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MacDon FlexDraper FD2 Series Operator's Manual

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FD2 Series

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FlexDraper

Header with

FM200 Float Module

Operator's Manual

MD #262653 Revision A

Original Instruction

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Page 1 FD2 Series ® FlexDraper Header with FM200 Float Module Operator’s Manual MD #262653 Revision A Original Instruction...
Page 2 © 2024 MacDon Industries, Ltd. The information in this publication is based on the information available and in effect at the time of printing. MacDon Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the...
Page 3: Declaration Of Conformity
Unterlagen zu erstellen: Guillaume Quenot Guillaume Quenot Guillaume Quenot Guillaume Quenot Directeur général, MacDon Europe GmbH Gerente general - MacDon Europe GmbH Peadirektor, MacDon Europe GmbH General Manager, MacDon Europe GmbH Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59...
Page 4 Guillaume Quenot Guillaume Quenot Guillaume Quenot Guillaume Quenot Ģenerāldirektors, MacDon Europe GmbH General Manager, MacDon Europe GmbH Vezérigazgató, MacDon Europe GmbH Generalinis direktorius, MacDon Europe GmbH Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59 65203 Wiesbaden (Vācija)
Page 5 Unterlagen zu erstellen: Guillaume Quenot Guillaume Quenot Guillaume Quenot Guillaume Quenot Directeur général, MacDon Europe GmbH Gerente general - MacDon Europe GmbH Peadirektor, MacDon Europe GmbH General Manager, MacDon Europe GmbH Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59...
Page 6 Guillaume Quenot Guillaume Quenot Guillaume Quenot Guillaume Quenot Ģenerāldirektors, MacDon Europe GmbH General Manager, MacDon Europe GmbH Vezérigazgató, MacDon Europe GmbH Generalinis direktorius, MacDon Europe GmbH Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59 65203 Wiesbaden (Vācija)
Page 7 680 Moray Street, [5] 22-Apr-24 Winnipeg, Manitoba, Canada R3J 3S3 [6] _____________________________ [2] Combine Header Adrienne Tankeu [3] MacDon FD2 Series Product Integrity We, [1] Declare, that the product: Machine Type: [2] Name & Model: [3] Serial Number(s): [4] fulflls all relevant provisions of the Supply of Machinery (Safety) Regulatons 2008...
Page 8 UK Declaraton of Conformity [4] As per Shipping Document MacDon Industries Ltd. 680 Moray Street, [5] 22-Apr-24 Winnipeg, Manitoba, Canada R3J 3S3 [2] Float Module [6] _____________________________ Adrienne Tankeu [3] MacDon FM200 Product Integrity We, [1] Declare, that the product: Machine Type: [2] Name &...
Page 9 Header. When setting up the machine or making any adjustments, review and follow the recommended machine settings in all relevant MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous situation.
Page 10 (www.macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login required). Call your MacDon Dealer if you need assistance, information, or additional copies of this manual. Figure 1: Manual Storage Location This manual is available in the following languages: •...
Page 11: Summary Of Changes
Summary of Changes The following list provides an account of major changes from the previous version of this document. Section Summary of Change Internal Use Only Updated the Declaration of Technical Publications Declaration of Conformity, page i Conformity documents for model year 2025.
Page 12 Section Summary of Change Internal Use Only Added a new multi-brand procedure ECN 65347 for replacing the reel speed sensor, Replacing Reel Speed Sensor, page 461 and removed the outdated procedures. ™ 4.17.3 Changing VertiBlade Vertical Knife Updated the procedure. ECN 65405 Position, page 486 Added bundle number for upper...
Page 13: Recording Model And Serial Number
Recording Model and Serial Number Record the model number, serial number, and model year of the header, float module, and transport/stabilizer wheel option (if installed) in the spaces provided. FD2 Series FlexDraper ® Header Header Model: Serial Number: Model Year: The header’s serial number plate (A) is located on the back of the header, beside the left endsheet.
Page 15: Table Of Contents
TABLE OF CONTENTS Declaration of Conformity ..........................i Introduction ............................. vii Summary of Changes........................... ix Recording Model and Serial Number......................xi Chapter 1: Safety ............................1 1.1 Safety Alert Symbols ..........................1 1.2 Signal Words ............................2 1.3 General Safety ............................3 1.4 Maintenance Safety ..........................5 1.5 Hydraulic Safety .............................7 1.6 Welding Precautions ..........................8 1.7 Decommissioning and Disposing of Agricultural Equipment................9...
Page 16 TABLE OF CONTENTS Installing Outboard Flex Linkage Covers ..................56 3.2.6 Daily Start-Up Check ........................59 3.3 Break-in Period ............................ 60 3.4 Shutting Down Combine ........................61 3.5 Cab Controls ............................62 3.5.1 Integrated Header Controls – Case Combines..................62 3.5.2 Side Draper Speed Control –...
Page 17 TABLE OF CONTENTS Locking / Unlocking Header Float ....................151 Operating in Flex Mode ......................151 Operating in Rigid Mode ......................154 Removing Flex Frown Limiter ...................... 155 Installing Flex Frown Limiter ....................... 155 3.9.5 Checking and Adjusting Wing Balance.................... 156 3.9.6 Reel Speed..........................
Page 18 TABLE OF CONTENTS Checking Voltage Range from Combine Cab – Case IH, 120, 230, 240, and 250 Series Combines ..... 227 Calibrating Auto Header Height Control – Case IH 120, 230, 240, and 250 Series Combines with Software Version below 28.00 ..................229 Calibrating Auto Header Height Control –...
Page 19 TABLE OF CONTENTS Adding Oil to Header Drive Main Gearbox..................291 Changing Oil in Header Drive Main Gearbox .................. 292 4.3.6 Lubricating Header Drive Completion Gearbox ................292 Checking Oil Level in Header Drive Completion Gearbox..............292 Adding Oil to Header Drive Completion Gearbox ................293 Changing Oil in Header Drive Completion Gearbox .................
Page 20 TABLE OF CONTENTS Adjusting Hold-Down – Pointed Knife Guards ................350 Replacing Pointed Center Knife Guard – Double-Knife Header ............351 Checking Center Hold-Down on Double-Knife Header – Pointed Knife Guards ........353 Adjusting Center Hold-Down on Double-Knife Header – Pointed Knife Guards ........355 4.8.6 Short Knife Guards and Hold-Downs....................
Page 21 TABLE OF CONTENTS 4.12.9 Installing Side Draper Deck Idler Roller..................416 4.12.10 Removing Side Draper Drive Roller .................... 418 4.12.11 Replacing Side Draper Drive Roller Bearing.................. 420 4.12.12 Installing Side Draper Drive Roller....................421 4.13 Reel..............................424 4.13.1 Reel-to-Cutterbar Clearance ....................... 424 Measuring Reel-to-Cutterbar Clearance ..................
Page 22 TABLE OF CONTENTS 4.16.4 Changing Tow-Bar Hitch Connection from Pintle to Clevis..............477 4.16.5 Changing Tow-Bar Hitch Connection from Clevis to Pintle..............479 ™ 4.17 VertiBlade Vertical Knife (Option)....................... 482 4.17.1 Replacing Vertical Knife Sections....................482 4.17.2 Lubricating Vertical Knife ......................485 ™...
Page 23 TABLE OF CONTENTS 6.3 Reel Delivery ............................. 516 6.4 Troubleshooting Header and Drapers..................... 518 6.5 Cutting Edible Beans ........................... 520 Chapter 7: Reference ..........................523 7.1 Torque Specifications .......................... 523 7.1.1 Metric Bolt Specifications ......................523 7.1.2 Metric Bolt Specifications – Cast Aluminum ..................525 7.1.3 O-Ring Boss Hydraulic Fittings –...
Page 25: Chapter 1: Safety
Chapter 1: Safety Understanding and consistently following these safety procedures will help to ensure the safety of those operating the machine and of bystanders. 1.1 Safety Alert Symbols The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: •...
Page 26: Signal Words
SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words, IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if it is not prevented, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if it is not prevented, could result in death or serious injury.
Page 27: General Safety
SAFETY 1.3 General Safety Operating, servicing, and assembling machinery presents several safety risks. These risks can be reduced or eliminated by following the relevant safety procedures and wearing the appropriate personal protective equipment. CAUTION The following general farm safety precautions should be part of your operating procedure for all types of machinery.
Page 28 SAFETY • Wear close-fitting clothing and cover long hair. NEVER wear dangling items such as hoodies, scarves, or bracelets. • Keep all shields in place. NEVER alter or remove safety equipment. Ensure that the driveline guards can rotate independently of their shaft, and that they can telescope freely.
Page 29: Maintenance Safety
SAFETY 1.4 Maintenance Safety Maintaining your equipment safely requires that you follow the relevant safety procedures and wear the appropriate personal protective equipment for the task. To ensure your safety while maintaining the machine: • Review the operator’s manual and all safety items before operating or performing maintenance on the machine.
Page 30 SAFETY • Wear protective gear when working on the machine. • Wear heavy gloves when working on knife components. Figure 1.10: Personal Protective Equipment 262653 Revision A...
Page 31: Hydraulic Safety
SAFETY 1.5 Hydraulic Safety Because hydraulic fluid is under extreme pressure, hydraulic fluid leaks can be very dangerous. Follow the proper safety procedures when inspecting hydraulic fluid leaks and servicing hydraulic equipment. • Always place all hydraulic controls in NEUTRAL before leaving the operator’s seat.
Page 32: Welding Precautions
SAFETY 1.6 Welding Precautions To prevent damage to sensitive electronics, NEVER attempt welding on the header while it is connected to a combine. WARNING NEVER attempt welding on the header while it is connected to a combine. Severe damage to sensitive, expensive electronics can result from welding on the header while it is connected to a combine.
Page 33: Decommissioning And Disposing Of Agricultural Equipment
SAFETY 1.7 Decommissioning and Disposing of Agricultural Equipment When agricultural equipment is no longer serviceable and needs to be decommissioned and disposed of, recyclable materials including ferrous and non-ferrous metals, rubber, and plastics; fluids such as lubricants, refrigerants, and fuels; and hazardous materials found in batteries, some light bulbs, and electronic equipment must be handled safely and not introduced into the environment.
Page 34 SAFETY • Use appropriate personal protective equipment when removing and handling objects and materials. • Use appropriate personal protective equipment when handling objects with residue from pesticides, fertilizers, or other agricultural chemicals. Follow local regulations when handling and disposing of these objects. •...
Page 35: Safety Signs
SAFETY 1.8 Safety Signs Safety signs are decals placed on the machine where there is a risk of personal injury, or where the Operator should take extra precautions before operating the controls. They are usually yellow. • Keep safety signs clean and legible at all times. •...
Page 36: Safety Decal Locations
SAFETY 1.9 Safety Decal Locations Safety signs are usually yellow decals and are placed on the machine where there is a risk of injury or where the Operator should take extra precautions before working. Figure 1.19: Reel Arms and Endsheets A - MD #360541 –...
Page 37 SAFETY Figure 1.20: Backtube, FD225 A - MD #313733 – Header Crushing Hazard B - MD #113482 – General Hazard C - MD #174436 – High Pressure Fluid 262653 Revision A...
Page 38 SAFETY Figure 1.21: Backtube, FD230 and Larger A - MD #313725 – Read Manual / High Pressure Fluid / Header Hazard B - MD #311493 – Center Prop Lock C - MD #313733 – Header Crushing Hazard 262653 Revision A...
Page 39 SAFETY Figure 1.22: FM200 Float Module A - MD #360655 – Released Spring Energy Hazard B - MD #313728 – Read Manual / Fluid Spray Hazard Figure 1.23: Upper Cross Auger (Optional) A - MD #279085 – Auger Warning 262653 Revision A...
Page 40 SAFETY Figure 1.24: Transport System – Tow-Bar (Short Bar Shown; Medium and Long Bar Similar) (Optional) A - MD #327588 – Hitch Damage Hazard Figure 1.25: Vertical Knife (Optional) A - MD #313881 – Knife Hazard 262653 Revision A...
Page 41 SAFETY Figure 1.26: Stabilizer Wheels (Optional) A - MD #327086 – Released Spring Energy Hazard 262653 Revision A...
Page 42: Understanding Safety Signs
SAFETY 1.10 Understanding Safety Signs Safety sign decals use illustrations to convey important safety or equipment maintenance information. MD #174436 High-pressure oil hazard WARNING High-pressure hydraulic fluid can penetrate human skin, which can cause serious injury such as gangrene, which can be fatal. To prevent this: •...
Page 43 SAFETY MD #288195 Rotating object pinch hazard CAUTION To prevent injury: • Shut down the engine and remove the key from the ignition before opening the shield. • Do NOT operate the machine without shields in place. Figure 1.30: MD #288195 MD #311493 Reel crushing hazard DANGER...
Page 44 SAFETY MD #313725 Read manual / high pressure fluid / header crushing hazard DANGER To prevent 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 45 SAFETY • If you are injured, seek emergency medical help. Immediate surgery is required to remove oil. MD #313728 General hazard pertaining to machine operation and servicing / Hot fluid spray hazard DANGER To prevent injury or death from improper or unsafe machine operation: •...
Page 46 SAFETY MD #313733 Header crushing hazard DANGER To prevent injury or death from the fall of a raised header: • Fully raise the header, shut down the engine, remove the key from the ignition, and engage the mechanical safety locks on the combine before going under the header. •...
Page 47 SAFETY MD #313881 General hazard pertaining to machine operation and servicing / knife hazard DANGER To prevent 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 48 SAFETY MD #327086 Released spring energy hazard WARNING To prevent injury: • When servicing wheel axle components, the lift-assist spring no longer has counterweight and becomes energized. • Do NOT attempt to pry the adjustment handle out of a position slot before releasing tension from the assist springs. Figure 1.36: MD #327086 MD #327588 Hitch damage hazard...
Page 49 SAFETY MD #360541 Reel entanglement / reel crushing hazard DANGER To prevent injury from entanglement with a rotating reel: • Stand clear of the header while the machine is running. • To prevent injury from the fall of a raised reel, fully raise the reel, shut down the engine, remove the key from the ignition, and engage the mechanical safety lock on each reel support arm before working on or under the reel.
Page 51: Chapter 2: Product Overview
Combined gross vehicle weight CGVW Export header The header configuration typical outside North America MacDon FD225, FD230, FD235, FD240, FD241, FD245, FD250, and FD261 FlexDraper ® FD2 Series Header Headers Flats from finger tight FFFT...
Page 52 PRODUCT OVERVIEW Table 2.1 Definitions (continued) Term Definition Society of Automotive Engineers A headed and externally threaded fastener that threads into preformed threads or forms Screw its own thread when it is inserted into a mating part A flexible joint made by use of a fastener in which the joining materials compress or relax Soft joint over a period of time Strokes per minute...
Page 53: Product Specifications
Cutterbar lift range Varies with combine model Knife Single-knife drive (FD225–FD240): hydraulic motor mounted to enclosed heavy duty MacDon knife drive box on the left side of header. Double-knife drive (FD235–FD261): one hydraulic motor, untimed, one mounted to enclosed heavy-duty MacDon knife drive box on each side of the header.
Page 54 PRODUCT OVERVIEW ™ ™ Guard: ClearCut PlugFree , forged and double heat treated (DHT) Hold-down: forged, dual adjustment bolts Cutterbar Wearplates and Standard Skid Shoes The FD2 Series includes wearplates across the width of the cutterbar. FD225 4 Skid Shoes FD230, FD235, FD240, FD241, FD245, FD250, FD261 6 Skid Shoes Guard Angle (Cutterbar on the Ground)
Page 55 PRODUCT OVERVIEW 205 mm (8 in.) 130 mm (5 in.) 205 mm (8 in.) 205 mm (8 in.) FD241 216 mm (8.5 in.) 216 mm (8.5 in.) 216 mm (8.5 in.) 216 mm (8.5 in.) FD245 216 mm (8.5 in.) 216 mm (8.5 in.) 216 mm (8.5 in.) 216 mm (8.5 in.)
Page 56 PRODUCT OVERVIEW 4321–4442 Export FD241 (9526–9793) 4566–4692 North America (10,066–10,344) FD245 4,703–4,829 Export (10,368–10,646) 4755–4886 North America (10,483–10,772) FD250 4915–5046 Export (10,836–11,125) 5669 FD261 North America (12498) 262653 Revision A...
Page 57: Fd2 Series Flexdraper
PRODUCT OVERVIEW ® 2.3 FD2 Series FlexDraper Header Dimensions When operating a header, it is important to know the dimensions of the machine. Figure 2.1: Header Dimensions Table 2.2 Header Dimensions Frame and Structure Feature Being Measured Reference to Figure 2.1, page 33 Dimension Cut width + 500 mm...
Page 58: Fd2 Series Flexdraper Header Component Identification
PRODUCT OVERVIEW ® 2.4 FD2 Series FlexDraper Header Component Identification Familiarizing yourself with the main components of the header will make it easier to follow the operation and maintenance instructions provided in this manual. ® Figure 2.2: FD2 Series FlexDraper Header Components A - Wing Float Linkage B - Center Reel Arm...
Page 59: Fm200 Float Module Component Identification
PRODUCT OVERVIEW 2.5 FM200 Float Module Component Identification Familiarizing yourself with the main components of the float module will make it easier to follow the instructions provided in this manual. Figure 2.3: Header Side of FM200 Float Module with Integrated Hydraulic System (IHS) A - Feed Auger B - Header Float Springs (x4) C - Center-Link...
Page 60 PRODUCT OVERVIEW Figure 2.4: Combine Side of FM200 Float Module with Integrated Hydraulic System (IHS) A - Main Gearbox B - Completion Gearbox C - Reservoir Oil Level Sight Glass D - Center-Link E - Header Height Control Indicator (x2) F - Bubble Level G - Drain Plug (x2) H - Float Lock Handle (x2)
Page 61 PRODUCT OVERVIEW Figure 2.6: Combine Side of FM200 Float Module with Modular Hydraulic System (MHS) A - Main Gearbox B - Completion Gearbox C - Reservoir Oil Level Sight Glass D - Center-Link E - Header Height Control Indicator (x2) F - Drive Support G - Drain Plug (x2) H - Float Lock Handle (x2)
Page 63: Chapter 3: 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 64: Operational Safety
OPERATION 3.2 Operational Safety Follow all the safety and operational instructions given in this manual. 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 65: Reel Safety Props
OPERATION 3.2.2 Reel Safety Props The reel safety props are located on the reel arms. When engaged, the reel safety props prevent the reel from falling unexpectedly. IMPORTANT: To prevent damage to the reel support arms, do NOT transport the header with the reel safety props engaged. Engaging Reel Safety Props Engage the reel safety props anytime you need to work around a raised reel.
Page 66: Disengaging Reel Safety Props
OPERATION Center reel arm – double- and triple-reel headers 5. Rotate handle (A) to release the spring tension and push the handle inboard to ensure the pin is engaged in the locked position. NOTE: For triple-reel headers, the illustration shows the center right arm.
Page 67: Header Endshields
OPERATION Center reel arm – double- and triple-reel headers 4. Move handle (A) outboard and into slot (B) to put the pin into the unlocked position. 5. On triple-reel headers, repeat the previous step on the center left arm. 6. Lower the reel fully. 7.
Page 68: Closing Header Endshields
OPERATION 2. Pull header endshield (A) open. NOTE: The header endshield is retained by tab (B) and will open in direction (C). Figure 3.9: Left Header Endshield 3. If additional clearance is required, pull the header endshield free of tab (A), then swing the shield toward the rear of the header.
Page 69 OPERATION 3. While closing endshield (A), ensure that it does not contact the top of endsheet (B). If adjustment is required, refer to Checking and Adjusting Header Endshields, page IMPORTANT: Ensure that the header endshield does NOT rest on the aluminum endsheet.
Page 70: Checking And Adjusting Header Endshields
OPERATION Checking and Adjusting Header Endshields The header endshields can warp due to extreme changes in temperature. Adjust the position of the header endshield to compensate for dimensional changes. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 71 OPERATION Figure 3.17: Clearance Specifications at the Front of the Endshield 4. Measure clearance (A) between the front of the header endshield and pin (B). The clearance should be 8–18 mm (1/32–11/16 in.) 5. Measure clearance (C) between the front of the header endshield and support bracket (D). The clearance should be 6–10 mm (1/4–3/8 in.).
Page 72 OPERATION 6. If the clearances at the front of the endshield are insufficient, adjust the position of hinge arm (A) as follows: Loosen four nuts (B). b. Slide brackets (C) and hinge arm (A) fore or aft as required to achieve the correct clearance. Retighten the hardware.
Page 73 OPERATION Figure 3.20: Two-Stage Endshield Latch 1 - Endshield Latch Stage One 2 - Endshield Latch Stage Two When the endshield is closed, latch (A) should engage bolt (B). As the endshield is pressed fully closed, two-stage latch (A) engages lever (C) to secure endshield bolt (B). Confirm the endshield latch functions properly by following Step 9, page 49 to Step 11, page...
Page 74: Removing Header Endshields
OPERATION 12. Check that bolt (A) is tight. If adjustment is required, tighten nut (B) until there is no gap under the nut. Figure 3.21: Endshield Bolt Removing Header Endshields Remove the endshields to increase access to the components inside. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 75: Reel Drive Cover
OPERATION 2. Guide the header endshield onto hinge arm (C) and slowly slide it downwards. IMPORTANT: Ensure that the header endshield does NOT rest on the aluminum endsheet. 3. Install self-tapping screw (B). Torque the screw to 7 Nm (5.2 lbf·ft [62 lbf·in]). 4.
Page 76 OPERATION 5. Rotate spring latch (A) up and over the back plate. Figure 3.24: Upper Drive Cover 6. Unclip upper cover (A) from the lower cover at locations (B), and remove the upper cover. Keep the two clips engaged on the lower cover. Figure 3.25: Upper Drive Cover 7.
