5650-5690 Balance Repair manual

8/19/2019 5650-5690 Balance Repair manual

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WORKSHOP MANUAL

SAME DEUTZ-FAHR DEUTSCHLAND GmbH

Combine5650 H, 5660 HTS

5670 H / HTS 5680 H, 5690 HTS


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The technical informations and data in this Service documentation were correct when the manual was printed.We are constantly seeking to improve our products and therefore reserve the right to introduce all changesand improvements that we consider appropriate. However, we undertake no obligation to apply suchimprovements to previously supplied machines and additional equipment.

This document may not be copied - even in part - without our consent. We reserve all rights under Germancopyright law and accept no liability for possible mistakes.

This document describes the full equipment level, including special accessories that are not part of thestandard equipment version.No claims regarding the equipment of machines already delivered or to be delivered may be derived from thisdescription. The price list applicable at the time of purchase is decisive.

Products made by other manufacturers (GPS, printer, etc.) and the associated software are described withoutobligation and based on information provided by the manufacturer in each case. The safety regulationscontained in the normal operating manual also apply here.

Impressum:

Manufacturer

SAME DEUTZ-FAHR DEUTSCHLAND GmbH

Deutz-Fahr-Straße 1D-89415 Lauingen/DonauGermany

Telefon/Phone +49 (0) 90 72 / 9 97 0Fax +49 (0) 90 72 / 9 97 - 300WWW: http://www.deutz-fahr.de

Copyright © 2006 by SAME DEUTZ-FAHR DEUTSCHLAND GmbHDeutz-Fahr-Str. 1D-89415 Lauingen/Donau

Contents DF-EZ (Technical Documentation)Layout DF-EZ (Technical Documentation)Order DF-LC (Spare Parts Department)

All rights reserved.

1. Edition, 10.2006

Part No.: 307.1133.3.6

Printed in the Federal Republic of Germany

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Summary 5650H – 5690HTS

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Engine Assembly, Engine Parts, Engine Control, Engine Power Take-Off . . . . A

Front axle, gearbox, Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B

Belt drive clutches, Greasing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D

Feed passage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E

Cabin, Driver's stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H

Air condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I

Threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K

Cleaning aggregates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L

Grain elevator, Grain tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M

Cutting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P

Straw chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .U

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General Safety Instructions

Before starting assembly, repair or maintenance work, make sure you read and follow these safetyinstructions. Please also transmit all safety instructions to all other people concerned.In this manual, we have marked all points relevant to your safety with the following symbol:

WARNING!

This combine harvester is designed exclusively for normal use in agricultural work(intended use).

Any use of the machine beyond the above description does not conform to the intended use.The manufacturer shall not accept any liability for any damage resulting from such use;the user shall bear all risks relating to such use.

Conformity with the intended use includes adherence to the operating, servicing and maintenance conditionsspecified by the manufacturer.

This combine harvester may only be operated, serviced and repaired by persons familiar with the machineand instructed in the dangers involved.

The manufacturer shall not accept any liability for any damage resulting from modifications to the machine bypersons not authorised by the manufacturer.

General regulations on safety and accident prevention:

1. In addition to the instructions contained in this manual, you must strictly follow all relevant accidentprevention regulations and other generally recognised rules of technical and occupational safety.The legal operating specifications laid down in the Operating Manual for driving the combine on the road

and for working use also apply to this manual and must therefore also be observed.2. Before starting the engine, make sure that no gear is engaged or, in the case of hydromatic systems,

that the drive lever is in the '0' position, and that all protective devices are fitted and in the protectionposition.

3. Only start the engine from the driver's cab. The engine must not be started by short-circuiting theelectrical connections of the starter motor, because otherwise the machine may start moving immediately.

4. Before driving off, check the zone immediately around the combine harvester.Make sure you have sufficient visibility. Sound the horn as a warning signal.

5. Do not leave the engine running in enclosed spaces.

6. On leaving the combine harvester, protect it from rolling free (parking brake, wheel chock).Switch off the engine and remove the key. If applicable, lock the cab door.

7. Before leaving the combine, fully lower all front attachments (cutting table etc.).

8. Take care when handling fuel – increased fire risk. Never refuel the combine close to naked flames orignitable sparks. Do not smoke when refuelling.

9. Before refuelling, switch off the engine. Do not refuel in enclosed areas.Immediately wipe away any spilt fuel.

10. To prevent fire risk, keep the machine clean.

11. Take care when handling brake fluid and battery acid (toxic and liable to cause chemical burns).

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Safety instructions for maintenance and repair

General:

1. As a general rule, the drive train must be disengaged and the engine stopped before carrying out anyassembly, repair, maintenance and cleaning work or before remedying malfunctions.Remove the ignition key.

2. Fluids escaping at high pressure (fuel, hydraulic oil etc.) can pierce the skin and cause severe injury.In the event of injury, immediately call a doctor, because otherwise there is a grave risk of infection.

3. Care is required when handling fuel – increased fire risk. Never refuel the combine close to naked flamesor ignitable sparks. Do not smoke when refuelling.

4. To prevent fire risk, keep the machine clean.

Electrical system:

1. When working on the electrical system, always remove the cable from the negative pole of the battery.

2. Make sure that the battery is correctly connected. First connect the positive pole and then the negative.

3. Take care with battery gases, since they are highly explosive.Avoid generating sparks or naked flames close to batteries.

4. Only use OEM fuses of the specified ratings. If any of the fuses used are too highly rated, the electricalsystem may be destroyed.

5. Before starting any electric welding work on the combine harvester, disconnect the cables from the

alternator and battery.6. Take care when handling battery acid (toxic and corrosive).

7. Only operate the starter motor for a limited period, because otherwise the winding will overheat.Allow the starter to cool down.

Brakes, brake fluid:

1. Check that the brakes are working correctly before each use.

2. The brake systems must be regularly submitted to a thorough test.

3. Settings and repairs to the brake system must only be carried out by qualified workshops or recognisedbrake services.

4. When driving on public roads, the individual wheel braking mode must be deactivated(interlock the pedals).

5. Regularly check the brake fluid level. Only use the specified brake fluid and change as specified.

6. Take care when handling brake fluid (toxic and liable to cause chemical burns).Do not spill brake fluid.

7. Dispose of brake fluid in accordance with the applicable regulations.

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Hydraulic system:

1. The hydraulic system is under high pressure. When searching for leaks, use a suitable aid(e.g. piece of cardboard) to protect against the risk of injury.

2. Before carrying out any work on the hydraulic system, depressurise the system and lower any frontattachments.

3. When working on the hydraulic system, switch off the engine and remove the key.Prevent the combine harvester from rolling (handbrake, wheel chocks).

4. When connecting hydraulic equipment, make sure that the hydraulic hoses are correctly connected.If the hoses are connected to the wrong points, the switch functions will be inverted (e.g. raise/lower).Risk of accident.

5. Regularly inspect hydraulic hoses and replace if damaged or aged.The replacement hoses must conform to the technical specifications of the device manufacturer.

6. The hydraulic accumulator contains pressurised gas.Do not drop the accumulator or expose it to temperatures above 150°C

Air conditioning system:

1. Avoid all contact with the liquid refrigerant of the air conditioning system. If refrigerant is sprayed into theeyes, call a doctor immediately.

2. All maintenance, installation and repair work must be carried out exclusively by qualified personnel.

3. No welding work may be performed on components of the refrigerant circuit or in its immediate vicinity.Risk of poisonous fumes.

4. Maximum ambient temperature for refrigerant: 80°C.

5. When draining the air conditioning system, dispose of the refrigerant in accordance with the applicableregulations.

Tyres, screwed fixings:

1. When working on the wheels, make sure that the combine harvester is safely immobilised and preventedfrom rolling (wheel chocks).

2. When working under the jacked combine, allow no-one on the machine.

3. Make sure that the lifting device has sufficient load-bearing capacity.

4. Removing and refitting tyres requires sufficient knowledge and specified fitting tools.

5. Check the tyre pressures regularly. Excessive tyre pressure leads to a risk of bursting.

6. All fixing screws and nuts for the front and rear wheels and track adjusting components must beretightened in accordance with the manufacturer's specifications.

