John Deere BZ13788, BZ100157 User Manual

GreenStar Equipment

for

7000 Series Forage

Harvesters

BZ13788, BZ100157

INSTALLATION INSTRUCTIONS

GreenStar Equipment for 7000

Series Forage Harvesters (BZ13788,

BZ100157)

Z103757 13DEC06 (ENGLISCH)

7000 Series Forage Harvesters

John Deere Werke Zweibru¨cken

Z103757 (13DEC06)

COPYRIGHT  2006

DEERE & COMPANY

European Office Mannheim

All rights reserved

A John Deere ILLUSTRUCTION

Z103757-19-13DEC06



Manual

Contents of Bundle BZ13788

Installation Instructions

A—Z73362 Plate (1x) D—AZ59199 Job computer (1x) G—AZ101120 Wiring harness J—PF80209 Bracket (1x)
B—Z72204 Plate (1x) E—H204964 Decal (1x) (1x) K—AZ71569 Connector (1x)
C—AZ57754 Holder (1x) F—N302284 Decal (1x) H—AZ63280 Potentiometer

(1x)

NOTE: The bundle contains a hardware bag.

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Installation Instructions

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Contents of Bundle BZ100157

Installation Instructions

A

B

E

C

D

ZX1039590

A—Z102720 Support (1x) C—AZ102637 Cover Plate D—Z102760 Fixing Plate (1x) E—AZ102820 Sensor Support
B—Z101939 Shield (1x) (1x)

NOTE: The bundle contains a hardware bag including

(7x) 14M7298 M8 flange nuts, (2x) 14M7396
M8 self locking nuts, (10x) 19M7865 M8X16

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2

screws, (6x) 19M7867 M8X25 screws, (3x)
19M7897 M8X35 screws and (2x) 24M7207

8.4X24X2 washers.

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Installation Instructions

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Installation Instructions

Contents of Bundle BZ100157—Continued

A—Z103667 Bracket (2x) B—Z103666 Template (1x) C—19M7865 Cap Screw M8X16 D—14M7298 Flange Nut M8

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(4x) (4x)

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Installation Instructions

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Parts to Order

Installation Instructions

B

A

ZX1039591

A—BZ100165 NIR Sensor (1x) B—AZ101740 Wear Plate for C—Z101953 Wear Plate for Flat

To complete the bundle BZ100157 installation the
parts or bundles above illustrated must be ordered
separately.

Z103757 (13DEC06)

High arc Spout (1x) Spout (1x)

4

C

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Installation Instructions

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Installation Instructions

Mount and Dismount Safely With the Moisture Sensor

Hold handrail with one hand and carry the moisture
sensor with the other.

Maintain Stability

Keep work surfaces dry and clean. Maintain balance while
transporting and installing the moisture sensor onto the
forage harvester’s spout.

Care should also be observed while servicing the sensor.

ZX1039668

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ZX1039668 –UN–29AUG06

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Installation Instructions

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Modify High Arc Spout

Installation Instructions

ZX1039636 –UN–12JUL06

On machines with old high arc type spout, proceed as
follows to install NIR sensor brackets:

1. On both sides of the spout, release the side wear plate
fixing screws (A) and rear wear plate fixing screws (B).
Remove and discard rear wear plate. Remove both
side wear plates.

2. Install template Z103666 (C) over spout as shown
using original hardware (A). Pull up template Z103666
(C) to set it correctly in position then tighten fixing
screws (A).

3. Mark area (D) to cut a hole 102 mm (4.01 in.) diameter
then drill two holes 11x20 mm (0.43x0.78 in.) at
locations (E).

4. Install brackets Z103667 (F) on template Z103666 (C)
with four screws 19M7865 M8X16 and flange nuts
14M7298. Make sure brackets (F) are in contact with
spout sides then weld at front and rear of the brackets
(F) (see arrows) on spout.

IMPORTANT: Grind spout sides at locations where

weld will be carried out.

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5. Remove template Z103666 (C) then finalize welding
process on top of brackets Z103667 (F) (see arrow).

A—Fixing Screws
B—Fixing Screws
C—Template Z103666
D—Area to Cut
E—Drilling Holes
F—Brackets Z103667

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Installation Instructions

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Installation Instructions

IMPORTANT: Grind weld at top of brackets Z103667

(F) so that weld surface is flush with the
bracket surface.

