How it Works
MacDon
Loading...
FlexDraper FD135
Operator's Manual
628 pgs63.99 Mb0
Table of contents
Loading...

MacDon FlexDraper FD1 Series, FM100, FlexDraper FD145, FlexDraper FD130, FlexDraper FD135 Operator's Manual

...
FD1 Series
FlexDraper
®®
Combine Header
Operator ’s Manual
214683 Revision A
2019 Model Year
Original Instruction
The harvesting specialists.
FD1 Series FlexDraper®Header
1016679
Published: June 2018

Declaration of Conformity

1026043
214683 i Revision A
1026044
214683 ii Revision A
1026045
214683 iii Revision A
1026044
214683 iv Revision A

Introduction

This instructional manual contains information on the FD1 Series FlexDraper®and the FM100 Combine Float Module. It must be used in conjunction with your combine operator's manual.
®
The FD1 Series FlexDraper above the ground, using a three-piece flexible frame to closely follow ground contours. The FM100 Combine Float Module is used to attach an FD1 Series FlexDraper
Carefully read all the material provided before attempting to use the machine.
Use this manual as your first source of information about the machine. If you follow the instructions provided, your header will work well for many years. If you require more detailed service information, a technical manual is available from your MacDon Dealer.
MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual. A copy of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided to you by your Dealer. Damage resulting from any of the following conditions will void the warranty:
• Accident
• Misuse
• Abuse
• Improper maintenance or neglect
• Abnormal or extraordinary use of the machine
is specially designed to work well in all straight cut conditions, whether cutting on or
®
to most makes and models of combines.
• Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions
The following conventions are used in this document:
• Right and left are determined from the operator’s position. The front of the header faces the crop; the back of the header attaches to the combine.
• Unless otherwise noted, use the standard torque values provided in Chapter 8.1 Torque Specifications, page
577.
When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous situation.
The Table of Contents and Index will guide you to specific areas of this manual. Study the Table of Contents to familiarize yourself with how the information is organized.
214683 v Revision A
1024245
A
Keep this manual handy for frequent reference and to pass on to new Operators or Owners. A manual storage case (A) is located inside the header left endshield.
Call your MacDon Dealer if you need assistance, information, or additional copies of this manual.
NOTE:
Keep your MacDon publications up-to-date. The most current version can be downloaded from our website (www.macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login required).
This document is available in English, Czech, German, French, Portuguese, Russian, and Ukrainian.
Figure 1. Manual Storage Location
214683 vi Revision A

List of Revisions

Summary of Change Refer To
Updated Declaration of Conformity for model year 2019.
Added Ukrainian to the list of languages available.
Added FM100 safety decal locations. 1.7 Safety Decal Locations, page 8
Added safety decal MD #252996. 1.8 Understanding Safety Signs, page 13
Updated illustrations of endshield hinge plate. Added note to ensure hinge arm is installed in outboard hole on the hinge bracket.
Updated illustrations to show transport lights.
Revised the high voltage limit adjustment instructions.
Added topic.
Added step and image showing the header control switch.
Added settings for HEIGHT/TILT RESPONSE and AUTO HEIGHT OVERRIDE.
Declaration of Conformity, page i
Introduction, page v
• Removing Endshields, page 36
• Installing Endshields, page 37
Repositioning Fore-Aft Cylinders on Non-European­Configured Headers with Multi-Crop Rapid Reel Conversion Option, page 108
Adjusting Voltage Limits: One-Sensor System, page 131
Replacing Float Indicator Cable, page 135
Calibrating Auto Header Height Control (Case IH 5130/ 6130/7130, 5140/6140/7140), page 146
Calibrating the Auto Header Height Control (Case Combines with Version 28.00 or Higher Software), page 160
Added settings specific to the two-sensor system.
Added steps to set center link to D, unlock float, and lock wings.
Added steps for calibrating feeder house speed.
Removed unnecessary steps involving header float; these steps are not applicable to reel height sensor calibration.
Deleted note with link to height sensor adjustment; the note isn’t relevant to feeder house speed calibration.
Added step to lock wings before calibration.
• Setting up the Header on the Combine Display
(Case IH 5130/6130/7130; 5140/6140/7140), page 142
• Calibrating the Auto Header Height Control
(Case IH 7010/8010, 7120/8120/9120, 7230/8230/9230, 7240/8240/9240), page 156
• Calibrating the Auto Header Height Control (Case
Combines with Version 28.00 or Higher Software), page 160
Calibrating the Auto Header Height Control (Case Combines with Version 28.00 or Higher Software), page 160
Calibrating the Auto Header Height Control (John Deere S and T Series), page 215
Calibrating Reel Height Sensor (John Deere S and T Series), page 227
Calibrating Feeder House (John Deere S7 Series), page 236
Calibrating the Auto Header Height Control (CLAAS 600 and 700 Series), page 251
214683 vii Revision A
Added topics.
• Calibrating Reel Height Sensor (CLAAS 600 and
700 Series), page 258
• Adjusting Auto Reel Height (CLAAS 600 and 700
Series), page 260
Revised caution statement about reduced header stability when cornering.
• Removed mentions of discontinued flighting bundles B6215 and B6216.
• Updated feed auger illustrations.
Updated feed auger illustrations.
• Added changing oil in header drive gearbox (first 50 hours only).
• Added lubricating center draper roller bearings (every 50 hours).
• Added checking draper roller bearings for heat (every 200 hours)
Towing the Header, page 291
4.1 Float Module Feed Auger Configurations, page 307
• 5.7.2 Checking Auger Drive Chain Tension, page
421
• 5.7.3 Adjusting Auger Drive Chain Tension, page
423
• 5.7.4 Removing Auger Drive Chain, page 424
• 5.7.5 Installing Auger Drive Chain, page 426
5.3.1 Maintenance Schedule/Record, page 385
Added checking and adjusting finger timing instructions.
Revised topic—No adjustment is required if spring retainers are within +6 to –3 of flush and feed draper is tracking properly.
Updated torque value for center reel arm brace bolts. Updated illustration to show new bolt orientation.
Updated reel speed sensor illustrations.
Updated load range D tire pressure to 75 psi.
Added topics.
• Checking Auger Finger Timing, page 434
• Adjusting Auger Finger Timing, page 435
5.10.2 Adjusting Feed Draper Tension, page 468
5.15.3 Centering Double Reel, page 507
• Replacing AGCO (Challenger, Gleaner, and
Massey Ferguson) Sensor, page 538
• Replacing John Deere Reel Speed Sensor, page
540
5.17.3 Checking Tire Pressure, page 544
• 6.4.6 Center Skid Shoes Kit, page 554
• 6.5.9 European Combine Upper Cross Auger
(UCA), page 559
214683 viii Revision A