7. This retightening is also required after each track adjustment and wheel change.


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Engine:

1. Do not carry out maintenance work while the engine is running.Remove the ignition key.

2. When working on the engine, disconnect the battery (negative terminal).

3. Only refill the fuel tank when the engine is at standstill. Do not smoke while refuelling.

4. Take care whenever hot oil may be released – risk of burns.

5. Make sure that the oil and fuel used are of the specified quality, and only store them in approvedcontainers.

6. Dispose of oils, fuels and filters in accordance with the relevant regulations.

Miscellaneous:

1. Before throwing away used and apparently empty pressurised cans (paint sprays etc.),empty them fully in a well-ventilated area away from sparks and naked flame.

2. If any parts have to be replaced, only authentic original DEUTZ-FAHR spare parts may be used.

The use of spare parts, accessories and auxiliary devices that do not originate from DEUTZ-FAHR andare not tested and approved by DEUTZ-FAHR can have a negative effect on the specified characteristicsor reliability and thereby detract from active and/or passive driving and working safety(accident protection etc.).

DEUTZ-FAHR cannot accept any liability for any damage caused by the useof non-DEUTZ-FAHR original parts, accessories and auxiliary devices.

3. Replace all protective devices and guards after maintenance and repair work.

4. Do not carry out any welding, drilling, sawing and grinding work on the cab frame or the safety frame.Replace any damaged parts.

5. When replacing the cab ventilation filter, dispose of the used filter in accordance with regulations.

6. Auxiliary heaters must never be operated in closed rooms or during refuelling.

7. When carrying out electric welding work on the combine harvester,

disconnect the alternator cable and battery.


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Notes


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5650H – 5690HTSGeneral information on repair and maintenance

Table of Contents

Combine Harvester Type 5650H 5680H5660HTS 5690HTS

Conversion table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03 X X

Tightening torques, bolting classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 X X

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05 X X

Sealing, Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 X X

Single-component adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07 X X

Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 – 09 X X

Operating fluids, filling levels and oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 X X

Release list DEUTZ lube oil quality stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 X X

Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13 X X

Tightening torques for adapter sleeve bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 X X

Check tension of chain and belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 19 X X

Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 X X

Servicing and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 X X

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 X X

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Conversion Tables

Conversion factor

Conversion from mm to inches

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1 mm 1,0 mm 0,03937 in. 0,00328 ft

1 in. 25,4 mm 1,0 in. 0,08333 ft

1 ft 304,8 mm 11,9999 in. 1,0 ft1 cm2 1,0 cm2 0,155 sq.in.

1 sq.in. 6,4516 cm2 1,0 sq.in.

1 cm3 1,0 cm3 0,001 l 0,06102 cu.in. 0,00026477 USgall 0,00021998 Imp.gall

1 l 1000 cm3 1,0 l 61,024 cu.in. 0,26417 USgall 0,21998 Imp.gall

1 cu.in. 16,3870 cm3 0,016387 l 1,0 cu.in. 0,04329 USgall 0,03604 Imp.gall

1 US gall 3785,4 cm3 3,7854 l 23,1 cu.in. 1,0 USgall 0,8327 Imp.gall

1 Imp.gall 4546 cm3 4,546 l 277,41 cu.in. 1,20091 USgall 1,0 Imp.gall

1 g 1,0 g 0,001 kg 0,03527 oz 0,0022046 Ibs

1 kg 1000 g 1,0 kg 35,27 oz 2,2046 Ibs

1 oz 28,353 g 0,028353 kg 1,0 oz 0,0625 Ibs

1 Ibs 453,59 g 0,45359 kg 15,9983 oz 1,0 Ibs

1 kp/cm2 1,0 kp/cm2 14,21 Ibs/sq.in. 0,981 bar

1 Ibs/sq.in. 0,0703 kp/cm2

1,0 Ibs/sq.in. 0,06903 bar1 bar 1,0193 kp/cm2 14,485 Ibs/sq.in. 1,0 bar

1 kpm 1,0 kpm 7,233 ft.Ibs 9,81 Nm 0,981 daNm

1 ft.lbs 0,1383 kpm 1,0 ft.lbs 1,356 Nm 0,1356 daNm

1 Nm 0,1019 kpm 0,7373 ft.Ibs 1,0 Nm 0,1 daNm

1 daNm 1,019 kpm 7,373 ft.lbs 10,0 Nm 1,0 daNm

1 PS 1,0 PS 0,98632 BHP 0,736 kW

1 BHP 1,0139 PS 1,0 BHP 0,7462 kW

1 kW 1,36 PS 1,3405 BHP 1,0 kW

mm 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9

0 - 0,00394 0,00787 0,0118 0,0157 0,0197 0,0236 0,0276 0,0315 0,03541 0,0394 0,0433 0,0472 0,0512 0,0551 0,0591 0,0630 0,0669 0,0709 0,0748

2 0,0787 0,0827 0,0866 0,0906 0,0945 0,0984 0,1024 0,1063 0,1102 0,1142

3 0,1181 0,1220 0,1260 0,1299 0,1339 0,1378 0,1417 0,1457 0,1496 0,1535

4 0,1575 0,1614 0,1654 0,1693 0,1732 0,1771 0,1811 0,1850 0,1890 0,1929

5 0,1969 0,2008 0,2047 0,2087 0,2126 0,2165 0,2205 0,2244 0,2283 0,2323

6 0,2362 0,2402 0,2441 0,2480 0,2520 0,2559 0,2598 0,2638 0,2677 0,2717

7 0,2756 0,2795 0,2835 0,2874 0,2913 0,2953 0,2992 0,3031 0,3071 0,3110

8 0,3150 0,3189 0,3228 0,3268 0,3307 0,3346 0,3386 0,3425 0,3465 0,3504

9 0,3543 0,3583 0,3622 0,2661 0,3701 0,3740 0,3780 0,3819 0,3858 0,3898

10 0,3937 0,3976 0,4016 0,4055 0,4094 0,4134 0,4173 0,4213 0,4252 0,4291


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Conversion Tables

Conversion from degrees Celsius (°C) to degrees Fahrenheit (°F)

Conversion from degrees Celsius (°C) to degrees Kelvin (K)

°C °F °C °F °C °F °C °F °C °F °C °F

0 32 18 64,4 35 95 52 125,6 69 156,2 86 186,81 33,8 19 66,2 36 96,8 53 127,4 70 158 87 188,62 35,6 20 68 37 98,6 54 129,2 71 159,8 88 190,43 37,4 21 69,8 38 100,4 55 131 72 161,6 89 192,24 39,2 22 71,6 39 102,2 56 132,8 73 163,4 90 1945 41 23 73,4 40 104 57 134,6 74 165,2 91 195,86 42,8 24 75,2 41 105,8 58 136,4 75 167 92 197,67 44,6 25 77 42 107,6 59 138,2 76 168,8 93 201,28 46,4 26 78,8 43 109,4 60 140 77 170,6 94 2039 48,2 27 80,6 44 111,2 61 141,8 78 172,4 95 204,8

10 50 28 82,4 45 113 62 143,6 79 174,2 96 206,611 51,8 29 84,2 46 114,8 63 145,4 80 176 97 208,412 53,6 30 86 47 116,6 64 147,2 81 177,8 98 210,213 55,4 31 87,8 48 118,4 65 149 82 179,6 99 21214 57,2 32 89,6 49 120,2 66 150,8 83 181,4 100 –

15 59 33 91,4 50 122 67 152,6 84 183,2 – –16 60,8 34 93,2 51 123,8 68 154,4 85 185 – –17 62,6 – – – – – – – – – –

°C K °C K °C K °C K °C K °C K

0 273 18 291 35 308 52 325 69 342 86 3591 274 19 292 36 309 53 326 70 343 87 3602 275 20 293 37 310 54 327 71 344 88 3613 276 21 294 38 311 55 328 72 345 89 3624 277 22 295 39 312 56 329 73 346 90 3635 278 23 296 40 313 57 330 74 347 91 3646 279 24 297 41 314 58 331 75 348 92 3657 280 25 298 42 315 59 332 76 349 93 3668 281 26 299 43 316 60 333 77 350 94 3679 282 27 300 44 317 61 334 78 351 95 368

10 283 28 301 45 318 62 335 79 352 96 36911 284 29 302 46 319 63 336 80 353 97 37012 285 30 303 47 320 64 337 81 354 98 37113 286 31 304 48 321 65 338 82 355 99 37214 287 32 305 49 322 66 339 83 356 100 37315 288 33 306 50 323 67 340 84 357 – –16 289 34 307 51 324 68 341 85 358 – –17 290 – – – – – – – – – –

