Case IH AFX-8010 Service Manual

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Page 1

REPAIR MANUAL

AFX8010

AFX 1 27/05/2004

Page 2

Contents

INTRODUCTION DISTRIBUTION SYSTEMS A POWER PRODUCTION B POWER TRAIN C TRAVELLING D BODY AND STRUCTURE E TOOL POSITIONING G CROP PROCESSING K

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INTRODUCTIO

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Contents

INTRODUCTION

Foreword(-A.1

AFX8010

0.A.40)

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Foreword ( - A.10.A.40)

AFX8010

Technical Information

INTRODUCTION

This manual has technical information electronically through CDROM and in paper manuals. A coding system called ICE has been developed to link the technical information to other Product Support functions e.g. Warranty.

Technical information is written to support the maintenance and service of the functions or systems on a customers machine. When a customer has a concern on his machine it is usually because a function or system on his machine is not working technical information in this manual to resolve that customers concern, you will find all the information classified using the new ICE coding, according to the functions or systems on that machine. Once you have located the technical inf components, assemblies and sub-assemblies for that function or system. You will also find all the types of information that have been written for that function or system, the technical data (specifications), the functional data (how it works), the d

By integrating this new ICE coding into technical information , you will be able to search and retrieve just the right piece of tech attaching 3 categories to each piece of technical information during the authoring process.

The first ca

LOCATION - is the component or function on the machine, that the piece of technical information is going to

• describe e.

INFORMATION TYPE - is the piece of technical information that has been written for a particular component or

• function o

of fuel held by the Fuel tank.

been produced by a new technical information system. This new system is designed to deliver

at all, is not working efficiently, or is not responding correctly to his commands. When you refer to the

ormation for that function or system then you will find all the mechanical, electrical or hydraulic devices,

iagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.).

nical information you need to resolve that customers concern on his m achine. This is made possible by

tegory is the Location, the second category is the Information Type and the third category is the Product:

g. Fuel tank.

n the machine e.g. Capacity would be a type of Technical Data that would describe the amount

PRODUCT -

•

Every piece of technical information will have those 3 categories attached to it. You will be able to use any combinat concern on his machine .

That inf

•

ion of those categories to find the right piece of technical information you need to resolve that customers

ormation could be:

the description of how to remove the cylinder head

a table of specifications for a hydraulic pump

afault

a troubleshooting table

a special tool

is the model that the piece of technical information is written for.

code

How to Use this Manual

This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included

end of a Chapter. Page number references are included for every piece of technical information listed in

at the the Chapter Contents or Chapter Index.

Each C

•

hapter is divided into four Information types:

Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components and,

mblies.

asse

Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components and

•

emblies.

ass

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INTRODUCTION

Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or

• hydraulic devices, components and assemblies.

Service data ( re move disassembly, assemble, install) for all the mechanical, electrical or hydraulic devices,

• components and assemblies.

Sections

Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by a letter A, B, C etc. The amount of Sections included in the manual will depend on the type and function of the machine that t table illustrates which Sections could be included in a manual for a particular product.

PRODUCT

Tractors X X X X X X X X

Vehicles wi

excavators, s kid steers, .....

Combines,

Seeding, planting, floating, spraying equipment

Mounted equipment and tools, ..... X X X X

he manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This

SECTION

A - Distribution Systems

B-PowerProd

uction

C-PowerTrain

D - Travellin

E - Body and Structure

F-FramePos

itioning

G - Tool Positioning

H-WorkingA

J - Tools and Couplers

K - Crop Processing

L-FieldProcessing

th working arms: backhoes,

forage harvesters, balers, ....

X X X X X X X X X

X X X X X X X X X X

X X X X X X X X X

,....

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INTRODUCTION

This manual contains these Sections. The contents of each Section are explained over the following pages.

Contents

INTRODUCTION

DISTRIBUTION S

POWER PRODUCTI

POWER TRAIN C

TRAVELLING

BODY AND STRUC

TOOL POSITIO

CROP PROCESS

tion Contents

Sec

SECTION A, DISTRIBUTION SYSTEMS

s Section covers the main systems that interact with most of the functions of the product. It includes the central

Thi parts of the hydraulic, electrical, electronic, pneumatic, lighting and grease lubrication systems. The components that are dedicated to a specific function are listed in the Chapter where all the technical information for that function

included.

Contents of DISTRIBUTION SYSTEMS - A

YSTEMS

TURE

NING

ING

PRIMARY HYDRAULIC POWER SYSTEM

X8010

SECONDARY HYDRAULIC POWER SYSTEM

X8010

ELECTRICAL POWER SYSTEM

FX8010

LIGHTING SYSTEM

FX8010

ELECTRONIC SYSTEM

AFX8010

10.A

12.A

.30.A

.40.A

A.50.A

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SECTION B, POWER PRODUCTION This Section cov

ers all the functions related to the production of power to move the machine and to drive various

devices.

INTRODUCTION

Contents of POW

ENGINE

ER PRODUCTION - B

B.10.A

AFX8010

FUEL AND INJECTION SYSTEM

B.20.A

AFX8010

AIR INTAKE SYSTEM

B.30.A

AFX8010

EXHAUST SYSTEM

B.40.A

AFX8010

ENGINE COOLANT SYSTEM

B.50.A

AFX8010

LUBRICATION SYSTEM

B.60.A

AFX8010

STARTING SYSTEM

B.80.A

AFX8010

SECTION C, POWER TRAIN This Section covers all the functions related to the transmission of power from the engine to the axles and to internal

r external devices and additional Process Drive functions.

Contents of POWER TRAIN - C

POWER COUPLING Fixed Coupling C.10.B

FX8010

TRANSMISSION Mechanical C.20.B

AFX8010

TRANSMISSION Hydrostatic C.20.F

AFX8010

FRONT PTO Mechanical C.42.B

AFX8010

PROCESS DRIVE Primary process drive C.50.B

AFX8010

TRANSMISSION LUBRIC ATION SYSTEM C.90.A

AFX8010

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INTRODUCTION

SECTION D, TRAVELLING This Section cov

ers all the functions related to moving the machine, including tracks, wheels, steering and braking.

It covers all the axles both driven axles and non-driven axles, including any axle suspension.

Contents of TRA

FRONT AXLE

VELLING - D

D.10.A

AFX8010

REAR AXLE D.12.A

AFX8010

2WD-4WD SYSTEM Hydraulic D.14.C

AFX8010

STEERING Hydraulic D.20.C

AFX8010

SERVICE BRAKE Hydraulic D.30.C

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PARKING BRAKE Hydraulic D.32.C

AFX8010

WHEELS AND TRACKS Wheels D.50.C

AFX8010

SECTION E, BODY AND STRUCTU RE This Section covers all the main functions and systems related to the structure and body of the machine. Including

he frame, the shields, the operator’s cab and the platform.

Contents of BODY AN D STRUCTURE - E

.10.B

FRAME Primary frame

FX8010

SHIELD

.20.A

AFX8010

OPERATOR AND SERVICE PLATFORM

E.30.A

AFX8010

USER CONTROLS AND SEAT

E.32.A

AFX8010

USER CONTROLS AND SEAT Operator seat E.32.C

AFX8010

USER CONTROLS AND SEAT Instructor seat

E.32.D

AFX8010

USER PLATFORM

E.34.A

AFX8010

ENVIRONMENT CONTROL Heating, Ventilation and Air Conditioning

E.40.D

AFX8010

SAFETY SECURITY ACCESSORIES Safety

E.50.B

AFX8010

DECALS AND PLATES

E.60.A

AFX8010

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INTRODUCTION

SECTION G, TOOL POSITIONING This Section cov

ers all the functions related to the final and/or automatic positioning of the tool once the tool is

positioned using the Working Arm or the machine frame.

Contents of TOO

LPOSITIONING-G

LIFTING G.10.A

AFX8010

TILTING G.20.A

AFX8010

LEVELING G.30.A

AFX8010

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SECTION K, CROP PROCESSING This Section cov

ers all the functions relatedtocropprocessing.

Contents of CROP PROCESSIN G - K

INTRODUCTION

FEEDING Reel feeding

K.25.B

AFX8010

FEEDING Header feeding

K.25.D

AFX8010

FEEDING Feeder housing

K.25.E

AFX8010

FEEDING Transition cone

K.25.K

AFX8010

THRESHING Axial flo w threshing K.40.C

AFX8010

SEPARATING Rotary separator K.42.C

AFX8010

STORING AND HANDLING Grain storing

K.60.B

AFX8010

CLEANING Primary cle a ning

K.62.B

AFX8010

CLEANING Tailings return system K.62.C

AFX8010

CLEANING Self-levelling frame

K.62.D

AFX8010

RESIDUE HANDLING Straw chopper K.64.C

AFX8010

RESIDUE HANDLING Chaff Spreader

K.64.D

AFX8010

RESIDUE H AND LING Straw beater

K.64.E

AFX8010

UNLOADING Grain unloading

AFX801

PROTECTION SYSTEMS Stone trapping

AFX801

K.72.B

K.90.E

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INTRODUCTION

Chapters

Each Chapter is identified by a letter and number combination e.g. Engine B.10.A The first letter is identical to the Section letter i.e. Chapter B.10 is inside Section B, Power Production. CONTENTS The Chapter Contents lists all the technical data (specifications), functional data (how it works), service data (remove, install adjust, etc..) and diagnostic data (fault codes and troubleshooting) that have been written in that Chapter for tha

Contents

POWER PRODUC TION

ENGINE _ 10.A

TECHNICAL DATA

ENGINE - General specification (B.10.A - D.40.A.10)

AFX8010

FUNCTIONAL DATA

t function or system on the machine.

ENGINE - Dynamic description (B.10.A - C.3 0.A .10)

AFX8010

SERVICE

ENGINE - Remove (B.10.A - F.10.A.10)

AFX8010

DIAGNOSTIC

ENGINE - Troubleshooting (B.10.A - G.40.A.10)

AFX8010

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INTRODUCTION

INDEX The Chapter Inde

x lists in alphabetical order all the types of information (called Information Units) that have been

written in that Chapter for that function or system on the machine.

Index

POWER PRODUCTION - B

ENGINE

ENGINE - Dynamic description (B.10.A - C.30.A.10)

AFX8010

ENGINE - General specification (B.10.A - D.40.A.10)

AFX8010

ENGINE - Remove (B.10.A - F.10.A.10)

AFX8010

ENGINE - Troubleshooting (B.10.A - G.40.A.10)

AFX8010

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INTRODUCTION

Information Units and Information Search

Each chapter is composed of information units. Each information unit has the ICE code shown in parentheses which indicates the function and the type of information written in that information unit. Each information unit has a page reference with technical information you are looking for.

example information unit Stack valve - Sectional View (A.10.A.18 - C.10.A.30)

Information Unit ICE code

ICE code classification

in that Chapter. The information units provide a quick and easy way to find just the right piece of

A10.A18

Distribution systems

Primary hydraulic

Stack valve

Functional data

10.A.30

Sectional view

power

CRIL03J033E01 1

Navigate to the correct information unit you are searching for by identifying the function and information type from the ICE cod e .