Model and Serial Number

1020884
A
1020665
A
Record the model number, serial number, and model year of the header, combine float module, and transport / stabilizer wheel option (if installed) in the spaces provided.
NOTE:
Right and left designations are determined from the operator’s position, facing forward.
®®
FlexDraper
Header Model:
Serial Number:
Year:
The serial number plate (A) is located in the upper corner on the left endsheet.
Header
Figure 2. Header, Left Side Endshield
Combine Float Module
Float Module Model:
Serial Number:
Year:
The serial number plate (A) is located at the top left side of the float module.
Figure 3. Float Module
214683 ix Revision A
1005072
A
Slow Speed Transport / Stabilizer Wheel Option
Serial Number:
Year:
The serial number plate (A) is located on the right axle assembly.
Figure 4. Transport/Stabilizer Option
214683 x Revision A
TABLE OF CONTENTS
Declaration of Conformity............................................................................................................................ i
Introduction...............................................................................................................................................v
List of Revisions ...................................................................................................................................... vii
Model and Serial Number.......................................................................................................................... ix
Chapter 1: Safety .................................................................................................................................... 1
1.1 Safety Alert Symbols ............................................................................................................................1
1.2 Signal Words .......................................................................................................................................2
1.3 General Safety.....................................................................................................................................3
1.4 Maintenance Safety .............................................................................................................................5
1.5 Hydraulic Safety...................................................................................................................................6
1.6 Safety Signs ........................................................................................................................................7
1.6.1 Installing Safety Decals ...............................................................................................................7
1.7 Safety Decal Locations.........................................................................................................................8
1.8 Understanding Safety Signs................................................................................................................ 13
Chapter 2: Product Overview ............................................................................ ................................ 19
2.1 Definitions .........................................................................................................................................19
2.2 Specifications ....................................................................................................................................21
2.3 Component Identification ....................................................................................................................25
®
2.3.1 FD1 Series FlexDraper
2.3.2 FM100 Float Module..................................................................................................................26
............................................................................................................25
Chapter 3: Operation ...........................................................................................................................29
3.1 Owner/Operator Responsibilities.........................................................................................................29
3.2 Operational Safety .............................................................................................................................30
3.2.1 Header Safety Props .................................................................................................................30
3.2.2 Reel Safety Props .....................................................................................................................31
Engaging Reel Safety Props......................................................................................................31
Disengaging Reel Safety Props .................................................................................................32
3.2.3 Endshields................................................................................................................................33
Opening Endshields..................................................................................................................33
Closing Endshields ...................................................................................................................34
Checking and Adjusting Endshields ...........................................................................................35
Removing Endshields ...............................................................................................................36
Installing Endshields .................................................................................................................37
3.2.4 Linkage Covers.........................................................................................................................37
Removing Linkage Covers ........................................................................................................37
Installing Linkage Covers ..........................................................................................................38
3.2.5 Daily Start-Up Check .................................................................................................................39
3.3 Break-in Period..................................................................................................................................40
3.4 Shutting down the Combine ................................................................................................................41
3.5 Cab Controls .....................................................................................................................................42
214683 xi Revision A
TABLE OF CONTENTS
3.6 Header Setup ....................................................................................................................................43
3.6.1 Header Attachments..................................................................................................................43
3.6.2 Header Settings ........................................................................................................................ 43
3.6.3 Optimizing Header for Straight Combining Canola .......................................................................54
Checking and Adjusting Feed Auger Springs .............................................................................. 54
3.6.4 Reel Settings ............................................................................................................................56
3.7 Header Operating Variables................................................................................................................58
3.7.1 Cutting off the Ground ...............................................................................................................58
Adjusting Stabilizer / Slow Speed Transport Wheels ....................................................................59
Adjusting Stabilizer Wheels .......................................................................................................60
3.7.2 Cutting on the Ground ............................................................................................................... 62
Adjusting Inner Skid Shoes .......................................................................................................62
Adjusting Outer Skid Shoes.......................................................................................................63
3.7.3 Header Float............................................................................................................................. 64
Checking and Adjusting Header Float ........................................................................................64
Locking/Unlocking Header Float ................................................................................................ 69
Locking/Unlocking Header Wings .............................................................................................. 70
Operating in Flex Mode.............................................................................................................70
Operating in Rigid Mode............................................................................................................ 71
3.7.4 Checking and Adjusting Header Wing Balance ............................................................................ 73
Checking Wing Balance ............................................................................................................73
Adjusting Wing Balance ............................................................................................................79
3.7.5 Header Angle............................................................................................................................81
Adjusting Header Angle from Combine.......................................................................................83
3.7.6 Reel Speed............................................................................................................................... 89
Optional Reel Drive Sprockets...................................................................................................89
