John Deere Compact Loader BZ100157 User Manual

GreenStar Equipment  
for  
7000 Series Forage  
Harvesters  
BZ13788, BZ100157  
INSTALLATION INSTRUCTIONS  
GreenStar Equipment for 7000  
Series Forage Harvesters (BZ13788,  
BZ100157)  
Z103757 13DEC06 (ENGLISCH)  
7000 Series Forage Harvesters  
John Deere Werke Zweibrucken  
¨
Z103757 (13DEC06)  
COPYRIGHT 2006  
DEERE & COMPANY  
European Office Mannheim  
All rights reserved  
A John Deere ILLUSTRUCTION Manual  
Z103757-19-13DEC06  
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Installation Instructions  
Contents of Bundle BZ13788  
A—Z73362 Plate (1x)  
B—Z72204 Plate (1x)  
C—AZ57754 Holder (1x)  
D—AZ59199 Job computer (1x) G—AZ101120 Wiring harness  
J—PF80209 Bracket (1x)  
K—AZ71569 Connector (1x)  
E—H204964 Decal (1x)  
F—N302284 Decal (1x)  
(1x)  
H—AZ63280 Potentiometer  
(1x)  
NOTE: The bundle contains a hardware bag.  
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Installation Instructions  
Contents of Bundle BZ100157  
A
B
E
C
D
ZX1039590  
A—Z102720 Support (1x)  
B—Z101939 Shield (1x)  
C—AZ102637 Cover Plate  
D—Z102760 Fixing Plate (1x)  
E—AZ102820 Sensor Support  
(1x)  
NOTE: The bundle contains a hardware bag including  
(7x) 14M7298 M8 flange nuts, (2x) 14M7396  
M8 self locking nuts, (10x) 19M7865 M8X16  
screws, (6x) 19M7867 M8X25 screws, (3x)  
19M7897 M8X35 screws and (2x) 24M7207  
8.4X24X2 washers.  
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Installation Instructions  
Contents of Bundle BZ100157—Continued  
A—Z103667 Bracket (2x)  
B—Z103666 Template (1x)  
C—19M7865 Cap Screw M8X16 D—14M7298 Flange Nut M8  
(4x) (4x)  
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Installation Instructions  
Parts to Order  
B
A
C
ZX1039591  
A—BZ100165 NIR Sensor (1x)  
B—AZ101740 Wear Plate for  
High arc Spout (1x)  
C—Z101953 Wear Plate for Flat  
Spout (1x)  
To complete the bundle BZ100157 installation the  
parts or bundles above illustrated must be ordered  
separately.  
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Installation Instructions  
Mount and Dismount Safely With the  
Moisture Sensor  
Hold handrail with one hand and carry the moisture  
sensor with the other.  
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Maintain Stability  
Keep work surfaces dry and clean. Maintain balance while  
transporting and installing the moisture sensor onto the  
forage harvester’s spout.  
Care should also be observed while servicing the sensor.  
ZX1039668  
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Installation Instructions  
Modify High Arc Spout  
On machines with old high arc type spout, proceed as  
follows to install NIR sensor brackets:  
1. On both sides of the spout, release the side wear plate  
fixing screws (A) and rear wear plate fixing screws (B).  
Remove and discard rear wear plate. Remove both  
side wear plates.  
2. Install template Z103666 (C) over spout as shown  
using original hardware (A). Pull up template Z103666  
(C) to set it correctly in position then tighten fixing  
screws (A).  
3. Mark area (D) to cut a hole 102 mm (4.01 in.) diameter  
then drill two holes 11x20 mm (0.43x0.78 in.) at  
locations (E).  
4. Install brackets Z103667 (F) on template Z103666 (C)  
with four screws 19M7865 M8X16 and flange nuts  
14M7298. Make sure brackets (F) are in contact with  
spout sides then weld at front and rear of the brackets  
(F) (see arrows) on spout.  
IMPORTANT: Grind spout sides at locations where  
weld will be carried out.  
5. Remove template Z103666 (C) then finalize welding  
process on top of brackets Z103667 (F) (see arrow).  
A—Fixing Screws  
B—Fixing Screws  
C—Template Z103666  
D—Area to Cut  
E—Drilling Holes  
F—Brackets Z103667  
Continued on next page  
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IMPORTANT: Grind weld at top of brackets Z103667  
(F) so that weld surface is flush with the  
bracket surface.  