Temp. °C = (t °F – 32)59

Temp. °F = (t °C + 32)59

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5650H – 5690HTSTightening value for bolts according to in-house standard H0385-1Bolting class II

Bolts and nuts are to be tightened by means of a torque wrench

Bolting class II

d Strengh Tightening torques M A nennmm class Nm

8,8 2,5M4 10,9 3,5

12,9 4,5

8,8 5,0M5 10,9 7,5

12,9 8,5

8,8 8,5M6 10,9 13

12,9 13

8,8 14M7 10,9 20

12,9 24

8,8 20M8 10,9 30

12,9 36

8,8 42M10 10,9 60

12,9 70

8,8 70M12 10,9 110

12,9 1208,8 110

M14 10,9 17012,9 200

8,8 180M16 10,9 260

12,9 300

8,8 260M18 10,9 360

12,9 420

8,8 360M20 10,9 500

12,9 600

8,8 480M22 10,9 70012,9 800

8,8 600M24 10,9 850

12,9 1000

8,8 900M27 10,9 1300

12,9 1500

8,8 1200M30 10,9 1700

12,9 2000

Bolting class II

d Strengh Tightening torques M A nennmm class Nm

8,8 22M8 x1 10,9 34

12,9 38

8,8 46M10 x 1, 10,9 70

12,9 80

8,8 44M10 x 1,25 10,9 65

12,9 75

8,8 80M12 x 1,25 10,9 110

12,9 140

8,8 75M12 x 1,5 10,9 110

12,9 130

8,8 120M14 x 1,5 10,9 180

12,9 210

8,8 190M16 x 1,5 10,9 280

12,9 320

8,8 280M18 x 1,5 10,9 400

12,9 480

8,8 260M18 x 2 10,9 380

12,9 440

8,8 400M20 x 1,5 10,9 550

12,9 650

8,8 360M20 x 2 10,9 550

12,9 600

8,8 550M22 x 1,5 10,9 75012,9 850

8,8 500M22 x 2 10,9 700

12,9 850

8,8 700M24 x 1,5 10,9 1000

12,9 1200

8,8 650M24 x 2 10,9 950

12,9 1100

8,8 650M27 x 2 10,9 950

12,9 11008,8 1400

M30 x 2 10,9 190012,9 2300

Shoulder stud with metric fine threadFriction factor µges. = 0,12

Shoulder stud with standard metric threadFriction factor µges. = 0,12


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Lubricants

Solid lubricants

Grease

Cooling System Protection

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DEUTZ F 15 0100 9454 –20°bis +140° Emteka NU 15

Material Part No. Operating temperature Equivalent manufacturer's

specification range in °C

DEUTZ S 1 0134 0198 –180°bis +1400° Never SeizeDEUTZ S 2 0100 5149 –125°bis +1450° Molykote Paste G-n Rapid

DEUTZ S 5 0101 6126 –130°bis +1130° Molykote BR 2

5l Container 0101 1490




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Sealants

Adhesives

Material KHD Part No. Operating temperature Equivalent manufacturer'sspecification range in °C designation

DEUTZ KL 1 0100 1300 – 30°to + 200° Gupalon normal

DEUTZ KL 1 0292 5947 Epple adhesive 56

DEUTZ KL 5 0100 8365 – 60°to + 180° Loctite – IS – 414

DEUTZ KL 5A 0100 9331 – 60°to + 180° Loctite – IS – 495

DEUTZ KL 5B 0100 9332 – 60°to + 180° Loctite – IS – 416

DEUTZ KL 8 0131 9914 – 30°to + 120° Terostat 58

DEUTZ KL 9 0100 4131 – 30°to + 120° Terokal

DEUTZ KL 14 0100 9506 – 30°to + 200° Gupalon express

Material KHD Part-No. Operating temperature Equivalent manufacturer's

specification range in °C designation

DEUTZ DW 25 0100 1306 –190°to + 250° Thread tape

DEUTZ DW 30 –190°to + 700° Devametal NiCuFe 10.83/8-3WDEUTZ DW 40 –190°to + 350° Reinz 4402

Ferrolastic

DEUTZ DW 43 0100 9463 –135°to + 100° Terostat 8585

DEUTZ DW 44 0100 8379 –130°to + 150° Terolan 3531

DEUTZ DW 47 0100 8383 –165°to + 230° Silastic Q3-3305

DEUTZ DW 48 0134 0088 –173°to + 230° Silastic 732 RTV

DEUTZ DW 50 0100 1286 –190°to + 110° CurilTeroson-Fluid

DEUTZ DW 53 0100 8329 –190°to + 150° Sealing compound G

DEUTZ DW 55 0131 9907 –155°to + 150° Loctite Prod.-No. 601



DEUTZ DW 59 0134 0167 –155°to + 150° Loctite Prod.-No. 270DEUTZ DW 60 0100 1254 –155°to + 150° Loctite Prod.-No. 582

DEUTZ DW 61 0131 9912 Loctite Prod.-No. 747 (activator T)






Sealing Compound 0633 9192 Sikaflex


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Single-component adhesives

Use of single-component adhesives

For particularly important screwed connections and for snug-fit connections subject to high stress, a single-componentadhesive is factory-applied, to guarantee increased protection against loosening and undoing. When the machine is

repaired, the parts to be glued together must first be cleaned carefully with commercially available cleaning agents orpurified gasoline. The threads or surfaces to be glued must be free of oil and grease and must be dry.

Adhesive application:

For threaded connections, it is sufficient to apply the adhesive to the outside thread.For tapped blind holes, the adhesive must always be applied to the internal thread, since otherwise the adhesive would beforced out by the air escaping as the part is screwed in.For snug-fit and joint connections with low play on one part, if there is relatively high play on both parts, apply theadhesive as a closed ring and mount with a gentle rotating movement.

Hardening:

The adhesive takes 6–24 hours to harden at a room temperature of 20°C, which must be maintained constant for theentire hardening period. Since this is not always possible for outside assemblies, we recommend that the relevant site belocally heated by heaters. About 1–4 hours at 60 °C will be sufficient to harden the adhesive. Do not move the parts.Accelerated hardening is also achieved by pretreatment with an activator. The use of activators reduces the strength ofthe adhesive, and so if necessary the strongest adhesive should be used. The following table provides a list of adhesivesof different makes used in combine harvesters.

KHD KHD Loctite Omnifit Conloc Guidelines for useDesignation Part No. Type Type Type

DEUTZ DW 55 0100 1251 601 M 150 CL 202 for play of 0.02–0.03, makes threads harder to loosen,secures screws up to M16

DEUTZ DW 56 0109 8072 586 (AVX) M 80 CL 103 for play of 0.02–0.02, makes threads harder to loosen,red secures screws up to M20

DEUTZ DW 57 0100 1256 221 L 150 CL 051 Improved press-fit 0–0.03, easily loosened,green screws up to M14

DEUTZ DW 59 0100 1252 270 M 250 CL 301 for play of 0.02–03, very firm connection,violet only for large-size threads

DEUTZ DW 60 0100 1254 582 (CVX) H 150 CL 303 for play of 0.03–0.5, extra-firm connection for temperaturesgreen up to 100°, only for large-size threads

DEUTZ DW 61 0109 8073 747 Activator CL for faster hardening(Activator T) RS Activator

US

0114 5546 648 high-strength connection for joints shafts hubs


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Maintenance and Inspection Schedule for Combine Harvesters

5 Threshing Mechanism, Cleaning System, Grain Tank

5.9 Check grain pan sections for firm fit X X X

5.10 Check fan variator X X X

5.11 Check grain elevator chain, tighten if necessary X X X

5.12 Check grain tank tube lock X X

5.13 Check, adjust friction clutch X X

5.14 Check grain tank and unloading system for leaks X X

5.15Remove accumulations of crop residuals: Concave, threshing drum, grain pan, under-walker return floor,augers, hollow space above fan

