H 108

Supply for diagnosis connector


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

sw
br
br
br
br

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

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

SOLARI 1.she

Motor

Fahrzeug

16

9
1

56-116

56-055

10

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Notes

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Electronic cutting table control
EMR-D Self-levelling control / AutoControl
Function
The EMR-D self-levelling control / AutoControl system is
used for automatic control of the cutting table levelling
system on the combine harvester.
The electronic control unit EMR-D processes the actualvalue signals (position sensor, pressure sensor, tracker
bar sensor), compares them with the predefined settings
(operating control) and transmits the appropriate control
signals to the control valves (for a more detailed
description, please refer to the Operating Instructions).
Components of the
EMR-D Self-levelling control / AutoControl:
Electronic EMR-D control unit (in the control box)
EMR-D control valve (on left as seen in direction of
travel, mounted on the grain tank next to the grain tank
discharge tube)
Electronic tilt control unit, AutoControl
(in the control box)
Tilt control valve (on left as seen in direction of travel,
built into the control valve block, next to the grain tank
tube)
Control panel (control box)
Control functions in the Commander Stick
Position sensor (mounted on the centre of rotation of
the feed passage, to the right as seen in the direction
of travel)
Pressure sensor with activating valve and pressure
accumulator (mounted on the drive axle)
Tracker rod sensors (up to 3)
(4 k potentiometer on the front attachment)
Floating frame with hydraulic cylinders for tilt control
(AutoControl)
Note:
Tilt control is also termed "lateral flotation" or "field
tracking".

Switching logic
Operating standby / "Diagnostic" standby
(precondition for adjustment)
1. First calibration completed
2. Front attachment and electrical connector connected
3. Ignition switch to position (1)
4. Engine running
5. Working master switch
6. Threshing mechanism engaged
7. Desired operating mode selected
8. Automatic button in commander stick pressed

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Electronic cutting table control
EMR-D Self-levelling control / AutoControl
Layout of controls
Layout of the control panel for EMR-D self-levelling (basic variant) and AutoControl (variant with tilt control):
Item No.Self-levelling / Autocontrol version
(1)

Mode selector switch

(2)

Overstroke button (Important: only press briefly until reaching the cylinder end-stop).

(3)

Contact pressure preselection

(4)

Cutting height preselection

(5)

Diagnostic indicator light red LED

(6)

Status indicator light (comes on in automatic mode) green LED

Layout of controls of the Commander Stick


Item No. Topliner
(10)

Raise front attachment normal fast mode

(11)

Lower front attachment normal fast mode

(12)

Raise reel

(13)

Lower reel

(14)

Tilt front attachment, right side down

(15)

Tilt front attachment, left side down

(16)

Automatic mode

(17)

Reel back

(18)

Reel forward

Extra equipment:
(19)

Cutting angle adjustment: up

(20)

Cutting angle adjustment: down

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1.3

1.4

1.2

1.1

6
5

33918

19
12
13

10
11

18

20
17

14
15

16

17

16

307.1133.3.6 englisch (en) 10.2006

WS/GR

WS/GE

GR/BR

GE

GR/PK

19

PK

VI

GN

BR

WS

14
15

RT/BL

GR

BL

SW

RT

hebl
hegn

BN/GN

AUTO

20

WS/BL

13 18

WS/RT

12

WS/SW

11

10

hebl

hegn

5
7

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Electronic cutting table control
EMR-D Self-levelling control / AutoControl
Calibration
Calibrating the EMR-D Self-levelling control /
AutoControl
Reason: To adapt the EMR-D to the relevant front
attachment for optimal levelling and guidance of the front
attachment.
When?
When using for the first time
When changing tyres or changing front attachment
When fitting an extra hydraulic cylinder
If the combine sinks deeply on soft ground
Conditions:
The front attachment and combine must be standing on
flat ground; the skids and tracker bars must be resting on
the ground.

Second calibration stage (2)


Determines and stores the weight of the front
attachment.
Required:
after performing the first calibration stage, if the weight of
the front attachment has been changed.
Procedure:
Steps 1. 5.
The front attachment must hover just above the
ground (50 ... 100 mm).
Press the "Lower front attachment" and "Raise front
attachment" push-buttons simultaneously and hold
them down for at least 7 seconds.
The status indicator light flashes 8 times to confirm
calibration.

Comment
In the Balance version, the drive axle must be in neutral
position (mid-position).

The second calibration stage (2) is complete.

First calibration stage (1)

Determines and stores the weight of the front attachment


at maximum raised height.

Determines and stores the position of the feed passage


when the front attachment is rested on the ground, and
registers the sensor values at the skids.

Required:
after carrying out the second calibration stage.

Conditions:
The front attachment and combine must be standing on
flat ground; the skids and tracker bars must be resting on
the ground.
Procedure:
1. Switch the ignition lock to position "I".
2. Start the engine.
3. Switch on the main switch for the hydraulic functions
(threshing section master switch).
4. Switch the mode selector switch to the transport
position (calibration).
5. Raise or lower the front attachment at least 100 mm,
and then lower to ground.

The front attachment must rest on the ground.


Press the "Lower front attachment" and "Automatic"
push-buttons simultaneously and hold them down for
at least 7 seconds.
The status indicator light flashes 5 times to confirm
calibration.

Third calibration stage (3)

Procedure:
Steps 1. 5.
The front attachment must be raised to just under its
maximum raised height (the cylinder end stop must
not be reached).
Press the "Automatic" push-button and hold it down
for at least 7 seconds.
The status light flashes 12 times to confirm
calibration.
The third calibration step (3) is complete.
To repeat a calibration step, switch off the engine and
restart the calibration process from the beginning.

Note::
The field tracker remains active while the ground
clearance and contact pressure are adjusted, even if
the automatic function is not active.
(signal change 2 Volt required to switch off).

The first calibration stage (1) is complete.

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Electronic cutting table control
EMR-D Self-levelling control / AutoControl
Fault diagnostics
The EMR-D control unit constantly monitors the system for faults. Faults are classified in three classes.
The EMR-D electronic cutting table control responds differently according to the error class.
Reaction to faults:
Major faults:
The EMR-D control action is stopped and locked in position.
The relay is switched off (output stage protection).
Driver warning: the red diagnostics indicator (5) emits the fault code. Error output is terminated when the
control system is restarted.
To restart the control system: remedy the fault and restart with the ignition key.
The front attachment can now only be raised or lowered by manually operating the control valves.
Medium-severity faults:
The EMR-D control action is stopped and locked in position.
Work can continue in any unaffected operating mode.
EMR-D functions in the "TRANSPORT" position.
Driver warning: the diagnostics indicator (5) emits the fault code.
To restart the control system:
Remedy the fault and release EMR-D by pressing the "Raise / Lower front attachment" buttons.
The red LED (5) only goes out after pressing the operating buttons if the fault has been remedied.
If a fault code has been started it will be finished.
Minor faults:
The EMR-D control action continues.
Driver warning: the red diagnostics indicator (5) emits the fault code.
The diagnostics indicator light goes out after the push-buttons have been pressed, provided that the fault has
been remedied. If a fault code has been started it will be finished.

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Electronic cutting table control
EMR-D Self-levelling control / AutoControl
Fault diagnostics
Fault code list for EMR-D
With the aid of the fault code list, faults can be located and identified. The next few pages specify the fault codes and
associated fault descriptions. The fault codes are divided into major faults, medium-severity faults and minor faults. The
error message for a fault is divided into two sequences of flashes. The first flash sequence specifies the fault class and
represents the first digit (tens) of the 2-digit fault code.
First flash sequence:
10

Major fault

Two flashes ()

20

Medium-severity fault

Three flashes ()

30

Minor fault

One flash

()

The second sequence of flashes follows after a short pause and subdivides the class or severity of the fault. It
corresponds to the second digit (ones) of the 2-digit fault code.
The fault code is obtained by counting the number of flashes in the first flash sequence and entering this number in
the tens position, and then counting the number of flashes in the second sequence and entering it in the ones position.
The relevant fault description for this fault code can then be found by looking up the code in the fault code list.
The diagnostics indicator light repeats the error message until the fault is remedied.
Examples: Fault 22
If the signal line to the "cutting height" setting potentiometer is broken, the indicator light will show e.g. Fault 22.
Two flashes - short pause - two flashes - long pause - REPEAT
- - - - - - - -- - - - - - - -- - - - - - - -

Fault 22

Examples: Fault 35
(Low battery voltage):
Three flashes - short pause - five flashes - long pause - REPEAT
- -- - - - - -- -- - - - - -

Fault 35

Simultaneous faults
If a number of faults occur at the same time, the other fault codes are displayed after the long pause. After all faults have
been indicated, the diagnostics indicator repeats all fault codes from the start.
Examples: Fault codes 22 and 35
Two flashes - short pause - two flashes - long pause - three flashes - short pause - five flashes long pause - REPEAT
- - - - - - - -- -- - - - - -- - - - - - - -- -
- - - - - - Fault 22 and Fault 35
By switching the ignition off and on again, the error message is always restarted from the start of the first fault code and is
then repeated.

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5650H 5690HTS
Electronic cutting table control
EMR-D Self-levelling control / AutoControl
Fault diagnostics
List of fault codes for EMR-D

Fault
Code

Brief Description

Major faults

Pin No.

Fault Description

11

RAISE output stage

37

The output stage for the "Raise front attachment" solenoid valve
is defective, or the line from the raise/lower solenoid valve to
pin 35 of the EMR-D control unit is broken.

12

LOWER output stage

19

The output stage for the "Lower front attachment" solenoid valve
is defective, or the line from the raise/lower solenoid valve to
pin 35 of the EMR-D control unit is broken.

13

Short-circuit

35

The current measured across pin 35 is too high.

Short-circuit between pins 19 and 35


or between pins 37 and 35 (solenoid coil short-circuit
possible).

14

Cable break

35

No current is measured across pin 35, even though the solenoid


coils are energised.

Possible cable break in the supply lines to the solenoid


coils (pin 19, 37 or 35).

Possible defect in the solenoid coils.

Possible absence of battery voltage at pin 29


(defective fuse).

Defective control box.

15

Commander Stick
Raise/Lower/Fast

Push-button signal is incorrect.


Malfunction of the RAISE, LOWER or FAST push-button.

16

Power supply

2
20

The operating voltage supply is incorrect.


Fault in 9.5 V supply or earth.

17

Battery

29

Battery voltage exceeds 18 Volt.

18

Mode selector switch

21

Selector lever signal is incorrect.


Cable break or signal not connected.

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5650H 5690HTS
Electronic cutting table control
EMR-D Self-levelling control / AutoControl
Fault diagnostics
List of fault codes for EMR-D

Medium-severity faults

Fault
Code

Brief Description

Pin No.

21

Position sensor

Position

22

Cutting height setting


potentiometer

22

Signal of the setting potentiometers incorrect.

Cable break or potentiometer not connected.

23

Pressure sensor

Contact pressure signal incorrect.


(only responds if pressure control is preselected with the
preselection switch).

24

Contact pressure
setting potentiometer

Signal of the setting potentiometer incorrect.


(only responds if pressure control is preselected with the
preselection switch).

25

"FAST" push-button

14

The "FAST" push-button is activated even though the "RAISE"


or "LOWER" button is inactive.

Fault
Code

Brief Description

Pin No.

Fault Description
signal incorrect.
Cable break or sensor not connected.
Short-circuit or short-circuit to chassis earth.
Incorrect calibration of the position sensor.

Minor faults

Fault Description

31

Tracker bar sensor,


right

26

The signal from the right-hand sensor is incorrect.

Cable break or sensor not connected.

Possible short-circuit or short-circuit to chassis earth.


(This diagnosis is only carried out when tracker bar feedback
control is active, i.e. only when the belt clutch for the threshing
or pressing mechanism is engaged and "clearance control"
mode is selected).

32

Tracker bar sensor,


left

The signal from the left-hand sensor is incorrect.

Cable break or sensor not connected.

Possible short-circuit or short-circuit to chassis earth.

33

Commander Stick tilt


(right/left)
and automatic

27

Push-button signal incorrect, or malfunction of the "TILT,


RIGHT", "TILT, LEFT" or "AUTOMATIC" operating function.

35

Battery

29

Low battery voltage (less than 12 Volt).

36

Valve defect or
no oil pressure

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Despite activated RAISE current at pin 37 of the EMR-D box,


the front attachment is not raised even though the engine
is running. No pressurised oil supply available, or the valve is
sticking.

H 119

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5650H 5690HTS
Control unit EMR-D (Bosch), connector pin assignment A3
Illustration seen from the cable side
pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44-45
46
47-50
51
52-55

signification
angle transmitter feed passage ground
power supply EMR-D control unit
MF handle lift/lower fast
Release EMR-D automatic
Setpoint pression on the support
Angle transmitter feed passage signal
Cutting mechanism skid left signal
Pressure transmitter signal
MF handle vers. lift/lower
not used
longitudinal slope from Balance
Status indication (LED green)
MF handle automatic
Cutting mechanism coding >7,2 m
Lateral tilt left input, pin 5
not used
MF handle lift
Solenoid valve reservoir
Solenoid valve lower
Control unit ground
Control unit operation mode
Setpoint cutting height
Cutting mechanism skid centre signal
Ignition terminal 15
not used
cutting mechanism skid right signal
MF handle vers. autom. lateral tilt
Ground terminal 31
Power supply terminal 30
Overstroke key
Diagnosis indication (LED red)
MF handle left turn
MF handle right turn
Lateral tilt right input pin 4
MVs ground lift/lower
MF handle lower
Solenoid valve lift
Pressure transmitter ground
Pressure-/angle transmitter/skids vers.
not used
Cutting mechanism skids ground
not used
Coding cutting mechanism > 7,2 m
not used
Lateral tilt/MV reservoir ground
not used
Lateral tilt power supply, pin 2
not used

colour
sw-vi
rt
br-gn
bl-gn
br
sw-bl
gn
ws-ge
sw

signal
0V
9,5V
0V/2,7V
11V/0V
0V...9,5V
2,4V...7,1V
2,4V...7,1V
2,4V...7,1V
5V

gr-sw
rt-bl
rs
br
rt-sw

Frequenz 392,5 Hz...2000 Hz


0V/5V
0V/6,3V
5V/0V with cutting mechanism >7,2 m jumper to PIN 43 inserted
PWM 10V/0V, 125Hz

rt
gr-ws
br-sw
bl
ws
or
or
sw

0V/3,5V
0V/12V, 2A
PWM 0V/12V, 1...3,2 A, 1kHz/80Hz
0V
6,4V/ 5,7V/ 3,3V/ 4,9V
0V...9,5V
2,4V...7,1V
12V

ge
rt-bl
br
rt
gr
sw-ws
ws-gr
ge-br
sw-ge
br
bl
ws
ws-bl
gr

2,4V...7,1V
11V
0V
12V
11V/0V
0V/5V
0V/6,3V
0V/6,3V
PWM 10V/0V, 125Hz
0V
0V/3,5V
PWM 0V/12V, 1...3,2 A, 1kHz/80Hz
0V
9,5V
1 EMR-D control unit (Bosch), A3
2 Lateral tilt control unit for EMR-D, A12
0V
3 Connector view EMR-D control unit seen from
cable side
4 Connector view lateral tilt control unit from
0V
cable side
5 Connector pin assignment EMR-D control unit
0V
A4
6 Jumper for coding MW > 7,2m
12V
7 Ferrite ring for electromagnetic shielding of
control unit A3 and A12

br
br
br
sw

Connector pin assignment for lateral tilt control unit EMR-D (Bosch) A12
pin
1
2
3
4
5
6

H 120

signification
MV right turn
Lateral tilt power supply
MV left turn
Lateral tilt right input
Lateral tilt left input
Lateral tilt ground

colour
sw-gn
sw
rt-gn
sw-ge
rt-sw
br

signal
PWM,
12V
PWM,
PWM,
PWM,
0V

12/0V, 1,2...2,2A, 125Hz


12/0V, 1,2...2,2A, 125Hz
10V/0V, 125Hz
10V/0V, 125Hz

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5 4

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

10 11 12 13 14 15 16 17 18 19
5

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

Pin Nr.

5
A3
20

H33

H32

S13
2

21
31

S12

12
Cutting height

R2
R1

Contact pressure

22
5
30
H017-1

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Electronic cutting table control


Topliner 4060 4090H as from chassis No.: ...7296
EMR-D Self-levelling / AutoControl
Measuring diagram
For testing, use measuring adapter 16017182

Earth

Earth

Control panel

Status indicator

red

0 V or 5 V

green

0 V or 5 V

Setpoint,
stubble height
Setpoint,
contact pressure

valve

solenoid

Lower

valve

open Threshing section


open Straw chopper
closed Power press

0 V or 12 V

open Threshing section


open Powerpress
closed Straw chopper

Right

Supply

Tilt prop.

Solenoid energisation

valve

solenoid

Tilt

Left

EMR-D control unit

solenoid

Cutting table
Accumulator

0 V or 12 V

Rise

Activation
Tilt

Valves

For version without tilt control, Nos. 7, 16 and 18 do not apply.

Overtravel push-button

(Earth)

All unmarked lines 1.0 mm 2


Ends marked with contact No.

Supply
Selector lever
1 = Stubble height with
1 = tracking control
2 = Contact pressure
3 = Stubble height without
3 = tracking control
4 = Transport
Diagnostics indicator

Earth
Stationary state detection

S1 = open:
S1 = closed:
bl/br

Tracker control inactive


Tracker control active
11 V or 0 V

Energisation
via threshing
section/powerpress relay R 28
Activation via
relay K 12

Connector, rear view

15

ws

rt

sw

bl

br

white

red

black

blue

brown

A00262

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5650H 5690HTS
Electronic cutting table control
EMR-D Self-levelling / AutoControl
13-pin

EMR-D control unit

Tracking sensor,
middle

Self-levelling

Supply
Signal
Earth

variant without tilt control,


with one tracking sensor

Supply
Signal
Earth

Tracking sensor L

Supply
Signal
Earth
Supply
Signal
Earth

Tracking sensor R

Supply
Signal
Earth

7 8

Tracking sensor middle

10 11 12

13-pol.

Position measurement

yellow

Sensors

Measuring diagram (continued)

The sensor voltage increases with increasing ground clearance and must be less than 6.8 V.
Supply
Signal
Earth

Cutting table / PU operation

Fast mode,
Up

0 V / 2,7 V

Raise

0 V / 3,5 V

Lower

0 V / 3,5 V

Fast mode,
Down

5V
11 V
Automatic
mode

0 V / 6,3 V

Turn
anticlockwise

0 V / 6,3 V

Turn
clockwise

0 V / 6,3 V

12 b

Multifunction lever

12 a

Pressure measurement

Battery terminal 30 (not via ignition lock)

Supply

Battery (line to earth)


Ignition terminal 15

8
4

13

12a

14

12b

11

15

ge

dubl

hebl

sw

hegn

ws

sw

ws

white

black

white

7 6
3 2

yellow

5
1

8
4

7 6
3 2

5
1

dark blue

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8
4

7 6
3 2

5
1

pale blue

8
4

7 6
3 2

black

5
1

8
4

7 6
3 2

5
1

pale green

H 123

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Service
Training

5650H 5690HTS
Electronic cutting table control
EMR-D Self-levelling / AutoControl

Feed passage position sensor


Basic setting:
The turning slot of the position sensor shaft (3) must
run in line (parallel) with the clamp lever (2). The
adjusting mark on the position sensor shaft (3) must
point in the direction of the connector (4) rough
setting.
Basic length of the coupling rod 173 mm (see
drawing) fine setting.

173

Checking the basic setting:


Required conditions: the combine must be standing on a
flat surface, with front attachment mounted.
When the front attachment is lowered, the signal voltage
(pin 2) must be 0.25 ! supply voltage VS (pin 3). When
the front attachment is fully raised, the signal voltage
(pin 2) must 0.75 ! supply voltage VS (pin 3).
For testing, use measuring adapter 16031484 or
16017182.
Signal voltage at maximum raised height (overtravel
button, cylinder end-stop): 7.1 Volt. Cut-off threshold
when raising the front attachment with the multifunction
lever: 6.8 V (signal voltage).
Checking the overtravel distance:
With the front attachment fully raised, a cylinder travel of
at least 30 mm must be available up to the cylinder endstop, i.e. when the overtravel button is pressed, the
cylinders must extend a further 30 mm before reaching
their end-stop.
I
After resetting the position sensor, the calibration
procedure must be repeated.
1

Position sensor (rotation angle sensor)

Clamping lever

Position sensor shaft

Connector

H0506

Tracker bar sensors Installation


The potentiometers must be fitted to the skids as
shown in Figure 31053. The potentiometers (10) must be
placed on the skids at an offset angle of 15 to allow the
engaging piece to be inserted in the bolt slot. The
electrical connection must point upwards. The potentiometer must then be rotated until the fixing screws (11) are
located roughly in the middle of the oblong holes.
Potentiometer resistance: 4 k
The tracker bar sensors are automatically calibrated
during the calibration process, i.e. if a tracker bar sensor
is changed, full recalibration is necessary.

11

10

H 124

31053

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Service
Training

5650H 5690HTS
Electronic cutting table control
EMR-D Self-levelling / AutoControl
1

AutoControl version

Self-levelling version

13-pin socket on the cutting table

10 Tracker bar sensor, left

8
8

12 Tracker bar sensor, right

10
2

11 Tracker bar sensor, middle

11

3
13

Testing the tracker bar sensors (potentiometer)

12

Potentiometer resistance: 4 k
Supply voltage: (pin 9): 9.5 V
Earth connection (pin 7): 0 V
(Pin 5: Tracker bar sensor, Left)
Tracker skid:

raised

lowered

Signal voltage:

2.4 V (min.)

6.8 V (max.)

(Pin 8: Tracker bar sensor, Middle)


(Pin 11: Tracker bar sensor, Right)

0V

9,5V

2,46,8V ( 2V)

0V

Make sure that the signal voltage is always within the


"signal window" range (2.4 to 6.8 V).
The operating range of 2 V for the tracker bar sensors
is preset by the tracker bar travel (chain length left / right
400 mm, middle 350 mm).
Note:
After replacing or resetting a potentiometer, the calibration
procedure must be repeated.

0V

2,46,8V ( 2V)
9,5V

2,46,8V ( 2V)

9,5V

0V

9,5V

2,46,8V ( 2V)

The operating range of the tracker bar sensors must be at


least 2 Volt ( 2 V).

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5650H 5690HTS
Electronic cutting table control
EMR-D Self-levelling / AutoControl
13-pin connector - Pin layout
Cutting table connector:
Male

Cutting table
potentiometer middle
Cutting table
potentiometer left

+ rt/ws
S or
br
S

rt/bl
+ sw

Reel speed sensor

Reel speed variator


Rape cutting table

Cutting table
potentiometer right

Female
AutoControl
version
(3 tracker
skids)

Potentiometer Middle

Potentiometer Left

Reel speed sensor


Rape cutting table

Female
Self-levelling
version
1 tracker
skid)

9
1

10
2

4
5

11

3
13

12

+ rt/ws
S gge
br

+ bl
g g
S ge/gn
br
+ bl
g g
S ge/gn
br

br

8
7

+ bl
g g
S ge/gn
br

Potentiometer Middle

S
+

9
1

10
2

4
5

11

3
13

br

bl
bl
+

br

Potentiometer Right

12

g g
ge/gn
bl
br
8
7

Reel speed sensor

Reel speed variator


Rape cutting table

H 126

br/sw

bl/rt
g
gn/ge
g
+
g
br/ge

+ bl

Reel speed variator

gn
g

bl

9
1

10
2

4
5

br

br

bl

bl
+
br

11

3
13

12

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Balance Description

5650H 5690HTS
Balance

4 6

Brief description

5 1

BALANCE

3 8

AUTO

The purpose of the Balance control is to keep the combine


harvester in a horizontal position within certain limits when
driving on a slope. The machine is levelled both laterally and
longitudinally.
Longitudinal levelling can be deactivated in special
situations.