(1) Function and (2) Information type.

•

(A) corresponds to the sections of the repair manual.

•

(B) corresponds to the chapters of the repair manual. (C) corresponds to the type of information listed in the chapter contents, Technical data, Functional Data,

Diagnostic or Service. (A) and (B) are also shown in the page numbering on the page footer. THE REST OF THE CODING IS NOT LISTED IN ALPHA-NUMERIC ORDER IN THIS MANUAL.

You will find a table of contents at the beginning and end of each section and chapter.

• You will find an alphabetical index at the end of each chapter.

By referring to (A), (B) and (C) of the coding, you can follow the contents or index (page numbers) and quickly

• find the information you are lo oking for.

Page Header and Footer

The page header will contain the following references:

Section and Chapter description

•

The page footer will contain the following references:

Publication number for that Manual, Section or Chapter.

•

Version reference for that publication.

•

Publication date

•

Section, chapter and page reference e.g. A.10.A / 9

•

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REPAIR MANUAL

DISTRIBUTION SYSTEMS

AFX8010

9664 1 27/05/2004

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Contents

DISTRIBUTION S

PRIMARY HYDRAULIC P OWER SYSTEM

AFX8010

SECONDARY HYDRAULIC POWE R SYSTEM

AFX8010

ELECTRICAL PO

AFX8010

LIGHTING SYSTEM

AFX8010

ELECTRONIC SYSTEM

AFX8010

WER SYSTEM

YSTEMS - A

A.10.A

A.12.A

A.30.A

A.40.A

A.50.A

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DISTRIBUTIO

N SYSTEMS - A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A

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A.10.A / 1

Page 18

FUNCTIONAL

Description Page

Basic Principles Of The System 5......................................................

General Information 7................................................................

Specifications 8.....................................................................

Hydraulic System 9..................................................................

Hydraulic Component Locations 10....................................................

Oil Supply 11........................................................................

Filtration 12........................................................................

Cooling 12.........................................................................

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

DISTRIBUTION SYSTEMS - A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A

CONTENTS

Gear Pumps 13.....................................................................

Hydraulic Schematic 14..............................................................

PFC Pump Hydraulic System 18......................................................

PFC Pump Schematic 18............................................................

PFC Component Locations 19........................................................

Signal Circuits 29...................................................................

Steering Priority Valve 30............................................................

Electrical Monitoring Circuits 36.......................................................

Regulated Pressure 37..............................................................

Park Brake / Regulated Pressure Valve 37.............................................

Component Location 38.............................................................

Regulated Pressure Schematic 38....................................................

Regulated Pressure Valve Operation 39................................................

Electrical Monitoring Circuits 40.......................................................

Control Pressure 41.................................................................

Control Pressure Pump 45...........................................................

Filtration 46........................................................................

Control / Lubrication Pressure Valve 47................................................

Control Pressure Schematic 48.......................................................

Electrical Monitoring Circuits 50.......................................................

A.10.A / 2

Page 19

PTO Gearbox Cooling and Lubrication System 51.......................................

Lubrication System 52...............................................................

PTO Gearbox Cooling 55............................................................

Electrical Monitoring Circuits 56.......................................................

DIAGNOSTIC

Hydraulic System Testing Procedures 57...............................................

Diagnostic Test Equipment 58........................................................

Hydraulic System Testing Procedures 60...............................................

# 1 Low Pressure Standby 61........................................................

# 2 High Pressure Standby 63........................................................

# 3 Steering Relief Setting 65.........................................................

# 4 Bench Testing Components 67....................................................

# 5 Control Pressure Test 69.........................................................

# 6 PTO Gear Box Lubrication Pressure Test 71.........................................

# 7 Regulated Pressure Test 73.......................................................

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

#8 Spreader Pump Flow Test 75......................................................

# 9 Fan Pump Flow Test 77..........................................................

#10PFCPumpFlow 79.............................................................

Signal valve

Sensing system

# 11 Control Pressure Pump Flow Test 81..............................................

Signal valve -- Unidentified failure (A.10.A.12 -- G.30.B.46) 83.............................

Sensing system Differential pressure switch -- Short circuit to B+ (A.10.A.95.81--G.30.B.54) 87

Sensing system Temperature sensor -- Short circuit to B+ (A.10.A.95.90--G.30.B.54) 90......

Sensing system Temperature sensor -- Short circuit to ground (A.10.A.95.90--G.30.B.53) 93...

Sensing system Temperature sensor -- Open circuit (A.10.A.95.90--G.30.B.50) 96............

Sensing system Reservoir level sensor -- Short circuit to B+ (A.10.A.95.93--G.30.B.54) 101...

A.10.A / 3

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

A.10.A / 4

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

BASIC PRINCIPLES OF THE SYSTEM

Combines use a combination of Pressure Flow Compensated (PFC) and open-center hydraulics. In a PFC system, oil flow is minimal unless there is a hydraulic demand. In an open-center system, oil is constantly pumped through the system regardless of hydraulic demand.

Flow Across a Restriction

The hydraulic system of the combine uses the principle of flow across a restriction for some functions. It is important to understand this basic principle in order to understand how the system works, or more importantly, why the system may not be working.

1. When oil flows through an unrestricted passage, the pressure inthis passage, if any, will remain constant as long as pump flow remains constant.

2. When oil in a passage flows across a restriction, the pressure after the restriction will be less than the pressure before that restriction. Flow must exist for this to happen.A restriction can occur by any component causing aresistancetoflow.

3. When oil in a passage is fully restricted from flow (no-flow), the pressure in the passage will build until it reaches the relief valve setting. This relief pressure will be maintained as long as the flow is blocked and the pump is functioning normally. This is true regardless of what component is blocking flow. No flow will create constant pressure in the passage based on the relief valve setting.

M133599

M133699

A.10.A / 5

M133799

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

BASIC PRINCIPLES OF THE SYSTEM

Pilot Operated Hydraulic System

1. Pilot-operated hydraulic system has two basic parts or sections: A pilot (also called primary) section, and a main (also called secondary) section.

2. When a pilot-operated system is actuated, the pilot (primary) always moves first. Once the pilot has operated, the main (secondary) section always moves last. This is true whether the system is being activated or deactivated.

3. The movement of the pilot (primary) controls a very small amount of oil flow (pilot flow). The movement of the main (secondary) controls the majority of the oil flow (main flow) and is responsible for actuating a given system.

The header raise/header lower and reel drive valve are three examples of a pilot operated system used on the combine.

A.10.A / 6

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

GENERAL INFORMATION

The AFX Axial-Flow combines use a very extensive hydraulic system to operate machine functions that are normally associated with belts and chains, along with the normal hydraulic functions. This section will cover the basics of the hydraulic supply system, each actual function will be included with that function’s sections.

This section will cover the reservoirs, filtration, gear pumps, PFC pump and cooling. Since the machine incorporates two reservoirs, the hydraulic system is easily broken into two separate systems.

1. Hydraulics: Operator control functions

2. Control Pressure: Hydrostatic drives, associated

valves and clutches

HYDRAULICS

Hydraulic Reservoir

Steering Ground Drive Header Raise / Lower Rotor Drive Reel Fore / Aft, Raise, and Drive Feeder Drive Lateral Tilt Chopper Clutch Unloading Auger Swing Unloader Clutch Fan Drive Lubrication Spreader Drive Rotary Air Screen Parking Brake / Tow Valve Regulated Pressure

The two systems will incorporate several hydraulic pumps and motor to complete the required operations.

HYDRAULICS

Hydraulic Reservoir

PFC Pump Steering

Header Raise / Lower Lateral Tilt Unloading Auger Swing Reel Fore / Aft and Raise Reel Drive Park Brake / Tow Valve

Regulated Pressure Fan Pump Fan Drive Motor Lube Pump Lubrication Spreader Pump Spreader Drive Motor and Rotary Air

Screen Motor

Control Circuit Pump Beater/Chopper Clutch

CONTROL PRESSURE

PTO Gearbox Reservoir

HYDROSTATICS

PTO Gearbox Reservoir

Unloader Clutch Ground Drive Rotor Drive Feeder Drive

A.10.A / 7

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

SPECIFICATIONS

Component Specification

Electrical Parking Brake / Regulated pressure sensor Control pressure sensor Hydraulic filter restriction switch N/O, Closes at 2.75 bar (40 PSID) Control pressure filter restriction switch N/O, Closes at 2.75 bar (40 PSID) Hydraulic return oil temperature sensor Motor Temp. (Ground Drive) sensor Reservoir tank level switch N/C, Closed with low oil 0.0 ohms Hydraulic Spreader motor relief 210 bar (3000 PSI) Rotary air screen motor relief 24 bar (350 PSI) Fan motor relief 241 bar (3500 PSI) Oil cooler by-pass (Hydraulic cooler) 7.6 bar (110 PSI) Hydraulic filter by-pass 3.45 barD (50 PSID) Regulated pressure 22--25 bar (320--360 PSI) Control pressure filter by-pass 3.45 barD (50 PSID) Control pressure relief 20--22 bar (290--320 PSI) Hot

Lubrication pump / cooler relief 20 bar (290 PSI) Lubrication system relief 3.5 bar (50 PSI) PFC pump low pressure stand-by 26--28 bar (375--400 PSID) PFC pump high pressure stand-by 207--214 bar (3000--3100 PSI) Steering relief 183--190 bar (2650--2750 PSI) Reel drive relief 138 bar (2000 PSI) Header Tilt cushion relief 207 bar (3000 PSI) Feeder lift cylinder thermal relief 276 bar (4000 PSI) Spreader drive pump flow 63 l/m (16.5 GPM) Fandrivepumpflow 51 l/m (13.5 GPM) PFC pump flow 152 l/m (42 GPM) Control pressure pump flow 150 l/m (39.5 GPM) Lubrication pump flow 92.7 l/m (23.5 GPM)

0.0 PSI = 0.5V signal wire C Normal PSI = 3V signal wire C

2500ohms @ room temperature 83 ohms @ 128°C (262°F)

23--25 bar (340--360 PSI) Cold

A.10.A / 8

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

HYDRAULIC SYSTEM

20041519

A.10.A / 9

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Component Locations

1. Supply to Spreader and Fan Pumps 2&3. Gear Pump Assembly, Spreader and Fan Drive

13. PFC Piston Pump

14. Hydraulic Reservoir

15. Signal Line to Compensator

18. PFC Pump Discharge Line

22. PFC Pump Case Drain

24. PFC Pump Suctions

25. Main Valve Assembly

26. Header Lift Valve

27. Park Brake / Regulated Pressure Valve

28. Reel Drive Valve

29. Feeder Valve Assembly

30. Hydraulic Return Filter

A.10.A / 10

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Oil Supply

1. Oil Level Sight Glass

2. Oil Level Sensor

3. Reservoir Tank

4. Outlet Strainer

5. Tank Drain

The hydraulic system is supplied with Hy-Tran Ultra from a central reservoir tank that is mounted behind the PTO gearbox. The tank contains approximately 57L (15 gal) of oil and should be changed out every 1000 hours of operation.

