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MAC215986

266

Revision A

4.2

Maintenance Requirements

Regular maintenance is the best insurance against early wear and untimely breakdowns. Following the maintenance
schedule will increase your machine

’

s life. Log hours of operation, use the maintenance record, and keep copies of your

maintenance records (refer to

4.2.1 Maintenance Schedule/Record, page 266

Periodic maintenance requirements are organized according to service intervals. If a service interval specifies more than
one timeframe, e.g., 100 hours or annually, service the machine at whichever interval is reached first.

IMPORTANT:

Recommended intervals are for average conditions. Service the machine more often if operating under adverse conditions
(severe dust, extra heavy loads, etc.).

When servicing the machine, refer to the appropriate section in this Maintenance and Servicing chapter and use only
specified fluids and lubricants. Refer to inside back cover for recommended fluids and lubricants.

CAUTION

Carefully follow safety messages. For instructions, refer to

4.1 Preparing Machine for Servicing, page 265

and

.

4.2.1

Maintenance Schedule/Record

Recording maintenance allows the user to keep track of when maintenance is performed.

Action:

ü

–

Check

S

–

Lubricate

p

–

Change

!

Hour meter reading

!

Service date

!

Serviced by

First Use

Refer to

4.2.2 Break-In Inspection, page 269

.

End of Season

Refer to

4.2.4 Equipment Servicing

End-of-Season, page 270

10 Hours or Daily

(Whichever Occurs First)

ü

Hydraulic hoses and lines; refer to

4.2.5 Checking Hydraulic Hoses and Lines, page 271

ü

Knife sections, guards, and hold-downs; refer to

4.8 Knife, page 330

ü

Tire pressure; refer to

4.16.3 Checking Tire Pressure, page 472

S

Feed draper rollers; refer to

Every 10 Hours, page 272

ü

Link holder hooks; refer to

4.10.7 Checking Link Holder Hooks, page 392

ü

Axle bolt torque; refer to

4.16.2 Checking Transport Assembly Bolt Torque, page 470

25 Hours

ü

Hydraulic oil level at reservoir; refer to

4.4.1 Checking Oil Level in Hydraulic Reservoir, page 292

S

Knifeheads; refer to

Every 25 Hours, page 273

50 Hours or Annually

MAINTENANCE AND SERVICING

69. MacDon recommends keeping a record of daily maintenance as evidence of a properly maintained machine.

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Summary of Contents for CASE IH FlexDraper FD225

Page 1: ...FD2 Series FlexDraper Header with FM200 Float Module Operator s Manual 215986 Revision A Original Instruction ...

Page 2: ...cation is based on the information available and in effect at the time of printing MacDon Industries Ltd makes no representation or warranty of any kind whether expressed or implied with respect to the information in this publication MacDon Industries Ltd reserves the right to make changes at any time without notice ...

Page 3: ...ƵŝŶĂ Ϯ EŽŵďƌĞ Ǉ ŵŽĚĞůŽ ϯ EƷŵĞƌŽƐ ĚĞ ƐĞƌŝĞ ϰ ĐƵŵƉůĞ ĐŽŶ ƚŽĚĂƐ ůĂƐ ĚŝƐƉŽƐŝĐŝŽŶĞƐ ƉĞƌƟŶĞŶƚĞƐ ĚĞ ůĂ ĚŝƌĞĐƚƌŝǌ ϮϬϬϲ ϰϮ Ğ ƵƟůŝǌĂƌŽŶ ŶŽƌŵĂƐ ĂƌŵŽŶŝǌĂĚĂƐ ƐĞŐƷŶ ůŽ ĚŝƐƉƵĞƐƚŽ ĞŶ Ğů ĂƌơĐƵůŽ ϳ ϮͿ E K ϰϮϱϰ ϭ ϮϬϭϯ E K ϰϮϱϰ ϳ ϮϬϬϵ ƵŐĂƌ Ǉ ĨĞĐŚĂ ĚĞ ůĂ ĚĞĐůĂƌĂĐŝſŶ ϱ ĚĞŶƟĚĂĚ Ǉ ĮƌŵĂ ĚĞ ůĂ ƉĞƌƐŽŶĂ ĨĂĐƵůƚĂĚĂ ƉĂƌĂ ĚƌĂǁ ƌĞĚĂĐƚĂƌ ůĂ ĚĞĐůĂƌĂĐŝſŶ ϲ EŽŵďƌĞ Ǉ ĚŝƌĞĐĐŝſŶ ĚĞ ůĂ ƉĞƌƐŽŶĂ ĂƵƚŽƌŝǌĂĚĂ ƉĂƌĂ ĞůĂďŽƌĂƌ Ğů ĞǆƉĞĚŝĞŶƚĞ ƚĠĐŶŝ...

Page 4: ...ŶƟƚĂƚĞĂ ƕŝ ƐĞŵŶĉƚƵƌĂ ƉĞƌƐŽĂŶĞŝ ŠŵƉƵƚĞƌŶŝĐŝƚĞ ƉĞŶƚƌƵ ŠŶƚŽĐŵŝƌĞĂ ĚĞĐůĂƌĂƜŝĞŝ ϲ EƵŵĞůĞ ƕŝ ƐĞŵŶĉƚƵƌĂ ƉĞƌƐŽĂŶĞŝ ĂƵƚŽƌŝǌĂƚĞ ƉĞŶƚƌƵ ŠŶƚŽĐŵŝƌĞĂ ĐĉƌƜŝŝ ƚĞŚŶŝĐĞ ĞŶĞĚŝŬƚ ǀŽŶ ZŝĞĚĞƐĞů DĂŶĂŐĞƌ ĞŶĞƌĂů DĂĐ ŽŶ ƵƌŽƉĞ ŵď ĂŐĞŶĂƵĞƌ ƚƌĂƘĞ ϱϵ ϲϱϮϬϯ tŝĞƐďĂĚĞŶ ĞƌŵĂŶŝĂͿ ďǀŽŶƌŝĞĚĞƐĞůΛŵĂĐĚŽŶ ĐŽŵ s sŝ ϭ ŶƚǇŐĂƌ ĂƩ ƉƌŽĚƵŬƚĞŶ DĂƐŬŝŶƚǇƉ Ϯ EĂŵŶ ŽĐŚ ŵŽĚĞůů ϯ ĞƌŝĞŶƵŵŵĞƌ ϰ ƵƉƉĨǇůůĞƌ ĂůůĂ ƌĞůĞǀĂŶƚĂ ǀŝůůŬŽƌ ŝ ĚŝƌĞŬƟǀĞƚ ϮϬϬϲ ϰϮ ĂƌŵŽŶŝĞ...

Page 5: ...Ğ Ǉ ŵŽĚĞůŽ ϯ EƷŵĞƌŽƐ ĚĞ ƐĞƌŝĞ ϰ ĐƵŵƉůĞ ĐŽŶ ƚŽĚĂƐ ůĂƐ ĚŝƐƉŽƐŝĐŝŽŶĞƐ ƉĞƌƟŶĞŶƚĞƐ ĚĞ ůĂ ĚŝƌĞĐƚƌŝǌ ϮϬϬϲ ϰϮ Ğ ƵƟůŝǌĂƌŽŶ ŶŽƌŵĂƐ ĂƌŵŽŶŝǌĂĚĂƐ ƐĞŐƷŶ ůŽ ĚŝƐƉƵĞƐƚŽ ĞŶ Ğů ĂƌơĐƵůŽ ϳ ϮͿ E K ϰϮϱϰ ϭ ϮϬϭϯ E K ϰϮϱϰ ϳ ϮϬϬϵ ƵŐĂƌ Ǉ ĨĞĐŚĂ ĚĞ ůĂ ĚĞĐůĂƌĂĐŝſŶ ϱ ĚĞŶƟĚĂĚ Ǉ ĮƌŵĂ ĚĞ ůĂ ƉĞƌƐŽŶĂ ĨĂĐƵůƚĂĚĂ ƉĂƌĂ ĚƌĂǁ ƌĞĚĂĐƚĂƌ ůĂ ĚĞĐůĂƌĂĐŝſŶ ϲ EŽŵďƌĞ Ǉ ĚŝƌĞĐĐŝſŶ ĚĞ ůĂ ƉĞƌƐŽŶĂ ĂƵƚŽƌŝǌĂĚĂ ƉĂƌĂ ĞůĂďŽƌĂƌ Ğů ĞǆƉĞĚŝĞŶƚĞ ƚĠĐŶŝĐŽ ĞŶĞĚŝŬƚ ǀ...

Page 6: ...ŶƟƚĂƚĞĂ ƕŝ ƐĞŵŶĉƚƵƌĂ ƉĞƌƐŽĂŶĞŝ ŠŵƉƵƚĞƌŶŝĐŝƚĞ ƉĞŶƚƌƵ ŠŶƚŽĐŵŝƌĞĂ ĚĞĐůĂƌĂƜŝĞŝ ϲ EƵŵĞůĞ ƕŝ ƐĞŵŶĉƚƵƌĂ ƉĞƌƐŽĂŶĞŝ ĂƵƚŽƌŝǌĂƚĞ ƉĞŶƚƌƵ ŠŶƚŽĐŵŝƌĞĂ ĐĉƌƜŝŝ ƚĞŚŶŝĐĞ ĞŶĞĚŝŬƚ ǀŽŶ ZŝĞĚĞƐĞů DĂŶĂŐĞƌ ĞŶĞƌĂů DĂĐ ŽŶ ƵƌŽƉĞ ŵď ĂŐĞŶĂƵĞƌ ƚƌĂƘĞ ϱϵ ϲϱϮϬϯ tŝĞƐďĂĚĞŶ ĞƌŵĂŶŝĂͿ ďǀŽŶƌŝĞĚĞƐĞůΛŵĂĐĚŽŶ ĐŽŵ s sŝ ϭ ŶƚǇŐĂƌ ĂƩ ƉƌŽĚƵŬƚĞŶ DĂƐŬŝŶƚǇƉ Ϯ EĂŵŶ ŽĐŚ ŵŽĚĞůů ϯ ĞƌŝĞŶƵŵŵĞƌ ϰ ƵƉƉĨǇůůĞƌ ĂůůĂ ƌĞůĞǀĂŶƚĂ ǀŝůůŬŽƌ ŝ ĚŝƌĞŬƟǀĞƚ ϮϬϬϲ ϰϮ ĂƌŵŽŶŝĞ...

Page 7: ...ŽĚƵĐƚ ŶƚĞŐƌŝƚǇ tĞ ϭ ĞĐůĂƌĞ ƚŚĂƚ ƚŚĞ ƉƌŽĚƵĐƚ DĂĐŚŝŶĞ dǇƉĞ Ϯ EĂŵĞ Θ DŽĚĞů ϯ ĞƌŝĂů EƵŵďĞƌ ƐͿ ϰ ĨƵůĮůůƐ Ăůů ƌĞůĞǀĂŶƚ ƉƌŽǀŝƐŝŽŶƐ ŽĨ ƚŚĞ ƵƉƉůǇ ŽĨ DĂĐŚŝŶĞƌǇ ĂĨĞƚǇͿ ZĞŐƵůĂƟŽŶƐ ϮϬϬϴ ĞƐŝŐŶĂƚĞĚ ƐƚĂŶĚĂƌĚƐ ƵƐĞĚ ĂƌĞ E K ϰϮϱϰ ϭ ϮϬϭϱ E K ϰϮϱϰ ϳ ϮϬϭϳ WůĂĐĞ ĂŶĚ ĚĂƚĞ ŽĨ ĚĞĐůĂƌĂƟŽŶ ϱ ĚĞŶƟƚǇ ĂŶĚ ƐŝŐŶĂƚƵƌĞ ŽĨ ƚŚĞ ƉĞƌƐŽŶ ĞŵƉŽǁĞƌĞĚ ƚŽ ĚƌĂǁ ƵƉ ƚŚĞ ĚĞĐůĂƌĂƟŽŶ ϲ h ĞĐůĂƌĂƟŽŶ ŽĨ ŽŶĨŽƌŵŝƚǇ MAC215986 v Revision A ...

Page 8: ...ƚ ŶƚĞŐƌŝƚǇ tĞ ϭ ĞĐůĂƌĞ ƚŚĂƚ ƚŚĞ ƉƌŽĚƵĐƚ DĂĐŚŝŶĞ dǇƉĞ Ϯ EĂŵĞ Θ DŽĚĞů ϯ ĞƌŝĂů EƵŵďĞƌ ƐͿ ϰ ĨƵůĮůůƐ Ăůů ƌĞůĞǀĂŶƚ ƉƌŽǀŝƐŝŽŶƐ ŽĨ ƚŚĞ ƵƉƉůǇ ŽĨ DĂĐŚŝŶĞƌǇ ĂĨĞƚǇͿ ZĞŐƵůĂƟŽŶƐ ϮϬϬϴ ĞƐŝŐŶĂƚĞĚ ƐƚĂŶĚĂƌĚƐ ƵƐĞĚ ĂƌĞ E K ϰϮϱϰ ϭ ϮϬϭϱ E K ϰϮϱϰ ϳ ϮϬϭϳ WůĂĐĞ ĂŶĚ ĚĂƚĞ ŽĨ ĚĞĐůĂƌĂƟŽŶ ϱ ĚĞŶƟƚǇ ĂŶĚ ƐŝŐŶĂƚƵƌĞ ŽĨ ƚŚĞ ƉĞƌƐŽŶ ĞŵƉŽǁĞƌĞĚ ƚŽ ĚƌĂǁ ƵƉ ƚŚĞ ĚĞĐůĂƌĂƟŽŶ ϲ h ĞĐůĂƌĂƟŽŶ ŽĨ ŽŶĨŽƌŵŝƚǇ MAC215986 vi Revision A ...

Page 9: ...ipment component or part in accordance with the manufacturer s instructions Your manual 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 Contact your Dealer if you need assistance information or additional copies of thi...

Page 10: ... macdon com or from our Dealer only site https portal macdon com login required Call your MacDon Dealer if you need assistance information or additional copies of this manual This document is available in the following languages Czech Danish English Estonian French German Latvian Lithuanian Polish Portuguese Romanian Russian Spanish These manuals can be ordered from MacDon downloaded from the MacD...

Page 11: ...updates ECN 62924 Installing Outboard Flex Linkage Covers page 46 Edited instructions and illustrations to describe hardware updates ECN 62924 3 8 1 FM200 Feed Auger Configurations page 89 Added optional configuration for Case combines to narrow feed auger ECN 62723 ECN 62746 Checking and Adjusting Header Float page 129 Added IMPORTANTs Added two WARNING statements Clarified language Added Place t...

Page 12: ...age 288 Modified instructions to reflect changes to the oil checking procedure ECN 63056 Adding Oil to Header Drive Completion Gearbox page 289 Modified instructions to reflect changes to the oil filling procedure ECN 63056 Changing Oil in Header Drive Completion Gearbox page 290 Modified instructions to reflect changes to the oil changing procedure ECN 63056 4 12 3 Adjusting Deck Height page 400 ...

Page 13: ...y MACB7335 Added FD225 information ECN 62171 Technical Publications 5 4 2 EasyMove Transport System page 494 Added a note that the FD225 is not compatible with the transport system Technical Publications Added FD225 information Technical Publications 5 4 8 Sunflower Attachment page 497 Added new topic ECN 62663 Recommended Fluids and Lubricants page Inside back cover Updated lubrication specificat...

Page 14: ... located on the back of the header beside the left endsheet 1028872 A Figure 3 Float Module Serial Number Plate Location FM200 Float Module for Combine Serial Number Model Year The float module s serial number plate A is located on the top left side of the float module 1029209 A Figure 4 EasyMove Transport Option EasyMove Transport Option Serial Number Model Year The EasyMove transport s serial nu...

Page 15: ...FM200 Float Module Component Identification 29 Chapter 3 Operation 31 3 1 Owner Operator Responsibilities 31 3 2 Operational Safety 32 3 2 1 Header Safety Props 32 3 2 2 Reel Safety Props 33 Engaging Reel Safety Props 33 Disengaging Reel Safety Props 34 3 2 3 Header Endshields 35 Opening Header Endshields 35 Closing Header Endshields 36 Checking and Adjusting Header Endshields 37 Removing Header E...

Page 16: ...arrow Configuration Auger Flighting 95 Medium Configuration Auger Flighting 98 Wide Configuration Auger Flighting 100 Ultra Wide Configuration Auger Flighting 103 Auger Flighting 105 3 8 2 Removing Feed Auger Fingers 112 3 8 3 Installing Feed Auger Fingers 114 3 8 4 Setting Auger Position 116 3 8 5 Checking and Adjusting Feed Auger Springs 118 3 8 6 Stripper Bars 119 3 9 Header Operating Variables...

Page 17: ...9 14 Crop Dividers 184 Removing Crop Dividers 184 Installing Crop Dividers 186 Removing Floating Crop Dividers 187 Installing Floating Crop Dividers 189 Adjusting Floating Crop Dividers 192 3 9 15 Crop Divider Rods 199 Removing Crop Divider Rods 199 Installing Crop Divider Rods 200 Optional Rice Divider Rods 201 3 10 Auto Header Height Control 202 3 10 1 Auto Header Height Control Sensor Operation...

Page 18: ... Towing 243 Attaching Header to Towing Vehicle 244 Precautions for Towing Header 244 3 14 3 Converting from Transport to Field Position Option 245 Moving Left Outboard Wheel From Transport to Working Position ContourMax Option 245 Removing Tow Bar 246 Storing Tow Bar 249 Moving Front Left Wheels into Field Position 250 Moving Rear Right Wheels into Field Position 252 3 14 4 Converting from Field t...

Page 19: ... 6 Header Drive 296 4 6 1 Removing Driveline Connecting Float Module to Combine 296 4 6 2 Installing Driveline 298 4 6 3 Removing Driveline Guard 301 4 6 4 Installing Driveline Guard 303 4 6 5 Adjusting Chain Tension Main Gearbox 305 4 6 6 Adjusting Chain Tension Completion Gearbox 306 4 7 Auger 308 4 7 1 Adjusting Feed Auger to Pan Clearance 308 4 7 2 Checking Feed Auger Chain Tension 310 Checkin...

Page 20: ...rt Knife Guards or End Knife Guards 358 Checking Hold Down Short Knife Guards 360 Adjusting Hold Down Short Knife Guards 360 Replacing Center Knife Guard Double Knife 361 Checking Center Hold Down Short Knife Guards 364 Adjusting Center Hold Down Short Knife Guards 364 4 8 9 Knifehead Shield 365 Installing Knifehead Shield 365 4 9 Knife Drive System 367 4 9 1 Knife Drive Box 367 Checking Oil Level...

Page 21: ...ering Reel 425 4 13 4 Reel Fingers 426 Removing Steel Fingers 427 Installing Steel Fingers 427 Removing Plastic Fingers 428 Installing Plastic Fingers 429 4 13 5 Tine Tube Bushings 430 Removing Bushings from Reels 430 Installing Bushings onto Reels 435 4 13 6 Reel Endshields 441 Replacing Reel Endshields at Outboard Cam End 442 Replacing Reel Endshields at Inboard Cam End 444 Replacing Reel Endshi...

Page 22: ... 483 5 1 1 Crop Lifter Kit 483 5 1 2 Crop Lifter Storage Rack Kit 483 5 1 3 Crop Divider Storage Bracket Kit 484 5 1 4 Floating Crop Dividers 484 5 1 5 Full Length Upper Cross Auger 485 5 1 6 Rice Divider Rod Kit 486 5 1 7 VertiBlade Vertical Knife Kit 486 5 2 Cutterbar Kits 487 5 2 1 Rock Retarder Kit 487 5 2 2 Four Point Knife Guard 487 5 3 FM200 Float Module Kits 488 5 3 1 10V Sensor Adapter Ki...

Page 23: ...er 7 Reference 515 7 1 Torque Specifications 515 7 1 1 Metric Bolt Specifications 515 7 1 2 Metric Bolt Specifications Cast Aluminum 518 7 1 3 O Ring Boss Hydraulic Fittings Adjustable 519 7 1 4 O Ring Boss Hydraulic Fittings Non Adjustable 520 7 1 5 O Ring Face Seal Hydraulic Fittings 521 7 1 6 Tapered Pipe Thread Fittings 522 7 2 Conversion Chart 524 Index NOTE Add the prefix MAC to part numbers...

Page 24: ......

Page 25: ...ety Alert Symbols The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine 1000915 Figure 1 1 Safety Symbol 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 ...

Page 26: ...oided 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 IMPORTANT Indicates a situati...

Page 27: ...gloves Wet weather gear Respirator or filter mask 1000005 Figure 1 3 Safety Equipment In addition take the following precautions Be aware that exposure to loud noises can cause hearing impairment Wear suitable hearing protection devices such as earmuffs or earplugs to help protect against loud noises 1010391 Figure 1 4 Safety Equipment Provide a first aid kit in case of emergencies Keep a properly...

Page 28: ...r the functionality and or safety of the machine It may also shorten the machine s service life To avoid injury or death from the unexpected startup of the machine ALWAYS stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000009 Figure 1 7 Safety around Equipment Keep the machine service area clean and dry Wet and or oily floors are slippery Wet...

Page 29: ... servicing and or disconnecting the machine Ensure that all components are tight and that steel lines hoses and couplings are in good condition before applying pressure to hydraulic systems Keep hands feet clothing and hair away from all moving and or rotating parts Clear the area of bystanders especially children when carrying out any maintenance repairs or adjustments Install the transport lock ...

Page 30: ...draulic system operates under extremely high pressure Makeshift repairs can fail suddenly and create hazardous conditions 1001207 Figure 1 12 Hydraulic Pressure Hazard Wear proper hand and eye protection when searching for high pressure hydraulic fluid leaks Use a piece of cardboard as a backstop instead of your hands to isolate and identify a leak If injured by a concentrated high pressure stream...

Page 31: ... original part on which a safety sign was installed is replaced ensure that the repair part displays the current safety sign Replacement safety signs are available from your Dealer 1 6 1 Installing Safety Decals Replace any safety decals that are worn or damaged 1 Decide exactly where you are going to place the decal 2 Clean and dry the installation area 3 Remove the smaller portion of the split b...

Page 32: ...re placed on the machine where there is a risk of personal injury or where the operator has to take extra precaution before operating controls 1036745 A B Figure 1 15 Reel Arms and Endsheets A MAC360541 Reel Entanglement Hazard Two Locations B MAC288195 Danger Rotating Part Two Locations SAFETY ...

Page 33: ...MAC215986 9 Revision A 1029324 A A B B C C Figure 1 16 Backtube A MAC313725 Read Manual High Pressure Fluid Header Hazard B MAC311493 Center Prop Lock C MAC313733 Header Crushing Hazard SAFETY ...

Page 34: ...vision A ϭϬϯϵϯϮϮ A A B B Figure 1 17 FM200 Float Module A MAC313728 Read Manual Fluid Spray Hazard B MAC360655 Released Spring Energy Hazard 1029300 A A A Figure 1 18 Upper Cross Auger A MAC279085 Auger Warning SAFETY ...

Page 35: ...6 11 Revision A 1032196 A A Figure 1 19 EasyMove Transport System Tow Bar Short Bar Shown Long Bar Similar A MAC327588 Hitch Damage Hazard 1031139 A A Figure 1 20 Vertical Knife A MAC313881 Knife Hazard SAFETY ...

Page 36: ...MAC215986 12 Revision A ϭϬϯϵϮϮϵ A A Figure 1 21 Stabilizer Wheels A MAC327086 Released Spring Energy Hazard SAFETY ...

Page 37: ...ressure in the hydraulic system before loosening any hydraulic fittings If you are injured seek emergency medical help IMMEDIATE surgery is required to remove hydraulic fluid which has penetrated the skin 1003331 Figure 1 23 MAC220799 MAC220799 Loss of control hazard WARNING To prevent serious injury or death from loss of control Ensure that the tow bar lock mechanism is locked 1019658 Figure 1 24...

Page 38: ...e key before opening the shield Do NOT operate without shields in place 1031144 Figure 1 26 MAC311493 MAC311493 Reel Crushing Hazard DANGER To prevent injury from the fall of a raised reel fully raise the reel Stop the engine and remove the key and engage the mechanical safety lock on each reel support arm before working on or under the reel SAFETY ...

Page 39: ...op the engine and remove the key from the ignition before servicing adjusting lubricating cleaning or unplugging the machine Engage the safety locks to prevent lowering of raised unit before servicing in the raised position Use a slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law To prevent injury or death from fall of a raised header Fully r...

Page 40: ...event injury from entanglement with the rotating reel stand clear of the header while the machine is running To prevent injury from the fall of the raised reel fully raise the reel stop the engine remove the key and engage the mechanical safety lock on each reel support arm before working on or under the reel SAFETY ...

Page 41: ...ring operation Keep riders off of the machine Keep all shields in place and stay clear of moving parts Disengage the header drive put the transmission in Neutral and wait for all movement to stop before leaving the operator s position Stop the engine and remove the key from the ignition before servicing adjusting lubricating cleaning or unplugging the machine Engage safety locks to prevent the low...

Page 42: ... prevent injury or death from the fall of a raised header Fully raise the header stop the engine remove the key and engage the mechanical safety locks on the combine before going under the header Alternatively rest the header on the ground stop the engine and remove the key before servicing SAFETY ...

Page 43: ...uring operation Keep riders off of the machine Keep all shields in place and stay clear of moving parts Disengage the header drive put the transmission in Neutral and wait for all movement to stop before leaving the operator s position Stop the engine and remove the key from the ignition before servicing adjusting lubricating cleaning or unplugging the machine Engage the safety locks to prevent lo...

Page 44: ...longer has counterweight and becomes energized Do NOT attempt to pry adjustment handle out of a position slot before releasing tension from the assist springs 1032194 Figure 1 33 MAC327588 MAC327588 Hitch damage hazard DANGER To prevent serious injury or death Remove the left contour wheel before transporting the header with transport Do NOT tow a header if the transport hitch is damaged SAFETY ...

Page 45: ...aces or components are making contact with each other and the fitting has been tightened by hand to a point where the fitting is no longer loose and cannot be tightened further by hand FM200 The float module used with an FD2 Series FlexDraper header for combining FSI Float setting indicator GVW Gross vehicle weight Hard joint A joint made with use of a fastener where joining materials are highly i...

Page 46: ...ns N or pounds lb This term can also be used to describe the force a belt exerts on a pulley or sprocket TFFT Turns from finger tight Torque The product of a force the length of a lever arm usually measured in Newton meters Nm or foot pounds lbf ft Torque angle A tightening procedure in which a fitting is assembled to a specified tightness usually finger tight and then the nut is turned farther by...

Page 47: ... model S Knife Single knife drive FD225 FD240 hydraulic motor mounted to enclosed heavy duty MacDon knife drive box on the left side of header OF Double knife drive FD235 FD250 one hydraulic motor untimed one mounted to enclosed heavy duty MacDon knife drive box on each side of header OF Knife stroke 76 mm 3 in S Single knife speed strokes per minute FD225 and FD235 1200 1400 spm S Single knife sp...

