Page 1 FD1-Series ® FlexDraper Combine Header IMPORTANT: PAGE 29 HAS BEEN UPDATED SINCE THIS MANUAL WAS PUBLISHED. Operator’s Manual 147831 Revision A 2016 Model Year Original Instruction Featuring MacDon FLEX-FLOAT Technology ™ The harvesting specialists.
Page 2 ® FD1-Series FlexDraper Header for Combines Published: April 2016...
Page 3 Declaration of Conformity 147831 Revision A...
Page 4 147831 Revision A...
Page 5 147831 Revision A...
Page 6 147831 Revision A...
Page 7 Keep this manual handy for frequent reference and to pass on to new Operators or Owners. A manual storage case is located inside the header left endshield. Call your MacDon Dealer if you need assistance, information, or additional copies of this manual. Figure 1: Manual Storage Location...
Page 9 Model and Serial Number Record the model number, serial number, and model year of the header, combine ﬂoat module, and transport/stabilizer wheel option (if installed) in the spaces provided. NOTE: Right-hand (RH) and left-hand (LH) designations are determined from the operator’s position, facing forward. ®...
Page 11: Table Of Contents
TABLE OF CONTENTS Declaration of Conformity ........................i Introduction ............................. v Model and Serial Number........................ vii Safety ..............................1 Safety Alert Symbols........................1 Signal Words........................... 2 General Safety ..........................3 Maintenance Safety ......................... 5 Hydraulic Safety ..........................6 Safety Signs ............................ 7 1.6.1 Installing Safety Decals ......................
Page 12 TABLE OF CONTENTS Operating in Flex Mode ....................62 Operating in Rigid Mode....................63 3.7.3 Checking and Adjusting Header Wing Balance................. 64 Checking Wing Balance ....................65 Adjusting Wing Balance ....................70 3.7.4 Header Angle......................... 72 Adjusting Header Angle....................73 3.7.5 Reel Speed..........................
Page 13 TABLE OF CONTENTS Checking Voltage Range from the Combine Cab (Challenger and Massey Ferguson) ........................124 Engaging the Auto Header Height Control (Challenger and Massey Ferguson) ....126 Calibrating the Auto Header Height Control (Challenger and Massey Ferguson) ....126 Adjusting the Header Height (Challenger and Massey Ferguson)........128 Adjusting the Header Raise/Lower Rate (Challenger and Massey Ferguson) .....129 Setting the Sensitivity of the Auto Header Height Control (Challenger and Massey Ferguson) ........................130...
Page 14 TABLE OF CONTENTS Checking Voltage Range from the Combine Cab (New Holland) ........181 Engaging the Auto Header Height Control (New Holland CR/CX Series) ......183 Calibrating the Auto Header Height Control (New Holland CR/CX Series)......184 Adjusting Header Raise Rate (New Holland CR/CX Series) ..........186 Setting the Header Lower Rate (New Holland CR/CX Series) ...........187 Setting the Sensitivity of the Auto Header Height Control (New Holland CR/CX Series)........................188...
Page 15 TABLE OF CONTENTS 4.4.1 Attaching Header to a Challenger, Gleaner, or Massey Ferguson Combine .......252 4.4.2 Detaching Header from a Challenger, Gleaner, or Massey Ferguson Combine ......257 John Deere Combines ........................260 4.5.1 Attaching Header to John Deere Combine ................260 4.5.2 Detaching Header from John Deere Combine .................264 Lexion Combines ..........................267 4.6.1...
Page 16 TABLE OF CONTENTS Replacing Feed Auger Finger Guides................343 Knives............................345 5.8.1 Replacing Knife Section......................345 5.8.2 Removing Knife........................347 5.8.3 Removing Knifehead Bearing....................347 5.8.4 Installing Knifehead Bearing....................348 5.8.5 Installing Knife ........................348 5.8.6 Spare Knife...........................349 5.8.7 Knife Guards.........................349 Adjusting Knife Guards....................350 Replacing Pointed Guards....................350 Replacing Stub Guards ....................352 Checking Knife Hold-Downs ...................354 5.8.8...
Page 17 TABLE OF CONTENTS 5.13 Reel.............................404 5.13.1 Reel Clearance to Cutterbar....................404 Measuring Reel Clearance .....................404 Adjusting Reel Clearance ....................407 5.13.2 Reel Frown ...........................407 Adjusting Reel Frown .....................407 5.13.3 Centering Double Reels......................408 5.13.4 Reel Fingers .........................409 Removing Steel Fingers ....................409 Installing Steel Fingers ....................409 Removing Plastic Fingers ....................410 Installing Plastic Fingers....................
Page 18 TABLE OF CONTENTS 6.2.3 Stub Guard Conversion Kit ....................448 6.2.4 Vertical Knife Mounts......................448 Header............................449 6.3.1 Divider Latch Kit ........................449 6.3.2 Stabilizer Wheels ........................449 6.3.3 Stabilizer/Slow Speed Transport Wheels.................449 Crop Delivery ..........................450 6.4.1 FM100 Feed Auger Flighting ....................450 6.4.2 Draper Deﬂector (Narrow)......................450 6.4.3 Draper Deﬂector (Wide) ......................451 6.4.4...
Page 19: Safety
1 Safety 1.1 Safety Alert Symbols This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read follow safety message accompanying this symbol.
Page 20: Signal Words
SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The appropriate signal word for each situation has been selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
Page 21: General Safety
SAFETY 1.3 General Safety CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself. • When assembling, operating, and servicing machinery, wear all the protective clothing and personal safety devices that could be necessary for the job at hand.
Page 22 SAFETY • Wear close-ﬁtting clothing and cover long hair. Never wear dangling items such as scarves or bracelets. • Keep all shields in place. Never alter or remove safety equipment. Make sure driveline guards can rotate independently of the shaft and can telescope freely. •...
Page 23: Maintenance Safety
SAFETY 1.4 Maintenance Safety To ensure your safety while maintaining the machine: • Review the operator’s manual and all safety items before operation and/or maintenance of the machine. • Place all controls in Neutral, stop the engine, set the park brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing.
Page 24: Hydraulic Safety
SAFETY 1.5 Hydraulic Safety • Always place hydraulic controls Neutral before dismounting. • Make sure that all components in the hydraulic system are kept clean and in good condition. • Replace any worn, cut, abraded, ﬂattened, or crimped hoses and steel lines. •...
Page 25: Safety Signs
SAFETY 1.6 Safety Signs • Keep safety signs clean and legible at all times. • Replace safety signs that missing become illegible. • If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the current safety sign.
Page 26: Safety Decal Locations
SAFETY 1.7 Safety Decal Locations Figure 1.15: Upper Cross Auger A - MD #174682 Figure 1.16: Slow Speed Transport A - MD #220799 147831 Revision A...
Page 27 SAFETY Figure 1.17: Slow Speed Transport Tow-Bar A - MD #220797 B - MD #220798 Figure 1.18: Vertical Knife A - MD #174684 147831 Revision A...
Page 28 SAFETY Figure 1.19: Endsheets, Reel Arms, and Backsheet A - MD #174632 B - MD #131393 C - MD #184422 D - MD #131392 (Double Reel Only) E - MD #131391 (Two Places) F - MD #166466 147831 Revision A...
Page 29: Understanding Safety Signs
SAFETY 1.8 Understanding Safety Signs MD #113482 General hazard pertaining machine operation and servicing CAUTION To avoid injury or death from improper or unsafe machine operation: • Read the operator’s manual and follow all safety instructions. If you do not have a manual, obtain one from your Dealer.
Page 30 SAFETY MD #131392 Crushing hazard WARNING • To avoid injury from fall of raised reel; fully raise reel, stop the engine, remove the key, and engage safety prop on each reel support arm before working on or under reel. • Refer to header operator’s manual. Figure 1.22: MD #131392 MD #131393 Reel hazard...
Page 31 SAFETY MD #174436 High pressure oil hazard WARNING • Do not go near leaks. • High pressure oil easily punctures skin causing serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. •...
Page 32 SAFETY MD #184372 General hazard pertaining machine operation and servicing CAUTION To avoid injury or death from improper or unsafe machine operation: • Read the operator’s manual and follow all safety instructions. If you do not have a manual, obtain one from your Dealer.
Page 33 SAFETY MD #220797 Tipping hazard in transport mode WARNING • Read the operator’s manual for more information on potential tipping or roll-over of header while transporting. Figure 1.29: MD #220797 MD #220798 Loss of control hazard in transport CAUTION • Do not tow the header with a dented or otherwise damaged tow pole (the circle with the red X shows a dent in the pole).
Page 35: Product Overview
A hydraulic cylinder link between the header and the machine to which it is attached: Center-link It is used to change header angle CGVW Combined vehicle gross weight MacDon D115, D120, D125, D130, D135, D140, or D145 combine draper header D1-Series header from the D1 model number series Double knife Double-knife drive...
Page 36 PRODUCT OVERVIEW Term Deﬁnition Not applicable An internally threaded fastener that is designed to be paired with a bolt National Pipe Thread: A style of ﬁtting used for low pressure port openings Threads on NPT ﬁttings are uniquely tapered for an interference ﬁt O-ring boss: A style of ﬁtting commonly used in port opening on manifolds, pumps, and motors O-ring face seal: A style of ﬁtting commonly used for connecting hoses and tubes...
Page 37: Specifications
PRODUCT OVERVIEW 2.2 Speciﬁcations The following symbol and letters are used in Table : • S: standard • O : optional (factory installed) • O : optional (dealer installed) • — : not available | FD1 | FM100 | Attachments S: standard / O : optional (factory installed) / O : optional (dealer installed) / –: not available...
Page 38 PRODUCT OVERVIEW Cutterbar Effective cutting width (distance between crop divider points) 30-foot header 30 foot (360 in. [914.4 cm]) 35-foot header 35 foot (420 in. [1066.8 cm]) 40 foot (480 in. [1219.2 cm]) 40-foot header 45-foot header 45 foot (540 in. [1371.6 cm]) Cutterbar lift range Varies with combine model Knife...
Page 39 PRODUCT OVERVIEW Conveyor (Draper) and Decks Draper width 41-19/32 in. (1057 mm) Draper drive Hydraulic Draper speed: FM100 Float Module controlled 0–464 fpm (141 m/min.) Delivery opening width 73-19/32 in. (1870 mm) PR15 Pick-Up Reel Quantity of tine tubes 5-, 6-, or 9-tine tubes Center tube diameter 8 in.
Page 40 PRODUCT OVERVIEW Figure 2.1: Header Width 147831 Revision A...
Page 41 PRODUCT OVERVIEW Table 2.1 Header Attachments FM100 Float Module Width 78-11/16 in. (2000 mm) Feed draper 350–400 fpm Speed (107–122 m/min) Width 65-5/16 in. (1660 mm) Outside diameter 22 in. (559 mm) Feed auger Tube diameter 14 in. (356 mm) Speed (varies with 150 rpm combine model)
Page 42: Component Identification
PRODUCT OVERVIEW 2.3 Component Identiﬁcation ® 2.3.1 FD1-Series FlexDraper ® Figure 2.2: FD1-Series FlexDraper 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...
Page 43: Fm100 Float Module
PRODUCT OVERVIEW 2.3.2 FM100 Float Module Figure 2.3: Header Side of FM100 Float Module A - Feed Auger B - Header Float Springs C - Center-Link D - Hydraulic Reservoir E - Gearbox F - Header Support Arms H - Hydraulic Filter G - Feed Draper 147831 Revision A...
Page 44 PRODUCT OVERVIEW Figure 2.4: Combine Side of FM100 Float Module A - Float Module Gearbox B - Hydraulic Compartment Cover C - Reservoir Oil Level Sight Glass D - Center-Link E - Header Height Control Indicator F - Torque Wrench G - Drain Tube (x2) H - Float Lock Handle (x2) J - Auto Header Height Control (AHHC) Sensor...
Page 45: Operation
• It is your responsibility to read and understand this manual completely before operating the header. Contact your MacDon Dealer if an instruction is not clear to you. • Follow all safety messages in the manual and on safety decals on the machine.
Page 46: Operational Safety
OPERATION 3.2 Operational Safety CAUTION Adhere to the following safety precautions: • Follow all safety and operational instructions provided in your operator’s manuals. If you do not have a combine manual, get one from your Dealer and read it thoroughly. •...
Page 47: Header Safety Props
OPERATION 3.2.1 Header Safety Props The header safety props, located on the header lift cylinders, prevent the lift cylinders from unexpectedly retracting and lowering the header. Refer to your combine operator’s manual for instructions. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason.
Page 48: Disengaging Reel Safety Props
OPERATION 3. Use handle (A) to move lock rod to inboard position (B), which engages pin (C) under prop. 4. Lower reel until safety props contact the outer arm cylinder mounts and the center arm pins. Figure 3.4: Reel Safety Prop – Center Arm Disengaging Reel Safety Props 1.
Page 49: Endshields
OPERATION 3. Use the handle (B) to move the lock rod (A) to the outboard position. Figure 3.6: Reel Safety Prop – Center Arm 3.2.3 Endshields A hinged, polyethylene endshield is ﬁtted on each end of the header. Opening Endshields 1.
Page 50: Closing Endshields
OPERATION 4. Pull the endshield free of hinge tab (A) if additional clearance is required, and swing shield towards the rear of the header. 5. Engage safety catch (B) on hinge arm to secure the shield in fully open position. Figure 3.9: Left Endshield Closing Endshields 1.
Page 51: Removing Endshields
OPERATION Removing Endshields 1. Fully open endshield. Refer to Opening Endshields, page 2. Engage lock (A) to prevent endshield movement. 3. Remove self-tapping screw (B). 4. Slide endshield upwards and remove from hinge arm. 5. Place endshield away from work area. Figure 3.12: Left Endshield Installing Endshields 1.
Page 52: Checking And Adjusting Endshields
OPERATION Checking and Adjusting Endshields Endshields are subject to expansion or contraction caused by large temperature variations. The position of the top pin and lower catch can be adjusted to compensate for dimensional changes. 1. Check gap (X) between front end of shields and header frame and compare to the values in Table 3.1 Endshield Gap at Various Temperatures, page...
Page 53 OPERATION 4. Pull endshield at handle depression (A). Endshield is retained by a hinge tab (B) and will open in direction (C). Figure 3.16: Left Endshield 5. Pull the endshield free of hinge tab (A) if additional clearance is required, and swing shield towards the rear of the header.
Page 54 OPERATION 8. Loosen the three bolts (A) on latch assembly (B). 9. Adjust latch assembly to achieve the desired gap between the front end of shield and header frame in accordance with Table 3.1 Endshield Gap at Various Temperatures, page 10.
Page 55: Linkage Covers
OPERATION 3.2.4 Linkage Covers Plastic covers are attached to the header frame to protect the header wing balance mechanism from debris and weather. Removing Linkage Covers 1. Remove screw (A) and lift outboard end of cover (B). Figure 3.22: Linkage Cover 2.
Page 56: Installing Linkage Covers
OPERATION Installing Linkage Covers 1. Position inboard end of cover (A) over linkage and behind indicator bar (B). 2. Lower cover until secure and against header tube. Figure 3.24: Linkage Cover 3. Install screw (A) to hold cover (B) in place. Figure 3.25: Linkage Cover 147831 Revision A...
Page 57: Daily Start-Up Check
OPERATION 3.2.5 Daily Start-Up Check CAUTION • Clear the area of other persons, pets, etc. Keep children away from machinery. Walk around the machine to be sure no one is under, on, or close to it. • Wear close-ﬁtting clothing and protective shoes with slip-resistant soles.
Page 58: Break-In Period
OPERATION 3.3 Break-in Period CAUTION Before investigating an unusual sound or attempting to correct a problem, shut off engine and remove key. NOTE: Until you become familiar with the sound and feel of your new header, be extra alert and attentive. After attaching the header to the combine for the ﬁrst time, follow these steps: 1.
Page 59: Shutting Down The Machine
OPERATION 3.4 Shutting down the Machine DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. To shut down, and before leaving the combine seat for any reason, follow these steps: •...
Page 60: Cab Controls
OPERATION 3.5 Cab Controls CAUTION Be sure all bystanders are clear of machine before starting engine or engaging any header drives. Refer to your combine operator’s manual for identiﬁcation of the following in-cab controls: • Header engage/disengage control • Header height •...
Page 61: Header Setup
3.6 Header Setup 3.6.1 Header Attachments Several attachments to improve the performance of your FD1 header are available as options that can be installed at your MacDon Dealer. Refer to for descriptions of available items. 6 Options and Attachments, page 445 3.6.2 Header Settings...
Page 62 OPERATION Stubble Draper Reel Skid Upper Divider Header Reel Reel Crop Crop Stabilizer Height Speed Speed Shoe Cross Type Condition Rods Angle Position Wheels in. (mm) Setting Position Auger Light 5–10 Down 6 or 7 Middle or Normal 4–8 down B –...
Page 63: Optimizing Header For Straight Combining Canola
OPERATION Stubble Draper Reel Skid Upper Divider Header Reel Reel Crop Crop Stabilizer Height Speed Speed Shoe Cross Type Condition Rods Angle Position Wheels in. (mm) Setting Position Auger Light 5–10 6 or 7 Normal B – C Up or Recom- Storage Peas...
Page 64: Checking And Adjusting Feed Auger Spring Tension
OPERATION Checking and Adjusting Feed Auger Spring Tension The feed auger has an adjustable spring tensioning system that allows the auger to ﬂoat on top of the crop instead of crushing and damaging it. The tension is factory-set and is adequate for most crop conditions. DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 65: Reel Settings
OPERATION 3.6.4 Reel Settings Table 3.3 FD1-Series Recommended Reel Settings Cam Setting Number Reel Position Reel Finger Pattern (Finger Speed Gain) Number 1 (0) 6 or 7 2 (20%) 6 or 7 147831 Revision A...
Page 66 OPERATION Cam Setting Number Reel Position Reel Finger Pattern (Finger Speed Gain) Number 3 (30%) 3 or 4 4 (35%) 2 or 3 NOTE: • Adjust the reel forward to get closer to the ground while tilting the header back. Fingers/tines will dig into the ground at extreme reel-forward positions, so adjust skid shoes or header angle to compensate.
Page 67: Header Operating Variables
OPERATION 3.7 Header Operating Variables Satisfactory function of the header in all situations requires making proper adjustments to suit various crops and conditions. Correct operation reduces crop loss and increases productivity. As well, proper adjustments and timely maintenance will increase the length of service you receive from your machine. The variables listed in Table and detailed on the following pages will affect the 3.4 Operating Variables, page 49...
Page 68 OPERATION Adjusting Stabilizer/Slow Speed Transport Wheels A properly adjusted header will achieve a balance between the amount of header weight carried by the ﬂoat and the amount carried by the stabilizer/slow speed transport wheels. Refer to for recommended use in speciﬁc crops and crop conditions. 3.6.2 Header Settings, page 43 DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key...
Page 69 OPERATION 12. Lower the header to the desired cutting height using the combine controls and check the load indicator. Figure 3.30: Load Indicator IMPORTANT: Continuous operation with excessive spring compression (i.e., load indicator reading greater than 4 or a compressed length [A] less than 11-5/8 in.
Page 70 OPERATION 2. Support the wheel weight by lifting slightly with one hand on handle (B), and pull up on the handle (A) to release the lock. 3. Lift the wheel using handle (B), and engage the support channel into the center slot (C) in the upper support. 4.
Page 71: Cutting On The Ground
OPERATION Cutting on the Ground Cutting on the ground is performed with the header fully lowered 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.