Page 77: Installing Reel Drive Cover
OPERATION Installing Reel Drive Cover The reel drive cover protects the drive components from weather and debris. Do NOT operate the header without the reel drive cover. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 78: Flex Linkage Cover
OPERATION 6. Rotate spring latch (A) down to secure the upper cover to the reel drive. Ensure that V-shaped loop (C) points down, and the spring end remains inserted into back plate hole (B) on both sides of the reel drive. Figure 3.29: Reel Drive 3.2.5 Flex Linkage Cover Plastic covers are attached to the header frame to protect the header wing balance mechanism from debris and weather.
Page 79: Installing Inboard Flex Linkage Covers
OPERATION Installing Inboard Flex Linkage Covers The inboard flex linkage covers protect the header wing balance mechanism from debris and weather. They are secured to the header with pins. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 80: Installing Outboard Flex Linkage Covers
OPERATION 1. Lower the header. 2. Shut down the engine, and remove the key from the ignition. 3. FD245, FD250, and FD261 headers: Remove screws (A) and the nuts (not shown) securing middle linkage cover (B) to the bracket (not shown). 4.
Page 81 OPERATION 2. Position the left outboard linkage cover so that hole (A) goes over the wing lock. Figure 3.35: Left Linkage Cover – Rear of Header 3. Seat the notch in the cover behind bracket (A) on the backtube, and line up the end so that it is flush with manifold (B).
Page 82 OPERATION 4. Secure the outboard linkage cover as follows: Install screw (A) and nyloc nut (B). The nut fits into a hex shape indent in the hydraulic line clamp. b. Install screw (C). The nut is integrated into the bracket. Install screw (D) and hex nut (E) to secure the front of the cover to the bracket.
Page 83: Daily Start-Up Check
OPERATION 3.2.6 Daily Start-Up Check Perform these checks daily before attempting to operate the machine. CAUTION • Clear the area of bystanders. Keep children away from machinery. Walk around the machine to be sure no one is under, on, or close to it. •...
Page 84: Break-In Period
OPERATION 3.3 Break-in Period During the first 50 hours of operation, certain systems on the header will require extra attention. Follow this procedure to ensure the service life of the header. NOTE: Until you become familiar with the sound and feel of your new header, be extra attentive. DANGER Before investigating an unusual sound or attempting to correct a problem, shut off the engine and remove the key from the ignition.
Page 85: Shutting Down Combine
OPERATION 3.4 Shutting Down Combine Before leaving the operator's seat for any reason, shut down the combine. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. DANGER Ensure that all bystanders have cleared the area.
Page 86: Cab Controls
OPERATION 3.5 Cab Controls The header is controlled from the combine cab. DANGER Ensure that all bystanders have cleared the area. For instructions, refer to your combine operator’s manual to identify the following in-cab controls: • Header engage/disengage control • Header height •...
Page 87: Side Draper Speed Control - Case Ih Combines
OPERATION 3.5.2 Side Draper Speed Control – Case IH Combines The lateral belt speed can be adjusted on the touch screen display from the cab. The header needs to be configured for integrated control (standard on model year 2024 and later) and the combine has to have software version 36.4 or later. Combines and headers that do not meet the requirements will need to use the conventional draper speed control dial.
Page 88: Reel Reverse Function - Case Ih Combines
OPERATION 4. Use scrollbar (A) to navigate down to LATERAL BELT SPD (B). NOTE: The lateral belt speed can be adjusted using side arrows (C). Select ENTER (D) after adjusting the belt speed. 1042880 Figure 3.42: Case IH Combine Display 5.
Page 89 OPERATION 1. Select TOOLBOX (A) on the MAIN page. Figure 3.44: Case IH Combine Display 2. Select HEAD 1 tab (A). NOTE: To locate the HEAD 1 tab, you may need to use side arrows (B). Figure 3.45: Case IH Combine Display 3.
Page 90 OPERATION 5. Return to the HEAD 1 page and choose FLEXHEAD from FRAME TYPE drop-down menu (A). Figure 3.47: Case IH Combine Display 6. Select HEAD 2 tab (A). 7. In HEADER SENSORS field (B), select ENABLE. 8. In HEADER PRESSURE FLOAT field (C), select NO. 9.
Page 91: Reel Reverse Function - New Holland Cr Series And Ch
OPERATION 13. In OVERLAP MODE field (A), select MANUAL. 14. In WORK WIDTH RESET field (B), select MANUAL. Figure 3.50: Case IH Combine Display 3.5.4 Reel Reverse Function – New Holland CR Series and CH You can allow the reel to reverse with the feeder house on New Holland CR Series and CH combines. DANGER Ensure that all bystanders have cleared the area.
Page 92 OPERATION 2. Select HEAD 1 tab (A). NOTE: To locate the HEAD 1 tab, you may need to use side arrows (B). Figure 3.52: New Holland Combine Display 3. Locate the HEADER SUB TYPE field. 4. Select the following value from the HEADER SUB TYPE window: •...
Page 93 OPERATION 6. Select HEAD 2 tab (A). 7. In HEADER SENSORS field (B), select ENABLE. 8. In HEADER PRESSURE FLOAT field (C), select NO. 9. In HEIGHT/TILT RESPONSE field (D), select FAST. NOTE: AUTO HEADER LIFT field (E) can be set to the user’s preference.
Page 94: Header Attachment/Detachment
OPERATION 3.6 Header Attachment/Detachment This chapter includes instructions for configuring, attaching, and detaching the header. Combine Refer to Case IH Models: 5/6/7088, 7/8010, 7/8/9120, 130, 140, 150, 160, 230, 240, 250, 260 Series 3.6.1 Case IH Combines, page 70 Case IH Models: 21XX/23XX/25XX Case IH Models AF9, 10, 11 Series NOTE: Ensure that the applicable functions (automatic header height control [AHHC], draper header option, hydraulic center-link...
Page 95 OPERATION IMPORTANT: Feeder house faceplate (A) is recommended to be in mid-position (B). For instructions on adjusting the faceplate, refer to the combine operator’s manual. NOTE: A rock trap prevents rocks or debris from entering the combine, and is located on the front of the combine and behind the feeder house.
Page 96 OPERATION 3. Slowly drive the combine up to the header until feeder house saddle (A) is directly under float module top cross member (B). 4. Raise the feeder house slightly to lift the header. Ensure that the feeder saddle is properly engaged in the float module’s frame.
Page 97 OPERATION Figure 3.62: AF11 Locking Pins Alignment 9. AF11 combines: To ensure the header is attached to the feeder house securely, and to prevent the locking pins from binding, ensure that the locking pins are engaged and centered in float module adjuster plates (A) on both sides of the feeder house.
Page 98 FB E Figure 3.65: Multicoupler and Electrical Connections 12. If MacDon in-cab controls are installed: Remove the cap from connector C81B (A). 13. Remove the cap from connector C72B (B). 14. Remove the cover from hydraulic receptacle (C). Clean the receptacle mating surfaces.
Page 99 OPERATION 20. If MacDon in-cab controls are installed: Remove cab control kit connector C81A (H) from its storage location on the combine and connect it to C81B (A). Turn the collar on the connector to lock it in place. 21. Pull driveline collar (A) back to release the driveline from the support bracket.
Page 100: Detaching Header From Case Ih Combine
OPERATION 23. Proceed as follows: • Disengage the float locks by pulling each float lock handle (A) away from the float module and into unlocked position (B). • If the header is NOT going to be used in the field, engage the float locks by pushing each float lock handle (A) toward the float module and into locked position (C).
Page 101 OPERATION 4. Engage the float locks by pulling each float lock handle (A) away from the float module and setting it in locked position (B). NOTE: The illustration shows the float lock handle on the right side of the header. The float lock handle on the left side of the header is the opposite.
Page 102 OPERATION 6. Store the driveline on driveline support bracket (B) by pulling back collar (A) on the driveline and fitting it onto support bracket (B). Release the collar so it locks into place on the support bracket. Figure 3.72: Driveline in Storage Position – Driveline B7038 or B7039 Figure 3.73: Driveline in Storage Position –...
Page 103 OPERATION 9. Position multicoupler (A) onto storage plate (B) on the combine. 10. Place electrical connector (C) in storage cup (D). Figure 3.75: Multicoupler Storage 11. Push handle (A) on the float module receptacle to the closed position until lock button (B) snaps out. Close the cover.
Page 104: Header Setup
OPERATION 3.7 Header Setup For optimal performance, the header must be configured specifically for various harvesting conditions and crops. 3.7.1 Header Attachments Optional attachments can improve performance in specific conditions or add features to the header. Optional attachments can be ordered and installed by your Dealer. Refer to Chapter 5 Options and Attachments, page 493 for the descriptions of available items.
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Page 115: Optimizing Header For Straight-Combining Canola
OPERATION 3.7.3 Optimizing Header for Straight-Combining Canola Ripe canola can be straight-combined, but most varieties are susceptible to pod shatter and subsequent seed loss. This section provides information on the recommended attachments, settings, and adjustments to optimize FD2 Series FlexDraper ®...
Page 116 OPERATION Table 3.10 FD2 Series Recommended Reel Settings Cam Setting Reel Ground to Number (Finger Reel Finger Pattern Position Stubble Height Speed Gain) Number 1 (0%) 25 mm (0.98 in.) 5 or 6 2 (20%) 25 mm (0.98 in.) 6 or 7 262653 Revision A...
Page 117 OPERATION Table 3.10 FD2 Series Recommended Reel Settings (continued) Cam Setting Reel Ground to Number (Finger Reel Finger Pattern Position Stubble Height Speed Gain) Number 3 (30%) 102 mm (4 in.) 4 (35%) 150 mm (5.9 in.) 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 the skid shoes or header angle to compensate.
Page 118: Floating Crop Divider Settings (Optional)
OPERATION 3.7.5 Floating Crop Divider Settings (Optional) Floating crop dividers can be adjusted for different crop conditions. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason. For instructions on how to make adjustments to the floating crop divider, refer to Adjusting Floating Crop Dividers, page 195.
Page 119 OPERATION Table 3.12 Stubble Height 20 mm to 100 mm (3/4 in. to 4 in.) Side Header Header Stubble Fore Aft Top Deflector DownStop Deflector Deflector Main Angle Height Position Whisker Height Height Shoes 100 mm (4 in.) Normal 100 mm (4 in.) 20 mm (3/4 in.)
Page 120 OPERATION Table 3.13 Stubble Height 16 mm to 50 mm (5/8 in. to 2 in.) Cutterbar on Ground Side Header Header Stubble Fore Aft Top Deflector DownStop Deflector Deflector Main Angle Height Position Whisker Height Height Shoes 50 mm (2 in.) Normal 50 mm (2 in.)
Page 121: Float Module Setup
OPERATION 3.8 Float Module Setup The following sections outline the recommended float module setup guidelines for your specific combine model and crop type; however, the recommendations cannot cover all conditions. If feeding problems develop with the float module, refer to Chapter 6 Troubleshooting, page 511.
Page 122 OPERATION Medium Configuration: Medium Configuration uses 4 short bolt-on flightings (2 on the left and 2 on the right) and 22 feed auger fingers. NOTE: Dimensions (A) and (B) are the same for both ends of the auger. They should be within 15 mm (9/16 in.) of the numbers given. Medium Configuration is standard for the following combines: •...
Page 123: Ultra Narrow Configuration - Auger Flighting
OPERATION Ultra Wide Configuration: Ultra Wide Configuration uses only factory-welded flighting (A) is responsible for conveying the crop. No bolt-on flighting is installed and a total of 30 auger fingers are recommended for this configuration. Ultra Wide Configuration is optional for wide feeder house combines.
Page 124 2 - Wide Configuration 3 - Ultra Narrow Configuration 46. MD #357234 is available only through MacDon Parts. B7345 is available only through MacDon Whole Goods. Both kits contain wear-resistant flightings. 47. The quantity of existing short flightings is either 0, 2, or 4, depending on the current configuration.
Page 125 OPERATION NOTE: If you are converting the auger from Ultra Wide Configuration, there is no existing bolt-on flighting to remove because that configuration uses only the factory-welded flighting (A). Figure 3.86: Ultra Wide Configuration 262653 Revision A...
Page 126 OPERATION Figure 3.87: Ultra Narrow Configuration A - Left Long Flighting (MD #287889) B - Right Long Flighting (MD #287890) C - M10 x 20 mm Carriage Bolt (MD #136178) E - Drilled Holes – 11 mm (7/16 in.) 48 F - M10 x 20 mm Button Head Bolt (MD #135723) 49 D - M10 Center Lock Flange Nut (MD #135799) G - M10 x 20 mm Flange Head Bolt (MD #152655) 50...
Page 127: Narrow Configuration - Auger Flighting
OPERATION Narrow Configuration – Auger Flighting Narrow Configuration uses four long bolt-on flightings (two on the left and two on the right), and 18 auger fingers. Figure 3.88: Narrow Configuration A - Left Long Flighting (MD #287889) B - Right Long Flighting (MD #287890) To convert the auger to Narrow Configuration from Ultra Narrow Configuration: Remove four flightings (A) from the auger and install additional...
Page 128 (A). Figure 3.91: Ultra Wide Configuration 51. MD #357234 is available only through MacDon Parts. B7345 is available only through MacDon Whole Goods. Both kits contain wear-resistant flightings. 52. The quantity of existing short flightings is either 0, 2, or 4, depending on the current configuration.
Page 129 OPERATION Figure 3.92: Narrow Configuration A - Left Long Flighting (MD #287889) B - Right Long Flighting (MD #287890) C - M10 x 20 mm Carriage Bolt (MD #136178) D - M10 Center Lock Flange Nut (MD #135799) 262653 Revision A...
Page 130: Medium Configuration - Auger Flighting
Figure 3.94: Auger Configurations – Rear View 1 - Wide Configuration 2 - Medium Configuration 53. MD #357233 is available only through MacDon Parts. B7344 is available only through MacDon Whole Goods. Both kits contain wear-resistant flightings. 262653 Revision A...
Page 131 OPERATION To convert to Medium Configuration from Narrow or Ultra Narrow Configuration: Two flighting kits (MD #357233 or B7344 ) are required. You will need to replace long flightings (A) with short flightings (B) and install additional auger fingers. A total of 22 auger fingers is recommended for this configuration.
Page 132: Wide Configuration - Auger Flighting
OPERATION Figure 3.97: Medium Configuration A - Left Short Flighting (MD #287888) B - Right Short Flighting (MD #287887) C - M10 x 20 mm Carriage Bolt (MD #136178) D - M10 Center Lock Flange Nut (MD #135799) Wide Configuration – Auger Flighting Wide Configuration uses two short bolt-on flightings (one on the left and one on the right), and 30 auger fingers are recommended.
Page 133 OPERATION Figure 3.98: Wide Configuration A - Left Short Flighting (MD #287888) B - Right Short Flighting (MD #287887) To convert to Wide Configuration from Medium Configuration: Remove existing flightings (A) from the auger and install additional auger fingers. A total of 30 auger fingers is recommended for this configuration.
Page 134 2 - Ultra Narrow Configuration 3 - Wide Configuration 55. MD #357233 is available only through MacDon Parts. B7344 is available only through Whole Goods. Both kits contain wear-resistant flightings. 56. The quantity of existing long flightings is either 4 or 8, depending on the current configuration.
Page 135: Ultra Wide Configuration - Auger Flighting
OPERATION Figure 3.102: Wide Configuration A - Left Short Flighting (MD #287888) B - Right Short Flighting (MD #287887) C - M10 x 20 mm Carriage Bolt (MD #136178) D - M10 Center Lock Flange Nut (MD #135799) Ultra Wide Configuration – Auger Flighting Ultra Wide Configuration uses no bolt-on flighting;...
Page 136 OPERATION Figure 3.103: Ultra Wide Configuration A - Factory-Welded Flighting To convert to Ultra Wide Configuration: Remove all existing bolt-on flightings (A) from the auger and install additional auger fingers if required. A total of 30 auger fingers is recommended for this configuration. •...
Page 137: Auger Flighting
OPERATION Auger Flighting The auger flighting on the FM200 can be configured for particular harvesting and crop conditions. For instructions, refer to 3.8.1 FM200 Feed Auger Performance Configurations, page 97 for combine/crop specific configurations. Removing Bolt-On Flighting The feed auger flighting can be customized for different combines. Before removing the bolt-on flighting, determine the quantity and the type of flighting required.
Page 138 OPERATION NOTE: The illustration shows new long flighting (A) installed. Figure 3.107: Long Flighting – Right Side 6. Install slot plug (A) with M6 bolt (B) and tee nut (C) at each location from which the flighting was removed. Torque the hardware to 9 Nm (6.64 lbf∙ft [80 lbf∙in]).
Page 139 OPERATION 8. Reinstall access cover(s) (A) using retained bolts (B) and the welded nuts inside the auger. Coat the bolts with medium- strength threadlocker (Loctite® 243 or equivalent) and torque the hardware to 9 Nm (6.64 lbf∙ft [80 lbf∙in]). Figure 3.110: Access Cover – Right Side Installing Bolt-On Flighting The feed auger has removable flighting that can be customized to the different models of combines.
Page 140 OPERATION 5. Align the new bolt-on flighting (A) to determine which slot plugs to remove from the auger. The new flighting overlaps on the outboard side of the adjacent flighting. Figure 3.112: Right Side of Auger 6. Remove applicable slot plugs(s) (A). Figure 3.113: Right Side of Auger 7.
Page 141 OPERATION NOTE: The illustration shows long flighting (A) installed. Figure 3.115: Long Flighting – Right Side 9. Repeat Step 3, page 115 to Step 8, page 116 to install flighting (A) on the left side of the auger. NOTE: Flighting performs best when no gaps are present. If desired, use silicone sealant to fill the gaps.
Page 142 OPERATION Installing Additional Bolt-On Flighting – Ultra Narrow Configuration Only When converting the feed auger to an Ultra Narrow Configuration, drilling is required to install the additional flighting. NOTE: This procedure assumes the feed auger is currently in Narrow Configuration (4 long flightings [A] installed). Figure 3.118: Narrow Configuration To install the four additional long flightings for an Ultra Narrow Configuration, follow the steps below: 1.
Page 143 OPERATION 8. Drill two 11 mm (7/16 in.) holes at the locations (A) you marked in Step 5, page 118. 9. Reinstall the bolt-on flighting. IMPORTANT: Ensure that the carriage bolt heads are on the inside of the auger to prevent damage to the internal components. Figure 3.120: Drilling Locations 10.
Page 144: Removing Feed Auger Fingers
OPERATION 13. Mark four hole locations (A) on the new flighting and drill 11 mm (7/16 in.) holes in the auger tube. Figure 3.123: Flighting on Left Side of Auger 14. Remove the nearest access cover(s) (B). Retain the cover for reinstallation.
Page 145 OPERATION WARNING To prevent bodily injury from the fall of a raised reel, always engage the reel safety props before going under the raised reel for any reason. IMPORTANT: Remove the auger fingers from the feed auger from outside inward. Make sure that there is an equal number of fingers on each side of the auger.
Page 146 OPERATION 7. Remove and retain two bolts (A) and tee nuts (not shown) securing finger guide (B) to the auger. 8. Remove guide (B). Figure 3.127: Auger Finger Hole 9. Position plug (A) into the hole from inside the auger. Secure the plug with two M6 hex head bolts (B) and tee nuts.
Page 147: Installing Feed Auger Fingers
OPERATION 3.8.3 Installing Feed Auger Fingers The feed auger uses fingers to bring the crop into the feeder house. The quantity of fingers varies for the different models of combines. DANGER Ensure that all bystanders have cleared the area. WARNING To prevent bodily injury from the fall of a raised reel, always engage the reel safety props before going under the raised reel for any reason.
Page 148: Setting Auger Position
OPERATION 8. Secure access cover (B) in place with bolts (A). Torque the bolts to 9 Nm (6.64 lbf∙ft [80 lbf∙in]). NOTE: Bolts (A) come with a threadlocker patch that will wear off if the bolts are removed. If you are reinstalling bolts (A), apply medium-strength threadlocker (Loctite®...
Page 149 OPERATION If bolt (A) is next to floating symbol (B), the auger is in the floating position. If bolt (A) is next to fixed symbol (C), the auger is in the fixed position. CAUTION Make sure the left and the right brackets are set to the same position;...
Page 150: Checking And Adjusting Feed Auger Springs
OPERATION 5. Using a breaker bar in the square hole on arm (B), move arm (B) forward until bolt (A) is in the slot on the bracket next to the fixed symbol. NOTE: If you are changing the auger position from fixed to floating, move the arm in the opposite direction.
Page 151: Stripper Bars
OPERATION 5. Check the thread length protruding past nut (A). The length should be 22–26 mm (7/8–1 in.). Figure 3.137: Spring Tensioner If adjustment is required, follow these steps: 6. Loosen upper jam nut (A) on the spring tensioner. NOTE: The upper jam nut is located on other side of the plate.
Page 152: Header Operating Variables
OPERATION 3.9 Header Operating Variables Adjusting the header correctly will reduce crop loss and speed up harvesting. Proper adjustments, along with timely maintenance, will increase the service life of the header. Most of the settings below have been configured at the factory, but they can be changed for various crops and/or different harvesting conditions.
Page 153: Adjusting Stabilizer Wheels
OPERATION Adjusting Stabilizer Wheels A properly adjusted header will achieve a balance between the amount of header weight carried by the float and the amount of header weight carried by the stabilizer wheels. Refer to 3.7.2 Header Settings, page 80 for recommended use in specific crops and crop conditions.
Page 154: Adjusting Easymove ™ Transport Wheels
OPERATION ™ Adjusting EasyMove Transport Wheels A properly adjusted header will achieve a balance between the amount of header weight carried by the float and the amount of header weight carried by the transport wheels. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 155: Extending/Retracting Contour Wheels
OPERATION 12. Use the combine’s auto header height control (AHHC) to automatically maintain the cutting height. For instructions, refer to 3.10 Auto Header Height Control System, page 210 and your combine operator’s manual. NOTE: The height sensor on the FM200 Float Module must be connected to the combine header control module in the cab. Extending/Retracting Contour Wheels The contour wheels allow the header to follow the contours of the ground, and can be adjusted between 25 mm (1 in.) and 457 mm (18 in.) from the ground surface.