3.7.7 Ground Speed ..........................................................................................................................90
3.7.8 Draper Speed ...........................................................................................................................91
Adjusting Header Draper Speed ................................................................................................92
Feed Draper Speed ..................................................................................................................93
3.7.9 Knife Speed Data ...................................................................................................................... 94
Checking Knife Speed ..............................................................................................................95
3.7.10 Reel Height............................................................................................................................. 95
Checking and Adjusting Reel Height Sensor..... ..........................................................................96
Replacing Reel Height Sensor...................................................................................................98
3.7.11 Reel Fore-Aft Position .............................................................................................................. 99
Adjusting Reel Fore-Aft Position .............................................................................................. 100
Repositioning Fore-Aft Cylinders on Non-European-Configured Headers....................................101
Repositioning Fore-Aft Cylinders on European-Configured Headers........................................... 104
Repositioning Fore-Aft Cylinders on Non-European-Configured Headers with Multi-Crop Rapid
Reel Conversion Option..............................................................................................108
3.7.12 Reel Tine Pitch ...................................................................................................................... 111
Reel Cam Settings.................................................................................................................. 111
Adjusting Reel Cam ................................................................................................................ 113
3.7.13 Crop Dividers ........................................................................................................................ 115
Removing Crop Dividers with Latch Option from Header............................................................ 115
Removing Crop Dividers without Latch Option from Header ....................................................... 116
Installing Crop Dividers with Latch Option onto Header.............................................................. 116
Installing Crop Dividers without Latch Option onto Header ......................................................... 118
214683 xii Revision A
TABLE OF CONTENTS
3.7.14 Crop Divider Rods ................................................................................................................. 119
Removing Crop Divider Rods .................................................................................................. 120
Installing Crop Divider Rods .................................................................................................... 120
Rice Divider Rods...................................................................................................................121
3.7.15 Setting Auger Position ...........................................................................................................121
3.8 Auto Header Height Control (AHHC)..................................................................................................124
3.8.1 Sensor Operation....................................................................................................................125
3.8.2 Sensor Output Voltage Range – Combine Requirements ...........................................................126
10 Volt Adapter (MD #B6421) – New Holland Combines Only .................................................... 126
Manually Checking Voltage Range: One-Sensor System ........................................................... 127
Manually Checking Voltage Range: Two-Sensor System ........................................................... 129
Adjusting Voltage Limits: One-Sensor System ..........................................................................131
Adjusting Voltage Limits: Two-Sensor System.... .......................................................................131
Replacing the Auto Header Height Control (AHHC) Sensor (One-Sensor System)....................... 133
Replacing Float Indicator Cable ............................................................................................... 135
3.8.3 Case IH 5088/6088/7088 Combines ......................................................................................... 139
Calibrating the Auto Header Height Control (Case IH 5088/6088/7088) ...................................... 139
Setting the Sensitivity of the Auto Header Height (Case IH 5088/6088/7088)...............................140
3.8.4 Case IH 5130/6130/7130 and 5140/6140/7140 Mid-Range Combines......................................... 142
Setting up the Header on the Combine Display (Case IH 5130/6130/7130;
5140/6140/7140)........................................................................................................142
Checking Voltage Range from Combine Cab (Case IH 5130/6130/7130;
5140/6140/7140)........................................................................................................144
Calibrating Auto Header Height Control (Case IH 5130/6130/7130, 5140/6140/7140) .................. 146
Setting Preset Cutting Height (Case 5130/6130/7130, 5140/6140/7140) ..................................... 147
3.8.5 Case IH 7010/8010, 7120/8120/9120, 7230/8230/9230 and 7240/8240/9240 Combines .............. 150
Checking Voltage Range from the Combine Cab (Case 8010)....................................................150
Setting Header Controls (Case 8010).......................................................................................153
Checking Voltage Range from the Combine Cab (Case IH 7010/8010, 7120/8120/9120,
7230/8230/9230, 7240/8240/9240).............................................................................. 153
Calibrating the Auto Header Height Control (Case IH 7010/8010, 7120/8120/9120,
7230/8230/9230, 7240/8240/9240).............................................................................. 156
Calibrating the Auto Header Height Control (Case Combines with Version 28.00 or Higher
Software)................................................................................................................... 160
Checking Reel Height Sensor Voltages (Case IH) .....................................................................164
Setting Preset Cutting Height (Case 7010/8010, 7120/8120/9120, 7230/8230/9230,
7240/8240/9240)........................................................................................................165
3.8.6 Challenger and Massey Ferguson 6 and 7 Series Combines ......................................................166
Checking Voltage Range from the Combine Cab (Challenger and Massey Ferguson) .................. 166
Engaging the Auto Header Height Control (Challenger and Massey Ferguson) ........................... 168
Calibrating the Auto Header Height Control (Challenger and Massey Ferguson).......................... 169
Adjusting the Header Height (Challenger and Massey Ferguson) ............................................... 171
Adjusting the Header Raise/Lower Rate (Challenger and Massey Ferguson) .............................. 171
Setting the Sensitivity of the Auto Header Height Control (Challenger and Massey
Ferguson).................................................................................................................. 172
3.8.7 Gleaner R65/R66/R75/R76 and S Series Combines .. ................................................................ 173
Checking Voltage Range from the Combine Cab (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ................................................................................................................... 173
Engaging the Auto Header Height Control (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ................................................................................................................... 175
214683 xiii Revision A
TABLE OF CONTENTS
Calibrating the Auto Header Height Control (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ................................................................................................................... 177
Turning off the Accumulator (Gleaner R65/R66/R75/R76 and Pre-2016 S Series) ....................... 178
Adjusting the Header Raise/Lower Rate (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ................................................................................................................... 179
Adjusting Ground Pressure (Gleaner R65/R66/R75/R76 and Pre-2016 S Series) .. ...................... 179
Adjusting the Sensitivity of the Auto Header Height Control (AHHC) (Gleaner
R65/R66/R75/R76 and Pre-2016 S Series) ..................................................................180
Troubleshooting Alarms and Diagnostic Faults (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ................................................................................................................... 181
3.8.8 Gleaner S9 Series Combines ................................................................................................... 183
Setting up the Header (Gleaner S9 Series) ...............................................................................183
Setting up Reel Settings (Gleaner S9 Series)............................................................................ 188
Setting up Automatic Header Controls (Gleaner S9 Series).. ...................................................... 189
