307.W.H020.en.6.02 20150217183249

5650 H COM 3 ->13500
5660 H COM 3 ->13500

5660 HTS COM 3 ->13500
5665 HTS COM 3 ->13500
5690 H COM 3 ->13500
5690 HTS COM 3 ->13500
5695 HTS COM 3 ->13500
Workshop manual
CONTENTS
0 - Introduction
0.1 - General safety instructions 0-2
0.1.1 - General safety and accident prevention provisions 0-2
0.2 - Safety instructions - maintenance and repair 0-3
0.2.1 - General information: 0-3
0.2.2 - Electrical system: 0-3
0.2.3 - Brake system, brake fluid: 0-3
0.2.4 - Hydraulic system: 0-3
0.2.5 - Air conditioning system: 0-3
0.2.6 - Tyres, threaded fixings: 0-4
0.2.7 - Engine: 0-4
0.2.8 - Miscellaneous: 0-4
10 - General information
10.1 - Conversion tables 10-2
10.1.1 - Conversion factor 10-2
10.1.2 - Converting mm into inches 10-2
10.1.3 - Converting Celsius degrees (°C) into Fahrenheit degrees (°F) 10-2
10.1.4 - Converting Celsius degrees (°C) into Kelvin degrees (K) 10-3
10.2 - Tightening values, screwing classes 10-4
10.3 - Lubricants 10-6
10.3.1 - Solid lubricants 10-6
10.3.2 - Grease 10-6
10.3.3 - Cooling system protection 10-6
10.4 - Seal materials 10-7
10.4.1 - Glues 10-7
10.5 - One-component adhesive 10-8
10.5.1 - Using one-component adhesives 10-8
10.6 - Maintenance and inspection schedule 10-9
10.7 - Oil quantity and quality 10-18
10.7.1 - Fuel, quantity 1) and quality of oil 10-18
10.8 - Approved list of lubricating oil quality class - DEUTZ 10-19
10.9 - Components working speed 10-20
10.10 - Securing bush support tightening values 10-21
10.11 - Check the tension of the belts and chains on the LH side 10-22
10.11.1 - Check of spring preload dimension L 10-22
10.12 - Check the tension of the belts and chains on the RH side 10-24
10.12.1 - Check of spring preload dimension R 10-24
10.13 - Maintenance and repair 10-25
10.13.1 - General information 10-25
10.14 - Care and maintenance 10-26
10.14.1 - General information 10-26
10.15 - Special tools 10-28
III
CONTENTS
20 - Engine
20.1 - Tools for engine disassembly and reassembly 20-2
20.1.1 - Commercially available tools 20-2
20.2 - Workshop tools for engine disassembly and reassembly (Lv.3) 20-5
20.2.1 - Workshop tools for engine disassembly and reassembly (Lv.3) 20-5
20.3 - Test and adjustment data (L3) 20-12
20.3.1 - T00 81 20-12
20.3.2 - T00 81 20-12
20.3.3 - T01 63 20-12
20.3.4 - T01 63 20-12
20.3.5 - T13 054 20-13
20.3.6 - T13 054 20-13
20.4 - Tightening torque (L3) 20-14
20.5 - Check the compression value (L3) 20-24
20.5.1 - Compression test 20-24
20.6 - Assembly and disassembly of the engine on the assembly stand (L3) 20-27
20.6.1 - Assembly of the engine on the stand 20-27
20.6.2 - Disassembly of the engine from the assembly stand 20-29
20.7 - Valve clearance adjustment (L3) 20-32
20.7.1 - Bring the engine to valve overlap position 20-32
20.7.2 - Adjustment of valve clearance 20-33
20.8 - Disassembly and assembly of the rocker and support (L3) 20-36
20.8.1 - Removal of the rocker arms and pedestals 20-36
20.8.2 - Refitting the rocker arms and pedestals 20-37
20.8.3 - Checking endfloat of rocker 20-38
20.9 - Removing and refitting the rocker and mount, checking (L3) 20-40
20.9.1 - Disassembly of the rocker support 20-40
20.9.2 - Checking rocker (intake valves) 20-40
20.9.3 - Replace the ball pin 20-41
20.9.4 - Checking rocker (exhaust valves) 20-42
20.9.5 - Replace the ball pin 20-43
20.9.6 - Checking rocker rod 20-43
20.9.7 - Completion of the rocker support 20-44
20.10 - Grinding the cylinder head seal surface (L3) 20-45
20.10.1 - Preparation of the cylinder head 20-45
20.10.2 - Flattening the cylinder head 20-45
20.10.3 - Check of the sealing surface of the cylinder head 20-46
20.11 - Disassembly and assembly of the cylinder head (L3) 20-48
20.11.1 - Disassembly of the cylinder head 20-48
20.11.2 - Assembly of the cylinder head 20-49
20.12 - Measuring piston protrusion (L3) 20-51
20.12.1 - Measuring piston protrusion 20-51
20.13 - Valve assembly and disassembly (L3) 20-54
20.13.1 - Valve disassembly 20-54
20.13.2 - Valve assembly 20-55
IV
CONTENTS
20.14 - Valve check (L3) 20-58
20.14.1 - Check the diameter of the valve stem 20-58
20.14.2 - Check the thickness of the valve edge 20-58
20.14.3 - Check the diameter of the valve head 20-59
20.15 - Check the valve guide (L3) 20-60
20.15.1 - Check the valve guide 20-60
20.15.2 - Measure the valve stem clearance 20-60
20.16 - Replacing the valve guide (oversized - press-fit) (L3) 20-62
20.16.1 - Check the valve guide 20-62
20.16.2 - Pushing out the valve guide 20-62
20.16.3 - Checking the valve guide seat hole 20-63
20.16.4 - Make the housing hole for the valve guide (increased dimension) 20-63
20.16.5 - Pressure insertion of the valve guide 20-65
20.17 - Check the valve residual (L3) 20-68
20.17.1 - Check the valve residual 20-68
20.18 - Replacing the lined valve seat (oversized) (L3) 20-69
20.18.1 - Checking the inserted valve seat 20-69
20.18.2 - Disassembly of the inserted valve seat 20-70
20.18.3 - Check the hole of the housing for the inserted valve seat 20-71
20.18.4 - Make the housing hole for the inserted valve seat (interference) 20-72
20.18.5 - Pressure insertion of the inserted valve seat 20-73
20.19 - Check the endfloat of the crankshaft (crankshaft removed) (L3) 20-76
20.19.1 - Check the endfloat 20-76
20.20 - Check the endfloat of the crankshaft (crankshaft installed) (L3) 20-78
20.20.1 - Check the endfloat 20-78
20.20.2 - Replacing the thrust ring halves 20-79
20.21 - Crankshaft check (L3) 20-84
20.21.1 - Check the diameter of the main bearing pins 20-87
20.21.2 - Check the diameter of the connecting rod pins 20-87
20.21.3 - Check the coaxiality 20-87
20.21.4 - Measuring the length of the flanged bearing 20-88
20.22 - Replace the crankshaft O-ring (flywheel end) (L3) 20-89
20.22.1 - Removal of the crankshaft oil seal 20-89
20.22.2 - Fit the crankshaft O-ring 20-90
20.23 - Replace the crankshaft O-ring (opposite end to flywheel) (L3) 20-93
20.23.2 - Fit the crankshaft O-ring 20-95
20.24 - Connecting rod drum check (L3) 20-98
20.24.1 - Check of the piston pin bush 20-98
20.24.2 - Checking piston pins 20-99
20.24.3 - Calculate the piston pin clearance 20-99
20.24.4 - Check the connecting rod bearing hole 20-100
20.24.5 - Check the internal diameter of the connecting rod bearing shells 20-101
20.24.6 - Check the diameter of the connecting rod pins 20-104
20.24.7 - Determine the clearance of the connecting rod bearing 20-104
20.24.8 - Check the connecting rod drum 20-105
V
CONTENTS
20.25 - Fitting and removing piston pin bush (L3) 20-107
20.25.1 - Disassembly of the piston pin bush 20-107
20.25.2 - Assembly of the piston pin bush 20-109
20.26 - Assembly and disassembly of the crankshaft (L3) 20-112
20.26.1 - Disassembly of the crankshaft 20-112
20.26.2 - Assembly of the crankshaft 20-116
20.27 - Disassembly and assembly of the piston and connecting rod drum (L3) 20-126
20.27.1 - Disassembly of the piston and connecting rod drum 20-126
20.27.2 - Assembly of the piston and connecting rod drum 20-128
20.28 - Check the piston (L3) 20-133
20.28.1 - Check of the piston pin hole 20-133
20.28.2 - Check the piston diameter 20-134
20.29 - Check the piston rings and piston grooves (L3) 20-136
20.29.1 - Check the piston rings and piston grooves 20-136
20.29.2 - Check the coupling clearance of the piston rings 20-137
20.29.3 - Assembly of the piston ring 20-138
20.29.4 - Check the endfloat of the piston ring 20-139
20.30 - Fitting and removing piston cooling nozzle (L3) 20-140
20.30.1 - Disassembly of the piston cooling nozzle 20-140
20.30.2 - Assembly of the piston cooling nozzle 20-140
20.30.3 - Measuring spray angle of piston cooling nozzle 20-140
20.31 - Removing and fitting crankcase breather (oil separator) (L3) 20-143
20.31.1 - Removal of the crankcase breather 20-143
20.31.2 - Refitting the crankcase breather 20-145
20.32 - Checking the cylinder sleeve (L3) 20-148
20.32.1 - Cylinder liner check 20-148
20.33 - Fitting and removing the cylinder sleeve (L3) 20-151
20.33.1 - Disassembly of the cylinder liner 20-151
20.33.2 - Assembly of the cylinder liner 20-153
20.34 - Checking cylinder sleeve protrusion (L3) 20-156
20.34.1 - Check the protrusion of the cylinder liner 20-156
20.35 - Removing and fitting ancillary mount (L3) 20-158
20.35.1 - Disassembly of the assembly support 20-158
20.35.2 - Fitting the ancillary mount 20-163
20.36 - Removing and fitting ancillary mount (L3) 20-172
20.36.1 - Disassembly of the assembly support 20-172
20.36.2 - Refitting the ancillary mount 20-175
20.37 - Removing and refitting rear cover (L3) 20-181
20.37.1 - Removing the rear cover 20-181
20.37.2 - Fitting the rear cover 20-182
20.38 - Disassembly and assembly of the connector box (L3) 20-184
20.38.1 - Disassembly of the connector box 20-184
20.38.2 - Assembly of the connector box 20-186
20.39 - Correcting contact points of cylinder sleeve (L3) 20-190
20.39.1 - Grinding the mating surface 20-190
VI
CONTENTS
20.39.2 - Grinding the mating surface to clean 20-191
20.39.3 - Check 20-192
20.39.4 - Grinding 20-193
20.39.5 - Check 20-194
20.39.6 - Finishing 20-194
20.39.7 - Installation 20-195
20.40 - Fitting and removing the camshaft bearings, checking (L3) 20-197
20.40.1 - Check the camshaft bearings 20-197
20.40.2 - Disassembly of the camshaft bearings 20-198
20.40.3 - Assembly of the camshaft bearings 20-200
20.41 - Fitting and removing tappets, checking tappet holes (L3) 20-204
20.41.1 - Disassembly of the tappet 20-204
20.41.2 - Measuring the tappet holes 20-204
20.41.3 - Assembly of the tappet 20-205
20.42 - Disassembly and assembly of the gear case cover (L3) 20-206
20.42.1 - Disassembly of the gear case cover 20-206
20.42.2 - Assembly of the gear case cover 20-208
20.43 - Disassembly and assembly of the gear case cover (L3) 20-211
20.43.1 - Disassembly of the gear case cover 20-211
20.43.2 - Assembly of the gear case cover 20-213
20.44 - Assembly and disassembly of the camshaft (L3) 20-215
20.44.1 - Disassembly of the camshaft 20-215
20.44.2 - Assembly of the camshaft 20-223
20.44.3 - Calculate the camshaft endfloat 20-225
20.44.4 - Check the clearance of the tooth side on the intermediate wheel (bench B) 20-229
20.44.5 - Check the clearance of the tooth side on the intermediate wheel (bench A) 20-230
20.44.6 - Check the clearance of the tooth side of the injection pump camshaft gear wheel 20-232
20.44.7 - Check and adjust the endfloat of the injection pump camshaft 20-234
20.45 - Check the camshaft (L3) 20-239
20.45.1 - Check the camshaft 20-239
20.45.2 - Checking the camshaft gear wheel 20-240
20.46 - Fitting and removing the injection pump camshaft (L3) 20-242
20.46.1 - Removing the injection pump camshaft 20-242
20.46.2 - Fitting the injection pump camshaft 20-252
20.46.3 - Fit the camshaft gear wheel. 20-255
20.46.4 - Calculate the camshaft endfloat 20-257
20.46.5 - Check the clearance of the tooth side on the intermediate wheel (bench B) 20-262
20.46.6 - Check the clearance of the tooth side on the intermediate wheel (bench A) 20-262
20.46.7 - Check the clearance of the tooth side of the injection pump camshaft gear wheel 20-265
20.47 - Replace the crankshaft O-ring (flywheel end) 20-273
20.47.2 - Assembly of the crankshaft O-ring 20-274
20.48 - Fitting and removing seal seat 20-276
20.48.1 - Removing the seal seat 20-276
20.48.2 - Fitting the seal seat 20-277
VII
CONTENTS
20.48.3 - Technical data 20-278
20.49 - Removal and refitting of the oil sump pan. 20-279
20.49.1 - Removal of the oil sump pan. 20-279
20.49.2 - Refitting the oil sump pan. 20-281
20.50 - Disassembly and assembly of the lubricant oil sump (L3) 20-284
20.50.2 - Refitting the oil sump pan. 20-286
20.51 - Disassembly and assembly of the lubricant oil sump (L3) 20-290
20.51.2 - Assembly of the lubricant oil sump with gasket 20-292
20.52 - Assembly and disassembly of the flywheel (L3) 20-298
20.52.1 - Removal of the flywheel 20-298
20.52.2 - Refitting the flywheel 20-299
30 - Engine accessories
30.1 - Fitting and removing the rotation tool (L3) 30-2
30.1.1 - Fitting the rotation device 30-2
30.1.2 - Removal of the rotation device 30-3
30.2 - Removing and fitting the exhaust manifold (L3) 30-4
30.2.1 - Removal of the exhaust manifold 30-4
30.2.2 - Assembly of the exhaust manifold 30-4
30.3 - Removing and fitting the exhaust manifold 30-6
30.3.1 - Disassembly of the exhaust manifold 30-6
30.4 - Removing and fitting the exhaust manifold (Bank B) (L3) 30-8
30.4.1 - Disassembly of the exhaust manifold 30-8
30.5 - Disassembly and assembly of the turbocharging air duct (L3) 30-10
30.5.1 - Removal of the charge air duct 30-10
30.5.2 - Refitting the charge air duct 30-11
30.6 - Disassembly and assembly of the connecting line (L3) 30-13
30.6.1 - Disassembly of the connecting line 30-13
30.6.2 - Assembly of the connecting line 30-17
30.7 - Disassembly and assembly of the connecting line (L3) 30-22
30.7.1 - Disassembly of the connecting line 30-22
30.7.2 - Assembly of the connecting line 30-25
30.8 - Disassembly and assembly of the turbocharger (L3) 30-31
30.8.1 - Removal of the turbocharger 30-31
30.8.2 - Refitting the turbocharger 30-34
30.9 - Removing and fitting the turbocharger (Bank A) (L3) 30-38
30.10 - Removing and fitting the turbocharger (Bank B) (L3) 30-43
VIII
CONTENTS
30.11 - Removing and fitting the air intake pipe 30-47
30.11.1 - Disassembly of the supply air pipe 30-47
30.11.2 - Assembly of the supply air pipe 30-49
30.12 - Removing and fitting the air intake pipe 30-52
30.12.1 - Disassembly of the supply air pipe 30-52
30.12.2 - Assembly of the supply air pipe 30-53
30.13 - Replacing the injection pipes (Bench A) (L3) 30-55
30.13.1 - Removal of the injection pipes 30-55
30.13.2 - Refitting the injection pipes 30-56
30.14 - Replacing the injection pipes (Bench A) (L3) 30-60
30.14.1 - Removal of the injection pipes 30-60
30.14.2 - Refitting the injection pipes 30-61
30.15 - Fitting and removing injection valves (L3) 30-65
30.15.1 - Disassembly of the injection valve 30-65
30.15.2 - Disassembly of the blocked injection valve 30-66
30.15.3 - Disassemble the fixed O-ring on the cylinder head 30-67
30.15.4 - Assembly of the injection valve 30-69
30.16 - Removing and refitting the injection valve (L3) 30-71
30.16.1 - Disassembly of the injection valve 30-71
30.16.2 - Refitting the injection valve 30-71
30.17 - Checking and adjusting the injection valves (L3) 30-75
30.17.1 - Assembly of the injection valve on the injector tester 30-75
30.17.2 - Check the opening pressure 30-76
30.17.3 - Check the air-tightness 30-76
30.17.4 - Checking the mobility of the jet needle 30-77
30.17.5 - Disassembly of the injection valve from the injector tester 30-78
30.18 - Removing and fitting fuel delivery pump (L3) 30-79
30.18.1 - Removal of the fuel lift pump 30-79
30.18.2 - Refitting the fuel lift pump 30-81
30.19 - Assembly and disassembly of the fuel pressure regulating valve (L3) 30-83
30.19.1 - Disassembly of the of the fuel pressure regulating valve 30-83
30.19.2 - Assembly of the of the fuel pressure regulating valve 30-85
30.20 - Assembly and disassembly of the fuel pressure regulating valve (L3) 30-89
30.20.1 - Disassembly of the of the fuel pressure regulating valve 30-89
30.20.2 - Assembly of the of the fuel pressure regulating valve 30-91
30.21 - Assembly and disassembly of the oil intake pipe (L3) 30-95
30.21.1 - Removal of the oil pickup pipe 30-95
30.21.2 - Refitting the oil pickup pipe 30-95
30.22 - Assembly and disassembly of the oil intake pipe (L3) 30-97
30.22.1 - Removal of the oil pickup pipe 30-97
30.22.2 - Refitting the oil pickup pipe 30-97
30.23 - Disassembly and assembly of the oil radiator (L3) 30-99
30.23.1 - Removal of the oil cooler 30-99
30.23.2 - Refitting the oil cooler 30-102
30.24 - Fitting and removing transition pipe 30-106
30.24.1 - Removing the transition pipe 30-106
IX
CONTENTS
30.24.2 - Fitting the transition pipe 30-106
30.25 - Line 30-108
30.26 - Fitting and removing the oil pressure transducer (L3) 30-109
30.26.1 - Removing the oil pressure transducer 30-109
30.26.2 - Fitting the oil pressure transducer 30-110
30.27 - Fitting and removing the regulator valve (L3) 30-111
30.27.1 - Removing the regulator valve 30-111
30.27.2 - Fitting regulator valve 30-115
30.28 - Closing components 30-119
30.29 - Topping up with oil 30-120
30.30 - Removing and fitting the coolant pump (L3) 30-121
30.30.1 - Removal of the water pump 30-121
30.30.2 - Refitting the water pump 30-123
30.31 - Check the thermostat (after removal) (L3) 30-126
30.31.1 - Testing the thermostat 30-126
30.32 - Removal and refitting of the flywheel (fixing elements) 30-128
30.32.1 - Removal of the flywheel 30-128
30.32.2 - Refitting the flywheel 30-128
30.33 - Removal and refitting of the cylinder head cover 30-130
30.33.1 - Removal of the cylinder head cover 30-130
30.33.2 - Refitting the cylinder head cover 30-131
30.34 - Fitting and removing the thermostats (L3) 30-133
30.34.1 - Removing the thermostats 30-133
30.34.2 - Fitting the thermostats 30-134
30.35 - Removing and fitting the thermostat housing (L3) 30-135
30.35.1 - Removing the thermostat housing 30-135
30.35.2 - Refitting the thermostat housing 30-138
30.36 - Support 30-142
30.37 - Intermediate gear 30-143
30.38 - Disassembly and assembly of the torsional vibration damper (L3) 30-144
30.38.1 - Removal of the torsional vibration damper 30-144
30.38.2 - Refitting the torsional vibration damper 30-145
30.39 - Lubricating oil filter console 30-146
30.40 - Replacing the starter ring gear on the flywheel (L3) 30-147
30.40.1 - Disassembly of the starter ring gear 30-147
30.40.2 - Assembly of the starter ring gear 30-148
30.41 - Removing and fitting the hydraulic pump drive (L3) 30-149
30.41.1 - Disassembly of the hydraulic pump drive 30-149
30.41.2 - Assembly of the hydraulic pump drive 30-150
30.42 - Disassembly and assembly of the connector box 30-153
X
CONTENTS
30.46 - Removal and refitting of the crankshaft speed sensor (L3) 30-161
30.46.1 - Removal of the speed sensor 30-161
30.46.2 - Refitting the speed sensor 30-162
30.47 - Removal and refitting of the camshaft speed sensor (L3) 30-167
30.47.1 - Removal of the speed sensor 30-167
30.47.2 - Refitting the speed sensor 30-169
30.48 - Removing and fitting the exhaust pipe 30-174
30.48.2 - Refitting the exhaust manifold 30-175
30.51 - Removing and fitting the exhaust pipe (Bank B) (L3) 30-182
30.52 - Assembly and disassembly of the spark plug (L3) 30-184
30.52.1 - Disassembly of the spark plug 30-184
30.52.2 - Assembly of the spark plug 30-185
30.53 - Assembly and disassembly of the spark plug (L3) 30-187
30.53.1 - Disassembly of the spark plug 30-187
30.53.2 - Assembly of the spark plug 30-189
30.54 - Disassembly and assembly of the fuel cutoff valve (spark plugs) (L3) 30-193
30.54.1 - Disassembly of the fuel cutoff valve 30-193
30.54.2 - Assembly of the fuel cutoff valve 30-194
30.55 - Disassembly and assembly of the fuel cutoff valve (spark plugs) (L3) 30-198
30.55.1 - Disassembly of the fuel cutoff valve 30-198
30.55.2 - Assembly of the fuel cutoff valve 30-200
30.56 - Disassembly and assembly of the fuel pipes (spark plugs) (L3) 30-203
30.56.1 - Removal of fuel lines 30-203
XI
CONTENTS
30.56.2 - Refitting fuel lines. 30-204
30.57 - Disassembly and assembly of the fuel pipes (spark plugs) (L3) 30-207
30.58 - Assembly and disassembly of the temperature sender (L3) 30-211
30.58.1 - Removal of the temperature sender 30-211
30.58.2 - Refitting the temperature sender 30-212
30.59 - Disassembly and assembly of the fuel pipes (L3) 30-214
30.60 - Disassembly and assembly of the fuel pipes (L3) 30-227
30.61 - Assembly and disassembly of the temperature sender (L3) 30-233
30.61.1 - Removal of the temperature sender 30-233
30.61.2 - Refitting the temperature sender 30-234
30.62 - Disassembly and assembly of the cable bundle (L3) 30-235
30.62.1 - Removal of the engine wiring loom 30-235
30.62.2 - Refitting the engine wiring loom 30-244
30.63 - Removing and fitting the alternator (driven by toothed belt) (L3) 30-255
30.63.1 - Removal of the alternator 30-255
30.63.2 - Refitting the alternator 30-257
30.63.3 - Checking the tension of the V-belt using the belt tension gauge 30-259
30.64 - Disassembly and assembly of the starter (L3) 30-262
30.64.1 - Disassembly of the starter 30-262
30.64.2 - Assembly of the starter 30-263
30.65 - Removal and refitting of the supply air pressure/temperature sender (L3) 30-264
30.65.1 - Removal of the temperature/pressure sender 30-264
30.65.2 - Refitting the temperature/pressure sender 30-264
30.66 - Fitting and removing the injection pumps (cylinder A1) (L3) 30-266
30.66.1 - Disassembly of the injection pump 30-266
30.66.3 - Assembly of the injection pump housing 30-270
30.66.4 - Assembly of the injection pump 30-271
30.67 - Fitting and removing the injection pumps (cylinder A2-B3) (L3) 30-276
30.67.1 - Removing the injection pump 30-276
30.67.3 - Assembly of the injection pump housing 30-278
30.67.4 - Fitting the injection pump 30-280
30.68 - Checking and adjusting maximum injection pump aperture stroke (L3) 30-283
30.68.1 - Check of the maximum opening stroke of the injection pumps 30-283
30.68.2 - Adjusting maximum aperture stroke of injection pumps 30-287
30.69 - Removal and refitting of the oil cooler 30-297
30.69.1 - Removal of the oil cooler 30-297
30.69.2 - Refitting the oil cooler 30-297
XII
CONTENTS
40 - Pivot points
40.1 - Safety instructions for tyres and wheel studs 40-2
40.2 - Brakes, brake fluid safety instructions 40-3
40.3 - Axles maintenance tables 40-4
40.3.1 - Driving axle maintenance and inspection 40-4
40.3.2 - Drive axle / Steering axle 40-4
40.4 - Transmission oil check and oil change 40-5
40.4.1 - Checking the oil level 40-5
40.4.2 - Oil change 40-5
40.5 - Check and change final drive oil 40-6
40.5.1 - Checking the oil level 40-6
40.5.2 - Oil change 40-6
40.6 - Check and change final drive oil - BALANCE 40-7
40.6.1 - Check oil level 40-7
40.6.2 - Change oil 40-7
40.7 - Braking system 40-8
40.7.1 - Brake fluid level / linings check 40-8
40.7.2 - Replacing fixed calliper brake linings: 40-8
40.7.3 - Replacing the brake linings 40-10
40.7.4 - Checking brake disc wear 40-11
40.7.5 - Bleeding the air and checking the brake fluid level 40-11
40.7.6 - Parking brake: 40-12
40.8 - Tyres and wheel rims 40-14
40.8.1 - Wheels camber = E 40-14
40.9 - Front axle 40-15
40.10 - Front axle - BALANCE version 40-17
40.10.1 - Fitting / Removing 40-18
40.11 - Transmission ZNK 25 - 1604 0895/20 40-19
40.11.1 - Gearbox ZNK 25 (1604 0895/20) 40-19
40.12 - Transmission fork adjustment - transmission ZNK25 - 1604 0895/20 40-21
40.12.1 - Transmission ZNK25 (1604 0895/20), gearbox 40-21
40.13 - Transmission control linkage 40-24
40.13.1 - Gearbox 40-24
40.14 - Final drive 40-26
40.14.1 - Final drive (1604 0897) 40-26
40.15 - Steering axle 40-28
40.15.1 - Steering axle setup 40-29
40.15.2 - Wheel hub fitment instructions 40-30
XIII
CONTENTS
50 - Belts and chains
50.1 - Electrical drive of belt clutches, overview 50-2
50.1.1 - Belt clutches operation criteria 50-3
50.1.2 - Belt clutches operation with the engine switched off 50-3
50.2 - Powershift control unit (CCP2) 50-5
50.2.1 - Description 50-7
50.3 - Straw chopper clutch 50-9
50.4 - Grain tank discharge clutch 50-10
50.5 - Threshing section clutch 50-11
50.6 - Feed passage clutch 50-12
50.7 - Diagram of lubrication control valve lines 50-13
50.7.1 - LH lubricant control valve 50-13
50.7.2 - RH lubricant control valve 50-13
50.7.3 - Troubleshooting instructions 50-13
50.8 - Diagram of centralised lubrication system lines 50-14
50.8.1 - Balance lubricant control valve 50-14
50.8.2 - Troubleshooting instructions 50-14
60 - Hydraulic system
60.1 - Hydraulic system - Safety warnings 60-2
60.1.1 - Maintenance 60-2
60.2 - Hydraulic circuit - hydraulic connection diagram 60-3
60.2.1 - Hydraulic circuit connection logic: 60-3
60.3 - Hydraulic circuit connection diagram for Balance 60-5
60.4 - Hydraulic circuit pipes diagram for Balance 60-7
60.5 - Control valves block 60-10
60.6 - Control valves block connection plate 60-12
60.6.1 - Flow regulator valve with integral pressure relief valve 60-12
60.7 - Single-acting control valve 60-14
60.7.1 - Function: 60-14
60.8 - Double-acting control valve 60-16
60.8.1 - Function: 60-16
60.9 - Engagement valve for the hydraulic accumulator, with pressure sensor 60-19
60.9.1 - Engagement valve function: engage/disengage hydraulic accumulator (3) 60-19
60.9.2 - Hydraulic accumulator supplementary valve connection logic: 60-19
60.10 - EMR-D control valve 60-21
60.10.1 - Neutral position 60-21
60.10.2 - Raise cutting table 60-23
60.10.3 - Lower cutting table 60-24
60.11 - Self-levelling balancing control hydraulic connection diagram 60-27
60.11.1 - BALANCE control connection logic: 60-27
60.12 - Pilot equipment 60-29
60.12.2 - Neutral circulation 60-29
60.12.3 - Working position 60-29
XIV
CONTENTS
60.12.4 - Removing / Fitting 60-30
60.13 - Control valves block with integral check valve 60-31
60.13.1 - Operating description 60-32
60.14 - Tilt cylinder 60-33
60.14.1 - Hose burst safety valve 60-33
60.15 - Cutter bar self-levelling system 60-34
60.16 - Hydraulic cutting angle control 60-35
60.17 - Lifting cylinder - cutting table (feed passage) 60-36
60.17.1 - Repair work 60-36
60.18 - Hydraulic cylinder - steering axle 60-38
60.18.1 - Repair work 60-38
60.19 - Hydraulic cylinder - repair 60-39
60.19.1 - A - Vertical reel (cutter bar width 4.2 - 7.2 m) 60-39
60.19.2 - B - LH horizontal reel 60-40
60.19.3 - C - Grain tank discharge pipe 60-41
60.19.4 - D - Grain tank discharge pipe block 60-42
60.19.5 - Vertical and horizontal reel single and double-acting cylinder (synchronous cylinder) 60-43
60.19.6 - Grain tank extension hydraulic drive 60-44
60.20 - Hydraulic steering system 60-45
60.20.2 - Execution 60-45
60.20.3 - Function 60-45
60.20.4 - Emergency steering (manual) 60-45
60.21 - Danfoss Lenkorbitrol type OSPC 160 ON 60-47
60.21.1 - Lenkorbitrol repair work / general overhaul 60-48
60.22 - Steering system check 60-49
60.22.1 - Steering cylinder internal sealing check 60-49
60.22.2 - Steering system internal sealing check 60-49
60.23 - Hydraulic circuit - Troubleshooting 60-50
60.24 - General warnings 60-52
60.24.1 - Equipment of combine harvesters with hydrostatic units 60-52
60.25 - Basic structure 60-53
60.25.1 - Description of hydrostatic system operation 60-54
60.26 - BoWex clutch between hydrostatic pump and engine 60-55
60.26.1 - Assembly warnings 60-55
60.27 - Gear control 60-57
60.27.1 - Toothed rod device 60-57
60.28 - Hydrostatic transmission - Hydrostatic pump HPV 105/135 60-59
60.28.1 - Basic structure 60-59
60.28.2 - Tightening torques for the valves 60-59
60.28.3 - Cam adjustment 60-61
60.29 - Hydrostatic transmission - Hydrostatic pump HPV 105/135 60-63
60.29.1 - Measure and check 60-63
60.29.2 - General information for pressure measurement 60-63
XV
CONTENTS
60.30 - HMF type hydrostatic motor 60-65
60.30.1 - Hydrostatic motor HMF 105, HMF 135 60-65
60.30.2 - HMF type hydrostatic motor 60-66
60.31 - Troubleshooting 60-68
60.31.1 - 1. During start-up of the system loud cavitation noises are emitted 60-68
60.31.2 - 2. Insufficient performance of the system at normal supply pressure and without any
significant cavitation noise 60-68
60.31.3 - 3. The system shuts down 60-68
60.31.4 - 4. Combine cannot reach top speed 60-68
60.31.5 - 5. When the travel lever is activated the combine fails to move forward or in reverse 60-69
60.31.6 - 6. Oil temperature too high, max. 95 °C 60-69
60.31.7 - 7. Zero point position cannot be reached 60-70
60.31.8 - 8. No feed pressure 60-70
60.31.9 - 9. Combine travels in only one direction 60-70
60.31.10 - 10. In one direction of travel the speed changes in an irregular manner or traction force
is reduced 60-70
70 - Feed passage
70.1 - Feed passage 70-2
70.2 - Feed passage - slipping clutch 70-3
70.3 - Feed passage - stabiliser shaft for feed chain 70-5
70.4 - Engagement of the feed passage 70-7
70.5 - Protection against clogging of feed passage 70-8
70.6 - Protection against clogging between feed channel chain sprockets 70-9
70.6.1 - (Auxiliary equipment for threshing of flax) 70-9
70.7 - Feed passage reversal device 70-10
70.8 - Feed passage oscillating frame, orientable adapter 70-11
70.8.1 - Orientable adapter for the cutting table (without hydraulic adjustment of the cutting angle) 70-11
70.8.2 - Orientable adapter for the cutting table (with hydraulic adjustment of the cutting angle) 70-11
80 - Cab
80.1 - Operator station control console 80-2
80.2 - Commander Control 2000, EMR-D control unit 80-5
80.2.1 - Commander Control 2000 80-5
80.2.2 - EMR-D control panel 80-5
80.3 - Operator station, Commander Stick, control consoles 80-6
80.4 - Operator station - steering wheel 80-8
80.5 - Cab - control pedals, parking brake 80-9
80.6 - Cab, controls 80-10
80.7 - Cab, control devices, seats 80-11
80.7.1 - Aero-Fit seat (air sprung) (optional) 80-11
80.8 - Cab - controls 80-13
80.9 - Cab, control elements, emergency exit 80-14
80.10 - Cab, rear-view mirror control devices 80-15
80.10.1 - Electrical adjustment of the rear-view mirrors (optional) 80-15
XVI
CONTENTS
80.11 - On-board computer (optional) 80-16
80.11.1 - System description 80-16
80.11.2 - Description of the function keys 80-16
80.12 - Cab suspension 80-18
80.13 - Safe maintenance and repair of the air conditioning system 80-20
80.13.1 - Personnel qualifications 80-20
80.13.2 - Personal protective equipment 80-21
80.13.3 - Handle refrigerant and the refrigerant tank with care 80-21
80.13.4 - First aid in the case of contact with refrigerant 80-22
80.13.5 - Safety measures for welding work 80-22
80.14 - Overview of functional components in the cab roof 80-23
80.15 - Electrical diagram for electric heater and air conditioner in cab roof 80-25
80.16 - Operating description of the air conditioning system 80-26
80.16.1 - Refrigerant liquid circuit 80-26
80.17 - Refrigerant fluid and oil 80-28
80.17.1 - Refrigerant 80-28
80.17.2 - Refrigerant 80-28
80.17.3 - PAG oils 80-29
80.18 - Air conditioning system components 80-30
80.19 - Compressor 80-31
80.19.1 - Operation 80-31
80.19.2 - Pressure limiting valve 80-31
80.20 - Electromagnetic clutch 80-32
80.21 - Compressor lubrication 80-33
80.21.1 - Check oil level 80-33
80.21.2 - Warnings for maintenance 80-33
80.22 - Liquid tank with dryer 80-34
80.22.1 - Operation 80-34
80.22.2 - Moisture is one of the main problems for an air conditioning system 80-34
80.22.3 - Warnings for maintenance 80-34
80.23 - Thermostatic expansion valve (TEV) 80-36
80.23.1 - Construction 80-36
80.23.2 - Operation 80-37
90 - Electrical equipment
90.1 - Electrical system - safety warnings 90-2
90.2 - Serdia 90-3
90.2.1 - “Serdia 3.5 level III” software 90-3
90.3 - SERDIA 2000 level III” software 90-4
90.3.1 - SERDIA 2000 level III” software 90-4
90.4 - Table of abbreviations 90-5
90.5 - Cable colours and connector colours identification. 90-6
90.5.1 - Identification on the electrical diagram 90-6
90.6 - View of control console 90-7
90.6.1 - Standard execution 90-7
XVII
CONTENTS
90.7 - Control devices in cab roof 90-8
90.7.1 - Air conditioning system control panel 90-8
90.7.2 - Lighting control panel 90-8
90.8 - Control console, switches and lights 90-9
90.9 - Commander Control 2000 operating controls 90-10
90.10 - Plug distributor / Engine frame plug connector 90-11
90.10.1 - Engine frame plug connector 90-11
90.10.2 - List of connectors on engine frame 90-12
90.11 - Actuator connector pins assignment 90-15
90.12 - Diagram of Commander Control 2000 CAN-Bus with central display 90-17
90.13 - Straw chopper straw guide plate adjustment diagram 90-19
90.13.1 - Pins assignment 90-19
90.13.2 - Identification 90-19
90.14 - CAN-Bus system of Commander Control with central display installation procedure 90-21
90.15 - Type of function and programming of CAN modules 90-22
90.16 - Central display 90-27
90.16.1 - Connectors electrical diagram - Connectors assignment 90-28
90.17 - Central display and Commander Control 2000, control and command functions overview 90-29
90.17.1 - Relay unit 90-29
90.18 - Checking functions by means of Commander Control 2000 90-31
90.19 - Switches and sensors for Commander Control 2000 control 90-34
90.19.1 - Gearbox cover inductive transducer for speed measurement 90-34
90.19.2 - Inductive sensor for speeds control and adjustment 90-35
90.19.3 - Inductive sensor as control switch 90-35
90.19.4 - Mechanical control switches 90-35
90.19.5 - Engine coolant and oil temperature switch (5650H, 5660H/HTS, 5665HTS, 5690H/HTS,
5695HTS)90-36
90.19.6 - Capacitive transducer for grain tank filling indicator 90-36
90.20 - Description of inductive sensor functions 90-37
90.21 - Sensors, overview 90-39
90.21.1 - Sensors on RH side of combine harvester 90-39
90.21.2 - Combine harvester LH sensors 90-40
90.21.3 - Sensors on engine (Sensors for EEC see section A) 90-41
90.22 - Multifunction lever, rack device / sensor adjustment 90-43
90.22.1 - Settings on rack device and cable-pull 90-44
90.22.2 - Fitment instructions 90-44
90.23 - EEC control unit, accelerator adjustment module 90-45
90.23.1 - A2 Pins assignment 90-46
90.24 - Cutting table electronic control 90-48
90.24.1 - Operation 90-48
90.24.2 - EMR-D Level control / AutoControl components 90-48
90.24.3 - Switching logic 90-49
90.24.4 - Assignment of operating elements 90-50
90.24.5 - Assignment of Commander Stick 90-50
90.24.6 - Calibration 90-51
XVIII
CONTENTS
90.24.7 - Fault diagnosis 90-52
90.24.8 - Fault diagnosis (List of fault codes for EMR-D) 90-53
90.25 - Assignment of connectors EMR-D 90-56
90.25.1 - Assignment of connectors for EMR-D (Bosch) control unit transverse tilt, A12 90-58
90.25.2 - Cutting table electronic control, EMR-D Level control / AutoControl 90-59
90.25.3 - Cutting table electronic control, EMR-D Level control / AutoControl 90-62
90.26 - Balance system 90-65
90.26.1 - Balance description 90-65
90.26.2 - Operation 90-66
90.26.3 - Calibration of the position controller 90-67
90.26.4 - Adjustment of the response time for automatic cutting angle control 90-70
90.26.5 - Balance with automatic cutting angle 90-72
90.26.6 - Balance-Shaft cutting angle transducer 90-73
90.26.7 - Check / Adjust 90-75
90.26.8 - Balance II power supply diagram and cutting angle control 90-76
90.26.9 - Balance II connectors assignment with automatic cutting angle system 90-77
90.26.10 - Balance II connectors assignment with automatic cutting angle system 90-79
90.26.11 - Faults / Troubleshooting 90-81
90.27 - Hourly production monitoring system / Job calculator 90-82
90.27.1 - Functionality check - Hourly production control system 90-83
90.27.2 - Assignment of connections on the distribution circuit board, measurement values 90-83
90.27.3 - Indicator device connector pins assignment 90-83
90.27.4 - Grain loss monitor adjustment knobs 90-84
90.27.5 - Work calculator LH 1000 90-85
90.28 - Wiring looms and components index 90-89
90.28.1 - List of wiring looms 90-89
90.28.2 - Index by part description 90-89
90.28.3 - Index by part code 90-95
90.28.4 - Index by connector 90-97
90.29 - Worklights 90-106
90.30 - Windscreen wiper 90-109
90.31 - BALANCE 90-110
90.32 - Solenoid valves 90-113
90.33 - Electric motors 90-115
90.34 - Grain tank sensors 90-117
90.35 - Attachment 90-119
90.36 - Feed passage sensors 90-121
90.37 - Lights 90-122
90.38 - Air conditioner 90-125
90.39 - Front wiring loom - 0.015.5469.4/20 90-127
90.40 - Battery positive lead - 16002049 90-129
90.41 - Battery negative lead - 16002046 90-130
90.42 - Cab console wiring - TS8799/1, TS8799/3 90-131
90.43 - Engine interface wiring - 0.015.5475.4/10 90-133
XIX
CONTENTS
90.44 - Engine wiring loom - 0.015.5471.4/20 90-134
90.45 - Fuse box wiring - 0.015.5312.4/20 90-136
90.46 - Grain tank wiring loom - 0.015.5473.4/10 90-139
90.47 - Charge circuit wiring loom - 0.015.5464.4/10 90-141
90.48 - Attachment electrical socket wiring loom - 0.015.5466.4/10 90-142
90.49 - Rear number plate light wiring loom - 16056728/10 90-143
90.50 - Coolant temperature sensor wiring loom - 16062294 90-144
90.51 - BALANCE wiring - 0.015.5467.4/10 90-145
90.52 - Electric motor wiring loom - 0.015.5472.4/10 90-147
90.53 - Returns elevator emergency switch - 16050268 90-149
90.54 - Roof lining electrics wiring loom - 980157 90-150
90.55 - BALANCE WIRING LOOM - 16052333 90-151
90.56 - Cab roof worklights wiring loom - 980060 90-152
90.57 - Air conditioner wiring loom - 540465 90-153
90.58 - Air conditioning system filter-dryer wiring loom - 16050276 90-154
90.59 - Rear wiring - 0.015.5470.4/20 90-155
90.60 - Rear lateral light wiring loom - 16013845 90-159
90.61 - Sieve lighting wiring loom - 16050274 90-160
90.62 - Side lights wiring loom - 16056753 90-161
90.63 - Side lights wiring loom - 16056731/10 90-162
90.64 - Feed passage reversing device wiring loom - 16062550 90-163
90.65 - Feed passage sensors wiring loom - 0.015.5465.4 /10 90-164
90.66 - Chassis wiring loom - 0.015.5474.4/10 90-166
90.67 - Grain tank worklight wiring loom - 16062565/10 90-168
90.68 - Solenoid valves assembly wiring loom - 0.015.5468.4/10 90-169
90.69 - Cutting table cutting angle sensor wiring loom - 16062568/10 90-171
90.70 - Multifunction lever wiring loom - TS8799/2 90-172
90.71 - Steering column switch wiring loom - 980062201 90-173
90.72 - Straw chopper wiring loom - 16050256 90-174
100 - Threshing unit

100.1 - Threshing section clutch 100-2
100.1.1 - Belt guide for threshing drum slipping clutch 100-2
100.2 - Assembling the threshing drum 100-3
100.3 - Concave electrical adjustment 100-4
100.4 - Concave suspension, de-awner covers 100-6
100.4.1 - De-awner covers 100-6
100.5 - Assembling the reversing drum 100-8
100.5.1 - Reversing drum with synchronous drive (from 2007) 100-8
100.6 - Threshing drum speed variator 100-10
100.7 - Installing the variator pulley 100-12
100.8 - Variator adjustment 100-13
XX
CONTENTS
100.8.1 - Variator switching elements 100-13
100.9 - Changing the variator belt 100-15
100.10 - Dust plate and gaskets on threshing section 100-16
100.11 - Threshing drum speed reduction 100-17
100.11.1 - Conversion to reduced speed 100-19
100.11.2 - Oil change, oil level check 100-19
100.11.3 - Replacement of single parts 100-19
100.12 - Turbo separator 100-20
100.12.1 - Turbo separator - Basic electrical selector setting 100-20
100.12.2 - Turbo separator drive 100-20
100.13 - Installing the maize concave 100-22
100.14 - Threshing drum - maize harvesting, welding of threshing drum beater bars 100-23
110 - Cleaning unit

110.1 - Straw walkers drive 110-2
110.2 - Straw walker transmission adjustment 110-3
110.3 - Straw walker supports assembly 110-4
110.4 - Assembling straw walker shafts and straw walker 110-6
110.4.1 - Assembly dimensions and assembly of straw walker shafts and straw walker. 110-6
110.5 - Installation of straw walker rakes 110-8
110.6 - Sieve crankshaft 110-9
110.6.1 - Installation of the sieves crankshaft 110-9
110.6.2 - Connecting rod mechanism 110-9
110.7 - Stepped gain pan with removable segments 110-11
110.7.1 - Fitting the stepped grain pan swinging arm 110-11
110.8 - Stepped grain pan and sieve box with transmission 110-12
110.9 - Fan speed variator 110-14
110.9.1 - Speed variator adjustments 110-14
110.9.2 - Operation and maintenance recommendations: 110-14
110.10 - Fan - shroud 110-16
110.11 - Tailings elevator (returns elevator) 110-17
110.12 - Electric sieve adjustment 110-18
110.12.1 - Control device function 110-19
110.12.2 - Control device basic setting 110-19
110.12.3 - Removing the sieves 110-19
110.12.4 - Installing the sieves: (the servomotor must be fully retracted) 110-19
120 - Grain tank - Elevator

120.1 - Grain elevator with elevator head 120-2
120.2 - Elevator head, speed control 120-4
120.2.1 - Speed control 120-4
120.3 - Elevator head for grain tank extension 120-6
120.4 - Grain tank clutch 120-8
120.4.1 - Controls in engaged position 120-9
XXI
CONTENTS
120.5 - Emptying the grain tank 120-10
120.6 - Grain discharge system 120-11
120.7 - Bevel gear in elbow pipe 120-14
120.7.1 - Lower bevel gear 120-14
120.8 - Support for grain tank pipe, block 120-15
120.8.1 - Swivel grain tank pipe hydraulic control 120-17
120.9 - Grain tank level sensors 120-18
130 - Cutting table

130.1 - Controls diagram, speed 130-2
130.2 - Cutting table drive, reel variator 130-3
130.3 - Slipping clutch for intake auger and reel 130-5
130.4 - Intake auger 130-7
130.5 - Intake auger settings 130-9
130.6 - Blade mechanism - 80 mm stroke 130-10
130.6.1 - Transmission assembly 130-11
130.7 - Blade mechanism - 85 mm stroke 130-12
130.8 - Blade control transmission check; changing the blade 130-14
130.9 - Assembly of potentiometer for cutting table adjustment 130-16
130.10 - Connectors assignment, 13 pin socket 130-17
130.11 - Diagram of pipelines and connection diagram for hydraulic system on rape header 130-18
130.12 - Rape header drive 130-20
140 - Attachments and accessories

140.1 - Straw guide plate adjustment 140-2
140.2 - Straw chopper V-belt clutch 140-4
140.2.1 - Clutch control 140-5
140.3 - Speed monitoring 140-6
140.3.1 - Function of switch 3 140-7
140.4 - Conversion of straw chopper for threshing maize and sunflowers 140-8
140.5 - Lining for straw hood 140-10
140.5.1 - KPAB straw chopper 140-10
140.6 - Electrically driven movement from straw guide plate to straw chopper 140-11
XXII
0 - Introduction
0-1
Introduction
0.1 - General safety instructions
Before starting any fitting, maintenance or repair work, read and observe all the safety instructions! All safety instructions must be
communicated to all the persons involved. All parts of this manual concerning safety are marked with the symbol shown alongside:
DANGER
This combine harvester is designed solely for use in conventional agricultural applications (“authorised use”). Use for
any other purpose is considered to be contrary to this authorisation. The manufacturer accepts no liability for possible
injuries injury resulting from such misuse; the relative risks must be borne exclusively by the user. Strict compliance
with the conditions of operation, service and repair specified by the manufacturer is also an essential element of the
authorised use. The combine harvester may only be operated, serviced and repaired by persons familiar with the ma-
chine and informed of the dangers involved. Any unauthorised modifications to the machine shall automatically cancel
all liability of the manufacturer for any resulting damage.
0.1.1 - General safety and accident prevention provisions

1. In addition to the specific instructions in this manual, you must observe the specific accident prevention regulations and all
other regulations generally recognised in relation to technical safety, occupational medicine and traffic circulation. The com-
pany regulations and prescriptions given in the relative instructions for use during travel on public roads and field work are
applicable also to this manual and must therefore be strictly complied with.
2. Before starting the engine, make sure that no gear is engaged and the gear lever is set to 0 in the case of the Hydromat and
that all guards and protective devices are correctly fitted and in the required protection position!
3. Start the engine only when seated in the operator’s cab. The engine must not be started by shorting the starter motor contacts
because this action may cause immediate movement of the combine harvester.
4. Before starting the engine, make sure that no-one is inside danger zone around vehicle. For safety reasons always sound the
alarm signal!
5. Do not run engine in an enclosed place.
6. When parking the combine harvester protect against rolling (handbrake, wheel chocks, in gear). Switch off the engine, remove
ignition key and lock cab!
7. Before leaving the combine harvester unattended, lower front attachments to the ground (cutting table, etc.)!
8. Take care when handling fuel: fire risk. Never refill fuel tank near naked flames or sparks! Do not smoke when refuelling!
9. Always switch off engine and remove ignition key before refuelling. Do not refuel the combine harvester in enclosed places
and wipe up any fuel spills immediately!
10. Always keep combine harvester clean to avoid risk of fire!
11. Take care when handling brake fluid and battery acid (toxic and corrosive)!
12. Before working under front attachments (cutting table) and under the feed passage install adequate stands!
0-2
Introduction
0.2 - Safety instructions - maintenance and repair
0.2.1 - General information:
1. In general, before carrying out assembly, repair, maintenance and cleaning works and before troubleshooting operations,
decouple drive train, switch off engine and remove ignition key.
2. If fluids such as fuel, hydraulic oil etc. are protected at high pressure from pipes, hoses etc., they can pierce the skin and cause
severe injury. In the event of injury, seek immediate medical attention due to the severe risk of infection.
3. Take care when handling fuel: fire risk!
Never refill the fuel tank close to naked flames or sparks. Never smoke while refuelling!
4. Always keep the combine harvester clean to avoid risk of fire!
0.2.2 - Electrical system:

1. Before working on the electrical system, always disconnect the battery negative lead.
2. Make sure the battery is correctly connected. - First connect the positive pole and then the negative.
3. Battery gases are highly explosive - use appropriate caution. Avoid generating sparks or naked flames close to batteries.
4. Only use fuses of the specified ratings. If any of the fuses used are rated too highly, the electrical system may be severely
damaged.
5. Only use fuses of the specified ratings. If any of the fuses used are rated too highly, the electrical system may be severely
damaged.
6. Take care when handling battery acids (electrolyte is toxic and corrosive)
7. Only operate the starter motor for short intervals to avoid overheating the windings.
Allow the starter motor to cool.
0.2.3 - Brake system, brake fluid:

1. Before travelling with the combine harvester check that the brakes are working correctly.
2. The braking system must be checked at regular intervals.
3. Settings and repairs of the brake system may only be carried out by authorised workshops or recognised brake service sta-
tions.
4. For travel on public roads, individual wheel braking must be deactivated (interlock the brake pedals).
5. Check the brake fluid level regularly. Only use recommended brake fluids and change according to the prescriptions.
6. Take care when handling brake fluids (toxic and corrosive) and avoid spills.
7. Ensure brake fluid is disposed of in compliance with the relevant legislation.
0.2.4 - Hydraulic system:

1. The hydraulic system contains highly pressurised hydraulic fluid! While seeking possible leakage points use adequate auxil-
iary means to avoid the risk of personal injury!
2. For all work on the hydraulic system, the pressure must be discharged and mounted front attachments must be lowered to
the ground!
3. For all work on the hydraulic system, the engine must be switched off, the ignition key removed and combine harvester wheels
immobilised to avoid accidental movements (apply the parking brake, insert chocks under the wheels).
4. Whenever hydraulic components are connected, make sure the flexible hoses are connected according to prescriptions!
Functions will be inverted if hydraulic connections are inadvertently switched (e.g. lower/ raise).
5. Check hydraulic flexible pipes at regular intervals and renew if damaged or worn!
New hydraulic hoses must be in compliance with the technical requirements of the device manufacturer.
6. The hydraulic accumulator contains compressed gas. Take care not to drop the accumulator and do not expose it to tempera-
tures in excess of 150°!
0.2.5 - Air conditioning system:

1. Avoid all contact with the refrigerant fluid of the air conditioning system! If refrigerant is sprayed into the eyes, seek urgent
medical attention!
2. All maintenance, fitting and repair works must be carried out only by specialised personnel!
3. Never weld any parts of the refrigerant circuit or perform welding work in the immediate vicinity of the refrigerant circuit!
4. Maximum ambient temperature for refrigerant: 80 °C
5. After complete draining of the refrigerant circuit, dispose of the air conditioning system in compliance with the relevant legisla-
tion.
0-3
Introduction
0.2.6 - Tyres, threaded fixings:
1. When working on the wheels, park the combine harvester on level ground and protect against rolling (chocks)!
2. When working on the combine harvester raised from the ground it is prohibited for any persons to remain on the machine!
3. Make sure the lifting devices feature sufficient load capacity!
4. Fitting and removing tyres requires specialised knowledge and the proper tools!
5. Check tyre pressure at regular intervals! Risk of tyres bursting in the event of overpressure!
6. Tighten all nuts and fixing screws of the rear and front wheels as well and also the track width adjusting elements in accor-
dance with the manufacturer’s instructions!
7. After any adjustment to the track width and after changing the wheels, tighten the relative nuts and bolts to the prescribed
torque values!
0.2.7 - Engine:
1. Always switch off the engine before carrying out maintenance work. Remove the ignition key!
2. Before working on the electrical system, always disconnect the battery negative lead!
3. Always switch off the engine before refuelling - do not smoke!
4. Take care when discharging the oil at working temperature - Risk of burns!
5. Only use oil and fuel of the specified quality and store both liquids in approved containers.
6. Ensure used oil, fuel and spent filters are disposed of in compliance with the relevant legislation!
0.2.8 - Miscellaneous:
1. Before discarding spray canisters that seem empty (paint etc.), empty them completely in a well ventilated place well clear of
sparks and open flames!
2. Should components ever require replacement, use only genuine original DEUTZ-FAHR replacement parts!
The use of spare parts, accessories and supplementary equipment that are not genuine original DEUTZ-FAHR components
and that have not been checked and authorised by DEUTZ-FAHR may change or compromise the prescribed construction
characteristics, operation, quality, safety, and working life and consequently impair active and/or passive occupational safety
and safety during vehicle travel (protection against accidents and injury, etc.).
The manufacturer declines all liability for any damage caused by using parts, accessories and supplementary equipment
neither produced by DEUTZ-FAHR nor checked and authorised by DEUTZ-FAHR.
3. After completing maintenance and repair works, refit the protective devices.
4. Never perform welding, drilling, cutting or sanding work on the cab frame or the safety frame.
Renew any damaged components.
5. Each time the cab ventilation filter is renewed, dispose of the used filter in accordance with statutory legislation.
6. Do not run supplementary heating systems in enclosed places or when refuelling!
7. Before starting any electric welding work on the combine harvester, the cables of the alternator and battery must be discon-
nected.
0-4
10 - General information
10-1
General information
10.1 - Conversion tables
10.1.1 - Conversion factor
Table 1
1 mm 1.0 mm 0.03937 in. 0.00328 ft - -
1 in. 25.4 mm 1.0 in. 0.08333 ft
1 ft 304.8 mm 11.9999 in. 1.0 ft
1 cm2 1.0 cm2 0,155 sq.in. -
1 sq.in. 6.4516 cm2 1.0 sq.in.
1 cm3 1.0 cm3 0.001 l 0.06102 cu.in. 0.00026477 USgall 0.00021998 Imp.gall
1l 1000 cm3 1.0 l 61.024 cu.in 0,26417 USgall 0,21998 Imp.gall
1 cu.in. 16.3870 cm3 0.016387 l 1.0 cu.in. 0.04329 USgall 0.03604 Imp.gall
1 US gall 3785.4 cm3 3.7854 l 23.1 cu.in. 1.0 USgall 0.8327 Imp.gall
1 Imp.gall 4546 cm3 4.546 l 277.41 cu.in. 1.20091 USgall 1.0 Imp.gall
1g 1.0 g 0.001 kg 0.03527 oz 0.0022046 lbs -
1 kg. 1000 g 1.0 kg 35.27 oz 2.2046 lbs
1 oz 28.353 g 0.028353 kg 1.0 oz 0.0625 lbs
1 lbs 453.59 g 0.45359 kg 15.9983 oz 1.0 lbs
1 kp/cm2 1.0 kp/cm2 14.21 lbs/sq.in. 0.981 bar -
1 lbs/sq.in. 0.0703 kp/cm2 1.0 lbs/sq.in. 0.06903 bar
1 bars 1.0193 kp/cm2 14.485 lbs/sq.in. 1.0 bar
1 kpm 1.0 kpm 7.233 ft.lbs 9.81 Nm 0.981 daNm
1 ft.lbs 0,1383 kpm 1.0 ft.lbs 1.356 Nm 0,1356 daNm
1 Nm 0.1019 kpm 0.7373 ft.lbs 1.0 Nm 0.1 daNm
1 daNm 1.019 kpm 7.373 ft.lbs 10.0 Nm 1.0 daNm
1 PS 1.0 PS 0.98632 BHP 0.736 kW -
1 BHP 1.0139 PS 1.0 BHP 0.7462 kW
1 kW 1.36 PS 1.3405 BHP 1.0 kW
10.1.2 - Converting mm into inches

Table 2
mm 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
0 - 0.00394 0.00787 0.0118 0.0157 0.0197 0.0236 0.0276 0.0315 0.0354
1 0.0394 0.0433 0.0472 0.0512 0.0551 0.0591 0.0630 0.0669 0.0709 0.0748
2 0.0787 0.0827 0.0866 0.0906 0.0945 0.0984 0.1024 0.1063 0.1102 0.1142
3 0.1181 0.1220 0.1260 0.1299 0.1339 0.1378 0.1417 0.1457 0.1496 0.1535
4 0.1575 0.1614 0.1654 0.1693 0.1732 0.1771 0.1811 0.1850 0.1890 0.1929
5 0.1969 0.2008 0.2047 0.2087 0.2126 0.2165 0.2205 0.2244 0.2283 0.2323
6 0.2362 0.2402 0.2441 0.2480 0.2520 0.2559 0.2598 0.2638 0.2677 0.2717
7 0.2756 0.2795 0.2835 0.2874 0.2913 0.2953 0.2992 0.3031 0.3071 0.3110
8 0.3150 0.3189 0.3228 0.3268 0.3307 0.3346 0.3386 0.3425 0.3465 0.3504
9 0.3543 0.3583 0.3622 0.2661 0.3701 0.3740 0.3780 0.3819 0.3858 0.3898
10 0.3937 0.3976 0.4016 0.4055 0.4094 0.4134 0.4173 0.4213 0.4252 0.4291
10.1.3 - Converting Celsius degrees (°C) into Fahrenheit degrees (°F)

Table 3
Max °F Max °F Max °F Max °F Max °F Max °F
0 32 18 64.4 35 95 52 125.6 69 156.2 86 186.8
1 33.8 19 66.2 36 96.8 53 127.4 70 158 87 188.6
2 35.6 20 68 37 98.6 54 129.2 71 159.8 88 190.4
3 37.4 21 69.8 38 100.4 55 131 72 161.6 89 192.2
4 39.2 22 71.6 39 102.2 56 132.8 73 163.4 90 194
5 41 23 73.4 40 104 57 134.6 74 165.2 91 195.8
6 42.8 24 75.2 41 105.8 58 136.4 75 167 92 197.6
7 44.6 25 77 42 107.6 59 138.2 76 168.8 93 201.2
8 46.4 26 78.8 43 109.4 60 140 77 170.6 94 203
9 48.2 27 80.6 44 111.2 61 141.8 78 172.4 95 204.8
10 50 28 82.4 45 113 62 143.6 79 174.2 96 206.6
11 51.8 29 84.2 46 114.8 63 145.4 80 176 97 208.4
12 53.6 30 86 47 116.6 64 147.2 81 177.8 98 210.2
13 55.4 31 87.8 48 118.4 65 149 82 179.6 99 212
10-2
General information
Max °F Max °F Max °F Max °F Max °F Max °F
14 57.2 32 89.6 49 120.2 66 150.8 83 181.4 100 -
15 59 33 91.4 50 122 67 152.6 84 183.2 - -
16 60.8 34 93.2 51 123.8 68 154.4 85 185 - -
17 62.6 - - - - - - - - - -
10.1.4 - Converting Celsius degrees (°C) into Kelvin degrees (K)

Table 4
Max K Max K Max K Max K Max K Max K
0 273 18 291 35 308 52 325 69 342 86 359
1 274 19 292 36 309 53 326 70 343 87 360
2 275 20 293 37 310 54 327 71 344 88 361
3 276 21 294 38 311 55 328 72 345 89 362
4 277 22 295 39 312 56 329 73 346 90 363
5 278 23 296 40 313 57 330 74 347 91 364
6 279 24 297 41 314 58 331 75 348 92 365
7 280 25 298 42 315 59 332 76 349 93 366
8 281 26 299 43 316 60 333 77 350 94 367
9 282 27 300 44 317 61 334 78 351 95 368
10 283 28 301 45 318 62 335 79 352 96 369
11 284 29 302 46 319 63 336 80 353 97 370
12 285 30 303 47 320 64 337 81 354 98 371
13 286 31 304 48 321 65 338 82 355 99 372
14 287 32 305 49 322 66 339 83 356 100 373
15 288 33 306 50 323 67 340 84 357 - -
16 289 34 307 51 324 68 341 85 358 - -
17 290 - - - - - - - - - -
Table 5
Temp. mp. °C = 5/9 (t °F - 32) - Temp. °F = 5/9 (t °C + 32)
10-3
General information
10.2 - Tightening values, screwing classes
Tighten screws and nuts using a torque wrench.
Screws with metric normalised thread shank.
Friction coefficient µges = 0.12
Table 6
d Resistance class Screw class II
Tightening torques M xxx
mm Nm
M4 8.8 2.5
10.9 3.5
12.9 4.5
M5 8.8 5.0
10.9 7.5
12.9 8.5
M6 8.8 8.5
10.9 13
12.9 13
M7 8.8 14
10.9 20
12.9 24
M8 8.8 20
10.9 30
12.9 36
M10 8.8 42
10.9 60
12.9 70
M12 8.8 70
10.9 110
12.9 120
M14 8.8 110
10.9 170
12.9 200
M16 8.8 180
10.9 260
12.9 300
M18 8.8 260
10.9 360
12.9 420
M20 8.8 360
10.9 500
12.9 600
M22 8.8 480
10.9 700
12.9 800
M24 8.8 600
10.9 850
12.9 1000
M27 8.8 900
10.9 1300
12.9 1500
M30 8.8 1200
10.9 1700
12.9 2000
Screws with micrometric thread shank.
Friction coefficient µges = 0.12
10-4
General information
Table 7
d Resistance class Screwing class II
Tightening torques M A nenn
mm Nm
M8 x1 8.8 22
10.9 34
12.9 38
M10 x 1. 8.8 46
10.9 70
12.9 80
M10 x 1.25 8.8 44
10.9 65
12.9 75
M12 x 1.25 8.8 80
10.9 110
12.9 140
M12 x 1.5 8.8 75
10.9 110
12.9 130
M14 x 1.5 8.8 120
10.9 180
12.9 210
M16 x 1.5 8.8 190
10.9 280
12.9 320
M18 x 1.5 8.8 280
10.9 400
12.9 480
M18 x 2 8.8 260
10.9 380
12.9 440
M20 x 1.5 8.8 400
10.9 550
12.9 650
M20 x 2 8.8 360
10.9 550
12.9 600
M22 x 1.5 8.8 550
10.9 750
12.9 850
M22 x 2 8.8 500
10.9 700
12.9 850
M24 x 1.5 8.8 700
10.9 1000
12.9 1200
M24 x 2 8.8 650
10.9 950
12.9 1100
M27 x 2 8.8 650
10.9 950
12.9 1100
M30 x 2 8.8 1400
10.9 1900
12.9 2300
10-5
General information
10.3 - Lubricants
10.3.1 - Solid lubricants
Table 8
Material indication Part number Thermal operation range The Manufacturer name
in °C corresponds to
DEUTZ S 1 0134 0198 -180° up to +1400° Never Seize
DEUTZ S 2 0100 5149 -125° up to +1450° Molykote Paste G-n Rapid
DEUTZ S 5 0101 6126 -130° up to +1130° Molykote BR 2
10.3.2 - Grease
Table 9
DEUTZ F 15 0100 9454 -20° up to +140° Emteka NU 15
10.3.3 - Cooling system protection

Table 10
5 l packaging 0101 1490
10-6
General information
10.4 - Seal materials
Table 11
DEUTZ DW 25 0100 1306 -190° up to + 250° Thread tape
DEUTZ DW 30 - -190° up to + 700° Deva-Metall NiCuFe 10.83/8-
3W
DEUTZ DW 40 - -190° up to + 350° Reinz 4402
Ferrolastic
DEUTZ DW 43 0100 9463 -135° up to + 100° Terostat 8585
DEUTZ DW 44 0100 8379 -130° up to + 150° Terolan 3531
DEUTZ DW 47 0100 8383 -165° up to + 230° Silastic Q3-3305
DEUTZ DW 48 0134 0088 -173° up to + 230° Silastic 732 RTV
DEUTZ DW 50 0100 1286 -190° up to + 110° Curil
Teroson-Fluid
DEUTZ DW 53 0100 8329 -190° up to + 150° Sealant G
DEUTZ DW 55 0131 9907 -155° up to + 150° Loctite identification no. 601
DEUTZ DW 61 0131 9912 - Loctite identification no. 747
(Aktivator T)
Sealant 0633 9192 - Sikaflex
10.4.1 - Glues
Table 12
DEUTZ KL 1 0100 1300 -30° up to + 200° Normal Gupalon
DEUTZ KL 1 0292 5947 - Glue Epple 56
DEUTZ KL 5 0100 8365 -60° up to + 180° Loctite - IS - 414
DEUTZ KL 5A 0100 9331 -60° up to + 180° Loctite - IS - 495
DEUTZ KL 5B 0100 9332 -60° up to + 180° Loctite - IS - 416
DEUTZ KL 8 0131 9914 -40° up to + 200° Terostat 58
DEUTZ KL 9 0100 4131 -30° up to + 120° Terokal
DEUTZ KL 14 0100 9506 -30° up to + 200° Gupalon express
10-7
General information
10.5 - One-component adhesive
10.5.1 - Using one-component adhesives
For particularly important threaded couplings and for heavy-duty high load through connections, a single component adhesive is
utilised in the factory to ensure greater safety against the risk of independent loosening or detachment.
When the combine harvester is in need of repair, clean the surfaces to be glued thoroughly with recognised detergents or purified
benzene solvent before assembly. The threads or surfaces to be glued must be dry and free of oil and grease.
Using the threadlocker:
Apply the threadlocker to the external thread, in presence of threaded unions.
In the case of stopped threaded holes, it is essential to apply the threadlocker exclusively to the internal thread. Otherwise, the thre-
adlocker would be forced out by the escaping air when tightening the male thread into the hole.
In the case of through connections or connections of joints, if the degree of play is minimal the threadlocker can be applied to just one
half of the joint, while if the degree of play is greater it is good practice to apply the thread locker to both sides of the joint and then
assemble with a slight rotary movement.
Hardening:
The hardening process lasts from 6 to 24 hours, at an ambient temperature of 20 °C, which must be ensured for the entire process
duration. Since, in the case of external assemblies, this is not always possible, we recommend local heating of the elements to be
assembled, using a heating device. 1 to 4 hours at a temperature of 60 °C are sufficient for the hardening process. In this phase do
not move the assembled parts.
Accelerated hardening can be achieved by means of a preliminary treatment with an activator. The use of the activator reduces the
strength of the adhesive, so if this is necessary, ensure you use an adhesive offering the highest possible resistance level. The list of
the different brands of adhesives to be used with the combine harvesters is given below.
Table 13
Trade name KHD KHD part number Loctite type Omnifit type Conloc type Operation pre-
scriptions
DEUTZ DW 55 0131 9907 601 M 150 CL 202 for clearances of
0.02-0.3, thread
loosening more un-
likely, threadlocker
for screws up to M16
DEUTZ DW 56 0109 8072 586 (AVX) M 80 - red CL 103 for clearances of
0.02-0.2, thread
loosening more un-
likely, threadlocker
for screws up to M20
DEUTZ DW 57 0101 6113 221 L 150 - green CL 051 improvement of fixed
coupling 0-0,03,
easily unscrewed,
screws up to M14
DEUTZ DW 59 0134 0167 270 M 250 - purple M 250 for clearances 0.02-
0.3, high-strength
threadlocker for
large threads only
DEUTZ DW 60 0100 1254 582 (CVX) H 150 - green CL 303 for clearances of
0.03-0.5, high-
strength threadlock-
er for temperatures
up to 100 °C, for
large threads only.
DEUTZ DW 61 0131 9912 747 (activator T) activator - RS - US CL -activator for fast hardening
- 0114 5546 648 - - high-strength thread-
locker for shaft - hub
couplings
10-8
General information
10.6 - Maintenance and inspection schedule
Table 14
- first service after x regularly after x operating hours
operating hours
Maintenance and inspection at every once 5 20 50 50 100 250 500 1000
schedule for DEUTZ-FAHR deliv- day a year
combine harvesters ery
These tasks must be per- X - X - X X
formed exclusively by SAME
DEUTZ-FAHR authorized
workshops
1 - Engine - for maintenance Oil quality: Deutz DQC III-05, ACEA E4-99/E6-04* -
and inspection information
refer also to the engine
handbook
1.1 Check the oil level (twice X X - - - - - - - - -
a day while the engine is
being run-in)
1.2 Change the engine oil (at - - X - - X - - X - -
least once a year)
1.3 Change the air cleaner - - - - - X - - X - -
element
1.4 Check coolant level (an- X X - - - - - - - - -
tifreeze)
1.5 Change the coolant every 2 years -
1.6 Check the engine mount- - - - - - X - - - X -
ings
1.7 Check engine seals (oil X - - X - - X - - - -
leaks)
1.8 Check valve clear- - - - - - X - - - X -
ance (with cold engine
- at least 2 hours after
switching off)
1.9 Check tension and condi- X - - - - X - - X - -
tion of the drive belt: en-
gine, radiator fan, blower
1.10 Change fuel filter ele- - - - - - X - - - - X
ment
1.11 Drain the fuel tank com- X - X - - - - - - - -
pletely
1.12 Drain water from the fuel X - - - - X - - X - -
pre-filter
1.13 Fuel prefilter, renew filter - - X - - - - - - - -
element
1.14 Clean the air filter car- - - - - - - - - - - -
tridge, if indicated by in-
dicator light
1.15 Change the air cleaner - - X - - - - - - - -
element after the fifth
time the element has
been cleaned or in sur-
roundings subject to the
presence of soot
1.16 Renew air filter safety el- at least every 2 years -
ement
1.17 Check security of fixing X - X - - X - - X - -
and proper sealing of the
air intake and exhaust
systems
10-9
General information
operating hours
workshops
1 - Engine - for maintenance Oil quality: Deutz DQC III-05, ACEA E4-99/E6-04* -
and inspection information
refer also to the engine
handbook
1.18 Check hose clamps and X - - - - X - - X - -
the condition of air and
coolant hoses
1.19 Air conditioning system - X - - - - - - - - -
and fuel supply system
1.20 Discharge condensate X - X - - - - - - - -
from the air conditioning
system heat exchanger
1.21 Check sealing and condi- X - - - - - - - X - -
tion of the oil return line
1.22 Check the warning devic- X - X - - - - - - - -
es (air cleaner, oil pres-
sure, coolant tempera-
ture and level)
1.23 Check gaskets of the X - - - - - - - X - -
cooler surround and the
sieve rotary drum
1.24 Clean the engine com- - X - - - - - - - - -
partment
*** DEUTZ TLX-W 40FE lubricating oil, or type of oil according to the DEUTZ, DQC 3 quality class (ACEA E4-99 or those indicated
in the lubricating oils table.)
10-10
General information
Table 15
operating hours
workshops
2. Transmission cables Daily X X Gearbox oil API-GL 5 (MIL-L-2105D) 5 SAE 90
visual check for oil leaks
2.1 Gearbox - Change the oil - - X - - X - - - X -
(at least once a year)
Check oil level X - - - - - - - X - -
2.2 Check the gearshift and X - - - - X - - - X -
adjust if necessary
2.3 Final drives Change oil - - X - - X - - - X -
check oil level X - - - - - - - X - -
2.4 Threshing drum gearbox - - X - - X - - - X -
Change oil (at least once
a year)
2.5 Grain tank lower right- - - X - - X - - - X -
angle drive Change oil
2.6 Check tension of belts X - - - X - - X - - -
and chains and re-ten-
sion if necessary
2.7 Check belt guides and X - X - - - - - - - -
adjust if necessary
Table 16
operating hours
workshops
3. Hydraulic system Hydraulic oil HLP 46 DIN 51524 2nd part -
3.1 Check hydraulic oil level X X - - - - - - - - -
3.2 Clean oil reservoir - - X - - - - - - - -
breather filter
3.3 Change hydraulic oil (at - - X - - - - - - X -
least once a year)
3.4 Check hydraulic system X - - - X - - - X - -
for leaks
3.5 Check hydraulic func- X - - - - - - - - - -
tions
3.6 Check hydrostatic power X - - - - - - - - - -
steering
3.7 Check the hydrostatic X - - - - X - - - X -
travel deactivation device
10-11
General information
operating hours
workshops
3. Hydraulic system Hydraulic oil HLP 46 DIN 51524 2nd part -
3.8 Change interchange- - - - - - X - - - X -
able filter cartridge in the
hydraulic “travel” circuit
(Hydromat)
3.9 Check secure connection X - - - - - - - - - -
of high pressure oil hos-
es to pump and engine
3.10 Clean the oil cooler if - - - - - - - - - - -
fouled
3.11 Clean or change travel - - - - - X - - - X -
hydraulic circuit line filter
once a year
3.12 Check condition of hy- X - X - - - - - - - -
draulic lines
Table 17
operating hours
workshops
4. Feed passage - -
and chains
4.2 Check clutch coupling X - X - - - - - - - -
and adjust if necessary
4.3 Check that power invert- X - X - - - - - - - -
er is functioning correctly
check electrical inverter
efficiency
4.4 Check freedom of move- - X - - - - - - - - -
ment of rotary parts and
remove any crop resi-
dues
4.5 Check tension of feed X - - - X - X - - - -
chains and re-tension if
necessary
4.6 Check cutting table lock- X - X - - - - - - - -
ing devices
4.7 Adapt cutting table to X - - - - - - - - - -
terrain by means of the
diagonal linkages in the
feed elevator
10-12
General information
Table 18
operating hours
workshops
5. Threshing components, - -
cleaning unit, grain tank
5.1 Check threshing drum X - X - - X - - - - -
and basic alignment of
concave
5.2 Check drum speed varia- X - - - - - - - - X -
tor
5.3 Check basic set-up of X - - - - - - - - X -
turbo separator
5.4 Empty stone trap - X - - - - - - - - -
5.5 Check anti-projection de- X - - - - - - - - X -
flectors
5.6 Check rpm of straw walk- X - X - - - - - - - -
er drive shaft
5.7 Check sieve box trans- X - - - - X - - - X -
mission and rubber bear-
ings
5.8 Check straw walkers, X - - - X - - - X - -
check fixing of sieves
and gaskets
5.9 Check stability of the X - - - X - - - X - -
segments of the stepped
grain pan
5.10 Check suction fan speed X - - - - X - - - X -
variator
5.11 Check grain elevator X - - - X - - X - - -
chain and tension if nec-
essary
5.12 Check secure fastening X - X - - - - - - - -
of cereal tank discharge
pipe
5.13 Check slipping clutches X - X - - - - - - - -
and adjust if necessary
5.14 Check sealing of grain X - X - - - - - - - -
tank and unloading sys-
tem
5.15 Remove crop residues: - X - - - - - - - - -
concave, threshing drum,
stepped grain pan, straw
walkers table, augers,
fan housing
5.16 Check that the cleaning X X - - - - - - - - -
and maintenance flaps
are securely closed and
the various caps and
plugs are fully tightened.
10-13
General information
Table 19
operating hours
workshops
6. Table trolley - -
6.1 Check parking brake and X - X - - X - - - X -
brake linings
6.2 Check brake fluid X - - - - X - - X - -
6.3 Change brake fluid every 2 years
6.4 Check parking brake and X - - - - X - - X - -
adjust if necessary
6.5 Tighten threaded unions: X - - - X - - - - - -
gearbox, final drives, sur-
round
6.6 Tighten wheel studs in X - - X X X - - - - -
compliance with pre-
scriptions, drive wheels
750 Nm - steer wheels
310 Nm
6.7 Check adjustable steer- X - - - X - - - - - -
ing axle fixing screws
and torque to 410 Nm if
necessary
6.8 Check track of steer X - - - - - - - X - -
wheels and adjust if nec-
essary
6.9 Check and adjust clear- X - - - X - - - X - -
ance of the steer wheel
bearings
6.10 Check tyre inflation pres- X X - - - - - - - - -
sure
Table 20
operating hours
workshops
7 - Greasing (refer to the - -
greasing diagram) - clean
lubrication points thor-
oughly before injecting
new grease
7.1 Check for grease seep- X - - - - - X - - - -
ing out from the lubrica-
tion points (pipe con-
nections, condition of
lubrication circuit piping)
7.2 Central display - X - - - - - - - - -
10-14
General information
Table 21
operating hours
workshops
8. Electrical system - -
8.1 Check lighting systems X - X - - - - - - - -
8.2 Check headlight adjust- X - X - - - - - - - -
ment
8.3 Check the electrical sys- X - X - - - - - - - -
tem
8.4 Check the wiring and - - X - - - - - - - -
electrical connectors for
damage
8.5 Check that battery is se- X - - - X - - - X - -
cure and terminals are
tight
8.6 Check battery electrolyte X - X - - - - - X - -
level and acid specific
gravity
8.7 Check efficiency of alarm X - X - - - - - - - -
devices
8.8 Check the threshing X - X - - - - - - - -
drum, turbo separator
electrical switch and ad-
just if necessary
8.9 Check the on-board X - X - - - - - - - -
computer and grain loss
monitor
8.10 Clean the grain loss sen- - - - - - - - - - - -
sors if they are contami-
nated
8.11 Calibrate the electro X - - - - - - - - - -
hydraulic cutting table
control system (EMR-D)
whenever the threshing
equipment is changed
8.12 Check the Balance con- X - X - - - - - - - -
trol and calibrate if nec-
essary
Table 22
operating hours
workshops
9. Cab, compressor and cab - -
cooling and heating system
9.1 Check gasket and air fil- X - X - - - - - - - -
ter
10-15
General information
operating hours
workshops
9. Cab, compressor and cab - -
cooling and heating system
9.2 Clean fresh air and re- - X - - - - - - - - -
cycled air filter (renew if
necessary)
9.3 Check that compressor X - X - - - - - - - -
and heating system are
functioning correctly
9.4 Tension air conditioner X - - - X - - - X - -
drive belt
9.5 Check electrical system X - X - - - - - - - -
9.6 Clean the evaporator and - - - - - - - - - - -
condenser following con-
tamination
9.7 Change refrigerant con- - - - - - - - - - - -
tainer if the moisture indi-
cator has changed colour
9.8 Check efficiency and X - X - - - - - - - -
sealing of cab heating
system
Table 23
operating hours
workshops
10. Cutting table, table - -
trolley, rape harvesting
attachment installed
and chains
10.2 Check slipping clutch X - X - - - - - - - -
10.3 Check intake auger set- X - X - - - - - - - -
tings
10.4 Check functionality of X - - - - - - - - - -
reel hydraulic system
10.5 Check knives gear X - X - X - - - - - -
(knives head)
10.6 Check knives for friction - - - - - - - - X - -
10.7 Check and clean the feel- - X - - - - - - - - -
er skids
10.8 Tighten wheel screws X - - X X X - - - - -
and wheel studs of table
trolley
10-16
General information
operating hours
workshops
10. Cutting table, table - -
trolley, rape harvesting
attachment installed
10.9 Check the oil level in the X - - - - - X - X - -
rape cutting front attach-
ment
10.10 Change hydraulic oil and - - X - - X - - - X -
renew return filter
Table 24
operating hours
workshops
11. Cutting table with table Maintenance and inspection operations in compliance with the specific -
trolley, headers for spe- Operating Instructions
cial products, maize shell-
er, straw chopper, chaff
separator, etc.
- - - - - - - - - - - - - - -
Table 25
operating hours
workshops
12. 10. Accident prevention - -
regulations
12.1 Inform personal with re- X - - - - - - - - - -
gard to legislative pre-
scriptions (see operating
instructions)
12.2 Check protective and X - X - - - - - - - -
locking devices
12.3 Have fire extinguishers every 2 years -
checked to ensure they
are efficient
12.4 Installation of parts made - - - - - - - - - - -
by other manufacturers
is permitted only when
authorised in writing by
SAME DEUTZ-FAHR
Erntesysteme GmbH
10-17
General information
10.7 - Oil quantity and quality
10.7.1 - Fuel, quantity 1) and quality of oil
Table 26
Name 5650H - 5660H / HTS - 5690H / HTS - filling level change intervals Fuel specifica-
5665HTS 5695HTS check 2) 3) tions
fuel tank approx.555 l approx.555 l every day - diesel fuel, sulphur
contents no higher
than 0.5%
DEUTZ engine 20.0 l 20.0 l 10 h 50 h and then every DEUTZ TLX-10W
with replacement of 21.0 l 21.0 l 250 h 40FE lubricating
oil filter oil, or type of oil ac-
cording to the Deutz
DQC III-05 quality
class (ACEA E4-99/
E6-04)4)
Cooling system 55.0 l 55.0 l every day 2000 h or every 2 Protective agent
years for DEUTZ cooling
systems, order no.
01011490 (5l)
Gearbox 17.0 l 17.0 l 250 h 50 h and then every Gearbox oil API-GL
500 h 5 (MIL-L 2105 D)
SAE 90
Final drive 10.0 l 10.0 l 250 h 50 h and then every Gearbox oil API-GL
500 h 5 (MIL-L 2105 D)
SAE 90
hydraulic system 44) 65 l 65 l every day 50 h and then every Hydraulic oil DIN
500 h 51524 Part 2 HLP46
(ISO)
rape header 6l 6l 50 h 50 h and then every Hydraulic oil DIN
500 h 51524 Part 2 HLP46
(ISO)
Hydraulic brakes cir- 0.3 l 0.3 l 100 h every 2 years brake fluid DOT 4
cuit yellow / DOT 3 or
SAE J 1703
rape header - thresh- 1.0 l 1.0 l 250 h 50 h and then every Gearbox oil API-GL
ing drum reduction 500 h 5 (MIL-L 2105 D)
gear SAE 90
Air conditioning sys- 2.0 kg 207 cm3 2.0 kg 207 cm3 once a year - refrigerant fluid,
tem 5) - Compressor R134a refrigerant oil
SP20 for R134a
Grain tank pipe low- 0.75 l 0.75 l 250 h 50 h and then every Gearbox oil API-GL
er right-angle drive 500 h 5 (MIL-L 2105 D)
SAE 90
chaff spreader gear- 0.4 l 0.4 l - 50 h and then every Gearbox oil API-GL
box 500 h 5 (MIL-L 2105 D)
SAE 90
Chains, articulated as needed as needed - - SAE EP- NLGI2 uni-
couplings versal grease
1) The specified quantities are approximate guideline values. The respective control devices are decisive.
2) Daily visual check for oil leaks.
3) Oil change at least once a year.
4) In case of air high temperatures use oil with higher levels of viscosity.
5) All work on the compressor cooling system may only be carried out by authorised workshops.
10-18
General information
10.8 - Approved list of lubricating oil quality class - DEUTZ
Table 27
Manufacturer Type of lubricating oil SAE class Availability
DEUTZ DEUTZ OILTLX-10W40FE 10W-40 Europe
ADDINOL ADDINOL Super Truck MD 10W-40 Europe, Asia
1048
ADDINOL Ultra Truck MD 0538 5W-30 Europe, Asia
AGIP Agip Sigma Ultra TFE 10W-40 Worldwide
Autol Valve Ultra FE 10W-40 Germany
Akros Akros Synth. Gold 10W-40 Europe
ARAL Aral MegaTurboral 10W-40 Worldwide
Aral SuperTurboral 5W-30 Worldwide
AVIA TURBOSYNTH HT-E 10W-40 Germany
BAYWA BayWa Super Truck 1040 MC 10W-40 South Germany
BayWa Turbo 4000 10W-40 South Germany
BP OIL International BP Vanellus E7 Plus 10W-40 Europe
BP Vanellus E7 Supreme 10W-40 Europe
BP Vanellus C8 Ultima 5W-30 Europe
Castrol Castrol Enduron Plus 5W-40 Australia, South Africa, Europe,
America
Castrol Enduron 10W-40 Australia, South Africa, Europe,
America
Castrol Elexion 5W-30 USA
CEPSA EUROTRANS SHPD 10W-40 Spain, Portugal
CHEVRON Chevron Delo 400 Synthetic 5W-40 North America
DEA DEA Cronos Synth 5W-30 Germany, Europe
DEA Cronos Premium LD 10W-40 Germany, Europe
DEA Cronos Premium FX 10W-40 Europe
ESSO Essolube XTS 501 10W-40 Europe
FUCHS EUROPE Fuchs Titan Cargo MC 10W-40 Worldwide
Fuchs Titan Unic Plus MC 10W-40 Worldwide
MOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, Middle East, Africa
Mobil Delvac 1 5W-40 Worldwide
Mobil Delvac XHP Extra 10W-40 Europe, South East Asia
OMV AG OMV super Truck 5W-30 Europe
OMC truck FE plus 10W-40 Europe
Ravensberger Schmierölver- Ravenol Performance Truck 10W-40 Germany
trieb
Lube oil refinery Salzbergen Wintershall TFG 10W-40 Europe
Shell International Shell Myrina TX/Shell Rimula 5W-30 Europe, the definition varies ac-
Ultra cording to the country
Shell Myrina TX/Shell Rimula 10W-40 Europe, the definition varies ac-
Ul-tra cording to the country
Texaco Ursa Super TDX10W-40 10W-40 Europe
- Ursa Premium FE 5W-30 5W-30 Europe
TOTAL TOTAL RUBIA TIR 8600 10W-40 Worldwide
- EXPERTY 10W-40 Worldwide
10-19
General information
10.9 - Components working speed
Table 28
Combine harvesters 5650H - 5695 HTS

1 Engine without switching 2425 ±15
on the threshing section
1 Engine with switching on 2415 +15
the threshing section
2 Drum variator control de- 945 + 25/-40
vice
3 Threshing drum 405 -1265 ± 50
4 Grain tank discharge tube 530 ± 40
5 Fan 410 - 950 +50/-30 Fig. 1
8 Cereals straw walker 206 ±2
Rice straw walker 213 ±2
12 Straw chopper (3840 -
RPM)
Table 29
Combine harvesters 5650H - 5695 HTS

6 Sieve surfaces movement 301 ± 5
7 Return elevators 1170 ±30
850 ±20
9 Feed passage top roller 430 +20
10 Cereals turbo separator 805 +30/-20
Maize turbo separator 390 ±30
11 Synchronized reversing -
drum
Fig. 2
1) Starting from the year of construction (2007) the reversing drum is activated by the threshing drum.
10-20
General information
10.10 - Securing bush support tightening values
Table 30
Support Bearings Tightening torque
Threshing drum/Turbo separator Deep groove bearing 140 Nm
Reversing drum on the left Deep groove bearing 140 Nm
Reversing drum on the right Oscillating bearing 180 Nm
Straw walker bearing Deep groove bearing Preload momentum of 50 Nm + rotation
angle of 180°
Sieve crankshaft Roller bearing 100 +20 Nm
Feed passage intermediate shaft Roller bearing 56 Nm
10-21
General information
10.11 - Check the tension of the belts and chains on the LH side
10.11.1 - Check of spring preload dimension L
Fig. 3 - Check of spring preload dimension L

Table 31
Pos./Imm Tensioning device Length Note
1 reel drive chain tensioning de- - rigid
vice
2 bevel sprocket drive chain ten- - rigid
sioning device
3 turbo separator drive tensioning L -
idler roller
4 Straw walker countershaft drive L -
tensioning idler roller
5 blade sprocket drive idler roller - rigid
6 intake auger drive chain ten- - rigid
sioning sprocket
7 intake auger drive chain ten- L -
sioning sprocket
8 pick-up reel synchronous drive L -
idler roller
9 sieve box reduction gear drive L -
idler roller
10 grain auger drive chain idler L -
roller
11 returns elevator shaft drive - rigid
chain idler roller
L = length according to standards / adjustment instructions
10-22
General information
DANGER
Belt clutches control and adjustment, see chapter C
10-23
General information
10.12 - Check the tension of the belts and chains on the RH side
10.12.1 - Check of spring preload dimension R
Fig. 4 - Belts and chains on right-hand side

Table 32
Pos./Imm Tensioning device Length Note
12 Dust fan - -
13 filter basket V-belt R -
14 fuel pump / alternator V-belt - -
15 air conditioner compressor V- - -
belt
16 grain tank emptying device R -
drive idler pulley
17 grain tank intake auger drive - -
tensioning device
18 Elevator chain tensioning de- - -
vice
19 variator movement chain R -
20 variator movement chain - -
21 fan transmission idler roller R -
22 straw walker transmission idler R -
pulley
23 straw chopper transmission R -
idler pulley
24 Check belt sliding and adjust if - check visually
necessary
L = length according to standards / adjustment instructions
10-24
General information
10.13 - Maintenance and repair
10.13.1 - General information
Observe all the accident prevention regulations for all maintenance and repair work.
DANGER
When working on the combine harvester make sure that the engine cannot be started by third parties: remove the
ignition key and deactivate the battery master switch!
Dispose of fuel, in compliance with environment regulations.