AUTO
8
2

If hydraulic cutting angle adjustment is installed, the control


system can adjust the cutting angle of the cutting table
within a certain range so that the cutting table remains
parallel with the ground.

NEUTRAL

DEUTZ-FAHR

Pos. Control element/indicator

35395

The Balance control is not operational (4 LED's (9) are


lighting), until

the engine is running,

the charge control light is extinguished,

the main working switch is on and

the parking brake (handbrake) has been released.

Function

Key LIFT

- Machine is being lifted horizontally / automatic mode is deactivated


- Key (2) simultaneously pressed: Activation of dual-line control
- Key (7) simultaneously pressed: Delay cutting angle controller 0 s

Key LOWER

- Machine is being lowered horizontally / automatic mode is deactivated


- Key (1) simultaneously pressed: Activation of dual-line control
- Key (7) simultaneously pressed: Delay cutting angle controller 1 s

Key TILT RIGHT

- Machine is being tilted to the right / automatic mode is deactivated


- Key (4) simultaneously pressed: Activation of single-line controller**
- Key (7) simultaneously pressed: Delay cutting angle controller 3 s

Key TILT LEFT

- Machine is being tilted to the left / automatic mode is deactivated


- Key (3) simultaneously pressed: Activation of single-line controller*
- Key (7) simultaneously pressed: Delay cutting angle controller 2 s

Key AUTO

- Switching on automatic mode..


- Keep key (7) simultaneously pressed while switching on: Calibration mode
on
- Key (1) simultaneously pressed: Slow position controller is being activated
- Key (2) simultaneously pressed: Fast position controller is being activated

LED AUTO

Display automatic mode On/Off:


LED is constantly lighting:
Fast position controller is activated
LED is flashing:
Slow position controller is activated.

Key NEUTRAL

- Causes the axle cylinder to travel into half extended position (keep pressed until
middle LED (8) is lighting / automatic mode is deactivated
- Keep key (5) simultaneously pressed while switching on: Calibration mode on
- Key (1) simultaneously pressed: Delay cutting angle controller 0 s
- Key (2) simultaneously pressed: Delay cutting angle controller 1 s
- Key (4) simultaneously pressed: Delay cutting angle controller 2 s
- Key (3) simultaneously pressed: Delay cutting angle controller 3 s

LEDs (10 pcs)

Indication of axle cylinder position

LEDs AUTO key (4 pcs)

are flashing if calibration mode is selected.


When single-line control is active, all LEDs are momentarily lighting while pressing the key (5) AUTO.

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5650H 5690HTS
Balance

Operation
Driving on roads
Prior to on-road driving the machine shall be
completely lowered.
Activate Balance for this purpose (activate engine and
working master switch, release parking brake) and lower the
machine completely by means of pressing the key "LOWER
(2) (both lower LEDs (8) are lighting).
Manual operation:
The machine can be moved into any required position via the
four yellow buttons ("LIFT" (1), "LOWER" (2), "TILT RIGHT"
(3) and "TILT LEFT" (4)) on the control unit. The machine
then remains in this position.
Neutral position:
The "NEUTRAL" button (7) is used to set the machine to a
neutral middle position in which it remains parallel with the
ground. The button must be pressed until the machine has
reached its neutral middle position (the middle LEDs (8) light
up).
However, the machine does not adjust to the topological
features in this case.

4 6

5 1

BALANCE

AUTO

CAUTION!
If the gear is engaged or the service brake is
activated, the combine harvester is moving
forward or backward in case of being lifted or
lowered by means of the Balance control.

AUTO
8
2
DEUTZ-FAHR

Automatic mode:

7
NEUTRAL

35395

Activate:
TPress "AUTO key (5).
LED "AUTO (6) is lighting. The machine is being held in
horizontal position through automatic correction.
Deactivate:
Press "LIFT key (1) or
"LOWER key (2) or
"TILT RIGHT key (3) or
"TILT LEFT key (4) or
Press "NEUTRAL key (7).
LED "AUTO (6) extinguishes. The machine is in manual
mode.

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Single-line and dual-line control:

5650H 5690HTS
Balance

Activation of single-line control (lateral tilt control):

The control by the longitudinal axle (longitudinal


control) is being deactivated.

Press the keys "TILT RIGHT (3) and "TILT LEFT (4)
simultaneously.
- The single-line control is activated.

Activate automatic mode by pressing the "AUTO key (5).


- Serving as a function indication all LEDs are
momentarily lighting when the automatic mode is
activated.

Activation of dual-line control


(Logitudinal and lateral tilt control):
35396

The control by the longitudinal axle (longitudinal


control) is being reactivated.

Press the keys "LIFT (1) and "LOWER (2)


simultaneously.
- The dual-line control is activated.

Activate automatic mode by pressing the "AUTO key (5).


- Serving as a function indication the LEDs are not lit
when the automatic mode is activated.

Activation of position controller

35397

4 6

5 1

BALANCE

3 8

AUTO

Activation of the fast position controller:


Press the keys "AUTO (5) and "LOWER (2)
simultaneously.

8
DEUTZ-FAHR

307.1133.3.6 englisch (en) 10.2006

Activation of the slow position controller:


Press the keys "AUTO (5) and "LIFT (1)
simultaneously.
- Status indication: In automatic mode the LED "AUTO
(6) is flashing.

AUTO
2

The fast position controller is activated as factory


default and after each calibration.

- Status indication: In automatic mode the LED "AUTO


(6) is lighting continuously.

NEUTRAL

35395

H 129

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5650H 5690HTS
Balance
Calibration of position controller

AUTO

The calibration of the position controller shall be


carried out prior to adjusting the EMR-D.

Start the engine (charge warning indicator must be off).

Switch on the main work switch.

Park the combine harvester so that it is level in all


directions. Set Balance to "NEUTRAL" (press button
down until machine is in a horizontal position).

Put on the parking brake (handbrake).

Press and hold the buttons "AUTO" and "NEUTRAL".

Release the parking brake (handbrake).

NEUTRAL

After 10 seconds the Balance is switching over to


calibration mode.
The four middle LEDs (9) flash.
One LED on the right and left light up continuously.
The machine begins to move.
The Balance is in calibration mode.

Press "LIFT" continuously until the machine reaches its


upper dead centre.

Press "LOWER" continuously until the machine reaches


its bottom dead centre.

Press "LIFT", "LOWER", "TILT RIGHT" and "TILT LEFT"


to adjust the machine until it is absolutely horizontal in all
directions. Use a spirit level to check the adjustment if
necessary.

Bild 22
BALANCE

AUTO

AUTO
9
DEUTZ-FAHR

H 130

NEUTRAL

Bild 23

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Training
Briefly press "LIFT" and "LOWER" simultaneously.

5650H 5690HTS
Balance

4 6

The data is being saved.

5 1

BALANCE

3 8

AUTO

The calibration process is finished:


- The middle LEDs (9) light up. One LED (8) lights up in
the middle of the light bands on the right and left.
- Lateral and longitudinal levelling is active.
- Automatic mode is inactive.
- The fast position controller is activated, delay cutting
angle controller 0 s
- The dual-line control is activated.

AUTO
8

If the machine was not absolutely horizontal


during calibration , it may move a few
centimetres when switching over between
AUTOMATIC and NEUTRAL.
The calibration should be repeated if the
deviation is too large.

NEUTRAL

DEUTZ-FAHR

35395

Operation of the automatic cutting angle control

11

Machine requirements:

10

All electrical leads connected

All position encoders correctly installed and set

35398

12

By factory default and after each calibration the


delay for the cutting angle controller is set to 0 s.

The automatic cutting angle control is active when the


Balance control unit is ready for operation and when the
cutting angle control has been switched on by
simultaneously pressing the keys "CUTTING ANGLE
FORWARD (11) and "CUTTING ANGLE BACKWARD (10).
Indication is done through control lamp (12).
When the machine is shut down or when the Balance
control unit is switched off, the cutting angle control will also
be deactivated and must be reactivated if required.

35430

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Service
Training

5650H 5690HTS
Balance

Manual operation:

1
35398

Can be used immediately after starting the machine and


switching on the main working switch.
Otherwise deactivate automatic cutting angle control by
simultaneously pressing "CUTTING ANGLE FORWARD" (2)
and "CUTTING ANGLE BACK" (3). Indicator (12) is off.
The cutting angle can be set as required via the buttons
"CUTTING ANGLE FORWARD" (2) and "CUTTING ANGLE
BACK" (3) on the multi-purpose lever.
Automatic operation:

12

35430

Release parking brake (handbrake).

Engage threshing section.

Set the EMR-D operating mode (pressure or position


control).

Press (1) to set automatic cutting table control to


Automatic.

Set required setpoint on EMR-D control.

Activate automatic cutting angle control by simultaneously


pressing "CUTTING ANGLE FORWARD" (2) and
"CUTTING ANGLE BACK" (3). Indicator (12) lights up.

Set the machine to a neutral position on level ground.

Adjust the cutting table so that the earlifter skids are


parallel to the ground.

Completely lower the machine and then completely raise


it again. With proper calibration and recommended tyres
the sliding surfaces of the crop lifters are aligned nearly
parallel to the ground during the entire adjusting process.
Correct the cutting table position or bearing pressure
again if necessary.

Indicator (12) flashes when the cutting table is disengaged


and automatic cutting table control (EMR-D) is switched off.
Cutting angle control remains active. The cutting angle is
also adjusted if the machine is adjusted via the Balance
control (e.g. for manoeuvering on a slope).
If the cutting angle is changed (e.g. when disengaging the
cutting table), the new value upon activation of the automatic
system is adopted as the new default. The adjustment must
be repeated.

Automatic cutting angle control must be


deactivated in order to lower the cutting
mechanism onto the transport cart!

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Service
Training

5650H 5690HTS
Balance

10

Calibration / adjust delay for automatic


cutting angle control

11

Calibration of cutting angle control limit positions


Press the keys "CUTTING ANGLE FORWARD (10) and
"CUTTING ANGLE BACK (11) simultaneously and keep
pressed for at least 10 seconds, until the control lamp (12)
flashes fast.
35398

4 6

5 1

BALANCE

3 8

AUTO

Adjusting the response delay of the cutting angle


controller

AUTO
8
2

The cutting angle adjustment drives to both end positions and


stores the values. During operation, the cylinders will be
electrically deactivated just before they reach the mechanical
end position.

It is recommended to work with a response delay of


2 seconds.

NEUTRAL

DEUTZ-FAHR

35395

Delay in
seconds
0
1
2
3

Press the keys


simultaneously to select:
NEUTRAL and LIFT
NEUTRAL and LOWER
NEUTRAL and TILT LEFT
NEUTRAL and TILT RIGHT

(7 and 1)
(7 and 2)
(7 and 4)
(7 and 3)

The selected setting will be memorized until the next change


is carried out.

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Service
Training

2
3

8
10

11
H 134

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H
Service
Training

5650H 5690HTS
Balance with automatic cutting angle control
1 Control cabinet
2 Multifunction handle
3 Balance control unit
4 Status light for automatic cutting angle control
5 Pilot control unit MO for Balance hydraulic system
6 Control unit for cutting angle control
7 Angular rotation transmitter Balance axle
8 Control valve block left
M1 Connector without colour coding sw (black)
M3 -

Connector rt (red)

M2 -

Connector bl (blue)

9 Control valve block right


M4 -

Connector without colour coding sw (black)

M6 -

Connector rt (red)

M5 -

Connector bl (blue)

10 Balance Control Unit


Observe mounting position:
- Adhesive label with arrow for driving direction located at the inner housing opposite to the relay.
- Observe the marking of CON1 and of CON2 and of the slot.
- The connectors CON1 and CON2 must not be interchanged
11 Angular rotation transmitter for cutting angle (mounted on the right side at the feed passage).

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Service
Training

2.2

2.1
30

5
3.1

30
91
,3

3
1

26

4.1

5
4.1

H 136

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Service
Training

5650H 5690HTS
Balance
Rotation angle transmitter - Balance axle
The rotation angle tansmitters are mounted on the left and right side at the cross member and are connected each with
the final drive by means of a steering rod. When mounting the transmitter the punch mark (4,1) on the shaft must point at
the plug-in connection.
The ball head (3.1) for the steering rod must be screwed in at the final drive in the depicted position. Final drive is in
neutral position.
1

Balance axle

Final drive bearing tube

2.1 lifted position


2.2 lowered position
3

Steering rod

3.1 Ball head for steering rod at final drive


4

Rotation angle transmitter

4.1 Centre punch on the transmitter shaft


5

Clamping lever

Testing / Setting
Direction of Travel
Voltage supply

Left
8.5 V 5 %

Right
8.5 V 5 %

Vehicle raised to top end-stop


Signal voltage

6.3 V

2.1 V

Vehicle lowered to bottom end-stop


Signal voltage

2.1 V

6.3 V

Use test plug (1603 1484) to test the sensors.


Basic setting

Fully lower the Balance system (the tilt adjusting cylinders must be fully retracted; if necessary change to the
calibration mode).

Set the steering rod (3) to a length of 261 mm

Release the clamping lever (5)

Set the rotation angle transmitter to the specified signal voltage.

Angle transmitter for cutting angle


When mounting the transmitter the punch mark (6) on the shaft must point at the plug-in connection.
Precision adjustment of the transmitter by means of twisting turning the shaft inside of clamping lever (5):
- Signal voltage approx. 2,1 V with retracted cutting angle adapter

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Service
Training

5650H 5690HTS
Balance
Circuit diagram power supply Balance II and cutting angle control

A19

Control unit Balance II

K59

Relay cutting angle upwards

K67

ground at D+

K75, K76 Relay power supply Balance II


K80

Relay cutting angle downwards

S54

Push-button switch cutting angle up/down

S55

Hand brake switch

Y11

Solenoid valve cutting angle upwards

Y12

Solenoid valve cutting angle downwards

Relays K59, K80 must not be plugged when equipped with Balance.

H 138

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hrt

307.1133.3.6 englisch (en) 10.2006

hrt

hbl

SW2

87a

hrt
30

4
85

87

86

87a

8
85

dgr

2
87

87a
87a

4
4

X512.17

3
Hand brake switch

5
K76

S55

87

sw/gr

1
1
K75

F15
15

S54

2
86
86

X9

4
3

Cutting angle up

87a
30
Light at D+

Y11

hbl
85

X30

br

8
5
K67

RT3

con2.35
X92.35
GND

87

ge/rt

X29

Threshing mechanism on

rs/ws

15b

X30

K59

Working master switch on

con1.9
X91.9
Solenoid valve cutting
angle up

X30

ws/bl

15a

tr

hrt
30

con2.18
X92.18
+UB

bl/sw

bl/rt

X29

ws/sw

86

X30

K80
85

con2.5
X92.5
Push-button cutting
angle up

vi/ws

bg/ws

dgr

X9

con2.23
X92.23
Push-button cutting
angle down
con1.8
Solenoid valve cutting X91.8
angle down

A19

Cutting angle down

Y12

Service
Training

30

15

D+

F40
15

3
3
1

30
30
86

87
85

D2
2

D3

ws/bl

ws/sw

bl/rt
ge/rt
.19 .18

X192

Multifunction lever

H 139

H
Service
Training

5650H 5690HTS
Connector pin assignment Balance II with automatic cutting angle control
signal

colour

signification

Connector CON1

signification

colour

signal

17

control unit 12V

bg

12V

16

control unit R3

gr

MUX

15

control unit R2

vi

MUX

14

control unit. R1

rs

MUX

Pin No.
18
35

MUX

rt

control unit SP1

34

MUX

bl-ws

control unit SP2

33

MUX

gn-ge

control unit SP3

32

MUX

ws

control unit SP4

31

MUX

sw-ws

control unit. SP5

30

13
12
MUX

gr-ws

0V

sw

control unit SP6

29

control unit GND

28

11
10
0V

br-ws

12V/0V

27
GND MVs SW

MV cutting angle upwards rs-ws

12V/0V

MV cutting angle downwards vi-ws

12V/0V

Status cutting angle auto or-ws

12V/0V

6*

Freq. longitudinal slope gr-sw

26

2k

25
24
23

(Pin 11 EMR-D)
5

Programming
connector

22

rt

sw

RS232-TXD

21

bl

RS232-RXD

20

br

RS232-GND

Boot

---

3
2
19
1

H 140

down = 2000 Hz, up = 392,5 Hz

1
2
3
4
5
6
7
8
9

Vehicle ground cable


Rotation angle transmitter for cutting angle
Rotation angle transmitter balance axle left
Rotation angle transmitter balance axle right
Solenoid valves M4 - M6 right
Solenoid valves M1 - M3 left
Connector X28 - X31 at cabinet bottom
Programming connector
Resistor 2 kOhm
307.1133.3.6 englisch (en) 10.2006

H05VV-F 2x1-3200
br
bl

307.1133.3.6 englisch (en) 10.2006

H 141
56-200

1 gn-ge

21 20 19

9 24 22

4 3 2 1

H05VV-F 3G1-3200
br
gn-ge
bl

H05VV-F 3G1-1250
br
gn-ge
bl

3 2 1

H05VV-F 3G1-1250
br
gn-ge
bl

28

M6
rt

FLYY 6x1-1550
br
gn

29

M5
bl

ws
ge

30

M4
sw

sw
rt

Masse

CON 2

31

2 1

M3
rt

FLYY 6x1-1550
br
gn

32

M2
bl

ws
ge

33

M1
sw

sw
rt

26

3 2 1

lflex-100/03 25x0,75-4000
(Lapp 0010034 )
rt-ws
gr-ws

18 35 5 23

tr
bl-sw
bg-ws
ro

6 34

gr
tr-ws

sw-ws
gr-ws
bg
sw
bl-ws
gn-ge
ws
6 27

7 14 15 9 8 16

X 29

8 7 6 5 4 3 2 1

br-ws
or-ws
rt-ws
vi-ws
bl
or

8
Service
Training

H
Service
Training

5650H 5690HTS
Connector pin assignment Balance II with automatic cutting angle control
signal

colour

0V

br

signification

Connector CON2

GND

bl

M0

34

0V/12V

sw

M1

33

0V/12V

ws

M2

32

0V/12V

br

M3

31

0V/12V

sw

M4

30

0V/12V

ws

M5.

29

br

M6

colour

signal

18

+UB

tr

12V

17

M0.GND

or

0V

16

M1.GND

rt

0V

15

M2.GND

ge

0V

14

M3.GND

gn

0V

13

M4.GND

rt

0V

12

M5.GND

ge

0V

11

M6.GND

gn

0V

angle transmitter cutting angle br

8V

angle transmitter feed passage tr-ws

2,4V...7,1

push button switch SW up

0V/12V

35

0V/12V

0V/12V

signification

Pin No.

28
10
27
9

0V/5V

rt-ws EMR-D-LED green

26
8
25
7

2V...6V

gn-ge angle transmitter SW signal

24

0V12V

bg-ws push button switch SW down 23

0V

bl angle transmitter SW GND

22

br angle transmitter left VCC

21

bl-sw

1
2
3
4
5
6
7
8
9

2V...6V

gn-ge angle transmitter left signal

20

0V

bl angle transmitter left GND

19

angle transmitter right VCC br

8V

angle transmitter right signal gn-ge

2V...6V

angle transmitter right GND bl

0V

Vehicle ground cable


Rotation angle transmitter for cutting angle
Rotation angle transmitter balance axle left
Rotation angle transmitter balance axle right
Solenoid valves M4 - M6 right
Solenoid valves M1 - M3 left
Connector X28 - X31 at cabinet bottom
Programming connector
Resistor 2 kOhm

H 142

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H05VV-F 2x1-3200
br
bl

307.1133.3.6 englisch (en) 10.2006

H 143
56-200

1 gn-ge

21 20 19

9 24 22

4 3 2 1

H05VV-F 3G1-3200
br
gn-ge
bl

H05VV-F 3G1-1250
br
gn-ge
bl

3 2 1

H05VV-F 3G1-1250
br
gn-ge
bl

28

M6
rt

FLYY 6x1-1550
br
gn

29

M5
bl

ws
ge

30

M4
sw

sw
rt

Masse

31

CON 2

2 1

M3
rt

FLYY 6x1-1550
br
gn

32

M2
bl

ws
ge

33

M1
sw

sw
rt

26

3 2 1

lflex-100/03 25x0,75-4000
(Lapp 0010034 )
rt-ws
gr-ws

18 35 5 23

tr
bl-sw
bg-ws
ro

6 34

gr
tr-ws

sw-ws
gr-ws
bg
sw
bl-ws
gn-ge
ws
6 27

7 14 15 9 8 16

X 29

8 7 6 5 4 3 2 1

br-ws
or-ws
rt-ws
vi-ws
bl
or

8
Service
Training

H
Service
Training

5650H 5690HTS
Balance
Troubleshooting
Problem

Cause / Remedy

No display on control panel

Engine not running


Handbrake on
Threshing main switch not ON
Fuse No. 40 (15 A) blown
Microrelay K67, K75 or K76 defective

Balance "hunting" or in constant motion

Rotation angle transmitter incorrectly set or steering rod bent


Dirt in valve seat, causing lowering and therefore
constant readjustment

Uncontrolled movements

Repeat calibration procedure


Check setting of rotation angle transmitter

Balance rises on one side, lowers on one side

Check the setting of the rotation angle transmitter and


check that the steering rods are correctly fitted

Control panel display indicates end-stop although


the tilt adjusting cylinders are not fully extended/retracted

The rotation angle transmitter are out of adjustment.


heck setting.

Balance no longer extends/retracts fully

Incorrect calibration values have been stored


(calibration error).
Repeat calibration procedure

Various push-buttons and LEDs on the control panel


are not functioning

Faulty control panel.


Faulty cable connection between the microcontroller
and the control panel

Balance does not remain longitudinally and laterally


horizontal after calibration

Check that the control unit (microcontroller) is mounted


parallel to the drive axle in the longitudinal and
transverse direction.
Compensate with spacing washers.

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Service
Training

Notes

307.1133.3.6 englisch (en) 10.2006

H 145

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Service
Training

5650H 5690HTS
Throughput Monitor (Grain Loss Monitor) / On-board Computer
LH-865 / 1000
1
1.1
2
3
4
4.1
4.2
5
6
7
8
9
10

Display unit grain loss monitor


Wiring harness (5-core) to control cabinet
LH-1000 on-board computer
Light sensor (mounted on cab roof)
Straw walker sensors (plate sensor)
Wiring harness (3-core) from Straw walker sensor, left
Wiring harness (3-core) from Straw walker sensor, right
Pulse generator, feed passage
Sieve pan sensor (pipe sensor)
Magnet (2x) at feed passage
Junction box with circuit board
Wheel sensor
Control cabinet

Function check throughput monitor


Switch on the ignition.
Tap the left and right straw walker sensors in turn. The needle for "straw walker grain loss" must move. Tap the tubular
sensor mounted on the sieve box. The needle for "sieve box grain loss" must move.

Connector pin assignment of distributing


circuit board measured values
Terminal strip I
No. Cable

Function

colour

Connector pin assignment for display unit


Pin No

Cable colour Function

Measuring

white

Supply for sensors +

value

brown

Power supply +

green

Power supply -

yellow

Signal wheel sensor

grey

Brightness sensor

black 1

Power supply -

0V

black 2

Power supply +

11V

black 4

Signal wheel sensor

11V, 1.5V

green/yellow Signal sieve pan sensor

black 3

Signal straw walker sensor 8.3V .... 6V

pink

Brightness sensor

blue

wheel sensor

11V

blue

Signal straw walker sensor

brown

wheel sensor

0V

red

Signal sieve pan sensor

green/yellow Sieve pan sensor +

11V

black 2

Signal sieve pan sensor

8.3V .... 6V

10

black 1

Sieve pan sensor -

0V

8.3V .... 6V

Terminal strip II
No Cable

Function

colour

Measuring
value

1
2

black 1

Straw walker sensor 1 -

0V

black 2

Signal straw walker sensor 1 8.3V .... 6V

green/yellow Straw walker sensor 1 +

11V

black 1

Straw walker sensor 2 -

0V

black 2

Signal straw walker sensor 2 8.3V .... 6V

green/yellow Straw walker sensor 2 +

11V

8
9
10

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Service
Training

H0508-2

H0518-1

307.1133.3.6 englisch (en) 10.2006

H0520-2

H 147

H
Service
Training

4
2

33734

7
5

56-202

31536

H 148

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Service
Training

5650H 5690HTS
Adjustments at grain loss monitor
The travel of the pointer for the grain loss indication through sieve pan (3) and straw walker (4) is adjusted with rotary
knobs (1, 2). Depending on the cutting mechanism width, the rotary knobs are to be adjusted such that the indicator
needle points to the transitional green/red area of the display field indicating that the grain loss is still acceptable.

