Service School Handout

Service School Handout
AMADAS Self-Propelled Peanut
Combine Diagnostics and
Service Manual
MAN137
July 2013
Table of Contents
 Anatomy of an Amadas Self
Propelled Peanut Combine
 Amadas Self Propelled
Diagnostics and Repair
 Field Performance
 Warranty Information
Anatomy of an
Amadas Self
Propelled Peanut
Combine
Amadas Specific
• Header
• Main Chassis
• Threshing and Separation System
• Peanut Basket
• Unloading Conveyor
• Auxiliary Hydraulics
Anatomy of an
Amadas Self
Propelled Peanut
Combine
•
•
•
•
•
•
•
John Deere Supplied
Steering System
Cab
Major Drive Train System
Engine Platform
Main Hydraulic System
HVAC System
Electrical System
Differences in the John Deere
Supplied Systems as used in the SP
Peanut Combine
• Steering System: Some hose lengths are specific to
Amadas. The rear axles with two steering cylinders are
identical to a Deere CWS combine. Rear axles with a single
steering cylinder use an Amadas center and Deere STS
components.
• Cab: The cab is a Deere production cab with minor
changes. These are: 10% engine speed control, Amadas
labeling for certain switches or displays, and a switch for
header reversing either internal (9970) or external (all other
models).
• Major Drive Train System: These components, such as
the hydrostat, transmissions, final drives, etc., are completely
Deere items. Hose, cables, and steel lines that support these
are custom for Amadas. The shafts that connect the final
drives to the transmission are also specific to Amadas
combines.
• Engine Platform: Includes the engine, main gear case,
coolant system, and the platform they are mounted on.
Through the 9960 model combines these were CWS
(Walker) combine units.
The 9970 uses a Deere engine platform and the 9970(s)
uses a S550 engine platform but retains the 9570 engine
harness and separator engage valve. In addition, the STS
rotor drive is not used. All engines use an Amadas specific
ECU program.
Differences in the John Deere
Supplied Systems as used in the SP
Peanut Combine
• Main Hydraulic System: The hydrostat system is identical
to Deere although most hose lengths are specific to
Amadas. The main pump stack is the same as a grain
combine. Up through the 9960 combines, the pumps were
used as the same function as the grain combine. The 9970
uses the HillMaster version header lift pump to power the
OCS conveyor (if equipped). The valve stack pump is flow
divided and used to power both the valve stack and header
lift. All other pumps on the 9970 are used for the original
Deere purpose. The main valve stacks are Deere supplied
on combines up to 9960s. Beginning with the 9970
combines, the valve stack is Amadas specific.
• HVAC System: Except for some hose lengths, the system
is the same as a Deere combine.
• Electrical System: All Amadas SP combines use the
Deere electrical system from the equivalent Deere combine.
All major components such as relay boards, controllers and
engine harness panels are Deere products. Main harnesses
are Amadas specific. The controls are all Deere, although
some circuits are used to control different items on the
Amadas combine. All controllers on the 9960 use Deere
9560 STS programs. The 9970 payloads are all Deere 9570
STS payloads except the ADU, which is specific for Amadas.
Amadas Self Propelled
Diagnostics and Repair
•
•
•
•
•
Amadas/John Deere Comparable
Machines
Available Information and How to
Access it
Diagnosing Electrical Problems
Hydraulic Diagnostics
Basic Mechanical Repairs
Amadas/John Deere
Comparable Machines
Comparable Machines
Amadas Model Number
John Deere Grain
Combine Model
Number
9970(S)
9570 STS (6.8L) *
9970
9570 STS (6.8L)
9960
9560 CWS (6.8L)
9900
9510 CWS (8.1L)
9865
9500 CWS (7.6L)
9665
9500 CWS (7.6L)
NOTE: The 9970 (S) uses a Deere S550 Engine platform
but the engine harness and separator valve are 9570
components.