Page 72 OPERATION Adjusting Inner Skid Shoes DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. 1. Raise header to full height, engage safety props. 2.
Page 73: Header Float
OPERATION 4. Remove the lynch pin (A) from each skid shoe (B). 5. Hold the shoe (B) and remove the pin (C) by disengaging from the frame and pulling away from the shoe. 6. Raise or lower the skid shoe (B) to achieve the desired position using the holes in the support (D) as a guide.
Page 74: Checking And Adjusting Header Float
OPERATION 2. Set the ﬂoat for cutting off the ground as follows: a. Set up the stabilizer wheels. Refer to Cutting ® in the FD1 FlexDraper off the Ground, page 49 Combine Header Operator’s Manual. b. Note the ﬂoat value on the ﬂoat indicator and maintain this value during operation (disregard minor ﬂuctuations on the indicator).
Page 75 OPERATION 4. Adjust the reel fore-aft position to between 5 and 6 on the position indicator decal (A) located on the right side reel arm. 5. Lower the reel fully. 6. Stop the engine and remove key from the ignition. Figure 3.40: Fore-Aft Position 7.
Page 76 OPERATION 8. Disengage both header ﬂoat locks by pushing down ﬂoat lock handle (A) and placing it under the hook (UNLOCK). Figure 3.42: Header Float Lock 9. Place stabilizer wheels and slow speed transport wheels (if equipped) in storage position as follows: a.
Page 77 OPERATION 10. Remove the supplied torque wrench (A) from its storage position at the right-hand side of the ﬂoat module frame. Pull in the direction shown to disengage the wrench from the hook. Figure 3.44: Torque Wrench Storage Location 11. Place the supplied torque wrench (A) onto the ﬂoat lock (B).
Page 78 OPERATION 13. Push down on the wrench until indicator (A) reaches a maximum reading and then begins to decrease. Note the maximum reading and repeat at opposite side. Figure 3.47: Indicator 14. Use the following table as a guide for ﬂoat settings: Table 3.5 Float Settings •...
Page 79: Locking/Unlocking Header Float
NOTE: If adequate header ﬂoat cannot be achieved using all of the available adjustments, an optional heavy duty spring is available. See your MacDon Dealer or refer to the parts catalog for ordering information. 19. Proceed to 3.7.3 Checking and Adjusting Header Wing Balance, page Locking/Unlocking Header Float Two header ﬂoat locks—one on each side of the ﬂoat module—lock and unlock the header ﬂoat system.
Page 80: Locking/Unlocking Header Wings
OPERATION To disengage ﬂoat locks (unlock), push down ﬂoat lock handle (A) and place it under the hook. In this position, the header is unlocked, and can ﬂoat with respect to the ﬂoat module. To engage ﬂoat locks (lock), push down ﬂoat lock handle (A) away and out of the hook.
Page 81: Operating In Rigid Mode
OPERATION NOTE: The following steps are only required if the above has not worked. 3. Remove the linkage cover. Refer to Removing Linkage Covers, page 4. Retrieve the supplied torque wrench (A) that is stored on the ﬂoat module frame on the right-hand side. Figure 3.51: Torque Wrench 5.
Page 82: Checking And Adjusting Header Wing Balance
OPERATION NOTE: The following steps are only required if the above has not worked. 3. Remove the linkage cover. Refer to Removing Linkage Covers, page 4. Retrieve the supplied torque wrench (A) that is stored on the ﬂoat module frame on the right-hand side. Figure 3.54: Torque Wrench 5.
Page 83: Checking Wing Balance
OPERATION Checking Wing Balance This procedure describes how to check the balance of each wing. IMPORTANT: To ensure correct wing balance readings, make sure the header ﬂoat is set properly before proceeding. Refer Checking and Adjusting Header Float, page WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine.
Page 84 OPERATION 5. Remove linkage cover (A) by removing bolt (B) and rotating cover upward until inboard end can be lifted off. Figure 3.59: Linkage Cover NOTE: Refer to the decal (A) inside each linkage cover. Figure 3.60: Linkage Cover 6. Unlock the wings by moving spring handles (A) to lower (UNLOCK) position.
Page 85 OPERATION 7. Retrieve wrench (A) from right-hand ﬂoat module leg. Figure 3.62: Torque Wrench 8. Place torque wrench (A) onto bolt (B). Figure 3.63: Balance Linkage 9. Check that pointer (D) is properly positioned as follows: a. Use wrench (A) to move bell crank (B) so that lower edge of bell crank is parallel to top-link (C).
Page 86 OPERATION 10. Move wing upward with torque wrench (A) until pointer lower alignment tab (C) lines up with upper edge of top-link (B). Observe indicator reading (A) on wrench and record it. Figure 3.65: Balance Linkage 11. Move wing downward with torque wrench (A) until pointer upper alignment tab (C) lines up with the lower edge of the top-link (B).
Page 87 OPERATION • If the indicator range is as shown at right, the wing is too heavy. Figure 3.68: Wrench Indicator 12. If no adjustment is required, place wrench (A) back onto the right-hand ﬂoat module leg. Figure 3.69: Torque Wrench 13.
Page 88: Adjusting Wing Balance
OPERATION Adjusting Wing Balance WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine. This procedure describes how to adjust the balance of each wing. Before proceeding, refer to Checking Wing to determine if adjustments are necessary.
Page 89 10. If the cutterbar is not straight when wings are in lock mode, then further adjustments are required. Contact your MacDon Dealer. Figure 3.74: Wing Lock in Lock Position 9. These dimensions are initial settings. Further adjustment will be required if any optional kits have been installed.
Page 90: Header Angle
OPERATION 11. Return the torque wrench (A) to the storage location on the ﬂoat module frame. Figure 3.75: Torque Wrench 12. Reinstall linkage cover (A) and secure it with bolt (B). NOTE: Adjustment to the main ﬂoat may be required to maintain good wing balance when operating in the ﬁeld.
Page 91: Adjusting Header Angle
Refer to Table 73, and 3.7 Optional Reel Drive Sprockets, page contact your MacDon Dealer for ordering information. Table 3.7 Optional Reel Drive Sprockets Optional Drive Machine Hydraulics...
Page 92: Ground Speed
OPERATION For installation details, refer to 5.14.3 Replacing Reel Drive Sprocket, page 429. 3.7.6 Ground Speed Operating at the proper ground speed will result in cleanly cut crops and evenly distributed material into the combine. Reduce ground speed in difﬁcult cutting conditions to reduce loads on cutting components and drives. Use lower ground speeds in very light crops (e.g., short soybeans) to allow the reel to pull in short plants.
Page 93: Draper Speed
OPERATION 3.7.7 Draper Speed Correct draper speed is an important factor for achieving good ﬂow of the cut crop away from the cutterbar. The side drapers and feed draper operate independently of each other, therefore, the speeds are controlled differently. The side draper speed is adjusted with a manually adjustable control valve that is mounted on the ﬂoat module.
Page 94: Feed Draper Speed
OPERATION The ﬂow control (A) valve has settings from 0–9 on the barrel to indicate the draper speed. The ﬂow control valve is factory-set to 6 which should be sufﬁcient for normal crop feeding. To change the draper speed, shut down the combine and rotate the ﬂow control valve dial to adjust the control.
Page 95: Knife Speed
OPERATION 3.7.8 Knife Speed The header knife drive is powered by the ﬂoat module’s hydraulic pump which is driven by the combine feeder house. There is no separate adjustment to control the knife speed. IMPORTANT: Table 3.8 Feeder House Speed For variable speed feeder houses, the rpm values in Feeder House Speed Combine...
Page 96: Reel Height
6. Compare pulley rpm measurement with the rpm values in the knife speed chart. Refer to 3.7.8 Knife Speed, page 7. Contact your MacDon Dealer if the pulley rpm Figure 3.84: Knife Drive Pulley measurement exceeds the speciﬁed rpm range for your header.
Page 97: Manually Checking Voltage Range
OPERATION • Crop being pushed down by the tine tubes The following conditions might result if the reel is set too high: • Cutterbar plugging • Crop lodging and being left uncut • Grain stalks dropping ahead of cutterbar Refer to to determine recommended reel heights for speciﬁc crops and 3.6.2 Header Settings, page 43 crop conditions.
Page 98: Adjusting Reel Height Sensor
OPERATION CAUTION Check to be sure all bystanders have cleared the area. 5. Raise the reel fully. 6. Use a voltmeter to measure the voltage between the ground (Pin 2 wire) and the signal (Pin 3 wire) at the reel height sensor (A). Ensure the voltage is within the X voltage range.
Page 99 OPERATION 1. Lower the reel fully, shut down engine, and remove key from ignition. 2. Loosen two center lock ﬂange nuts (A), and adjust sensor mounting bracket (B) until the threaded rod (C) is parallel with the sensor arm (D). Tighten center lock ﬂange nuts.
Page 100: Reel Fore-Aft Position
OPERATION 3.7.10 Reel Fore-Aft Position Reel fore-aft position is a critical factor for achieving the best results in adverse conditions. The reel position is factory-set for normal conditions, but it can be adjusted forwards or backwards as required using the controls inside the cab.
Page 101 OPERATION 2. Operate the hydraulics to move the reel to the desired position while using the decal (A) as a reference. 3. Check the reel clearance to cutterbar after making changes to the cam setting. Refer to the following for measurement and adjustment procedures: •...
Page 102: Repositioning Fore-Aft Cylinders
OPERATION Repositioning Fore-Aft Cylinders The reel can be moved approximately 9 in. (227 mm) further aft by repositioning the fore-aft cylinders on the reel arms. This may be desirable when straight-combining canola. If the Multi-Crop Rapid Reel Conversion option is installed, refer to Repositioning Fore-Aft Cylinders with Multi-Crop Rapid Reel Conversion Option, page DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key...
Page 103 OPERATION Reposition right arm cylinder as follows: NOTE: Reel components not shown in illustration for improved clarity. 1. Remove four bolts (A) securing cylinder bracket (B) to the reel arm. 2. Push reel back until bracket (B) lines up with the aft set of holes (C).
Page 104 OPERATION Reposition the left reel arm cylinder as follows: NOTE: Reel components not shown in illustration for improved clarity. 1. Remove pin (A) securing cylinder (B) to bracket/light assembly (C). 2. Remove bolts (D) securing bracket/light assembly (C) to the reel arm, and remove the bracket/light assembly. 3.
Page 105: Repositioning Fore-Aft Cylinders With Multi-Crop Rapid Reel Conversion Option
OPERATION Repositioning Fore-Aft Cylinders with Multi-Crop Rapid Reel Conversion Option The reel can be moved approximately 9 in. (227 mm) further aft by repositioning the fore-aft cylinders on the reel arms. The Multi-Crop Conversion option is applicable to double-reel headers only. DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 106 OPERATION Reposition the center arm cylinder as follows: NOTE: Reel components not shown in illustration for improved clarity. 1. Remove cotter pin (A) and clevis pin (B). 2. Push the reel back until the cylinder barrel (C) lines up with the aft holes in bracket (D). 3.
Page 107: Reel Tine Pitch
OPERATION Reposition the right arm cylinder as follows: NOTE: Reel components not shown in illustration for improved clarity. 1. Remove cotter pin (A) and clevis pin (B). 2. Push the reel back until cylinder rod (C) lines up with the aft holes in bracket (D). 3.
Page 108 OPERATION Cam Position 1, Reel Position 6 or 7 delivers the most even crop ﬂow onto the drapers without ﬂufﬁng or disturbing the material. • This setting will release crop close to the cutterbar and works best if the cutterbar is on the ground. •...
Page 109: Adjusting Reel Cam
OPERATION Cam Position 4, Reel Position 2 or 3 is used with the reel fully forward to leave the maximum amount of stubble in lodged crops. • This position allows the reel to reach forward and lift the crop across the knife and onto the drapers. •...
Page 110: Crop Dividers
OPERATION 1. Turn the latch pin (A) counterclockwise using a 3/4 in. wrench to release the cam disc. 2. Use the wrench on bolt (B) to rotate the cam disc and align the latch pin (A) with the desired cam disc hole position (C) (1 to 4).
Page 111: Removing Crop Dividers Without Latch Option From Header
OPERATION 5. Lift crop divider off endsheet and store as follows: a. Insert pin (A) on crop divider into hole in endsheet at location shown. b. Lift crop divider and position lugs (B) on crop divider into bracket on endsheet. Ensure lugs engage bracket.
Page 112 OPERATION 4. Open or remove endshields. Refer to 3.2.3 Endshields, page 5. Remove crop divider from storage location by lifting crop divider to disengage lugs (A) at lower end and then lowering it slightly to disengage pin (B) from endsheet. Figure 3.112: Stored Crop Divider 6.
Page 113: Installing Crop Dividers Without Latch Option Onto Header
OPERATION 9. Pull at the tip of the crop divider and ensure there is no lateral movement. If necessary, adjust bolts (A) to tighten crop divider and eliminate lateral movement. 10. Close or install endshields. Refer to 3.2.3 Endshields, page Figure 3.114: Crop Divider Installing Crop Dividers without Latch Option onto Header DANGER...
Page 114: Crop Divider Rods
OPERATION 6. Position crop divider as shown by inserting lugs (A) into holes in endsheet. Figure 3.116: Crop Divider 7. Lift forward end of crop divider and install bolt (A) and special stepped washer (B) (step towards divider). Tighten bolt. 8.
Page 115: Removing Crop Divider Rods
OPERATION Removing Crop Divider Rods 1. Loosen bolt (A) and remove crop divider rod (B) from both sides of header. Figure 3.118: Crop Divider Rod 2. Store both crop divider rods inboard on the right side endsheet. Figure 3.119: Right Side Endsheet Installing Crop Divider Rods 1.
Page 116: Rice Divider Rods
OPERATION 2. Position crop divider rod (B) on tip of crop divider as shown and tighten bolt (A). 3. Repeat procedure at opposite end of header. Figure 3.121: Divider Rod on Crop Divider Rice Divider Rods Optional rice divider rods provide improved performance in tall and tangled rice crops.
Page 117: Auto Header Height Control (Ahhc)
OPERATION 3.8 Auto Header Height Control (AHHC) MacDon’s auto header height control (AHHC) feature works in conjunction with the AHHC option available on certain combine models. A sensor is installed in the ﬂoat indicator box (A) on the FM100 Float Module. This sensor sends a signal to the combine allowing it to maintain a consistent cutting height and an optimum ﬂoat as the header follows...
Page 118 OPERATION Refer to the following instructions for your speciﬁc combine model: • 3.8.2 Case IH 2500 and 5088/6088/7088 Combines, page 110 • 3.8.3 Case IH 5130/6130/7130, 7010/8010, 7120/8120/9120, and 7230/8230/9230 Combines, page 112 • 3.8.4 Challenger and Massey Ferguson Combines, page 124 •...
Page 119: Sensor Output Voltage Range - Combine Requirements
OPERATION 3.8.1 Sensor Output Voltage Range – Combine Requirements The auto header height control (AHHC) sensor output must be within a speciﬁc voltage range for each combine, or the AHHC feature will not work properly. Table 3.13 Combine Voltage Limits Range (Difference Combine Low Voltage Limit...
Page 120 OPERATION 2. Check that ﬂoat lock linkage is on down stops (washer [A] cannot be moved) at both locations. NOTE: If the header is not on down stops during the next two steps, the voltage may go out of range during operation causing a malfunction of the AHHC system.
Page 121 OPERATION 4. Use a voltmeter (A) to measure the voltage between the ground (Pin 2) and signal (Pin 3) wires at the AHHC sensor in the ﬂoat indicator box. Ensure it is at the high voltage limit for the combine. Refer to Table 3.13 Combine Voltage Limits, page 101.
Page 122: Manually Checking Voltage Range (Two-Sensor System)
OPERATION Manually Checking Voltage Range (Two-Sensor System) FM100 ﬂoat modules equipped with the optional two-sensor system will have a left- and right-hand sensor located on the back frame of the ﬂoat module. To manually check the sensor’s output voltage range, follow these steps: 1.
Page 123 OPERATION 3. Adjust the cable take-up bracket (B) (if necessary) until the pointer (A) on the ﬂoat indicator is on the 0. Figure 3.130: Float Indicator Box 4. Use a voltmeter to measure the voltage between the ground (Pin 2) and signal (Pin 3) wires of the AHHC sensor (A) at the back of the ﬂoat module side frame.
Page 124: Adjusting Voltage Limits (One-Sensor System)
OPERATION 7. Using a voltmeter, measure the voltage between the ground (Pin 2) and signal (Pin 3) wires of the AHHC sensor (A) at the back of the side frame. It should be at the low voltage limit for the combine—refer to Table 3.13 Combine Voltage Limits, page 101.
Page 125 OPERATION 1. Complete the following steps to adjust the upper voltage limit: a. Extend guard angle fully; the header angle indicator should be at D. b. Position header 6–10 in. above the ground; the ﬂoat indicator should be at the 0. c.
Page 126: Adjusting Voltage Limits (Two-Sensor System)
OPERATION Adjusting Voltage Limits (Two-Sensor System) DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. 1. Extend guard angle fully; the header angle indicator should be at D. 2.
Page 127 OPERATION 4. Adjust right-hand sensor voltage: a. Loosen sensor mounting nuts (A). b. Rotate sensor clockwise to lower the voltage. Rotate sensor counterclockwise to raise the voltage. c. Check that the right-hand sensor is at the correct upper voltage limit according to Table 3.13 Combine Voltage Limits, page 101.
Page 128: Case Ih 2500 And 5088/6088/7088 Combines
OPERATION 3.8.2 Case IH 2500 and 5088/6088/7088 Combines Calibrating the Auto Header Height Control (Case IH 2500 and 5088/6088/7088) For best performance of the auto header height control (AHHC) system, perform ground calibration with center-link set to D. When calibration is complete, adjust the center-link back to desired header angle. Refer to 3.7.4 Header Angle, page NOTE:...
Page 129: Setting The Sensitivity Of The Auto Header Height (Case Ih 2500 And 5088/6088/7088)
OPERATION Figure 3.140: Joystick Lever (Case IH 5088/6088/7088) Setting the Sensitivity of the Auto Header Height (Case IH 2500 and 5088/6088/7088) The sensitivity adjustment controls the distance 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.
Page 130: Case Ih 5130/6130/7130, 7010/8010, 7120/8120/9120, And 7230/8230/9230 Combines
OPERATION Figure 3.142: Height Sensitivity Change Page 3.8.3 Case IH 5130/6130/7130, 7010/8010, 7120/8120/9120, and 7230/8230/9230 Combines Checking Voltage Range from the Combine Cab (Case 8010) NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates.
Page 131 OPERATION 2. Check that ﬂoat lock linkage is on down stops (washer [A] cannot be moved) at both locations. NOTE: If the header is not on down stops during the next two steps, the voltage may go out of range during operation causing a malfunction of the AHHC system.
Page 132 OPERATION 4. Ensure header ﬂoat is unlocked. 5. Select DIAG (A) on the Universal display MAIN page. The DIAG page displays. Figure 3.145: Case 8010 Combine Display 6. Select SUB SYSTEM (A). The SUB SYSTEM page displays. Figure 3.146: Case 8010 Combine Display 7.
Page 133: Checking Voltage Range From The Combine Cab (Case Ih 5130/6130/7130, 7010/8010; 7120/8120/9120; 7230/8230/9230)
OPERATION 8. Select LEFT SEN (A). The exact voltage is displayed. Raise and lower the header to see the full range of voltage readings. Figure 3.148: Case 8010 Combine Display 9. If the sensor voltage is not within the low and high limits, or if the range between the low and high limits is insufﬁcient, adjust the voltage limits.
