1999 CH2500 Oper & Test Eng

CAMECO ®
CH2500 CHOPPER COMBINE

1999 OPERATIONS AND TESTS
Table of Contents
Introduction
Section 1—Safety Recommendations
Section 0001—General Specifications
Section 0002—General Information
Section 0100—Hydrostatic Transmission
Section 0200—Hydraulic System
Section 0300—Steering System
Section 0400—Park Brake System
Section 0600—Operator’s Station
Section 1000—Engine System
Section 1400—Electrical System
Section 3100—Topper System
Section 3200—Crop Divider System
Section 3300—Basecutter System
Section 3400—Feed Roller System
Section 3500—Chopper System
Section 3600—Primary Extractor System
Section 3700—Elevator System
INDEX
cp1999250002c
CH2500
Chopper Combine
Operations and Test Manual
Safety Recommendations Preliminary Service Intervals ........................ 0001-6

Common Engine Wear Parts ......................... 0001-6
Safety and You ..................................................... 1-3
Transmission—Track ..................................... 0001-7
Operation Safety .................................................. 1-3
Varitorq Transmission—Wheel ...................... 0001-7
Service Safety ...................................................... 1-4
Oil Cooler Fan Motor ..................................... 0001-8
Safety in Your Service Area ................................ 1-5
Steering Circuit—Wheel ................................ 0001-8
Safety when Cleaning or Storing ....................... 1-6
Cylinder Control Circuit ................................. 0001-8
Safety Nevers ....................................................... 1-6
Topper—Whole Top (106 L/Min—28 GPM) .... 0001-8
Recognize Safety Information ............................ 1-7
Topper—Shredder (106 L/Min—28 GPM) ...... 0001-8
Understand Signal Words ................................... 1-7
Topper Collectors ........................................... 0001-9
Follow Safety Instructions .................................. 1-8
Basecutter—302.4 L/Min (80 GPM) ................ 0001-9
Protect Bystanders .............................................. 1-8
Basecutter—226.8L/Min (250 HP, 60 GPM) .... 0001-9
Use Handles and Steps ....................................... 1-9
Crop Dividers ................................................. 0001-9
Prevent Machine Runaway ................................. 1-9
Power Feed Roller—Low Basecutter ............. 0001-10
Avoid Exhaust Fumes ......................................... 1-10
Power Feed Roller—High Basecutter ............ 0001-10
Keep Riders off Machine ..................................... 1-10
Chopper Drums—196.5 L/Min (52 GPM) ....... 0001-10
Handle Fuel Safely—Avoid Fires ........................ 1-11
Chopper Drums—145.5L/Min (38.5 GPM) ..... 0001-10
Safely Service Accumulator ............................... 1-11
Feed Roller Oil Division—98.25 L/Min
Safely Service Cooling System .......................... 1-12
(26 GPM) ..................................................... 0001-11
Prepare For Emergencies ................................... 1-12
Front Feed Roller Set—75.6 L/Min (20 GPM)
Wear Protective Clothing .................................... 1-13
System ........................................................ 0001-11
Use Safety Lights and Devices ........................... 1-13
Feed Roller—A1, A2, B1, & BL (Buttlifter) ...... 0001-11
Use Cylinder Safety Stops .................................. 1-14
Rear Feed Roller Set—196.6 L/Min (52 GPM)
Practice Safe Maintenance ................................. 1-14
System ........................................................ 0001-11
Avoid High Pressure Fluids ................................ 1-15
Feed Roller—B2 ............................................. 0001-11
Use Caution on Hillsides .................................... 1-15
Feed Roller—A3, A4, A5, B3, B4, and B5 ....... 0001-11
Stopping and Parking ......................................... 1-16
Fixed Primary Extractor ................................. 0001-12
Service Tires Safely ............................................ 1-17
Variable Primary Extractor ............................ 0001-12
Transport Combine Safely .................................. 1-17
Secondary Extractor ...................................... 0001-12
Avoid Electrical Power Lines .............................. 1-18
Elevator .......................................................... 0001-13
Keep Hands Away From Knives ......................... 1-18
Elevator Functions ......................................... 0001-13
Avoid Contact with Moving Parts ....................... 1-19
Secondary Extractor ...................................... 0001-13
Dispose of Waste Properly .................................. 1-19
Fire Prevention .................................................... 1-20
General Information
Specifications Diagnostic Sections ....................................... 0002-3
Troubleshooting Tools ................................... 0002-3
Description ..................................................... 0001-4
Troubleshooting ............................................. 0002-3
Preliminary Service Intervals ........................ 0001-4
Visually Inspect Hydraulic System ............... 0002-4
Common Engine Wear Parts ......................... 0001-4
Hydraulic System Testing Precautions ......... 0002-5
Description ..................................................... 0001-6
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TABLE OF CONTENTS
Visually Inspect Electrical System ................ 0002-5 Ground Drive Wheel Hydraulic Schematic .... 0100-10
Electrical System Safety Precautions ........... 0002-6 Ground Drive Track Hydraulic Schematic ..... 0100-11
Battery Specifications .................................... 0002-6 Positrac Circuit Electrical Schematic ............ 0100-12
Oil Storage and Filling .................................. 0002-7 Machine Moves Sluggishly or Has No
Oil Filtration ................................................... 0002-7 Movement— Wheeled Combine ................ 0100-13
Hydraulic Components .................................. 0002-7 Machine Moves Sluggishly or Has No
Aeration and Cavitation ................................. 0002-7 Movement—Wheeled Combine (Continued) 0100-14
Troubleshooting Tips ..................................... 0002-8 Machine Moves Sluggishly or Has No
Movement—Tracked Combine .................. 0100-15
HYDRAULIC CIRCUIT SYMBOLS Machine Moves Sluggishly or Has No
Lines ............................................................... 0002-9 Movement—Tracked Combine (Continued) 0100-16
Fluid Storage .................................................. 0002-9 Positrac Control Does Not Operate with
Pumps ............................................................ 0002-9 On/Off Switch ............................................. 0100-17
Motors ............................................................. 0002-9 Varitorq Control Problem .............................. 0100-18
Cylinder .......................................................... 0002-10 Positrac Control Does Not Operate Properly
Valves ............................................................. 0002-10 When Brake Pedals Are Pressed or Positrac
Miscellaneous Symbols ................................ 0002-11 Circuit Constantly Stays On ...................... 0100-19
Methods of Operation .................................... 0002-11
Electric Circuit Symbols ................................ 0002-12
Quick Field Test .............................................. 0002-13 Hydraulic System
Hydrostatic Pump Charge Pressure Check .. 0002-14
Hydrostatic Pump Vacuum Pressure Check . 0002-15 Hydraulic System Theory of Operation ......... 0200-3
Hydrostatic Pump Pilot Line Check .............. 0002-16 Right Side Triple Pump .................................. 0200-3
Left Side Triple Pump .................................... 0200-3
Basecutter Motor ............................................ 0200-3
Hydrostatic System Five Bank Directional Valve ........................... 0200-4
System Operation .......................................... 0200-4
Transmission Theory of Operation ................ 0100-3 Specifications ................................................. 0200-4
Hydrostatic Transmission Pump Theory of Control For Basecutter and Topper Lift ......... 0200-4
Operation .................................................... 0100-3 Main Relief Test Procedure ............................ 0200-4
High Pressure Relief Valve ............................ 0100-3 Electrical Control Over Hydraulic Pilot
Charge Relief Valve ........................................ 0100-4 Operation Lines ......................................... 0200-4
Pump Control Operation—Neutral ................ 0100-4 Main Relief ...................................................... 0200-5
Pump Control Operation—Initial Movement 0100-4 Load Check ..................................................... 0200-5
Flow / Pressure Specifications ...................... 0100-4 Anti-Cavitation Relief ..................................... 0200-5
Hydrostatic Transmission Control Operation 0100-4 Cylinder Lock Cartridge ................................. 0200-5
Crossover Relief Settings .............................. 0200-5
TRACK Elevator Controls Hydraulic Schematic ........ 0200-6
Hydrostatic Motor Description ....................... 0100-5 Chopper and Feed Rollers
Hydrostatic Motor Theory of Operation ......... 0100-5 Hydraulic Schematic .................................. 0200-7
Operation In Neutral ....................................... 0100-5 Crop Dividers Hydraulic Schematic .............. 0200-8
Operation In Forward ..................................... 0100-5 Topper Hydraulic Schematic ......................... 0200-9
Flushing Valve Operating Charge Pressure .. 0100-6 Basecutter Hydraulic Schematic ................... 0200-10
Relief Valve .................................................... 0100-6 Five Bank Swing Pedal Hydraulic Schematic0200-11
Primary Extractor Hydraulic Schematic ........ 0200-12
WHEEL Ground Drive Wheel Hydraulic Schematic .... 0200-13
Hydrostatic Motor Description ....................... 0100-7 Ground Drive Track Hydraulic Schematic ..... 0200-14
Theory of Operation ....................................... 0100-7 Park Brake Hydraulic Schematic ................... 0200-15
Control—Neutral ............................................. 0100-7 Five Bank Swing Pedal
Displacement Regulation ............................... 0100-7 Hydraulic Schematic .................................. 0200-16
Loop Flushing Components .......................... 0100-8 Elevator Drive And Secondary Extractor
Hydraulic Schematic .................................. 0200-17
Oil Cooler Fan Does Not Operate .................. 0200-18
POSITRAC
Theory of Operation ....................................... 0100-9
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TABLE OF CONTENTS
Steering System Refrigerant Cautions ...................................... 0600-7

R134A Component Oil Charge ....................... 0600-7
Front Suspension and Steering .................... 0300-3 R134A Refrigerant Recover, Recycling and
Steering Pivot Assembly ............................... 0300-3 Charging System Installation Procedure . 0600-7
Steering Circuit Specifications ...................... 0300-3 Recover R134A System .................................. 0600-8
Steering Test Procedure ................................ 0300-3 Evacuate R134A System ................................ 0600-8
Troubleshooting ............................................. 0300-4 Air Conditioning System Test ........................ 0600-9
Slow Steering, Hard Steering, or Loss of Charge R134A System ................................... 0600-9
Power Assist ............................................... 0300-4 Air Conditioning Operational Checks ........... 0600-10
Wander—The Tendency To Deviate From Visual Inspection of Components ................. 0600-10
Operator Directed Course ........................... 0300-4 System Operating Checks ............................. 0600-11
Drift—The Tendency To Deviate From System Performance Checks ........................ 0600-11
Non-Operator Directed Course .................. 0300-4 Blower/Air Conditioning Circuit .................... 0600-12
Slip—When A Slow Movement of Steering Wheel Low Refrigerant Pressure Switch Test .......... 0600-12
Fails To Cause Any Movement of Steered Volt-Ohm-Amp Meter ...................................... 0600-12
Wheels ........................................................ 0300-4 Insufficient Heating ........................................ 0600-13
Temporary Hard Steering or Hang-Up Inadequate Removal of Ice or Fog ................ 0600-13
(A Momentary Increase In Steering Wheel Heater Valve Not Shutting Off Coolant Flow . 0600-13
Torque During Steering Reversal or Initial Air Conditioning System Does Not Operate . 0600-13
Input) .......................................................... 0300-5 Air Conditioner Does Not Cool Cab Interior . 0600-13
Erratic Steering .............................................. 0300-5 Air Conditioner Runs Constantly, Too Cold .. 0600-14
Spongy or Soft Steering ................................ 0300-5 Cab and Air Conditioner
Free Wheeling—Steering Wheel Turns Freely Electrical Schematic .................................. 0600-15
With No Feeling of Pressure and No Action On
Steered Wheels ......................................... 0300-5
Elevator Drive and Secondary Extractor Engine System
Five Bank Joystick and Swing Pedal Check Radiator Cap ....................................... 1000-3
Hydraulic Schematic .................................. 0300-7 Check Coolant Level and Condition ............. 1000-3
Steering Does Not Operate ............................ 0300-8 Check Radiator Outside Air Flow .................. 1000-3
Check Radiator Internal Core ........................ 1000-3
Check Radiator For Bubbles .......................... 1000-4
Park Brake Check Fan Shroud and Fan Guard ................ 1000-4
Check Fan ....................................................... 1000-4
Park Brake Electrical Theory of Operation .... 0400-3 Check Fan Belt ............................................... 1000-4
Park Brake Electrical Schematic ................... 0400-4 Engine Will Not Crank .................................... 1000-4
Park BrakeHydraulic Schematic .................... 0400-5 Engine Cranks But Will Not Start or Is Hard
Park Brake Cannot Be Cancelled ................... 0400-6 To Start ....................................................... 1000-5
Park Brake Does Not Engage ........................ 0400-7 Engine Knocks, Runs Irregularly or Stops ... 1000-5
Engine Not Developing Full Power ............... 1000-6
Engine Overheats ........................................... 1000-7
Operator’s Station Coolant Temperature Too Low ....................... 1000-7
Oil In Coolant Or Coolant In Crankcase ........ 1000-7
Operator’s Station Theory of Operation ........ 0600-3 Low Engine Oil Pressure ............................... 1000-7
Glass and Moldings ....................................... 0600-3 High Engine Oil Pressure .............................. 1000-8
Air Intake (Pressurizer) System ..................... 0600-3 Engine Uses Too Much Oil ............................ 1000-8
Air Conditioning System ............................... 0600-3 Oil Dripping From Turbocharger Adapter ..... 1000-8
Air Conditioning Circuit ................................ 0600-4 Excessive Drag In Turbocharger Rotating
Receiver/Dryer Operation ............................... 0600-4 Members ..................................................... 1000-8
Thermostat Switch Operation ........................ 0600-5 Engine Uses Too Much Fuel .......................... 1000-9
Expansion Valve Operation .......................... 0600-5 Excessive Black Smoke ................................. 1000-9
Compressor Relief Valve Operation .............. 0600-6 Excessive Blue or White Smoke .................... 1000-9
Heating System .............................................. 0600-6 Detonation ...................................................... 1000-9
Air Conditioning Specifications .................... 0600-6 Abnormal Noise ............................................. 1000-9
AC Circuit Operational Information ............... 0600-6
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TABLE OF CONTENTS
Turbocharger Excessively Noisy or Elevator On/Off Switch .................................. 1400-24

Vibrates ..................................................... 1000-10 Reverse Alarm and Brake Pedal Switches .... 1400-24
Starter Circuit Electrical Schematic .............. 1000-11 Air Cleaner Restriction Indicator ................... 1400-24
Engine Cranks Properly, But Does Not Start 1000-12 Hydraulic Filter Restriction Indicator ............ 1400-25
Engine Will Not Crank .................................... 1000-13 Hydraulic Float Level Check .......................... 1400-25
Engine Will Not Crank—Continued ............... 1000-14 Cab Harness ................................................... 1400-26
Positrac Circuit (Wheel)Electrical Schematic 1400-27
Starter Circuit Electrical Schematic .............. 1400-28
Electrical System Cab and Air Conditioner
Electrical Schematic .................................. 1400-29
Visually Inspect Electrical System ................ 1400-5 Elevator Control Electrical Schematic .......... 1400-30
Safety Precautions ......................................... 1400-5 Gauges Electrical Schematic ........................ 1400-31
Alternator And Battery ................................... 1400-7 Turn Signal Light Circuit
Theory of Operation ....................................... 1400-7 Electrical Schematic ................................. 1400-32
Cleaning Battery Posts ................................... 1400-7 Primary Extractor Tachometer
Jumping the Battery ....................................... 1400-7 Electrical Schematic .................................. 1400-33
Charging The Batteries .................................. 1400-8 Reverse Alarm Track & Wheel
Precautions For Alternators .......................... 1400-8 Electrical Schematic .................................. 1400-34
Electrical Lighting Theory of Operation ........ 1400-8 Horn Electrical Schematic ............................. 1400-35
Oil Pressure Sending Unit ............................. 1400-10 Safety Shutdown Electrical Schematic ......... 1400-36
Oil Pressure Switch ....................................... 1400-10 Park Brake Circuit Electrical Schematic ....... 1400-37
Engine Coolant Temperature ......................... 1400-10 Crop Divider Electrical Schematic ................ 1400-38
Gauge Sender ................................................. 1400-10 Topper and Side Knives
Engine Coolant Temperature Switch ............. 1400-10 Electrical Schematic .................................. 1400-39
Hydraulic Oil Temperature Sender ................ 1400-11 Basecutter and Chopper
Fuel Sending Unit .......................................... 1400-11 Electrical Schematic .................................. 1400-40
Hydraulic Filter Pressure Switch ................... 1400-11 Primary Extractor Electrical Schematic ........ 1400-41
Air Filter Restriction Switch .......................... 1400-11 Chopper/Height Indicator Lights
Front Solenoid 22 Pin Connector Breakout .. 1400-13 Electrical Schematic .................................. 1400-42
Engine 22 Pin Connector Breakout ............... 1400-14 Electrical System Has Low Voltage Problem 1400-43
Elevator 22 Pin Connector Breakout ............. 1400-15 Ignition Power Problem ................................. 1400-44
Battery Visual Inspection ............................... 1400-16 Front Working Lights Do Not Operate ........... 1400-45
Battery Hydrometer Test ................................. 1400-16 Accessory Power Problem ............................ 1400-46
Battery Load Test ............................................ 1400-16 Radiator Level Light and Buzzer Stay On ..... 1400-47
Ignition Switch Check .................................... 1400-17 Radiator Level Light and Buzzer Do Not
Diode Check ................................................... 1400-17 Activate ....................................................... 1400-47
Switch Check .................................................. 1400-17 Side Working Lights Do Not Operate ............ 1400-48
Joystick Switch Check: Horn ......................... 1400-19 Elevator Working Lights Do Not Operate ...... 1400-49
Joystick Switch Check: Lh Scroll Up/Down .. 1400-19 Warning Lights Do Not Work .......................... 1400-50
Joystick Switch Check: Rh Scroll Up/Down . 1400-19 Tail Lights Do Not Operate ............................ 1400-51
Check Relay .................................................... 1400-20 Dash Lights Do Not Operate .......................... 1400-52
Solenoid Check Number One ........................ 1400-20 Headlights Do Not Operate ............................ 1400-53
Solenoid Check Number Two ........................ 1400-20 Safety Shut Down Button Will Not Remain In
Fuse Breaker Check ....................................... 1400-21 The Depressed Position After Engine
Relay Check .................................................... 1400-21 Start-Up ..................................................... 1400-54
Starter Solenoid Check .................................. 1400-21 Safety Shut Down Button Will Not Remain In
Fuse Breaker Check ....................................... 1400-22 The Depressed Position After Engine
Head Light Switch and Warning Switch Start-Up ..................................................... 1400-55
Check .......................................................... 1400-22 Oil Pressure Light Stays On .......................... 1400-56
Turn Signal Switch Check ............................. 1400-22 Water Temperature Buzzer Stays On ............. 1400-57
Primary Extractor Fan Tachometer Check: Engine Air Filter Indicator Stays On ............. 1400-58
Operation .................................................. 1400-23 Engine Air Filter Indicator Does Not Light ... 1400-59
Engine Tachometer Check: Operation ........... 1400-23 Hydraulic Filter Restriction Indicator Does Not
Engine Tachometer Check ............................. 1400-23 Go “Out” ..................................................... 1400-60
Elevator On/Off Switch .................................. 1400-24 Hydraulic Filter Restriction Indicator Does
Not Work. .................................................... 1400-61
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Hydraulic Oil Temperature Gauge Does Basecutter System

Not Register ............................................... 1400-62
Water Temperature Gauge Does Not Register 1400-63 Basecutter Theory of Operation ..................... 3300-3
Fuel Gauge Does Not Register ...................... 1400-64 Basecutter Electrical System Operation ...... 3300-3
Oil Pressure Gauge Does Not Register ......... 1400-65 Hydraulic System Operation .......................... 3300-3
Battery Voltage Gauge Does Not Register ..... 1400-66 Basecutter Specifications .............................. 3300-4
Primary Extractor Digital Tachometer Does Basecutter Control ......................................... 3300-4
Not Function .............................................. 1400-67 Test Procedure: Basecutter Control Valve
Primary Extractor Tachometer Reading Does Main Relief ................................................. 3300-4
Not Match Fan Speed ................................ 1400-67 Basecutter And Chopper
Reverse Alarm Does Not Sound .................... 1400-68 Electrical Schematic .................................. 3300-5
Windshield Washer Does Not Operate ........... 1400-69 Chopper, Feed Rollers, and Basecutter
Hydraulic Schematic ................................ 3300-6
Basecutter Does Not Operate
Topper System Electrical Check ........................................ 3300-7
Basecutter Does Not Operate ......................... 3300-8
Topper Electrical Theory of Operation .......... 3100-3 Basecutter Does Not Lift Correctly
Topper Hydraulic Operation Theory .............. 3100-3 Or Leaks Down—Track ............................. 3300-9
Topper/Side Knives Electrical Schematic ..... 3100-4 Basecutter Does Not Lift Correctly
Topper (Track and Wheel) Or Leaks Down—Wheel ............................ 3300-10
All Functions on Topper Do Not Operate—
Whole or Shredder ..................................... 3100-6 Feed Roller System
All Functions On Topper Do Not Operate—
Whole or Shredder (Continued) ............... 3100-7 Description ..................................................... 3400-3
All Topper Functions Do Not Operate— Feed Roller Circuit Relief ............................... 3400-4
Whole or Shredder .................................... 3100-8 Feed Roller Specifications ............................ 3400-4
Feed Roller Control Operation ...................... 3400-4
Buttlifter Theory of Operation ........................ 3400-4
Crop Divider Front Feed Roller Test Procedure ................. 3400-4
Rear Feed Roller Test Procedure ................... 3400-4
Crop Divider Theory of Operation ................. 3200-3 Power Feed Roller Theory of Operation ........ 3400-5
Crop Divider Hydraulic Theory of Operation 3200-3 Power Feed Roller Electrical System
Crop Divider Electrical Theory of Operation . 3200-3 Operation .................................................... 3400-5
Crop Divider Specifications ........................... 3200-3 Power Feed Roller Hydraulic System
Crop Divider Control Operation .................... 3200-3 Operation .................................................... 3400-5
Crop Divider Electrical Schematic ................ 3200-4 Power Feed Roller Specifications ................. 3400-5
Crop Divider Hydraulic Schematic ................ 3200-5 Power Feed Roller Control ............................ 3400-6
Twin Crop Divider Showing ........................... 3200-6 Power Feed Roller Test Procedure ................ 3400-6
Slow or No Operation .................................... 3200-6 Feed Roller Hydraulic Schematic .................. 3400-7
Twin Crop Dividers Showing Slow or No Rear Set Feed Roller Forward/Reverse
Operation .................................................... 3200-7 and Billet Selector Do Not Operate or
Crop Dividers Showing .................................. 3200-8 Operate Slowly [EC] ................................... 3400-8
Slow or No Operation .................................... 3200-8 Rear Set Feed Rollers Forward/Reverse
Crop Dividers Show Slow or No Operation .. 3200-9 and Billet Selector Do Not Operate or Operate
Crop Divider Lift Does Not Operate Properly 3200-10 Slowly [HC] ............................................... 3400-9
Crop Divider Lift Does Not Operate Properly 3200-11 Feed Rollers Forward/Reverse Do Not
Side Knives Do Not Operate .......................... 3200-12 Operate and Chopper Blades Operate ..... 3400-10
Side Knives Do Not Operate .......................... 3200-13 Power Knockdown Feed Rollers have Slow
or No Operation and Other Basecutter
Functions Operate [EC] ............................. 3400-11
Power Knockdown Feed Rollers has Slow
or No Operation Other Basecutter Functions
Operate [HC] .............................................. 3400-12
Power Feed Rollers Do Not Operate and
Other Basecutter Functions Operate ......... 3400-13
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TABLE OF CONTENTS
Chopper System Hydraulic Theory of Operation ...................... 3700-4

Elevator Control Electrical Schematic .......... 3700-5
Chopper Theory of Operation ........................ 3500-3 Elevator Controls Hydraulic Schematic ........ 3700-6
Chopper Electrical System Operation ........... 3500-3 Elevator Forward Does Not Engage,
Chopper Hydraulic System Operation .......... 3500-3 Other Elevator Functions Operate [EC] .... 3700-7
Chopper Specifications ................................. 3500-3 Elevator Forward Does Not Engage,
Control ............................................................ 3500-3 Other Elevator Functions Operate [HC] .... 3700-8
Set Chopper Shaft Timing ............................. 3500-4 Momentary Elevator Forward/Reverse
Chopper Test Procedure ................................ 3500-4 Does Not Engage, All Other Elevator
Basecutter and Chopper Functions Operate [EC] ............................. 3700-9
Electrical Schematic .................................. 3500-5 Momentary Elevator Forward/Reverse
Chopper and Feed Roller Does Not Operate All Other Elevator
Hydraulic Schematic .................................. 3500-6 Functions Operate [HC] ............................. 3700-10
Chopper Blades Show Slow or No Elevator Lowers But Does Not Raise [EC] .... 3700-11
Operation .................................................... 3500-7 Elevator Lowers But Does Not Raise [HC] .... 3700-12
Elevator Raises But Does Not Lower [EC] .... 3700-13
Elevator Raises But Does Not Lower [HC] .... 3700-14
Extractor System Secondary Hood Rotate Does
Not Operate [EC] ........................................ 3700-15
Primary Hood Rotate System Secondary Hood Rotate Does
Theory of Operation ................................... 3600-3 Not Operate [HC] ........................................ 3700-16
Hydraulic System Operation .......................... 3600-3 Secondary Extractor Fan Having Slow or
Electrical System Operation .......................... 3600-3 No Operation .............................................. 3700-17
Specifications ................................................. 3600-3 Bin Flap Does Not Operate ............................ 3700-18
Control Operation .......................................... 3600-3 Horn Does Not Operate .................................. 3700-19
Primary Extractor Theory of Operation ......... 3600-4
Electrical System Operation .......................... 3600-4
Variable Primary Extractor ............................ 3600-4
Hydraulic System Operation .......................... 3600-4
Specifications ................................................. 3600-4
Control Operation .......................................... 3600-4
Primary Extractor Tachometer
Electrical Schematic .................................. 3600-5
Primary Extractor Electrical Schematic ........ 3600-6
Primary Extractor Hydraulic Schematic ........ 3600-7
Fixed Speed Primary Extractor
Fixed Speed Primary Extractor Does
Not Operate ................................................ 3600-9
Variable Primary Extractor Shows
Slow or No Operation ................................ 3600-10
Elevator System
Elevator System On/off and
Forward/Reverse ........................................ 3700-3
Elevator System Up/Down
Electrical System Operation ...................... 3700-3
Secondary Extractor
Hood Rotate Extractor
Bin Flap Extractor
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CH2500 Chopper Harvester
INTRODUCTION
Read this manual carefully to learn how to correctly operate and service your harvester. Failure
to do so could result in personal injury or equipment damage.
This manual should be considered a permanent part of your machine and should remain with the
harvester.
Measurements in this manual are given in both customary US units and metric equivalents. Use
only specified replacement parts and fasteners. Inch and metric fasteners require a specific inch or
metric wrench or socket.
Right-hand and left-hand sides are determined by facing in the direction of forward travel.
All information, illustrations, specifications, and recommendations in this manual are based on
the latest information available at the time of publication. CAMECO reserves the right to make changes
at any time without notice or obligation.
Write the product serial number in a secure place away from the harvester. An appropriate place
would be in the parts manual since it is recommended to have your serial number available when ordering
parts. This number will also aid in tracing the harvester in the event that it is stolen.
Carefully read all safety messages in this manual and on your harvester. Precautionary statements
like CAUTION and IMPORTANT are followed by specific instructions for personal and machine safety.
Please take time to read them.
CAMECO INDUSTRIES, INC.

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INTRODUCING THE HARVESTER
Sugar Cane Flow

The gathering discs, located on each side of the topper, gather the cane tops and feed them to the topper
severing disc, located in the center of the topper. The crop dividers then separate the rows of down or
tangled cane. The knockdown roller pushes the cane forward and down into the fin roller which separates
and feeds the cane to the basecutter. The basecutter cuts the bottom of the stalk. The butt lifter roller then
sends the cane up into the feed rollers, which regulate the canes speed and gives the size (billet length) that is
cut next by the choppers. The choppers cut clean, even billets by pinching the cane between two opposing
blades and drops them into the elevator basket. From there, the billets are delivered to the elevator. Meanwhile,
the primary extractor fan draws trash, leaves and dirt from the cane and directs it onto the ground behind the
harvester. The elevator system delivers the cane to a container system either to the rear, left or right sides of
the harvester. As the cane falls from the end of the elevator into the transport, the remaining loose material is
removed by the secondary extractor fan in the final stage of the process. This trash is directed away from the
transport and harvester by the rotating secondary extractor hood.
Topper
Severs the top leaves from the cane.
Crop Divider
Separates rows of down or tangled cane. It uses
dual croplift scrolls that turn in a screwing motion to pick-
up the down cane and separates it from the next row.
Power Knockdown Roller

Pushes cane into optimal position for feeding. Also
helps in feeding heavily lodged cane into the throat and to
prevent the cane from getting hung-up on the front of the
harvester.

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Fin Roller
Feeds cane into the basecutter.
Basecutter
Cuts the cane at ground level. Directs the cane
flow upward into the feedrollers with the help of the
buttlifter.
Basket
Collects cane from chopper and transports it to the
elevator system
Primary Extractor
Removes leaves, trash and dirt from cane.

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Elevator
The elevator system delivers cane to a
container system either to the rear, left or right
sides of the harvester. The perforated floor
allows loose material to fall through, which is
an additional feature of the cleaning process.
Secondary Extractor
Removes any leftover debris.

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SECTION 1
SAFETY RECOMMENDATIONS
Safety and You .......................................................................................... 1-3
Operation Safety ....................................................................................... 1-3
Service Safety ........................................................................................... 1-4
Safety in Your Service Area ..................................................................... 1-5
Safety when Cleaning or Storing ............................................................ 1-6
Safety Nevers ............................................................................................ 1-6
Recognize Safety Information ................................................................. 1-7
Understand Signal Words ........................................................................ 1-7
Follow Safety Instructions ....................................................................... 1-8
Protect Bystanders ................................................................................... 1-8
Use Handles and Steps ............................................................................ 1-9
Prevent Machine Runaway ...................................................................... 1-9
Avoid Exhaust Fumes .............................................................................. 1-10
Keep Riders off Machine .......................................................................... 1-10
Handle Fuel Safely—Avoid Fires ............................................................. 1-11
Safely Service Accumulator .................................................................... 1-11
Safely Service Cooling System ............................................................... 1-12
Prepare For Emergencies ........................................................................ 1-12
Wear Protective Clothing ......................................................................... 1-13
Use Safety Lights and Devices ................................................................ 1-13
Use Cylinder Safety Stops ....................................................................... 1-14
Practice Safe Maintenance ...................................................................... 1-14
Avoid High Pressure Fluids ..................................................................... 1-15
Use Caution on Hillsides ......................................................................... 1-15
Stopping and Parking .............................................................................. 1-16
Service Tires Safely ................................................................................. 1-17
Transport Combine Safely ....................................................................... 1-17
Avoid Electrical Power Lines ................................................................... 1-18
Keep Hands Away From Knives .............................................................. 1-18
Avoid Contact with Moving Parts ............................................................ 1-19
Dispose of Waste Properly ....................................................................... 1-19
Fire Prevention ......................................................................................... 1-20
cp1999250002c
cp1999250002c
Safety and You 11. The symbol below identifies all important safety
We at CAMECO are very concerned for your messages on your harvester. When you see this
safety when you are operating or servicing your harvester. symbol, be alert to the possibility of personal injury.
With this in mind, the following section should be read and Carefully read any message following this symbol.
studied by you. Hopefully you will take every precaution
cm199899001
seriously and use good old-fashioned common sense
before attempting to use or service your harvester.
Of course, CAMECO cannot anticipate every
possible circumstance that might involve a potential
hazard. The warnings that we provide are, therefore, not
all-inclusive. If a procedure, tool, or work method not
specifically recommended by CAMECO is used, you must
satisfy yourself that it is safe for you and others and also
that the machine will not be damaged or made unsafe by
the procedures that you choose.
Operation Safety
The following is a list of safe operation procedures
that you should practice at all times:
1. Be sure to read the operation manual and all

safety precautions before starting the harvester.
2. Dress for the job. Any loose clothing, jewelry 12. Use step and grab handles when mounting or
(especially rings), belts, or scarves will present a dismounting the harvester. Clean all mud or debris
definite safety hazard. from steps, walkways, and work areas. Always
face the equipment when using its steps or ladder.
3. When either stopping or starting the machine,
make sure the area is clear of personnel. 13. Maintain your CAMECO equipment as if your
life depends on itIt does. Improper lubrication
4. Before leaving the machine unattended, lower all
and maintenance can be dangerous and could
implements to the lowest position.
result in injury or death.
5. DO NOT allow riders or any passenger on the
machine when it is in operation.
6. Keep a fully charged fire extinguisher on or near
the operators station. It must be easily accessible
when needed. Know how to operate it.
7. Keep a fully stocked first aid kit on the operators
station. Know basic first aid.
8. Keep the operation area free of all loose objects
such as tools, lunch kits, soft drink cans, etc.
9. Never allow an open flame within 3.05 M (10
feet) of the harvester.
10. Be sure that all shields, guards, and safety
equipment are in their proper place and in good
condition.
1-3
cp1999250002c
Service Safety Use the following Lock-Out Tag-Out Procedure:

When a service person or mechanic is unfamiliar A. Parking Procedure
with all systems on this harvester, extra caution should be a. Lower topper.
used when performing service work. A good working b. Lower crop dividers.
knowledge of the system and its components is important c. Lower elevator.
for removal or disassembly. The following is a list of d. Before stopping engine that has been
basic precautions that should always be observed. operating at working load, idle at least
one minute to cool turbocharger.
1. Make sure that you read and understand all
warning plates and decals before lubricating or B. Install safety stops on basecutter. Note: In
performing other maintenance. the event the engine cannot run, block the
2. Always wear protective glasses and footwear basecutter lift cylinder with 2 x 2 x ¼
when working. In particular, wear safety glasses x____angle-iron.
when pounding on any part of the machine or
attachments with a hammer. Use protective C. In the event you cannot lower the topper, crop
clothing when welding. Do not wear any loose divider or elevator, block cylinders to stop all
fitting or torn clothing. Remove all rings from movement with 2 x 2 x ¼ x angle-iron.
fingers before working on equipment.
D. Stop engine, remove ignition key, remove
3. Before starting work on the machine, disconnect
battery disconnect key, the remove negative
battery and hang this DO NOT START sign in
battery cables from battery and install lock out
the operators station.
device lock and tag. Also install tag on steering
wheel or track control.
cm199899038
E. Before beginning any hydraulic repairs you

must first relieve pressure from main hydraulic
tank then close the two 1½ vertical block
valves located on rear of harvester.
F. In the event repairs need to be made to the

basecutter lift or topper lift, the hydraulic
pressure should be bled off of the accumulator
by lowering the basecutter or topper.
4. If at all possible, make all repairs with the machine

parked on level ground. Block the machine so it
cannot roll. DO NOT work on any machine that
is supported only by lift jacks or a hoist.
5. Relieve all pressure in air, oil, or water systems
before any lines, fittings, or related parts are
disconnected or removed. Always make sure
IMPORTANT:
Ø Before climbing on machine, ensure that no one is
that all raised components and implements are
working in or on it. correctly blocked. Be alert for possible pressure
when disconnecting any device from a system
Ø Ensure that all operators blow the horn several that utilizes pressure.
times before starting the machine.
6. Lower all implements to the ground prior to
Ø Ensure that any persons near the machine know working on the machine. If this cannot be done,
that when the horn blows, the machine is about to make sure the implement is properly blocked to
be started, and to move away as soon as possible. prevent it from dropping unexpectedly.
1-4
cp1999250002c
7. To avoid back injuries, use a hoist when lifting

components that weigh over 23 kgs (50 lbs). * CAUTION *
Liquid escaping from a very small hole can be
When using a hoist, make sure all hooks are almost invisible. Use wood or cardboard, instead
correctly positioned. of your hand, when searching for suspected leaks.
8. To avoid burns, be alert for hot parts located on
the machine after it has stopped. Be particularly
careful of hot fluids in lines, tubes, and 16. If you are injured by escaping fluid under pressure,
components. see a doctor at once. A serious infection or
reaction may result if proper medical attention is
9. Be careful when removing cover plates.
not received immediately.
Gradually loosen the last two bolts or nuts located
at the opposite ends of the cover or device. 17. Do Not operate the harvester if any rotating part
Carefully pry the cover loose to relieve any spring is damaged or contacts any other part during
or other tension before removing it completely. operation. Any high-speed rotating component
that has been damaged or altered must be checked
10. Be careful when removing filler caps, breathers,
for balance before operation.
or plugs on the machine. Hold a rag over the cap
or plug to prevent being sprayed or splashed by 18. Avoid working on equipment with the engine
fluids under pressure. running. If it is absolutely necessary to make
checks with the engine running, always use two
11. Always use tools that are in good condition.
men: one to operate the controls and the other to
Before performing any service, make sure you
work where the operator can see him. The
know how to use the proper tools.
transmission must be in neutral, the braking
12. Replace all fasteners with the same SAE or system set, and all pertinent safety locks set.
metric grade. Never substitute a softer part where
a hardened part is used, conversely never
substitute a harder part where a softer part is Safety in Your Service Area
used. To maintain proper safety procedure in the service
13. Take precautions to prevent damage to wiring area, the following should be observed:
during removal. After reinstalling the wiring,
double check to make sure it is was not damaged 1. Keep the service area clean and dry. Wet or oily
during removal or installation. Ensure that the floors are slippery and wet spots can be dangerous
wiring does not touch any hot, sharp, or moving when working with electrical equipment.
parts after it is installed. 2. Make sure the service area is adequately
14. Ensure that all protective devices and guards are ventilated. Periodically check the shop exhaust
properly installed and are functioning correctly system for leakage.
before starting any repairs. If a guard or shield 3. Be sure that all electrical outlets and tools are
must be removed to perform repair work, use properly grounded.
extra caution while working.
4. Use adequate lighting for the job.
15. Escaping fluid under pressure can have sufficient
5. Be prepared if an accident or fire should occur.
force to penetrate the skin. Therefore, before
Know where the first aid kit and fire extinguishers
disconnecting any lines, be sure all pressure in
are located. Know how to use both of them.
the system is relieved. Before applying pressure,
make sure all lines, fittings, and connections are
tight and undamaged.
1-5
cp1999250002c
Safety when Cleaning or Storing Safety Nevers

The following practices should be observed whenever The following is a list of practices that you should
you clean or store your equipment: Never use:
1. Never smoke while refueling or handling
* CAUTION * flammable materials.
Engine exhaust gas is dangerous. 2. Never refuel the engine while it is running. Use
care during refueling when the engine is hot.
1. Always stop the engine before cleaning the 3. Never use open pans of gasoline or diesel fuel
harvester. for cleaning parts. A good commercial,
nonflammable solvent is preferred.
2. Keep the operators station clean. Do Not use it
for a storage area. 4. Never check the charging battery by placing metal
objects across the posts. Provide adequate
3. Avoid a possible fire hazard. Keep the radiator
ventilation when charging batteries.
and engine closure screens free of foreign
material. 5. Never allow sparks or flames near the batteries.
This includes smoking near the batteries.
4. Keep all equipment free of dirt and oil. In bad
weather beware of snow, ice, and mud on ladders, 6. Never check fuel, battery electrolyte, or coolant
steps, and in the operators station. levels with an open flame nearby.
5. When preparing the engine for storage, remember 7. Never use an open flame to look for leaks
that inhibitors are volatile and therefore, anywhere on the equipment.
dangerous. Seal and tape openings after adding 8. Never use an open flame as a light anywhere on
the inhibitor. Keep the inhibitor container tightly or near the equipment.
closed when not in use.
9. Never adjust the fuel system while the machine
is in motion.
1-6
cp1999250002c
Recognize Safety Information
cm199899002
This is the safety-alert symbol. When you see this
symbol on your machine or in this manual, be alert to the
potential for personal injury.
Follow recommended precautions and safe operating
practices.
cm199899003
Understand Signal Words
A signal wordDANGER, WARNING, or
CAUTIONis used with the safety-alert symbol.
DANGER identifies the most serious hazards.
Safety signs with signal word DANGER or
WARNING are typically near specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety messages
in this manual.
1-7
cp1999250002c
Follow Safety Instructions
cm199899004
Carefully read all safety messages in this manual
and on your harvester safety signs. Keep safety signs in
good condition. Replace missing or damaged safety signs.
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate it without
proper instruction.
Keep your harvester in proper working condition.
Unauthorized modifications to the machine may impair
the function and/or safety and affect machine life.
cm199899005
Protect Bystanders
Be sure everyone is clear of the harvester before
starting the engine or moving the steering wheel.
1-8
cp1999250002c
Use Handles and Steps
cm199899006
Clean off mud, grease, and any crop residue that
may have accumulated on the steps and operators
platform of your harvester. Remember that chains and
tools carried on the platform may interfere with pedal
operation or cause a fall from the harvester. Remove
them.
cm199899007
Prevent Machine Runaway
Avoid possible injury or death from machine
runaway.
DO NOT start engine by shorting across starter
terminals. Machine will start in gear if normal circuitry is
bypassed.
Start engine only from operators seat, with
transmission in neutral or park.
1-9
cp1999250002c
Avoid Exhaust Fumes
cm199899008
Never run engine in a closed building. Make sure
service area is adequately ventilated.
Avoid inhaling exhaust gases produced by a running
engine. Exhaust gases, particularly carbon monoxide, may
build up. Carbon monoxide is colorless, odorless, and
potentially lethal.
cm199899009
Keep Riders off Machine
Only allow the operator on the machine. Keep riders
off.
Riders on machine are subject to injury such as being
struck by foreign objects and being thrown off the
machine. Riders also obstruct the operators view resulting
in the machine being operated in an unsafe manner.
1-10
cp1999250002c
Handle Fuel Safely—Avoid Fires
cm199899010
Handle fuel with care; it is highly flammable. Do
not refuel the machine while smoking or when near an
open flame or sparks.
Always stop engine before refueling. Fill fuel tank
outdoors.
Prevent fires by keeping machine clear of
accumulated trash, grease, and debris. Always clean up
spilled fuel.
cm199899011
Safely Service Accumulator
Accumulators contain gas and oil under pressure.
To avoid injury from escaping fluid, relieve all pressure
from accumulator before disconnecting brake accumulator
or brake valve. To do so, open bleed screws and pump
brake pedal with engine stopped, until pedal easily goes
all the way down.
The accumulator is charged with dry nitrogen to at
least a pressure of 3450 kPa (35 bar) (500 PSI). If it
needs recharging, have the job done only by a qualified
service person and only with dry nitrogen.
1-11
cp1999250002c
Safely Service Cooling System
cm199899012
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Remove filler cap when cool enough
to touch with bare hand. To relieve pressure, slowly loosen
cap to first stop, and then remove completely.
cm199899013
Prepare For Emergencies
Be prepared if a fire starts. Keep a first aid kit and
fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your telephone.
1-12
cp1999250002c
Wear Protective Clothing
cm199899014
Wear close fitting clothing and safety equipment
appropriate to the job.
Operating equipment safely requires the full attention
of the operator. Do not wear music headphones or talk
on a cellular phone while operating the machine.
cm199899015
Use Safety Lights and Devices
When transporting your machine on a road or
highway, whether it is at night or during the day, use the
necessary safety lights. Check local government
regulations.
Keep safety items in good condition. Replace missing
or damaged items.
1-13
cp1999250002c
Use Cylinder Safety Stops
cm199899016
When working under the harvester, always raise the
machine all the way up. Apply stops to the lift cylinders
and lower harvester onto the stops. If a hose should bust,
the harvester will remain raised.
cm199899017
Practice Safe Maintenance
Understand service procedures before doing work.
Keep area clean and dry.
Never lubricate or service machine while it is moving.
Keep hands, feet, and clothing away from power-driven
parts. Disengage all power and operate controls to relieve
pressure. Lower equipment to the ground. Stop the
engine, remove the key, and allow machine to cool.
Securely support any machine elements that must
be raised for service work.
Keep all parts in good condition and properly
installed. Fix damaged parts immediately. Replace worn
or broken parts. Remove any buildup of grease, oil, or
debris.
Disconnect battery ground cable (-) before making
adjustments on electrical systems or welding on machine.
1-14
cp1999250002c
Avoid High Pressure Fluids
cm199899018
Escaping fluid under pressure can penetrate the skin
causing serious injury. Relieve pressure before removing
hydraulic lines or any other lines. Tighten all connections
before applying pressure. Keep hands and body away
from pinholes and nozzles that eject fluids under high
pressure. Use a piece of cardboard to search for leaks.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a doctor familiar
with this type of injury or gangrene may result.
cm199899019
Use Caution on Hillsides
Avoid holes, ditches, and obstructions that may cause
the harvester to tip, especially on hillsides.
Never drive near the edge of a gully or steep
embankment because it may cave in.
Be especially careful when using single wheels. The
danger of an overturn increases greatly with narrow tread,
2032 mm (80") or less, and with high speed.
For hillside operation, always use front and rear dual
wheels. Avoid sharp, uphill turns.
Keep hydraulic oil level at upper level when operating
on hillsides. Low oil level might result in loss of steering.
If this should happen, hold harvester with brakes, shift to
NEUTRAL, apply park brake, stop engine, and add
hydraulic oil to proper level.
Before operating on extremely steep slopes, fill
hydraulic system beyond overfull sight glass 4 to 8 L (1 to
2 gal). This is particularly important when using large
hydraulic cylinders, due to the volume of oil used to extend
them.
1-15
cp1999250002c
Stopping and Parking

