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D65 Harvest Header for Combines

1. 169593 105 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 4 2 Break In Inspections ITEM REFER TO ATSMNUTES Secon Check For Loose Hardware Section 8 3 1 Recommended Torques Tighten To Required Torque AT 5 HOURS Check Sickle Drive Belts Tension Section 8 9 8 Sickle Drive Belts Non Timed Drive Periodically Check For First 50 Hours 10 HOURS Sickle Drive Box Mounting Section 8 9 10 1 Mounting Bolts olts Change Adapter Gearbox Oil Section 8 4 5 4 Main Drive Gearbox Lubrication Change Adapter Hydraulic Oil Filter Section 8 5 2 Hydraulic Oil Filter AT 50 HOURS Change Lubricant Section 8 9 10 6 Changing Oil Check Gearbox Chain Tension Section 8 7 5 Gearbox Drive Chain Adjustment 169593 106 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 4 3 Pre Season Annual Service 8 4 4 End of Season 169593 Perform the following the beginning of each operating season A CAUTION Review the Operator s Manual to refresh your memory on safety and operating recommendations e Review all safety decals and other decals on the header and note hazard areas e Be sure all shields and guards are properly installed and secured Never alter or remove safety equipment e Be sure you understand and have practiced safe use of all controls Know the capacity and operating characteristics of the machine e Check the first aid kit and fire ex
2. eed etu Utt a 85 7 13 UINPEUGGING ADAP LIN Mu 85 7 14 UPPER GROSSAUGER 86 TAD TRANSPORTING HEADER cairear ana 87 7 15 1 TT 87 7 15 2 TOWN epee cab acl M M 87 7 15 3 Converting from Transport to Field 88 7 15 4 Converting from Field to Transport 93 8 MAINTENANCE AND SERVICING PONENS SINN SINN URS 96 8 1 PREPARATION FOR SERVICING eeeeeee emen mm nmrI ese enn 96 8 2 HECOMMENDED SAFETY PROCEDURES iota eret eite rubro bes 96 8 3 MAINTENANCE SPECIFICATION erui ot eum ee aep ko ete mee due tuos 97 8 3 1 8010111121999 97 8 3 2 PONE CAIDAS ANAT ON rs is EUM ro ADS cue Du 100 8 3 3 Sealed Bearing Installation 100 8 3 4 Recommended Fluids eee ca tae deep eas 101 8 3 5
3. 35 New Holland 43 IS 196 Auger drive chain 126 drive chain 116 6 125 jer wt nc DEUS 29 tine replacement sabe dec sedibus ine 128 Bearing sealed WAS TAN AMO MERE 100 cet een RR 97 Break In 59 CA25 Delicate Seed Saver 198 Cam AGIOS UMMC ia n 79 operatio mt TET 78 GS OMMDO MEMS N 19 Crop dividers and 80 Cutting 63 e 152 18 Detachment AGCO 50 Case IH 7010 8010 33 SAM ds pP Dom 41 John Deere 60 70 37 New Holland 45 Drapers 149 GICAL ACC 152 145 147 roller maintenance 150 roller seal 151 none TREO 72 TOM SI ON Mop 147 Drive Chain replacement Dm 127 Driveline NER 122 IS Tal AH OM 2 e
4. x 1 3558 Torque pound inches or inch pounds lbf in 16 x 0 1129 miles per hour x 1 6063 kilometers per hour Volume ounces x 29 5735 milliliters 169593 102 Revision B 169593 SECTION 8 MAINTENANCE AND SERVICING 8 4 MAINTENANCE REQUIREMENTS The following maintenance schedule is a listing of periodic maintenance procedures organized by service intervals Regular maintenance is the best insurance against early wear and untimely breakdowns Following this schedule will increase machine life For detailed instructions refer to the specific headings in this section Use the fluids and lubricants specified in Section 8 3 4 Recommended Fluids and Lubricants Log hours of operation and the Maintenance Record on the next page to keep a record of scheduled maintenance You will want to make copies of the Maintenance Record page for this purpose Service Intervals The recommended service intervals are in hours of operation Where a service interval is given in more than one time frame e g 100 hours or Annually service the machine at whichever interval is reached first IMPORTANT Recommended intervals are for average conditions Service the machine more often if operated under adverse conditions severe dust extra heavy loads etc A CAUTION Carefully follow safety messages given under Section 8 1 PREPARATION FOR SERVICING and Section 8 2 RECOMMENDED SAFETY PROCEDURES
5. 197 EVID ICS NS 101 Main Dive GeatbOXcu eames 116 Maintenance and 96 Metric Conversions 102 Operating 63 23 Seo DT 196 Owner Operator Responsibilities 23 5 107 Reel ENT 155 fore aft position 74 KEON nr eee 74 Optional 70 reel cutterbar 153 92 me T S 70 speed SENSO M i 174 a 78 Reel and Reel 153 ReelDrive r E 156 Reel Drive 169 Reel Drive 163 166 Reel Endshield 197 Reel Frown 155 Reel Tines RO PCR T 178 replacement oroen n e e 177 cie a E E 177 Rice Divider 198 Rock Retarder 198 Revision B miele IEEE NL mI 100 Safety decal locations N A uisi rti
6. 16 9 DEFRININONS EET 18 5 19 5 1 COMBINE HEADER 19 5 2 COMBINE ADAPT ilm 20 6 SPECIFICATIONS 21 OPERATION Imc 23 7 1 OWNER OPERATOR RESPONSIBILITIES ine ose tantis ufa ute rada Fatto Debe ete cenam atus 23 7 2 OPERATIONAL SAFETY osea D ales eee ees ees 23 721 LOCKS 24 7 2 2 24 LES 6 a II DI IM dM DE 25 7 2 4 Daly Star UD CNOC aii pta to os eee ME I ee ee 27 7 9 HEADER ATTAGHMENT DETACHMENT eiiis 28 7 3 1 PO ADICl OOl UDe me 28 7 3 2 Case IH 7010 8010 7120 8120 5088 6088 7088 sessi 31 donn Deere 60 and S SCHCS 35 7 3 4 TT 39 7 359 Now oland CR Or dE 43 7 3 6 47 7 4 ATTACHING AND DETACHING HEADER WITH ADAPTER esee 52 7 4 1 PI CTAC MING m KC c 5 52 7 4 2 55 1 5 BREAK IN PERIOD sui aE M tU M Ed 59 7 6 SHUTDOWN PROCEDURE odua Uds 59 Taf HEADER GONTPHOLES istoka ain
7. 155 8 12 4 lg ole GITE cee NET TU PEOR 156 8 12 5 Heel Dnve SDIDOKOE 163 8 12 6 Heel Drive UJoint Double e E ber dra ash 167 8 12 7 FACE DAVE MOON 169 8 12 8 FAC CRC 174 8 12 9 iz TINGS T X 177 8 12 10 Tute DO USOS case 179 8 13 TRANSPORT SY SIEM OPTIONAL a a 183 8 13 1 183 8 13 2 AXIS em Pe 183 8 13 3 TEANA EE 184 9 TROUBLESHOOTING 185 9 1 OROPTIOSSATGUITEBRBADEB nisi eas eat tee cee aes 185 9 2 CUTTING ACTION AND SICKLE COMPONENTS eese nnne nnne nennen nnn nnns 186 9 3 REEL DELIVER irana CET 188 9 4 AND DRAPES cond Jod tu de tae 190 9 5 CUTHNG EDIBLE BEANS aera chen Galt led 193 10 OPTIONS AND ATTACHMENTS 196 10 1 ADJUSTABLE SKID SHOES WITH POLY COVER ororen nnna a aa 196
8. 183 Heladio 93 184 transport nt 88 wheel 183 Transporting Header COM DING E 87 opc ETE TEPORE 87 Troubleshooting GChODNOSS ca sap TP TNR 185 CUTTING ACTION dese tages 186 UE RE 190 edible DEANS 193 heade 190 reel delivery d T 188 SICKIe CORmDOHGbls 186 IMO AGI o MR ERE 199 WIG GUT RT 85 169593 2 INDEX Upper Cross Auger S 86 a utat 197 Vertical MOUMLS 2 197 Vibration Dampers pad 130 Sickle Drive Box OICMANO sedscas afamat eunti audacius aui caet 144 Sickle Drive Box 143 DOS e Een 142 pulley removal installation 142 142 Revision NOTES 169593 202 Revision B AM Ble a MacDon Industries Ltd 680 Moray Street Winnipeg Manitoba Canada 353 t 204 885 5590 f 204 832 7749 MacDon Inc 10708 N Pomona Avenue Kansas City Missouri United States 64153 1924 t 816 891 7313 f 816 891 7323 MacDon Australia Pty Ltd A C N 079 393 721 P O Box 243 Suite 3
9. 122 FEIMOV 5 utei geo edited 121 HONS ANd WINO a 121 Feed Draper tensio Neea a 145 Flighting Extensions essere 28 Float hedde elc M T 66 RT RO MER 66 Gearbox drive chain 124 MAUI GUIV 116 116 169593 INDEX Oevel EE 116 PTT 109 111 113 114 115 Ground Po 65 Ground Speed 71 Guards alid ime AU sro beiodedecatesatesdi S 133 EET PN 133 134 135 replacement aaa 133 Si 134 135 196 Header CONIDOBDOLDIS 19 CONTOS dep Mr oT EE 59 E 66 MO at eT RR E EE D D DO 66 IOV GING e 84 PUD 60 Header m 02i MEE IR NET 66 Header Adapter detach ait acis 52 PLY FAWN 101 Hydraulics dtp 98 MOSESANG MNCS 120 120 6 6 118 OCRA NN 119 S E E rc 120 TM MR 118 POSEN IU RE RECEN E TP EM 118 Knie Tlead Shield uscite Dre vet ore 83 198 SPEEA av dens 73 NUR 121 Lodged Crop Reel Finger Kit
10. rotam rupi a ea estes ees 59 7 8 HEADER SETUP ctia iid delta s bcm assai Eo S Statum 60 7 8 1 Odd c meti d ree 60 7 8 2 PICKUP TAC Cl SC TAGS ds 61 7 9 HEADER OPERATING VARIABLES a e n atate d ra iocos etae ma te haria 63 7 9 1 GT 111819 ge 11010 seer eee meee ieee eRe CAN T ERREUR 63 7 9 2 gla 12 0 2 eee nen A T TETTE eee 66 7 9 3 PACA CI PAGO eC TET acta aa RE 69 7 9 4 E 70 7 9 5 Ground SOC CO see cae ta ciate 71 7 9 6 Bianor oe O RE 72 7 9 7 73 7 9 8 cin ci tia taal 74 7 9 9 POLE 74 7 9 10 THC PUGH Cc 78 7 9 11 ROO ee 80 7 9 12 TOE E E Pe Pe 80 169593 3 Revision B CONTENTS Section Title Page 7 9 13 MCE MEM 82 7 10 BINT ER Ee TS LIU EL Ata 83 7 11 HEADER LEVELLING um Soin 84 7 12 LINPEUGGING
11. 102 8 4 MAINTENANCE menn nenne ene eser ene rsen ese ese eser nnns 103 8 4 1 Maintenance Schegule Recold i9 toe tate tos OR Roue rs Senex Ehe tein e oue 104 8 4 2 sl zi eilsiarsio coegi TE TES 106 8 4 3 Fre SeasoW Annual 107 8 4 4 ASO MR TERR RT MP 107 8 4 5 PD 108 8 5 en a 118 8 5 1 118 8 5 2 PAV ORANG QT oTi cT EP 120 8 5 8 TP T TENERO ET 120 8 6 zziii dc HIPH MN EIER 121 8 7 tee EUR I ME ILI eR ce 121 8 7 1 TACINIOV AL ERE m 121 8 7 2 a Eee RNC 122 8 7 3 sits RR TITRE 122 8 7 4 ATION CETT TNR 123 8 7 5 Gearbox Drive ham Adjustment in dae nx re 124 8 8 Pee 125 8 8 1 FAN GIS AIAG C at ada Sa aca den esd 125 8 8 2 Auger Drive AQS esate ates 126 8 8 3 Auger Drive Chain Replacement tees ot ees Anas 127 8 8 4 Auger LING HeDIacetmefhlszssu civi cay rast FE 128 8 9 SICKLE AND SICKLE DRIVE attese a ba ate e Errare be be nadie ease Meee 130 8 9 1 SICKO OCON M 130 8 9 2