Available Information and How to
Access it
• Parts Catalogs
• Front pages identifies the equivalent Deere
combine
• Hydraulic hose routing
• Combine shaft speeds
• Listing of John Deere Filters
• Operators Manuals
• General Operation instructions
• Basic DTC’s
• Electrical Manuals
•
•
•
•
•
Function cross reference
Circuit code listings
Connector Information
Schematics
Machine Settings
• Operators Quick Reference
• Technical Information
• Information on specific topics
• 9970 Payloads
• Access: www.amadas.com
www.amadas.com
Select Product Catalogs & Manuals
NOTE: The Amadas website is being updated, the
content in the Catalogs and Manuals section will not
change but the access may vary from what is
illustrated here.
Product Catalogs & Manuals
Select “Agricultural
Technical Information”
for additional
information
Select “Amadas
Agricultural Equipment
Catalogs” for parts
catalogs or manuals
Agricultural Equipment Catalogs &
Operator Manuals
Select “Self Propelled
Peanut Combine” for
parts catalogs or manuals
Self-Propelled Combines Parts
Catalogs & Operators Manuals
Diagnostics of the
Electrical System
• Using the Electrical Manuals
• 9970 Electrical Manual (MAN 111)
• 9960 Electrical Manual (MAN 132)
• How to Access, Select and Load 9970
payloads into Service Advisor
• Diagnosing Header Engage and
Reversing Problems
Using the Electrical
Manuals
• Determining use of a circuit
• Using the schematics to follow a
•
•
•
•
circuit and see differences (if
any) from Deere
Circuit wire color and harness
connector location
Connector illustration and circuit
locations
Machine settings
OCS timer box schematic
Circuit Code Numbers with John
Deere Amadas 9970 Functions
Use to determine function of a circuit and what
page(s) the circuit is found in the schematic
Circuit Code Numbers with John
Deere Functions and Amadas 9960
Functions
Use to determine function of a circuit and what
page(s) the circuit is found in the schematic
9970 Electrical Schematic
Use to follow a circuit and determine differences if use
is not the same as Deere
9960 Electrical Schematic
Use to follow a circuit and determine differences if use
is not the same as Deere
9960 Electrical Schematic
For the 9960, if the schematic directs you to another
page, always use the SE #’s to follow the circuit
9960 Electrical Schematic
If the circuit code matches vertically and horizontally
then the function is the same as Deere.
If Amadas-specific use, then the vertical circuit code
name will be the Deere use and the horizontal name
will be the Amadas use.
Circuit Codes within the Amadas 9970
Harness with Wire Color, Connector
ID, and Pin Numbers
Used to identify the wire color and connector
locations of a circuit.
Circuit Codes within Amadas 9960
Harnesses with Wire Color,
Connector ID, and Pin Numbers
Used to identify the wire color and
connector locations of a circuit.
9970 Main Harness Connectors and
Terminal Information
Illustrates connectors and position of circuits within it.
Note: The 9970 uses one main harness.
SP 9960 Connector Terminals
for 16371 Harness
Illustrates connectors and position of circuits within it
Note: The 9960 uses Left and Right Hand Main
Harnesses
9970 Machine Settings
This section of the 9970 manual identifies by
controller the payload used and the Machine Settings
that must be set or verified when a controller is
replaced
9960 Machine Settings
These are the 9960 Amadas Machine Settings by
controller and address. Unless equipped with OCS,
only the Cornerpost controller (C03) requires any
machine setting changes. If equipped with OCS, then
controller E01 addresses 100 & 101 must be set as
well.
O.C.S. Timer Box Drawing
Illustration, parts listing and schematic of systems
that the conveyor and basket auger valves.
NOTES: cc# 38 supplies power for valves, cc#319 controls
both relays, the resistors are used to meet minimum amp
draw requirement of cc# 319
If timer relay fails and replacement is unavailable a short
term repair can be made by using two jumpers. One
between terminals 2 & 3, the second between 6 & 7
Selecting and Installing
9970 Payloads into the
Service Advisor
• Go to Technical Information
• Selecting Payloads
• General
• Autotrac
• How to download and install
payloads into Service Advisor
Note: This is under the Technical Information Section
Selecting Payloads for 9970 SP
Combines
The payload selected depends on the Control Unit as
follows:
For the following
controller:
Use payload file:
CAB
AH234251A
CDU
AH231068A_9101
LC1
AH234513A
RCU
AH233044A
LC2
AH233046A
SSU
AH234469A
NOTE: SSU payload shown is for a combine with
a Serial number of 500003 or higher with a one
connector SID for all other applications use
AH234469A.