A float type gauge that is mounted in the top of the tanks monitorsthe proper oil level. Thefloat provides an Open/Closed signal to the Universal Display Plus monitor. The switch is N.C. when held in the operating position, open when oil is present.

The tank incorporates a discharge port strainer and tank breather. The strainer is rated at 100 micron of protection and supplies the gear pumps.

A.10.A / 11

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Filtration

2. Discharge Port

3. Not used on the hydraulic filter

4. Inlet Port

10. Filter By-Pass

11. Restrictions Indicator

12. Back Flow Check Valve

The hydraulic filter is on the return side of the hydraulic system, prevent trash from reaching the reservoir tank. It is imperative that only CLEAN Hy-Tran Ultra is placed in the tank. The filter base incorporates a filter restriction sensor (11) that monitors the condition of the filter element. If the restriction increases above 2.76 bar (40 PSID) differential pressure the sensor will CLOSE to create a signal to the Universal Display Plus monitor for operator warning. The filter base incorporates a filter by-pass valve that will open at 3.45 bar (50 PSID) differential pressure to prevent over pressuring the filter.Thesensor is set toactivate prior to the by-pass valve opening.

Cooling

1. Intercooler

2. Radiator

3. PTO Gearbox Oil Cooler

4. Hydraulic Oil Cooler

5. Air Conditioning Condenser

6. Fuel Cooler

The hydraulic cooler is mounted behind the rotary air screen and is the Lower third of the center cooler. There is a 7.6 bar (110 PSI) oil cooler by-pass valve mounted in the lower front corner to protect the cooler.

20030149

A.10.A / 12

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Gear Pumps

1. Fan Drive Output (rear pump)

2. Spreader and Rotary Air Screen Output (center

pump)

3. Control Pressure Output (front pump)

4. Supply From PTO Gearbox, (for pump 3)

5. Supply From Hydraulic Reservoir, (for pumps 1 and

The gear pump assembly is mounted in the PTO gearbox and incorporates three separate gear pumps.

-- T h e Control Pressure pump, (pump 3, nearest to the drive shaft), is supplied oil from the PTO gearbox and all of its flow is returned to the PTO gearbox. See specification page.

-- T h e Spreader/Rotary Air Screen Drivepumpis supplied oil from the hydraulic reservoir and returns all of its flow back to the reservoir. See specification page.

-- T h e Fan Drive pump is supplied oil from the hydraulic reservoir and returns all of its flow back to the reservoir. See specification page.

NOTE: If the seal was to leak between the front and center pumps oil could transfer between reservoirs.

A.10.A / 13

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Schematic

1. Reservoir Strainer

2. Spreader/Rotary Air Screen Drive Pump

3. Fan Drive Pump

4. Spreader Drive Valve

5. Rotary Air Screen Valve

6. Oil Cooler

7. Oil Cooler By-Pass Valve

8. Fan Drive Valve

9. Return Filter Base

10. Filter By-Pass Valve

11. Filter Restriction Indicator Switch

12. Back Flow Check Valve

13. PFC Piston Pump

14. Reservoir Tank

15. Return From All Hydraulic Functions

A.10.A / 14

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Schematic

Spreader Pump

The spreader pump (2) will pull oil from the hydraulic reservoir (14) and direct it to the spreader valve (4). The spreader valve willdirect the full flow of pump on to the rotary air screen valve (5) once the spreader operation is completed. The rotary air screen valve will direct the full flow of pump on to the oil cooler (6) once the air screen operation is completed. In cold whether the cooler may cause excessive restriction

so the by-pass valve (7) candirect the oil flow around the cooler the filter housing (9). The filter restriction is monitored by the filter sensor (11) and is protected by the by-pass valve (10). The filter directs the flow to the PFC pump inlet and the reservoir tank.

IMPORTANT: The spreader pump being a gear pump is associatedwith anopen center system. Inan open center system the pump flow is constant and MUST be routed back to the reservoir at all times. It can not be deadheaded or serious failures can occur.

A.10.A / 15

Page 32

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Schematic

1. Reservoir Strainer

2. Spreader/Rotary Air Screen Drive Pump

3. Fan Drive Pump

4. Spreader Drive Valve

5. Rotary Air Screen Drive Valve

6. Oil Cooler

7. Oil Cooler By-Pass Valve

8. Fan Drive Valve

9. Return Filter Base

10. Filter By-Pass Valve

11. Filter Restriction Indicator Switch

12. Back Flow Check Valve

13. PFC Piston Pump

14. Reservoir Tank

15. Return From All Hydraulic Functions

A.10.A / 16

Page 33

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Schematic

Fan Pump

The fan pump (3) will pull oil from the hydraulic reservoir (14)and direct ittothefan valve (8). The fan valve willdirect the fullflow of pump into the flowfrom the spreader pump headed to the filter base (9). The filter restriction is monitored by the filter sensor (11) and is protected by the by-pass valve (10). The filter directs the flow to the PFC pump inlet and the reservoir tank.

IMPORTANT: The fan pump being a gear pump is associated with an open center system. In an open center system the pump flow is constant and MUST be routed back to the reservoir at all times. It can not be deadheaded or serious failures can occur.

A.10.A / 17

Page 34

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Pressure Flow Compensating (PFC) Pump Hydraulic System

PFC Pump Schematic

9. Return Filter Base

13. PFC Pump Assembly

14. Hydraulic Reservoir

15. Signal Line to Compensator

16. Signal Line Screen

17. Flow Control Spool

18. Pump Discharge Port

19. High Pressure Spool

20. Servo Piston (swashplate)

21. Rotating Assembly

22. Case Drain

23. Temperature Sensor

24. Supply Manifold

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Page 35

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PFC Component Locations

1. Supply to Spreader and Fan Pumps

2&3. Gear Pump Assembly, Spreader and Fan Drive

13. PFC Piston Pump

14. Hydraulic Reservoir

15. Signal Line to Compensator

18. PFC Pump Discharge Line

22. PFC Pump Case Drain

24. PFC Pump Suctions

A.10.A / 19

Page 36

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic System

PFC Piston Pump

The PFC pump assembly is mounted to and driven by the PTO gearbox. The PFC pump will only produce the pressure and flow required meeting system demands when they occur. When discussing PFC hydraulics, it is important to realize that with the engine running the hydraulic system will always be in one of three modes:

• Low-pressure standby (could be thought of as neutral).

• Pressure and flow compensation (when the system is meeting the demand for oil).

• High-pressure standby (could be thought of as high-pressure relief).

The pump output is alsodirected to the parkingbrake / tow valve where a regulated pressure is created and maintained for the pilot operated valve assembles.

A.10.A / 20

Page 37

PFC Piston Pump

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

M207703A

1. High Pressure Spool Adjustment

2. Flow Control Spool Adjustment

3. Case Drain to Tank

M207003

4. Signal Line to Compensator

5. Temperature Switch

A.10.A / 21

Page 38

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Systems

PFC Pump Operation

The PFC pump assembly is located directly in front of the reservoir. The PFC pump is an axial-piston type pump. When the drive shaft of the piston pump is rotated, the piston cylinder block, which is splined to the drive shaft, also turns. The piston block contains nine piston assemblies which have free swiveling slippers attached to the ball-end of the piston assembly. The slippers ride against the machined surface of the swash plate.

When the swash plate is tilted from neutral to its maximum angle by the swash plate control spring, the piston slippers follow the inclined surface of the swash plate and begin moving in and out of the piston block bore. Half of the piston assemblies are being pulled out of the piston block while the remaining half of the pistons are being pushed back into the piston block. As thepistons are pulled from the pistonblock, they draw oil into the piston block bores. This supply oil comes from the kidney shaped intake port. As the piston crosses over top dead center, the piston push the oil out of the piston block bores into a kidney shaped outletpressure port. Each of the nine pistons completes this cycle for each revolution of the pump shaft. This causes a continuous even flow of oil from the pump.

The greater the swash plate angle, the greater the piston stroke. Thisincrease in stroke causes more oil to be pulled into the pump and discharged out of the

pressure port.When the engine is at high idle andthe swash plate is at itsmaximum anglethe pump output is approximately 152 l/m (40 GPM).

NOTE: The pump is always engaged by the swash plate spring to its maximum output. The compensator is always reducing the pumps output.

Pump Compensator

The pumpcompensator assembly controls the angle of the swash plate by directing oil to the swash plate control piston. The swash plate control piston will over come the swash platecontrol spring, placing the swash plate at the proper angle.

The main valve assembly, feeder valve assembly and steering hand pump each contain a signal port. The signal port and associated lines direct a signal pressure to the pump compensator. This signal pressure is equal to the system work pressure. The pump compensator will use this signal to place the piston pump swash plate at the proper angle to meet the system demand. Theoutlet pressureat the pump will be 27.6 bar (400 psi) higher than the signal line pressure due to the 27.6 bar (400 psi) spring in the compensator.Thepumpoutletpressure will continue to be 27.6 bar (400 psi) higher than signal line pressure until the high-pressure standby pressure is reached. After high pressure standby is reached, the pump outlet pressure andthe signal line pressure will become equal.

A.10.A / 22

Page 39

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Systems

Low Pressure Standby

20043057

4 6

(Pump assembly is a representative drawingonly.)

M207703B

A.10.A / 23

Page 40

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Systems

Low Pressure Standby

When there is no demand for oil flow, the pump will go into the low-pressure standby mode. Low-pressure standby means low pressure and minimal flow in the system. When the engine is not running, no pressure exists in any circuit. In this state, the swash plate control spring is holding the piston pump at full stroke. When the engine is started and the pump begins to rotate, it will momentarily try to pump oil. This creates outlet pressure at the pump. This pressure is directed to the flow compensator spool and the high-pressure spool through passages in the piston pump back plate. The two spools in the pump compensator are both spring biased. The flow compensator spool has a 27.6 bar (400 psi) spring while the high-pressure spool has a 186.3 bar (3050 psi) spring. The pump pressure is directed to the non-spring side of these two spools. As pressure builds, it will cause the flow compensator spool to shift against its 27.6 bar (400 psi) spring. When the spool shifts it allows pump oil to pass to the pump control piston. This piston will extend and cause the swash plate to move against the control spring. The swash plate will move to a nearly zero degree angle,

de-stroking the pump. In this condition, the pump will only move enough oil to make up for internal leakage within the system and maintain 31--41.5 bar (450--600 psi). The pump will remain in this position until there is a demand for oil. In low-pressure standby mode the pump produces less heat and uses less horsepower than an open-center system. Low pressure standby also makes starting the engine easier.

