FX25, FX28, FX38, FX45, FX48, FX58 Service Manual

FX25, FX45, FX28, FX38, FX48, FX58
REPAIR MANUAL
COMPLETE CONTENTS
SECTION 00 - GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 14 - LIVE P.T.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 21 - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 23 - 4WD LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 25 - FRONT MECHANICAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 29 - HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 33 - BRAKES AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 35 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 50 - CAB CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 55 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 60 - PRODUCT FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 64 - CUTTERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 70 - EJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
The following pages are the collation of the contents pages from each section and
chapter of the FX25 -- FX58 Repair manual. Complete Repair part # 87051240.
The sections used through out all New Holland product Repair manuals may not be
used for each product. Each Repair manual will be made up of one or several books.
Each book will be labeled as to which sections are in the overall Repair manual and
which sections are in each book.
The sections listed above are the sections utilized for the FX25 -- FX58 Forage
Harvesters.
© 2004 CNH America LLC 87051246 7/04

Printed In U.S.A.
SECTION 00 - GENERAL INFORMATION
BOOK 1 - 87051241
Chapter 1 - General
CONTENTS
Section Description Page

00.000 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Explanation of machine and attachment serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Units of measure -- conversion chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drivelines and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubricant application guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 10 - ENGINE
BOOK 1 - 87051241
Chapter 1 - Iveco Aifo Engine

CONTENTS

10.101 Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10.106 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10.218 Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.242 Removal and installation of fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10.400 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2
SECTION 14 -- LIVE P.T.O.
BOOK 1 - 87051241
Chapter 1 - Main Drive Gearbox

CONTENTS

14.100 Removal of the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal of shields and doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal of p.t.o. shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of the battery box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of the fuel reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of the main drive belt assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal of the hydraulic and the hydrostatic pump assembly . . . . . . . . . . . . . . . . . . . . . . 9
Removal of the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacing the rubber damper on the engine output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Splitting the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly and assembly of the components in the rear half of the gearbox . . . . . . . . . 14
Disassembly and assembly of the front half of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal and disassembly of hydraulic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal and installation of the pressure hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing clutch plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing the seals in the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal and installation of the clutch driven shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation of the clutch into the gearbox half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting the two gearbox halves together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation of the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installing the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation of the hydraulic and the hydrostatic pump assemblies . . . . . . . . . . . . . . . . 31
Installation of the main drive belt assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation of the fuel reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installing the battery box and the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installing the PTO shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Starting up the forage harvester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3
SECTION 21 -- TRANSMISSION
BOOK 1 - 87051241
Chapter 1 - Traction Gearbox

CONTENTS

21.145 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gearbox shafts and shifting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 23 -- 4WD LINES

BOOK 1 - 87051241
Chapter 1 - 4WD Angle Gearbox

CONTENTS

23.000 Removal from the base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly of 4WD angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly of 4WD angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation on base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 25 -- FRONT MECHANICAL DRIVE

BOOK 1 - 87051241
Chapter 1 - Final Drives

CONTENTS

25.310 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly and assembly of final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4
SECTION 29 -- HYDROSTATIC TRANSMISSION
BOOK 2 - 87051242
Chapter 1 -- Hydrostatic Transmission

CONTENTS

29.212 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic circuit and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filling and bleeding the hydrostatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
29.216 Hydrostatic pump -- Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation of the multifunction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydrostatic motor -- Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 33 -- BRAKES AND CONTROL

BOOK 2 - 87051242
Chapter 1 -- Brakes and Control

CONTENTS

33.110 Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
33.202 Replacement of the brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bleeding the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly and assembly of brake shoes and discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 35 -- HYDRAULIC SYSTEM

BOOK 2 - 87051242
Chapter 1 -- General
CONTENTS

35.000 Torque tables for hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.304 Disassembly and assembly of pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5
BOOK 2 - 87051242
Chapter 2 -- Work Hydraulics -- Attachment Height Control

CONTENTS

35.000 Circuit diagrams -- Attachment height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.300 Hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Non return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
35.304 Work hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
35.410 Attachment height control valve (EMR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Attachment compensation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hydropneumatic accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Attachment lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

BOOK 2 - 87051242
Chapter 3 -- Work Hydraulics -- Base Unit

CONTENTS

35.000 Circuit diagrams -- Base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.310 Stack valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Load sensing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cutterhead reverse drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spout rotation pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Quick release couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Spout lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6
BOOK 2 - 87051242
Chapter 4 -- Steering Hydraulics

CONTENTS

35.000 Circuit diagrams -- Steering hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.310 Steering hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

BOOK 2 - 87051242
Chapter 5 -- Low Pressure Hydraulics

CONTENTS

35.000 Circuit diagrams -- Low pressure hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.300 Low pressure hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil change and fill procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
35.310 Low pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Low pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main drive belts tensioning cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spout deflector cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

BOOK 2 - 87051242
Chapter 6 -- Hi--Flow Hydraulics

CONTENTS

35.000 Circuit diagrams -- Hi--flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7
SECTION 50 -- CAB CLIMATE CONTROL
BOOK 2 - 87051242
Chapter 1 -- Cab Cimate Control

CONTENTS

50.000 Correct use of the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Storage maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
50.200 Air conditioning circuit and component specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compressor clutch replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
50.206 Ventilation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 55 -- ELECTRICAL SYSTEM

BOOK 3 - 87051243
Chapter 1 -- Electrical Circuits

CONTENTS

55.000 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55.100 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

BOOK 3 - 87051243
Chapter 3 -- Wiring Diagrams FX NA

CONTENTS

55.000 Wiring diagrams FX NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8
BOOK 4 - 87051244
Chapter 4 -- Can Network Basics

CONTENTS

55.000 General layout electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Can spy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Error codes messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fault finding routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

BOOK 4 - 87051244
Chapter 5 -- Calibration
CONTENTS

55.000 Machine calibration with Laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Machine calibration with PDT tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

BOOK 4 - 87051244
Chapter 6 -- Software Update

CONTENTS

55.000 Software update with Laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Software update with PDT tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
9
BOOK 4 - 87051244
Chapter 7 -- Troubleshooting
CONTENTS

55.000 Error messages overview
-- Machine error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
-- Attachment height control error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
-- Caterpillar error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
List of Can identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Detailed analysis per function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
SECTION 60 -- PRODUCT FEED

BOOK 5 - 87051245
Chapter 1 -- Feed Rolls

CONTENTS

60.103 Removal and installation of lower feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
60.107 Inspection between upper feed rolls and cutterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flip down upper feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Detaching -- attaching of attachment with upper feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal -- installation of upper feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly and assembly of upper feed roll drive chain box . . . . . . . . . . . . . . . . . . . . . . . 22
10
BOOK 5 - 87051245
Chapter 2 -- Length-Of-Cut and Feed Roll Drive Gearbox

CONTENTS

60.122 Gearbox shafts and shifting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal of length-of-cut gearbox from the chopperbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Length-of-cut gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Length-of-cut gearbox disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation of length-of-cut gearbox on the chopperbody . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

BOOK 5 - 87051245
Chapter 3 -- Electromagnetic Reversing Gearbox

CONTENTS

60.165 Operation of electromagnetic reversing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removing the reversing gearbox from the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly and assembly of the electromagnetic clutch (type Warner) . . . . . . . . . . . . . . . 8
Burnishing procedure of the electromagnetic clutch (type Warner). . . . . . . . . . . . . . . . . . . . 11
Disassembly and assembly of the electromagnetic clutch (type Stromag) . . . . . . . . . . . . 13
Removal and installation of feed roll and attachment drive safety clutch . . . . . . . . . . . . . . 18
Disassembly and assembly of the reversing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11
SECTION 64 -- CUTTERHEAD
BOOK 5 - 87051245
Chapter 1 -- Chopping
CONTENTS

64.000 Splitting of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Attaching and detaching the attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal -- installation of chopper body with A-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal -- installation of chopper body with hydraulic jack . . . . . . . . . . . . . . . . . . . . . . . . . 12
64.106 Removal -- installation of rotor and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
64.130 Removal -- installation of cutterhead gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly and assembly of cutterhead gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
64.150 Removal -- installation of shearbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal and installation of shearbar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 70 -- EJECTION
BOOK 5 - 87051245
Chapter 1 -- Blower
CONTENTS

70.000 Inspection between cutterhead and blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
70.120 Removal and installation of blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
70.100 Removal and installation of blower gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly and assembly of blower gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
12
SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 1
SECTION 00 -- GENERAL INFORMATION
CONTENT

00.000 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Explanation of machine and attachment serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Units of measure -- conversion chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drivelines and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubricant application guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1
GENERAL INSTRUCTIONS -- to prevent damaging the seal lip on the shaft,
position a protective guard during installation
IMPORTANT NOTICE operations
All maintenance and repair work described in this

manual must be performed exclusively by NEW
HOLLAND service technicians, in strict accordance O--RING SEALS
with the instructions given and using any specific
tools necessary. Lubricate the O--RING seals before inserting them in
Anyone performing the operations described herein the seats, this will prevent them from overturning and
without strictly following the instructions is personally twisting, which would jeopardise sealing efficiency.
responsible for any eventual injury or damage to
property.
SEALING COMPOUNDS
SHIMMING Apply one of the following sealing compounds on the

mating surfaces marked with an X: RTV SILMATE,
For each adjustment operation, select adjusting RHODORSIL CAF 1 or LOCTITE PLASTIC
shims and measure individually using a micrometer, GASKET.
then add up the recorder values. Do not rely on Before applying the sealing compound, prepare the
measuring the entire shimming set, which may be in- surfaces as follows:
correct, or the rated value indicated for each on shim.
-- remove any incrustations using a metal brush;
ROTATING SHAFT SEALS -- thoroughly de--grease the surfaces using one of

the following cleaning agents: trichlorethylene,
For correct rotating shaft seal installation, proceed as petrol or a water and soda solution.
follows:
-- before assembly, allow the seal to soak in the oil

it will be sealing for at least thirty minutes BEARINGS
When installing bearings it is advised to:

-- thoroughly clean the shaft and check that the
working surface on the shaft is not damaged -- heat the bearings to 80 to 90 0C before fitting on
the shafts;
-- position the sealing lip facing the fluid; with hy-
drodynamic lips, take into consideration the shaft -- allow the bearings to cool before installing them
rotation direction and position the grooves so that from the outside.
they will deviate the fluid towards the inner side
of the seal
-- coat the sealing lip with a thin layer of lubricant SPRING PINS
(use oil rather than grease) and fill the gap be-
tween the sealing lip and the dust lip on double When fitting split socket spring pins, ensure that the
lip seals with grease pin notch is positioned in the direction of the force re-
quired to stress the pin.
Spiral spring pins do not require special positioning.
-- insert the seal in its seat and press down using
a flat punch, do not tap the seal with a hammer
or mallet
-- whilst inserting the seal, check that the it is per-

pendicular to the seat; once settled, make sure
that it makes contact with the thrust element, if re-
quired
SPARE PARTS
Only use original NEW HOLLAND spare parts bearing the logo shown below.
Only original spare parts guarantee the same quality, -- essential for reliable repair operations
duration and safety as they are the same parts that
are assembled during production.
-- accurately built and rigorously tested so as to
Only original NEW HOLLAND parts can offer this
offer efficient and long--lasting operation
guarantee.
When ordering spare parts, always provide the fol-
lowing information: By using these tools, Repair Personnel will benefit
Before applying the sealing compound, prepare the from:
surfaces as follows:
-- operating in optimal technical conditions
-- Forage Harvester model (commercial name) and
serial number -- obtaining the best results
-- engine type and number -- saving time and effort
-- part number of the ordered part, which can be -- working in safe conditions
found in the ”Microfiches” or the ”Spare Parts
Catalogue”, used for order processing
NOTE
TOOLS Wear limit values indicated for certain parts should
be considered to be recommended, but not binding.
The tools that NEW HOLLAND propose and illustrate The terms ”front”, ”rear”, ”right--hand” and ”left--
in this manual are: hand” (when referred to different parts) are intended
as seen from the driving position with the Forage
-- specifically researched and designed for use Harvester in the normal direction of movement.
with NEW HOLLAND Forage Harvesters
MOVING THE FORAGE HARVESTER WITH THE
BATTERY REMOVED
External power supply cables should only be con-

nected to the respective positive and negative cable
terminals, using efficient clamps that guarantee ad-
equate and secure contact.
Disconnect all services (lights, windshield wipers,
etc.) before starting the Forage harvester.
If the Forage harvester electrical system requires
checking, carry out operations with the power supply
connected. Once checking is completed, disconnect
all services and switch off the power supply before
disconnecting the cables.
SAFETY REGULATIONS
WARNING AND DANGER SYMBOL

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

sitting in the driver’s seat, unless the person is a
trained technician who is assisting with the oper-
Most accidents or injuries that occur in workshops ation in question.
are the result of non--observance of simple and fun-
damental safety regulations. For this reason, IN • Do not operate the machine or use any of the im-
MOST CASES THESE ACCIDENTS CAN BE plements from different positions, other than the
AVOIDED by foreseeing possible causes and conse- driver’s seat.
quently acting with the necessary caution and care.
• Do not carry out operations on the machine with

Accidents may occur with all types of machine, re- the engine running, unless specifically indicated.
gardless of how well the machine in question was de-
signed and built.
• Stop the engine and check that the hydraulic cir-
cuits are pressure--free before removing caps,
A careful and judicious service technician is the best covers, valves, etc.
guarantee against accidents.
• All repair and maintenance operations must be

Precise observance of the most basic safety rule is carried out using extreme care and attention.
normally sufficient to avoid many serious accident
DANGER • Service steps and platforms used in the work-

shop or elsewhere should be built according to
Never carry out any cleaning, lubrication or mainten-
standard accident prevention regulations.
ance operations when the engine is running.
• Disconnect the batteries and label all controls to

indicate that the Forage Harvester is being ser-
viced. Any parts that are to be raises must be
locked in position.
SAFETY URLE
• Do not check or fill fuel tanks, accumulator bat-
General guidelines
teries, nor use starting liquid when smoking or
• Carefully follow specified repair and mainten- near naked flames, as these fluids are inflam-
ance procedures. mable.
• Do not wear rings, wristwatches, jewellery, un- • Brakes are inoperative when manually released
buttoned or loose articles of clothing such as: for repair or maintenance purposes. Use blocks
ties, torn clothing, scarves, open jackets or shirts or similar devices to control the machine in these
with open zips that may remain entangled in conditions.
moving parts. It is advised to wear approved
safety clothing, e.g.: non--slip footwear, gloves,
safety goggles, helmets, etc.
• The fuel nozzle should always be in contact with • Do not smoke, use naked flames, or cause
the filling aperture. Maintain this position until fill- sparks in the area when fuel filling or handling hi-
ing operations are completed in order to avoid ghly inflammable liquids.
possible sparks caused by the accumulation of
static electricity.
• Never use naked flames for lighting when wor-
king on the machine or checking for leaks.
• Only use specified towing points for towing the
Forage Harvester. Connect parts carefully. Make
• All movements must be carried out carefully
sure that all pins and/or locks are secured in posi-
when working under, on or near the Forage Har-
tion before applying traction. Never remain near
vester. Wear protective equipment: helmets,
the towing bars, cables or chains that are operat-
goggles and special footwear.
ing under load.
• When carrying out checks with the engine run-

• Transport Forage Harvesters that cannot be dri-
ning, request the assistance of an operator in the
ven using a trailer or a low--loading platform trol-
driver’s seat. The operator must maintain visual
ley, if available.
contact with the service technician at all times.
• When loading or unloading the Forage Harvester

• If operating outside the workshop, position the
from the trailer (or other means of transport), se-
Forage Harvester on a flat surface and lock in po-
lect a flat area capable of sustaining the trailer or
sition. If working on a slope, lock the Forage Har-
truck wheels. Firmly secure the Forage Harve-
vester in position. Move to a flat area as soon as
ster to the truck or trailer and lock the wheels in
is safely possible.
the position used by the carrier.
• Damaged or bent chains or cables are unreliable.

• Electric heaters, battery--chargers and similar
Do not use them for lifting or towing. Always use
equipment must only be powered by auxiliary po-
suitable protective gloves when handling chains
wer supplies with efficient ground insulation to
or cables.
avoid electrical shock hazards.
• Chains should always be safely secured. Make

• Always use suitable hoisting or lifting devices
sure that the hitch--up point is capable of sustai-
when raising or moving heavy parts.
ning the load in question. Keep the area near the
hitch--up point, chains or cables free of all bystan-
• Take extra care if bystanders are present. ders.
• Never pour gasoline or diesel oil into open, wide • Maintenance and repair operations must be car-
or low containers. ried out in a CLEAN and DRY area. Eliminate any
water or oil spillage immediately.
• Never use gasoline, diesel oil or other inflamma-
ble liquids as cleaning agents. Use non--inflam- • Do not create piles of oil or grease--soaked rags
mable, non toxic commercially available sol- as they represent a serious fire hazard. Always
vents. store rags in a closed metal container.
Before starting the Forage harvester or imple-
ments, make sure that the driver’s seat is locked
• Wear safety goggles with side guards when clea-
in position. Also check that there are no persons
ning parts with compressed air.
within the Forage harvester or implement range
of action.
• Limit the air pressure to a maximum of 2.1 bar,
according to local regulations.
• Empty pockets of all objects that may fall unob-
served into the Forage harvester parts.
• Do not run the engine in confined spaces without
suitable ventilation.
• In the presence of protruding metal parts, use
protective goggles or goggles with side guards,
helmets, special footwear and gloves.
• When welding, use protective safety devices: tin- ELECTRICAL SYSTEMS
ted safety goggles, helmets, special overalls,
gloves and footwear. All persons present in the • If it is necessary to use auxiliary batteries, re-
area where welding is taking place must wear tin- member that both ends of the cables must be
ted goggles. NEVER LOOK DIRECTLY AT THE connected as follows: (+) with (+) and (--) with (--).
WELDING ARC WITHOUT SUITABLE EYE Avoid short--circuiting the terminals. GAS RE-
PROTECTION. LEASED FROM BATTERIES IS HIGHLY IN-
FLAMMABLE. During charging, leave the batte-
ry compartment uncovered to improve
• Metal cables tend to fray with repeated use. Al- ventilation. Never check the battery charge using
ways use suitable protective devices (gloves, ”jumpers” (metal objects placed on the termi-
goggles, etc.) when handling cables. nals). Avoid sparks or flames near the battery zo-
ne. Do not smoke to prevent explosion hazards.
• Handle all parts carefully. Do not put your hands
or fingers between moving parts. Wear suitable • Before servicing operations, check for fuel or cur-
safety clothing -- safety goggles, gloves and rent leaks.Eliminate any eventual leaks before
shoes. proceeding with work.
• Never charge batteries in confined spaces.Make

sure that there is adequate ventilation in order to
prevent accidental explosion hazards as a result
START UP of the accumulation of gases released during
charging operations.
• Never run the engine in confined spaces that are
not equipped with adequate ventilation for ex- • Always disconnect the batteries before perfor-
haust gas extraction. ming any kind of servicing on the electrical sy-
stem.
• Never place the head, body, limbs, feet, hands or
fingers near fans or rotating belts.
HYDRAULIC SYSTEMS
• A liquid leaking from a tiny hole may be almost in-

visible but, at the same time, be powerful enough
ENGINE to penetrate the skin. Therefore,NEVER USE
HANDS TO CHECK FOR LEAKS but use a piece
of cardboard or wood for this purpose. If any li-
• Always loosen the radiator cap slowly before re- quid penetrates skin tissue, call for medical aid
moving it to allow any remaining pressure in the immediately. Failure to treat this condition with
system to be discharged. Filling up with coolant correct medical procedure may result in serious
should only be carried out with the engine stop- infection or dermatosis.
ped or idling (if hot)..
• In order to check the pressure in the system use
• Never fill up with fuel when the engine is running, suitable instruments.
especially if hot, in order to prevent the outbreak
of fire as a result of fuel spillage.
• Never check or adjust fan belt tension when the

engine is running. WHEELS AND TYRES
Never adjust the fuel injection pump when the
Forage Harvester is moving.
• Make sure that the tyres are correctly inflated at
the pressure specified by the manufacturer.
• Never lubricate the Forage Harvester when the Periodically check the rims and tyres for damage.
engine is running.
• Stand away from (at the side of) the tyre when REMOVAL AND RE--FITTING
checking inflation pressure.
• Lift and handle all heavy parts using suitable hoi-

• Do not use parts of recovered wheels as incor-
sting equipment. Make sure that parts are sustai-
rect welding brazing or heating may weaken and
ned by appropriate hooks and slings. Use the
eventually cause damage to the wheel.
hoisting eyebolts for lifting operations. Extra care
should be taken if persons are present near the
• Never cut or weld a rim mounted with an inflated load to be lifted.
tyre.
• Handle all parts carefully. Do not put your hands
• To remove the wheels, lock both the front and or fingers between parts. Wear suitable safety
rear wheels. After having raised the Forage Har- clothing -- safety goggles, gloves and shoes.
vester, position supports underneath, according
to regulations in force.
• Avoid twisting chains or metal cables. Always
wear safety gloves when handling cables or
• Deflate the tyre before removing any objects that chains.
may be jammed in the tyre tread.
• Never inflate tyres using inflammable gases, as

this may result in explosions and injury to bystan-
ders.
EXPLANATION OF MACHINE AND ATTACH- FX300 = 27 FX25 = 39
MENT SERIAL NUMBERS FX375 = 29
FX450 = 30 FX45 = 47
FX28 = 13 FX28NA = 23
FX38 = 14 FX38NA = 24
MACHINE SERIAL NUMBER
FX48 = 15
FX58 = 16 FX58NA = 26
FX300-375-450/ Series 01 to 14
FX9630-9640-9645 305033001 : The third digit indicates the product line.
There are 5 product lines in Zedelgem:
FX25-45 Series 01 to 06
TX/TF combine harvesters: 1
Example : n° 2901001
TC/L combine harvesters: 2
Combine headers: 3
2901001: The first two digits identify the model: Balers: 4
Forage Harvesters: 5
FX300 = 27 9630 = 19
FX375 = 29 9640 = 21 305033001 : These 3 digits indicate the batch in
FX450 = 30 9645 = 22 which the machine was made.
FX25 = 39
FX45 = 47 305033001 : Product line number (5) and batch
(033) together form the series number (5033).
2901001: The third and the fourth digit indicates the
serie in which the machine was made. 305033001 : The last 3 digits are a sequential
number for each model within a batch.
2901001: The last 3 digits are a sequential number
for each model within a serie. Summarizing we can say that this machine is the first
FX 450 of serie 5033.
So this machine is the first FX375 of serie 01.
ATTACHMENT SERIAL NUMBER
PRODUCT IDENTIFICATION
Example : n° 5320502
FX300-375-450/ Series 5033 to 5080
FX25-45 5320502 : Code for header type
FX28-58 Series 8083 to ...
FX28NA-58NA 5320502 : Serie in which the machine was made.
Example : n° 305033001 5320502 : Attachment number and colour
305033001: The first two digits identify the model

within a product line:
AVAILABLE HEADERS
300N6 (Fiatagri): 5320501

300N6 (New Holland): 5320001
340WX, 350Wx, 360N
These headers have a nonsequential serial numbe-

ring. For details ask your national service organiza-
tion.
CONVERSION CHART
Linear
1 mm = 0.03937 in 1 in = 25.4 mm
1 Km = 0.6214 miles 1 mile = 1.6093 km
1m = 3.281 ft 1 ft = 0.3048 m
Area
1 ha = 2.471 acre 1 acre = 0.4047 ha
Volume
1 litre = 0.0063 barrel 1 barrel = 158.987 litre

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

1 kPa = 0.145 lbf/in2(psi) 1 lbf/in2(psi) = 6.894 kPa
1 pa = 10 --5 bar 1 bar = 100 kPa
Temparature
1 °C = ((1.8 x ° C) + 32) ° F 1 °F = (0.56 x (° F -- 32))°C

MINIMUM HARDWARE TIGHTENING TORQUES
IN NEWTON-METRES -- Nm (FOOT POUNDS -- LBF. FT)
FOR NORMAL ASSEMBLY APPLICATIONS
METRIC HARDWARE AND LOCKNUTS

CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT
NOMINAL CL.8
SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8
W/ZnCr W/ZnCr W/ZnCr BOLT
M4 1.7 (15*) 2.2 (19*) 2.6 (23*) 3.4 (30*) 3.7 (33*) 4.8 (42*) 1.8 (16*)
M6 5.8 (51*) 7.6 (67*) 8.9 (79*) 12 (102*) 13 (115*) 17 (150*) 6.3 (56*)
M8 14 (124*) 18 (159*) 22 (195*) 28 (248*) 31 (274*) 40 (354*) 15 (133*)
M10 28 (21) 36 (27) 43 (32) 56 (41) 61 (45) 79 (58) 30 (22)
M12 49 (36) 63 (46) 75 (55) 97 (72) 107 (79) 138 (102) 53 (39)
M16 121 (89) 158 (117) 186 (137) 240 (177) 266 (196) 344 (254) 131 (97)
M20 237 (175) 307 (226) 375 (277) 485 (358) 519 (383) 671 (495) 265 (195)
M24 411 (303) 531 (392) 648 (478) 839 (619) 897 (662) 1160 (855) 458 (338)
NOTE: Torque values shown with * are inch pounds.

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

CLASSES 05 AND UP
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS CLOCK MARKING

MINIMUM HARDWARE TIGHTENING TORQUES
IN NEWTON-METRES -- Nm (FOOT POUNDS -- LBF. FT)
FOR NORMAL ASSEMBLY APPLICATIONS
INCH HARDWARE AND LOCKNUTS

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS
NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL
SIZE or W/ZnCr or W/ZnCr or W/ZnCr w/GR5 w/GR8 SIZE
PLATED PLATED PLATED BOLT BOLT
SILVER GOLD SILVER GOLD SILVER GOLD
1/4 6.2 (55*) 8.1 (72*) 9.7 (86*) 13 (112*) 14 (121*) 18 (157*) 6.9 (61*) 9.8 (86*) 1/4
5/16 13 (115*) 17 (149*) 20 (178*) 26 (229*) 28 (250*) 37 (324* ) 14 (125* ) 20 (176*) 5/16
3/8 23 (17) 30 ( 22) 35 (26) 46 (34) 50 (37) 65 (48) 26 (19) 35 (26) 3/8
7/16 37( 27) 47 (35) 57 (42) 73 (54) 80 (59) 104 (77) 41 (30) 57 (42) 7/16
1/2 57 (42) 73 (54) 87 (64) 113 (83) 123 (91) 159 (117) 61 (45) 88 (64) 1/2
9/16 81 (60) 104 (77) 125 (92) 163 (120) 176 (130) 229 (169) 88 (65) 125 (92) 9/16
5/8 112 (83) 145 (107) 174 (128) 224 (165) 244 (180 ) 316 (233) 122 (90) 172 (127) 5/8
3/4 198 (146) 256 (189) 306 (226) 397 (293) 432 (319) 560 (413) 217 (160) 306 (226) 3/4
7/8 193 (142) 248 (183) 495 (365) 641 (473) 698 (515) 904 (667) 350 (258) 494 (364) 7/8
1 289 ((213) 373 (275) 742 (547) 960 ( 708) 1048 (773) 1356 (1000) 523 (386) 739 (545) 1
NOTE: Torque values shown with * are inch pounds.

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

HEX NUTS HEX NUTS
LOCKNUTS
GRADE A NO MARK
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION
GRADE IDENTIFICATION GRADE IDENTIFICATION
GRADE A NO MARKS
GRADE A NO NOTCHES
GRADE B THREE MARKS
GRADE B ONE CIRCUMFERENTIAL NOTCH
GRADE C SIX MARKS
GRADE C TWO CIRCUMFERENTIAL NOTCHES
MARKS NEED NOT BE LOCATED
AT CORNERS
DRIVELINES AND COMPONENTS
Listed below and in the figure on the opposite page are all the forage harvester functional components and their
drives.
FX300-375-450 / FX9630-9640-9645 / FX25-45 Series 01 to 14

Series 5033 to 5080
The speeds and torques mentioned apply to the nominal engine speed of 1950 rpm. At this speed the engine
will deliver its maximum power.
Speed (rpm)/
Torque (Nm)
1. Lower front feed roll (or metal detector roll) 54-91-132-221
2. Smooth roll 120-202-291-487
3. Upper front feed roll 55-93-134-225
4. Upper front feed roll drive chain
5.
6. Upper rear feed roll 98-164-237-396
7. Cutterhead 1141
8. Cutterhead gearbox
9. Cutterhead drive shaft 2568
10. Blower 686 (760)
11. Reversing gearbox drive shaft 1950
12. Main drive belt
13. Cutterhead reverse drive hydraulic motor 750 - 800
14. Engine 1950
15. Main drive transfer gearbox
16. Hydrostatic pump 2791
17. Work hydraulics pump 2791
18. Steering hydraulics pump 2791
19. Low pressure hydraulics pump 2791
20. Electromagnetic clutch (forward drive) 1500 Nm
21. Electromagnetic clutch (reverse drive) 1500 Nm
22. Reversing gearbox
23. Stop pawl wheel 497 (172 reverse)
24. Cut-out clutch 1900 Nm
25. Blower gearbox
26. Lower crop processor roll 3780
27. Upper crop processor roll 3360
28. Crop processor drive belt
29. Feed rolls drive shaft 497 (172 reverse)
30. Upper feed rolls slip clutch 1000 Nm
31. Length-of-cut gearbox
32. Attachment drive p.t.o. shaft 383 (133 reverse)
52661
1
FX28-38-48 / FX28NA-38NA Series 8083 to ....
FX58 / FX58NA Series 8083 to ....
The speeds and torques mentioned apply to the nominal engine speed of 1950 rpm for FX28--38--48 or to the
nominal engine speed of 2100 rpm for FX58. At this speed the engine will deliver its maximum power.
FX28-38-48 FX58
Speed (rpm)/ Speed (rpm)/
Torque (Nm) Torque (Nm)
1. Lower front feed roll (or metal detector roll) 54-91-132-221 58-98-142-238
2. Smooth roll 120-202-291-487 129-218-313-524
3. Upper front feed roll 55-93-134-225 59-100-144-242
4. Upper front feed roll drive chain
5.
6. Upper rear feed roll 98-164-237-396 106-177-255-426
7. Cutterhead 1141 1229
8. Cutterhead gearbox
9. Cutterhead drive shaft 2568 2765
10. Blower 686 (760) 663 (735)
11. Reversing gearbox drive shaft 1950 2100
12. Main drive belt
13. Cutterhead reverse drive hydraulic motor 750 - 800 808 - 862
14. Engine 1950 2100
15. Main drive transfer gearbox
16. Hydrostatic pump 2791 3006
17. Work hydraulics pump 2791 3006
18. Steering hydraulics pump 2791 3006
19. Low pressure hydraulics pump 2791 3006
20. Electromagnetic clutch (forward drive) 1500 Nm (1100 lbf.ft) 1500 Nm (1100 lbf.ft)
21. Electromagnetic clutch (reverse drive) 1500 Nm (1100 lbf.ft) 1500 Nm (1100 lbf.ft)
22. Reversing gearbox
23. Stop pawl wheel 497 (172 reverse) 535 (185 reverse)
24. Cut-out clutch 1900 Nm (1400 lbf.ft) 1900 Nm (1400 lbf.ft)
25. Blower gearbox
26. Lower crop processor roll 3780 4070
27. Upper crop processor roll 3360 3620
28. Cop processor drive belt
29. Feed rolls drive shaft 497 (172 reverse) 535 (185 reverse)
30. Upper feed rolls slip clutch 1200 Nm (800 lbf.ft) 1200 Nm (800 lbf.ft)
31. Length-of-cut gearbox
32. Attachment drive p.t.o. shaft 383 (133 reverse) 412 (143 reverse)
52870
2
LUBRICANT APPLICATION GUIDE
Item Servicing interval Amount NEW HOLLAND NEW HOL- Lubric- International
/unit Brand name LAND ant specification
[litres] Specifica- grade
tion
Grease 10 h -- AMBRA GR9 NH710A NLGI2
fittings 50 h -- or or
100 h -- AMBRA GR75 MD NH720A NLGI2
Feed roll Change: 6.3 AMBRA NH520A SAE API GL5
gearbox -- after first 100 h HYPOIDE 90 80W-90
-- every 300 h or MIL-L-2105D
annually
Cutterhead Change: 4.3 AMBRA NH520A SAE API GL5
annually
Reversing Change: 4 AMBRA NH520A SAE API GL5
annually
Blower Change: 1.4 AMBRA NH520A SAE API GL5
annually
Four-wheel Change: 1.4 AMBRA NH520A SAE API GL5
drive -- after first 100 h HYPOIDE 90 80W-90
gearbox -- every 300 h or MIL-L-2105D
annually
Traction Change: 15 AMBRA NH520A SAE API GL5
annually
Final drive Change: 5 AMBRA NH520A SAE API GL5
annually
Steering axle Change: 10 AMBRA NH520A SAE API GL5
mechanical -- after first 100 h HYPOIDE 90 80W-90
four-wheel -- every 600 h or MIL-L-2105D
drive annually
[option]
tion
Rear-wheel Change: 1 AMBRA NH520A SAE API GL5

planetary -- after first 100 h HYPOIDE 90 80W-90
drives -- every 600 h or MIL-L-2105D
[option] annually
tion
Upper feed Change: 0.5 AMBRA NH520A SAE API GL5
roll drive -- after first 100 h HYPOIDE 90 80W-90
chain box -- every 600 h or MIL-L-2105D
annually
Chains -- weekly Sparing- AMBRA NH520A SAE API GL5
Threaded ly HYPOIDE 90 80W-90
rods -- every 200 h MIL-L-2105D
Pivot points -- every 200 h
Engine Check daily FX28-38 AMBRA NH330G SAE API CF4/SG

(oil + filters) Change: -48: 23 SUPERGOLD 15W-40
-- after first 100 h MULTIGRADE MIL-L-2104E
FX28-38-48: FX58:
-- every 300 h 34
FX58:
-- every 250 h
Brake Change every Reser- AMBRA NH800A -- NHTSA 116

system two years voir: 0.5 SYNTFLUID 4 DOT4,
MULTIGRADE ISO 4925
System:
2
Hydraulic Check daily Reser- AMBRA NH646H ISO VG DIN 51524
and Change: voir: 38 HYDROSYSTEM 46 part 2
hydrostatic -- after first 100 h 46HV
system -- every 600 h or System:
(oil + filters) annually 93
Main Check daily Reser- AMBRA NH646H ISO VG DIN 51524
hydraulic Change: voir: 7 HYDROSYSTEM 46 part 2
clutch -- after first 100 h 46HV
-- every 600 h or System:
annually 10
High Check daily Reser- AMBRA NH646H ISO VG DIN 51524
capacity Change: voir: 70 HYDROSYSTEM 46 part 2
rear -- after first 100 h 46HV
hydraulics -- every 600 h or System:
(oil + filter) annually 77
[accessory]
SECTION 10 -- ENGINE -- CHAPTER 1 1
SECTION 10 -- ENGINE
Chapter 1 -- Iveco Aifo Engine
CONTENT

10.101 Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10.106 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10.218 Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.242 Removal and installation of fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10.400 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 SECTION 10 -- ENGINE -- CHAPTER 1
CYLINDER HEAD BOLTS
Cylinder head seal has a “TOP” mark. Oil cylinder
head screws with UTOM oil and tighten to 150 Nm
following sequence given in Figure 12. Repeat
tightening at same torque. Now tighten the bolts in
the same sequence over 2 x 120° in 2 steps.
52023
VALVE CLEARANCE
Adjust the clearance between the rockers and the
valves using wrench 1 and feeler gauge 2. Running
clearance is intake 0.30 mm and exhaust 0.40 mm.
Bring the cylinder to be adjusted at expansion stroke.
The cylinder valves will be closed while the rockers
of the symmetrical cylinders are balancing. Sym-
metrical cylinders are 1--6, 2--5 and 3--4.
NOTE: When reassembling the engine, to adjust the

clearance between the rockers and the valves faster,
proceed as follows: 30365
1. Rotate the crankshaft. 2
2. Balance cylinder N° 1 valves and adjust the

valves marked with an asterisk, following the se-
quence indicated in the scheme.
Cylinder N° 1 2 3 4 5 6
Intake -- -- * -- * *
Exhaust -- * -- * -- *
3. Balance valves of cylinder N° 6 and adjust the

valves marked with an asterisk, following the se-
quence indicated in the scheme.
Cylinder N° 1 2 3 4 5 6
Intake * * -- * -- --
Exhaust * -- * -- * --
FUEL INJECTORS
Fuel injector components
1. Exhaust union
2. Washers
3. Casing
4. Washers
5. Union
6. Adjust washer
7. Spring
8. Cap
9. Spacer 51864
10. Nozzle
3
11. Retaining nut
Injectors consists of a nozzle holder and a nozzle.

The injector function is to admit atomised fuel under
pressure into the combustion chamber.
NOTE: The injectors are the same as used on the

TX68 and TF78 combines but the calibration pres-
sure is different!
Bench test and calibration
To calibrate an injector means to give its spring such

a load that the pressure preset for injection is necess-
ary to lift up the nozzle needle.
Correct calibration pressure is obtained by changing

the adjusting washer 6 (Fig. 3) thickness, so as to
suitably changes spring load 7.
Injector 1 test and calibration are carried out using

tool 2 (Ref. IVECO 99301116). The calibration value 51865
should be 250 +-- 08 bar. 4
After calibration, verify the nozzle seal acting on the

pump until the gauge indicates a pressure of 120 bar.
Check that a pressure drop from 120 to 70 bar takes
place in 4” to 20”.
Injector mounting bolts torque: 21 Nm.

FUEL INJECTION PUMP
Removal (Fig. 5 to 7)
1. Clean the pump area carefully.
2. Disconnect all components and assemblies

which may interfere with the disassembly pro-
cedure in the injection pump area.
3. Disconnect the throttle control actuator.
4. Remove delivery pump 1. 55152
5
5. Unscrew the fittings of high--pressure lines 2
from both the pump and the injectors.
6. Remove the brackets used to secure lines 2 to

the engine and move them inwards.
7. Remove fuel and oil supply lines 3 and return

lines 4.
8. Disconnect all remaining lines.
9. Disconnect the engine stop solenoid cable 5.
10. Remove mounting bolts 6 and nuts 7.
11. Remove the pump carefully. 55153
12. Plug up all openings of the lines and pump care- 6

fully to avoid dust ingress.
WARNING
Handle all components with great care.
Do not insert your hands or fingers in between com-
ponents.
Wear appropriate safety clothing, including goggles,
gloves and safety boots.
55159
7
Installation
1. Make sure the O--ring seals are correctly fitted on

the pump lubrication duct and distribution crank-
case.
2. Slide the pump on the drive shaft ensuring the

larger tooth and slot are properly matched.
3. Position the pump is such a way as to ensure that

the slotted holes in the pump housing are proper-
ly aligned with the pump mounting studs.
55155
4. Tighten nuts 7 and bolts 6.
8
5. Turn the flywheel until the injection timing 10
(Fig. 8) is accurately aligned with indicator 11.
The advance for the different engine types is: the

correct injection timing is stamped in the fly-
wheel.
6. Reassemble fuel and oil lines and engine con-

trols.
TIMING
If you have doubts about the exact timing you can

verify the relationship between the start of the injec-
tion and the plunger position.
1. Remove the inspection cap 19 (Fig. 9) corre-

sponding to plunger N° 1 from the pump.
2. Ensure plunger N° 1 is in the initial delivery posi-

tion (IDP), i.e. lower position.
3. Use special tool 12 (Ref. IVECO 99365183), in- 55154
cluding gauge 13. Place the tool’s stem on top of 9

the pump tappet.
4. Pre--charge the gauge by 2 to 3 mm.
5. Turn the flywheel to find the lowest position of

plunger N° 1.
6. Reset the gauge to zero.
7. Turn the flywheel by approximately half a turn in

the opposite direction to normal rotation.
8. Now turn the flywheel the other way and check

when the injection advance mark on the flywheel
coincides with the window indicator, the plunger
stroke should be: 55157
10
Engine hp Timing Piston travel
degree mm
300 hp 19° 3.35 -- 3.55
375 hp 8° 5.00 -- 5.10
450 hp 8° 5.00 -- 5.10
9. If you obtain a different measurement:
-- Loosen bolts 15 (Fig. 10).

-- Change the position of cam 16 (Fig. 10) in
order to obtain the correct pre--stroke (375
and 450 hp only).
55156
-- On the 300 hp engine rotate plate 17
(Fig. 11). 11
-- Check the stroke again and tighten nuts 15 to
100 Nm.
If a gauge is not available, the pump can be correctly

timed by means of the overflow DROP SYSTEM.
Proceed as follows (Fig. 12):
1. Remove the electric stop and put the accelerator
at maximum speed.
2. Close plunger outlets 2, 3, 4, 5, 6.
3. Position the throttle control lever on minimum

(1/4 of its travel).
4. Connect hand pump 17 (Ref. IVECO 99365034)

to the injection pump inlet port and close the
pump outlet port.
55158
5. Bleed the system. 12
6. Position the flywheel so as to align the 8° or 19°
mark (item 10 -- Fig. 8) with indicator 11.
7. Remove cap 19 (Fig. 9) and check that plunger

N° 1 is in the initial delivery position, i.e. lower
position.
8. Alternatively, check whether the valves of the

N° 1 cylinder are closed. N° 6 cylinder valves will
be balanced. If they are not, turn the engine
crankshaft one full turn.
9. Turn the engine crankshaft clockwise about half

a turn while looking at the flywheel.
30361
10. Operate hand pump 17 while at the same time
turning the engine crankshaft counterclockwise. 13
NOTE: This procedure must be carried out slowly but

steadily, with no interruptions.
11. Stop the crankshaft rotation as soon as fuel stops

flowing from the N° 1 plunger connector.
12. Check that the 8° or 19° mark (item 10 -- Fig. 8)

is aligned with indicator 11. If necessary, change
position of cam 16 (Fig. 10 -- 375 and 450 hp) or
plate 17 (Fig. 11 -- 300 hp).
13. Complete the procedure as described above

under item 9 on previous page.
COOLING SYSTEM
The engine cooling system consists of a centrifugal

pump driven by a crankshaft. Two thermostats on
cylinder head outlet end 9 control the engine running
temperature.
55160
14
Longitudinal section of water pump
1. Seal
2. Pump body
3. Seal
4. Control gear
5. Bearing
6. Seal gasket
7. Seal ring
8. Wheel
51867
15
Coolant thermostat
-- Beginning of opening: 79° C + 2° C
-- End of opening: 95° C
51866
16
SECTION 14 -- LIVE P.T.O. -- CHAPTER 1 1
SECTION 14 -- LIVE P.T.O.
Chapter 1 -- Main Drive Gearbox
CONTENT

14.100 Removal of the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal of shields and doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal of p.t.o. shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of the battery box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of the fuel reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of the main drive belt assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal of the hydraulic and the hydrostatic pump assembly . . . . . . . . . . . . . . . . . . . . . . 9
Removal of the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacing the rubber damper on the engine output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Splitting the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly and assembly of the components in the rear half of the gearbox . . . . . . . . . 14
Disassembly and assembly of the front half of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal and disassembly of hydraulic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal and installation of the pressure hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing clutch plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing the seals in the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal and installation of the clutch driven shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation of the clutch into the gearbox half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting the two gearbox halves together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation of the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installing the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation of the hydraulic and the hydrostatic pump assemblies . . . . . . . . . . . . . . . . 31
Installation of the main drive belt assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation of the fuel reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installing the battery box and the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installing the PTO shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Starting up the forage harvester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2 SECTION 14 -- LIVE P.T.O. -- CHAPTER 1
REMOVAL OF THE MAIN DRIVE GEARBOX
1. Park the machine on a place where it is possible

to reach with a forklift from the rear and the right--
hand sides.
There must also be about 1,5 m of free space
above the rear end of the spout.
2. Stop the engine and remove the ignition key.
3. Apply the hand brake.
4. Switch off the battery switch.
DANGER
Wait until all rotating parts have come to a complete
stop before opening the safety guards.
Removal of shields and doors
5. Open door 1. Disconnect the wires to the rotary

screen motor and the brush actuator. Lift away
the door from the machine.
6. Remove shield 2 from the machine.
1
7. Open door 1. Disconnect the wires to the rotary
screen drive motor and the brush actuator and lift
away the door.
8. Open doors 2 and 3 and remove them from the

machine.
2
9. Pull out cover plates 1 and 2.
3
10. Remove PTO guards 1 and 2.
11. Disconnect cutterhead speed sensor 3 with its

bracket.
12. Remove grease guard plate 1 Fig. 5.
4
Removal of p.t.o. shafts
13. Remove the cutterhead drive shaft bolts at 4

Fig. 4. Remove the main drive shaft bolts at 4 and
the conical bolt at 2. Remove shaft 3 from the ma-
chine.
NOTE: The cutterhead drive shaft is difficult to re-

move when the chopper body is installed on the for-
age harvester. However, it is possible to remove the
rear half of the drive shaft and to lift it over the cutter-
head gearbox to the front.
Before disconnecting both drive shaft halves from
each other, check whether the position marks are still 5
visible. If not, make new marks.
14. Remove the 4WD shaft (if installed).
Removal of the battery box
15. Switch off main battery switch 2.
16. Remove cover 1 of the battery box.
6
17. Mark battery cables 1 and 2 and disconnect
them.
18. Remove the batteries from the battery box.
19. Mark and disconnect all the other wires that

come into the battery box at 3.
7
20. Loosen the ten screws 1 that secure the battery
box to the machine frame and the right--hand
side platform.
DANGER
Be careful when loosening these screws. Even with-
out batteries in it, the battery box is quite heavy. Two
persons are needed to do this job.
21. Pull the battery box carefully away from the for-
age harvester and do not damage the free wires.
22. Tie up the wires away from the working area so

they do not get damaged.
8
Removal of the fuel reservoir
23. Remove fuel cap 1 together with the filler filter.
24. Drain the fuel reservoir through the filler opening

by means of a pump, or by creating a siphon.
The remaining fuel can be drained via the plastic
screw on the deposit bassin (lowest part of the
fuel reservoir).
NOTE: Take care not to spill fuel nor to pollute the

drained fuel or the fuel reservoir. The plastic screw
(with gasket) has to be reinstalled with a torque of 15 9
Nm (11 lbf. ft).
When a forklift with long forks and a sufficient capac-
ity is available, it is not necessary to drain all the fuel
from the fuel reservoir.
NOTE: Mark the items before removal so you can
easily reconnect them later.
25. Disconnect the two electric connectors 2 from the

fuel level sender Fig. 10 and 11.
26. Disconnect the two fuel pipes 1 from the fuel level
sender Fig. 10 and 11.
27. Remove round plate 3 together with the fuel level

10
28. Remove nut 5 and washer 4 Fig. 10 and 11 if

installed.
NOTE: IVECO engines: Fig. 10.
NOTE: CATERPILLAR engines: Fig. 11.
11
29. Remove the two screws 1 securing the water
separator to the protection plate of the fuel reser-
voir.
12
30. Remove clamp 1 (securing one of the hydraulic
hoses coming from the steering cylinder to the
protection plate of the fuel reservoir).
31. Support the fuel reservoir and the protection

plate from underneath, for example with a forklift
equipped with long lifter arms.
Drive in the forklift arms preferably from the rear.
13
32. Remove the six screws 1 (four at the front, two at
the rear) attaching the protection plate of the fuel
reservoir to the frame of the machine.
14
33. Simultaneously loosen the nuts on the three rods
1 (two on the left--hand side and one on the right--
hand side) to lower the fuel reservoir.
15
34. If a forklift or a platform with a capacity of at least
5000 kg is available: lift the forage harvester rear
end using the lift eyes on the rear bumper.
DANGER
Make sure that the forage harvester can not move
while lifting.
DANGER
Make sure that the connections between the forklift
or the platform and the lifting eyes are strong enough
and that they are installed in a safe way.
16
35. Pull the fuel reservoir and its protection plate out
to the rear.
36. If no forklift or platform is available, use a jack 1.
37. Install jack 1 under rear axle 2 on the right--hand

side and remove the rear wheel.
38. Jack up the forage harvester until the fuel reser-

voir filler neck can pass under the forage harvest-
er frame and pull out the fuel reservoir and its
protection plate to the right--hand side of the ma-
chine.
17
Removal of the main drive belt assembly
39. Remove plastic straps 1 from the wiring loom to

the cutterhead speed sensor.
40. Remove upper protection plate 2 of the fuel res-

ervoir.
41. Remove the main drive belt assembly as is de-

scribed earlier in this section.
18
Removal of the hydraulic and the hydrostatic

pump assembly
42. Drain the hydraulic and hydrostatic oil reser-

voir(s) through hoses 1.
NOTE: Note the correct routing of hoses and pipes.
NOTE: Collect all oil that is dripping from the hydrau-

lic components.
IMPORTANT: Protect all hose endings, pipe endings

and all pump ports from dirt. Any dirt in the system 19
can cause severe damage to the system or even total
destruction of pumps, valves, etc.
43. Disconnect hose 7 Fig. 20 and 3 Fig. 21 from the

low pressure pump.
44. Disconnect hose 6 Fig. 20 and 4 Fig. 21 from the

hydraulic pump for steering.
45. Disconnect hose 5 Fig. 20 and 5. Fig. 21 from the

work hydraulic pump.
20
46. Disconnect hoses 2, 3 and 4 from the left hand
side of the hydrostatic pump Fig. 20.
47. Disconnect hose 6 underneath the hydrostatic

pump (Fig. 21).
48. Disconnect the hydraulic pipe or (hose) 7 on the

right hand side of the hydrostatic pump in both
ends (Fig. 21).
49. Loosen or remove the hydraulic pipe 1 Fig. 20

and 21.
21
50. Disconnect the electric connector 1 from the
right--hand side of the hydrostatic pump.
22
51. Disconnect hydraulic pipe 1 from the top of the

main drive clutch housing.
52. Remove hydraulic pipe 2 from the machine.
53. Disconnect return oil hose 3 from the clutch

housing.
NOTE: Collect the oil coming from the low pressure

circuit.
NOTE: Drain the remaining oil (about 4 litres)

through the plug at the bottom of the main drive gear-
box housing.
23
54. Check that all connections to the pumps have
been disconnected and nothing hinders the re-
moval of the pumps. The pump group is heavy.
Make sure it is well supported before removal.
55. Remove the three bolts 1 and pull the pump
group away from the gearbox.
24
Removal of the main drive gearbox
56. Remove screws, washers and nuts 1 and also

the screws, washers and nuts on the sides. Re-
move the shielding plates 3, 2 and 4 between the
engine and the main drive gearbox.
25
57. Remove all but the two upper screws 1 which se-
cure the main drive transfer gearbox to the en-
gine.
58. Check that no obstacle hinders the removal of

the main drive transfer gearbox.
26
59. Drive a fork lift or a cart with special tool 1 Fig. 27
and 28 or a jack underneath the main drive
transfer gearbox and create a solid support be-
tween the main drive transfer gearbox and the
supporting device.
NOTE: The gearbox is heavy, about 125 kg.
60. Remove the two remaining screws 1 Fig. 26.
27
28
61. Pull the gearbox until the drive shaft is free from
the coupler to the engine and remove the assem-
bly from the machine as shown in Figure 27.
62. When placing the main drive gearbox on the floor

or on a work table, protect input shaft splines 1
from damage with wooden blocks.
29
REPLACING THE RUBBER DAMPER ON THE
ENGINE OUTPUT SHAFT
63. Check the condition of the rubber vibration

damper 3 whenever the main drive transfer gear-
box or the engine are removed from the machine.
If any signs of damage are visible then replace
the damper.
64. Remove screws and washers 1 and lift away

flange 2.
65. Note the position of the parts and dismount

damper 3 from flange 2 and splined hub 4.
30
NOTE: The rubber dampers must be installed in a
predetermined way. The wide end of the triangular
mark 1 must be turned towards the nut.
31
66. Install the rubber damper 3 onto the splined hub
4. The sharp end of the triangular mark on the
rubber damper must point towards the screw
head 5.
67. Install the hub and rubber damper assembly 3, 4

onto the flange 2 and tighten up the damper
fastening screws to a torque of 400 Nm (295 lbf.
ft).
68. Install the pre--assembled flange 2 onto the fly-

wheel of the engine and tighten screws 1.
32
SPLITTING THE MAIN DRIVE GEARBOX
69. Install special tool 3, or a similar one. A chain can

also be used. The important thing is that the
upper gearbox half 1 is well balanced and stays
parallel to the lower gearbox half 2.
70. Drive down, or remove guide pins 4 at both ends

of the gearbox.
71. Remove all Allen screws 5.
33
72. Separate the two gearbox halves 1 and 2.
NOTE: The gearbox halves are sealed with a liquid

sealant and may be glued together.
34
DISASSEMBLY AND ASSEMBLY OF THE
COMPONENTS IN THE REAR HALF OF
THE GEARBOX
73. Pull out the shaft and gear assembly 3 from gear-
box housing 2.
74. Pull out gear assembly 4 from gearbox half 2.
35
75. Remove circlip 5 from the shaft and gear assem-
bly 3.
76. Mark gear 6 so it can be reinstalled in the same

way onto shaft 3 as when it was removed.
36
77. Press shaft 3 out from gear 6.
78. Pull away the bearing inner race from shaft 3.
37
79. Remove the bearing outer races 7 from gear 6.
NOTE: There is a circlip between the bearings inside

the gear.
NOTE: The bearing inner races 8 must be installed

with the wide edge to the outside.
38
80. Install circlip 9 into the gear 6.
81. Drive bearing inner race 8 onto shaft 3. Note the

wide side of the inner race should be seated
against the shaft head.
82. Install bearing outer races 7 into gear 6.
83. Install gear 6 with bearing components 7 and 8

onto shaft 3.
84. Install circlip 5.
85. Install O--rings 10 and 11 onto shaft 3.
39
86. Remove bearings 12 and 13 from gear 4.
87. Install new bearings 12 and 13 onto gear 4.
NOTE: The open bearing (no seals) 12 is installed on

the shorter shaft side of gear 4.
Bearing 13 with a seal on one side is installed on the
longer shaft side of the gear 4 with the seal towards
the end of the shaft.
40
88. Turn gearbox half 2 to the position shown in Fig-
ure 41 and support it well.
89. Remove Allen screws 1 and remove cover 3 over

shaft 4.
41
90. Remove seal 5 from cover 3.
91. Open up stake washer 6 and remove special nut

7 from shaft 4, with the special tool as shown in
Figure 43.
42
92. Special tool 8.
43
93. Drive shaft 4 out of gearbox half 2.
94. Remove the two asymmetric bearings from gear-

box half 2.
44
95. Remove Allen screws 2.
96. Remove gear 3 from shaft 4.
97. Remove outer clutch body 1 from shaft 4.
45
98. Install outer clutch body 1 onto shaft 4.
99. Install gear 3 onto shaft 4.
100. Install Allen screws 2 and secure them in place.
101. Use a thread retainer when installing screws 2

Fig. 45 and 46.
102. Tighten screws 2 to a torque of 17 Nm

(12.5 lbf. ft) Fig. 45.
46
103. Install the asymmetric bearings 1 into gearbox
half 2.
NOTE: The wide surfaces of the outer races of the

bearings should touch each other, the narrow sur-
faces should be seated against the shoulder in gear-
box half 2 and against locking nut 7.
104. Lift gearbox half 2 on top of the shaft assembly

and drive the bearings onto shaft 4 using a suit-
able pipe.
47
105. Install washer 6 and special nut 7 and lock the
bearings in place. Use special tool 8 Fig. 43.
48
106. Install new O-ring to cover 1.
107. Install cover 1 with the pre--installed seal. Install

Allen screws 2 with some thread locking com-
pound.
108. Tighten Allen screws 2 to a torque of 17 Nm

(12.5 lbf. ft).
49
109. Turn the gearbox half 2 as shown in Figure 50
and support it well.
110. Pre--install gear assemblies 3 and 4 into gear-

box half 2.
50
111. Install a new pilot bearing 1 into shaft 2.
51

FRONT HALF OF THE GEARBOX
Removal and disassembly of hydraulic clutch
112. Turn gearbox half 1 as shown in Figure 52 and

support it well.
113. Remove bearing 4 from shaft 6.
NOTE: Replace this bearing 4 every time the gear-

box is opened up.
Check shaft 6 for wear and replace if damaged.
114. Disconnect hydraulic hose 5 from gearbox

housing 1.
52
115. Check circlips 2 and 3 Fig. 52.
Replace if damaged.
116. Remove the circlip 1 from shaft 6.
53
117. Remove positioning screw 1 for the clutch pres-
sure sleeve Fig. 54 and 55.
NOTE: Replace this screw if damaged or bent.
54
118. Grip pressure sleeve 3 (a sleeve connected to
hydraulic hose 2) and clutch assembly 4 Fig. 55
and 56 with both hands and lift the clutch as-
sembly over the shaft and out from the gearbox
housing half.
55
119. Sometimes clutch assembly 4 is so tight that a
puller is needed.
NOTE: Sleeve 3 is a matched part of clutch 4. If the

sleeve is, or gets damaged a new clutch assembly
needs to be installed Fig. 55.
56
Removal and installation of the pressure hose
NOTE: The sealing elements inside sleeve 3 Fig. 55

are made of a soft metal and are very sensitive to
damage. Be careful not to damage them and oil the
surfaces before assembly.
NOTE: Mark sleeve 3 and clutch cylinder 4 before re-

moving sleeve 3. The sleeve must be installed with
the hole for the positioning screw 1 in a correct posi-
tion.
120. Remove and discard the old hydraulic hose as-

sembly 5.
121. Install the new hose assembly 5 onto the sleeve 57

as shown in Figures 57 and 58 but do not
tighten completely.
122. Loosen hose 5 at the connection to banjo 7

Fig. 57 and turn hose 5 as shown in Figure 58
(50 to 55_ from the horizontal plane) and then
tighten into this position (25--30 Nm) (19 -- 22
lbf. ft).
58
123. Let sleeve 3 rest on clutch cylinder 4.
124. Adjust banjo connector 7 and hose 5 to the posi-

tion shown in Figure 59.
125. Hose 5 should pass clutch cylinder 4 at a dis-

tance of 0,5 mm from the clutch as shown in Fig-
ure 59.
126. Tighten banjo connector 7 (52--58 Nm) (39 -- 42

lbf. ft) and hose 5 into this position.
59
Replacing clutch plates
127. Remove Allen screws 1 from pressure plate 2.
NOTE: The Allen screws 1 are installed with a thread

retainer.
128. Install two M10 x 50 screws 3 and press up

pressure plate 2.
60
129. Remove the old disc pack 4 and check inner
body 6 for any damage.
130. Remove springs 5 and check them for any dam-

age.
131. Clean holes 7 for the Allen screws from oil and
dirt.
132. Install new disc pack 4. Install alternately ”inner”

and ”outer” discs. The first and the last disc
should be an inner disc.
61
133. Install springs 5 Fig. 61.
134. Install pressure plate 2 Fig. 62.
135. Use two M6 x 50 screws and two M6 nuts and

washers as guiding and installation tools for the
pressure plate. Press the pressure plate onto
the inner body with the M6 nuts until Allen
screws 1 can be installed.
136. Install Allen screws 1 with a thread locking com-

pound and tighten to a torque of 17 Nm (12.5 lbf.
ft).
62
Replacing the seals in the clutch
137. Mark sleeve 3 and clutch cylinder 4.
138. Remove sleeve 3 with a rotating movement

from clutch cylinder 4. Do not use tools.
NOTE: The sleeve is a matched part with the clutch

cylinder. If the ring is worn, or damaged then replace
the clutch cylinder.
63
139. Remove Allen screws 8 from clutch cylinder 4.
NOTE: The Allen screws are installed with a thread

locking compound.
64
140. Mark clutch cylinder 4 and clutch piston 9 in
order to make a correct installation possible.
141. Install two screws M6 x 70 and press up the pis-

ton/cylinder assembly from the inner clutch
body.
65
142. Check the condition of roll pins 1 and replace as
necessary.
143. Mark the position of oil hole 2 close to one of the

roll pins 1 and replace the O--ring if necessary.
66
144. Carefully split piston 9 from cylinder 4.
145. Remove seal 5 and the two O--rings behind it .
67
146. Install O--rings 1 into groove 2 of the piston and
make sure they are next to each other and not
crossed.
147. Install seal 3 on top of the previously installed

O--rings 1.
NOTE: It is possible to install the seal without special

tools.
68
148. Remove inner seal 1 and the O--ring behind it
from the inner surface of the piston.
69
149. Install O--ring 1 into inner groove 2.
150. Install seal 3 into the groove on top of O--ring

1.
NOTE: It is possible to install the seal without special

tools.
70
151. Check the condition of O--ring 1 and replace as
necessary.
152. Mark the position of the oil hole and check that
roll pins 2 are intact.
NOTE: Pay attention: it is possible to install the ”pis-

ton and cylinder assembly” 180_ wrong.
It would be impossible to engage the clutch then.
It is also possible to replace the clutch plates now.
71
153. Oil the parts and install piston 1 into cylinder 2.
72
154. Install piston/cylinder assembly 1 on to the
clutch body.
NOTE: Make sure that the oil channels are in the cor-
rect position.
155. Clean the holes for the Allen screws and install
Allen screws 2 with a thread locking compound
and tighten to a torque of 17 Nm (12.5 lbf. ft).
73
156. Lubricate and install sleeve/hose assembly 1
carefully with a rotating movement onto the
clutch cylinder as shown in Figure 74.
NOTE: Do not use tools for this installation.
74
Removal and installation of the clutch driven
shaft
157. Remove spacer bushings 1 and spacer

washers 2 from shaft 3.
75
158. Press out shaft 2 from gearbox half 1.
159. Check the shaft for any wear or damage and re-
place as necessary.
76
160. Remove seal 2 from gearbox half 1.
NOTE: The seal will be damaged at removal and

must be replaced.
77
161. Remove circlip 2 from gearbox housing half 1.
162. Replace bearing 3 in gearbox housing.
163. Reinstall circlip 2.
164. Install a new seal 2 (Fig. 77).
78
165. Install and press shaft 2 into gearbox half 1.
79
Installation of the clutch into the gearbox half
166. Install two spacer washers 1 and two spacer

bushings 3 onto shaft 2.
167. Screw in guide bolt 4 so it just enters inside the

gearbox half.
80
168. Grip pressure sleeve 3, hydraulic hose 2 and
clutch assembly 1 Fig. 81 and 82) with both
hands and lift the clutch assembly over shaft 4.
169. Screw guide bolt 5 into the hole in sleeve 3.

Make sure sleeve 3 is free on bolt 5 and clutch
1. Tighten guide bolt 5 to 37--43 Nm (28 -- 31 lbf.
ft).
NOTE: Use some thread locking compound when

securing bolt 5 in place.
81
170. Install circlip 1 onto shaft 2.
NOTE: There should be a maximum axial play of 1

mm between clutch and circlip.
171. If the play is more than 1 mm, remove the clutch

and insert an extra spacer washer 1 (Fig. 80).
82
172. Install special tool 2 as shown in Figure 83, to
align the clutch into its operating position.
173. Connect hydraulic hose 3 to gearbox half 1

(25--30 Nm) (19 -- 22 lbf. ft).
NOTE: Make sure the hose connector and the con-

nector in the gearbox housing line up. If not reinstall
the hose as shown in Fig. 58 and 59.
174. Check that hose 3 does not touch the walls of

gearbox housing 1.
175. Check that the pressure sleeve is free and

square on the clutch. If not then re--adjust the
hydraulic hose installation. 83
176. Remove special tool 2 from gearbox half 1.
CONNECTING THE TWO GEARBOX HALVES TO-

GETHER
177. Align clutch plates 1.
84
178. Install special tool 1 on top of clutch plates 3.
NOTE: Use an old or new outer body of the clutch as

special tool.
85
179. Connect a hydraulic hand pump 1 to the gear-
box at connecting union 2 (Figures 85 and 86).
180. Apply and keep applying sufficient hydraulic

pressure to lock the clutch pack.
181. Remove special tool 1 (Fig. 85).
86
182. Keep the clutch plates locked and move gear-
box half 1 on top of gearbox half 2 as shown in
Figure 87.
183. Apply a liquid sealant on the contact surface of

gearbox half 2.
184. Lower gearbox half 1 on top of gearbox half 2.

Make sure you do not damage the clutch plates.
87
185. Drive in or install guide pins 4 at both ends of the
gearbox.
186. Install all Allen screws 5.
187. Remove special tool 3, or any other arrange-

ment from gearbox half 1.
88
INSTALLATION OF THE MAIN DRIVE
GEARBOX
Installing the main drive gearbox
188. Install gearbox 1 onto special support 2, or any

other sturdy support.
89
189. Attach the support with gearbox 1 to a forklift
equipped with long forks.
NOTE: The gearbox is heavy, about 125 kg (see

fig. 27).
190. Clean gearbox contact surface 3 and the corre-

sponding surface on the engine.
191. Apply pressure resistant grease (NLGI class 2)

to the splines of shaft 2.
192. Move the gearbox inside the machine and push

it in place.
90
193. Install the two screws 1.
194. Remove the gearbox support from the ma-

chine.
195. Install the rest of the screws 1 and secure in

place.
91
196. Install shielding plates 3, 2 and 4 (Fig. 92) be-
tween the engine and the main drive gearbox,
with screws, washers and nuts 1 and also the
screws,--washers and nuts on the sides.
92
Installation of the hydraulic and the hydrostatic
pump assemblies
197. Install the hydraulic and the hydrostatic pump

assemblies onto the main drive gearbox.
198. Install screws 1 using a thread locking com-

pound (type 2).
93
199. Connect return oil hose 3 to the gearbox hous-
ing.
200. Install hydraulic pipe 2 between the gearbox

and the low pressure valve.
201. Connect hydraulic pipe 1 to the gearbox hous-

ing.
NOTE: The hydraulic tubes should be installed with-

out interference and tension.
94
202. Connect electric connector 1 to the right--hand
side of the hydrostatic pump.
IMPORTANT: Make sure all hydraulic and hydro-

static connecting unions are clean before assembly.
Torque tables for ferrules, connections and ball type
unions are shown in Section 35 - Hydraulic system
of the Repair Manual.
95
203. Connect or install hydraulic pipe 1 Fig. 96
and 97 (2 x 125 Nm) (2 x 92 lbf. ft).
204. Connect hydraulic pipe (or hose) 7 to the right--

hand side of the hydrostatic pump
205. Connect hose 6 underneath the hydrostatic

pump and tighten the nut to a torque of 210 Nm
(155 lbf. ft).
206. Connect hoses 2, 3 and 4 to the left--hand side

of the hydrostatic pump Fig. 97. Tighten screws
2 and 4 to 105 Nm (77 lbf. ft) and union nut 3 to
34 Nm (25 lbf. ft).
96
207. Connect hose 5 Fig. 97 and pipe 5 Fig. 96 to the
work hydraulic pump.
208. Connect hose 6 Fig. 97 and pipe 4 Fig. 96 to the

hydraulic pump for steering.
209. Connect hose 7 Fig. 97 and hose 3 Fig. 96 to

the low pressure pump. Tighten the screws for
hose 7 to a torque of 115 Nm (85 lbf. ft).
NOTE: Do not fill up the hydraulic and hydrostatic cir-

cuits at this point in time.
97
Installation of the main drive belt assembly
210. Install the main drive belt assembly as de-

scribed earlier in this section.
211. Install upper protection plate 2 of the fuel reser-

voir.
212. Install plastic straps 1 to hold the wiring loom to

the cutterhead speed sensor.
98
Installation of the fuel reservoir
213. If a jack 1 is used.
214. Jack up the forage harvester until the fuel reser-

voir filler neck can pass under the forage har-
vester frame and push in the fuel reservoir to-
gether with its protection plate from the right
hand side of the machine, until the assembly is
in a correct position to be lifted up (use a forklift
with long forks).
215. Install the rear wheel and remove jack 1. The

rear wheel bolts torque is 220 Nm (162 lbf. ft) for
2WD and 450 Nm (332 lbf. ft) for 4WD.
99
216. If a fork lift or a platform with a capacity of at

least 5000 kg is available: lift the forage har-
vester rear end using the lift eyes on the rear
bumper.
DANGER
Make sure that the forage harvester can not move
while lifting.
DANGER
Make sure that the connections between the fork lift
or the platform and the lifting eyes are strong enough
and that they are installed in a safe way. 100
217. Push the fuel reservoir and its protection plate

in from the rear.
218. Carefully lift up the fuel reservoir with its protec-
tion plate until the three rods (two on the left--
hand side and one on the right--hand side) and
the left--hand side support plate can be secured
in place with washers and nuts 1.
101
219. Install six screws 1. (four at the front, two at the
rear) to attach the protection plate of the fuel
reservoir to the frame of the machine.
220. Remove the tool you used to lift up the fuel res-
ervoir.
102
221. Install clamp 1 that secures one of the hydraulic
hoses coming from the steering cylinder to the
protection plate of the fuel reservoir.
103
222. Install the two screws 1 and the water separator
to the protection plate of the fuel reservoir.
104
223. Install nut 5 and washer 4 Fig. 105 and 106.
224. Install round plate 3 together with the fuel level

225. Connect the two fuel pipes 1 to the fuel level

226. Connect the two electric connectors 2. to the

fuel level sender Fig. 105 and 106.
NOTE: IVECO engines: Fig. 105.
105
NOTE: CATERPILLAR engines: Fig. 106.
106
227. Install fuel cap 1 together with the filler filter.
228. Check that the plastic screw (with gasket) has

been installed on the deposit bassin. The screw
should be installed with a torque of 15 Nm (11
lbf. ft).
107
Installing the battery box and the batteries
DANGER
The battery box is quite heavy. Two persons are
needed to do this job.
229. Prepare the removed wires so they can be

routed to the inside of the battery box.
230. Install the battery box and secure in place with

screws and washers 1.
108
231. Install the wires at 3.
232. Lift the batteries into the battery box and secure
them in place with the clamp.
233. Install battery cables 1 and 2.
109
234. Install cover 1 of the battery box.
110
Installing the PTO shafts
235. Install the 4WD shaft (on a 4WD machine).
236. Install grease guard plate 1.
237. Install main drive shaft 3 and secure in place

with screws and washers 4 and the conical bolt
at 2 (60 Nm) (44 lbf. ft).
238. Bring the cutterhead drive shaft into the ma-

chine from the front.
111
239. Install the cutterhead drive shaft with screws
and washers 4.
240. Connect the cutterhead speed sensor 3 with its

bracket.
241. Install PTO guards 1 and 2.
112
Starting up the forage harvester
242. Fill up the fuel reservoir and bleed the fuel sys-
tem as described in chapter 5.16.1 Fuel sys-
tem, paragraph Bleeding the fuel system in the
Operator’s Manual.
NOTE: Do not start the engine at this point.
243. Fill up and bleed the low pressure hydraulic sys-

tem as described in Section 35 Hydraulic sys-
tem, chapter 5, paragraph Filling the system
after (re) installing the main drive gearbox in the
Repair Manual.
NOTE: Do not start the engine at this point.
244. Fill up and bleed the hydrostatic system as de-

scribed in Section 1, chapter 29, paragraph Fill-
ing and bleeding the hydrostatic system in the
Repair Manual.
NOTE: Switch on the main electric switch 2 fig. 110

at the battery box. Start the engine and follow the pro-
cedures as described above.
245. Install doors 3 and 2 onto the forage harvester
246. Lift door 1 in place and connect the wires to the

rotary screen drive motor and brush actuator
113
247. Install cover plates 2 and 1.
114
248. Install shield 2 onto the machine.
249. Lift door 1 in place and connect the wires to the

rotary screen drive motor and brush actuator.
115
Test all functions of the machine and repair if necess-
ary.
SECTION 21 -- TRANSMISSION -- CHAPTER 1 1
SECTION 21 -- TRANSMISSION
Chapter 1 -- Traction Gearbox
CONTENT

21.145 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gearbox shafts and shifting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 SECTION 21 -- TRANSMISSION -- CHAPTER 1
LUBRICATION
Oil change
• After the first 100 operating hours
• Thereafter, every 600 operating hours or annual-

ly
Gearbox capacity
15 litres
Oil specification
Use AMBRA HYPOIDE 90 oil (ref. NH520A) or an oil

meeting the following specification:
-- API GL5 or MIL--L--2105 D
-- Viscosity grade: SAE 80W -- 90

GEARBOX SHAFT
Shaft A: half--shafts from differential
Shaft B: transmission main shaft
Shaft C: countershaft
Shaft D: drive shaft
51140
1
SHIFTING DIAGRAM
First gear: 1 -- 2 -- 3 -- 4 differential
Second gear: 1 -- 2 -- 5 -- 6 differential
Third gear: 1 -- 2 -- 7 -- 8 differential
Fourth gear: 1 -- 2 -- 9 differential
2
DISASSEMBLY OF TRACTION GEARBOX
General
1. Remove the chopper body from the base unit.
2. Remove the blower from the base unit.
3. Remove the hydrostatic motor with the housing

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

upper part of the gearbox: 3
-- Shifter shaft
-- Differential cable
-- Handbrake cable
-- Electric wires
5. Note the position of the differential lock lever and

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

remove selector forks D. Ensure balls and
springs do not fall into the gearbox.
4
Removal of drive shaft
1. Remove the selector fork and shifter shafts.
2. Remove cover E.
3. Remove circlip F and slide it halfway the shaft G.
4. Drive shaft G to the left--hand side.
5
5. Remove ball bearing H and slide circlip F and
gear I from shaft G.
6. Remove shaft G from the left--hand side.
6
Removal of the countershaft
NOTE: This shaft can be removed without removing

shifter shafts C (Fig. 4) or input shaft G (Fig. 5).
1. Remove the four--wheel drive (refer to paragraph

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

paragraph headed “Disassembly of brake shoe
and discs”).
7
3. Remove the five nuts J (Fig. 7) and drive out
bearing housing K (Fig. 8) from the inside using
a plastic hammer.
4. Install special tool L (part n° 80434443) and in-

stall bearing housing K the other way around
(Fig. 9).
5. Drive the shaft out to the right until the left--hand

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

8
(Fig. 9).
7. Remove the shaft together with gears M and N.