12. M d Have someone check the rom of the sickle 700 850 drive box pulley using a hand held tachometer e Shut down the combine 600 700 3 60 70 600 750 f Compare actual pulley rom with the values in 550 650 the chart in the previous column g If adjustment to the sickle drive box pulley rom 40 525 600 550 700 IS necessary contact your acDon Dealer or 045 NA refer to the Header Technical Manual Refer also to Section 7 8 1 Header Settings for recommended knife speeds in specific crops and crop conditions A WARNING Stop combine engine and remove key before making adjustments to machine A child or even a pet could engage the drive 169593 73 Revision SECTION 7 OPERATION 7 9 8 Heel Height Depending on crop height adjust reel height to carry material through the sickle onto the drapers Operate combine hydraulics as required Refer also to Section 7 9 9 Reel Fore Aft Position REEL HEIGHT CHART CROP CONDITION REEL POSITION Down Also Increase Reel Speed and or Cam Setting Combining Down Rice Bushy or Heavy Standing Indications that reel may be too low are e crop loss over the header back tube e disturbance of crop on the drapers by the reel fingers or e crop being pushed down by the tine tubes IMPORTANT Maintain adequate clearance prevent fingers contacting the knife or the ground Refer to Section 8 12 1 Reel Clearance to Cutte
13. DO HOT tow with aw hi ay capable yehide Weigh of foin vehicle must exceed header vaghi Useonly Tractor AG Combine or proper y configured Macfionm bull Vil ndeoveer Bo low header DO NOT lew 21 tps than 25 maler hi 40 ken bo bess han 5 mio eh Por correr amd sippery or conditions DO HOT when making or coming eut of a urn TOW BAR 129261 193147 FRONT TRANSPORT LEG 193147 LA WARNING sanae niten members wit careto prevent dents Dents will severely weaken hitch inspect hitch before and after each use HITCH MAY BUCKLE IF DENTED RESULTING IN LOSS OF HEADER CONTROL Do not use damaged hitch components Replace immediately Do not attempt to repair damaged hitch components See Manual TOW BAR 193113 169593 11 Revision B SECTION 3 SAFETY Safety Decal Locations cont d UPPER CROSS AUGER 11174682 LH AND RH VERTICAL KNIFE 11174684 169593 12 Revision B SECTION 3 SAFETY 3 3 3 Safety Sign Definitions General Hazard Pertaining To Machine Operation And Servicing CAUTION To avoid injury or death from improper or unsafe machine operation Read the Operator s Manual and follow all safety instructions If you do not have a manual obtain one from your dealer Do not allow untrained persons to operate the machine Review safety instructions with all operators annually Ensure that all s
14. WHY IS SAFETY IMPORTANT TO YOU e ACCIDENTS DISABLE AND KILL e ACCIDENTS COST e ACCIDENTS CAN BE AVOIDED 169593 3 2 SIGNAL WORDS Note the use of the signal words DANGER WARNING and CAUTION with safety messages The appropriate signal word for each message has been selected using the following guidelines A DANGER Indicates an imminently hazardous situation that if not avoided will result in death or serious injury A WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury It is also used to alert against unsafe practices A CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It is also used as a reminder of good safety practices 3 3 SAFETY DECALS a b The safety decals appear on the header at the locations shown on pages 7 to 11 Keep safety decals clean and legible at all times Replace safety decals that are missing or become illegible If original parts on which safety decal was installed are replaced be sure the repair part also bears the current safety decal Safety decals are available from your MacDon Dealer Parts Department 3 3 1 Safety Decal Installation a Be sure the installation area is clean and dry Decide on the exact location before you remove the decal backing paper Remove the smaller portion of the split backing paper Place the dec
15. c After adjusting all hold downs run header at a low engine speed and listen for noise due to insufficient clearance Insufficient clearance will also result in overheating of the sickle and guards Re adjust as necessary 8 9 7 2 Stub Guard Adjustment To adjust the clearance between the hold down and sickle for all stub guards 0 004 0 016 in 0 1 0 4 mm 4 0 040 in 1 0 mm a Torque nuts E to 35 46 N m b Turn the adjuster bolts F Using a feeler gauge clearance from hold down to sickle section should be e 0 004 0 016 in 0 1 0 4 mm at guide tip and e 0 004 0 040 in 0 1 1 0 mm at rear of guide Torque nuts E to 53 72 Revision B 169593 SECTION 8 MAINTENANCE AND SERVICING 8 9 8 Sickle Drive Belts Non Timed Drive This section applies to Single Knife headers and 40 and 45 ft Double Knife headers For Double Knife headers with timed drives refer to Section 8 9 9 Double Knife Drive Belts Timed Drive 8 9 8 1 Tension Adjustment IMPORTANT To prolong belt and drive life do NOT over tighten belt A CAUTION To avoid personal injury before servicing machine or opening drive covers follow procedures in Section 8 1 PREPARATION FOR SERVICING a Open endshield LH SHOWN RH OPPOSITE FOR DK Loosen two bolts A on sickle drive mounting bracket Turn adjuster bolt B to move drive motor until a force of 20 lbf 80 N deflect
16. 10 Torque to 75 85 ft lbf 102 115 11 Remove temporary reel support 12 Re install drive covers 169593 161 9 f Adjust the chain tension ethod 2 Breaking the Chain Grind off head of a link rivet on chain H punch out the rivet and remove chain Grind off the head from one of the link rivets on the new chain and punch out rivet to separate the chain Locate ends of chain on sprocket Install pin connector J not available as a MacDon part into chain preferably from sprocket backside Install connector K onto pins Install spring clip L onto front pin M with closed end of clip in direction of sprocket rotation Locate one leg of clip in groove of aft pin N Press other leg of spring clip over face of aft pin N until it slips into groove Do not press clip lengthwise from closed end Ensure clip is seated in grooves of pins Hefer to Section 8 12 4 1 Tension Adjustment High Torque Drive g HRe install drive covers Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 4 5 Drive Chain Replacement Single Reel Standard Torque Drive a Lower header and reel shut down combine and remove key from ignition b Remove four screws A and remove reel drive cover B d Remove chain F e Position new chain F around sprockets f Slide motor D and motor mount E until tension on chain D is such that hand force deflects the chain 1 8 inch 8 mm a
17. carefully as wheels will drop once the mechanism is released c Carefully pull handle C to release the spring and let the wheel drop to the ground d Lift wheel and linkage with handle D and position linkage in second slot from bottom i Pull pin J swivel wheel clockwise as shown Lower handle C to lock and lock with pin J E a ne 00900998 7 1 n ie 0 ee T Ti z FIELD TO TRANSPORT RH SIDE FIELD TO TRANSPORT RH WHEEL f Remove pin E and install at F to secure j Swivel the right axle K to front of header linkage Turn pin E to lock continued next page g To position the left wheel G pull pin H swivel wheel counterclockwise and re lock with pin H 169593 94 Revision B SECTION 7 OPERATION k Remove pin L raise support M to position shown and re insert pin L IMPORTANT Ensure pin L engages the tube on the axle Swing brace N into position as shown and insert brace into slot O behind cutterbar Position brace so that pin P engages hole in bracket Q m Right hand wheel is now in Transport position 169593 95 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 MAINTENANCE AND SERVICING The following instructions are provided to assist Operator in the use of header Detailed maintenance service and parts information are contained in the Technical Manual and the Parts Catalog whic
18. D65 Harvest Header for Combines OPERATOR S MANUAL Part 169593 Rev 15 The harvesting specialists worldwide This Manual contains instructions for SAFETY OPERATION MAINTENANCE SERVICE information for your new MacDon Model 065 Harvest Header for combines MACDON D65 HARVEST HEADER 1 INTRODUCTION This instructional manual contains information on the D65 Harvest Header and the CA25 Combine Adapter must be used in conjunction with your Combine Operator s Manual The D65 Harvest Header is specially designed as a straight cut header and is equipped to work well in all straight cut conditions whether cutting on or above the ground The CA25 Combine Adapter allows any D65 header to be easily attached to your specific combine CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD ASSEMBLE OR USE THE MACHINE Use this manual as your first source of information about the machine If you follow the instructions given here your header will work well for many years If you require more detailed service information a Service Manual is available from your MacDon Dealer The Table of Contents and the Index will guide you to specific areas Study the Table of Contents to familiarize yourself with how the material is organized Keep this manual handy for frequent reference and to pass on to new Operators or Owners A storage case for this manual is located inside the