Your ability to stop your harvester and park it safely
is just as important as being able to get it underway safely.
Harvester up-sets, collisions, runaway tractors, and
people being crushed under machines can happen when
operators ignore safety.
To avoid these accidents, take some precautions:
Ø Signal before stopping, turning, or slowing down
on highways.
Ø Pull over to right-hand shoulder of highway
before stopping, if possible.
Ø Slow down before braking.
Ø Pump brakes when stopping on slippery
surfaces like ice, snow, mud, or loose gravel.
Ø Shift to park or set parking brake.
Ø Lower all equipment when leaving harvester.
ØTurn off all electrical switches and remove key.
cm199819020
cm199899021
1-16
cp1999250002c
Service Tires Safely
cm199899022
Explosive separation of a tire and rim can cause
serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not
inflate the tires above the recommended pressure. Never
weld or heat a wheel and tire assembly. The heat can
cause an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to stand to one
side and NOT in front of or over the tire assembly. Use a
safety cage if available.
Check wheels for low pressure, cuts, bubbles,
damaged rims, or missing lug bolts and nuts.
cm199899023
Transport Combine Safely
Before driving combine on public roads, raise the
crop dividers. It must not, however, obstruct operators
view of the road.
1-17
cp1999250002c
Avoid Electrical Power Lines
cm199899024
Put the topper and elevator in transport position
before driving on public roads.
Secure radio aerial in its transport position before
driving on public roads, it may come into contact with
low-hanging electrical cables. This would result in the
operator suffering a severe electrical shock.
cm199899025
Keep Hands Away From Knives
Never attempt to clear obstructions in cutting areas
unless engine is shut off and key removed.
Everyone must be clear of the combine before
starting the engine.
1-18
cp1999250002c
Avoid Contact with Moving Parts
cm199899026
Keep hands, feet, and clothing away from power
driven parts. Never clean, lubricate, or adjust machine
when it is running.
cm199899029
Dispose of Waste Properly
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with Cameco equipment includes such items as oil, fuel,
coolant, filters, and batteries.
Use leakproof containers when draining fluids. Do
not use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or
into any water source.
Inquire about the proper way to recycle or dispose
of waste at your local environment or recycling center.
1-19
cp1999250002c
Fire Prevention
1. Machines should be cleaned of debris at least 6. Any portable extinguisher or fire suppression
daily, particularly around engine, exhaust, and system carried on the machine that has been
driveline components. previously used should be recharged or replaced
before the machine resumes operation.
2. Machines should be inspected at least daily for
potential fire hazards at electrical, exhaust, 7. Prior to welding or brazing on any part of the
driveline, fuel, hydraulic, and brake systems. machine, the part and the surrounding area should
Repairs should be made immediately. be cleaned and a fire extinguisher should be made
readily available.
3. Operating personnel must be instructed on what
to do when a fire starts, how to use the fire 8. Smoking, open flames, etc., should not be
extinguisher, and must follow such instructions. permitted around any machine during fueling
Operators should be required to demonstrate an operations and/or when the fuel system is open
ability to use fire suppression equipment. to the atmosphere.
4. Hydraulic leaks, accumulation of grease, fuel, and
oil (including spillage) should be eliminated
immediately.
5. The radiator and the engine cooling system should
be cleaned and serviced daily to maintain
moderate engine temperatures.
cm199899027
cm199899028
1-20
cp1999250002c
SECTION 0001
SPECIFICATIONS
Description ............................................................................................... 0001-4
Preliminary Service Intervals .................................................................. 0001-4
Common Engine Wear Parts ................................................................... 0001-4
Description ............................................................................................... 0001-6
Preliminary Service Intervals .................................................................. 0001-6
Common Engine Wear Parts ................................................................... 0001-6
Transmission—Track ............................................................................... 0001-7
Varitorq Transmission—Wheel ................................................................ 0001-7
Oil Cooler Fan Motor ............................................................................... 0001-8
Steering Circuit—Wheel .......................................................................... 0001-8
Cylinder Control Circuit ........................................................................... 0001-8
Topper—Whole Top (106 L/Min—28 GPM) .............................................. 0001-8
Topper—Shredder (106 L/Min—28 GPM) ................................................ 0001-8
Topper Collectors ..................................................................................... 0001-9
Basecutter—302.4 L/Min (80 GPM) .......................................................... 0001-9
Basecutter—226.8L/Min (250 HP, 60 GPM) .............................................. 0001-9
Crop Dividers ........................................................................................... 0001-9
Power Feed Roller—Low Basecutter ....................................................... 0001-10
Power Feed Roller—High Basecutter ...................................................... 0001-10
Chopper Drums—196.5 L/Min (52 GPM) ................................................. 0001-10
Chopper Drums—145.5L/Min (38.5 GPM) ............................................... 0001-10
Feed Roller Oil Division—98.25 L/Min (26 GPM) .................................... 0001-11
Front Feed Roller Set—75.6 L/Min (20 GPM) System ............................. 0001-11
Feed Roller—A1, A2, B1, & BL (Buttlifter) ................................................ 0001-11
Rear Feed Roller Set—196.6 L/Min (52 GPM) System ............................ 0001-11
Feed Roller—B2 ....................................................................................... 0001-11
Feed Roller—A3, A4, A5, B3, B4, and B5 ................................................. 0001-11
Fixed Primary Extractor ........................................................................... 0001-12
Variable Primary Extractor ...................................................................... 0001-12
Secondary Extractor ................................................................................ 0001-12
Elevator .................................................................................................... 0001-13
Elevator Functions ................................................................................... 0001-13
Secondary Extractor ................................................................................ 0001-13
cp1999250002c
cp1999250002c
GENERAL SPECIFICATIONS
For additional information, refer to the Caterpillar Engine Manual.
Engine Type ....................................................... Caterpillar 3306TA
Number of Cylinders ......................................... 6
Horsepower ....................................................... 250 HP at 2000 RPM
Aspiration .......................................................... Turbocharger
Oil Capacity ....................................................... 28 Liters (30 US Quarts)
Oil Filter ............................................................. Combination Filter Full Flow Combined with Optional
Bypass Filter. Spinon/ Spinoff Type Element.
Coolant Capacity ............................................... 50.6 Liters (13 US Gallons)
Coolant Additive Element ................................. Canister Type (Optional)
IMPORTANT: DO NOT Mix Coolant Additive and Additive Elements

or Use Together. Use Only One Method Exclusively.
Fuel Filters ........................................................ Primary: Strainer

Final: Canister Type Element
Safety Shutoff .................................................... Solenoid Operated Shutoff Lever Operating on Low Oil
Pressure, Low Hydraulic Oil Level, Swing Out Door with Shutoff
Override Control. Optional High Water Temperature Safety
Shutoff.
Electrical System .............................................. 12 Volt Battery
0001-3
cp1999250002c
Description
The Caterpillar 3306TA engine has six in-line cylinders, 250 HP, is turbocharged and after cooled.
Please refer to the Caterpillar Maintenance Manual for further repair information.
Preliminary Service Intervals

After the first 100 hours of operation, or after rebuilding your engine, do the following:
Ø Change the engine oil and filter
Ø Change all fuel filters
Every 250 hours of operation thereafter, do the following:

Refer To Maintenance, Section 11, For Complete Service Intervals.
Common Engine Wear Parts

1. Primary Fuel Element .......................................................................... 0060008892
2. Fuel Separator Element Kit ................................................................. 0061304870
3. Final Fuel Element ............................................................................... 0060009676
4. Oil Filter ............................................................................................... 0060034329
5. Belts—Set of 3 ...................................................................................... 0190040211
6. A/C Belt ................................................................................................. 0191340539
0001-4
cp1999250002c
For additional information, refer to the Caterpillar Engine Manual.
Engine Type ....................................................... Caterpillar 3306TA
Number of Cylinders ......................................... 6
Horsepower ....................................................... 325 HP at 2000 RPM
Aspiration .......................................................... Turbocharger and After cooled
Oil Capacity ....................................................... 25 Quarts
Oil Filter ............................................................. Combination Filter Full Flow Combined with Optional Bypass
Filter. Spinon/Spinoff Type Element.
Coolant Capacity ............................................... 50.6 Liters (13 US Gallons)
Coolant Additive Element ................................. Canister Type (Optional)
IMPORTANT: DO NOT Mix Coolant Additive and Additive Elements

or Use Together. Use Only One Method Exclusively.
Fuel Filters ........................................................ Primary: Strainer

Final: Canister Type Element
Safety Shutoff .................................................... Solenoid Operated Shutoff Lever Operating on Low Oil
Pressure, Low Hydraulic Oil Level, Swing Out Door with
Shutoff Override Control. Optional High Water Temperature
Safety Shutoff.
Electrical System .............................................. 12 Volt Battery
0001-5
cp1999250002c
Description
The Caterpillar 3306TA engine has six in-line cylinders, 325 HP, is turbocharged and after cooled.
Please refer to the Caterpillar Maintenance Manual for further repair information.
Preliminary Service Intervals

After the first 100 hours of operation, or after rebuilding your engine, do the following:
Every 250 hours of operation thereafter, do the following:

Refer To Maintenance, Section 11, For Complete Service Intervals.
Common Engine Wear Parts

1. Primary Fuel Element ............................................................. 0060008892
2. Fuel Separator Element Kit ..................................................... 0061304870
3. Final Fuel Element .................................................................. 0060009676
4. Oil Filter ................................................................................... 0060034329
5. Belts—Set of 3 ......................................................................... 0190040211
6. A/C Belt .................................................................................... 0191340539
0001-6
cp1999250002c
Transmission—Track
Pump ........................................ Variable Piston ...................................... 0-6.1 IN3
Charge Pump ........................... Orbital ................................................... 1.2 IN3
Charge Flow ............................................................................................. 49.1 L/Min (13 GPM)
Charge Relief ............................................................................................ 24.8 Bar (360 PSI)
Main Relief ................................ Multifunction ......................................... 380 Bar (6000 PSI)
Pressure Limiter ....................... Multifunction ......................................... 351.7 Bar (5500 PSI)
Control ...................................... Manual Input with Pressure Compensated Override
Motor ........................................ Fixed Piston .......................................... 4.9 IN3
Loop Flush Flow ...................................................................................... 7.5 L/ Min (2 GPM)
Varitorq Transmission—Wheel
Pump ........................................ Variable Piston ...................................... 0-3.4 IN3
Charge Pump ........................... Orbital ................................................... 0.9 IN3
Charge Flow ............................................................................................. 9.4 GPM
Charge Relief ............................................................................................ 360 PSI
Main Relief ................................ Multifunction ......................................... 6000 PSI
Pressure Limiter ....................... Multifunction ......................................... 5500 PSI
Control ...................................... Manual Input with Pressure Compensated Override
Motor ........................................ Variable Piston ...................................... 4.9 - 2.0 IN3

Proportional Max to Min Shift
On Pilot Signal With Pressure
Override to Max Position
Motor Control ........................... 4.9 IN3 .................................................... 100 - 210 PSI
Pilot Pressure ........................... Begin of Shift ........................................ 100 PSI
Loop Flush Flow ...................................................................................... 2 - 3 GPM
0001-7
cp1999250002c
Oil Cooler Fan Motor

Oil Supply ...................................... Gear Pump ............................................ 45.4 L/ Min (12 GPM)
Pump Protection In-line Relief Valve ........................................................... 186.2 Bar (3250 PSI)
Drive Motor ..................................................................................................... 2.0 IN3
Fan Speed ...................................................................................................... 1250 RPM
Steering Circuit—Wheel
Relief Valve ............................... Integral to Priority Valve ....................... 120.7 Bar (1750 PSI)
Cylinder Control Circuit

Oil Supply ...................................... Gear Pump on Track Combine ............ 45.4 L/ Min (12 GPM)
Main Relief Valve ............................................................................................ 172.4 Bar (2500 PSI)
Elevator Swing Relief ..................................................................................... 172.4 Bar (2500 PSI)
Basecutter Lift Circuit.. ............ Counterbalance ..................................... 172 Bar (2500 PSI)
Topper—Whole Top (106 L/Min—28 GPM)

Oil Supply ...................................... Gear Pump ............................................ 106 L/ Min (28 GPM)
Valve ............................................... Directional Control Motor Spool with Port Relief/Anti-Cavitation
Relief Valve ............................... Port and Main ........................................ 207 Bar (3000 PSI)
Drive Motor ..................................... Gear ....................................................... 5.9 IN3
Disc Speed ..................................................................................................... 1290 RPM
Topper—Shredder (106 L/Min—28 GPM)

Valve ............................................... Directional Control Motor Spool with Port Relief/Anticavitation
Relief Valve ............................... Port and Main ........................................ 206.9 Bar (3000 PSI)
Drum Speed .................................................................................................... 1380 RPM
0001-8
cp1999250002c
Topper Collectors
Drive Motor ..................................... Orbital (Wheel Mounted) ...................... 18.7 IN3
Drum Speed .................................................................................................... 150 RPM
Topper Collectors ........................... Relief Valve ........................................... 172.4 Bar (2500 PSI)
Basecutter—302.4 L/Min (80 GPM)

Oil Supply ...................................... 2 Gear Pump Sections at 3.7 IN3 .................. 302.4 L/ Min (80 GPM)
Control Valve .................................................................................................. Manual Directional Control
Main Relief Valve ............................ Relief Integral to Valve ......................... 189.6 Bar (2750 PSI)
Shaft Speed .................................................................................................... 1812 RPM
Disc Speed ..................................... High Drive ............................................. 624 RPM
Basecutter—226.8L/Min (250 HP, 60 GPM)

Oil Supply ...................................... 1 Gear Pump Section ........................... 3.08 IN3
1 Gear Pump Section ............................. 2.46 IN3
Total ........................................................ 5.54 IN3

Shaft Speed .......................................... 1848 RPM
Disc Speed ..................................... High Drive ............................................. 670 RPM
Crop Dividers
Control Valve .................................................................................................. VG20 Directional Valve
Relief Valve ............................... VG20 Directional Valve ......................... 179.3 Bar (2600 PSI)
Drive Motor ..................................... Orbital 24 IN3
Scroll Speed ................................................................................................... 193 RPM
0001-9
cp1999250002c
Power Feed Roller—Low Basecutter

Oil Supply ...................................... Basecutter Motor as Flow Divider ....... 75.6 L/ Min (20 GPM)
Control Valve .................................. Basecutter Control
Relief Valve ..................................... Mounted on Basecutter Valve Outlet ... 179.3 Bar (2600 PSI)
Drive Motor ..................................... 2 Orbital at 30 IN3 Each .................. 60 IN3
Power Feed Roller Speed .............................................................................. 77 RPM
Power Feed Roller—High Basecutter

Oil Supply ...................................... Basecutter Motor as Flow Divider ....... 75.6 L/ Min (20 GPM)
Control Valve .................................................................................................. Basecutter Control
Relief Valve ..................................... Mounted on Basecutter Valve Outlet ... 179.3 Bar (2600 PSI)
Drive Motor ..................................... 2 Orbitals at 24 IN3 Each ....................... 48 IN3
Power Feed Roller Speed .............................................................................. 96 RPM
325 HP, 80GPM
Chopper Drums—196.5 L/Min (52 GPM)

Control Valve .................................. Manual Directional Control Motor Spool
Relief ............................................... Integral to Control Valve ...................... 189.6 Bar (2750 PSI)
Motor .............................................. 2 Orbitals at 30 IN3 Each ....................... 60 IN3
Shaft Speed .................................................................................................... 235 RPM
250HP, 60GPM
Chopper Drums—145.5L/Min (38.5 GPM)

Oil Supply ...................................... Gear Pump ............................................ 145.5L/Min (38.5 GPM)
Drive Motor ..................................... 1 Orbital ................................................ 19 IN3

1 Orbital ................................................ 23 IN3
Total ................................................ 42 IN3 ..................................................... 145.5L/Min (38.5 GPM)
Shaft Speed ........................................... 220 RPM
0001-10
cp1999250002c
Feed Roller Oil Division—98.25 L/Min (26 GPM)

Oil Supply ...................................... Flow From Chopper Motors ................ 98.25 L/ Min (52 GPM)
Q-Brand Flow Divider (0-100% Range Setting)
Setting ............................................................................................................ Flow Rate (GPM)
0% ................................................................................................................... 0
50% ................................................................................................................. 13
100% ............................................................................................................... 26
Relief ............................................... Anti-Cavitation Valve with Relief .......... 172.4 Bar (2500 PSI)
Front Feed Roller Set—75.6 L/Min (20 GPM) System
Feed Roller—A1, A2, B1, & BL (Buttlifter)
Oil Supply ...................................................................................................... Basecutter Motor as Flow Divider
Section (3) ...................................... 5.1 IN3—Front Roller ............................. 75.6 L/ Min (20 GPM)
Relief ............................................... In Line Relief Valve ............................... 172.4 Bar (2500 PSI)
Drive Motor ..................................... 2 Orbitals at 30 IN3 Each ....................... 60 IN3
Roller Speed ................................................................................................... 86 RPM
Rear Feed Roller Set—196.6 L/Min (52 GPM) System
Feed Roller—B2
Oil Supply ...................................... Q-Brand Flow Divider ........................... 102.05 L/ Min (26.1 GPM)
Control Valve .................................................................................................. VG35 Directional Valve
Relief Valve ............................... In Line Relief Valve ............................... 172.4 Bar (2500 PSI)
Drive Motor B2 ............................... 2 Orbitals at 15 IN3 Each ....................... 30 IN3
Feed Roller—A3, A4, A5, B3, B4, and B5

Oil Supply ...................................................................................................... Roller B2 as 50/50 Flow Divider
Drive Motor: A3, A4, A5, B3, B4, and B5 ................................................... Orbital 15 IN3
0001-11
cp1999250002c
Fixed Primary Extractor

Control Valve .................................. Pilot Operated Relief with .................... 206.9 Bar (3000 PSI)
Solenoid Pilot Control
Drive Motor ..................................... Gear Type .............................................. 6.4 IN3
Fan Speed ...................................................................................................... 1210 RPM
Variable Primary Extractor

Oil Supply ...................................... Variable Pump ...................................... 0-2.6 IN3
Pump .............................................. Piston .................................................... 0-102 L/ Min (0-27 GPM)
Oil Supply ...................................................................................................... 0.86 IN3
Charge Pump ................................................................................................. 30.2 L/ Min (8 GPM)
Charge Relief .................................. Pump Mounted ............................... 24.8 Bar (360 PSI)
High Pressure Relief. ..................... Pump Mounted—Port A ....................... 75.8 Bar (1100 PSI)
—Port B ..................... 317.2 Bar (4600 PSI)
Control ............................................ Manual Input—Pressure Compensated Override
Motor .............................................. Fixed ..................................................... 4.9 IN3
Motor Shaft Speed ......................................................................................... 0-1378 RPM
Flushing Block ............................... Shuttle Type .......................................... 7.6 L/ Min (2 GPM)
Secondary Extractor
Control Valve .................................. Pilot Operated Relief with .................... 241.4 Bar (3500 PSI)
Solenoid Pilot Control
Fan Speed ...................................................................................................... 1541 RPM
0001-12
cp1999250002c
Elevator
Main Relief ...................................................................................................... 241.3 Bar (3500 PSI)
Port Relief for Elevator Valve ......................................................................... 172.4 Bar (2500 PSI)
Motor .............................................. 2 Orbitals at 24 IN3 Each ...................... 48 IN3
Shaft Speed .................................................................................................... 240 RPM
Elevator Functions
Pump Protection In Line Relief Valve ........................................................... 172.4 Bar (2500 PSI)
Secondary Extractor
Oil Supply ...................................... Gear Pump (Series with Elevator) ....... 105.8 L/ Min (28 GPM)
Motor .............................................. Gear ....................................................... 3.4 IN3
Fan Speed ...................................................................................................... 1630 RPM
0001-13
cp1999250002c
SECTION 0002
GENERAL INFORMATION
Introduction .............................................................................................. 0002-3
Diagnostic Sections ................................................................................. 0002-3
Troubleshooting Tools ............................................................................. 0002-3
Troubleshooting ....................................................................................... 0002-3
Visually Inspect Hydraulic System ......................................................... 0002-4
Hydraulic System Testing Precautions ................................................... 0002-5
Visually Inspect Electrical System .......................................................... 0002-5
Electrical System Safety Precautions ..................................................... 0002-6
Battery Specifications .............................................................................. 0002-6
Oil Storage and Filling ............................................................................ 0002-7
Oil Filtration ............................................................................................. 0002-7
Hydraulic Components ............................................................................ 0002-7
Aeration and Cavitation ........................................................................... 0002-7
Troubleshooting Tips ............................................................................... 0002-8
HYDRAULIC CIRCUIT SYMBOLS

Lines ......................................................................................................... 0002-9
Fluid Storage ............................................................................................ 0002-9
Pumps ...................................................................................................... 0002-9
Motors ....................................................................................................... 0002-9
Cylinder .................................................................................................... 0002-10
Valves ....................................................................................................... 0002-10
Miscellaneous Symbols .......................................................................... 0002-11
Methods of Operation .............................................................................. 0002-11
Electric Circuit Symbols .......................................................................... 0002-12
Quick Field Test ........................................................................................ 0002-13

Hydrostatic Pump Charge Pressure Check ............................................ 0002-14
Hydrostatic Pump Vacuum Pressure Check ........................................... 0002-15
Hydrostatic Pump Pilot Line Check ........................................................ 0002-16
cp1999250002c
cp1999250002c
GENERAL INFORMATION
Introduction Troubleshooting
The key to a timely and accurate diagnosis of To prevent unnecessary loss of time and money;
electrical or hydraulic problems is to: the service technician should use the following seven steps
1. Have a basic understanding of electrical and for a quick and accurate diagnosis:
hydraulic principles and component operations. 1. Know the combine in other words: Do your
homework.
2. Be able to read and interpret electric and
hydraulic schematics. Ø Study the Operators Manual along with this
3. Have a systematic approach for identifying manual, to understand how the individual
specific causes of electrical or hydraulic problems. component works and what function they serve
in the overall system.
Ø Keep up with the latest service information.
Read upon receipt and then file it in this
Diagnostic Sections manual or another useful place. Information
This manual is set up in diagnostic sections. Within received today may have the cause and
each section there is a theory of operation, hydraulic and remedy of a problem being encountered.
electrical schematics, test and troubleshooting procedures 2. Consult the operator ask the operator how
and fault logic diagrams. the combine was performing when it started to
Electrical and hydraulic troubleshooting information fail.
is combined in each diagnostic section. This information
provides a step-by-step diagnostic procedure to help isolate Ø Find out what was unusual.
failed components. Ø Find out if any do-it-yourself service was
Schematic diagrams show the complete electrical performed. (You may find the problem
and hydraulic system with all components pertinent to that somewhere else, but you should know if any
section. corrective measures have already been
The tests provided in each section are designed to taken.)
give the information you need to reach a logical conclusion Ø Ask how the combine is used and how often it
and solve the problem, once the tests have been is serviced. Many problems are caused by
performed. If, after performing any test, you cannot solve poor maintenance or abuse.
the problem, you should review your testing procedure. 3. Operate the combine if the machine is
Be certain that you are performing the test correctly and operable, operate it yourself. Do not rely
your procedure is valid. completely on the operators storycheck it out.
It is important to troubleshoot the combine one
Ø Are gauges reading normally? If not, maybe
problem at a time. Repairing one systems problem may
the component being monitored is not
solve a problem in another system.
functioning correctly or the gauge is faulty.
Remember the most complex circuits are
Ø How is the performance? Is the action perhaps
constructed from combinations or variations of basic
too fast or too slow, erratic, or none at all?
circuits. By using this manual and following a logical
troubleshooting sequence, you can effectively solve any Ø Do the controls feel solid or spongy? Do
problem. they seem to be sticking?
Ø Do you smell or see any signs of smoke?
Ø Do you hear any unusual sounds? Where?
Troubleshooting Tools 4. Inspect the combine get off the combine and
Multimeter (Volt-Ohmmeter) make a visual check. Use your eyes, ears and
nose to spot any signs of trouble.
Pressure Gauge ................. 0-690 bar (0-10,000 PSI)
Ø Look closely at the components. Inspect for
cracked welds, loose hardware, damaged
Flow Meter (0841337666) ... 473 L/Min (125 GPM)
linkages, worn or broken lines, etc.
Ø During the inspection, make notes of all trouble
signs.
0002-3
cp1999250002c
GENERAL INFORMATION
5. Make a list of the problems possible cause(s), external oil leakage around seals, gaskets, or
with the information obtained during steps 1 hydraulic connections. Check for pinched or
through 4. kinked lines that could restrict oil flow and cause
overheating.
Ø What were the signs you found while inspecting
the combine? 4. Check for broken drives, broken or binding
Ø What is the most likely cause? linkages, or other mechanical failures.
6. Reach some conclusionslook over the list of 5. Check hydraulic oil level. Only use oil specified
possible causes and decide which are the most by CAMECO to fill tank.
likely and which are the easiest to verify.
6. Check hydraulic oil for a milky, dirty, or discolored
7. Test your conclusions before repairing appearance. Smell the oil. A distinctive burned
components in the system, test your conclusions odor indicates excessive heat that can destroy
to see which are correct. the oils lubricating qualities. Determine the cause
Ø Some of the possible causes may be verified of the condition, correct it, and change oil.
without further testing. Check these
possibilities first.
Ø Testing will narrow down the remaining list of * CAUTION *
possible causes and soon the actual cause(s) Keep hands away from moving parts. Shut off engine
of trouble will be pinpointed. before checking lines located near moving parts.
With the cause(s) accurately located, it is now a
simple matter to remove and repair the component(s) at 7. Check for a plugged or damaged hydraulic oil
fault. filter. A failed filter will permit contaminants to
circulate in the system, affecting system operation
and tests. If the filter is plugged, an examination
Visually Inspect Hydraulic System of the contaminant may indicate the cause of the
failure.
* CAUTION * 8. Check maintenance records to determine if the

Use caution when dealing with pressurized hydraulic recommended service procedures have been done
fluid. Hydraulic fluid escaping under pressure can have at correct intervals. Note any previous reports of
sufficient force to penetrate skin causing serious injury. unusual, frequent, or similar failures.
This fluid may be hot enough to burn. Serious infection
or reactions can develop if proper medical treatment is 9. If possible, operate the combine. Use hydraulic
not administered immediately. functions and be alert for conditions that could
isolate the problem. Also be alert for conditions
Before performing any diagnosis on the hydraulic that could cause further damage and be prepared
system, use the following steps for locating problems. to stop the engine immediately.
Many hydraulic system failures can be located by making 10. With the engine running, check for external and
preliminary checks of hydraulic system operation. internal leaks. With all hydraulic functions in
No special tools are required for these preliminary neutral, check function component return lines
checks, so repair obvious problems before performing and housings for heating. Return lines will be hot
further tests. if component control valves are leaking.
1. Become acquainted with the hydraulic system and
its components. Read all new Service Information 11. If these preliminary checks have failed to isolate
Bulletins. the hydraulic problem, list the possible causes of
failure and proceed to fault logic diagrams for
2. If possible, talk with the operator about how the the particular problem.
machine performs.
3. With the engine stopped, check for evidence of
0002-4
cp1999250002c
GENERAL INFORMATION
Hydraulic System Testing Precautions Visually Inspect Electrical System

If any fluid is injected into the skin, it must be
surgically removed within a few hours by a doctor familiar * CAUTION *
with this injury type or gangrene may result. Wear eye protection and remove rings, metal
When disconnecting a line or hose from a hydraulic watchbands, and other metal jewelry when working on
component, always mark it and the port from which it the electrical system.
was removed. This will enable it to be reconnected to the
proper port when reassembling. If lines or hoses are not
cm19989999014
connected to the proper ports, serious damage can result
to the component or to the entire hydraulic system.
Avoid excessive twisting by using two wrenches
when attaching a hose or line to a fitting. Check the entire
length of lines and hoses to be certain they are not rubbing
on moving parts or vibrating because of loose clamps.
* CAUTION *
Use caution when dealing with pressurized hydraulic
fluid. Hydraulic fluid escaping under pressure can have
sufficient force to penetrate skin causing serious injury.
This fluid may be hot enough to burn. Serious infection
or reactions can develop if proper medical treatment is
not administered immediately.
cm19989999011
Make the following visual electrical inspection prior

to starting the combine:
1. Look for bare wires that could ground a
component or short across to another component.
2. Look for a missing or worn conduit. This could
indicate a wire problem.
3. Look for loose or broken connectors and wires.
4. Inspect batteries for:
Ø Corroded terminals.
Ø Loose terminals or battery posts.
Ø Dirty condition.
Ø Cracked case.
Ø Proper electrolyte level.
5. Check alternator belt tension.
* CAUTION * 6. After combine has been shut down for five
Escaping fluid under pressure can penetrate the skin minutes inspect for overheated parts. They will
causing serious injury. Relieve pressure before
disconnecting hydraulic or other lines. Tighten all
often smell like burned insulation. Put your hand
connections before applying pressure. Keep hands and on the alternator. Heat in these parts happens
body away from pinholes and nozzles, which eject fluids when the unit has not been operated for some
under high pressure. Use a piece of cardboard or paper time is a sure clue to charging circuit problems.
to search for leaks. DO NOT use your hand.
0002-5
cp1999250002c
GENERAL INFORMATION
7. If your visual inspection does not indicate the

possible malfunction, but your inspection does
indicate that the machine can be run, turn the key
switch to IGN. Try out the accessory circuits,
indicators, lights and gauge lights, etc. How does
each of these components work? Look for sparks
or smoke that might indicate shorts.
8. Start combine. Check all gauges for good
operation and check to see if system is charging
or discharging.
9. In general, look for anything unusual. Many
electrical failures cannot be detected even if the
combine is running. Therefore, a systematic and
complete inspection of the electrical system is * CAUTION *
Explosive gas is produced when a battery is in use or
necessary.
being charged.
Electrical System Safety Precautions

1. Keep all flames/sparks away from battery.
2. Charge battery in a well-ventilated area.
3. Always remove negative (-) battery cable first

and replace it last.
4. Never lay a metal object on top of a battery: a
short circuit can result, damaging the battery and
metal object.
5. If acid spills on clothing, immediately remove
clothing.
6. If acid contacts skin, rinse affected area with
running water for 1-15 minutes. * CAUTION *
Sulfuric acid in battery electrolyte is poisonous.
7. If acid splashes into eyes, hold eyelids open and Electrolyte can cause severe burns if it contacts the eyes
flood eyes with running water for 10-15 minutes, or skin. Always wear eye and face protection when
then see a doctor at once. working around electrolyte.
8. Do Not use any medication or eye drops unless

prescribed by a doctor.
9. To neutralize acid spilled on the floor or combine, Battery Specifications
flood the spill with one of the following mixtures, Your combine is equipped with a negative ground
then rinse thoroughly with clean water: electrical system. It uses 12 volt batteries. Use only
batteries meeting the following specifications:
Ø 0.5 kg (1 lb) of baking soda in 4 L (1 gal) of
water
Part Number ......................................... 0360030641
Ø 0.4 (1 pt) of household ammonia in 4 L (1 gal) BCI Group Size .................................... 31 A
of water Cold Cranking Amps At -18° C (0° F) ... 925
Reserve Capacity At 25 Amps .............. 190 Minutes
0002-6
cp1999250002c
GENERAL INFORMATION
Oil Storage and Filling body should be wiped clean before installing the new
The most important element in maintaining hydraulic element and a new body gasket should be installed at this
system performance is proper system maintenance. time.
Experience has shown that almost 75% of all
hydraulic system problems can be traced to the hydraulic
fluid. Frequently the problem is caused by contamination Hydraulic Components
of the fluid by air, water, or solid particles which interfere The hydraulic components, on your CAMECO
with hydraulic component operation. In some cases, it is equipment, are precision units and will run dependably
simply a matter of using the wrong fluid, or even not having when operating on clean fluid in sufficient volume. Do
sufficient fluid in the system. not overlook some of the simpler possibilities for trouble.
Once you have the correct fluid, the next most For example, loose mounting bolts or brackets can permit
important step is to prevent the introduction of misalignment of the pump driveshaft. This will lead to
contaminants into the system. This includes using care in excessive shaft seal wear and bearing failure. In fact,
the storage and handling of bulk fluids prior to use. Always any cause of undue side loading should be prevented.
store drums in a clean, dry spot. Position them on their Operating components at an excessive speed causes
sides and keep them covered to prevent an accumulation loss of lubrication and possible cavitation that, in turn, can
of dirt, water, or dust. Drums should also be kept as full cause early failure.
as possible and protected from sudden changes in
temperature. This will prevent or minimize moisture
condensation inside the drum. Aeration and Cavitation
Before opening the drum, be sure to wipe the top Aeration and cavitation can cause damage. Free air
carefully to remove any dirt or dust which may enter the in the fluid can make it spongy, which will make the system
fluid upon opening the drum. If you have reason to suspect pressure erratic and reduce the effectiveness of the fluid
that dirt has gotten into your fluid, strain the fluid using a as a lubricant. It may also accelerate breakdown of the
100-mesh screen. fluid.
Before removing the tank filler cap to add fluid in Excessive air can be taken into the fluid in several
your system, wipe off the filler plug and filler nozzle with ways, the most common is when the fluid level in the tank
a clean, lint-free cloth. CAMECO highly recommends is too low to fully cover the intake opening. Any time a
that a micron filter be used on the filler nozzle. After filling whirlpool can be seen at the intake, air is being pulled into
the tank, replace the filler cap and close it properly. the pump with the oil. Restrictions in the inlet piping can
If you have the correct fluid and have filled your create pressure drops that allow free air to be formed
system without introducing contaminants, the next most and be taken into the pump inlet.
important factor for efficient system performance and Air will mix with oil in the tank under the following
long life is filtration. conditions:
Ø If the return line opens above the fluid level
Ø If the flow in the tank is turbulent
Oil Filtration Ø If filter check valves open above the fluid level
When systems operate at high speeds and pressures, Ø If shrouds over the filter cartridge are not
contaminants take their toll in excessive wear and power sealed
loss. This can cause malfunction of hydraulic components. Other possibilities are a leaking seal in the system,
CAMECOS recommendations for changing the filter or any leaking connection in the inlet line that is not
cartridges should be followed as closely as possible (see submerged. These leaks often can be found by squirting
CAMECO Operators Manual, Section 10: Periodic oil around the possible leakage points and listening for
Maintenance). However, there can be a wide variation in changes in the pump noise. The oil will temporarily seal
the length of service periods and only experience can dictate the leak and the pump will run quieter. The leak can then
how long the interval must be for a particular application. be eliminated.
A good preventive maintenance program should include
regular filter element changes. Before servicing the filter,
the hydraulic system must be shut down and the filter and
surrounding piping wiped clean. The inside of the filter
0002-7
cp1999250002c
GENERAL INFORMATION
Regular inspection and maintenance are the best Troubleshooting Tips

ways to prevent air from being introduced into the Proper maintenance can keep hydraulic system
hydraulic system. Keeping all connections and fittings tight problems to a minimum, but you cannot expect to be totally
is the easiest way to avoid the introduction of air. trouble-free. Thus, troubleshooting should be a regular
After a system has been completely drained and part of your maintenance routine.
flushed, a tendency for the fluid to aerate may exist until Maintenance experience is most beneficial, when it
all air is purged from all lines and components. To correct is documented by good reports and records. These records
this condition, a thorough purging of the entire system should include:
should be performed. 1. A description of the symptoms and the date
Cavitation occurs when components are not detected.
completely fill with fluid. The characteristic sound of
2. A description of the preliminary investigation and
cavitation is a high pitched scream which increases with
its results.
the degree of cavitation and with increased operating
pressure, this occurs in motors and cylinders where the 3. An explanation of the corrective action taken,
load overruns delivery of fluid from the pump. replacement parts required, and length of
Cavitation may be caused by a restricted inlet line, downtime.
sharp bends in the inlet line, by a clogged inlet filter or by
4. A record of when oil is added or changed, filter
a fluid that is too high in viscosity. Another cause can be a
cartridges replaced, or strainer elements cleaned.
vacuum in a non-vented tank caused by the oil shrinking
in volume as it cools. This can be avoided by momentarily These reports and records, if analyzed frequently,
cracking the tank filler cover whenever the machine is will indicate areas that required special attention as well
started cold. Cavitation, caused by fluid that is too thick, as recurring troubles that may be anticipated and corrected
is sometimes avoided by operating at reduced pump speed before a breakdown occurs.
until the fluid is warmed up and becomes less viscose.
Whenever cavitation is detected, it should be
corrected or the life of your components will be shortened.
When cavitation is suspected, a vacuum gauge should be
used to determine if corrective action is required.
0002-8
cp1999250002c
GENERAL INFORMATION
cm19989999030
Lines
Main Working Crossing
Line Lines
Pilot Control Crossing

Line Lines
Lines
Liquid Drain Joining
Line Lines
Component Line with

Enclosure Fixed Restriction
Hydraulic Flexible
Flow Line
Station, Testing,
Pneumatic Measurement,
Flow PowerTake-Off
or Plugged Port
Fluid Storage
Fluid Storage
Return to Tank Lines
Vented Tank
(Reservoir) A. Above Fliud Level A. B.
B. Below Fluid Level
Pressurized Vented
Tank (Reservoir) Manifold
Pumps
Pumps
Fixed Variable
Displacement Displacement
Unidirectional Unidirectional
Motors
Motors
Fixed Variable
Displacement Displacement
Unidirectional Unidirectional
0002-9
cp1999250002c
GENERAL INFORMATION
cm19982500037
Cylinders
Single Double Acting
Acting Adjustable Cushion
(Advance Only)
Double Acting
Cylinder Double Acting
Single Rod End Differential Piston
Valves
Double Acting
Double Rod End
Valves
Check Adjustable Flow
On/Off Two Position

(Manual Shutdown) Four Connection
Three Position
Pressure Relief Four Connection
Adjustable Flow Control

(Non-Compensated)
0002-10
cp1999250002c
GENERAL INFORMATION
cm19989999039
Miscellaneous Symbols
Internal Combustion Temperature
Engine Control
Electric Motor M Filter/Strainer
Spring Loaded Pressure Switch

Accumulator
Gas Charged Pressure Indicator

Accumulator
Heater Temperature
Indicator
Direction of Shaft
Cooler Rotation - Assume
Arrow on Near Side
of Shaft
Methods of Operation
Spring Detent
Pressure
Manual Compensated
Single Winding
Push Button Solenoid
Push-Pull Lever Servo Motor
Remote Supply
Pedal or Treadle Pilot Pressure
Miscellaneous Symbols Internal Supply

Mechanical Pilot Pressure
Methods of Operation
0002-11
cp1999250002c
GENERAL INFORMATION
cm19989999040
Electric Circuit Symbols
External Relay with Diode

(Wired Ground)
A/C Compressor
Battery with Solenoid
Key Switch Internal Ground
Buzzer Ground Solenoid
Alarm Single Filiment Bulb
Horn Variable Resistor
Fuse Multi-Connector
Air Filter Single Connector
Electric Circuit Symbols
Hydraulic Oil Level Diode
0002-12
cp1999250002c
GENERAL INFORMATION
Quick Field Test

To check a solenoid for proper mechanical operation:
1. Turn switch on.
2. Unplug and reconnect the solenoid several times.
3. Listen and feel for the solenoid to click when
engaged.
To check a solenoid for proper electrical operation:

1. Turn switch on.
2. Place a steel object against the top of solenoid
and check for magnetism.
3. If solenoid is magnetized, the electrical circuit is
good, but the mechanical part should also be
checked.
0002-13
cp1999250002c
GENERAL INFORMATION
Hydrostatic Pump
Charge Pressure Check
1. Engage the parking brake.

2. Remove all hoses connected to test port.
3. Bring hydraulic oil temperature to 38° C (100° ± 10° F).
4. Connect a 0-41 bar (600 PSI) gauge at test port on side opposite pump inlet.
5. Start engine and select NEUTRAL on forward/reverse control.
6. Bring engine to full throttle and check pressure.
7. Pressure should be 25 bar (360 ± 10 PSI).
8. If it is necessary to adjust pressure, do so by loosening adjustment screw
locknut located, as shown below on top center pump port end. Screw
inward to increase pressure and outward to decrease.
9. After making adjustment, secure locknut.
10. Proceed with troubleshooting, if necessary.
Charge Pressure
B 25 bar
(360 ± 10 PSI)
Charge Pressure
Test Gauge
Fitting A
0002-14
cp1999250002c
GENERAL INFORMATION
Hydrostatic Pump
Vacuum Pressure Check
1. Remove plug on ground drive pump and install vacuum gauge.