Finally remove gear O (Fig. 9).
9
Removal of transmission main shaft
NOTE: This shaft can be removed without removing

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

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

(refer to paragraph headed “Disassembly of
brake shoes and discs”).
10
3. Remove the selector forks and shifter shafts
(refer to paragraph headed “Removal of selector
forks and shifter shafts”).
4. Remove bearing housing P by removing the six

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

S (part n° 84014512) on the right--hand side.
11
6. Drive the shaft to the left--hand side and remove

slotted nut 1, lock washer 2 and bearing R1.
12
7. Remove ring 3, gear 5, needle bearing 6 and cir-
clip 7 through the aperture in the left--hand side
of the gearbox (Fig. 13).
8. Remove the shaft with the remaining gears from

the gearbox.
51141
13
Removal of the half--shaft from the differential

2. Remove the brake shoes and discs on both sides

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

clip U on both sides.
14
4. Pull out both shafts V together with bearings W.
15
Removal of the differential
NOTE: For a possible disassembly of the differential

control lever, refer to Fig. 16.
1. Remove both half--shafts (Fig. 15).
2. Remove six nuts 8 (Fig. 17).
3. Remove bearing housing 9 by screwing in two

bolts 10 (M8x60) instead of two M8x16 bolts
(Fig. 17). 51144
16
4. Proceed in the same way on the other side and
remove differential 11 (Fig. 17).
NOTE: Remove the differential lock jaws and spring

together with the left--hand bearing housing 9
(Fig. 17).
51143
17
ASSEMBLY OF TRACTION GEARBOX
Assembly of the differential
1. Install the bearing housing 12 with six nuts 8 on

the right--hand side (Fig. 17).
2. Position the differential between bearing housing

12 and bearing housing 9, and drive bearing
housing 9 to the right--hand side (Fig. 17).
NOTE: Before driving bearing housing 9 to the right--

hand side, install the differential lock jaws and spring
between the differential and bearing housing 9
(Fig. 17).
3. Install the six nuts 8 on the left--hand side secur-

ing bearing housing 9 (Fig. 17).
Assembly of the half--shafts of the differential
1. Install bearing W on shaft V (Fig. 18).
2. Install shaft V, circlip U, O--ring X and oil seal ring

T. Ensure that oil seal ring T is installed as deep
as possible (Fig. 19).
3. Proceed in the same way on both sides.
NOTE: An alternative way to disassemble the left--

hand half--shaft V with the differential lock is:
18
-- Before installation of housing 9 on the gearbox,
pre--assemble housing 9 together with shaft V,
bearing W, O--ring X, oil seal T and circlip U as
one unit.
-- Slide the differential lock jaws and spring onto

half--shaft V.
-- Slide the whole unit into the gearbox and secure

with nuts 8
19
Assembly of transmission main shaft
1. Position shaft 36 in its aperture in the gearbox

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

ing gear 30, shifter ring 31 (Fig. 20).
-- Needle bearing 28, gear 29, sleeve 27, ring
26, ring 25, needle bearing 23, gear 24, shift-
ing gear 21, shifter ring 22 and circlip 20
(Fig. 20).
-- Ring 19, needle bearing 17, gear 18 and ring
16 (Fig. 20).
20
2. Install special tool Z (part n° 80434446) (Fig. 21).
3. Install bearing R1 on the left--hand side of the

shaft and drive it further with the shaft in the gear-
box (Fig. 21).
4. Install special tool Y (part n° 80434450) (Fig. 21).
5. Install bearing R on the right--hand side (Fig. 21)

and bearing housing P (Fig. 22). Drive bearing
housing P to the left--hand side and tighten it with
nuts Q (Fig. 22).
6. Remove special tools Z and Y.

21
7. Drive the shaft and bearing R1 to the right--hand
side.
8. Install lock washer 2 and slotted nut 1 (Fig. 12).

Tighten nut 1 with a torque of 130 Nm.
22
Assembly of the countershaft
Install following parts on the shaft outside the gear-

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

on the right--hand side is part of the shaft).
2. Narrow ring 42.
3. Gear 41, with the wider part of the hub to the left-
hand side.
23
4. Wide ring 40.
5. Gear 39, with the wider part of the hub to the left-
hand side (Fig. 23).
Introduce the reassembled shaft in the gearbox and

install:
6. Gear 38, with the wider part of the hub to the

right--hand side (Fig. 23).
7. Gasket together with bearing housing K using

special tool Z (part n° 80434446) (Fig. 24).
Tighten bearing housing K with nuts J (Fig. 7).
24
8. Left--hand bearing 37, maintaining a minimum
axial clearance between the gears (Fig. 23).
Assembly of the drive shaft
1. Install input shaft G with the pre--assembled left-

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

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

ing a minimum clearance and ensuring that the
filler opening in the bearing outer ring is located 25
at ±25° before the vertical axial line.
Assembly of selector shafts and forks
1. Install ball and spring in selector forks A using

special tool B (part n° 80434416) (Fig. 26).
26
2. Slide selector shafts C in forks D (the notch point-
ing upwards) and secure the latter with pins B
which are themselves secured with a piece of
wire (Fig. 27).
27
Calculation of shims to be installed on the shafts
ON INPUT, DRIVE OR CLUTCH SHAFT AND THE

COUNTERSHAFT
The permissible axial clearance of these shafts is 0.2

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

2. Raised part on the clutch hous- 1.2 mm
ing:
Difference: 0.8 mm 51142
3. Thickness of gasket: 0.15 mm 28

Total: 0.95 mm
Shims to be installed: 0.75 to 0.35 mm.
ON TRANSMISSION MAIN SHAFT
The permissible axial clearance of this shaft is 0.5 to

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

explained above.
Assembly of the cover
Install the cover and adjust pawl 45 (Fig. 28) as fol-

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

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

Turn in adjusting bolt 47 until it is tight and un- 51144
screw one turn. Tighten the lock nut.
29
NOTE: Make sure the differential lock control is cor-

rectly assembled, and that the fork goes into its slot
(Fig. 29).
Fill the gearbox with 15 litres SAE 80W--90 (API--

GL5) oil.
NOTE: To remove bearing R (Fig. 11), special puller

S has to be used. The previous version (part
n° 80434463) cannot be used any longer, but it can
be modified. 51146
Refer to Fig. 31, and to Fig. 30 for the bore diameter.
To have good results, make the finger out of 30
42CrMoS4V+S material.
51145
31
SECTION 23 -- 4WD LINES -- CHAPTER 1 1
SECTION 23 -- 4WD LINES
Chapter 1 -- 4WD Angle Gearbox
CONTENT

23.000 Removal from the base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly of 4WD angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly of 4WD angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation on base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 SECTION 23 -- 4WD LINES -- CHAPTER 1
REMOVAL FROM BASE UNIT
1. Drain the oil from the gearbox.
2. Remove the drive shaft to the rear axle by remov-

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

the clutch at B.
30642
1
4. Remove bolts A and B, remove rubber coupling
C (Fig. 2).
5. Remove gearbox fastening bolts at D. Note the

location and number of shims, if installed. Re-
move the gearbox from the machine (Fig. 2).
DISASSEMBLY OF 4 WHEEL DRIVE ANGLE

GEARBOX -- Figure 2
1. Remove bolts G and cover H.

Cover H was sealed with a liquid sealant.
2. Remove bolts E and remove the input gear as-

sembly from the gearbox. Do not damage O--ring
J and shims K.
3. If necessary, separate shaft M from gear L. Do

not damage O--ring N.
4. Remove seal P (will be damaged), lock nut R and

lock washer Q.
5. Press gear L out of housing F, and remove bear-

ings S from housing F.
6. Remove bolts T and pull out shaft V together with

the clutch assembly.
7. Remove lock nut W and lock washer AA, and

press shaft V out of the clutch assembly.
8. Remove seal BB, bearing race EE, circlip CC and

bearing DD.
9. Remove lock nut GG, lock washer HH, ring JJ,

and press shaft KK out of the gearbox housing.
30642
2
ASSEMBLY OF 4 WHEEL DRIVE ANGLE
GEARBOX -- Figure 3
1. Install bearing outer races LL in the gearbox

housing.
2. Press bearing LL onto shaft KK. Press in shaft KK

with installed gear until the bearing seats against
the gear.
3. Install the second bearing LL onto the shaft end.

Install ring JJ, lock washer HH and lock nut GG.
4. Tighten the lock nut GG until the bearing preten-

sion is 1.0 to 2.5 Nm. Lock the nut in place with
washer HH.
5. Install bearings EE, circlip CC, and seal BB into

the clutch housing.
6. Install lock washer AA and lock nut W until the

bearing pretension is 1.0 to 2.5 Nm. Lock the nut
in place with washer AA.
7. Install the drive housing with bolts FF. Install the

shaft and clutch assembly V and secure with
bolts T.
8. Install bearings S into housing F, and gear L.

Press gear L into place. Secure with lock washer
Q and lock nut R.
9. Tighten lock nut R until the bearing pretension is

1.0 to 2.5 Nm and lock the nut in place with
washer Q.
10. Install seal P.
11. Install O--ring N. Press shaft M into gear L, and

secure in place.
12. Install the input shaft assembly into the gearbox.

Do not forget the O--ring J, and adjust the back-
lash to 0.2 -- 0.3 mm with shims K.
13. Apply liquid sealant on the contact surfaces and

install cover H with bolts G.
30642
3
INSTALLATION ON BASE UNIT
1. Install drive flange MM on the handbrake shaft

(Fig. 3).
2. Install the centering flange shown in Figure 4

(special tool) on flange MM (Fig. 3).
3. Install bearing shaft M with the gearbox on the

flange (Fig. 3).
4. Install bolts D with sufficient shims between the

gearbox and the base unit frame, and fasten the 30643
gearbox with bolts D (Fig. 3).
4
5. Remove the special tool and install rubber
coupler C (Fig. 3).
6. Install drive shaft F with bolts A.
7. Connect the hydraulic pipe to the clutch housing

at B.
8. Fill the gearbox housing with 1.4 litre hydraulic

oil.
Use AMBRA HYPOIDE 90 oil (ref. NH520A) or

an oil meeting the following specification:
-- Viscosity grade: SAE 80W--90
30642
9. Bleed the system:
a) Put the gearbox in neutral.

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

25.310 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly and assembly of final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1
LUBRICATION DISASSEMBLY OF FINAL DRIVES
General data Output shaft
The filler and oil level plugs are positioned at a differ- 1. After draining the oil, remove cover P, three bolts
ent height as the final drives are installed inclined. G, washer F, shims H and the cover on top of the
housing.
Depending on whether the final drive is installed on 2. Press output shaft B out of the housing, keeping
the left or the right--hand side, one plug is for check- bearing C and seal D installed on the shaft.
ing the oil level and one for filling. The lower plug will
always be the oil level plug. 3. Remove the rings of bearings C and E out of the
housing.
Type 4. Remove sealing D from the output shaft.
Gear ratio 10/75
Input shaft
Maintenance
1. Remove bearing covers and S and shims I.
Change the oil
-- after first 100 working hours 2. Push the shaft out of the housing.
-- every 600 working hours, or annually
3. Remove the bearing rings out of the housing and
remove the bearings from the shaft.
Gearbox capacity
5 litres (each gearbox)
Oil specification
Use AMBRA HYPOIDE 90 oil (ref. NH520A) or an oil

50361
1
ASSEMBLY OF FINAL DRIVES Output shaft
1. Install the rings of bearings C and E in the hous-

Input shaft ing.
2. Grease seal D (with multipurpose grease NLGI2)

1. Install both bearings on the shaft and oil the bear- and install the seal and bearing C on shaft B.
ings.
3. Introduce the gear in the housing.
2. Introduce the preassembled shaft in the housing.
4. Push shaft B in the housing until the seal is com-
3. Install the bearing rings of bearings L and M. pletely inside.
4. Install bearing cover R using sealing paste. 5. Lay the housing flat on the wheel flange.
5. Install a new seal in bearing cover S and install
6. Install circlips N, bearing E and washer F.
the cover.
7. Press the bearing on the shaft by tightening bolts
G to 90 Nm (66 lbf.ft) torque.
End play adjustment
1. Tighten the bolts of cover S to 34 Nm (25 lbf.ft) Preload adjustment

torque.
1. Loosen the three bolts G until a small end play is
2. Loosen the bolts. obtained on the output shaft.
3. Tighten the bolts again and at the same time 2. Install a dial gauge on washer F and tighten the
check with a dial gauge on the top of shaft K three bolts G uniformly until an end play = O is ob-
whether the end play is still 0.1 mm (0,004’’).
tained.
4. Measure the end play between the housing and 3. Remove the three bolts G and washer F.
bearing cover S and install shims I for the same
value. Tighten the bolts again to 34 Nm (25 lbf.ft) 4. Measure distance X between the shaft end and
torque. Check the end play again which should the bearing edge.
now be 0.05 to 0.1 mm (0,002’’ -- 0,004’’). If not
so, shims should be removed or added. 5. Install shims to the same value as the measured
value X -- 0.3 mm (X -- 0,012’’).
5. Apply sealing paste between bearing cover S
and the housing, and between the separate 6. Install washer F and bolts G and tighten the bolts
shims. to 235 Nm (173 lbf.ft) torque.
6. Tighten the bolts of bearing cover S to 34 Nm 7. Apply sealing paste to cover P and install the
(25 lbf.ft) torque. cover. Install the housing cover with a new
gasket.
8. Fill the final drive housings with 5 litres oil each.
Use AMBRA HYPOIDE 90 oil (ref. NH520A) or

50361
2
SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1 1
SECTION 29 -- HYDROSTATIC TRANSMISSION
Chapter 1 -- Hydrostatic Transmission
CONTENT

29.212 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic circuit and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filling and bleeding the hydrostatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
29.216 Hydrostatic pump -- Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation of the multifunction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydrostatic motor -- Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1
LUBRICATION
IMPORTANT: Pay attention to CLEANLINESS:

Dirt or other contamination are in most cases the rea-
son for the breakdown of a hydraulic circuit.
Oil level
Ensure that all hydraulic cylinders are retracted be-
fore checking the oil level.
Check the oil level daily on the oil dipstick fitted to cap
1 (Fig. 1). If necessary, add oil through the filler open-
ing.
Keep the oil level between the minimum and maxi-
mum marks on the oil dipstick.
58205
Recommended oil and filter change intervals
• After the first 100 operating hours

• Thereafter, every 600 operating hours, or once
every year.
To change oil and filter, proceed as follows:
1. Thoroughly clean the surrounding area of the

reservoir and filler cap 1 (Fig. 1).
2. Remove the filler cap/oil dipstick B (Fig. 1).

30484
3. Drain the oil from the reservoir through drain

hose F (Fig. 3).
4. Remove hydrostatic oil filter D (Fig. 2).
5. Fill the hydrostatic filter bowl with oil.
6. Apply a film of oil to the gasket and screw on the

new filter by hand. Tighten firmly but DO NOT
USE TOOLS.
7. Fill the reservoir up to the maximum mark on the

oil level dipstick B (Fig. 1).
30479
3
8. Start the engine. The low hydrostatic charge
pressure warning light must extinguish as soon
as the engine starts. If not, contact your dealer for
assistance (Fig. 4).
9. Run the engine at idle speed for five minutes and

move the ground speed control lever slowly for-
ward and backward with the gearshift lever in
neutral and the rear--wheel drive [if installed] dis-
engaged.
Oil capacity
30535
Reservoir: 38 litres.
4
Entire system capacity: 93 litres.
Oil specification
Use AMBRA HYDROSYSTEM 46HV (ref. NH646H)

or an oil meeting the following specification:
-- DIN 51524 part 2 or ISO VG46
-- Viscosity grade: 46
HYDROSTATIC CIRCUIT AND COMPO-
NENTS
Circuit
A Engine 1 Pump with variable displacement
B Main drive transfer gearbox 2 Charge pump (gerotor--type pump)
C Hydrostatic pump housing 3 Pump charge pressure relief valve (24 bar)
D Work hydraulic pump housing 4 Displacement control valve (electrical)
E Steering hydraulic pump 5 Servo pressure relief valves
F Low pressure pump 6 Multifunction valves

G To low pressure relief valve (see Hydraulics, 6a Set at 420 bar
Section 7)
6b Set at 450 bar
H Hydrostatic motor
6c By--pass
R1 Hydrostatic oil reservoir
6d Charge check valves
R2 Hydraulic oil reservoir
7 Motor charge pressure relief valve (24 bar)
R3 Low pressure circuit hydraulic oil reservoir
8 Shuttle valve (spring--centred to a closed posi-
tion)
The shuttle valve establishes a circuit between
the main line that is at the low pressure side and
the charge pressure relief valve 7.
9 Motor with fixed displacement
10 Filter
11 Reservoir
12 Cooler
13 Thermovalve
14 Servocylinder
15 Orifice check valves
16 Filler cap breather
5
6
Pump operation (Fig. 5 and 6)
NEUTRAL
The hydropump swash plate is perpendicular to the
axis of rotation. There is no axial movement of the
pistons so there is no displacement in the high pres-
sure lines. The charge pump turns and serves oil to
the check valves which are open and to the charge
pump relief valve. If the pressure exceeds 24 bar, the
charge pump relief valve 3 will open and oil will flow
through this valve to the pump case.
RIGHT--HAND ROTATION
The operator moves the control handle of control
valve 4, thereby actuating the servocylinders. The
swash plate is now positioned at a certain angle.
The hydropump pushes oil under pressure to the hy-
dromotor. The charge check valve on the high pres-
sure side is closed. The hydromotor runs. The shuttle
valve is actuated. Oil flows from the low pressure side
through the charge pressure relief valve (24 bar) to
the motor case. This oil serves as a coolant for the hy-
dromotor and will be added to the lubrication oil. Via
a case drain line the oil will flow to the pump case,
through the pump case and over the heat exchanger
back to the reservoir.
LEFT--HAND ROTATION
With the handle in the rearward position, the servocy-
linders are actuated in the opposite direction and the
swash plate is moved to the opposite angle. The hy-
dropump pushes the oil under high pressure to the
other side of the hydromotor causing the output shaft
to turn in the opposite direction.
FILLING AND BLEEDING THE HYDRO-
STATIC SYSTEM
After repair or replacement of a hydrostatic element

a complete refill is required.
NOTE: Before mounting a new motor or a new pump,

shipment oil should be drained from the new pump or
motor case.
1. Place the machine on level ground.

43156
2. Place wooden blocks or similar in front of and be-
7
hind the traction wheels to keep the machine sta-
tionary.
3. Place the ground speed control lever and the

gearshift lever in the cab in neutral position.
4. Fill the hydrostatic oil reservoir up to the maxi-

mum mark on the oil dipstick B (Fig. 1) with an
approved hydrostatic oil.
5. Loosen the charge pump line at the inlet of the

charge pump (port S) and bleed the system until
oil comes through the charge pump port S
(Fig. 7).
6. Loosen the overflow plug C of the hydrostatic 51133

motor (Fig. 8).
8
7. Loosen the pipe connection between the hydro-
static pump and the thermostatic valve at the
pump R (Fig. 7). Fill oil through the hydrostatic
pump until oil comes out through overflow open-
ing C (Fig. 8) of the hydrostatic motor.
8. Retighten overflow plug C. Continue to fill oil until

the pump casing is full. Reconnect the pipe con-
nections to the motor and pump and tighten to
34 Nm torque (Fig. 7 and 8).
9. Disconnect the connector A of the stop solenoid

in the engine compartment (Fig. 9).
10. Connect a manometer, preferably a damped

30675
one, with a 500 bar range in gauge connection Q
(high pressure forward) (Fig. 7). 9
11. Crank the engine with the starter motor for 30

seconds, wait for one minute to cool the starter
motor, crank again for 30 seconds or until a mini-
mum pressure of 2 bar has been reached.
12. Reinstall electric connector A to the stop solenoid

in the engine compartment (Fig. 9).
13. Start the engine, let it run on low idle until the re-
corded pressure is at least 20 bar.
14. Let the engine run at low idle, shift to fourth gear
and apply the foot brake pedals firmly. Gently
push the hydrostatic control lever forward a short
stroke, so a minimum pressure of 30 and a maxi-
mum pressure of 300 bar is recorded. Keep the
pressure on for one minute.
15. Repeat the procedure described in the previous

paragraph, but reverse.
16. Check the oil level in the reservoir. If necessary,

add oil to the maximum level on the oil dipstick
and check the system for leaks.
17. With the engine running on low idle shift the gear-
box to neutral, position the hydrostatic control
lever at half stroke for one minute, both forward
and in reverse.
18. Increase the engine speed to high idle, position

the hydrostatic control lever at maximum forward
and maximum rearward for two minutes each.
19. Measure and write down the gauge pressure at

full stroke in reverse position. This pressure
should be 25 +/--4 bar (flush pressure).
20. With the hydrostatic control lever in neutral posi-

tion and the engine at high idle, measure and
write down the pressure reading. This pressure
(charge pressure) should be 4 +/--2 bar higher
than the value measured in step 19.
21. With the engine at high idle, shift to fourth gear,

press down both brake pedals firmly and apply
the handbrake. Move the hydrostatic control
lever fully forward for a maximum of 10 seconds.
The measured pressure should be between 420
and 450 bar (high pressure forward).
22. Stop the engine, remove the manometer, check

the oil level and possible leaks and correct, if
necessary.
HYDROSTATIC PUMP
50820
10
A. Input shaft
B. Charge pump
C. Cylinder block assembly
D. Swash plate
The hydrostatic pump characteristics can be found
on the identification plate which is installed on the
pump.
90 R 100 EA 1A8 S 3 C7 E0S GBA 424228
90 Series 90, closed circuit

R Right--hand rotation pump
100 100 cm3/rev max. displacement
EA Electrical displacement control (linear)
1 Pressure limiter in port A and B
N SAE A with sealed cover 9T -- 16/32
8 Twin ports
S Possible to connect a suction filter
3 No limiters
C7 Splined shaft 23T -- 16/32 pitch
E 20 cm3/rev charge pump displacement
03 Control orifice dia 0.81 mm
GBA Downhill kit
42 420 bar high pressure port B
42 420 bar high pressure port A
28 28 bar charge pressure setting
OPERATION OF THE MULTIFUNCTION
VALVE (4 FUNCTIONS)
50823
11
A. High pressure
B. Charge pressure
L. To servo control cylinder
The multifunction valves 6 (Fig. 11) or G (Fig. 12) are

incorporated in the pump.
42567
12
1. CHARGE CHECK VALVES (ITEM 6d, Fig. 6)
When the pressure on carrier C is greater than
the pressure of spring D, carrier C moves to the
left taking piston E with it. Oil flows from B to A to
fill up the system.
2. PRESSURE LIMITER (P.O.R.) -- 420 BAR (item

6a, Fig. 6)
(Pressure override)
When the high pressure exceeds 420 bar, the
pressure on poppet F pushes it to the left and al-
lows oil to flow to the servo control cylinder
through port L.
3. HIGH PRESSURE RELIEF VALVE -- 450 BAR

(item 6b, Fig. 6)
The flow for the pressure limiter stage must pass
through the orifice G in piston E, generating a
pressure differential across the orifice.
When the pressure in piston E exceeds the clos-
ing force of the internal valve pressure (due to the
pressure drop across the orifice) acting on the left
side plus the force of spring D, piston E moves to
the left and allows oil to flow to the charge circuit.
4. BY--PASS (item 6c, Fig. 6)

When the external hex part H is turned 3.5 revol-
utions counter--clockwise, the force exerted on
poppet F is reduced.
This sets the pressure limiter at a very low set-
ting. When the pump shaft is not turning but pres-
sure is generated in the high pressure lines due
to external influences (motor working as a
pump), poppet F moves to the left and oil flows
through part L. At this stage, piston E can easily
move to the left and the oil from A (high pressure)
flows to port B.
NOTE: When the machine has to be towed, shift the

gearbox to neutral.
HYDROSTATIC MOTOR
50821
13
E. Cylinder block assembly
F. Output shaft
G. Motor swash plate
H. Shuttle valve
The hydrostatic motor characteristics can be found
on the identification plate which is installed on the
motor.
90 M 100 NC 0 N 8 N 0 C7 W 00 NNN 000024
90 Series 90, closed circuit

M Bi--directional motor
100 100 cm3/rev max. displacement
NC Standard execution
0 Standard execution
N Standard execution
8 Twin ports
N Standard execution
0 Standard execution
C7 Shaft 23 teeth -- 16/32 pitch
W Loop flushing valve
00 Not applicable
NNN Not applicable
00 Not applicable
00 Not applicable
24 24 bar charge pressure
SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1 1
SECTION 33 -- BRAKES AND CONTROL
Chapter 1 -- Brakes and Control
CONTENT

33.110 Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
33.202 Replacement of the brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bleeding the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly and assembly of brake shoes and discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1
PARKING BRAKE ADJUSTMENT
1. Disengage the handbrake in the cab.
2. Check if the dimension is 219 mm as shown in

Fig. 1.
NOTE: When measuring the above dimension, en-

sure that cable A is tensioned by pulling lever B.
3. Loosen lock nuts C and thereafter bolts D.

52001
4. If necessary (see step 2), adjust the dimension to

219 mm with nuts E. Make sure that cable A is
straight. Tighten nuts E.
5. Tighten bolts D simultaneously by hand until they

touch the brake blocks (Fig. 1).
6. Engage and disengage the handbrake in the cab

a few times.
7. Check the tightness of bolts D. If possible, tighten

them simultaneously by hand. Turn them an
extra quarter of a turn with a spanner (Fig. 1).
30225
8. Engage and disengage the handbrake in the cab 2

a few times.
9. Loosen bolts D and tighten them simultaneously

by hand, if possible (Fig. 1).
10. The adjustment is correct when, while engaging

the handbrake in the cab, the tension begins at
the 6th or 7th tooth of the locking ratchet. If not,
repeat steps 8 and 9 until the adjustment is cor-
rect.
11. Tighten lock nuts C (ensure that bolts D are not

turning with nuts C (Fig. 1).
12. Check again that the dimension still is 219 mm.

If not, repeat the adjustment from step 2 on-
wards.
REPLACEMENT OF THE BRAKE LININGS
Removal
1. Bring the brake fluid level to a minimum.
2. Remove cover B.
3. Disconnect the electric wires on connectors C.
30254
4. Remove pins D out of the bracket housings.
5. Take out the brake linings.
CAUTION
If the seals (VITON type), protecting the cylinders,
have been exposed to temperatures in excess of
315°C, the material will not burn, but will decompose
and one of the products formed is hydrofluoric acid.
This is an extremely corrosive acid which is almost
impossible to remove once it has contaminated the
30253
skin.
4
Installation
1. Press the cylinders in the brake lining housings

to the outside.
2. Install the new brake linings.
3. Secure the brake linings with pins D (Fig. 4).
4. Connect the electric wires.
5. Check the brakes.

BRAKE CYLINDERS
Functioning of the brake main cylinder
The two main cylinders are mutually connected with

connectors B and C, further with pipe K to the fluid
reservoir and with pipes D to the brake cylinders.
Fluid from the fluid reservoir enters the brake main

cylinder through port E (pedal not engaged).
When both brake pedals are engaged, port E is shut

off by seal I, and fluid is pressed through port F to the 50587
brake cylinder. Ball H is lifted up in both main cylin- 5

ders A by plunger J.
When only one brake pedal is engaged, port E is also

shut off by seal I and fluid is pressed through port F
to the brake cylinder.
In the other main cylinder, ball H is pressed down by

the fluid pressure coming from the first cylinder
through connector B and seat G. The fluid flow is
stopped by seal P.
50588
6
BLEEDING BRAKES
Bleeding the left--hand side circuit
1. Slide one end of a transparent hose over bleed

screw F1 and insert the other end of the hose in
a can partially filled with brake fluid.
2. Open the brake cylinder bleed screw F1.
3. Depress the left--hand side brake pedal several

times until fluid flows into the can.
50587
4. Close bleed screw F1. 7
5. Depress the left--hand side brake pedal several

times to build up a pressure.
6. Keep the pedal depressed.
7. Open the bleed screw F1 slightly to allow air and

fluid to escape through the transparent hose.
8. Close bleed screw F1.
9. Release the brake pedal.
10. Remove the transparent hose from bleed screw

F1 and repeat steps 1 to 10 for bleed screws F2
and F3.
Bleeding the connection pipe between the two

main cylinders
1. Slide the transparent hose over the right--hand

side bleed screw F1.
2. Open the right--hand side bleed screw F1.
3. Depress and hold the right--hand side brake

pedal depressed.
4. Depress the left--hand side brake pedal once and

keep it depressed.
5. Release the right--hand side pedal and then the

left--hand side pedal
6. Repeat steps 3, 4 and 5.

Bleeding the right--hand side circuit
1. With the transparent hose slide over the right--

hand side bleed screw F1 depress the right--
hand side brake pedal several times until brake
fluid flows into the can.
2. Close the right--hand side bleed screw F1.
3. Depress the right--hand side brake pedal several

times to build up a pressure.
4. Keep the pedal depressed.
5. Open slightly the right--hand side bleed screw F1

to allow air to escape through the transparent
hose.
6. Close bleed screw F1.
7. Release the brake pedal.
8. Repeat steps 3 to 7 until fluid free of air bubbles

flows through the transparent hose.
9. Remove the transparent hose from bleed screw

F1 and repeat steps 1 to 9 for bleed screws F2
and F3.
DISASSEMBLY AND ASSEMBLY OF BRAKE
SHOES AND DISCS
Disassembly of brake shoes

2. Remove handbrake shoe A by loosening two

bolts.
3. Remove brake line B by loosening bolts C on 30298
both sides. 8
4. Loosen brake line D from the bleed nipple holder

E on both sides.
5. Remove brake shoes F by loosening bolts G

through the holes of the disc on both sides.
30296
Disassembly of brake discs
1. Remove circlip H and hand brake disc J on the

right--hand side.
2. Remove slotted nut K, lock washer L and brake

disc M on both sides.
Assembly of brake discs
1. Install brake disc M, lock washer L and slotted nut 30299
K. Tighten nut K with a torque of 180 Nm on both 10

sides.
2. Install circlip N on the transmission main shaft.
3. Install handbrake disc J and circlip H.

Assembly of brake shoes
1. Install bleed nipple P in bleed nipple holder E on

both sides.
2. Install brake line D on the lower brake shoes F

and ensure that there is a washer between the
nipple and the brake shoe.
3. Install brake shoe F and fasten with bolts G on

both sides. Tighten bolts G with a torque of 266
Nm.
30296
11
4. Install brake line B with nipples R on both sides

and ensure there is a washer between the nipple
and the brake shoe and between the nipple and
the bolt.
5. Install brake shoe A and fasten it with two bolts.
6. Install the four--wheel drive on the right--hand

30298
12
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 1
CONTENT

35.000 Torque tables for hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.304 Disassembly and assembly of pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
TORQUE TABLES FOR HYDRAULIC COM-
PONENTS
UNION NUTS AND FERRULES
Union nuts
55009
Ferrules
The ferrule must be pre-assembled on the tube.
Tighten the union nut as specified in the table below.
The ferrule and screw thread are greased.
Tube outer Torque Nm (lbf.ft)

diameter
mm (in) Min. Max.
8 (0.32) 15 (11) 20 (15)

10 (0.4) 25 (18) 30 (22)
12 (0.47) 35 (26) 40 (29) 55010
16 (0.63) 50 (37) 55 (40) 2

18 (0.71) 60 (44) 70 (51)
22 (0.87) 100 (74) 110 (81)
28 (1.10) 110 (81) 120 (88)
METRIC FITTINGS
Unions
Are suitable for use with union nuts and ferrules and
ball-type nipples.
55011
3
Connections
Are screwed in ISO metric thread - tolerance class
6H - with a tightening torque as specified in the table
below.
Tube outer Torque Nm (lbf.ft)

diameter
mm (in) Min. Max.
8 (0,32) 40 (29) 45 (33)

10 (0,40) 65 (48) 70 (51)
12 (0,47) 80 (59) 85 (63)
55012
16 (0,63) 100 (74) 120 (88)

4
18 (0,71) 120 (88) 140 (103)
22 (0,87) 200 (147) 220 (164)
28 (1,10) 350 (257) 380 (280)
Swivel nut with ball-type nipple

Are suitable for use with female unions
D1 Torque Nm (lbf.ft.)
6H Min. Max.
M14 x 1.5 -- --
M16 x 1.5 15 (11) 20 (15)
M18 x 1.5 20 (15) 25 (18)
M24 x 1.5 30 (22) 35 (26)
55013
M26 x 1.5 -- --
5
M30 x 2 -- --
M36 x 2 -- --
PUMP GROUP -- DISASSEMBLY AND AS-
SEMBLY
The pump group consists of four pumps driven by the
engine A via the main drive transfer gearbox B.
C: Hydrostatic pump: see Section 29.

-- Traction
-- Four-wheel drive clutch (option)
D: Work hydraulics pump:

-- Attachment height control
-- Reverse drive of the cutterhead
-- Spout rotation and vertical movement
55014
-- Auxiliary rear hydraulics (option)
-- Auxiliary front hydraulics 6
E: Steering hydraulics pump:

-- Steering
-- Auto-Pilot [accessory]
F: Low pressure pump:

-- Main drive clutch
-- Main drive belts stretching cylinder
Disassembly of the pum group
WARNING
Before starting a service job, always:
Shut off the engine.
Remove the ignition key.
Switch off the battery switch.
Wait until all parts have completely stopped
rotating.
In this paragraph, the following will be explained:

-- Removal of the three hydraulic pumps from the
hydrostatic pump.
-- Separation of the three hydraulic pumps.
Removal of the triple pump from the hydrostatic
pump
1. Drain the hydraulic oil reservoir.
NOTE:
FX / 96: Series 13
FX 25 / 45: Series 05
From these Series onwards, the hydrostatic and hy-
draulic oil reservoirs are no longer separate, except
for the lower part (Refer to paragraph headed ‘‘Hy-
draulic reservoir R2’’ further in this Section).
In order to drain the reservoir completely (e.g. when 30479
the oil in the reservoir has to be changed), oil should
be drained through both drain hoses. 7
2. Remove the left-hand side shielding.
43138
8
3. Remove hoses a and b from the low pressure
pump F (Fig. 9 and 11).
4. Remove hose c and pipe d from the steering hy-

draulic pump E.
5. Remove hose e and pipe f from the work hydrau-

lic pump D.
6. Unscrew cap screws g.
7. Remove the triple pump from the hydrostatic

pump.
52624
55015
10
Splitting of the triple pump
The triple pump consists of four main components
(Fig. 11 to 14):
D: Work hydraulics pump
E: Steering hydraulics pump
U: Connecting piece (Fig. 14)
F: Low pressure pump
The low pressure pump F is connected to the con-
necting piece U with two cap screws h.
The connecting piece is connected to the steering 52592
hydraulic pump with four cap screws j.
11
55119
12
55120
13
55122
14
1. Four cap screws h (M8)

2. Two cap screws j (M10)
3. Four nuts (M8)
4. Four washers (M8)
5. Two washers (M10)
6. O-ring seal (towards the steering hydraulics pump)
7. O-ring seal (towards the low pressure pump)
8. Intermediate piece
9. Fitting sleeve (connection between drive shafts)
The steering hydraulics pump E is connected to the

work hydraulics pump D with 4 long stud bolts k (M10
x 185.5 mm) (Fig. 13).
These bolts are screwed into the part that connects

the triple pump to the hydrostatic pump.
The steering and the work hydraulics pumps are

tightened to each other with special M10 nuts l on
these stud bolts (Fig. 13).
The drive shafts of the latter pumps are connected to

each other with coupling m (Fig. 13 and 15).
Assembly of the pump group
Assemble in the reverse order of the disassembly se-
quence.
IMPORTANT: Below is a list of recommended

torques. Ignoring these torques may lead to severe
damage to the pumps.
Verify the seals for wear or damage. Replace when
necessary. Also verify that the seals are properly
seated before attaching the pumps to each other.
Cap screw h: 44 - 54 Nm (32--40 lbf.ft)
Cap screw j: 26 - 31 Nm (19--23 lbf.ft)
Stud bolt k in the connecting piece (to the hydrostatic

pump): 5 - 10 Nm (4--7 lbf.ft)
Nut l (on stud bolt k): 44 - 54 Nm (32--40 lbf.ft)
Hose a: 110 - 120 Nm (81--88 lbf.ft)
Torque tables for ferrules, connections and ball-type

nipples can be found in paragraph headed ‘‘Torque
tables for hydraulic components” at the beginning of 40537
this section.
15
Installation of the pump group to the hydrostatic

pump
Cap screws g: 27 - 37 Nm (20--27 lbf.ft)
Chapter 2 -- Work Hydraulics -- Attachment Height Control
CONTENT

35.000 Circuit diagrams -- Attachment height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.300 Hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Non return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
35.304 Work hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
35.410 Attachment height control valve (EMR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Attachment compensation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hydropneumatic accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Attachment lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
WORK HYDRAULICS -- ATTACHMENT
HEIGHT CONTROL
1A FX/96 Series 01 to 10
FX25/45 Series 01 and 02
Circuit diagram -- Figure 1
A Engine
B Main drive transfer gearbox
C Hydrostatic pump
D Work hydraulics pump
E Steering hydraulics pump
F Low pressure pump
G High pressure relief valve
H Attachment height control valve (E.M.R.)
J Pressure sensor
K Compensation valve
L Accumulators
M Non-return valve
N Low pressure filter
P Filler opening with filter
Q Drain hose
R Oil reservoir

R3 Low pressure hydraulic oil reservoir
S Breather with filter and non-return valve

T To/from steering valve (without Auto-Pilot)
V Stack valve
X To steering valve (with Auto-Pilot)
Y From steering valve (with Auto-Pilot)
1 From cutterhead reverse drive motor
10 Attachment lift cylinders
52593
1
1B FX300-375 / 9630-9640 / 28--38 Series 13 > ............
FX450 / 9645 / 48--58 >> 1C
FX25/45 Series 05 > ............
A Engine
C Hydrostatic pump
F Low pressure pump
J Pressure sensor
L Accumulators
M Non-return valve
NN High pressure filter
OC Oil cooler
Q Drain hose
R Oil reservoir
R1 = R2 Hydraulic oil reservoir

R3 Low pressure hydraulic oil reser-
voir

SF Suction filter
TV Thermovalve
V Stack valve
1B FX300-375 / 9630-9640 / 28--38 Series 13 > ............
FX450 / 9645 / 48--58 >> 1C
FX25/45 Series 05 > ............
52594
2
1C FX300-375 / 9630-9640 / 28--38 << 1B
FX450 / 9645 / 48--58 Series 13 > ............
FX25/45 << 1B
A Engine
C Hydrostatic pump
F Low pressure pump
J Pressure sensor
L Accumulators
M Non-return valve
OC Oil cooler
Q Drain hose
R Oil reservoir
R1 = R2 Hydraulic oil reservoir

R3 Low pressure hydraulic oil reser-
voir

SF Suction filter
TV Thermovalve
V Stack valve
1C FX300-375 / 9630-9640 / 28--38 << 1B
FX450 / 9645 / 48--58 Series 13 > ............
FX25/45 << 1B
52595
3
HYDRAULIC RESERVOIR -- Figures 4 and 5
(Item R2 -- Fig. 1, 2 or 3)
Oil specification
Use AMBRA HYDROSYSTEM 46HV oil (ref.

NH646H) or an oil meeting the following specifica-
tion:
-- DIN 51524 Part 2 or ISO VG46
-- Viscosity grade: 46
Oil change
-- After the first 100 operating hours
-- Thereafter, every season or every 600 operating

hours.
Refer to the Operator’s Manual, chapter 3.5.
Capacity
Figure 4:
FX/96 Series 01 to 10
Reservoir: 20 litres (21 qts.)

Entire system: 35 litres (37 qts.)
The reservoir consists of two completely separate

reservoirs: the hydraulic reservoir (R2) and the hy-
drostatic reservoir (R1).
The hydraulic reservoir is used for the work hydrau- 55144
lics system and the steering hydraulics system.

4
Figure 5:
FX/96 Series 13 > ............

FX25/45 Series 05 > ............
Reservoir: 38 litres (40 qts.)

Entire system: 93 litres (98 qts.)
(i.e. hydraulic + hydrostatic system)
Both the hydraulic system (work hydraulics and

steering hydraulics) and the hydrostatic system use
oil from one reservoir.
52587
The separation plate inside the reservoir is perfo-
rated, except for the lower part (¦ 1/4 of the complete 5
volume). That is to ensure a minimum oil level
(¦ 3 litres) (3,2 qts.) for the steering system in case
the hydraulic or the hydrostatic system is leaking oil.
LOW PRESSURE FILTER -- Figures 4 and 5

(Item N -- Fig. 1, 2 or 3)
The low pressure filter is installed on top of the hy-
draulic reservoir and has a by-pass (non-return)
valve set to 1.15 bar (17 psi).
Filter change
At every (hydraulic) oil change.
HIGH PRESSURE FILTER -- Figure 6

(Item NN - Fig. 2 or 3)
FX/96 Series 13 > ............

FX25/45 Series 05 > ............
The high pressure filter NN is installed between the

electronic box and the spout base and has a by-pass
(non-return) valve set to 3.5 bar (51 psi).
Filter change
At every oil change the filter element has to be 52588
changed.
6
NON--RETURN VALVE
(Item M -- Fig. 1, 2 or 3)
Function
This valve is set to 2 bar (29 psi). The valve is meant
to ensure an oil pressure in the return line from the
stalk valves V. This is to prevent the cutterhead re-
verse drive motor from running dry while the cutter-
head is running in forward direction (refer to Chapter
3 -- Figures 1 and 2).
Figure 4:
This non-return valve is installed in front of the low

pressure filter (Fig. 1).
In case the valve had to be replaced, tighten the valve

with a torque of 120 to 140 Nm (88 to 103 lbf.ft.). The
elbow must be installed on the valve with a torque of
40 to 50 Nm (29 to 37 lbf.ft.).
FX/96 Series 13 > ............

FX25/45 Series 05 > ............
The non-return valve is situated between the stalk

valves V (Fig. 2 or 3) and the high pressure filter NN.
NOTE: Ensure to install non-return valve M accord-

ing to the symbol mark.
(Oil flow is from stack valves V towards oil reservoir
R2).
BREATHER Legend to Figure 7
(Item S -- Fig. 1, 2 or 3)
The breather allows the air in the reservoir to escape 1. Set of two bushings
whenever a considerable oil flow arrives at the reser- 2. Pump housing
voir (e.g. when lowering the attachment). 3. Cover plate (to the hydrostatic pump)
4. Cover plate (to the steering hydraulics pump)
5. Driving gear
6. Driven gear
7. Anti-extrusion seal (2 off)
WORK HYDRAULICS PUMP -- Figure 7 8. Seal (2 off)
9. Plug
Specifications 10. Plug
Gear pump 11. M5 cap screw (torque 2.5 - 3.4 Nm) (1.8 - 2.5 lbf.ft)
(2 off)
Output per revolution: 19.2 cc (1,17 cu.in.)
12. Circlip
Direction of rotation: clockwise 13. Dowel pin (4 off)
Pression on suction side: 0.3 - 1 bar (absolute) 14. O-ring (2 off)
(4,3--14,5 psi) 15. Lip seal (2 off)
Maximum pressure: 210 bar (3045 psi) 16. O-ring
Maximum peak pressure: 230 bar (3335 psi)
Maximum speed: 3000 rpm
Minimum speed with maximum pressure: 1000 rpm
55124
7
HIGH PRESSURE RELIEF VALVE -- Figures 8
and 9 (Item G -- Fig. 1, 2 or 3)
The high pressure relief valve G is situated on the

right-hand side of the hydraulic reservoir.
This valve is set at 160 bar (2320 psi) and protects

the hydraulic circuit.
NOTE: On machines equipped with an 8-row maize

attachment (600 N8) or a Kemper Champion 6000
attachment, this valve must be replaced with a simi- 55146
lar valve set at 180 bar (2610 psi). 8

Exception:
Models FX450 / 9645 / 48--58 from Series 13 on-
wards, which have larger diameter attachment lift
cylinders, can keep the 160 bar (2320 psi) relief
valve.
51726
ATTACHMENT HEIGHT CONTROL VALVE

(EMR) -- Figures 10 and 11
(Item H -- Fig. 1, 2 or 3)
This valve is situated on the right-hand side of the for-

age harvester, under the stack valve.
Figure 11 shows both a schematic drawing and a

section of the attachment height control valve.
55145
10
Legend to Figure 10 and 11 a Load sensing valve
b Attachment height control spool
D Oil flow from work hydraulics pump c Pilot line
K Oil flow from or to the compensation valve d Pilot line
10 Oil flow from or to attachment lift cylinders e Restriction
V Oil flow to stack valve f Flow limiter valve
VB Oil flow from or to the cutterhead reverse drive g Non-return valve
engaging valve
h Pressure relief valve (200 bar)
1 Oil flow from or to the cutterhead reverse drive
motor i Adjustable restriction
R2 Oil flow to hydraulic reservoir j Restriction
A Port to K, 10 k Restriction
P Port to D l Spring
N Port to V m Restricting pilot line
R Port to R2 n Chamber
p Restriction grooves
q Pressure line
s Restriction
t Chamber
v Chamber
w Restriction grooves
z Chamber
52596
11
Neutral position According to the level of the inlet pressure, the load
sensing valve a will find an equilibrium position. Most
of the oil flow will now go through the more opened
The attachment height control spool b is not acti-
restriction e to stack valve V.
vated and thus remains in neutral position.
The work hydraulics pump D pumps oil to port P:
• Maximum pressure (due to pressure relief valve

G):
Attachment lifting position
a. Standard: 160 bar (2320 psi)
b. Machines equipped with an 8-row maize at- The attachment height control spool b is moved to
tachment (600N8) or a Kemper Champion the left (according to the cross-section in Fig-
6000 attachment: ure 11).
-- 180 bar (2610 psi): all models, except for
FX450 / 9645 / 48--58 from Series 13 on-
The distance of movement of spool b depends on the
wards
average voltage that is put on the pushing solenoid.
-- 160 bar (2320 psi): model FX450 / 9645 This average voltage depends on the input signal
/ 48--58 up to Series 13 which the electronic attachment height control mod-
ule receives. This input signal can come from either
the attachment height control switch on the multi-
• 52 l/min (55 qts/min) (engine speed: 1900 rpm). function lever or from the pressure sensor on com-
pensation valve K (see further).
The load sensing valve a divides this oil flow first in
two flows: The signal from the attachment height control switch
is always the same, which results in a definite posi-
1. A small oil flow (± 4 litres/min) (4,2 qts/min) goes tion of the attachment height control spool b and, as
through restriction e to stack valve V. a result, in a definite lifting (or lowering) speed of the
attachment.
2. The second flow (about the same amount) goes
through restriction k.
The signal from the pressure sensor on the compen-
Control spool b does not permit any oil flow via line sation valve depends on the difference between the
q. On the contrary, some oil can flow through pilot line calibrated and the measured pressure.
d, via restrictions j, s and i to reservoir R2.
As a result, in this case the position of the attachment
The inlet pressure (port P) is also seated at the bot- height control spool b varies with the measured dif-
tom of the load sensing valve a through pilot line c. ference in pressure.
When the inlet pressure is high enough to overcome In lifting position, oil can flow via restriction k through
the force of spring l and the pressure on this side of line q, to chamber n.
the load sensing valve a, valve a will move against
spring l. Another oil flow reaches chamber n through pilot
lines d and m.
This movement will open restriction e and close re-
striction k. Both oil flows result in a drop of pressure in the neigh-
bourhood of valve a. This means that load sensing
Closing restriction k causes the pressure in the pilot valve a will now find an equilibrium that closes restric-
line c to drop. This will move valve a over a certain tion e and that opens restriction k.
distance back again, which closes restriction e and
opens restriction k.
NOTE: The oil flow to the stack valve V, via restriction side is in between inlet pressure and return pressure
e, is at least 3.8 l/min. due to restriction i. This means that this pressure is
higher than the pressure in chamber t.
Depending on the distance spool b was moved, re-
striction p will be more or less open. The grooves on This difference in pressure moves valve f to open the
spool b provide a more sensitive control of the small non-return valve g, which results in a lowering of the
oil flows through p. The grooves also result in a attachment.
smoother transition when spool b starts moving.
The oil flow from port A to control spool b results in
Pressure now builds up in chamber t, which forces a rise of pressure in chamber t. This moves valve f
valve f to move to the right (according to the cross- back again and tries to close the non-return valve g.
section on Figure 11). The pressure on the other side The heavier the attachment, the more valve g will be
of valve f is on or below return oil pressure. closed to reduce the lowering speed.
Namely, restriction j is closed and restriction i brakes The lowering speed of the attachment is adjustable
any pressure from the return circuit side. with the adjustable restriction i. Permitting more oil
flow from pilot line d through restruction i to the return
circuit, decreases the pressure on the rear side of
Valve f moving to the right, unlocks the opening to
valve f. This will reduce the lowering speed. Less oil
non-return valve g. Now oil can flow through cham-
flow through restriction i will increase the lowering
ber v via port A to Attachment lift cylinders 10 (and
speed.
compensation valve K) .
Pressure relief valve h

Attachment lowering position
This valve is set to 200 bar (2900 psi). It protects the

The attachment height control spool b is moved to
non-return valve g against overpressure in chamber
the right (according to the cross-section in Figure 11)
z.
over a certain distance, depending on the average
voltage put on the left-hand side solenoid.
Overpressure can originate when driving over
bumpy surfaces.
Restriction p is closed. So, there is no oil flow through
line q.
Restriction w is more or less opened to the return cir-

cuit and allows the oil pressure in chambers v and t
Emergency hand buttons
to drop to oil return pressure.
With these buttons, situated on both sides of the at-

The high oil pressure in chamber z, due to the weight
tachment height control valve H (Fig. 2 and 3) and
of the attachment, and the low pressure in chamber
18), the attachment height control spool b can be ac-
v cause the non-return valve g to close.
tivated manually.
Similar to the neutral position, load sensing valve a

This is meant to be used in emergency cases.
moves to the right (according to the cross-section in
Figure 11).
It may also be a useful instrument to check whether
an error is situated in the electric wiring to the sole-
The inlet oil flow is now divided into two flows.
noids or in the attachment height control valve H it-
self.
The major flow goes via restriction e to stack valve V.
Push the rear button (closest to the door) to lower the
The minor flow goes via restriction k and pilot line d attachment. Use the front button (closest tot the cab)
towards the rear side of valve f. The pressure on this to lift the attachment.
Specifications
Solenoid: 0-12 V
ATTENTION
Never put 12V continuously to a solenoid as this will
cause the solenoid to burn.
It is allowed to put 12V on a solenoid as a pulse or
maximum 7V continuously!
Maximum permitted pressures:
-- port P: 250 bar (3625 psi)

-- port R 5 bar (72,5 psi)
-- port N 200 bar (2900 psi)
Maximum oil flow:
-- lifting attachment: 45 l/min (12 gpm)

-- lowering attachment: 63 l/min (17 gpm)
ATTACHMENT COMPENSATION VALVE --
Figures 12 and 13
(Item K -- Fig. 1, 2 or 3)
The compensation valve K is situated between the

blower and the reversing gearbox above the traction
axle.
The attachment height control can be achieved in

three modes.
These modes can be chosen with the attachment

height control selector switch on the arm rest module
(refer to chapter 2.6 in the Operator’s Manual). 55147
12
The electric circuit pilots the attachment height con-
trol valve H in these three modes:
-- Transport mode:
Manual operation of the attachment.
-- Stubble height mode:

Atachment operates at a preset height.
-- Compensation mode:
Attachment remains on the ground with a preset
pressure.
In position 0, when the solenoid a is not activated, the

attachment cylinders 10e and 10f are not directly
connected with the accumulator(s). The oil flows be-
tween ports s and z via pilot line g, through valve h
and orifice j. This is to increase the reaction time
when lifting or lowering the attachment.
In position 1, the solenoid is activated and pushes

valve h against the spring. In this position oil can flow
freely between ports S and Z via the outside of valve
h.
The attachment cylinders are directly connected with

the accumulators, which absorb pressure shocks.
55140
13
The compensation valve K functions as follows: Stubble height mode

a. When pressing the automatic attachment height
Transport mode control button:
Always open (Solenoid a activated) Compensation valve is closed.
Compensation valve opens 3.5 seconds after the
button was released.
Compensation mode
b. While working in stubble height mode:
a. When pressing the automatic attachment height
always open.
control button:
The compensation valve is closed until the at- c. While lifting or lowering the attachment with the
tachment touches the ground. At that moment attachment height control switch (leaving stubble
the compensation valve is opened. height mode):
Compensation valve is closed.
b. While working in compensation mode:
Compensation valve opens 2 seconds after the
always open.
switch was released.
c. While lifting or lowering the attachment with the
attachment height control switch (leaving com-
Pressure sensor J measures the pressure in the at-
pensation mode):
tachment cylinders to give input for the attachment
Compensation valve is closed.
compensation system.
Compensation valve opens 2 seconds after the
switch was released.
Specifications
Solenoid: 0-12 V
ATTENTION
Switching only happens when the oil flow is about

0 l/min.
Nominal oil flow: 100 l/min (26 gpm).
Max. permitted pressure: 200 bar (2900 psi).
PRESSURE SENSOR
(Item J -- Fig. 1, 2 or 3)
This sensor measures the pressure in the attach-

ment lift cylinders.
The electronic attachment height control module

compares this measured pressure with the pressure
chosen with the ground pressure potentiometer on
the arm rest module (refer to chapters 2.6 and 4.16
in the Operator’s Manual).
The electronic attachment height control module

translates this difference in pressure in a voltage sig-
nal to one of the solenoids on the attachment height
control valve H (Fig. 2 and 3).
For instance, when the attachment (in compensation

mode) is lifted by a stone, the pressure in the attach-
ment cylinders drops below the chosen pressure.
The electronic attachment height control module ac-
tivates the front (lifting) solenoid of the attachment
height control valve to compensate for the drop of
pressure with an oil flow towards the attachment lift
cylinders.
The magnitude of the oil flow (i.e. the distance the at-
tachment height control spool b moves) depends on
the average voltage put on the solenoid of the attach-
ment height control valve, which depends on the
measured difference in pressure.
Specifications
Pressure: 0-160 bar (0--2320 psi)
Supply: 8-12V
Signal: Supply voltage + [0.25 to 0.75V]

HYDROPNEUMATIC ACCUMULATORS
(Item L -- Fig. 2 and 3)
When the attachment has to be changed from maize

attachment to pick-up attachment, or vice versa, the
pressure in the lift cylinders changes because of the
difference in weight.
This difference affects the required ground pressure

level and, consequently, the accumulators required.
FX/96 Series 01 to 10 FX300-375 / 9630-9640 FX450 / 9645 / FX 48--58

FX 28--38 Series 13 > ..........
Series 13 > ..........
Attachment (Figure 3)
FX25/45 FX25/45
Series 01 and 02 Series 05 and 06
(Figures 1 and 2) (Figure 2)
340W Two accumulators: Two accumulators: Three accumulators:
350W -- accumulator b: 70 bar -- 70 bar -- 85 bar
345W -- accumulator c: 35 bar -- 35 bar -- 55 bar
355W Between the two accumu- Tap deleted. -- 30 bar
365W lators, a tap d is installed. No tap.
360N4
300N6 Always leave tap d in open
position.
Kemper Add a 100 bar accumulator Add a 100 bar accumula-
Champion 4500 (instead of tap d). tor.
600N8 Add a 100 bar accumulator Add a 100 bar accumulator
Kemper (instead of tap d) and re- and replace the 160 bar
Champion 6000 place the 160 bar high high pressure relief valve
pressure relief valve G by G by a 180 bar valve.
a 180 bar valve.
ATTENTION It may even be necessary to check the potentiometer

adjustment (measuring the height of the attach-
To improve the stability of the forage harvester when
ment). Refer to chapter 5.21 in the Operator’s Manu-
equipped with heavy attachment, counterweight
al.
must be installed. Refer to paragraph 9.1 in the Oper-
ator’s Manual to know the recommended amount
and combination of counter weights used. One side of a hydropneumatic accumulator is filled
with nitrogen.
Furthermore, changing the attachment implies a
recalibration of the ground level, the stubble height The other side is connected to the hydraulic lines to
level and the ground pressure. The calibration proce- the attachment lift cylinders.
dure is explained in chapter 4.16 in the Operator’s
Manual.
Apart from this, the InfoView monitor must also be

recalibrated for a new attachment width and attach-
ment height.
Refer to paragraph 4.17.4 in the Operator’s Manual.
Filling
Required tools:
-- Bottled nitrogen
-- Special tool (valve + pressure gauge)
(Bosch ref. No. 0538103012)
Procedure
1. First loosen the umbracco screw on the accumu-
lator.
2. Connect the special tool to the accumulator and

to the bottle of nitrogen.
3. Open valve m and read the pressure registered

on the pressure gauge. If necessary, add nitro-
gen by opening valve l. When the correct pres-
sure is obtained, close valves m and l, bleed ex-
cess pressure through valve n and disconnect
the special tool.
40573
4. Tighten the umbracco screw. 14

ATTACHMENT LIFT CYLINDERS
(Item 10 -- Fig. 2 and 3)
a Piston rod e Seal ring

b Cylinder f Seal ring
c Locking wire g Scraper ring
d Piston guide ring (2x) h (Dis)assembly groove
j Locking groove
55141
15
55142 55143
a b
16
To disassemble piston rod a (and the seal rings
thereafter), move piston rod a until locking wire c is
visible through the hydraulic line connection on cylin-
der b. Through this opening, locking wire c can be
pushed (Fig. 16a) into groove h. In this position, lock-
ing wire c allows piston rod a to be pulled out.
To reassemble, replace seals e and f installing them
with their grooves (Fig. 14) facing inward using the
special tool, as shown in Figure 17. Then install
scraper ring g.
After assembly of piston rod a, reinstall locking wire
c in its original groove j (Fig. 16b).
30238 30239
a b
17
Chapter 3 -- Work Hydraulics -- Base Unit
CONTENT

35.000 Circuit diagrams -- Base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.310 Stack valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Load sensing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cutterhead reverse drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spout rotation pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Quick release couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Spout lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CIRCUIT DIAGRAMS -- BASE UNIT
Circuit diagram -- Figure 1 1 Cutterhead reverse drive motor

A Engine 2 Pressure relief valve
B Main drive transfer gearbox 3 Spout rotation motor
C Hydrostatic pump 4 Front hydraulics quick-release couplings
D Work hydraulics pump 5 External front hydraulics
E Steering hydraulics pump 6 Rear hydraulics quick-release couplings[acces-
sory]
F Low pressure pump
7 External rear hydraulics
8 Orifice
9 Spout lift cylinder
L Accumulators
M Non-return valve
Q Drain hose
R Oil reservoir


V Stack valve
VA Load sensing valve

VB Cutterhead reverse drive engaging valve
VC Spout rotation control
VD Auxiliary front hydraulics control valve
VE Auxiliary rear hydraulics control valve[ac-
cessory]
VF Spout height control valve
VG Top plate

52597
1
2B FX/96 Series 13 > 5080
FX25/45 Series 05 > 5080
Circuit diagram -- Figure 2 TV Thermovalve

A Engine V Stack valve
C Hydrostatic pump
CV Check valve
F Low pressure pump cessory]
G High pressure relief valve VF Spout height control valve
H Attachment height control valve (E.M.R.) VG Top plate
K Compensation valve X To steering valve (with Auto-Pilot)

M Non-return valve Y From steering valve (with Auto-Pilot)
OC Oil cooler
1 Cutterhead reverse drive motor
2 Pressure relief valve
Q Drain hose
3 Spout rotation motor
R Oil reservoir
4 Front hydraulics quick-release couplings
R1 = R2 Hydraulic oil reservoir 5 External front hydraulics
R3 Low pressure hydraulic oil reser- 6 Rear hydraulics quick-release couplings[acces-
voir sory]
S Breather with filter and non-return valve 7 External rear hydraulics
SF Suction filter 8 Orifice
T To/from steering valve (without Auto-Pilot) 9 Spout lift cylinder

2B FX/96 Series 13 > 5080
FX25/45 Series 05 > 5080
52598
2
2C FX28--58 Series 5083 > .........
Circuit diagram -- Figure 3 TV Thermovalve

A Engine V Stack valve
C Hydrostatic pump
CV Check valve
F Low pressure pump cessory]
G High pressure relief valve VF Spout height control valve
H Attachment height control valve (E.M.R.) VG Top plate
K Compensation valve X To steering valve (with Auto-Pilot)

M Non-return valve Y From steering valve (with Auto-Pilot)
OC Oil cooler
1 Cutterhead reverse drive motor
2 Pressure relief valve
Q Drain hose
3 Spout rotation motor
R Oil reservoir
4 Front hydraulics quick-release couplings
R1 = R2 Hydraulic oil reservoir 5 External front hydraulics
R3 Low pressure hydraulic oil reser- 6 Rear hydraulics quick-release couplings[acces-
voir sory]
S Breather with filter and non-return valve 7 External rear hydraulics
SF Suction filter 8 Orifice
T To/from steering valve (without Auto-Pilot) 9 Spout lift cylinder

2C FX28--58 Series 5083 > .........
31345
3
HYDRAULIC RESERVOIR R2
LOW PRESSURE FILTER N
HIGH PRESSURE FILTER NN
NON-RETURN VALVE M
BREATHER S
WORK HYDRAULICS PUMP D
HIGH PRESSURE RELIEF VALVE G
ATTACHMENT HEIGHT CONTROL VALVE H
(EMR)
Refer to paragraph ‘‘Work hydraulics - Attachment

height control’’.
STACK VALVE -- Figure 4
(Item V -- Fig. 1 , 2 or 3)
The stack valve is a modular system. This means that
control valves can be added or removed quickly.
When (re)assembling the stack valve, pay attention
to the sequence (1 - 2 - 3) and the tightening torques
of the bolts.
Also adhere to the original sequence of installation of
the valves and orifices.
43165
51139
5
Repair of control valves
If a control valve does not respond to a switch com-

mand, either an electrical or a hydraulic problem may
be the cause.
• Electrical cause: No power supply to the solenoid

spool or failure of solenoid spool.
Result: The solenoid does not operate the valve
spool.
In this case, the valve spool can be manually acti-
vated by pushing on the rubber cap of the sole-
noid and moving the valve spool into an operat-
ing position.
DANGER
Before activating a solenoid manually, ensure that
everybody stands clear of the machine. Activate it
just long enough to notice that the valve works.
Front button Rear button

(closest to the (closest to the
cab) door)
VF Spout height control valve DOWN UP
VE Auxiliary rear hydraulics control valve Pressure RIGHT Pressure LEFT
VD Auxiliary front hydraulics control valve Pressure RIGHT Pressure LEFT
VC Spout rotation control valve RIGHT LEFT
VB Cutterhead reverse drive -- ON
As a provisional solution, if there is no power

available on a solenoid, the electrical wires of an-
other valve (which is not needed at that moment)
may be connected to the failed solenoid.
ATTENTION
• Hydraulic cause: Repair of an individual valve is

not possible. Only replacement of the seal rings
is possible.
LOAD SENSING VALVE -- Figure 6
(Item VA -- Fig. 1, 2 or 3)
System in neutral
The work hydraulics pump D pumps oil via the attach-

ment height control valve H (EMR) to the load sens-
ing valve VA (Fig. 1 or 2 or 3).
As no control valve (VB ... VF) is activated yet, pres-

sure builds up between ports P and a.
At the spring side c of the load sensing spool d, the

pressure is approximately identical to the return oil
pressure.
When the pressure between ports P becomes high

enough to surpass spring c (6 bar) and the return oil
pressure, the load sensing spool d moves to the left
(position 1). This connects inlet port P directly to re-
turn port R. The oil flows straight to hydraulic reser-
voir R2.
48103
6
CUTTERHEAD REVERSE DRIVE MOTOR
(Item 1 -- Fig. 1, 2 or 3)
The cutterhead reverse drive motor is situated on the
right-hand side of the forage harvester at the front
side of the engine (Fig. 7).
Specifications
-- Gear motor
-- Output per revolution: 26.5 cc (1,62 cu.in)
-- Max. pressure: 210 bar (3045 psi)
-- Max. peak pressure: 230 bar (3335 psi)
55006
-- Max. speed: 3,000 rpm
-- Min. speed at max. pressure: 800 rpm 7
When the motor (i.e. valve solenoid VB) is not acti-

vated and the cutterhead is engaged (in forward
drive), the motor works as an idling pump (Fig. 1, 2
or 3)
The hydraulic line to the return circuit adds oil to the
pump (motor) circuit or returns oil from that circuit.
Another hydraulic line (dotted line in Figure 1, 2 or
3) returns the motor leak oil straight to the reservoir
R2.
FX/96 Series 13 > 5080

FX25/45 Series 05 > 5080
Figures 2 and 8
Machines of the Series mentioned are equipped with
a check valve CV. This non-return valve is situated
between the pressure side (VB) and the return side
(R2).
The purpose of this valve is to avoid underpressure
at the pressure side (VB) when the engine speed
drops while driving the cutterhead in reverse.
NOTE: If the check valve is installed in the wrong

8
direction, the cutterhead reverse drive motor will not
be able to drive the cutterhead (no pressure).
NOTE: The non-return valve inside valve VB (Fig. 1)

is removed from the above-mentioned Series on-
wards (Fig. 2 or 3).
FX28--58 Series 5083 > .........
Figures 3 and 9
Machines of the Series mentioned are equipped with

a reverse drive motor with built--in non--return valve.
NOTE: It’s possible to install this reverse drive motor

on older units.
9
FX/96 Series 01 > 5080
FX25/45 Series 01 > 5080
43158
10
1. Dowel pin (4 off) 12. Cover plate

2. Plastic plugs (2 off) 13. Cover plate
3. Bolt (M10) (16 off) 14. Pump gear
4. Washer (M10) (16 off) 15. Pump gear
5. Circlip 16. Anti-extrusion seal (2 off)
6. O-ring (4 off) 17. --
7. O-ring (2 off) 18. --
8. O-ring (2 off) 19. Joint (2 off)
9. Seal 20. --
10. Bushing (2 off) 21. Gear pump chamber plate (2 off)
11. Pump house 22. Draining plug
SPOUT ROTATION PRESSURE RELIEF
VALVE
(Item 2 -- Fig. 1, 2 or 3)
This valve is mounted on top of the spout rotation mo-
tor. It protects motor 3 and its support from excessive
tension when the spout reaches its mechanical
stops.
As shown in the circuit diagram (Fig. 1, 2 or 3), this
valve protects both directions of rotation.
FX 300--450/9635--9645
FX 25/45
The valves 4 and 5 open when the difference in pres-
11
sure is 65 bar (950 psi) (at 60 l/min) (13,2 gpm).
The valves are factory-set and sealed.
FX 28/58
The valve 1 opens when the difference in pressure is
65 bar (950 psi) at 50 l/min (13,2 gpm). The valve 1
is factory--set and sealed.
SPOUT ROTATION MOTOR

(Item 3 -- Fig. 1, 2 or 3)
This is an Orbit-type motor.7
Specifications
-- Geometric displacement: 200 cc/rev (12,2 cu.in./

rev)
-- Max. speed continuous/intermitting: 300/375
rpm
-- Max. oil flow cont./int.: 60/75 l/min (16/20 gpm)
-- Max. differential pressure cont./int: 100/140 bar 12
(1450/2030 psi)
-- Max. inlet or outlet pressure: 140/175 bar
(2030/2540 psi)
-- Max. torque cont./int.: 24.3/33.5 Nm (18/24,5
lbf.ft)
-- Max. performance: 6.4/8.4 kW
When installing the motor or the worm wheel, special

attention has to be paid to the adjustment of motor
and worm wheel in relation to each other and to their
supports (Fig. 13).
Adjust the worm wheel as close as possible to the

crown gear and eliminate possible axial play of the
worm.
To adjust, proceed as follows:
1. Check worm gear a for axial play.