Page 48: ...6 Skid Shoes S Guard Angle Cutterbar on the Ground Center link retracted 1 7 degrees S Center link extended 8 9 degrees S Draper and Decks Draper width 1 27 m 50 in S Draper drive Hydraulic S Draper speed FM200 Float Module controlled 209 m min 687 fpm S Delivery opening width 1905 mm 75 in S PR15 Pick Up Reel Quantity of tine tubes 5 or 6 Center tube diameter 203 mm 8 in S Finger tip radius Facto...

Page 49: ... Width 2 m 78 11 16 in S Feed draper Speed 107 122 m min 350 400 fpm S Feed auger Width 1 630 m 64 1 8 in S Feed auger Outside diameter 559 mm 22 in S Feed auger Tube diameter 356 mm 14 in S Feed auger Speed varies with combine model 191 195 rpm varies with combine model S Oil reservoir capacity 95 liters 25 US gallons S Oil type Single grade transmission hydraulic fluid THF THF viscosity at 40 C ...

Page 50: ...329 3447 kg 7331 7597 lb FD230 North America 3701 3743 kg 8160 8253 lb FD235 North America 3901 4036 kg 8600 8898 lb FD240 North America 4050 4315 kg 8928 9512 lb FD241 Export 4 287 4 340 kg 9 452 9 569 lb FD245 North America 4 498 4 555 kg 9 916 10 043 lb Export 4 635 4 692 kg 10 218 10 345 lb FD250 North America 4693 4756 kg 10 346 10 485 lb Export 4 853 4 916 kg 10 699 10 838 PRODUCT OVERVIEW ...

Page 51: ... transport position with FM200 installed shortest center link A Gearbox rotated storage dividers removed refer to 2 1 page 27 2 6 m 103 in Header width in transport position with FM200 installed shortest center link B Gearbox operational standard dividers installed refer to 2 1 page 27 3 5 m 138 in Header width in transport position with reel fully retracted and FM200 installed shortest center lin...

Page 52: ...d maintenance instructions provided in this manual 1032262 A B C D E F G H J K L M Figure 2 2 FD2 Series FlexDraper Header Components A Wing Float Linkage B Center Reel Arm C Reel Fore Aft Cylinder D Endshield E Reel Lift Cylinder F Knife Drive Box inside endshield G Side Draper H Center Reel Drive J Pick up Reel K Reel Endshield L Crop Divider M Header Light except Europe PRODUCT OVERVIEW ...

Page 53: ... make it easier to follow the operation and maintenance instructions provided in this manual 1029303 A B B C D E F G G H J Figure 2 3 Header Side of FM200 Float Module A Feed Auger B Header Float Springs x4 C Center Link D Hydraulic Reservoir E Main Gearbox F Completion Gearbox G Header Support Arms x2 H Feed Draper J Driveline PRODUCT OVERVIEW ...

Page 54: ...Module A Main Gearbox B Completion Gearbox C Reservoir Oil Level Sight Glass D Center Link E Header Height Control Indicator x2 F Bubble Level G Drain Plug x2 H Float Lock Handle x2 J Auto Header Height Control AHHC Sensor x2 K Hydraulic Filter L Knife Side Draper and Feed Draper Pump PRODUCT OVERVIEW ...

Page 55: ...he people around you Before allowing someone to operate the header for however short a time or distance make sure they have been instructed in its safe and proper use Review the manual and all safety related items with all Operators annually Be alert for other Operators not using recommended procedures or not following safety precautions Correct these mistakes immediately before an accident occurs...

Page 56: ...Be sure to keep transmission in gear when travelling downhill Never attempt to get on or off a moving machine Do NOT leave the operator s station while the engine is running To avoid bodily injury or death from the unexpected startup of a machine always stop the engine and remove the key before adjusting or removing plugged material from the machine Check for excessive vibration and unusual noises...

Page 57: ... To prevent damage to the reel support arms do NOT transport the header whilen the reel safety props are engaged Engaging Reel Safety Props Engage the reel safety props anytime you need to work around a raised reel When engaged the reel safety props prevent the reel from unexpectedly lowering Outer reel arms 1028195 A B Figure 3 3 Outer Right Arm 1 Raise reel to the maximum height 2 Lift up on saf...

Page 58: ...riple reel headers repeat the previous step on the center left arm 6 Lower the reel until the safety props contact the outer arm cylinder mounts and the center arm pins Disengaging Reel Safety Props To ensure the proper operation of the reel and header disengage the reel safety props once you have completed working on or around a raised reel Outer reel arms 1028195 A B Figure 3 6 Reel Safety Prop ...

Page 59: ...p on the center left arm 3 2 3 Header Endshields A hinged polyethylene endshield is fitted on each end of the header to protect critical drive components Opening Header Endshields The header endshields covers knife drive components hydraulic hoses electrical connections the header wrench the spare knife and the optional transport hitch To access the components you will need to open the endshield 1...

Page 60: ...ge safety latch B on hinge arm C to secure the shield in the fully open position Closing Header Endshields The header endshields covers knife drive components hydraulic hoses electrical connections the header wrench the spare knife and the optional transport hitch After accessing the components you will need to close the endshield 1028864 A B Figure 3 11 Left Header Endshield 1 If the endshield is...

Page 61: ...e two stage latch C with a firm push A B 1028858 Figure 3 14 Two Stage Latch IMPORTANT Check that the header endshield is locked Ensure bolt A is fully engaged on two stage latch B to prevent the header endshield from opening while operating the header If adjustment is required refer to Checking and Adjusting Header Endshields page 37 NOTE The header endshield is transparent in the illustration to...

Page 62: ...een header endshield B and endsheet C is 1 3 mm 0 04 0 12 in 1028840 A B Figure 3 16 Header Endshield Support Bracket 2 If adjustment is required adjust support bracket A as follows a Loosen bolts B b Move support bracket A up or down as required to achieve the correct clearance c Retighten the hardware OPERATION ...

Page 63: ...ont of the header endshield and support bracket B is 8 18 mm 0 3 0 7 in 1028857 A B B C C Figure 3 18 Left Header Endshield 4 If adjustment is required adjust the position of hinge arm A as follows a Loosen four nuts B b Slide brackets C and hinge arm A fore or aft as required to achieve the correct clearance c Retighten the hardware OPERATION ...

Page 64: ...on two stage latch B to prevent the header endshield from opening during operation NOTE The header endshield is shown transparent in the illustration 9 If adjustment is required loosen nuts D and slide bracket C up or down 10 Once complete tighten nuts D and check Steps 5 page 40 to 7 page 40 again Removing Header Endshields Remove the endshields when servicing the end shields 1028869 A B C C Figu...

Page 65: ...he header endshield For instructions refer to Closing Header Endshields page 36 NOTE Header endshields may expand or contract when subjected to large temperature changes The header endshield position can be adjusted to compensate for dimensional changes For instructions refer to Checking and Adjusting Header Endshields page 37 3 2 4 Reel Drive Cover The reel drive cover protects the reel drive com...

Page 66: ...he back plate 1029084 A B Figure 3 24 Upper Drive Cover 6 Unclip upper cover A from the lower cover at locations B and remove the upper cover Keep the two clips engaged on the lower cover 1028877 B A A Figure 3 25 Lower Drive Cover 7 If necessary remove lower cover B by removing three bolts A OPERATION ...

Page 67: ... stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and remove the key from the ignition 1028877 B A A Figure 3 26 Lower Drive Cover 2 Position lower drive cover B if previously removed onto the reel drive and secure with three bolts A 1028879 A B Figure 3 27 Upper Drive Cover 3 Position upper cover A onto the reel drive an...

Page 68: ... Flex Linkage Covers Remove the flex linkage covers to access the header wing balance mechanism or the hydraulic lines DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Lower the header fully 2 Shut down the engine and remove the key from the ignition 1034359 ...

Page 69: ...r outboard so that tab D extends beyond the slot 1034359 A C B Figure 3 31 Inboard Flex Linkage Cover Left Side 3 Secure flex linkage cover C with hair pin A and lynch pin B Removing Outboard Flex Linkage Covers Remove the flex linkage covers to access the header wing balance mechanism or the hydraulic lines DANGER To prevent injury or death from the unexpected start up of the machine always stop ...

Page 70: ... Cover 5 Remove linkage cover as follows a Remove screw A The nut is integrated into the hydraulic line clamp b Remove screw B and nut not shown The Nyloc nut fits into a hex shape spot in the hydraulic line clamp but it is removable c Remove screw C and hex nut d Lift cover away from wing lock handle Installing Outboard Flex Linkage Covers Flex linkage covers protect the header wing balance mecha...

Page 71: ...lush with manifold B ϭϬϯϵϳϬϵ A B C E D Figure 3 36 Outboard Linkage Cover Rear of Header 3 Secure the outboard linkage cover as follows a Install screw A and Nyloc nut B The nut fits into a hex shape indent in the hydraulic line clamp b Install screw C The nut is integrated into the bracket c Install screw D and hex nut E to secure the front of the cover to the bracket OPERATION ...

Page 72: ...Remove potentially hazardous objects from the machine and from the surrounding area Carry with you any protective clothing and personal safety devices that could be necessary through the day Do NOT take chances Personal safety devices that may be needed include a hard hat protective glasses or goggles heavy gloves a respirator or filter mask or wet weather gear Protect against noise Wear a suitabl...

Page 73: ...gating an unusual sound or attempting to correct a problem shut off the engine and remove the key from the ignition After attaching the header to the combine for the first time follow these steps 1 Operate the machine with the reels drapers and knives running slowly for five minutes Watch and listen FROM THE OPERATOR S SEAT for binding or interfering parts NOTE The reels and side drapers will not ...

Page 74: ...the engine and remove the key from the ignition before leaving the operator s seat for any reason To shut down the combine do the following 1 Park on level ground whenever possible 2 Lower the header fully 3 Place all controls in NEUTRAL or PARK 4 Disengage the header drive 5 Lower and fully retract the reel 6 Shut down the engine and remove the key from the ignition 7 Wait for the machine to stop...

Page 75: ... are clear of the machine before starting the engine or engaging any header drives For instructions refer to your combine operator s manual for identification of the following in cab controls Header engage disengage control Header height Header angle Ground speed Reel speed Reel height Reel fore aft position OPERATION ...

Page 76: ...evant procedure in this section Refer to the table below for information on the New Holland combine models that are compatible with this header Table 3 1 New Holland Combine Compatibility New Holland Combine Series Combine Model 920 940 960 970 980 CR 9020 9040 9060 9065 9070 9080 6090 7090 8080 8090 9090 6 80 6 90 7 90 8 90 9 90 10 90 840 860 870 880 CX 8070 8080 8090 8080 Elevation 8090 Elevatio...

Page 77: ...y to lift the header ensuring the feeder saddle is properly engaged in the float module frame 5 Shut down the engine and remove the key from the ignition 1001141 B C A D E Figure 3 41 Feeder House Locks 6 Lift lever A on the float module on the left side of the feeder house and push handle B on the combine to engage locks C on both sides of the feeder house 7 Push down on lever A so the slot in th...

Page 78: ...te on the combine Clean the mating surface of the coupler 13 Position coupler F onto the float module receptacle C and push handle E to engage the pins into the receptacle 14 Push handle E to closed position until lock button D snaps out 15 Remove combine connector G from the storage location on the combine and connect it to receptacle B Turn the collar on the connector to lock it in place 16 Remo...

Page 79: ...ehill Hillside Driveline MACB7180 MACB7181 or MACB7326 17 Pull driveline collar A back to release the driveline from the support bracket Remove the driveline from the support bracket 1001472 A Figure 3 45 Driveline and Output Shaft 18 Pull back the collar on the end of the driveline and push the driveline onto combine output shaft A until the collar locks OPERATION ...

Page 80: ...ht side of the header The float lock on the left side of the header is opposite Detaching Header from New Holland CR CX Combine The header will need to be physically disconnected from the combine and the hydraulic and electrical connections removed DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leavin...

Page 81: ...nsport Wheels page 122 IMPORTANT If stabilizer wheels are installed set the wheels to the storage or uppermost working position otherwise the header may tilt forward making reattachment difficult For instructions refer to Adjusting Stabilizer Wheels page 121 3 Engage the float locks by pulling each float lock handle A away from the float module and setting it in locked position B NOTE The illustra...

Page 82: ...ll Hillside Driveline MACB7180 MACB7181 or MACB7326 5 Store the driveline on driveline support bracket B by pulling back collar A on the driveline and fitting it onto support bracket B Release the collar so it locks into place on the bracket 1001503 C B A Figure 3 51 Float Module Connections 6 Push in lock button B and pull handle C to release multicoupler A OPERATION ...

Page 83: ...o the closed position until lock button B snaps out Close the cover 1001146 B A Figure 3 53 Combine Coupler 8 Position hydraulic quick coupler A onto storage plate B on the combine 1002536 A Figure 3 54 Float Module Connections 9 Remove electrical connector A from the float module OPERATION ...

Page 84: ...ical connector to the combine at location A 1016561 A Figure 3 56 Float Module Receptacles 11 Replace cover A on the float module receptacle 1001142 B A C Figure 3 57 Feeder House Locks 12 Lift lever A and pull and lower handle B to disengage feeder house float module lock C OPERATION ...

Page 85: ...eder deflectors Table 3 2 FM200 Feeder Kits for CR Model Combines Feeder House Size Feeder Kit Size Part Number 1250 1350 mm 49 65 in Narrow 200 mm 7 7 8 in MAC328082 328083 1100 mm 43 1 2 in and below Wide 325 mm 12 13 16 in MAC314690 314691 3 6 2 Attaching Header to Detaching Header from FM200 Float Module To attach the float module to or detach it from the header follow the relevant procedure T...

Page 86: ...on 1001215 Figure 3 59 Cutterbar Hazard WARNING Keep hands clear of the area between guards and knife at all times WARNING Wear heavy gloves when working around or handling knives 1031942 A B Figure 3 60 Center Link 1 Start the engine and then lower header 2 Increase clearance under the float module feed draper by tilting the header and fully extending cylinder A until indicator B is at position E...

Page 87: ...n the back of the float module frame remove bolts A to release the tension on trim springs B 9 Unhook trim springs B from spring tensioners C Allow the springs to hang on balance channel D 10 Reinstall the springs tensioner s onto the float module Secure with bolts A 11 Repeat on the opposite side 1013336 A B C Figure 3 64 Fillers 12 Remove two bolts A and fillers B from transition pan support ang...

Page 88: ... screw A 18 Repeat for the opposite side of the feed draper deck DANGER Ensure that all bystanders have cleared the area 19 Disengage the reel safety props start the engine lower the reel and fully raise the header 20 Stop the engine remove the key from the ignition and engage the combine safety props 1004592 A B Figure 3 66 Float Module Underside 21 Loosen nut and bolt A and disengage hook B from...

Page 89: ...clear of the bracket c Reinstall pin B on the bracket and secure with lynch pin A NOTE It may be necessary to raise or lower the feeder house to adjust the length of the center link and relieve excess load on the center link 1031961 A B Figure 3 70 Header Connections NOTE If on the ground Push reel fully forward to reduce oil loss If on transport Pull reel fully back 26 Disconnect electrical conne...

Page 90: ...unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason NOTE The transport wheels can be used to support the header For instructions refer to Adjusting EasyMove Transport Wheels page 122 1031996 A B Figure 3 71 Center Link 1 Prop up hydraulic center link A with a pin or equivalent tool at location B as shown 1...

Page 91: ...ulics to approximately align center link eye B with the hole in the header bracket 8 Shut down the engine and remove the key from the ignition 9 Remove lynch pin C and pull pin D partially out of the bracket NOTE Be careful when pulling out the pin there may be some washers on the pin to remove excessive play from the center link when installed 10 Remove the item used to prop up center link A ϭϬϯϵ...

Page 92: ...reposition hook B as shown to engage float module arm Tighten bolt and nut A 1033979 A B C D Figure 3 77 Trim Springs Left side 19 On the back of the float module frame remove bolts A and spring tensioners C 20 Hook trim springs B that are hang on balance channel D to spring tensioners C 21 Reinstall the springs tensioners onto the float module Tighten bolts A all the way 22 Repeat on the opposite...

Page 93: ... tube 1017134 A B C Figure 3 79 Float Module Latch 25 Use a 24 mm 15 16 in wrench on hex bolt C to rotate latch downwards and slightly raise the feed deck Install nut and bolt B to lock the latch position 26 Install screw A 27 Repeat for the opposite side of the feed draper deck 1013336 A B C Figure 3 80 Fillers 28 Install fillers B on transition pan support angle C using two bolts A NOTE Ensure t...

Page 94: ...rt DR on manifold red cable tie Case drain to port CD on manifold 31 Attach electrical connector C20C A 32 Check the float and confirm the header is level For instructions refer to the following 3 9 3 Header Float page 128 3 11 Leveling Header page 239 CAUTION Be sure all bystanders are clear of machine before starting engine or engaging any header drives 33 Start the combine and perform the follo...

Page 95: ...MacDon Dealer Refer to 5 Options and Attachments page 483 for descriptions of available items 3 7 2 Header Settings The following tables provide a guideline for setting up the header for various harvesting conditions and crops For information on the reel settings refer to 3 7 4 Reel Settings page 84 For information on configuring the FM200 auger refer to 3 8 1 FM200 Feed Auger Configurations page ...

Page 96: ... for lodged crop conditions middle or down for other crop conditions Crop Condition Divider Rods Draper Speed Setting 5 Header Angle 6 7 Reel Cam Reel Speed 8 Reel Position Upper Cross Auger Light Off 8 B C 4 10 15 6 or 7 Not required Normal On 7 A 2 10 6 or 7 Not required Heavy On 7 A 2 10 6 or 7 Recommended Lodged Off 7 D 3 or 4 5 10 4 or 5 Not required OPERATION 4 Stabilizer wheels are used to ...

Page 97: ...els As required Skid Shoe Position Not applicable Crop Condition Divider Rods Draper Speed Setting 5 Header Angle 6 7 Reel Cam Reel Speed 8 Reel Position Upper Cross Auger Light Off 8 A 4 10 15 6 or 7 Not required Normal On 7 A 2 10 6 or 7 Not required Heavy On 7 B C 2 10 6 or 7 Not required Lodged Off 7 B C 3 or 4 5 10 4 or 5 Not required OPERATION ...

Page 98: ...required Normal On 7 B C 2 10 6 or 7 Not required Heavy On 7 B C 2 10 6 or 7 Not required Lodged On 7 D 2 5 10 6 or 7 Not required OPERATION 9 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 10 Setting on FM200 draper control 11 Set header angle as shallow as possible setting A with center link and skid shoes whi...

Page 99: ...mmended Normal On 7 B C 2 10 6 or 7 Recommended Heavy On 7 B C 2 10 4 or 5 Recommended Lodged On 7 D 2 5 10 4 or 5 Recommended OPERATION 14 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 15 Setting on FM200 draper control 16 Set header angle as shallow as possible setting A with center link and skid shoes while ...

Page 100: ... 8 in Stabilizer Wheels 19 As required Skid Shoe Position Not applicable Crop Condition Divider Rods Draper Speed Setting 20 Header Angle 21 22 Reel Cam Reel Speed 23 Reel Position Upper Cross Auger Light On 7 A 2 5 10 6 or 7 Recommended Normal On 7 B C 2 10 6 or 7 Recommended Heavy On 8 B C 1 or 2 10 3 or 4 Recommended Lodged On 7 D 2 or 3 5 10 3 or 4 Recommended OPERATION 19 Stabilizer wheels ar...

Page 101: ... Condition Divider Rods 25 Draper Speed Setting 26 Header Angle 27 28 Reel Cam Reel Speed 29 Reel Position Upper Cross Auger Light Rice divider rod 4 D 3 10 15 6 or 7 Not required Normal Rice divider rod 4 B C 3 10 6 or 7 Not required Heavy Rice divider rod 4 B C 3 10 6 or 7 Not required Lodged Rice divider rod 4 D 4 5 10 6 or 7 Not required OPERATION 24 Stabilizer wheels are used to limit the sid...

Page 102: ...MAC215986 78 Revision A Table 3 7 Recommended FD2 Series FM200 Draper Header Settings for California Rice continued OPERATION ...

Page 103: ...oe Position Not applicable Crop Condition Divider Rods 25 Draper Speed Setting 26 Header Angle 27 28 Reel Cam Reel Speed 29 Reel Position Upper Cross Auger Light Rice divider rod 4 A 3 10 15 6 or 7 Not required Normal Rice divider rod 4 B C 3 10 6 or 7 Not required Heavy Rice divider rod 4 B C 3 10 6 or 7 Not required Lodged Rice divider rod 4 D 4 5 10 6 or 7 Not required OPERATION ...

Page 104: ...quired Skid Shoe Position Not applicable Crop Condition Divider Rods Draper Speed Setting 31 Header Angle 32 33 Reel Cam Reel Speed 34 Reel Position Upper Cross Auger Light Off 6 A 2 or 3 10 15 6 or 7 Not required Normal Off 6 B C 2 or 3 10 6 or 7 Not required Heavy Off 6 B C 2 or 3 10 6 or 7 Not required Lodged Off 6 D 3 or 4 5 10 4 or 5 Not required OPERATION 30 Stabilizer wheels are used to lim...

Page 105: ... required Normal On 7 B C 2 10 6 or 7 Not required Heavy On 7 B C 2 10 6 or 7 Not required Lodged On 7 D 2 5 10 6 or 7 Not required OPERATION 35 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 36 Setting on FM200 draper control 37 Set header angle as shallow as possible setting A with center link and skid shoes w...

Page 106: ...r Light On 8 B C 2 5 10 6 or 7 Not required Normal On 7 A 2 10 6 or 7 Not required Heavy On 7 B C 2 10 6 or 7 Not required Lodged On 7 D 2 5 10 6 or 7 Not required OPERATION 40 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 41 Setting on FM200 draper control 42 Set header angle as shallow as possible setting A w...

Page 107: ...tension on the auger spring For instructions refer to 3 8 5 Checking and Adjusting Feed Auger Springs page 118 Set the reel speed so that it is equal to the combine s ground speed Increase the speed as needed For instructions refer to 3 9 6 Reel Speed page 154 Set the side draper speed to position six on in cab side draper speed control For instructions refer to 3 9 8 Side Draper Speed page 157 Ad...

Page 108: ...o learn how various combinations of reel position and cam setting affect the reel finger profile Table 3 11 FD2 Series Recommended Reel Settings Cam Setting Number Finger Speed Gain Reel Position Number Reel Finger Pattern 1 0 6 or 7 1001819 2 20 6 or 7 1001820 OPERATION ...

Page 109: ...ound while keeping material flowing onto drapers To leave the maximum amount of stubble in lodged crop raise the header and increase the header tilt to keep the reel close to the ground Position the reel fully forward The reel may have to be moved back to prevent lumps or plugging on the cutterbar in thinner crops Minimum crop carrying capacity the minimum area of exposed draper between the reel a...

Page 110: ...fer to the applicable stubble height table below Table 3 12 Stubble Height 50 mm to 125 mm 2 in to 5 in Header Angle45 Stubble Height Header Main Shoes DownStop Fore Aft Position Top Deflector Height Side Deflector Height Top Deflector Whisker A 125 mm 5 inch Down 2 1 1 C In Normal A 125 mm 5 inch Down 2 3 1 C In E 50 mm 2 inch Down 1 1 1 5 C In E 50 mm 2 inch Down 1 3 1 5 C In A 125 mm 5 inch Dow...

Page 111: ...2 4 2 C Out E 20 mm 3 4 inch MID 1 3 1 D Out E 20 mm 3 4 inch MID 1 4 2 D Out A 100 mm 4 inch MID 2 3 4 3 D Out Severely Lodged A 100 mm 4 inch MID 2 3 5 4 D Out E 20 mm 3 4 inch MID 1 4 3 C Out E 20 mm 3 4 inch MID 1 5 4 C Out Table 3 14 Stubble Height 16 mm to 50 mm 5 8 in to 2 in Cutterbar on Ground Header Angle45 Stubble Height Header Main Shoes DownStop Fore Aft Position Top Deflector Height ...

Page 112: ...oes DownStop Fore Aft Position Top Deflector Height Side Deflector Height Top Deflector Whisker Lodged A 50 mm 2 inch Up 3 4 1 C Out E 16 mm 5 8 inch Up 1 3 4 2 D Out E 16 mm 5 8 inch Up 1 3 4 2 D Out A 50 mm 2 inch Up 2 3 4 3 D Out Severely Lodged A 50 mm 2 inch Up 2 3 5 4 D Out E 16 mm 5 8 inch Up 1 4 2 5 C Out E 16 mm 5 8 inch Up 1 5 4 C Out OPERATION ...

Page 113: ...1024961 A B Figure 3 82 Ultra Narrow Configuration Rear View A 760 mm 29 15 16 in B 602 mm 23 11 16 in NOTE Dimensions A and B are the same for both ends of the auger They should be within 15 mm 9 16 in of the numbers given NOTE You will need to drill holes in the flighting and in the drum to install the extra flighting For more information on converting to Ultra Narrow configuration refer to Ultr...

Page 114: ...rting to Medium configuration refer to Medium Configuration Auger Flighting page 98 Wide configuration The wide configuration uses 2 short bolt on flightings 1 on the left and 1 on the right and 30 feed auger fingers 1021136 A B Figure 3 85 Wide Configuration Rear View A 257 mm 10 1 8 in B 257 mm 10 1 8 in NOTE Dimensions A and B are the same for both ends of the auger They should be within 15 mm ...

Page 115: ...his configuration may improve feeding for wide feeder house combines For more information on converting to Ultra Wide configuration refer to Ultra Wide Configuration Auger Flighting page 103 Ultra Narrow Configuration Auger Flighting Ultra Narrow configuration uses eight long bolt on flightings four on the left and four on the right and 18 auger fingers are recommended NOTE You will need to drill ...

Page 116: ...nfiguration 3 Ultra Narrow Configuration To convert to Ultra Narrow configuration from Medium Wide or Ultra Wide configuration Two flighting kits MAC357234 or MACB734546 and some hole drilling is required to convert to this configuration You will need to replace existing short flightings A 47 with long flightings B Add or remove auger fingers as necessary to optimize feeding for your combine and c...

Page 117: ... 1034027 A A Figure 3 90 Ultra Wide Configuration NOTE If converting from Ultra Wide configuration there is no existing bolt on flighting to remove because that configuration uses only the factory welded flighting A OPERATION ...

Page 118: ...D M10 Center Lock Flange Nut MAC135799 E Drilled Holes 11 mm 7 16 in 48 F M10 x 20 mm Button Head Bolt MAC135723 49 G M10 x 20 mm Flange Head Bolt MAC152655 50 OPERATION 48 Each of the four additional flightings require six drilled holes to install four in the auger and two in the adjacent flighting 49 Used on the holes drilled in the existing flighting 50 Used on the holes drilled in the auger ...

Page 119: ...A A 1 2 Figure 3 93 Auger Configurations Rear View 1 Ultra Narrow Configuration 2 Narrow Configuration To convert to Narrow configuration from Ultra Narrow Configuration Remove four flightings A from the auger and install additional auger fingers A total of 18 auger fingers is recommended for this configuration For flighting removal instructions refer to Removing Bolt On Flighting page 105 For fin...