19. KNIFE DRIVE PUMP DRIVELINE TRANSITION FRAME HEADER FLOAT LOCK HOSES TO HEADER 169593 20 Revision B SECTION 6 SPECIFICATIONS 6 SPECIFICATIONS enone en on en eerie OVERALL Transport Reel Full Aft 106 2684 Long Dividers Installed Width with CA25 Adapter 98 2500 Long Dividers Removed Inches mm 255 6479 315 8003 375 9527 435 11051 495 12575 555 14099 505 3 4 Not Applicable 12845 Length Transport 547 1 2 601 1 2 Inches mm with Tow Pole RES 13907 15278 2318119080 Height Transport 97 in 2464 mm Estimated Weight Range 3500 4100 4200 5100 4700 5700 5400 5800 Base Header No Adapter Ib kg 3400 1944 1589 1861 1907 2315 2134 2588 2451 2633 6200 2815 CUTTERBAR 1 5 16 in 32 mm Shortest Center Link below ground 52 5 16 in 13 16 in 20 mm below ground 52 13 16 in 1340 mm above Header Cutting 1328 mm above Height 4 5 8 in 117 mm below Longest Center Link ground 46 7 8 in 1192 mm 4 1 8 in 105 mm below ground 47 3 8 in 1204 mm above above Guard Angle Cutterbar on Ground 7 0 12 4 2 0 7 4 SICKLE Single Knife SK Hydraulic Motor C Belt Heavy Duty MD Sickle Drive Box Drive Type Two Hydraulic Motors To C Hydraulic Motor Two B Timing Belts Two Heavy Duty MD Double Knife DK Sickle Drive Boxes Belts Untimed To Heavy Duty MD
20. Re install plate L in the endsheet Close left endshield Re adjust tension of BET new belt after a shot run in period about 5 hours Tension Adjustment Left Drive Double V Belts Loosen two bolts A on endsheet 139 Loosen two bolts B on sickle drive mounting bracket Turn adjuster bolt C to move drive motor until a force of 12 53 deflects V belts D 1 8 in 8 mm at mid span Tighten bolts A and B Re adjust tension of a new belt after a short run in period about 5 hours Removal Left Drive V Belts Loosen two bolts A on endsheet Loosen two bolts B on sickle drive mounting bracket Turn adjuster bolt C to loosen the two V belts D and remove belts Installation Left Drive V Belts IMPORTANT Sickle drive V belts are a matched set Replace both drive belts even if only one needs replacing Do NOT pry belt over pulley loosen adjusting device sufficiently to allow easy installation Install belts D onto drive pulleys Turn adjuster bolt C to move drive motor until a force of 12 53 deflects V belts D 1 8 in 3 mm at mid span Tighten bolts A and B on drive mounting bracket Re adjust tension of a new belt after a short run in period about 5 hours Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 9 2 Right End Drive A CAUTION To avoid personal injury before servicing machine or opening drive covers follow pro
21. anco ri MEER e POA An PS ye Hrej KNIFE DRIVE SHAFT DK TIMED KNIFE DRIVE BEARING DK TIMED DRIVE BOTH SIDES DRIVE BOTH SIDES 15 PUMPS MINIMUM 169593 110 Revision B SECTION 8 MAINTENANCE AND SERVICING EVERY 100 HOURS High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base FLOAT SPRING TENSIONER LH FLOAT PIVOT 2 PLCS TENSIONER RH igi REEL DRIVE CHAIN 1 PLC DR SHOWN SR SIMILAR SEE SECTION 8 12 4 DRIVELINE GUARD 2 PLCS UPPER CROSS AUGER BEARING 1 PLC 169593 111 Revision B Z 2 at SECTION 8 MAINTENANCE AND SERVICING EVERY 100 HOURS cont d BETWEEN LOWER HOLE AND END OF DIPSTICK f SICKLE DRIVE BOX MAIN DRIVE GEARBOX OIL LEVEL CHECK OIL LEVEL WITH TOP OF SICKLE SEE SECTION 8 4 5 4 DRIVE BOX HORIZONTAL 169593 112 Revision B SECTION 8 MAINTENANCE AND SERVICING EVERY 250 HOURS U JOINT HAS AN EXTENDED LUBRICATION CROSS AND BEARING KIT STOP GREASING WHEN GREASING BECOMES DIFFICULT High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide OR IF U JOINT STOPS TAKING GREASE OVERGREASING WILL NLGI Grade 2 Lithium Base DAMAGE U JOINT 6 8 PUMPS IS SUFFICIENT AT FIRST GREASE FACTORY DECREASE GREASE INTERVAL AS U JOINT WEARS AND REQUIRES MORE THAN 6 PUMPS P P rd i s i i i d L T T 2
22. halfway up to open position continued next page Revision B SECTION 7 OPERATON NEW HOLLAND CR CX I Remove hydraulic quick coupler H from Rotate disc P on adapter driveline storage storage plate on combine and clean mating hook and remove driveline from hook surface of coupler p Pull back collar on end of driveline and push onto combine output shaft Q until collar locks Position coupler H onto adapter receptacle and push handle to engage pins into receptacle k Push handle L to closed position until lock button K snaps out Remove cover on adapter electrical receptacle m Remove connector N from combine n Align lugs on connector N with slots in adapter receptacle and push connector onto receptacle Turn collar on connector to lock it in place UNLOCK q Disengage both adapter float locks by moving latch R away from adapter and moving lever S at each lock to lowest position 169593 44 Revision B 7 3 5 2 SECTION 7 OPERATION NEW HOLLAND CR CX co p Detachment a Choose a level area Position header slightly 169593 off the ground Stop engine and remove key A DANGER To avoid bodily injury or death from fall of raised machine always engage lift cylinder stops before going under header for any reason See your Combine Operator s Manual for instructions for use and storage of header lift cylinder stops A CAUTION Stop e
23. 0 prop remains in stored position when not in use yet can be engaged with hand force At center arm use handle C to move lock rod to inboard position E engaging pin D into lock arm Lower reel until props contact cylinder mounts on outer reel arms and pin at center arm Disengage Props Raise reel to maximum height At outer arms push props A back inside arms At center arm use handle C to move lock rod to outboard position F Revision B SECTION 7 OPERATION 7 2 3 Endshields Headers are fitted with a hinged polyethylene endshield on both ends of the header 7 2 3 1 Opening a Remove lynch pin A and tool B from pin C at top rear of endshield b Use tool B to unlock latch D at lower rear corner of endshield c Lift shield at aft end to clear pin C d Swing shield out and away from header while maintaining forward pressure to prevent shield from slipping out of tab E at front of endsheet IMPORTANT Shield is designed to open sufficiently for normal access to the drive system and manual case as shown 169593 25 7 2 3 2 a Maintain forward pressure and swing rear of NOTE more access 15 required to front of drives area carefully disengage front of shield from tab E and swing front of shield away from header IMPORTANT Do NOT force shield once it has reached its end of travel as damage to the shield structure can occur NOTE If complete a
24. 10 2 STUB GUARD CONVERSION KIT 2o 196 10 3 STABILIZER WHE 196 10 4 STABIEIZER TRANSPORT WHE EL S itis mico tinis A A a te ino oe nl ipsae Ido cone ore dt 196 10 5 LODGED CROP REEL FINGER KID iic oae 197 10 6 VERTICAETANIEE MOUDLES ei octets iuc cos eve suae Iu eo Ve Ya eoe ua qc tes veo Ce rio hc eos Yee soto eee 197 10 7 HJPPER GROSSJAUGEBPI o ves ote deu tale ae ved ced Cu eles 197 10 8 mic mi Die plici EA petu PC D 197 10 9 ue 198 10 10 IRICE DIVIDER 3 EE LU OU eae 198 198 1012 IDELIGATE SEED SAVER ate pases Le a ai ee e Rt i 198 1013 KNIFE HEAD SHIELD icone 198 10 14 DRAPER WIDE DEFLECTOR nenne nnn nnn nnn nnns 198 UNEOADING AND ASSEMBLY 2 Lue eed RIDE UE 199 INDEX 200 169593 5 Revision SECTION 3 SAFETY 3 SAFETY 3 1 SAFETY ALERT SYMBOL This safety alert symbol indicates important safety messages in this manual and on safety decals on the machine This symbol means e ATTENTION e BECOME ALERT e YOUR SAFETY IS INVOLVED Carefully read and follow the safety message accompanying this symbol
25. 356 mm with 4 inch 102 mm Flighting Speed 150 rom Combine Dependent Drive Hydraulic Motor from Combine Driven Pump Self Tracking Rubber Coated Polyester Fabric With Rubber Slats Type Feed Draper Width 78 3 4 inches 2000 mm Speed 350 400 ft min 107 122 meters min Reservoir Capacity 16 U S gal 60 liters Maximum Operating Pressure 3500 psi 24132 kPa Piston Pump 3700 psi 25510 kPa Gear Pump Filter 10 micron 151975 Header Draper Drive Pump 1 01 in 16 5 cc Gear Pump Sickle Drive Pump 1 8 2 7 in 29 5 44 2 cc Piston Pump Adapter Header Flotation 7 8 inches 178 203 mm vertical 4 degrees rotation Mechanical or Hydraulic From Combine Hydraulic Oil Supply Header Angle Control With Solenoid Valve To Toggle To Reel Fore aft Header Tilt Combine Requirement Class 5 or Higher See chart under Knife Speed for recommended range NOTES 1 Specifications and design are subject to change without notice or obligation to revise previously sold units 2 Weights do not include options 169593 22 Revision B SECTION 7 OPERATION 7 OPERATION 7 1 OWNER OPERATOR RESPONSIBILITIES A CAUTION 169593 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 Remember that YOU are the key to safety Good
26. A at each lock until it latches into the lock position IMPORTANT If slow speed transport wheels are installed header may be detached in either Transport or Field mode If detaching with wheel in Field mode set wheels to storage or uppermost working position Otherwise header may tilt forward so that re attachment will be difficult Refer to Section 7 9 1 Cutting Height 169593 50 IMPORTANT If stabilizer wheels are installed set wheels to storage or uppermost working position Otherwise header may so that re attachment will be difficult Refer to Section 7 9 1 Cutting Height c Disconnect driveshaft B from combine and slide driveshaft in hook C so that disc D drops to secure driveshaft d Disconnect harness at connector E e Move handle F on combine multi coupler to full open position to release coupler G from combine continued next page Revision B SECTION 7 OPERATON AGCO f Raise handle on adapter and place coupler G on adapter receptacle g Lower handle H to lock coupler h Retract lugs J at base of feeder house with lock handle K 169593 51 Lower feeder house until saddle L disengages and clears adapter support Slowly back combine away from adapter Revision B SECTION 7 OPERATION ADAPTER 7 4 ATTACHING AND DETACHING HEADER WITH ADAPTER Using this procedure the adapter remains attached to the combine and is a