Page 156: Extending/Retracting Contour Wheels Using Integrated Controls
OPERATION NOTE: When the contour wheels are fully retracted, the cutterbar can be on the ground when the header angle is set approximately between (B) and (E); the contour wheels will contact the ground when the header angle is set between (A) and (B). Figure 3.142: Header Angle Indicator Extending/Retracting Contour Wheels using Integrated Controls The height of the contour wheels can be adjusted using the multifunction handle.
Page 157 OPERATION DANGER Ensure that all bystanders have cleared the area. NOTE: Set the header float before leveling the contour wheels. For instructions, refer to Checking and Adjusting Header Float, page 140. NOTE: Set the wing balance before leveling the contour wheels. For instructions, refer to 3.9.5 Checking and Adjusting Wing Balance, page 156.
Page 158 OPERATION 7. Lower the header until auto header height indicator arm (A) is at number 2 (B). 8. Shut down the engine, and remove the key from the ignition. Figure 3.145: Auto Header Height Indicator 9. At the center of the header, measure distance (A) from the ground to the tip of the center guard.
Page 159: Cutting On Ground
OPERATION 15. Remove pin (A). 16. Reposition adjuster plate (B) in the slot to align with a different hole. There is approximately a 24 mm (1/2 in.) difference between each of the holes. • If the measurement is less than the measurement at the center of the header, move the adjuster plate TOWARD the cutterbar.
Page 160: Adjusting Inner Skid Shoes
OPERATION Adjusting Inner Skid Shoes The skid shoes and the center-link allow you to adjust to the field conditions and maximize the amount of material cut while reducing damage to the knife caused by stones and debris. DANGER Ensure that all bystanders have cleared the area. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason.
Page 161: Adjusting Outer Skid Shoes
OPERATION Adjusting Outer Skid Shoes The skid shoes and the center-link allow you to adjust to the field conditions and maximize the amount of material cut while reducing damage to the knife caused by stones and debris. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason.
Page 162 OPERATION Header angle (A) is the angle between the header and the ground. When cutting the crop at ground level, the header angle controls distance (B) between the cutterbar knife and the ground. Adjusting the header angle pivots the header at the point of skid shoe/ground contact (C).
Page 163: Adjusting Header Angle From Combine
OPERATION Adjusting Header Angle from Combine The header angle is adjusted from the combine cab using a switch on the operator’s control handle and an indicator on the center-link or on the monitor in the cab. The header angle is determined by the length of the center-link between the combine float module and the header, or by the degree of feeder house tilt on certain combine models.
Page 164: Header Float
OPERATION 3.9.4 Header Float The header float system supports the weight of the header to reduce the pressure of the ground on the cutterbar, allowing the header to more easily follow the ground and quickly respond to sudden changes or obstacles. The header float is indicated by float indicator (A).
Page 165 OPERATION When adjusting the float, use the following guidelines: • Set the header float as light as possible, but not so light that the header bounces when the combine is moving. This will help prevent knife breakage, soil pushing, soil build-up at the cutterbar in wet conditions, and excessive wear to the skid shoes and cutterbar wearplates.
Page 166 OPERATION 4. Adjust the reel fore-aft position so that the indicator on left indicator bracket (A) is at position 6. Figure 3.159: Fore-Aft Position 5. Adjust center-link (A) so that indicator (B) is at position D on the gauge. 6. Lower the reel fully. 7.
Page 167 OPERATION 13. Disengage both of the header float locks by pulling float lock handle (A) away from the float module and push the float lock handle down and into position (B) (UNLOCK). Figure 3.162: Header Float Lock in Locked Position 14.
Page 168 OPERATION Setting the float setting levers 17. On the left side of the float module, lift float setting lever (A) by hand so that the lever is free of slack. NOTE: Some parts have been removed from the illustration for clarity.
Page 169 OPERATION Adjusting the float 24. On the left side of the float module, loosen bolts (C). Rotate spring locks (B) so that bolt heads (A) are accessible. 25. Increase or decrease the float on the left side of the float module as needed: •...
Page 170: Changing Float Spring Configuration - Float Levers With Two Holes
OPERATION 30. On both sides of the float module, lock adjustment bolts (A) with spring locks (B). Ensure that bolt heads (A) are engaged in the spring lock cutouts. Tighten bolts (C) to secure the spring locks. Figure 3.168: Left Float Adjustment Releasing the float setting levers WARNING Release the float setting lever before resuming operation.
Page 171 OPERATION If the weight of the header has changed (for example, due to the addition of optional equipment), the float spring configuration (A) (single spring or double spring) or location [float lever front hole (B) or back hole (C)] may need to be changed.
Page 172 OPERATION Table 3.16 Header Component Weights (continued) Knife Category Reel Configuration Weight Header Model Configuration 3225 kg (7100 lb.) FD245 Double 3400 kg (7500 lb.) FD250 Double 3800 kg (8378 lb.) FD261 Double Divider Option Installed 20 kg (50 lb.) (B) Dividers –...
Page 173 OPERATION Example Example of header weight calculation for FD235 FlexDraper ® Header, single knife, double reel, no UCA, no options: Base header weight (A) = 2600 kg (5750 lb.) Weight of vertical knives (B) = (70 kg (150 lb.) Weight of UCA (C) = 0 kg (0 lb.) Weight of options (D) = 0 kg (0 lb.) Total header weight = (A) + (B) + (C) + (D) = 2670 kg (5900 lb.) 2.
Page 174 OPERATION Table 3.17 Float Spring Installation Location in Float Lever (continued) Spring Weight Weight Configuration Header Float Lever Float Lever Range Range See Table 3.18, Model Hole Hole (Light) (Heavy) page 150 Knife Configuration: Double Reel Configuration: Double 2900–3400 kg 3401–3700 kg FD240 Back...
Page 175: Locking / Unlocking Header Float
OPERATION Locking / Unlocking Header Float Two header float locks—one on each side of the float module—lock and unlock the header float system. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 176 OPERATION 2. Ensure spring handle (A) is in the lower slot to unlock the wing. You should hear the lock disengage. 3. If the lock link does not disengage, move the wing by raising and lowering the header, changing the header angle, or driving the combine until it disengages.
Page 177 OPERATION 9. Use multi-tool (A) on plate (B) to move the wing up and down until the lock disengages. Figure 3.175: Wing Lock in Unlocked Position 10. Detach flex checker cable (A) from flex checker cable lock (B). NOTE: The parts in the illustration have been made transparent for clarity.
Page 178: Operating In Rigid Mode
OPERATION Operating in Rigid Mode The header is designed to operate with the cutterbar on the ground. Locking the wings allows the header to operate as a rigid header with the cutterbar straight. When the three sections of the header are locked, the cutterbar is rigid and moves up and down at the same time.
Page 179: Removing Flex Frown Limiter
OPERATION Removing Flex Frown Limiter Removing the flex frown limiter increases the extent to which the header wings can flex. You may wish to remove the flex frown limiter to improve the header’s ability to adjust to changes in the terrain elevation and/or when you are harvesting tall crops such as standing cereals and canola.
Page 180: Checking And Adjusting Wing Balance
OPERATION 1. Park the combine on a level surface. 2. Lock the header wings. For instructions, refer to Operating in Rigid Mode, page 154. 3. Lower the header. 4. Extend the hydraulic center-link fully. 5. Shut down the engine, and remove the key from the ignition. 6.
Page 181 OPERATION Figure 3.183: Decal Locations – Wing Adjustment (B) and RH Wing Adjustment (C) NOTE: This procedure is summarized on decals (B) and (C) for left wing and right wing adjustments on locations (A). NOTE: The header wings are balanced when it takes an equal amount of force to move a wing up or down. If the header wings tend to be in a smile (A) or a frown (B) position, and the header is missing crop or pushing soil, adjust the wing balance.
Page 182 OPERATION 1. Park the combine on a level surface. 2. Adjust the reel fore-aft position so that the indicator on left indicator bracket (A) is at position 6. 3. Lower the reel fully. Figure 3.185: Fore-Aft Position 4. Adjust center-link (A) so that indicator (B) is at position D on the gauge.
Page 183 OPERATION 9. Remove the linkage cover. For instructions, refer to Removing Inboard Flex Linkage Covers, page 10. Attach flex checker cable (A) to flex checker cable lock (B). NOTE: Some parts have been made transparent in the illustration to better show the cable lock. 11.
Page 184 OPERATION 16. Unlock the wing that you are checking by moving spring handle (A) to the lower UNLOCK position. Unlock ONLY the wing being checked. Ensure that the other wing is locked. NOTE: You should hear a click after moving the spring handle; this click indicates that the internal mechanism has engaged or disengaged.
Page 185 OPERATION 21. Interpret the reading on the flex checker plate as follows: • If the wing is too light (A), make it heavier by depressing flex adjustment lock (H) and turning adjuster bolt (D) to move clevis (E) in direction (F). Recheck the wing balance.
Page 186: Reel Speed
OPERATION 23. Remove flex checker cable (A) from flex checker cable lock (B). IMPORTANT: The flex checker cable may be damaged if it is left in place. 24. Repeat this procedure to set the wing balance on the other wing. Figure 3.195: Left Flex Checker Cable Lock 25.
Page 187: Optional Reel Drive Sprockets
OPERATION Optional Reel Drive Sprockets Optional sprockets for use in specific crop conditions are available as an alternative to the factory-installed single sprocket. The header is factory-equipped with a 19-tooth reel drive single sprocket, which is suitable for most crops. Replacing the 19-tooth reel drive single sprocket with optional dual reel drive sprocket (A) will provide more torque to the reel in heavy cutting conditions.
Page 188: Ground Speed
OPERATION 3.9.7 Ground Speed Operating the header at an appropriate ground speed results in cleanly cut crop and even feeding. Reduce the vehicle’s ground speed in difficult cutting conditions to reduce equipment wear. When harvesting very light crops (for example, short soybeans), use lower ground speeds to allow the reel to pull in short plants.
Page 189: Adjusting Side Draper Speed
NOTE: For Case IH combine compatibility with integrated draper speed controls, refer to the combine operator's manual. Combines with MacDon In-Cab Side Draper Speed Control Rotate knob (A) to set the draper speed. For the recommended header settings, refer to one of the following: •...
Page 190: Feed Draper Speed
OPERATION NOTE: For Case IH combines, the switch to activate the header tilt and reel fore-aft controls is located behind the ground speed lever (GSL). Figure 3.201: Case IH In-Cab Side Draper Speed Control 3.9.9 Feed Draper Speed The feed draper moves the cut crop from the side drapers into the float module feed auger. Float module feed draper (A) is driven by a hydraulic motor and a pump that is powered by the combine feeder house drive through a gearbox on the float module.
Page 191: Checking Knife Speed
OPERATION Table 3.21 FD2 Series Header Knife Speed Recommended Knife Drive Speed Range (rpm) Header Single-Knife Drive Double-Knife Drive — FD225 600–700 — FD230 600–750 FD235 600–700 600–750 FD240 600–650 600–750 — FD241 600–750 — FD245 600–750 — FD250 600–750 —...
Page 192: Reel Height
OPERATION 6. Measure the rpm of flywheel (A) with a hand-held photo tachometer. NOTE: One revolution (rpm) is equivalent to two knife strokes (spm) (1 rpm = 2 spm). 7. Shut down the engine, and remove the key from the ignition. Figure 3.203: Flywheel Table 3.23 FD2 Series Header Knife Speed 8.
Page 193: Checking And Adjusting Reel Height Sensor Orientation
OPERATION If the reel is set too low, the following conditions may happen: • Crop loss over the header backtube • Crop disturbance on the drapers caused by the reel fingers • Crop pushed down by the tine tubes • Tall crop wrapped around the reel drive and ends If the reel is set too high, the following conditions may happen: •...
Page 194: Replacing Reel Height Sensor
OPERATION Figure 3.204: Reel Height Sensor Location 4. On the right endsheet, locate reel height sensor (A). The sensor connects to the right reel arm. 5. Ensure that the sensor is configured properly for the header: • Configuration (1) is incorrect. Round end (B) of the sensor arm is attached to rod (E). •...
Page 195: Checking And Adjusting Reel Height Sensor Voltage
OPERATION 4. Disconnect the harness from sensor (A). 5. Remove two nuts (B) securing sensor (A). Retain the hardware for reinstallation. 6. Remove sensor (A). 7. Verify the sensor arm orientation. For instructions, refer to Checking and Adjusting Reel Height Sensor Orientation, page 169 Figure 3.205: Reel Height Sensor –...
Page 196: Reel Fore-Aft Position
OPERATION 1. Verify that the reel fore-aft sensor is oriented correctly for the model of combine before checking the voltage. For instructions, refer to Checking and Adjusting Reel Height Sensor Orientation, page 169. 2. Park the combine on a level surface. 3.
Page 197: Adjusting Reel Fore-Aft Position
OPERATION The reel position indicator (A) is located at the left reel arm. Bracket (B) is the reel fore-aft position marker. For straight standing crop, center the reel over the cutterbar (4–5 on indicator). For crops that are down, tangled, or leaning, it may be necessary to move the reel ahead of the cutterbar.
Page 198: Repositioning Fore-Aft Cylinders
OPERATION Repositioning Fore-Aft Cylinders To accommodate certain crop conditions, you can move the reel approximately 155 mm (6 in.) farther aft by repositioning the fore-aft cylinders on the reel arms. DANGER Ensure that all bystanders have cleared the area. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 199 OPERATION 5. Refer to Figure 3.211, page 175 to determine the fore-aft cylinder adjustment procedures for your header type. The number on the illustration refers to one of the following procedures: • For reel arms with fore-aft cylinder adjustment [1] at the front, refer to Step 6, page 176.
Page 200 OPERATION To change the reel position on the fore-aft cylinders that adjust at the front of the reel arm, follow these steps: 6. Remove split ring (A), clevis pin (B), and flat washer (not shown) securing the adjustable fore-aft cylinder in the forward position.
Page 201 OPERATION To change the reel position on the fore-aft cylinders that adjust at the back of the reel arm, follow these steps: NOTE: The slotted cylinder bracket shown in the following illustrations is mounted on the outboard side of the reel arm. 9.
Page 202: Checking And Adjusting Fore-Aft Position Sensor Voltage
OPERATION Checking and Adjusting Fore-Aft Position Sensor Voltage The fore-aft position sensor indicates the position of the reel in the fore-aft plane. The sensor arm’s orientation needs to be set for the correct model. DANGER Ensure that all bystanders have cleared the area. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 203: Checking And Adjusting Fore-Aft Position Sensor Orientation
OPERATION 7. Shut down the engine, and remove the key from the ignition. 8. Locate fore-aft position sensor on the left reel arm. Figure 3.219: Fore-Aft Position Sensor 9. Loosen hardware (A) and move sensor support (B) until the voltage is in the correct range. 10.
Page 204 OPERATION 3. Locate fore-aft position sensor on the left reel arm. Figure 3.221: Fore-Aft Position Sensor Figure 3.222: Sensor Arm Position 4. Check the installation location of sensor mounting bolt, If the bolt is in the incorrect location, proceed to the next step. •...
Page 205: Reel Tine Pitch
OPERATION 3.9.13 Reel Tine Pitch Reel tine pitch describes the position of the reel fingers in relation to the cutterbar. You can change it by changing the reel fore-aft position and the reel cam setting. You may also wish to change the reel tine pitch to suit different harvesting conditions.
Page 206 OPERATION Cam Position 3, Reel Position 8 is mainly used to leave long stubble. • This position allows the reel to reach forward and lift the crop across the knife and onto the drapers. • This setting results in the reel fingertip speed being approximately 30% faster than the reel speed.
Page 207: Adjusting Reel Cam
OPERATION NOTE: Using higher cam settings when the reel’s fore-aft position is set between 4 and 5 results in drastically decreased draper capacity. This happens because the reel fingers continually engage with crop that is already moving on the drapers, disrupting flow into the combine feeder house.
Page 208: Upper Cross Auger
OPERATION 5. Turn latch pin (A) CLOCKWISE to engage and lock the cam disc. IMPORTANT: Ensure that the cam is secured into position before operating the machine. 6. Repeat Step 3, page 183 to Step 5, page 184 for all of the reel cams. 3.9.14 Upper Cross Auger The upper cross auger (UCA) improves crop feeding into the center of the header in heavy crop conditions.
Page 209 OPERATION The mount(s) are initially installed in the rear-most position, so that front bolt (A) is in the primary position. This position is the recommended configuration for most conditions. When front bolt (A) is in the primary position, the auger and the reel are safe to operate in any position.
Page 210 OPERATION Move the auger forward to • Help convey light crops, especially on side hills • Improve the feeding of light crops • Reduce the reel carry over or reduce the crop flow disruption caused by the reel Move the auger rearward to •...
Page 211: Checking Upper Cross Auger For Interference
OPERATION Checking Upper Cross Auger for Interference If the upper cross auger (UCA) is out of adjustment, it can contact the reel or the header frame. The clearance between the UCA and certain header components will need to be inspected. DANGER To prevent injury or death from the unexpected startup of the machine, stop the engine and remove the key from the ignition before you make adjustments to the machine.
Page 212: Removing Crop Dividers
OPERATION Removing Crop Dividers Crop dividers can be removed to allow the installation of other options or to decrease the transport width. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason.
Page 213: Installing Crop Dividers
OPERATION 10. If the optional storage bracket is installed, put crop divider (A) in position on bracket (B). 11. If the optional storage bracket is not installed, store the crop dividers in a safe location. Figure 3.239: Optional Crop Divider Storage Installing Crop Dividers Follow these instructions to properly install the crop dividers.
Page 214 OPERATION 9. Insert crop divider lugs (A) into holes in the endsheet. 10. Remove lynch pin (B) from latch (C). Figure 3.241: Crop Divider with Latch 11. Lift the forward end of latch (A) and crop divider (B). Figure 3.242: Crop Divider with Latch 12.
Page 215: Removing Floating Crop Dividers
OPERATION Removing Floating Crop Dividers Remove the floating crop dividers to install other attachments or the standard crop dividers. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 216: Installing Floating Crop Dividers
OPERATION 10. Tilt the floating crop divider forward and pull it out of the header. 11. Reinstall lynch pin (A). 12. Close the endshield. 13. Repeat Step 4, page 191 to Step 12, page 192 on the opposite end of the header to remove the opposite floating crop divider.
Page 217 OPERATION 5. Remove lynch pin (A) from quick latch (B). 6. Attach multi-tool (C) (stored on the left endsheet) to hex shaft (D) and rotate to release latch (B). 7. If crop dividers (E) are installed, lift latch (B) off of bolt (F) and set the crop dividers aside.
Page 218 OPERATION 9. Lift the forward end of quick latch (A), and rotate crop divider (B) up into position. 1038253 Figure 3.248: Quick Latch 10. Engage quick latch (A) onto the bolt. 11. Make sure the latch closes tightly and crop divider stop (B) contacts header stop (C).
Page 219: Adjusting Floating Crop Dividers
OPERATION 12. If the latch requires adjustment, loosen nut (A), and adjust the length of bolt (B) until it takes 40–54 Nm (30–40 lbf∙ft) of torque on hex shaft (C) to close the latch. 13. Retighten nut (A). 14. Attach multi-tool (D) onto hex shaft (C) and rotate the multi-tool to lock the latch.
Page 220 OPERATION 3. Shut down the engine, and remove the key from the ignition. 4. Refer to the chart according to the stubble height range and reel configuration: • Field with a stubble height of 50–125 mm (2–5 in.), double- or triple-reel headers: refer to Step 5, page 197.
Page 221 OPERATION 262653 Revision A...
Page 222 OPERATION 262653 Revision A...
Page 223 OPERATION 262653 Revision A...
Page 224 OPERATION 262653 Revision A...
Page 225 OPERATION 262653 Revision A...
Page 226 OPERATION 262653 Revision A...
Page 227 OPERATION 11. Down stop: Remove lynch pin (A) from the clevis pin, and remove the clevis pin. Retain both the lynch pin and the clevis pin for reinstallation. 12. Tilt the divider, then reinstall the clevis pin into the appropriate numbered hole “1” to “3”. Secure the clevis pin with the lynch pin.
Page 228 OPERATION 14. Top deflector height: Loosen the nuts on bolts (A). Slide the center support to the desired setting (1 to 4.5), then tighten the nuts. • Align the dots with the support to set half-increments. Example (B) is 2.5. •...
Page 229 OPERATION 16. Top deflector side rod: Loosen nut (A) and bolt (B), then swing rod (C). Tighten nut (A) to 39 Nm (29 lbf·ft). Tighten bolt (B) to 52 Nm (38 lbf·ft). Figure 3.255: Top Deflector Side Rod Adjustment 262653 Revision A...
Page 230: Crop Divider Rods
OPERATION Figure 3.256: Floating Crop Divider Range of Motion 17. Range of motion check: Lift and lower the floating crop divider through the range of motion (A) set by the down-stop. Confirm the floating divider does NOT contact reel supports (B) or reel (C). IMPORTANT: When checking for interference between the floating crop dividers and a SINGLE REEL, also make sure that the floating crop dividers do NOT contact the reel drive.
Page 231: Removing Crop Divider Rods
OPERATION Removing Crop Divider Rods Crop divider rods can be removed from the ends of the crop dividers and stored on the header. 1. Loosen bolt (B) and remove crop divider rod (A) from both sides of the header. Figure 3.257: Crop Divider Rod 2.