X

5.16 Check inspection and service flaps for tightness and proper closed locks. X X

6 Wheels and Brakes

6.1 Check service brake, free movement of brake pads X X X X

6.2 Check brake fluid level X X X

6.3 Replace brake fluid

6.4 Check parking brake, readjust if necessary X X X

6.5 Retighten screwed connections: Shift gear, final drive, chassis to axle X X

6.6Retighten wheel nuts to specified torqueDrive wheels 750 Nm Rear wheels310 Nm

X X X X

6.7 Check screw connections on the adjustable steering axle to specifications, retighten 410 Nm X X

6.8 Check toe-in of the rear wheels, adjust if necessary X X

6.9 Check bearing play of the rear wheels, readjust X X X

6.10 Check tyre pressure X X

7

7.1 Check for grease escape at points of lubrication (hose connection, condition of lubrication hoses) X X

7.2 Check for grease escape at relief pressure valve with centralised lubrication system X

8 Electrical System

8.1 Check lighting equipment X X

8.2 Check adjustment of headlights X X

8.3 Check electrical system X X

8.4 Check wiring harness and plugs for pinches or damage X

8.5 Check battery fastening, terminals X X X

8.6 Check battery electrolyte level and density of acid X X X

8.7 Check warning devices X X

8.8 Check electrical adjustment of concave and turbo separator, calibrate with Com. Control if necessary X X

8.9 Check on-board computer, grain loss monitoring system X X

8.10 Clean grain loss sensors when contaminated

8.11 Calibrate electronic cutting mechanism control (EMR-D) with each change of front attachment X

8.12 Check Balance control, recalibrate if necessary X X

9 Cabin, Compressor Cooling System, Cabin Heating

9.1 Check sealing of fresh air filters X X

9.2 Clean fresh air filter and recirculating air filter (replace if required) X

9.3 Check correct functioning of compressor cooling system X X

9.4 Retighten V-belt for air conditioning compressor X X X

9.5 Check correct coolant filling level, check for leaks X X

9.6 Clean evaporator, condenser when contaminated

9.7 Replace fluid container when humidity indicator changes its colour

9.8 Check cabin heating for proper functioning and for leaks X X

10 Cutting Mechanism, Trailer, Front Attachment for Rape

10.1 Check tension of V-belt and chains X X X

10.2 Check friction clutches X X

10.3 Check settings of intake auger X X

10.4 Check proper functioning of reel hydraulics X

10.5 Check knife gear (head bearing) X X X

10.6 Check knife guide for wear X

10.7 Check sensing skids for free movement, remove contamination X

10.8 Retighten trailer wheel bolts, wheel nuts X X X X

10.9 Check oil level of front attachment for rape X X X

10.10 Change hydraulic oil, replace return filter X X X

11

12 Accident Prevention Regulations

12.1Inform operators about compliance with legal requirements(see operating instructions)

X

12.2 Check protective and locking devices X X

12.3 Let fire extinguishers be checked for proper functioning

12.4omponents ma e y ot er manu acturers may only e installe wit t e written

consent of SAME DEUTZ-FAHR

every two years

for the first time after operating hours

after everyoperating hours

Maintenance and Inspection Schedule

for DEUTZ-FAHR Combine Harvesters

All maintenance and inspection operations must complywith the individual operating instructions

Cutting Mechanism with Trailer, Front Attachments for Special Crops, Maize Header, Straw

Chopper, Chaff Spreader etc.

Lubrication (see Lubrication Schedule)Thoroughly clean points of lubrication prior to greasing

every two years


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Manufacturer Lubricant type SAE class AvailabilityDEUTZ DEUTZ OIL TLX-10W40FE 10W-40 Europe

ADDINOL ADDINOL Super Truck MD 1048 10W-40 Europe, AsiaADDINOL Ultra Truck MD 0538 5W-30 Europe, Asia

AGIP Agip Sigma Ultra TFE 10W-40 worldwide

Autol Valve Ultra FE 10W-40 Germany

Akros Akros Synth. Gold 10W-40 EuropeARAL Aral MegaTurboral 10W-40 worldwide

Aral SuperTurboral 5W-30 worldwideAVIA TURBOSYNTH HT-E 10W-40 Germany

BAYWA BayWa Super Truck 1040 MC 10W-40 South GermanyBayWa Turbo 4000 10W-40 South Germany

BP OIL International BP Vanellus E7 Plus 10W-40 Europe

BP Vanellus E7 Supreme 10W-40 EuropeBP Vanellus C8 Ultima 5W-30 EuropeCastrol Castrol Enduron Plus 5W-40 Europe, America,

Australie, Afrique du SudCastrol Enduron 10W-40 Europe, Amérique,

Australia, South Africa

Castrol Elexion 5W-30 USACEPSA EUROTRANS SHPD 10W-40 Spain, Portugal

CHEVRON Chevron Delo 400 Synthtic 5W-40 North AmericaDEA DEA Cronos Synth 5W-30 Germany, Europe

DEA Cronos Premium LD 10W-40 Germany, EuropeDEA Cronos Premium FX 10W-40 Europe

ESSO Essolube XTS 501 10W-40 EuropeFUCHS EUROPE Fuchs Titan Cargo MC 10W-40 worldwide

Fuchs Titan Unic Plus MC 10W-40 worldwideMOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, SE Asia, -

Africa

Mobil Delvac 1 5W-40 worldwide

Mobil Delvac XHP Extra 10W-40 Europe, SE Asia

OMV AG OMV super Truck 5W-30 EuropeOMC truck FE plus 10W-40 Europe

Ravensberger Ravenol Performance Truck 10W-40 GermanySchmierölvertrieb

Lube oil refinery Wintershall TFG 10W-40 EuropeSalzbergenShell International Shell Myrina TX/Shell Rimula Ultra 5W-30 Europe, designation

varies nationally

Shell Myrina TX/Shell Rimula Ul-tra 10W-40 Europe, designationvaries nationally

Texaco Ursa Super TDX10W-40 10W-40 EuropeUrsa Premium FE 5W-30 5W-30 Europe

TOTAL TOTAL RUBIA TIR 8600 10W-40 worldwideEXPERTY 10W-40 worldwide

Release list DEUTZ lube oil quality stage DQC III-05


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5650H – 5690HTSSpeeds

Combine Harvester 5670 5680 5650, 5660

5690 -12225 5680, 5690 + 12226

1 Engine 1/min 2610 – 2655 2425 ±15 2390 ±15

with threshing mechanism disengaged

1 Engine 1/min 2590 – 2635 2415 ±15 2385 ±15

with threshing mechanism engaged

2 Straw stripper drum 1) 1/min 930 +25/–40 945 +25/–40 945 +25/–40

3 Threshing drum 1/min 400 – 1250 ±50 405 – 1265 ±50 405 – 1265 ±50

4 Grain tank discharge 1/min 560 ±40 530 ±40 530 ±40

5 Fan 1/min 400 – 900 +50/–30 410 – 950 +50/–30 410 – 950 +50/–30

6 Sieve box 1/min 285 +15 301 ±5 301 ±5

7 Returns elevator – grain 1/min 1110 ±30 1170 ±30 1170 ±30

Returns elevator – maize 1/min 795 ±20 850 ±20 850 ±20

8 Straw walkers – grain 1/min 201 +5 206 ±2 206 ±2

Straw walkers – rice 1/min 210 +5/ –6 213 ±2 213 ±2

9 Feed passage shaft, top 1/min 425 +/ –2 430 ±20 430 ±20

10 Turbo Separator Grain 1/min 790 ±20 805 +30/ –20 805 +30/ –20

Turbo Separator Maize 1/min 380 ±30 390 ±30 390 ±30

1) As of year of manufacture 2007 the straw stripper drum is driven by the threshing drum.


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A00005

A00006


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5650H – 5690HTSTightening values of adapter bearings

Bearing point Bearing Tightening torque

Threshing drum/turbo separator Grooved ball bearing 140 Nm

Straw stripper drum left side Grooved ball bearing 140 Nm

Straw stripper drum right side Ball joint bearing 180 Nm

Straw walker bearing Grooved ball bearing Pretensioning torque 50 Nm+ Swivelling angle 180°

Shaft of sieve box drive Swivel-joint roller bearing 100 +20 Nm

Countershaft inside of feed passage Swivel-joint roller bearing 56 Nm


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Notes


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34940-1

3535533815

7

1

9

L

35035

4

L

L

5

30969

10

L

32983

2

35371 35036

3

L

6

32983

8

K0036-2

11

90009

1

2

5 6

L

11


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34939-2

16 1913

22 2123

5650H – 5690HTSCheck tension of chain and belt at right side

12 14 17

15

2024

18

Check spring tension L

Caption Tension spring Length Comment

12 Dust extractor fan –

13 Idler pulley, cooler drive L

14 Fuel pump, generator V-belt –

15 Air-conditioning compressor V-belt –

16 Idler pulley, grain tank discharge drive L17 Block tightener grain tank filler auger drive chain –

18 Tension device elevator chain –

19 Idler pulley, threshing drum drive L

20 Chain variator adjustment –

21 Idler pulley, fan drive L

22 Idler pulley, straw walker drive L

23 Idler pulley, straw chopper drive L

24 Chaff spreader: Check belt alignment, correct if necessary – Visual inspection

L = Length according to adjustment gauge


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5650H – 5690HTSMaintenance and repair

General instructions

Observe the general accident prevention regulations with all repair and maintenance works.