2. Start engine, engage park brake and run engine at full throttle.
3. Stroke pump to FORWARD or REVERSE and check inlet
vacuum.
4. Vacuum should be:
Normal in HG 10
Bar (ABS) 0.34
Cold in HG 25
Bar (ABS) 0.85
5. If pressure is not normal, check the hose for any obstruction.
6. If pressure is not normal and hose is unobstructed, repair pump.
Remove Plug fl
— Install
Vacuum Gauge Here
Ground Drive Pump
0002-15
cp1999250002c
GENERAL INFORMATION
Hydrostatic Pump Pilot

Line Check
1. Plug pressure gauge into test port,

aligning with function being tested. Yes
2. Engage park brake and start engine. Done.
3. Observe gauge reading.
Is 25 bar (360 PSI) measured?
No
1. Clean and inspect solenoid valve. Yes Repair or replace

2. Ensure that spool is shifting freely in Yes Inspect solenoid manifold
charge pump.
solenoid valve. block for cracks.
Is solenoid valve good? Is block OK?
No No
Replace solenoid valve. Replace manifold.
Add tee and

install test
Manifold Block
gauge
Add tee and install

test gauge
Solenoid Valve
0002-16
cp1999250002c
SECTION 0100
HYDROSTATIC SYSTEM
Transmission Theory of Operation .......................................................... 0100-3
Hydrostatic Transmission Pump Theory of Operation ........................... 0100-3
High Pressure Relief Valve ...................................................................... 0100-3
Charge Relief Valve .................................................................................. 0100-4
Pump Control Operation—Neutral .......................................................... 0100-4
Pump Control Operation—Initial Movement .......................................... 0100-4
Flow / Pressure Specifications ................................................................ 0100-4
Hydrostatic Transmission Control Operation ......................................... 0100-4
TRACK
Hydrostatic Motor Description ................................................................. 0100-5
Hydrostatic Motor Theory of Operation ................................................... 0100-5
Operation In Neutral ................................................................................. 0100-5
Operation In Forward ............................................................................... 0100-5
Flushing Valve Operating Charge Pressure ............................................ 0100-6
Relief Valve ............................................................................................... 0100-6
WHEEL ..................................................................................
Hydrostatic Motor Description ................................................................. 0100-7
Theory of Operation ................................................................................. 0100-7
Control—Neutral ....................................................................................... 0100-7
Displacement Regulation ......................................................................... 0100-7
Loop Flushing Components .................................................................... 0100-8
POSITRAC
Ground Drive Wheel ................................................................................. 0100-10
Hydraulic Schematic ................................................................................ 0100-10
Ground Drive Track .................................................................................. 0100-11
Hydraulic Schematic ................................................................................ 0100-11
Positrac Circuit ......................................................................................... 0100-12
Electrical Schematic ................................................................................ 0100-12
Machine Moves Sluggishly or Has No Movement—Wheeled Combine 0100-13
Machine Moves Sluggishly or Has No Movement—Tracked Combine . 0100-15
Positrac Control Does Not Operate with On/Off Switch ......................... 0100-17
Varitorq Control Problem ........................................................................ 0100-18
Positrac Control Does Not Operate Properly .......................................... 0100-19
When Brake Pedals Are Pressed Or ........................................................ 0100-19
Positrac Circuit Constantly Stays On ...................................................... 0100-19
cp1999250002c
cp1999250002c
HYDROSTATIC SYSTEM
Transmission Theory of Operation The displacement control valve is mounted on the

The CH2500 Combinetransmission is a hydrostatic servo area of the pump housing. When the operator selects
system. The hydrostatic pump and motor provides infinitely forward, neutral or reverse, control oil is sent to the
variable speeds in forward and reverse. With this displacement control valve. The displacement control
hydrostatic transmission, the operator can set the engine valve, in turn, directs oil to the servo piston which angles
speed for optimum hydraulic performance. the swashplate. The pump pistons then pump oil to the
This type of transmission is common to CAMECO hydrostatic motor.
designed equipment. There is a control circuit, a charge A pressure override (POR) valve is used in the
circuit and a high-pressure closed-loop circuit. There is closed-loop circuit to limit the maximum pressure and
also a flushing circuit to maintain cooling flow through the automatically vary the swashplate angle to maintain that
transmission pump. pressure. The POR valve prevents continuous dumping
The transmission hydraulic system is separate from of high pressure oil over the high pressure relief valves.
the combinemain hydraulic system. This insures that there The transmission has a charge circuit and a high
is no cross contamination in the event of debris being pressure closed-loop circuit. A flushing circuit maintains
generated in one of the hydraulic systems. cooling flow through the transmission pump.
The integral transmission charge pump draws oil
from the tank through a ten micron, double oil filter. The
Hydrostatic Transmission Pump Theory of oil filters are mounted just outside the pump drive
Operation compartment for accessibility.
The pump, a swashplate designed variable When the forward/reverse control is moved, a push/
displacement axial piston pump, is mounted to the pump pull cable moves the pump control. This movement directs
drive gear box and is driven at a higher RPM than the pump control flow to one side of the displacement control
engine. piston, directing forward or reverse movement is routed
The pump swashplate rotates in both directions from to the tank.
neutral. The swashplate rides on a cradled roller bearing On the CH2500 Chopper Combinewheel model, the
and a wire pin insures that the bearing moves with the hydrostatic motors have a high and low range. This is
swashplate. (The degree of swashplate movement attained by using charge pressure to control the motors
determines the length of cylinder block piston stroke.) displacement with a two piston valve.
The input shaft drives the rotary group and the
integral charge pump. A single lip seal is used to seal the
pump case and the rotating input shaft. High Pressure Relief Valve
The rotary group consists of the cylinder block and One high-pressure relief valve protects the high-
nine piston assemblies. The cylinder block concave end pressure circuit during forward operation and the other,
rides on and self-centers on a spherical valve plate. The during reverse.
piston slippers ride on the swashplate and, depending on The pilot-operated relief valves are screw adjustable.
the angle of the swashplate, they pump oil to the High-pressure oil from the closed-loop goes through the
transmission motor. orifice piston to the pilot poppet. When pressure spikes in
The rocker cam swashplate controls pump the system exceed the valve setting, the pilot poppet comes
displacement. It is controlled by the displacement control off its seat and dumps the oil between the pilot poppet
valve and servo piston. The swashplate can swivel on its and the main relief poppet. The high closed-loop pressure
bearings in either direction from neutral. then moves the orifice piston upward, sealing the orifice
The internal gear charge pump, mounted at the rear against the pilot poppet, and moves the poppet upward
of the axial piston pump, is on the pump port block. It is routing the oil to the low pressure side of the closed-loop.
protected by a neutral charge pressure relief valve. The
charge pump draws oil to the tank through a filter.
The end cap houses two high-pressure relief valves,
while the pressure override check valve is housed on the
block.
0100-3
cp1999250002c
HYDROSTATIC SYSTEM
Charge Relief Valve Flow leaving the pump cylinder barrel is at high
The charge pressure relief valve is a direct acting pressure which closes the check valve in the pump high-
screw adjustable relief valve. It maintains maximum pressure side. This pressurized oil is then routed to the
pressure in the charge circuit. When charge pressure hydrostatic motor.
exceeds the valve setting, the poppet leaves its seat and
allows oil to return to tank.
The charge pressure relief can be adjusted by turning Flow / Pressure Specifications
the screw clockwise to increase pressure and Hydrostatic transmission pump flow is approximately
counterclockwise to decrease. 238 L/Min (63 GPM), with the engine at full throttle.
Charge Pressure—25 bar (360 PSI)

Pump Control Operation—Neutral High Pressure—352 bar (5500 PSI)
The hydrostatic pump control consists of a manual
displacement control and servo piston. The servo piston
is connected to the pump swashplate by a link. Hydrostatic Transmission Control
When the control lever is in neutral, oil moves from Operation
the tank and oil filter to the charge pump. The charge The hydrostatic transmission is controlled by a push/
pump pushes the oil past the pressure relief valve and pull cable which moves the pump control. This movement,
into the main pump. The pump swashplate remains in directs pump control flow to one side of the displacement
neutral and the pump pistons are not reciprocating; control piston, thus controlling forward and reverse
therefore no oil is being pumped to the motor. Trapped motion.
oil, at charge pressure, is held in the motor cylinder barrel, Return flow from the pump and motor is routed to
in the connecting lines between the pump and motor (by tank.
check valves) and in the pump cover.
Because oil is not being pumped to the motor, the
motor cylinder barrel is stationary, and the combinedoes
not move.
Pump Control Operation—Initial Movement

When the operator selects either forward or reverse,
a signal from the control cable shifts the displacement
control valve spool in one direction, forcing the pump
swashplate (which is connected to the servo cylinder) to
tilt to that direction.
When the swashplate reaches its desired tilt,
determined by speed range control valve lever piston, the
control valve spool returns to neutral. This traps oil to the
servo piston and holds the swashplate in a tilted position.
The swashplate will remain in this position until the
varitorque/speed range valve is moved by the operator.
With the pump driveshaft rotating counterclockwise and
the swashplate tilted, a reciprocating action is created by
the pump cylinder barrel pistons, generating a flow. The
further the swashplate is tiled, the more oil the pump
receives.
0100-4
cp1999250002c
HYDROSTATIC SYSTEM
TRACK Operation In Forward

Hydrostatic Motor Description When the directional control lever is moved forward,
The track combinehas a fixed displacement, plug- the cable shifts the pump out of neutral. This allows oil, at
in, motor. This motor is an axial piston motor with a bent control pressure, to flow into one servo cylinder sleeve
axis design, and a manifold mounted flushing valve. forcing the pump swashplate (which is connected to the
The fixed motor is installed so that the external loads servo cylinder) to tilt in one direction. Oil expelled by the
are transmitted by the pilot diameters. The friction locks opposite servo sleeve returns through the displacement
between the combineframe, the wheels or sprockets and control valve to the pump case.
the drive flanges, generated by the fastening bolts, transmit When the swashplate reaches its desired tilt, this
the torque. movement traps oil to the servo sleeves and holds the
The sprocket must be fitted onto the drive without swashplate in a tilted position. The swashed will remain
hammer blows or force. in this position until the directional control lever is moved
The hydraulic motor case drain port is mounted in by the operator.
the up position to maintain an oil filled case. Check the oil With the pump shaft rotating clockwise and the
before initial start-up and periodically, thereafter. swashplate tilted, a reciprocating action is created by the
pistons in the pump cylinder barrel, generating oil flow.
Oil, at high pressure, leaves the pump cylinder barrel
Hydrostatic Motor Theory of Operation which closes the check valve in the pump high pressure
The hydrostatic motor, a fixed displacement axial side.
piston motor, has a bent-axis rotary group that drives the High pressure oil enters the motor end cover and is
output shaft. The shaft, supported by two tapered roller directed towards the pistons. This oil flow causes the
bearings, is sealed by a single lip seal. pistons to push against the fixed swashplate. The pistons
The motor rotary group works similarly to the pump slide down the inclined surface, rotating the cylinder block
rotary group; it utilizes a spherical valve plate which allows and driveshaft, which in turn overcomes resistance on
the work ports to be close to the centerline of the cylinder the driveshaft and thus drives the combineforward.
block. The cylinder block houses seven conically designed
pistons, which have two pressure-balanced piston rings.
The pistons provide high volumetric efficiency along with
low friction.
Operation In Neutral
With the directional control valve in neutral, oil moves
from the tank and oil filters to the charge pump. The charge
pump pushes the oil past the pressure relief valve and into
the main pump.
The pump swashplate remains in neutral and the
pistons in the pump are not reciprocating, therefore no oil
is being pumped to the motor.
Trapped oil at charge pressure, is held in the motor
cylinder barrel, in the pump cover and in the connecting
lines between the pump and motor by check valves.
Since oil is not being pumped to the motor, the cylinder
in the motor is stationary and the combinedoes not move.
0100-5
cp1999250002c
HYDROSTATIC SYSTEM
Flushing Valve Operating Charge Pressure

Relief Valve
Valve shuttle spool B and operating charge pressure
relief valve E are used to provide a regulated flow of oil
into motor case C. This oil is used to cool and flush the
motor bearings. The valve is mounted to the rear cover
of the motor case.
The high pressure oil of closed-loop X shuttles spool
B which routes low pressure oil Y through an orifice located
in relief valve E and on into the motor case. The orifice
ensures that the charge pressure does not decrease in
the closed-loop circuit.
D F
Neutral Forward
To Case C C To Case
Shuttle E Relief Valve

Shuttle Spool B
E Relief
Spool B Valve
A G
A G
From Forward From Reverse
From Forward From Reverse
Side of Side of
Side of Side of
Closed-Loop Closed-Loop Closed-Loop
Closed-Loop
X High Pressure
Y Charge Pressure
Z Return Pressure
0100-6
cp1999250002c
HYDROSTATIC SYSTEM
WHEEL Control—Neutral
Hydrostatic Motor Description The ground drive motor is controlled by the motor
The standard wheeled combinehas a variable displacement control valves, motor servo piston, the rate-
displacement, plug-in motor. It is an axial piston motor of-shift orifice, and the pressure override valve.
with a bent axis design. A flushing valve is manifold In neutral, the oil in the closed-loop is at charge
mounted in the motor. pressure. There is no oil movement in the motor. The
The varitorq option, on the wheeled harvester, has a charge oil is routed through the motor inlet check valves
variable displacement motor with a motor controller in to the displacement control. Oil coming from the motor
the operators cabin. This controller sets the displacement control shuttle valve and the closed-loop oil, at the
of the motor to determine the maximum speed of the displacement control valve, is blocked by the valve spool.
harvester. Oil to the end of the servo piston is connected to return by
The variable motor is installed so that the external the displacement control valve.
loads are transmitted by the pilot diameters. The friction There are two adjustment screws on the motor
locks between the combineframe, the wheels and the drive housing. The limiting screw is used to determine the
flanges, generated by the fastening bolts, transmit the minimum displacement angle of the motor. The motor
torque. displacement control valve adjustment screw determines
The wheel must be fitted onto the drive without when the motor servo starts to deswash the motor from
hammer blows or force. maximum displacement towards minimum.
The hydraulic motor drain case port is mounted in
the up position to maintain an oil filled case. Check the
oil level before initial start-up and periodically, thereafter. Displacement Regulation
The motor has a HZ type displacement control. The
HZ control consists of a cover plate mounted directly on
Theory of Operation the end cap. A ball type shuttle valve provides internal
The hydrostatic motor, a variable displacement axial servo pressure supply to the control valve in the end cap.
piston motor, has a bent-axis rotary group which drives Feedback springs and a threshold spring are installed
the output shaft. The shaft, supported by two tapered in the end cap. These springs provide a force to the end
roller bearings, is sealed by a single lip seal. The of the control spool. The threshold springs force is
combine(wheel models only) hydrostatic motors have both externally adjustable with an adjusting screw. The
a high and a low range. feedback spring is positioned between the control spool
The motor rotary group works similarly to the pump and a feedback lug attached to the servo piston. The force
rotary group; it utilizes a spherical valve plate which allows of the feedback spring increases as the motors
the work ports to be close to the centerline of the cylinder displacement decreases.
block. The cylinder block houses seven conical pistons Pilot oil pressure is applied to the end of the control
which have two pressure-balanced piston rings. The spool opposite the feedback and threshold springs. An
pistons provide high volumetric efficiency and low friction. increase in pilot pressure, above the threshold pressure
The motor output is set at maximum displacement and within modulating pressure range, will result in a
when in neutral. As the combinestarts to move, the motor decrease in motor displacement, while an increase in pilot
stays at maximum displacement (maximum torque, pressure will result in an increase in motor displacement.
minimum speed) until the control circuit pressure builds.
When the control pressure signals, the motor displacement
control valve moves the displacement control valve, spool
and high pressure oil from the closed-loop and acts on the
motor servo piston. The piston moves the valve plate and
cylinder block towards minimum displacement (minimum
torque, maximum speed).
The displacement control valve actuates the servo
piston which is connected to the motor valve plate.
0100-7
cp1999250002c
HYDROSTATIC SYSTEM
Loop Flushing Components
cm19992500010
The motors used in closed circuit applications
incorporated an integral loop flushing valve as standard
equipment. Fluid to be removed from the main hydraulic
circuit for fluid cooling requirements can benefit from loop
flushing.
The motors equipped with an integral loop flushing
valve also include a charge pressure relief valve. The
setting of the motor charge relief valve affects the function
of the flushing circuit. Higher motor charge relief settings
reduce the loop flushing flow and increase the flow over
the pump charge pressure relief valve when the circuit is
operating. Lower motor charge relief settings increase
the loop flushing flow and may increase the motor case
pressure when the circuit is operating.
An appropriate combination of pump and motor
charge pressure settings should be maintained to insure
the proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all conditions
of operation to maintain pump control performance in
closed loop systems.
0100-8
cp1999250002c
HYDROSTATIC SYSTEM
POSITRAC
Theory of Operation
The positrac ON/OFF switch is located on the front
instrument panel above the chopper pressure gauge. The
momentary brake pedals are located on the cab floor, near
the steering column. The brake pedal switches are located
below the cab floor, against the brake pedals.
The positrac system consists of two pumps; one for
the left wheel motor and one for the right. A hose connects
the two allowing hydraulic oil to flow freely between them.
For example, when turning to the right, the right motor
uses less oil, causing more oil to flow to the left motor,
thus enabling the combineto turn properly.
When one of the brake pedals is pressed, the brake
pedal switches are closed, allowing current to flow through
the brake pedal switch. Current then flows through the
green/yellow wire and energizes the positrac solenoid
valve. The solenoid valves are normally open, but close
when one of the brake pedals is pressed. The solenoid
valves stop hydraulic oil flow between the two motors.
This forces the motors to work independently while
destroking the pump on the side which is being pressed.
This enables the combineto have a smaller turning radius.
Releasing both brake pedals de-energizes the
positrac solenoid valve.
The positrac on/off switch receives power directly
from positrac fuse 8. Depressing the positrac on/off
switch sends power through the green/yellow wire directly
to the positrac solenoid valves.
Engage the positrac system only when
necessarycontinuous use causes overheating of
hydraulic oil.
P1A
PB1
P2A
CP2
T P2B
Positrac
Solenoid
0100-9
cp1999250002c
HYDROSTATIC SYSTEM
Ground Drive Wheel

Hydraulic Schematic
1671354117
0100-10
cp1999250002c
HYDROSTATIC SYSTEM
Ground Drive Track

Hydraulic Schematic
1671354128
0100-11
cp1999250002c
HYDROSTATIC SYSTEM
Positrac Circuit
Electrical Schematic
7243003023
0100-12
cp1999250002c
HYDROSTATIC SYSTEM
Machine Moves Sluggishly or Has No Movement—

Wheeled Combine
Hydraulic Check
1. Replace hydrostatic filters.

2. Ensure hydrostatic system is Yes
free of air—bleed air from all Release park brake.
bleed points on top of filter tank.
Is the park brake applied?
No
Yes Push lever FORWARD or pull
Is ground drive lever in neutral? lever back to shift into gear.
No
1. Check hose for obstruction.

Perform a charge pressure No Perform vacuum test. Yes 2. Drain hydraulic tank.
test, see test section. Is vacuum higher than
3. Clean tank.
Is pressure 25 bar (360 PSI)? normal?
4. Ensure all ballvalves are
opened.
Yes No
1. Turn positrac switch ON.

2. Engage park brake. Repair or replace charge pump.
3. Place a 690 bar (10,000 PSI) gauge
at test port on B side of ground
drive pump.
4. Start engine and run at full throttle.
5. Put ground drive lever in REVERSE Yes
and record pressure. Check torque hub.
6. Repeat with gauge at test port A.
7. Put ground drive lever in
FORWARD and record pressure.
Is pressure 352 bar (5500 PSI)?
No
Can relief valve be adjusted?
No
1. Disconnect and plug hose from positrac

valve to A and B test ports on pump.
2. Cap pump connections. Yes
3. Place a 690 bar (10,000 PSI) gauge at Replace positrac valve.
test port.
Continued
No
on
next page
0100-13
cp1999250002c
HYDROSTATIC SYSTEM

Wheeled Combine (Continued)
From Previous Page

No
1. On B side of first ground drive pump, disconnect

and plug hose connected to the right wheel
motor. Cap the pump connection.
2. Place a 690 bar (10,000 PSI) gauge at test port
on B side of front pump.
4. Put ground drive lever in REVERSE to stroke
pump. Record pressure.
Remove and
5. On A side of first ground drive pump, disconnect
Yes inspect ground Yes 1. Check torque hub.
and plug hose connected to the right wheel
drive motors. 2. Check brake in
motor. Cap the pump connection.
Are motors OK? torque hub.
6. Place a 690 bar (10,000 PSI) gauge at test port
on A side of front pump.
7. Start engine and run at full throttle. No
8. Put ground drive lever in FORWARD to stroke
pump. Record pressure.
9. Repeat the pressure tests for the other ground Repair or replace.
drive pump which drives the left wheel motor.
No
Check relief valve or repair pump.
Charge pressure
test ports
A
0100-14
cp1999250002c
HYDROSTATIC SYSTEM

Tracked Combine
Hydraulic Check
1. Replace hydrostatic filters.

2. Ensure hydrostatic system is Yes
free of air—bleed air from all Release park brake.
bleed points on top of filter tank.
Is the park brake applied?
No
Yes
Is ground drive lever in neutral? Push lever FORWARD or pull
lever back to shift into gear.
No
1. Check hose for obstruction.
Perform a charge pressure test, Perform vacuum test. Yes 2. Drain hydraulic tank.
No
see page 0002-15. Is vacuum higher than 3. Clean tank.
Is pressure 25 bar (360 PSI)? normal? 4. Ensure all ball valves are
opened.
No
Yes
Repair or replace
1. Engage park brake. charge pump.
2. Place a 690 bar (10,000 PSI) gauge
at test port on B side or grounddrive
pump.
4. Put ground drive lever in REVERSE Yes
and record pressure. Check torque hub.
5. Repeat with gauge at test port A.
6. Put ground drive lever in FORWARD
and record pressure.
No
Yes
Can relief valve be
Adjust per manufacture’s specifications.
adjusted?
No
Continued
on
next page
0100-15
cp1999250002c
HYDROSTATIC SYSTEM

Tracked Combine(Continued)
From Previous Page

No
1. On “A” side of first ground drive pump,

disconnect and plug hose connected to
the left wheel motor. Cap the pump connection.
2. Place a 690 bar (10,000 PSI) gauge at test
port on “A” side of front pump.
4. Put ground drive lever in “reverse” to
stroke pump. Record pressure.
Remove and
5. On “B” side of right ground drive pump,
Yes inspect ground Yes 1. Check torque hub.
disconnect and plug hose connected to
drive motors. 2. Check brake in
the left wheel motor. Cap the pump connection.
Are motors OK? torque hub.
6. Place a 690 bar (10,000 PSI) gauge at test
port on “B” side of front pump.
7. Start engine and run at full throttle. No
8. Put ground drive lever in “forward” to
stroke pump. Record pressure.
9. Repeat the pressure tests for the other ground Repair or replace.
drive pump which drives the right track motor.
No
Check relief valve or repair pump.
0100-16
cp1999250002c
Positrac Control Does Not Operate
Electrical Check
with On/Off Switch
1. Engage park brake, stop engine No
and turn key switch to IGN. Replace fuse and check for a
2. Check 10 amp positrac fuse. shorted circuit or component.
Is fuse good?
Yes
No Yes
Measure voltage at positrac fuse. Refer to the Ignition Does the positrac Done.
Is 12VDC measured? Diagnostic Chart. control operate?
Yes No
1. Push positrac switch ON.

2. Check ground connection of No 1. Disconnect multiconnector at the Yes Perform a check on No
positrac switch. Repair or replace
positrac solenoid, harness side. positrac switch. switch.
3. Measure voltage of green/yellow 2. Measure voltage at red/white wire. Is switch good?
wire. Is 12VDC measured?
Is 12VDC measured? Yes
0100-17
No
Yes Check green/yellow wire

Hydraulic Check Check red/white wire between between positrac switch
fuse and switch. and solenoid valve.
Check the charge pressure on the
HYDROSTATIC SYSTEM
ground drive pump closest to the No Repair ground

pump drive (right side).
drive pump.
Is pressure greater than 14 bar
(200 PSI)?
Yes
Remove and inspect the valve

solenoid. Check for mechanical Yes Check valve
or hydraulic problems. cartridge relief valve.
Is solenoid good?
No
Replace valve solenoid.
cp1999250002c
HYDROSTATIC SYSTEM
Varitorq Control Problem
Hydraulic Check
1. Engage park brake and stop

engine.
2. Check the charge pressure
of outside ground drive 1. Disconnect and plug hose at
pump. No test port. No
3. Place a 41 bar (600 PSI) 2. Cap tee at test port. Repair or replace
gauge at test port on under 3. Repeat charge pressure test. charge pump.
side of ground drive pump. 4. Is pressure 25 bar (360 PSI)?
4. Start engine and run at full
throttle. Yes
Yes
Reconnect hose to tee.
1. Place a 41 bar (600 PSI) gauge

at test port located under
right fender.
2. Start engine and run at full Yes
throttle. Repair or replace
3. Turn varitorq control knob to motor.
0 (zero).
Does gauge read 7 bar (100 PSI)?
4. Turn varitorq control knob to
9 (nine).
Does gauge read 17 bar (250 PSI)?
No
Adjust or replace
varitorq valve cartridge.
Test Port
0100-18
cp1999250002c
HYDROSTATIC SYSTEM
Positrac Control Does Not Operate Properly

When Brake Pedals Are Pressed Or
Positrac Circuit Constantly Stays On
Electrical Check
1. Stop engine, engage park brake 1. Perform a switch check

and turn key switch to IGN. Yes No
on brake pedal switch. Adjust or
2. Perform a switch check on 2. Check switch adjustment. replace switch.
Positrac on/off switch. Is switch good?
Is switch good?
Yes
No
Check green/yellow wire between
Yes
Replace Positrac brake pedal switch and Positrac Done.
on/off switch. solenoid for unwanted 12 V supply.
Does Positrac work?
No
Inspect Positrac solenoid in

Positrac block.
0100-19
cp1999250002c
SECTION 0200
HYDRAULIC SYSTEM
Hydraulic System Theory Of Operation .................................................. 0200-3
Right Side Triple Pump ............................................................................ 0200-3
Left Side Triple Pump .............................................................................. 0200-3
Basecutter Motor ...................................................................................... 0200-3
Five Bank Directional Valve ..................................................................... 0200-4
System Operation .................................................................................... 0200-4
Specifications ........................................................................................... 0200-4
Control For Basecutter and Topper Lift ................................................... 0200-4
Main Relief Test Procedure ...................................................................... 0200-4
Electrical Control over Hydraulic Pilot Operation Lines ........................ 0200-4
Main Relief ................................................................................................ 0200-5
Load Check ............................................................................................... 0200-5
Anti-Cavitation Relief ............................................................................... 0200-5
Cylinder Lock Cartridge ........................................................................... 0200-5
Crossover Relief Settings ........................................................................ 0200-5
Elevator Controls Hydraulic Schematic .................................................. 0200-6
Chopper and Feed Rollers Hydraulic Schematic ................................... 0200-7
Crop Dividers Hydraulic Schematic ........................................................ 0200-8
Topper Hydraulic Schematic ................................................................... 0200-9
Basecutter Hydraulic Schematic ............................................................. 0200-10
Five Bank Swing Pedal Hydraulic Schematic ........................................ 0200-11
Primary Extractor Hydraulic Schematic .................................................. 0200-12
Ground Drive Wheel Hydraulic Schematic .............................................. 0200-13
Ground Drive Track Hydraulic Schematic ............................................... 0200-14
Park Brake Hydraulic Schematic ............................................................. 0200-15
Five Bank Swing Pedal Hydraulic Schematic ........................................ 0200-16
Elevator Drive And Secondary Extractor Hydraulic Schematic ............. 0200-17
Oil Cooler Fan Does Not Operate ............................................................ 0200-18
cp1999250002c
cp1999250002c
HYDRAULIC SYSTEM
Hydraulic System Theory of Operation Basecutter Motor

The hydraulic system in the CH2500 combine The basecutter motor also acts as a flow divider,
consists of five separate open center systems. These with three sections creating a three circuit family. Flow is
systems are supplied oil from separate sections of two divided equally to all three circuits.
hydraulic pumps. The (blind end) section divided flow to the power
The five systems share a common hydraulic tank, feed roller then to the knockdown roller to the directional
located on the rear of the combine. This tank has a valve.
separate smaller return tank that houses three 10 micron The (center) section divided flow to the buttlifter
filter elements. rollers, to the rollers B1, A2, A1, to the collector drums
then to the return valve.
The (shaft end) section divided flow to the directional
Right Side Triple Pump valve then back to the tank.
The right side triple pump supplies oil to three of the
six systems.
The end section (blind end) directs flow to the oil
cooler fan, then to the steering priority valve and the five
bank valve.
The center section directs flow to the chopper valve
that controls flow to the chopper motors. Flow is directed
through the chopper motors, and then downstream to feed
roller motors and the star gathering drum motors. All
motors in this circuit are supplied oil after the choppers.
The feed rollers are protected by a separate relief valve
located in a manifold on the left side of the combine, near
the rear. Return flow is directed through a ten micron
double filter assembly, and back to tank.
The front (input shaft end) section directs flow to
the elevator manifold block, which is controlled by a
solenoid.
Left Side Triple Pump

The left side triple pump supplies oil to two of the
six systems.
The end section (blind end) directs flow to the topper
manifold block, which is controlled by a solenoid.
The center and front (input shaft end) sections direct
flow to the basecutter valve. Oil passes through the open
center spool of the valve and back to tank. This valve
controls its portion of flow to the topper severing disc
motor. Oil flow will take the path of least resistance, which
is through the open center spool of the valve and back to
tank. Oil flow from the other port of the rear section is
directed to the valve inlet and on through to tank when in
neutral position.
0200-3
cp1999250002c
HYDRAULIC SYSTEM
Five Bank Directional Valve 5. Adjust main relief to 172 bar (2500 PSI) if
When the spool is moved to one side, it restricts or necessary, in order to set swing port (crossover)
shuts off the neutral passage in ports, and builds pressure relief. To set, loosen the main relief screw jamnut
in the lift check passage. A pressure passage is connected and turn inward to increase pressure, outward to
to a work port and a return passage is connected to the decrease pressure.
other work port. 6. After making adjustment, secure locknut.
As pressure in the lift check passage increases
enough to overcome the load, the lift check allows oil to
flow to the pressurized work port. The lift check also
prevents the load from dropping before adequate pressure Electrical Control Over Hydraulic Pilot
is reached. Metering is accomplished at both the neutral Operation Lines
passage and the return work port by moving the spool.
A
B
System Operation C
The front section (input shaft side) of the two section D
gear pumps delivers oil flowing at 45 l/min (12 GPM) to

E
the cooler fan motor through the five bank valve on the
track combine. On the wheeled combine, this flow will
pass through a priority valve that assures the steering
circuit of adequate oil flow. Any flow not required by the
steering is sent to the inlet section supplying the five bank
valve.
Specifications
Pump flow for the five bank valve, delivered from A. Basecutter Lift
the flow divider end section, is approximately 45 L/min B. Topper Lift
(12 GPM), with the engine at high idle. C. Crop Divider LiftRH
System relief pressure is 172 bar (2500 PSI). D. Crop Divider LiftLH
E. Elevator Swing
Control For Basecutter and Topper Lift

The basecutter and topper lift are controlled by a
joystick.
Main Relief Test Procedure

1. Bring hydraulic oil temperature to 38°C
(100°±10°F).
2. Connect a 0-345 bar (0-5000 PSI) gauge to the
test port located on the top section of flow divider.
3. Start engine and bring to high idle.
4. Operate any five bank valve section, except the
swing elevator, to send system oil over relief check
pressure.
0200-4
cp1999250002c
HYDRAULIC SYSTEM
Main Relief
When system oil reaches a pressure higher than
spring tension, it forces the poppet backward. This allows
oil to bypass, traveling on downstream to tank. This relief
is not pilot operated, but is a direct acting relief. It operates
solely on the force of the spring holding the poppet onto
the seat inside poppet body.
Load Check
On the base of each working valve section, there is
a plug that holds the spring and poppet for load check.
The load check stops back flow when an operating work
port is under load. This allows smoother valve operation.
Anti-Cavitation Relief
The fifth (from the top) spool section of the valve is
for the elevator swing circuit. There are anti-cavitation
reliefs on both ports, which stack together in the valve
body and are screw adjustable.
The anti-cavitation port relief acts as a crossover
relief that allows oil to pass from one port to the other, at
a set pressure. This causes a cushioning effect when the
spool centers during swing and prevents damage to the
elevator by allowing it to swing, if it is hit.
Cylinder Lock Cartridge

The first (from the top) spool section, located next
to the outlet section, is used to raise and lower the
basecutter height. It has a cylinder lock valve cartridge
on both work ports. The cylinder lock valve cartridge acts
as a safeguard; it will not allow movement unless system
pressure is applied. Therefore, when the combine is not
running, this valve section will not operate.
Crossover Relief Settings

1. The inlet section of the valve has an adjustable
relief that is set at 172 bar (2500 PSI).
2. The main relief and port reliefs are adjusted by
loosening the locking jamnut with a 9/16" wrench.
Using a 1/8" allen wrench, screw inward to
increase pressure and outward to decrease. After
adjusting, tighten the locking jamnut.
0200-5
cp1999250002c
HYDRAULIC SYSTEM
Elevator Controls
Hydraulic Schematic
1671354116
0200-6
cp1999250002c
HYDRAULIC SYSTEM
Chopper and Feed Rollers

Hydraulic Schematic
1671354101
0200-7
cp1999250002c
HYDRAULIC SYSTEM
Crop Dividers
Hydraulic Schematic
1671354118
0200-8
cp1999250002c
HYDRAULIC SYSTEM
Topper
Hydraulic Schematic
1671354099
0200-9
cp1999250002c
HYDRAULIC SYSTEM
Basecutter
Hydraulic Schematic
1671354100
0200-10
cp1999250002c
HYDRAULIC SYSTEM
Five Bank Swing Pedal

Hydraulic Schematic
1671354770
0200-11
cp1999250002c
HYDRAULIC SYSTEM
Primary Extractor
Hydraulic Schematic
1671354114
0200-12
cp1999250002c
HYDRAULIC SYSTEM
Ground Drive Wheel

Hydraulic Schematic
1671354117
0200-13
cp1999250002c
HYDRAULIC SYSTEM
Ground Drive Track

Hydraulic Schematic
1671354128
0200-14
cp1999250002c
HYDRAULIC SYSTEM
Park Brake
Hydraulic Schematic
LEFT GROUND DRIVE PUMP

CHARGE PRESSURE 360 PSI
HYDROSTATIC HYDROSTATIC
MOTOR MOTOR
MOTOR LEFT SIDE MOTOR RIGHT SIDE
Park Brake, Spring Applied, and Hydraulically Released
0200-15
cp1999250002c
HYDRAULIC SYSTEM
Five Bank Swing Pedal

Hydraulic Schematic
1671354109
0200-16
cp1999250002c
HYDRAULIC SYSTEM
Elevator Drive And Secondary Extractor

Hydraulic Schematic
1671354111
0200-17
cp1999250002c
HYDRAULIC SYSTEM
Oil Cooler Fan Does Not Operate
Hydraulic Check
1. Plug pressure gauge to in-line relief

valve located in engine screen.
2. Start engine, engage park brake and run at Inspect and
full throttle. No adjust in-line Yes Flow rate gear pump. No
3. Turn 5 bank valve up to 295 bar (3500 PSI). relief valve. Is flow less than 42 Done.
4. Lift basecutter to highest position and Is valve good? L/min (12 GPM)?
hold joystick in “up” position.
Can in-line relief valve be set to 273 ± 7 bar No Yes
(3250 ± 100 PSI)?
Replace in line
Change pump.
relief valve.
Yes
No
Can fan blades be turned manually? Check motor for jamming.
Yes
Check motor and hub assy.
0200-18
cp1999250002c
SECTION 0300
STEERING SYSTEM
Front Suspension And Steering .............................................................. 0300-3
Steering Pivot Assembly ......................................................................... 0300-3
Steering Circuit Specifications ................................................................ 0300-3
Steering Test Procedure .......................................................................... 0300-3
Troubleshooting ....................................................................................... 0300-4
Slow Steering, Hard Steering, Or Loss Of Power Assist ........................ 0300-4
Wander—The Tendency To Deviate From Operator Directed Course ..... 0300-4
Drift—The Tendency To Deviate From Non-Operator Directed Course .. 0300-4
Slip—When A Slow Movement Of Steering Wheel Fails To Cause Any
Movement Of Steered Wheels .............................................................. 0300-4
Temporary Hard Steering Or Hang-Up. (A Momentary Increase In Steering
Wheel Torque During Steering Reversal Or Initial Input) .................... 0300-5
Erratic Steering ........................................................................................ 0300-5
Spongy Or Soft Steering ......................................................................... 0300-5
Free Wheeling—Steering Wheel Turns Freely With No Feeling Of Pressure
And No Action On Steered Wheels ...................................................... 0300-5
Elevator Drive and Secondary Extractor Hydraulic Schematic ............. 0300-6
Five Bank Joystick and Swing Pedal Hydraulic Schematic ................... 0300-7
Steering Does Not Operate ...................................................................... 0300-8
cp1999250002c
cp1999250002c
STEERING SYSTEM
Front Suspension And Steering

The steering is operated by a 45.4 L/min (12 GPM)
oil supply from a flow divider which is supplied by a pump.
This is routed through a priority valve and controlled by
an orbital motor which acts upon two 2-1/2" cylinders.
The cylinders are connected to a bellcrank which, in turn,
is connected to the LH and RH tie rods on the lift cylinder
steering arms.
The basecutter lift cylinder is the kingpin and it has
the axle spindle incorporated at the butt end. The rod end
is connected to the frame, underneath the platform. The
butt end connection is the kingpin, which is mounted within Valve
a ball bearing located in the trunnion block. Four strut arm Adjustment
Test Port
172 bar (2500 PSI)
assemblies, with ball bushings, connect the trunnion block
to the main frame. Bolts retain the strut arm assemblies.
The front wheel hub turns on tapered roller bearings
and the rim is detachable from the bearing hub.
Valve Adjustment
120 ± 4 bar
Steering Pivot Assembly (1750 ± 50 PSI)
The steering pivot assembly is mounted under the
cab in the center of the combine. The two steering
cylinders are attached to it with a pin locked in place with
a nut and lockwasher. The left and right tie-rod ends are
secured to the pivot with a castlenut and cotter pin. The
other tie-rod ends are connected to lugs located on the lift
cylinders.
Steering Circuit Specifications

Priority Relief ................................. 121 bar (1750 PSI) Steering Valve
Steering Test Procedure

1. Bring hydraulic oil temperature to 38°C
(100°±10°F).
2. Connect a 0-345 bar (0-5000 PSI) gauge to the
test port located on end section of flow divider.
4. Rotate steering wheel all the way in one direction;
check pressure.
5. Adjust to 121 bar (1750 PSI), if necessary, by
removing priority valve return hose and fitting.
There is a hex screw inside this port. Using a 7/
32" hex head wrench, turn inward to increase
pressure, outward to decrease (1/4 turn at a time).
6. Replace hose and fittings. Retest and repeat
procedure, if necessary.
0300-3
cp1999250002c
STEERING SYSTEM
Troubleshooting 3. Binding of linkage or cylinder rod.

Most steering problems can be corrected if the Ø Repair or replace.
problem is properly defined. The entire steering system
should be evaluated before removing any components. 4. Loose cylinder piston.
Usually the steering control valve is not the cause of most Ø Repair or replace.
problems. The following is a list of steering problems and
their possible cause along with suggested corrections 5. Leaking crossover relief or anticavitation
arrowed directly underneath. valve in cylinder lines.
Ø Repair or replace.
Slow Steering, Hard Steering, Or Loss Of 6. Severe wear in steering valve.

Power Assist Ø Repair or replace.
1. Worn or malfunctioning pump.
Ø Repair or replace pump.
Drift—The Tendency To Deviate From Non-
2. Stuck flow divider piston. Operator Directed Course
Ø Repair or replace flow divider. 1. Single rod end cylinder slowly extends
without turning the steering wheel.
3. Worn pump compensator (allows the system Ø A small rate of extension may be normal on a
pressure to be less than specified). closed center system.
Ø Repair or replace compensator or pump.
2. Worn or damaged steering linkage.
4. Malfunctioning relief valve (allows the system Ø Repair or replace linkage and align front end.
pressure to be less than specified).
Ø Repair or replace the relief valve.
Slip—When A Slow Movement Of Steering
5. Overloaded steering axle. Wheel Fails To Cause Any Movement Of
Ø Reduce load. Steered Wheels
1. Leakage of cylinder piston seals or accessory
6. Leaking or kinked supply line for load sensor. valve between cylinder lines or ports.
Ø Trace line and tighten fittings or replace hose. Ø Replace seals, repair or replace accessory valve.
7. Malfunctioning priority valve. 2. Worn steering valve geroler.

Ø Check for sticking spring or spool. Ø Repair or replace steering valve.
Ø Check damping orifices in both ends of main bore
for Debris.
Ø Check system pressure at SCU inlet for proper
pressure, if incorrect: replace priority valve relief
cartridge.
Wander—The Tendency To Deviate From

Operator Directed Course
1. Air in system due to low oil level, cavitating
pump, loose fittings, kinked hose, etc.
Ø Check system for the above and add system fluid
to correct.
2. Worn mechanical linkage.

Foam on top of the oil in the tank is usually a sign of air in the system.
0300-4
cp1999250002c
STEERING SYSTEM
Temporary Hard Steering Or Hang-Up. (A Free Wheeling—Steering Wheel Turns

Momentary Increase In Steering Wheel Freely With No Feeling Of Pressure And No
Torque During Steering Reversal Or Initial Action On Steered Wheels
Input) 1. Steering column upper shaft is loose or
1. Thermal shock. damaged.
Ø Check valve for proper operation and cause of Ø Tighten steering wheel nut, repair or replace
thermal shock. column.
2. Lower splines of column may be disengaged

Erratic Steering or broken.
1. Air in system due to low oil level, cavitating Ø Repair or replace column.
Ø Check system for the above and add system fluid 3. Steering valve geroler is low on oil. (This can
to correct. happen on start-up, after repair, or after long
periods of nonuse.)
2. Loose cylinder piston. Ø Starting engine will usually cure this problem.
Ø Repair or replace cylinder.
4. No flow to steering unit caused by low oil.
3. Thermal shock damage. Ø Add oil and check for leaks or ruptured hose.
Ø Repair or replace steering valve.
5. Internal steering valve damaged due to
4. Sticking flow control valve. thermal shock.
Ø Repair or replace flow control valve. Ø Repair or replace the valve.
Spongy Or Soft Steering

1. Air in system due to low oil level, cavitating
Ø Check system for the above and add system fluid
to correct.
2. Air in hydraulic system. (Most likely air is

trapped in cylinders or lines.)
Ø Bleed air from system.
3. Low oil level.

Ø Add oil and check for leaks.
Thermal shock is a condition caused when the hydraulic system is operated for some time without turning the steering wheel.
This may cause the oil in the hydraulic system to be hot and the steering wheel may be relatively cool (more than a 10°C [50°F]
temperature differential). When the steering wheel is turned quickly the result is temporary seizure and possible damage to
internal parts of the steering valve. This seizure may be followed by total free wheeling.
Foam on top of the oil in the tank is usually a sign of air in the system.
0300-5
cp1999250002c
STEERING SYSTEM
Elevator Drive and Secondary Extractor

Hydraulic Schematic
1671354111
0300-6
cp1999250002c
STEERING SYSTEM
Five Bank Joystick and Swing Pedal

Hydraulic Schematic
1671354770
0300-7
cp1999250002c
STEERING SYSTEM
Steering Does Not Operate
Hydraulic Check
1. Start engine, engage park 1. Check and adjust in

brake and run at full throttle. No line relief valve. Yes Flow rate right gear pump.
2. Lift up topper or crop divider. 2. Pressure should be Is flow less than 45
Is it lifting at a normal 193 bar (2800 PSI). L/Min (12 GPM)?
operating rate? Is valve OK?
Yes
No
No
Yes Change pump.
Replace in line Done.
relief valve.
1. Plug a 345 bar (5000 PSI) gauge
at test port “B” on steering
priority valve “A”.
2. Disconnect hose to port labeled
“Tank” and remove fitting from No
priority valve. Replace relief valve.
3. Adjust relief valve inside tank
port “C” on priority valve.
Can relief be adjusted to 121 bar
(1750 PSI)?
Yes
With engine at full throttle, flow No

rate left and right motor ports Replace motor.
that go to cylinders.
Is flow rate 45 L/Min (5 GPM)?
OK
Yes
Refer to Oil Cooler Fan.
Check cylinders for

internal leakage.
Steering Priority
Valve “A”
Tank port “C”
Test gauge port “B”
0300-8
cp1999250002c
SECTION 0400
PARK BRAKE
Park Brake Electrical Theory Of Operation ............................................. 0400-3
Park Brake Electrical Schematic ............................................................. 0400-4
Park Brake Hydraulic Schematic ............................................................. 0400-5
Park Brake Cannot Be Cancelled ............................................................. 0400-6
Park Brake Does Not Engage .................................................................. 0400-7
cp1999250002c
cp1999250002c
PARK BRAKE
Park Brake Electrical Theory Of Operation

The park brake switch is located below the voltage
gauge on the front instrument panel. The park brake
indicator light is activated when the park brake is engaged.
The park brake, spring applied and hydraulically
released, is located inside both left and right torque hubs.
The park brake relay controls both the solenoid and
indicator light.
The park brake is applied when the key switch is
turned Off or when the park brake switch is turned On.
The park brake is released when the park brake switch
is turned Off or when the engine is running and the charge
pressure is ok.
If the engine stops, either by turning the key switch
Off or if the engine dies with the park brake switched
Off, the park brake will automatically engage by loss of
power to the red/white wire on terminal 30 of the park
brake reset relay. When the engine is restarted, the park
brake reset relay and park brake relay is de-energized.
With the park brake relay de-energized, current
flows through terminal 87A bringing power to the park
brake solenoid. The solenoid valve is normally open, but
closes when energized, thus stopping charge pressure at
the solenoid valve and the brakes remain spring applied.
The park brake switch must be turned on to energize
the park brake reset relay. This allows current to flow
out of terminal 87 and supply power at the park brake
switch.
When the park brake switch is turned off, current
flows through the park brake switch to the brown/white
wire to terminal 86. The park brake relay is now energized
stopping current flow to terminal 87A and causing the
park brake solenoid to lose power. This opens the solenoid
which allows charge pressure to build, compressing the
spring and releasing the park brake.
0400-3
cp1999250002c
PARK BRAKE
Park Brake
7243002801
0400-4
cp1999250002c
PARK BRAKE
Park Brake
Hydraulic Schematic
LEFT GROUND DRIVE

PUMP CHARGE
PRESSURE 360 PSI
HYDROSTATIC HYDROSTATIC
MOTOR MOTOR
MOTOR LEFT SIDE MOTOR RIGHT SIDE
Park Brake, Spring Applied, and Hydraulically Released
0400-5
cp1999250002c
PARK BRAKE
Park Brake Cannot Be Cancelled

Electrical Check
1. Stop engine, engage park brake

and turn key switch to IGN. No Check white wire between park
2. Disconnect multiconnector at brake switch and park brake
park brake switch. relay terminal 30.
3. Measure voltage of white wire.
Is 12VDC measured?
Yes
Perform a park brake switch check. No

Is switch good? Replace park brake switch.
Yes
1. Reconnect multiconnector onto park

brake switch.
2. Remove park brake reset relay. No Check brown wire between park
3. Turn park brake switch ON. brake switch and reset relay.
4. Measure voltage at terminal 87 and 86.
Is 12VDC measured?
Yes
Check park brake reset relay No

terminal 85 for ground. Replace wire to ground.
Is ground good?
Yes
Perform relay check on park brake

relay and reset relay. No
Replace bad relay.
Are relays good?
Yes
1. Reinstall park brake reset relay.