Page 232: Optional Rice Divider Rods
OPERATION 2. Undo lynch pin (A) securing divider rods (B) to the header endsheet. 3. Remove the divider rods from their storage location. 4. Reinstall lynch pin (A). Figure 3.259: Divider Rods 5. Position crop divider rod (A) on the tip of the crop divider. Tighten bolt (B).
Page 233 OPERATION Rice divider rods are stored at the rear of both endsheets on storage bracket (A) and secured in place with pin (B). The installation and removal of these rods follow the same procedures as standard crop divider rods. Figure 3.262: Rice Divider Rod Storage 262653 Revision A...
Page 234: Auto Header Height Control System
OPERATION 3.10 Auto Header Height Control System The auto header height control (AHHC) system works in conjunction with the AHHC option available on certain combine models. Two Hall effect sensors (A) are installed on the float setting indicators on the float module. These sensors send signals to the combine, which allow the combine to maintain the header at a consistent cutting height and the optimum float setting as the header follows the contours of the ground.
Page 235: Manually Checking Voltage Limits
OPERATION 3.10.2 Manually Checking Voltage Limits For the auto header height (AHHC) system to function correctly, the voltages reported to the combine by the header height sensors must occur within the specified range. NOTE: One of the following plugs will be installed in connector P600 (A). This plug determines how the voltage signal is sent to the combine: 5 6 7 8...
Page 236 OPERATION CAUTION To prevent cuts, pinches, and other bodily harm to the person checking the down stops, ensure that nobody is manually lifting, bouncing, or moving the header in any way while the down-stop washer is being touched and checked for movement.
Page 237 OPERATION 7. Locate connector P600 (A) at the left of the float module. 8. Remove plug (B). 9. Insert the key into the ignition and turn it to the RUN position. 5 6 7 8 10. Using a digital multimeter, check connector P600 for power from the combine.
Page 238: Case Ih 130 And 140 Series Mid-Range Combines
OPERATION Checking sensor lower voltage limit 14. Extend the guard angle until header angle indicator (A) is at position E on the center-link. 15. Lower the header. 16. Shut down the engine, and remove the key from the ignition. Figure 3.270: Center-Link 17.
Page 239: Checking Voltage Range From Combine Cab - Case Ih 5130, 5140, 6130, 6140, 7130, And 7140
OPERATION Table 3.35 Header Settings – Case IH 130, 140, 150, and 160 Series (continued) Setup Parameter Suggested Setting Header pressure float Not installed Two sensor Installed Header lateral tilt One sensor Not installed Auto tilt sensitivity Two sensor HHC height sensitivity One sensor HHC tilt sensitivity 19-tooth sprocket (standard)
Page 240 OPERATION CAUTION To prevent cuts, pinches, and other bodily harm to the person checking the down stops, ensure that nobody is manually lifting, bouncing, or moving the header in any way while the down-stop washer is being touched and checked for movement.
Page 241 OPERATION 7. On the main page of the combine display, select DIAGNOSTICS (A). The DIAGNOSTICS page appears. Figure 3.274: Case IH Combine Display 8. Select SETTINGS (A). The SETTINGS page appears. 9. From the GROUP menu, select HEADER (B). Figure 3.275: Case IH Combine Display 10.
Page 242: Setting Up Header On Combine Display - Case Ih 5130, 5140, 6130, 6140, 7130, And 7140
OPERATION 11. The SETTINGS page updates to display the voltage in VALUE/STATUS field (A). Lower the feeder house fully, and then raise it 254–356 mm (10–14 in.) off the ground to view the full range of voltage readings. 12. If the sensor voltage is not within the limits, or if the range between the lower and upper limits is insufficient, refer to 3.10.2 Manually Checking Voltage Limits, page 211.
Page 243 OPERATION 4. Select HEAD 2 tab (A). The HEADER SETUP 2 page appears. 5. From HEADER PRESSURE FLOAT menu (B), select NOT INSTALLED. Figure 3.280: Case IH Combine Display 6. Locate HHC HEIGHT SENSITIVITY field (A). Enter the following settings: •...
Page 244: With Software Version Below 28.00
OPERATION 9. From REEL HEIGHT SENSOR menu (A), select YES. Figure 3.283: Case IH Combine Display 10. Locate AUTOTILT field (A). • Two-sensor system: Select YES. • Single-sensor system: Select NO. Figure 3.284: Case IH Combine Display Calibrating Auto Header Height Control – Case IH 5130, 5140, 6130, 6140, 7130, and 7140 Combines with Software Version below 28.00 The auto header height control (AHHC) sensor output must be calibrated for each combine.
Page 245 OPERATION 2. Ensure that the header is level with the ground. If adjustment is required: • Ensure that the combine is parked on a level surface. • If equipped, use the combine’s lateral tilt to level the feeder house with the ground. •...
Page 246 OPERATION CAUTION To prevent cuts, pinches, and other bodily harm to the person checking the down stops, ensure that nobody is manually lifting, bouncing, or moving the header in any way while the down-stop washer is being touched and checked for movement.
Page 247: Setting Preset Cutting Height - Case Ih 5130, 5140, 6130, 6140, 7130, And 7140
OPERATION Setting Preset Cutting Height – Case IH 5130, 5140, 6130, 6140, 7130, and 7140 The header’s cutting and raised positions can be configured as presets on the combine’s control console. NOTE: Changes may have been made to the combine controls or the display since this document was published. For the most up- to-date information, refer to the combine operator’s manual.
Page 248 OPERATION 6. Move the header to a second desired cutting height. 7. Press 2 on button (A). A yellow indicator next to the button will light up. 8. Move the reel to the desired working position. 9. Press 2 on button (A). A yellow indicator next to the button will light up.
Page 249: Case Ih 120, 230, 240, 250 And 260 Series Combines
OPERATION 11. The maximum working height can be adjusted on the HEADER SETUP page on the combine display. Enter the desired height in MAXIMUM WORKING HEIGHT field (A). Figure 3.293: Case Combine Display – Header Setup Page 12. If necessary, adjust the position of one of the presets by using button (A) on the combine console.
Page 250 OPERATION Suggested Setting Setup Parameter 250, 260 series 250, 240 series 240 series (Ver. 36.4.X.X) (Ver. 28 to Ver. 36) (Prior to Ver. 28) 8010 Set according to header specification Head width — Header sensors Enable Enable Header pressure float —...
Page 251: Checking Voltage Range From Combine Cab - Case Ih, 120, 230, 240, And 250 Series Combines
OPERATION Checking Voltage Range from Combine Cab – Case IH, 120, 230, 240, and 250 Series Combines In order for the auto header height control (AHHC) system to work correctly, the header height sensors must detect the correct voltage readings. The sensor outputs can be viewed using the combine display. NOTE: Changes may have been made to the combine controls or the display since this document was published.
Page 252 OPERATION 6. If pointer (C) is NOT at 0 (D), loosen the nut on bolt (A) and rotate float indicator plate (B) until the pointer is aligned with zero dot (E). Tighten the nut on bolt (A). NOTE: After adjusting the indicator plate, the float sensor voltage limits must be checked.
Page 253: Software Version Below 28.00
OPERATION 11. Select HEADER HEIGHT/TILT (A). The PARAMETER page opens. Figure 3.299: Case IH Combine Display 12. Select LEFT HEADER HEIGHT SEN (A), and then select 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.
Page 254 OPERATION NOTE: If the header float is set too light, it can prevent the calibration of the AHHC. In order to prevent the header from separating from the float module, it may be necessary to change the float to a heavier setting during calibration. 1.
Page 255 OPERATION CAUTION To prevent cuts, pinches, and other bodily harm to the person checking the down stops, ensure that nobody is manually lifting, bouncing, or moving the header in any way while the down-stop washer is being touched and checked for movement.
Page 256 OPERATION 11. Select HEADER tab (A). NOTE: To locate the HEADER tab, you may need to use side arrows (C). 12. Set HEADER STYLE (B) to FLEXHEAD. Figure 3.304: Case IH Combine Display 13. Set AUTO REELSPEED SLOPE. NOTE: The AUTO REELSPEED SLOPE value automatically maintains the speed of the reel relative to ground speed.
Page 257 OPERATION 16. Locate HHC HEIGHT SENSITIVITY field (A), and set it as follows: • Two-sensor systems: Set HHC HEIGHT SENSITIVITY to 250. • Single-sensor systems: Set HHC HEIGHT SENSITIVITY to 180. NOTE: If the combine continually raises and lowers the header during operation (a behavior termed “hunting”), decrease the HHC HEIGHT SENSITIVITY setting by 20 points at a time until hunting no longer occurs.
Page 258: Software
OPERATION 23. From the REEL HEIGHT SENSOR menu, select YES (A). Figure 3.310: Case IH Combine Display 24. Locate AUTOTILT field (A) and set it as follows: • Two-sensor system: Select YES. • Single-sensor system: Select NO. NOTE: If the float was changed to a heavier setting to complete the AHHC calibration procedure, adjust it to the recommended operating float after calibration is complete.
Page 259 OPERATION 1. Park the combine on a level surface. 2. Ensure that the header is level with the ground. If adjustment is required: • Ensure that the combine is parked on a level surface. • If equipped, use the combine’s lateral tilt to level the feeder house with the ground.
Page 260 OPERATION CAUTION To prevent cuts, pinches, and other bodily harm to the person checking the down stops, ensure that nobody is manually lifting, bouncing, or moving the header in any way while the down-stop washer is being touched and checked for movement.
Page 261 OPERATION Adjusting combine display settings 12. Select TOOLBOX icon (A) on the MAIN page. Figure 3.315: Case IH Combine Display 13. Select HEAD 1 tab (A). NOTE: To locate the HEAD 1 tab, you may need to use side arrows (B). 14.
Page 262 OPERATION 16. Return to the HEAD 1 page and choose FLEXHEAD from FRAME TYPE drop-down menu (A). Figure 3.318: Case IH Combine Display 17. Select HEAD 2 tab (A). 18. In HEADER SENSORS field (B), select ENABLE. 19. In HEADER PRESSURE FLOAT field (C), select NO. 20.
Page 263 OPERATION 25. From the REEL HEIGHT SENSOR menu, select YES (A). Figure 3.321: Case IH Combine Display 26. Scroll to the AUTOTILT field (A), and set it as follows: • Two-sensor system: Select YES. • Single-sensor system: Select NO. Figure 3.322: Case IH Combine Display Calibrating auto header height control 27.
Page 264: Checking Reel Height Sensor Voltages - Case Ih Combines
OPERATION 29. Follow the calibration steps as they appear. As you proceed through the calibration process, the display automatically updates to show the next step. NOTE: Pressing the ESC key during any of the steps or letting the system sit idle for over 3 minutes will stop the calibration procedure.
Page 265 OPERATION 1. On the main page of the combine display, select DIAGNOSTICS (A). The DIAGNOSTICS page appears. Figure 3.326: Case IH Combine Display 2. Select SETTINGS tab (A). The SETTINGS page appears. 3. From the GROUP menu, select HEADER (B). 4.
Page 266: Setting Preset Cutting Height - Case Ih 120, 230, 240, And 250 Series Combines
OPERATION Setting Preset Cutting Height – Case IH 120, 230, 240, and 250 Series Combines Once the auto header height control (AHHC) system has been configured to work with the header, the preset cutting height can be configured. The preset cutting height refers to the header height that the AHHC system will attempt to maintain as the combine moves forward.
Page 267: Reel Speed Sensor Compatibility - Case Ih Combines
OPERATION 9. Press SET #2 switch (B). The light beside switch (B) will light up. 10. To swap between the set points, press HEADER RESUME (A). 11. To raise the header, hold SHIFT button (B) behind the control handle and press HEADER RESUME switch (A). To lower the header, press HEADER RESUME switch (A).
Page 268 OPERATION 3. Select HEAD 2 tab (A). 4. Locate REEL SPROCKETS RATIO field (B), and select the appropriate sprocket ratio. NOTE: Sprocket ratio 19/56 is the default setting, while sprocket ratios 10/56 and 20/52 are optional settings. 1042890 Figure 3.333: Case IH Combine Display 262653 Revision A...
Page 269: Unplugging Cutterbar
OPERATION 3.11 Unplugging Cutterbar If the cutterbar is not working correctly, clear the cutterbar of any obstructions. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 270: Unplugging Float Module Feed Draper
OPERATION 3.12 Unplugging Float Module Feed Draper Crop sometimes gets wedged between the feed draper and the feed deck. Follow this procedure to safely clear any obstructions in the float module’s feed draper. DANGER Ensure that all bystanders have cleared the area. 1.
Page 271: Transport
OPERATION 3.13 Transport There are two ways to transport the header: you can attach it to the front of a combine or tow it behind a combine or an agricultural tractor. For more information, refer to: • 3.13.1 Transporting Header on Combine, page 247 •...
Page 272: Attaching Header To Towing Vehicle
OPERATION Attaching Header to Towing Vehicle The header can be towed using a properly configured windrower, a combine, or an agricultural tractor. CAUTION Follow the instructions below to prevent loss of control leading to bodily injury and/or machine damage: • The weight of the towing vehicle must exceed the weight of the header to ensure adequate control and braking performance.
Page 273: Converting From Transport To Field Position (Option)
OPERATION 3.13.3 Converting from Transport to Field Position (Option) Convert the header back to field position after you have towed it to a new location. Moving Left Outboard Wheel From Transport to Working Position – ContourMax ™ Option The left outboard wheel needs to be repositioned to the working position after being in the transport position. DANGER To avoid bodily injury or death from unexpected startup or fall of raised header, stop the engine, remove the key, and engage the safety props before going under the header.
Page 274: Removing Tow-Bar
OPERATION Removing Tow-Bar Remove the tow bar from the transport location when converting the header from the transport position. 1. Block the header tires with wheel chocks (A) to prevent the header from rolling. Figure 3.336: Tire Blocking 2. Disconnect electrical connector (A) and safety chain (B) from the towing vehicle and store it as shown.
Page 275 OPERATION 6. Secure tow-bar harness (A) in storage location. 7. Lift up on the hitch near the latch connection to take weight off of the latch. While lifting, pull up on latch handle (B) to clear the tow-bar lug, then slowly lower the assembly to the ground.
Page 276 OPERATION 12. Lift extension (A) and pull it away from transport pivot (B). 13. Secure extension harness (C) inside tow-bar extension tube (A). 14. Reinstall the lynch pin in the left transport pivot for safe keeping. 15. For tow-bar storage, refer to Storing Tow-Bar, page 253.
Page 277: Storing Tow-Bar
OPERATION 18. Lift tow-bar (A) and pull it away from transport pivot (B). 19. Reinstall the lynch pin in the left transport pivot for safe keeping. 20. For tow-bar storage, refer to Storing Tow-Bar, page 253. Figure 3.345: Tow-Bar and Left Transport Pivot Storing Tow-Bar Store the tow bar in the backtube when it is not in use.
Page 278: Moving Front (Left) Wheels Into Field Position
OPERATION Tow-bar 4. Open the left endshield. For instructions, refer to Opening Header Endshields, page 5. With the tow chain and harness (A) facing up, insert hitch end (B) of the tow-bar into the left backtube. IMPORTANT: The header endshield has been removed from the illustration for clarity.
Page 279 OPERATION 3. Engage the header safety props. For instructions, refer to the combine operator’s manual. 4. Turn left transport wheel assembly (A) 90° in the direction shown. Figure 3.350: Left Transport Wheels in Transport Mode 5. Remove lynch pin (A). Pull handle (B) to engage latch (C)— this will prevent the transport wheel assembly from rotating.
Page 280 OPERATION 7. To unlock the pivot, use your foot to apply pressure to bolt (B) while pushing handle (A) downward. Figure 3.353: Left Transport Wheels – Pivot Released 8. Lift up on handle (A) while pulling back on handle (B) to lift the left wheel assembly into the highest storage position.
Page 281: Moving Rear (Right) Wheels Into Field Position
OPERATION Moving Rear (Right) Wheels into Field Position This procedure explains how to move the wheels to the highest storage position, but you may want to use a lower position, depending on whether or not you want the wheels to support the header during field operations. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason.
Page 282 OPERATION 8. Lift and rotate right transport axle (A) in the direction shown using the wheel handle. Figure 3.357: Right Transport Axle Rotation 9. Using wheel handle (A), lift and position right transport axle (B) to field support (C) to engage latch (D). Figure 3.358: Right Transport Axle Latched in Field Position 10.
Page 283: Converting From Field To Transport Position (Option)
OPERATION 3.13.4 Converting from Field to Transport Position (Option) Convert the header to the transport position before towing it to a new location. Moving Left Outboard Wheel From Working to Transport Position – ContourMax ™ Option The left outboard wheel needs to be moved to the transport position before you can tow the header. DANGER To avoid bodily injury or death from unexpected startup or fall of raised header, stop the engine, remove the key, and engage the safety props before going under the header.
Page 284: Moving Front (Left) Wheels Into Transport Position
OPERATION Moving Front (Left) Wheels into Transport Position The front (left) wheels are located closest to the towing vehicle. To prepare the header for transport, lower the wheels to the ground and rotate them to face the direction of travel. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason.
Page 285 OPERATION 5. Secure the left transport pivot by pushing pivot handle (A) forward until the latch is engaged. 6. Pull back on the pivot handle to ensure that the latch is fully engaged. Figure 3.363: Front Transport Wheels 7. Remove clevis pin (A) securing the latch. 8.
Page 286: Moving Rear (Right) Wheels Into Transport Position
OPERATION Moving Rear (Right) Wheels into Transport Position The header must be converted into transport position before towing the header. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason.
Page 287 OPERATION 5. Lift wheel handle (A) to remove right transport axle (B) from right field support (C), then lower the right transport axle to the ground. Figure 3.368: Right Field Support 6. Use the wheel handle and rotate right transport axle (A) under the header frame.
Page 288: Removing Tow-Bar From Storage
OPERATION Removing Tow-Bar from Storage When you are converting the header to the transport position, you must remove the tow-bar from its backtube storage location. Tow-Bar Extension 1. Remove strap (A) from cradle (B) to release tow-bar extension (C). 2. Rotate the tow-bar extension to unlock it from pin (D). 3.
Page 289: Attaching Tow-Bar
OPERATION Attaching Tow-Bar The tow-bar consists of two sections which make storage and handling easier. 1. Block the header tires with wheel chocks (A) to prevent the header from rolling. 2. Remove the tow-bar from storage. For instructions, refer to Removing Tow-Bar from Storage, page 264.
Page 290 OPERATION 8. Connect extension wiring harness (A) to left transport pivot harness (B). Figure 3.375: Tow-Bar Electrical Connection 9. Remove lynch pin (E) from latch (B). 10. Position end of tow-bar (C) on the extension lugs, then lower the tow-bar to the ground. 11.
Page 291 OPERATION 15. Retrieve tow-bar wiring harness (A) and safety chain (B) from its storage location. 16. Connect the tow-bar wiring harness to the vehicle, and secure the safety chain from the tow-bar to the tow vehicle. 17. Turn on the tow vehicle’s 4-way flashers and check that all of the lights on the header are working.
Page 292 OPERATION 23. Retrieve tow-bar wiring harness (A) and safety chain (B) from its storage location. 24. Connect the tow-bar wiring harness to the vehicle, and secure the safety chain from the tow-bar to the tow vehicle. 25. Turn on the tow vehicle’s 4-way flashers and check that all of the lights on the header are working.
Page 293: Chapter 4: Maintenance And Servicing
Chapter 4: Maintenance and Servicing This chapter contains the information necessary to perform routine maintenance and occasional servicing tasks on your machine. The word “maintenance” refers to scheduled tasks that help your machine operate safely and effectively; “Service” refers to tasks that must be performed when a part needs to be repaired or replaced. For advanced service procedures, contact your Dealer.
Page 294: Maintenance Requirements
Driveline and driveline universals; refer to Every 50 Hours, page 278 Upper cross auger right bearing; refer to Every 50 Hours, page 278 73. MacDon recommends keeping a record of daily maintenance as evidence of a properly maintained machine. 262653 Revision A...
Page 295 MAINTENANCE AND SERVICING Upper cross auger sliding hubs; refer to Every 50 Hours, page 278 Upper cross auger center support and U-joint; refer to Every 50 Hours, page 278 Float module auger pivots; refer to Every 50 Hours, page 278 Feed draper roller bearings, 3 locations;...
Page 296 MAINTENANCE AND SERVICING 250 Hours or Annually (Whichever Occurs First) Reel shaft bearings; refer to Every 250 Hours, page 284 Reel drive U-joint; refer to Every 250 Hours, page 284 Flex linkage; refer to Every 250 Hours, page Contour wheel end play; refer to 4.15.4 ü...
Page 297: Break-In Inspection
MAINTENANCE AND SERVICING 4.2.2 Break-in Inspection Break-in inspection involves checking belts, fluids, and performing general machine inspections for loose hardware or other areas of concern. Break-in inspections ensure that all components can operate for an extended period without requiring service or replacement. The break-in period is the first 50 hours of operation after the machine’s initial start up. Inspection Item Refer to...
Page 298: Equipment Servicing - End-Of-Season
MAINTENANCE AND SERVICING 4.2.4 Equipment Servicing – End-of-Season Inspect and service the necessary equipment at the end of each operating season. DANGER Ensure that all bystanders have cleared the area. WARNING Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable.
Page 299 MAINTENANCE AND SERVICING WARNING • Avoid high-pressure fluids. Escaping fluid can penetrate the skin and cause serious injury. • Before disconnecting hydraulic lines, relieve the pressure in the hydraulic system. Before adding pressure to the hydraulic system, tighten all of the system’s connections. •...
Page 300: Lubrication
MAINTENANCE AND SERVICING 4.3 Lubrication Grease zerk locations are marked on the machine by decals showing a grease gun and the greasing interval, which will be specified in terms of hours of header operation. Refer to the inside back cover for information on the recommended lubricants.
Page 301: Every 25 Hours
MAINTENANCE AND SERVICING IMPORTANT: When lubricating bearing (A), clear any debris and excess grease from around the bearing housing. Inspect the condition of the roller and the bearing housing. Lubricate the bearing until grease comes out of the seal. The initial greasing on a new header may require an additional 5-10 pumps of grease.