Tighten the threaded connections securely after assembly after several hours at work, for example the wheel studs and the axle
screws.
Check operation after repairs on the hydraulic system and check the oil level. Check the system for possible leaks.
Promptly change hydraulic or fuel system hoses if they are porous or damaged.
Check for possible damaged or crushed cables.
Comply with fire protection precautions when performing welding work on the combine harvester.
Remove all dust and crop residues. Ensure wiring looms, hydraulic hoses and sealing elements are protected from sources of heat.
Remove plugs from electric hydraulic diverters.
While fitting the locking ring supports tighten the locking ring in the direction of rotation of the shaft.
Fit the supports of the locking rings in compliance with internal factory prescriptions.
Remedy the cause of vibrations immediately. For example: imbalance caused by residues on the threshing drum bars or broken
blades of the straw chopper, damaged/stretched V-belts, imbalance of idle pulleys caused by the build-up of dust.
10-25
General information
10.14 - Care and maintenance
10.14.1 - General information
V-belts
Since new V-belts stretch, their tension must checked more frequently during the
first few operating hours.
l The tension of V-belts equipped with a fixed idle pulley is correct when the
free length of belt can be deflected moderately by exerting pressure with
your thumb. If belts are not correctly tensioned they will be subject to rapid
wear.
l The V-belt guide is used to restrain the belt if it comes out of the pulley
grooves so that it does not interfere with the pulley. The distance between
the guide and the taut belt must be 8 mm.
l Never attempt to force a taut belt out of its pulley groove either with your
Fig. 5
hands or using tools.
l A contaminated V-belt can be cleaned with a solution of glycerine and al-
cohol in the proportions 1:10. Do not use petrol, benzole, white spirit or
similar.
l Avoid mechanical damage to the V-belt. During winter storage, make sure
that the belt pulleys do not rust.
Chains
The drive chains must be lubricated regularly with gearbox oil. At the end of the
season the chains must be removed, cleaned with diesel fuel, immersed in warm
grease for drive chains, and then refitted.
l Chain split links must always be fitted so that they cannot open indepen-
dently: for example, spring links must be fitted with the closed end facing
the direction of chain travel.
l Always use a new safety pin when opening chain split links.
Fig. 6
Speed variators
Remove any deposits of dust and dirt from between the mobile pulley discs.
To ensure that the film of lubricant is uniformly distributed over the pulley surfaces, the speed variators of the pick-up reel and th-
reshing drum must be lubricated before adjusting.
Threaded fasteners
All threaded fastener connections, especially those of the sieve box, must be
checked regularly, tightening any screws that have worked loose.
Check also nuts secured with split pins.
Fig. 7
10-26
General information
Fuel and oil tanks
To avoid water condensation, the tanks must be topped up immediately after finishing work, especially in the presence of significant
temperature differences between the working hours and idle hours.
Tyres
Check inflation pressures regularly and check that the wheel studs are securely tightened.
10-27
General information
10.15 - Special tools
Table 33
Grooved nut wrench to fit the tightening bushes
Operation Part number Note
Sieve crankshaft bearing, Feed passage 0043 6070 -
intermediate shaft
Straw walker bearing d 40 0041 6050 -
Drum, straw pick-up, Turbo separator bear- 0041 6055 -
ing
Table 34
Grooved nut wrench to fit the tightening bushes
Miscellaneous Part number Note
Pipe support to loosen the pulley - variator 0043 6021 -
pulley on the straw pick-up shaft
Heavy puller 0041 6010 -
Pipe wrench SW36/46 0620 8673 -
Torque bar 0041 6031 -
Small straight key remover 0041 6100 -
Big straight key remover 0041 6101 -
Curved key remover 1601 2260 -
Screw M16x140 to detach the pulley by 0625 7346 -
pressing - separator pulley (drum variator,
speed variator)
Screw M16x140 to withdraw the drum vari- 0041 6070 -
ator control device
3-pole measurement adapter for EMR-D 1603 1484 -
indicator, Balance
55-pole measurement adapter for EMR-D 1601 7182 -
control panel
Balance and Commander Control pro- 1605 0267 -
gramming cable
10-28
20 - Engine
20-1
Engine
20.1 - Tools for engine disassembly and reassembly
20.1.1 - Commercially available tools
Deutz TCD 3.6 engine
Table 35
No. Figure Code, description & function Q.ty
1 Code 01899034 (8005) 1
Compression value test for diesel engines. (10 - 40 bar) Check of the
compression value.
© 35410-2
Fig. 8
2 01899035 / 5.9035.102.0 (8008) 1
Tool for testing injectors with nebulised spray collection container. Check
the injectors.
© 35411-2
Fig. 9
3 Code 01899037 (8011) 1
Pliers for hose clips. For loosening and tightening cable clamps (e.g. fuel
return line)
© 39426-1
Fig. 10
4 Code 01899041 (8015) 1
Box spanner insert. Wrench width 14, reinforced For loosening and tight-
ening big end bearing screw.
© 37503-1
Fig. 11
5 Code 01899042 (8016) 1
Box spanner insert. Wrench width 17, reinforced For loosening and tight-
ening flywheel nuts.
© 37504-1
Fig. 12
20-2
Engine
6 Code 01899044 7 5.9035.104.0 (8018) 1
Socket wrench. Wrench width 17, reinforced For loosening and tighten-
ing injection line sleeve nut.
© 37506-1
Fig. 13
7 Code 01899050 (8024) 1
Assembly pliers: Removal of the valve stem gaskets.
© 37509-4
Fig. 14
8 Code 01899062 (8115) 1
V-belt tension tester from 150 to 600 N. Checking the V-belt tension.
© 35416-3
Fig. 15
9 Code 01899093 (8190) 1
Rotation angle gauge with magnet. Adjustment of valve clearance.
© 42528-1
Fig. 16
10 Code 01899094 (8191) 1
Slotted head screwdriver bit (8x16). Valve clearance adjustment.
© 43060-0
Fig. 17
11 Code 01899099 (8196) 1
Open-ended wrench: SW 13, for the torque wrench. Tighten the check
nuts of the valve clearance adjustment screw.
© 43197-0
Fig. 18
20-3
Engine
12 Code ... (8198) 1
Bradawl: Disassembly of the shaft seal ring.
© 43206-1
Fig. 19
13 Code 01899110 (9017) 1
Assembly lever. (e.g. valve assembly and disassembly)
© 37511-1
Fig. 20
20-4
Engine
20.2 - Workshop tools for engine disassembly and reassembly
(Lv.3)
20.2.1 - Workshop tools for engine disassembly and reassembly (Lv.3)
Deutz TCD 3.6 engine
Table 36
1 Code 01899000 (6066) 1
Taking up weight of engine on both sides Max. load at centre of gravity
approx. 1,200 Kg
© 35451-2
Fig. 21
2 Code 01899002 (6066/151) 1
Support for taking up weight of engine on both sides. Connected to as-
sembly stand code 01899099 (6066).
© 37601-1
Fig. 22
3 Code 02992013 (100130) 1
Connection. In combination with compression tester, code 01899034 /
5.9035.101.0 (8005)
© 37602-1
Fig. 23
4 Code 02992022 (100300) 1
Rotation device. With mechanical TDC indicator and graduated scale for
checking start of delivery. Rotating and immobilising crankshaft.
© 37603-1
Fig. 24
5 Code 02992025 (100350) 1
Rotation device. Rotating crankshaft from V-belt pulley.
© 37604-1
Fig. 25
20-5
Engine
6 Code 01899126 / 5.9035.068.0 (100400) 1
Dial gauge with stop wheel. Measurement range 0 -10 mm / 0.01 mm
© 37605-1
Fig. 26
7 Code 01899127 (100410) 1
Digital dial gauge. Measurement range 0 -30 mm / 0.01 mm
© 43205-0
Fig. 27
8 Code ... (100850) 1
Measurement tool with measurement plate Piston protrusion check.
© 37606-1
Fig. 28
9 Code 02992066 (101830) 1
Dial gauge-adapter: Measuring insertion of speed sensor in respective
seat
© 45906-0
Fig. 29
10 Code 02992073 (102560) 1
Tester. Base tool with two measurement rods Measuring spray angle of
piston cooling nozzle (previous version)
© 37608-1
Fig. 30
11 Code 02992074 (102565) 1
Measurement rod. With tester, code 02992073 (102560). Measuring
spray angle of piston cooling nozzle (new version)
© 37628-1
Fig. 31
20-6
Engine
12 Code 02992081 (103240) 1
Dial gauge mount. With probe extension (diameter 5/100 mm) Checking
maximum aperture stroke of injection pumps
© 43927-3
Fig. 32
13 Code 02992084 / 5.9035.126.0 (110030) 1
Extractor. In combination with slide hammer extractor, code 02992294 /
5.9035.094.0 (150800). Removing injection valve.
© 35433-2
Fig. 33
14 Code 02992089 / 5.9035.127.0 (110110) 1
Support. Wrench aperture 11. Tighten injection valve in screw clamp.
© 35434-2
Fig. 34
15 Code 02992091 (110130) 1
Ring gear nut wrench. Tightening and loosening injection valve sleeve
nut.
© 37610-1
Fig. 35
16 Code 02992112 / 5.9035.072.0 (110500) 1
Special wrench. Wrench opening 17. Fitting and removing injection pipes
© 35436-1
Fig. 36
17 Code ... (110510) 1
Special wrench. Removing and fitting air intake pipe
© 43928-3
Fig. 37
20-7
Engine
18 Code 01899132 / 5.9035.075.0 (110700) 1
Box spanner insert. Wrench width 27. Long. Fitting and removing oil
pressure transducer
© 42341-2
Fig. 38
19 Code 02992127 / 5.9035.245.0 (110901) 1
Disassembly tool. For removing O-rings.
© 45950-1
Fig. 39
20 Code 02992136 / 5.9035.246.0 (120660) 1
Extraction device. In combination with slide hammer extractor, code
02992294 / 5.9035.094.0 (150800). Removing fixed seal ring on injec-
tion valve
© 45421-0
Fig. 40
21 Code 02992139 / 5.9035.078.0 (120900) 1
Adjustable support stand. For tightening cylinder head fasteners
© 35438-2
Fig. 41
22 Code 02992140 / 5.9035.079.0 (120910) 1
Base plate. In combination with support stand, code 02992139 /
5.9035.078.0 (120900), if support stand is not fixed with screws.
© 35439-2
Fig. 42
23 Code 02992145 / 5.9035.081.0 (121410) 1
Assembly tool. Assembly of the valve stem gasket.
© 37614-1
Fig. 43
20-8
Engine
24 Code ... (121420) 1
Assembly bushes. Set of assembly bushes for the valve stem gasket.
© 43210-0
Fig. 44
25 Code 02992155 / 5.9035.083.0 (130300) 1
Universal pliers for piston rings. Disassembly and assembly of piston
rings.
© 35441-2
Fig. 45
26 Code 02992161 (130400) 1
Trapezoidal groove wear gauge. Check piston ring groove.
© 36461-1
Fig. 46
27 Code 02992179 (130650) 1
Piston ring compression collar. Disassembly and assembly of piston
rings.
© 35443-2
Fig. 47
28 Code 02992187 (131200) 1
Base plate. In combination with assembly tool set, code 02992188
(131210) For press-fitting and removing small end bushing
© 37616-1
Fig. 48
29 Code 02992188 (131210) 1
Set of assembly tools. In combination with base plate, code 02992187
(131200) For press-fitting and removing small end bushing
© 37617-1
Fig. 49
20-9
Engine
30 Code 02992210 (142640) 1
Assembly tool. Fitting crankshaft O-ring (on side opposite flywheel)
© 37618-1
Fig. 50
31 Code 02992211 (142650) 1
Assembly tool. Fitting crankshaft O-ring (flywheel side).
© 37619-1
Fig. 51
32 Code 02992250 (143830) 1
Assembly tool. Fitting and removing camshaft bearings
© 37621-1
Fig. 52
33 Code 02992259 (144150) 1
Counterhead. Fastening camshaft gear wheel
© 37622-1
Fig. 53
34 Code 02992277 (150030) 1
Tool set. Correcting contact points of cylinder sleeve
© 40221-0
Fig. 54
35 Code ... (150120) 1
Assembly tool. Installing cylinder liner
© 37624-1
Fig. 55
20-10
Engine
36 Code ... (150130) 1
Extraction device. Removing cylinder liner
© 37625-1
Fig. 56
37 Code 02992294 / 5.9035.094.0 (150800) 1
Slide hammer extractor. Disassembly of the injection valve.
© 35449-2
Fig. 57
38 Code 0189 9142 / 5.9035.176.0 (170050) 1
Special wrench. Removal of the filter cartridges.
© 37629-1
Fig. 58
39 Code 02992329 (170100) 1
Special wrench. Removing and fitting turbocharger lubricant oil line.
© 37626-1
Fig. 59
40 Code 02992331 (170120) 1
Assembly and disassembly tool. Press-fitting and removing the rocker
shaft ball pin.
© 37627-1
Fig. 60
41 Code 01899144 / 5.9035.095.0 (170160) 1
Plugs and caps: 1 set of different sized plugs and caps. For closing the
holes in the fuel distribution system.
© 43663-0
Fig. 61
20-11
Engine
20.3 - Test and adjustment data (L3)
20.3.1 - T00 81
1. Cylinder and side view
TCD 2015 V06 engine
A3
A2
A1
B3
B2
B1
© 45418-0
Fig. 62
20.3.2 - T00 81
1. Cylinder and side view
TCD 2015 V06 engine A4
A3
A2
A1 B4
B3
B2
B1
© 45885-0
Fig. 63
20.3.3 - T01 63
Valve clearance setting
TCD 2015 V06 engine
Firing order: A1-B3-A3-B2-A2-B1
Table 37
Cylinder overlap angle Cylinder adjustment
A1 B2
B3 A2
A3 B1
B2 A1
A2 B3
B1 A3
20.3.4 - T01 63
Valve clearance setting
TCD 2015 V08 engine
Firing order: A1-B4-A4-B1-B3-A3-B2-A2
Table 38
A1 B3
20-12
Engine
B4 A3
A4 B2
B1 A2
B3 A1
A3 B4
B2 A4
A2 B1
20.3.5 - T13 054

1. Injection pump wiring diagram
TCD 2015 V06 engine
Table 39
Position Components Cylinder alloca-

tion 1 2 3
1 Y15.1 A1
2 Y15.5 A2
3 Y15.3 A3
4 Y15.6 B1
5 Y15.4 B2
6 Y15.2 B3 4 5 6
© 40971-0
Fig. 64
20.3.6 - T13 054

Injection pump wiring diagram
TCD 2015 V08 engine
Table 40
Position Components Cylinder allocation
Y15.1 A1
Y15.8 A2
Y15.6 A3
Y15.3 A4
Y15.4 B1
Y15.7 B2
Y15.5 B3
Y15.2 B4
20-13
Engine
20.4 - Tightening torque (L3)
Table 41
Designation Type of Indications/ Series Pretighten- Retightening
screw observa- ing value value
tions
Clamping sup- Elastic assem- TCD 2015 106 Nm
port in corre- bly feet/engine
spondence of mounts on
the crankcase crankcase
Rigid assem- TCD 2015 30 Nm +45°
bly feet/engine
mounts on
crankcase, oil
lightly
Clamping sup- TCD 2015 90 Nm
port in cor-
respondence
of assembly
stand adapter
Engine sup- elastic TCD 2015 106 Nm
port/installa- rigid, oil lightly TCD 2015 30 Nm +45°
tion feet in the
crankcase
Cylinder head In the case of TCD 2015 50 Nm +120° +120°
in correspon- written certi- +60°
dence of the fication, the
crankcase cylindrical
head screws
can be used a
maximum of 3
times, other-
wise replace
them each
time they are
removed. Oil
slightly
Rocker support TCD 2015 61 Nm
in correspon-
dence of the
cylinder head
Check nut, 20 Nm
valve clear-
ance adjust-
ment wrench
Cylinder head oil slightly TCD 2015 22 Nm
cover to cylin-
der head
Cylinder head M8x3 oil the re- TCD 2015 22 Nm
cover on cylin- cessed hexa-
der head case gon lightly
Counterweight oil slightly TCD 2015 50 Nm +30° +60° +60°
on crankshaft
20-14
Engine
tions
Main bearing Screws and In the case of TCD 2015 50 Nm +60° +60°
cover, vertical washers written certi- +120°
screws fication, the
cylindrical
head screws
can be used a
maximum of 3
times, other-
wise replace
them each
time they are
removed. Oil
slightly
Main bearing Where certi- TCD 2015 80 Nm +30° +30°
cover, horizon- fied in writ-
tal screws ing, screws
may be used
up to 3 times.
Otherwise, re-
place with new
screws after
each removal.
Connecting rod The screws TCD 2015 50 - 60 Nm +60° +60°
bearing cover must be re-
in correspon- newed after
dence of the being re-
connecting rod moved.
drum
Rear cover on with DEUTZ TCD 2015 21 Nm
crankcase DW 59 assem-
bly product
Ancillary mount M10 TCD 2015 55 Nm
on crankcase
Lubricant oil Steel ribbing TCD 2015 28 Nm
sump in corre- gasket. Ob-
spondence of serve the indi-
the crankcase cated tighten-
ing sequence.
TCD 2015 24 Nm
(Railway)
Oil drain screw oil slightly TCD 2015 120 Nm
on lubricant oil TCD 2015 120 Nm
sump (Railway)
Half flange on M8x30-10.9 TCD 2015 30 Nm
mating flange (Railway)
Mating flange M10x20-10.9 TCD 2015 30 Nm
on oil lubricant (Railway)
sump
Valve hous- oil slightly TCD 2015 50 Nm 210 Nm
ing (regula-
tor valve) on
crankcase
Crankcase Pipe bracket TCD 2015 8 Nm
breather
20-15
Engine
tions
Air vent pipe Sleeve tighten- TCD 2015 6.5 Nm
on intake mani- ing clip
fold/oil separa-
tor
Air vent pipe TCD 2015 20 Nm
(mount) on
wiring harness
guide
Pipe (crank- TCD 2015 20 Nm
case breather) (Railway)
on wiring har-
ness guide
Duct (crank- Sleeve tighten- TCD 2015 6.5 Nm
case breather) ing clip (Railway)
Connector cas- TCD 2015 70 Nm
ing on lubricant
oil sump
Connector box M12x1.5x35 with DEUTZ TCD 2015 30 Nm +30° +30°
in correspon- DW 59 assem-
dence of the bly product
crankcase
Connector box M12x1.5x90 with DEUTZ TCD 2015 30 Nm +60° +60°
crankcase
Connector box M8x16 with DEUTZ TCD 2015 21 Nm
cover DW 59 assem-
bly product
Connector box M12x190 with DEUTZ TCD 2015 30 Nm +60° +60° +60°
crankcase
Connector box M12x175 with DEUTZ TCD 2015 30 Nm +60° +90°
crankcase
Centre screw oil slightly TCD 2015 50 Nm +150°
for camshaft
gear wheel on
camshaft
Sliding cover with DEUTZ TCD 2015 22 Nm
(camshaft) on DW 72 assem-
cylinder block bly product
Camshaft gear oil slightly TCD 2015 30 Nm
wheel on inter-
mediate wheel
Injection pump TCD 2015 30 Nm +30°
camshaft gear
wheel
Injection pump Plug fastener TCD 2015 8.5 Nm
camshaft cover screw
element on
crankcase
20-16
Engine
tions
Fastener screw TCD 2015 80 Nm
for intermedi-
ate wheel on
ancillary mount
Hole blanking oil slightly TCD 2015 79 Nm
screw for inter-
mediate wheel
pins
Screw for inter- M12x100 oil slightly TCD 2015 70 Nm
mediate wheel
pins
Thrust bearing oil slightly TCD 2015 30 Nm
on crankcase
Gearbox cover TCD 2015 21 Nm
on crankcase M8x35 M8x45 TCD 2015 21 Nm
(Railway)
Crankcase with DEUTZ TCD 2015 20 Nm
cover DW 72 assem-
bly product
Crankshaft TCD 2015 8 Nm
speed sensor
on connector
casing
Camshaft TCD 2015 8 Nm
speed sensor
on cover
Exhaust pipe Apply DEUTZ TCD 2015 60 Nm
connected to S1 assembly
the cylinder product.
head
Exhaust pipe Apply DEUTZ TCD 2015 22 Nm
on exhaust S1 assembly
manifold product.
Exhaust pipe Nut Apply DEUTZ TCD 2015 18 Nm
on exhaust S1 assembly
pipe product.
Exhaust mani- TCD 2015 28 Nm
fold on connec-
tor casing
Exhaust mani- Apply DEUTZ TCD 2015 35 Nm
fold on exhaust S1 assembly (Railway)
pipe product.
Turbocharger Apply DEUTZ TCD 2015 35 Nm
on exhaust Nut S1 assembly TCD 2015 10 Nm 35 Nm
manifold product. (Railway)
Intake manifold Hose clamp. TCD 2015 5 Nm
on turbocharg- Position of up-
er per hose clamp
housing on
head
Section on pipe Sleeve tighten- TCD 2015 5 Nm
on ATL ing clip (Railway)
Charge air duct TCD 2015 20 Nm
connected to
cylinder head
20-17
Engine
tions
Charge air duct M10 x 85 M10 TCD 2015 60 Nm
on air intake x 65
pipe
Connection TCD 2015 20 Nm
line on air in- Nut TCD 2015 20 Nm
take pipe (Railway)
Cover plate on TCD 2015 57 Nm
connector line
Mount on ex- TCD 2015 20 Nm
haust manifold (Railway)
Screw plug on TCD 2015 34 Nm
charge air duct
Connector el- Nut TCD 2015 20 Nm
bow on charge Stud screw 4.5 Nm
air duct
Connector line TCD 2015 20 Nm
on mount TCD 2015 20 Nm
(Railway)
Mounting plate TCD 2015 20 Nm
on ancillary
mount
Injection valve Sleeve screw no oil leaks. TCD 2015 70 Nm
on cylinder Apply DEUTZ
head S1 assembly
product.
Injection noz- Nozzle fasten- TCD 2015 40 - 50 Nm
zle on injection er nut
valve
Injection line Sleeve nut TCD 2015 25 Nm
on injection
valve/injection
pump
Hose fastener M6x12 TCD 2015 10 Nm
collar for injec-
tion line
Injection pump oil slightly TCD 2015 60 Nm
housing on
crankcase
Injection pump oil slightly TCD 2015 60 Nm
on injection
pump housing
Fuel line on TCD 2015 25 Nm
injection pump TCD 2015 25 Nm
housing (Railway)
Fuel line on Sleeve nut TCD 2015 20 Nm
fuel cutoff valve
(glow plugs)
Temperature TCD 2015 22 Nm
sender on
union
Fuel delivery TCD 2015 42 Nm
pump bearing
seat on ancil-
lary mount
20-18
Engine
tions
Fuel pipe on Hollow screw TCD 2015 max. 35 Nm
the fuel supply
pump
Fastening the Hose fastener TCD 2015 8.5 Nm
fuel pipe clamp/mount.
Oil the threads
Fastening the Pipe bracket TCD 2015 8.5 Nm
fuel pipe (Railway)
Adapter (glow M45x1.5 SW50 TCD 2015 50 Nm
plug) on intake (Railway)
air pipe
Ground cable TCD 2015 7.5 Nm
on checknut (Railway)
(glow plugs)
Glow plug on Checknut TCD 2015 25 Nm
connector line
Union (fuel Sleeve nut TCD 2015 42 Nm
pressure regu- TCD 2015 42 Nm
lator valve) on (Railway)
fuel line
Relief valve on TCD 2015 39 Nm
union TCD 2015 39 Nm
(Railway)
Threaded TCD 2015 18 Nm
union on fuel
cutoff valve
Threaded M16x1.5 TCD 2015 42 Nm
union on relief (Railway)
valve
Fuel cutoff Pipe bracket TCD 2015 20 Nm
valve (glow
plugs) on
crankcase
(thermostat
housing)
Intermediate TCD 2015 50 Nm
piece on oil fil-
ter unions (an-
cillary mount)
Oil pressure Oil the threads TCD 2015 40.5 Nm
pump on ancil- and the head
lary mount contact sur-
face.
Connector on Oil the threads TCD 2015 21 Nm
oil pump and the head
contact sur-
face.
Lubricant oil Hollow screw TCD 2015 18 Nm
line on ancillary
mount
Lubricant oil Sleeve nut TCD 2015 20 Nm
line on fuel de-
livery pump
20-19
Engine
tions
Oil pump pick- M8x16 TCD 2015 22 Nm
up line. M8x20 TCD 2015 22 Nm
(Railway)
Oil pickup line M8x25 TCD 2015 22 Nm
on mounting TCD 2015 22 Nm
plate (main (Railway)
bearing cover)
Oil pickup line TCD 2015 22 Nm
mount M8x16 TCD 2015 22 Nm
(Railway)
Hoses on Sleeve nut TCD 2015 30 Nm
threaded
unions (lubri-
cant oil sump)
unions (hose)
on lubricant oil
sump
Lubricant oil Nut for M14 x TCD 2015 39 Nm
line on turbo- 1.5 unions
charger
Oil return line TCD 2015 20 Nm
on turbocharg- TCD 2015 20 Nm
er/crankcase (Railway)
Pressurised oil Hose clips TCD 2015 8.5 Nm
duct on gear-
box cover
Pressurised oil Pipe bracket TCD 2015 20 Nm
duct on ancil- (Railway)
lary mount
Oil cooler TCD 2015 20 Nm
frame cover on
ancillary mount
Oil cooler on TCD 2015 20 Nm
ancillary mount
Screw plug on hex socket TCD 2015 180 Nm
valve hous-
ing (regulator
valve)
Lubricant oil TCD 2015 TCD 20 Nm 28 Nm
line mount 2015
on ancillary
mount/gearbox
cover Piston
cooling nozzle
pressure relief
valve on crank-
case
Oil pressure M14 x 1.5 TCD 2015 20 Nm
transducer on
oil cooler frame
20-20
Engine
tions
Thermostat TCD 2015 20 Nm
housing on
crankcase
Mount on ther- Mount for pipe 20 Nm
mostat housing retainer clamp
(fuel line)
Outlet unions TCD 2015 20 Nm
on thermostat
housing
Coolant pump oil slightly TCD 2015 21 Nm
on ancillary
mount
Inlet unions on oil slightly TCD 2015 20 Nm
coolant pump
Temperature TCD 2015 22 Nm
sender on ther-
mostat housing
Flywheel to en- M16x70 Always replace TCD 2015 50 Nm +30° +60° +60°
gine block screws after
removal. oliare
leggermente
Flanged hub oil slightly TCD 2015 30 Nm +120°
(torsional vi-
bration damp-
er) connected
to crankshaft
V-belt pulley/ oil slightly TCD 2015 30 Nm
torsional vibra-
tion damper
connected to
flanged hub
Bearing seat M10x55 oil slightly TCD 2015 30 Nm +60°
(hydraulic
pump drive) in
crankcase
Housing with M10x110 oil slightly TCD 2015 30 Nm +120°
flange on the
bearing hous-
ing (hydraulic
pump actua-
tion)
Housing with M10x210 oil slightly TCD 2015 30 Nm +180°
flange on the
bearing hous-
ing (hydraulic
pump actua-
tion)
Mount on gear- M8x16-8.8 TCD 2015 18 Nm
box cover TCD 2015 20 Nm
(Railway)
Heat shield on M8x16-10.9 TCD 2015 20 Nm
mount (gear-
box cover)
Fuel line to Sleeve nut TCD 2015 20 Nm
glow plug
20-21
Engine
tions
Pressurised oil Sleeve nut TCD 2015 39 Nm
duct TCD 2015 45 Nm
(Railway)
Flexible fuel Banjo bolt TCD 2015 13 Nm
hose on union M10x1 Fastening pipe TCD 2015 18 Nm
(fuel relief with 6 mm pipe (Railway)
valve/cutoff ring section
valve)
Hose end fit- Hollow screw Breather pipe TCD 2015 39 Nm
ting M14x1.5 on oil radiator
cover
Pipe fitting with M16x1.5 Fuel line on TCD 2015 40 Nm
hollow screw fuel pressure
regulator valve
Hose fastener M6 TCD 2015 8.5 Nm
clamps, fuel
line on connec-
tor pipe
Flexible fuel Pipe bracket 8.5 Nm
hose on air in-
take pipe
Cable clamp M6 18 Nm
on mount (cen-
tral connector)
Air vent pipe Pipe bracket TCD 2015 30 Nm
connected to (Railway)
mount
unions (lubri- (Railway)
cant oil lines)
on turbocharg-
er
Starter on Nut TCD 2015 30 Nm +60° +60°
crankcase
Starter motor M12x22 TCD 2015 70 Nm
heat shield on M12x28
crankcase
Alternator on TCD 2015 Hand-tighten 20 Nm
plate (console)
Alternator on TCD 2015 Hand-tighten 20 Nm
the console
Checknut (V- Screw Check- TCD 2015 Hand-tighten 42 Nm
belt) on alter- nut
nator mount
Alternator TCD 2015 42 Nm
mount on ancil-
lary mount
Cable to glow M5 nut TCD 2015 max. 5 Nm
plug TCD 2015 5 Nm
(Railway)
Cable on the M4 nut TCD 2015 2 Nm
preheating re-
lay
20-22
Engine
tions
Cable on the M6 nut TCD 2015 7.5 Nm
preheating re-
lay
Pressure/tem- TCD 2015 9 Nm
perature send-
er connected to
connector line
Cable on injec- TCD 2015 1.0 Nm
tion pump TCD 2015 5 Nm
(Railway)
Wiring harness M8 x 20 M8 x TCD 2015 18 Nm
mount on con- 16
nector line M8 TCD 2015 20 Nm
(Railway)
Wiring harness M6 TCD 2015 7.5 Nm
guide connect- M6x12 M6x16 TCD 2015 8 Nm
ed to mount (Railway)
Mount (wiring TCD 2015 70 Nm
harness) on (Railway)
connector cas-
ing
20-23
Engine
20.5 - Check the compression value (L3)
Commercially available tools:
l Compression value test: 8005
Special tools:
l Pipe union: 100130
l Wrench for nut with slots: 110130
20.5.1 - Compression test

1. m Check the valve clearances and adjust if necessary.
See para. 20.7 - Valve clearance adjust... - page 20-32
m Disassemble the injection valves.
See para. 30.15 - Fitting and removing i... - page 30-65
m Fit seal (1)
Note 2
Use the O-ring (1) for the injection valve.
m Fit union (2). 1
© 40640-0
Fig. 65
2. m Tighten the swivel nut with the wrench for nut with slots.
[LNK]
© 40643-0
Fig. 66
3. m Connect adapter (1) to the union.
© 40641-0
Fig. 67
20-24
Engine
4. m Connect the pressure gauge for the adapter compression value.
m Turn the engine over with the starter.
See para. 20.3 - Test and adjustment da... - page 20-12
© 40642-0
Fig. 68
5. Note
The pressure reading will depend on the number of starter No.
Kompression in bar
revolutions during the testing process and on the altitude at Compression value in bar
Pression en bar
which the test is performed. The limit values therefore can- Dat. _________
10 15 20 25 30 35 40
not be defined with precision. We recommend that the read-
Zyl.
ings obtained are used solely for comparison between the 1
different cylinders. A difference between cylinders of over 2
3
15% should be investigated by dismantling the cylinder giv- 4
5
ing the low reading. 6
7
8
DBGM Made in German y
MOTOMETER
© 33771-5
Fig. 69
6. m Remove the compression tester.
m Remove adapter (1).
1
© 40641-0
Fig. 70
20-25
Engine
7. m Unscrew the swivel nut with the wrench for nut with slots.
© 40643-0
Fig. 71
8. m Remove the union (2).
m Remove seal (1)
m Assemble the injection valves.
© 40640-0
Fig. 72
20-26
Engine
20.6 - Assembly and disassembly of the engine on the assembly
stand (L3)
l Lifting device
l Loading rope
Special tools:
l Assembly stand with adapter plates: 6066
l Clamping support: 6066/151
Note
The repair process shown does not take specific customer equipment into account; components not included
in the standard equipment are not shown.
20.6.1 - Assembly of the engine on the stand

1. m Remove the alternator.
See para. 30.63 - Removing and fitting t... - page 30-255
m Remove screws (1).
m Remove the heat guard cover (2). 1
2
© 40644-1
Fig. 73
2. m Fit and tighten the (1).
m Hang the engine from the workshop crane.
1 1
© 40645-0
Fig. 74
20-27
Engine
3. m Remove all the screws (1).
m Remove all the assembly feet (2).
1
© 40652-0
Fig. 75
4. m Fit all the fasteners (1).
m Tighten screws (2).
See para. 20.4 - Tightening torque (L3) - page 20-14
2 2
1 1
2 2
© 40646-1
Fig. 76
5. m Remove screws (1).
m Remove all the assembly feet (2).
1
1
© 40651-0
Fig. 77
20-28
Engine
6. m Fit the engine on the assembly stand.
m Fit the fasteners on the adapter plates.
m Align all the tightening devices (1) with the adapter plates (2) of the
assembly stand.
m Tighten the screws.
See para. 20.4 - Tightening torque (L3) - page 20-14 1
© 40649-0
Fig. 78
7. m Align the engine on the assembly stand.
© 40653-0
Fig. 79
20.6.2 - Disassembly of the engine from the assembly stand

1. m Hang the engine from the workshop crane.
m Unscrew the screws.
m Disassemble all the tightening devices (1) from the adapter plates
(2).
m Lift the engine from the assembly stand.
1
© 40649-0
Fig. 80
20-29
Engine
2. m Fit all the assembly feet (1).
m Tighten screws (2). 1
2 2
© 40991-0
Fig. 81
m Remove all the fasteners (1).
2 2
1 1
2 2
© 40646-1
Fig. 82
4. m Fit all the assembly feet (2).
m Tighten all the screws (1).
© 40652-0
Fig. 83
20-30
Engine
5. m Deposit the engine.
m Undo the eyebolts (1). 1
1
© 40645-0
Fig. 84
6. m Fit the heat guard cover (2).
m Tighten screw (1).
m Fit the alternator.
1
2
© 40644-1
Fig. 85
20-31
Engine
20.7 - Valve clearance adjustment (L3)
1. Commercially available tools:
m Rotation angle gauge: 8190
m Screwdriver insert for slot head screws: 8191
m Insertion tool with collet opening, wrench width 13: 8196
NOTE 2
Before adjusting the valve clearances, allow the engine to

cool down for at least 30 minutes. Engine oil temperature <
80 °C. The following work procedure describes the adjust- 1 1
ment of the exhaust valve clearance. To set up an intake
valve, proceed in the same manner, taking the adjustment
dimension into account.
m Remove screws (1). © 40627-0
m Remove the cylinder head cover (2). Fig. 86

m Remove the gasket.
m Fit the rotation device.
See para. 30.1 - Fitting and removing t... - page 30-2
20.7.1 - Bring the engine to valve overlap position

1. m Turn the crankshaft with the rotation tool into the valve overlap posi-
tion for cylinder A1.
© 40463-1
Fig. 87
2. Valve overlap means that:
the intake valve starts to open and the exhaust valve starts
to close.
© 40629-0
Fig. 88
20-32
Engine
3. Positions of the intake and exhaust valves:
IN = intake valve. EX = exhaust valve
IN IN
EX EX
© 40630-0
Fig. 89
20.7.2 - Adjustment of valve clearance

1. m Loosen locknut (1).
m Turn adjustment screw (2) to take up the clearance.
© 40631-0
Fig. 90
2. m Position rotation angle disc with screwdriver insert on adjuster screw.
m Fix the magnet of the rotation angle gauge to the cylinder head.
m Bring rotation angle disc to “0” .
NOTE
Do not move the adjustment screw.
© 40632_1
Fig. 91
20-33
Engine
3. m Turn the adjustment screw in the direction of the arrow.
© 40633-0
Fig. 92
4. m Tighten the check nut (1) using the open-ended wrench.
NOTE
Do not move the adjustment screw.
m Remove the rotation angle gauge.

NOTE
Adjust all the other valves in according to the valve
adjustment diagram T01 63.
1
© 40638_1
Fig. 93
5. m Clean the mating surfaces.
m Fit the new gasket (1).
1
NOTE
Observe the installation position. Position the profile
gasket (2).
© 40802-0
Fig. 94
20-34
Engine
6. m Fit the cylinder head cover.
NOTE
2
Do not insert the profile gasket (1) under the sealing 1
surface (2) of the cylinder head cover.
© 40803-0
Fig. 95
7. m Lightly oil screws (1).
m Tighten (1) the screws.
m Remove the rotation device.
1 1
© 40804-0
Fig. 96
20-35
Engine
20.8 - Disassembly and assembly of the rocker and support (L3)
m Feeler gauges
m Sealant: DEUTZ DW 59
20.8.1 - Removal of the rocker arms and pedestals

1. m Remove the injection pipes (bench A).
See para. 30.13 - Replacing the injectio... - page 30-55
See para. 30.14 - Replacing the injectio... - page 30-60 1 1
m Remove the injection pipes (bench B).
2
m Remove cylinder head cover (2).
1
© 42215-1
Fig. 97
2. m Unscrew the screws (arrowed).
NOTE
1
Loosen uniformly to prevent straining the rocker
mounts excessively.
3
m Remove the rockers (1), (2) and the rocker mounts (3) together. 3 2
NOTE
Put the components to one side in the order in which
they were removed.
© 42217-1
Fig. 98
3. m Withdraw pushrods (1).
NOTE 1
they were removed.
© 42219-1
Fig. 99
20-36
Engine
4. m Carry out a visual inspection of the components.
© 34824-2
Fig. 100
20.8.2 - Refitting the rocker arms and pedestals

1. m Insert pushrods (1).
NOTE 1
Note the relative connection positions of the wiring!
© 42219-1
Fig. 101
2. NOTE
The ball ends of the pushrods must locate in the cups of the
tappets.

© 40490-0
Fig. 102
20-37
Engine
3. m Turn the crankshaft into the base circle position of the intake and
exhaust cams for the respective cylinder.
m Fit the rocker mount.
WARNING 2
The long part (1) must face up.

1
NOTE
The ball heads (2) must be in the pivots of the pushrods.
© 45805-0
Fig. 103
4. m Turn the rocker towards the pushrods and align the valves.
m Tighten the screws in alternate sequence (1).
1 1
© 45806-0
Fig. 104
20.8.3 - Checking endfloat of rocker

1. m Measure the endfloat between the rocker mount (1) and the rocker
(2) with a feeler gauge.
NOTE 1
The rocker (2) must be on the opposite side of the
rocker mount (3). Adjust by sliding the rocker mounts. 3
© 42221-1
Fig. 105
20-38
Engine
2. m Tighten the screws (1) alternately.
m Check the valve clearances and adjust if necessary.
See para. 20.7 - Valve clearance adjust... - page 20-32
1
1
© 42222-1
Fig. 106
1
m Fit a new seal.
m Fit the cylinder head cover.
m Fit the screws. 2
2
Screw length:
M8 x 80 mm (1),M8 x 70 mm (2),M8 x 30 mm (3).
3
© 42216-1
Fig. 107
4. m Tighten the screws.
m Assemble injection pipes (bench A).
m Assemble injection pipes (bench B).
© 42223-1
Fig. 108
20-39
Engine
20.9 - Removing and refitting the rocker and mount, checking (L3)
m Internal bore meter
m Palmer
Special tools:
m Dial gauge: 100400
m Assembly/disassembly tool: 170120
20.9.1 - Disassembly of the rocker support

1. m Disassemble the rocker and the support.
See para. 20.8 - Disassembly and assemb... - page 20-36
© 34824-2
Fig. 109
20.9.2 - Checking rocker (intake valves)

1. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in
an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-
nal bore meter.

n Adjust the bracket measurement screw to 28 mm.
n Apply the internal bore meter between the test surfaces of
the palmer and in the return point of the pointer, bring the dial
gauge to “0”.
© 34768-2
Fig. 110
2. m Measure the rocker hole.
NOTE
The rocker wear limit was reached, replace it.
© 34825-2
Fig. 111
20-40
Engine
m Make sure the ball pins (1) and the adjustment screws (2) are not 1
worn.
NOTE
If strongly worn, replace the components.
m Check that the oil channel (3) is completely clear.
3
2
© 36749-1
Fig. 112
20.9.3 - Replace the ball pin

1. m Lower the assembly/disassembly tool (1).
m Applying pressure, extract the ball pin.
© 34827-3
Fig. 113
2. m Fit a new ball pin (1).
NOTE
The notch (2) must be aligned vertically towards the
rocker shaft. 1
© 34828_3
Fig. 114
20-41
Engine
3. m Lower the installation/removal tool.
m Insert the ball pin (1) applying pressure.
m Ensure that the oil channel is not obstructed.
© 34829_3
Fig. 115
20.9.4 - Checking rocker (exhaust valves)

1. m Measure the rocker hole.
NOTE
The rocker wear limit was reached, replace it.
© 34830-2
Fig. 116
m Make sure the ball pins (1) and the adjustment screws (2) are not 1
worn.
NOTE
If strongly worn, replace the components.
© 36750-1
Fig. 117
20-42
Engine
20.9.5 - Replace the ball pin
m Applying pressure, extract the ball pin.
© 34832_3
Fig. 118
m Fit a new ball pin (2), pressing into place.
© 34833_3
Fig. 119
20.9.6 - Checking rocker rod

1. m Use the palmer to measure the diameter.
NOTE
If the rocker axis wear limit was reached, replace it.
m Check that the oil channels are not obstructed.
© 34834-2
Fig. 120
20-43
Engine
20.9.7 - Completion of the rocker support
1. m Slide the rocker along the rocker shaft.
NOTE 1
The oil passage holes (1) must be turned upwards
while the holes (2) for the rocker mount screws must
be turned towards the adjustment screws.
© 36751-1
Fig. 121
2. m Slide the rocker mounts along the rocker shaft.
WARNING
The long part (1) must face up. The fastener grooves (2)
must face towards the adjustment screws (3). 1
2 3
© 45385_1
Fig. 122
3. m Fit all the screws (1).
m Assemble the rockers and support.
1
© 34837_3
Fig. 123
20-44
Engine
20.10 - Grinding the cylinder head seal surface (L3)
m Flattener
m Roughness gauge
m Depth gauge
NOTE
When the flattener is used, following the specific instructions of the manufacturer.
20.10.1 - Preparation of the cylinder head

1. m Disassemble the valves.
See para. 20.13 - Valve assembly and dis... - page 20-54
m Deburr the top of the cylinder head.
NOTE
To ensure a correct fit, the cylinder head surface
must be free of burr or gasket residue.
© 39757-1
Fig. 124
20.10.2 - Flattening the cylinder head

1. m Tighten the cylinder head on the flattener.
m Align the cylinder head.
m Flattener tool for aligning the cylinder head.
© 39758-1
Fig. 125
20-45
Engine
2. m Flattening the sealing surface of the cylinder head.
m Check the cylinder head seal surface
NOTE
The lapping procedure must be repeated if the seal
surface of the cylinder head is not perfectly flat (rec-
ognisable by variations in colour in the ground sur-
face). The tool supply dimension is maximum 0.2 mm
for the flattening process.
© 39759-1
Fig. 126
20.10.3 - Check of the sealing surface of the cylinder head

1. m Visual inspection of the sealing surface of the cylinder head.
m Visually inspect the surface of the combustion chamber.
m Measure the roughness of the cylinder head seal surface with the
roughness gauge.
NOTE
If the value measured is not within the permissible
range, the cylinder head seal surface must be lapped
again using different settings for the lapping machine.
© 39760-1
Fig. 127
2. m Measure the height of the cylinder head with a depth gauge.
NOTE
The cylinder head wear limit was reached, replace it.
© 39761-1
Fig. 128
20-46
Engine
3. m Remove the cylinder head from the flattener.
© 39758-1
Fig. 129
4. m Apply the repair date and factory mark on the cylinder head.
WARNING
Do not apply the label to a sealing surface.
NOTE
Mark the cylinder head after each repair.
m Assemble the valves.

© 39744-1
Fig. 130
20-47
Engine
20.11 - Disassembly and assembly of the cylinder head (L3)
m Box spanner insert: 8016
m Rotation angle gauge: 8190
20.11.1 - Disassembly of the cylinder head

1. m Disassemble the supply air pipe (bench A).
m Disassemble the supply air pipe (bench B).
m Disassemble the exhaust pipe (bench A).
m Disassemble the exhaust pipe (bench B).
© 40578-0
Fig. 131
2. m Disassemble the rocker and the support.
NOTE
they were removed.
© 42234-1
Fig. 132
3. m Unscrew the screws (1) using the box spanner insert.
m Remove the cylinder head.
m Carry out a visual inspection of the components. 1
© 42235-1
Fig. 133
20-48
Engine
20.11.2 - Assembly of the cylinder head
1. m Measure the piston protrusion.
See para. 20.12 - Measuring piston protr... - page 20-51
NOTE
Identify the most suitable cylinder head gasket for
each cylinder.
© 45811_0
Fig. 134
2. m Select a new cylinder head seal based on the measured piston pro-
trusion..
NOTE
Example: a piston protrusion of 0.05 mm requires a
head gasket with 1 holes (arrow).
© 45811_1
Fig. 135
m Apply a new cylinder head seal.
NOTE
The sealing surfaces of the cylinder head seal must
be clean and free of oil. The mark IN ALTO / TOP is
facing the direction of the cylinder head.
© 45812_1
Fig. 136
20-49
Engine
4. m Insert the cylinder head.
m Slightly lubricate the cylinder head screws.
WARNING
In the case of written certification, the screws can be used a
maximum of 3 times.
m Fit the screws.
© 34976-2
Fig. 137
5. m Alternatively tighten the screws with the rotation angle gauge and
the box spanner insert.
© 40582-0
Fig. 138
6. m Assemble the rockers and support.
m Assemble the supply air pipe (bench A).
m Assemble the supply air pipe (bench B).
m Assemble the exhaust pipe (bench A).
m Assemble the exhaust pipe (bench B).
See para. 30.48 - Removing and fitting t... - page 30-174 © 40583-0
See para. 30.49 - Removing and fitting t... - page 30-177 Fig. 139
20-50
Engine
20.12 - Measuring piston protrusion (L3)
m Magnetic stand for measurements
Special tools:
m Measurement tool with measurement plate 100850
20.12.1 - Measuring piston protrusion

1. m Disassemble the cylinder head.
m Insert the screws and washers (1) offset diagonally.
m Tighten the screws to the end stop of the cylinder sleeve.
Washers:
n max. thickness 4 mm
1
Screw length:
n M16 x 90
© 45424-0
Fig. 140
2. m Fit the rotation tool
m Turn the crankshaft until the respective piston is positioned just be-
fore the top dead centre (arrow).
© 45763-0
Fig. 141
3. m Check that the bushes (arrowed) are present.
© 45766-0
Fig. 142
20-51
Engine
4. m Place the measurement tool (1) against the measurement plate (2).
m Apply the pre-loaded dial gauges (3) in the measurement tool. 3
m Turn the dial until the pointer indicates “0”.
© 37242-0
Fig. 143
5. m Place the measurement tool over the locating doweles (arrows).
m Read the values measured on both dial gauges.
m 1. Dial gauge:
n Make a note of dimension (a).
m 2. Dial gauge:
n Make a note of dimension (b).
© 45767-0
Fig. 144
6. m Calculate and note the average value.
Table 42
Calculation example:
Target: Measurement x (average dial gauge
reading)
Data: -
Measured value: Measurement a (value measured
by 1st dial gauge). Measurement b
(value measured by 2nd dial gauge).
Calculation: Measurement x = (measurement a +
measurement b): 2, (0.39 mm + 0.45
mm): 2 © 45767-2
The results of all this are: = 0.42 mm Fig. 145

20-52
Engine
m Assemble the cylinder head.
1
© 45424-0
Fig. 146
20-53
Engine
20.13 - Valve assembly and disassembly (L3)
m Sliding gauge
m Assembly pliers: 8024
m Assembly lever: 9017
Special tools:
m Support stand: 120900
m base plate: 120910
m Assembly tool: 121410
m Assembly bushes: 121420
20.13.1 - Valve disassembly

See para. 20.11 - Disassembly and assemb... - page 20-48 1
m Assemble the support stand (1) on the base plate (2).
m Assemble the cylinder head on the support stand.
© 42227-1
Fig. 147
2. m Fit the assembly lever (1).
m Push the valve spring downwards with the assembly lever.
m Remove the two retaining tapered rings (2). 1
m Remove the collets, valve springs and valves.
m Disassemble the assembly lever.
© 42337-1
Fig. 148
3. m Disassemble the valve stem gasket using the assembly pliers.
© 42336-1
Fig. 149
20-54
Engine
4. m Clean the cylinder head.
m Check the cylinder head.
m Carry out a visual inspection of the components.
© 42335-1
Fig. 150
20.13.2 - Valve assembly

1. m Measure the length of the valve spring using the sliding gauge.
NOTE
If the valve spring wear limit was reached, replace it.
© 35856-2
Fig. 151
2. m Oil the valve stem lightly
m Insert and retain the valve.
m Push the locating dowel (2) through the valve key seats (1).
© 42334-1
Fig. 152
20-55
Engine
3. m Using the specific tool, slide the new valve seat seal (1) onto the
locating dowel in the valve guide.
m Remove the assembly bush.
© 42332-1
Fig. 153
4. m Insert the valve spring (1).
m Insert the collet (2).
2
© 42331-1
Fig. 154
5. m Apply the assembly lever.
m Push the valve spring downwards with the assembly lever and insert
two retaining tapered rings (1).
NOTE
Make sure the position of the retaining tapered rings
in the valve key seats is correct.
© 42330-1
Fig. 155
20-56
Engine
6. m Disassemble the assembly lever.
m Disassemble the cylinder head from the support stand.
© 42329-1
Fig. 156
20-57
Engine
20.14 - Valve check (L3)
m Palmer
m Sliding gauge
NOTE
Clean the valve before testing. If the valve wear limit was reached, replace it.
20.14.1 - Check the diameter of the valve stem

m Use the palmer to measure the diameter of the valve stem.
© 42182-1
Fig. 157
20.14.2 - Check the thickness of the valve edge

1. m Use the sliding gauge to measure the thickness of the valve edge.
© 42183-1
Fig. 158
20-58
Engine
20.14.3 - Check the diameter of the valve head
1. m Use the sliding gauge to measure the diameter of the valve head.
© 42184-1
Fig. 159
20-59
Engine
20.15 - Check the valve guide (L3)
Special tools:
NOTE
New valves are used for the check. The valve guide wear limit was reached, replace it.
20.15.1 - Check the valve guide

m Visually check the wear of the valve guide.
© 40713-0
Fig. 160
20.15.2 - Measure the valve stem clearance

1. m Apply the magnetic stand for measurements.
m Insert the dial gauge.
m Fit a new valve.
m Preload the probe on the valve head (arrow).
© 40714-0
Fig. 161
20-60
Engine
2. m Move the valve backwards and forwards in the direction of the arrow
NOTE
The end of the valve stem must close flush with the
valve guide. Take the entire overturning stroke into
consideration.
© 40715-0
Fig. 162
3. m Remove the magnetic stand for measurements.
m Disassemble the dial gauge.
© 40639-0
Fig. 163
20-61
Engine
20.16 - Replacing the valve guide (oversized - press-fit) (L3)
m Reamers
m Limit plug gauges
m Machine for working the cylinder heads
m Press
m Presser chuck
m Presser
m Industrial aspirator
m Nitrogen (liquid)
DANGER
Risk of accident, do not touch super cooled components or liquid nitrogen! Wear protective gloves and safety
goggles!
WARNING
The process of pressure fitting must be carried out quickly due to the thermal shock between the cylinder head
and the inserted valve seat. The necessary work steps must be carried out before pressure fitting.
NOTE
When using the machine to process the cylinder heads, following the specific instructions provided by the
manufacturer.
20.16.1 - Check the valve guide

1. m Check the valve guide.
See para. 20.15 - Check the valve guide ... - page 20-60
m Check the valve guide with a limit plug gauge (1).
NOTE
1
The reference side of the limit plug gauge must be
able to move up and down with slight shrinkage.
© 39737-1
Fig. 164
20.16.2 - Pushing out the valve guide

1. m Push out the valve guide with the presser chuck (1).
© 39749-1
Fig. 165
20-62
Engine
20.16.3 - Checking the valve guide seat hole
1. m Visually inspect the seat hole (arrow).
NOTE
If accentuated scoring is visible in the seat hole, ream
the seat hole to the next highest oversizing step.
© 36630-1
Fig. 166
2. m Check the housing hole for the valve guide using the limit plug
gauge (1).
© 39750-1
Fig. 167
3. NOTE
The reference side of the limit plug gauge must be able to move up and down with slight shrinkage. The no-go
end of the go-no-go gauge must not pass through the seat hole. If the no-go end of the gauge fits in the hole,
grind the hole to the next highest interference size. Replace the cylinder head when wear reaches the 2nd
oversizing step.
20.16.4 - Make the housing hole for the valve guide (increased dimension)
1. m Tighten the cylinder head on the machine for processing the cylinder
heads.
m Close the coolant channels.
© 39751-1
Fig. 168
20-63
Engine
2. m With the guide bolt (1) align the drilling unit with respect to the hous-
ing hole.
NOTE
The housing holes may have different diameters,
therefore select a guide bolt suitable for aligning the
drilling units. The guide bolt must move easily without 1
noticing resistance in the housing hole.
© 39752-1
Fig. 169
3. m Widen the seat hole to the correct oversizing step.
WARNING
The reamer twists in an anticlockwise direction and there-
fore must always be turned clockwise. Never turn the ream-
er anticlockwise. The shavings that form when removing
material can block and destroy the cutting edges.
m Blow compressed air through the housing hole.
© 39753-1
Fig. 170
4. m Check the housing hole for the valve guide using the limit plug
gauge (1).
NOTE
Use a suitable go-no-go gauge. The reference side
of the limit plug gauge must be able to move up and 1
down with slight shrinkage.
© 39750-1
Fig. 171
20-64
Engine
5. NOTE
The no-go end of the go-no-go gauge (1) must not pass
through the seat hole. If the no-go end of the gauge fits in
the hole, grind the hole to the next highest interference size.
If the wear limit reached the 2nd degree of oversizing, re- 1
place the cylinder head.
© 39750-1
Fig. 172
6. m Release the cylinder head.
m Blow compressed air on the cylinder head.
© 39751-1
Fig. 173
20.16.5 - Pressure insertion of the valve guide

1. m Apply the cylinder head.
m Select a valve guide suitable for the housing hole.
© 39754-1
Fig. 174
20-65
Engine
2. m Supercool the valve guide with liquid nitrogen.
NOTE
Use containers suitable for liquid nitrogen and a tool
suitable for the component insertion and removal op-
erations. When starting to cool the metal, the liquid
nitrogen will boil intensely, the effervescence pro-
cess is maintained until the metal components reach
the temperature of the liquid nitrogen (-196 °C). The
guide valve will have the correct temperature once
the effervescence process of the nitrogen is con-
cluded.
© 36636-1
Fig. 175
3. m Slide the valve guide (1) onto the presser chuck (2).
NOTE
Be careful to fit the guide valve the right way round.
The flat side (arrow) must face towards the presser
chuck.
© 39755-1
Fig. 176
4. m Press the valve guide into the presser chuck against the stop.
m Remove the presser chuck.
m Remove the cylinder head.
© 39756-1
Fig. 177
20-66
Engine
WARNING
NOTE

© 39744-1
Fig. 178
20-67
Engine
20.17 - Check the valve residual (L3)
m Depth gauge
Special tools:
m Support stand: 120900
m base plate: 120910
WARNING
If the wear limit of the inserted valve seat and/or the valve is reached, replace them.
20.17.1 - Check the valve residual

m Assemble the support stand (1) on the base plate (2). 1
m Assemble the cylinder head on the support stand.
© 40650_1
Fig. 179
2. m Place the depth gauge on the seal surface of the cylinder head.
m Measure the valve resistance.
© 42228-1
Fig. 180
3. m Disassemble the cylinder head from the support stand (1).
m Disassemble the base plate support stand (2).
m Assemble the cylinder head. 1
© 40650_1
Fig. 181
20-68
Engine
20.18 - Replacing the lined valve seat (oversized) (L3)
m Pin milling cutter, 10 mm
m Sliding gauge
m Machine for working the cylinder heads
m Press
m Industrial aspirator
m Presser
m Vertical drill
m Nitrogen (liquid)
DANGER
Risk of accident, do not touch super cooled components or liquid nitrogen! Wear protective gloves and safety
goggles!
WARNING
The process of pressure fitting must be carried out quickly due to the thermal shock between the cylinder head
and the inserted valve seat. The necessary work steps must be carried out before pressure fitting.
NOTE
When using the machine to process the cylinder heads, following the specific instructions provided by the
manufacturer. To replace an inserted valve seat, the respective valve guide must be present.
2. m Check the valve residual.

See para. 20.17 - Check the valve residu... - page 20-68
m Disassemble the valves.
© 40639-0
Fig. 182
20.18.1 - Checking the inserted valve seat

1. m Check the inserted valve seat (1).
NOTE
Check the installation position is correct. 1
© 39739-1
Fig. 183
20-69
Engine
20.18.2 - Disassembly of the inserted valve seat
1. m Tighten the cylinder head.
m Align the inserted valve seat with the pin milling cutter.
© 39740-1
Fig. 184
2. m Laterally cut the inserted valve seat (arrow) until it can be removed
without tension.
WARNING
Do not damage the cylinder head.
© 39741-1
Fig. 185
3. m Apply a protective sublayer (arrow).
m Remove the inserted valve seat by applying leverage.
WARNING
Do not damage the cylinder head.
m Release the cylinder head.
© 39742-1
Fig. 186
20-70
Engine
20.18.3 - Check the hole of the housing for the inserted valve seat
1. NOTE
Measurement diagram hole of the housing in points “a and
b”, central in surface “1”. 1
© 36640-1
Fig. 187
2. m Measure the hole of the housing with an internal bore meter.
NOTE
Measurement points, see diagram.
m Read the value measured.

NOTE
If the wear limit reached the 2nd degree of oversiz-
ing, replace the cylinder head.
© 39743-1
Fig. 188
3. NOTE
Alternatively, determine the diameter of the seat hole with a
measuring ring (1). For example, a lined valve seat lathed to
half its height may be used as a measurement ring, which is
then inserted in the hole to measure the diameter.
© 36641-1
Fig. 189
20-71
Engine
20.18.4 - Make the housing hole for the inserted valve seat (interference)
1. m Set the cutting tool.
© 36620-1
Fig. 190
2. m Tighten the cylinder head on the machine for processing the cylinder
heads.
m Close the coolant channels.
© 39745-1
Fig. 191
3. NOTE
The valve guides may have different diameters, therefore
select a guide bolt suitable for aligning the drilling units. The
1
guide bolt must move easily without noticing resistance in
the valve guide.
m With the guide bolt (1) align the drilling unit with respect to the hous-
ing hole.
© 39746-1
Fig. 192
20-72
Engine
4. m Enlarge the housing hole based on the degree of oversizing.
WARNING
The inserted valve seat support (arrow) must not be ma-
chined with a cutting tool.
m Remove the shavings from the bottom.
© 36624-1
Fig. 193
5. m Measure the hole of the housing with an internal bore meter.
© 39747-1
Fig. 194
20.18.5 - Pressure insertion of the inserted valve seat

1. m Apply the cylinder head.
m Select a inserted valve seat suitable for the housing hole.
© 39748-1
Fig. 195
20-73
Engine
20-74
Engine
WARNING
NOTE
© 39744-1
Fig. 199
6. m Assemble the valves.
m Check the valve residual.
See para. 20.17 - Check the valve residu... - page 20-68
© 40639-0
Fig. 200
20-75
Engine
20.19 - Check the endfloat of the crankshaft (crankshaft re-
moved) (L3)
l Palmer
l Internal bore meter
20.19.1 - Check the endfloat

1. m Disassemble the crankshaft.
See para. 20.26 - Assembly and disassemb... - page 20-112
© 40485-0
Fig. 201
2. m Adjust the palmer to 38 mm.
m Push the internal bore meter between the test surfaces of the palm-
er and bring to “0”.
© 35825-2
Fig. 202
3. m Measure the width of the flanged bearing.
m Make a note of dimension (a).
© 42324-1
Fig. 203
20-76
Engine
4. m Apply the thrust ring halves on the flanged bearing cover (arrows).
m Measure the width with the palmer.
m Make a note of dimension (b).
m Determine the endfloat.
Table 43
Target: Endfloat
Data: -
Measured value: (a) = 38.6 mm, (b) = 38.4 mm
Calculation: Endfloat = measurement (a) - mea-
surement (b), 38.6 mm - 38.4 mm
The results of all this are: = 0.2 mm
© 40600-0
See para. 20.3 - Test and adjustment da... - page 20-12 Fig. 204
5. m Assemble the crankshaft.
© 40485-0
Fig. 205
20-77
Engine
20.20 - Check the endfloat of the crankshaft (crankshaft in-
stalled) (L3)
l Magnetic stand for measurements
l Palmer
l Box spanner insert, wrench opening 24, reinforced
l Box spanner insert: 8035
l Rotation angle gauge: 8190
Special tools:
l Dial gauge: 100400
20.20.1 - Check the endfloat

1. m Disassemble the assembly support.
See para. 20.35 - Removing and fitting a... - page 20-158
m Disassemble the rear cover.
See para. 20.37 - Removing and refitting... - page 20-181
© 40479-0
Fig. 206
m Apply the preloaded probe on the end of the crankshaft.
m Press the crankshaft towards the arrow.
© 40589-0
Fig. 207
20-78
Engine
3. m Press the crankshaft towards the arrow.
If there is a difference in the endfloat:
Note the value measured (a). Correct the endfloat by
replacing the thrust ring halves.
© 40588-0
Fig. 208
20.20.2 - Replacing the thrust ring halves

1. m Undo the screws (arrows) with the socket wrench insert 8035.
© 40593-0
Fig. 209
2. m Undo the screws (1) with the socket wrench insert (wrench size 24).
m Remove flanged bearing cover (2). 1
m Remove the lower bearing shell.
m Remove the lower halves of the thrust ring (arrows).
© 40594-0
Fig. 210
20-79
Engine
3. m Remove the upper halves of the thrust ring (arrows).
© 40595-0
Fig. 211
4. m Measure the thickness of the upper and lower halves of the thrust
ring.
m Calculate the wall thickness for the new thrust ring halves.
Table 44
Target: Wall thickness of new thrust ring
halves
Data: (x) = standard thickness, oversize
steps 1 and 2
(y) = endfloat (nominal) (values de- © 43504-0
termined from technical data) Fig. 212

Measured value: (a) = 0.4 mm endfloat (effective),
(b) = 3.26 mm (thickness of previ-
ous thrust ring halves), (x) - (b) =
(c), 3.36 mm - 3.26 mm = 0.1 mm.
Measurement (a) - measurement (c)
The results of all this are: = 0.3 mm. The value must be within
the indicated limits for endfloat (y).
m Select the new thrust ring halves using the calculated value.
5. m Assemble the upper thrust ring halves based on the measured end-
float.
NOTE 2
The oil grooves (1) of the thrust ring halves are facing
the crankshaft shoulder disc (2). Insert the thrust ring
halves between the crankcase and the crankshaft 1
shoulder (arrow).
© 40596-0
Fig. 213
20-80
Engine
20-81
Engine
WARNING
1
maximum of 3 times.
© 40599-0
Fig. 217
10. m Tighten the screws (arrows) with the socket wrench insert (wrench
size 24) and the rotation angle gauge.
© 40491-0
Fig. 218
11. m Undo the screws (arrows) with the socket wrench insert 8035 and
tighten the rotation angle gauge.
© 40492-0
Fig. 219
20-82
Engine
12. m Check the crankshaft endfloat.
© 45417-0
Fig. 220
m Assemble the assembly support.
m Assemble the rear cover.
© 40479-0
Fig. 221
20-83
Engine
20.21 - Crankshaft check (L3)
m Palmer
m Prisms
m Hardness tester
Special tools:
2. m Disassemble the crankshaft.

m Rest the crankshaft on the prisms.
© 40485-0
Fig. 222
3. m Remove the gear wheel (1).
m Remove the friction plate.
© 40585-0
Fig. 223
© 40586-0
Fig. 224
20-84
Engine
20-85
Engine
8. m Lift (1) the probe and press the release device (2).
NOTE
1
The probe (1) falls downward, briefly hits the surface
and goes up to the measurement value.
2
© 44445-0
Fig. 228
9. m Read the value indicated (arrow) by the hardness tester.
NOTE
The measurement values must be converted using
the tester table.
© 43515-1
Fig. 229
10. NOTE
Measurement diagram of the main journals on points 1 and
2 in surfaces a and b.
© 36424-2
Fig. 230
20-86
Engine
20.21.1 - Check the diameter of the main bearing pins
1. m Measure the main bearing pins with the palmer.
NOTE
© 42327-1
Fig. 231
20.21.2 - Check the diameter of the connecting rod pins

1. m Measure the main journal with the palmer.
NOTE
© 42326-1
Fig. 232
20.21.3 - Check the coaxiality

m Apply the preloaded probe on the main bearing pins (arrow) and
adjust the dial gauge to “0”.
m Uniformly turn the crankshaft and check the coaxiality.
m Remove the magnetic stand for measurements.
© 42325-1
Fig. 233
20-87
Engine
20.21.4 - Measuring the length of the flanged bearing
1. m Adjust the palmer to 38 mm.
© 35825-2
Fig. 234
2. m Measure the width of the flanged bearing using the internal bore
meter between the support surfaces of the thrust rings.
© 42324-1
Fig. 235
© 40485-0
Fig. 236
20-88
Engine
20.22 - Replace the crankshaft O-ring (flywheel end) (L3)
l Depth gauge
l Bradawl: 8198
l Assembly lever: 9017
Special tools:
l Assembly tool: 142650
l Self-tapping screw
l Washer
20.22.1 - Removal of the crankshaft oil seal

1. m Remove the flywheel.
m Loosen the crankshaft O-ring in its seat in a uniform manner using
a bolt.
m Using a bradawl, make a hole in the old crankshaft O-ring.
WARNING
Take care not to damage the rear cover or the crankshaft!
© 40656-0
Fig. 237
2. m Screw a self-tapping screw, fitted with a washer, into the hole.
© 42091-2
Fig. 238
3. m Extract the crankshaft O-ring using the assembly lever.
© 36764-1
Fig. 239
20-89
Engine
4. m Carry out a visual inspection of the sealing surfaces.
© 40657-0
Fig. 240
20.22.2 - Fit the crankshaft O-ring

1. m Select the spacer disc (1).
NOTE
Use the spacer disc with the “Rep-Stufe” reference. 1
© 36756-2
Fig. 241
2. m Fit spacer (1).
NOTE
Check that locating dowel (2) is aligned with the mat-
ing hole (3).
2
© 36755-1
Fig. 242
20-90
Engine
3. m Tighten the pin (1) with the thread (2) in the crankshaft.
1
© 36757-1
Fig. 243
4. NOTE
Use a new crankshaft O-ring.
m Lightly oil the lip of the crankshaft O-ring.

m Carefully place the crankshaft O-ring on the sliding surface.
NOTE
The seal lip should be facing the engine crankcase.
© 36758-1
Fig. 244
5. m Place the assembly bush (1) on the pin (2).
m Press the assembly bush.
NOTE
The locating dowel must be evenly in contact with the 1
crankshaft O-ring.
2
© 36759-1
Fig. 245
20-91
Engine
6. m Place the pressure crosspiece (1) on the pin (2).
m Fit the washers.
m Tighten the nuts.
2
© 36760-1
Fig. 246
7. m Tighten the screw (1) until it comes into contact with the assembly
bush (2).
m Remove the installation tool.
2
© 36761-1
Fig. 247
8. m Check the insertion depth (1) with the depth gauge.
m Fit the flywheel.
© 40960-0
Fig. 248
20-92
Engine
20.23 - Replace the crankshaft O-ring (opposite end to flywheel)
(L3)
l Depth gauge
l Bradawl: 8198
Special tools:
l Washer

m Remove the flanged hub with the torsional vibration damper and
the V-belt.
NOTE
1
Counterhold the flywheel using a suitable tool.
© 40659-0
Fig. 249
2. m Loosen the crankshaft O-ring in its seat in a uniform manner using
a bolt.
m Using a bradawl, make a hole in the old crankshaft O-ring.
WARNING
Take care not to damage the ancillary mount or crankshaft!
© 40660-0
Fig. 250
20-93
Engine
3. m Screw a self-tapping screw, fitted with a washer, into the hole.
© 40661-0
Fig. 251
© 40662-0
Fig. 252
5. m Carry out a visual inspection of the sealing surfaces.
© 40663-0
Fig. 253
20-94
Engine
20.23.2 - Fit the crankshaft O-ring
1. m Select the spacer disc (1).
NOTE
Use the spacer disc with the “Rep-Stufe” reference. 1
© 37153-2
Fig. 254
2. m Fit spacer (1).
© 37211-1
Fig. 255
3. m Tighten the pin (1) with the thread (2) in the crankshaft.
© 37208-1
Fig. 256
20-95
Engine
4. NOTE
Use a new crankshaft O-ring.
m Lightly oil the lip of the crankshaft O-ring.

m Carefully place the crankshaft O-ring on the sliding surface.
NOTE
The seal lip should be facing the engine crankcase.
© 35203-2
Fig. 257
5. m Place the assembly bush (1) on the pin (2).
m Press the assembly bush.
NOTE
The locating dowel must be evenly in contact with the
crankshaft O-ring. 1
© 35204-2
Fig. 258
6. m Place the pressure crosspiece (1) on the pin (2).
m Fit the washers.
m Tighten the nuts.
© 35205-2
Fig. 259
20-96
Engine
7. m Tighten the screw (1) until it comes into contact with the assembly
bush (2).
m Remove the installation tool. 2
© 35206-2
Fig. 260
8. m Check the insertion depth (1) with the depth gauge.
© 35201-3
Fig. 261
9. m Fit the flanged hub with the torsional vibration damper and V-belt.
m Lightly oil screws (1).
NOTE
1
m Tighten all screws (1) alternately.

© 40659-0
Fig. 262
20-97
Engine
20.24 - Connecting rod drum check (L3)
m Palmer
m Connecting rod tester
Special tools:
2. m Disassemble the piston and connecting rod drum.

© 40592-0
Fig. 263
20.24.1 - Check of the piston pin bush


nal bore meter.

n Set the bracket measurement screw to 52 mm.
gauge to “0”.
© 34768-2
Fig. 264
2. NOTE
Measurement diagram of the piston pin bush in points “a”
and “b” in surfaces “1” and “2”.
© 37239-1
Fig. 265
20-98
Engine
3. m Insert the internal bore meter.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer.
NOTE
© 34770-2
Fig. 266
20.24.2 - Checking piston pins

1. m Measure the piston pin with the palmer.
© 35908-2
Fig. 267
20.24.3 - Calculate the piston pin clearance

NOTE
The clearance of the piston pin results from the difference between the inner diameter of the connecting rod bearing
shell (a) and the diameter of the main journal (b).

Table 45
Target: Piston pin clearance
Data: -
Measured value: Inner diameter of piston pin bush (a)
(a) = 52.040 mm
Piston pin diameter (b), (b) = 52.000 mm
Calculation: Measurement (a) - measurement (b), 52.040 mm - 52.000 mm
20-99
Engine
20.24.4 - Check the connecting rod bearing hole
1. m Apply the flanged bearing cover.
WARNING 1
Pay attention to coupling the flanged bearing cover. The nu-
meric marks (1) on the connecting rod drum and on the con-
necting rod bearing cover must be identical and positioned
in front of each other during assembly.
© 34771-2
Fig. 268
© 34772-2
Fig. 269

nal bore meter.

gauge to “0”.
© 36094-1
Fig. 270
20-100
Engine
4. NOTE
Measurement diagram of the connecting rod bearing hole in
points “a” and “b” in surfaces “1” and “2”.
© 37239-1
Fig. 271
pointer.
NOTE
If the measured values diverse minimally, take addi-
tional measurements with new bearing shells.
© 34775-2
Fig. 272
20.24.5 - Check the internal diameter of the connecting rod bearing shells
1. m Unscrew the screws.
m Remove the flanged bearing cover.
m Insert the connecting rod bearing shell into the connecting rod drum. 2
WARNING
Take care to couple the bearing shells. Insert the connecting
rod bearing shell with the black anodized back (arrow) into
the connecting rod drum.
The anti-twist safety (1) must enter the groove (2). 1
© 36768-1
Fig. 273
20-101
Engine
2. m Insert the connecting rod bearing shell into the relative flanged bear-
ing cover.
WARNING
Take care to couple the bearing shells. The anti-twist safety
(1) must enter the groove (2).
© 36769-1
Fig. 274
WARNING 1
© 34771-2
Fig. 275
© 34778-2
Fig. 276
20-102
Engine

nal bore meter.

gauge to “0”.
© 36094-1
Fig. 277
6. NOTE
Measurement diagram of the internal diameter of the con-
necting rod bearing shells in points “a” and “b” in surfaces
“1” and “2”.
© 37239-1
Fig. 278
pointer.
NOTE
If the values are within 0.015 mm above the bearing
tolerance value, the connecting rod shank may be re-
used. If the limit is reached, the connecting rod drum
must be replaced.
© 34775-2
Fig. 279
20-103
Engine
20.24.6 - Check the diameter of the connecting rod pins
1. NOTE
© 36424-2
Fig. 280
2. m Measure the main journal with the palmer.
NOTE
© 45399-0
Fig. 281
20.24.7 - Determine the clearance of the connecting rod bearing

Table 46
Target: Clearance of the connecting rod bearing
Data: -
Measured value: Inner diameter of big end bearing shell (a)
(a) =88.060 mm
Crankpin diameter (b), (b) = 88.000 mm
Calculation: Measurement (a) - measurement (b), 88.060 mm - 88.000 mm
20-104
Engine
m Remove the flanged bearing cover.
m Remove the connecting rod bearing shells.
© 34778-2
Fig. 282
20.24.8 - Check the connecting rod drum

1. WARNING
It is not permitted to straighten the connecting rod drum.
m Check the parallelism of the connecting rod drum.

NOTE
Check the connecting rod drum without the bearing
shells on the connecting rod tester. Permitted devia-
tion (a) in the case of a distance of (x).
© 35880-2
Fig. 283
2. m Check the angulation of the connecting rod drum.
NOTE
Maximum permitted difference between (A) and (B)
with distance (x).
© 35881-2
Fig. 284
20-105
Engine
3. m Assemble the piston and the connecting rod drum.
© 40592-0
Fig. 285
20-106
Engine
20.25 - Fitting and removing piston pin bush (L3)
l Press or threaded pin
Special tools:
l base plate: 131200
l Set of assembly tools: 131210
l Nitrogen (liquid)
l Degreaser/detergent
l Compressed air
l Heating device
DANGER
Risk of accident, do not touch hot components! Risk of accident, do not touch super cooled components or liquid
nitrogen! Wear protective gloves and safety goggles!
WARNING
The process of pressure fitting must be carried out quickly due to the thermal shock between the bush of the piston pin
and the connecting rod drum. The necessary work steps must be carried out before pressure fitting.
NOTE
The extraction of the piston pin bush is illustrated with a pneumatic press. Alternatively, also a threaded pin can be
used.
20.25.1 - Disassembly of the piston pin bush

1. WARNING
Never force the piston pin bush! 3
1
m Insert the housing of the connecting rod bearing (3) in the base plate
(2).
m Insert the disassembly gauge (1) in the base plate.
WARNING
Do not mix up the disassembly gauge and the assembly
gauge!
2
NOTE © 40404-0
The groove (arrow) must face the housing of the connect- Fig. 286
ing rod bearing. Make sure that the disassembly gauge is
perfectly levelled.
20-107
Engine
2. m Insert the lower part of the assembly tool (3) from below in the disas-
sembly gauge. 1
m Position the connecting rod drum (1) on the base plate. 2
NOTE
The flat side (arrow) of the connecting rod drum must
face downwards.
m Rotate the lower part (3) in the upper part (2) of the assembly tool.
© 40403-0
Fig. 287
3. m Align the upper part (1) of the assembly tool with the disassembly
gauge (2).
NOTE
The upper part of the assembly tool and the disas-
sembly gauge are flush with the angular surfaces (ar- 1
row) of the connecting rod bearing.
Fig. 288
4. m Tighten the upper part (1) and the lower part (2) of the assembly
tool.
© 40402-0
Fig. 289
20-108
Engine
5. m Align the pneumatic press horizontally with the base plate.
NOTE
The extractor punch must be situated in the centre
above the top of the assembly tool.
© 36284-2
Fig. 290
6. m Remove the piston pin bush with slight pressure.
m Clean the hole in the bush.
NOTE
The hole in the bush must be free of grease and dirt.
© 36285-2
Fig. 291
20.25.2 - Assembly of the piston pin bush

1. m Insert the housing of the connecting rod bearing (3) in the base plate
(2). 3
m Insert the assembly gauge (1) in the base plate.
NOTE
The groove (arrow) must face the housing of the con- 1
necting rod bearing. Make sure that the assembly
gauge is perfectly levelled.
© 40405-0
Fig. 292
20-109
Engine
2. m Heat the connecting rod shank (1).
m Position the connecting rod drum on the base plate (2). 1
NOTE
The flat side (arrow) of the connecting rod drum must
face downwards.
© 40406-0
Fig. 293
3. m Chill the piston pin bush (1) in liquid nitrogen.
© 36288-2
Fig. 294
4. m Position the supercooled bush of the piston pin (1) on the assembly
bolt (3).
NOTE 1
The index (2) must be situated in the groove (indi-

cated by arrow) in the piston pin bush.
2
3
© 40407-0
Fig. 295
20-110
Engine
5. m Insert the assembly bolt (1) with the piston pin bush (2) in the hole
of the connecting rod.
NOTE
The piston pin bush must be inserted without force 1
into the connecting rod hole. Pay attention to the as-
sembly position of the piston pin bush.
m Remove the assembly bolt. 2
NOTE
The piston pin bush must not slip any more.
© 36290-3
Fig. 296
6. m Check the assembly position.
NOTE
Position of bush separation line (indicated by arrow)
as seen when looking towards the flat side of the
connecting rod shank.
© 40968-1
Fig. 297
7. NOTE
After the assembly operation, mechanically adjust the piston
pin bush.
m Turn the piston pin bush to dimension A.

Table 47
Dimension Maximum dimension Minimum dimension

Hole of the piston pin 52.055 mm 52.040 mm
bush, dimension A
Piston pin diameter 52.000 mm 51.992 mm
Theoretical clearance 0.063 mm 0.040 mm © 39730-2
Fig. 298
20-111
Engine
20.26 - Assembly and disassembly of the crankshaft (L3)
l Box spanner insert, wrench opening 24, reinforced
l Socket wrench insert, wrench size 14, reinforced: 8015
l Socket wrench insert, wrench size 22, reinforced: 8035
Special tools:
l Rotation device: 100350
20.26.1 - Disassembly of the crankshaft

1. m Disassemble the injection valves.
m Disassemble the assembly support.
m Disassemble the rear cover.
© 40479-0
Fig. 299
2. m Screw in all the screws (1).
© 40470-0
Fig. 300
3. m Apply rotation device (1).
© 40471-0
Fig. 301
20-112
Engine
4. m Move the counterweights (1) of cylinders A1/B1 to bottom dead cen-
tre. 1
m Rotate the crankshaft using the rotation device.
m Remove the counterweights (1).
NOTE 2 2

they were removed.
© 42140-1
Fig. 302
5. m Move the counterweights (1) of cylinders A3/B3 to bottom dead cen-
tre.
m Remove the counterweights (1).
NOTE 2 2
they were removed.
© 40480-0
Fig. 303
6. m Move the connecting rod pins of the respective cylinder to the lower
dead centre.
WARNING
Do not bend the connecting rod drums while rotating the
crankshaft.
© 40496-0
Fig. 304
20-113
Engine
20-114
Engine
10. m Remove flanged bearing cover (1).
m Remove the flanged bearing shell.
m Remove the lower halves of the thrust ring (arrows). 1
m Remove all the main bearing covers (2).
m Remove the main bearing shells.
NOTE
1 - 2724 A
2 - 2724 A
3 - 2724 A
4 - 2724 A
they were removed. Note the cylinder order.
© 42144-1
Fig. 308
11. m Delicately extract the connecting rod drums from the relative pins.
© 40484-0
Fig. 309
12. m Remove the rotation device.
m Extract the crankshaft by applying leverage.
m Rest the crankshaft on the prisms.
© 42145-1
Fig. 310
20-115
Engine
13. m Remove the upper halves of the thrust ring (arrows).
m Remove all the main bearing shells (1).
m Remove all the connecting rod bearing shells (2).
NOTE
Put the components to one side in the order in which 1
© 37041-1
Fig. 311
14. m Check the crankshaft.
See para. 20.21 - Crankshaft check (L3) - page 20-84
m Check the endfloat of the crankshaft (disassembled crankshaft).
See para. 20.19 - Check the endfloat of ... - page 20-76
© 40485-0
Fig. 312
20.26.2 - Assembly of the crankshaft

1. m Insert the upper shells of the main bearings.
WARNING
1
© 37042-1
Fig. 313
20-116
Engine
2. m Insert the lower shells of the main bearings in the relative main bear-
ing covers. 1
WARNING
© 37043-1
Fig. 314
3. m Insert the connecting rod bearing shell into the connecting rod drum.
WARNING
Take care to couple the bearing shells. Fit the big end bear- 1
ing shell with the anodized black rear side in the connecting
rod shank. The anti-twist safety (1) must enter the groove
(2)
© 37044-1
Fig. 315
4. m Fit the connecting rod bearing shells in the relative connecting rod
bearing cover.
WARNING
© 36769-1
Fig. 316
20-117
Engine
5. m Oil the surfaces of the bearings.
© 40488-0
Fig. 317
6. m Delicately insert the crankshaft in the crankcase.
WARNING
Do not bend the connecting rod drums while inserting the
crankshaft!
m Align the crankshaft with (1) the camshaft.