6. Cut out previously marked area (D).  
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Installation Instructions  
Replace Spout Wear Plate  
A
B
ZX1039595  
Using original hardware, install wear plate AZ101740 (A)  
on high arc type spout or wear plate Z101953 (B) on flat  
spout.  
On new high arc type spout, use a hammer to remove  
pre-cut part (C) of spout as shown.  
C
A—Wear plate—AZ101740—High arc spout  
B—Wear plate—Z101953—Flat spout  
C—Part to remove  
ZX1039594  
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Installation Instructions  
Install NIR Sensor BZ100165  
1. Pre-assemble NIR sensor BZ100165 (A) with the  
shield Z101939 (B) using 6 flange screws M8X16 (C).  
2. Install support Z101720 (D) using 4 flange screws  
M8X16 (C).  
3. Place three screws M8X35 (E) and three flange nuts  
(F) on sensor support as shown.  
4. Insert sealing ring Z101944 (G) on glass adapter of  
sensor BZ100165 (A).  
IMPORTANT: To install the sealing ring (G) correctly,  
align its centering protrusion with the  
groove of glass adapter.  
5. Install support AZ102820 (H) on spout using four  
flange screws M8X25 (I) and flange nuts.  
A—NIR sensor—BZ100165  
B—Shield—Z101939  
C—Flange screws M8X16  
D—Support Z101720  
E—Flange screws M8X35  
F—Flange nut  
G—Sealing ring—Z101944  
H—Support—AZ102820  
I—Flange screws M8X25  
Continued on next page  
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6. Attach sensor assembly (A) to support AZ102820 (B)  
using two flange screws M8X25 (C), two washers  
8.4X24X2 (D) and two self-locking nuts (E) as shown.  
IMPORTANT: To ease sensor assembly fold/unfold,  
place washers (D) between support (B)  
and sensor assembly brackets. Do not  
overtighten self-locking nuts (E). Sensor  
assembly (A) must remain easily  
foldable.  
The NIR sensor (A) is delivered with a dedicated wave  
length standard (F). To avoid NIR sensor and non  
dedicated wave length standard mix up, it is strongly  
recommended to report the NIR sensor serial number  
on its relevant wave length standard cover (G).  
IMPORTANT: Prior to operating the NIR sensor (A),  
carry out an initial wave length standard  
measurement as described in Harvest  
Monitor System Operator’s Manual.  
If the wave length standard  
measurement is not successful then a  
black and white calibration of the NIR  
sensor is required. Proceed as  
described in the forage harvester  
Technical Manual.  
The wave length standard (F) must be kept in good  
condition for future measurement. In this way, special  
attention must be paid so that the wave length  
standard (F) doesn’t come in contact with chemical  
products such as:  
Diesel  
Gasoline (Leaded or unleaded)  
Thinners  
Engine cleaner  
Cavity sealing  
After cleaning  
Finishing paint  
Blackboard lacquer  
Freeze protection  
A—Sensor assembly  
B—Support—AZ102820  
C—Flange screws M8X25  
D—Washers 8.4X24X2  
E—Self-locking nuts  
F—Wave length standard  
G—Cover  
Continued on next page  
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Installation Instructions  
NOTE: Do not disconnect sensor (A) from machine wiring  
harness until sensor shuts down completely.  
Before disconnecting sensor turn forage harvester  
ignition off. Wait at least 30 seconds before  
disconnecting the sensor.  
Continued on next page  
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Installation Instructions  
E
F
F
E
A
D
B
C
ZX1039600  
A—Adapter glass  
B—Wear plate  
C—Front point setting  
D—Rear point setting  
E—Flange screw  
F—Flange nut  
7. Place sensor into working position but do not latch  
it. Adjust sensor assembly position so that tip of  
adapter glass (A) is flush with wear plate (B) at  
front point (C) and about 1 mm (0.08 in.) below  
surface of wear plate (B) at rear point (D) as  
shown. Use the three flange screws (E) to adjust  
then secure with flange nuts (F).  
IMPORTANT: To allow a proper adapter glass  
self-cleaning process, make sure  
that sensor position is correctly set.  
NOTE: Arrow is showing the crop flow direction.  
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Installation Instructions  
Install Feed Roll Potentiometer AZ63280  
Install Upper Plate Z72204 and Holder AZ57754  
1. Remove right-hand feed roll spring (A) by loosening  
eye-bolt (B).  
2. Install plate Z72204 (C) and holder AZ57754 (D) in the  
free holes.  