Page 302: Every 50 Hours
MAINTENANCE AND SERVICING Every 50 Hours Regular maintenance is required to keep your machine operating at peak performance and to help you identify issues early. Figure 4.7: Reel A - Reel Drive Chain. To lubricate the chain, refer to 4.3.3 Lubricating Reel Drive Chain, page 288.
Page 303 MAINTENANCE AND SERVICING Use high-temperature extreme-pressure (EP2) performance grease with 1% max. molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise specified. Figure 4.8: Two-Piece Upper Cross Auger A - Upper Cross Auger U-joints (Two Places) B - Upper Cross Auger Sliding Hubs (Two Places) C - Upper Cross Auger Center Bearings (Two Places) D - Right End Bearing IMPORTANT:...
Page 304 MAINTENANCE AND SERVICING Figure 4.9: Three-Piece Upper Cross Auger A - Upper Cross Auger U-joints (Two Places) B - Upper Cross Auger Sliding Hubs (Two Places) C - Upper Cross Auger Center Bearings (Two Places) D - Right End Bearing IMPORTANT: The upper cross auger (UCA) must be greased regularly even when it is turned off as components of the UCA move when the header flexes, regardless of whether the auger is turning or not.
Page 305 MAINTENANCE AND SERVICING Figure 4.10: FM200 B - Driveline Slip Joint 74 A - Driveline Universal (Two Places) Figure 4.11: FM200 A - Remote Grease Line for Auger Pivot (Right Side) B - Remote Grease Line for Auger Pivot (Left Side) C - Auger Pivot (Left Side) D - Auger Pivot (Right Side) 74.
Page 306: Every 100 Hours
MAINTENANCE AND SERVICING Every 100 Hours Maintenance is required to keep your machine operating at peak performance and to help you identify issues early. Use high-temperature extreme-pressure (EP2) performance grease with 1% max. molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise specified. Figure 4.12: FM200 A - Driveline Guards (Both Ends) B - Float Pivots (Right and Left)
Page 307 MAINTENANCE AND SERVICING Figure 4.13: FM200 A - Main Gearbox Oil Level. To lubricate the main gearbox, refer to 4.3.5 Lubricating Header Drive Main Gearbox, page 290. B - Completion Gearbox Oil Level. To lubricate the completion gearbox, refer to 4.3.6 Lubricating Header Drive Completion Gearbox, page 292.
Page 308: Every 250 Hours
MAINTENANCE AND SERVICING Figure 4.15: Inner Contour Wheel Assemblies A - Inner Wheel Assemblies (Two Places) Every 250 Hours Maintenance is required to keep your machine operating at peak performance and to help you identify issues early. Use high-temperature extreme-pressure (EP2) performance grease with 1% max. molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise specified.
Page 309 MAINTENANCE AND SERVICING Figure 4.16: Reel A - Reel Right Bearing (One Place) B - Reel Center Bearing (One Place) C - Reel Left Bearing (One Place) Figure 4.17: Reel A - Reel U-joint (One Place) 75 B - Flex Linkage (Two Places) – Both Sides 75.
Page 310: Every 500 Hours
MAINTENANCE AND SERVICING Every 500 Hours Maintenance is required to keep your machine operating at peak performance and to help you identify issues early. Use high temperature extreme pressure (EP2) performance grease with 1% max. molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise specified.
Page 311: Greasing Procedure
MAINTENANCE AND SERVICING Figure 4.19: Contour Wheel Bearings B - Wheel Bearings (Six Places) Lubricate the bearings on all six contour wheels as follows: 1. Remove rubber plug (A) from the contour wheel hub. Retain the plug for reinstallation. 2. Apply grease at lubrication point (B), and allow the excess grease to flow out the front of the axle hub. IMPORTANT: Grease the lubrication point SLOWLY.
Page 312: Lubricating Reel Drive Chain
MAINTENANCE AND SERVICING Figure 4.22: FD2 Series Grease Point Layout Decal 4.3.3 Lubricating Reel Drive Chain Lubrication protects the chain and the drive sprockets against wear. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 313: Lubricating Auger Drive Chain
MAINTENANCE AND SERVICING 4.3.4 Lubricating Auger Drive Chain Lubricate the auger drive chain according to the interval specified in the maintenance schedule. NOTE: Lubricating the auger drive chain is easier when the header is detached from the combine. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 314: Lubricating Header Drive Main Gearbox
MAINTENANCE AND SERVICING 3. Apply a liberal amount of grease to chain (A), drive sprocket (B), and idler sprocket (C). 4. Rotate the auger and apply grease to more areas of the chain, if necessary. Figure 4.25: Auger Drive Chain 5.
Page 315: Adding Oil To Header Drive Main Gearbox
MAINTENANCE AND SERVICING DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1. Lower the header. 2. Shut down the engine, and remove the key from the ignition. 3.
Page 316: Changing Oil In Header Drive Main Gearbox
MAINTENANCE AND SERVICING Changing Oil in Header Drive Main Gearbox Change the header drive gearbox oil after the first 50 hours of operation and every 1000 hours (or 3 years) thereafter. WARNING Ensure that all bystanders have cleared the area. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 317: Adding Oil To Header Drive Completion Gearbox
MAINTENANCE AND SERVICING 3. Remove oil level plug (A) from the completion gearbox. The oil should be at the level of the port. 4. If there is an insufficient amount of oil in the completion gearbox, remove filler plug (B) and add oil. For instructions, refer to Adding Oil to Header Drive Completion Gearbox, page...
Page 318: Changing Oil In Header Drive Completion Gearbox
MAINTENANCE AND SERVICING 3. Remove filler plug (B) and oil level plug (A). 4. Add oil into filler hole (B) until the oil runs out of hole (A). Refer to the inside back cover for the recommended fluids and lubricants. 5.
Page 319 MAINTENANCE AND SERVICING 2. Raise or lower the header to position oil drain plug (A) at its lowest point. 3. Shut down the engine, and remove the key from the ignition. 4. Place a suitable container (approximately 4 liters [1 US gal]) underneath the gearbox drain to collect the oil.
Page 320: Hydraulics
MAINTENANCE AND SERVICING 4.4 Hydraulics The float module frame acts as an oil reservoir. Refer to the inside back cover for more information on the float module’s oil requirements. 4.4.1 Checking Oil Level in Hydraulic Reservoir You can inspect the oil level in the header’s hydraulic oil reservoir via the sight glass on the float module. DANGER Ensure that all bystanders have cleared the area.
Page 321: Changing Oil In Hydraulic Reservoir
MAINTENANCE AND SERVICING 1. Clean any dirt or debris from filler cap (A). CAUTION The oil reservoir may be under pressure; remove the cap slowly. 2. Turn filler cap (A) counterclockwise to remove it. 3. Fill the hydraulic oil reservoir with warm oil (approximately 21°C [70°F]) until the appropriate fill level is reached.
Page 322: Changing Oil Filter
MAINTENANCE AND SERVICING 3. Place a container with a capacity of at least 50 L (13 gal) under both oil drain plugs (A). 4. Remove oil drain plugs (A) with a 7/8 in. hex socket. Allow the oil to drain completely. 5.
Page 323 MAINTENANCE AND SERVICING 3. To change the oil filter on an FM200 with a modular hydraulic system (MHS), do the following: Clean around the mating surfaces of filter (A) and modular manifold (B). b. Place a suitably sized container (of a capacity of at least 1 liter [0.26 gallons]) under oil drain spout (C).
Page 324: Electrical System
MAINTENANCE AND SERVICING 4.5 Electrical System The electrical system for the header is powered by the combine. The header has various lights and sensors that require power. 4.5.1 Replacing Light Bulbs Lights are an important safety feature. Replace damaged or malfunctioning bulbs or lamps immediately. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 325: Header Drive
MAINTENANCE AND SERVICING 4.6 Header Drive The header drive consists of a driveline from the combine to the FM200 Float Module gearbox that drives the feed auger and hydraulic pumps. The pumps provide hydraulic power to the drapers, knives, and optional equipment. 4.6.1 Removing Driveline The driveline transfers power from the combine power take-off (PTO) to the header float module completion gearbox.
Page 326 MAINTENANCE AND SERVICING 6. Slide shield (A) along the driveline to access quick disconnect collar (B). NOTE: If the shield does not slide, use a prying tool. 7. Pull back quick disconnect collar (B) to release the driveline yoke. Slide the driveline off of the gearbox shaft. 8.
Page 327: Installing Driveline
MAINTENANCE AND SERVICING 4.6.2 Installing Driveline The driveline transfers power from the combine power take-off (PTO) to the header’s float module completion gearbox. It will need to be installed on the float module. DANGER Ensure that all bystanders have cleared the area. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 328 MAINTENANCE AND SERVICING 6. On the end of driveline (D) which has arrow (C) pointing toward the collar, pull back quick disconnect collar (A). 7. Slide the yoke onto support bracket (B). 8. Connect safety chain (E) to the support bracket. Figure 4.47: Driveline Shield Figure 4.48: Optional Side-Hill Driveline Shield 9.
Page 329 MAINTENANCE AND SERVICING 10. Slide the driveline through shield (A). Pull back quick disconnect collar (B) to release the driveline yoke. 11. Slide the driveline onto the gearbox shaft until it locks onto the shaft. Figure 4.50: Driveline Shield 12. Slide the shield toward the gearbox until clips (A) secure shield (B).
Page 330: Removing Driveline Guard
MAINTENANCE AND SERVICING 4.6.3 Removing Driveline Guard The main driveline guard must remain attached to the driveline during operation, but you can remove it for maintenance purposes. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 331 MAINTENANCE AND SERVICING 5. Use a slotted screwdriver to release grease fitting/lock (A). Figure 4.55: Driveline Guard 6. Rotate driveline guard locking ring (A) counterclockwise using a screwdriver until lugs (B) line up with the slots in the guard. 7. Pull the guard off the driveline. Figure 4.56: Driveline Guard 262653 Revision A...
Page 332: Installing Driveline Guard
MAINTENANCE AND SERVICING 4.6.4 Installing Driveline Guard Install the driveline guard before operating the header. 1. Slide the guard onto the driveline, and line up the slotted lug on locking ring (A) with arrow (B) on the guard. Figure 4.57: Driveline Guard 2.
Page 333 MAINTENANCE AND SERVICING 4. Push grease fitting (A) back into the guard. Figure 4.60: Driveline Guard 5. Assemble the driveline. IMPORTANT: The splines are keyed to align the universals. Align weld (A) with missing spline (B) when assembling. Failing to align the halves of the shaft can cause excessive vibration and feed auger/gearbox failures.
Page 334: Adjusting Chain Tension - Main Gearbox
MAINTENANCE AND SERVICING 4.6.5 Adjusting Chain Tension – Main Gearbox The tension of the gearbox drive chain is set at the factory, but adjustment is required after the first 50 hours, then every 500 hours or annually (whichever comes first). With the exception of oil changes, the gearbox drive chain requires no other regular maintenance.
Page 335: Adjusting Chain Tension - Completion Gearbox
MAINTENANCE AND SERVICING 8. If necessary, turn bolt (B) slightly until retainer plate (A) can be installed. Figure 4.65: Main Gearbox Chain Tensioner 9. Reinstall chain adjusting cover (B) and gasket (C). 10. Install four bolts (A). Torque the bolts to 9.5 Nm (7 lbf∙ft [84 lbf∙in]).
Page 336 MAINTENANCE AND SERVICING 4. Remove three bolts (A) securing input driveline guard base (B). Figure 4.67: Completion Gearbox Chain Tensioner Cover 5. Loosen six bolts (B) securing chain tension hub (A) to the gearbox. 6. Locate machined feature (C). Using a wrench, turn hub (A) clockwise to tighten the chain.
Page 337: Feed Auger
MAINTENANCE AND SERVICING 4.7 Feed Auger The FM200 Float Module feed auger feeds the cut crop from the draper decks into the combine feeder house. 4.7.1 Checking Feed-Auger-to-Pan Clearance There must be an adequate clearance between the feed auger and the pan on the float module to ensure that the crop feeds smoothly.
Page 338 MAINTENANCE AND SERVICING 5. Before adjusting the auger-to-pan clearance, check the auger float position to determine how much clearance is required: IMPORTANT: Ensure that bolts (A) are set at the same location on both ends of the header to prevent damage to the machine during operation.
Page 339: Checking Feed Auger Chain Tension
MAINTENANCE AND SERVICING 6. Check clearance (C) between the feed auger flighting and the pan. • If the feed auger is in the fixed position, the clearance should be 24–28 mm (15/16–1 1/8 in.). • If the feed auger is in the floating position, the clearance should be 11.5–15.5 mm (7/16–5/8 in.).
Page 340 MAINTENANCE AND SERVICING WARNING To prevent bodily injury from the fall of a raised reel, always engage the reel safety props before going under the raised reel for any reason. WARNING Ensure that all bystanders have cleared the area. NOTE: There are two methods for checking the auger drive chain tension: the quick method is intended for frequent checks;...
Page 341: Checking Feed Auger Drive Chain Tension - Thorough Method
MAINTENANCE AND SERVICING 8. Measure the distance between two lines (B). For a new chain: • If distance (B) is 1–4 mm (0.04–0.16 in.), no adjustment is required. • If distance (B) is greater than 4 mm (0.16 in.), the auger drive chain tension needs adjusting. For instructions, refer 4.7.3 Adjusting Feed Auger Drive Chain Tension, page 320.
Page 342 MAINTENANCE AND SERVICING 6. On the front left side of the feed auger, remove bolts (A) and remove indicator/clamp (B). 7. Remove bolts (C) from the retaining plate. 8. Remove bolt and washer (D) securing bottom cover (E). Figure 4.76: Feed Auger Drive – Front View 9.
Page 343 MAINTENANCE AND SERVICING 12. Check the chain at midspan (A). There should be 4 mm (1/8 in.) of deflection. If adjustment is required, refer to 4.7.3 Adjusting Feed Auger Drive Chain Tension, page 320. Figure 4.78: Feed Auger Chain – Rear View 13.
Page 344: Adjusting Feed Auger Drive Chain Tension
MAINTENANCE AND SERVICING 15. Install bolts (C) in retaining plate. 16. Secure the bottom cover to the top cover with clamp/ indicator (B) and bolts (A). 17. Install bolt and washer (D) to secure bottom cover (E). Figure 4.80: Feed Auger Drive – Front View 4.7.3 Adjusting Feed Auger Drive Chain Tension The auger is chain-driven by the float module drive system sprocket attached to the side of the auger.
Page 345 MAINTENANCE AND SERVICING 6. Remove four bolts (A) and inspection panel (B) to view the chain. Figure 4.81: Left Side of Auger Drive – Rear View 7. Loosen jam nut (B). 8. Loosen idler nut (A) slightly to allow the idler to move by turning adjuster (C).
Page 346: Auger Flighting
MAINTENANCE AND SERVICING 10. Turn adjuster thumbscrew (A) clockwise to increase the tension until chain deflection (B) is 4 mm (1/8 in.) at the midspan. IMPORTANT: Do NOT overtighten the chain. NOTE: The covers have been removed from the illustration for clarity.
Page 347: Auger Fingers
MAINTENANCE AND SERVICING 4.7.5 Auger Fingers The FM200 feed auger uses retracting tines to feed the crop into the combine feeder house. Some conditions may require removing or installing the fingers for optimal crop feeding. Replace any worn or damaged fingers. Removing Feed Auger Fingers The feed auger has fingers that extend and retract to pull crop into the feeder house on the combine.
Page 348 MAINTENANCE AND SERVICING 6. Remove hairpin (A). Pull finger (B) out of finger holder (C). 7. If the finger is broken, remove any remnants from holder (C) and from inside the drum. Figure 4.87: Auger Finger 8. Remove and retain two bolts (A) and the tee nuts (not shown) securing finger guide (B) to the auger.
Page 349: Installing Feed Auger Fingers
MAINTENANCE AND SERVICING 12. Position access cover (B) as shown, and secure with bolts (A). 13. Torque the bolts to 9 Nm (6.63 lbf∙ft [80 lbf∙in]). NOTE: Bolts (A) come with a threadlocker patch that will wear off if the bolts are removed. If you are reinstalling bolts (A), apply medium-strength threadlocker (Loctite®...
Page 350 MAINTENANCE AND SERVICING 4. Remove bolts (A) and access cover (B) closest to the finger you are removing. Retain the parts for reinstallation. Figure 4.91: Auger Access Hole Cover 5. Remove two bolts (B), tee nuts (not shown), and plug (A). Figure 4.92: Auger Finger Hole 6.
Page 351: Checking Auger Finger Timing
MAINTENANCE AND SERVICING 8. From inside of the drum, insert auger finger (A) up through the bottom of guide (B) and insert the other end into holder (C). 9. Secure the finger by inserting hairpin (D) into the holder. Ensure that the round end (the S-shaped side) of the hairpin faces the chain drive side of the auger.
Page 352: Adjusting Auger Finger Timing
MAINTENANCE AND SERVICING 4. Check that indicator (C) is set to the same position at each end of the auger. NOTE: There are two different auger finger extension positions: A and B. Position A is used for canola and position B is used for grains.
Page 353 MAINTENANCE AND SERVICING 4. Locate finger timing indicator (C) at the end of the auger. There are two auger finger extension positions: Position A and position B. 5. Loosen nuts (D) and adjust finger timing indicator (C) to the desired position. IMPORTANT: Both finger timing indicators MUST be set to the same position;...
Page 354 MAINTENANCE AND SERVICING 6. Once adjustment is complete, torque nuts (A) to 115 Nm (85 lbf·ft). 7. Disengage the reel safety props. For instructions, refer to Disengaging Reel Safety Props, page Figure 4.100: Auger Finger Timing Indicator 262653 Revision A...
Page 355: Cutterbar
MAINTENANCE AND SERVICING 4.8 Cutterbar The knives on the cutterbar cut the crop. The knives, guards, and knifehead will require maintenance from time to time. WARNING Keep hands clear of the area between the guards and the knife at all times. WARNING Wear heavy gloves when working around or handling knives.
Page 356: Removing Knife
MAINTENANCE AND SERVICING 4. Identify the damaged knife section. If there is a hold-down, loosen nuts (A) securing hold-down (B) to access the damaged knife section. Figure 4.102: Cutterbar 5. Remove bolts and nuts (B). Retain the hardware. NOTE: If the knife hardware is under a hold-down, rotate the knife flywheel to reposition the knife.
Page 357: Installing Knife
MAINTENANCE AND SERVICING NOTE: On single-knife headers, the knifehead is located on the left side of the knife. On double-knife headers, there are two knifeheads located on the right and left sides of the knife. For double-knife headers, check which knife needs to be removed before starting the procedure.
Page 358 MAINTENANCE AND SERVICING WARNING Stand to the rear of the knife during removal to reduce the risk of injury from cutting edges. Wear heavy gloves when handling the knife. 1. Shut down the engine, and remove the key from the ignition. 2.
Page 359: Spare Knives
MAINTENANCE AND SERVICING 6. Secure the knifehead pin with M16 x 85 mm bolt (A) and nut (B). Install the bolt from the inboard side of the arm. Torque the bolt to 220 Nm (162 lbf·ft). 7. Rotate the flywheel attached to the knife drive box to position knife arm to the inside limit of travel.
Page 360: Pointed Knife Guards And Hold-Downs
MAINTENANCE AND SERVICING 4.8.5 Pointed Knife Guards and Hold-Downs Knife guards help align the knife bar. Hold-downs hold the sections on the knife bar down against the knife guards to ensure proper cutting. The following knife guards and hold-downs are used in pointed guard configurations: NOTE: Pointed knife guard configurations require two short knife guards, one at each end of the cutterbar.
Page 361 MAINTENANCE AND SERVICING Figure 4.111: Guard and Hold-Down Types Used in Pointed Knife Guard Configurations A - Pointed Hold-Down (MD #286329) B - Pointed Knife Guard (MD #286315) C - Pointed-End Knife Guard (without Wear Bar) (MD #286316) 76 ™ D - PlugFree End Hold-Down (MD #286331) End Knife Guard (without Wear Bar) (MD #286319) 77...
Page 362: Pointed Knife Guard Configuration On Single-Knife Headers
MAINTENANCE AND SERVICING Pointed Knife Guard Configuration on Single-Knife Headers Guards are configured differently on different sized headers. The illustration provided here shows pointed knife guards installed on single-knife headers. Figure 4.112: Pointed Knife Guard and Hold-Down Locations – Single-Knife Headers A - Pointed Hold-Down (MD #286329) B - Pointed Knife Guard (MD #286315) ™...