Minimum system pressure is 31--41.5 bar (450--600 psi) in the low-pressure standby mode. There is a

0.61 mm (0.024in) dynamic sensor orifice located in the steering priority spool. The dynamic sensor orifice connects the pump outlet port to the signal port of the pump compensator through the orifice check valve. If the oil in the signal line can flow through the steeringhand pump too freely a 0.78mm (0.031″) orifice in the steering hand pump signal passage provides back pressure in the signal line. This signal pressure of 3.45--10.3 bar (50--150 psi) is sent to thespring-end of the flow compensatorspool. The spring pressure of 27.6 bar (400 psi) plus the signal line back pressure puts the pump into low pressure standby mode ranging from 31--41.5 bar (450--600 psi).

1. Signal Line-In

2. Flow Control Spool

3. High Pressure Spool

4. To Control Piston

5. Drain to Tank

6. Pump Output

A. Low Pressure Standby Oil B. Drain Oil C. Trapped Oil

A.10.A / 24

Page 41

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Systems

Pressure and Flow Compensation

4 6

20043058

(Pump assembly is a representative drawingonly.)

M207703B

A.10.A / 25

Page 42

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Systems

Pressure and Flow Compensation

The flow of oil from the pump is controlled by the difference in pressure at opposite ends of the flow compensator spool. When a valve is opened to operate a function on the combine, the outlet pressure of the pump will drop. This drop in pressure is detected on the non-spring end of the flow compensator spool. The spring will now shift the spool and allow oil to drain from the pump control piston into the pump case. The swash plate control spring will tilt the swash plate, causing the pump to

1. Signal Line-In

2. Flow Control Spool

3. High Pressure Spool

4. To Control Piston

5. Drain to Tank

6. Pump Output

provide more oil flow. When the flow demand of the system ismet,the swash plate willbe tilted toprovide only the flow required by the component(s) in use. The workingpressurein thesystem is fed back to the spring-end of the flow compensator spool through the signal line. The pump must produce flow at a pressure equal to the working pressure desired, plus enough to overcome the 27.6 bar (400 psi) spring on the flow compensator spool. When the outlet pressure is high enough to overcome both the spring and work pressure, the flow compensator spool will shift allowing oil to flow to the control piston, causing the pump to destroke to match the demand.

A. Pressurized Oil B. Drain Oil

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Page 43

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Systems

High Pressure Standby

4 6 2

20043059

(Pump assembly is a representative drawingonly.)

M207703B

A.10.A / 27

Page 44

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic Systems

High Pressure Standby

Should the hydraulic system stall-out under a high load, or a cylinder reach the end of its stroke, the pump will go into high-pressure standby until the load is overcome or the valve is returned to neutral. When the system stalls-out, there will be no flow across the controlling valve. The pressure will then equalize on both ends of the flow compensator spool. The spring will then cause the flow compensator spool to shift. Atthesametime,thepressurewillstarttoriseinthe system until it is able to move the spring-loaded high-pressure spool. This spring is set at

182.85--189.75 bar (3050 psi). When the high-pres-

sure compensator spool shifts, it directs oil to the swash plate control piston, de-stroking the pump.

1. Signal Line-In

2. Flow Control Spool

3. High Pressure Spool

4. To Control Piston

5. Drain to Tank

6. Pump Output

The pump will remain in the high-pressure standby mode until the load is overcome or the valve is returned to neutral. When the valve is returned to neutral, pressure is no longer available to the signal line. The flowcompensator spool willshift allowing oil to extend the control piston and destroke the pump. Signal line pressure is bled-off through a 0.5 mm (0.020″) signal orifice check valve threaded into the steering priory valve, a 0.89 mm (0.035″) dampening orifice located in the steering priority valve, a 0.78 mm (0.031″) orifice in the steering hand pump and then to the reservoir. When the signal pressure is bled-off, the flow compensator spool will return the system to low pressure standby.

A. Maximum High Pressure Oil B. Drain Oil

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Page 45

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Signal Circuits

The signal circuit pressure may be generated from the following sources:

• Steering Circuit

• Header Raise Circuit

• Signal Valve Circuit

• Lateral Tilt Valve

• Reel Drive Valve

The steering, header raise, field tracker and reel drive circuits react differently than the reel raise, reel fore/aft and unloading auger swing circuits. This is due to the location of the signal line. The steering, reel drive, terrain tracker and header raise rates are variable by the operator, unlike the other functions, which are not adjustable. For example, the steering speed can be affected by how fast the operatorturns the steering wheel. The header raise rate can be increased or decreased by changing the raise rate setting on the Universal Display Plus monitor. However, the adjustments for speed of reel raise, reel fore/aft andunloading auger swing are set by the size of the orifices in each valve.

The signal line for the variable control systems (steering, terraintracker,reel drive and headerraise) is located after each control valve, (monitoring the circuit work pressure). In this location, the signal line will sense actual working pressure in the cylinder(s).

The reel raise, reel fore/aft and unloading auger swing can NOT create a signal. When any of these functions are activated the jammer valve is also activated. The jammer valve is used to direct full pump pressure into the signal line, this causes the PFC pump to go the high pressure standby. Asupply side orifice in each valve controls the speed at which these function operated.

The jammer valve is connected before the orifices that control the actuation speed. As a result, the signal pressure sensed is not the actual working pressure at the cylinder(s), but full system pressure. In this case, no pressure drop is detected and the oil pressure on either side of the flow compensator spool will remain equal. This situation will cause the system to go on high-pressure standby whenever reel raise, reel fore/aft and unloading auger swing are operated.

Within the PFC system there are five checks valves located in the signal lines. One at the header valve, one at the steering priority valve, one in the reel drive valve and two in the lateral tilt valve. The purpose of these checks is to allow the highest signal line pressure to get back to the compensator. This will make sure that the component with the highest-pressure demand is satisfied.

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Page 46

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Steering Priority Valve

Main Machine Stack Valve

1. Signal from Steering

2. Supply to Feeder

Valve

3. Supply to Steering Hand pump

4. Not indicated

5. Screen

6. Steering Signal

Check Valve

7. Signal Bleed Off Orifice

8. Dynamic Orifice

9. Not indicated

10. Screen

11. Damping Orifice

12. Pump PSI

13. Signal PSI

14. Spring

15. DIAG Test Port

16. From PFC Pump

17. Signal Line Test Port

A.10.A / 30

M210303 A

M210103

Page 47

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

STEERING CIRCUIT

Steering Priority Valve

The steering priority valve is integral with the main stack valve on the left side of the combine. The primary function of the steering priority valve is to maintain a priority flow of oil to the steering system. Oil from the PFC pump is directed to the inlet of the steering priority valve. Inside the valve is the priority spool, which is spring biased. The spring will position the spool so incoming oil will to go to the steering hand pump first.

When steering is not being used, pressure will increase due to the closed-center steering hand pump. This build-up of pressure is directed to the non-spring end (12) of the priority spool through a screened 0.79 mm (0.031 in) damping orifice (11). At the same time, a screened 0.64 mm (0.025 in) dynamic sensor orifice (8) directs oil to the spring-end of the priority spool and tothe signal line.The dynamic sensor orifice keeps the signal line filled with oil to keep the steering responsive. Atthe same time this oil is allowed to drain to the reservoir through the orifice in the steering hand pump spool. If the oil in the signal line can flow through the steering hand pump too freely, the 0.79 mm (0.031 in) orifice in the steering hand pump will create a back pressure of 10.3 bar (50--150 psi) in the signal line. This pressure in the signal line plus the 27.6 bar (400 psi) springs in the compensator act together to put the system at low pressure standby. With the oil on the spring-side (13)

of the priority spool draining to the reservoir, and the increased pressure on the opposite end, the spool will shift against the spring. The priority spool will meter just enough oil to the steering circuit to make-up for the oil being bled-off through the 0.79 mm (0.031 in) orifice in the steering hand pump during low pressure standby. On the spring-end of the steering priority spool is an orifice (8) fitting that connects the steering hand pump signal line to the steering priority valve. This orifice fitting has a 0.79 mm (0.031 in) orifice in it, which serves as a dampening orifice to control priority spool movement.

The steering hand pump circuit is opened when steering is required. This will cause a pressure drop on the non-spring end of the priority spool. The spring will shift the priority spool to direct oil out to the steering hand pump. The PFC pump will stroke to meet the steering demand. When steering demand is satisfied, pressure will start to build on the non-spring endof the priority spool. The pressurewill overcome the spring, shifting the priority spool, thus allowing excess oil to be supplied to the main valve assembly if required.

Threaded into the steering priority valve is a screened 0.50--mm (0.020in) orifice check. This orifice check allows oil pressure to get to the compensator when in low-pressure standby mode and when steering the combine. It also allows signal line pressure, once a function has been completed, to bleed from the compensator to reservoir through the steering hand pump, which de-strokes the pump.

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Page 48

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Steering Hand Pump

M231303

M231203

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Page 49

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

STEERING CIRCUIT

Steering Hand Pump

AFX Series Combines use an Eaton steering hand pump. This hand pump is a closed-center, load-sensing design to minimize horsepower consumption and heat generation. The NAunit is328 cc with 4.5 turns lock to lock and the EUR unit is 320 cc with 4.7 turns lock to lock. Two 2.25″ X 13.4″ cylinders are used to turn the wheels.

Steering Neutral

When there is no demand for steering, the spring-centered main spool and sleeve block the oil inlet port and the ports to the steering cylinder. At the same time the main spool and sleeve open a passage so the signal line can drain to the reservoir. The 0.64 mm (0.025 in) dynamic sensor orifice directs oil to the spring-end of the priority spool and to the signal line. The dynamic sensor orifice keeps the signal line filled with oil to keep the steering responsive. At the same time this oil is allowed to drain to the reservoir through the orifice (1) in the steering hand pump. The orifice in the steering hand pump will create a back pressure of 10.3 bar (50--150 psi) in the signal line. This pressure in the signal line plus the 27.6 bar (400 psi) spring in the compensator act together to put the system at low pressure standby. The internal check valve between the supply and return passages is closed at this time.

Power Turn (left or right)

Oil from the PFC pump enters the steering hand pump at the supply port. This opens the spring-loaded check valve and seats the recirculation check. As the steering wheel is rotated (left or right), the main spool will move within the sleeve. This movement will direct oil to the metering section as well as to the signal line. The metering section begins to rotate with the rotation of the steering wheel. This moves oil from the PFC pump to the rod-end or the base end of thecylinder depending on the direction of rotation. At this point the oil pressure going to the cylinders is also transmitted back to the compensator by way of the signal line.

Oil returning from the cylinder is directed back to the main spool and sleeve, then out the return port of the steering hand pump to the oil filter. When rotation of the steering wheel is stopped, the spring-centered main spool and sleeve return to the neutral position. This stops oil flow to the metering section and traps oil in the cylinder.