Make sure that the engine cannot be started by a second person while working at the combine harvester: Removestart key and battery master switch!

Operating media must be disposed environmental fairly.

Retighten highly stressed screwed connections subsequent to reassembly after a few operating hours, e.g. wheel nuts,bolts on axles.

Perform a functional test and check the oil level after carrying out repair works at the hydraulic system. Check hydraulicsystem for leaks.

Replace porous or damaged hydraulic or fuel hoses in due time.

Check cable harnesses for pinched spots or damages.

Observe fire protection requirements while carrying out welding works at the combine harvester. Thoroughly removedust and crop residuals. Protect cable harnesses, hydraulic hoses and sealing elements against impact of heat. Removeconnectors from electronic control units.

Tighten the circlip to rotational direction of shaft while assembling circlip bearings.

Mount adapter bearing according to factory specification.

Causes for vibration must be remedied immediately. E.g. imbalance caused by foulings on beating arms of the threshing

drum or by broken chopper knives, by v-belts with grinding marks or by imbalance of tensioning pulleys by dust deposit.


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Servicing and Maintenance

General Instructions

V-Belts

Since new V-belts still stretch, their tension must bemonitored more frequently during the first few operatinghours. V-belts with fixed idler pulley are correctly tensioned if

they can still be pressed down slightly. Belts that aretoo loose are subject to greater wear.

The V-belt guide must be designed to prevent thedisengaged belt rubbing against the belt pulley. Thegap between the guide and the tensioned V-belt mustbe 8 mm.

Never pull the V-belt over a pulley violently or witha tool.

We recommend that dirty V-belts should be cleanedwith a 1:10 solution of glycerine spirit solution (orsimilar). Do not use petrol, benzene, terpentine etc.

Avoid mechanically stressing the V-belts. During winterstorage, make sure that the pulleys are not attacked byrust.

Chains

The drive chains must be regularly lubricated with trans-mission oil. After the harvest season, remove the drivechains, clean with diesel fuel, dip in warm chain greaseand refit. Always mount chain locking links so that they cannot

catch, e.g. with the closed side of the retaining springfacing the direction of drive.

Always use new locking wire if chain locks have beenopenend.

Variator drives

Remove dust and dirt deposits between the pulley halves.The variator drives (reel, threshing drum and cleaning fan)must be adjusted after lubricating in order to ensure thatthelubricating film spreads evenly over the friction surfaces.

Screwed fixings

Check that all screwed fixings are secure, especially onthe sieve box, and retighten if necessary.

Check nuts secured with split pins.

Fuel and oil tanks

Refill the tanks after ending work, in order to prevent

condensation, especially if the difference between workingand non-working temperatures is high.

Tyres

Regularly check the tyre pressures and the tightness ofthe wheel nuts.

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A00160

A00161

A00162


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5650H – 5690HTSEngineTable of Contents

Combine Harvester Type 5650H 5680H5660HTS 5690HTS

Index of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 X X

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 X X

Technical data DEUTZ engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04 X X

Rating plate / serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 – 06 X X

Bolt tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 X X

Description of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 – 09 X X

EMR, electronic engine controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 15 X X

Overview power supply EMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 – 17 X X

Control unit EMR, gas control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 – 19 X XPlug assignments of the EMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 – 21 X X

Sensor and transmitters overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 – 23 X X

Fuel system, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 – 25 X X

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 X X

Clean/replace fuel pre-filter, filter element; bleeding of fuel system . . . . . . . . . . . . . . . . . . .27 X X

Change fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 X X

Change fuel oil leakage pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 X X

Fuel injection valve, injection pipes assembly, disassembly . . . . . . . . . . . . . . . . . . . . . . . . .30 – 31 X X

Testing and setting of injectors free from leak-off fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 – 33 X X

Cooling circuit, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 – 35 X X

Draining / filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 X X

Mounting of the coolant temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 X X

Replacement of thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 X X

Mounting of coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 X X

Maintenance and inspection Deutz engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 X X

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 X X

Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 X X

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 X X

Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 X X

Release list DEUTZ lube oil quality stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 X X

Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 X XV-Belt generator tensioning/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 X X

Checking, adjusting valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 X X

Adjustment instruction for valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 X X

Determination of cylinder-head gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 – 53 X X

Mounting of the cylinder-head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 X X

Tightening of the cylinder head screws sequential order . . . . . . . . . . . . . . . . . . . . . . . . . . .55 X X

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 – 57 X X

Charge cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 X X

Cooling fan drive, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 X X

Exhauster drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 – 61 X XRotating sieve pan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 – 63 X X

Driven shaft of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 – 67 X X

Mounting of hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 X X

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5650H – 5690HTSEngine, driven shaft of engine

Index of abbreviations

ATL Exhaust-driven turbochargerBh Running hoursEMR Electronic engine controller

Further technical documentation for the engine of Deutz AG:

Operating instructions engine 1012/1013 0297 7379Workshop manual BFM 1012/1013 de, en, fr, es 0297 7438System description EMR de, en 0297 7432Manual SERDIA, LEVEL III 0297 7482

Fault diagnosis, main focus on fuel injection system 0297 7509


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5650H – 5690HTS Maintenance andInspection DEUTZ Engine:

General

Safety Instructions

Engine:

1. Do not maintain the engine while running. Removethe ignition key!

2. On principle always disconnect the battery (negativepole) while working at the engine!

3. Only fill up fuel with the engine stopped – Nosmoking!

4. Caution while draining hot lube oil – danger ofburning!

5. Observe the specified quality of oil and fuel and storeboth only in approved containers!

6. Provide for collection of leakage fuel and waste oil inaccordance with anti-pollution regulations!

7. Dispose of properly oils, fuels and filters!

8. After maintenance and repair works: Check whetherall safety devices have been remounted and all toolshave been removed from the engine!

9. Only carry out cleaning jobs with the engine stopped!

10. Battery gases are explosive! Avoid sparking and openfire near the batteries! Do not spill acid on skin orclothes! Wear safety goggles! Do not put tools on thebatteries!

11. Also observe the additional safety instructions in thischapter!

A00009


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5650H – 5690HTSTechnical Data DEUTZ EngineType BFM 1013 EFour-Stroke Diesel Engine with Direct Injection

BF6M 1013 E

Number of cylinders / configuration 6 in tandem

Bore [mm] 108

Stroke [mm] 130

Total cylinder capacity [ltr.] 7,1

Method of operation / method of combustion Four-stroke diesel with direct injection

and exhaust-driven supercharger.

Firing order 1 - 5 - 3 - 6 - 2 - 4

Rotational direction when facing flywheel: left

Rated speed [rpm] see engine name plate

Power [kW] see engine name plate

Valve clearance inlet / exhaust [mm] 0,3+0,1 / 0,5+0,1

Commencement of delivery see engine name plate

Injector opening pressure [bar] 275

+8

Min. oil pressure [bar], at lower idle speed and 0,8

warmed-up engine (120 °C operating temperature)

Method of cooling Liquid cooled with integrated lube oil cooler

Coolant quantity [approx. ltr.]

Engine and cooling system 55

Thermostat starts opening at [°C] 83

Thermostat fully open from [°C] 95


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5650H – 5690HTSRating Plate, Engine Serial NumberEngine Data

The type (A), the engine serial number (B) and the performancedata are stamped on the rating plate.When ordering spare parts, it is essential to quote the type andthe engine serial number.

The rating plate (C) is affixed to the crankcase.

The engine serial number is stamped on the crankcase itself(arrow) as well as on the rating plate.