For additional information refer to “How to Select
the Correct Autotrac Payload for 9970 SP
Combines” Chart.
How to Select the Correct Autotrac
Payload for 9970 SP Combines
There are two Autotrac Payload files available. The
serial number of your combine and/or the number of
SID connectors determine which file to use.
NOTE: The SID is located under the cab near the
bottom of the steering column.
If the combine:
Has a serial number of
500002 or LOWER
OR
The SID has 2
connectors
Has a serial number of
500003 or HIGHER
OR
The SID has 1
connector
Use payload file:
AH234469A
AXE17165A
(Use generic serial #
HQ98705735000)
How to Install a Payload into the
Service Advisor
NOTE: The payload file is in a zipped folder. If your
operating system is Windows Vista or 7, clicking on
the folder will automatically unzip it. If your operating
system is Windows XP or an earlier version, you will
need WINZIP software to unzip the folder.
1. Use the “How to Select Payloads for 9970 SP
Combine” chart to select the correct payload.
2. Click the appropriate payload file from the menu.
3. When the “File Download” screen displays, click
Save
4. When the Directory screen displays, save the file
as follows:
Open your C:\ directory. Locate the folder labeled
sds; then open the folder labeled payloadsn
OR
Save the file to whatever directory you generally
save downloads, but note that you will need to
copy the file to the payloadsn directory.
How to Install a Payload into the Service Advisor
Page 2
5. Once you have selected the directory, click Save
6. When “Download Complete” displays, click Close.
7. Open the directory in which you saved the folder.
If the folder was not saved to the payloadsn
folder, copy the folder to it.
8. Click the folder; the payload file is listed with a .pld
extension.
NOTE: You must click on the zipped folder to
open it or use WINZIP, depending on your
operating system. The payload file will not work if
you do not see a file with the .pld extension in the
payloadsn folder.
9. Close all folders.
NOTE: If you are unable to download the file
successfully after several attempts, you may send an
email to [email protected] to request the file be sent
as an email attachment.
In the email, you must
indicate that you are requesting a payload file, the
name of the specific file, and the email address to
which the file is to be sent, if different than the
requesting email address.
Diagnosing Header Engage and
Reversing Problems
• Will header engage in either forward or reverse ?
NO!
• Make sure there is hydraulic flow. Check for pump belt
(except 9970). Increase header valve flow to maximum.
• Make sure header motor(s) chain(s) are in place.
• If hydraulics and chain are good then disconnect, clean,
inspect and reconnect header connector.
• Have someone engage separator and header and test
both header valve coils for magnetism.
• Perform same test while trying to reverse header.
• If strong magnetism, hydraulic flow, and chains are
present then problem is likely the header valve is
seized.
• If no magnetism is present then either both coils have
failed, the reverse switch has failed, or header engage
circuit has failed.
• Test resistance on both coils. It should be 3 -3.5 ohms.
• The valve can also be tested by disconnecting one of
the square connectors and apply 12 VDC to the coil with
the separator engaged. If the header turns in one
direction then the problem is either the reverse switch
has failed or the header engage power is not present.
Diagnosing Header Engage and
Reversing Problems
• Will header engage in either forward or reverse but
not both?
• Yes!
• Swap square connectors on header valve and see if
problem reverses. If so then either a coil or reversing
switch is the problem.
• Test resistance on both coils. It should be 3 -3.5 ohms
• If resistance is good then swap position of the coils and
retest. If reverse switch has failed (in one position) then
no change should occur.