Depending on the crop, the grain loss sensor sensitivity can be adjusted in three steps:

low sensitivity for big grains like beans or maize


medium sensitivity for cereal
high sensitivity for small grains like rape, mustard, linseed

Corresponding dot markings (7) at the sensor casing ease proper positioning of the switch.
Sieve pan sensor: Adjustment through toggle switch (5)
Straw walker sensors: Adjustment through rotary switch (6)

307.1133.3.6 englisch (en) 10.2006

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H
Service
Training

4
7

30672

8
30768

10

H0519

9
10

10
56-202

H 150

31534

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
On-board Computer LH 1000
Key functions:
1

Working time (hours and minutes)

Hectaremeter (partial count)

Hectaremeter (total count)

Speed (km/h)

Working with input in cm

Wheel circumference input in cm

Resetting of counters (consumption of hectares and time), input of 0

For proper functioning of the work computer the wheel sensor (9) at the rear wheel and the pulse transmitter (8) at the
feed passage are required. The pulse transmitter must be adjusted such that both magnets (10) overlap the face side of
the transmitter with the cutting mechanism lifted.
The clearance between magnet and sensor should be adjusted to 5 8 mm.

Cable pin assignment


Item 6: blue, power supply 12V
Item 5: brown, ground
Item 4: Sensor input wheel sensor
Item 2: Sensor input pulse transmitter feed passage

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Service
Training

5650H 5690HTS
On-board Computer LH 1000
The work computer is equipped with 3 function sets
Function set 1:

Time counting, hectare counting, speed


(Working width and wheel circumference must be entered beforehand)

1. Time function
Starting the timer
Press this key to start the timer (the colon starts flashing)

The on-board computer will now start counting the elapsed time (hours and minutes). If you select another
function, the timer will continue running in the background. This key can be pressed at any time to stop and
restart the timer.

2. Hectaremeter
Hectares per field "partial area"

ha

Press this key to display the area worked in hectares. The area is indicated with two decimal
places in the range from 0 99.99 ha and with 1 decimal place in the range from 100 999.9 ha.

Hectares per field "total area"

ha

Press this key to display the total area worked in hectares. The area is indicated with two decimal
places in the range from 0 99.99 ha, with 1 decimal place in the range from 100 999.9 ha and
without decimals in the range from 1000 9999 ha.
This function is used to totalize the complete area worked.

3. Speed indicator
Press this key to display the forward speed in km/h.

kmh

If the hectaremeter is stopped while the speed indicator is displayed, the letter "r" is displayed in
front of the speed.

Function Set 2: Odometer, wheel revolutions


1. Odometer
Basic setting

ha

Press this key

Then press this key followed by

9
ha
H 152

Enter

When you press this key again the distance covered will be displayed in metres.
307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
On-board Computer LH 1000
2. Wheel revolutions
This function is mainly used to count the number of wheel revolutions when determining and entering the
wheel diameter.
Basic setting

kmh

Press this key

Then press this key followed by:

9
kmh

Enter

When you press this key again the distance covered will be displayed in metres.

Function Set 3: Sensortest


First enter a working width of 8888 by pressing the following keys in the order shown below:

Then select the timer function:

Press this key to select the timer function.

The display will now read


"h", if the wheel sensor is activated
"r", if the pulse transmitter of the feed passage is activated
Note: the letter "r" is also displayed when the hectaremeter is stopped.

Error message
The message "FEJL" appears in the display when the supply voltage is less than 12 Volt.

307.1133.3.6 englisch (en) 10.2006

H 153

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Training

Notes

H 154

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Appendix A

Wiring Diagrams

5650H 5690HTS

307.1133.3.6 englisch (en) 10.2006

HA 1

H
Service
Training

5650H 5690HTS
Appendix A
Wiring layouts

HA 2

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Appendix A
Table of contents

running
No.
1.
2.
3.
4.
5.
6.
7.
8.

designation
wiring diagram
wiring diagram
wiring diagram
wiring diagram
wiring diagram
cable harness engine
cable harness engine
cable harness

307.1133.3.6 englisch (en) 10.2006

topic
control console
control console
Steering column
cabin
cabin
Engine 5670
Engine 5680/90
Control valves work hydraulics

drawing No.
1605 2333 page
1605 2333 page
1605 2333 page
1605 2333 page
1605 2333 page

11
12
41
42

HA 3

H
Service
Training

5650H 5690HTS
Wiring layouts

1. Wiring diagram control console

H39
H40
H41
H42
H43
H44
S38
S40
S41
S42
S43
S44
S49
S66
S67

HA 4

1605 2333 page 1 1

All-wheel on off
All-wheel differential lock
Deflectors left centre
Deflectors left outside
Deflectors right centre
Deflectors right outside
Partial width change-over with TERIS/TCS
Working master switch
All-wheel on-off
Colza cutting mechanism on-off
Reverse cutting mechanism
Grain tank interior light
Deflector adjustment
Switch straw guide plate
Grain tank extension lift lower

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

2333_1-1

307.1133.3.6 englisch (en) 10.2006

HA 5

H
Service
Training

5650H 5690HTS
Wiring layouts

2. Wiring diagram control console

1605 2333 page 1 2

H34 Error lamp EEC


H35 Indicator light chopper operation
H36 Indicator light cutting angle automatic
H61 Indicatorlight automatic wind system
S2

Ignition start switch

S5

Throttle control half-/full throttle

S33 Switch hazard warning signal flasher


S68 Switch mirror adjustment

HA 6

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

2333_1-2

307.1133.3.6 englisch (en) 10.2006

HA 7

H
Service
Training

2333_5

HA 8

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
Wiring layouts

3. Wiring diagram steering column

307.1133.3.6 englisch (en) 10.2006

1605 2333

page 5

HA 9

H
Service
Training

5650H 5690HTS
Wiring layouts

4. Wiring diagram cabin

S6

1605 2333 page 4 1

Working lights front rear

S34 Light switch


S35 Change-over switch dipped beam main beam top down
S36 Wind screen wiper
S37 Revolving light

HA 10

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

2333_4-1

307.1133.3.6 englisch (en) 10.2006

HA 11

H
Service
Training

5650H 5690HTS
Wiring layouts

5. Wiring diagram cabin

HA 12

1605 2333 page 4 2

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

HA-015

X513.3
X513.4
X513.5
X513.6
X513.7
X513.8

X513.16
X513.15
X513.14
X513.1
X513.2

0,34 sw
0,34 ws
0,34 vi
0,34 bl
0,34 gr-ro
0,34 ro

-5000
-5000
-5000
-5000
-5000
-5000

0,34 gr
0,34 ge
0,34 gn
0,34 br
0,34 rt

-5000
-5000
-5000
-5000
-5000

3
4
5
6
7
8

16
15
14
1
2

HA-014

26-13
25-12
24-11
23-10

..

R3
R2
R1
3

22-9
21-8
20-7
19-6
18-5
17-4
16-3
15-2
14-1

SP1
SP2
SP3
SP4
SP5
SP6
12V
GND

12 11 10
15 14 13

HA-013

18 17 16
21 20 19

2333_4-2

307.1133.3.6 englisch (en) 10.2006

HA 13

H
Service
Training

X2

X1

X3

X4

X21

X22

GE

WS

DGN

SW

HGR

DBL

20

19
21

42

X1

16

43

HR
T

X1

SW

X1

17

40

WS

GE

X1

41

18

3
15
14
4
13

5
6

12

7
11
8
10

HA-001

HA 14

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5670
6. Cable harness engine

Speed monitoring elevator head

Connector at engine frame, X140 X143

Minimum pressure switch air filter

Junction box grain loss sensors

Ground collective terminal at engine frame

br

Reverse gear buzzer

vi/ge

Sensor grain tank tube

ws/bl

Transducer fuel tank level

vi/ws

Speed sensor straw walker

ws/ge

10

Temperature sensor hydraulic oil

vi

11

Starter terminal 50

sw

12

Temperature sensor cylinder head

bl/gn

13

Temperature switch cylinder head

bl/sw

14

Oil pressure switch

bl/ge

15

Temperature sensor engine oil

sw/vi

16

Switch at tensioning pulley cooling ventilator belt

bl/rt

17

Generator terminal B+, D+, W

rt, bl, or

18

Servo motor threshing drum variator

sw/ge, sw/gn

19

Screw type terminal B+ at control cabinet

rt

20

Connector X1 X4, X21, X22 at control cabinet

21

Terminating resistor 120 Ohm (pin 5-6) for CAN bus line

307.1133.3.6 englisch (en) 10.2006

br/ws, br

gn, br

HA 15

H
Service
Training

5650H 5690HTS
7. Cable harness engine

Speed monitoring elevator head

2.

Connector at engine frame, X140 X143

3.

Minimum pressure switch air filter

4.

Junction box grain loss sensors

5.

Ground collective terminal at engine frame

br

6.

Temperature sensor/switch engine oil

sw/vi, vi/gn

7.

Reverse gear buzzer

vi/ge

8.

Sensor grain tank tube

ws/bl

9.

Transducer fuel tank level

vi/ws

10.

Speed sensor straw walker shaft

ws/ge

11.

Temperature sensor hydraulic oil

vi

12.

Generator terminal B+, D+, W

rt, bl, or

13.

Oil pressure switch

bl/ge

14.

Temperature sensor/switch coolant

bl/gn, bl/sw

15.

Starter terminal 50

sw

16.

Servo motor threshing drum variator

sw/ge, sw/gn

17.

Screw type terminal B+ at control cabinet

rt

18.

Connector X1 X4, X21, X22 at control cabinet

19.

Terminating resistor 120 Ohm (pin 5-6) for CAN bus line

HA 16

br/ws, br

gn, br

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

X2

X1

X3

X4

X21

X22

GE

WS

DGN

SW

HGR

DBL

18

17
19
1

42

43

HR
X1 T

X1

SW

X1

WS

16

40

GE

X1
41

15

14
4
5
6
13

7
12

8
11
9

10
HA-002

307.1133.3.6 englisch (en) 10.2006

HA 17

H
Service
Training

X9

X25

X10

DGR

HGN

ELB

10
RT

1
BR
2
GE

9
BL
8
SW

3
GR
7
GN

6
OR

4
WS

5
VI

14
BL

13
BR

HA-003

11
RT

d
12
SW

SW 12

11 RT

RT

10

BR

BL

GE

SW 8

GR

GN

WS

OR

VI

d
11 RT

BR

13

14 BL
12 SW

HA-012

HA-004

HA 18

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

5650H 5690HTS
8. Cable harness for control valves work hydraulics

Connector X9, X10, X25 at control cabinet

The 2-pin connectors for the control valve solenoids are marked with cable binders in different colours.

Control block small consumers

Control valve for cutting mechanism bank: In case of Balance combine harvesters this valve is located separately
next to the control block.

Control valve cutting mechanism lift lower

307.1133.3.6 englisch (en) 10.2006

HA 19

H
Service
Training

Notes

HA 20

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000

Appendix B

Commander Control 2000


Operating Instructions

5650H - 5690HTS

307.1133.3.6 englisch (en) 10.2006

HB 1

Commander Control 2000

11
12

4
13

Cal

Diag

Setup

10

The key functions are only active when the main


work switch is on.

35402

HB 2

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


No

Controls

Function/Operation

Screen: Select the main screen here.

Status indicators for


Grain tank clutch engaged
Threshing section clutch engaged
Cutting table clutch engaged

Blank field = Disengaged


Flashing symbol =
Clutch currently engaging
Symbol = Engaged

35402

35402

Swivel grain tank discharge pipe in/out:


Press key I:
The grain tank pipe swings out. Press one of the keys again to stop
the pipe movement.
Press key 0: The grain tank pipe swings in. Press one of the keys again to stop
the pipe movement.
Pay attention to the indicator "grain tank pipe released" on the central
instrument cluster or on the TERIS/TCS screen.
The grain tank clutch for emptying the grain tank is engaged with the pedal
switch. If the grain tank pipe is fully retracted while the grain tank clutch is
engaged, the grain tank clutch will be automatically disengaged.

35402

Engaging/disengaging the threshing section:


Key I: Engage threshing mechanism.
Key 0: Disengage threshing mechanism (if the cutting table is activated, it too will
be disengaged).
To engage the threshing section, the main work switch must be switched
on, and the engine must be running at slow idling speed.
If the straw chopper is activated (straw guide plate in the chopping
position), when the threshing key is pressed, the straw chopper will
automatically be engaged first, followed by the threshing section. On
disengaging, the threshing section is disengaged first, followed by the
straw chopper.

35402

Engaging/disengaging the cutting table


Key I: Engage the cutting table.
Key 0: Disengage the cutting table.

307.1133.3.6 englisch (en) 10.2006

To engage the clutch, the threshing section must be activated.

HB 3

Commander Control 2000

11
12

4
13

Cal

Diag

Setup

10

The key functions are only active when the main


work switch is on.

35402

HB 4

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


No

Controls

Function/Operation
Press 1 x Concave clearances: Open the "Set Clearances" menu to set the
concave clearances for the threshing drum and turbo separator (the
main work switch must be switched on).

35402

Press 2x Sieve adjustment: Open the "Set Clearances" menu to adjust the
sieves (the main work switch must be switched on).
Concave rapid opening: Hold down the key for 3 seconds. See section on
"Concave rapid opening".

Return to main screen/Load settings.

35402

Open the "Speed Monitor" menu to set the speed warning limits for the tailings
elevator, straw walker shaft and grain tank auger.
With TERIS/TCS, this function is inactive. Activate the function with the
terminal.

Return to main screen/Load settings.

Setting the winnowing fan speed:


(To set the fan speed, the threshing section must be in operation).
Setup
Setup

Setup

35402

key:
key:

Increase fan speed (indicator at (13))


Decrease fan speed (indicator at (13))

Setup Menu:
Hold down the Setup + and
keys simultaneously for 3 seconds. The "Setup
Menu" for setting the language appears. See the section on "Language Selection".
Only use the Setup menu to set the language version. All other
functions are intended for customer service only.

35065

35066

307.1133.3.6 englisch (en) 10.2006

35402

HB 5

Commander Control 2000

11
12

4
13

Cal

Diag

Setup

10

The key functions are only active when the main


work switch is on.

35402

HB 6

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


No

Controls

Function/Operation

Threshing drum speed adjustment:


(to adjust the drum, the threshing section must be activated).
Diag
Diag

Diag

key:
key:

Increase threshing drum speed (indicated by 11))


Decrease threshing drum speed (indicated by (11))

The diagnosis menu is only intended for customer service.

35402

10

If the diagnosis menu is selected inadvertently, it can be closed by


pressing keys Cal + and
simultaneously.

Reel speed adjustment:


(to adjust the pick-up reel speed, the cutting table must be in operation)
Manual speed adjustment:
Cal + key:
Increase reel speed
Cal
key:
Decrease reel speed

Cal

Activate/deactivate automatic reel speed adjustment:


Press Cal + and
keys simultaneously.
(see section on "Setting automatic reel speed adjustment".)

35402

When automatic reel speed adjustment is activated, the ratio of the reel
speed to the travel speed can be adjusted by pressing the Cal + and
keys simultaneously.

Calibration menu:
Hold down keys Cal
menu" will appear.

11

and

simultaneously for 3 seconds. The "Calibration

Threshing drum speed display (rpm)


35402

12

Travel speed display (km/h)


35402

13

Winnowing fan speed display (rpm)


35402

307.1133.3.6 englisch (en) 10.2006

HB 7

Commander Control 2000


System start and shutdown
CAUTION
When switching on the ignition, the clutch
servomotors may move, because the
clutches are automatically driven to the
disengaged position.

The Commander Control 2000 is switched on with the


ignition. Two audible signals are sounded, and the start
screen is displayed.
On starting the engine, the system is restarted.

35402

35405

The bottom two lines of the start screen show


the installed software version with the release
date.

The main screen is then displayed, and Command


Control 2000 is ready for operation.

If the battery charge lamp is lit or if the message


"Low battery" is displayed, the Commander
Control 2000 is not ready for operation.
If necessary, briefly increase the engine speed.

The Commander Control 2000 is switched off by


switching off the ignition.

35429

HB 8

35402

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


Selecting the language /
Setting the view angle
To set the desired language and view angle, open the
Setup menu.
Hold down the Setup + and
simultaneously for 3 seconds.

keys (1)

The Setup menu must only be used to set the


language version and the view angle. All
other functions are intended for customer
service only.
Cal

Diag

Setup

Language selection
When the Setup menu is displayed, the highlighted cursor
bar is on "Language" (if not, select the "Language" line
with the Diag (2) keys).

Select the desired language with the Setup (1) keys.

35429

35402

Save the selection by pressing the Cal + and


keys (3) simultaneously.
The selected language is activated immediately.
The main screen is displayed again.

Setting the view angle


Language:

Select the view angle with the Diag (2) keys.

English

Front tyres:
Radial 800/65R32

Change the view angle with the Setup (1) keys.

Turbo separator:

Save the selection by pressing the Cal + and


keys (3) simultaneously.
The change is activated immediately.

yes
View angle:

Cal

Diag

Setup

35402

307.1133.3.6 englisch (en) 10.2006

In the Setup menu, if more than 10 seconds


elapse without any user input, the system
automatically returns to the main screen. In this
case, the settings entered while the Setup menu
was open will not be saved.

35406

HB 9

Commander Control 2000


Setting the speed warning limits

With TERIS/TCS, this function is inactive. Activate


it on the terminal.

The speeds of the returns elevator, straw walker shaft


and grain tank delivery auger are continuously monitored.
A minimum warning limit can be set for each speed. If the
speed falls to the set warning limit, the audible and visual
alarm is activated.
The warning limit can be set to a speed reduction of
between 5 % and 50 % (relative to the nominal speed).
To set the speed warning limits, open the "Speed
monitor" menu in the main screen.
Cal

Diag

Setup

Press key (1).

35402

The Speed Monitor menu appears.

Setting the warning limits:


Grain tank delivery auger keys (3)
Straw walker shaft
keys (4)
Returns elevator
keys (5)

Speed Monitor

Deactivating the alarm:


Set the warning limit to the bottom value, i.e. 50 %
reduction.
Hold down the
key for 5 seconds.
The selected warning will be deactivated, and the symbol
appears next to the display bar (as shown in the
illustration opposite for the delivery auger).
Activating the alarm:
Press the + key.
Cal

Diag

Select each warning limit as required.

Setup

Saving the values:


Press key (1). The main screen is displayed.

In the absence of any user input for a period of


more than 10 seconds, the system automatically
returns to the main screen. In this case, any
settings previously entered will not be saved.
To quit the menu without saving the values,
press key (2).

35402

HB 10

35407

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


Setting the automatic reel speed
control
(optional)
The automatic reel speed control enables the reel speed
to be adapted automatically to the travel speed (ground
drive speed).
Activating/deactivating:
Press the Cal + and

(1) keys simultaneously.

After switching on automatic reel speed control, the


symbol
appears next to the reel speed symbol to
indicate automatic reel speed control mode (2).

Cal

Diag

Standby/active mode:
The automatic reel speed control is in standby mode if
the symbol (2) remains continuously lit. If the symbol is
flashing, automatic control is active.
At full throttle in the operating range from 2.0 to 9.0 km/h,
the automatic reel speed control automatically switches
from standby mode to active mode.

Setup

1
Adjusting the reel speed ratio:
Switch on the automatic reel speed control.
35402

Increase the speed ratio

Cal

Decrease the speed ratio

Cal

key
key

When adjusting the ratio, the control is automatically


switched to standby mode. Ten seconds after completing
the adjustment process, the system automatically returns
to active mode with the new ratio of reel speed to travel
speed.

35409

When automatic reel speed control is


deactivated, the reel speed is directly adjusted
with the Cal + and
keys.

Displaying the adjustment process:


Manual or automatic adjustment of the reel speed is
indicated by arrows above or below the symbol for
automatic reel speed control (2). If the arrow points
upwards (3), the reel speed is increasing, and if it points
downwards (4) the speed is being reduced.

35411

35410

307.1133.3.6 englisch (en) 10.2006

HB 11

Commander Control 2000


Setting the concave clearances
Caution
The servomotors and linkage mechanisms
move are moving parts.
The clearances of the concave and separator concave
can be set in this menu.
Precondition: the main work switch must be on.
To set the concave clearances in the main screen, open
the "Set clearances" menu.
Cal

Diag

Press key (2).

Setup

35402

The "Set clearances" menu is displayed.


The clearance is set in discrete increments (steps).
Set clearances

Selecting clearances:
Turbo separator concave
Threshing concave, rear
Threshing concave, front

Keys (3) 5 steps


Keys (4) 15 steps
Keys (5) 15 steps

Saving values:
Press key (2). The adjustment process is started, and on
completion the main menu is displayed.

Cal

Diag

Setup

35402

HB 12

If the selected settings are in the prohibited


range, they are automatically corrected to the
permitted minimum/maximum value when saved
(otherwise the threshing drum would strike the
concave).
In the absence of any user input for a period of
more than 10 seconds, the main screen
automatically reappears. In this case, any
settings previously entered will not be saved.
To quit the menu without saving the values,
press key (1).

35407

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000

If you attempt to adjust the clearances while


adjustment is prohibited (main work switch off),
the following message appears on the screen:
Set clearances

Clearance
adjustment is
prohibited.

35402

Switch back to the main screen with key


(1) or (2).

Rapid opening of threshing


concave/separator concave
CAUTION
Servomotors and linkage mechanisms are
moving parts.
The rapid open function immediately opens the threshing
concave and separator concave (e.g. to prevent blockage
of the threshing mechanism).
Activating the rapid opening function:
Hold down key (2) for three seconds.
The "Rapid opening" information window is displayed.
Cal

Diag

Setup

Rapid opening
of thr. drum and
Turbosep. active

35412

35402

When the opening process has been successfully


completed, the information window "Rapid opening is
terminated" is displayed.

Rapid opening
is
terminated.

35413

307.1133.3.6 englisch (en) 10.2006

HB 13

Commander Control 2000


Resetting rapid opening:
Briefly press the Setup

or

key (3).

The previous settings for the threshing and separator


concaves will be restored.

Error message:
Interruption of rapid opening is indicated by the "Error"
window:

Error
Cal

Diag

Setup

Rapid opening not


complete.
Engine fault!

35414

35402

HB 14

Possible causes of failure:


Clogging/fouling by threshed crop.
Servo drives not running smoothly.
Switch off the ignition. Remedy the fault and repeat the
calibration procedure. If the error message is displayed
again, call a specialist workshop.

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


Sieve adjustment
The top and bottom sieves are adjusted in a single
window.
Activating sieve adjustment:
Press key (2) briefly twice.

35402

CAUTION
The servomotors are moving parts.

35429

The "Set clearances" window is displayed.


The sieve clearances are set in millimetres, with a range
of 1 to 14 mm.

Set clearances

Setting the clearances:


Top sieve
Cal keys (4)
Bottom sieve Setup keys (3)

Saving values:
Press key (2). The adjustment process is started, and
then the main menu appears (if the gap has been
reduced, the sieves are first closed further before being
driven outwards to the new setting).
Cal

Diag

Setup

35402

307.1133.3.6 englisch (en) 10.2006

In the absence of any input for a period of more


than 10 seconds, the system automatically
returns to the main screen. In this case, any
settings previously entered will not be saved.
To quit the menu without saving the values,
press key (1).