3. Put the eye-bolt (B) back in place and tighten the  
spring to its original setting.  
A—Feed roll spring  
B—Eye-bolt  
C—Plate Z72204  
D—Holder AZ57754  
Continued on next page  
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Installation Instructions  
Install Lower Plate Z73362  
1. Drill two 9 mm (0.35 in.) diameter holes on cutterhead  
frame (A) as shown.  
2. Install plate Z73362 (D) on frame (A) with two cap  
screws M8x40 (E) and nuts, as shown.  
A—Cutterhead frame  
B—75 mm (2.95 in.)  
C—34 mm (1.34 in.)  
D—Plate Z73362  
E—Cap screws M8x40  
F—15 mm (0.59 in.)  
Continued on next page  
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Installation Instructions  
Install Feed Roll Potentiometer AZ63280  
1. Install potentiometer AZ63280 (A) between plate  
Z72204 (B) and plate Z73362 (C) with screws (D)  
M12x35, flange nuts and lock nuts as shown.  
2. Connect potentiometer AZ63280 (A) to free connector  
(E) of machine wiring harness.  
IMPORTANT: The potentiometer (A) should be  
mounted so that the wiring harness  
connector is in top position.  
A—Potentiometer AZ63280  
B—Plate Z72204  
C—Plate Z73362  
D—Screws M12x35  
E—Connector  
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Installation Instructions  
Install Job Computer AZ59199 and Wiring Harness AZ101120  
1. Install job computer AZ59199 (A) as shown on the  
bottom left side of load center with three screws M8x60  
(B) using existing nuts in the wall.  
2. Connect main connector (C) of wiring harness  
AZ101120 (D) to job computer (A).  
3. Disconnect A7-CAN bus terminator (E) located near  
the board A3. Connect CAN bus terminator (E) to  
relevant connector (F) of wiring harness AZ101120 (D),  
then connect wiring harness AZ101120 to terminator  
(E) original connector as shown.  
4. Locate free connectors X27 (G) and X30 (H), then  
connect them to the relevant machine wiring harness  
free connections using parts of connector AZ71569 (I)  
and following tables:  
X27 Connector AZ71569 Pin Connections  
Pin Number  
Wire  
Pin #1 .......................................... 552C  
Pin #2 .......................................... 974  
Pin #3 .......................................... 975  
Pin #4 .......................................... 050B  
Pin #5 .......................................... not used  
Pin #6 .......................................... not used  
A—Job computer AZ59199  
B—Screws M8x60  
C—Main connector  
D—Wiring harness AZ101120  
E—A7 CAN bus terminator  
F—Connector  
G—X27 Connector  
H—X30 Connector  
I—AZ71569 Connector  
Continued on next page  
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X30 Connector AZ71569 Pin Connections  
Pin Number  
Wire  
Pin #1 .......................................... 584  
Pin #2 .......................................... 586  
Pin #3 .......................................... 585  
Pin #4 .......................................... 571  
Pin #5 .......................................... not used  
Pin #6 .......................................... not used  
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5. Connect part of wiring harness AZ101120 with  
15A-fuse (A) to connecting point 002 (B) located on  
board A3 as shown.  
6. Remove closing plate from bottom of load center (not  
illustrated) and pass wiring harness AZ101120 (C)  
through the opening until guide plate (D) can be  
installed using original hardware previously removed.  
A—Fuse  
B—Connecting point  
C—Wiring harness AZ101120  
D—Guide plate  
Continued on next page  
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Installation Instructions  
A—Inoculant dosing device  
connector  
B—NIR sensor connector  
C—Wiring harness AZ101120  
D—Connection box  
7. Using above illustration, route connectors (A) and  
(B) of wiring harness AZ101120 (C) underneath the  
connection box (D), alongside the left-hand side of  
machine frame then behind the cab.  
Continued on next page  
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IMPORTANT: Route wiring harness AZ101120 (C)  
NOTE: Use the existing machine wiring harnesses  
and/or hydraulic hoses to fix the wiring  
harness AZ101120 (C) with plastic clamps so  
that it will not be left loose in a way it can be  
caught by any moving part.  
alongside machine wiring harness  
and secure with tie bands.  
NOTE: Connector (A) shall be used for inoculant  
dosing device connection.  
Connector (B) shall be stored in a safe place if  
NIR sensor is not installed on spout.  
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8. Route inoculant dosing device connector (A) outside  
the rear right-hand side of the cab as shown.  