The cylinders are numbered consecutively, beginning at flywheelend.

A B

26 332_3

26 231_1

26 232_1

26 233_0


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5650H – 5690HTSTechnical data DEUTZ engineRating Plate

Pos. Description Remark

1 Type of engine e.g. BF6M 1013 EC2 Code with engines according to specifications of

commission 88/195/EWG

3 engine number –

4 kW (G) "overall power” (G-power), cooling fan is not running.

5 kW (S) "nominal power” (S-power), cooling fan is running at

full speed.

6 1/min Nominal speed of the engine.

7 Commencement of delivery and Commencement of delivery in degrees.

type of camshaft Letter stands for type of camshaft

8 kW (W) "Active vent” (fan/blower) as a part of the specified

power.

9,10 For free disposal.

11 Statement of standard and/or regulation

12 kW (G) red. Reduced "overall power”, conditions on site

pos. 14, 15.

13 kW (S) red. Reduced "nominal power”, conditions on site pos.

14, 15.

14 Air temperature in °C For environmental conditons on site.

15 Altitude above sealevel in m For environmental conditons on site.

16 Injection pump code Code for cylinder related statement about the tool-

fitting dimension of the pump determined at

manufacturing (beginning from above with

cylinder #1)

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Flywheel Initial tightening value:Bolts 30 – 45 mm long 20-30 Nm

If traceable use bolts 5 times max. Bolts 50 – 85 mm long 30-40 Nm

1. retightening angle

Bolts 30 – 85 mm long 60°


Bolts 30 mm long 30°

Bolts 35 – 85 mm long 60°

Cover for wheelhouses 21±2 Nm

V-belt pulley Initial tightening value: 40-50 Nm


If traceable use bolts 5 times max. Bolts 60 mm long 60°

Bolts 80 mm long 60°2. retightening angle



Note: Use Torx socket wrench E20

Front covers 21±2 Nm

Vibration damper with clutch flange

(bolts fixed with glue) 70 Nm

Cylinder head bolts Initial tightening value:

(Observe sequential order) 1. step 50 Nm

2. step 130 Nm

Retightening 90°

Rocker arm support 21 NmRocker arm locknut 20±2 Nm

Crank case vent 8,5±1 Nm

Cylinder head cover 9±1 Nm

Connection nut fuel injection valve 40-50 Nm

Grip holder for fuel injection valve 16 + 5 Nm

Injection pipe Initial tightening 5 Nm

Retightening 25 + 3,5 Nm

Pressure control valve 30 Nm

Charging air pipe at cylinder head 11±1 Nm

Coolant tube at cylinder head 21±2 Nm

Coolant pump 21±2 Nm

Exhaust manifold 25±2 NmExhaust-driven supercharger - Bolts M8 21±2 Nm

- Bolts M10 40,5±4 Nm

Pressure oil pipe at turbocharger 21±2 Nm

Pressure oil pipe at crank case 39±3 Nm

Oil return pipe 21±2 Nm

Lube oil cooler 21±2 Nm

Connection piece at fuel filter casing 50±5 Nm

Oil pan - sheet metal oil pan 21±2 Nm

Connection case at flywheel M12 99±10 Nm

M16 243±25 Nm

Starter 70 Nm

Shut-off solenoid 21 Nm

Positioning element (observe sequential order) 17±1,5 Nm

Oil pressure switch, oil pressure transducer 18±2 Nm

5650H – 5690HTSTechnical data DEUTZ engineBolt Tightening Torques(for further statements see workshop manual BFM 1012/1013)


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5650H – 5690HTSDescription engine BFM 1013 EOverview

1 Oil filling tube2 Coolant pump3 Fuel pump4 Vibration damper (2 pieces)5 Exchangeable fuel filter6 not applicable7 Exchangeable oil filter8 Oil sump9 Oil-level dip-stick

10 Lube oil cooler11 Attachment facility for hydraulic pump resp. compressor12 Fuel oil leakage pipe with pressure control valve

13 Cylinder head14 Transport device15 Crank case venting valve16 Speed controller17 SAE housing18 Flywheel19 Starter20 Exhaust-driven supercharger21 not applicable22 Exhaust manifold23 Intake

A Coolant inlet


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Use of EMRThe electronic engine controller (EMR) serves as speed controller of DEUTZ Diesel engines of product line 1012/1013(1015) for use in agricultural and construction machines as well as in aggregates. It has been designed for heavyoperation even under difficult environmental conditions and has been approved the corresponding protection classes.

The controller includes all functions of the mechanical controller (all speed control, torque limitation, LDA function) andprovides moreover further functions.

System overviewThe EMR mainly consists of the sensors, the control unit and the manipulating element (actuator). All eqipment pertainingto the engine as well as pertaining to the vehicle/system are connected to the EMR control unit by means of separate

prefabricated cable harnesses. The cabling pertaining to the vehicle is carried out by the manufacturer of thevehicle/system.

5650H – 5690HTSEMR Electronic engine controllerSystem description

Schalter Motordrehzahl:

- unterer Leerlauf

- erhöhter Leerlauf- Nenndrehzahl

Gasverstellmodul

+Schalter S5

charging air pressuresensor

adjusting rod positiontransmitter/ actuator

temperature sensorcoolant

speed sensorcamshaft

lifting magnet(optional)

power supply

gas control unit+switch S5

switch motorspeed:- lower idle speed- increased idle speed- nominal speed

Droop switchoverK11

key switchstart/stop

indicator lampmalfunctionEMR

diagnosis plug-socketoil pressuresensor (optional)

Equipment pertaining to the vehicleEMR

control unitEquipment pertaining to the engine

Fuel temperatureEMR 2


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The sensors mounted on the engine supply the electronics in the control unit with all relevant physical dimensions.

According to these informations about the actual engine condition and according to the setpoints (gas control unit) the

EMR excites a turning magnet actuating the adjusting rod of the injection pumps and thereby metering the fuel amount.

The exact position of the adjusting rod is fed back and corrected if necessary by means of the adjusting rod position

transmitter located in a housing together with the turning magnet, the "manipulating element”.

The EMR is equipped with safety facilities and safety measures both in hard- and software, in order to ensure emergency

operating functions (limp home).

The EMR is cut off from the power supply by means of the ignition switch in order to shut down the engine. A sufficiently

strong spring inside of the manipulating element is pushing the adjusting rod into its neutral position when the power isdisconnected. As an option it is possible to additionally excite a lifting magnet for shut-down of the engine.

At first the EMR is programmed non-specifically with respect to the engine. On the test cell the engine is tested, adjusted

and programmed together with the EMR. After this programming, the EMR is assigned to this specific engine and

contains a engine specific data record.

For the various cases of application, e.g. with regard to a defined scope of functions, the EMR is being customized ex

works by means of the band end programming via the ISO 9141 interface.

System functions

The EMR provides a broad choice of functions, which can be activated through an application dependant configurationand by means of assigning the inputs and outputs. It enables a signal exchange between the engine (via the engine plug)

as well as between the vehicle (via the vehicle plug) and the EMR. The signals may be analog, digital or pulse width

modulated (PWM) signals.

Which of the functions will be used depends on the operating conditions of the engine. Accordingly there are different

variants of the functions and of the pin assignment of the plugs.

The functions of the EMR refer to the speed control, fuel metering (injection), monitoring, vehicle and device functions as

well as to communication and diagnosis interfaces.

Droop

In contrast to a mechanic controller, it is a special feature of an electronic controller to be able to adjust the droop

percentage to 0% and to switch over between two fixed droop percentages. The maximum value is at 80%.

For emulation of the droop behaviour of the mechanic controller a speed dependant droop function is provided

(characteristic with 8 speed bases).


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The EMR offers a basic configuration, upon which all variants optionally are based:

Key start/stop

The EMR must be switched off by means of the ignition key in order to shut down the engine. With this shutdown the

adjusting rod is moved to the stop position by the spring-loaded actuator.

As soon as the start speed signal is detected by the control unit, the adjusting rod is released for the start-up.