6. Cut out previously marked area (D).

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Installation Instructions

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Replace Spout Wear Plate

Installation Instructions

A

B

ZX1039595

Using original hardware, install wear plate AZ101740 (A)
on high arc type spout or wear plate Z101953 (B) on flat
spout.

On new high arc type spout, use a hammer to remove
pre-cut part (C) of spout as shown.

A—Wear plate—AZ101740—High arc spout
B—Wear plate—Z101953—Flat spout
C—Part to remove

ZX1039594

ZX1039595 –UN–10APR06

C

ZX1039594 –UN–10APR06

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Installation Instructions

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Installation Instructions

Install NIR Sensor BZ100165

1. Pre-assemble NIR sensor BZ100165 (A) with the
shield Z101939 (B) using 6 flange screws M8X16 (C).

2. Install support Z101720 (D) using 4 flange screws
M8X16 (C).

3. Place three screws M8X35 (E) and three flange nuts
(F) on sensor support as shown.

4. Insert sealing ring Z101944 (G) on glass adapter of
sensor BZ100165 (A).

IMPORTANT: To install the sealing ring (G) correctly,

align its centering protrusion with the
groove of glass adapter.

5. Install support AZ102820 (H) on spout using four
flange screws M8X25 (I) and flange nuts.

A—NIR sensor—BZ100165
B—Shield—Z101939
C—Flange screws M8X16
D—Support Z101720
E—Flange screws M8X35
F—Flange nut
G—Sealing ring—Z101944
H—Support—AZ102820
I—Flange screws M8X25

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Installation Instructions

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Installation Instructions

6. Attach sensor assembly (A) to support AZ102820 (B)
using two flange screws M8X25 (C), two washers

8.4X24X2 (D) and two self-locking nuts (E) as shown.

IMPORTANT: To ease sensor assembly fold/unfold,

place washers (D) between support (B)
and sensor assembly brackets. Do not
overtighten self-locking nuts (E). Sensor
assembly (A) must remain easily
foldable.

The NIR sensor (A) is delivered with a dedicated wave
length standard (F). To avoid NIR sensor and non
dedicated wave length standard mix up, it is strongly
recommended to report the NIR sensor serial number
on its relevant wave length standard cover (G).

IMPORTANT: Prior to operating the NIR sensor (A),

carry out an initial wave length standard
measurement as described in Harvest
Monitor System Operator’s Manual.

If the wave length standard
measurement is not successful then a
black and white calibration of the NIR
sensor is required. Proceed as
described in the forage harvester
Technical Manual.

The wave length standard (F) must be kept in good
condition for future measurement. In this way, special
attention must be paid so that the wave length
standard (F) doesn’t come in contact with chemical
products such as:

• Diesel

• Gasoline (Leaded or unleaded)

• Thinners

• Engine cleaner

• Cavity sealing

• After cleaning

• Finishing paint

• Blackboard lacquer

• Freeze protection

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A—Sensor assembly
B—Support—AZ102820
C—Flange screws M8X25
D—Washers 8.4X24X2
E—Self-locking nuts
F—Wave length standard
G—Cover

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Installation Instructions

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Installation Instructions

NOTE: Do not disconnect sensor (A) from machine wiring

harness until sensor shuts down completely.
Before disconnecting sensor turn forage harvester
ignition off. Wait at least 30 seconds before
disconnecting the sensor.

Continued on next page

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Installation Instructions

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F

Installation Instructions

E

E

A

B

ZX1039600

A—Adapter glass C—Front point setting E—Flange screw F—Flange nut
B—Wear plate D—Rear point setting

7. Place sensor into working position but do not latch
it. Adjust sensor assembly position so that tip of
adapter glass (A) is flush with wear plate (B) at

C

IMPORTANT: To allow a proper adapter glass

self-cleaning process, make sure
that sensor position is correctly set.

front point (C) and about 1 mm (0.08 in.) below
surface of wear plate (B) at rear point (D) as

NOTE: Arrow is showing the crop flow direction.

shown. Use the three flange screws (E) to adjust
then secure with flange nuts (F).