Maximum allowed axial play: 0.25 mm (0,01”).
2. To remove possible play, loosen bolts b and in-

stall shims between worm bracket g and bearing
block d at e. Retighten bolts b.
3. Loosen the four worm gear bracket bolts f + j and 30584

adjust bracket g with bolts h so that there is no ro-
tational play on the spout. 13
4. Rotate the spout a full cycle both left and right to

ensure it moves freely. Readjust, if necessary.
5. Retighten all hardware and install all grease lines

and covers.
6. Tighten bolts f + j to 95 Nm (70 lbf.ft) torque and

retighten them after the first 50 operating hours.
NOTE: Covers and grease lines are removed for

clarity
FX/96 Series 13 > ............

FX25/45 Series 05 > ............
1. Check worm gear a for axial play.

Maximum allowed axial play: 0.25 mm (0,01”).
2. To remove possible play, loosen bolts b and in-

stall shims between worm bracket g and bearing
block d at e. Retighten bolts b.
3. The worm gear assembly pivots around the bolt

and bushing connection j.
4. Loosen the three worm gear bracket bolts f and

adjust bracket g with bolts h so that there is no ro-
tational play on the spout.
5. Rotate the spout a full cycle both left and right to

ensure it moves freely. Readjust, if necessary.
6. Retighten all hardware and install all grease lines

and covers.
Tighten bolts f to 95 Nm (70 lbf.ft) torque and re-
tighten them after the first 50 operating hours.
QUICK--RELEASE COUPLINGS
(Items 4 and 6 -- Fig. 1, 2 or 3)
Specifications
Maximum oil flow: 15 l/min (4 gpm)

Maximum pressure: 160 (180) bar
(2320/2610 psi)
(pressure relief valve G)
SPOUT LIFT CYLINDER
(Item 9 -- Fig. 1, 2 or 3)
Cylinder disassembly and assembly
43168
14
a Piston j Hole
b Cylinder k Seal ring
c Piston guide l O-ring
d Piston guide m Seal ring
e Bolt n O-ring
f Washer p Scraper ring
g Guide ring q Rod
h Seal ring
1. Unscrew piston guide c using a hook spanner 5. Remove all seals (be careful not to scratch the
(hole j). grooves).
2. Pull out the ‘‘rod q - piston a - piston guide d’’ as-

sembly. 6. Replace the seals, taking into account the direc-
tion of the seal grooves.
3. Unscrew bolt e attaching piston a to piston guide
d.
7. When reassembling the cylinder, tighten bolt e
4. Remove piston a from piston guide d. with a torque of 142 Nm (105 lbf.ft).
Reinstallation of spout lift cylinder
Pay attention to following remarks:
-- Clean the ball joints r before reinstalling them.

-- Adjust the ball joints in such a way that, when the
cylinder is fully retracted, the rubber cushion un-
derneath the spout lies on the spout support.
-- The depth to which the ball joints are screwed in,
must at least be equal to the diameter width of
their threaded rod (M20 or M30).
-- Tighten the ball joints r to a torque of 170 to 180
Nm (125--132 lbf.ft).
-- Tighten nuts s to a torque of 190 Nm (140 lbf.ft)
-- Do not forget to reinstall orifice t.
43169
15
Orifice t is installed in the connection to the cylinder.
FX/96 Series 06 > ............

FX25/45 Series 01 > ............
Orifice t is installed in the connection of the same hy-

draulic line to the stalk valve VF.
Chapter 4 -- Steering Hydraulics
CONTENT

35.000 Circuit diagrams -- Steering hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.310 Steering hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING HYDRAULICS -- 4WD WITHOUT
AUTO--PILOT
3A FX/96 Series 01 > ..........
FX25/45 Series 01 > ..........
A Engine
C Hydrostatic pump
F Low pressure pump
H From/ to header height control valve (EMR)
M Non-return valve
Or Orifice
Q Drain hose
R Oil reservoir


T Steering valve (without Auto-Pilot)
V From stack valve
11 Steering cylinders
3A FX/96 Series 01 > ..........
FX25/45 Series 01 > ..........
52599
1
STEERING HYDRAULICS -- 2WD WITHOUT
AUTO--PILOT
3B FX/96 Series 01 > ..........
FX25/45 Series 01 > ..........
A Engine
C Hydrostatic pump
F Low pressure pump
H From/ to header height control valve (EMR)
M Non-return valve
Or Orifice
Q Drain hose
R Oil reservoir


T Steering valve (without Auto-Pilot)
V From stack valve
3B FX/96 Series 01 > ..........
FX25/45 Series 01 > ..........
52800
2
HYDRAULIC RESERVOIR R2
LOW PRESSURE FILTER N
NON-RETURN VALVE M
BREATHER S
Refer to paragraph ‘‘Work hydraulics - Attachment

height control’’.
ORIFICE 0r
FX/96 Series 13 > ..........

FX25/45 Series 05 > ..........
From these Series onward, an orifice has been

installed at pressure port P of steering valve T.
STEERING HYDRAULICS PUMP
55123
3
1. Bushing 9. Shaft coupling
2. Pump housing 10. Plug (2 off)
3. Cover plate 11. --
4. Cover plate 12. M5 bolt (torque: 2.45 to 3.43 Nm!) (1,8 -- 2,5 lbf.ft)
5. Driving pump gear 13. Dowel pin (4 off)
6. Driven pump gear 14. O-ring
7. Anti-extrusion seal (2 off) 15. O-ring (2 off)
8. Seal
Specifications -- Maximum pressure: 250 bar (3625 psi)
-- Gear pump -- Maximum peak pressure: 280 bar (4060 psi)
-- Output per revolution: 6 cc (0,37 cu.in.) -- Maximum speed: 4,000 rpm
-- Direction of rotation: clockwise -- Minimum speed at maximum pressure: 1,400

rpm
-- Pressure on suction side: 0.3 -- 1 bar (absolute)
(4,35 -- 14,5 psi)
STEERING VALVE
The steering valve is situated at the front under the
cab.
The Danfoss steering valve OSPC 100 ON consists

of a selector valve and an orbit pump.
The purpose of having an orbit pump built in the valve

is to have a perfect ratio between the steering wheel
and the steering cylinder, and to guarantee a manual
operation in case of breakdown. 50482
4
The steering wheel controls the selector valve and
the orbit pump. The valve sleeve is held in neutral by
leaf springs.
These leaf springs only allow a minor shifting be-

tween the valve sleeve and the spool when turning
the steering wheel.
Four ports discharge into the valve body.
P: Pressure inlet
T: Return to reservoir
L and R: Left and right cylinder connection
to steering.
A ball is fitted between the ports P and T. During nor-

mal operation the ball is pushed on its seat, closing
the connection between P and T.
When no oil under pressure (e.g. failure of hydraulic

pump) flows from the pump into port P, steering will
still be possible as the return oil pushes the ball from
its seat and flows into suction line P.
The pressure relief valve, situated between inlet P

and return T, is set to 140 bar (2030 psi).
The double-acting shock-valve situated between

ports L and R is set to 200 bar (2900 psi).
STEERING CYLINDERS
Disassembly and assembly -- Figure 5
WARNING
This cylinder has an important safety function. Do not
attempt to repair it unless you are totally familiar with
it.
Only use new genuine NEW HOLLAND parts.
1. Unscrew piston guide c using a hook spanner

(hole j).
2. Pull out the ‘‘rod q - piston a - piston guide d’’ as-

sembly.
3. Unscrew bolt e attaching piston a to piston guide

d.
4. Remove piston a from piston guide d.
5. Remove all seals (be careful not to scratch the

grooves).
6. Replace the seals, taking into account the direc-

7. When reassembling the cylinder, tighten bolt e

with a torque of:
-- 108 Nm (79 lbf.ft) for 2WD steering cylinders
-- 164 Nm (120 lbf.ft) for 4WD steering cylinder
43157
5
a Piston j Hole
b Cylinder k Seal ring
c Piston guide l O-ring
d Piston guide m Seal ring
e Bolt n O-ring
f Washer p Scraper ring
g Guide ring q Rod
h Seal ring
Toe--in adjustment, steering ball joints, steering

wheel stops

STEERING HYDRAULICS -- 4WD WITH
AUTO-PILOT
3C FX/96 Series 01 > ..........
FX25/45 Series 01 > ..........
A Engine
C Hydrostatic pump
F Low pressure pump
H From/ to attachment height control valve (EMR)
M Non-return valve
Or Orifice
Q Drain hose
R Oil reservoir


V From stack valve
W Pressure relief valve
X Steering valve (with Auto-Pilot)
Y Selector valve
Z Auto-Pilot valve
3C FX/96 Series 01 > ..........
FX25/45 Series 01 > ..........
52601
6
STEERING HYDRAULICS -- 2WD WITH
AUTO-PILOT
3D FX/96 Series 01 > ..........
FX25/45 Series 01 > ..........
A Engine
C Hydrostatic pump
F Low pressure pump
H From/ to attachment height control valve (EMR)
M Non-return valve
Or Orifice
Q Drain hose
R Oil reservoir


V From stack valve
W Pressure relief valve
X Steering valve (with Auto-Pilot)
Y Selector valve
Z Auto-Pilot valve
3D FX/96 Series 01 > ..........
FX25/45 Series 01 > ..........
52602
7
Contrary to the steering valve T used without Auto-
Pilot (type OSPC 100 ON), this steering valve X (type
OSPB 100 ON) does not contain a selector valve nor
a pressure relief valve.
This steering valve only consists of an orbit pump.
The selector valve Y is integrated in the Auto-Pilot

valve Z.
The pressure relief valve W is a separate component

on the forage harvester.
At port P of the steering valve X an orifice Or (dia. 2.5

mm) (0,1”) is installed. The widest part of it has to
face port P.
Chapter 5 -- Low Pressure Hydraulics
CONTENT

35.000 Circuit diagrams -- Low pressure hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35.300 Low pressure hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil change and fill procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
35.310 Low pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Low pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main drive belts tensioning cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spout deflector cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
LOW PRESSURE HYDRAULICS -- 4WD
4A FX/96 Series 01 > 13
FX25/45 Series 01 > 05
A Engine
C Hydrostatic pump
F Low pressure pump
G Low pressure valve
H Main hydraulic clutch (is part of B).
K Filter
P Pressure contacts
Q Drain hose
R Oil reservoir

12 Main drive belts tensioning cylinder

13 Four-wheel drive clutch
4A FX/96 Series 01 > 13
FX25/45 Series 01 > 05
52603
1
4B FX Series 14 > ..........
FX25/45 Series 06 > ..........
A Engine
C Hydrostatic pump
F Low pressure pump
K Filter
P Pressure contacts
Q Drain hose
R Oil reservoir


13 Hydraulic spout deflector cylinder
14 Four--wheel drive clutch
4B FX Series 14 > ..........
FX25/45 Series 06 > ..........
31340
2
LOW PRESSURE HYDRAULICS -- 4WD +
HYDRAULIC DEFLECTOR (FIELD
INSTALLED KIT)
4C FX/96 Series 01 > 13
FX25/45 Series 01 > 05
A Engine
C Hydrostatic pump
F Low pressure pump
K Filter
P Pressure contacts
Q Drain hose
R Oil reservoir


13 Four--wheel drive clutch
4C FX/96 Series 01 > 13
FX25/45 Series 01 > 05
34341
3
4D FX/96 Series 01 to 09
FX25/45 Series 01
A Engine
C Hydrostatic pump
F Low pressure pump
K Filter
P Pressure contacts
Q Drain hose
R Oil reservoir


4D FX/96 Series 01 to 09
FX25/45 Series 01
52604
4
4E FX/96 Series 10 > 13
FX25/45 Series 02 > 05
A Engine
C Hydrostatic pump
F Low pressure pump
K Filter
P Pressure contacts
Q Drain hose
R Oil reservoir


4E FX/96 Series 10 > 13
FX25/45 Series 02 > 05
52605
5
4F FX Series 14 > ..........
FX25/45 Series 06 > ..........
A Engine
C Hydrostatic pump
F Low pressure pump
K Filter
P Pressure contacts
Q Drain hose
R Oil reservoir


4F FX Series 14 > ..........
FX25/45 Series 06 > ..........
31342
6
LOW PRESSURE HYDRAULICS -- 2WD +
HYDRAULIC DEFLECTOR (FIELD
INSTALLED KIT)
4G FX/96 Series 01 > 13
FX25/45 Series 01 > 05
A Engine
C Hydrostatic pump
F Low pressure pump
K Filter
P Pressure contacts
Q Drain hose
R Oil reservoir


4G FX/96 Series 01 > 13
FX25/45 Series 01 > 05
31343
7
LOW PRESSURE HYDRAULIC RESERVOIR
R3
Oil level
The oil level should be checked daily on the dipstick
of filler cap 1.
Capacity
Reservoir: 7 litres (7.4 qts)
Entire system: 10 litres (10,6 qts)
58209
8
Oil specification
Use AMBRA HYDROSYSTEM 46HV oil (ref.
NH646H) or an oil meeting the following specifica-
tion:
DIN 51524 Part 2 or ISO VG46
Viscosity grade: 46
Oil change
After the first 100 operating hours
Thereafter:
-- when the flow indicator 2 becomes red
(Fig. 8) or,
-- every 600 operating hours or,
-- every year
OIL FILTER
This self-indicating filter must be changed at every oil
change.
NOTE: Check the flow indicator with the engine run-

ning.
58210
9
OIL CHANGE AND FILL PROCEDURES 3. Unscrew the suction line from the low pressure
pump.
Oil change
4. Fill the suction line with oil.
1. Drain the oil reservoir.
5. Screw the section line back to the pump.
2. Thoroughly clean the surrounding area of filter 3.
6. Carry out the oil pressure check procedure be-
3. Remove the filter bowl. low.
4. Fill the reservoir to the dipstick mark.

Oil pressure check procedure
5. Fill the new filter bowl with new hydraulic oil.
1. First check the oil level in the reservoir.
6. Apply a film of oil to the gasket of the new filter
bowl. 2. Start the engine and let it run at low idle.
7. Screw on the new filter by hand. Tighten firmly 3. Switch ON the Harvest switch.
but DO NOT USE TOOLS. Check if the main drive belts are tensioned by the
cylinder.
If not, shutt off the engine and check whether the
8. Carry out the oil pressure check procedure be- suction line to the low pressure pump is filled with
low. oil.
4. If the belts are tensioned, reverse the feed rolls

Filling the system when (re)installing the low
to lift the pawl and switch ON the cutterhead drive
pressure pump
switch.
1. Fill the suction line before connecting it to the
pump. 5. Increase the engine speed to at least 1700 rpm.
2. Carry out the oil pressure check procedure be- 6. Watch the ‘‘Main drive clutch oil pressure’’ warn-
low. ing light on the instrument panel.
7. This warning light should not be illuminated or at

least disappear within 15 seconds.
Flling the system after (re)installing the main
If the warning light remains illuminated, stop the
drive transfer gearbox
engine and search for the cause.
1. First fill the main drive transfer gearbox from the With the engine running at 1900 rpm and the cut-
top until the oil level in the reservoir rises (i.e. 4 terhead engaged, the pressure measured at
to 5 litres of oil). pressure check point W should be:
• 31-33 bar (450--480 psi) at an oil temperature

2. Fill the oil reservoir through the filler cap to the of 30-40_C (86--104_F)
dipstick mark.
• 30 bar (435 psi) at an oil temperature of
75-85_C (170--190_F)
LOW PRESSURE PUMP
55121
55121
10
1. Bushing 12. Plastic plug
2. Bushing 13. Plastic plug
3. Pump house 14. --
4. Cover plate 15. --
5. Cover 16. Circlip
6. Driven pump gear 17. Circlip
7. Driven pump gear 18. Dowel pin
8. Anti-extrusion seal 19. O-ring
9. Inner seal 20. --
10. Outer seal (2 off) 21. Oil baffle
11. Bolt (4 off)
Specifications -- Pressure on suction side: 0.3 to 1 bar (absolute)

(4,5 to 14,5 psi)
-- Gear pump
-- Maximum pressure: 210 bar (3045 psi)
-- Output per revolution: 6 cc (0,37 cu.in.)
-- Maximum peak pressure: 230 bar (3335 psi)
(0,1 cu.in.)
-- Maximum speed: 5,000 rpm
-- Direction of rotation: clockwise
-- Minimum speed at max. pressure: 1,200 rpm
LOW PRESSURE VALVE
The low pressure valve is situated above the hydro-
static pump.
FX/96 Series 01 > 13

FX25/45 Series 01 > 05
A To main hydraulic clutch

B To/from hydraulic cylinder (main drive belts)
11
A1 Not used
A2 To 4-WD clutch (option)
A3 Not used
MP Pressure contact 24 bar (350 psi) (main drive
clutch)
MP1 Pressure contact 5 bar (70 psi) (hydrostatic
charge pump)
P From low pressure pump
P1 From hydrostatic charge pump
T To return circuit (hydraulic reservoir)
To the main drive transfer gear-box gears
T1 To return circuit (low pressure hydraulic reser- 12
voir)
W Pressure check point
FX/96 Series 14 > ...........
FX25/45 Series 06 > ...........
A To main hydraulic clutch

B To/from hydraulic cylinder (main drive belts)
A1 To/from hydraulic spoat deflector cylinder
A2 To/from hydraulic spoat deflector cylinder
A3 To 4-WD clutch (option)
A4 Not used
13
MP Pressure contact 24 bar (350 psi) (main drive
clutch)
MP1 Pressure contact 5 bar (70 psi) (hydrostatic
charge pump)
P From low pressure pump
P1 From hydrostatic charge pump
T To return circuit (hydraulic reservoir)
To the main drive transfer gear-box gears
T1 To return circuit (low pressure hydraulic reser-
voir)
W Pressure check point
Valve a -- main drive clutch and main drive
belts cylinder
52085
14
-- When starting the forage harvester, the solenoid This oil flow is meant to cool and lubricate the ro-
of valve a is automatically activated into position tating parts inside the main drive transfer gear-
1. box and flows via the overflow line r to the oil res-
The low pressure pump F pumps oil via port P. ervoir R3.
This oil flow is divided in an oil flow straight to the The pressure at port B (the hydraulic cylinder) is
oil reservoir R3 (hydraulic line n) and an oil flow not high enough to stretch the main drive belts.
to the main drive transfer gearbox (hydraulic line
q).
-- When switching ON the Harvest switch, none of
the solenoids of valve a is activated.
The valve moves back to neutral position. The
NOTE: The main drive clutch H is part of the main pressure is now completely on the hydraulic cyl-
drive transfer gearbox. inder, which stretches the main drive belts.
-- When switching ON the cutterhead drive switch, Valve b -- 4WD clutch
valve a is activated into position 2.
This valve is activated when:

NOTE: To achieve this step, the Harvest switch must
-- The Harvest switch is switched ON
be switched ON and the pawl of the metal detection
stop system must be lifted from the pawl wheel. -- The 4-wheel drive switch is switched ON
The pressure contact at port MP 1 switches off when

The low pressure pump will pump oil via port A to the the pressure, delivered by the charge pump of the hy-
main hydraulic clutch H (hydraulic line s). drostatic pump C, drops below 5 bar (73 psi).
In that case, the feed rolls will stop immediately.
The flow resistance of the clutch is such that the pres-
sure on port B is still high enough to keep the main After 5 seconds the main clutch will be disengaged
drive belts tensioned. giving the cutterhead, blower and spout time to clear.
The oil flow through the main hydraulic clutch H ar- The engine slows down to low idle.
rives at reservoir R3 via hydraulic line r.
Another 5 seconds later the engine will stop.
The pressure in this system is maximum 30 bar (435
psi), due to the pressure relief valve k.
Check the hydrostatic system.
The pressure contact at port MP warns the operator

through the ‘‘main drive clutch oil pressure’’ warning
light that the pressure has dropped below 24 bar (348
psi).
This is to protect the main clutch from slipping.
ATTENTION
The warning will only be activated in following condi-

tions:
-- When the cutterhead is engaged

-- When the engine speed is at least 1700 rpm
Valve c Valve D
Valve d is not used.

FX/96 Series 01 > 13
FX25/45 Series 01 > 05
Valve c is not used (Fig. 14).
NOTE: Valves c and d are used in case the forage

harvester is rebuilt with a field installed hydraulic
spout deflector cylinder.
FX/96 Series 14 > ..........

FX25/45 Series 06 > ..........
Valve C controls the hydraulic spout deflector cylin-

der (Fig. 15).
The valve is activated when:
-- The harvest switch is switched on.

-- Spout deflector rocker switch is activated (up or
down).
31344
15
MAIN DRIVE BELTS TENSIONING CYLIN-
DER
43160
16
a Piston
b Cylinder
c Locking wire
d Piston guide ring (2x)
f Seal ring
g Guide ring
h Seal ring
The disassembly and assembly instructions are simi-

lar to those for the attachment lift cylinders.
SPOUT DEFLECTOR CYLINDER
17
1. Bolt 8. Piston
2. Washer 9. Piston guide
3. Piston guide 10. O--ring
4. Guide ring 11. Seal ring
5. Seal ring 12. O--ring
6. Seal ring 13. Cavity
7. Cylinder 14. Scraper ring
1. Unscrew piston guide 9 using a hook spanner

(cavity 13).
2. Pull out the “piston 8 -- piston guide 3” assembly.
3. Unscrew bolt 1 attaching piston 8 to piston guide

3.
4. Remove piston 8 from piston guide 3.
5. Remove all seals (be careful not to scratch the

grooves).
6. Replace the seals taking into account the direc-

7. When reassembling the cylinder, tighten bolt 1

with a torque of 34 Nm (25 lbf.ft).
Chapter 6 -- Hi--Flow Hydraulics
CONTENT

35.000 Circuit diagrams -- Hi--flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HI--FLOW HYDRAULICS -- EUROPE
5A FX/96 Series 01 > 5080
FX28--48 Series 5083 > ......
A Engine
B Supporting bearing
C Pump
D Control valve
E Quick--release couplings
F Pressure relief valve
Q Drain plug
R Oil reservoir
5A FX/96 Series 01 > 5080
FX28--48 Series 5083 > ......
52606
52606
HI--FLOW HYDRAULICS -- EUROPE
5B FX58 Series 5083 > ......
A Engine
C Pump
D Control valve
F Pressure relief valve
Q Drain plug
R Oil reservoir
5B FX58 Series 5083 > ......
31347
2
HI--FLOW HYDRAULICS -- NORTH AMERICA
5C FX25/45 Series 01 > 06
FX58 Series 5083 > ......
A Engine
C Pump
D Control valve
F Pressure relief valve with extra, controlled oil
return flow
Q Drain plug
R Oil reservoir
5C FX25/45 Series 01 > 06
FX58 Series 5083 > ......
52607
3
HI--FLOW HYDRAULICS -- NORTH AMERICA
5D FX25/45 Series 5033 > 5080
FX28--48 Series 5083 > ......
A Engine
C Pump
D Control valve
F Pressure relief valve with extra, controlled oil
return flow
Q Drain plug
R Oil reservoir
5D FX25/45 Series 5033 > 5080
FX28--48 Series 5083 > ......
31346
4
SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1 1
SECTION 50 -- CAB CLIMATE CONTROL
Chapter 1 -- Cab Cimate Control
CONTENT

50.000 Correct use of the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Storage maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
50.200 Air conditioning circuit and component specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compressor clutch replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
50.206 Ventilation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1
CORRECT USE OF THE AIRCONDITIONING
SYSTEM
-- Keep door and window closed.
-- Use the airconditioning as much as possible.
-- Use the airconditioning only with the ventilator in

position I or II.
-- Control the desired temperature with the air-

conditioning knob (thermostat).
Regularly pay attention to the following:
-- The status of the sight glass and the moisture

indicator (Fig. 2).
-- The cleanliness of the condenser and evapor-

ator.
-- The cleanliness of the air intake filters.
-- The cleanliness of the air recycling filter 4

(Fig. 3).
-- The water dropping at the drain tubes.
STORAGE MAINTENANCE
Operate the airconditioning unit with the engine on

idle speed and the ventilator on position II for at least
five minutes once a month during the storage period
(i.e. to oil all compressor seals and to avoid leak-
ages).
NOTE: The airconditioning system must only be op-

erated if the cab temperature is 21°C or more.
The airconditioning system must only be operated if
the ambient temperature is higher than 10°C.
ATTENTION: It is fully recommended to have the air-

conditioning system checked yearly by a specialist
(before the start of the harvest season).
ATTENTION: After recharging of the system by a

specialist, ensure the engine speed is set at low idle,
then engage and run the airconditioning system for
two (2) minutes to allow the system gas and lubrica-
tion to normalise.
After this initial run--up the system can be used nor-

mally.
AIR CONDITIONING CIRCUIT
Components
1. Compressor
2. High pressure switch
3. High pressure charge port
4. Condenser
5. Filter--drier
6. Expansion valve
7. Evaporator
8. Low pressure charge port
9. Low pressure switch
51125
1
SPECIFICATIONS NOTE: The use of R134a in an automotive aircondi-
tioning compressor requires special attention to lu-
brication.
Refrigerant A specific PAG--type oil, Sanden SP--20, has been
developed to suit the SD7H15. Care must be taken
Specification: R134 a to avoid incorrect oils being used as SP--20 is the
only lubricant approved for use with the SD7H15.
Amount: 2100 gr
Compressor clutch
Rated voltage: DC 12V

Compressor
Break--away torque: 34 Nm (3.5 kgf.m)
Type: SANDEN SD7H15KG7862
Minimum engagement voltage: 7.5 V
Displacement per revolution: 154.9 cc
Power consumption: 49 W
Oil capacity: 360 cc (Sanden SP--20) (135 cc in com-
pressor + 225 cc in circuit) Belt type: A type
Circuit parameters
Airconditioning Ambient temperature °C Low pressure bar High pressure bar

Not in operation 20 4.5 4.5
Not in operation 30 6.5 6.5
In operation 20 0.5 to 1 11
In operation 30 1 14
Low pressure switch High pressure switch

Switch normally open: non adjustable Switch normally closed: non adjustable
Cut--in set point: 2.5 bar ± 0.3 bar Cut--out set point: 28 bar ± 1.5 bar
Cut--out set point: 0.3 bar ± 0.15 bar Cut--in set point: 19 bar ± 1.5 bar
Switch body colour: bronze Switch body colour: green
Filter--drier
A sight glass and a ring--shaped moisture indicator

serve for determining the condition of the R134 a.
IF:
-- The glass shows a milky refrigerant without air
bubbles, then the refrigerant is OK.
-- The glass shows air bubbles: lack of refrigerant.
-- The moisture indicator is blue: filter and refriger-

ant are OK.
-- The moisture indicator is red: too much moisture:

filter--drier has to be replaced.
-- The moisture indicator is brown or black: too

much contamination: filter--drier has to be re-
placed.
NOTE: The filter--drier must be replaced when the

airconditioning circuit has been opened.
1. Outlet
2. Sight glass and moisture indicator
3. Inlet
51126
2
COMPRESSOR CLUTCH REPLACEMENT
Clutch removal
Insert the two pins of the front plate spanner into any
two threaded holes of the clutch front plate. Hold the
clutch plate stationary. Remove the hex nut with a
19 mm socket.
30288
3
Remove the clutch plate using a puller. Align the
puller centre bolt to the compressor shaft. Thumb
tighten the 3 puller bolts into the threaded holes.
Turn the centre bolt clockwise until the front plate is
loosened.
30287
4
Remove the shaft key by lightly tapping it loose with
a slot screw driver and hammer.
30291
5
Remove the internal bearing snap ring.
30290
6
Remove the front housing external snap ring.
30292
7
Remove the rotor pulley assembly:
-- Insert the lips of the jaws into the internal bearing
snap ring groove.
-- Place the rotor puller shaft protector over the ex-
posed shaft.
30295
30289
9
Align the thumb head bolts to the puller jaws and
finger--tighten.
30286
10
Turn the puller centre bolt clockwise until the rotor
pulley is free.
30280
11
Remove the field coil
Loosen the coil lead wire from the clip on top of the
compressor front housing.
30281
12
Remove the snap ring and the field coil.
30294
13
Clutch installation
Install the field coil: the coil flange protrusion must

match the hole in the front housing to prevent coil
movement and the lead wire must be correctly lo-
cated.
Replace the rotor pulley.
30293
14
Support the compressor on the 4 mounting ears at
the compressor rear side. If using a vise, clamp only
the mounting ears, never the compressor body itself.
Align the rotor assy squarely on the front housing
hub.
Using a hammer and a special tool, tap until the rotor
bottoms to the compressor front housing hub.
30283
15
Reinstall the internal bearing snap ring.
Reinstall the front housing external snap ring.
30284
16
Replace the front plate assy.
Check that the original clutch shims are in place on
the compressor shaft.
Replace the compressor shaft key.
Align the front plate keyway to the compressor shaft
key.
Using a shaft protector, tap the front plate to the shaft
until it has bottomed to the clutch shims.
30282
17
Replace the shaft hex nut and torque to 35 to 40 Nm
(3.5 to 4 kgf.m).
Check the air gap with a feeler gauge (0.4 to 0.8 mm).
If the air gap is not consistent around the circumfer-
ence, lightly pry up at the minimum variations. Lightly
tap down at points of maximum variation.
30285
18
VENTILATION UNIT IMPORTANT:
-- If the drink storage door is open, the ventilator
The ventilation unit is situated underneath the seat. and airconditioning system are switched off.
1. Ventilator -- Flipping up the operator’s seat to get access to
2. Thermostat the ventilation unit does NOT switch off the venti-
3. Evaporator lator and airconditioning system!
4. Air recycling filter • Take care not to injure your fingers.
5. Drink storage place • The ventilator will now have very low resis-
tance, which can cause the fuse (F3) to be
blown.
51124
19
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 1
Chapter 1 -- Electrical Circuits

CONTENT
55.000 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55.100 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1
GENERAL INFORMATION
Wires
The wiring diagram is drawn following the DIN 40719

standards.
Each page contains a part of the complete wiring

diagram, not necessarily a complete group.
Color code
Ten colours of wires are used on the combine, each

color having its specific signification.
-- Red (rd):+ 12 V without passing the ignition

switch
-- Black (zw): directly earthed to the frame
-- White (wt): connected with the pin of a switch

which engages a system that increases
something (e.g. increase of drum rpm)
-- Grey (gr): connected with the pin of a switch

which disengages a system that decreases
something
-- Brown (br): signal wire from the rpm monitor to a

sensor
-- Blue (bl): earth of sensors through the monitor
-- Green (gn): wire to non rpm sensors (e.g. engine

oil pressure, temperature, etc)
-- Orange (or): lighting
-- Yellow (ge): lighting
-- Purple (pu): to rear direction indicator lights.
On the upper part of the page, the + 12 V lines are

drawn.
The line at the top (first line) always is at + 12 V (when
the main battery switch is engaged).
Lines 2 and 3 have + 12 V when relays K6 and K9 are

820
energized. This happens when the ignition switch is E.g.
engaged.
60 70 80 90 100 110 120 130

52865
1
Wire identification
The wiring diagram is marked as follows:
-- X16p01:
Connector X16, position 01
-- 893:
Wire number
-- 6:
Wire section is 6 mm2
52866
-- wt: 2
Wire color (white)
-- X108p02:
Connector X108, position 02
This information is printed at regular distances on the

wire itself, e.g.
X16/01 < - 893 - > X108/02
Thick drawn lines in the wiring diagrams do not

exist as a wire but are lines in the printed circuit.
51844
3
Fuses
A fuse can protect one or more electrical circuits.
When more circuits are protected, the first time the

fuse is mentioned, the drawing is as follows (really
connected):
51845
4
The other circuits that are protected by the same fuse

are drawn as follows:
(*): The line reference indicates the line on which

all connections (lines) with that particular fuse
are mentioned.
51846
5
SYMBOLS
All symbols used in the wiring diagram are drawn

according to the DIN 40719 standard and are marked
with a letter and a number.
Each letter represents a group of similar

components.
The letters used can be found in following list:
Letter Component Example
A Monitors, prints Radio, CB, displays
B Commutator from non-electrical Sensor, horn, sender elements of water, air, oil tem-
into electrical signals, and vice perature and pressure, buzzer
versa
C Condensers
D Accumulator equipment Accumulators
E Lighting All lamps, except warning lights, dashboard lights
F Safety components All fuses
G Generators Battery, alternator
H Control components All control lamps
K Relays All relays, flasher unit, 12/24 V transformer
L Inductive components Coils in relays Motors
M Motors Varistor motors, ventilator, actuators
N Amplifier, controller Voltage controller
P Measuring instrument Clock, fuel and water temperature gauge
R Resistances Potentiometer, preheating
S Switch All switches
T Transformer Ignition coils
U Commutator from electrical sig- Frequence commutator, converter

nals into other electrical signals
V Semi-conductors Diodes, transistors, thyristors
W Wiring looms, antennas CB and radio antenna, coax wires
X Connectors All connectors, plugs
Y Mechanical components electri- Hydraulic valve, electromagnetic clutches, electrical

cally energized valve on injection pump.
Z Electrical filter Suppressor

The letters used can be found in following list:
Symbol Description
Electrical motor, actuator
Lamp
Double-acting lamp
Diode
Led (light emitting diode)
Fuse
Socket (female)
Plug in (male)
Automatic fuse
Buzzer
Inductive sensor
Symbol Description
Horn
Ignition switch
Solenoid for control valves
Flashing unit
Battery
Gauge
Electromagnetic clutch
Adjustable resistance
Bipolar switch
Loudspeaker
Alternator
Symbol Description
Wiper motor
Electric starter motor
Normally closed switch, manually controlled
Normally open switch, mechanical control by pedal
Normally open switch, mechanically controlled
Normally open switch, mechanically controlled
Normally closed switch, mechanically controlled
Normally open switch, controlled by a pressure sender
Normally open switch, controlled by under-pressure

Symbol Description
Normally closed switch, controlled by over-pressure
Normally open switch, controlled by a temperature sender
Normally closed switch, controlled by a level indicator
Normally open switch, controlled by the grain level indicator
Relay
Airconditioning ventilation motor
Mirror motor
The switches are drawn in the position as they are removed from the forage harvester.
Relays
A fuse can protect one or more electrical circuits.
NOTE: Never use relays with a diode parallel with the

coil or without a suppressor.
Relays with terminal references 1 - 2 - 3 - 4 - 5 (see
diagrams) have no suppressor and are soldered
to the printed circuit.
The relays can be recognized by the drawing on the
relay housing (Figures 6 to 8).
52867
Use relays with drawing as shown in Figure 6.
6
Do not use relays with drawings as shown in Figures
7 and 8.
52868
7
52869
8
CONNECTORS
X168 X199 X328 X500 X625 X630 X653
ZDA0428A
9
X106
10
X194 X195 X196
1 3
2 4
ZDA0429A
11
X193 X198
12
X92 X604 X625
13
X401 X402 X403 X404 X405 X406
X407 X408 X409 X410 X411 X412
X413 X414 X416 X417 X421 X422
X423 X424 X431 X433 X480
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
ZDA0436A
14
X303 X415 X432 X434
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
ZDA0437A 13
15
X57
53 52 51 50 49 48 47 46 45 44 43 42 41 40
35 34 33 25 24 23 22
17 16 15 14 6 5 4 3
ZDA0438A
16
X91 X121 X131 X132 X169 X170 X257 X608
X620 X638 X644 X645
2 3
ZDA0425A
17
X105 X134 X171 X191 X331 X600
X601 X606 X607 X612 X615 X616
X635 X636 X637 X639 X641
2 3
ZDA0427A
18
X329
19
X21 X184 X323 X609 X614 X621 X649
2 1
ZDA0447A
20
X318 X319 X613
21
X192 X617 X618 X619 X640 X648
3 1
5 4
8 6
ZDA0446A
22
X26 X302 X306 X503 X505 X512 X513
3 2
6 4
10 7
13 11
16 14
15
ZDA0444A
23
X332 X511
2 1
ZDA0439A
24
X06 X500 X502 X507
4 1
9 5
15 10
20 16
24 21
ZDA0441A
25
X509
3 1
6 4
9 7
ZDA0440A
26
X501
4 1
9 5
15 10
22 16
28 23
33 29
37 34
ZDA0442A
27
X10 X305 X504 X506 X508
1
3 2
8 4
14 9
19 15
21 20
22
ZDA0443A
28
X260
29
X155
30
X627
31
Chapter 3 -- Wiring Diagrams FX NA
CONTENT
55.000 Wiring diagrams FX NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ELECTRICAL DIAGRAMS
Ref. Line Group / Series
1a 10 STARTER CIRCUIT 24V

FX25 39.01 > 5080 FX45 47.01 > 5080
1b 10 STARTER CIRCUIT 24V

FX28NA 5083 > 5168 FX38NA 5083 > 5168
1c 10 STARTER CIRCUIT 24V

FX28NA 5186 > 5206 FX38NA 5186 > 5206
1d 10 STARTER CIRCUIT 24V IVECO

FX28NA 5218 > .... FX38NA 5218 > ....
1e 10 STARTER CIRCUIT 24V CATERPILLAR

FX58NA 5083 > 5168
1f 10 STARTER CIRCUIT 24V CATERPILLAR

FX58NA 5186 > 5206
1g 10 STARTER CIRCUIT 24V CATERPILLAR

FX58NA 5218 > ....
2a 520 ENGINE THROTTLE CONTROL

FX25 39.01 > 5080 FX45 47.01 > 5080
2b 520 ENGINE THROTTLE CONTROL

FX28NA 5083 > 5168 FX38NA 5083 > 5168
2c 520 ENGINE THROTTLE CONTROL

FX28NA 5186 > 5206 FX38NA 5186 > 5206
2d 520 ENGINE THROTTLE CONTROL IVECO

FX28NA 5218 > .... FX38NA 5218 > ....
2e 520 ENGINE THROTTLE CONTROL CATERPILLAR

FX58NA 5083 > 5168
2f 520 ENGINE THROTTLE CONTROL CATERPILLAR

FX58NA 5186 > 5206
2g 520 ENGINE THROTTLE CONTROL CATERPILLAR

FX58NA 5218 > ....
3a 690 HYDROSTATIC CONTROL

FX25 39.01 > 5080 FX45 47.01 > 5080
3b 690 HYDROSTATIC CONTROL

FX28NA 5083 > 5206 FX38NA 5083 > 5206
3c 690 HYDROSTATIC CONTROL IVECO

FX28NA 5218 > .... FX38NA 5218 > ....
3d 690 HYDROSTATIC CONTROL CATERPILLAR

FX58NA 5083 > 5206
3e 690 HYDROSTATIC CONTROL CATERPILLAR

FX58NA 5218 > ....
4a 860 FOUR--WHEEL DRIVE

FX25 39.01 > 39.05 FX45 47.01 > 47.05
4b 860 FOUR--WHEEL DRIVE

FX25 39.06 > 5080 FX45 47.06 > 5080
4c 860 FOUR--WHEEL DRIVE

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
5a 1030 ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1

FX25 39.01 > 39.04 FX45 47.01 > 47.04
5b 1030 ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1

FX25 39.05 > 5080 FX45 47.05 > 5080
5c 1030 ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
6a 1540 ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1

FX25 39.01 > 5080 FX45 47.01 > 5080
6b 1540 ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1

FX28NA 5083 > 5206 FX38NA 5083 > 5206 FX58NA 5083 > 5206
6c 1540 ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1

FX28NA 5218 > .... FX38NA 5218 > .... FX58NA 5218 > ....
7a 2050 ELECTRONIC SYSTEM: ELECTRONIC BOX 2

FX25 39.01 > 39.04 FX45 47.01 > 47.04
7b 2050 ELECTRONIC SYSTEM: ELECTRONIC BOX 2

FX25 39.05 > 5080 FX45 47.05 > 5080
7c 2050 ELECTRONIC SYSTEM: ELECTRONIC BOX 2

FX28NA 5083 > 5206 FX38NA 5083 > 5206 FX58NA 5083 > 5206
7d 2050 ELECTRONIC SYSTEM: ELECTRONIC BOX 2

FX28NA 5218 > .... FX38NA 5218 > .... FX58NA 5218 > ....
8a 2390 CPU INPUTS AND DISPLAY

FX25 39.01 > 39.05 FX45 47.01 > 47.05
8b 2390 CPU INPUTS AND DISPLAY

FX25 39.06 > 5080 FX45 47.06 > 5080
8c 2390 CPU INPUTS AND DISPLAY

FX28NA 5083 > 5168 FX38NA 5083 > 5168
8d 2390 CPU INPUTS AND DISPLAY

FX28NA 5174 > 5206 FX38NA 5174 > 5206
8e 2390 CPU INPUTS AND DISPLAY

FX58NA 5083 > 5168
8f 2390 CPU INPUTS AND DISPLAY

FX58NA 5174 > 5206
8g 2390 CPU INPUTS AND DISPLAY

FX28NA 5218 > .... FX38NA 5218 > .... FX58NA 5218 > ....
9a 2900 ENGINE PROTECTION

FX25 39.01 > 39.05 FX45 47.01 > 47.05
9b 2900 ENGINE PROTECTION

FX25 39.06 > 5080 FX45 47.06 > 5080
9c 2900 ENGINE PROTECTION

FX28NA 5083 > 5206 FX38NA 5083 > 5206
9d 2900 ENGINE PROTECTION IVECO

FX28NA 5218 > .... FX38NA 5218 > ....
9e 2900 ENGINE PROTECTION CATERPILLAR

FX58NA 5218 > ....
10a 3410 SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 39.01 > 39.01 FX45 47.01 > 47.01
10b 3410 SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 39.02 > 39.04 FX45 47.02 > 47.04
10c 3410 SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 39.05 > 39.05 FX45 47.05 > 47.05
10d 3410 SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 39.06 > 5074 FX45 47.06 > 5074
10e 3410 SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 5080 > 5080 FX45 5080 > 5080
10f 3410 SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX28NA 5083 > 5168 FX38NA 5083 > 5168 FX58NA 5083 > 5168
10g 3410 SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX28NA 5186 > .... FX38NA 5186 > .... FX58NA 5186 > ....
11a 3920 METAL DETECTOR

FX25 39.01 > 39.01 FX45 47.01 > 47.01
11b 3920 METAL DETECTOR

FX25 39.02 > 5080 FX45 47.02 > 5080
11c 3920 METAL DETECTOR

FX28NA 5083 > 5168 FX38NA 5083 > 5168
11d 3920 METAL DETECTOR IVECO

FX28NA 5186 > 5206 FX38NA 5186 > 5206
11e 3920 METAL DETECTOR IVECO

FX28NA 5218 > .... FX38NA 5218 > ....
11f 3920 METAL DETECTOR CATERPILLAR

FX58NA 5083 > 5168
11g 3920 METAL DETECTOR CATERPILLAR

FX58NA 5186 > 5206
11h 3920 METAL DETECTOR CATERPILLAR

FX58NA 5218 > ....
12a 4260 CROP PROCESSOR

FX25 39.01 > 5080 FX45 47.01 > 5080
12b 4260 CROP PROCESSOR

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
13a 4430 SPOUT CONTROL

FX25 39.01 > 39.05 FX45 47.01 > 47.05
13b 4430 SPOUT CONTROL

FX25 39.06 > 5080 FX45 47.06 > 5080
13c 4430 SPOUT CONTROL

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
14a 4770 ROTARY DUST SCREENS AND CENTRAL GREASING SYSTEM

FX25 39.01 > 39.01 FX45 47.01 > 47.01
14b 4770 ROTARY DUST SCREENS AND CENTRAL GREASING SYSTEM

FX25 39.02 > 5080 FX45 47.02 > 5080
14c 4770 ROTARY DUST SCREENS

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
15a 4940 REVERSE DRIVE CUTTERHEAD AND SHARPENING

FX25 39.01 > 5080 FX45 47.01 > 5080
15b 4940 REVERSE DRIVE CUTTERHEAD AND SHARPENING

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
16a 5450 AUTOMATIC GREASING SYSTEM

FX25 39.02 > 5080 FX45 47.02 > 5080
16b 5450 AUTOMATIC GREASING SYSTEM

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
17a 5790 SHEARBAR ADJUSTMENT

FX25 39.01 > 5080 FX45 47.01 > 5080
17b 5790 SHEARBAR ADJUSTMENT

FX28NA 5083 > 5168 FX38NA 5083 > 5168 FX58NA 5083 > 5168
17c 5790 SHEARBAR ADJUSTMENT

FX28NA 5186 > .... FX38NA 5186 > .... FX58NA 5186 > ....
18a 6300 SILAGE ADDITIVE APPLICATION

FX25 39.01 > 39.01 FX45 47.01 > 47.01
18b 6300 SILAGE ADDITIVE APPLICATION

FX25 39.02 > 5080 FX45 47.02 > 5080
18c 6300 SILAGE ADDITIVE APPLICATION

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
19a 6470 AUTO--PILOT

FX25 39.01 > 5080 FX45 47.01 > 5080
19b 6470 AUTO--PILOT

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
20a 6810 HEADER HEIGHT CONTROL (HHC)

FX25 39.01 > 5080 FX45 47.01 > 5080
20b 6810 HEADER HEIGHT CONTROL (HHC)

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
21a 7320 COOLANT TEMPERATURE AND FUEL GAUGE

FX25 39.01 > 39.05 FX45 47.01 > 47.05
21b 7320 COOLANT TEMPERATURE AND FUEL GAUGE

FX25 39.06 > 5080 FX45 47.06 > 5080
21c 7320 COOLANT TEMPERATURE AND FUEL GAUGE

FX28NA 5083 > 5206 FX38NA 5083 > 5206
21d 7320 COOLANT TEMPERATURE AND FUEL GAUGE IVECO

FX28NA 5218 > .... FX38NA 5218 > ....
21e 7320 COOLANT TEMPERATURE AND FUEL GAUGE IVECO

FX58NA 5083 > 5206
21f 7320 COOLANT TEMPERATURE AND FUEL GAUGE CATERPILLAR

FX58NA 5218 > ....
22a 7830 PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
FX25 39.01 > 5080 FX45 47.01 > 5080
22b 7830 PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
23a 8340 DIRECTION INDICATOR AND HAZARD WARNING LIGHTS

FX25 39.01 > 5080 FX45 47.01 > 5080
23b 8340 DIRECTION INDICATOR AND HAZARD WARNING LIGHTS

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
24a 8680 OPERATING LIGHTS AND BEACONS

FX25 39.01 > 5080 FX45 47.01 > 5080
24b 8680 OPERATING LIGHTS AND BEACONS

FX28NA 5083 > 5206 FX38NA 5083 > 5206
24c 8680 OPERATING LIGHTS AND BEACONS IVECO

FX28NA 5218 > .... FX38NA 5218 > ....
24d 8680 OPERATING LIGHTS AND BEACONS

FX58NA 5083 > 5206
24e 8680 OPERATING LIGHTS AND BEACONS

FX58NA 5218 > ....
25a 9190 AIR CONDITIONING

FX25 39.01 > 39.01 FX45 47.01 > 47.01
25b 9190 AIR CONDITIONING

FX25 39.02 > 39.05 FX45 47.02 > 47.05
25c 9190 AIR CONDITIONING

FX25 39.06 > 5080 FX45 47.06 > 5080
25d 9190 AIR CONDITIONING

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
26a 9700 CAB

FX25 39.01 > 39.01 FX45 47.01 > 47.01
26b 9700 CAB

FX25 39.02 > 39.04 FX45 47.02 > 47.04
26c 9700 CAB

FX25 39.05 > 5080 FX45 47.05 > 5080
26d 9700 CAB

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
27a 10210 MIRROR CONTROL AND WINDSHIELD HEATING

FX25 39.01 > 39.04 FX45 47.01 > 47.04
27b 10210 MIRROR CONTROL AND WINDSHIELD HEATING

FX25 39.05 > 5080 FX45 47.05 > 5080
27c 10210 MIRROR CONTROL AND WINDSHIELD HEATING

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
28a 10720 FLIP--UP MAIZE HEADER

FX25 39.01 > 5080 FX45 47.01 > 5080
28b 10720 FLIP--UP MAIZE HEADER

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
29a 10890 HIGH FLOW REAR HYDRAULICS

FX25 39.01 > 39.04 FX45 47.01 > 47.04
29b 10890 HIGH FLOW REAR HYDRAULICS

FX25 39.05 > 5080 FX45 47.05 > 5080
29c 10890 HIGH FLOW REAR HYDRAULICS

FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
30a 11560 ELECTRONIC ENGINE CONTROL CATERPILLAR

FX58NA 5083 > 5206
30b 11560 ELECTRONIC ENGINE CONTROL CATERPILLAR

FX58NA 5218 > ....
31a 11900 ELECTRONIC ENGINE CONTROL IVECO

FX28NA 5218 > .... FX38NA 5218 > ....
LIST OF SYMBOLS AND WHERE TO FIND THEM
A. Prints and Monitors
Code Description Location Line
A1. Radio Cab roof 9900
A2. CB Cab roof 9910
A8. InfoView monitor display (print) InfoView monitor 2780
A9. Header height indicator Instrument panel 2840
A10. CPU print Central electronic box 1810
A11. Engine surveillance CPU print 2970
A12. RH–side door sensor interface CPU print 3620
A13. Crop processor roll clearance measur- CPU print 4360

ing
A14. Bosch interface CPU print 7280
A15. Sensor interface CPU–print 2610
A16. Meter input CPU print 7410
A17. AC–compressor surveillance CPU print 9400
A18. Engine rpm control CPU print 620
A20. Adjust–o–Matic print Central electronic box 1690
A21. Ground speed control Adjust–o–Matic print 710
A22. Switch–on control Adjust–o–Matic print 3570
A23. Sharpening control Adjust–o–matic print 5300
A24. Shearbar adjustment control Adjust–o–Matic print 6100
A25. Metal detector control Adjust–o–Matic print 3990
A30. Lights print Central electronic box 1960
A31. Reverse buzzer control Lights print 820
A32. 12 V Auto–Pilot Lights print 6480
A34. Silage additive control Lights print 6390
A35. Brake lights control Lights print 8310
A36. Operating lights and beacons control Lights print 8870
A37. AC–compressor control Lights print 9350
A40. Actuator print Central electronic box 2110

A41. Throttle control Actuator print 550
A42. Engine protection Actuator print 3040
A43. Spout deflector control (electrically) Actuator print 4630
A44. Crop processor roll clearance control Actuator print 4270
A45. Bosch interface Actuator print 7220
A46. Auto–Pilot amplifier Actuator print 6680
A47. Rotary screen control Actuator print 4780
A48. Flip–up control Actuator print 10740
A49. Feed rolls reverse control Actuator print 3470
Engine rpm CPU 620
A50. Valve print Central electronic box 2250
A51. 4WD control Valve print 900
A52. Switch–on control Valve print 3440
A53. Auxiliary hydraulics control Valve print 3880
A54. Spout rotation control (hydraulically) Valve print 4570
A55. Cutterhead reverse drive control Valve print 4970
A56. High flow rear hydraulics control Valve print 10910
A60. Bosch HHC module Central electronic box 7220
A70. Auto–Pilot module Central electronic box 6650
A80. Direction indicator print Central electronoc box 8530
A81. Electronic control box Engine 11870
A82. Electronic injection box Engine 11800
A83. CAN gateway 4100
A84. Engine electronic control box Engine 11960
A116. High flow rear hydraulics switch–on Dashboard print 11020
A150. Dashboard LED’s Dashboard print 1370
A151. Alarm LED print Instrument panel 2980
A152. LED control Instrument panel 3530
A153. Metal detector LED control Dashboard print 4150
A154. LED control Dashboard print 5060

A156. Compressor LED’s control Dashboard print 9470
A160. 3 switch print Instrument panel 1630
A163. Switch–on input 3 switch print in dashboard 3630
A171. Sharpening control print Adjust–o–Matic panel 5170
A172. Shearbar adjustment output Adjust–o–Matic panel 5890
A180. Multifunctional lever print Underneath multifunctional lever 1100
A181. Ground speed control Multifunctional lever print 750
A182. Switch–on control Multifunctional lever print 3750
A183. Spout control Multifunctional lever print 4610
A184. Header height operation Multifunctional lever print 6950
A185. Auto–Pilot control Multifunctional lever print 6720
A190. Arm rest module print Arm rest module 6900
A300. Dashboard print Instrument panel 1240
A301. Engagement switch print Instrument panel 3470
A302. Adjust–o–Matic control Dashboard print 5000
A303. Switch on operating lights and beacons Dashboard print 8740
A304. Silage additive application operation Dashboard print 6330
A305. Auto–Pilot operation Dashboard print 6760
A306. Crop processor roll clearance operation Dashboard print 4350
A307. Metal detector switch–on Dashboard print 4080
A320. CAN–Dashboard print Instrument panel 1240
A321. Start input Instrument panel 300
A322. Auxiliary hydraulics control Dashboard print 3810
Spout height control Cab floor 4480
A323. Brake contact input Dashboard print 8270
A324. Air conditioning operation Dashboard print 9200
A325. Meter control Dashboard print 7330

A326. Brake alarm input Instrument panel 2660
A327. Operator’s seat control print in dashboard 3800
B. Sensors, limit switches, buzzers, speakers
B1. Engine oil pressure contact 2910
B2. Engine coolant temperature contact 2930
B3. Engine oil temperature contact Engine 2950
11680
B4. Hydrostatic oil pressure contact 2970
B5. Hydrostatic oil temperature contact 2410
B7. Air filter underpressure contact Air filter 2440
B11. Engine temperature sender Engine 7400
B12. Fuel level sender In fuel tank 7420
B13. Header pressure sensor Behind blower 7130
B16. Ground speed sensor Traction gearbox 2570
B23. Engine speed sensor Engine tailshaft pulley 2540
B29. Horn Underneath steering platform 7840
B31. Loudspeaker 1 Cab roof 9850
B40. Reverse buzzer Left–hand side of the machine at the 810

rear
B41. Wheel sensor On steering axle, left–hand side 6630
B42. Air temperature sensor Engine 11570
B43. Engine rpm sensor 1 Engine 11610

B45. Turbo pressure sensor Engine 11720
B46. Air pressure sensor Engine 11760
B47. Oil pressure sensor Engine 11800
B48. Fuel temperature sensor Engine 11830
B50. Knock sensor left Shearbar left 6260
B51. Oil temperature sender Engine 7380
B61. Thermostat switch Dashboard print 9230
B100. Main clutch oil pressure contact Low pressure valve 2460
B101. Cutterhead speed sensor Rear right–hand cutterhead drive 2600

pulley
B102. Right–hand side door sensor Right–hand side door 3640
B103. Spout end of travel sensor Spout base 4640
B104. Crop processor roll speed sensor 4360
B105. Coolant temperature contact Cutterhead gearbox 2470
B106. Knock sensor Shearbar right–hand adjuster arm 6240
Knock sensor right Shearbar right 6240
B107. Sharpening stone cover sensor On top of the chopper body 5220
B108. Adjust sharpening stone sensor Left–hand side of chopper body 5370
B109. Sharpening stone home position Left–hand side of chopper body 5340
B110. Metal detector Lower front feed roll 3990
B111. Maize header sensor – right–hand side At front of maize header 6560
B112. Maize header sensor – left–hand side At front of maize header 6510
E. Lighting
E1. Beacon 1 Behind cab 8960
E3. Brake light, left Rear of machine 8300
Direction indicator, left rear Dashboard 8630
Parking light, left Rear of machine 8010
E5. Brake light, right Rear of machine 8320
Direction indicator, right rear Dashboard 8570
Parking light, right Rear of machine 8150
E7. Direction indicator, left front Dashboard 8610
Parking light, front left Front of machine 7970
E8. Additional parking light, front left Front of machine 7990
Direction indicator, left front additional Dashboard 8630
E11. Direction indicator, right front Dashboard 8590
Parking light, front right Front of machine 8110
E12. Additional parking light, front right Front of machine 8130
Direction indicator, right front additional Dashboard 8560
E15. Head lights, left Front of machine 8200
E16. Head lights, right Front of machine 8240
E17. Additional brake light (Germany) Rear of machine 8290
Additional parking light (Germany) 8170
E27. Operating light, left 1 Railing platform 8760
Operating light, left 2 8780
E28. Operating light, right 1 Railing platform 8790
Operating light, right 2 8810
E29. Spot light, left Cab roof 8850
E30. Spot light, right Cab roof 8870
E34. Stubble light, left Cab roof 8820
E35. Stubble light, right Cab roof 8840
E37. Cab spot light Cab roof 9970

E38. Cab interior light Cab roof 10010
E41. Licence plate lights Rear of machine 8030
E45. Reverse drive operating light Rear of engine hood 9000
E100. Spout operating light Spout 8930

F. Fuses
F2. 15A Horn lights Fuse print 7840
F3. 25A Operator’s seat fan + gauges Fuse print 7330
Air conditioning fan 9230
F4. 15 A Printed circuits fuse after contact Fuse print 1650
CPU print 2060
Metal detector 3930
HHC contact 6990
F5. 10A Direction indicators Fuse print 8350
F6. 25A Windshield wiper + mirrors Fuse print 9760
10190
F7. 10A Automatic greasing after contact Fuse print 4900
5460
F8. 25A Silage application Bottom of central electronic box 6440
40A Silage application fuse behind relay Bottom of central electronic box 6440
F9. 15A Parking lights, right--hand side Fuse print 8090
F10. 15A Parking lights, left--hand side Fuse print 7950
F11. 15A Contact Fuse print 260
25A Contact Fuse print 260
F12. 10A Dashboard 12 V sockets Fuse print 9710
F13. 10A Automatic greasing Fuse print 4880
Clock, radio, CB, cab lights 9870
F14. 25A Road lights Fuse print 7850
F15. 10A CPU print Fuse print 1760
F16. 15A Hazard warning lights Fuse print 8360
F17. 25A Valve print Fuse print 2200
HHC print 6980
F18. 30A Adjust–o–Matic print Fuse print 1640
F19. 25A Actuator print Fuse print 2050
F20. 30A Operating lights print Fuse print 1890

F23. 15A Main beam head lights Fuse print 8190
F24. 15A Dipped head lights Fuse print 8230
F42. Rear windshield heating Cab roof 10530
F43. Fan Central electronic box 9330
G. Generators, batteries
G1. Battery In battery box 30
G2. Battery In battery box 60
G3. Alternator Left–hand side of engine 200

H. Control lights (mostly LED’s)
H1. Engine oil pressure LED Instrument panel 2910
H2. Engine oil and coolant temp. LED Instrument panel 2930
H3. Battery charge/voltage LED Instrument panel 2400
H4. Hydrostatic oil temperature LED Instrument panel 2410
H5. Hydrostatic oil pressure LED Instrument panel 2970
H6. Air filter obstruction LED Instrument panel 2440
H7. Brake linings/brake fluid level LED Instrument panel 2490
H8. Parking brake LED Instrument panel 2500
H13. Compressor overpressure LED Instrument panel 9460
H14. Compressor underpressure LED Instrument panel 9470
H15. Main beam head lights indicator light Steering column 7880
H16. Direction indicators control light Steering column 8440
H17. Trailer direction indicators control light Steering column 8370
H18. HHC red control LED Arm rest module 6820
H19. HHC green control LED Arm rest module 6840
H20. Auto–Pilot ON control light Steering column 6640
H21. Field mode LED Instrument panel 3530
H22. Metal detector LED Instrument panel 4140
H24. Main drive clutch oil pressure LED Instrument panel 2460
H25. Sharpening stone cover LED Instrument panel 5050
H26. Cutterhead gearbox oil temp. LED Instrument panel 2470
H120. Shearbar adjustment routine LED LED # 2 in Adjust–o–Matic panel 5860
H121. 1 minute sharpening LED LED # 3 in Adjust–o–Matic panel 5100
H122. 2 minutes sharpening LED LED # 4 in Adjust–o–Matic panel 5120
H124. Interrupt sharpening routine LED LED # 6 in Adjust–o–Matic panel 5160
H125. Shearbar adjustment rpm fault LED LED # 7 in Adjust–o–Matic panel 5780
H126. Shearbar adjustment motor fault LED LED # 8 in Adjust–o–Matic panel 5800
H127. Shearbar adjustment sensor fault LED LED # 9 in Adjust–o–Matic panel 5820
H128. Adjust cutterhead knives LED LED # 10 in Adjust–o–Matic panel 5840
H129. Adjust–o–Matic ready to use LED LED # 1 in Adjust–o–Matic panel 5860
K. Relays
K1. 12 V after contact relay Fuse print in central electronic box 310
K2. Silage additive relay Fuse print in central electronic box 6430
K3. Parking lights relay Fuse print in central electronic box 7930
K51. 12/24 V start relay In battery box 140
K52. Start relay In battery box 180
210
K53. Mirror control relay, right–hand side Cab roof 10310
K54. Mirror control relay, left–hand side Cab roof 10350
K55. Rear windshield heating relay Cab roof 10460
K56. Fan relay Console module in cab 9280
K57. Fan ground relay Console module in cab 9310
K58. Grease pressure switches relay 5540
K68. Pre--heating 12040
K69. Electronic motor control 180

M. Motors
M1. Starter motor Engine 130
M2. Throttle actuator Left–hand side of engine 540
M11. Fan motor Underneath operator’s seat 9310
M12. Front windshield wiper motor Cab roof 9810
M13. Right–hand side mirror Right–hand side of cab 10410
M14. Left–hand side mirror Left–hand side of cab 10360
M15. Additional mirror, right–hand side (Ger- Right–hand side of cab 10490
many only)
M19. Additional fan 9290
M20. Spout deflector motor Near spout deflector 4590
M21. Crop processor roll clearance motor On top of chopper body 4280
M22. Sharpening stone cover motor Right–hand side of chopper body 5290
M23. Sharpening stone motor Left–hand side of chopper body 5410
M24. Shearbar left–hand adjuster motor Left–hand side of chopper body 6140
M25. Shearbar right–hand adjuster motor Right–hand side of chopper body 6170
M26. Left–hand rotary screen drive motor Left–hand door 4780
M27. Right–hand rotary screen drive motor Right–hand door 4800
M28. Rotary screen brush actuator Left 4820
M29. Rotary screen brush actuator Right 4850
M31. Rear windshield wiper motor Rear windshield 10140
M32. Front windshield washer pump Cab roof 9830
M33. Side windows washer pump Side windows 10150
M34. Rear windshield washer pump Rear windshield 10150
M35. Right–hand side window wiper motor Right–hand side window 10140
M36. Left–hand side window wiper motor Left–hand side window 10140
P. Measuring equipment
P1. Engine temperature meter Console module in cab 7330
P2. Fuel gauge Console module in cab 7350
P4. Clock Cab roof 9850
R. Resistances
R1. Engine heating Engine 12040
R4. Header height sensor Chopper body, left–hand side 7160
R5. Multifunctional lever position potentio- Underneath multifunctional lever 750

meter
R6. Stubble height control potentiometer Arm rest module 6820
R7. Ground pressure control potentiometer Arm rest module 6850
R14. Auto–Pilot centering potentiometer Steering column 6610
R15. Rear windshield heating Rear windshield 10480
R30. Crop processor roll clearance potentio- Left–hand side of chopper body 4300
meter
R31. CAN resistance Engine 11740

S. Switches
S17. Contact switch Instrument panel 250
S20. Header down switch Multifunctional lever 6920
S22. Header up switch Multifunctional lever 6940
S28. Emergency stop switch Button # 4 in multifunctional lever 3710
S29. Reverse feed rolls switch Switch # 1 in multifunctional lever 3720
S30. Automatic header height control switch Switch # 6 in multifunctional lever 3740
(former override switch) 6930
S31. Multifunctional lever neutral position Underneath multifunctional lever 710

switch
S35. HHC selector switch Arm rest module 6870
S36. Handbrake contact Handbrake 2650
S37. Fan + air conditioning switch Console module in cab 9250
S38. Front windshield wiper switch Cab roof 9760
S39. Mirror control switch Cab roof 10260
S40. Mirror selection + heating switch Cab roof 10510
S41. Auxiliary hydraulics up Cab floor 3800
Spout up foot switch 4440
S42. Auxiliary hydraulics down Cab floor 3820
Spout down foot switch 4460
S45. Brake fluid level contact Brake fluid 2670
S58. Brake contact Underneath steering platform 8240
S59. Combined light switch Steering column 7850
8450
S60. Air conditioning safety switch Console module in cab 9230
S62. Compressor overpressure contact Compressor 9380
S63. Compressor underpressure contact Compressor 9420
S64. Main battery switch At the front of the battery box 30
S65. Hazard warning lights switch Steering column 8400
S66. Brake linings sensor Disc brakes 2500

S67. Greasing pump 5490
S74. Cold start switch Console module in cab 250
S77. Auto–Pilot engagement switch 6580
S78. Shearbar left–hand end of travel micro Left–hand adjuster motor 5960
switch (cutterhead) (cutterhead)
S79. Shearbar left–hand end of travel micro Left–hand adjuster motor 6020
switch (scraper)
S80. Shearbar right–hand end of travel Right–hand adjuster motor 5990
microswitch(cutterhead)
microswitch(scraper)
S82. Sharpening stone cover closed micro- Inside sharpening stone cover motor 5260
switch
S83. Seat switch Operator’s seat 3740
S84. Cab door switch Cab door 9980
S85. Switch for spout rotation to the right– Switch # 2 in multifunctional lever 4670
slow
S86. Switch for spout rotation to the left – Switch # 2 in multifunctional lever 4650
fast
slow
S88. Spout deflector down switch Switch # 2 in multifunctional lever 4730
S89. Spout deflector up switch Switch # 2 in multifunctional lever 4710
S90. Feed rolls forward switch Switch # 1 in multifunctional lever 3680
S91. Auto–Pilot button Multifunctional lever 6720
S91. Auto–Pilot switch Switch # 5 in multifunctional lever 3760
S92. Stop feed rolls switch Switch # 1 in multifunctional lever 3700
S93. Switch for spout rotation to the right – Switch # 2 in multifunctional lever 4690
fast
S101. Cutterhead switch Switch # 14 in instrument panel 3630
S102. 4WD tumbler switch Switch no. 15 in instrument panel 890
S103. Engine throttle control switch Switch in instrument panel 550

S105. Safe harvest switch Switch # 2 in instrument panel 3440
S106. Metal detector switch Switch # 3 in instrument panel 4070
S108. Auto–Pilot main switch Switch # 5 in instrument panel 6750
S109. Silage additive application switch Switch # 6 in instrument panel 6320
S110. Operating lights switch Switch # 7 in dashboard 8710
S111. Beacons switch Switch # 8 in dashboard 8790
S112. Power reverse switch Switch # 9 in instrument panel 3520
S113. Adjust–o–Matic switch Switch # 10 in instrument panel 5050
S114. Cutterhead reverse drive switch Switch # 11 in instrument panel 4970
S115. Crop processor roll clearance switch Switch # 12 in instrument panel 4340
S120. Shearbar adjustment switch Switch # 2 in Adjust–o–Matic panel 5820
S121. 1 minute sharpening switch Switch # 3 in Adjust–o–Matic panel 5100
S122. 2 minutes sharpening switch Switch # 4 in Adjust–o–Matic panel 5120
S124. Interrupt sharpening routine switch Switch # 6 in Adjust–o–Matic panel 5160
S125. Additional mirror switch, right–hand Cab roof 10480

side (Germany only)
S126. Front windshield washer switch Cab roof 9810
S127. Side windows wiper/washer switch Cab roof 10080
S128. Rear windshield wiper/washer switch Cab roof 10070
S129. Flip–up selector switch Console module 10760
S130. Engine electronic control box diagnos- 12000

tics switch
S137. High flow rear hydraulics switch Dashboard 11010
S138. Grease pressure switch 8R or 6R 5560
S139 Grease pressure switch cutterhead 5570
S140 Automatic greasing switch 5530