Page 134 OPERATION 2. Check that ﬂoat lock linkage is on down stops (washer [A] cannot be moved) at both locations. NOTE: If the header is not on down stops during the next two steps, the voltage may go out of range during operation causing a malfunction of the AHHC system.
Page 135 OPERATION 4. Ensure header ﬂoat is unlocked. 5. Select DIAGNOSTICS (A) on the MAIN page. The DIAGNOSTICS page opens. 6. Select SETTINGS. The SETTINGS page opens. Figure 3.152: Case IH Combine Display 7. Select the GROUP arrow (A). The GROUP dialog box. Figure 3.153: Case IH Combine Display 8.
Page 136: Calibrating The Auto Header Height Control (Case Ih 5130/6130/7130, 7010/8010; 7120/8120/9120; 7230/8230/9230)
OPERATION 9. Select LEFT HEADER HEIGHT SEN (A), and then select the GRAPH button (B). The exact voltage is displayed at top of page. Raise and lower the header to see the full range of voltage readings. 10. If the sensor voltage is not within the low and high limits or, if the range between the low and high limits is insufﬁcient, adjust the voltage limits.
Page 137 OPERATION 5. Set AUTO REEL SPEED SLOPE. 6. Set HEADER PRESSURE FLOAT to NO if equipped, and ensure REEL DRIVE is HYDRAULIC. Figure 3.157: Case IH Combine Display 7. Install REEL FORE-BACK (if applicable). 8. Set HEIGHT SENSITIVITY to desired value. recommended starting point is 180.
Page 138: Calibrating The Auto Header Height Control (Case Combines With Version 28.00 Or Higher Software)
OPERATION 10. Press HEAD2 at bottom of page. 11. Ensure HEADER TYPE is DRAPER. NOTE: If recognition resistor is plugged in to header harness, you will not be able to change this. 12. Set cutting type to PLATFORM. 13. Set appropriate HEADER WIDTH...
Page 139 OPERATION 5. Locate the HEADER SENSORS and HEADER PRESSURE FLOAT ﬁelds. They will be located on either the HEAD 1 or the HEAD 2 tab. 6. Select ENABLE (A) in the HEADER SENSORS ﬁeld. 7. Select HEADER PRESSURE FLOAT ﬁeld. Figure 3.162: Case IH Combine Display 8.
Page 140: Setting Preset Cutting Height (Case 7010/8010, 7120/8120/9120, 7230/8230/9230)
OPERATION 11. Follow the calibration steps in the order in which they appear in the dialog box. As you proceed through the calibration process, the display will automatically update to show the next step. NOTE: Pressing the ESC key during any of the steps or letting the system sit idle for more than three minutes will cause the calibration procedure to stop.
Page 141 OPERATION 6. To swap between set points, press HEADER RESUME (A). 7. To pick up header at headlands, press HEADER RESUME (A) twice. To lower, press HEADER RESUME (A). NOTE: You can ﬁne adjust these set points by using the FINE ADJUST switch (A).
Page 142: Challenger And Massey Ferguson Combines
OPERATION 3.8.4 Challenger and Massey Ferguson Combines Checking Voltage Range from the Combine Cab (Challenger and Massey Ferguson) NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates. 1.
Page 143 OPERATION 4. Go to the FIELD page on the combine monitor, and then press the diagnostics icon. MISCELLANEOUS page displays. 5. Press the VMM DIAGNOSTIC button (A). The VMM DIAGNOSTIC page displays. Figure 3.171: Challenger Combine Display 6. Go to the ANALOG IN tab, and then select VMM MODULE 3 by pressing the text box below the four tabs.
Page 144: Engaging The Auto Header Height Control (Challenger And Massey Ferguson)
OPERATION Engaging the Auto Header Height Control (Challenger and Massey Ferguson) NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates. The following system components are required in order for the auto header height control (AHHC) to work: •...
Page 145 OPERATION 2. On the FIELD page, press the DIAGNOSTICS icon. The MISCELLANEOUS page appears. Figure 3.175: Challenger Combine Display 3. Press CALIBRATIONS button. CALIBRATIONS page appears. Figure 3.176: Challenger Combine Display 4. Press the HEADER button. The HEADER CALIBRATION page displays a warning. Figure 3.177: Challenger Combine Display 147831 Revision A...
Page 146: Adjusting The Header Height (Challenger And Massey Ferguson)
OPERATION 5. Read the warning message, and then press the green check mark button. Figure 3.178: Challenger Combine Display 6. Follow the on-screen prompts to complete calibration. NOTE: The calibration procedure can be cancelled at anytime by pressing the cancel button in the bottom right corner of the screen.
Page 147: Adjusting The Header Raise/Lower Rate (Challenger And Massey Ferguson)
OPERATION The selected AHHC height is adjusted using the HEIGHT ADJUSTMENT knob on the control console. Turning the knob clockwise increases the selected height, and turning the knob counterclockwise decreases the selected height. Figure 3.180: Height Adjustment Knob on the Combine Control Console Adjusting the Header Raise/Lower Rate (Challenger and Massey Ferguson) NOTE:...
Page 148: Setting The Sensitivity Of The Auto Header Height Control (Challenger And Massey Ferguson)
OPERATION 3. Go to the TABLE SETTINGS tab. 4. Press up arrow on MAX UP PWM to increase percentage number and increase raise speed; Press down arrow on MAX UP PWM to decrease percentage number and decrease raise speed. 5. Press up arrow on MAX DOWN PWM to increase percentage number and increase lower speed;...
Page 149 OPERATION 3. Adjust the sensitivity to the maximum setting. 4. Activate the AHHC, and press the HEADER LOWER button on the control handle. 5. Decrease the sensitivity until the feeder house remains steady and does not bounce up and down. NOTE: This is the maximum sensitivity and is only an initial setting.
Page 150: Gleaner R65/R66/R75/R76 And S Series Combines
OPERATION 3.8.5 Gleaner R65/R66/R75/R76 and S Series Combines Checking Voltage Range from the Combine Cab (Gleaner R65/R66/R75/R76 and S Series) NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates. 1.
Page 151: Engaging The Auto Header Height Control (Gleaner R65/R66/R75/R76 And S Series)
OPERATION Figure 3.188: Combine Heads Up Display 4. Ensure header ﬂoat is unlocked. 5. Press and hold button (A) on the heads-up display for three seconds to enter diagnostic mode. 6. Scroll down using button (B) until LEFT is displayed on the LCD screen. 7.
Page 152 OPERATION Figure 3.189: Combine Auto Header Height Controls 1. Press the AUTO MODE (A) button until the AHHC LED light (B) begins ﬂashing. If the RTC light is ﬂashing, press the AUTO MODE (A) button again until it switches to AHHC. 2.
Page 153: Calibrating The Auto Header Height Control (Gleaner R65/R66/R75/R76 And S Series)
The engine rpm must be above 2000 rpm. The header tilt option on 2004 and earlier model combines does not work with MacDon headers. This system will have to be removed and disabled in order to calibrate the auto header height control (AHHC).
Page 154: Turning Off The Accumulator (Gleaner R65/R66/R75/R76 And S Series)
OPERATION 5. Press CAL2 button (G) until lower header light (E) stops ﬂashing, and release it when the raise header light (D) begins ﬂashing. 6. Raise header to its maximum height (ensure the header is resting on the down-stop pads). 7.
Page 155: Adjusting Ground Pressure (Gleaner R65/R66/R75/R76 And S Series)
OPERATION The auto header height control (AHHC) system’s stability is affected by hydraulic ﬂow rates. Ensure that the header raise (A) and header lower (B) adjustable restrictors in the hydraulic valve block are adjusted so that it takes approximately six seconds to raise the header from ground level to maximum height (hydraulic cylinders fully extended), and approximately six seconds to lower the header from maximum height to ground level.
Page 156: Adjusting The Sensitivity Of The Auto Header Height Control (Gleaner R65/R66/R75/R76 And S Series)
OPERATION NOTE: The ideal ground pressure, in most cases, is one number of separation on the AHHC from having the header fully suspended off the ground (B) to just resting on the ground (A). Figure 3.195: Float Indicator Box Adjusting the Sensitivity of the Auto Header Height Control (Gleaner R65/R66/R75/R76 and S Series) NOTE: Changes may have been made to the combine controls or display since this document was published.
Page 157: Troubleshooting Alarms And Diagnostic Faults (Gleaner R65/R66/R75/R76 And S Series)
OPERATION The SENSITIVITY ADJUSTMENT dial (A) controls the distance the cutterbar must travel up or down before the AHHC reacts and raises or lowers the feeder house. When the SENSITIVITY ADJUSTMENT dial (A) is set to maximum (turned completely clockwise), only small changes in ground height are needed to cause the feeder house to raise or lower.
Page 158 OPERATION Displayed on LCD (A) as XX in. or XXX cm. Figure 3.198: Combine Heads up Display Alarm conditions: If an error message is received from the fuse panel, an audible alarm sounds. The LCD on the electronic instrument panel (EIP) indicates the header system in error as HDR CTRL followed by HGT ERR for height, and HDR CTRL followed by TILT ERR for tilt.
Page 159 OPERATION Diagnostic fault failures: Refer to Figure 3.198: Combine Heads up Display, page 140. Pressing the header height switch (B) for a minimum of ﬁve seconds will put the EIP in header diagnostic mode. The LCD (shown on previous page) will display the message HDR DIAG when the EIP has entered header diagnostic mode.
Page 160: John Deere 60 Series Combines
OPERATION 3.8.6 John Deere 60 Series Combines Checking Voltage Range from the Combine Cab (John Deere 60 Series) NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates. CAUTION Check to be sure all bystanders have cleared the area.
Page 161: Calibrating The Auto Header Height Control (John Deere 60 Series)
OPERATION Figure 3.201: John Deere Combine Display 4. If the sensor voltage is not within the low and high limits or if the range between the low and high limits is insufﬁcient, refer to Adjusting Voltage Limits (One-Sensor System), page 106.
Page 162 OPERATION 5. Press the DIAGNOSTIC button (A) on the monitor. DIA appears on the monitor. 6. Press the CAL button (B). DIA-CAL appears on the monitor. Figure 3.202: John Deere Combine Display 7. Press the UP or DOWN buttons until HDR appears on the monitor.
Page 163: Turning The Accumulator Off (John Deere 60 Series)
OPERATION 10. Press the CAL button (A) to save the calibration of the header. HDR H-UP appears on the monitor. 11. Raise the header three feet off the ground and press the CAL (A) button. EOC appears on the monitor. 12.
Page 164: Setting The Sensitivity Of The Auto Header Height Control (John Deere 60 Series)
NOTE: Do NOT use the active header ﬂoat function (A) in combination with the MacDon auto header height control (AHHC)—the two systems will counteract one another. The header symbol (B) on the display should NOT have a wavy line under it and should...
Page 165: Adjusting The Threshold For The Drop Rate Valve (John Deere 60 Series)
OPERATION 1. Press the DIAGNOSTIC button (A) on the monitor. DIA appears on the monitor. 2. Press the UP button (B) until EO1 appears on the monitor, and press ENTER (D). This is the header adjustment. 3. Press the UP (B) or DOWN (C) button until 112 is displayed on the monitor.
Page 166 OPERATION 1. Press the DIAGNOSTIC button (A) on the monitor. DIA appears on the monitor. 2. Press the UP button (B) until EO1 appears on the monitor and press ENTER (C). This is the header adjustment. 3. Press the UP (B) or DOWN button until 114 is displayed on the top portion of the monitor.
Page 167: John Deere 70 Series Combines
OPERATION 3.8.7 John Deere 70 Series Combines Checking Voltage Range from the Combine Cab (John Deere 70 Series) NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates. CAUTION Check to be sure all bystanders have cleared the area.
Page 168 OPERATION 4. Press the HOME PAGE button (A) on the main page of the monitor. Figure 3.212: John Deere Combine Display 5. Ensure the three icons (A) depicted in the illustration at right appear on the monitor. Figure 3.213: John Deere Combine Display 6.
Page 169 OPERATION 7. Use the scroll knob to highlight DIAGNOSTIC ADDRESSES (A) from the right column and select it by pressing the check mark button. 8. Use the scroll knob to highlight drop down box (B) and press the check mark button to select it. Figure 3.215: John Deere Combine Display 9.
Page 170: Calibrating Feeder House Speed (John Deere 70 Series)
OPERATION 13. Check the sensor reading on the monitor. 14. Raise the header so it is just off the ground and recheck the sensor reading. 15. If the sensor voltage is not within the low and high limits or if the range between the low and high limits is insufﬁcient, refer to Adjusting Voltage Limits (One-Sensor System), page 106.
Page 171 OPERATION 7. Select HEADER in box (A) by scrolling down to the box using the scroll knob, and then pressing the check mark button (knob and button are shown in Figure 3.220: John Deere Combine Control Console, page 153). 8. Scroll down to the lower right icon that resembles an arrow in a diamond (B) and press the check mark button to select it.
Page 172: Setting The Sensitivity Of The Auto Header Height Control (John Deere 70 Series)
OPERATION Setting the Sensitivity of the Auto Header Height Control (John Deere 70 Series) The sensitivity adjustment controls the distance 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.
Page 173 OPERATION 1. Press button (A) and the current raise/lower rate setting will appear on the monitor (the lower the reading, the slower the rate). 2. Use scroll knob (B) to adjust the rate. The adjustment will be saved automatically. NOTE: If the page remains idle for a short period of time, it will automatically return to the previous page.
Page 174: John Deere S And T Series Combines
OPERATION 3.8.8 John Deere S and T Series Combines Checking Voltage Range from the Combine Cab (John Deere S and T Series) NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates.
Page 175 OPERATION 4. Press the CALIBRATION icon (A) on the main page of the monitor. The CALIBRATION page appears. Figure 3.227: John Deere Combine Display 5. Press DIAGNOSTIC READINGS icon on the CALIBRATION page. The DIAGNOSTIC READINGS page appears. This page provides access to calibrations, header options, and diagnostic information.
Page 176 • CENTER HEADER HEIGHT • RIGHT HEADER HEIGHT A reading is displayed for both left- and right sensor. On the MacDon header, there are two sensors located at the back of the ﬂoat module side frame. Figure 3.231: John Deere Combine Display 10.
Page 177: Calibrating The Auto Header Height Control (John Deere S And T Series)
OPERATION Calibrating the Auto Header Height Control (John Deere S and T Series) For best performance of the auto header height control (AHHC), perform these procedures with the center-link set to D. When setup and calibration are complete, adjust the center-link back to desired header angle. Refer to 3.7.4 Header Angle, page NOTE: Changes may have been made to the combine controls or display since this document was published.
Page 178 OPERATION 6. Select FEEDER HOUSE SPEED (A) and calibrate. 7. Select HEADER (B) and calibrate. Figure 3.234: John Deere Combine Display 8. Press icon (A) with either FEEDER HOUSE SPEED or HEADER selected and the icon will turn green. Figure 3.235: John Deere Combine Display 9.
Page 179: Setting The Sensitivity Of The Auto Header Height Control (John Deere S And T Series)
OPERATION Setting the Sensitivity of the Auto Header Height Control (John Deere S and T Series) The sensitivity adjustment controls the distance 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.
Page 180 OPERATION 1. Press button (A) and the current sensitivity setting will appear on the monitor. Figure 3.239: John Deere Combine Command Center 2. Press the - or + icon (A) to adjust rates. NOTE: The numbers depicted on the displays in these illustrations are for reference purposes only;...
Page 181: Calibrating Feeder House Fore/Aft Tilt Range (John Deere S And T Series)
OPERATION Calibrating Feeder House Fore/Aft Tilt Range (John Deere S and T Series) For best performance of the auto header height control (AHHC), perform these procedures with the center-link set to D. When setup and calibration are complete, adjust the center-link back to desired header angle. Refer to 3.7.4 Header Angle, page This procedure applies only to model year 2015 and later John Deere S and T Series combines.
Page 182 OPERATION 4. Press the DIAGNOSTIC icon (A) on the main page of the monitor. The CALIBRATION page displays. Figure 3.244: John Deere Combine Display 5. Select the CALIBRATIONS drop-down menu (A) to view the list of calibration options. Figure 3.245: John Deere Combine Display 6.
Page 183 OPERATION 7. Press the ENTER icon (A). Figure 3.247: John Deere Combine Display 8. Follow the instructions that appear on the screen. As you proceed through the calibration process, the display will automatically update to show the next step. NOTE: If an error code appears during calibration, the sensor is out of voltage range and will require adjustment.
Page 184: Lexion 500 Series Combines
OPERATION 3.8.9 Lexion 500 Series Combines Calibrating the Auto Header Height Control (Lexion 500 Series) For best performance of the auto header height control (AHHC), perform these procedures with the center-link set to D. When setup and calibration are complete, adjust the center-link back to desired header angle. Refer to 3.7.4 Header Angle, page NOTE: Changes may have been made to the combine controls or display since this document was published.
Page 185 OPERATION 5. Use the < or > key to select CUTT.HEIGHT LIMITS, and press the OK key (C). 6. Follow the procedure displayed on the screen to program the upper and lower limits of the header into the CEBIS. Figure 3.251: Lexion Combine Display 7.
Page 186: Setting Cutting Height (Lexion 500 Series)
OPERATION Setting Cutting Height (Lexion 500 Series) Cutting heights can be programmed into the preset cutting height and auto contour systems. Use the preset cutting height system for cutting heights above 5.9 in. (150 mm), and use the auto contour system for cutting heights below 5.9 in.
Page 187 OPERATION 8. Brieﬂy press button (A) or button (B) in order to select the set point. 9. Repeat Step for the set point. 7., page 168 Figure 3.256: Joystick Buttons Setting Cutting Height Manually (Lexion 500 Series) CAUTION Check to be sure all bystanders have cleared the area. NOTE: Changes may have been made to the combine controls or display since this document was published.
Page 188: Setting The Sensitivity Of The Auto Header Height Control (Lexion 500 Series)
OPERATION Setting the Sensitivity of the Auto Header Height Control (Lexion 500 Series) The sensitivity adjustment controls the distance 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.
Page 189 OPERATION Figure 3.260: Flow Chart for Setting the Sensitivity of the Float Optimizer 147831 Revision A...
Page 190: Adjusting Auto Reel Speed (Lexion 500 Series)
OPERATION Adjusting Auto Reel Speed (Lexion 500 Series) The preset reel speed can be set when the automatic header functions are activated. NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates.
Page 191 OPERATION 5. Press and hold button (A) or button (B) for three seconds to store the setting into the CEBIS (an alarm will sound when the new setting has been stored). NOTE: Whenever button (A) or button (B) is pressed for three seconds, the current positions for reel speed and cutting height are stored.
Page 192 OPERATION 7. Press the OK key (E), and use the < key (C) or the > key (D) to select the REEL FORE AND AFT window. 8. Use the – key (A) or the + key (B) to set the reel fore-aft position.
Page 193: Lexion 600 And 700 Series Combines
OPERATION 3.8.10 Lexion 600 and 700 Series Combines Calibrating the Auto Header Height Control (Lexion 600 and 700 Series) For best performance of the auto header height control (AHHC), perform these procedures with the center-link set to D. When setup and calibration are complete, adjust the center-link back to desired header angle. Refer to 3.7.4 Header Angle, page NOTE: Changes may have been made to the combine controls or display since this document was published.