NOTE
1
The notch in the crankshaft gear must be between
the reference points on the camshaft gear.
© 37045-1
Fig. 318
© 40470-0
Fig. 319
20-118
Engine
8. m Assemble the upper thrust ring halves based on the measured end-
float.
NOTE
2
The oil grooves (1) face towards the shoulder disc
(2) of the crankshaft. Insert the thrust ring halves
between the crankcase and the crankshaft shoulder
(arrows).
© 42180-1
Fig. 320
9. m Assemble the lower thrust ring halves based on the measured end-
float.
m Fix the thrust ring halves with a small amount of grease on the
flanged bearing cover.
NOTE
Use the halves of the thrust ring with the key (arrow).
The oil grooves (1) face towards the shoulder disc of
the crankshaft. Flanged bearing cover marked with
“3”.
1
© 40489-0
Fig. 321
10. m Insert the flanged bearing cover (1).
m Fit all the big end bearing covers (2).
NOTE 1
Pay attention to the attribution and assembly posi-

tion: Identifying main bearing cover: With marking “1”
= flywheel side. With marking “4” = side opposite fly-
1 - 2724 A
2 - 2724 A
3 - 2724 A
4 - 2724 A
wheel. Marking visible from flywheel side.
2 2 2
© 42146-2
Fig. 322
20-119
Engine
1
WARNING
maximum of 3 times.
1
© 42147-1
Fig. 323
12. m Lightly oil the screws.
m Screw in all the screws (1).
WARNING
maximum of 3 times.
m Turn the crankshaft backwards and forwards. 1

NOTE
This will orient the flanged bearing correctly.
© 42148-1
Fig. 324
13. m Tighten all the screws (arrows) with the socket wrench insert (wrench
size 24) and the rotation angle gauge.
WARNING
Do not over-tighten the main bearing covers.
© 40491-0
Fig. 325
20-120
Engine
14. m Tighten all the screws (arrows) with the socket wrench insert 8035
and the rotation angle gauge.
© 40492-0
Fig. 326
15. m Check the assembly position of the connecting rod drums.
NOTE
The flat side (arrow) must face towards the flywheel
on bank A and towards the ancillary mount on bank
B.
© 37204-1
Fig. 327
16. m Carefully tighten the connecting rod drums on the connecting rod
pins.
© 42151-1
Fig. 328
20-121
Engine
17. m Move the connecting rod pins of the respective cylinder to the lower
dead centre.
WARNING
Make sure the connecting rod drums do not bend at an an-
gle during crankshaft rotation.
© 40493-0
Fig. 329
WARNING
Pay attention to the attribution and the assembly position:
The numeric marks (1) on the connecting rod drum and on
the connecting rod bearing cover must be identical and po-
sitioned in front of each other during assembly. 1
© 37055-1
Fig. 330
19. m Tighten the new screws using the socket wrench insert 8015 and the
rotation angle gauge.
© 37056-1
Fig. 331
20-122
Engine
20. m Bring the crankpins of the respective cylinder to bottom dead centre.
m Pay attention to the tightening bushes (1).
1 1
© 42152-1
Fig. 332
21. WARNING
1 1 1
Pay attention to the attribution and the assembly position:
Counterweight positions: counterweight with marking “1” =
flywheel side. The flat sides (1) must face towards the main
bearing cover.
1
© 37057-2
Fig. 333
22. m Fit the counterweights according to the markings. 2
© 42153-1
Fig. 334
20-123
Engine
23. m Lightly oil the screws.
Fig. 335
24. m Remove rotation device (1).
© 40471-0
Fig. 336
© 40470-0
Fig. 337
20-124
Engine
26. m Check the endfloat of the crankshaft (assembled crankshaft).
© 40494-0
Fig. 338
27. m Assemble the rear cover.
m Assemble the assembly support.
© 40495-0
Fig. 339
20-125
Engine
20.27 - Disassembly and assembly of the piston and connecting rod
drum (L3)
l Circlip pliers
Special tools:
l Piston ring compression collar 130650
20.27.1 - Disassembly of the piston and connecting rod drum

NOTE
1
Washers: maximum thickness 4 mm. Screw length:
M16 x 90
© 40873-0
Fig. 340
2. m Remove the oil suction pipe.
m Remove the oil pickup pipe (Railway).
© 40591-0
Fig. 341
3. m Move the piston to bottom dead centre.
m Unscrew the screws (1) using the box spanner insert.
© 42375-1
Fig. 342
20-126
Engine
4. m Remove the big end bearing cover with the bearing shell.
NOTE

© 40821-0
Fig. 343
5. m Move the piston to top dead centre.
m Withdraw the connecting rod bearing shell.
m Withdraw the piston and connecting rod drum by placing pressure
on them.
WARNING
During removal, do not bend the connecting rod shank in-
side the cylinder sleeve!
NOTE
Put the components to one side in the order in which they
were removed. Note the cylinder order.
© 42376-1
Fig. 344
© 40592-0
Fig. 345
20-127
Engine
7. m Disassemble the safety ring using the specific pliers.
m Pressure remove the piston pin.
m Disassemble the safety ring using the specific pliers.
WARNING
Ensure that the surface of the piston is easily accessible.
© 42377-1
Fig. 346
20.27.2 - Assembly of the piston and connecting rod drum

1. m Insert a new circlip.
NOTE
Check the installation position is correct.
© 42378-1
Fig. 347
2. m Insert the connecting rod drum.
WARNING
The concave surface (arrow) of the connecting rod shank
must face towards the aperture (1) for the piston cooling
nozzle on the piston.
© 40967-0
Fig. 348
20-128
Engine
3. m Lightly oil the piston pin.
m Fit the piston pin into the piston.
m Insert a new circlip.
NOTE
Check the installation position is correct.
© 42379-1
Fig. 349
4. WARNING
Take care to couple the bearing shells. Insert the connecting 2
rod bearing shell with the black anodized back (arrow) into
the connecting rod drum. The anti-twist safety (1) must enter
the groove (2).
m Insert the connecting rod bearing shell into the connecting rod drum.
© 36768-1
Fig. 350
5. m Insert the connecting rod bearing shell into the relative flanged bear-
ing cover.
WARNING
© 36769-1
Fig. 351
20-129
Engine
6. m Offset the piston ring joints by approx. 120°.
m Check the piston rings and grooves.
See para. 20.29 - Check the piston rings... - page 20-136
© 42380-1
Fig. 352
7. m Lightly oil the cylinder sliding surface, piston, piston rings and con-
necting rod pins.
m Tighten the piston rings with a compression collar (1).
NOTE
Never rotate the piston rings.
1
© 36771-1
Fig. 353
8. m Move the connecting rod pins to the bottom dead centre.
m Insert the piston and connecting rod drum in the cylinder liner.
NOTE
Pay attention to the piston cylinder allocation. Mark
(1) the assembly position on the underside of the pis-
1
ton. The arrow must face towards the exhaust side.
The piston ring compression collar must rest lightly
on the cylinder liner.
© 36772-1
Fig. 354
20-130
Engine
9. m Check the assembly position of the connecting rod drums.
WARNING
1 1
The flat side (1) must face towards the adjacent crank shoul-
der (2). 2
2
© 40964-1
Fig. 355
10. m Delicately press the connecting rod drum against the connecting rod
pins.
WARNING
Do not bend the connecting rod drum with the crankshaft.
Do not damage the piston cooling nozzle.
© 42381-1
Fig. 356
WARNING
© 42382-1
Fig. 357
20-131
Engine
12. m Tighten the new screws with the box spanner insert and the rotation
angle gauge.
© 42383-1
Fig. 358
13. m Fit the oil suction pipe.
m Fit the oil pickup pipe (Railway).
© 40591-0
Fig. 359
14. m Remove the screws and washers (1).
© 40873-0
Fig. 360
20-132
Engine
20.28 - Check the piston (L3)
l Palmer
Special tools:
NOTE
If the piston wear limit was reached, replace it.
20.28.1 - Check of the piston pin hole

© 42229-1
Fig. 361

nal bore meter.

gauge to “0”.
© 34768-2
Fig. 362
20-133
Engine
3. NOTE
Measurement diagram of the piston pin hole in points “a”
© 37239-1
Fig. 363
pointer.
NOTE
© 36484-2
Fig. 364
20.28.2 - Check the piston diameter

1. NOTE
Measurement diagram of the piston diameter in points “1, 2
and 3”, transversal to the piston pin hole.
© 37244-1
Fig. 365
20-134
Engine
2. m Use the palmer to measure the diameter.
NOTE
© 40969-0
Fig. 366
© 40592-0
Fig. 367
20-135
Engine
20.29 - Check the piston rings and piston grooves (L3)
l Feeler gauges
Special tools:
l Universal pliers for piston rings: 130300
l Trapezoidal groove wear gauge: 130400
20.29.1 - Check the piston rings and piston grooves

m Set the universal pliers for the rings based on the piston diameter.
m Disassemble the piston ring with universal pliers.
© 42323-1
Fig. 368
2. m Clean the piston.
m Clean the piston ring grooves.
© 42322-1
Fig. 369
3. m Measure the race of the first piston ring using a trapezoidal race
wear gauge.
© 33866-2
Fig. 370
20-136
Engine
4. NOTE
If there is a distance “S” between the trapezoidal race wear S
gauge and the piston, the piston can still be used.
© 33867-2
Fig. 371
5. NOTE
If the trapezoidal race wear gauge rests on the piston (ar-
row) the latter must be replaced.
© 33868-2
Fig. 372
20.29.2 - Check the coupling clearance of the piston rings

1. m Insert the piston ring (1) in the cylinder.
m Align the rings, pushing the piston into the cylinder.
© 42321-1
Fig. 373
20-137
Engine
2. m Measure the coupling clearance of the piston rings with the feeler
gauge.
NOTE
The piston ring wear limit was reached, replace it.
© 42320-1
Fig. 374
20.29.3 - Assembly of the piston ring

1. Sequence and position of the piston rings viewed from
the bottom of the piston: 1
dual trapezoid section rings (1), conical section ring (2), oil
2
scraper ring with spiral spring (3). The marking “Top“ in (1)
and (2) is facing towards the combustion chamber
3
© 42319-1
Fig. 375
2. m Assemble the piston ring with universal pliers.
NOTE
Offset the flexible coupling of the oil scraper ring by
180° with respect to the ring coupling.
© 42318-1
Fig. 376
20-138
Engine
20.29.4 - Check the endfloat of the piston ring
1. NOTE
Perform the check with new piston rings.
m Check the endfloat between the piston and the groove of the piston
ring using the feeler gauge.
NOTE
If the piston wear limit was reached, replace it.
© 42317-1
Fig. 377
© 40592-0
Fig. 378
20-139
Engine
20.30 - Fitting and removing piston cooling nozzle (L3)
Special tools:
l Tester: 102560
l Measurement rod: 102565
20.30.1 - Disassembly of the piston cooling nozzle

m Remove the pressure cut-off valve (1).
m Remove the piston cooling nozzle (2).
2
1
© 42353-1
Fig. 379
20.30.2 - Assembly of the piston cooling nozzle

1. m Fit the piston cooling nozzle.
m Screw the pressure cut-off valve firmly into its seat.
NOTE
The flat side (1) must face towards the cylinder
sleeve.
1
© 42354-1
Fig. 380
20.30.3 - Measuring spray angle of piston cooling nozzle

1. WARNING
Take care not to damage the cylinder sleeve when applying
the tester.
1
m Place the tester inside the cylinder sleeve.
m Place the tester with the holes (1) over the locating doweles (2).
© 40787-0
Fig. 381
20-140
Engine
2. m Insert the measurement rod (1) in the holes (2) of the tester.
1
2
© 42356-2
Fig. 382
3. m Insert the tip of the measurement rod (1) into the hole of the piston
cooling nozzle (2).
NOTE
Rotate the piston cooling nozzle during this step.
1
WARNING 2
Replace the piston cooling nozzle if it cannot be rotated!

Do not bend the piston cooling nozzle! The piston cooling
nozzle must be aligned correctly with the measurement rod!
© 42357-1
Fig. 383
4. m Tighten the pressure cut-off valve.
WARNING
Prevent the piston cooling nozzle from turning.
© 42358-1
Fig. 384
20-141
Engine
5. m Remove the measurement rod.
m Remove the tester.
m Assemble the piston and the connecting rod drum.
© 40992-0
Fig. 385
20-142
Engine
20.31 - Removing and fitting crankcase breather (oil separator)
(L3)
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
20.31.1 - Removal of the crankcase breather

1. m Remove screw (1).
© 40664-0
Fig. 386
2. m Loosen hose clip (1),
m Loosen hose clip (2),
m Remove the pipe (3).
m Remove the intake manifold (4).
4
2 3
© 45807-0
Fig. 387
3. m Loosen the hose clips (1).
© 40667-0
Fig. 388
20-143
Engine
4. m Loosen the hose clamp (1).
© 40668-0
Fig. 389
5. m Remove the oil separator (1) together with the pipe.
© 40669-0
Fig. 390
6. m Remove the pipe (1).
© 45401-0
Fig. 391
20-144
Engine
© 40671-0
Fig. 392
20.31.2 - Refitting the crankcase breather

1. m Connect the pipe (1).
m Fill the oil trap (2) with lubricant oil.
1
© 40670-0
Fig. 393
2. m Fit the oil separator (1) on the flanged pipe (2).
NOTE
1
Do not move the spring (arrow).
© 40672-0
Fig. 394
20-145
Engine
3. m Fit the intake manifold (4).
NOTE
Observe the installation position.
1
m Position the sleeve tightening clip (1).
m Tighten the pipe retaining clip (1).
m Connect the pipe (3).
m Fit the hose clamp (2)
m Tighten the hose clip (2). 4
2 3
© 45807-0
Fig. 395
4. m Locate hose clip (1).
m Tighten the hose clamp (1).
© 45808-0
Fig. 396
5. m Fit the hose clamps (1).
m Tighten the hose clamps (1).
© 40667-0
Fig. 397
20-146
Engine
6. m Tighten screw (1).
© 40664-0
Fig. 398
20-147
Engine
20.32 - Checking the cylinder sleeve (L3)
l Depth gauge
l Palmer
Special tools:
NOTE
The following procedure must be carried out for each cylinder unit in a cylinder set.
20.32.1 - Cylinder liner check

1. m Disassemble the cylinder liner.
m Check the sliding surface of the cylinder.
© 45423-0
Fig. 399

nal bore meter.

n Adjust the bracket measurement screw to 132 mm.
gauge to “0”.
© 36094-1
Fig. 400
20-148
Engine
3. NOTE
Diagram for measuring the cylinder sleeve at points “a” and
“b” on surfaces “1” - “4”. 1
© 37238-1
Fig. 401
4. m Remove the shim (1).
m Visually check that the support surface is levelled (arrow).
1
m Visually inspect the sealing surface.
© 40677-0
Fig. 402
pointer.
NOTE
Measurement points, see diagram. Replace the cyl-
inder sleeve if the wear limit has been reached.
© 42394-1
Fig. 403
20-149
Engine
6. m Measure the shoulder height in the zone (X) with the palmer.
NOTE
X
Carry out the measurement in different points of the
support.
m Assemble the cylinder liner.

© 42395-1
Fig. 404
20-150
Engine
20.33 - Fitting and removing the cylinder sleeve (L3)
l Depth gauge
Special tools:
l Assembly device: 150120
l Extraction device: 150130
l Assembly product: DEUTZ AP1908
20.33.1 - Disassembly of the cylinder liner

© 40826-0
Fig. 405
2. m Mark the installation position of the cylinder sleeve in the cylinder
block.
m Mark the cylinder sleeve with the respective marking for the cylinder.
© 51521-1
Fig. 406
3. m Turn the plate over and fit the extractor.
n Fit the plate (1) with the surfaces supported on the cylinder
liner (2) and keep it supported.

n Fit the tailstock (3) on the crankcase (4).
1
3
WARNING
Do not damage the sliding and sealing surfaces. Do not
damage the piston cooling nozzle.
NOTE 4
2
The crankshaft counterweights must face towards the lubri-
cant oil sump.
© 36782-1
Fig. 407
20-151
Engine
4. m Withdraw the cylinder liner towards the top.
NOTE
Turn the nut in the direction of the arrow.
m Disassemble the extraction device.

m Withdraw the cylinder liner towards the top.
© 42230-1
Fig. 408
5. m Remove the shim (1).
m Visually check that the support surface is levelled (arrow).
1
m Visually inspect the sealing surface.
© 40677-0
Fig. 409
6. m Remove the two O-rings (arrows).
m Check the cylinder sleeves.
See para. 20.32 - Checking the cylinder ... - page 20-148
© 42231-1
Fig. 410
20-152
Engine
20.33.2 - Assembly of the cylinder liner
1. m Fit new O-rings (arrowed).
NOTE
Gently move the O-rings away to prevent them from
dropping during assembly.
© 42231-1
Fig. 411
2. m Measure that the support surface is level using a depth gauge.
NOTE
Carry out the measurement in different points of the
support.
© 42392-1
Fig. 412
3. m Insert the shim (1).
NOTE 1
A centring pin (2) faces upward.

2
© 39911-0
Fig. 413
20-153
Engine
20-154
Engine
7. m Press the cylinder sleeve fully into its seat.
© 42233-1
Fig. 417
8. m Check the protrusion of the cylinder liner.
See para. 20.34 - Checking cylinder slee... - page 20-156
m Assemble the piston and the connecting rod drum.
© 40583-0
Fig. 418
20-155
Engine
20.34 - Checking cylinder sleeve protrusion (L3)
Special tools:
20.34.1 - Check the protrusion of the cylinder liner

NOTE
1
Washers: maximum thickness 4 mm. Screw length:
M16 x 90
© 45424-0
Fig. 419
m Apply the preloaded dial gauge probe on the sealing surface of the
crankcase (arrow).
m Turn the dial until the needle indicates “0”
© 45762-0
Fig. 420
m Carefully turn the magnetic measurement stand until the probe is in
contact with the seal surface of the cylinder sleeve (arrow).
m Apply the magnetic stand for measurements.
NOTE
Take the measurement in at least 3 other points.
© 45761-0
Fig. 421
20-156
Engine
© 45424-0
Fig. 422
20-157
Engine
20.35 - Removing and fitting ancillary mount (L3)
l Insertion open-ended wrench, wrench width 22
l Sealant: DEUTZ DW 47
NOTE
20.35.1 - Disassembly of the assembly support

m Remove holder (2). 2
© 40519-0
Fig. 423
m Remove holder (2).
m Unscrew banjo bolt (3)
m Remove seals (4).
1
2 3
© 40520-1
Fig. 424
3. m Unscrew nuts (1).
© 40521-0
Fig. 425
20-158
Engine
4. m Unscrew banjo bolt (1)
NOTE
Retain the overflow valve.
m Remove fuel line (3).

m Remove oil seals (2). 1
3
© 45803_0
Fig. 426
5. m Disassemble the thermostat box.
m Disassemble the coolant pump.
m Remove all the screws (1). 1
m Remove the flanged hub with the torsional vibration damper and
the V-belt.
NOTE
© 40531-0
Fig. 427
6. m Remove cable tie (1)
© 40532-0
Fig. 428
20-159
Engine
© 40533-0
Fig. 429
© 40534-0
Fig. 430
9. m Disassemble the oil intake pipe.
© 40535-0
Fig. 431
20-160
Engine
10. m Unscrew the union nuts (1).
m Remove the lubricant oil pipe.
m Remove the seals.
1
© 40536-0
Fig. 432
1
2
1
© 40538-0
Fig. 433
m Remove the support.
© 40539-0
Fig. 434
20-161
Engine
1
© 40540-0
Fig. 435
1
2
© 40541-0
Fig. 436
m Remove the gasket. 1
WARNING
When removing the ancillary mount, take care not to dam-
age the crankpin. 1
NOTE
The teeth of the oil pump wheels and the intermediate wheel
must engage in the teeth of the wheel actuating the crank-
shaft. Use a suitable hoist.
© 40542-0
Fig. 437
20-162
Engine
© 40543-0
Fig. 438
17. m Remove the crankshaft O-ring (1).
WARNING
Be careful not to damage the mating surfaces when remov-
ing the front cover.
© 40544-0
Fig. 439
20.35.2 - Fitting the ancillary mount

m Fix the new O-rings (1) in place with a little grease.
1 1
© 40545-0
Fig. 440
20-163
Engine
2. m Fix the new gasket (1) to the crankcase with a little grease.
NOTE
1
The seal surface of the oil sump relative to the crank-
case must face upwards. Make sure the cylindrical
pins (arrow) are present.
© 40546-0
Fig. 441
3. m Assemble the assembly support.
NOTE 1
Use a suitable hoist.
m Align the ancillary mount on the cylindrical pins.

m Fasten the ancillary mount with the screws (1).
NOTE
The teeth of the oil pump wheels and the interme-
diate wheel must engage in the teeth of the wheel
actuating the crankshaft. Screw length:
M10 x 150 mm
© 40547-0
Fig. 442
4. m Tighten the screws in alternate sequence (1).
Screw length: 1
M10 x 150 mm
© 40548-0
Fig. 443
20-164
Engine
5. m Screw in the screws alternately
Screw length
M10 x 65 mm (1), M10 x 100 mm (2)
1
2
© 40541-0
Fig. 444
6. m Tighten the screws in alternate sequence (1).
Screw length: 1
M10 x 110 mm
1
© 40540-0
Fig. 445
7. m Fit the mount.
NOTE
Tighten the screws only after fitting the connector
line.
© 40539-0
Fig. 446
20-165
Engine
8. m Screw in the screws alternately
Screw length:
1
M10 x 70 mm (1), M10 x 110 mm (2)
2
1
© 40538-0
Fig. 447
9. m Tighten the screws in alternate sequence.
© 40551-0
Fig. 448
10. m Trim any protruding gasket (arrowed) flush with the mating surface
of the oil sump pan.
© 40549-0
Fig. 449
20-166
Engine
11. m Insert the new O-rings.
m Connect the lubricating oil pipe.
m Screw in banjo bolt (2).
m Screw the sleeve nuts (1).
1
© 40536-0
Fig. 450
12. m Tighten hollow screw (2).
m Tighten the union nuts (1).
1
© 40536-0
Fig. 451
m Fit the oil suction pipe.
NOTE
Before fitting the lubricant oil sump, fill the detach-
ment points between the crankcase/ancillary mount
(arrows) with sealant.
© 40550-0
Fig. 452
20-167
Engine
14. m Fasten the cable bundle with the clamps (1) without tension.
© 40534-0
Fig. 453
© 40533-0
Fig. 454
m Fit the front crankshaft oil seal (opposite end to flywheel)
See para. 20.23 - Replace the crankshaft... - page 20-93
© 40532-0
Fig. 455
20-168
Engine
17. m Fit the torsional vibration damper.
NOTE
1
m Assemble the coolant pump.

m Assemble the thermostat box.
© 40531-0
Fig. 456
18. m Fit new O-rings (3).
m Fit fuel line (2).
1
3
© 45803_0
Fig. 457
19. m Lightly oil the threads.
m Fit support (2).
m Screw in nut (1);
© 40521-0
Fig. 458
20-169
Engine
20. m Fit new seals (4).
m Fit support (2).
m Lightly oil the threads and the head contact surface.
m Screw in the screw (1). 1
2 3
© 40520-1
Fig. 459
NOTE
1
m Tighten nut (2).
© 40565-0
Fig. 460
m Tighten hollow screw (2).
1
© 40555-0
Fig. 461
20-170
Engine
23. m Fit support (2).
See para. 30.11 - Removing and fitting t... - page 30-47 2
1
© 40519-0
Fig. 462
20-171
Engine
20.36 - Removing and fitting ancillary mount (L3)
20.36.1 - Disassembly of the assembly support
1. m Disassemble the assembly support.
m Remove screw (1). 1
m Remove the shim (2).
m Remove the intermediate wheel (3).
2
© 40556-0
Fig. 463
m Remove the lubricant oil pump (3).
1
3 1
© 40557-0
Fig. 464
3. m Remove the connection fitting (1).
© 40558-0
Fig. 465
20-172
Engine
m Remove the intermediate piece (2).
m Remove the O-ring.
2
© 45371_1
Fig. 466
m Remove the bearing seat (2).
NOTE
1
The fuel delivery pump, intermediate wheel and fuel
lines must remain fastened to the bearing seat. 2
© 40559-0
Fig. 467
m Remove the ground cable (2).
3 1
1
© 40560_1
Fig. 468
20-173
Engine
1
© 40561-0
Fig. 469
m Remove oil radiator cover (4).
3 4 1
2
2
© 40562_1
Fig. 470
m Remove oil cooler (2)
1
1
© 40563-0
Fig. 471
20-174
Engine
20.36.2 - Refitting the ancillary mount
m Fit the new O-rings (1).
1 1
2 2
© 40564-0
Fig. 472
2. m Fit the lubricant oil cooler (2).
1
1
© 40563-0
Fig. 473
m Fit a new seal.
m Fit the oil radiator cover (4).
m Fit support (1).
m Tighten all the screws. 3 4 1
Screw length:
M8 x 35 mm (2), M8 x 65 mm (3)
2
2
© 40562_1
Fig. 474
20-175
Engine
© 40523-0
Fig. 475
5. m Align the oil radiator cover correctly.
NOTE
The support surfaces of the oil radiator casing and
1
the assembly support must be resting on the sup-
ports. Do not move the gasket.
© 40524-0
Fig. 476
NOTE
Only tighten the screws for the two mounts after fit- 1
ting the connector line.
© 40525-0
Fig. 477
20-176
Engine
m Connect the ground cable (2).
m Tighten (1) the screws. 2
3 1
1
© 40560_1
Fig. 478
8. m Fit a new O-ring.
m Fit the bearing seat (2).
© 40559-0
Fig. 479
9. m Fit the O-rings.
m Fit the intermediate piece (2).
m Tighten nut (1).
2
© 45371_1
Fig. 480
20-177
Engine
20-178
Engine
13. m Fit a new O-ring.
© 34738-2
Fig. 484
14. m Fit the lubricant oil pump (3).
m Lightly oil the screws.
m Fit the screws.
1
Screw length:
M10 x 75 mm (1), M8 x 45 mm (2).
3 1
© 40557-0
Fig. 485
15. m Tighten (1) the screws.
© 40648-0
Fig. 486
20-179
Engine
16. m Lightly oil the bearing pins (1).
m Lightly oil the bearing bush (2). 3
m Fit the intermediate wheel (3).
NOTE
The shim (arrow) of the intermediate wheel must face
towards the ancillary mount.
© 40529-0
Fig. 487
17. m Fit the shim (2).
NOTE
The bevelled side of the shim (arrow) must face up-
wards. 2
© 40530-0
Fig. 488
m Assemble the assembly support. 1
© 40537-0
Fig. 489
20-180
Engine
20.37 - Removing and refitting rear cover (L3)
20.37.1 - Removing the rear cover

1. m Disassemble the connector box.
m Remove the oil sump pan.
1
m Remove all the screws (1).
m Remove the rear cover (2).
2
© 40684-0
Fig. 490
2. m Remove crankshaft seal (1).
WARNING
Do not damage the mating surfaces.
© 37207-1
Fig. 491
© 40685-0
Fig. 492
20-181
Engine
20.37.2 - Fitting the rear cover
1. m Clean the sealing surfaces
m Check that the bushes (arrowed) are present.
NOTE
The slots in the locating dowel must face downwards.
© 40686-0
Fig. 493
2. m Fit a new gasket (1)
© 40687-0
Fig. 494
3. m Fit the rear cover.
NOTE
Use new seals.
1
m Fit the screws.

m Fit screws (1) using thread locking agent.
Screw length: 3 3
M8 x 30 mm (1),(3), M8 x 45 mm (2)
2
m Tighten the screws in alternate sequence.

See para. 20.4 - Tightening torque (L3) - page 20-14 © 40688_1
Fig. 495
20-182
Engine
4. NOTE
Trim any protruding gasket (arrowed) flush with the mating
surface of the oil sump pan.
© 40689-0
Fig. 496
5. m Fit the oil sump pan.
m Assemble the connector box.
m Replace the crankshaft O-ring (flywheel end).
© 40655-0
Fig. 497
20-183
Engine
20.38 - Disassembly and assembly of the connector box (L3)
20.38.1 - Disassembly of the connector box

1. m Remove the crankshaft speed sensor.
See para. 30.46 - Removal and refitting ... - page 30-161
m Disassemble the starter.
m Disassemble the exhaust manifold.
m Remove the flywheel.
© 40690-0
Fig. 498
© 40691-0
Fig. 499
m Remove the housing with flange (3).
2
3
© 40692-0
Fig. 500
20-184
Engine
m Unscrew the screws (arrowed).
© 40693-0
Fig. 501
m Remove the connector box.
© 45394-0
Fig. 502
© 40899-0
Fig. 503
20-185
Engine
20.38.2 - Assembly of the connector box
1. m Clean the support surfaces.
m Apply sealant to the mating surface of the connector casing (arrow).
© 42087-1
Fig. 504
2. NOTE
Make sure the cylindrical pins (arrow) are present.
© 40695-0
Fig. 505
3. m Apply the connector box.
NOTE
Align on the cylindrical pins.
1
m Fit the screws.

NOTE 2
Apply the specified threadlocker to the screws before
fitting. Note that the screws are of different lengths
M12 x 35 mm (1), M12 x 90 mm (2).
© 40694-0
Fig. 506
20-186
Engine
© 40696-0
Fig. 507
5. m Fit the screws.
NOTE
fitting. Note that the screws are of different lengths
1
M12 x 200 mm (1), M12 x 175 mm (arrows).
m Tighten the screws (1) alternately.
© 40693-0
Fig. 508
6. m Tighten the screws (arrowed).
© 40697-0
Fig. 509
20-187
Engine
7. m Fit a new O-ring (1).
m Apply the fastening product on the resting surface (arrow).
© 45409-0
Fig. 510
8. m Fit the housing with flange (3).
Screw length:
M10 x 110 mm 1

Screw length:
2
M10 x 210 mm
3
© 40692-0
m Tighten (1) the screws. Fig. 511

© 40698-0
Fig. 512
20-188
Engine
10. m Tighten the screws (arrowed).
© 40691-0
Fig. 513
11. m Fit the flywheel.
m Assemble the starter.
m Fit the crankshaft speed sensor.
m Assemble the exhaust manifold.
© 40451-0
Fig. 514
20-189
Engine
20.39 - Correcting contact points of cylinder sleeve (L3)
Special tools:
l Tool set: 150030
l Repair kit
l Assembly product: DEUTZ AP 1908
l Detergent (e.g. commercially available detergent for brakes).
NOTE
In the event of coolant leakage or damage to the cylinder block/cylinder sleeve/cylinder head gasket, the mating
surface between the cylinder sleeve collar and the cylinder block may be corrected. The following procedure must be
carried out for each cylinder unit in a cylinder set.
20.39.1 - Grinding the mating surface

1. m Disassemble the cylinder liner.
m Close the interior spaces of the cylinder block with cover plates (1). 1
© 39914-0
Fig. 515
2. m Clean the mating surface (1).
m Clean the spaces inside the crankcase.
NOTE
Use detergent.
1
© 39902-0
Fig. 516
20-190
Engine
20.39.2 - Grinding the mating surface to clean
1. m Apply finishing paste (1) on the support surface (2).
m Add a bit of clean water. 1 2
© 39908-0
Fig. 517
2. m Fit brackets and handles on the grinding disc/check plate.
NOTE
A
Pay attention to the different working sides of the con-
trol plate/grinding disc: A - grinding side, B - checking
side. Grinding side “A“ faces down.
m Place the ground side “A“ on the support surface.
© 39904-0
Fig. 518
3. m Turn the control plate/grinding disc (1) forward and backward in an
even manner (approx. 180°).
m Lightly grind the mating surface.
NOTE
Pay attention to a possible slight grinding noise.
1
m Clean the support surface.

m Remove the abrasive paste and the abrasive particles.
NOTE
Use detergent.
© 39906-0
Fig. 519
20-191
Engine
20.39.3 - Check
1. m Move the bracket on the control plate/grinding disc.
NOTE
B
The checking side “B” must face downwards.
m Apply a thin film of marking dye paste on the check side “B“.
NOTE
Do not apply an excessively thick layer of paste, as
this would impede identification of any concavity in
the mating surface.
© 39916-0
Fig. 520
2. m Place the check side “B“ against the mating surface.
NOTE
Pay attention to the different working sides of the
control plate/grinding disc: A - grinding side, B -
checking side.
m Correct the mating surface.
© 39906-1
Fig. 521
3. NOTE
Use the checking and correction procedure to identify and
correct any concavity (1) in the mating surface. 1
© 39913-0
Fig. 522
20-192
Engine
20.39.4 - Grinding
NOTE
A
Grinding side “A“ faces down.
© 39904-0
Fig. 523
2. m Apply rough grinding paste (1) on the mating surface (2).
m Add a bit of clean water. 1
© 39907-0
Fig. 524
3. m Place the ground side “A“ on the support surface.
m Turn the control plate/grinding disc (1) forward and backward in an
NOTE
Lift the control plate/grinding disc various times in
1
order to distribute the abrasive paste. During the pro-
cedure, listen for excessively rough grinding noise.
NOTE
Use detergent.
© 39906-0
Fig. 525
20-193
Engine
20.39.5 - Check
1. m Check the contact surface.
NOTE
The contact surface must be uniform. If not, repeat
the grinding and checking procedure.
© 39912-0
Fig. 526
20.39.6 - Finishing
NOTE
A
Grinding side “A“ faces down.
© 39904-0
Fig. 527
2. m Apply finishing paste (1) on the support surface (2).
m Add a bit of clean water. 1
© 39907-0
Fig. 528
20-194
Engine
3. m Turn the control plate/grinding disc (1) forward and backward in an
NOTE
Lift the control plate/grinding disc various times in or-
der to distribute the abrasive paste. Pay attention to 1
a possible slight grinding noise.
NOTE
Repeat the checking procedure one more time.
© 39906-0
Fig. 529
4. m Clean the spaces inside the crankcase.
m Remove the cover plates (1).
m Ensure that the interior of the cylinder block is clean. 1
NOTE
Clean the set of tools and lightly oil the grinding disc/
checking plate to prevent corrosion.
© 39914-0
Fig. 530
20.39.7 - Installation
1. m Fit the new O-rings (1).
m Apply a thin coating of assembly product to the O-rings.
1
© 39917-0
Fig. 531
20-195
Engine
2. m Insert the shim (1).
1
NOTE
A centring pin (2) faces upward.
2
© 39911-0
Fig. 532
3. m Install a new cylinder sleeve (1).
1
© 39918-0
Fig. 533
20-196
Engine
20.40 - Fitting and removing the camshaft bearings, checking (L3)
l Palmer
Special tools:
20.40.1 - Check the camshaft bearings

1. m Disassemble the camshaft.
© 42126-1
Fig. 534

nal bore meter.

n Adjust the palmer to 70 mm.
gauge to “0”.
© 34768-2
Fig. 535
3. NOTE
Measurement diagram of the camshaft bearing in points “a”
© 37239-1
Fig. 536
20-197
Engine
pointer.
NOTE
Measurement points, see diagram. If the camshaft
bearing wear limit was reached, replace it.
© 42127-1
Fig. 537
20.40.2 - Disassembly of the camshaft bearings

1. m Insert the chuck (1) with the extractor fitting (2) in the side opposite
the flywheel.
© 34711-2
Fig. 538
2. m Apply the tailstock (1) on the flywheel side.
1
© 34712-1
Fig. 539
20-198
Engine
3. m Fit the spacer bush (1)
m Fit the ball bearing (2).
m Tighten the nut.
1
© 34713-2
Fig. 540
4. m Remove the camshaft bearings in sequence.
NOTE
Do not remove the flywheel side camshaft bearings.
© 34714-2
Fig. 541
5. m Insert the spindle with the extraction bush in the flywheel side.
m Apply the tailstock (1) to the side opposite the flywheel.
m Fit the spacer bush.
m Fit the ball bearings.
m Tighten the nut.
1
m Remove the flywheel side camshaft bearings.
© 34716-2
Fig. 542
20-199
Engine
20.40.3 - Assembly of the camshaft bearings
1. NOTE
Camshaft bearing installation depth.
Table 48
Depth measured on flywheel side D C B A

A 0 mm
B 172.5 (+ 0.2, - 0.2) mm
C 337.5 (+ 0.2, - 0.2) mm
D 502.5 (+ 0.2, - 0.2) mm
© 45415-1
Fig. 543
2. m Fit the new camshaft bearing (flywheel side) with the slot (1) facing
towards the flywheel.
NOTE
The image shows the camshaft bearing assembled.
The camshaft bearing (flywheel side) has two holes
for lubricant oil.
Pay attention to aligning the holes for the lubricant
oil (2) with the camshaft bearing and the crankcase.
1
© 37179-1
Fig. 544
3. m Fit the chuck with the tailstock in the side opposite the flywheel.
m Insert the extractor fitting into the camshaft bearing and slide it along
the chuck.
© 34718-2
Fig. 545
20-200
Engine
4. m Fit the spacer bush.
m Tighten the nut.
m Press the camshaft bearing (flywheel side) into its seat.
NOTE
Insertion depth, see diagram.
© 34720-2
Fig. 546
5. m Check the alignment of the lubricant oil holes (1).
NOTE
If the lubricant oil hole is not aligned, assemble and
disassemble the camshaft bearing one more time.
© 40900-0
Fig. 547
6. m Fit the new central flywheel side camshaft bearings with the slot (1)
facing towards the flywheel.
NOTE 1
The central camshaft bearings have three holes for
lubricant oil. Pay attention to aligning the holes for
the lubricant oil (2) with the camshaft bearing and the
crankcase.
2
© 37180-1
Fig. 548
20-201
Engine
7. m Fit the new camshaft bearing (side opposite flywheel) with the slot
(1) facing towards the flywheel.
NOTE 2
The camshaft bearing (side opposite flywheel) has
three holes for lubricant oil. Pay attention to aligning
the holes for the lubricant oil (2) with the camshaft
bearing and the crankcase.
1
© 37181-1
Fig. 549
8. m Fit the extractor fitting into the camshaft bearing.
m Insert the spindle with the extraction bush in the flywheel side.
© 34723-2
Fig. 550
9. m Fit the counterhead.
m Fit the spacer bush.
m Tighten the nut.
m Install the camshaft bearings in sequence.
WARNING
Take care not to damage the camshaft bearings when re-
placing the installation tool!
NOTE
Insertion depth, see diagram.
© 34714-2
Fig. 551
20-202
Engine
10. m Check the alignment of the lubricant oil holes (1).
NOTE
If the lubricant oil hole is not aligned, assemble and 1
disassemble the camshaft bearing one more time.
m Assemble the camshaft.

© 40901-0
Fig. 552
20-203
Engine
20.41 - Fitting and removing tappets, checking tappet holes (L3)
l Palmer
20.41.1 - Disassembly of the tappet

m Removing the tappet.
NOTE
© 37198-1
Fig. 553
© 40699-0
Fig. 554
20.41.2 - Measuring the tappet holes

1. m Adjust the bracket measurement screw to 25 mm.
© 35825-2
Fig. 555
20-204
Engine
2. m Measure the tappet holes with a bore gauge.
X
© 34707-4
Fig. 556
20.41.3 - Assembly of the tappet

1. m Lightly oil all the tappets.
m Insert all the tappets.
NOTE
Pay attention to couple the tappets.

© 37199-1
Fig. 557
20-205
Engine
20.42 - Disassembly and assembly of the gear case cover (L3)
NOTE
20.42.1 - Disassembly of the gear case cover

1. m Remove the turbocharger.
© 40700-0
Fig. 558
m Remove the pipe (2).
1
2
© 40701-0
Fig. 559
© 40702-0
Fig. 560
20-206
Engine
m Remove the spacer bushes.
m Unscrew all the screws (2).
1
m Remove the heat shield (3). 2
© 40703-0
Fig. 561
© 40704-0
Fig. 562
m Remove the hose clip (2).
© 40705-0
Fig. 563
20-207
Engine
m Remove the gear box cover (2).
© 40706-0
Fig. 564
© 40707-0
Fig. 565
20.42.2 - Assembly of the gear case cover

1. WARNING
Do not damage the mating surfaces.
1
2
2
m Clean the mating surfaces.
m Apply sealant evenly to the sealing surface.
m Fit the gear box cover (1).
m Fit support (2).
© 40708-0
Fig. 566
20-208
Engine
2. m Fit the hose clip (2).
© 40705-0
Fig. 567
© 40704-0
Fig. 568
4. m Fit the heat shield (3).
m Fit the spacer bushes with the screws (1).
1
m Screw in all the screws (2). 2
m Tighten all the screws.
3
© 40703-0
Fig. 569
20-209
Engine
© 40702-0
Fig. 570
6. m Connect the pipe (2).
1
2
© 40701-0
Fig. 571
7. m Fit the turbocharger.
1
© 40700-0
40703-0
Fig. 572
20-210
Engine
20.43 - Disassembly and assembly of the gear case cover (L3)
NOTE
20.43.1 - Disassembly of the gear case cover

1. m Unlock and disconnect wiring connectors (1).
m Remove cable tie (2)
m Release the cables.
© 42108-1
Fig. 573
m Disassemble the discs.
m Remove the fuel pressure regulator valve.
See para. 30.19 - Assembly and disassemb... - page 30-83 1
© 45777-0
Fig. 574
m Remove the disc. 3
m Remove the spacer bush (2).
m Loosen the hose clamp (3).
© 45775-0
Fig. 575
20-211
Engine
m Remove the disc.
1
2
© 45776-0
Fig. 576
© 42416-2
Fig. 577
© 40707-0
Fig. 578
20-212
Engine
20.43.2 - Assembly of the gear case cover
m Fit a new seal.
1
© 42416-2
Fig. 579
m Fit support (2).
3
m Fit the washer.
1
2
© 45776-0
Fig. 580
m Locate spacer (2). 3
m Fit the washer.
2
© 45775-0
Fig. 581
20-213
Engine
4. m Position the cable bundle guide with the cable bundle.
m Locate hose clip (1).
m Insert the shims.
1
m Fit the screws. 3
Note that the screws are of different lengths
M6 x 12 mm (1), M6 x 16 mm (2)
m Tighten the screws. 2

© 45778-1
Fig. 582
5. m Fit the fuel pressure regulator valve.
© 45779-1
Fig. 583
6. m Reconnect wiring connector (1).
NOTE
Make sure the cables are connected correctly.
m Secure the cables with cable tie (2).

1
© 42108-1
Fig. 584
20-214
Engine
20.44 - Assembly and disassembly of the camshaft (L3)
l Lifting device
l Depth gauge
Special tools:
l Counterhead: 144150
l Adhesives/sealants: DEUTZ DW 72
20.44.1 - Disassembly of the camshaft

1. m Disassemble the rocker support.
m Disassemble the crankshaft.
m Disassemble the speed indicator (camshaft).
© 40409-0
Fig. 585
2. m Disassemble the injection pumps (cylinder A1).
m Disassemble the injection pumps (cylinder A2-B3).
See para. 30.66 - Fitting and removing t... - page 30-266 1
NOTE 2
Do not disassemble the injection pump housing.

m Set aside the flexible fuel pipe (2).
m Remove the seals.
© 40458-0
Fig. 586
20-215
Engine
20-216
Engine
© 40413-0
Fig. 590
1 2
© 40414-0
Fig. 591
© 40415-0
Fig. 592
20-217
Engine
m Remove cover (2).
m Remove cover (3).
3
2
© 40416-0
Fig. 593
m Remove the axial segment support (2).
1
© 40417-0
Fig. 594
m Remove the ring gear (2).
WARNING 2
Make sure no parts fall into the crankcase.
NOTE
The hidden screws become accessible by turning the cam-
shaft with the rotation device. Push back the injection pump 1
camshaft to the end stop.
© 40418-0
Fig. 595
20-218
Engine
© 40419-0
Fig. 596
© 40420-0
Fig. 597
14. m Remove the pin (1).
© 40421-0
Fig. 598
20-219
Engine
© 40422-0
Fig. 599
© 40423-0
Fig. 600
© 40424-0
Fig. 601
20-220
Engine
m Remove cover (2).
Fig. 602
19. m Insert the blocking element (1) into the teeth of the camshaft gear
wheel.
© 40426-0
Fig. 603
20. m Turn the camshaft gear wheel in direction of bench A.
m Block the camshaft gear wheel with the blocking element on the
crankcase (arrow).
© 40427-0
Fig. 604
20-221
Engine
21. m Loosen screw (1).
m Turn the camshaft gear wheel backwards.
m Remove counterhead (2).
© 40428-0
Fig. 605
m Locate spacer (2).
NOTE
Push back the injection pump camshaft to the end
2
stop.
© 40429-0
Fig. 606
23. m Turn the engine over.
m Push back all the tappets.
m Detach the engine from the assembly stand on one side.
m Carefully remove the camshaft (1) on the flywheel side.
© 40430-0
Fig. 607
20-222
Engine
24. m Check the camshaft.
See para. 20.45 - Check the camshaft (L3) - page 20-239
© 36812-1
Fig. 608
20.44.2 - Assembly of the camshaft

1. m Lightly oil the camshaft bearings.
m Lightly oil the camshaft pins.
m Delicately insert the camshaft.
NOTE
The mating hole (1) of the camshaft must face to-
wards the lubricant oil sump.
© 37079-1
Fig. 609
2. m Measure the protrusion of the cylindrical pin with the depth gauge.
m Correct the protrusion.
© 40431-0
Fig. 610
20-223
Engine
3. m Fit the camshaft gear wheel (2).
m Lightly oil the screw (1).
m Screw in the screw (1).
NOTE
Pay attention to aligning the cylindrical on the cam- 2
shaft gear wheel with the coupling hole in the cam-

shaft.
© 40429-0
Fig. 611
wheel.
m Turn the camshaft gearwheel in the direction of bank B.
crankcase (arrow).
1
© 40432-0
Fig. 612
5. m Tighten the screw (arrowed).
m Turn the camshaft gear wheel backwards.
m Remove the counterhead.
© 40433-0
Fig. 613
20-224
Engine
20.44.3 - Calculate the camshaft endfloat
1. m Push the camshaft back to the end stop.
m Use a depth gauge to measure the remaining part of the camshaft
from the support surface of the camshaft gear wheel with respect to
the crankcase (arrows).
© 40434-0
Fig. 614
2. m Fit the new gasket (1).
m Use a depth gauge to measure the height of the flange from the slid-
ing surface to the support surface (arrows).
Table 49
Target: Endfloat
Data: -
1
© 42273-2
surement (b), 45.80 mm - 45.50 mm Fig. 615
m Use gaskets to correct any differences.

3. m Fit the cover (2).
NOTE
fitting.
1
m Fit the new O-rings.
© 40425-0
Fig. 616
20-225
Engine
m Lightly lubricate the O-ring.
m Check that the oil channel (arrow) is completely free.
1
© 40435-0
Fig. 617
5. m Lightly oil the bearing shell (1) with lubricant oil.
NOTE
The shoulder (arrow) is facing towards the bearing
bush.
© 40438-0
Fig. 618
6. m Insert the pin (1).
© 40437-0
Fig. 619
20-226
Engine
7. m Lightly oil the screw (1).
Screw length:
M12 x 80 mm
© 40423-0
Fig. 620
© 40422-0
Fig. 621
1
© 40435-0
Fig. 622
20-227
Engine
NOTE
bush.
© 40436-0
Fig. 623
© 40439-0
Fig. 624
Screw length:
1
M12 x 100 mm
Fig. 625
20-228
Engine
© 40419-0
Fig. 626
20.44.4 - Check the clearance of the tooth side on the intermediate wheel (bench B)
m Turn the intermediate wheel in the direction of the arrow to the end
stop.
m Place the preloaded probe on one side of the teeth.
m Adjust the dial gauge to “0”.
© 40440-0
Fig. 627
2. m Turn the intermediate wheel in the direction of the arrow to the end
stop.
NOTE
Repeat the measurement on different sides of the
teeth.

© 40441-0
Fig. 628
20-229
Engine
20.44.5 - Check the clearance of the tooth side on the intermediate wheel (bench A)
stop.
© 40442-0
Fig. 629
stop.
NOTE
teeth.

© 40443-0
Fig. 630
3. m Position the injection pump camshaft.
NOTE
The coupling hole (arrow) is facing upwards.
© 40444-0
Fig. 631
20-230
Engine
4. m Fit the camshaft gear wheel.
NOTE
The marking (1) must face towards the crankshaft.
© 42289-1
Fig. 632
5. General check of the distribution gears and control time
notes: 1
injection pump camshaft gear wheel (1). Camshaft gear 2

wheel (2). Intermediate wheel (3). Crankshaft gear wheel
(4). Marking of the injection pump/intermediate wheel cam-
shaft (5). Markings on camshaft/crankshaft (6). 3
5
4
6
© 40445-1
Fig. 633
6. m Position the injection pump camshaft gear wheel.
NOTE
The marking (1) is facing towards the camshaft gear
wheel.
© 40446-0
Fig. 634
20-231
Engine
7. m Insert the injection pump camshaft gear wheel into the camshaft
gear wheel.
NOTE
The marking on the intermediate wheel must remain
between the markings of the injection pump cam-
shaft gear wheel (1).
© 40447-0
Fig. 635
8. WARNING

NOTE
The hidden screws become accessible by turning the
camshaft with the rotation device.
1
© 40448-0
Fig. 636
20.44.6 - Check the clearance of the tooth side of the injection pump camshaft gear
wheel
m Turn the gear wheel in the direction of the arrow to the end stop.
© 40449-0
Fig. 637
20-232
Engine
2. m Turn the gear wheel in the direction of the arrow to the end stop.
NOTE
teeth.

© 40450-0
Fig. 638
NOTE
Do not fit the turbocharger.
m Assemble the rocker support.

m Check and adjust the maximum opening stroke of the injection
pumps.
See para. 30.68 - Checking and adjusting... - page 30-283
© 40503-0
Fig. 639
4. m Tighten all the screws (1).
NOTE
© 40464-0
Fig. 640
20-233
Engine
5. m Fit the axial segment support (2).
© 40989-0
Fig. 641
20.44.7 - Check and adjust the endfloat of the injection pump camshaft
1. m Slide the feeler gauge blade between the injection pump camshaft
gear wheel and the axial segment support (arrow).
m Press the axial segment support to the end stop in the feeler gauge
blade. 1
m Check the endfloat.
© 40512-0
Fig. 642
blade.
© 40513-0
Fig. 643
20-234
Engine
m Recheck the endfloat.
NOTE 1
Check the endfloat on both sides between the sup-
port of the axial segment and the gear wheel (ar-
rows).
© 40514-0
Fig. 644
m Fit a new O-ring (1).
© 40515-0
Fig. 645
5. m Fully press down the cover (3).
m Fit the cover (2).
NOTE
3
fitting. 2

© 40460-0
Fig. 646
20-235
Engine
6. m Fix the cable tie (1).
© 40459-0
Fig. 647
m Apply the sealant evenly on the sealing surfaces of the gear case.
NOTE
Use DEUTZ DW 48 sealant.
2
2
m Fit the gear box cover (1). 1

m Fit support (2).
© 40516-0
Fig. 648
© 40456-0
Fig. 649
20-236
Engine
© 40455-0
Fig. 650
m Insert the screws (3) with the spacer bushes. 1
m Tighten the screws (2 and 3) alternately.
© 40517-0
Fig. 651
© 40453-0
Fig. 652
20-237
Engine
m Position the flexible fuel pipe (2).
1
© 40458-0
Fig. 653
13. m Assemble the speed indicator (camshaft).
m Assemble the injection pumps (cylinder A1).
m Assemble the injection pumps (cylinder A2-B3).
m Fit the turbocharger.
© 40518-0
Fig. 654
20-238
Engine
20.45 - Check the camshaft (L3)
l Depth gauge
l Palmer
20.45.1 - Check the camshaft

m Visually check the wear of the cams and main journal.
NOTE
The camshaft cannot be repaired. The camshaft
must be replaced.
© 36812-1
Fig. 655
2. NOTE
© 36424-2
Fig. 656
3. m Measure the diameter of the main journals with the palmer.
NOTE
Measurement points, see diagram. Replace the cam-
shaft if the wear limit is reached.
© 42128-1
Fig. 657
20-239
Engine
20.45.2 - Checking the camshaft gear wheel
© 40601-0
Fig. 658
2. m Remove the intermediate wheel (1).
m Visually inspect the intermediate wheel (1) to determine the state
2
of wear.
m Visually inspect the camshaft gear wheel (2) to determine the state
1
of wear.
© 40602-1
Fig. 659
3. m Fit the cylindrical pin (1).
© 40603-0
Fig. 660
20-240
Engine
© 40604-0
Fig. 661
5. m Place the camshaft gear against the intermediate wheel.
NOTE
2
Observe the installation position. The marking (1) on
the intermediate wheel must face towards the cam-
shaft gear. The markings (1) and (2) must be aligned
and facing each other.
© 40605-1
Fig. 662
© 40601-0
Fig. 663
20-241
Engine
20.46 - Fitting and removing the injection pump camshaft (L3)
l Depth gauge
Special tools:
l Counterhead: 144150
NOTE
20.46.1 - Removing the injection pump camshaft

1. m Disassemble the speed indicator (camshaft).
m Disassemble the injection pumps (cylinder A1).
m Remove the turbocharger.
© 40497-0
Fig. 664
m Remove the seals.
© 40458-0
Fig. 665
20-242
Engine
20-243
Engine
© 40456-0
Fig. 669
1
© 40457-0
Fig. 670
© 40459-0
Fig. 671
20-244
Engine
m Remove cover (2).
m Remove cover (3).
3
2
© 40460-0
Fig. 672
m Fit the rotation device. 1
© 40417-0
Fig. 673
11. m Loosen all the screws (1).
NOTE
© 40464-0
Fig. 674
20-245
Engine
12. m Turn the crankshaft until reaching the overlap angle, cylinder no. B2
Valve overlap means that:
the intake valve starts to open and the exhaust valve
starts to close.
© 40465-0
Fig. 675
13. NOTE
The rotation device stop pin must be engaged in the slot of
the starter ring gear tooth (1). The second slot of the tooth
(2) must be facing bench B.
1
2
© 40466-0
Fig. 676
14. WARNING

m Tighten the stop pin.
NOTE
camshaft with the rotation device. 1 1
Fig. 677
20-246
Engine
15. m Turn the crankshaft until reaching the overlap angle, cylinder no. B2
m Remove the ring gear (2).
WARNING 2
NOTE
1
Push back the injection pump camshaft to the end stop.
m Remove the rotation device. © 40467-0
See para. 30.1 - Fitting and removing t... - page 30-2 Fig. 678
16. m Disassemble the rocker support.
m Disassemble the connector box.
m Remove the O-ring from the crankshaft (flywheel side).
1
m Remove screw (1).
© 40419-0
Fig. 679
© 40420-0
Fig. 680
20-247
Engine
© 40421-0
Fig. 681
© 40422-0
Fig. 682
© 40423-0
Fig. 683
20-248
Engine
© 40424-0
Fig. 684
m Remove cover (2).
© 40468-0
Fig. 685
wheel.
© 40469-1
Fig. 686
20-249
Engine
© 40470-0
Fig. 687
25. m Apply rotation device (1).
© 40471-0
Fig. 688
26. m Turn the camshaft gear wheel in direction of bench A.
crankcase (arrow).
© 40472-0
Fig. 689
20-250
Engine
© 40473-0
Fig. 690
28. m Turn the crankshaft evenly.
NOTE
The notch on the crankshaft gearwheel must be lo- 1
cated between the notches on the camshaft gear
wheel (1).
© 40474-0
Fig. 691
m Remove the camshaft gear wheel (2).
NOTE
Push the camshaft back gently until it stops. 2
© 45381-0
Fig. 692
20-251
Engine
30. m Tighten screws (1).
m Gently remove the injection pump camshaft
WARNING
Do not damage the camshaft or the camshaft support. 1
© 40475-0
Fig. 693
© 40476-0
Fig. 694
20.46.2 - Fitting the injection pump camshaft

© 40993-0
Fig. 695
20-252
Engine
2. m Screw in the screw (1).
m Remove the cover (2).
Fig. 696
3. m Lightly oil the camshaft bearings.
m Lightly oil the camshaft pins.
m Gently fit the injection pump camshaft
© 40995-0
Fig. 697
4. WARNING
Do not damage the camshaft or the camshaft support.
m Pass the injection pump camshaft over the side opposite the fly-
wheel.
NOTE
Use a suitable tool.
© 40996-0
Fig. 698
20-253
Engine
© 40475-0
Fig. 699
© 40997-0
Fig. 700
m Remove screw (1).
© 40994-0
Fig. 701
20-254
Engine
© 40993-0
Fig. 702
20.46.3 - Fit the camshaft gear wheel.

1. General check of the distribution gears and control time
notes: 1
injection pump camshaft gear wheel (1). Camshaft gear 2

wheel (2). Intermediate wheel (3). Crankshaft gear wheel
(4). Marking of the injection pump/intermediate wheel cam-
shaft (5). Markings on camshaft/crankshaft (6). 3
5
4
6
© 40445-1
Fig. 703
© 40431-0
Fig. 704
20-255
Engine
3. m Fit the camshaft gear wheel.
NOTE
wheel (1). Pay attention to aligning the cylindrical on
the camshaft gear wheel with the coupling hole in the
camshaft.
© 40474-0
Fig. 705
© 40473-0
Fig. 706
wheel.
m Rotate the crankshaft with the rotation tool until the retainer element
of the crankcase bank B fastens (arrow).
© 40477-0
Fig. 707
20-256
Engine
© 40473-0
Fig. 708
NOTE
wheel (1).
© 40474-0
Fig. 709
20.46.4 - Calculate the camshaft endfloat

1. m Push the camshaft back to the end stop.
m Use a depth gauge to measure the remaining part of the camshaft
from the support surface of the camshaft gear wheel with respect to
the crankcase (arrows).
© 40478-0
Fig. 710
20-257
Engine
m Use a depth gauge to measure the height of the flange from the slid-
ing surface to the support surface (arrows).
Table 50
Target: Endfloat
Data: -
1
© 42273-2
surement (b), 45.80 mm - 45.50 mm Fig. 711
m Use gaskets to correct any differences.

NOTE
fitting.
1
m Fit the new O-rings.
© 40425-0
Fig. 712
1
© 40435-0
Fig. 713
20-258
Engine
NOTE
bush.
© 40438-0
Fig. 714
© 40437-0
Fig. 715
Screw length:
M12 x 80 mm
© 40423-0
Fig. 716
20-259
Engine
© 40422-0
Fig. 717
1
© 40435-0
Fig. 718
NOTE
bush.
© 40436-0
Fig. 719
20-260
Engine
© 40439-0
Fig. 720
Screw length:
1
M12 x 100 mm
Fig. 721
© 40419-0
Fig. 722
20-261
Engine
20.46.5 - Check the clearance of the tooth side on the intermediate wheel (bench B)
stop.
© 40440-0
Fig. 723
stop.
NOTE
teeth.

© 40441-0
Fig. 724
20.46.6 - Check the clearance of the tooth side on the intermediate wheel (bench A)
stop.
© 40442-0
Fig. 725
20-262
Engine
stop.
NOTE
teeth.

© 40443-0
Fig. 726
3. m Position the injection pump camshaft.
NOTE
The coupling hole (arrow) is facing upwards.
© 40444-0
Fig. 727
NOTE
wheel (1).
Fig. 728
20-263
Engine
5. m Remove rotation device (1).
Fig. 729
Fig. 730
7. m Position the injection pump camshaft gear wheel.
NOTE
The marking (1) is facing towards the camshaft gear
wheel.
Fig. 731
20-264
Engine
8. m Insert the injection pump camshaft gear wheel into the camshaft
gear wheel.
NOTE
The marking on the intermediate wheel must remain
between the markings of the injection pump cam-
shaft gear wheel (1).
Fig. 732
WARNING
1
Fig. 733
20.46.7 - Check the clearance of the tooth side of the injection pump camshaft gear
wheel
m Turn the gear wheel in the direction of the arrow to the end stop.
Fig. 734
20-265
Engine
2. m Turn the gear wheel in the direction of the arrow to the end stop.
NOTE
teeth.

© 40450-0
Fig. 735
3. m Fit the O-ring on the crankshaft (flywheel side).
m Assemble the connector box.
NOTE
Do not fit the turbocharger.

Fig. 736
4. WARNING

NOTE
1
Fig. 737
20-266
Engine
5. m Assemble the assembly support.
m Assemble the rocker support.
m Check and adjust the maximum opening stroke of the injection
pumps.
© 40503-0
Fig. 738
NOTE
© 40464-0
Fig. 739
© 40989-0
Fig. 740
20-267
Engine
blade. 1
© 40512-0
Fig. 741
blade.
© 40513-0
Fig. 742
NOTE 1
rows).
© 40514-0
Fig. 743
20-268
Engine
© 40515-0
Fig. 744
NOTE
3
fitting. 2

© 40460-0
Fig. 745
© 40459-0
Fig. 746
20-269
Engine
NOTE
Use DEUTZ DW 48 sealant.
2
2
m Fit the gear box cover (1). 1

m Fit support (2).
© 40516-0
Fig. 747
© 40456-0
Fig. 748
© 40455-0
Fig. 749
20-270
Engine
© 40517-0
Fig. 750
© 40453-0
Fig. 751
1
© 40458-0
Fig. 752
20-271
Engine
13. m Assemble the injection pumps (cylinder A1).
m Assemble the speed indicator (camshaft).
© 40518-0
Fig. 753
20-272
Engine
20.47 - Replace the crankshaft O-ring (flywheel end)
Special tools:
l Bradawl: 01899103
l Washer

1. m 1 - Gasket housing
m 2 - Shaft O-ring
m 3 - Hex screw
m 188 - Sealant
Fig. 754
Construction unit
05
m Using a bradawl, make a hole about 3 mm in diameter in the old

crankshaft oil seal.
WARNING
Take care not to damage the seal seat or the crankshaft!
Fig. 755
3. m Insert a self-tapping screw (1) with washer.
Fig. 756
20-273
Engine
NOTE
Be careful not to damage the crankshaft.
m Carefully examine the crankshaft O-ring sliding surfaces.
Fig. 757
20.47.2 - Assembly of the crankshaft O-ring

1. m Fit guide bush (1).
Note
The holes in the guide bush must be aligned with the
threaded holes in the crankshaft flange.
Fig. 758
2. m Carefully place the crankshaft O-ring on the sliding surface.
Note
Do not oil the waxed crankshaft O-rings. The seal lip
should be facing the engine crankcase.
Fig. 759
20-274
Engine
3. m Fit installation bush (1).
m Push the crankshaft O-ring to the support.
m Insert bearing (2).
m Screw in nut (3);
Fig. 760
4. m Screw in the nut until it seats against installation bush (1).
NOTE
Installation depth is determined by the installation
tool.

m Fit the flywheel.
Construction unit
05
Fig. 761
20-275
Engine
20.48 - Fitting and removing seal seat
Readily available commercial tools:
l Pin punch
20.48.1 - Removing the seal seat

1. m 1 - Gasket housing
m 2 - Shaft O-ring
m 3 - Hex screw
m 188 - Sealant
© 50518-0
Fig. 762
n See para. 30.32 - Removal and refitting ... - page 30-128
m Disassemble the connector box.

n See para. 30.42 - Disassembly and assemb... - page 30-
153
299
155
157
159
m Remove the oil sump pan. © 50519-0
n See para. 20.49 - Removal and refitting ... - page 20-279 Fig. 763
m Remove all the screws (1).
m Remove the seal seat (2).
20-276
Engine
20.48.2 - Fitting the seal seat
m Apply sealant (1) evenly to the mating surface.
NOTE
Sealing edge thickness, approx. 0.5 - 0.6 mm.
© 50521-0
Fig. 765
2. m Fit the seal seat.
© 50522-0
Fig. 766
3. Note
Trim any protruding gasket (arrows) flush with the mating
surface of the oil sump pan.
© 50523-0
Fig. 767
20-277
Engine
20.48.3 - Technical data

Tightening torque
Table 51
ID no. Designation Indications/ob- Value
servations
A01 095 Seal seat on crankcase Observe the indi- 20 Nm
cated tightening se-
quence.
NOTE
Tighten to +/- 10% of the specified torque using a torque wrench.
20-278
Engine
20.49 - Removal and refitting of the oil sump pan.
Special tools:
l Tool for truncation: 02992301
WARNING
Make sure that no sealant residue enters the engine crankcase! Close all holes.
NOTE
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.
20.49.1 - Removal of the oil sump pan.

1. m 1 - Lubricant oil sump
m 2 - Nut
m 3 - Torx screw
m 244 - Sealant
© 51286-0
Fig. 769
2. m Drain, collect and dispose of used oil in accordance with the appli-
cable regulations.
m Remove all the screws (arrowed).
m Remove the lubricant oil sump (1).
© 51287-0
Fig. 770
20-279
Engine
3. m Insert lever (1) up to shoulder (2).
WARNING
The lever may only be used on the engine crankcase. Do
not use it to apply leverage on aluminium castings. Do not
damage the mating surfaces.
© 51288-0
Fig. 771
4. m Insert the second lever (1) up to shoulder (2).
WARNING
The lever may only be used on the engine crankcase. Do
not use it to apply leverage on aluminium castings. Do not
damage the mating surfaces.
© 51289-0
Fig. 772
5. m Prise the sump pan off the crankcase.
m Remove the sump pan.
© 51290-0
Fig. 773
20-280
Engine
20.49.2 - Refitting the oil sump pan.
1. m Remove the old sealant using the lever.
WARNING
Wear eye protection.
m Clean the mating surfaces with a wire brush.

Note
The mating surfaces must be clean, dry and free of
grease or other contaminants.
© 51291-0
Fig. 774
2. WARNING
Wear eye protection.
m Clean the mating surfaces of the oil sump pan with a wire brush.
NOTE
© 51292-0
Fig. 775
3. m To align the oil sump pan with crankcase, screw four stud bolts (1)
into the crankcase as shown.
© 45678-1
Fig. 776
20-281
Engine
NOTE
m Apply sealant on the separation points (arrows).
© 51293-0
Fig. 777
5. m Apply sealant evenly to the sealing surface.
© 51294-0
Fig. 778
6. m Line the oil sump pan up using the stud bolts as guides.
m Fit the oil sump pan.
WARNING
Once positioned on the crankcase, be careful not to disturb
the oil sump pan. Allow the sealant to cure.
m Unscrew the stud bolts.

© 51295-0
Fig. 779
20-282
Engine
7. m Tighten the screws in the sequence indicated: 20 Nm.
m Top up the engine oil following the instructions provided.
© 51296-0
Fig. 780

Tightening torque
Table 52
ID no. Designation Screws type Indications/observa- Value
tions
A02 030 Lubricant oil sump in Observe the indicated 20 Nm
correspondence of the tightening sequence!
crankcase
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.
20-283
Engine
20.50 - Disassembly and assembly of the lubricant oil sump (L3)
l Lubricant oil
NOTE
Collect auxiliary materials in suitable containers and dispose of them in compliance with the applicable regulations.
The engine oil should be drained and replenished following the instructions given in the operation manual.

1. m Disassemble the starter.
m Do not fully unscrew drain plug (1).
m Drain, collect and dispose of used oil in accordance with the appli-
cable regulations.
1
© 40836-1
Fig. 781
2. m Oil the hole blanking screw lightly.
m Fit a new seal.
m Fit and tighten plug (1).
1
© 40836-1
Fig. 782
3. m Remove dipstick (1)
m Turn the engine over.
© 40837-0
Fig. 783
20-284
Engine
© 40838-0
Fig. 784
m Remove the cables (2).
NOTE
The supports (3) remain on the cable.
© 40839-0
Fig. 785
6. m Remove the sump pan.
m Remove seal (1).
© 40840-0
Fig. 786
20-285
Engine
m Remove the hose union (2).
m Unscrew the threaded fitting.
© 40841-0
Fig. 787
20.50.2 - Refitting the oil sump pan.

1. m Tighten the threaded fitting (1).
m Fit the sleeve.
1
m Tighten the sleeve nut.
© 40842-0
Fig. 788
1 1
NOTE
The mating surfaces must be free of grease and dirt.
m To align the oil sump pan with crankcase, screw four stud bolts (1)
1 1
© 40843-1
Fig. 789
20-286
Engine
20-287
Engine
m Line the oil sump pan up using the stud bolts as guides.
NOTE
Check that the gasket assembly position is correct.
WARNING
m Unscrew the stud bolts.

© 40846-0
Fig. 793
m Fit the cable (2).
m Fit the washers.
NOTE
Tighten the screws only with the washers.
1
m Tighten the screws in alternate sequence (1).
© 40839-0
Fig. 794
1
© 40838-0
Fig. 795
20-288
Engine
9. m Tighten all the screws.
NOTE
Tightening sequence, see graph.
© 45421-1
Fig. 796
10. m Turn the engine over.
m Insert dipstick (1)
© 40837-0
Fig. 797
11. m Top up the engine oil following the instructions provided.
m Assemble the starter.
© 40848-0
Fig. 798
20-289
Engine
20.51 - Disassembly and assembly of the lubricant oil sump (L3)
l Lubricant oil
NOTE

1. m Do not fully unscrew drain plug (1).
m Drain, collect and dispose of used oil in accordance with the appli-
cable regulations.
© 42439-1
Fig. 799
2. m Oil the hole blanking screw lightly.
m Fit a new seal.
© 45860-0
Fig. 800
m Remove all the flange halves (2).
m Remove the two flanged connectors (3).
1
© 45867-0
Fig. 801
20-290
Engine
m Remove the mating flange (2).
2
1
© 42441-1
Fig. 802
1
© 42442-1
Fig. 803
NOTE 2 1
The supports (3) remain on the cable.
m Loosen the oil sump pan.

3
© 45861-0
Fig. 804
20-291
Engine
7. m Pull the lubricant oil sump in the direction indicated by the arrow.
m Remove the sump pan.
© 45868-2
Fig. 805
8. m Remove the inserts (1).
© 45862-0
Fig. 806
20.51.2 - Assembly of the lubricant oil sump with gasket

NOTE 1 1
The mating surfaces must be free of grease and dirt.
m To align the oil sump pan with crankcase, screw four stud bolts (1)
1 1
© 42445-2
Fig. 807
20-292
Engine
2. m Apply sealant on the separation points (arrows).
© 42445-3
Fig. 808
NOTE
The light coloured side of the gasket must face to-
wards the crankcase.
1
© 45864-1
Fig. 809
m Line the oil sump pan up using the stud bolts as guides.
WARNING
© 45868-3
Fig. 810
20-293
Engine
© 45863-0
Fig. 811
6. m Insert the inserts (1).
WARNING
Take care not to move or damage the O-rings.
1
© 45868-1
Fig. 812
7. m Fit the mounts (arrows).
m Fit the cable.
m Fit the washers
NOTE
Tighten the screws only with the washers.
m Screw in the screws alternately
© 42447-1
Fig. 813
20-294
Engine
8. m Tighten all the screws.
NOTE
Tightening sequence, see graph.
© 45421-1
Fig. 814
© 37110-1
Fig. 815
10. m Fit the mating flange (2).
WARNING EX IN
The “IN“ and “EX“ markings on the mating flange must be
aligned with the corresponding markings on the lubricant oil
sump.
1
1
© 42448-1
Fig. 816
20-295
Engine
© 37112-1
Fig. 817
12. m Fit the semi-flange (1).
m Insert the shims.
m Fit the flanged connectors (3).
3
© 45870-0
Fig. 818
m Insert the shims.
© 45871-0
Fig. 819
20-296
Engine
m Insert the shims.
m Fit the flanged connectors (2).
m Centre the two flanged connectors. 2
m Tighten all the screws.
© 45872-0
Fig. 820
1
m Top up the engine oil following the instructions provided.
2
© 42442-1
Fig. 821
20-297
Engine
20.52 - Assembly and disassembly of the flywheel (L3)
Special tools:
l Shop-made guide pin
WARNING
Do not turn the crankshaft without screws/guide bolt. The crankshaft gear wheel is positioned using the screws/guide
bolt. If fastening is not completed, the position of the crankshaft toothed screw will change.
20.52.1 - Removal of the flywheel

NOTE
1
2
m Remove the thrust washer (2).
© 40902_1
Fig. 822
2. m Fit the shop-made guide bolt.
m Remove the flywheel.
m Remove the friction plate.
WARNING
Do not turn the crankshaft without screws/guide bolt. The
crankshaft gear wheel is positioned using the screws/guide
bolt. If fastening is not completed, the position of the crank-
shaft toothed screw will change.
© 34985-2
Fig. 823
20-298
Engine
© 40903-0
Fig. 824
20.52.2 - Refitting the flywheel

1. m Fit the friction disc.
NOTE
Check that bush (1) is present.
m Fit the flywheel. 1

NOTE
Ensure that the locating dowel is correctly aligned
with the mating hole.
© 40966-0
Fig. 825
2. m Insert the thrust washer (2).
m Withdraw the implemented guide bolt.
1
WARNING
2
The screws must be renewed after being removed.
m Tighten all the screws (1) with the socket wrench insert.
NOTE
© 40658_1
Fig. 826
20-299
Engine
PAGE LEFT INTENTIONALLY BLANK
20-300
30 - Engine accessories
30-1
Engine accessories
30.1 - Fitting and removing the rotation tool (L3)
Special tools:
NOTE
Depending on the number of gear teeth, the rotation tool 100350 may also be used on the front side of the crankshaft.
30.1.1 - Fitting the rotation device

m Remove cover (2)
2
1
© 40461-0
Fig. 827
2. m Insert rotation device (1).
m Fit the centring pins (2) in the threaded hole (3).
1 2
© 40462-0
Fig. 828
NOTE
The toothed screw of the rotation tool engages with
the starter ring gear.
© 40463-0
Fig. 829
30-2
Engine accessories
30.1.2 - Removal of the rotation device
© 40463-0
Fig. 830
m Fit a new seal.
m Fit the cap (2).
2
1
© 40461-0
Fig. 831
30-3
Engine accessories
30.2 - Removing and fitting the exhaust manifold (L3)
30.2.1 - Removal of the exhaust manifold
1. m Remove the turbocharger.
m Disassemble the exhaust pipe (bench A).
m Disassemble the exhaust pipe (bench B).
© 40731-0
Fig. 832
m Remove the exhaust manifold (2).
1
© 40732-0
Fig. 833
30.2.2 - Assembly of the exhaust manifold

1. m Assemble the exhaust manifold (2).
1
© 40732-0
Fig. 834
30-4
Engine accessories
2. m Assemble the exhaust pipe (bench A).
m Assemble the exhaust pipe (bench B).
© 40451-0
Fig. 835
30-5
Engine accessories
30.3 - Removing and fitting the exhaust manifold
(Bank A) (L3)
l Assembly product: DEUTZ S1
30.3.1 - Disassembly of the exhaust manifold

1. m Remove the turbocharger (bank A).
m Unscrew nuts (1).
m Remove the screws.
1
2
© 42079-1
Fig. 836
© 42081-2
Fig. 837

m Assemble the exhaust manifold (2).
m Apply a thin film of assembly product on the screws.
m Insert the screws.
m Insert the shims.
m Tighten nuts (1).
© 42081-2
Fig. 838
30-6
Engine accessories
m Tighten nuts (1).
m Fit the turbocharger (bench A).
2
© 42079-1
Fig. 839
30-7
Engine accessories
30.4 - Removing and fitting the exhaust manifold (Bank B) (L3)
30.4.1 - Disassembly of the exhaust manifold

1. m Remove the turbocharger (bank B).
© 42080-1
Fig. 840
© 42082-2
Fig. 841

m Assemble the exhaust manifold (2).
m Tighten nuts (1). 2
© 42082-2
Fig. 842
30-8
Engine accessories
2. m Fit the turbocharger (bench A).
© 42080-1
Fig. 843
30-9
Engine accessories
30.5 - Disassembly and assembly of the turbocharging air duct (L3)
30.5.1 - Removal of the charge air duct

m Remove the charge air duct (2) with the connector.
© 40764-0
Fig. 844
2. m Remove the connection fitting (1).
© 40765-1
Fig. 845
m Remove charge air manifold (2).
© 45403-0
Fig. 846
30-10
Engine accessories
30.5.2 - Refitting the charge air duct
1. m Fit a new seal.
m Fit charge air manifold (2).
m Fit the washers and tighten the nuts.
m Tighten nuts (1). 1
© 45403-0
Fig. 847
1
© 40767-0
Fig. 848
3. m Install the connection fitting (1).
© 40768-1
Fig. 849
30-11
Engine accessories
m Fit the charge air duct.
Screw length:
1
M10 x 65 mm (1). M10 x 85 mm (2)
2
© 40769-0
Fig. 850
30-12
Engine accessories
30.6 - Disassembly and assembly of the connecting line (L3)
30.6.1 - Disassembly of the connecting line
1. m Disassembly of the fuel lines (spark plugs).
© 40737-0
Fig. 851
© 40738-0
Fig. 852
NOTE
Mark the cables and the respective connections be-
fore continuing with disassembly. 1
m Remove the cables (2) from the two glow plugs.
© 40739-0
Fig. 853
30-13
Engine accessories
m Remove the screws. 1
© 40740-0
Fig. 854
m Place the cable bundle aside.
© 40741-0
Fig. 855
1
1
© 40742-0
Fig. 856
30-14
Engine accessories
© 40743-0
Fig. 857
© 40744-0
Fig. 858
© 40745-0
Fig. 859
30-15
Engine accessories
© 40746-0
Fig. 860
11. m Remove the connecting line (1).
m Remove the gaskets.
© 40747-0
Fig. 861
© 40748-0
Fig. 862
30-16
Engine accessories
30.6.2 - Assembly of the connecting line
m Fit the new gaskets.
m Apply the connecting line (1).
© 40747-0
Fig. 863
2. m Tighten the nuts (1).
© 40746-0
Fig. 864
m Tighten the nuts (1).
© 40745-0
Fig. 865
30-17
Engine accessories
© 40744-0
Fig. 866
© 40743-0
Fig. 867
1
1
© 40742-0
Fig. 868
30-18
Engine accessories
7. m Tighten the nuts (arrow).
© 40749-0
Fig. 869
8. m Position the cables.
Screw length: 2
M8 x 20 mm (1). M8 x 16 mm (2)
1
© 40750-0
Fig. 870
m Remove the protective cover
1
© 40751-0
Fig. 871
30-19
Engine accessories
m Fit the protective cover
m Insert the screws. 1
Screw length:
M10 x 45 mm (1). M10 x 55 mm (2)
© 40752-0
Fig. 872
m Tighten the nuts (arrow).
1
© 40950-0
Fig. 873
12. m Fit the cables (2) on the two glow plugs.
WARNING
Observe the assignment and polarity of the electric connec-
1
tions!
NOTE
Connect the cables according to the marks made during
2
disassembly.
m Fit the washer.

m Tighten nut (1).
See para. 20.4 - Tightening torque (L3) - page 20-14 © 40739-0
Fig. 874
30-20
Engine accessories
© 40738-0
Fig. 875
14. m Fit the fuel lines (spark plugs).
© 40737-0
Fig. 876
30-21
Engine accessories
30.7 - Disassembly and assembly of the connecting line (L3)
NOTE
30.7.1 - Disassembly of the connecting line

© 45926-0
Fig. 877
m Remove the elastic washers.
m Remove the ground cable.
NOTE
fore continuing with disassembly.
© 45907-0
Fig. 878
3. m Disassemble the fuel lines (spark plugs) (Railway).
© 42025-2
Fig. 879
30-22
Engine accessories
1
1
© 42185-2
Fig. 880
5. m Remove the cables (1).
NOTE
1
© 42192-2
Fig. 881
m Move the fuel cutoff valve aside (2).
© 42186-1
Fig. 882
30-23
Engine accessories
m Place the cable bundle aside.
© 42418-1
Fig. 883
8. m Remove the screws (1)
m Loosen the mount (2).
1 2
© 42419-1
Fig. 884
© 42501-1
Fig. 885
30-24
Engine accessories
m Move the cables aside.
1
1
© 45850-0
Fig. 886
11. m Unscrew all the nuts (1).
m Remove the connecting line (2).
1
1
© 45851-1
Fig. 887
30.7.2 - Assembly of the connecting line

m Apply the connecting line (1).
© 42421-1
Fig. 888
30-25
Engine accessories
2. m Insert the shims.
m Fit support (1).
m Tighten the nuts.
1
1
© 45850-0
Fig. 889
3. m Tighten all the nuts (1).
1
1
© 45852-1
Fig. 890
© 42501-1
Fig. 891
30-26
Engine accessories
5. m Tighten all the nuts (1).
1
1
© 45852-1
Fig. 892
6. m Position the support (2).
1 2
© 42419-1
Fig. 893
7. WARNING
Route the cables without friction or tension points.

© 42418-1
Fig. 894
30-27
Engine accessories
8. m Fit the fuel cutoff valve (2).
m Locate the hose clip.
2
© 42186-1
Fig. 895
9. m Position the fuel cutoff valve.
NOTE
Pay attention to assembly dimension (X). X
© 45909-0
Fig. 896
10. WARNING
tions!
m Connect the positive cable (R3.1) to the spark plug (1). 1

m Connect the positive cable (R3.2) to the spark plug (2).
m Insert the shims.
m Tighten the nuts.
2
© 45928-0
Fig. 897
30-28
Engine accessories
11. m Tighten nuts (1).
m Assemble the fuel lines (spark plugs) (Railway).
1
1
© 42185-2
Fig. 898
12. m Connect the ground cable.
m Fit the spring washer.
© 45907-0
Fig. 899
© 42423-1
Fig. 900
30-29
Engine accessories
NOTE
© 45926-0
Fig. 901
30-30
Engine accessories
30.8 - Disassembly and assembly of the turbocharger (L3)
Special tools:
l Special wrench: 170100
NOTE
30.8.1 - Removal of the turbocharger

1. m Disassemble the turbocharging air duct.
© 40753-0
Fig. 902
2. m Unscrew union nuts (1) using the special wrench.
m Unscrew the threaded fitting.
m Remove the seals.
1
© 40754-0
Fig. 903
m Remove support (2).
m Remove lubricating oil pipe (3).
© 40755-0
Fig. 904
30-31
Engine accessories
m Loosen the hose clips (2).
© 40756-0
Fig. 905
5. m Remove the pipe.
m Remove the intake manifold (1).
1
© 40757-0
Fig. 906
© 40758-0
Fig. 907
30-32
Engine accessories
7. m Remove oil return pipe (1).
© 40759-0
Fig. 908
m Remove exhaust gas turbocharger (2).
© 40760-0
Fig. 909
m Remove oil return pipe (2).
© 40761-0
Fig. 910
30-33
Engine accessories
© 40762-0
Fig. 911
30.8.2 - Refitting the turbocharger

1. m Fit the new gaskets.
m Fit oil return pipe (2).
© 40761-0
Fig. 912
m Fit turbocharger (2).
© 40760-0
Fig. 913
30-34
Engine accessories
3. m Fit oil return pipe (1)
© 40759-0
Fig. 914
© 40758-0
Fig. 915
5. m Fit the intake manifold (1).
NOTE
Observe the installation position. 1
m Fit the pipe.
© 40757-0
Fig. 916
30-35
Engine accessories
6. m Position the hose clips.
m Tighten the hose clip (2).
m Tighten screw (1). 3
© 45402-0
Fig. 917
7. m Fit lube oil pipe (3).
m Position the support (2).
© 45373-0
Fig. 918
m Tighten the threaded union.
m Tighten the two sleeve nuts (1) with the special wrench.
© 40763-0
Fig. 919
30-36
Engine accessories
9. m Assemble the turbocharging air duct.
© 40753-0
Fig. 920
30-37
Engine accessories
30.9 - Removing and fitting the turbocharger (Bank A) (L3)
NOTE

m Loosen hose clip (2)
2 1
© 42048-1
Fig. 921
m Remove lube oil pipe (2).
© 42049-1
Fig. 922
m Remove oil return pipe (2).
1
© 42050-1
Fig. 923
30-38
Engine accessories
4. m Loosen the hose clip (1)
m Loosen the hose clips (2).
2
© 42051-2
Fig. 924
5. m Disconnect the piece of flexible pipe (1).
m Remove breather pipe (2).
m Remove the breather pipe (3). 2
© 42052-2
Fig. 925
6. m Unscrew the nuts (arrowed).
m Remove turbocharger (1).
© 42053-1
Fig. 926
30-39
Engine accessories
7. m Unscrew the threaded fitting (1).
m Remove the seal.
1
© 42054-1
Fig. 927

m Tighten the threaded fitting (1).
1
© 42054-1
Fig. 928
© 42053-1
Fig. 929
30-40
Engine accessories
3. m Fit the breather pipe (3).
m Fit the breather pipe (2).
m Connect the piece of flexible pipe (1). 2
© 42052-3
Fig. 930
4. m Position the sleeve tightening clip (1).
m Locate hose clip (2). 1
2
© 42051-2
Fig. 931
m Fit oil return pipe (2).
1
© 42050-1
Fig. 932
30-41
Engine accessories
m Screw on the union nuts (1).
© 42049-1
Fig. 933
2 1
© 42048-1
Fig. 934
30-42
Engine accessories
30.10 - Removing and fitting the turbocharger (Bank B) (L3)
NOTE

m Remove lube oil pipe (2).
1
© 42056-1
Fig. 935
m Remove oil return pipe (2). 1
© 42057-1
Fig. 936
m Loosen hose clip (2),
1
© 42059-2
Fig. 937
30-43
Engine accessories
4. m Disconnect the piece of flexible pipe (1).
m Remove breather pipe (2).
m Remove the breather pipe (3).
2
1
© 42058-2
Fig. 938
m Remove turbocharger (1).
© 42055-1
Fig. 939
m Remove the seal.
1
© 42054-1
Fig. 940
30-44
Engine accessories
1
© 42054-1
Fig. 941
1
© 42055-1
Fig. 942
3. m Fit the breather pipe (3).
m Fit the breather pipe (2).
m Connect the piece of flexible pipe (1).
2
1
© 42058-2
Fig. 943
30-45
Engine accessories
4. m Position the sleeve tightening clip (1).
m Locate hose clip (2).
© 42059-2
Fig. 944
m Fit oil return pipe (2). 1
© 42057-1
Fig. 945
1
© 42056-1
Fig. 946
30-46
Engine accessories
30.11 - Removing and fitting the air intake pipe
(Bank A) (L3)
Special tools:
30.11.1 - Disassembly of the supply air pipe

1. m Disassemble the connecting line.
m Remove the injection pipes (bench A).
© 40552-0
Fig. 947
2. m Remove the crankcase breather.
See para. 20.31 - Removing and fitting c... - page 20-143
m Remove screw (1).
© 40553-0
Fig. 948
1 2
© 40554-0
Fig. 949
30-47
Engine accessories
2 1
© 40566-0
Fig. 950
5. m Unscrew the screws (1) using the special wrench.
m Remove screws (2). 3
m Remove the supply air pipe (3).
1 2
© 40567-0
Fig. 951
© 40568-0
Fig. 952
30-48
Engine accessories
30.11.2 - Assembly of the supply air pipe
NOTE
1
m Screw all the screws (1) a few thread turns.
Screw length:
M8 x 65 mm
© 40574-0
Fig. 953
2. m Fit the supply air pipe.
Screw length:
M8 x 100 mm 1
© 40575-0
Fig. 954
3. m Fit the spacer bushes (arrow).
m Fit the mount.
Screw length:
M8 x 120 mm
© 40576-0
Fig. 955
30-49
Engine accessories
© 40553-0
Fig. 956
5. m Alternatively tighten the screws (1) using the special wrench.
1 1
1 1
© 40577-0
Fig. 957
6. m Position the flexible fuel pipe (2).
m Fit the crankcase breather.
1 2
© 40554-0
Fig. 958
30-50
Engine accessories
7. m Assemble injection pipes (bench A).
m Fit the connecting line.
© 40552-0
Fig. 959
30-51
Engine accessories
30.12 - Removing and fitting the air intake pipe
(Bank B) (L3)
Special tools:
30.12.1 - Disassembly of the supply air pipe

1. m Disassemble the connecting line.
© 40552-0
Fig. 960
© 40569-0
Fig. 961
3. m Unscrew the screws (1) using the special wrench.
3
m Remove the supply air pipe (3).
1
© 40570-0
Fig. 962
30-52
Engine accessories
© 40571-0
Fig. 963
30.12.2 - Assembly of the supply air pipe

NOTE
1
m Screw all the screws (1) a few thread turns.