V. Semi--conductors (diodes)
V21. Direction indicators diode, left Lights print in central electronic box 10970
V22. Direction indicators diode, right Lights print in central electronic box 10950
V24. Pawl system diode Adjust–o–Matic print in central 3960

electronic box
X. Connectors
X130. Direction indicator socket, rear right Rear of machine 8550
X130. Trailer 12 V socket Rear of machine 8050
X147. 12 V socket, right–hand side Right–hand side, underneath head 7950

light
X148. 12 V socket, left–hand side Left–hand side, underneath head 8090

light
X150. 12 V socket Console module 9710
X456. CAN/RS232 connector Instrument panel 2800
X510. Silage additive application socket Bottom of central electronic box 6440
X511. Automatic greasing system socket Bottom of central electronic box 4880
Y. Valves
Y19. Header down valve Stack valve 7020
Y20. Header up valve Stack valve 7040
Y21. Cols start aid 250
Y22. Electro–mechanical valve Low pressure hydraulic valves 870
Y23. Engine stop solenoid Near injection pump on LH side of 3030

engine
Y25. Compensation valve 7060
Y27. Compressor Left–hand side of engine 9340
Y28. Hydrostatic pump Mounted on LH side of main drive 700

gearbox
Y31. Cutterhead reverse drive valve Stack valve 4950
Y32. Spout rotation left Stack valve 4540
Y33. Spout rotation right Stack valve 4570
Y34. Front auxiliary hydraulics up valve Stack valve 3830
Y35. Front auxiliary hydraulics down Stack valve 3860
Y36. Rear auxiliary hydraulics up valve Stack valve 3870
Y37. Rear auxiliary hydraulics down valve Stack valve 3900
Y38. Spout height up Stack valve 4500
Y39. Spout height down Stack valve 4530
Y40. Main drive clutch neutral position valve Low pressure valve 3450
Y41. Electro–magnetic feed roll clutch Behind reversing gearbox 3480

forward
Y42. Stop pawl solenoid Above pawl wheel 4020
Y43. Electro–magnetic feed roll clutch Behind reversing gearbox 3510

reverse
Y44. Valve for main drive clutch + Low pressure valve 3420
main drive belt idler
Y45. Spout deflector up Stack valve 4580
Y46 Spout deflector down Stack valve 4610
Y48. Ticker solenoid (test signal generator) Shearbar right–hand adjuster arm 6200
Y49. Tip trailer up valve Right–hand side of engine 10890

Y50. Tip trailer down valve Right–hand side of engine 10920
Y51. Valve for Auto–Pilot left Underneath steering platform 6550
Y52. Valve for Auto–Pilot right Underneath steering platform 6580
Y57. Pressure relief valve 10940
Y61. Valve A, fold up -- fold down side row 10820

units
Y62. Valve B, fold up -- fold down side row 10830

units
Y63. Valve A, slide--in -- slide out side row 10800

units
Y64. Valve B, slide in -- slide out side row 10810

units
Y65. Valve A, swing in -- swing out crop 10780

guide tubes
Y66. Valve B, swing in -- swing out crop 10790

guide tubes
1a STARTER CIRCUIT 24V
FX25 39.01 > 5080 FX45 47.01 > 5080
F11. 15A Contact Fuse print 260
G1. Battery In battery box at right–hand side of 30

machine

machine
K1. 12 V after contact relay Fuse print 310
Line: 10 -- 340
1b STARTER CIRCUIT 24V
FX28NA 5083 > 5168 FX38NA 5083 > 5168
F11. 15Acontact Fuse print 260

machine
machine
Line: 10 -- 340
1c STARTER CIRCUIT 24V IVECO
FX28NA 5186 > 5206 FX38NA 5186 > 5206
F11. 15A contact Fuse print 260

machine
machine
Line: 10 -- 340
1d STARTER CIRCUIT 24V IVECO
FX28NA 5218 > .... FX38NA 5218 > ....

machine
machine
K69. Electronic motor control 180
Line: 10 -- 340
1e STARTER CIRCUIT 24V CATERPILLAR
FX58NA 5083 > 5168

machine
machine
Line: 10 -- 340
1f STARTER CIRCUIT 24V CATERPILLAR
FX58NA 5186 > 5206

machine
machine
Line: 10 -- 340
1g STARTER CIRCUIT 24V CATERPILLAR
FX58NA 5218 > ....

machine
machine
Line: 10 -- 340
2a ENGINE THROTTLE CONTROL
FX25 39.01 > 5080 FX45 47.01 > 5080
Line: 520 -- 680

2b ENGINE THROTTLE CONTROL
FX28NA 5083 > 5168 FX38NA 5083 > 5168
Line: 520 -- 680

2c ENGINE THROTTLE CONTROL
FX28NA 5186 > 5206 FX38NA 5186 > 5206
Line: 520 -- 680

2d ENGINE THROTTLE CONTROL IVECO
FX28NA 5218 > .... FX38NA 5218 > ....
Line: 520 -- 680

2e ENGINE THROTTLE CONTROL CATERPILLAR
FX58NA 5083 > 5168
A49. Engine rpm CPU 620
Line: 520 -- 680

2f ENGINE THROTTLE CONTROL CATERPILLAR
FX58NA 5186 > 5206
Line: 520 -- 680

2g ENGINE THROTTLE CONTROL CATERPILLAR
FX58NA 5218 > ....
Line: 520 -- 680

3a HYDROSTATIC CONTROL
FX25 39.01 > 5080 FX45 47.01 > 5080

rear

meter

switch
Y28. Hydrostatic pump Mounted on left–hand side of main 700

drive gearbox
Line: 690 -- 850

3b HYDROSTATIC CONTROL
FX28NA 5083 > 5206 FX38NA 5083 > 5206

rear

meter

switch

drive gearbox
Line: 690 -- 850

3c HYDROSTATIC CONTROL IVECO
FX28NA 5218 > .... FX38NA 5218 > ....

rear

meter

switch

drive gearbox
Line: 690 -- 850

3d HYDROSTATIC CONTROL CATERPILLAR
FX58NA 5083 > 5206

rear

meter

switch

drive gearbox
Line: 690 -- 850

3e HYDROSTATIC CONTROL CATERPILLAR
FX58NA 5218 > ....

rear

meter

switch

drive gearbox
Line: 690 -- 850

4a FOUR--WHEEL DRIVE
FX25 39.01 > 39.05 FX45 47.01 > 47.05
Line: 860 -- 1020

4b FOUR--WHEEL DRIVE
FX25 39.06 > 5080 FX45 47.06 > 5080
Line: 860 -- 1020

4c FOUR--WHEEL DRIVE
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
Line: 860 -- 1020

5a ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1
FX25 39.01 > 39.04 FX45 47.01 > 47.04
Line: 1030 -- 1530

5b ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1
FX25 39.05 > 5080 FX45 47.05 > 5080
Line: 1030 -- 1530

5c ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
Line: 1030 -- 1530

6a ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1
FX25 39.01 > 5080 FX45 47.01 > 5080
F4. 15A -- Printed circuits Fuse print 1650
F15. 10A -- CPU print Fuse print 1760
F18. 30A -- Adjust–o–Matic print Fuse print 1640
F20. 30A -- Operating lights Fuse print 1890
Line: 1540 -- 2040

6b ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1
FX28NA 5083 > 5206 FX38NA 5083 > 5206 FX58NA 5083 > 5206
Line: 1540 -- 2040

6c ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1
FX28NA 5218 > .... FX38NA 5218 > .... FX58NA 5218 > ....
Line: 1540 -- 2040

7a ELECTRONIC SYSTEM: ELECTRONIC BOX 2
FX25 39.01 > 39.04 FX45 47.01 > 47.04
F17. 25A -- Valve print Fuse print 2200
F19. 25A -- Actuator print Fuse print 2050
Line: 2050 -- 2380

7b ELECTRONIC SYSTEM: ELECTRONIC BOX 2
FX25 39.05 > 5080 FX45 47.05 > 5080
Line: 2050 -- 2380

7c ELECTRONIC SYSTEM: ELECTRONIC BOX 2
FX28NA 5083 > 5206 FX38NA 5083 > 5206 FX58NA 5083 > 5206
Line: 2050 -- 2380

7d ELECTRONIC SYSTEM: ELECTRONIC BOX 2
FX28NA 5218 > .... FX38NA 5218 > .... FX58NA 5218 > ....
Line: 2050 -- 2380

8a CPU INPUTS AND DISPLAY
FX25 39.01 > 39.05 FX45 47.01 > 47.05
B101. Cutterhead speed sensor Cutterhead drive pulley 2600
S36 Handbrake contact Handbrake 2650
Line: 2390 -- 2890

8b CPU INPUTS AND DISPLAY
FX25 39.06 > 5080 FX45 47.06 > 5080
Line: 2390 -- 2890

8c CPU INPUTS AND DISPLAY
FX28NA 5083 > 5168 FX38NA 5083 > 5168
Line: 2390 -- 2890

8d CPU INPUTS AND DISPLAY
FX28NA 5174 > 5206 FX38NA 5174 > 5206
Line: 2390 -- 2890

8e CPU INPUTS AND DISPLAY
FX58NA 5083 > 5168
Line: 2390 -- 2720

8f CPU INPUTS AND DISPLAY
FX58NA 5174 > 5206
Line: 2390 -- 2720

8g CPU INPUTS AND DISPLAY
FX28NA 5218 > .... FX38NA 5218 > .... FX58NA 5218 > ....
Line: 2390 -- 2890

9a ENGINE PROTECTION
FX25 39.01 > 39.05 FX45 47.01 > 47.05
B3. Engine oil temperature contact 2950
Y23. Engine stop solenoid Near fuel injection pump on left– 3030
hand side of engine
Line: 2900 -- 3060

9b ENGINE PROTECTION
FX25 39.06 > 5080 FX45 47.06 > 5080
hand side of engine
Line: 2900 -- 3060

9c ENGINE PROTECTION
FX28NA 5083 > 5206 FX38NA 5083 > 5206
hand side of engine
Line: 2900 -- 3060

9d ENGINE PROTECTION IVECO
FX28NA 5218 > .... FX38NA 5218 > ....
Line: 2900 -- 3060

9e ENGINE PROTECTION CATERPILLAR
FX58NA 5218 > ....
Line: 2900 -- 3060

10a SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 39.01 > 39.01 FX45 47.01 > 47.01

A301. Switches Instrument panel 3470
A327. Seat switch input Dashboard print 3800
(former override switch)
Y35. Front auxiliary hydraulics down valve Stack valve 3860
Y41. Electro–magnetic feed roll clutch for- Behind reversing gearbox 3480
ward
Y43. Electro–magnetic feed roll clutch re- Behind reversing gearbox 3510
verse
Y44. Valve for main drive clutch + main drive Low pressure valve 3420
belt idler
Line: 3410 -- 3910
10b SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 39.02 > 39.04 FX45 47.02 > 47.04

ward
verse
belt idler
Line: 3410 -- 3910

10c SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 39.05 > 39.05 FX45 47.05 > 47.05

ward
verse
belt idler
Line: 3410 -- 3910

10d SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 39.06 > 5074 FX45 47.06 > 5074

ward
verse
belt idler
Line: 3410 -- 3910

10e SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX25 5080 > 5080 FX45 5080 > 5080

ward
verse
belt idler
Line: 3410 -- 3910

10f SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX28NA 5083 > 5168 FX38NA 5083 > 5168 FX58NA 5083 > 5168

ward
verse
belt idler
Line: 3410 -- 3910

10g SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HY-
DRAULICS
FX28NA 5186 > .... FX38NA 5186 > .... FX58NA 5186 > ....

ward
verse
belt idler
Line: 3410 -- 3910

11a METAL DETECTOR
FX25 39.01 > 39.01 FX45 47.01 > 47.01
F4. 15A -- Metal detector Fuse print 3930
Line: 3920 -- 4250

11b METAL DETECTOR
FX25 39.02 > 5080 FX45 47.02 > 5080

electronic box
Line: 3920 -- 4250

11c METAL DETECTOR
FX28NA 5083 > 5168 FX38NA 5083 > 5168

electronic box
Line: 3920 -- 4250

11d METAL DETECTOR IVECO
FX28NA 5186 > 5206 FX38NA 5186 > 5206

electronic box
Line: 3920 -- 4250

11e METAL DETECTOR IVECO
FX28NA 5218 > .... FX38NA 5218 > ....

electronic box
Line: 3920 -- 4250

11f METAL DETECTOR CATERPILLAR
FX58NA 5083 > 5168

electronic box
Line: 3920 -- 4250

11g METAL DETECTOR CATERPILLAR
FX58NA 5186 > 5206

electronic box
Line: 3920 -- 4250

11h METAL DETECTOR CATERPILLAR
FX58NA 5218 > ....
A83. CAN gateway 4100

electronic box
Line: 3920 -- 4250

12a CROP PROCESSOR
FX25 39.01 > 5080 FX45 47.01 > 5080

ing
meter
Line: 4260 -- 4420

12b CROP PROCESSOR
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....

ing
meter
Line: 4260 -- 4420

13a SPOUT CONTROL
FX25 39.01 > 39.05 FX45 47.01 > 47.05
A322. Spout height control Cab floor 4480
M20. Spout deflector motor Near spout deflector 4590
S41. Spout up foot switch Switch in cab floor 4440
S42. Spout down foot switch Switch in cab floor 4460
slow
fast
slow
fast
Line: 4430 -- 4760

13b SPOUT CONTROL
FX25 39.06 > 5080 FX45 47.06 > 5080
slow
fast
slow
fast
Line: 4430 -- 4760

13c SPOUT CONTROL
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
slow
fast
slow
fast
Line: 4430 -- 4760

14a ROTARY DUST SCREENS AND CENTRAL GREASING SYSTEM
FX25 39.01 > 39.01 FX45 47.01 > 47.01
A47. Rotary dust screen control Lights print 4790
F7. 10A -- Automatic greasing after contact Fuse print 4860
F13. 10A -- Automatic greasing before con- Fuse print 4880

tact
X511. Automatic greasing system socket Bottom of central electronic box 4880
Line: 4770 -- 4930

14b ROTARY DUST SCREENS
FX25 39.02 > 5080 FX45 47.02 > 5080
A47. Rotary screen control 4780
Line: 4770 -- 4930

14c ROTARY DUST SCREENS
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
A47. Rotary screen control 4780
Line: 4770 -- 4930

15a REVERSE DRIVE CUTTERHEAD AND SHARPENING
FX25 39.01 > 5080 FX45 47.01 > 5080
B109. Sharpening stone home position sen- Left–hand side of chopper body 5340
sor
switch
Line: 4940 -- 5440

15b REVERSE DRIVE CUTTERHEAD AND SHARPENING
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
B109. Sharpening stone home position sen- Left–hand side of chopper body 5340
sor
switch
Line: 4940 -- 5440

16a AUTOMATIC GREASING SYSTEM
FX25 39.02 > 5080 FX45 47.02 > 5080
S139. Grease pressure switch cutterhead 5570
S140. Automatic greasing switch 5530
Line: 5450 -- 5610

16b AUTOMATIC GREASING SYSTEM
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
S139. Grease pressure switch cutterhead 5570
S140. Automatic greasing switch 5530
Line: 5450 -- 5610

17a SHEARBAR ADJUSTMENT
FX25 39.01 > 5080 FX45 47.01 > 5080
S78. Shearbar left–hand end of travel micro- Left–hand adjuster motor (cutter- 5960
switch (cutterhead) head)
S79. Shearbar left–hand end of travel micro- Left–hand adjuster motor 6020
switch (scraper)

microswitch (cutterhead)

microswitch (scraper)
Line: 5790 -- 6290

17b SHEARBAR ADJUSTMENT
FX28NA 5083 > 5168 FX38NA 5083 > 5168 FX58NA 5083 > 5168
switch (scraper)
Line: 5790 -- 6290

17c SHEARBAR ADJUSTMENT
FX28NA 5186 > .... FX38NA 5186 > .... FX58NA 5186 > ....
switch (scraper)
Line: 5790 -- 6290

18a SILAGE ADDITIVE APPLICATION
FX25 39.01 > 39.01 FX45 47.01 > 47.01
F8. 25A -- Silage application Bottom of central electronic box 6440
K2. Silage additive relay Fuse print 6430
Line: 6300 -- 6460

18b SILAGE ADDITIVE APPLICATION
FX25 39.02 > 5080 FX45 47.02 > 5080
Line: 6300 -- 6460

18c SILAGE ADDITIVE APPLICATION
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
Line: 6300 -- 6460

19a AUTO--PILOT
FX25 39.01 > 5080 FX45 47.01 > 5080
Line: 6470 -- 6800

19b AUTO--PILOT
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
Line: 6470 -- 6800

20a HEADER HEIGHT CONTROL (HHC)
FX25 39.01 > 5080 FX45 47.01 > 5080
F4. 15A -- HHC contact Fuse print 6990
F17. 25A -- HHC print Fuse print 6980
S30. Automatic HHC button Multifunctional lever 6930
Line: 6810 -- 7310

20b HEADER HEIGHT CONTROL (HHC)
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
F4. 15A -- HHC contact Fuse print 6990
F17. 25A -- HHC print Fuse print 6980
S30. Automatic HHC button Multifunctional lever 6930
Line: 6810 -- 7310

21a COOLANT TEMPERATURE AND FUEL GAUGE
FX25 39.01 > 39.05 FX45 47.01 > 47.05
F3. 25A -- Operator’s seat fan + gauges Fuse print 7330
Line: 7320 -- 7480

21b COOLANT TEMPERATURE AND FUEL GAUGE
FX25 39.06 > 5080 FX45 47.06 > 5080
Line: 7320 -- 7480

21c COOLANT TEMPERATURE AND FUEL GAUGE
FX28NA 5083 > 5206 FX38NA 5083 > 5206
Line: 7320 -- 7480

21d COOLANT TEMPERATURE AND FUEL GAUGE IVECO
FX28NA 5218 > .... FX38NA 5218 > ....
Line: 7320 -- 7480

21e COOLANT TEMPERATURE AND FUEL GAUGE CATERPILLAR
FX58NA 5083 > 5206
Line: 7320 -- 7480

21f COOLANT TEMPERATURE AND FUEL GAUGE CATERPILLAR
FX58NA 5218 > ....
Line: 7320 -- 7480

22a PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
FX25 39.01 > 5080 FX45 47.01 > 5080

E3. Parking light, left Rear of machine 8010
E5. Parking light, right Rear of machine 8150
E7. Parking light, front left Front of machine 7970
E11. Parking light, front right Front of machine 8110
E17. Additional parking light (Germany) Rear of machine 8170
F2. 15A -- Horn lights Fuse print 7840
F9. 15A -- Parking light, right Fuse print 8090
F10. 15A -- Parking light, left Fuse print 7950
F14. 25A -- Road lights Fuse print 7850
F23. 15A -- Main beam head lights Fuse print 8190
F24. 15A -- Fuse dipped head lights Fuse print 8230
K3. Parking lights relay Fuse print 7930
8170
8300
X147. 12 V socket, right–hand side Right–hand side of machine, 7950
underneath head light
X148. 12 V socket, left–hand side Left–hand side of machine, 8090
Line: 7830 -- 8330

22b PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....

E3. Parking light, left Rear of machine 8010
E5. Parking light, right Rear of machine 8150
E7. Parking light, front left Front of machine 7970
E11. Parking light, front right Front of machine 8110
E17. Additional parking light (Germany) Rear of machine 8170
F2. 15A -- Horn lights Fuse print 7840
F9. 15A -- Parking light, right Fuse print 8090
F10. 15A -- Parking light, left Fuse print 7950
F14. 25A -- Road lights Fuse print 7850
F23. 15A -- Main beam head lights Fuse print 8190
F24. 15A -- Fuse dipped head lights Fuse print 8230
K3. Parking lights relay Fuse print 7930
8170
8300
X147. 12 V socket, right–hand side Right–hand side of machine, 7950
X148. 12 V socket, left–hand side Left–hand side of machine, 8090
Line: 7830 -- 8330
23a DIRECTION INDICATOR AND HAZARD WARNING LIGHTS
FX25 39.01 > 5080 FX45 47.01 > 5080
A80. NA Direction indicator print 8530
E3. Direction indicator, left rear Dashboard 8630
E5. Direction indicator, right rear Dashboard 8570
E8. Direction indicator, left front additional Dashboard 8630
E12. Direction indicator, right front additional Dashboard 8560
F5. 10A -- Direction indicator Fuse print 8350
F16. 15A -- Hazard warning lights Fuse print 8360
S59. Combined switch Steering column 8450
X130. Connector tow hook Rear of machine 8550

8640
Line: 8340 -- 8670

23b DIRECTION INDICATOR AND HAZARD WARNING LIGHTS
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
A80. NA Direction indicator print 8530
E3. Direction indicator, left rear Dashboard 8630
E5. Direction indicator, right rear Dashboard 8570
E8. Direction indicator, left front additional Dashboard 8630
E12. Direction indicator, right front additional Dashboard 8560
F5. 10A -- Direction indicator Fuse print 8350
F16. 15A -- Hazard warning lights Fuse print 8360
S59. Combined switch Steering column 8450
X130. Connector tow hook Rear of machine 8550

8640
Line: 8340 -- 8670

24a OPERATING LIGHTS AND BEACONS
FX25 39.01 > 5080 FX45 47.01 > 5080
Line: 8680 -- 9010

24b OPERATING LIGHTS AND BEACONS
FX28NA 5083 > 5206 FX38NA 5083 > 5206
Line: 8680 -- 9010

24c OPERATING LIGHTS AND BEACONS IVECO
FX28NA 5218 > .... FX38NA 5218 > ....
Line: 8680 -- 9010

24d OPERATING LIGHTS AND BEACONS
FX58NA 5083 > 5206
Line: 8680 -- 9010

24e OPERATING LIGHTS AND BEACONS
FX58NA 5218 > ....
Line: 8680 -- 9010

25a AIR CONDITIONING
FX25 39.01 > 39.01 FX45 47.01 > 47.01
F3. 25A -- Air conditioning fan Fuse print 9230
Line: 9190 -- 9520

25b AIR CONDITIONING
FX25 39.02 > 39.05 FX45 47.02 > 47.05
Line: 9190 -- 9520

25c AIR CONDITIONING
FX25 39.06 > 5080 FX45 47.06 > 5080
Line: 9190 -- 9520

25d AIR CONDITIONING
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
Line: 9190 -- 9520

26a CAB
FX25 39.01 > 39.01 FX45 47.01 > 47.01
F6. 25A -- Windshield wiper + mirrors Fuse print 9760
F12. 10A -- Dashboard 12 V sockets Fuse print 9710
F13. 10A -- Clock, radio, CB, cab lights Fuse print 9870
M12. Windshield wiper motor Cab roof 9820
S38. Windshield wiper switch Cab roof 9760
Line: 9700 -- 10030

26b CAB
FX25 39.02 > 39.04 FX45 47.02 > 47.04
Line: 9700 -- 10030

26c CAB
FX25 39.05 > 5080 FX45 47.05 > 5080

10190
Line: 9700 -- 10200

26d CAB
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....

10190
Line: 9700 -- 10200

27a MIRROR CONTROL AND WINDSHIELD HEATING
FX25 39.01 > 39.04 FX45 47.01 > 47.04
F42. Rear windshield heating circuit breaker Cab roof 10530
M15. Additional mirror, right–hand side Right–hand side of cab 10490

(Germany only)
Line: 10210 -- 10540

27b MIRROR CONTROL AND WINDSHIELD HEATING
FX25 39.05 > 5080 FX45 47.05 > 5080

(Germany only)

side (Germany only)
Line: 10210 -- 10540

27c MIRROR CONTROL AND WINDSHIELD HEATING
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....

(Germany only)

side (Germany only)
Line: 10210 -- 10540

28a FLIP--UP MAIZE HEADER
FX25 39.01 > 5080 FX45 47.01 > 5080

units

units

units

units

guide tubes
Y66. Valve B, swing in -- swing out braces 10790

crop guide tubes
Line: 10720 -- 10880

28b FLIP--UP MAIZE HEADER
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....

units

units

units

units

guide tubes
Y66. Valve B, swing in -- swing out braces 10790

crop guide tubes
Line: 10720 -- 10880

29a HIGH FLOW REAR HYDRAULICS
FX25 39.01 > 39.04 FX45 47.01 > 47.04
V21. Diode high pressure valve 10970
Y57. High pressure valve trailer 10940
Line: 10890 -- 11050

29b HIGH FLOW REAR HYDRAULICS
FX25 39.05 > 5080 FX45 47.05 > 5080
Line: 10890 -- 11050

29c HIGH FLOW REAR HYDRAULICS
FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....
Line: 10890 -- 11050

30a ADDITIONAL LIGHTS FOR FLIP--UP ATTACHMENTS
FX58NA 5083 > 5206
A81. Electronic cintrol box Engine 11870
B3. Oil temperature sensor Engine 11680
Line: 11560 -- 11890

30b ELECTRONIC ENGINE CONTROL CATERPILLAR
FX58NA 5218 > ....
A81. Electronic cintrol box Engine 11870
B3. Oil temperature sensor Engine 11680
Line: 11560 -- 11890

31a ELECTRONIC ENGINE CONTROL IVECO
FX28NA 5218 > .... FX38NA 5218 > ....
A84. Engine electronic control box Engine 11960
K68. Pre--heating 12040
R1. Engine heating Engine 12040
S130. Engine electronic control box diagnos- 12000

tics switch
X189. Engine electronic control box connector 12020
Line: 11900 -- 12060

Chapter 4 -- Can Network Basics
CONTENT

55.000 General layout electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Can spy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Error codes messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fault finding routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
CAN NETWORK BASICS
The main reason for building an integrated electrical / electronic system is the increasing demand for more func-
tions and ease of operation!
The CAN (Controller Area Network) is a communication system that links several microprocessors, using two
leads to send information between them. These two leads are known as the bus.
Instead of leading wiring harnesses all over the machine, functions are grouped and collected into Input and Out-
put stations (on electronic printed circuits). These I/O stations are linked by only a small number of wires with
a serial data transmission network. The network connects all stations. As such it is merely a way of transporting
information/messages from one place to another in the machine.
GENERAL LAYOUT ELECTRONIC SYSTEM c Metal Detector

Electronic components
Contains node M.
a Cab area
d Caterpillar Engine (Only for FX58)
Cab sections connected to the network:
A communication link is established between the
• InfoView Monitor: contains nodes A and S controller of the Caterpillar engine and the Electronic
Remark: Box to exchange information between both systems.
Node A: InfoView/dashboard operation The electronic control unit can only be updated and
configured by an official Caterpillar representative.
Node S: Symbols and languages
• Instrument Panel Conclusion

• Multifunction lever and armrest module The electronics on the Forage Harvester contain four
• Floor console module memories, located on several electronic printed cir-
cuits, which are responsible for the functional oper-
ation of the machine.
They are all flash memories that can be updated by
means of PC laptop or PDT tool. This means that
b Electronic Box
when a new software revision is released, no hard-
ware changes have to be carried out and no
Printed circuits located in the electronic box and con- EPROM’s have to be changed.
nected to the network:
Only a new installation disk (for PC laptop) or a new
• CPU printed circuit: contains node B cartridge (for PDT tool) is necessary to install the new
• AOM printed circuit: contains node D software revision. This happens via a DIN connector
• Lights printed circuit underneath the dashboard.
• Electric motor and actuator printed circuit REMARK:
Module: used to indicate the hardware and printed
• Valve printed circuit
circuit boards all over the machine.
• Bosch module Node: used to indicate the software that translates all
• Auto–Pilot module [accessory] input messages to output messages.
ZDA0481A
2
ELECTRONIC SYSTEM LAYOUT
3
Input Analog signals (from input or to output)
Switches Examples:
Sensors:
• 0 or 12V constant voltage (from switches;
Pressure / Temperature sensors most end users)
Header height sensors
RPM sensors • 0 or 12V variable voltage (potentiometer)
Proximity sensors • PWM variable voltage (to proportional
Potentiometers signal electro valves)
PWM: pulse width modulation.
Digital Information
(see also picture 2)
All information that passes through the CAN Net-

Output work.
To end users: The medium can be:
Electromagnetic valves Fibre optics
Electromagnetic clutches Flat cable
Actuators Standard cable
Solenoids
Electric motors
Lights Interfaces
(located on the printed circuit boards)
Translates an analog signal to a digital signal, or

Translates a digital signal to an analog signal.
Software
A sequential decision making process, where the

presence of particular input signals result in a de-
sired task (output) being achieved. If all the necess-
ary input signals are not present, or are introduced
in the wrong sequence, then the desired task or ac-
tion will not be achieved. The software program de-
termines the function of the machine, where all in-
puts and requisites for a particular task or action
are specified.
Changing the software program can effect the ma-

chine function as a result of the input requirement
specifications for a particular output being changed.
Calibrations
Calibration effect machine function and error code

reporting. Calibrations are achieved through the Info-
View monitor and by using the PDT tool (or P.C.). The
calibration procedure dictated a choice to the soft-
ware program. This change in the software decision
making process enables us to adapt the mode of
operation of the machine to respect any additional
equipment that is installed, or refine the operation of
a particular function to suit the working environment.
Additional info:
1. Each Node contains a particular software pro-

gram that is unique to that location. Therefore the
Software cannot be transferred from one Node to
another.
2. The calibrations preferences are held on Three

Nodes, when the engine is started these pre-
ferred choice or setting on each Node are com-
pared. If the choices or settings on one Node are
different from the others the Nodes in the majority
will influence and change choices or settings of
the Node that is in the minority.
3. With an integrated system, the functionality of the

system can NOT be deduced from the wiring dia-
gram (in comparison with a classical wired sys-
tem).
CAN SPY
Decimal and hexadecimal counting

To enable us to count up to Sixteen and only use One
digit position (to enable the large volume of informa-
tion to be displayed) the Hexadecimal counting sys-
tem has been introduced.
Decimal
Numbe 0 1 2 3 4 5 6 7 8 9
r
NOTE: Zero is a number in the decimal counting sys- If only One digit position is available on the display,
tem and can be considered as the first option in the then 0 -- 9 (Ten options) can be expressed.
sequence of Ten numbers.
If Two digit positions are available on the display,
then 0 -- 99 (One Hundred options) can be ex-
Thousands Hundreds Tens Units pressed.
0 0 0 0
In simple terms:
1 1 1 1
2 2 2 2 28 is formed of Eight Units and Two groups of Ten
(= 2 x 10 + 8).
3 3 3 3
6789 is formed of Nine Units, Eight groups of Ten,
4 4 4 4 Seven groups of One Hundred and Six groups of
One Thousand (= 6 x 1000 + 7 x 100 + 8 x 10 +
5 5 5 5 9).
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
Hexadecimal
Decimal number 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Hexadecimal number 0 1 2 3 4 5 6 7 8 9 A B C D E F
NOTE: Zero is a number in the hexadecimal counting Units are expressed in one digit from 0 -- F. Then
system and can be considered as the first option in groups of Sixteen are expressed in the first digit posi-
the sequence of Sixteen numbers. tion and the Units shown in the Second giving 00 --
FF.
To enable us to express the Eleventh option and be- Some calculators have an automatic hexadecimal --
yond, letters of the Alphabet are used (A, B, C, D, E, decimal conversion option.
F).
The same counting principals apply in hexadecimal
counting as in decimal counting.
Sixteen X Sixteen X Sixteens Units
Sixteen X Sixteen
Sixteen
0 0 0 0
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
A A A A
B B B B
C C C C
D D D D
E E E E
F F F F
Example:
Hexade- Decimal
cimal
20 (2 x 16) + 0 = 32
2FA3 (2 x 163)+(F x 162)+(A x 161)+3
2FA3 (2 x 4096)+(15 x 256)+(10 x 16)+3
2FA3 8192+3840+160+3 = 12195
A clear example of hexadecimal counting can be ob-

served when recalling identifier 1327 of the CAN--
SPY mode. This is the CAN identifier for date and
time. The counting of the seconds gives a fair idea of
what hexadecimal counting is.
How to use the CAN Identifiers
The CAN--system provides the ability to obtain ”in-

side information” for component or continuity fault di-
agnosis. This system is called the ”CAN--SPY
troubleshooting”.
The CAN--SPY system enables us to check the pres-

ence and status of input and output signals within the
electronic system for each component or function.
This information can be recalled on the InfoView
monitor and used in conjunction with the Can Spy
notes.
Once the CAN--SPY mode and the right identifier are

selected, you are able to compare the expected va-
lues given in the CAN--SPY notes with the values
provided by the electronic system. Any difference be-
tween these two values, for any given situation can
be of help to isolate the location of a fault in the elec-
tronic system. A logical process of elimination should
be used, where each expected value from the inputs,
prerequisites or outputs for a particular function are
checked in sequence.
When checking Output and Status values it is often

necessary to follow normal operating procedures
during testing. Some individual Output or Status va-
lues will not be available unless all preceding inputs
or functions are present.
How to Enter CAN--SPY
Simultaneously press MEM and ESC on the InfoView

panel. The Can Spy screen will appear and shows
the following information:
• The identifier number or ”Page number” (e.g.

1280). This can be changed with the scroll but-
tons.
• Four words in the bottom text line (shown as xxxx
xxxx xxxx xxxx). Each word contains four digits.
The four words in the bottom text line contain the in-
formation of the CAN system in hexadecimal
numbers.
ZDA482A
CAN--SPY in practice:
The CAN identifier values are shown in four columns

known as ’Words’. In each word there are four digit
positions. There are four basic rules that must be
used to calculate the appropriate value from the
notes:
1. Only add values together. Never subtract.
2. Identify the function status statements that

match the current machine situation (’true state-
ments’) and add the relevant values together.
3. Only add values in the same word and the same

digit position.
4. Calculate the ’expected value’ on paper and then

check that it corresponds to the value given on
the Info View screen.
NOTE: Values in the same Word that are not relevant

to the function description are shown in the notes as =.
CAN ID Data description word1 word2 word3 word4
1282 Header down switch Pressed 8===
1282 Header down switch Not Pressed 4===
1282 Feed rolls reverse switch Pressed 2===
1282 Feed rolls reverse switch Not Pressed 1===
Word One, Digit Position One

Function Description Function Status Statement
Can Identifier (Page) Number
The function descriptions are found in group of four a value of 8, 4, 2 or 1. No matter how these values or
(A group is defined by the digit position within a par- combination (using each value only once) of values
ticular word), where each individual status is given by are added together a unique value will result.
Example 1

1282 Header down switch Pressed 8===
1282 Header down switch Not Pressed 4===
1282 Feed rolls reverse switch Pressed 2===
1282 Feed rolls reverse switch Not Pressed 1===
1. Enter the CAN--SPY on page 1282, It is likely that 2. Press and hold the header down switch. The ma-
no switches on the multifunction lever are chine status has now changed, so we must add
pressed. the corresponding values shown in the notes that
Therefore the ’true statements’ are: are relevant to the new situation. These are:
• Header down switch, not pressed. Which has • Header down switch, is pressed. Which has
a value of 4. a value of 8.
• Feed rolls reverse switch not pressed. Which • Feed rolls reverse switch not pressed. Which
has a value of 1. has a value of 1.
If these two values are added together the ’expected If these two values are added together the ’expected
value’ on the InfoView monitor in word one, digit posi- value’ on the InfoView monitor in word one, digit posi-
tion one is 5. Look at the InfoView monitor in identifier tion one is 9. Look at the InfoView monitor in identifier
(’page’) number 1282 and confirm that a value of 5 is (’page’) number 1282 and confirm that a value of 9 is
shown in word one, digit position one. If there is a shown in word one, digit position one. If there is a
value of 5 is shown continue in a logical sequence. value of 9 is shown continue in a logical sequence.
3. Press and hold both the header down switch and there is a value of A the following conclusions can be
the feed roll reverse switch simultaneously. The made.
machine status has now changed again, so we
must add the corresponding values shown in the
Conclusion:
notes that are relevant to this new situation.
These are: By pressing and holding the switches (to change the
machine status) and checking that the values shown
• Header down switch, is pressed. Which has
on the InfoView monitor against the relevant value in
a value of 8.
the notes. We not only confirm the correct function of
• Feed rolls reverse switch not pressed. Which the switch but also the connections through classical
has a value of 2. wiring, PCB tracks and in some case the Optical
Fibre communications.
If these two values are added together the ’expected
value’ on the InfoView monitor in word one, digit posi- Having checked the function of these two switches
tion one is 10 (expressed in decimal terms). The Info- and found a satisfactory result the CAN--SPY system
View monitor must express this value using only one can be used to check each individual input or status
digit position and uses the hexadecimal expression that the Software requires to implement an output
for a decimal 10 which is A. Look at the InfoView signal or change in status. These other functions
monitor at identifier number 1282 and confirm that a may be found on other pages. Knowledge of the
value of A is shown in word one, digit position one. If function of the machine is a benefit when diagnosing
complex failures.
Example 2
CAN ID Data description word1 word2 word3 word4 Comments

1282 Multifunction Lever Out of =2==
Neutral
1282 Header down switch In Neutral =1==
1282 Ground Speed ==XX In Neutral XX=5C±20
Potentiometer or 48 <XX<71.
Limit 00 <XX<D0±10
In the CAN--SPY notes the value XX is shown in word of the potentiometer. If the multifunction lever is
3, digit position 3 & 4. XX refers to a variable input removed from the position where the neutral switch
ceived from a sensor, in this case the ground speed value changes from 2 to 1(either from FWD to neu-
control potentiometer located below the multifunc- tral, or from REV to neutral), the XX value should be
tion lever. The values in word 3, digit position 2 refer in a range of 5C (Hexadecimal) plus or minus a deci-
to the status of the neutral switch, which is also lo- mal value of twenty, or a range (in hexadecimal
cated below the multifunction lever. In neutral the terms) of 48 -- 71. The acceptable range over the total
switch has an added value of 1, out of neutral it has travel of the potentiometer is from 00 to D0 ± 10 (deci-
an added value of 2, in word 3, digit position 2. mal).
The comment column gives the parameters within
which the XX value must be set and the overall range
Example 3

1283 Adjust O--Matic Main switch Switched ON 8===
1283 Cutterhead Reversing switch Switched OFF 4===
1283 Power Reverse switch Switched ON 2===
1283 Crop Processor roll clearance Pressed 1===
close switch
1. When the ignition switched on, enter CAN--SPY NOTE: The other functions relevant to this word and
on page 1283. Ensure that none of the relevant digit position are either not pressed or are off. There-
switches are switched on or pressed, the only fore these statements can be considered as not true
true statement is: and the relevant values do not need to be con-
• Cutterhead reversing switch, switched off. sidered. In addition the comment column tells that
Which has a value of 4. when the switch is open then the value is 0.
In this situation the value shown in word two, digit

3. Switch on the Adjust--o--Matic main switch. Leav-
position one should be 4.
ing the cutterhead reverse switch off and the
power reverse switch off. The machine status
has now changed again, so we must add the
NOTE: the other functions relevant to this word and
corresponding values shown in the notes that are
digit position are either not pressed or are off. There-
relevant to the new situation. These are:
fore these statements can be considered as not true
and the relevant values do not need to be con- • Cutterhead reversing switch, switched off.
sidered. In addition the comment column tells that Which has a value of 4.
when the switch is open then the value is 0. • Power reverse switch on. Which has a value
of 2.
2. Switch on the power reverse switch. The ma- • Adjust--o--Matic Main switch on. Which has a
chine status has now changed, so we must add value of 8.
the corresponding values shown in the notes that
If these three values are added together the ’ex-
are relevant to the new situation. These are:
pected value’ on the InfoView monitor in word two,
• Cutterhead reversing switch, switched off. digit position one is 14 (decimal). The InfoView moni-
Which has a value of 4. tor must express this value using only one digit posi-
• Power reverse switch, switched on. Which tion and uses the hexadecimal expression for a deci-
has a value of 2. mal 14 which is E. Look at the InfoView monitor at
identifier (’page’) number 1283 and confirm that a
If these two values are added together the ’expected value of E is shown in word two, digit position one. If
value’ on the InfoView monitor in word two, digit posi- there is a value of E, continue in a logical sequence.
tion one is 6. Look at the InfoView monitor at identifier
(’page’) number 1283 and confirm that a value of 6 is
shown in word two, digit position one. If a value of 6 NOTE: The other functions relevant to this word and
is shown, continue in a logical sequence. digit position are either not pressed or are off. There-
fore these statements can be considered as not true
and the relevant values do not need to be con-
sidered. In addition the comment column tells that
when the switch is open then the value is 0.
4. Press and hold the crop processor clearance
close switch. Leaving the Adjust--o--Matic main
switch on, the cutterhead reverse switch off and
the power reverse switch on. The machine status
• Crop processor clearance close switch,

pressed. Which has a value of 1.
• Cutterhead reversing switch, switched off.
Which has a value of 4.
• Power reverse switch, switched on. Which
has a value of 2.
• Adjust--o--Matic main switch, switched on.
Which has a value of 8.
If these four values are added together the ’expected

value’ on the InfoView monitor in word two, digit posi-
tion one is 15 (decimal). The InfoView monitor must
express this value using only one digit position and
uses the hexadecimal expression for a decimal 15
which is F. Look at the InfoView monitor at identifier
(’page’) number 1283 and confirm that a value of F
is shown in word two, digit position one. If there is a
value of F, continue in a logical sequence.
5. Switch the cutterhead reversing switch, and hold

the crop processor clearance close switch. Leav-
ing the Adjust--o--Matic main switch on, and the
power reverse switch on. The machine status
• Crop processor clearance close switch,

pressed. Which has a value of 1.
• Power reverse switch on. Which has a value
of 2.
• Adjust--o--Matic Main switch on. Which has a
value of 8.
If these three values are added together the ’ex-

pected value’ on the InfoView monitor in word two,
digit position one is 11 (decimal). The InfoView moni-
tor must express this value using only one digit posi-
tion and uses the hexadecimal expression for a deci-
mal 11 which is B. Look at the InfoView monitor at
identifier (’page’) number 1283 and confirm that a
value of B is shown in word two, digit position one. If
there is a value of B, the following conclusions can be
made.
ERROR CODES MESSAGES
All interfaces are built in such a way that they can de-
duce an interruption in the signal. This interruption
can be a short circuit or an open circuit from the sen-
sor / switch or to an end user (motor, valve).
The interface will send a message on the CAN sys-

tem, which will be translated into an error message
on the InfoView monitor.
Also refer to chapter 9/4b ’’Error messages over-
view’’.
Once an interruption in the signal for an end user is

detected, the electronic system will automatically
stop to power the output line.
Possible causes:
-- Open or short circuit in wiring loom or con-
nectors.
-- Sensor or end user shorted or damaged.
-- Interface defect.
Action:
1. Check wiring and connections.
2. Check switch/sensor or end user (motor, valve).
3. Check interface visually (located on printed cir-

cuit boards).
Wiring checking procedure:
1. Is there an open circuit in the wiring?
Check each cable separately for infinity resis-
tance.
And
2. Is there a shorted circuit in the wiring loom?

Check each pair of cables for 0 resistance.
And
EL--003
3. Is there a shorted circuit with the ground?

Check each cable separately with ground for 0
resistance.
REMARK: If a problem only occurs now and then,

the problem will most likely be related to bad contacts
in connectors or bad connections in switches.
In this case, it is recommended to test with a new
(self--made) wiring loom directly connected between
the output on the electronic printed circuit and the
end user. Make sure you never contact the original
wiring loom and disconnect all original cables at the
beginning and at the end.
9
ATTENTION
• Never put 12 V (battery voltage) to an end
user (electric motor, actuator or electro
valve) when the wiring loom is still connected
to the printed circuit, as this will burn the
electronic components on the printed circuit.
• Always disconnect the end user from the
central electronic box before testing it.
• When doing this test, be sure the end user
can stand 12 V power supply. Some valves
have a supply voltage of 7V.
10
FAULT FINDING ROUTINE 7. If there is no error code related to the problem,

check the output of the Bus CAN with the CAN
1. After listening to the customer, try to check the identifiers and the functional classification. If the
faulty function to make sure the malfunction is not output of the Bus CAN is OK, check the connec-
due to a user mistake or to the calibration. Try re- tions on the printed circuit, the wiring and the final
lated functions to reduce scope of diagnosis. element (as described in point 5).
Consult the Operator’s Manual or the Repair
Manual. 8. If the wiring and the final element are OK, the fail-
ure is probably due to the output interface. Check
2. Make sure it is not a mechanical, hydraulic or the electrical diagrams to locate the correspon-
fuse failure. ding printed circuit and replace it.
3. Check the InfoView memory in the Service Mode 9. In case the outputs of the Bus CAN are incorrect,
for errors related to this problem. If so, delete all check the inputs one by one with the identifier list
the errors, switch on the engine and perform the and the detailed analysis per function (refer to
failed function. Then check if the error has reap- section 55 chapter 7).
peared in the memory.
10. If an input identifier is incorrect, check the el-
4. If the error has reappeared, the problem is prob- ement relating to this identifier.
ably electrical. Consult the error code list and the
electrical diagrams to locate the problem. 11. If the input (switch or sensor) is correct, the fail-
ure is probably related to the printed circuit.
5. If there is a network error code, solve this first be-
fore checking anything else. A printed circuit or
connections between printed circuits can cause
a network error.
6. If the error code concerns an output, a quick way

to check is to power the element directly from the
central box. Disconnect the connection at the
printed circuit and power the pins related to the
problem from the fuse, which powers the printed
circuit. In this way a simultaneous check of the
wiring and of the final element is performed. If the
wiring or the final element is not OK, use the elec-
trical diagrams.
Listen to the customer. Check
faulty function yourself.
Try related oper-

ations to reduce
scope of diagnosis
Malfunction
Yes
due to user Explain how to use
mistake or the function correctly
calibration
No
Hydraulic Yes Perform repair of

or mechanic or hy-
Mechanical draulic circuit.
Fault Use Repair Manual
No
Yes
Fuse Replace fuse.
burned?
No
Error Codes in Yes Solve this first before

InfoView Error Yes Network checking anything else.
list, related to Error Code Consult Error Code List
the problem stored? and Electrical Diagrams
No
No
Perform output and wiring
Yes test by powering the end
Yes Error Code user, disconnected at the
Is the problem CAN--ID for concerns an printed circuit.
related to the end user is output Consult Error Code List
end user? correct? and Electrical Diagrams.
Yes No
Consult Error Code
Perform output and wiring test
by powering the end user. Dis- Check CAN--ID for inputs list and Electrical Dia-
connect at printed circuit one by one grams
A
Yes Test CAN--ID Yes

successfull? for Input
is correct Check next Input
No No
Interface can be de- Repair elec- Check input switch/sensor

fective. trics or replace
Replace printed circuit end user
Yes Repair electrics or re-

Input switch/
place input switch/
sensor
sensor
defect
Interface can be defective.

Replace printed circuit.
Chapter 5 -- Calibration
CONTENT

55.000 Machine calibration with Laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Machine calibration with PDT tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MACHINE CALIBRATION WITH LAPTOP
Apart from the calibrations and settings carried out
on the InfoView monitor like e.g. the Attachment
Height Control calibration (see section 4.17.4 of the
Operator’s Manual), an initial machine (re) calibra-
tion can be carried out with a Laptop--PC, e.g. after
a rework or after installing different tyres.
The latter is normally carried out in the plant before

shipment, but there may be circumstances in which
the calibration has to be repeated.
The following calibrations can be found in the Lap-

top--program and on the PDT cartridge:
PC# Calibration
a Serial number
b Maximum handle position
c Minimum forward current to hydro-
static pump
d Minimum backward current to hy-
drostatic pump
e Acceleration hydrostatic pump
f Caterpillar / New Holland Engine
g Rear auxiliary hydraulics
h High flow hydraulics
i Four wheel drive
j Rotary screens
k Rotary screen brushes
l Air conditioning
m Latched header height
n Low pressure valves
o Stromag feed rolls engagement
clutch
How to use the system 5. Connect the update cable to your computer and
To enter the machine calibration program, proceed to the instrument panel.
as follows:
6. Type ‘CANMENU’ and press the ENTER key.
1. Put your laptop PC on the steering wheel. The menu is shown on the display and the direc-
tory has changed into ‘C:\CANHARV>’.
2. Switch ON the computer.
7. Type ‘FX’ and press the ENTER key to enter the
When working in Windows 3.1 or 3.11, EXIT
correct directory (C:\CANHARV\FX>).
Windows first.
When working in Windows 95 or later, go to 8. Type ‘CALIBR’ and press the ENTER key to start
“Start -- Shut Down” menu and “Restart the the update procedure.
computer in MS--DOS Mode”.
9. The following menu will appear on the screen.
3. When arriving in DOS, ‘C:\’ must be visible on the
screen. If necessary type ‘CD\’ and press the NOTE: The PC--calibration file CAL_PDT for the
ENTER key to return to the root directory C:\>. European service people is included on the installa-
tion disk and will therefore automatically be stored on
4. Make sure the proper REV--level machine soft-
the hard disk of the computer when the software is in-
ware is installed on your computer.
stalled.
European service people (cal_pdt)
Calibration of:
a: Serial number
b: Maximum handle position
c: Minimum forward current to hydrostatic pump
d: Minimum backward current to hydrostatic pump
e: Acceleration hydrostatic pump
f: Caterpillar / New Holland Engine
g: Rear auxiliary hydraulics
h: High flow hydraulics
i: Four wheel drive
j: Rotary screens
k: Rotary screen brushes
l: Air conditioning
m: Latched header height
n: Low pressure valves
o: Stromag feedrolls engagement clutch
x: eXit
Make your choice:

Calibration instruction
Pick one of the calibrations from the menu and follow
the instructions on the screen. Text NOT printed in
bold is informative and merely meant to elucidate
the calibration.
a : Serial number
Do you want to input serial number ? [y,n]
Type y in case you want to do so.
Give serial number :
Insert the machine serial number and press Enter to confirm.
b : Maximum handle position
Do you want to calibrate maximum handle position ? [y,n]
Type y if you want to do so.
Move the handle to its maximum forward position and press the enter key.
c : Minimum forward current to hydrostatic pump
Do you want to calibrate minimum forward current to hydrostatic pump ? [y,n]
Type y if you want to do so.
Set ground speed to minimum forward speed and press the enter key.
Choose second or third gear with the engine at low idle.

Now move the handle slowly forwards until the machine starts to crawl.
Now move slowly backwards until the machine stops and press the enter key.
d : Minimum backward current to hydrostatic pump
Do you want to calibrate minimum backward current to hydrostatic pump ? [y,n]
Type y in case you want to do so.
Set ground speed to minimum backward speed and press the enter key.
Choose second or third gear with the engine at low idle.

Now move the handle slowly backwards until the machine starts to crawl.
Now move slowly forwards until the machine stops and press the enter key.
e : Acceleration hydrostatic pump
Low acceleration hydrostatic pump ? [y,n]
For low acceleration of the hydrostatic pump below 20 Km/h, press y

This calibration is compulsory for Germany, Austria, Switzerland and Italy.
So, for these countries always press y.
For other countries, normal acceleration of the hydrostatic pump may be used, press n.
f : Caterpillar / New Holland Engine
Caterpillar engine installed ? [y,n]
Only for FX58 Caterpillar machines, press y.

For all other FX Forage Harvesters with Iveco--Aifo engines, press n.
g : Rear auxiliary hydraulics
Rear hydraulics installed ? [y,n]
When rear auxiliary hydraulics are installed on your machine,

press y ; otherwise press n
h : High flow hydraulics
High flow hydraulics installed ? [y,n]
When high flow hydraulics are installed on your machine, press y.

Otherwise press n.
i : Four wheel drive
Four wheel drive installed ? [y,n]
When four wheel drive is installed on your machine, press y.

Otherwise press n.
j : Rotary screens
Rotary screens installed ? [y,n]
When rotary screens are installed on your machine, press y.

Otherwise press n.
k : Rotary screen brushes
Rotary screen brushes installed ? [y,n]
When rotary screen brushes are installed on your machine, press y.

Otherwise press n.
l : Air conditioning
Air conditioning installed ? [y,n]
When there is Air Conditioning installed on your machine, press y.

Otherwise press n.
m : Latched header height
Do you want to change latched header height ? [y,n]
This calibration is compulsory for Italy only. So, for Italy always choose y.
Set header to latched height and press the enter key.
Set machine at HARVEST mode and choose the latched header height.
Now press the enter key.
When switching to ROAD mode, the header will latch at the calibrated height.
n : Low pressure valves
Low pressure valves installed ? [y,n]
Only for European pre series machines (series 01), press n.

For all other machines (European and USA), press y.
o : Stromag feedrolls engagement clutch
Reverse feedrolls engagement output for Stromag clutch on actuator print ? [y,n]
On machines from serial nr 5083 (season 1999) onwards, the reverse feedrolls engagement
output is moved to the actuator printed circuit. For these machines press y.
For all other machines, before serial nr 5083, press n.
x : eXit
Choose x to leave the calibration program and return to the c:\canharv\fx directory.
MACHINE CALIBRATION WITH PDT--TOOL
The Portable Diagnostic Tool (PDT) is a hand--held

tool used to download software and perform calibra-
tion of the FX Forage Harvesters.
The download software and calibration programme
is stored on a cartridge, which is plugged into the
base of the PDT unit.
When replacing the cartridge, the PDT tool can also
be used to download software and perform diagnos-
tic routines on other New Holland products.
52526
Installing and operating the pdt tool
NOTE: Text that is typed bold is text that appears on

the display of the PDT.
Plug the cartridge into the adapter slot located at the

bottom of the PDT tool.
Be careful:
It is possible to plug in the cartridge upside down.
If so, the PDT tool cannot function.
Connect the different connectors of the adapter

cable to the top of the diagnostic tool, to the power
plug in the operator’s cab and to the DIN plug at the
bottom of the instrument panel.
After a few seconds, the following text appears on the

screen: Select Operation
This is the main menu.
With the UP/DOWN arrow keys the arrow > can be 1 > Download
moved. 2 - Calibrate
Use the UP/DOWN arrow keys on the PDT tool to se-
lect the required function and press Enter, or press
1 to choose Download Software, or 2 to Calibrate the
FX forage harvester.
If a mistake is made when selecting the required
function, press the MODE key on the PDT tool and
it will recall the previous page on the display.
Machine calibration
Starting from the main menu, use the UP/DOWN Select Device :
arrow keys on the PDT tool to select Calibrate and
press the Enter key, or press the corresponding num- 1 > Serial Number
ber. 2 - Max Handle Pos
The following ‘calibration menu’ appears on the 3 - Pump Fwd Current
screen:
4 - Pump Back Current
lect the item you want to calibrate and press Enter, or 5 - Acceleration
choose one of the numbers 1 to 9. 6 - CAT / NH Engine
7 - Rear Aux. Hydr.
8 - High Flow Hydr.
9 - Four wheel drive
10- Rotary Screens
11- Rot. Screen Brush
12- Air Conditioning
13- Latched Header
14- Low Press. Valve
15- Stromag Clutch
The following pages explain how to calibrate your

machine.
NOTE: Before calibrating, switch on the ignition key!

If not, no calibration is possible and no error mess-
ages will appear on the screen.
1. Calibration of Serial Number
Do you want to input
Select ‘1--Serial Number’ in the calibration menu. a Serial Number ?
Press ‘1--Yes’ to continue the calibration. 1-Yes 2-No

Press ‘2--No’ to stop the calibration and return to the
calibration menu.
When ‘1--Yes’ is pressed, the following message will

appear. Enter Serial Number
Insert the machine serial number and press Enter to XXXXXXXXX
confirm.
Press
Enter to confirm
The serial number is now entered into the memory of

your machine. CALIBRATING ...
2. Calibration of maximum handle position
Do you want to
Select ‘2--Max Handle Pos’ in the calibration menu. Calibrate Maximum
Handle Position ?
Press ‘1--Yes’ to continue the calibration.
1-Yes 2-No
calibration menu.

appear. Set handle into
Move the ground speed handle to its maximum for- maximum forward
ward position and press the Enter key. position
Press Enter
Your selection is now transferred into the memory of

3. Calibration of minimum forward current to
hydrostatic pump. Do you want to cali-
brate Min Forward
Select ‘3--Pump Forw Current’ in the calibration Current to pump ?
menu.
1-Yes 2-No
calibration menu.

appear and 8 red warning lights under the display will WARNING :
start flashing. This may cause
sudden movement.
Press Enter
When the Enter key is pressed, the following mess-

age will appear. Move handle forward
until machine crawls.
Choose second or third gear with the engine at low Back off, until stop
idle. Move the handle slowly forwards until the ma- Press Enter
chine starts to crawl. Now move the handle slowly
backwards until the machine stops. Press the Enter
key.

4. Calibration of minimum backward current to
hydrostatic pump. Do you want to cali-
brate Min Backward
Select ‘3--Pump Back Current’ in the calibration Current to pump ?
menu.
1-Yes 2-No
calibration menu.

appear and 8 red warning lights under the display will WARNING :
start flashing. This may cause
sudden movement.
Press Enter
When the Enter key is pressed, the following mess-

age will appear. Move handle forward
until machine crawls.
Choose second or third gear with the engine at low Back off, until stop
idle. Move the handle slowly backwards until the ma- Press Enter
chine starts to crawl. Now move the handle slowly
forwards until the machine stops. Press the Enter
key.

5. Calibration of hydrostatic pump acceleration
Low Acceleration of
Select ‘5--Acceleration’ in the calibration menu. Hydrostatic Pump
1 > Installed
For low acceleration of the hydrostatic pump below 2 - Not Installed
20 km/h, select ‘1--Installed’.
This calibration is compulsory for Germany, Austria,
Switzerland and Italy. So, for these countries always
choose 1.
For other countries, normal acceleration of the hy-
drostatic pump may be used, select ‘2--Not In-
stalled’.
After your selection, the following message will ap-

pear. Do you want to clear
the old calibration
Press ‘1--Yes’ to continue the calibration. figures ?
calibration menu. 1-Yes 2-No
After ‘1--Yes’ is pressed, your selection is transferred

into the memory of your machine. CALIBRATING ...
6. Calibration of Caterpillar / New Holland En-
gine. CATERPILLAR Engine
(only for FX58) ?
Select ‘6--CAT / NH Engine’ in the calibration menu. 1 > Installed
2 - Not Installed
Only for FX58 Caterpillar machines, select ‘1--In-
stalled’.
For all other FX Forage Harvesters with Iveco--Aifo
engines, select ‘2--Not Installed’.

the old calibration

7. Calibration of Rear auxiliary hydraulics.
Rear Hydraulics
Select ‘7--Rear Aux. Hydr’ in the calibration menu. 1 > Installed
2 - Not Installed
Select ‘1--Installed’ if rear auxiliary hydraulics is in-
stalled on your machine.
Select ‘2--Not Installed’ if rear auxiliary hydraulics is
not installed.
Rear hydraulics is an option.

the old calibration

8. Calibration of high flow hydraulics.
High Flow Hydraulics
Select ‘8--High flow Hydr’ in the calibration menu. 1 > Installed
2 - Not Installed
Select ‘1--Installed’ if high flow hydraulics is installed
on your machine.
Select ‘2--Not Installed’ if high flow hydraulics is not
installed.
High flow hydraulics is an option.

the old calibration

9. Calibration of four wheel drive.
Four Wheel Drive
Select ‘9--Four Wheel Drive’ in the calibration menu. 1 > Installed
2 - Not Installed
Select ‘1--Installed’ if four wheel drive is installed on
your machine.
Select ‘2--Not Installed’ if four wheel drive is not in-
stalled.
Four wheel drive is an option.

the old calibration

10. Calibration of rotary screens.
Rotary Screens
Select ‘10--Rotary Screens.’ in the calibration 1 > Installed
menu. 2 - Not Installed
Select ‘1--Installed’ if rotary screens are installed on

your machine.
Select ‘2--Not Installed’ if rotary screens are not in-
stalled.
Rotary screens are an option on the FX300.

the old calibration

11. Calibration of rotary screen brushes.
Rotary Screen
Select ‘11--Rot. Screen Brush’ in the calibration Brushes
menu. 1 > Installed
2 - Not Installed
Select ‘1--Installed’ if rotary screen brushes are in-
stalled on your machine.
Select ‘2--Not Installed’ if rotary screen brushes are
not installed.
Rotary screen brushes are an option.

the old calibration

12. Calibration of Air Conditioning.
Air Conditioning
Select ‘12--Air Conditioning’ in the calibration 1 > Installed
Select ‘1--Installed’ if Air Conditioning is installed on

your machine.
Select ‘2--Not Installed’ if Air Conditioning is not in-
stalled.
Air Conditioning is an option.

the old calibration

13. Calibration of latched header height.
Do you want to clear
Select ‘13--Latched Header’ in the calibration menu. the old calibration
figures ?
1-Yes 2-No
calibration menu.
After ‘1--Yes’ is pressed, the following message will

appear. Do you want to
Set a latch
This calibration is compulsory for Italy only. So, for Header Height
Italy always choose ‘1--Yes’.
1-Yes 2-No
For other countries, choose ‘2--No’ .
After ‘1--Yes’ is pressed, the following message will

appear. Select Harvest mode
and choose the
Set machine at HARVEST mode and choose the latched height.
latched attachment height. Now press the Enter key. If done, press Enter
When switching to ROAD mode, the header will latch
at the calibrated height.
When the enter key is pressed, your selection is

transferred into the memory of your machine. CALIBRATING ...
14. Calibration of low pressure valves.
Low Press. Valve
Select ‘14--Low Press. Valve’ in the calibration 1 > Installed
Check the serial number of the machine involved.

Only for European pre series machines (series 01),
select ‘2--Not Installed’ .
For all other machines (European and USA), select
‘1-- Installed’ .

the old calibration

15. Calibration of Stromag feedrolls engagement
clutch. Stromag Feedrolls
Engagement Clutch
Select ‘15--Stromag Clutch’ in the calibration on Actuator Print
menu.
1-Yes 2-No
Check the serial number of the machine involved.
On machines from serial nr 5083 (season 1999) on-
wards, the reverse feed rolls engagement output is
moved to the actuator printed circuit. For these ma-
chines, select ‘1--Yes’.
For all other machines, before serial nr 5083, select
‘2--No’.

the old calibration

Chapter 6 -- Software Update
CONTENT

55.000 Software update with Laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Software update with PDT tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SOFTWARE UPDATE WITH LAPTOP
10 step software installation guide
NOTE: Although most commands in this instruction

are typed in CAPS, it is not necessary to use caps.
Action Comments
1 Switch on the computer
2 When working in Windows 3.1 or 3.11, EXIT To Exit Windows,

Windows first. • close all applications by double clicking in
When working in Windows 95 or later, go to the top left corner.
“Start -- Shut Down” menu and “Restart the
or
• key simultaneously Alt and F4.
3 When arriving in DOS, C:\> must be visible on To return to the root directory :
the screen. • Type CD\ and press ENTER.
(also called the “root directory”) • Type CD.. + ENTER a few times until you
see C:\>.
On computers with AZERTY--keyboards,
press AltGr and the key with the \ on it.
4 Insert the floppy disk with the correct Machine

Software Revision in the Floppy Disk Drive.
5 Type A: and press the ENTER key.
6 Type INSTALL and press the ENTER key.
7 Follow the instructions on the screen. For complete installation, always answer Y to
the questions that appear on the screen.
8 When the files have been copied to the hard

disk, remove the floppy disk.
9 When the installation is finished, return to the To see how to return to the root directory (C:\>)
root directory of your computer. see point 3 above.
10 Type CANMENU and press the ENTER key The program offers several help--possibilities.
to proceed to the update or calibration proce- Choose either one of the help comments that
dures. are displayed.
10 step machine software update guide
NOTE: Although most commands in this instruction

are typed in CAPS, it is not necessary to use caps.
Action Comments
1 Put your laptop PC on the steering wheel
2 Switch ON the computer. To Exit Windows,

When working in Windows 3.1 or 3.11, EXIT • close all applications by double clicking in
Windows first. the top left corner.
When working in Windows 95 or later, go to or
“Start -- Shut Down” menu and “Restart the
• key simultaneously Alt and F4.
3 When arriving in DOS, C:\> must be visible on To return to the root directory :
the screen. • Type CD\ and press ENTER.
(also called the “root directory”) • Type CD.. + ENTER a few times until you
see C:\>.
On computers with AZERTY--keyboards,
press AltGr and the key with the \ on it.
4 Connect the update cable to your computer

and to the instrument panel.
5 Type CANMENU and press the ENTER key. The program offers several help--possibilities.
The menu is shown on the display and the Choose either one of the help comments that
directory is changed to C:\CANHARV\. are displayed.
Type FX or TF and press the ENTER key de-
pending on the machine to update.
(C:\CANHARV\FX or C:\CANHARV\TF)
6 Type UPDATE and press the ENTER key to

start the update procedure.
7 Choose the node you want to update. Possibilities :

• A+S, B, D, or M for FX machines.
• A+S, B, C for TF Combines.
8 Choose the communication mode. With your computer configuration only the
Always type 0. RS232 (0) option is valid.
9 As soon as the message “... waiting for com- XX = FX or TF depending your selection in step
munication with node” appears on the screen, 5.
switch on ignition.
When the update procedure was successful
and the computer returns to the C:\CAN-
HARV\XX directory, switch off ignition.
10 Repeat steps 6 to 10 until all nodes have

been updated successfully.
SOFTWARE UPDATE WITH PDT--TOOL.
The Portable Diagnostic Tool (PDT) is a hand--held

tool used to download software and perform calibra-
tion of the FX Forage Harvesters.
The download software and calibration programme
is stored on a cartridge, which is plugged into the
base of the PDT unit.
When replacing the cartridge, the PDT tool can also
be used to download software and perform diagnos-
tic routines on other New Holland products.
52526
INSTALLING AND OPERATING THE PDT TOOL
NOTE: Text that is typed bold is text that appears on

the display of the PDT.
Plug the cartridge into the adapter slot located at the

bottom of the PDT tool.
Be careful:
It is possible to plug in the cartridge upside
down.
If so, the PDT tool cannot function.
Connect the different connectors of the adapter

cable to the top of the diagnostic tool, to the power
plug in the operator’s cab and to the DIN plug at the
bottom of the instrument panel.
After a few seconds, the following text appears on the

screen: Select Operation
This is the main menu.
With the UP/DOWN arrow keys the arrow > can be 1 > Download
moved. 2 - Calibrate
lect the required function and press Enter, or press
1 to choose Download Software, or 2 to Calibrate the
FX forage harvester.
If a mistake is made when selecting the required
function, press the MODE key on the PDT tool and
it will recall the previous page on the display.
SOFTWARE DOWNLOAD
Select FX Node :
Starting from the main menu, use the UP/DOWN
arrow keys on the PDT tool to select Download and 1 > Display (A&S)
press the Enter key, or press the corresponding num- 2 - Central box
ber. 3 - Adjustomatic
The following ‘Download menu’ appears on the 4 - Metal Detector
screen:
lect the node(s) you want to download and press
Enter, or choose one of the numbers 1 to 4.
When downloading, the operator can see the prog-
ress of the download (expressed in percentages) on
the display.
After downloading software, the PDT will automati-
cally verify if the download was successful.
NOTE: The download of nodes A and S is performed

consecutively and may take about 30 minutes.
After completion of the download process, use Up/

Down arrow keys to select the next node, or choose
the corresponding number of the node to be down-
loaded.
Example of downloading ‘Central Box’ Node:
When selection 2 has been entered, the following DOWNLOAD NODE B
message will appear. RAM : bootb.chx
Display view 1 ROM : haksb.chx
Press Enter
When the Enter key is pressed, next message ap-

pears. TURN IGNITION KEY
Switch on ignition without starting the engine. At the OFF
same time a running light (warning LED’s) on the ma- AND THEN ON AGAIN
chine dashboard will start functioning.
Display view 2
Display view 3
DOWNLOADING BOOT
FILE TO RAM
PROGRESS = XX %
Display view 4
********************
ERASING
PROGRAM MEMORY
********************
Display view 5
DOWNLOAD IN PROGRESS
NODE : ”B”
Progress = XX %
After finishing the download, the PDT continues ver-

ifying the programme memory. VERIFYING
Display view 6 PROGRAM MEMORY
Progress = XX %
Display view 7
*****************
WRITING
VERIFICATION
BYTES TO MEMORY
Software download process has been finished.

Press Enter to return to the Download menu. *****************
Display view 8 PROGRAM MEMORY
Download is correct
Press Enter
NOTE: If a problem occurs during downloading, the

following message will appear: *****************
PROGRAM MEMORY
Download is correct
Press Enter to return to the Download menu and try
again to download the software node. Press Enter
Chapter 7 -- Troubleshooting
CONTENT

55.000 Error messages overview
-- Machine error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
-- Attachment height control error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
-- Caterpillar error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
List of Can identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Detailed analysis per function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
MACHINE ERROR MESSAGES
Error Code Description Importance

001 LCD NETWORK ERROR High
Explanation : General CAN network failure.
Information sent out by the different nodes, through the optical fibres and the flat cable, is
not arriving.
If the outgoing communication from the InfoView monitor to dashboard can node, from the
dashboard can node to the AOM node and from the AOM node to the CPU node is inter-
rupted.
All the nodes react as if there is no network, as if they are not connected to the network.
This failure can be caused by any node on the network or by a network path that generates
so many errors that all the nodes can not communicate any more.
Action :
Check software revision
on service page.
Is x.x displayed?
Yes
Check software rev. of

each node on CANSPY.
Press “Mem“ and “ESC“
button before switching on
ignition
Communication from
AOM white connector to
Restart the machine. If
Is only CAN. Id of Node B Yes CPU black connector is in-
Yes problem persists, restart
incorrect? Value “00“ dis- correct.
Possible to download check routine from begin-
played? ning?
Software Node B?
No No
Is CAN--ID of Node B, Disconnect fiber optic

Node D 2 Node M incor- cable at CPU black con- Yes Try new CPU printed cir-
rect? nector. Red light is visible cuit of known performan-
Value “00” displayed for at end of fiber optic? ce.
these Nodes?
Yes
No
Replace the flat Check flat cable connec- Disconnect fiber optic
cable between tion between dashboard cable arriving from dash-
No Install new small fiber
dashboard and CAN Node and InfoView board at AOM black con- optic cable and try new
InfoView moni- monitor. Connection and nector? Red light is visible AOM printed circuit of
tor flat cable correct at end of fiber optic? known performance
Yes No
Try new Dashboard CAN Try new Dashboard CAN

printed circuit of known printed circuit of known
performance Problem performance
Solved?
No
Try new AOM printed cir-

cuit of known performance
002 OTHER NETWORK ERROR High
Explanation : General CAN network failure.
Information sent out by the different nodes, through the optical fibres and the flat cable, is
not arriving.
This error is caused by a lot of erroneous message transmissions and indicates a low quality
communication combined with a lot of network traffic.
Action : See ERROR 1.

003 NETWORK OVERLOAD High
Explanation : Too much or unclear data information on the CAN Bus. This error report will be always ac-
companied by error 001 and/or 002.
Too busy traffic on the local network. Software revision necessary.
Action : Load the latest software revision.

004 SOFTWARE ERROR High
Explanation : Software fault or failure has been detected.
Action : Load the latest software revision.