Page 194 OPERATION 5. Use control knob (A) to highlight the icon that resembles a header with up and down arrows (C), and press control knob (A) to select it. Figure 3.271: Lexion Combine Display, Console, and Joystick Lever 6. Use control knob (A) to highlight the icon that resembles a screwdriver (B).
Page 195: Setting Cutting Height (Lexion 600 And 700 Series)
OPERATION 13. Ensure the progress bar chart displays 100% (A). The calibration procedure is now complete. NOTE: If the voltage is not within the range of 0.5–4.5 volts at any time throughout the calibration process, the monitor will indicate learning procedure not concluded. NOTE: If header ﬂoat is set too light, an error message will appear.
Page 196 OPERATION 1. Use control knob (A) to highlight the HEADER/REEL icon (B), and press control knob (A) to select it. The HEADER/REEL dialog box opens. 2. Select HEADER icon. Figure 3.276: Lexion Combine Display, Console, and Joystick Lever 3. Select the FRONT ATTACHMENT PARAMETER SETTINGS icon (A).
Page 197: Adjusting Auto Reel Speed (Lexion 600 And 700 Series)
OPERATION Adjusting Auto Reel Speed (Lexion 600 and 700 Series) NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates. 1. Use control knob (A) to highlight the HEADER/REEL icon (B), and press control knob (A) to select it.
Page 198 OPERATION 3. Select ACTUAL VALUE (A) from the AUTO REEL SPEED dialog box (if you are using Auto Reel Speed). The ACTUAL VALUE dialog box indicates the auto reel speed. Figure 3.281: Lexion Combine Display, Console, and Joystick Lever 4. Use control knob (A) to raise or lower the reel speed. NOTE: This option is only available at full throttle.
Page 199: New Holland Combines
OPERATION 3.8.11 New Holland Combines NOTE: For New Holland CR models 6.80, 6.90, 7.90, 8.90, 9.90, and 10.90, refer to 3.8.12 New Holland Combines (CR Series—Model Year 2015 and Later), page 191. Checking Voltage Range from the Combine Cab (New Holland) NOTE: Changes may have been made to the combine controls or display since this document was published.
Page 200 OPERATION 3. Adjust the cable take-up bracket (B) (if necessary) until the pointer (A) on the ﬂoat indicator is on the 0. Figure 3.285: Float Indicator box 4. Ensure header ﬂoat is unlocked. 5. Select DIAGNOSTICS (A) on the main page. The DIAGNOSTICS page displays.
Page 201: Engaging The Auto Header Height Control (New Holland Cr/Cx Series)
OPERATION 8. Select HEADER HEIGHT/TILT(A). The PARAMETER page displays. Figure 3.288: New Holland Combine Display 9. Select LEFT HEADER HEIGHT SEN (A), and then select GRAPH button (B). The exact voltage is displayed at the top of the page. 10. Raise and lower the header to see the full range of voltage readings.
Page 202: Calibrating The Auto Header Height Control (New Holland Cr/Cx Series)
OPERATION 3. Select HEADER AUTOFLOAT, and press ENTER. 4. Use the up and down navigation keys to move between options, and select INSTALLED. Figure 3.291: New Holland Combine Display Calibrating the Auto Header Height Control (New Holland CR/CX Series) For best performance of the auto header height control (AHHC), perform these procedures with the center-link set to D.
Page 203 OPERATION 2. Select HEADER (A), and press ENTER. The CALIBRATION dialog box opens. NOTE: You can use the up and down navigation keys to move between options. Figure 3.292: New Holland Combine Display 3. Follow the calibration steps in the order in which they appear in the dialog box.
Page 204: Adjusting Header Raise Rate (New Holland Cr/Cx Series)
OPERATION IMPORTANT: • If the value is set too low, area may NOT be counted since the header is sometimes raised above this threshold although the combine is still cutting. • If the value is set too high, the area counter will keep counting even when the header is raised (but below this threshold) and the combine is no longer cutting crop.
Page 205: Setting The Header Lower Rate (New Holland Cr/Cx Series)
OPERATION 1. Select HEADER RAISE RATE on the combine display. 2. Use the + or – buttons to change the setting. 3. Press ENTER to save the new setting. NOTE: The raise rate can be changed from 32–236 in steps of 34. The factory setting is 100. Figure 3.296: New Holland Combine Display Setting the Header Lower Rate (New Holland CR/CX Series) If necessary, the header lower rate (the automatic header height control button or second speed on the header...
Page 206: Setting The Sensitivity Of The Auto Header Height Control (New Holland Cr/Cx Series)
OPERATION Setting the Sensitivity of the Auto Header Height Control (New Holland CR/CX Series) The sensitivity adjustment controls the distance 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.
Page 207 OPERATION 1. Engage the threshing mechanism and the feeder with switches (A) and (B). 2. Set HEADER MEMORY rocker switch (D) in STUBBLE HEIGHT/AUTOFLOAT MODE position (A) or (B). 3. Lower the header to the desired cutting height using the HEADER HEIGHT AND HEADER LATERAL FLOTATION rocker switch (C).
Page 208 OPERATION Conﬁguring Reel Fore-Aft, Header Tilt, and Header Type (New Holland CR Series) This procedure applies only to 2016 New Holland CR models 6.90, 7.90, 8.90, and 9.90. NOTE: Changes may have been made to the combine controls or display since this document was published. Refer to the combine operator’s manual for updates.
Page 209: New Holland Combines (Cr Series-Model Year 2015 And Later)
There are now two different buttons for ON GROUND presets. The toggle switch that was present on previous models is now conﬁgured as shown at right. MacDon headers only require the ﬁrst two buttons (A and B). The third button down (C) is not conﬁgured.
Page 210 OPERATION 2. Check that ﬂoat lock linkage is on down stops (washer [A] cannot be moved) at both locations. NOTE: If the header is not on down stops during the next two steps, the voltage may go out of range during operation causing a malfunction of the AHHC system.
Page 211 OPERATION 4. Ensure header ﬂoat is unlocked. 5. Select DIAGNOSTICS (A) on the main page. The DIAGNOSTICS page displays. Figure 3.307: New Holland Combine Display 6. Select SETTINGS (A). The SETTINGS page displays. Figure 3.308: New Holland Combine Display 7. Select HEADER HEIGHT/TILT (A) from the GROUP drop-down menu.
Page 212: Engaging The Auto Header Height Control (New Holland Cr Series)
OPERATION 9. Select GRAPH (A). The exact voltage (B) is displayed at the top of the page. 10. Raise and lower the header to see the full range of voltage readings. 11. If the sensor voltage is not within the low and high limits, or if the range between the low and high limits is insufﬁcient, adjust the voltage limits.
Page 213 OPERATION 3. Simultaneously press both the UNLOAD (A) and RESUME (B) buttons on the hydro handle. Figure 3.312: New Holland Combine Controls 4. Select HEAD 1 (A). The HEADER SETUP 1 page displays. 5. Select the CUTTING TYPE drop-down arrow (B) and change the CUTTING TYPE to PLATFORM (C).
Page 214 OPERATION 7. Select 80/90 (A). Figure 3.315: New Holland Combine Display 8. Select HEAD 2 (A). The HEADER SETUP 2 page displays. Figure 3.316: New Holland Combine Display 9. Select the AUTOFLOAT drop-down arrow and set AUTOFLOAT to INSTALLED (A). 10.
Page 215: Calibrating The Auto Header Height Control (New Holland Cr Series)
OPERATION 12. Set the values for HHC HEIGHT SENSITIVITY (A) and HHC TILT SENSITIVITY (B) for best performance according to ground conditions. Figure 3.318: New Holland Combine Display Calibrating the Auto Header Height Control (New Holland CR Series) For best performance of the auto header height control (AHHC), perform these procedures with the center-link set to D.
Page 216 OPERATION 1. Select CALIBRATIONS (A) on the main page. The CALIBRATION page displays. Figure 3.319: New Holland Combine Display 2. Select the CALIBRATION drop-down arrow (A). Figure 3.320: New Holland Combine Display 3. Select HEADER (A) from the list of calibration options. Figure 3.321: New Holland Combine Display 147831 Revision A...
Page 217: Setting Auto Height (New Holland Cr Series)
The console has two buttons used for auto height presets. The toggle switch that was present on previous models is now conﬁgured as shown at right. MacDon headers only require the ﬁrst two buttons (A and B). The third button (C) is not conﬁgured.
Page 218: Setting Maximum Work Height (New Holland Cr Series)
OPERATION 2. Select RUN SCREENS (A) on the main page. Figure 3.325: New Holland Combine Display 3. Select the RUN tab that shows MANUAL HEIGHT. NOTE: The MANUAL HEIGHT ﬁeld may appear on any of the RUN tabs. When an auto height set point button is pressed, the display will change to AUTO HEIGHT (A).
Page 219: Sensor Operation
OPERATION 2. Select FEEDER (A). The FEEDER SETUP page displays. 3. Select the MAXIMUM WORK HEIGHT ﬁeld (B). Figure 3.328: New Holland Combine Display 4. Set MAXIMUM WORK HEIGHT to desired value. 5. Press SET and then press ENTER. Figure 3.329: New Holland Combine Display 3.8.13 Sensor Operation The position sensors supplied with the auto header height control (AHHC) system are hall-effect sensors...
Page 220: Levelling The Header
OPERATION 3.9 Levelling the Header The ﬂoat module is factory-set to provide the proper level for the header and should not normally require adjustment. If the header is NOT level, perform the following checks prior to adjusting the levelling linkages: •...
Page 221 OPERATION NOTE: Ensure a minimum clearance of 1/8 in. (2–3 mm) (A) between the frame and the back of the bell crank lever. NOTE: Check the ﬂoat after levelling header. Refer to Checking and Adjusting Header Float, page Figure 3.333: Bell Crank 147831 Revision A...
Page 222: Unplugging The Cutterbar
OPERATION 3.10 Unplugging the Cutterbar DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop engine and remove key before leaving the operator’s seat, and always engage safety props before going under the machine for any reason.
Page 223: Unplugging The Float Module
OPERATION 3.11 Unplugging the Float Module 1. 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 manufacturers speciﬁcations (reverse feed varies among different combine models).
Page 224: Upper Cross Auger (Uca)
IMPORTANT: If the UCA is installed, a case drain line must be installed on the right-hand draper motor. See your MacDon Dealer for details. Figure 3.334: Upper Cross Auger 3.12.1 Removing Beater Bars Beater bars are standard on 45-foot header only.
Page 225 OPERATION 1. Lower the header to the ground, stop the engine, and remove the key from the ignition. IMPORTANT: Lift reel and engage safety props if working on double reel header. 2. Position one beater bar (B) and one clamp set (C) onto the auger tube and loosely secure with carriage bolt (A) and nut.
Page 226: Transporting Header
• Travel at safe speeds to ensure complete machine control and stability at all times. 3.13.2 Towing Headers with the Slow Speed Transport/Stabilizer Wheel option can be towed behind a properly conﬁgured MacDon windrower or an agricultural tractor. Refer to the combine operator’s manual for instructions.
Page 227: Attaching Header To Towing Vehicle
• Connect header 7-pole plug wiring harness to mating receptacle on towing vehicle. (The 7-pole receptacle is available from your MacDon Dealer parts department). • Ensure lights are functioning properly and clean the slow moving vehicle sign and other reﬂectors. Use ﬂashing warning lights unless prohibited by law.
Page 228: Converting From Transport To Field Position
OPERATION 3.13.3 Converting from Transport to Field Position Removing Tow-Bar 1. Block the tires to prevent the header from rolling, and unhook the header from the towing vehicle. 2. Disconnect the electrical connector (A) on the tow-bar. 3. Remove pin (B) from the tow-bar, and disassemble the outer section (C) from the inner section (D).
Page 229: Storing The Tow-Bar
OPERATION Storing the Tow-Bar 1. Place the inner end of the outer half of the tow-bar into the cradle (A) on the left side of the header backtube. 2. Secure clevis/pintle end of the tow-bar in support (B) on the endsheet using hitch pin (C). Secure with lynch pin. 3.
Page 230: Moving Front (Left) Wheels Into Field Position
OPERATION 7. Place the inner end of the inner half of the tow-bar into the cradle (A) on the right side of the header backtube. 8. Secure the tube end of the tow-bar in support (B) on the endsheet using clevis pin (C). Secure with hairpin. 9.
Page 231 OPERATION 1. Raise the header fully and engage the header safety props. 2. Swivel the front wheel assembly (A) so the wheels are aligned with the lower frame. 3. Remove pin (B) and pull the wheel assembly towards the rear of header. Store the pin in hole (C) at the top of the leg.
Page 232: Moving Rear (Right) Wheels Into Field Position
OPERATION 7. Lift the wheel assembly to the desired height and slide the linkage (A) into the appropriate slot in the vertical support. 8. Push down on the handle (B) to lock. Figure 3.345: Front (Left) Wheels Moving Rear (Right) Wheels into Field Position 1.
Page 233 OPERATION 6. Pull the pin (A) on brace (B) on the left-hand wheel in front of the cutterbar. Disengage the brace from the cutterbar, and lower the brace against the axle (C). 7. Remove pin (D), lower support (E) onto axle, and reinsert pin into support.
Page 234 OPERATION 13. Complete the conversion by ensuring the left side (A) and right side (B) wheels are in the position shown. Figure 3.350: Field Position 147831 Revision A...
Page 235: Converting From Field To Transport Position
OPERATION 3.13.4 Converting from Field to Transport Position Moving Front (Left) Wheels into Transport Position DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. CAUTION Stand clear of wheels and release linkage carefully as wheels will drop once the mechanism is released.
Page 236: Moving Rear (Right) Wheels Into Transport Position
OPERATION 7. Remove the pin (A) from storage at the top of the leg (B). 8. Move and swivel the wheels clockwise until the connector (C) is turned towards the front end of the header. 9. Insert pin (A) and turn to lock. 10.
Page 237 OPERATION 6. Remove the pin (A) and install at location (B) to secure the linkage. Turn the pin to lock. 7. Pull the pin (D), swivel the wheel (C) counterclockwise 90°, and release the pin to lock. Figure 3.356: Wheel Position 8.
Page 238 OPERATION 10. Lock the wheel (A) with pin (B). Move the right axle (C) to the front of the header. Figure 3.359: Right Rear Wheel 11. Remove the pin (A), raise support (B) to the position shown, and reinsert pin. IMPORTANT: Ensure the pin (A) engages the tube on the axle.
Page 239: Attaching Tow-Bar
OPERATION Attaching Tow-Bar The tow-bar consists of two sections which make storage and handling easier. 1. Unhook the rubber strap (D) from the cradle (A) on the right side of the header. 2. Remove the clevis pin (C) and detach the tube end from the support (B).
Page 240 OPERATION 8. Connect the outer half (B) of the tow-bar to the inner half (A). Figure 3.363: Tow-Bar Assembly 9. Lift the outer half (B) and insert it into the inner half (A). Figure 3.364: Tow-Bar Assembly 10. Secure the two halves together with the L-pin (A) and then turn to lock.
Page 241 OPERATION 12. Position the tow-bar (A) onto the axle, and push against the latch (B) until the tow-bar pins drop into the hooks (C). 13. Check that latch (B) has engaged the tow-bar. 14. Install the clevis pin (D) and secure with hairpin. Figure 3.366: Attaching Tow-Bar 15.
Page 242: Storing The Header
OPERATION 3.14 Storing the Header Perform the following procedures at the end of each operating season: CAUTION Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or ﬂammable. CAUTION Cover cutterbar and knife guards to prevent injury from accidental contact. 1.
Page 243: Header Attachment/Detachment
4 Header Attachment/Detachment This chapter includes instructions for setting up, attaching, and detaching the header. Combine Refer to Case IH 7010, 8010, 7120, 8120, 9120, 5130, 6130, 4.3 Case IH Combines, page 244 7130, 7230, 8230, 9230 John Deere 60, 70, and S Series 4.5 John Deere Combines, page 260 Lexion 500, 700 (R Series) 4.6 Lexion Combines, page 267...
Page 244 HEADER ATTACHMENT/DETACHMENT Conﬁguration B is a standard conﬁguration for the following: • Gleaner (R6/75, R6/76, S6/77, S6/7/88, S96/7/8) • New Holland (920/940/960, 9020/40/60/65, 6090/7090, 8060/8070/8080) To convert to conﬁguration B from conﬁguration A or C, refer to 4.1.3 Converting from Conﬁguration A or C to Conﬁguration B, page 230.
Page 245: Converting From Configuration B Or D To Configuration A
HEADER ATTACHMENT/DETACHMENT Conﬁguration D is an optional narrow conﬁguration for rice harvesting. NOTE: This conﬁguration may improve feeding performance on certain combines while harvesting rice. To convert to conﬁguration D from conﬁguration A or C, refer to 4.1.8 Converting from Conﬁguration A or C to Conﬁguration D, page 236.
Page 246 HEADER ATTACHMENT/DETACHMENT 4. Install two bolt-on ﬂightings (MD #213359) (A) on the right-hand side as shown, and secure each ﬂighting with six carriage head bolts (MD #184657) and six nuts (MD #135799) at location (B). IMPORTANT: Bolt heads must be installed on inside of auger to prevent damage to internal components.
Page 247: Converting From Configuration C To Configuration A
HEADER ATTACHMENT/DETACHMENT 4.1.2 Converting from Conﬁguration C to Conﬁguration A One kit (MD #287031) is required to convert to this conﬁguration. Auger conﬁguration A shown at right. Flighting (A) is installed when converting from conﬁguration C. Figure 4.10: Conﬁguration A (Rear View) NOTE: Some parts are removed from the illustration for clarity.
Page 248: Converting From Configuration A Or C To Configuration B
HEADER ATTACHMENT/DETACHMENT 5. Repeat Steps at the 1., page 229 2., page 229 left-hand side of auger. 6. Install ﬂighting (MD #213360) (A) on the left-hand side as shown, and secure with six carriage head bolts (MD #184657) and six nuts (MD #135799) at location (B).
Page 249 HEADER ATTACHMENT/DETACHMENT NOTE: Some parts are removed from the illustration for clarity. 1. Remove bolts (A) and access cover (B) from the right-hand side of the auger. Retain for reassembly. 2. Remove hardware (C) and bolt-on ﬂighting (D) from the auger.
Page 250: Converting From Configuration D To Configuration B
HEADER ATTACHMENT/DETACHMENT 10. Install two bolt-on ﬂightings (MD #213362) (A) on the left-hand side as shown, and secure each ﬂighting with two button head bolts (MD #135723) and nuts at location (B), and four carriage head bolts (MD #184657) and nuts at location (C). IMPORTANT: Bolt heads at location (B) must be installed on the crop side (inboard) and nuts on the outboard...
Page 251: Converting From Configuration A To Configuration C
4.1.5 Converting from Conﬁguration A to Conﬁguration C Four ﬂighting plugs (MD #213084), M6 bolts (MD #252522), and M6 tee nuts (MD #197263) are recommended to cover the ﬂighting mounting holes after the ﬂightings are removed. These parts can be ordered from a MacDon Dealer.
Page 252: Converting From Configuration B Or D To Configuration C
One kit (MD #287031) is required to convert to this conﬁguration. Two ﬂighting plugs (MD #213084), two M6 bolts (MD #252522, and two M6 tee nuts (MD #197263) are recommended to close the ﬂighting mounting locations. These parts can be ordered from a MacDon Dealer. Existing auger conﬁgurations B and D shown at right.