Screw length:
M8 x 65 mm
© 40572-0
Fig. 964
2. m Fit the supply air pipe.
Screw length:
M8 x 100 mm
1
© 40569-0
Fig. 965
30-53
Engine accessories
3. m Alternatively tighten the screws (1) using the special wrench.
1
1
1
1
© 40573-0
Fig. 966
m Fit the connecting line.
© 40552-0
Fig. 967
30-54
Engine accessories
30.13 - Replacing the injection pipes (Bench A) (L3)
Special tools:
l Plugs and caps: 170160
DANGER
After switching off the engine, wait at least 30 seconds before carrying out any work on the fuel system!
WARNING
During work on the fuel system always maintain conditions of the maximum cleanliness. Before proceeding with re-
moval, remove any paint residue or debris. Thoroughly clean the area around the components to be worked on. Dry
any wet areas with a compressed air jet. When handling fuel observe the safety directives and specific local regula-
tions. All fuel lines and unions should be closed immediately after opening using new, clean plugs or caps. Remove
plugs and caps only immediately prior to assembly. Collect auxiliary materials in suitable containers and dispose of
them in compliance with the applicable regulations. After any operation, bleed the fuel distribution system - see the
user manual, chapter “6 Fuel distribution system”.
30.13.1 - Removal of the injection pipes

m Remove the cylinder head cover (2).
1 1
© 40627-0
Fig. 968
© 40792-0
Fig. 969
30-55
Engine accessories
m Remove the injection pipe.
NOTE
they were removed. Attention to the cylinder alloca- 1
tion.
© 40793-0
Fig. 970
m Replacing the gaskets of the damaged profile.
© 40796-0
Fig. 971
30.13.2 - Refitting the injection pipes

1. m Insert the new injection pipe.
WARNING
When fitting the injection pipe, ensure it is not under tension. 1
NOTE
Make sure the injection pipes are positioned correctly.
1
© 40793-0
Fig. 972
30-56
Engine accessories
2. m Oil the injection pipe in the area of the profile gasket (1).
m Position the profile gasket (1).
NOTE
The profile gasket must rest on the upper rib (arrow)
1
of the cylinder head casing.
© 40634-0
Fig. 973
3. m Tighten the sleeve nut (1) using the special wrench.
© 40800-0
Fig. 974
© 40801-0
Fig. 975
30-57
Engine accessories
© 40792-0
Fig. 976
NOTE 1
Respect the assembly position. Position the profile

gasket (2).
© 40802-0
Fig. 977
NOTE
2
© 40803-0
Fig. 978
30-58
Engine accessories
1 1
© 40804-0
Fig. 979
30-59
Engine accessories
30.14 - Replacing the injection pipes (Bench A) (L3)
Special tools:
DANGER
WARNING
30.14.1 - Removal of the injection pipes

m Remove the cylinder head cover (2).
1 1
© 40627-0
Fig. 979
© 40792-0
Fig. 979
30-60
Engine accessories
m Remove the injection pipe.
NOTE
tion.
© 40793-0
Fig. 979
m Replacing the gaskets of the damaged profile.
© 40796-0
Fig. 979
30.14.2 - Refitting the injection pipes

1. m Insert the new injection pipe.
WARNING
When fitting the injection pipe, ensure it is not under tension. 1
NOTE
Make sure the injection pipes are positioned correctly.
1
© 40793-0
Fig. 979
30-61
Engine accessories
2. m Oil the injection pipe in the area of the profile gasket (1).
m Position the profile gasket (1).
NOTE
The profile gasket must rest on the upper rib (arrow)
1
of the cylinder head casing.
© 40634-0
Fig. 979
© 40800-0
Fig. 979
© 40801-0
Fig. 979
30-62
Engine accessories
© 40792-0
Fig. 979
NOTE 1
Respect the assembly position. Position the profile

gasket (2).
© 40802-0
Fig. 979
NOTE
2
© 40803-0
Fig. 979
30-63
Engine accessories
1 1
© 40804-0
Fig. 979
30-64
Engine accessories
30.15 - Fitting and removing injection valves (L3)
l Assembly pliers: 8024
Special tools:
l Extractor: 110030
l Wrench for nut with slots: 110130
l Disassembly tool: 110901
l Extraction device: 120660
l Slide hammer extractor: 150800
DANGER
WARNING
30.15.1 - Disassembly of the injection valve

1. m Remove the injection pipes (bench A).
© 40957-0
Fig. 980
30-65
Engine accessories
2. m Unscrew the swivel nut with the wrench for nut with slots.
© 40643-0
Fig. 981
3. m Withdraw the injector (1) and the O-ring (arrow).
© 40815-0
Fig. 982
30.15.2 - Disassembly of the blocked injection valve

1. m Assemble the slide hammer extractor (1) and extractor (2).
m Tighten the check nut (3).
© 40958-0
Fig. 983
30-66
Engine accessories
2. m Fit the slide hammer extractor on the injection valve.
m Withdraw the blocked injection valve.
© 40816-0
Fig. 984
3. m Grip the fixed seal (1) with the special pliers (2) and remove it by
twisting it slightly.
WARNING
Take care not to damage the nozzle cap!
© 43303-0
Fig. 985
30.15.3 - Disassemble the fixed O-ring on the cylinder head

1. m Insert removal tool (1).
NOTE
The tool (arrowed) must locate in the seal.
© 45419-0
Fig. 986
30-67
Engine accessories
2. m Tighten the threaded shaft.
NOTE
Fasten the O-ring to the extractor tool. Counterhold
1
the removal tool.
m Fit adapter (1) and slide hammer puller (2) to the removal tool.
m Remove the fixed seal.
2
© 45420-0
Fig. 987
3. m Remove seal (1) using the removal tool.
© 40607-1
Fig. 988
m Check the injection valve.
© 45414-0
Fig. 989
30-68
Engine accessories
30.15.4 - Assembly of the injection valve
1. m Fit a new O-ring (arrowed).
m Apply the assembly product on the thread (1).
© 40818-0
Fig. 990
2. m Apply assembly sealant in the area (X) of the injector holder stem.
m Apply assembly sealant to the sliding surface of the O-ring (arrow).
m Fit a new O-ring (1) on the injection valve.
X
1
© 40819-0
Fig. 991
3. m Fit the sleeve screw (1) in the direction indicated by the arrow.
WARNING
Take care not to damage the O-ring.
© 40820-0
Fig. 992
30-69
Engine accessories
4. m Fit the injection valve.
m Tighten the swivel nut with the wrench for nut with slots.
© 40643-0
Fig. 993
© 40957-0
Fig. 994
30-70
Engine accessories
30.16 - Removing and refitting the injection valve (L3)
Special tools:
l Support: 110110
30.16.1 - Disassembly of the injection valve

1. m Disassemble the injection valves.
m Check and adjust the injection valves.
m Insert the injection valve in the support.
m Loosen the fastener nut with the socket wrench insert.
© 36271-2
Fig. 995
2. m Remove the injection valve.
NOTE
Put the components to one side in the order in which 6
they were removed. 5
4
3
2
n Shim (1).
n Compression spring (2).
n Screw tie-rod (3).
n Intermediate piece (4).
n Injector (5).
n Fastener nut (6).
m Clean the components with new diesel fuel.

© 36269-2
m Dry the components with air.
Fig. 996
30.16.2 - Refitting the injection valve

1. m Check the injector.
WARNING
Do not touch the needle! The needle (1) and nozzle body 1
(2) form a single component and are not exchangeable or
replaceable individually! 2
© 33904-2
Fig. 997
30-71
Engine accessories
2. NOTE
The needle (1) must return slowly and without impediment
into its seat in the vertical nozzle (2) by gravity. If the needle
does not move freely, clean the nozzle again in a diesel fuel 1
bath and replace if necessary. In case of replacement, also
clean the new nozzle in new diesel fuel. 2
© 33904-2
Fig. 998
3. m Ensure that the mating surfaces of the intermediate piece are not
worn.
NOTE
Make sure the cylindrical pins (arrow) are present.
© 33905-2
Fig. 999
4. m Select the shim washer necessary to set the correct aperture pres-
sure.
NOTE
The aperture pressure depends on the thickness of
the shim washer fitted. Using a thicker shim washer
produces a higher aperture pressure.
m Fit the shim.
© 36274-2
Fig. 1000
30-72
Engine accessories
5. m Insert the compression spring.
© 33907-2
Fig. 1001
6. m Fit the screw tie-rod.
© 33908-2
Fig. 1002
7. m Fit the intermediate piece with the centring pins in the holes in the
injector carrier.
NOTE
The flanged side must face towards the screw tie-
rod.
© 33909-2
Fig. 1003
30-73
Engine accessories
8. m Fit the injector, with the centring pins in the centring holes in the
intermediate piece.
NOTE
Do not let the needle fall out of the nozzle body.
© 33910-2
Fig. 1004
9. m Tighten the nozzle fastener nut.
© 33911-2
Fig. 1005
10. m Tighten the nozzle fastener nut.
m Remove the injector from the mount.
m Check and adjust the injection valves.
© 33912-2
Fig. 1006
30-74
Engine accessories
30.17 - Checking and adjusting the injection valves (L3)
m Box spanner insert: 8017
m Injector control equipment: 8008
Special tools:
m Support: 110110
DANGER
Risk of accident when handling the nozzle tester. The injec-
tor jet causes the fuel to penetrate deep under the skin! Risk
of septicaemia!
WARNING
After operating the manual lever three or four times, the © 45414-0
Fig. 1007
spring chamber fills with diesel fuel/test oil to above the in-
jection valve needle. Afterwards, it is not possible to oper-
ate the manual lever. Before every test procedure, carefully
loosen the nozzle fastener nut to release pressure from the
spring chamber. To check the injection valves, use only pure
ISO 4113 standard test oil or clean diesel fuel.
30.17.1 - Assembly of the injection valve on the injector tester

1. m Insert the injection valve in the support.
m Loosen the nozzle tightening nut by approx. 180° using the box
spanner insert (pressure reduction) and then retighten it.
© 36271-2
Fig. 1008
2. m Fit the injection valve on the injector tester.
© 35889-2
Fig. 1009
30-75
Engine accessories
30.17.2 - Check the opening pressure
1. m Slightly push the injector tester lever down with the pressure gauge
inserted.
NOTE
The pressure at which the pointer stops or goes
down suddenly is the opening pressure. Repeat the
check 3 times.
© 36293-2
Fig. 1010
2. m Compare the values measured.
NOTE
The measurement values of the three tests must co-
incide with the control value.
m Remove or replace the injection valve if the value measured devi-

ates from the specified value.
© 36293-2
Fig. 1011
30.17.3 - Check the air-tightness

1. m Dry the injectors and injector holders with a jet of air.
m Press down lightly on the manual tester lever until arriving at approx.
20 bar below the opening pressure read previously.
© 36293-2
Fig. 1012
30-76
Engine accessories
2. NOTE
The injector is air sealed if it does not drip within 10 seconds.
© 36294-2
Fig. 1013
3. m Remove or replace the injection valve if fuel drips from the injector.
WARNING
Retouch work is not permitted!
© 36295-2
Fig. 1014
30.17.4 - Checking the mobility of the jet needle

1. m Turn off the tester pressure gauge.
m Perform the noise and needle jet test.
NOTE
Check the mobility of the jet needle in the body of the
injector by means of an acoustic noise test. Due to
the increasing wear in the seat of the injection valve
needle, the acoustic behaviour of the injectors will
change. Quickly operating the lever of a worn injec-
tion valve emits a sound that can be heard and the
fuel is finely pulverised.
© 36296-2
Fig. 1015
30-77
Engine accessories
2. m Remove and clean the injector if it does produce an audible sound
during operation.
NOTE
Replace the injector if it still makes no clearly audible
sound after cleaning. The jet is quite different than
that from a new injection valve.
© 36296-2
Fig. 1016
30.17.5 - Disassembly of the injection valve from the injector tester

1. m Loosen the nozzle tightening nut by approx. 180° using the box
spanner insert (pressure reduction) and then retighten it.
WARNING
Before installing the injection valves, reduce the pressure in
the spring chamber.

© 36271-2
Fig. 1017
30-78
Engine accessories
30.18 - Removing and fitting fuel delivery pump (L3)
Special tools:
WARNING
30.18.1 - Removal of the fuel lift pump

m Remove support (2).
2
1
© 40827-0
Fig. 1018
2. m Unscrew hollow screws (1)
m Remove the fuel lines (2).
m Remove the seals.
© 40828-0
Fig. 1019
30-79
Engine accessories
m Unscrew the union nuts (2).
m Remove the lubricant oil pipe.
m Remove the seals. 1
© 40829-0
Fig. 1020
m Remove the fuel delivery pump (2).
© 40830-0
Fig. 1021
© 40961-0
Fig. 1022
30-80
Engine accessories
30.18.2 - Refitting the fuel lift pump
1
© 42286-2
Fig. 1023
2. m Fit the fuel lift pump.
m Fit the pump (1) in the groove (2).
© 40831-0
Fig. 1024
© 40832-0
Fig. 1025
30-81
Engine accessories
m Connect the lubricating oil pipe.
m Tighten the union nuts (2). 1
2
© 40829-0
Fig. 1026
m Install the fuel lines (2).
m Tighten hollow screws (1)
© 40828-0
Fig. 1027
2
1
© 40827-0
Fig. 1028
30-82
Engine accessories
30.19 - Assembly and disassembly of the fuel pressure regulating
valve (L3)
Special tools:
WARNING
30.19.1 - Disassembly of the of the fuel pressure regulating valve

© 40519-0
Fig. 1029
m Remove the seals.
1
2 3
© 40520-0
Fig. 1030
30-83
Engine accessories
© 40521-0
Fig. 1031
NOTE

1
m Remove the seals.
2
© 40522-0
Fig. 1032
m Remove the seals.
m Laterally move the flexible pipe (2).
1
© 40948-0
Fig. 1033
30-84
Engine accessories
6. m Counterhold the union.
m Unscrew the overflow valve (3).
m Remove the seal.
m Remove the union (2). 1
© 40949-0
Fig. 1034
© 45848-0
Fig. 1035
30.19.2 - Assembly of the of the fuel pressure regulating valve

m Tighten the overflow valve (1).
1
© 40947-0
Fig. 1036
30-85
Engine accessories
2. m Fit union (2).
NOTE
Observe the installation position. The flexible hose
union must face towards the rear protective shield. 1
m Counterhold the union.

m Tighten the sleeve nut (1) with the fixed, open-ended wrench.
2
© 40949-0
Fig. 1037
3. m Counterhold the union.
m Tighten the relief valve (1) with the fixed, open-ended wrench.
© 40949-0
Fig. 1038
4. m Position the flexible pipe (1).
m Fit new seals (3).
2
WARNING
1
Route the flexible pipe without friction or tension points.
3
© 40948-1
Fig. 1039
30-86
Engine accessories
m Install the fuel lines (2).
© 40522-0
Fig. 1040
m Fit support (2).
m Screw in nut (1);
© 40521-0
Fig. 1041
m Fit support (2).
2 3
© 40520-0
Fig. 1042
30-87
Engine accessories
NOTE
1
m Tighten nut (2).
© 40565-0
Fig. 1043
1
© 40555-0
Fig. 1044
© 40519-0
Fig. 1045
30-88
Engine accessories
30.20 - Assembly and disassembly of the fuel pressure regulating
valve (L3)
Special tools:
WARNING
30.20.1 - Disassembly of the of the fuel pressure regulating valve

1. m Retain the overflow valve (1).
m Unscrew the threaded fitting (2).
m Remove the seal.
2
1
© 45925-1
Fig. 1046
2. m Block the union (1).
m Unscrew the overflow valve (2).
m Remove the seal.
© 45915-1
Fig. 1047
30-89
Engine accessories
m Remove the washer.
m Loosen the hose clip. 1
© 45916-0
Fig. 1048
m Remove the seals.
2
m Remove the union.
3 1
© 45917-0
Fig. 1049
© 45769-0
Fig. 1050
30-90
Engine accessories
30.20.2 - Assembly of the of the fuel pressure regulating valve
m Tighten the overflow valve (1).
1
© 40947-0
Fig. 1051
m Tighten the threaded union (1).
© 45770-0
Fig. 1052
3. m Fit flexible pipe (1).
m Insert the new O-rings.
© 45918-0
Fig. 1053
30-91
Engine accessories
4. m Attach the fitting.
© 45919-0
Fig. 1054
5. m Fit the union (1).
NOTE
Lay the hexagonal surface horizontally (1). The union
(2) must be rotated approximately 45° to the left.
1
© 45920-0
Fig. 1055
m Tighten the sleeve nut (2) with the fixed, open-ended wrench.
© 45921-1
Fig. 1056
30-92
Engine accessories
m Tighten the relief valve (2) with the fixed, open-ended wrench.
© 45922-1
Fig. 1057
8. m Retain the overflow valve (1).
2
1
© 45925-1
Fig. 1058
m Fit the washer.
m Tighten (2) the screw.
© 45924-0
Fig. 1059
30-93
Engine accessories
NOTE
Pay attention to the assembly angle dimension X =
10°.
1
WARNING X
m Tighten hollow screw (2). 1

© 45910-0
Fig. 1060
30-94
Engine accessories
30.21 - Assembly and disassembly of the oil intake pipe (L3)
NOTE
30.21.1 - Removal of the oil pickup pipe

1. m Remove the oil sump pan.
m Remove oil pickup pipe (2). 1
© 40833-0
Fig. 1061
2
© 40834-0
Fig. 1062
30.21.2 - Refitting the oil pickup pipe

2
© 40834-0
Fig. 1063
30-95
Engine accessories
m Fit a new seal.
m Fit the oil intake pipe (2).
WARNING 1
Make sure the assembly position is correct. When fitting the
pipe, ensure that it is not under tension.
1
© 40833-0
Fig. 1064
© 40835-0
Fig. 1065
© 40962-0
Fig. 1066
30-96
Engine accessories
30.22 - Assembly and disassembly of the oil intake pipe (L3)
NOTE
30.22.1 - Removal of the oil pickup pipe

1. m Remove the oil sump pan (Railway).
m Remove oil pickup pipe (2). 2
© 45859-0
Fig. 1067
© 42171-1
Fig. 1068
30.22.2 - Refitting the oil pickup pipe

© 42171-1
Fig. 1069
30-97
Engine accessories
m Fit a new seal.
m Fit the oil intake pipe (2).
NOTE
Check the installation position is correct. Note that
the screws are of different lengths M8 x 25 mm (1).
M8 x 20 mm (2)
1 2
© 42170-1
Fig. 1070
WARNING
Ensure that parts are not under tension when installed!
1 2
m Fit the oil sump pan (Railway).
© 42170-1
Fig. 1071
30-98
Engine accessories
30.23 - Disassembly and assembly of the oil radiator (L3)
NOTE
30.23.1 - Removal of the oil cooler

m Disassemble the thermostat box.
© 40849-0
Fig. 1072
© 40519-0
Fig. 1073
1
2
© 40850-0
Fig. 1074
30-99
Engine accessories
© 40851-0
Fig. 1075
NOTE
1
m Remove the seals.
2
© 40852-0
Fig. 1076
1
1
© 40853-0
Fig. 1077
30-100
Engine accessories
m Remove oil radiator cover (2).
© 40854-0
Fig. 1078
m Remove oil cooler (2)
1 1
© 40855-0
Fig. 1079
© 40856-0
Fig. 1080
30-101
Engine accessories
30.23.2 - Refitting the oil cooler
1 1
2 2
© 40857-0
Fig. 1081
m Align the oil radiator.
1 1
© 40855-0
Fig. 1082
m Fit a new seal.
m Fit the oil radiator cover.
m Fit support (1).
Screw length:
M8 x 35 mm
2 2
Screw length:
M8 x 65 mm 3
© 40858-0
Fig. 1083
30-102
Engine accessories
4. m Align the oil radiator cover (2) correctly.
NOTE
The support surfaces of the oil radiator casing and
the assembly support must be resting on the sup- 1
ports. Do not move the gasket.
2
© 40854-0
Fig. 1084
1
1
© 40853-0
Fig. 1085
© 40852-0
Fig. 1086
30-103
Engine accessories
m Fit support (2).
m Screw in nut (1);
© 40851-0
Fig. 1087
1
2
© 40850-0
Fig. 1088
© 40519-0
Fig. 1089
30-104
Engine accessories
NOTE
1
3
2
m Tighten nut (2).
m Tighten banjo bolt (3).
© 40859-0
Fig. 1090
11. m Assemble the thermostat box.
© 40849-0
Fig. 1091
30-105
Engine accessories
30.24 - Fitting and removing transition pipe
30.24.1 - Removing the transition pipe

1. m 1 - Transition pipe
m 2 - Torx screw
m 3 - Hole blanking screw: 35 Nm
m 291 - Sealant
© 50424-0
Fig. 1092
2. m Remove the oil sump pan.
Construction unit
02

m Remove the transition pipe (2)
m Carry out a visual inspection of the component.
© 50425-0
Fig. 1093
30.24.2 - Fitting the transition pipe

WARNING
Keep the sealant out of the oil channel (1)!
© 50723-1
Fig. 1094
30-106
Engine accessories
2. m Apply sealant (1) evenly to the mating surface.
© 51276-0
Fig. 1095
m Fit the transition pipe (1)
m Tighten the screws (2): 20 Nm.
Construction unit
02
© 50427-0
Fig. 1096

Tightening torque
Table 53
tions
A01 016 Transition pipe on crank- 20 Nm
case
NOTE
30-107
Engine accessories
30.25 - Line
1. m 1 - Pipe retaining clip
m 2 - Pipe
m 3 - Spring clip
m 4 - Rubber sleeve
m 5 - Intake manifold
m 6 - Spring clip
m 7 - Hex screw: 8 Nm
© 50658-0
Fig. 1097
30-108
Engine accessories
30.26 - Fitting and removing the oil pressure transducer (L3)
Special tools:
NOTE
Read the error memory of the engine control device with SERDIA.
30.26.1 - Removing the oil pressure transducer

1. m Unplug cable connector (1).
© 40860-0
Fig. 1098
2. m Undo the oil pressure transducer (1) with the socket wrench insert.
© 40861-0
Fig. 1099
© 40862-0
Fig. 1100
30-109
Engine accessories
30.26.2 - Fitting the oil pressure transducer
1. m Fit a new gasket.
m Fit the oil pressure transducer (1).
m Tighten the oil pressure transducer with the socket wrench insert. 1
© 40861-0
Fig. 1101
NOTE
Delete the error condition from the engine control de- 1
vice error memory with SERDIA.
© 40860-0
Fig. 1102
30-110
Engine accessories
30.27 - Fitting and removing the regulator valve (L3)
l Depth gauge
NOTE
30.27.1 - Removing the regulator valve

© 40863-0
Fig. 1103
m Unlock and disconnect wiring connector (2).
© 40608-0
Fig. 1104
© 40609-0
Fig. 1105
30-111
Engine accessories
© 40864-0
Fig. 1106
© 40613-0
Fig. 1107
© 40972-0
Fig. 1108
30-112
Engine accessories
© 40973-0
Fig. 1109
8. m Do not fully unscrew drain plug (1).
m Remove the seal.
© 40865-0
Fig. 1110
9. m Undo the valve housing (1).
m Remove the seal.
NOTE
1
Do not squeeze the regulation pins (2).
© 40866-0
Fig. 1111
30-113
Engine accessories
10. NOTE
To ensure that the same pressure value is set again, mea-
sure the protrusion of the adjustment pins before removal.
m Measure the protrusion (X) of the adjuster pins (1) relative to the
crankcase using a depth gauge.
1
Write down the measured value.
X
m
© 40867-0
Fig. 1112
11. m Undo the adjustment pins (1).
m Remove the compression spring.
m Remove the valve piston.
1
© 40868-0
Fig. 1113
n Adjustment pins (1).
n Compression spring (2).
n Valve piston (3).
1 2 3
© 42460-1
Fig. 1114
30-114
Engine accessories
30.27.2 - Fitting regulator valve
1. NOTE
Protrusion (X) relative to base setting of adjustment pin. To
set the same pressure value as before, set the same protru-
sion value (X) measured before removal.
© 35022-2
Fig. 1115
2. m Fit the valve piston.
m Insert the compression spring.
m Tighten the adjustment pins (1).
See para. 20.3 - Test and adjustment da... - page 20-12 1
NOTE
Set the protrusion of the adjustment pin correctly.
© 40868-0
Fig. 1116
m Oil the threads of the valve housing lightly.
m Tighten the valve housing (1).
NOTE
Do not squeeze the regulation pins (2).
1
© 40869-0
Fig. 1117
30-115
Engine accessories
© 40865-0
Fig. 1118
5. m Fit fuel line (2).
© 40973-0
Fig. 1119
m Fit support (2).
m Tighten nuts (1).
1
© 40972-0
Fig. 1120
30-116
Engine accessories
7. m Tighten the union nuts (1).
© 40990-0
Fig. 1121
© 40613-0
Fig. 1122
© 40864-0
Fig. 1123
30-117
Engine accessories
© 40609-0
Fig. 1124
11. m Connect cable connector (2).
m Fix the cable tie (1).
© 40608-0
Fig. 1125
12. m Assemble the supply air pipe (bench B).
© 40848-0
Fig. 1126
30-118
Engine accessories
30.28 - Closing components
1. NOTE
Collect used lubricating oil and dispose of it in accordance
with the applicable regulations.

m 2 – O-ring
NOTE
Use a new O-ring.
© 50331-0
Fig. 1127
30-119
Engine accessories
30.29 - Topping up with oil
1. m 1 - Oil filler pipe
m 3 - Closing plug
m 4 - Gasket
NOTE
Use a new gasket.
© 50668-0
Fig. 1128
30-120
Engine accessories
30.30 - Removing and fitting the coolant pump (L3)
Special tools:
NOTE
30.30.1 - Removal of the water pump

m Remove the inlet unions (2)
© 40870_1
Fig. 1129
© 45393-0
Fig. 1130
© 40871-0
Fig. 1131
30-121
Engine accessories
NOTE
1 1
Use three M8 stud bolts to remove the coolant pump
from the ancillary mount.
m Remove the coolant pump.

© 40872-0
Fig. 1132
m Remove seal (1) using the removal tool.
m Remove seal (2) using the removal tool.
© 36828_1
Fig. 1133
© 40874-0
Fig. 1134
30-122
Engine accessories
30.30.2 - Refitting the water pump
1. m Insert new O-rings.
O-ring:
75 x 3 mm (1), 80 x 3 mm (2)
1
© 36828_1
Fig. 1135
NOTE
Check that the drain holes (arrows) are completely
clear.
© 40876-0
Fig. 1136
3. m Tighten the stud bolts (1).
NOTE
1 1
For fastening the seal and coolant pump.
m Fit a new seal.
© 40877-0
Fig. 1137
30-123
Engine accessories
4. m Insert the coolant pump.
NOTE
The gear wheel (1) must engaged in the teeth of the
intermediate wheel (2).
WARNING 1
Do not damage the gasket. Do not move the gasket. 2
© 40875-0
Fig. 1138
1
m Undo the stud bolts (2). 2 2
© 40878-0
Fig. 1139
See para. 20.4 - Tightening torque (L3) - page 20-14 1 1
© 40879-0
Fig. 1140
30-124
Engine accessories
m Fit a new seal.
m Fit the inlet unions (2)
© 40870_1
Fig. 1141
30-125
Engine accessories
30.31 - Check the thermostat (after removal) (L3)
l Thermometer
DANGER
Risk of injury! Hot water and hot thermostat.
30.31.1 - Testing the thermostat

1. m Remove the thermostats.
m Measure dimension (a), with thermostat closed.
© 34679-3
Fig. 1142
2. m Place the thermostat in water and heat the water.
m Determine the temperature at which the thermostat starts to open.
NOTE
To ensure an accurate reading, measure the tem-
perature as near to the thermostat as possible. Do
not touch the thermostat. To ensure that the heat is
evenly distributed, the water should be in constant
motion. The temperature should not increased at a
rate of more than 1°C/min., otherwise opening of the
thermostat will be delayed.
© 34680-2
Fig. 1143
3. m Measure dimension (b), with thermostat open.
© 34679-2
Fig. 1144
30-126
Engine accessories
4. m Calculate the stroke of the thermostat valve.
Table 54
Target: Valve stroke
Data: -
Measured value: Stroke start, dimension (a). Stroke
end, dimension (b)
Calculation: (b) - (a)
The results of all this are: = Valve stroke
m Compare this value with the nominal value. © 34679-1
See para. 20.3 - Test and adjustment da... - page 20-12 Fig. 1145
m Fit the thermostats.
30-127
Engine accessories
30.32 - Removal and refitting of the flywheel (fixing elements)
Special tools:
l Guide pin (shop-made tool)
l M10x120 auxiliary screws
l Rotation angle gauge 01899093
30.32.1 - Removal of the flywheel

1. m 1 – Flywheel
m 2 – Ring gear
m 3 – Screw
m 4 - Bearing bush
© 51460-0
Fig. 1146
2. m Hold the crankshaft from the central screw.
m Fit service screws (1).
m Remove the flywheel using the service screws.
© 51462-0
Fig. 1147
30.32.2 - Refitting the flywheel

1. m Insert the shop-made guide pin
NOTE
The holes in the flywheel must coincide with the
threaded hole in the V-belt pulley.
m Fit the flywheel using the service screws.
© 51463-0
Fig. 1148
30-128
Engine accessories
2. WARNING
The screws must be renewed after being removed.
m Tighten the screws in alternate sequence.

n Stage 1: 30 Nm.
m Tighten the screws using the rotation angle gauge.

n Stage 2: 60°
n Stage 3: 30°
m Withdraw locating dowel “A”.
m Unscrew the service screws.
© 51464-0
Fig. 1149

Tightening torque
Table 55
tions
A05 001 Flywheel to engine block Stage 1: Use new screws 30 Nm
A05 001 Flywheel to engine block Stage 2: 60°
A05 001 Flywheel to engine block Stage 3: 30°
NOTE
30-129
Engine accessories
30.33 - Removal and refitting of the cylinder head cover
30.33.1 - Removal of the cylinder head cover
1. m 1 - Cylinder head cover
m 2 - Gasket
m 3 – Screw
m 4 - Closing plug
m 5 - Connector
© 50507-0
Fig. 1150
Construction unit
01

m Remove cylinder head cover (2).
© 50508-0
Fig. 1151
3. m Remove seal (1).
© 50509-0
Fig. 1152
30-130
Engine accessories
30.33.2 - Refitting the cylinder head cover
© 50509-0
Fig. 1153
2. m Fit cylinder head cover (1).
© 50510-0
Fig. 1154
3. m Tighten the screws in the sequence indicated: 8.5 Nm
Construction unit
01
© 50511-0
Fig. 1155
30-131
Engine accessories
Tightening torque
Table 56
tions
A08 004 Cylinder head cover to 8.5 Nm
cylinder head
NOTE
30-132
Engine accessories
30.34 - Fitting and removing the thermostats (L3)
NOTE
30.34.1 - Removing the thermostats

1. m Disassemble the thermostat box.
m Remove all the screws (1). 2
m Remove water outlet elbow (2).
1
© 40880_1
Fig. 1156
2. m Remove the thermostats (1).
© 40881-0
Fig. 1157
m Check the thermostats.
See para. 30.31 - Check the thermostat (... - page 30-126
© 40882-0
Fig. 1158
30-133
Engine accessories
30.34.2 - Fitting the thermostats
1. m Select the correct thermostats.
m Apply the assembly product on the O-rings.
1
m Tighten the new O-rings (1).
NOTE
Note that the thermostats have different aperture
temperatures (arrows).
© 40883-0
Fig. 1159
2. NOTE
Observe the installation position. The markings (3) must
face upwards. 3
Ensure that the thermostat is installed in the correct posi- 1 2
tion.
m Insert the thermostat (1).
m Insert the thermostat (2).
© 40884_2
Fig. 1160
3. m Fit the exhaust aperture (2).
2
m Assemble the thermostat box.
© 40880_1
Fig. 1161
30-134
Engine accessories
30.35 - Removing and fitting the thermostat housing (L3)
NOTE
30.35.1 - Removing the thermostat housing

© 40885-0
Fig. 1162
© 40886-0
Fig. 1163
m Set the mount aside (2).
© 40887-0
Fig. 1164
30-135
Engine accessories
m Remove the spacer bush.
m Set the pipe aside.
© 40888-0
Fig. 1165
m Remove the seals.
© 40889-0
Fig. 1166
6. m Unscrew screw (2)
© 40890-0
Fig. 1167
30-136
Engine accessories
© 40891-0
Fig. 1168
8. m Remove thermostat housing (1).
© 40892-0
Fig. 1169
© 40893-0
Fig. 1170
30-137
Engine accessories
30.35.2 - Refitting the thermostat housing
m Fit a new gasket.
m Install thermostat housing (1). 1
NOTE
Do not move the gasket.
2
m Connect cable connector (2).
© 40892-0
Fig. 1171
2. m Fit the screws.
NOTE
Note that the screws are of different lengths M8 x 90
mm (1). M8 x 65 mm (2)
2 1 2
© 40894-0
Fig. 1172
Screw length:
M8 x 140 mm. Tighten the screw only after fitting the 1
fuel lines (glow plugs).
m Fit the connector (3).

3
© 40890-0
Fig. 1173
30-138
Engine accessories
2 1 2
© 40894-0
Fig. 1174
© 40889-0
Fig. 1175
6. m Connect the fuel pipe.
m Position the spacer bush.
© 40888-0
Fig. 1176
30-139
Engine accessories
NOTE X
Pay attention to assembly dimension (X).
© 45406-0
Fig. 1177
© 40888-0
Fig. 1178
Screw length:
M8 x 150 mm
2
© 40887-0
Fig. 1179
30-140
Engine accessories
© 40886-0
Fig. 1180
© 40956-0
Fig. 1181
30-141
Engine accessories
30.36 - Support
1. WARNING
Ensure maximum cleanliness during all work. Before pro-
ceeding with removal, remove any paint residue or debris.
Thoroughly clean the area around the components to be
worked on. Dry any wet areas with an air jet. All fuel lines
and unions should be closed immediately after opening us-
ing new, clean plugs or caps. Remove plugs and caps only
immediately prior to assembly.
m 1 – Mount
m 2 - Speed sensor
m 3 - Hex screw: 8.5 Nm
© 51285-0
n Position 2:
Fig. 1182
NOTE
Use a new O-ring.
30-142
Engine accessories
30.37 - Intermediate gear
1. m 1 - Intermediate gear
m 2 - Shaft
© 51284-0
Fig. 1183
30-143
Engine accessories
30.38 - Disassembly and assembly of the torsional vibration damp-
er (L3)
30.38.1 - Removal of the torsional vibration damper
m Remove V-belt pulley (2).
© 40965-0
Fig. 1184
2. m Withdraw torsional vibration damper (1).
DANGER 1
Risk of injury!
© 40897-0
Fig. 1185
© 40898-0
Fig. 1186
30-144
Engine accessories
30.38.2 - Refitting the torsional vibration damper
1. m Fit torsional vibration damper (1).
1
© 40897-0
Fig. 1187
2. m Fit V-belt pulley (2).
© 40965-0
Fig. 1188
30-145
Engine accessories
30.39 - Lubricating oil filter console
1. NOTE
Collect operating materials in suitable containers and dis-
pose of them in compliance with the applicable regulations.
To drain and replenish the engine fluids and lubricants, fol-
low the instructions provided.
m 1 - Replacement filter: 12 Nm
m 2 - Threaded bush
m 3 - Cover
m 4 - O-ring
NOTE
Use a new O-ring. © 50390-0
Fig. 1189
30-146
Engine accessories
30.40 - Replacing the starter ring gear on the flywheel (L3)
DANGER
Risk of accident, do not touch hot components!
30.40.1 - Disassembly of the starter ring gear

m Check the notches.
NOTE
The notch (arrow) is located on the flywheel and is
exactly in the centre of the slot of the
tooth of the starter ring gear.
© 40904-0
Fig. 1190
2. m Remove the starter ring gear with a suitable tool.
© 34764-2
Fig. 1191
3. m Visually inspect the collar and mating surface (arrow).
m Clean the flywheel.
NOTE
The collar and mating surface must be clean with no
traces of grease or dirt.
© 34765-2
Fig. 1192
30-147
Engine accessories
30.40.2 - Assembly of the starter ring gear
1. m Check the notch of the new starter ring gear.
NOTE
The notch (arrow) is located on the flywheel and is
exactly in the centre of the slot of the
tooth of the starter ring gear.
© 40905-0
Fig. 1193
2. m Heat the starter ring gear to 220 °C.
m Position the starter ring gear on the flywheel.
NOTE
The notches on the flywheel and on the ring gear
must be aligned.
The starter ring gear must rest evenly on the flywheel
support flange.
© 40906-0
Fig. 1194
3. m Fit the flywheel.
© 40907-0
Fig. 1195
30-148
Engine accessories
30.41 - Removing and fitting the hydraulic pump drive (L3)
Special tools:
NOTE
30.41.1 - Disassembly of the hydraulic pump drive

1. m Disassemble the exhaust pipe (bench A).
m Remove screw (1).
m Remove lubricating oil pipe (3).
3 2
© 40908-0
Fig. 1196
m Remove the housing with flange (2).
1
2
© 40909-0
Fig. 1197
m Remove the hydraulic pump drive (2).
1
© 40910-0
Fig. 1198
30-149
Engine accessories
4. m Remove seal (1) using the removal tool.
© 42200-2
Fig. 1199
30.41.2 - Assembly of the hydraulic pump drive

m Apply a thin smear of assembly product to the O-ring.
© 42200-2
Fig. 1200
2. m Fit the hydraulic pump drive.
NOTE
2
The gear wheel (1) must engaged in the teeth of the
intermediate wheel (2).
© 40913-0
Fig. 1201
30-150
Engine accessories
1
© 40914-0
Fig. 1202
m Apply the fastening product on the resting surface (arrow).
© 45409-0
Fig. 1203
5. m Fit the housing with flange (1).
Screw length:
2 1
M10 x 110 mm

Screw length: 3
M10 x 210 mm
© 40915-0
Fig. 1204
30-151
Engine accessories
1
© 45395-0
Fig. 1205
m Tighten the union nuts (2). 1
m Assemble the exhaust pipe (bench A). 3 2
© 40908-0
Fig. 1206
30-152
Engine accessories
30.42 - Disassembly and assembly of the connector box
1. m 1 - Connector box
m 2 - Hex screw
m 3 - Bush
© 50430-0
Fig. 1207
Construction unit
05
m Remove screw (1).

m Withdraw the connector box (2).
© 50431-0
Fig. 1208

NOTE
Check that tightening bush (1) is present.
© 50432-0
Fig. 1209
30-153
Engine accessories
2. m Position the connector box (1).
m Centre the connector box above the tightening bushes.
© 50433-0
Fig. 1210
m Tighten all screws (1) alternately: 170 Nm.
m Fit the flywheel.
Construction unit
05
© 50434-0
Fig. 1211

Tightening torque
Table 57
tions
A52 080 Connector box in corre- Tighten alternatively 170 Nm
spondence of the crank-
case
NOTE
30-154
Engine accessories
m 2 - Hex screw
m 3 - Bush
© 51359-0
Fig. 1212
Construction unit
05
m Remove screw (1).

© 50431-0
Fig. 1213

NOTE
© 50432-0
Fig. 1214
30-155
Engine accessories
© 50433-0
Fig. 1215
m Fit the flywheel.
Construction unit
05
© 50434-0
Fig. 1216

Tightening torque
Table 58
tions
case
NOTE
30-156
Engine accessories
m 2 - Hex screw
m 3 - Bush
© 51360-0
Fig. 1217
Construction unit
05
m Remove screw (1).

© 50431-0
Fig. 1218

NOTE
© 50432-0
Fig. 1219
30-157
Engine accessories
© 50433-0
Fig. 1220
m Fit the flywheel.
Construction unit
05
© 50434-0
Fig. 1221

Tightening torque
Table 59
tions
case
NOTE
30-158
Engine accessories
m 2 - Bush
© 51358-0
Fig. 1222
Construction unit
05
m Remove screw (1).

© 50431-0
Fig. 1223

NOTE
© 50432-0
Fig. 1224
30-159
Engine accessories
© 50433-0
Fig. 1225
m Fit the flywheel.
Construction unit
05
© 50434-0
Fig. 1226

Tightening torque
Table 60
tions
case
NOTE
30-160
Engine accessories
30.46 - Removal and refitting of the crankshaft speed sensor (L3)
Special tools:
l Dial gauge-adapter: 101830
NOTE
30.46.1 - Removal of the speed sensor

1. m Fit the rotation device.
m Unlock and detach connectors (1).
1
© 40710-0
Fig. 1227
© 40932-0
Fig. 1228
30-161
Engine accessories
m Remove speed sensor (2).
© 40711-0
Fig. 1229
m Clean the components.
© 45879-1
Fig. 1230
30.46.2 - Refitting the speed sensor

NOTE
No holes (arrow) must be visible on the flywheel
through the installation aperture for the speed sen-
sor.
© 45900-0
Fig. 1231
30-162
Engine accessories
2. m Insert the dial gauge in the adapter (1).
© 45897-0
Fig. 1232
3. m Insert the loaded dial gauge in the base plate (1).
m Fasten the dial gauge in the adapter.
© 45898-0
Fig. 1233
4. m Insert the adapter with the dial gauge to the end stop in the connec-
tor box and press.
NOTE
The dial gauge probe must be in contact with the flat
surface of the flywheel.
m Write down the measured value.

m Apply 120° reference marks on the vibration damper.
WARNING
Remove the adapter and dial gauge before turning the
crankshaft.
© 45899-0
m Continue to turn the crankshaft to the next 120° notch in the direc- Fig. 1234
tion of rotation.
m Select the lowest value measured after 3 attempts, dimension (a).
30-163
Engine accessories
5. m Measure the distance, dimension (b): 24 (+0.1, -0.2 mm).
m Calculate the difference between dimension (a) and dimension (b),
dimension (y).
Table 61
Calculation example: b
Target: Dimension (y)
Data: Dial gauge-adapter dimension =
24.00 mm
Measured value: Dimension a = Dial gauge-adapter
dimension + lowest value measured.
Measurement (a) = 24.00 mm + 0.49 © 45878-1
mm. Measurement (a) = 24.49 mm. Fig. 1235

Measurement (b) = 24.00 mm
Calculation: Dimension (y) = dimension (a) - di-
mension (b). Measurement (y) =
24.49 mm - 24.00 mm
The results of all this are: Measurement (y) = 0.49 mm
6. m Calculate the speed indicator gasket, maintaining the permitted dis- c
tance equal to dimension (c).
Table 62 1
Target Maintenance of the permitted dis-
tance, dimension (c). Gasket
Data: Minimum value for measurement
(c1) = 1.00 mm. Dimension (y). Gas-
ket thickness = 0.30 mm. Gasket
thickness = 0.50 mm. 2
Measured value: -
Calculation: Dimension (c) = minimum distance © 45904-0
dimension (c1) - dimension (y) + Fig. 1236

gasket thickness. Measurement (c)
= 1.00 mm - 0.49 mm + 0.50 mm.
Measurement (c) = 1.01 mm.
The results of all this are: Measurement (c) is the permissible
distance. Use a seal measuring 0.50
mm in thickness.
m Permitted distance (c) between the flywheel (1) and speed indicator
(2).
30-164
Engine accessories
7. m Select the new gaskets.
NOTE
The gaskets are available with a thickness of 0.3 mm
and 0.5 mm. The correct distance (c) is obtained by
fitting the suitable number of gaskets.
© 45882-0
Fig. 1237
8. m Fit the new gasket/gaskets based on the calculated distance.
m Fully press down the speed indicator (2).
WARNING
Take care not to damage the components
1
2
© 40711-0
Fig. 1238
© 40932-0
Fig. 1239
30-165
Engine accessories
NOTE
1

NOTE
2
Delete the error condition from the engine control de-
© 40710-0
Fig. 1240
30-166
Engine accessories
30.47 - Removal and refitting of the camshaft speed sensor (L3)
Special tools:
l Dial gauge-adapter: 101830
NOTE
30.47.1 - Removal of the speed sensor

© 40700-0
Fig. 1241
2. m Unlock and detach connectors (1).
© 40717-0
Fig. 1242
30-167
Engine accessories
© 40718-0
Fig. 1243
m Remove cover (2).
© 40719-0
Fig. 1244
m Remove speed sensor (2).
1
© 40720-0
Fig. 1245
30-168
Engine accessories
6. m Remove the protective film.
m Clean the components. 1
© 00000-0
Fig. 1246
30.47.2 - Refitting the speed sensor

NOTE
The pin (arrow) must be in the centre of the assembly
aperture.
© 45901-0
Fig. 1247
2. m Insert the dial gauge in the adapter (1).
© 45897-0
Fig. 1248
30-169
Engine accessories
3. m Insert the loaded dial gauge in the base plate (1).
m Fasten the dial gauge in the adapter.
© 45898-0
Fig. 1249
4. m Insert the adapter with the dial gauge to the end stop in the connec-
tor box and press.
NOTE
The dial gauge probe must be in contact with the
camshaft gear pin.

m Apply 120° reference marks on the vibration damper.
WARNING
Remove the adapter and dial gauge before turning the
crankshaft.
© 45902-0
m Continue to turn the crankshaft to the next 120° notch in the direc- Fig. 1250
tion of rotation.
m Select the lowest value measured after 3 attempts, dimension (a).
5. m Measure the distance, dimension (b): 24 (+0.1, -0.2 mm).
m Calculate the difference between dimension (a) and dimension (b),
dimension (y).
Table 63
Calculation example: b
Target: Dimension (y)
Data: Dial gauge-adapter dimension =
24.00 mm
Measured value: Dimension a = Dial gauge-adapter
dimension + lowest value measured.
Measurement (a) = 24.00 mm + 0.76 © 45878-1
mm. Measurement (a) = 24.76 mm. Fig. 1251

(Measurement B) 23.90 mm =
Calculation: Dimension (y) = dimension (a) - di-
mension (b). Measurement (y) =
24.76 mm - 23.90 mm
The results of all this are: Measurement (y) = 0.86 mm
30-170
Engine accessories
6. m Calculate the speed indicator gasket, maintaining the permitted dis- c
tance equal to dimension (c).
Table 64 1
Target Maintenance of the permitted dis-
tance, dimension (c). Gasket
Data: Minimum value for measurement
(c1) = 0.30 mm. Dimension (y). Gas-
ket thickness = 0.30 mm. Gasket
thickness = 0.50 mm. 2
Measured value: -
Calculation: Dimension (c) = minimum distance © 45903-0
dimension (c1) - dimension (y) + Fig. 1252

gasket thickness. Measurement (c)
= 0.30 mm - 0.86 mm +(2 x 0.50
mm). Measurement (c) = 0.44 mm.
The results of all this are: Measurement (c) is the permissible
distance. Use two seals measuring
0.50 mm in thickness.
m Permitted distance (c) between the flywheel (1) and speed indicator
(2).
7. m Select the new gaskets.
NOTE
The gaskets are available with a thickness of 0.3 mm
and 0.5 mm. The correct distance (c) is obtained by
fitting the suitable number of gaskets.
© 45882-0
Fig. 1253
8. m Disassemble the dial gauge.
m Apply assembly sealant to the ring seal (1).
© 45878-2
Fig. 1254
30-171
Engine accessories
NOTE
Make sure the cables are connected correctly. 1
m Wrap protective film around the cable connector.
© 00000-0
Fig. 1255
m Fit the new gasket/gaskets based on the calculated distance.
m Fully press down the speed indicator (2).
1
WARNING
Take care not to damage the components
2

© 40720-0
Fig. 1256
1
© 40719-0
Fig. 1257
30-172
Engine accessories
© 40718-0
Fig. 1258
NOTE
1
© 40717-0
Fig. 1259
14. m Fit the turbocharger.
NOTE
© 40716-0
Fig. 1260
30-173
Engine accessories
30.48 - Removing and fitting the exhaust pipe
(Bank A) (L3)

1. m Disassemble the exhaust pipe (bench A).
© 40722-0
Fig. 1261
2. m Loosen screws (1).
© 40723-0
Fig. 1262
m Remove exhaust manifold (2).
© 45810-0
Fig. 1263
30-174
Engine accessories
© 40725-0
Fig. 1264
© 40726-0
Fig. 1265
30.48.2 - Refitting the exhaust manifold

NOTE
Observe the installation position. The tab (arrow)
must face towards the cylinder head.

© 45374-0
Fig. 1266
30-175
Engine accessories
2. m Fit exhaust pipe (2).
© 45810-0
Fig. 1267
3. m Tighten all the screws (1) alternatively, starting with those in the cen-
tre and working outwards.
© 40986-0
Fig. 1268
4. m Assemble the exhaust pipe (bench A).
© 40722-0
Fig. 1269
30-176
Engine accessories
(Bank B) (L3)

1. m Disassemble the exhaust pipe (bench B).
m Loosen screws (1). 1
© 40727-0
Fig. 1270
m Remove exhaust manifold (2).
© 45809-0
Fig. 1271
© 40730-0
Fig. 1272
30-177
Engine accessories
© 40729-0
Fig. 1273

NOTE
Observe the installation position. The tab (arrow)
must face towards the cylinder head.

© 45375-0
Fig. 1274
2. m Fit exhaust pipe (2).
© 45809-0
Fig. 1275
30-178
Engine accessories
3. m Tighten all the screws (1) alternatively, starting with those in the cen-
tre and working outwards.
m Assemble the exhaust pipe (bench B). 1
© 40985-0
Fig. 1276
30-179
Engine accessories
(Bank A) (L3)

m Remove the screws. 1
m Remove the seals.
m Remove the exhaust pipe (2).
2
© 40733-0
Fig. 1277

1. m Position the exhaust pipe (1).
2
NOTE
Install in the correct position
1
m Insert the O-ring.

NOTE
Observe the installation position. The cone (arrow)
faces the exhaust pipe.
m Fit the flange (2) on the exhaust manifold.

m Apply a thin film of assembly product on the screws. 3
m Tighten screws (3). © 36795-1
Fig. 1278
2. m Insert the O-ring.
NOTE 1

m Fit the flange (1) on the exhaust pipe.

3
2
© 36796-1
Fig. 1279
30-180
Engine accessories
NOTE
Make sure that the flange joint (arrow) is at an even
distance.
© 37216-1
Fig. 1280
4. m Tighten the nuts in order (1).
NOTE
distance.
© 40736-0
Fig. 1281
30-181
Engine accessories
30.51 - Removing and fitting the exhaust pipe (Bank B) (L3)

m Remove screws (1). 1
m Remove the seals.
m Remove the exhaust pipe (2).
© 40734-0
Fig. 1282

1. m Position the exhaust pipe (1).
NOTE
1
2
m Insert the O-ring.
NOTE
m Fit the flange (2) on the exhaust manifold.

3
m Tighten screws (3). © 36799-1
Fig. 1283
2. m Insert the O-ring.
NOTE 1

m Fit the flange (1) on the exhaust pipe.

2 3
© 36800-1
Fig. 1284
30-182
Engine accessories
NOTE
distance.
© 37218-1
Fig. 1285
4. m Tighten the nuts in order (1).
NOTE
distance.
© 40735-0
Fig. 1286
30-183
Engine accessories
30.52 - Assembly and disassembly of the spark plug (L3)
Special tools:
WARNING
30.52.1 - Disassembly of the spark plug

m Unscrew nuts (1). 1
NOTE
Mark the cables and the respective connections be- 2
© 40770-0
Fig. 1287
2. m Loosen locknut (1).
m Undo the glow plug (2).
2 1
© 40771-0
Fig. 1288
30-184
Engine accessories
© 40772-0
Fig. 1289
30.52.2 - Assembly of the spark plug

m Screw the glowplug.
NOTE
Pay attention to screwing dimension (X).
© 45404-0
Fig. 1290
© 40773-0
Fig. 1291
30-185
Engine accessories
3. m Tighten the check nut (1).
© 40774-0
Fig. 1292
4. m Fit the wiring connector (2).
1
WARNING
2
tions!
NOTE
disassembly.
m Fit the washer.

m Tighten nut (1).
Fig. 1293
30-186
Engine accessories
30.53 - Assembly and disassembly of the spark plug (L3)
Special tools:
WARNING
30.53.1 - Disassembly of the spark plug

m Remove the elastic washers.
m Remove the ground cable.
NOTE
© 45907-0
Fig. 1294
2. m Disassemble the fuel lines (spark plugs) (Railway).
© 42025-2
Fig. 1295
30-187
Engine accessories
1
1
© 42185-2
Fig. 1296
4. m Remove the cables (1).
NOTE
1
© 42192-2
Fig. 1297
5. m Disengage locknut (2).
m Undo the glow plug (1).
m Remove the insulator washer (3).
2
3
© 42187-1
Fig. 1298
30-188
Engine accessories
6. m Undo the adapter (1).
m Remove the seal.
© 42188-1
Fig. 1299
7. m Undo the checknut.
© 42191-2
Fig. 1300
30.53.2 - Assembly of the spark plug

m Tighten the adapter (1).
© 42188-1
Fig. 1301
30-189
Engine accessories
2. m Tighten the checknut.
© 42191-2
Fig. 1302
3. m Fit the insulator washer (1).
m Tighten the glow plug (2).
© 42187-2
Fig. 1303
4. m Position the spark plug.
NOTE
Pay attention to screwing dimension (X). The thread-
ed union (1) must face towards the crankshaft at a 1
right angle (90°).
X
© 45911-0
Fig. 1304
30-190
Engine accessories
5. m Tighten the check nut (1).
© 45927-0
Fig. 1305
6. WARNING
tions!
m Connect the positive cable (R3.1) to the spark plug (1). 1

m Connect the positive cable (R3.2) to the spark plug (2).
© 45928-0
Fig. 1306
7. m Insert the shims.
m Tighten the nuts.
m Tighten nuts (1).
m Assemble the fuel lines (spark plugs) (Railway).
© 42185-2
Fig. 1307
30-191
Engine accessories
8. m Connect the ground cable.
m Fit the spring washer.
© 45907-0
Fig. 1308
30-192
Engine accessories
30.54 - Disassembly and assembly of the fuel cutoff valve (spark
plugs) (L3)
Special tools:
WARNING
30.54.1 - Disassembly of the fuel cutoff valve

© 40951-0
Fig. 1309
2. m Restrain the threaded fitting.
m Restrain the threaded fitting.
m Remove the flexible fuel hose (3). 1
© 40776-0
Fig. 1310
30-193
Engine accessories
m Remove the spacer bush.
m Remove the fuel cutoff valve (2).
1
m Remove the hose clip.
© 40778-0
Fig. 1311
© 40779-0
Fig. 1312
30.54.2 - Assembly of the fuel cutoff valve

© 40779-0
Fig. 1313
30-194
Engine accessories
2. m Locate the hose clip.
m Screw the sleeve nuts (1). 1
© 40780-0
Fig. 1314
3. m Screw the sleeve nuts (1).
© 40781-0
Fig. 1315
4. m Position the spacer bush.
© 40782-0
Fig. 1316
30-195
Engine accessories
NOTE X
Pay attention to assembly dimension (X).
© 45406-0
Fig. 1317
© 40783-0
Fig. 1318
7. m Position the spark plug.
NOTE
Install at the correct angle and with the correct di-
mension (X).
© 45407-0
Fig. 1319
30-196
Engine accessories
8. WARNING
Install the fuel pipes without tension.
1
© 40784-0
Fig. 1320
© 40951-0
Fig. 1321
30-197
Engine accessories
30.55 - Disassembly and assembly of the fuel cutoff valve (spark
plugs) (L3)
Special tools:
WARNING
30.55.1 - Disassembly of the fuel cutoff valve

© 42020-2
Fig. 1322
m Remove the seals.
NOTE
Collect any leaked fuel and dispose of it properly.
1
m Plug the hose (2).
© 42021-1
Fig. 1323
30-198
Engine accessories
© 42022-1
Fig. 1324
m Remove the fuel cutoff valve (2).
m Remove the hose clip.
1
2
© 42023-1
Fig. 1325
© 45913-0
Fig. 1326
30-199
Engine accessories
30.55.2 - Assembly of the fuel cutoff valve
m Fit the hose clip (2).
1 2
© 45912-0
Fig. 1327
1
© 42024-1
Fig. 1328
© 42023-2
Fig. 1329
30-200
Engine accessories
NOTE
Pay attention to assembly dimension (X). X
© 45909-0
Fig. 1330
© 42023-2
Fig. 1331
WARNING
Install the fuel pipes without tension.
© 42022-1
Fig. 1332
30-201
Engine accessories
WARNING
m Insert the new O-rings. 1

© 42021-1
Fig. 1333
NOTE
© 42020-2
Fig. 1334
30-202
Engine accessories
30.56 - Disassembly and assembly of the fuel pipes (spark plugs)
(L3)
Special tools:
DANGER
WARNING
30.56.1 - Removal of fuel lines

m Remove screw (1).
m Loosen hose clip (2)
1
© 40785-0
Fig. 1335
1
1
© 45378-0
Fig. 1336
30-203
Engine accessories
3. m Remove the fuel lines (1).
© 45376-0
Fig. 1337
© 45377-0
Fig. 1338
30.56.2 - Refitting fuel lines.

1. m Install the fuel lines (1).
© 45376-0
Fig. 1339
30-204
Engine accessories
1
1
© 45378-0
Fig. 1340
© 40785-0
Fig. 1341
WARNING
When installing the fuel line, make sure it is not under ten- 1
sion.
© 40952-0
Fig. 1342
30-205
Engine accessories
WARNING
When installing the fuel line, make sure it is not under ten-
sion.
© 40789-0
Fig. 1343
m Assemble the turbocharging air duct.
1
© 45379-0
Fig. 1344
30-206
Engine accessories
30.57 - Disassembly and assembly of the fuel pipes (spark plugs)
(L3)
Special tools:
DANGER
WARNING

m Unscrew screw (2)
m Loosen the hose clip.
© 42025-1
Fig. 1345
1
1
© 42026-1
Fig. 1346
30-207
Engine accessories
1 2
© 42028-1
Fig. 1347
m Remove the distributor (2).
2
© 42029-1
Fig. 1348

1. m Fit distributor (2).
NOTE
Observe the installation position. 2
© 42029-1
Fig. 1349
30-208
Engine accessories
1 2
© 42028-1
Fig. 1350
1
1
© 42026-1
Fig. 1351
4. WARNING
sion.
1
© 42027-1
Fig. 1352
30-209
Engine accessories
5. WARNING
sion. 1

2
© 42030-1
Fig. 1353
m Tighten (2) the screw.
m Position the wiring loom and secure it with the cable ties (1).
© 42025-1
Fig. 1354
30-210
Engine accessories
30.58 - Assembly and disassembly of the temperature sender (L3)
WARNING
any wet areas with a compressed air jet.
When handling fuel observe the safety directives and specific local regulations. All fuel lines and unions should be
closed immediately after opening using new, clean plugs or caps. Remove plugs and caps only immediately prior to
assembly. Collect auxiliary materials in suitable containers and dispose of them in compliance with the applicable
regulations. After any operation, bleed the fuel distribution system - see the user manual, chapter “6 Fuel distribution
system”.
NOTE
30.58.1 - Removal of the temperature sender

1. m Disassemble the supply air pipe (bench B).
© 40822-0
Fig. 1355
© 40823-0
Fig. 1356
30-211
Engine accessories
3. m Unscrew temperature sensor (1)
© 40824-0
Fig. 1357
© 40825-0
Fig. 1358
30.58.2 - Refitting the temperature sender

1. m Screw in and tighten temperature sensor (1)
© 40824-0
Fig. 1359
30-212
Engine accessories
© 40823-0
Fig. 1360
3. m Assemble the supply air pipe (bench B).
NOTE
© 40822-0
Fig. 1361
30-213
Engine accessories
30.59 - Disassembly and assembly of the fuel pipes (L3)
Special tools:
WARNING
NOTE

© 40606-0
Fig. 1362
m Detach the cables (2) from all the injection pumps.
NOTE
© 45384-0
Fig. 1363
30-214
Engine accessories
© 40608-0
Fig. 1364
© 40609-0
Fig. 1365
© 40610-0
Fig. 1366
30-215
Engine accessories
1 1
© 40611-0
Fig. 1367
m Unscrew nuts (2).
m Remove the cable.
NOTE 2
1
m Set aside the cable bundle guide with the cable bundle.
© 40612-0
Fig. 1368
© 40613-0
Fig. 1369
30-216
Engine accessories
m Remove the seals. 1
2 3
© 40623-0
Fig. 1370
10. m Unscrew the nuts (1)
© 40614-0
Fig. 1371
NOTE
Hold the relief valve.
1
m Remove the seals.
2
© 40615-0
Fig. 1372
30-217
Engine accessories
m Remove the seals.
© 40615-0
Fig. 1373
© 40617-0
Fig. 1374
© 40618-0
Fig. 1375
30-218
Engine accessories
© 40619-0
Fig. 1376
© 40620-0
Fig. 1377

1. m Fit new gaskets (1).
© 40621-0
Fig. 1378
30-219
Engine accessories
2. NOTE
Note the relative connection positions of the wiring! The
safety (1) must enter the groove (2).
2 1
© 42115-1
Fig. 1379
NOTE
1
Do not move the gaskets while replacing the fuel
pipes.
© 40619-0
Fig. 1380
© 40618-0
Fig. 1381
30-220
Engine accessories
m Fit support (2).
m Tighten nuts (1).
1
© 40617-0
Fig. 1382
© 40622-0
Fig. 1383
1
© 40616-0
Fig. 1384
30-221
Engine accessories
© 40615-0
Fig. 1385
m Fit support (2).
m Screw in nut (1);
© 40614-0
Fig. 1386
m Fit support (2).
m Lightly oil the threads and the head contact surface. 1
2 3
© 40623-0
Fig. 1387
30-222
Engine accessories
NOTE

2
m Tighten nut (2).
© 40625-0
Fig. 1388
© 40624-0
Fig. 1389
© 40613-0
Fig. 1390
30-223
Engine accessories
m Collect the cables.
WARNING
Observe the assignment and polarity of the electric connec- 2
tions! 1
NOTE
disassembly.
m Insert the shims.

m Tighten nuts (1). © 40612-0
See para. 20.4 - Tightening torque (L3) - page 20-14 Fig. 1391
m Tighten nuts (2).
1 1
© 40611-0
Fig. 1392
© 40610-0
Fig. 1393
30-224
Engine accessories
© 40609-0
Fig. 1394
© 40608-0
Fig. 1395
19. NOTE
Connect all the injection pumps.
m Insert the cables (2).

[LNK]
1
2
© 45384-0
Fig. 1396
30-225
Engine accessories
20. m Assemble the supply air pipe (bench A).
© 40495-0
Fig. 1397
30-226
Engine accessories
30.60 - Disassembly and assembly of the fuel pipes (L3)
Special tools:
WARNING
NOTE

NOTE
m Remove the cable.

1
© 42107-2
Fig. 1398
© 42108-1
Fig. 1399
30-227
Engine accessories
© 45854-0
Fig. 1400
m Set aside the cable bundle guide with the cable bundle.
© 42110-1
Fig. 1401
m Remove the seals.
1
© 42112-1
Fig. 1402
30-228
Engine accessories
© 45856-1
Fig. 1403
© 40620-0
Fig. 1404

1. m Fit new gaskets (1).
1 1
1 1
© 42114-2
Fig. 1405
30-229
Engine accessories
2. NOTE
Note the relative connection positions of the wiring! The
safety (1) must enter the groove (2).
2 1
© 42115-1
Fig. 1406
NOTE
Do not move the gaskets while replacing the fuel 2
pipes.
1
© 45856-1
Fig. 1407
4. m Fit flexible pipe (2).
m Insert the new O-rings.
1
© 42112-1
Fig. 1408
30-230
Engine accessories
m Fit the hose clamp (arrow).
m Fit the screws.
M6 x 12 mm (1). M6 x 16 mm (2) 1
1
© 42111-1
Fig. 1409
NOTE 1
Pay attention to the assembly angle dimension X =

10°.

See para. 20.4 - Tightening torque (L3) - page 20-14 X
1
2
© 45910-2
Fig. 1410
m Connect cable connector (2).
© 45854-0
Fig. 1411
30-231
Engine accessories
m Secure the cables with cable tie (2).
© 42108-1
Fig. 1412
9. NOTE
Connect all the injection pumps.
m Insert the cables (1).

[LNK]
1
WARNING
tions!
NOTE
© 45858-0
Connect the cables according to the marks made during Fig. 1413
disassembly.

30-232
Engine accessories
30.61 - Assembly and disassembly of the temperature sender (L3)
NOTE
30.61.1 - Removal of the temperature sender

© 40895-0
Fig. 1414
2. m Unscrew temperature sensor (1)
© 40896-0
Fig. 1415
© 44084-0
Fig. 1416
30-233
Engine accessories
30.61.2 - Refitting the temperature sender
1. m Screw in and tighten temperature sensor (1)
© 40896-0
Fig. 1417
NOTE
© 40895-0
Fig. 1418
30-234
Engine accessories
30.62 - Disassembly and assembly of the cable bundle (L3)
WARNING
Observe the assignment and polarity of the electric connections!
30.62.1 - Removal of the engine wiring loom

© 40916-0
Fig. 1419
2. m Disconnect the leads from the negative terminal of the battery.
m Disconnect the wiring connectors.
© 40917-0
Fig. 1420
© 40534-0
Fig. 1421
30-235
Engine accessories
© 40918-0
Fig. 1422
1
© 40919-0
Fig. 1423
m Remove the disc.
NOTE
Mark the cables and the respective connections be- 1
© 40920-0
Fig. 1424
30-236
Engine accessories
© 40921-0
Fig. 1425
© 40922-0
Fig. 1426
m Detach the cables from all the injection pumps.
NOTE
© 40923-0
Fig. 1427
30-237
Engine accessories
m Release and disconnect the connectors (2).
© 40924-0
Fig. 1428
© 40925-0
Fig. 1429
© 40926-0
Fig. 1430
30-238
Engine accessories
1 1 1
© 40927-0
Fig. 1431
m Unscrew nuts (2).
1
m Remove the cable.
NOTE
© 40928-0
Fig. 1432
© 40929-0
Fig. 1433
30-239
Engine accessories
16. NOTE
Mark the cables and the respective connections before con- 1
tinuing with disassembly. 2
m Unscrew nuts (1).

m Remove the disc.
© 40930-0
Fig. 1434
© 40931-0
Fig. 1435
© 40933-0
Fig. 1436
30-240
Engine accessories
© 40934-0
Fig. 1437
m Remove the fuel pipe.
© 40935-0
Fig. 1438
21. m Unplug cable connector (1).
© 40936-0
Fig. 1439
30-241
Engine accessories
© 40943-0
Fig. 1440
© 40532-0
Fig. 1441
© 40937-0
Fig. 1442
30-242
Engine accessories
© 40938-0
Fig. 1443
© 40939-0
Fig. 1444
27. m Release the central connector (1) (arrow) and withdraw the support.
© 40940-0
Fig. 1445
30-243
Engine accessories
© 40941-0
Fig. 1446
30.62.2 - Refitting the engine wiring loom

1. m Ensure that the wiring loom is positioned correctly.
m Connect the wiring connectors to the various components.
© 40942-0
Fig. 1447
2. m Slide the central connector into the support.
© 40939-0
Fig. 1448
30-244
Engine accessories
Screw length:
M8 x 20 mm (1). M8 x 16 mm (2) 2
© 40987-0
Fig. 1449
© 40937-0
Fig. 1450
5. m Position the wiring loom and secure it with the cable ties (1).
© 40532-0
Fig. 1451
30-245
Engine accessories
© 40943-0
Fig. 1452
© 40936-0
Fig. 1453
8. m Connect the fuel pipe.
m Locate the hose clip.
© 40935-0
Fig. 1454
30-246
Engine accessories
WARNING
1
sion.
© 40934-0
Fig. 1455
© 40933-0
Fig. 1456
© 40935-0
Fig. 1457
30-247
Engine accessories
© 40931-0
Fig. 1458
13. m Insert the cables (2).
1
WARNING
2
tions!
NOTE
disassembly.
m Fit the washer.

m Tighten nut (1).
Fig. 1459
© 40929-0
Fig. 1460
30-248
Engine accessories
15. m Collect the cables.
WARNING 1

tions!
NOTE
disassembly. 2
m Insert the shims.

m Tighten nuts (1).
m Tighten nuts (2). Fig. 1461
16. m Fit the wiring loom and secure it with the cable clamp (1).
1 1 1
© 40927-0
Fig. 1462
© 40926-0
Fig. 1463
30-249
Engine accessories
© 40925-0
Fig. 1464
© 40924-0
Fig. 1465
20. m Connect the cables to all the injection pumps.
[LNK]
WARNING
tions!
NOTE 1

disassembly.

Fig. 1466
30-250
Engine accessories
© 40922-0
Fig. 1467
© 40921-0
Fig. 1468
WARNING
tions! 1
NOTE
2
disassembly.
m Fit the washer.

m Tighten nut (1).
Fig. 1469
30-251
Engine accessories
30-252
Engine accessories
27. m Re-connect the wiring connectors
m Re-connect the lead to the negative terminal of the battery.
© 40917-0
Fig. 1473
28. m Assemble the turbocharging air duct.
© 40956-0
Fig. 1474
3 2
© 40908-0
Fig. 1474
30-253
Engine accessories
3 2
© 40908-0
Fig. 1474
30-254
Engine accessories
30.63 - Removing and fitting the alternator (driven by toothed
belt) (L3)
l V-belt tension tester: 8115
WARNING
Only check/re-tension/change the V-belt while the engine is stationary.
NOTE
After fitting a new V-belt, check the tension again after running the engine for 15 minutes.
30.63.1 - Removal of the alternator

m Disconnect the alternator wiring.
Note the relative connection positions of the wir-
ing! 1
(1) = W terminal, (2) = terminal D+, (3) = B+ terminal
3
© 45411-0
Fig. 1475
© 40975-0
Fig. 1476
30-255
Engine accessories
© 40976-0
Fig. 1477
© 45412-0
Fig. 1478
5. m Press the alternator in the direction of the arrow.
m Remove V-belt (1).
© 40978-1
Fig. 1479
30-256
Engine accessories
NOTE
Keep the nuts.
m Remove alternator (2)

1
2
© 40979-0
Fig. 1480
© 40980-0
Fig. 1481
30.63.2 - Refitting the alternator

1. m Fit the alternator.
M10 x 100 mm (1), M10 x 120 mm (2) 1
m Fit the screws.

NOTE
Keep the nuts.
© 40988-1
Fig. 1482
30-257
Engine accessories
NOTE
Keep the nuts.
© 45396-0
Fig. 1483
3. m Fit the V-belt (1).
© 40978-0
Fig. 1484
4. m Tension V-belt (1) by screwing in tensioner screw (2).
2 1
© 40977-1
Fig. 1485
30-258
Engine accessories
30.63.3 - Checking the tension of the V-belt using the belt tension gauge
1. m Lower the indicator arm (1) of the belt tension gauge.
© 39582_2
Fig. 1486
2. m Apply the tension gauge to the V-belt.
NOTE
The V-belt must be between the guides on the gauge
(arrowed).
© 40981-0
Fig. 1487
3. m Press the gauge against the V-belt by depressing button (1) until
you hear a click.
© 40982-0
Fig. 1488
30-259
Engine accessories
4. m Read off the value at the point where the indicator arm crosses the
numbered scale on the gauge (arrowed).
NOTE
Note the two different units of measurement on the
scale.
m If the nominal value is not obtained, repeat the tensioning procedure.
© 45413-0
Fig. 1489
© 40983-0
Fig. 1490
6. m Tighten nut (1).
© 40984-0
Fig. 1491
30-260
Engine accessories
7. m Connect the wiring to the alternator terminals.
Note the relative connection positions of the wir-
ing!
1
(1) = W terminal, (2) = terminal D+, (3) = B+ terminal
3
© 45411-0
Fig. 1492
30-261
Engine accessories
30.64 - Disassembly and assembly of the starter (L3)
30.64.1 - Disassembly of the starter

m Disconnect the wiring connectors.
© 40917-0
Fig. 1493
m Remove the starter motor.
© 40944-1
Fig. 1494
© 40945-0
Fig. 1495
30-262
Engine accessories
30.64.2 - Assembly of the starter
1. m Fit a new O-ring (arrowed).
m Apply a thin smear of assembly product to the O-ring.
© 42096-1
Fig. 1496
2. m Locate the starter motor.
m Tighten nuts (1).
© 40944-1
Fig. 1497
3. m Re-connect the wiring connectors
© 40917-0
Fig. 1498
30-263
Engine accessories
30.65 - Removal and refitting of the supply air pressure/tempera-
ture sender (L3)
NOTE
30.65.1 - Removal of the temperature/pressure sender

1
© 40919-0
Fig. 1499
m Remove the temperature/pressure sender.
© 40946-0
Fig. 1500
30.65.2 - Refitting the temperature/pressure sender

m Apply a thin coating of assembly product to the O-ring.
© 42002-2
Fig. 1501
30-264
Engine accessories
2. m Fit the temperature/pressure sender carefully.
© 40946-0
Fig. 1502
NOTE 1

© 40919-0
Fig. 1503
30-265
Engine accessories
30.66 - Fitting and removing the injection pumps (cylinder A1) (L3)
Special tools:
WARNING
During work on the fuel system always maintain conditions of the maximum cleanliness.
Before proceeding with removal, remove any paint residue or debris. Thoroughly clean the area around the compo-
nents to be worked on. Dry any wet areas with a compressed air jet.
When handling fuel observe the safety directives and specific local regulations. All fuel lines and unions should be
closed immediately after opening using new, clean plugs or caps. Remove plugs and caps only immediately prior to
assembly. Collect auxiliary materials in suitable containers and dispose of them in compliance with the applicable
regulations. After any operation, bleed the fuel distribution system - see the user manual, chapter “6 Fuel distribution
system”.
NOTE
30.66.1 - Disassembly of the injection pump

© 40552-0
Fig. 1504
© 40808-0
Fig. 1505
30-266
Engine accessories
m Remove the seals.
1
2 3
© 40520-0
Fig. 1506
© 40521-0
Fig. 1507
NOTE

1
m Remove the seals.
2
© 40522-0
Fig. 1508
30-267
Engine accessories
m Disconnect the cable (2).
© 40809-0
Fig. 1509
NOTE
Loosen the screws evenly to avoid excessive tension
of the injection pump.
1
m Remove the injection pump (2).
NOTE
they were removed. 2
© 45386-0
Fig. 1510
8. m Remove the roller tappet (1).
WARNING
1
Be careful not to damage the tappets!
NOTE
were removed.
© 40810-0
Fig. 1511
30-268
Engine accessories
© 40807-0
Fig. 1512

1. m Remove the fuel lines.
m Disassemble the fuel lines (Railway).
m Remove the injection pump housing (2).
NOTE
1
they were removed. Ensure that the parts are as-
signed correctly to the respective cyinders.
© 45387-0
Fig. 1513
© 40812-0
Fig. 1514
30-269
Engine accessories
30.66.3 - Assembly of the injection pump housing
© 45390-1
Fig. 1515
2. m Lightly oil the injection pump housing shank.
m Press the injection pump housing to the end stop in the crankcase.
NOTE
Attention to the cylinder allocation. The guide pin (1)
must engage in the groove (arrow).
1
© 40813-0
Fig. 1516
© 45388-0
Fig. 1517
30-270
Engine accessories
4. m Fit the fuel lines.
m Fit the fuel lines (Railway).
NOTE
Do not fit the fuel line (1). Do not fit the intake air pipe
(bank A).
© 45391-0
Fig. 1518
30.66.4 - Assembly of the injection pump

1. NOTE
If replacing the injection pump and/or the roller tappet, ob-
serve the arrangement of the injection pump and the roller
tappet.
© 40807-0
Fig. 1519
m Turn the injection pump camshaft using the rotation device to bring
the injection pump camshaft to the base circle position (arrow).
© 42163-1
Fig. 1520
30-271
Engine accessories
3. m Lightly lubricate the roller tappet.
m Insert the roller tappet.
NOTE
The guide pin (1) must engage in the groove (arrow).
1
© 42164-1
Fig. 1521
m Lightly lubricate the O-rings.
© 42165-2
Fig. 1522
5. m Insert the injection pump (1).
NOTE
The electrical connectors (3) of the injection pumps 1
must face towards the ancillary mount.
2
3
© 40954-0
Fig. 1523
30-272
Engine accessories
WARNING
Do not turn the camshaft until all the injection pumps are
installed. Risk of breaking the tappet!
1
© 40953-0
Fig. 1524
[LNK]
NOTE

2
© 40809-0
Fig. 1525
© 40522-0
Fig. 1526
30-273
Engine accessories
m Fit support (2).
m Screw in nut (1);
© 40521-0
Fig. 1527
m Fit support (2).
2 3
© 40520-0
Fig. 1528
NOTE
1
m Tighten nut (2).
© 40565-0
Fig. 1529
30-274
Engine accessories
1
© 40555-0
Fig. 1530
NOTE 2

1
© 40808-0
Fig. 1531
30-275
Engine accessories
30.67 - Fitting and removing the injection pumps (cylinder A2-B3) (L3)
Special tools:
WARNING
NOTE
30.67.1 - Removing the injection pump

m Remove the injection pipes (bench A).
See para. 30.13 - Replacing the injectio... - page 30-55 1 2
© 40554-0
Fig. 1532
m Disconnect the cable (2).
© 45384-0
Fig. 1533
30-276
Engine accessories
NOTE
Loosen the screws evenly to avoid excessive tension
of the injection pump.
1
m Remove the injection pump (2).
NOTE
they were removed. Attention to the cylinder alloca-
2
tion.
© 40805-0
Fig. 1534
4. m Remove the roller tappet (1).
WARNING
Be careful not to damage the tappets! 1
NOTE
were removed. Attention to the cylinder allocation.
© 40806-0
Fig. 1535
© 40807-0
Fig. 1536
30-277
Engine accessories
1. m Remove the fuel lines.
2
m Remove the injection pump housing (2).
NOTE
tion.
© 40811-0
Fig. 1537
© 40812-0
Fig. 1538
30.67.3 - Assembly of the injection pump housing

© 42159-2
Fig. 1539
30-278
Engine accessories
2. NOTE
The injection pump housings on the two banks are not the
same. Fit the injection pump housing with the slot (arrow)
on bank B.
© 42160-1
Fig. 1540
3. m Lightly oil the injection pump housing shank.
m Press the injection pump housing to the end stop in the crankcase.
NOTE
Attention to the cylinder allocation. The guide pin (1)
must engage in the groove (arrow).
1
© 45389-0
Fig. 1541
m Fit the fuel lines.
© 40814-0
Fig. 1542
30-279
Engine accessories
30.67.4 - Fitting the injection pump
1. NOTE
If replacing the injection pump and/or the roller tappet, ob-
serve the arrangement of the injection pump and the roller
tappet.
© 40807-0
Fig. 1543
m Turn the injection pump camshaft using the rotation device to bring
the injection pump camshaft to the base circle position (arrow).
© 42163-1
Fig. 1544
NOTE
The guide pin (1) must engage in the groove (arrow).
1
© 42164-1
Fig. 1545
30-280
Engine accessories
m Lightly lubricate the O-rings.
© 42165-2
Fig. 1546
5. m Insert the injection pump (1).
NOTE
Bank A: The electrical connectors (3) of the injection
pumps must face towards the ancillary mount. Bank 2
3
B:
The electrical connectors (3) of the injection pumps
must face towards the flywheel.
© 45382-0
Fig. 1547
WARNING
Do not turn the camshaft until all the injection pumps are
installed. Risk of breaking the tappet! 1
© 45383-0
Fig. 1548
30-281
Engine accessories
[LNK]
NOTE

2
© 45384-0
Fig. 1549
8. m Position the flexible fuel pipe (2).
1 2
© 40554-0
Fig. 1550
NOTE
© 40956-0
Fig. 1551
30-282
Engine accessories
30.68 - Checking and adjusting maximum injection pump aperture
stroke (L3)
l Feeler gauges
Special tools:
l Dial gauge support with probe extension: 103240
l Measuring pin: 110180
WARNING
NOTE
30.68.1 - Check of the maximum opening stroke of the injection pumps

1. m Disassemble the injection pumps (cylinder A1).
NOTE
Do not disassemble the injection pump housing.

© 40495-0
Fig. 1552
30-283
Engine accessories
30-284
Engine accessories
m Remove the seals.
© 40458-0
Fig. 1556
6. NOTE
The cylinder A1 injection pump cam must be in contact with
the base circle (arrow).
© 42163-1
Fig. 1557
NOTE
Ensure that the roller tappet is installed correctly. The
guide pin (1) must engage in the groove (arrow). 1
© 42164-1
Fig. 1558
30-285
Engine accessories
8. m Fit the dial gauge support (1).
© 40499-0
Fig. 1559
9. m Fit the dial gauge (1) with the probe extension.
m Place the probe tip on the roller tappet with a preload of 6 mm.
m Rotate the crankshaft repeatedly backwards and forwards.
m Check that the dial gauge is positioned correctly.
NOTE 1
The dial gauge must run on the base circle of the in-
jection pump camshaft. The needle of the dial gauge
should not move.
© 40500-0
Fig. 1560
10. m Use the rotation device to rotate the crankshaft in the engine rotation
direction (arrow) to the ignition TDC, N. A1.
NOTE
The stop pin of the rotation tool must engage with the
starter ring gear
© 40502-0
Fig. 1561
30-286
Engine accessories
11. m Read and note the value measured.
© 40503-0
Fig. 1562
30.68.2 - Adjusting maximum aperture stroke of injection pumps

1. NOTE
Remove all the injection pumps.
1

m Remove the turbocharger (bank A, Railway).
m Remove the turbocharger (bank B, Railway).
© 40504-0
Fig. 1563
m Remove the spacer bushes. 1
m Unscrew all the screws (2).
m Remove the heat guard cover (1).
© 40517-0
Fig. 1564
30-287
Engine accessories
30-288
Engine accessories
© 40459-0
Fig. 1568
m Remove cover (2).
m Remove cover (3).
3
2
© 40460-0
Fig. 1569
© 40508-0
Fig. 1570
30-289
Engine accessories
9. m Loosen all the screws (1).
© 40464-0
Fig. 1571
10. m Push the stop pin (1).
m Turn the crankshaft in the direction opposite to the engine rotation
direction (arrow) by ¼ a turn using the rotation device.
1
NOTE
The dial gauge should read “0” again.
© 40501-0
Fig. 1572
11. m Use the rotation device to rotate the crankshaft in the engine rotation
direction (arrow) to the ignition TDC, N. A1.
NOTE
The stop pin of the rotation tool must engage with the
starter ring gear.
© 40502-0
Fig. 1573
30-290
Engine accessories
12. m Rotate the injection pump camshaft in the direction of rotation of
the engine (arrow) via the screws to reach the specified maximum
aperture stroke.
© 40509-0
Fig. 1574
13. m Preload the screws (1).
NOTE
When pre-tightening the screws, push the gear wheel
gently against the tooth flanks in the opposite direc-
tion to engine rotation premere (arrow).
m Check again that the maximum aperture travel is set correctly.
© 40510-0
Fig. 1575
14. m Disassemble the dial gauge.
m Disassemble the dial gauge support.
© 40511-0
Fig. 1576
30-291
Engine accessories
m Tighten the stop pin.
NOTE
© 40464-0
Fig. 1577
© 40989-0
Fig. 1578
blade. 1
© 40512-0
Fig. 1579
30-292
Engine accessories
blade.
© 40513-0
Fig. 1580
1
NOTE
rows).
© 40514-0
Fig. 1581
© 40515-0
Fig. 1582
30-293
Engine accessories
NOTE
Insert the screws with the fastening product DEUTZ
3
DW 72. 2

© 40460-0
Fig. 1583
6. m Secure the cable with the cable ties (1).
© 40459-0
Fig. 1584
m Fit support (2).
2
© 40516-0
Fig. 1585
30-294
Engine accessories
© 40456-0
Fig. 1586
© 40455-0
Fig. 1587
© 40517-0
Fig. 1588
30-295
Engine accessories
m Fit the turbocharger (bank A, Railway).
m Fit the turbocharger (bank B, Railway).
© 40453-0
Fig. 1589
1
© 40458-0
Fig. 1590
13. m Assemble the injection pumps (cylinder A1).
NOTE
© 40518-0
Fig. 1591
30-296
Engine accessories
30.69 - Removal and refitting of the oil cooler
NOTE
30.69.1 - Removal of the oil cooler

1. m 1 - Lubricant oil radiator
m 2 - Gasket
m 3 - Hex screw
© 50278-0
Fig. 1592
m Remove oil cooler (2).
m Remove seal (3).
NOTE
Collect used lubricating oil and dispose of it in accor-
dance with the applicable regulations.
© 50279-0
Fig. 1593
30.69.2 - Refitting the oil cooler

m Tighten the screws (arrowed).
n M8x20-10.9
m Fasten the new gasket (1) to the oil cooler with the screws.
© 50280-0
Fig. 1594
30-297
Engine accessories
m Tighten all screws (2) alternately: 30 Nm
© 50281-0
Fig. 1595

Tightening torque
Table 65
tions
A15 051 Oil cooler housing in 30 Nm
correspondence of the
crankcase
NOTE
30-298
Engine accessories
m 2 - Hex screw: 8.5 Nm
m 3 - Covering case
m 4 - Hex screw
m 5 - Bush
© 50662-0
Fig. 1596
Construction unit
05
m Remove screw (1).