010 AOM DASHBOARD NETW. High
Explanation : The dashboard CAN node, closest to the LCD, is not transmitting CAN messages on a reg-
ular basis (at least 1 message / 2 seconds).
It is possible that all communication between the LCD and the other nodes is correct al-
though this dashboard CAN node is not transmitting messages to the InfoView monitor
node on a regular basis.
On machines sold before 1996, this node is located just behind the AOM user panel. On
the machines sold from 1996 on, this node is the main dashboard node mounted in the
centre of the dashboard.
Action : Check the flat cable connection between the dashboard CAN node and LCD node. If not
correct, replace the flat cable between dashboard and InfoView monitor. If correct, replace
the dashboard CAN node for latest type of dashboards or replace old type of dashboard
by new type. If the problem persists, try a new InfoView monitor of known performance (Do
not forget to download software when changing InfoView monitor).
011 DASHBOARD NETW. ERROR High
Explanation : The dashboard CAN node is not transmitting messages on a regular basis (at least 1 mess-
age / 2 seconds).
This error is only valid for machines with an old dashboard where two microprocessors are
located. This error code is related to the dashboard printed circuit, mounted in the centre
of the dashboard. This dashboard node serves the dashboard switches and the warning
lights above the switches.
On new type of dashboards, this error message should not appear as the function of both
microprocessors is grouped in one microprocessor.
Action : Replace the old type of dashboard by new type.

012 HANDLE NETWORK ERROR High
Explanation : The multifunction handle node is not transmitting CAN messages on a regular basis (at
least 1 message / 2 seconds).
though this handle node is not transmitting messages to the InfoView monitor node on a
regular basis.
Action : Refer to wiring diagram: line 1050.
Check the connection between the instrument panel and the multifunction lever. Check
for open and shorted circuits at power wire 1001--wt, at ground wires 1002--br and
1074--bl and at CAN communication wires 1003--gn and 1004--ge. If wiring is not correct,
locate and repair open or shorted circuit. If wiring is correct, replace the vertical handle
printed circuit.
If the problem persists, try a new dashboard with known performance.
013 CENTRAL NETW. ERROR High
Explanation : The CPU node in the central box is not transmitting CAN messages on a regular basis (at
though this CPU node is not transmitting CAN messages to the AOM node on a regular
basis.
Action : Communication from CPU

white connecter to AOM
black connector is incor- Yes Restart the machine and
rect? check software revision.
Possible to download Soft-
ware Node B
No
Disconnect fiber optic

cable at the AOM black Yes Try New AOM printed cir-
connector arriving from the cuit of known performance
CPU printed circuit. Red
light is visible at end of fiber
optic?
No
Install new small fiber

optic cable and try new
CPU printed circuit of
known performance.
015 AOM NETWORK ERROR High
Explanation : The AOM node in the central box is not transmitting CAN messages on a regular basis (at
though this AOM node is not transmitting CAN messages to the dashboard node on a reg-
ular basis.
Mostly error messages 15 and 13 appear together.
Action :
Communication from AOM
white connector to Dash-
board black connector is Yes Restart the machine and
incorrect? Possible to check software revision
download software node D
No
Disconnect fiber optic

cable at the dashboard Yes Try new Dashboard CAN
black connector arriving printed circuit of known
from the AOM printed cir- performance
cuit
Red light is visible at end of
fiber optic
No
Clean fiber optic cables

between dashboard and
AOM printed circuit.
Problem persists?
Yes
Try new AOM printed cir-

cuit of known performance
100 TOTAL ENGINE HOURS = Medium
Explanation : There is more than 10 hours difference between the total amount of engine hours stored
in the CPU Memory and the total engine hours in the InfoView monitor memory.
Remark: Switching off the battery key before turning off the ignition may result in memoris-
ing an incorrect engine hour value in the InfoView Monitor or in the CPU.
Different total hours are detected in the nodes on the network. REMARK: This error is dis-
played in a special error page format. REMARK: The error counter is automatically cleared
when the selection of the right total engine hours is made. So the error will not be displayed
any more showing the right total engine hours or showing engine hours differences of < 10h
while looking up the errors through the error overview.
Action : The total amount of engine hours, stored in the CPU and InfoView monitor, can only be
equalised when the error report automatically appeared after starting the engine.
On the special error 100 layout, the two different engine hours are indicated. One of the
values has an arrow in front of it. Move the arrow in front of the selected hour value with
the help of the ”ARROW” keys. Confirm your choice by pressing the “Enter” key. The se-
lected engine hours are now stored in both memories, together with the related threshing
hours and hectares (or acres). Press the “ESC” button to return to work screen. This error
will not be stored in the error overview list.
113 CROP. PROC. SENSOR O Medium
Explanation : The crop processor RPM sensor is disconnected from the CPU printed circuit.
Action : If no crop processor is installed, check in the InfoView calibration for “CROP PROCESSOR
: NO”.
If the crop processor is installed, refer to the wiring diagram: sensor B104, line 4350. Open
the connector at the crop processor rpm sensor. Turn on ignition and check for 8 Volts at
the end of wire 2047--BR. If not correct, locate and repair the open circuit in the brown wire.
If correct, check for ground at the end of wire 2048--BL. If not correct, locate and repair the
open circuit in the blue wire. If correct, replace the sensor.
No Check info view calibra-

Crop Processor installed? tion for “Crop Processor:
No”
Yes
Open connector at the Crop

Processor RPM Sensor. No
Locate and repair the open
Check for 8V at the end of circuit in the brown wire.
the brown wire
Yes
Check for ground at end of No Locate and repair the open

wire 2048 -- bl circuit in the blue wire.
Yes
Replace CP RPM Sensor

(B104).
114 CROP. PROC. SENSOR -- Medium
Explanation : The power wire (brown) of the crop processor RPM sensor is shorted to ground (blue wire
or frame ground).
: NO”.
If the crop processor is installed, refer to the wiring diagram: sensor B104, line 4350. Locate
and repair shorted circuit to ground in the wire 2097--BR. After repair, check if 8 Volts arrives
on the brown wire at the RPM sensor.

115 CROP. PROC. SENSOR + Medium
Explanation : The power wire (brown) of the crop processor RPM sensor is shorted to an external 12 Volts
power supply.
Action : If no crop processor is installed, check in the InfoView calibration for ”CROP PROCESSOR
: NO”.
If the crop processor is installed, refer to the wiring diagram: sensor B104, line 4350. Locate
and repair shorted circuit to 12 Volts in the wire 2097--BR. After repair, check if 8 Volts ar-
rives on the brown wire at the RPM sensor.
117 EMD NETWORK ERROR Medium
Explanation : This Error Code is related to the function of the network connections between the metal de-
tector itself and the AOM--print (A20). Physically these connections consist of the wires
2097 and 2098 and their connections to the printed circuit boards.
When there is no CAN--info available on the network for more than 60 seconds, while the
EMD--output signal is 12V, this Error Code will appear.
Error Code 117 overrides all Error Codes that are generated by the metal detector
(270--277).
Action : Refer to wiring diagram: line 3980 and 3990.
Check network connections. Locate and repair open circuit, shorted circuit, shorted circuit
to frame ground or to an external 12 V power supply in wires 2097 and 2098.
Disconnect wire 2097 and

2098 in central box and at metal
detector (see wiring diagram:
line 3980 and 3990)
Check for:
Open and short circuit,
Frame short circuit,
Short circuit to 12V.
Open or short Yes

circuit?
No Repair open or short circuit.

Reconnect wires 2097 and 2098
correctly.
Download the correct software.

Reconnect wires 2097 and
2098 correctly.
Problem solved?
No
Try with new electronic board

(A20) or a new metal detector.
Electronic Module
118 CATERP NETWORK ERROR Medium
Explanation : This Error Code is related to the function of the network connections between the Caterpillar
itself and the AOM--print (A20). Physically these connections consist of the wires 2097 and
2098 and their connections to the printed circuit boards.
When there is no CAN--info available on the network for more than 20 seconds, this Error
Code will appear.
Only valid for FX58.
Error Code 118 overrides all Error Codes that are generated by the Caterpillar engine.
Action : Check network connections (wire 2097 and 2098) for open circuit, shorted circuit, shorted
circuit to frame ground or to an external 12 V power supply.

120 GROUND SPEED SENS. O Medium
Explanation : The ground speed RPM sensor is disconnected.
Action : Refer to wiring diagram: sensor B16, line 2570.
Open the connector at the ground speed rpm sensor. Turn on ignition and check for 8 Volts
at the end of wire 263--BR. If not correct, locate and repair the open circuit in the brown wire.

121 GROUND SPEED SENS. -- Medium
Explanation : The power wire (brown) of the ground speed RPM sensor is shorted to ground (blue wire
or frame ground).
Action : Refer to the wiring diagram: sensor B16, line 2570.
Locate and repair shorted circuit to ground in the wire 263--BR. After repair, check if 8 Volts
arrives on the brown wire at the RPM sensor.

122 GROUND SPEED SENS. + Medium
Explanation : The power wire (brown) of the ground speed RPM sensor is shorted to an external 12 Volts
power supply.
Locate and repair shorted circuit to 12 Volts in the wire 263--BR. After repair, check if 8 Volts
125 ENGINE RPM SENSOR O Medium
Explanation : The engine RPM sensor is disconnected.
Suppressed for Caterpillar engine!
at the end of wire 274--BR. If not correct, locate and repair the open circuit in the brown wire.

126 ENGINE RPM SENSOR -- Medium
Explanation : The power wire (brown) of the engine RPM sensor is shorted to ground (blue wire or frame
ground).

127 ENGINE RPM SENSOR + Medium
Explanation : The power wire (brown) of the engine RPM sensor is shorted to an external 12 Volts power
supply.
Locate and repair shorted circuit to 12 Volts in the wire 274--BR. After repair, check if 8 Volts

130 CUTTERHEAD SENSOR O Medium
Explanation : The cutterhead RPM sensor is disconnected.
at the end of wire 2027--BR. If not correct, locate and repair the open circuit in the brown
wire. If correct, check for ground at the end of wire 2028--BL. If not correct, locate and repair
the open circuit in the blue wire. If correct, replace the sensor.
131 CUTTERHEAD SENSOR -- Medium
Explanation : The power wire (brown) of the cutterhead RPM sensor is shorted to ground (blue wire or
frame ground).

132 CUTTERHEAD SENSOR + Medium
Explanation : The power wire (brown) of the cutterhead RPM sensor is shorted to an external 12 Volts
power supply.
Locate and repair shorted circuit to 12 Volts in the wire 2027--BR. After repair, check if 8
Volts arrives on the brown wire at the RPM sensor.

145 ATTACHM HEIGHT S. O/-- Medium
Explanation : The attachment height sensor is disconnected or shorted to ground.
Action : Refer to wiring diagram: sensor R4, line 7150.
Locate and repair open circuit or shorted circuit to ground in the wire 229--GN, starting form
X415 p12 at the CPU printed circuit.
If the InfoView error message is accompanied by a header self--diagnostic message, refer
to the attachment control trouble--shooting section to check the attachment height sensor
circuit.

146 ATTACHM HEIGHT S. + Medium
Explanation : The attachment height sensor is shorted to an external 12V--power supply.
Action : Refer to wiring diagram: sensor R4, line 7150.
Locate and repair shorted circuit to 12 Volts in the wire 229--GN, starting form X415 p12
at the CPU printed circuit.
If the InfoView error message is accompanied by a header self--diagnostic message, refer
to the attachment control trouble--shooting section to check the attachment height sensor
circuit.
147 ATTACHM HEIGHT RANGE Medium
Explanation : The attachment height bargraph is not calibrated correctly. The same attachment height
is calibrated for ground and raised position.
Action : Restart the header height calibration routine and calibrate different attachment heights. if
error code returns, the sensor voltage does not change.
Check pivot arm and sensor.

148 CP DISTANCE SENS. O/-- Medium
Explanation : The crop processor distance sensor is disconnected or shorted to ground.
: NO”.
If the crop processor is installed, refer to wiring diagram: sensor R30, line 4300.
Locate and repair open circuit or shorted circuit to ground in the wires 2049, 2050 and
2051.

149 CP DISTANCE SENS. + Medium
Explanation : The crop processor distance sensor is shorted to an external 12V--power supply.
: NO”.
If the crop processor is installed, refer to wiring diagram: sensor R30, line 4300.
Locate and repair shorted circuit to 12 Volts in the wire 2051--GN.
150 CROP PROCESSOR SENS. Medium
Explanation : There is no voltage change of the crop processor distance sensor while the CP electric
motor is powered.
: NO”.
If the crop processor is installed, check crop processor sensor linkage. If correct, check po-
tentiometer voltage with different sensor angle. If same voltage, change potentiometer. If
different voltages, try other CPU printed circuit.
Check for correct CP No Repair Crop Processor

sensor linkage Sensor Linkage
Yes
Is the electric Motor rotating No Check CP Mechanical No Repair, grease or clear CP

while he is powered? Components mechanical Components
Turn Manually
Yes
Test CP Electric Motor No Try new electric motor of

Yes Function Correct? known performance.
Measure sensor voltage

with different angle posi-
tions.
Same voltage readings No Try other CPU printed cir-

with different angles? cuit.
Yes
Replace Sensor
170 DISPLAYTEMP TOO HIGH Medium
Explanation : The InfoView monitor temperature is too high.
If the monitor temperature is above 70 °C, the display will become blank and the contrast
light intensity will decrease. If the temperature decreases below 70 °C., then the display will
be reactivated again. At this time, the error report 170 will appear on the screen.
Action : Decrease the monitor ambient temperature by switching on the cab air conditioning system
or by driving the machine in the shadow.

171 SUPPLY VOLT = XX.X V Medium
Explanation : The battery voltage is lower than 10 Volts.
The actual voltage is shown at the bottom of the screen and will always be available through
the service page error overview.
Action : Recharge the battery or check the alternator for proper functioning.

180 CPU PRINT ERROR Medium
Explanation : Poor communication arriving at CPU printed circuit through the flat cable, that connects
CPU, light, actuator and valve printed circuits.
Action : Disconnect the flat cable at the rear of the CPU. Clear all error reports in the service over-
view. If the error 180 appears again, replace the CPU printed circuit. If this is not the case,
replace the flat cable.

181 LIGHTS PRINT DISCONN Medium
Explanation : Poor communication from light printed circuit through the flat cable, that connects CPU,
light, actuator and valve printed circuits.
Action : Check the flat cable male--female connections. If no visible damage, replace first the flat
cable. If the problem still persists, replace the light printed circuit.
182 ACTUATOR PRINT DISC Medium
Explanation : Poor communication from actuator printed circuit through the flat cable, that connects CPU,
cable. If the problem still persists, replace the actuator printed circuit.

183 HYDRO PRINT DISCONN Medium
Explanation : Poor communication from valve printed circuit through the flat cable, that connects CPU,
cable. If the problem still persists, replace the valve printed circuit.

220 ENGINE DOOR SENSOR O Medium
Explanation : The right hand side door sensor is disconnected.
Open the connector at the right hand side door sensor. Turn on ignition and check for 8 Volts
at the end of wire 2033--BR. If not correct, locate and repair the open circuit in the brown
wire. If correct, check for ground at the end of wire 2034--BL. If not correct, locate and repair
the open circuit in the blue wire. If correct, replace the sensor.

221 ENGINE DOOR SENSOR -- Medium
Explanation : The power wire (brown) of the right hand side door sensor is shorted to ground (blue wire
or frame ground).
arrives on the brown wire at the sensor.
222 ENGINE DOOR SENSOR + Medium
Explanation : The power wire (brown) of the right hand side door sensor is shorted to an external 12 Volts
power supply.
Volts arrives on the brown wire at the sensor.

223 STONE HOME SENSOR O Medium
Explanation : The sharpening stone home position sensor is disconnected.
Open the connector at the sharpening stone home position sensor. Turn on ignition and
check for 8 Volts at the end of wire 2068--BR. If not correct, locate and repair the open circuit
in the brown wire. If correct, check for ground at the end of wire 2069--BL. If not correct,
locate and repair the open circuit in the blue wire. If correct, replace the sensor.

224 STONE HOME SENSOR -- Medium
Explanation : The power wire (brown) of the sharpening stone home position sensor is shorted to ground
(blue wire or frame ground).

225 STONE HOME SENSOR + Medium
Explanation : The power wire (brown) of the sharpening stone home position sensor is shorted to an ex-
ternal 12 Volts power supply.
226 COVER CUTTERH. SENS. O Medium
Explanation : The sharpening stone cover sensor is disconnected.
Open the connector at the sharpening stone cover sensor. Turn on ignition and check for
8 Volts at the end of wire 2060--BR. If not correct, locate and repair the open circuit in the
brown wire. If correct, check for ground at the end of wire 2061--BL. If not correct, locate
and repair the open circuit in the blue wire. If correct, replace the sensor.

227 COVER CUTTERH. SENS. -- Medium
Explanation : The power wire (brown) of the sharpening stone cover sensor is shorted to ground (blue
wire or frame ground).

228 COVER CUTTERH. SENS. + Medium
Explanation : The power wire (brown) of the sharpening stone cover sensor is shorted to an external 12
Volts power supply.

229 OUT OF STONE SENS. O Medium
Explanation : The adjust sharpening stone sensor is disconnected.
Open the connector at the adjust sharpening stone sensor. Turn on ignition and check for
8 Volts at the end of wire 2066--BR. If not correct, locate and repair the open circuit in the
brown wire. If correct, check for ground at the end of wire 2067--BL. If not correct, locate
and repair the open circuit in the blue wire. If correct, replace the sensor.
230 OUT OF STONE SENS. -- Medium
Explanation : The power wire (brown) of the adjust sharpening stone sensor is shorted to ground (blue
wire or frame ground).

231 OUT OF STONE SENS. + Medium
Explanation : The power wire (brown) of the sharpening stone home position sensor is shorted to an ex-
ternal 12 Volts power supply.
232 SPOUT LIMIT SWITCH Medium
Explanation : The spout rotation valve is activated for more than 5 seconds while the spout end of travel
sensor is still detecting metal.
Is spout rotating when pres- No Try Manual override on hy- No Check and repair hy-
sing the spout left/right draulic valve spout rotat- draulic circuit
FAST buttons ing?
Yes Yes
No Check spout end of travel Consult spout rotation

Readjust spout end of
sensor adjustment. fault finding routine
travel sensor
Adjustment correct?
Yes
Check for 8 Volt at end of

Locate and repair open or No wire 2041 -- br check for
shorted circuit ground at end of wire 2042
-- bl
Yes
Replace spout end of

travel sensor.
Problem solved?
No
Try new actuator printed

circuit of known perform-
ance.
270 EMD NOISE LEVEL LOW Medium
Explanation : When there is a low signal from one ore both channels during working operation (cutterhead
and feed rolls engaged), this error code is generated. This message can only appear 12
seconds after the feed rolls are engaged.
It indicates a bad contact between the sensor and the electronics of the metal detector or
inside the electronics.
Action : Remove the metal detector and check the connections between the sensor and the elec-
tronics.
Try temporary with higher feed

roll speed.
Yes
Problem solved?
No
Too low magnetic noise from
Check on which channel (left or
feed rolls.
right) the peak noise reading is
lower than 03, whatever the
feed roll speed is.
See CAN Identifier page 1276, If possible, continue working in
word 3 and 4. a higher feed roll speed. But do
not charge any electronic com-
ponent.
Remove metal detector and dis-

connect wiring loom from sensor
to electronic Module.
Check coil resistance of both

channels
Yes Open or short Yes

Open or short
circuit in wiring
circuit?
loom to coils?
No No
Replace EMD Replace upper part If possible, repair open or short

electronic module: (coils and magnets). circuit in wiring loom.
271 EMD OUTPUT LINE -- Medium
Explanation : This Error Code is related to the (classical) output line (wire 2096).
When there is no detection, this output signal is 12 Volt; if a metal detection takes place,
the voltage will drop to 0 Volt for 1 second.
In case the metal detector determines an output voltage that is < 7.5V, while it expects the
signal to be high (=12V), this error code is generated. It is likely that the wire is short--cir-
cuited to earth. This message can only appear after the feed rolls have been activated for
the first time. Thereafter this test is executed until the ignition is switched off.
Check continuity of wire 2096. Locate and repair the frame short circuit in wire 2096. If
no frame short circuit can be found in the wire 2096, replace the EMD electronic module.

272 EMD OUTPUT LINE + Medium
Explanation : This Error Code is related to the (classical) output line (wire 2096).
In case the metal detector determines an output voltage that is > 1.0V, while it expects the
signal to be low (=0V) during a metal detection, this error code is generated. It is likely the
wire is shorted to 12V. This message can only appear after the feed rolls have been acti-
vated for the first time. Thereafter this test is executed until the ignition is switched off.
Check continuity of wire 2096. Locate and repair the short circuit to 12 V in the wire 2096.
If no short circuit to 12 V can be found in the wire 2096, replace the EMD electronic mod-
ule.
273 EMD CHANNEL FAULT Medium
Explanation : In case the coil and amplifier test fails during the run time test, this error code will be dis-
played.
The expected signal is a peak noise reading of 16 (hex). The allowed tolerance on the signal
ranges from OD to 1F (hex).
Action : Remove the detector and check the connections between the sensor and the electronic
module.
Check on which channel (left or

right) the peak noise reading is
not between OD and 1F during
the run time test.
See CAN Identifier page 1276,
word 3 and 4.
Remove metal detector and dis-

connect wiring loom from sensor
to electronic module.
Check coil resistance of both

channels
Yes Open or short Yes

Open or short
circuit in wiring
circuit?
loom?
No No
Replace EMD Replace upper part If possible, repair open or short

electronic module: (coils and magnets). circuit in wiring loom.
274 EMD NOISE LEVEL HIGH Medium
Explanation : This Error Code is related to the setting of the adaptive threshold.
This error message can be generated when during working operation the system becomes
so noisy that one of the adaptive thresholds is beyond the adaptive limits. Consequently,
there is a risk that small ferrous objects will not be detected.
Action : Work temporary in fixed mode.
Replace the metal detector feed roll and execute a quick adapt routine. If the problem per-
sists check if other feed rolls are creating excessive magnetic noise. At last, try new metal
detector of known performance.

275 EMD NETWORK ERROR Medium
Explanation : Suppressed in software Rev99 or later.
Remark: the metal detector can only report this error code after the CAN communication
problem has been repaired. By that time the problem has already been reported by the Ad-
just--O--Matic printed circuit by means of error code 117.
Action :

276 EMD PROCESSOR FAULT Medium
Explanation : There are 2 situations during which this Error Code will appear:
1. Flash Code “checksum” does not correspond with stored value. This error code can
only appear shortly after the ignition is switched ON.
2. There is a problem with the reading or writing of values to EEprom, e.g. the storing of
threshold settings.
Action : Load new software.
If this does not solve the problem, replace metal detector electronics.
277 EMD FRAME GROUND Medium
Explanation : In case the frame earth test fails during the run time test, this error code will be displayed.
Action : Check the following earth connections :
1. Flat earth strap connections between EMD electronic module and metal detector
shaft.
2. Flat earth strap connections between metal detector shaft and chopper body frame.
3. Earth connection between chopper body frame and base unit frame.
Check also for corrosion.

278 EMD OUTPUT FAILURE Medium
Explanation : This error code is generated when the (classical) output signal is low (0V) for more than 60
seconds, while the CAN--messages appear normal.
Check continuity in wire 2096. Locate and repair the open circuit in the wire 2096. If no open
circuit can be found in the wire 2096, check for voltage drop to 0 volt when a metal detection
is simulated while the wire 2096 is disconnected. If correct, try with new AOM printed circuit
of known performance. If not correct, try new EMD electronic module of known perform-
ance.

279 EMD POWER FAILURE Medium
Explanation : This error code is generated when the (classical) output signal is low (0V) for more than 60
seconds, while at the same time there are no CAN--messages for more than 60 seconds
either.
Possibly there is no power to the metal detector at all, or the power was interrupted.
Action : Check fuse F4.
Check continuity in wire 2094 (power supply).
Check continuity in wire 2096 (classic output line) and the continuity in wires 2097 and 2098
(CAN network lines).
(See flow chart)
Fuse F4 Yes
burned?
No
Replace fuse F4.
Disconnect wire 2094 and 2095
in central box and at metal de-
tector.
Check for:
Frame short circuit,
Short circuit to 12 V.
Open or short Yes

circuit?
No
Reconnect wires 2094 and 2095 Repair open or short circuit.

correctly.
Reconnect wires 2094 and

Disconnect wires 2096, 2097 2095 correctly.
and 2098 in central box and at
metal detector.
Check for:
Frame short circuit.
Open or short Yes

circuit?
No
Repair open or short circuit.
Reconnect wires 2096, 2097
and 2098 correctly.
Reconnect wires 2096,

Download the correct software. 2097 and 2098 correctly.
Problem solved?
No
Try with new electronic board

(A20) or a new metal detector
electronic Module.
301 DASHBOARD SWITCH 1 Medium
Explanation : Malfunction of the high capacity hydraulics rocker switch (1st dashboard switch).
Action : Replace switch. If problem persists, replace complete dashboard.
In case of several dashboard switch error reports, check all flat cables inside dashboard.

Explanation : Malfunction of the harvest function tumbler switch (2nd dashboard switch).

Explanation : Malfunction of the metal detector rocker switch (3rd dashboard switch).

Explanation : Not used
Action :
Explanation : Malfunction of the auto--pilot main switch (5th dashboard switch).

Explanation : Malfunction of the silage additive applicator tumbler switch (6th dashboard switch).

Explanation : Malfunction of the operating lights tumbler switch (7th dashboard switch).

Explanation : Malfunction of the beacon tumbler switch (8th dashboard switch).

Explanation : Malfunction of the power reverse tumbler switch (9th dashboard switch).
Explanation : Malfunction of the main Adjust--O--Matic tumbler switch (10th dashboard switch).

Explanation : Malfunction of the cutterhead reverse drive switch (11th dashboard switch).

Explanation : Malfunction of the crop processor roll clearance switch (12th dashboard switch).

Explanation : Not used
Action :

Explanation : Malfunction of the cutterhead drive tumbler switch (14th dashboard switch).
Explanation : Malfunction of the 4--wheel drive tumbler switch (15th dashboard switch).

Explanation : Malfunction of the throttle control rocker switch (16th dashboard switch).

330 HANDLE SWITCH 1 ^ Medium
Explanation : Malfunction of the feed rolls forward engagement switch (1st handle switch, up).
Action : Check connections on the vertical handle print. If correct, try another handle with known
performance. If correct, replace handle.

331 HANDLE SWITCH 1 v Medium
Explanation : Malfunction of the feed rolls stop switch (1st handle switch, down).
Action : Check connections on the vertical handle print. If correct, try another handle with known
performance. If correct, replace handle.

332 HANDLE SWITCH 2 < Medium
Explanation : Malfunction of the spout left switch, slow speed.
Action : Check connections on vertical handle print. If correct, try another handle with known per-
formance. If correct, replace handle.
333 HANDLE SWITCH 2 > Medium
Explanation : Malfunction of the spout right switch, slow speed.

334 HANDLE SWITCH 2^ Medium
Explanation : Malfunction of the spout deflector up switch.

335 HANDLE SWITCH 2v Medium
Explanation : Malfunction of the spout deflector down switch.

336 HANDLE SWITCH 2<< Medium
Explanation : Malfunction of the spout left switch, fast speed.

337 HANDLE SWITCH 2>> Medium
Explanation : Malfunction of the spout right switch, fast speed.
338 HANDLE SWITCH 3^ Medium
Explanation : Malfunction of the attachment up switch (3rd handle switch, up).

339 HANDLE SWITCH 3v Medium
Explanation : Malfunction of the attachment down switch (3rd handle switch, down).

340 HANDLE SWITCH 4 Medium
Explanation : Malfunction of the quick--stop handle switch (4th handle switch).

Explanation : Malfunction of the auto--pilot handle switch (5th handle switch).

Explanation : Malfunction of the automatic attachment height control switch (6th handle switch).
343 HANDLE SWITCH 1vv Medium
Explanation : Malfunction of the feed rolls reverse switch (1st handle switch, down -- down).

350 GROUND SPEED POT--M. Medium
Explanation : Malfunction of the ground speed potentiometer of the multi--function lever.
Action :
Check connectors at po-
tentiometer and vertical No Repair connections.
handle printed circuit.
Connections correct?
Yes
Check potentiometer fix- No Fixate potentiometer

ation with small gear
with gear.
Fixation correct?
Yes
Check potentiometer
value on CANSPY page
1282 word 3 digit 3 & 4.
Is value between range of No Readjust Neutral potentio-
48--71 (5C ± 20) at the mo- meter value
ment the neutral position
switch leaves the neutral
position (from 1 to 2)
Yes
Check potentiometer
value on CANSPY for full No Check potentiometer No Try with new potentio-
forward and reverse posi- manually does resistance meter
tion. Is value between 00 -- change correct?
DO ± 10?
Yes
Replace vertical handle

prinked circuit
351 STOP GROUND SPEED SW Medium
Explanation : Malfunction of the neutral position switch of the multi--function lever.
Action :
Check connections at
neutral position switch and No Repair connections.
Handle printed circuit
Connections correct?
Yes
Check neutral position No Improve adjustment of

switch adjustment the neutral position
Adjustment correct? switch
Yes
Check neutral position on

CANSPY page 1282, word
3 digit 2.
When moving the handle
Does the value “0“ ap-
pears?
Yes
Test out the switch man-

ually. No Replace neutral position
(Test normal open 2 Nor- switch.
mal closed positions
switch correct?
Yes
Replace vertical handle

printed circuit.
360 NO ENGINE OIL PRESS. Medium
Explanation : The engine oil pressure contact stays closed for more than 5 seconds after the engine is
started, as if the engine oil pressure stays low.
Check for shorted circuit to ground in wire 56--GN. If shorted circuit is found, repair first. If
no shorted circuit can be found, replace the engine oil pressure switch.

361 OIL PRESS SENS FAULT Medium
Explanation : The engine oil pressure contact is open, as if high engine oil pressure is detected, before
the engine is started.
Check for open circuit in wire 56--GN. If open circuit is found, repair first. If no open circuit
can be found, the replace the engine oil pressure switch.

362 NO HYDROST. PRESSURE Medium
Explanation : The hydrostatic oil pressure contact stays closed for more than 5 seconds, after the engine
is started, as if the hydrostatic oil pressure stays low.
Check for shorted circuit to ground in wire 58--GN. If shorted circuit is found, repair first. If
no shorted circuit can be found, replace the hydrostatic oil pressure switch.

363 HYDROST. SENSOR FAULT Medium
Explanation : The hydrostatic oil pressure contact is open, as if high hydrostatic oil pressure is detected,
before the engine is started.
Check for open circuit in wire 58--GN or wire 041--ZW. If open circuit is found, repair first.
If no open circuit can be found, replace the hydrostatic oil pressure switch.
364 CAT OIL TEMP. SENSOR Medium
Explanation : The CAT engine oil temperature sensor is open for app. 5 minutes after the engine is
started, as if high engine oil temperature is detected.
Only valid for FX58.
Action : Refer to the wiring diagram: sensor R51, line 7380.
Check for open circuit in wire 2183--GN. If open circuit is found, repair first. If no open circuit
can be found, replace the CAT engine oil temperature sensor.

370 COVER CUTTERHEAD EOT Medium
Explanation : Power was supplied to the sharpening cover electric motor but the sharpening cover did
not arrive to its home (closed) position.
Action : Refer to wiring diagram: sharpening cover closed limit switch S82
Readjust sharpening cover limit switch. Make sure the limit switch S82 (wires 2092--gn and
2093--bl) in the sharpening cover electric motor is open when the sharpening cover is
closed.
If error messages 370 and 483 appears together, repair first error message 483.

371 AOM POWER FAILURE Medium
Explanation : Fuse (F18) to power AOM printed circuit is blown.
Action : Replace Fuse F18 in central box. If problem persists, check connections of fuse holder with
the fuse printed circuit. If problem persists, try with other AOM printed circuit of known per-
formance.
400 CROP PROC.DIST. ACT. Medium
Explanation : Crop processor distance electric motor is open or shorted.
: NO”.
If the crop processor is installed, refer to the wiring diagram: Motor M21, line 4270.
Check CP mechanical
components CAN CP No Repair, grease or clean
been turned manually by CP mechanical compo-
key? nents.
Yes
Open connector at the CP Check for open or

electric motor check for shorted circuit in wires Try new actuator printed
No No
battery voltage at the con- 2052--gn and 2053--wt circuit with known per-
nector arriving from cen- open or shorted circuit? formance (A40)
tral box when the CP
switch is pressed.
(Select Harvest Mode
first) 12V measured
Locate and repair open or
shorted circuit
Yes
Power electric motor from

separate battery (Insert No
fuse in power cables.) Replace CP electric motor
Motor functioning?
Yes
Reconnect everything and

try again.
401 SPOUT DEFLECTOR ACT. Medium
Explanation : Spout deflector actuator or solenoid is open or shorted.
Action : Refer to the wiring diagram:
Motor M20, line 4600 for machines with electric deflector.
Hydraulic valve Y45 and Y46 for machines with hydraulic deflector.
Machines where spout deflector is moved by electric actuator (M20).
Machines where spout deflector is moved by hydraulic cylinder.
Open connector at spout Check for open or

deflector actuator. Check shorted circuit in wires Try new actuator printed
No No
for battery voltage at the 2039--wt and 2040--gr. circuit with known perfor-
connector when the spout Open or shorted circuit? mance
deflector switches are
pressed. 12V measured? Yes
Locate and repair open or

Yes shorted circuit
Power electric actuator

from separate battery (in- No
Replace spout deflector
sert fuse in power cables).
Motor functioning? actuator
Yes
Try again
Open both connectors at Check for open or shorted

electro valves on low pres- circuit in wiring loom where
sure valve. Check for bat- there was no battery volt- Try new actuator printed
tery voltage at both con- No age measured. No
circuit with known perform-
nectors when the correct 1. 2039--wt and 2030--zw ance
spout deflector switch is 2. 2040--gr and 2030--zw
pressed. 12V measured Open or shorted circuit
on both connectors? found?
Yes Yes
Check Hydraulic circuit Locate and repair open or

shorted circuit
420 HYDROSTATIC PUMP O Medium
Explanation : The hydrostatic pump is not functioning due to open circuit.
Action : Refer to wiring diagram: electro valve Y28, line 700.
Disconnect electro valve on hydrostatic pump and check for coil resistance of 24 Ohm. If
not correct, replace electro valve on hydrostatic pump. If correct, check for open circuit in
wires 394--wt and 395--gr. If open circuit is found, repair open circuit, otherwise try with new
Adjust--O--Matic printed circuit of known performance.

421 HYDROSTATIC PUMP -- Medium
Explanation : The hydrostatic pump is not functioning due to shorted circuit.
not correct, replace electro valve on hydrostatic pump. If correct, check for shorted circuit
or shorted circuit to ground in wires 394--wt and 395--gr. If shorted circuit is found, repair
shorted circuit, otherwise try with new Adjust--O--Matic printed circuit of known perform-
ance.

422 HYDROSTATIC PUMP + Medium
Explanation : The hydrostatic pump is not functioning due to shorted circuit to external 12 V power sup-
ply.
not correct, replace electro valve on hydrostatic pump. If correct, check for shorted circuit
to 12 V in wires 394--wt and 395--gr. If shorted circuit is found, repair shorted circuit, other-
wise try with new Adjust--O--Matic printed circuit of known performance.
440 AIRCONDITION. CLUTCH Medium
Explanation : The air conditioning electric clutch is open or shorted.
Action : Refer to wiring diagram: electric clutch Y27, line 9340.
If no air conditioning is installed on the machine, recalibrate the air conditioning option by
means of the PDT or PC calibration program.
If air conditioning is installed, disconnect the air conditioning clutch Y27. Check for battery
voltage at Y27 while the air conditioning is activated.
If no battery voltage can be measured, locate and repair the open or shorted circuit in wire
401--wt. If no open or shorted circuit can be found, try new lights printed circuit of known
performance.
If battery voltage is measured at the end connector, power the electric clutch with separate
battery (insert fuse in power cable). If the clutch is not functioning, try new electric clutch
Y27 of known performance. If the clutch can be activated with separate battery, connect
everything and try again.

446 ROTARY SCREEN MOTOR Medium
Explanation : The rotary screen electric motors are open or shorted.
Action : Refer to wiring diagram: electric motors M26 and M27, line 4780.
If no rotary screens are installed on the machine, recalibrate the rotary screen option by
means of the PDT or PC calibration program.
If rotary screens are installed, disconnect both connectors at rotary screen motors. Check
for battery voltage at M26 and M27 the engine is running.
2147--wt and/or 2149--wt. If no open or shorted circuit can be found, try new actuator printed
circuit of known performance.
If battery voltage is measured at the end connectors, power the electric motors with separ-
ate battery (insert fuse in power cable). If one or more rotary screen motor is not functioning,
try new electric motor of known performance. If both electric motors can be activated with
separate battery, connect everything and try again.
453 SPOUT RIGHT HYDR.SOL Medium
Explanation : The solenoid of the spout right rotation hydraulic valve is open or shorted.
Action : Refer to wiring diagram : hydraulic valve Y33, line 4570.
Disconnect the solenoid Y33 on the stack valve. Check for battery voltage at Y33 while the
spout right fast rotation switch is pressed.
2005--wt and/or wire 2006--zw. If no open or shorted circuit can be found, try new hydraulic
printed circuit of known performance.
If battery voltage is measured at the end connector, check coil resistance of the solenoid
(a resistance of app. 4 ohm should be measured) or eventually power the solenoid with sep-
arate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic
valve Y33 of known performance. If the coil resistance is correct and the hydraulic valve
is functioning, connect everything and try again.

454 SPOUT LEFT HYDR.SOL Medium
Explanation : The solenoid of the spout left rotation hydraulic valve is open or shorted.
Action : Refer to wiring diagram : hydraulic valve Y32, line 4550.
spout left fast rotation switch is pressed.
455 REAR HYDR. DOWN SOL. Medium
Explanation : The solenoid of the rear hydraulics down valve is open or shorted.
Action : Refer to wiring diagram : solenoid Y37, line 3900.
If no rear auxiliary hydraulics is installed on the machine, recalibrate the rear auxiliary hy-
draulics option by means of the PDT or PC calibration program.
If rear auxiliary hydraulics is installed, disconnect the solenoid Y37 on the stack valve.
Check for battery voltage at Y37 while the rear hydraulics down valve is activated.

456 REAR HYDR. UP SOL. Medium
Explanation : The solenoid of the rear hydraulics up valve is open or shorted.
If no rear auxiliary hydraulics is installed on the machine, recalibrate the rear auxiliary hy-
If rear auxiliary hydraulics is installed, disconnect the solenoid Y36 on the stack valve.
Check for battery voltage at Y36 while the rear hydraulics up valve is activated.
457 MAIN DRIVE HYDR.SOL. Medium
Explanation : The solenoid of the main drive hydraulic valve is open or shorted.
Action : Refer to wiring diagram : solenoid (Y44) and Y40, line 3430.
Disconnect the solenoid Y40 on the low pressure valve. Check for battery voltage at Y40
while the engine is running and the cutterhead is engaged.
(a resistance of app. 3--10 ohm should be measured) or eventually power the solenoid with
separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic

458 4 WHEEL DRIVE SOLEN. Medium
Explanation : The 4 wheel drive solenoid is open or shorted.
If no 4 wheel drive is installed on the machine, recalibrate the 4 wheel drive option by means
of the PDT or PC calibration program.
If 4 wheel drive is installed, disconnect the solenoid Y22 on the low pressure valve. Check
for battery voltage at Y22 while the 4 wheel drive is activated.
(a resistance of app. 3--10 ohm should be measured) or eventually power the solenoid with
separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic
459 SPOUT DOWN HYDR.SOL. Medium
Explanation : The solenoid of the spout down hydraulic valve is open or shorted.
spout down switch is pressed.
2017--gr and/or wire 2018--zw. If no open or shorted circuit can be found, try new hydraulic

460 SPOUT UP HYDR.SOL. Medium
Explanation : The solenoid of the spout up hydraulic valve is open or shorted.
spout up switch is pressed.
2015--gr and/or wire 2016--zw. If no open or shorted circuit can be found, try new hydraulic
461 REVERSER CUTTERHEAD Medium
Explanation : The solenoid of the reverse cutterhead hydraulic valve is open or shorted.
cutterhead reverse switch is switched on (harvest function activated).

463 REVERSE FEEDINGROLLS Medium
Explanation : The feed rolls reverse electro magnetic clutch is open or shorted.
Action : Refer to wiring diagram : electric clutch Y43, line 3510.
On machines build before season ’99 (up to serial number 5080), the feed rolls reverse out-
put is located on the hydraulic printed circuit. On machines build from season ’99 onwards
(serial number 5083 onwards), the feed rolls reverse output is located on the actuator
printed circuit. If the machine is installed with software revision REV99 or later, recalibrate
first the new ’stromag feed rolls engagement clutch’ option by means of PDT or PC calibra-
tion program.
If problem persists after recalibration, disconnect the electric clutch Y43. Check for bat-
tery voltage at Y43 while the feed rolls reverse output is activated (harvest function acti-
vated).
printed circuit on machines before season ’99 or try new actuator printed circuit on ma-
chines from season ’99 onwards.
If battery voltage is measured at the end connector, check coil resistance of the electric
clutch (a resistance of app. 1--2 ohm should be measured for the Stromag clutch) or event-
ually power the electric clutch with separate battery (insert fuse in power cable). If the clutch
is not functioning, try new electro magnetic clutch Y43 of known performance. If the coil re-
sistance is correct and the electro magnetic clutch is functioning, connect everything and
try again.
464 FRONT HYDR. UP SOL. Medium
Explanation : The solenoid of the front hydraulics up valve is open or shorted.
front hydraulics up valve is activated.

465 FRONT HYDR. DOWN SOL Medium
Explanation : The solenoid of the front hydraulics down valve is open or shorted.
front hydraulics down valve is activated.
467 HIGH CAP.HYDR.UP SOL Medium
Explanation : The solenoid of the high capacity up hydraulic valve is open or shorted.
If no high capacity hydraulics is installed on the machine, recalibrate the high capacity hy-
If high capacity hydraulics is installed, disconnect the solenoid Y49 on the hydraulic. valve.
Check for battery voltage at Y49 while the high capacity up hydraulic valve is activated.
(for open or shorted circuit) or eventually power the solenoid with separate battery (insert
fuse in power cable). If the valve is not functioning, try new hydraulic valve Y49 of known
performance. If the hydraulic valve is functioning, connect everything and try again.

468 HIGH CAP.HYDR.DO SOL Medium
Explanation : The solenoid of the high capacity down hydraulic valve is open or shorted.
If no high capacity hydraulics is installed on the machine, recalibrate the high capacity hy-
If high capacity hydraulics is installed, disconnect the solenoid Y50 on the hydraulic valve.
Check for battery voltage at Y50 while the high capacity down hydraulic valve is activated.
(for open or shorted circuit) or eventually power the solenoid with separate battery (insert
fuse in power cable). If the valve is not functioning, try new hydraulic valve Y50 of known
performance. If the hydraulic valve is functioning, connect everything and try again.
482 FEEDROLL FORW. CLUTCH Medium
Explanation : The feed rolls forward electro magnetic clutch is open or shorted.
Action : Refer to wiring diagram : electric clutch Y41, line 3490.
Disconnect the electric clutch Y41. Check for battery voltage at Y41 while the feed rolls for-
ward output is activated (machine started, cutterhead engaged).
2023--wt and/or wire 2030--zw. If no open or shorted circuit can be found, try new Adjust--
O--Matic printed circuit with known performance.
clutch (a resistance of app. 1--2 ohm should be measured for the Stromag clutch) or event-
ually power the electric clutch with separate battery (insert fuse in power cable). If the clutch
is not functioning, try new electro magnetic clutch Y41 of known performance. If the coil re-
sistance is correct and the electro magnetic is functioning, connect everything and try
again.

483 COVER CUTTERH. MOTOR Medium
Explanation : Sharpening stone cover electric motor is open or shorted.
Action : Refer to wiring diagram : electric motor M22, line 5300.
Disconnect the electric motor M22. Check for battery voltage at M22 while the cover motor
is activated (e.g. open cover for inspection).
2062--wt and/or wire 2063--gr. If no open or shorted circuit can be found, try new Adjust--
motor (a resistance of app. 0.4--1 ohm should be measured) or eventually power the electric
clutch with separate battery (insert fuse in power cable). If the motor is not functioning, try
new electric motor M22 of known performance. If the coil resistance is correct and the elec-
tric motor is functioning, connect everything and try again.
484 ACTIVE PAWL SOLENOID Medium
Explanation : The active pawl solenoid is open or shorted.
Disconnect the solenoid Y42. Check for battery voltage at Y42 while the quick stop switch
is pressed.
2025--wt and/or wire 2026--zw. If no open or shorted circuit can be found, try new Adjust--
O--Matic printed circuit with known performance. Check also diode V24.
If battery voltage is measured at the end connector, power the solenoid clutch with separate
battery (insert fuse in power cable). If the solenoid is not functioning, try new solenoid Y42
of known performance. If the solenoid is functioning, connect everything and try again.

485 AOM MOTOR L FAILURE Medium
Explanation : The shearbar left--hand adjuster electric motor is open or shorted.
Disconnect the electric motor M24. Check for battery voltage at M24 while the left AOM
electric motor is activated (e.g. during full pull).
486 AOM MOTOR R FAILURE Medium
Explanation : The shearbar right--hand adjuster electric motor is open or shorted.
Disconnect the electric motor M25. Check for battery voltage at M25 while the right AOM
electric motor is activated (e.g. during full pull).

487 SHARP MOTOR FAILURE Medium
Explanation : Sharpening stone electric motor is open or shorted.
Disconnect the electric motor M23. Check for battery voltage at M23 while the sharpening
stone motor is activated.

488 OUT OF STONE Medium
Explanation : The electronic system detected a worn sharpening stone.
Action : Readjust sharpening stone in holder, if necessary replace sharpening stone and/or readjust
magnetic sensor B108.
489 CUT.KNIVES WORN DOWN Medium
Explanation : The electronic system detected one or more worn knives.
Action : 1. The shearbar has travelled to its rearmost position and needs readjusting. Clean space
between shearbar and scraper, and adjust shearbar forward by means of the full pull
procedure. Subsequently adjust the cutterhead knives.
Or
2. The space between the shearbar and the cutterhead frame is filled with dirt and crop.
Move the shearbar away from the cutterhead (full pull) and remove the dirt/crop be-
tween shearbar and cutterhead frame.

490 AOM NOISE TOO HIGH Medium
Explanation : The electronic system detected a too high AOM noise at the beginning or during the shear-
bar procedure.
Action : Reduce or increase the engine speed. If this does not help, search machine for loose parts
generating a hammering noise. If problem remains unsolved, check and replace if necess-
ary cutterhead bearings.
Refer to wiring diagram : AOM sensors B106 and B50, line 6230.
Check for open or shorted circuit in wiring loom to AOM sensors, wires 2058--gn and/or
2059--bl. On machines from season ’99, two AOM sensors are installed in parallel.
If problem remains unsolved, try first with new AOM sensor(s) and later with new Adjust--
O--Matic printed circuit of known performance.

545 FUEL LEVEL SENS -- Low
Explanation : Fuel level potentiometer is shorted to ground.
Action : Refer to wiring diagram : sensor B12, line 7420.
Disconnect fuel level sensor and check resistance range of sensor between 3 and 350
Ohm. If not correct, try with new sensor of known performance.
If correct, locate and repair shorted circuit to ground in the wire 291--gn.
If problem remains unsolved, try with new CPU printed circuit of known performance.
546 FUEL LEVEL SENS O/+ Low
Explanation : Fuel level potentiometer disconnected or shorted to external power supply.
Disconnect fuel level sensor and check resistance range of sensor between 3 and 350
Ohm. If not correct, try with new sensor of known performance.
If correct, locate and repair open circuit or shorted circuit to 12 Volt in wires 291--gn and/or
292--zw.
If problem remains unsolved, try with new CPU printed circuit of known performance.

550 ENGINE TEMP SENS -- Low
Explanation : Engine coolant temperature sensor shorted to ground
Locate and repair shorted circuit to ground in the wire 290--gn.
If problem remains unsolved, try first with new engine coolant temperature sensor and later
with new CPU printed circuit of known performance.

551 ENGINE TEMP SENS O/+ Low
Explanation : Engine coolant temperature sensor disconnected or shorted to external power supply.
Locate and repair open circuit to shorted circuit to 12 Volt in the wire 290--gn.
If problem remains unsolved, try first with new engine coolant temperature sensor and later
with new CPU printed circuit of known performance.
ATTACHMENT HEIGHT CONTROL ERROR
MESSAGES
The blinking sequence of the red self--diagnostic

control light identifies an error report.
The blinking sequence always consists of 2 periods

separated by a short interval. Then, after a longer in-
terval, the blinking sequence will repeat again.
The first period indicates the first digit of the error re-
port, the second period indicates the second digit.
Example
Error report 23
52002
General Information:
After repair, most of the attachment height control
error reports must be cleared by switching off the
ignition.
Error reports
Code 11 Connector X57 Pin 37 -- (35)

Explanation
Open circuit of the power line to the attachment height control module A60 (fuse F17).
Or output failure of the attachment height control module A60.
Remarks: If the open circuit occurs before the attachment lift solenoid was activated, then error 14
appears.
Action
Refer to the wiring diagram: line 6980.
Check for 12 Volts at X57/29 of the attachment height control module A60. If not correct, locate and
repair open circuit at fuse F17 or wiring 1030 rd.
If the previous step was correct, replace the attachment height control module A60.
Code 12 Connector X57 Pin 19 -- (35)

Explanation
Open circuit of the power line to the attachment height control module A60 (fuse F17).
Or output failure of the attachment height control module A60.
Remarks: If the open circuit occurs after the attachment lowering solenoid was activated, then error
14 appears.
Action
Check for 12 Volts at X57/29 of the header height control module A60. If not correct, locate and re-
pair open circuit in fuse F17 or wire 1030 rd.
If the previous step was correct, replace the header height control module A60.
Code 13 ... Pin 35 -- (37) -- (19)

Explanation
Shorted circuit of the wires from the attachment height control module A60 to the attachment lift and/
or lowering solenoid. This shorted circuit may blow fuse F17.
Remarks: A shorted circuit to the common ground wire will create error 13 and cuts off the power
automatically. A shorted circuit to the frame creates no error and will blow up the fuse
F17.
Action
Locate and repair the shorted circuit in the wires 226 gr and/or 227 Wt, or at the lowering (Y19) and/
or lift solenoid (Y20).
Code 14 ... Pin 35 -- (37) -- (19) -- (29)
Explanation
No current coming back from the attachment lift or lowering solenoids at the attachment height con-
trol connector X57/35. This can be due to:
-- Open circuit at the solenoid wires
-- Solenoid failure.
-- No input power at the attachment height control module connector X57/29 (fuse F17).
-- Attachment height control module A60 failure.
Action
Refer to the wiring diagram: line 7030. Locate and repair open circuit in the wires 225 zw, 226 gn,
227 Wt or at the lowering (Y19) and lift solenoid. (Y20).
Check for 12 Volts at X57/29 of the attachment height control module A60. If not correct, locate and
repair open circuit in fuse F19 or wire 235 Rd.
If all previous steps were correct, replace the attachment height control module A60.
Code 15 ... Pin 9

Explanation
The common power wire to the attachment height control switches is shorted to the ground or to an
external 12 Volts power supply.
Remark: The Attachment height control switches are simulated by the actuator printed circuit on
wires 209 wt, 210 wt, 211 wt and 212 wt.
Common power wire: 209 -- wt
fast speed wire: 212 -- wt
Header down wire: 210 -- wt
Header up wire: 211 -- wt
Action
Locate and repair shorted circuit in the wire 209 Wt of the attachment height control switches.
Code 16 ... Pin 2 -- 20

Explanation
Open or shorted to ground wires of the attachment control selector switch (S35).
Remark: The attachment control selector switch S35 is simulated by the actuator printed circuit on
wires 214--bl, 221--br, 222--gn.
common power wire: 214--bl
selector switch wires: 221--br and 222--gn
Action
Refer to the wiring diagram: line 7160. Locate and repair open circuit or shorted circuit in the wires
214 Bl, 221 Br and/or 222 Gn (together with error 18).
Remark: Shorted circuit in wire 221 Br will lock the attachment height control without error messages.
Code 17 ... Pin 29
Explanation
Battery voltage higher than 18 Volts.
Action
Check and repair the alternator regulator.
Code 18 ... Pin 21

Explanation
Incorrect signal from the attachment control selector switch S35 due to open wire or shorted to an
unacceptable external power supply.
Action
If error 18 is accompanied of error 16, locate and repair open circuit in wire 222 Gn.
If not, locate and repair shorted circuit to 12 Volt at wire 222 -- Gn.
Refer to the header lift trouble shooting section for correct voltages at the header control module
connector X57/21.
Code 21 ... Pin 6

Explanation
Incorrect signal from the attachment height sensor R4.
Action
Check attachment height sensor R4 adjustment and recalibrate the attachment height control (Info
View Calibration).
Locate and repair open circuit in wires 228 Bl or 238 Br.
Remark: open circuit in sensor information wire 229 Gn will not create an error report.
Or locate and repair shorted circuit to ground in the sensor information wire 229 Gn.
Remark: shorted circuit to ground of the wire 238 Br will lock to attachment height control
without creating a error report; Each time the sorted circuit is interrupted, both con-
trol lights (green and red) will blink to start up the attachment height control.
Or replace the header height sensor R4.
Code 22 ... Pin 22

Explanation
Incorrect signal from the stubble height potentiometer R6.
Remark: The stubble height potentiometer R6 Voltage is simulated by the actuator printed circuit
on wire 216 gn.
Action
Locate and repair open circuit in wire 216 Gn.
Remark: shorted circuit to ground of the wire 216 Gn will not create an error report but will unable
the stubble height control.
Code 23 ... Pin 8
Explanation
Incorrect signal from the attachment lift cylinder oil pressure sensor B13.
Action
Locate and repair open circuit in wires 236 Bl or 238 Br.
Remark: open circuit in sensor information wire 229 Gn will not create an error report.
Or locate and repair shorted circuit to ground in the sensor information wire 237 Gn.
Remark: shorted circuit to ground of the wire 238 Br will lock to attachment height control
without creating a error report. Each time the sorted circuit is interrupted, both con-
trol lights (greeen and red) will blink to start up the attachment height control.
Or replace the oil pressure sensor B13.
Code 24 ... Pin 5

Explanation
Incorrect signal from the compensation potentiometer R7.
Remark: the compensation potentiometer R7 Voltage is simulated by the actuator printed circuit on
wire 2176 zw (X57/05).
Action
Locate and repair open circuit in wire 217 Gn.
Remark: shorted circuit to ground of the wire 217 Gn will not create an error report but will unable
the compensation control.
Code 25 ... Pin 3 -- 36

Explanation
The attachment fast moving switch was activated before the lift or lowering switch was activated.
Remark: The attachment height control switches are simulated by the actuator printed circuit on wires
209 -- wt, 210 --wt, 211 -- wt and 212 -- wt. This means Voltage on wire 212 -- wt arrives be-
fore voltage on wire 210 -- wt or 211-- wt at attachment height control module A60.
Action
Refer to the wiring diagram: line 7090. Locate and repair open circuit in wire 210 Wt or 211 Wt.
Or replace the header lift/lowering switches.
Code 33 ... Pin 27

Explanation
Shorted to ground circuit at the automatic switch S30.
Action
If the error 33 appears after ignition and activating the automatic switch S30, locate and repair
shorted circuit to ground in wire 208 Wt (from the header height module A3 connector X57/13).
Code 35 ... Pin 29
Explanation
Battery voltage lower than 10 Volts.
Action
Recharge battery or check alternator and repair if necessary.
Code 36
Explanation
Failure of the hydraulic header lift control valve. Electrical components are correct.
Action
Clean the hydraulic spools or replace the hydraulic control valve.
CATERPILLAR ERROR MESSAGES
Error Description CID--FMI Flash CAN--ID

Nr Code Page 1353
Cylinder 1 Fault 1--11 72 Word 2 : 8===
Cylinder 5 Fault 5--11 74 Word 2 : =8==
Cylinder 6 Fault 6--11 74 Word 2 : =4==
Check Timing Sensor Calibration 22--13 42 Word 2 : =2==
8 Volt Supply Above Normal 41--03 21 Word 2 : =1==
8 Volt Supply Below Normal 41--04 21 Word 2 : ==8=
Invalid Throttle Signal 91--08 32 Word 2 : ==4=
Throttle Sensor Calibration 91--13 28 Word 2 : ==2=
Low Fuel Pressure Warning 94--01 -- Word 2 : ==1=
Fuel Pressure Sensor Open Circuit 94--03 37 Word 2 : ===8
Fuel Pressure Sensor Short Circuit 94--04 37 Word 2 : ===4
Low Oil Pressure Warning 100--01 -- Word 2 : ===2
Oil Pressure Sensor Open Circuit 100--03 24 Word 2 : ===1
Oil Pressure Sensor Short Circuit 1100--04 24 Word 3 : 8===
Very Low Oil Pressure 100--11 -- Word 3 : 4===
Boost Pressure Reading Stuck High 102--00 25 Word 3 : 2===
Boost Pressure Sensor Open Circuit 102--03 25 Word 3 : 1===
Boost Pressure Sensor Short Circuit 102--04 25 Word 3 : =8==
High Inlet Manifold Temperature Warning 105--00 -- Word 3 : =4==
Inlet Manifold Temp Sensor Open Circuit 105--03 38 Word 3 : =2==
Inlet Manifold Temp Sensor Short Circuit 105--04 38 Word 3 : =1==
Very High Inlet Manifold Temperature 105--11 -- Word 3 : ==8=
Atmospheric Pressure Sensor Open Circ 108--03 26 Word 3 : ==4=
Atmospheric Pressure Sensor Short Circ 108--04 26 Word 3 : ==2=
High Coolant Temperature Warning 110--00 -- Word 3 : ==1=
Coolant Temperature Sensor Open 110--03 27 Word 3 : ===8
Coolant Temperature Sensor Short 110--04 27 Word 3 : ===4
Error Description CID--FMI Flash CAN--ID
Nr Code Page 1353
Very High Coolant Temperature 110--11 -- Word 3 : ===2
Low Coolant Level Warning 111--01 -- Word 3 : ===1
Intermittent Battery 168--02 51 Word 4 : 8===
High Fuel Temperature Warning 174--00 -- Word 4 : 4===
Fuel Temperature Sensor Open Circuit 174--03 13 Word 4 : 2===
Fuel Temperature Sensor Short Circuit 174--04 13 Word 4 : 1===
Engine Overspeed Warning 190--00 35 Word 4 : =8==
Loss of Engine RPM Signal 190--02 34 Word 4 : =4==
5 Volt Supply Above Normal 232--03 21 Word 4 : =2==
5 Volt Supply Below Normal 232--04 21 Word 4 : =1==
Incorrect Engine Software 252--11 59 Word 4 : ==8=
Personality Module Fault 252--12 -- Word 4 : ==4=
Check Customer or System Parameters 253--02 56 Word 4 : ==2=
LIST OF CAN IDENTIFIERS
Identifier Function Comments

Page Number
1275 Data from metal detector to central box Magn noise, thresholds, detection
1276 Data from metal detector to central box Hardw & softw level, peak values,
1277 Data from central box to metal detector Not used
1278 Data from central box to metal detector Switch status, fixed thresholds
1279 Not used
1280 Not available for user Used during PC -- calibrations
1281 Not available for user Used for supplier testing
1282 Multifunction lever inputs
1283 Dashboard switches inputs
1284 Not used
1285 Not used
1286 AOM panel on dashboard inputs
1287 Armrest module inputs
1288 Ground speed
1289 Engine rpm
1290 Crop processor rpm
1291 Not used
1292 Not used
1293 Cutterhead rpm
1294 Not used
1295 Not used
1296 Not used
1297 Not used
1298 Not used
1299 Not used
1300 Not used
1301 Missed metal detection date
1302 Not available for user
1303 CPU print inputs and outputs
1304 Adjust--o--Matic inputs and outputs
Page Number
1305 Total cutterhead and engine hours
1306 Total hectares
1307 Not used
1308 Not used
1309 Not used
1310 Not used
1311 Not used
1312 Not used
1313 Header height, ground press, CP rolls
1314 Dashboard leds
1315 Adjust--o--Matic leds on dashboard
1316 Not used
1317 Header height control leds
1318 Fuel level and engine temperature
1319 Limb home and Adjust--o--Matic
1320 Not available for user Used for internal communication
1325 Not used
1326 Software revisions (node A and S)
1327 Date and time
1328 Not available for user Used for softw download to EMD
1329 Not available for user Used for softw download to EMD
1330 Not used
1331 Memorised calibration data in node A Speed calibrations, serial nr
1332 Memorised calibration data in node B Speed calibrations, serial nr
1333 Not used
1334 Memorised calibration data in node D Speed calibrations, serial nr
1335 Not available for user Used for plant testing
Page Number
1339 Memorised calibration data in node A PC calibrations (auto--voting)
1340 Memorised calibration data in node B PC calibrations (auto--voting)
1341 Not used
1342 Memorised calibration data in node D PC calibrations (auto--voting)
1343 Memorised calibration data in node A PC calibrations (auto--voting)
1344 Memorised calibration data in node B PC calibrations (auto--voting)
1345 Memorised calibration data in node D PC calibrations (auto--voting)
1346 Not used
1347 CPU print outputs
1348 CPU print outputs
1349 Adjust--o--Matic outputs
1350 Not used
1351 Not used
1352 Caterpillar engine
1353 Caterpillar engine
CAN ID Group Data Description word1 word2 word3 word4 Comments
1276 Data from Metal detector to Central Box
1276 Metal detector Not used =8==
1276 Metal detector Run time test procedure In operation =1== =0== : not in operation
1276 Metal detector EMD hardware version ==XX
1276 Software EMD software version : node M XX== See software revisions
1276 Metal detector Error code 277 Set ==8= ==0= : not set
1276 Metal detector Error code 273 Set ===8 ===0 : not set
1276 Metal detector Peak noise level left channel, + values XX== Limits : 00 < XX < 7F
1276 Metal detector Peak noise level left channel, -- values ==XX Limits : 00 < XX < 7F
1276 Metal detector Peak noise level right channel, + values XX== Limits : 00 < XX < 7F
1276 Metal detector Peak noise level right channel, -- values ==XX Limits : 00 < XX < 7F
1278 Identifier to Metal detector
1278 Metal detector Cutterhead disengaged Status 8=== 0=== : cutterhead engaged
1278 Metal detector Feed rolls stopped Status 6===
1278 Metal detector Feed rolls reverse Status 4===
1278 Metal detector Feed rolls forward Status 2===
1278 Metal detector Adaptive mode selected 1=== 0=== : Fixed mode selected
1278 Metal detector EMD threshold setting in fixed =X== = 0 when adaptive mode is selected
mode = 0 < X < 8 when fixed mode is selected
1278 Metal detector Forage harvester stopped Status ===6
1278 Metal detector Forage harvester driving back- Status ===4

wards
1278 Metal detector Forage harvester driving for- Status ===2

wards
1278 Metal detector Quick Adapt routine activated Status ===1 ===1 : Quick adapt routine started
1282 Input identifiers from Multifunction Lever
1282 Header Header down switch Pressed 8===
1282 Header Header down switch Not pressed 4===
1282 Feed rolls Feed rolls reverse switch Pressed 2===
1282 Feed rolls Feed rolls reverse switch Not pressed 1===
1282 Not used =8==
1282 Not used =4==
1282 Spout Spout fast right switch Pressed =2==
1282 Spout Spout fast right switch Not pressed =1==
1282 Header Header up switch Pressed ==8=
1282 Header Header up switch Not pressed ==4=
1282 Not used ==2=
1282 Not used ==1=
1282 Header Header height override switch Pressed ===8
1282 Header Header height override switch Not pressed ===4
1282 Feed rolls Feed rolls stop switch Pressed ===2
1282 Feed rolls Feed rolls stop switch Not pressed ===1
1282 Spout Spout slow left switch Pressed 8=== Attention : (also for spout right switch)
1282 Spout Spout slow left switch Not pressed 4=== When the fast switch is pressed,
1282 Spout Spout fast left switch Pressed 2=== also the slow switch is pressed.
1282 Spout Spout fast left switch Not pressed 1=== (internal structure of the multifunction lever)
1282 Spout Spout deflector up switch Pressed =8==
1282 Spout Spout deflector up switch Not pressed =4==
1282 Spout Spout deflector down switch Pressed =2==
1282 Spout Spout deflector down switch Not pressed =1==
1282 Auto--Pilot Auto--Pilot switch Pressed ==8=
1282 Auto--Pilot Auto--Pilot switch Not pressed ==4=
1282 Spout Spout slow right switch Pressed ==2=
1282 Spout Spout slow right switch Not pressed ==1=
1282 Quick stop Quick stop switch Pressed ===8
1282 Quick stop Quick stop switch Not pressed ===4
1282 Feed rolls Feed rolls forward switch Pressed ===2
1282 Feed rolls Feed rolls forward switch Not pressed ===1
1282 Ground speed Multifunction lever Out of neutral ===1 =2==
1282 Ground speed Multifunction lever In neutral =1==
1282 Ground speed Ground speed Potentiometer ==XX In neutral XX = 5C +/-- 20 or 48<XX<71
limits : 00 < XX < D0 +/-- 10
1283 Input Identifiers from Dashboard Switches
1283 Spout Spout up switch Pressed 8=== 0=== : switch not pressed ; 8=== : pressed
1283 Spout Spout down switch Pressed 4=== 0=== : switch not pressed ; 4=== : pressed
1283 Seat Seat switch Person on seat 2=== 0=== : switch open ; 2=== : switch closed
1283 Not used 1===
1283 Brakes Brakes pressure switch Sufficient press =8== =0== : switch open ; =8== : switch closed
1283 Brakes Brakes fluid level switch (for Insufficient fluid =4== =0== : switch open ; =4== : switch closed
brake lights)
1283 Not used =2==
1283 Not used =1==
1283 Not used ==8=
1283 Not used ==4= Airco switch is a combination of several switches
1283 Not used ==2= See troubleshooting -- air conditioning
1283 Airco Airco switch in cab Closed ==1= ==0= : switch open ; ==1= : switch closed
1283 Not used ===8
1283 Not used ===4
1283 CP Crop processor roll clearance Pressed ===2 ===0 : switch not pressed ; ===2 : pressed
open switch
1283 Brakes Parking brake switch Engaged ===1 ===0 : switch open ; ===1 : switch closed
1283 AOM Adjust--O--Matic main switch Switched ON 8=== 0=== : switched off
1283 Cutterhead Cutterhead reversing switch Switched OFF 4=== 0=== : switched on
1283 Power reverse Power reverse switch Switched ON 2=== 0=== : switched off
1283 CP Crop processor roll clearance Pressed 1=== 0=== : switch not pressed ; 1=== : pressed
close switch
1283 AOM Adjust--O--Matic main switch Switched OFF =8== =0== : switched on
1283 Cutterhead Cutterhead reversing switch Switched ON =4== =0== : switched off
1283 Power reverse Power reverse switch Switched OFF =2== =0== : switched on
1283 Not used =1==
1283 Acid plug Silage additive applicator main Switched ON ==8= ==0= : switched off
switch
1283 Lights Operating lights switch Switched OFF ==4= ==0= : switched ON to operating lights
1283 Auto--Pilot Auto--Pilot main switch Switched OFF ==2= ==0= : switched on
1283 Lights Operating lights switch (spot Switched ON ==1= ==0= : switched ON to operating lights
lights)
1283 Acid plug Silage additive applicator main Switched OFF ===8 ===0 : switched on
switch
1283 Lights Beacon lights switch Switched OFF ===4 ===0 : switched on
1283 Auto--Pilot Auto--Pilot main switch Switched OFF ===2 ===0 : switched on
1283 Lights Operating lights switch (spot Switched ON ===1 ===0 : switched ON to operating lights
lights)
1283 Harvest functs Harvest switch Switched ON 8=== = harvest mode ; 0=== : switched off
1283 Metal detector Metal detector on switch Pressed 4=== 0=== : not pressed
1283 High flow High flow hydraulics open Pressed 2=== 0=== : not pressed
switch
1283 Not used 1===
1283 Harvest functs Harvest switch Switched OFF =8== = road mode ; =0== : switched on
1283 Metal detector Metal detector off switch Pressed =4== =0== : not pressed
1283 High flow High flow hydraulics close Pressed =2== =0== : not pressed
switch
1283 Not used =1==

1286 Input Identifiers from AOM on Dashboard
1286 Not used 8===
1286 Not used 4===
A--o--m stop sharpening/adjust-

1286 AOM Pressed 2=== 0=== : not pressed
ment switch
A--o--m sharpening routine (3

1286 AOM Pressed 1=== 0=== : not pressed
min) switch

1286 AOM Pressed =8== =0== : not pressed
min) switch

min) switch
A--o--m shearbar adjustment

switch
1286 Not used =1==
1286 Not used ==8=
1286 Not used ==4=
1286 Cutterhead Cutterhead engaging switch Switched OFF ==2= ==0= : switched on
1286 4WD Four--wheel drive switch Switched OFF ==1= ==0= : switched on
1286 Engine Throttle up switch Pressed ===8 ===0 : not pressed
1286 4WD Four--wheel drive switch Switched ON ===4 ===0 : switched off
1286 Cutterhead Cutterhead engaging switch Switched ON ===2 ===0 : switched off
1286 Engine Throttle down switch Pressed ===1 ===0 : not pressed
1287 Identifiers From Armrest Module
1287 Bosch Ground pressure potentiometer ==XX Limits : 00 < XX < E5 +/-- 10
1287 Bosch Stubble height potentiometer XX== Limits : 00 < XX < E5 +/-- 10
1287 Bosch Stubble height /Ultrasonic not 08==

mode selected
1287 Bosch Stubble height / Ultrasonic mode 04==

selected
1287 Bosch Compensation mode selected 10==
1287 Bosch Transport mode selected 00==
1288 Ground Speed Identifier
1288 Ground speed Ground speed based on PC XXXX Ground speed in mm/s based on PC calibration
calibration
1288 Ground speed Ground speed displayed XXXX Ground speed in mm/s based on display ca-
libration
1289 Engine RPM Identifier
1289 Engine Engine rpm XXXX Rotation per minute -- hexadecimal code
1289 Engine Calibrated maximum engine XXXX Rotation per minute -- hexadecimal code
speed
1290 Crop Processor RPM Identifier
1290 CP Crop processor rpm XXXX Rotation per minute -- hexadecimal code
1293 Cutterhead RPM Identifier
1293 Cutterhead Cutterhead rpm XXXX Rotation per minute -- hexadecimal code
1301 Missed Metal Detection Date
1301 Metal detector Missed metal detection date XXXX XXXX XXXX Hours : Minutes Day Month Year
(decimal code)
1303 Identifiers From CPU Print
1303 Not used 8===
1303 Brakes Brakes worn out Worn out 4=== 0=== : switch open ; 4=== : switch closed
1303 Airco Airco low pressure switch Insufficient press 2=== 0=== : switch open ; 2=== : switch closed
1303 Airco Airco high pressure switch Excessive press 1=== 0=== : switch open ; 1=== : switch closed
1303 Not used =8==
1303 Engine Engine oil pressure switch Insufficient press =4== =0== : switch open ; =4== : switch closed
1303 Cutterhead Cutterhead gearbox oil temperature