35415

HB 15

Commander Control 2000


Calibration

All calibrations are carried out in the factory


before delivery.

Recalibration is necessary e.g. after:


Fitting other sieves
Changing the mechanical basic setting
Replacing servomotors
Reinstalling software

Cal

Diag

After changing the sieves several times, check


the sieve setting and if necessary calibrate.
Recommendation: carry out a sieve calibration
at least once a year.

Setup

To open the calibration menu:


Hold down the Cal + and
keys (1)
simultaneously for 3 seconds.

1
CAUTION
The servomotors move during the calibration
processes.
35402

The "Calibration menu" is displayed.


Selecting the function:
Calibration menu

Mark the line of the desired function with the Diag


and
keys (2).

Sieves
Sieves
Straw guide plate
Spreader plates
Concave clearances

Open the selected function with the Setup + or


keys (3).
The calibration menu of the selected function is
displayed.

Cal

Diag

Setup

35402

HB 16

The Calibration menu or any specific calibration


menu can be closed at any time by pressing the
Cal + and
keys (1) simultaneously. Any
calibration that has started will be aborted.
In the absence of any input for a period of more
than 10 seconds, the system automatically
returns to the main screen. In this case, any
settings previously entered will not be saved.

35415

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


Calibrating sieve adjustment
(Electric sieve adjustment optional)

CAUTION
Park the combine and secure it against
rolling.
The servomotors move during calibration.

5
33992

Preconditions:
The basic sieve setting must be correct.
The engine must be switched off with the ignition on.
The sieve box light must be switched on with button
(3).
The sieves must be cleaned.

Calibration menu

Sieves
Sieves

Straw guide plate


Spreader plates
Concave clearances

Always make sure that the louvres of the left and


right-hand sieve are opened the same distance.
If necessary, slightly modify the basic setting.

Calibration:
Hold down the Cal + and
keys (1)
simultaneously for 3 seconds.
The "Calibration" (6) menu is displayed

In the "Calibration menu", select "Sieves"


(with the Diag + and
keys).
Press the Setup

Sieve adj. calib.

Calib. Procedure
1.Open sieves
2.Close sieves
position and
both keys.
3.Close sieves
position and
both keys.

to 14 mm
press

to 0 mm*
press

35417

Sieve adj. calib.

Top sieve
Potentiometer
Cal. min.
Cal. max.

2.02V
2.02V
6.96V

Sieve adj. calib.

2.02V
2.02V
6.96V

Bottom sieve
Potentiometer
Cal. min.
Cal. max.

2.45V
2.45V
6.21V

35419

307.1133.3.6 englisch (en) 10.2006

or

keys.

The "Sieve adj. calib." window (7) appears.

Top sieve calibration:


Fully open the top sieve with key (1).
Close the top sieve with key (2) until the sieve
aperture is 14 mm.
Hold down keys (1) and (2) simultaneously for at least
1 second.
Fully close the top sieve with key (2),
and then open approx. 0.5 1 mm.
Hold down keys (1) and (2) simultaneously for at least
1 second.
The calibration values of the top sieve appear in
the window (8).

35418

Top sieve
Potentiometer
Cal. min.
Cal. max.

Bottom sieve calibration:


Fully open the bottom sieve with key (4).
Close the top sieve with key (5) until the sieve
aperture is 14 mm.
Hold down keys (4) and (5) simultaneously for at least
1 second.
Fully close the bottom sieve with key (5),
and then open approx. 0.5 1 mm.
Hold down keys (4) and (5) simultaneously for at least
1 second.
The calibration values of the top sieve appear in
the window (9).

HB 17

Commander Control 2000

Back to main screen:


Press keys Cal

and

simultaneously.

Checking the settings:


Set the sieve aperture successively to 4, 8 and 12 mm
and check.

Cal

Diag

Setup

35429

HB 18

In the event of any deviations, repeat the basic


setup (see section on the "Threshing Section")
and calibration.

35402

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


Calibrating the straw guide plate
CAUTION
The servomotors move during calibration.

Calibration menu

Sieves
Straw guide plate
Spreader plates
Concave clearances

Preconditions:
The engine must be switched off, with the ignition on.

Calibration:
Hold down the Cal + and
keys simultaneously
for 3 seconds.
The "Calibration menu" (1) is displayed.

In the Calibration Menu, select "Straw guide" (2)


(with the Diag + and
keys).

Str. guide calib.


Calibrate

Press the Setup

or

keys.

The "Str. guide calib." window (3) is displayed.


The adjusting motor is automatically driven to the
two end positions, and the result is evaluated.

After successful calibration, the message "Calib.:


successful" is displayed in the window with the
average values (4).

If calibration is unsuccessful, the message


"Cal.: Error" is displayed in the window (5).

35420

Str. guide calib.


Calib.: successful
Potentiometer
Cal. min.
Cal. max.

2.27V
2.29V
5.70V

35421

Str. guide calib.


Cal.: Error

Possible causes of error:


Clogging/fouling with straw
Servomotor not running smoothly.
Switch off the ignition and remedy the fault, and
then repeat the calibration procedure. If the error
message appears again, have the machine
inspected by a specialist workshop.

35422

307.1133.3.6 englisch (en) 10.2006

Back to the main screen:


Press keys Cal

and

simultaneously.

HB 19

Commander Control 2000


Calibrating the spreader plates

1.1

Preconditions:
The engine must be switched off, with the ignition on.

Calibration:
Hold down the Cal + and
keys simultaneously
for 3 seconds.
The "Calibration menu" (4) is displayed.

1.2

35379

Calibration menu

Sieves
Straw guide plate
Spreader plates
Concave clearances

Spreader plate calib.


Drive the motor to both
end positions and press
key.

In the Calibration Menu, select "Spreader plates" (5)


(with the Diag + and
keys).
Press the Setup

or

keys.

The "Spreader calib." window (6) is displayed.

Drive the adjusting motor to the two end positions with


key (1):
Key (1.1): drive the straw spreader plates to the right
as far as they will go and then check that the straw
guide plates are in the end position.
Key (1.2): drive the spreader plates to the left as far
as they will go and then check that the straw guide
plates are in the end position.

Press the Setup

or

key.

35423

Spreader plate calib.


Calib.: successful
Potentiometer
Cal. min.
Cal. max.

0.15V
0.14V
6.43V

After successful calibration, the message "Calib.:


successful" is displayed in the window with the
average values (7).

35424

HB 20

Back to the main screen:


Press keys Cal

and

simultaneously.

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


Calibrating the concave clearances
Preconditions:
The engine must be switched off, with the ignition on.
The basic mechanical basic must be correct.
Calibration menu
Sieves
Straw guide plate
Spreader plates
Concave clearances

CAUTION
The servomotors move during calibration.

Calibration:
Hold down the Cal + and
keys simultaneously
for 3 seconds.
The "Calibration menu" (1) is displayed.

In the Calibration Menu, select "Conc. clearances" (2)


(with the Diag + and
keys).

Set clearances

Press the Setup

or

keys.

Calibration starts automatically. The servomotors


are driven to the end positions, and the result is
evaluated. The calibration process can be
monitored with the clearance indicators in the
"Set clearances" menu (3).

After successful calibration, the information


window (4) is displayed.

If calibration is unsuccessful, the error message


is displayed (5).

35403

Set clearances

Calibration of
concv. clearance
successful!

35421

Set clearances

Error
Calibration of
concv. clearance
has failed!

Possible causes of error:


Clogging/fouling by threshed crop.
Servomotors not running smoothly.
Switch off the ignition and remedy the fault, and
then repeat the calibration procedure. If the error
message appears again, have the machine
inspected by a specialist workshop.

35422

307.1133.3.6 englisch (en) 10.2006

Back to the main screen:


Press keys Cal

and

simultaneously.

HB 21

Commander Control 2000


Error messages and warnings
Error messages and warnings appear in the form of a
window on top of the existing display. In machines with
TERIS/TCS, error messages are generally output on the
TERIS/TCS monitor. However, if the connection to
TERIS/TCS is blocked due to a fault, the error messages
are displayed on the Commander Control.
The Commander Control handles error messages as
follows:
When an error occurs, a message appears on the
display. At the same time, an audible signal is sounded
for 2.5 to 5 seconds.
The message disappears when:

the cause of the error is no longer present

the message is acknowledged by pressing a key


(except for the warnings "Engine speed/Engine oil
temperature too high").
If more than one incident requiring a message occurs,
the incident with the highest priority is displayed.
The individual messages are listed in descending order of
priority in the list that follows.
Messages are displayed as Warnings or Errors.
Example "Warning":
"Engine speed too high"
This message:
has the highest priority and appears when the engine
speed rises above 2900 rpm.
cannot be cancelled by pressing a key.
automatically disappears when the engine speed
drops back below 2800 rpm.

Warning
Engine speed
too high!

35427

When driving downhill, brake and shift down a


gear.

Example "Error":
"Overload in Command. Control pot supply"
This message:
appears when the 5 V potentiometer supply falls below
4.5 V due to overload.

Error

Overload in
Command.Control pot
supply!

Switch the ignition off and on again. If the error


message appears again, call a specialist
workshop (servomotors not functioning, possible
short circuit).

35428

HB 22

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


List of warning and error messages
Message text

Type*

Engine speed too high

Description/Cause

Remedy

has top priority if the engine speed rises above


2900 rpm.

When driving downhill, brake and


shift down a gear.

cannot be cancelled; automatically


disappears when the engine speed falls below
2800 rpm.
Engine speed too low

appears when the engine speed falls below


the value set in the Setup menu during one
second.

Reduce engine load.


Set a lower warning limit.

Engine oil temperature


is too high

appears when the engine oil temperature


switch is closed.
cannot be cancelled; automatically disappears
when the engine oil temperature drops.

Reduce engine load.


Allow the engine to idle.
Check/remove any fouling
of the radiator.

Cooling water level

appears if the coolant level in the tank is too


low

Replenish coolant

Overload in
Command.Control
pot supply

appears when the 5 V potentiometer supply


falls below 4.5 V due to overload.

Switch the ignition off and on


again. If the message appears
again, call a specialist workshop
(servomotors not functioning,
possible short circuit).

Chopper speed too slow

appears when chopper speed falls below


1200 rpm for one second at nominal engine
speed.
drive belt is slipping.

Reduce load.

appears when the speed of the returns


elevator falls below the limit set in the Speed
Monitor menu for one second.
drive belt is slipping.

Reduce load.

appears when the speed of the straw walker


shaft falls below the limit set in the Speed
Monitor menu for one second.
drive belt is slipping.

Reduce load.
Set lower warning limit.

appears when the speed of the grain tank


delivery auger falls below the limit set in the
Speed Monitor menu for one second.
drive belt is slipping.

Reduce load.
Set lower warning limit.

appears when the grain tank extension is


extended, with the main work switch off and
the ground travel speed is more than 2.0 km/h.
if the grain tank cover is opened.

Retract grain tank extension

Ret. elevator speed


too slow

Straw walker speed


too slow

Delivery auger speed


too slow

The grain tank cover


is extended

* W = Warning

Check drive/belt tension.

Check drive/belt tension.

Check drive/belt tension.

Check drive/belt tension.

Close grain tank cover

E = Error

307.1133.3.6 englisch (en) 10.2006

HB 23

Commander Control 2000


Message text

Type*

Adjusting motor,
concave, rear

Description/Cause

Remedy

appears in the event of adjusting motor


malfunction for the rear concave clearance.
Possible causes:

Switch the ignition off and on,


and try again.

clogging of threshing section

Clear the blockage.

mechanical defect

Check the adjusting


mechanism.

Fuse F50 faulty


Relay K60, K81 faulty

Check the fuse and relay, and


replace if necessary.

Electrical system faulty

Check the electrical


connections.
If the fault cannot be remedied,
call a specialist workshop.

Adjusting motor,
concave, front

appears in the event of adjusting motor


malfunction for the rear concave clearance.
Possible causes:

Switch the ignition off and on,


and try again.

clogging of threshing section

Clear the blockage.

mechanical defect

Check the adjusting


mechanism.

Fuse F49faulty
Relay K18, K39 faulty

Check the fuse and relay, and


replace if necessary.

Electrical system faulty

Check the electrical


connections.
If the fault cannot be remedied,
call a specialist workshop.

Adjusting motor,
turbo separator

appears in the event of adjusting motor


malfunction for the rear concave clearance.
Possible causes:

Switch the ignition off and on,


and try again.

clogging of threshing section

Clear the blockage.

mechanical defect

Check the adjusting


mechanism.

Fuse F51 faulty


Relay K19, K49 faulty

Check the fuse and relay, and


replace if necessary.

Electrical system faulty

Check the electrical


connections.
If the fault cannot be remedied,
call a specialist workshop.

Grain tank pipe,


swivelled in

Handbrake applied

* W = Warning
HB 24

appears when the grain tank pipe is swivelled


out, the main work switch is switched off, and
the travel speed is above 2.0 km/h.

Swivel the grain tank pipe


inwards.

Proximity switch faulty

Check the proximity switch and


replace if necessary.

appears when the handbrake is applied and


the travel speed is above 2.0 km/h.

Release handbrake.

switch faulty.

Check the switch, and replace


if necessary.

E = Error
307.1133.3.6 englisch (en) 10.2006

Commander Control 2000


Message text

Type*

TCS/Teris not
addressable

Description/Cause

Remedy

appears when the TERIS/TCS is set in Setup


but cannot be accessed via the CAN bus
(only for TERIS/TCS).

Switch the ignition off and on.

EMERGENCY MODE
No functions are monitored any
longer.
Fuse F38 faulty

Check the fuse, and replace if


necessary.

Fuse (10 A) in voltage stabilisation module


A14 faulty.

Check the fuse, and replace if


necessary.

Voltage stabilisation module A14 faulty.

Check the indicator lamps, and


replace the module if necessary.
If the fault cannot be remedied,
allow the machine to run until
empty and immediately call a
specialist workshop.

Sieve adjusting is not


addressable

appears when electric sieve adjustment is set


in Setup, but the relevant electronic module
cannot be accessed via the CAN bus (only for
units with electric sieve adjustment).

Switch the ignition off and on,


and try again.

Fuse F57 faulty.

Check the fuse, and replace if


necessary.
If the fault cannot be remedied,
call a specialist workshop.

Straw guide is not


addressable

appears when electric straw guide plate


adjustment is set in Setup, but the relevant
electronic module cannot be accessed via the
CAN bus (only for units with electric straw
guide plate adjustment).

Switch the ignition off and on,


and try again.

Fuse F56 faulty.

Check the fuse, and replace if


necessary.
If the fault cannot be remedied,
call a specialist workshop.

Spreader plates are not


addressable

appears when electric spreader adjustment is


set in Setup, but the relevant electronic
module cannot be accessed via the CAN bus
(optional equipment).

Switch the ignition off and on,


and try again.

Fuse F55 faulty.

Check the fuse, and replace if


necessary.
If the fault cannot be remedied,
call a specialist workshop.

* W = Warning

E = Error

307.1133.3.6 englisch (en) 10.2006

HB 25

Commander Control 2000


Message text

Type*

Straw guide adjusting


motor is faulty

Description/Cause

Remedy

appears in the event of malfunction of the


adjusting motor for the straw guide plate.

Switch the ignition off and on,


and try again.

Clogging/fouling

Clear the blockage/fouling.

Mechanical fault

Check the adjusting mechanism.

Fuse F13 faulty


Relays K16, K37 faulty

Check the fuse and relays, and


replace if necessary.

Electrical fault

Check the electrical


connections.
If the fault cannot be remedied,
call a specialist workshop.

Top sieve adjusting


motor is faulty.

appears in the event of malfunction of the


adjusting motor for the top sieves (optional
equipment).

Switch the ignition off and on,


and try again.

Mechanical fault

Check the adjusting mechanism.

Fuse F52 faulty


Relays K20, K41 faulty

Check the fuse and relays, and


replace if necessary.

Electrical fault

Check the electrical


connections.
If the fault cannot be remedied,
call a specialist workshop.

Bottom sieve adjusting


motor is faulty.

appears in the event of malfunction of the


adjusting motor for the bottom sieves
(optional equipment).

Switch the ignition off and on,


and try again.

Mechanical fault

Check the adjusting mechanism.

Fuse F53 faulty


Relays K62, K83 faulty

Check the fuse and relays, and


replace if necessary.

Electrical fault

Check the electrical


connections.
If the fault cannot be remedied,
call a specialist workshop.

* W = Warning
HB 26

E = Error
307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Appendix C

Commander Control 2000


Setup and Diagnosis
5650H - 5690HTS

307.1133.3.6 englisch (en) 10.2006

HC 1

H
Service
Training

Setup menu

If there is no input in the setup menu for


more than 10 seconds, the main screen
automatically reappears. Settings carried out
in the meantime will not be saved.

Calling the setup menu:


Press the keys Setup + and
simultaneously for 3 seconds.

Cal

Diag

(1)

Setup

35429 35402

The first page of the setup menu appears.

Setup

1/4

The setup menu consists of 4 pages. The page


number (4) is displayed on top at the right side in the
menu window:
1/4 = page 1 of 4

Language:: english
Front tires:
R adial 650/75R32
Turbo separator:

yes

LCD View angle;

Page selection:
Keys (3): Cal

Parameter selection:
Keys (2): Diag
Cal

Diag

Setup

or

Parameter setting:
Keys (1): Setup

or

or

Saving of adjusted values:


Keys (3): Cal + and

simultaneously.

35402/35406

HC 2

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Setup menu
Example:
Adjustment of speed alarm limit
Setup

1/4

In this example the speed alarm limit is supposed to


be adjusted from 0% to -20%.

Language:: english
Front tires:
R adial 650/75R32
Turbo separator:

yes

LCD View angle;

Setup
Setup

4/4
4/4

Alternat
oo
rrss
pp
::
Alternat
DZ
Lichtm.:

8040

Eng.sp.
factor:
MotorDZFaktor

3.32
3.32

DZ
Motor:
Engine
Motore
NG:
Warngrenze:

2421
2421

W arning limit:

0%

Setup
Setup

4/4
4/4

Press the keys Setup + and


simultaneously for 3 seconds.

and

The first page of the setup menu (1) appears.


2

Press the key Cal

3x.

8040
fourth page of the setup menu (2)
The
appears. The first line is marked.

0%

Alternat
or sp:
DZ
Lichtm.:

8040
8040

MotorDZFaktor
Eng.sp.
factor:

3.32
3.32

DZ
Motor:
Motore
NG:
Engine
Warngrenze:
Warngrenze

2421
2421

W arning limit:

0%

Setup
Setup

4/4
4/4

0%

Alternat
or sp:
DZ
Lichtm.:

8040
8040

Eng.sp.
factor:
MotorDZFaktor

3.32
3.32

DZ
Motor:
Motore
NG:
Engine
Warngrenze:
Warngrenze

2421
2421

W arning limit:

-20%

-20%

3x.

Press the key Diag

The fourth line alarm limit (3) is marked.


3

Press the key Setup + or


as often as
necessary in order to set the desired %-value of
-20% (4).

Press the keys: Cal

and

simultaneously.

main screen appears, the set value is


The
saved.

35406/35429
307.1133.3.6 englisch (en) 10.2006

HC 3

H
Service
Training

SETUP MENU
The four pages of the setup menu:
Setup

1/4

Machine type:
Maschinentyp
Maschinentyp:

Language:: english
Front tires:
R adial 650/75R32
Turbo separator:
LCD View angle;

Setup
Setup

yes

2/4
2/4
5670
5670

Setup
Setup

3/4
3/4

Setup
Setup

El.sieve adj:

yes

Alternator sp:
DZ
Lichtm.:

El.straw guide

no

el.Siebverst.:

ja

4/4
4/4
8040

8040

Chopper:

yes

TERIS/TCS:

yes

ja

el.Hckslerk.:
nein
El.spread.pl:
no

Eng.
p.
actor:
Eng.
ss
p.
ffactor:
3.32
MotorDZFaktor:
3.32

ja
no

el.Strohvert.: nein

DZ
Motor:
Motore
NG:
Engine
Warngrenze

Hcksler:

TerisTCS:
GTL sensor #2:
KTFSGeber
R evers. drum: #2

nein
no

Wendetrommel:

nein

W arning limit:

2421
2421
0%

0%

Adjustment range of parameters in the setup menu


Parameter

Adjustment range

page 1:
language

deutsch - (englisch)

front tyres

Radial 800/65R32

this input is necessary for the exact calculation

Radial 650/75R32

of the ground speed

Radial 620/75R30
Radial 620/75R26
Diagonal 30,5-32
Diagonal 24,5-32
Diagonal 23,1-30
Diagonal 23,1-26

turbo separator

yes - no

LCD viewing angle

0 ... 9

page 2:
type of machine

5670 - 5680 - 5690

chopper

yes - no

Teris TCS

yes - no

KTFS transmitter #2
(grain tank level transmitter no. 2)

yes - no

impeller

yes - no

page 3:
electrical sieve adjustment*

yes - no

electrical chopper flap adjustment*

yes - no

electrical straw spreader adjustment*

yes - no

page 4:
engine speed coefficient

0.10 ... 9.99

dynamo machine speed to engine speed ratio


alarm limit engine speed

0% ... -50% ... (aus)

* * Programming of CAN modules see chapter H

HC 4

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Diagnosis
CAUTION
After calling the diagnosis menu no machine
functions will be monitored or controlled any
more. All safety functions are switched off.

Calling the diagnosis menu:


Press the keys Diag + and
(1)
simultaneously for 3 seconds.

Cal

Diag

In order to completely engage or disengage,

Setup

actuate the servo motor until the clutch


control power unit switches off the servo
motor in the final.

35429 35402

The diagnosis menu appears.


2
Enabling of the actuators:

Diagnosis menu
Speeds
Concave Clearances
Main Clutches
Grain Tank
Threshing Mode
Ground Drive Mode
Indicator Lights
CAN

Press the keys (2) and (3) simultaneously.

The actuators are enabled.


3

Cal

Diag

It is necessary to enable the actuators in the


diagnosis menu. Otherwise no adjustment is
possible in the diagnosis.

Selecting the function:


Mark the line of the desired function by means of
the keys Diag + and
(1).

Setup

An arrow at the beginning or at the end of the


menu window indicates further hidden lines.

Call the desired function by means of the keys


Setup + or
(4).

5
both:
Quit
menu

Line

Call

35402/25Men

307.1133.3.6 englisch (en) 10.2006

The first page of this function appears.

It is possible to quit the menu or any page


anytime by means of pressing the keys
Cal + und
(5) simultaneously.
HC 5

H
Service
Training

Diagnosis Speed 1/2


Reel
Reel
0UPM
Rel.: Faster
+I+
Rel.: Slower
-IThreshing Drum
Rel.: Faster
Rel.: Slower

Diagnosis
Example for display of pages

The first page (1) of the menu item Speeds appears


after selection by means of the keys Setup + or
.
page display 1/2 (2) indicates: Page 1
The
of 2.

0UPM
-I-I-

The speed (RPM) is shown in the status


display (3).

Fan Speed
1302UPM
Rel.: Faster
-IRel.: Slower
-I-

Diagnosis Speed
Reel
Rel.: Faster
Rel.: Slower

Switching over the status display (3):


Press the keys Diag + und
simultaneously.

1/2
2.4Hz
-I-I-

Threshing Drum
Drum 0.0Hz
Threshing
Rel.: Faster
-IRel.: Slower
-IFan Speed
Rel.: Faster
Rel.: Slower

display will be shown successively


The
in RPM, Hz and static sensor signal.

21.7Hz
-I-I-

Diagnosis Speed

Press the keys Diag


once more.