27. NORMALLY REQUIRED BUT IS AT THE Section 8 4 5 OWNER OPERATOR S DISCRETION 25 HOURS Hydraulic Oil Level at Reservoir Section 8 5 1 1 Sickle Head s Section 8 4 5 continued next page 169593 104 Revision B SECTION 8 MAINTENANCE AND SERVICING 50 HOURS Draper Roller Bearings Section 8 4 5 Driveline and Driveline Universals Section 8 4 5 Sickle Drive Shaft Bearings DK Section 8 4 5 A Sickle Drive Box Oil First 50 Hours Only Section 8 9 10 6 250 HOURS OR ANNUALLY Y Draper Seal Section 8 11 4 Adapter Auger Pivots Section 8 4 5 Upper Cross Auger Center Support Section 8 4 5 Reel Drive U joint Section 8 4 5 Transport Axle Pivot Bushings Section 8 4 5 A Hydraulic Oil Filter Section 8 5 2 500 HOURS OR ANNUALLY v Draper Seal Section 8 11 5 Reel Shaft Bearings Section 8 4 5 Stabilizer Transport Wheel Bearings Section 8 4 5 Y Gearbox Chain Tension Section 8 7 5 1000 HOURS OR 3 YEARS A Sickle Drive Box Lubricant Section 8 9 10 6 1500 HOURS OR 3 YEARS A Change Hydraulic Oil Section 8 5 1 3 A Change Gearbox Lubricant Section 8 4 5 4
28. Push down on handle C to lock Revision B SECTION 7 OPERATION 7 15 3 2 Rear Wheels To Field Position TRANSPORT TO FIELD LH WHEEL a Pull pin A at left wheel swivel wheel clockwise and lock with pin A EA TRANSPORT TO FIELD RH WHEEL f At right cutterbar wheel pull pin F on brace G disengage brace from cutterbar and lower the brace against axle H g Remove pin J lower the support K onto axle and re insert pin into support h Swing axle clockwise to rear of header TRANSPORT TO FIELD LH WHEEL Remove pin at B Store pin at C as shown c Pull handle D to release d Lift wheel to desired height and engage support channel into slot E in upper support e Push down on handle D to lock i Pul pin L at right wheel swivel wheel counterclockwise to position shown and lock with pin j Remove hairpin M from latch N k Lift wheel lift latch N and engage lug O onto left axle Ensure latch closes l Secure latch with hairpin M continued next page 169593 91 Revision B SECTION 7 OPERATION IMPORTANT Check that wheels are locked and that handle is in locked position FIELD POSITION LH FIELD POSITION RH SIDE m The conversion is complete when the wheels are as shown 169593 92 Revision B SECTION 7 OPERATION C 7 15 4 Converting from Field to Transport Position Raise header fully and proceed as follows A DANGE
29. TRANSPORT TO FIELD RH SIDE Remove hairpin D from latch Disengage latch E and lift right wheel out of hook and place on ground as shown This reduces weight of assembly and makes adjusting wheel position easier Support left wheel weight by lifting slightly with one hand Pull up on handle F to release lock Lift left wheel to desired height and engage support channel into slot G in upper support Push down on handle F to lock Lift right hand wheel back into field position and ensure latch E is engaged Secure latch with hairpin D 64 2 Adjust left wheels as follows l Support wheel weight by lifting slightly with one hand Pull up on handle F to release lock Lift wheels to desired height and engage support channel into slot H in upper support Iii Push down on handle F to lock IV Lower header to desired cutting height using combine controls and check load indicator as shown below Re adjust wheels as required to achieve range between 2 and 3 as shown below IMPORTANT Continuous operation with excessive spring compression i e load indicator reading greater than 4 can result in damage to Suspension system Adjust header angle to desired working angle with the machine s header angle controls angle is not critical set it to mid position Use the combine AHHC to automatically maintain cutting height Refer to your combine Operators Manual and AHHC instru
30. The draper rollers have bearings non greaseable The external seal should be checked every 200 hours and more frequently in sandy conditions to obtain the maximum bearing life A DANGER Engage header lift cylinder stops and reel props before working under header or reel 8 11 4 1 Drive Roller Removal a Raise header and reel and engage cylinder and reel stops b On deck shift headers position deck so drive roller is easily accessible c Loosen and uncouple draper Refer to Section 8 11 2 Replacing Split Draper d Loosen the two set screws in access hole A in the drive roller hub at motor end e Remove the four bolts B that hold hydraulic motor to arm and pull motor off roller f Remove bolt C at forward end of roller and remove roller from deck 169593 150 8 11 4 2 Drive Roller Installation A DANGER Engage header lift cylinder stops and reel props before working under header or reel Refer to illustrations opposite a Position roller in deck arms and secure forward end with bolt C and washer Do not tighten at this time b Apply SAE Multi Purpose grease to motor shaft locate motor on roller arm and engage motor shaft into roller c Secure motor with shoulder bolts B and tighten The shoulder bolts allow clearance between the motor and arm The motor is NOT secured tightly to arm d Push roller against shoulder on motor shaft and hand tighten the two set s
31. an idling machine Raise header fully stop engine and remove key Engage header lift cylinder stops Check that draper guide rubber track on under side of draper is properly engaged in groove of drive roller and that idler roller is between the guides Loosen jam nut A Hold nut B with a wrench and turn bolt C clockwise to increase tension 169593 145 IMPORTANT Adjust both sides equal amounts e Correct tension is when retainer D is flush with bracket E and bolt F is free f Tighten jam nut A 8 10 2 Replacing Draper The draper should be replaced or repaired if it is torn missing slats or cracked a If adapter is attached to combine and header disconnect header See Section 7 3 HEADER ATTACHMENT DETACHMENT b Raise header fully stop engine and remove key Engage header lift cylinder stops c Loosen draper as follows 1 Loosen jam nut A 2 Hold nut B with a wrench and turn bolt C counterclockwise to release tension d Repeat on opposite side of adapter e Disengage header lift cylinder stops and lower feeder house and adapter onto blocks to keep adapter slightly off the ground continued next page Revision B SECTION 8 MAINTENANCE AND SERVICING Remove nuts screws G and straps H along draper joint g Pull draper from deck 169593 Install new draper over drive roller J with chevron cleat K pointing to front of
32. and check gap X between deflector and pan Maintain 7 8 1 8 in 22 3 Revision B SECTION 7 OPERATION CASE IH 7 3 2 Case 7010 8010 7120 8120 5088 6088 7088 p 7 3 2 1 Attachment a Slowly drive combine up to adapter until feeder house saddle A is directly under the adapter top cross member B b Raise feeder house slightly to lift adapter ensuring feeder saddle is properly engaged in adapter frame A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine 169593 31 Lift lever C on adapter at left side of feeder house and push handle D on combine to engage locks E on both sides of the feeder house Push down on lever C so that slot in lever engages handle to lock handle in place If lock E does not fully engage pin on adapter when C and D are engaged loosen bolts F and adjust lock as required Re tighten bolts Connect combine hydraulic quick coupler to receptacle G on adapter as follows 1 Open cover H 2 Push in lock button J and pull handle K to full open position 3 Remove coupler L from combine and clean mating surfaces continued next page Revision B 169593 SECTION 7 OPERATION CASE IH 4 Position onto adapter receptacle G and push handle K to engage coupler pins into receptacle 5
33. point where cutterbar contacts the ground 169593 147 8 11 2 Replacing Split Draper The draper should be replaced or repaired if it is torn missing slats or cracked A CAUTION To avoid bodily injury from fall of raised reel always engage reel props before going under raised reel for any reason A DANGER To avoid bodily injury or death from unexpected start up fall of raised machine stop engine remove key and engage lift cylinder locks before going under machine for any reason 8 11 2 1 Draper Removal a Raise reel and engage reel props b Raise header and install lift cylinder locks c Stand in draper opening or on combine feed draper and move draper until draper joint is in work area NOTE Deck can also be shifted towards center to provide opening at endsheet d Release tension on the draper Refer to previous section e Remove nuts C and tube connectors D at draper joint f Pull draper from deck Revision B SECTION 8 MAINTENANCE AND SERVICING 8 11 2 2 Draper Installation a Insert draper into deck at outboard end under the rollers Pull draper into deck while feeding it at the end b Feed in the draper until it can be wrapped around the drive roller c Similarly insert the other end into the deck over the rollers Pull draper fully into the deck d Attach ends of draper with tube connectors D Install screws C with heads facing the center opening f Ad