D

F

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Installation Instructions

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Installation Instructions

Install Feed Roll Potentiometer AZ63280

Install Upper Plate Z72204 and Holder AZ57754

1. Remove right-hand feed roll spring (A) by loosening
eye-bolt (B).

2. Install plate Z72204 (C) and holder AZ57754 (D) in the
free holes.

3. Put the eye-bolt (B) back in place and tighten the
spring to its original setting.

A—Feed roll spring
B—Eye-bolt
C—Plate Z72204
D—Holder AZ57754

Continued on next page

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Installation Instructions

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Installation Instructions

Install Lower Plate Z73362

1. Drill two 9 mm (0.35 in.) diameter holes on cutterhead
frame (A) as shown.

2. Install plate Z73362 (D) on frame (A) with two cap
screws M8x40 (E) and nuts, as shown.

A—Cutterhead frame
B—75 mm (2.95 in.)
C—34 mm (1.34 in.)
D—Plate Z73362
E—Cap screws M8x40
F—15 mm (0.59 in.)

Continued on next page

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Installation Instructions

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Installation Instructions

Install Feed Roll Potentiometer AZ63280

1. Install potentiometer AZ63280 (A) between plate
Z72204 (B) and plate Z73362 (C) with screws (D)
M12x35, flange nuts and lock nuts as shown.

2. Connect potentiometer AZ63280 (A) to free connector
(E) of machine wiring harness.

IMPORTANT: The potentiometer (A) should be

mounted so that the wiring harness
connector is in top position.

A—Potentiometer AZ63280
B—Plate Z72204
C—Plate Z73362
D—Screws M12x35
E—Connector

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Installation Instructions

Install Job Computer AZ59199 and Wiring Harness AZ101120

1. Install job computer AZ59199 (A) as shown on the
bottom left side of load center with three screws M8x60
(B) using existing nuts in the wall.

2. Connect main connector (C) of wiring harness
AZ101120 (D) to job computer (A).

3. Disconnect A7-CAN bus terminator (E) located near
the board A3. Connect CAN bus terminator (E) to
relevant connector (F) of wiring harness AZ101120 (D),
then connect wiring harness AZ101120 to terminator
(E) original connector as shown.

4. Locate free connectors X27 (G) and X30 (H), then
connect them to the relevant machine wiring harness
free connections using parts of connector AZ71569 (I)
and following tables:

X27 Connector AZ71569 Pin Connections

Pin Number Wire

Pin #1 .......................................... 552C

Pin #2 .......................................... 974

Pin #3 .......................................... 975

Pin #4 .......................................... 050B

Pin #5 .......................................... not used

Pin #6 .......................................... not used

ZX1037466 –UN–13SEP05

ZX1037467 –UN–13SEP05ZX1037468 –UN–13SEP05ZX1037469 –UN–13SEP05

A—Job computer AZ59199
B—Screws M8x60
C—Main connector
D—Wiring harness AZ101120
E—A7 CAN bus terminator
F—Connector
G—X27 Connector
H—X30 Connector
I—AZ71569 Connector

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Installation Instructions

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X30 Connector AZ71569 Pin Connections

Pin Number Wire

Pin #1 .......................................... 584

Pin #2 .......................................... 586

Pin #3 .......................................... 585

Pin #4 .......................................... 571

Pin #5 .......................................... not used

Pin #6 .......................................... not used

Installation Instructions

OUCC002,00021CA –19–18NOV06–2/8

5. Connect part of wiring harness AZ101120 with
15A-fuse (A) to connecting point 002 (B) located on
board A3 as shown.

6. Remove closing plate from bottom of load center (not
illustrated) and pass wiring harness AZ101120 (C)
through the opening until guide plate (D) can be
installed using original hardware previously removed.

A—Fuse
B—Connecting point
C—Wiring harness AZ101120
D—Guide plate

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Installation Instructions

A—Inoculant dosing device B—NIR sensor connector C—Wiring harness AZ101120 D—Connection box

connector

7. Using above illustration, route connectors (A) and
(B) of wiring harness AZ101120 (C) underneath the

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18

connection box (D), alongside the left-hand side of
machine frame then behind the cab.

Continued on next page

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Installation Instructions

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Installation Instructions

IMPORTANT: Route wiring harness AZ101120 (C)

alongside machine wiring harness
and secure with tie bands.

NOTE: Connector (A) shall be used for inoculant

dosing device connection.
Connector (B) shall be stored in a safe place if

NIR sensor is not installed on spout.

8. Route inoculant dosing device connector (A) outside
the rear right-hand side of the cab as shown.

9. Drill a suitable hole near the cab closing plate (B) so
that connector sleeve (C) can be inserted and fixed to
the cab wall as shown.

IMPORTANT: Open plate (B) and check that no wiring

harness is being damaged while drilling
the hole!