Temp
switch
too high =2== =0== : switch open ; =2== : switch closed
1303 Cutterhead Main drive oil pressure switch Insufficient press =1== =0== : switch open ; =1== : switch closed
1303 Ground speed Hydrostatic oil pressure switch Insufficient press ==8= ==0= : switch open ; ==8= : switch closed
1303 Ground speed Hydrostatic / hydraulic oil temp switch

Temp too high ==4= ==0= : switch open ; ==4= : switch closed
1303 Engine Engine air filter under pressure switch

Insufficient press ==2= ==0= : switch open ; ==2= : switch closed
1303 Harvest functs Harvest mode activated Status ==1= ==0= : switch open ; ==2= : switch closed
1303 Feed rolls Feed rolls reverse engaged Output status ===8 ===0 : feed rolls reverse not engaged
1303 Not used ===4
1303 Not used ===2
1303 Cutterhead Main drive clutch engaged Output status ===1 ===0 : main drive not engaged
1303 Not used 8===
1303 Not used 4===
1303 Bosch Automatic header height control selected

Status 2=== Bosch automatic resume given
1303 Latched height Header height latched Status 1=== Header latched at calibrated height (Italy)
1303 Engine Engine quick stop disabled Status =8== Engine started after quick stop
1303 4WD Four--wheel drive engaged Output status =4== =0== : four wheel drive not engaged
1303 Engine Engine quick stop activated Status =2== =0== : engine emergency stop not activated
1303 Cutterhead Cutterhead reverse engaged Output status =1== =0== : cutterhead reverse not engaged
1303 Engine Alternator charging Input status ==8= ==0= : alternator not charging
1303 Spout Spout rotation end--of--travel sensor

Activated ==4= ==0= : spout not end of course
1303 Harvest functs Right--hand screen door sensor Door closed ==2= ==0= : screen door open
1303 Engine Engine oil temperature switch Temp too high ==1= ==0= : switch open ; ==1= : switch closed
1303 Engine Engine coolant temperature switch

Temp too high ===8 ===0 : Switch open ; ===8 : Switch closed
1303 Not used ===4
1303 Not used ===2
1303 Lights Park lights on Output status ===1 ===0 : lights off ; ===1 : lights on
1303 Software Software version : Node B See software revisions

1304 Identifiers From Adjust--O--Matic Print
1304 Ground speed Driving backwards Status 8=== 0=== : not driving
1304 Ground speed Driving forwards Status 4=== 0=== : not driving
1304 AOM Sharpener door open Input status 2=== 0=== : sharpener door between open and closed
1304 AOM Sharpener door closed Input status 1=== 0=== : sharpener door between open and closed
1304 Not used =8==
1304 Metal detector Metal detected Input status =4== =0== : no metal detected
1304 Feed rolls Feed rolls forward engaged Output status =2== =0== : feed rolls forward not engaged
1304 Not used =1==
1304 AOM Adjust--O--Matic mode Status ==8= ==8= : set ; ==0= : not set
1304 AOM Continue AOM adjustment re- Status ==4= ==4= : set ; ==0= : not set
quest
1304 AOM Check AOM sensors request Status ==2= ==2= : set ; ==0= : not set
1304 AOM Activate Reverse Buzzer Status ==1= ==1= : set ; ==0= : not set
1304 AOM Sharpener stone worn out Input status ===8 ===0 : sharpener stone not worn out
1304 AOM Sharpener stone at home posi- Input status ===4 ===0 : sharpener stone not at home position
tion
1304 Ground speed Ground speed > 90 % Vmax Status ===2 ===0 : ground speed < 90 % Vmax
calibrated by PC
1304 Metal detector Metal detector status Status ===1 ===0 : enabled ; ===1 : disabled
1304 AOM Measured background noise and measured thresh- XX== Normal value : +/-- 60 ;
old limit during adjust operation max value for still good operation : AA
1304 AOM Last measured knives hit peak value ==XX Always some digits higher than the
during adjust operation measured background noise.
1304 Software Software version : Node D XXXX See software revisions
1304 Ground speed Current to hydrostatic pump XXXX Limits: 0000 < XXXX < +/--1199 (= +/-- 105 mA)
1305 Identifier Total Hours
1305 Totals Total cutterhead hours XXXX XXXX Cutterhead hrs in seconds -- hexadecimal
code.
Only visible after 10 sec when engine is
started.
1305 Totals Total engine hours XXXX XXXX Engine hrs in seconds -- hexadecimal code.
started.
1306 Identifier Total HA
1306 Totals Total ha XXXX XXXX Total ha in 0,01 -- hexadecimal code.

started.
1313 Identifier Header Height / Pressure / CP Dis-

tance
1313 Header Header height ==XX Limits : 40 < XX < A0 +/-- 10
1313 Header Ground pressure ==XX Not used
1313 CP Crop processor distance ==XX Limits : 3B < XX < 79

1314 Identifiers Dashboard Leds
1314 Not used 8===
1314 Ground speed Hydrostatic oil pressure led Lights up 4=== 0=== : extinguished
1314 Engine Engine air filter under pressure Lights up 2=== 0=== : extinguished
led
1314 Brakes Brakes led Lights up 1=== 0=== : extinguished
1314 Ground speed Hydrostatic / hydraulic oil tem- Lights up =8== =0== : extinguished
perature led
1314 Engine Battery alternator led Lights up =4== =0== : extinguished
1314 Engine Engine temperature led Lights up =2== =0== : extinguished
1314 Engine Engine oil pressure led Lights up =1== =0== : extinguished
1314 Not used ==8=
1314 Not used ==4=
1314 Not used ==2=
1314 Cutterhead Main drive clutch oil pressure Lights up ==1= ==0= : extinguished
led
1314 Not used ===8
1314 Metal detector Metal detector led Lights up ===4 ===0 : extinguished
1314 Harvest functs Harvest/Road mode led Lights up ===2 ===0 : extinguished = harvest mode
1314 Brakes Parking brake led Lights up ===1 ===0 : extinguished
1314 Not used 8===

1314 Airco Airco High pressure led Lights up 4=== 0=== : extinguished
1314 Airco Airco Low pressure led Lights up 2=== 0=== : extinguished
1314 Cutterhead Cutterhead gearbox oil tem- Lights up 1=== 0=== : extinguished
perature led
1314 AOM Sharpener door led Lights up =8== =0== : extinguished
1314 Header Header height indication led Lights up ==X= XX== Red led : 0 09 ; lowest yellow led : 0 05 ;
bar all yellow leds : F F7
1315 Identifiers Adjust O Matic Leds
1315 AOM A--o--m sharpening routine 2 Lights up 8=== 0=== : extinguished

min led
1315 AOM A--o--m sharpening routine 1 Lights up 4=== 0=== : extinguished

min led
1315 AOM A--o--m shearbar adjustment Lights up 2=== 0=== : extinguished

led
1315 AOM A--o--m OK led Lights up 1=== 0=== : extinguished
1315 AOM A--o--m service led Lights up =8== =0== : extinguished
1315 AOM A--o--m sensor fault led Lights up =4== =0== : extinguished
1315 AOM A--o--m motor fault led Lights up =2== =0== : extinguished
1315 AOM A--o--m rpm fault led Lights up =1== =0== : extinguished
1315 Not used ==8=
1315 Not used ==4=
1315 Not used ==2=
1315 Not used ==1=
1315 Not used ===8
1315 Not used ===4
A--o--m stop sharpening/adjust-

1315 AOM Lights up ===2 ===0 : extinguished
ment led
A--o--m sharpening routine 3

1315 AOM Lights up ===1 ===0 : extinguished
min led
1317 Identifiers Header Height Control Leds
1317 Header Red self--diagnostic control led Lights up 2=== ===0 : extinguished
1317 Header Green auto--diagnostic indica- Lights up 4=== ===0 : extinguished

tor led
1318 Identifiers Analog Sensors (Fuel, Temp)
1318 Engine Fuel level sensor Reference value XXXX Limits : 0176 < XXXX < 09A6
1318 Engine Engine coolant temperature Reference value XXXX Limits :

sensor
1319 Identifiers Limb Home and AOM
1319 Limb Home Activate limb home request Status XXXX 53CA : to raise the request ; else 0000
1319 Limb Home Answer on limb home request Status XXXX 0000 : not answered yet ; 55CC : ’yes’ is
answered ; 1111 : ’no’ is answered
1319 AOM Stop AOM adjustment during Status ===2 ===2 : set ; ===0 : not set
forward drive
1319 AOM Continue AOM adjustm. during Status ===1 ===1 : set ; ===0 : not set
forward drive
1326 Identifiers From InfoView Monitor
1326 Software Software version : node A ( XXXX See software revisions

functions )
1326 Software Software version : node S ( XXXX See software revisions

symbols )
1327 Identifiers Date & Time
1327 Software Hours XX== Hexadecimal code
1327 Software Minutes ==XX Hexadecimal code
1327 Software Day XX== Hexadecimal code
1327 Software Month ==XX Hexadecimal code
1327 Software Year XXXX Hexadecimal code
1327 Software Year of construction XXXX Hexadecimal code

1331 Calibration Identifiers stored in NODE A
1331 Calibrations Calibrated maximum speed XXXX mm/s (hexadecimal code)
1331 Calibrations Calibrated maximum current to XXXX Maximal value : 1199 (= +/-- 105 mA)
hydr. pump
1331 Calibrations Serial number XXXX XXXX Hexadecimal code
1332 Calibration Identifiers stored in NODE B
hydr. pump
1334 Calibration Identifiers stored in NODE D
hydr. pump

1339 Calibration Identifiers (2) stored in NODE A

Same as page 1342
1340 Calibration Identifiers (2) stored in NODE B

Same as page 1342
1342 Calibration Identifiers (2) stored in NODE D
1342 Calibrations Calibrated ground speed con- =XXX Hexadecimal code

stant
1342 Calibrations Calibrated rear hydraulics 8=== 0=== : not calibrated (no) ; 8=== : calibrated
(yes)
1342 Calibrations Calibrated low pressure valve 4=== 0=== : not calibrated (no) ; 4=== : calibrated
(yes)
1342 Calibrations Calibrated values initialised 2=== always 2===
1342 Calibrations Calibrated min forward hydro- XXXX Hexadecimal code

static current
1342 Calibrations Calibrated min backward hy- XXXX Hexadecimal code

drostatic current
1342 Calibrations Calibrated maximum handle XX== Hexadecimal code

position
1342 Calibrations Calibrated latched header ==XX Hexadecimal code

height
1343 Calibration Identifiers (3) stored in NODE A

Same as page 1345
1344 Calibration Identifiers (3) stored in NODE B
Same as page 1345
1345 Calibration Identifiers (3) stored in NODE D
1345 Calibrations Calibrated rotary screen =1== =0==: not calibrated (no); =1==:calibrated (yes)
brushes
1345 Calibrations Calibrated stromag clutch on =2== =0==: not calibrated (no); =2==:calibrated (yes)
actuator print
1345 Calibrations Calibrated Caterpillar engine =4== =0==: not calibrated (no); =4==:calibrated (yes)
1345 Calibrations Calibrated low acceleration hy- =8== =0==: not calibrated (no); =8==:calibrated (yes)
drostatic pump
1345 Calibrations Calibrated four--wheel drive ==1= ==0=: calibrated (yes); ==1=: not calibrated (no)
1345 Calibrations Calibrated sharpen on the Only NA ==2= ==0=: calibrated (yes); ==2=: not calibrated (no)
move
1345 Calibrations Calibrated air conditioning ==4= ==0=: not calibrated (no); ==4=:calibrated
(yes)
1345 Calibrations Calibrated high flow hydraulics ==8= ==0=: not calibrated (no); ==8=:calibrated
(yes)
1345 Calibrations Calibrated rotary screens ===1 ===0: not calibrated (no); ===1: calibrated (yes)
1345 Calibrations Calibrated active pal stop sys- ===2 ===0: not calibrated (no); ===2: calibrated (yes)
tem
1345 Calibrations Calibrated fixed deflector posi- Only NA ===4 ===0: not calibrated (no); ===4: calibrated (yes)
tion
1345 Calibrations Calibrated full engine speed in Only NA ===8 ===0: not calibrated (no); ===8: calibrated (yes)
road mode
1345 Calibrations Calibrated shearbar gap ===X Possible values : 2 to 8

1347 Output Identifiers from CPU print
1347 Spout Spout deflector up Output status =8== =8== : activated ; =0== : not activated
1347 Spout Spout deflector down Output status =2== =2== : activated ; =0== : not activated
1347 Engine Engine speed down Output status ==2= ==2= : activated ; ==0= : not activated
1347 Engine Engine speed up Output status ==1= ==1= : activated ; ==0= : not activated
1347 CP Close crop processor Output status ===2 ===2 : activated ; ===0 : not activated
1347 CP Open crop processor Output status ===1 ===1 : activated ; ===0 : not activated
1347 Rotary Screens Rotary screens Output status 4=== 4=== : activated ; 0=== : not activated
1347 Header Bosch header down switch si- Output status 2=== 2=== : activated ; 0=== : not activated
mulation
1347 Header Bosch header up/down fast Output status =8== =8== : activated ; =0== : not activated
switch simulation
1347 Auto--Pilot Auto--Pilot resume switch si- Output status =2== =2== : activated ; =0== : not activated
mulation
1347 Engine Engine stop solenoid -- hold Output status =1== =1== : activated ; =0== : not activated
1347 Header Bosch automatic resume switch Output status ==4= ==4= : activated ; ==0= : not activated
simulation
1347 Header Bosch ground press mode switch Output status ==2= ==2= : activated ; ==0= : not activated
simulation
1347 Header Bosch stubble height mode Output status ==1= ==1= : activated ; ==0= : not activated
switch simulation
1347 Header Bosch header up switch si- Output status ===2 ===2 : activated ; ===0 : not activated
mulation
1347 Header Bosch transport mode off switch Output status ===1 ===1 : activated ; ===0 : not activated
simulation
1347 Header Bosch stubble height pot si- Output status XX== Limits : OA < XX < E5 +/-- 10
mulation
1347 Header Bosch ground pressure pot si- Output status ==XX Limits : OA < XX < E5 +/-- 10
mulation
1348 Output Identifiers from CPU print
1348 Lights Work lights (operating lights) Output status 8=== 8=== : activated ; 0=== : not activated
1348 Lights Work lights (operating and spot Output status 4=== 4=== : activated ; 0=== : not activated
lights)
1348 Lights Work lights (rear) Output status 2=== 2=== : activated ; 0=== : not activated
1348 Not used 1===
1348 Not used =8==
1348 Lights Operating lights Output status =4== =4== : activated ; =0== : not activated
1348 Lights Spots lights Output status =2== =2== : activated ; =0== : not activated
1348 Lights Spout light Output status =1== =1== : activated ; =0== : not activated
1348 Not used ==8=
1348 Lights Rear drive buzzer Output status ==4= ==4= : activated ; ==0= : not activated
1348 Lights Brake lights Output status ==2= ==2= : activated ; ==0= : not activated
1348 Lights Beacon lights Output status ==1= ==1= : activated ; ==0= : not activated
1348 Auto--Pilot Power to Auto--Pilot Output status ===8 ===8 : activated ; ===0 : not activated
1348 Airco Airco compressor clutch Output status ===4 ===4 : activated ; ===0 : not activated
1348 Acid plug Power to silage additive appli- Output status ===2 ===2 : activated ; ===0 : not activated
cator
1348 Not used ===1
1348 Not used 8===

1348 Cutterhead Main drive clutch engaged Output status 4=== 4=== : engaged ; 0=== : not engaged
1348 Rear Hydr Rear hydraulics up Output status 2=== 2=== : activated ; 0=== : not activated
1348 Rear Hydr Rear hydraulics down Output status 1=== 1=== : activated ; 0=== : not activated
1348 Not used =8==
1348 Not used =4==
1348 Spout Spout rotation Left Output status =2== =2== : activated ; =0== : not activated
1348 Spout Spout rotation Right Output status =1== =1== : activated ; =0== : not activated
1348 Not used ==8=
1348 Not used ==4=
1348 Feed rolls Feed rolls reverse engaged Output status ==2= ==2= : engaged ; ==0= : not engaged
1348 Cutterhead Main drive belt not tensioned Output status ==1= ==1= : not tensioned ; ==0= : tensioned
1348 Cutterhead Cutterhead reverse engaged Output status ===8 ===8 : engaged ; ===0 : not engaged
1348 Spout Spout up Output status ===4 ===4 : activated ; ===0 : not activated
1348 Spout Spout down Output status ===2 ===2 : activated ; ===0 : not activated
1348 4WD Four--wheel drive engaged Output status ===1 ===1 : engaged ; ===0 : not engaged
1348 Not used =8==
1348 Front Hydr Front hydraulics down Output status =4== =4== : activated ; =0== : not activated
1348 Not used =2==
1348 Front Hydr Front hydraulics up Output status =1== =1== : activated ; =0== : not activated
1348 Spout Spout rotation L & R pwm Output status ==XX Hexadecimal code
1349 Output Identifiers from AOM print
1349 AOM Chopper body not fitted Status =2== =2== : not fitted ; =0== : fitted
1349 AOM Ticker solenoid activated Output status =1== not longer used
1349 AOM Sharpener door open Output status ==8= ==8= : activated ; ==0= : not activated
1349 AOM Sharpener door close Output status ==4= ==4= : activated ; ==0= : not activated
1349 AOM Left AOM electric motor for- Output status ==2= ==2= : activated ; ==0= : not activated
ward
1349 AOM Left AOM electric motor to Output status ==1= ==1= : activated ; ==0= : not activated
knives
1349 AOM Right AOM electric motor for- Output status ===8 ===8 : activated ; ===0 : not activated
ward
1349 AOM Right AOM electric motor to Output status ===4 ===4 : activated ; ===0 : not activated
knives
1349 AOM Active stop pawl system Output status ===2 ===2 : activated ; ===0 : not activated
1349 AOM Sharpen routine engaged Output status ===1 ===1 : activated ; ===0 : not activated
1352 CATERPILLAR Engine Information
1352 CAT Engine Coolant temperature Status XX== Range : --40°C to +210°C (1C/bit)
1352 CAT Engine Fuel temperature Status ==XX Range : --40°C to +210°C (1C/bit)
1352 CAT Engine Inlet air temperature Status XX== Range : --40°C to +210°C (1C/bit)
1352 CAT Engine Load percentage at current en- Status ==XX Range : 0% to 125% (1%/bit)
gine speed
1352 CAT Engine Inlet manifold pressure Status XX== Range : 0kPa to +500 kPa (2kPa/bit)
1352 CAT Engine Engine oil pressure Status ==XX Range : 0kPa to +1000kPa (4kPa/bit)
1352 CAT Engine Calibrated maximum engine Status XXXX Range : 0 to 8031.875 rpm (0.125 rpm/bit)
rpm
1353 CATERPILLAR Engine Information
1353 CAT Engine Engine rpm Status XXXX Range : 0 to 8031.875 rpm (0.125 rpm/bit)
1353 CAT Engine Error codes report Status XXXX XXXX XXXX See detailed list
DETAILED ANALYSIS PER FUNCTION
Function Operators manual section
1. Electric conditions, engine running or not running 4.1//6.7
2. Engine quick stop system 2.4
3. Harvest mode 2.3
4. Engine acceleration 2.3
5. Cutterhead engagement 2.3/4.2
6. Feed rolls forward engagement 2.3/4.2
7. Feed rolls reverse engagement 2.3/4.2
8. Power reverse 4.3.2
9. Four--wheel drive 4.12.2
10. Spout rotation 4.11
11. Raise/lower spout 4.11
12. Spout deflector 4.11
13. Reverse cutterhead 5.5
14. Auxiliary front hydraulics 4.15
15. Auxiliary rear hydraulics 4.15
16. Air conditioning 4.13
17. Silage additives application 4.10
18. Knife sharpening 2.5//4.7.1//5.5.3//6.2
19. Adjust --O-- Matic routine 2.5//4.7.2//5.5.4//6.3
20. Crop processor 5.6.1
21. Metal detector operation and trouble shooting 4.5//5.3//6.6
22. Attachment Height Control 4.3//5.23.1
23. Ground speed 6.5
24. High flow Hydraulics 2.3//4.15
25. Rotary Screens 5.19
26. Rotary Screen Brushes 5.19
27. Caterpillar engine
28. CAN netwerk

1. ELECTRIC CONDITIONS, ENGINE RUN- Conditions for “engine is not running”
NING OR NOT RUNNING
1. Insufficient charge of the alternator
and
Reason
Insufficient engine oil pressure
The system must know if the engine is running or not. and

A lot of functions can only be activated when the en- No information from engine rpm sensor
gine is physically running.
or
2. Insufficient charge of the alternator

Indication
and
An indication for the engine running or not running Insufficient hydrostatic oil pressure
are the rotary screens.
As soon as one of the three conditions for “engine is and
running” is valid, also the rotary screens will rotate.
No information from engine rpm sensor
Or, if the rotary screens rotate (engine running or
not), this means that for the electronics the engine is
started.
REMARK: If the engine is running, but there is no ro-

tary screen rotation, possible consequences are:
Conditions for “engine is running”
• No engagement of the cutterhead and feed rolls.
• No pawl stop system.
1. Indication that the alternator is charging • Engine rpm not displayed on the screen.
or • Engine oil pressure led, battery alternator led and
hydrostatic oil pressure led remain illuminated.
2. Sufficient engine oil pressure and sufficient hy-
drostatic oil pressure
or
3. Information from engine rpm sensor

Can Spy
CAN DATA DESCRIPTION word1 word2 word3 word4 COMMENTS

ID
1303 Alternator charging Input status ==8= ==0=: Alternator not charging
1303 Engine oil pressure Insufficient press =4== =0==: Switch open;
switch =4==: Switch closed
1303 Hydrostatic oil pres- Insufficient press ==8= ==0=: Switch open;
sure switch ==8=: Switch closed
1289 Engine rpm XXXX Rotation per minute --
Hexadecimal code
Error messages
Error Code Key words

125 Engine rpm sensor O
126 Engine rpm sensor --
127 Engine rpm sensor +
360 No engine oil press.
361 Oil press sens fault
362 No hydrost. pressure
363 Hydrost. sensor fault
Electrical diagrams
Group 1: Alternator loading
Group 9: Engine protection
Group 8: Engine speed sensor
2. ENGINE QUICK--STOP SYSTEM
Engine oil Engine oil Engine coolant Hydrostatic oil

pressure temperature temperature pressure
switch switch switch switch
Engine oil Engine oil Hydrostatic Engine quick-- Engine stop

pressure temperature oil pressure stop procedure solenoid
Led Led Led activated Y23
When: Engine oil pressure < 1.3 bar

or Engine oil temperature > 126°C
or Engine coolant temperature > 110°C
or Hydrostatic oil pressure < 5 bar
the “engine quick--stop status” becomes high, the corresponding led starts to blink and the buzzer will sound.
When the feed rolls are engaged, they will be disengaged immediately. 5 seconds later, the main drive clutch
will be disengaged and the engine speed will drop, giving the cutterhead and the blower time to clear. After 10
seconds, the engine will stop automatically.
problems occurs 5 sec 10 secs
Led starts to blink, alarm sounds Main drive disengaged Engine stops
and feed rolls disengage Engine speed to low idle automatically
To restart, start the engine twice without switching off the ignition.
REMARK: sponding led will start to flash).
1. When a problem occurs and it only lasts for 5 sec- Once the engine is started, everything will func-
onds, work can be continued. However, the sys- tion normally.
tem will keep these 5 seconds in memory. When 3. When a temperature sensor has a shorted cir-
later on the problem starts again, the system will cuit, an indication of the problem is shown on the
stop the engine after 5 seconds. dashboard when switching on the ignition. Once
2. When a pressure sensor has an open circuit, an the engine is started, the quick--stop system is
indication of the problem is shown on the dash- activated and the engine will stop after 15 sec-
board when switching on the ignition (the corre- onds.
Can Spy

ID
1303 Engine oil pressure Insufficient press =4== =0==: Switch open;
1303 Engine oil temperature Temp. too high ==1= ==0=: Switch open;
switch ==1=: Switch closed
1303 Engine coolant tem- Temp. too high ===8 ===0: Switch open;
perature switch ===8: Switch closed
1303 Hydrostatic oil pres- Insufficient press ==8= ==0=: Switch open;
sure switch ==8=: Switch closed
1314 Engine oil pressure led Lights up =1== =0==: Extinguished
1314 Engine temperature Lights up =2== =0==: Extinguished
led
1314 Hydrostatic / hydraulic Lights up =8== =0==: Extinguished
oil temperature led
1303 Engine quick--stop Status =2== =0==: Engine quick--stop not
activated activated
1303 Engine quick--stop dis- Status =8== Engine started after engine
abled quick--stop
Error messages

360 No engine oil press.
361 Oil press sens fault
Electrical diagrams
Group 9 : Engine quick--stop system
3. HARVEST MODE
Harvest Quick--stop Right--hand Ground speed

switch switch screen door sensor
sensor
Harvest Mode Harvest/

activate Road Mode
(Status) Led
When switching on the contact, the machine is always in Road Mode.
For switching to Harvest mode, four conditions must be met:
1. The quick--stop switch may not be pressed
and 2. The right--hand screen door must be closed
and 3. The ground speed must be slower than 90% of the calibrated maximum ground speed
and 4. The Harvest switch must be switched into Harvest Mode after previous conditions are done.
When all these conditions are met, the Harvest/Road Mode led on the dashboard is not longer illuminated.
The machine switches immediately into ROAD Mode (with ignition on) when:
1. The Harvest switch is switched into ROAD mode
or 2. The quick--stop switch is pressed
or 3. The ground speed has reached 90% of the calibrated maximum ground speed
or 4. The right--hand screen door has been opened.
The Harvest/Road mode led illuminates again.

The Harvest tumbler switch must be switched to its HARVEST position in order to be able to harvest. When
switched to ROAD position, the following functions will not be operational:
• Spout rotation
• Spout height control
• Auto--Pilot (accessory)
• Adjust--O--MaticTM shearbar adjustment and knife sharpening
• Cutterhead engagement and, therefore, feed roll and attachment engagement
• 4--wheel drive (optional)
• Metal detector
• Auxiliary hydraulics
• Silage applicator
Can Spy

ID
1283 Harvest switch Switched ON 8=== = Harvest Mode,
0===: Switched off
1283 Harvest switch Switched OFF =8== = Road Mode,
=0==: Switched on
1282 Quick--stop switch Pressed ===8
1282 Quick--stop switch Not pressed ===4
1303 Right--hand screen Door closed ==2= ==0=: Screen door open
door sensor
1288 Ground speed based XXXX Ground speed in mm/s based
on PC calibration on PC calibration
1304 Ground speed > 90% Status ===2 ===0: Ground speed < 90% V
Vmax calibrated by PC max
1303 Harvest mode acti- Status ==1= ==0=: Road Mode
vated
1314 Harvest/Road mode Lights up ===2 ==0=: Extinguished = Harvest
led Mode
Error messages

302 Dashboard switch 2
(Harvest switch)
340 Handle switch 4
(quick--stop switch)
220 Engine door sensor O
221 Engine door sensor --
222 Engine door sensor +
120 Ground speed sens. O
121 Ground speed sens. --
122 Ground speed sens. +
Electrical diagrams
Group 8: Ground speed sensor (B16)
Group10: Engine door sensor (B102)
4. ENGINE ACCELERATION
Harvest Mode Throttle Throttle control Engine RPM Full engine speed in
control up down switch sensor Road Mode (NA)
See group 3 switch (PC Calibration)
Engine Throttle
Throttle Control Manual or
actuator Automatic
(PC Calibration)
A selection between Manual and Automatic Engine throttle control is available by means of a PC/PDT calibration.
When Manual Throttle control is selected, the engine speed will rise or lower as long as the engine throttle switch
is pressed. Once the engine speed reaches 1850 rpm in Harvest mode, the engine speed will automatically rise
to full engine speed.
When Automatic Throttle Control is selected, the engine speed rises automatically to 1750 rpm (1650 rpm for
Caterpillar engines) in ROAD Mode and 270 rpm in Harvest Mode with one single pulse on the engine speed
up bottom. Pushing once on the engine speed down button, the engine speed will automatically drop to low idle.
As intermediate engine speed can be selected by giving a counter pulse on the engine speed button.
Scheme
European machines
Switch Harvest switch 900 rpm IVECO Switch Harvest switch

into Road Mode into Harvest Mode
850 rpm CAT
"
Low Idle
Throttle up A Throttle up
engine engine
speed speed
Throttle down Throttle down
engine speed engine speed
B B
Switch Harvest switch into Road Mode Full engine speed
1750 rpm IVECO A (2100 rpm
1650 rpm CAT
IVECO, CAT)
"
Switch Harvest switch into Harvest Mode
and throttle up engine speed
North American machines
Answer Y (yes) to the question: “Do you want full engine speed in Road mode? (y, n)” during PC calibration (for
NA only)
Full engine speed

(2100 rpm)
Y
Throttle up Throttle down
engine speed engine speed
B
Low idle
REMARK: In case engine speed is higher than low idle speed, the engine speed automatically drops to low idle
in the following cases:
1. Driver leaves seat (seat switch)
2. The cutterhead is engaged
3. The cutterhead is reversed
4. The A.O.M. shearbar adjustment is started
The engine speed can only be increased 5 seconds after starting the engine.
Can Spy

ID
vated
1286 Throttle up switch Pressed ===8 ===0: Not pressed
1286 Throttle down switch Pressed ===1 ===0: Not pressed
Hexadecimal code
1347 Engine speed down Output status ==2= ==2=: Activated; ==0=: Not
activated
1347 Engine speed up Output status ==1= ==1=: Activated; ==0=: Not
activated
1345 Calibrated full engine NA only ===8 ===0: not calibrated (no)
speed in road mode ==8=: calibrated (yes)
Error messages

(Throttle switch)
340 Handle switch 4 (quick--stop
switch)
Electrical diagrams
Group 2: Throttle actuator
Group 10: Engine rpm sensor and seat switch
5. CUTTERHEAD ENGAGEMENT
Harvest Mode Cutterhead Engine Cutterhead Chopper Attachment

engaging RPM RPM body height over-
See group 3 switch sensor sensor not present ride switch
Low pressure Main drive

valve installed clutch oil
(PC--Calibration) pressure switch
Main drive Main drive Main drive

belt clutch clutch oil
tensioned engaged pressure led
Road mode Harvest mode Cutterhead

engaged
Y40 12V 0V 0V
(Main drive clutch neutral position valve)
Y44 (Main drive belt + Main drive clutch) 0V 0V 12V
Main drive belt Not tensioned Tensioned
See electrical diagrams
To engage the cutterhead:
1. Switch ON the ignition and start the engine.
2. Switch ON the Harvest switch.
3. Switch ON the cutterhead switch.
4. REVERSE the feed rolls.

REMARK: ive cutterhead engagement switch OFF and ON
1. All European machines (from Series 02 on- again.
wards) and North American machines have a low 6. In case the cutterhead speed sensor has failed,
pressure valve installed. and you want to engage the cutterhead in the op-
Only European preseries machines (Series 01) posite direction, the system is not able to check
do not have a low pressure valve installed. whether the cutterhead speed has actually
Wrong calibration causes no cutterhead engage- dropped or not. In order to prevent damage to
ment. mechanical or hydraulic components, a 100 sec-
2. To engage the cutterhead, the system must know onds count--down is started as soon as the cut-
whether the engine is running. terhead is disengaged.
(See Group 1 -- Electronic conditions: Engine The following message appears on the screen:
Running/Not Running). “WAIT UNTIL ENGAGE TIMER = 100”.
When 0 has been reached, the cutterhead drive
3. The cutterhead can be engaged only 5 sec after
can be switched ON. The message “Reengage
starting the engine.
cutterhead” will appear.
4. After cutterhead engagement, the engine rpm
7. Once the oil pressure switch on the low pressure
will drop automatically to low idle. The engine
valve has detected a pressure lower than 24 bar,
speed must be throttled up again.
the led on the instrument panel will flash. This is
5. When the direction of rotation of the cutterhead only when the engine is running at full speed to
is changed while the cutterhead is running (from avoid slipping of the main drive belt.
forward to reverse, or vice versa), the drive will be
8. When the chopper body is not present, it is no
disengaged first and the machine will wait until
longer possible to engage the cutterhead in for-
the cutterhead speed has dropped to less than
ward or reverse in the normal way.
10 rpm. If you try to engage in the other direction
For test reasons, the output shaft can be en-
of rotation, the user message “CUTTERHEAD
gaged (forward direction) by simultaneously
RPM IS STILL > 10” will appear on the InfoView
pressing the attachment height override
monitor display. As soon as the cutterhead has
switch and the cutterhead engagement
stopped, the next user message “REENGAGE
switch.
CUTTERHEAD” is displayed.
Only then the cutterhead can be reengaged in
the other direction of rotation. Switch the respect-
Can Spy

ID
vated
1342 Calibrated low pres- 4=== 0===: Not calibrated (no)
sure valve 4===: Calibrated (yes)
1286 Cutterhead engaging Switched ON ===2 ===0: Switched off
switch
1286 Cutterhead engaging Switched OFF ==2= ==0=: Switched on
switch
Hexadecimal code
1293 Cutterhead rpm XXXX Rotation per minute --
Hexadecimal code
1303 Main drive clutch en- Output status ===1 ===0: Main drive not engaged
gaged
1348 Main drive belt ten- Output status ==1= ==1=: Not tensioned; ==0=:
sioned Tensioned
1348 Main drive clutch en- Output status 4=== 4===: Engaged; 0===: Not
gaged engaged
1303 Main drive oil pressure Insufficient press =1== =0==: Switch open;
1314 Main drive clutch oil Lights up ==1= ==0=: Extinguished
pressure led
1349 Chopper body not Statuts =2== =2==: Not present; =0==:
present Present
1282 Attachment height Pressed ===8
override switch
1282 Attachment height Not pressed ===4
override switch
Error messages

(Cutterhead engagement switch)
342 Handle switch 6 (Attachment
height override switch)
130 Cutterhead sensor O
131 Cutterhead sensor --
132 Cutterhead sensor +
457 Main drive hydr. sol.
462 Main clutch idler
Electrical diagrams
Group 8 Engine and cutterhead rpm (BE3 & B101)
Main drive clutch oil pressure switch (B100)
Group 10 Main drive clutch and belt solenoid (Y40 & Y44)
6. FEED ROLLS FORWARD ENGAGEMENT
Harvest Mode Cutterhead Feed rolls Feed rolls

engaged forward stop switch Seat switch
See group 3 See group 5 switch
Feed rolls Pawl

forward stop
engaged system
To engage the feed rolls forward drive:
1. Switch ON ignition and start the engine.
3. Engage the cutterhead.
4. Engage the feed rolls forward drive by pressing twice the upper side of the feedroll drive button.
The feed rolls will stop automatically in the following cases:
1. The feed rolls stop button is pressed (lower side of feedroll drive button).
2. The seat switch is opened for at least 5 seconds.
3. The cutterhead is disengaged (see Cutterhead Engagement).
4. The Harvest mode is no longer active (see Harvest Mode).
5. When a metal detection takes place.
REMARK:
1. When pressing the quick--stop button, the electromagnetic clutch is no longer activated.
The pawl stop system will be powered so that crop feeding is stopped immediately.
2. When the classical output line of the metal detector is open, it is not longer possible to engage the feedrolls
forward (see group 21).
Can Spy

ID
vated
gaged
1282 Feed rolls forward Pressed ===2
switch
1282 Feed rolls forward Not pressed ===1
switch
1282 Feed rolls stop switch Pressed ===2
1282 Feed rolls stop switch Not pressed ===1
1383 Seat switch Person on seat 2=== 0===: Switch opne;
2===: Switch closed
1304 Feed rolls forward en- Output status =2== =0==: Feed rolls forward not
gaged engaged
Error messages

330 Handle switch 1 ^
(Feed rolls forward switch)
331 Handle switch 1 v
(Feed rolls stop switch)
482 Feedroll forw. clutch
Electrical diagrams
Group 10 Electromagnetic clutch for feed rolls forward drive (Y41)
Seat switch (S83)
7. FEED ROLLS REVERSE ENGAGEMENT
Harvest Mode Feed rolls Stromag feed rolls

reverse engagement clutch
See group 3 switch (or calibration)
Feed rolls
reverse
engaged
To reverse the feed rolls:
3. Reverse the feed rolls drive: Press and hold the feed rolls reverse key.
The feed rolls will stop in the following cases:
1. When releasing the feed rolls reverse key.
2. When disengaging the cutterhead (see Cutterhead engagement).
3. When the Harvest mode is no longer active (see Harvest mode).
REMARK:
1. When the feed rolls rotate forward, first press the feed rolls stop switch.
2. It is not necessary to switch on the cutterhead in order to power the feedroll clutch.
3. With the introduction of a new actuator printed circuit, which from S’99 onwards is responsible for the reverse
engagement of the Stromag electro-magnetic clutch, a new calibration feature is introduced.
NOTE: Previously the reverse clutch activation was controlled by the valve printed circuit. With the new software
both outputs on the actuator and the valve printed circuits are activated. The PC-calibration suppresses the error
report from the valve printed circuit (series 5083 onwards) or suppresses the error report from the actuator printed
circuit on machines before series 5083.
Can Spy

ID
vated
1282 Feed rolls reverse Pressed 2===
switch
1282 Feed rolls reverse Not pressed 1===
switch
1303 Feed rolls reverse en- Output status ===8 =0==: Feed rolls reverse not
gaged engaged
Error messages

343 Handle switch 1 v v
(Feed rolls reverse switch)
463 Feed roll reverse
Electrical diagrams
Group 10: Electromagnetic clutch for feed rolls reverse drive (Y43)
8. POWER REVERSE
Harvest Mode Feed rolls Feed rolls Power

forward reverse Reverse
See group 3 switch switch switch
Front
Front
Hydraulics
Hydraulics UP
DOWN
When the Power Reverse is installed:

• The pick--up windguard can be lifted hydraulically.
• The eccentric position of the retractable pick--up fingers can be inversed hydraulically.
The windguard flips up when the feed rolls are reversed.

It will only flip down again when the feed rolls are reengaged.
Operation
3. Switch ON the Power Reverse switch.
Front hydraulics Up is activated (12 V to electrovalve Y34) during 5 seconds when the feed rolls reverse switch
is pressed.
Front hydraulics Down is activated (12 V to electrovalve Y35) during 5 seconds when the feed rolls are reen-
gaged.
Can Spy

ID
vated
1283 Power Reverse switch Switched ON 2=== 0===: Switched off
1283 Power Reverse switch Switched OFF =2== 0===: Switched on
1282 Feed rolls forward Pressed ===2
switch
1282 Feed rolls forward Not pressed ===1
switch
switch
1282 Feed rolls reverse Not pressed 1===
switch
1348 Front hydraulics up Output status =1== =1==: Activated; =0==: Not
activated
1348 Front hydraulics down Output status =4== =4==: Activated; =0==: Not
activated
Error messages

(Power Reverse switch)
(Feed rolls forward switch)
343 Handle switch 1 v v
(Feed rolls reverse switch)
464 Front hydr. up sol.
465 Front hydr. down sol.
Electrical diagrams
Group 10: Auxiliary front hydraulics electrovalves Y34 & Y35.
9. FOUR--WHEEL DRIVE
Harvest Mode Four--wheel Four--wheel

drive switch drive calibrated
See group 3 (PC--Calibration)
Four--wheel
drive
engaged
To engage the four--wheel drive:
3. Switch ON the four--wheel drive switch.
The four--wheel drive will be disengaged when:

1. The four--wheel drive switch is switched OFF.
2. The Harvest mode is no longer active (see Harvest mode)
REMARK: From Series 10 on (Series 02 North--America), 2WD machines are delivered without 4WD engaging
solenoid on the low pressure valve. An additional calibration has to be carried out to avoid error messages. Refer
to the PC calibration instructions.
Can Spy

ID
vated
1286 Four--wheel drive Switched OFF ==1= ==0=: Switched on
switch
1286 Four--wheel drive Switched ON ===4 ===0: Switched off
switch
1345 Calibrated four--wheel ==1= ==0=: Calibration (yes);
drive ==1=: Not calibrated (no)
1303 Four--wheel drive en- Output status =4== =0==: Four--wheel drive not
gaged engaged
Error messages

(4WD switch)
458 4 wheel drive solen
Electrical diagrams
Group 4: Four--wheel drive.
10. SPOUT ROTATION
Harvest Mode Spout fast Spout slow Spout fast Spout slow Spout rotation
right switch right switch left switch left switch end--of travel
See group 3 sensor
Spout rotation Spout rotation

Right engaged Left engaged
To rotate the spout:
3. Rotate the spout using the spout operating switch.
REMARKS:
1. Depending on the selection in the InfoView monitor calibration (Type), it is possible to activate the spout de-
flector and the spout rotation at the same time.
2. The spout rotation speed depends on the value calibrated in the InfoView monitor (Type).
Values are 80 minimum to 245 maximum.
A good average slow speed is 150.
When no slow speed can be obtained with an average calibrated value of 150 -- 160, check both diodes in-
stalled parallel to the spout rotation outputs.
These two diodes are mounted on the new value printed circuit board (84068781).
3. Once the spout has reached its end--of--travel sensor (B103), the electrovalves Y32 or Y33 are no longer
powered, and the rotation will stop.
Release the rotation switch. It is possible to continue the rotation to the mechanical stop by pressing the re-
leased switch again.
Can Spy

ID
vated
1282 Spout slow right switch Pressed ==2=
1282 Spout slow right switch Not pressed ==1=
1282 Spout fast right switch Pressed =2== Attention (also for spout left
switch):
1282 Spout fast right switch Not pressed =1== When the fast switch is
1282 Spout slow left switch Pressed 8=== pressed, also the slow switch
is pressed (internal structure
1282 Spout slow left switch Not pressed 4=== of the MF Lever).
1282 Spout fast left switch Pressed 2===
1282 Spout fast left switch Not pressed 1===
1303 Spout rotation end of Activated ==4= ==0=: Spout not end--of--
travel sensor travel
1348 Spout rotation left Output status =2== =2==: Activated; =0==: Not
activated
1348 Spout rotation right Output status =1== =1==: Activated; =0==: Not
activated
Error messages

332 Handle switch 2 <
333 Handle switch 2 >
336 Handle switch 2 < <
337 Handle switch 2 > >
453 Spout right hydr. sol.
454 Spout left hydr. sol.
Electrical diagrams
Group 13: Spout control.
11. RAISE/LOWER SPOUT
Harvest Mode Spout Up Spout Down

switch switch
See group 3
Spout Up Spout Down

engaged engaged
To raise or lower the spout:
3. To raise the spout, press the spout UP switch.
4. To lower the spout, press the spout DOWN switch.

Can Spy

ID
vated
1283 Spout up switch Pressed 8=== 0===: Switch not pressed;
8===: Pressed
1283 Spout down switch Pressed 4=== 0===: Switch not pressed;
4===: Pressed
1348 Spout up Output status ===4 ===4: Activated;
===0: Not activated
1348 Spout down Output status ===2 ===2: Activated;
===0: Not activated
Error messages

459 Spout down hydr. sol.
460 Spout up hydr. sol.
Electrical diagrams
Group 13: Spout control.
12. SPOUT DEFLECTOR
Spout Spout Fixed deflector

deflector up deflector position
switch down switch (PC calibration)
Spout deflector
Spout deflector
down
up engaged
engaged
To raise or lower the spout deflector:
2. To raise the spout deflector, press the spout deflector UP switch.
3. To lower the spout deflector, press the spout deflector DOWN switch.
REMARKS:
1. Depending on the selection in the InfoView monitor calibration (Type), it is possible to activate the spout de-
flector and the spout rotation at the same time.
2. Fixed deflector position (PC Calibration): NA machines only
So: for Eur machines: answer No
for NA machines: answer Yes
On European machines, when switching on the Harvest switch, the spout deflector will automatically open up
to halfway. When switching OFF the Harvest switch, the spout deflector will close automatically.
On North American machines, switching between Harvest and Road Mode does not affect the deflector position.
Can Spy

ID
1282 Spout deflector up Pressed =8==
switch
1282 Spout deflector up Not pressed =4==
switch
1282 Spout deflector down Pressed =2==
switch
1282 Spout deflector down Not pressed =1==
switch
1347 Spout deflector up Output status =8== =8==: Activated; =0==: Not
activated
1347 Spout deflector down Output status =2== =2==: Activated; =0==: Not
activated
1345 Calibration fixed de- NA only ===4 ===0: Not calibrated (no);
flector position ===4: Calibrated (yes)
Error messages

335 Handle switch 2 v
401 Spout deflector act.
Electrical diagrams
Group 13: Spout control
13. REVERSE CUTTERHEAD
Harvest Mode Cutterhead Engine Cutterhead Chopper

reversing RPM RPM body
See group 3 switch sensor sensor not present
Main drive Cutterhead

Main drive
clutch reverse
belt tensioned
engaged engaged
To reverse the cutterhead:
3. Switch ON the cutterhead reversing switch.
The output status is: Voltage

Main clutch is not engaged Y44 0V
Main drive belt is not tensioned Y40 12 V
Cutterhead reverse valve is engaged Y31 12 V
REMARKS: (see cutterhead engagement: group 5) stopped, the next user message “REENGAGE
1. To reverse the cutterhead, the system must know CUTTERHEAD” is displayed.
whether the engine is running. Only then the cutterhead can be reengaged in
(See Group 1 -- Electronic conditions: Engine the other direction of rotation. Switch the respect-
Running/Not Running). ive cutterhead engagement switch OFF and ON
again.
2. The cutterhead can be reversed only 5 sec after
starting the engine. 5. In case the cutterhead speed sensor has failed,
and you want to engage the cutterhead in the op-
3. After cutterhead engagement, the engine rpm
posite direction, the system is not able to check
will automatically drop to low idle. Throttle up en-
whether the cutterhead speed has actually
gine speed again.
dropped or not. In order to prevent damage to
4. When the direction of rotation of the cutterhead mechanical or hydraulic components, a 100 sec-
is changed while the cutterhead is running (from onds count--down is started as soon as the cut-
forward to reverse, or vice versa), the drive will be terhead is disengaged.
disengaged first and the machine will wait until The following message appears on the screen:
the cutterhead speed has dropped to less than “WAIT UNTIL ENGAGE TIMER = 100”.
10 rpm. If you try to engage in the other direction When 0 has been reached, the cutterhead drive
of rotation, the user message “CUTTERHEAD can be switched ON. The message “REEN-
RPM IS STILL > 10” will appear on the InfoView GAGE CUTTERHEAD” will appear.
monitor display. As soon as the cutterhead has
Can Spy

ID
vated
1283 Cutterhead reversing Switched OFF 4=== 0===: Switched on
switch
1283 Cutterhead reversing Switched ON =4== =0==: Switched off
switch
Hexadecimal code
Hexadecimal code
1303 Cutterhead reverse Output status =1== =0==: Cutterhead reverse not
engaged engaged
1303 Main drive clutch en- Output status ===1 Must be ===0
gaged
1348 Main drive belt ten- Output status ==1= ==1=: Not tensioned; ==0=:
sioned Tensioned
1349 Chopper body not Statuts =2== =2==: Not present; =0==:
present Present
Error messages

(Cutterhead reversing switch)
130 Cutterhead rpm sensor O
131 Cutterhead rpm sensor --
132 Cutterhead rpm sensor +
457 Main drive hydr. sol.
461 Cutterhead reverse
462 Main clutch idler
Electrical diagrams
Group 15: Cutterhead reverse
14. AUXILIARY FRONT HYDRAULICS
Harvest Mode Spout Up Spout Down Attachment

switch switch height override
See group 3 switch
Front
Front
Hydraulics
Hydraulics UP
DOWN
To use the auxiliary front hydraulics:
The front auxiliary hydraulic valves are powered (12 V on output) with the spout up/down switches in the cab
floor, in combination with the attachment height override switch.
Can Spy

ID
vated
8===: Pressed
4===: Pressed
1282 Attachment height Pressed ===8
override switch
1282 Attachment height Not pressed ===4
override switch
1348 Front hydraulics down Output status =4== =4==: Activated; =0==: Not
activated
1348 Front hydraulics up Output status =1== =1==: Activated; =0==: Not
activated
Error messages

342 Handle switch 6
(Attachment height override
switch)
464 Front hydr. up sol.
465 Front hydr. down sol.
Electrical diagrams
Group 10: Auxiliary hydraulics
15. AUXILIARY REAR HYDRAULICS
Harvest Mode Spout Up Spout Down Auto--Pilot Rear Hydraulics

switch switch switch installed
See group 3 (PC--Calibration
Rear Rear
Hydraulics Hydraulics
UP DOWN
To use the auxiliary rear hydraulics:
The rear auxiliary hydraulic valves are powered (12 V on output) with the spout up/down switches in the cab
floor, in combination with the Auto--Pilot switch.
REMARKS:
Auxiliary rear hydraulics are an accessory.
Machines without auxiliary rear hydraulics are delivered without electrovalve.
An additional calibration has to be carried out to avoid error messages.
Refer to the PC calibration instructions.
Can Spy

ID
vated
8===: Pressed
4===: Pressed
1282 Auto--Pilot switch Pressed ==8=
1282 Auto--Pilot switch Not pressed ==4=
1348 Rear hydraulics up Output status 2=== 2===: Activated; =0==: Not
activated
1348 Rear hydraulics down Output status 1=== 1===: Activated; 0===: Not
activated
1342 Calibrated rear hy- 8=== 0===: not calibrated (no);
draulics 8===: calibrated (yes)
Error messages

341 Handle switch 5
(Auto--Pilot switch)
456 Rear hydr. down sol.
456 Rear hydr. up sol.
Electrical diagrams
Group 10: Auxiliary hydraulics
16. AIR CONDITIONING
Airco thermo Airco high Airco low

switch in cab pressure pressure
switch switch
Airco Airco high Airco low

compressor pressure pressure
clutch led led
Switch on the air conditioning with the airco switch in the cab. This causes the electromagnetic clutch of the airco
compressor to be powered (12V on output: see electrical diagrams).
The airco switch in the cab is in fact a combination of three conditions:
Airco Switch ON = Fan speed switch (S37) in position 1, 2 or 3
and
Airco thermo switch (B61) closed
and
Air conditioning safety switch (S60) closed
Airco Switch OFF = Fan speed switch in position O
or
Airco thermo switch (B61) open
or
Air conditioning safety switch (S60) open

REMARKS: 3. The system must only be operated when the en-
1. When the compressor pressure is too low or too gine is warm and the interior temperature of the
high, the power to the electromagnetic clutch will cab is 15°C minimum.
automatically drop to 0 volt to avoid damage of
the compressor.
(When the pressure is too low, there is no noise, ATTENTION
only the led starts to blink).
Ignoring this precaution may cause damage to the
2. The system should be informed if the air condi- system.
tioning system is not installed to avoid continu-
ous warning signals in the cab. See PC calibra-
tion.
Can Spy

ID
1283 Airco switch in cab Closed ==1= ==0=: Switch open;
==1=: Switch closed
1303 Airco low pressure Press too low 2=== 0===: Switch open;
switch 2===: Switch closed
1303 Airco high pressure Press too high 1=== 0===: Switch open;
switch 1===: Switch closed
1314 Airco high pressure led Lights up 4=== 0===: Extinguished
1314 Airco low pressure led Lights up 2=== 0===: Extinguished
1348 Airco compressor Output status ===4 ===4: Activated; ===0: Not
clutch activated
Error messages

440 Airconditiong clutch
Electrical diagrams
Group 24: Air conditioning
17. SILAGE ADDITIVES APPLICATION
Harvest Mode Cutterhead Feed rolls Drive Forward Silage additive

Engaged Engaged applicator
See group 3 See group 5 See group 6 See group 23x main switch
Power to
silage additive
applicator
Conditions:
3. Switch ON the silage additive applicator switch.
4. Engage cutterhead.
5. Engage feed rolls forward drive.
6. Drive forward.
REMARKS: The 12 V silage additives application socket output can be checked (silage additives applicator in-
stalled):
1. Switch the Harvest switch to Road position.
2. Switch ON the silage additive applicator switch.
Can Spy

ID
vated
1283 Silage additive appli- Switched ON ==8= ==0=: Switched off
cator main switch
1283 Silage additive appli- Switched OFF ===8 ==0=: Switched on
cator main switch
gaged
1304 Feed rolls forward en- Output status =2== =0==: Feed rolls forward not
gaged engaged
1304 Driving forward Status 4=== 0===: Not driving
1348 Power to silage addi- Output status ===2 ===2: Activated; ===0: Not
tive applicator activated
Error messages

(Silage additive applicator
switch)
Electrical diagrams
Group 17: Silage additive applicator
18. KNIFE SHARPENING
Reverse Throttle AOM sharpening Home grinding reset sharpening

Cutterhead switch dashboard door open position 1’,2’ or 3’ button on the
See group switch sensor sharpening aom move (NA)
13 stone panel pc
sensor calibration
Sharpening motor motor AOM 1’ 2’ 3’ Reset

Door sharpening sharpening panel sharpening sharpening sharpening button
Open LED door stone “ok” LED LED LED LED
LED
“cutterhead speed “Failure of “Sharpening

too low” LED sharpening stone stone worn out”
drive motor” LED LED
Conditions
1. Start the engine and set speed at low idle
2. Disengage the feed rolls by pushing the feed roll drive switch (MF lever)
3. Disengage the cutterhead by switching off the cutterhead drive switch. Wait until the cutterhead has stopped
rotating.
4. Ensure the harvest switch is switched to its harvest position
5. Switch on reverse drive cutterhead switch
6. Throttle up the engine speed until the cutterhead speed is at least 750 rpm. This will ensure a good sharpen-
ing quality. The higher the speed, the better the sharpening.
7. Switch ON the Adjust--O--MaticTM
switch (instrument panel). The OK--light on the Adjust--O--MaticTM
panel is illuminated.
Press one of the automatic knife sharpening routine keys (1, 2 or 3 minutes). As a guide--line, the shortest
time (one minute) is recommended, unless the knives are really worn. The light on the chosen key will illumi-
nate during the sharpening operation.
8. The sharpener door warning light will start flashing, meaning the sharpener door is opening.
9. The Adjust--O--MaticTM system will now start sharpening the knives during 1, 2 or 3 minutes, depending on
the selection that was made. During sharpening the sharpener door warning light will be illuminated.
10. The sharpener routine will stop after 1, 2 or 3 minutes, unless the routine is interrupted with the interrupt key.
At the end of the sharpening cycle, the stone will travel across the cutterhead knives slowly for at least half
a cycle. This is done to make sure the knives are properly sharpened and burrs are removed.
11. When sharpening is finished, the sharpener door closes automatically and the OK--light (Adjust--O--MaticTM
panel) will illuminate.
REMARK: You can also sharpen the knifes with the cutterhead turning forward, however it is recommended to
sharpen in reverse. The routine stays the same.
Can Spy

ID
1283 AOM main switch Switched ON 8=== 0=== : switched off
1283 Cutterhead reversing Switched OFF 4=== 0=== : switched on
switch
1283 AOM main switch Switched OFF =8== =0== : switched on
1283 Cutterhead reversing Switched ON =4== =0== : switched off
switch
1286 AOM stop sharp./adj. Pressed 2=== 0=== : not pressed
switch
1286 AOM sharp. rout. 3’ Pressed 1=== 0=== : not pressed
1286 AOM sharp. rout. 2’ Pressed =8== =0== : not pressed
1286 AOM sharp. rout. 1’ Pressed =4== =0== : not pressed
hexadecimal code
1303 Cutterhead reverse Output status =1== =0== : cutterhead reverse not
engaged engaged
1304 Sharpener door open Input status 2=== 0=== : sharpener door between
open and closed
1304 Sharpener door closed Input status 1=== 0=== : sharpener door between
open and closed
1304 AOM Mode Status ==8= ==8= : set ; ==0= : not set
1304 Sharpener stone worn Input status ===8 ===0 : sharpener stone not
out worn out
1304 Sharpener stone at Input status ===4 ===0 : sharpener stone not at
home position home position
1314 Sharpener door LED Lights up =8== =0== : extinguished
1315 AOM 2’ LED Lights up 8=== 0=== : extinguished
1315 AOM 1’ LED Lights up 4=== 0=== : extinguished
1315 AOM OK LED Lights up 1=== 0=== : extinguished
1315 AOM Service LED Lights up =8== =0== : extinguished
1315 AOM Motor fault LED Lights up =2== =0== : extinguished
1315 AOM rpm fault LED Lights up =1== =0== : extinguished
1315 AOM stop sharp. LED Lights up ===2 ===0 : extinguished
1315 AOM sharp routine 3’ Lights up ===1 ===0 : extinguished
LED
ID
1349 Sharpener door open Output status ==8= ==8= : activated ; ==0= : not
activated
1349 Sharpener door close Output status ==4= ==4= : activated ; ==0= : not
activated
1349 Sharpener routine en- Output status ===1 ===1 : activated ; ===0 : not
gaged activated
Error messages
Error Code Description

223 Stone home sensor O
224 Stone home sensor --
225 Stone home sensor +
226 Cover cutterh. sensor O
227 Cover cutterh. sensor --
228 Cover cutterh. sensor +
229 Out of stone sens. O
230 Out of stone sens. --
231 Out of stone sens. +
370 Cover cutterhead EOT
371 AOM Power failure
483 Cover cutterh. Motor
487 Sharp motor failure
488 Out of stone
489 Cut. knives worn down
Electrical scheme
Group 15
19. ADJUST--O--MATIC ROUTINE
There are two possibilities to start an automatic shearbar adjustment: With cutterhead turning forward and cutter-
head turning backward.
Reverse cutter- AOM Shearbar Knocksensor(s) interrupt button pc calibr

head group Adj. switch AOM routine shearbar
13 or engage Dashboard on AOM panel on gap
cutterhead for- switch AOM panel
ward group 5
AOM AOM shearbar AOM OK cutter head Shearbar Knives

motor motor adj. LED speed too adj. motor worn
LED on low LED failure LED Led
Left Right on AOM AOM panel on AOM AOM AOM
panel panel Panel panel
Interrupt Rear
LED drive
AOM
Panel Buzzer
Primarily checks
1. Lock the stone pawl first to avoid the stone can lower during a sharpening cycle.
Sharpen for at least three minutes to obtain a complete parallel cutterhead.
2. Check for play at the electric motors fixation points.
3. Verify the noise sensor installation.

Max. 20 Nm
Place sensor connector as high as possible.
4. Check all frame ground on sensor and Ticker Solenoid.

5. Check knock sensor
To start up the knock sensor check procedure, the engine has to be shut down, the contact must be ON; push
the aom reset button while switching on the AOM dashboard switch. The ’sharpening stone’ warning led (Op.
Manual symbol 10 page 2--19) on the aom display panel lights up to confirm you are in sensor test mode.
To do the actual testing you have to hit the shearbar or somewhere close with a piece of iron (keys, screw-
driver,...). If the sensor(s) is ok the reverse buzzer and LCD buzzer will sound, simultaneously the knock sensor
led on the aom display lights up for a few seconds. After the buzzing stopped you can try again as long as you
stay in the test mode.
6. Clean the area between shearbar and scraper.
7. Execute a full pull : Switch on ignition and AOM

Press ’Stop’ and ’Shearbar adjust’ button on AOM--Panel.
8. If necessary adjust all knives. (See procedure described in Operator’s Manual).
9. Clean the area between shearbar and cutterhead properly.
10. Check shearbar for scratches. If necessary turn or replace.
11. Verify messing plate under the shearbar.

Conditions and description of Shearbar adjustment Procedure.
Start the engine
Switch on safe harvest button
Switch on reverse cutterhead button
Switch on aom dashboard button (ok LED aom display illuminates)
When the shearbar adjustment button is pressed, the shearbar adjustment led illuminates during the whole ad-
justomatic procedure and
1°) First the engine rpm drops to low idle.
2°) Then the shearbar turns backwards (towards feed rolls). This includes :
the LHS electric motor is powered first for 1 rotation &
the RHS electric motor is powered also for 1 rotation.
Check the output of the electric motors on CAN SPY Page :

1349 word 1 : ==2= (Left motor)
1349 word 2 : ===8 (Right motor)
3°) error check during AOM procedure

From time to time the knock sensors are being checked on optimum working condition. When at the be-
ginning of an AOM procedure one or two sensors seem to work less, an error question message ”check
sensors continue? Yes/no?” is displayed.
As soon as this message appears you are in the sensor check procedure as described under primarily
checks 5°. This way you can check the sensors even while the cutterhead is turning.
* When ”yes” has been confirmed two situations may occur
Or during testing now or later in the test procedure described under primarily checks 5°, whether
the sensors needed repair or not, the sensor check was successful (equal to buzzer went off), the
AOM procedure will continue its cycle.
Or if there was no check, bad repair or no repair (equal to buzzer did not go off), the message ”ad-
just manually” will appear on the screen for a few seconds and the AOM procedure is terminated.
* When ”No” has been confirmed, the AOM procedure stops.
The measured machine background noise is displayed on:
Page 1304, Word 2 : XX==.
4°) The limit for background noise has been brought to 170 (= AAhex) Maximum and 60 (= 3Chex) average.
If the first background noise measurement is too high, error 490 “AOM NOISE TOO HIGH” (= new)
comes up the screen while sensor error led lights up on the aom panel. The background noise level is
measured again.
When the shearbar threshold is calculated, this value is displayed on
Page 1304, Word 2 : XX==
The last measured information from the sensor is displayed on :

Page 1304, word 2, ==XX and is always a few digits higher than page 1304, Word 2 : CC==
5°) Then the Shearbar adjustment is started and the shearbar turns forward (towards knives). First the LHS
electric motor is powered for maximum 1 2/8 rotations.
When the impact of the shearbar with the knives (measured noise) becomes higher than the Shearbar
threshold, the forward rotation is stopped and the motor starts to back off the shearbar from the knives
in parts of 1/18 rotation as long as the measured noise stays higher than the shearbar threshold. Then
the LHS motor backs off for an extra 5/9 rotation.
1349 word 1 : ==2= (Left motor, back off)
1349 word 1 : ==1= (Left motor, towards knives)
1349 word 2 : ===8 (Right motor, back off)
1349 word 1 : ===4 (Right motor, towards knives)
6°) The same procedure is repeated for the RHS electric motor.
7°) Steps 6 and 7 are again repeated for the LHS and RHS electric motor. Only instead of 5/9 rotation extra
back off, the system backs off the calibrated shearbar gap (default setting is 4/8).
At the end of the aom procedure the LHS motor is turned 1/8th turn extra in order to establish a parallel
shearbar.
REMARK I: When one adjustment step is finished (step 6--8) the system will wait one second before the next
adjustment step (at the other side) will start, this to allow the Shearbar can stretch itself.
REMARK II: AOM procedure, cutterhead turning forward.

When executing the AOM procedure with the cutterhead turning forward, the AOM stops
at each phase until the sensors heard a hit, from then on everything happens automatically.
When nothing is heard, the operator has to acknowledge at each phase if he wants to con-
tinue or not. This way the operator has the time to react when the shearbar should hit the
drum.
There is no acknowledging procedure when turning the cutterhead backward.
REMARK III: Once the shearbar has touched the knives, the system has to detect four knife approaches after
each other (2 left and 2 right) without interruption. When during the shearbar adjustment the shear-
bar does not touch the knives, the counter for 4 knife approaches is reset.
This happens when the shearbar goes direction knives but the shearbar does not touch the knives.
This results in the powering of the electric motor at the other side.
This symptom will create a constant shearbar adjustment.
Possible causes :
--) Round shape of the cutterhead.
--) Play in the electric motor fixation points
--) Shearbar pivoting around midpoint
Can Spy

ID
1283 AOM main switch Switched ON 8=== 0=== : switched off
1283 Cutterhead reversing Switched ON 4=== 0=== : switched on
switch
1283 AOM main switch Switched OFF =8== =0== : switched on
1283 Cutterhead reversing Switched ON =4== =0== : switched off
switch
1286 AOM sharpening/ad- Pressed 2=== 0=== : not pressed
justment switch
1286 AOM shearbar adj. Pressed =2== =0== : not pressed
switch
1286 Cutterhead engage Switched OFF ==2= ==0= : switched on
switch
1286 Cutterhead engage Switched ON ===2 ===0 : switched off
switch
hexadecimal code
1304 AOM mode Status ==8= ==8= : set ; ==0= : not set
1304 Continue AOM adjust- Status ==4= ==4= : set ; ==0= : not set
ment request
1304 Check AOM sensors Status ==2= ==2= : set ; ==0= : not set
request
1304 Activate Reverse Buz- Status ==1= ==1= : set ; ==0= : not set
zer
1304 Measured background XX== Normal value : +/-- 60 ;
noise and measured max value for still good oper-
threshold limit during ation : AA
adjust operation
1304 Last measured knives ==XX Always some digits higher
hit peak value than the measured back-
during adjust operation ground noise.
1315 AOM OK LED Lights up 1=== 0=== : extinguished
1315 AOM Service LED Lights up =8== =0== : extinguished
1315 AOM Sensor fault LED Lights up =4== =0== : extinguished
1315 AOM Motor fault LED Lights up =2== =0== : extinguished
1315 AOM rpm fault LED Lights up =1== =0== : extinguished
1315 AOM shearbar adjust- Lights up ===2 ===0 : extinguished
ment led
ID
1345 Calibrated shearbar ===X Possible values : 2 to 8
gap
1348 Rear drive buzzer Output status ==4= ==4= : activated ; ==0= : not
activated
1349 Left AOM electric Output status ==2= ==2= : activated ; ==0= : not
motor forward activated
1349 Left AOM electric Output status ==1= ==1= : activated ; ==0= : not
motor to knives activated
1349 Right AOM electric Output status ===8 ===8 : activated ; ===0 : not
motor forward activated
1349 Right AOM electric Output status ===4 ===4 : activated ; ===0 : not
motor to knives activated
Error codes

371 Power failure AOM
485 AOM Motor left failure
486 AOM Motor right failure
489 Cut. knives worn down
490 AOM Noise too high
Electrical scheme
See group 16
20. CROP PROCESSOR
Harvest CP CP CP CP
Mode dashboard Potentiometer Rpm sensor Calibration
See group 3 switch 12 (InfoView Monitor)
CP LCD
Electric Motor CP clearance
Readout
Conditions:
Put contact on.
Go to safe harvest mode using the safe harvest button.
Push the crop processor switch up to widen the crop processor gap ( up to 20 mm max) and down to make the
gap smaller (up to 2 mm min).
REMARK:
1. To view the cp rpm on can spy, the engine has to be running and the cutterhead has to be engaged.
2. The users message “crop processor slippage” comes up when the speed of the crop processor rolls drop
below 2.5 times the cutterhead speed. With 0% slippage the cp roll speed is 3.2 times higher than cutterhead
speed. When the cutterhead speed for instance is 1000 rpm, then the cp speed is 3200. When cp speed drops
below 2500 (or 09C4Hex on can id page 1290) the user message comes up.
3. The electronic system should be informed if the crop processor is installed to avoid error reports. See Info-
View Monitor calibration.
Can Spy

ID
1283 CP roll clearance open Pressed ===2 ===0 : switch not pressed ;
switch ===2 : pressed
1283 CP roll clearance close Pressed 1=== 0=== : switch not pressed ;
switch 1=== : pressed
1290 CP Rpm XXXX Rotation per minute --
hexadecimal code
1313 CP distance ==XX Limits : 3B < XX < 79
1347 Close CP Output status ===2 ===2 : activated ; ===0 : not
activated
1347 Open CP Output status ===1 ===1 : activated ; ===0 : not
activated
Error codes
Error Code Error code description

113 Crop. proc. sensor O
114 Crop. proc. sensor --
115 Crop. proc. sensor +
148 CP Distance sens. O/--
149 CP Distance sens. +
150 Crop Processor Sens.
400 Crop. proc. dist. act.
Electrical scheme
See group 12
21. METAL DETECTOR OPERATION AND TROUBLESHOOTING
Introduction
The model FX/96 forage harvester is equipped with the Metalert III®/TM electronic metal detector (EMD).
Metalert III®/TM has the following advantages over previous generations I and II:
-- Modular construction: individual components can be replaced
-- Adaptive threshold adjustment
-- Manual threshold adjustment (fixed mode)
-- On--board diagnostics (= Run time test)
-- Display of important information on the InfoView monitor (noise readings, thresholds)
-- Error codes
-- CAN Identifiers
The general function of the metal detector is explained in the Operator’s Manual, chapter 4.5 “Metal detector”.
METAL DETECTOR HARDWARE

The metal detector consists of two parts:
1. The sensor (upper part)
2. The electronic module (lower part)

The sensor
The heart of the metal detector is the sensor that contains the magnets and the coils.
Left Channel
Right Channel
It consists of 2 rows of permanent magnets. The magnets in one row are arranged offset to the other row. One
row of magnets starts at the far left--hand side of the sensor. The other row starts at the far right--hand side.
Between the two rows of magnets a permanent magnetic field exists. This magnetic field crosses the boundaries
of the feed roll shell and ‘fills’ the space between the upper and lower front feed rolls. Since the magnetic field
must not be disturbed by the feed roll, the feed roll is made of low magnetic stainless steel and demagnetised
steel.
Above the rows of magnets the coils are placed next to each other. Those coils are wired in two series. One row
of coils starts at the far left--hand side of the sensor: this row is called the left channel. The other row starts at
the far right--hand side and is called the right channel.
NOTE: On the metal detector diagnostic page of the InfoView monitor, the left and right channel are referred to
as channel A and channel B in order to avoid confusion as to where metal has entered the machine.
When metal passes over the sensor, the magnetic field between the magnets is disturbed. A disturbance of the
magnetic field will generate a current through the coils (channels). Depending on where the metal enters, the
current may be generated in the coils of the left or right channel, or both.
The electronic module
The current through the coils which is generated by a disturbance in the magnetic field is a relatively weak signal.
If this signal would be sent directly to the electronic box on the base unit, it would be subjected to electromagnetic
influences. Therefore, this signal is amplified first.
Since the CAN system can only use digital information, the analog signal (magnetic noise) is converted to a digital
signal by means of an A/D converter.
Then the control unit compares the (digital) magnetic noise to the threshold level (available from adaptive or fixed
mode).
This depends on 2 parameters
-- The extent to which the noise levels increase
-- The setting of the thresholds (or trip levels).
So, the thresholds determine at which noise level a detection will take place.
Since there are 2 channels, and positive and negative values for each channel, there are 4 thresholds in total.
As soon as one of the thresholds is exceeded, the metal detector will trip.
This will result in the following:
-- The output voltage will drop from 12 Volt to 0 Volt for 1 second
-- A CAN message will be transmitted informing that a metal detection has taken place.
These signals will have the following consequences:
-- The stop pawl solenoid will be activated, which will stop the feed rolls
-- The feed rolls forward electromagnetic clutch will be disengaged
-- The metal detector diagnostic page will appear on the InvoView monitor screen.
The classic signal and the CAN message work completely independent from each other. This means that when
the classic signal is not functioning for whatever reason, the CAN message will make sure the detection message
is passed on, and vice versa.
X619
Amplifier 12 V
1Ground
ADC
Con- Output 0 V : Detection
trol
12 V : No Detection
ADC Unit
CAN Network
Amplifier
Coils Electronic Processor Connector and wir-

ing
loom to central box
INFOVIEW MONITOR
6 52706
2
The metal detector page can be displayed on the InfoView monitor after key 10 is pressed.
Since there are 2 channels, left and right, there are 2 bargraphs, CHAN A and CHAN B, as shown on the InfoView
monitor display (Fig. 2).
The black segments (A) on both bargraphs represent the peak magnetic noise readings in the two channels
(measured during a period of 6 1/4 seconds).
In case the machine would be perfectly quiet (which in reality is rare), the bargraphs would be empty. As soon
as magnetic noise is detected, part of the histogram will be filled around the midpoint with black sections.
The resolution of the noise readings is half a bargraph segment.
NOTE: In case the background magnetic noise is high and the size or speed of the ferrous object is small, the
magnetic disturbance caused by the object may not be able to exceed the magnetic noise. It will not be detected
in that case, regardless, of the position of the threshold.
The 4 lines B above the black sections represent the actual (fixed or adptative) threshold levels (or trip levels).
When the magnetic noise readings exceed a threshold level, a metal detection will take place.
FIXED AND ADAPTIVE MODE
There are 2 ways for setting the thresholds:

-- Fixed: Manual setting of the thresholds
-- Adaptive: Automatic setting in function of the average peak noise level.
At the top of the InvoView screen the thresholds will either be marked “A” or “F” (see Figure 1).
-- “A” stands for Adaptive Mode.
-- “F” stands for Fixed Mode.
To switch between adaptive and fixed mode, press the scroll down and scroll up buttons simultaneously when
the metal detector page is displayed. The “A” will change to “F”, or vice versa.
The range within which the thresholds can be set is the same, both for the adaptive and the fixed mode. It ranges
from 1 1/2 to 5 1/2 blocks above or below the midpoint.
Fixed mode
The fixed thresholds are set manually between 1 1/2 to 5 1/2 blocks from the midpoint. It is generally recom-
mended to set the fixed thresholds at 1 1/2 blocks removed from the noisiest reading (feed rolls engaged at full
speed). These fixed thresholds are set symmetrically (same setting for all 4 thresholds).
NOTE: The arrows to the left--hand side of the bargraph indicate the adaptive threshold levels. In the fixed mode,
these are purely informative.
These thresholds have to be adjusted manually by moving the lines B above and below the black sections. To
do so, use the scroll up and down buttons and confirm the new settings by pressing the Enter key. After confirma-
tion, the right--hand side arrows will jump to the same level as the lines B.
Adaptive mode
The adaptive thresholds are set automatically in function of the average peak noise readings, regardless of differ-
ences between the 4 noise levels. This means the thresholds are not necessarily set symmetrically, but can in
fact differ significantly.
To prevent the adaptive thresholds from changing too quickly, they represent a slow moving average of the peak
noise readings of the last couple of minutes.
During each 6.25 seconds, the 4 peak noise values are stored. These peak readings are averaged with the peak
readings of the last 31 samples.
When the background noise level of the feed rolls increases with time, the adaptive thresholds are automatically
adjusted.
When, however, the threshold limit of 5 1/2 blocks is crossed, the system will notify the operator by means of
an error code.
The figure below shows how Metalert II and III compare regarding the reaction of increased magnetic noise in
function of time.
CEILING MAXIMUM LIMITATION
II III
FIXED DETECTION LEVEL

AVERAGE DETECTION
LEVEL
VOLTS
1 2 3 4 5 1 2 3 4 5
YEARS YEARS
TIME ⇒ TIME ⇒
3
Quick adjustment of the adaptive mode
Although the adaptive thresholds are set relatively fast, there may be circumstances that letting them adjust auto-
matically in the field is not fast enough, e.g.
-- When the metal detector was replaced
-- When the feed roll shell was replaced or demagnetized
-- When a dent in the feed roll shell has increased the magnetic noise.
In these cases the following can be done:

-- Switch to fixed mode, or
-- Carry out the quick--adjust routine of the adaptive mode.
The quick--adjust routine will allow the adaptive thresholds to be set within a minute.
Proceed as follows:
1. Start the engine.
2. Engage the cutterhead.
3. Engage the feed rolls.
4. Throttle up to full engine speed.
5. Recall the metal detector page of the InfoView monitor by pressing key 10 (refer to Figure 2).
6. Press key 6 on the InfoView monitor to start the quick adjustment procedure (refer to Figure 2).
Run time test (On--board diagnostics)
The run time test is on--board diagnostic routine, initiated each 90 seconds when the cutter head is not engaged,
However, the first run time test after disengaging the cutterhead starts after 120 seconds.
This on--board diagnostic routine runs a test on the metal detector hardware to check if the left and right channel
hardware components (coils, amplifiers, A/D converter and frame ground) are still working properly.
The run time test consists of two parts:
1. The microprocessor checks the continuity of the coils in the EMD.