Page 120: ...ct hardware in the correct location to prevent damage and to maximize performance For flighting replacement instructions refer to Removing Bolt On Flighting page 105 and Installing Bolt On Flighting page 107 For finger removal instructions refer to 3 8 2 Removing Feed Auger Fingers page 112 1034027 A A Figure 3 95 Ultra Wide Configuration NOTE If converting from Ultra Wide configuration there is n...

Page 121: ... Revision A 1035110 A B B C D Figure 3 96 Narrow Configuration A Left Long Flighting MAC287889 B Right Long Flighting MAC287890 C M10 x 20 mm Carriage Bolt MAC136178 D M10 Center Lock Flange Nut MAC135799 OPERATION ...

Page 122: ...Configuration To convert to Medium configuration from Wide configuration One flighting kit MAC357233 or MACB734453 is required You will need to install new flightings A and remove the extra auger fingers A total of 22 auger fingers is recommended for this configuration For flighting installation instructions refer to Installing Bolt On Flighting page 107 For finger removal instructions refer to 3 ...

Page 123: ...nstalling Bolt On Flighting page 107 For finger installation instructions refer to 3 8 3 Installing Feed Auger Fingers page 114 1034027 A A Figure 3 100 Ultra Wide Configuration To convert to Medium configuration from Ultra Wide configuration Two flighting kits MAC357233 or MACB734453 are required You will need to install four short flightings onto the existing welded flightings A and remove the e...

Page 124: ... x 20 mm Carriage Bolt MAC136178 D M10 Center Lock Flange Nut MAC135799 Wide Configuration Auger Flighting Wide configuration uses two short bolt on flightings one on the left and one on the right and 30 auger fingers are recommended NOTE This configuration may increase combine capacity on wide feeder house combines in certain crop conditions OPERATION ...

Page 125: ...ration 2 Wide Configuration To convert to Wide configuration from Medium Configuration Remove existing flightings A from the auger and install additional auger fingers A total of 30 auger fingers is recommended for this configuration For flighting removal instructions refer to Removing Bolt On Flighting page 105 For finger installation instructions refer to 3 8 3 Installing Feed Auger Fingers page...

Page 126: ... Narrow Configuration 3 Wide Configuration To convert to Wide configuration from Narrow or Ultra Narrow configuration One flighting kit MAC357233 or MACB734455 is required You will need to replace existing long flightings A 56 with short flightings B and install additional auger fingers A total of 30 auger fingers is recommended for this configuration For flighting replacement instructions refer t...

Page 127: ...10 Center Lock Flange Nut MAC135799 Ultra Wide Configuration Auger Flighting Ultra Wide configuration uses no bolt on flighting only factory welded flighting is responsible for conveying the crop A total of 30 auger fingers is recommended for this configuration NOTE This configuration may increase combine capacity on wide feeder house combines in certain crop conditions OPERATION ...

Page 128: ...n 3 Narrow Configuration To convert to Ultra Wide configuration Remove all existing bolt on flightings A from the auger and install additional auger fingers if required A total of 30 auger fingers is recommended for this configuration For flighting removal instructions refer to Removing Bolt On Flighting page 105 For finger installation instructions refer to 3 8 3 Installing Feed Auger Fingers pag...

Page 129: ...lighting configurations refer to 3 8 1 FM200 Feed Auger Configurations page 89 To remove bolt on flighting follow these steps 1 To improve access to the feed auger remove the float module from the combine B 1033992 A Figure 3 109 Auger Access Cover Right Side 2 Rotate the auger as needed NOTE The illustrations in this procedure show the feed auger separated from the float module for clarity The pr...

Page 130: ...tall slot plug A with M6 bolt B and tee nut C at each location from which the flighting was removed Torque to 9 Nm 80 lbf in NOTE If the plug bolts are NOT new coat them with medium strength threadlocker Loctite 243 or equivalent prior to installation A 1033998 Figure 3 113 Short Flighting Left Side 6 Repeat this procedure to remove flighting A from the left side of the auger OPERATION ...

Page 131: ...f flighting required For information on the different flighting configurations refer to 3 8 1 FM200 Feed Auger Configurations page 89 To install bolt on flighting follow these steps 1 To improve access to the feed auger and ease installation remove the float module from the combine 1035120 B A Figure 3 115 Auger Access Cover Right Side 2 Rotate the auger as needed NOTE The illustrations in this pr...

Page 132: ...35118 A B Figure 3 118 Short Flighting Right Side 6 Install flighting A using M10 x 20 mm square neck carriage bolts and center lock nuts at locations B IMPORTANT The bolt heads must be installed on the inside of the auger to prevent damage to the auger s internal components IMPORTANT The bolts that attach the flightings to each other must have the bolt heads on the inboard crop side of the flight...

Page 133: ...resent If desired use silicone sealant to fill the gaps 1033991 A B Figure 3 121 Access Cover Right Side 9 Reinstall access cover s A using retained bolts B and the welded nuts inside the auger Coat bolts with medium strength threadlocker Loctite 243 or equivalent and torque to 9 Nm 80 lbf in 10 If converting to Ultra Narrow configuration and drilling is required to install the remaining flighting...

Page 134: ...ve access to the feed auger and ease installation remove the float module from the combine 1034011 A B C Figure 3 123 Left Side of Auger 2 Rotate the auger as needed NOTE The illustrations in this procedure show the feed auger separated from the float module for clarity This procedure can be performed with the feed auger installed in the float module 3 Place new flighting A outboard of existing fl...

Page 135: ...4012 A B C Figure 3 125 Left Side of Auger 9 Place new flighting A into position on the auger outboard of existing flighting B 10 Secure with two M10 x 20 mm button head bolts and center lock nuts C IMPORTANT Ensure the bolt heads are on the inboard side crop side and the nuts are on the outboard side of the flighting 1017333 A Figure 3 126 Flighting Stretched Axially 11 Stretch flighting A to fit...

Page 136: ... desired use silicone sealant to fill any gaps 18 Add or remove auger fingers as necessary to optimize feeding for your combine and crop conditions For instructions refer to 3 8 2 Removing Feed Auger Fingers page 112 or 3 8 3 Installing Feed Auger Fingers page 114 19 If you are not adding or removing auger fingers reinstall all access covers Coat the retained bolts with medium strength threadlocke...

Page 137: ...cess cover B closest to the finger you are removing Retain parts for reinstallation 1033303 B D C A Figure 3 130 Auger Finger 6 Remove finger as follows a Remove hairpin A Pull finger B out of finger holder C b Push finger B through guide D and into the drum Pull the finger out of the drum access hole NOTE If the finger is broken remove any remnants from holder C and from inside the drum 1017301 A...

Page 138: ...g bolts A apply medium strength threadlocker Loctite 243 or equivalent before installation 3 8 3 Installing Feed Auger Fingers The feed auger uses fingers to bring crop into the feeder house The quantity of fingers varies for the different models of combines DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key b...

Page 139: ...he finger by inserting hairpin D into the holder Make sure the round end the S shaped side of the hairpin faces the chain drive side of the auger Make sure the closed end of the hairpin points in the direction of auger forward rotation IMPORTANT Position the hairpin as described in this step to prevent the hairpin from falling out during operation If fingers are lost the header might not be able t...

Page 140: ... the auger is in the fixed position CAUTION Make sure left and right brackets are set to the same position two bolts A must be in the same location to prevent damage to the machine during operation DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine remove the key and engage the safety props before going under the header for any ...

Page 141: ...on bracket next to the fixed symbol NOTE If changing the auger position from fixed to floating move the arm in the opposite direction 7 Tighten bolt A to 122 Nm 90 lbf ft IMPORTANT Bolt A must be properly seated in the recess on the bracket before tightening the bolt If arm B can be moved after tightening the bolt then bolt A is not seated properly 8 Repeat on the opposite side IMPORTANT Bolt A on...

Page 142: ...instructions refer to the combine operator s manual 2 Raise the header fully 3 Shut down the engine and remove the key from the ignition 4 Engage the header safety props Refer to the combine operator s manual for instructions 1028401 A A Figure 3 141 Spring Tensioner 5 Check the thread length protruding past nut A The length should be 22 26 mm 7 8 1 in If adjustment is required follow these steps ...

Page 143: ... A stripper bar kit may have been supplied with your header Installing the stripper bar kit improves feeding in certain crops such as rice For information on removing and installing the stripper bars refer to 4 11 Stripper Bars page 395 OPERATION ...

Page 144: ... Fore Aft Position page 165 Reel tine pitch 3 9 12 Reel Tine Pitch page 178 Crop divider rods 3 9 14 Crop Dividers page 184 Feed auger configurations 3 8 1 FM200 Feed Auger Configurations page 89 3 9 1 Cutting off Ground The header s design allows you to cut crop above the ground which results in stubble being cut to a uniform height Follow these recommendations when configuring the header to cut ...

Page 145: ... stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Raise the header until the stabilizer wheels are off the ground 2 Shut down the engine and remove the key from the ignition 1032896 A B C Figure 3 143 Stabilizer Wheel 3 Hold axle pivot handle B do NOT lift NOTE Lifting the handle will make the system harder to take out from slot C 4 Pull susp...

Page 146: ...B 5 Pull suspension handle A rearward to remove pin from slot B 6 Adjust wheel to desired slot position 7 Suspension handle A should snap into slot If not push in for middle position or pull in for top position suspension handle to ensure it is seated into the slot 1032933 A B Figure 3 145 Left Wheel 8 Hold axle pivot handle A do NOT lift NOTE Lifting the handle will make the system harder to take...

Page 147: ...ill move regardless of the fore aft header tilt switch position 4 To ensure the hydraulic cylinders are properly phased press and hold the REEL AFT button on the combine multifunction handle to extend the wheels all the way down then hold the button for 30 seconds Press and hold the REEL FORE button on the combine multifunction handle to fully retract the wheels then hold the button for 30 seconds...

Page 148: ...machine stop engine remove key and engage lift cylinder lock out valves before going under machine for any reason WARNING Ensure that all bystanders have cleared the area NOTE The header float must be set before leveling the ContourMax For instructions refer to Checking and Adjusting Header Float page 129 NOTE The wing balance must be set before leveling the ContourMax For instructions refer to 3 ...

Page 149: ...e center guard and record the measurement 10 At each end of the header measure the distance A from the ground to the tip of the end guard and record both of the measurements If the difference between the end measurements and the center measurement is less than 25 mm 1 in no adjustment is required If the difference between the end measurements and the center measurement is greater than 25 mm 1 in a...

Page 150: ...wered and the cutterbar on the ground The orientation of the knife and knife guards relative to the ground header angle is controlled by the skid shoes and the center link it is NOT controlled by the header lift cylinders The skid shoes center link and flex lockout allow you to adjust to field conditions and maximize the amount of material cut while reducing damage to the knife caused by stones an...

Page 151: ...tion using the machine s header angle controls If the header angle is not critical set it to the mid position 11 Check the header float For instructions refer to 3 9 3 Header Float page 128 Adjusting Outer Skid Shoes The skid shoes and center link allow you to adjust to field conditions and maximize the amount of material cut while reducing damage to the knife caused by stones and debris DANGER To...

Page 152: ...r Left Side Header float is indicated on the float indicator A Values 0 to 4 represent the force of the cutterbar on the ground with 0 being the minimum and 4 being the maximum They also represent where the header is at in the float range 0 being the bottom end of the float range and 4 being the top end of the float range NOTE The indicator on the left side of the float module is for float indicat...

Page 153: ...t satisfactory the float will need to be inspected and adjusted IMPORTANT Do NOT use the float module springs to level the header Use the following guidelines when adjusting the float Set the header float as light as possible but not so light that the header bounces when the combine is moving This will help prevent knife breakage soil pushing soil build up at the cutterbar in wet conditions and ex...

Page 154: ... the ground 1028940 A Figure 3 156 Fore Aft Position 4 Adjust the reel fore aft position so that the indicator on left indicator bracket A is at position 6 1029058 A B Figure 3 157 Center Link 5 Adjust center link A so that indicator B is at position D on the gauge 6 Lower the reel fully 7 Shut down the engine and remove the key from the ignition 8 Lock the header wings For instructions refer to L...

Page 155: ...ll the float lock handle down and into position B UNLOCK 11 Repeat the previous step on the right side of the float module 12 Open the left endshield For instructions refer to Opening Header Endshields page 35 1028898 A B B Figure 3 159 Multi Tool Location 13 Remove hairpin A securing multi tool B to the bracket on the left endsheet 14 Remove multi tool B Replace the hairpin OPERATION ...

Page 156: ...with it injury can occur ϭϬϯϵϮϴϵ A B Figure 3 161 Left Float Setting Lever in Set Position 17 Pull multi tool B toward the back of the float module until float setting lever A is locked into place and will not return to its original position Remove the multi tool 18 Repeat Steps 15 page 132 to 17 page 132 to set the right float setting lever IMPORTANT BOTH the left and the right float setting leve...

Page 157: ...the float on the left side of the float module as needed To increase the float turn both left adjustment bolts A clockwise To decrease the float turn both left adjustment bolts A counterclockwise NOTE Each pair of bolts A must be adjusted by the same amount 24 Set the left float again Refer to Step 20 page 132 for instructions 25 Check the left FSI indicator again Refer to Step 21 page 133 for ins...

Page 158: ...fe header the spring should be placed in the front hole NOTE This procedure is not required for the FD241 double knife header the spring should be placed in the front hole 1 Shut down the engine and remove the key from the ignition 1035180 A B Figure 3 164 Left Float Spring Installed in Rear Float Lever Hole 2 Calculate the float spring configuration as follows a Determine the total header weight ...

Page 159: ...nt hole on the float lever FD245 double knife 3225 kg 7100 lb FD250 double knife 3400 kg 7500 lb B Dividers select one if installed Rice divider rods 20 kg 50 lb Vertical knives 185 kg 407 lb 57 C Optional Upper Cross Auger select one if installed58 9 1 m 30 ft two piece auger 142 kg 312 lb 10 7 m 35 ft two piece 156 kg 343 lb 12 2 m 40 ft three piece 168 kg 370 lb 12 5 m 41 ft two piece 163 kg 36...

Page 160: ...Back 3151 3515 kg 6901 7750 lb Front FD240 single knife 2800 3200 kg 6150 7000 lb Back 3201 3615 kg 7001 7950 lb Front FD240 double knife Use the front hole on the float lever FD241 double knife Use the front hole on the float lever FD245 double knife 3225 3475 kg 7100 7650 lb Back 3476 4050 kg 7651 8900 lb Front FD250 double knife 3400 3800 kg 7500 8350 lb Back 3801 4215 kg 8351 9300 lb Front 102...

Page 161: ... and rotating spring locks B forward 5 Loosen adjustment bolts A equally until the springs are loose NOTE The adjustment bolts will rise slightly above the washers when the springs are loose 1035183 A B C Figure 3 167 Left Float Spring Installed in Rear Float Lever Hole 6 Remove cotter pin C from pin A 7 Remove pin A and washers B OPERATION ...

Page 162: ...A or back B float lever hole according to the float requirements in Table 3 18 page 136 D 1035182 A B C Figure 3 169 Left Float Spring Installed in Rear Float Lever Hole 9 Install pin A with two washers B into the new hole 10 Secure the pin with cotter pin C 11 Repeat Step 6 page 137 to Step 10 page 138 for other spring D OPERATION ...

Page 163: ...ment bolts A an equal amount to ensure the float springs are the same length 13 Repeat Step 4 page 137 to Step 12 page 139 on the pair of float springs B on the opposite side of the float module 14 Check the float For instructions refer to Checking and Adjusting Header Float page 129 OPERATION ...

Page 164: ...this position the header is unlocked and can float with respect to the float module To engage lock the float locks push float lock handle A into position C In this position the header cannot move with respect to the float module Locking Unlocking Header Wings Locking the wings allows the FlexDraper header to be operated as a rigid header with the cutterbar straight Unlocking the wings allows the t...

Page 165: ... does not disengage proceed to Step 2 page 141 Open the left endshield For instructions refer to Opening Header Endshields page 35 1028898 A B B Figure 3 174 Left Endsheet 2 Remove hairpin A securing the multi tool to the holder bracket on the left endsheet 3 Remove multi tool B and reinstall the hairpin to the tool holder 1034099 A B Figure 3 175 Flex Checker Cable Lock Left Side 4 Attach flex ch...

Page 166: ... Figure 3 177 Flex Checker Cable Lock Left Side 6 Detach flex checker cable A from flex checker cable lock B NOTE Parts have been removed from the illustration for clarity 1028898 A B B Figure 3 178 Left Endsheet 7 Return multi tool B to its storage position and secure with hairpin A 8 Close the left endshield For instructions refer to Closing Header Endshields page 36 OPERATION ...

Page 167: ...disengage move the wing by raising and lowering the header changing the header angle or driving the combine until it disengages 3 If the lock still does not disengage continue to next step 4 Open the left endshield For instructions refer to Opening Header Endshields page 35 1028898 A B B Figure 3 180 Left Endsheet 5 Remove hairpin A securing the multi tool to bracket on the left endsheet 6 Remove ...

Page 168: ... Wing Balance page 148 1034362 A B C Figure 3 184 Wing Movement Indicator on Top of Flex Linkage Cover Left Side Shown NOTE With the header attached to a combine wings locked and straight lynch pin A should point to the center of indicator B If not calibrate the indicator by loosening bolts C that fasten to the shield and adjust the indicators position While harvesting with the wings unlocked the ...

Page 169: ...ing the header angle or driving the combine until it engages 3 If the lock still does not engage continue to Step 4 page 145 4 Remove the flex linkage cover For instructions refer to Removing Inboard Flex Linkage Covers page 44 1028898 A B B Figure 3 186 Left Endsheet 5 Remove hairpin A securing multi tool to the holder bracket on the left endsheet 6 Remove multi tool B from its storage location a...

Page 170: ...le to be as close and will require adjustment Refer to 4 13 1 Reel Clearance to Cutterbar page 417 for specifications 1 Park the combine on a level surface 2 Lock the header wings For instructions refer to Locking Unlocking Header Wings page 140 3 Extend the hydraulic center link fully 4 Lower the header fully 5 Shut down the engine and remove the key from the ignition 1029097 A B Figure 3 188 Fle...

Page 171: ...eel to cutterbar clearance will be to closer and should be adjusted Refer to 4 13 1 Reel Clearance to Cutterbar page 417 for specifications 1 Park the combine on a level surface 2 Lock the header wings For instructions refer to Locking Unlocking Header Wings page 140 3 Lower the header fully 4 Extend the hydraulic center link fully 5 Shut down the engine and remove the key from the ignition 102929...

Page 172: ... balance readings make sure the header float is set properly before proceeding For instructions refer to Checking and Adjusting Header Float page 129 The float module must be sitting level before performing any adjustments NOTE The header wings are balanced when it takes an equal amount of force to move a wing up or down 1009084 A B Figure 3 192 Wing Imbalance If a header wing has a tendency to be...

Page 173: ...ff the ground 1029208 A Figure 3 195 Spirit Level 7 Locate spirit level A on top of the float module frame Ensure that the bubble is in the center If adjustment is required refer to 3 11 Leveling Header page 239 8 Shut down the engine and remove the key from the ignition 9 Remove the linkage cover For instructions refer to Removing Inboard Flex Linkage Covers page 44 1034099 A B Figure 3 196 Flex ...

Page 174: ... position Unlock ONLY the wing you are checking Ensure the opposite wing is locked NOTE There should be an audible click when you move the spring handle indicating that the internal mechanism engaged or disengaged 15 If the internal lock mechanism does not engage move the wing with multi tool B until you hear an audible click 1032839 B A x2 x2 Figure 3 199 Checker Plate Assembly 16 Ensure float ch...

Page 175: ...Wing Balance Adjustment Left Side Shown 21 Interpret the reading on the flex checker plate as follows If the wing is too light A make it heavier by turning adjuster bolt D to move clevis E in direction F Recheck the wing balance Adjust as required until wing is balanced C and then proceed to the next step If the wing is too heavy B make it lighter by turning adjuster bolt D to move clevis E in dir...

Page 176: ...cking and Adjusting Header Float page 129 28 If the cutterbar is not straight when the wings are in lock mode then further adjustments are required Contact your MacDon Dealer 3 9 5 Header Angle Header angle is adjustable to accommodate different crop conditions and or soil types and can be adjusted using the center link between the combine and the header Refer to Adjusting Header Angle from Combin...

Page 177: ...ize damage to the knife in stony fields b Use steeper settings E position E on the indicator for lodged crops and crops that are close to the ground such as soybeans 1032676 A E Figure 3 206 Guard Angles Shallowest angle A center link fully retracted is at 1 7 and produces the highest stubble when cutting on the ground Steepest angle E center link fully extended is at 8 9 and produces the lowest s...

Page 178: ... to tilt the header back shallower angle 1024039 1024039 1024040 A B C Figure 3 208 New Holland CR CX Controls 3 9 6 Reel Speed Reel speed is one of the factors that determines how crop is moved from the cutterbar onto the drapers The reel performs best when it appears to be driven by the ground It should move the cut crop evenly through the cutterbar and onto the drapers without bunching and with...

Page 179: ...ctory installed single sprocket The header is factory equipped with a 19 tooth reel drive single sprocket which is suitable for most crops Replacing the 19 tooth reel drive single sprocket with optional dual reel drive sprocket A will provide more torque to the reel in heavy cutting conditions With the optional dual reel drive sprocket installed an optional 52 tooth sprocket B can also be added on...

Page 180: ...t plants Start at 4 8 5 8 km h 3 0 3 5 mph and adjust the speed as needed Higher ground speeds may require heavier float settings to prevent excessive bouncing which can result in uneven cutting and possible damage to the cutting components If ground speed is increased draper and reel speeds should generally be increased to handle the extra material Figure 3 210 page 156 illustrates the relationsh...

Page 181: ...s it into the combine The speed is adjustable to suit a variety of crops and crop conditions A 1006122 Figure 3 211 Side Drapers Side drapers A are driven by hydraulic motors and a pump that is powered by the combine feeder house drive through a gearbox on the float module Side draper speed is adjustable in cab on the side draper speed control which regulates the flow to the draper hydraulic motor...

Page 182: ...lic motor and a pump that is powered by the combine feeder house drive through a gearbox on the float module The feed draper speed is determined by the combine feeder house speed and cannot be independently adjusted 3 9 9 Knife Speed Information The float module is driven by a driveline that is attached to the combine feeder house The driveline attaches to a gearbox that drives the knife drive pum...

Page 183: ...revent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and remove the key from the ignition 2 Open the endshield For instructions refer to Opening Header Endshields page 35 DANGER Ensure that all bystanders have cleared the area 3 Start the engine For ins...

Page 184: ... normal cutting conditions 9 Contact your MacDon Dealer if the pulley rpm measurement exceeds the specified rpm range for your header 3 9 10 Reel Height The reel operating position depends on the type of crop and cutting conditions Set the reel height and fore aft position to carry material past the knife and onto the drapers with minimal damage to the crop The reel height is controlled manually o...

Page 185: ...nt fingers contacting the knife or the ground For instructions refer to 4 13 1 Reel Clearance to Cutterbar page 417 Checking and Adjusting Reel Height Sensor The orientation of the reel height sensor arm must be checked manually at the sensor and the output voltage range of the sensor can be checked either manually at the sensor or from inside the cab IMPORTANT Ensure the minimum reel height is pr...

Page 186: ...n Sensor and Sensor Arm 4 Check that sensor arm C and pointer D are configured properly for your machine refer to Figure 3 217 page 162 NOTE In configuration A the arrow indicates that the pointed end of the sensor arm is pointed toward the back of the header In configuration B the arrow indicates that the pointed end of the sensor arm is pointed toward the front of the header 5 If the sensor arm ...

Page 187: ...from the ignition ϭϬϯϴϱϮϲ C A B D E Figure 3 218 Reel Height Sensor Right Reel Arm with Reel Down 11 Using a voltmeter measure the voltage between the ground pin 2 wire and the signal pin 3 wire at reel height sensor B 12 Check if the voltage is within the recommended voltage range If the voltage is not within range loosen jam nuts D and E and adjust the rod length Hand tighten the jam nuts and th...

Page 188: ...eel fully 21 Recheck the voltage range and ensure it is still within the range specified Adjust if required Replacing Reel Height Sensor The reel height sensor is used to reference where the reel is positioned above from the cutterbar DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before making adjust...

Page 189: ... For instructions refer to Checking and Adjusting Reel Height Sensor page 161 3 9 11 Reel Fore Aft Position Reel fore aft position is a critical factor for achieving the best results in adverse conditions The factory recommended reel position has the position marker centered over numbers 4 5 on the indicator This suits normal conditions but the fore aft position can be adjusted as required using t...

Page 190: ...sted as required using the controls inside the cab To adjust the reel fore aft position follow these steps 1 Select FORE AFT mode on the selector switch in the cab 1028230 A B Figure 3 224 Fore Aft Indicator 2 Operate the hydraulics to move the reel to the desired position while using fore aft indicator A as a reference Bracket B is the position marker 3 Check the reel clearance to cutterbar after...

Page 191: ...ition 1028898 A B B Figure 3 225 Left Endsheet 3 Remove hairpin A securing multi tool to holder bracket on left endsheet 4 Remove multi tool B and reinstall hairpin to holder Reposition the outer right cylinder as follows 1031715 A B Figure 3 226 Right Arm Cylinder Forward Position 1 Remove split ring A clevis pin B and flat washer securing the right fore aft cylinder in the forward position OPERA...

Page 192: ...B rotates on bottom pin E 1031720 A B Figure 3 228 Right Arm Cylinder Aft Position 3 When the bracket holes are lined up secure in aft position with clevis pin A washer and split ring B Reposition the outer left cylinder as follows 1031725 A B C Figure 3 229 Left Arm Cylinder Forward Position 1 Remove split ring A and clevis pin B securing the left cylinder in forward position on cylinder bracket ...

Page 193: ...or adjustment procedures refer to 3 9 12 Reel Tine Pitch page 178 Repositioning Fore Aft Cylinders Double Reel The reel can be moved approximately 155 mm 6 in farther aft by repositioning the fore aft cylinders on the reel arms This may be desirable when straight combining canola DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key...

Page 194: ...TE There are two center cylinders on triple reel headers 1031711 A B Figure 3 233 Center Arm Cylinder Forward Position 5 Remove split ring A clevis pin B and the washer securing the center fore aft cylinder in the forward position 1031712 A B C D E Figure 3 234 Center Arm Cylinder Forward Position 6 Use multi tool A to push bracket B rearward until hole C aligns with hole D The reel will move rear...

Page 195: ...ght cylinder 1031715 A B Figure 3 236 Right Arm Cylinder Forward Position 1 Remove split ring A clevis pin B and flat washer securing the right fore aft cylinder in the forward position 1031719 A B C D E Figure 3 237 Right Arm Cylinder Forward Position 2 Use multi tool A to push bracket B rearward until hole C aligns with hole D The reel will move rearward as bracket B rotates on bottom pin E OPER...