34. 103 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 4 1 Maintenance Schedule Record ACTION Y Check Lubricate Change o Hour Meter Reading 2 oc Date Zor Serviced By FIRST USE Refer To Section 8 4 2 Break In Inspections 100 HOURS OR ANNUALLY Auger to Pan and Feed Draper Clearance Section 8 8 1 Draper Seal Section 8 11 5 Gearbox Lubricant Level Section 8 4 5 4 Reel Drive Chain Tension Section 8 12 4 Reel Tine Cutterbar Clearance Section 8 12 1 Sickle Drive Belt Tension Section 8 9 8 Wheel Bolt Torque Section 8 13 1 Sickle Drive Box Lubricant Level Section 8 4 5 Sickle Drive Box Mounting Bolts Section 8 9 10 1 Auger Drive Chain Section 8 8 2 Float Pivots Section 8 4 5 Float Spring Tensioners Section 8 4 5 Reel Drive Chain Section 8 4 5 Upper Cross Auger RH Bearing Section 8 4 5 END OF SEASON Refer To Section 8 4 4 End of Season 10 HOURS OR DAILY eo ef lt lt S S S S SS Hydraulic Hoses and Lines Section 8 5 3 Sections Guards Hold downs Sections 8 9 1 8 9 6 8 9 7 v Tire Pressure Section 8 13 3 NOTE A RECORD OF DAILY MAINTENANCE IS NOT Sickle except in sandy conditions
35. 143 Main Street Greensborough Victoria Australia 3088 t 03 9432 9982 f 03 9432 9972 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 f 7 495 967 7600 CUSTOMERS www macdon com DEALERS www macdondealers com Trademarks of products are the marks of their respective manufacturers and or distributors Printed Canada
36. 505 1028 Note 5 Stabilizer wheels B C 550 600 Center or Down Not Required A are used to limit D 525 600 the side to side cutting off the 550 600 Not Applicable Not Required ground in rolling sora 3 ee minimize bouncing s B C 550 600 Up or Center Storage Not Required 7 Note 6 525 600 Available through your Dealer Parts Department D mE 600 650 EM neon Not Required Whisker divider not f required on both 5 0 ends of header 600 650 550 600 EM Up or Center Storage Recommended 525 600 525 600 5 00 Note 7 600 650 510 Setting on CA25 Up or Center Storage Not Required draper control ee 525 600 510 169593 60 Revision B SECTION 7 OPERATION 7 8 2 Pickup Reel Settings The following chart illustrates the profile of the reel at each cam or finger pitch setting as well as the reel position relative to the ground at different positions on the reel arm Refer to the chart in the previous section for applicability of each finger pattern and reel position See NOTES on the next page CAM SETTING NUMBER REEL POSITION Finger Speed Gain NUMBER REEL FINGER PATTERN 3 30 6 or 7 4 35 169593 61 Revision B SECTION 7 OPERATION NOTES a 169593 Adjust reel forward to get closer to ground when tilting header back Fingers Tines will dig into ground at extreme reel forward positions
37. Add SAE 85W 140 oil at C until it runs out of hole at A Gearbox holds approximately 5 US pints 2 5 liters f Replace oil level plug B and filler plug C 169593 117 Revision B 8 5 1 1 169593 SECTION 8 MAINTENANCE AND SERVICING 8 5 HYDRAULICS The CA25 Combine Adapter s hydraulic system provides oil for the header draper and knife drives as well as the adapter feed draper Reel hydraulics are provided by the combine 8 5 1 Reservoir The adapter frame is used as a reservoir Refer to Section 8 3 4 Recommended Fluids and Lubricants for proper oil Oil Level Side Hills Maximum Flat Terrain Minimum 5 Check oil level every 25 hours at sights A and B with cutterbar just touching ground Check when oil is cold and with center link retracted e Nominal Normal Terrain Maintain level so lower sight A is full and upper sight B is empty e Maximum Hilly Terrain Maintain level so lower sight A is full and upper sight B is up to one half filled e Minimum Level Ground For slopes of 6 or less oil level may be kept slightly lower if desired Maintain level so lower sight A is one half filled or higher NOTE 118 8 5 1 2 a b When ambient temperatures are above 95F 35 C to prevent overflow at breather under operating temperatures it may be necessary to lower oil level slightly Adding Hydraulic Oil A CAUTION Stop engine and rem
38. Indicator reading will increase NOTE Installation of the auto header height controller attachment is recommended for cutting on the ground if the combine is equipped to interface with it When cutting on ground adjust header angle to achieve desired stubble height Header angle indicator indicates A for shallowest angle higher stubble and D for steepest angle lower stubble Decrease header angle to minimize pushing soil NOTE Header angle and reel fore aft position changes do not significantly affect header float downforce Revision B SECTION 7 OPERATION The following table summarizes the adjustment range Header angle is the angle between the drapers and the ground and is adjustable to HEADER SIZE DRAPER GUARD accommodate crop conditions and or soil type FT ANGLE ANGLE 20 and 25 ft 13 07 18 4 7 0 12 4 7 9 3 Header Angle 30 35 40 and 45 ft 13 0 18 4 7 9 3 1 Angle Adjustment GUARD ANGLE HEADER ANGLE LONGEST CENTER LINK GUARD ANGLE HEADER ANGLE Guard angle is similar to header angle which is the angle between the guard upper surface and the ground Refer to illustration above Flatter header angles are recommended for normal crop conditions and for stony ground because it minimizes sickle section breakage and reduces soil scooping or build up at the cutterbar in wet conditions The header angle is varied by adjusting the length of the center link between
39. J counterclockwise Use the following guidelines when adjusting float 1 For Single Knife Headers Adjust the float so the wrench reading is equal for both sides 2 For 40 and 45 ft Double Knife Headers Adjust the float so that torque settings are equal for both sides and then loosen both right side spring bolts two turns 3 Turn each bolt pair equal amounts After adjustment has been made repeat torque wrench reading procedure 4 To avoid frequent breakage of sickle components scooping soil or soil build up at cutterbar in wet conditions header float should be set as light as possible without Causing excessive bouncing 5 With a light float setting it may be necessary to use a slower ground speed to avoid excessive bouncing and leaving a ragged cut 6 The stabilizer wheels may be used in conjunction with float to minimize bouncing at the header ends and control cut height when cutting off the ground Refer to Section 7 9 1 Cutting Height for details 68 NOTE If adequate header float cannot be achieved using all of the available adjustments an optional heavy duty spring is available See your MacDon Dealer or Parts Catalog for ordering information 7 9 2 3 Setting Feeder House Height and Header Angle Adjust feeder house height while watching float indicator to set cutterbar down force normally 2 on indicator Lower feeder house height to increase ground pressure decrease float
40. Loosen bolt B and adjust arm C until desired measurement is obtained between reel tube and cutterbar NOTE Allow the reel tubes to find a natural curve and position the hardware appropriately 3 Re install bolts A in aligned holes and tighten 155 8 12 3 Reel Centering The reel s should be centered between the endsheets 8 12 3 1 Double Reel Header a Loosen bolt D on each brace E b Move forward end of reel center support arm F laterally as required to center both reels Tighten bolts 0 and torque to 265 359 N m 8 12 3 2 Single Reel Header a Loosen bolt G on brace H at both ends of reel b Move forward end of reel support arm J laterally as required to center reel Tighten bolts and torque to 265 359 N m Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 4 Reel Drive Chain 8 12 4 1 Tension Adjustment High Torque Drive a Lower header and reel shut down combine and remove key from ignition b Remove reel drive cover c Tension on chain E should be such that hand 1 Double Reel Remove six screws A and force deflects the chain 1 8 inch 3 mm at remove upper cover B mid span Adjust as follows 2 Single Reel High Torque Remove four screws C and remove cover D 1 Loosen six nuts F on motor mount continued next page 169593 156 Revision B SECTION 8 MAINTENANCE AND SERVICING 2 Slide
41. SERVICING 8 9 9 3 Sickle Drive Timing Double Knife Harvest Headers 35 ft and smaller require that sickles are properly timed to move in opposite directions To adjust sickle timing proceed as follows a Remove right sickle drive belt Refer to Removal Right End Timing Belt on previous page LEFT DIRECTION OF RIGHT SICKLE MOVEMENT SICKLE SECTIONS CENTERED BETWEEN GUARDS b Rotate left sickle drive box driven pulley A clockwise until left sickle B is at the center of the inboard stoke moving towards center of header NOTE Center stroke is when sickle sections are centered between guard points as shown 169593 141 LEFT DIRECTION OF RIGHT SICKLE MOVEMENT SICKLE SECTIONS CENTERED BETWEEN GUARDS Rotate right sickle drive box pulley C counterclockwise until right sickle D is at the center of the inboard stroke Install right sickle drive box drive belt and adjust tension Refer to Installation Right End Timing Belt on previous page IMPORTANT To maintain timing sickle drive box driver and driven pulleys must NOT rotate as the belt is tightened Check that timing belts are properly seated in grooves on both driver and driven pulleys Check for correct sickle timing by rotating the drive slowly by hand and observe sickles where they overlap at center of the header IMPORTANT Sickles must move in opposite directions and must begin moving at exactly the same time If timing is