•
Note: On both 9960 and 9970 combines you cannot
test for header engage power without it being connected
to a good coil. The combine will not sense current draw
and will remove power from the circuit.
Hydraulic Diagnostics
•
Troubleshoot Header Problems
•
Test and Set Header Relief
Pressure
•
Test and Set OCS Conveyor
Pressure
•
Diagnosing loss of valve stack
functions
How to Troubleshoot and Correct
Header Power Problems
•
Check the belt tension on the drive to the pump.
•
Inspect the sheaves for excessive wear or heat.
•
Test header pressure (See next page)
•
Make sure the system has enough oil in it.
•
Inspect the header for damage, making sure the teeth
are not being run in the dirt too low. If a large number of
pickup teeth are missing then replace.
•
Inspect the picking cylinders for broken or missing teeth.
If a large number are missing, especially in one area,
this will cause the header to feed incorrectly.
•
Check the clearance between the auger and the header
concave. If the auger has worn or the clearance is high,
this will cause too much material to be pulled in at one
time. If the header has run for some time and is still set
at the factory setting, it will need to be adjusted.
•
Make sure the header is being run as fast as possible
for the conditions. (The slower the header is run, the
more oil is bypassed, creating heat and reducing
horsepower.)
How to Test and Set Header Relief
Pressure
• The test port is the same as used on Deere equipment
and teed in at the Header speed control valve.
• The header speed control valve for the 9970 is located
in the engine platform area over the main engine gear
case.
• On all other model combines the header speed control
valve high is on the left side behind the air lift duct.
• The 9970 uses a direct coupled header pump. All other
models use a belt drive. This must be in good condition
(belt tight, sheaves not worn) before testing the
pressure.
• Connect a 5000 psi rated gauge to the test port.
• Disconnect one of the two hoses going to the header.
This will “dead head” the system.
• Before starting, ensure no one is near the combine.
• Start the combine and engage the separator just long
enough to take a reading.
• The pressure should be set between 3400 - 3600 psi
with warm oil.
• If this reading is not achieved, adjust the pressure relief
valve as needed. (clockwise to increase pressure,
counter clockwise to decrease)
• If the above pressure cannot be met, then either the
relief valve or pump is faulty.
How to Test and Set OCS System
Pressure
• The test port is the same as used on Deere equipment
and teed in on the pressure side of the valve block that
controls the conveyor and the augers. This is at the
rear of the basket on the right hand side.
• The 9970 uses a direct coupled pump. All other models
use a belt drive. This must be in good condition (belt
tight, sheaves not worn) before testing the pressure.
• Connect a 5000 psi rated gauge to the test port.
• Disconnect one of the two hoses going to the conveyor.
This will “dead head” the system.
• Before starting, ensure no one is near the combine.
• The pump will start with the engine. Start the combine
just long enough to take a reading.
• The pressure should be set between 2800 - 3000 psi
with warm oil.
• If this reading is not achieved, adjust the pressure relief
valve as needed. (clockwise to increase pressure,
counterclockwise to decrease)
• If the above pressure cannot be met, then either the
relief valve or pump is faulty.
Diagnosing Loss of Valve Stack
Functions
•
•
•
•
•
•
•
•
The valve stacks controls, Header Raise/Lower, Basket
Up/Down, Cylinder Speed, and, if equipped, Conveyor
Swing or Bin Lip Extension.
If a customer reports the loss of one function, have them
check the remaining.
If all functions have stopped functioning, the problem is
likely loss of oil pressure signal.
For safety, the combine controls will not allow any valve
stack functions to work unless the engine is running which
is determined by the oil pressure switch being close to
ground.
This problem can exist without a low oil pressure alert
though typically it will present as such:
Start by testing the oil pressure switch. It should close
when the engine is started. If it doesn’t, then replacing the
switch should resolve the problem.
If it does, try adding an additional ground to the black wire
side of the oil pressure switch connector.
If neither resolves the problem, then troubleshoot the
circuit as described by Service Advisor. This system is
identical to a Deere combine.