Calibrating the Header (Gleaner S9 Series) ..............................................................................192
Operating Header (Gleaner S9 Series).....................................................................................195
Header In-Field Settings .........................................................................................................196
3.8.9 John Deere 60 Series Combines .............................................................................................. 197
Checking Voltage Range from the Combine Cab (John Deere 60 Series)....................................197
Calibrating the Auto Header Height Control (John Deere 60 Series) ...........................................200
Turning the Accumulator Off (John Deere 60 Series) .................................................................201
Setting the Sensing Grain Header Height to 50 (John Deere 60 Series) ......................................202
Setting the Sensitivity of the Auto Header Height Control (John Deere 60 Series) ........................ 203
Adjusting the Threshold for the Drop Rate Valve (John Deere 60 Series) .................................... 204
3.8.10 John Deere 70 Series Combines ............................................................................................ 205
Checking Voltage Range from the Combine Cab (John Deere 70 Series)....................................205
Calibrating Feeder House Speed (John Deere 70 Series) ..........................................................208
Calibrating the Auto Header Height Control (John Deere 70 Series) ...........................................208
Setting the Sensitivity of the Auto Header Height Control (John Deere 70 Series) ........................ 210
Adjusting the Manual Header Raise/Lower Rate (John Deere 70 Series) .................................... 211
3.8.11 John Deere S and T Series Combines.....................................................................................212
Checking Voltage Range from the Combine Cab (John Deere S and T Series)............................212
Calibrating the Auto Header Height Control (John Deere S and T Series).................................... 215
Setting the Sensitivity of the Auto Header Height Control (John Deere S and T Series) ................ 218
Adjusting the Manual Header Raise/Lower Rate (John Deere S and T Series)............................. 219
Setting Preset Cutting Height (John Deere S and T Series)........................................................ 220
Calibrating Feeder House Fore-Aft Tilt Range (John Deere S and T Series) ................................ 222
Checking Reel Height Sensor Voltages (John Deere S and T Series) .........................................225
Calibrating Reel Height Sensor (John Deere S and T Series) .....................................................227
3.8.12 John Deere S7 Series Combines............................................................................................ 230
Setting up Header (John Deere S7 Series) ...............................................................................230
Checking Voltage Range from the Combine Cab (John Deere S7 Series) ................................... 234
Calibrating Feeder House (John Deere S7 Series) ....................................................................236
Calibrating Header (John Deere S7 Series) .............................................................................. 239
3.8.13 CLAAS 500 Series Combines.................................................................................................242
Calibrating the Auto Header Height Control (CLAAS 500 Series)................................................242
Setting Cutting Height (CLAAS 500 Series) .............................................................................. 244
Setting the Sensitivity of the Auto Header Height Control (CLAAS 500 Series) ............................246
Adjusting Auto Reel Speed (CLAAS 500 Series) .......................................................................248
3.8.14 CLAAS 600 and 700 Series Combines.. .................................................................................. 251
Calibrating the Auto Header Height Control (CLAAS 600 and 700 Series)...................................251
Setting Cutting Height (CLAAS 600 and 700 Series).................................................................. 254
214683 xiv Revision A
TABLE OF CONTENTS
Setting the Sensitivity of the Auto Header Height Control (CLAAS 600 and 700 Series)................ 255
Adjusting Auto Reel Speed (CLAAS 600 and 700 Series) . .........................................................256
Calibrating Reel Height Sensor (CLAAS 600 and 700 Series) .................................................... 258
Adjusting Auto Reel Height (CLAAS 600 and 700 Series) ..........................................................260
3.8.15 New Holland Combines (CR/CX Series—Pre-2015 Model Year) ............................................... 261
Checking Voltage Range from the Combine Cab (New Holland).................................................261
Setting up Auto Header Height Control (New Holland CR/CX Series) . ........................................264
Calibrating the Auto Header Height Control (New Holland CR/CX Series) ...................................265
Adjusting Header Raise Rate (New Holland CR/CX Series) .......................................................268
Setting the Header Lower Rate (New Holland CR/CX Series).....................................................268
Setting the Sensitivity of the Auto Header Height Control (New Holland CR/CX Series)................269
Setting Preset Cutting Height (New Holland CR/CX Series) .......................................................270
3.8.16 New Holland Combines (CR Series—Model Year 2015 and Later) ............................................271
Checking Voltage Range from the Combine Cab (New Holland CR Series) ................................. 271
Setting up Auto Header Height Control (New Holland CR Series) ...............................................274
Calibrating the Auto Header Height Control (New Holland CR Series).........................................277
Checking Reel Height Sensor Voltages (New Holland) .............................................................. 280
Setting Preset Cutting Height (New Holland CR Series – 2015 and Later) ................................... 281
Setting Maximum Work Height (New Holland CR Series) ........................................................... 283
Configuring Reel Fore-Aft, Header Tilt, and Header Type (New Holland CR Series) .....................284
3.9 Leveling the Header ......................................................................................................................... 286
3.10 Unplugging the Cutterbar................................................................................................................ 288
3.11 Unplugging the Float Module...........................................................................................................289
3.12 Transporting the Header . ...............................................................................................................290
3.12.1 Transporting Header on Combine ...........................................................................................290
3.12.2 Towing..................................................................................................................................290
Attaching Header to Towing Vehicle ......................................................................................... 291
Towing the Header..................................................................................................................291
3.12.3 Converting from Transport to Field Position .............................................................................292
Removing Tow-Bar ................................................................................................................. 292
Storing the Tow-Bar ................................................................................................................293
Moving Front (Left) Wheels into Field Position .......................................................................... 295
Moving Rear (Right) Wheels into Field Position.........................................................................296
3.12.4 Converting from Field to Transport Position .............................................................................298
Moving Front (Left) Wheels into Transport Position ...................................................................298
Moving Rear (Right) Wheels into Transport Position ..................................................................300
Attaching Tow-Bar ..................................................................................................................303
3.13 Storing the Header ......................................................................................................................... 306
Chapter 4: Header Attachment/Detachment................................................................................ 307
4.1 Float Module Feed Auger Configurations ........................................................................................... 307
4.1.1 Converting from Ultra Narrow Configuration or Narrow Configuration to Medium
Configuration....................................................................................................................310
4.1.2 Converting from Wide Configuration to Medium Configuration .................................................... 313
4.1.3 Converting from Medium Configuration or Wide Configuration to Narrow Configuration ................315
4.1.4 Converting from Ultra Narrow Configuration to Narrow Configuration ..........................................317
4.1.5 Converting from Medium Configuration to Wide Configuration .................................................... 318
4.1.6 Converting from Ultra Narrow or Narrow Configuration to Wide Configuration .............................. 320
214683 xv Revision A