42. SOKOR ONOI secun Ne a at ee 131 8 9 3 Sickle Head Bearing 131 8 9 4 oce Inetallallgl ti 132 8 9 5 ha Ge 2 ene 132 8 9 6 SICKIe D M ENDE 133 8 9 7 SICK EC molle E 135 8 9 8 Sickle Drive Belts Non Timed Drive 136 8 9 9 Double Knife Drive Belts Timed 137 169593 4 Revision B CONTENTS Section Title Page 8 9 10 DICKS DIVE BON cp 142 8 10 ADAPTER REED DRAM ER 55 ein 145 8 10 1 Draper Tension ensue 145 8 10 2 TEAC I em 145 8 11 HEADER T 147 8 11 1 Header Draper Tension Adjustment 147 8 11 2 FACDIAGCINO 147 8 11 3 Header ce ene Entum AME E MEMINI E 149 8 11 4 Draper Roller Maintenance iussit etus sua ve pe ha vsu oa eh ca TUS R 150 8 11 5 U 152 8 12 DD V4 am c 153 8 12 1 Heel Glearance Oto EUR od fa OU Da UR E uen akon idu E LUDUM Em MEE 153 8 12 2 FICE Frown Adjustment EP 155 8 12 3 a l
43. Sickle Drive Boxes Sickle Speed Single Knife SK Not Applicable 1200 1450 1200 1400 1100 1300 1050 1200 Not Applicable Strokes Per Minute Double Knife DK 1400 1700 1200 1500 1100 1400 Stroke 3 in 76 mm Sections Over Serrated and Bolted serrations inch 4 9 14 Case Hardened or Double Heat Treated Sheet Metal Adjuster Bolt Stub Sheet Metal HD Not Applicable Guards and Hold Downs 9 WN z e9 Q Q CONVEYOR AND DECKS Draper Drive Hydraulic Draper Width 41 5 8 in 1057 mm Draper Speed 247 464 ft min 75 141 m min Delivery Opening Width 73 5 8 in 1870 mm REEL Drive Hydraulic From Combine Hydraulic Oil Supply Speed 0 67 rpm 6 9 5 6 Quantity of Tine Tubes Effective Reel Diameter 65 in 1650 mm Tip Radius Range 30 3 16 31 1 2 in 766 800 mm HD Plastic SR Fingers Type Steel HD Plastic Steel or Plastic DR Spacing 6 in 152 mm continued next page 169593 21 Revision B SECTION 6 SPECIFICATIONS UPPER CROSS AUGER IM STABILIZER WHEELS SLOW SPEED TRANSPORT Size 51205 75 R15 Not Applicable Pressure COMBINE ADAPTER Width 151 inches 8835 mm Load Range E 85 psi 586 kPa Length 70 inches 1778 mm Height Weight 50 inches 1270 mm 2 050 Ib 930 kg Main Drive Combine Driven Piston Pump and Gear Pump Through Gearbox Gearbox Capacity 5 Pints 2 5 liters Drive Chain Auger Type Auger 14 inches
44. Start at 3 0 3 5 mph 4 8 5 8 km h and adjust as required Higher ground speeds require heavier float settings to prevent excessive bouncing that would result in increased cutting component damage In most cases aS ground speed is increased draper and reel soeed should be increased to handle the extra material The chart below indicates the relationship between ground speed and area cut for the four header sizes Example shown below At a ground speed of 6 miles per hour 9 7 km h with a 45 ft header the area cut in one hour would be approximately 33 acres 13 4 hectares kilometers hour 3 2 4 8 6 4 8 0 11 3 12 9 ro 5 lt x a hectares hour 169593 71 miles hour Revision B SECTION 7 OPERATION Refer to the Section 7 8 1 Header Settings for 7 9 6 Draper Speed guidelines on setting the proper draper speed for optimum feeding of the crop NOTE If sufficient draper speed cannot be achieved a possible cause is low relief pressure Refer to the Technical Service Manual for checking and adjusting relief pressure The adapter feed draper C is driven by the adapter mounted hydraulic pump The speed is factory set and cannot be adjusted The speed of the header side drapers A is adjusted at the flow control B on the CA25 adapter The control has values 0 9 on the barrel with a notch on the hyd
45. Testing and Materials American Society Of Testing and Materials Testing and Materials A hydraulic cylinder or turnbuckle type link between the header and the Center link machine that tilts the header DK Knife PEE Lever machine that cuts and lays crop into a windrow and is attached to self propelled windrower or combine Header mm Revolutions per minute Revolutions per minute 0 minute P Society Of Automotive Engineers Agricultural type tractor Truck four wheel highway road vehicle weighing no less than ii Ib 3400 kg 169593 18 Revision B SECTION 5 COMPONENT IDENTIFICATION 5 COMPONENT IDENTIFICATION 5 1 COMBINE HEADER CENTER REEL ARM PICK UP REEL REEL DRIVE AND CAM CENTER LINK CA25 ADAPTER PROP HANDLE u HYDRAULIC CONNECTIONS REEL FORE AFT CYLINDER TRANSPORT LIGHT REEL ENDSHIELDS CROP DIVIDER SICKLE DRIVE BOX REEL LIFT CYLINDER ENDSHIELD 169593 19 Revision B SECTION 5 COMPONENT IDENTIFICATION 5 2 COMBINE ADAPTER AUGER HEADER FLOAT SPRINGS CENTER LINK HYDRAULIC RESERVOIR N j 9 E lt b 5 b gt gt d Lo d T La 7 LI EI h c L d FEED DRAPER HEADER SUPPORT ARM HEADER FLOAT SPRINGS COMBINE HYDRAULICS RESERVOIR OIL LEVEL TORQUE WRENCH MULTI COUPLER SIGHT GLASS DRAPER
46. Tighten nut to next slot S if required 169593 171 If STANDARD TORQUE drive 1 Install flat washer G lock washer and bolt F 2 Torque bolt to 18 24 N m Tighten chain E Refer to Section 8 12 4 1 Tension Adjustment High Torque Drive Re attach hydraulic lines M to motor N continued next page Revision B SECTION 8 MAINTENANCE AND SERVICING t Re install drive cover s 1 Double Reel Position upper cover B onto drive and secure with six screws A 2 Single Reel High Torque Position cover D onto drive and secure with four screws C 169593 172 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 7 2 Single Reel Drive Motor Replacement Standard Torque a Lower header and reel shut down combine and remove key from ignition f Remove four nuts and bolts and remove motor H b Remove four screws A and remove reel drive g Position new hydraulic motor H on chain case cover B J and install four countersunk bolts G through holes in chain case to secure motor h Install nuts F and torque to 75 102 N m i Re install sorocket and speed sensor disc D Refer to Section 8 12 5 2 Sprocket Replacement Single Reel Standard Torque Drive j Tension the chain C Section 8 12 4 1 Tension Adjustment High Torque Drive Re attach hydraulic lines E to motor Re attach reel drive cover B with 4 sc
47. adapter and ensuring draper guides fit in drive roller grooves L Pull draper along bottom of adapter deck and over draper supports M Connect draper with straps H screws G and nuts with screw heads facing rear of deck Tighten nuts so that end of screw is approximately flush with nut Adjust draper tension Refer to Section 8 11 1 Header Draper Tension Adjustment 146 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 11 HEADER DRAPERS A CAUTION To avoid personal injury before servicing machine or opening drive covers follow procedures in Section 8 1 PREPARATION FOR SERVICING 8 11 1 Header Draper Tension Adjustment Draper tension should be just enough to prevent slipping and keep draper from sagging below cutterbar Set draper tension as follows a Check that draper guide rubber track on under side of draper is properly engaged in groove of drive roller and that idler roller is between the guides LH IDLER ROLLER ADJUST RH OPPOSITE b Turn bolt A clockwise tighten and the white indicator bar B will move inboard in direction of arrow indicating that draper is tightening Tighten until bar is about halfway in window IMPORTANT To avoid premature failure of draper draper rollers and or tightener components do NOT operate with tension set so that white bar is not visible Also to prevent draper from scooping dirt ensure draper is tight enough that it does not sag below
48. adjust tracking if required Refer to Section 8 11 3 Header Draper Alignment 8 11 4 5 Draper Roller Bearing Seal Replacement a Remove roller assembly Refer to Section 8 11 4 1 Drive Roller Removal or Section 8 11 4 3 Idler Roller Removal b Remove bearing assembly E and seal D from roller tube F as follows 1 Attach a slide hammer to threaded shaft 2 Tap out the bearing assembly c Clean inside of roller tube F Check tube for wear or damage Replace if necessary continued next page Revision B d f SECTION 8 MAINTENANCE AND SERVICING Install bearing and seal as follows 9 16 in 14 mm 1 Install bearing assembly E into roller by pushing on outer race of bearing The bearing is fully positioned when the 9 16 inch 14 mm dimension is achieved 2 Apply grease in front of bearing Refer to Section 8 3 4 Recommended Fluids and Lubricants Install seal D as follows 1 Locate seal at roller opening and position a flat washer 1 in 1 0 X 2 in O D on seal 2 Using a suitable socket to locate on the washer tap seal into roller opening until it seats on the bearing assembly The seal is fully positioned when the 1 8 in 3 mm dimension is achieved See illustration above Re install roller assembly Refer to Section 8 11 4 Draper Roller Maintenance 8 11 5 Deck Height 169593 To prevent material from entering drapers and cutterbar maintain dec