Note: On combines up to the 9960, the oil pressure switch
provides ground for the Engine Run relay. On 9960 and 9970
combines, the oil pressure signal is connected to the ECU
then transmitted via the Can Bus.
Basic Mechanical
Repairs
•
Change the No. 1 Disc Separator
Shaft
•
Adjust the Shaker Arms
•
9970 Header Clutch Changes
How to Change the Number 1 Disc
Separator Shaft
SP Combines and PT Combines up to 2005 only
•
Remove any ductwork on the machine that is in the way.
•
Remove the snubber idler, main chain, small chain
sprocket, and both upper disc shaft shields from the
machine.
•
Take the lock collars off of the bearings of the number one
shaft.
•
On the right side of the machine, cut the machine below
the shaft so that the entire shaft can be removed
assembled.
•
Install the new shaft assembled, centering it in the
machine and locking the bearings down.
•
Weld the side of the machine back together and paint it
AMADAS blue. A piece of flat bar can be welded to one
side of the cut and bolted to the other instead of welding.
This will allow access in the future.
•
Replace the sprockets, chains, disc shields, and
ductwork, and snubber idler.
•
Make sure the blades bisect the number two shaft blades;
refer to the number three shaft as an example. The first
and third shafts should match.
•
Run the machine to check that it is properly installed.
Illustration on where to cut to
change #1 Disc Separator
Shaft
Make cut in frame below
2nd bearing hole.
How to Adjust the Shaker Arms
Make sure the stemmer bottom is running as squarely as
possible. If a stemmer is striking, it will damage the
stemmer bottom. This contact can be caused by several
things, such as mud build up, over speed (more than
110% on PT’s only), loose or lost bolts on the stemmer
bottom hinges, worn grommets on the stemmer pegs,
and cracked and damaged rubber hinges.
•
With only one arm connected, stroke the machine forward
(toward the tongue or cab) as far as possible. If the pegs are
striking the machine side, lengthen the arm until you have ½ to ¾
of an inch of clearance.
•
Once the stroke is set, install the bolt attaching the arm to the
eccentric on the opposite side. Do not force the bolt to line up;
instead, adjust the rod end in or out until the bolt lines up.
•
Stroke the machine all the way to the rear and make sure it does
not strike. If there is no striking, then ensure that both arms are
tightened (including adjusting rod jam nuts).
•
For older PT combines without cross augers, check for clearance
in front and back of the peanut funnel.
•
If all looks well, then run the machine starting at a slow speed
listening for any striking noises. If there are none, then increase
to operating speed. If no striking noise is heard, the repair is
complete.
9970 Header Clutch Changes
Stronger, independent springs for each paw.
Requires new springs, clips and 90 degree cotter pins
Field Performance
• Theory of Operation
• Performance Troubleshooting
• Shaft Speeds Value and Use
• Basic Things to check on Service
Call
Theory of Operation
Theory of Operation
•
The header pickup lifts the peanuts and vines off of the ground. The
header auger feeds them into the spring tooth cylinders.
•
The spring tooth cylinders strip the peanuts from the vines. Large
amounts of dirt and foreign material are removed by the cleaning area
of the cylinder dirt removal screens under each cylinder.
•
The first and fourth spring tooth cylinders have sets of adjustable
overhead teeth which increase picking aggressiveness when engaged.
An adjustable retention board controls the time that the vines remain in
the fourth cylinder.
•
Optional adjustable concave teeth are available for the first, second,
and third cylinders for increased harvesting aggressiveness.
•
Peanuts and vine material fall through the extraction holes in the fourth
cylinder concave onto the disc separator, or travel back into the walker
cylinders.
•
The walker cylinders separate the good peanuts from the coarse vine
material and carry the vine material out of the machine. Peanuts sift
out of the cam actuated walker cylinders and are swept down to the
disc separator for final separation.
•
At the disc separator, the good peanuts are separated from vine
material and other light trash.
•
The cleaning fan agitates the material on the disc separator to aid in
separation and blows light material such as leaves, pops, and other
light trash over the tail board and out of the back of the combine.