Page 363: Pointed Knife Guard Configuration On Double-Knife Header - Fd235
MAINTENANCE AND SERVICING Pointed Knife Guard Configuration on Double-Knife Header – FD235 Guards are configured differently on different headers. The illustration provided here shows pointed knife guards installed on FD235 double-knife headers. Figure 4.113: Pointed Knife Guard and Hold-Down Locations – FD235 A - Pointed Hold-Down (MD #286329) 79 B - Pointed Center Hold-Down (MD #286332) C - Pointed Center Knife Guard (MD #286317)
Page 364: Pointed Knife Guard Configuration On Double-Knife Header - Fd240
MAINTENANCE AND SERVICING Pointed Knife Guard Configuration on Double-Knife Header – FD240 Knife guards help align the knife bar. Hold-downs hold the sections on the knife bar down against the knife guards to ensure proper cutting. Figure 4.114: Pointed Knife Guard and Hold-Down Locations – FD240 Double-Knife Header A - Pointed Hold-Down (MD #286329) B - Pointed Center Hold-Down (MD #286332) C - Pointed Center Knife Guard (MD #286317)
Page 365: Pointed Knife Guard Configuration On Double-Knife Header - Fd241 And Fd261
MAINTENANCE AND SERVICING Pointed Knife Guard Configuration on Double-Knife Header – FD241 and FD261 Guards are configured differently on different sized headers. The illustration provided here shows pointed knife guards installed on FD241 and FD261 double-knife headers. Figure 4.115: Pointed Knife Guard and Hold-Down Locations A - Pointed Hold-Down (MD #286329) 80 B - Pointed Center Hold-Down (MD #286332) C - Pointed Center Knife Guard (MD #286317)
Page 366: Pointed Knife Guard Configuration On Double-Knife Header - Fd245
MAINTENANCE AND SERVICING Pointed Knife Guard Configuration on Double-Knife Header – FD245 Guards are configured differently on different sized headers. The illustration provided here shows pointed knife guards installed on FD245 double-knife headers. Figure 4.116: Pointed Knife Guard and Hold-Down Locations – FD245 Double-Knife Header A - Pointed Hold-Down (MD #286329) 81 B - Pointed Center Hold-Down (MD #286332) C - Pointed Center Knife Guard (MD #286317)
Page 367: Pointed Knife Guards Configuration On Double-Knife Header - Fd250
MAINTENANCE AND SERVICING Pointed Knife Guards Configuration on Double-Knife Header – FD250 Guards are configured differently on different sized headers. The illustration provided here shows pointed knife guards installed on FD250 double-knife headers. Figure 4.117: Pointed Knife Guard and Hold-Down Locations – FD250 Double-Knife Header A - Pointed Hold-Down (MD #286329) B - Pointed Center Hold-Down (MD #286332) C - Pointed Center Knife Guard (MD #286317)
Page 368: Adjusting Knife Guards And Guard Bar
MAINTENANCE AND SERVICING Adjusting Knife Guards and Guard Bar If a knife guard or the guard bar is misaligned due to contact with a rock or obstruction, use the guard straightening tool to correct the alignment. DANGER Ensure that all bystanders have cleared the area. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 369 MAINTENANCE AND SERVICING 4. To adjust the guard tips upward, position the guard straightening tool as shown and pull the tool up. Figure 4.118: Upward Adjustment – Pointed Guard Figure 4.119: Upward Adjustment – Short Knife Guard 5. To adjust the guard tips downward, position the guard straightening tool as shown and push the tool down.
Page 370: Replacing Pointed Knife Guards
MAINTENANCE AND SERVICING Figure 4.121: Downward Adjustment – Short Knife Guard 6. To adjust the guard bar, position the guard straightening tool as shown, then push down or pull up on the tool accordingly. Figure 4.122: Guard Bar Adjustment – No Guards Replacing Pointed Knife Guards The guards eventually become dull and need to be replaced.
Page 371 MAINTENANCE AND SERVICING WARNING Wear heavy gloves when working around or handling knives. IMPORTANT: When replacing the pointed knife guards, ensure that the hold-down sequence is correct for your header type and width. For more information, refer to 4.8.5 Pointed Knife Guards and Hold-Downs, page 336.
Page 372: Checking Hold-Down - Pointed Knife Guards
MAINTENANCE AND SERVICING 9. Position plastic wearplate (A) and replacement pointed knife guard (B) under the cutterbar. Figure 4.125: Pointed Knife Guard and Wearplate 10. Position hold-down (A) (if applicable), then loosen adjustment bolt (C) so that it does not protrude from the bottom of the hold-down.
Page 373 MAINTENANCE AND SERVICING WARNING To prevent bodily injury from the fall of a raised reel, always engage the reel safety props before going under the raised reel for any reason. WARNING Wear heavy gloves when working around or handling knives. 1.
Page 374: Adjusting Hold-Down - Pointed Knife Guards
MAINTENANCE AND SERVICING Adjusting Hold-Down – Pointed Knife Guards Following the checking procedure, if a pointed or four-point knife guard hold-down is binding the knife, adjust the hold-down. This procedure applies to standard hold-downs. To adjust the center hold-down on double-knife headers, refer to Adjusting Center Hold-Down on Double-Knife Header –...
Page 375: Replacing Pointed Center Knife Guard - Double-Knife Header
MAINTENANCE AND SERVICING Replacing Pointed Center Knife Guard – Double-Knife Header The guard at the center of a double-knife header (where the two knives overlap) requires a different replacement procedure than a pointed knife guard. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 376 MAINTENANCE AND SERVICING IMPORTANT: Ensure that the replacement guard is the correct guard with offset cutting surfaces (A). Figure 4.130: Pointed Center Knife Guard 6. Before installing the new pointed center knife guard, ensure that overlap shim (A) is present under the cutterbar, and that the thick end of the shim is positioned under the center guard.
Page 377: Checking Center Hold-Down On Double-Knife Header - Pointed Knife Guards
MAINTENANCE AND SERVICING 8. Install three adjustment bolts (A) so that they are protruding 4 mm (5/32 in.) from the bottom of pointed center hold-down (B). 9. Position center hold-down (B) onto the cutterbar. Figure 4.133: Pointed Center Knife Guard 10.
Page 378 MAINTENANCE AND SERVICING WARNING Wear heavy gloves when working around or handling knives. 1. Raise the reel fully. 2. Shut down the engine, and remove the key from the ignition. 3. Engage the reel safety props. For instructions, refer to Engaging Reel Safety Props, page 4.
Page 379: Adjusting Center Hold-Down On Double-Knife Header - Pointed Knife Guards
MAINTENANCE AND SERVICING Adjusting Center Hold-Down on Double-Knife Header – Pointed Knife Guards Following the checking procedure, if the pointed center knife guard hold-down is binding the knife, adjust it. DANGER Ensure that all bystanders have cleared the area. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 380: Short Knife Guards And Hold-Downs
MAINTENANCE AND SERVICING 4.8.6 Short Knife Guards and Hold-Downs Short knife guards make the knife less likely to plug in wet or muddy conditions and in tough crops such as grasses and canola. The following knife guards and hold-downs are used in short knife guard configurations: Figure 4.137: Guard and Hold-Down Types used in Short Knife Guard Configurations ™...
Page 381: Short Knife Guard Configuration On Single-Knife Headers
MAINTENANCE AND SERVICING Short Knife Guard Configuration on Single-Knife Headers The guards are configured differently on different sized headers. The illustration provided here shows short knife guards installed on single-knife headers. Figure 4.138: Short Knife Guard and Hold-Down Locations – Single-Knife Headers ™...
Page 382: Short Knife Guard Configuration On Double-Knife Headers - All Except Fd241 And Fd261
MAINTENANCE AND SERVICING Short Knife Guard Configuration on Double-Knife Headers – All Except FD241 and FD261 The guards are configured differently on different sized headers. The illustration provided here shows short knife guards installed on double-knife headers. Figure 4.139: Short Knife Guard and Hold-Down Locations – Double-Knife Headers ™...
Page 383: Short Knife Guard Configuration On Double-Knife Headers - Fd241 And Fd261
MAINTENANCE AND SERVICING Short Knife Guard Configuration on Double-Knife Headers – FD241 and FD261 The guards are configured differently on different sized headers. The illustration provided here shows short knife guards installed on FD241 and FD261 double-knife headers. Figure 4.140: Short Knife Guard and Hold-Down Locations ™...
Page 384: Replacing Short Knife Guards Or End Knife Guards
MAINTENANCE AND SERVICING Replacing Short Knife Guards or End Knife Guards Short knife guards or end knife guards are installed at the factory and make the knife less likely to plug in wet or muddy conditions or in tough crops such as grasses and canola. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 385 MAINTENANCE AND SERVICING IMPORTANT: The end knife guards are the first four knife guards (A) on the drive sides of the header and they do NOT have wear bars. Install the proper replacement knife guards at these locations. Figure 4.142: End Knife Guard and Short Knife Guards ™...
Page 386: Checking Hold-Down - Short Knife Guards
MAINTENANCE AND SERVICING 11. Check the clearance. • If the clearance is acceptable, the installation of the hold-down is complete. • If the clearance is unacceptable, repeat Step 9, page 361 to Step 11, page 362. 12. Disengage the reel safety props. For instructions, refer to Disengaging Reel Safety Props, page Checking Hold-Down –...
Page 387: Adjusting Hold-Down - Short Knife Guards
MAINTENANCE AND SERVICING Adjusting Hold-Down – Short Knife Guards Following the checking procedure, if a short guard hold-down is binding its knife, adjust the hold-down. Adjusting Center Hold-Down on Double-Knife Headers – To adjust the center hold-down on double-knife headers, refer to Short Knife Guards, page 368.
Page 388: Replacing Center Knife Guard - Double-Knife Headers
MAINTENANCE AND SERVICING Replacing Center Knife Guard – Double-Knife Headers The offset guard at the center of a double-knife header (where the two knives overlap) requires a slightly different replacement procedure than a standard guard. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 389 MAINTENANCE AND SERVICING IMPORTANT: Ensure that the replacement center knife guard is the correct guard with offset cutting surfaces (A). Figure 4.148: Center Knife Guard 6. Before installing the new center knife guard, ensure that overlap shim (A) is under the cutterbar, and that the thick end of the shim is positioned under the center knife guard.
Page 390: Checking Center Hold-Down On Double-Knife Headers - Short Knife Guards
MAINTENANCE AND SERVICING 8. Thread three adjustment bolts (A) so that they protrude 4 mm (5/32 in.) from the bottom of center hold-down (B). 9. Position center hold-down (B) onto the cutterbar. Figure 4.151: Center Knife Guard 10. Secure center hold-down (A) with two bolts and nuts (B), but do NOT tighten the nuts at this time.
Page 391 MAINTENANCE AND SERVICING WARNING Wear heavy gloves when working around or handling knives. 1. Raise the reel fully. 2. Shut down the engine, and remove the key from the ignition. 3. Engage the reel safety props. For instructions, refer to Engaging Reel Safety Props, page 4.
Page 392: Adjusting Center Hold-Down On Double-Knife Headers - Short Knife Guards
MAINTENANCE AND SERVICING Adjusting Center Hold-Down on Double-Knife Headers – Short Knife Guards Following the checking procedure, If a short knife guard hold-down is binding the knife, adjust the hold-down. DANGER Ensure that all bystanders have cleared the area. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 393: Knifehead Shield
MAINTENANCE AND SERVICING 4.8.7 Knifehead Shield The knifehead shield attaches to the endsheet and reduces the knifehead opening to prevent cut crop from accumulating in the knifehead cutout. IMPORTANT: Remove the shields when using the cutterbar on the ground in muddy conditions. The mud may pack into the cavity behind the shield, resulting in knife drive box failure.
Page 394 MAINTENANCE AND SERVICING 6. Place knifehead shield (A) against the endsheet as shown. Align the shield so that the cutout matches the profile of the knifehead and/or the hold-downs. 7. Align the mounting holes and secure the shield with two M10 x 30 hex head bolts, washers (B), and nuts.
Page 395: Knife Drive System
MAINTENANCE AND SERVICING 4.9 Knife Drive System The knife drive system transforms pumped hydraulic pressure into a mechanical motion that strokes a series of serrated knife blades at the front of the header to cut a variety of crops. 4.9.1 Knife Drive Box The knife drive box is driven by a hydraulic motor and converts rotational motion into the reciprocating motion of the knife.
Page 396: Checking Mounting Bolts
MAINTENANCE AND SERVICING 6. Remove oil level dipstick (A), wipe it, and then reinstall it. Tighten it until it is finger-tight. 7. Remove the dipstick again to check the oil level. The oil level must be within range (B), between the lines near the bottom of the dipstick.
Page 397 MAINTENANCE AND SERVICING 4. Under the knife drive box, place a container large enough to hold approximately 1.5 L (0.4 US gal) of oil. 5. Remove dipstick (A) and drain plug (C). 6. Allow the oil to drain from the knife drive box and into the container below it.
Page 398: Feed Deck
MAINTENANCE AND SERVICING 4.10 Feed Deck The feed deck is located on the FM200 Float Module. It uses a feed draper which conveys the cut crop to the feed auger. 4.10.1 Replacing Feed Draper The feed draper on the float module delivers harvested crop into the combine’s feeder house. If the feed draper is torn, cracked, or missing slats, replace it.
Page 399 MAINTENANCE AND SERVICING 13. Remove five countersunk screws (A) and retainer (B). 14. Remove one button head screw and washer (C). 15. Flip mid-filler (D) over. A A A 16. Repeat Steps 13, page 375 15, page 375 on the other side of the feed deck.
Page 400 MAINTENANCE AND SERVICING NOTE: The chevron cleat on draper (A) should point towards the front. Figure 4.164: Float Module Feed Draper Orientation 22. Connect the draper joint with connector straps (B). Secure the straps with nuts and screws (A). Torque the nuts to 7 Nm (5 lbf·ft [60 lbf·in]).
Page 401: Checking And Adjusting Feed Draper Tension
MAINTENANCE AND SERVICING 30. Position mid-filler (D) as shown. Reinstall retainer (B). 31. Secure the retainer and the mid-filler with one button head screw and washer (C) and five countersunk screws (A). 32. Repeat the previous two steps on the opposite side of the A A A feed deck.
Page 402 MAINTENANCE AND SERVICING 5. Check the position of spring retainer disc (A). If the feed draper tracks properly and the spring retainers on both sides of the draper are correctly positioned, then no adjustment is necessary. NOTE: The starting position of spring retainer disc (A) is centered within the U shape on indicator (B);...
Page 403: Feed Draper Drive Roller
MAINTENANCE AND SERVICING 4.10.3 Feed Draper Drive Roller The feed draper drive roller is hydraulically driven to rotate the feed draper and convey the crop toward the feed auger. Removing Feed Draper Drive Roller The feed draper drive roller needs to be removed when repairing or replacing it. DANGER Ensure that all bystanders have cleared the area.
Page 404 MAINTENANCE AND SERVICING 7. Remove nuts and screws (A). Remove draper connector straps (B). 8. Lift the sides of the draper to expose the rollers. Figure 4.170: Draper Connector 9. On the right side of the deck, remove two nuts (A) and bolts from drive roller bearing housing (B).
Page 405: Installing Feed Draper Drive Roller
MAINTENANCE AND SERVICING 10. Slide the drive roller with bearing assembly (A) to the right until the left end comes off of the motor spline. 11. Remove both covers (B). 1038379 Figure 4.172: Drive Roller 12. Lift the left end out of the frame. 13.
Page 406: Removing Feed Draper Drive Roller Bearing
MAINTENANCE AND SERVICING 3. Slide the left end of drive roller (A) onto spline of motor (B). Figure 4.175: Feed Draper Motor 4. Install two bolts (A) into the feed deck. 5. Install both covers (B) onto the two bolts. IMPORTANT: Position the covers in the order shown.
Page 407 MAINTENANCE AND SERVICING 1. Raise the reel fully. 2. Raise the header fully. 3. Shut down the engine, and remove the key from the ignition. 4. Engage the reel safety props. For instructions, refer to Engaging Reel Safety Props, page 5.
Page 408 MAINTENANCE AND SERVICING 9. Remove two nuts (A). Figure 4.179: Feed Draper Drive Roller Bearing 10. Remove bearing housing (A). NOTE: If the bearing is seized on the shaft, it may be easier to remove the drive roller assembly. For instructions, refer to Removing Feed Draper Drive Roller, page 379.
Page 409: Installing Feed Draper Drive Roller Bearing
MAINTENANCE AND SERVICING Installing Feed Draper Drive Roller Bearing The bearing is held in place with bolts and a lock collar. 1. Install two bolts (A) into the feed deck. 2. Install both covers (B) onto the two bolts. IMPORTANT: Position the covers in the order shown.
Page 410 MAINTENANCE AND SERVICING 5. Engage the header safety props. For instructions, refer to the combine operator’s manual. 6. Locate the feed draper tensioner. Loosen jam nut (A). Turn bolt (B) counterclockwise to relieve the tension on the draper. Figure 4.182: Feed Draper Tensioner 7.
Page 411 MAINTENANCE AND SERVICING 11. Remove the hardware that secures the bearing housing to the deck skid and the tensioner from locations (A). • Socket head bolt, washer, and nut. 12. Remove bearing housing (B) from the idler roller. 13. Repeat Step 10, page 386 to Step 12, page 387...
Page 412: Installing Feed Draper Idler Roller
MAINTENANCE AND SERVICING Installing Feed Draper Idler Roller The feed draper idler roller needs to be installed after it has been repaired or replaced. 1. Slide cover (A) over one end of the idler roller. 2. Brush idler roller shaft (B) with oil. 3.
Page 413 MAINTENANCE AND SERVICING 7. Install the bolt from inside of the feed deck to secure idler cover (A). 8. Install nut (B). Do NOT overtighten the nut. The nut should hold the idler cover in place and move with the idler roller. Figure 4.191: Idler Cover –...
Page 414: Replacing Feed Draper Idler Roller Bearing
MAINTENANCE AND SERVICING 13. Rotate idler roller housing (A) until the holes in the lower tabs align with the hole in welded tab (B). 14. Align the hole in cast support (D) with the holes in the upper tab on idler roller housing (A). 15.
Page 415 MAINTENANCE AND SERVICING DANGER Ensure that all bystanders have cleared the area. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 416 MAINTENANCE AND SERVICING 7. Remove the hardware that secures the bearing housing to the deck skid and the tensioner from location (A): • Socket head bolt, washer, and nut. 8. Remove dust cap (B). NOTE: Model year 2024 and newer FM200 float modules will have the grease zerk on the dust cap, not on the bearing housing.
Page 417 MAINTENANCE AND SERVICING 10. Remove retaining ring (A), bearing (B), and seals (C) from bearing housing (D). 11. Apply oil to the bore before assembling the parts. 12. Install seals (C) into bearing housing (D). NOTE: Ensure that the flat side of the seal is facing inward. 13.
Page 418: Lowering Feed Deck Pan
MAINTENANCE AND SERVICING 18. Rotate idler roller housing (A) until the holes in the lower tabs align with the hole in welded tab (B). 19. Align the hole in cast support (D) with the holes in the upper tab on idler roller housing (A). 20.
Page 419 MAINTENANCE AND SERVICING 4. On the underside of the feed deck, rotate latch (A) to unlock handle (B). Repeat this step on the opposite end of the feed deck. Figure 4.205: Underside of Feed Deck 5. Hold pan (A) and rotate handle (B) downward to release the pan.
Page 420: Raising Feed Deck Pan
MAINTENANCE AND SERVICING 4.10.6 Raising Feed Deck Pan The feed deck pan protects the feed draper from items on the ground. It can be opened and closed to access the feed draper. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 421: Checking Breakaway Hooks
MAINTENANCE AND SERVICING 3. Rotate handles (A) upwards, bringing the feed deck pan into the locked position. NOTE: Ensure that all three deck pan hooks (B) are secured on the lock handle. 4. Hold the feed deck pan in place, and rotate latch (C) to lock handle (A).
Page 422 MAINTENANCE AND SERVICING NOTE: Figure 4.212, page 398 shows an undamaged breakaway hook (A) and a damaged breakaway hook (B). A stretched breakaway hook is not shown. Figure 4.212: Link Breakaway Hooks NOTE: To move hook (A) to the storage position, loosen bolt (B) and rotate the hook by 90°.
Page 423: Stripper Bars
MAINTENANCE AND SERVICING 4.11 Stripper Bars Stripper bars are installed into the float module opening to improve feeding in crops such as rice. They may need to be removed depending on the desired float module configuration. 4.11.1 Removing Stripper Bars The stripper bars are secured to the float module frame with four bolts and nuts.
Page 424 MAINTENANCE AND SERVICING 2. Position stripper bar (B) as shown so the notch is at the corner of the frame. 3. Secure stripper bar (B) to the float module with four bolts and nuts (A). Ensure that the nuts face the combine. NOTE: If the lower bolts and nuts are too difficult to install, install the upper two bolts only.
Page 425: Header Side Drapers
MAINTENANCE AND SERVICING 4.12 Header Side Drapers There are two drapers, one on each side of the header. They convey cut crop to the float module feed draper and auger. Replace the drapers if they are torn, cracked, or missing slats. 4.12.1 Removing Side Drapers Replace the drapers if they are torn, cracked, or missing slats.
Page 426 MAINTENANCE AND SERVICING 7. Locate draper tension adjuster (A). 8. Turn bolt (B) counterclockwise to decrease the tension on the draper. Tension indicator (C) will move outboard to show that the draper is loosening. IMPORTANT: To avoid premature failure of the draper, draper rollers, and/or tightener components, do NOT operate the header when the tension indicator is not visible.
Page 427: Installing Side Drapers
MAINTENANCE AND SERVICING 10. Remove nuts and screws (A), and tube connectors (B) from the draper joint. 11. Remove screws (C), bridge connector (D), and nuts from the front end of the draper joint. 12. Remove the side draper from the deck. Figure 4.219: Draper Connectors 4.12.2 Installing Side Drapers The side drapers bring cut crop to the center of the header.
Page 428 MAINTENANCE AND SERVICING 6. Place draper on feed draper deck. 7. Insert the end of draper (A) into the inboard end of side draper deck (B) under drive roller (C). NOTE: The slats on the draper should be facing down. Figure 4.220: Draper 8.
Page 429: Adjusting Side Draper Deck Height
MAINTENANCE AND SERVICING 9. Attach the ends of the draper with tube connectors (B), screws (A) (with the heads facing the center opening), and nuts. NOTE: The two short tube connectors are attached at the front and the rear of the draper. 10.
Page 430 MAINTENANCE AND SERVICING 1. Lower the header to a comfortable working position 2. Shut down the engine, and remove the key from the ignition. NOTE: Take measurements at deck supports (A), refer to illustration at right, when the header is in the working position.
Page 431: Adjusting Side Draper Tension
MAINTENANCE AND SERVICING NOTE: The draper has been removed in the image to show the deck. 7. Loosen two lock nuts (A) on deck support (B) by one half-turn ONLY. 8. Tap deck (C) with a hammer and a block of wood to lower the deck relative to the deck supports.