2. Turn park brake switch OFF.
3. Remove park brake relay. Check brown/white wire
No
4. Check voltage at terminal 86. between park brake switch
Is 12VDC measured? and park brake relay.
Yes
Check park relay terminal 85
for ground. No
Replace wire ground connection.
Is ground good?
Yes
Replace park brake relay.
0400-6
cp1999250002c
Electrical Check
Park Brake Does Not Engage
1. Stop engine and turn key
switch to IGN. No Replace fuse and check for a
2. Check 10 amp brake
shorted circuit or component.
fuse.
Is fuse good?
Yes
Measure voltage at fuse. No Yes

Refer to the Accessory Diagnostic Chart. Done.
Is 12VDC measured?
Does park brake engage?
Yes
No
1. Check ground connection at
park brake solenoid harness
side black wire. Check voltage of white wire at park Yes Check green wire
No Yes Perform a relay check
2. Measure voltage at green brake reset relay terminal 30. between park brake
on the park brake
wire. Is 12VDC measured? relay terminal 87 A
relay and park brake
Is 12VDC measured? and solenoid.
reset relay.
No Are the relays good?
Yes Check harness.

Hydraulic Check
0400-7
No
PARK BRAKE
Perform a solenoid check on No

park brake solenoid; check for Replace relay.
Replace park brake solenoid.
mechanical or hydraulic
problems.
Is solenoid good?
Yes
No Check charge pressure at ground drive
No
Check charge pressure at torque hub. pump on right side.
Is pressure greater than 14 bar (200 PSI)? Repair or replace charge pump.
Yes No
Remove and inspect torque hub assy. Repair or replace park brake solenoid spool.
cp1999250002c
SECTION 0600
OPERATOR’S STATION
Operator’s Station Theory of Operation .................................................. 0600-3
Glass and Moldings ................................................................................. 0600-3
Air Intake (Pressurizer) System ............................................................... 0600-3
Air Conditioning System ......................................................................... 0600-3
Air Conditioning Circuit .......................................................................... 0600-4
Receiver/Dryer Operation ......................................................................... 0600-4
Thermostat Switch Operation .................................................................. 0600-5
Expansion Valve Operation .................................................................... 0600-5
Compressor Relief Valve Operation ........................................................ 0600-6
Heating System ........................................................................................ 0600-6
Air Conditioning Specifications .............................................................. 0600-6
AC Circuit Operational Information ......................................................... 0600-6
Refrigerant Cautions ................................................................................ 0600-7
R134A Component Oil Charge ................................................................. 0600-7
R134A Refrigerant Recover, Recycling and Charging System
Installation Procedure ....................................................................... 0600-7
Recover R134A System ............................................................................ 0600-8
Evacuate R134A System .......................................................................... 0600-8
Air Conditioning System Test .................................................................. 0600-9
Charge R134A System ............................................................................. 0600-9
Air Conditioning Operational Checks ..................................................... 0600-10
Visual Inspection of Components ........................................................... 0600-10
System Operating Checks ....................................................................... 0600-11
System Performance Checks .................................................................. 0600-11
Blower/Air Conditioning Circuit .............................................................. 0600-12
Low Refrigerant Pressure Switch Test .................................................... 0600-12
Volt-Ohm-Amp Meter ................................................................................ 0600-12
Insufficient Heating .................................................................................. 0600-13
Inadequate Removal of Ice or Fog .......................................................... 0600-13
Heater Valve Not Shutting Off Coolant Flow ........................................... 0600-13
Air Conditioning System Does Not Operate ........................................... 0600-13
Air Conditioner Does Not Cool Cab Interior ........................................... 0600-13
Air Conditioner Runs Constantly, Too Cold ............................................ 0600-14
Cab and Air Conditioner Electrical Schematic ....................................... 0600-15
cp1999250002c
cp1999250002c
Blower
Condensor
Receiver/Dryer
High Pressure
Switch
Expansion
Valve
Evaporator/Heater
Core
Compressor
Operator’s Station Theory of Operation The blowers must work before heater or air
The operators station forms a base for mounting conditioning system will work.
the air conditioning and heating controls and
instrumentation.
The operators station is not a roll over protection Air Conditioning System
structure (ROPS). It will not provide protection if a roll- The compressor draws low pressure refrigerant from
over occurs. the evaporator and compresses it to a high pressure.
Increasing the pressure of the refrigerant causes its boiling
point to rise to a temperature higher than the outside air.
Glass and Moldings As the high pressure gas passes through the
All glass in the cab is tempered safety plate type condenser, heat is removed and transferred to the cooler
glass which has been tinted to reduce glare. Both curved outside air being forced through the condenser core. This
and flat glass is used. cools the gas and condenses it into a liquid that is still
under high pressure.
The refrigerant flows from a receiver/dryer, where
Air Intake (Pressurizer) System contaminants are filtered and the refrigerant is stored until
The pressurizer system can be turned on without it is required by the expansion valve at the evaporator.
operating either the heating or air conditioning systems. The expansion valve is a variable orifice used to cause a
By turning the blower on, the cab becomes pressurized pressure and temperature drop in the refrigerant and
by forcing air into the cab and out any small cracks and regulate flow into the evaporator.
holes in the cab. This air being forced out keeps dirt from The evaporator is where the actual cooling and
coming in. drying of air takes place. The temperature of the
To pressurize blowers, pull outside air through air refrigerant was lowered by going through the expansion
intake openings on both sides of the cabs roof. This air valve. This liquid refrigerant flows through the
is pulled through an outside air filter into the first air evaporator, and warm cab air flowing through the
chamber. Air is pulled through a recirculating filter from evaporator core causes the refrigerant to vaporize.
inside cab and mixed with air from the outside filter. The moisture from the air that is collected on the
Together this air is pulled through the evaporator-heater evaporator core during the cooling process is drained
core into a second air chamber. From here the blowers away. The cab air is now cooled and dehumidified. This
force air through louvers in the inner roof and into cab will produce a desirable effect in a few cycles.
interior.
0600-3
cp1999250002c
Air Conditioning Circuit Desiccant is used to absorb moisture. If too much

Power flows from the accessory terminal of the key moisture gets into the system, the desiccant may not be
switch white wire to terminal 86 of accessory relay (25), able to absorb it all. When moisture is combined with
energizing it. With the accessory relay energized, power refrigerant oil, a sludge is formed. This sludge does not
flows through the red/white wire to terminal 86 of air permit moving parts to be adequately lubricated. When
conditioning relay (19), energizing it. Power flows moisture is combined with refrigerant, hydrofluoric and
through 30 amp fuse (15) to terminal 30 on air hydrochloric acids are formed. These acids are very
conditioning relay (19). When air conditioning relay (19) corrosive to metal surfaces and leakage will eventually
is energized, power flows out of terminal 87 through the develop. If the air conditioning system is left open for a
red wire to (B) on the blower switch. With the blower period of time or if the plugs are removed from the
switch in low or medium position, power is sent through receiver/dryer, the desiccant will absorb moisture from
the resistor to reduce the voltage. The blower motor runs the air. Evacuating the system will not remove moisture
in low or medium speed. On high, power bypasses the from the desiccant.
resistor and 12 volts are applied to the blower motor, A sight glass is installed in the receiver/dryer outlet
causing it to run at high speed. Power also flows from port. If the refrigerant level is low, a steady stream of gas
(C) terminal of the blower switch through the orange wire, bubbles will be present in the liquid flowing from the
to the thermostatic switch. Power then flows through the receiver/dryer. These gas bubbles can be seen in the sight
orange wire to the low pressure switch. With the low glass and are an indication that the system needs charging.
pressure switch closed, power flows through the orange However, bubbles may be present when the compressor
wire to the high pressure switch. With the high pressure clutch first engages but must disappear after a few
switch closed, power flows through the orange wire to seconds. If the sight glass is clear, the system either has a
the air-conditioning compressor clutch terminal which sufficient charge or is completely discharged.
energizes the air conditioning compressor.
Receiver/Dryer Operation
The receiver/dryer is a tank to store excess liquid
B
refrigerant in the system. Excess refrigerant is required A
C
for two reasons:
1. Outside air temperature and humidity have an
effect on the minimum quantity of refrigerant
required in the system for the air conditioner to
operate at maximum efficiency. The higher the
temperature and humidity, the more refrigerant
required in the system. More refrigerant is
required, due to the expansion valve opening D
farther allowing more refrigerant into the low
pressure side of the system.
E
2. Refrigerant hoses allow a small amount of
refrigerant to migrate through their walls. Extra F
refrigerant stored in the system allows for a E

longer period of time before additional refrigerant
G
is needed.
The receiver/dryer also contains two filters (E) and
a desiccant (F) between the filters. The filters remove
solid failure, debris left in the system due to improper A. Inlet Port E. Filter
service procedures, or particles caused by corrosion of B. Sight Glass F. Desiccant
metal parts due to moisture and acids in the system (also C. Outlet Port G Strainer
caused by improper service procedures). D. Pickup Tube
0600-4
cp1999250002c
The low temperature limit of the switch is set to

prevent the evaporator from becoming cold enough to
D freeze moisture that condenses on the evaporator. For
this reason, the sensing line must be placed in the correct
E
location to sense the coldest temperature in the evaporator
core. It is also important to insert the correct length of
sensing line into the core.
F
C G
H
C
D
B A I
B
A. Diaphragm F. Spring E
B. Sensing Line G. Adjusting Screw F
C. Lever H. Lever
D. Control Shaft I. Switch Points
G
A
E. Cam
H
Thermostat Switch Operation
The thermostat switch is used to regulate the
temperature in the evaporator core to produce the air A. Sensing Bulb E. Orifice
B. Equalizer LineC F. Valve Seat
temperature selected by the operator. Diaphragm G. Spring
The switch receives current from the blower switch D. Inlet Passage H. Outlet Passage
when the blower switch is turned ON. The current flows
from the thermostat control switch to the low pressure
switch, high pressure switch, and to the compressor. Expansion Valve Operation
When the control knob is turned OFF, cam (E) moves The expansion valve is used to regulate the amount
lever (C) to the left. This mechanically prevents lever of refrigerant flowing into the evaporator. Since more
(H) from pivoting downward far enough to close the points. refrigerant can be vaporized by warm, moist air than cool,
When the control knob is turned clockwise, lever (H) is dry air; the expansion valve adjusts flow to the maximum
free to pivot downward and close the points. amount that can be vaporized in the evaporator, depending
Turning the control knob changes the tension of upon the heat and humidity of the air.
spring (F) connected to lever (H). The colder the setting, The expansion valve is also an orifice used to cause
the less tension there is in the spring. a pressure drop in the liquid refrigerant to lower its boiling
The spring works against diaphragm (A) connected point, causing the refrigerant to vaporize as it is heated
to gas filled sensing line (B) inserted into the evaporator by the air flowing through the evaporator. Since heat is
core. The warmer the temperature setting, the more required to vaporize a liquid, the heat is removed from
tension there is in the spring, and the warmer the the air and added to the refrigerant.
temperature must be in the evaporator core to produce The expansion valve is controlled by gas filled
the required gas pressure in the bellows to overcome spring sensing bulb (A) connected to diaphragm (C). The sensing
tension and close points (I). If the temperature setting is bulb is fastened to the evaporator outlet line and senses
reduced, spring tension is released. The evaporator must the temperature of the refrigerant leaving the evaporator.
be cooled to a lower temperature to reduce gas pressure The bulb and line are wrapped with insulating tape to keep
in the bellows enough for spring tension to move lever outside air temperature from affecting valve operation. If
(H) upward, allowing the points to open. This is how the too much refrigerant is flowing through the evaporator,
compressor is turned on and off to regulate the the liquid refrigerant will still be evaporating as it leaves
temperature in the evaporator. the evaporator, causing a low temperature at the evaporator
0600-5
cp1999250002c
outlet. The low temperature causes the gas pressure in Air Conditioning Specifications
the sensing bulb to decrease. Spring (G) moves valve seat
(F) closer to orifice (E), reducing the refrigerant flow. If High Pressure Switch (Normally Closed)
outlet temperature is too warm, gas pressure in the sensing
bulb will increase, causing diaphragm (C) to move valve Open above ................. 2410 ± 100 kPa (350 ± 15 PSI)
seat (F) away from orifice (E), thus increasing refrigerant
Closes below .............. 1517 ± 100 kPa (220 ± 15 PSI)
flow.
If the expansion valve sensing bulb does not make
good contact with the evaporator outlet line, or if the Low Pressure Switch (Normally Open)
insulating tape is missing, frost will form on the
evaporator outlet line. Frost forms because the sensing Closes above .................... 276 ± 20 kPa (40 ± 3 PSI)
bulb will not be cooled to the actual line temperature.
This will keep the expansion valve open too far and the Opens below ..................... 220 ± 20 kPa (32 ± 3 PSI)
refrigerant will still be evaporating as it leaves the
evaporator, cooling the line to less than 0°C (32°F).
External equalizer line (B) is connected to the Compressor Relief Valve (Normally Closed)
evaporator outlet line to transmit evaporator outlet
Open above .................................... 4137 kPa (600 PSI)
pressure to the spring side of the diaphragm. Using an
external equalizer line provides a more stable valve
operation. Temperature Control Switch
Opens below ..................... -1.6 to 0.60°C (29 to 32°F)

Compressor Relief Valve Operation Closes above .................... 2.2 to 3.3°C (36 to 38°F)
The compressor relief valve is a direct acting, Compressor Belt Tension 12 mm (0.50 in.)
pressure limiting valve. If a malfunction in the system Deflection with 5 N
(12 lb) Force
occurs that would cause high pressure, such as a restricted
line, the valve will open at 450±55 kPa (31±3.8 bar)
(3100±380 PSI) and will remain open until pressure drops
to below the valve setting. AC Circuit Operational Information
If the relief valve opens, a loud popping noise will The following conditions must exist for air
be heard. Some oil may also be lost from the system. conditioning circuit to function:
Correct any condition that causes the valve to open. 1. Key switch ON.
2. Machine running.
3. Air conditioning switch ON.
Heating System
Coolant from the block is carried by hoses to the 4. Blower switch on LOW, MEDIUM OR HIGH.
heater core and then to the heater control valve. The 5. Thermostat on COLD.
control valve restricts flow of coolant to regulate
temperature, as desired by the operator.
To activate the system two valves on the engine,
one on the front and one on the back, must be opened.
When these two valves and the control valve are opened,
coolant returns to the water pump bypass through a return
hose.
The air conditioning blower draws air through the
heater core and directs it inside the cab.
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cp1999250002c
Refrigerant Cautions IMPORTANT: DO NOT add any more oil than

required or maximum cooling will
* CAUTION * be reduced.
DO NOT allow liquid refrigerant to contact eyes or skin. DO NOT leave the system or the
Liquid refrigerant will freeze eyes or skin on contact. R134a compressor oil container
Wear goggles, gloves and protective clothing. open—this oil easily absorbs
If liquid refrigerant contacts eyes or skin, DO NOT rub
the area. Splash large amounts of COOL water on moisture.
affected areas. Go to a physician or hospital DO NOT spill R134a compressor
immediately for treatment. oil on acrylic or ABS plastic—this
DO NOT allow refrigerant to contact open flames or very oil will rapidly deteriorate these
hot surfaces such as electric welding arc, electric
materials.
heating element and lighted smoking materials.
DO NOT heat refrigerant over 52°C (125°F) in a closed Identify R134a oil containers and
container. Heated refrigerant will develop high pressure take measures to eliminate
which can burst the container. accidental mixing of different oils.
Keep refrigerant containers away from heat sources.
Store refrigerant in a cool place.
DO NOT handle damp refrigerant container with your
bare hands. Skin may freeze to container—Wear gloves. R134A Refrigerant Recover, Recycling and
If skin freezes to container, pour COOL water over Charging System Installation Procedure
container to free the skin. Go to a physician or hospital
immediately for treatment.
* CAUTION *
DO NOT remove high pressure relief valve (B). The air
R134A Component Oil Charge conditioning system will discharge rapidly causing
possible injury.
1. When installing a new or remanufactured
compressor, drain the oil. Replace with 50 mL
(1.6 fl oz) of new oil.
2. When components are replaced add refrigerant IMPORTANT: Use correct refrigerant recovery,
oil as listed below. recycling and charging stations.
DO NOT mix refrigerant, hoses,
fittings, components or refrigerant
Specifications oils.
Component .................................... Oil Charge
Evaporator ..................................... 44 mL (1.5 fl oz)
Condenser ...................................... 65 mL (2.2 fl oz)
1. Close both high side and low side valves on
Receiver-Dryer ............................... 30 mL (1.02 fl oz) refrigerant recovery, recycling and charging
Compressor ................................... 50 mL (1.6 fl oz) system (8).
Hoses ............................................. 15 mL (0.51 fl oz) 2. Remove cap from low-side test port (6).
Hoses = 3 mL per 30 cm (0.1 fl oz per ft) 3. Connect low side blue hose (9) from refrigerant
Approximate total system length = 600 cm (20 ft) recovery, recycling and charging system (8) to
low side test port (6) on compressor.
If any section of hose is removed and flushed or
4. Connect high pressure red hose (5) to high
replaced, measure the length of hose and use the above
pressure quick disconnect (2).
formula to determine the correct amount of oil to be added
to the system. 5. Follow the manufactures instructions when using
the refrigerant recovery, recycling and charging
system.
Dispose of oil drained from the compressor in accordance with Federal, State and Local regulations. Do not reuse oil drained
from the system. Always add NEW oil to the system. Oil in new or remanufactured compressors must be replaced to maintain proper
fill.
0600-7
cp1999250002c
Recover R134A System (980 bar) (29 in Hg) for each 300 m (1000 ft) of
elevation above sea level. If 98 kPa (980 bar)
* CAUTION * (29 in Hg) vacuum cannot be obtained in 15
DO NOT remove high pressure relief valve (B). The air minutes, test the system for leaks and correct as
conditioning system will discharge rapidly causing necessary.
possible injury.
5. When vacuum is 98 kPa (980 bar) (29 in Hg),
close low side and high side valves. Turn vacuum
Run the air conditioning system for three minutes to pump off.
help in the recovery process. Turn air conditioning system
off before proceeding with recovery steps. 6. If the vacuum decreases more than 3.4 kPa (34
bar) (1 in Hg) in 5 minutes, there is a leak in the
IMPORTANT: Use correct refrigerant recovery, system.
recycling and charging stations. 7. Repair leak.
fittings, components or refrigerant 8. Start to evacuate.
oils. 9. Open low side and high side valves.
1. Connect refrigerant recovery, recycling and 10. Evacuate system for 50 minutes after 98 kPa (980
charging system. bar) (29 in Hg) vacuum is reached.
2. Follow the manufactures instructions when using 11. Close low side and high side valves.
the refrigerant recovery, recycling and charging 12. Stop evacuation.
system.
13. Charge the system.
A
Evacuate R134A System
* CAUTION *
DO NOT remove high pressure relief valve (B). The air B
conditioning system will discharge rapidly causing C
possible injury. E
D
F G
IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations.
fittings, components or refrigerant
oils.
DO NOT run compressor while
evacuating.
I
H
1. Connect refrigerant recovery, recycling and
charging system.
2. Open low side and high side valves on refrigerant
recovery, recycling and charging system. A. High Pressure Switch
B. High Pressure Quick Disconnect
3. Follow the manufactures instructions and C. High Pressure Hose
evacuate the system. D. Low Pressure Hose
E. Red Hose
4. Evacuate system until low side gauge registers F. Low Side Test Port
98 kPa (989 bar) (29 in Hg) vacuum. The vacuum G. High Pressure Relief Valve
specifications listed are for sea level conditions. H. Refrigerant
Subtract 3.4 kPa (34 bar) (1 in Hg) from 98 kPa I. Recovery, Recycling and Charging System
0600-8
cp1999250002c
Air Conditioning System Test SPECIFICATIONS:

1. Connect air conditioning gauge set or refrigerant
recover, recycling and charging system (see C° (F°) Low Side High Side
installation procedure in this section.)
27° (80°) ....... 0.69-1.72 bar ......... 10.34-14.4 bar
2. Start engine and run at 1500 RPM. (10-25 PSI) (150-210 PSI)
3. Turn temperature control switch to the maximum 35° (95°) .......... 1.17-2.0 bar ........... 12.41-17.93
cooling position. (17-29 PSI) (180-260 PSI)
4. Turn blower switch to high speed.
5. Check sight glass in receiver/dryer.
6. Run unit for at least 5 minutes.
Charge R134A System

1. Connect refrigerant recovery, recycling and
charging system. (See installation procedure
in this section.)
2. Evacuate the system. (See Evacuate Air
Conditioning System in this section.)
3. Follow the manufacturers instructions and charge
the system.
4. Add refrigerant until system is charged with (5

lbs 8 oz)
5. Do air conditioner check and test for leaks.
Low Side High Side Discharge Discharge

Condition Kpa (Bar/PSI) Kpa (Bar/PSI) Sight Glass Suction Line Receiver-Drier Liquid Line Line Air
Lack of Very low Very low Clear Slightly Cool Slightly Warm Slightly Warm Slightly Warm Warm
Refrigerant
Loss of Low Low Bubbles Cool Warm to Hot Warm Warm to Hot Slightly Cool
Refrigerant
Lack of Normal Occasional
Refrigerant & (won't drop) Normal bubbles Warm to Hot Warm Warm Warm Slightly Cool
Air in System
Compressor High Low Clear Cool Warm Warm Warm Slightly Cool
Failure
Clear to
Condenser High High occasional Slightly Cool Hot Hot Hot Warm
Malfunction bubbles to Warm
Moisture in Normal Normal Clear Cool Warm Warm Hot Cool to Warm
System (may drop) (may drop)
Refrigerant
Contaminated High High Bubbles Warm to Hot Warm Warm Hot Warm
and Air in
System
Cold-sweating
Expansion High High Clear or frosting Warm Warm Hot Slightly Cool
Valve Open heavily
Cold-sweating
Expansion Low Low Clear or frosting Warm Warm Hot Slightly Cool
Valve Closed heavily at
valve outlet
0600-9
cp1999250002c
Air Conditioning Operational Checks 4. Are compressor mounting brackets in good

This procedure is designed so the mechanic can condition, and bracket bolts tight?
make a quick check of the system using a minimum 5. Are electrical connections to compressor
amount of diagnostic equipment. If you need additional clutch clean and tight? Is wiring to compressor
information, read Theory of Operation. in good condition?
The engine or other major components must be at Yes—Check complete.
operating temperature for some checks. No—Repair or replace component as required.
Locate system check, and read each check
completely before performing.
At the end of each check, if no problem is found, Ø Check Condenser:
that check is complete. When a problem is indicated, 1. Engine OFF.
additional checks or repair information will be given. 2. Inspect condenser cores.
3. Is condenser core free of dirt or debris?
4. Does condenser show signs of leakage, dust
Visual Inspection of Components accumulation or oily areas?
5. Are condenser fins straightNOT bent or
Ø Check Lines and Hoses: damaged?
1. Engine OFF. 6. Inspect engine fan. Are fan blades in good
2. Are lines and hoses straightNOT kinked or condition, not worn, bent, broken or missing?
Yes—Check complete.
worn from rubbing on other machine parts or
No—Clean, repair or replace condenser core. Replace
weather checked? engine fan.
3. Are hose and line connections clean NOT
showing signs of leakage, such as oil or dust
accumulation at fittings?
Ø Check Freeze Control Switch Sensing
4. Are all hose and line clamps in place and
Tube:
tightclamps must have rubber inserts or
1. Engine OFF.
cushions in place to prevent clamps from
2. Inspect switch sensing tube. Is sensing tube
crushing or wearing into hoses or lines?
straightNOT kinked or broken?
No—Reposition hoses or lines and tighten or replace 3. Is sensing tube inserted into evaporator core
clamps. Tighten fittings or replace hoses or lines as and secured in plate.
required. Yes—Check complete.
No—If sensing tube is kinked, replace clutch cycle
switch.
No—If tube is positioned in evaporator incorrectly,
Ø Check Evaporator Core: reroute.
1. Engine OFF.
2. Inspect core. Are fins straight?
3. Is evaporator core free of dirt and debris?
Ø Check Cab Door and Window Seals:
No—Repair, replace or clean evaporator.
1. Open and close door and windows. Inspect
seals.
2. Do door and windows contact seals evenly?
3. Are seals in position and in good condition?
Ø Check Air Conditioner Compressor:
1. Inspect compressor. Is compressor drive belt No—Adjust door and windows to close against seals
tight? properly. Replace seals as necessary.
2. Is belt in good conditionNOT frayed, worn
or glazed?
3. Is compressor belt pulley in good condition
NOT worn or grooved?
0600-10
cp1999250002c
System Operating Checks Ø Check High Pressure Switch:

1. Engine OFF. Key switch ON. Blower switch
Ø Check Blower Motor: on LOW. Air conditioning switch ON.
1. Engine OFF. Key switch ON. 2. Disconnect high pressure switch wiring leads.
2. Turn blower switch to LOW, MEDIUM, and 3. Does compressor clutch solenoid click when
HIGH. wiring leads are disconnected?
3. Does fan have three speeds? 4. Connect high pressure switch wiring leads to
4. Does air exit from ducts? harness.
Yes—Check complete. 5. Does compressor clutch solenoid click when
No—See Circuit Checks. Check wiring harness. wires are reconnected?
No—If compressor clutch solenoid does not “click”
Ø Check Heater: as specified, high pressure switch has failed. Replace
1. Start engine and allow to warm several high pressure switch.
minutes.
2. Turn heater temperature to maximum heat.
Turn blower switch to high speed. Ø Check Compressor Clutch:
3. Does warm air exit from ducts? 1. Engine OFF. Key switch ON. Blower switch
Yes—Check complete. on LOW.
No—See Circuit Checks. Check wiring harness. 2. Push air conditioner switch to OFF position.
Push air conditioner switch to ON position.
3. Does compressor clutch click as switch is
Ø Check Air Conditioner: pushed?
1. Start engine and run at full throttle. Yes—Check complete.
2. Turn air conditioner switch to ON position. No—Check air conditioner switch and harness.
Replace compressor clutch.
3. Turn blower switch to high speed.
4. Wait several minutes for any warm air in duct
system to escape.
5. Is air from ducts cool? System Performance Checks
No—See Blower/Air Conditioning Circuit Checks and Ø Check Evaporator:
Charging the System. 1. Is ice forming on evaporator core?
2. Is fan motor failing or fan blades damaged?
3. Is evaporator/heater sensing tube properly
Ø Check Low Pressure Switch: positioning in evaporator?
1. Engine OFF. Key switch ON. Blower switch 4. Is freeze control switch functioning?
on LOW. Air conditioning switch ON. 5. Is heater temperature control valve out of
2. Disconnect low pressure switch wiring leads. adjustment or damaged?
3. Does compressor clutch solenoid click when 6. Is evaporator drain tube free of kinks or
wiring leads are disconnected? restrictions?
4. Connect low pressure switch wiring leads to Yes—Check complete.
harness. No—Go to Freeze Control Switch Bench Test.
5. Does compressor clutch solenoid click as
wiring leads are reconnected?
No—If compressor clutch solenoid does not “click”
as specified, low pressure switch has failed. Replace
low pressure switch.
0600-11
cp1999250002c
Blower/Air Conditioning Circuit Low Refrigerant Pressure Switch Test
Ø Check Blower Switch: Switch Specifications:

1. Disconnect harness from blower switch.
2. Using a multimeter, check for continuity. Switch opening pressure .................... 220 ± 20 kPa
3. Move blower switch to LOW, MEDIUM and (2.2 ± 0.2 bar) (40 ± 3 PSI)
Switch closing pressure ...................... 280 ± 20 kPa
HIGH checking terminals B to L and C, B to
(2.8 ± 0.2 bar) (40 ± 3 PSI)
M and C and B to H and C. Is continuity
measured?
Yes—Blower switch is good. Go to next step.
Ø Service Equipment and Tools:
No—Replace blower switch.
Volt-Ohm-Amp Meter
1. Turn key switch ON but do not start engine. Turn
Ø Check Blower Resistor:
blower switch ON. Turn temperature control
1. Measure ohms between terminals 3 and 1.
switch to the maximum cooling position.
2. Does ohmmeter read 1.0 ohm?
3. Measure ohms between terminals 3 and 2. 2. Disconnect and connect low pressure switch
4. Does ohmmeter read 0.5 ohm? connector. Compressor clutch must engage and
Yes—Check Complete. disengage (click).
No—Replace resistor. Check wiring harness.
NOTE: Low pressure switch fitting has a valve
installed in it to prevent discharging the
air conditioning system when switch is
Ø Check Heater/Blower Motor:
removed.
1. Disconnect harness from heater blower motor.
3. Remove low pressure switch. Connect low
2. Connect 12 volt supply to heater blower
pressure switch connector. Compressor clutch
motor, and ground motor.
must NOT engage.
3. Does heater blower motor operate?
Yes—Check complete. 4. The actual pressure setting of switch can be
No—Replace heater blower motor. Check wiring checked by connecting it to a pressure source
harness. such as a regulated air supply or hydraulic hand
pump.
5. Switch must not have continuity between
Ø Check Freeze Control Switch:
terminals A and C until pressure increases to
1. Disconnect harness from switch.
switch closing pressure specification: 2.8 ± 0.2
2. Measure continuity across switch terminals.
bar (40 ± 3 PSI). Slowly release pressure, switch
Is continuity measured?
must have continuity until pressure decreases to
3. Remove switch from system.
switch opening pressure specification 2.2 ± 0.2
4. Measure continuity across switch terminals.
bar (40 ± 3 PSI).
Yes—Check Complete. Diagnosis charts are arranged from the most
No—Check temperature in evaporator core. probable and simplest problems to verify, to the least likely
If OK replace switch. Check wiring harness. to occur and most difficult to verify.
Ø Check Air Conditioning Compressor

Clutch Coil:
1. Disconnect harness from clutch.
2. Connect battery voltage to clutch terminal that
has orange wire. Ground black wire terminal.
3. Does clutch click?
Yes—Check Complete.
No—Replace clutch coil. Check wiring harness.
0600-12
cp1999250002c
Insufficient Heating 4. Air conditioner switch.

1. Faulty engine thermostat. Ø See system operating checks: Check Air
Ø Replace. conditioner switch (page 0611-10).
2. Foreign material in heater core or hoses. 5. Low pressure switch.
Ø Clean as required. Ø See system operating checks: Check low
3. Heater valve not working properly. pressure switch (page 0611-10).
6. High pressure switch.
Ø Replace valve.
4. Pressurizer blowers not working properly. Ø See system operating checks: Check High
pressure switch (page 0611-10).
Ø Check circuits.
7. Compressor clutch coil.
Ø Replace blowers if required.
5. Obstruction in air inlet. Ø See system operating checks: Check
Compressor Clutch (page 0611-10).
Ø Clean as required.
8. Wiring harness.
Ø Check filter element.
Ø See Blower/Air Conditioning Operational
Checks.
Inadequate Removal of Ice or Fog
1. Redirect air louvers.
Air Conditioner Does Not Cool Cab Interior
Ø Check effect if louvers are in different
1. Compressor belt loose.
positions.
2. Pressurizer blowers not working properly. Ø See Compressor Belt Tension adjustment.
2. Fresh air filter clogged.
Ø Check circuits.
Ø Replace blowers if required. Ø Clean or replace filter.
3. Heater valve not working properly. 3. Recirculating air filter clogged.
Ø Replace valve. Ø Clean or replace filter.
4. Refrigerant hose kinked, pinched or collapsed.
Ø Reroute, replace collapsed hoses.
Heater Valve Not Shutting Off Coolant Flow 5. Condenser fins clogged with debris.
1. Inlet and outlet hoses reversed.
Ø Clean condenser fins.
Ø Reverse hoses. 6. Heater or evaporator core fins clogged with dirt
2. Defective valve. or dust.
Ø Replace valve Ø Clean heater or evaporator core fins.
7. Heater/air conditioner blower motor failed or
operating too slowly.
Air Conditioning System Does Not Operate
1. Blower/compressor fuse. Ø See System Operating Checks: Check Blower
Motor (page 0611-10).
Ø Replace fuse. 8. Compressor clutch slipping or failed.
2. Blower switch
Ø Inspect and/or replace compressor clutch.
Ø See Blower/Air Conditioning circuit: Check 9. Warm outside air leaking into cab.
blower switch (page 0611-11).
3. Freeze control switch. Ø Inspect, repair or replace door and window
seals.
Ø See Blower/Air Conditioning circuit: Check 10. Heater valve remaining open.
freeze control switch (page 0611-11).
Ø Inspect, repair, adjust or replace heater valve.
11. System refrigerant charge low.
0600-13
cp1999250002c
Ø Inspect system for leaks, then recharge.

See Charge System (page 0611-8).
12. Evaporator fins frosting or freezing.
Ø Freeze control switch sensing tube not
positioned correctly.
Ø System has too much refrigerant. See
Evacuate and Recharge System (page 0611-
7).
13. Freeze control switch not operating properly.
Ø Inspect and/or replace freeze control switch.
Air Conditioner Runs Constantly, Too Cold

1. Freeze control switch failed or sensing tube not
positioned in evaporator correctly.
Ø Replace Freeze Control Switch. Reposition
sensing tube in evaporator core.
2. Heater valve closed completely.
Ø Inspect, adjust or replace heater valve.
3. Compressor clutch engaged constantly.
Ø Inspect and/or replace freeze control switch.
0600-14
cp1999250002c
Cab and Air Conditioner

1190330110
0600-15
cp1999250002c
SECTION 1000
ENGINE SYSTEM
Check Radiator Cap ................................................................................. 1000-3

Check Coolant Level and Condition ....................................................... 1000-3
Check Radiator Outside Air Flow ............................................................ 1000-3
Check Radiator Internal Core .................................................................. 1000-3
Check Radiator For Bubbles .................................................................... 1000-4
Check Fan Shroud and Fan Guard .......................................................... 1000-4
Check Fan ................................................................................................. 1000-4
Check Fan Belt ......................................................................................... 1000-4
Engine Will Not Crank .............................................................................. 1000-4
Engine Cranks But Will Not Start Or Is Hard To Start ............................ 1000-5
Engine Knocks, Runs Irregularly Or Stops ............................................ 1000-5
Engine Not Developing Full Power ......................................................... 1000-6
Engine Overheats ..................................................................................... 1000-7
Coolant Temperature Too Low ................................................................. 1000-7
Oil In Coolant Or Coolant In Crankcase .................................................. 1000-7
Low Engine Oil Pressure ......................................................................... 1000-7
High Engine Oil Pressure ........................................................................ 1000-8
Engine Uses Too Much Oil ...................................................................... 1000-8
Oil Dripping From Turbocharger Adapter ............................................... 1000-8
Excessive Drag In Turbocharger Rotating Members .............................. 1000-8
Engine Uses Too Much Fuel .................................................................... 1000-9
Excessive Black Smoke ........................................................................... 1000-9
Excessive Blue Or White Smoke ............................................................. 1000-9
Detonation ................................................................................................ 1000-9
Abnormal Noise ....................................................................................... 1000-9
Turbocharger Excessively Noisy Or Vibrates ......................................... 1000-10
Starter Circuit Electrical Schematic ........................................................ 1000-11
Engine Cranks Properly, But Does Not Start .......................................... 1000-12
Engine Will Not Crank .............................................................................. 1000-13
Engine Will Not Crank—Continued ......................................................... 1000-14
cp1999250002c
cp1999250002c
ENGINE SYSTEM
Check Radiator Cap 5. Is coolant and level ok?

* CAUTION * No—Add or replace coolant.
To avoid personal injury, DO NOT remove radiator cap Check Radiator Outside Air Flow
unless engine is cool. When engine is hot and cap is
removed, hot coolant or steam will spray out causing
1. Open grille to radiator.
serious burns. 2. Inspect fins for mud and debris.
1. Engine OFF. 3. Inspect radiator for bent or damaged fins.

2. Open upper radiator door. LOOKRadiator must be free of mud, leaves,
grass, and other debris.
3. Remove and inspect cap:
FEELThe radiator cap has a stop position and LOOKFins must be straight and not broken or
must be pushed down to turn and remove. cracked.
LISTENIf radiator is warmer than air 4. Is radiator ok?
temperature a whoosh must be heard when
cap is turned to first stop. Yes—Go to next check.
No—Clean outside of radiator; straighten fins. Replace
LOOKCap must have a good seal and gasket. radiator if severely damaged.
The seal must turn freely and spring must not be
corroded.
LOOKThe vacuum release valve (in center * CAUTION *
of seal) must move freely and holes must not be To prevent personal injury, DO NOT remove cap unless
plugged. engine is cool.
NOTE: If vacuum release valve is plugged, the

upper radiator hose may collapse when
the engine is stopped and radiator is Check Radiator Internal Core
cooling. 1. Open upper radiator door.
4. Is cap and vacuum release valve ok?
2. Remove radiator cap.
No—Replace radiator cap. 3. Drain coolant into a clean container until core
tubes are visible.
4. Inspect radiator core.
* CAUTION *
DO NOT remove high pressure relief valve (B). The air LOOKRadiator core must be free of rust or
conditioning system will discharge rapidly causing corrosion and passages in core must NOT be
possible injury.
plugged.
5. Is radiator core ok?
Yes—Go to next check.
No—Remove and clean radiator or replace radiator.
Check Coolant Level and Condition Refill cooling system with correct coolant.
1. Engine OFF. Engine cold.
2. Remove radiator cap.
3. Inspect coolant level.
4. Inspect coolant condition:
LOOKWith engine cold, coolant level must
be just below filler neck in radiator.
LOOKCoolant must NOT be oily, foamy, or
rusty.
1000-3
cp1999250002c
ENGINE SYSTEM
Check Radiator For Bubbles 3. Is fan ok?

1. Fill radiator to proper level. Yes—Go to next check.
2. Install radiator cap and tighten. No—If blades are bent, replace fan. If blades are nicked,
repair. Remove and install fan correctly.
3. Operate engine until it is at normal operating
temperature. Check Fan Belt
4. Place radiator overflow tube in a clear jar of 1. Inspect condition of belts.
water. LOOKThere must NOT be any oil or grease
5. Operate engine at full throttle. Operate any on fan belt or pulley. Inside surface of belt must
hydraulic function over relief setting to load NOT have any cracks or contact bottom of pulley
engine. groove.
LOOKBubbles from overflow tube should 2. Check fan belt for tightness.
flow intermittently. LOOK AND FEELBelt deflection must be
6. Are bubbles flowing intermittently? ½ with a 15 lb push.
Yes—Check complete. 3. Is belt ok?
No—If there is a constant flow of bubbles, a loose Yes—Check complete.
cylinder lead or a damaged head gasket could be No—Adjust belt deflection or replace belt.
indicated. Go to CTM-8 for engine repair.
Diagnostic charts are arranged from the most

Check Fan Shroud and Fan Guard probable and simplest problems to verify, to the least
1. Check fan-to-fan shroud clearance. likely to occur and more difficult to verify.
2. Inspect fan guard.
LOOKFan must be centered in fan shroud.
Engine Will Not Crank
LOOKGuard must NOT be bent or damaged. 1. Battery disconnect switch off.
All mounting brackets must be intact and all
hardware must be tight. Ø Turn switch on.
2. Low battery power.
3. Is fan and guard ok?
Ø Check charging circuit. Charge or install new
Yes—Go to next check. batteries.
No—Center fan in fan shroud. Repair or replace guard.
3. Resistance in starting circuit.
Tighten hardware.
Ø Clean and tighten battery and starter
connections. Check ground connections.
Check Fan 4. Starter malfunction.
1. Inspect fan blades for damage.
Ø Replace starter.
LOOKFan blades must not have any nicks or 5. Start circuit.
bends.
Ø Check start cable relay, key switch and
2. Check fan for correct installation. wiring harness connections. Replace as
LOOKCupped portion of fan blades must be required.
toward radiator. 6. Neutral start switch.
NOTE: If fan is installed backwards, about 50% Ø Check hydrostatic lever in neutral.
of its capacity is lost.
1000-4
cp1999250002c
ENGINE SYSTEM
Engine Cranks But Will Not Start or Is Hard 16. Electric shut-off.
To Start Ø Check shut-off solenoid. Inspect wiring and
1. No fuel. linkage. See your authorized injection pump
Ø Add fuel. Bleed air. service center. Perform safety shut-off check.
2. Wrong fuel. 17. Injection pump.
Ø Use correct fuel. Ø Remove and test pump. See your

3. Water in fuel or water frozen in fuel line. authorized injection pump service center.
18. Injection nozzle(s).
Ø Drain water from fuel tank trap. Inspect fuel
filter for water. Change filter. Ø Remove and test nozzles.
4. Fuel tank vent cap clogged. 19. Starter.
Ø Loosen cap and listen for air entering tank. Ø Replace starter.
Install new cap. 20. Worn compression rings or low compression.
5. Fuel filter plugged. Ø Check compression.
Ø Replace fuel filter. Bleed air. Clean fuel tank 21. Blown head gasket.
strainer. Ø Route tube between radiator and overflow than
6. Debris in fuel. into container of fluid and check for bubbles.
Ø Drain fuel tank. Clean tank strainer. Add clean Bubbles indicate head gasket leakage.
fuel.
7. Air in fuel system.
Engine Knocks, Runs Irregularly or Stops
Ø Check for bubbles in fuel filter and tighten 1. Air in fuel.
connections. Bleed air.
8. Fuel pump primer lever left up. Ø Inspect filter for evidence of air in fuel.
Tighten connections and bleed fuel
Ø Push primer lever down. system.
9. Fuel pump diaphragm leaking. 2. Engine oil low.
Ø Check engine oil for fuel dilution. Replace Ø Find source of oil consumption and repair
fuel pump. as required.
10. Fuel pump pressure. 3. Fuel tank vent cap clogged.
Ø Check fuel pump pressure. Ø Remove cap and listen for sound of air
11. Low battery power. entering tank. Install new cap.
Ø Charge or install new batteries. 4. Debris in fuel.
12. Slow cranking speed (poor electrical connection). Ø Drain fuel tank. Clean tank strainer. Add clean
ØClean and tighten battery and starter connections. fuel.
Incorrect engine oil (cold weather). 5. Wrong fuel.
13. Wrong engine oil (cold weather). Ø Use correct fuel.
6. Water in fuel.
Ø Use correct oil.
14. Air filter plugged. Ø Drain tank water trap. Inspect filter element
for water. Replace filters.
Ø Check air filter restriction indicator and air 7. Fuel filter plugged.
filter elements. Clean.
15. Injection pump metering valve sticking. Ø Replace filter.
8. Air intake system restricted.
Ø Lightly tap injection pump housing. If engine
now starts, repair metering valve. See your Ø Clean filter and system.
authorized injection pump service center.
1000-5
cp1999250002c
ENGINE SYSTEM
9. Return line from injection pump to tank restricted. Engine Not Developing Full Power
1. Fuel filter plugged.
Ø Route return line at the pump into a separate
container. If engine now operates normally, Ø Change filter. Bleed air.
check return line to tank of restriction. 2. Air filter plugged.
Replace.
10. Fuel injection pump out of time. Ø Clean or replace air cleaner elements.
3. Clogged vent in fuel tank cap.
Ø Time injection pump.
11. Restrictor fitting on top fitting in injection pump Ø Inspect. Install new cap.
plugged. 4. Debris in fuel.
ØDrain fuel tank. Clean tank strainer.
Ø Remove, inspect and clean. Determine source
5. Wrong fuel.
of debris. See your authorized injection pump
service center. Ø Use correct fuel.
12. Injection pump metering valve sticking. 6. Fuel tank outlet fitting plugged.
Ø Remove pump top cover and inspect. Replace Ø Clean.
metering valve. See your authorized injection 7. Fast idle speed incorrect.
pump service center.
13. Idle speed adjustment too low. Ø Do fast idle speed adjustment.
8. Area between turbocharger and manifold has air
Ø Adjust slow idle speed. leaks.
14. Engine overheating.
Ø Repair.
Ø Test cooling system. 9. Turbocharger malfunction.
15. Fuel pump.
Ø Inspect and repair. See your authorized dealer.
Ø Test pump pressure. 10. Hydraulic system leakage.
16. Fuel injection pump.
Ø Repair leak.
Ø Remove and test fuel injection pump. See your 11. Fuel line to pump or pump return to tank
authorized injection pump service center. restricted.
17. Injection nozzle(s).
Ø Check, repair.
Ø Remove and test nozzle(s). 12. Fuel pump.
18. Improper valve clearance.
Ø Do fuel pump pressure test.
Ø Check and adjust valve clearance. 13. Timing incorrect.
19. Valve sticking or burned.
Ø Check injection pump timing. See Service
Ø Do compression pressure test. Manual.
20. Bent push rods. 14. Injection nozzles.
Ø Inspect. Replace. Ø Remove and test injection nozzles. See
21. Worn or broken compression rings or cylinder Service Manual.
head gasket leaking. 15. Low compression.
Ø Route tube between radiator and overflow Ø Do compression pressure test. See Service
tank into a container or fluid and check for Manual.
bubbles. Bubbles indicate head gasket 16. Injection pump delivery or governor.
leakage.
Ø Repair pump. See your authorized injection
pump service center.
17.Valves burned, warped.
Ø Repair valves.
1000-6
cp1999250002c
ENGINE SYSTEM
Engine Overheats Coolant Temperature Too Low