(This is done by injecting a small current into the coils to simulate a disturbance in the magnetic field. This
current is again measured by the microprocessor and verified if it corresponds with the injected current or
within a small deviation).
If this test fails, the run time test will be interrupted and an error code 273 will be communicated by the EMD
microprocessor to the InfoView monitor.
2. The microprocessor checks the continuity of the metal detector frame ground. Flat earth cables can be found
between the electronic module and the metal detector shaft, between the metal detector shaft and right--hand
side of the chopper body unit. A good frame ground between chopper body unit and base unit is also necess-
ary.
If this test does not succeed, an error code 277 will be generated.
TROUBLESHOOTING
52715
4
Conditions
When ignition is switched on, all information, such as threshold settings in InfoView Monitor, cutterhead and feed
rolls status and machine driving status, is provided to the EMD microprocessor through the CAN network. (See
CAN--Identifier 1278), who decides which actions need to be executed.
When the cutterhead is engaged (even if feed rolls are not running yet), the EMD microprocessor monitors if
metal is passing through the feed rolls. In other words, the EMD microprocessor continuously compares the
measured magnetic noise with the calculated adaptive thresholds or the selected fixed thresholds.
However, the adaptative thresholds calculation routine works only when the cutterhead and the feed rolls forward
drive is engaged and the machine is driving forward.
-- When the cutterhead is disengaged, every 90 seconds a “run time” test routine will be initiated to check all
EMD components.
However, the first “run time” test after disengaging the cutterhead starts after 120 seconds.
-- When a metal detection takes place during working operation (cutterhead engaged), it will always be com-
municated by the metal detector to the Adjust--O--Matic printed circuit (the classic output line drops to 0 Volts
and a CAN message is transmitted: see CAN Identifier 1304 first word: “Metal Detected”).
The decision to stop the feedrolls is made by the Adjust--O--Matic based on the AOM “metal detector status”
(see CAN Identifier 1304, first word: ===1).
The AOM “metal detector status” is enabled when the engine is started, harvest node is switched ON and the
cutterhead is engaged (see CAN Identifier 1304, first word: ===1).
The AOM “metal detector status” is disabled by means of the metal detector rocker switch on the instrument
panel.
The metal detector can be enabled by pressing the other side of the metal detector rocker should or by restarting
the machine.
When the AOM “Metal detector status” is enabled and a metal detection takes place, the following will happen:
-- The stop pawl solenoid will be activated, which will stop the feed rolls
-- The electromagnetic clutch will be disengaged
-- The metal detector diagnostic page will appear on the InfoView monitor screen.
However, when AOM “metal detector status” is disabled and a metal detection then takes places:
-- The stop pawl solenoid will not be activated, which will not stop the feed rolls.
-- The electromagnetic clutch will not be disengaged.
-- The metal detector diagnostic page will not appear on the InfoView monitor screen.
but:
-- A user message “Metal Detector OFF” will appear on the InfoView monitor every 30 seconds together with
one single beep.
-- The date and hour of the metal detection will be stored in the “Missed Metal Detection Date” (See CAN Ident-
ifier page 1301).
When the classic output line (wire 2096) suddenly has an open circuit or is short--circuited to earth, the pawl stop
system will be activated, although the signal is not generated by the metal detector.
Also, it is not possible to reactivate the metal detector by pressing the feed rolls reverse switch as long as the
problem is not solved.
The following table explains whether the pawl stop system will be activated or not when a metal detection takes
place.
Classic output
Wire 2096 not damaged Wire 2096 shorted to 12 V
CAN Network
EMO no network error Feed rolls will stop Feed rolls will stop (NEW)
EMO network error (117) Feed rolls will stop Feed rolls will not stop
ATTENTION: When diode V24 (located in the central box on X432) is defective or incorrectly installed, the Ad-
just--O--Matic printed circuit can be damaged and the metal detector stop system will no longer work.
During working operation, several test routines are watching the EMD functionality. If one test is unsuccessful,
it will be announced by means of an Error message.
CAN Identifiers

ID
1276 RUN time test procedure Running =1== =0==: Not running
1276 EMD hardware version ==XX
1276 EMD software version: XX== See software revisions
Node M
1276 Error code 277 Set ==8= ==0=: Not set
1276 Error code 273 Set ===8 ==0=: Not set
1276 Peak noise level left chan- XX== Limits: 00 < XX < 7F
nel, + values
1276 Peak noise level left chan- ==XX Limits: 00 < XX < 7F
nel, -- values
1276 Peak noise level right chan- XX== Limits: 00 < XX < 7F
nel, + values
1276 Peak noise level right chan- ==XX Limits: 00 < XX < 7F
nel, -- values
1278 Cutterhead disengaged Status 8=== 0===: Cutterhead engaged
1278 Feed rolls stopped Pressed 6===
1278 Feed rolls forward Pressed 2===
1278 Adaptive node selected 1=== 0===: Fixed mode selected
1278 EMD threshold setting in =X== = 0 when adaptive mode is
fixed node selected.
= 0 < X < 8 when fixed mode

is selected
1278 Forage Harvester stopped Status ===6
1278 Forage Harvester driving Status ===4
backwards
1278 Forage Harvester driving Status ===2
forwards
1278 Quick Adapt routine acti- Status ===1 ===1: Quick adapt routine
vated started
1283 Metal detector ON switch Pressed 4=== 0===: Not pressed
1283 Metal detector OFF switch Pressed =4== =0==: Not pressed
ID
1301 Missed metal detection date XXXX XXXX XXXX Hours: Minutes Day Month
Year (decimal code)
1303 Harvest mode activated Status ==1= ==0=: Road mode
1303 Feed rolls reverse engaged Output ===8 ===0: Feed rolls reverse not
status engaged
1303 Main drive clutch engaged Output ===1 ===0: Main drive not engaged
status
1304 Metal detected Input status =4== =0==: No metal detected
1304 Feed rolls forward engaged Output =2== =0==: Feed rolls forward not
status engaged
1304 Metal detector status Status ===1 ===0: Enabled
===1: Disabled
1314 Metal detector led Lights up ===4 ===0: Extinguished
1349 Active stop pawl stop sys- Output ===2 ===2: Activated
tem status ===0: Not activated
Error Messages
Error codes related to the electronic metal detector:
Error Code Key Words

117 EMD Network error
270 EMD Noise level low
271 EMD Output line --
272 EMD Output line +
273 EMD Channel fault
274 EMD Noise level high
275 EMD Network error
276 EMD Processor fault
277 EMD Frame ground
278 EMD Output failure
279 EMD Power failure
REMARK: Error 275 is suppressed by software.

22. ATTACHMENT HEIGHT CONTROL
1°) Calibration
To avoid error messages during the attachment height calibration, first check the voltages for the minimum and
maximum attachment height positions on the display, before starting the calibration procedure.
The voltage when the attachment is raised must be higher than : 6,2 V. Preferably not higher than 6.7 V.
The voltage when the attachment is lowered must be lower than : 5,0 V.
To start the attachment height calibration :
1. Start the engine.
2. Press the “CAL” button on the InfoView Monitor.
3. Select and Enter “2--Attachment calibration”.
4. Go to “Semi Automatic HHC Calibration” and Enter “Yes”.
Calibration procedure :
1. Calibration of the attachment height range: ground level.

The attachment is lowered to ground level, which for the Bosch module corresponds with a pressure in the
cyclinders of 0 bar.
-- start from a level above ground.

-- push “attachment down” for 2 seconds.
-- the attachment will automatically lower to ground level.
-- green LED: 5 blinks.
-- beep tone.
2. Calibration of the attachment height range: upper position.
Smax has to be higher than 6,2 V.
-- push “attachment up” for 2 seconds.

-- the attachment will automatically raise to its upper position.
-- beep tone
If Smax is lower than 6,2 V, the calibration procedure will interrupt and the following message will be displayed.
Stop the machine and adjust first the attachment height sensor before restarting the attachment calibration pro-
cedure.
CALIBRATION
SEMI AUTOMATIC HHC

CALIBRATION
INTERRUPTED
ATTACHM HEIGHT SENS.

OUT OF RANGE
READJUST SENSOR
06,0 V
3. Calibration of oil the pressure range: lower position.
The attachment will lower to to S1 = Smin + 0,9 V.
S1 has to be lower than 6,4 V.
-- push “attachment down” for 2 seconds.

-- the attachment will automatically lower to just above ground level
-- green LED: 8 blinks
-- beep tone
When the header is lowered for a second time, the system calculates the expected
S1 = Smin + 0,9 V. has to be lower than 6,4 V.
If this value is higher than 6,4 V, the system interrupts the calibration procedure with the following message:
CALIBRATION
SEMI AUTOMATIC HHC

CALIBRATION
INTERRUPTED
ATTACHM HEIGHT SENS.

OUT OF RANGE
MIN > 5,5 V
READJUST SENSOR
06,5 V
NOTE: If wait messages remains on screen at this point for more than 2 minutes, check performance at pressure
sensor B13.
4. Calibration of the oil pressure range: upper position.
The attachment is raised completely, and then lowered to level S2 = Smax -- 0,1 V.
And S2 has to be higher than S1 + 0,8 V.
-- push ”attachment up” for 2 seconds.

-- the attachment will automatically raise just under upper position
-- green LED: 12 blinks
-- beep tone
After reaching the last point S2, the system verifies the difference between S2 and S1.
If the result is lower than 0,8 V, a build--in standard curve will be applied.
This is indicated by the following message:
CALIBRATION
SEMI AUTOMATIC HHC

CALIBRATION
DEFAULT CALIBRATION
APPLIED
06,5 V
When the difference between S2 and S1 is higher than 0,8 V, the calibration procedure will finish and the follow-
ing message will be displayed.
CALIBRATION
SEMI AUTOMATIC HHC

CALIBRATION
SUCCESSFUL
05,0 V
Conclusion:
Allowed voltage range for Smin, Smax, S1 and S2.
An example is worked out for a machine on which Smax = 6.8 V.
Conditions for Smin
Calibration successful Default Calibration not possible

calibration
Smax = 6,8 V
S2 = 6,7 V (Smax -- 0,1 V)
S1 < 5,9 V (S2 -- 0,8 V)
Smin < 5,0 V (S1 -- 0,9 V)
If the attachment lowest position was lower than 5,0 V, the calibration would have been successful.
In case the lowest position would have been between 5,0 V and 5,5 V, which does not agree with condition S2
-- S1 > 0,8 V, the default calibration will be applied (a standard height--pressure line foreseen by Bosch).
In case the lower position would be higher than 5,5 V, the calibration procedure cannot be carried out as the at-
tachment is positioned to close to ground level in raised position.
2°) Functional Operation
a) Compensation mode
1) True compensation or floatation ( compensation mode selected).
1. Attachment bumps: attachment raises -- pressure drops

2. Compensation reaction: attachment raises -- pressure raises
3. Attachment drops: attachment drops -- pressure raises
4. Compensation reaction: attachment drops -- pressure drops
This mode is recommended when using a pick--up attachment.

Start the engine and engage the cutterhead.
Turn the attachment height control selector switch into ”pressure” position.
Give a pulse on the automatic attachment height button.
The attachment will automatically lower to the pre--selected pressure.
Adjust the required ground pressure during harvesting by means of the ground pressure potentiometer.
In this mode, the working pressure Pwork is adjusted with the potentiometer between 80% and 108% of the cali-
brated pressure P1 (= pressure calibrated in the low position, at sensor position S1). A line is drawn parallel to
the line between P1 and P2 that runs through Pwork. The system will always try to maintain a position on this curve
in function of sensor position S, for as long as the potentiometer remains in that position.
2) Compensation in stubble height mode.
1. Attachment bumps: attachment raises -- pressure drops

2. Compensation reaction: attachment raises -- pressure raises
3. Obstruction passed: returns to preset stubble height
In the stubble height mode, the compensation will start working when the pressure drops below P1 -- 4 bar (P1
is the pressure at the calibration point just above ground level) at any stubble height. If for example P1 = 45 bar,
then the compensation will always start working at 45 -- 4 bar = 41 bar, also if the pressure at the selected stubble
height actually is 50 bar. So P1 determines the pressure at which the compensation will start working in stubble
height control.
b) Stubble height mode

This mode is recommended when harvesting standing crops (e.g. maize) or when operating in stony conditions.
Start the engine and engage the cutterhead.
Turn the attachment height control selector switch into ”Stubble height” position.
Give a pulse on the automatic attachment height button.
The attachment will automatically lower to the pre--selected height.
Adjust the required attachment height during harvesting by means of the stubble height potentiometer.
It is possible to adjust the attachment in the following stubble height range :
Bottom level : Ground level determined during calibration (Smin)

--5% of the attachment height sensor operating range.
Top level : Ground level determined during calibration (Smin)

+ 45% of the attachment height sensor operating range.
See following picture.

3) Additional information :
a) All signals from switches are communicated over the CAN network, but the attachment height control module
(A60) does not communicate to the CAN network. For this reason all signals are again simulated by the actua-
tor printed circuit.
Simulated functions:
Attachment up and down switches :

Common wire : 209--wt to X57/P09 ; 5 Volts.
Switch up : 210--wt to X57/P36.
Switch down : 211--wt to X57/17.
Fast up or down (when harvest mode is selected) : 212--wt to X57/P03.
Automatic Attachment height control button S30.

Wire 206--wt to X57/P27 and wire 208--wt.
Attachment height control selector switch S35;
Wire 221--br to X57/P02, wire 214--bl to X57/P20 and wire 222--gn to X57/P21.
Measured voltage at X57/P21 with selector switch S35 in following positions :

Transport : between 63% and 80% of voltage at X57/P02.
Compensation : between 21% and 42% of voltage at X57/P02.
Stubble height : between 57% and 62% of voltage at X57/P02.
Compensation potentiometer R7.

Wire 2176--zw at X57/P05 ; between 0 and 10 Volts.
Stubble height potentiometer R6.

Wire 216--zw at X57/P22 ; between 0 and 10 Volts.
Green led :
Wire 215--gn at X57/P12.
Red led :
Wire 213--gn at X57/P31.
b) The attachment height sensor R4:
Disconnect sensor : measured voltages with ground.

X57/P39 : 9,5 Volts
X57/P06 : 7,2 Volts
Reconnect sensor.
Sensor fully in : 7,2 Volts (app. 75% of voltage at X57/P39).
Sensor fully out : 2,2 Volts (app. 25% of voltage at X57/P39).
c) Oil pressure sensor B13.
Disconnect sensor : measured voltages with ground.

X57/P39 : 9,5 Volts
X57/P08 : 7,2 Volts
Reconnect sensor.
Oil pressure sensor on Max pressure (160 bar) : 7,2 Volts (app. 75% of voltage at X57/P39).
Oil pressure sensor on Min pressure (0 bar) : 2,2 Volts (app. 25% of voltage at X57/P39).
4) Error messages :
Refer to Attachment height control error messages list
23. GROUND SPEED
Hydrostatic Hydrostatic Limb

oil oil home
pressure temp. procedure
switch switch
Engine MF MF Ground speed Mechanical PC

running handle forward handle Rpm sensor conditions: Calibrations
See group 1 = Drive backward = * No handbrake
forward Reverse * Machine in
drive gear
Speed Servo valve Reverse Hydrostatic oil Hydrostatic

indication on hydrostatic buzzer pressure led temperature
LCD pump led
Conditions
1. Engine is running.
2. Hydrostatic oil pressure is ok.
3. Hydrostatic oil temperature is ok.
4. Machine is not in limb home procedure.
5. Machine is in gear and handbrake is off.
6. To drive forward, the MF handle has to be moved to the front.

To drive in reverse the MF handle has to be moved to the back. The reverse buzzer will sound as soon as
the handle is out of neutral when moved to the back.
What causes the machine to move?
In short:
A switch inside the handle monitors if the handle is in neutral. When moving the MF handle to the front or the
rear the switch detects an out of neutral position. At the same time a potentiometer moves along with the move-
ment of the handle. An electronic circuit inside the handle assembly makes sure that this movement is translated
into a current which is transported to the hydrostatic servo valve in the hydrostatic pump. This valve again trans-
lates the current into a mechanical movement which controls the oil flow to the hydrostatic motor. This motor is
responsible for the movement of the machine.
Important things to know

I: * In Road mode, the ground speed sensor is used to determine and regulate the maximum allowed
speed.
* In harvest mode, the ground speed sensor is NOT used to regulate the forward speed.
A linear hydrostatic current curve is used to increase the forward speed. A maximum current of app. 105
mA (ID1304 word 4 = 1199) related to a maximum forward speed of app. 20 km/h in 3th gear.
* When driving in harvest mode and exceeding a speed that is higher than 90% of the maximum cali-
brated forward speed, the machine will automatically go to ROAD mode, which means the engine rpm
will drop back to 1650 rpm (Caterpillar engine) or 1750 rpm (Iveco engine).
* If the ground speed sensor information is not available, the forward speed in ROAD mode will be set
to a maximum of 90% of its maximum calibrated speed.
* North America machines have the ability to select full engine speed in ROAD mode.
II: It is not advisable but possible to move the machine with the handbrake on, however you will hear a warn-
ing signal from the LCD buzzer and the hand brake warning led on the dashboard will start blinking.
III: Together with software introduction REV’99 a new function, the ’limb home’ procedure ( can id 1319) has
been introduced:
If a fault in the CAN communication between Multi--function Lever and dashboard occurs or if a Multi--
function Lever errors code (error 12 or a combination of errors 350 & 351 together) occurs, resulting oper-
ator being unable to move the machine. The message ”urgent drive procedure continue yes/no” ap-
pears on the InfoView Monitor.
1. When choosing ”yes”, machine can be driven forward and rearwards at a speed of approximately
3 km /hour (depending of maximum speed calibration) using the crop processor gap adjustment
switch on the dashboard (up = forward, down = rearward, spring loaded to centre = neutral). To es-
cape from this mode switch off the contact.
2. When choosing ”no” the procedure is terminated. The fault must be repaired before the machine will
move.
IV: PC Calibration settings and LCD calibration settings are very important for ground speed troubleshoot-
ing. Before starting troubleshooting see that all calibrations are correctly done by following the instruc-
tions on laptop or pdt tool.
They are for pc/pdt: * Maximum handle position
* Minimum forward current to hydrostatic pump
* Minimum backward current to hydrostatic pump
* Ground speed constant
* Maximum forward speed
* Full engine speed in road mode (NA machines)
All these calibrations can be checked through can id.
And for LCD: * ground speed tuning in calibration mode on InfoView; its only purpose is displaying the
correct speed on the info view, you cannot manipulate the real speed of the machine by
changing the numbers.
To make the meaning of the calibration values more clearly a potentiometervalue/speed diagram is given.
As we can see here, when moving the handle forward, at first there is no movement of the machine until
potentiometer value of 71Hex is reached. From then on we have a linear function until 90% of the maxi-
mum speed calibration has been reached. At this point the curve is no longer linear to prevent the ma-
chine from going above the calibrated speed.
As for the reverse drive it is possible to drive up to about 15 kph, depending of the calibrated maximum
speed, from there on the current to the pump stays the same.
The hexadecimal numbers on the diagram are a reference, they don’t have to be exactly the same when
checking a machine through can spy 1282, word 3.
SPEED (V)
Vmax Max. calibrated speed (¦ 30 km/h)
90% of max. calibrated speed (CANSPY page 1304)
FORWAR
D
DRIVE
Vmin, FW
CANSPY
Page 1283 -- word 3 =
potentiometer value
in HEX.
Vmin, BW
REVERSE
DRIVE
Vmax, BW
(¦ 15km/h)
CAN SPY
CAN DESCRIPTION word1 word2 word3 word4 COMMENTS

ID
1282 Multifunction lever Out of neutral =2==
1282 Multifunction lever In neutral =1==
1282 Ground speed poten- ==XX In neutral XX = 5C +/-- 20 or
tiometer 48<XX<71
limits : 00 < XX < D0 +/-- 10
1288 Ground speed based XXXX Ground speed in mm/s based on
on PC calibration PC calibration
1288 Ground speed dis- XXXX Ground speed in mm/s based
played on display calibration
1303 Hydrost. oil press. Insufficient press ==8= ==0= : switch open ; ==8= :
switch switch closed
1303 Hydrost. oil temp. Temp too high ==4= ==0= : switch open ; ==4= :
switch switch closed
1304 Drive backwards Status 8=== 0=== : not driving
1304 Drive forwards Status 4=== 0=== : not driving
1304 Ground speed > 90% Status ===0 : ground speed < 90 %
V max. calibr. by pc Vmax
1304 Current to hydrostatic XXXX Limits: 0000 < XXXX < +/--1199
pump (= +/-- 105 mA)
1314 Hydrostatic oil pres- Lights up 4=== 0=== : extinguished
sure LED
1314 Hydrostatic oil temp. Lights up =8== =0== : extinguished
LED
1319 Activate Limb Home Status XXXX 53CA : to raise the request ;
Request else 0000
1319 Answer Limb Home Status XXXX 0000 : not answered yet ;
Request 55CC : ’yes’ is answered ;
1111 : ’no’ is answered
1331 Calibrated max speed XXXX mm/s (hexadecimal code)
1331 Calibrated max current XXXX Maximal value : 1199 (= +/--
to hydrost. pump 105 mA)
1342 Calibrated ground =XXX Hexadecimal code
speed constant
1342 Calibrated min forward XXXX Hexadecimal code
current
1342 Calibrated min back- XXXX Hexadecimal code
ward current
1342 Calibrated max handle XX== Hexadecimal code
pos.
1345 Calibrated low acceler- =8== =0==: not calibrated (no);
ation hydr. pump =8==:calibrated (yes)
1345 Calibrated full engine ===8 ===0: not calibrated (no); ===8:
speed road mode calibrated (yes)
Error codes
Error Codes Description

120 Ground speed sensor O
121 Ground speed sensor --
122 Ground speed sensor +
350 Ground speed POT--M
351 Stop ground speed SW
420 Hydrostatic pump O
421 Hydrostatic pump --
422 Hydrostatic pump +
Electrical scheme
See group 3
24. HIGH FLOW HYDRAULICS
Harvest Mode High capacity High capacity PC Calibration

hydraulics hydraulics High Flow
See group 3 switch UP switch down Hydraulics
High capacity
High capacity
Hydraulics
Hydraulics UP
down
To use the high capacity hydraulics.
3. Press the high capacity hydraulics UP switch to power the high capacity UP valve.
Press the high capacity hydraulics DOWN switch to power the high capacity DOWN valve.
REMARKS: High capacity hydraulics are an accessory.

To use the high capacity hydraulics, first the switch needs to be installed in the dashboard and the PC calibration
“High Flow Hydraulics” needs to be set (check on CAN SPY page 1345).
Afterwards the output lines can be powered.
Can Spy

ID
1283 High Flow Hydraulics Pressed 2=== 0=== : not pressed
open switch
1283 High Flow Hydraulics Pressed =2== =0== : not pressed
close switch
1345 Calibrated High Flow ==8= ==0=: not calibrated (no);
Hydraulics ==8=:calibrated (yes)
Error Codes

467 High cap. hydr. up sol.
468 High cap. hydr. down sol.
Electrical diagram
Group 28: High capacity rear hydraulics.
25. ROTARY SCREENS
Engine PC calibration
running rotary screen
See group 1
Rotary Rotary
screen screen
motor left motor right
Conditions:
As soon as the engine starts running, the rotary screens start rotating.
REMARK: The electronic system should be informed if rotary screens are installed to avoid error reports. See
PC Calibration.
Can Spy

ID
1345 Calibrated rotary ===1 ===0: not calibrated (no); ===1:
screens calibrated (yes)
1347 Rotary screens Output status 4=== 4=== : activated ; 0=== : not
activated
Error codes

446 Rotary screen motor
26. ROTARY SCREEN BRUSHES
Safe Harvest PC LCD

calibration calibration
See group 3
Dust screen
brush
actuator
Conditions:
To enable the brushes to clean the rotary screens, the pc calibration ’rotary brushes’ has to be set first (check
on can spy page 1345) . In the calibration/type menu of the LCD there are two options out of which you can choose
to determine the frequency of the brush cleaning. There is a ’frequent’ option for heavy conditions (= every 8
minutes the brush engages 2 minutes) and there is a ’standard’ option (= brush engages 1 minute every 15 min-
utes). This feature is introduced with software version REV’99.
Can Spy
CAN DATA DESCRIPTION word1 word2 word3 word4 Comments

ID
1345 Calibrated rotary screen ==1= =0==: not calibrated (no);
brushes =1==:calibrated (yes)
Error codes

445 Rotary screen brush
REMARK: Error 405 is suppressed by software.

The actuator contains end of stroke switches which will create an error code every time the actuator is extracted
or retracted. For this reason the error code is suppressed.
27. CATERPILLAR ENGINE
6
General Information
1°) Power Supply

Power (12 V) is supplied from the actuator printed circuit X413 p07 to the Caterpillar electronic Control Module.
Same output as the engine stop solenoid hold current on Aifo/Iveco engines. See electrical drawing group 9.
Conclusion:
-- 12 V after ignition, to be able to start the engine.
-- Engine will stop immediately or can not be started when output line becomes low (0V).
REMARK: Output current is approximately 3 Amp.
2°) Engine Throttle control
New CPU printed circuit available for FX 58.
Can also be used on other FX forage Harvesters.
Special PWM output line only used for FX 58 on X415 p04.

Frequency: 500 Hz Nominal (between 300 and 700 Hz)
Pulse width minimum engine rpm (850 rpm): 20%
Pulse width maximum engine rpm (2100 rpm): 80%
The engine rpm in road mode for the Caterpillar engine is 1650 rpm, on Aifo machines it is 1750 rpm.
See electrical diagram group 2.
3°) CAN Network
The CAN communication wires to the Caterpillar engine are parallel on the CAN wires of the metal detector.
See electrical diagram group 11.
New AOM printed circuit involved, only for FX 58.

Can not be used on other FX forage Harvesters.
A CAN resistor R31 of app. 120 Ω is installed close to the Caterpillar electronic control Module to obtain a correct
CAN communication.
CAN IDENTIFIER LIST
See complete CAN Identifier List
CAN Identifier 1352 & 1353

ID
1352 Coolant temperature Status XX== Range : --40°C to +210°C
(1C/bit)
1352 Fuel temperature Status ==XX ==XX Range : --40°C to +210°C
(1C/bit)
1352 Inlet air temperature Status XX== Range : --40°C to +210°C
(1C/bit)
1352 Load percentage at current Status ==XX Range : 0% to 125% (1%/bit)
engine speed
1352 Inlet manifold pressure Status XX== Range : 0kPa to +500 kPa
(2kPa/bit)
1352 Engine oil pressure Status ==XX Range : 0kPa to +1000kPa
(4kPa/bit)
1352 Calibrated maximum engine Status XXXX Range : 0 to 8031.875 rpm
rpm (0.125 rpm/bit)
1353 Engine rpm Status XXXX Range : 0 to 8031.875 rpm
(0.125 rpm/bit)
1353 Error codes report Status XXXX XXXX XXXX See detailed list
4°) Error codes reporting

Two wires from Caterpillar electronic control module towards the CPU printed circuit are used for error code re-
porting.
When the Caterpillar electronic control module detects an error, the corresponding CAT error code number is
shown on the InfoView Monitor below the engine rpm bargraph.
Detailed list of Caterpillar error codes: see section 55--7B.
Error codes

118 Caterpillar Network Error
340 No Engine oil press.
361 Oil press. sens. fault
364 Cat. oil temp. sensor
5°) Engine protection
-- From an engine coolant temperature of 103° C the Caterpillar software reduces the available engine power
in steps of 25% per ° C.
-- The engine is shut down by the NH electronic system (see point 1: power supply) when the engine coolant
temperature reaches 105° C or when the engine oil pressure is less than 1 Bar.
-- An additional engine oil temperature sensor located in the oil sump will stop the engine at a temperature of
app. 118° C.
This sensor is connected to the NH electronic system (see electrical wiring diagram: group 20) and is used as
a back--up sensor to protect the Caterpillar engine when a CAN network fault occurs.
This engine protection device is programmed to wait 10 minutes with engine below 1500 rpm or 3 minutes with
the engine above 1500 rpm. This is to allow the oil temperature to rise above the minimum operating limit of the
sensor.
If the sensor or wiring to this sensor becomes defective, the engine shuts down.
REMARK: Both protection devices work parallel to each other.

The first who indicates an excessive temperature or pressure will activate the engine shut down procedure.
So the engine will stop after 10 seconds.
If the engine has been shut down, restart the engine by leaving the contact on and restart. Afterwards the mess-
age “AUTOMATIC ENGINE SHUT OFF DISABLED” will appear on the InfoView monitor.
6°) Caterpillar operation

A FX machine with Caterpillar engine (FX 58) is operated a complete identical way as other FX for age Har-
vesters.
Exceptions:
-- The engine load bargraph at the right--hand side of the screen represents the engine power consumption.
The top (narrow) segment represents the engine power range from 95% to 100%.
The lower (wide) segment represents the engine power range from 100% to 110%.
-- When the engine rpm drops below 1850 rpm and the power consumption is above 98%, a buzzer will warn
the driver to slow down. Also the engine symbol will blink.
28. CAN NETWORK
B B B B B B
InfoView Dashboard Adjust-- CPU

Monitor Node O--Matic Node
Node
Y
B B
Caterpillar
EMD
Only FX 58
General procedure to diagnose CAN--NETWORK

-- Verify Software Revision on Service page.
• If Rev99 or later is displayed, correct software is installed and no network fault is present.
• If Rev X.X is displayed, incorrect software revision is installed or a network fault is present.
-- Check software revision CAN--Identifiers in CAN SPY
Node Location CAN--Identifier

A&S InfoView Monitor 1326 ==== ==== ==XX ==XX
B CPU printed circuit 1303 ==== ==== ==XX ====
D AOM printed circuit 1304 ==== ==== ==XX ====
M Metal Detector 1276 ==== XX== ==== ====
-- If one or more nodes contain a “00” --value or not the correct value, try to download the correct software re-
vision in the corresponding nodes.
REMARK: If the AOM printed circuit is defective and a “OO” value is displayed on the CAN--Identifiers 1304, most
probably a “00” will also be displayed for the B Node and M Node, as all communication goes over the AOM
printed circuit.
Conclusion:
-- If B, D and M node indicate a “00” value, start to focus on the D--Node.
• If the software download is finished correctly, check if the problem persists by starting the engine and
clearing all error codes in the error overview.
• If the software download procedure will not start, or is not finished correctly, a hardware problem is caus-
ing the problem.
-- First check all power supplies to all printed circuits.

• Check fuses F4 and F11.
• Check for battery voltage when ignition is switched on:
at X303 p07 in Dashboard
at X417 p15 on CPU printed circuit
at X413 p08 on Actuate printed circuit
at X619 p02 at Metal detector
at X57 p24 at Bosh Module
• Check for ground
at X303 p10 in Dashboard
at X433 p01/02 on AOM printed circuit
at X619 p03 at Metal detector
at X57 p28/07 at Bosh Module
If necessary, locate and repair open or shorted circuit in Electronic box. Replace fuses.
Start engine again to verify if problem persists.
-- Check fibber optics and flat cables and their connections.

Refer also to error code list: errors 1 to 15.
To understand better the function of the network error codes imagine you are in the InfoView monitor.
• Information sent out from the InfoView towards the CPU Node through the flat cable and optical fibbers is
not arriving in one node.
However the communication lines towards the InfoView Monitor are still correct.
These nodes will lose synchronisation in communicating to each other and the InfoView monitor can not un-
derstand any longer the messages. For this reason, the InfoView monitor will display an Error 1 (and 2).
• If information sent out from the CPU--Node towards the InfoView monitor is interrupted somewhere, the
closest node can still communicate in a correct way and indicate he does not receive good information from
the other node.
In this way:
an error 10 will be displayed in case of incorrect communication from dashboard to InfoView Monitor
an error 13 will be displayed in case of incorrect communication from CPU--Node to AOM--node
an error 15 will be displayed in case of incorrect communication from AOM--Node to dashboard.
REMARK:
An error 117 will be displayed in case of incorrect communication with the Metal detector.
An error 118 will be displayed in case of incorrect communication with the Caterpillar electronic Module (only for
FX 58).
Additional Information
Difficulties to download software:

1. Software download does not start.
2. Software download interrupts after a few seconds.
We recommend to proceed as follows in case of a problem:

1. Make sure the batteries are fully charged.
2. When the software download does not start, try to switch the ignition key off and on again several times.
3. When the software download interrupts, it is possible to download an individual software node by connecting
the fibre optics from the dashboard directly to the printed circuit you want to update.
REMARK: Always write down the position of the optical wires before disconnecting so that you can reinstall them
in the original position after software download.
For FX/96 Forage Harvesters proceed as follows:
a) Download of node A and S (in InfoView monitor)

Disconnect optical wires (from dashboard) in central box on the Adjust--O--Matic printed circuit. Only the Info-
View can receive the CAN messages.
After software download, (re)connect all optical wires to the original positions.
b) Download of node B (in CPU printed circuit)

Disconnect the small optical wires (from Adjust--O--Matic print) in the central box on the CPU printed circuit.
Remove the optical wire (from the dashboard) located in the white sender of the AOM print and connect to
the white sender of the CPU print. Proceed in the same way with the other optical wire in the black receiver.
Only the InfoView and the CPU print can receive the CAN messages.
After software download, (re)connect all optical wires to the original positions.
c) Download of node D (in AOM printed circuit)

Disconnect the small optical fibres in the central box on the CPU printed circuit.
Disconnect the CAM communication line to the metal detector. Disconnect for example X431 on AOM printed
circuit or X627 above RHS tractor wheel.
Only the InfoView and the AOM print can receive the CAN messages.
After software download, (re)connect all optical fibres to the original positions.
How to recognize a network error code:
If a AOM network failure occurred, all AOM Leeds on the dashboard will illuminate, the led of the sharpening cover
will start to flash and the work lights will illuminate.
If a CPU network failure occurred, the engine oil pressure led, the engine coolant led, the battery led, the airco
leds will illuminate or will start to flash, also the work lights will illuminate.
REMARK: Since 1996, the errors 1 to 15 will only appear on the InfoView Monitor when the problem occurred
while the engine was running.
In all other cases, the errors will not appear, but the above described symptoms will indicate the presence of a
Network failure.
The Auto Voting PC--calibrations exchange
The calibration preferences are stored on three nodes, e.g. InfoView Monitor, CPU and AOM printed circuits.
When the engine is started these calibration settings are compared.
If the choises or settings on one Node is different from the others, the Nodes in majority will influence and change
the choises or settings of the node that is in the minority.
For this reason never exchange two printed circuits at the same time.
Software download
The Auto--Voting PC--calibrations exchange does not apply to the software itself, so always check new printed
circuit boards if the correct software is installed (by means of the CAN--Identifiers),
If not correct, always download the correct software first.
12 V battery voltage after ignition
Engine hours cutterhead hours, hectare information and calibrations settings need to be stores after the engine
has been stopped.
Therefore permanent battery voltage need to arrive on InfoView Monitor, CPU and AOM printed circuit to store
this information.
REMARK: 12 V battery voltage can be found on flat cable, position 15 and 16 in InfoView Monitor.
When no battery voltage arrives in InfoView Monitor you will not hear a relays click after 3 to 5 seconds after igni-
tion has been switched off.
This can result in an Error Code 100 after some time.
SECTION 60 -- PRODUCT FEED -- CHAPTER 1 1
Chapter 1 -- Feed Rolls
CONTENT

60.103 Removal and installation of lower feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
60.107 Inspection between upper feed rolls and cutterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flip down upper feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Detaching -- attaching of attachment with upper feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal -- installation of upper feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly and assembly of upper feed roll drive chain box . . . . . . . . . . . . . . . . . . . . . . . 22
2 SECTION 60 -- PRODUCT FEED -- CHAPTER 1
REMOVAL AND INSTALLATION OF LOWER
FEED ROLLS
LOWER FRONT FEED ROLL
Removal and disassembly
1. Remove the upper feed roll module from the

chopper body.
2. On the right-hand side, remove plates C and D by

removing bolts A and B.
55126
3. Disconnect the metal detector cable at connector

E and the ground cable at F.
4. Support the right-hand end of the lower feed roll

and remove the locking bolt of the drive collar A.
(Fig. 4). Push the collar towards the length-of-cut
gearbox on the left-hand end of the feed roll
(Fig. 4).
55127
5. Remove bolts G and H, loosen bolts J (Fig. 2)

and lift away the side plate K.
6. Remove the lower front roll by lifting it out to the

right.
55128
3
7. Remove mounting bolts B.
8. Pull flange and shaft assembly C out of the feed

roll.
9. Pull the metal detector shaft D with flange and

bearing assembly E out of the feed roll.
NOTE: If the electronic box needs to be replaced, this

can be done now.
30655
10. Remove ground cable A and the four electronic

box fastening bolts B and tilt the box to the side.
55129
5
11. Remove the wire clamps C and disconnect the
wires at connectors.
12. Install a new electronic box in reverse order of

disassembly.
55130
13. Disassemble the flange assemblies E and F from

the metal detector shaft D.
14. Disassemble bearings and seals and replace, if

necessary.
30656
Assembly
Install the lower front feed roll in the correct way. The
arrow shows the feeding direction of the roll (Fig. 4).
To assemble, proceed in reverse order of the disas-

sembly sequence.
Ensure to seal off possible openings in the feed roll

with sealing paste.
SMOOTH ROLL
Removal
1. Remove the upper feed roll assembly.
2. On the right-hand side, remove plates C and B by

removing bolts A and B (Fig. 1).
3. Support the right-hand end of the lower feed roll.
4. Remove bolts G and H, loosen bolts J (Fig. 2)

and lift away side plate K (Fig. 3).
5. Remove the smooth roll scraper. 55131
6. Remove bolt A from the smooth roll drive sleeve 8

B.
7. Remove bolts C and remove the smooth roll to

the right from the chopper body.
55132
8. Remove sleeve B from shaft G.
9. Remove circlip D, special bearing E and O-ring

F from shaft G.
55133
10
10. Remove circlip H, locking collar J, bearing hous-
ing K with bearing, anti-wrap shield L and bush-
ing M from shaft N.
55134
11
Assembly
To assemble, proceed in reverse order of the re-

moval sequence.
NOTE: Before installing the smooth roll into the

chopper body, push drive sleeve B onto shaft G
(Fig. 10). Make sure the sleeve does not bind on the
shaft.
Install bushing M (Fig. 11) with the rounded surface

towards the smooth roll.
Bearing housing K has oblong holes C (Fig. 11). Ad-

just bearing housing K so that the smooth roll dis-
tance to the shearbar support P is the same on both
ends of the smooth roll (Fig. 9).
Adjust the smooth roll scraper so that there is a maxi-

mum clearance of 0.1 mm to the smooth roll.
INSPECTION BETWEEN UPPER FEED
ROLLS AND CUTTERHEAD
NOTE: The attachment must remain attached to the

forage harvester.
Opening up the assembly
1. Lower the chopper body until the attachment

rests on the ground.
2. Disconnect the two quick–release hydraulic

couplings 2. 12
3. Maize attachment with Auto-Pilot only:

Disconnect electric cable 3.
4. Remove the cover on the left-hand side.
5. If the chopper body is fitted with an automatic

greasing system, disconnect the grease line(s)
between the upper feed roll module and the
chopper body. If there is a grease line to the at-
tachment that is not coming from the upper feed
rolls module, disconnect that one as well.
6. Disconnect attachment drive p.t.o. shaft 4.
58227
13
7. Remove cover 7 and bolt 6. Remove upper feed

roll drive shaft 5 by pulling out shaft 8.
14
8. Unscrew clamping rods 9 between the upper
feed roll module and the cutterhead.
9. Extend the hydraulic cylinders by giving the ‘‘at-

tachment up’’ command from the multifunction
lever.
58228
15
10. Install safety latches 10 by removing lynch pins
11 on both sides.
A V–shaped gap will appear between the feed rolls

and the cutterhead. This will enable you to inspect
the cutterhead knives and the shearbar in a quick
way (Fig. 17).
If necessary, the cover above the cutterhead can be

removed for an even better access.
16
Closing the assembly
1. Lift safety latches 10 from the cylinders and se-

cure them with lynch pins 11 (Fig. 16).
2. Give the ‘‘attachment down’’ command from the

multifunction lever to retract the hydraulic cylin-
ders after ensuring nobody is near the machine.
30521
17
3. Reinstall clamping rods 9 between the upper
feed roll module and the cutterhead, and tighten
firmly.
58228
18
4. Reinstall attachment drive p.t.o. shaft 4.
58227
19
5. Reinstall upper feed roll drive shaft 5 with shaft

8 and bolt 6. Reinstall cover 7.
NOTE: Make sure that the drive yokes on each end

of the attachment drive shaft are in phase.
Make sure that the attachment drive shaft is installed
in such a way that the shaft end cannot touch the feed
roll gearbox.
6. If the machine is fitted with an automatic greasing

system, connect the grease line(s) to the upper
feed roll module and the attachment.
7. Reinstall the cover on the left–hand side. 20

Connect electric cable 3.
9. Connect the two quick–release hydraulic cou-

plings 2, if needed.
21
FLIP DOWN UPPER FEED ROLLS
1. Detach the attachment as described in para-

graph headed ‘‘Attachment’’.
3. If the attachment is fitted with an automatic

to the upper feed roll module.
22
roll shaft 5 by pulling out shaft 8.

feed rolls and the cutterhead.
58228
23
6. Place a wooden block (approximate height

25 cm) on the workshop floor where profile 10 is
supposed to come. This is to protect your feet.
7. Flip down the upper feed roll module until it

touches the wooden block.
WARNING
Flipping down the upper feed rolls is a job to be car-
ried out by at least three people. Utmost care should
be taken.
58230
24
1. Lift up the upper feed roll module.
2. Reinstall clamping rods 9 between the upper

feed roll module and the cutterhead, and tighten
firmly.
58228
25

8 and bolt 6.

of the drive shaft are in phase.
roll gearbox.

greasing system, connect the grease line to the
upper feed roll module.
26
5. Reinstall the cover on the left-hand side.
DETACHING -- ATTACHING OF ATTACH-
MENT WITH UPPER FEED ROLLS 1
Detaching
1. Install supports 1 on both sides of the pick-up at-

tachment.
30884
27
In case of a maize attachment, lower supports 1
on both sides.
28
2. Remove the two pins 2 of the upper feed roll mod-
ule underneath the chopper body (left and right-
hand side).
3. Lower the attachment to the ground until it rests

on its supports and skids.
29
4. Disconnect quick-release hydraulic couplings 2.

Disconnect electric cable 3.
7. If the chopper body is fitted with an automatic

between the upper feed roll module and the
chopper body. If there is a grease line to the at-
tachment that is not coming from the upper feed
roll module, disconnect that one as well.
30
8. Disconnect attachment drive p.t.o. shaft 4.
58227
31
roll drive shaft 5 by pulling out shaft 8.
32
feed roll module and the cutterhead.
11. Lower further until the lower feed rolls are loose.
12. Carefully reverse the harvester.
58228
33
13. Now all upper feed rolls are accessible.
30523
34
The cutterhead and the shearbar are accessible
(Fig. 34 and 35).
52490
35
The accessibility to the cutterhead can be im-
proved by removing cover 10 above the cutter-
head.
58229
36
Attaching
1. Drive up to the attachment and lift the chopper

body.
2. Reinstall the two pins 2 underneath the chopper

body connecting the upper feed roll module to the
chopper body.
3. Lower the attachment until the gap is closed (if

necessary, use the attachment supports).
37
4. Reinstall clamp rods 9 between the upper feed
roll module and the cutterhead, and tighten firm-
ly.
58228
38
5. Reinstall attachment drive p.t.o. shaft 4.
58227
39

8 and bolt 6.

of the attachment drive shaft are in phase.
roll gearbox.

greasing system, connect the grease line(s) to
the upper feed roll module and the attachment.
40
9. Connect hydraulic quick-release couplings 2, if

needed.

Connect electric cable 3.
41
11. Relocate the supports at 1 of the pick-up attach-
ment. 1
30884
42
In case of a maize attachment pull up the sup-
ports 1 on both sides.
43
REMOVAL -- INSTALLATION OF UPPER
FEED ROLLS
Removal
1. Drain the oil from the upper feed roll chain box
through plug 2.
2. Remove the upper feed roll module from the

chopper body.
3. Release the feed roll spring tension and discon-

nect the springs from the upper feed roll assem-
bly.
4. Remove support assembly A on both sides of the

feed roll assembly.
58200
5. On both sides, remove bolt C and screw bolts D 44

in to pull out pivot shafts B.
NOTE: Pivot shaft B in the chain box is installed with

O–rings C (Fig. 46).
6. Remove bolts D so the side plates are loose from

the roll supporting bearing housings.
7. Remove bolts E and cover F.
8. Remove dowel pin G and pull out the drive shaft

55125
yoke. Do not lose shims W.
45
9. Remove bolts H, J and L.
10. Remove four bolts K and lift out the cross bar.
11. Make an extractor plate and pull out chain box M

from feed roll shafts P and Q.
12. Pull the left–hand shaft suspension casting N

from shafts P and Q.
13. Remove circlip S and pull out bearing R.
14. Remove circlip GG and pull out bearing T.

15. Remove ring AA, journal bearing BB and ring V Assembly
from shaft Q.
16. Remove circlip FF, ring CC, journal bearing EE sembly sequence.
and ring DD from shaft Q.
17. To disassemble the chain box, refer to paragraph NOTE: Install the pivot shafts using a liquid sealant.
headed “Upper feed roll drive chain box”.
30653
46
FX/96 Series 13 > .........
FX25-45 Series 05 > .........
Removal
1. Detach the attachment as described in para-

graph headed ‘‘Attachment’’.
2. Drain the oil from the upper feed roll chain box
through plug 2.
3. Flip down the upper feed roll module as de- 58200
scribed in previous paragraph. 47

4. Release the feed roll spring tension and discon-
nect the springs 1 from the upper feed roll assem-
bly. Hold nut 6 in place with a flat wrench and
loosen bolt 2.
58417
48
5. Loosen locknuts 2, remove cotterpins 3, remove
nuts 4 and remove locknuts 2 on both sides.
49
6. Remove support A on both sides of the feed roll
assembly.
7. On both sides, remove bolt C and screw in bolts

D to pull out pivot shafts B.
NOTE: Pivot shaft 28 in the chain box is installed with

O–rings 29 (Fig. 52).
Write down the quantity and position of shims at 15
and at 27. Retain them for the reassembly.
55125
50
8. Disconnect the shock absorbers at 1 and 2 on
both sides.
51
9. Remove the upper feed roll assembly with a lift-
ing tool out of the module.
10. Remove bolts 17, 24, 30 and covers 18, 25, 31

(Fig. 52).
11. Remove bolts 21 so the side plates are loose

from the roll supporting bearing housings
12. Remove dowel pin 11 and pull out the drive shaft
yoke 10.
13. Remove bolts 16, 26 and 32.
14. Remove eight bolts 34 and lift out the cross bar
33.
15. Pull out chain box 23 with an extractor plate from

feed roll shafts 5 and 22.
16. Pull the suspension casting 14 from shafts 5 and

22.
17. Remove circlip 19 and pull out bearing 20.
18. Pull out bearing 13.
19. Remove shims 12, ring 9, journal bearing 8,

shims 6 and washer 7 from shaft 5.
20. Remove ring 1, journal bearing 2, shims 4 and

washer 3 from shaft 5.
21. To disassemble the chain box, refer to next para-

graph.
Assembly

sembly sequence.
NOTE: Install the pivot shafts using a liquid sealant.
52
DISASSEMBLY AND ASSEMBLY OF UPPER which tensions the chain more is available from Ser-
FEED ROLL DRIVE CHAIN BOX vice Parts.
Disassembly 3. Remove bolts E and pull apart the two chain box
halves A and B (Fig. 54).
1. Remove the chain box from the chopper body as
described in previous paragraph headed “Re-
NOTE: The chain box halves are sealed with a liquid
moval -- Installation of the upper feed rolls“.
sealant.
2. Remove oil dipstick A, bolts B and cover C
4. Remove sprockets G and H. Replace if neces-
(Fig. 53).
sary (Fig. 54).
NOTE: If only the chain is slack:

NOTE: Always replace both sprockets and the chain
Remove bolts K and replace chain tensioner
at the same time.
D(Fig. 53).
If the original version of the chain tensioner is not giv-
ing proper tension to the chain, a second version 5. If necessary, replace bearings C, F, J and L, and
seals D and K (Fig. 54).
30658
53
30659
54
Assembly
1. Assemble the box in reverse order of disassem-

bly.
2. Fill the gearbox with 0.5 litre of oil with the follow-
ing specifications:
Chapter 2 -- Length-Of-Cut and Feed Roll Drive Gearbox
CONTENT

60.122 Gearbox shafts and shifting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal of length-of-cut gearbox from the chopperbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Length-of-cut gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Length-of-cut gearbox disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation of length-of-cut gearbox on the chopperbody . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
GEARBOX SHAFTS AND SHIFTING DIA-
GRAM
GEARBOX SHAFTS FROM THE LEFT
Shaft A: Input shaft

Shaft B: Counter shaft
Shaft C: Upper feed roll drive intermediate shaft
Shaft D: Upper feed roll drive gear
Shaft E: Attachment drive shaft
Shifter rod H: Long shifter rod for gear positions 1 and
54831
2
Shifter rod J: Short shifter rod for gear positions LOW 1
and HIGH
GEARBOX SHAFTS FROM THE RIGHT
Shaft A: Input shaft (not visible)

Shaft B: Counter shaft
Shaft C: Upper feed roll drive intermediate shaft
Shaft D: Upper feed roll drive gear
Shaft E: Attachment drive shaft
Shaft F: Lower front feed roll (electronic metal de-
tector roll) drive shaft
Shaft G: Smooth roll drive shaft
54832
2
SHIFTING DIAGRAM
31058
3
REMOVAL OF THE LENGTH-OF-CUT GEAR-
BOX FROM THE CHOPPER BODY
1. Drain the oil from the gearbox.
2. Remove guards A and B.
54833
4
3. Remove the p.t.o. shaft B from the gearbox.
4. Remove bolts D and cover E, and pull out upper

feed roll drive shaft C. Remove shaft A.
5. Slide the smooth roll drive bushing towards the

smooth roll.
6. Slide the lower front feed roll bushing towards the

gearbox.
54834
5
7. Support the gearbox with a hoist or other lifting
gear.
8. Remove the gearbox mounting bolts and bush-

ings. If shims are installed, note the position and
the quantity of shims installed.
9. Pull and lift the gearbox away with a hoist using

the lifting eye provided.
NOTE: The gearbox is heavy, take the necessary

precautions to avoid accidents. 54835
6
LENGTH-OF-CUT GEARBOX DISASSEM- 4. Open stake lock washer Q and remove lock nut
BLY P and washer Q.
REMOVAL AND DIS ASSEMBLY OF THE INPUT 5. Press shaft A out of bearing housing F and re-
SHAFT GROUP move bearing T from shaft A.
1. Mark the position of bearing cap M and bearing 6. Remove bearing cones D and J and seal S from
housing F and remove grease fitting H. bearing housing F.
2. Remove the four bolts and hardened washers G

NOTE: Seals N and S will be damaged when they are
and pull out the input shaft assembly. Be careful
removed.
not to damage shims at E or the O--ring C.
3. Remove bolts and washers L and remove cover

M from the bearing housing F. If damaged re-
move seal N. Take care not to damage O--ring K.
31059
7
REMOVAL OF UPPER FEED ROLL DRIVE SHAFT 3. Remove bushing K from shaft D.
D AND INTERMEDIATE DRIVE SHAFT ASSEM-
BLY C 4. Remove bearings E, G, M, and N from the shafts
or bearing housings. Remove ring L.
1. Remove bolts and washers H and cover Q.
5. Remove seals F and J.
NOTE: Cover Q was installed with liquid sealant.

NOTE: Seals F and J will be damaged when they are
2. Pull out shafts D and C and remove gear P from removed.
shaft C.
31060
8
REMOVAL OF SMOOTH ROLL DRIVE SHAFT G 3. Remove circlip V and tap out shaft assembly G.
1. Remove bolts and washers C, bearing cap H and 4. Remove circlips S, W, and M.
shims J. Take care not to damage O--ring D.
Retain the shim pack J for later use. 5. Remove bearing components K and L, ring N and
seal P.
NOTE: The removal of bearing cap H is necessary

only if gear A or shaft B need to be removed from the NOTE: Seal P will be damaged when it is removed.
gearbox or bearing F needs to be replaced.
6. Pull bearing F and gear A from shaft B.
Note the way gear A is installed on the shaft.
2. Remove bolts Q and tap out housing R together
with shaft assembly G and bearing cone E. Note
the positions of the bolts.
31073
9
REMOVING COVER C FROM THE GEARBOX 6. Remove bolts and hardened washers A and note
the location of the bolts. Replace damaged
1. Remove bolts and washers D and cover H. Take washers.
care not to damage O--ring J.
7. Tap cover C loose from the gearbox and pull it
2. Remove circlip G from the shaft HH. away over the shafts.
3. Remove circlip M from shaft F.

NOTE: Cover C was installed with liquid sealant.
4. Remove bolts and washers Q and the bearing
8. If damaged, remove the bearings JJ, AA, T and
cap P. Take care not to damage seal L or O--ring
R , circlips KK, FF, W, V and S from cover C and
K.
ring EE from shaft F.
5. Remove circlip N.
31072
10
DISASSEMBLY OF SHAFT AND SPROCKET AS- 6. Pull and lift out the shaft and gear assembly B
SEMBLIES B, E AND F (Fig. 13). Gear L and the bearing components A
and C have to be removed at a later stage.
1. Remove bearing race H, circlip G, spacer ring J,
gear D and the needle bearings C from shaft F 7. Remove nut M (installed with thread retainer),
(Fig. 11). lock washer N, washer P and spring Q from
shifter shaft J (Fig. 14).
2. Pull gear C from shaft E and remove needle bear-
ings B and D from gear C and shaft E (Fig. 12). 8. Remove shifter fork R (Fig. 14) and and shifter
gear A (Fig. 12) simultaneously.
3. Remove nut K (installed with thread retainer) and
washer G from shifter shaft H (Fig. 14). 9. Remove circlip J from the end of the shaft E and
drive out the shaft (Fig. 12).
4. Remove shifter fork L (Fig. 14) and shifter gear
A (Fig. 11) simultaneously. 10. Remove seal H, spacer K and O--ring L (Fig. 12).
5. Remove bolt E, special washer D and oil plate G

from shaft B (Fig. 13). NOTE: Seal H will be damaged when it is removed.
31063
11
11. Remove circlip S and pull out shifter fork T 15. Remove Allen screw FF, spring DD, ball CC,
(Fig. 14) together with shaft and bearing assem- spring V and circlips W and AA. Pull the shifter
bly F (Fig. 11). Remove gear L (Fig. 13) from the shaft J out of the gearbox housing (Fig. 14).
gearbox.
12. Remove failed bearings, rings and seals from the NOTE: O--ring BB will be damaged when shaft J is
housings of the gearbox main casting removed (Fig. 14).
(Fig. 11, 12 and 13).
16. Remove washers and bolts J and bearing cap K
13. Remove the bearing inner race C from gear L and shims H (Fig. 13). Retain the shims for later
(Fig. 13). use.
14. Remove Allen screw C, spring D and ball B from 17. Remove bearing cone A from the gearbox hous-
the gearbox housing and circlip F from shaft H. ing. (Fig. 13).
(Fig. 14) Pull shaft H out of the gearbox housing.
NOTE: O--ring E will be damaged when shaft H is re-

moved (Fig. 14).
31064
12
54749
13
LENGTH-OF-CUT GEARBOX ASSEMBLY INSTALLATION OF THE (LONG) SHIFTER SHAFT
J INTO THE GEARBOX HOUSING
INSTALLATION OF THE (SHORT) SHIFTER
SHAFT H INTO THE GEARBOX HOUSING 1. Remove any paint from shaft J and lubricate the
shaft.
1. Remove any paint from shaft H and lubricate the
shaft. 2. Move circlip EE on the shaft as close as possible
to the black knob.
2. Move circlip A on the shaft as close as possible
to the black knob. 3. Introduce shaft J into the gearbox. Slide the O--
ring BB onto the lubricated shaft. Move shaft J so
3. Introduce the shaft into the gearbox. As soon as far that the O--ring can be installed in its groove
possible slide the O--ring E onto the lubricated at BB. Install circlips AA and W into their grooves.
shaft H so that it is seated in its groove at E.
4. Pull O--ring BB into the housing far enough to in-
4. Pull O--ring K into the housing far enough to install circlip EE.
stall circlip A. Install circlip F.
5. Install ball CC, spring DD and Allen screw FF.
5. Install ball B, spring D and Allen screw C. Lock Secure screw FF in place with thread retainer.
screw C in place with thread retainer.
31066
14
INSTALLATION OF SHAFTS AND GEARS INTO 4. Drive bearing inner race L onto shaft F and install
THE GEARBOX HOUSING circlip N. Keep the bearing outer race M together
with this assembly.
Preassembly of lower feed roll drive shaft F
NOTE: Bearing component L may be heated up to

1. Install the two needle bearings J, gear H and
100°C maximum to facilitate the installation.
spacer ring G and onto shaft F.
2. Install a set of three needle bearings E, gear NOTE: The disassembly is done in reverse order of
carrier K and shifter gear D onto shaft F. the assembly sequence.
3. Install rings C and B and gear A onto shaft F.
31085
15
Preassembly of counter shaft B 5. Tighten the lock nut H until there is no axial play
in the assembly. A slight preload is needed, the
1. Install bearing cups C and E into the gear assem- shaft should not turn freely.
bly D.
6. Secure nut H with washer J.
2. Install bearing A on shaft B and drive it in until it
is properly seated. 7. Install bearing inner race G.
3. Install gear assembly D onto shaft B and install

bearing F onto shaft B. NOTE: Bearing component G may be heated up to
100° C maximum to facilitate the installation.
NOTE: You can also heat up the bearing compo-

nents A and F to 100° C maximum to facilitate the in- NOTE: The disassembly is done in the reverse order
stallation. of the assembly sequence.
4. Install locking washer J and stake nut H on shaft

B.
31068
16
SHAFTS, GEARS AND BEARINGS 5. Install spring V on shifter shaft J (Fig. 14) and
simultaneously install shifter fork T and the pre
1. Install dual roller bearing G in the gearbox hous- assembled shaft F (Fig. 15) as shown in Figure
ing and install the circlip M (Fig. 17). 18. Install circlip S on the shifter shaft J (Fig. 14)
2. Install the bearing cup A and cover K with bolts 6. Install needle bearing N on shaft E (Fig. 17).
and washers J. Do not install shims at this time
(Fig. 19). 7. Install shaft E in place (Fig. 17) . Lubricate and in-
stall O--ring L, spacer ring K, circlip M and seal J.
3. Install bearing C onto gear L (Fig. 19) and lift the
gear assembly into the gearbox housing.
NOTE: Glue seal J in place with “Loctite 480”.
NOTE: The gear assembly must be in place before 8. Install the countershaft assembly B (Fig. 19) into
the shaft assembly F (Fig. 18) is installed. the gearbox housing. At the same time gear L
must be installed on shaft B (Fig. 19).
NOTE: Bearing component B may be heated up to 9. Install needle bearing C into gear D and bearing
100° C maximum to facilitate the installation. inner race B onto gear D. Retain the bearing, the
ring and the circlip for later use (Fig. 17).
4. Install bearing M into the gearbox housing
(Fig. 18).
NOTE: Secure bearing C in place with “Loctite 601”.
31069
17
10. Install gear assembly A--D on shaft E (Fig. 17) 12. Install the two needle bearings C into gear D
simultaneously with shifter fork R (Fig. 14). (Fig. 18).
Install spring Q washer P lock washer N and nut
M (Fig. 14). 13. Install the gear and bearing assembly onto shaft
F. (Fig. 18).
NOTE: Nut K should be installed with locking com-

14. Install ring J circlip G and drive the bearing inner
pound “Loctite 243” and tensioned to a torque of 70
race H until it is seated on circlip F (Fig. 18).
Nm.
11. Simultaneously install shifter ring A (Fig. 18) and NOTE: Bearing component H may be heated up to
shifter fork L, washer G and nut K (Fig. 14). 100°C to facilitate the installation.
NOTE: Nut K should be installed with locking com-

pound “Loctite 243” and tensioned to a torque of 70
Nm.
31070
18
54749
19
INSTALLATION OF COVER C
1. Install bearing R and circlip S (Fig. 21) in the

gearbox cover at shaft position G.
2. Install circlip W, bearing T and circlip V in the

cover at shaft position B.
3. Install bearing AA and circlip FF in the cover at

shaft position F. Retain the ring and circlips for
later use.
54836
4. Install circlip KK and bearing GG in the housing
at shaft position E. 20
5. Coat the gearbox contact surfaces with cover C

with liquid sealant “Loctite 573”.
6. Lift the cover in place and secure it with hardened

washers and bolts A.
NOTE: Install bolts A with thread retainer “Loctite

243”. Torque the guide bolts to 22 Nm and the other
bolts to 40 Nm.
7. Install the ring, circlip G on gear HH and O--ring

J into cover H. Install the cover with bolts and
washers D.
8. Install the ring, circlip N on shaft F and O--ring K

into bearing cap P. Install cap P with washers and
bolts Q. Install seal L.
NOTE: Glue seal K in place with “Loctite 480”.
9. Install circlip M.
31072
21
INSTALLATION OF THE SMOOTH ROLL DRIVE 5. Install spacer N, seal P and circlip M.
SHAFT G
1. Install gear A and bearing F onto shaft B. NOTE: Glue seal P in place with “Loctite 480”.
6. Cover the contact surfaces of cover R with liquid

NOTE: Bearing component F may be heated up to sealant “Loctite 573”. Install the preassembled
100° C maximum to facilitate the installation. cover R onto the gearbox and fasten with
washers and bolts Q.
NOTE: Gear A should be installed with the bearing

puller grooves towards the shaft end. NOTE: Install bolts Q with thread retainer “Loctite
243”. Torque the guide bolts to 22 Nm and the other
2. Install circlip S, bearing K and circlip V in bearing bolts to 40 Nm.
housing R.
7. Install bearing cup E in cover R.
3. Install ring T and circlip W on shaft G.
8. Install O--ring D into cover H. Install cover H on
4. Install bearing inner races L and AA on shaft G the housing R with washers and bolts C.
and slide the shaft assembly through bearing K.
NOTE: Do not install shims at this time.

NOTE: Bearing components L and AA may be
heated up to 100°C maximum to facilitate the in-
stallation.
31073
22
ASSEMBLY AND INSTALLATION OF INPUT
SHAFT A
• Measuring the shimming value for bevel gear D

and gearbox housing J.
1. Turn the gearbox so that the cover H (Fig. 22)

faces down.
2. Tap shaft B down so it is perfectly seated at bear-

ing F (Fig. 22).
54837
3. Remove bearing cap K. Install a sufficient quan-
tity of shims, reinstall bearing cap K and tighten 23
it until there is no radial or axial play in shaft B.
Turn shaft B a few turns so it centres perfectly.
4. Measure distance A and write it down.