Page 253: Optional Modification To Configuration C
ﬂightings (A). Four ﬂighting plugs (MD #213084), M6 bolts (MD #252522), and M6 tee nuts (MD #197263) are recommended to cover the ﬂighting mounting holes. These parts can be ordered from a MacDon Dealer. Figure 4.27: Conﬁguration C (Rear View) 147831 Revision A...
Page 254: Converting From Configuration A Or C To Configuration D
HEADER ATTACHMENT/DETACHMENT 1. Remove two bolts and access cover (A). 2. Remove hardware (B), and bolt-on ﬂighting (C). 3. Install ﬂighting slot plugs in the ﬂighting mounting locations (D). 4. Repeat at the left-hand side of the auger. 5. Install additional ﬁngers. A total of 30 ﬁngers are recommended for this conﬁguration.
Page 255 HEADER ATTACHMENT/DETACHMENT NOTE: Some parts are removed from the illustration for clarity. 1. Remove bolts (A) and access cover (B) from the right-hand side of the auger. Retain for reassembly. 2. Remove hardware (C) and bolt-on ﬂighting (D) from the auger. 3.
Page 256 HEADER ATTACHMENT/DETACHMENT 8. Position another bolt-on ﬂighting (MD #213361) (A) outboard of the temporarily installed ﬂighting (B). Mark hole locations (C) of the bolt-on ﬂighting onto the temporarily installed bolt-on ﬂighting. 9. Remove temporarily installed bolt-on ﬂighting from the auger and drill two 7/16” (11 mm) holes at the marked locations.
Page 257 HEADER ATTACHMENT/DETACHMENT 17. Place bolt-on ﬂighting (MD #213362) (A) outboard of the other ﬂighting (B) on the left-hand side of the auger, as shown. 18. Temporarily secure bolt-on ﬂighting (A) with two button head bolts (MD #135723) and nuts (MD #135799) at location (C).
Page 258: Converting From Configuration B To Configuration D
HEADER ATTACHMENT/DETACHMENT 25. Place bolt-on ﬂighting (MD #213361) (A) outboard of the other ﬂighting (B) on the right-hand side of the auger as shown. 26. Temporarily secure bolt-on ﬂighting (A) with two button head bolts (MD #135723) and nuts (MD #135799) at location (C).
Page 259 HEADER ATTACHMENT/DETACHMENT 1. Place new bolt-on ﬂighting (MD #213362) (A) outboard of the existing ﬂighting (B) on the left-hand side of the auger, as shown. 2. Mark hole locations (C) of the new bolt-on ﬂighting (A) onto existing bolt-on ﬂighting (B). 3.
Page 260 HEADER ATTACHMENT/DETACHMENT 10. With ﬂighting on desired position, mark holes (A) and drill 7/16 in. (11 mm) holes on auger tube. 11. Remove nearest access cover(s). Retain for reinstallation. 12. Secure bolt-on ﬂighting on the newly drilled holes (A) using four ﬂange head bolts (MD #152655) and nuts (MD #135799).
Page 261: Float Module Setup
The auger speed is determined by the combine input shaft and is matched to each speciﬁc combine model; therefore, no adjustment is necessary. However, optional 20-, 24-, 31-, 33-, and 35-tooth drive sprockets are available to change the ﬂoat module feed auger speed and optimize performance. See your MacDon Dealer. Table 4.1 Drive Sprockets...
Page 262: Case Ih Combines
HEADER ATTACHMENT/DETACHMENT 4.3 Case IH Combines 4.3.1 Attaching Header to Case IH Combine DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. 1.
Page 263 HEADER ATTACHMENT/DETACHMENT 8. Open the cover on the receptacle (A) located on the left side of the ﬂoat module. 9. Press the lock button (B) and pull the handle (C) to the fully open position. 10. Clean the receptacle mating surfaces. Figure 4.48: Float Module Receptacle 11.
Page 264 HEADER ATTACHMENT/DETACHMENT 14. Remove the cover from the electrical receptacle (A). Ensure the receptacle is clean and has no signs of damage. Figure 4.51: Electrical Receptacle 15. Remove the electrical connector (A) from the storage cup on the combine and route it to the ﬂoat module receptacle.
Page 265 HEADER ATTACHMENT/DETACHMENT 17. Pull handle (A) to release bolt from slot and remove the driveline from the support bracket (B). Figure 4.54: Float Module Driveline Storage Hook 18. Pull back the collar (A) on the end of the driveline and push the driveline onto the combine output shaft (B) until the collar locks.
Page 266 HEADER ATTACHMENT/DETACHMENT 19. Disengage both header ﬂoat locks by pushing down ﬂoat lock handle (A) and placing it under the hook (UNLOCK). Figure 4.56: Float Lock in UNLOCK Position 147831 Revision A...
Page 267: Detaching Header From Case Ih Combine
HEADER ATTACHMENT/DETACHMENT 4.3.2 Detaching Header from Case IH Combine DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. 1.
Page 268 HEADER ATTACHMENT/DETACHMENT 5. Store the driveline in the storage holder (C) and secure strap (B) with bolt (A). Figure 4.59: Driveline 6. Remove the electrical connector (A) and replace the cover (B). 7. Push in the lock button (C) and pull the handle (D) to release the multicoupler (E).
Page 269 HEADER ATTACHMENT/DETACHMENT 10. Push the handle (A) on the ﬂoat module receptacle to the closed position until the lock button (B) snaps out. Close the cover. Figure 4.62: Float Module Receptacle 11. Lift the lever (A) and pull and lower the handle (B) to disengage the feeder house/ﬂoat module lock (C).
Page 270: Agco (Challenger, Gleaner, And Massey Ferguson) Combines
HEADER ATTACHMENT/DETACHMENT 4.4 AGCO (Challenger, Gleaner, and Massey Ferguson) Combines 4.4.1 Attaching Header to a Challenger, Gleaner, or Massey Ferguson Combine DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. 1.
Page 271 HEADER ATTACHMENT/DETACHMENT NOTE: Your combine feeder house may not be exactly as shown. Figure 4.66: AGCO Group Alignment Pins 3. Raise the feeder house slightly to lift the header, ensuring the feeder house saddle (A) is properly engaged in the ﬂoat module frame. 4.
Page 272 HEADER ATTACHMENT/DETACHMENT NOTE: The FM100 Float Module is equipped with a multicoupler that connects to the combine. If your combine is equipped with individual connectors, a multicoupler kit (single-point connector) must be installed. Refer to Table for a list of kits and installation instructions that are available 4.2 Multicoupler Kits, page 254 through your combine Dealer.
Page 273 HEADER ATTACHMENT/DETACHMENT 10. Push the handle (A) on the combine to the fully open position. 11. Clean the mating surfaces of the multicoupler (B) and receptacle if necessary. Figure 4.71: Combine Receptacle 12. Position the multicoupler (A) onto the combine receptacle, and pull the handle (B) to fully engage the multicoupler into the receptacle.
Page 274 HEADER ATTACHMENT/DETACHMENT 15. Pull back the collar (A) on the end of the driveline, and push the driveline onto the combine output shaft (B) until the collar locks. Figure 4.74: Driveline 147831 Revision A...
Page 275: Detaching Header From A Challenger, Gleaner, Or Massey Ferguson Combine
HEADER ATTACHMENT/DETACHMENT 4.4.2 Detaching Header from a Challenger, Gleaner, or Massey Ferguson Combine DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. 1.
Page 276 HEADER ATTACHMENT/DETACHMENT 5. Store the driveline in the storage holder (C) and secure strap (B) with bolt (A). Figure 4.77: Driveline 6. Disconnect the harness at the connector (A). 7. Move the handle (B) on the combine multicoupler to the full open position to release the multicoupler (C) from the combine.
Page 277 HEADER ATTACHMENT/DETACHMENT 10. Use the lock handle (B) to retract the lugs (A) at the base of the feeder house. Figure 4.80: Challenger and Massey Ferguson Figure 4.81: Gleaner R and S Series 11. Lower the feeder house until the saddle (A) disengages and clears the ﬂoat module support (B).
Page 278: John Deere Combines
HEADER ATTACHMENT/DETACHMENT 4.5 John Deere Combines The FD1-Series FlexDraper® Header is compatible with John Deere 60, 70, S, and T Series combines. 4.5.1 Attaching Header to John Deere Combine DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 279 HEADER ATTACHMENT/DETACHMENT 6. Position the multicoupler (A) onto the receptacle, and pull the handle (B) to engage the lugs on the multicoupler into the handle. 7. Pull the handle (B) to a horizontal position and ensure the multicoupler (A) is fully engaged into the receptacle.
Page 280 HEADER ATTACHMENT/DETACHMENT 12. Pull handle (A) to release bolt from slot and remove the driveline from the support bracket (B). Figure 4.88: Driveline 13. Pull back the collar (A) on the end of the driveline, and push the driveline onto the combine output shaft (B) until the collar locks.
Page 281 HEADER ATTACHMENT/DETACHMENT 14. Disengage both header ﬂoat locks by pushing down ﬂoat lock handle (A) and placing it under the hook (UNLOCK). Figure 4.90: Float Lock in UNLOCK Position 147831 Revision A...
Page 282: Detaching Header From John Deere Combine
HEADER ATTACHMENT/DETACHMENT 4.5.2 Detaching Header from John Deere Combine DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. 1.
Page 283 HEADER ATTACHMENT/DETACHMENT 5. Store the driveline in the storage holder (C) and secure strap (B) with bolt (A). Figure 4.93: Driveline 6. Lift the handle (A) on the ﬂoat module. Figure 4.94: Multicoupler Storage 7. Disconnect the harness (A) from the combine connector.
Page 284 HEADER ATTACHMENT/DETACHMENT 10. Position the multicoupler (A) on the ﬂoat module receptacle and lower the handle (B) to lock the multicoupler. Figure 4.96: Multicoupler Storage 11. Push the handle (A) on the combine towards the feeder house to disengage the feeder house pin (B) from the ﬂoat module.
Page 285: Lexion Combines
HEADER ATTACHMENT/DETACHMENT 4.6 Lexion Combines The FD1-Series FlexDraper® Header is compatible with Lexion 500, 600, and 700 Series combines. 4.6.1 Attaching Header to Lexion Combine DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 286 HEADER ATTACHMENT/DETACHMENT 5. Remove the locking pin (B) from the ﬂoat module pin (A). Figure 4.101: Locking Pins 6. Lower the handle (A) to engage the ﬂoat module pins (B) into the feeder house. Reinsert the locking pin (C) and secure with the hairpin. 7.
Page 287 HEADER ATTACHMENT/DETACHMENT 9. Place the ﬂoat module receptacle cover (A) onto the combine receptacle. Figure 4.104: Receptacle Cover 10. Clean the mating surface of the coupler (A) and position onto the ﬂoat module receptacle (B). 11. Turn the knob (C) to secure the coupler to the receptacle.
Page 288 HEADER ATTACHMENT/DETACHMENT 12. Connect combine harness reel fore-aft/header tilt receptacle (A). Figure 4.106: Coupler 13. Pull handle (A) to release bolt from slot and remove the driveline from the support bracket (B). Figure 4.107: Driveline 14. Attach the driveline (A) to the combine output shaft. Figure 4.108: Driveline and Output Shaft 147831 Revision A...
Page 289 HEADER ATTACHMENT/DETACHMENT 15. Disengage both header ﬂoat locks by pushing down ﬂoat lock handle (A) and placing it under the hook (UNLOCK). Figure 4.109: Float Lock in UNLOCK Position 147831 Revision A...
Page 290: Detaching Header From Lexion Combine
HEADER ATTACHMENT/DETACHMENT 4.6.2 Detaching Header from Lexion Combine DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. 1. Choose a level area and position the header slightly above the ground.
Page 291 HEADER ATTACHMENT/DETACHMENT 5. Store the driveline in the storage holder (C) and secure strap (B) with bolt (A). Figure 4.112: Driveline 6. Remove the electrical connector from the ﬂoat module receptacle (A). 7. Unscrew the knob (B) on the coupler (C) to release the coupler from the ﬂoat module.
Page 292 HEADER ATTACHMENT/DETACHMENT 9. Position the coupler (A) onto the combine receptacle, and turn the knob (B) to secure the coupler to the receptacle. Figure 4.115: Combine Coupler 10. Place the cover (A) on the ﬂoat module receptacle. Figure 4.116: Float Module 11.
Page 293 HEADER ATTACHMENT/DETACHMENT 14. Lower the feeder house until the feeder house posts (A) disengage the ﬂoat module (B). 15. Back the combine away slowly from the ﬂoat module. Figure 4.118: Header on Combine 147831 Revision A...
Page 294: New Holland Combines
HEADER ATTACHMENT/DETACHMENT 4.7 New Holland Combines The FD1-Series FlexDraper is compatible with the following New Holland combines: Series Combine Model 920, 940, 960, 970, 980 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 8070, 8080, 8090 8080 Elevation, 8090 Elevation...
Page 295 HEADER ATTACHMENT/DETACHMENT 5. Lift lever (A) on the ﬂoat module on the left side of the feeder house, and push the handle (B) on the combine to engage the locks (C) on both sides of the feeder house. 6. Push down on the lever (A) so the slot in the lever engages the handle and locks the handle in place.
Page 296 HEADER ATTACHMENT/DETACHMENT 12. Position the coupler (A) onto the ﬂoat module receptacle, and push the handle (B) to engage the pins into the receptacle. 13. Push the handle (B) to closed position until the lock button (C) snaps out. 14. Remove the cover on the ﬂoat module electrical receptacle.
Page 297 HEADER ATTACHMENT/DETACHMENT 19. Disengage both header ﬂoat locks by pushing down ﬂoat lock handle (A) and placing it under the hook (UNLOCK). Figure 4.127: Float Lock in UNLOCK Position 147831 Revision A...
Page 298: Detaching Header From New Holland Cr/Cx Combine
HEADER ATTACHMENT/DETACHMENT 4.7.2 Detaching Header from New Holland CR/CX Combine DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. 1.
Page 299 HEADER ATTACHMENT/DETACHMENT 5. Store the driveline in the storage holder (C) and secure strap (B) with bolt (A). Figure 4.130: Driveline 6. Push in the lock button (B), and pull the handle (C) to release the multicoupler (A). Figure 4.131: Float Module Connections 7.
Page 300 HEADER ATTACHMENT/DETACHMENT 8. Position the hydraulic quick coupler (A) onto the storage plate (B) on the combine. Figure 4.133: Combine Coupler 9. Remove the electrical connector (A) from the ﬂoat module. Figure 4.134: Float Module Connections 10. Connect the electrical connector to the combine at the location shown (A).
Page 301 HEADER ATTACHMENT/DETACHMENT 11. Replace the cover (A) on the ﬂoat module receptacle. Figure 4.136: Float Module Receptacles 12. Lift the lever (A) and pull and lower the handle (B) to disengage the feeder house/ﬂoat module lock (C). Figure 4.137: Feeder House Locks 13.
Page 302: Cr Feeder Deflectors
HEADER ATTACHMENT/DETACHMENT 4.7.3 CR Feeder Deﬂectors For New Holland combines only: Short feeder deﬂectors have been factory-installed on the ﬂoat module to improve feeding into the feeder house. Remove the feeder deﬂectors if necessary. Refer to 5.11.3 Replacing Feed Deﬂectors on New Holland CR Combines, page 385.
Page 303: Attaching And Detaching Header From Float Module
HEADER ATTACHMENT/DETACHMENT 4.8 Attaching and Detaching Header from Float Module Attaching/detaching procedures are the same for all makes and models of combines. Headers can be attached to the ﬂoat module from either ﬁeld or transport conﬁgurations. The procedures in this manual require that the ﬂoat module remains attached to the combine. Attach/detach the ﬂoat module only if performing the following tasks: •...
Page 304 HEADER ATTACHMENT/DETACHMENT 6. Engage both ﬂoat locks by pushing each ﬂoat lock handle (A) down, away, and out of the hook (LOCK). Figure 4.141: Float Locked 7. Remove two bolts (A) and ﬁllers (B) from the transition pan support angle (C). Repeat on opposite side. Figure 4.142: Fillers 147831 Revision A...
Page 305 HEADER ATTACHMENT/DETACHMENT 8. Remove bolt (A). 9. Remove the 9/16 in. nut from bolt (B). 10. Use a 15/16 in. (24 mm) wrench on hex bolt (C) to rotate latch downwards and slightly raise the feed deck to remove bolt (B). 11.
Page 306 HEADER ATTACHMENT/DETACHMENT 18. Place a 6 in. (150 mm) block (A) under the header leg. This will assist with disconnecting the center-link. 19. Disengage combine lift cylinder locks, start engine, and lower header until the header leg rests on the block or stabilizer wheels are the ground.
Page 307 HEADER ATTACHMENT/DETACHMENT 24. Disconnect the quick disconnects (if installed) as follows: a. Line up the slot (A) in the collar with the pin (B) on the connector. b. Push the collar towards the pin, and pull the connector to disengage. c.
Page 308: Attaching Header To Float Module
HEADER ATTACHMENT/DETACHMENT 4.8.2 Attaching Header to Float Module The FD1 header can be attached to the ﬂoat module from either ﬁeld or transport conﬁguration. DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 309 HEADER ATTACHMENT/DETACHMENT 3. Start engine, and lower the combine feeder house so that ﬂoat module arms (A) are aligned with header balance channels (B). 4. Drive slowly forward, maintaining alignment between ﬂoat module arms (A) and header balance channels (B). 5.
Page 310 HEADER ATTACHMENT/DETACHMENT CAUTION Always connect center-link before fully raising header. 10. Match the colored cable ties and connect the reel hydraulics (A) at the right end of the ﬂoat module. CAUTION Be sure all bystanders are clear of machine before starting engine or engaging any header drives.
Page 311 HEADER ATTACHMENT/DETACHMENT 19. Remove screw (A) and remove nut and bolt (B) from both sides of the opening to allow the attachment of the ﬂoat module deck. 20. Rotate the latch (C) forward and down to engage the transition pan tube. Figure 4.160: Float Module Latch 21.
Page 312 HEADER ATTACHMENT/DETACHMENT 25. Use a clean cloth to remove debris from couplers and receptacles. 26. Connect the following hydraulic hoses at the coupler bracket (A): • Knife pressure • Knife return • Draper pressure • Draper return • Case drain 27.
Page 313: Maintenance And Servicing
5 Maintenance and Servicing The following instructions provide information about routine header service. Detailed maintenance and service information is available in the technical service manual that is available from your Dealer. A parts catalog is provided in the plastic manual case inside the left endshield. Log hours of operation and use the maintenance record provided (refer to 5.3.1 Maintenance Schedule/Record, 299) to keep track of your scheduled maintenance.
Page 314: Maintenance Specifications
MAINTENANCE AND SERVICING 5.2 Maintenance Speciﬁcations 5.2.1 Recommended Fluids and Lubricants Ensure your machine operates at top efﬁciency by using clean ﬂuids and lubricants only. • Use clean containers to handle all ﬂuids and lubricants. • Store ﬂuids and lubricants in an area protected from dust, moisture, and other contaminants. Table 5.1 Recommended Fluids and Lubricants Lubricant Speciﬁcation...
Page 315: Installing A Sealed Bearing
MAINTENANCE AND SERVICING 5.2.2 Installing a Sealed Bearing 1. Clean the shaft and apply a rust preventive coating. 2. Install the ﬂangette (A), bearing (B), second ﬂangette (C), and lock the collar (D). NOTE: The locking cam is on only one side of the bearing.