TABLE OF CONTENTS
4.1.7 Optional Modification to Wide Configuration ..............................................................................322
4.1.8 Converting from Medium Configuration or Wide Configuration to Ultra Narrow
Configuration....................................................................................................................323
4.1.9 Converting from Narrow Configuration to Ultra Narrow Configuration ..........................................327
4.2 Float Module Setup .......................................................................................................................... 331
4.2.1 Using Auger Flighting ..............................................................................................................331
4.2.2 Using Stripper Bars .................................................................................................................331
4.3 Case IH Combines ...........................................................................................................................332
4.3.1 Attaching Header to Case IH Combine......................................................................................332
4.3.2 Detaching Header from Case IH Combine.................................................................................337
4.4 AGCO (Challenger, Gleaner, and Massey Ferguson) Combines ..........................................................340
4.4.1 Attaching Header to a Challenger, Gleaner, or Massey Ferguson Combine.................................. 340
4.4.2 Detaching Header from a Challenger, Gleaner, or Massey Ferguson Combine............................. 345
4.5 John Deere Combines ......................................................................................................................348
4.5.1 Attaching Header to John Deere Combine ................................................................................ 348
4.5.2 Detaching Header from John Deere Combine ...........................................................................352
4.6 CLAAS Combines ............................................................................................................................355
4.6.1 Attaching Header to CLAAS Combine....................................................................................... 355
4.6.2 Detaching Header from CLAAS Combine.................................................................................. 360
4.7 New Holland Combines ....................................................................................................................363
4.7.1 Attaching Header to New Holland CR/CX Combine....................................................................363
4.7.2 Detaching Header from New Holland CR/CX Combine...............................................................367
4.7.3 CR Feeder Deflectors..............................................................................................................371
4.8 Attaching and Detaching Header from Float Module ........................................................................... 372
4.8.1 Detaching Header from Float Module........................................................................................ 372
4.8.2 Attaching Header to Float Module.............................................................................................377
Chapter 5: Maintenance and Servicing .........................................................................................383
5.1 Preparing Machine for Servicing........................................................................................................ 383
5.2 Maintenance Specifications ..............................................................................................................384
5.2.1 Installing a Sealed Bearing.......................................................................................................384
5.3 Maintenance Requirements .............................................................................................................. 385
5.3.1 Maintenance Schedule/Record ................................................................................................ 385
5.3.2 Break-In Inspection ................................................................................................................. 388
5.3.3 Preseason Servicing ............................................................................................................... 388
5.3.4 End-of-Season Service............................................................................................................389
5.3.5 Checking Hydraulic Hoses and Lines........................................................................................390
5.3.6 Lubrication and Servicing.........................................................................................................390
Service Intervals.....................................................................................................................390
Greasing Procedure................................................................................................................ 399
Lubricating Reel Drive Chain ...................................................................................................400
Lubricating Auger Drive Chain .................................................................................................402
Lubricating Header Drive Gearbox ........................................................................................... 404
214683 xvi Revision A
TABLE OF CONTENTS
5.4 Hydraulics ....................................................................................................................................... 407
5.4.1 Checking Oil Level in Hydraulic Reservoir .................................................................................407
5.4.2 Adding Oil to Hydraulic Reservoir .............................................................................................408
5.4.3 Changing Oil in Hydraulic Reservoir .........................................................................................409
5.4.4 Changing Oil Filter ..................................................................................................................410
5.5 Electrical System ............................................................................................................................. 411
5.5.1 Replacing Light Bulbs.............................................................................................................. 411
5.6 Header Drive ...................................................................................................................................412
5.6.1 Removing Driveline .................................................................................................................412
5.6.2 Installing Driveline ...................................................................................................................413
5.6.3 Removing Driveline Guard ....................................................................................................... 414
5.6.4 Installing Driveline Guard.........................................................................................................416
5.6.5 Adjusting Gearbox Drive Chain Tension ....................................................................................418
5.7 Auger..............................................................................................................................................419
5.7.1 Adjusting Auger to Pan Clearance ............................................................................................419
5.7.2 Checking Auger Drive Chain Tension........................................................................................421
5.7.3 Adjusting Auger Drive Chain Tension ........................................................................................423
5.7.4 Removing Auger Drive Chain ................................................................................................... 424
5.7.5 Installing Auger Drive Chain..................................................................................................... 426
5.7.6 Using Auger Flighting ..............................................................................................................428
5.7.7 Auger Fingers ......................................................................................................................... 428
Removing Feed Auger Fingers ................................................................................................429
Installing Feed Auger Fingers ..................................................................................................431
Checking Auger Finger Timing.................................................................................................434
Adjusting Auger Finger Timing.................................................................................................435
5.8 Knife ............................................................................................................................................... 437
5.8.1 Replacing Knife Section ...........................................................................................................437
5.8.2 Removing Knife ...................................................................................................................... 438
5.8.3 Removing Knifehead Bearing...................................................................................................439
5.8.4 Installing Knifehead Bearing.....................................................................................................440
5.8.5 Installing Knife ........................................................................................................................ 440
5.8.6 Spare Knife.............................................................................................................................441
5.8.7 Knife Guards...........................................................................................................................441