Page 432 MAINTENANCE AND SERVICING IMPORTANT: The draper tension is set at the factory, and should not require adjustment. If adjustment is necessary, ensure that the tension is set so that the draper does not slip or sag below the cutterbar. Excessive tension on the draper can damage the draper drive and rollers.
Page 433 MAINTENANCE AND SERVICING 6. Ensure that idler roller (A) is between guides (B). Figure 4.231: Idler Roller 7. Tighten adjuster bolt (A) until the tensioner indicator covers the inboard half of the window. Tensioner indicator (B) will move inboard to show that the draper is tightening. IMPORTANT: To avoid premature failure of the draper, draper rollers, and/or the tightener components, do NOT operate the...
Page 434: Adjusting Side Draper Tracking
MAINTENANCE AND SERVICING 4.12.5 Adjusting Side Draper Tracking If the side drapers rub the header frame during operation, the draper tracking may need to be adjusted. Figure 4.233: Draper Tracking Adjustments – Left Draper A - Drive Roller B - Idler Roller C - Drive Roller Adjust D - Idler Roller Adjust E - Draper Direction...
Page 435: Inspecting Draper Roller Bearing
MAINTENANCE AND SERVICING 2. Adjust drive roller (A) to change C (refer to Table 4.2, page 410 and Figure 4.233, page 410) as follows: Loosen nuts (F), (M), and (N), and jam nut (G). b. Turn adjuster nut (H). Tighten nuts (F), (M), and (N), and jam nut (G). 3.
Page 436 MAINTENANCE AND SERVICING WARNING To prevent bodily injury from the fall of a raised reel, always engage the reel safety props before going under the raised reel for any reason. 1. Engage the header until you can access the side draper connector from the outboard end of the deck. 2.
Page 437: Replacing Side Draper Deck Idler Roller Bearing
MAINTENANCE AND SERVICING 8. Remove screws (C), bridge connector (D), and the nuts from the front end of the draper joint. 9. Remove nuts and screws (A) and tube connectors (B) from the draper joint. 10. Pull the draper off the idler roller. Figure 4.236: Draper Connectors 11.
Page 438 MAINTENANCE AND SERVICING 2. Clamp idler roller tube (C) in a vise with a cloth wrapped around the roller to prevent damage to the roller. 3. Remove bearing assembly (A) and seal (B) from roller tube (C) as follows: Attach slide hammer (D) to threaded shaft (E) in the bearing assembly.
Page 439 MAINTENANCE AND SERVICING 5. Cut relief (A) into a block of wood. 6. Place the end of idler roller (B) onto the block of wood, with the protruding bearing assembly inside of relief (A). Figure 4.240: Idler Roller 7. Install new bearing assembly (C) by pressing the outer race of the bearing into the tube until it is 14–15 mm (9/16–19/32 in.) (B) from the outside edge of the tube.
Page 440: Installing Side Draper Deck Idler Roller
MAINTENANCE AND SERVICING 4.12.9 Installing Side Draper Deck Idler Roller The side draper deck has a roller on each end of the deck. One roller is the idler roller and one roller is the drive roller. If the idler roller is worn or damaged, it will need to be replaced. DANGER Ensure that all bystanders have cleared the area.
Page 441 MAINTENANCE AND SERVICING 8. Secure the ends of the draper with tube connectors (B) and screws and nuts (A). IMPORTANT: Install the screws so that the heads face inboard. NOTE: The two short tube connectors are attached at the front and rear of the draper.
Page 442: Removing Side Draper Drive Roller
MAINTENANCE AND SERVICING 4.12.10 Removing Side Draper Drive Roller The side draper deck has a roller on both ends of the deck. One roller is the idler roller and the other roller is the drive roller. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 443 MAINTENANCE AND SERVICING 8. Remove nuts and screws (A), and tube connectors (B) from the draper joint. 9. Remove screws (C), bridge connector (D), and the nuts from the front end of the draper joint. 10. Pull the draper off the drive roller. Figure 4.247: Draper Connectors 11.
Page 444: Replacing Side Draper Drive Roller Bearing
MAINTENANCE AND SERVICING NOTE: It may be necessary to pry between the roller and bracket (A) to remove the roller from the shaft. Retain the key. Figure 4.249: Drive Roller 13. Loosen two bolts (A) securing support arm (B). 14. Remove bolt (C) and the washer securing the opposite end of the drive roller to support arm (B).
Page 445: Installing Side Draper Drive Roller
MAINTENANCE AND SERVICING 3. Remove bearing assembly (A) and seal (B) from roller tube (C) as follows: Attach slide hammer (D) to threaded shaft (E) in the bearing assembly. b. Tap out bearing assembly (A) and seal (B). 4. Clean the inside of roller tube (C), check the tube for signs of wear or damage, and replace it if necessary.
Page 446 MAINTENANCE AND SERVICING WARNING To prevent bodily injury from the fall of a raised reel, always engage the reel safety props before going under the raised reel for any reason. 1. Raise the header fully. 2. Raise the reel fully. 3.
Page 447 MAINTENANCE AND SERVICING 14. Wrap the draper over the drive roller and attach the ends of the draper with tube connectors (B), screws (A) (with the heads facing the center opening), and nuts. NOTE: The two short tube connectors are attached at the front and the rear of the draper.
Page 448: Reel
MAINTENANCE AND SERVICING 4.13 Reel The reel features a uniquely shaped cam, which allows the fingers to get underneath lodged crop and pick it up before it is cut. CAUTION To avoid personal injury, before servicing the machine or opening the drive covers, refer to 4.1 Preparing Machine for Servicing, page 269.
Page 449 MAINTENANCE AND SERVICING 3. Single-reel headers: Raise the header high enough to place two 254 mm (10 in.) high blocks (A) under the cutterbar, just inboard of the wing flex points. Block Locations – ® Figure 4.258: FlexDraper Single Reel 4.
Page 450 MAINTENANCE AND SERVICING 7. Rotate the reel by hand until a tine tube is directly above the cutterbar. 8. Measure and record clearance (A) between the tip of the fingers and one of the guards at the end of the reels, either pointed guard (B) or short guard (C).
Page 451: Adjusting Reel-To-Cutterbar Clearance
MAINTENANCE AND SERVICING Double-reel measurement locations (A): Outer ends of the reels and at both hinge points (four places). Measurement Locations – Figure 4.263: FlexDraper ® Double Reel Triple-reel measurement locations (A): Both ends of three reels (six places). 9. Adjust the reel-to-cutterbar clearance, if necessary. For instructions, refer to Adjusting Reel-to-Cutterbar Clearance, page...
Page 452 MAINTENANCE AND SERVICING 2. Adjust the clearance at the outboard ends of the reel as follows: Loosen bolt (A) on the outer arm cylinder. b. Adjust cylinder rod (B) as needed: • To increase the clearance between the reel fingers and the cutterbar, turn cylinder rod (B) out of the clevis.
Page 453: Reel Frown
MAINTENANCE AND SERVICING 13. Check the reel-to-cutterbar clearance measurements again. If necessary, repeat the adjustment procedures. 14. Move the reel back to ensure that the reel fingers do not contact the deflector shields. 15. If the reel fingers contact the deflector shields, adjust the reel upward to maintain the clearance at all reel fore-aft positions.
Page 454: Centering Reel
MAINTENANCE AND SERVICING 4.13.3 Centering Reel The reel needs to be centered on the header to avoid any contact with the end panels. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key before adjusting the machine.
Page 455: Removing Air From Reel Lift Hydraulic System
MAINTENANCE AND SERVICING 5. Loosen bolt (A) on brace (B) on the center support arm. 6. Move the forward end of reel support arm (C) laterally as needed to center the reel. 7. Torque bolt (A) to 457 Nm (337 lbf·ft). Figure 4.270: Center Support Arm 4.13.4 Removing Air from Reel Lift Hydraulic System Purge air from the hydraulic reel lift system after replacing a component.
Page 456: Removing Steel Reel Fingers
MAINTENANCE AND SERVICING Removing Steel Reel Fingers Damaged steel fingers will need to be cut off of the reel tine tube. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 457: Removing Plastic Reel Fingers
MAINTENANCE AND SERVICING DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. WARNING To prevent bodily injury from the fall of a raised reel, always engage the reel safety props before going under the raised reel for any reason.
Page 458: Installing Plastic Reel Fingers
MAINTENANCE AND SERVICING ® 5. Remove screw (A) using a Torx Plus 27 IP socket wrench. Figure 4.274: Removing Plastic Finger 6. Push the clip at the top of the finger back toward the reel tube as shown and remove the finger from the tube. Figure 4.275: Removing Plastic Finger Installing Plastic Reel Fingers Once the old plastic reel finger has been removed, the new one can be installed.
Page 459: Tine Tube Bushings
MAINTENANCE AND SERVICING 1. Position the new finger on the rear of the tine tube. Engage the lug at the bottom of the finger in the lower hole in the tine tube. 2. Lift the top flange and rotate the finger as shown until the lug in the top of the finger engages the upper hole in the tine tube.
Page 460 MAINTENANCE AND SERVICING IMPORTANT: Support the tine tube at all times to prevent damage to the tube and other components. 1. Lower the header. 2. Raise the reel fully. 3. Shut down the engine, and remove the key from the ignition. 4.
Page 461 MAINTENANCE AND SERVICING 8. Rotate tine tube arm (A) until it is clear of the disc, and then slide the arm inboard off of bushing (B). 9. Remove bushing halves (B). If necessary, remove the next finger, so that the arm can slide off of the bushing. Refer to the following procedures as needed: •...
Page 462: Installing Bushings Onto Reels
MAINTENANCE AND SERVICING Installing Bushings onto Reels Once the old tine tube bushing halves have been removed, the new ones can be installed. NOTE: This procedure assumes the steps for Removing Bushings from Reels, page 435 have been completed. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 463 MAINTENANCE AND SERVICING 5. Install bushing clamp (A) onto the tine tube adjacent to the flangeless end of bushing (B). 6. Position clamp (A) on bushing (B) so that the edges of the clamp and the bushing are flush when the clamp fits into the groove on the bushing and when the lock tabs are engaged.
Page 464 MAINTENANCE AND SERVICING 9. Install bolts (A) securing tine tube arm (B) to the center disc. 10. Install tine tube arm (B) and endshield support (C) onto the tail end of the reel at the applicable tine tube location. Secure the support with bolts (A). NOTE: There are no endshields on the center discs.
Page 465: Reel Endshields
MAINTENANCE AND SERVICING 16. Install bushing clamp (A) onto the tine tube adjacent to the flangeless end of bushing (B). 17. Position clamp (A) on bushing (B) so that the edges of the clamp and the bushing are flush when the clamp fits into the groove on the bushing and when the lock tabs are engaged.
Page 466: Replacing Reel Endshields At Outboard Cam End
MAINTENANCE AND SERVICING There are four kinds of reel endshields. Ensure that you are installing the correct reel endshield to the proper location as shown in Figure 4.294 Reel Endshields, page 442. Figure 4.294: Reel Endshields A - Tail End, Outboard (MD #311695) B - Cam End, Inboard (MD #273823) C - Tail End, Inboard (MD #311795) D - Cam End, Outboard (MD #311694)
Page 467 MAINTENANCE AND SERVICING 3. Rotate the reel manually until reel endshield requiring replacement (A) is accessible. 4. Remove three bolts (B). Figure 4.295: Reel Endshields – Outboard Cam End 5. Remove two screws and nuts (A). Remove the outboard cam deflector. 6.
Page 468: Replacing Reel Endshields At Inboard Cam End
MAINTENANCE AND SERVICING 8. Slightly lift the end of old reel endshield (A) off of support (B). 9. Position new reel endshield (C) onto support (B) under old reel endshield (A). 10. Position the other end of new reel endshield (C) onto other support (D) over old reel endshield (E).
Page 469 MAINTENANCE AND SERVICING 6. Remove and retain two screws (A), the cam deflector, and the nuts from the reel endshield. 7. Lift the end of reel endshield (B) off support (C). Figure 4.300: Reel Endshields – Inboard Cam End 8. Remove the reel endshield from supports (A). Figure 4.301: Reel Endshield Removed –...
Page 470: Replacing Reel Endshields At Outboard Tail End
MAINTENANCE AND SERVICING Replacing Reel Endshields at Outboard Tail End If the reel endshield is damaged, it will need to be replaced. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 471: Replacing Reel Endshields At Inboard Tail End
MAINTENANCE AND SERVICING 7. Remove the reel endshield from supports (A). 8. Remove the reel paddle, if it is installed on the reel endshield. NOTE: Reel end paddles (B) are installed alternately on the reel endshields. Figure 4.305: Reel Endshield Removed – Outboard Tail End 9.
Page 472 MAINTENANCE AND SERVICING 4. Rotate the reel manually until reel endshield requiring replacement (A) is accessible. 5. Remove six M10 screws and nuts (B). Figure 4.307: Reel Endshields – Inboard Tail End 6. Lift other endshield (A) to disengage the tab from endshield (B).
Page 473 MAINTENANCE AND SERVICING 11. Position new reel endshield (A) as shown. Insert the endshield tab into neighboring endshield (B). 12. Position the other end of new endshield (A) on the tine tube. Secure the endshield with bushing (C). Figure 4.310: Reel Endshields – Inboard Tail End 13.
Page 474: Replacing Reel Endshield Supports
MAINTENANCE AND SERVICING Replacing Reel Endshield Supports The reel endshield supports need to be replaced if they are damaged. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 475 MAINTENANCE AND SERVICING 9. Secure support (A) to the disc sector with bolt and nut (B). Do NOT tighten the hardware yet. 10. Secure reel endshields (C) to support (A) with bolt and nut (D). Do NOT tighten the hardware yet. 11.
Page 476: Reel Drive
MAINTENANCE AND SERVICING 4.14 Reel Drive The hydraulically driven reel motor drives a chain that is attached to the center arm between the reels on a double-reel header, and to the left-center arm on a triple-reel header. 4.14.1 Reel Drive Chain The reel drive chain transfers power from the hydraulically driven reel motor to the sprockets that rotate the reels.
Page 477: Tightening Reel Drive Chain
MAINTENANCE AND SERVICING IMPORTANT: Do NOT loosen the motor mount, as it is factory-adjusted and secured with Belleville washers. Adjust the chain tension without loosening the drive mounting bolts. 8. Push tension retainer (A) clockwise with your thumb, and hold it in the unlocked position. 9.
Page 478: Reel Drive Sprocket
MAINTENANCE AND SERVICING 5. Place multi-tool (A) onto chain tensioner (B). IMPORTANT: Do NOT loosen the motor mount, as it is factory-adjusted and secured with Belleville washers. Adjust the chain tension without loosening the drive mounting bolts. 6. Rotate multi-tool (A) downward until the chain is tight. Figure 4.319: Reel Drive 7.
Page 479: Removing Reel Drive Single Sprocket
MAINTENANCE AND SERVICING NOTE: A two-speed reel drive option is available. Order kit MD #311882. Removing Reel Drive Single Sprocket The reel drive sprocket is attached to the reel drive motor. The speed and torque of the reel can be changed by changing the drive and driven sprockets.
Page 480: Installing Reel Drive Single Sprocket
MAINTENANCE AND SERVICING Installing Reel Drive Single Sprocket The reel drive sprocket is attached to the reel drive motor. The speed and torque of the reel can be changed by changing the drive and driven sprockets. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 481 MAINTENANCE AND SERVICING Figure 4.326: Reel Drive Configurations—Optional Dual Sprockets A - Dual Sprocket in High-Torque Configuration WITH the Optional 52-Tooth Sprocket Installed but NOT Required B - Dual Sprocket in High-Torque Configuration WITHOUT the Optional 52-Tooth Sprocket C - Dual Sprocket in High-Speed Configuration WITH the Optional 52-Tooth Sprocket Installed and Required DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 482 MAINTENANCE AND SERVICING 3. Loosen reel drive chain (A). For instructions, refer to Loosening Reel Drive Chain, page 452. 4. Remove reel drive chain (A) from reel drive dual sprocket (B). Figure 4.327: Dual Sprocket in High-Torque Configuration 5. Remove the cotter pin and slotted nut (A) from motor shaft (B).
Page 483: Installing Reel Drive Optional Dual Sprocket
MAINTENANCE AND SERVICING Installing Reel Drive Optional Dual Sprocket Follow the procedure to install the reel drive optional dual sprocket. Figure 4.329: Reel Drive Configurations—Optional Dual Sprockets A - Dual Sprocket in High-Torque Configuration WITH the Optional 52-Tooth Sprocket Installed but NOT Required B - Dual Sprocket in High-Torque Configuration WITHOUT the Optional 52-Tooth Sprocket C - Dual Sprocket in High-Speed Configuration WITH the Optional 52-Tooth Sprocket Installed and Required The optional dual sprocket, when paired with the factory-installed 56-tooth sprocket, will provide more torque to the reel...
Page 484 MAINTENANCE AND SERVICING 1. Position the dual sprocket so that smaller sprocket (A) is closer to reel motor (B). 2. Align the keyway in the sprocket with the key on the motor shaft, and slide the sprocket onto the shaft. Secure the sprocket with slotted nut (C).
Page 485: Changing Reel Speed Chain Position With Two Speed Kit Installed
MAINTENANCE AND SERVICING 4.14.3 Changing Reel Speed Chain Position with Two Speed Kit Installed The reel drive sprocket is attached to the reel drive motor. The speed and torque of the reel can be changed by changing the drive and driven sprockets. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 486 MAINTENANCE AND SERVICING Table 4.4 Reel Speed Sensor Combine Compatibility Combine Brand Combine Model Series Sensor Type 5/6/7088; 7/8010; 7/8/9120; 130, 140, 150, 230, 240, 65T disc with sensor 328329 Case IH 250; AF9/10/11 Series Type 2 in Figure 4.335, page 463 2.
Page 487 MAINTENANCE AND SERVICING Figure 4.335: Reel Speed Sensor and Disc Configurations 6. Remove the top nut from the new sensor and position sensor (B) onto the support. Secure it with top nut (A). 7. Use Table and Figure 4.335, page 463 to determine the sensor type for the combine, and adjust the sensor nuts to set gap (C) to the following specification: •...
Page 488 MAINTENANCE AND SERVICING 8. Connect electrical connector (A) to the header harness, and slide the connector forward to engage the retaining clip. IMPORTANT: Ensure that the sensor electrical harness does NOT contact the chain or sprocket. 9. Reinstall the drive cover. For instructions, refer to Installing Reel Drive Cover, page Figure 4.336: Reel Speed Sensor...
Page 489: Contour Wheels - Option
MAINTENANCE AND SERVICING 4.15 Contour Wheels – Option The ContourMax™ Contour Wheels option allows the header to flex with the contours of the field leaving a consistent stubble height while cutting up to 46 cm (18 in.) above the ground. 4.15.1 Checking Wheel Bolt Torque —...
Page 490: Leveling Contour Wheel Height
MAINTENANCE AND SERVICING 4.15.2 Leveling Contour Wheel Height The contour wheels allow the header to follow the contours of the ground, and can be adjusted between 25 mm (1 in.) and 457 mm (18 in.) from the ground surface. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 491 MAINTENANCE AND SERVICING 7. Lower the header until auto header height indicator arm (A) is at number 2 (B). 8. Shut down the engine, and remove the key from the ignition. Figure 4.340: Auto Header Height Indicator 9. At the center of the header, measure distance (A) from the ground to the tip of the center guard.
Page 492: Lubricating Contour Wheel System
MAINTENANCE AND SERVICING 15. Remove pin (A). 16. Reposition adjuster plate (B) in the slot to align with a different hole. There is approximately a 24 mm (1/2 in.) difference between each of the holes. • If the measurement is less than the measurement at the center of the header, move the adjuster plate TOWARD the cutterbar.
Page 493 MAINTENANCE AND SERVICING 1. Raise the header fully. 2. Shut down the engine, and remove the key from the ignition. 3. Engage the header safety props or support the header on blocks on level ground. If you are using blocks to support the header, ensure the header is approximately 914 mm (36 in.) off the ground.
Page 494: Checking Contour Wheel End Play
MAINTENANCE AND SERVICING 6. Apply grease at lubrication point (A), and allow the excess grease to flow out the front of the axle hub. IMPORTANT: Grease the lubrication point SLOWLY. Rapid greasing may force the rear seal to move. 7. Reinstall rubber plug (B). 8.
Page 495 MAINTENANCE AND SERVICING 2. Check the end play on wheel assemblies (A). Figure 4.347: Contour Wheel Assemblies 3. If end play (A) is greater than 0.3 mm (0.012 in.), remove dust cap (B). Figure 4.348: Contour Wheel End Play and Dust Cap 262653 Revision A...
Page 496: Contour Wheels - Zeroing Mechanical Indicator
MAINTENANCE AND SERVICING 4. Remove cotter pin (A). 5. Tighten castle nut (B) until it is snug, then back off to the next slot in the castle nut. IMPORTANT: There should be some play in the wheel assembly. Overtightening the castle nut can cause failure. 6.
Page 497 MAINTENANCE AND SERVICING Figure 4.350: Mechanical Indicator 1. Shut down the engine, and remove the key from the ignition. 2. Check that the mechanical indicator is zeroed by ensuring that the notch in indicator (A) aligns with hole (B) under the following conditions: •...
Page 498: Transport System - Option
MAINTENANCE AND SERVICING 4.16 Transport System – Option The header can be equipped with a set of transport wheels, so that the header can be towed by a combine or tractor. ™ Refer to Adjusting EasyMove Transport Wheels, page 130 for more information.
Page 499 MAINTENANCE AND SERVICING Figure 4.352: Transport System Assembly Bolts 1. Check the following bolts DAILY to ensure that the bolts are torqued to the specified values: • Bolts (A) to 234 Nm (173 lbf·ft) • Bolts (B) to 343 Nm (253 lbf·ft) •...