Page 316: Maintenance Requirements
MAINTENANCE AND SERVICING 5.3 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 5.3.1 Maintenance Schedule/Record, page 299).
Page 317: Maintenance Schedule/Record
Hydraulic hoses and lines; refer to 5.3.5  Checking Hydraulic Hoses and Lines, page NOTE: MacDon recommends keeping a record of daily Knife sections, guards, and hold-downs; refer  maintenance as evidence of a properly maintained 5.8 Knives, page 345 machine;...
Page 318 MAINTENANCE AND SERVICING Reel ﬁnger/cutterbar clearance; refer to  Adjusting Reel Clearance, page 407 Knife drive belt tension; refer to 5.9.2 Knife  Drive Belts, page 367 Wheel bolt torque; refer to 5.15.1 Checking  Wheel Bolt Torque, page 441 Knife drive box lubricant level;...
Page 319: Break-In Inspection
MAINTENANCE AND SERVICING Header drive gearbox chain tension; refer to  5.7.2 Adjusting Auger Drive Chain Tension, page 333 1000 Hours or 3 Years (Whichever Occurs First) Knife drive box lubricant; refer to Changing Oil ▲ in Knife Drive Box, page 367 Header drive gearbox lubricant;...
Page 320: Preseason Servicing
MAINTENANCE AND SERVICING 5.3.3 Preseason Servicing Perform the following procedures at the beginning of each operating season: CAUTION • Review this manual to refresh your memory on the safety and operating recommendations. • Review all the safety decals and other decals on the header and note the hazard areas. •...
Page 321: Checking Hydraulic Hoses And Lines
MAINTENANCE AND SERVICING 10. Check for broken components and order replacements from your Dealer. Immediate repair of these items will save time and effort at the beginning of next season. 11. Replace or tighten any missing or loose hardware. Refer to 8.1 Torque Speciﬁcations, page 467.
Page 322: Service Intervals
MAINTENANCE AND SERVICING Service Intervals Every 10 Hours Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise speciﬁed. Knife: Lubricate the knife every 10 hours or daily, except in sandy conditions. Figure 5.4: Every 10 Hours or Daily 147831 Revision A...
Page 323 MAINTENANCE AND SERVICING Every 25 Hours Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise speciﬁed. Knifehead: Lubricate the knifehead (A) every 25 hours. Check for signs of excessive heating on the ﬁrst few guards after greasing.
Page 324 MAINTENANCE AND SERVICING Every 50 Hours Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise speciﬁed. Figure 5.6: Every 50 Hours C - Driveline Slip Joint 11 A - Drive Roller Bearing B - Idler Roller Bearing (Both Sides) D - Driveline Universal (Two Places) 11.
Page 325 MAINTENANCE AND SERVICING Every 100 Hours Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise speciﬁed. Figure 5.7: Every 100 Hours A - Float Pivot - Right- and Left-Hand B - Auger Drive Chain. Refer to Lubricating Auger Drive Chain, page 315 C - Driveline Guard - Two Places D - Reel Drive Chain- One Place.
Page 326 MAINTENANCE AND SERVICING Figure 5.8: Every 100 Hours A - Knife Drive Box (Check Oil Level Between Lower Hole and End of Dipstick [B]) C - Upper Cross Auger Bearing (One Place) D - Main Drive Gearbox Oil Level. Refer to Lubricating Header Drive Gearbox, page 318 147831 Revision A...
Page 327 MAINTENANCE AND SERVICING Every 250 Hours Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise speciﬁed. Figure 5.9: Every 250 Hours A - Upper Cross Auger U-joint and Bearing 12 B - Upper Cross Auger Bearing (Two Places) C - Reel U-joint (One Place) D - Flex Linkage (Two Places) - Both Sides...
Page 328 MAINTENANCE AND SERVICING Figure 5.10: Every 250 Hours A - Auger Pivots B - Front Wheel Pivot (One Place) C - Frame/Wheel Pivot (One Place) - Both Sides 147831 Revision A...
Page 329 MAINTENANCE AND SERVICING Figure 5.11: Every 250 Hours A - Double Reel U-joint 13 13. 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).
Page 330 MAINTENANCE AND SERVICING Every 500 Hours Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise speciﬁed. Figure 5.12: Every 500 Hours A - Reel Right Bearing (One Place) B - Reel Center Bearing (One Place) C - Wheel Bearings (Four Places) D - Reel Left Bearing (One Place) 147831...
Page 331: Greasing Procedure
MAINTENANCE AND SERVICING Greasing Procedure Greasing points are marked on the machine by decals showing a grease gun and grease interval in hours of operation. Master grease point location decals are provided on the header and the ﬂoat module back frame. DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 332: Lubricating Reel Drive Chain
MAINTENANCE AND SERVICING 1. Wipe grease ﬁtting with a clean cloth before greasing to avoid injecting dirt and grit. 2. Inject grease through ﬁtting with grease gun until grease overﬂows ﬁtting (except where noted). 3. Leave excess grease on ﬁtting to keep out dirt. 4.
Page 333: Lubricating Auger Drive Chain
MAINTENANCE AND SERVICING 4. Apply a liberal amount of grease to the chain (A). Figure 5.18: Drive Chain 5. Position the lower drive cover (B) onto the reel drive (if previously removed) and secure with three bolts (A). Figure 5.19: Lower Drive Cover – Double Reel 6.
Page 334 MAINTENANCE AND SERVICING Lubricate the auger drive chain every 100 hours. Lubrication can be done with the ﬂoat module attached to the combine, but it is easier with the ﬂoat module detached. 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 grease the chain.
Page 335 MAINTENANCE AND SERVICING 4. Reinstall metal inspection panel (B) and secure with four bolts (A). Figure 5.23: Auger Drive Inspection Panel 147831 Revision A...
Page 336: Lubricating Header Drive Gearbox
MAINTENANCE AND SERVICING Lubricating Header Drive Gearbox Checking Oil Level in Header Drive Gearbox Check the header drive gearbox oil level every 100 hours. DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 337 MAINTENANCE AND SERVICING Changing Oil in Header Drive Gearbox Change the header drive gearbox oil after the ﬁrst 50 hours of operation and every 1000 hours (or 3 years) thereafter. DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 338: Hydraulics
MAINTENANCE AND SERVICING 5.4 Hydraulics The FM100 Float Module’s hydraulic system drives the ﬂoat module feed draper, header drapers, and knife drives. The combine’s hydraulic system drives the reel hydraulics. The ﬂoat module frame acts as an oil reservoir. Refer to 5.2.1 Recommended Fluids and Lubricants, page 296 oil requirements.
Page 339: Changing Oil In Hydraulic Reservoir
MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Clean any dirt or debris from the ﬁller cap (A). 3. Loosen and remove the ﬁller cap (A) by turning it counterclockwise. 4. Add warm oil (approximately 70°F [21°C.]) and ﬁll to the required level.
Page 340: Changing Oil Filter
5.4.4 Changing Oil Filter Change the oil ﬁlter after the ﬁrst 50 hours of operation and every 250 hours thereafter. Obtain ﬁlter part MD #202704 from your MacDon Dealer. DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 341: Electrical System
MAINTENANCE AND SERVICING 5.5 Electrical System Use electrical tape and wire clips as required to prevent wires from dragging or rubbing. Keep lights clean and replace defective bulbs. 5.5.1 Replacing Light Bulbs 1. Use a Phillips screwdriver to remove the screws (A) from the ﬁxture and remove the plastic lens.
Page 342: Header Drive
MAINTENANCE AND SERVICING 5.6 Header Drive The header drive consists of a driveline from the combine to the FM100 Float Module gearbox that drives the feed auger and a hydraulic pump. The pump provides hydraulic power to the drapers, knives, and optional equipment. 5.6.1 Removing Driveline DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key...
Page 343: Installing Driveline
MAINTENANCE AND SERVICING 5.6.2 Installing Driveline DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. IMPORTANT: If the combine output shaft splines match the ﬂoat module input shaft splines, ensure the driveline is installed with the longer guard at the ﬂoat module gearbox end.
Page 344: Removing Driveline Guard
MAINTENANCE AND SERVICING 5.6.3 Removing Driveline Guard The main driveline guard must remain attached to the driveline during operation, but it can be removed for maintenance purposes. DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 345 MAINTENANCE AND SERVICING 4. Use slotted screwdriver release grease zerk/lock (A). Figure 5.38: Driveline Guard 5. Rotate driveline guard locking ring counterclockwise using a screwdriver until the lugs (B) line up with the slots in the guard. 6. Pull the guard off the driveline. Figure 5.39: Driveline Guard 147831 Revision A...
Page 346: Installing Driveline Guard
MAINTENANCE AND SERVICING 5.6.4 Installing Driveline Guard 1. Slide the guard onto the driveline, and line up the slotted lug on the locking ring (A) with the arrow (B) on the guard. Figure 5.40: Driveline Guard 2. Push the guard onto the ring until the locking ring is visible in the slots (A).
Page 347 MAINTENANCE AND SERVICING 4. Push the grease zerk (A) back into the guard. Figure 5.43: Driveline Guard 5. Assemble the driveline. NOTE: The splines are keyed to align the universals. Align weld (A) with the missing spline (B) when assembling. Figure 5.44: Driveline 6.
Page 348: Adjusting Tension On Gearbox Drive Chain
MAINTENANCE AND SERVICING 5.6.5 Adjusting Tension on Gearbox Drive Chain The gearbox drive chain tension is factory-set, but tension adjustments are required every 500 hours or annually (whichever comes ﬁrst). The gearbox drive chain, located inside the gearbox, requires no other regular maintenance.
Page 349: Auger
MAINTENANCE AND SERVICING 5.7 Auger The FM100 Float Module auger feeds the cut crop from the draper decks into the combine feeder house. 5.7.1 Adjusting Auger to Pan Clearance DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 350 MAINTENANCE AND SERVICING 5. Before adjusting the auger to pan clearance, check the auger ﬂoat position to determine how much clearance is required: • If the bolt head (A) is closest to the ﬂoating symbol (B), the auger is in the ﬂoating position. CAUTION Make sure the two bolts (A) are in the same location to prevent damage to the machine during...
Page 351: Adjusting Auger Drive Chain Tension
MAINTENANCE AND SERVICING 6. Loosen two nuts (B). 7. Using the adjuster bolt (A), set clearance (C) to 13/16 to 1-1/16 in. (20.5 to 26.5 mm) if feed auger is in rigid position, and 3/8 to 5/8 in. (9 to 15 mm) if feed auger is in ﬂoating position.
Page 352 MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Detach the header from the combine. Refer to Header Attachment/Detachment, page 225. 3. Remove the four bolts (A) and the inspection panel (B). Figure 5.51: Auger Drive 4.
Page 353: Removing Auger Drive Chain
MAINTENANCE AND SERVICING 9. Reinstall the inspection panel (B) and secure with four bolts (A). Figure 5.53: Auger Drive 5.7.3 Removing Auger Drive Chain The chain tensioner can take up slack for only a single pitch. Replace the chain when the chain has worn or stretched beyond the limits of the tensioner.
Page 354 MAINTENANCE AND SERVICING 3. Remove the four bolts (A) and the inspection panel (B). 4. Remove the bolt and clamp (C) that holds the two covers (G and H) together. 5. Remove the two bolts (D) that secure the bottom cover. 6.
Page 355 MAINTENANCE AND SERVICING 10. Remove the two bolts and nuts (A), and separate the drum support arm from the casting. NOTE: You may need a second person to lift or support the drum to remove the bolts NOTE: The bolts on the left side of the drum are longer than the bolts on the right side.
Page 356: Installing Auger Drive Chain
MAINTENANCE AND SERVICING 5.7.4 Installing Auger Drive Chain 1. Place the drive chain (B) over the sprocket on the left side of the drum assembly (A). Figure 5.59: Auger Drive 2. Put the drive sprocket (A) into the chain (B) and align the sprocket onto the shaft.
Page 357: Using Auger Flighting
MAINTENANCE AND SERVICING 4. Remove the block from under the auger. 5. Rotate the auger in reverse to take up the slack in the lower strand of the chain. IMPORTANT: Do NOT loosen the thin nut (E) on the inboard side of the idler sprocket spindle.
Page 358: Auger Fingers
MAINTENANCE AND SERVICING 5.7.6 Auger Fingers The FM100 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 DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop engine...
Page 359: Installing Feed Auger Fingers
6. Remove the bolts (A) securing the plastic guide (B) to the auger, and remove the guide from inside the auger. Figure 5.66: Auger 7. Position plug (A) (MD #187137 available from MacDon Parts) into the hole from inside the auger, and secure ®...
Page 360 MAINTENANCE AND SERVICING 1. Raise the reel. 2. Shut down the combine, and remove the key from the ignition. 3. Engage the reel safety props. 4. Remove bolts (A), and remove access cover (B). Figure 5.69: Auger 5. Remove the two bolts (B) and remove the plug (A). Figure 5.70: Auger 6.
Page 361: Replacing Feed Auger Finger Guides
MAINTENANCE AND SERVICING 7. From inside the auger, insert the ﬁnger (B) through the plastic guide (D). 8. Insert the ﬁnger into bushing (C) and secure with hairpin (A). NOTE: Note the orientation of the hairpin. The round part should face the direction of rotation. Figure 5.72: Auger 9.
Page 362 MAINTENANCE AND SERVICING 2. From inside the auger, position the plastic guide (B) from inside the auger and secure with bolts (A). 3. Replace the ﬁnger. Refer to Installing Feed Auger Fingers, page 341. Figure 5.75: Auger 147831 Revision A...
Page 363: Knives
MAINTENANCE AND SERVICING 5.8 Knives WARNING Keep hands clear of the area between guards and knife at all times. CAUTION Wear heavy gloves when working around or handling knives. CAUTION To avoid personal injury, before servicing machine or opening drive covers, refer to 5.1 Preparing Machine for Servicing, page 295.
Page 364 MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Stroke the knife as required to center the knife section (A) between the guards. 3. Remove nuts (B). 4. Remove bars (C) and lift the knife section off the knife bar.
Page 365: Removing Knife
MAINTENANCE AND SERVICING 5.8.2 Removing Knife WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine. WARNING Stand to rear of knife during removal to reduce risk of injury from cutting edges. Wear heavy gloves when handling knife.
Page 366: Installing Knifehead Bearing
MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Remove the knife. Refer to 5.8.2 Removing Knife, page 347. NOTE: Because the bearing is being replaced, it is not necessary to wrap the knifehead to protect the bearing.
Page 367: Spare Knife
MAINTENANCE AND SERVICING 1. Slide the knife into place and align the knifehead with the output arm. NOTE: Remove the grease zerk from the knifehead pin for easier removal and installation of knifehead pin. 2. Install the knifehead pin (A) through the output arm (C) and into the knifehead.
Page 368: Adjusting Knife Guards
To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine. NOTE: Use guard straightening tool (MD #140135) available from your MacDon Dealer. 1. Position the tool as shown, and pull up to adjust the guard tips upwards.
Page 369 MAINTENANCE AND SERVICING Replacing Normal and Drive Side Guard 1. Shut down the combine, and remove the key from the ignition. 2. Stroke the knife manually until the knife sections are spaced midway between the guards. 3. Remove two nuts (B) and bolts attaching the guard (A) and hold-down (C) (if applicable) to the cutterbar.
Page 370: Replacing Stub Guards
MAINTENANCE AND SERVICING Replacing Center Guard NOTE: The guard at the center of a double-knife header (where the two knives overlap) requires a slightly different replacement procedure. 1. Shut down the combine, and remove the key from the ignition. 2. Remove the two nuts (B) and bolts attaching the guard (A) and top guide (C) to the cutterbar.
Page 371 MAINTENANCE AND SERVICING Normal, Drive Side, and End Guard Replacement 1. Shut down the combine, and remove the key from the ignition. 2. Stroke the knife manually until the knife sections are spaced midway between the guards. 3. Remove the two nuts (A) and bolts attaching the guard (B) and top guide (C) to the cutterbar.
Page 372: Checking Knife Hold-Downs
MAINTENANCE AND SERVICING 5. Position the plastic wear plate (if applicable), replacement guard (B), adjuster bar (D), top guide (C), and install bolts and nuts (A). Do NOT tighten. 6. Check and adjust the clearance between the hold-downs and the knife. Refer to Checking Knife Hold-Downs, page 354.
Page 373 MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Use a feeler gauge to measure the clearance between the normal guard hold-down (A) and the knife section. Ensure the clearance is 0.004–0.024 in. (0.1–0.6 mm). 3.
Page 374: Knifehead Shield
The knifehead shield attaches to the endsheet and reduces the knifehead opening to prevent cut crop from accumulating in the knifehead cut-out. The shields and mounting hardware are available from your MacDon Dealer. IMPORTANT: Remove the shields when cutting with 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.
Page 375: Installing Knifehead Shield
MAINTENANCE AND SERVICING Installing Knifehead Shield The knifehead shield is supplied in ﬂattened form, but it can be bent to suit installation on pointed or stub guard cutterbars. Knifehead shields differ slightly depending on header size and guard conﬁguration, so ensure you are using the proper knifehead shield for your header.
Page 376: Knife Drive
MAINTENANCE AND SERVICING 5.9 Knife Drive 5.9.1 Knife Drive Box CAUTION To avoid personal injury, before servicing machine or opening drive covers, refer to 5.1 Preparing Machine for Servicing, page 295. Single knife headers have knife drive boxes located at the left end of the header;...
Page 377: Checking Knife Drive Box
MAINTENANCE AND SERVICING Checking Knife Drive Box To access the knife drive box(es), endshield(s) must be fully opened. WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine. 1.
Page 378: Checking Mounting Bolts
MAINTENANCE AND SERVICING IMPORTANT: The knife drive box breather is shipped in position (A) (forward) to prevent oil loss during transport. The breather plug MUST be repositioned to location (B) to prevent oil loss during normal operation. Failure to do so can result in damage to the knife drive box.
Page 379 MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Open the endshield. Refer to Opening Endshields, page 3. Loosen the two bolts (A) securing the motor assembly to the header endsheet. 4. Loosen the belt tension by turning the tensioning bolt (B) counterclockwise.
Page 380: Removing Knife Drive Box Pulley
MAINTENANCE AND SERVICING 8. Stroke the knife manually to its outer limit. 9. Clean the area around the knifehead. 10. Remove bolt (A). 11. Remove the grease zerk (B) from the pin. 12. Use a screwdriver or chisel in slot (C) to release the load on the knifehead pin.
Page 381: Installing Knife Drive Box Pulley
MAINTENANCE AND SERVICING 1. Loosen and remove the knife drive box pulley clamping bolt (A) and nut (B). 2. Remove the knife drive box pulley (C) using a three-jaw puller. Figure 5.108: Knife Drive Box and Pulley Installing Knife Drive Box Pulley Before removing the knife drive box pulley, remove the knife drive box from the header.
Page 382 MAINTENANCE AND SERVICING CAUTION Knife drive box with pulley weighs over 65 lb. (35 kg). Use care when removing or installing. Lug (L) can be used for lifting. 1. Position the knife drive box onto the header mount and install the belt onto the pulley. 2.
Page 383 MAINTENANCE AND SERVICING 6. Position the output arm (A) to the farthest outboard position. Move the output arm (A) up or down on the splined shaft until it is almost contacting the knifehead (B) (exact clearance [C] is set during the knifehead pin installation).