Adjusting Knife Guards ...........................................................................................................441
Replacing Pointed Guards.......................................................................................................443
Replacing Stub Guards ...........................................................................................................446
Checking Pointed Guard Hold-Downs ...................................................................................... 447
Adjusting Hold-Downs with Pointed Guards..............................................................................448
Adjusting Hold-Down at Double-Knife Center Pointed Guard .....................................................449
Checking and Adjusting Stub Guard Hold-Downs......................................................................450
Adjusting Hold-Downs with Stub Guards .................................................................................. 451
5.8.8 Knifehead Shield.....................................................................................................................452
Installing Knifehead Shield ......................................................................................................453
5.9 Knife Drive System...........................................................................................................................454
5.9.1 Knife Drive Box .......................................................................................................................454
214683 xvii Revision A
TABLE OF CONTENTS
Checking Knife Drive Box........................................................................................................454
Checking Mounting Bolts.........................................................................................................455
Removing Knife Drive Box.......................................................................................................456
Removing Knife Drive Box Pulley.............................................................................................458
Installing Knife Drive Box Pulley.. .............................................................................................458
Installing Knife Drive Box ........................................................................................................459
Changing Oil in Knife Drive Box .... ........................................................................................... 461
5.9.2 Knife Drive Belts .....................................................................................................................462
Knife Drive Belts.....................................................................................................................462
5.10 Feed Draper ..................................................................................................................................466
5.10.1 Replacing Feed Draper..........................................................................................................466
5.10.2 Adjusting Feed Draper Tension...............................................................................................468
5.10.3 Feed Draper Drive Roller ....................................................................................................... 469
Removing Feed Draper Drive Roller......................................................................................... 469
Installing Feed Draper Drive Roller .......................................................................................... 472
Replacing Feed Draper Drive Roller Bearing ............................................................................ 473
5.10.4 Feed Draper Idler Roller.........................................................................................................475
Removing Feed Draper Idler Roller ..........................................................................................475
Installing Feed Draper Idler Roller............................................................................................476
Replacing Feed Draper Idler Roller Bearing.............................................................................. 477
5.11 Lowering Float Module Feed Deck Pan ............................................................................................479
5.12 Raising Float Module Feed Deck Pan .............................................................................................. 481
5.13 Float Module Stripper Bars and Feed Deflectors...............................................................................482
5.13.1 Removing Stripper Bars.........................................................................................................482
5.13.2 Installing Stripper Bars........................................................................................................... 483
5.13.3 Replacing Feed Deflectors on New Holland CR Combines .......................................................483
5.14 Header Drapers .............................................................................................................................485
5.14.1 Removing Side Drapers.........................................................................................................485
5.14.2 Installing Side Drapers ...........................................................................................................486
5.14.3 Adjusting Draper Tension ....................................................................................................... 488
5.14.4 Adjusting Header Draper Tracking ..........................................................................................490
5.14.5 Adjusting Deck Height ........................................................................................................... 492
5.14.6 Header Draper Roller Maintenance.........................................................................................494
Inspecting Draper Roller Bearing .. ........................................................................................... 494
Draper Deck Idler Roller..........................................................................................................494
Draper Deck Drive Roller ........................................................................................................ 497
5.15 Reel ..............................................................................................................................................502
5.15.1 Reel Clearance to Cutterbar...................................................................................................502
Measuring Reel Clearance ...................................................................................................... 502
Adjusting Reel Clearance........................................................................................................ 505
5.15.2 Reel Frown ...........................................................................................................................506
Adjusting Reel Frown..............................................................................................................506
5.15.3 Centering Double Reel...........................................................................................................507
5.15.4 Reel Fingers .........................................................................................................................507
Removing Steel Fingers..........................................................................................................507
Installing Steel Fingers............................................................................................................508
Removing Plastic Fingers.
.......................................................................................................509
214683 xviii Revision A
TABLE OF CONTENTS
Installing Plastic Fingers .........................................................................................................510
5.15.5 Tine Tube Bushings............................................................................................................... 511
Removing Bushings from Five-, Six-, or Nine-Bat Reels............................................................. 511
Installing Bushings on Five-, Six-, or Nine-Bat Reels .................................................................516
5.15.6 Reel Endshields ....................................................................................................................523
Replacing Reel Endshields......................................................................................................523
Replacing Reel Endshield Supports .........................................................................................525
5.16 Reel System .................................................................................................................................. 526
5.16.1 Reel Drive Cover...................................................................................................................526
Removing Reel Drive Cover .................................................................................................... 526
Installing Reel Drive Cover ...................................................................................................... 527
5.16.2 Reel Drive Chain Tension....................................................................................................... 528
Loosening Reel Drive Chain ....................................................................................................528
Tightening Reel Drive Chain ....................................................................................................528
5.16.3 Reel Drive Sprocket............................................................................................................... 530
Removing Reel Drive Sprocket ................................................................................................530