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Page 50

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Steering Relief Valve

A. Steering Handpump B. To Steering Cylinders C. Return Line D. Signal Line

E. Supply Line F. Steering Priority Valve G. Check Valve

M231403

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Page 51

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

STEERING RELIEF VALVE

If the steering wheels are turned to their stops, or the wheels can no longer be turned, the steering system pressure increases until it goes on relief. When the pressure increases above 182.7--189.6 bar (2650--2750 psi), a simple relief valve (2) located in the steering hand pump signal line will open. An orifice (1) is located in the hand pump to limit the amount of oil that is being feed into the signal line, so that the relief valve canlimit thepressure in the signal line. This will limit the signal pressure available tothe steering priority valve and the compensator. The purpose of this relief valve is to limit the maximum pressure available to the spring-side of the priority spool, thus allowing oil to flow to the main valve assembly. If the steering relief pressure is set too close to the high-pressure stand-by pressure, the oil flow to the main valve assembly may be cut off when the steering relief valve opens. This relief valve is factory set to provide a pump supply pressure between 182.7--189.6 bar (2650--2750 psi).

Manual Steering

The steering circuit will permit manual steering control of the combine in the event of a dead engine; however, steering effort is more demanding. Manual steering uses the existing oil in the steering circuit for the oil supply, and the operator turning the steering wheel as input power. In manual steering operation,

the metering section (turned by the operator) is used as the pump to supply oil to the steering cylinder.

Manual Turn (left or right)

As the operator rotates the steering wheel, the centering springs compress and the main spool changes relationship to the sleeve. Since there is no supply of hydraulic oil from the PFC pump, the inlet check valve will be held on its seat by the spring. At this point, the recirculation check ball will not be seated due to the fact there is no incoming oil. This allows oil from the return port to be drawn past the recirculation check, through the main spool and sleeve, to supply the metering section, which is now acting as the pump. The metering section controls the amount of oil being directed to the cylinder based on the rotation speed of the steering wheel. Oil flow from the metering section is then directed to the spool and sleeve, then out to the steering cylinder.

Oil returning from the steering cylinder is directed back to the main spool and sleeve, then to the return port. Since return port oil is now the supply to the metering section, and the recirculation ball is off its seat, the oil can again be directed to the metering section for a continuous supply.

When the rotation of the steering wheel is stopped, the centering springs return the main spool and sleeve to a neutral position.

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Page 52

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

HYDRAULIC SYSTEM

Electrical Monitoring Circuits

The system uses a number of sensors to monitor the systems operations.

HYDRAULIC FILTER RESTRICTIONS SWITCH

Reference Material:

Electrical schematic frames #10

Key Components:

Hydraulic Filter Restriction Switch S--32, CCM1, ground (1)

The filter restriction switch is used to monitor the condition of the filter. The switch is a N/O switch. When the pressure differential on the filter exceeds the specifications the switch piston will shuttle over connecting the power wire to the filter base, providing a ground. The filter restriction indicator should illuminate prior to the filter by-pass opening, providing the operator time to replace the filter.

Power is supplied to the sensor from the CCM1 connector X019 terminal J2--34 to the sensor terminal B. The sensor terminal A is directed to the chassis ground (1).

HYDRAULIC OIL TEMPERATURE SENSOR

Reference Material:

Electrical schematic frames #10

The reservoir tank temperature sensor monitors the oil temperature in the reservoir tank. If the temperature should climb above 128 resistance of the sensor will be reduced to a point at which enough current will flow through it providing the CCM1 with a signal. At room temperature the sensor readsapproximately 2500 ohms andreduces as the temperature increases.

Power is supplied to the sensor from the CCM1 connector X019 terminal J2--24 to the sensor terminal B. The sensor terminal A is directed back to the CCM1 connector X019 terminal J2--14.

NOTE: The diagnostic screen on the Universal Display Plus monitor monitors the supply wire B.

C (260oF), the

RESERVOIR TANK LEVEL SWITCH

Reference Material:

Electrical schematic frames #10

Key Components:

Hydraulic Oil Level Switch S--33, CCM2, ground (1)

The reservoir tank level sensor monitors the oil level in the reservoir tank. If the levelshould fall too low the sensor will close, providing a complete circuit.

Power is supplied to the sensor from the CCM2 connector X016 terminal J2--39 to the sensor terminal B. The sensor terminal A is directed to the chassis ground (1).

Key Components:

Hydraulic Oil Temperature Sensor B--18, CCM1

Located:

In the PFC pump inlet manifold

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Page 53

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

REGULATED PRESSURE

Park Brake / Regulated Pressure Valve

1. Park Brake/Regulated Pressure Assembly

Park Brake / Regulated Pressure Valve

Regulated pressure is used for two functions:

1. To control thesecondary portionof pilot operated valve assembles, Header Raise / Lower and Reel Drive valve. The primary spool uses regulated pressure to control the position of the secondary spool, the secondary spools will be controlling the operating flow from the PFC pump.

2. To release the Parking Brake and provide oil for the tow valve assembly.

10035346

A.10.A / 37

Page 54

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Location

M227503

Regulated Pressure Schematic

M227403

1. Park Brake/Reg. Valve Assembly

2. Supply From PFC Pump

3. Return to Tank

4. Regulated Pressure Valve

5. Pilot Line

6. To Regulated Circuits

7. Park Brake Valve

8. Tow Valve (Hand Pump)

9. Isolation Valve (Tow Operations)

10. Regulated Pressure Sensor

11. Park Brake Release

12. Regulated Test Port

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Page 55

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Regulated Pressure Valve Operation

Reference Material:

Hydraulic Schematic

Key Components:

Regulated/Park Brake/Tow Valve Assembly

Regulated Pressure

The Regulating /Park Brake valve is teed into the hydraulic supply linefrom the PFC pump so when the PFC pump is operating, regardless of output pressure, the valve is receiving pump working pressure. PFC pump low pressure stand-by may vary between 31--41 bar(450--600 PSI) so it is the job of the regulated valve to maintain a regulated pressure of 22--25 bar (320--360 PSI) for the complete regulated circuit.

PFC is supplied at port (2) and is directed to the regulated valve assembly. All regulated functions are closed circuit operations, meaning they don’t require large volumes of oil BUT demand constant pressure. Since there is no real flow of oil through the circuits the pressure will stabilize at the current PFC working pressure which is to high. The regulating valve, through the pilot line (5), is monitoring the regulated pressure AFTER the valve. As the regulated pressure increasethepressure is also directed tothe non-spring end of the regulating valve and shuttles it against the spring, restricting the inflow of oil into the regulated circuit, maintaining the circuit pressure.

Regulated pressure may be tested at the test port (12).

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Page 56

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Electrical Monitoring Circuits

Park Brake Pressure Sensor

Reference Material:

Electrical schematic frames #9, #27

Key Components:

Park Brake Sensor B--53, CCM2

A pressure sensor is used to monitor the parking brake release pressure, in turn monitoring the regulated pressure. The sensor provides a constant voltage reading to the CCM2, and the CCM2 places a message on the data bus for the Universal Display

Plus monitor. If the pressure falls below specification the park brake indicator lamp will illuminate warning to the operator. The sensor is a variable resistance sensor.

A 5V power is supplied to the sensor from the CCM2 connector X017 terminal J3--26 to the sensor terminal B. The sensor terminal A is directed back to the CCM2 connector X0016 terminal J2--14. The sensor terminal C is providing a variable signal voltage to the CCM2 connector X017 terminal J3--34.

NOTE: The diagnostic screen on the Universal Display Plus monitor is monitoring the signal wire C.

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Page 57

Control Pressure

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

50035347

1. Supply from PTO Gearbox

2. Control Pressure Pump

3. Control Pressure Manifold and Sensor

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Page 58

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

CONTROL PRESSURE SYSTEM

On the AFX combines there are three individual hydrostatic drives, they all share common components. In the past we were accustomed to having a charge pump and filtering system for each hydrostatic drive, this system will use a common charge pump and filter for all drives. We would normally have call this the CHARGE pump and filter for the hydrostatic drive, it is now the CONTROL PRESSURE circuit.

Normally the hydrostatic drive charge pump is mounted inside the hydrostatic pump end cover, not

so on the AFX combine. Since the control pump will be supplying all three hydrostatic drives a larger pump is required. The control pump is the largest gear pump section of the gear pump assembly. The customary charge pump that is incorporated into the ground drive hydrostatic pumpassembly will be used ONLY for PTO gearbox cooling lubrication.

NOTE: The Charge pressure is identified as “Control Pressure.”

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Page 59

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

M207903

1. Supply From PTO Gearbox

3. Control Pressure Pump

12. Control Pressure Test Port and Sensor

17. PTO Gearbox

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Page 60

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

M208303 B

2. Control Circuit Filter

3. Gear Pump Assembly

6. Control / Lube Pressure Regulating Valve

18. Pump to Filter Line

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Page 61

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control Pressure Pump

1. Fan Drive Output (rear pump)

2. Spreader and Rotary Air Screen Output (center

pump)

3. Control Pressure Output (front pump)

4. Supply From PTO Gearbox, (for pump 3)

5. Supply From Hydraulic Reservoir, (for pumps 1 and

The gear pump assembly is mounted in the PTO gearbox and incorporates three separate gear pumps.

The Control Pressure pump, (pump 3, nearest to the drive shaft), is supplied oil from the PTO gearbox and all of its flow is returned to the PTO gearbox. See specification page.

The Spreader/Rotary AirScreen Drive pump is supplied oil from the hydraulic reservoir and returns all of its flow back to the reservoir. See specification page.

M207203

The Fan Drive pump is supplied oil from the hydraulic reservoir and returns all of its flow back to the reservoir. See specification page.

NOTE: If the seal was to leak between the front and center pumps oil could transfer between reservoirs.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Filtration

2. Filter Base

4. Restrictions Indicator

5. Filter By-Pass Port

The control pressure filter is onthe supply side of the control pressure circuits, the filter is a pressure filter. The filter base incorporates a filter restriction sensor (4) that monitors the condition of the filter element. If the restriction increases above 2.76 bar (40 PSID) differential pressure the sensor will CLOSE to create a signal to the Universal Display Plus monitor for operator warning.

The filter baseincorporates a filter by-pass valve that will open at 3.45 bar (50 PSID) differential pressure to prevent over pressuring the filter. Since the flow is supplying the hydrostatic pumps and motor the filter by-pass does NOT permit dirty oil to flow through the filter base down stream. The filter base directs the by-pass out port (5) to the return manifold. The sensor is set to activate prior to the by-pass valve opening.