© 50671-0
Fig. 1597

NOTE
© 50672-0
Fig. 1598
30-299
Engine accessories
© 50673-0
Fig. 1599
m Fit the flywheel.
Construction unit
05
© 50674-0
Fig. 1600

Tightening torque
Table 66
tions
case
NOTE
30-300
40 - Pivot points
40-1
Pivot points
40.1 - Safety instructions for tyres and wheel studs
1. When working on the wheels, park the combine harvester on level ground and protect against rolling (chocks)!
2. Make sure the lifting device (jack) has sufficient load capacity.
3. Fitting and removing tyres requires specialised knowledge and the proper tools!
4. Check tyre inflation pressure at regular intervals! Risk of burst in the case of over-inflation of tyres!
5. Tighten all nuts and fixing screws of the rear and front wheels as well as the track width adjusting elements in accordance with
the manufacturer’s instructions!
40-2
Pivot points
40.2 - Brakes, brake fluid safety instructions
1. Always check that the brakes are functioning correctly before driving the combine!
2. Check the brake system regularly!
3. Settings and repairs of the brake system may only be carried out by authorised workshops or recognised brake service sta-
tions.
4. For travel on public roads, individual wheel braking must be deactivated (interlock the brake pedals).
5. Check brake fluid level at regular intervals Only use recommended brake fluids and change according to the prescriptions!
6. Take care when handling brake fluids (toxic and corrosive) and avoid spills.
7. Ensure brake fluid is disposed of in compliance with the relevant legislation!
8. During repairs of the brake system take care to ensure no contaminants enter the braking circuit!
9. After completing braking system maintenance or repairs, check that the circuit is sealed and that the brakes are working cor-
rectly and efficiently!
40-3
Pivot points
40.3 - Axles maintenance tables
40.3.1 - Driving axle maintenance and inspection
Table 67
Maintenance / Inspection Maintenance interval
Oil change - Gearbox after the first 50 hours and thereafter every 500 operating hours
or at least once a year
Oil level - Final drive after the first 50 hours and thereafter every 500 operating hours
or at least once a year
Oil level - Check gearbox / final drive at delivery of combine harvester, every 250 operating hours
Check the gearbox control mechanism and adjust if necessary at delivery, after 100 operating hours, and thereafter every 500
operating hours
40.3.2 - Drive axle / Steering axle

Table 68
Maintenance / Inspection Maintenance interval
Check the brake system at delivery, after 50 operating hours, and thereafter every 500
operating hours or at least once a year
Checking brake fluid level at delivery, after 50 operating hours, and thereafter every 250
operating hours
Change the brake fluid at least every two years
Check the parking brake, tighten if necessary at delivery, after 50 operating hours, and thereafter every 250
operating hours
Tighten screwed fixings at delivery, after 20 operating hours, after 50 operating hours,
then after 500 operating hours
Tighten the wheel bolts as prescribed at delivery, after 5, 20, 50 operating hours, and thereafter every
250 operating hours
Check toe-in of steer wheels at delivery, after 500 operating hours
Check and adjust, if necessary, clearance of wheel bearings at delivery, after 20 operating hours, after 250 operating hours
Check tyre inflation pressure at delivery, every day
Visual check for transmission cables and brake system brake every day
fluid leaks
40-4
Pivot points
40.4 - Transmission oil check and oil change
40.4.1 - Checking the oil level
Oil level plug (1) is located on top of the gearbox.
Check the oil using the dipstick attached to the plug.
Fig. 1601
40.4.2 - Oil change

The oil change must be performed when the gearbox is at operating temperature.
l To change the oil unscrew oil drain plug (2).
l After draining the oil, screw oil drain plug (2) back into place.
l Pour new oil into (1), up to the top notch of the oil dipstick.
NOTE
For oil change intervals refer to the lubrication plan, but in all cases
the oil must be changed at least after the harvest season at the
time of winter storage preparations.
Fig. 1602
40-5
Pivot points
40.5 - Check and change final drive oil
40.5.1 - Checking the oil level
Check the oil level by means of the threaded level plug (3). Bleed the side gears
by means of breather valve (5). Keep the valve clean at all times.
Fig. 1603
40.5.2 - Oil change

The oil change must be performed when the gearbox is at operating temperature.
l To change the oil unscrew oil drain plug (4).
l After draining the oil, screw oil drain plug (4) back into place.
l Pour fresh oil into (5), up to the bottom rim of threaded hole (3).
l Fit and tighten oil level plug (3)
NOTE
For oil change intervals refer to the lubrication plan, but in all cases
the oil must be changed at least after the harvest season at the
time of winter storage preparations.
Fig. 1604
40-6
Pivot points
40.6 - Check and change final drive oil - BALANCE
The gear case is vented through venting valve (1).
Fig. 1605
40.6.1 - Check oil level

l Set the machine in neutral (the front gear cover must be perpendicular - 90°
to the ground).
l Check the oil level by means of level plug (2).
Fig. 1605
40.6.2 - Change oil

l Remove level plug (2).
l Remove oil drain plug (3), drain oil.
l Refit oil drain plug (3).
l Pour in new oil through the opening of level plug (2) until oil level reaches
the opening.
l Screw in level plug (2).
l Check oil drain plug (3) and level plug (2) for leakage.
Fig. 1605
40-7
Pivot points
40.7 - Braking system
The combine harvesters are equipped with hydraulic disc brakes. (starting from type: 4040 with dual calliper disc brakes).
40.7.1 - Brake fluid level / linings check
DANGER
For safety reasons, it is imperative that both brake systems are inspected thoroughly at regular intervals. This work
must be performed in a specialised workshop!
Checking brake fluid level

Check the expansion tank level (B).
Before opening the threaded plug remove any dirt residues.
Fig. 1606
Replacing the brake pads:

If the brake pad friction facing is worn down to 2 mm.
l
If the pads are unevenly worn.

l
Always renew the pads of all the brake callipers on the same axle simultaneously.
Only use brake pads approved by the combine harvester manufacturer or brakes
manufacturer!
Fig. 1607
40.7.2 - Replacing fixed calliper brake linings:

When replacing the brake pads always clean the guide surfaces or the seat in the
well of the frame. Never use solvents containing mineral oil or sharp metal tools.
Check that protective covers and circlips are seated correctly. Change any dam-
aged protective covers and fit new covers in their place.
To avoid brake fluid overflowing from the compensation tank when pressing the
plunger backwards, first draw out a small amount of brake fluid with a suction line.
You can also open the bleed valve of the corresponding disc brake in such a way
that the brake fluid compressed by the plunger can flow into a collection container
through a bleed tube attached to the bleed valve.
If the plungers are pushed back to their starting position, before activating the
plungers reset device close the bleed valve.
Remove all rust residues from the edge of the brake disc.
Check disc brakes for wear using a brake disc calliper gauge.
1. Fixed brake calliper
2. Repair unit
3. Brake pads set
4. Calibrated screw
5. Hexagon socket head
6. Bleed valve Fig. 1608
40-8
Pivot points
After removing the brake pads:
Insert a 20° plug gauge (3) in the frame well and check whether the clearance of
the plunger corresponds to the oblique cross-section of the plug gauge.
Use plunger rotation pliers to position the plunger correctly with respect to the
gauge.
Fig. 1609
1 Brake disc direction of rotation during forward travel

2b Lower support surface in the frame well
3 Plug gauge with measurement edge of 20°
4 Plunger clearance
5 Hole to insert the plunger rotation pliers
Fit new brake pads in frame wells. Secure the pads with new expansion springs
and support pins.
DANGER
When installing the supporting pins note that the supporting sur-
face of the clamping bush case will disappear completely in the
bore. Do not strike the head of the clamping bush rivet.
Fig. 1610
Final works:
Operate the brake pedals so that the linings come into contact with the brake disc.
Check the brake liquid level in the expansion tank and top up if necessary.
Check the brake system conditions and performance and check for leaks!!
Fig. 1611
Table 69
Special tool: support pins fitting

Pin punch - Stop bush C4 - prepare according to the drawing
Fig. 1612
40-9
Pivot points
40.7.3 - Replacing the brake linings
Special tools
1 Puller for brake disc linings
P/N. 03.9314-1400.2/01 (1)
Fig. 1613
2 Plunger reset device

P/N. 03.9314-4950.3/01
Fig. 1614
3 Plunger rotation pliers to adjust the 20° plunger shoulder

P/N. 03.9314-5700.3/01
Fig. 1615
4 Plug gauge to check adjustment of the 20° plunger shoulder

for plungers - Ø 42 - 48 mm
P/N. 03.9314-0900.1/02
for plungers - Ø 52-57 mm
P/N. 03.9314-0600.1/02
for combine harvester types:
4030, 4035, 4040, 4045H
Fig. 1616
5 Gauge to measure the degree of wear of brake discs

P/N. 03.9314-6170.3/01
Fig. 1617
40-10
Pivot points
40.7.4 - Checking brake disc wear
Wear is measured by means of a brake disk thickness gauge.
Perform measurement with brake installed. After removing the brake pads and
retracting the plungers the measurement is performed via the brake pad well.
Depending on the friction contact side of the disc, the finish must be max. 0.5 mm.
As a general rule both brake discs on the same axle should be replaced at the
same time.
Fig. 1618
Finish dimensions
Table 70
- Original disc thickness Minimum thickness after finish
5650H - 5695HTS 22 mm 21 mm
Condition:
a) If considered necessary the brake disc can be subjected to a finishing opera-
tion.
b) Pronounced scoring and ridge on disc outer edge. Depth of wear is decisive in
relation to finishing; wear must never be greater than the maximum permissible
value.
c) Brake disc displays taper type wear pattern.
Brake disc must be replaced immediately due to risk of breakage of the frame
between the seal ring groove and the protective cover seat. (Fig. B-24)
Fig. 1619
Brake disc sectional view
Fig. 1620
40.7.5 - Bleeding the air and checking the brake fluid level
General information:
If repair works or renewal of equipment, armour, hoses or pipes have been performed on the braking system, top up the brake fluid
and bleed the air from the entire system. For this purpose use a brake fluid filling and air bleeding device.
During bleeding operations and brake fluid changing, bleed air from all bleed valves and drain off all the brake fluid.
40-11
Pivot points
Operation:
Air bleeding (filling) with pressurised bleeding device:
Remove dirt from the expansion tank unions, air bleed nipple and surrounding area.
Connect the pressurised air bleed device - set up for a filling pressure of 2 bar in compliance with the manufacturer’s instructions - to
the compensation tank and open the shut-off valve on the filling line.
The system is now pressurised.
Connect the transparent hose (about 1.3 m long) to the bleed valves.
Insert the free ends of the hose in a container placed at roughly the same height as the bleed valve.
Maintain the bleeding valves open until pure brake fluid is discharged without air bubbles.
When bleeding the air operate the pedals alternately to allow air to escape from the primary zone of the master cylinder.
After air bleed operations and brake fluid changes, refit the dust plugs on the bleed valves!
Air bleeding (filling) without pressurised bleed device:
Top up the system until the brake fluid level in the expansion tank reaches the maximum notch.
Connect the transparent hose (about 1.3 m long) to the bleed valve.
Insert the free end of the hose in a container placed at roughly the same height as the bleed valve.
Fully open the bleed valve
Slowly and evenly apply pressure to the brake pedal until it reaches its end-stop, then release the pedal slowly and completely.
Repeat this procedure until pure brake fluid is discharged without air bubbles
After pressing the pedal close the bleed valves!
DANGER
The brake master cylinder is equipped with feed pressure valves so it is not necessary to close the bleed valves after
each depression of the brake pedal. If, after the air bleed operation the actuation stroke of the brake pedal is too long
or if the generation of pressure is too spongy, after having activated the brakes several times and forcefully, the bleed-
ing operation must be repeated.
40.7.6 - Parking brake:

The parking brake is installed on the RH side of the gearbox.
Remove the brake as shown in figure B-26.
Check all components for wear and renew if necessary.
40-12
Pivot points
Adjustment:
Fig. 1621 - Parking brake

With the handbrake engaged the toothed ratchet of the brake lever must engage in the first third of the toothed segment. The
handbrake is adjusted by means of forks on the control tie rod or the flexible cable control.
Read the Operating Instructions!
1 - Brake lever
4 - Toroidal ring
5 - Brake plate
6 - Shaft
8 - Shoes with linings
17 - Flange
18 - Brake drum
19 - Pressure plate
40-13
Pivot points
40.8 - Tyres and wheel rims
40.8.1 - Wheels camber = E
For wheels with standard tyres the camber of the rims and the distance from exter-
nal edge to hub external edge establish the track width. The wheel camber must
therefore be defined by the vehicle manufacturer. If wheel camber is zero, track
width is defined by the distance from the outer edges of the wheel hubs.
Normally adopted procedure:
positive camber
E Wheels camber (protrusion of rim)
1 Wheel rim central point
2 Internal mating surface
3 hole
4 Hub hole
Fig. 1622
Special execution:
negative camber
E Wheels camber (protrusion of rim)
1 Wheel rim central point
2 Internal mating surface
3 hole
4 Hub hole
Fig. 1623
40-14
Pivot points
40.9 - Front axle
Fig. 1624 - Front axle

1. Side shafts end float
2. Parking brake
3. Brake calliper
4. Profiled sleeve
4.1. Screw m10 x 85
40-15
Pivot points
Fig. 1625 - Front axle

l 3. Brake calliper
l 5. Calibrated screws m14 d. 1.5 - 10.9 fixed with Loctite 243.
Table 71
Hydraulic motor HMF 105 CC: 5650H - 5660H / HTS - 5665HTS
- HMF 135 CC: 5660H / HTS - 5665HTS BALANCE;
5690H / HTS - 5695HTS
WARNING
Fire risk! Remove any crop deposits from the brake callipers daily.
40-16
Pivot points
40.10 - Front axle - BALANCE version
Fig. 1626 - Front axle - BALANCE version

1. Axle support
2. Final drives
3. Multi-segment plate
4. Screw M20, 10.9 fixed with Loctite 243
5. Clearance shim
6. Clearance ring
7. Shims
8. Support plate
9. Support bush, secured with Loctite 648
40-17
Pivot points
10. Distance collar between profiled sleeves
11. Lubrication pipe for external profiled sleeves
12. Screw M10x85, 10.9
13. Tie-rod
14. Lift cylinder
15. Shims as needed
16. Intermediate shaft
17. External support bush lubrication pipe
18. Internal support bush lubrication pipe
40.10.1 - Fitting / Removing

Levelling cylinder removing
Lift the combine harvester and prop it on stands (oscillating cylinders fully extended).
Loosen hydraulic connections, remove the bolt and detach the front oscillating cylinder, slide out the rear oscillating cylinder from the
bolt (first remove the safety screw).
DANGER
With the drive axle unloaded (resting on a stand), tighten strut (13) to 020 Nm and secure with the safety plate - In-
termediate shafts end float (16): maximum 3 mm - secure support bushes (9) with Loctite 648: clean the axial pipe
and support bushes and secure contact surfaces with Loctite - Retract the external support bushes with the head joint
downward and the internal support bushes with the head joint upward. Check that the axial pipe lubrication hole and
support bush are aligned. Remove Loctite from the lubrication hole, fill lubrication pipes (17, 18) with grease - Adjust
final drive end float to 0.2 - 0.7 mm in the axial tube with shims (7) - After refitting the final drives lubricate the axial
tube until the grease comes out from the sides - Clean and degrease the contact surfaces between multi-segment
plate (3) and final drives (2).
DANGER
To disassemble and refit the gearbox control mechanism the support plates (8) must be removed and the final drives
must be pulled slightly outwards in order to free the profiled sleeves.
40-18
Pivot points
40.11 - Transmission ZNK 25 - 1604 0895/20
40.11.1 - Gearbox ZNK 25 (1604 0895/20)
Fig. 1627 - Transmission ZNK 25 - 1604 0895/20

1. Direct drive shaft
2. Secondary shaft
3. 1st and 2nd gear engagement sleeve
4. 3rd and 4th gear engagement sleeve
5. Handbrake
6. Direct drive shaft with brake disc
7. Differential lock device, actuator not coupled
40-19
Pivot points
8. Differential
9. Washer shim thickness for axial adjustment of bearing play 0.3 -0.8 mm
Fitment instructions:
l Cover and flange are sealed to the gearbox hermetically with filler.
l Fix the screws with filler in gearbox through holes.
40-20
Pivot points
40.12 - Transmission fork adjustment - transmission ZNK25 - 1604
0895/20
40.12.1 - Transmission ZNK25 (1604 0895/20), gearbox
Fig. 1628 - Transmission ZNK25

l 1 - Gearbox cover
l 2 - Gearbox cover
l 3 - Shaft for control finger
l 4 - Control finger
l 5 - Locating dowel (two parts)
l 10 - 1st and 2nd gear fork
l 11 - 3rd and 4th gear fork
40-21
Pivot points

l 1 - Gearbox cover
l 4 - Control finger
l 6 - Threaded plug, depth of insertion into gearbox cover: 0.5 mm
l 7 - Ball, compression spring to stop the gear lever pin
l 8 - Gearbox locking balls
l 9 - Gear lever pin for gearbox fork
l 10 - 1st and 2nd gear fork
l 11 - 3rd and 4th gear fork
l 12 - Stud screws with locknuts, fixed with Loctite 262
40-22
Pivot points
Gearbox fork adjustment

l The pins of the gear lever (9) pins are in the neutral position, section view A - A.
l Loosen stud screws (12) and adjust gearbox fork axially, so that distances A, B between disengagement sleeve and gears are
identical (difference between measurements A and B: 0.5 mm max. see previous page).
l Tighten the stud screws in sequence to 30-40 Nm. On performing this operation the gearbox fork must not move on the gear
lever pin (9).
l Secure the stud screws with locknuts torqued to 55-65 Nm. The screws must not turn when applying the locknuts.
l Change gears and check whether the disengagement sleeve is secured axially by means of gearbox fork (10, 11) (otherwise,
check the gearbox fork position).
40-23
Pivot points
40.13 - Transmission control linkage
40.13.1 - Gearbox
Fig. 1630 - Transmission control linkage

1. Gear lever
2. Gears support
3. Cross with control finger
4. Strut
5. Lever
6. Plate
7. Strut
40-24
Pivot points
8. Strut
9. Lever
10. Lever
11. Pin
X Gear lever support rotation rod (2) - gear selection
Y Rotation axis of the gear lever cross (3) - gear engagement
Gear selection positions
Table 72
- A B
5650H, 5660H / HTS, 5665HTS - 5690H / 1 and 2 3 and 4
HTS, 5695HTS
40-25
Pivot points
40.14 - Final drive
40.14.1 - Final drive (1604 0897)
Fig. 1631 - Final drive

1. Drive shaft, supports preload 0 - 0.05 mm
2. Intermediate shaft, supports preload 0.03 - 0.05 mm
3. Wheel axle
4. Clearance ring, coupled heated
5. Locking ring pressed on the wheel axle, tightening torque 450 Nm
6. Shims
7. Pressure plate
8. Shaft oil seal
40-26
Pivot points
Fitment instructions:
Oil shaft oil ring (8) and the taper roller bearing. Preload the taper roller bearing of wheel axle (3) with the cylindrical gear disassem-
bled until rolling resistance torque is 15 - 17 Nm.
Simultaneously move the wheel axle to and fro several times.
Calculate the thickness of shims (6) between pressure plate (7) and the axle clearance washer. Install the wheel axle with the shims
and tighten ringnut (5) on the block. Re-check again rolling resistance torque and adjust if necessary. Fit the axle with the cylindrical
gear, tighten locking ring (5) to 450 Nm and secure in the wheel axle splines.
Lubricate shaft oil ring (8) between the sealing lips.
Detail of final (1604 1806) for Balance axle
Fig. 1632 - Final drive detail

1. Drive shaft
2. Circlip
3. Shaft ring gasket
4. Shims
5. Thrust washer
WARNING
To check the oil level, move swinging axle to neutral position (the side gear cover will be positioned vertically).
40-27
Pivot points
40.15 - Steering axle
Fig. 1633 - Steering axle

Key
1. Steering axle connection
1.1. Steering axle connecting hole
2. Swinging stop
3. Stub axle
4. Transverse strut
5. Steering cylinder
6. Ball joint, castellated nut tightening torque M20x1.5: 230 Nm
7. Stop screw
8. Steering angle
40-28
Pivot points
40.15.1 - Steering axle setup
Fig. 1633 - Steering axle

Key
1. Steering axle connection
1.1. Steering axle connecting hole
2. Swinging stop
3. Stub axle
4. Transverse strut
5. Steering cylinder
6. Ball joint, castellated nut tightening torque M20x1.5: 230 Nm
7. Stop screw
8. Steering angle
40-29
Pivot points
40.15.2 - Wheel hub fitment instructions
Fig. 1634 - Wheel hub

Key
l 3 - Stub axle
l 9 - Wheel hub
l 10 - Washer
l 11 - Support plate
l 12 - Castellated nut, locked with split pin
l 13 - Starter washer
l 14 - Compression washer
l 15 - Pulley cover with spring pin (torsion resistant)
l 16 - Starter washer, shims
l Note which way round the compression washer and starter washer are fitted (14, 13): bevel (a) of compression washer (14)
and oil passage (b) of starter washer (13).
l Pack with grease wheel hub (9) and bearing.
l If the steering axle is connected in the last hole (1.1), the swinging axle stop (2) must be mounted at the lowermost position
of the steering axle linkage.
40-30
50 - Belts and chains
50-1
Belts and chains
50.1 - Electrical drive of belt clutches, overview
Fig. 1635 - Electrical drive of belt clutches

l A8 = Powershift device
l A30 = Commander Control
l B19 = Straw chopper speed sensor
l B38 = Straw chopper cover position sensor
l B39 = Grain discharge pipe sensor
l B40 = Central display
l F ... = Fuses
l G3 = Alternator
l H35 = Straw chopper cover indicator light
50-2
Belts and chains
l K50, K71 = Discharge pipe oscillation relay
l M4 = Threshing section clutch servomotor
l M5 = Feed passage clutch servomotor
l M6 = Grain tank clutch servomotor
l M7 = Straw chopper clutch servomotor
l S22 = Cutting table stop pedal switch
l S23 = Grain tank clutch pedal switch
l S40 = Work master switch
l X ... = Connectors
WARNING
The cutting table clutch is also designated feed passage clutch. The long straw cover is also denominated straw chop-
per cover.
50.1.1 - Belt clutches operation criteria

l Low engine speed (charge warning light extinguished)
l Work master switch S40 on
l The grain tank clutch can be activated only after the grain tank discharge pipe is swung outboard. Sensor B39 must be operat-
ing.
50.1.2 - Belt clutches operation with the engine switched off

l Hold down Commander Control while turning the starter key to I.
l Switch on the main work switch.
50-3
Belts and chains
Fig. 1635 - Electrical drive of belt clutches
50-4
Belts and chains
50.2 - Powershift control unit (CCP2)
Fig. 1636 - CCP2 electronic control unit
50-5
Belts and chains
Fig. 1637 - CCP2 electronic control unit

Table 73
1-4 Servomotor load relay:
1 Threshing mechanism
2 Feed passage
3 Grain tank discharging
4 Straw chopper
F1 - F4 Servomotor fuses
X1- X6 Connections by means of connectors
H1b - H4b Commander Control input LEDs
H1a - H4a Load output LEDs
R1 - R4 Potentiometer to adjust servomotor disengagement current
Table 74
Indicators (LEDs)
- red: disengagement - green: engagement
H1b - H4b LEDs for indicating switch status at control input (signals from
control unit) for belt clutches 1 - 4
H1a - H4a LEDs for indicating switching status at load output (connectors
X1 - X4) for belt clutches 1 - 4
Table 75
Adjustment of switching threshold under load
R1 - R4 Potentiometer to adjust deactivation thresholds (preload of cor-
responding clutch spring)
Clockwise rotation: increase load current (spring preload)
Counterclockwise rotation: decrease load current (spring preload)
1 rotation = adjust load current by approx. 2.8 A
50-6
Belts and chains
NOTE
Use a screwdriver with a 1.2 mm blade! The potentiometers do not have a mechanical limit stop.
DANGER
Before connecting power, make sure polarity is correct.
50.2.1 - Description
Fig. 1637 - CCP2 control unit

Table 76
Device un- Connec- Pin Function Cable co- Connec- Pin Com.Con- Pin
der load tors lour tors trol
A8 X5 6 Cutting table black-brown X 507 1 A 30 1
activated
A8 X5 2 Cutting table white X 507 2 A 30 2
deactivated
A8 X5 9 Threshing Grey X 507 3 A 30 3
drum acti-
vated
A8 X5 8 Threshing blue-yellow X 507 4 A 30 4
drum deacti-
vated
A8 X5 19 Straw chop- purple X 507 5 A 30 5
per activated
A8 X5 18 Straw chop- yellow X 507 6 A 30 6
per deacti-
vated
50-7
Belts and chains
Device un- Connec- Pin Function Cable co- Connec- Pin Com.Con- Pin
der load tors lour tors trol
A8 X5 22 Grain-tank green-pink X 507 7 A 30 7
discharge
system acti-
vated
A8 X5 21 Grain-tank green-blue X 507 8 A 30 8
discharge
system deac-
tivated
- - - Grain tank purple-yellow X 515 2 A 30 52
clutch pedal
switch
- - - Cutting table orange-green X 515 1 A 30 20
stop pedal
switch
- - - Grain dis- white-blue X 509 5 A 30 53
charge pipe
sensor
- - - Straw chop- green-black X 508 11 A 30 34
per cover
sensor
50-8
Belts and chains
50.3 - Straw chopper clutch
Fig. 1638 - Straw chopper clutch

Basic adjustment:
l Spring preload engaged (dimension A): 110 mm
l Adjust by means of the potentiometer of the corresponding load relay on the control panel.
l Servomotor stroke (dimension B): 60 mm
l Adjust by means of adjuster screw (C).
l Control dimension D must be at least 115 mm in engaged status.
l If dimension D is less than the afore-mentioned value adjust the idler and stroke of the servomotor.
50-9
Belts and chains
50.4 - Grain tank discharge clutch
Fig. 1639 - Grain tank discharge clutch

Basic adjustment:
50-10
Belts and chains
50.5 - Threshing section clutch
Fig. 1640 - Threshing section clutch

Basic adjustment:
50-11
Belts and chains
50.6 - Feed passage clutch
Fig. 1641 - Feed passage clutch

Basic adjustment:
l Adjust by means of adjuster screw (G).
50-12
Belts and chains
50.7 - Diagram of lubrication control valve lines
50.7.1 - LH lubricant control valve
1. Discharge pipe elbow
2. Elbow swivel crown
3. Elbow swivel crown
4. Discharge tank bevel gear
5. Turbo separator
6. Pick-up reel
Fig. 1642
7. Threshing drum
8. Sieve box transmission
9. Feed passage bearing
10. Feed passage shaft bearing
NOTE
For further information on the lubricant control valves see “RH lu-
bricant control valve”.
50.7.2 - RH lubricant control valve

1. Feed passage bearing
2. Feed passage shaft bearing
3. Elevator head
4. Threshing drum
5. Pick-up reel
6. Turbo separator
7. Engine support
8. Sieve box transmission
The lubrication lines diagram shows the distribution and coordination of lubricated
points corresponding to the divider block valve.
NOTE
The pipes are replaced and must be connected in compliance with Fig. 1643
the indications of the lubrication lines diagram because the quantity

of grease delivered to each lubrication point is individually metered
by means of the corresponding valve of the divider block valve!
50.7.3 - Troubleshooting instructions

DANGER
Individual lines from the divider block to the lubrication point (e.g. a ruptured flexible hose) must not be plugged, the
remaining lubrication points of the divider block will anyway be deactivated.
l If the divider block is not lubricated, check clogged lubrication points and reopen them.
l Alternatively, contact a specialised service centre.
50-13
Belts and chains
50.8 - Diagram of centralised lubrication system lines
50.8.1 - Balance lubricant control valve
1 + 2 Axle bearing
3 + 4 Axle bearing
5 + 6 Rear hydraulic cylinder
7 + 8 Front hydraulic cylinder
NOTE
For further information on the lubricant control valves see “LH lu-
bricant control valve”.
Fig. 1644
50.8.2 - Troubleshooting instructions

Table 77
Group No. Indication
1 Pump unit of centralised lubrication system
2 Divider block right
3 Divider block
4 Divider block
5 Rear axle divider block
6 Divider block
7 Divider block above front axle (only with Balance)
8 Divider block left
9 Divider block feed passage
DANGER
Individual lines from the divider block to the lubrication point (e.g. a ruptured flexible hose) must not be plugged, the
remaining lubrication points of the divider block will anyway be deactivated.
l If the divider block is not lubricated, check clogged lubrication points and reopen them.
l Alternatively, contact a specialised service centre.
50-14
Belts and chains
Fig. 1645 - Diagram of centralised lubrication system lines

A.....
B....
C......
D.....
E....
50-15
Belts and chains
50-16
60 - Hydraulic system
60-1
Hydraulic system
60.1 - Hydraulic system - Safety warnings
1. The hydraulic system is under very high pressure!
2. While seeking possible leakage points use adequate auxiliary means to avoid the risk of personal injury!
3. Hydraulic oil projected at high pressure can pierce the skin and cause severe injury; In the event of injury, seek immediate
medical attention due to the severe risk of infection!
4. Before performing any work on the hydraulic system, the pressure must be discharged and front attachments lowered to the
ground!
5. Before working on the hydraulic system, the engine must be switched off, the ignition key removed and the combine harvester
wheels immobilised to avoid accidental movements (parking brake, chocks)!
60.1.1 - Maintenance
1. Whenever hydraulic components are connected, make sure hydraulic pipes are connected according to prescriptions!
2. If unions are inadvertently switched over this will result in inversion of the connected functions (e.g. lower/ raise)!
3. The hydraulic accumulator contains compressed gas.
Take care not to drop the accumulator and do not expose it to temperatures in excess of 150°!
4. Check that the hydraulic lines are in good condition and renew if damaged or degraded (aged)!
New hydraulic hoses must be in compliance with the technical requirements of the device manufacturer!
5. Ensure used oil and spent filters are disposed of in compliance with the relevant legislation!
6. Before opening hydraulic units always clean the surrounding area carefully. Keep all parts and equipment scrupulously clean
during maintenance and repairs!
60-2
Hydraulic system
60.2 - Hydraulic circuit - hydraulic connection diagram
60.2.1 - Hydraulic circuit connection logic:
Table 78
Control Magnet M1 M2 M3 M4 M5 M6 M9 M10 M11 M12 M14 M15 M16 M17
function
Cutting table Raise - ■ - - - - - - - - - - - -
Lower ■ - - - - - - - - - - - - -
Reel vertical Raise - - ■ - - - - - - - - - - -
adjustment Lower - - - ■ - - - - - - - - - -
Grain tank Swing out- - - - - ■ - - - - - - - - -
discharge board
pipe Swing in- - - - - - ■ - - - - - - - -
board
Reel horizon- Forward - - - - - - ■ - - - - - - -
tal adjust- Back - - - - - - - ■ - - - - - -
ment
Grain tank Extending - - - - - - - - - - - - ■ -
extension Retracting - - - - - - - - - - - - - ■
Cutting angle Forward - - - - - - - - ■ - - - - -
Back - - - - - - - - - ■ - - - -
Cutting table Left side - - - - - - - - - - ■ - - -
tilt down
Right side - - - - - - - - - - - ■ - -
down
1 - Hydraulic pump
1.1 - Gear pump for cutting table lift - lower (14 cc/rev)
1.2 - Gear pump for small users control block (4 cc/rev)
1.3 - Gear pump for steering (8 cc/rev)
2 - Pressure relief valve for cutting table, 180 bar
3 - Regulator valve for cutting table
4 - Engagement valve for the hydraulic accumulator, with pressure switch
5 - Two hydraulic accumulators, filling pressure 45 bar and 70 bar
6 - Control block for small users
7 - Steering hydraulics
8 - Oil cooler for hydraulic circuit (not installed on 5650H, 5660H/HTS, 5665HTS Standard)
60-3
Hydraulic system
Fig. 1646 - Hydraulic connection diagram
60-4
Hydraulic system
60.3 - Hydraulic circuit connection diagram for Balance
Fig. 1647 - Hydraulic circuit connection diagram for Balance

1. Hydraulic pump
1.1. Cutting table raise/lower (14cc / rev)
1.2. Small users (8cc / rev)
1.3. Steering system (8cc / rev)
2. Pressure relief valve ( 200 bar )
3. Switching inductor
60-5
Hydraulic system
4. Solenoid valves block
4.1. Vertical reel
4.2. Grain tank discharge tube
4.3. Horizontal reel
4.4. Grain tank extension (5690H/HTS, 5695HTS )
4.5. Hydraulic cutting angle control
5. Cutting table self-levelling control block
5.1. Cutting table tilt control valve (proportional valve)
5.2. Pressure holding valve
6. 150 bar pressure relief valve for cutting table self-levelling cylinder
7. Regulator valve for cutting table
7.1. Engagement valve for the hydraulic accumulator, with pressure sensor
7.2. Two hydraulic accumulators, filling pressure 45 bar and 70 bar
8. 180 bar pressure relief valve for cutting table regulator valve
9. Oil cooler
10. Oil reservoir with return filter
A - Hydraulic system Balance
B - Steering system
60-6
Hydraulic system
60.4 - Hydraulic circuit pipes diagram for Balance
Fig. 1648 - Hydraulic circuit pipes diagram for Balance

1. Hydraulic pump
1.1. Cutting table raise/lower (14cc / rev)
1.2. Small users (8cc / rev)
1.3. Steering system (8cc / rev)
2. Pressure relief valve ( 200 bar )
3. Power control valve
60-7
Hydraulic system
4. Control block
4.1. Vertical reel
4.2. Grain tank discharge tube
4.3. Horizontal reel
4.4. Grain tank extension ( 5690H/HTS, 5695HTS )
4.5. Hydraulic cutting angle control
5. Cutting table self-levelling control block
5.1. Cutting table tilt control valve (proportional valve)
5.2. Pressure holding valve
5.3. Union plate with pressure relief valve 170 +5 bar
5.4. End plate
5.5. 2.5 mm diaphragm in the oil pressure passage
5.6. Circuit selector
6. 150 bar pressure relief valve for cutting table self-levelling cylinder
7. Regulator valve for cutting table
8. 180 bar pressure relief valve for cutting table regulator valve
9. Oil cooler
DANGER
Oil cooler flow inlet is connected to union N of the cutting table regulator valve.
Hydraulic circuit Balance
Steering system
Cutting table self-levelling cylinder
Grooved nut tightening torque to the end plate (5.4)

= 25+8 Nm
60-8
Hydraulic system
= 25+8 Nm
= 13.5+4.5 Nm
60-9
Hydraulic system
60.5 - Control valves block
DANGER
Shared oil tank for the hydraulic equipment circuit and the hydrostatic traction circuit.
Capacity/fill quantity:
Filling quantity for entire hydraulic circuit system and traction circuit: around 70 ... 75 l (depending on the version)
Depending on the equipment variant the control valve for the grain tank support, cutting table self-levelling and cutting angle
adjustment may not be present.
DANGER
It is not permitted to switch the various control valves over.
Valve identification is achieved on the basis of the dataplate on the rear of the valve showing the Bosch type number.
Table 79
Bosch type no. Function
1 525 503 524 Connection plate with pressure relief valve
0 521 608 851 Single-acting control valve, reel vertical adjustment
0 521 608 852 Double-acting control valve, extending/retracting grain tank dis-
charge pipe
0 521 608 854 Double-acting control valve, reel horizontal adjustment
0 521 608 848 Double-acting control valve, extending/retracting grain tank sup-
port
0 521 608 854 Double-acting control valve, cutting angle hydraulic adjustment
0 521 608 825 Double-acting control valve (proportional valve), self-levelling
0 521 608 853 control (for Balance in separate valves block)
Comply with sequence a → b → c and observe the tightening torques of the struts
l The directional control spool valves may seize.
Solenoid:
UNenn 12 V, Umax 14 V, Umin 11.5 V
(0 521 608 851 ... 0 521 608 854)
Solenoid: cutting table self-levelling
0 ... 12 V
(0 521 608 853) Proportional solenoid
Repair work on the valve is restricted to sealing repairs and cleaning.
It is not possible to renew individual spools.
l Replace the complete control valve if necessary.
DANGER
The valve control functions (lowering / retraction) are available only when the engine is running (pressurised oil must
be supplied in order to open the shut-off valves).
Table 80
1 Control valves block bl/rt = blue/red
2 Manual activation to left and right br = brown
3 Multi-way valves (in all control devices) br/ge = brown/purple
4 Factory punch marks for unloading of di- ge/rt = yellow/red
rectional control valve
5 Interception plate (fitted only in cutting ta- gn = green
ble control device)
6 EMR-D valve gn/ge = green/yellow
7 Pressure relief valve gn/rt = green/red
8 3-function hydraulic pump or = orange
60-10
Hydraulic system
9 Discharge valve rt = red
10 Return filter sw = black
11 Hydraulic oil tank for hydraulic circuit and ws = white
hydrostatic traction circuit
Fig. 1649 - Control valves block
60-11
Hydraulic system
60.6 - Control valves block connection plate
60.6.1 - Flow regulator valve with integral pressure relief valve
Fig. 1650
Key
1. Pressure balance
2. Pressure relief valve
3. Spring
4. Control orifice LS
60-12
Hydraulic system
Fig. 1651
Key
l 1 - Pressure balance
l 2 - Pressure relief valve
l 3 - Spring
l 4 - Control orifice LS
l A - Union
l B - Union
l P - Pump
l R - Return
l LS - Control according to load
Function
The connection plate forms the basic control element in accordance with the load of the valves control block.
Neutral circulation
If no control valve is operated, control orifice LS (4) is connected to the final plate by means of return passage (R) = (i.e. zero pres-
sure).
If the pressure on connection (P) exceeds the force exerted by the spring [ = 3 bar (3)], the pressure valve (1) opens proportionally
on the basis of the discharge flow of the pump towards neutral circulation (R).
Circulation in pressure
When also a control valve is actuated (in this case the spool valve connects the control orifice LS with passage P), pressure (P),
by means of control orifice LS (4) increases the force of the spring [?P = 3 bar (3)]. Consequently the pressure valve (1) closes the
neutral circulation. Pressure (P) increases up to the load pressure and then the oil flow can reach the user (A/B).
In the case of overloads or if the maximum working pressure is reached (by means of control orifice LS 4), the pressure relief valve
will open (170 + 5 bar). The pressure scale (1) constitutes the main stage of the pressure relief valve (2).
l Pressure relief valve setting: 170 + 5 bar
CAUTION
Check and adjust the pressure relief valve only with a pressure gauge connected to the corresponding test union.
60-13
Hydraulic system
60.7 - Single-acting control valve
60.7.1 - Function:
Neutral circulation
The control valve spool is in the neutral position 0. By means of the multi-way valve (3), the control orifice LS (4) is connected to the
return (R) in the end plate. The oil pressure (P) is blocked by the control valve spool (1). Shut-off valves (2) are closed.
Position 1: raise
When the solenoid (1.1) is activated the control valve spool (1) is moved to the left so assuming position 1. The oil pressure (P) is
now connected with control orifice LS (4) (by means of (4) neutral circulation is closed in the connecting plate) and with passage (B).
When load pressure (B) is reached shut-off valve (2) opens. Pressurised oil flow (P) can now flow to user union (B).
Position 2: lower
When the solenoid (1.2) is activated the control valve spool (1) is moved to the right so assuming position 2. The oil pressure (P) is
now present in passage (A) and it moves floating piston (5) to the left, thus causing mechanical opening of shut-off valve (2). Oil return
flow (B) flows again from union (B) to return (R).
DANGER
In all the single-acting control valves, excluding the cutting table raise/lower control valve (Powerliner), the second
opening of shut-off valve (2) is blocked by copper discs (2.3). Take this into account during disassembly/assembly
procedures! Removal of the control valve spool (1) is possible only in the direction of the arrow.
Fig. 1652 - Control valve

A - Union
B - Union
P - Pump
R - Return
1 - Directional control valve
60-14
Hydraulic system
1.1 - Solenoids
1.2 - Solenoids
2 - Shut-off valve
2.3 - Copper discs
3 - Multi-way valve
4 - Control orifice LS
5 - Floating piston
LS Control in proportion to the load
60-15
Hydraulic system
60.8 - Double-acting control valve
l Swing the grain tank discharge tube inboard/outboard.
l Reel horizontal adjustment
l Retracting/extending the grain tank extension (if present)
l Swing cutting table (swinging arm) (if present)
l Cutting angle adjustment (if present)
60.8.1 - Function:
Neutral circulation
The control valve spool is in the neutral position 0. By means of the multi-way valve (3), the control orifice LS (4) is connected to the
return (R) in the end plate. The oil pressure (P) is blocked by the control valve spool (1). Shut-off valves (2.1) and (2.2) are closed.
Position 1: (oil supply pressurised towards A)
When the solenoid (1.1) is activated the valve spool (1) is moved to the left and hence it assumes position 1. The oil pressure (P)
is now connected with control orifice LS (4) (by means of (4) neutral circulation is closed in the connecting plate) and with passage
(B). When load pressure (A) is reached shut-off valve (2.1) opens and simultaneously shut-off valve (2.2) is opened mechanically by
means of floating piston (5). Pressurised oil (P) can now flow to user union (A) and return oil flows again from union (B) to return (R).
Position 2: (oil supply pressurised towards B)
When the solenoid (1.2) is activated the control valve spool (1) is moved to the right so assuming position 2. The oil pressure (P) is
now connected with control orifice LS (4) (by means of (4) neutral circulation is closed in the connection plate) and with passage (B).
When load pressure (B) is reached shut-off valve (2.2) opens and simultaneously shut-off valve (2.1) opens mechanically by means
of floating piston (5). Pressurised oil (P) can now flow to user union (B) and return oil flows again from union (A) to return (R).
DANGER
In all the double-acting control valves the second opening of shut-off valves (2.1), (2.2) is blocked by copper discs
(2.3). Take this into account during disassembly/assembly procedures! Removal of the control valve spool (1) is pos-
sible only in the direction of the arrow.
60-16
Hydraulic system

A - Union
B - Union
P - Pump
R - Return
1.1 - Solenoids
1.2 - Solenoids
2.1 - Shut-off valve
2.2 - Shut-off valve
2.3 - Copper discs
3 - Multi-way valve
4 - Control hole LS
5 - Floating piston
LS Control in proportion to the load
60-17
Hydraulic system
60-18
Hydraulic system
60.9 - Engagement valve for the hydraulic accumulator, with
pressure sensor
The hydraulic accumulator and engagement valve with pressure sensor are installed on the front axle, on the right.
60.9.1 - Engagement valve function: engage/disengage hydraulic accumulator (3)
In engagement position 0 solenoid (1.1) is not activated. By means of the interception port (1.2.) of the directional control spool valve
(1), the hydraulic accumulators (3) may receive only a modest oil flow (hydraulic accumulator interception function).
By activating the solenoid (1.1) the valve spool (1) shifts leftwards to engagement position 1 and, by means of control port (1.3) it
activates the connection from A to B. This means that hydraulic accumulators (3) are now connected to cutting table cylinders (4).
60.9.2 - Hydraulic accumulator supplementary valve connection logic:
The hydraulic accumulators are always activated (selected) with the exception of:
1. Raise / lower with manual control:
the hydraulic accumulators are blocked for approximately 3 seconds from the start of the command pulse.
2. Remote control operating mode
If the cutting table feeler sensors (skids) are activated, the hydraulic accumulators are blocked.
Table 81
Technical data:
Pressure: P = 45 bar P = 70 bar
Volume: V = 0.5 litres V = 0.5 litres
Pressure sensor:
Pressure sensor (2) absorbs the pressure in the cutting table cylinders and transmits the corresponding signal as an effective value
input to the EMR-D control unit.
Table 82
Technical data:
Supply voltage: 9.5 V
Signal: 2.4 ... 7.1 V
Pressure: 0 ... 160 bar
Fig. 1656 - Hydraulic accumulator engagement valve

60-19
Hydraulic system
1.1 - Solenoids
1.2 - Interception orifice
1.3 - Control edge
2 - Pressure sensor
3 - Hydraulic accumulator
4 - Cutting table cylinder
Fig. 1657 - Hydraulic accumulator engagement valves
60-20
Hydraulic system
60.10 - EMR-D control valve
60.10.1 - Neutral position
Neutral circulation of (P) (pump) after (N) (oil tank) in flow control valve (1) is achieved as follows: after having overcome the force of
the spring (Δρ = 3 bar, spring chamber connected with control valve (2) with (R)), the flow control valve spool (1) moves to the right
so that the corresponding oil flow can be transferred to (N) (oil tank).
A minimum oil flow of approximately 4 l/min is assured in all positions by means of the control edges (1.1) of the control valve (1).
The shut-off valve (6) controls the load on union (A) (cutting table cylinder).
The peak pressure values are absorbed by means of antishock valve (4) (200 bar) and the oil is dumped to the return line (R).
The electric control of proportional solenoids (7) and (8) of the EMR-D control valve is received by means of frequency and pulse
width signals from the electronic controller, which are controlled in accordance with the effective - nominal values.
DANGER
Never apply a constant voltage of 12 V to the solenoids because this may damage them. A maximum permanent volt-
age of 7 V is permissible. Solenoids (7) and (8) must never be switched over.
If the electronic circuit fails, control valve EMR-D can be activated manually by pressing the solenoids on the front.

A - Work cylinder
N - Neutral circulation
P - Pump
R - Return
1 - Flow control valve (pressure balance)
2 - Directional control valve spool (proportional valve)
3 - Lowering rate control valve
4 - Pressure relief valve (cylinder relief valve 200 bar)
60-21
Hydraulic system
5 - Lowering valve with load compensation
6 - Shut-off valve
7 - Proportional magnet - Lower
8 - Proportional magnet - Raise
Table 83
Neutral circulation or oil return circulation
Control oil flow
Lowering oil flow or lifting oil flow
Flow direction
Residual oil flow
Fig. 1659
60-22
Hydraulic system

60.10.2 - Raise cutting table
Proportional solenoid (8) moves control valve spool (2) towards the left to the lifting position. In this manner, by means of the control
valve spool (2) the oil flow (without pressure) is blocked by the spring chamber of the flow control valve (1) towards return (R) so that,
following the action of (P) and Δρ (spring force equivalent to 3 bar) the spool of flow control valve (1) is moved to the left so that it
blocks the oil flow towards neutral circulation (N).
A minimum oil flow to (N) of approximately 4 l/min is assured by means of the control edges (1.1).
Pressure (P) increases until reaching the load pressure (A) and the opening of shut-off valve (6).
By means of control orifice (2.1) in control valve spool (2), the load pressure is present also in the spring chamber of flow control valve
(1). as soon as pressure (P) reaches the load pressure e ?P (spring force of 3 bar), the flow control valve spool (1) moves to the right
and releases the corresponding oil flow towards (N) to neutral circulation.
The lifting oil flow varies in accordance with the transverse section of opening on the control edge (2.3) the spool (2), i.e. it is propor-
tional to the control current on the solenoid (8).
60-23
Hydraulic system

60.10.3 - Lower cutting table
The proportional solenoid (7) moves the spool (2) to the lowering position. By means of the spring chamber of the flow control valve
(1) a control flow is sent to the lowering valve (5), thus causing mechanical opening of shut-off valve (6) by means of a specific pin.
The lowering oil flow is transferred from union (A) to return (N) via the open control edge (2.2) of the spool (2).
The different load (A) is compensated by means of lowering valve (5) in conjunction with shut-off valve (6).
The lowering speed is established by regulator valve (3) and by the adjustment travel of spool (2).
DANGER
Regulator valve (3) is pre-adjusted in the factory and should not be altered.
60-24
Hydraulic system

A - Work cylinder
N - Neutral circulation
P - Pump
R - Return
1 - Flow control valve (pressure balance)
2 - Directional control valve spool (proportional valve)
3 - Lowering rate control valve
4 - Pressure relief valve (cylinder relief valve 200 bar)
5 - Lowering valve with load compensation
6 - Shut-off valve
60-25
Hydraulic system
7 - Proportional magnet - Lower
8 - Proportional magnet - Raise
Table 84
Neutral circulation or return
Control oil flow
Lowering oil flow or lifting oil flow
Flow direction
Residual oil flow
Fig. 1662
60-26
Hydraulic system
60.11 - Self-levelling balancing control hydraulic connection
diagram
1 Oil tank for hydraulic circuit and traction working circuit
2 Hydraulic pump: flow rate 19 cm3 / rev.
The hydraulic pump for self-levelling control is flanged to the feed pump of the hydrostatic transmission.
3 Pilot equipment:
neutral circulation shut-off valve M0 with pressure relief valve (175 bar)
4 Control valves block “Balance” on left
5 Control valves block “Balance” on right
6 Shut-off - safety valve to protect against hose bursts (integrated in hydraulic cylinder)
7 External current control solenoid valves + SR2
DANGER
Observe proper mounting position!
A1.1 - A2.2 Cylinder connections to control valves block

→ The arrow shows the travel direction
60.11.1 - BALANCE control connection logic:
Table 85
Control function: M0 M1 M2 M3 M4 M5 M6
Extend lifting cylinders on the left and ■ ■ - - ■ - -
right, raise the front of the combine
Retract lifting cylinders on the left and ■ - ■ ■ - ■ ■
right, lower the front of the combine
Extend the lifting cylinders on the left, ■ ■ - - - ■ ■
retract the cylinders on the right, from
the central position tilt the combine to
the right
Extend the lifting cylinders on the right, ■ - ■ ■ ■ - -
retract the cylinders on the left, from
the central position tilt the combine to
the left
60-27
Hydraulic system
Fig. 1663 - Hydraulic connection diagram
60-28
Hydraulic system
60.12 - Pilot equipment
1 Pilot equipment control valves block
2 Pilot equipment (M0)
2.1 Solenoid
2.2 Pilot cone
2.3 Opening spring
2.4 Pilot orifice
2.5 Valve piston
2.6 Check valve
2.7 Magnetic keeper
2.8 Valve seat
3 Pressure relief valve 175 bar Fig. 1664
3.1 Pressure control device
3.2 Valve body
3.3 Compression spring
3.4 Spring holder plate
3.5 Cone
3.6 Valve seat
4 Toroidal ring
5 Metal G1/8” union for pressure measurement
60.12.2 - Neutral circulation

In neutral circulation solenoid (2.1) is not powered. Pilot cone (2.2) is raised by the force of spring (2.3). This causes hydraulic ope-
ning of the pistons of the valves (2.5) and the oil can flow from P to T.
60.12.3 - Working position
If solenoid (2.1) is powered (12 V), pilot cone (2.2) closes against the force of the spring (2.3). Otherwise valve (2.5) piston remains
closed.
Pressure (P) is generated until pressure relief valve (3) reaches opening pressure (175 bar) previously set (by means of 3.1).
60-29
Hydraulic system
60.12.4 - Removing / Fitting
Fig. 1665 - Pilot equipment

Valve bodies (2.2 ... 2.8),(3.1 ... 3.6) (glued and welded) cannot be removed.
DANGER
If the pressure relief valve (3) or pilot valve (2) are disassembled, toroidal ring (4) will be damaged. Fit a new gasket
at the time of reassembly!
Solenoid (2.1) is equipped with an integral diode:

Unom: 12 V
R: 8 Ω
P: 18 W
60-30
Hydraulic system
60.13 - Control valves block with integral check valve
Fig. 1666 - Control valves block

1. Balancing valves block.
2. Electromagnetic coils.
3. 2/2 way valves (M1, M2, M4, M5).
4. 3/2 way valves (M3, M6).
5. Toroidal seal ring.
6. Flow control valve -SR1.
7. Check valve (RV1, RV2).
8. Check valve with hydraulic unlocking (ERV).
9. Machining holes (no functional purpose).
60-31
Hydraulic system
10. Test connections M1, M2, (M14 x 1,5).
11. Current control valve + SR 2 external in return pipeline.
DANGER
Observe proper mounting position!
60.13.1 - Operating description

Cylinder extension (lifting)
If electromagnet coil M1 (M4) is powered, pressurised oil flows to the cylinder connection by way of check valve RV2 A1.1 A1.2.
The generation of pressure causes opening of check valve (8) with hydraulic unlocking and this enables the return of oil to tank.
After having reached the load pressure, an oil flow that is maintained constant by the flow control valve (-SR1) is delivered to the
oscillation cylinder.
Retraction (lowering)
If power is present (12 V) on M2 (M5) and M3 (M6) solenoid valve M2 (M5) opens and, by means of the flow control valve (+SR2), it
enables the return oil flow. Simultaneously, solenoid valve M3 (M6) transfers pressurised oil (P) to connection A2 by means of piston
(4.2). The eternal flow control valve (+SR2) maintains the oil return flow constant.
Removing / Fitting
It is not possible to disassemble the valve bodies (3.4) (4.1) (glued and welded).
DANGER
If solenoid valves M1 - M6 are to be removed, toroidal ring (5) will be damaged. The directions of assembly of the flow
control valves (-SR1, +SR2) are different (see figure). Take account of this at the time of reassembly!
60-32
Hydraulic system
60.14 - Tilt cylinder
60.14.1 - Hose burst safety valve
1. Piston rod
2. Hose burst safety valve
Fig. 1667
60-33
Hydraulic system
60.15 - Cutter bar self-levelling system
Fig. 1668 - Cutter bar self-levelling system

2 Pressure holding valve (35 bar)
3 Anti-shock valves 150 bar (no longer installed from chassis No.8646)
Observe the correct basic adjustment of the cutter bar self-levelling system, i.e. max. oscillation angles for transverse tilt to right / left
must be identical.
In both the final positions the piston rods must reach their stroke end simultaneously.
The adjustment is performed by means of the adjustment thread on the lift cylinders (by turning the swivel ends).
Basic adjustment of the lift cylinders in the retracted condition.
Dimension B 514 mm
60-34
Hydraulic system
60.16 - Hydraulic cutting angle control
Fig. 1669 - Hydraulic cutting angle control

l Basic adjustment of the lift cylinders in the retracted condition with respect to the cutting angle.
At 515 mm, stroke approximately 200 mm
The adjustable frame must not rest on the feed passage union.
DANGER
A shut-off valve is fitted on union (1) (Note the assembly position). Observe the minimum screw insertion depth of 24
mm of the piston rod (a) in the swivel end (b).
60-35
Hydraulic system
60.17 - Lifting cylinder - cutting table (feed passage)
60.17.1 - Repair work
Fig. 1670 - Lifting cylinder - cutting table
Fig. 1671 - Lifting cylinder - cutting table

Carefully tighten the cylinder hose into the vice.
Insert a screwdriver through the oil connection opening.
Press the screwdriver on the end of the circlip (1) and rotate the piston to cause circlip (1) to slide over the piston.
It is now possible to withdraw the piston from the hydraulic cylinder easily.
With a screwdriver, extract wiper ring (2) and grooved ring (3) by pressure.
60-36
Hydraulic system
Keep all parts and equipment scrupulously clean when carrying out repair work on the hydraulic cylinders!
Always install new gaskets on reassembly. Use the repair kit
1. Circlip
2. Wiper ring
3. Grooved ring
60-37
Hydraulic system
60.18 - Hydraulic cylinder - steering axle
60.18.1 - Repair work
Fig. 1672
1. Guide bush
2. Safety wire
3. Castellated nut ( m16 d.1.5 )
4. Oil control ring
5. Oil seal
Repair work:
l Tighten guide bush (1) in a vice.
l Raise safety wire (2) in the pressure cylinder bore.
l Turn guide of piston rod (1) clockwise and extract safety wire (2).
l It is now possible to withdraw piston rod guide (1) and piston rod from the hydraulic cylinder.
l Wiper ring (4) and oil seals (5) can be renewed after undoing castellated nut (3).
60-38
Hydraulic system
60.19 - Hydraulic cylinder - repair
60.19.1 - A - Vertical reel (cutter bar width 4.2 - 7.2 m)
Fig. 1673 - Hydraulic cylinder

1. Wiper ring
2. Oil seal
3. Safety wire
4. Toroidal ring
5. Piston seal
60-39
Hydraulic system
60.19.2 - B - LH horizontal reel

1. Wiper ring
2. Oil seal
3. Safety wire
4. Toroidal ring
Piston seal
5. Waste oil compensation
60-40
Hydraulic system
60.19.3 - C - Grain tank discharge pipe

1. Wiper ring
2. Oil seal
3. Safety wire
4. Toroidal ring
Piston seal
60-41
Hydraulic system
60.19.4 - D - Grain tank discharge pipe block

1. Circlip
2. Grooved ring
3. Wiper ring
60-42
Hydraulic system
60.19.5 - Vertical and horizontal reel single and double-acting cylinder (synchronous
cylinder)
Fig. 1675 - Vertical and horizontal reel cylinder

l 1 - Connection P or R
l 2 - Air bleed
l A1 - A2 - Horizontal reel
l A1 - B - Vertical reel
60-43
Hydraulic system
60.19.6 - Grain tank extension hydraulic drive
Fig. 1676 - Grain tank extension

l A - For air bleeding remove the 0.6 mm union
60-44
Hydraulic system
60.20 - Hydraulic steering system
The fully hydraulic steering is constituted by a system wherein steering controls are transmitted to the steering mechanism hydrau-
lically.
There is no form of mechanical connection between the steering wheel and the steer wheels.
60.20.2 - Execution
ON = Open centre Non-reaction
l In the Lenkorbitrol Opencenter valve the neutral position features an open connection between pump and tank.
l The Lenkorbitrol Non-reaction device prevents external forces acting on the wheels from activating rotary movement of the
steering wheel when the Lenkorbitrol valve is in the neutral position.
60.20.3 - Function
In the neutral position the oil flows freely through the Lenkorbitrol valve from P to T. If the steering wheel is turned in a given direction,
this causes rotation between the valve spools (5, 6). With a 1.5° rotation the passages that lead to the chambers start to rotate. At
4° the passages in the neutral position are completely closed. At 6° the passages leading to the chambers are completely open.
Reciprocal rotation of the spools (5, 6) is restricted to ± 8°.
The supply of the set of rotors (8, 9) with pressurised oil, produces the following effects:
l Rotation of rotor (9).
l Feeding to pressurised cylinders of a quantity of oil that is proportional to the rotation, which thus moves the steer wheels.
l Internal mechanical return from the rotor to the external spool, so the valve passages close when the rotor rotates with the
same rotation angle as that of the steering wheel.
60.20.4 - Emergency steering (manual)

If the system for feeding pressurised oil from the pump should fail, when the steer-
ing wheel is turned the internal spool drives also the external spool and, by means
of cardan shaft (7) it also causes the rotation of rotor (9) in the ring of rotor (8). The
rotor set is thus transformed into a manual pump that consequently pumps oil to
the steering cylinder.
By way of open check valve (4) (ball valve), oil is sucked from the rotor set return
pipe between T and P. In this case the steering is very heavy although the combine
harvester is still fully controllable.
Fig. 1677
60-45
Hydraulic system
Fig. 1678 - Hydraulic steering system

1. Steering column
2. Neutral position springs
3. Case
4. Check valve (short-circuit valve)
5. Internal spool
6. External spool
7. Cardan shaft
8. Toothed ring (rotor ring)
9. Gear (rotor)
10. Antishock valve
11. Top-up valve
12. Check valve (valve TÜV = for overhaul)
13. Pressure relief valve
60-46
Hydraulic system
60.21 - Danfoss Lenkorbitrol type OSPC 160 ON
Fig. 1679 - Danfoss Lenkorbitrol type OSPC 160 ON

1. Antishock valves (205 bar)
2. Pressure relief valve (150 bar)
3. Case
4. Check valve (short-circuit valve)
5. Internal spool
6. External spool
7. Cardan shaft
8. Toothed ring (rotor ring)
9. Gear (rotor)
60-47
Hydraulic system
10. Filling valves
11. Check valve (valve TÜV = for overhaul)
12. Toroidal rings
13. Axial needle roller bearing
14. Dust seal
15. Springs in neutral position
16. Distribution plate
17. Cover
18. Plates
19. Screws (tighten crosswise)
20. Name plate
21. Pressure adjustment screw
60.21.1 - Lenkorbitrol repair work / general overhaul

For safety reasons, it is advisable to leave Lenkorbitrol repair works/overhauls to an authorized Danfoss workshop.
Precautions for refitting operations
Special tools are needed to assemble the Lenkorbitrol unit (oil seal assembly tools).
(Purchased from authorised Danfoss dealers)
Measuring the pressure
Check only when the motor is hot (oil temperature at about 60°).
l Connect the oil pressure gauge (200 bar) to the test connection (pressurised line between pump and Lenkorbitrol).
l Start the diesel engine.
l Fully turn the steering wheel and immobilise at full lock. Read the pressure value on the pressure gauge.
Pressure relief valve adjustment (OSPC 160 ON)
150 bar + measured circulation pressure, i.e., if, for example the neutral circulation pressure (steering neutral position) is 6 bar, the
pressure limiting valve must be adjusted to 150 + 6 = 156 bar.
Antishock valve adjustment: 205 bars
A pressure check of the antishock valves pressure can be performed only on a test bench after removing the Lenkorbitrol.
DANGER
Before disassembling the antishock valves define the depth of insertion of the pressure adjuster screw and check this
dimension after assembly.
60-48
Hydraulic system
60.22 - Steering system check
60.22.1 - Steering cylinder internal sealing check
For this purpose, fully retract the piston rod, undo the flexible hose on the cylinder RH side, start the diesel engine (nominal speed)
and activate the maximum working pressure on the connection LH side.
No oil must be delivered from the open RH connection. Check also the other side.
60.22.2 - Steering system internal sealing check
Remove a connecting hose from the cylinder. After plugging the hose and steering cylinder unions turn the steering wheel. If it proves
impossible to turn the steering wheel the loss of pressure is to be found in the steering cylinder, otherwise the pressure loss is in the
Lenkorbitrol unit.
l Turn the steering wheel until it stops with a torque of 25 Nm. If you can turn the steering wheel at more than 4 rpm (in both
directions):
a) the shock valve is leaking,
b) the rotor or control valve spool are worn.
l Connect the pressure gauge to the test union and measure the pressure. If pressure is too low:
a) adjust pressure setting,
b) check pressure relief valve (probably leaking).
l Check pump using a flowmeter.
l Make sure piston rod is straight.
l Check that kingpin slides freely.
l Check steering column:
steering column clearance must be of about 1 mm in relation to the Lenkorbitrol Danfoss internal spool floor. (Adjust by means
of spacers between circlip and steering column).
Steering column height clearance = 0.1 - 0.3 mm.
l After operation, the steering wheel must return automatically to the neutral position. (Check with the diesel engine stopped).
DANGER
The air must always be bled from the system after working on the steering hydraulic circuit.
60-49
Hydraulic system
60.23 - Hydraulic circuit - Troubleshooting
Table 86
Fault Probable cause Corrective action
Steering wheel can only be turned with dif- 1. No oil pressure or insufficient pressure 1. -
ficulty a) Pump not working. a) Activate pump.
b) Faulty pump. b) Repair or renew.
c) Pump incorrect direction of run. c) Correct direction of run of pump or re-
new.
d) Worn pump. d) Renew pump.
2. Pressure relief valve is jammed open or 2. Repair or clean pressure relief valve. Ad-
opening pressure adjustment is too low. just valve to correct opening pressure.
3. Excessive friction on mechanical parts of 3. Lubricate and if necessary repair bear-
steering device. ings and components of steering device.
Check assembly of steering column.
Permanent corrections required on steer- 1. Leaf springs not correctly tightened or 1. Renew leaf springs.
ing (cornering performance). broken.
2. Broken spring in double shock valve. 2. Renew shock valve.
3. Worn gear train. 3. Renew worn gear train.
4. Cylinder cracked or piston seals worn. 4. Renew defective parts.
Steering wheel does not return to neutral 1. Steering column and steering unit not 1. Centre steering column in conformity
position. centred. with steering unit.
2. No clearance or insufficient clearance 2. Adjust clearance and if necessary short-
between steering column and steering unit en the linkage rod.
control shaft.
3. Seizure between internal control valve 3. Contact your nearest Danfoss service
spool and external sleeve. centre.
Steering wheel continues to turn unassist- 1. Leaf springs not correctly tightened or 1. Renew leaf springs.
ed after being turned by operator. broken.
2. Seizure between internal control valve 2. Clean steering unit or contact your near-
spool and external sleeve probably caused est Danfoss service centre.
by the presence of contaminants.
Steering wheel play. 1. Cardan shaft clevis worn or broken. 1. Renew cardan shaft.
2. Leaf springs not correctly tightened or 2. Renew leaf springs.
broken.
3. Steering column teeth worn. 3. Renew steering column.
Steer wheels tend to vibrate. (Wide tread 1. Air in steering cylinder. 1. Bleed air from cylinders, identify and
tyres can cause vibrations). eliminate cause of air accumulation.
2. Defect of steering cylinder piston seal. 2. Renew or repair cylinder.
3. Worn gear train. 3. Renew worn gear train.
4. No spacer above cardan shaft. 4. Fit spacer.
Steering wheel can be turned to one or two 1. One or possibly both suction valves are 1. Renew defective valves.
positions without the wheels turning. not sealing properly or are missing.
2. One or possibly both shock valves are 2. Clean/renew or fit defective or missing
either not sealing properly or are missing. valves.
When you attempt to turn the steering 1. The steering unit is not receiving suffi- 1. Renew pump or increase pump speed.
wheel rapidly the response is slower and cient oil, the pump is faulty, or the pump
heavier. speed is too slow.
2. Pressure relief valve is jammed due to 2. Clean the valve and set it to the correct
the presence of contamination. opening pressure.
Steering control system kick-back to steer- 1. Fault in system. 1. Contact your nearest Danfoss service
ing wheel. Kick-back from wheels. centre.
Intense kick-back of steering wheel on both 1. Incorrect adjustment of cardan shaft and 1. Adjust correctly or consult your Danfoss
locks. gear train. service centre.
When the steering wheel is turned the steer 1. Incorrect connection between steering 1. Renew steering hoses.
wheels move in the opposite direction. unit and steering cylinder.
Steering force is too low. (Problem prob- 1. Insufficient steering pump pressure. 1. Set correct pump pressure.
ably present on one lock only). 2. Steering cylinder is too small. 2. Fit oversized cylinders.
3. Surface of piston rod is too great com- 3. Fit cylinders with more slender piston
pared to piston diameter. rods or fit 2 differential cylinders.
60-50
Hydraulic system
Fault Probable cause Corrective action
Leakage from drive shaft, end cover, train 1. Defective gasket. 1. Renew gasket or consult Danfoss ser-
of gears, casing or at upper part. vice centre.
2. Screws have worked loose. 2. Tighten screws to torque of 3 - 5 daNm.
3. Defective washers or toroidal rings. 3. Renew washers and toroidal ring.
60-51
Hydraulic system
60.24 - General warnings
l Use the gearbox only when the combine is not running and with the gear lever in neutral position.
l Load the hydraulic travel circuit only from engine speeds of at least 1000 rpm (manoeuvre).
l Regularly clean the cooler.
l Keep all parts and equipment scrupulously clean when refilling/topping up with oil, changing the oil, changing the filter or dur-
ing repair works.
l After changing the filter, run the engine briefly at low speed and with the travel lever in the neutral position to allow air to es-
cape from the supply circuit. Check oil level.
l If the hydrostatic pump or engine fail, check hoses and pipes for metal particles. If in doubt, carefully flush carefully the cool-
ing circuit, high pressure pipes and return pipe, before fitting a new or reconditioned assembly (remove also the oil cooler, if
necessary).
l When changing the hydrostatic motor, drain the oil from the gearbox and top up with new oil.
l Observe the safety instructions!
60.24.1 - Equipment of combine harvesters with hydrostatic units

Table 87
Type of combine harvester Hydrostatic pump Hydrostatic motor
5650, 5660 H / HTS, 5665 HTS (Standard) HPV 105-02 HMF 105-02
5660 H / HTS, 5665 HTS (Balance) HPV 135-02 HMF 135-02
5690 H / HTS, 5695 HTS (Standard) HPV 135-02 HMF 135-02
5690 H / HTS, 5695 HTS (Balance) HPV 135-02 HMF 135-02
60-52
Hydraulic system
60.25 - Basic structure
Fig. 1680 - Hydrostatic drive

l Pipes diagram
l Connection diagram
1. Hydrostatic pump (inclined cam pump)
2. Integral bypass valve in the interchangeable filter
3. Feed pump
4. Oil cooler assembly on the air shroud
5. Interchangeable filter
6. High-pressure valve
7. High-pressure valve
8. Axial piston pump
9. Feed pressure valve opening pressure
10. Cold starting valve
11. Hydrostatic motor
12. Servo control
13. Travel lever with cable-pull
14. Oil reservoir (tank)
15. Oil return pipe
16. High-pressure circuit
17. Changeover valve
18. Return valve
19. Return filter Note the assembly position
DANGER
Note the position
60-53
Hydraulic system
60.25.1 - Description of hydrostatic system operation
Hydraulic pump (1) is driven directly by the diesel engine. When the inclined cam is in the neutral position (zero position) no axial
movement occurs so there is no oil flow.
The gear pump (feed pump) (3), which is flanged as a monobloc onto the inclined cam pump, draws oil from the pump casing and
transfers it to the axial piston pump (8) after flowing through oil cooler (4), interchangeable filter (5) and the feed valves incorporated
in the high pressure valve (6 and 7).
Cold starting valve (10) protects oil cooler (4) and is activated in the event of unusually high flow resistance (e.g. starts in very low
ambient temperature conditions)
All the oil that is not used to compensate for possible leakage past seals and for hydraulic control of the pump (power steering) flows
through the pressurised feed valve (9), which simultaneously maintains the supply pressure and thus guarantees the required pres-
sure in the high pressure circuit.
Depending on the direction of oscillation (“forward” or “backward”) of the inclined cam pump (8), the oil is transferred to the hydraulic
motor (11) and consequently a high pressure value is generated, which simultaneously closes the feed valve incorporated in the high
pressure valve (6 or 7).
If the pressure exceeds 420 bar on the combined feed and high pressure valve (6 or 7), the oil escapes from the low pressure side
by means of the connecting passage and the feed valve on the opposite side (6 or 7).
The changeover valve (17) incorporated in hydraulic motor (11) connects the low pressure side with return valve (18), which is adju-
sted to 10 bar. By means of the return valve, a metered quantity of oil returns to the crankcase for cooling and scavenging of the
crankcase and then, by way of oil return pipe (15) and return filter (19), it flows back to the oil tank.
Fig. 1681 - Hydrostatic drive
60-54
Hydraulic system
60.26 - BoWex clutch between hydrostatic pump and engine
1 - Flange for mounting hydrostatic pump
2 - Clutch plate
2.1 - Screw M10 x 35, with threadlocker
3 - Locking hub with safety ring
4 - Diesel engine flywheel
Fig. 1682
60.26.1 - Assembly warnings
Fig. 1683 - BoWex clutch
60-55
Hydraulic system
The locking hub (3) must not press against the engine flywheel in an axial direction.
60-56
Hydraulic system
60.27 - Gear control
1. Control nut
2. Support
3. Travel lever
4. Toothed rod device
5. Ball coupling
6. Neutral stop notch
Check or adjust the neutral position of the travel control (the check must be carried out when, with the combine harvester on level
ground with the travel lever in neutral it tends to move slowly forwards or in reverse, or when gear changes are accompanied by
anomalous gearbox noise).
l Raise the combine harvester on stands under the drive axle LH side and insert chocks to avoid accidental movements.
l Release the parking brake.
l Run the engine at low speed and with the 1st gear engaged, operate the forward travel lever and then move it back to neutral.
l Operate the lever for reverse travel and then move it back to neutral.
The drive wheel must stop each time the travel lever is set to neutral. Otherwise adjust the cable-pull by means of nuts (1) in
support (2). Repeat the check.
If it is not possible to select the neutral position, check free travel of the cable-pull or actuator device.
l Play in the connection between travel lever (3) and toothed rod device (4)
l Play in toothed rod device (4)
l Play in ball coupling (5)
l Excessive play in neutral detent notch (6) of the travel lever.
60.27.1 - Toothed rod device

1. Connecting fork
2. Toothed rod
3. Guide bush
When replacing the cable-pull or repairing the toothed rod device make sure that the assembly is correct.
In the illustrated position of attachment fork (1) for the travel lever, toothed rod (2) must be aligned (X) with guide bush (3).
60-57
Hydraulic system
Fig. 1684 - Travel lever
60-58
Hydraulic system
60.28 - Hydrostatic transmission - Hydrostatic pump HPV 105/135
60.28.1 - Basic structure
Fig. 1685 - Hydrostatic pump

1. Adjustment of inclined cam
2. Interchangeable filter
3. Pressure relief valve (cold starting 30 bar)
4. Gear pump (feed pump)
5. Pressure relief valve (feed pressure)
6. Pressure limiting valve (combined feed and high pressure limiting valve)
7. Gear pump pressure discharge side (A)
8. Shaft
9. Flange
10. Work piston (number: 9)
11. Cylinder block
12. Plate
13. Suction air filter for feed pump
60.28.2 - Tightening torques for the valves

Table 88
Valve HPV 105 HPV 135
Valve for cold starting 3 30 Nm 40 Nm
Feed valve 30 Nm 40 Nm
High pressure valve 6 140 Nm 170 Nm
60-59
Hydraulic system
60-60
Hydraulic system
60.28.3 - Cam adjustment

Structure
Function
Inspection
1. Adjustment
2. Cam
3. Control lever
4. Stop screws
5. Nozzles
6. Hollow screw
7. Mark
8. Pilot
9. Feed pump
10. Control piston
11. Control piston
12. Spring (mechanical 0 position)
13. Support plate
14. Flange
Working rotation direction: right-handed (view → X)
Delivery of pressurised oil to P by rotating adjustment lever from 0 in direction I
60-61
Hydraulic system
Delivery of pressurised oil to S by rotating adjustment lever from 0 in direction II
a. Mechanical zero position centring
The inclined cam is centred in its zero position by means of two retaining springs (12) on adjuster pistons (10, 11). This adjustment
is performed in the factory during pump installation and it must not be altered subsequently.
b. Adjustment of maximum supply flow rate
The maximum supply flow rate is factory set on a test bench by means of two threaded studs (4); this adjustment must not be altered.
c. Checking and adjustment of the hydraulic zero position
Set the adjuster lever (cam) to the neutral position as marked on cam (7) and more or less parallel to pilot casing (6). The hydraulic
zero position can be corrected by rotating the hollow screw (6).
DANGER
These adjustments have already been carried out on a test bench in the factory and should not be altered.
60-62
Hydraulic system
60.29 - Hydrostatic transmission - Hydrostatic pump HPV 105/135
60.29.1 - Measure and check
l Summary of unions and pressure test points
l Connection diagram
Table 89
P, S Compressed air union
A Fuel pump pressure union
B Fuel pump intake union
F Control pressure, feed, filter inlet
X Test connection - feed pressure, M14x1.5
Ms, Mp Test connections, high pressure, M14x1.5
L, U Oil drain unions
L1, L2 Air bleed unions
Table 90
Pos. Element HPV 105 HPV 135
1 Feed pressure relief valve set- 19 bars 20 bars
ting:
2 Cold starting pressure relief 25 bars 25 bars
valve setting:
3 Combined feed and high pres- 420 bars 420 bars
sure limiting valve setting:
4 Replacement filter - -
→ The arrow shows the travel direction
60.29.2 - General information for pressure measurement
l Check hydraulic oil level.
l Warm up the hydrostatic system, oil temperature approx. 60C°.
l The feed pressure must not fall below 10 bar even under load.
l If you are unsure of whether low feed pressure is caused by the hydraulic pump or hydraulic motor, close the pump high pres-
sure unions and repeat the measurement.
l Perform high pressure measurement only for a limited time: risk of valves overheating.
60-63
Hydraulic system
Fig. 1689 - Hydrostatic motor
60-64
Hydraulic system
60.30 - HMF type hydrostatic motor
60.30.1 - Hydrostatic motor HMF 105, HMF 135

HMF type hydrostatic motors are axial piston units featuring inclined cam design.
1 - Control shaft
2 - Retaining plate
3 - Working piston with sliding shoe
4 - Cylinder block
5 - High pressure unions
6 - Supply outlet
6.1 - Return valve (10 bar)
6.2 - Changeover valve
7 - Waste oil / return oil, max. casing pressure: 1.5 bar
8 - Plate
9 - Inclined cam
60-65
Hydraulic system
60.30.2 - HMF type hydrostatic motor

l Connection diagram (valid also for BMF type)
l Shaft radial oil seal
l Outlet supply device
1 - Changeover valve
2 - Shaft radial oil seal
3 - Shaft seals support
4 - Changeover valve
4.1 - Closing plug M 22 x 1.5 - V80
4.2 - Toroidal ring 23.52 x 1.8 - V80
4.3 - Spring
4.4 - Thrust washer
4.5 - Valve piston
4.6 - Valve bush
5 - Return valve 10 bar / 9 l/min
5.1 - Plug
5.2 - Key
5.3 - Spring
5.4 - Ball
5.5 - Valve bush (assembled with adhesive)
5.6 - Toroidal ring 11 x 2 - V80
6 - Return oil / Waste oil connection
Disassembly/Assembly of shaft radial oil seal (2)
l Detach circlip (1).
l Blow compressed air into the waste oil connection (6) to remove the shaft oil seal rings support (3) including the shaft radial
oil seal (2).
60-66
Hydraulic system
NOTE
Fix the cam to the shaft end with the screw to avoid detachment of cover (3).
The outlet supply device is used for flushing of the circuit and the casing.
Outlet flow rate: approximately 12 l/min
Return valve opening pressure: 10 bar
NOTE
The bushing of the valve (4.6) of the changeover valve (4) is secured with adhesive. Take this into account during
disassembly/assembly procedures! (Disassembly: heat to about 200 °C)
60-67
Hydraulic system
60.31 - Troubleshooting
60.31.1 - 1. During start-up of the system loud cavitation noises are emitted
The supply flow of the feed pump is insufficient to compensate for the rate of leakage.
The supply pressure falls substantially.
Table 91
Pipes between pump and motor yes → Seal pipelines, top up with new
are leaking oil, bleed air from hydraulic cir-
no cuit
↓
Insufficient flow rate of feed yes → Renew feed pump, clean strain-
pump er
no
↓
Cold start valve is set too low yes → Renew cold starting valve
no
↓
Excessive internal oil leaks in yes → Repair or renew hydraulic motor
motor
no See Linde repair manual
↓
Excessive internal oil leaks in yes → In the presence of evident leak-
pump age repair or renew pump
Check feed pressure with system loaded.
60.31.2 - 2. Insufficient performance of the system at normal supply pressure and with-
out any significant cavitation noise
Table 92
High pressure valve not sealing yes → Tighten high pressure valve in
on cutting edge and on valve compliance with prescriptions
seat
no
↓
High pressure valve setting is yes → Renew high pressure valve
too low
no
↓
Worn sliding surfaces on cylin- yes → Renew hydraulic pomp and mo-
ders block and on control base tor
Sliding (internal connection) from high pressure side to low pressure side.
General information
To check for possible wear (scoring) on the control base caused by the pump or hydraulic motor, disassemble the feed pump and
check for the presence of metal particles in the strainer.
60.31.3 - 3. The system shuts down
Table 93
Motor piston seized yes → Renew hydraulic motor
60.31.4 - 4. Combine cannot reach top speed

Table 94
Incorrectly adjusted cable-pulls yes → Adjust tie-rod or cable-pull with
respect to pump so that the final
stop on the travel lever and the
final stop of the pump coincide.
60-68
Hydraulic system
Check whether the pump con- - - -
trol lever has been brought to
its end position by means of the
tie-rod or cable-pull.
60.31.5 - 5. When the travel lever is activated the combine fails to move forward or in
reverse
Table 95
Insufficient hydraulic oil in tank yes → Top up
no
↓
Jammed tie-rod or cable-pull yes → Repair or renew.
no
↓
Faulty Centaflex clutch between yes → Renew Centaflex clutch
motor and pump
no
↓
No oil feed pressure yes → Check feed circuit (feed pump,
no pressure feed valve, cold start-
↓ ing valve)
Power steering nozzles dirty yes → Clean nozzles
Refer to Linde repair manual
Check:
Remove pump cover with control levers.
60.31.6 - 6. Oil temperature too high, max. 95 °C
Table 96
Oil cooler fouled yes → Clean oil cooler, seal any non-
no hermetic parts on the air duct or
↓ cyclone (avoid ingress of dirt)
Insufficient supply of cooling air yes → Check for possible insufficient
no air supply
↓
Faulty temperature transducer yes → Renew temperature transducer
no
↓
Operation with high load using yes → Select lower gear
excessively high gear
no
↓
Cooler dynamic pressure too yes → Renew cooler and pipelines
high, cooler and pipes are dis-
torted
no
↓
Cold start valve is set too low yes → Renew cold starting valve
no
↓
High pressure valve setting is yes → Renew high pressure valve
too low
no
↓
Excessively high oil leaks in yes → Renew hydraulic pomp and mo-
hydraulic motor and hydraulic tor
pump
60-69
Hydraulic system
60.31.7 - 7. Zero point position cannot be reached
Table 97
Poorly adjusted cable-pull or tie yes → Adjust tie rod or cable-pull so
rod that position of travel lever and
pump control are simultaneous-
ly in neutral.
60.31.8 - 8. No feed pressure

Table 98
Insufficient hydraulic oil in tank yes → Top up
no
↓
Insufficient flow rate of feed yes → Renew feed pump
pump
no
↓
Cold start valve is set too low yes → Renew cold starting pump
no
↓
Pressure feed valve is set too yes → Renew pressure feed pump
low
no
↓
Excessive internal oil leaks in yes → Repair or renew hydraulic motor
hydraulic motor
no
↓
Excessive external oil leaks yes → In the presence of evident leak-
from pump age repair or renew pump
60.31.9 - 9. Combine travels in only one direction

Table 99
Jammed tie rod or cable-pull yes → Repair or renew
no
↓
Check high pressure valve yes → Renew high pressure valve
(jammed, dirty or faulty)
no
↓
Servocontrol nozzle clogged yes → Clean nozzle
no
↓
Servocontrol steering piston yes → Repair or renew pump
damaged or leaking
60.31.10 - 10. In one direction of travel the speed changes in an irregular manner or trac-
tion force is reduced
Table 100
Broken spring in hydrostatic yes → Repair changeover valve
motor changeover valve or
valve piston fails to close fully
60-70
70 - Feed passage
70-1
Feed passage
70.1 - Feed passage
By tightening or loosening diagonal struts (1) using nuts (2), the cutting table can be adjusted in a direction parallel to the ground.
Before tightening a diagonal strut, tension screws (3) on the left and right and loosen the diagonal strut on the opposite side.
Fig. 1693 - Feed passage

1. Diagonal struts
2. Nuts
3. Screws
4. Loosened bearings
70-2
Feed passage
70.2 - Feed passage - slipping clutch
Fig. 1694 - Feed passage - slipping clutch

1. Screw M10
2. Shim
3. Lubricate the surface of the bearing and half-bearing housing
Before each harvest season ventilate the slipping clutches and cause them to slip long and hard.
70-3
Feed passage
Fig. 1695 - Feed passage - slipping clutch

1. Prior to assembly, degrease the metal surfaces thoroughly and coat them with anticorrosion agent i RC 123 V
(Fuchs) 9 9097 123 400 40 (drying time approx. 4 hours at 20 °C)
2. Greased with Molykote BR2 0 9097 127 544 50
3. Slipping torque 450 Nm
70-4
Feed passage
70.3 - Feed passage - stabiliser shaft for feed chain
Fig. 1696 - Feed passage - stabiliser shaft for feed chain

1. Tightening torque: 400 Nm (M24x1.5)
2. Upper stop for oscillating arm
3. Lower stop for oscillating arm (for threshing maize turn through 180 °C)
4. Ringnuts tightening torque: 56 nM
5. Tensioning device for feed chain
Positioning shaft (2) for feed chain.
For threshing of maize or sunflowers lock in the upper position or remove positioning shaft (2).
70-5
Feed passage
Fig. 1697 - Feed passage - stabiliser shaft for feed chain

1. Intermediate roller
2. Positioning shaft
70-6
Feed passage
70.4 - Engagement of the feed passage
Fig. 1698 - Engagement of the feed passage

1. Control dimension for stroke (60 mm) of control motor during engagement.
2. Spring preload dimension with feed channel engaged
(adjustment by means of load relay potentiometer, see section C).
3. Servomotor stroke adjustment by shifting spring pack on threaded rod (3).
70-7
Feed passage
70.5 - Protection against clogging of feed passage
Table 101
Pos. Name Parts

1 Protection against left- 1
hand clogging
2 Protection against right- 1
hand clogging
3 “U” profile 2
4 Screw M10x80 6
5 Screw M10x85 6 Fig. 1699
6 Stud screw M10x90 1
7 Screw M10x100 1
8 Spring washer A10 10
9 Wide diameter round 4
head screw M8x30
10 Washer 8.4x18x2 4
11 Spring washer A8 4
12 Nut M8 4
13 Washer 10.5x30x3 4
14 Lock nut M10 2
70-8
Feed passage
70.6 - Protection against clogging between feed channel chain
sprockets
70.6.1 - (Auxiliary equipment for threshing of flax)
1. Plastic sliding plate
Fig. 1700
70-9
Feed passage
70.7 - Feed passage reversal device
1 - Plate
2 - Relay for electromagnetic switch
3 - Insulators
X - Connection for thermal overload switch (see connection diagram)
Fig. 1701
1 - Plate
2 - Self-tapping screws M10x35
Fig. 1702
Part Z1:
Net distance of 5.5 mm between crown wheel and relay shaft.
Adjust by shifting plate (1) in the slot.
Part Z2:
Axial distance of 3 mm between crown wheel and pinion.
Adjust by shifting the flywheel on the relay shaft.
Fig. 1703
70-10
Feed passage
70.8 - Feed passage oscillating frame, orientable adapter
70.8.1 - Orientable adapter for the cutting table (without hydraulic adjustment of the cut-
ting angle)
Adapted to adjust cutting table cutting angle to match the tyre size by means of adjustment of tensioning devices (1).