Page 384 13. Move the output arm to the mid-stroke position, and ensure the knife bar doesn’t contact the front of the ﬁrst guard. If the knife drive box requires adjustment, contact your MacDon Dealer. 14. Install and tension the knife drive belts. For untimed belts refer to Tensioning Knife Drive Belts, page 369.
Page 385: Changing Oil In Knife Drive Box
MAINTENANCE AND SERVICING Changing Oil in Knife Drive Box WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine. Change the knife drive box lubricant after the ﬁrst 50 hours of operation and every 1000 hours (or 3 years) thereafter. 1.
Page 386 MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Open the endshield. Refer to Opening Endshields, page 3. Loosen the two bolts (A) securing the motor assembly to the header endsheet. 4. Loosen the belt tension by turning the tensioning bolt (B) counterclockwise.
Page 387 MAINTENANCE AND SERVICING Installing Knife Drive Belts The procedure for installing non-timed knife drive belts is the same for both sides of the header. WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine.
Page 388 MAINTENANCE AND SERVICING 3. Loosen the two bolts (A) securing the motor assembly to the header endsheet. 4. Turn the adjuster bolt (B) clockwise to move the drive motor until a force of 30 lbf (133 N) deﬂects the belt (C) 61/64–1-3/32 in.
Page 389: Feed Draper
MAINTENANCE AND SERVICING 5.10 Feed Draper The feed draper is located on the FM100 ﬂoat module. CAUTION To avoid personal injury, before servicing machine or opening drive covers, refer to 5.1 Preparing Machine ® for Servicing, page 295 in the FD1 FlexDraper Combine Header Operator’s Manual.
Page 390: Adjusting Feed Draper Tension
MAINTENANCE AND SERVICING 8. Install new draper (A) over the drive roller (B). Make sure the draper guides ﬁt into the drive roller grooves (C). 9. Pull draper along bottom of ﬂoat module deck and over idler roller (D). Figure 5.127: Float Module Feed Draper 10.
Page 391: Feed Draper Drive Roller
MAINTENANCE AND SERVICING 4. Loosen jam nut (A) and turn bolt (C) clockwise to increase draper tension or counterclockwise to decrease draper tension. 5. Adjust the draper tension until the white indicator (C) is centered within the indicator window on the spring box. IMPORTANT: Adjust both sides equally.
Page 392 MAINTENANCE AND SERVICING 5. Remove the nuts (A) and connector straps (B) and open the feed draper. Figure 5.131: Draper Connector 6. Remove two bolts (D) from the drive roller cover (A). Figure 5.132: Drive Roller Bearing 7. Move the drive roller cover plate (A) to the left. Figure 5.133: Drive Roller 147831 Revision A...
Page 393: Installing Feed Draper Drive Roller - Fm100
MAINTENANCE AND SERVICING 8. Slide drive roller (A) with bearing assembly (B) to the right until left-hand comes off of spline. Figure 5.134: Drive Roller 9. Lift left-hand end out of the frame. 10. Slide assembly (A) to the left, guiding bearing housing (B) through frame opening (C).
Page 394: Replacing Feed Draper Drive Roller Bearing - Fm100
MAINTENANCE AND SERVICING 4. Slide left-hand end of drive roller (A) onto spline of motor (B). Figure 5.137: Motor 5. Secure the bearing and housing (A) with the drive roller cover plate on the frame using two bolts (B). 6. Install the feed deck draper. Refer to 5.10.1 Replacing Feed Draper, page 371.
Page 395 MAINTENANCE AND SERVICING 4. Loosen jam nut (A) and turn bolt (B) counterclockwise to release the draper tension. Repeat at the opposite side. Figure 5.139: Feed Draper Tensioner 5. Loosen the setscrew (B) on the bearing lock (A). 6. Using a hammer and punch, tap the bearing lock in the direction opposite to the auger rotation to release the lock.
Page 396 MAINTENANCE AND SERVICING 9. Remove bearing housing (A). NOTE: If bearing is seized on shaft, it may be easier to remove the drive roller assembly. For instructions refer to Removing Feed Draper Drive Roller – FM100, page 373. Figure 5.142: Feed Draper Drive Roller Bearing Installing Feed Draper Drive Roller Bearing –...
Page 397: Feed Draper Idler Roller
MAINTENANCE AND SERVICING 5. Turn adjuster bolt (A) clockwise until it touches the bearing housing (B). Secure with the jam nut (C). 6. Tension the feed draper. Refer to 5.10.2 Adjusting Feed Draper Tension, page 372. Figure 5.145: Feed Draper Drive Roller Bearing 5.10.4 Feed Draper Idler Roller Removing Feed Draper Idler Roller –...
Page 398: Replacing Feed Draper Idler Roller Bearing - Fm100
MAINTENANCE AND SERVICING 6. Remove nut (D) to have better access to the other two nuts (C). 7. Remove two bolts (A) and nuts (C)from both ends of the idler roller. 8. Remove the idler roller assembly (B). Figure 5.148: Idler Roller Replacing Feed Draper Idler Roller Bearing –...
Page 399: Installing Feed Draper Idler Roller - Fm100
MAINTENANCE AND SERVICING 4. Secure the housing (D) and remove the internal retaining ring (A), bearing (B), and two seals (C). 5. Apply oil to bore before assembly. 6. Install the seals (C) into the housing (D). NOTE: Ensure the ﬂat side of the seal is facing inboard. 7.
Page 400 MAINTENANCE AND SERVICING 3. Install nut (A). IMPORTANT: Maintain a 2–4 mm gap (C) between the plate (B) and nut (A) to allow the idler roller to ﬂoat and to move when belt is tensioned or adjusted. Figure 5.154: Idler Roller 4.
Page 401: Float Module Stripper Bars And Feed Deflectors
MAINTENANCE AND SERVICING 5.11 Float Module Stripper Bars and Feed Deﬂectors 5.11.1 Removing Stripper Bars 1. Detach the header from the combine. Refer to Header Attachment/Detachment, page 225. 2. Remove the four bolts and nuts (A) securing the stripper bar (B) to the ﬂoat module frame, and remove the stripper bar.
Page 402: Installing Stripper Bars
MAINTENANCE AND SERVICING 5.11.2 Installing Stripper Bars 1. Detach the header from the combine. Refer to Header Attachment/Detachment, page 225. 2. Position the stripper bar (A) so the notch (B) is at the corner of the frame. 3. Secure the stripper bar (A) to the ﬂoat module with four bolts and nuts (C).
Page 403: Replacing Feed Deflectors On New Holland Cr Combines
MAINTENANCE AND SERVICING 5.11.3 Replacing Feed Deﬂectors on New Holland CR Combines 1. Detach the header from the combine. Refer to 4 Header Attachment/Detachment, page 225. 2. Remove the two bolts and nuts (B) securing the feed deﬂector (A) to the ﬂoat module frame, and remove the feed deﬂector.
Page 404: Header Drapers
MAINTENANCE AND SERVICING 5.12 Header Drapers There are two header drapers. They convey cut crop to the ﬂoat module feed draper and auger. Replace the drapers if torn, cracked, or missing slats. 5.12.1 Removing Drapers DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop engine and remove key before leaving the operator’s seat, and always engage safety props before going under the machine for any reason.
Page 405 MAINTENANCE AND SERVICING 1. Apply talc, baby powder, or talc/graphite lubricant mix to the draper surface that forms the seal with the cutterbar and to the underside of the draper guides. 2. Insert the draper into the deck at the outboard end under the rollers.
Page 406: Adjusting Draper Tension
MAINTENANCE AND SERVICING 8. Check the draper seal between the drapers and the cutterbar. Ensure there is a 0.04–0.08 in. (1–2 mm) gap (A) between the cutterbar (C) and the draper (B). 9. Refer to 5.12.5 Adjusting Deck Height, page 391 achieve the proper gap.
Page 407 MAINTENANCE AND SERVICING 1. Ensure the white indicator bar (A) is at the halfway point in the window. WARNING Check to be sure all bystanders have cleared the area. 2. Start the engine and raise the header. 3. Stop the engine, remove the key from the ignition, and engage the header safety props.
Page 408: Adjusting Header Draper Tracking
MAINTENANCE AND SERVICING IMPORTANT: Do NOT adjust nut (C). This nut is used for draper alignment only. 6. Turn the adjuster bolt (A) counterclockwise to loosen. The white indicator bar (B) will move outboard in the direction of arrow (D) to indicate that the draper is loosening.
Page 409: Adjusting Deck Height
MAINTENANCE AND SERVICING 1. Refer to Table 5.2 Header Draper Tracking, page 390 determine which roller requires adjustment and which adjustments are necessary. NOTE: To change X, adjust the back end of the roller using the adjuster mechanism at the inboard end of the deck.
Page 410 MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Check the deck height and ensure the draper (B) runs just below the cutterbar (C) with a gap (A) of 1/8 in. (3 mm) between the top of the deck front track and the cutterbar.
Page 411 MAINTENANCE AND SERVICING 8. Set the deck (A) to a gap (B) of 1 mm + measurement noted in Step below the cutterbar (C) to 5., page 392 create a seal. 9. Tighten the deck support hardware (D). 10. Recheck the gap (B) to ensure it is properly set. Refer to Step 8., page 393.
Page 412: Header Draper Roller Maintenance
MAINTENANCE AND SERVICING 5.12.6 Header Draper Roller Maintenance The draper rollers have non-greaseable bearings; however, the external seal should be checked every 200 hours (more frequently in sandy conditions) to achieve maximum bearing life. Inspecting Draper Roller Bearing Using an infrared thermometer, check for bad draper roller bearings as follows: 1.
Page 413 MAINTENANCE AND SERVICING 5. Remove the screws (A), tube connectors (B), and nuts from the draper joint to uncouple the draper. 6. Pull the draper off the idler roller. Figure 5.180: Draper Connector 7. Remove the bolts (A) and washer at the ends of the idler roller.
Page 414 MAINTENANCE AND SERVICING 2. Remove the bearing assembly (A) and seal (B) from the roller tube (C) as follows: a. Attach a slide hammer (D) to the threaded shaft (E) in the bearing assembly. b. Tap out the bearing assembly (A) and seal (B). 3.
Page 415: Draper Deck Drive Roller
MAINTENANCE AND SERVICING Installing Header Draper Idler Roller 1. Position the stub shaft into the idler roller in the forward arm (B) on the deck. 2. Push on the roller to slightly deﬂect the forward arm so the stub shaft at the rear of the roller can be slipped into the rear arm (C).
Page 416 MAINTENANCE AND SERVICING 4. Remove the tube connectors (B), screws (A), and nuts from the draper joint to uncouple the draper. 5. Pull the draper off the drive roller. Figure 5.186: Draper Connector 6. Align the setscrews with the hole (A) in the guard. Remove the two setscrews holding the motor onto the drive roller.
Page 417 MAINTENANCE AND SERVICING 2. Remove the bearing assembly (A) and seal (B) from the roller tube (C) as follows: a. Attach a slide hammer (D) to the threaded shaft (E) in the bearing assembly. b. Tap out the bearing assembly (A) and seal (B). 3.
Page 418 MAINTENANCE AND SERVICING Installing Draper Drive Roller 1. Position the drive roller (B) between the roller support arms. 2. Install the bolt (A) to secure the drive roller to the arm closest to the cutterbar. Torque bolt to 70 ft·lbf (95 N·m).
Page 419: Replacing Draper Deflectors
MAINTENANCE AND SERVICING 7. Tension the draper. Locate adjuster bolt (A) and follow the directions on the decal for the proper draper tensioning or refer to 5.12.3 Adjusting Draper Tension, page 388. 8. Disengage the reel and header safety props. 9.
Page 420: Installing Narrow Draper Deflectors
MAINTENANCE AND SERVICING 7. Remove four screws (A) and remove the deﬂector (B). 8. Repeat for the opposite end of the header. Figure 5.196: Forward Deﬂector Installing Narrow Draper Deﬂectors Narrow draper deﬂectors can replace wide deﬂectors if bunching occurs at the ends of the header when decks are set for center delivery.
Page 421 MAINTENANCE AND SERVICING 8. Position the aft deﬂector (C) as shown and install three 3/8 in. x 3/4 in. carriage bolts (B) and lock nuts. ® 9. Install two Torx head screws (A) and lock nuts with the heads facing down. 10.
Page 422: Reel
MAINTENANCE AND SERVICING 5.13 Reel CAUTION To avoid personal injury, before servicing machine or opening drive covers, refer to 5.1 Preparing Machine for Servicing, page 295. 5.13.1 Reel Clearance to Cutterbar The minimum clearance between the reel ﬁngers and the cutterbar ensures that the reel ﬁngers do not contact the cutterbar during operation.
Page 423 MAINTENANCE AND SERVICING 2. Move spring handles (A) down to (UNLOCK) position. Figure 5.200: Wing Lock in UNLOCK Position 3. Raise header and place two 6 in. (150 mm) blocks (A) under the cutterbar, just inboard of the wing ﬂex points. 4.
Page 424 MAINTENANCE AND SERVICING 8. Measure the clearance (X) between points (B) and (C) at the ends of each reel (A), and at the ﬂex locations (B). NOTE: The reel is factory-set to “frown” (provide more clearance at the center of the reel than at the ends) to compensate for reel ﬂexing.
Page 425: Adjusting Reel Clearance
MAINTENANCE AND SERVICING Adjusting Reel Clearance DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. 1. Stop the engine and remove the key. 2.
Page 426: Centering Double Reels
MAINTENANCE AND SERVICING 1. Position the reel over the cutterbar (between 4 and 5 on the fore-aft position decal) (A) to provide adequate clearance at all reel fore-aft positions. 2. Record the measurement at each reel disc location for each reel tube. Figure 5.207: Fore-Aft Position Decal 3.
Page 427: Reel Fingers
MAINTENANCE AND SERVICING 5.13.4 Reel Fingers IMPORTANT: Keep the reel ﬁngers in good condition and straighten or replace them as necessary. Removing Steel Fingers WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason.
Page 428: Removing Plastic Fingers
MAINTENANCE AND SERVICING 1. Remove the applicable ﬁnger. Refer to Removing Steel Fingers, page 409. 2. Slide the new ﬁngers and reel arm (A) onto the end of the tube. 3. Install the tine tube bushings. Refer to 5.13.5 Tine Tube Bushings, page 411.
Page 429: Installing Plastic Fingers
MAINTENANCE AND SERVICING Installing Plastic Fingers WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. 1. Position the ﬁnger on the rear of the ﬁnger tube and engage the lug at the bottom of the ﬁnger in the lower hole in the ﬁnger tube.
Page 430 MAINTENANCE AND SERVICING NOTE: If replacing only the cam end bushing, refer to Step 8., page 413. Center Disc and Tail-End Bushings 3. Remove the reel endshields and endshield support (C) from the tail end of the reel at the applicable tine tube location.
Page 431 MAINTENANCE AND SERVICING Cam End Bushings 8. Remove the endshields and endshield support (A) at the applicable tine tube location on the cam end. NOTE: Removing cam end bushings requires the tine tube be moved through the disc arms to expose the bushing.
Page 432 MAINTENANCE AND SERVICING 12. Remove bolt (A) from the cam linkage so the tine tube (B) is free to rotate. Figure 5.222: Cam End 13. Release the bushing clamps (A) at the cam disc using a small screwdriver to separate the serrations. Move the clamps off the bushings.
Page 433 MAINTENANCE AND SERVICING Tine Tube Bushings (If Installed) 16. Locate the support (A) that requires a new bushing. 17. Remove the four bolts (B) securing channels (C) to the support (A). 18. Remove screw (E) and remove the ﬁnger (D) if it is too close to the support to allow access to the bushing.
Page 434: Installing Bushings On Five-, Six-, Or Nine-Bat Reels
MAINTENANCE AND SERVICING 20. Slide the support (A) off the bushing halves (B). NOTE: Two tine tubes have opposite supports (C). Rotate the supports until the ﬂanges clear the channels before moving them off the bushing (B). Move the tine tube outwards slightly if necessary. 21.
Page 435 MAINTENANCE AND SERVICING NOTE: Use a pair of modiﬁed channel lock pliers (A) to install bushing clamps (C). Secure pliers in a vice and grind a notch (B) into the end of each arm to ﬁt the clamp as shown. Figure 5.230: Modiﬁed Pliers Cam End Bushings 1.
Page 436 MAINTENANCE AND SERVICING 6. Tighten the clamp (A) using modiﬁed channel lock pliers (B) until ﬁnger pressure will NOT move the clamp. IMPORTANT: Over-tightening clamp may result in breakage. Figure 5.233: Installing Clamp 7. Line up the tine bar (B) with the cam arm and install bolt (A).
Page 437 MAINTENANCE AND SERVICING 10. Install the endshield support (A) at the applicable tine tube location at the cam end. 11. Reinstall the reel endshields. Refer to 5.13.6 Reel Endshields, page 423. Figure 5.236: Cam End Center Disc and Tail End Bushings 12.
Page 438 MAINTENANCE AND SERVICING 17. Tighten the clamp (A) using modiﬁed channel lock pliers (B) until ﬁnger pressure will NOT move the clamp. IMPORTANT: Over-tightening clamp may result in breakage. Figure 5.239: Installing Clamp 18. Install the bolts (A) securing the arm (B) to the center disc.
Page 439 MAINTENANCE AND SERVICING Tine Tube Support (If installed) Bushings 20. Position the bushing halves (B) on the tine tube with the ﬂangeless end adjacent to the reel arm, and position the lug in each bushing half into the hole in the tine tube.
Page 440 MAINTENANCE AND SERVICING 24. Tighten the clamp (A) using modiﬁed channel lock pliers (B) until ﬁnger pressure will NOT move the clamp. IMPORTANT: Over-tightening clamp may result in breakage. Figure 5.244: Installing Clamp 25. Reattach the channels (C) to the support (A) with screws (B) and nuts.
Page 441: Reel Endshields
MAINTENANCE AND SERVICING 5.13.6 Reel Endshields Reel endshields and supports do not require regular maintenance, but they should be checked periodically for damage and loose or missing fasteners. Slightly dented or deformed endshields and supports are repairable, but it’s necessary to replace severely damaged components. You can attach reel endshields to either end of the reel.
Page 442: Replacing Reel Endshield Supports
MAINTENANCE AND SERVICING 5. Remove the reel endshield from the supports. Figure 5.249: Reel Endshields 6. Remove the reel endshield (A) from support (B). 7. Install new reel endshield (C) onto support (B). 8. Reattach reel endshield (A) onto support (B) ensuring it is installed on top of the reel endshield (C).
Page 443 MAINTENANCE AND SERVICING 5. Move the reel endshields (A) away from the tine tube and rotate the support (B) towards the reel to remove it. 6. Insert tabs of new support (B) into the slots in the reel endshields (A). Ensure the tabs engage both reel endshields.
Page 444: Reel Drive
MAINTENANCE AND SERVICING 5.14 Reel Drive The reel is hydraulically driven through a chain case that is attached between the reels on a double-reel header. 5.14.1 Replacing Reel Drive Cover Removing Reel Drive Cover DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 445: Adjusting Reel Drive Chain Tension
MAINTENANCE AND SERVICING 1. Position the lower drive cover (B) onto the reel drive (if previously removed) and secure with three bolts (A). Figure 5.255: Lower Drive Cover – Double Reel 2. Position the upper drive cover (B) onto the reel drive and lower cover (C) and secure with six bolts (A).
Page 446: Tightening Reel Drive Chain
MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Remove the drive cover. Refer to Removing Reel Drive Cover, page 426. 3. Loosen six nuts (A). Slide the motor (B) and motor mount (C) down towards the reel shaft. Figure 5.257: Reel Drive (Parts Removed for Clarity) Tightening Reel Drive Chain...