Page 500: Checking Tire Pressure
MAINTENANCE AND SERVICING 4.16.3 Checking Tire Pressure Proper tire pressure ensures the tires perform properly and wear evenly. WARNING • During inflation, a tire can explode and cause serious injury or death. • Do NOT stand over the tire. Use a clip-on chuck and an extension hose.
Page 501: Changing Tow-Bar Hitch Connection From Pintle To Clevis
MAINTENANCE AND SERVICING 4.16.4 Changing Tow-Bar Hitch Connection from Pintle to Clevis The transport tow-bar includes clevis and pintle ring towing mounts. 1. Remove the hairpin from clevis pin (A) and disconnect chain (B). Store clevis pin (A) with the pintle hitch adapter. 2.
Page 502 MAINTENANCE AND SERVICING 6. Retrieve the clevis adapter. 7. Insert transport connector (A) of the electrical harness through opening (B) in the ring on the clevis adapter. 8. Secure pull-line (C) to the harness. Using the pull-line, gently pull the harness through the tow-bar. 9.
Page 503: Changing Tow-Bar Hitch Connection From Clevis To Pintle
MAINTENANCE AND SERVICING 13. Tighten nuts (A) in the cross pattern shown. Recheck each nut in sequence until they are torqued to 310 Nm (229 lbf·ft). 14. Insert the hitch pin into the clevis adapter. Secure the pin with the lynch pin. NOTE: The pins are not shown in the illustration.
Page 504 MAINTENANCE AND SERVICING 3. Tape or tie 6 m (20 ft.) of pull-line to harness transport end (A). 4. Remove bolt (B) securing the harness in the P-clip. Retain the bolt for reinstallation. 5. From hitch end (C), gently pull the harness out through the opening in clevis (D) until you can see the pull-line, then disconnect the pull-line and set the clevis adapter aside.
Page 505 MAINTENANCE AND SERVICING 10. Reinstall four nuts, four bolts, and eight flat washers (A) to secure the pintle ring adapter to the tow-bar. NOTE: Ensure that hardware (A) is reinstalled with the four bolt heads on the same side. 11. Reconnect the chain with clevis pin (B) and secure it with the cotter pin.
Page 506: Vertiblade ™ Vertical Knife (Option)
MAINTENANCE AND SERVICING ™ 4.17 VertiBlade Vertical Knife (Option) The optional vertical knife kit is a vertical crop cutter that is mounted to each end of the header. The vertical knife slices through tangled, shatter-prone crops such as canola to reduce seed loss. 4.17.1 Replacing Vertical Knife Sections ™...
Page 507 MAINTENANCE AND SERVICING 6. Remove three bolts (A) securing milling bar (B) to the blade bracket and knife section assembly (C). 7. Tilt milling bar (B) upward. 8. Slide assembly (C) out. A A A Figure 4.365: Vertical Knife – Guard Removed NOTE: If you cannot tilt milling bar (A) upward enough to slide knife section assembly (B) out, remove bolts (C) securing...
Page 508 MAINTENANCE AND SERVICING 9. Remove two screws (A) and nuts (B) securing knife section (C) to bracket (D). 10. Apply medium-strength threadlocker (Loctite ® 243 or an equivalent) to two new screws (A) (MD #313790). 11. Secure new knife section (C) (MD #313788) to bracket (D) using two screws (A) and nuts (B) (MD #313789).
Page 509: Lubricating Vertical Knife
MAINTENANCE AND SERVICING 4.17.2 Lubricating Vertical Knife Each vertical knife has two lubrication points, which you can access by removing the knife’s service panel. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 510: Changing Vertiblade ™ Vertical Knife Position
MAINTENANCE AND SERVICING 4. Apply grease to push rod grease zerks (A). Figure 4.371: Grease Zerks on Vertical Knife Push Rods 5. Reinstall access cover (B). 6. Secure the access cover with screws (A). 7. Repeat Step 3, page 485 to Step 6, page 486 to lubricate...
Page 511 MAINTENANCE AND SERVICING 2. Remove lynch pin (B), then detach vertical knife shield (A). Figure 4.373: Vertical Knife 3. Remove bolt, washers, nuts (A), and hex socket screws (B). 4. Remove both knifehead outer covers (C). Figure 4.374: Knifehead Outer Covers 5.
Page 512 MAINTENANCE AND SERVICING 7. Support both knife assemblies (C), then remove three bolts (A) securing outer knifehead (B). 8. Remove bolt (D), and then remove outer knifehead (B). Figure 4.376: Outer Knifehead 9. Remove three bolts (A) securing inner knifehead (B) to inner knife assembly (C).
Page 513 MAINTENANCE AND SERVICING 13. Support knife assembly (A). 14. Remove bolts and washers (B). Clean any existing threadlocker from the bolts. 15. Apply medium-strength threadlocker (Loctite ® 243 or equivalent) to the threads of the retained bolts. 16. Reposition knife assembly (A) until the correct configuration holes line up with the holes on the frame.
Page 514 MAINTENANCE AND SERVICING 21. Install the original outer knifehead at inner knifehead (A) position. NOTE: The extended part of the knifehead should face down when combine configured. 22. Install bolt (C) to secure inner knifehead (A) to the ball joint. NOTE: The bolt head should be on the inboard side of the ball joint.
Page 515 MAINTENANCE AND SERVICING 29. Install both knifehead outer covers (C). 30. Install bolts, washers, nuts (A), and hex socket screws (B). Figure 4.383: Knifehead Outer Covers 31. Install vertical knife shield (A) and secure it with lynch pin (B). Figure 4.384: Vertical Knife 262653 Revision A...
Page 517: Chapter 5: Options And Attachments
Chapter 5: Options and Attachments The following options and attachments are available for use with your header. See your Dealer for availability and ordering information. 5.1 Crop Delivery Kits Crop delivery is the process of how the crop gets from the cutterbar to the feeder house. Optional crop delivery kits can optimize header performance for specific crops or conditions.
Page 518: Crop Divider Storage Bracket Kit
OPTIONS AND ATTACHMENTS 5.1.3 Crop Divider Storage Bracket Kit The crop divider storage bracket kit can store standard, rice, or floating crop dividers on the header. Installation instructions are included in the kit. B7030 Figure 5.3: Divider Storage Bracket Kit 5.1.4 Floating Crop Dividers Floating crop dividers help the header follow contours in the ground, improve crop dividing, and reduce trampling.
Page 519: Full Length Upper Cross Auger
OPTIONS AND ATTACHMENTS 5.1.5 Full Length Upper Cross Auger The upper cross auger (UCA) attaches to the header in front of the backtube and improves crop feeding to the center of the header in heavy crop conditions. The upper cross auger (A) is ideal for the high-volume harvesting of forages, oats, canola, mustard, and other tall, bushy, hard-to-feed crops.
Page 520: Lodged Crop Reel Finger Kit
OPTIONS AND ATTACHMENTS 5.1.6 Lodged Crop Reel Finger Kit The steel fingers attach to the ends of every other tine bar and help clear material in heavy, hard-to-cut crops such as lodged rice. Each kit contains three fingers for the cam end and three fingers for the tail end of the reel.
Page 521: Sunflower Attachment Kit
OPTIONS AND ATTACHMENTS 5.1.8 Sunflower Attachment Kit This kit allows the FD2 Series FlexDraper ® Header (with pointed guards only) to be converted to a sunflower header. Figure 5.8: Sunflower Attachment Order the Sunflower Attachment Kit according to the size of the header: •...
Page 522: Vertiblade ™ Vertical Knife Kit
OPTIONS AND ATTACHMENTS Deflectors – contain lean bar panels and additional cutterbar pan supports: • FD230 – B7304 • FD235 – B7305 • FD240 triple reel – B7395 • FD240 double reel – B7306 • FD241 double reel – B7306 •...
Page 523: Cutterbar Kits
OPTIONS AND ATTACHMENTS 5.2 Cutterbar Kits The cutterbar is located on the front of the header. It supports the knife and the guards, which together, are used to cut the crop. 5.2.1 Rock Retarder Kit A rock retarder extends the height of the cutterbar lip to help prevent rocks from rolling onto the draper decks. Order bundles by header size: •...
Page 524: Fm200 Float Module Kits
OPTIONS AND ATTACHMENTS 5.3 FM200 Float Module Kits The float module is used to attach the header to the combine. It combines the crop flow from both side drapers and also pulls crop into the combine feeder house. 5.3.1 Crop Deflector Kits This kit includes different sizes of crop deflectors to be installed on the float module depending on the size of the feeder house.
Page 525: Feed Auger High-Wear Flighting Extension Kit
OPTIONS AND ATTACHMENTS Figure 5.13: Extended Center Filler 5.3.3 Feed Auger High-Wear Flighting Extension Kit The flighting extension kit improves the feed of crop in green/wet straw conditions (for example, rice and green cereals). Refer to 3.8.1 FM200 Feed Auger Performance Configurations, page 97 for a list of possible flighting combinations.
Page 526: Full Interface Filler Kit
OPTIONS AND ATTACHMENTS 5.3.4 Full Interface Filler Kit The Full Interface Filler kit provides additional sealing between the float module and the header. NOTE: This kit is only available for European-configured headers. Installation instructions are included in the kit. B7217 Figure 5.15: Full Interface Filler Kit 5.3.5 Hydraulic Reservoir Extension Kit The Hydraulic Reservoir Extension kit extends the breather cap position, allowing the float module to operate on steep...
Page 527: Auto Header Height And Tilt Plug Kits
OPTIONS AND ATTACHMENTS 5.3.6 Auto Header Height and Tilt Plug Kits These kits modify the FM200 Float Module’s auto header height control. Depending on how the combine is configured, you may need to interchange these plugs. • B7196 (Lateral Tilt Plug): This plug sends the combine signals from the left and right sensors and averages the two signals for any center signals required.
Page 528: Header Kits
OPTIONS AND ATTACHMENTS 5.4 Header Kits Header kits add features or enhancements to the header. ™ 5.4.1 ContourMax Contour Wheels Kit ™ The ContourMax provides flex and auto header height control (AHHC) for stubble heights of 25–457 mm (1–18 in.) (standard header provides 0–152 mm [0–6 in.]) ™...
Page 529: Easymove ™ Transport System
OPTIONS AND ATTACHMENTS ™ 5.4.2 EasyMove Transport System ™ The EasyMove Transport System makes it faster than ever to move your header from field to field. When operating in the field, the wheels can also be used as stabilizer wheels. Installation instructions are included in the kit.
Page 530: Inboard Steel End Finger Kit
OPTIONS AND ATTACHMENTS 5.4.3 Inboard Steel End Finger Kit Optional fingers to be used in difficult crops, lodged canola, and forage, where the angled plastic finger yields and distorts from heavy crop loads. Installation instructions are included in the kit. MD #311972 Figure 5.21: Inboard Steel End Finger 5.4.4 Outboard Steel End Finger Kit...
Page 531: Plastic Reel Finger Kit
OPTIONS AND ATTACHMENTS 5.4.5 Plastic Reel Finger Kit Order one of the following based on your header size: • FD225, Single Reel, 6 bat to 9 bat – B7361 • FD230, Double Reel, 6 bat to 9 bat – B7362 •...
Page 532: Side Hill Stabilizer Kit
OPTIONS AND ATTACHMENTS 5.4.7 Side Hill Stabilizer Kit The Side Hill Stabilizer kit is recommended for cutting on side hills with a grade steeper than 5°. Installation instructions are included in the kit. B7028 Figure 5.25: Side Hill Stabilizer Kit 5.4.8 Stabilizer Wheel Kit Stabilizer wheels stabilize the header’s lateral movement when cutting at heights higher than possible with the standard skid shoes.
Page 533: Steel Skid Shoes Kit
OPTIONS AND ATTACHMENTS 5.4.9 Steel Skid Shoes Kit This kit provides extended-wear skid shoes for use in rocky, abrasive conditions. IMPORTANT: This kit is not recommended for use in wet mud or conditions that are prone to sparking. The kit contains two skid shoes. To fully replace a set of standard skid shoes, order the following quantities based on header size: •...
Page 534 OPTIONS AND ATTACHMENTS Table 5.2 Compatibility Table Model Model Year Case IH – AF9, AF10, AF11 Case IH – 7250, 8250, 9250 2019 and newer Case IH Mid-Range – 5160, 6160, 7160 2024 and newer Installation instructions are included with the kit. B7575 86.
Page 535: Chapter 6: Troubleshooting
Chapter 6: Troubleshooting Troubleshooting tables are provided to help you diagnose and solve any problems you may have with the header. 6.1 Crop Loss at Cutterbar Use the following tables to determine the cause of crop loss at the cutterbar and the recommended solution. Table 6.1 Troubleshooting –...
Page 536 TROUBLESHOOTING Table 6.1 Troubleshooting – Crop Loss at Cutterbar (continued) Problem Solution Refer to Reel not frowning or not centered Adjust the reel horizontal position or 3.9.12 Reel Fore-Aft Position, page in header the reel frown • Adjusting Hold-Down – Pointed Adjust the hold-down so that the Knife Guards, page 350 Knife hold-down not adjusted properly...
Page 537: Cutting Action And Knife Components
TROUBLESHOOTING 6.2 Cutting Action and Knife Components Use the following table to determine the cause of the cutting action and knife component problems and the recommended repair procedure. Table 6.2 Troubleshooting – Cutting Action and Knife Components Problem Solution Refer to Symptom: Ragged or uneven cutting of crop •...
Page 538 TROUBLESHOOTING Table 6.2 Troubleshooting – Cutting Action and Knife Components (continued) Problem Solution Refer to Ground speed too high Decrease the ground speed 3.9.7 Ground Speed, page 164 • Adjusting Hold-Down – Pointed Knife Guards, page 350 Improper knife hold-down adjustment Adjust the hold-down •...
Page 539 TROUBLESHOOTING Table 6.2 Troubleshooting – Cutting Action and Knife Components (continued) Problem Solution Refer to Straighten the cutterbar Bent cutterbar Dealer Symptom: Excessive breakage of knife sections or guards • Adjusting Hold-Down – Pointed Knife Guards, page 350 Knife hold-down not adjusted properly Adjust the hold-down •...
Page 540: Reel Delivery
TROUBLESHOOTING 6.3 Reel Delivery Use the following tables to determine the cause of reel delivery problems and the recommended repair procedure. Table 6.3 Troubleshooting – Reel Delivery Problem Solution Refer to Symptom: Reel not releasing material in normal standing crop Reel speed too fast Reduce the reel speed 3.9.6 Reel Speed, page 162...
Page 541 TROUBLESHOOTING Table 6.3 Troubleshooting – Reel Delivery (continued) Problem Solution Refer to Low oil reservoir level on combine NOTE: Fill to the proper level Combine operator’s manual There may be more than one reservoir Replace the relief valve Combine operator’s manual Relief valve malfunction •...
Page 542: Troubleshooting Header And Drapers
TROUBLESHOOTING 6.4 Troubleshooting Header and Drapers Use the following table to determine the header and draper problems and the recommended repair procedure. Table 6.4 Troubleshooting – Header and Drapers Problem Solution Refer to Symptom: Insufficient header lift Low relief pressure Increase the relief pressure Combine Dealer Symptom: Insufficient side draper speed...
Page 543 TROUBLESHOOTING Table 6.4 Troubleshooting – Header and Drapers (continued) Problem Solution Refer to Drapers running too fast in light crop Reduce the draper speed 3.9.8 Side Draper Speed, page 164 Symptom: Material accumulates on the end deflectors and releases in bunches For headers with manual deck shift, trim the deflector or replace with a 3.11 Unplugging Cutterbar, page 245...
Page 544: Cutting Edible Beans
TROUBLESHOOTING 6.5 Cutting Edible Beans Use the following tables to determine the cause of any cutting edible bean problems and the recommended solutions. Table 6.5 Troubleshooting – Cutting Edible Beans Problem Solution Refer to Symptom: Plants are being stripped and left complete or partial plants are being left behind Lower the header to the ground Header off the ground 3.9.2 Cutting on Ground, page 135...
Page 545 TROUBLESHOOTING Table 6.5 Troubleshooting – Cutting Edible Beans (continued) Problem Solution Refer to Parts of vines get caught in pointed guard tips 4.8.6 Short Knife Guards and Hold-Downs, Install the short knife guard NOTE: page 356 conversion kit This problem occurs more in row- cropped beans that are hilled from cultivating.
Page 546 TROUBLESHOOTING Table 6.5 Troubleshooting – Cutting Edible Beans (continued) Problem Solution Refer to Header too heavy Make the header lighter 3.9.4 Header Float, page 140 Header angle too steep Decrease the header angle 3.9.3 Header Angle, page 137 4.8.6 Short Knife Guards and Hold-Downs, Guards plug with debris and/or soil Install short knife guards page 356...
Page 547: Chapter 7: Reference
Chapter 7: Reference Refer to the procedures and information in this chapter as needed. 7.1 Torque Specifications The following tables provide torque values for various bolts, cap screws, and hydraulic fittings. Refer to these values only when no other torque value has been specified in a given procedure. •...
Page 548 REFERENCE Table 7.2 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) 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 18.8 20.8 *167 *185 Figure 7.2: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...
Page 549: Metric Bolt Specifications - Cast Aluminum
REFERENCE Table 7.4 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) 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 7.4: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...
Page 550: O-Ring Boss Hydraulic Fittings - Adjustable
REFERENCE 7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable The standard torque values are provided for adjustable hydraulic fittings. If a procedure specifies a different torque value for the same type and size of fitting found in this topic, refer to the value specified in the procedure instead. 1.
Page 551: O-Ring Boss Hydraulic Fittings - Non-Adjustable
REFERENCE Table 7.6 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable and Non-Adjustable Torque Value Thread Size (in.) SAE Dash Size lbf·ft (*lbf·in) 5/16–24 10–11 *89–97 3/8–24 18–20 *159–177 7/16–20 29–32 21–24 1/2–20 32–35 24–26 9/16–18 40–44 30–32 3/4–16 70–77 52–57 7/8–14 115–127 85–94...
Page 552: O-Ring Face Seal Hydraulic Fittings
REFERENCE Table 7.7 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable and Non-Adjustable (continued) Torque Value Thread Size (in.) SAE Dash Size lbf·ft (*lbf·in) 7/16–20 29–32 21–24 1/2–20 32–35 24–26 9/16–18 40–44 30–32 3/4–16 70–77 52–57 7/8–14 115–127 85–94 1 1/16–12 183–201 135–148 1 3/16–12...
Page 553: Tapered Pipe Thread Fittings
REFERENCE 2. Apply hydraulic system oil to O-ring (B). 3. Align the tube or hose assembly so that the flat face of sleeve (A) or (C) comes into full contact with O-ring (B). 4. Thread tube or hose nut (D) until it is hand-tight. The nut should turn freely until it bottoms out.
Page 554 REFERENCE 3. Thread the fitting into the port until it is hand-tight. 4. Torque the connector to the appropriate torque angle. The turns from finger tight (TFFT) and flats from finger tight (FFFT) values are shown in Table 7.9, page 530.
Page 555: Conversion Chart
REFERENCE 7.2 Conversion Chart This manual uses both SI units (including metric) and US customary units (sometimes referred to as standard units) of measurement. A list of those units along with their abbreviations and conversion factors is provided here for your reference.
Page 557: Index
Index preset cutting height ........242 calibrating AHHC, See auto header height control auto header height control......229 augers ..............313 sensor output voltage auger drive sprockets checking voltage range from the cab....227 adjusting auger drive chain tension ....320 Case IH 240 Series combines .......
Page 558 INDEX crop divider storage bracket kit....... 494 crop dividers............187 bearings floating crop dividers feed draper adjusting ............195 installing drive roller bearing......385 adjusting settings..........94 removing drive roller bearing ......382 installing ............192 side draper removing............191 inspecting draper roller bearing......
Page 559 INDEX removing ............207 wide configuration ..........108 draper roller bearings feed auger flighting..........501 inspecting ............411 feed deck drapers checking breakaway hooks ......... 397 adjusting side draper tracking......410 feed deck pan float modules lowering ............394 adjusting, checking draper tension....377 raising .............
Page 560 INDEX installing ..........123, 325 greasing schedule/records ........270 removing ..........120, 323 ground speed ............164 auger to pan clearance ........313 optional feed auger flighting ......501 feed deck............374 checking breakaway hooks ......397 header angle ............137 feed draper header drapers, See drapers draper tension header drives............
Page 561 INDEX checking oil level ........... 290 lubricating gearbox ........290 inspections reel drive chain..........288 break-in inspections .......... 273 integration kits contour wheels..........132 maintenance and servicing........269 ™ ContourMax checking end play .......... 470 knife drive boxes lubricating ............ 468 changing oil............
Page 562 INDEX reel plastic finger kits ........507 recommended fluids and lubricants ......541 steel finger kits .......... 507 reel clearance stabilizer wheels ..........508 measuring............424 sunflower attachment kit ........ 497 reel drive systems knifehead shields ..........369 adjusting reel shape .......... 429 installing ............
Page 563 INDEX hydraulic safety ............7 side draper speed..........164 maintenance safety ..........5 adjusting ............165 operational safety ..........40 sprockets ............454 reel safety props ..........41 adjusting reel drive chain tension......452 safety sign decals ..........11 optional reel drive sprocket ........ 163 installing decals ..........
Page 564 INDEX front (left) wheels to field position ....254 rear (right) wheels to field position....257 removing tow-bar .......... 250 removing tow-bar from storage......264 storing tow-bar..........253 moving left outboard wheel from transport to working position ............249 tire inflation/pressures........476 transporting header...........
Page 565: Recommended Fluids And Lubricants
Recommended Fluids and Lubricants Ensure that 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. Specification Description Capacities...
Page 566 CUSTOMERS M M a a c c D D o o n n . . c c o o m m DEALERS P P o o r r t t a a l l . . M M a a c c D D o o n n . . c c o o m m Trademarks of products are the marks of their respective manufacturers and/or distributors.

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