49. and detailed on the following pages will affect the performance of the machine You will quickly become adept at adjusting the machine to give you the desired results VARIABLE SECTION Cutting Height 7 9 1 Header Float 7 9 2 Header Angle 7 9 3 Reel Speed 7 9 4 Ground Speed 7 9 5 Draper Speed 7 9 6 Knife Speed 7 9 7 Reel Height 7 9 8 Reel Fore Aft Position 7 9 9 Reel Tine Pitch 7 9 10 Crop Divider Rods 7 9 11 7 9 1 Cutting Height Harvest Headers are designed to allow an Operator to cut the crop above the ground for a desired stubble height or to cut the crop at ground level with the header on the ground Cutting height will vary depending on factors including whether windrowing straight cutting type of crop etc 7 9 1 1 Cutting Off The Ground Cutting height is controlled with a combination of header lift cylinder adjustment and a stabilizer wheel system or a stabilizer slow speed transport wheel system The stabilizing wheel system in both options is designed to minimize bouncing at the header ends and may be used to float the headers to achieve an even cutting height when cutting above ground level in cereal grains The system can provide very even stubble height and greatly reduced operator fatigue 63 The proper setting requires balancing the amount of header weight carried by the float and the stabilizer wheels Refer to Section 7 8 1 Header Settings for recommended use in specific crops and
50. broken components and repair or order replacement from your MacDon Dealer Attention to these items right away will save time and effort at beginning of next Season Replace or tighten any missing or loose hardware Refer to Section 8 3 1 Recommended Torques Revision B SECTION 8 MAINTENANCE AND SERVICING T T h Master grease point location decals as shown 8 4 5 Lubrication and Servicing below are provided on the header and adapter back frames A CAUTION To avoid personal injury before servicing header or opening drive covers follow procedures in Section 8 1 PREPARATION FOR SERVICING Log hours of operation and use the Maintenance Record provided to keep a record of scheduled maintenance Refer to Section 8 4 1 Maintenance Schedule Record 8 4 5 1 Service Intervals Refer to the illustrations on the following pages to identify the various locations that require lubrication and servicing Illustrations are organized by the frequency of service that 1 required 8 4 5 2 Greasing Procedure A DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine 200 H a he greasing points are marked on the machine by decals showing a grease gun and grease interval in hours of operation b Use the recommended lubricants specified in this manual See Section 8 3 4 Recommended Fluids and Lubricants c Wipe grease fitti
51. chain bars Case Stone retarding drum installed or smooth feeder chain bars installed See your MacDon Dealer Refer to your Combine Operator s Manual continued next page Refer to your Technical Service Manual 169593 190 Revision B SECTION 9 TROUBLESHOOTING Material overload on drapers Add flighting extensions Add flighting extensions extensions s E 1 1 Hesitation In Flow Of Bulky accumulation at auger Crop Case Stone retarder blocks Adjust blocks to minimum interfering with crop flow height Side drapers running too fast piling material in center of feeder draper Feed chain drum too low Move drum to corn position Crop susceptible to wrapping Add flighting extensions or 7 3 1 1 Adapter Auger Wraps Crop flax stripper bars ve a 1 2 Auger speed too fast Install slow down kit Combine Feeder Drum fey to wrapping Clean debris from poly pan debris from Clean debris from poly pan pan Check feed draper tension 8 11 3 Replace roller bearing s Reduce header side draper 7 9 6 speed B kkk Check feed draper motor Check auger clearance 881 Heavy crop plugging between See also Adapter Auger adapter auger and feed draper Back Feeds on previous Crop Backs Up Or Hesitates On Feed Draper page Auger speed too low Install auger speed up kit Excessive clearance from Feed Draper Auger speed to
52. continued next page Refer to your Technical Service Manual 169593 189 Revision B SECTION 9 TROUBLESHOOTING 9 4 HEADER AND DRAPERS SYMPTOM PROBLEM SOLUTION SECTION Header Lift Insufficient Low relief pressure Increase relief pressure Speed control set too low Speed control set too low set too low Increase control setting 796 Increase relief pressure to Relief pressure too low recommended setting u Insufficient Side Draper Speed Worn out gear pump Replace pump Adjust to soi for Combine header drive too slow Pressure compensator V7 Bal Adjust to increase setting Drive or idler roller wrapped Loosen draper and clean with material rollers 8 11 1 Slat or connector bar jammed Loosen draper and clear Draper Will Not Drive by frame or material obstruction Low hydraulic oil Fill reservoir to full level 85 12 5 8512 _ 2 Incorrect relief d at flow Install stub guards Material not feeding evenly off Draper Stalling sickle Check reversing mechanism ki inside Auger set too high Lower auger auger 8 8 1 John Deere Feeder chain Run feeder chain at high running too slow speed John Deere Equipped with Replace with 6 pitch per bar feeder chain with 4 pitches feeder chain or remove bar every other bar di Adapter Auger Back Feeds Install standard drum or fill slots in stone retarding drum or install serrated feed
53. continued next page Refer to your Technical Service Manual 169593 193 Revision B SECTION 9 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Ground too wet Allow soil to Dirt packing on bottom of dry cutterbar with poly wear strips on cutterbar and raises Manually clean the bottom of cutterbar off the ground cutterbar when accumulation gets unacceptable Complete Or Partial Plants has been installed over top of plastic wear strips for L s steel wear plates eft Behind con d cutterbar Header is not level Level header Parts of vines get caught in pointed guard tip Occurs more in row cropped beans Install stub guard kit that are hilled from cultivating Raise header fully at each Cutterbar has filled up with trash with draper to cutterbar ste us ba E Maris as gap properly adjusted help clean out cutterbar Between Top Of Draper And Cutterbar Shifting of decks with header Manually remove debris from raised does not clean out cutterbar cavity to prevent cutterbar debris damage to drapers Increase finger aggressiveness cam position Reel finger pitch not aggressive enough Crop Accumulating At Re adjust reel minimum Guards And Not Moving Reel too high relative to knife height with cylinders fully Rearward Onto Drapers retracted Reel too far forward of i cutterbar C section Re position reel Float insufficient Increase float Consider inst
54. crop conditions A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine Raise the header so that the stabilizer wheels are off the ground Shut down engine and remove the key Check that the float is working properly See Section 7 9 2 Header Float Set up the stabilizer wheels if installed as follows Otherwise proceed to step d on next page A CAUTION Handle may be under tension especially when the wheels are on the ground Raise header so that wheels are off the ground before making adjustments 1 Support wheel weight by lifting slightly with one hand on handle B Pull up on handle A to release lock 2 Lift wheel with handle B and engage support channel into center slot C in upper support 3 Push down on handle A to lock continued next page Revision B 4 d Set tran SECTION 7 OPERATION Lower header to desired cutting height using combine controls and check spring length as shown Re adjust wheels as required to achieve range IMPORTANT Continuous operation with excessive spring compression i e spring length shorter than 11 5 8 in 295 can result in damage to Suspension system up the stabilizer slow speed sport wheels if installed as follows Otherwise proceed to step e 1 Adjust right wheels as follows Vi Vil 169593
55. equipment and experience to perform the job Take the tire and rim to a qualified tire repair shop Revision B SECTION 9 TROUBLESHOOTING 9 TROUBLESHOOTING 9 1 CROP LOSS AT CUTTERBAR SYMPTOM PROBLEM SOLUTION SECTION Cutterbar too high Lower cutterbar E Header angle too flat Steepen header angle Reel too far back too far back Move reel forward reel forward 7 799 9 Does Not Pick Up Down Crop speed too fast for reel LL ground speed or E 36 V amp speed increase reel speed Increase finger pitch 7 9 10 Heel fingers not lifting crop aggressiveness in sufficiently Install lifter guards Reel speed too fast Reduce reel speed Heads Shattering Or Breaking Off Ground speed too fast Reduce ground speed Operate at night when Crop too ripe humidity is higher Ground speed too slow Ground speed too slow too slow Increase ground speed Increase ground speed speed 7 E E 5 Reel speed too slow Increase reel speed Cutterbar too high Lower cutterbar Cut Grain Falling Ahead Of Cutterbar Reel too far forward Move reel back on arms Cutting at soeeds over 6 mph Replace with high speed 10 km h with high torque 19 tooth reel drive 8 12 5 10 tooth reel drive sprocket sprocket Worn or broken sickle E epics Crowding uncut crop Allow enough room for crop Strips Of Uncut Material to fed to cutterbar Broken sickle sect