1. Tensioning devices
2. Joining plate
70.8.2 - Orientable adapter for the cutting table (with hydraulic adjustment of the cutting
angle)
With the lift cylinder piston rods fully retracted, the oscillating adapter must not rest on the feed channel. If necessary, adjust the piston
rods at the swivel end.
The piston rod (1) must be screwed into the swivel end (2) by at least 24 mm. Control dimension between clearance washer of piston
rod and locknut: mg/kg. 26 mm.
70-11
Feed passage
70-12
80 - Cab
80-1
Cab
80.1 - Operator station control console
1 Instrument panel
1.1 Central display
1.2 Hydraulic oil temperature gauge
1.3 Coolant temperature gauge
2 Gear lever
3 Commander Control 2000
4 EMR-D control unit
5 Control consoles
6 Commander Stick
Fig. 1706 - Operator station control console

7 Ignition switch
8 Hazard warning lights on/off switch
9 Indicator light, straw chopper on/off
10 Indicator light, one-point lubrication system
11 Automatic cutting angle control
12 Grain tank cover raise/lower
13 Grain tank light on/off switch
14 Indicator light, 4-wheel drive on/off
15 Rocker switch, reversing system on/off
16 Rocker switch, side cutting table on/off
17 Width segment switch (TCS only)
18 LH/RH spreader plates adjustment switch
19 Indicator lights, spreader plates right
80-2
Cab
20 Hour meter
21 12 Volt socket
22 Cigar lighter
23 Switch, straw guide plate, short/long straw
24 Work master switch
25 Indicator lights, spreader plates left
26 Indicator light, differential lock, on/off
27 Switch, 4-wheel drive on/off
28 Indicator light, automatic fan control on gradients on/off
29 Fault indicator light, engine speed management (EMR)
30 Engine speed switch with three positions:
l lower idling
l increased idling speed
l Nominal engine speed
Fig. 1707 - Control console

18.1 Spreader plates right control button
18.2 Spreader plates left control button
19.1 Indicator light, spreader plates half-right
19.2 Indicator light, spreader plates full right
25.1 Indicator light, spreader plates half-left
25.2 Indicator light, spreader plates full left
80-3
Cab
Fig. 1708 - Control console
80-4
Cab
80.2 - Commander Control 2000, EMR-D control unit
80.2.1 - Commander Control 2000
General information
The Commander Control 2000 is operated by a membrane keypad with 14 keys.
1 Screen
2 Swivel grain tank discharge pipe in/out
3 Threshing section engaged/disengaged
4 Cutting table engaged/disengaged
5 Clearances adjustment
6 Speed adjustment
7 Winnowing fan speed adjustment/Setup menu*
8 Threshing drum speed adjustment/Diagnosis menu*
9 Pick-up reel speed adjustment/Calibration menu*
* Press + and - keys simultaneously
For detailed information and instructions on the function and operation please
refer to section H.
Fig. 1709
80.2.2 - EMR-D control panel

1 Mode selector
1.1 Transport position adjustment
1.2 Cutting height preselection
1.3 Ground pressure control (for AutoControl version with lateral tilt control))
1.4 Clearance control (for AutoControl version with lateral tilt control)
2 Overstroke button
3 Ground contact pressure preselection
4 Cutting height preselection
5 Diagnosis indicator (red LED)
6 Status indicator (green LED)
For detailed information and instructions on the function and operation please Fig. 1710
refer to section H.
80-5
Cab
80.3 - Operator station, Commander Stick, control consoles
1 Gear lever - Diagram showing position of gears
Fig. 1711
Gear lever boot
Fig. 1712
DANGER
Gears must only be shifted when the combine harvester is stationary!
2 Commander Stick
3 Cutting angle forward/back adjustment
4 Pick-up reel lower/raise
5 Orient front attachment to right side down/left side down
6 Lift/lower front attachment
7 Reel forward/retract
8 Automatic system for EMR-D
Fig. 1713
9 Air conditioning system control panel

10 Heater control knob
11 Fan control knob
12 Air conditioning system control knob
13 Air conditioning system on/off switch
14 Air conditioning system fault warning light
15 Blank position
16 Digital clock
17 Loudspeaker
Fig. 1714
80-6
Cab
18 Rotary beacons
19 Windscreen wiper
20 Lighting control panel
21 Worklights:
off
4 Headlights
All lights
22 Upper/lower headlights
23 Headlights:
off
sidelights Fig. 1715
running lights
80-7
Cab
80.4 - Operator station - steering wheel
l 1 - Steering wheel adjustment lever
l 2 - Steering column switch with the following functions:
l 3 - Grain loss monitor
Fig. 1716
l 2 - Steering column switch with the following functions:

m 2.1 - Push: Horn
m 2.2 - Forward: RH turn signal
m 2.3 - Up: High beam headlights
m 2.4 - Back: LH turn signal
m 2.5 - Downward: low beams, running lights (only when ignition is on)
m 2.6 - Fully down: Headlight flasher
Fig. 1717
l 4 - Ignition switch with the following functions:

m 0 - Resetting
m I = Ignition circuit on (with the engine stopped the battery charge and
oil pressure warning lights remain lit)

m II - Engine starting
Fig. 1718
DANGER
The servomotors of the belt clutches may move when switching on the ignition and starting the engine. The clutches
will be driven to the disengaged position.
DANGER
After switching off the engine, always remove the key from the ignition before alighting from the cab.
NOTE
The engine can be started only when the Commander Stick is in the Neutral position.
80-8
Cab
80.5 - Cab - control pedals, parking brake
1 Cover for button (3)
2 Cutting table red emergency stop button
3 Grain tank yellow discharge button
Fig. 1719
4 Right-hand wheel brake pedal

5 Interlock latch plate
6 Left-hand wheel brake pedal
Fig. 1720
7 Lock button
8 Parking brake lever
Fig. 1721
80-9
Cab
80.6 - Cab, controls
1 Interior light indicator
2 Interior light switch
3 Spot
4 Spot switch
Fig. 1722
5 Air conditioning evaporator access hatch
Fig. 1723
6 Fresh air and recirculated air
Fig. 1724
7 Fresh air filters
Fig. 1725
80-10
Cab
80.7 - Cab, control devices, seats
1 Storage drawer
2 Storage compartment
Fig. 1726
3 Crank handle: - Seat height adjustment (seat unloaded) - Weight adjustment

(operator seated)
4 Weight indication
5 Seat forward/back
6 Backrest angle adjustment
7 Armrest angle adjustment
8 Folding armrest
Fig. 1727
9 Passenger seat
Fig. 1728
80.7.1 - Aero-Fit seat (air sprung) (optional)

DANGER
Never adjust the seat while the vehicle is in motion. Danger of accidents!
1 Headrest, height adjustable and removable

2 Lumbar support
3 Backrest angle = backrest adjustment
4 Weight and height display
5 Combined (continuous) adjustment in relation to operator’s weight and height
Weight adjustment
Raise or push the handle slightly until the green marking on the weight and height display is visible.
80-11
Cab
Height adjustment
Fully raise or press the handle until the desired position is obtained.
(the green mark must be visible.)
DANGER
The weight and height adjuster can only be operated when the ig-
nition is on. The adjuster should not be operated continuously for
longer than 1 minute!!
6 Longitudinal adjustment
7 Safety belt fixing
8 Folding armrest
9 Armrest height adjustment
Fig. 1729
10 Armrest angle
80-12
Cab
80.8 - Cab - controls
1 Demister vents
Fig. 1730
2 Air vents
3 Air vents
Fig. 1731
4 Inspection window
5 Beverage holder
Fig. 1732
80-13
Cab
80.9 - Cab, control elements, emergency exit
1 Lever:
- orientation towards the exterior of the window
- Emergency exit: if necessary, raise the lever and disengage it from catch (2) then
push the window until it is fully open.
Fig. 1733
2 Catch
Fig. 1734
3 Door handle
Fig. 1735
4 Pushbutton (door opening from the outside)
Fig. 1736
80-14
Cab
80.10 - Cab, rear-view mirror control devices
1 Hex screws:
- Basic adjustment
Fig. 1737
2 Screws
- tighten in such a way that if the mirror strikes an obstacle while the vehicle is
travelling, it will fold without breaking.
Fig. 1738
80.10.1 - Electrical adjustment of the rear-view mirrors (optional)

3 Switch
Fig. 1739
Press on the side of the knob to adjust the mirror to the required position.
Table 102
↑ up
↓ down
→ right
← left
The mirror must be adjusted in relation to the seat position and operator’s height.
80-15
Cab
80.11 - On-board computer (optional)
80.11.1 - System description
The hectare meter comprises the following units:
Table 103
1. Control instrument: for display and operation.
2. Wheel sensor: transmits one pulse per wheel revolution to the control instrument
to enable the various functions to be controlled and calculated.
3. Electromagnetic switch: starts and stops the hectare meter. If the hectare meter is
stopped, the letter “r” appears on the left-hand side of the display
next to the speed indicator.
The electromagnetic switch is located on the right-hand side of the feed channel bearing. The hectare meter is started or stopped by
raising or lowering the cutting table. The switching threshold is set to a cutting table height of about 40 - 50 cm above the ground. The
operation of this solenoid switch can be monitored by switching over from hectare meter to speed indicator.
80.11.2 - Description of the function keys
Fig. 1740 - On-board computer

1. Time employed (hours and minutes)
2. Hectare meter (partial area)
3. Hectare meter (total area)
4. Speed (km/h)
5. Working width input
6. Wheel circumference input
7. Zero reset for all functions: time, surface area and total surface area.
This key is also used to enter the number 0
80-16
Cab
Fig. 1741 - On-board computer

8. Connection to 12 V power supply.
9. Connection for wheel sensor.
10. Connection for electromagnetic switch.
80-17
Cab
80.12 - Cab suspension
Fig. 1742 - Cab suspension

1. front silent block, marking 510 - 5 - N - S
2. rear silent block, marking 510 - 3 - N - S, colour coding green - white
3. silent block marking
4. spacer plate
5. disc
6. Screw M12x8
Observe the following during assembly:
Do not switch the front and rear bearings. Pay attention to the markings.
80-18
Cab
Observe the assembly position of the rubber bearings.
80-19
Cab
80.13 - Safe maintenance and repair of the air conditioning system
80.13.1 - Personnel qualifications
Only qualified and specialised personnel can carry out maintenance and repair
work
l on the air conditioning system,
l adhere strictly to the instructions given in the workshop manual.
All personnel must follow a training course for air conditioning system mainte-
nance work, e.g. c/o the SAME DEUTZ-FAHR Assistance Service.
Fig. 1743
80-20
Cab
80.13.2 - Personal protective equipment
The refrigerant evaporates coming into contact with the atmospheric pressure.
Contact with refrigerant can cause frostbite of the hands.
Frequent contact with PAG oils will harm the skin.
Protect your hands and eyes from the refrigerant and refrigerant oil (PAG).
l Wear heavy-duty gloves (leather)!
l Wear safety goggles or a visor!
Fig. 1744
80.13.3 - Handle refrigerant and the refrigerant tank with care

Put on protective gloves before working with refrigerant and refrigerant cylinders!
Store the refrigerant cylinders away from heat sources and do not heat to temperatures higher than 50 °C. Do not expose to direct
sunlight and keep clear of central heating radiators.
Increasing temperature values increase the tank pressure. With a significant pressure increase thin-wall tanks may burst!
Do not fill refrigerant cylinders completely.
When heated refrigerant expands.
After withdrawing refrigerant, close rechargeable steel cylinders immediately by means of the shut-off valve.
Protect the shut-off valve from damage!
Fit the safety cap and screw cap.
Take care when handling refrigerant cylinders.
Avoid impact!
Never re-use damaged cylinders. Clearly mark the cylinders, for example, as follows: “Defective cylinder. Do not re-use - Danger of
accidents!”
For reasons of safety empty single use cylinders completely in the service station.
Close the empty cylinders.
Refrigerant is heavier than air. If a refrigerant line ruptures the refrigerant gas will flow downwards. This may result in high concen-
trations of refrigerant gas in the air you are breathing. Risk of suffocation!
Leave the room immediately. Return to the room only after it has been sufficiently aired.
If necessary, use respiratory passage protective devices, for example a compressed air respirator.
Do not release refrigerant gas in closed rooms.
80-21
Cab
Always ensure ventilation is adequate, for example switch on extractor fans.
Maintenance work in the cab:
Do not allow refrigerant to escape in the closed cab. Open the cab door and ventilate the cab thoroughly!
80.13.4 - First aid in the case of contact with refrigerant
Inhalation of refrigerant gas:
Take victim outdoors immediately and place in comfortable position.
Call medical personnel!
If victim loses consciousness or suffers respiratory arrest, apply artificial respiration.
Refrigerant in contact with eyes:
Do not rub eyes. Lift eyelids and rinse eyes for at least 15 minutes with plenty of warm water. Call medical personnel immediately!
Refrigerant in contact with skin:
In the case contact of refrigerant with skin rinse the affected area immediately with plenty of water.
80.13.5 - Safety measures for welding work
At temperatures in excess of 800 °C for example, contact of refrigerant with a naked flame or incandescent metal surface (welding
operations) will cause the chemical decomposition of R134a. This results in the release of highly toxic phosgene gas (carbon oxych-
loride). Breathing these gases will result in serious health impairment!
A pungent odour is a clear indication of the presence of noxious gas.
Leave the room immediately. Air the workplace thoroughly.
For soldering work adopt the following precautions:
It is essential to keep sources of heat well away from all parts of the air conditioning system!
The high temperatures generated when soldering can cause system components to explode.
Do not place refrigerant in contact with open flames or incandescent metal (e.g. during welding work)!
Do not smoke when performing maintenance and repair work!
When painting the combine harvester:
Empty the air conditioning system circuit if the vehicle is to remain for more than 20 minutes at a temperature of 80° C in a drying
oven.
Do not paint the evaporator or condenser!
80-22
Cab
80.14 - Overview of functional components in the cab roof
Fig. 1745 - Overview of functional elements

1 - Relay for air conditioning compressor and fan
2 - Fan
3 - Wiper motor
4 - Connectors X135, X36 for lights
5 - Flexible hoses for coolant
5.1 - Flexible pressure hose
80-23
Cab
5.2 - Flexible suction hose
6 - Hoses for heating
7 - Heating valve with servomotor
DANGER
Observe proper mounting position: in delivery line, in direction of flow!
8 - Connectors X115, X134, X182

9 - Interior courtesy light
10 - Since construction year 2002 the recirculated air thermal probe is no longer considered
11 - Recirculated air filter
12 - Air conditioner/heating control panel
12.1 - Air conditioner control device (electric thermostat)
13 - Temperature sensor
14 - Heat exchanger for heating
15 - Evaporator for air conditioner
16 - Expansion valve
17 - Left and right fresh air filter
18 - Master cylinder for service brake
80-24
Cab
80.15 - Electrical diagram for electric heater and air conditioner
in cab roof
Relays K1-K4 are installed in the cab roof
High-low pressure switch:
Switch opens at 1.2 bar or 28 bar.
Switch closes at 2.4 bar or 19.5 bar.
Fig. 1746 - Electric heating and air conditioner
80-25
Cab
80.16 - Operating description of the air conditioning system
80.16.1 - Refrigerant liquid circuit
Table 104
Position Name Function
1 Compressor Draws in gaseous refrigerant from the evaporator
and compresses it. This causes the refrigerant to
heat up (formation of pressure).
2 Pulley with electromagnetic clutch The compressor is driven by a V-belt, a pulley, and
an electromagnetic clutch. Switching the electro-
magnetic clutch on and off causes the compressor
to disengage from the drive mechanism.
3 Filling unions (Service valves) The pressure test unions in the refrigerant line on
the compressor are equipped with threaded insert
type Schrader valves.
4 Condenser The compressed refrigerant is cooled in the con-
denser. This causes it to change to the liquid phase
(condensing process).
5 Liquid tank (Dryer element) Receives the liquid refrigerant.
6 Dryer (1 The dryer removes any accumulated moisture (wa-
ter) from the refrigerant
7 High/low pressure switch Stops the air conditioner if the pressure between
compressor and expansion valve falls below 1.2 bar
or rises above 28 bar. Simultaneously the red fault
warning light will illuminate.
8 Fresh air fans Draw / blow fresh air through the evaporator
9 Expansion valve Separation point between high and low pressure
sides of the circuit. From here, the fluid refrigerant
reaches the evaporator, where it starts to expand.
10 Evaporator The refrigerant expands in the evaporator and evap-
orates completely, thereby changing to the gaseous
phase. The necessary energy (in the form of heat)
is extracted from the ambient air that flows over the
evaporator fins. The thus cooled air is drawn in by
the fan and transferred to the interior of the cab.
11 Temperature sensor Measures the temperature of the cooled air down-
stream of the evaporator.
12 Control device (electric thermostat) Starts or stops the refrigerant compressor by means
of relay K1.
13 Rotary potentiometer Adjustment of air temperature (cooling capacity)
14 Rocker switch Utilised to activate the air conditioning system. The
rotary fan selector must be set at least to level I.
15 Red fault warning light Illuminates as soon as the air conditioning system
is deactivated by means of the high/low pressure
switch.
16 Fan rotary selector Activation/deactivation of fresh air intake fan, with 3
speed settings.
(1 Installed in front of the cooler pack
80-26
Cab
Fig. 1747 - Operation of the air conditioning system
80-27
Cab
80.17 - Refrigerant fluid and oil
80.17.1 - Refrigerant
The combine harvester air conditioning system utilises chlorine-free R 134a refrigerant.
With reference to behaviour relative to pressure and temperature the refrigerant is similar to the previously employed refrigerant type
R 12.
DANGER
Risk of injury! Comply with safety regulations before handling refrigerant! Read the EC technical safety datasheet of
the refrigerant producer.
R 134a refrigerant has a low boiling point.

Boiling point: -26.1 °C with normal atmospheric pressure of approximately 1 bar.
The boiling point temperature varies with the pressure.
The following table provides the facility to establish the corresponding evaporation temperature.
Table 105
Temperature in °C Pressure in bar (Absolute pressure
0 2.92
5 3.49
10 4.14
15 4.88
20 5.71
25 6.65
30 7.69
35 8.86
40 10.16
45 11.59
50 13.17
55 14.90
60 16.81
65 18.89
70 21.17
75 23.65
80 26.35
85 29.29
90 32.48
95 35.95
100 39.72
The absolute pressure is the measured pressure minus ambient pressure.
Ambient pressure is equivalent to atmospheric pressure.
The pressure in the closed system is 1 bar lower than shown in the table.
80.17.2 - Refrigerant
The R 134a refrigerant can absorb heat rapidly (heat absorption) and release it equally rapidly (heat dispersal). Thanks to these
characteristics R 134a is particularly suitable as an agent for the transmission of heat in air conditioning systems.
l If utilised properly R 134a is inflammable and non-explosive both in the liquid and gaseous phase. However, R 134a may ignite
if mixed with an air concentration of more than 60 percent and if the pressure is higher than atmospheric pressure.
Therefore:
Never inject compressed air into refrigerant cylinders, into the air conditioning system, or into the charging station!
l The refrigerant is colourless and odourless.
l In the form of vapour the refrigerant has no effect on food and hence does not contaminate it or make it inedible. However, R
134a refrigerant fluid enriched with PAG oil can attack copper and certain plastics.
l With a high concentration of R 134a in the air breathed respiratory problems may result because the oxygen has been re-
placed by the gaseous refrigerant.
80-28
Cab
DANGER
Material damage! Do not charge the air conditioning system with R 12 refrigerant. Do not mix R 134a with R 12! The
refrigerant oil, gaskets and pipes material and the system pressure are different in R 12 and R 134a refrigerant cir-
cuits. The use of the incorrect refrigerant type may result in chemical reactions with the refrigerant oil and corrosion
of components of the circuit.
80.17.3 - PAG oils

PAG oils are synthetic and highly hygroscopic oils (i.e. they take in moisture).
Moisture in the refrigerant reduces the efficiency of an air conditioning system.
Therefore:
l use PAG oils in the smallest possible packages.
l use immediately.
l dispose of remains immediately and properly.
For storage in larger packs, e.g. in charging station:
l keep the oil in airtight tanks!
Filling capacity
Table 106
Refrigerant Filling capacity
R 134 a 2000 g
Table 107
Refrigerant oil Filling capacity
PAG (polyethylene oxide) * 207 cm3 (for new compressors)
* The compressor nameplate shows the type of oil with which it was filled in the factory!
DANGER
Material damage! Excess refrigerant in the compressor reduces the cooling capacity of the air conditioning system
and can damage the circuit!
80-29
Cab
80.18 - Air conditioning system components
See para. 80.19 - Compressor - page 80-31
See para. 80.20 - Electromagnetic clutch - page 80-32
80-30
Cab
80.19 - Compressor
The combine harvester is equipped with a fixed displacement axial piston compressor.
The compressor is driven by a V-belt. The compressor is connected via an electromagnetic clutch, which is activated when the air
conditioning system is switched on.
The compressor draws gaseous refrigerant from the evaporator, compresses it, and then forces it through the refrigerant circuit.
80.19.1 - Operation
The axial piston compressor features 7 cylinders with fixed displacement. An angled disc causes movement of the plunger on the
double acting piston. The pistons are guided by shoes.
In the downward stroke of the pistons the gaseous refrigerant is drawn into the piston chamber. In addition, a suction valve opens
between the valves plate and the piston chamber.
The refrigerant is compressed during the upward stroke. The suction valve is then closed and the discharge valve between the valves
plate and the head cover is opened.
1 - Electromagnetic clutch
2 - Electrical plug (electric connection)
3 - Oil filling plug
4 - Union of discharge pipe to condenser (high pressure)
5 - Union of suction pipe from evaporator (suction pressure)
6 - Pressure limiting valve (incorporated exclusively in Sanden type C compres-
sor).
Fig. 1748
7 - High pressure test and charging connection

8 - Low pressure test and charging connection
Fig. 1749
80.19.2 - Pressure limiting valve

The pressure limiting valve protects the compressor from possible damage deriving from incorrect operation of the air conditioning
system.
DANGER
Material damage! Refrigerant compressors are suitable exclusively for condensing gas. Do not charge the suction
side of the compressor with liquid refrigerant!
80-31
Cab
80.20 - Electromagnetic clutch
The cooling capacity of the air conditioning system is controlled by engaging and disengaging the electromagnetic clutch.
The control device in the cab controls the engagement or disengagement of the electromagnetic clutch.
The high/low pressure switch in the high pressure circuit of the system opens the electromagnetic clutch when the disengagement
pressure is exceeded (28 bar), or if the pressure falls below 1.2 bar.
Fig. 1750 - Electromagnetic clutch

1. Solenoid
2. Circlip
3. Ball bearing
4. Pulley
5. Dust shield
6. Drive assembly
80-32
Cab
80.21 - Compressor lubrication
The compressor is filled with 207 cm3 of special refrigerant oil.
This oil quantity mixes with the refrigerant. The oil circulates constantly in the circuit and lubricates moving parts, e.g. the piston and
expansion valve. Compressor bearing is lubricated via the lubrication passages and by the oil entrained in the refrigerant.
80.21.1 - Check oil level
During operation, the oil in the compressor is distributed throughout the system by means of the refrigerant.
When the air conditioning system is switched off the refrigerant oil deposits in the various system components.
This makes it impossible to check the oil level in the compressor.
Only by emptying all parts in which the refrigerant has accumulated is it possible to check the exact oil level.
Therefore, each oil change is based on the assumption that the exact quantity of oil removed can be measured.
DANGER
Material damage! Excess refrigerant in the compressor reduces the cooling capacity of the air conditioning system
and can damage the circuit!
80.21.2 - Warnings for maintenance

Table 108
Oil type Oil quantity
PAG-oil for R 134a * 207 cm3 (in new compressors)
* The compressor nameplate shows the type of oil with which it was filled in the factory!
Before recharging the air conditioning system with refrigerant:
l Check the oil level in the compressor.
l Replenish the amount of oil that was eliminated (accumulated in the filling station) during suction of evacuation of the system
l Fill with fresh refrigerant from the compressor suction side.
l Make sure the compressor is firmly secured.
l Check tension and condition of the drive belt.
l Once a month the air conditioning system should run for around 10 minutes.
This allows the refrigerant oil to spread throughout the circuit freely thereby protecting the various parts from corrosion.
80-33
Cab
80.22 - Liquid tank with dryer
The liquid refrigerant flows directly from the condenser to the dryer.
The tank with the dryer perform the following functions:
l The liquid refrigerant accumulates in the liquid tank.
l The solid media dryer binds the water particles and debris present in the refrigerant fluid.
The dryer is composed of a mixture of silica gel, molecular sieves, and aluminium oxide, which are agglomerated together with the
resin to form a solid element.
80.22.1 - Operation
The liquid refrigerant enters from the side and gathers in the tank. In the tank, the refrigerant flows through the solid media dryer,
which removes moisture and contaminants.
The thus purified refrigerant now flows towards the expansion valve.
80.22.2 - Moisture is one of the main problems for an air conditioning system
Depending on the model, the dryer can absorb from approximately 6 to 12 g of water. When the solid media dryer has absorbed this
quantity of liquid it is saturated. At this point the moisture present in the refrigerant flows through to the expansion valve nozzle. Here,
the water turns into ice and consequently clogs the nozzle. The situation in which the expansion valve is iced up is indicated by the
condition wherein the air delivered to the cab is sometimes cooled and sometimes not cooled.
Table 109
The cab temperature drops, normal cooling Expansion valve ices up → Cab temperature rises, no cooling capacity
capacity ← Expansion valve defrosts
80.22.3 - Warnings for maintenance

l On the sight-glass observe the position of the liquid when the compressor is running.
System filled with a sufficient quantity of refrigerant:
white ball floats in moisture indicator sight glass.
l Read the moisture absorption value on the moisture indicator sight glass.
The dryer is saturated with moisture:
The blue oval has turned purple.
l Renew the liquid tank.
DANGER
Material damage! Do not leave the dryer open. Atmospheric humidity will saturate the solid media dryer so that it can-
not be used. Remove the cap only a few moments prior to installation. Change the dryer after having performed any
work on the air conditioning system.
Traces of rust visible in the sight glass:
With refrigerant temperatures in excess of 112 °C a fusible link in the tank has melted as a safety precaution. After evacuating the
refrigerant, the liquid tank is no longer fit for use.
80-34
Cab
Fig. 1751 - Liquid tank with dryer

1. Tank
2. Inlet connection
3. Drain connection
4. Sight glass
5. Discharge pipe
6. Microfilter
7. Hygroscopic material
8. Pressure switch connection
80-35
Cab
80.23 - Thermostatic expansion valve (TEV)
The thermostatic expansion valve (TEV) is the point of separation between the high pressure and low pressure sides of the refrige-
rant circuit. This is the point at which the refrigerant condenses.
The expansion valve (TEV) always delivers to the evaporator exactly the quantity of liquid refrigerant needed to ensure optimal eva-
poration. This means that excessive amounts in the evaporator are avoided.
This adjustment depends on:
l suction pressure (compressor side)
l evaporator outlet temperature
80.23.1 - Construction
Fig. 1752 - Expansion valve

Table 110
Position Name Operation
1 Pipe union The liquid refrigerant flows from the dryer
to the thermostatic expansion valve (TEV).
2 Pipe union The liquid refrigerant flows into the evapo-
rator.
80-36
Cab
Position Name Operation
3 Pipe union The gaseous refrigerant flows from the
evaporator to the thermostatic expansion
valve (TEV).
4 Pipe union The compressor sucks in the gaseous re-
frigerant.
5 Thermal sensor Measures the temperature at the evapora-
tor outlet. Filled with a substance that ex-
pands when heated.
6 Diaphragm Below the diaphragm the thermal sensor
agent pressure is active (evaporation side),
above the diaphragm the suction pressure
is active (compressor side).
7 Valve tappet Activates valve 8. The tappet is connected
to the diaphragm. Valve tappet movement
is caused by movement of the diaphragm.
8 Valve The valve is opened by the valve tappet.
The liquid refrigerant is then injected into
the evaporator.
9 Isolating cap An isolating cap is fitted on the expansion
valve thermal sensor.
80.23.2 - Operation
The thermal sensor pressure is applied above diaphragm (6) while the evaporator outlet suction pressure is applied below diaphragm
(6).
If the air conditioning system is switched off, the diaphragm pressure is balanced and the spring closes valve (8).
If the air conditioning system is switched on, the compressor draws in the gaseous refrigerant from the evaporator.
The evaporator pressure decreases and consequently the pressure below diaphragm (6) falls.
A pressure difference is detected on the diaphragm because the pressure of the thermal sensor above it is higher.
Diaphragm (6) moves downward. Valve tappet (7) follows this movement and opens valve (8).
The liquid refrigerant is now injected into the evaporator.
The temperature created inside the evaporator (cooling due to evaporation) is detected by the thermal sensor. The agent in the ther-
mal sensor changes its volume in accordance with the temperature, thus establishing the pressure above the diaphragm. (6). If the
temperature decreases, also the pressure decreases and valve (8) closes.
This continuous control operation ensures:
l only the quantity of liquid refrigerant required to ensure optimum evaporation is transferred to the evaporator
l the compressor draws in only gaseous refrigerant.
80-37
Cab
80-38
90 - Electrical equipment
90-1
Electrical equipment
90.1 - Electrical system - safety warnings
1. Before working on the electrical system, always disconnect the battery
negative lead.
2. Make sure that the battery is correctly connected. First connect the battery
positive pole and then the negative!
3. Battery gases are highly explosive - use appropriate caution! Avoid gener-
ating sparks or naked flames close to batteries!
4. Only use original fuses. If any of the fuses used are rated too highly, the
electrical system may be severely damaged!
5. The battery leads and alternator leads must be disconnected before start-
ing any electric welding work.
6. Take care when handling the battery (battery acid is toxic and corrosive)!
7. Only operate the starter motor for short intervals to avoid overheating the Fig. 1753
windings. Allow the starter motor to cool!
8. Never place tools on the battery!
Note
The electrical system is described with reference to the complete combine harvester equipment package. However,
depending on the version, individual components may not be fitted on the combine harvester that is undergoing main-
tenance (such as a printer, PC keyboard, etc.).
90-2
90.2 - Serdia
90.2.1 - “Serdia 3.5 level III” software
To enable correct analysis of faults, facilitate the procedure of putting the tractor into service and check correct operation of the engi-
ne electrical components, the Technician is provided with a software application called SERDIA (P/N 5.9030.740.4/10), for installation
on a portable computer. With SERDIA, the technician can:
l display errors (faults) that have occurred;
l program the control unit;
l carry out sensor calibration or setting procedures.
Description of the kit
The SERDIA software is supplied to Authorised Workshops in a carrying case with all the basic items needed for operation. The case
contains:
Fig. 1754
Table 111
Pos. P/N Description Qty
5.9030.740.4/10 Case, complete 1
1 5.9030.740.0 . Installation disk 1
2 5.9030.740.2 . Level III interface General overhaul 1
3 5.9030.741.0 Adapter cable (not included in kit) 1
Data is exchanged between the SERDIA software and the control units by way of a diagnostic socket incorporated in the tractor
wiring. Accordingly, the SERDIA package is supplied with an interface cable that must be used on the particular model and version
of tractor being serviced.
90-3
90.3 - SERDIA 2000 level III” software
90.3.1 - SERDIA 2000 level III” software
To enable correct analysis of faults, facilitate the procedure of putting the tractor into service and check correct operation of the
engine electrical components, the Technician is provided with a software application called SERDIA (P/N. 5.9030.740.4/30), for in-
stallation on a portable computer. With SERDIA, the technician can:
l display errors (faults) that have occurred;
l program the control unit;
l carry out sensor calibration or setting procedures.
Description of the kit
The SERDIA software is supplied to Authorised Workshops in a carrying case with all the basic items needed for operation. The case
contains:
Fig. 1755
Table 112
Pos. Code Description Qty
5.9030.740.4/30 Case, complete 1
1 5.9030.740.0/10 . Installation disk 1
2 5.9030.740.2/10 . Level III interface, General revision + USB cable 1
3 5.9030.741.0 Adapter cable (not included in kit) 1
Data is exchanged between the SERDIA software and the control units by way of a diagnostic socket incorporated in the tractor
wiring.
Accordingly, the SERDIA package is supplied with an interface cable that must be used on the particular model and version of tractor
being serviced.
90-4
90.4 - Table of abbreviations
l AHS: Work master switch
l CCP: Clutch Control Power Unit (integrated under load)
l EEC: Engine control unit (Electronic Engine Control)
l EMR-D: Electronic cutting table adjustment
l GPS: Global Positioning System
l KT: Grain tank
l KTS:Grain tank discharge auger
l MF: Multifunction lever (Commander Stick)
l MV:Solenoid valve
l MW:Cutting mechanism
l TS: Turbo separator
l CS: Terminal Control System (job calculator)
l SMPS: Device for supplying 5V/12V stabilised power
90-5
90.5 - Cable colours and connector colours identification.
Table 113
Basic colours used for cables Other colour identifications for connectors
Abbreviation Colour Abbreviation Colour
bl Blue DBL Dark blue
br Brown DBR Dark brown
ge Yellow DGR Dark grey
gn Green DGN Dark green
gr Grey DRT Dark red
nat Natural ELB Ivory
or Orange GE Yellow
pk Pink HBL Light blue
rs Pink HBR Light brown
rt Red HGN Light green
sw Black HGR Light grey
tr Transparent HRT Light red
vi Purple NAT Natural
wz White OR Orange
- - SW Black
- - WS White
In general the basic colour is indicated first, followed by the identification colours.
Example
l rt/ws/bl is a cable whose base colour is red, while ws and bl are the identification colours at the cable ends
90.5.1 - Identification on the electrical diagram

1. Pin number
2. Device number
1. Pin number
2. Connector X512
90-6
90.6 - View of control console
90.6.1 - Standard execution
1 - Instrument panel
1.1 - Central display
1.2 - Hydraulic system temperature gauge
1.3 - Coolant temperature gauge
2 - Gear lever
3 - Commander Control 2000
4 - EMR-D Control unit
5 - Control console
6 - Commander Stick
Fig. 1756
90-7
90.7 - Control devices in cab roof
90.7.1 - Air conditioning system control panel
8 - Rotary selector for heating (type 5680/5690 only)
9 - Rotary selector
10 - Cab air conditioning system control knob
11 - Air conditioning system START/STOP switch
12 - Air conditioning system fault warning light
13 - Blank position
14 - Digital clock
15 - Loudspeaker
Fig. 1757
90.7.2 - Lighting control panel

16 - Rotary beacons
17 - Wipers
18 - Control panel
19 - Worklights:
Off
l
4 Headlights
l
l All lights
20 - Upper / Lower headlights

21 - Headlights:
l Off Fig. 1758
l sidelights
l running lights
90-8
90.8 - Control console, switches and lights
1 - Starter switch
2 - Hazard warning lights switch on/off
3 - Straw guide plate indicator light (chopper operation position)
4 - Indicator light, one-point lubrication system
5 - Automatic cutting angle control
6 - Grain tank extend/retract
7 - Grain tank light on/off switch
9 - Feed passage reversing device rocker switch
10 - Side cutter bars activation/deactivation switch (equipment for rapeseed cutter)
12 - Deflector adjustment switch, left and right
14 - Operating counter Fig. 1759
15 - 12V outlet socket
16 - Cigar lighter
18 - Work master switch
23 - Engine control system fault lamp (EEC)
24 - Engine speed switch with three positions:
l Lower idling speed
l Medium speed
l Top speed
25 - Buzzer
90-9
90.9 - Commander Control 2000 operating controls
The Commander Control 2000 is operated by a membrane keypad with 14 keys.
1. Level indicator
2. Grain tank pipe retract/ extend
3. Threshing section start/stop (straw chopper)
4. Cutting mechanism start/stop
5. Menu button to set concave - and TS clearance, or for concave rapid open-
ing)
6. Menu button to set speed warning threshold
Menu keypad special function:
Hold down button in pos. I and keep it pressed when turning on ignition
switch. After the audible warning signal has sounded, the belt clutches can
be activated with the engine switched off. Main work switch (18) must be
engaged.
7. Fan speed control
Setup menu* Fig. 1760
8. Drum speed control
Diagnostics menu*
9. Reel speed control or activation of automatic speed adjustment *
10. Calibration menu*
* Buttons ‘+’ and ‘-’ pressed simultaneously (see instructions)
90-10
90.10 - Plug distributor / Engine frame plug connector
90.10.1 - Engine frame plug connector
A - Pneutron connector
Table 114
Connector No. Connector designation Colour Function assignment
1 x140 WS Rear flashing lights, rear lights /
brake lights, returns elevator
2 X141 GE Flashing light, headlight /brake
light - Trailer
3 X142 SW Air conditioning, straw hood
clogging sensor, straw chopper
speed sensor, lighting
4 X143 HRT Grain tank pipe / straw guide
plate sensors, hydraulic system
oil temperature sensor, sieve
box light system
5 X147 HBR Sieve control button
6 X144 HGN Sieve actuators
7 X145 OR Straw guide plate drive, straw
chopper potentiometer / actua-
tor
8 X146 HBL Straw guide plate potentiometer
/ actuator
B - AMP Grain loss system sensor connectors
Table 115
PIN Colour Function assignment Junction box wiring
5 rt Sieve box grain loss sensor gn/ge
4 ge Wheel speed sensor for LH sw 4
1000
3 bl Straw walker grain loss sensor sw 3
2 ws Grain loss sensors system pow- sw 2
er supply
1 br Grain loss sensors ground sw 1
C - Trailer power outlet socket
Table 116
PIN Colour Function assignment
1 sw/ws LH turn signal
2 - Not used
3 br Ground
4 sw/ws RH turn signal
5 gr/sw Rear sidelight, right
6 sw/rt Brake lights, left/right
7 gr/swr Rear sidelight, left
90-11
Fig. 1761 - Engine frame plug connector

90.10.2 - List of connectors on engine frame
Engine wiring loom side (from control panel)
Table 117
8 HBL X146 1 vi-sw 1.02 2 br-sw 1.02 3 ws-sw 1.02 4 -
Straw chopper cover poten- Straw chopper cover poten- Straw chopper cover poten- -
tiometer tiometer - Ground tiometer - power
5 br 2.52 6 ws 2.52 7 - 8 -
Straw chopper cover actua- Straw chopper cover actua- - -
tor tor
90-12
7 OR X145 1 sw 1.02 2 br 1.02 3 bl 1.02 4 -
Chaff spreader potentiom- Chaff spreader potentiom- Chaff spreader potentiom- -
eter eter - Ground eter - Power
5 gn 2.52 6 rt 2.52 7 - 8 -
Chaff spreader actuator, left Chaff spreader actuator, - -
right
6 HGN X144 1 ws 2,52 2 ws-ge 2,52
3 ws 1,02 4 br-ge 1,02
Bottom sieve actuator Bottom sieve actuator Bottom sieve potentiometer Top/bottom sieve potenti-
ometer - Ground
5 gr 2,52 6 sw-gr 2,52 7 gr 1,02 8 gr-rt 1,02
Top sieve actuator Top sieve actuator Top sieve potentiometer Top/bottom sieve potenti-
ometer - Power
5 HBR X147 1 - 2 - 3 ws-vi 1,02 4 ws-ge 1,02
- - Bottom sieve pushbutton, Bottom sieve pushbutton,
closed open
5 - 6 - 7 gr-ge 1,02 8 sw-gr 1,02
- - Top sieve pushbutton, Top sieve pushbutton, open
closed
4 HRT X143 1 ws-bl 1,02 2 gn-sw 1,02 3 bl-vi 1,02 4 ge 2,52
Grain tank discharge pipe Straw chopper cover sensor Hydraulic oil circuit temper- Worklight Sieve box
sensor ature indicator
5 - 6 - 7 - 8 -
- - - -
3 SW X142 1 - 2 - 3 sw-ge 1,02 4 sw-rt-gn 2,52
- - Air conditioning pressure Air conditioning compressor
switch clutch
5 ge-rt 1,02 6 gn-rt 1,02 7 sw-bl 2,52 8 gn 2,52
Straw chamber clogging Straw chopper speed sen- Rear rotary beacon Worklight, rear
warning sensor sor
2 GE X141 1 sw-ws 2,52 2 sw-gn 2,52 3 gr-sw 1,52 4 gr-rt 1,52
LH turn signal Trailer RH turn signal, rear Trailer Rear sidelight, left Trailer Rear sidelight, right Trailer
5 sw-rt 2,52 6 - 7 - 8 -
Brake lights, left and right - - -
Trailer
1 WS X140 1 sw-ws 2,52 2 sw-gn 2,52 3 gr-sw 1,52 4 gr-rt 1,52
LH turn signal, rear RH turn signal, rear Rear sidelight, left Rear sidelight, right
5 sw-rt 2,52 6 sw-rt 2,52 7 bl-gr 1,02 8 bl-ws 1,02
Brake lights, left Brake lights, right Returns elevator clogging Speed sensor Pick-up reel
emergency switch elevators
90-13
Hood wiring loom
Table 118
8 HBL X146 1 - 2 ws-sw 1,02 3 br-sw 1,02 4 vi-sw 1,02
- Straw chopper cover poten- Straw chopper cover poten- Straw chopper cover poten-
tiometer - power tiometer - Ground tiometer
5 - 6 - 7 ws 2,52 8 br 2,52
- - Straw chopper cover actua- Straw chopper cover actua-
tor tor
7 OR X145 1 - 2 bl 1,02 3 br 1,02 4 sw 1,02
- Chaff spreader potentiom- Chaff spreader potentiom- Chaff spreader potentiom-
eter - Power eter - Ground eter
5 - 6 - 7 rt 2,52 8 gn 2,52
- - Chaff spreader actuator, Chaff spreader actuator, left
right
6 HGN X144 1 No.3 1,02 2 No.2 1,02 3 ws-ge 2,52 4 ws 2,52
Top/bottom sieve potenti- Bottom sieve potentiometer Bottom sieve actuator Bottom sieve actuator
ometer Ground
5 No.1 1,02 6 No.2 1,02 7 sw-gr 2,52 8 gr 2,52
Top/bottom sieve potenti- Top sieve potentiometer Top sieve actuator Top sieve actuator
ometer - power
5 HBR X147 1 ws-ge 1,02 2 ws-vi 1,02 3 - 4 -
Bottom sieve pushbutton, Bottom sieve pushbutton, - -
open closed
5 sw-gr 1,02 6 gr-ge 1,02 7 - 8 -
Top sieve pushbutton, open Top sieve pushbutton, - -
closed
4 HRT X143 1 ge 2,52 2 bl-vi 1,02 3 gn-sw 1,02 4 ws-bl 1,02
Worklight Sieve box Hydraulic oil circuit temper- Straw chopper cover sensor Grain tank discharge pipe
ature indicator sensor
5 - 6 - 7 - 8 -
- - - -
3 SW X142 1 sw-rt-gn 2,52 2 sw-ge 1,02 3 - 4 -
Air conditioning compressor Air conditioning pressure - -
clutch switch
5 gn 2,52 6 sw-bl 2,52 7 gn-rt 1,02 8 ge-rt 1,02
Worklight, rear Rear rotary beacon Straw chopper speed sen- Indicator switch Straw
sor chamber covers
2 GE X141 1 gr-rt 1,52 2 gr-sw 1,52 3 sw-gn 2,52 4 sw-ws 2,52
Rear sidelight, right Trailer Rear sidelight, left Trailer RH turn signal, rear Trailer LH turn signal Trailer
5 - 6 - 7 - 8 sw-rt 2,52
- - - Brake lights, left and right
Trailer
1 WS X140 1 gr-rt 1,52 2 gr-sw 1,52 3 sw-gn 2,52 4 sw-ws 2,52
Rear sidelight, right Rear sidelight, left RH turn signal, rear LH turn signal, rear
5 bl-ws 1,02 6 bl-gr 1,02 7 sw-rt 2,52 8 sw-rt 2,52
Speed sensor Pick-up reel Returns elevator clogging Brake lights, right Brake lights, left
elevators emergency switch
90-14
90.11 - Actuator connector pins assignment
Table 119
Connector X700 to concave front servomotor
Function Colour of cable to servo- Pin-No. Combine harvester wiring
motor loom
Servomotor rt 1 ge
Servomotor sw 2 sw/ge
Power supply poles gr 4 ge/rt
Signal poles ge 5 ge
Ground poles gn 6 br/ge
Table 120
Connector X701 to rear concave servomotor
Function Colour of cable to servo- Pin-No. Combine harvester wiring
motor loom
Servomotor rt 1 gn
Servomotor sw 2 sw/gn
Power supply poles gr 4 ge/rt
Signal poles ge 5 gn
Table 121
Connector X702 to turbo separator servomotor
Function Colour of cable to servo- Pin No. Combine harvester wiring
motor loom
Servomotor rt 1 bl
Servomotor sw 2 sw/bl
Power supply poles gr 4 bl/rt
Signal poles ge 5 bl
Table 122
Connector X703 to top sieve servomotor
motor loom
Servomotor sw 1 Cable No. 1
Servomotor tr 2 Cable No. 2
Power supply poles rt 3 Cable No. 3
Signal poles ge 4 Cable No. 4
Ground poles sw 5 ge/gn
Table 123
Connector X704 to bottom sieve servomotor
motor loom
Servomotor sw 1 Cable No. 1
Servomotor tr 2 Cable No. 2
Power supply poles rt 3 Cable No. 3
Signal poles ge 4 Cable No. 4
Ground poles sw 5 ge/gn
Table 124
Connector X705 to straw chopper-straw guide plate servomotor
motor loom
Servomotor sw 1 ws/sw
Servomotor tr 2 vi/sw
Power supply poles rt 3 br/sw
Signal poles ge 4 ws
Ground poles sw 5 br
90-15
Table 125
Connector X706 to straw chopper-guide plate servomotor
motor loom
Servomotor br 1 sw
Servomotor bl 2 bl
Power supply poles sw 3 br
Signal poles gn, ws 4 gn
Ground poles ge,rt 5 rt
90-16
90.12 - Diagram of Commander Control 2000 CAN-Bus with central
display
A25 - CAN module spreader plates adjustment
A26 - Option not available
A30 - Commander Control 2000
B40 - Central display
K16 - Straw chopper spreaders relay
K17 - Straw guide plates relay, left
K38 - Straw guide plates relay, right
M12 - Straw guide plate servomotor
1 - 120Ω Terminal resistor: terminal connector (Pin 7, 8) on the control console
2 - 120Ω Terminal resistor: connector X22 (Pin 5, 6) on the exterior of the control panel
The Commander Control 2000 performs the following functions:
l control
l speed monitor
l indications (Commander Control 2000 and central display)
Central display information is controlled by the Commander Control 2000.
90-17
Fig. 1762 - Diagram of Commander Control 2000 CAN-Bus
90-18
90.13 - Straw chopper straw guide plate adjustment diagram
A25 - CAN module - straw guide plate adjustment
K17 - Straw guide plates relay, left
K38 - Straw guide plates relay, right
M12 - Straw guide plates actuator with potentiometer
90.13.1 - Pins assignment
DI - Digital IN
DO - Digital OUT
AI - Analog IN
AO - Analog OUT
90.13.2 - Identification
Table 126
Pin No.
Channel
Digital OUT
90-19
Fig. 1763 - Straw chopper straw guide plate adjustment diagram
90-20
90.14 - CAN-Bus system of Commander Control with central display
installation procedure
Table 127
A25 Straw guide plate adjustment CAN module UNIT 19
A26 Straw guide plate adjustment CAN module UNIT 19
A27 Sieve adjustment CAN module UNIT 19
A30 Commander Control 2000 UNIT 18
1. Terminal resistor 120 Ω to Terminal Connector in control console
2. Terminal resistor 120 Ω to Connector X22 External control panel
Table 128
CAN-Bus resistor Line with 2 terminal resistors 120 W
CAN-Bus module measurement value
without A30, without CAN-Module 60 Ohm
with A30 without CAN-Module 44 Ohm
with A30 and 1 Can-Module 35 Ohm
with A30 and 2 Can-Modules 29 Ohm
Table 129
Internal resistance of CAN-Bus modules
Com.Control A30, Pin 94 - 95 163 Ohm
CAN-Module, Pin 4 - 12 163 Ohm
Fig. 1764 - Commander Control CAN-Bus system with central display
90-21
90.15 - Type of function and programming of CAN modules
The modules are physically identical and interchangeable. The same software is
installed on all the modules.
The only difference lies in the CAN-Bus address, whereby it is possible to interro-
gate individual modules and hence their relative functions. This operative address
is assigned by Commander Control 2000 with the setup procedure.
In addition, Commander Control 2000 transmits the future operative address to the
module’s programming address with a specific message. The programming ad-
dress is identical for all modules so only one module can be connected by means
of the foregoing procedure. The operative address can be freely reassigned by
means of the Commander Control 2000, this makes it possible to interchange the
modules on the combine harvester.
Execution of programming (in the case of updating or changeover of a module):
1. -
2. switch off the ignition
3. remove modules that do not require programming; only a single module Fig. 1765
can be connected to the CAN-Bus (however, the card-slot does not par-
ticipate in programming operations, which require exclusively the CAN-Bus
and power supply)
4. Switch on the ignition (do not start the diesel engine!!)
5. On the Commander Control 2000 simultaneously press the RH buttons <+>
and <->, the program will go to “Setup”
A - With these buttons:
lselect the page
lquit the menu
B - With these buttons:
lselect the row
C - Press both buttons simultaneously:
lcall setup
With buttons:
l Confirm your choice
The LC display will now present the following screen:

A - current page
B - Number of pages in this menu
Fig. 1766
90-22
With one of the LH buttons <+> or <-> go to page 3:
A - Selected row
Fig. 1767
With one of the central buttons <+> or <-> go to the corresponding line and confirm
with one of the two RH buttons <+> or <->:
Fig. 1768
For programming press one of the central buttons <+> or <-> to select “yes” and
con firm with one of the RH buttons <+> or <->:
Fig. 1769
90-23
If no modules are found the illuminated bar will remain on “no” as shown in fig. 4.
If the module enters the system without faults on the CAN-Bus the bar will show
“yes”:
Fig. 1770
Confirm with one of the RH buttons <+> or <->. The operative address is transmit-
ted by the Commander Control to the module and stored in a non-volatile memory
(EEPROM):
Fig. 1771
Simultaneously press the left buttons <+> and <-> to quit the setup routine.
l Switch off the ignition
l Reconnect all the devices.
The module has now entered the network on the Commander Control and the
relative functions and diagnostic pages are available:
Fig. 1772
90-24
If the module should develop a fault, the Commander Control 2000 will transmit
an anomaly message:
Fig. 1773
If a module no longer responds and no spare part is available, or if a machine must

be restored to an earlier equipment condition, the relative module on the Com-
mander Control must be removed from the system. This precaution will prevent
the generation of unjustified anomaly messages.
Remove the CAN module from the system:
l Switch on the ignition
l On the Commander Control 2000 simultaneously press the RH buttons <+>
and <->; the program will go to “Setup”
Fig. 1774
With one of the two LH buttons <+>or<-> go to page 3:
Fig. 1775
90-25
With one of the two central buttons <+> or <-> go to the corresponding row and
confirm with one of the RH buttons <+> or <->:
Fig. 1776
To quit the system confirm with the RH buttons <+> or <->. The relative module is now no longer acknowledged by the Commander
Control 2000 and the functions and diagnostic pages are no longer available; the fault monitoring function is no longer activated for
this module.
90-26
90.16 - Central display
1. Straw chopper - engine speed
2. Grain tank discharge pipe
3. Straw chamber (straw walker)
4. Returns elevator
5. Grain tank - Grain tank filling indicator
6. Air filter - engine
7. Cylinder head temperature - engine, or engine oil temperature
8. Centralised indicator light
9. Parking brake
10. Cooling fan - Drive belt 5670
11. Oil pressure - engine
12. Full beam headlights
13. Charge control
14. Direction indicator - Trailer
15. Direction indicator - Combine harvester
16. Tank contents - Diesel fuel
17. Engine oil temperature (continuous)
18. Travel speed
Set the start switch to Pos I to illuminate the indicator lights (positions 1-11 and
13) for about 3 seconds. At the same time the audible warning signal is sounded.
During operation a fault is indicated by flashing of the individual lights in the central Fig. 1777
display. At the same time the audible warning signal is sounded and the central-
ised indicator light starts to flash. (Pos. 8). A warning message appears also on the
Commander Control display.
The control function of the sensor is conceived, with the exception of the tem-
perature switch for the cylinder head and engine oil, as a contact that is normally
connected to ground in rest conditions. The benefit is that even a fault of the line
system (cable connections) is signalled as an anomaly.
90-27
90.16.1 - Connectors electrical diagram - Connectors assignment
Table 130
Connector X170 (ws)

Pin Cable colour Function
1 ws Full beam headlights (12)
2 bl Charge control (13)
3 bl/ws Direction indicator
Trailer (14)
4 bl Direction indicator
Combine harvester (15)
5 sw + 12V
6 ws/rt Travel speed
7 sw/ge Centralised indicator light
(8)
8 sw/rt Parking brake (9)
9 bl/rt Cooling fan - Engine (10) Fig. 1778
10 - Not used
11 bl/ge Engine oil pressure (11)
12 - Not used
Table 131
Connector X171 (sw)

Pin Cable colour Function
1 vi/ws Tank contents - Diesel
fuel (16)
2 sw/vi Oil temperature - engine
(17)
3 gn/sw Straw chopper - engine
speed (1)
4 ws/bl Grain tank discharge tube
control (2)
5 ge/rt Straw chamber (3)
6 bl/gr Returns elevator (4)
7 or Grain tank filling indicator
(5)
8 gn Air filter - engine (6)
9 bl/sw Cylinder head tempera-
ture - engine (7)
10 br Ground
*11 br/rt Terminal G
*12 gr Central display light
DANGER
* In the equipment for TERIS/TCS a jumper must be installed on
connector X171 (Connector II, black of central display from Pin 10
to Pin 11.
90-28
90.17 - Central display and Commander Control 2000, control and
command functions overview
A8 - CCP II powershift device for clutches
AHS - Work master switch S40
B7 - Audible signal
B40 - Central display
K98 - Reversing motor relay
M19 - Reversing motor
S43 - Reversing device switch
90.17.1 - Relay unit
K50, K71 - Grain tank pipe, swivel outboard/inboard
Speed adjustment:
K14, K35 - Reel variator relay unit
K15, K36 - Fan variator relay unit
K56, K77 - Threshing drum variator relay unit
Threshing drum distances:
K18, K39 - Concave forward relay unit
K19, K40 - Turbo separator up/down relay unit
K60, K81 - Concave backward relay unit
90-29
Fig. 1779 - Central display and Commander Control 2000
90-30
90.18 - Checking functions by means of Commander Control 2000
Commander Control 2000 (4) monitors and adjusts combine harvester speeds and operation by means of switches and sensors.
Speed control: interpretation of frequency of interruptions generated by a rotating shaft in inductive sensor (B).
Operating conditions: monitoring according to rest-state current principle If operation is correct, the electrical circuit between the
Commander Control 2000 and the switch/sensor is closed. In case of a break of this circuit when the sensor trips or in case of wire
breakage or faulty switch/sensor, the Commander Control 2000 emits a warning signal: display (5), central display (1) or buzzer (3).
Exception: temperature switch (E) for the cylinder head or engine coolant and engine oil: The switch contacts close to ground when
the temperature limit is exceeded.
Table 132
Function of alternator terminals D+ and W:
Terminal D+: Checking alternator functions (Charge control).
Belt clutches release by means of main work switch (in the event
a loss of power to terminal D+ all belt clutches are disengaged).
Terminal W: Engine speed monitoring and control
Threshing mechanism clutch release, when engine speed is low-
er than approximately 1500 rpm.
90-31
Fig. 1780 - Functions control by Commander Control 2000

Key:
1 - Central display
2 - Alternator
3 - Buzzer
4 - Commander Control 2000
5 - Screen
6 - Pulse transmitter (installed on shaft)
A - Gearbox inductive transducer
90-32
B - Inductive sensor as speed sensor
C - Inductive sensor as control switch
D - Mechanical control switch
E - Engine temperature switch
F - Capacitive transducer for grain tank filling indicator
90-33
90.19 - Switches and sensors for Commander Control 2000 control
90.19.1 - Gearbox cover inductive transducer for speed measurement
Fig. 1781 - Switches and sensors for Commander Control 2000 control
Check dimension for installation: 1±0.5 mm gap between sensor and gear.
Sensor internal resistor: R = 1.05 kΩ ±100Ω
Resistance towards enclosure > 500kΩ
90-34
90.19.2 - Inductive sensor for speeds control and adjustment
Check dimension for installation: 4 mm gap between pulse transducer (6) and sensor head.
The LED illuminates when pulse counter (6) covers sensor head.
Table 133
Speed sensors:
Straw walker Checking speed by means of Commander Control 2000
Elevator head
Returns elevator
Straw chopper
Threshing drum Speed indicator and speed check control by means of Command-
Fan er Control 2000
Reel drive
90.19.3 - Inductive sensor as control switch

Check dimension for installation: gap of at least 4 mm between sensor head and lever, grain tank pipe, etc.
Grain tank pipe sensor:
LED illuminates with grain tank pipe swung outboard.
l until grain tank pipe is fully swung inboard, central display indicator light 2 is illuminated.
l Grain tank clutch disengages automatically when discharge pipe is swung inboard (indicator light 2 switches off).
DANGER
With faulty sensor or wire breakage grain tank clutch is locked.
Grain tank cover sensor:

LED illuminates with grain tank extension lowered and grain tank cover closed.
l Warning message on display, when:
m grain tank cover is open
m threshing section and main work switch are off
m Travel speed > 2 km/h
Straw guide plate sensor:

LED illuminates when straw guide plate is set to long straw. In straw chopper position sensor activates following functions:
l indicator light (3) on console illuminates (see console figure).
l activation of straw chopper clutch with threshing section on / off.
l Straw chopper speed control.
90.19.4 - Mechanical control switches

Table 134
Monitored function Type of switch*
Straw chamber 2 x straw walker Rest contact
Returns elevator cover 2 x Working contact
Handbrake Working contact
Cooling fan belt (engine BF6L.913 C) Rest contact
Engine oil pressure switch Working contact
Air cleaner minimum pressure switch Rest contact
* Switching status of switch when activated from initial position.
Rest contact: switching contacts open when activated
Working contact: switching contacts close when activated
90-35
90.19.5 - Engine coolant and oil temperature switch (5650H, 5660H/HTS, 5665HTS, 5690H/
HTS, 5695HTS)
Switching contacts close when temperature values exceed permissible limit (with exception of rest current principle).
90.19.6 - Capacitive transducer for grain tank filling indicator
Capacitive sensor opens to ground (Pin 2 to 3) when it is covered by grain ejector cone. Then red LED at top of transducer switches
off and Commander Control 2000 emits a warning signal.
The grain tank can be equipped with one or two transducers
Table 135
Single transducer version: With a full grain tank, indicator light No. 5 illuminates in central
display, audible signal sounds and revolving lights also illuminate.
Two-transducer version: 1st transducer: indicates that grain tank is 3/4 full, indicator light
No. 5 flashes, warning lights are in flashing mode.
2nd transducer: indicates that grain tank is full. Indicator light 5
switches on, buzzer and warning lights are activated.
90-36
90.20 - Description of inductive sensor functions
Fig. 1782 - Inductive sensor diagram

Key
1. Inductive sensor
2. Metal body
3. LED
4. Connector AMP 282 104-1
Inductive sensor (1) is a proximity switch that changes its status if distance Ds (switching distance) of metal element (2) to sensor
head is greater than or less than approximately 8 mm.
In this way, the position of levers, covers and speeds can be monitored.
Depending on the assignment of the electrical connection, the inductive sensor is connected as a working contact or a contact con-
nected to ground in rest conditions.
Working contact:
l with a sensor distance greater than 8mm the sensor current increases to
approx. 10mA; LED (3) illuminates.
l with a sensor distance less than 8mm the sensor current decreases to
0.5mA, LED (3) switches off
Fig. 1783
Rest contact:
l with a sensor distance lower than 8mm the sensor current decreases to
about 0.5mA;
LED (3) switches off.
Fig. 1784
LED (3) always illuminates in the switch closed condition, irrespective of the connection assignment.
On the combine harvester all inductive sensors are connected as work contacts. To protect from damage, keep a distance Dmin
between the sensor head and the monitored function element of at least 4 mm.
90-37
The inductive sensor should not be connected to a 12V voltage source without a resistor (approx 70 Ohm), because it could be
damaged.
Maximum current load of 400mA.
90-38
90.21 - Sensors, overview
90.21.1 - Sensors on RH side of combine harvester
Fig. 1785 - Sensors on RH side

1. Air cleaner minimum pressure switch
2. Straw walker grain loss sensor (right and left)
3. Straw chamber clogging sensor switch
4. Potentiometer in straw guide plates servomotor
5. Straw chopper speed sensor
6. Straw guide plate position sensor:
7. Potentiometer in straw guide plate servomotor
8. Sieve box grain loss sensor
9. Wheel speed sensor for grain loss monitoring system and work calculator LH 1000 (omitted for TERIS/TCS)
10. Returns elevator cover switch
11. Returns elevator speed sensor
12. Returns elevator hourly production sensor (for TERIS/TCS only)
13. Potentiometer in top/bottom sieve servomotor, open /closed (TERIS/TCS only)
14. Sieve box angle sensor (TERIS/TCS only)
15. Turbo separator speed sensor (TERIS/TCS only)
16. Gearbox speed sensor
17. Balance shaft rotation angle sensor
18. Pressure sensor for cutting table adjustment
19. Feed passage intermediate shaft speed sensor (TERIS/TCS only)
20. Rotation angle sensor for cutting table angle - (for Balance only)
21. Feed passage position sensor for work calculator LH-1000 (omitted for TERIS/TCS)
22. Feed passage position transducer for cutting table adjustment
23. Potentiometer in servomotor for concave rear clearance
24. Brake lights switch
25. Handbrake switch
26. Sensors for anti-starter system and audible warning for reverse travel on multifunction lever grip
27. Light sensor for grain loss monitoring system
28. Grain elevator speed sensor
29. Elevator head hourly production sensor (for TCS only)
30. Humidity sensor in grain tank intake pipe (for TCS only)
31. Potentiometer in turbo separator raise/lower servomotor
90-39
90.21.2 - Combine harvester LH sensors
Fig. 1786 - Sensors on LH side

1. Potentiometer for feeler skids
2. Reel speed sensor
3. Potentiometer in servomotor for concave front clearance
4. Balance shaft rotation angle sensor
5. Drum speed sensor
6. Fan speed sensor
7. Returns elevator cover switch
8. Returns elevator hourly production sensor (for TERIS/TCS only)
9. Straw walker speed sensor
10. Transducer for fuel tank level indicator
11. Hydraulic oil temperature sensor (in hydrostatic pump)
12. Grain tank pipe sensor
13. Grain tank cover sensor
14. Transducer for full grain tank filling indicator
15. Transducer for 3/4 full grain tank filling indicator
90-40
90.21.3 - Sensors on engine (Sensors for EEC see section A)
Fig. 1787 - Sensors on engine

16. Cylinder head temperature transducer/switch
l 5670: Transducer installed on 1st cylinder head, switch on 2nd cylinder head.
l 5650 - 5690: Transducer and switch, single component.
17. Engine oil temperature transducer / switch (only temperature transducer for 5670)
18. Oil pressure switch 5670
19. Oil pressure switch
20. Switch on cooling fan tensioning pulley (BF6L 913C engine only)
90-41
21. Coolant level switch
90-42
90.22 - Multifunction lever, rack device / sensor adjustment
Fig. 1788 - Multifunction lever for rack sensors adjustment

1. Grooved bush
2. LED, illuminates in reverse gear
3. B46 inductive sensor for reverse gear siren
4. B45 inductive sensor for neutral gear sensor anti-start system (Four -wheel drive gearbox release)
5. LED (function check, does not illuminate in position 0)
6. Rack device
7. Operating plate
8. Cable-pull
V = Forward travel
R = Reverse travel
90-43
90.22.1 - Settings on rack device and cable-pull
1. Mechanical zero position
2. Electrical zero position
3. Position 0 on hydrostatic pump (see section D)
DANGER
These three settings must correspond!
90.22.2 - Fitment instructions

l Move multifunction lever from position 0 to reverse travel.
l Screw down the inductive sensors by means of splined bushes in rack device until they come to a stop in the distribution
groove.
l Undo by one full turn (M12x1 thread) and secure with plate nut.
l Move multifunction lever to forward and reverse travel positions.
Minimum distance of sensor active surface for activation disc: 1 + 0.5 mm.
In multifunction lever 0 position, LEDs (2) and (5) must not illuminate!
90-44
90.23 - EEC control unit, accelerator adjustment module
Fig. 1789
Key
1. A1 EEC control unit
2. Engine side connector
3. Combine side connector
4. A2 Accelerator adjustment module
5. Diagnostic Power Socket
6. LED UB, power supply
7. LED VCC, power supply from EEC
8. LED TH/2, reduced accelerator
90-45
9. LED TH/1, full accelerator
10. LED SDW, Threshing section; run = 15b, (LED on = drum operation)
NOTE
At full accelerator and with the threshing mechanism engaged all LEDs illuminate
90.23.1 - A2 Pins assignment
Fig. 1790
Table 136
Pin Name Cable colour Measurement value
1 Half accelerator input from S5 gr/rt 0V/12V
2 Full accelerator input from S5 gr/bl 0V/12V
3 Accelerator potentiometer br -
ground-
4 Accelerator potentiometer slider bl/ws 1.2V accelerator from stopped
2.8V half accelerator
4.1V full accelerator
90-46
Pin Name Cable colour Measurement value
5 Accelerator potentiometer pow- ws/rt 5V
er supply
6 P-Grad input switching from sw/gn 0V/12V
K11
7 P-Grad output switching from ws/gn digit
A1
8 P-Grad switching ground br -
9 12V power supply from X8 con- sw 12V
trol panel
10 Power supply A1 sw 12V
11 - - -
12 Connector diagnostics power sw 12V
supply
13 Connector diagnostics ground br -
14 Ground for A1 br -
15 Ground for A1 br -
16 Connector diagnostics ground br -
90-47
90.24 - Cutting table electronic control
90.24.1 - Operation
The EMR-D cutting table Level control / AutoControl provides automatic control of cutting table guidance on threshing section.
The EMR-D electronic control unit processes absolute value signals (position sensor, pressure sensor, sensing plate sensor), com-
pares them with the nominal preset values (control equipment) and transmits corresponding control signals to the control valves (for
a more detailed description refer to operating instructions).
90.24.2 - EMR-D Level control / AutoControl components
l EMR-D electronic control unit (in instrument panel)
l EMR-D control valve (in travel direction to left, alongside grain tank pipe)
l Electronic control unit for transverse angle, AutoControl (in instrument panel)
l Transverse tilt control valve (in travel direction to left, alongside grain tank pipe, integrated in valves control block)
l Control unit (in instrument panel)
l Control functions on CommanderStick
l Position sensor (on rotation point of feed passage, mounted to right in direction of travel)
l Pressure sensor with clutch valve and hydraulic accumulator (mounted on drive axle)
l Sensing plate sensors (up to 3 parts) (4 k potentiometer Ω on front attachment)
l Adjustable frame with hydraulic cylinder for transverse tilt (AutoControl)
DANGER
The transverse tilt function is also described with term “self-levelling”.
90-48
90.24.3 - Switching logic
Fig. 1791 - Switching logic

Key
1. First calibration performed.
2. Front attachment coupled and plug-in electrical connection executed.
3. Ignition switch in position (1)
4. Engine running.
5. Hydraulic functions main switch (threshing section main switch) is engaged.
6. Threshing section coupled
7. The required operating mode has been selected.
90-49
8. CommanderStick automatic pushbutton has been pressed.
Ready for operation / “Ready for diagnostics”
(adjustment criteria)
90.24.4 - Assignment of operating elements
Assignment of EMR-D level control (basic option) and AutoControl (option with transverse tilt) control panel:
Table 137
Position Level control /AutoControl version
(1) Cutting commands control panel
(2) Overstroke button (important: press only briefly with cylinder fully
down).
(3) Ground contact pressure selector
(4) Cutting height selector
(5) Diagnosis indicator - Red LED
(6) Status indicator (illuminates in Automatic mode) (green LED)
Fig. 1792 - Assignment of operating elements

90.24.5 - Assignment of Commander Stick
Table 138
Action Control
(10) Raise front attachment → Normal → High speed
(11) Lower front attachment → Normal → High speed
(12) Raise reel
(13) Lower reel
(14) Swing front attachment to right
90-50
Action Control
(15) Swing front attachment to left
(16) Automatic
(17) Retract reel
(18) Advance reel
Auxiliary equipment:
(19) Cutting angle adjustment: increase
(20) Cutting angle adjustment: decrease
Fig. 1793 - Assignment of Commander Stick

90.24.6 - Calibration
EMR-D Level control / AutoControl calibration
Cause:
adaptation of EMR-D to respective front attachment for optimal guidance of front attachment.
When?
l When using the machine for first time
l If tyres or front attachment must be changed
l In case of supplementary lift cylinder installation
l In the case of vehicle sinking into soft terrain
Precondition:
Front attachment and combine harvester must be standing on level ground; skids and sensing plate must rest on ground.
NOTE
In Balance execution drive axle must be in neutral position (central position).
90-51
First calibration step (1)
Establishment and saving of position of feed passage when front attachment is placed on ground and to record sensor values on
sensing plates.
Precondition:
Front attachment and combine harvester must be standing on level ground; skids and sensing plate must rest on ground.
Execution:
1. Turn ignition key to position “I”.
2. Start engine.
3. Activation of main switch for hydraulic functions (Threshing section main switch).
4. Switch mode selector switch to Transport position (calibration)
5. Move front attachment at least 100 mm (raise or lower) and then lower it completely.
l Front attachment must be resting on ground.
Simultaneously press “Lower front attachment” and “Automatic” buttons and hold them down for at least 7 seconds.
l Status LED flashes 5 times to confirm calibration.
The first calibration step (1) is complete.
Second calibration step (2)
To determine and save the weight of the front attachment.
Required:
If weight of front attachment changes after performing first calibration.
Execution:
Points 1. - 5.
l The front attachment must be suspended just off the ground (50 ... 100 mm).
l Simultaneously press “Lower front attachment” and “Automatic” buttons and hold them down for at least 7 seconds.
l The status LED flashes 8 times to confirm calibration.
The second calibration step (2) is complete.
Third calibration step (3)
Determination and saving of front attachment weight with attachment raised to maximum height.
Required:
After performing second calibration step.
Execution:
Points 1. - 5.
l The front attachment must be raised to just above maximum height (without reaching the lift cylinder stroke limit).
Press the “Automatic” button and hold it down for at least 7 seconds.
l The status LED flashes 12 times to confirm calibration.
Third calibration step (3) is complete.
If a calibration procedure must be repeated, switch engine off and restart calibration procedure.
DANGER
Self levelling remains active for adjustment of the distance and ground contact pressure also when the automatic func-
tion is not active. (Modification of ≥ Δ2 V signal required for disengagement)
90.24.7 - Fault diagnosis

The EMR-D control unit monitors the system constantly in order to identify possible faults.
Faults are grouped within three classes. The EMR-D electronic cutting control system table responds differently depending on the
fault class.
90-52
Fault response:
Serious faults:
l Control is interrupted and blocked.
l The relay is de-energized (to protect the output stage).
l Note for the Operator: the red diagnostics indicator (5) shows the fault code. The code indication terminates once the control
procedure is resumed.
l Control resumed: remedy fault and switch on ignition.
l The front attachment can be raised or lowered only by means of manual operation of the relative control valves.
Moderate faults:
l It may be possible to continue operation in a mode that is unaffected by the fault.
l The EMR-D remains functional in “TRANSPORT” position.
l Note for the Operator: the red diagnostics indicator (5) shows the fault code.
l Control resumed:
→ remedy fault and reset EMR-D by pressing “Raise front attachment” or “Lower front attachment” button. After pressing the control
button, diagnostic red LED (5) switches off if the fault has been remedied. If display of the code has already started it will be allowed
to continue until complete.
Minor faults:
l Note for the Operator: the red diagnostics indicator (5) shows the fault code.
After pressing the control button the diagnostic indicator switches off if the fault has been remedied.
If display of the code has already started it will be allowed to continue until complete.
90.24.8 - Fault diagnosis (List of fault codes for EMR-D)
Faults can be pinpointed and identified with aid of list of fault codes. The following pages contain the fault codes and the correspon-
ding fault descriptions. Fault codes are subdivided in serious faults, moderate faults and minor faults. The error message is subdi-
vided into two flashing sequences. The first sequence of flashes indicates the fault type and occupies the position of the tens in the
fault code.
First string of flashes:
one flash (•) → 10 → serious fault
two flashes (••) → 20 → moderate fault
three flashes (•••) → 30 → minor fault
The second sequence of flashes is emitted after a short pause. This sequence defines the type and severity of the fault. This sequen-
ce represents the units digit in the fault code.
To obtain the associated fault code count the number of flashes of the first sequence, which occupies the position of tens, and then
the number of flashes of the second “units” sequence.
On the basis of the resulting fault code go to the corresponding description in the fault codes list.
The diagnostic indication repeats the fault code message until the fault in question has been remedied.
Example: Fault 22
In the event of a break in the signal line to the “cutting height” setpoint potentiometer, for example, fault 22 is emitted.
two flashes - short pause - two flashes - long pause - → REPEAT
• • - - • • - - - - - - • • - - • • - - - - - - • • - - • • - - - - - - → Fault 22
Example: Fault 35
(Working voltage too low):
three flashes - short pause - five flashes - long pause - → REPEAT
• • • - - • • • • • - - - - - - • • • - - • • • • • - - - - - - → Fault 35
Several faults
If more than one fault occurs, each additional fault code will be displayed after a long pause. After all the fault codes have been
indicated, the diagnostic signals will repeat all the fault codes from the beginning and proceed in this manner until all the faults have
been remedied.
Examples: Fault 22 and fault 35
90-53
two flashes - short pause - two flashes - long pause - three flashes - short pause - five flashes - long pause - → REPEAT
• • - - • • - - - - - - • • • - - • • • • • - - - - - - • • - - • • - - - - - - • • • - - • • • • • - - - - - - → Fault 22 and fault 35
After switching the ignition off and on again, the fault code indication always starts from the beginning of the fault message and is
subsequently repeated.
Serious faults
Table 139
Fault codes Short description Pin No Fault description
11 LIFTING output stage 37 The output stage for the “Front attachment
lifting” solenoid valve is malfunctioning or
the line from the Lift / Lower solenoid valve
to connection 35 of the EMR-D control unit
is interrupted.
12 LOWERING output stage 19 The output stage for the “Front attachment
lowering” solenoid valve is malfunctioning
or the line from the Lift / Lower solenoid
valve to connection 35 of the EMR-D con-
trol unit is interrupted.
13 Short-circuit 35 The current measured at pin 35 is too high.
→ Short-circuit between connectors 19
and 35 or connectors 37 and 35 (probable
short-circuit on solenoid coil).
14 Cable breakage 35 Despite control of the electromagnetic
coils, no current can be measured on con-
nection 35.
→ Probable breakage of solenoid valve
power cable(s) (connections 19, 37 or 35).
→ Probable solenoid valve coil fault.
→ No battery power present on connection
29 (blown fuse).
→ Faulty control box
15 Lifting/Lowering/High Speed Commander- 9 Pushbutton signal not OK. Anomaly in one
Stick cable breakage of the control button functions LIFTING,
LOWERING or HIGH SPEED.
16 Power supply 2 Power supply not OK.
20 9.5 V supply or ground connection not OK.
17 Battery 29 Battery voltage over 18 V
18 Operating mode selector 21 Selector lever signal not OK. Wire break or
signal not connected
Moderate faults
Table 140
21 Position sensor 6 Position signal not OK
→ Wire break or sensor not connected
→ Probable short-circuit or ground fault.
→ Position sensor calibration not OK.
22 Cutting height setpoint values potentiom- 22 Signal from setpoint potentiometer not OK.
eter → Wire break or potentiometer not con-
nected
23 Pressure sensor 8 Signal from pressure sensor not OK (only
responds when pressure control is set on
selection switch).
24 Ground pressure setpoint values potenti- 5 Signal from setpoint potentiometer not OK
ometer (only responds when pressure control is
set on selection switch).
90-54
25 “HIGH SPEED” pushbutton 14 “HIGH SPEED” pushbutton is active al-
though “LIFT” or “LOWER” pushbutton is
not active.
Minor faults
Table 141
31 Sensing plate sensor, right 26 Signal from right-hand sensor not OK.
(This fault can only be diagnosed if sens-
ing plate control is active, i.e. if the belt
clutch for the threshing section or ground
contact pressure control are engaged and
“Distance control” mode has been set).
32 Sensing plate sensor, left 7 Signal from left-hand sensor not OK.
33 Commander Stick Swivel (right/left) and 27 Pushbutton signal not OK or one of the
Automatic “TILT RIGHT”, “TILT LEFT” or “AUTOMAT-
IC” functions is defective.
35 Battery 29 Battery voltage too low (less than 12 V)
36 Valve faulty or no oil pressure - Even if the LIFT current is active on con-
nection 37 of the EMR-D control box, the
front attachment will not be lifted if the en-
gine is not running. No supply of hydraulic
fluid or valve jammed.
90-55
90.25 - Assignment of connectors EMR-D
Illustration of connector viewed from cable side:
Table 142
Pin Name Colour Signal
1 Feed passage angle transducer sw-vi 0V
ground
2 EMR control unit power supply rt 9.5V
3 Multifunction lever - rapid raise/ br-gn 0V/2.7V
lower
4 EMR automatic system release bl-gn 11V/0V
5 Contact pressure nominal value br 0V...9.5V
6 Feed passage angle transducer sw-bl 2.4V...7.1V
signal
7 cutting mechanism to left skid gn 2.4V...7.1V
signal
8 Pressure transducer signal ws-ge 2.4V...7.1V
9 Multifunction lever adjustment sw 5V
raise/lower
10 Not used - -
11 Balance longitudinal tilt gr-sw Frequency 392.5 Hz...2000 Hz
12 Status indicator (green LED) rt-bl 0V/5V
13 Multifunction lever automation rs 0V/6.3V
14 Code of cutting mechanism > br 5V/0V for cutting mechanism
7.2 m >7.2 m jumper to pin 43
15 Input of transverse tilt to left , rt-sw PWM 10V/0V, 125Hz
Pin 5
16 Not used - -
17 Multifunction lever - raise rt 0V/3.5V
18 Solenoid valve, deposit gr-ws 0V/12V, 2A
19 Solenoid valve, lower br-sw PWM 0V/12V, 1...3.2 A,
1kHz/80Hz
20 Control unit, ground bl 0V
21 Control unit, operation type ws 6.4V/ 5.7V/ 3.3V/ 4.9V
22 Cutting height nominal value or 0V...9.5V
23 Cutting mechanism mid point or 2.4V...7.1V
skid signal
24 Terminal 15, ignition on sw 12V
25 Not used - -
26 Cutting mechanism to right skid ge 2.4V...7.1V
signal
27 Multifunction lever multifunction rt-bl 11V
lever - transverse tilt
28 Terminal 31 ground br 0V
29 Terminal 30 power rt 12V
30 Overstroke pushbutton gr 11V/0V
31 Diagnostic indicator (red LED) sw-ws 0V/5V
32 Multifunction lever - turn left ws-gr 0V/6.3V
33 Multifunction lever - turn right ge-br 0V/6.3V
34 Transverse tilt to right, Pin 4 in- sw-ge PWM 10V/0V, 125Hz
put
35 El. Value Ground raise / lower br 0V
36 Multifunction lever - lower bl 0V/3.5V
37 Solenoid valve, raise ws PWM 0V/12V, 1...3,2 A,
1kHz/80Hz
38 Pressure transducer ground ws-bl 0V
39 Feeler skids angle transducer. gr 9.5V
40 Not used - -
41 cutting mechanism guides, br 0V
ground
42 Not used - -
90-56
43 Code of cutting mechanism > br 0V
7.2 m
44-45 Not used - -
46 Transverse tilt / El. value de- br 0V
posit, ground
47-50 Not used - -
51 Power supply transverse tilt, Pin sw 12V
2
52-55 Not used - -
Fig. 1794 - Cutting commands control unit

1. EMR-D- control unit (Bosch), A3
2. EMR-D control unit transverse tilt, A12
3. Figure showing connector EMR-D- Control device from cable side
4. Figure showing transverse angle connector - Control device from cable side
5. Assignments of EMR-D connectors control device A4
6. Cable jumper for MW code > 7.2m
7. Ferrit ring for Electromagnetic shielding from A3 and A12 control units
90-57
Fig. 1795 - Cutting commands control panel

90.25.1 - Assignment of connectors for EMR-D (Bosch) control unit transverse tilt, A12
Table 143
1 Right turn el. value sw-gn PWM, 12/0V, 1,2...2,2A, 125Hz
2 Traverse tilt power supply sw 12V
3 Left turn el. value rt-gn PWM, 12/0V, 1,2...2,2A, 125Hz
4 Transverse tilt to right, input sw-ge PWM, 10V/0V, 125Hz
5 Transverse tilt to left, input rt-sw PWM, 10V/0V, 125Hz
6 Transverse tilt, ground br 0V
90-58
90.25.2 - Cutting table electronic control, EMR-D Level control / AutoControl
Measurement procedure (Use for measurement of adapter 16017182)
Fig. 1796 - Cutting table electronic control
90-59
Measurement procedure (continued)
Fig. 1797 - Cutting table electronic control
90-60
Feed passage position sensor
Basic setting:
l Position sensor shaft rotating notch (3) must run along a parallel line with
respect to locking lever (2). The adjustment notch on position sensor shaft
(3) must be facing pin connection (4) - course adjustment.
l Basic dimension of coupling rod = 173 mm (see drawing) - Fine adjustment.
Checking basic setting:

Precondition: level surface, front attachment installed.
With front attachment lowered, signal voltage (pin 2) must be 0.25 * times power
supply voltage VS (pin 3). With front attachment fully raised, signal voltage (pin 2)
must be 0.75 * times power supply voltage VS (pin 3).
Fig. 1798
To check setting, use adapters 16031484 or 16017182.

Signal voltage at maximum height (overstroke pushbutton, cylinder stroke limit
position): 7.1 V disengagement threshold with activation of multifunction lever
“Raise”: 6.8 V (signal voltage).
Checking overstroke:
With front attachment completely raised there must still be a minimal residual
stroke of 30 mm to the cylinder stroke limit, i.e. when the raising overstroke button
is pressed the lift cylinders must extend by a further 30 mm approximately until
reaching their stroke limit.
l Each time position sensor is adjusted, repeat calibration procedure.
1. Position sensor (rotation angle transducer)
2. Locking lever
3. Position sensor shaft
4. Plug connection
Fig. 1799
Sensing plate sensors - Fitting

The potentiometers must be installed on the skids in compliance with figure 31053.
For this purpose potentiometers (1) are fitted with approximately 15° rotation in the
skids in such a way that the driver tab can be inserted in the pin slot. The electrical
connection must face upwards. After fitting, the potentiometers must be rotated so
that fixing screws (11) are approximately at mid point of slots.
Potentiometers impedance: 4 kΩ
During calibration procedures automatic compensation of sensing plate sensors
is performed, i.e. when a sensing plate sensor is replaced calibration procedure
must be repeated!
Fig. 1800
90-61
90.25.3 - Cutting table electronic control, EMR-D Level control / AutoControl
Fig. 1801 - Cutting table 13 pin socket

Key
l 1 - AutoControl execution
l 2 - Level control execution
l 8 - 13 pin socket on cutting table
l 10 - Sensing plate to left sensor
l 11 - Sensing plate mid position sensor
l 12 - Sensing plate to right sensor
90-62
Checking the sensing plate sensor (potentiometer)
Potentiometer impedance: 4 kΩ
Supply voltage: (pin 9): 9.5 V
Connection to ground (pin 7): 0 V
Table 144
Feeler skids: raised lowered
Signal voltage: 2.4 V (min.) 6.8 V (max.)
(pin 5: Sensing plate to left sensor)
(pin 8: Sensing plate mid position sensor)
(pin 11: Sensing plate to right sensor)
Working range of sensing plate sensors must be at least 2 V (≥ Δ 2 V).
Make sure signal voltage is always within the “signal window” (2.4 ... 6.8 V).
Working range of sensing plate sensors of ≥ Δ 2 V is finally established by sensing plate stroke (chain length to right / left = 400 mm,
mid position = 350 mm).
DANGER
After replacing or readjusting a potentiometer repeat the calibration procedure.
Assignment of 13 pin connectors, cutting table plug connection
Fig. 1802 - Dowel

Key
l A - Cutting table potentiometer, mid position
l B - Cutting table potentiometer, left
l C - Reel speed sensor
l D - Reel variator
l E - Cutting table
l F - Cutting table potentiometer, right
90-63
Fig. 1803 - Auto Control Execution Socket (3 feeler skids)

Key
l A - Potentiometer in mid position
l B - Potentiometer on left
l C - Reel speed sensor
l D - Reel variator
l E - Cutting table for rape harvesting
l F - RH potentiometer
Fig. 1804 - Level Adjustment Execution Socket (1 feeler skid)

Key
l A - Potentiometer in mid position
l B - Reel speed sensor
l C - Reel variator
l D - Cutting table for rape harvesting
90-64
90.26 - Balance system
90.26.1 - Balance description
Short description
The purpose of the Balance control is to keep the combine harvester in a hori-
zontal position within certain limits when driving on a slope. The adjustment is
performed longitudinally and transversally with respect to the travel direction.
Longitudinal levelling can be deactivated in special situations.
If hydraulic cutting angle adjustment is installed, the control system can adjust the
cutting table cutting angle within a certain range so that the cutting table remains
parallel to the ground.
The Balance control unit is ready to operate only when LEDs (9) are illuminated:
l engine is running,
l charge control light is extinguished,
l main working switch is on, and Fig. 1805
l parking brake (handbrake) is released
Table 145
Pos. Control element/indica- Function
tor
1 LIFT button Machine lifted horizontally / automatic mode deactivated
Key (2) simultaneously pressed: Activation of dual-line control
Key (7) simultaneously pressed: Delay cutting angle controller 0 s
2 LOWER button Machine lowered horizontally / automatic mode deactivated
Key (1) simultaneously pressed: Activation of dual-line control
3 TILT RIGHT button Machine tilted to right / automatic mode deactivated
Key (4) simultaneously pressed: Activation of single-line control-
ler*
4 TILT LEFT button Machine tilted to left / automatic mode deactivated
Key (3) simultaneously pressed: Activation of single-line control-
ler*
5 AUTO key Switch on automatic mode..
Keep key (7) simultaneously pressed while switching on: Calibra-
tion mode on
Key (1) simultaneously pressed: Slow position controller acti-
vated
Key (2) simultaneously pressed: Fast position controller activated
6 AUTO LED Automatic mode display On/Off:
LED steadily illuminated: Fast position controller activated
LED flashing: Slow position controller activated.
7 NEUTRAL key moves the axis cylinders to the half extended position (keep this
button pressed until central LED (8) illuminates) / automatic func-
tion deactivated
Keep key (5) simultaneously pressed while switching on: Calibra-
tion mode on
8 LEDs (10 pcs) Indication of axle cylinder position.
9 AUTO LEDs - Key (4 pcs) Flashes if calibration mode is selected.
*When single-line control is active, all LEDs illuminate momen-
tarily while pressing key (5) AUTO.
90-65
90.26.2 - Operation
Road driving
DANGER
Before driving on the road the machine must be completely lowered.
To activate Balance control (start engine, activate working master switch, release parking brake) and lower the machine completely,
press “LOWER” key (2) (both lower LEDs (8) illuminate)
Manual operating mode:
The machine can be moved into any required position with the four yellow keys (“LIFT” (1), “LOWER” (2), “TILT RIGHT” (3) and “TILT
LEFT” (4)) on the control unit. The machine then remains in the selected position.
Neutral position:
NEUTRAL” button (7) is used to set the combine to a horizontal position. The machine assumes a position parallel to the ground.
The button must be pressed until the machine has reached its neutral central position (central LEDs (8) illuminate).
In this case however the machine does not adjust to follow the ground contours.
DANGER
If the gear is engaged or the service brake is activated, the combine harvester moves forward or in reverse if it is lifted
or lowered with the Balance control.
Automatic operating mode:

Activate:
l Press “AUTO” key (5).
“AUTO” LED (6) illuminates. The machine should assume horizontal posi-
tion by means of subsequent automatic correction.
Deactivate:
l Press
“LIFT” key (1) or
“LOWER” key (2) or
“TILT RIGHT” key (3) or
“TILT LEFT” key (4) or
“NEUTRAL” key (7). Fig. 1805
“AUTO” LED (6) extinguishes. The machine is in manual mode.
Single-line and dual-line control:

Activation of single-line control (lateral tilt control):
NOTE
Control of the longitudinal axis (longitudinal control) is deactivated.
l Press the “TILT RIGHT” (3) and “TILT LEFT” (4) keys simultaneously.
m Single-line control is activated.
l Activate automatic mode by pressing “AUTO” key (5).

m as a function indicator all the LEDs illuminate momentarily when
automatic mode is activated. Fig. 1806
90-66
Activate dual-line control (Longitudinal and lateral tilt control):
NOTE
Longitudinal axis control (longitudinal control) is reactivated.
l Press the “LIFT” (1) and “LOWER” (2) keys simultaneously.

m Dual-line control is activated.
l Activate automatic mode by pressing “AUTO” key (5).

m As a function indicator, when automatic mode is activated the LEDs
do not illuminate.
Fig. 1807
Select the position controller

NOTE
The fast position controller is activated as factory default and after
each calibration.
Activation of the slow position controller:

l Press the “AUTO” (5) and “LIFT” (1) keys simultaneously.
m Status indicator: In automatic mode the “AUTO” LED (6) flashes.
Activation of the fast position controller:

l Press the “AUTO” (5) and “LOWER” (2) keys simultaneously.
m Status indicator: In automatic mode the “AUTO” LED (6) illuminates
Fig. 1808
steadily.
90.26.3 - Calibration of the position controller

NOTE
The position controller must be calibrated before adjusting the
EMR-D.
l Start the engine (charge warning indicator must be off).

l Switch on the main work switch.
l Park the combine harvester so that it is level in all directions.
l Apply the parking brake.
l Press and hold the “AUTO” and “NEUTRAL” keys.
l Release the parking brake (handbrake).
m After 10 seconds the Balance system switches to calibration mode. Fig. 1809
m The four middle LEDs (9) flash.
One LED on the right and left illuminate steadily.

The machine begins to move.
m The Balance system is in calibration mode.
l Release the “AUTO” and “NEUTRAL” keys.

l Press “LIFT” continuously until the machine reaches its upper dead centre.
90-67
l Press “LOWER” continuously until the machine reaches its bottom dead centre.
l Press “LIFT”, “LOWER”, “TILT RIGHT” and “TILT LEFT” to adjust the machine until it is absolutely horizontal in all directions;
use a spirit level to check the adjustment if necessary.
Fig. 1810 - Calibration of the position controller
90-68
Briefly press “LIFT” and “LOWER” simultaneously. The data will be saved.
The calibration process is now finished:
l The central LEDs illuminate. A LED illuminates in the middle of the light
bands on the right and left.
l Lateral and longitudinal levelling is active.
l Automatic mode is inhibited.
l The fast position controller is activated, cutting angle controller delay 0 s
l Dual-line control is activated.
DANGER
If the machine was not absolutely horizontal during calibration, it
Fig. 1810
may move a few centimetres when switching over between AUTO-
MATIC and NEUTRAL. The adjustment should be repeated in the
case of a greater magnitude of adjustment. In case of higher differ-
ence values, repeat calibration.
Operation of automatic cutting angle control

Machine requirements:
l All electrical leads connected.
l All angle transducers correctly installed and adjusted.
NOTE
By factory default and after each calibration the cutting angle con-
troller delay interval is set to 0 s.
Automatic cutting angle control is active when the Balance control is active and
cutting angle control has been switched on by simultaneously pressing the “CUT-
TING ANGLE FORWARD” (11) and “CUTTING ANGLE BACK” (10) buttons. Fig. 1811
This function is indicated by indicator light (12).
Cutting angle control is deactivated when the machine is switched off or when Bal-
ance control is deactivated and must then be reactivated if required.
Fig. 1812
Manual operating mode:

Can be used immediately after starting the machine and switching on the main
working switch.
Otherwise the automatic cutting angle control function must be deactivated.
This is done by pressing the “CUTTING ANGLE FORWARD” (2) and “CUTTING
ANGLE BACK” (3) keys simultaneously. Indicator lamp (12) is extinguished.
The cutting angle can be set as required via the “CUTTING ANGLE FORWARD”
(2) and “CUTTING ANGLE BACK” (3) keys on the multi-purpose lever.
Fig. 1813
90-69
Automatic operating mode:
l Release the parking brake (handbrake).
l Engage the threshing section.
l Set the operating mode of the EMR-D electronic cutting table adjustment
system (pressure or position control).

l Press (1) to set automatic cutting table control to Automatic.
l Activation of the automatic cutting angle control. This is achieved by simul-
taneously pressing the “CUTTING ANGLE FORWARD” (2) and “CUTTING

ANGLE BACK” buttons (3). Indicator light (12) illuminates.
l Set the machine to a neutral position on level ground.
l Adjust the cutting table so that the ear lifter skids are parallel to the ground.
l Completely lower the machine and then completely raise it again. When
Fig. 1813
correctly adjusted and when fitted with the recommended tyres, the ear
lifter skids remain virtually parallel to the ground throughout the entire ad-
justment process.
l Completely lower the machine and then completely raise it again. If calibra-
tion has been performed correctly and the machine is fitted with the recom-
mended tyres, the ear lifter skids remain virtually parallel to the ground
throughout the entire adjustment process.
Correct the cutting table position or bearing pressure again if necessary.
Indicator (4) flashes when the cutting table is disengaged and automatic cutting
table control (EMR-D) is switched off. Cutting angle control remains active. The
cutting angle is adjusted again if the machine is adjusted via the Balance system
e.g. in the event of turns on slopes).
If the cutting angle is changed (e.g. when disengaging the cutting table), after ac-
tivation of automatic mode the new value is set as the new default. After this, the
adjustment procedure must be repeated.
DANGER
To deposit the cutting platform on the table trolley automatic cutting
angle adjustment must be first deactivated!
90.26.4 - Adjustment of the response time for automatic cutting angle control
Calibration of cutting angle control limit positions
l Press the “CUTTING ANGLE FORWARD” (10) and “CUTTING ANGLE
BACK” (11) buttons simultaneously and keep them pressed for at least 10
seconds until the control indicator light (12) starts flashing rapidly.
m The cutting angle adjustment system assumes both end stroke posi-
tions and stores the relative values.