1. Coolant level low. 1. Thermostat stuck open.
Ø Fill cooling system and check for leaks. Ø Replace thermostat.
2. Thermostat stuck closed or missing. 2. Temperature gauge.
Ø Test and/or reinstall. Ø Install new gauge or sending unit.
3. Radiator plugged.
Ø Remove and clean.
Oil In Coolant or Coolant In Crankcase
4. Radiator oil cooler cores plugged with dirt or fins
1. Oil cooler leaking.
bent.
Ø Test, repair.
Ø Check air flow. Clean radiator. Straighten fins.
2. Intercooling leaking.
5. Air filter plugged.
Ø Clean or replace elements.
3. Head gasket leaking.
6. Gauge or sender.
Ø Inspect and replace.
Ø Check gauge and sender.
4. Cylinder head cracked.
7. Fan belts loose, belts soaked with oil or pulleys
worn excessively. Ø Check, replace.
5. Liner packing leaking and/or cracked cylinder
Ø Inspect, replace. See Operators Manual or
block.
Repair Manual.
8. Shroud or baffles missing. Ø Remove pan, inspect bottom end, repair, verify
and replace if necessary.
ØInspect. Repair or replace.
9. Fan blade on backward.
Ø Reinstall. Low Engine Oil Pressure
10. Fan belt loose. 1. Oil level low.
Ø Adjust. Ø Fill.
11. Radiator cap or water in radiator. 2. Oil filter plugged.
Ø Test, replace cap. Ø Install new oil filter.
12. Operating in wrong mode. 3. Oil pump intake screen plugged or loose.
Ø Use correct operating mode. Ø Clean or tighten.
13. Hydraulic system overheating. 4. Wrong grade of oil or fuel dilution.
Ø Verify, repair Ø Use correct grade of oil. Refer to Operators
14. Cooling system passages dirty. Manual.
5. Engine oil pressure regulating valve.
Ø Flush cooling system.
15. Water pump. Ø Repair valve.
6. Oil pump gear and/or housing worn.
Ø Repair.
16. Fuel injection pump timing. Ø Repair.
7. Excessive main or connecting rod bearing
Ø Check injection pump timing.
clearance.
17. Fuel delivery excessive.
Ø Replace main bearings or connecting rod
Ø Remove and adjust fuel injection pump. See
bearings.
your authorized injection pump service center.
1000-7
cp1999250002c
ENGINE SYSTEM
High Engine Oil Pressure Oil Dripping From Turbocharger Adapter

1. Oil viscosity wrong (too thick). 1. Engine not to operating temperature.
Ø Drain and refill with correct oil. Refer to Ø Bring engine up to operating temperature.
Operators manual. 2. Damaged or worn bearings and/or worn seals.
2. Pressure regulating valve stuck or improperly
Ø Inspect compressor and turbine wheel for
adjusted.
damaged blades. Check for proper engine
Ø Verify, repair. service intervals or dirt entering engine.
3. Piston cooling spray orifices plugged. 3. Excessive crankcase pressure.
Ø Check, clean. Ø Check for plugged oil drain line. Clean.
4. Engine oil has antifreeze. 4. Turbocharger oil return line carbon buildup
where line passes exhaust manifold.
Ø Verify, repair. Change oil.
Ø Remove line. Inspect and clean.
Engine Uses Too Much Oil

1. Wrong oil. Excessive Drag In Turbocharger Rotating
Ø Use correct oil. Refer to Operators Manual. Members
2. Oil level too high. 1. Carbon buildup behind turbine wheel caused by
combustion deposits.
Ø Correct. Check to see if some other fluid is
leaking into oil. Ø Inspect and clean.
3. Oil leaks. 2. Dirt buildup behind compressor wheel caused by
air intake leaks.
Ø Check engine oil drain plug.
4. Air cleaner plugged. Ø Inspect and repair.
3. Bearing seizure or dirty or worn bearing caused
Ø Clean air cleaner elements or install new by excessive temperature, unbalanced wheel,
elements. dirty oil, starvation, or insufficient lubrication.
5. Crankcase breather restricted.
Ø Check for plugged air filter.
Ø Remove, clean. 4. Pistons or liners scored.
6. Engine operating too hot or oil cooler water
Ø Check, repair pistons or liners.
passage plugged.
5. Piston rings worn, broken or stuck.
Ø Test cooling system.
Ø Do compression pressure test.
7. Main or connecting rod bearing clearance
6. Oil return slots in piston clogged.
excessive.
Ø Clean.
Ø Replace main bearings or connecting rod
7. Crankshaft thrust bearing worn (misaligned
bearing.
piston and rod).
8. Air leak in engine, intake or exhaust manifold.
Ø Check piston and rod assembly.
Ø Inspect and repair.
8. Valve guides or valve stems worn.
9. Improper clearance between turbine wheel and
turbine housing. Ø Check, repair.
Ø Remove exhaust elbow and air inlet hose.
Inspect and repair.
10. Broken blades on turbine.
Ø Remove exhaust elbow and air inlet hose.
Inspect and repair.
1000-8
cp1999250002c
ENGINE SYSTEM
Engine Uses Too Much Fuel Excessive Blue or White Smoke

1. Engine overloaded. 1. Cranking speed too slow.
Ø Check by reducing load. Ø Check batteries and connections.
2. Fuel system leakage. 2. Injection pump timing.
Ø Tighten connections. Ø Check injection pump timing.
3. Air system restricted. 3. Engine running too cold.
Ø Repair, clean filters. Ø Check thermostat.
4. Plugged or dirty air intake. 4. Wrong fuel.
Ø Clean air intake system. Ø Use correct fuel.
5. Wrong fuel. 5. Liners have wear and/or piston ring stuck.
Ø Use correct fuel. Ø Do compression pressure test.
6. Injection pump timing.
Detonation
7. Injection nozzles.
1. Fuel injection pump timing incorrect and/or
Ø Test, repair nozzles. injection pump advance faulty.
Excessive Black Smoke
1. Engine overloaded.
Abnormal Noise
Ø Check by reducing load. 1. Oil level low.
2. Wrong fuel.
Ø Check and add oil.
Ø Use correct fuel. 2. Wrong engine oil.
3. Plugged or dirty air intake or exhaust system.
Ø Use correct oil.
Ø Clean air intake and exhaust system. 3. Engine oil diluted with fuel.
4. Injection pump timing.
Ø Inspect engine oil. Inspect fuel pump spindle,
Ø Check injection pump timing. seal and housing.
5. Over-fueling. 4. Valve clearance excessive.
Ø Remove and adjust fuel injection pump. See Ø Check, adjust valve.
your authorized injection pump service center. 5. Engine timing incorrect.
6. Injection nozzle orifice plugged.
Ø Check, adjust.
Ø Check and repair. 6. Push rods bent.
Ø Inspect, replace push rods.
7. Main and/or connecting rod bearing caps loose
or worn.
Ø Inspect main bearing cap screws and
connecting rod cap screws.
8. Piston scored.
Ø Replace piston.
9. Piston pin bushings worn.
Ø Replace pins and bushings.
1000-9
cp1999250002c
ENGINE SYSTEM
Turbocharger Excessively Noisy or

Vibrates
1. Bearings not lubricated.
Ø Insufficient oil pressure. Check for restricted
turbocharger oil line.
2. Worn bearings.
Ø Replace.
1000-10
cp1999250002c
Starter Circuit
1190330145
1000-11
ENGINE SYSTEM
cp1999250002c
ENGINE SYSTEM
Engine Cranks Properly, But Does Not Start

Electrical Check
Check fuel solenoid fuse

Replace fuse and
located below dash in No check for a shorted
fuse panel.
circuit or component.
Is fuse good?
Yes
Measure voltage at No
fuel solenoid fuse. Check wire harness. Refer to
Is 12 VDC measured? Ignition Diagnostic Chart.
Yes
No
Check safety shutoff fuse. Replace fuse and check for a
Is fuse good? shorted circuit or component.
Yes
Measure voltage at safety No

shutoff fuse. Check wire harness. Refer to
Is 12 VDC measured? Ignition Diagnostic Chart.
Yes
1. Check ground connected at fuel
1. Depress safety shutoff button. solenoid: Is a 14 gauge white
2. Turn key switch to IGN. Yes 2. CUMMINS ONLY!!! Place key switch in No wire connected to
3. Check voltage of yellow wire at cranking position. Check voltage of starter motor
fuel solenoid. white wire. terminal or to S
Is 12 VDC measured? Is 12 VDC measured? terminal on starter
solenoid?
No Yes
Yes
1. Remove fuel solenoid relay.
No Check red wire between
2. Measure voltage of red wire
fuel solenoid fuse and Replace solenoid.
at terminal 30.
terminal 30.
Is 12 VDC measured?
Yes
1. Check black/white wire for a 1. Check ground connection on 1. Depress safety button.
good ground connection. No terminal G of safety shutoff Yes 2. Measure voltage at
2. Depress safety shutoff button. switch. terminal NC on safety
3. Turn key switch to IGN. 2. Turn key switch to IGN. shutoff switch.
4. Measure voltage of blue wire at 3. Measure voltage at terminal Is 12 VDC measured?
fuel solenoid relay terminal 86. B.
Is 12 VDC measured? Is 12 VDC measured? No
Yes
Yes No Change switch.
Change fuel solenoid relay or Check red/white wire

check the 12 gauge yellow wire Check blue wire
between safety shutoff fuse
between relay and fuel solenoid. between safety
and safety shutoff switch.
shutoff button and
fuel solenoid relay.
1000-12
cp1999250002c
ENGINE SYSTEM
Engine Will Not Crank

Electrical Check
1. Disengage harvesting functions. Check the 30 amp battery fuse.

2. Turn key switch to IGN and engage No Check connections of battery
park brake. cable and recharge battery.
Is voltmeter on dash registering Refer to Battery Diagnostic Chart.
between 12.2 V and 12.7 V?
Yes
Yes No Check connections and

Turn key switch to START. Is RPM greater than 100? recharge battery. Refer to
Is engine cranking? Battery Diagnostic Chart.
Yes
No Refer to engine cranks but does not start Electrical Check
1. Ensure the ground drive forward/

reverse handle is in neutral. No Return handle to If engine will not start, go to
2. Ensure that harvesting functions neutral or adjust Safety Shutdown Diagnostic
are disengaged. ground drive cable. Chart.
Are these conditions met?
Yes
No Continued
Does engine crank now?
on next page
Yes
Done.
Located in cab and

inside the console.
Starter Solenoid
Relay
1000-13
cp1999250002c
Engine Will Not Crank—Continued
Continued
from
previous
page.
Go to console in cab and 1. Turn key switch to START.
No measure voltage of start relay No 2. Measure voltage of 10 No Replace fuse. Refer to No Replace
Does engine
white/black wire while cranking amp start fuse. Ignition Switch Check. switch.
crank now?
engine. Is 12 VDC measured? Is switch good?
Is 12 VDC measured?
Yes Yes
Yes
1. Disconnect multiconnectors at Ensure the white/black wire
neutral start switches. between the fuse and switch
1. Ensure black/white wire for ground
2. Measure voltage of white/black wire. is clean and tightly connected.
is clean and tightly connected.
2. Ensure red power wire at starter Is 12 VDC measured?
relay is clean and tightly connected.
3. Measure voltage at red power wire. Yes No
Is 12 VDC measured?
Check white/black wire between
Perform a switch check start fuse and safety start switches.
Yes No
on neutral start switches.
1000-14
Check red power wire Are switches good? No Replace starter relay.
1. Ensure the white wire at the starter between starter and
solenoid is clean and tightly connected. starter relay. Located in cab and
ENGINE SYSTEM
Yes inside the console.

2. Place key switch in START.
3. Measure voltage at starter(s) terminal
white wire. Ensure the white/black wire between Starter Solenoid
Is 12 VDC measured? starter relay and neutral start switches Relay
are clean and tightly connected.
Yes
No
Repair or replace starter
motor/solenoid unit.
Repair or replace battery

cable or components.
cp1999250002c
SECTION 1400
ELECTRICAL SYSTEM
Visually Inspect Electrical System .......................................................... 1400-5
Safety Precautions ................................................................................... 1400-5
Alternator and Battery .............................................................................. 1400-7
Cleaning Battery Posts ............................................................................. 1400-7
Jumping the Battery ................................................................................. 1400-7
Charging The Batteries ............................................................................ 1400-8
Precautions For Alternators .................................................................... 1400-8
Electrical Lighting Theory of Operation .................................................. 1400-8
Oil Pressure Sending Unit ....................................................................... 1400-10
Oil Pressure Switch ................................................................................. 1400-10
Engine Coolant Temperature ................................................................... 1400-10
Gauge Sender ........................................................................................... 1400-10
Engine Coolant Temperature Switch ....................................................... 1400-10
Hydraulic Oil Temperature Sender .......................................................... 1400-11
Fuel Sending Unit .................................................................................... 1400-11
Hydraulic Filter Pressure Switch ............................................................. 1400-11
Air Filter Restriction Switch .................................................................... 1400-11
Front Solenoid 22 Pin Connector Breakout ............................................ 1400-13
Engine 22 Pin Connector Breakout ......................................................... 1400-14
Elevator 22 Pin Connector Breakout ....................................................... 1400-15
Battery Visual Inspection ......................................................................... 1400-16
Battery Hydrometer Test ........................................................................... 1400-16
Battery Load Test ...................................................................................... 1400-16
Ignition Switch Check .............................................................................. 1400-17
Diode Check ............................................................................................. 1400-17
Switch Check ............................................................................................ 1400-17
Switch Check ............................................................................................ 1400-18
Joystick Switch Check: Horn ................................................................... 1400-19
Joystick Switch Check: Lh Scroll Up/Down ............................................ 1400-19
Joystick Switch Check: Rh Scroll Up/Down ........................................... 1400-19
Check Relay .............................................................................................. 1400-20
Solenoid Check Number One .................................................................. 1400-20
Solenoid Check Number Two .................................................................. 1400-20
Fuse Breaker Check ................................................................................. 1400-21
Relay Check .............................................................................................. 1400-21
Starter Solenoid Check ............................................................................ 1400-21
Fuse Breaker Check ................................................................................. 1400-22
Head Light Switch and Warning Switch Check ....................................... 1400-22
Turn Signal Switch Check ....................................................................... 1400-22
Primary Extractor Fan Tachometer Check: Operation ............................ 1400-23
Engine Tachometer Check: Operation ..................................................... 1400-23
Engine Tachometer Check ....................................................................... 1400-23
Elevator On/Off Switch ............................................................................ 1400-24
Elevator On/Off Switch ............................................................................ 1400-24
Reverse Alarm And Brake Pedal Switches ............................................. 1400-24
Air Cleaner Restriction Indicator ............................................................. 1400-24
Hydraulic Filter Restriction Indicator ...................................................... 1400-25
Hydraulic Float Level Check .................................................................... 1400-25
cp1999250002c
cp1999250002c
SECTION 1400
ELECTRICAL SYSTEM (CONTINUED)
Cab Harness ............................................................................................. 1400-26
Positrac Circuit (Wheel) Electrical Schematic ........................................ 1400-27
Starter Circuit Electrical Schematic ........................................................ 1400-28
Cab and Air Conditioner Electrical Schematic ....................................... 1400-29
Elevator Control Electrical Schematic ................................................... 1400-30
Gauges Electrical Schematic .................................................................. 1400-31
Turn Signal Light Circuit Electrical Schematic ...................................... 1400-32
Primary Extractor Tachometer Electrical Schematic .............................. 1400-33
Reverse Alarm Track & Wheel Electrical Schematic ............................... 1400-34
Horn Electrical Schematic ....................................................................... 1400-35
Safety Shutdown Electrical Schematic ................................................... 1400-36
Park Brake Circuit Electrical Schematic ................................................. 1400-37
Crop Divider Electrical Schematic .......................................................... 1400-38
Topper and Side Knives Electrical Schematic ....................................... 1400-39
Basecutter and Chopper Electrical Schematic ....................................... 1400-40
Primary Extractor Electrical Schematic .................................................. 1400-41
Chopper/Height Indicator Lights Electrical Schematic .......................... 1400-42
Electrical System Has Low Voltage Problem .......................................... 1400-43
Ignition Power Problem ........................................................................... 1400-44
Front Working Lights Do Not Operate ..................................................... 1400-45
Accessory Power Problem ...................................................................... 1400-46
Radiator Level Light and Buzzer Stay On ............................................... 1400-47
Radiator Level Light and Buzzer Do Not Activate .................................. 1400-47
Side Working Lights Do Not Operate ...................................................... 1400-48
Elevator Working Lights Do Not Operate ................................................ 1400-49
Warning Lights Do Not Work .................................................................... 1400-50
Tail Lights Do Not Operate ...................................................................... 1400-51
Dash Lights Do Not Operate .................................................................... 1400-52
Headlights Do Not Operate ...................................................................... 1400-53
Safety Shut Down Button Will Not Remain In The Depressed Position .
After Engine Start-Up ............................................................................ 1400-54
Safety Shut Down Button Will Not Remain In The Depressed Position .
After Engine Start-Up ............................................................................ 1400-55
Oil Pressure Light Stays On .................................................................... 1400-56
Water Temperature Buzzer Stays On ....................................................... 1400-57
Engine Air Filter Indicator Stays On ....................................................... 1400-58
Engine Air Filter Indicator Does Not Light ............................................. 1400-59
Hydraulic Filter Restriction Indicator Does Not Go “Out” ..................... 1400-60
Hydraulic Filter Restriction Indicator Does Not Work. ............................ 1400-61
Hydraulic Oil Temperature Gauge Does Not Register ............................ 1400-62
Water Temperature Gauge Does Not Register ......................................... 1400-63
Fuel Gauge Does Not Register ................................................................ 1400-64
Oil Pressure Gauge Does Not Register ................................................... 1400-65
Battery Voltage Gauge Does Not Register ............................................... 1400-66
Primary Extractor Digital Tachometer Does Not Function. .................... 1400-67
Primary Extractor Tachometer Reading Does Not Match Fan Speed. ... 1400-67
Reverse Alarm Does Not Sound .............................................................. 1400-68
Windshield Washer Does Not Operate ..................................................... 1400-69
cp1999250002c
cp1999250002c
ELECTRICAL SYSTEM
Visually Inspect Electrical System 7. If your visual inspection does not indicate the
Make the following visual electrical inspection prior possible malfunction, but your inspection does
to starting the harvester: indicate that the machine can be run, turn the key
switch to IGN. Try out the accessory circuits,
* CAUTION * indicators, lights and gauge lights, etc. How does
Wear eye protection and remove rings, metal each of these components work? Look for sparks
watch bands and other metal jewelry when working or smoke which might indicate shorts.
on the electrical system.
8. Start harvester. Check all gauges for good
operation and check to see if system is charging
cm19989999014
or discharging.
9. In general, look for anything unusual. Many
electrical failures cannot be detected even if the
combine is running. Therefore, a systematic and
complete inspection of the electrical system is
necessary.
* CAUTION *
Explosive gas is produced when a battery is in
use or being charged.
1. Look for bare wires that could ground a

component or short across to another component.
2. Look for a missing or worn conduit. This could
indicate a wire problem.
3. Look for loose or broken connectors and wires.
Safety Precautions
4. Inspect batteries for:
1. Keep all flames/sparks away from battery.
Ø Corroded terminals. 2. Charge battery in a well-ventilated area.
Ø Loose terminals or battery posts.
Ø Dirty condition. 3. Always remove negative (-) battery cable first
and replace it last.
Ø Cracked case.
Ø Proper electrolyte level. 4. Never lay a metal object on top of a battery: a
short circuit can result, damaging the battery and
5. Check alternator belt tension. metal object.
6. After combine has been shut down for five 5. If acid spills on clothing, immediately remove
minutes inspect for overheated parts. They will clothing.
often smell like burned insulation. Put your hand 6. If acid contacts skin, rinse affected area with
on the alternator. Heat in these parts when the running water for 1-15 minutes.
unit has not been operated for some time is a
sure clue to charging circuit problems.
1400-5
cp1999250002c
ELECTRICAL SYSTEM
7. If acid splashes into eyes, hold eyelids open and

flood eyes with running water for 10-15 minutes, * CAUTION *
Sulfuric acid in battery electrolyte is poisonous.
then see a doctor at once. DO NOT use any Electrolyte can cause severe burns if it contacts the
medication or eye drops unless prescribed by a eyes or skin. Always wear eye protection when working
doctor. around electrolyte.
8. To neutralize acid spilled on the floor or harvester,

flood the spill with one of the following mixtures,
then rinse thoroughly with clean water:
Ø 0.5 kg (1 lb) of baking soda in 4 L (1 gal) of
water
Ø 0.4 (1 pt) of household ammonia in 4 L (1 gal)
of water.
Battery Specifications:
Your combine is equipped with a negative ground

electrical system. It uses 12 volt batteries. Use only
batteries meeting the following specifications:
Part Number ......................................... 0360030641

BCI Group Size .................................... 31
Cold cranking amps at -18°C (0°F) ...... 925
Reserve capacity at 25 amps ............... 190 minutes
1400-6
cp1999250002c
ELECTRICAL SYSTEM
ALTERNATOR AND BATTERY Cleaning Battery Posts
* CAUTION *
Always remove the grounded (-) battery. Clamp
it first and replace it last.
1. Disconnect battery clamps, grounded (-) clamp

first, and wipe clean with a damp cloth.
2. If terminals are corroded, wash with a stiff brush
and an ammonia solution.
3. After washing, flush battery and compartment
with clear water. Keep caps in place while
cleaning.
4. Apply lubricating grease around the battery
terminal base only.
Theory of Operation
5. Install and retighten clamps; grounded clamp last
A battery is a device for converting chemical energy
(-).
to electrical energy. It is not a storage tank for electricity,
but stores electrical energy in chemical form.
Because of the constant chemical to electrical
change, the battery has a limited life. Proper care will Jumping the Battery
extend the life of the battery. 1. When possible, use equipment with a switch in
In a fully charged battery, the electrolyte solution is the line connecting the booster battery to the
approximately 1.27 times heavier than water. The amount battery to be jumped.
that the solution is heavier than water is called specific
2. Connect the booster cable to the batteries in
gravity.
parallel (positive to positive and negative to
All batteries will self-discharge over a period of time.
negative).
Temperature and amount of time will both determine the
rate of discharge. If a machine is not used for a period of 3. Rock the connector clips to ensure that they are
time, the batteries must be stored in a cool place. fastened securely
The batteries provide the energy to start the engine 4. If only jumper cables are available, always make
and power the electrical loads when they exceed the the last connection from the negative terminal of
alternators capacity. the booster battery to a ground point on the
The alternator provides power for the electrical
machine frame, away from the batteries.
equipment when the combine is running. If the electrical
load exceeds the alternators capacity for short periods,
the batteries will supply the necessary power as long as
possible.
The alternator is belt driven by the engine crankshaft
and can provide power immediately after start-up.
NOTE: Before diagnosing an alternator battery

problem, be sure accessory electrical
equipment has not been added that
might exceed the alternator’s capacity.
If excessive load has been added, the
ability to recharge the batteries could
be affected.
The Combine electrical system has a negative (-) ground.
1400-7
cp1999250002c
ELECTRICAL SYSTEM
Charging The Batteries NOTE: Halogen bulbs require special handling:

Touching the bulb can cause the bulb
to explode when it is turned ON. (When
* CAUTION * touched, oil from your skin remains on
DO NOT charge a battery if it is frozen — it may explode. the bulb that causes heat concentrations
Warm the battery to 10°C (50°F), before charging.
when turned on that can damage the
bulb.)
1. To start the engine using a battery charger; turn
off the charger before connecting and The light switch has three light positions:
disconnecting.
OFF .................................... All Lights Off
2. Do Not use a battery charger as a booster if the
battery has a 1.15 specific gravity reading or H ......................................... Head, Dash & Tail
lower.
F ......................................... Field, Head & Dash Lights
3. To charge a battery, disconnect positive and
negative cables before charging.
The service engine, warning, turn signal, head light
4. If a unit has more than one battery, each battery and light switch is connected directly to the battery through
must be charged separately. 10 amp light switch fuse. The turn signals and lights
operate when the turn/warning switch or light switch is
activated.
The turn signal/warning switch receives power
Precautions For Alternators
through the 12 V flasher. Power is supplied to the left
When batteries are connected follow these rules.
turn amber through turn signal switch green/yellow wire.
1. Disconnect the negative (-) cable when you work Power is supplied to the right turn amber through turn
on or near the alternator. signal switch green/white wire.
2. Do Not try to polarize the alternator. When the warning switch is turned on, current flows
through one amp diode to turn signal switch terminal 2B,
3. Be sure that alternator wires are connected 5B. The left and right amber will flash at a rate of 60
correctly before connecting batteries. FPM unless a turn signal direction is selected. When the
4. Do Not ground alternator output terminal. turn signal switch is turned to the left or right, while the
warning lights are ON, the amber will flash 60 FPM on
5. Do Not disconnect or connect any alternator wire the selected side. The opposite light will not flash; it will
while batteries are connected or while the stay continuously ON until the turn signal switch is turned
alternator is working. OFF. The turn signals will operate in both warning and
6. Connect batteries or booster battery in the correct highway light switch positions.
polarity (positive [+] to positive [+] and negative When the light switch is turned to H, current flows
[-] to negative [-]). from headlight switch terminal 3 through the brown wire
to terminal 86 and energizes the head light relay. The relay
7. Do Not disconnect the batteries when the engine
receives battery power through the head light fuse to
is running and the alternator is charging.
terminal 30. Once the relay is energized, current flows
8. Disconnect the battery cables before you connect from terminal 30 to terminal 87. The brown wire also
a battery charger to the batteries. supplies current to the engine tachometer light, the digital
tachometer, and the dash lights. Current is supplied to the
two tail lights through the purple/black wire.
When the light switch is turned to F, current flows
Electrical Lighting Theory of Operation
through the brown/white wire to terminal 86 and energizes
The lighting system has been designed to provide
the front work light relay, side work light relay, and elevator
area lighting for night operation and for low light conditions.
work light relay.
Many of the systems use halogen lights to provide the
most effective lighting. Some of these lights use halogen
bulbs.
1400-8
cp1999250002c
ELECTRICAL SYSTEM
The front work light relay receives power from the

battery. Current flows through the 30 amp front light
fuse to front work light relay terminal 30. Once the relay
is energized, current flows from terminal 30 to terminal
87. Current flows through the brown/white wire to each
flood light assembly to operate the work lights.
The side work light relay receives power from the
battery. Current flows through the 30 amp side light fuse
to side work light relay terminal 30. Once the relay is
energized, current flows from terminal 30 to terminal 87.
Current flows through the brown/white wire to each flood
light assembly to operate the work lights.
The elevator work light relay receives power from
the battery. Current flows through the 30 amp elevator
work light fuse to elevator work light relay terminal 30.
Once the relay is energized, current flows from terminal
30 to terminal 87. Current flows through the brown/white
wire to each flood light assembly to operate the work
lights.
The dome light, located above the operator, is
controlled by a switch mounted on the dome light assembly.
The dome light can be operated anytime the ignition switch
is on.
1400-9
cp1999250002c
ELECTRICAL SYSTEM
Oil Pressure Sending Unit Engine Coolant Temperature

Gauge Sender
Temperature Resistance
Pressure Resistance
38°C (100°F) .................................... 1000 Ohms
0 Bar (0 PSI) .................................... 240 Ohms
104°C (220°F) .................................. 87 Ohms
1.7 Bar (25 PSI) ............................... 153 Ohms
6.9 Bar (100 PSI) ............................. 33.5 Ohms
Oil Pressure Switch Engine Coolant Temperature Switch
Black wire—Normally close

White wire—Common
Red wire—Normally open
Red
Black
B
White
Normally Open Normally Open

Closes Above ................................. 0.83 Bar (12 PSI) Closes Above ....................................... 210°F
Normally Close Normally Close
Open Below .................................... 0.83 Bar (12 PSI) Open Above .......................................... 210°F
1400-10
cp1999250002c
ELECTRICAL SYSTEM
Hydraulic Oil Temperature Sender Hydraulic Filter Pressure Switch
Temperature Resistance Normally Open

100°F ............................................... 1000 Ohms Closes When A Pressure Of More Than 1.4 Bar
220°F ............................................... 87 Ohms (20 PSI) Is Measured.
Fuel Sending Unit Air Filter Restriction Switch

Fuel Gauge Reading Resistance
Full ............................................ 33.5 Ohms
Half ............................................ 103 Ohms
Empty ....................................... 240 Ohms
Normally Open
Closes Above ................................. 6.2 ± 1.2 KPaG
(25 ± 5 in H2O)
1400-11
cp1999250002c
ELECTRICAL SYSTEM
Head Ignition
Light Acc
Front Gnd
Work Acc
Light Bat
Side Work Gnd Elev Fwd

Light & Rev
2 1
Elev. HEAD LIGHT Elevator
Light 20A 30A BATTERY
Reset
FRONT
L I GH T
20A blank
Oil SIDE LIGHT
Parking
Press. 20A 30A CAB A/C
Brake
ELEVATOR LIGHT
Water
L I GH T 20A 10A SWITCH Parking
Brake
Temp. Reset
BREAKERS FUSES
Cab A/C 4 3 Horn

REV ALARM
Blower B/C (ON/OFF)
5A 10A BEACON
WIPER/DOM
RELAYS
ELEVATOR
5A 10A WASHER Fuel
Solenoid
BRAKE
5A 10A SEAT
RADIO
blank 5A ACCESSORY RELAYS
6 5
PRIMARY
POSITRAC
EXTRACTOR 5A 5A
SAFETY
TOPPER
SHUT OFF 5A 5A
GAUGES SIDE KNIFE
5A 5A
HORN JOYSTICK
10A 5A
8 7
FUEL
BIN FLAP
5A 20A SOLENOID
SECOND’Y
START
EXTRACTOR 5A 5A
ELEVATOR 12V SOURCE
LI F T 5A 10A / LIGHTER
blank 5A BATTERY
ACCESSORY
FUSES FUSES
Fuse & Relay Panel
1400-12
cp1999250002c
ELECTRICAL SYSTEM
Front Solenoid 22 Pin Connector Breakout
Wire Type No. From To

A Plug
B Plug
14 Ga. Violet C Basecutter Timer (Forward) #5 Basecutter Solenoid
14 Ga. Violet/Black D Basecutter Timer (Reverse) #8 Basecutter Solenoid
14 Ga. Blue E Topper Timer #5 (Left) Topper Solenoid
14 Ga. Blue/Black F Topper Timer #8 (Right) Topper Solenoid
G Plug
H Plug
14 Ga. Red I #87 Left Crop Divider Up Relay Left Crop Divider Solenoid
14 Ga. Red/Black J #87 Left Crop Divider Down Relay Left Crop Divider Solenoid
14 Ga. White K #87 Right Crop Divider Up Relay Right Crop Divider Solenoid
14 Ga. White/Black L #87 Right Crop Divider Down Relay Right Crop Divider Solenoid
14 Ga. Orange M S On Fuel Gauge Fuel Sending Unit
N Plug
14 Ga. Green O Left Side Knife Switch (A) Forward To Left Side Knife Solenoid
14 Ga. Green/White P Left Side Knife Switch (C) Reverse Left Side Knife Solenoid
14 Ga. Brown Q Right Side Knife Switch (A) Forward Right Side Knife Solenoid
14 Ga. Brown/Black R Right Side Knife Switch (C) Right Side Knife Solenoid
14 Ga. Red/White S Positrac Fuse Brake Pedal Switch (A) and to Positrac Switch (A)
14 Ga. Green/White T Brake Pedal Switch (C) Engine 22 Pin Connector To Positrac Solenoid
12 Ga. Black U Disconnect Switch Solenoid Ground
14 Ga. Yellow/Blue V Washer Switch Washer Pump
1400-13
cp1999250002c
ELECTRICAL SYSTEM
Engine 22 Pin Connector Breakout
Wire Type No. From To

12 Ga. Yellow A # 87 Fuel Solenoid Relay Fuel Solenoid
14 Ga. Yellow/Blue B S On Oil Temp Gauge Oil Temp Sending Unit
14 Ga. Red/White C Reverse alarm fuse Reverse alarm switch
14 Ga. Yel/Blk/Grn D # 85 Water Temp Relay Water Temp Switch
14 Ga. Yellow/Green E S On Water Temp Gauge Water Temp Sending Unit
14 Ga. Orange F Thermostat Sw A/C High Pressure Switch
14 Ga. Violet G A/C High Pressure Light A/C High Pressure Switch
14 Ga. White/Black H Start fuse Neutral start switch
14 Ga. White I Starter relay Neutral start switch
14 Ga. Pink/White J Safety Shut Off Sw 2 Hyd Oil Level
14 Ga. Brown/Black K Engine Screen Light Sw Engine Screen Light
14 Ga. Brown/White L # 87 Side Work Light Relay Side Work Lights
14 Ga. Yellow M S On Oil Pressure Gauge Oil Pressure Sending Unit
14 Ga. Yellow/Black N # 85 Oil Press Relay Oil Press Switch
16 Ga. Green O # 87 A Park Brake Relay Park Brake Solenoid
Positrac Sitch (B) and Brake Pedal

14 Ga. Green/Yellow P Positrac Solenoid
Switch (C)
14 Ga. Pink Q Safety Shut Off Sw 1 Water Temp, Oil Press, Hyd Oil Level
14 Ga. Orange/Black R Air Filter Restriction Light Air Filter Restriction Switch
14 Ga. Violet/Red S S On Engine Tach Engine Tach Sender
Water temp sending unit T Plug
12 Ga. Black U Disconnect Switch Solenoid Ground
V Plug
1400-14
cp1999250002c
ELECTRICAL SYSTEM
Elevator 22 Pin Connector Breakout
Wire Type N o. From To

# 87 Secondary Ext Hood Rotate
12 Ga. Orange A Secondary Ext Hood Rot Solenoid
Clockwise Relay
14 Ga. # 87 Secondary Ext Hood Rotate

B Secondary Ext Hood Rot Solenoid
Orange/Black Counter-Clockwise Relay
14 Ga. Yellow C # 87 Bin Flap Relay Out Bin Flap Solenoid
14 Ga. Yellow/Black D # 87 Bin Flap Relay In Bin Flap Solenoid
14 Ga. Red E Elev Switch Up (A) Elevator Lift Solenoid
14 Ga. Red/Black F Elev Switch Down (C) Elevator Down Solenoid
# 87 Primary Ext Hood Rotate

14 Ga. Yellow/Blue G Hood Rotate Solenoid
Clockwise Relay
# 87 Primary Ext Hood Rotate

14 Ga. Yel/Blk/Grn H Hood Rotate Solenoid
Counter-Clockwise Relay
14 Ga. Yel/Grn I Primary Ext On/Off Switch B Secondary Extractor Solenoid
14 Ga. Black/Red J Secondary Ext On/Off Switch B Secondary Extractor Solenoid
14 Ga. Blue K # 87 A Elevator Fwd/Rev Relay Elevator Fwd Solenoid
14 Ga. Blue/Black L # 87 Elevator Fwd/Rev Relay Elevator Rev Solenoid
14 Ga. Brown M # 87 Elevator Light Relay Elevator Light
14 Ga. Brown/Black N # 87 Elevator Light Relay Elevator Light
16 Ga. Pink O Digital Tach (S) Tach Sender
14 Ga. Pink/White P Digital Tach (S) Tach Sender
14 Ga. Green/Yellow Q Hydraulic Filter Restriction Light Hydraulic Restriction Switch
14 Ga. Green/White R Radiator Indicator Light Radiator Float Switch male 1-way
12 Ga. Black S Disconnect Switch Solenoid Ground
12 Ga. Black T Disconnect Switch Solenoid Ground
12 Ga. White/Black U Chopper Flywheel Module Magnetic Sender
14 Ga. White/Black V Chopper Flywheel Module Magnetic Sender
1400-15
cp1999250002c
ELECTRICAL SYSTEM
Battery Visual Inspection Battery Load Test

1. Check for obvious damage such as a cracked or 1. Using an accurate DC voltmeter, test open circuit
broken case that shows a loss of electrolyte. voltage. If below 12.4 volts, the battery may not
perform acceptably.
2. Check for terminal damage.
2. Connect battery load tester to battery terminals
3. Is there obvious damage?
in accordance with test instructions.
Yes—Replace battery.
No—Check electrolyte level. 3. Place engine under load and test battery for at
least 15 seconds.
1. Is electrolyte level below the top of the plates in 4. Is battery voltage at least 9.6 VDC or greater?
one or more cells?
Yes—Done
Yes—Add water to proper level. Charge for 15 minutes No—Charge battery the equivalent of 40 Amp hours.
at 15-25 Amps. Remove non-safety vent caps, but leave (10 Amps for 4 hours or 20 Amps for 2 hours) For a
safety vent caps in place. completely discharged battery, double charging time.
No—Proceed to hydrometer test. Do not charge at more than a 20 Amp rate. Repeat
voltage test.
Battery Hydrometer Test 1. Is battery less than 9.6 VDC?

1. If necessary, fill cells with water to recommended Yes—Done
level. No—Replace battery.
2. Operate engine for a few minutes to mix
electrolyte.
3. Check ambient temperature and correct
hydrometer reading by adding four gravity points
(0.004) for every 5.6º C (10º F) above 26.6º C
(80º F) or subtracting the same number of points
for every 5.6º C (10º F) below 26.6º C (80º F).
4. Does the battery have a specific gravity reading
of 1.260-1.280?
Yes—Proceed to load test.
No—Charge battery. Test again.
1. Does battery hold charge at this level?

Yes—Proceed to load test.
No—Replace battery.
1400-16
cp1999250002c
ELECTRICAL SYSTEM
Ignition Switch Check

1. Key switch ON. 1
0
2
2. Connect an ohmmeter to battery terminal, 3
accessory terminal and then ignition terminal.

BAT ACC
3. Turn the key switch to START position. Connect Key

ohmmeter to battery terminal and starter terminal.
IGN
Switch
Is continuity measured? ST
Yes—Go to the next check. G

No—Key switch has failed. Replace.
Diode Check
A diode can fail in two modes, either shorted or open.
Continuity will be measured in one direction only in the
serviceable diode.
1. Remove diode from connector.
2. Connect an ohmmeter to diode terminals. Is
continuity measured?
3. Reverse ohmmeter probes. Is continuity
measured?
Yes—If continuity is measured in both checks, diode
has failed in a shorted mode. Replace.
No—If continuity is NOT measured, diode has failed in
an open mode. Replace.
No—If continuity is measured in one check and not
the other, diode is OK.
Switch Check
The following switches may be checked:
Ø Beacon
Ø Lock
Ø Positrac
Ø Secondary Extractor
Ø Primary Extractor
1. Disconnect harness from switch.
2. Push toggle switch to ON position.
3. Connect ohmmeter to switch connector terminals
4 & 5. Is continuity measured?
Yes—If continuity is measured, switch is OK.
No—If continuity is NOT measured, switch has failed.
4. Push toggle switch to OFF position.

5. Connect ohmmeter to switch terminals 4 & 5. Is
Yes—If continuity is measured, replace switch.
No—If continuity is NOT measured, switch is OK.
1400-17
cp1999250002c
ELECTRICAL SYSTEM
Switch Check Switch Check

The following switch may be checked The following switch may be checked
Ø Elevator Up/Down Ø Park Brake
Ø Elevator Forward/Reverse Ø Topper
Ø Bin Flap In/Out Ø Basecutter
Ø Secondary Extractor Hood Rotate Ø Side Knives
1. Disconnect harness from switch. 1. Disconnect harness from switch.
2. Hold toggle switch to ON. 2. Push toggle switch to ON.
3. Connect ohmmeter to switch connector terminals 3. Connect ohmmeter to switch connector terminals
4 & 5. 1 & 2.
4. Is continuity measured? 4. Is continuity measured?
Yes—If continuity is measured, switch is OK. Yes—If continuity is measured, switch is OK.
No—If continuity is NOT measured, switch has failed. No—If continuity is NOT measured, switch has failed.
4. Hold toggle switch to ON position. 4. Push toggle switch to ON position.

5. Connect ohmmeter to switch terminals 5 & 6. 5. Connect ohmmeter to switch terminals 2 & 3.
6. Is continuity measured? Yes—If continuity is measured switch is OK.
No—If continuity is NOT measured switch has failed.
Yes—If continuity is measured switch is OK switch.
No—If continuity is NOT measured switch has failed.
6. Push toggle switch in the OFF position.
6. With toggle switch in the OFF position. 7. Connect ohmmeter to switch connectors 1 and 2,
2 and 3.
7. Connect ohmmeter to switch connectors 4 and 5,
5 and 6. Yes—If continuity is NOT measured switch is OK.
No—If continuity is measured switch has failed.
8. Is continuity measured?
Yes—If continuity is NOT measured switch OK switch.
No—If continuity is measured switch is has failed.
1400-18
cp1999250002c
ELECTRICAL SYSTEM
Joystick Switch Check: Horn Joystick Switch Check: RH Scroll Up/Down

1. Unplug three-way and four-way joystick 1. Unplug three-way connector and four-way
connectors. connector on joystick.
2. Connect ohmmeter to red wire on three-way 2. Connect ohmmeter to red wire on three-way
connector B and brown wire on three-way connector B and yellow wire on four-way
connector A. connector C.
3. Depress horn switch. Is continuity measured? 3. Depress top of right switch. Is continuity
measured?
No—If continuity is not measured, switch has failed. Yes—If continuity is measured switch is OK.
No—If continuity is not measured, switch has failed.
Joystick Switch Check: LH Scroll Up/Down 4. Connect ohmmeter to red wire on three-way
1. Unplug three-way joystick plug and four-way connector B and blue wire on four-way connector
joystick plug. D.
2. Connect ohmmeter to red wire on three-way 5. Depress bottom of right switch. Is continuity
connector B and orange wire on four-way measured?
connector A. YesIf continuity is measured switch is OK.
3. Depress top of left switch. Is continuity NoIf continuity is not measured, switch has failed.
measured?
No—If continuity is not measured, switch has failed.
4. Connect ohmmeter to red wire on three-way

connector B and black wire on four-way
connector B.
5. Depress bottom of left switch. Is continuity
measured?
A-Orange
Yes—If continuity is measured, switch is OK. B-Black
No—If continuity is not measured, switch has failed. C-Yellow
D-Blue
AB C A BC D
A-Brown
B-Red
C-Green
1400-19
cp1999250002c
ELECTRICAL SYSTEM
Check Relay
1. Remove relay from holder.
2. Connect ohmmeter to terminals 30 and 87.
3. Connect battery voltage to terminal 86.
4. Ground terminal 85.
5. Does relay click and does ohmmeter read
continuity?
Yes—Relay is OK. Check harness.
No—Relay has failed. Replace.
Solenoid Check Number One About 8 Ohms

About 7 Ohms
1. This test is performed with engine off and
electrical system on.
2. Depress switch to ON position.
3. Place a wrench or metal object on the solenoid.
4. Is metal object attracted to solenoid?
Yes—Solenoid is OK.
No—Solenoid might have failed or there might be a
short before the solenoid. Proceed to next test.
About 5 Ohms
Solenoid Check Number Two
1. Disconnect harness from solenoid.
2. Connect ohmmeter between solenoid connector
terminals.
3. Does ohmmeter read continuity?
Ø About 5 ohms see above figure.
Ø About 7 ohms see above figure.
Yes—Solenoid is OK. Check harness.

No—Solenoid has failed. Replace.
1400-20
cp1999250002c
ELECTRICAL SYSTEM
Fuse Breaker Check

1. Remove circuit breaker from fuse box.
2. Connect one probe of ohmmeter to each terminal
of circuit breaker.
Yes—Circuit breaker is OK. Check harness.
No—Circuit breaker has failed. Replace.
Relay Check
1. Remove relay from holder.
2. Connect battery voltage to terminal 86. 86 12V
3. Ground terminal 85. 30

87A 87
4. Does relay click?