Page 196: ...nd split ring B Repositioning the outer left cylinder 1031725 A B C Figure 3 239 Left Arm Cylinder Forward Position 1 Remove split ring A and clevis pin B securing the left cylinder in forward position on cylinder bracket C 1031726 A B Figure 3 240 Left Arm Cylinder Forward Position 2 Slide cylinder guides A along the bracket slot and into aft position B OPERATION ...

Page 197: ...sitioning the fore aft cylinders on the reel arms This may be desirable when straight combining canola DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason IMPORTANT Ensure all fore aft cylinders are set to the same position 1 Position the reel fully aft with the s...

Page 198: ...fore aft cylinder in the forward position 1031712 A B C D E Figure 3 244 Center Left Arm Cylinder Forward Position 6 Use multi tool A to push bracket B rearward until hole C aligns with hole D The reel will move rearward as bracket B rotates on bottom pin E 1031713 A B Figure 3 245 Center Left Arm Cylinder Aft Position 7 Secure the center left cylinder in the aft position with clevis pin A and spl...

Page 199: ...gure 3 247 Outer Left Arm Cylinder Forward Position 2 Slide cylinder guides A along the bracket slot and into aft position B 1031727 A B C Figure 3 248 Outer Left Arm Cylinder Aft Position 3 Reinstall clevis pin A and split ring B to secure the cylinder in aft position C on the bracket 4 Ensure clearance between reel and backsheet upper cross auger if installed and reel braces 5 For recommended re...

Page 200: ...move the key from the ignition before leaving the operator s seat for any reason 1 Park the combine on a level surface 2 Shut down the engine and remove the key from the ignition 3 Check the orientation of sensor arm C and hardware D Ensure that the sensor arm is configured properly for your machine refer to Figure 3 249 page 176 1033353 A B C C D D Figure 3 249 Sensor Arm Configurations A Incorre...

Page 201: ...uld be 62 72 mm 2 4 2 8 in 1032694 A 1 2 3 Figure 3 251 Fore Aft Sensor 8 Use the combine display or a voltmeter if measuring the sensor manually to measure the voltage range If using a voltmeter check sensor A voltage between pin 2 ground and pin 3 signal The range should be For Case and New Holland combines 0 7 1 1 V 9 Shut down the engine and remove the key from the ignition 1032693 A B Figure ...

Page 202: ...e visible above the slots on the cam disc For instructions refer to Adjusting Reel Cam page 180 NOTE For the recommended reel tine pitch setting to use in various harvesting conditions refer to 3 7 2 Header Settings page 71 1001819 Figure 3 253 Finger Profile Position 1 Cam Position 1 Reel Position 6 or 7 delivers the most even crop flow onto the drapers without fluffing or disturbing the material...

Page 203: ... than the reel speed 1001822 Figure 3 257 Finger Profile Position 4 Cam Position 4 Header Angle at Maximum and Reel Fully Forward provides the maximum amount of reel reach below the cutterbar to pick up lodged crops This position leaves a significant amount of stubble when the cutting height is set to approximately 203 mm 8 in In damp materials such as rice it is possible to double the combine s g...

Page 204: ...gine and remove the key from the ignition 1028898 A B B Figure 3 258 Left Endsheet 2 Remove hairpin A securing multi tool B to bracket on the left endsheet 1036838 A B C Figure 3 259 Cam Disc Positions 3 Turn latch pin A COUNTERCLOCKWISE using multi tool to release the cam disc IMPORTANT Refer to the cam latch decal for the locking unlocking rotation direction Forcing the cam latch in the wrong di...

Page 205: ...that allows the auger position to be adjusted for different harvesting conditions Headers with three piece augers have two adjustable mounts one on each end of the center auger NOTE For information on the positions of the primary and secondary front bolts refer to Figure 3 263 page 182 1029776 A B Figure 3 261 Initial Position of Adjustable Mounts Two Piece Auger The mount s are initially installe...

Page 206: ... the UCA from interfering with the feed auger and the header frame IMPORTANT When the front bolt is in one of secondary positions B and the reel is in its rear most position the reel fingers and cam arms may contact the UCA When the reel is moved fully back for example when harvesting canola the UCA must also be moved fully back in order to allow for sufficient clearance between the reel fingers a...

Page 207: ...enough to allow the adjustable mount to slide 4 Move the mount to the desired position 5 Retighten nuts A and B Torque the nuts to 69 Nm 51 lbf ft 6 If a three piece UCA is installed repeat this procedure on the second adjustable mount IMPORTANT On headers with three piece augers ensure that both mounts are in the same position 7 Check for interference between the reel fingers and the UCA Check fo...

Page 208: ...justing Upper Cross Auger Position page 181 3 9 14 Crop Dividers Crop dividers are used to separate the crop when harvesting They are removable to allow the installation of vertical knives or the sunflower attachment and to decrease transport width Standard crop dividers are provided with all headers Optional floating crop dividers may also be purchased Refer to 5 1 4 Floating Crop Dividers page 4...

Page 209: ...vider latch C forward to disengage it from bolt D 1029302 A Figure 3 267 Crop Divider with Latch 8 Lower crop divider A and remove it from the endsheet 9 Close the endshield For instructions refer to Closing Header Endshields page 36 1029353 A B Figure 3 268 Optional Crop Divider Storage 10 If installed place crop divider A onto optional storage position on bracket B 11 If not installed place crop...

Page 210: ...rom the ignition 5 Engage the header safety props Refer to the combine operator s manual for instructions 1029352 A B C Figure 3 269 Optional Crop Divider 6 If optional storage bracket is installed Remove crop divider A from storage position by lifting the crop divider so that bolt B clears the slot in storage bracket C 7 If not installed retrieve crop dividers from where they were stored 8 Open t...

Page 211: ...o Closing Header Endshields page 36 Removing Floating Crop Dividers Floating crop dividers can be removed to allow installation of other attachments or the standard crop dividers DANGER To avoid bodily injury or death from unexpected start up or fall of a raised machine always stop the engine and remove the key from the ignition before making adjustments to the machine If it is impossible to engag...

Page 212: ...dsheet 7 Remove lynch pin B 8 Install multi tool A onto hex shaft C 9 Rotate the multi tool downwards until latch D releases from bolt E 10 Lift latch D up and off bolt E ϭϬϯϴϮϳϳ A Figure 3 274 Latch Released 11 Tilt the crop divider forward and pull it out of the header 12 Reinstall lynch pin A 13 Close the endshield OPERATION ...

Page 213: ...k the header NEVER climb onto or go underneath an unsupported header 1 Start the engine For instructions refer to the combine operator s manual 2 Lower the reel fully 3 Raise the header 60 90 cm 2 3 ft off the ground 4 Shut down the engine and remove the key from the ignition 5 Open the endshield 1032632 D A C E B F Figure 3 275 Crop Divider Installed 6 Remove lynch pin A from quick latch B 7 Atta...

Page 214: ...A Figure 3 276 Crop Divider Installation 9 Insert crop divider lugs A into the slots in the header frame ϭϬϯϴϮϱϯ A B Figure 3 277 Quick Latch 10 Lift the forward end of quick latch A and rotate crop divider B up into position OPERATION ...

Page 215: ...shaft C to close the latch 14 Retighten nut A 15 Attach multi tool D onto hex shaft C and rotate the multi tool to lock the latch 16 Install lynch pin E to secure the quick latch in place 17 Repeat Step 6 page 189 to Step 16 page 191 at the opposite end of the header to install the opposite crop divider 18 Close the endshield For instructions refer to Closing Header Endshields page 36 19 Check the...

Page 216: ... climb onto or go underneath an unsupported header 1 Start the engine For instructions refer to the combine operator s manual 2 Lower the reel fully 3 Raise the header 60 90 cm 2 3 ft off the ground 4 Shut down the engine and remove the key from the ignition 5 Refer to the chart according to the stubble height range and reel configuration Field with a stubble height of 50 125 mm 2 5 in Refer to St...

Page 217: ...own stop does NOT contact the reel supports or the reel For instructions refer to Step 9 page 196 to Step 15 page 198 Stubble Height Header Angle 61 Header Skid Shoes Down Stop Nose Cone Fore Aft Position Top Deflector Height Side Deflector Height Top Deflector Side Rod Standing Crop 125 mm 5 in A Down 2 1 or 3 1 C In 50 mm 2 in E Down 1 1 or 3 1 5 C In Lodged 125 mm 5 in A Down 2 3 or 4 1 C Out 5...

Page 218: ... or the reel For instructions refer to Step 9 page 196 to Step 15 page 198 Stubble Height Header Angle 63 Header Skid Shoes Down Stop Nose Cone Fore Aft Position Top Deflector Height Side Deflector Height Top Deflector Side Rod Standing Crop 100 mm 4 in A Middle 2 1 or 3 1 C In 20 mm 3 4 in E Middle 1 1 or 3 1 C In Lodged 100 mm 4 in A Middle 2 3 1 C Out 100 mm 4 in A Middle 2 4 2 C Out 20 mm 3 4 ...

Page 219: ...oes NOT contact the reel supports or the reel For instructions refer to Step 9 page 196 to Step 15 page 198 Stubble Height Header Angle 65 Header Skid Shoes Down Stop Nose Cone Fore Aft Position Top Deflector Height Side Deflector Height Top Deflector Side Rod Standing Crop 50 mm 2 in A Up 2 1 or 3 1 C In 16 mm 5 8 in E Up 1 1 2 C In 16 mm 5 8 in E Up 1 3 1 C In Lodged 50 mm 2 in A Up 2 3 1 C Out ...

Page 220: ... install the clevis pin into a numbered hole 1 to 3 Secure the clevis pin with the lynch pin ϭϬϯϴϮϯϵ A B C Figure 3 281 Nose Cone Fore aft Adjustment 11 Nose cone fore aft Remove bolt A move the tube in or out and install the bolt into one of the five tube holes NOTE In example B the bolt is installed in tube hole 1 In example C the bolt is installed in tube hole 5 OPERATION ...

Page 221: ...ting 1 to 4 5 and tighten the nuts Align the dots with the support to set half increments Example B is 2 5 Align the number with the support to set full increments Example C is 2 ϭϬϯϴϮϰϲ B A A B Figure 3 283 Side Deflector Height Adjustment 13 Side deflector height Loose the nuts on bolts A slide deflectors until notch B is at the desired setting A to E and tighten nuts OPERATION ...

Page 222: ...C outward or inward Tighten nut A to 39 Nm 29 lbf ft Tighten bolt B to 52 Nm 38 lbf ft Figure 3 285 Floating Crop Divider Range of Motion A A ϭϬϯϴϯϯϴ B C 15 Range of motion check Lift and lower the floating crop divider through the range of motion A set by the down stop Confirm the floating divider does NOT contact reel supports B or reel C OPERATION ...

Page 223: ...With Divider Rods Without Divider Rods Alfalfa Lodged cereal Edible beans Canola Peas Milo Flax Soybeans Rice Grass seed Sudan grass Soybeans Lentils Winter forage Standing cereal Removing Crop Divider Rods Crop divider rods can be removed from the ends of the crop dividers and stored on the header 1029244 A B Figure 3 286 Crop Divider Rod 1 Loosen bolt B and remove crop divider rod A from both si...

Page 224: ... Storage Location at Right Header Endsheet 2 Undo lynch pin A securing divider rods B to the header endsheet and remove the divider rods from the storage location 3 Reinstall lynch pin A 1029244 A B Figure 3 289 Divider Rod on Crop Divider 4 Position crop divider rod A on the tip of the crop divider as shown and tighten bolt B 5 Repeat the procedure at the opposite end of the header 6 Close the ri...

Page 225: ... Rice Rice divider rods provide improved performance in tall and tangled rice crops For more bundle information refer to 5 1 6 Rice Divider Rod Kit page 486 1029355 A B Figure 3 291 Rice Divider Rod Storage Rice divider rods are stored at the rear of both endsheets on storage bracket A and secured in place with pin B The installation and removal of these rods are the same as the procedures for sta...

Page 226: ...ndicators on the float module These sensors send signals to the combine allowing it to maintain a consistent cutting height and an optimum float as the header follows ground contours 1031564 A Figure 3 292 FM200 Float Module To configure the AHHC system for your specific combine model refer to the relevant procedure 3 10 6 New Holland Combines CR CX Series 2014 and Prior page 210 3 10 7 New Hollan...

Page 227: ...aise and lower the feeder house to maintain a consistent cutting height and optimum float Normal operating signal voltages for the sensors fall between 10 0 5 VDC and 90 4 5 VDC An increase in sensor voltage correlates to an increase in header height Any sensor error results in a 0 V signal which indicates either a faulty sensor or lack of supply voltage Before using the AHHC feature you must do t...

Page 228: ... Sensor Range too Close to the High Voltage Limit A High Voltage B Low Voltage C Sensor Operating Range A sensor that is adjusted too close to the high voltage or low voltage limit will have difficulty staying within the sensor s operating range of 0 5 4 5 V If the sensor moves out of range the AHHC will stop functioning correctly 1028309 2 5V Min 4 5V Max A B C Figure 3 296 Sensor Range too Narro...

Page 229: ... function properly the voltage needs to be set properly NOTE Some combines can check the voltages from the cab For instructions refer to the instructions for your combine DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Start the engine For instructions refer...

Page 230: ...ignition 1029102 A Figure 3 299 Down Stop Washer 7 Check that the float lock linkage is on the down stops washer A cannot be moved at both locations NOTE If the header is NOT on its down stops the voltage may go out of range during operation causing a malfunction of the AHHC system If the header is not on down stops refer to 3 11 Leveling Header page 239 for instructions OPERATION ...

Page 231: ... pins 1 and 8 and right sensor pins 3 and 8 For voltage Refer to 3 10 2 Sensor Output Voltage Range Combine Requirements page 205 Pin 1 FM3326A left sensor signal Pin 3 FM3328A right sensor signal Pin 8 FM2515E ground NOTE If the standard plug is installed in P600 the plug sends the average of both sensors to the combine If the optional lateral tilt plug is installed then the plug sends separate v...

Page 232: ...l tilt plug is installed then the plug sends separate voltage signals from both sensors to the combine 3 10 4 Replacing Float Height Sensor Two magnetic sensors are installed on the float setting indicators As the header follows ground contours the sensors communicate with the combine causing it to raise and lower the feeder house to maintain a consistent cutting height and optimum float DANGER To...

Page 233: ...Sensor 8 Remove two bolts and nuts A 9 Remove and discard old sensor B 10 Install new sensor B with the plug facing down 11 Install two bolts and nuts A NOTE Bolt heads should be on the same side as the decal 1032143 A B C Figure 3 305 Float Setting Indicator Left 12 Install indicator plate B complete with the sensor 13 Install bolt A 14 Connect harness plug C 15 Check the voltage range For instru...

Page 234: ...bines you must set your combine s header configuration options for the particular model of header configure the reel speed settings set up the AHHC controls and calibrate the AHHC system to ensure that it is working correctly This section applies only to pre 2015 CR CX models Checking Voltage Range from Combine Cab New Holland CR CX Series The auto header height control AHHC sensor needs to operat...

Page 235: ...n stops during the next two steps the voltage may go out of range during operation causing a malfunction of the AHHC system If the header is not on the down stops refer to 3 11 Leveling Header page 239 for instructions 1031914 A B C D Figure 3 308 Float Indicator 4 If the pointer is not on zero loosen bolt A and slide float indicator plate B until pointer C is on 0 D 5 Tighten bolt A OPERATION ...

Page 236: ...OSTICS A on the main page The DIAGNOSTICS page appears 8 Select SETTINGS The SETTINGS page appears 1003673 A Figure 3 310 New Holland Combine Display 9 Select GROUP drop down menu A The GROUP dialog box appears 1003674 A Figure 3 311 New Holland Combine Display 10 Select HEADER HEIGHT TILT A The PARAMETER page appears OPERATION ...

Page 237: ... Holland CR series combine header setup and calibration procedures Table 3 31 Header Settings New Holland CR Series Setup Parameter Suggested Setting Cutting type Platform Header sub type 80 90 Autofloat Installed Auto header lift Installed Manual HHC raise lower rate Set for best performance HHC height sensitivity Set for best performance HHC tilt sensitivity Set for best performance Reel height ...

Page 238: ...ontrol AHHC sensor output must be calibrated for each combine or the AHHC feature will not work properly DANGER Ensure that all bystanders have cleared the area NOTE Changes may have been made to the combine controls or the display since this document was published Refer to the combine operator s manual for the most up to date information NOTE For New Holland CR models 6 80 6 90 7 90 8 90 9 90 and...

Page 239: ... lateral float buttons are NOT pressed The ESC key is NOT pressed To calibrate the AHHC follow these steps 1 Select CALIBRATION on the combine display and press the RIGHT ARROW navigation key to enter the information box 1003605 A Figure 3 315 New Holland Combine Display 2 Select HEADER A and press ENTER The CALIBRATION dialog box opens NOTE You can use the up and down navigation keys to move betw...

Page 240: ...ounter will start and stop counting harvested area NOTE Changes may have been made to the combine controls or the display since this document was published Refer to the combine operator s manual for the most up to date information IMPORTANT If the value is set too low the area counter may NOT be accurate since the header is sometimes raised above this threshold although the combine is still cuttin...

Page 241: ...an be adjusted NOTE Changes may have been made to the combine controls or the display since this document was published Refer to the combine operator s manual for the most up to date information NOTE For New Holland CR models 6 80 6 90 7 90 8 90 9 90 and 10 90 refer to 3 10 7 New Holland Combines CR Series 2015 and Later page 220 1003628 Figure 3 319 New Holland Combine Display 1 Select HEADER RAI...

Page 242: ... the cutterbar must travel up or down before the auto header height control AHHC reacts and raises or lowers the feeder house When the sensitivity is set to maximum only small changes in ground height are needed to cause the feeder house to raise or lower When the sensitivity is set to minimum large changes in the ground height are needed to cause the feeder house to raise or lower NOTE Changes ma...

Page 243: ...ne controls or the display since this document was published Refer to the combine operator s manual for the most up to date information NOTE For New Holland CR models 6 80 6 90 7 90 8 90 9 90 and 10 90 refer to 3 10 7 New Holland Combines CR Series 2015 and Later page 220 1031919 C A B D Figure 3 322 Float Indicator NOTE Indicator A should be at position 0 B with the header 254 356 mm 10 14 in off...

Page 244: ...TERAL FLOAT rocker switch A slow up down to raise or lower header to the desired value Lightly press AUTOMATIC HEADER HEIGHT CONTROL button B for a minimum of 2 seconds to store the new height position A beep confirms setting NOTE Fully pressing AUTOMATIC HEADER HEIGHT CONTROL button B will disengage float mode NOTE It is not necessary to press rocker switch C again after changing header height se...

Page 245: ... Lock 3 Check that the float lock linkage is on the down stops washer A cannot be moved at both locations NOTE If the header is not on the down stops during the next two steps the voltage may go out of range during operation causing a malfunction of the auto header height control AHHC system If the header is not on the down stops refer to 3 11 Leveling Header page 239 for instructions 1031914 A B ...

Page 246: ... The DIAGNOSTICS page appears 1016050 A Figure 3 328 New Holland Combine Display 8 Select SETTINGS A The SETTINGS page appears 1016053 A B Figure 3 329 New Holland Combine Display 9 Select HEADER HEIGHT TILT A from the GROUP drop down menu 10 Select HEADER HEIGHT SENS L B from the PARAMETER drop down menu OPERATION ...

Page 247: ...tup and calibration are complete adjust the center link back to desired header angle NOTE Changes may have been made to the combine controls or the display since this document was published Refer to the combine operator s manual for the most up to date information NOTE This section applies only to 2015 and later CR models 6 80 6 90 7 90 8 90 9 90 and 10 90 For other pre 2015 New Holland combine mo...

Page 248: ...der type from DEFAULT to 80 90 at the main menu This is now a dealer setting If you need to change the dealer setting contact your MacDon Dealer 1016105 A B C Figure 3 333 New Holland Combine Display 6 Select HEAD 1 A The HEADER SETUP 1 page displays 7 Select CUTTING TYPE drop down arrow B and change the CUTTING TYPE to PLATFORM C ϭϬϯϴϱϲϬ A Figure 3 334 New Holland Combine Display 8 Select HEADER ...

Page 249: ...wn menu and set AUTO HEADER LIFT to INSTALLED B NOTE With AUTO HEADER LIFT installed and AHHC engaged the header will lift up automatically when you pull back on the control handle 12 Set the values for MANUAL HHC RAISE RATE C and MANUAL HHC LOWER RATE D for best performance according to ground conditions 1016147 A B Figure 3 337 New Holland Combine Display 13 Set the values for HHC HEIGHT SENSITI...

Page 250: ...this document was published Refer to the combine operator s manual for the most up to date information NOTE This section applies only to 2015 and later CR models 6 80 6 90 7 90 8 90 9 90 and 10 90 1 Shut down the engine 2 Turn the key to the run position 3 Make sure the combine display software is updated to these versions or later Model year 2015 2018 UCM v38 10 0 0 Model year 2019 UCM v1 4 0 0 1...

Page 251: ...ACEMENT PER REVOLUTION C and enter the appropriate value according to the reel drive configuration according to Table Table 3 32 Reel Displacement per Revolution Chart Drive Sprocket Size Number of Teeth Driven Sprocket Size Number of Teeth Reel Displacement Per Revolution 19 standard 56 769 14 high torque low speed 67 56 1044 20 low torque high speed 68 52 679 Calibrating Auto Header Height Contr...

Page 252: ...ader height control AHHC system perform the ground calibration with the center link set to D When calibration is complete adjust the center link back to the desired header angle For instructions refer to 3 9 5 Header Angle page 152 Check the following conditions before starting the header calibration procedure The header is attached to the combine The combine is on level ground with the header lev...

Page 253: ...ure 3 345 New Holland Combine Display 4 Follow the calibration steps in the order in which they appear on the page As you proceed through the calibration process the display updates to show the next step NOTE Pressing the ESC key during any of the steps or letting the system sit idle for more than 3 minutes stops the calibration procedure NOTE Refer to your combine operator s manual for an explana...

Page 254: ...reel height sensor and the reel fore aft sensor DANGER Ensure that all bystanders have cleared the area NOTE Changes may have been made to the combine controls or the display since this document was published Refer to the combine operator s manual for the most up to date information NOTE This section applies only to 2015 and later CR models 6 80 6 90 7 90 8 90 9 90 and 10 90 To calibrate the reel ...

Page 255: ... Display 3 Select CALIBRATION drop down menu A 1035153 A Figure 3 349 New Holland Combine Display 4 Select REEL POSITION A from the list of calibration options 1035155 A Figure 3 350 New Holland Combine Display 5 A CAUTION statement A will appear Press ENTER OPERATION ...

Page 256: ... sit idle for more than 3 minutes will cause the calibration procedure to stop NOTE Refer to your combine operator s manual for an explanation of any error codes 8 When all steps have been completed CALIBRATION COMPLETED message is displayed on the page Checking Reel Height Sensor Voltages New Holland CR Series Check the reel height sensor voltages to ensure they are within the prescribed range NO...

Page 257: ... view low voltage C The voltage should be 0 5 0 9 V Setting Preset Cutting Height New Holland CR Series The cut height setting can be stored in the combine When harvesting the setting can be selected from the control handle NOTE Changes may have been made to the combine controls or the display since this document was published Refer to the combine operator s manual for the most up to date informat...

Page 258: ...the separator and the header 2 Select preset button 1 A A yellow light on the button lights up 3 Raise or lower the header to the desired cutting height 1024067 C Figure 3 358 New Holland Combine Multifunction Handle 4 Hold RESUME button C on the multifunction handle to set the preset until the monitor beeps NOTE When setting presets always set the header position before setting the reel position ...

Page 259: ...1 Press one of the auto height preset buttons to select a preset cutting height Setting Maximum Work Height New Holland CR Series The maximum work height can be set using the combine display NOTE Changes may have been made to the combine controls or the display since this document was published Refer to the combine operator s manual for the most up to date information NOTE This section applies onl...

Page 260: ...HEIGHT field B 1016064 Figure 3 363 New Holland Combine Display 4 Set MAXIMUM WORK HEIGHT to the desired value 5 Press SET and then press ENTER Configuring Reel Fore Aft Header Tilt and Header Type New Holland CR Series The reel fore aft header tilt and header type settings for the auto header height control AHHC system can be changed by accessing the HEAD menus NOTE This procedure applies only to...

Page 261: ...ey to the run position 1015005 A B Figure 3 364 New Holland Combine Controls 3 Simultaneously press UNLOAD A and RESUME B buttons on the control handle 1015006 A Figure 3 365 New Holland Combine Display 4 On the HEAD 1 page change the CUTTING TYPE from FLEX to PLATFORM as shown at location A 1015007 A Figure 3 366 New Holland Combine Display 5 On the HEAD 2 page change HEADER SUB TYPE from DEFAULT...

Page 262: ...mbine Controls There are now two different buttons for the ON GROUND presets The toggle switch that was present on previous models is now configured as shown at right MacDon headers only require first two buttons A and B Third button down C is not configured OPERATION ...

Page 263: ... from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Park the combine on a level surface 2 Position the header so that the cutterbar is 254 356 mm 10 14 in off the ground 3 Shut down the engine and remove the key from the ignition 4 Lock the header wings For instructions refer to Locking Unlocki...

Page 264: ...her direction may adversely affect header float 1032848 A B Figure 3 370 Left Float Indicator 8 After adjusting the high side of the header reset float indicator needle A to zero by loosening the nut that secures bolt B and center the indicator needle on zero 1017045 A Figure 3 371 Bell Crank NOTE Ensure a minimum clearance of 2 3 mm 1 8 in A between the frame and the back of the bell crank lever ...

Page 265: ...nives IMPORTANT Lowering a rotating reel on a plugged cutterbar will damage the reel components To unplug the cutterbar reverse the combine feeder house If the cutterbar is still plugged do the following 1 Stop the forward movement of the machine and disengage the header drives 2 Raise the header to prevent it from filling with dirt and engage the header drive clutch 3 If the plug does NOT clear d...

Page 266: ...Stop the forward movement of the machine and disengage the header drives 2 Raise the header slightly off the ground and raise the reel 3 Reverse the combine feed according to the manufacturer specifications reverse feed varies among different combine models 4 Turn the side draper speed down to 0 5 Engage the header drive 6 Slowly increase the side draper speed to the previous settings once the plu...

Page 267: ... flashing amber lamps red tail lamps and head lamps are clean and working properly Pivot amber lamps for best visibility by approaching traffic Always use lamps when travelling on roads to provide adequate warning to other vehicles Do NOT use field lamps on roads they may confuse other drivers Before driving on a roadway clean slow moving vehicle signs and reflectors adjust rear view mirrors and c...

Page 268: ...porting Connect hitch to towing vehicle using a proper hitch pin with a spring locking pin or other suitable fastener Attach hitch safety chain to towing vehicle Adjust safety chain length to provide only enough slack to permit turning Connect header seven pole plug wiring harness to mating receptacle on towing vehicle The seven pole receptacle is available from your MacDon Dealer parts department...

Page 269: ...device to support the header be sure that the header is secure before proceeding 1 Start the engine 2 Raise the header fully 3 Shut down the engine and remove the key from the ignition 4 Engage the header safety props or support the header on blocks on level ground If using blocks to support the header ensure the header is approximately 914 mm 36 in off the ground 1034133 A B C D Figure 3 372 Left...