During operation, the cylinders will be electrically deactivated just
before they reach the mechanical stroke end position.
Fig. 1813
90-70
Adjusting the cutting angle controller response delay interval
NOTE
It is recommended to work with a response delay of 2 seconds.
Table 146
Delay in seconds: Press the keys simultaneously

to select:
0 NEUTRAL and LIFT (7 and 1)
1 NEUTRAL and LOWER (7 and 2)
Fig. 1813
2 NEUTRAL and TILT LEFT (7 and 4)
3 NEUTRAL and TILT RIGHT (7 and 3)
The selected setting will stored until the next time it is modified.
90-71
90.26.5 - Balance with automatic cutting angle
Fig. 1814 - Balance system diagram

Key
1. Instrument panel
2. Multifunction lever grip
3. Balance control unit
4. Automatic cutting angle status indicator
5. MO pilot equipment for Balance hydraulics
6. Control unit for cutting angle control
7. Balance-Shaft cutting angle transducer
90-72
8. Control valves block, left
M1- connector without colour identification sw (black)
M3 - connector rt (red)
M2 - connector bl (blue)
9. Control valves block, right
M4 - connector without colour identification sw (black)
M6 - connector rt (red)
M5 - connector bl (blue)
10. Balance control unit
Observe the assembly position:
m Decal with direction of run arrow on inside of case in front of relay.
m Pay attention to the marks with CON1 and CON2 and their engagement position.
m Connectors CON1 and CON2 must not be exchanged.
11. Rotation angle transducer for cutting angle (installed on RH side of feed passage)
90.26.6 - Balance-Shaft cutting angle transducer

The rotation angle transducers are installed on right and left of axle support and
aligned in middle by means of final drive connecting rod. To install the transducer,
grub screw (4.1) on the shaft must be facing the plug connector.
Fig. 1815
Ball end (3.1) for the linkage rod must be screwed to the final drive in the indicated position. The final drive is in neutral.
90-73
Fig. 1816 - Balance-Shaft cutting angle transducer

Key
1. Balance shaft
2. Final drive support sleeve
2.1. Incorrect position
2.2. Lowered position
3. Coupling rod
3.1. Ball end for the linkage rod to the final drive
4. Rotation angle sensor
4.1. Grub screw on transducer shaft
5. Locking lever
90-74
90.26.7 - Check / Adjust
Table 147
Travel direction Left Right
Power supply 8.5 V ± 5% 8.5 V ± 5%
Vehicle raised to top stroke limit position 6.3 V 2.1 V
Signal voltage
Vehicle lowered to bottom stroke limit posi- 2.1 V 6.3 V
tion
Signal voltage
For the measurement use test gauge (1603 1484)
Basic adjustment
l Lower balancing system completely (oscillating cylinders must be completely retracted, if necessary change calibration mode).
l Adjust linkage rod (3) to a length of 261 mm.
l Loosen locking lever (5).
l Set the rotation angle sensor to the prescribed signal voltage.
Rotation angle transducer for cutting angle
To install the transducer, grub screw (6) on the shaft must be facing the plug con-
nector.
Micro-adjustment of the transducer by rotating the shaft in locking lever (5):
l Signal voltage of approx. 2.1 V with cutting angle adapter retracted
Fig. 1817
90-75
90.26.8 - Balance II power supply diagram and cutting angle control
Fig. 1818 - Balance power supply diagram

Key
l A19 - Balance II control unit
l K59 - Cutting angle relay, up
l K67 - Ground for D+
l K75, K76 - Balance II power supply relay
l K80 - Cutting angle relay, down
l S54 - Cutting angle increase/decrease button
l S55 - Handbrake switch
90-76
l Y11 - Cutting angle up solenoid valve
l Y12 - Cutting angle down solenoid valve
DANGER
Relays K59, K80 should not be installed in the Balance version.
90.26.9 - Balance II connectors assignment with automatic cutting angle system
Fig. 1819 - Balance connectors assignment

* lower = 2000 Hz, upper = 392.5 Hz
90-77

Key
1. Combine ground lead
2. Rotation angle sensor for cutting angle
3. Balance shaft rotation angle sensor, left
4. Balance shaft rotation angle sensor, right
5. Magnetic valves M4 - M6 on right
6. Magnetic valves M1 - M3 on left
7. Connectors X28 - X31 at bottom of control panel
8. Processor connector
9. 2kOhm resistor
90-78
90.26.10 - Balance II connectors assignment with automatic cutting angle system
90-79

Key
1. Combine ground lead
2. Rotation angle sensor for cutting angle
3. Balance shaft rotation angle sensor, left
4. Balance shaft rotation angle sensor, right
5. Magnetic valves M4 - M6 on right
6. Magnetic valves M1 - M3 on left
7. Connectors X28 - X31 to bottom of control panel
8. Programmer connector
9. 2kOhm resistor
90-80
90.26.11 - Faults / Troubleshooting
Table 148
Problem Cause / Remedy
No indication on control unit The engine not running.
Parking brake applied.
Main threshing mechanism switch not set to On.
Fuse F40 (15 A) blown.
Micro relay K67, K75 or K76 faulty.
Balance system displays irregular operation or moves constantly Rotation angle sensor incorrect setting or tie rod bent.
Dirt on valve seat causing lowering and continual compensatory
adjustments.
Uncontrolled movements Repeat calibration procedure.
Check rotation angle sensor setting.
Balance system lifts only on one side and lowers only on one side Check rotation angle sensor setting and coupling rod position.
The indication on the control unit shows a stroke limit condition Rotation angle sensors have been modified.
even though the oscillating cylinders are not completely extended Check adjustment.
or retracted
The Balance does not fully raise / lower anymore Incorrect calibration values have been stored in memory (calibra-
tion error). Repeat calibration procedure.
Several buttons and LEDs on the control device are not associ- Control device is faulty.
ated with a function Defective cable connection between adjustment device and con-
trol device. Check clutch connections
Following calibration, balancing is not horizontal in the longitudi- Check whether control device (Microcontroller) is installed paral-
nal and/or transverse direction lel to the drive axle in the longitudinal and transverse directions.
Compensate with suitable shims.
90-81
90.27 - Hourly production monitoring system / Job calculator
Fig. 1823 - Work calculator

Key
1. Indicator - Grain loss monitor
1.1. Wiring loom (5 wires) to operator cab
2. Work calculator LH-1000
3. Light sensor (mounted on cab roof)
4. Straw walker sensor (plate sensor)
4.1. Wiring (three wires) from plate sensor - LH straw walker
4.2. Wiring (three wires) from plate sensor - RH straw walker
90-82
5. Feed passage pulse transducer
6. Sieve box sensor (tubular sensor)
7. Magnet (2 parts) to feed passage
8. Junction box with circuit board
9. Wheel sensor
10. Instrument panel
90.27.1 - Functionality check - Hourly production control system

Switch on the ignition
Tap alternately on the LH and RH straw walker sensors. The “Grain loss” monitor needle moves.
Tap lightly and repeatedly on the sieve box sensor tube. The “Grain loss” monitor needle moves.
90.27.2 - Assignment of connections on the distribution circuit board, measurement val-
ues
Table 149
Terminal strip I
No. cable colour Function Measurement value
1 black 1 power- 0V
2 black 2 power+ 11V
3 black 4 Wheel sensor signal 11V, 1.5V
4 green/yellow Sieve box sensor signal 8.3V .... 6V
5 black 3 Straw walker sensor signal 8.3V .... 6V
6 Blue Wheel sensor 11V
7 brown Wheel sensor 0V
8 green/yellow Sieve box sensor + 11V
9 black 2 Sieve box sensor signal 8.3V .... 6V
10 black 1 Sieve box sensor- 0V
Table 150
Terminal strip II
No. cable colour Function Measurement value
1 - - -
2 black 1 Straw walker sensor 1 - 0V
3 black 2 Signal of straw walker sensor 1 8.3V .... 6V
4 green/yellow Straw walker sensor 1 + 11V
5 black 1 Straw walker sensor 2 - 0V
6 black 2 Signal of straw walker sensor 2 8.3V .... 6V
7 green/yellow Straw walker sensor 2 + 11V
8 - - -
9 - - -
10 - - -
90.27.3 - Indicator device connector pins assignment

Table 151
Pin-No. cable colour Function
1 white sensors power supply +
2 brown power +
3 green power -
4 yellow Wheel sensor signal
5 Grey Light sensor
6 Pink Light sensor
7 Blue Straw walker sensor signal
8 red Sieve box sensor signal
90-83
90.27.4 - Grain loss monitor adjustment knobs
Knobs (1, 2) serve to adjust the offset of the needle for the grain loss monitoring
device on sieve box (3) and straw walker (4). Depending on the width of the cut-
ting table, the knobs are adjusted in such a way that the indicator needle lies in the
transition area between the red and green areas of the panel. In this situation the
grain losses are always acceptable.
Fig. 1824
Grain sensor sensitivity can be set to three alternative levels in relation to the product:
low sensitivity for coarse crops such as beans or maize
medium sensitivity for cereals
high sensitivity for fine crops, such as rape, mustard and flax
Grain sensor sensitivity can be adjusted to three levels in relation to the product:
The sensor casing features a series of locating dots in relief (7) for positioning of
the switches.
Sieve box sensors: setting by rocker switch (5)
Fig. 1825
90-84
Straw walker sensors: setting by rotary switch (6)
Fig. 1826
90.27.5 - Work calculator LH 1000

Description of the function keys:
1. Working time in hours and minutes
2. “Partial area” hectare meter
3. “Total area” hectare meter
4. Speed (km/h)
5. Entering the working width in cm
6. Entering the wheel circumference in cm
7. Delete the counters (hectare and working time), enter 0
Fig. 1827
Rear wheel sensor (9) and pulse transducer (8) to the feed passage are required
for work counter operation. The pulse transducer must be adjusted so that the two
magnets (10) brush against the front of the transducer with the cutting table raised.
Fig. 1828
90-85
The distance between magnet and sensor must be set to 5 - 8 mm.
Fig. 1829
Cable connection assignments

Pos. 6: blue, 12V power supply
Pos. 5: brown, earth
Pos. 4: wheel sensor input
Pos. 2: feed passage pulse transducer sensor input
Fig. 1830
The work counter features three function sets:

Function set 1: time counter, hectare counter, speed counter (working width and wheel circumference must be entered)
l 1. Time function:
Starting the timer
Press this key to start the timer (the colon starts flashing).
The on-board computer will now start counting the elapsed time (hours and minutes). If you select another
function, the timer will continue running in the background. This key can be pressed at any time to stop
and restart the timer.
l Hectare meter
90-86
“Partial area” hectare meter
Press this key to display the area worked in hectares. The area is indicated with two decimal places in the
range from 0 - 99.99 ha and with 1 decimal place in the range from 100 - 999.9 ha.
“Total area” hectare meter

Press this key to display the area worked in hectares. The area is indicated with two decimal places in the
range from 0 - 99.99 ha, with 1 decimal place in the range from 100 - 999.9 ha and without decimals in the
range from 1000 - 9999 ha. This function is used to totalize the complete area worked.
1. Speed counter
Press this key to display the ground speed in km/h.
If the hectare meter is stopped while the speed indicator is displayed, the letter “r” is displayed in front of
the speed.
Function set 2: Metres odometer, reset

1. Metres odometer
Press the + key
Press the + key
Enter
1. Wheel revolutions
This function is mainly used to count the number of wheel revolutions when determining and entering the wheel diameter.
90-87
Basic adjustment
Press the + key
Function set 3: Sensors test

First enter a working width of 8888:
Press the following keys in the order shown:
Then select the timer function.

Press the + key.
The display will now read:

l “h” if the wheel sensor is activated
l “r” if the electromagnetic switch is activated.
DANGER
the letter “r” is also displayed when the hectare meter is stopped.
Error message
The message “FEJL” appears in the display when the supply voltage is less than 12V.
90-88
90.28 - Wiring looms and components index
90.28.1 - List of wiring looms
Table 152
Description Code Wiring
Feed passage reversing device wiring loom 16062550 90-163
Wiring loom for lateral headlights (for extra wide 16056753 90-161
tyres)
Wiring loom for lateral headlights 16056731/10 90-162
Grain tank worklight wiring loom 16062565/10 90-168
Air conditioning system filter-dryer wiring loom 16050276 90-154
Sieve lighting wiring loom 16050274 90-160
Returns elevator switch wiring loom 16050268 90-149
Rear lateral light wiring loom 16013845 90-159
Rear number plate light wiring loom 16056728/10 90-143
Rotation angle sensor wiring loom for cutting angle 16062568/10 90-171
Coolant temperature sensor wiring loom 16062294 90-144
BALANCE wiring loom 16052333 90-151
Straw chopper wiring loom 16050256 90-174
Front wiring loom 0.015.5469.4/20 90-127
BALANCE wiring loom 0.015.5467.4/10 90-145
Fuse box wiring loom 0.015.5312.4/20 90-136
Air conditioner wiring loom 540465 90-153
Cab console wiring loom TS8799/1-TS8799/3 90-131
Steering column switch wiring loom 980062201 90-173
Cab roof worklights wiring loom 980060 90-152
Solenoid valves assembly wiring loom 0.015.5468.4/10 90-169
Electrical system / Roof lining wiring loom 980157 90-150
Engine interface wiring loom 0.015.5475.4/10 90-133
Multifunction lever wiring loom TS8799/2 90-172
Engine wiring 0.015.5471.4/20 90-134
Electric motors wiring loom 0.015.5472.4/10 90-147
Rear wiring loom 0.015.5470.4/20 90-155
Attachment electrical socket wiring loom 0.015.5466.4/10 90-142
Charge circuit wiring loom 0.015.5464.4/10 90-141
Feed passage sensors wiring loom 0.015.5465.4/10 90-164
Grain tank wiring loom 0.015.5473.4/10 90-139
Chassis wiring loom 0.015.5474.4/10 90-166
Battery negative lead 16002046 90-130
Battery positive lead 16002049 90-129
90.28.2 - Index by part description

Table 153
Component description Component code Connector System
Cigar lighter 2.7099.770.0 C12 -
Alternator - B03(B+; D+; W) -
RH loudspeaker 0.012.1725.0 - -
LH loudspeaker 0.012.1726.0 - -
Threshing mechanism control - M02 90-115
Chaff spreader actuators - P05 (A,B,C,D,E) -
Horn - A03 (A,B) -
Battery 16017111 B00 (+30; GND) 90-106
90-109
90-110
90-113
90-115
90-117
90-119
90-121
90-122
90-89
Fuse box - F00 (30) 90-106
90-109
90-110
90-113
90-115
90-117
90-119
90-121
90-122
F00 (GND) 90-106
90-110
90-113
90-115
90-117
90-119
90-122
Reverse travel selected buzzer 0.0112938.0 E01 -
Buzzer 16037038 - -
Grain loss monitor control unit 16055798 - -
Safety control unit 2.8519.066 F03 -
BALANCE electronic control unit 16062496 L11 (A, B) 90-110
CCP2 electronic control unit 16027466 - -
EMR-D electronic control unit 2.8519.065.0 F04 90-110
90-113
90-119
90-121
HLHP electronic control unit 2.8519.074.0 F01 -
CAN module electronic control unit 16050210 F02 (A,B,C) -
Straw chopper electronic control unit 16057402 - -
Centralised lubrication control - M07 90-115
Starter switch 0.015.0485.4 C21 90-106
90-109
90-110
90-115
90-117
90-119
Compressor - P20 90-125
AGRO LH 1000 work computer 6546411 C06 -
O21 -
BALANCE work computer 16025444 O06 90-110
Commander Control work computer 16050200 C01 90-115
Diagnostics connector - F06 -
CAN diagnostics connector - F05 -
BALANCE electronic control unit programming connec- - L12 90-110
tor
Commander Control programming connector - C07 -
Fuse box connector for grain tank electric motor - 90 90-115
Fuse box connector for threshing drum electric motor - 91 90-115
Fuse box connector for straw chopper electric motor - 92 90-115
Fuse box connector for cutter bar electric motor - 93 90-115
Reel lowered solenoid valve - V12 90-113
Reel raised solenoid valve - V08 90-113
Reel forward solenoid valve - V11 90-113
Reel retracted solenoid valve - V09 90-113
Cutter bar to right solenoid valve - V01 90-113
Cutter bar to left solenoid valve - V02 90-113
Cutter bar lowered solenoid valve - V05 90-113
Cutter bar raised solenoid valve - V10 90-113
Feed passage solenoid valve - S03 90-121
Feed passage lowered solenoid valve - V03 90-113
Feed passage raised solenoid valve - V04 90-113
Grain tank extension solenoid valve - V14 90-113
Grain tank discharge pipe extension solenoid valve - V13 90-113
90-90
Grain tank retraction solenoid valve - V06 90-113
Grain tank discharge pipe retraction solenoid valve - V07 90-113
Rear worklight 01145071 - -
Central lights - P17 (A, B, C, D, 90-122
E, F)
RH side light - P24 -
LH side light - P25 -
RH rear light 16005189 P03 (A, B, C, D, 90-122
E)
LH rear light 16005190 P08 (A, B, C, D, 90-122
E)
Warning plates rear light 16049688 J01 (A, B) -
Supplementary front headlight 16037015 O03 (A, B) 90-122
Worklight 16037017 O01 (A, B, C, D, 90-106
E, F)
Worklight (Xenon) 16062476 O01 (B, E) -
Grain tank worklight 06537048 R05 (A, B) -
Straw hopper internal lighting 16046038 - -
Front RH sidelight and direction indicator - A09 90-122
Front LH sidelight and direction indicator - A16 90-122
RH rear worklight 16046038 P14 (A, B) 90-106
LH rear worklight 16046038 P01 (A, B) 90-106
Grain tank discharge pipe light 16046038 U01 90-106
Front rotary beacon 16050281 O05 90-106
Rear rotary beacon 16050281 P02 (A, B) 90-106
BALANCE / rotation angle sensor for cutting angle wir- - G3 90-110
ing junction
Fuse box / front wiring junction - GA 90-115
90-122
Fuse box / BALANCE wiring junction - GL 90-110
Fuse box / cab console wiring junction - GC1 90-113
90-115
90-119
90-122
90-109
90-110
90-115
90-117
90-119
90-119
90-121
90-115
90-117
90-119
Fuse box / cab console wiring junction - GC7 -
Fuse box / steering column switch wiring junction - GW 90-122
Fuse box / solenoid valves assembly wiring junction - GV 90-113
Fuse box / roof lining electrics wiring junction - GO1 90-106
90-109
90-122
Fuse box / roof lining electrics wiring junction - GO2 90-106
90-122
Fuse box / roof lining electrics wiring junction - GO3 -
Fuse box / roof lining electrics wiring junction - G04 90-110
Fuse box / multifunction lever wiring junction - GY1 90-110
90-113
Fuse box / multifunction lever wiring junction - GY2 90-110
90-91
Fuse box / engine wiring junction - GE1 90-106
90-122
Fuse box / engine wiring junction - GE2 90-106
90-122
Fuse box / electric motors wiring junction - GM1 90-115
Fuse box / electric motors wiring junction - GM2 90-115
Fuse box / Attachment socket wiring loom wiring junc- - GI 90-119
tion
Fuse box / feed passage sensors wiring junction - GS 90-121
Fuse box / grain tank wiring junction - GR 90-106
90-117
Fuse box / chassis wiring junction - GT -
Engine interface / fuse box wiring junction - G6 -
Engine interface / prewired engine junction - G4 -
Engine interface / prewired engine junction - G5 -
Engine / rear wiring junction - G1 90-122
Engine / rear wiring junction - G2 90-106
90-122
Grain tank / grain tank worklight wiring junction - G7 90-106
Returns elevator emergency switch / rear wiring junc- 16050180 G8 (A, B) -
tion
Roof lining electrics / cab console wiring junction - X134 90-125
Hour meter display 01141925 - -
Fuel filter clogged indicator - P18 -
Centralised main display 06527010 C02 -
Temperature gauge 16028967 - -
Temperature gauge 06261946 - -
Coolant temperature gauge 01231716 - -
Hydraulic oil temperature display 01175706 C09 -
Grain tank opening pedal switch - C04 -
Cutting table stop pedal switch - C03 -
Grain tank extension raised / lowered switch 01175755 C13 -
Returns elevator emergency switch 01175754 N01 -
Cutting table start / stop switch - C20 -
Worklights switch 2.7659.291.0 O09 90-106
Upper / lower worklights switch 2.7659.290.0 O10 90-122
Grain tank worklight switch 2.7659.296.0 - -
Straw hood worklight switch 01145154 - -
RH chaff spreader flap switch - P16 (A, B) -
LH chaff spreader flap switch - P13 (A, B) -
Front/Rear rotary beacon switch 2.7659.290.0 O07 90-106
Cutting table reversing drive switch 2.7659.296.0 C19 -
Sidelights / low beam switch 2.7659.291.0 O11 90-122
Emergency hazard lights switch 2.7659.293.0 C11 -
Brake lights switch - A02 (A, B) 90-122
Feeding reversal motor switch 16048750 T09 -
Q02 -
Brake pedal switch 04191001 C05 -
Air conditioning system pressure switch - P21 90-125
Work master switch 2.7659.296.0 C10 -
Cooling system main switch 2.7659.292.0 O14 90-125
EMR Engine speed switch 2.7659.294.0 C18 -
Straw guide plate adjustment switch 2.7659.297.0 C16 -
Straw guide plate left / right adjustment switch 2.7659.295.0 C17 -
Rear-view mirrors adjustment switch 2.7659.305.0 C14 -
O23 -
Battery master switch 01141854 B02 -
Window wiper switch 2.7659.290.0 O08 90-109
Grain tank cover open / closed switch 2.7659.295.0 - -
Steering column switch lever - W01 90-122
RH high beam headlight 2.8039.005.0 A06 90-122
LH high beam headlight 2.8039.005.0 A13 90-122
90-92
RH low beam headlight 2.8039.004.0 A08 90-122
LH low beam headlight 2.8039.004.0 A15 90-122
Sieve RH light - P10 -
RH direction indicator 2.8059.014.0 A07 90-122
LH direction indicator 2.8059.014.0 A14 90-122
RH lateral running light - P22 90-122
RH lateral running light (for extra wide tyres) 01145200 P24 -
RH lateral running light 06538036 P26 -
LH lateral running light - P23 90-122
LH lateral running light (for extra wide tyres) 01145200 P25 -
LH lateral running light 06538036 P27 -
RH sidelight 2.8039.011.0 A04 90-122
LH sidelight 2.8039.011.0 A11 90-122
Sieve box light - P15 -
Sieve LH light - P09 -
Multifunction lever 16027010 Y01 90-110
90-113
Terminal block 15 - F09 90-106
90-109
90-110
90-115
90-117
90-119
Terminal block 30 - F08 90-106
90-109
90-110
90-113
90-115
90-117
90-119
90-121
90-122
GND Terminal block - F10 90-106
90-110
90-115
90-117
90-119
90-122
Grain tank opening / closing electric motor - M06 90-115
Cutter bar electric motor - M01 90-115
Threshing drum electric motor - E07 -
Straw chopper electric motor 16034344 M05 90-115
Turbo separator electric motor - M03 (A, B) 90-115
Starter motor - B01 (30) 90-109
Feeding reversal motor 16028248 Q01 -
Variator adjustment servomotor 16045076 O17 90-125
RH electric motor for concave adjustment 16062307 A01 (A, B) 90-115
LH electric motor for concave adjustment 16027276 A10 (A, B) 90-115
Chaff spreader motor 16056355 P04 -
Windscreen wiper motor - O22 90-109
Fan motor - T05 -
Digital clock 04412337 O20 -
EMR-D control panel 16017104 Y02 90-110
Interior light - O04 -
Windscreen washer pump - E03 -
Lower turbo fan potentiometer - F07 -
7 pin outlet socket 01174711 Z01 -
12V outlet socket 16055916 C15 -
13 pin Attachment socket 01231937 I01 90-119
Warm air control 16057677 O19 90-125
Cool air control 16057677 O18 90-125
Ventilation control 16057280 O13 90-125
NTC resistor for thermostat - O24 90-125
90-93
Feed passage height sensor - T02 -
Feed passage angle sensor - S01 90-121
Rotation angle sensor 16062478 P07 -
Rotation angle sensor for cutting angle - L01 90-110
Rotation angle sensor for cutting angle 16062478 X01 90-110
Cutting angle sensor - T01 -
Turbo fan speed sensor - T06 -
Sieve box sensor 06302736 - -
Grain tank sensor 3/4 16050164 R01 90-117
Grain tank sensor 4/4 16050180 R02 90-117
Grain loss control sensor (L= 1468 mm) 16055794 - -
Light sensor 16055790 O12 -
Position sensor (L= 5000 mm) 16000333 - -
RH cutting sensor - L02 90-110
LH cutting sensor - L03 90-110
Air cleaner sensor 16052332 E04 -
Straw chopper speed sensor (L= mm 5000) 16000333 - -
Straw walker shaft speed sensor 16050180 - -
Cutter bar speed sensor - P06 -
Auger speed sensor 16050180 P19 -
Elevator speed sensor 16050180 P12 -
Turbo fan speed sensor - T04 -
Fan speed sensor 16050180 - -
Work hydraulics pressure switch 16056711 - -
Feed passage pressure sensor - S02 90-121
Cooling system main sensor - E11 (A, B) -
Fuel tank sensor 16028967 E10 -
Engine coolant temperature sensor 16061798 K01 (A, B) -
Reversing motor temperature sensor - Q03 -
Engine oil temperature sensor 06253949 E08 -
Grain tank cover open / closed sensor 16055791 R04 90-117
Conveyor sensor - E09 -
Grain loss conveyor sensor - E05 -
Discharge pipe extended / retracted sensor - E02 -
Threshing drum speed sensor 16050180 T07 -
Gearbox speed sensor 06262123 T08 (A, B) -
Auger filling speed sensor - E06 -
Feed passage speed sensor - T03 -
Turbo separator speed sensor - M04 90-115
Straw chopper servomotor - Z02 -
RH rear-view mirror - A05 -
LH rear-view mirror - A12 -
Air conditioner fault indicator light - O25 90-125
Thermostat - O02 90-125
Reel lowering valve - L07 90-110
Cutting table lowering valve - L10 90-110
Main valve - L04 90-110
Reel raising valve - L09 90-110
Cutting table raising valve - L08 90-110
Grain tank discharge pipe extended valve - L05 90-110
Grain tank discharge pipe retracted valve - L06 90-110
Dryer Fan - O16 90-125
Evaporator Fan - O15 90-125
90-94
90.28.3 - Index by part code
Table 154
Component code Component description Connector System
0.011.2938.0 Reverse travel selected buzzer E01 -
0.012.1725.0 RH loudspeaker - -
0.012.1726.0 LH loudspeaker - -
0.015.0485.4 Starter switch C21 90-106
90-109
90-110
90-115
90-117
90-119
06537048 Grain tank worklight R05 (A, B) -
06546411 AGRO LH 1000 work computer C06 -
O21 -
16000333 Position sensor (L= 5000 mm) - -
16000333 Straw chopper speed sensor (L= mm 5000) - -
16017104 EMR-D control panel Y02 90-110
16017111 Battery B00 (+30; GND) 90-106
90-109
90-110
90-113
90-115
90-117
90-119
90-121
90-122
16025444 BALANCE work computer O06 90-110
16027010 Multifunction lever Y01 90-110
90-113
16027276 LH electric motor for concave adjustment A10 (A, B) 90-115
16027466 CCP2 electronic control unit - -
16028248 Feeding reversal motor Q01 -
16028967 Temperature gauge - -
16028967 Fuel tank sensor E10 -
16034344 Straw chopper electric motor M05 90-115
16037015 Supplementary front headlight O03 (A, B) 90-122
16037017 Worklight O01 (A, B, C, D, 90-106
E, F)
16037038 Buzzer - -
16045076 Variator adjustment servomotor O17 90-125
16046038 Straw hopper internal lighting - -
16046038 RH rear worklight P14 (A, B) 90-106
16046038 LH rear worklight P01 (A, B) 90-106
16046038 Grain tank discharge pipe light U01 90-106
16048750 Feeding reversal motor switch T09 -
Q02 -
16049688 Warning plates rear light J01 (A, B) -
16050164 Grain tank sensor 3/4 R01 90-117
16050180 Returns elevator emergency switch / rear wiring junc- G8 (A, B) -
tion
16050180 Auger speed sensor P19 -
16050180 Straw walker shaft speed sensor - -
16050180 Threshing drum speed sensor T07 -
16050180 Elevator speed sensor P12 -
16050180 Fan speed sensor - -
16050180 Grain tank sensor 4/4 R02 90-117
16050200 Commander Control work computer C01 90-115
16050210 CAN module electronic control unit F02 (A, B, C) -
16050281 Front rotary beacon O05 90-106
16050281 Rear rotary beacon P02 (A, B) 90-106
16052332 Air cleaner sensor E04 -
90-95
16055790 Light sensor O12 -
16055791 Grain tank cover open / closed sensor R04 90-117
16055794 Grain loss control sensor (L= 1468 mm) - -
16055798 Grain loss monitor control unit - -
16055916 12V outlet socket C15 -
16056355 Chaff spreader motor P04 -
16056711 Work hydraulics pressure switch - -
16057280 Ventilation control O13 90-125
16057402 Straw chopper electronic control unit - -
16057677 Cool air control O18 90-125
16057677 Warm air control O19 90-125
16061798 Engine coolant temperature sensor K01 (A, B) -
16062307 RH electric motor for concave adjustment A01 (A, B) 90-115
16062476 Worklight (Xenon) O01 (B, E) -
16062478 Rotation angle sensor for cutting angle X01 90-110
16062478 Rotation angle sensor P07 -
16062496 BALANCE electronic control unit L11A, L11B 90-110
01141854 Battery master switch B02 -
01141925 Hour meter display - -
01145071 Rear worklight - -
01145154 Straw hood worklight switch - -
01145200 RH lateral running light P24 -
01145200 LH lateral running light P25 -
01174711 7 pin outlet socket Z01 -
01175706 Hydraulic oil temperature display C09 -
01175754 Returns elevator emergency switch N01 -
01175755 Grain tank extension raised / lowered switch C13 -
01231716 Coolant temperature gauge - -
01231937 13 pin Attachment socket I01 90-119
04191001 Brake pedal switch C05 -
04412337 Digital clock O20 -
06253949 Engine oil temperature sensor E08 -
06261946 Temperature gauge - -
06262123 Gearbox speed sensor T08 (A, B) -
06527010 Centralised main display C02 -
06537048 Grain tank worklight R05A -
06538036 RH lateral running light P26 -
06538036 LH lateral running light P27 -
16005189 RH rear light P03 (A, B, C, D, 90-122
E)
16005190 LH rear light P08 (A, B, C, D, 90-122
E)
2.7099.770.0 Cigar lighter C12 -
2.7659.290.0 Upper / lower worklights switch O10 90-122
2.7659.290.0 Front/Rear rotary beacon switch O07 90-106
2.7659.290.0 Window wiper switch O08 90-109
2.7659.291.0 Worklights switch O09 90-106
2.7659.291.0 Sidelights / low beam switch O11 90-122
2.7659.292.0 Cooling system main switch O14 90-125
2.7659.293.0 Emergency hazard lights switch C11 -
2.7659.294.0 Engine speed switch C18 -
2.7659.295.0 Straw guide plate left / right adjustment switch C17 -
2.7659.295.0 Grain tank cover open / closed switch - -
2.7659.296.0 Cutting table reversing drive switch C19 -
2.7659.296.0 Grain tank worklight switch - -
2.7659.296.0 Work master switch C10 -
2.7659.297.0 Straw guide plate adjustment switch C16 -
2.7659.305.0 Rear-view mirrors adjustment switch C14 -
O23
2.8039.004.0 RH low beam headlight A08 90-122
2.8039.004.0 LH low beam headlight A15 90-122
2.8039.005.0 RH high beam headlight A06 90-122
90-96
2.8039.005.0 LH high beam headlight A13 90-122
2.8039.011.0 RH sidelight A04 90-122
2.8039.011.0 LH sidelight A11 90-122
2.8059.014.0 RH direction indicator A07 90-122
2.8059.014.0 LH direction indicator A14 90-122
2.8519.065.0 EMR-D electronic control unit F04 90-110
90-113
90-119
90-121
2.8519.066 Safety control unit F03 -
2.8519.074.0 HLHP electronic control unit F01 -
90.28.4 - Index by connector

Table 155
Connector Wiring code Wiring Component Component
code description
90 0.015.5312.4/20 90-136 - Fuse box con-
nector for grain
tank electric mo-
tor
91 0.015.5312.4/20 90-136 - Fuse box con-
nector for thresh-
ing drum electric
motor
92 0.015.5312.4/20 90-136 - Fuse box con-
nector for straw
chopper electric
motor
93 0.015.5312.4/20 90-136 - Fuse box con-
nector for cutter
bar electric motor
A01 (A, B) 0.015.5469.4/20 90-127 16062307 RH electric motor
for concave ad-
justment
A02 (A, B) 0.015.5469.4/20 90-127 - Brake lights
switch
A03 (A, B) 0.015.5469.4/20 90-127 - Horn
A04 0.015.5469.4/20 90-127 2.8039.011.0 RH sidelight
A05 0.015.5469.4/20 90-127 - RH rear-view mir-
ror
A06 0.015.5469.4/20 90-127 2.8039.005.0 RH high beam
headlight
A07 0.015.5469.4/20 90-127 2.8059.014.0 RH direction indi-
cator
A08 0.015.5469.4/20 90-127 2.8039.004.0 RH low beam
headlight
A09 0.015.5469.4/20 90-127 - Front RH side-
light and direction
indicator
A10 (A, B) 0.015.5469.4/20 90-127 16027276 LH electric motor
for concave ad-
justment
A11 0.015.5469.4/20 90-127 2.8039.011.0 LH sidelight
A12 0.015.5469.4/20 90-127 - LH rear-view mir-
ror
A13 0.015.5469.4/20 90-127 2.8039.005.0 LH high beam
headlight
90-97
code description
A14 0.015.5469.4/20 90-127 2.8059.014.0 LH direction indi-
cator
A15 0.015.5469.4/20 90-127 2.8039.004.0 LH low beam
headlight
A16 0.015.5469.4/20 90-127 - Front LH sidelight
and direction indi-
cator
B00(+30) 16002049 90-129 16017111 Battery
B00(GND) 16002046 90-130
B01(30) 0.015.5464.4/10 90-141 - Starter motor
B02 16002046 90-130 01141854 Battery master
switch
B03(B+) 0.015.5464.4/10 90-141 - Alternator
0.015.5471.4/20 90-134
B03(D+) 0.015.5471.4/20 90-134
B03(W) 0.015.5471.4/20 90-134
C01 TS8799/3 90-131 16050200 Commander
Control work
computer
C02 TS8799/3 90-131 06527010 Centralised main
display
C03 TS8799/3 90-131 - Cutting table stop
pedal switch
C04 TS8799/3 90-131 - Grain tank open-
ing pedal switch
C05 TS8799/3 90-131 04191001 Brake pedal
switch
C06 TS8799/3 90-131 06546411 AGRO LH 1000
work computer
C07 TS8799/3 90-131 - Commander
Control program-
ming connector
C09 TS8799/3 90-131 01175706 Hydraulic oil tem-
perature display
C10 TS8799/1 90-131 2.7659.296.0 Work master
switch
C11 TS8799/1 90-131 2.7659.293.0 Emergency haz-
ard lights switch
C12 TS8799/1 90-131 2.7099.770.0 Cigar lighter
C13 TS8799/1 90-131 01175755 Grain tank exten-
sion raised / low-
ered switch
C14 TS8799/1 90-131 2.7659.305.0 Rear-view mir-
rors adjustment
switch
C15 TS8799/1 90-131 16055916 12V outlet socket
C16 TS8799/1 90-131 2.7659.297.0 Straw guide
plate adjustment
switch
C17 TS8799/1 90-131 2.7659.295.0 Straw guide plate
left / right adjust-
ment switch
C18 TS8799/1 90-131 2.7659.294.0 EMR Engine
speed switch
C19 TS8799/1 90-131 2.7659.296.0 Cutting table
reversing drive
switch
90-98
code description
C20 TS8799/1 90-131 - Cutting table start
/ stop switch
C21 TS8799/1 90-131 0.015.0485.4 Starter switch
E01 0.015.5471.4/20 90-134 0.0112938.0 Reverse travel
selected buzzer
E02 0.015.5471.4/20 90-134 - Discharge pipe
extended / re-
tracted sensor
E03 0.015.5471.4/20 90-134 - Windscreen
washer pump
E04 0.015.5471.4/20 90-134 16052332 Air cleaner sen-
sor
E05 0.015.5471.4/20 90-134 - Grain loss con-
veyor sensor
E06 0.015.5471.4/20 90-134 - Auger filling
speed sensor
E07 0.015.5471.4/20 90-134 - Threshing drum
electric motor
E08 0.015.5471.4/20 90-134 06253949 Engine oil tem-
perature sensor
E09 0.015.5471.4/20 90-134 - Conveyor sensor
E10 0.015.5471.4/20 90-134 16028967 Fuel tank sensor
E11 (A, B) 0.015.5471.4/20 90-134 - Cooling system
main sensor
F00 (30) 0.015.5312.4/20 90-136 - Fuse box
F00 (GND)
F01 0.015.5312.4/20 90-136 2.8519.074.0 HLHP electronic
control unit
F02 (A, B, C) 0.015.5312.4/20 90-136 16050210 CAN module con-
trol unit
F03 0.015.5312.4/20 90-136 2.8519.066 Safety control
unit
F04 0.015.5312.4/20 90-136 2.8519.065.0 EMR-D electronic
control unit
F05 0.015.5312.4/20 90-136 - CAN diagnostics
connector
F06 0.015.5312.4/20 90-136 - Diagnostics con-
nector
F07 0.015.5312.4/20 90-136 - Lower turbo fan
potentiometer
F08 0.015.5312.4/20 90-136 - Terminal block 30
F09 0.015.5312.4/20 90-136 - Terminal block 15
F10 0.015.5312.4/20 90-136 - GND Terminal
block
G1 0.015.5471.4/20 90-134 - Engine / rear wir-
0.015.5470.4/20 90-155 ing junction
G2 0.015.5471.4/20 90-134 - Engine / rear wir-
0.015.5470.4/20 90-155 ing junction
G3 0.015.5467.4/10 90-145 - BALANCE / rota-
16062568/10 90-171 tion angle sensor
for cutting angle
wiring junction
G4 0.015.5475.4/10 90-133 - Engine interface
- - / prewired engine
junction
90-99
code description
- - / fuse box wiring
junction
0.015.5312.4/20 90-136 / fuse box wiring
junction
G7 0.015.5473.4/10 90-139 - Grain tank / grain
16062565/10 90-168 tank worklight
wiring junction
G8 (A, B) 0.015.5470.4/20 90-155 16050180 Returns eleva-
16050268 90-149 tor emergency
switch / rear wir-
ing junction
GA 0.015.5312.4/20 90-136 - Fuse box / front
0.015.5469.4/20 90-127 wiring junction
GC1 0.015.5312.4/20 90-136 - Fuse box / cab
TS8799/1 90-131 console wiring
junction
GC2 0.015.5312.4/20 90-136 - Fuse box / cab
junction
GC3 0.015.5312.4/20 90-136 - Fuse box / cab
junction
GC4 0.015.5312.4/20 90-136 - Fuse box / cab
junction
GC5 0.015.5312.4/20 90-136 - Fuse box / cab
junction
GC6 0.015.5312.4/20 90-136 - Fuse box / cab
junction
GC7 0.015.5312.4/20 90-136 - Fuse box / cab
junction
GE1 0.015.5312.4/20 90-136 - Fuse box / engine
0.015.5471.4/20 90-134 wiring junction
GE2 0.015.5312.4/20 90-136 - Fuse box / engine
0.015.5471.4/20 90-134 wiring junction
GI 0.015.5312.4/20 90-136 - Fuse box / At-
0.015.5466.4/10 90-142 tachment socket
wiring loom wir-
ing junction
GL 0.015.5312.4/20 90-136 - Fuse box / BAL-
0.015.5467.4/10 90-145 ANCE wiring
junction
GM1 0.015.5312.4/20 90-136 - Fuse box / elec-
0.015.5472.4/10 90-147 tric motors wiring
junction
GM2 0.015.5312.4/20 90-136 - Fuse box / elec-
0.015.5472.4/10 90-147 tric motors wiring
junction
GO1 0.015.5312.4/20 90-136 - Fuse box / roof
980157 90-150 lining electrics
wiring junction
90-100
code description
GO2 0.015.5312.4/20 90-136 - Fuse box / roof
wiring junction
GO3 0.015.5312.4/20 90-136 - Fuse box / roof
wiring junction
GO4 0.015.5312.4/20 90-136 - Fuse box / roof
wiring junction
GO4 0.015.5312.4/20 90-136 - Fuse box / roof
wiring junction
GR 0.015.5312.4/20 90-136 - Fuse box / grain
0.015.5473.4/10 90-139 tank wiring junc-
tion
GS 0.015.5312.4/20 90-136 - Fuse box / feed
0.015.5465.4/10 90-164 passage sensors
wiring junction
GT 0.015.5312.4/20 90-136 - Fuse box / chas-
0.015.5474.4/10 90-166 sis wiring junction
GV 0.015.5312.4/20 90-136 - Fuse box / sole-
0.015.5468.4/10 90-169 noid valves as-
sembly wiring
junction
GW 0.015.5312.4/20 90-136 - Fuse box / steer-
980062201 90-173 ing column switch
wiring junction
GY1 0.015.5312.4/20 90-136 - Fuse box / multi-
TS8799/2 90-172 function lever wir-
ing junction
GY2 0.015.5312.4/20 90-136 - Fuse box / multi-
TS8799/1 90-172 function lever wir-
ing junction
I01 0.015.5466.4/10 90-142 01231937 13 pin Attach-
ment socket
J01 (A, B) 16056728/10 90-143 16049688 Warning plates
rear light
K01 (A, B) 16062294 90-144 16061798 Engine coolant
temperature sen-
sor
L01 0.015.5467.4/10 90-145 - Rotation angle
sensor for cutting
angle
L02 0.015.5467.4/10 90-145 - RH cutting sen-
sor
L03 0.015.5467.4/10 90-145 - LH cutting sensor
L04 0.015.5467.4/10 90-145 - Main valve
L05 0.015.5467.4/10 90-145 - Grain tank dis-
charge pipe ex-
tended valve
L06 0.015.5467.4/10 90-145 - Grain tank dis-
charge pipe re-
tracted valve
L07 0.015.5467.4/10 90-145 - Reel lowering
valve
90-101
code description
L08 0.015.5467.4/10 90-145 - Cutting table rais-
ing valve
L09 0.015.5467.4/10 90-145 - Reel raising valve
L10 0.015.5467.4/10 90-145 - Cutting table low-
ering valve
L11 (A,B) 0.015.5467.4/10 90-145 16062496 BALANCE elec-
tronic control unit
L12 0.015.5467.4/10 90-145 - BALANCE elec-
tronic control unit
programming
connector
M01 0.015.5472.4/10 90-147 - Cutter bar electric
motor
M02 0.015.5472.4/10 90-147 - Threshing mech-
anism control
M03 (A, B) 0.015.5472.4/10 90-147 - Turbo separator
electric motor
M04 0.015.5472.4/10 90-147 - Turbo separator
speed sensor
M05 0.015.5472.4/10 90-147 16034344 Straw chopper
electric motor
M06 0.015.5472.4/10 90-147 - Grain tank open-
ing / closing elec-
tric motor
M07 0.015.5472.4/10 90-147 - Centralised lubri-
cation control
N01 16050268 90-149 01175754 Returns eleva-
tor emergency
switch
O01 (A, B, C, D, 980157 90-150 16037017 Worklight
E, F) 980060 90-152
O01 (B, E) 980157 90-150 16062476 Worklight (Xe-
980060 90-152 non)
O02 540465 90-153 - Thermostat
O03 (A, B) 980157 90-150 16037015 Supplementary
980060 90-152 front headlight
O04 980157 90-150 - Interior light
O05 980157 90-150 16050281 Front rotary bea-
con
O06 980157 90-150 16025444 BALANCE work
16052333 90-151 computer
O07 980157 90-150 2.7659.290.0 Front/Rear rotary
beacon switch
O08 980157 90-150 2.7659.290.0 Window wiper
switch
O09 980157 90-150 2.7659.291.0 Worklights switch
O10 980157 90-150 2.7659.290.0 Upper / lower
worklights switch
O11 980157 90-150 2.7659.291.0 Sidelights / low
beam switch
O12 980157 90-150 16055790 Light sensor
O13 540465 90-153 16057280 Ventilation con-
trol
O14 540465 90-153 2.7659.292.0 Cooling system
main switch
O15 540465 90-153 - Evaporator fan
O16 540465 90-153 - Condenser fan
16050276 90-154
90-102
code description
O17 540465 90-153 16045076 Variator adjust-
ment servomotor
O18 540465 90-153 16057677 Cool air control
O19 540465 90-153 16057677 Warm air control
O20 980157 90-150 04412337 Digital clock
O21 980157 90-150 - AGRO LH 1000
work computer
O22 980157 90-150 - Windscreen wip-
er motor
O23 980157 90-150 2.7659.305.0 Rear-view mir-
rors adjustment
switch
O24 540465 90-153 - NTC resistor for
thermostat
O25 - 90-153 - Air conditioner
malfunctioning in-
dicator light
P01 (A, B) 0.015.5470.4/20 90-155 16046038 LH rear worklight
P02 (A, B) 0.015.5470.4/20 90-155 16050281 Rear rotary bea-
con
P03 (A, B, C, D, 0.015.5470.4/20 90-155 16005189 RH rear light
E)
P04 0.015.5470.4/20 90-155 16056355 Chaff spreader
motor
P05 (A, B, C, D, 0.015.5470.4/20 90-155 - Chaff spreader
E) actuators
P06 0.015.5470.4/20 90-155 - Cutter bar speed
sensor
P07 0.015.5470.4/20 90-155 16062478 Rotation angle
sensor
P08 (A, B, C, D, 0.015.5470.4/20 90-155 16005190 LH rear light
E)
P09 16050274 90-160 - Sieve LH light
P10 16050274 90-160 - Sieve RH light
P12 0.015.5470.4/20 90-155 16050180 Elevator speed
sensor
P13 (A, B) 0.015.5470.4/20 90-155 - LH chaff spread-
er flap switch
P14 (A, B) 0.015.5470.4/20 90-155 16046038 RH rear worklight
P15 0.015.5470.4/20 90-155 - Sieve box light
P16 (A, B) 0.015.5470.4/20 90-155 - RH chaff spread-
er flap switch
P17 (A, B, C, D, 0.015.5470.4/20 90-155 - Central lights
E, F)
P18 0.015.5470.4/20 90-155 - Fuel filter clogged
indicator
P19 0.015.5470.4/20 90-155 16050180 Auger speed sen-
sor
P20 0.015.5470.4/20 90-155 - Compressor
P21 0.015.5470.4/20 90-155 - Air conditioning
system pressure
switch
P22 0.015.5470.4/20 90-155 - RH lateral run-
ning light
P23 0.015.5470.4/20 90-155 - LH lateral running
light
P24 16056731/10 90-162 - RH side light
90-103
code description
P24 16056753 90-161 01145200 RH lateral run-
ning light (for ex-
tra wide tyres)
P25 16056731/10 90-162 - LH side light
P25 16056753 90-161 01145200 LH lateral running
light (for extra
wide tyres)
P26 16013845 90-159 06538036 RH lateral run-
ning light
P27 16013845 90-159 06538036 LH lateral running
light
Q01 16062550 90-163 16028248 Feeding reversal
motor
Q02 16062550 90-163 - Feeding reversal
motor switch
Q03 16062550 90-163 - Reversing motor
temperature sen-
sor
R01 0.015.5473.4/10 90-139 16050164 Grain tank sensor
3/4
R02 0.015.5473.4/10 90-139 16050180 Grain tank sensor
4/4
R04 0.015.5473.4/10 90-139 16055791 Grain tank cover
open / closed
sensor
R05 (A, B) 0.015.5473.4/10 90-139 06537048 Grain tank work-
light
S01 0.015.5465.4/10 90-164 - Feed passage
angle sensor
S02 0.015.5465.4/10 90-164 - Feed passage
pressure sensor
S03 0.015.5465.4/10 90-164 - Feed passage
solenoid valve
T01 0.015.5474.4/10 90-166 - Cutting angle
sensor
T02 0.015.5474.4/10 90-166 - Feed passage
height sensor
T03 0.015.5474.4/10 90-166 - Feed passage
speed sensor
T04 0.015.5474.4/10 90-166 - Turbo fan speed
sensor
T05 0.015.5474.4/10 90-166 - Fan motor
T06 0.015.5474.4/10 90-166 - Turbo fan speed
sensor
T07 0.015.5474.4/10 90-166 16050180 Threshing drum
speed sensor
T08 (A, B) 0.015.5474.4/10 90-166 06262123 Gearbox speed
sensor
T09 0.015.5474.4/10 90-166 16048750 Feeding reversal
motor switch
U01 16062565/10 90-168 16046038 Grain tank dis-
charge pipe light
V01 0.015.5468.4/10 90-169 - Cutter bar to right
solenoid valve
V02 0.015.5468.4/10 90-169 - Cutter bar to left
solenoid valve
90-104
code description
V03 0.015.5468.4/10 90-169 - Feed passage
lowered solenoid
valve
V04 0.015.5468.4/10 90-169 - Feed passage
raised solenoid
valve
V05 0.015.5468.4/10 90-169 - Cutter bar low-
ered solenoid
valve
V06 0.015.5468.4/10 90-169 - Grain tank re-
traction solenoid
valve
V07 0.015.5468.4/10 90-169 - Grain tank dis-
charge pipe re-
traction solenoid
valve
V08 0.015.5468.4/10 90-169 - Reel raised sole-
noid valve
V09 0.015.5468.4/10 90-169 - Reel retracted
solenoid valve
V10 0.015.5468.4/10 90-169 - Cutter bar raised
solenoid valve
V11 0.015.5468.4/10 90-169 - Reel forward so-
lenoid valve
V12 0.015.5468.4/10 90-169 - Reel lowered so-
lenoid valve
V13 0.015.5468.4/10 90-169 - Grain tank dis-
charge pipe ex-
tension solenoid
valve
V14 0.015.5468.4/10 90-169 - Grain tank ex-
tension solenoid
valve
W01 980062201 90-173 - Steering column
switch lever
X01 16062568/10 90-171 16062478 Rotation angle
sensor for cutting
angle
X134 TS8799/1, TS8799/3 H.Z43.01.HH.02.00.00.04 - Roof lining elec-
980157 90-150 trics / cab console
wiring junction
Y01 TS8799/2 90-172 16027010 Multifunction le-
ver
Y02 TS8799/2 90-172 16017104 EMR-D control
panel
Z01 16050256 90-174 01174711 7 pin outlet sock-
et
Z02 16050256 90-174 - Straw chopper
servomotor
90-105
90.29 - Worklights
Fig. 1831 - Worklights

Components key
l B00 (+30), Battery
l B00 (GND), Battery
l C21, Ignition switch
l F00 (30), Fuse box
l F00 (GND), Fuse box
l F08, Terminal block 30
l F10, GND Terminal block
l FT2, Worklights contactor (A - F)
l FT3, Grain tank worklight contactor
l FT4, Front rotary beacon contactor
l FT5, Rear rotary beacon contactor
l FT21, Ignition contactor
l FT23, Worklights contactor (B - E)
l FT24, Worklights contactor (C - D)
l FT25, Rear worklights contactor
l G2, Engine / rear wiring junction
l G7, Grain tank / grain tank worklight wiring junction
l GC2, Fuse box / cab console wiring junction
l GE1, Fuse box / engine wiring junction
l GND6, Earthing point on roof lining system
l GND9, Earthing point on fuse box
l GO1, Fuse box / roof lining system wiring junction
90-106
Fig. 1831 - Worklights

l GR, Fuse box / grain tank wiring junction
l O05, Front rotary beacon
l O07, Front/Rear rotary beacon switch
l O09, Worklights switch
l O01A, Worklight
l O01B, Worklight / Xenon worklight
l O01C, Worklight
l O01D, Worklight
l O01E, Worklight / Xenon worklight
l O01F, Worklight
l P01A, LH rear worklight
l P01B, LH rear worklight
l P02A, Rear rotary beacon
l P02B, Rear rotary beacon
l P14A, RH rear worklight
l P14B, RH rear worklight
l U01, Grain tank discharge pipe light
90-107
List of wiring looms
l 16002046 - Battery negative lead
m See para. 90.41 - Battery negative lead ... - page 90-130
l 16002049 - Battery positive lead

m See para. 90.40 - Battery positive lead ... - page 90-129
l TS8799/1 - Cab console wiring loom

m See para. 90.42 - Cab console wiring - T... - page 90-131
l 0.015.5312.4/20 - Fuse box wiring loom

m See para. 90.45 - Fuse box wiring - 0.01... - page 90-136
l 0.015.5471.4/20 - Engine wiring loom

m See para. 90.44 - Engine wiring loom - 0... - page 90-134
l 16062565/10 - Grain tank worklight wiring loom

m See para. 90.67 - Grain tank worklight w... - page 90-168
l 0.015.5473.4/10 - Grain tank wiring loom

m See para. 90.46 - Grain tank wiring loom... - page 90-139
l 0.015.5470.4/20 - Rear wiring loom

m See para. 90.59 - Rear wiring - 0.015.54... - page 90-155
l 980157 - Roof lining system wiring loom

m See para. 90.54 - Roof lining electrics ... - page 90-150
90-108
90.30 - Windscreen wiper
Fig. 1832 - Windscreen wiper

Components key
l O08, Screen wiper switch
l O22, Wiper motor




90-109
90.31 - BALANCE
Fig. 1833 - BALANCE

Components list
l FT80, Cutting angle up contactor
l FT59, Cutting angle down contactor
l FT76, BALANCE contactor
l FT75, BALANCE contactor
l FT55, Cutter bar release contactor
l FT34, Cutter bar automatic release contactor
l G3, BALANCE / Wiring loom of rotation angle sensor for cutting angle
l GL, Fuse box / BALANCE wiring junction
l GND15, Earthing point on BALANCE wiring
l GND16, Earthing point on BALANCE wiring
l GY1, Fuse box / multifunction lever wiring junction
l L01, Rotation angle sensor for cutting angle
l L02, RH cutting sensor
l L03, LH cutting sensor
90-110
Fig. 1833 - BALANCE

l L04, Main valve
l L05, Grain discharge pipe extend valve (M5)
l L06, Grain discharge pipe retract valve (M6)
l L07, Reel lowering valve (M4)
l L08, Cutting table raising valve (M2)
l L09, Reel raising valve (M3)
l L10, Cutting table lowering valve (M1)
l L11A, BALANCE electronic control unit
l L11B, BALANCE electronic control unit
l L12, BALANCE electronic control unit programming connector
l O06, BALANCE work computer
l Y01, Multifunction lever
l Y02, EMR-D control panel
l X01, Rotation angle sensor for cutting angle

l 0.015.5467.4/10 - BALANCE wiring

m See para. 90.51 - BALANCE wiring - 0.015... - page 90-145



90-111
l TS8799/2 - Multifunction lever wiring loom
m See para. 90.70 - Multifunction lever wi... - page 90-172
l 16062568/10, Rotation angle sensor for cutting angle wiring loom

m See para. 90.69 - Cutting table cutting ... - page 90-171
90-112
90.32 - Solenoid valves
Fig. 1834 - Solenoid valves

Components list
l F04, EMR-D electronic control unit
l FT7, Reel up contactor
l FT8, Grain tank up contactor
l FT28, Reel down contactor
l FT29, Grain tank down contactor
l FT49, Reel forward contactor
l FT50, Grain discharge pipe extend contactor
l FT59, Cutting angle down contactor
l FT70, Reel back contactor
l FT71, Grain discharge pipe retract contactor
l FT80, Cutting angle up contactor
l GV, Fuse box / solenoid valves assembly wiring junction
l V01, Cutter bar to right solenoid valve
l V02, Cutter bar to left solenoid valve
l V03, Feed passage down solenoid valve
l V04, Feed passage up solenoid valve
l V05, Cutter bar down solenoid valve
90-113
Fig. 1834 - Solenoid valves

l V06, Grain tank retracted solenoid valve
l V07, Grain tank discharge tube retract solenoid valve
l V08, Reel raised solenoid valve
l V09, Reel retracted solenoid valve
l V10, Cutter bar raised solenoid valve
l V11, Reel forward solenoid valve
l V12, Reel lowered solenoid valve
l V13, Grain tank discharge tube extension solenoid valve
l V14, Grain tank extension solenoid valve



l 0.015.5468.4/10, Solenoid valves assembly wiring loom

m See para. 90.68 - Solenoid valves assemb... - page 90-169
l TS8799/2, Multifunction lever wiring loom

m See para. 90.70 - Multifunction lever wi... - page 90-172
90-114
90.33 - Electric motors
Fig. 1835 - Electric motors

Components key
l 90, Fuse box connector for grain tank electric motor
l 91, Fuse box connector for threshing drum electric motor
l 92, Fuse box connector for straw chopper electric motor
l 93, Fuse box connector for cutter bar electric motor
l A01A, RH electric motor for concave adjustment (back)
l A01B, RH electric motor for concave adjustment (back)
l A10A, LH electric motor for concave adjustment (front)
l A10B, LH electric motor for concave adjustment (front)
l C01, Commander Control Work computer
l FT18, Threshing drum forward contactor, closed
l FT19, Turbo separator down contactor
l FT39, Threshing drum forward contactor, open
l FT40, Turbo separator up contactor
l FT60, Threshing drum back contactor, closed
l FT81, Threshing drum back contactor, open
l GA, Fuse box / front wiring junction
90-115
Fig. 1835 - Electric motors

l GM1, Fuse box / electric motors wiring junction
l M01, Cutter bar electric motor
l M02, Threshing drum actuator
l M03A, Turbo separator electric motor
l M03B, Turbo separator electric motor
l M04, Turbo separator speed sensor
l M05, Straw chopper electric motor
l M06, Grain tank opening / closing electric motor
l M07, Centralised lubrication control


l 0.015.5472.4/10 - Electric motors wiring loom

m See para. 90.52 - Electric motor wiring ... - page 90-147
l 0.015.5469.4/20 - Front wiring loom

m See para. 90.39 - Front wiring loom - 0.... - page 90-127

90-116
90.34 - Grain tank sensors
Fig. 1836 - Grain tank sensors

Components list
l R01, Grain tank sensor 3/4
l R04, Grain tank cover open / closed sensor


90-117
l 0.015.5473.4/10 - Grain tank wiring loom

m See para. 90.46 - Grain tank wiring loom... - page 90-139
90-118
90.35 - Attachment
Fig. 1837 - Attachment

Components list
l FT14, Reel speed increase contactor
l FT35, Reel speed decrease contactor
l FT51, Crop selection contactor on cutting mechanism
l GI, Fuse box / Implement socket wiring junction
l I01, 13 pin Attachment socket

90-119

l 0.015.5466.4/10 - Implement socket wiring loom

m See para. 90.48 - Attachment electrical ... - page 90-142
90-120
90.36 - Feed passage sensors
Fig. 1838 - Feed passage sensors

Components list
l GS, Fuse box / feed passage sensors wiring junction
l S01, Feed passage angle sensor
l S02, Feed passage pressure sensor
l S03, Feed passage hood solenoid valve



l 0.015.5465.4/10, Feed passage sensors wiring loom

m See para. 90.65 - Feed passage sensors w... - page 90-164
90-121
90.37 - Lights
Fig. 1839 - Lights

Components list
l A02, Brake lights switch
l A04, RH sidelight
l A06, RH high beam headlight
l A07, RH direction indicator
l A08, RH low beam headlight
l A09, Front RH sidelight and direction indicator
l A11, LH sidelight
l A13, LH high beam headlight
l A14, LH direction indicator
l A15, LH low beam headlight
l A16, Front LH sidelight and direction indicator
l FT1, Sidelights / direction indicators contactor
l FT43, Full beam headlights general contactor
l FT44, Full beam headlights contactor, up / down, left
l FT45, Full beam headlights contactor, up / down, right
l FT54, Low beam headlights general contactor
l FT65, Low beam headlights contactor, up / down, left
l FT66, Low beam headlights contactor, up / down, right
90-122
Fig. 1839 - Lights

l GW, Fuse box / steering column switch wiring junction
l O03A, Supplementary front headlight
l O03B, Supplementary front headlight
l O10, Upper / lower worklights switch
l O11, Sidelights / running lights switch
l P03, RH rear light
l P08, LH rear light
l P17, Central lights
l P22, RH lateral running light
l P23, LH lateral running light
l X134, Roof lining system / cab console wiring junction
l W01, Steering column switch stalk


l 0.015.5469.4/20 - Front wiring loom

m See para. 90.39 - Front wiring loom - 0.... - page 90-127
l 0.015.5471.4/20 - Engine wiring loom

m See para. 90.44 - Engine wiring loom - 0... - page 90-134
90-123


l 980062201 - Steering column switch wiring loom

m See para. 90.71 - Steering column switch... - page 90-173
90-124
90.38 - Air conditioner
Fig. 1840 - Air conditioner

Components list
l GND3, Earthing point on rear wiring loom
l GND4, Air conditioner earthing point
l K1, Air conditioning contactor 1
l O02, Thermostat
l O13, Ventilation control
l O14, Cooling system main switch
l O15, Evaporator fan
l O16, Condenser fan
l O17, Variator adjustment servomotor
l O18, Cool air control
l O19, Warm air control
l O24, NTC resistor for thermostat
l O25, Air conditioner fault indicator light
l P20, Compressor
l P21, Air conditioning system pressure switch
l X134, Roof lining system / cab console wiring junction
l 540465 - Air conditioner wiring loom
m See para. 90.57 - Air conditioner wiring... - page 90-153

90-125
90-126
90.39 - Front wiring loom - 0.015.5469.4/20
Fig. 1841 - Front wiring loom

Connectors list
l A02A, Brake lights switch
l A02B, Brake lights switch
l A03A, Horn
l A03B, Horn
l A04, RH sidelight
l A05, RH rear-view mirror
l A11, LH sidelight
l A12, LH rear-view mirror
90-127
Fig. 1842 - Front wiring line diagram

Connectors list
l A02A, Brake lights switch
l A02B, Brake lights switch
l A03A, Horn
l A03B, Horn
l A04, RH sidelight
l A05, RH rear-view mirror
l A11, LH sidelight
l A12, LH rear-view mirror
90-128
90.40 - Battery positive lead - 16002049
Fig. 1843 - Battery positive lead

Connectors list
l B00(+30), Battery
l B01(30), Starter motor
90-129
90.41 - Battery negative lead - 16002046
Fig. 1844 - Battery negative lead

Connectors list
l B00(GND), Battery
l B02, Battery isolator switch (negative pole)
90-130
90.42 - Cab console wiring - TS8799/1, TS8799/3
Fig. 1845 - Cab console wiring

Connectors list
l C01, Commander Control operating computer
l C02, Centralised main display
l C03, Cutting table stop pedal switch
l C04, Grain tank opening pedal switch
l C05, Brake pedal switch
l C06, AGRO LH 1000 operating computer
l C07, Commander Control programming connector
l C09, Hydraulic oil temperature display
90-131
Fig. 1846 - Cab console wiring

Connectors list
l C10, Work master switch
l C11, Emergency flashing lights switch
l C12, Cigar lighter
l C13, Grain tank extension raised / lowered switch
l C14, Rear-view mirrors adjustment switch
l C15, 12V outlet socket
l C16, Straw guide plate adjustment switch
l C17, Straw guide plate adjustment switch, to right and left
l C18, Engine speed switch
l C19, Cutting table reversing drive switch
l C20, Cutting table start / stop switch
l C21, Starting switch
90-132
90.43 - Engine interface wiring - 0.015.5475.4/10
Fig. 1847 - Engine interface wiring

Connectors list
l G4, Engine interface wiring junction
l G6, Engine interface / fuse box wiring junction
Fig. 1848 - Engine interface wiring line diagram

Connectors list
90-133
90.44 - Engine wiring loom - 0.015.5471.4/20
Fig. 1849 - Engine wiring

Connectors list
l B03(B+), Alternator
l B03(D+), Alternator
l B03(W), Alternator
l E01, Reverse travel selected buzzer
l E02, Discharge pipe extended / retracted sensor
l E03, Water pump for windscreen washing
l E04, Air filter clogged sensor
l E05, Grain loss conveyor sensor
l E06, Auger filling speed sensor
l E07, Threshing drum electric motor
l E08, Engine oil temperature sensor
l E09, Conveyor sensor
l E10, Fuel tank sensor
l E11A, Cooling system main sensor
l E11B, Cooling system main sensor
90-134
Fig. 1850 - Engine wiring line diagram

Connectors list
l B03(D+), Alternator
l B03(W), Alternator
l E01, Reverse travel selected buzzer
l E02, Discharge pipe extended / retracted sensor
l E03, Water pump for windscreen washing
l E04, Air filter clogged sensor
l E05, Grain loss conveyor sensor
l E06, Auger filling speed sensor
l E07, Threshing drum electric motor
l E08, Engine oil temperature sensor
l E09, Conveyor sensor
l E10, Fuel tank sensor
l E11A, Cooling system main sensor
l E11B, Cooling system main sensor
90-135
90.45 - Fuse box wiring - 0.015.5312.4/20
Fig. 1851 - Fuse box wiring

Connectors list
l 90, Fuse box connector for grain tank electric motor
l 91, Fuse box connector for threshing drum electric motor
l 92, Fuse box connector for straw chopper electric motor
l 93, Fuse box connector for cutter bar electric motor
90-136

Connectors list
l G01, Fuse box / roof lining electrics wiring junction
l GO2, Fuse box / roof lining electrics wiring junction
l GT, Fuse box / chassis wiring junction
90-137

Connectors list
l F01, HLHP electronic control unit
l F02A, CAN module control unit
l F02B, CAN module control unit
l F02C, CAN module control unit
l F03, Safety control unit
l F05, CAN diagnostics connector
l F06, Diagnostics connector
90-138
90.46 - Grain tank wiring loom - 0.015.5473.4/10
Fig. 1854 - Grain tank wiring loom

Connectors list
l R04, Grain tank extension open / closed sensor
l R05A, Grain tank worklight
l R05B, Grain tank worklight
90-139
Fig. 1855 - Grain tank wiring loom

Connectors list
l R04, Grain tank extension open / closed sensor
l R05A, Grain tank worklight
l R05B, Grain tank worklight
90-140
90.47 - Charge circuit wiring loom - 0.015.5464.4/10
Fig. 1856 - Charge circuit wiring loom

Connectors list
l B01(30), Starter motor
90-141
90.48 - Attachment electrical socket wiring loom - 0.015.5466.4/10
Fig. 1857 - Attachment electrical socket wiring loom

Connectors list
Fig. 1858 - Attachment electrical socket wiring line diagram

Connectors list
90-142
90.49 - Rear number plate light wiring loom - 16056728/10
Fig. 1859 - Rear number plate light wiring loom

Connectors list
l J01A, Warning plates rear light
l J01B, Warning plates rear light
90-143
90.50 - Coolant temperature sensor wiring loom - 16062294
Fig. 1860 - Coolant temperature sensor wiring loom

Connectors list
l K01A, Engine coolant temperature sensor
l K01B, Engine coolant temperature sensor
90-144
90.51 - BALANCE wiring - 0.015.5467.4/10
Fig. 1861 - BALANCE wiring

Connectors list
l G3, BALANCE / Cutting angle sensor for cutting table wiring junction
l L01, Cutting angle sensor for cutting table
l L04, Main valve
l L05, Grain tank discharge extended pipe valve
l L06, Grain tank discharge retracted pipe valve
l L07, Reel lowering valve
l L08, Cutting table raising valve
l L09, Reel raising valve
l L10, Cutting table lowering valve
90-145
Fig. 1862 - BALANCE wiring line diagram

Connectors list
l G3, BALANCE / Cutting angle sensor for cutting table wiring junction
l L01, Cutting angle sensor for cutting table
l L04, Main valve
l L05, Grain tank discharge extended pipe valve
l L06, Grain tank discharge retracted pipe valve
l L07, Reel lowering valve
l L08, Cutting table raising valve
l L09, Reel raising valve
l L10, Cutting table lowering valve
90-146
90.52 - Electric motor wiring loom - 0.015.5472.4/10
Fig. 1863 - Electric motor wiring loom

Connectors list
l M02, Threshing mechanism control
90-147
Fig. 1864 - Electric motors wiring line diagram

Connectors list
l M02, Threshing mechanism control
90-148
90.53 - Returns elevator emergency switch - 16050268
Fig. 1865 - Returns elevator emergency switch

Connectors list
l G8A, Recovery elevator emergency switch / rear wiring junction
l G8B, Recovery elevator emergency switch / rear wiring junction
l N01, Returns elevator emergency switch
90-149
90.54 - Roof lining electrics wiring loom - 980157
Fig. 1866 - Roof lining electrics wiring loom

Connectors list
l O01A, Worklight
l O01B, Worklight
l O01C, Worklight
l O01D, Worklight
l O01E, Worklight
l O01F, Worklight
l O04, Interior light
l O05, Front rotary beacon
l O06, BALANCE operating computer
l O08, Screen wiper switch
l O09, Worklights switch
l O10, Upper / lower worklights switch
l O11, Sidelights / low beam switch
l O12, Light sensor
l O20, Digital clock
l O21, AGRO LH 1000 operating computer
l O22, Wiper motor
l O23, Rear-view mirrors adjustment switch
90-150
90.55 - BALANCE WIRING LOOM - 16052333
Fig. 1867 - BALANCE wiring loom

Connectors list
l O06, BALANCE operating computer
90-151
90.56 - Cab roof worklights wiring loom - 980060
Fig. 1868 - Cab roof worklights wiring loom

Connectors list
l O01A, Worklight
l O01B, Worklight
l O01C, Worklight
l O01D, Worklight
l O01E, Worklight
l O01F, Worklight
90-152
90.57 - Air conditioner wiring loom - 540465
Fig. 1869 - Air conditioner wiring loom

Connectors list
l O02, Thermostat
l O13, Ventilation control
l O14, Cooling system main switch
l O15, Evaporator fan
l O16, Condenser fan
l O18, Cool air control
l O19, Warm air control
l O24, NTC resistor for thermostat
l O25, Air conditioner fault indicator light
l X134, Roof lining electrics / cab console wiring junction
90-153
90.58 - Air conditioning system filter-dryer wiring loom - 16050276
Fig. 1870 - Air conditioning system filter-dryer wiring loom

Connectors list
l O16, Dryer motor
90-154
90.59 - Rear wiring - 0.015.5470.4/20
Fig. 1871 - Rear wiring

Connectors list
l P03A, RH rear light
l P03B, RH rear light
l P03C, RH rear light
l P03D, RH rear light
l P03E, RH rear light
l P04, Chaff spreader motor
l P05A, Chaff spreader actuators
l P05B, Chaff spreader actuators
l P05C, Chaff spreader actuators
l P05D, Chaff spreader actuators
l P05E, Chaff spreader actuators
l P06, Cutter bar speed sensor
l P07, Cutting angle sensor
l P08A, LH rear light
l P08B, LH rear light
l P08C, LH rear light
l P08D, LH rear light
l P08E, LH rear light
l P12, Elevator speed sensor
l P13A, LH chaff spreader flap switch
l P13B, LH chaff spreader flap switch
90-155
Fig. 1871 - Rear wiring

l P14A, RH chaff spreader
l P14B, RH chaff spreader
l P15, Sieve box light
l P16A, RH chaff spreader flap switch
l P16B, RH chaff spreader flap switch
l P17A, Central lights
l P17B, Central lights
l P17C, Central lights
l P17D, Central lights
l P17E, Central lights
l P17F, Central lights
l P18, Fuel filter clogged indicator
l P19, Auger speed sensor
l P20, Compressor
l P22, RH lateral dimensional clearance
l P23, LH lateral dimensional clearance
90-156
Fig. 1872 - Rear wiring line diagram

Connectors list
l P03A, RH rear light
l P03B, RH rear light
l P03C, RH rear light
l P03D, RH rear light
l P03E, RH rear light
l P04, Chaff spreader motor
l P05A, Chaff spreader actuators
l P05B, Chaff spreader actuators
l P05C, Chaff spreader actuators
l P05D, Chaff spreader actuators
l P05E, Chaff spreader actuators
l P06, Cutter bar speed sensor
l P07, Cutting angle sensor
l P08A, LH rear light
l P08B, LH rear light
l P08C, LH rear light
l P08D, LH rear light
l P08E, LH rear light
l P12, Elevator speed sensor
l P13A, LH chaff spreader flap switch
l P13B, LH chaff spreader flap switch
l P14A, RH chaff spreader
90-157
Fig. 1872 - Rear wiring line diagram

l P14B, RH chaff spreader
l P15, Sieve box light
l P16A, RH chaff spreader flap switch
l P16B, RH chaff spreader flap switch
l P17A, Central lights
l P17B, Central lights
l P17C, Central lights
l P17D, Central lights
l P17E, Central lights
l P17F, Central lights
l P18, Fuel filter clogged indicator
l P19, Auger speed sensor
l P20, Compressor
l P22, RH lateral dimensional clearance
l P23, LH lateral dimensional clearance
90-158
90.60 - Rear lateral light wiring loom - 16013845
Fig. 1873 - Rear lateral light wiring loom

Connectors list
90-159
90.61 - Sieve lighting wiring loom - 16050274
Fig. 1874 - Sieve lighting wiring loom

Connectors list
l P09, Sieve LH light
l P10, Sieve RH light
90-160
90.62 - Side lights wiring loom - 16056753
Fig. 1875 - Side lights wiring loom

Connectors list
90-161
90.63 - Side lights wiring loom - 16056731/10
Fig. 1876 - Side lights wiring loom

Connectors list
l P24, RH side light
l P25, LH side light
90-162
90.64 - Feed passage reversing device wiring loom - 16062550
Fig. 1877 - Feed passage reversing device wiring loom

Connectors list
l Q01, Feeding reversal motor
l Q02, Feeding reversal motor switch
l Q03, Reversing motor temperature sensor
90-163
90.65 - Feed passage sensors wiring loom - 0.015.5465.4 /10
Fig. 1878 - Feed passage sensors wiring loom

Connectors list
l S03, Feed passage sieve box solenoid valve
Fig. 1879 - Feed passage sensors wiring loom

Connectors list
90-164
l S03, Feed passage sieve box solenoid valve
90-165
90.66 - Chassis wiring loom - 0.015.5474.4/10
Fig. 1880 - Chassis wiring loom

Connectors list
l T01, Cutting angle sensor
l T02, Feed passage height sensor
l T03, Feed passage speed sensor
l T04, Turbo fan speed sensor
l T05, Fan motor
l T07, Threshing drum speed sensor
l T08A, Gearbox speed sensor
l T08B, Gearbox speed sensor
l T09, Feeding reversal motor switch
90-166
Fig. 1881 - Chassis wiring loom

Connectors list
l T01, Cutting angle sensor
l T02, Feed passage height sensor
l T03, Feed passage speed sensor
l T05, Fan motor
l T07, Threshing drum speed sensor
l T08A, Gearbox speed sensor
l T08B, Gearbox speed sensor
l T09, Feeding reversal motor switch
90-167
90.67 - Grain tank worklight wiring loom - 16062565/10
Fig. 1882 - Grain tank worklight wiring loom

Connectors list
l U01, Grain tank discharge pipe light
90-168
90.68 - Solenoid valves assembly wiring loom - 0.015.5468.4/10
Fig. 1883 - Solenoid valves assembly wiring loom

Connectors list
l V01, Right hand cutter bar solenoid valve
l V02, Left hand cutter bar solenoid valve
l V03, Feed passage lowered solenoid valve
l V04, Feed passage raised solenoid valve
l V05, Cutter bar lowered solenoid valve
l V07, Grain tank discharge tube retracted solenoid valve
l V13, Grain tank discharge tube extend solenoid valve
l V14, Grain tank extend solenoid valve
90-169
Fig. 1884 - Solenoid valves assembly wiring loom

Connectors list
l V01, Cutter bar to right solenoid valve
l V02, Cutter bar to left solenoid valve
l V03, Feed passage lowered solenoid valve
l V04, Feed passage raised solenoid valve
l V05, Cutter bar lowered solenoid valve
l V07, Grain tank discharge tube retracted solenoid valve
l V13, Grain tank discharge tube extended solenoid valve
l V14, Grain tank extended solenoid valve
90-170
90.69 - Cutting table cutting angle sensor wiring loom - 16062568/10
Fig. 1885 - Rotation angle sensor wiring loom for cutting angle
Connectors list
l G3, BALANCE / Wiring loom of rotation angle sensor for cutting angle
l X01, Rotation angle sensor for cutting angle
90-171
90.70 - Multifunction lever wiring loom - TS8799/2
Fig. 1886 - Multifunction lever wiring loom

Connectors list
l Y02, EMR-D control panel
90-172
90.71 - Steering column switch wiring loom - 980062201
Fig. 1887 - Steering column switch wiring loom

Connectors list
l W01, Steering column switch stalk
90-173
90.72 - Straw chopper wiring loom - 16050256
Fig. 1888 - Straw chopper wiring loom

Connectors list
l Z01, 7-pin outlet socket
l Z02, Straw chopper servomotor
90-174
100 - Threshing unit
100-1
Threshing unit
100.1 - Threshing section clutch
Spring pretension (A) to engaged condition
Control dimension (B) for servomotor stroke (maximum stroke 100 mm).
Table 156
- Dimension A Dimension B
5650, 5660 142 mm 80 mm
5680, 5690 140 mm 82 mm
The pretensioning adjustment of spring (A) is performed on the potentiometer of

Fig. 1889
the corresponding load relay (see chapter C).
The servomotor stroke (control dimension (B)) is adjusted on adjuster screw (4).
After adjusting, tighten the locknuts with care.
Always adjust dimension A first and then dimension B!
If the excursion of adjuster screw (4) is insufficient, adjust height of support (5) of
idle pulley (6).
Rotate support (5) through 180° to further increase the height of idle pulley (6) if
necessary.
Each time idler pulley (6) is adjusted, readjust belt guide.
1 - Tensioning pulley
2 - Support
3 - Idle pulley
4 - Adjuster screw
100.1.1 - Belt guide for threshing drum slipping clutch

5 - Leveller
6 - upper belt guide
7 - front belt guide
8 - lower belt guide
Adjust belt guides with belts installed in such a way that the belt does not drive.
Front belt guide (7) must be 8 mm from edge of the belt over the entire length.
Leveller (5) must be adjusted in such a way that the disengaged belt does not
drive the pulley and cannot escape from the sides of the pulley grooves.
Fig. 1890
100-2
Threshing unit
100.2 - Assembling the threshing drum
1 - Flanged shaft
1.1 - Reduction gear flanged shaft
2 - M12x40 screws with threadlocker. Screw quality 10.9 (Loctite 243).
3 - Left and right ringnut tightening torque 140 Nm
4 - Screw quality 10.9
In the case of repairs, adhere to the following instructions:
Always replace tines in pairs.
Fit balancing weights always in the same position at which they were fitted in the factory.
Fig. 1891 - Assembling the threshing drum
100-3
Threshing unit
100.3 - Concave electrical adjustment
Table 157
A Concave front clearances adjustment, view from the left
(1) Servomotor for concave front clearances
(3) Concave front suspension support pipe
(4) Traction harness for front suspension of the concave
B Servomotor:
(8) Servomotor potentiometer
(9) Servomotor sliding tube
C Concave rear clearances adjustment, view from the right-hand
side
(2) Concave rear clearances support tube
(5) Traction harness for rear suspension of the concave
(6) Servomotor for concave rear clearances (the motor is in-
stalled horizontally!)
The stroke of both servomotors is 127 mm max. Integral potentiometer (8) detects the travel of sliding tube (9). The potentiometer
signal voltage is processed by Commander Control 2000 for display and control of concave clearances.
Observe the following points when installing the servomotors:
The potentiometer resistance is about 800 Ω, measured on the yellow and grey wire with the sliding tube fully retracted (9).
Basic adjustment of concave clearance:
1. Retracted servomotors mounting dimension:
m Left servomotor (1): 402 mm
m Right servomotor (6): 413 mm
Tighten nuts M16 (7) fully after adjusting.