85
5. Connect an ohmmeter to terminals 30 and 87. Is
Yes—Relay is OK.
No—Relay has failed. Replace.
Fi 8
Starter Solenoid Check

1. Disconnect metal strap from starter motor
terminal. * CAUTION *
2. Connect battery voltage to solenoid small terminal Starter will crank engine if metal strap is NOT
disconnected from starter motor.
using a jumper wire.
3. Ground metal strap from solenoid with heavy
gauge wire.
4. Does solenoid click?
5. Remove jumper wires.
Yes—Solenoid is OK. Check starter motor.
No—Replace starter solenoid.
1400-21
cp1999250002c
ELECTRICAL SYSTEM
Fuse Breaker Check

1. Battery disconnect switch ON.
2. Key switch ON.
3. Connect black (-) probe of multimeter to frame
ground.
4. Set multimeter to measure 12 volts.
5. Touch multimeter read (+) probe to slots in each
fuse. Is 12 volts measured on both slots in each
fuse?
Yes—Fuses are OK. Check harness.
No—Fuse has failed if voltage is NOT measured in both
slots. Replace fuse.
Head Light Switch and Warning Switch

Check
1. Push headlight switch to field position.
2. Connect ohmmeter between terminals 5B and 6.
3. Connect ohmmeter between 2B and 3. Is

Turn Signal Switch Check

1. Push turn switch ON.
3. Push turn switch to opposite direction.

5. Push switch to ON.

7. Push switch to opposite direction.

1400-22
cp1999250002c
ELECTRICAL SYSTEM
Primary Extractor Fan Tachometer Check: Voltage Calibration

For Label
Operation Lighting
Negative
1. Magnetic pulses from the gear teeth are converted Ground
Terminal
to electrical pulses by the magnetic pickup. Gate Time
Selector
Switch
2. Electrical pulses from magnetic pickups are RPM Back
counted by the tachometer circuit and DATCON

converted to RPMs. Connect to
Front Tach Sender(s)
3. To set magnetic pickups, screw sender inward
unit until it touches the gear tooth, then back it (Air Gap-.030 Typ
.040 Max)
out 1/2 turn. (Air gap: 0.030 Typ, 0.040 Max). Gear
Magnetic Pick-Up
Tach Light Bulb

Engine Tachometer Check: Operation
1. Magnetic pulses from the gear teeth are converted Pulse Input
Selector
to electrical pulses by the magnetic pickup. 8
6 A Mounting
Bolts
2. Electrical pulses from magnetic pickups are 4 B
counted by the tachometer circuit and
converted to RPMs.
Calibration
Adjustment
Magnetic Tach Ignition
Sender Single
Connection Ground
Engine Tachometer Check

1. When ignition key is ON, pointer must be at zero. To "S"
2. Narrowing the magnetic pickups air gap must

not change tachometer reading.
3. Pulse input selector must be set to 6. Air Gap-.030 Typ
.040 Max
4. To set magnetic pickups, screw sender inward
Gear
until it touches the gear tooth, then back it out 1/
2 turn. (Air gap: 0.030 Typ., 0.040 Max).
1400-23
cp1999250002c
ELECTRICAL SYSTEM
Elevator On/Off Switch

1. Disconnect harness from switch. Push switch to
ON.
Ohmmeter
B and C. Does ohmmeter read continuity?
Yes—Switch is OK.
No—Switch has failed. Replace.
CBA
Elevator On/Off Switch
1. Disconnect harness from switch. Push switch to
OFF.
2. Connect ohmmeter to switch connect terminal B
and A. Does ohmmeter read continuity?
YesSwitch is OK.
NoSwitch has failed. Replace.
Reverse Alarm And Brake Pedal Switches

1. Disconnect harness from switch. Ohmmeter

A and B.
3. Push switch lever, as shown. Does ohmmeter read
continuity?
Yes—Switch is OK.

A and C.
2. Does ohmmeter read continuity when switch is
NOT pressed and loose continuity when switch
is pressed?
Yes—Switch is OK. Continue.
Air Cleaner Restriction Indicator Ohmmeter

Indicates Servicecloses circuit at 6.2 ± 1.2 kPaG
(25 ± 5 In. of H2O).
1400-24
cp1999250002c
ELECTRICAL SYSTEM
Hydraulic Filter Restriction Indicator

1. Remove switch from tank.
2. Connect ohmmeter, as shown. Ohmmeter
3. Does ohmmeter read continuity?

Yes—Switch has failed. Replace.
No—Switch is OK. Continue.
4. Apply more than 20 PSI to switch.

5. Does ohmmeter read continuity? Apply Pressure Here
Yes—Switch is OK. Continue.

Hydraulic Float Level Check

1. Fill hydraulic oil tank.
2. Connect ohmmeter as shown.
Yes—Float level switch is good.
No—Replace float level gauge.
1400-25
cp1999250002c
ELECTRICAL SYSTEM
Cab Harness
CAMECO
Cab Harness
Brown/White
Green/Yellow
Violet/Black
Green/White
Yellow
Blue
John Deere
Cab Harness A B C D E F
Pink/Black
Brown
Orange
Brown
Black
Red
A B C D E F
Plug C2
A B C D E F
Green/White
Brown/White
Green/Yellow
Violet/Black
Yellow
Blue
Plug C1 From Console Harness

A B C D E F
12 Ga Red
Orange
Black
Brown
Brown
Black
From Console Harness
1400-26
cp1999250002c
ELECTRICAL SYSTEM
Positrac Circuit (Wheel)

7243003023
1400-27
cp1999250002c
ELECTRICAL SYSTEM
Starter Circuit
1190330145
1400-28
cp1999250002c
ELECTRICAL SYSTEM
Cab and Air Conditioner

1190330110
1400-29
cp1999250002c
ELECTRICAL SYSTEM
Elevator Control
7243002791
1400-30
cp1999250002c
ELECTRICAL SYSTEM
Gauges
1190330095
1400-31
cp1999250002c
ELECTRICAL SYSTEM
Turn Signal Light Circuit

1193002324
1400-32
cp1999250002c
ELECTRICAL SYSTEM

1190328254
1400-33
cp1999250002c
ELECTRICAL SYSTEM
Reverse Alarm Track & Wheel

1190328253
1400-34
cp1999250002c
ELECTRICAL SYSTEM
Horn
1190330115
1400-35
cp1999250002c
ELECTRICAL SYSTEM
Safety Shutdown
1190330148
1400-36
cp1999250002c
ELECTRICAL SYSTEM
Park Brake Circuit

7243002801
1400-37
cp1999250002c
ELECTRICAL SYSTEM
Crop Divider
1190330105
1400-38
cp1999250002c
ELECTRICAL SYSTEM
Topper and Side Knives

7243002990
1400-39
cp1999250002c
ELECTRICAL SYSTEM
Basecutter and Chopper

7243002970
1400-40
cp1999250002c
ELECTRICAL SYSTEM
Primary Extractor
1671356392
1400-41
cp1999250002c
ELECTRICAL SYSTEM
Chopper/Height Indicator Lights

7241355749
1400-42
cp1999250002c
ELECTRICAL SYSTEM
Electrical System Has Low Voltage Problem
Check battery terminal for tightness No

and/or corrosion. Repair or replace battery.
Are they OK?
Yes
Check alternator drive system No Repair or replace parts

for tightness and condition. as necessary.
Is it OK?
Yes
1. Turn headlights “On” for 15 seconds and turn Batteries may be discharged or
off. (This removes surface charge). No No
defective, charge them. Replace.
2. Measure voltage across the batteries. Do batteries accept charge?
Is measurement greater than 11 VDC?
Yes
Charge until specific gravity is greater
Yes
than 1.265 and voltage is at least greater
than 12.4 V after surface charge removal.
1. Engage park brake, start engine and

No Measure voltage at alternator No Check wire harness
run at full throttle.
2. When voltage stabilizes, measure field power connection. between starter and
alternator output at its terminals. Is 12 VDC measured? alternator.
Is measurement greater than 13 VDC? Yes
Yes Replace alternator.
Measure negative (-) side Yes Check and repair the following: (-)
voltage drop. (Alternator case No Repair or replace
alternator wire, (-) battery cable or
to (-) battery post). ground connection chassie and as necessary.
Is measurement greater than starter.
0.5 VDC?
No
Measure positive (+) side No Repair or replace

voltage drop. (Alternator output Yes Check the following: (+) alternator as necessary.
terminal to positive (+) battery wire, (+) battery cable or connection
post). at battery terminal. Yes
Is measurement greater than Are they OK? Test alternator and
0.5 VDC? replace if necessary
No
Check the following to determine why system voltage is low:
Yes 1. Excessive electrical loads from accessories.
Measure voltage across each
2. Defect in alternator drive system, belts, adjustments, etc.
battery’s posts while cranking
3. Batteries are nearing the end of their useful life.
engine, using pointed probes to
touch the posts.
Is voltage of each battery the No
same within 0.5 VDC? Battery with higher reading does not have a good condition.
Go battery check.
1400-43
cp1999250002c
Ignition Power Problem
Check 30 amp battery fuse. No Replace fuse and check for a
Yes
No
Measure voltage at fuse. Check red white wire between
Is 12 VDC measured? fuse box and starter positive.
Yes
Measure voltage at battery No

Check wire harness between
terminal of ignition switch. battery fuse and ignition switch.
Is 12 VDC measured?
Yes
Perform a switch check on No

ignition switch. Replace ignition switch.
Is switch good?
Yes
1400-44
1. Turn key switch to IGN. No
2. Measure voltage at ignition
Replace ignition switch.
switch IGN terminal.
ELECTRICAL SYSTEM
Is 12 VDC measured?
Yes
1. Turn key switch to IGN.

1. Turn key switch to OFF. Yes Check black/white Yes Perform a relay check No
2. Measure voltage at Yes
2. Remove ignition relay Replace relay.
red/white wire terminal ground connection at on the ignition relay.
and measure voltage at terminal 85. Is the relay good?
86.
terminal 30. Is connection OK?
Is 12 VDC measured?
Is 12 VDC measured? Yes
No No
No Check red/white wire
Repair ground. between ignition relay
Check red wire between Check red/white wire terminal 87 and fuse box.
ignition relay terminal 30 between ignition relay
and starter positive. terminal 86 and ignition
switch.
cp1999250002c
Front Working Lights Do Not Operate
Electrical Check
1. Turn light switch to field position. Yes No

2. Measure voltage at brown/white wire at Check black wire at light for ground.
Repair ground.
light assy. Is ground good?
Is 12 VDC measured?
Yes
No
No Replace light assy.
Check 20 amp front light fuse. Replace fuse.
Is fuse good?
Yes
Measure voltage at front No

light fuse. Check red wire powering light fuse .
Is 12 VDC measured?
Yes
1. Disconnect relay and turn light
switch to field position. No Check brown/white
2. Measure voltage at terminal 30 Check red wire between side light fuse and terminal 30. wire between light
1400-45
front light relay. switch and relay.
Is 12 VDC measured?
Yes
Yes
1. Check ground at terminal 85 on front light relay. No Yes Measure voltage at 10 Yes
ELECTRICAL SYSTEM
Check 10 amp amp light switch fuse. Perform a switch

2. Measure voltage of brown/white wire at terminal 86. light switch fuse. check at light switch.
Is 12 VDC measured? Is 12 VDC?
No No No
Yes
Check red wire between
1. Reinstall front light relay. Replace fuse. Repair or
Yes fuse and starter positive.
2. Measure voltage of brown/ replace switch.
white wire at terminal 86. Replace flood light assy.
Is 12 VDC measured?
1. Repair loose connection between
No
relay and light.
No
2. Perform a relay check and
replace it if necessary
Measure voltage of terminal Yes Check brown/white Is relay OK?
87 on front lights relay. wire between relay
Is 12 VDC measured? and flood light
cp1999250002c
ELECTRICAL SYSTEM
Accessory Power Problem
Check 30 amp battery fuse. No Replace fuse and check for a

Yes
Measure voltage at fuse. No

Refer to Battery Diagnostic Chart.
Is 12 VDC measured?
Yes
Measure voltage at battery

terminal of ignition switch. No Check wire harness between
Is 12 VDC measured? battery fuse and ignition switch.
Yes
Perform an ignition No
switch check. Replace ignition switch.
Is switch good?
Yes
1. Turn key switch to ACC.

2. Measure voltage at No
switch ACC terminal. Replace the switch.
Is 12 VDC measured?
Yes
Measure battery power 1. Turn key switch to

by removing accessory ACC. Check black/white Perform a relay
relay and measuring Yes 2. Measure voltage at Yes Yes check on the
ground connection
voltage at terminal 30. white wire at terminal at terminal 85. ignition relay.
Is 12 VDC measured? 86. Is connection ok? Is the relay good?
Is 12 VDC measured?
No
No Yes No
No
Check red wire between Repair. Check white Replace
accessory relay terminal Check white wire between relay, wire between relay.
and starter positive. terminal 86 and ignition switch. accessory relay,
terminal 87 and
fuse box.
1400-46
cp1999250002c
ELECTRICAL SYSTEM
Radiator Level Light and Buzzer Stay On

No
Is radiator fluid level full? Fill radiator.
Yes
Disconnect radiator level switch. Is No

radiator light and buzzer still on? Replace radiator level switch.
Yes
Check for green/white wire

short to ground.
Radiator Level Light and Buzzer Do Not Activate
Drain radiator to a level low enough

Yes
to set off indicator light. Done.
Did light turn on?
No
1. Disconnect radiator level

switch. No Check red/white wire at Check red/white wire
No
2. Check red/white wire at the radiator level indicator. between indicator light
radiator level switch. Is 12 VDC measured? and oil pressure gauge.
Is 12 VDC measured?
Yes
Yes
No
Is indicator bulb good? Replace bulb.
Check for proper ground
at black/white wire.
Is ground good? No Yes
Repair ground.
Yes Check green/white wire between

indicator light and float switch.
Replace radiator level float switch.
1400-47
cp1999250002c
Side Working Lights Do Not Operate
1. Turn light switch to F field position. Yes Check black wire at light for ground. No
2. Measure voltage at brown/white wire at Repair ground.
Is ground good?
light assy.
Is 12VDC measured? Yes
Replace light assy.
No
Check 30 amp side light fuse. No
Replace fuse.
Is fuse good?
Yes
Measure voltage at side light
No Check red wire between side working
fuse.
Is 12VDC measured? lights and starter terminal.
Yes
Check brown/white
1. Disconnect relay and turn light
wire between light
switch to position F field position. No Check red wire between side switch and relay.
2. Measure voltage at terminal light fuse and terminal 30.
30 front light relay.
Yes
1400-48
Is 12 VDC measured?
Yes Measure voltage at 10 Perform a switch

Check 10 amp light Yes
1. Check ground at terminal 85 on side light relay. amp light switch fuse. Yes check at light
No switch fuse.
2. Measure voltage of brown/white wire at terminal Is 12 VDC measured? switch.
Is fuse good?
ELECTRICAL SYSTEM
86. Is switch good?

Is 12VDC measured? No No
No
Yes Replace fuse.
Check red wire between Repair or
1. Reinstall side light relay. fuse and starter positive. replace
2. Measure voltage at single Yes switch.
Replace flood light assy.
connection flood light assy.
Is 12 VDC measured?
No
No 1. Repair loose connection
between relay and light.
Measure voltage of terminal 87 Check brown/white wire 2. Perform a relay check
Yes between relay and flood
on side lights relay. and replace if necessary.
Is 12 VDC measured? light assy.
cp1999250002c
Elevator Working Lights Do Not Operate
1. Stop engine, engage park and turn keyswitch to ACC.
2. Turn light switch to position F field position. Yes Check black wire at light for ground. No
3. Measure voltage at brown/white wire at light assy. Is ground good? Repair ground.
Is 12 VDC measured?
Yes
No Replace light assy.
Check 30 amp side light fuse. No
Replace fuse.
Is fuse good?
Yes
Measure voltage at side light No
fuse. Check red wire between working lights
Is 12 VDC measured? and starter terminal.
Yes
1. Disconnect relay and turn light Check brown/white

switch to position F field position. wire between light
No
2. Measure voltage at terminal 30 Check red wire between elevator light fuse and terminal 30. switch and relay.
elevator light relay.
Is 12 VDC measured? Yes
Yes
1400-49
Measure voltage at 10 Perform a switch
Check 10 amp light Yes amp light switch fuse. Yes check at light
1. Check ground at terminal 85 on elevator light relay. No switch fuse. switch.
Is 12 VDC measured?
2. Measure voltage of brown/white wire at terminal 86. Is fuse good? Is switch good?
Is 12 VDC measured?
No No
ELECTRICAL SYSTEM
No
Yes Replace fuse.
Check red wire between Repair or
1. Reinstall elevator light relay. fuse and starter positive. replace
2. Measure voltage at single Yes switch.
Replace flood light assy.
connection flood light assy.
Is 12 VDC measured?
No 1. Repair loose connection
No
etween relay and light.
2. Perform a relay check
Measure voltage of terminal 87
Yes Check brown/white wire and relay if necessary.
on elevator working lights
relay. between relay and flood
Is 12 VDC measured? light assy.
cp1999250002c
ELECTRICAL SYSTEM
Warning Lights Do Not Work
No
Do the headlights operate? Refer to Headlight Diagnostic Chart.
Yes
1. Turn the warning switch

ON.
2. Check voltage of yellow/ No Check yellow/green/black wire
green on turn signal between the light switch and turn
switch at terminal 2. signal switch .
Is 12 VDC measured?
Yes
Measure voltage on turn signal No Check wires and diodes

switch terminals 2B and 5B. between warning and turn
Is 12 VDC measured? signal switch.
Yes
Measure voltage at both left and

right dual lamp assys—measure No Yes
Check ground connection
both green/white wires at A side at dual lamp assy. Replace bulbs.
of turn light. Is ground OK?
Is 12 VDC measured?
Yes
Yes
Repair Ground.
Check harness between
dual light assy and turn
signal switch.
1400-50
cp1999250002c
ELECTRICAL SYSTEM
Tail Lights Do Not Operate
Turn light switch to H. No

Are headlights On? Refer to Headlight Diagnostic Chart.
Yes
1. Disconnect weatherpack
connector at tail light assy.
Measure voltage on the light Yes 2. Measure voltage of the purple/ Yes 1. Check ground connection.
2. Check and replace bulb, if
switch terminal 3. black wire on B side of the necessary.
Is 12 VDC measured? connector.
Is 12 VDC measured?
No
No
Perform a switch check.
Is switch OK? Check purple/black wire
between light switch
No Yes and tail light assy.
Replace switch. Repair loose

connection at
switch.
1400-51
cp1999250002c
ELECTRICAL SYSTEM
Dash Lights Do Not Operate
1. Turn lights switch to H.

2. Check ground connection at tachometer No Check brown wire between tachometer No
light stud. light studs and 87 on head light. Repair wire.
3. Measure voltage of the brown wire. Is wire OK?
Is 12 VDC measured?
Yes
Yes
Refer to Headlight
Check bulb in dash lights. Yes Check and Diagnostic Chart.
Is bulb OK? repair ground.
No
Replace bulb.
1400-52
cp1999250002c
Headlights Do Not Operate
1. Turn light switch to H.

Yes Check black wire ground connection No
2. Measure voltage at brown wire
at light. Repair ground.
at the headlight assy.
Is connection good?
Is 12 VDC measured?
Yes
No Replace light assembly.
Check 30 amp headlight fuse. No Replace fuse and check for a

Is fuse OK? shorted circuit or component.
Yes
Measure voltage at 30 amp No Check red wire between headlight
headlight fuse.
fuse and starter terminal.
Is 12 VDC measured?
Yes
1. Disconnect headlight relay and
turn light switch to H. No Check wire between headlight fuse
2. Measure voltage at headlight
and terminal 30.
relay terminal 30.
1400-53
Is 12 VDC measured?
Yes
No Yes Measure voltage at 10 No Perform a switch Yes Check brown wire
1. Check ground at terminal 85 on Check 10 amp light fuse.
amp light switch fuse. check at light switch. between light switch
headlight relay. Is fuse good?
ELECTRICAL SYSTEM
Is 12 VDC measured? Is switch ok? and headlight relay.

2. Measure voltage of brown wire
at terminal 86. No
Yes No
Is 12 VDC measured? Replace fuse.
Refer to Accessory Repair or replace switch.
Yes Diagnostic Chart.
Measure voltage at terminal 87 on

headlight relay. Yes Perform a relay check on headlight relay. Yes Check brown wire between headlight
Is 12 VDC measured? Is relay ok? relay and headlight assy.
No No
Check brown 151 wire Replace relay.

between relay andlight.
cp1999250002c
ELECTRICAL SYSTEM
Safety Shut Down Button Will Not Remain In

The Depressed Position After Engine Start-Up
NOTE: Combines with the High Coolant Temperature
Protection installed will have the red wire, located
on the water temperature switch, connected to the
pink wire, located on the engine.
Combines without this feature will have a jumper

wire across the pink wire on the engine.
Is radiator door closed properly and is No
Close door or adjust switch.
switch adjusted properly?
Yes
Yes
Is engine overheated? Repair overheat problem.
No
No Yes
Is engine oil pressure at Is oil level ok?
Refer to Engine Section.
least .83 bar (12 PSI)?
No
Yes Fill with oil and recheck.
Is the hydraulic oil level ok? No

Fill hydraulic tank.
Yes
Visually check wiring for loose

connections or damaged wires on:
Ø Radiator Door Switch
Ø Oil Pressure Switch No
Repair or replace.
Ø Water Temperature Switch
Ø Hydraulic Oil Level Switch
Are wires and connections ok?
Yes
Check the 5 amp gauges fuse. No

Replace fuse.
Is fuse good?
Yes
1. Check one black/white ground wire at G on the

Murphy switch.
2. Disconnect the pink and pink/white wires from Problem is either:
Yes Ø Open circuit.
SW1 and SW2 on the Murphy switch.
3. Place a temporary jumper wire between SW1
and SW2.
Ø Unwanted ground.
4. Restart engine. Ø High resistance in pink
Does push button stay IN and pink/white wires.
with the engine running?
No
Continued on
Replace Murphy Switch. Next Page
1400-54
cp1999250002c
ELECTRICAL SYSTEM
Safety Shut Down Button Will Not Remain In

The Depressed Position After Engine Start-Up
Continued from
Previous Page Problem is either:
Yes Ø Open Circuit
Ø Unwanted Ground
Ø High resistance in pink
and pink/white wire.
Using an Ohmmeter, test the pink and No

Check wire harness
pink/white wire for continuity.
for bad connection.
Is resistance 25 ohms or less?
Yes
1. Disconnect the hydraulic oil level switch, oil Perform switch checks on the following:
pressure switch, the radiator door switch, and the 1. Water Temperature Switch.
water temperature switch. No 2. Oil Pressure Switch.
2. Check for continuity at the pink wire to ground at 3. Hydraulic Oil Level Switch.
each switch. 4. Radiator Door Switch
3. Check for continuity at the pink/white wire to Are switches ok?
ground at hydraulic oil level switch.
Does continuity exist? No
Yes
Yes Replace bad switch(es).
Repair shorted wire.

Check the pink and pink/white
wires for an open circuit.
1400-55
cp1999250002c
ELECTRICAL SYSTEM
Oil Pressure Light Stays On
1. Check engine oil level.

No Yes Replace oil pressure
Observe engine oil pressure gauge. 2. Install manual oil pressure gauge.
Is pressure at least .83 bar (12 PSI)? Is pressure more than sending unit.
.83 bar (12 PSI)?
Yes No
1. Stop engine, engage park brake Repair engine.

and turn key switch to IGN.
2. Disconnect oil pressure relay.
3. Check yellow/black wire for 1. Reconnect oil pressure relay.
ground at terminal 85 on oil No 2. Place a jumper wire to ground Yes Replace oil
pressure relay. yellow/black wire.
pressure switch.
Is there a ground? Does light go OFF?
Yes No
Replace relay. Check yellow/black wire between oil

pressure relay and switch.
1400-56
cp1999250002c
ELECTRICAL SYSTEM
Water Temperature Buzzer Stays On
Check engine. Yes

Repair overheating problem.
Is engine overheated? Refer to Cooling System Check.
No

2. Disconnect water temperature
relay. 1. Reconnect water temperature relay.
No Replace water
3. Check yellow/black/green wire for 2. Place a jumper wire to ground Yes
a ground at water temperature temperature
yellow/black/green wire.
relay terminal 85. switch.
Does the buzzer go OFF?
Is terminal grounded?
No
Yes
Check yellow/black/green
wire between water
Replace relay.
temperature switch and relay.
1400-57
cp1999250002c
ELECTRICAL SYSTEM
Engine Air Filter Indicator Stays On
Check and clean air filter. Yes Clean primary element. No

Done.
Is air filter dirty? Is indicator still ON?
Yes
No
Replace primary element. No
Done.
Is indicator still ON?
Start the engine.
Is the air filter Yes
indicator still ON?
Replace safety element.
No Yes
With engine still running,

Done. No Replace air filter
disconnect orange/black wire
from indicator. indicator switch.
Is indicator ON?
Yes
Check wire between air filter

indicator switch and indicator
light for a shorted circuit.
1400-58
cp1999250002c
ELECTRICAL SYSTEM
Engine Air Filter Indicator Does Not Light
1. With engine stopped,

turn key switch to
IGN and engage park
brake. Yes Check black/white wire. Yes Check the air filter No
Is there a good ground indicator switch. Replace switch.
2. Place a jumper wire
connection? Is switch good?
from the orange/black
wire at the air filter Yes
No
indicator to ground.
Is the light ON? Stone filter located inside air filter
Clean and tighten housing clogged. Remove restriction
connection. switch and spray cleaner through port.
No Blow out with compressed air.
1. Disconnect multiconnector at air

filter indicator. No
Check red/white wire between the
2. Measure voltage of red/white wire. air filter indicator and dash gauge.
Is 12 VDC measured?
Yes
1. Replace air filter

indicator bulb.
2. Check orange/black
wire between air
restriction switch and
indicator.
1400-59
cp1999250002c
ELECTRICAL SYSTEM
Hydraulic Filter Restriction Indicator Does Not Go Out

Important: Make sure upper hydraulic tank gate valve
is open.
Important: If the hydraulic oil is cold, the indicator may

be on, but should go “Out” when oil reaches
normal operating temperature.
1. Start engine and run at full
throttle with functions on and
park brake on. No
Done.
2. Allow hydraulic oil to reach
operating temperature.
Is indicator still ON?
Yes
Disconnect electrical plug from

filter restriction switch located on Check green/yellow wire
No
back side of hydraulic filter tank between restriction switch
in engine compartment. and indicator for a short.
Does indicator go OFF?
Yes
1. Drain hydraulic filter tank.

2. Change hydraulic filters inside Yes
of tank. Done.
Does the indicator go OFF?
No
Replace hydraulic filter switch which

caused indicator to go OFF when wire
was disconnected.
1400-60
cp1999250002c
Hydraulic Filter Restriction Indicator Does Not Work.

and turn key switch to IGN. Check ground wire at filter
Yes Yes
2. Disconnect filter restriction restriction switch.
Check restriction switch.
switch electrical plug (located on Is ground good?
rear of hydraulic filter tank).
3. Install a jumper wire to ground No
green/yellow wire.
Is indicator ON? Repair ground
connection.
No
Measure voltage at red/white Measure voltage at 5 amp Check red/white wire

Yes
1400-61
wire at terminal I on engine No Check gauge fuse. Yes
gauge fuse. between gauge fuse
tachometer. Is fuse good? Is 12 VDC measured? and dash.
Is 12 VDC measured?
No No
Yes
ELECTRICAL SYSTEM
Replace fuse and check Refer to Ignition

Check red/white wire between for shorted circuit or Diagnostic Chart.
fuel gauge and indicator. component.
Is wire ok?
Yes No
Replace indicator bulb. Repair

wire.
cp1999250002c
Hydraulic Oil Temperature Gauge Does Not Register
1. Stop engine, turn key switch to Check the yellow/blue wire

IGN and engage park brake. between hydraulic
2. Place a jumper wire from the S temperature gauge and
Yes Yes Replace hydraulic oil
terminal to ground. hydraulic temperature
Does the needle move and sender. temperature sending unit.
register maximum hydraulic Is wire Ok?
oil temperature?
No
No
Repair wire.
1400-62
Measure voltage at red/white wire Check red/white wire
No Yes Measure voltage at 5 amp Yes between gauge fuse
at terminal I on hydraulic oil Check gauge fuse. gauge fuse. and hydraulic oil
temperature gauge. Is fuse good? Is 12 VDC measured? temperature gauge.
Is 12 VDC measured?
ELECTRICAL SYSTEM
No
Yes No
Refer to Ignition
Diagnostic Chart. Replace fuse and check for
Replace hydraulic oil
shorted circuit component.
temperature gauge.
cp1999250002c
Water Temperature Gauge Does Not Register
1. Stop engine, turn key switch to Check the yellow/green

IGN and engage park brake. wire between water
temperature gauge and Yes Replace water temperature
2. Place a jumper wire from the S Yes
terminal to ground. water temperature sending unit.
Does the needle move and register sender.
maximum water temperature? Is wire Ok?
No
No
Repair wire.
1400-63
Measure voltage of red/white wire Check red/white wire
No Yes Measure voltage at 5 amp Yes
at terminal I on water Check gauge fuse. between gauge fuse and
gauge fuse.
temperature gauge. Is fuse good? water temperature gauge.
ELECTRICAL SYSTEM
Is 12 VDC measured?
Is 12 VDC measured?
No
Yes No
Refer to Ignition
Diagnostic Chart. Replace fuse and check for
Replace water
shorted circuit component.
temperature gauge.
cp1999250002c
Fuel Gauge Does Not Register
No Fill tank.
Does combine have adequate fuel?
Yes
1. Stop engine, turn key switch to Check ground connection

Check white wire between fuel Yes
IGN and engage park brake. between tank and fuel gauge Yes Replace fuel gauge
Yes gauge and gauge sender.
2. Place a jumper wire from the S sending unit. sending unit.
terminal to ground. Is wire Ok?
Is connection good?
Does the needle move to FULL? No
No
Repair wire.
No Repair connection.
1400-64
Measure voltage at 5 amp Yes Check red/white wire
Measure voltage at red/white wire No Yes
Check gauge fuse. gauge fuse. between gauge fuse
at terminal I on fuel gauge.
Is fuse good? Is 12 VDC measured? and fuel gauge.
Is 12 VDC measured?
ELECTRICAL SYSTEM
Yes No No
Refer to Ignition Replace fuse and check for

Replace fuel gauge.
Diagnostic Chart. shorted circuit or component.
cp1999250002c
Oil Pressure Gauge Does Not Register
1. Stop engine, turn key switch to

IGN and engage park brake. Check yellow wire between
2. Place a jumper wire from the S Yes oil pressure gauge and oil Yes
terminal to ground. pressure sender. Replace oil pressure sending unit.
Does the needle move to register Is wire Ok?
maximum oil pressure?
No
Repair wire.
No
Measure voltage at red/white wire Yes Check red/white wire between

No Yes Measure voltage at the 5
1400-65
at terminal I on the oil pressure Check gauge fuse. gauge fuse and oil pressure
amp gauge fuse.
gauge. Is fuse good? gauge.
Is 12 VDC measured?
Is 12 VDC measured?
No
No
Yes
ELECTRICAL SYSTEM
Refer to Ignition
Replace fuse and check for
Replace oil pressure gauge. Diagnostic Chart.
cp1999250002c
Battery Voltage Gauge Does Not Register
Check battery terminals for No

Tighten and/or clean
tightness and/or corrosion. connections.
Are they good?
Yes
Measure voltage across battery No Problem may be a discharged or Yes Recharge until voltage is at
terminals. defective battery. Charge battery. least 12.4 V after service
Is 12.4 VDC or greater measured? Does battery accept charge? charge removal.
No
Yes
1400-66
Replace battery.
1. Stop engine, turn key switch to Check red/white wire
IGN and engage park brake. Yes Measure voltage at 5 amp Yes between gauge fuse
No Check gauge fuse.
2. Measure voltage at the red/white gauge fuse. and battery voltage
Is fuse good?
ELECTRICAL SYSTEM
wire at terminal I on the battery Is 12 VDC measured? gauge.

voltage gauge.
Is 12 VDC measured? No No
Yes Replace fuse and check for

Check red/white wire
between gauge fuse
Replace battery voltage gauge. and ignition relay
terminal 87. No
Is wire Ok? Repair wire.
Yes
Refer to Ignition
Relay Check.
cp1999250002c
ELECTRICAL SYSTEM
Primary Extractor Tachometer Reading

Does Not Match Fan Speed.
Is the gate time adjustment No
Adjust screw to number 2.
screw set to number 2?
Yes
1. Start engine, engage park brake

and run at full throttle.
2. Set primary extractor fan cable at
maximum RPM setting.
3. Using an external tachometer, No
Replace Digital Tachometer.
measure the fan speed and
adjust the “Primary Extractor Fan
Digital Tachometer” to match
reading.
Does Tachometer adjust correctly?
Yes
Done.
Primary Extractor Digital Tachometer

Does Not Function.
1. Stop engine and engage park brake.
2. Inspect pink and pink/white wires Yes Repair or replace
between the magnetic sender and
bad connections.
digital tachometer.
Are the wires damaged?
No
Adjust the sender position to 0.076 mm

Is magnetic pickup too Yes (0.030'') — or ½ turn away from the Yes
far from the Primary Done.
gear.
Extractor Motor gear? Does tachometer work?
No
No
Replace magnetic pickup.
1400-67
cp1999250002c
Reverse Alarm Does Not Sound

IGN and engage park brake. No Replace fuse and check for
2. Check 30 amp fuse. shorted circuit or component.
Is fuse good?
Yes
Measure voltage at the No Yes

reverse alarm fuse. Refer to Accessory Diagnostic Chart.
Done
Is 12 VDC measured? Does the alarm work?
Yes No
1400-68
1. Reconnect multiconnector to
1. Disconnect multiconnector at reverse Perform a switch alarm switch.
2. Pull hydrostatic lever to the Check red wire
alarm switches. Yes check at the reverse Yes No between horn
2. Measure voltage at the red wire. alarm switch. reverse position.
ELECTRICAL SYSTEM
Is 12 VDC measured? 3. Check mechanical ground and and alarm

Is the switch good? switches.
red power wire at alarm
mounting area.
No No Are the connections good and
is 12 VDC measured?
Check red wire between reverse Repair or replace Yes

alarm fuse and multiconnector at switch.
reverse alarm switches.
Repair or replace
alarm assembly.
cp1999250002c
Windshield Washer Does Not Operate
Check 10 amp washer fuse. No

Replace fuse.
Is the fuse good?
Yes
Check for 12 VDC at washer fuse. No Check wire between accessory

Is 12 VDC measured? relay terminal 87 and washer fuse.
Repair connection.
Yes
No
1. Check fluid level in washer 1. Disconnect yellow/blue wire
tank. at washer tank. Check the black/ Check multiconnector
2. Stop engine and turn key No 2. Press and hold washer Yes white wire for good Yes at washer tank for good
switch to IGN. switch. ground connection. connection.
3. Press and hold washer 3. Measure voltage at washer Is ground Ok? Is connection good?
switch. tank, yellow/blue wire.
No Yes
1400-69
Is washer pump operating? Is 12 VDC measured?
Repair wire.
Yes No Replace washer pump.
Yes
Inspect washer nozzle.
ELECTRICAL SYSTEM
Clean nozzle. Measure voltage of red/white No Check red/white wire

Is the nozzle clogged? between washer fuse
wire at the washer switch.
Is 12 VDC measured? and washer switch.
No
Yes
Inspect screen on bottom of pump.
Perform a switch check on Yes
Is screen clogged? Repair yellow/blue wire between
washer switch.
washer switch and motor.
No Is switch ok?
Yes
Replace washer pump. No
Replace switch.
Drain washer bucket
and clean pump.
cp1999250002c
SECTION 3100
TOPPER SYSTEM
Topper Electrical Theory of Operation ................................................... 3100-3

Topper Hydraulic Operation Theory ....................................................... 3100-3
Topper/Side Knives Electrical Schematic ............................................. 3100-4
Topper (Track and Wheel) Hydraulic Schematic ................................... 3100-5
All Functions on Topper Do Not Operate—Whole or Shredder ............ 3100-6
All Functions on Topper Do Not Operate—Whole or Shredder
(Continued) ........................................................................................... 3100-7
All Topper Functions Do Not Operate—Whole or Shredder ................. 3100-8
cp1999250002c
cp1999250002c
TOPPER SYSTEM
Topper Electrical Theory Of Operation Topper Hydraulic Operation Theory

Battery power goes through the red wire to the The left triple vane pump supplies oil flow from its
terminal 30 ignition relay and to the battery fuse. The rear (blindend section to the pilot operated directional valve
current then flows from the battery fuse to keyswitch and back to the tank when the valve is in neutral.
battery terminal. The topper hydraulic controls are located on the
The topper switch is located on the side mounted joystick. This is used to raise and lower the topper. Push
console. To engage the topper, turn key switch to IGN the joystick right to lower the topper and pull the joystick
and depress topper switch to the desired topper rotational left to raise.
direction. Wait 15 seconds for topper to start rotation. When the control switch is activated, it energizes
Current flows through the white wire to the ignition the solenoid which in turn shifts the spool located in the
relay terminal 86, energizing the relay. Current flows out lowest section of the five bank directional control valve.
of terminal 87 through the white wire to the topper fuse. Oil flows from the directional valve to the topper motor
Current flows from the topper fuse, through the white wire which turns the topper disc at approximately 1290 RPMs.
to the topper switch. Oil flows from the motor back to the directional valve and
When the topper switch is pushed to the right, current then back to the tank.
flows through the blue/black wire to the topper time The topper collector drums are also activated through
terminal 12 and through a 1 amp diode, to terminal 14, the same pilot control. The collector drums will not
causing the timer to energize. After 15 seconds, the function unless the main control is turned on in a specific
contacts close and the current flows from terminal 8, to direction.
the front 22-pin connector, pin F, blue/black wire, to topper
right control solenoid. This causes the topper to rotate to
the right.
When the topper switch is pushed to the left, current
flows through the blue wire to the topper timer terminal 9,
and through a 1 amp diode to terminal 14, causing the
timer to energize. After 15 seconds, the contacts close
and current flows from terminal 5 to the front 22-pin
connector, pin E, blue wire to the topper left control
solenoid. This causes the topper to rotate to the left.
Located Under Left Fender
Left Topper
Solenoid
Right Topper
Solenoid
3100-3
cp1999250002c
TOPPER SYSTEM
Topper/Side Knives
7243002990
3100-4
cp1999250002c
TOPPER SYSTEM
Topper (Track and Wheel)

Hydraulic Schematic
1671354099
3100-5
cp1999250002c
All Functions on Topper Do Not Operate—Whole or Shredder
Electrical Check

IGN and engage park brake. No 1. Replace fuse.
2. Check topper fuse. 2. Check harness for a short circuit to ground.
Is fuse good?
Yes
Measure voltage at topper fuse. No

Refer to Ignition Diagnostic Chart.
Is 12 VDC measured?
Yes
1. Remove solenoid 1. Disconnect multiconnector

Push topper switch to the left connector. at topper switch. Check red/white
No
position and then to right. No 2. Check voltage at right No 2. Measure voltage at red/white wire between
3100-6
Does light come on in the solenoid blue or left blue/black wire. topper fuse and
connector? wire. Is 12 VDC measured? switch.
Is 12 VDC measured?
TOPPER SYSTEM
Yes
Yes Yes
Continue on next page. Check black/white wire Perform a switch check. No

Replace switch.
for a good connection. Is the switch good?
Is ground wire OK?
Yes
Yes No
Continue on next page.

Replace DIN connector on solenoid. Repair ground wire.
cp1999250002c
TOPPER SYSTEM
All Functions on Topper

Do Not Operate—Whole or Shredder (Continued)
Electrical Check
1. Reconnect switch.
2. Push switch to left or right. No Replace one amp diode at timer.
Is 12 VDC measured at terminal
14 topper 30 second timer?
Yes
Check voltage at timer terminal 9 or 12. No

Is 12 VDC measured? Check harness between timer and topper
Yes
Check voltage at timer terminal 8 or 5. No

Check ground connection at timer terminal 13.
Is 12 VDC measured?
Is ground good?
Yes Yes No
Repair ground
Check wire between timer and
Replace timer. connection.
topper solenoid.
3100-7
cp1999250002c
TOPPER SYSTEM
All Topper Functions Do Not Operate—Whole or Shredder
Hydraulic Check
Perform a charge pressure check.