Installing Reel Drive Sprocket..................................................................................................531
5.16.4 Double-Reel U-Joint .............................................................................................................. 532
Removing Double-Reel U-Joint . .............................................................................................. 532
Installing Double-Reel U-Joint .................................................................................................533
5.16.5 Reel Drive Motor ................................................................................................................... 534
Removing Reel Drive Motor.. ...................................................................................................534
Installing Reel Drive Motor ..... .................................................................................................534
5.16.6 Replacing Drive Chain on Double Reel ..... ..............................................................................535
5.16.7 Replacing Drive Chain on Single Reel.....................................................................................537
5.16.8 Replacing Reel Speed Sensor................................................................................................538
Replacing AGCO (Challenger, Gleaner, and Massey Ferguson) Sensor ..................................... 538
Replacing John Deere Reel Speed Sensor...............................................................................540
Replacing CLAAS 400 Series Reel Speed Sensor ....................................................................540
Replacing CLAAS 500/700 Series Reel Speed Sensor .............................................................. 541
5.17 Transport System (Optional) ........................................................................................................... 542
5.17.1 Checking Wheel Bolt Torque .................................................................................................. 542
5.17.2 Checking Axle Bolt Torque .....................................................................................................543
5.17.3 Checking Tire Pressure.......................................................................................................... 544
Chapter 6: Options and Attachments............................................................................................545
6.1 Float Module.................................................................................................................................... 545
6.1.1 Hillside Extension Kit ............................................................................................................... 545
6.2 Reel................................................................................................................................................ 546
6.2.1 Multi-Crop Rapid Reel Conversion Kit ....................................................................................... 546
6.2.2 Reel Arm Extension Kit (European-configured Headers Only).....................................................546
6.2.3 Lodged Crop Reel Finger Kit .................................................................................................... 547
6.2.4 PR15 Tine Tube Reel Conversion Kit ........................................................................................547
6.2.5 Reel Endshield Kit................................................................................................................... 547
6.2.6 Tine Tube Reinforcing Kit.........................................................................................................548
6.3 Cutterbar.........................................................................................................................................549
214683 xix Revision A
TABLE OF CONTENTS
6.3.1 Cutterbar Wearplate ................................................................................................................ 549
6.3.2 Knifehead Shield.....................................................................................................................549
6.3.3 Extended Center Filler ............................................................................................................. 550
6.3.4 Rock Retarder.........................................................................................................................550
6.3.5 Stub Guard Conversion Kit.......................................................................................................550
6.3.6 FD1 Series Vertical Knife Mounts and Double Vertical Knife Hose Kits ........................................551
6.3.7 Vertical Knife Plumbing Kits .....................................................................................................551
6.3.8 Roto-Shear Completion Package ............................................................................................. 551
6.4 Header............................................................................................................................................ 552
6.4.1 Divider Latch Kit.. ....................................................................................................................552
6.4.2 Stabilizer Wheels ....................................................................................................................552
6.4.3 Secondary Stabilizer Wheel .....................................................................................................553
6.4.4 Stabilizer Wheels and Slow Speed Transport Package...............................................................553
6.4.5 Backsheet Extension Kit ..........................................................................................................554
6.4.6 Center Skid Shoes Kit..............................................................................................................554
6.5 Crop Delivery................................................................................................................................... 555
6.5.1 FM100 Dual Auto Header Height Control (AHHC) Sensor Kit......................................................555
6.5.2 FM100 Feed Auger Flighting .................................................................................................... 555
6.5.3 In-Cab Draper Speed Control (ICDSC) Kit................................................................................. 556
6.5.4 Draper Deflector (Narrow)........................................................................................................556
6.5.5 Draper Deflector (Wide) ........................................................................................................... 557
6.5.6 Stripper Bars...........................................................................................................................557
6.5.7 Auger Dent Repair Kit..............................................................................................................558
6.5.8 Upper Cross Auger (UCA) ....................................................................................................... 558
6.5.9 European Combine Upper Cross Auger (UCA) ..........................................................................559
6.5.10 Rice Divider Rods..................................................................................................................559
Chapter 7: Troubleshooting.............................................................................................................561
7.1 Crop Loss at Cutterbar .....................................................................................................................561
7.2 Cutting Action and Knife Components ............................................................................................... 564
7.3 Reel Delivery ...................................................................................................................................567
7.4 Header and Drapers.........................................................................................................................570
7.5 Cutting Edible Beans........................................................................................................................ 572
Chapter 8: Reference .........................................................................................................................577
8.1 Torque Specifications .......................................................................................................................577
8.1.1 Metric Bolt Specifications......................................................................................................... 577
8.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ................................................................ 579
8.1.3 Flare-Type Hydraulic Fittings... .................................................................................................580
8.1.4 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) .................................................................... 581
8.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable).............................................................583
8.1.6 O-Ring Face Seal (ORFS) Hydraulic Fittings .............................................................................584
8.1.7 Tapered Pipe Thread Fittings ...................................................................................................585
214683 xx Revision A
TABLE OF CONTENTS
8.2 Conversion Chart.............................................................................................................................586
8.3 Unloading and Assembly .................................................................................................................. 587
Index.......................................................................................................................................................589
Recommended Fluids and Lubricants ............................................................. Inside Back Cover
214683 xxi Revision A
1 Safety
1000915