Page 270: ... Figure 3 375 Tow Bar Assembly 2 Disconnect electrical connector A and safety chain B from towing vehicle and store as shown 3 If removing a tow bar with an extension proceed to Step 4 page 246 If removing a tow bar without an extension proceed to Step 16 page 248 Removing tow bar installed with an extension 1032173 A B C Figure 3 376 Tow Bar Extension Harness 4 Disconnect tow bar harness A from e...

Page 271: ...le B to clear tow bar lug and then slowly lower assembly to the ground 8 Lift end of tow bar C and pull away from extension D 1031994 A B Figure 3 378 Tow Bar Electrical Connection 9 Unplug tow bar extension electrical harness A from left transport pivot harness B 1033034 D A B C Figure 3 379 Tow Bar Extension and Transport Pivot 10 Remove lynch pin A from transport pivot B 11 Push back on latch C...

Page 272: ... pin in left transport pivot for safe keeping 15 For tow bar storage refer to Storing Tow Bar page 249 Removing tow bar installed without an extension 1031994 A B Figure 3 381 Tow Bar Electrical Connection 16 Unplug tow bar extension electrical harness A from left transport pivot harness B 1033035 A B Figure 3 382 Tow Bar and Left Transport Pivot 17 Remove lynch pin A then push back on latch B to ...

Page 273: ...g Tow Bar Store the tow bar in the backtube when not in use Tow bar Extension 1031935 A B C D E Figure 3 384 Tow Bar Extension Storage 1 Insert tube end B of tow bar extension A onto pin C 2 Rotate tow bar extension to cradle D NOTE To prevent tow bar extension from shaking loose ensure extension bar engages groove in bracket E 1031978 A B Figure 3 385 Tow Bar Extension Storage 3 Secure tow bar ex...

Page 274: ...dure explains how to move the wheels to the highest storage position but you may wish to use a lower position depending on whether or not you want the wheels to support the header during field operations This procedure assumes that the tow bar has been removed DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine remove the key and...

Page 275: ... the direction shown 1036103 A B C Figure 3 389 Left Transport Wheels Rotation Lock Latch Disengaged 6 Remove lynch pin A Pull handle B to engage latch C this will prevent the transport wheel assembly from rotating 1036107 A B Figure 3 390 Left Transport Wheels Rotation Lock Latch Engaged 7 Secure latch B with lynch pin A OPERATION ...

Page 276: ... been removed from the illustration for clarity 1036115 A B Figure 3 393 Left Transport Wheel Pivot Pin in Highest Storage Position 10 Ensure that pin A is visible at the highest storage position in plate B Moving Rear Right Wheels into Field Position The rear right transport wheels can be converted from transport to field storage position with a few simple steps This procedure demonstrates how to...

Page 277: ...blocks to support the header so that the transport wheels are 51 102 mm 2 4 in off the ground 3 Shut down the engine and remove the key from the ignition 4 Engage the header s safety props For instructions refer to the combine operator s manual 1034034 A B C Figure 3 394 Right Transport Axle Latched in Transport Position 5 On the right transport axle remove lynch pin A from the right transport axl...

Page 278: ...d to Transport Position Option The header needs to be converted to the transport when being towed to a new location Moving Left Outboard Wheel From Working to Transport Position The left outboard wheel need to be moved to the transport position before the header can be towed DANGER To avoid bodily injury or death from unexpected startup or fall of raised header stop the engine remove the key and e...

Page 279: ...nt bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine remove the key and engage the safety props before going under the header for any reason CAUTION Stand clear of the wheels and release the linkage carefully the wheels will drop suddenly once the mechanism is released 1 Start the engine 2 Raise the header fully 3 Shut down the engine and remove...

Page 280: ...xle pivot handle B until transport position is reached 1029289 A Figure 3 401 Gauge Wheel 6 Secure left transport pivot by pushing pivot handle A forward until latch is engaged 7 Pull back on pivot handle to verify that latch is fully engaged 1029290 A B Figure 3 402 Gauge Wheel 8 Remove clevis pin A securing latch 9 Push pivot handle B up to unlock wheel assembly OPERATION ...

Page 281: ...ty props before going under the header for any reason CAUTION Stand clear of the wheels and release the linkage carefully the wheels will drop suddenly once the mechanism is released 1 Fully raise the skid shoe at the right transport axle For instructions refer to Adjusting Inner Skid Shoes page 126 1032236 A B Figure 3 404 Gauge Wheels 2 Adjust gauge wheel height to transport position lowest slot...

Page 282: ... B to unlock 1032244 A B C Figure 3 406 Right Field Support 5 Lift wheel handle A to remove right transport axle B from right field support C then lower right transport axle to the ground 1032247 A Figure 3 407 Right Transport Axle 6 Use wheel handle and rotate right transport axle A under the header frame OPERATION ...

Page 283: ...3 409 Tow Bar Extension in Storage 1 Remove strap A from cradle B to free tow bar extension C 2 Rotate tow bar extension to unlock from pin D 3 Lift tow bar extension away C from pin D Tow Bar 1029081 A C B Figure 3 410 Tow Bar in Storage 4 Open left endshield For instructions refer to Opening Header Endshields page 35 5 Pull tow bar forward until it hits the stop Lift the tow bar to free clevis s...

Page 284: ...d to Step 4 page 260 If installing tow bar only proceed to Step 18 page 262 Installing tow bar and extension 1032185 D A B C E Figure 3 412 Tow Bar Extension to Left Transport Pivot 4 Remove lynch pin A from left transport pivot B 5 Push extension D into lugs of left transport pivot until latch C engages 6 Reinstall lynch pin A to transport pivot to secure extension 7 Retrieve the end of extension...

Page 285: ...storage location 1032173 A B C Figure 3 415 Tow Bar Extension Harness 13 Connect tow bar harness A to extension harness B 14 Reinstall lynch pin C to latch to secure tow bar 1032172 A B Figure 3 416 Tow Bar Wiring Harness 15 Retrieve tow bar wiring harness A and safety chain B from storage location 16 Connect tow bar wiring harness to vehicle and secure safety chain from tow bar to tow vehicle 17 ...

Page 286: ...w bar 21 Retrieve the end of tow bar harness E 1031994 A B Figure 3 418 Tow Bar Electrical Connection 22 Connect extension wiring harness A to left transport pivot harness B 1032172 A B Figure 3 419 Tow Bar Wiring Harness 23 Retrieve tow bar wiring harness A and safety chain B from storage location 24 Connect tow bar wiring harness to vehicle and secure safety chain from tow bar to tow vehicle 25 ...

Page 287: ... The weight of water and snow accumulation puts significant stress on the drapers and the header frame 3 Lower the header onto blocks to keep the cutterbar off of the ground 4 Lower the reel completely If the header will be stored outdoors tie the reel to the frame to prevent rotation caused by the wind 5 Repaint all worn or chipped painted surfaces to prevent rust from forming 6 Loosen the drive ...

Page 288: ......

Page 289: ...rd page 266 to keep track of your scheduled maintenance 4 1 Preparing Machine for Servicing Observe all safety precautions before beginning service on the machine DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going under the mach...

Page 290: ...tructions refer to 4 1 Preparing Machine for Servicing page 265 and 1 Safety page 1 4 2 1 Maintenance Schedule Record Recording maintenance allows the user to keep track of when maintenance is performed Action ü Check S Lubricate p Change Hour meter reading Service date Serviced by First Use Refer to 4 2 2 Break In Inspection page 269 End of Season Refer to 4 2 4 Equipment Servicing End of Season ...

Page 291: ...age 368 p Header drive main gearbox lubricant first 50 hours only refer to Changing Oil in Header Drive Main Gearbox page 287 p Header drive completion gearbox lubricant first 50 hours only refer to Changing Oil in Header Drive Completion Gearbox page 290 100 Hours or Annually Whichever Occurs First ü Auger to pan and feed draper clearance refer to 4 7 1 Adjusting Feed Auger to Pan Clearance page ...

Page 292: ...ours page 280 p Hydraulic oil filter refer to 4 4 4 Changing Oil Filter page 294 500 Hours or Annually Whichever Occurs First S Gauge wheel slow speed transport wheel bearings refer to Every 500 Hours page 282 S Contour wheel hub refer to 4 15 2 Lubricating Contour Wheel System page 466 ü Header drive main gearbox chain tension refer to 4 6 5 Adjusting Chain Tension Main Gearbox page 305 ü Header ...

Page 293: ...un up and after the hydraulic hoses have filled with oil 4 4 1 Checking Oil Level in Hydraulic Reservoir page 292 5 Hours Check for loose hardware and tighten to required torque 7 1 Torque Specifications page 515 10 Hours Check auger drive chain tension Checking Feed Auger Drive Chain Tension Thorough Method page 312 10 Hours Check knife drive box mounting bolts Checking Mounting Bolts page 368 10...

Page 294: ...over the cutterbar and the knife guards to prevent injury from accidental contact 1 Clean the header thoroughly 2 Store the header in a dry protected place if possible If storing the header outdoors always cover the machine with a waterproof canvas or other protective material NOTE If storing the machine outdoors remove the drapers and store them in a dark dry place If not removing the drapers sto...

Page 295: ...urs by a doctor familiar with this type of injury or gangrene may result 1001205 Figure 4 2 Testing for Hydraulic Leaks Use a piece of cardboard or paper to search for leaks IMPORTANT Keep hydraulic coupler tips and connectors clean Allowing dust dirt water or foreign material to enter the system is the major cause of hydraulic system damage Do NOT attempt to service hydraulic systems in the field...

Page 296: ...rms of hours of header operation Maintaining accurate maintenance records is the best way to ensure these procedures are performed in a timely fashion Every 10 Hours Daily maintenance is required to keep your machine operating at peak performance It also allows you to do a visual inspection of the machine that may help identify issues early Use high temperature extreme pressure EP2 performance gre...

Page 297: ...mperature extreme pressure EP2 performance grease with 1 max molybdenum disulphide NLGI Grade 2 lithium base unless otherwise specified 1028971 A Figure 4 6 Knifehead Lubricate knifehead A every 25 hours Check for signs of excessive heating on the first few guards after greasing If required relieve the pressure by pressing the check ball in the grease fitting IMPORTANT Overgreasing the knifehead p...

Page 298: ...tify issues early ϭϬϯϴϳϳϬ A A Figure 4 7 Reel A Reel Drive Chain To lubricate refer to 4 3 3 Lubricating Reel Drive Chain page 284 IMPORTANT Use chain oil that has a viscosity of 100 150 sCt at 40 C typically medium to heavy chain oil or mineral oil Sae 20W50 that has no detergents or solvents NOTE If chain is dry at next oiling interval decrease the oiling interval MAINTENANCE AND SERVICING ...

Page 299: ... B B Figure 4 8 Two Piece Upper Cross Auger A Upper Cross Auger U joints Two Places B Upper Cross Auger Sliding Hubs Two Places C Upper Cross Auger Center Bearings Two Places D Right End Bearing IMPORTANT The Upper Cross Auger must be greased regularly even when turned off as components of the UCA move when the header flexes regardless of whether the auger is turning or not MAINTENANCE AND SERVICI...

Page 300: ...s Two Places B Upper Cross Auger Sliding Hubs Two Places C Upper Cross Auger Center Bearings Two Places D Right End Bearing IMPORTANT The Upper Cross Auger must be greased regularly even when turned off as components of the UCA move when the header flexes regardless of whether the auger is turning or not MAINTENANCE AND SERVICING ...

Page 301: ...032021 A B Figure 4 11 FM200 A Remote Grease Line for Auger Pivot Right Side B Remote Grease Line for Auger Pivot Left Side C Auger Pivot Left Side D Auger Pivot Right Side MAINTENANCE AND SERVICING 70 Use high temperature extreme pressure EP2 performance grease with 10 max molybdenum disulphide NLGI Grade 2 lithium base ...

Page 302: ...help identify issues early Use high temperature extreme pressure EP2 performance grease with 1 max molybdenum disulphide NLGI Grade 2 lithium base unless otherwise specified 1029009 B C A A A B B C Figure 4 12 FM200 A Driveline Guards Both Ends B Float Pivots Right and Left C Auger Drive Chain To lubricate refer to 4 3 4 Lubricating Auger Drive Chain page 285 MAINTENANCE AND SERVICING ...

Page 303: ...ating Header Drive Main Gearbox page 286 B Completion Gearbox Oil Level To lubricate refer to 4 3 6 Lubricating Header Drive Completion Gearbox page 288 ϭϬϯϴϳϳϭ A A Figure 4 14 Knife Drive Box B Knife Drive Box Oil Level To lubricate refer to Checking Oil Level in Knife Drive Box page 367 MAINTENANCE AND SERVICING ...

Page 304: ...tion of the machine that may help identify issues early Use high temperature extreme pressure EP2 performance grease with 1 max molybdenum disulphide NLGI Grade 2 lithium base unless otherwise specified 1029313 A B C A B C Figure 4 15 Reel A Reel Right Bearing One Place B Reel Center Bearing One Place C Reel Left Bearing One Place MAINTENANCE AND SERVICING ...

Page 305: ...NTENANCE AND SERVICING 71 U joint has an extended lubrication cross and bearing kit Stop greasing when greasing becomes difficult or if U joint stops taking grease Overgreasing will damage U joint Six to eight pumps are sufficient at first grease factory Increase grease interval as U joint wears and requires more than six pumps ...

Page 306: ...chine operating at peak performance It also allows you to do a visual inspection of the machine that may help identify issues early Use high temperature extreme pressure EP2 performance grease with 1 max molybdenum disulphide NLGI Grade 2 lithium base unless otherwise specified 1036850 A Figure 4 18 Every 500 Hours A Wheel Bearings Four Places MAINTENANCE AND SERVICING ...

Page 307: ...of operation and use the Maintenance Record provided to keep a record of scheduled maintenance Refer to 4 2 1 Maintenance Schedule Record page 266 1035875 Figure 4 20 FM200 Grease Point Layout Decal 1 Wipe the grease fitting with a clean cloth before greasing to avoid injecting it with dirt and grit IMPORTANT Use clean high temperature extreme pressure grease only 2 Inject the grease through the f...

Page 308: ...e reel drive cover For instructions refer to Removing Reel Drive Cover page 41 IMPORTANT Use a chain oil with a viscosity of 100 150 sCt at 40 C 104 F typically medium to heavy chain oil or a mineral oil SAE 20W50 that has no detergents or solvents 1028887 A Figure 4 22 Drive Chain 2 Apply a liberal amount of chain oil with an oil can brush or aerosol to the inside of chain A while manually rotati...

Page 309: ...e always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason The auger drive cover consists of an upper and lower cover and a metal inspection panel Only the metal inspection panel needs to be removed to perform this procedure 1012538 B A Figure 4 23 Auger Drive Inspection Panel 1 Remove four bolts A and metal inspection panel B 1013273 A B C Figu...

Page 310: ...he unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Lower the header fully 2 Shut down the engine and remove the key from the ignition 1028292 A B Figure 4 26 Header Drive Main Gearbox 3 Remove oil level plug A from main gearbox B and check that the oil level is up to the bottom of the hole 4 Add oil ...

Page 311: ... plug hole A Refer to the inside back cover for recommended fluids and lubricants 3 Replace oil level plug A and filler plug B NOTE The oil drain plug is magnetic Ensure the magnetic plug is installed in the oil drain position Changing Oil in Header Drive Main Gearbox Change the header drive gearbox oil after the first 50 hours of operation and every 1000 hours or 3 years thereafter DANGER To prev...

Page 312: ... C until it runs out of oil level hole B Refer to this manual s inside back cover for recommended lubricants NOTE The main gearbox holds approximately 2 75 liters 2 9 quarts of oil 9 Replace oil level plug B and filler plug C 4 3 6 Lubricating Header Drive Completion Gearbox Checking Oil Level in Header Drive Completion Gearbox Check the header drive gearbox oil level every 100 hours DANGER To pre...

Page 313: ...l level plug A Adding Oil to Header Drive Completion Gearbox The completion gearbox includes fill check and drain plugs for quickly checking and servicing the gear lubricant while mounted to the float module DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Lo...

Page 314: ...gnetic plug is installed in the oil drain position Changing Oil in Header Drive Completion Gearbox Change the header drive gearbox oil after the first 50 hours of operation and every 1000 hours or 3 years thereafter DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any rea...

Page 315: ...move oil drain plug A and filler plug C and allow the oil to drain 7 Replace oil drain plug A NOTE The oil drain plug is magnetic Ensure the magnetic plug is installed in oil drain position A not in oil level check position B 8 Remove oil level plug B 9 Add oil through filler plug C until it runs out of oil level hole B Refer to this manual s inside back cover for recommended lubricants NOTE The h...

Page 316: ...per sight B is empty Hilly terrain 2 Maintain level so lower sight A is full and upper sight B is up to one half filled NOTE It may be necessary to slightly reduce the oil level when ambient temperatures are above 35 C 95 F to prevent overflow at the breather when normal operating temperatures are reached NOTE It is OK to use the hilly terrain oil level even in normal terrain as long as the fill n...

Page 317: ...anging Oil in the Hydraulic Reservoir Change the hydraulic oil in the reservoir every 1000 hours or 3 years whichever comes first DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Start engine 2 Engage the header to warm up the oil 3 Shut down the engine and r...

Page 318: ...s of filter A and integrated pump B 3 Place a suitably sized container approximately 1 liter 0 26 gallons under the filter to collect oil runoff 4 Twist off filter A by hand and clean the exposed filter port in the integrated pump 5 Apply a thin film of clean oil to the O ring provided with the new filter 6 Turn the new filter onto integrated pump B until the O ring contacts the mating surface Tig...

Page 319: ...the machine Use bulb trade 1156 for amber transport lights and 1157 for the red tail light Slow Speed Transport option Clearance Lights North America Only 1029253 A Figure 4 36 Left Clearance Light 1 Use a Phillips screwdriver to remove the three screws A from the fixture and remove the plastic lens Retain screws A 2 Replace the bulb and reinstall the plastic lens and screws Slow Speed Transport L...

Page 320: ... to be removed when disconnecting the header float module from the combine DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Start the engine For instructions refer to the combine operator s manual 2 Lower the reel fully 3 Lower the header fully 4 Shut down th...

Page 321: ...de the driveline off of the gearbox shaft 9 Slide the driveline through the shield then lower it to the ground 1034014 B A C D Figure 4 41 Driveline Shield ϭϬϯϴϱϳϰ A D B C Figure 4 42 Optional Side Hill Driveline Shield 10 Disconnect chain D from support bracket B 11 On the opposite end of driveline C pull back quick disconnect collar A to release the driveline yoke 12 Slide the yoke off of suppor...

Page 322: ... the key from the ignition before leaving the operator s seat for any reason 1 Start the engine For instructions refer to the combine operator s manual 2 Lower the reel fully 3 Lower the header fully 4 Shut down the engine and remove the key from the ignition ϭϬϯϴϲϵϬ B A Figure 4 43 Driveline Support Bracket 5 Position driveline support bracket A supplied with the driveline on the left inside of t...

Page 323: ...ll Driveline Shield 6 On the end of driveline D which has arrow C pointing toward the collar pull back quick disconnect collar A 7 Slide the yoke onto support bracket B 8 Connect safety chain E to the support bracket ϭϬϯϳϬϴϲ B A Figure 4 46 Driveline Shield 9 Pry clips A up to release shield B MAINTENANCE AND SERVICING ...

Page 324: ...o release the driveline yoke 11 Slide the driveline onto the gearbox shaft until it locks onto the shaft 1028483 B A Figure 4 48 Driveline Shield 12 Slide the shield towards the gearbox until clips A secure shield B 1034703 A Figure 4 49 Driveline Shield 13 Attach driveline safety chain A to the slot on the aluminum plate MAINTENANCE AND SERVICING ...

Page 325: ...driveline does NOT need to be removed from the float module in order to remove the driveline guard 1 Shut down the combine and remove the key from the ignition 1020759 A B C Figure 4 50 Combine End of Driveline 2 Pull driveline collar A away from power take off PTO support B Slide yoke C off support B and release collar A 1014179 A B Figure 4 51 Separated Driveline 3 Lift the combine end of drivel...

Page 326: ... a slotted screwdriver to release grease fitting lock A Figure 4 53 Driveline Guard 5 Rotate driveline guard locking ring A counterclockwise using a screwdriver until lugs B line up with the slots in the guard 6 Pull the guard off the driveline MAINTENANCE AND SERVICING ...

Page 327: ...54 Driveline Guard 1 Slide the guard onto the driveline and line up the slotted lug on locking ring A with arrow B on the guard 1001399 A Figure 4 55 Driveline Guard 2 Push the guard onto the ring until the locking ring is visible in slots A 1001401 A Figure 4 56 Driveline Guard 3 Use a slotted screwdriver to rotate ring A clockwise MAINTENANCE AND SERVICING ...

Page 328: ...th missing spline B when assembling Failure to align the halves of the shaft can cause excessive vibration and feed auger gearbox failures 1020614 A D C B Figure 4 59 Combine End of Driveline 6 Position the combine end of driveline A on power take off PTO storage support B Pull back collar C on the driveline and slide the driveline onto the support until driveline yoke D locks onto the support Rel...

Page 329: ...regular maintenance DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1028057 A B C Figure 4 60 Main Gearbox Chain Tensioner Cover 1 Remove four bolts A cover B and gasket C from the main gearbox 1028063 A B Figure 4 61 Main Gearbox Chain Tensioner 2 Remove reta...

Page 330: ...er the first 50 hours then every 500 hours or annually whichever comes first With the exception of oil changes the gearbox drive chain requires no other regular maintenance DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Start the engine For instructions ref...

Page 331: ... A clockwise to tighten the chain 8 With light pressure on the wrench determine which mark D on the gearbox housing aligns with the indicator pointer on the hub 9 Set proper chain tension by slightly turning hub A back one mark 10 Tighten six bolts B that secure cover A Torque bolts to 25 Nm 18 lbf ft 1029311 B A Figure 4 66 Completion Gearbox Chain Tensioner Cover 11 Install driveline guard base ...

Page 332: ...tance between the feed auger and the feed auger pan Too little clearance may result in the fingers or flighting contacting and damaging the feed draper or pan when operating the header at certain angles Look for evidence of contact when greasing the float module 1 Extend the center link to the steepest header angle setting E and position the header 254 356 mm 10 14 in off the ground 2 Lock the hea...

Page 333: ...ce is required IMPORTANT Make sure bolts A are set at the same location on both ends of the header to avoid damaging the machine during operation If bolt head A is closest to floating symbol B the auger is in the floating position 1028423 A A B Figure 4 69 Fixed Position If bolt head A is closest to fixed symbol B the auger is in the fixed position MAINTENANCE AND SERVICING ...

Page 334: ...the other side Always double check both sides of the auger after making final adjustments 10 Tighten nuts B on both ends of the feed auger Torque the nuts to 96 Nm 70 lbf ft 11 Rotate the feed auger and double check clearances 4 7 2 Checking Feed Auger Chain Tension The auger is chain driven by the float module drive system sprocket attached to the side of the auger There are two methods for check...

Page 335: ... used when the auger drive chain is reinstalled or replaced 1 Start the engine For instructions refer to the combine operator s manual 2 Lower the header fully 3 Raise the reel fully 4 Shut down the engine and remove the key from the ignition 5 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 33 1036816 A B Figure 4 71 Feed Auger Drive 6 Rotate auger A by hand...

Page 336: ...lways stop the engine and remove the key from the ignition before leaving the operator s seat for any reason WARNING To prevent bodily injury from the fall of a raised reel always engage the reel safety props before going under the raised reel for any reason WARNING Ensure that all bystanders have cleared the area NOTE There are two methods for checking the auger drive chain tension the thorough m...

Page 337: ...cator clamp D that holds the two covers together 9 Remove bolt E 10 Remove bolt and washer H that secure the bottom cover 11 Rotate bottom cover F forward to remove 1028460 A Figure 4 74 Feed Auger Chain Rear View 12 Check chain at midspan A There should be 4 mm 0 16 in of deflection If adjustment is required refer to 4 7 5 Adjusting Feed Auger Drive Chain Tension page 320 MAINTENANCE AND SERVICIN...

Page 338: ...ack for only a single pitch Replace the chain when the chain has worn or stretched beyond the limits of the tensioner DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason NOTE Replace the chain with endless chain MAC220317 NOTE Illustrations show the left side of t...

Page 339: ...e bumper B Repeat on the opposite side 1034605 A B F C C D G H J E Figure 4 78 Auger Drive 5 On the left side of the auger remove bolts E and remove cover retainer F 6 Remove four bolts A and inspection panel B 7 Remove bolts C and remove indicator clamp D that holds top cover G and bottom cover H together 8 Remove bolt and washer J that secure bottom cover H 9 Rotate top cover G and bottom cover ...

Page 340: ...spindle 11 Loosen idler sprocket nut A and raise sprocket B to the uppermost position to release the tension on the chain Tighten nut A to hold sprocket in place 12 Remove screw F and washer G 1013212 A Figure 4 80 Auger Support Arm 13 Remove two bolts and nuts A NOTE A second person may be needed to lift or support the auger to completely remove the bolts 1025323 A B C Figure 4 81 Auger 14 Using ...

Page 341: ... A sideways and forward so that endless chain B can be removed from the auger 4 7 4 Installing Auger Drive Chain The auger drive chain transfers power from the main gearbox to the feed auger NOTE Illustrations show the left side of the auger 1017224 A B Figure 4 84 Auger Drive 1 Place drive chain B over the sprocket on the drive side of auger A MAINTENANCE AND SERVICING ...

Page 342: ...f drive sprocket B should face the auger 1034599 A B Figure 4 86 Auger Drive 3 Apply medium strength threadlocker Loctite 243 or equivalent to threads of screw A 4 Install washer B and secure it with screw A 1013212 A Figure 4 87 Auger Drive 5 Slide the auger drum assembly toward the casting and then reinstall two bolts and nuts A MAINTENANCE AND SERVICING ...

Page 343: ...ONLY IMPORTANT Do NOT overtighten 8 Tighten idler nut A and torque to 265 Nm 195 lbf ft 1034600 A Figure 4 89 Auger Drive 9 Tighten jam nut A 1034605 A B F C C D G H J E Figure 4 90 Auger 10 Position bottom cover H and secure with bolt and washer J 11 Position top cover G Secure top and bottom covers with clamp indicator D and bolts C 12 Install inspection panel B and secure with four bolts A Tigh...

Page 344: ...e ignition before leaving the operator s seat for any reason WARNING To prevent bodily injury from the fall of a raised reel always engage the reel safety props before going under the raised reel for any reason WARNING Ensure that all bystanders have cleared the area 1 Start the engine For instructions refer to the combine operator s manual 2 Lower the header fully 3 Raise the reel fully 4 Engage ...