M207103

M208003 B

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control / Lubrication Pressure Valve

M208103

M208003 C

5. Filter Base By-Pass IN Port

6. Valve Body

7. Control Pressure Regulating Valve

8. Screen

9. Orifice

The Control/Lube pressure control valve regulates both the control pressure and lube pressure. The valve is supplied oil from the control pressure pump at port (18) and is exposed to the regulator (7). The regulator is adjustable to maintain a control pressure of 20--22 bar (290--320 PSI). If the pressure exceeds the spring setting the valve will shuttle and direct the flow to the return port (RET).

The valve body also receives the filter by-pass oil at port (5) and combines it with the oil from both pressure regulators. The combined oil is directed out the return port (RET) to the return filter and back to the PTO reservoir or the lubrication pump.

11. Lubrication Pressure Regulating Valve

18. Control Pressure Supply

19. Control Pressure OUT Port

20. Lubrication Pressure Switch

The lubrication pressure is checked at the diagnostic test port (20). The lubrication oil is supplied from the lubrication pump, which discussed later in this section.

NOTE: The screen and orifice provide for an air bleed on initial start up at the plant or if the system is drained completely. If the orifice was plugged the control pressure pump could have problemspriming. It will bleed approximately 1.9 L/m (0.5 GPM) to the PTO gearbox.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control Pressure Schematic

M208003

1. PTO Reservoir

2. Control Pressure Circuit Filter

3. Control Circuit Pump

4. Filter Restriction Switch

5. Filter By-Pass Port

6. Control / Lubrication Pres. Reg. Valve

7. Control Pressure Valve

8. Screen

9. Orifice

10. Drain

11. Lubrication Pressure Valve

12. Control Pressure Distribution Manifold

13. Control Pressure Test Port

14. Control Pressure Sensor

15. Return Manifold

16. To The Lubrication Pump / Tank

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control Pressure Schematic

The control circuit pump is used to supply the ground, rotor, and feeder drive hydrostatics and their associated control valves, the unloading auger and chopper/separator clutches. Excess oil is bypassed through the controlvalve and isreturned to thereturn manifold. All the oil from the return manifold is directed to the lubrication pump inlet, then to the control pump inlet. These two pumps will consume all the return flow and still need more oil to pump. The control circuit pump will receive the remaining oil from the PTO gearbox reservoir/sump.

1. The control circuit pump pulls oil from the return manifold and the PTO gearbox and directs it to the control circuit filter base

2. The filter base monitors the filter restriction and by-pass the oil if needed and directs the oil to the Control/Lube Pressure regulating valve.

3. The control pressure is regulated by an adjustable relief valve and directed out to the distribution manifold. All excess oil that is bleed off by the regulatingvalve is directed to the return manifold and sent to the PTO gearbox and charge the lubrication and control circuit pump.

4. The distribution manifold contains a pressure sensor to monitor the Control Pressure, sending a signal to the Universal Display Plus monitor for operator information.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Electrical Monitoring Circuits

The systemusestwo sensors to monitor the systems operations.

Control Pressure Filter Restrictions Switch

Reference Material:

Electrical schematic frames #10

Key Components:

Filter Restrictions Switch S--34, CCM1

The filter restriction switch is used to monitor the condition of the filter. The switch is a N/O switch. When the pressure differential exceeds the specifications the switch piston will shuttle over connecting the power wire to the ground.

Power is supplied from the CCM1 connector X019 terminal J2--35 to the B terminal on the switch. The A terminal is directed to chassis ground point (1).

Control Pressure Sensor

Reference Material:

Electrical schematic frames #10, #27

Key Components:

Control Pressure Sensor B--35, CCM2

Location:

In the control pressure manifold at the feeder drive pump.

The control pressure sensor is used to monitor the control pressure. The sensor provides a constant pressure reading to the CCM2. The CCM2 places a message on the data bus for the Universal Display Plus monitor to display and provides a warning if the pressure should drop, providing a warning to the operator.

A 5V power supply from the CCM2 connector X016 terminal J2--31 is directed to the B terminal of the sensor and a return wire from the A terminal is directed back to the CCM2 connector X016 terminal J2--14. The sensors C wire provides the pressure signal to the CCM2 connector X016 terminal J2--19. When the pressure is normal, a signal voltage above 3V is normal. The reading may be monitor on the Universal Display Plus monitor diagnostic screen.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PTO GEARBOX COOLING AND LUBRICATION SYSTEM

50041513

A.10.A / 51

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

LUBRICATION SYSTEM

1. PTO Gearbox Reservoir / To Lube Pump

4. Ground Drive Hydro. Pump

5. Lube Filter

M208503

6. To Oil Cooler

12. Return Manifold

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

1. PTO Gearbox Reservoir

2. Lubrication Pump

3. Filter and Cooler Relief

4. Ground Drive Hydro. Pump

5. Lube Filter

6. Lube Cooler

7. Lube Relief

M208403

8. Lube Pressure Sensor

9. Lube to PTO Gearbox

10. Lube to PTO Gearbox

11. Control / Lube Regulator Valve

12. Return Manifold

13. Motor Temp. (ground drive motor) Sensor

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Lubrication System

The lubrication system is used toprovide coolingand lubrication to the PTO gearbox and all components housed with init. The system consist of a lube pump, pump relief, lube filter, oil cooler, lube relief and required plumbing. The pump and pump relief is enclosed in the ground drive hydrostatic pump, we would think of them as the hydro charge pump and charge pressure relief.

If the lube pump relief (3) valve opens the flow is dumped into the ground drive hydro. pump and directed out the pump case drain. The relief protects the pump, filter and cooler from being over pressurized. The cooler is located behind the rotary

air screen and is the upper section of thefirst layer of coolers.

The lube regulating valve (7) limits the maximum lube pressure in the system. The minimum lube pressure will be determined by the output of the lube pump. The pressure may be monitored on the Universal Display Plus monitor from the pressure sensor at port (8).

The ground drive hydrostatic motor case drain (13) is monitor for temperature before it enters the return manifold. The motor case drain should be the hottest return oil in the system.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PTO Gearbox Cooling

1. Intercooler

2. Radiator

3. PTO Gearbox Oil Cooler

4. Hydraulic Oil Cooler

5. Air-Conditioning Condenser

6. Fuel Cooler

Cooling

The PTO gearbox cooler is mounted behind the rotary air screen and is the UPPER two thirds of the center cooler.

20030149

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Lubrication System

Electrical Monitoring Circuits

The system uses a sensor to monitor the systems operations.

Ground Drive Motor Temperature Sensor, (case drain)

Reference Material:

Electrical schematic frames #08, #26

Key Components:

Hydrostatic Motor Temperature Sensor B--46, CCM1

The ground drive motor temperature sensor monitors the oil temperature from the case drain of the ground drive hydrostatic motor. The sensor provides a constant temperature reading to the CCM1, the CCM1 then places a message on the data bus. If the temperature rises above specification the CCM1 will place a warning message on the data bus for the Universal Display Plus monitor to display, provide a warning to the operator. The temperature may be monitor on the Universal Display Plus monitor.

Power is supplied to the sensor from the CCM1 connector X020 terminal J3--31 to the B terminal and the sensors A terminal is directed back to the CCM1 connector X020 terminal J3--18. As the temperature increases the resistance of the sensor decreases, providing for a voltage drop on the supply wire. The signal voltage may be monitored on the Universal Display Plus monitor diagnostic screen.

Lubrication Pressure Sensor, (PTO Gearbox)

Reference Material:

Electrical schematic frames #10 and 26

Key Components:

CCM1, Lubrication Pressure Sensor B--60

The lubrication pressure sensor is mounted in the control / lubrication control valve block and is used to monitor the lube pressure to the PTO gearbox components. The sensor provides a constant pressure reading to the CCM1, then places a message on the data bus. If the pressure goes outside of the normal limits the CCM1 will place a message on the data bus for the Universal Display Plus monitor to display awarning tothe operator. The pressure may be monitor on the Universal Display Plus monitor.

Power (5V) is supplied to the sensor from the CCM1 connector X019 terminal J2--31 to the B terminal and a sensor return (ground) from terminal A back to the CCM1 connector X019 terminal J2--14. The sensor provides a signal from terminal C to the CCM1 connector X019 terminal J2--29. The signal voltage may be monitored on the Universal Display Plus monitor diagnostic screen.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

HYDRAULIC SYSTEM TESTING PROCEDURES

When diagnosing a hydraulic system problem, check the electrical circuits first by verifying that the proper solenoids are activated at the correct time. This will isolate hydraulic problems from electrical problems.

BEFORE STARTING ANY TESTS:

• Be sure all oil filters are clean and the reservoir is full of clean oil.

• Check the tension andcondition of thedrive belt.

• Verify the pump is being driven.

• Check the high and low idle settings of the

engine.

• Inspect the hydraulic system for leaks and replace hoses and tubing that show damage or wear.

• All tests are to be conducted with an oil temperature of at least 37

C (100oF).

CAUTION

Hydraulic oil escaping under pressure can have enough force to penetrate the skin. Hydraulic oil may alsoinfecta minor cut or openinginthe skin. If injured by escaping oil, see a doctor at once. Serious infection orreaction can result if medical treatment is not given immediately.Make sure all connections are tight and that hoses and lines are in good condition before applying pressure to the system. Relieve all pressure before disconnecting the linesorperforming otherwork on the hydraulic system.

To find a leak under pressure, use a small piece of cardboard or wood, never use hands.

Clean all connecting points thoroughly before disconnecting any lines. Cap all disconnected lines that are not used to maintain system cleanliness.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

DIAGNOSTIC TEST EQUIPMENT

Test Couplers and Hoses

Quick Couplers Style Case Part # Parker Number Aeroquip Number

Male Tips 1/8 NPT Female PD322 FD90--1034--02--04

1/8 NPT Male H434164 PD323 FD90--1012--02--04 1/4 NPT Female PD342 FD90--1034--04--04 1/4 NPT Male S243718 PD343 FD90--1012--04--04 3/8″-- 2 4 O R i n g FD90--1044--03--04 7/16--20 O Ring R55912 PD341--6 FD90--1044--04--04 1/2--20 O Ring PD351 FD90--1045--03--04 9/16--18 O Ring 1541849c1 PD361--6 FD90--1046--03--04 M14X1.5 O Ring 84320565 PD367A--6 M18X1.5 O Ring 358968A1 PD3127--6 M18X1.5 O Ring 325647A2 PD3127--743--6 7/16″ -- 20 JIC (1/4″ tube) R54805 PD34BTX 9/16″ -- 18JIC (3/8″) PD36BTX 3/4″--16JIC (1/2″ Tube PD38BTX 1-1/16″ 12 JIC (3/4″ Tube) D137625 PD312BTX FD90--1046--06--04 1/2″ Tube O Ring Face Seal PD38BTL

Female Tips 1/8″ NPT Female PD222 FD90--1021--02--04

1/4 NPT Female 1543171C1 PD242 FD90--1021--04--04 1/4 NPT Male PD243 7/16--20 Female O Ring PD240 9/16--18 Female O Ring PD260 9/16″-- 1 8 O R F S 190117A1 PD34BTL--6 11/16″-- 1 6 O R F S 190119A1 PD36BTL--6 13/16″-- 1 6 O R F S 190316A1 PD38BTL--6 1″-- 1 4 O R F S 377921A1 PD310BTL--6 M22X1.5 Metric PD296

Shut off Valve 14--99--7

1 per hose

Test Hose CAS--1281--2 Hose Adapters Converts hose to 1/4 Male

pipe 211863 2 per hose

1. Hose is rated for 8,500 psi working pressure and is 8 ft. long.

• M14X1.5 Male coupler from OTC includes a special steel washer around the O Ring which is required on the “88” Series Excavators.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Digital Pressure & Temperature Analyzer

Test Tools Adapters

Digital Pressure & Temperature Analyzer From OTC Tool Comp., A

500 PSI Sensor, B OEM1602 5,000 PSI Sensor, B OEM1603 20ft. Extension Cable, C OEM1607; two cables K-Type Thermocouple, D 231509

Additional Items

10,000 PSI Sensor OEM1604 Gauge Protector (500psi) OEM1661 12ft. Cable Extension OEM1606 6ft. Cable Extension OEM 1605

Digital Pressure Analyzer

Kit # OEM1653

Inc. One each of the units listed below.