1/2

Reel
Rel.: Faster
Rel.: Slower

status display will be switched over to Hz


The
(4).

and

simultaneously

static sensor signal (5) is shown in the


The
status display (this only makes sense for
evaluation when the drive has stopped).

Threshing Drum
Rel.: Faster
Rel.: Slower
Fan Speed
Rel.: Faster
Rel.: Slower

Calling of page 2:

Diagnosis Speed

2/2

Chopper
0UPM
Straw Walker
0UPM
Returns Elevator 0UPM
Filling Auger
0UPM
Dynamo Machine 8050UPM
Engine
2424UPM
Wheel Imp.
0UPM

Press the keys (1): Cal

or

The page 2/2 will be displayed (6).


Switching over of the status display is done on this
page in the same way as described before.

HC 6

All further key functions are described in the


following descriptions of the menu items.

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Diagnosis
Display of sensor and switching statuses
Symbol

Status
Sensor dampened

Sensor non dampened

Switch closed

Switch opened

Status display of servo drives


Symbol

Status

Servo drive is switched off

|+

Failure: Line disconnection or short circuit behind power supply

+|

Failure: Short circuit to ground

+|+

Servo drive is switched on

Subsequently all menu items with the appropriate pages are discussed in the successive order of the
diagnosis menu:
Menu items
Speeds
Concave clearances
Main clutches
Grain tank
Threshing mode
Ground drive mode
Indicator lights
CAN
System

307.1133.3.6 englisch (en) 10.2006

Page title
Diagnosis Speeds
Diagnosis CCo
Diagnosis MC
Diagnosis GT
Diagnosis TM
Diagnosis GDM
Diagnosis IL
Diagnosis CAN
Diagnosis Syst.

HC 7

H
Service
Training

Diagnosis
speeds
Speed adjustments may only be carried out
when the drive is running and the clutch is
engaged.

Diagnosis Speed 1/2


Reel
Reel
0UPM
Rel.: Faster
+I+
Rel.: Slower
-IThreshing Drum
Rel.: Faster
Rel.: Slower

0UPM
-I-I-

Key functions:
Page selection:
keys (1): Cal

Fan Speed
1302UPM
Rel.: Faster
-IRel.: Slower
-I-

Line selection:
keys (2): Diag
Cal

Diag

Page

Line

both:

both:

return
to the
Diagnosis
menu

Status
display

Speed adjustment:
keys (3): Setup

Setup

or

or

or

The speed of the drive selected on


page 1 (4) is altered directly by
means of actuating the servo drive.

Adjustment is done as long as the key is pressed:


Setup + Speed is increased
Setup
Speed is decreased

Speed
adjustment

Status display:
keys (2): Diag
28Diag 35402

and

simultaneously

In the status display the speed


(RPM), Hz and static sensor signal
will be shown successively (this only
makes sense when the drive has
stopped).

Return to the Diagnosis menu:


keys (1): Cal + and
simultaneously

Diagnosis Speed 1/2


Reel
Reel
0UPM
Rel.: Faster
+I+
Rel.: Slower
-IThreshing Drum
Rel.: Faster
Rel.: Slower

0UPM
-I-I-

Fan Speed
1302UPM
Rel.: Faster
-IRel.: Slower
-I-

Diagnosis Speed

A sensor and two relays are assigned to each


actuator.

2/2

Chopper
0UPM
Straw Walker
0UPM
Returns Elevator 0UPM
Filling Auger
0UPM
Dynamo Machine 8050UPM
Engine
2424UPM
Wheel Imp.
0UPM

HC 8

Page 1/2:
Speeds which can be altered:
Reel speed
Threshing drum speed
Fan speed

Page 2/2:
Indication of speeds which cannot be altered with the
Commander Control 2000.

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Diagnosis DCC
Concave controller (concave clearances)
Diagnosis CC

1/3

Key functions:

Rear concave
Pot.
Cal. min.
Cal. max.
Actual value
Rel.: Extend
Rel.: Retract

3.21V
0.48V
4.40V
69.4%
-I-I-

Page selection:
keys (1): Cal

Diag

or

Actuation of servo drive:


keys (2): Setup + or

Cal

The servo drive of the selected


page/function will be activated.

Setup

Adjustment is done as long as the key is pressed:


Setup + Servo drive is extending
Setup
Servo drive is retracting

1
Page
both:

Return to the Diagnosis menu:


keys (1): Cal + and
simultaneously

2
Actuate
servo drive

return
to the
Diagnosis
menu

30Diag 35402
Diagnosis CC

1/3

Rear concave
Pot.
Cal. min.
Cal. max.
Actual value
Rel.: Extend
Rel.: Retract

Diagnosis CC

3.21V
0.48V
4.40V
69.4%
-I-I-

2/3

Front concave
Pot.
Cal. min.
Cal. max.
Actual value
Rel.: Extend
Rel.: Retract

Diagnosis CC

3.97V
0.48V
4.40V
89.0%
-I-I-

307.1133.3.6 englisch (en) 10.2006

On each page is displayed:


Pot.
the electrical measuring value at the
servo potentiometer
Cal.min./max. the calibration values as saved with
the last calibration process.
Actual value

the relative position of the servo


drive as a result of the measuring
value of the potentiometer within the
calibrated stroke.

Rel.: Extending/Retracting
Electrical status of the servo drive

3/3

Turboseparator
Pot.
Cal. min.
Cal. max.
Actual value
Rel.: Extend
Rel.: Retract

Page 1/3: Concave adjustment rear.


Page 2/3: Concave adjustment front.
Page 3/3: Separating grate adjustment of
turboseparator

Note:
0.43V
0.48V
4.40V
-3.7%
+I+
-I-

In case of manual adjustment of the clearances an


actual value of 0% resp. 100% must be reached in
the limit stop positions. Repeat the calibration
procedure if the displayed value differs significantly
from the actual value.

HC 9

H
Service
Training

Diagnosis MC
Main clutches
Diagnosis MC

The individual outputs can be switched


independently from each other and are not
subject to any automatic monitoring ensuring
proper operation.

1/2

Threshing mechanism
mechanism
Threshing
Status
-IRel.: engage
+I+
Rel.: disengage
-ICutting mechanism
Status
-IRel.: engage
-IRel.: disengage
-ISwitch CM

Cal

Diag

Key functions:
Page selection:
keys (1): Cal

Line selection:
keys (2): Diag

Setup

Actuate servo drive:


keys (3): Setup

Page

Line

Actuate
servo
drive
or
Status
outputs
on/off

both:
return
to the
Diagnosis
menu

or

or

or

The servo drive of the selected clutch


(4) is activated.

Adjustment is done as long as the key is pressed:


Setup + engage
Setup
disengage
32HK12 35402

In the diagnosis menu it is not possible to operate the


grain tank tube and the clutches by means of the
respective function keys
and 0 .
Switching of status outputs:
First select the lineStatus (5) of the desired function.
keys (3):

Setup
Setup

Diagnosis MC

1/2

Threshing mechanism
mechanism
Threshing
Status
-IRel.: engage
+I+
Rel.: disengage
-ICutting mechanism
Status
-IRel.: engage
-IRel.: disengage
-ISwitch CM

Diagnosis MC

2/2

Chopper
Status
Status
Rel.: engage
Rel.: disengage

+I+
-I-I-

Grain tank discharge


Rel.: engage
-IRel.: disengage
-ISwitch GTD

HC 10

Switch on status output


Switch off status output

Return to the Diagnosis menu:


keys (1): Cal + and
simultaneously

Page 1/2:
Threshing mechanism clutch
Cutting mechanism clutch
Switch CM = Foot switch cutting mechanism stop

Page 2/2:
Chopper clutch
Grain tank clutch
Switch GTD = Foot switch grain tank discharge

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Diagnosis GT
Grain tank
Diagnosis GT

1/1

Key functions:

Grain tank tube


V.: Swing in
-IU.: Swing out
+I+
Status NS GTT
-INS grain tank tube
Grain tank top
Level transmitter 1
Level transmitter 2

Line selection:
keys (2): Diag

Diag

or

Swinging of grain tank tube:


Start the swinging procedure by means of the keys (3):
Setup
Setup

Cal

Swing out grain tank tube


Swing in grain tank tube

Setup

Terminate the swinging procedure with the


keys (3) Setup

Page

Line

Swing
in/swing
out

return
to the
Diagnosis
menu

or

Switching of status output:


First select the line Status (4).

1
both:

keys (3):

Setup
Setup

Switch on status output


Switch off status output

Start/Stop

32HK12 35402

Diagnosis GT

1/1

Grain tank tube


V.: Swing in
-IU.: Swing out
+I+
Status NS GTT
-INS grain tank tube
Grain tank top
Level transmitter 1
Level transmitter 2

307.1133.3.6 englisch (en) 10.2006

Return to the Diagnosis menu:


keys (1): Cal + and
simultaneously

The menu item diagnosis grain tank consists of one


page.

HC 11

H
Service
Training

Diagnosis TM

1/1

Diagnosis TM
Threshing Mode

Working master sw.


Straw guide plate
Straw chamber warn. sw.#1
Straw chamber warn. sw.#2
Returns elevator #1
Returns elevator #2
Feed passage
Angle transmitter 2.75V

One page:
Switches and sensors for monitoring of the threshing
process.

Diagnosis GDM

Ground Drive Mode GDM

1/1

Overspeed engine
+I+
D+
Engine excess temp.
Engine oil excess temp.
Engine oil pressure sw.
Engine cooling fan
Engine air filter
Hand brake

Return to the Diagnosis menu:


keys Cal + and
simultaneously

One page:
Switches and sensors for monitoring of the ground
drive mode.
Line selection:
keys Diag

or

Switching the status output:


First select the lineOverspeed Engine (1).
keys:

Setup
Setup

Switching on the status


output
Switching off the status
output

Return to the Diagnosis menu:


keys Cal + und
simultaneously

HC 12

307.1133.3.6 englisch (en) 10.2006

H
Service
Training

Diagnosis IL
Engine oil pressure
Charge control
Central warning
Hand brake
Grain tank level
Chopper speed
Engine excess temp.
Engine cooling fan
Engine air filter
Straw chamber monitoring
Diagnosis IL
Returns elevator
Grain tank tube
Chopper mode
Revolving light
Buzzer

1/2
+I+
-I-I+I+
+I+
+I+
-I-I+I+
-I-

Diagnosis IL
Indicator Lights
Pages 1/2 and 2/2:
Indicator lights of the combined instrument gauge and
further optical and acoustical signal transmitters.

Line selection:
keys Diag

or

2/2
+I+
-I-I+I+
-I-

Switching the status output:


First select the desired function.
keys:

Setup
Setup

Switching on the status output


Switching off the status output

Return to the Diagnosis menu:


keys Cal + and
simultaneously

307.1133.3.6 englisch (en) 10.2006

HC 13

H
Service
Training

Diagnosis CAN
CAN modules
Diagnosis CAN

1/4

Key functions:

El. adjustment:
Upper sieve
Pot.
Cal. min.
Cal. max.
Actual value
Extend key
Retract key
Rel.: extend
Rel.: retract

Page selection:
keys (1): Cal

3.41V
2.22V
6.02V
31.3%

Line selection:
keys (2): Diag

-I-I-

Actuating servo drive:


keys (3): Setup
Cal

Diag

Setup

Page

Line

Swing
in/Swing
out

both:

or

or

The servo drive of the selected


function is activated.

Adjustment is done as long as the key is pressed:


Setup + Servo drive is extending
Setup
Servo drive is retracting

return
to the
Diagnosis
menu

or

Switching the power outputs:


First select the line of the desired function.
keys (3):

Start/Stop

Setup
Setup

Switch on power output


Switch off power output

32HK12 35402

Return to the Diagnosis menu:


keys (1): Cal + und
simultaneously

Diagnosis CAN
El. adjustment
Straw guide plate

Option is not
available!

3/4

It is possible to check the proper function of the CAN


modules by means of the CAN diagnosis. The CAN
modules must be activated in the menu Setup.
If a CAN module is not activated or if it is not
displayed on the bus, the message "Option not
available appears on the corresponding page. See
example opposite (4).

Note:
In case of manual operation of the individual functions
an actual value of 0% resp. 100% must be reached in
the limit stop positions. Repeat the calibration
procedure if the displayed value differs significantly
from the actual value.

HC 14

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H
Service
Training

2
1

Diagnosis CAN

1/4

El. adjustment:
Upper sieve
Pot.
Cal. min.
Cal. max.
Actual value
Extend key
Retract key
Rel.: extend
Rel.: retract

3.41V
2.22V
6.02V
31.3%
-I-I-

3
Diagnosis CAN

2/4

El. adjustment:
Lower sieve
Pot.
Cal. min.
Cal. max.
Actual value
Extend key
Retract key
Rel.: extend
Rel.: retract

4.05V
2.61V
5.91V
43.4%
-I-I-

4
Diagnosis CAN

3/4

El. adjustment:
Straw guide plate
Pot.
Cal. min.
Cal. max.
Actual value
Chopper switch
Rel.: Extend
Rel.: Retract

4.41V
2.05V
6.17V
57.0%
-I+I+

5
6

Diagnosis CAN

4/4

El. adjustment:
Deflector
Pot.
Cal. min.
Cal. max.
Actual value
0% ... 20%
20% ... 40%
60% ... 80%
80% ... 100%

Diagnosis CAN
CAN modules

3.6V
0.00V
8,07V
45.0%
-I+I+
-I-I-

307.1133.3.6 englisch (en) 10.2006

Pages 1/4 and 2/4:


Electrical adjustment upper sieve and lower sieve.
On these pages is depicted:
Pot.
the electrical measuring value at the
servo potentiometer
Cal.min./max.
the calibration values as saved with the
last calibration process.
Actual value
the relative position of the servo drive
as a result of the measuring value of the
potentiometer within the calibrated
stroke.
Key extending/retracting
Operating keys for sieve adjustment at
the rear ladder
Rel.: extending/retracting
Electrical status of the servo drive

Page 3/4:
Electrical adjustment straw guide plate.
On this page is depicted:
Pot.
the electrical measuring value at the
servo potentiometer
Cal.min./max.
the calibration values as saved with the
last calibration process.
Actual value
the relative position of the servo drive
as a result of the measuring value of the
potentiometer within the calibrated
stroke.
Chopper switch Switch at the straw guide plate
Rel.: extending/retracting
Electrical status of the servo drive

Page 3/4:
Electrical adjustment deflectors.
On this page is depicted:
Pot.
the electrical measuring value at the
servo potentiometer
Cal.min./max.
the calibration values as saved with the
last calibration process.
Actual value
the relative position of the servo drive
as a result of the measuring value of the
potentiometer within the calibrated
stroke.
0% ... 100%.
Status of the four indicator lights

HC 15

H
Service
Training

Diagnosis Syst.

1/1

Commander Control:
Battery
12.4V
pot. Exc.
4.97V
CAN modules:
El. sieve adjustment
pot. Exc.
0.01V
El. straw guide plate
pot. Exc.
7.95V
El. deflector
pot. Exc.
8.04V

Component

Range of operation

Commander Control 2000


Battery
Pot. Exc.

10,00 ... 16,00 V


4,80 ... 5,20 V

El. sieve adjustment


Pot. Exc.

7.75 ... 8.25V

El. straw guide plate adjustment


Pot. Exc.

7.75 ... 8.25V

El. deflector adjustment


Pot. Exc.

7.75 ... 8.25V

HC 16

Diagnosis Syst.
System
One page:
Electric power supply, Commander Control 2000 and
CAN modules.

Return to the Diagnosis menu:


keys: Cal + and
simultaneously

The opposite table shows the permissible range for


the electric power supply and the supply voltage of
the servo potentiometers (pot. Exc.).

307.1133.3.6 englisch (en) 10.2006

I
Service
Training

5650H - 5690HTS
Air condition
Table of Contents
Type of combine harvester

5650H
5680H
5660HTS 5690HTS

Safe maintenance and repair of air condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 03

Overview function elements in cabin roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 05

Circuit diagram for electric system heating und cooling system in cabin roof . . . . . . . . . . . . . .06 07

Functional description of the air condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 - 09

Refrigerant and PAG oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 11

Components of the air condition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 - 13

Magnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Compressor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Components of the air condition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 - 17

Expansion valve (TEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 - 19

307.1133.3.6 englisch (en) 10.2006

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I
Service
Training

Safe maintenance and repair of air


condition
Qualification of personnel
For all persons involved in maintenance or repair of the air
condition system it is mandatory
- to be qualified for these works and to be adequately
trained
- to carefully observe the instructions in the repair manual.
You and your employees should be trained and specially
instructed for maintenance works on air condition systems.
Training can be carried out by the after-sales service of
SAME DEUTZ.

SZ-0115

Personal safety equipment


Liquid refrigerant evaporates under atmospheric pressure.
The skin of your hands may freeze when contacting with
refrigerant.
PAG oils damage the skin surface upon frequent contact.
Protect your hands and eyes from refrigerant and
refrigerant oil (PAG).
Wear solid safety gloves (leather)!
Wear safety goggles or face screen!

Handle refrigerant and refrigerant container carefully.


SZ-0102

Never touch liquid refrigerant and refrigerant bottles without


wearing safety goggles!
Do not expose refrigerant bottles to direct heat impact and
never heat above 50 C. Do not expose to direct sunlight or
to heat radiators.
Rising temperatures cause the pressure inside the
container to increase. A strong pressure increase may
cause thin-walled bottles to explode!
Do not fill refrigerant bottles to maximum level. By doing this
the refrigerant can expand when temperature is rising.
Shut multiple-use steel bottles immediately by means of a
shutoff valve after taking out refrigerant.
Protect the shutoff valve against damage! Screw on safety
plug and screw cap.
Always move refrigerant bottles carefully. Avoid shock!
Never refill damaged bottles. Mark the containers clearly,
e.g. "Bottle damaged. Do not refill - Danger of accident!
When opened, drain non-returnable refrigerant bottles into
the service station for safety reasons.
Close drained bottles.

I2

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Service
Training

Safe maintenance and repair of air


condition
Refrigerant is heavier than ambient air. It will sink down in
case of a leakage in refrigerant pipes. In the course of this
high refrigerant concentrations are occuring in the ambient air.
There is danger of suffocation!
Leave the room immediately. Re-enter the room only after
sufficient ventilation.
If possible, use breathing protection, e.g. a compressed air
breathing apparatus.
Never drain refrigerant in closed rooms. Make sure that there
is good ventilation, e.g. switch on the air exhauster.
Maintenance works in the drivers cabin:
Never allow refrigerant to be drained into the closed cabin.
Open the cabin door and make sure that there is good
ventilation!

SZ-0010

First aid in case of contact with refrigerant


After inhaling:
Take the person to fresh air immediately and lay down
carefully.
Call a medical doctor!
Give artificial respiration in case of unconsciousness or
respiratory paralysis.
After contact with the eyes:
Do not rub out the eyes. Force apart the eyelids and rinse with
plenty of lukewarm water for at least 15 minutes. Go and see a
medical doctor immediately!
After contact with the skin:
In case of contact of refrigerant with the skin sponge down
with plenty of water.
Safety measures with welding works
In case of temperatures above 800 C, e.g. contact of
refrigerant with naked flame or glowing metal (welding works),
the R134a is decomposed chemically. In the course of this
highly toxic phosgene gases (chlorocarbonic oxide gases) are
formed. Inhaling of these gases is causing serious damage to
health!
A pungent stench is a clear sign of the formation of such toxic
gases.
Leave the room immediately. Ventilate the place of work
extensively.
Observe with soldering and welding works:
By all means avoid heat exposure to the components of the air
condition!
Parts of the system may explode due to strong heat during
welding.
Never touch refrigerant with naked flames or glowing metal
(e.g. welding works)!
Do not smoke while carrying out maintenance and repair
works!
While varnishing the machine:
Drain the air condition in advance, if the vehicle is supposed to
stay in the drying oven for more than 20 minutes with 80 C.
Never varnish the evaporator and the condenser!
307.1133.3.6 englisch (en) 10.2006

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Service
Training

K1

K3

K4

X135 X136

K5

6
12.1
7

16

15

14

13

12

17

11

10

18

5.2
21

20

I4

5.1

19

307.1133.3.6 englisch (en) 10.2006

I
Service
Training

5650H 5690HTS
Overview function elements in cabin roof

Relay for cooling compressor and blower

Blower

Wiper motor

Connector X135, X136 for headlamps

Coolant hoses

5.1 Pressure hose


5.2 Flexible suction tube
6

Hoses for heating

Heating valve with servo motor


Observe proper mounting position: In header line, in direction of flow!

Connector X115, X134, X182

Interior lighting

10

Temperature sensor air recirculation, no longer utilised as of year of construction 2002

11

Circulating air filter

12

Control panel air condition, heating

12.1 Control unit air conditioning (electric thermostate)


13

Temperature sensor

14

Heat exchanger heating

15

Evaporator air condition system

16

Expansion valve

17

Fresh air filter left and right

18

Master cylinder service brake

19

Disconnect for coolant- and heating hoses

20

Refrigerator section

21

Cabin floor

307.1133.3.6 englisch (en) 10.2006

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Service
Training

5650H 5690HTS
Circuit diagram for electric system heating und cooling system in cabin roof
Relay K1-K4 are mounted in the cabin roof

Low/high pressure switch:


Switch is opening at 1.2 bar and at 28 bar resp.
Switch is closing at 2,4 bar and at 19,5 bar resp.

I6

307.1133.3.6 englisch (en) 10.2006

307.1133.3.6 englisch (en) 10.2006

Low/high pressure switch

Compressor

Malfunction control

Water
potentiometer

Electrical thermostat

Air conditioning
potentiometer
Air conditioning
switch

Water valve

Evaporator fan M2

Fan switch

Evaporator fan M1

Service
Training

5650H 5690HTS
Circuit diagram for electric system heating und cooling system in cabin roof

56-077

I7

I
Service
Training

10

12

9
11

16

15

14

13

1
3
5
7

X142

I0074

I8

307.1133.3.6 englisch (en) 10.2006

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Service
Training

5650H 5690HTS
Functional description of the air condition
Coolant circuit
Position

Designation

Function

Compressor

Takes in gaseous refrigerant from the evaporator for compression.


In the course of this the refrigerant is warming up (pressure build-up).

Belt pulley with


magnetic clutch

The compressor is driven via v-belt, belt pulley and magnetic clutch. Activation
and deactivation of the magnetic clutch causes the compressor to be separated
from the drive.

Filling connections
(service valves)

The pressure gauge ports in the refrigerant pipes at the compressor are equipped
with spindle valves made by Schrader.

Condenser

The compressed refrigerant is cooled down in the condenser. In the course of this
it is liquefied (condensed).

Container
(part of the dryer)

Absorbs the liquid refrigerant.

Dryer (1

The dryer withdraws possibly existing humidity (water) of the refrigerant.

High/low pressure switch

Deactivates the cooling system if the pressure between compressor and


expansion valve falls below 1.2 bar or exceeds 28 bar. At the same time the red
failure lamp is lighting.

Fresh air blower

Blows the intake air through the evaporator

Expansion valve

Point of separation between high pressure and low pressure side.


From there a metered quantity of liquid refrigerant is entering the evaporator and
starts to expand here.

10

Evaporator

In the evaporator the refrigerant is expanding and completely evaporating,


changing into gaseous condition at the same time. The required energy (heat) for
this is withdrawn from the ambient air flowing by the evaporator fins. The air is
cooled down, taken in by the blower and routed to the cabin.

11

Temperature sensor

Captures the temperature of the cooled down air after the evaporator.

12

Control unit
(electronic thermostat)

Activates or deactivates the refrigerating compressor by means of K1.

13

Rotary potentiometer

Air temperature adjustment (cooling capacity)

14

Toggle switch

Used for commissioning of the air conditioning system The rotary switch for the
fan must be switched at least to stage 1.

15

Failure lamp red

Lighting as soon as the air conditioning system is deactivated by means of the


high/low pressure switch.

16

Rotary switch for fan

Activation /deactivation of the fresh air fan; with 3 speed stages.