Page 447: Replacing Reel Drive Sprocket
MAINTENANCE AND SERVICING 3. Slide the motor (A) and motor mount (B) upwards until the chain (C) is tight. Figure 5.259: Single-Reel Drive Shown – Double Reel Similar 4. Tighten six nuts (A). 5. Ensure there is 1/8 in. (3 mm) of slack at the chain midspan.
Page 448: Removing Reel Drive Sprocket
MAINTENANCE AND SERVICING Removing Reel Drive Sprocket DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. 1. Shut down the combine, and remove the key from the ignition.
Page 449: Replacing Double-Reel U-Joint
MAINTENANCE AND SERVICING 1. Align the keyway in sprocket (D) with the key on the motor shaft, and slide the sprocket onto the shaft. Secure with ﬂat washer (C) and slotted nut (B). 2. Torque slotted nut (B) to 40 ft·lbf (54 N·m). 3.
Page 450: Installing Double-Reel U-Joint
MAINTENANCE AND SERVICING 3. Support the inboard end of the right reel with a front end loader and nylon slings (A) (or equivalent lifting device). IMPORTANT: Avoid damaging or denting the center tube by supporting the reel as close to the end disc as possible.
Page 451: Replacing Reel Drive Motor
Figure 5.270: Supporting Reel 5.14.5 Replacing Reel Drive Motor The reel drive motor does not require regular maintenance or servicing. If problems occur with the motor, remove it and have it serviced at your MacDon Dealer. Removing Reel Drive Motor DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 452: Installing Reel Drive Motor
MAINTENANCE AND SERVICING 4. Disconnect the hydraulic lines (A) at the motor (B). Cap or plug open ports and lines. NOTE: Mark the hydraulic lines (A) and their locations in the motor (B) to ensure correct reinstallation. 5. Remove four nuts and bolts (C) and remove the motor (A).
Page 453: Replacing Drive Chain On Double Reel
MAINTENANCE AND SERVICING 5. Remove the caps or plugs from the ports and lines and connect the hydraulic lines (A) to the hydraulic ﬁttings (B) on the motor (C). NOTE: Ensure the hydraulic lines (A) are installed at their original locations. Figure 5.274: Reel Motor and Hoses 6.
Page 454 MAINTENANCE AND SERVICING 4. Remove the four bolts (A) securing the reel tube to the U-joint ﬂange (B). Figure 5.276: U-Joint 5. Move the right-hand reel sideways to separate the reel tube (A) from the U-joint (B). 6. Remove the drive chain (C). 7.
Page 455: Replacing Reel Speed Sensor
MAINTENANCE AND SERVICING 12. Remove the temporary reel support (A). Figure 5.279: Supporting Reel 5.14.7 Replacing Reel Speed Sensor The reel speed sensors, and the procedures for replacing them, vary with the combine model. Replacing AGCO Sensor DANGER To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 456: Replacing John Deere Sensor
MAINTENANCE AND SERVICING 4. Cut the cable tie (A) securing the harness to the cover. 5. Remove two screws (B) and remove the sensor (C) and harness. Bend the cover (D) (if necessary) to remove the harness. 6. Feed the wire of the new sensor behind the cover (D) and through the chain case.
Page 457: Replacing Lexion 400 Series Sensor
MAINTENANCE AND SERVICING 3. Disconnect the electrical connector (D). 4. Remove the top nut (C) and remove the sensor (B). 5. Remove the top nut from the new sensor and position the sensor into the support. Secure with top nut (C). 6.
Page 458 MAINTENANCE AND SERVICING 1. Shut down the combine, and remove the key from the ignition. 2. Remove the drive cover. Refer to Removing Reel Drive Cover, page 426. 3. Disconnect the electrical connector (C). 4. Remove screw (D) and remove the sensor (B). 5.
Page 459: Transport System (Optional)
MAINTENANCE AND SERVICING 5.15 Transport System (Optional) Refer to for more information. 6.3.3 Stabilizer/Slow Speed Transport Wheels, page 449 5.15.1 Checking Wheel Bolt Torque If a transport system is installed, adhere to the following procedure for torquing the wheel bolts: WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine.
Page 460: Checking Axle Bolt Torque
MAINTENANCE AND SERVICING 5.15.2 Checking Axle Bolt Torque If a transport system is installed, adhere to the following procedure for torquing the axle bolts: Figure 5.287: Axle Bolts 1. Check and tighten axle bolts DAILY until torque is maintained as follows: •...
Page 461: Checking Tire Pressure
MAINTENANCE AND SERVICING 5.15.3 Checking Tire Pressure Check the tire inﬂation pressure and inﬂate according to the information provided in Table 5.4 Tire Pressure, page 443. Table 5.4 Tire Pressure Size Load Range Pressure 65 psi (448 kPa) ST205/75 R15 80 psi (552 kPa) WARNING...
Page 463: Options And Attachments
6 Options and Attachments The following options and attachments are available for use with your header. See your MacDon Dealer for availability and ordering information. 6.1 Reel 6.1.1 Multi-Crop Rapid Reel Conversion Kit For use on double-reel headers only, the multi-crop rapid...
Page 464: Pr15 Tine Tube Reel Conversion Kit
They are standard equipment on all headers (except nine-bat reels). Hardware and installation instructions are included in the kit. See your MacDon Dealer for more information. Figure 6.3: Reel Endshields 6.1.5 Tine Tube Reinforcing Kit Tine tube reinforcing kits are available for ﬁve- and six-bat reels.
Page 465: Cutterbar
OPTIONS AND ATTACHMENTS 6.2 Cutterbar 6.2.1 Cutterbar Wearplate Cutterbar wearplates are recommended for cutting on the ground when the soil is adhering to the steel. Order one of the following bundles according to your header size: • 30 foot – MD #B4839 •...
Page 466: Stub Guard Conversion Kit
The vertical knife mounts allow the installation of vertically oriented knives onto both ends of the header. The vertical knives themselves are not sold by MacDon and must be purchased from a separate Supplier Installation and adjustment instructions are included in the bundle.
Page 467: Header
OPTIONS AND ATTACHMENTS 6.3 Header 6.3.1 Divider Latch Kit Divider latch kits attach to the endsheets. They allow for quick removal and storage of endsheet divider cones and, if required, reduce the transport width of the header. Installation instructions are included in the kit. MD #B5607 Figure 6.9: Divider Latch 6.3.2 Stabilizer Wheels...
Page 468: Crop Delivery
OPTIONS AND ATTACHMENTS 6.4 Crop Delivery 6.4.1 FM100 Feed Auger Flighting Auger ﬂighting (A) on the FM100 can be conﬁgured to speciﬁc combines and crop conditions. Refer to Float Module Feed Auger Conﬁgurations, page 225 combine/crop speciﬁc conﬁgurations. Figure 6.11: FM100 Feed Auger Flighting 6.4.2 Draper Deﬂector (Narrow) Narrow metal draper deﬂectors attach to the inboard side of the endsheets to prevent material from falling through the...
Page 469: Draper Deflector (Wide)
OPTIONS AND ATTACHMENTS 6.4.3 Draper Deﬂector (Wide) Wide metal draper deﬂectors attach to the inboard side of the endsheets to prevent material from falling through the gap between the endsheet and the draper. Refer to your parts catalog for the necessary parts. Figure 6.13: Draper Deﬂector (Wide) 6.4.4 Stripper Bars Stripper bars improve feeding in certain crops such as rice.
Page 470: Rice Divider Rods
OPTIONS AND ATTACHMENTS 6.4.6 Rice Divider Rods Rice divider rods attach to the left- and right-hand crop dividers and divide tall and tangled rice crops in a similar manner to standard crop divider rods performing in standing crops. Installation instructions are included in the kit.
Page 471: Troubleshooting
3.7.11 Reel Tine Pitch, Reel ﬁngers not lifting crop aggressiveness page 89 sufﬁciently Install lifter guards See your MacDon Dealer Reel speed too fast Reduce reel speed 3.7.5 Reel Speed, page 73 Reel too low Raise reel 3.7.9 Reel Height, page 78 Heads shattering or 3.7.6 Ground Speed, page...
Page 472 6.2.3 Stub Guard Replace 3–4 end guards proper feeding due to Conversion Kit, page with stub guards material bridging the or see your MacDon cutter guards Dealer Bushy or tangled Divider rods providing crop ﬂows over 3.7.12 Crop Dividers, page Install long divider rods insufﬁcient separation...
Page 473: Cutting Action And Knife Components
Straighten bent knife and of cutting parts align guards 5.8.7 Knife Guards, page Cutting edge of guards not close enough or parallel to Align guards knife sections your MacDon • See Dealer • Checking Knife Tangled/tough-to-cut crop Install stub guards Hold-Downs, page 354 •...
Page 474 TROUBLESHOOTING Symptom Problem Solution Section • 3.7.9 Reel Height, page Reel too high or too Lower reel or move far forward reel rearward • 3.7.10 Reel Fore-Aft Position, page 82 3.7.6 Ground Speed, page Ground speed to slow Increase ground speed Tensioning Knife Drive Adjust drive belt tension Loose knife drive belt...
Page 475 Section, page 345 Incorrect knife speed Adjust knife speed 3.7.8 Knife Speed, page 77 Excessive vibration Driveline U-joints worn Replace U-joints See your MacDon Dealer of ﬂoat module and header Bent cutterbar Straighten cutterbar See your MacDon Dealer Knife hold-downs not...
Page 476: Reel Delivery
Wrapping on reel end 3.7.5 Reel Speed, page Reel speed too fast Reduce reel speed Crop conditions Install optional endshields See your MacDon Dealer Reel not centered in 5.13.3 Centering Double Center reel in header header Reels, page 408 Reel tines not aggressive 3.7.11 Reel Tine Pitch,...
Page 477 TROUBLESHOOTING Symptom Problem Solution Section 3.7.5 Reel Speed, page Reel speed too fast Reduce reel speed Move to a more Reel ﬁngers not 3.7.11 Reel Tine Pitch, aggressive ﬁnger aggressive enough page 89 pitch notch 3.7.9 Reel Height, page Reel too low Raise reel Relief valve on combine Increase relief pressure...
Page 478: Header And Drapers
7.4 Header and Drapers Symptom Problem Solution Refer to Low relief pressure Increase relief pressure See your MacDon Dealer Header lift insufﬁcient Increase speed 3.7.7 Draper Speed, page Speed control set too low control setting Increase relief pressure to Relief pressure too low...
Page 479 TROUBLESHOOTING Symptom Problem Solution Refer to Drapers running too slow Increase draper speed Drapers back-feed in heavy crop 3.7.7 Draper Speed, page Crop is thrown across Drapers running too fast Reduce draper speed opening and under in light crop opposite side draper Material accumulates Deck height 5.12.5 Adjusting Deck...
Page 480: Cutting Edible Beans
53 Dirt packs on bottom Install plastic wear strips of cutterbar and raises on bottom of cutterbar and See your MacDon Dealer cutterbar off the ground skid shoes Ground too wet – allow Dirt packing on bottom soil to dry...
Page 481 TROUBLESHOOTING Symptom Problem Solution Refer to Plastic wear strip for Remove steel cutterbar cutterbar has been wear plates when — installed over top of installing the plastic steel wear plates wear strips for cutterbar 3.9 Levelling the Header, Header not level Level header page 202 Plants being stripped...
Page 482 TROUBLESHOOTING Symptom Problem Solution Refer to 3.7.10 Reel Fore-Aft Reel too far forward Reposition reel Position, page 82 3.7.5 Reel Speed, page Reel speed too high Reduce reel speed Cut at night when heavy Reel shattering pods — Bean pods are too dry dew is present and pods have softened Increase ﬁnger...
Page 483 TROUBLESHOOTING Symptom Problem Solution Refer to Reel ﬁngers (steel) bent — and hooking plants from Straighten ﬁngers (steel) crop ﬂow on drapers Reel occasionally 3.7.9 Reel Height, page Raise reel carries over plants Dirt accumulation on in same location end of ﬁngers preventing Adjust reel fore-aft position plants from dropping off 3.7.10 Reel Fore-Aft...
Page 485: Reference
8 Reference 8.1 Torque Speciﬁcations The following tables provide the correct torque values for various bolts, cap screws, and hydraulic ﬁttings. • Tighten all bolts to the torque values speciﬁed in the charts (unless otherwise noted throughout this manual). • Replace hardware with the same strength and grade of bolt. •...
Page 486 REFERENCE Table 8.2 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 *167 *185 18.8 20.8 Figure 8.2: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...
Page 487 REFERENCE Table 8.4 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 10.7 11.8 *105 8-1.25 Figure 8.4: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...
Page 488: Metric Bolt Specifications Bolting Into Cast Aluminum
REFERENCE 8.1.2 Metric Bolt Speciﬁcations Bolting into Cast Aluminum Table 8.5 Metric Bolt Bolting into Cast Aluminum Bolt Torque Nominal 10.9 Size (A) (Cast Aluminum) (Cast Aluminum) ft·lbf N·m ft·lbf N·m – – – – – – – Figure 8.5: Bolt Grades –...
Page 489 REFERENCE Table 8.6 Flare-Type Hydraulic Tube Fittings Torque Value Flats from Finger Tight (FFFT) SAE Dash Size Thread Size (in.) Swivel Nut or ft·lbf N·m Tube Hose — — 5/16–24 3–4 4–5 5–6 7–8 — — 3/8–24 7/16–20 13–14 18–19 2-1/2 1/2–20 14–15...
Page 490: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)
REFERENCE 8.1.4 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off the lock nut (C) as far as possible. Ensure that washer (D) is loose and is pushed toward the lock nut (C) as far as possible.
Page 491 REFERENCE Table 8.7 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque Value SAE Dash Size Thread Size (in.) ft·lbf (*in·lbf) N·m 5/16–24 *53–62 6–7 3/8–24 *106–115 12–13 7/16–20 14–15 19–21 1/2–20 15–24 21–33 9/16–18 19–21 26–29 3/4–16 34–37 46–50 7/8–14 55–60 75–82 1-1/16–12 88–97...
Page 492: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)
REFERENCE 8.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Check that O-ring (A) is NOT on the threads and adjust if necessary. 3. Apply hydraulic system oil to the O-ring. 4.
Page 493: O-Ring Face Seal (Orfs) Hydraulic Fittings
REFERENCE 8.1.6 O-Ring Face Seal (ORFS) Hydraulic Fittings 1. Check components to ensure that the sealing surfaces and ﬁtting threads are free of burrs, nicks, scratches, or any foreign material. Figure 8.10: Hydraulic Fitting 2. Apply hydraulic system oil to the O-ring (B). 3.
Page 494 REFERENCE Table 8.9 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) ft·lbf N·m – – Note 3/16 9/16 18–21 25–28 Note 5/16 – – 11/16 29–32 40–44 13/16 41–45 55–61 59–65 80–88 1-3/16 85–94...
Page 495: Conversion Chart
REFERENCE 8.2 Conversion Chart Table 8.10 Conversion Chart Inch-Pound Units SI Units (Metric) Factor Quantity Unit Name Abbreviation Unit Name Abbreviation Area acres acres x 0.4047 = hectares US gallons Flow x 3.7854 = liters per minute L/min per minute Force pounds force x 4.4482 =...
Page 496: Unloading And Assembly
8.3 Unloading and Assembly Refer to the instructions for your speciﬁc header for unloading, assembly, and setup procedures that are included with your shipment. The instruction part numbers are shown in the following table: MacDon Instruction Shipping Destination Header Description Part Number ®...
Page 497: Index
Index sensitivity ..........111 calibrating AGCO combines AHHC ............110 attaching header to combine ......252 maximum stubble height ......185 replacing reel speed sensors......437 how AHHC works.......... 99 AHHC sensor operation ......... 201 deﬁnitions ............17 sensor output voltage See also auto header height control checking voltage range manually ....
Page 498 INDEX sensor output voltage combine output voltage requirements..101 checking voltage range from the cab..115 Gleaner R62/R72 series combines checking voltage range manually ....101 calibrating combine output voltage requirements..101 maximum stubble height ......185 Case IH 7230/8230/9230 combines ....112 combine output voltage requirements ...
Page 499 INDEX AHHC ............. 152 maximum stubble height ......185 feeder house speed ......... 152 how AHHC works.......... 99 maximum stubble height ......185 sensor operation ......... 201 how AHHC works.......... 99 sensor output voltage sensor operation ......... 201 checking voltage range manually ....101 sensor output voltage New Holland 2015 CR series ......
Page 500 INDEX installing ............. 381 transporting header ........208 removing ............ 379 component identiﬁcation........24 ® beater bars FD1 FlexDraper ..........24 installing ............206 FM100 ﬂoat module.......... 25 removing ............206 conversion charts ..........477 belts CR feeder deﬂectors .......... 284 knife drive ............
Page 501 INDEX drapers adjusting tension ..........388 FD1-Series headers adjusting tracking ........... 390 deﬁnitions ............17 drive roller feed deﬂectors........... 284 installing ............. 400 ﬂoat module ........... 383 removing ............ 397 installing ............. 385 drive rollers feed draper removing ............ 397 drive rollers ............
Page 502 INDEX setup ............. 243 adjusting speed..........75 stripper bars........... 383 draper roller maintenance ....... 394 installing ............. 384 idler roller bearings kits ............. 243 replacing ............ 395 removing ............ 383 header drives ............ 324 unplugging ............. 205 adjusting tension on gearbox drive chain..330 FM100 feed auger ﬂighting .........
Page 503 INDEX replacing............380 installing ............. 348 idler roller bearings removing ............ 347 installing ............381 knifehead shields ........... 356 removing ............379 installing ............. 357 idler rollers removing ............347 draper spare knife location ........349 removing idler roller........394 troubleshooting ..........
Page 504 INDEX detaching from header ........257 divider latch kits .......... 449 replacing reel speed sensors......437 rice divider rods .......... 452 metric bolts stabilizer/slow speed transport wheels..449 torque speciﬁcations........467 knifehead shields ........356–357 model numbers PR15 pick-up reels records .............
Page 505 INDEX covers reel fore-aft positions ........... 82 installing..........426 adjusting ............82 removing..........426 reel height sensors replacing ..........426 adjusting ............80 drive chains reel safety props ..........29 loosening ..........427 disengaging ............. 30 tightening ..........428 engaging ............29 drive sprockets reel speeds ............
Page 506 INDEX spare knives............349 O-ring boss (ORB) ﬁttings speciﬁcations ............19 (non-adjustable) ........... 474 torque speciﬁcations........467 O-ring boss (ORB) hydraulic ﬁttings speed (adjustable) ..........472 draper speed............ 75 O-ring face seal (ORFS) ﬁttings....... 475 feed draper speed ..........76 tow-bars ground speed...........
Page 507 INDEX unplugging the cutterbar........204 tires upper cross augers ........206, 451 tire inﬂation/pressures ......... 443 installing beater bars ........206 wheel bolt torques .......... 441 removing beater bars........206 windrowers header attachment/detachment ....... 225 wing balance adjusting wing balance ........70 checking wing balance........
Page 510 10708 N. Pomona Avenue Kansas City, Missouri United States 64153-1924 t. (816) 891-7313 f. (816) 891-7323 MacDon Australia Pty. Ltd. A.C.N. 079 393 721 P.O. Box 243, Suite 3, 143 Main Street Greensborough, Victoria, Australia 3088 t. 03 9432 9982 f.

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