With servomotors (1, 6) retracted traction brackets (4, 5) must not collide with support tubes (2, 3).
2. Basic adjustment of the distance of the concave to the drum by adjusting traction brackets (4, 5). Servomotors are fully re-
tracted:
Indicator on Commander Control for concave front (11) and rear (12) distance on stop notch 1.
Table 158
Threshing drum clearance Concave
- Cereal Maize
Front 4th bar: 6 mm 3rd bar: 30 mm
Rear last bar: 3 mm last bar: 10 mm
After assembling (or renewing) the servomotors, perform the calibration of threshing drum setting on the Commander Control 2000.
For this purpose, both servomotors are extended and retracted and the relative potentiometer values are saved to the memory.
100-4
Threshing unit
Fig. 1892 - Electrical setting
100-5
Threshing unit
100.4 - Concave suspension, de-awner covers
1. Concave front clearance adjustment servomotor
2. Concave rear suspension support sleeve
3. Concave front suspension support sleeve
4. Forward drive bracket
5. Reverse drive bracket
6. Concave rear clearance adjustment servomotor
7. Seal plate
Fig. 1893 - Concave suspension

100.4.1 - De-awner covers
Table 159
1 De-awner cover 1 to 5
2 Actuator lever
Fig. 1894
100-6
Threshing unit
Table 160
3 Locking bar for fifth de-awning plate

cover
4 Clamping screw for locking bar
Fig. 1895
The fifth cover of the de-awning plate can be disengaged, if necessary. To do this,
loosen screw (4) and remove locking bar (3).
Adjustment of operation by means of slots in actuator lever:
when the de-awner cover is closed the actuator lever must rotate under tension
beyond the dead point.
Fig. 1896
100-7
Threshing unit
100.5 - Assembling the reversing drum
1. Preassembly value to fit the shaft in the reversing drum
2. Tolerance for regular operation of the assembled shaft 0.2 mm max.
3. Assembly value for reversing drum assembly
4. Check if the reversing drum is in the centre of the feed passage
5. Direction of rotation
6. Lubrication hole
DANGER
Before fitting a new bearing check whether lubrication holes (6) in the bearing cover and the lubrication passage in the
outer race of the bearing are positioned one on top of the other
Fig. 1897 - Assembling the reversing drum

100.5.1 - Reversing drum with synchronous drive (from 2007)
1. Drum shaft
2. Reversing drum shaft, tubular shaft and screw connected shaft drive
3. Reversing drum, support on shaft (2)
4. RH bearing cap
5. Bearing inner flange
6. Bearing outer flange
7. Tensioning device for V-belt
Dimension A: reversing drum assembly value on shaft
Dimension B: reversing drum control value with shaft and frame
Precautions for refitting operations:
l Fit preassembled shaft in reversing drum.
l Position preassembled reversing drum in frame and screw down outer bearing flange (6) while supporting RH side of revers-
ing drum.
l Align V-belt pulley on drum shaft with reversing drum V-belt pulley.
100-8
Threshing unit
Fig. 1898 - Reversing drum with synchronous drive
100-9
Threshing unit
100.6 - Threshing drum speed variator
1. Nuts tightening torque of 460 Nm secured with DW 59.
Position the fixed disc by tapping the mobile disc and torque the nut to 460 Nm.
Special tool to loosen fixed disc: 0043 6020.
2. Clean the cavity, specifically before and threshing of rape.
3. The bearing pin must be parallel to the threshing drum. Align with inserts, if necessary.
4. Compensation washers
5. Fit cover with silicone
6. Control dimension for belt alignment
7. Loosen supporting struts only with slack belt.
100-10
Threshing unit
Fig. 1899 - Threshing drum speed variator
100-11
Threshing unit
100.7 - Installing the variator pulley
1. Compensation washers for transmission alignment
Fig. 1900 - Variator pulley
100-12
Threshing unit
100.8 - Variator adjustment
l Variator belt and control device are disassembled.
l Insert the sliding disc on the fixed disc; place the 1 mm feeler gauge between the contact surfaces.
l Measure dimension D with thrust disc (1) inserted.
l For adjustment of the speed variator, screw adjuster disc (3) onto the adjuster bush until reaching dimension D.
l Adjust control ring (2) so that the cams of control ring (2) and adjuster disc (3) prevent any further rotation of adjuster disc (3)
and the minimum axial distance in the area of the cams 0.5 mm.
l Secure control ring (2) with 2 cylinder screws.
l Turn compensation disc (3) back by 1 turn; check that the cams do not come into contact with one another.
l Fit and adjust the variator control device.
l Adjust the variator control device upwards until the chain wheel is locked.
l Check 1 mm clearance S between washers.
If the variator has been disassembled: tighten stop nuts (4) on the guide pins so that, with the variator in its rear position the variator
belt does not disengage from the lower adjuster rings and does not run in contact with the base of the upper adjuster rings.
NOTE
The new adjustment of the variator adjustment device must be performed on all machines in which the adjuster rings
are not blocked during the upward adjustment.
100.8.1 - Variator switching elements

1 - Pressure disc (observe proper mounting position)
2 - Adjuster ring
3 - Adjuster disc
4 - Stop nuts
5 - Clearance of bearing C4 (clearance of bearing larger than normal)
D - Measure dimension D with the pressure disc inserted and clearance dimension S = 1 mm
100-13
Threshing unit
Fig. 1901 - Variator adjustment
100-14
Threshing unit
100.9 - Changing the variator belt
1. Adjust the variator to the maximum speed to open the driven disc.
2. Screw in the two hex head screws (M16x140) in order to keep the driven
disc open by the maximum distance.
(The screws are provided with the on-board tools).
3. Open the servomotor chain.
4. Turn chain wheel (1) clockwise to open driving disc.
5. Unscrew nuts (C) and swing the struts to the sides. Renew the belt. Clean
the area between the adjuster discs thoroughly.
6. After installing a new variator belt, adjust at maximum and minimum speed.
You must check whether the belt runs at the base of one discs pack or
whether it runs over the edge of the disc in the other discs pack. Adjust the
variator upper disc stop nuts if necessary, or correct the variator settings. Fig. 1902
Servomotor (B) for adjusting threshing drum speed is mounted on support plate
(A)
Fig. 1903
Idler pulley compression spring (2) must be adjusted to shim pack dimension Q
= 150 mm.
Fig. 1904
1 - Chain wheel
2 - Compression spring
A - Support plate
B - Servomotor
C - Nuts
100-15
Threshing unit
100.10 - Dust plate and gaskets on threshing section
3 - Gasket
4 - Dust plate in front of threshing drum (to be removed for threshing maize)
5 - Dust plate with sealing strips (5.1) on threshing drum
6 - Dust plate (spring plate) behind straw walker, only for combine harvesters without Turbo separator.
7 - Deflector flap
8 - Gasket
9 - Gasket (felt strips)
Distance X between dust plate (4) and gaskets (5.1) must be no greater than 10 mm. A distance too great and defective dust plates
can cause higher levels of dust at feed passage inlet.
Fig. 1905 - Dust plate and gaskets on threshing section
100-16
Threshing unit
100.11 - Threshing drum speed reduction
I - Direct drive 1:1
Pulley (6) is connected to driver (7) by means of threaded pin (5).
II - Reduced speed 1:1.93
Driver (7) is connected to frame lateral wall by means of threaded pin M16 x 1.5 (5) (at about 11h position)
3 - Screw tightening torque 210 Nm
4 - Molykote Langterm 2PLU
5 - Threaded pin
6 - Pulley
7 - Driver
8 - Shims as required
IMPORTANT
For adaptation of the threshing drum in the channel fit shims (8) as needed between the bearing inner race and
the shaft flange. When assembling threshing drum shaft, first tighten screw M16 (3), then LH locking bush support.
Threaded pin (5) must be retightened after 10 h of operation at low speed and no later.
100-17
Threshing unit
Fig. 1906 - Threshing drum speed reduction
100-18
Threshing unit
100.11.1 - Conversion to reduced speed
Secure gear driver with threaded pin to lateral wall (at about 11h position)
1 - Threaded hole for M16 x 1.5 screws
Fig. 1907
100.11.2 - Oil change, oil level check

To drain the gear reducer oil turn the reduction gear so that screw (1) is at the
bottom.
Filling with oil: 1 l gearbox oil SAE 90, API GL 5
To check the oil level turn the reduction gear so that both shafts (planet wheel and
compensation mass) are positioned horizontally and the level plug (1) is at the
bottom left.
1 - Level and drain plug Fig. 1908
100.11.3 - Replacement of single parts

The reduction gear components can be changed individually, except for the fol-
lowing aspects.
In case renewal of the of V-belt pulley (1) or the entire casing, after having com-
pleted the installation procedure perform static balancing of speed reducer filled
with about 1 litre of oil, running the unit at a minimum speed of 300 rpm. (balancing
holes on V-belt pulley bar with R 202 Ø 20).
It is not permitted to perform balancing on a test bench or balancing without oil.
Driver (2) is balanced separately together with threaded pin (3) and ring (4).
1 - V-belt pulley
2 - Driver Fig. 1909
3 - Threaded pin
4 - Ring
100-19
Threshing unit
100.12 - Turbo separator
Concave to threshing drum clearance in the lowest position.
Distance B - last bar 25 mm
Distance A - first bar approx. 30 mm
1. Assembly dimension for turbo separator shaft
2. Securing bush support tightening torque, LH and RH side, 140 Nm
3. Fixing of rotor bars with M12x30 hex socket screw and support disc 1601
5594
Tightening torque 120 Nm with 10.9 screws and nuts
4. Adjustment movement
5. The straw guide rake must rest on the separator concave
6. separator concave
DANGER
Fig. 1910
Always change the rotor bars in pairs
100.12.1 - Turbo separator - Basic electrical selector setting

1. Servomotor
2. Actuator tube
3. Strut
4. Support plate
5. Guide plates
Basic adjustment:
Assembly dimension for retracted servomotor: 405 mm
Clearance of the turbo separator drum from the separator grille: 30 mm (to con-
cave inlet)
Adjust LH and RH tie-rods (3) with the servomotor fully retracted:
The basic adjustment of the turbo separator drum can be checked approximately
from the exterior:
lVertical clearance between bearing plate (4) and guide plates (5) = about
5 mm. Fig. 1911
Control and adjustment of the servomotor are identical to the situation for adjust-
ment of the concave.
100.12.2 - Turbo separator drive

Drive is provided by a duplex V-belt from pulley (A) to pulley (B)
Pulleys A and B have two different diameters to provide two speed transmission
ratios.
The choice of the speed range and distance of the drum is made on the basis of
the threshing table.
Table 161
Speed range Rpm V-belt on

pulley pulley
I 790 ± 20 A1 B1
II 380 ± 20 A2 B2 Fig. 1912
DANGER
For threshing of maize or sunflowers adjust to low speed
100-20
Threshing unit
Repositioning the V-belt:
Release idler pulley C, (attach tube to pin (1)) lock with nut (2) and tensioner arm.
Fig. 1913
100-21
Threshing unit
100.13 - Installing the maize concave
When the machine is prepared for threshing maize, disassemble standard stone trap (3) and front plate (4).
The stone trap fixing rods (6) are inserted in the infeed plate (2).
For threshing of maize, remove dust protection plate (7).
Attach maize concave to lower hole (1) in front drive bracket.
Table 162
- Basic concave adjustment
Maize concave version Concave input Concave output last
bar
Maize concave (10 rasp bars) 3. bar 30 mm 10 mm
CCM concave 2. round rod 30 mm 10 mm
100-22
Threshing unit
100.14 - Threshing drum - maize harvesting, welding of threshing
drum beater bars
1. Weld bead start
2. Weld the drum bars with washers
Fig. 1914
100-23
Threshing unit
100-24
110 - Cleaning unit
110-1
Cleaning unit
110.1 - Straw walkers drive
Straw walkers shaft transmission by means of V-belt. Preload of compression
spring (1) for 70 mm idler roller. The height of Idler roller (2) is adjustable. If neces-
sary, the speed of the straw walkers can be adjusted by installing supplementary
shims (3) on the V-belt rear pulley.
1. Compression spring
2. Idler roller
3. Shims
Fig. 1915
110-2
Cleaning unit
110.2 - Straw walker transmission adjustment
Idler roller loaded by strong spring
1 - Spring preload 72 mm.
Fig. 1916
Idler roller for sieves crankshaft drive belt.

2 - Spring preload of 65 mm.
Fig. 1917
Clamp wheel for grain auger drive chain.

3 - Spring preload of 60 mm.
Fig. 1918
Slipping clutch as overload protection device for grain tank auger. Reaction torque
of approx. 400 Nm with 22 mm preload of the plate springs.
Fig. 1919
110-3
Cleaning unit
110.3 - Straw walker supports assembly
Precautions for refitting operations:
l Degrease shaft and bush
l Bearing inner races must be coated with oil (hydraulic oil)
l Fit bushes by tapping axially with a mallet
l Ensure the two halves of the locking bushes are identically distanced from each other.
Fig. 1920 - Supports assembly

Key
110-4
Cleaning unit
1. Nut
Fit outer bearings with the ringnut facing the centre of the combine.
2. Degrease bearings seat and outer ring.
The outer race is equipped with a uniform protection 3x based on a liquid protectant.
3. Ringnut tightening:
Preload to 50 Nm.
Tighten additionally through 180 degrees.
Ringnut wrench 0041 6050.
4. Cover plate.
A cover plate is installed on all the bearings of the straw walker front shaft in combine harvesters without turbo separator.
110-5
Cleaning unit
110.4 - Assembling straw walker shafts and straw walker
1. Position the shafts of the straw walkers axially at the centre of the frame so that the distance of the outer bearings of the straw
walkers is identical with respect to the side wall. The distance of the rear shaft of the straw walkers with respect to the front
shaft must be identical on the left and right (use the paint mark of the bearings rear shield as a point of reference).
2. Fit all straw walkers and tighten straw walker front bearings; tighten the straw walker rear bearing screws only by hand. Rotate
the straw walker shafts by hand to activate elbows synchronous operation.
3. Tighten the straw walker external bearings and rotate the shafts by hand. The force applied must remain constant. If this is
not the case loosen the bearings again and rotate the rear shaft slightly to activate exact synchronous operation with respect
to the front shaft. Repeat the procedure.
If the slots in the rear support frame are insufficient, move the rear shaft to a horizontal position (longitudinal slots in the straw
hood in specific models).
4. Tighten the other straw walker bearings in sequence and rotate the shafts by hand. In bearings that are still loose, while the
shaft is turning there must be no movement between the bearing shield and the straw walker support stands.
If you encounter cyclic stiffness while rotating the straw walkers, the probable cause is that the straw walker shaft is bent and
distorted (if there are no nuts on the bearings).
Renew bent or distorted straw walker shafts.
110.4.1 - Assembly dimensions and assembly of straw walker shafts and straw walker.
Fig. 1921
Key
1. Straw walker rear shaft
2. Straw walker front shaft
3. The long end of the shaft must be on the right hand side.
110-6
Cleaning unit
Table 163
Types of Number Values Tightening torque
combine of straw a b c d e
harvest- walkers
ers
5650 - 5660 5 206 206 252 237 1008 Preload torque 50 Nm
5670 - 5690 6 206 206 252 237 1260 + rotation angle
110-7
Cleaning unit
110.5 - Installation of straw walker rakes
Fig. 1922 - Straw walker rakes

Straw walker rakes arrangement
l 8 rakes for 5650 H - 5660 H / HTS - 5665 HTS
l 9 rakes for 5690 H / HTS - 5695 HTS
110-8
Cleaning unit
110.6 - Sieve crankshaft
110.6.1 - Installation of the sieves crankshaft
1 - Special ringnut wrench: 0043 6070
Fig. 1923 - Installation of the sieves crankshaft

110.6.2 - Connecting rod mechanism
1 - Stand
2 - Support bracket
2.1 - M14 screw, 10.9
2.2 - M10 screws
3 - Swinging lever
4 - Connecting rod
5 - Head bearing
Support bracket (2) must be supported in parallel to the front side of the shaft by stand (1).
First fit screw M14 (2.1) and then check the position of the support brackets in accordance with the screwing points on the frame. If
necessary, adjust the support bracket or fit shims underneath it.
110-9
Cleaning unit
Fig. 1924 - Connecting rod mechanism
110-10
Cleaning unit
110.7 - Stepped gain pan with removable segments
When fitting segment plates (2), ensure they are lodged correctly in the relative
clamp (1.1). The segment plates are installed in stepped grain pan frame (1)
through front cover (3).
Front cover (3) is fixed to stepped grain pan frame by means of three nuts (4).
Fig. 1925
110.7.1 - Fitting the stepped grain pan swinging arm

A: Standard Combine Harvester
B: Balance Combine Harvester
5 - Swinging arm
6 - Distance plate
7 - Distance tube
Installation and length (L) of stepped grain pan (5) swinging arms is different for Standard and Balance combine harvesters.
A: Standard Combine Harvester L = 232 mm
A distance plate (6) is interposed between the lower bearing cover and the frame
support stand.
Fig. 1926
B: Balance Combine Harvester: L = 210 mm

Distance tube (7) is fitted between the top bearing shield and stepped grain pan.
Fig. 1927
110-11
Cleaning unit
110.8 - Stepped grain pan and sieve box with transmission
Fig. 1928 - Sieve box with transmission

Key
1. Connecting rod - Basic setting 584 mm
2. Swinging lever
3. Support stand - horizontally adjustable on left hand side
4. Stepped grain pan
4.1. Stepped grain pan swinging arm
5. Top sieve box
6. Bottom sieve box
7. Straw walker returns pan
8. Suspension for stepped grain pan, bottom sieve box and straw walker returns pan
9. Swinging arm for top sieve box and straw walkers returns pan
In the longitudinal direction, the stepped grain pan and sieve box parts must swing in parallel to the frame. Sliding wooden adjustment
elements (a) must not chafe against the frame side walls. If necessary, alter the length of connecting rod (1) to the left or to the right.
Moreover, support frame (2) on the LH side can be moved slightly in the horizontal plane in the relative slots.
During assembly procedures the stepped grain pan and the upper and lower parts of the sieve box must be perfectly aligned (4, 5,
6) in an axial direction to ensure the presence of sufficient clearance between mobile elements.
Compensate for end float of the bushes support (2.1) with spacers.
DANGER
The rubber mounts for the suspensions (8) of the stepped grain pan, bottom sieve box and straw walker returns pan,
and the M12 screws (9.1) of oscillating arm (9) must be tightened in the centre of oscillating lever (2).
Swinging arms (9) must be installed without preload. Sliding wooden adjusters (b) of the straw walker returns pan must not rest
against frame side walls. If necessary, move support frame (9.2).
110-12
Cleaning unit
DANGER
Observe different length L of the grain pan oscillating arm for Standard and Balance combine harvesters: Standard: L
= 232 mm - Balance: L = 210 mm
The Graepel frogmouth sieve (5.1) is screwed to the top sieve box (5) and features adjustable inclination.
The frogmouth sieve inclination angle must be parallel to the stepped grain pan (4).
Fig. 1929 - Sieve box with transmission

Key
1. Connecting rod - Basic setting 584 mm
2. Swinging lever
3. Support stand - horizontally adjustable on left hand side
4. Stepped grain pan
4.1. Stepped grain pan swinging arm
5. Top sieve box
6. Bottom sieve box
7. Straw walker returns pan
8. Suspension for stepped grain pan, bottom sieve box and straw walker returns pan
9. Swinging arm for top sieve box and straw walkers returns pan
9.1. M12 screws
9.2. Supporting frame
110-13
Cleaning unit
110.9 - Fan speed variator
1 - Servomotor
2 - Adjustable variator
3 - Tensioning device for variator lower belt
90 mm spring preload with max. rpm
4 - Compression spring
5 - Adjusting nuts
6 - Nuts
7 - Support pin
8 - Sliding washer
9 - Fixed washers
10 - Grease nipple Fig. 1930
110.9.1 - Speed variator adjustments

I Restore variator preload:
l Set adjustable variator (2) to central position.
l Loosen pivot pins.
l Restore correct tension of the belt by means of adjuster nuts (5), turning the threshing mechanism.
l Re-tighten pivot pins (7).
II Adjust the control zone:
l Set adjustable variator to end position.
(maximum and minimum speed).
l A gap of at least 1 mm must be left between sliding washer (8) and fixed washers (9).
l Set control range of servomotor (1) with reference to motor baseplate by means of nuts (6).
l Fully tighten nuts (6).
DANGER
Check control range with each belt change.
110.9.2 - Operation and maintenance recommendations:

The speed variator should not run at same speed for prolonged periods of time.
The speed of the winnowing fan should be slightly adjusted at least once a day.
The sliding surfaces of the sliding washer must be lubricated at least one a day:
Grease nipple (10).
110-14
Cleaning unit
Fig. 1931 - Fan speed variator
110-15
Cleaning unit
110.10 - Fan - shroud
Fig. 1932 - Fan

Key
1. Fan (12 mm between fan and plates)
2. Shim
3. Bottom diffuser element
4. Top diffuser element
5. Adjustment lever to left and to right
6. Adjustment scale to left and to right
7. Cover
Use adjustment lever (5) to set up the upper diffuser element (4) by inclining it about centre of rotation (z). Value of digits on
adjustment scale (6) corresponds to distance between lower edge of diffuser element (4) and top of wind tunnel.
The adjustment affects the amount of air turbulence in the drop step between pan and sieve box.
Low scale value: less air turbulence in drop step
High scale value: more air turbulence in drop step
Scale value is factory set to 20
For light grain crops (e.g. rape, oats) in several circumstances a setting to a lower value of scale can be preferable (e.g. 15).
Ensure the adjustment is the same on the left and on the right.
Table 164
Control sequence with respect to adjustment of the installation position:
a Parallelism of fan wheel (1) with respect to trough and central
axial installation.
b Parallelism of sealing plate (2) with respect to fan wheel. Sealing
plate (2) must rest on the shroud over its entire length.
c Parallel position of diffuser wedges (3, 4) in the wind shroud.
110-16
Cleaning unit
110.11 - Tailings elevator (returns elevator)
Fig. 1933 - Tailings elevator (returns elevator)

Key
1. Grain auger
2. Bar rotor
3. Stepped plate - low speed for threshing maize and beans
4. Cover with interchangeable friction insert - smooth or grooved
5. LH and RH feeler switch (close contact) for cover control (when cover is closed, switch is pressed)
6. Speed control - Distance between sensor (6) and pulse transducer (6.1): 4mm
Before fitting the bar rotor (2) on the auger shaft, orient it at the centre with respect
to the guard.
DANGER
Observe proper mounting position: smooth surface of bars must be
facing rotation sensor.
Replace damaged rotor bars - risk of damage caused by imbalance.

DANGER
Note position of pressure tab (4.1) for returns elevator flap (4). The
short leg of the tab must press against flap (4).
Compression spring preload 35 mm. Fig. 1934
110-17
Cleaning unit
110.12 - Electric sieve adjustment
DANGER
Pay attention to the assembly position of the lever struts. The top sieve struts are different from the bottom sieve struts.
Fig. 1935 - Electric sieve adjustment

Key
1. Servomotor (stroke 115mm) with integrated potentiometer (1kΩ)
2. Drive shaft, integrated in the sieve box
3. Strut of drive shaft in top sieve box
4. Strut of drive shaft in bottom sieve box
5. Ball pin for adjustment of sieve box (1 ball pin for each sieve unit)
6. Cover
7. Adjustment device on each sieve unit
8. Adjustable bar for sieve blades
9. Top and bottom sieve
110-18
Cleaning unit
110.12.1 - Control device function
The stroke of servomotor (1) is transmitted by means of drive shaft (2) through cover (6) on adjustable bar (8) of sieves (9).
The sieve blades open when the servomotor is retracted.
The sieve blades close when the servomotor is extended.
110.12.2 - Control device basic setting
With the sieve blades closed cover (6) must protrude above the front corner of the sieve by 42 mm. With the sieves installed the
servomotor must be in its fully extended position when the sieve box blades are closed.
110.12.3 - Removing the sieves
l Loosen the sieve fixings (always loosen both sieves, even when only one of them is to be disassembled).
l Activate the pushbutton to open the sieve until the servomotor is in its fully retracted position; Ball pin (5) oscillates outside
cover (6).
l The sieves can now be extracted.
110.12.4 - Installing the sieves: (the servomotor must be fully retracted)
Fig. 1936 - Electric sieve adjustment

l Clean the sieve guides, removing grain and chaff, paying special attention to the sieve front stop.
l Push the sieve into the sieve box until cover (6) engages with ball pin (5).
l Press the pushbutton to “close the sieve”; when you do this, check whether the sieve is pulled forward or whether the blades
close.
l Install the sieve fasteners.
l Press the relevant pushbutton to open the top and bottom sieves fully and then close them half-way: check to ensure that
opening of the right and left sieves is identical.
If opening of the sieves is not identical, adjust the cover on the adjuster device.
For calibration of the top and bottom sieve adjustment: (see Teris/TCS operating instructions).
110-19
Cleaning unit
110-20
120 - Grain tank - Elevator
120-1
Grain tank - Elevator
120.1 - Grain elevator with elevator head
Fig. 1937 - Grain elevator

Key
1. Grain tank delivery auger
2. Elevator chain fixing plates
3. Elevator chain gear
4. Distance collar
5. Gear Z13, or Z18 for increased speed for threshing maize
6. Cross coupling
6.1. Union - intake auger and engagement shaft
7. Elevator box
8. Elevator chain
9. Grain auger
10. Ratchet clutch
120-2
l When fitting, push grain auger (9) fully to right so that distance tube (4) is on the internal ring of the support. First tighten the
right hand side of the collar.
l Elevator chain (8) must be brought to the central position of elevator box by means of chain gears (3).
l If necessary, adjust chain gears (3) in elevator housing, or shorten distance tubes (4).
Elevator chain tightening
Adjust fixing plates (2) uniformly on the left and right by means of the fixing screws.
Tighten elevator chain only to the point at which the links of the lower chain (3) can
still be pushed sideways.
The ratchet clutch Belleville springs are fitted counterclockwise and individually
on the hub.
Fig. 1938
120-3
120.2 - Elevator head, speed control
120.2.1 - Speed control
Fig. 1939 - Elevator head

Key
1. Hermetic seal
2. Elevator chain fixing plate
3. Elevator head
4. Hermetic seal between elevator box and grain tank floor
5. Elevator chain direction of travel
6. Pulse generator
120-4
7. Inductive sensor (distance from pulse generator 4 mm)
120-5
120.3 - Elevator head for grain tank extension
Fig. 1940 - Elevator head

Key
1. Filling pipe with auger, moves upwards when the grain tank extension is deployed
2. Straight support
2.1. Seal plate
3. Auger flights
4. Short intake auger
5. Clutch shaft
When fitting the auger observe proper mounting position of intake auger and auger flights (3) against one another.
120-6
Fig. 1941 - Elevator head support

Key
l 2 - Straight support
m 2.1 - Seal plate
120-7
120.4 - Grain tank clutch
Fig. 1942 - Grain tank clutch

Key
1. Fixing clamp
2. Belt guides
3. Compression spring
4. Servomotor
5. Stop nut
120-8
120.4.1 - Controls in engaged position
l Spring A preload = 135 mm (Adjustment on the device under load)
l Servomotor B stroke = 60 mm (Stop nuts (5) adjustment). Tighten nuts fully home.
l Distance of belt guides (2) to pulley 8 mm.
120-9
120.5 - Emptying the grain tank
1. Grain tank discharge auger
2. Cover plate
3. RH support for cover plate
4. Control plate
With control plates (4) the load flow to the intake auger (1) is limited in accordance
with the flowability of the crop. In case of overloading of the emptying system (pul-
leys slipping), the control plates must be positioned lower down.
With low flowability crops (e.g. grass seeds) you can attach cover plate (2) on the
RH side in the upper hole of support (3).
Fig. 1943
120-10
120.6 - Grain discharge system
Fig. 1944 - Discharge system

Key
1. Lower bevel gear
2. Swivel crown
3. Vertical auger
4. Calibrated screw M12, 10.9
5. Belleville spring
6. Retaining nut M12
7. Upper bevel gear
7.1. Fixing bolts
8. Cross pin with bush
9. Grain tank discharge auger (separate in 5 m pipe)
120-11

10. Straight support for 5 m pipe
11. Bearing
12. Supporting washers
13. Spring pin

1. When fitting auger into discharge pipe observe proper mounting position of vertical auger (10) and auger coils. Adjust the
protrusion of 88 mm from the auger shaft to the emptying pipe with a corresponding number of washers (12) between bearing
(11) and spring pin (13).
2. At the time of assembly of the emptying pipe on the elbow pay attention to the pitch position of the auger on the vertical auger
(3) and the auger tube (9).
120-12
3. After refitting the emptying pipe, loosen fixing screws (7.1) for bevel gear (7). Rotate emptying system. This allows the bevel
gears to align centrally on the auger.
DANGER
Re-tighten fixing screws (7.1). Tighten the M12 fixing nut (6) on calibrated screw (4) only to the degree necessary to
clamp the Belleville spring (5). Secure the nut with Loctite. Observe the proper mounting position: Belleville spring (5)
and fixing nut (6) must be fitted in the corresponding spot facing of the auger shaft.
120-13
120.7 - Bevel gear in elbow pipe
1 - Fit the pinion holder shafts in such a way that the holes are offset by 1 tooth
with respect to each other
2 - Adjust backlash to 0.2 mm by means of shims between the casing cover and
the bearing.
3 - Fill void between casing cover and bearing with grease.
Quantity of grease in casing, approximately 250 g of EP gear grease
Fig. 1946
120.7.1 - Lower bevel gear

Table 165
Oil filling -
Gearbox oil SAE 90, GL5 0.75 l
Teeth backlash 0.15 - 0.40 mm
Rolling resistance torque of input shaft 0.4 - 0.8 Nm
(1)
Rolling resistance torque of output shaft 0.1 - 0.4 Nm
(2)
Fig. 1947
3 - Fill void between bearing and shaft gasket on output shaft (2) with grease.
4 - Oil level plug
5 - Grease nipple
DANGER
After changing pinion shafts, bevel gears or bearings, check gear
tooth flanks.
Fig. 1948
120-14
120.8 - Support for grain tank pipe, block
By means of inductive sensor (5) message “Grain tank pipe swung outboard” appears in cab
Inductive sensor (4) remains ON in conjunction with electronic control for engagement of grain tank: with grain tank pipe swung in-
board, grain tank clutch disengages automatically if the operator has not already disengaged it.
DANGER
If the sensor is defective or disconnected (5), the grain tank clutch control is blocked.
DANGER
Before driving on public roads, make sure grain tank handle (2) is engaged in the closed position!
120-15
Fig. 1949 - Support for grain tank pipe

Key
1. Support, height-adjustable
2. Handle
3. Pull spring
4. Release cylinder
5. Inductive sensor
120-16
120.8.1 - Swivel grain tank pipe hydraulic control
Adjust support screw (2) up to the side of the frame.
Adjust head (4) on piston connecting rod so that discharge pipe fully reaches support (Pos. 1 above).
Fig. 1950 - Swivel grain tank pipe hydraulic control

Key
1. Console
2. Securing screw with flexible protection pipe
3. Lift cylinder
4. Head
5. Gear reversal lever
6. Vertical tube
120-17
120.9 - Grain tank level sensors
1. 4/4 grain level sensor (Full)
2. 3/4 grain level sensor (75%)
3. Grain tank cover sensor
4. Grain tank cover CLOSED and grain tank extension LOWERED position
sensor.
Fig. 1951
Grain level transducers (1) and (2) must be installed so that a distance of at least 25 mm is maintained between the front face of the
transducer and the centrelines of the clamps.
Ensure that the grain level transducers are cleaned regularly.
If the message “Grain tank full” continues to be displayed even when the tank has been emptied, inspect the transducer and remove
any dust or chaff.
120-18
Fig. 1952 - Grain tank cover position sensor
120-19
120-20
130 - Cutting table
130-1
Cutting table
130.1 - Controls diagram, speed
Fig. 1953 - Controls diagram, speed

Speed
1. Transmission shaft: 480 ± 20 min-1
2. Reel variator: 260 - 860 rpm
3. Double gear (Series Z55/7)
4. Reel with two sprockets (3) Z55/7: 15 - 49 rpm
with double sprocket (3) Z75/7: 11 - 36 rpm
5. Blade mechanism with 80-90 mm stroke: 600 ± 20 rpm
130 mm stroke: 580 ± 20 rpm
6. Intake auger 192 rpm
Reduced speed: 172 rpm
130-2
Cutting table
130.2 - Cutting table drive, reel variator
Fig. 1954 - Cutting table drive

Key
l 4 - Pressure disc
m 4.1 - Lock nut
l 6 - Tie-rod
l 7 - Washer
l 8 - Movement screw
l 9 - Spacer bush
l 10 - Circlip
l 11 - Driver
l 12 - Swinging motor
Control dimension (63.5 mm) for belt alignment, measured from fixed pulley to fixed pulley.
Variator movement control: (V-belt is disassembled)
Retract tie-rod (6) until adjuster screw (8) locks using servomotor. Screw pressure plate (4) onto tie rod (6) in such a way that when
fully home half pulleys (X) remain at distance of 1 mm. Secure (4) pressure disc with M10 fixing nut (4.1).
130-3
Cutting table
Fig. 1955 - Pick-up reel speed variator

Key
1. Drive shaft
2. Variator - actuator assembly
2.1. Intake auger drive sprocket
2.2. M16 threaded hole to press sliding disc when changing drive belt
3. Variator assembly - driven
3.1. Reel drive sprocket
4. Pressure disc
4.1. Lock nut
5. Variator assembly support sleeve
5.1. Fixing bolt
6. Tie-rod
7. Washer
8. Movement screw
9. Spacer bush
10. Circlip
11. Driver
130-4
Cutting table
130.3 - Slipping clutch for intake auger and reel
A Slipping clutch - intake auger, 3/4” sprocket
Fig. 1956
B Reel slipping clutch
Fig. 1957
130-5
Cutting table
1. Hub
2. Pressure plate
3. Sprocket
4. Friction linings (on clutch C bevel (a) of the linings must face the pressure
plate)
5. Bearing bush, fitted with grease
6. Round head screws, class 8.8
7. Stop latch, locks clutch in reversing mode
Fig. 1958
Slipping torque set in workshop:

Slipping clutch
A: 700 Nm
B: 350 Nm
After prolonged disuse of the combine harvester release and slide slipping clutch.
130-6
Cutting table
130.4 - Intake auger
Fig. 1959 - Intake auger

Key
l 1 - Transmission shaft
l 2 - Support plate
l 3 - Feed blade protection prong adjustable segment
l 4 - Support shaft and camshaft, right
l 5 - Feed blade protection prong shaft
l 6 - Intermediate shaft with bearing
l 7 - Single blade protection prong
l 8 - Blade protection prong in middle of auger
l 12 - Lock piece
Remove intake auger: remove adjustable segment (3) and supporting plate (2) on left and right.
Slide auger out of cutting table floor on right hand side.
Fig. 1960 - Intake auger
130-7
Cutting table
Key
l 4 - Support shaft and camshaft, right
l 5 - Feeding blade protection prong shaft
l 6 - Intermediate shaft with bearing
l 7 - Single blade protection prong
l 8 - Blade protection prong in middle of auger
l 9 - Blade protection prong hub
l 10 - Spring pin
l 11 - Locking pin (grain loss safety device)
l 12 - Lock part
l 13 - Lock screw M12x50, 10.9
l 14 - Calibrated screw M12x70; 10.9
130-8
Cutting table
130.5 - Intake auger settings
1 - Intake auger support plate
2 - Adjustable segment to control the feed blade guard tooth
Fig. 1961
3 - Scrapers, 2 parts
4 - Feed blade guard tooth
5 - Camshaft for feed blade guard tooth
Fig. 1962
The standard distance between the auger and the base of the cutting table is 6 - 12 mm. For thick stalk crops (e.g. rapeseed, broad
beans) it may be necessary to set the auger higher, at a distance of approximately 20 mm. Adjustment of the height is performed at
the left and right of support plate (1). This means that scrapers (3) must be further adjusted: set the scrapers as close as possible to
the auger flights to prevent fouling.
With adjustable segment (2) camshaft (5) for the feed teeth is caused to rotate.
6 - Extension for auger flight (installed on combine harvesters with 5 straw walk-
ers)
7 - Feed passage angle bracket between feed blade guard teeth:
- 1x long feed angle bracket, 2x feed angle bracket, angle bracket
toothed feed passage angle bracket as from 2001 construction.
Fig. 1963
130-9
Cutting table
130.6 - Blade mechanism - 80 mm stroke
l up to cutting table No. 29107 from 3 m to 7.20 m
l from cutting table No. 29108 from 3 m to 4.80 m
Fig. 1964 - Blade mechanism

Key
l 1 - V-belt pulley halves
m 1.1 - Shims, 4 items
l 2 - Guard
l 3 - Rotor
l 4 - Crank (coloured mark on toothspace for connecting rod pin)
m 4.1 - Connecting rod pin
l 5 - Needle roller bearing

l 6 - Oil seal
l 7 - Lubricating grease hole, ø 6 mm
l 8 - Circlip
l 9 - Pinion (highlighted by a dot on the front)
l 10 - Ring gear
l 11 - Connecting rod head
l 12 - Main bearing
l 13 - Shims
l X - The bearings are glued to the outer race, DW 59
l H - Connecting rod pin direction of travel (4.1)
130-10
Cutting table
Approximate grease filling capacity 100 g of Lithium grease K2. Lubrication every 200 operating hours.

Key
l 1 - V-belt pulley halves
m 1.1 - Shims, 4 items
l 3 - Rotor
l 4 - Crank (coloured mark on toothspace for crank pin)
l 5 - Needle roller bearing
l 6 - Oil seal
l 8 - Circlip
l 9 - Pinion (highlighted by a dot on the front)
l 12 - Main bearing
l 13 - Shims
130.6.1 - Transmission assembly

NOTE
For correct assembly of the transmission connecting rod pin (4.1) must move in parallel with the holes for screws A-B
(longer side) in the casing.
1. Assembly of pinion (9) and crank (4) in rotor (3):

The indicated tooth of pinion (9) must be opposite the toothspace marked on crank (4).
2. Fitting rotor (3) with crank (4) in casing (2):
Turn rotor crank (4) in rotor (3) so that rotor, lever and connecting rod pin central notches are aligned (direction of travel H),
and connecting rod pin (4.1) is facing exterior of rotor.
In this position fit rotor in casing making sure that connecting rod pin (4.1) is facing exactly towards casing side B-C. Pinion (9)
and ring gear (10) must be able to co penetrate without rotation.
Before installing, pack bearing and ring gear with grease.
130-11
Cutting table
130.7 - Blade mechanism - 85 mm stroke

Key
l 1 - V-belt pulley halves (centrifugal weight)
l 2 - Shims (2x2 mm between discs, 1x2 mm, 1x1 mm outside)
l 3 - Casing
l 4 - Rotor
l 5 - Ring gear
m 5.1* - Toroidal ring, seal disc
l 6 - Pinion shaft, (for repair operations replace with Pos. 5)

l 7 - Underside of crank
l 8 - M8x35 screws; 12.9; with threadlocker
l 9 - M10x35 screws, 12.9
l 10 - Bearing support
l 11 - Head bearing
l H - Head bearing direction of travel
For assembly the 4 dots (P) must be stacked one above the other (1 for casing, 2 for rotors, 1 for underside of crank)
Before installing, pack casing and ring gear with grease. Subsequently, lubricate head bearing and casing with Lithium grease K2
every 50 working hours.
*) In 2001 production the attachment of ring gear (5) was changed on the screw connection from the internal side of the crankcase.
The toroidal ring and seal disc 5.1 are not provided anymore.
130-12
Cutting table

Key
l 4 - Rotor
l 5 - Ring gear
m 5.1* - Toroidal ring, seal disc
l 6 - Pinion shaft, (for repair operations replace with Pos. 5)

l 7 - Underside of crank
l 8 - M8x35 screws; 12.9; with threadlocker
l 9 - M10x35 screws, 12.9
l 10 - Bearing support
l 11 - Head bearing
130-13
Cutting table
130.8 - Blade control transmission check; changing the blade
Fig. 1968 - Blade drive transmission check

Key
1. Blade head
2. M6 x 28 - 10.9 screws, tightening torque 15 Nm
3. M6 x 18 - 10.9 screws, tightening torque 15 Nm
4. Pressure nut
5. Rubber bush
6. Head bearing
7. Bearing support
8. M10 x 35 screws
1. Synchronism of the head bearing (6) and the blade:
The head bearing (6) must move in parallel to the direction of travel of the blade. The blade head (1) must not be pushed either in
horizontal direction (X) or in vertical direction (Y) towards the blade guide in the cutter bar. For relative movement of head bearing (6)
in direction X the blade mechanism in the gearbox console must be rotated slightly.
2. Check stroke reversal: H = blade stroke.
For reversal of the blade stroke the overlap of the blade (Z) between the blade centre and the blade guard tooth centre must be iden-
tical. In the case of excessively large differences the blade mechanism in the gearbox console must be shifted in the stroke direction.
130-14
Cutting table
Fig. 1969 - Blade drive transmission check

Changing the blade, starting from the 5.40 m cutting table
l Loosen screws (8) on the bearing support.
l Remove blade with head bearing from cutter bar.
l Fit loosened head bearing in new blade.
l Fasten screws (8). Tightening torque 80 Nm.
l Align head of blade (1) on head bearing (6) in a vertical direction.
l Tighten screw (1.1) making sure the blade head does not move any longer on the head bearing.
130-15
Cutting table
130.9 - Assembly of potentiometer for cutting table adjustment
1. Feeler skid (1 part for level control, 3 parts for auto-control)
2. Skid support
3. Support plate
4. Potentiometer centring ring
5. Driver
6. Potentiometer
7. Screw M5 with spring washer and disc
Fig. 1970
Observe mounting position of potentiometers. The plug connection must be at the

top while the guard must be screwed fully down in the centre of the slots.
At the time of assembly make sure that the oscillation angle A (approx. 30°) of the
feeler skid is within rotation angle B (120°) of the potentiometer rotating body (oth-
erwise the potentiometer will be damaged). A return spring in the potentiometer
pulls the rotating body towards the lower position of the feeler skid.
Fig. 1971
Driving pin (5) must not jam in the potentiometer in either a radial or axial direction:
check the depth of the groove of the feeler skid and the length of driving pin (5). Do
not overtighten screw (7) (may result in seizure of the potentiometer).
Fig. 1972
Potentiometers control (see also chapter H):

Signal voltage between 2.4 V and 6.8 V with feeler skid raised or freely suspended.
If the voltage range is above or below the prescribed limits, turn the potentiometer case in the relative slots.
From the lowest to the highest position of the feeler skid the signal voltage should change by more than 2 V. Swing angle of the feeler
skids approx. 30°.
130-16
Cutting table
130.10 - Connectors assignment, 13 pin socket
Fig. 1973 - Power socket - Execution with level control (1 feeler guide)
130-17
Cutting table
130.11 - Diagram of pipelines and connection diagram for hydrau-
lic system on rape header
Fig. 1974 - Pipes diagram

Key
1. Hydraulic pump, driven by blade mechanism (displacement 11cm3/rev)
3. Pressure relief valve 150 bar
4. Engagement valve for LH side blade
5. Hydraulic motor, right (absorption volume 12.5 cm3/rev)
6. Hydraulic motor, left (absorption volume 12.5 cm3/rev)
7. Pressurised pipes
8. Return pipes
9. Oil discharge line for RH hydraulic motor (not present if exclusively RH lateral blade is fitted)
10. LED in engagement valve connector
With engagement valve (4) not powered only hydraulic motor (5) is running. With the engagement valve powered both hydraulic
motors are activated in sequence.
130-18
Cutting table
Fig. 1975 - Connection diagram

Key
1. Hydraulic pump, driven by blade mechanism (displacement 11cm3/rev)
3. Pressure relief valve 150 bar
4. Engagement valve for LH side blade
5. Hydraulic motor, right (absorption volume 12.5 cm3/rev)
6. Hydraulic motor, left (absorption volume 12.5 cm3/rev)
130-19
Cutting table
130.12 - Rape header drive
Fig. 1976 - A HMW 1131 - 1133 up to 7.20 m

Key
1. Blade mechanism on rape header
2. Hydraulic pump
2.1. Flexible coupling
3. Idler roller
4. Idler pulley
5. Reel loading arm
6. Blade mechanism on cutting table
7. Freewheel V-belt pulley
7.1. Bearing
130-20
Cutting table
Fig. 1977 - B HMW 1133 8.10 m and 9 m (Blade mechanism with angle gear)
Key
2. Hydraulic pump
3. Idler roller
4. Idler pulley
5. Reel loading arm
7.1. Bearing
Fig. 1978 - Rape header drive

Key
130-21
Cutting table
Fig. 1978 - Rape header drive

2. Hydraulic pump
3. Idler roller
4. Idler pulley
5. Reel loading arm
7.1. Bearing
When installing the rape header the pick-up reel lifting cylinders must be fitted in the lower hole (X) on the reel holder arm.
To drive the 8, 10 m and 9 m rape header the V-belt pulleys of the cutter bar mechanism are switched over. The V-belt pulley is in-
stalled on the cutting table blade mechanism with freewheel bearing (7).
130-22
140 - Attachments and
accessories
140-1
Attachments and accessories
140.1 - Straw guide plate adjustment
Fig. 1979 - Straw guide plate adjustment

Key
1. Lower straw guide plate
2. Front stop for lower straw guide plate
2.1. Lobed knob
3. Rear stop for lower straw guide plate
4. Upper straw guide plate
5. Coupling rod
6. Gas spring
7. Straw guide rake (for combines with 5 straw walkers fit only 1 rake)
Rear stop (3) and coupling rod (5) must be adjusted in such a way that the straw guide plates form a flat surface in the long straw
position (1 and 4). The bottom straw guide plate must rest on the top straw guide plate stop (a).
140-2
Fig. 1980 - Straw guide plate adjustment

Key
1. Lower straw guide plate
2. Front stop for lower straw guide plate
2.1. Lobed knob
140-3
140.2 - Straw chopper V-belt clutch
Fig. 1981 - V-belt clutch

Key
1. Clutch roller
2. Servomotor
3. Belt guides
4. Tensioning device
5. Locking nuts
140-4
140.2.1 - Clutch control
Fig. 1982 - V-belt clutch

Key
1. Clutch roller
2. Servomotor
3. Belt guides
4. Tensioning device
5. Locking nuts
Adjust spring A preload with belt engaged on potentiometer (10) of load relay.
Turn potentiometer clockwise to increase load current (smaller measurement A), turn it counterclockwise to decrease pressure cur-
rent (greater measurement A).
Adjust stroke B of servomotor (2) by means of nuts (5).
Remaining bellow measurement D = 115 mm (belt compression), move the relay shaft downwards.
Spring A preload = 110 mm
Stroke B = 60 mm
140-5
140.3 - Speed monitoring
Fig. 1983 - Straw guide plate position monitoring

Key
l 1 - Inductive switch (sensor)
l 2 - Pulse transmitter
l 3 - Straw guide plate position inductive switch
l 4 - Lower straw guide plate
l A - Straw guide plate in straw chopper engaged position
l B - Straw guide plate in straw chopper disengaged position
140-6
140.3.1 - Function of switch 3
Switch (3) activates or deactivates monitoring of the position and controls engagement of the straw chopper if straw guide plates (4)
are positioned in the “straw chopper engaged” mode (Position A).
140-7
140.4 - Conversion of straw chopper for threshing maize and sun-
flowers
Fig. 1984 - Straw chopper belt pulley

Key
l 1 - V-belt pulley to reduce speed
l 2 - V-belt pulley on straw chopper shaft
l 3 - Idler roller for KPAB straw chopper
1 - Speed reduction:
A larger diameter V-belt pulley (1) is fitted on straw chopper drive pulley (2). Set idler roller (3) higher on KPAB straw chopper.
1.1 - Speed reduction for KPAB straw chopper type SRX (5650H-5660HTS, 5680H-5690HTS from year of construction 2007):
Fit V-belt pulley (4) of intermediate shaft on straw chopper drive belt pulley (2).
Fig. 1985 - Straw chopper double pulley
140-8
Key
l 2 - V-belt pulley on straw chopper shaft
l 4 - Dual pulley on countershaft for KPAB SRX straw chopper
2 - Fitting a guide plate (6) in the straw hood as an extension of upper straw guide plate (5).
Detach connecting rod (7) for top straw guide plate.
3 - Remove back blade. The KPAB straw chopper is equipped with a cover plate (8) in front of the back blades housing.
Remove one blade every two.
4 - Disassemble friction bars (9) on bottom plate.
Fig. 1986 - Straw guide plate

Key
l 5 - Upper straw guide plate
l 6 - Guide plate
l 7 - Coupling rod
l 8 - Back blade cover plates for KPAB straw chopper
l 9 - Friction bar
140-9
140.5 - Lining for straw hood
140.5.1 - KPAB straw chopper
The straw hood lining (1) is an optional extra (see price list).
For thick rape stalks the flow of straw to the straw chopper must be increased
Table 166
- KPAB
5650 - 5660 1602 6810
5680 - 5690 1602 6812
Fig. 1987
140-10
140.6 - Electrically driven movement from straw guide plate to
straw chopper
Fig. 1988 - Electrically driven movement from straw guide plate to straw chopper
Key
l 1 - Servomotor for straw guide plate
m 1.1 - Servomotor control panel
l 2 - Straw hood connector

l A25 - CAN module
l F14 - Servomotor fuse
l F55 - CAN module fuse
l K17 - Relay for adjustment of straw guide plate to left
l K38 - Relay for adjustment of straw guide plate to right
l S49 - Straw guide plate adjustment switch with position indicators
l X26 - Control panel connector
l X145 - Engine frame connector
l X320 - Analog ground, isolated from multiple ground terminal in control cabinet
Before using for the fist time or after changing the servomotor perform calibration on the Commander Control for movement of the
straw chopper cover.
140-11
140-12
INDEX
“
“Serdia 3.5 level III” software 90-3
(
(Auxiliary equipment for threshing of flax) 70-9
1
1. During start-up of the system loud cavitation noises are emitted 60-68
10. In one direction of travel the speed changes in an irregular manner or traction force is reduced 60-70
2
2. Insufficient performance of the system at normal supply pressure and without any significant cavitation 60-68
noise
3
3. The system shuts down 60-68
4
4. Combine cannot reach top speed 60-68
5
5. When the travel lever is activated the combine fails to move forward or in reverse 60-69
6
6. Oil temperature too high, max. 95 °C 60-69
7
7. Zero point position cannot be reached 60-70
8
8. No feed pressure 60-70
9
9. Combine travels in only one direction 60-70
A
A - Vertical reel (cutter bar width 4.2 - 7.2 m) 60-39
A2 Pins assignment 90-46
I
INDEX
Actuator connector pins assignment 90-15
Adjusting maximum aperture stroke of injection pumps 30-287
Adjustment of the response time for automatic cutting angle control 90-70
Adjustment of valve clearance 20-33
Aero-Fit seat (air sprung) (optional) 80-11
Air conditioner 90-125
Air conditioner wiring loom - 540465 90-153
Air conditioning system components 80-30
Air conditioning system control panel 90-8
Air conditioning system filter-dryer wiring loom - 16050276 90-154
Air conditioning system: 0-3
Approved list of lubricating oil quality class - DEUTZ 10-19
Assembling straw walker shafts and straw walker 110-6
Assembling the reversing drum 100-8
Assembling the threshing drum 100-3
Assembly and disassembly of the camshaft (L3) 20-215
Assembly and disassembly of the crankshaft (L3) 20-112
Assembly and disassembly of the engine on the assembly stand (L3) 20-27
Assembly and disassembly of the flywheel (L3) 20-298
Assembly and disassembly of the fuel pressure regulating valve (L3) 30-83, 30-89
Assembly and disassembly of the oil intake pipe (L3) 30-95, 30-97
Assembly and disassembly of the spark plug (L3) 30-184, 30-187
Assembly and disassembly of the temperature sender (L3) 30-211, 30-233
Assembly dimensions and assembly of straw walker shafts and straw walker. 110-6
Assembly of potentiometer for cutting table adjustment 130-16
Assembly of the camshaft 20-223
Assembly of the camshaft bearings 20-200
Assembly of the connecting line 30-17, 30-25
Assembly of the connector box 20-186, 30-153, 30-
155, 30-157, 30-159,
30-299
Assembly of the crankshaft 20-116
Assembly of the crankshaft O-ring 20-274
Assembly of the cylinder head 20-49
Assembly of the cylinder liner 20-153
Assembly of the engine on the stand 20-27
Assembly of the exhaust manifold 30-4, 30-6, 30-8
Assembly of the fuel cutoff valve 30-194, 30-200
Assembly of the gear case cover 20-208, 20-213
Assembly of the hydraulic pump drive 30-150
Assembly of the injection pump 30-271
Assembly of the injection pump housing 30-269, 30-278
Assembly of the injection valve 30-69
Assembly of the injection valve on the injector tester 30-75
Assembly of the lubricant oil sump with gasket 20-292
Assembly of the of the fuel pressure regulating valve 30-85, 30-91
Assembly of the piston and connecting rod drum 20-128
Assembly of the piston cooling nozzle 20-140
Assembly of the piston pin bush 20-109
Assembly of the piston ring 20-138
Assembly of the spark plug 30-185, 30-189
Assembly of the starter 30-262
Assembly of the starter ring gear 30-148
Assembly of the supply air pipe 30-49, 30-53
Assembly of the tappet 20-205
Assembly warnings 60-55
Assignment of Commander Stick 90-50
Assignment of connections on the distribution circuit board, measurement values 90-83
Assignment of connectors EMR-D 90-56
Assignment of connectors for EMR-D (Bosch) control unit transverse tilt, A12 90-58
Assignment of operating elements 90-50
Attachment 90-119
Attachment electrical socket wiring loom - 0.015.5466.4/10 90-142
Axles maintenance tables 40-4
B
B - LH horizontal reel 60-39
BALANCE 90-110
BALANCE control connection logic: 60-27
Balance description 90-65
Balance II connectors assignment with automatic cutting angle system 90-77, 90-79
Balance II power supply diagram and cutting angle control 90-75
Balance lubricant control valve 50-14
Balance system 90-65
BALANCE wiring - 0.015.5467.4/10 90-145
II
INDEX
BALANCE WIRING LOOM - 16052333 90-151
Balance with automatic cutting angle 90-71
Balance-Shaft cutting angle transducer 90-73
Basic structure 60-53, 60-59
Battery negative lead - 16002046 90-130
Battery positive lead - 16002049 90-129
Belt clutches operation criteria 50-3
Belt clutches operation with the engine switched off 50-3
Belt guide for threshing drum slipping clutch 100-2
Bevel gear in elbow pipe 120-14
Blade control transmission check; changing the blade 130-14
Blade mechanism - 80 mm stroke 130-10
Blade mechanism - 85 mm stroke 130-12
Bleeding the air and checking the brake fluid level 40-11
BoWex clutch between hydrostatic pump and engine 60-55
Brake fluid level / linings check 40-8
Brake system, brake fluid: 0-3
Brakes, brake fluid safety instructions 40-3
Braking system 40-8
Bring the engine to valve overlap position 20-32
C
C - Grain tank discharge pipe 60-40
Cab - control pedals, parking brake 80-9
Cab - controls 80-13
Cab console wiring - TS8799/1, TS8799/3 90-131
Cab roof worklights wiring loom - 980060 90-152
Cab suspension 80-18
Cab, control devices, seats 80-11
Cab, control elements, emergency exit 80-14
Cab, controls 80-10
Cab, rear-view mirror control devices 80-15
Cable colours and connector colours identification. 90-6
Calculate the camshaft endfloat 20-225, 20-257
Calculate the piston pin clearance 20-99
Calibration 90-51
Calibration of the position controller 90-67
Cam adjustment 60-60
CAN-Bus system of Commander Control with central display installation procedure 90-21
Capacitive transducer for grain tank filling indicator 90-36
Care and maintenance 10-26
Central display 90-27
Central display and Commander Control 2000, control and command functions overview 90-29
Change oil 40-7
Changing the variator belt 100-15
Charge circuit wiring loom - 0.015.5464.4/10 90-141
Chassis wiring loom - 0.015.5474.4/10 90-166
Check 20-192, 20-194
Check / Adjust 90-75
Check and adjust the endfloat of the injection pump camshaft 20-234, 20-268, 30-292
Check and change final drive oil 40-6
Check and change final drive oil - BALANCE 40-7
Check of spring preload dimension L 10-22
Check of spring preload dimension R 10-24
Check of the maximum opening stroke of the injection pumps 30-283
Check of the piston pin bush 20-98
Check of the piston pin hole 20-133
Check of the sealing surface of the cylinder head 20-46
Check oil level 40-7, 80-33
Check the air-tightness 30-76
Check the camshaft 20-239
Check the camshaft (L3) 20-239
Check the camshaft bearings 20-197
Check the clearance of the tooth side of the injection pump camshaft gear wheel 20-232, 20-265
Check the clearance of the tooth side on the intermediate wheel (bench A) 20-229, 20-262
Check the clearance of the tooth side on the intermediate wheel (bench B) 20-229, 20-262
Check the coaxiality 20-87
Check the compression value (L3) 20-24
Check the connecting rod bearing hole 20-99
Check the connecting rod drum 20-105
Check the coupling clearance of the piston rings 20-137
Check the diameter of the connecting rod pins 20-87, 20-104
Check the diameter of the main bearing pins 20-87
Check the diameter of the valve head 20-58
III
INDEX
Check the diameter of the valve stem 20-58
Check the endfloat 20-76, 20-78
Check the endfloat of the crankshaft (crankshaft installed) (L3) 20-78
Check the endfloat of the crankshaft (crankshaft removed) (L3) 20-76
Check the endfloat of the piston ring 20-138
Check the hole of the housing for the inserted valve seat 20-70
Check the internal diameter of the connecting rod bearing shells 20-101
Check the opening pressure 30-76
Check the piston (L3) 20-133
Check the piston diameter 20-134
Check the piston rings and piston grooves 20-136
Check the piston rings and piston grooves (L3) 20-136
Check the protrusion of the cylinder liner 20-156
Check the tension of the belts and chains on the LH side 10-22
Check the tension of the belts and chains on the RH side 10-24
Check the thermostat (after removal) (L3) 30-126
Check the thickness of the valve edge 20-58
Check the valve guide 20-60, 20-62
Check the valve guide (L3) 20-60
Check the valve residual 20-68
Check the valve residual (L3) 20-68
Checking and adjusting maximum injection pump aperture stroke (L3) 30-283
Checking and adjusting the injection valves (L3) 30-75
Checking brake disc wear 40-11
Checking cylinder sleeve protrusion (L3) 20-156
Checking endfloat of rocker 20-38
Checking functions by means of Commander Control 2000 90-31
Checking piston pins 20-99
Checking rocker (exhaust valves) 20-42
Checking rocker (intake valves) 20-40
Checking rocker rod 20-43
Checking the camshaft gear wheel 20-240
Checking the cylinder sleeve (L3) 20-148
Checking the inserted valve seat 20-69
Checking the mobility of the jet needle 30-77
Checking the oil level 40-5, 40-6
Checking the tension of the V-belt using the belt tension gauge 30-259
Checking the valve guide seat hole 20-63
Closing components 30-119
Clutch control 140-5
Combine harvester LH sensors 90-40
Commander Control 2000 80-5
Commander Control 2000 operating controls 90-10
Commander Control 2000, EMR-D control unit 80-5
Commercially available tools 20-2
Completion of the rocker support 20-43
Components working speed 10-20
Compression test 20-24
Compressor 80-31
Compressor lubrication 80-33
Concave electrical adjustment 100-4
Concave suspension, de-awner covers 100-6
Connecting rod drum check (L3) 20-98
Connecting rod mechanism 110-9
Connectors assignment, 13 pin socket 130-17
Connectors electrical diagram - Connectors assignment 90-27
Construction 80-36
Control console, switches and lights 90-9
Control device basic setting 110-19
Control device function 110-19
Control devices in cab roof 90-8
Control valves block 60-10
Control valves block connection plate 60-12
Control valves block with integral check valve 60-31
Controls diagram, speed 130-2
Controls in engaged position 120-9
Conversion factor 10-2
Conversion of straw chopper for threshing maize and sunflowers 140-8
Conversion tables 10-2
Conversion to reduced speed 100-18
Converting Celsius degrees (°C) into Fahrenheit degrees (°F) 10-2
Converting Celsius degrees (°C) into Kelvin degrees (K) 10-3
Converting mm into inches 10-2
Coolant temperature sensor wiring loom - 16062294 90-144
Cooling system protection 10-6
Correcting contact points of cylinder sleeve (L3) 20-190
Crankshaft check (L3) 20-84
IV
INDEX
Cutter bar self-levelling system 60-34
Cutting table cutting angle sensor wiring loom - 16062568/10 90-171
Cutting table drive, reel variator 130-3
Cutting table electronic control 90-48
Cutting table electronic control, EMR-D Level control / AutoControl 90-58, 90-62
Cylinder liner check 20-148
D
D - Grain tank discharge pipe block 60-41
Danfoss Lenkorbitrol type OSPC 160 ON 60-47
De-awner covers 100-6
Description 50-7, 60-29, 60-35, 60-
45
Description of hydrostatic system operation 60-54
Description of inductive sensor functions 90-37
Description of the function keys 80-16
Determine the clearance of the connecting rod bearing 20-104
Diagram of centralised lubrication system lines 50-14
Diagram of Commander Control 2000 CAN-Bus with central display 90-17
Diagram of lubrication control valve lines 50-13
Diagram of pipelines and connection diagram for hydraulic system on rape header 130-18
Disassemble the fixed O-ring on the cylinder head 30-67
Disassembly and assembly of the cable bundle (L3) 30-235
Disassembly and assembly of the connecting line (L3) 30-13, 30-22
Disassembly and assembly of the connector box 30-153, 30-155, 30-
157, 30-159, 30-299
Disassembly and assembly of the connector box (L3) 20-184
Disassembly and assembly of the cylinder head (L3) 20-48
Disassembly and assembly of the fuel cutoff valve (spark plugs) (L3) 30-193, 30-198
Disassembly and assembly of the fuel pipes (L3) 30-214, 30-227
Disassembly and assembly of the fuel pipes (spark plugs) (L3) 30-203, 30-207
Disassembly and assembly of the gear case cover (L3) 20-206, 20-211
Disassembly and assembly of the lubricant oil sump (L3) 20-284, 20-290
Disassembly and assembly of the oil radiator (L3) 30-99
Disassembly and assembly of the piston and connecting rod drum (L3) 20-126
Disassembly and assembly of the rocker and support (L3) 20-36
Disassembly and assembly of the starter (L3) 30-262
Disassembly and assembly of the torsional vibration damper (L3) 30-144
Disassembly and assembly of the turbocharger (L3) 30-31
Disassembly and assembly of the turbocharging air duct (L3) 30-10
Disassembly of the assembly support 20-158, 20-172
Disassembly of the blocked injection valve 30-66
Disassembly of the camshaft 20-215
Disassembly of the camshaft bearings 20-198
Disassembly of the connecting line 30-13, 30-22
Disassembly of the connector box 20-184
Disassembly of the connector box 30-153, 30-155, 30-
157, 30-159, 30-299
Disassembly of the crankshaft 20-112
Disassembly of the cylinder head 20-48
Disassembly of the cylinder liner 20-151
Disassembly of the engine from the assembly stand 20-29
Disassembly of the exhaust manifold 30-6, 30-8
Disassembly of the fuel cutoff valve 30-193, 30-198
Disassembly of the gear case cover 20-206, 20-211
Disassembly of the hydraulic pump drive 30-149
Disassembly of the injection pump 30-266, 30-269, 30-278
Disassembly of the injection valve 30-65, 30-71
Disassembly of the injection valve from the injector tester 30-78
Disassembly of the inserted valve seat 20-70
Disassembly of the of the fuel pressure regulating valve 30-83, 30-89
Disassembly of the piston and connecting rod drum 20-126
Disassembly of the piston cooling nozzle 20-140
Disassembly of the piston pin bush 20-107
Disassembly of the rocker support 20-40
Disassembly of the spark plug 30-184, 30-187
Disassembly of the starter 30-262
Disassembly of the starter ring gear 30-147
Disassembly of the supply air pipe 30-47, 30-52
Disassembly of the tappet 20-204
Double-acting control valve 60-16
Drive axle / Steering axle 40-4
Driving axle maintenance and inspection 40-4
Dust plate and gaskets on threshing section 100-16
V
INDEX
E
EEC control unit, accelerator adjustment module 90-45
Electric motor wiring loom - 0.015.5472.4/10 90-147
Electric motors 90-115
Electric sieve adjustment 110-18
Electrical adjustment of the rear-view mirrors (optional) 80-15
Electrical diagram for electric heater and air conditioner in cab roof 80-25
Electrical drive of belt clutches, overview 50-2
Electrical system - safety warnings 90-2
Electrical system: 0-3
Electrically driven movement from straw guide plate to straw chopper 140-11
Electromagnetic clutch 80-32
Elevator head for grain tank extension 120-6
Elevator head, speed control 120-4
Emergency steering (manual) 60-45
Emptying the grain tank 120-10
EMR-D control panel 80-5
EMR-D control valve 60-21
EMR-D Level control / AutoControl components 90-48
Engagement of the feed passage 70-7
Engagement valve for the hydraulic accumulator, with pressure sensor 60-19
Engagement valve function: engage/disengage hydraulic accumulator (3) 60-19
Engine coolant and oil temperature switch (5650H, 5660H/HTS, 5665HTS, 5690H/HTS, 5695HTS) 90-36
Engine frame plug connector 90-11
Engine interface wiring - 0.015.5475.4/10 90-133
Engine wiring loom - 0.015.5471.4/20 90-134
Engine: 0-4
Equipment of combine harvesters with hydrostatic units 60-52
Execution 60-45
F
Fan - shroud 110-16
Fan speed variator 110-14
Fault diagnosis 90-52
Fault diagnosis (List of fault codes for EMR-D) 90-53
Faults / Troubleshooting 90-81
Feed passage 70-2
Feed passage - slipping clutch 70-3
Feed passage - stabiliser shaft for feed chain 70-5
Feed passage clutch 50-12
Feed passage oscillating frame, orientable adapter 70-11
Feed passage reversal device 70-10
Feed passage reversing device wiring loom - 16062550 90-163
Feed passage sensors 90-121
Feed passage sensors wiring loom - 0.015.5465.4 /10 90-164
Final drive 40-26
Final drive (1604 0897) 40-26
Finishing 20-194
First aid in the case of contact with refrigerant 80-22
Fit the camshaft gear wheel. 20-255
Fit the crankshaft O-ring 20-90, 20-95
Fitment instructions 90-44, 120-3, 120-12
Fitting / Removing 40-18
Fitting and removing injection valves (L3) 30-65
Fitting and removing piston cooling nozzle (L3) 20-140
Fitting and removing piston pin bush (L3) 20-107
Fitting and removing seal seat 20-276
Fitting and removing tappets, checking tappet holes (L3) 20-204
Fitting and removing the camshaft bearings, checking (L3) 20-197
Fitting and removing the cylinder sleeve (L3) 20-151
Fitting and removing the injection pump camshaft (L3) 20-242
Fitting and removing the injection pumps (cylinder A1) (L3) 30-266
Fitting and removing the injection pumps (cylinder A2-B3) (L3) 30-276
Fitting and removing the oil pressure transducer (L3) 30-109
Fitting and removing the regulator valve (L3) 30-111
Fitting and removing the rotation tool (L3) 30-2
Fitting and removing the thermostats (L3) 30-133
Fitting and removing transition pipe 30-106
Fitting regulator valve 30-115
Fitting the ancillary mount 20-163
VI
INDEX
Fitting the injection pump 30-280
Fitting the injection pump camshaft 20-252
Fitting the oil pressure transducer 30-110
Fitting the rear cover 20-181
Fitting the rotation device 30-2
Fitting the seal seat 20-277
Fitting the stepped grain pan swinging arm 110-11
Fitting the thermostats 30-134
Fitting the transition pipe 30-106
Flattening the cylinder head 20-45
Flow regulator valve with integral pressure relief valve 60-12
Front axle 40-15
Front axle - BALANCE version 40-17
Front wiring loom - 0.015.5469.4/20 90-127
Fuel, quantity 1) and quality of oil 10-18
Function 60-45
Function of switch 3 140-7
Function: 60-14, 60-16
Functionality check - Hourly production control system 90-83
Fuse box wiring - 0.015.5312.4/20 90-136
G
Gear control 60-57
Gearbox 40-24
Gearbox cover inductive transducer for speed measurement 90-34
Gearbox ZNK 25 (1604 0895/20) 40-19
General information 10-25, 10-26
General information for pressure measurement 60-63
General information: 0-3
General safety and accident prevention provisions 0-2
General safety instructions 0-2
General warnings 60-52
Glues 10-7
Grain discharge system 120-11
Grain elevator with elevator head 120-2
Grain loss monitor adjustment knobs 90-84
Grain tank clutch 120-8
Grain tank discharge clutch 50-10
Grain tank extension hydraulic drive 60-44
Grain tank level sensors 120-18
Grain tank sensors 90-117
Grain tank wiring loom - 0.015.5473.4/10 90-139
Grain tank worklight wiring loom - 16062565/10 90-168
Grease 10-6
Grinding 20-192
Grinding the cylinder head seal surface (L3) 20-45
Grinding the mating surface 20-190
Grinding the mating surface to clean 20-190
H
Handle refrigerant and the refrigerant tank with care 80-21
HMF type hydrostatic motor 60-65, 60-65
Hose burst safety valve 60-33
Hourly production monitoring system / Job calculator 90-82
Hydraulic accumulator supplementary valve connection logic: 60-19
Hydraulic circuit - hydraulic connection diagram 60-3
Hydraulic circuit - Troubleshooting 60-50
Hydraulic circuit connection diagram for Balance 60-5
Hydraulic circuit connection logic: 60-3
Hydraulic circuit pipes diagram for Balance 60-7
Hydraulic cutting angle control 60-35
Hydraulic cylinder - repair 60-39
Hydraulic cylinder - steering axle 60-38
Hydraulic steering system 60-45
Hydraulic system - Safety warnings 60-2
Hydraulic system: 0-3
Hydrostatic motor HMF 105, HMF 135 60-65
Hydrostatic transmission - Hydrostatic pump HPV 105/135 60-59, 60-63
VII
INDEX
I
Identification 90-19
Identification on the electrical diagram 90-6
Index by connector 90-97
Index by part code 90-95
Index by part description 90-89
Indicator device connector pins assignment 90-83
Inductive sensor as control switch 90-35
Inductive sensor for speeds control and adjustment 90-35
Installation 20-195
Installation of straw walker rakes 110-8
Installation of the sieves crankshaft 110-9
Installing the maize concave 100-22
Installing the sieves: (the servomotor must be fully retracted) 110-19
Installing the variator pulley 100-12
Intake auger 130-7
Intake auger settings 130-9
Intermediate gear 30-143
K
KPAB straw chopper 140-10
L
Lenkorbitrol repair work / general overhaul 60-48
LH lubricant control valve 50-13
Lifting cylinder - cutting table (feed passage) 60-36
Lighting control panel 90-8
Lights 90-122
Line 30-108
Lining for straw hood 140-10
Liquid tank with dryer 80-34
List of connectors on engine frame 90-12
List of wiring looms 90-89
Lower bevel gear 120-14
Lower cutting table 60-24
Lubricants 10-6
Lubricating oil filter console 30-146
M
Maintenance 60-2
Maintenance and inspection schedule 10-9
Maintenance and repair 10-25
Make the housing hole for the inserted valve seat (interference) 20-72
Make the housing hole for the valve guide (increased dimension) 20-63
Measure and check 60-63
Measure the valve stem clearance 20-60
Measuring piston protrusion 20-51
Measuring piston protrusion (L3) 20-51
Measuring spray angle of piston cooling nozzle 20-140
Measuring the length of the flanged bearing 20-88
Measuring the tappet holes 20-204
Mechanical control switches 90-35
Miscellaneous: 0-4
Moisture is one of the main problems for an air conditioning system 80-34
Multifunction lever wiring loom - TS8799/2 90-172
Multifunction lever, rack device / sensor adjustment 90-43
N
Neutral circulation 60-29
Neutral position 60-21
VIII
INDEX
O
Oil change 40-5, 40-6
Oil change, oil level check 100-19
Oil quantity and quality 10-18
On-board computer (optional) 80-16
One-component adhesive 10-8
Operating description 60-32
Operating description of the air conditioning system 80-26
Operation 80-31, 80-34, 80-37,
90-48, 90-66
Operation and maintenance recommendations: 110-14
Operator station - steering wheel 80-8
Operator station control console 80-2
Operator station, Commander Stick, control consoles 80-6
Orientable adapter for the cutting table (with hydraulic adjustment of the cutting angle) 70-11
Orientable adapter for the cutting table (without hydraulic adjustment of the cutting angle) 70-11
Overview of functional components in the cab roof 80-23
P
PAG oils 80-29
Parking brake: 40-12
Personal protective equipment 80-20
Personnel qualifications 80-20
Pilot equipment 60-29
Pins assignment 90-19
Plug distributor / Engine frame plug connector 90-11
Powershift control unit (CCP2) 50-5
Preparation of the cylinder head 20-45
Pressure insertion of the inserted valve seat 20-73
Pressure insertion of the valve guide 20-65
Pressure limiting valve 80-31
Protection against clogging between feed channel chain sprockets 70-9
Protection against clogging of feed passage 70-8
Pushing out the valve guide 20-62
R
Raise cutting table 60-23
Rape header drive 130-20
Rear lateral light wiring loom - 16013845 90-159
Rear number plate light wiring loom - 16056728/10 90-143
Rear wiring - 0.015.5470.4/20 90-155
Refitting fuel lines. 30-204, 30-208, 30-
219, 30-229
Refitting the alternator 30-257
Refitting the ancillary mount 20-175
Refitting the charge air duct 30-10
Refitting the crankcase breather 20-145
Refitting the cylinder head cover 30-130
Refitting the engine wiring loom 30-244
Refitting the exhaust manifold 30-175, 30-178, 30-
180, 30-182
Refitting the flywheel 20-299, 30-128
Refitting the fuel lift pump 30-81
Refitting the injection pipes 30-56, 30-61
Refitting the injection valve 30-71
Refitting the oil cooler 30-102, 30-297
Refitting the oil pickup pipe 30-95, 30-97
Refitting the oil sump pan. 20-281, 20-286
Refitting the rocker arms and pedestals 20-37
Refitting the speed sensor 30-162, 30-169
Refitting the temperature sender 30-212, 30-234
Refitting the temperature/pressure sender 30-264
Refitting the thermostat housing 30-138
Refitting the torsional vibration damper 30-144
Refitting the turbocharger 30-34, 30-40, 30-45
Refitting the water pump 30-123
Refrigerant 80-28, 80-28
Refrigerant fluid and oil 80-28
IX
INDEX
Refrigerant liquid circuit 80-26
Relay unit 90-29
Removal and refitting of the camshaft speed sensor (L3) 30-167
Removal and refitting of the crankshaft speed sensor (L3) 30-161
Removal and refitting of the cylinder head cover 30-130
Removal and refitting of the flywheel (fixing elements) 30-128
Removal and refitting of the oil cooler 30-297
Removal and refitting of the oil sump pan. 20-279
Removal and refitting of the supply air pressure/temperature sender (L3) 30-264
Removal of fuel lines 30-203, 30-207, 30-
214, 30-227
Removal of the alternator 30-255
Removal of the charge air duct 30-10
Removal of the crankcase breather 20-143
Removal of the crankshaft oil seal 20-89, 20-93, 20-273
Removal of the cylinder head cover 30-130
Removal of the engine wiring loom 30-235
Removal of the exhaust manifold 30-4, 30-174, 30-177,
30-180, 30-182
Removal of the flywheel 20-298, 30-128
Removal of the fuel lift pump 30-79
Removal of the injection pipes 30-55, 30-60
Removal of the oil cooler 30-99, 30-297
Removal of the oil pickup pipe 30-95, 30-97
Removal of the oil sump pan. 20-279, 20-284, 20-290
Removal of the rocker arms and pedestals 20-36
Removal of the rotation device 30-3
Removal of the speed sensor 30-161, 30-167
Removal of the temperature sender 30-211, 30-233
Removal of the temperature/pressure sender 30-264
Removal of the torsional vibration damper 30-144
Removal of the turbocharger 30-38
Removal of the turbocharger 30-31, 30-43
Removal of the water pump 30-121
Removing / Fitting 60-29
Removing and fitting ancillary mount (L3) 20-158, 20-172
Removing and fitting crankcase breather (oil separator) (L3) 20-143
Removing and fitting fuel delivery pump (L3) 30-79
Removing and fitting the air intake pipe 30-47
(Bank A) (L3)
(Bank B) (L3)
Removing and fitting the alternator (driven by toothed belt) (L3) 30-255
Removing and fitting the coolant pump (L3) 30-121
Removing and fitting the exhaust manifold (Bank B) (L3) 30-8
Removing and fitting the exhaust manifold (L3) 30-4
Removing and fitting the exhaust manifold 30-6
(Bank A) (L3)
Removing and fitting the exhaust pipe (Bank B) (L3) 30-182
Removing and fitting the exhaust pipe 30-174, 30-180
(Bank A) (L3)
Removing and fitting the exhaust pipe 30-177
(Bank B) (L3)
Removing and fitting the hydraulic pump drive (L3) 30-149
Removing and fitting the thermostat housing (L3) 30-135
Removing and fitting the turbocharger (Bank A) (L3) 30-38
Removing and fitting the turbocharger (Bank B) (L3) 30-43
Removing and refitting rear cover (L3) 20-181
Removing and refitting the injection valve (L3) 30-71
Removing and refitting the rocker and mount, checking (L3) 20-40
Removing the injection pump 30-276
Removing the injection pump camshaft 20-242
Removing the oil pressure transducer 30-109
Removing the rear cover 20-181
Removing the regulator valve 30-111
Removing the seal seat 20-276
Removing the sieves 110-19
Removing the thermostat housing 30-135
Removing the thermostats 30-133
Removing the transition pipe 30-106
Repair work 60-36, 60-38
Replace the ball pin 20-41, 20-42
Replace the crankshaft O-ring (flywheel end) 20-273
Replace the crankshaft O-ring (flywheel end) (L3) 20-89
Replace the crankshaft O-ring (opposite end to flywheel) (L3) 20-93
Replacement of single parts 100-19
X
INDEX
Replacing fixed calliper brake linings: 40-8
Replacing the brake linings 40-10
Replacing the injection pipes (Bench A) (L3) 30-55, 30-60
Replacing the lined valve seat (oversized) (L3) 20-69
Replacing the starter ring gear on the flywheel (L3) 30-147
Replacing the thrust ring halves 20-79
Replacing the valve guide (oversized - press-fit) (L3) 20-62
Returns elevator emergency switch - 16050268 90-149
Reversing drum with synchronous drive (from 2007) 100-8
RH lubricant control valve 50-13
Roof lining electrics wiring loom - 980157 90-150
S
Safe maintenance and repair of the air conditioning system 80-20
Safety instructions - maintenance and repair 0-3
Safety instructions for tyres and wheel studs 40-2
Safety measures for welding work 80-22
Seal materials 10-7
Securing bush support tightening values 10-21
Self-levelling balancing control hydraulic connection diagram 60-27
Sensors on engine (Sensors for EEC see section A) 90-40
Sensors on RH side of combine harvester 90-39
Sensors, overview 90-39
Serdia 90-3
SERDIA 2000 level III” software 90-4, 90-4
Settings on rack device and cable-pull 90-44
Side lights wiring loom - 16056731/10 90-162
Side lights wiring loom - 16056753 90-161
Sieve crankshaft 110-9
Sieve lighting wiring loom - 16050274 90-160
Single-acting control valve 60-14
Slipping clutch for intake auger and reel 130-5
Solenoid valves 90-113
Solenoid valves assembly wiring loom - 0.015.5468.4/10 90-169
Solid lubricants 10-6
Special tools 10-28
Speed control 120-4
Speed monitoring 140-6
Speed variator adjustments 110-14
Standard execution 90-7
Steering axle 40-28
Steering axle setup 40-28
Steering column switch wiring loom - 980062201 90-173
Steering cylinder internal sealing check 60-49
Steering system check 60-49
Steering system internal sealing check 60-49
Stepped gain pan with removable segments 110-11
Stepped grain pan and sieve box with transmission 110-12
Straw chopper clutch 50-9
Straw chopper straw guide plate adjustment diagram 90-19
Straw chopper V-belt clutch 140-4
Straw chopper wiring loom - 16050256 90-174
Straw guide plate adjustment 140-2
Straw walker supports assembly 110-4
Straw walker transmission adjustment 110-3
Straw walkers drive 110-2
Support 30-142
Support for grain tank pipe, block 120-15
Switches and sensors for Commander Control 2000 control 90-34
Switching logic 90-48
Swivel grain tank pipe hydraulic control 120-17
System description 80-16
T
T00 81 20-12, 20-12
T01 63 20-12, 20-12
T13 054 20-13, 20-13
Table of abbreviations 90-5
Tailings elevator (returns elevator) 110-17
XI
INDEX
Technical data 20-278, 20-283, 30-
107, 30-129, 30-132,
30-154, 30-156, 30-
158, 30-160, 30-298,
30-300
Test and adjustment data (L3) 20-12
Testing the thermostat 30-126
Thermostatic expansion valve (TEV) 80-36
Threshing drum - maize harvesting, welding of threshing drum beater bars 100-23
Threshing drum speed reduction 100-17
Threshing drum speed variator 100-10
Threshing section clutch 50-11, 100-2
Tightening torque (L3) 20-14
Tightening torques for the valves 60-59
Tightening values, screwing classes 10-4
Tilt cylinder 60-33
Tools for engine disassembly and reassembly 20-2
Toothed rod device 60-57
Topping up with oil 30-120
Transmission assembly 130-11
Transmission control linkage 40-24
Transmission fork adjustment - transmission ZNK25 - 1604 0895/20 40-21
Transmission oil check and oil change 40-5
Transmission ZNK 25 - 1604 0895/20 40-19
Transmission ZNK25 (1604 0895/20), gearbox 40-21
Troubleshooting 60-68
Troubleshooting instructions 50-13, 50-14
Turbo separator 100-20
Turbo separator - Basic electrical selector setting 100-20
Turbo separator drive 100-20
Type of function and programming of CAN modules 90-22
Tyres and wheel rims 40-14
Tyres, threaded fixings: 0-4
U
Using one-component adhesives 10-8
V
Valve assembly 20-55
Valve assembly and disassembly (L3) 20-54
Valve check (L3) 20-58
Valve clearance adjustment (L3) 20-32
Valve disassembly 20-54
Variator adjustment 100-13
Variator switching elements 100-13
Vertical and horizontal reel single and double-acting cylinder (synchronous cylinder) 60-42
View of control console 90-7
W
Warnings for maintenance 80-33, 80-34
Wheel hub fitment instructions 40-29
Wheels camber = E 40-14
Windscreen wiper 90-109
Wiring looms and components index 90-89
Work calculator LH 1000 90-85
Working position 60-29
Worklights 90-106
Workshop tools for engine disassembly and reassembly (Lv.3) 20-5, 20-5
XII
MODIFICATIONS SINCE LAST VERSION
Workshop tools for engine disassembly and reassembly (Lv.3) 20-5
Disassembly and assembly of the torsional vibration damper (L3) 30-144
Test and adjustment data (L3) 20-12
Removing and refitting rear cover (L3) 20-181
Replacing the starter ring gear on the flywheel (L3) 30-147
Replace the crankshaft O-ring (opposite end to flywheel) (L3) 20-93
Check the endfloat of the crankshaft (crankshaft installed) (L3) 20-78
Fitting and removing the camshaft bearings, checking (L3) 20-197
Valve check (L3) 20-58
Check the valve guide (L3) 20-60
Replacing the valve guide (oversized - press-fit) (L3) 20-62
Disassembly and assembly of the rocker and support (L3) 20-36
Check the compression value (L3) 20-24
Fitting and removing the oil pressure transducer (L3) 30-109
Disassembly and assembly of the lubricant oil sump (L3) 20-284
Disassembly and assembly of the lubricant oil sump (L3) 20-290
Topping up with oil 30-120
Fitting and removing the rotation tool (L3) 30-2
Fitting and removing the injection pumps (cylinder A1) (L3) 30-266
Removing and fitting fuel delivery pump (L3) 30-79
Removing and fitting the coolant pump (L3) 30-121
Fitting and removing the thermostats (L3) 30-133
Assembly and disassembly of the oil intake pipe (L3) 30-95
Removing and fitting the turbocharger (Bank B) (L3) 30-43
Disassembly and assembly of the fuel pipes (L3) 30-227
(Bank B) (L3)
Removal and refitting of the camshaft speed sensor (L3) 30-167
Assembly and disassembly of the spark plug (L3) 30-184
Assembly and disassembly of the spark plug (L3) 30-187
SERDIA 2000 level III” software 90-4
Line 30-108
Disassembly and assembly of the connector box 30-299
Removal and refitting of the flywheel (fixing elements) 30-128
Measuring piston protrusion (L3) 20-51
Fitting and removing seal seat 20-276
Check the endfloat of the crankshaft (crankshaft removed) (L3) 20-76
Crankshaft check (L3) 20-84
Replacing the lined valve seat (oversized) (L3) 20-69
Correcting contact points of cylinder sleeve (L3) 20-190
Removal and refitting of the oil cooler 30-297
Fitting and removing the injection pump camshaft (L3) 20-242
Fitting and removing the injection pumps (cylinder A2-B3) (L3) 30-276
Disassembly and assembly of the connecting line (L3) 30-22
Disassembly and assembly of the turbocharger (L3) 30-31
Assembly and disassembly of the temperature sender (L3) 30-233
Disassembly and assembly of the fuel pipes (spark plugs) (L3) 30-203
Disassembly and assembly of the fuel pipes (spark plugs) (L3) 30-207
Serdia 90-3
Tools for engine disassembly and reassembly 20-2
Removing and fitting ancillary mount (L3) 20-158
Removing and fitting the hydraulic pump drive (L3) 30-149
Closing components 30-119
Tightening torque (L3) 20-14
Check the piston (L3) 20-133
Assembly and disassembly of the crankshaft (L3) 20-112
Assembly and disassembly of the camshaft (L3) 20-215
Check the camshaft (L3) 20-239
Disassembly and assembly of the gear case cover (L3) 20-206
XIII
Disassembly and assembly of the gear case cover (L3) 20-211
Support 30-142
Valve clearance adjustment (L3) 20-32
Check the valve residual (L3) 20-68
Grinding the cylinder head seal surface (L3) 20-45
Disassembly and assembly of the cylinder head (L3) 20-48
Fitting and removing tappets, checking tappet holes (L3) 20-204
Disassembly and assembly of the oil radiator (L3) 30-99
Removing and refitting the injection valve (L3) 30-71
Checking and adjusting maximum injection pump aperture stroke (L3) 30-283
Assembly and disassembly of the fuel pressure regulating valve (L3) 30-89
Disassembly and assembly of the connecting line (L3) 30-13
Removing and fitting the exhaust manifold 30-6
(Bank A) (L3)
Disassembly and assembly of the turbocharging air duct (L3) 30-10
Removing and fitting the turbocharger (Bank A) (L3) 30-38
(Bank B) (L3)
Disassembly and assembly of the fuel pipes (L3) 30-214
(Bank A) (L3)
Removing and fitting the exhaust pipe (Bank B) (L3) 30-182
Removal and refitting of the crankshaft speed sensor (L3) 30-161
Disassembly and assembly of the starter (L3) 30-262
Disassembly and assembly of the fuel cutoff valve (spark plugs) (L3) 30-193
Disassembly and assembly of the fuel cutoff valve (spark plugs) (L3) 30-198
Grain tank level sensors 120-18
Removing and fitting ancillary mount (L3) 20-172
Removing and fitting crankcase breather (oil separator) (L3) 20-143
Disassembly and assembly of the connector box (L3) 20-184
Fitting and removing transition pipe 30-106
Assembly and disassembly of the flywheel (L3) 20-298
Fitting and removing piston pin bush (L3) 20-107
Disassembly and assembly of the piston and connecting rod drum (L3) 20-126
Check the piston rings and piston grooves (L3) 20-136
Fitting and removing piston cooling nozzle (L3) 20-140
Checking the cylinder sleeve (L3) 20-148
Fitting and removing the cylinder sleeve (L3) 20-151
Checking cylinder sleeve protrusion (L3) 20-156
Replace the crankshaft O-ring (flywheel end) (L3) 20-89
Replace the crankshaft O-ring (flywheel end) 20-273
Connecting rod drum check (L3) 20-98
Intermediate gear 30-143
Removing and refitting the rocker and mount, checking (L3) 20-40
Removal and refitting of the cylinder head cover 30-130
Valve assembly and disassembly (L3) 20-54
Assembly and disassembly of the engine on the assembly stand (L3) 20-27
Fitting and removing the regulator valve (L3) 30-111
Lubricating oil filter console 30-146
Removal and refitting of the oil sump pan. 20-279
Replacing the injection pipes (Bench A) (L3) 30-55
Replacing the injection pipes (Bench A) (L3) 30-60
Fitting and removing injection valves (L3) 30-65
Checking and adjusting the injection valves (L3) 30-75
Assembly and disassembly of the fuel pressure regulating valve (L3) 30-83
Check the thermostat (after removal) (L3) 30-126
Removing and fitting the thermostat housing (L3) 30-135
Assembly and disassembly of the oil intake pipe (L3) 30-97
Removing and fitting the exhaust manifold (L3) 30-4
Removing and fitting the exhaust manifold (Bank B) (L3) 30-8
(Bank A) (L3)
XIV
(Bank A) (L3)
Disassembly and assembly of the cable bundle (L3) 30-235
Removing and fitting the alternator (driven by toothed belt) (L3) 30-255
Assembly and disassembly of the temperature sender (L3) 30-211
Removal and refitting of the supply air pressure/temperature sender (L3) 30-264
XV
*307.W.H020.en.6.02*
02/2015
SAME DEUTZ-FAHR ITALIA S.p.A.
Viale F. Cassani, 15 - 24047 Treviglio (BG) Italy
T + 39.0363.4211 F + 39.0363.421638
www.samedeutz-fahr.com
Deutz-Fahr is a trademark
www.deutz-fahr.com

307.W.H020.en.6.02 20150217183249

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307.W.H020.en.6.02 20150217183249

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5650 H COM 3 ->13500

5660 H COM 3 ->13500

100 - Threshing unit

110 - Cleaning unit

120 - Grain tank - Elevator

130 - Cutting table

140 - Attachments and accessories

0.1.1 - General safety and accident prevention provisions

0.2.2 - Electrical system:

0.2.3 - Brake system, brake fluid:

0.2.4 - Hydraulic system:

0.2.5 - Air conditioning system:

10.1.2 - Converting mm into inches

10.1.3 - Converting Celsius degrees (°C) into Fahrenheit degrees (°F)

10.1.4 - Converting Celsius degrees (°C) into Kelvin degrees (K)

10.3.3 - Cooling system protection

Combine harvesters 5650H - 5695 HTS

Combine harvesters 5650H - 5695 HTS

Fig. 3 - Check of spring preload dimension L

Fig. 4 - Belts and chains on right-hand side

Dispose of fuel, in compliance with environment regulations.

20.3.5 - T13 054

Position Components Cylinder alloca-

20.3.6 - T13 054

20.5.1 - Compression test

Use the O-ring (1) for the injection valve.

m Fit union (2). 1

20.6.1 - Assembly of the engine on the stand

20.6.2 - Disassembly of the engine from the assembly stand

Before adjusting the valve clearances, allow the engine to

m Remove the cylinder head cover (2). Fig. 86

20.7.1 - Bring the engine to valve overlap position

20.7.2 - Adjustment of valve clearance

See para. 20.3 - Test and adjustment da... - page 20-12

m Remove the rotation angle gauge.

20.8.1 - Removal of the rocker arms and pedestals

20.8.2 - Refitting the rocker arms and pedestals

m Fit the rotation device.

The long part (1) must face up.

20.8.3 - Checking endfloat of rocker

20.9.1 - Disassembly of the rocker support

20.9.2 - Checking rocker (intake valves)

an internal bore meter.

nal bore meter.

m Check that the oil channel (3) is completely clear.

20.9.3 - Replace the ball pin

20.9.4 - Checking rocker (exhaust valves)

20.9.6 - Checking rocker rod

m Check that the oil channels are not obstructed.

20.10.1 - Preparation of the cylinder head

20.10.2 - Flattening the cylinder head

20.10.3 - Check of the sealing surface of the cylinder head

m Assemble the valves.

20.11.1 - Disassembly of the cylinder head

m Fit the screws.

20.12.1 - Measuring piston protrusion

The results of all this are: = 0.42 mm Fig. 145

20.13.1 - Valve disassembly

20.13.2 - Valve assembly

20.14.1 - Check the diameter of the valve stem

20.14.2 - Check the thickness of the valve edge

20.15.1 - Check the valve guide

20.15.2 - Measure the valve stem clearance