9. Drill a suitable hole near the cab closing plate (B) so  
that connector sleeve (C) can be inserted and fixed to  
the cab wall as shown.  
IMPORTANT: Open plate (B) and check that no wiring  
harness is being damaged while drilling  
the hole!  
-If an inoculant dosing device is used, route dosing  
device connecting wires through opening of closing  
plate and refer to “Connecting Inoculant Dosing  
Device” for proper device connection.  
-If no inoculant dosing device is used, keep connector  
(A) protected behind closing plate (B).  
A—Connector for inoculant dosing device  
B—Closing plate  
C—Connector sleeve  
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10. In Case Bundles BZ100157 and BZ100165 are Not  
Installed on Spout:  
Route and store NIR sensor connector (A) near the  
spout motor (B). Make sure to store the cable so that  
it will not be caught by any moving part.  
A—NIR sensor connector  
B—Spout motor  
Continued on next page  
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11. In Case Bundles BZ100157 and BZ100165 are  
Installed on Spout:  
Route NIR sensor connector (A) to the right-hand side  
of the spout motor (B) then alongside the spout wiring  
harness (C) up to the NIR sensor BZ100165 (D) as  
shown. Secure cable with tie bands.  
Make sure to route the cable so that it will not be  
caught by any moving part.  
12. Connect NIR sensor connector (A) to NIR sensor  
BZ100165 (D) then engage the three latches (E) to  
maintain NIR sensor BZ100165 (D) in working  
position as shown.  
IMPORTANT: Route cable as shown on illustration  
and make sure to keep sufficient play to  
cable so that NIR sensor assembly can  
be folded/unfolded without  
disconnecting connector (A).  
NOTE: If connection box BZ100168 has been installed on  
NIR sensor BZ100165 then connect NIR  
connector (A) to the connection box (not  
illustrated).  
NOTE: Do not disconnect sensor (D) from spout wiring  
harness until sensor shuts down completely.  
Before disconnecting sensor turn forage harvester  
ignition off. Wait at least 30 seconds prior to  
disconnecting the sensor.  
A—NIR sensor connector  
B—Spout motor  
C—Spout wiring harness  
D—NIR sensor—BZ100165  
E—Latch (3 used)  
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Installation Instructions  
Connecting Inoculant Dosing Device  
To enable the dosing device system, the connector (A)  
MUST be connected to the relevant connector of inoculant  
dosing device control unit in the following manner (refer to  
table for connector (A) pin connections).  
Tx wire1 of dosing device connector to Rx wire2 of  
wiring harness AZ101120 connector (A).  
GND wire3 of dosing device connector to GND wire of  
wiring harness AZ101120 connector (A).  
A—Connector for inoculant dosing device  
Rx wire of dosing device connector to Tx wire of wiring  
harness AZ101120 connector (A).  
Connector (A) Pin Connections  
Pin Number  
Wire  
Pin #A .......................................... 589—Tx  
Pin #B .......................................... 590—GND  
Pin #C ......................................... 591—Rx  
1Tx wire: Means wire that transmits the signal  
2Rx wire: Means wire that receives the signal  
3GND wire: Means ground wire  
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Installation Instructions  
Install Bracket PF80209 in Cab  
1. Install monitor bracket PF80209 (A) on right-hand  
corner post as shown using corner post fixing screws  
(B).  
2. Pull down cab roof trim (C) and look for monitor wiring  
harness (D). Extract it from cab roof and route it up to  
the bracket PF80209 as shown. Keep the wiring  
harness (D) connectors free for further monitor  
installation.  
A—Bracket PF80209  
B—Screws  
C—Cab roof trim  
D—Monitor wiring harness  
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Installation Instructions  
Attach GreenStar Decals  
Attach decal H204964 (A) to left hand side of the  
harvester as indicated.  
Attach decal N302284 (B) as indicated in front of the  
display (C), on inside of cab.  
A—Decal H204964  
B—Decal N302284  
C—Display  
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Installation Instructions  
Load Software  
Load Display Software  
To load new software:  
1. Install PC Card containing NEW software in card slot A  
of mapping processor.  
2. Turn ignition key to RUN position.  
3. Press INFO” key to enter INFO mode.  
4. Press key B in “INFO” to select “Keycard”.  
5. Press key A to select “Devices on CAN Bus”. Actual  
Version Display Software and Version Harvest Mon  
are then displayed.  