Repair

It is only possible to replace all components (no repair) which are all available individually. As the control unit needs to be

programmed with a engine specific data record, the following information is necessary:

number of engine

complete part number

Caution:

Prior to carry out electric welding works the plug-in connections at the control unit need to be disconnected in

order to avoid damage of the control units!

micro-processor

program

memory

parameters

characteristic

characteristic

diagram

underlined =basic configuration

actuator functions

actuating magnetlifting magnet

setpoint

pedal positiontransmitter

manual gasswitch for

changeover

gas control unit

interfaces

power supply

diagnosis interfaces

CAN bus

display functions

speed

torque

warning signals

error lamp

sensor inputs for:

displacement ofadjusting rod speedcoolant temperaturecharging air pressure

oil pressureFuel temperature

EMR 2


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Diagnosis

Self-diagnosis with error lamp

The EMR provides a multitude of protective functions for the engine – depending on the available points of measurementresp. sensors. According to the severity of the detected error the engine can either keep on running (eventually with

restrictions, error lamp is permanently lit) or it will be shut off (error lamp is flashing).

Lighting of the error lamp indicates either a wiring fault (short circuit, cable break) or a malfunction with the displays or

the corresponding sensors. As further error sources falling below or exceeding of measuring value limits may come into

question (see table hereafter).

All detected errors in the electronic system will be indicated in the control unit and by means of the error lamp. As soon

as the error is not pending any more, the error lamp is extinguished; only if the electronic system has been changing

over to emergency run (speed), the engine needs to be shut off shortly by means of the ignition key in order to terminate

flashing of the error lamp.

Even recovered resp. non-current errors will be memorized in the control unit and can be read out or erased by means of

the diagnosis software SERDIA, see following chapter.

Diagnosis options with software SERDIA

The error messages stored in the control unit can be read out resp. evaluated by means of the diagnosis software

SERDIA.

Hereby information is displayed about:

- Error location (e.g. "pedal value transmitter”,* "coolant temperature sensor”).- Type of error (e.g. "lower limit exceeded”, "sporadic error”)- Environmental data (e.g. speed at the moment of error occurrence)

- Number of error locations

- Frequency

- Error status ("1” for active, "0” for passive).

Error messages of non-current/recovered errors can be erased with SERDIA.

SERDIA (service diagnosis) is a software program which makes it possible for the user to monitor measuring values by

means of a PC while the Diesel engine is running and hence be able to recognize an incorrect operational behaviour.

Then upon standstill of the engine it is possible to selectively preset specific parameters from the PC via the control unit

(parameterization), in order to change the operational behaviour.

For this, the PC must be connected with the diagnosis interface via an interface. Communication with the control unit is

done via a special EMR protocol.

For handling of SERDIA see separate operating instructions.

* With the combine harvester, the pedal value transmitter corresponds to the gas control unit.

5650H – 5690HTSEMR Electronic engine controllerDiagnosis


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SensorCharge Air PressureOil Pressure

Temperature Sensor CoolantTemperature Switch/Sensor

Connector X 107at Engine

Connector X 107at Engine

5650H – 5690HTSEngine - Sensors


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K11 K12

K0

D+ W

S5

F34

A30

K48

EEC

A1

AHS

012

S40

Commander

Control

2000

G3

75

B7

15a

A2

15

F1930

F39

H34

F7 F42

15

15b

K22

A13

M1

5 a

B48

30

1 2 3 4 5

u l l

s t

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5650H – 5690HTSOverview power supply EMR, engine monitoring in addition to EMR (EEC)Start system

A1 Control unit EEC (electronic controller Diesel engine)A2 Gas control unit for control unit EEC (A1)A13 Logic unitA30 Commander Control 2000B7 BuzzerB40 Combined instrument gaugeB45 Sensor multifunction handle neutral (start interlock)B46 Sensor multifunction handle reverse (reverse gear horn)B48 Reverse gear hornF.. FusesG3 GeneratorH34 Failure lamp engineK0 70 A relay for terminal 15K11 Relay release threshing mechanism on, terminal 15b, droop switchoverK22 Relay starterK48 Relay power supply EECM1 StarterS2 Ignition start switchS5 Switch engine speedS40 Working master switch

1 Low-pressure switch air filter2 Temperature switch coolant3 Temperature switch engine oil

4 Oil pressure switch5 Coolant level switch


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5650H – 5690HTSControl unit EMRGas control unit

1 A1 control unit EMR2 Connector on the engine side

3 Connector on the vehicle side

4 A2 Gas control unit

5 Diagnosis plug-socket

6 LED UB, power supply

7 LED VCC, supply from EMR

8 LED TH/2, half throttle

9 LED TH/1, full throttle

10 LED SDW, threshing mechanism on = 15b, (LED on = threshing operation)

Note: Upon full throttle and switched-on threshing mechanism all LEDs are lit.

Subsequent to a replacement of the gas control unit a calibration of the setpoint generator must be carried out (seeSERDIA manual, parameterization page 10).

A2 pin assignment

Pin Designation Cable colour Measuring value

1 Input half throttle from S5 gr/rt 0V/12V

2 Input full throttle from S5 gr/bl 0V/12V

3 Pot. throttle ground br

1,2V idle throttle

4 Pot. throttle slider ws/bl 2,8V half throttle

4,1V full throttle

5 Pot. throttle supply ws/rt 5V

6 Input droop changeover from K11 sw/gn 0V/12V

7 Output droop changeover to A1 ws/gn digit

8 Ground droop changeover br

9 Supply 12V from control cabinet X8 sw 12V

10 Supply A1 sw 12V11

12 Supply for diagnosis connector sw 12V

13 Ground for diagnosis connector br

14 Ground for A1 br

15 Ground for A1 br

16 Ground for diagnosis connector br

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1

4

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6

8 9 10

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M 1 AR S 1

556-055

9 16

1 8

4

56-116

X8

A1

A2

4

Engine Vehicle


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Pin-No Designation Description

1 x U Batt - Negative pole at battery (clamp 31)

2 x GND Reference potential for signal

3 Output: digital 2 PWM or digital output,various functions

4 x Input / output: DigInOut Fault lamp and diagnostic button

5 Output: PWM 1/Dig 1 PWM or digital output, variousfunctions

6 Multi-function input: Genset applications/gear shift/motorDigin 3 brake

7 Input: digital 10/velocity Speed signal (tacho input)

8 NC Not occupied9 NC Not occupied

10 x L-line Serial ISO 9141 interface

11 x K-line Serial ISO 9141 interface

12 x CAN high Interface for CAN-Bus

13 x CAN low Interface for CAN-Bus

14 x U Batt + Positive pole for battery (clamp 15)

15 Output: digital 5 Digital output, various functions

16 Output: digital 7/Frequency Frequency, PWM or digital output,various functions

17 x Ground Reference potential for signal at

pins 18, 19 and 21.

18 Input: digital 1 / PWM 1 PWM 1 or digital input 1, variousfunctions

19 Multi-function input: DigIn 4 Performance curve switching/gensetapplications

20 Multi-function input: Hand hand throttle/genset applications,digi tal 8 / analog 3 Digi tal (8) or analog input (3)

21 x Input: digital 2 / PWM 2 PWM 2 or digital input 2,

various functions

22 Screen Screening (e.g. for lines 9 handthrottle or PWG)

23 x GND Reference potential for signal at

pin 24

24 x Input: analog 1 / digital 6 Analog input 1 (pedal value

sensor, PWG) digital input 6

25 x +5V REF +5 V Reference voltage for signal

at Pin 24

5650H – 5690HTS

Plug assignments of the EMR 2 control unit

Pin No. Designation Description

1 Reserve Reserve

2 Output: digital 3 Digital output for solenoid 1)

3 Output: digital 4 For heating flange (optional)/ glow plug (optional)

4 Input (optional) Temp 1 Fuel temperature 2)

5 Input (optional) Temp 2 Charge air temperature

6 Input (optional) DigIn 5 Coolant level / oil level

7 Output: PWM2/digital 6

8 GND Reference potential for analog signal at pin 9

9 Input: analog 7 Analog input for Coolant temperaturesensor (NTC)

10 GND Reference potential for signal at pin 11

11 Multi-function input: Digital input second engine speedspeed 2/DigIn 2 (crankshaft) (optional) and speed signal

(optional)


13 Input: speed 1 Digital input first engine speed(camshaft)

14 STG - PWM output, signal for actuator coil

15 STG + PWM output, signal for actuator coil

16 Screen Screening regulating rod travel sensor(for lines 17, 18, 19)

17 RF - General connection forreference and measuring coil

18 RF REF Analog input, reference signal

of the reference coil

19 RF MESS Analog input, measuring signal

of the measuring coil


21 Input: analog 4/digital 9 Analog input 4 (sensor signal oilpressure sensor) or digital input 9

22 +5 V REF +5 V Reference voltage for signal at pin21 (max. 15 mA)