Page 345: ... idler nut A slightly to allow idler to move by turning adjuster C 10 Rotate the auger in reverse to take up slack in the upper strand of the chain 1031636 B A Figure 4 94 Feed Auger Chain Deflection 11 Turn adjuster thumbscrew A clockwise to increase tension until chain deflection B is 4 mm 0 16 in at midspan IMPORTANT Do NOT overtighten NOTE The covers have been removed from the illustration for...

Page 346: ...e crop specific configurations 4 7 7 Auger Fingers The FM200 auger uses retracting tines to feed the crop into the combine feeder house Some conditions may require the removal or installation of fingers for optimal crop feeding Replace any worn or damaged fingers Removing Feed Auger Fingers The feed auger has fingers that extend and retract to pull crop into the feeder house on the combine Fingers...

Page 347: ...ine and remove the key from the ignition 4 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 33 1033135 A A B Figure 4 97 Auger Access Hole Cover 5 Locate the access cover closest to the finger to be removed Remove and retain bolts A and access cover B 1033303 B D C A Figure 4 98 Auger Finger 6 Remove hairpin A Pull finger B out of finger holder C 7 If the fing...

Page 348: ... NOTE Bolts B come with a threadlocker patch that will wear off if the bolts are removed If reinstalling bolts B apply medium strength threadlocker Loctite 243 or equivalent before installation 1019338 B A Figure 4 101 Auger Access Hole Cover 10 Secure access cover B with bolts A Torque the bolts to 9 Nm 80 lbf in NOTE Bolts A come with a threadlocker patch that will wear off if the bolts are remo...

Page 349: ...ore going under the machine for any reason WARNING Ensure that all bystanders have cleared the area IMPORTANT When installing additional fingers ensure you install an equal number on each side of the auger 1 Raise the reel fully 2 Shut down the engine and remove the key from the ignition 3 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 33 1019338 B A Figure ...

Page 350: ...er by inserting hairpin D into the holder Ensure that the round end S shaped side of the hairpin faces the chain drive side of the auger Make sure the closed end of the hairpin points in the direction in which the auger rotates IMPORTANT Position the hairpin as described in this step to prevent the hairpin from falling out during operation If fingers are lost the header might not be able to feed c...

Page 351: ...ere are two different auger tine extension positions A and B Position A is used for canola and position B is used for grains The factory setting for the indicator is position B IMPORTANT To avoid damaging the auger beyond repair it is extremely important that both sides are at the same setting 6 To adjust the indicator position refer to Adjusting Auger Finger Timing page 327 7 Disengage the reel s...

Page 352: ... of the auger There are two auger tine extension positions Position A and position B 6 Loosen nuts D and adjust finger timing indicator C to the desired position IMPORTANT The timing indicator on both ends of the auger must be set at the same position if not the auger will be damaged beyond repair 1026139 Figure 4 109 Auger Position A NOTE If the finger timing indicator is pointing at position A i...

Page 353: ... This allows the crop to be engaged and released later before entering the feeder house This setting is best used for grains or beans 1027651 A Figure 4 111 Auger Tine Timing Indicator 7 Tighten nuts A once adjustment is complete Torque nuts to 115 Nm 85 lbf ft 8 Disengage the reel safety props For instructions refer to Disengaging Reel Safety Props page 34 MAINTENANCE AND SERVICING ...

Page 354: ...s can be replaced without removing the knife from the cutterbar DANGER To prevent injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key from the ignition before leaving the operator s seat or making adjustments to the machine Never work on or beneath an unsupported header If the header is fully raised always engage the safety props If th...

Page 355: ... on the same knife 8 For sections near the drive end reposition bars C 9 If a hold down was removed earlier install it along with bolts and nuts B NOTE Ensure bolt heads fully engage into oblong holes on the knife back bar 10 Torque nuts B to 12 Nm 9 lbf ft 11 If necessary replace hold downs that were removed To check hold down adjustment refer to Checking Hold Down Pointed Knife Guards page 347 o...

Page 356: ...fehead 4 Clean the area around the knifehead 5 Remove grease fitting A from the pin NOTE Removing the grease fitting will make it easier to reinstall the knifehead pin later 6 Remove bolt and nut B 7 Use a screwdriver or chisel in slot C to release the load on the knifehead pin 8 Use a screwdriver or chisel to pry the knifehead pin upwards in the pin groove until the knifehead pin is clear of the ...

Page 357: ...uring removal to reduce the risk of injury from cutting edges Wear heavy gloves when handling the knife 1 Raise the reel fully 2 Shut down the engine and remove the key from the ignition 3 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 33 4 Remove the knife For instructions refer to 4 8 2 Removing Knife page 331 NOTE Because the bearing is being replaced it ...

Page 358: ...cing outwards IMPORTANT To prevent premature knifehead or knife drive box failure ensure there is a tight fit between the knifehead pin and the needle bearing and between the knifehead pin and the output arm 4 Install the knife For instructions refer to 4 8 5 Installing Knife page 334 4 8 5 Installing Knife Inspect the knife daily and ensure it is not damaged If it is damaged it will need to be re...

Page 359: ...arm 1036590 A B C Figure 4 121 Knifehead 7 Secure the knifehead pin with M16 x 85 mm hex bolt A and hex nut B Install the bolt from the inboard side of the arm Torque the bolt to 220 Nm 162 lbf ft 8 Rotate he flywheel attached to the knife drive box to manually stroke knife arm A to the inside limit of travel and ensure there is still 0 2 1 2 mm 1 64 3 64 in clearance C between the drive arm and t...

Page 360: ...nife drive arm to the mid stroke position and ensure the knife back bar doesn t contact the front of first guard A 12 If the knife back bar contacts the front of the first guard remove bolts B reposition the guard forward and reinstall the bolts Torque bolts to 85 Nm 63 lbf ft If the necessary clearance zero contact between back bar and front of first guard is not achievable then additional shims ...

Page 361: ...Pointed Center Knife Guard MAC286317 75 G Pointed Center Hold Down MAC286332 75 Guards are configured differently on different headers When replacing pointed guards and hold downs ensure you use the correct sequence for your header The following will guide you to the different configurations Pointed Knife Guards on Single Knife Headers page 338 Pointed Knife Guards on FD235 Double Knife Header pag...

Page 362: ...rds to ensure proper cutting 1028482 A A A D D B B B C C C E F Figure 4 126 Pointed Knife Guard and Hold Down Locations Single Knife Headers A Pointed Hold Down MAC286329 B Pointed Knife Guard MAC286315 C Pointed End Knife Guard without Wear Bar MAC286316 D Short Knife Hold Down MAC286331 E Short Knife Guard without Wear Bar MAC286319 F Short Knife Guard MAC286318 MAINTENANCE AND SERVICING ...

Page 363: ...tting D C 1029106 A B E E E D A A D F F E E E G G H Figure 4 127 Pointed Guard and Hold Down Locations A Pointed Hold Down MAC286329 B Pointed Center Hold Down MAC286332 C Pointed Center Knife Guard MAC286317 D Pointed Knife Guard MAC286315 E Pointed End Knife Guard without Wear Bar MAC286316 F Short Knife Hold Down MAC286331 G Short Knife Guard without Wear Bar MAC286319 H Center of Header MAINTE...

Page 364: ...B E E E D C D A A D F F E E E G G H Figure 4 128 Pointed Knife Guard and Hold Down Locations FD240 Double Knife Header A Pointed Hold Down MAC286329 B Pointed Center Hold Down MAC286332 C Pointed Center Knife Guard MAC286317 D Pointed Knife Guard MAC286315 E Pointed End Knife Guard without Wear Bar MAC286316 F Short Knife Hold Down MAC286331 G Short Knife Guard without Wear Bar MAC286319 H Center ...

Page 365: ...ng D 1028470 A B E E E D A A D F F E E E G G H C Figure 4 129 Pointed Knife Guard and Hold Down Locations A Pointed Hold Down MAC286329 B Pointed Center Hold Down MAC286332 C Pointed Center Knife Guard MAC286317 D Pointed Knife Guard MAC286315 E Pointed End Knife Guard without Wear Bar MAC286316 F Short Knife Hold Down MAC286331 G Short Knife Guard without Wear Bar MAC286319 H Center of Header MAI...

Page 366: ...tting D C 1028471 A B E E E D A A D F F E E E G G H Figure 4 130 Pointed Guard and Hold Down Locations A Pointed Hold Down MAC286329 B Pointed Center Hold Down MAC286332 C Pointed Center Knife Guard MAC286317 D Pointed Knife Guard MAC286315 E Pointed End Knife Guard without Wear Bar MAC286316 F Short Knife Hold Down MAC286331 G Short Knife Guard without Wear Bar MAC286319 H Center of Header MAINTE...

Page 367: ... A B E E E D C D A A D F F E E E G G H Figure 4 131 Pointed Knife Guard and Hold Down Locations FD250 Double Knife Header A Pointed Hold Down MAC286329 B Pointed Center Hold Down MAC286332 C Pointed Center Knife Guard MAC286317 D Pointed Knife Guard MAC286315 E Pointed End Guard without Wear Bar MAC286316 F Short Knife Hold Down MAC286331 G Short Knife Guard without Wear Bar MAC286319 H Center of ...

Page 368: ...nd remove the key before leaving the operator s seat and always engage the safety props before going under the machine for any reason WARNING Wear heavy gloves when working around or handling knives 1 Raise the reel fully 2 Shut down the engine and remove the key from the ignition 3 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 33 1033967 Figure 4 132 Upwar...

Page 369: ...he guard tips downwards position tool A as shown and push down 1033965 Figure 4 135 Downward Adjustment Short Knife Guard 1033973 Figure 4 136 Guard Bar Adjustment No Guards 6 To adjust the guard bar up or down position tool A as shown and push on the tool accordingly MAINTENANCE AND SERVICING ...

Page 370: ...r position 1 outboard guard is a short knife guard On the drive side s of the header positions 2 3 and 4 are pointed end knife guards without wear bar Starting at position 5 the remaining guards are pointed knife guards Ensure that the proper replacement guards are installed at these locations IMPORTANT Double knife headers A pointed center knife guard installed where the two knives overlap The po...

Page 371: ...justment bolt C so that it is not protruding from the bottom of the hold down 11 Secure the pointed knife guard wearplate and hold down if applicable with two bolts and nuts B Tighten nuts to 85 Nm 63 lbf ft 12 If there is a hold down at this location proceed with adjustment Refer to Adjusting Hold Down Pointed Knife Guards page 348 Checking Hold Down Pointed Knife Guards Perform DAILY inspections...

Page 372: ... B 7 Push down on knife section A with approximately 44 N 10 lbf of force and use a feeler gauge to measure the clearance between hold down B and the knife section Ensure the clearance is 0 1 0 5 mm 0 004 0 020 in 8 If adjustment is required refer to Adjusting Hold Down Pointed Knife Guards page 348 9 Close the endshield For instructions refer to Closing Header Endshields page 36 Adjusting Hold Do...

Page 373: ...ighten nuts to 85 Nm 63 lbf ft 5 Run the header at low engine speed and listen for noise caused by insufficient clearance Readjust as necessary IMPORTANT Insufficient hold down clearance will result in overheating of the knife and guards Replacing Pointed Center Knife Guard Double Knife The guard at the center of a double knife header where the two knives overlap requires a slightly different repl...

Page 374: ...te and hold down B 1028440 A Figure 4 144 Pointed Center Knife Guard IMPORTANT Ensure the replacement guard is the correct guard with offset cutting surfaces A 1029116 A Figure 4 145 Cutterbar 6 Before installing the new pointed center knife guard ensure overlap shim A is present under the cutterbar and the thick end of the shim is positioned under the center guard MAINTENANCE AND SERVICING ...

Page 375: ...ighten at this time IMPORTANT Hold down A must accommodate the two overlapping knives at the center guard location Ensure the proper replacement guard is installed at this location 11 Adjust the hold down until the clearance is acceptable For adjustment instructions refer to Adjusting Center Hold Down Pointed Knife Guards page 352 For clearance specifications refer to Checking Center Hold Down Poi...

Page 376: ...l the knife sections are under hold down A Repeat for the opposite knife 6 Push down on the knife section with approximately 44 N 10 lbf of force and use a feeler gauge to measure the clearance between hold down A and the knife section Ensure the clearance is as follows At tip B of hold down 0 1 0 5 mm 0 004 0 020 in At rear C of hold down 0 1 1 0 mm 0 004 0 040 in 7 If adjustment is required refe...

Page 377: ...kwise tighten To decrease the clearance turn adjuster bolts A counterclockwise loosen 6 To adjust clearance at tip only adjust using only center rear adjustment bolt C To increase the clearance turn adjuster bolt C counterclockwise loosen To decrease the clearance turn adjuster bolt C clockwise tighten 7 Tighten nuts B to 85 Nm 63 lbf ft 8 Recheck clearances and make further adjustments if necessa...

Page 378: ...6333 78 F PlugFree Center Knife Guard MAC286320 78 Guards are configured differently on different headers When replacing short knife guards and hold downs ensure you use the correct sequence for your header The following will guide you to the different configurations Short Knife Guards on Single Knife Headers page 355 Short Knife Guards on Double Knife Headers All Sizes Except 12 5 m 41 ft page 35...

Page 379: ...B B B C D C D C D C B Figure 4 152 Short Knife Guard and Hold Down Locations Single Knife Headers A Short Knife Hold Down MAC286330 B Short Knife Guard MAC286318 C Short Knife End Hold Down x4 MAC286331 D Short Knife End Knife Guard without Wear Bar x5 MAC286319 MAINTENANCE AND SERVICING ...

Page 380: ... 4 153 Short Knife Guard and Hold Down Locations Double Knife Headers A Short Knife Hold Down MAC286330 B Short Knife Guard MAC286318 C Short Knife End Hold Down x6 MAC286331 D Short Knife End Knife Guard without Wear Bar x8 MAC286319 E Short Knife Center Hold Down MAC286333 F Short Knife Center Knife Guard MAC286320 G Center of Header MAINTENANCE AND SERVICING ...

Page 381: ...ife Guard and Hold Down Locations 12 5 m 41 ft Double Knife Header A Short Knife Hold Down MAC286330 B Short Knife Guard MAC286318 C Short Knife End Hold Down x6 MAC286331 D Short Knife End Knife Guard without Wear Bar x8 MAC286319 E Short Knife Center Hold Down MAC286333 F Short Knife Center Knife Guard MAC286320 G Center of Header MAINTENANCE AND SERVICING ...

Page 382: ...nives IMPORTANT Double knife headers have an offset center knife guard installed where the two knives overlap The center knife guard has a slightly different replacement procedure For instructions refer to Replacing Center Knife Guard Double Knife page 361 To replace a short knife guard or end knife guard follow these steps 1 Raise the reel fully 2 Shut down the engine and remove the key from the ...

Page 383: ...hort Knife Guard 7 Position hold down A and loosen two adjustment bolts B so that they are not protruding from the bottom of the hold down 8 Secure the short knife guard wearplate and hold down with two bolts and nuts C but do NOT tighten yet 9 Adjust the hold down until the clearance is acceptable For adjustment instructions refer to Adjusting Hold Down Short Knife Guards page 360 For clearance s...

Page 384: ...9 Short Knife Guards 4 Manually stroke the knife to position the section under hold down A 5 Push down on knife section with approximately 44 N 10 lbf of force and use a feeler gauge to measure the clearance between the tip of hold down B and the knife section Ensure the clearance is 0 1 0 5 mm 0 004 0 020 in 6 If adjustment is required refer to Adjusting Hold Down Short Knife Guards page 360 Adju...

Page 385: ...ther adjustments if necessary 6 Run the header at low engine speed and listen for noise caused by insufficient clearance Readjust as necessary IMPORTANT Insufficient hold down clearance will result in overheating of the knife and guards Replacing Center Knife Guard Double Knife The offset guard at the center of a double knife header where the two knives overlap requires a slightly different replac...

Page 386: ...wearplate and hold down B 1029147 A Figure 4 162 Center Knife Guard IMPORTANT Ensure the replacement center knife guard is the correct guard with offset cutting surfaces A 1029148 A Figure 4 163 Cutterbar 6 Before installing the new center knife guard ensure overlap shim A is present under the cutterbar and the thick end of the shim is positioned under the center knife guard MAINTENANCE AND SERVIC...

Page 387: ...MPORTANT Hold down A must accommodate the two overlapping knives at the center knife guard location Ensure the proper replacement center knife guard is installed at this location 11 Adjust the hold down until the clearance is acceptable For adjustment instructions refer to Adjusting Center Hold Down Short Knife Guards page 364 For clearance specifications refer to Checking Center Hold Down Short K...

Page 388: ...ection with approximately 44 N 10 lbf of force and use a feeler gauge to measure the clearance between hold down A and the knife section Ensure the clearance is as follows At tip B of hold down 0 1 0 5 mm 0 004 0 020 in At rear C of hold down 0 1 1 0 mm 0 004 0 040 in 6 If adjustment is required refer to Adjusting Center Hold Down Short Knife Guards page 364 7 If no adjustment is required tighten ...

Page 389: ... 4 8 9 Knifehead Shield The knifehead shield attaches to the endsheet and reduces the knifehead opening to prevent cut crop from accumulating in the knifehead cutout IMPORTANT Remove the shields when using the cutterbar on the ground in muddy conditions Mud may pack into the cavity behind the shield which could result in knife drive box failure Installing Knifehead Shield The knifehead shield is p...

Page 390: ...ign the mounting holes and secure with two M10 x 30 hex head bolts washers B and nuts 8 Tighten bolts B just enough to hold knifehead shield A in place while allowing it to be adjusted as close to the knifehead as possible 9 Manually rotate the knife drive box pulley to move the knife and check for areas of contact between the knifehead and knifehead shield A Adjust the shield to eliminate interfe...

Page 391: ...e double knife headers have a knife drive box and motor at each end Checking Oil Level in Knife Drive Box Single knife headers have one knife drive box and double knife headers have two knife drive boxes To access the knife drive box es the endshield s must be fully opened DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key...

Page 392: ...e torque on the four knife drive box mounting bolts A and B after the first 10 hours of operation and every 100 hours thereafter 1028009 A B Figure 4 172 Knife Drive Box View from Below 1 Ensure all bolts are torqued to 343 Nm 253 lbf ft Torque side bolts A first then torque bottom bolts B Changing Oil in Knife Drive Box Change the knife drive box lubricant after the first 50 hours of operation an...

Page 393: ...ife drive box and into the container placed below it 6 Reinstall drain plug C 7 Add 1 5 L 0 4 US gal of oil to the knife drive box Refer to the inside back cover for recommended fluids and lubricants NOTE Check the oil level with the top of knife drive box horizontal and with oil level dipstick A screwed in 8 Check that the oil level is within range B 9 Close the endshield For instructions refer t...

Page 394: ...ise the header fully 2 Raise the reel fully 3 Shut down the engine and remove the key from the ignition 4 Engage the header s safety props For instructions refer to the combine operator s manual 5 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 33 ϭϬϯϴϰϵϴ A A A B A B C D Figure 4 174 Draper Seal 6 To access the draper Remove five countersunk screws A and reta...

Page 395: ...he frame to aid in draper replacement 1019330 A B Figure 4 177 Feed Deck Pan Handle and Left Side Pan Handle Latch 10 Unlatch feed deck pan handle A from handle latch supports B on both sides of the feed deck This will drop the door down and allow access to the feed deck draper and rollers 1012873 A B Figure 4 178 Draper Connector 11 Remove nuts and screws A and remove draper connector straps B 12...

Page 396: ...deck and tighten only until the end of the screws are flush with the nuts ϭϬϯϴϱϬϭ B A Figure 4 181 Idler Roller Bearing Housing 16 Move the idler back to the operating position Apply medium strength threadlocker Loctite 243 or equivalent to bolt threads and reinstall the following hardware A to secure idler roller casting B to the frame Repeat this step on the opposite side of the feed deck Socket...

Page 397: ...ip or have tracking issues DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going under the machine for any reason NOTE Illustrations show the left side of the float module The right side is opposite 1 Raise the header fully 2 Shut ...

Page 398: ...on adjustments and to avoid uneven draper tracking you may need to adjust both sides of the draper equally 8 If the draper is not tracking properly retainer disc C can be adjusted so that it is NOT in the middle of indicator D but within the following range Loosened to 3 mm 1 8 in retainer disc C will move towards the front of the deck from center of indicator D Tightened to 6 mm 1 4 in retainer d...

Page 399: ...g Reel Safety Props page 33 6 Engage the header s safety props For instructions refer to the combine operator s manual B 1027877 A Figure 4 186 Feed Draper Tensioner 7 To release the draper tension loosen jam nut A and turn bolt B counterclockwise Repeat at the opposite side of the header 1012873 A B Figure 4 187 Draper Connector 8 Remove nuts and screws A and remove draper connector straps B 9 Li...

Page 400: ...ϯϴϯϳϵ B B Figure 4 189 Drive Roller 11 Slide the drive roller with bearing assembly A to the right until the left end comes off of the motor spline 12 Remove both covers B A ϭϬϯϴϯϴϬ B C Figure 4 190 Drive Roller 13 Lift the left end out of the frame 14 Slide assembly A to the left guiding bearing housing B through frame opening C 15 Remove roller A MAINTENANCE AND SERVICING ...

Page 401: ...ed after it has been repaired or replaced ϭϬϯϴϯϴϭ A B Figure 4 191 Drive Roller Bearing End 1 Apply grease to the motor spline 2 Guide bearing end A of the drive roller through frame opening B 1028086 A B Figure 4 192 Motor 3 Slide the left end of drive roller A onto spline of motor B MAINTENANCE AND SERVICING ...

Page 402: ... Drive Roller Bearing The feed draper drive roller bearing helps the roller turn The bearing needs to be removed when replacing it DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going under the machine for any reason 1 Raise the r...

Page 403: ...Repeat at the opposite side of the header ϭϬϯϴϯϲϭ A B Figure 4 195 Feed Draper Drive Roller Bearing 7 Loosen set screw A on bearing lock B 8 Using a hammer and punch tap bearing lock B in the direction opposite to the auger rotation to release the lock A ϭϬϯϴϯϲϮ A Figure 4 196 Feed Draper Drive Roller Bearing 9 Remove two nuts A MAINTENANCE AND SERVICING ...

Page 404: ...ith bolts and a lock collar ϭϬϯϴϯϳϭ D D C B D D A A B E F Figure 4 198 Feed Draper Drive Roller Bearing 1 Install two bolts A into the feed deck 2 Install both covers B onto the two bolts IMPORTANT Position the covers in the order shown 3 Install drive roller bearing housing C onto the shaft 4 Secure the housing using two nuts D 5 Install bearing lock collar E onto the shaft 6 Using a hammer and p...

Page 405: ...seat and always engage the safety props before going under the machine for any reason 1 Raise the reel fully 2 Raise the header fully 3 Shut down the engine and remove the key from the ignition 4 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 33 5 Engage the header s safety props For instructions refer to the combine operator s manual B 1027877 A Figure 4 19...

Page 406: ...ve the following hardware from location A that secures the bearing housing to the deck skid and tensioner Socket head bolt washer and nut 12 Remove bearing housing B from the idler roller 13 Repeat Step 10 page 382 to Step 12 page 382 on the opposite side of the feed deck 1028320 A B Figure 4 203 Idler Roller Cover 14 On one side of the deck frame remove nut A and cover B MAINTENANCE AND SERVICING...

Page 407: ...gure 4 205 Idler Roller 1 Slide cover A over one end of the idler roller 2 Brush idler roller shaft B with oil 3 Carefully rotate bearing assembly C onto the shaft by hand to prevent seal damage IMPORTANT Ensure the bearing assembly is square to the shaft to prevent seal damage during installation 1028339 A Figure 4 206 Idler Roller 4 After the bearing and both seals are seated around the shaft in...

Page 408: ...the nut It should be snug as it holds the idler cover in place and it must move with the idler roller 1028257 A B Figure 4 209 Feed Deck Left Side 8 Slide the idler roller out through the cutout on the opposite side of the deck frame 9 Brush idler roller shaft A with oil 10 Carefully rotate bearing assembly B onto shaft A by hand to prevent seal damage IMPORTANT Ensure the bearing assembly is squa...

Page 409: ... hole in cast support D with the holes in the upper tab on idler roller housing A 16 Apply medium strength threadlocker Loctite 243 or equivalent to the bolt threads and then insert the following hardware at location E Socket head bolt washer and nut 17 Tighten bolts C and E to 12 Nm 9 lbf ft IMPORTANT Do NOT fully tighten bolts C and E 18 Repeat Step 13 page 385 to Step 17 page 385 on the opposit...

Page 410: ... death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going under the machine for any reason 1 Raise the reel fully 2 Raise the header fully 3 Shut down the engine and remove the key from the ignition 4 Engage the reel safety props For instructions refer to Engaging Reel...

Page 411: ... B on both sides of the feed deck This will drop the door down and allow access to the feed deck draper and rollers ϭϬϯϴϯϴϵ A A B Figure 4 216 Idler Roller Bearing Left Side 8 Remove the following hardware from location A that secures the bearing housing to the deck skid and tensioner Socket head bolt washer and nut 9 Remove dust cap B MAINTENANCE AND SERVICING ...

Page 412: ...e internal retaining ring A bearing B and two seals C 12 Apply oil to the bore before assembling the parts 13 Install seals C into housing D NOTE Ensure the flat side of the seal is facing inward 14 Pack bearing B with grease and install as shown 15 Install retaining ring A 1028257 A B Figure 4 219 Idler Roller Bearing Left Side 16 Brush idler roller shaft A with oil 17 Carefully rotate bearing as...

Page 413: ...h the holes in the upper tab on idler roller housing A 22 Apply medium strength threadlocker Loctite 243 or equivalent to the bolt threads and then insert the following hardware at location E Socket head bolt washer and nut 23 Tighten bolts C and E to 12 Nm 9 lbf ft IMPORTANT Do NOT fully tighten bolts C and E 24 Repeat Step 8 page 387 to Step 23 page 389 on the opposite side ϭϬϯϴϯϵϭ A Figure 4 22...

Page 414: ... and always engage the safety props before going under the machine for any reason 1 Raise the header fully 2 Engage the header safety props Refer to the combine operator s manual for instructions 3 Shut down the engine and remove the key from the ignition 1028363 A B Figure 4 223 Underside of Feed Deck 4 On the underside of the feed deck rotate latch A to unlock handle B Repeat on the opposite end...

Page 415: ... be opened and closed to access the feed draper DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going under the machine for any reason 1028375 A Figure 4 226 Feed Deck Pan 1 Raise feed deck pan A MAINTENANCE AND SERVICING ...

Page 416: ...ace and rotate latch C to lock handle A 4 10 7 Checking Link Holder Hooks Check the left and right link holder hooks DAILY to ensure they are not cracked or broken DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine remove the key and engage the safety props before going under the header for any reason 1 Raise the header fully 2 ...

Page 417: ...4 Before operation ensure both link holder hooks A are engaged on the float module under the feed deck as shown A 1028962 B Figure 4 230 Link Holder Hooks Undamaged link holder hook A Damaged broken link holder hook B Stretched link holder not shown MAINTENANCE AND SERVICING ...

Page 418: ...MAC215986 394 Revision A B 1028969 A Figure 4 231 Link Holder Hook in Storage Position NOTE To move hook A to the storage position loosen bolt B and rotate the hook 90 MAINTENANCE AND SERVICING ...