6. Press key G once to go back.  
7. Press key C to select “Program Target”.  
8. Press key A to select “GreenStar Display”.  
9. Press relevant key to choose “PF303182B” software  
version, or higher.  
10. While programming (about 30 seconds):  
- DO NOT REMOVE PC CARD  
- DO NOT REMOVE POWER  
11. When programming is complete, the  
PROGRAMMING COMPLETE screen will appear.  
CYCLE POWER will be displayed in lower left  
corner.  
Turn ignition switch OFF.  
Load Job Computer Software  
To load new software:  
1. Install PC Card containing NEW software in card slot A  
of mapping processor.  
2. Turn ignition key to RUN position.  
Continued on next page  
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Installation Instructions  
3. Press INFO” key to enter INFO mode.  
4. Press key B in “INFO” to select “Keycard”.  
5. Press key A to select “Devices on CAN Bus”. Actual  
Version Display Software and Version Harvest Mon  
are then displayed.  
6. Press key G once to go back.  
7. Press key C to select “Program Target”.  
8. Press key A to select “Harvest Mon”.  
9. Press relevant key to choose “PF311135C” software  
version, or higher.  
10. While programming (about 30 seconds):  
- DO NOT REMOVE PC CARD  
- DO NOT REMOVE POWER  
11. When programming is complete, the  
PROGRAMMING COMPLETE screen will appear.  
CYCLE POWER will be displayed in lower left  
corner.  
Turn ignition switch OFF.  
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Installation Instructions  
Check Yield Monitoring Functionality  
Calibrate Mass-Flow Sensor  
1. Turn ignition key to RUN position.  
2. Press SETUP” key to enter SETUP mode.  
3. Press key C in “SETUP” to select “GreenStar  
Display”.  
4. Select your native language and units then press key  
G once to go back.  
5. Press key A to select “Harvest Mon”.  
6. Make sure that “Recording ON/OFF By:” is set on  
HEADER” then press key G once to go back.  
7. Press key D to select “Yield Calibration”.  
8. Press key A to start calibration. Wait until feedroll  
height is 10 mm (0.4 in.).  
9. Press RUN key.  
Check Monitoring Functions  
1. Turn ignition key to start harvester engine.  
2. Press INFO” key to enter INFO mode.  
3. Press key A in “INFO” to select “Harvest Mon”.  
4. Press key F to select “Diagnostics”.  
5. Press key B to select “Mass-Flow System”. Engage  
main clutch and harvesting unit then check the  
following points:  
Height right—should be between 0.2 and 0.6 V.  
Vref—Should be between 4.8 and 5.1 V.  
If any of these points are not OK, contact your John  
Deere dealer.  
Press key G once to go back.  
Continued on next page  
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Installation Instructions  
6. Press key C to select “SPFH Network” and check  
communication between SPFH and Harvest Monitor.  
7. Press RUN key.  
OUZXMAG,0001BF6 –19–18NOV03–2/2  
Check Inoculant Dosing Functionality  
1. Turn ignition key to start harvester engine.  
2. Press SETUP” key to enter SETUP mode.  
3. Press key A in “SETUP” to select “Harvest Mon”.  
4. Press PAGE” key to go to “SETUP - Harv Mon -  
PAGE 2” screen then press key “F” to toggle inoculant  
dosing support state from OFF to ON or vice versa.  
5. Press RUN key.  
6. The inoculant dosing device can be engaged if:  
The road safety switch is in field operating mode  
The forage harvester is travelling forward  
The ground speed is greater than 2 km/h (1.24 mph)  
The feedrolls are turning in forward direction  
The header is in harvesting position  
7. Press once the liquid injection pump switch (A). Carry  
out a test to make sure that inoculant device is  
properly connected to the wiring harness AZ101120.  
If this is not the case check wiring harness connection  
or contact your John Deere dealer.  
NOTE: For a proper use of the liquid injection pump  
switch (A), refer to the forage harvester Operator’s  
Manual.  
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Installation Instructions  
Use of Cover Plate AZ102637  
In case the spout is operated without the NIR sensor it is  
necessary to install cover plate AZ102637 (A) to close  
opening in wear plate AZ101740 or Z101953.  
NOTE: The illustration shows the cover plate AZ102637  
(A) installed on a high arc type spout. In case of  
flat spout, it is necessary to use the supplied  
fixing plate Z102760 to maintain cover plate  
AZ102637 in place using original spout wear plate  
fixing hardware—Not illustrated.  
A—Cover Plate—AZ102637  
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