20041514

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

HYDRAULIC SYSTEM TESTING PROCEDURES

# 1 Low Pressure Standby A.10.A / 61........................................................

# 2 High Pressure Standby A.10.A / 63.......................................................

# 3 Steering Relief Setting A.10.A / 65........................................................

# 4 Bench Testing Components A.10.A / 67....................................................

# 5 Control Pressure Test A.10.A / 69.........................................................

# 6 PTO Gear Box Lubrication Pressure Test A.10.A / 71........................................

# 7 Regulated Pressure Test A.10.A / 73......................................................

#8 Spreader Pump Flow Test A.10.A / 75......................................................

# 9 Fan Pump Flow Test A.10.A / 77..........................................................

# 10 PFC Pump Flow A.10.A / 79............................................................

# 11 Control Pressure Pump Flow Test A.10.A / 81.............................................

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 1 Low Pressure Standby

M216703 B

13. Pump Pressure Port 14. Signal Line Test Port

M207003

1. High Pressure Compensator Spool 2. Flow Compensator Spool

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

(p)

(

)

# 1 Low Pressure Standby

This test is used to determine low-pressure standby. There are two items responsible for low-pressure standby, the 26--28 bar (375--400 PSI) spring on the flow compensator spool and the 0.078 mm (0.031 in) orifice inthe steering handpump – which creates back pressure in the signal line of approximately

3.45--10.3 bar (50--150 psi). The 26--28 bar (375--400

PSI) spring plus the back pressure will equal low-pressure standby. The following test will show the spring setting of the flow compensator spool.

Test Procedure

1. Attach a69 bar(1000 psi) gauge to the signal line pressure test port (14) on the main valve assembly. It is recommended to install a needle valve in the test hose to prevent damage to the gauge. With the needle valve closed, start the engine. At low idle, open the needle valve on the gauge. Make sure that the steering wheel is

not moved or that other hydraulic functions are not activated otherwise the gauge could be damaged. The signal line pressure should be

approximately 3.45--10.4 bar (50--150 PSI). Record this number for use later.

2. Then attach the SAME 69 bar (1000 psi) gauge to the PFC pump pressure test port (13) on the main valve assembly. With the needle valve closed, start the engine. At low idle open the needle valve on the gauge. Make sure that the

steering wheel is not moved or that other

hydraulic functions are not activated otherwise the gauge could be damaged. The PFC

pump pressure port should read 26--28 bar (375--400 PSI) above the reading that was recorded from the signal line.

If the PFC pump pressure port does not read 26--28 bar (375--400 PSI) ABOVE the signal line, adjustment of the flow compensator spool spring is required. The adjustment procedure is as follows:

Example:

Signal line pressure port reading

Flow compensator spool spring setting

PFC pump pressure port readin

3. Remove the cap for the adjustment screw

4. Loosen the jam nut.

5. Use an allen wrench to adjust the pressure to

6. Tighten the jam nut. Repeat test to verify the

7. If not correct, make adjustment again. If it is

FTER adjustment

located on the compensator.

match the number calculated. (See example.)

low-pressure standby setting.

correct, replace the cap.

7.7 bar (112 psi)

+ 27.5

±1.7 bar

400±25 psi)

(

35.3±1.7 bar 512±25psi

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 2 High Pressure Standby

M216703 B

13. Pump Pressure Port 14. Signal Line Test Port

M207003

1. High Pressure Compensator Spool 2. Flow Compensator Spool

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 2 High Pressure Standby

This test is usedto determine the spring setting of the high-pressure spool in the compensator. High-pressure standby is the maximum pressure that the PFC pump will develop. High pressure stand-by on is 207--214 bar (3000--3100 PSI). There is no relief valve inthe PFC circuit so the high-pressure standby limit serves as the system relief.

Test Procedure

Attach a 345 bar (5000 psi) gauge to the PFC pump pressure test port (13). Disconnect the reel lift hose

from the feeder house if a grain header is attached. With the engine at high idle, activate the reel raise circuit. Thegauge should read between 207--214 bar (3000--3100 PSI).

If adjustment is required remove the cap for the adjustment screw located on the compensator. Use an allen wrench to adjust the spring setting. After the adjustment has been made, the test should be repeated to verify the spring setting.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 3 Steering Relief Setting

3. From Steering Hand Pump Signal

4. To Steering Hand Pump Supply

M216703 B

13. Pump Pressure Test Port

14. Signal Line Test Port

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 3 Steering Relief Setting

This test is used to determine the relief valve setting of the steering signal circuit. Thesteering signal relief valve is set to provide an operating pressure of

182.7--189.6 bar (2650--2750 psi). If the steering signal is too high the steering circuit can limit or completely stop the oil flow to the other hydraulic functions.

Test Procedure

Attach a 345 bar (5000 psi) gauge to the pump pressure DIAG port located on the Main Valve Stack. With the engine at low idle, turn the steering wheel until the steering stops are reached and hold the wheel. The relief valve in the steering hand pump will open. The reading on the gauge should be between

182.7--189.6 bar (2650--2750 psi).

The relief is located in the steering hand pump and is set from the factory. If adjustment is needed, the

steering hand pump must be removed from the combine. The relief valve adjustment is an allen plug located on the mounting surface of the hand pump. The plug will be filled with wax. After removing the wax, turn the threaded plug in to increase the relief valve setting, and out to decrease the setting. After the adjustment has been made, the test should be repeated to verify the spring setting. Before installing the hand pump in the combine, replace the wax with LOCTITE to prevent the adjusting plug from moving.

NOTE: Steering from full RIGHT to full LEFT should take approximately 4.5 turns. If the steering system requires more turns, it could be a sign of a handpump that has too much internal leakage or a steering cylinder with internal leakage. When holding the steering wheel against the stop, continue to apply normal steering pressure on the wheel, there should not be more then approx. 1.5 wheel rotation per minute due to internal leakage.

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# 4 Bench Testing Components

20041515

1. Needle Valve

2. Gauge

3. Test Block 206934

Pressurizing the valve from the side.

“Terrain Tracker Relief”

Pressurizing the valve from the end.

• Spreader Drive Relief

• Feeder Thermal Relief

• Fan Drive Relief

20041516

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20041517

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 4 Bench Testing Components

Field Tracker, Spreader Relief and Feeder Thermal Relief Valves

This test is used to determine the pressure settings of the relief valves when the system can not be loaded to relief valve settings.

Test Procedure

To bench test relief valves use special tool CAS--1905--2, CAS--1905--3 and adapter 1252331C1. A hydraulic hand pump or tractor remote valve can be used to supply pressure to the test block 206934.

Terrain Tracker Relief Valve

To test the terrain tracker relief valves, thread it in to the test block and attach the supply hose to the test block so that the pressure will act on the side of the relief valve. Create enough pressure to open the relief valve. The reading on the gauge should read 207 bar (3000 psi). If adjustment is required, remove the cap and use an allen wrench to turn the threaded plug. Turn the plug in to increase the relief pressure setting, or turn the plug out to decrease the relief pressure setting. After the adjustment has been made, the test should be repeated to verify the relief valve setting.

Spreader Relief Valve

To test the spreader relief valve, thread it into the test block and attach the supply hose to the test block so

that the pressure willact ontheendofthe reliefvalve. Create enoughpressure to openthe relief valve. The reading on thegauge shouldread 210 bar (3000 psi). If adjustment isrequired, remove the capon the relief valve and loosen the jam nut. Use an allen wrench to adjust the screw. Turn the screw in to increase the relief pressure setting, or turn the screw out to decrease the relief pressure setting. After the adjustment has been made the test should be repeated to verify the relief valve setting.

Fan Drive Relief Valve

To test the fan drive relief valve, thread it into the test block and attach the supply hose to the test block so that the pressure willact ontheendofthe reliefvalve. Create enoughpressure to openthe relief valve. The reading on thegauge shouldread 241 bar (3500 psi). If adjustment isrequired, remove the capon the relief valve and loosen the jam nut. Use an allen wrench to adjust the screw. Turn the screw in to increase the relief pressure setting, or turn the screw out to decrease the relief pressure setting. After the adjustment has been made the test should be repeated to verify the relief valve setting.

Feeder Lift Cylinder Thermal Relief Valve

To test the feeder thermal relief valve, thread it into the test block and attach the supply hose to the test block so that the pressure will act on the end of the relief valve. Create enough pressure to open the relief valve. The reading on the gauge should read

276 bar (4000 psi). If the valve drips before it

opens at the set pressure the header will settle.

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# 5 Control Pressure Test

M205503 C

Control Pressure Test Port

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 5 Control Pressure Test

This test is used to determine the control pressure relief valve setting. The control pressure relief valve is set to provide an operating pressure of 20--22 bar (290--320 psi).

NOTE: This can be checked on the Universal Display Plus monitor by placing the “Control Pressure” on one of the RUN screens.

Test Procedure

Attach a 41 bar (600 psi) gauge to the control pressure DIAG port located on the Control Pressure/Lubrication Valve. With the engineat HIGH idle the pressure reading should be within specification.

The relief is located in the valve body. If adjustment is needed, loosen the jam nut and using an allen wrench turn the center screw in to increase pressure and out to decrease pressure. After the adjustment has been made, the test should be repeated to verify the spring setting.

NOTE: Activate all associated clutches and hydrostatic drives to determine if any circuit has excessive leakage. The pressure MUST be maintained during clutch and hydro. activation. The pressure will normally be on the low side when the engine is low idle.