(1 Installed in front of the cooler package.

307.1133.3.6 englisch (en) 10.2006

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Service
Training

Refrigerant and PAG oils


Refrigerant
In the air condition system of the combine harvester the refrigerant R 134a is used which is free from chlorine.
Its pressure and temperature response is similar to the type R 12 applied in the past.
CAUTION!
Danger of injury!

Observe the safety regulations when handling refrigerants!


Read the EC safety data sheet of the refrigerant producer.
The refrigerant R 134a is a low-boiling agent.
Boiling point: -26,1 C at normal atmospheric pressure of approx. 1 bar.
Boiling point temperatures depending on the pressure
Determine the corresponding evaporation temperature with the following table.

Temperature in C

Pressure in bar (absolute pressure)

0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100

2,92
3,49
4,14
4,88
5,71
6,65
7,69
8,86
10,16
11,59
13,17
14,90
16,81
18,89
21,17
23,65
26,35
29,29
32,48
35,95
39,72

Absolute pressure is measured pressure minus ambient pressure.


Ambient pressure is air pressure.
For the pressure in the closed system subtract 1 bar of the value in the table.

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Service
Training

Refrigerant and PAG oils


Refrigerant
Refrigerant R 134a is able to absorb heat quickly (thermal absorption) and to also dissipate it quickly
(heat dissipation). Due to these qualities R 134a is very well suitable for serving as heat transport agent in air condition
systems.
If appropriately handled R 134a is not inflammable or explosive, neither in liquid condition nor in gaseous condition

However, R 134a may light off if mixed with an air concentration of more than 60% and the pressure is above the
atmospheric pressure.
Therefore:
Never fill pressurized air into refrigerant bottles, the air condition system or into the filling station!
It is colourless and odourless.
Refrigerant in vapour state does not change the quality of food. It will not be poisoned or become inedible.
However, liquid R 134a enriched with PAG oil may corrode copper and a few types of plastic.
In case of a strong enrichment of R 134a in the breathing air difficulties of breathing may occur, as the oxygen will be
displaced by the gaseous refrigerant.
IMPORTANT!
Material damage!

Do not fill up the air condition system with the refrigerant R 12. Never mix the refrigerant R 134a with R 12!
Refrigerator oil, seal and piping materials as well as the system pressure are different with R 12 and R 134a air
condition systems.
Using the wrong refrigerant may cause chemical reactions with the refrigerator oil and corrosion of the
components.

PAG oils
PAG oils are synthetic oils that are very hygroscopic, i.e. they are storing up humidity.
Humidity reduces the efficiency of an air condition system.
Therefore:
Only use PAG oils in small barrels if possible.
Consume immediately.
Dispose of the remainders properly.
In case of storage in larger barrels, e.g. in the filling station:
Store the oil in airtight containers!

Filling amounts

Refrigerant

Filling amount

R 134 a

2000 g

Refrigerator oil

Filling amount

PAG (Polyglycol) *

207 cm3 (in case of new compressors)

* The type of oil filled in ex works is printed on the rating plate of the compressor!

IMPORTANT!
Material damage!

Too much refrigerator oil in the compressor


- reduces the refrigerating capacity of the air condition and
- may damage the system!

307.1133.3.6 englisch (en) 10.2006

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Service
Training

3
4
7

5
2

1
6
2
I0001

I0014

I0002

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Components of the air condition system


Compressor
The combine harvester is equipped with an axial-flow cornpressor with constant working volume.
The compressor is driven by means of a v-belt. Frictional connection is achieved through a magnetic clutch which is
activated when the air condition is switched on.
The compressor takes in gaseous refrigerant from the evaporator, then compresses and pumps it into the cooling circuit.
Function
The compressor is of the axial-flow type with 7 pistons and constant working volume. A slanted swash plate is actuating the
double action pistons. The pistons are guided by guide shoes.
During downstroke of the piston cold gaseous refrigerant is taken into the piston chamber. For that purpose an inlet valve
is opening between valve plate and piston chamber.
During upstroke of the piston the refrigerant is compressed. For that purpose the inlet valve is closing and the exhaust
valve between valve plate and cylinder head cover is opening.
1
2
3
4
5
6
7
8

Magnetic clutch
Connecting plug (electrical connection)
Oil fill screw
Connection pressure line to condenser
(high pressure)
Connection suction line from evaporator
(suction pressure)
Pressure relief valve (built-in only with compressor Sanden type C)
Gauge and filling port high pressure
Gauge and filling port suction pressure

Pressure relief valve


The pressure relief valve protects the compressor against damage in case of an air condition system malfunction.
IMPORTANT!
Material damage!

Chillers are suitable only for gas compression.


In case of taking in liquid refrigerant the compressor will be damaged!
Never fill up the inlet side of the compressor with liquid refrigerant!

Compressor
Magnetic clutch
The refrigerating capacity of the air condition system is controlled by activating and deactivating of the magnetic clutch.
The control unit in the cabin controls activation and deactivation of the magnetic clutch.
The high/low pressure switch located in the high pressure circuit of the system opens the magnetic clutch when the shut
down pressure (28 bar) is exceeded or when the pressure falls below 1,2 bar.

1
2
3
4
5
6

Solenoid
Retaining ring
Ball bearing
Belt pulley
Dust cover
Driving plate

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Compressor
Lubrication
The compressor is filled with 207 cm3 of special refrigerator oil.
This oil quantity is mixed with the refrigerant. It permanently circulates in the circuit and lubricates all movable components,
e.g. pistons and expansion valve. The compressor bearings are lubricated through oil holes and splash lubrication.
Checking the oil level
During operation the oil contained in the compressor is distributed within the entire system by means of the refrigerant.
When the air condition is shut down the refrigerator oil is depositing in the individual components.
Therefore the oil level cannot be checked at the compressor.
The exact oil level can only be checked by draining every component where refrigerator oil is depositing.
For this reason filling up the oil everytime requires the exact acquisition of the sampled oil amount.
IMPORTANT!
Material damage!

Too much refrigerator oil in the compressor reduces the refrigerating capacity of the air condition and may
damage the system!
Service notes
Types of oil

Quantities

PAG oil for R 134a *

207 cm3 (with new compressors)

* The type of oil filled in ex works is printed on the rating plate of the compressor!
Prior to refilling the air condition system with refrigerant
Check the oil level in the compressor.
Substitute the oil quantity (collects in the filling station) which is separated during suction resp. evacuation of the system.
Refill new refrigerator oil on the inlet side of the compressor.
Check the attachment of the compressor.
Check the v-belt tension and its proper condition.
Switch on the air condition once a month for about 10 minutes.
By this means the refrigerator oil is distributed and provides for lubrication and corrosion protection of all components in
the system.

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Notes

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4
gaseous

liquid

6
7
1
2
3
4
5
6
7
8

Container
Inlet connection
Outlet connection
Sight glass
Inlet pipe
Fine filter
Hygroscopic material
Connection pressure switch

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Components of the air condition system


Container with dryer
The liquid refrigerant is flowing directly from the condenser into the dryer.
The container with dryer has the following functions:
The liquid refrigerant is collected in the container.
The solid-state dryer stores up water and dirt particles of the refrigerant.
The dryer consists of a mixture of silica gel, molecular sieves and aluminium oxide.
These components are agglomerated to a solid body by means of resin.
Function
The liquid refrigerant enters the container at the side where it is collected. Inside of the container the refrigerant flows
through the solid-state dryer which filters off existing humidity and dirt particles.
Subsequently it continues to flow towards the expansion valve.
Humidity is the biggest problem of an air condition system.
The dryer is able to store up 6 12 g of water, depending on the type. The solid-state dryer is saturated when it has stored
up this amount of liquid. In this case the water existing in the liquid refrigerant is flowing until reaching the nozzle of the
expansion valve. There the water is freezing, thus clogging the nozzle opening. You can recognize a frozen expansion
valve when the air is flowing into the cabin alternating between cooled and uncooled.

Temperature in the cabin is


decreasing,
Refrigerating capacity normal

Expansion valve frozen

Temperature in the cabin


increasing,
no refrigerating capacity

Expansion valve defrosting

Service notes
Read liquid level at sight glass with running compressor.
The system is filled sufficiently with refrigerant:
White ball is floating inside of sight glass.
Read water absorption at sight glass.
Dryer is saturated with humidity:
Oval blue ball has changed its colour to violet.
Replace container.
IMPORTANT!
Material damage!

Never leave the dryer unsealed. The humidity of the air is saturating the solid-state dryer causing it to become
defective.
Open the sealing plug short time before mounting.
Replace the dryer every time when works are carried out at the air condition system.
Rusty spots can be seen in the sight glass:
Replace container.
When refrigerant temperatures exceed 112 C a safety fuse is smelting in the container. After draining the refrigerant the
container is defective.
Replace container.

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6
5

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Components of the air condition system


Expansion valve (TEV - Thermostatic Expansion Valve)
The thermostatic expansion valve (TEV) is the point of separation between high pressure and low pressure area in the
refrigeration cycle. The refrigerant evaporates at this location.
Through the TEV always the exact amount of liquid refrigerant evaporating under optimum conditions - is flowing into the
evaporator.
This is preventing overdosing of refrigerant in the evaporator.
This control is depending on:
Suction pressure (compressor side)
Temperature at evaporator outlet

Layout
Position

Designation

Function

Connection

Liquid refrigerant is flowing from the dryer into the TEV.

Connection

Liquid refrigerant is flowing from the dryer into the evaporator.

Connection

Gaseous refrigerant is flowing from the evaporator into the TEV.

Connection

The compressor is taking in gaseous refrigerant.

Temperature sensor

Measures the temperature at the evaporator outlet. It is filled with an agent which
is expanding when heated up.

Diaphragm

Below, the pressure of the temperature probe agent is acting (evaporator side);
above, the suction pressure is acting (compressor side).

Valve tappet

Actuates the valve 8. It is firmly connected with the diaphragm. The movement of
the valve tappet is determined by the movement of the diaphragm.

Valve

Is opened by the valve tappet. At the same time liquid refrigerant is injected into
the evaporator.

Insulating cap

An insulating cap must be mounted at the temperature probe of the expansion valve.

Function
Above the diaphragm (6) the pressure of the temperature sensor is acting, below the diaphragm (6) the suction pressure of
the evaporator outlet is acting.
When the air condition is switched off, equal pressure prevails at the diaphragm and the compression spring is closing the
valve (8).
When the air condition is switched on, the compressor takes in gaseous refrigerant from the evaporator.
At the same time the pressure in the evaporator is decreasing and because of that also the pressure below the diaphragm (6).
A differential pressure is acting at the diaphragm, as the pressure of the temperature sensor above the diaphragm is higher.
The diaphragm (6) is moved downwards. The valve tappet (7) is following this movement and opens the valve (8).
At this moment liquid refrigerant is ejected into the evaporator.
The temperature arising in the evaporator (evaporation heat) is determined by the temperature sensor. The agent inside of
the temperature sensor is changing its volume depending on the temperature and hereby determines the pressure above the
diaphragm (6). When the temperature is decreasing, the pressure is decreasing and the valve (8) is closed.
This continuous control process ensures:
- that only an amount of liquid refrigerant which can be vaporized under optimum conditions is allowed to enter the evaporator
- that the compressor only takes in gaseous refrigerant.

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Notes

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5650H - 5690HTS
Threshing mechanism
Table of contents
Combine Harvester Types

5650H
5680H
5660HTS 5690HTS

Threshing section clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 03

Installation of the threshing drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 05

Electrical concave adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 07

Concave suspension, disawner plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 09

Installation of the rear beater drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 11

Drum variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 13

Assembling the variator gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 15

Setting the variator adjusting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 17

Changing the variator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 19

Dust shields and sealing at threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .20 21

Drum reduction gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 27

Electrical turbo separator clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .28 31

Installation of maize threshing concave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 33

Threshing drum - maize threshing, weld drum bars with rosettes . . . . . . . . . . . . . . .34 35

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5650H 5690HTS
Threshing section clutch
Spring tension (A) with clutch engaged.
Gauging length (B) for the servomotor stroke (maximum stroke: 100 mm)
Length A

Length B

5650, 5660

142 mm

80 mm

5680, 5690

140 mm

82 mm

The spring tension (A) is set at the potentiometer of the relevant load relay (see Chapter C).
The stroke (gauging length (B)) of the servomotor is set by the setscrew (4). After setting, lock the nuts firmly.
Always set length A first, then length B.
If the adjustment range of the setscrew (4) is insufficient, the mounting (2) of the guide pulley (3) can be adjusted in
height. By turning the support (2) through 180, the guide pulley (3) can be positioned even higher. After each adjustment
of the guide pulley (3), the upper belt guide must also be readjusted.
1

Clutch pulley

Support

Guide pulley

Setscrew

Belt guide for clutch belt


5

Hold-down device

Upper belt guide

Front belt guide

Lower belt guide

Adjust belt guides with engaged belt such that the belt is not rubbing. The front belt guide (7) shall have a clearance of 8
mm to the backside of the belt on the entire circumference.
The hold-down device (5) must be adjusted such that the disengaged belt will not rub at the drive pulley and cannot
escape laterally leaving the running grooves.

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K006-1

8 mm

8m

7
K 0037

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K3

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5650H 5690HTS
Installation of the threshing drum
1

Flanged shafts

1.1 Flanged shaft with reducing gear


2

M12x40 screws adhesive-bonded. Screw quality 10.9 (Loctite 243)

Tightening torque of the slotted nut to the left and right: 140 Nm

Screw quality 10.9

For repairs, please note:


Always change the drum bars in pairs.
Always mount the balancing weights in the same position as they were mounted by the manufacturer.

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K0010

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5650H 5690HTS
Electrical concave adjustment

A concave clearance adjustment front, left view


(1) Servo motor for concave clearance front
(3) Bearing shaft concave suspension front
(4) Tension brackets front concave suspension
B Servo motor:
(8) Potentiometer in servo motor
(9) Slide shaft of the servo motor
C Concave clearance adjustment rear, right view:
(2) Bearing shaft concave suspension rear
(5) Tension brackets rear concave suspension
(6) Servo motor for rear concave clearance (motor is mounted horizontally!)
The stroke of both servo motors is 127 mm max. An integrated potentiometer (8) measures the displacement of the slide
shaft (9). The signal voltage of the potentiometer is processed in the Commander Control 2000 in order to display and
control the concave clearance.
Observe upon mounting the servo motors:
The resistance of the potentiometer is approx. 800, measured at the yellow and grey cable when the slide shaft (9) is
completely retracted.

Basic adjustment of concave adjustment and concave clearance:


1. Assembly dimension of the retracted servo motors:
- left servo motor (1):
402 mm
- right servo motor (6): 413 mm
Firmly secure nuts M16 (7) after adjustment.
The tension brackets (4,5) must not touch the bearing shaft (2,3) with retracted servo motor (1,6).
2. Basic adjustment of the clearance between concave and threshing drum by means of readjusting the tension brackets
(4,5). Servo motors are completely retracted:
The display - indication for the Concave Clearance front (11) and rear (12) is set to position 1.
Concave clearance

concave
Cereals

maize

Front

4th rail: 6 mm

3rd rail: 30 mm

Rear

last rail: 3 mm

last rail: 10 mm

After installing (or replacing) the servo motors calibration of the concave adjustment must be carried out with the
Commander Control 2000. At the same time both servo motors are completely extended and retracted and the corresponding potentiometer values are stored.

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2
3

402

2x
3

Set clearances

35
16052636-1

11

12
1

35403

B
8
5
413

16052636-2

56-078

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3
2
4

5
5

7
7
6

K0601-2

2
1

K0038

K0039

K8

K0040

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5650H 5690HTS
Concave suspension, disawner plates
1

Servo motor for concave clearance front

Bearing tube for concave suspension rear

Bearing tube for concave suspension front

Tension plates front

Tension plates rear

Servo motor for concave clearance rear

Sealing plate

Disawner plates
1

Disawner plates 1 to 5

Control lever

Locking rod for fifth disawning plate

Tightening screw for locking rod

The fifth disawning plate can be removed if required. For this purpose loosen screw (4) and remove locking rod (3).
Adjustment of actuation via oblong hole at control lever:
Upon closing of the disawning plates the control lever must revolve under tension beyond the dead centre.

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5650H 5690HTS
Installation of the rear beater drum
1

Premounting dimension for inserting the shaft in the rear beater drum

Radial eccentricity of the installed shaft max. 0.2 mm

Assembly dimension for the complete beater drum

Check that the beater drum is positioned centrally in the threshing channel

Direction of rotation

Lubrication hole
Check prior to assembly of a new bearing whether the lubrication hole (6) in the bearing case and the lubrication
groove in the outer bearing race are lying upon each other.

5650H 5690HTS
Rear beater with synchronous drive (as of year of manufacture 2007)
1

Threshing drum shaft

Beater shaft, tubular shaft and stub shaft screwed together

Beater mounted on shaft (2)

Right bearing cover

Inner bearing flange

Outer bearing flange

Tension device for v-belt

Dimension A: Assembly dimension for beater on the shaft


Dimension B: Reference dimension for beater with shaft and frame
Mounting instruction:
Install pre-assembled shaft in beater.
Insert pre-assembled beater in the frame and tighten outer bearing flange (6) while supporting beater on the right side.
Align v-belt pulley on the threshing drum shaft with the v-belt pulley for the beater.

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K0014-3

0,2

150

298.5

4
5

7
298.5

A
2

89.5

283.5

B
4

5
6

20
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K0017

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5650H 5690HTS
Drum variator
1

Nut tightening torque 460 Nm, secured with DW 59 adhesive.


Fit the fixed pulley by hammering the sliding pulley. Retighten the nut with 460 Nm.
Special tool for loosening the fixed pulley: 0043 6020

Clean the cavity, especially before and after rape threshing

The journal must be parallel to the beater drum: align with shims if necessary.

Shim

Paste cover with silicone

Inspection dimension for belt alignment

Loosen support strut only when belt is slack

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5650H 5690HTS
Threshing section
Assembling the variator gear
1

Shims for aligning the reduction gear

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K0018

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K0019

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5650H 5690HTS
Setting the variator adjusting mechanism
Remove the belt and adjusting mechanism of the variable-speed drive.
Push the sliding pulley on to the fixed pulley. Insert the 1 mm feeler gauge between the contact surfaces.
Measure dimension D with inserted pressure ring (1).
At the variator adjusting mechanism, screw the adjusting ring (3) on to the adjusting sleeve
until dimension D is attained.
Adjust the guide ring (2) so that the cams of the setter ring (2) and adjusting disc (3) prevent any further rotation
of the adjusting disc (3), and an axial distance of at least 0.5 mm is provided in the cam area.
Secure the setter ring (2) with 2 cheese-head screws.
Turn the adjusting disc (3) back one turn; the cams must not touch each other.
Install the variator adjusting mechanism and set the drive to reduced speed.
Set the variator adjusting mechanism to higher speed until the chain sprocket blocks.
Check gap S of 1 mm between the control pulleys.
If the variator was dismantled: screw the stop-nuts (4) on to the guide bolts so that when the adjusting mechanism is set
to reduced speed the variator belt does not slip out of the lower control pulleys nor stick in the upper control pulleys.
Note:
The variator adjustment must be reset for all machines in which the control pulleys stick when increasing the speed.

Individual components of the variator adjusting mechanism


1

Pressure disc (check installation position)

Setter ring

Adjusting disc

Stop nuts

Ball-bearing C4 (more bearing tolerance as normal)

Determine dimension D between inserted pressure disc and gap S = 1 mm

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5650H 5690HTS
Changing the variator belt
1. Set the variator to maximum speed in order to open the driven pulley.
2. Screw in the two hexagon-head screws (M16x140) in order to hold the driven pulley open to its maximum distance
(the screws are included in the on-board tool kit).
3. Open chain of servo motor.
4. Turn sprocket (1) clockwise in order to open the traction sheave.
5. Take out nuts (C) and swivel struts sidewards. Replace belt. Thoroughly clean the space between the pulley halves.
6. Reassemble in reverse sequence.
7. After mounting a new variator belt, set the variator to maximum and minimum speed.
Check that the belt does not stick in one pulley set or jump over the rim of the other pulley set.
If necessary, readjust the stop nuts of the upper variator pulley or reset the adjusting mechanism.
The servomotor (B) for adjusting the speed of the threshing drum is fixed to the mounting plate (A).
The pressure spring (2) of the idling pulley must be set to a length Q = 150 mm.

Sprocket

Pressure spring

A Mounting plate
B Servomotor
C Nuts

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M16
M16

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5650H 5690HTS
Dust shields and sealing at threshing mechanism
3 Sealing
4 Dust shield in front of threshing drum (should be removed when threshing maize)
5 Dust shield with sealing strip (5.1) above the threshing drum
6 Dust plate (spring-loaded) behind the rear beater; only in case of combines without turbo separator.
7 Deflector curtain
8 Sealing
9 Sealing (felt strip)
The clearance X of the dust shield (4) and the sealing strip (5.1) must not exceed 10 mm. If the clearance is too big or in
case of a damaged dust shield excessive dust formation may occur at the feed passage inlet.

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5
5.1

X
6

X
4

7
8
9

307.1133.3.6 englisch (en) 10.2006

K0027-1

K 21

K
Service
Training

5650H 5690HTS
Drum reduction gear
I

Direct drive 1:1


Belt pulley (6) connected to driver (7) by stud (5).

II

Reduced speed 1:1.93


Driver (7) connected with frame side wall via stud M16 x 1.5 (5) (position approx. 11 o'clock)

Screw tightening torque 210 Nm

Molykote long-term 2PLU

Stud

Belt pulley

Driver

Fitting washer if necessary

Important:
If required, install washers (8) between inner raceway of the bearing and shaft shoulder for proper centring of the threshing drum in the threshing canal.
On mounting the reduction gear shaft, first tighten the M16 screw (3) and then the clamping sleeve bearing on the left.
Tighten the stud (5) at the latest after 10 operating hours at reduced speed.

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120 Nm

K0025-1

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II

K0026-2

56-079
K0027

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5650H 5690HTS
Drum reduction gear
Converting to reduced speed
Fix driver of the gear at the sidewall by means of threaded bolt (position approx. 11 o'clock).
1

Threaded hole for puller screw M16 x 1,5

5650H 5690HTS
Oil changing, Checking oil level
To drain the transmission oil, rotate the reduction gear so that the screw (1) is at the bottom.
Oil filling: 1 litre transmission oil SAE 90, API GL 5
To check the oil level, rotate the gear so that both shafts (planetary gear set and compensating weight) are horizontal and
the inspection screw (1) is at the bottom left.
1

Control and drain plug

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K 25

K
Service
Training

5650H 5690HTS
Drum reduction gear
Replacing individual parts
The components of the reduction gear are individually interchangeable, except for the special features described below.
When replacing the V-belt pulley (1) or the complete housing, it is necessary to balance the gear unit statically with
approx. 1 litre of oil at a speed of at least 300 rpm after completing assembly (balancing holes on the web of the V-belt
pulley with R 202, 20).
Balancing on the balancing block or balancing without oil are not permitted.
The driver (2) must be separately balanced with the stud (3) and O-ring (4).

V-belt pulley

Driver

Stud

O-ring

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K0028

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6
K0029-1

405

5
A

K 28

25

30

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5650H 5690HTS
Turbo separator
Distance of the turbo separator drum to the separator concave in the lowest position.
Distance B last bar 25 mm
Distance A first bar approx. 30 mm
1

Installation length for turbo separator shaft

Tightening torque for the clamping sleeve bearing to left and right: 140 Nm

Fixing of the paddle bars with Allen screw M12x30 and support washer 1601 5594
Tightening torque 120 Nm for screw and nut quality 10.9
Always replace paddle bars in pairs

Adjusting movement

The transfer rack must rest on the separator concave

Separating grate

5650H 5690HTS
Electrical turbo separator clearance adjustment
1

Servo motor

Control shaft

Tie rod

Bearing plate

Guide plates

Basic adjustment:
Assembly dimension of the retracted servo motor:
Clearance between turbo separator drum and separating grate:

405 mm
30 mm (at grate inlet)

Adjustment at the tie rods (3) left and right must be done with completely retracted servo motor.
The basic adjustment of the turbo separator drum can be checked approximately from outside:
Vertical distance between bearing plate (4) and guide plates (5) = approx. 5 mm.