Example Distance A = 33,30 mm
54838
24
• Measuring the shimming value for the input shaft

assembly.
1. Measure distance C on input shaft A. Measure

this distance on different sides of the gear. Write
down this measurement.
54839
25
2. Install oil seal S into bearing housing F. The open
side of the seal should be towards the splined
end of the shaft.
NOTE: Glue seal S in place with “Loctite 480”.
3. Press bearing T onto shaft A until it is firmly

seated against the gear.
NOTE: Bearing T is thicker than bearing R. Ensure

to install them in the correct order on shaft A. 31074
26
NOTE: Bearing component T may be heated up to
100° C to facilitate the installation.
4. Install bearing cup D into bearing housing F.
5. Install the gear and bearing assembly A into the

bearing housing F (Fig. 26) and rotate the shaft
15 full turns so the bearing halves seat properly.
6. Measure distance D on different sides of the

shaft. Write down the measurement.
7. Determine distance B from the following formula:

B = D -- C
Example: 54840
C = 32.80 mm
D = 61.30 mm 27
B = 61.30 mm -- 32.80 mm = 28.50 mm
Note down value B.
8. The number of 0,05 mm thick shims needed at E

(Fig. 26 and 28) can be determined from the
table here below.
Example
A = 33.30 mm
B = 28.50 mm
The number of shims needed is 9.
A Number of 0.05 mm shims needed

B = 28.3 B = 28.4 B = 28.5 B = 28.6
33.2 7 9 11 13
33.3 5 7 9 11
33.4 3 5 7 9
33.5 1 3 5 7
33.6 0 1 3 5
33.7 0 0 1 3
PREASSEMBLY OF THE INPUT SHAFT AND 7. Install O--ring K into bearing cap M and install the
BEARING HOUSING latter onto bearing housing F with bolts and
washers L.
1. Remove shaft A from bearing housing F.
NOTE: Install bolts L with thread retainer and torque

2. Install bearing cup J into bearing housing F.
to 8 Nm.
3. Install bearing housing F onto the shaft A .

8. Install seal N with the open side towards the shaft
end.
4. Install bearing R onto shaft A and press it in place
but leave some axial play.
NOTE: Glue seal S in place with “Loctite 480”.
5. Install stake washer Q and stake nut P and
tighten up the assembly until there is no axial 9. Install O--ring C, install the predetermined quan-
play. Make sure there is no radial play on the tity of shims at E. Install the preassembled input
shaft. Lock nut P in place with washer Q. shaft into the gearbox and secure in place with
washers and bolts G.
NOTE: A slight preload is better than any axial or
radial play. NOTE: Install bolts G with thread retainer and torque
to 40 Nm.
6. Install grease fitting H into the bearing housing F.
31075
28
BACKLASH ADJUSTMENT OF THE INPUT GEAR
AND SHIMMING OF THE CONICAL BEARINGS
ON COUNTER SHAFT B
1. Turn the gearbox as shown and tap down shaft

B.
2. Lock shaft B with a large screwdriver.
3. Now measure the backlash = X on the input shaft

A and write it down.
54841
4. The thickness of the shim pack needed at J
(Fig. 31) can be calculated with the following for- 29
mula:
(X -- 0,1) x 2 + 0,05 mm = shim pack in mm
Example:
Measured value X = 0,25 mm
(O,25 mm -- 0,1) x 2 + 0,05 mm = 0,35 mm.
Note down the shim pack value,which for this
example is 0.35 mm.
5. Loosen, but do not remove the bearing cap K

(Fig. 29).
6. Turn the gearbox. Remove cover H and install

the predetermined shim pack at J. Reinstall O--
ring D. Install cover H with bolts and washers C.
Give the bearing housing a light hit to free the
bearing from any tension.
31076
30
54842
31
7. Turn the gearbox and remove bolts and washers
J, cover K and previously installed shims
(Fig. 29). Push bearing J as far down as possible
(also refer to Fig. 33).
54749
32
8. Measure the distance Y from the upper side of

the bearing to the surface of the casting and note
down the value.
54843
33
9. Measure the distance Z on the bearing cap K

(refer to Fig. 23).
10. The thickness of the shim pack needed at H

(Fig. 32) can be calculated with the following for-
mula:
Y -- Z -- 0,05 = shim pack in mm
11. Install the pre determined shim pack at H

(Fig. 32) and install bearing cap K with bolts and
washers J.
54844
34
NOTE: Install bolts J with thread retainer “Loctite
243” and torque them to 20 Nm.
12. Check the backlash of the input shaft again which

should be between 0,11 and 0,17 mm. If not, re-
adjust.
13. Install plate G, washer D and bolt E (Fig. 32).

INSTALLATION OF INTERMEDIATE GEAR, 4. Install ring L into the bearing housing in cover Q.
SHAFT ASSEMBLY C AND UPPER FEED ROLL
DRIVE GEAR ASSEMBLY D 5. Install preassembled shaft D in cover Q.
1. Install gear P onto shaft C 6. Apply some good quality grease in both bearing
housings of shaft C.
2. Install bearings E and N onto shaft C.
Apply some good quality grease into the bearing 7. Apply liquid sealant on cover Q and install it on
housing in cover Q. Install the assembly into the gearbox with washers and bolts H.
cover Q.
8. Install seals F and J.
3. Pre install bearings G and M and bushing K onto
shaft D.
NOTE: Glue seals F and J in place with “Loctite 480”.
NOTE: The chamfered end of bushing K should be

turned away from bearing M.
31078
35
INSTALLATION OF LENGTH-OF-CUT
GEARBOX ON THE CHOPPERBODY
1. Install the gearbox in reverse order of the disas-

sembly sequence.
2. Install shafts, clutches and bushings.
3. Fill the gearbox with oil.
Gearbox capacity: 6,3 litres
Oil specification:
AMBRA HYPOIDE 90 oil (ref. NH520A) or an oil

Chapter 3 -- Electromagnetic Reversing Gearbox
CONTENT

60.165 Operation of electromagnetic reversing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removing the reversing gearbox from the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly and assembly of the electromagnetic clutch (type Warner) . . . . . . . . . . . . . . . 8
Burnishing procedure of the electromagnetic clutch (type Warner). . . . . . . . . . . . . . . . . . . . 11
Disassembly and assembly of the electromagnetic clutch (type Stromag) . . . . . . . . . . . . 13
Removal and installation of feed roll and attachment drive safety clutch . . . . . . . . . . . . . . 18
Disassembly and assembly of the reversing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION OF ELECTROMAGNETIC RE-
VERSING GEARBOX 2 1
The reversing gearbox uses a planetary gear system

controlled by an electromagnetic clutch and a three--
position switch to turn the feed rolls in forward and re-
verse.
• The planetary gear system:
1. Sun gear
2. Planet gears 4 3
ZDA0412A
3. Planet gear carrier
1
4. Ring gear
• The electromagnetic clutch: Type Warner

(Fig. 2): 1 2 3
1. Forward magnet (rotating)

2. Armature
3. Reverse magnet (stationary)
The forward magnet 1 is directly connected to the

sun gear. As the sun gear is directly driven by the
blower drive train, the forward magnet will always ro-
tate when the main clutch is engaged.
The armature 2 is connected to the planet gear

carrier.
The revers magnet 3 is rigidly installed on the revers-

ing gearbox housing and will not rotate.
Both magnets 1 and 3 have a 2,62 ohm resistance,

are four pole and are able to transfer a 1.500 Nm
torque when the voltage is 11V or more.
ZDA0413A
2
• Type Stromag :
1. Forward magnet (stationary)

2. Forward drive plate (rotating)
3. Armature
4. Reverse magnet
The forward magnet 1 is held stationary by a support

plate which is installed onto the reversing gearbox.
The forward drive plate 2 is directly connected to the

sun gear. As the sun gear is directly driven by the
blower drive train, the forward drive plate will always
rotate when the main clutch is engaged.
The armature 3 is connected to the planet gear

carrier.
The reverse magnet 4 is rigidly installed on the re-

versing gearbox housing and will not rotate.
Both magnets have a xxxx ohm resistance, are x pole

and are able to transfer a 1500 Nm torque when the
voltage is 11 V or more.
3
• Switch
The switch 1 installed on the multifunction lever has

three positions:
1. Push the upper part two times for feeding mater-

ial.
2. Push the lower part once to stop the feed rolls.
3. Push the lower part a second time and the feed

rolls will reverse as long as the switch is pressed
down. 4
FORWARD (Feed rolls feed crop into the ma-
chine)
• TYPE WARNER
Press the upper part of the switch two times. The ar-
mature is attracted by the forward magnet rotate
along with the forward magnet. As the planet gear
carrier is connected to the armature, it will also rotate.
This rotation causes the ring gear to rotate in the
same direction and makes the feed rolls rotate for-
ward.
• TYPE STROMAG
5
Press the upper part of the switch two times. The ar-
mature is attracted by the stationary forward magnet
and is pulled against the forward drive plate and ro-
tates along with the forward drive plate. As the planet
gear carrier is connected to the armature, it will also
rotate. This rotation causes the ring gear to rotate in
the same direction and makes the feed rolls rotate
forward.
NEUTRAL (Feed rolls remain immobile)
Press the lower part of the switch once and the gear-
box goes into neutral.
• TYPE WARNER
The armature is separated from both magnets.
• TYPE STROMAG
The armature is separated from the reverse magnet

and the forward drive plate.
The sun gear causes the planet gears as well as the 6

planet gear carrier to rotate. The ring gear remains
immobile, the feed rolls do not rotate.
REVERSE (Feed rolls feed the crop out of the ma-

chine)
Press the lower part of the switch a second time and

hold it depressed. The armature is attracted by the
reverse magnet and both remain immobile. The
planet gear carrier also remains immobile. The sun
gear makes the planet gears rotate, which in turn ro-
tate the ring gear. This rotation makes the feed rolls
turn in reverse.
7
Item Description Number
of teeth
1. Input gear (from main clutch) 28
2. Intermediate gear (1) 57
1
3. Intermediate gear (2) to 39 9
electromagnetic clutch
4. Sun gear 16 2
5. Planet gears 15
6
6. Ring gear 47
7. Intermediate gear 22 7 5
3
8. Output gear 62 4 10
9. Input shaft 2000 rpm
10. Intermediate shaft rpm 5
11. Output shaft rpm 11
8
ZDA0411A
8
REMOVING THE REVERSING GEARBOX
FROM THE MACHINE
Removing the gearbox from the machine (both

versions)
1. Drain the oil from the gearbox through hose A.
54845
9
2. Remove the three drive shafts A, B and C from
the gearbox .
54846
10
3. Disconnect the electric cable to the stopping sys-
tem at A.
54847
11
4. Disconnect the cable to the electromagnetic
clutch at B.
54848
12
5. Remove the lock nut and washers D (Fig. 11
and 13). Remove the bolt, nut, washer and bush-
ing at B (Fig. 11). Support the metal detector
stopping system assembly. Remove the three
bolts and washers C (Fig. 11) and lift out the stop-
ping system.
6. Remove rod and washers E and bolt and

washers F from the left hand end of the gearbox.
54849
13
7. Remove the bolts and washers G and lift the
gearbox out from the forage harvester.
54850
14
ELECTROMAGNETIC CLUTCH (TYPE
WARNER)
NOTE: The electromagnetic clutch can be disas-

sembled without removing the reversing gearbox
from the machine.
Disassembly
1. Remove the grease shield H from the machine.
54850
15
2. Unplug the two wires from the stationery magnet

at A and B. Note the position of the wires.
54851
16
3. Cut the plastic strap at CC, Unplug the two wires

G at the brush holder F and unscrew the brush
holder F from the shaft (Fig. 17 and 21).
54852
17
4. Bend up tab washer D and remove nut E. Re-
move the four nuts J and lock washers K (Fig. 18
and 21).
5. Pull away the magnet A. Note the position and

the quantity of washers and shims L installed be-
tween magnet A and hub H (Fig. 19 and 21).
54853
18
6. Pull out hub H (Fig. 19 and 21).
7. If oil seal C is leaking, the seal can now be re-

placed (Fig. 21).
NOTE: The seal should be glued in place with “Loc-

tite 480”.
54854
19
8. Remove circlip B (Fig. 21). Remove shims N,

note down the thickness of the shim pack and
keep for later use. Remove clutch plate AA
(Fig. 20 and 21). Remove shims Q and note
down the thickness of the shim pack and retain
it for later use. Remove the circlip V (Fig. 21).
9. If oil seal T is leaking, the seal can now be re-

placed (Fig. 21).

tite 480”. 54855
20
10. Remove the four nuts W, lock washers R and
spacer rings S. Remove stationary magnet P
from shaft BB (Fig. 21).
31085
21
Assembly
1. Assemble the clutch in reverse order of disas-

sembly.
2. Adjust the air gap between the clutch plate AA

and the magnets P and A to 0,8 -- 2,0 mm by ad-
ding or reducing the number of shims at N and Q.
It may also be necessary to add or reduce the
number of washers at L.
3. Tighten nut E to a torque of 170 Nm (125 lbf.ft)

and secure with the tab washer D.
BURNISHING PROCEDURE OF THE ELEC- 7. Start the engine and run it at low idle.
TROMAGNETIC CLUTCH (TYPE WARNER) WARNING
Make sure the exhaust gasses are properly evacu-
When a new electro magnetic clutch, or new compo- ated and nobody is standing in the vicinity of the ma-
nents of an electromagnetic clutch are installed, the chine.
new components need to be “burnished”.
Proceed as follows: 8. Engage the cutterhead. the engine must remain

on low idle.
1. Get hold of an electromagnetic clutch magnet.
9. Push wire C (the wire coming from pin 5 in con-
2. Make three single threaded jumper wires of ap- nector X432) against connector X40 on the fuse
proximately 75 cm length. The cross section printed circuit E inside the electronic box.
should be at least 2 mm. The metal detector stop pawl will be activated.
Activate the stop pawl for max 2 seconds at
3. Wires A and B need a ring terminal on one end a time.
and a pin terminal in the other end. Wire C needs
a pin terminal in both ends. 10. Push wire A (the wire coming from the loose
clutch) against connector X41 on the fuse printed
4. Secure the ring terminals of wires A and B to the circuit E inside the electronic box.
terminals of the loose clutch D. Activate the clutch for maximum one second.
5. Disconnect connector X432 from the Adjust-- 11. After one second, remove wires A and C from the
O--Matic printed circuit board inside the central connectors X41 and X40.
electronic box.
12. Wait at least one minute to allow the clutch to cool
down.
WARNING
Make sure the ignition is switched OFF or the battery
13. Repeat steps 9 to 12 ten times.
switch is in the OFF position.
NOTE: The feed roll cut--out clutch may create a rat-

6. Install wires B and C to the pins 5 and 7 on the tling noise when slipping.
female side (loose end) of the connector X432.
54856
22
ELECTROMAGNETIC CLUTCH (TYPE
STROMAG)
NOTE: The electromagnetic clutch can be disas-

sembled without removing the reversing gearbox
from the machine.
Disassembly
1. Remove the grease shield 1 from the machine.
2. Cut plastic strap at 2 and unplug the connectors

at 1 and 3 from the magnets. Note the position of
the connectors.
3. Remove clutch plate 5 by removing six bolts 6.
23
4. Remove rubber damper 1 by loosening nuts 2. If

necessary remove plate 3.
24
5. Remove six bolts 5 and lock plate 10.
6. Pull away the magnet assembly 1. Note the posi-

tion and the quantity of washers and shims at 4
(Fig. 26) installed between magnet assembly 1
and hub 6 (Fig. 26).
25
7. Remove nut 8 and washer 7. Pull out hub 6.
26
8. If oil seal 9 is leaking, the seal can now be re-

placed .

tite 480”.
9. Remove circlip 12 and shim pack13, note down

the thickness of the shim pack and keep for later
use.
10. Remove clutch plate 14.
27
11. If oil seal 18 is leaking, the seal can now be repla-

ced.
12. If oil seal 18 is leaking, the seal can now be re-

placed .

tite 480”.
13. Remove four nuts 19 and lock washers. Remove

stationary magnet 17.
28
Assembly
1. Check the condition of seal 18. If oil seal is leak-

ing, the oil seal can be replaced.

tite 480”.
2. Install stationary magnet 17 and tighten four bolts

19.
3. Install circlip16, shimpack 15 and armature14.

Adjust air gap between armature 14 and station- 29
ary magnet 17 to 0.2 -- 0.4 mm at minimum open-
ing and 0.2 -- 0.7 mm at maximum opening by ad-
ding or reducing the number of shims at 15.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15
16
17
19 18
ZDA0421A
30
4. Install shimpack 13 and circlip 12. It may also be
necessary to add or reduce the number of shims
at 13.
31
5. If oil seal 9 is leaking, the oil seal can be replaced.

tite 480”.
32
6. Install bolts 11 with Loctite in hub 6 and tighten by
hand .
7. Install hub 6, washer 7 and nut 8 on shaft

(Fig. 32) . Tighten up nut to 170 Nm.
33
8. Install shim pack 4 and rotating magnet 1. Adjust
air gap between armature 14 and rotating
magnet 1 to 0.2 -- 0.4 mm at minimum opening
and 0.2 -- 0.7 mm at maximum opening by adding
or reducing the number of shims at 4 (Fig. 30).
9. Secure nut 8 with lock plate 10.
34
10. Install rubber damper 1 and fix with nuts 2
(Fig. 35). If removed, reinstall plate 3.
35
11. Reinstall clutch plate 5 with bolts 6.
12. Reinstall electric connectors 1 and 3 from the

magnets. Install plastic strap at 2.
13. Reinstall grease shield 4.
36
REMOVAL AND INSTALLATION OF FEED
ROLL AND ATTACHMENT DRIVE SAFETY
CLUTCH
NOTE: The feed roll and attachment drive safety

clutch can be removed from the machine without re-
moving the reversing gearbox from the machine.
Removal
NOTE: The metal detector stopping system must be

removed before the clutch assembly can be remo-
ved.
1. Remove the feed roll and attachment drive shaft

A by removing the bolts B.
54857
37
2. Remove bolt C and bushing D and pull out the

clutch and ratchet wheel assembly E.
54858
38
3. Remove special washer F and replace if dama-

ged.
54859
39
Installation
NOTE: The clutch must be installed on the reversing

gearbox before the metal detector stopping system
is installed.
1. Install the washer F onto the shaft with the

“chamfered“ side facing towards the clutch.
54859
40
2. Install the clutch and ratchet wheel assembly E

onto the shaft.
3. Install the bushing D and the bolt C. Apply “Loc-

tite 242” on the threads of bolt C and tighten to a
torque of 107 Nm (80 lbf.ft).
54858
41
REVERSING GEARBOX
Optional high blower speed
1. If installed, remove the high blower speed shaft

F from the gearbox.
2. Remove bolts A and pull out cover B. Remove

seal C.
30660
3. Pull out shaft F with bearings D and E.
42
4. Assemble in reverse order when the rest of the
gearbox has been assembled.
This section covers two versions of reversing gear-

boxes.
FX300-375-450/ Series 01 to 12
FX9630-9640-9645
Gearboxes with a serial no: 746 or smaller.
FX300-375-450/ Series 13 to 14
FX9630-9640-9645 Series 5033 to ...
Series 5033 to ...
FX28-38-48-58 Series 5083 to ...
Gearboxes with a serial no: 747 or higher.
NOTE: Do check the serial number of the gearbox,

because an older machine can be equipped with a
recent gearbox.
4. Remove seal N and circlip P and drive out the
FX300-375-450/ Series 01 to 12
planet carrier assembly H from the gearbox
FX9630-9640-9645 housing E.
5. Disassembly planet carrier H proceeding in re-
Gearboxes with a serial no: 746 or smaller. verse order of the assembly procedure. See
further under subheading “Reversing gearbox
assembly”.
A. Reversing gearbox disassembly 6. Remove circlip J and bearing Q.
1. Remove bolts and washers A and T and pull 7. Remove circlip KK and spacer JJ and lift away
apart the gearbox halves E and MM. ring gear R.
NOTE: The gearbox halves are sealed with a liquid 8. Remove shaft gear BB from the gearbox.
sealant. Remove spacer ring AA and bearings S and V.
Also remove seal W.
NOTE: Gear shafts C and G are symmetrical. They
should be marked before removal. 9. Remove needle bearing CC and ring DD from
shaft L.
2. Remove shaft C with bearings D and NN. Re-
move seals B and PP. Remove bearings D and 10. Remove the three bolts HH and the three
NN from shaft C. washers GG. Lift away the gear and shaft L from
the gear box half MM
NOTE: The seals will be damaged when removed.
11. Remove circlip FF and bearing EE from shaft L
3. Remove gear G with bearings F and LL. Remove
bearings F and LL from shaft G.
31086
43
B. Reversing gearbox assembly
Disassembly of the planet carrier assembly is done

in revers order of assembly.
-- Preassembly of the planet carrier
1. Press bushing A into the gear E and clean away

possible metal residue.
54860
44
2. Press bushings G into the planet carrier H.
NOTE: The outer bushing should be pushed so far

that there is 3 mm free space between the bushing
and the seal.
NOTE: The bushings G should be installed into H

with “Loctite 641”.
3. Install spacers F, the preassembled gears E,

spacers B and circlip C onto shafts D.
31087
45
-- Preassembly of shafts and bearings -- Figure 46
1. Install bearings D and NN onto shaft C.
2. Install bearings F and LL onto gear G.
3. Install bearing EE onto shaft L and secure with

circlip FF.
4. Install bearings S and V, and spacer AA onto

shaft BB.
-- Installation of the preassembled parts into the

gearbox housings MM and E -- Figure 46
1. Install the preassembled shaft L and bearing EE

into the gearbox half MM and secure in place with
washers GG and bolts HH.
2. Install the preassembled planet carrier in gear-

box half E and install the circlip P.
3. Install the preassembled shaft G into the gearbox 11. Replace studs K if they are damaged.
half MM. Install the new studs with the shorter thread side
into the gearbox using a thread locking com-
4. Install the preassembled shaft BB into the gear pound.
box half MM.
12. Install the electromagnetic and the header drive
5. Install the ring gear R, ring JJ and circlip KK on safety clutches onto the reversing gearbox as de-
shaft L. scribed at the beginning of this section.
6. Install the preassembled shaft C into the gearbox 13. Install the optional high blower speed kit if it was
half MM removed.
7. Install bearing Q and circlip J into the gearbox 14. Install the gearbox into the machine in reverse
housing half E. order of the removal sequence.
8. Install the preassembled planet carrier in gear- 15. Fill the gearbox with oil:
box half E and install the circlip P.
Gearbox capacity: 4 litres
9. Coat the lower gearbox half contact surface with
liquid sealant (Loctite 573). Oil specification:
Install the second gearbox half and secure it in
place with washers and bolts A and T. Use AMBRA HYPOIDE 90 oil ( ref. NH520A) or
10. Install the seals B, N, M, W and PP. -- API GL5 or MIL--L--2105 D
NOTE: Glue the seals in place with “Loctite 480”
31086
46
3. Remove gear G with bearings F and NN. Re-
FX300-375-450/ Series 13 to 14
move bearings F and NN from shaft G.
FX9630-9640-9645 Series 5033 to ...
FX25-45 Series 05 to 06 4. Remove seal N and circlip P and drive out planet
carrier assembly H from gearbox housing E.
Series 5033 to ...
FX28-38-48-58 Series 5083 to ... 5. Disassemble planet carrier H proceeding in re-

verse order of the assembly procedure. See
Gearboxes with a serial no: 747 or higher. further under subheading ‘Reversing gearbox
assembly”.
A. Reversing gearbox disassembly 6. Remove circlip J and bearing Q.
7. Remove circlip MM and spacer LL and lift away

the ring gear R.
1. Remove bolts and washers A and T and pull
apart the gearbox halves E and PP.
8. Remove shaft gear BB from the gearbox. Re-
move spacer ring AA and bearings S and V. Also
NOTE: The gearbox halves are sealed with a liquid remove seal W.
sealant.
9. Remove needle bearing CC and ring DD from
shaft L.
NOTE: Gear shafts C and G are symmetrical. They
should be marked before removal. 10. Remove three bolts KK and three washers JJ. Lift
away the gear and shaft L from the gear box half
2. Remove shaft C with bearings D and QQ. PP. It may be necessary to remove cover FF from
Remove seals B and RR. Remove bearings D the gearbox half PP, Allen screw HH and special
and QQ from shaft C. washer GG and to tap out the shaft and the bear-
ing EE.
NOTE: The seals will be damaged when they are re-

moved. NOTE: Cover FF will be damaged when removed.
31089
47
B. Reversing gearbox assembly
Disassembly of the planet carrier assembly is done

in revers order of assembly.
-- Preassembly of the planet carrier
1. Press bushing A into gears E and clean away

possible metal residue.
54860
48
2. Press bushings G into planet carrier R and install
circlip J.
NOTE: Bushings G should be installed with “Loctite

641”.
3. Install spacer rings F, the preassembled gears E,

spacers B and circlip C onto shafts D.
31088
49
-- Preassembly of shafts and bearings -- Figure 50
1. Install bearings D and QQ onto shaft C.
2. Install bearings F and NN onto gear G.
3. Install bearing EE on shaft L and secure it with

special washer GG and Allen screw HH.
4. Install bearings S and V, and spacer AA onto

shaft BB.
-- Installation of the preassembled parts into the

gearbox housings PP and E -- Figure 50
1. Install the preassembled shaft L and bearing EE

into the gearbox half PP and secure in place with
washers JJ and bolts KK.
2. Install ring DD and needle bearing CC onto shaft

L.
3. Install the preassembled shaft G into the gearbox 11. Replace studs K if they are damaged.
half PP. Install new studs with the shorter thread side into
the gearbox using a thread locking compound .
4. Install preassembled shaft BB in gear box half
PP. 12. Install the electromagnetic and the header drive
safety clutches onto the reversing gearbox as de-
5. Install ring gear R, ring LL and circlip MM on shaft scribed at the beginning of this section.
L.
13. Install the optional high blower speed kit if it was
6. Install preassembled shaft C in gearbox half PP. removed.
14. Install the gearbox in the machine in reverse

7. Install bearing Q and circlip J in gearbox housing order of the removal sequence.
half E.
15. Fill the gearbox with oil:
8. Install preassembled planet carrier H into gear-
box half E and install circlip P. Gearbox capacity: 4 litres
9. Coat the lower gearbox half contact surface with Oil specification:
liquid sealant (Loctite 573). Install the second
gearbox half and secure in place with washers Use AMBRA HYPOIDE 90 oil ( ref. NH520A) or
and bolts A and T. an oil meeting the following specification:
10. Install seals B, N, M, W and RR. Also install cover
FF.
NOTE: Glue the seals and the cover in place with

“Loctite 480”.
31089
50
SECTION 64 -- CUTTERHEAD -- CHAPTER 1 1
SECTION 64 -- CUTTERHEAD
Chapter 1 -- Chopping
CONTENT

64.000 Splitting of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Attaching and detaching the attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal -- installation of chopper body with A-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal -- installation of chopper body with hydraulic jack . . . . . . . . . . . . . . . . . . . . . . . . . 12
64.106 Removal -- installation of rotor and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
64.130 Removal -- installation of cutterhead gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly and assembly of cutterhead gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
64.150 Removal -- installation of shearbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal and installation of shearbar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2 SECTION 64 -- CUTTERHEAD -- CHAPTER 1
SPLITTING OF COMPONENTS
WARNING
Splitting of components must always be carried out
with the utmost care and attention. Failure to do so
may lead to severe injuries or even death.
The forage harvester offers several possibilities to

detach functional elements of the machine in an easy
way. These possibilities allow you to check, repair or
replace almost every part of the chopper body and
the blower in a quick way.
58225
1. Attaching and detaching the attachment WARNING

2. Inspection between the upper feed rolls and Follow the correct sequence of the proper procedure
the cutterhead (refer to Section 60 -- chapter 1) as detailed further in this paragraph.
3. Attaching and detaching the attachment with
the upper feed rolls (refer to Section 60 -- chap-
ter 1)
4. Flip down the upper feed rolls (refer to Section
60 -- chapter 1)
5. Inspection between the cutterhead (or the crop
processor) and the blower(refer to Section 70 --
chapter 1)
6. Dismounting and mounting the chopper body
ATTACHING AND DETACHING THE AT-
TACHMENT 1
Detaching
1. Install supports 1 on both sides of the pick-up at-

tachment (Fig. 3). In case of a maize attachment,
lower supports 1 on both sides (Fig. 4).
2. Disconnect the two quick-release hydraulic cou-

plings 2 (Fig. 6).
30884

Disconnect electric cable 3 (Fig. 6).

to the attachment.
5. Disconnect attachment drive p.t.o. shaft 4

(Fig. 7).
6. Release quick-attach lever 5 on the right-hand

side (Fig. 5).
58226
7. Lower the attachment until it rests both on the

supports and on the skids. Lower further until the
chopper body is completely released from the at-
tachment.
8. Carefully reverse the machine and ensure the at-

tachment is released from the chopper body.
4
Attaching
1. Drive up to the attachment and lower the chopper

body until the hook mounted on the front of the
chopper body can enter the attachment.
2. Lift the chopper body until it properly picks up the

attachment.
3. Attach the quick attach lever 5 so that the hooks

6 are in full contact with pins 7. If not, adjust lever
5 with bolts 8 so that some resistance is felt when
engaging latch 9 on pin 10 (Fig. 5).

Connect electric cable 3 (Fig. 6).

greasing system, connect the grease line(s) to
the attachment.
6. Connect the two quick-release hydraulic cou-

plings 2, if needed (Fig. 6).
7. Install attachment drive main shaft 4 (Fig. 7).

of the attachment drive p.t.o. shaft are in phase.
Make sure that the attachment drive shaft is installed 6
roll gearbox.
8. Relocate the supports at 1 (Fig. 2) of the pick-up

attachment. In case of a maize attachment, raise
the supports (Fig. 4) on both sides.
58227
7
REMOVAL -- INSTALLATION OF CHOPPER
BODY WITH A-FRAME
WARNING
This operation should be carried out with utmost care
and attention. Only an experienced tractor driver
should be allowed to do this job.
The cutterhead is removed from the machine with an
A-frame that is mounted in a tractor’s 3-point hitch.
This tractor must be at least 100 hp and sufficient
front weight should be installed. The weight of the 58233
cutterhead/feed roll combination is almost 2000 kg.
The tractor hydraulics should be in good condition to 8
allow precise height control.
Removal
1. Detach the attachment as described in the pre-

vious paragraph.
2. Lower the cutterhead to its lowest position. 58234
9
Keep them in a safe place so that they cannot be
pinched between the cab and the chopper body
3. Disconnect all electric cables:

-- 1 and 2 (Fig. 8)
-- 4 and 5 (Fig. 9)
pinched between the cab and the chopper body.
4. Remove the left-hand side cover of the chopper

body. Remove the cutterhead drive shaft cover
on the right-hand side of the chopper body.
58235

10
system, disconnect the grease line(s) to the
chopper body.
6. Disconnect coolant tubes 3 (Fig. 8) to the cutter-

head gearbox.
7. Unscrew clamping rods 6 (Fig. 10) and 7

(Fig. 11).
58236
11
8. Unlock pin 8 and push it towards the cutterhead.
This pin will limit the chopper body’s rotation.
Lock the pin in that position.
58236
12
IMPORTANT: Do not try to install both pin 8 (Fig. 12)
and clamping rods 6 and 7 (Fig. 12) at the same time.
Doing this and lifting the chopper body afterwards
would cause irreparable damage to the chopper
body’s triangular frame.
58235
13
58235
9. Remove feed roll drive shaft 9.
The cutterhead drive shaft 10 (Fig. 13) does not
necessarily have to be removed.
14
10. Remove hydraulic cylinder pins 11 underneath
the chopper body on both sides.
11. Remove safety latches 12 by removing lynch

pins 13 on both sides of the chopper body.
58237
15
12. Now install the A-frame 14 on the tractor and
drive towards the chopper body (Fig. 17). The
tractor must be perfectly in line with the chopper
body.
CAUTION
Do not use the A-frame for anything else than to carry
the chopper body.
Check the A-frame, and especially pin 15 on the up-

per part, for cracks before using it. 30531
16
13. Pick up the chopper body with pin 15 that is
welded on top of the A-frame.
14. Adjust the third hitch point until the lower guides
16 come in the position as shown in the Figure.
15. Lift the tractor hitch until the lower part of the A-
frame is pushing firmly against the chopper body.
16. Install the chain safety bolt on pin 15 of the A-

frame.
58238
17
17. Remove the upper clamping rods 17 (Fig. 18)
and 18 (Fig. 19).
18. Flip up clamps 19 (Fig. 18) and 20 (Fig. 19).
19. Lift the chopper body with the tractor hydraulics

until the chopper body’s triangular frame is com-
pletely released from its brackets.
NOTE: Do not lift the chopper body higher than nec-

essary as this will damage the steering platform. 58235
18
20. Slowly drive forward ensuring that the chopper
body does not interfere with the underside of the
cab. Keep in mind that the chopper body now
stands completely free of the base unit.
58236
19
21. Install the support legs under the chopper body.
For the rear legs, use pins 11 (Fig. 15). Secure
the pins!
22. Lower the 3-point hitch until the A-frame is re-

leased from the chopper body.
23. Drive the tractor away.
30532
20
24. Remove part 21 of the cutterhead drive shaft
from the cutterhead gearbox.
58239
21
25. Reinstall this part on cutterhead drive shaft 22.
NOTE: Make sure the drive yokes on each end of the

cutterhead drive shaft are in phase.
58240
22
Mounting
1. Pick up the chopper body with the A-frame

[mounted in the 3-point hitch of the tractor].
2. Remove the support legs from the chopper body.
NOTE: Make sure the feed roll and cutterhead drive

shaft are lifted in such a way that they do not interfere
with the chopper body.
58239
23
3. Carefully drive backward to the harvester making
sure upper tube 23 of the chopper body’s triangu-
lar frame fits smoothly in its supports 24.
4. Lower the chopper body.
58240
24
5. Flip down clamps 19 (Fig. 25) and 20 (Fig. 26).
6. Reinstall clamping rods 17 (Fig. 25) and 18

(Fig. 26) around the upper tube and tighten firm-
ly.
58235
25
7. Lower the tractor hitch until lower tube 25
(Fig. 23) rests on base unit 26 (Fig. 24).
58236
26
8. Reinstall safety latches 12 with lynch pins 13 on
both sides.
58237
27
9. Reinstall hydraulic cylinders 27 (Fig. 28) with
pins 11 (Fig. 27).
10. Lower the tractor hitch until it is released from the

chopper body.
11. Drive the tractor away.
58240
28
12. Reinstall feed roll drive shaft 9.
29
13. Reinstall cutterhead drive shaft 10. It should be
separated some 5 mm from the end of the cutter-
head gearbox input shaft so that, when tightening
the bolts on the splined end, the splines do not
clamp on the broader spline-free end of the cut-
terhead gearbox input shaft.

58235
30
14. Unlock pin 8, pull it out and lock it.
58236
31
15. Reinstall front clamping rods 6 (Fig. 32) and 7
(Fig. 31).
58235
32
16. Connect the cutterhead gearbox coolant tubes 3.
17. Connect electric cables:

-- 1 and 2 (Fig. 33)
-- 4 and 5 (Fig. 34)

system, connect the grease line(s) to the chop-
per body.
58233
33
58234
34
REMOVAL -- INSTALLATION OF CHOPPER
BODY WITH HYDRAULIC JACK
Dismounting
WARNING
This operation should be carried out with utmost care
and attention on a level-paved surface. Only an ex-
perienced machine operator should be allowed to do
this job.
58237
1. Detach the attachment as described in the first
paragraph of this section. 35
2. Raise the chopper body to its highest position by
giving the “attachment up” command on the mul-
tifunction lever.
3. Apply safety latches 12 (Fig. 35) by removing

pins 13.
4. Install the hydraulic jack assembly 1 into the

mounting bracket 2 and secure with pin 3 and
hairpin cotter 4.
NOTE: The hydraulic cylinder 5 must be facing for- 58241

wards and the hydraulic hoses must be positioned
facing the right-hand side of the machine. 36
5. Connect quick-coupler hose ends to the auxiliary
front hydraulic ports 2.
6. Completely retract the hydraulic jack cylinder 5

(Fig. 36) as described in chapter 2.6, heading
‘‘Front auxiliary hydraulics control’’.
7. Lift up safety latches 12 (Fig. 35) and secure

them with lynch pins 13.
37
8. Lower the chopper body completely by giving the
“attachment down” command on the multifunc-
tion lever in the cab.
9. Remove the chopper body hydraulic cylinder

pins 11 (Fig. 37) on both sides of the chopper
body.
10. Install the right and left-hand front jack mounts

6 (Fig. 38) and secure them in place with the hy-
draulic cylinder pins 11.
58405
38
11. Disconnect all electric cables:
-- 1 and 2 (Fig. 39)
-- 4 and 5 (Fig. 40)
pinched between the cab and the chopper body.
12. Remove the left-hand side cover of the chopper

body. Remove the cutterhead drive shaft cover
on the right-hand side of the chopper body.
58233
39
system, disconnect the grease line(s) to the
chopper body.
14. Disconnect coolant tubes 3 (Fig. 39) to the cut-

terhead gearbox.
58234
40
15. Lower the hydraulic jack 1 using the front auxilia-
ry hydraulic system, as described in the Opera-
tor’s Manual -- Section 2.6, until the jack foot con-
tacts the ground surface.
58241
41
16. Install the front jacks 7 and adjust to contact the
ground surface.
58405
42
17. Unscrew clamping rods 6 (Fig. 43) and 7
(Fig. 44).
18. Unlock pin 8 (Fig. 44) and push it towards the cut-
terhead. This pin will limit the chopper body’s
rotation. Lock the pin in that position.
58235
43
IMPORTANT: Do not try to install both pin 8 and
clamping rods 6 (Fig. 43) and 7 (Fig. 44) at the same
time. Doing this and lifting the chopper body after-
wards would cause irreparable damage to the chop-
per body’s triangular frame.
58236
44
19. Remove feed roll drive shaft 9. The cutterhead
drive shaft 10 (Fig. 43) does not necessarily have
to be removed.
45
20. Remove safety latches 12 by removing lynch
pins 13.
58237
46
21. Remove the upper clamping rods 17 (Fig. 47)
and 18 (Fig. 48).
22. Flip up clamps 19 (Fig. 47) and 20 (Fig. 48).
23. Make sure that the forage harvester’s steering

wheels are in straight position allowing the forage
harvester to move in a straight line.
58235
47
24. Now raise the rear of the chopper body with the
hydraulic jack by activating the front auxiliary hy-
draulic system until the rear of the chopper body
clears the top mount area on the machine’s main
frame.
25. Do not touch the steering wheel!!

Slowly reverse the machine away from the chop-
per body. Travel rearward approximately 1 m
from the rear of the chopper body.
58236
48
26. Lock the hydraulic jack in place with pin 8.
27. Now the jack’s hydraulic hoses can be discon-

nected from the forage harvester.
58406
49
28. Remove part 21 of the cutterhead drive shaft
from the cutterhead gearbox.
58239
50
29. Reinstall this part on the cutterhead drive shaft
22.
58240
51
Mounting
1. Line up the forage harvester straight behind the

chopper body and drive it to a distance of about
1 m behind it.
58241
52
2. Connect the hydraulic hoses of jack cylinder 5
(Fig. 52) to the auxiliary front hydraulic ports 2.
53
3. Check that guide chains 9 and 10 and springs 11
support cylinder 12 so that the cylinder pin
mounts enter on the chopper body.
NOTE: Make sure the feed roll and cutterhead drive
shaft are lifted in such a way that they do not interfere
with the chopper body.
58407
54
4. Slowly drive the forage harvester up to the chop-
per body and check that the chopper body is at
the correct height to be attached to the forage
harvester. Adjust for height and inclination with
the jacks, if necessary.
58239
55
Drive forward until the upper tube 23 (Fig. 55) of
the chopper body’s triangular frame fits smoothly
in its supports 24.
58240
56
5. Lower the chopper body’s rear end and flip down
clamps 19 and 20 around the upper tube.
58235
57
Tighten firmly.
58238
58
6. Lower the chopper body’s front end with jacks 7
until lower tube 25 (Fig. 60) rests on base unit 26
(Fig. 61).
58405
59
7. Reinstall safety latches 12 (Fig. 62) with lynch
pins 13.
58239
60
8. Reinstall the hydraulic cylinders 27 with pins 11
(Fig. 62).
58240
61
9. Remove jacks 7 (Fig. 59).
58237
62
10. Reinstall feed roll drive shaft 9.
63
11. Reinstall cutterhead drive shaft 10. It should be
separated some 5 mm from the end of the cutter-
head gearbox input shaft so that, when tighten-
ing the bolts on the splined end, the splines do
not clamp on the broader spline-free end of the
cutterhead gearbox input shaft.

58235
64
12. Unlock pin 8, pull it out and lock it.
13. Reinstall front clamping rods 6 (Fig. 64) and 7.
58236
65
14. Connect the cutterhead gearbox coolant tubes 3.
58233
66
15. Connect electric cables:
-- 1 and 2 (Fig. 67)
-- 4 and 5 (Fig. 68)
58233
67
system, connect the grease line(s) to the chop-
per body.
582340
68
17. Lift the chopper body to its highest position and
lock it in place with the safety latches 12.
58237
69
18. Remove the hydraulic jack assembly 1 from un-
derneath the chopper body.
19. Lift away the safety latches 12 (Fig. 69).
20. Reinstall the safety covers.
58241
70
REMOVAL -- INSTALLATION ROTOR AND
BEARINGS
Removal
1. Remove the chopper body from the machine
2. Swing down the upper feed roll assembly.
3. Remove the sharpener stone guard on the right-

hand side of the chopper body.
4. Remove the cutterhead gearbox as described in

previous paragraph.
5. Remove bolt B and pull off the crop processor

drive pulley A together with the overrun clutch.
NOTE: If the crop processor is installed it should also

be removed as described in the Operator’s Manual.
71
6. On a chopper body without a crop processor, re-
move bolt B and spacer tube C
72
7. Drive shaft D out of the cutterhead
NOTE: Shaft D has conical splines and may be very

hard to remove.
73
8. Remove electrical wires and plastic straps from
the triangular frame A and the top part B.
Note the routing of the wires for reassembly.
74
9. Remove all bolts E holding the chopper body top
assembly B and lift away the assembly. Also re-
move the sharpener stone cover F.
75
10. Remove the front cross bar.
76
11. Remove bolts C on both sides of the chopper
body and lift away the triangular frame A
(Fig. 74).
77
12. Remove bolts A on both sides, remove the bear-
ing housings B and F.
NOTE: Note the quantity and the location of shims in-

stalled at A for possible reuse.
78
13. Lift away the cutterhead assembly K
79
FX300-375-450/ Series 01 to 10
FX9630-9640-9645
FX25-45 Series 01 -- 02
An additional cutterhead bearing protection 1 can be

installed on both sides of the cutterhead assembly K
(Fig. 79).
• Mark and drill six holes (6 x 60°) on ∅ 220 mm
and tap them for M6 screws.
• Install the grease shields 1 with lockwashers and
nuts 2.
80
Assembly
1. Press bearing cups D and G in the cutterhead as-

sembly.
2. Press bearing cones E and H in bearing housings

B and F.
3. Install the cutterhead assembly K into the chop-

per body (Fig. 80).
81
4. Lubricate grooves J before installing bearing
housings B and F (Fig. 81).
5. Install the bearing housings loosely in the chop-

per body.
6. Install the top of the chopper body B (Fig. 83) and

the front cross bar C (Fig. 82).
82
7. Center the cutterhead K by installing shims at C
and L. The maximum allowed distance between
the outer end of a knife and the chopper body
side plate is 3.2 mm (1/8’’) (Fig. 81).
83
8. Install shaft D as shown in the Figure.
84
9. Install the measuring gauge as shown in Figures
85 and 86.
10. The run-out should be measured on the outer

edge of the bearing housing at M, on both sides
of the chopper body. The allowed run- out is
+ 0.2 mm (0,008’’).
85
11. Adjust the bearing preload to between 4.5 and
6.75 Nm (3,3 -- 5 lbf.ft) by adding or removing the
same quantity of shims at C and L (Fig. 84). The
bearing housing bolts must be torqued to 240 Nm
(175 lbf.ft).
12. Before installing the cutterhead gearbox, check

the axial run-out at the inner end of the splines of
shaft D (Fig. 84) . The run-out must not exceed
0.2 mm (0.001’’). To reduce the run-out,turn the
shaft splines 40° at a time until the run-out is ac-
ceptable.
86
13. Install spacer tube C washer and bolt B. Tighten
up bolt B to 500 Nm (370 lbf.ft). The thread must
be dry and clean.
87
On a chopper body with a crop processor, install
a spacer tube, a ring, the overrun clutch with
pulley A, a second ring, two bearings, a washer
and bolt B. Tighten up bolt B to 500 Nm
(370 lbf.ft). The thread must be dry and clean.
88
14. Install cutterhead gearbox as described in pre-
vious paragraph.
15. If necessary, readjust the cutterhead knives as

described in the Operator’s Manual paragraph
“5.5.2 Regauging the knives”.
16. Swing up the upper feed roll assembly.
17. Install chopper body on the machine as de-

scribed in previous paragraph.
18. Sharpen the knives as described in the Oper-

ator’s Manual, paragraph “4.7.1. Automatic
sharpening”.
19. Adjust shearbar as described in the Operator’s

Manual, paragraph “4.7.2. Automatic shearbar
adjustment”.
IMPORTANT: Ensure all guards and covers are rein-

stalled and all hardware is securely tightened.
REMOVAL -- INSTALLATION OF CUTTER-
HEAD GEARBOX
Removal
1. Remove the chopper body from the machine.
2. Swing down the upper feed roll assembly.
3. Remove the sharpener stone guard on the right-

hand side of the chopper body.
4. Loosen or remove plastic straps and wires from

the cutterhead gearbox.
5. Remove the temperature sensor from the gear-

box and at the same time, drain the oil from the
gearbox
6. Remove cover A, nut B and special washer C and

the rubber clamping at D (Fig. 90). Mark the shaft
to gearbox position before removing the gear-
box. This is important to avoid vibrations when
reinstalling the gearbox.
NOTE: The gearbox is heavy, support it properly

when removing it from the shaft.
89
7. Install two M12 x 100 bolts in holes E and press
the gearbox from the conical splines of the shaft.
90
Installation
Install cutterhead gearbox in reverse order of re-

moval.
Nut B (Fig. 89) must be torqued to 500 Nm. The
thread must be dry and clean.
DISASSEMBLY AND ASSEMBLY OF CUT-
TERHEAD GEARBOX
Disassembly
REMOVAL OF THE OIL COOLER
The oil cooler can be pulled out of the gearbox hous-

ing.
1. Remove clamp A.
91
2. Carefully pull out the oil cooler.
3. Note that the two O-rings B and C are not identic-

al.
REMOVAL OF SHAFTS AND BEARINGS NOTE: A liquid sealant has been used at assembly
of cap G and shims H.
NOTE: It is not possible to remove seal J without
Input shaft damaging it.
NOTE: Be extremely careful not to damage the oil
cooler if it has been left inside the gearbox when re-
1. Remove bolts A, bearing cap B, shims C and moving the output shaft assembly.
shaft D.
2. Mark the position of the gearbox guide bracket K
NOTE: Mark the position of bearing cap B in the gear- and cover M.
box housing before removing it.
NOTE: A liquid sealant has been used at assembly 3. Remove bolts L, guide bracket K, cover M, bear-
of cap B and shims C. ing cup W, shims Y and seal Z
2. Remove the bearings from shaft D, the bearing
cup from bearing cap B, the bearing cup from the 4. Press out shaft N together with gear P in the di-
gearbox housing, shims Q and seal E rection of the arrow. Take care not to damage the
oil cooler.
NOTE: Bearing T may interfere with the input shaft

support inside the gearbox.
Output shaft 5. Remove bearings S and T from shaft N.
NOTE: Replace all bearings if other gearbox compo-

1. Remove bolts F, bearing cap G, shims H and seal nents are being replaced.
J. NOTE: Input shaft D and gear P are only available as
a matched set.
NOTE: Mark the position of bearing cap G in the
gearbox housing before removing it.
92
GEARBOX ASSEMBLY
Before installing input shaft D, the amount of shims

to be installed at Q must be determined.
Proceed as follows:
+ Input shaft code
+ Gearbox housing code
+ Bearing code
= Shim value expressed in hundreds of a

mm.
Code on input shaft D Code on gearbox housing
A number is stamped in one of the ends of shaft D. This code is stamped in the front of the gearbox, on
The code is derived from the following table: the upper side close to the bearing cap G,
Measure Code Measure Code
91.100 - 91.124 00 61.650 - 61.674 154
91.125 - 91.141 01 61.675 - 61.699 149
91.150 - 91.174 02 61.700 - 61.724 145
91.175 - 91.199 03 61.725 - 61.749 140
91.200 - 91.224 04 61.750 - 61.774 135
91.225 - 91.249 05 61.775 - 61.799 130
91.250 - 91.274 06 61.800 - 61.824 126
91.275 - 91.299 07 61.825 - 61.849 121
91.300 - 91.324 08 61.850 - 61.874 116
91.325 - 91.349 09 61.875 - 61.899 111
91.350 - 91.374 10 61.900 - 61.924 107
91.375 - 91.399 11 61.925 - 61.949 102
91.400 - 91.424 12 61.950 - 61.974 97
91.425 - 91.449 13 61.975 - 61.999 92
91.450 - 91.474 14 62.000 - 62.024 88
91.475 - 91.500 15 62.025 - 62.050 83
Bearing code
This code is determined by dimension X. New bear-

ings are packed together with a label indicating the
code or the dimension expressed in hundreds of a
mm.
Dimension X Code
28.000 - 28.025 7
28.026 - 28.050 6
28.051 - 28.075 5
93
28.076 - 28.100 4
28.101 - 28.125 3
28.126 - 28.150 2
28.151 - 28.175 1
28.176 - 28.200 0
Example:
Input shaft 91.310 = 08
Gearbox housing code 116 = 116
Bearing code 28.090 = 04
Total = 128
Total shims value to be installed at Q (Fig. 92) =

1.28 mm.
0.025 - 0.3 - 0.4 mm shims are available.
Assembly of input shaft 10. Press the output shaft N further in by tightening
bolts L until the backlash between gear P and the
input shaft gear D is 0.2 mm to 0.28 mm.
1. Install shims at Q to the value previously calcula-
ted.
11. Measure and install the required quantity of
shims at Y. Reinstall cover M and tighten bolts L.
2. Install the bearing cup on top of the shims Q.
12. Adjust the end float of the shaft to between 0.02
3. Install the preassembled input shaft D in the and 0.12 mm by adding or removing shims at H.
gearbox housing and install bearing cap B with-
out seal E.
13. Check the backlash. Readjust, if necessary, by
adding an equal number of shims at H and Y.
4. Install shims at C so that the bearing preload is
between 0.56 and 1.13 Nm. Note down the re-
14. Measure the torque for shafts N and D on shaft
quired number of shims for possible later refer-
D.
ence.
15. Add to the measured value 0.56 - 1.13 Nm. Add

Assembly of output shaf shims at H and Y until the new preload value has
been reached.
1. If gear P was replaced, install the new gear on

16. Recheck the backlash and reshim, if necessary.
shaft N. Make sure the gear is properly seated
and install bolts R.
17. Remove cover M and the bearing caps B and H.
2. Now check the run-out of gear P (measured on
the rear side). Maximum tolerance is 0.2 mm. 18. Install seals at E, J and Z.
3. Remove seals J and X if they are still installed. 19. Cover the gearbox and shim surfaces with liquid
sealant type 4 - ES 50.77.
4. Install bearing W into the bearing housing of
cover M. 20. Install bearing caps B and G, cover M and guide
ring K.
5. Install bearing S onto shaft N.
21. Install the oil cooler. Apply liquid sealant in the O-
ring grooves before installing the O-rings and
6. Install shaft assembly N into the gearbox hous-
push in the cooler.
ing. Do not damage the oil cooler, if installed.
22. Install fastening bracket A (Fig. NO TAG).

7. Install cover M with bearing W. Do not install the
shims at this time. Install bolts L but do not tighten 23. Reinstall the gearbox on the chopper body as de-
them completely. scribed in previous paragraph.
8. Install bearing T onto shaft N. 24. Fill up the gearbox with 1.9 litres of API-GL-5,
MIL-L-2105B, SAE 80W-90 oil. Check the oil
level with the dipstick.
9. Install bearing cup V into the gearbox and install
bearing cap G, but without shims. Tighten the
bearing cap mounting bolts F and loosen the
bolts again.
94
REMOVAL -- INSTALLATION OF SHEARBAR
Removal
1. Detach the attachment with upper feed rolls or

flip down the upper feed rolls as described in
Section 60 -- chapter 1.
2. Thoroughly clean the space between the scraper

and the shearbar 3 with a knife or a screwdriver
until it is absolutely clean. Use compressed air,
58423
if available.
95
3. Move the shearbar adjusting arms fully forward

(away from the cutterhead) by using the auto-
matic shearbar adjuster motors. Proceed as fol-
lows:
4. Turn the ignition key on, but do not start the en-
gine. Switch on the harvest tumbler switch and
then the Adjust-O-Matic™ tumbler switch. Wait
ROAD OFF
until the OK light on the Adjust-O-Matic™ panel
will illuminate.
HARVEST ON
30550
96
5. While pressing the INTERRUPT button, simulta-

neously press the ADJUST SHEARBAR Button
The shearbar will now automatically be moved
on both sides to its foremost position.
30549
97
6. While the shearbar is moving forward, the AD-
JUST SHEARBAR light is blinking and the buzz-
er beeps with short intervals. When the shearbar
reaches its foremost position, the blinking light
will extinguish and the buzzer stops beeping. The
OK light will illuminate.
The shearbar is pushed away from the knives by
the adjuster motors, operating alternately on the
left and the right-hand side, until the shearbar, or
the adjuster arms, meet(s) a mechanical stop.
Then each side is pulled towards the cutterhead
three times. Check if the shearbar is really fully
forward, but does not touch the scraper. 30549
98
7. Switch off the Adjust-O-Matic™ and the harvest
tumbler switches. Turn off the ignition key. Check
that the shearbar-to-chopper body frame clear-
ance is the same on both sides of the chopper
body. If not, adjust to the smaller clearance by
turning the adjuster rod.
WARNING
ROAD OFF
Adjusting the shearbar by turning the adjuster rods
without turning of the ignition key will cause electric
motor failure. HARVEST ON
30550
99
8. Remove clamping bolts 1 on both sides of the
chopper body. Observe the assembly order of
the washers and spacer, and retain them.
9. Remove mounting bolts 2 on both sides of the

machine. Observe the order of the washers and
retain them.
10. Remove the shearbar and the slide plate from the
right-hand side of the machine. On some ma-
chines it may be necessary to loosen the crop
guides to give more space for the shearbar. For
loosening of the crop guides, refer to the oper-
ator’s manual, paragraph “5.4.2. Crop guides”. 100
11. Clean the shearbar and the shearbar support

thoroughly (use an amery clotch to remove
eventual rust).
Installation
1. Install the slide plate and the new shearbar or

turn the old one. Spread a thin film of grease on
the shearbar and the shearbar support before
installing the shearbar.
IMPORTANT: The shearbar has two cutting edges.

It can be turned end for end, but never turned over.
2. Reinstall mounting bolts 2 on both sides of the

machine and make sure the washers are
installed in the correct order (the thin ones should
be installed towards the arm). Tighten bolts 2 to 101
a torque of 180 Nm (132 lbf.ft). Check that dis-
tance is equal on both sides of the machine.
If not so, adjust manually to the smaller measure-
ment.
3. Install clamping bolts 1 on both sides of the ma-
chine. Make sure to install the washers and the
spacer in the correct order and tighten bolts 1 to
a torque of 91 Nm (67 lbf.ft).
IMPORTANT: Spread a thin film of grease between

the clamping bolt washers and the shearbar. This is
to prevent the washers from binding onto the shear-
bar.
4. If necessary, readjust the cutterhead knives as

described in the Operator’s manual, paragraph
‘‘5.5.2 Regauging the knives’’.
5. Attach the attachment with upper feed rolls or flip

up the upper feed rolls as described in Section 60
-- chapter 1.
6. Sharpen the knives as described in the Opera-

tor’s Manual, paragraph ‘‘4.7.1. Automatic
sharpening’’.
7. Adjust the shearbar as described in the opera-

tor’s manual, paragraph ‘‘4.7.2. Automatic
shearbar adjustment ’’.
IMPORTANT: Ensure all guards and covers are rein-

stalled and all shearbar hardware is securely tight-
ened.
REMOVAL -- INSTALLATION OF SHEARBAR
SUPPORT
Removal
1. Detach the attachment with as described in para-

graph “Attaching and detaching the attachment”.
2. Flip down the upper feed rolls (refer to Section 60

-- chapter 1).
3. Remove the shearbar from the machine (refer to

previous paragraph).
4. Remove the scraper from the machine.
5. Remove bolts A and B and spacer C from both

sides of the chopper body.
102
6. Remove bolts D from underneath the machine.
103
7. Note the number and location of possible shims
between the shearbar support and the chopper
body frame at points E.
8. Remove the shearbar support to the right-hand

side of the machine.
104
Installation
1. Insert shearbar support from the right-hand side

into the chopper body.
2. if necessary, install shims between the shearbar

support and the chopper body frame at points E.
0.3 and 0.6 mm shims are available.
105
3. Install bolts D from underneath the machine.
106
4. Install spacer C, bolts B and A on both sides of
the chopper body.
5. Reinstall the scraper and adjust as described in

the Operator’s Manual, paragraph “5.4.1.
Smooth roll scraper”.
107
6. Install the shearbar as described in previous
paragraph.
7. Flip up the upper feed rolls.
8. Attach the attachment.

SECTION 70 -- EJECTION -- CHAPTER 1 1
SECTION 70 -- EJECTION
Chapter 1 -- Blower
CONTENT

70.000 Inspection between cutterhead and blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
70.120 Removal and installation of blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
70.100 Removal and installation of blower gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly and assembly of blower gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 SECTION 70 -- EJECTION -- CHAPTER 1
INSPECTION BETWEEN CUTTERHEAD
AND BLOWER
1. Lower the chopper body/attachment to the

ground.
3. Unscrew front clamping rods 1 (Fig. 1) and 2

(Fig. 2).
4. Unlock pin 3 (Fig. 2) and push it toward the cut- 58231
terhead. This pin will limit the chopper body’s 1

rotation. Lock the pin in that position.
IMPORTANT: Do not try to install both pin 3 (Fig. 2)

and clamping rods 1 (Fig. 1) and 2 (Fig. 2) at the
same time. Doing this and lifting the chopper body af-
terwards would cause irreparable damage to the
chopper body’s triangular frame
5. Lift the chopper body.
6. Install safety latches 10 (Fig. 3) by removing

lynch pins 11.
∧
A -shaped gap will appear between the cutterhead
(or crop processor) and the blower. Inspection of the
blower and the rear side of the cutterhead or the crop 58232
processor can now take place.
2
1. Lift safety latches 10 (Fig. 3) and secure them

with lynch pins 11.
2. Lower the chopper body.
3. Unlock pin 3 (Fig. 2), pull it out and lock it.
4. Reinstall the front clamping rods 1 (Fig. 1) and 2

(Fig. 2) and tighten them firmly.
5. Reinstall the cover on the left-hand side
3
REMOVAL AND INSTALLATION OF BLOW-
ER
1. Remove the chopper body from the base unit as
explained in section 64 paragraph ”Removal --
installation of chopperbody
2. Remove bolt 1and pull drive shaft 2 away from

blower gearbox.
3. Support the blower in hole 4.
4. Remove the three blower frame fastening bolts

3.
5. 1. First pull out the lower end and lower the

blower away from the spout.
6. Reinstall the blower in reverse order of the re-

moval sequence
7. Torque the blower fastening bolts 3 to 240 Nm

(177 lbf.ft). Replace the bolts, if damaged
54534
6
REMOVAL AND INSTALLATION OF BLOW-
ER GEARBOX
Removal
1. Remove the blower from the base unit as ex-

plained in previous paragraph ”Removal and
installation of blower”.
2. Remove the blower front plate 1 by removing all

nuts, washers and bolts 2 from the front plate pe-
rimeter.
3. Remove the eight bolts and washers 3 and the

coverplate. 7
4. Mark the position of the blower cone on the
blower gearbox shaft. Install two bolts (M 12 x
70) in the holes 4 and press out the blower cone.
NOTE: The blower cone is heavy; be careful when

handling it.
Mark the position of the gearbox on the blower frame.
5. Drain the oil from the blower gearbox through

hose E.
55098
8
6. Remove shielding from behind of the blower
7. Remove hoses E and F from the gearbox
8. Remove rods G and H from the gearbox
9. Support the gearbox well and remove bolts J.
10. Lift the gearbox away from the blower frame

Installation
11. To install the gearbox, proceed in reverse order

of the disassembly sequence.
12. Adjust the blower cone in the blower housing as

described in section 5 ”Adjustment and mainten-
ance” of the Operator’s Manual
13. Fill the gearbox with oil:
Gearbox capacity: 1.4 litres
Oil specification:
Use AMBRA HYPOIDE 90 oil ( ref. NH520A) or

GEARBOX DISASSEMBLY AND ASSEMBLY
FX300-375-450/ Series 01 to 14
FX9630-9640-9645 Series 5033 to 5077
Series 5033 to 5077
BLOWER GEARBOX Watteeuw
Disassembly
1. Remove bolts and washers FF and cover DD
2. Remove bolts and washers M and bearing cap G.
NOTE: Do not damage the seal J. If the seal has to

be removed, it will be damaged and must be replaced
3. Remove bolts and washers at E and input shaft

K together with the bearing housing F and the
bearing N
NOTE: Do not damage the shims at D. Keep the

shims for later use
4. If necessary, remove bearing inner race A from

shaft K and the bearing B from the gearbox hous-
ing C.
5. Loosen stake lock washer H from stake nut L and

remove the nut and the washer.
6. If necessary, press shaft K out of the bearing N

and bearing housing F and then bearing N out of
bearing housing F.
7. Remove bolts and washers AA, cover W and

shims BB from the gearbox housing C.
8. Remove cotter pin S, castle nut T and spacer 31079

washer V.
9
9. Reinstall nut T and drive or press out shaft KK, or
use two M12 x 70 bolts and pull out shaft KK
10. Carefully remove bearing CC, gear EE, spacer

GG and bearing HH. If necessary, remove the
bearing cups Q and LL from the housing C. If
damaged replace seal JJ.
Assembly
Output shaft
1. Check the condition of the seal JJ and replace if

damaged. Lubricate the seal cavity
2. Install bearing cup LL.
3. Carefully introduce shaft KK into the gearbox

housing C.
4. While installing shaft KK, install simultaneously

bearing HH, spacer GG and gear EE. Drive or
press them in place.
NOTE: Install gear S on the splines
5. Install bearing CC onto shaft KK and drive it in,

install spacer washer V and castle nut T onto
shaft KK.
6. Tighten up the assembly and install cotter pin S.

Make sure that all parts are well seated.
7. Install bearing cup Q into the housing and press 31080

it as far as it can go.
10
8. 1. Install bearing cap W in place and measure

distance Y. The thickness of the shim pack is Y
+ 0,025 mm (0.001”). Install the determined
amount of shims at BB. The axial play should be
0,01 -- 0,05 mm (0.0004” -- 0.002”) for shaft KK,
if not readjust.
NOTE: Install at least one 0,025 mm (0.001”) shim.
9. When the axial play is correct, coat the contact

surfaces of the gearbox housing, shims BB and
the bearing cap W with liquid sealant and reinstall
bearing cap W. Install washers and bolts AA and
torque to 52 Nm (38 lbf.ft) .
10. Recheck the axial play and readjust, if necess-

ary.
Input shaft
1. Install bearing N into bearing housing F.
2. Lock bearing N in place by installing stake lock-

washer H and stake nut L. Secure stake nut L in
place with stake lockwasher H.
3. Drive the bearing N and the bearing housing F

onto gear shaft K.
4. Install bearing inner race A and bearing B onto

shaft K.
5. Install the shaft assembly into gearbox housing

C. Do not tighten completely.
6. Adjust the backlash to 0,1 -- 0,15 mm (0.004” --

0.006”) by adding a sufficient number of shims at
D.
NOTE: The backlash is measured on the splines of

the input shaft K. There is no formula for the shim
pack calculation.
7. Apply liquid sealant to the surfaces of the hous- 31080

ing F, cap G and the shims D. Torque bolts E to
26 Nm (19 lbf.ft) and bolts M to 12Nm (9 lbf.ft). 11
8. Apply liquid sealant onto the cover DD and install

it with washers and bolts FF. Torque bolts FF to
26 Nm (19 lbf.ft).
FX300-375-450/ Series 5078 to ...
FX25-45 Series 5078 to ...
FX28-38-48-58 Series 5083 to ...
BLOWER GEARBOX CORNER
Disassembly
1. Remove bolts GG and cover EE.
2. Remove bolts M and lift out shaft K and bearing

housing L.
3. Remove shaft K from bearing housing L.
4. Remove seal J, circlip H, shims G and bearing

cup F from the bearing housing L.
NOTE: Measure the thicknes of shim pack G and

note it down.
5. Remove bearing E from shaft K.
6. Remove bearing C from shaft K and shims D.
NOTE: Do not damage the shims D. Keep the shims

for later use. Measure and note down the thickness
of shimpack D.
7. If necessary, remove bearing cup B from gearbox

housing CC.
8. Remove bolts AA, cover T and shims Q from the

gearbox housing CC. Keep the shims for later
use.
9. Remove cotter pin V, castle nut W and spacer

31081
washer BB.
12
10. Reinstall castle nut W and drive out shaft LL, or
use two M12 x 70 bolts and pull out shaft LL.
11. Carefully remove gear DD, shims FF, spacer HH

and bearing A and S. If necessary, remove bear-
ing cup JJ and S from the gearbox housing CC.
Measure the thicknes of shimpack FF and note
it down and keep the shims for later use.
NOTE: Do not damage seal KK. If the seal has to be

removed, it will be damaged and must be replaced.
Assembly
Input shaft
1. Install bearing E onto shaft K.
2. Install the same quantity of shims at D as you re-

moved during disassembly. If you need to restart
shimming from scratch then install a 1.00 mm
(0.04”) shim pack.
NOTE: No shimming codes are provided.
3. Install bearing C onto shaft K.
4. Install bearing cup B into the gearbox housing

CC.
5. Install the preassembled shaft K and bearingsC

and E into the gearbox housing CC.
6. Install bearing housing L with bolts M.
7. Install bearing cup F into housing L and press it

as far down as possible.
8. Install as many shims as possible between the 31082
bearing cup F and the circlip cavity H. Install cir- 13

clip H.
9. The rotating torque on shaft K should be 5 to 30

Nm (3.6 -- 22 lbf.ft) without oil seal J.
Output shaft
10. Check the condition of seal KK and replace, if

damaged. Lubricate the seal cavity.
11. Install bearing cup JJ if it was removed.
12. Carefully introduce shaft LL into the gearbox

housing CC.
13. While installing shaft LL, install simultaneously

bearing A, spacer HH, shims FF,gear DD. Drive
or press them in place.
14. Install the same quantity of shims at FF as you re-

moved during disassembly. If you need to restart
shimming from scratch then install a 1.50 mm
(0.06”) shim pack.
NOTE: No shimming codes are provided.

Install gear DD on the splines.
15. Install bearing S onto shaft LL and drive it fully in,
install spacer washer BB and castle nut W onto
shaft LL.
16. Tighten up the assembly and install cotter pin V.
17. Install bearing cup R into the bearing housing

and push it as far down as you can get it.
18. Measure the distance Y from the upper end of the

bearing to the surface of the casting CC, and note
down the value (Fig. 15).
19. Measure the distance Z on the cover T (Fig. 15).
20. The quantity of shims needed at Q can be calcu-

lated with the following formula:
Y -- Z + 0,25 = shim pack in mm.
Y -- Z + 0.01 = shim pack in Inch.
21. The quantity of shims needed at Q (Fig. 14) In-

stall bearing cap T with with the calkulated shim
pack at Q ensuring an axial play of 0,01 -- 0,05
mm (0.0004” -- 0.002”) for shaft LL.
22. Recheck the axial play and readjust, if necess- 31082

ary.
14
Adjusting the shimming
23. Block gear DD and measure the backlash on the

splines of shaft K. The backlash should be 0.1 to
0.2 mm (0.004” -- 0.008”).
24. If the backlash need to be adjusted it should be

done by removing shims at FF (reduces the
backlash) or by adding shims at FF (increases
the backlash).
15
25. When the backlash is within the permissible tol-
erance then check the tooth flank contact area.
26. The tooth contact area should be as shown.
27. If not then adjust by removing or adding shims at

D.
28. When the shimming is correct then install oilseal

J and cover EE. Tighten bolts GG to 26 Nm (19
lbf.ft), bolts AA to 52 Nm (38 lbf.ft) and bolts M to
26 Nm (19 lbf.ft). 31084
16

FX25, FX28, FX38, FX45, FX48, FX58 Service Manual

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SECTION 14 - LIVE P.T.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION 23 - 4WD LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 25 - FRONT MECHANICAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 29 - HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 33 - BRAKES AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 35 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 50 - CAB CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 55 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 60 - PRODUCT FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

© 2004 CNH America LLC 87051246 7/04

Section Description Page

Chapter 1 - Iveco Aifo Engine

Section Description Page

Chapter 1 - Main Drive Gearbox

Section Description Page

Chapter 1 - Traction Gearbox

Section Description Page

SECTION 23 -- 4WD LINES

Chapter 1 - 4WD Angle Gearbox

Section Description Page

SECTION 25 -- FRONT MECHANICAL DRIVE

Chapter 1 - Final Drives

Section Description Page

Chapter 1 -- Hydrostatic Transmission

Section Description Page

SECTION 33 -- BRAKES AND CONTROL

Chapter 1 -- Brakes and Control

Section Description Page

SECTION 35 -- HYDRAULIC SYSTEM

Section Description Page

Chapter 2 -- Work Hydraulics -- Attachment Height Control

Section Description Page

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 3 -- Work Hydraulics -- Base Unit

Section Description Page

Chapter 4 -- Steering Hydraulics

Section Description Page

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 5 -- Low Pressure Hydraulics

Section Description Page

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 6 -- Hi--Flow Hydraulics

Section Description Page

Chapter 1 -- Cab Cimate Control

Section Description Page

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 1 -- Electrical Circuits

Section Description Page

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 3 -- Wiring Diagrams FX NA

Section Description Page

Chapter 4 -- Can Network Basics

Section Description Page

SECTION 55 -- ELECTRICAL SYSTEM

Section Description Page

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 6 -- Software Update

Section Description Page

Section Description Page

SECTION 60 -- PRODUCT FEED

Chapter 1 -- Feed Rolls

Section Description Page

Chapter 2 -- Length-Of-Cut and Feed Roll Drive Gearbox