Page 419: ...combine For instructions refer to 3 6 Header Attachment Detachment page 52 1017291 B A Figure 4 232 Stripper Bar 2 Remove four bolts and nuts A securing stripper bar B to the float module frame and remove the stripper bar NOTE There may only be two upper bolts on stripper bar B 3 Repeat at the opposite side of the header 4 11 2 Installing Stripper Bars The stripper bars are installed in the lower ...

Page 420: ...peat at the opposite side of the header 4 11 3 Replacing Feed Deflectors on New Holland CR Combines Feed deflectors are used with New Holland CR combines only 1 Detach the header from the combine For instructions refer to 3 6 Header Attachment Detachment page 52 1032874 B A Figure 4 234 Feed Deflector 2 Remove two bolts and nuts B securing feed deflector A to the float module frame and remove the ...

Page 421: ... 4 in 5 Tighten nuts B 6 Repeat the previous steps for the opposite deflector 7 Attach the header to the combine For instructions refer to Chapter 3 6 Header Attachment Detachment page 52 8 After attaching the header to the combine fully extend the center link and check the gap between the deflector and pan Maintain the 4 6 mm 5 32 1 4 in gap MAINTENANCE AND SERVICING ...

Page 422: ...der the machine for any reason 1 Start the engine For instructions refer to the combine operator s manual 2 Raise the reel fully 3 Raise the header fully 4 Shut down the engine and remove the key from the ignition 5 Engage the header safety props Refer to the combine operator s manual for instructions 6 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 33 WARNI...

Page 423: ...ng under the machine for any reason 1 Start the engine For instructions refer to the combine operator s manual 2 Raise the reel fully 3 Raise the header fully 4 Shut down the engine and remove the key from the ignition 5 Engage the header safety props Refer to the combine operator s manual for instructions 6 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 33 ...

Page 424: ...e 402 15 Operate the drapers with the engine at idle so the talc or talc graphite lubricant makes contact and adheres to the draper seal surfaces 4 12 3 Adjusting Deck Height A properly adjusted deck height will prevent material from entering into the side drapers and stalling them DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the eng...

Page 425: ... per deck 1032731 A B C Figure 4 240 Draper Seal 3 Check that clearance A between draper B and metal seal C is 0 2 mm 0 004 0 08 in 4 Loosen the draper tension For instructions refer to 4 12 4 Adjusting Side Draper Tension page 402 1009729 A B Figure 4 241 Deck Support 5 Lift front edge of draper A past cutterbar B to expose the deck support 6 Measure and note the thickness of the draper belt MAIN...

Page 426: ...t the gap 10 To create a seal adjust deck A so that clearance B between metal seal C and deck is the same thickness as the draper belt plus 1 mm 0 04 in NOTE When checking clearance at either roller measure from the roller tube NOT the deck 11 Tighten deck support hardware D 12 Recheck gap B with thickness gauge For instructions refer to Step 9 page 402 4 12 4 Adjusting Side Draper Tension The dra...

Page 427: ...tart the engine For instructions refer to the combine operator s manual 3 Raise the header fully 4 Shut down the engine and remove the key from the ignition 5 Engage the header s safety props For instructions refer to the combine operator s manual 1008417 A Figure 4 245 Drive Roller 6 Check that the draper guide the rubber track on the underside of the draper is properly engaged in groove A of the...

Page 428: ...ter bolt until the tensioner indicator covers the inboard half of the window IMPORTANT To avoid premature failure of the draper draper rollers and or tightener components do NOT operate the header with the tensioner indicator not visible 4 12 5 Adjusting Side Draper Tracking The side draper tracking is adjusted by aligning the drive and idler draper rollers Draper tracking is set at the factory an...

Page 429: ...djuster Nut for Idler Roller M Nut on Drive Roller Side N Nut on Drive Roller Side 1 To determine which roller requires adjustment and which adjustments are necessary refer to the following table Table 4 2 Draper Tracking Tracking Location Adjustment Method Toward backsheet Drive roller Increase C Tighten adjuster nut H Toward Cutterbar Drive roller Decrease C Loosen adjuster nut H Toward backshee...

Page 430: ...ngage the header and run the drapers for approximately 3 minutes 2 Check the temperature of the draper roller bearings at each of roller arms A B and C on each deck Ensure the temperature does not exceed 44 C 80 F above the ambient temperature Replace roller bearings that exceed maximum recommended temperature For instructions refer to 4 12 8 Replacing Side Draper Deck Idler Roller Bearing page 40...

Page 431: ... the header s safety props For instructions refer to the combine operator s manual 1032009 A Figure 4 251 Tensioner Left Side Shown 6 Loosen the draper by turning adjuster bolt A counterclockwise until the adjuster bolt runs out of adjustment and hits a hard stop 1032007 A B B C D A B C D Figure 4 252 Draper Connectors 7 Remove screws C bridge connector D and nuts from the front end of the draper ...

Page 432: ...ove draper deck idler roller For instructions refer to 4 12 7 Removing Side Draper Deck Idler Roller page 406 1023314 A B C Figure 4 254 Idler Roller Bearing and Seal 2 Clamp idler roller A in a vise with cloth wrapped around the roller to prevent damage to the roller 3 Use a slide hammer to remove bearing assembly B and seal C from the roller 1023312 A B Figure 4 255 Idler Roller IMPORTANT When i...

Page 433: ...he tube until it is 14 15 mm 9 16 19 32 in B from the outside edge of the tube NOTE Before installing new seal fill area A with approximately 8 pumps of grease 1002535 A B Figure 4 258 Idler Roller Bearing 7 Install new seal A by pressing on the inner and outer race of the seal until it is 3 4 mm 1 8 3 16 in B from the outside edge of the tube NOTE The seal can be oriented in either direction 8 Re...

Page 434: ...n idler arms B and secure with two bolts C and washers Tighten the bolts to 95 Nm 70 lbf ft 1032007 A B B C D A B C D Figure 4 260 Draper Connector 2 Attach the ends of draper with tube connectors B screws A with the heads facing the center opening and nuts NOTE The two short tube connectors are attached at the front and rear of the draper 3 Install bridge connector D using screws C and the nuts a...

Page 435: ...cted start up or fall of a raised machine always stop the engine and remove the key from the ignition before leaving the operator s seat or making adjustments to the machine Never work on or beneath an unsupported header If the header is fully raised always engage the safety props If the header is off of the ground but not raised to its full height place blocks under the header DANGER Ensure that ...

Page 436: ...crews A and tube connectors B from the draper joint 10 Remove screws C bridge connector D and nuts from the front end of the draper joint 11 Pull the draper off the drive roller 1027893 A B C Figure 4 264 Drive Roller 12 Align the set screws with the hole A in the guard Remove the two set screws holding the motor onto the drive roller NOTE The set screws are 1 4 turn apart 13 Loosen two bolts B se...

Page 437: ...A securing support arm B 15 Remove bolt C and the washer securing the opposite end of the drive roller to support arm B 16 Remove drive roller D 4 12 11 Replacing Side Draper Drive Roller Bearing You will need a slide hammer to remove and replace the bearing on a drive roller 1 Remove the draper idler roller assembly For instructions refer to 4 12 10 Removing Side Draper Drive Roller page 411 MAIN...

Page 438: ...Bearing 4 Install new bearing assembly A by pressing the outer race of the bearing into the tube until it is 14 15 mm 9 16 19 32 in B from the outside edge of the tube 5 Apply grease in front of bearing assembly A Refer to the inside back cover of this book for grease specifications 6 Install new seal C at the roller opening and install a flat washer 1 0 in I D x 2 0 in O D on the seal 7 Tap seal ...

Page 439: ...olts C on the support arm 4 Torque bolt B to 95 Nm 70 lbf ft 5 Grease the motor shaft and insert it into the end of drive roller A 1027893 A B C Figure 4 270 Drive Roller 6 Secure the motor to the roller support with two bolts B Torque the bolts to 27 Nm 20 lbf ft 7 Ensure the motor is all the way into the roller and straight key is still in place when fully inserted 8 Tighten the two set screws n...

Page 440: ...e draper joint 1032009 A Figure 4 272 Draper Tensioner Left Side Shown 11 Tighten the draper by turning adjuster bolt A clockwise For instructions refer to 4 12 4 Adjusting Side Draper Tension page 402 12 Disengage the reel and header safety props For instructions refer to Disengaging Reel Safety Props page 34 DANGER Ensure that all bystanders have cleared the area 13 Start the engine and lower th...

Page 441: ...le 4 3 Finger to Guard Clearance Single Reel Header End Panels Beside Center Arm FD225 20 mm 0 80 in 45 mm 1 77 in Table 4 4 Finger to Guard Clearance Double Reel Header End Panels At Hinge Points FD230 20 mm 0 80 in 45 mm 1 77 in FD235 FD240 FD241 20 mm 0 80 in 20 mm 0 80 in FD240 20 mm 0 80 in 20 mm 0 80 in Table 4 5 Finger to Guard Clearance Triple Reel Header Outer End Panels Beside Center Arm...

Page 442: ...1034321 A B Figure 4 274 Reel Fore Aft Position 3 Adjust the reel fore aft position until the number seven on fore aft indicator A is hidden by sensor support B ϭϬϯϵϬϮϰ A Figure 4 275 FlexDraper Block Locations Single Reel 4 Single reel headers Raise the header high enough to place two 254 mm 10 in high blocks A under the cutterbar just inboard of the wing flex points MAINTENANCE AND SERVICING ...

Page 443: ... wings of triple reel headers 1029181 A Figure 4 277 Wing Lock in UNLOCK Position 6 Single reel and double reel headers Move wing lock spring handles A down to the UNLOCK position NOTE The reel clearance of triple reel headers must be measured while the wings are locked 7 Lower the header fully The wings of single reel and double reel headers should be in the full frown position the wings of tripl...

Page 444: ...s either pointed guard B or short guard C For the clearance specifications refer to 4 13 1 Reel Clearance to Cutterbar page 417 For the measurement locations refer to Single reel headers Figure 4 279 page 420 Double reel headers Figure 4 280 page 421 Triple reel headers Figure 4 281 page 421 1001595 A Figure 4 279 FlexDraper Measurement Locations Single Reel Single reel measurement locations A Out...

Page 445: ...Reel and Cutterbar Make sure there is sufficient clearance between the reel and cutterbar to prevent the knife from cutting reel finger tips off during operation To adjust the clearance between the reel and cutterbar follow these steps DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operato...

Page 446: ...igure 4 283 FlexDraper Block Locations Single Reel 4 Raise the header high enough to place two 254 mm 10 in high blocks A under the cutterbar just inboard of the wing flex points 1020913 A Figure 4 284 FlexDraper Block Locations Double Reel 5 Raise the header high enough to place two 254 mm 10 in high blocks A under the cutterbar just inboard of the wing flex points MAINTENANCE AND SERVICING ...

Page 447: ...ure 4 286 Outside Arm Cylinder 8 Adjust the clearance at the outboard ends of the reel as follows a Loosen bolt A on the outer arm cylinder b Adjust cylinder rod B as required To increase clearance to the cutterbar turn cylinder rod B out of clevis to raise the reel To decrease clearance to the cutterbar turn cylinder rod B into clevis to lower the reel c Tighten bolt A 9 Repeat Step 8 page 423 at...

Page 448: ...vis to increase the load on the cylinder rod Turn cylinder rod into the clevis to decrease the load on the cylinder rod 14 Tighten bolts A 15 Triple reel Repeat Step 10 page 424 to Step 14 page 424 for the other center reel arm DANGER Ensure that all bystanders have cleared the area 16 Start the engine 17 Raise the reel fully 18 Lower the reel fully and continue holding the control button down to ...

Page 449: ... at each reel disc location for each reel tube NOTE Measure the frown profile before disassembling the reel for servicing so the profile can be maintained during reassembly 3 Shut down the engine and remove the key from the ignition 1001603 A B C Figure 4 289 Center Reel Disc 4 Start with the reel disc closest to the center of the header and proceed outward towards the ends adjusting the header pr...

Page 450: ... same if the reel is centered 1029257 A B C Figure 4 291 Center Support Arm 6 Loosen bolt A on brace B at the center support arm 7 Move the forward end of reel support arm C laterally as required to center the reel 8 Tighten bolt A and torque to 457 Nm 337 lbf ft 4 13 4 Reel Fingers If a reel finger is damaged or worn it will need to be removed so it can be replaced Reel fingers are either steel o...

Page 451: ...Figure 4 292 Tine Tube Arm 6 Attach tine tube arms B to the reel disc at original attachment locations A 7 Cut the damaged finger so it can be removed from the tine tube 8 Remove bolts from the existing fingers and slide the fingers over to replace the finger that was cut off in Step 7 page 427 remove tine tube arms B from the tine tubes as necessary Installing Steel Fingers Once the old steel fin...

Page 452: ...tine tube with bolts and nuts B Removing Plastic Fingers Plastic reel fingers are secured to the tine tube with a single Torx screw WARNING To prevent bodily injury from the fall of a raised reel always engage the reel safety props before going under the raised reel for any reason 1 Lower the header fully 2 Raise the reel fully 3 Shut down the engine and remove the key from the ignition 4 Engage t...

Page 453: ... for any reason WARNING To prevent bodily injury from the fall of a raised reel always engage the reel safety props before going under the raised reel for any reason NOTE This procedure assumes a finger has been removed from the machine For information about removing fingers refer to Removing Plastic Fingers page 428 1001246 Figure 4 296 Installing Plastic Finger 1 Position the new finger on the r...

Page 454: ...o be replaced Removing Bushings from Reels The bushing clamps securing the tine tube to the bushing will need to be released so that the bushing halves can be removed WARNING To prevent bodily injury from the fall of a raised reel always engage the reel safety props before going under the raised reel for any reason IMPORTANT Ensure the tine tube is supported at all times to prevent damage to the t...

Page 455: ...re bolts A are reinstalled at the original locations 1001283 A Figure 4 299 Bushing Clamp 7 Release bushing clamps A using a small screwdriver to separate the serrations Pull the clamp off the tine tube 1004617 A B Figure 4 300 Bushing 8 Rotate tine tube arm A until clear of the disc and slide the arm inboard off of bushing B 9 Remove bushing halves B If required remove the next steel or plastic f...

Page 456: ...shield support C from the tail end of the reel at the applicable tine tube location NOTE There are no endshields on the center disc 12 Remove bolts A securing tine tube arms B to the tail and center discs Tine tube reinforcing kit option 1020907 B A Figure 4 303 Tine Tube Supports 13 Release the bushing clamps or disconnect the support channels from the tine tube support if installed depending on ...

Page 457: ...a small screwdriver to separate the serrations Move the clamps off the bushings 1004616 A B Figure 4 306 Cam End 16 Slide tine tube A outboard to expose bushing B 17 Remove bushing halves B If required remove the next steel or plastic finger so the arm can slide off the bushing Refer to the following procedures if necessary Removing Plastic Fingers page 428 Removing Steel Fingers page 427 MAINTENA...

Page 458: ...rew E and remove finger D if it is too close to the support to allow access to the bushing For instructions refer to Removing Plastic Fingers page 428 or Removing Steel Fingers page 427 1001283 A Figure 4 308 Bushing Clamp 21 Release bushing clamps A using a small screwdriver to separate the serrations 1009848 A Figure 4 309 Tine Tube Reinforcing Kit Bushing Clamp Option 22 Move clamps A off the b...

Page 459: ...B Move the tube slightly away from the reel if necessary 25 Remove bushing halves B from the tine tubes Installing Bushings onto Reels Once the old tine tube bushing halves have been removed the new ones can be installed NOTE This procedure assumes the steps for Removing Bushings from Reels page 430 have been completed WARNING To prevent bodily injury from the fall of a raised reel always engage t...

Page 460: ...ube 3 Slide tine tube A towards the tail end of the reel to insert bushing B into the tine tube arm If the tine tube supports are installed ensure the bushings at those locations slide into the support 4 Reinstall the previously removed fingers Refer to the following procedures as necessary Removing Plastic Fingers page 428 Removing Steel Fingers page 427 1001245 A B Figure 4 314 Bushing 5 Install...

Page 461: ...2 A B Figure 4 316 Cam End 8 Line up tine tube B with the cam arm and install bolt A Torque the bolt to 165 Nm 120 lbf ft 1004614 B C A Figure 4 317 Tail End 9 Install bolts A securing tine tube arm B to the center disc 10 Install tine tube arm B and endshield support C to the tail end of the reel at the applicable tine tube location and secure with bolts A NOTE There are no endshields on the cent...

Page 462: ...tion the lug in each bushing half into the hole in the tine tube 14 Slide tine tube A onto bushing B and position against the disc at the original location 15 Reinstall the previously removed fingers For instructions refer to Removing Plastic Fingers page 428 Removing Steel Fingers page 427 1001245 A B Figure 4 320 Bushing 16 Install bushing clamp A onto the tine tube adjacent to the flangeless en...

Page 463: ...ng tine tube arm B to the center disc 20 Install tine tube arm B and endshield support C to the tail end of the reel at the applicable tine tube location and secure with bolts A NOTE There are no endshields on the center discs Tine tube reinforcing kit option 1004616 A B Figure 4 323 Cam End 21 Position bushing halves B on tine tube A with the flangeless end adjacent to the tine tube arm and posit...

Page 464: ...upport A until its flanges clear channels C before moving the support onto bushing B NOTE If necessary move tine tube D slightly away from the reel to allow the support flange enough room to clear the channel 1001245 A B Figure 4 326 Bushing 24 Install bushing clamp A onto the tine tube adjacent to the flangeless end of bushing B 25 Position clamp A on bushing B so the edges of the clamp and bushi...

Page 465: ...ic Fingers page 429 Installing Steel Fingers page 427 1024528 A C D E B Figure 4 329 Tine Tube Reinforcing Kit Opposite Support Option 29 Reattach channels C to two left facing supports A on each reel with screws B and nuts Torque screws to 43 Nm 32 lbf ft 30 Using screws E reinstall any fingers D that were previously removed For instructions refer to Installing Plastic Fingers page 429 Installing...

Page 466: ... The procedure for replacing reel endshields is applicable to the inboard and outboard cam end Exceptions are noted where applicable DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason Endshields are different for inboard and outboard cam end Refer to Figure 4 330...

Page 467: ... accessible 4 Remove three bolts B 1032041 B C A Figure 4 332 Reel Endshields Outboard Cam End 5 Remove two screws A nuts and outboard cam deflector Retain for reinstallation 6 Lift the end of reel endshield B off support C 1032042 A A Figure 4 333 Reel Endshield Removed Outboard Cam End 7 Remove the reel endshield from supports A MAINTENANCE AND SERVICING ...

Page 468: ... End The procedure for replacing reel endshields is applicable to the inboard and outboard cam end DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason Endshields are different for inboard and outboard cam end Refer to Figure 4 330 page 442 NOTE Arrows in the follo...

Page 469: ...el endshield A off of support B 10 Position new reel endshield C onto support B under existing reel endshield A 11 Position the other end of new reel endshield C onto other support D over existing reel endshield E 12 Reinstall three bolts F 13 Reinstall two screws G cam deflector and nuts removed in Step 6 page 445 on the new reel endshield 14 Tighten all hardware Replacing Reel Endshields at Outb...

Page 470: ...d requiring replacement A is accessible 5 Remove three bolts B 1032027 A B Figure 4 340 Reel Endshields Outboard Tail End 6 Lift the end of reel endshield A off support B 1032032 A B Figure 4 341 Reel Endshield Removed Outboard Tail End 7 Remove the reel endshield from supports A 8 Remove the reel paddle if installed on the reel endshield NOTE Reel end paddles B are installed alternately on the re...

Page 471: ...l End The reel endshields need to be replaced if they are damaged DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason IMPORTANT Reel endshields are different for inboard and outboard tail end of header For illustration refer to 4 330 page 442 1 Lower the reel full...

Page 472: ... 8 Remove M10 bolt A nut B and end finger retainer C from tine tube that secure the bushing and tail end finger Retain for reassembly 9 Slide endshield bushing D to remove Retain the bushing for reassembly 10 Remove and discard damaged reel endshield E 1031439 B A C Figure 4 346 Reel Endshields Inboard Tail End 11 Position new reel endshield A and engage tab onto another endshield B 12 Position th...

Page 473: ...ix M10 screws and nuts C 17 Torque nuts C to 35 Nm 26 lbf ft Do NOT overtighten the nuts to prevent flattening of the tube Replacing Reel Endshield Supports The reel endshield supports need to be replaced if they are damaged DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat fo...

Page 474: ...he tine tube then remove the support from the endshields 8 Insert tabs of new support B into the slots in reel endshields A Ensure the tabs engage both reel endshields 1032055 C A B D E Figure 4 351 Reel Endshield Supports 9 Secure support A to the disc sector with bolt B and nut Do NOT tighten 10 Secure reel endshields C to support A with bolt D and nut Do NOT tighten 11 Reattach the other suppor...

Page 475: ...bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before making adjustments to the machine 1 Start the engine 2 Lower the header fully 3 Adjust the reel fully forward 4 Shut down the engine and remove the key from the ignition 5 Remove the reel drive cover For instructions refer to Removing Reel Drive Cover page 41 6 Open...

Page 476: ...ghtening Reel Drive Chain A correctly tensioned drive chain ensures optimum power transfer while minimizing component wear DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before making adjustments to the machine 1 Shut down the engine and remove the key from the ignition 2 Open the endshield For instru...

Page 477: ...onents to fail prematurely IMPORTANT There should be approximately 38 mm 1 1 2 in of play on one side A of the chain while it is tight on the other side B This level of tension and play in the chain is required to skip one notch on the chain tightener 1028902 1028902 A Figure 4 357 Reel Drive 8 Rotate the reel by hand to verify that the chain is still engaged properly on all teeth on lower sprocke...

Page 478: ...the engine and remove the key from the ignition 2 Remove the reel drive cover For instructions refer to Removing Reel Drive Cover page 41 1028883 B A Figure 4 358 Single Sprocket 3 Loosen reel drive chain A For instructions refer to Loosening Reel Drive Chain page 451 4 Remove reel drive chain A from reel drive sprocket B 1028886 B A Figure 4 359 Single Sprocket 5 Remove the cotter pin and slotted...

Page 479: ... A Figure 4 361 Single Sprocket 4 Install drive chain A onto drive sprocket B 5 Tighten the drive chain For instructions refer to Tightening Reel Drive Chain page 452 6 Reinstall the reel drive cover For instructions refer to Installing Reel Drive Cover page 43 4 14 3 Changing Reel Speed Chain Position with Two Speed Kit Installed The reel drive sprocket is attached to the reel drive motor By chan...

Page 480: ...e double reel drive U joint allows each reel to move independently Lubricate the U joint according to the specifications For instructions refer to 4 3 Lubrication page 272 Replace the U joint if severely worn or damaged For instructions refer to Removing Double Reel or Triple Reel Drive U Joint page 456 Removing Double Reel or Triple Reel Drive U Joint If the double reel U joint is worn or damaged...

Page 481: ...emove six bolts A attaching U joint flange B to driven sprocket C 6 Remove the U joint NOTE It may be necessary to move the right reel sideways so that the U joint can clear the tube ϭϬϯϴϱϬϳ A Figure 4 366 Shim Triple Reel Only 7 Triple reel only There is a shim A between the reel tube and the U joint Make sure to retain this shim for reinstallation MAINTENANCE AND SERVICING ...

Page 482: ...o move the right reel sideways so that the U joint can clear the reel tube ϭϬϯϴϱϬϳ A Figure 4 368 Shim Triple Reel Only 3 Triple reel only Make sure shim A is placed between the reel tube and the U joint Align the holes in the shim with the holes in the reel tube Figure 4 369 U Joint 4 Position the reel tube against the reel drive and engage the stub shaft into the U joint pilot hole 5 Rotate the ...

Page 483: ...have it serviced by your MacDon Dealer DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and remove the key from the ignition 2 Loosen the drive chain For instructions refer to Loosening Reel Drive Chain page 451 3 Remove the drive sprocke...

Page 484: ...talling Reel Drive Motor Follow this procedure to install the reel drive motor If problems occur with the motor remove it and have it serviced by your MacDon Dealer 1028916 B A Figure 4 373 Reel Drive Motor Mounting Holes 1 If mounting holes B are not accessible through the openings in the chain case loosen the mounting hardware on motor mount A and slide the motor mount up or down as required 102...

Page 485: ... chain A onto drive sprocket B 1028927 A B A C D Figure 4 377 Reel Drive Motor Mount 9 If mounting hardware A was loosened for this procedure ensure there are three stacked Belleville washers per bolt B before retightening 10 Orient the Bellville washers so that the outer edge of first washer C is against the casting and the outer edges of the next two washers D are facing each other 11 Tighten nu...

Page 486: ...gine and remove the key from the ignition before making adjustments to the machine 1 Shut down the engine and remove the key from the ignition 2 Remove the reel drive cover For instructions refer to Removing Reel Drive Cover page 41 3 Loosen the drive chain For instructions refer to Loosening Reel Drive Chain page 451 1013936 A Figure 4 379 Supporting Reel 4 Support the inboard end of the right re...

Page 487: ...pilot hole 10 Rotate the reel until the holes in end of the reel tube and U joint flange line up 11 Apply medium strength threadlocker Loctite 243 or equivalent to four 1 2 in bolts A and secure them to the flange with lock washers 12 Torque bolts A to 109 Nm 80 lbf ft 1013936 A Figure 4 383 Supporting Reel 13 Remove temporary reel sling A 14 Tighten the drive chain For instructions refer to Tight...

Page 488: ... for any reason WARNING Ensure that all bystanders have cleared the area NOTE The header float must be set before leveling the ContourMax For instructions refer to Checking and Adjusting Header Float page 129 NOTE The wing balance must be set before leveling the ContourMax For instructions refer to 3 9 4 Checking and Adjusting Wing Balance page 148 1 Unlock the header wings For instructions refer ...

Page 489: ...header measure the distance A from the ground to the tip of the end guard and record both of the measurements If the difference between the end measurements and the center measurement is less than 25 mm 1 in no adjustment is required If the difference between the end measurements and the center measurement is greater than 25 mm 1 in adjustment is required Continue to the next step WARNING Ensure t...

Page 490: ...again Verify that the three measurements are the same If more adjustment is required repeat Step 14 page 466 4 15 2 Lubricating Contour Wheel System Lubricating the contour wheel system will help ensure reliable operation and maximize the service life of the components The components of the contour wheel system require lubrication at different intervals Lubricate the inner wheel assemblies every 2...

Page 491: ...ϱ A A Inner Wheel Assemblies Two Places 5 Apply grease to lubrication points A at the two inner wheel assemblies 1036843 A Figure 4 389 Rubber Plug on Contour Wheel Axle 6 Remove rubber plug A from contour wheel hub Retain the plug for reinstallation MAINTENANCE AND SERVICING ...

Page 492: ...e procedure for the remaining contour wheels 4 15 3 Zeroing Mechanical Indicator Zero the mechanical indicator to make sure it operates accurately DANGER To avoid bodily injury or death from unexpected start up or fall of a raised machine always stop the engine and remove the key from the ignition before making adjustments to the machine If it is impossible to engage safety props and impractical t...