Control and calibration of the servo motor is identical with the concave adjustment.

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5650H 5690HTS
Turbo separator - drive
The turbo separator is driven by a double V-belt from pulley A to pulley B.
Pulleys A and B are of 2-stage diameter for two speed ranges.
The speed ranges and drum spacing are selected on the basis of the threshing table.
Speed
range

Speed
rpm

Pulley

V-belt on:
Pulley

790 20

A1

B1

II

380 20

A2

B2

For maize and sunflower threshing, the slow speed must be set.
Moving of v-belt:
Slacken tensioning pulley C, (attach tube at pin (1)) lock clamping arm with bolt (2).

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1
33648

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5650H 5690HTS
Installation of maize threshing concave
When converting to maize threshing, the standard-fitted stone trap (3) and front plate (4) must be removed.
Mark out the operating rods (6) for the stone trap on the intake plate (2).
Remove the dust cover (7) for maize threshing.
Hook maize concave into lower borehole (1) of the front tension plates.
Basic setting of the concave
Concave intake

Concave discharge
Last bar

Maize concave version


Maize concave
(10 Concave bars))

3rd bar

30 mm

10 mm

CCM-concave

2nd bar

30 mm

10 mm

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5650H 5690HTS
Threshing drum - maize threshing
Weld drum bars with rosettes
1

Start of seam

Weld rum bars with rosettes

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Notes

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5650H - 5690HTS
Cleaning system
Table of contents
Combine Harvester Types

5650H
5680H
5660HTS 5690HTS

Straw walker drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 03

Setting the drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 05

Mounting the straw walker bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 07

Mounting the straw walker shafts and straw walkers . . . . . . . . . . . . . . . . . . . . . . . .08 09

Mounting of straw walker guide rakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 11

Sieve pan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 13

Grain pan with removable segments

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 15

Grain pan, sieve box with drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 17

Fan variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 19

Fan Airflow guide system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 21

Returns elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 23

Electrical sieve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 25

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5650H 5690HTS
Straw walker drive
The rear straw walker shaft is driven by V-belt. The compression spring (1) for the idling pulley is set to a tension length
of 70 mm. The guide pulley (2) is height-adjustable. The straw walker speed can be adjusted if required by mounting or
removing additional spacing discs (3) on the rear V-belt pulley.

Compression spring

Guide pulley

Spacing discs

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5650H 5690HTS
Setting the drives
spring-loaded idling pulley
1

Spring tension 72 mm.

Idling pulley for sieve crankshaft drive belt


2

Spring tension 65 mm.

Tensioning sprocket for the grain auger drive chain


3

Spring tension 60 mm.

Slipping clutch as overload protection for the grain auger. Response torque approx. 400 Nm with cup spring bias set
to a dimension of 22 mm.

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L0006

2
L0007

L0008

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L0010

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5650H 5690HTS
Mounting the straw walker bearings
Mounting instructions:
Degrease shaft and sleeve
Wet the inner bearing ring with oil (hydraulic fluid)
Set the sleeves by hammering in the axial direction
Observe equal distance of clamping sleeve halves to each other

Slotted nut
Mount outer bearing with the slotted nut facing the centre of machine.

Degrease the bearing seat and outer bearing ring.


Secure the outer ring at 3 points of its circumference with liquid locking agent.

Tightening the slotted nut:


Pretighten to 50 Nm
Then tighten fully by turning 180
Slotted nut wrench 0041 6050

Cover plate
In case of combines without turbo separator, a cover plate is mounted at the front straw walker shaft on all bearings.

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5650H 5690HTS
Mounting the straw walker shafts and straw walkers
1.

Centre the straw walker shafts axially in the frame, so that the distance of the outer straw walker bearings to the side
wall is equal. The distance between the rear straw walker shaft and front straw walker shaft must be equal on the left
and right-hand sides (orientation on the paint mark of the rear bearing housing).

2.

Install all straw walkers and tighten the front straw walker bearing securely; the rear straw walker bearing should be
hand-tightened only. Turn the straw walker shafts by hand to synchronise the cranks.

3.

Tighten the bearings of the outer straw walkers and turn the shafts by hand. The effort required must be equal. If this
is not the case, loosen the bearings again and turn the rear shaft slightly to set precise synchronism with the front
shaft. Repeat the process.
If the oblong holes in the rear straw walker bearing blocks are not sufficient, the rear shaft must be shifted horizontally
(oblong holes in the straw hood).

4.

Tighten the other straw walker bearings one by one, in each case turning the straw walker shafts by hand. At the
bearings that have still not been tightened, there must be no displacement between the bearing housing and straw
walker bearing block during one revolution.
If different resistance is encountered when turning the straw walkers, one of the straw walker shafts may be bent or
twisted (if there is no bearing damage).
Bent or twisted straw walker shafts must be replaced.

5650H 5690HTS
Installation dimensions for straw walker shafts and bearings
1

Straw walker shaft, rear

Straw walker shaft, front

The long shaft end must be on the right-hand side

Combine Harvester Number of


Types
Straw Walkers

Dimensions
c

Tightening torque

5650 5660

206

206

252

237

1008

Prethigtening torque 50 Nm

5670 5690

206

206

252

237

1260

+ Retightening angle180

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left machine side

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3
2
1

5650 5660

5670 5690
L0020

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5650H 5690HTS
Mounting of straw walker guide rakes (Optional extra)
Arrangement of straw walker rakes
8 units for 5650 5660
9 units for 5670 5690

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5650H 5690HTS
Sieve pan drive

Mounting the sieve crankshaft


1

Special tool for tightening the slotted nut: 0043 6070

Crank drive
1

Bearing support

Support plate

2.1 Bolt M14, 10.9


2.2 Bolt M10
3

Swinging arm

Connecting rod

Head bearing

The support plate (2) must rest in parallel at the face side of the bearing support shaft (1). Tighten bolt M14 (2.1) first and
then check the position of the support plate versus the bolting face at the frame. Adjust support plate or add spacer discs
as necessary.

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L0015

2.2

2.1

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5650H 5690HTS
Grain pan with removable segments

When installing the segments (2), make sure that they engage in the catch (1.1). The segments are fixed to the grain pan
frame (1) through the front cover (3).
Front cover (3) is attached at the grain pan frame by means of 3 nuts (4).

Installation of the grain pan rocker


A: Standard combine harvester
B: Balance combine harvester
5

Rocker

Distance plate

Spacing sleeve

Assembly and length (L) of the grain pan rockers (5) is different for standard and balance combine harvesters.
A: Standard combine harvester: L = 232 mm.
A distance plate (6) shall be installed on the frame between the lower bearing case and the bearing support
B: Balance combine harvester: L = 210 mm.
The spacing sleeve (7) shall be installed between upper bearing case and grain pan.

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L0024-3

L
6
L0049

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L0027-2

L0028

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5650H 5690HTS
Grain pan, sieve box with drive
1

Pitman rod basic setting 584 mm

Rocking lever

2.1 Sleeve bearing


3

Bearing block horizontally adjustable on the left-hand side

Grain pan

4.1 Grain pan rocker


5

Sieve box, top

5.1 Graepel sieve cartridge


6

Sieve box, bottom

Straw walker return pan

Suspension for bottom section of sieve box, straw walker return pan

Rocker for top section of sieve box and straw walker return pan

9.1 M12 screws


9.2 Bearing blocks
The grain pan and sieve box sections must rock longitudinally in parallel in the frame. The guide shoes (a) must not touch
the frame side walls. If necessary, the length of the pitman rod (1) must be adjusted to the left or right. Also, the left-hand
bearing block (3) can be slightly adjusted horizontally.
During assembly, the grain pan and sieve box top and bottom sections (4, 5 and 6) on the rocking lever journals must be
precisely adjusted to one another in the axial direction to ensure sufficient clearance between the moving parts.
The axial play of the sleeve bearing (2.1) must be compensated with spacing discs.
The housings of the rubber bearings for the suspension (8) of the grain pan, sieve box bottom section, straw walker
return pan and the M12 screws (9.1) of the rocker (9) must be tightened with the rocking lever (2) in the mid position.
The rockers (9) must be mounted free of strain. The guide shoes (b) of the straw walker return pan must not make contact
with the frame side walls. If necessary, adjust the position of the bearing blocks (9.2).
Observe different length L of grain pan rocker with standard and balance combine harvesters:
Standard: L = 232 mm
Balance:
L = 210 mm
The Graepel sieve cartridge (5.1) is screwed in the upper part of the sieve pan (5) and its inclination is adjustable. The
inclination shall be in parallel with the grain pan (4).

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5650H 5690HTS
Fan variator
1

Servomotor

Swivelling variator

Tensioner for lower variator belt


Spring tension 90 mm at maximum revs

Compression spring

Adjusting nuts

Nuts

Bearing pin

Sliding pulley

Fixed pulley halfs

10 Grease nipple
Settings on the variator

Retightening the variator belt:


Set the swivelling variator (2) to the mid-position.
Loosen the bearing pin (7).
Retighten the belt with the adjusting nuts (5), fully turning the threshing mechanism.
Retighten the bearing pin (7).

II

Setting the variator adjustment range:


Set the swivelling variator to the end positions
(maximum and minimum speeds).
A gap S of at least 1 mm must remain between the sliding (8) and fixed (9) pulley halves.
Set the adjustment range using the nuts (6) on the mounting of the servomotor (1).
After adjusting, lock the nuts (6) tightly against one another again.
Check the adjustment range with every belt change.

Notes for operation and maintenance:


The variator should not be run continuously at constant speed for a long period.
At least once a day, the fan speed should be slightly modified.
The contact surface of the sliding pulley half must be lubricated at least once a day.
Grease nipple (10).

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L0040

L0041

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5650H 5690HTS
Fan Airflow guide system
1

Fan drum

Sealing plate

Diffuser wedge, lower

Diffuser wedge, upper

Adjusting lever left and right

Tuning scale left and right

Cover

It is possible to adjust the slope of the upper diffuser wedge (4) around the centre of rotation (z) by means of the adjusting
levers (5). The numerical value on the tuning scale (6) corresponds to the clearance between the leading edge of the
diffuser wedge (4) and the top of the wind duct.
The adjustement affects the amount of wind at the step between the grain pan and the sieve pan.
Small tuning scale value: less amount of wind at the step
High tuning scale value: more amount of wind at the step
A scale value of 20 is factory pre-adjusted.
In case of slightly granular threshing material (e. g. rape, oat) adjusting a smaller scale value (e. g. 15) might possibly be
more advantageous.
By this, observe a balanced adjustment on the left and on the right side.

Sequence for inspecting or setting the installation position:


a

Ensure that the fan drum (1) is parallel to the trough and is axially centred.

b Ensure that the sealing plate (2) is parallel to the fan drum.
The sealing plate (2) must lie flush with the air housing over the full width of the machine.
c Ensure that the diffuser wedge (3, 4) is parallel in the air passage.

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12-1

Z
20

100

0,

12+1

92

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L0045

4.1

35

6.1

4
M005

6
L0046

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5650H 5690HTS
Returns elevator
1

Elevator auger

Scoop wheel

Stepped pulley slow speed for threshing maize and beans

Cover with replaceable friction insert smooth or fluted

Momentary-contact switch ("make" contact) on left and right for monitoring the cover (when the cover is closed,
the switch is pressed).

Speed monitor distance between sensor (6) and puls transmitter (6.1): 4 mm

Centre the scoop wheel (2) in the housing before wedging it to the auger shaft.
Check installation position: the smooth surface of the scoop must face the direction of rotation.
Replace damaged scoop wheels risk of damage due to unbalance.
Check the installation position of the pressure clip (4.1) for the returns elevator cover (4).
The short side of the pressure clip must press against the cover (4).
Compression spring tension: 35 mm

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5650H 5690HTS
Electrical sieve adjustment
1

Servo motor (stroke 115mm) with integrated potentiometer (1k)

Control shaft, integrated in the sieve pan

Lever bracket on control shaft in upper sieve pan

Lever bracket on control shaft in lower sieve pan


Observe mounting position of lever brackets.
Brackets for upper and lower sieve are different.

Ball pivot for sieve adjustment (1 ball pivot for every sieve unit)

Ball socket

Adjusting device on every sieve unit

Adjusting rail for sieve plates

Upper resp. lower sieve

Function of adjusting device:


The stroke of the servo motor (1) is transferred to the adjusting rail (8) of the sieves (9) via the control shaft (2) through
the ball sockets (6).
The sieve plates are opening when the servo motor is retracting,
the sieve plates are closing when the servo motor is extending.
Basic adjustment of the adjusting device (7):
When the sieve plates are closed the ball socket (6) must project 42 mm over the front edge of the sieve. With mounted
sieves the servo motor must be completely extended when the sieve plates are closed.
Removal of the sieves:
Loosen sieve fixation (it is mandatory to always loosen both sieves, even if only one sieve shall be removed).
Press push-button switch for opening sieves until the servo motor is completely retracted; at the same time the ball
pivot (5) is swinging out of the ball socket (6).
The sieves can now be drawn out.
Installation of the sieves: (servo motor must be completely retracted)
Clear sieve guides from grains and chaff, especially the front sieve stop.
Insert sieve in sieve pan until ball socket (6) engages in ball pivot (5).
Press push-button switch for closing sieves; check at the same time whether the sieve is pulled to the front resp.
whether the sieve plates are closing.
Mount the sieve fixation.
Completely open upper and lower sieves by means of push-button switch and close halfway; check whether the sieve
opening at the right and the left side is the same.
If the sieve opening is not the same the ball socket (6) at the adjusting device must be readjusted.
Calibration of the sieve adjustment for upper and lower sieve: (see instruction manual TERIS/TCS)

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+
+ POTI ROT 1
Signal
signal POTI TRANS 2
POTI SCHWARZ3

6 Blindstopfen
5 MOTOR SCHWARZ
4 MOTOR GELB

4
2

115
9

25

27

31

42

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Notes

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5650H - 5690HTS
Grain elevator, grain tank
Table of contents
Combine Harvester Types

5650H
5680H
5660HTS 5690HTS

Grain elevator with elevator head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 03

Elevator head, speed monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 05

Elevator head at grain tank extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 07

Elevator head with TCS (grain throughput measurement) . . . . . . . . . . . . . . . . . . . . . . . . . .08 09

Grain tank clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 11

Grain tank unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 13

Unloading system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 15

Angular gear inside of tube bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 17

Support for grain tank tube, Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 19

Level transmitter, sensor for grain tank cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 21

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5650H - 5690HTS
Grain elevator with elevator head

Grain tank filling auger

Fixing plates for elevator chain

Chain wheel for elevator chain

Distance collar

Chain wheel Z13, or Z18 for increased speed in case of maize threshing

Cardan joint

6.1

Connection cardan joint - filling auger

Elevator housting

Elevator chain

Grain auger

10

Ratchet clutch

Assembly instructions:
-

Shift grain auger (9) entirely to the right while assembling, so that the distance collar (4) is resting against the inner
raceway of the bearing. Tighten the adjusting ring at the right side first.

The elevator chain (8) must be guided by the chain wheels (3) centrically inside of the elevator shaft. Center the chain
wheels (3) in the elevator shaft by means of adjusting washers if necessary, resp. shorten the distance collars (4).

Tensioning of the elevator chain:


Readjust fixing plates (2) evenly by means of the tightening screws left and right.
The elevator chain is to be tensioned only as far as the chain links can still be moved laterally at the lower chain wheel (3).

The belleville springs of the ratchet clutch are arranged individually in an opposite direction on the hub.

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1
4

M030

6.1

M040-1

M 001-1

10

3
4

M031

22

10

L0001-1

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2
3

6
6

7
4

M032-1

M4

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5650H - 5690HTS
Elevator head, speed monitoring

Sealing at feed pipe

Fixing plate for elevator chain

Elevator head

Sealing between elevator housing and bottom of grain tank

Running direction of elevator chain

Speed monitoring:
6

Pulse transmitter

Inductive sensor (distance to pulse transmitter 4 mm)

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5650H - 5690HTS
Elevator head at grain tank extension

Feed pipe with auger, swiveling to the top together with extending the grain tank extension.

Pedestal bearing

2.1

Sealing washer

Auger flight

Short Feed auger

Full floating axle

Observe the right position of the feed augers and of the auger flights (3) to each other while assembling.

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1
2

20
o

3
4

M011

X
2
2.1

M010

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1
2

5
M013

M014

1
3

M012

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5650H - 5690HTS
Elevator head with TCS (grain throughput measurement)

Tensioning the elevator chain


Check the following dimension subsequent to tensioning of the elevator chain:
The dimension (A) between guide plate (1) and rubber sheet (2) amounts to 12 mm

Replacement of elevator chain or guide plate


Subsequent to replacing the elevator chain or the guide plates:
Adjust the dimension (A) between rubber sheet (2) and guide plate (1) to 12 mm.

Checking cover with sealing


Observe passage (B) while mounting the cover (3) or the deflecting plate (4)!
Mount resp. adjust the cover slightly lower as against the deflecting plate, as shown in fig. M012.

Replacement of the grain humidity sensor


Observe the mounting position while replacing the sensor (5)! The arrow on the sensor must point from the ascending
pipe to the outside.

Service notes
Clean the deflecting plate (4) at the throughput sensor periodically.
At ascending pipe in front:
Clean grain humidity sensor (5) periodically.

307.1133.3.6 englisch (en) 10.2006

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5650H - 5690HTS
Grain tank clutch

Tensioning rocker

Belt guides

Compression spring

Servo-motor

Adjusting nut

Adjustments when engaged:


-

Initial tension of spring A = 135 mm (for adjustment at clutch control power unit, see chapter C)

Stroke of the servo-motor B = 60 mm (adjustment at the adjusting nuts (5). Fix nuts strongly by a locknut.

Clearing between the belt guides (2) and the V-belt 8 mm.

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M037

1
4
M021

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4
2

31653

M 12

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5650H - 5690HTS
Grain tank unloading

Feed auger inside of grain tank

Roofing sheet

Mounting for roofing sheet on right side

Adjusting plates

The purpose of the adjusting plates (4) is to limit the flow of material to the feed auger, depending on the pourability of the
harvest material. In case of overload of the unloading system (slipping through of V-belt) the adjusting plates must be
adjusted lower.
In case of hardly pourable harvest material (e.g. grass seed) it is possible to hang up the roofing sheet (2) on the right
side in the upper borehole of the mounting (3).

307.1133.3.6 englisch (en) 10.2006

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5650H - 5690HTS
Unloading system

Lower angular gear

Slewing rim

Ascending auger

Close-tolerance bolt M12, 10.9

Belleville spring

Locknut M12

Upper angular gear

7.1

Fastening screws

Tappet with bushings

Feed auger inside of unloading tube (divided at 5 m tube)

10

Pedestal bearing at 5 m tube

11

Bearing

12

Supporting rings

13

Spring pin

Assembly instructions:
1. Observe the mounting position of the pedestal bearing (10) and the position of the auger flights while mounting the
augers inside of the unloading tube. A projection length of 88 mm between auger shaft and unloading tube is to be
adjusted by means of a corresponding number of supporting rings (12) between bearing (11) and spring pin (13).
2. Observe the position of the auger flight of the ascending auger (3) and of the tube auger (9) while assembling the
unloading tube to the tube bend.
3. Subsequent to mounting of unloading tube the fastening screws (7.1) for the angular gear (7) are to be loosened.
Rotate the unloading system slowly. In the course of this the angular gear will be aligned towards the augers.
Retighten the fastening screws (7.1).

Tighten the locknut M12 (6) on the close-tolerance bolt (4) carefully such that the belleville
spring (5) is being tensioned.
Secure nut with loctite.
Observe mounting position: Plate spring (5) and locknut (6) must be mounted on the spot
faced circular area of the auger shaft.

M 14

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Training

3
M028

2
1

90Nm

10

M038

8
11

7.1

12

13

5
6

90Nm
M019

M036-1

88

M039

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M 15

M
Service
Training

2
3

1
3

M022

M023

1
5
4

M025

M 16

M024

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Training

5650H - 5690HTS
Angular gear inside of Tube bend

Insert the pinion shafts such that the boreholes are out-of-line to each other by one tooth.

Adjust tooth clearance of 0,2 mm between casing cover and bearing by means of fitting washers.

Fill hollow space between casing cover and bearing with grease.
Packing of grease inside of casing approx. 250g EP of gear grease

5650H - 5690HTS
Lower angular gear
Oil filling
Gear oil SAE 90, GL5

0,75 l

Tooth clearance

0,15 - 0,40 mm

Moment of friction primary shaft (1)

0,4 - 0,8 Nm

Moment of friction output shaft (2)

0,1 - 0,4 Nm

Hollow space between bearing and rotary shaft seal at the output shaft (2) is to be filled with grease.

Oil-level plug,

Lubricant nipple,

Check contact pattern of the tooth faces subsequent to replacing pinion shafts resp. bevel
wheels or bearings.

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M 17

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Training

5650H - 5690HTS
Support for grain tank tube, Interlock

Support, adjustable in height

Latch

Tension spring

Unlatching cylinder

Inductive sensor

The message "grain tank tube swivelled out in the cabin is activated through the inductive sensor (5). The inductive sensor
(5) continues to be connected with the electronic control system for the grain tank clutch: When the grain tank tube is swung
in, the grain tank clutch will automatically be disengaged if no manual shut-down has been caused by the driver.
The grain tank clutch control is blocked in case of a defective or not connected sensor (5).

Before driving on public roads, check whether the latch (2) of the grain tank tube is engaged!

5650H - 5690HTS
Hydraulic actuation grain tank tube swivel
1

Console

Supporting screw with Insulating plastic tube

Lifting cylinder

Head piece

Shift lever

Ascending pipe

Screw down supporting screw (2) as far as the sidewall of the frame.
Adjust head piece (4) on the piston rod such that the unloading tube is pulled entirely into the support (pos. 1 on top).

M 18

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1
3
4

M026-1

2
1

3
6
4

5
112

M027

307.1133.3.6 englisch (en) 10.2006

M 19

M
Service
Training

TOP

1
2

2
4

25

M035

M 20

307.1133.3.6 englisch (en) 10.2006

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Service
Training

5650H - 5690HTS
Level transmitter, sensor for grain tank cover

Level transmitter Grain tank full

Level transmitter Grain tank 80% full

Sensor for grain tank cover

Position of closed Grain tank cover and lowered Grain tank extension

A clearing of at least 25 mm between the face of the transmitter and the clamping jaws must be observed while mounting
the level transmitters (1) and (2).
Clean level transmitters periodically. The message "Grain tank full will not be deactivated any more by the transmitter in
case of adsorption of humid dust or chaff.