NOTE: Use the existing machine wiring harnesses

and/or hydraulic hoses to fix the wiring
harness AZ101120 (C) with plastic clamps so
that it will not be left loose in a way it can be
caught by any moving part.

OUCC002,00021CA –19–18NOV06–5/8

-If an inoculant dosing device is used, route dosing
device connecting wires through opening of closing
plate and refer to “Connecting Inoculant Dosing
Device” for proper device connection.

-If no inoculant dosing device is used, keep connector
(A) protected behind closing plate (B).

A—Connector for inoculant dosing device
B—Closing plate
C—Connector sleeve

10. In Case Bundles BZ100157 and BZ100165 are Not

Installed on Spout:

Route and store NIR sensor connector (A) near the
spout motor (B). Make sure to store the cable so that
it will not be caught by any moving part.

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OUCC002,00021CA –19–18NOV06–6/8

A—NIR sensor connector
B—Spout motor

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Installation Instructions

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ZX1037998 –UN–13SEP05

Installation Instructions

11. In Case Bundles BZ100157 and BZ100165 are

Installed on Spout:

Route NIR sensor connector (A) to the right-hand side
of the spout motor (B) then alongside the spout wiring
harness (C) up to the NIR sensor BZ100165 (D) as
shown. Secure cable with tie bands.

Make sure to route the cable so that it will not be
caught by any moving part.

12. Connect NIR sensor connector (A) to NIR sensor

BZ100165 (D) then engage the three latches (E) to
maintain NIR sensor BZ100165 (D) in working
position as shown.

IMPORTANT: Route cable as shown on illustration

and make sure to keep sufficient play to
cable so that NIR sensor assembly can
be folded/unfolded without
disconnecting connector (A).

NOTE: If connection box BZ100168 has been installed on

NIR sensor BZ100165 then connect NIR
connector (A) to the connection box (not
illustrated).

NOTE: Do not disconnect sensor (D) from spout wiring

harness until sensor shuts down completely.
Before disconnecting sensor turn forage harvester
ignition off. Wait at least 30 seconds prior to
disconnecting the sensor.

A—NIR sensor connector
B—Spout motor
C—Spout wiring harness
D—NIR sensor—BZ100165
E—Latch (3 used)

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Installation Instructions

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Installation Instructions

Connecting Inoculant Dosing Device

To enable the dosing device system, the connector (A)
MUST be connected to the relevant connector of inoculant
dosing device control unit in the following manner (refer to
table for connector (A) pin connections).

• Tx wire1of dosing device connector to Rx wire2of

wiring harness AZ101120 connector (A).

• GND wire3of dosing device connector to GND wire of

wiring harness AZ101120 connector (A).

ZX1037996 –UN–13SEP05

• Rx wire of dosing device connector to Tx wire of wiring

harness AZ101120 connector (A).

Connector (A) Pin Connections

Pin Number Wire

Pin #A .......................................... 589—Tx

Pin #B .......................................... 590—GND

Pin #C ......................................... 591—Rx

1

Tx wire: Means wire that transmits the signal

2

Rx wire: Means wire that receives the signal

A—Connector for inoculant dosing device

3

GND wire: Means ground wire

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Installation Instructions

Install Bracket PF80209 in Cab

1. Install monitor bracket PF80209 (A) on right-hand
corner post as shown using corner post fixing screws
(B).

2. Pull down cab roof trim (C) and look for monitor wiring
harness (D). Extract it from cab roof and route it up to
the bracket PF80209 as shown. Keep the wiring
harness (D) connectors free for further monitor
installation.

A—Bracket PF80209
B—Screws
C—Cab roof trim
D—Monitor wiring harness

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Installation Instructions

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Installation Instructions

Attach GreenStar Decals

• Attach decal H204964 (A) to left hand side of the

harvester as indicated.

• Attach decal N302284 (B) as indicated in front of the

display (C), on inside of cab.

A—Decal H204964
B—Decal N302284
C—Display

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Installation Instructions

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Installation Instructions

Load Software

Load Display Software

To load new software:

1. Install PC Card containing NEW software in card slot A
of mapping processor.

2. Turn ignition key to RUN position.

3. Press “INFO” key to enter INFO mode.

4. Press key B in “INFO” to select “Keycard”.

5. Press key A to select “Devices on CAN Bus”. Actual
Version Display Software and Version Harvest Mon
are then displayed.