Refer to page 0002-14 in repair No
Repair pump.
manual for proper procedure.
Is pressure OK?
Yes
Perform a pilot line check. Refer to

page 0002-16 in repair manual for No Check shuttle valve which is
proper procedure. located in pilot line circuit and
Is pilot line OK? turns collectors On and Off.
Yes
No Repair or change damaged spool

Is spool moving freely in valve?
in topper valve.
Yes
1. Install a 344 bar (5000 PSI)

No Check and change main relief. Yes
gauge into topper valve test Done.
port.
2. Block topper to prevent movement.
3. Turn port relief up over 241 bar No
(3500 PSI).
4. Engage park brake, start engine
and run at full throttle. Flow rate the gear pump. Yes
Repair pump.
5. Turn topper On. Is it less than 106 L/Min (28 GPM)?
Is main relief 241 bar (3500 PSI)?
No
Yes
Check main relief in topper valve.
Lower port relief pressure to 206

bar (3000 PSI). No
Is pressure 206 bar (3000 PSI)? Check topper motor.
Yes
Done.
3100-8
cp1999250002c
SECTION 3200
CROP DIVIDER SYSTEM
Crop Divider Theory of Operation ........................................................... 3200-3

Crop Divider Hydraulic Theory of Operation .......................................... 3200-3
Crop Divider Electrical Theory of Operation ........................................... 3200-3
Crop Divider Specifications ..................................................................... 3200-3
Crop Divider Control Operation .............................................................. 3200-3
Crop Divider Electrical Schematic .......................................................... 3200-4
Crop Divider Hydraulic Schematic .......................................................... 3200-5
Twin Crop Dividers Showing Slow or No Operation (Electrical) ........... 3200-6
Twin Crop Dividers Showing Slow or No Operation (Hydraulic) ........... 3200-7
Crop Dividers Showing Slow or No Operation (Electrical) .................... 3200-8
Crop Dividers Showing Slow or No Operation (Hydraulic) .................... 3200-9
Crop Divider Lift Does Not Operate Properly (Electrical) ....................... 3200-10
Crop Divider Lift Does Not Operate Properly (Hydraulic) ....................... 3200-11
Side Knives Do Not Operate (Electrical) ................................................. 3200-12
Side Knives Do Not Operate (Hydraulic) ................................................. 3200-13
cp1999250002c
cp1999250002c
CROP DIVIDER SYSTEM
Crop Divider Theory of Operation When the left crop divider switch is depressed in
The crop dividers are mounted on a frame attached the UP position, current flows out the 4-way joystick
to the front of the combine with two lift arms. These lift connector red wire to Front 22-Pin Connector I and to
arms raise and lower the crop dividers while maintaining the left crop divider solenoid. When the left crop divider
a 12.7 mm (1/2") clearance between the crop divider shoe switch is depressed in the DOWN position, current flows
and the ground. The height is adjusted by a hydraulic out the 4-way joystick connector red/black wire to Front
cylinder operated from the cab. 22-Pin Connector J and to the left crop divider solenoid.
A scroll assembly is mounted on the crop divider When the right crop divider switch is depressed in
frame. The scroll is a conical shaped section which has a the UP position, current flows out the 4-way joystick
welded spiraling flight. It is rotated by a hydraulic motor, connector white wire to Front 22-Pin Connector K and to
which also supports the top of the scroll with a splined the right crop divider solenoid. When the right crop divider
adapter. The bottom of the scroll is supported by a flange switch is depressed in the DOWN position, current flows
bearing mounted to the crop divider frame. out the 4-way joystick connector white/black wire to Front
The rear of the crop divider frame has a shoe 22-Pin Connector L and to the right crop divider solenoid.
assembly which floats to conform to ground conditions.
Crop Divider Specifications

Crop Divider Hydraulic Theory of Operation Pump flow for the crop divider circuit is 20 GPM
The triple pump supplies oil from its rear (blind end) and it comes from the right triple pump (blind end) section
section to a VG20 pilot operated directional valve. When at full throttle.
in Neutral, oil flows through the open center spool of the
valve and back to tank, taking the path of least resistance. Crop Divider Scroll ........... VG20—172 bar (2500 PSI)
With the valve in FORWARD, oil flow is directed to
the right crop divider scroll motor, then to the right twin
crop divider scroll motor (if so supplied). Then oil flows to Crop Divider Control Operation
the left crop divider scroll motor, then to the left twin crop The crop dividers are controlled by switches located
divider scroll motor (if so supplied) and back to the on the joysticks. Pump flow for the crop divider circuit
directional valve. From the directional valve oil flows back (20 GPM at full throttle) comes from the right triple pump
to the tank. (blind end) section.
Crop Divider Electrical Theory of Operation

Battery power comes from red wire to the 30 amp
fuse. Current flows from the battery fuse through the
red wire to ignition relay terminal 30 and key switch
terminal BAT. With the key switch ON, current flows
from IGN terminal through the red/white wire to ignition
relay terminal 86, energizing it. Current from terminal 30
goes through terminal 87 and exits through the red/white
wire to the 5 amp crop divider fuse. From the fuse, current
flows to 3-way joystick plug B red/white wire.
The crop divider switch is located on top of the
joystick. Pressing the bottom of the left joystick switch
lifts the left crop divider, while pressing the top of the left
switch lowers it. The right switch works the same as the
left.
3200-3
cp1999250002c
CROP DIVIDER SYSTEM
Crop Divider
1190330105
3200-4
cp1999250002c
CROP DIVIDER SYSTEM
Crop Divider
Hydraulic Schematic
1671354118
3200-5
cp1999250002c
CROP DIVIDER SYSTEM
Twin Crop Dividers Showing

Electrical Check Slow or No Operation
Stop engine, turn key switch to IGN and engage park
brake. Turn chopper/basecutter switch to FWD and then
Yes
REV. Wait 5 seconds for timer to engage. Go to Hydraulic Check.
Is light in solenoid connector lit?
No
Check 5 amp basecutter/chopper Replace fuse and check for a shorted
No
fuse. Is fuse good? circuit or component.
Yes
Measure voltage at basecutter/ Check voltage on red/white wire between
No 87 IGN relay terminal and basecutter/
chopper fuse. Is 12 VDC present?
chopper fuse and joystick. Refer to
Yes Ignition Circuit Check.
Disconnect multiconnector at
basecutter/chopper switch. Measure No Check red/white wire between basecutter/
for 12 VDC at red/white wire. Is chopper fuse and switch.
voltage present?
Yes
A A—Right Twin Crop Divider Motor
Perform switch check. No B—Left Twin Crop Divider Motor
Is switch good? Replace switch. C—Right Single Crop Divider Motor

D—Left Single Crop Divider Motor
Yes
Push basecutter switch to forward No
and check voltage at basecutter Check violet wire between basecutter
timer terminal 9. Is 12 VDC present? switch and basecutter timer. C
Yes D B
Check voltage at basecutter timer No Check diode at basecutter timer.

terminal 14. Is 12 VDC present? No Replace diode.
Is diode good?
Yes
Yes
Check voltage at basecutter timer No
terminal 5. Is 12 VDC present? Replace topper timer. Check violet/black wire
between basecutter switch
Yes and basecutter timer.
Check violet wire between basecutter
No
timer and basecutter solenoid. Is Repair wire.
wire good? Reverse —Yellow/Black
Forward — Yellow
Yes
Basecutter
Push basecutter switch to reverse
and check voltage at basecutter No Check violet/black wire between
timer terminal 12. Is 12 VDC present? basecutter switch and basecutter timer.
Located under left fender
Yes
Check voltage at basecutter timer No Check diode at basecutter No
terminal 14. Is 12 VDC present? Replace diode.
timer. Is diode good?
Yes Yes
Check voltage at basecutter timer No Replace basecutter Check violet/black wire
terminal 8. Is 12 VDC present? timer. between basecutter switch
Yes and basecutter timer.
Check violet/black wire between

basecutter timer and basecutter
solenoid.
3200-6
cp1999250002c
CROP DIVIDER SYSTEM
Twin Crop Dividers Showing Slow or No Operation

Hydraulic Check
No
Perform a charge pressure check. Repair
Is charge pressure OK? pump.
Reverse —Yellow/Black
Yes Forward — Yellow
Perform a pilot line check. No Basecutter
Check 12 V
Is pilot line OK? solenoid valve.
Yes
Located under left fender
No
Is spool moving Repair or
freely in valve? replace.
Yes
1. Block left side crop divider C and right side crop

divider D to stop all movement.
2. Install a 345 bar (5000 PSI) gauge at test port of VG Check inside crop divider motor.
20 valve located on right side under fender. 1. Hub spline adapter. No Repair or
No
3. Engage park brake, start engine and run at full 2. Internal damage. replace
throttle. Is motor OK? motor.
4. Engage crop dividers in forward.
5. Observe test gauge.
Is pressure 172 bar (2500 PSI)? Yes
Yes Flow rate gear pump. Yes Repair or replace

Is flow less than 64 L/ gear pump.
Min (17 GPM)?
Done.
No
Check flow rate VG20 valve. Yes Repair or replace

Is flow less than 64 L/min valve.
(17 GPM)?

B—Left Twin Crop Divider Motor No
C—Right Single Crop Divider Motor
Done.
D
B
3200-7
cp1999250002c
CROP DIVIDER SYSTEM
Electrical Check Crop Dividers Showing

Stop engine, turn key switch to IGN and Slow or No Operation
engage park brake. Turn chopper/
Yes
basecutter switch to FWD and then REV. Go to Hydraulic Check.
Wait 5 seconds for timer to engage.
No
Check five amp basecutter/chopper fuse. No Replace fuse and check for a
Yes
No Check voltage on red/white wire between 87
Measure voltage at basecutter/chopper fuse.
IGN relay terminal and basecutter/chopper
Is 12 VDC present?
fuse and joystick. Refer to Ignition Circuit
Yes
Disconnect multiconnector at basecutter/chopper No Check red/white wire
switch. Measure for 12 VDC at red/white wire. between basecutter/
Is 12 VDC present? chopper fuse and switch.
Yes A A—Right Twin Crop Divider Motor

B—Left Twin Crop Divider Motor
Perform switch check. No C—Right Single Crop Divider Motor
Replace switch. D—Left Single Crop Divider Motor
Is switch good?
Yes
Push basecutter switch to forward and No Check violet wire between
check voltage at basecutter timer terminal 9. basecutter switch and
C
Is 12 VDC present? basecutter timer.
Yes D B
No
Check voltage at basecutter timer No Check diode at Replace Diode.
terminal 14. basecutter timer.
Is 12 VDC present? Is diode good? Yes
Yes
Check violet wire between
Check voltage at basecutter timer terminal # 5. No basecutter switch and
Is 12 VDC present? Replace topper timer.
basecutter timer.
Yes
Check violet wire between basecutter timer No
and basecutter solenoid. Repair wire.
Is wire good?
Yes
Push basecutter switch to reverse and check voltage No
at basecutter timer terminal 12. basecutter switch and basecutter timer.
Is 12 VDC present?
Yes
Check voltage at basecutter timer terminal 14. No Check diode at basecutter timer. No
Replace diode.
Is 12 VDC present? Is diode good?
Yes
Yes
No
Check voltage at basecutter timer terminal 8. Replace basecutter timer.
Is 12 VDC present?
Check violet/black wire
between basecutter switch
Yes
and basecutter timer.
Check violet/black wire between basecutter
timer and basecutter solenoid.
3200-8
cp1999250002c
CROP DIVIDER SYSTEM
Crop Dividers Showing Slow or No Operation
Hydraulic Check
Perform a charge pressure check.

Refer to page 0002-15 for proper B—Left Twin Crop Divider Motor
procedure. C—Right Single Crop Divider Motor
Perform a pilot line check. Refer to

page 0002-17 for proper procedure.
Is spool moving freely in valve? No Change spool D B

or valve.
Yes
1. On left side, block the side crop divider C to

stop movement. Place a 345 bar (5000 PSI
gauge at test port on VG20 Valve located
under right fender.
2. Start engine and run at full throttle. Park
brake engaged. Engage crop dividers in
forward.
Yes
No
Done.
Check the inside crop divider motor:

Ø Hub spline adapters. No Repair or replace
motor.
Ø Internal damage.
Is motor OK?
No Flow rate VG20 Valve. Yes Repair or replace

Yes
Is flow less than 64 L/Min (17 GPM)? VG20 valve.
No
Flow rate gear pump. Is flow less Yes
than 64 L/Min (17 GPM)? Repair or replace gear pump.
Done.
3200-9
cp1999250002c
CROP DIVIDER SYSTEM
Crop Divider Lift Does Not Operate Properly
Electrical Check

IGN and engage park brake.
No Check 5 amp joystick fuse.
2. Press LH and RH crop divider No Change fuse and check for a
Is fuse good?
switch to UP position. shorted circuit or component.
Is red light located on solenoid
connector lit? Yes
Measure voltage at joystick 5 Check red/white wire between

Yes No IGN relay terminal 87 and crop
amp fuse.
Is 12 VDC measured? divider fuse. Refer to Ignition
Refer to crop divider lift Circuit Check.
does not operate properly Yes
hydraulic check.
1. Disconnect multiconnector at
joystick harness. No Check red/white wire between
2. Measure voltage at red/white joystick plug and crop divider
wire. fuse.
Is 12 VDC measured?
Yes
Perform switch check. No

Replace switch.
Is switch good?
Yes
Check wire between switch and

solenoid.
3200-10
cp1999250002c
CROP DIVIDER SYSTEM
Crop Divider Lift Does Not Operate Properly
Hydraulic Check
Check charge pressure. No

Repair pump.
Is charge pressure OK?
Yes
Check pilot line. No

Check 12 V solenoid valve.
Is pilot line OK?
Yes
No
Does spool move Repair or replace.
freely in valve?
Yes
1. Plug pressure gauge to in-line relief

valve located in screened engine
compartment. Yes Check cylinder for internal leakage. No
Done.
2. Start engine with park brake Is cylinder leaking?
engaged. Run to full throttle.
3. Turn 5-bank valve up to 3500 PSI. Yes
4. Pull joystick backward to basecutter
lift all the way up and hold.
Repair or replace cylinder.
5. Set in-line relief valve to 3250 PSI.
Is pressure 3250 PSI?
No
1. Inspect or repair valve in No

engine compartment. Flow rate gear pump. Yes
2. Perform test as above. Is flow less than 64 L/min Change pump.
Is pressure 3250 PSI? (17 GPM)?
No
Yes
Done.
Done.
3200-11
cp1999250002c
Side Knives Do Not Operate
Electrical Check
1. Stop engine, turn key switch

No Change fuse and check for a shorted
to IGN and engage park brake.
2. Check side knife fuse. circuit or component.
Is fuse good?
Yes
Measure voltage at 5 amp side No

knife fuse. Refer to Ignition Circuit Diagnostic
Is 12 VDC measured?
Yes
No Disconnect solenoid connector and 1. Disconnect multiconnector at
No Check red/white
Push the side knife switch to ON. measure voltage. side knife switch. No
wire between side
Is light on solenoid connector lit? Is 12 VDC measured? 2. Measure voltage of red/white wire.
knife fuse and
3200-12
Is 12 VDC measured?
switch.
Yes Yes
Yes
No No
Check solenoid ground connector. Perform a side knife
Replace switch.
CROP DIVIDER SYSTEM
Go To Hydraulic Check Is connector good? Repair switch check.

Next Page Is the switch good?
Yes
Yes
Yes
Replace DIN connector.
Done.
Does side knife work? Check wires between
side knife switch and
No side knife solenoid.
Go To Hydraulic Check
Next Page
cp1999250002c
CROP DIVIDER SYSTEM
Side Knives Do Not Operate

Hydraulic Check
From Previous Page
Perform a charge pressure check. Refer to No

page 0163-12 for proper procedure. Repair pump.
Is pressure OK?
Yes
Perform a pilot line check. Refer to No

page 0163-14 for proper procedure. Check 12 V solenoid valve.
Is Pilot line OK?
Yes
Is spool moving No Repair or change

freely in valve? damage valve.
Yes
1. Install a 344 bar (5000 PSI) gauge into side knives No Check and change relief. Yes
valve test port. Done.
2. Block side knives to prevent movement.
3. Turn port relief to over 241 bar (3500 PSI).
No
4. Engage park brake, start engine and run at full
throttle.
5. Turn topper ON. Flow rate the gear pump. Yes
Is main relief 241 bar (3500 PSI)? Is it less than 106 L/min (28 GPM)? Replace pump.
Yes No
No 1. Engage park brake, start engine and run

1. Lower port relief pressure to 172 bar at full throttle. No
(2500 PSI). 2. Flow rate the side knife motor on the Done.
2. Check or change port relief, return side of the motor.
Is pressure 172 bar (2500 PSI)? Is flow less than 106 L/min (28 GPM)?
Yes Yes
1. Check for broken motor shaft. No

Done.
2. Check motor for internal wear. Repair or replace
Is motor OK?
Yes
Stop engine and turn side knife No Check hub assy. No

manually. Done.
Is it Jammed?
Will side knife turn?
Yes
Yes
Repair or replace.
Done.
3200-13
cp1999250002c
SECTION 3300
BASECUTTER SYSTEM
Basecutter Theory of Operation ............................................................... 3300-3

Basecutter Electrical System Operation ................................................ 3300-3
Hydraulic System Operation .................................................................... 3300-3
Basecutter Specifications ........................................................................ 3300-4
Basecutter Control ................................................................................... 3300-4
Test Procedure: Basecutter Control Valve Main Relief ........................... 3300-4
Chopper, Feed Rollers, and Basecutter Hydraulic Schematic ................ 3300-6
Basecutter Does Not Operate (Electrical Check) ..................................... 3300-7
Basecutter Does Not Operate (Hydraulic Check) .................................... 3300-8
Basecutter Does Not Lift Correctly or Leaks Down—Track .................... 3300-9
Basecutter Does Not Lift Correctly or Leaks Down—Wheel ................... 3300-10
cp1999250002c
cp1999250002c
BASECUTTER SYSTEM
Basecutter Theory of Operation When the basecutter/chopper switch is activated in

The basecutter is powered by a gear type hydraulic REVERSE, current flows through the violet/black wire
motor. This motor turns a number of gears to supply the to the basecutter/chopper timer, terminal 12, and through
required torque to the basecutter blades that in turn cut a 1 amp diode to terminal 14, causing the timer to energize.
the cane. The basecutter cleanly cuts the cane without After 5 seconds, the contacts close and current flows
splitting and directs it into the feed rollers. Initial cleaning from terminal 8 to Front 22-Pin Connector, pin D. Current
occurs as loose material falls off the disc surface and back then flows to the basecutter/chopper reverse solenoid,
onto the ground. causing it to energize.
The solenoids are grounded through the Front 22-
Pin Connector, pin U to the dash ground.
Basecutter Electrical System Operation
Battery power goes through the red wire to terminal
30 accessory relay and to the battery fuse. Power then Hydraulic System Operation
continues on to the key switch battery terminal. The first two sections (input end) of the lower left
The basecutter and chopper switch is located on pump act as one pump because they are connected
the side console. To engage the basecutter/chopper, press internally. These sections have one outlet port that supplies
the switch in the direction of desired rotation. After about oil to the basecutter valve. The basecutter motor also
5 seconds, the basecutters, choppers, and feed rollers all acts as a flow divider with three sections creating a three
turn on at the same time. Current flows through the white circuit family. Flow is divided to the three circuits.
wire to relay terminal 86, energizing the relay. Current The bottom (output shaft end) section directs flow
then flows out terminal 87, through the white wire to the to the directional valve then back to tank.
basecutter on/off fuse. From the fuse, current then flows The center sections directs flow to the buttlifter and
through the white wire to the basecutter/chopper switch. feed rollers A1, A2, and B1. Oil returns through the
When the basecutter/chopper switch is activated to directional valve then back to tank.
FORWARD, current flows through the violet wire to the The blind end section directs flow to the power feed
basecutter/chopper timer terminal 9 and through a 1 amp roller. When the optional knockdown roller is installed, it
diode to terminal 14, causing the timer to energize. After is hooked up in a series, within this circuit.
5 seconds, the contacts close and current flows from There are also two 172 bar (2500 PSI) in line relief
terminal 5 to Front 22-Pin Connector, pin C. Current then valves installed in this circuit. These relief valves protect
flows to the basecutter and chopper forward solenoid, the motor in the circuit from the basecutter motor/flow
causing it to energize. divider and are located under the right front fender.
Main relief Valve
Test Gauge Fitting
3300-3
cp1999250002c
BASECUTTER SYSTEM
Basecutter Specifications
Pump flow for the basecutter circuits is
approximately 303 L/min (80 GPM) with the engine at
full throttle.
Basecutter Main Relief ...... 190 ± 7 bar (2750 ± 100 PSI)
Buttlifter and Power Feed

Roller Relief ................. 172.4 ± 7 bar (2500 ± 100 PSI)
Basecutter Control
The basecutter is controlled by the basecutter/
chopper control switch.
Test Procedure: Basecutter Control Valve

Main Relief
1. Block basecutter blades.
2. Bring hydraulic oil temperature to 38° ± 5° (100°F
± 10°).
3. Connect a 0-345 bar (0-5000 PSI) gauge to test
port located on basecutter valve.
4. Start engine and turn basecutter ON to normal
cutting mode.
5. Bring engine to full throttle; check pressure.
6. Adjust to 190 ± 7 bar (2750 ± 100 PSI), if
necessary, by loosening jamnut on main relief.
Screw inward to increase pressure; outward to
decrease pressure.
7. After making adjustment, secure jamnut.
3300-4
cp1999250002c
BASECUTTER SYSTEM

7243002970
3300-5
cp1999250002c
BASECUTTER SYSTEM
Chopper, Feed Rollers, and Basecutter

Hydraulic Schematic
1671354100
3300-6
cp1999250002c
BASECUTTER SYSTEM
Electrical Check
Stop engine, turn key switch to IGN and engage Yes
park brake. Turn chopper/basecutter switch to Continue troubleshooting in the Hydraulic Check section.
FWD and then REV. Wait 5 seconds for timer to
engage.
No
Check 5 amp basecutter/chopper fuse. No Replace fuse and check for a shorted circuit or component.
Is fuse good?
Yes
Measure voltage at basecutter/chopper fuse. No Check voltage on white wire between 87 ACC
Is 12 VDC present? relay terminal and basecutter/chopper fuse.
Yes
Disconnect multiconnector at basecutter/chopper No Check red/white wire between basecutter/chopper
switch. Is 12 VDC measured at red/white wire? fuse and switch.
Yes
No
Perform switch check. Is switch good? Replace switch.
Yes
Push basecutter switch to forward and check No Check violet wire between basecutter switch and
voltage at basecutter timer terminal 9.
basecutter timer.
Is 12 VDC pressure?
Yes
Is 12 VDC present? Is diode good? Replace diode.
Yes Yes
Check voltage at basecutter timer terminal 5. No Check violet wire between basecutter
Is 12 VDC present? Replace topper timer. switch and basecutter timer.
Yes
Check violet wire between basecutter timer and

No
basecutter solenoid. Repair wire.
Is wire good?
Yes
Push basecutter switch to reverse and check No Check violet/black wire between basecutter switch and
voltage at basecutter timer terminal 12. basecutter timer.
Is 12 VDC present?
Yes
Check voltage at basecutter timer terminal 14. No No Replace

Check diode at basecutter timer.
Is 12 VDC present? Is diode good? diode.
Yes
Yes
Check voltage at basecutter timer terminal 8. No
Replace basecutter timer.
Is 12 VDC present? Check violet wire
between basecutter
Yes switch and basecutter
timer.
basecutter timer and basecutter solenoid.
3300-7
cp1999250002c
BASECUTTER SYSTEM
Hydraulic Check
Perform a charge pressure No

check. Refer to page 0002-15 for Repair
proper procedure. Pump.
Yes
Perform a pilot line check. No Chck 12V

Refer to page 0002-17 for
solenoid valve
proper procedure.
Yes
Adjust
Is spool moving No for C2 Adjust
Change spool for C1
freely in valve? C1
or valve.
C2
Yes
1. Plug a 345 bar (5000 PSI) gauge in

test port.
2. Block basecutter to prevent
movement.
3. Start engine, engage park brake, and
bring low idle up to 1000 RPM’s.
4. Engage basecutter function in No Check or change relief. Yes
FORWARD. Is pressure 190 bar (2750 PSI)? Done.
5. Bring engine to full throttle and
observe gauge.
Is pressure 190 bar (2750 PSI)? No
Yes
Flow rate basecutter 302 L/Min (80 GPM) valve. Yes Repair or replace
Is rate less than 272 L/Min (72 GPM)? basecutter pump.
Done.
No
Flow rate basecutter 302L/Min (80 GPM) valve. Yes

Is rate less than 272 L/Min (72 GPM)? Repair or replace
basecutter valve.
Yes
No Repair or replace
Check basecutter motor for internal leakage.
Is motor OK? basecutter motor.
3300-8
cp1999250002c
BASECUTTER SYSTEM
Basecutter Does Not Lift Correctly

or Leaks Down—Track
Hydraulic Check
1. Plug pressure gauge to the in-line relief

valve, located in the screened engine Yes Check 5 bank relief pressure. No Adjust 5 bank relief to
compartment. Is pressure 172 bar (2500 PSI)? 172 bar (2500 PSI).
2. Start engine, engage park brake, and
run engine at full throttle. Yes
3. Turn 5-bank valve up to 3500 PSI. Check accumulator nitrogen Charge accumulator
No
4. Lift basecutter to highest position and pressure. with nitrogen.
hold that position with joystick. Is pressure 51.7 bar (750 PSI) ? Does it keep charge?
5. Set in-line relief valve to 3250 PSI.
Is pressure 3250 PSI? Yes No Yes
Test holding valve. Replace
No accumulator.
WARNING! Done.
Yes
Inspect or repair in-line relief valve.
Done. Before testing holding valves, block
Is pressure 3250 PSI?
cylinders to prevent movement.
No Check both holding
No 1. Disconnect hose located at C1 of valve reliefs.
holding valve. Is pressure 2500 PSI?
Flow rate gear pump. No
2. Plug hose and connect a manual Yes
Is flow less than 45 L/min (12 GPM)? No
hydraulic pump to holding valve.
3. Apply pressure.
Replace holding valve.
Yes 4. Disconnect other hose at C2
side.
Replace pump. 5. Repeat test.
Yes
Check cylinders for internal leakage.
Adjust Adjust
for C2 for C1
C1
C2
3300-9
cp1999250002c
BASECUTTER SYSTEM
Basecutter Does Not Lift Correctly

or Leaks Down—Wheel
Hydraulic Check
Check valve spool No

Is spool moving freely Repair or replace valve.
in valve?
Yes
No
Yes Check 5 bank relief pressure. Repair relief
1. Plug a 345 bar 5000 PSI gauge to in-line Is pressure 172 bar (2500 PSI)? valve.
relief valve located inside the engine
compartment Yes
2. Turn 5 bank relief valve up to over 207
bar (3000 PSI). Done.
3. Pull joystick backwards to raise
basecutter all the way up.
4. Observe gauge and record pressure. Test holding valve.
Is pressure 3250 PSI? WARNING!
No Before testing holding valves, block

Adjust both holding relief
cylinders to prevent movement.
to 172 bar (2500 PSI).
Inspect or repair in-line relief valve. Yes No Is pressure 172 bar
Is pressure 193 bar (2800 PSI)? 1. Disconnect hose located at C1 of
(2500 PSI)?
holding valve.
2. Plug hose and connect a manual No
No Yes
hydraulic pump to holding valve.
Yes 3. Apply pressure.
Flow rate gear pump. Replace holding valve.
Does valve open at 2500 PSI?
Is flow less than 45 L/min (12 GPM)?
No Yes No
Replace pump. 4. Disconnect other hose at C2 side.

Done. 5. Repeat test.
Yes Does valve open at 172 bar
(2500 PSI)?
3300-10
cp1999250002c
SECTION 3400
FEED ROLLER SYSTEM
Description ............................................................................................... 3400-3

Feed Roller Circuit Relief ......................................................................... 3400-4
Feed Roller Specifications ...................................................................... 3400-4
Feed Roller Control Operation ................................................................ 3400-4
Buttlifter Theory of Operation .................................................................. 3400-4
Front Feed Roller Test Procedure ........................................................... 3400-4
Rear Feed Roller Test Procedure ............................................................. 3400-4
Power Feed Roller Theory Of Operation ................................................. 3400-5
Power Feed Roller Electrical System Operation .................................... 3400-5
Power Feed Roller Hydraulic System Operation .................................... 3400-5
Power Feed Roller Specifications ........................................................... 3400-5
Power Feed Roller Control ...................................................................... 3400-6
Power Feed Roller Test Procedure .......................................................... 3400-6
Feed Roller Hydraulic Schematic ............................................................ 3400-7
Rear Set Feed Roller(s) Forward/Reverse and Billet Selector Do Not
Operate or Operate Slowly [EC] ........................................................... 3400-8
Rear Set Feed Rollers Forward/Reverse and Billet Selector Do Not
Operate or Operate Slowly [HC] ........................................................... 3400-9
Feed Rollers Forward/Reverse Do Not Operate and Chopper Blades
Operate .................................................................................................. 3400-10
Power Knockdown Feed Rollers have Slow or No Operation and Other
Basecutter Functions Operate [EC] ...................................................... 3400-11
Power Knockdown Feed Rollers has Slow or No Operation Other Basecutter
Functions Operate [HC] ........................................................................ 3400-12
Power Feed Rollers Do Not Operate and Other Basecutter Functions
Operate .................................................................................................. 3400-13
cp1999250002c
cp1999250002c
FEED ROLLER SYSTEM
A5
A4
A3
A2
B5
B4
A1
B3
B2
B1
BL
Description
ARollers above the crane
BRollers below the crane
BLButtlifter
The feed rollers consist of a buttlifter roller (BL), located directly behind the basecutter, and five fixed rollers
below the crane with five floating rollers above the cane.
3400-3
cp1999250002c
FEED ROLLER SYSTEM
Feed Roller Circuit Relief Rear Feed Roller Test Procedure

Flow for the feed rollers is delivered from the chopper Ensure that main relief on chopper control valve has
motor. The operator chosen billet length determines which correct pressure.
motor supplies oil to the front or rear feed rollers. 1. Bring hydraulic oil temperature to 38°C ± 5°
(100°F ± 10°).
2. Connect a 0-345 bar (0-5000 PSI) gauge to in-
Feed Roller Specifications line relief valve, located behind filter tank on left
The feed rollers are powered by motors. side of combine.
System Relief Pressure .................. 172 bar (2500 PSI) 3. Disconnect and plug hose A and cap fitting B.
4. Start engine and turn on chopper to FORWARD
cutting mode.
Feed Roller Control Operation
The feed rollers are controlled by the basecutter/ 5. Bring engine to full throttle; check pressure.
chopper control switch. 6. Adjust in-line relief valve to 172 bar (2500 PSI),
if necessary.
Buttlifter Theory of Operation

The buttlifter feed roller is powered by two geroler
type motors.
The buttlifter feed roller is designed to lift the cane
from the cut end and help direct it into the feed roller
system.
Front Feed Roller Test Procedure

Ensure that main relief on basecutter control valve
has correct pressure.
1. Bring hydraulic oil temperature to 38°C ± 5° B
(100°F ± 10°). A
2. Block power feed roller.
port, located on right side in-line relief valve.
4. Start engine and turn on basecutter to FORWARD
cutting mode.
6. Adjust in-line relief valve to 172 bar (2500 PSI),
if necessary.
3400-4
cp1999250002c
FEED ROLLER SYSTEM
Power Feed Roller Theory of Operation Power Feed Roller Hydraulic System
The power feed roller is powered by two geroler Operation
type motors. The power feed roller is designed to deliver The first two sections (shaft end) of the lower left
tangled or down cane to the rollers. The power feed roller pump function as one pump because they are connected
straightens the cane so that it can align with the combine internally. Oil flow is directed to the basecutter valve
and thus reduce cane loss at the rollers. then through the basecutter motor/flow divider while the
third section directs oil flow to the power feed rollers.
Power Feed Roller Electrical System

Operation Power Feed Roller Specifications
Battery power comes through the red/white wire to Pump flow for the basecutter circuits is
the 30 amp battery fuse. Current flows through the red approximately 303 L/Min (80 GPM) with the engine at
wire to ignition relay terminal 30 and key switch terminal full throttle.
BAT.
The basecutter and chopper switch is located on Basecutter Main Relief ............. 190 bar (2750 PSI)
the side console. To engage the basecutter/ chopper, press
the switch in the direction of the desired movement. After Power Feed .............................. 172 bar (2500 PSI)
5 seconds, the basecutter, feed rollers and choppers should
all turn ON at the same time. Current flows through the
red/white wire to ignition relay terminal 86, energizing the
relay. Current flows out terminal 87 through the red/white
wire to the basecutter on/off fuse. Current flows from
the fuse through the red/white wire to the basecutter/
chopper switch.
When the basecutter/chopper switch is activated to
FORWARD, current flows through the violet wire to the
basecutter/chopper timer terminal 9 and through a 1 amp Main relief Valve
diode to terminal 14, causing the timer to energize. A
after 5 seconds, the contacts close and current flows from
terminal 8 to Front 22-pin connector, pin C. The current
then flows to the basecutter and chopper forward solenoid,
causing it to energize.
When the basecutter/chopper switch is activated in
REVERSE, current flows through the violet/black wire
to the basecutter/chopper timer, terminal 12, and through
a 1 amp diode to terminal 14, causing the timer to energize.
After 5 seconds, the contacts close and current flows
from terminal 5 to Front 22-pin connector, pin D. Current
then flows to the basecutter/chopper reverse solenoid,
causing it to energize. Test Gauge Fitting
pin connector, pin U to the dash ground.
3400-5
cp1999250002c
FEED ROLLER SYSTEM
Power Feed Roller Control

The basecutter control operates the power feed
rollers.
Power Feed Roller Test Procedure

Ensure that main relief on basecutter control valve
has correct pressure.
1. Bring hydraulic oil temperature to 38°C ± 5°
(100°F ± 10°).
2. Block power feed roller.
port, located on right side in-line relief valve,
located under right fender.
4. Start engine and turn on basecutter to FORWARD
cutting mode.
6. Adjust in-line relief valve to 172 bar (2500 PSI),
if necessary.
3400-6
cp1999250002c
FEED ROLLER SYSTEM
Feed Roller
Hydraulic Schematic
1671354101
3400-7
cp1999250002c
FEED ROLLER SYSTEM
Rear Set Feed Roller(s) Forward/Reverse and Billet

Selector Do Not Operate or Operate Slowly [EC]
engage.
No
Is fuse good?
Yes
Measure voltage at basecutter/chopper fuse. No Check voltage on red/white wire between 87 ACC
Yes
Disconnect multiconnector at basecutter/chopper switch. No Check red/white wire between basecutter/chopper
Is 12 VDC measured at red/white wire? fuse and switch.
Yes
No
Yes
Push basecutter switch to FORWARD and No Check violet wire between basecutter switch and
check voltage at basecutter timer terminal 9.
basecutter timer.
Is 12 VDC present?
Yes
Yes Yes
Is 12 VDC present? Replace topper timer. switch and basecutter timer.
Yes

No
Is wire good?
Yes
Push basecutter switch to REVERSE and No Check violet/black wire between basecutter switch and
check voltage at basecutter timer terminal 12. basecutter timer.
Is 12 VDC present?
Yes

Yes
Yes
between basecutter
timer.
3400-8
cp1999250002c
FEED ROLLER SYSTEM
Rear Set Feed Rollers Forward/Reverse and Billet Selector

Do Not Operate or Operate Slowly
Hydraulic Check
Yes
No Check or change relief. Done.
Does chopper operate properly?
Yes
No
1. Disconnect hose fitting at A; plug
Refer to Chopper Check.
and cap.
2. Plug a 345 bar (5000 PSI) gauge
at B port of in-line relief valve.
3. Engage park brake, start engine
and bring low idle up to 1000
RPM. Flow rate feed roller Q-Brand
No flow divider between chopper Yes Repair or replace
4. Engage chopper function in
FORWARD. motor and Q-Brand (C). flow divider.
5. Bring engine to full throttle and Is flow less than 25 GPM?
observe gauge.
Is pressure 172 bar (2500 PSI)? No
Yes
Flow rate Q-Brand Flow Divider set on 100%, 50%,
Yes
Reconnect hose fitting A. 0% between Q-Brand and feed roller motor A.
Done.
Does feed roller operate properly? Flow check requirements:
@ 100%, flow should be 25 GPM.
No @ 50%, flow should be 12 GPM.
@ 0%, flow should be 0 GPM.
Stop engine. Is flow good?
Can all feed rollers be turned manually?
No Yes
No Yes
Check feed roller motors Repair or replace
Check bearings and for internal leakage. Q-Brand Flow Divider.
Done.
hub spline adapters.
3400-9
cp1999250002c
FEED ROLLER SYSTEM
Feed Rollers Forward/Reverse Do Not Operate and

Chopper Blades Operate
Perform Chopper Blade Diagnostic

Test before proceeding with this test.
Problem may be caused by faulty
chopper blade operation.
Yes
Do feed rollers operate properly? Done.
Hydraulic Check No
1. Stop engine and engage park brake. No Repair or replace

2. Perform feed roller test. in-line relief valve.
Yes
With the engine stopped:

Ø Check that all feed rollers can
be turned manually.
Ø Check bearings.
Ø Check hub spline adapters.
Ø Inspect feed roller motors.
3400-10
cp1999250002c
FEED ROLLER SYSTEM
Power Knockdown Feed Rollers have Slow or No

Operation and Other Basecutter Functions Operate [EC]
engage.
No
Is fuse good?
Yes
Measure voltage at basecutter/chopper fuse. No Check voltage on red/white wire between 87 IGN
Yes
Disconnect multiconnector at basecutter/chopper switch. No Check red/white wire between basecutter/chopper
Is 12 VDC measured at red/white wire? fuse and switch.
Yes
No
Yes
Push basecutter switch to forward and check No Check violet wire between basecutter switch and
voltage at basecutter timer terminal 9.
basecutter timer.
Is 12 VDC present?
Yes
Yes Yes
Is 12 VDC present? Replace topper timer.
switch and basecutter timer.
Yes

No
Is wire good?
Yes
Push basecutter switch to reverse and check No Check violet/black wire between basecutter switch and
voltage at basecutter timer terminal 12. basecutter timer.
Is 12 VDC present?
Yes

Yes
Yes
between basecutter
timer.
3400-11
cp1999250002c
FEED ROLLER SYSTEM
Power Knockdown Feed Rollers has Slow or No Operation

Other Basecutter Functions Operate
B
C
Hydraulic Check Power Feed

Roller Motor
1. Block the power knockdown

Knockdown
rollers to stop all movement. Motor
2. Place a 345 bar (5000 PSI) gauge
at test port on in-line relief valve.
3. Disconnect two hoses (A) on the
left power knockdown motor.
4. Plug the hose and cap the motor
A
connection.
5. With the engine at full throttle No Power Feed
and the basecutter engaged, Roller Motor
record pressure. Knockdown
Is pressure 179 bar (2500 PSI)? Motor
Yes
Repair or Replace right
power knockdown motor (C).
1. Block the power knockdown D
rollers.
2. Disconnect the two hoses (B)
at the right power knockdown
motor.
3. Plug the hose and cap the Yes
motor connection. Done.
4. With the engine at full throttle
and the basecutter engaged,
record pressure.
No
Repair or Replace left power

knockdown motor (D).
3400-12
cp1999250002c
FEED ROLLER SYSTEM
Power Feed Rollers Do Not Operate and

Other Basecutter Functions Operate
Hydraulic Check
1. Stop engine.
2. Check the two power feed rollers. No
3. Check hub spline adapter. Replace hub spline adapters.
Are they OK?
Yes
1. Block the power feed roller to stop all

movement.
2. Disconnect the hose (B) at the right
power feed roller motor. Yes Repair or replace right
3. Plug hose and cap motor connection
power feed roller motor.
at right motor B.
4. Place a 345 bar (5000 PSI) gauge on
in-line relief valve test port.
5. Run engine at full throttle.
No
1. Connect hose B on right power feed

roller.
2. Block power feed roller to stop all
movement.
3. Disconnect hose A at left power feed
roller motor coming from basecutter Yes Repair or replace left
motor A. power feed roller motor.
4. Plug hose and cap motor connection on
left motor.
5. Place 345 bar (5000 PSI) gauge on in-line
relief valve test port.
6. Run engine at full throttle.
No
Inspect basecutter motor Yes Check in-line

at power feed roller port.
relief valve.
Is motor OK?
No
Repair or replace motor.
B
RH Power Feed
Roller Motor
A
LH Power Feed
Roller Motor
3400-13
cp1999250002c
SECTION 3500
CHOPPER SYSTEM
Chopper Theory of Operation .................................................................. 3500-3

Chopper Electrical System Operation ..................................................... 3500-3
Chopper Hydraulic System Operation .................................................... 3500-3
Chopper Specifications ........................................................................... 3500-3
Control ...................................................................................................... 3500-3
Set Chopper Shaft Timing ....................................................................... 3500-4
Chopper Test Procedure .......................................................................... 3500-4
Chopper and Feed Roller Hydraulic Schematic ..................................... 3500-6
Chopper Blades Show Slow or No Operation ........................................ 3500-7
cp1999250002c
cp1999250002c
CHOPPER SYSTEM
Chopper Theory of Operation Chopper Hydraulic System Operation

By indexing the selector valves, the flows of 34 and The chopping system consists of two rotary shafts
17 L/Min (9 and 4.5 GPM) can be added to the 87.1 L/ with either two or three blades to each shaft. The six blade
Min (23 GPM) and fed into the feed roller motors. This system has three blades 120° apart on each shaft. The
addition speeds up the feed roller system and as the cane four blade system has two blades 180° apart on each shaft.
approaches the chopping mechanism it varies the billet The shafts are driven by individual orbital motors and
length. are synchronized by a flywheel.
Chopper Electrical System Operation Chopper Specifications

Battery power comes through the red wire to Pump flow for the chopper circuit is approximately
terminal 30 accessory relay and to the 30 amp battery 204 L/Min (54 GPM) with the engine at full throttle.
fuse. Current flows through the battery fuse to ignition
relay terminal 30 and key switch terminal BAT. Relief Pressure ................. 189±7 bar (2750±100 PSI)
The basecutter and chopper switch is located on
the side console. To engage the basecutter/ chopper, press
the switch in the direction of the desired movement. After Control
5 seconds, the basecutter, feed rollers and choppers should The chopper is controlled by the basecutter/chopper
all turn ON at the same time. Current flows through the control switch.
red wire to accessory relay terminal 86, energizing the
relay. Current flows out terminal 87 through the white
wire to the basecutter on/off fuse. Current flows from
the fuse through the red/white wire to the basecutter/
chopper switch.
When the basecutter/chopper switch is activated to
FORWARD, current flows through the violet wire to the
basecutter/chopper timer terminal 9 and through a 1 amp
diode to terminal 14, causing the timer to energize. After
5 seconds, the contacts close and current flows from
terminal 5 to Front 22-pin connector, pin C. Current then
flows to the basecutter and chopper forward solenoid,
When the basecutter/chopper switch is activated in
REVERSE, current flows through the violet/black wire
to the basecutter/chopper timer, terminal 12, and through
a 1 amp diode to terminal 14, causing the timer to energize.
After 5 seconds, the contacts close and current flows
from terminal 8 to Front 22-pin connector, pin D. Current
then flows to the basecutter/chopper reverse solenoid,
pin connector, pin U to the dash ground.
3500-3
cp1999250002c
CHOPPER SYSTEM
Set Chopper Shaft Timing Chopper Test Procedure
TOP
Chopper
Test
V l Gauge
Fi i
CANE
FLOW
Chopper Valve
190±7
Adj bar (2750 ±100
—Block
PSI)
—Engage
Ch in
F d
BOTTOM
1. Ensure that all blades are in their correct position. 1.Bring hydraulic oil temperature to 38°C±-12°F
The top blade must lead the bottom on cut rotation, (100F°±10°).
as shown above.
2. Turn the flywheel to rotate the chopper shafts, port, located on control valve.
apply paint (mark out blue) to both sets of bottom
3. Block chopper to prevent turning.
shaft blades. The top blades should mark the
bottom blades along the full width of the shaft. 4. Start engine and turn chopper ON in FORWARD
position.
3. If the lower blade is not marked, remove the small
inspection cover on the timing case, loosen the 5. Bring engine to full throttle, check pressure.
retaining bolts, move the gear slightly clockwise 6. Adjust to 190±7 bar (2750±100 PSI) if necessary,
and tighten to snag down the two opposing bolts. by loosening jamnut on main relief, located on the
Turn the flywheel slowly to check blade contact. chopper valve. Screw inward to increase
4. The correct adjustment has been achieved when pressure; outward to decrease.
a full contact is made blade to blade with a 7. After making adjustment; secure jamnut.
minimum amount of impact.
5. Securely tighten all bolts on timing gear, test
adjustment again, replace cover and check oil
level.
3500-4
cp1999250002c
CHOPPER SYSTEM

7243002970
3500-5
cp1999250002c
CHOPPER SYSTEM
Chopper and Feed Roller

Hydraulic Schematic
1671354101
3500-6
cp1999250002c
CHOPPER SYSTEM
Chopper Blades Show Slow or No Operation

Hydraulic Check
Are the blades jammed? No

Are the blades sharp? Repair
Yes

Check 12 V solenoid valve.
Is it OK?
Yes
Check spool in valve. No

Repair or replace valve.
Is spool moving freely?
Yes
1. Block choppers in FORWARD.

2. Plug a 345 bar (5000 PSI) Yes
Check that chopper
gauge at chopper valve. is not jammed.
No
1. Block chopper to stop all movement.