307.1133.3.6 englisch (en) 10.2006

M 21

M
Service
Training

Notes

M 22

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Training

5650H - 5690HTS
Cutting mechanism
Table of contents
Typ of cutting mechanism

HMW 1131-1133

Schematic diagram of drives, Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 03

Cutting mechanism drive, Reel variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 05

Slip clutch for feed auger and reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 07

Feed auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 09

Settings of feed auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 11

Cutter gear unit

80 mm stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 13

85 mm stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 15

Inspection of cutter actuation, Cutter replacement . . . . . . . . . . . . . . . . . . . . . . . . . .16 17

Potentiometer installation in case of cutting mechanism control . . . . . . . . . . . . . . .18 19

Connector pin assignment 13-pole plug-socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Wiring layout and circuit diagram for hydraulic system at rape attachment . . . . . . . .22 23

Rape attachment drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 25

307.1133.3.6 englisch (en) 10.2006

P1

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HMW 1131 - 1133


Schematic diagram of drives, Speeds

Speed
1

Drive shaft

480 20 min 1

Reel variator

260 - 860 min-1

Double chain wheel (series Z55/7)

Reel at double chain wheel (3) Z55/7

15 - 49 min-1

at double chain wheel (3) Z75/7


5

Cutter gear unit with 80-90 mm stroke


130 mm stroke

P2

11 - 36 min-1
600 20 min-1
580 20 min-1

Feed auger

192

min-1

reduced speed

172

min-1

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4
3
2

5
6

32861/2-1

307.1133.3.6 englisch (en) 10.2006

P3

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Service
Training

12
11
8

10

7
6
4
4.1
P001

X
5

200
Nm

5.1

3.1

11

10

63,5
2.2

2.1

P002

1
225

P4

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Service
Training

HMW 1131 - 1133


Cutting mechanism drive, Reel variator

Drive shaft

Variator pack - driving

2.1

Chain wheel for feed auger drive

2.2

Thread hole M16 for pressing on the sliding pulley in case of v-belt replacement

Variator pack - driven

3.1

Chain wheel for reel drive

Thrust washer

4.1

Counter nut

Bearing shaft for variator pack

5.1

Locating screw

Tie rod

Stop washer

Adjusting spindle

Distance bush

10

Circlip

11

Driving pin

12

Angular motor

Control dimension 63,5 mm for belt alignment, measured between fixed pulley and fixed pulley.
Setting of variator adjustment: (v-belt is removed)
Pull in the tie rod (6) by means of angular motor until the adjusting spindle (8) is blocked. Screw on thrust washer (4)
to the tie rod (6) as far as there remains a distance of 1 mm at the bottom of the pulley halves (X). Secure thrust
washer (4) by means of counter nut M10 (4.1).

307.1133.3.6 englisch (en) 10.2006

P5

P
Service
Training

HMW 1131 - 1133


Slip clutch for feed auger and reel

Slip clutch for feed auger, chain wheel 3/4.

Slip clutch for reel

Hub

Pressure plate

Chain wheel

Friction linings (the chamfer (a) of the linings must point to the pressure plate in case of clutch C)

Plain bearing bush, install by applying grease

Round head cap screws, grade 8.8

Ratchet, blocking the slip clutch while reversing

Slipping moment with factory setting:


Slip clutch

A: 700 Nm
B: 350 Nm

Release slip clutch after a longer standstill period and let it slip through.

P6

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4
1

40

2
P003

75
Nm

P005

B
3

1
21

P047

2
4
P006

307.1133.3.6 englisch (en) 10.2006

P7

P
Service
Training

12

12

P007

P050

12

5
14

13
10
9
7
8
M008

11
12

P8

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Service
Training

HMW 1131 - 1133


Feed auger

Drive shaft

Bearing plate

Adjusting segment for feed finger

Bearing shaft and drive shaft right

Bearing shaft for feed finger

Intermediate shaft with bearing

Single finger

Feed finger in centre of auger

Finger stroke

10

Spring clip

11

Spring pin (loss protection)

12

Clamping piece

13

Attachment screw M12x50; 10.9

14

Close-tolerance bolt M12x70; 10.9

Removing feed auger: Disassemble adjusting segment (3) and bearing plate (2) on left and right side.
Roll out auger from the cutting mechanism trough on the right side.

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P9

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HMW 1131 - 1133


Settings of the feed auger

Bearing plate for feed auger

Adjusting segment for feed finger control

Stripper, two pieces

Feed finger

Drive shaft for feed finger

The standard distance between auger flight and cutting mechanism trough amounts to 6 - 12 mm. In case of coarse
harvest material (e.g. rape, field beans) it may be necessary to adjust the auger higher, to approx. 20 mm distance. The
height adjustment is done on the left and on the right side at the bearing plate (1). Afterwards the strippers (3) are to be
readjusted: Adjust stripper as close as possible to the auger flight in order to avoid coiling up of the auger.
The drive shaft (5) for the feed fingers is turned round by means of the adjusting segment (2).

Extension for auger flight (mounted in case of combine harvesters equipped with 5 straw walkers)

Feed angle between the feed fingers:


- 1x long, 2x short feed angle
toothed feed angle as from year of construction 2001

P 10

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5
2
1

P046

6-12 mm
P011

6
P048

307.1133.3.6 englisch (en) 10.2006

P 11

P
Service
Training

7
5

1.1
X

1
2

8
P014

9
X

10

B
4.1

3
4
H
X
4.1

P013-1

C
P015

11

5
6

12

13

P016

P 12

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Service
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HMW 1131 - 1133 and rape attachment


Cutter gear unit 80 mm stroke

up to cutting mechanism no. 29107 from 3 m up to 7,20 m


as from cutting mechanism no. 29108 from 3 m up to 4,80 m

Belt pulley halves

1.1

Spacer disks, 4 pieces

Casing

Rotor

Crank (colour mark in tooth gap to crankpin)

4.1

Crankpin

Needle roller bearing

Sealing washer

Borehole for lubricating grease, 6 mm

Circlip

Pinion (dot mark on face)

10

Gear ring

11

Crank end

12

Crankshaft bearing

13

Adjusting washers

Bearings are glued in place at the outer ring, DW 59

Direction of stroke of the crankpin (4.1)

Charge of grease approx. 100 g lithium-base saponified grease K2. Relubrication every 200 operating hours.

Assembly of the gear unit


In case of a properly assembled gear unit the crankpin (4.1) must move parallel to the screw-down bores A-B (longer
side) inside of the casing

1. Assembly of pinion (9) and crank (4) in the rotor (3):


Marked pinion tooth (9) must be diametrically opposite to the marked tooth gap on the crank (4).
2. Assembly of rotor (3) with crank (4) in the casing (2):
Turn crank (4) inside of rotor (3) such that the centre points of rotor, of crank and of crankpin (4.1) are aligned
(direction of stroke H), letting the crankpin (4.1) point towards the outside of the rotor.
Insert the rotor into the casing in this position, whereas the crankpin (4.1) must point exactly towards the casing side B-C.
It must be possible to slide the pinion (9) and gear ring (10) into each other without twisting.
Fill the bearing and the gear ring with grease prior to assembly.

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P 13

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HMW 1131 - 1133 and rape attachment as from 5,40 m, as from cutting mechanism no. 30988
Cutter gear unit 85 mm stroke
1

V-belt pulley halves (flywheel mass)

Spacer disks (2x2 mm between the pulleys, 1x2 mm, 1x1 mm outside)

Casing

Rotor

Gear ring

5.1*

O-ring, sheet gasket

Pinion shaft, (replace together with item 5 in case of repair)

Crank base

Screws M8x35; 12.9; glued in place

Screws M10x35, 12.9

10

Bearing support

11

Head bearing

Direction of stroke of the head bearing

The 4 dot marks (P) must lie on top of each other while assembling (1x casing, 2x rotor, 1x crank base).
Fill casing and gear ring with grease prior to assembly. Relubricate head bearing and casing with lithium-base saponified
grease K2 every 50 operating hours.

*) In the year of production 2001 the fixation of the gear ring (5) has been changed to screw connection from the inside of
the casing. At this occasion the o-ring and the sheet gasket 5.1 were being dropped.

P 14

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4
3

P
P
10

H
P025

11

P026

80
9 Nm
4

10

5
6

5.1

11

P027

307.1133.3.6 englisch (en) 10.2006

P 15

P
Service
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80
8 Nm

3
2

Y
5
P028

P029

1.1

P030

P 16

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HMW 1131 1133


Inspection of cutter actuation, cutter replacement
1

Cutter head

Screws M6 x 28 - 10.9, tightening torque 15 Nm

Screws M6 x 18 - 10.9, tightening torque 15 Nm

Insert nut

Plastic sleeve

Head bearing

Bearing support

Screws M10 x 35

1. Synchronous operation of head bearing (6) and cutter:


The head bearing (6) must move in parallel to the direction of stroke of the cutter. The cutter head (1) must not be pushed
against the cutter guide in the cutter bar neither in horizontal (X) nor in vertical direction (Y). In case of a relative
movement of the head bearing (6) in X - direction the cutter gear unit in the gear console must be slightly turned round.

2. Checking the stroke change: H = Cutter stroke.


In case of stroke change of the cutter the overlap (Z) between blade centre and finger centre must be equal. If the
deviation is too big the cutter gear unit in the gear console must be displaced towards the direction of stroke.

Cutter replacement, as from cutting mechanism 5,40 m


-

Unscrew screws (8) at bearing support.

Extract cutter with head bearing from the cutter bar.

Insert head bearing loosely into new cutter.

Tighten screws (8). Tightening torque 80 Nm.

Vertically align cutter head (1) on the head bearing (6).

Tighten screw (1.1), take care at the same time that the cutter head will not move any more on the head bearing.

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P 17

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HMW 1131 1133


Potentiometer installation in case of cutting mechanism control
1

Sensing skid (1 piece in case of level control, 3 pieces in case of autocontrol)

Skid support

Bearing plate

Centering ring for potentiometer

Driving pin

Potentiometer

Screw M5 with spring lock washer and plain washer

Observe the installation position of the potentiometers. The plug-in connection must be on top and at the same time the
casing is tightened in the center of the oblong holes.
Verify while mounting that the pendulum angle A (approx. 30) of the sensing skid is located within the angle of rotation
B (120) of the rotary potentiometer (otherwise the potentiometer will be destroyed). A return spring inside of the
potentiometer pulls its moving part towards the lower position of the sensing skid.
The driving pin (5) must not jam in radial or axial direction inside of the potentiometer: Check the groove depth in the
sensing skid and the length of the driving pins (5). Tighten screw (7) but moderately (danger of potentiometer seizing).
Adjustment of the potentiometers (see also chapter H):
Signal voltage between 2,4 V and 6,8 V with lifted resp. freely hanging sensing skid.
In case of underflow or overflow of the voltage range turn round the potentiometer casing inside of the oblong holes.
The signal voltage is supposed to change for more than 2 V from the lowest to the highest position of the sensing skid.
Pendulum angle of the sensing skids approx. 30.

P 18

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B
120
30

310 mm

30

6
P-41

4
5
7
6
3

307.1133.3.6 englisch (en) 10.2006

P034

31053

P 19

P
Service
Training

Notes

P 20

307.1133.3.6 englisch (en) 10.2006

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Service
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HMW 1131 1133


Connector pin assignment 13-pole plugsocket

Plug

Plug-socket
Type
Autocontrol
(3 sensing
skids)

Plug-socket
Type
Level
control
(1 sensing
skid)

Rape cutting mechanism

307.1133.3.6 englisch (en) 10.2006

P 21

P
Service
Training

Wiring layout and circuit diagram for hydraulic system at rape attachment

Hydraulic system pump, driven by cutter gear unit (pump capacity 11cm3/rev.)

Oil container with return line filter

Pressure relief valve 150 bar

Control valve for left side cutter

Hydraulic system motor right (absorption capacity 12,5 cm3/rev.)

Hydraulic system motor left

Pressure lines

Return lines

Leakage oil line for right hydraulic system motor (being dropped, if only the right side cutter is mounted)

10

Shunt diode inside of plug at emergency valve

(absorption capacity 12,5 cm3/rev.)

In case of a de-energized control valve (4) only the right hydraulic system motor (5) is in operation. In case of an
energized control valve both hydraulic system motors are connected in series.

P 22

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Training

10

P037

P038

P039

307.1133.3.6 englisch (en) 10.2006

P 23

P
Service
Training

2
2.1
4
P040

P041

2
1

P043

7
P044

P 24

7.1

3
307.1133.3.6 englisch (en) 10.2006

P
Service
Training

Rape attachment drive

HMW 1131 1133 up to 7,20 m

HMW 1133 8,10 m and 9 m (cutter gear unit with angle drive)

Cutter gear unit at rape attachment

Hydraulic system pump

2.1

Flexible disk

Deflection pulleys

Tensioning pulley

Reel bracket

Cutter gear unit at cutting mechanism

V-belt pulley with free-wheel

7.1

Bearing

When mounting the rape attachment the reel lifting cylinders in the lower borehole (X) at the reel bracket must be
detached.
For driving of the rape attachment 8,10 m and 9 m the v-belt pulleys of the cutter gear unit are to be replaced. At the
cutter gear unit for the cutting mechanism the v-belt pulley (7) with bearing free-wheel is to be mounted.

307.1133.3.6 englisch (en) 10.2006

P 25

P
Service
Training

Notes

P 26

307.1133.3.6 englisch (en) 10.2006

U
Service
Training

5650H - 5690HTS
Straw Chopper
Table of Contents
Combine harvester type

5650H
5680H
5660HTS 5690HTS

Adjustment of the straw guide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 03

Belt coupling for chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 05

Speed monitoring, touch contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 07

Modification of the chopper for threshing of maize or sunflowers . . . . . . . . . . . . . . .08 09

Lining for straw hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 11

Electrical adjustment of straw guide plate (chopper flap) . . . . . . . . . . . . . . . . . . . . .12 13

Electrical adjustment of deflectors at chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 17

307.1133.3.6 englisch (en) 10.2006

U1

U
Service
Training

4
2

2.1

6
a

U001

5
3

6
7
U003

2
2.1
1

U006

U2

307.1133.3.6 englisch (en) 10.2006

U
Service
Training

5650H 5690HTS
Adjustment of the straw guide plates

Lower straw guide plate

Front limit stop for lower straw guide plate

2.1

Turn lock

Rear limit stop for lower straw guide plate

Upper straw guide plate

Tie rod

Gas strut

Swath rake (in case of combine harvesters equipped with 5 walkers only 1 rake is permitted to be installed)

The rear limit stop (3) and the tie rod (5) must be adjusted such that the straw guide plates (1 and 4) are forming a plane
surface in position long straw. The lower straw guide plate must rest against the limit stop (a) of the upper straw
guide plate.

It is possible to fold down the lower straw guide plate (1) to the front. For this purpose loosen the turn locks (2.1) outside
at the straw hood, slew the limit stops (2) upwards and unhook the tie rod (5).

307.1133.3.6 englisch (en) 10.2006

U3

U
Service
Training

2
U012

C0110

U4

307.1133.3.6 englisch (en) 10.2006

U
Service
Training

5650H 5690HTS
Belt coupling for chopper

Clutch pulley

Servo-motor

Belt guides

Tensioning device

Adjusting nuts

Belt coupling adjustment:


Adjust the spring load A at the potentiometer (10) of the power relay with belt engaged.
When the potentiometer is turned to the right the load current will increase (dimension A will decrease), turning the potentiometer to the left will cause the load current to decrease (dimension A will increase).
Adjust stroke B of the servo-motor (2) by means of nuts (5).
If the dimension D falls below D = 115 mm (belt displacement) adjust the intermediate drive downwards.

Spring load A

= 110 mm

Stroke B

= 60 mm

307.1133.3.6 englisch (en) 10.2006

U5

U
Service
Training

A
B

1
2

U016-1

U6

307.1133.3.6 englisch (en) 10.2006

U
Service
Training

5650H 5690HTS
Speed monitoring, touch contact

Proximity switch (speed sensor)

Pulse transmitter

Proximity switch for position of straw guide plates

Lower straw guide plate

Straw guide plate in position chopper on

Straw guide plate in position chopper off

Function of switch 3
The switch (3) activates or deactivates the speed monitor and controls the connection of the chopper clutch when the
straw guide plates (4) are set to chopper operation (position A).

307.1133.3.6 englisch (en) 10.2006

U7

U
Service
Training

Modification of the chopper for threshing of maize or sunflowers


1

V-belt pulley for reduced speed

V-belt pulley on the chopper shaft

Deflection pulley, in case of KPAB chopper

Double pulley at intermediate drive, in case of KPAB SRX chopper

Upper straw guide plate

Deflector

Tie rod

Cover plate for shear bar casing, in case of KPAB chopper

Rasp bar

1.

Speed reduction:
A v-belt pulley (1) with a bigger diameter is to be mounted on the drive pulley (2) of the chopper. Place the deflection pulley (3) higher in case of KPAB chopper.

1.1

Speed reduction in case of KPAB chopper type SR (5650H-5660HTS, 5680H-5690HTS as of year of manufacture 2007):
Mount v-belt pulley (4) from the intermediate drive to the v-belt pulley (2) on the chopper.

2.

Installation of a deflector (6) in the straw hood in alignment with the upper straw guide plates (5).
Unhook the tie rod (7) for the upper straw guide plate.

3.

Remove the shear bar. In front of the shear bar casing a cover plate (8) is to be mounted in case of the KPAB chopper.
Remove every second swinging flail.

4.

U8

Remove rasp bars (9) in the bottom plate.

307.1133.3.6 englisch (en) 10.2006

U
Service
Training

2
33645

33646

KPAB-SRX

2
U017-1

4
7
KPAB

33686

307.1133.3.6 englisch (en) 10.2006

9
U018

U9

U
Service
Training

495

U020

U 10

307.1133.3.6 englisch (en) 10.2006

U
Service
Training

5650H 5690HTS
Lining for straw hood

KPAB chopper

The lining (1) in the straw hood is an optional feature (see price list).
It helps to support the straw flow to the chopper in case of coarse-fibred rape straw.

KPAB
5650 5660

1602 6810

5680 5690

1602 6812

307.1133.3.6 englisch (en) 10.2006

U 11

U
Service
Training

5650H 5690HTS
Electrical adjustment of straw guide plate (chopper flap)
(Changeover from chopping to long straw shedding)

Servo motor for straw guide plate

1.1

Fork head

1.2

Circuit diagram

1.3

Connector view

Inductive sensor for straw guide plate position

Speed sensor straw chopper

Socket outlet for servo motor of chopper deflectors

Straw guide plate limit stop

A26

CAN module

F13

Fuse for servo motor

F56

Fuse for CAN module A26

K16

Relay straw guide plate chopper operation

K37

Relay straw guide plate long straw shedding

S66

Straw guide plate switch

X5

Connector at control cabinet

X146 Connector at engine frame


X705 Connector at servo motor
X320 Analog ground, insulated ground strip inside of control cabinet

Mounting instruction for the servo motor:


Adjust the fork head (1.1) such that the straw guide plate completely abuts the stop limits (5) in both positions in the straw
hood.
Before initial commissioning or after replacement of the servo motor the calibration of the chopper flap adjustment shall be
carried out at the Commander Control.

U 12

307.1133.3.6 englisch (en) 10.2006

U
Service
Training

K37/3

X5

S66

X146

A26

A26/13

5 6 2 1 3
8 7 3 4 2

5 6 2 1 3
8 7 3 4 2

br
8

A26/16

X320

K16/3

16

ws br vi ws
sw sw sw

X705 5 4 3 2 1
sw

ge

rt

tr

sw

U-004

1.3

X705

+
Signal

U-001

1.2
U-003

5
4

5
4 mm

1.1

307.1133.3.6 englisch (en) 10.2006

U-005

U 13

U
Service
Training
H43

H41

K38/3

X26

H42

S49

A25/16

X320

K17/3

A25/13

gn

rt

br

bl

sw

2/54 g

1L

3/31

6/54

7/58 L

gn

rt

br

bl

sw

gn

rt

br

bl

sw

sw

bl

br

H44
35379

A25

X145
9

16

U-006

X706

4
gn
ws

ge
rt

R
1 kOhm

U-007

1.1

X706

U-008

U 14

307.1133.3.6 englisch (en) 10.2006

U
Service
Training

5670H 5690HTS, until of year of manufacture 2006


Electrical adjustment of deflectors at chopper

Servo motor for deflectors

1.1

Circuit diagram for servo motor

Socket outlet at the straw hood

A25

CAN module

F14

Fuse for servo motor

F55

Fuse for CAN module

K17

Relay for deflector adjustment to left side

K38

Relay for deflector adjustment to right side

S49

Switch for deflector adjustment with position lights

X26

Connector at control cabinet

X145 Connector at engine frame


X706 Connector at servo motor
X320 Analog ground, insulated ground strip inside of control cabinet

Before initial commissioning or after replacement of the servo motor the calibration of the chopper deflector adjustment
shall be carried out at the Commander Control.

307.1133.3.6 englisch (en) 10.2006

U 15

U
Service
Training
H43

H41

K38/3

X26

H42

S49

A25/16

X320

K17/3

A25/13

gn

rt

br

bl

sw

2/54 g

1/L

3/31

6/54

7/58 L

sw

rt

rt

ws

bl

H44
35379

A25

X145
9

16

U-006

R
1 kOhm

U-007

1.1

U-008

U 16

307.1133.5.6 deutsch (de) 10.2006

U
Service
Training

5650H 5660HTS
5680H 5690HTS, as of year of manufacture 2007
Electrical adjustment of deflectors at chopper

Servo motor for deflectors

1.1

Circuit diagram for servo motor

Socket outlet at the straw hood

A25

CAN module

F14

Fuse for servo motor

F55

Fuse for CAN module

K17

Relay for deflector adjustment to left side

K38

Relay for deflector adjustment to right side

S49

Switch for deflector adjustment with position lights

X26

Connector at control cabinet

X145 Connector at engine frame


X320 Analog ground, insulated ground strip inside of control cabinet

Before initial commissioning or after replacement of the servo motor the calibration of the chopper deflector adjustment
shall be carried out at the Commander Control.

307.1133.3.6 englisch (en) 10.2006

U 17

U
Service
Training

Notes

U 18

307.1133.3.6 englisch (en) 10.2006

Der Nachdruck des Textes und der Abbildungen ist, auch auszugsweise, verboten.
La reproduction du prsent ouvrage, du texte et des llustratons, mme partelle est interdite.
Text and illustrations herewith enclosed may not be reproduced, not even in part and by any means.
E vietata la riproduzione, anche parziale, del testo e delle illustrazioni.
Se prohibe la reproduccin total o parcial del texto y de las ilustraciones.
A proibida a reproduo, at mesmo parcial, do texto e das ilustraces.

Der zeitliche Unterschied zwischen der Aktualisierung der Druckschriften und der Durchfhrung technischer Vernderungen (die stndig vorgenommen werden, um immer hochwertigere Erzeugnisse auf den Markt zu bringen) erfordern
aus Grnden der Korrektheit des Hinweises, dass die in dieser Ausgabe enthaltenen Daten jederzeit gendert werden
knnen und deshalb unverbindlich sind.
Le temps qui scoule entre la mise jour en impression et les modifications techniques (ces dernires changeant continuellement afin doffrir aux utilisateurs des produits toujours plus qualifis) nous oblige a vous signaler que les
donnes de la prsente publication pourraient tre susceptibles de variations. Elles sont donnes sans engagement de
notre part.
Because of the possible time lag between the introduction of technical modifications (an on-going process the aim of
which is to offer products which are being continually improved) and the latest update of the manual, we must point out,
for the sake of correctness,that the data contained in this edition are liable to change at any time and are therefore not
binding.
La differenza tra i tempi di aggiornamento in stampa e i tempi delle modifiche tecniche (variando queste ultime continuamente, ci al fine di offrire prodotti sempre pi qualificati) impongono di dichiarare, per correttezza, che i dati contenuti nella presente edizione sono suscettibili di variazione in qualsiasi momento e che quindi non sono impegnativi.
La diferencia entre los tiempos necesarios para poner al dia la impresin y los tiempos de las modificaciones tcnicas
(las que se verifican continuamente, con el objeto de ofrecer productos cada vez ms calificados) nos imponen
declarar, por correccin, que los datos contenidos en la presente edicin estn sujetos a variaciones en cualquier momento y que portanto no son obligativos.
A diferena entre os tempos necessrrios para actualizar a impresso e os tempos das modificaces tcnicas (que se
verificam continuamente, a fim de oferecer um produto cada vez mais qualificado), obrigam-nos a declarar, que os dados contidos neste manuel so susceptiveis de variaco em qualquer momento e que portanto no so vinculatrios.

NOTES

02 - 2007
By Personal computing

cod. 307.1132.3.6
Technical Publications Dep.

02-2007

307. 1133. 3. 6