6. Press key G once to go back.

7. Press key C to select “Program Target”.

8. Press key A to select “GreenStar Display”.

9. Press relevant key to choose “PF303182B” software
version, or higher.

10. While programming (about 30 seconds):

- DO NOT REMOVE PC CARD

- DO NOT REMOVE POWER

11. When programming is complete, the

PROGRAMMING COMPLETE screen will appear.
CYCLE POWER will be displayed in lower left

corner.
Turn ignition switch OFF.

Load Job Computer Software

To load new software:

1. Install PC Card containing NEW software in card slot A
of mapping processor.

2. Turn ignition key to RUN position.

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Installation Instructions

3. Press “INFO” key to enter INFO mode.

4. Press key B in “INFO” to select “Keycard”.

5. Press key A to select “Devices on CAN Bus”. Actual
Version Display Software and Version Harvest Mon
are then displayed.

6. Press key G once to go back.

7. Press key C to select “Program Target”.

8. Press key A to select “Harvest Mon”.

9. Press relevant key to choose “PF311135C” software
version, or higher.

10. While programming (about 30 seconds):

- DO NOT REMOVE PC CARD

- DO NOT REMOVE POWER

11. When programming is complete, the

PROGRAMMING COMPLETE screen will appear.
CYCLE POWER will be displayed in lower left

corner.
Turn ignition switch OFF.

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Installation Instructions

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Installation Instructions

Check Yield Monitoring Functionality

Calibrate Mass-Flow Sensor

1. Turn ignition key to RUN position.

2. Press “SETUP” key to enter SETUP mode.

3. Press key C in “SETUP” to select “GreenStar
Display”.

4. Select your native language and units then press key
G once to go back.

5. Press key A to select “Harvest Mon”.

6. Make sure that “Recording ON/OFF By:” is set on
“HEADER” then press key G once to go back.

7. Press key D to select “Yield Calibration”.

8. Press key A to start calibration. Wait until feedroll
height is 10 mm (0.4 in.).

9. Press RUN key.

Check Monitoring Functions

1. Turn ignition key to start harvester engine.

2. Press “INFO” key to enter INFO mode.

3. Press key A in “INFO” to select “Harvest Mon”.

4. Press key F to select “Diagnostics”.

5. Press key B to select “Mass-Flow System”. Engage
main clutch and harvesting unit then check the
following points:

• Height right—should be between 0.2 and 0.6 V.

• Vref—Should be between 4.8 and 5.1 V.

If any of these points are not OK, contact your John
Deere dealer.

Press key G once to go back.

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Installation Instructions

6. Press key C to select “SPFH Network” and check
communication between SPFH and Harvest Monitor.

7. Press RUN key.

Check Inoculant Dosing Functionality

1. Turn ignition key to start harvester engine.

2. Press “SETUP” key to enter SETUP mode.

3. Press key A in “SETUP” to select “Harvest Mon”.

4. Press “PAGE” key to go to “SETUP - Harv Mon ­PAGE 2” screen then press key “F” to toggle inoculant
dosing support state from OFF to ON or vice versa.

5. Press RUN key.

6. The inoculant dosing device can be engaged if:

OUZXMAG,0001BF6 –19–18NOV03–2/2

ZX1035268 –UN–26JUL04

• The road safety switch is in field operating mode

• The forage harvester is travelling forward

• The ground speed is greater than 2 km/h (1.24 mph)

• The feedrolls are turning in forward direction

• The header is in harvesting position

7. Press once the liquid injection pump switch (A). Carry
out a test to make sure that inoculant device is
properly connected to the wiring harness AZ101120.

If this is not the case check wiring harness connection
or contact your John Deere dealer.

NOTE: For a proper use of the liquid injection pump

switch (A), refer to the forage harvester Operator’s
Manual.

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Installation Instructions

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Installation Instructions

Use of Cover Plate AZ102637

In case the spout is operated without the NIR sensor it is
necessary to install cover plate AZ102637 (A) to close
opening in wear plate AZ101740 or Z101953.

NOTE: The illustration shows the cover plate AZ102637

(A) installed on a high arc type spout. In case of
flat spout, it is necessary to use the supplied
fixing plate Z102760 to maintain cover plate
AZ102637 in place using original spout wear plate
fixing hardware—Not illustrated.

A—Cover Plate—AZ102637

ZX1039593 –UN–10APR06

OUCC002,00021CF –19–18JUL06–1/1

Z103757 (13DEC06)

28

Installation Instructions

011507

PN=30