2. Disconnect hose from upper chopper motor.
3. Plug hose and cap motor.
4. Run engine at full throttle and observe
pressure.
No Yes
Repair or replace 1. Reconnect hose.

lower chopper motor. 2. Disconnect hose going to Yes 1. Flow rate chopper section of pump.
lower motor. 2. Rate should be 204 L/min (52 GPM).
3. Plug hose and cap motor. Is rate less than 182 L/min (48 GPM)?
4. Run engine at full throttle
and observe pressure.
Is pressure 190 bar (2750 PSI)? No Yes
Replace pump.
No 1. Place flow rate gauge on chopper
valve.
2. Rate should be 204 L/min (52 GPM).
Repair or replace Is rate less than 182 L/min (48 GPM)?
upper chopper motor.
Yes No
Replace valve. Done.
3500-7
cp1999250002c
SECTION 3600
EXTRACTOR SYSTEM
Primary Hood Rotate System Theory of Operation ................................ 3600-3

Electrical System Operation .................................................................... 3600-3
Specifications ........................................................................................... 3600-3
Control Operation .................................................................................... 3600-3
Primary Extractor Theory of Operation ................................................... 3600-4
Electrical System Operation .................................................................... 3600-4
Variable Primary Extractor ...................................................................... 3600-4
Specifications ........................................................................................... 3600-4
Control Operation .................................................................................... 3600-4
Primary Extractor Tachometer Electrical Schematic .............................. 3600-5
Primary Extractor Electrical Schematic .................................................. 3600-6
Primary Extractor Hydraulic Schematic .................................................. 3600-7
Fixed Speed Primary Extractor Hydraulic Schematic ............................ 3600-8
Fixed Speed Primary Extractor Does Not Operate ................................. 3600-9
Variable Primary Extractor Shows Slow or No Operation ..................... 3600-10
cp1999250002c
cp1999250002c
EXTRACTOR SYSTEM
Cartridge Relief Valve

CAdjustment
a r t ri d g
e 248
R el ±i 7
efbar
V al v e
A(3600 ± 100 PSI)
d j u s t me n t — 2 4 8 ± 7 bar
( 3 6 0 0 ± 1 0 0 P SI )
SSolenoid
ol e n oi Valve
d V al v e
PRIMARY HOOD ROTATE SYSTEM Specifications

Theory of Operation The gear pump flow for the fixed speed primary
The extractor fan consists of three curved blades extractor fan at maximum is approximately 155 L/Min
bolted to a hub. This fan forms a major part of the cleaning (41 GPM) with the engine at full throttle.
process by drawing loose materials such as trash, leaf, or The control valve has a pilot operated relief with a
dirt from the cane as it exits the choppers. solenoid pilot control.
The fixed primary extractor fan is powered by a
gear pump and driven by a gear motor. The extractor fan Control Pressure ............... 206.9 Bar (3000 PSI)
is designed to give a working area over the whole surface Fan Speed ......................... 1210 RPM
of the fan blade.
Control Operation
Hydraulic System Operation The primary extractor on/off switch is located on
The oil is supplied by a 155 L/Min (40 GPM) gear the main panel.
pump to the 6.4 in3 drive motor. The drive motor turns
the fans at approximately 1210 RPM.
Electrical System Operation

Battery power comes from Engine 22-pin connector
I through the red/white wire to the 30 amp fuse. Current
flows from the battery fuse through Engine 22-pin
connector K to ignition relay terminal 30 and key switch
terminal BAT. With the key switch ON, current flows
from IGN terminal through the red/white wire to the
primary extractor 5 amp fuse. Current flows through the
fuse to the primary extractor on/off switch. When the
switch is depressed, current flows through the yellow/
green wire and energizes the primary extractor solenoid
which in turn operates the primary extractor fan.
3600-3
cp1999250002c
EXTRACTOR SYSTEM
VARIABLE PRIMARY EXTRACTOR
Flow Adjustment
102 L/min (27 GPM)
Port B Test
Port B Pressure Gauge Fitting
Adjustment
317±7 bar (4600±100 PSI) Charge Pressure
25 bar (360 PSI±10)
Charge Pressure Test

Gauge Fitting Port A Test
Gauge Fitting
Port A Pressure Adjustment
76 bar (1100 PSI)
Primary Extractor Theory of Operation With the primary extractor switch ON, current flows
The extractor fan consists of three curved blades through the yellow/green wire to Elevator 22-pin connector
bolted to a hub. The hubs for both, primary and secondary I, which in turn flows to the primary extractor solenoid,
extractor fans, are the same. Blade lengths are different; energizing it.
the primary fan is 1188 mm (46") in diameter and the The primary extractor solenoid is grounded through
secondary is 864 mm (34"). The hub is bolted to a flanged the black wire to the platform ground.
shaft, which is mounted on two bearings and driven by a
motor. The variable primary extractor is driven by a bent
axial piston motor. Hydraulic System Operation
The extractor fans are designed to give a working The variable pump directs flow to the flushing block
area over the whole surface of the fan blade. located on the variable speed motor. The pump controls
flow to the motor.
Electrical System Operation

Battery power comes from Engine 22-pin connector Specifications
I through the red wire to the 30 amp battery fuse. Current The pump flow for the variable speed primary
then flows from the battery fuse through Engine 22-pin extractor fan at maximum is approximately 102 L/Min
connector K to ignition relay terminal 30 and key switch (27 GPM) with the engine at full throttle.
BAT terminal.
The fixed primary extractor switch is located on the Charge Pressure ................ 255 Bar (360 PSI)
side console. To activate the primary extractor, turn the High Pressure Port A ........ 76 Bar (1100 PSI)
key switch to IGN and push the switch downward. Current High Pressure Port B ........ 317±7 Bar (4600 ± 100 PSI)
flows through the red/white wire to ignition relay terminal
86, energizing the relay. The energized relay allows current
to flow from terminal 87 through the red/white wire to the Control Operation
5 amp primary extractor fuse. Current then flows from The fan is operated by a control cable.
the fuse to the primary extractor switch.
3600-4
cp1999250002c
1190328254
3600-5
EXTRACTOR SYSTEM
cp1999250002c
EXTRACTOR SYSTEM
Primary Extractor
1671356392
3600-6
cp1999250002c
EXTRACTOR SYSTEM
Primary Extractor
Hydraulic Schematic
1671354114
3600-7
cp1999250002c
EXTRACTOR SYSTEM
Fixed Speed Primary Extractor

Hydraulic Schematic
1671356909
3600-8
cp1999250002c
Fixed Speed Primary Extractor Does Not Operate
Electrical Check
1. Stop engine, turn key switch 1. Disconnect multiconnector

to ACC and engage park at the primary extractor
brake. No
switch. Yes Perform a switch check. Yes Check wire harness
2. Check ground connection of 2. Measure voltage of red/ between switch and
Is the switch good?
primary extractor solenoid. white wire. solenoid.
3. Measure voltage of blue wire. Is 12 VDC measured? No
Is 12 VDC measured?
No
Yes Repair or replace switch.
Hydraulic Check Refer to The Accessory
Diagnostic Chart.
1. Plug a 345 bar (5000 PSI) 1. Flow rate fixed

gauge on the primary primary extractor
Remove solenoid and
extractor pump, located No Yes Check cartridge Yes pump.
check for mechanical Yes
inside engine compartment. relief valve. 2. Rate should be
3600-9
Replace primary
or hydraulic problems.
2. Block fan to stop all Can it be adjusted? 151 L/Min (40 GPM). extractor pump.
Is solenoid good?
movement. Is rate less than 136
3. Start engine and run at full L/Min (36 GPM)?
No No
throttle.
Is 250 bar (3000 PSI) No
EXTRACTOR SYSTEM
Replace solenoid. Replace cartridge

measured?
relief valve.
Check primary Yes
Yes extractor fan motor. Done.
Is motor OK?
Inspect primary extractor fan Yes
No
motor. Done.
Is motor OK?
Repair or replace.
No
Repair or replace.
cp1999250002c
Variable Primary Extractor Shows Slow or No Operation
Hydraulic Check
1. Stop engine and engage park brake. No

2. Perform a charge pressure test. See Repair or replace charge pump.
test section for proper procedure.
Yes
1. Block primary extractor fan to

prevent all movement.
2. Place a 690 bar (10,000 PSI) at test Inspect variable No
port located on B side of primary Yes Does fan show slow Yes No Done.
Flow rate pump ports A and B. extractor fan motor.
extractor pump. or no operation? Is motor OK?
Is flow 102 L/Min (27 GPM)?
4. Bring fan to full speed. No
Yes No
Done. Repair or replace.
No
3600-10
1. Disconnect and plug hoses at A
and B ports.
2. Cap pump connection.
3. Place a 690 bar (10,000 PSI) at test No
Replace variable Ground
EXTRACTOR SYSTEM
ports on A and B sides. B

extractor pump. Drive
4. Start engine and run at full throttle. Pump
5. Bring fan to full speed.
B
Yes
Inspect variable No
extractor fan motor. Done.
Is motor OK?
A A
B A
No Variable
Ground
Primary
Drive
Repair or replace motor. Ground
Pump
cp1999250002c
SECTION 3700
ELEVATOR SYSTEM
Elevator System On/off and Forward/Reverse ........................................ 3700-3

Elevator System Up/Down Electrical System Operation ........................ 3700-3
Secondary Extractor Electrical System Operation ................................. 3700-4
Hood Rotate Extractor Electrical System Operation .............................. 3700-4
Bin Flap Extractor Electrical System Operation ..................................... 3700-4
Hydraulic Theory of Operation ................................................................ 3700-4
Elevator Control Electrical Schematic .................................................... 3700-5
Elevator Controls Hydraulic Schematic .................................................. 3700-6
Elevator Forward Does Not Engage, Other Elevator Functions
Operate [EC] .......................................................................................... 3700-7
Elevator Forward Does Not Engage, Other Elevator Functions
Operate [HC] .......................................................................................... 3700-8
Momentary Elevator Forward/Reverse Does Not Engage, All Other
Elevator Functions Operate [EC] .......................................................... 3700-9
Momentary Elevator Forward/Reverse Does Not Operate All Other
Elevator Functions Operate [HC] .......................................................... 3700-10
Elevator Lowers But Does Not Raise [EC] .............................................. 3700-11
Elevator Lowers But Does Not Raise [HC] .............................................. 3700-12
Elevator Raises But Does Not Lower [EC] .............................................. 3700-13
Elevator Raises But Does Not Lower [HC] .............................................. 3700-14
Secondary Hood Rotate Does Not Operate [EC] ..................................... 3700-15
Secondary Hood Rotate Does Not Operate [HC] ..................................... 3700-16
Secondary Extractor Fan Having Slow or No Operation ........................ 3700-17
Bin Flap Does Not Operate ...................................................................... 3700-18
Horn Does Not Operate ............................................................................ 3700-19
cp1999250002c
cp1999250002c
ELEVATOR SYSTEM
Bin Flap—In
Secondary Extractor Yellow/Black
Hood Rotate—Counterclockwise
Orange/Black Elevator—Down
Red/Black
Secondary Extractor
Hood Rotate—Clockwise
Orange Elevator—Up
Red
Bin Flap—Out
Yellow
Elevator System On/Off and Forward/ continues to elevator forward/reverse solenoid terminal
Reverse A, energizing the solenoid.
Battery power goes through the red wire to terminal The elevator reset and forward/reverse relay
30 accessory relay and to the battery fuse. From there it terminals 85 are both grounded with a black/white wire to
moves from the battery fuse and on to the key switch the dash ground.
battery terminal. Pushing the elevator forward/reverse switch to
The elevator on/off switch is located on the REVERSE, causes current to flow from the forward/
hydrostatic control knob. The elevator has a built in safety reverse switch black wire to the 5 amp diode and continue
feature: When engine is off with the elevator in the ON to the blue/black wire to forward/reverse relay terminal
position; the elevator will not engage when the engine is 86, energizing it. The current also flows through the diode
restarted. The elevator ON/OFF button must be turned to elevator forward/reverse relay terminal 30. Since the
OFF and then ON for the elevator to be started. relay is energized, current flows from terminal 87 blue/
With the elevator switch ON, if engine dies or key black wire to Elevator 22-pin connector L and to reverse
switch is turned OFF, elevator is canceled by loss of power solenoid terminal A, energizing it.
to white wire on elevator reset relay terminal 30. The
relay is de-energized, thereby canceling power to elevator
on/off solenoid. When the engine is restarted, elevator Elevator System Up/Down Electrical
reset relay will be de-energized and elevator will not System Operation
function. Battery power comes through the red wire to
To start elevator in forward, the elevator button must terminal 30 ignition relay and to the 30 amp battery fuse.
be depressed once, thus sending current from on/off Current flows through the battery fuse to the key switch
elevator switch white wire to the yellow/blue wire to terminal BAT.
elevator reset relay terminal 86, energizing the relay. Elevator UP/DOWN is engaged by a momentary
Current flows from elevator reset relay terminal 30 and rocker switch located on the side instrument panel. To lift
continues through the relay to terminal 87, yellow/blue elevator, depress switch to UP position; to lower, depress
wire, to terminal 86 thus latching the relay. The elevator switch to DOWN position.
button must be depressed once more, this sends the current With the key switch ON, current flows from IGN
from elevator reset relay terminal 87 yellow/blue wire to terminal through the red/white wire to ignition relay terminal
on/off elevator switch terminal B. Current flows out the 86, energizing it. Current from terminal 30 goes through
blue wire and through the 5 amp diode to the white wire terminal 87 and exits through the red/white wire to the 5
on elevator forward/reverse relay terminal 30. Since this amp elevator up/down fuse and flows from the fuse to
relay is not energized, current flows out of terminal 87A the elevator up/down connector.
through the blue wire to Elevator 22-pin connector K and
3700-3
cp1999250002c
ELEVATOR SYSTEM
When the switch is depressed in the UP position, solenoid terminal A. Depressing the bottom of the switch
current flows from the connector and through the red rotates the hood counterclockwise, by sending current flow
wire to Elevator 22-pin connector E. The red wire through the orange/black wire to Elevator 22-pin connector
energizes the elevator up/down solenoid. The solenoid is B and to hood rotate solenoid terminal A.
grounded through the black wire to the platform ground. The hood rotate solenoid is grounded through the
When the switch is depressed in the down position, black wire to the platform ground.
current flows through the red/black wire to Elevator 22-
pin connector F and on to the up/down solenoid valve.
The solenoid is grounded through the black wire, to the Bin Flap Extractor Electrical System
platform ground. Operation
Battery power goes through the red wire to terminal
30 accessory relay and to the battery fuse. Then the
Secondary Extractor Electrical System battery flows from the battery fuse and on to the key
Operation switch battery terminal.
Battery power goes through the red wire to terminal With the key switch ON, current flows from IGN
30 accessory relay and to the battery fuse. Then the terminal through the red/white wire to ignition relay terminal
battery power flows from the battery fuse and on to the 86, energizing it. Current from terminal 30 goes through
key switch battery terminal. terminal 87 and exits through the red/white wire to the 5
The secondary extractor is engaged by depressing amp bin flap fuse and from the fuse to the bin flap switch
the on/off rocker switch located on the side instrument connector.
panel. The bin flap switch is located on the side control
With the key switch in IGN, current flows through panel. Pushing the switch backwards, closes the bin flap
the red/white wire to ignition relay terminal 86, energizing by causing current to flow through the yellow/black wire
it. Current flows through terminal 30 and exits terminal to Elevator 22-pin connector D and to bin flap solenoid B.
87 through the red/white wire to 5 amp elevator secondary Pushing on the switch in the FORWARD direction, opens
extractor fuse. Current flows from the 5 amp secondary the bin flap by causing current to flow through the yellow
extractor fuse to the secondary extractor. wire to Elevator 22-pin connector C and to bin flap solenoid
When the secondary extractor switch is engaged, terminal A.
current flows from the connector through the violet/red The bin flap solenoid is grounded through the black
wire to Elevator 22-pin connector J and to secondary wire to the platform ground.
extractor solenoid terminal B. The secondary extractor
solenoid is grounded through the black wire to the platform
ground. Hydraulic Theory of Operation
The middle section of the lower right pump supplies
105 L/Min (28 GPM) to the elevator directional valve.
Hood Rotate Extractor Electrical System From there the directional valve flows to the two geroler
Operation motors which operate the elevator chains and slats that
Battery power goes through the red wire to terminal deliver the cane billets past the secondary extractor then
30 accessory relay and to the battery fuse. From the out to the loading carts.
battery fuse and on to the key switch battery terminal. Combines with a wiper side arm style primary fixed
With the key switch ON, current flows from IGN extractorThe blind end section of the two section gear
terminal through the red/white wire to ignition relay terminal pump delivers oil flowing at 14 L/Min (6 GPM) to the
86, energizing it. Current from terminal 30 goes through manifold valve located on the elevator. From the manifold
terminal 87 and exits through the red/white wire to the 5 valve oil flows to the primary extractor motor, rotating
amp secondary extractor fuse. From the fuse, current hood motor, bin flap or elevator lift, whichever is operator
flows to the hood rotate switch connector. selected.
The hood rotation switch is located on the side control
panel. Depressing the top of the switch rotates the hood
clockwise, by sending current flow through the orange
wire to Elevator 22-pin connector A and to hood rotate
3700-4
cp1999250002c
ELEVATOR SYSTEM
Elevator Control
7243002791
3700-5
cp1999250002c
ELEVATOR SYSTEM
Elevator Controls
Hydraulic Schematic
1671354116
3700-6
cp1999250002c
ELEVATOR SYSTEM
Elevator Forward Does Not Engage,

Other Elevator Functions Operate
Electrical Check
1. Engage park brake, stop engine and turn

key switch to IGN.
No Change fuse and check for a
2. Measure voltage of white at elevator on/off
switch terminal A. shorted circuit or component.
Is 12 VDC measured?
Yes
Measure voltage at fuse. No Check white wire between fuse

Is 12 VDC measured? and accessory relay terminal 87.
Yes
Push momentary elevator switch to FORWARD. No Refer to Diagnostic Chart:

Did elevator chains move?
Forward/Reverse Does Not Operate.
Yes
1. Engage park brake, stop engine and turn

key switch to IGN.
2. Check 5 amp elevator on/off and forward/ No Check white wire between
reverse fuses. elevator on/off fuse and switch.
Is the fuse good?
Yes
Perform a switch check on the No

elevator on/off switch. Repair or replace switch.
Is the switch good?
Yes
1. Connect elevator on/off switch.

2. Push elevator on/off switch on hydrostatic
lever, once or twice until voltage is Check yellow/blue wire between
No
measured at terminal 86 yellow/blue wire elevator reset relay terminal 86
on elevator reset relay. and elevator on/off switch.
Is 12 VDC measured?
Yes
Continued on next page
3700-7
cp1999250002c
ELEVATOR SYSTEM
Elevator Forward Does Not Engage,

Other Elevator Functions Operate
Continued from previous page
Check elevator reset relay No

terminal 85 for good ground. Repair ground.
Is ground OK?
Yes
Perform relay check on reset relay. No

Replace relay.
Is relay good?
Yes
Push elevator on/off switch, on the Remove and check 5 amp diode
No
hydrostatic lever, once or twice until No between elevator forward/reverse Replace diode.
voltage is measured at terminal 30 relay and elevator on/off switch.
on elevator forward/reverse relay. Is the diode good?
Is 12 VDC measured?
Yes Yes
Perform relay check on elevator

forward/reverse relay. No
Replace relay. Check wires for loose connections.
Is relay good?
Yes
Check blue wire between elevator

forward/reverse relay terminal 87A
and forward/reverse solenoid.
3700-8
cp1999250002c
ELEVATOR SYSTEM
Momentary Elevator Forward/Reverse Does Not Engage,

All Other Elevator Functions Operate
Electrical Check
1. Engage park brake, stop

engine and turn key switch
to IGN. No Replace fuse and check for a
2. Check 5 amp elevator on/off shorted circuit or component.
fuse.
Is the fuse good?
Yes between forward/reverse
fuse and switch.
Measure voltage at the fuse. No Check white wire between fuse
Is 12 VDC measured? and ignition relay terminal 87.
No
Yes
1. Disconnect the solenoid 1. Disconnect multiconnector
connector. elevator forward/reverse
Push momentary elevator switch to No No switch.
2. Measure voltage at the solenoid
FORWARD or REVERSE. 2. Check voltage at red/white
connector.
Is light in solenoid connector lit? wire.
Is 12 VDC measured?
Is 12 VDC measured?
Yes Yes Yes
Check solenoid connector ground. Perform a switch

Go to Is the ground good? check.
No Replace
Hydraulic Check Is the switch good? switch.
No Yes
on next page
Yes
Repair ground. Replace
Connector. Perform a relay
No Replace
check on elevator
reset and forward/ relay.
reverse relays.
Are relays good?
Yes
Reverse Check Forward Check

1. Push and hold momentary switch in REVERSE. 1. Push and hold momentary switch in
2. Check voltage at terminal 30 and 86 on FORWARD.
No elevator forward/reverse relay. 2. Check voltage at terminal 30 on elevator
Is 12 VDC measured? No
forward/reverse relay.
Is 12 VDC measured?
Yes
Yes
Check blue/black wire between
elevator forward/reverse relay Check blue wire between elevator
terminal 87 and reverse solenoid. forward/reverse relay terminal 87A
and forward solenoid.
Check wire and 5 amp diode

Check blue wire between elevator
between elevator forward/reverse
forward/reverse switch and relay.
switch and forward/reverse relay.
3700-9
cp1999250002c
Momentary Elevator Forward/Reverse Does Not Operate F
All Other Elevator Functions Operate B
Hydraulic Check

Check 12 V solenoid
Is it OK? valve.
Yes
Check spool in valve. No

Repair or replace
Is spool moving freely? valve.
Yes
Disconnect T at F then plug and
1. Block elevator drive.
No cap. Install pressure gauge on
2. Install pressure gauge on elevator Yes Reconnect hose. Yes
relief valve B in screen on left Repair or replace
valve test port. Does elevator drive Done.
side. Start engine and run at full motor.
3. Check pressure. operate properly?
throttle.
3700-10
Is pressure 255 bar (3700 PSI)? No Yes
Yes
No Yes Check elevator drive motor.
Does secondary extractor
Is there internal damage?
ELEVATOR SYSTEM
Check elevator. Yes Clear fan operate properly?

obstructions Repair or replace
Is elevator jammed? No
from elevator. relief.
Repair or replace port

No relief valve.
Check elevator drive Is pressure 172 bar
motor: (2500 PSI)?
Yes
Ø hub spline adapters Done.
Ø internal damage Yes
Is motor OK? Repair or replace main Yes
relief valve. Does elevator operate properly?
Is pressure 241 bar
No
(3500 PSI)? Yes No
Repair or replace
motor. Done. Check to see if
elevator is jammed.
cp1999250002c
Elevator Lowers But Does Not Raise
Electrical Check
Elevator Down
2. Lower elevator to lowest position. No
Replace fuse and check for a
3. Check 5 amp elevator Up/Down shorted circuit or component.
fuse. Located On
Is fuse good? Elevator
Elevator Up
Yes
Measure voltage of 5 amp fuse. No Check red/white wire between

Is 12 VDC measured? Up/Down switch and fuse.
Yes
3700-11
1. Disconnect red/white wire at
No 1. Disconnect solenoid connector. elevator Up/Down switch. No Check red/white wire
Push momentary elevator Up/ No
2. Measure voltage at red wire. 2. Measure voltage at red/white between Up/Down
Down switch to UP. switch and fuse.
Is 12 VDC measured? wire.
ELEVATOR SYSTEM
Is 12 VDC measured?
Yes
Yes Yes
Check solenoid connector ground.
Go to Hydraulic Check Is ground good? No
Perform a switch check. Replace switch.
on next page
Is the switch good?
No Yes
Yes
Repair ground. Replace connector.
Check black wire between Up/
Down switch and solenoid.
cp1999250002c
ELEVATOR SYSTEM
Elevator Down
(A)
Located on
Elevator
Elevator Up
(B)
Hydraulic Check
Plug a 344 bar (5000 PSI) gauge to the in-line
Does bin flap or secondary relief valve A located in the screened engine
No compartment. Disconnect -8 hose B between
hood rotation operate
properly? the in-line relief valve bulkhead fitting on top of
screen, then plug and cap hose. Start engine
and run at full throttle.
Yes Is pressure 2500 PSI?
Yes
Manually push spool B to No
raise elevator. Reconnect -8 hose. No
Does elevator raise? Does spool move
freely in valve?
Yes
Repair or No
Yes
Recheck electrical. replace valve.
Check elevator lift pilot-

operated check valve.
No
Is valve good?
Yes
Check flow rate of gear pump on
side of engine.
Is flow less than 4 GPM?
Yes
Repair or replace No
B pump.

Are cylinders OK?
No Yes
Repair or replace cylinder. Done.

A
3700-12
cp1999250002c
Elevator Raises But Does Not Lower
Electrical Check
Elevator Down
2. Lower elevator to lowest position. No Replace fuse and check for a
3. Check 5 amp elevator Up/Down shorted circuit or component.
fuse. Located On
Is fuse good? Elevator
Elevator Up
Yes
Measure voltage of 5 amp fuse. No Check red/white wire between

Is 12 VDC measured? Up/Down switch and fuse.
Yes
3700-13
1. Disconnect solenoid
Push momentary elevator Up/ No No 1. Disconnect red/white wire
connector.
Down switch to UP. at elevator Up/Down No Check red/white wire between
ELEVATOR SYSTEM
2. Measure voltage at
Is light in solenoid connector lit? switch. Up/Down switch and fuse.
red wire.
2. Measure voltage at red/
Is 12 VDC measured?
Yes white wire.
Is 12 VDC measured?
Yes
Go to Hydraulic Check
next page. Yes
Check solenoid connector
No
Repair ground. ground? No
Is ground good? Replace switch.
Is the switch good?
Yes
Yes
Replace Din Check red/black wire between

connector. Up/Down switch and solenoid.
cp1999250002c
ELEVATOR SYSTEM
Elevator Raises But Does Not Lower
Elevator Down
"A"
Located on
Elevator
Elevator UP
"B"
Hydraulic Check
Plug a 344 bar (5000 PSI) gauge to the in-line relief
No valve A in the screened engine compartment.
Does bin flap or Secondary hood Disconnect -8 hose B between the in-line relief valve
rotation operate properly? and bulkhead fitting on top of screen. Plug and cap
hose. Start engine and run at full throttle.
Yes No
Manually push spool A to
raise elevator. No Reconnect -8 hose. Check flow rate of gear pump on
Does elevator raise?
Is spool moving freely side of engine.
in valve? Is flow less than 6 GPM?
Yes
Yes Yes
No
Recheck Electrical components. Repair or replace pump.
Check elevator lift No
pilot operated check.
Is it OK?
Check cylinders for internal
Yes No leakage.
Are cylinders OK?
Done. Repair or replace valve.
No Yes
Done.
Repair or replace cylinder(s).
3700-14
cp1999250002c
ELEVATOR SYSTEM
Secondary Hood Rotate Does Not Operate
Electrical Check
1. Engage park brake, stop

engine and turn key switch to
IGN. No Change fuse and check for a
2. Check 5 amp secondary shorted circuit or component.
extractor fuse.
Is fuse good?
Yes Check red/white wire

Check red/white wire between between hood rotate
Measure voltage at fuse. No switch and fuse.
secondary hood rotate fuse
Is 12 VDC measured? and switch.
Yes
Push the secondary hood

Disconnect hood rotate Disconnect red/white wire
rotate switch clockwise or No
connector and check voltage No on hood rotate switch and No
counterclockwise.
at the solenoid connector. measure voltage.
Is light on solenoid
Is 12 VDC measured? Is 12 VDC measured?
connector lit?
Yes Yes
Yes
Repair ground. Is switch good?
Go to Hydraulic Check
next page. No
Yes
Replace switch.
Check and repair wire

between hood rotate
switch and solenoid.
Hood Rotate-CCW
Hood Rotate-CW
3700-15
cp1999250002c
ELEVATOR SYSTEM
Secondary Hood Rotate Does Not Operate

Hydraulic Check
Does bin flap or elevator Plug a 344 bar (5000 PSI) gauge to the in-line relief
No valve A in the screened engine compartment.
lift/raise operate properly?
Disconnect -8 hose B between the in-line relief valve
and bulkhead fitting on top of screen. Plug and cap
hose. Start engine and run at full throttle.
Yes No
Manually push spool Reconnect -8 hose. Check flow rate gear

No Is spool moving
to rotate hood. pump on side of engine.
Does hood rotate? freely in valve? Is flow less than 6 GPM?
Yes Yes No Yes
Recheck electrical.
Check motors for internal leakage. Repair or replace pump.
Are motors OK?
No Yes
Done.
Repair or replace motors.
Hood Rotate-CCW
Hood Rotate-CW
3700-16
cp1999250002c
ELEVATOR SYSTEM
Secondary Extractor Fan Having Slow or No Operation
Electrical Check
1. Engage park brake, stop engine

No Replace fuse and check for a
2. Check 5 amp secondary extractor
fan fuse. shorted circuit or component.
Is the fuse good?
Yes
Check red/white wire between
No secondary extractor switch
Measure voltage at fuse. Check red/white wire between
and fuse.
Is 12 VDC measured? up/down fuse and switch.
Yes No
1. Disconnect solenoid connector. 1. Disconnect multiconnector at

Push the secondary extractor
No 2. Check voltage at the violet/red No secondary extractor switch.
fan switch ON.
wire. 2. Check voltage at red/white
Is the light on the solenoid
Is the 12 VDC measured? wire.
connector lit?
Is 12 VDC measured?
Yes Yes
Hydraulic Check
Yes Replace Yes
Check solenoid connector connection.
Perform pilot line check.
ground. Yes Perform a switch check.
Is it OK?
Is ground good? Is switch good?
No
No No
Check 12 V solenoid valve. Yes
Replace ground. Replace switch.
Check violet/red wire between
Check valve spool. No on/off switch and solenoid.
Is spool moving freely?
Repair or replace
Yes valve.
1. Disconnect hose at fitting B No Repair or

1. Install 344 bar (5000 PSI) gauge
located in the screened replace relief.
in elevator block test port.
engine compartment.
2. Block secondary extractor fan No 2. Install pressure gauge on
to prevent movement.
relief valve A.
3. With engine at full throttle, turn
3. With engine at full throttle,
fan On and observe gauge.
check pressure.
Is pressure 248 bar (3600) PSI)?
Yes
Yes
Check secondary extractor Yes
Reconnect hose B. Done.
fan motor.
Does fan operate correctly?
Is there internal damage?
No B
Yes No
Repair Done. Yes

Does elevator drive operate properly?
motor.
Done. No
No Yes
Does secondary extractor Yes Repair or replace main relief valve.
A
fan operate properly? Is pressure 241 bar (3500 PSI)?
3700-17
cp1999250002c
ELEVATOR SYSTEM
Bin Flap Does Not Operate

Bin Flap-In
Electrical Check
"D"
1. Engage park brake, stop engine Bin Flap-Out
and turn switch to IGN. No Replace fuse and check for a
2. Check 5 amp bin flap fuse. shorted circuit or component.
Is fuse good?
Yes
Measure voltage at fuse. No Check red/white wire
between bin flap fuse
Is 12 VDC measured? between bin flap fuse
and switch.
and switch.
Yes
Push bin flap switch 1. Disconnect solenoid

to IN or OUT. No connector.
Is light in solenoid 2. Check voltage at Disconnect red/white wire on
connector lit? solenoid connector. No bin flap switch and measure No
Is 12 VDC measured? voltage.
Yes Is 12 VDC measured?
Yes
Yes
Check solenoid
connector ground. No
Is the ground good? Is switch good?
Yes No
Yes Replace switch.
Replace Repair ground. Check and repair wire
connection. between bin flap
switch and solenoid.
Hydraulic Check
Manually push spool No Does hood rotate No 1. Check in-line relief

to operate bin flap D. operate properly? valve pressure at A.
Does bin flap work? 2. With engine at full
Yes throttle, push switch
Yes
Yes to raise elevator.
Check bin flap.
Is pressure 172 bar
Check spool in valve. Is it jammed?
(2500 PSI)?
Does spool move freely?
Yes No
No
Yes No
B
Repair it. Flow rate gear pump. No
Done. Repair or replace Is flow less than 22.7 Done.
valve. L/Min (6 GPM)?
Check cylinder.
Is there internal Yes
Done. leakage?
Repair or replace
Yes pump.
A
Repair or replace
cylinder.
3700-18
cp1999250002c
Horn Does Not Operate
Electrical Check
1. Sound horn. Does it sound strange?

2. Disconnect harness from horn. Yes Check mechanical ground at horn Yes Check power connections at horn. Yes
mounting area. Replace horn.
3. Measure voltage. Are they tight and clean?
Is 12 VDC measured? Is it tight and clear?
No No
No
Clean and repair as required.

Check 5 amp joystick fuse and No
10 amp horn fuse. Replace fuse(s).
Is fuse good?
Yes
3700-19
No
Measure voltage at fuses. Yes
Refer to Ignition Diagnostic Chart. Does the horn operate? Done.
Is 12 VDC measured?
No
ELEVATOR SYSTEM
Yes
1. Stop engine, turn key switch to IGN and

engage park brake. 1. Depress horn switch and
2. Disconnect 3-way weatherpack connector Perform a switch check on Yes measure voltage at horn Perform a relay No Repair or
at base of joystick. Yes horn switch. relay terminals 30 and 86. Yes check on horn
3. Check voltage of red/white on connector. Is switch good? 2. Check ground connection replace
relay.
Is 12 VDC measured? at terminal 85 black/white relay.
Is the relay good?
No wire.
No Is 12 VDC measured?
Yes
Repair or replace switch.
No
Check wire harness.
Check the blue wire
Check wire harness.
between horn relay
and horn.
cp1999250002c
INDEX
A C
Accumulator Cab and Air Conditioner
Safely Service, 1-11 Electrical Schematic, 0600-15
Aeration and Cavitation, 0002-7 Cab Door, 0600-10
Air Conditioner, 0600-11 Check
Does Not Cool Cab Interior, 0600-13 Fuse Breaker, 1400-26
Runs Constantly, Too Cold, 0600-14 Relay, 1400-24
Air Conditioner Compressor, 0600-10 Chopper
Air Conditioning, 0600-6 Blades Show Slow or No Operation, 3500-5
Specifications, 0600-6 Control, 3500-1
System Test, 0600-9 Electrical System Operation, 3500-1
Air Conditioning Circuit, 0600-4 Hydraulic System Operation, 3500-1
Air Conditioning Compressor Clutch Coil, 0600-12 Set Chopper Shaft Timing, 3500-2
Air Conditioning Operational Checks, 0600-10 Specifications, 3500-1
Visual Inspection of Components Test Procedure, 3500-2
Air Conditioner Compressor, 0600-10 Theory of Operation, 3500-1
Cab Door and Window Seals, 0600-10 Compressor Clutch, 0600-11
Condenser, 0600-10 Compressor Relief Valve, 0600-6
Evaporator Core, 0600-10 Operation, 0600-6
Freeze Control Switch Sensing Tube, 0600-10 Condenser, 0600-10
Lines and Hoses, 0600-10 Cooling System
Anti-Cavitation Relief, 0200-3 Safely Service, 1-12
Crop Divider
B Lift Does Not Operate Properly, 3200-8
Crossover Relief Settings, 0200-3
Basecutter Cylinder Lock Cartridge, 0200-3
Control Valve Main Relief, 3300-2
Does Not Operate [EC], 3300-5 D
Does Not Operate [HC], 3300-6
Electrical System Operation, 3300-1 Diagnostic Sections, 0002-3
Hydraulic System Operation, 3300-1
Specifications, 3300-2 E
Theory of Operation, 3300-1
Battery, 0002-6 Electrical System, 0002-5
Specifications, 0002-6 Safety Precautions, 0002-6
Bin Flap, 3700-4 Electrical Theory of Operation, 0400-1
Bin Flap Does Not Operate Elevator
Electrical Check & Hydraulic Check, 3700-18 On/Off Switch, 1400-31
Blower Motor, 0600-11 Raises But Does Not Lower, 3700-11
Blower Resistor, 0600-12 Elevator Control
Blower/Air Conditioning Circuit, 0600-12 Electrical Schematic, 3700-5
Air Conditioning Compressor Clutch Coil, 0600-12 Elevator Controls
Blower Resistor, 0600-12 Hydraulic Schematic, 3700-6
Blower Switch, 0600-12 Elevator Forward Does Not Engage
Freeze Control Switch, 0600-12 Electrical Check, 3700-7
Heater/Blower Motor, 0600-12 Elevator Forward/Reverse Does Not Engage
Buttlifter Electrical Check, 3700-9
Theory of Operation, 3400-2 Elevator Forward/Reverse Does Not Operate
Hydraulic Check, 3700-10
Electrical Check, 3700-11
i
cp1999250002c
INDEX
Hydraulic Check, 3700-12 Visually Inspect, 0002-4

Elevator Raises But Does Not Lower Hydrostatic Pump, 0002-14
Electrical Check, 3700-13 Pilot Line Check, 0002-16
Elevator System, 3700-3 I
Hydraulic Theory of Operation, 3700-4
On/off and Forward/Reverse, 3700-3 Ice, 0600-13
Up/Down, 3700-3 Introduction, 0002-3
Evaporator, 0600-11
Evaporator Core, 0600-10
Exhaust Fumes, 1-10
L
Left Side Triple Pump, 0200-1
F Lines, 0002-10, 0600-10
Feedroller Low Pressure Switch, 0600-11
Circuit Relief, 3400-2 Low Refrigerant Pressure Switch Test, 0600-12
Control Operation, 3400-2
Front Feedroller Test Procedure, 3400-2, 3400-4
M
Rear Feedroller Test Procedure, 3400-2 Moldings, 0600-3
Feedrollers Motors, 0002-10
Description, 3400-1
Field Test, 0002-13
Fire Prevention, 1-20 O
Five Bank Directional Valve, 0200-2
Fixed Speed Primary Extractor Oil
Hydraulic Schemtic, 3600-8 Filtration, 0002-7
Fluid Storage, 0002-10 Oil Cooler, 0200-12
Fog, 0600-13 Operator's Station, 0600-3
Freeze Control Switch, 0600-12 Air Conditioning Circuit, 0600-4
Freeze Control Switch Sensing Tube, 0600-10 Air Conditioning Specifications, 0600-6
Front Feedroller Test Procedure, 3400-2 Air Conditioning System Test, 0600-9
Fuel Air Intake, 0600-3
Handle Safely - Avoid Fires, 1-11 Compressor Relief Valve Operation, 0600-6
Fuse Breaker Check, 1400-26 Expansion Valve Operation, 0600-5
Glass, 0600-3
G Heater Valve Not Shutting Off Coolant Flow, 0600-13
Heating System, 0600-6
Glass, 0600-3 Inadequate Removal of Ice or Fog, 0600-13
Insufficient Heating, 0600-13
H Low Refrigerant Pressure Switch Test, 0600-12
Head Light Switch, 1400-26 Moldings, 0600-3
Heater, 0600-11 R134A Charge System, 0600-9
Heater/Blower Motor, 0600-12 R134A Component Oil Charge, 0600-7
Heating System, 0600-6 R134A Evacuate System, 0600-8
High Pressure Switch, 0600-11 R134A Recover System, 0600-8
Hood Rotate, 3700-4 R134A Refrigerant Charging System Installation
Horn Does Not Operate Procedure, 0600-7
Electrical Check, 3700-19 R134A Refrigerant Recover, 0600-7
Horn Does Not Operate, 3700-17 R134A Refrigerant Recycling, 0600-7
Hoses, 0600-10 Receiver/Dryer Operation, 0600-4
Hydraulic Components, 0002-7 Theory Of Operation, 0600-3
Hydraulic Filter Restriction Indicator, 1400-32
Hydraulic System, 0002-4
P
Testing Precautions, 0002-5 Park Brake Hydraulic Schematic, 0200-11
Theory of Operation, 0200-1 Parking Safely, 1-16
ii
cp1999250002c
INDEX
Power Feedroller Test Procedure, 3400-4 Nevers, 1-6

Primary Extractor, 3600-4 Operation, 1-3
Control Operation, 3600-4 Practice Safe Maintenance, 1-14
Control Operation, 3600-1 Prepare For Emergencies, 1-12
Electrical Schematic, 3600-6 Prevent Machine Runaway, 1-9
Electrical System Operation, 3600-4 Protect Bystanders, 1-8
Electrical System Operation, 3600-1 Safely Service Accumulator, 1-11
Hydraulic Schemtic, 3600-7 Safely Service Cooling System, 1-12
Hydraulic System Operation, 3600-4 Safety Information, 1-7
Hydraulic System Operation, 3600-1 Service, 1-4
Specifications, 3600-4 Service Tires Safely, 1-17
Specifications, 3600-1 Stopping and Parking, 1-16
Theory of Operation, 3600-4 Transport Combine Safely, 1-17
Theory of Operation, 3600-1 Understand Signal Words, 1-7
Primary Extractor Does Not Operate (Fixed Speed) Use Caution on Hillsides, 1-15
Electrical Check & Hydraulic Check, 3600-9 Use Cylinder Safety Stops, 1-14
Primary Extractor Tachometer Use Handles and Steps, 1-9
Electrical Schematic, 3600-2 Use Safety Lights and Devices, 1-13
Electrical Schemtic, 3600-5 Wear Protective Clothing, 1-13
Primary Hood Rotate, 3600-3 When Cleaning or Storing, 1-6
Control Operation, 3600-3 Schematic, 3600-5
Electrical System Operation, 3600-3 Cab and Air Conditioner [EC], 0600-15
Hydraulic System Operation, 3600-3 Elevator Control [EC], 3700-5
Specifications, 3600-3 Elevator Controls [HC], 3700-6
Theory of Operation, 3600-3 Fixed Speed Primary Extractor [HC], 3600-8
Pumps, 0002-10 Primary Extractor [EC], 3600-6
Primary Extractor [HC], 3600-7
Primary Extractor Tachometer [EC], 3600-5
R Secondary Extractor, 3700-4
Secondary Extractor Fan Having Slow or No Operation
R134A Charge System, 0600-9 Electrical Check & Hydraulic Check, 3700-17
R134A Component Oil Charge, 0600-7 Secondary Hood Rotate
R134A Evacuate System, 0600-8 Does Not Operate, 3700-13
R134A Recover System, 0600-8 Secondary Hood Rotate Does Not Operate
R134A Refrigerant Charging System Installation Electrical Check, 3700-15
Procedure, 0600-7 Hydraulic Check, 3700-16
R134A Refrigerant Recover, 0600-7 Solenoid
R134A Refrigerant Recycling, 0600-7 Check Number One, 1400-24
Rear Feedroller Test Procedure, 3400-2 Check Number Two, 1400-24
Rear Set Feed Roller(s), 3400-6 Starter Solenoid Check, 1400-25
Refrigerant Cautions, 0600-7 Start Relay Check, 1400-25
Right Side Triple Pump, 0200-1 Starter Solenoid Check, 1400-25
Stopping Harvester, 1-16
S System Operating Checks, 0600-11
Safety, 1-3 Air Conditioner, 0600-11
Avoid Contact with Moving Parts, 1-19 Blower Motor, 0600-11
Avoid Electrical Power Lines, 1-18 Compressor Clutch, 0600-11
Avoid Exhaust Fumes, 1-10 Heater, 0600-11
Avoid High Pressure Fluids, 1-15 High Pressure Switch, 0600-11
Dispose of Waste Properly, 1-19 Low Pressure Switch, 0600-11
Fire Prevention, 1-20 System Operation, 0200-2
Follow Safety Instructions, 1-8 System Performance Checks, 0600-11
Handle Fuel Safely - Avoid Fires, 1-11 Evaporator, 0600-11
Keep Hands Away From Knives, 1-18
Keep Riders off Machine, 1-10
iii
cp1999250002c
INDEX
T
Tachometer
Engine Tachometer Check, 1400-30
Primary Extractor, 1400-30
Thermostat
Switch Operation, 0600-5
Tire
Service Safely, 1-17
Transport Combine Safely, 1-17
Troubleshooting, 0002-3, 0002-8
Tips, 0002-8
Tools, 0002-3
Turn Signal Switch Check, 1400-26
Twin Crop Divider
Showing Slow or No Operation, 3200-4
V
Variable Primary Extractor
Shows Slow or No Operation, 3600-4
Variable Primary Extractor Shows Slow or No Operation
W
Waste, 1-19
Window Seals, 0600-10
iv
cp1999250002c

1999 CH2500 Oper &amp; Test Eng

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1999 CH2500 Oper &amp; Test Eng

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CAMECO ®

CH2500 CHOPPER COMBINE

Safety Recommendations Preliminary Service Intervals ........................ 0001-6

Steering System Refrigerant Cautions ...................................... 0600-7

Turbocharger Excessively Noisy or Elevator On/Off Switch .................................. 1400-24

Hydraulic Oil Temperature Gauge Does Basecutter System

Chopper System Hydraulic Theory of Operation ...................... 3700-4

CAMECO INDUSTRIES, INC.

Sugar Cane Flow

Power Knockdown Roller

CAMECO INDUSTRIES, INC.

CAMECO INDUSTRIES, INC.

CAMECO INDUSTRIES, INC.

1. Be sure to read the operation manual and all

Service Safety Use the following Lock-Out Tag-Out Procedure:

E. Before beginning any hydraulic repairs you

F. In the event repairs need to be made to the

4. If at all possible, make all repairs with the machine

7. To avoid back injuries, use a hoist when lifting

Safety when Cleaning or Storing Safety Nevers

Recognize Safety Information

Follow Safety Instructions

Use Handles and Steps

Avoid Exhaust Fumes

Handle Fuel Safely—Avoid Fires

Safely Service Cooling System

Wear Protective Clothing

Use Cylinder Safety Stops

Avoid High Pressure Fluids

Stopping and Parking

Service Tires Safely

Avoid Electrical Power Lines

Avoid Contact with Moving Parts

For additional information, refer to the Caterpillar Engine Manual.

Engine Type ....................................................... Caterpillar 3306TA

Number of Cylinders ......................................... 6

Horsepower ....................................................... 250 HP at 2000 RPM

Aspiration .......................................................... Turbocharger

Oil Capacity ....................................................... 28 Liters (30 US Quarts)

Coolant Capacity ............................................... 50.6 Liters (13 US Gallons)

Coolant Additive Element ................................. Canister Type (Optional)

IMPORTANT: DO NOT Mix Coolant Additive and Additive Elements

Fuel Filters ........................................................ Primary: Strainer

Electrical System .............................................. 12 Volt Battery

Preliminary Service Intervals

Every 250 hours of operation thereafter, do the following:

Refer To Maintenance, Section 11, For Complete Service Intervals.

Common Engine Wear Parts

2. Fuel Separator Element Kit ................................................................. 0061304870

3. Final Fuel Element ............................................................................... 0060009676

4. Oil Filter ............................................................................................... 0060034329

5. Belts—Set of 3 ...................................................................................... 0190040211

6. A/C Belt ................................................................................................. 0191340539

For additional information, refer to the Caterpillar Engine Manual.

Engine Type ....................................................... Caterpillar 3306TA

Number of Cylinders ......................................... 6

Horsepower ....................................................... 325 HP at 2000 RPM

Aspiration .......................................................... Turbocharger and After cooled

Oil Capacity ....................................................... 25 Quarts

Coolant Capacity ............................................... 50.6 Liters (13 US Gallons)

Coolant Additive Element ................................. Canister Type (Optional)

IMPORTANT: DO NOT Mix Coolant Additive and Additive Elements

Fuel Filters ........................................................ Primary: Strainer

Electrical System .............................................. 12 Volt Battery

1999 CH2500 Oper & Test Eng

1999 CH2500 Oper & Test Eng