•
The higher density good peanuts fall through to the stemmer section,
while vine material and sticks advance across the disc separator and
out of the back of the combine. As the good peanuts fall into the
stemmer saws, their stems are removed. Cleaned peanuts fall into the
collection auger and are conveyed into the elevator air system, which
sends them up to the peanut dump bin.
Performance Troubleshooting
Performance Troubleshooting Page 2
Performance Troubleshooting Page 3
Basic Things to Check on Service Call
• Ensure belts are properly tightened and sheaves are not
severely worn.
• Make sure drive chains are tightened correctly.
• Check for failed bearings.
• Inspect and clean as needed area above #1 disc separator
shaft. Any build up or obstruction can affect cleaning system.
• Check for broken or missing picking cylinder teeth.
• Look for cleaning fan blades that are not cracked, bent or
worn badly.
• For air lift problem ensure elevator lift fan blades are not
badly worn or missing.
•
Inspect for missing or broken header pickup springs.
•
If harvesting in mud, make sure the cleaning fan and
housing are clean. Small amounts of mud disturb air flow
and the combine will not clean or cause fan failures.
•
Look for bent or missing cylinder bars. If any, also check for
bent lower concaves.
• Check for mud and/or foreign objects in the ductwork,
stemmer bottom and cross auger. This can affect both
cleaning and shelling.
•
Check ratchet clutch (drives back of machine) to see if it is
seized due to repeated jamming or lack of lubrication.
Why Use
Amadas Parts?
• Ensures the parts have been matched
to the application.
• You typically “get what you pay for.”
• Using inferior parts can cause
premature failure, resulting in a
dissatisfied customer.
• Amadas stands behind its product.
But when incorrect or inferior parts are
used, problems can be created that
using Amadas parts would have
prevented.
Critical Places to Use the
Correct Parts
•
Bearings:
•
All combine bearings should be Timken
•
Substituting other brands may create frequent failures due to
inadequate seals or bearing type for the application.
•
For example: The elevator and cleaning fans both have high
speed seals. The cleaning fan uses wide inner race for stability
and the main jack shaft must be well sealed.
•
Belts:
•
We use belts with backings rated for reverse bending where
ever an idler is used.
•
Do NOT substitute single belts in place of banded belts as a
long term fix. A banded belt is made up of multiple belts with a
common backing.
•
It is impossible to keep multiple singe belts at the same tension
so the total amount of horsepower will not be transmitted. This
will lead to speed fluctuation and/or belt failure.
•
Chains:
•
We use only domestic high quality chain, typically Diamond, on
our combines.
•
On all applications of #80 chain or higher, it is imperative to use
this chain.
•
Lower grade chain will stretch or break, which can cause tooth
wear on sprockets or failure that can damage and/or plug the
machine.
Warranty
Information
• SP 9970 Combine Warranty
• Product Identification Number
• Warranty Terms and Period
• Amadas Warranty Claim Form
SP 9970 Warranty
Product Identification Number
Model Number
Serial Number
For Amadas purposes,
use the Serial Number:
XXXXXX
Machine ID Number
For Amadas “New
Machine Warranty
Registration Form”:
Example above: 510007
XXXXXXX-X
Example above:
A9970SU-4
For John Deere, use the Model + Serial Number:
XXXXXXXXXXXXXXXXX
Example above: 1H09970TCDO510007
Dealer Warranty Policy
20% .
Amadas Warranty Claim Form
Requesting an Amadas Warranty Claim
Form:
• Request a claim form from the Amadas Territory
Sales Manger
• If not available, request a form from Willie Branch
or Roger Mercer at 1-757-539-0231
Completing an Amadas Warranty Claim
Form:
• Refer to the example on the next page to properly
complete an Amadas Warranty Claim Form.
Submitting a Warranty Claim Form:
• Once properly completed, return your Warranty
Claim Form to:
Amadas Industries, Inc.
Attn: Willie Branch
1100 Holland Road
Suffolk, VA 23434
Example Amadas Warranty
Claim Form
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