1.1 Safety Alert Symbols

This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine.
This symbol means:
• ATTENTION!
• BECOME ALERT!
• YOUR SAFETY IS INVOLVED!
Carefully read and follow the safety message accompanying this symbol.
Why is safety important to you?
• Accidents disable and kill
• Accidents cost
• Accidents can be avoided
Figure 1.1: Safety Symbol
214683 1 Revision A
SAFETY

1.2 Signal Words

Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Signal words are selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may be used to alert against unsafe practices.
214683 2 Revision A
1000004
1000005
1010391
SAFETY

1.3 General Safety

CAUTION
The following are general farm safety precautions that should be part of your operating procedure for all types of machinery.
Protect yourself.
• When assembling, operating, and servicing machinery, wear all protective clothing and personal safety devices that could be necessary for job at hand. Do NOT take chances. You may need the following:
• Hard hat
• Protective footwear with slip-resistant soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• Respirator or filter mask
• Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection devices such as earmuffs or earplugs to help protect against loud noises.
Figure 1.2: Safety Equipment
Figure 1.3: Safety Equipment
• Provide a first aid kit for use in case of emergencies.
• Keep a fire extinguisher on the machine. Be sure fire
extinguisher is properly maintained. Be familiar with its proper use.
• Keep young children away from machinery at all times.
• Be aware that accidents often happen when Operator is
tired or in a hurry. Take time to consider safest way. Never ignore warning signs of fatigue.
Figure 1.4: Safety Equipment
214683 3 Revision A
1000007
1000008
1000009
SAFETY
• Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets.
• Keep all shields in place. NEVER alter or remove safety equipment. Make sure driveline guards can rotate independently of shaft and can telescope freely.
• Use only service and repair parts made or approved by equipment manufacturer. Substituted parts may not meet strength, design, or safety requirements.
• Keep hands, feet, clothing, and hair away from moving parts. NEVER attempt to clear obstructions or objects from a machine while engine is running.
• Do NOT modify machine. Unauthorized modifications may impair machine function and/or safety. It may also shorten machine’s life.
Figure 1.5: Safety around Equipment
• To avoid bodily injury or death from unexpected startup of machine, ALWAYS stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
• Keep service area clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment. Be sure all electrical outlets and tools are properly grounded.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff on a hot engine is
a fire hazard. Do NOTallow oil or grease to accumulate on service platforms, ladders, or controls. Clean machines before storage.
• NEVER use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable.
• When storing machinery, cover sharp or extending components to prevent injury from accidental contact.
Figure 1.6: Safety around Equipment
Figure 1.7: Safety around Equipment
214683 4 Revision A
1000009
1008958
1000004
SAFETY

1.4 Maintenance Safety

To ensure your safety while maintaining machine:
• Review operator’s manual and all safety items before operation and/or maintenance of machine.
• Place all controls in Neutral, stop the engine, set the park brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing.
• Follow good shop practices:
– Keep service areas clean and dry
– Be sure electrical outlets and tools are properly
grounded
– Keep work area well lit
• Relieve pressure from hydraulic circuits before servicing
and/or disconnecting machine.
• Make sure all components are tight and that steel lines,
hoses, and couplings are in good condition before applying pressure to hydraulic systems.
Figure 1.8: Safety around Equipment
• Keep hands, feet, clothing, and hair away from all
moving and/or rotating parts.
• Clear area of bystanders, especially children, when
carrying out any maintenance, repairs, or adjustments.
• Install transport lock or place safety stands under frame
before working under machine.
• If more than one person is servicing machine at same
time, be aware that rotating a driveline or other mechanically-driven component by hand (for example, accessing a lubricant fitting) will cause drive components in other areas (belts, pulleys, and knives) to move. Stay clear of driven components at all times.
• Wear protective gear when working on machine.
• Wear heavy gloves when working on knife components.
Figure 1.9: Equipment NOT Safe for Children
Figure 1.10: Safety Equipment
214683 5 Revision A
1001205
1001207
1000013
SAFETY

1.5 Hydraulic Safety

• Always place all hydraulic controls in Neutral before dismounting.
• Make sure that all components in hydraulic system are kept clean and in good condition.
• Replace any worn, cut, abraded, flattened, or crimped hoses and steel lines.
• Do NOT attempt any makeshift repairs to hydraulic lines, fittings, or hoses by using tapes, clamps, cements, or welding. The hydraulic system operates under extremely high-pressure. Makeshift repairs will fail suddenly and create hazardous and unsafe conditions.
• Wear proper hand and eye protection when searching for high-pressure hydraulic leaks. Use a piece of cardboard as a backstop instead of hands to isolate and identify a leak.
Figure 1.11: Testing for Hydraulic Leaks
• If injured by a concentrated high-pressure stream of hydraulic fluid, seek medical attention immediately. Serious infection or toxic reaction can develop from hydraulic fluid piercing the skin.
• Make sure all components are tight and steel lines, hoses, and couplings are in good condition before applying pressure to a hydraulic system.
Figure 1.12: Hydraulic Pressure Hazard
Figure 1.13: Safety around Equipment
214683 6 Revision A
Loading...
+ 598 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use