Page 493: ... A is aligned with hole B under the following conditions Cable C is tight Pin is installed in hole D Cylinder E is fully retracted 3 If the notch is not aligned with the hole under those conditions adjust any or all of the following parts Loosen two nuts H and slide tube J up or down Tighten the nuts Adjust cable jam nuts at locations G or F Tighten the cable jam nuts to 6 Nm 4 lbf ft MAINTENANCE ...

Page 494: ...on before making adjustments to the machine 1 Shut down the engine and remove the key from the ignition 1001277 2 3 4 5 6 1 Figure 4 392 Bolt Tightening Sequence 2 Follow the bolt tightening sequence shown and torque the wheel bolts to 115 Nm 85 lbf ft IMPORTANT Whenever a wheel is removed and reinstalled check the wheel bolt torque after 1 hour of operation and every 100 hours thereafter 4 16 2 C...

Page 495: ... B C B Figure 4 393 Transport Assembly Bolts 1 Check the following bolts DAILY to ensure bolts are torqued to specified values Bolts A to 234 Nm 173 lbf ft Bolts B to 343 Nm 253 lbf ft Bolts C to 343 Nm 253 lbf ft MAINTENANCE AND SERVICING ...

Page 496: ...o escape at high speed and with great force An air leak of this nature can thrust the tire in any direction endangering anyone in the area Make sure all the air is removed from the tire before removing the tire from the rim Do NOT remove install or repair a tire on a rim unless you have the proper equipment and experience to perform the job Take the tire and rim to a qualified tire repair shop 1 C...

Page 497: ...e four nuts four bolts and eight flat washers C from the end of the tow bar Retain the hardware for reinstallation 1034554 A B C D Figure 4 396 Removing Pintle Towing Adapter 3 Tape or tie 6 m 20 ft of pull line to harness transport end A 4 Remove bolt B securing the harness in the P clip Retain the bolt 5 From hitch end C gently pull the harness out through the opening in pintle D until you can s...

Page 498: ...lt removed in Step 6 page 474 1034557 B A A Figure 4 398 Installing Clevis Ring Adapter 10 Install four nuts four bolts and eight flat washers A to secure the clevis adapter to the tow bar NOTE Ensure that hardware A is reinstalled in the same orientation it was in before it was removed 11 Reconnect the chain with clevis pin B and secure it with the cotter pin 1034546 A A B A Figure 4 399 Torque S...

Page 499: ...ts and eight flat washers C from the end of the tow bar Retain the hardware for reinstallation 1031909 A B C D Figure 4 401 Removing Clevis Towing Adapter 3 Tape or tie 6 m 20 ft of pull line to harness transport end A 4 Remove bolt B securing the harness in the P clip Retain the bolt for reinstallation 5 From hitch end C gently pull the harness out through the opening in clevis D until you can se...

Page 500: ...p 4 page 475 1031912 A B A Figure 4 403 Installing Pintle Ring Adapter 10 Reinstall four nuts four bolts and eight flat washers A to secure the pintle ring adapter to the tow bar NOTE Ensure that hardware A is reinstalled with the four bolt heads on the same side 11 Reconnect the chain with clevis pin B and secure it with the cotter pin 1034549 A A B A Figure 4 404 Torque Sequence 12 Tighten nuts ...

Page 501: ...ed start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going under the machine for any reason CAUTION Install vertical knife guards before attaching or removing vertical knives Wear heavy gloves when working around or handling knives 1 Raise the header 153 254 mm 6 10 in off of the ground 2 Shut...

Page 502: ... assembly B out remove two bolts C attaching hood D to the vertical knife assembly Loosen two nuts E to loosen slide rail F Milling bar A should now be loose enough to tilt upwards IMPORTANT You should not need to loosen clip hardware G and clips H to slide the knife section assembly out If you need to loosen this hardware make sure to tighten the hardware properly by following Step 13 page 479 du...

Page 503: ... nuts B MAC313789 12 Tighten nuts B to 7 Nm 5 lbf ft A 1032668 D C C E E A I B C E Figure 4 409 Gap Between Clip and Knife Section 13 If you loosened clip hardware A B and clips C tighten the hardware as follows a Tighten M8 nut A so that gap D at the tip of knife sections E does NOT exceed 3 mm 1 8 in b Make sure clips C do NOT clamp too tightly and restrict knife movement c Tighten two M10 nuts ...

Page 504: ...er initial installation and then every 50 hours thereafter To lubricate the vertical knife push rods follow these steps NOTE Some parts have been removed from the illustrations for clarity DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props b...

Page 505: ...pply grease to each push rod grease zerk A 2 per vertical knife as shown 1034825 A B Figure 4 413 Vertical Knife Access Cover Right Side Shown Left Side Opposite 5 Reinstall access cover B and secure it with hex socket button head screws A 6 Repeat the greasing procedure for the opposite vertical knife MAINTENANCE AND SERVICING ...

Page 506: ......

Page 507: ...r wants maximum possible stubble height 1029372 Figure 5 1 Grain Crop Lifter Kit Installation instructions are included in the kit Each kit MACB7022 contains 10 lifters Order the following number of kits depending on header size 7 6 m 25 ft 3 kits 9 1 m 30 ft 3 kits 10 6 m 35 ft 4 kits 12 1 m 40 ft 4 kits 12 5 m 41 ft 4 kits 13 7 m 45 ft 5 kits 15 2 m 50 ft 5 kits 5 1 2 Crop Lifter Storage Rack Ki...

Page 508: ...3 Divider Storage Bracket Kit MACB7030 Installation instructions are included in the kit MACB7030 5 1 4 Floating Crop Dividers ϭϬϯϴϵϮϯ Figure 5 4 Floating Crop Divider Floating dividers follow the ground contour and allow for improved dividing in both lodged and standing crops and reduce trampling Installation instructions are included in the kit MACB7346 OPTIONS AND ATTACHMENTS ...

Page 509: ...ing list of kits according to your header size 7 6 m 25 ft MAC6413 two piece 9 1 m 30 ft MACB6414 two piece 10 6 m 35 ft MACB6415 two piece 12 1 m 40 ft MACB6417 three piece 12 5 m 41 ft MACB6416 two piece 13 7 m 45 ft MACB6418 three piece 15 2 m 50 ft MACB6419 three piece Hydraulic Plumbing Package Required only for headers without factory installed UCA hydraulics Includes hydraulic lines to make...

Page 510: ...odged or tangled crops 1034419 Figure 5 7 VertiBlade Vertical Knife Kit Order the following bundles Base VertiBlade Includes knives mounts drive and hydraulic completion plumbing to complete installation on power divider ready header MACB7029 Hydraulic Plumbing Package The hydraulic plumbing packages are required only for headers without factory installed power divider hydraulics The package inclu...

Page 511: ...by header size FD225 FD230 FD235 and FD241 MACB7122 FD240 FD245 and FD250 MACB7123 NOTE Installation instructions are included in the kits 5 2 2 Four Point Knife Guard Four point guards provide increased knife protection in very rocky conditions and can improve header performance with shatter prone crops by reducing side to side crop motion ϭϬϯϵϲϯϱ Figure 5 9 Four Point Knife Guard Four point guar...

Page 512: ...10V sensors MACB7241 This kit is for the following NH CR CX Combines All CX800 CX8000 CX900 combines CR9040 CR9060 combines before serial number HAJ111000 CR9070 combines before serial number Y8G1412000 5 3 2 Crop Deflector Kits This kit installs different sizes of crop deflectors on the float module depending on feeder house size ϭϬϯϴϮϰϬ Figure 5 10 Crop Deflectors Combine Feeder House Size Bundl...

Page 513: ...re included in the kit 5 3 4 Feed Auger High Wear Flighting Extension Kit The flighting extension kit may allow better feeding of crop in green wet straw conditions for example rice and green cereals 1034300 Figure 5 12 Feed Auger High Wear Flighting Extension Kit Refer to 3 8 1 FM200 Feed Auger Configurations page 89 for a list of flighting combinations MACB6400 NOTE Installation instructions are...

Page 514: ...tions are included in the kit MACB7031 5 3 6 Hydraulic Reservoir Extension Kit The hydraulic reservoir fill extension kit extends the breather cap position This allows the float module to operate on steep hillsides while maintaining oil supply to the suction side of the pump 1017350 Figure 5 14 Hydraulic Reservoir Extension Kit This kit is recommended when operating on hills exceeding 5 MACB6057 N...

Page 515: ...recommended in cereal crops 1012739 Figure 5 16 Stripper Bar Kit Select the stripper bar kit based on combine feeder house width For information refer to Table 5 1 page 491 NOTE Installation instructions are included in the kits Table 5 1 Stripper Bar Configurations and Recommendations Bundle MAC Stripper Bar Length Opening Width Float Module Recommended Feeder House Width B6042 265 mm 10 1 2 in 1...

Page 516: ...ons and Recommendations continued Bundle MAC Stripper Bar Length Opening Width Float Module Recommended Feeder House Width B6046 403 mm 16 in 1041 mm 41 in For specialty crops only B6213 515 mm 20 in 817 mm 32 in For specialty crops only OPTIONS AND ATTACHMENTS ...

Page 517: ...ment from inside the combine cab Installation instructions are included in the kit Order the following bundles Base ContourMax Package Includes wheels mounts cylinders control valve and hydraulic plumbing to complete installation on ContourMax ready header MACB7335 Hydraulic Plumbing Package Includes hydraulic lines to make the header ContourMax ready if it is not factory configured Order from the...

Page 518: ... ft MACC2050 13 7 m 45 ft MACC2050 15 2 m 50 ft MACC2050 MACC2048 consists of Stabilizer Wheels Slow Speed Transport Base Kit MACB6288 Wheels and Tires MACB6275 Short Tow Pole MACB7391 MACC2050 consists of Stabilizer Wheels Slow Speed Transport Base Kit MACB6288 Wheels and Tires White Rims MACB6275 Long Tow Pole MACB7392 NOTE The EasyMove Transport System is not compatible with FD225 headers 5 4 3...

Page 519: ...orts from heavy crop loads ϭϬϯϴϯϲϵ Figure 5 20 Outboard Steel End Finger Installation instructions are included in the kit MAC311959 5 4 5 Side Hill Stabilizer Kit The side hill stabilizer kit is recommended for cutting on side hills with a grade steeper than 5 1034196 Figure 5 21 Side Hill Stabilizer Kit Installation instructions are included in the kit MACB7028 OPTIONS AND ATTACHMENTS ...

Page 520: ...are included in the kit MACC2051 5 4 7 Steel Skid Shoes Kit The steel skid shoes kit provides extended wear skid shoes for use in rocky abrasive conditions 1034301 Figure 5 23 Steel Skid Shoes Kit IMPORTANT Not recommended for wet mud or conditions that are prone to sparking The kit contains two skid shoes For full replacement of standard skid shoes order three bundles six shoes total MACB6801 NOT...

Page 521: ...ACC2088 12 5 m 41 ft double reel MACC2088 13 7 m 45 ft MACC2089 15 2 m 50 ft MACC2170 The collector contains Base Kit Pan and Deflectors Base Kit contains common brackets end dividers cutterbar pan supports lean bar components and hardware MACB7302 Pan Kit contains five pans per kit two spares Order the number of kits depending on headers size MACB7303 9 1 m 30 ft The base kit contains enough pans...

Page 522: ...anels and additional cutterbar pan supports 9 1 m 30 ft MACB7304 10 6 m 35 ft MACB7305 12 1 m 40 ft triple reel MACB7395 12 1 m 40 ft double reel MACB7306 12 5 m 41 ft double reel MACB7306 13 7 m 45 ft MACB7307 15 2 m 50 ft MACB7396 OPTIONS AND ATTACHMENTS ...

Page 523: ...ge 154 3 9 7 Ground Speed page 156 Reel fingers not lifting crop sufficiently Increase finger pitch aggressiveness 3 9 12 Reel Tine Pitch page 178 Reel fingers not lifting crop sufficiently Install crop lifters MacDon Dealer Symptom Heads shattering or breaking off Reel speed too fast Reduce reel speed 3 9 6 Reel Speed page 154 Reel too low Raise reel 3 9 10 Reel Height page 160 Ground speed too f...

Page 524: ...vel Level the header 3 11 Leveling Header page 239 Reel fingers not lifting crop properly ahead of knife Adjust reel position and or finger pitch 3 9 11 Reel Fore Aft Position page 165 3 9 12 Reel Tine Pitch page 178 Divider runs down thick crop at ends preventing proper feeding due to material bridging the guards Replace 3 4 end guards with short knife guard 4 8 8 Short Knife Guards and Hold Down...

Page 525: ...ar continued Problem Solution Refer to Cutting at speeds over 10 km h 6 mph with 10 tooth reel drive sprocket Replace with 19 tooth reel drive sprocket 4 14 2 Reel Drive Sprocket page 453 Worn or broken knife components Replace components 4 8 Knife page 330 TROUBLESHOOTING ...

Page 526: ...358 4 8 1 Replacing Knife Section page 330 Knife is not operating at recommended speed Feeder house speed set too low or knife speed not adjusted to proper range Checking Knife Speed page 159 Ground speed too fast for reel speed Reduce ground speed or increase reel speed 3 9 6 Reel Speed page 154 3 9 7 Ground Speed page 156 Reel fingers not lifting crop properly ahead of knife Adjust reel position...

Page 527: ...p properly ahead of knife Adjust the reel position finger pitch 3 9 11 Reel Fore Aft Position page 165 3 9 12 Reel Tine Pitch page 178 Steel pick up fingers contacting knife Increase the reel clearance to cutterbar or adjust frown 4 13 2 Reel Frown page 425 Float too heavy Adjust the springs for lighter float Checking and Adjusting Header Float page 129 Mud or dirt build up on cutterbar Raise the ...

Page 528: ...nt cutterbar Straighten the cutterbar MacDon Dealer Symptom Excessive breakage of knife sections or guards Knife hold down not adjusted properly Adjust the hold down Adjusting Hold Down Pointed Knife Guards page 348 or Adjusting Hold Down Short Knife Guards page 360 Cutterbar operating too low in stony conditions Raise cutterbar using skid shoes 3 9 2 Cutting on Ground page 126 Float is set too he...

Page 529: ... knifehead pin 4 8 3 Removing Knifehead Bearing page 333 and 4 8 4 Installing Knifehead Bearing page 334 Dull knife Replace the knife 4 8 2 Removing Knife page 331 and 4 8 5 Installing Knife page 334 Knife speed too fast Lower the knife speed Consult your MacDon Dealer Loose knife section hardware Check tighten all of the knife hardware TROUBLESHOOTING ...

Page 530: ...ise the reel 3 9 10 Reel Height page 160 Reel speed too fast Reduce the reel speed 3 9 6 Reel Speed page 154 Reel not centered in header Center the reel in the header 4 13 3 Centering Reel page 425 Symptom Reel releases crop too quickly Reel tines not aggressive enough Increase the cam setting to match reel delivery to the reel fore aft position 3 9 12 Reel Tine Pitch page 178 Reel too far forward...

Page 531: ...ket page 453 Install Two Speed Kit MAC311882 Symptom Plastic fingers cut at tip Insufficient reel to cutterbar clearance Increase the clearance 4 13 1 Reel Clearance to Cutterbar page 417 Symptom Plastic fingers bent rearward at tip Reel digging into ground with reel speed slower than ground speed Raise the header 3 9 2 Cutting on Ground page 126 Reel digging into ground with reel speed slower tha...

Page 532: ...of crop accumulating at cutterbar while maintaining reel operation Correct the plugging cutting issues 3 12 Unplugging Cutterbar page 241 Excessive plugging at cutterbar with wads of crop accumulating at cutterbar while maintaining reel operation Stop the reel before plugging becomes excessive 3 12 Unplugging Cutterbar page 241 TROUBLESHOOTING ...

Page 533: ...ecking and Adjusting Feed Draper Tension page 373 Drive or idler roller wrapped with material Loosen the draper and clean the rollers 4 10 2 Checking and Adjusting Feed Draper Tension page 373 Slat or connector bar jammed by frame or material Loosen the draper and clear the obstruction 4 10 2 Checking and Adjusting Feed Draper Tension page 373 Roller bearing seized Replace the roller bearing Repla...

Page 534: ...unning too slow in heavy crop Increase the draper speed 3 9 8 Side Draper Speed page 157 Symptom Crop is thrown across the opening and under opposite side draper Drapers running too fast in light crop Reduce the draper speed 3 9 8 Side Draper Speed page 157 Symptom Material accumulating on the end deflectors and releasing in bunches End deflectors too wide For headers with manual deck shift only t...

Page 535: ...nd and the header angle properly adjusted 3 9 11 Reel Fore Aft Position page 165 Header angle too shallow Adjust the header angle Adjusting Header Angle from Combine page 154 Header angle too shallow Increase the header angle by fully retracting lift cylinders if cutting on ground Adjusting Header Angle from Combine page 154 Reel too slow Adjust the reel speed to be marginally faster than ground s...

Page 536: ... between top of draper and cutterbar Cutterbar fills with debris when draper to cutterbar gap is properly adjusted Raise the header fully at each end of the field or as required and shift decks back and forth to help clean out the cutterbar Shifting the decks with the header raised does not clean out the cutterbar debris Manually remove the debris from the cutterbar cavity to prevent damaging the ...

Page 537: ...gle 3 9 5 Header Angle page 152 Guards plug with debris or and soil Install the short knife guard 4 8 8 Short Knife Guards and Hold Downs page 354 Insufficient support for the header Install the center skid shoes 3 9 2 Cutting on Ground page 126 Symptom Crop wrapping around reel ends Uncut crop interfering on reel ends Add reel endshields Header parts catalog Symptom Cutterbar fills up with dirt E...

Page 538: ...rain along length of field Cut at 90 to the rolling terrain provided knife floats across without digging in Symptom Reel carries over an excessive amount of plants or wads Excessive accumulation of crop on drapers up to reel center tube Increase the draper speed 3 9 8 Side Draper Speed page 157 Finger pitch too slow Increase the finger pitch 3 9 12 Reel Tine Pitch page 178 TROUBLESHOOTING ...

Page 539: ...d cap screws by reading the markings on their heads Jam nuts Jam nuts require less torque than nuts used for other purposes When applying torque to finished jam nuts multiply the torque applied to regular nuts by 0 65 to obtain the modified torque value Self tapping screws Refer to the standard torque values when installing the self tapping screws Do NOT install the self tapping screws on structur...

Page 540: ...1 75 95 105 70 78 14 2 0 152 168 113 124 16 2 0 236 261 175 193 20 2 5 460 509 341 377 24 3 0 796 879 589 651 1001370 1001370 A Figure 7 2 Bolt Grades Table 7 2 Metric Class 8 8 Bolts and Class 9 Distorted Thread Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 3 0 5 1 1 1 9 10 3 5 0 6 1 5 1 7 14 15 4 0 7 2 3 2 5 20 22 5 0 8 4 5 5 40 45 6 1 0 7 7 8 6 69 76 8 1 25 18 8 20 8 167 185...

Page 541: ... 132 145 97 108 14 2 0 210 232 156 172 16 2 0 326 360 242 267 20 2 5 637 704 472 521 24 3 0 1101 1217 815 901 1001370 1001370 A Figure 7 4 Bolt Grades Table 7 4 Metric Class 10 9 Bolts and Class 10 Distorted Thread Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 3 0 5 1 3 1 5 12 13 3 5 0 6 2 1 2 3 19 21 4 0 7 3 1 3 4 28 31 5 0 8 6 3 7 56 62 6 1 0 10 7 11 8 95 105 8 1 25 26 29 19 ...

Page 542: ...dware installed dry that is hardware with no grease oil or threadlocker on the threads or heads Do NOT add grease oil or threadlocker to bolts or cap screws unless you are directed to do so in this manual 1001370 1001370 A Figure 7 5 Bolt Grades Table 7 5 Metric Bolt Bolting into Cast Aluminum Nominal Size A Bolt Torque 8 8 Cast Aluminum 10 9 Cast Aluminum Nm lbf ft Nm lbf ft M3 1 M4 4 2 6 M5 8 5 ...

Page 543: ... as far as possible Ensure that washer D is loose and is pushed toward lock nut C as far as possible 3 Ensure that O ring A is NOT on the threads Adjust O ring A if necessary 4 Apply hydraulic system oil to O ring A 1003432 D A E B C Figure 7 7 Hydraulic Fitting 5 Install fitting B into the port until backup washer D and O ring A contact part face E 6 Position the angle fittings by unscrewing no m...

Page 544: ...ue values are provided for non adjustable hydraulic fittings If a procedure specifies a different torque value for the same type and size of fitting found in this topic refer to the value specified in the procedure instead Torque values are shown in the table below 1004663 A B C Figure 7 8 Hydraulic Fitting 1 Inspect O ring A and seat B for dirt or defects 2 Ensure that O ring A is NOT on the thre...

Page 545: ...2 270 298 199 220 32 2 1 2 12 332 365 245 269 7 1 5 O Ring Face Seal Hydraulic Fittings The standard torque values are provided for O ring face seal hydraulic fittings If a procedure specifies a different torque value for the same type and size of fitting found in this topic refer to the value specified in the procedure instead Torque values are shown in the Table 7 8 page 522 1001376 Figure 7 9 H...

Page 546: ...ble 7 8 O Ring Face Seal ORFS Hydraulic Fittings SAE Dash Size Thread Size in Tube O D in Torque Value81 Nm lbf ft 3 Note82 3 16 4 9 16 1 4 25 28 18 21 5 Note82 5 16 6 11 16 3 8 40 44 29 32 8 13 16 1 2 55 61 41 45 10 1 5 8 80 88 59 65 12 1 3 16 3 4 115 127 85 94 14 Note82 7 8 16 1 7 16 1 150 165 111 122 20 1 11 16 1 1 4 205 226 151 167 24 1 2 1 1 2 315 347 232 256 32 2 1 2 2 510 561 376 414 7 1 6 ...

Page 547: ... the direction of tightening Never loosen the threaded connectors to achieve alignment 5 Clean all residue and any excess thread conditioner with an appropriate cleaner 6 Inspect the final condition of the fitting Pay special attention to the possibility of cracks in the port opening 7 Mark the final position of the fitting If a fitting leaks disassemble the fitting and check it for damage NOTE Th...

Page 548: ...meter m x 3 2808 foot ft Power kilowatt kW x 1 341 horsepower hp Pressure kilopascal kPa x 0 145 pounds per square inch psi Pressure megapascal MPa x 145 038 pounds per square inch psi Pressure bar Non SI bar x 14 5038 pounds per square inch psi Torque Newton meter Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton meter Nm x 8 8507 pound inches or inch pounds lbf in Temperature degrees Ce...

Page 549: ...r height control 227 calibrating reel height and reel for aft 230 engaging auto header height control 223 sensor output voltage checking voltage range from the cab 220 setting preset cutting height 233 setting up reel speed 226 New Holland combines 10 V adapter 210 checking reel height sensor voltage 232 New Holland CR series combines setting maximum work height 235 New Holland CR CX series combin...

Page 550: ...g adjusting 86 installing on header 189 removing from header 187 installing on header 186 removing from header 184 crop lifter kit 483 crop lifter rack kit 483 cutterbars options 487 unplugging 241 cutting off the ground 120 adjusting stabilizer wheels 121 adjusting transport wheels 122 on ground level 126 D daily start up checks 48 decks side drapers adjusting deck height 400 definition of terms ...

Page 551: ...96 feed drapers adjusting draper tension 373 adjusting speed 158 checking draper tension 373 drive roller bearing installing 380 drive rollers 374 installing 377 removing 374 idler roller 381 installing idler roller 383 removing drive roller bearing 378 removing idler roller 381 replacing feed draper 370 replacing idler roller bearing 386 FFFT definition 21 finger tight definition 21 fingers auger...

Page 552: ...ain adding oil 287 adjusting chain tension 305 changing oil 287 checking oil level 286 lubricating 286 glossary 21 greasing every 10 hours 272 every 100 hours 278 every 25 hours 273 every 250 hours 280 every 50 hours 274 every 500 hours 282 greasing procedure 283 maintenance schedule records 266 ground speeds 156 guards adjusting knife guards 344 replacing center knife guards 361 replacing end kni...

Page 553: ...2 adding oil 292 checking oil level in reservoir 292 I inspections break in inspections 269 maintenance schedule records 266 ISC definition 21 J JIC definition 21 K knife definition 21 knife drive boxes changing oil 368 checking mounting bolts 368 checking oil level 367 knife drive system 367 knife drive box 367 knife guards pointed knife guards and hold downs 337 short knife guards and hold downs...

Page 554: ... 56 NPT definition 21 nut definition 21 O oils changing knife drive box oil 368 header drive completion gearbox adding oil 289 header drive main gearbox adding oil 287 operating modes flex mode 143 rigid mode 145 operating variables headers 120 operations 31 optimizing headers straight combining canola 83 options 483 contourMax 464 adjusting wheels with foot switch 123 leveling wheel height 124 46...

Page 555: ...eplacing outboard tail end 445 reel fingers 426 installing plastic fingers 429 installing steel fingers 427 removing plastic fingers 428 removing steel fingers 427 reel fore aft position 165 reel height 160 reel height sensor 161 replacing sensor 164 reel safety props 33 disengaging 34 engaging 33 reel speed 154 reel tine pitch 178 tine tube bushings 430 installing 435 removing 430 pointed knife g...

Page 556: ...ition 21 sensors AHHC sensors 203 checking and adjusting reel fore aft position 176 checking and adjusting reel height sensor 161 reel height sensor replacing 164 serial numbers locations xii records xii service intervals lubrication 272 servicing See maintenance and servicing short knife guards and hold down double knife short knife guard configuration 12 5 m 41 ft 357 short knife guard configura...

Page 557: ...nsport to field 245 moving wheels front left wheels to field position 250 rear right wheels to field position 252 removing tow bar 246 removing tow bar from storage 259 storing tow bar 249 moving left outboard wheel from transport to working position 245 transport assembly bolts 470 transport systems 470 converting from field to transport 254 moving wheels front left wheels to transport position 2...

Page 558: ... wheels and tires stabilizer wheel Kit option 496 tire inflation pressures 472 wheel bolt torques 470 wing balance checking and adjusting wing balance 148 wobble boxes See knife drive system knife drive box WOT definition 21 ...

Page 559: ...phide NLGI Grade 2 lithium base Driveline slip joints Gear lubricant SAE 85W 140 API service class GL 5 Knife drive box 1 5 liters 1 3 quarts Main gearbox 2 75 liters 2 9 quarts Completion gearbox 2 25 liters 2 4 quarts Hydraulic oil Single grade trans hydraulic oil Viscosity at 60 1 cSt 40 C 104 F Viscosity at 9 5 cSt 100 C 212 F Recommended brands Petro Canada Duratran John Deere Hy Gard J20C Ca...

Page 560: ...USTOMERS M Ma ac cD Do on n c co om m DEALERS P Po or rt ta al l M Ma ac cD Do on n c co om m Trademarks of products are the marks of their respective manufacturers and or distributors Printed in Canada ...

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