IMPORTANT: Do NOT exceed 25 bar (360 PSI) with cold oil, there should be approximately 20 bar (290 psi) at high idle with hot oil and all systems running.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 6 PTO Gear Box Lubrication Pressure Test

2. Control Circuit Filter

3. Gear Pump Assembly

M208303 B

6. Control / Lube Pressure Regulating Valve

18. Pump to Filter Line

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 6 PTO Gear Box Lubrication Pressure Test

This test is used to determinethe lube pressure relief valve setting. The lube pressure relief valve is set to provide an operating pressure of 3.4 bar (50 psi).

NOTE: This can be checked on the Universal Display Plus monitor by placing the “Lube Pressure” on one of the RUN screens. On some of the earlier machine there may be a test fitting in place of the sensor, in that case the pressure gauge will have to be used.

Test Procedure

Pressure may be tested by two different methods:

1. Remove the lube pressure sensor from the CONTROL/LUBE control valve and install a test fitting.

2. If the machine’s software has been updated it may be monitored on the Universal Display Plus monitor RUN screen after placing theitemon one of the RUN screens.

Attach a 41 bar (600 psi) gauge to the lube pressure DIAG port located on the Control Pressure/Lubrication Valve. With the engine at LOW idle the pressure reading should be within specification, check at HIGH idle to verify operation.

The relief is located in the valve body. The cartridge is NOT adjustable, if pressure is not correct the lubrication pump should be flow rated to verify it can produce the proper flow and pressure. If the pump is operating properly replace the LUBE regulating valve.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 7 Regulated Pressure Test

1. Park Brake/Tow Valve

10035346

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 7 Regulated Pressure Test

This test is used to determine the regulated pressure relief valve setting. The regulated pressure relief valve is set to provide an operating pressure of 22--25 bar (320--360 psi).

Test Procedure

Attach a 41 bar (600 psi) gauge to the regulated pressure DIAG port located on the Park Brake/Tow

Valve. With the engine at LOW idle the pressure reading should be within specification, check at HIGH idle to verify operation.

The relief is located in the valve body. The cartridge is adjustable; if pressure is not correct make the required adjustment.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 8 Spreader Pump Flow Test

1. Spreader Relief

2. Spreader Flow Control

3. Valve Outlet to Left Motor

10033639

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 8 Spreader Pump Flow Test

This test is used to determine the efficiency of the spreader pump. The pump will wear internally over time, causing the residue spreader speed to decrease.

NOTE: Since all the flow from the spreader pump is directed through the rotary air screen motor a quick RPM check of the screen may be all that is required to determine the condition of the pump. The screen should turn a minimum of 205 RPM. Be sure to verify the condition of the spreader relief valve.

Test Procedure

1. Remove the supply hose that runs between the spreader valve and the left hand spreader motor. Connect the inlet hose from a flow rater to the spreader valve and the outlet hose from the flow rater back to the hydraulic reservoir tank.

2. Turn the spreader valve flow control to the maximum flow setting.

3. Open the restriction valve on the flow rater completely.

If Flow Is Below Specifications

1. There could be a problem with the flow control o-rings.

2. There could be a problem with the relief valve o-rings

3. There could be a problem with the control solenoid o-rings and spool.

4. The pump could be worn excessively.

If the flow is below specifications the flow rater could be installed between the pump and the control valve.

CAUTION

Use extreme caution if this procedure is used. There is no relief valve in the system when testing in this manner. Be absolutely sure the flow meter restrictor is open when starting the combine engine. Once the machine is started, increase to full throttle and VERY SLOWLY restrict the flowmeter NOT to exceed pressure specifications.

4. Start themachine’s separator and run the engine at high idle.

5. The pump’s output should be above minimum specification.

6. Slowly turn in the flow raters restriction control to verify the systems relief valve, it should beabove minimum system specification.

7. The pump flow at approximately 21 bar (300 psi) below the relief valve settingshould still beabove minimum specification.

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# 9 Fan Pump Flow Test

M219503 A

1. Fan Valve Location

2. Fan Drive Motor

3. Supply Hose to Motor

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 9 Fan Pump Flow Test

This test is used to determine theefficiency of the fan drive pump. The pump will wear internally over time, causing the fan speed to decrease.

Test Procedure

1. Remove the supply hose that runs between the fan drive valve and the fan motor. Connect the inlet hose from a flow rater to the fan valve and the outlet hose from the flow rater back to the hydraulic reservoir tank.

2. Open the restriction valve on the flow rater completely.

3. Start themachine’s separator,using the operator controls setthe fan speed to the minimumsetting and run the engine at high idle.

4. While monitoring the fan pump’s output increase the fan speed, verifying the solenoid and software operation. The pump’s output shouldbe above minimum specification.

5. Slowly turn in the flow raters restriction control to verify the systems relief valve, it should beabove minimum system specification.

If Flow Is Below Specifications

1. If equipped, use the manual speed control adjustment screw on the top of the control solenoid to override the electrical system.

2. There could be a problem with the relief valve o-rings.

3. There could be a problem with the control solenoid o-rings and spool.

4. The pump could be worn excessively.

If the flow is below specifications the flow rater could be installed between the pump and the control valve.

CAUTION

6. The pump flow at approximately 21 bar (300 psi) below the relief valve settingshould still beabove minimum specification.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 10 PFC Pump Flow

20041518

1. PFC Pump

2. Flow Meter Load Control Valve

3. Compensator Shutoff Valve

A. Remove and Plug Signal Line B. Remove and Plug Outlet Line

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 10 PFC Pump Flow

This test is used to determine the oil flow of the PFC pump. When conducting this test, the flowmeter should read 151 l/m (40 gpm). If the reading is less than 143 l/m (38 gpm) there could be a problem with the PFC pump.

Test Procedure

Drain all hydraulic oil from the reservoir. Disconnect and cap the outlet line from the PFC pump. Attach the inlet hose for the flowmeter to the outlet of the PFC pump. Next, attach the outlet hose for the flowmeter to the line that was removed from the PFC pump.

Disconnect and cap the signal line. Tee a hose into the inlet hose of the flowmeter and connect it to the compensator. Refill the reservoir with Hy-Tran Ultra.

With the flowmeter restriction valve fully open, start the engine. Move throttle to high idle position and adjust restriction valve to produce a 138 bar (2000 psi) restriction. The flowmeter should read specification. If the reading is under specification the PFC pump could be damaged.

NOTE: The most common reason for low flow from a PFC pump is NOT due to pump failure, BUT a mis-adjusted or malfunctioning flow control spool in the compensator.

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# 11 Control Pressure Pump Flow Test

2. Control Circuit Filter

3. Gear Pump Assembly

M208303 B

6. Control / Lube Pressure Regulating Valve

18. Pump to Filter Line

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

# 11 Control Pressure Pump Flow Test

This test is used to determine the efficiency of the control pressure supply pump. The pump will wear internally over time.

Test Procedure

1. Remove the supply hose that runs between the control pressure pump and the pressure filter base. Connect the inlet hose from a flow rater to the control pressure pump and the outlet hose from the flow rater to the filter base.

CAUTION

2. Open the restriction valve on the flow rater completely.

3. Start and run the engine at LOW idle until you have verified the pressure on the flow rater, then increase engine speed to HIGH idle slowing while monitoring the system pressure.

4. The pump’s output should be above minimum specification.

5. Slowly turn in the flow raters restriction control to verify the systems relief valve, it should beabove minimum system specification.

6. The pump flow at approximately 21 bar (300 psi) below the relief valve settingshould still beabove minimum specification.

If Flow Is Below Specifications

1. The pump could be worn excessively.

2. There could be problem with the PTO gearbox supply screen.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Signal valve - Unidentified failure (A.10.A.12 - G.30.B.46)

AFX8010

E0190-11 - Jammer Valve

Cause:

The signal valve solenoid (L-43) circuit is open, or shorted to ground.

Possible failure modes:

Supply wiring damaged.

2. Bad solenoid.

Controller in

Solution:

Enter the Universal Display Plus "DIAG" screen. Select the "GRAIN HANDLING" or "HEADER" sort menu, and select "JAMMER VLV". Change the drop-down list to "STATUS", and press the "OFF" button to change the circuit

The "STATUS" screen should indicate "O K" if the circuit is working properly.

ternal failure (internal regulator failure).

output to "ON".

If the status screen indicates "ERROR", the circuit is open or shorted to ground. Continue with Step 2.

If the status screen indicates "OK", the circuit is working properly. Continue with Step 9.

Disconnec

t connector X022. Use a multimeter to check between connector X022 pin 1 or 8 (valve side) and

chassis ground.

If there is continuity, the signal valve solenoid is shorted to ground. Replace the solenoid.

If there is no continuity, continue with Step 3.

Use a multimeter to check for continuity between connector X022 pin 1 (harness side) and chassis ground. Flex the

Disconnect connector X008. Use a multimeter to check for continuity between connector X008 pin2and

main frame (MF) harness between the signal valve and connector X008 while making this check.

e is continuity to ground, continue with Step 4.

If ther

re is no continuity to ground, continue with Step 5.

If the

chassis ground. Flex the front frame (FF) harness between the connector X008 and connector X017 while

gthischeck.

makin

ere is no continuity to ground, the short to ground is in the main frame (MF) harness between

If th connector X008 and connector X022 wire 1119 white. Locate the short and repair.

If there is continuity to ground, the short to ground is in the front frame (FF) harness between connector X008 and connector X017 wire 1119 white. Locate the short and repair.

Disconnect connector X022. Use a multimeter to check the resistance of the signal valve coil between connector X022 pins 1 & 8. The proper resistance range is 7.2 - 11.2 ohms.

If there is no continuity, replace solenoid.

If the coil is within specification, continue with Step 6.

se a multimeter to check for continuity between connector X022 pin 8 (harness side) and chassis ground.

U Flex the main frame (MF) harness between the signal valve and front frame ground #2 while making this check.

If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X022 pin 8 and the front frame ground #2 wire 1121 black or 600 black. Locate the open and repair.

If there is continuity to ground, continue with Step 7.

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Turn the key switch to the ON position. Use the Universal Display Plus "DIAG" screen controls to manually power the signal valve. Use a multimeter to check for 12 volts between connector X022 pin 1 and chassis ground.

If 12 volts is n

If 12 volts is f

Turn the key switch to the ON position. Use the Universal Display Plus "DIAG" screen controls to manually

ot present, continue with Step 8.

ound, continue with Step 9.

power the signal valve. Use a multimeter to check for 12 volts between connector X008 pin 2 and chassis ground.

If 12 volts i

s present, the open circuit is in the main frame (MF) harness between connector X022 pin 1

and connector X008 pin 2 wire 1119 white. Locate the open circuit and repair.

If 12 volts is not present, there is an open circuit in the front frame (FF) harness between connector X008 pin 2 and connector X017 pin J3-12 wire 1119 white. Locate the open and repair.

Visually

inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or

broken wires.

If no damage is found, erase the fault code and continue operation.

9665 1 27/05/2004

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Case IH AFX-8010 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

DISTRIBUTION SYSTEMS