24 Input: analog 2/digital 7 Analog input 2 (sensor signal chargeair) or digital input 7

25 +5 V LDA +5 V Reference potential for signal atpin 24 (max. 15 mA)

x) Pin used for combines1) For continuous power: < 4 A2) Corresponds to special function”fuel temperature compensation at the

EMR (0211 2571)

13 2513

11

1414

25


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1

2

4

3

5

26337-2

2.1

7

9

6

8

26336-2


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811

17 13

12

16

14

18

19

10

56-069

15

A007

34926

2 31

4 5


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5650H – 5690HTSFuel system, overview

1 Injection pipe

2 Shut-off solenoid (until year of manufacture 2002)

3 Fuel oil leakage pipe from fuel injection valves (until year of manufacture 2002)

4 Pressure control valve 5 bar

5 Plug-in injection pump

6 Line to plug-in injection pumps

7 Line to fuel filter

8 Fuel pump

9 Fuel filter

10 Fuel suction line to fuel pump

11 Return line to fuel cooler

12 Fuel Cooler

13 Fuel suction line to pump

14 Tank stopcock

15 Vent pump

16 Fuel tank

17 Fuel pre-filter

18 Drain plug at pre-filter

19 Drain plug at fuel tank sump

Check for proper connection of fuel lines at the pre-filter:

— Line from bleed pump (16) to connection EIN / IN — Line to engine at connection AUS / OUT


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5650H – 5690HTS

Fuel pump

The fuel pump is a rotor pump which is driven by the wedge rib belt.

The pump disposes of a double valve (pos. 1 Popen: 6 ± 0,5 bar, pos. 2 Popen: 0,5 bar).

As of year of manufacture 2006 fuel pressure pumps with a relief pressure valve of 7 bar are being used

The relief pressure valve (1) is of the piston valve type and opens at 6 ± 0,5 bar and 7 bar resp. Furthermore the maximum

system pressure is limited to 10 ± 0,5 bar with this valve.

The bypass valve (2) is a ball valve. After draining of the fuel lines it is hereby possible to prefill the fuel system by means

of the hand feed pump. In this way a too long start process will be avoided (starter protection).

Note:Do not reduce the pipe diameter and the connection to the fuel pump (see installation manual), as otherwise loss of

nominal engine power may occur.

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5650H – 5690HTS

Clean/replace fuel pre-filter, filter element;

bleeding of fuel system

Changing interval filter element: 1000 op. hrs

Clean/replace filter element (8)

– Close tank stopcock (1).

– Open the venting screw (7).

– Loosen the drain plug (3) and drain the fuel.

– Unscrew tightening screw (6), remove filter housing (5).

– Replace filter cartridge (8) and if necessary the sealings (4). – Replace filter housing (5).and secure with screws (6).

– Tighten drain plug (3).

– Open tank stopcock (1).

– Open the venting screw (7) until fuel flows out.

– Actuate vent pump (2) until fuel flows hereable withoutair into the tank.

Venting the fuel system.

– Open the venting screw (7).

– Open tank stopcock (1).

– Actuate vent pump (2) until fuel flows out from theventing screw (7).

– Close the venting screw (7).

– Actuate vent pump (2) repeatedly.

– Start the engine.

Note: If the engine does not start up despite repeated

attempts:

- Vent the system again by means of the ventpump.

- Possibly loosen the pressure control valve (9)and actuate vent pump until fuel emerges fromthe pressure control valve. Retighten pressurecontrol valve and start the engine.

– Check system for leakage after start-up of the engine.

34923

30 084_0

2

3

1

25 801_0

4

765

3

8


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5650H – 5690HTS

Change fuel oil leakage pipe

Changing interval: 1000 operating hours, at least everysecond year.

Mounting tool: Hose clamp pliers TN8020

– Close tank stopcock.

– Take down the rocker assembly cover hood.

– Loosen hose clamps (6) by means of hose clamp pliersTN 8020.

– Disconnect rubber hoses (3) and hose clamps (6) fromthe fuel injection valves.

– Loosen the pressure control valve (9).

– Take down the hose clamps (6), rubber hoses (1), (3),(4) and the adapters (2) and the collar with socket pin /

threaded pin (5) and dispose of in accordance with anti-

pollution regulations.

Observe at assembly that the hose clamp lock is

pointing to the fuel injection valves and the hose

clamp cannot fall into the engine compartment.

– Attaching new oil leakage pipe:

Slide rubber hoses (3) (coat inside with sliding grease)

together with hose clamps (6) steadily onto the fuelinjection valves to the connection fitting stop at the fuel

control valve and close by means of hose clamp pliers

TN 8020.

– Assembly of pressure control valve (9):Tighten new collar piece with socket pin / threaded pin (5).

– Remount the rocker assembly cover hood.

– Open tank stopcock.

– Actuate vent pump repeatedly.

– Check for leakage after commissioning.

30034_1

30901_0

30 084_0


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Slide the new seal onto the fuel injection valve by usingsome grease and insert injection valve.

Note: The leakage oil line connection must point to theexhaust side.

Put on the grip holder. Screw in bolt slightly.

Attach new injection pipe with rubber seal. Screw onconnection nut slightly by hand.

Note: At assembly of the fuel injection pipes the sealingcones must match exactly.Subsequent bending is not permissible. The fuelinjection pipes may not be used twice.

Tighten the bolt of the gripholders with a tightening torqueof 16 + 5 Nm.

28-4-44

38-4-192

38-4-193

38-4-194

5650H – 5690HTS

Fuel injection valve, injection pipes

Assembly, disassembly


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Tighten the connection nuts of the fuel injection pipe atthe injection pump and the injection valve with a pre-tightening torque of approx. 5 Nm. Tighten theconnection nuts subsequently with a tightening torque of25 ± 3,5 Nm.

Attach oil leakage pipe and introduce through rubberseals.

Note: It is mandatory to replace used oil leakage pipes.

Attach pressure control valve with new copper seals andoil leakage pipe.Tighten pressure control valve with a tightening torque of30 Nm.

5650H – 5690HTS

Fuel injection valve, injection pipes

Assembly, disassembly

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38-4-146

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5650H – 5690HTS

Testing and setting of injectors free from

leak-off fuel

1. Testing the injector

The volume of leak-off fuel cannot drain and iscollected above the nozzle needle in thespring compartment of the injector. Now, thehand lever of the nozzle tester can no more beoperated.To have the pressure in the springcompartment relieved, prior to every test, thetensioning nut must be unscrewed and then

be tightened again as specified.

1.1 Unscrew tensioning nut by approx. 180°

and tighten it again.

Tightening instruction: 40 - 50 Nm

Special tool for taking the injector depending onengine type 6

1.2 Mount injector to nozzle tester.

Attention!Do not touch the nozzle jet. The fuel deeply entersthe flesh and can cause blood-poisoning.5

1.3 Slowly press down lever of the nozzle tester withconnected pressure gauge.The pressure at whichthe pointer stops or suddenly drops is the openingpressure.

Opening pressure: 275 + 8 bar

Reference: After having operated the hand lever of thenozzle tester for three to four times, thepressure in the spring compartment isestablished again. The tensioning nut must benewly unscrewed and tightened againaccording to the tightening instructions andthe test be repeated.5

1.4 If the measured values of 3 tests are identical, theycan be considered valid.

Chattering and spray pattern test

Disconnect pressure gauge of the tester. The chatteringtest permits to check the unhindered movement of thenozzle needle in the nozzle body via the developing noise.New injectors have a different chattering behaviour thanused ones. Due to wear in the needle seat area, itdeteriorates. If the injector does not chatter despite havingbeen cleaned, it must be replaced by a new one. A usedinjector must clearly chatter upon rapid lever operation

and inject with a good atomisation. The spray pattern can

considerably differ from that of a new injector.


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2. Setting the injector

2.1 If the opening pressure must be corrected,dismantleinjector from nozzle tester. Unscrew tensioning nut,dismantle all parts.

Special tools for taking the injector depending ofengine type.

2.2 Sequ

Documents

5650-5690 Balance Repair manual