56. header angle and fully lower the header Check that adapter float linkage 16 downstops washer A and nut B cannot be moved INCREASE CLEARANCE Loosen two nuts C Turn bolt head D clockwise to raise auger and increase pan draper clearance Repeat for other end of auger Check clearances and re adjust as required Tighten nuts C on both ends of auger Revision B SECTION 8 MAINTENANCE AND SERVICING 8 8 2 Auger Drive Chain Adjustment The auger is chain driven from adapter drive system by a sprocket that is attached to side of the auger To adjust chain tension proceed as follows A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine a Detach combine from adapter Refer to Section 7 3 HEADER ATTACHMENT DETACHMENT b Remove six bolts A securing top cover c Remove six bolts B securing bottom cover d Hinge covers C and D forward and remove to expose drives 169593 126 Loosen bolt E securing idler sprocket Rotate auger in reverse to take up slack in lower strand of chain F Push idler sprocket down to eliminate remaining slack in upper strands Rotate auger back and forth to check slack and repeat above step if necessary slight amount of slack is acceptable NOTE Do NOT use excessive force on idler to tighten chain Tighten idler bolt E and t
57. header left endshield Call your MacDon Dealer if you need assistance information or additional copies of this manual Published November 2012 169593 1 Revision B 2 MODEL AND SERIAL NUMBER NOTE Right hand RH and left hand LH designations are determined from the Operator s position facing forward Record the Model Number Serial Number and Model Year of the Header Slow Speed Transport Stabilizer Wheel Option if installed and the Combine Adapter on the lines below HEADER MODEL SERIAL NO YEAR Serial Number Plate is located on the underside of the LH endsheet ADAPTER MODEL SERIAL NO YEAR Serial Number Plate is located on the underside of the reservoir at the right end SLOW SPEED TRANSPORT STABILIZER WHEEL OPTION SERIAL NO YEAR Serial Number Plate is located on the left hand wheel pivot tube A a m in Form 169593 2 Revision B CONTENTS Section Title Page T INTRODUCTION 4 ie Op uda anu ieee uaa du addc Mutuo oe oun erie 1 2 MODEL AND SERIAL NUMBER ue duca Coon uuu Du 2 3 SAFETY 6 3 1 SAEETPYALERT teniente uiia 6 9 2 SIGNAL WORDS E a 6 3 3 a B 6 3 3 1 MEE 6 3 3 2 oalety Decal LOCAUOINS ra es E 7 3 3 3 SLY qm 13 3 4 GENERAESAFPETY
58. light assembly C 2 Remove bolts D securing bracket C to reel arm remove bracket light assembly 3 If necessary remove plastic tie securing harness to bracket or reel arm 4 Swivel light to working position as shown 5 Re position bracket light assembly C on reel arm as shown and re install the four bolts 0 to secure bracket to reel arm Tighten bolts 6 Push reel back and re install cylinder B to bracket with pin A Secure pin with cotter pin 7 Secure light harness to bracket with plastic tie wrap e Check reel clearance to back sheet upper cross auger if installed and reel braces f Adjust reel tine pitch if required Refer to Section 7 9 10 Reel Tine Pitch or Section 8 12 1 Reel Clearance to Cutterbar adjustment procedures 169593 76 Revision B 169593 SECTION 7 OPERATION 7 9 9 3 Fore Aft Cylinder Position Single Reel The reel can be moved approximately nine inches further aft by re positioning the cylinders on the reel arms This may be desirable when straight combining canola Position reel fully aft with support arms horizontal Stop engine and remove key A WARNING Stop combine engine and remove key before making adjustments to machine A child or even a pet could engage the drive Re position right arm cylinder as follows NOTE Reel components are not shown for Clarity 4 gt ait T 1
59. material in heavy hard to cut crops Installation and adjustment instructions are included with the kit The vertical knife mounts allow installation of vertically oriented sickles onto both ends of the header Two vertical knife suppliers are recommended e Sabre Vertical Knife available from Canadian Agri Technologies e Ziegler Vertical Knife available in North America from Sunova Implement Ltd See your MacDon Dealer for further details Installation and adjustment instructions are included with the kit 169593 197 Revision B SECTION 10 OPTIONS AND ATTACHMENTS 10 9 ROCK RETARDER KIT The rock retarder kit keeps rocks from rolling past the cutterbar and onto the drapers Installation instructions are included with the kit 10 10 RICE DIVIDER RODS The rice divider rods attach to the LH and RH endsheet cones and perform the same function in tall and tangled rice crops standard equipment crop dividers Installation instructions are included with the kit 10 11 DIVIDER LATCH kIT The latches which attach to the endsheets allow for quick removal of endsheet divider cones to accommodate storage and if required to reduce the transport width of the header Installation instructions are included with the kit 169593 198 10 12 DELICATE SEED SAVER kIT feed draper and side draper area near the front of the header and also includes side rubber flaps to close off areas in between the a
60. motor G and motor mount H up or down until required tension is achieved Tighten nuts F to 75 ft Ibf 102 N m d Re install drive cover 169593 157 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 4 2 Tension Adjustment Single Reel d Adjust tension as follows Standard Torque Drive a Lower header and reel shut down combine and remove key from ignition 1 Loosen four nuts D on motor mount 2 Slide motor E and motor mount F up or down until required chain tension is achieved 3 Tighten nuts D to 75 ft Ibf 102 N m b Remove four screws A and remove reel drive e Re install drive cover cover B c Tension on chain C should be such that hand force deflects the chain 1 8 inch 8 mm at mid span 169593 158 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 43 Drive Chain Replacement Single Reel High Torque Drive a Lower header and reel shut down combine and remove key from ignition Remove chain F Position new chain F around sprockets f Slide motor D and motor mount E upward until tension on chain F is such that hand force deflects the chain 1 8 inch 3 mm at mid span g Tighten nuts C and re check tension b Re install drive cover b Remove four screws A and remove reel drive cover B c Loosen nuts C Slide motor D and motor mount E down towards reel shaft 169593 159 Revision B SECTION 8 MAINTEN
61. new sensor behind cover G through chain case 5 Locate new sensor in support C and attach with two screws F 6 Adjust gap between sensor disc A and sensor B to 02 in 0 5 mm 7 Connect to harness at D 169593 176 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 9 Reel Tines IMPORTANT Keep reel tines in good condition Straighten or replace as required 8 12 9 1 Removal Steel Tines A CAUTION To avoid bodily injury from fall of raised reel always engage reel props before going under raised reel for any reason a Lower header raise reel and engage reel props b Remove tine tube bushings from the applicable tine tube at center and left discs Refer to Section 8 12 10 Tine Tube Bushings c Temporarily attach reel arms A to reel disc using original attachment locations B d Cut damaged tine s so that it can be removed from tube e Remove bolts on existing tines and slide tines over to replace tine cut off in previous step Remove reel arms A from tube as required 169593 177 8 12 9 2 Installation Steel Tines IMPORTANT Ensure tine tube is supported at all times to prevent damage to the tube or other components Slide new tines and reel arms A onto end of tube Install tine tube bushings Refer to Section 8 12 10 Tine Tube Bushings Attach tines to tine bar with bolts and nuts C Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 9 3 Remova
62. off proceed as follows 1 Loosen right belt sufficiently to allow skipping the belt one or more teeth as required Refer to Refer to 8 9 9 1 Left End Drive Tension Adjustment Timing Belt 2 If right sickle leads left sickle rotate RIGHT SIDE driven pulley C clockwise 3 If right sickle lags left sickle rotate RIGHT SIDE driven pulley C counterclockwise 4 Tighten right belt Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 10 Sickle Drive Box A CAUTION To avoid personal injury before servicing machine or opening drive covers follow procedures in Section 8 1 PREPARATION FOR SERVICING 8 9 10 1 Mounting Bolts Check four sickle drive box mounting bolts B torque after the first 10 hours operation and every 100 hours thereafter Torque should be 200 ft Ibf 270 N m 8 9 10 2 Sickle Drive Box Removal a Loosen sickle drive belt and slip it off sickle drive box pulley Refer to Section 8 9 8 Sickle Drive Belts Non Timed Drive b Remove sickle head pin Refer to Section 8 9 2 Sickle Removal steps a and b c Remove bolt A from pitman arm d Remove pitman arm from sickle drive box shaft Remove bolts B attaching sickle drive box to frame IMPORTANT Do NOT remove or loosen locating tab This is a factory adjustment f Remove sickle drive box 169593 142 8 9 10 3 Pulley Removal a Loosen nut and bolt from pulley b Remove pulley using a 3 jaw puller 8 9 1
63. relation to ground speed This can be under 11 gpm Above 10 mph achieved by increasing reel speed decreasing 16 km hr ground speed or both oprockets are available as an option to the factory installed sprocket See your MacDon Dealer Parts Department to order sprockets Excessive shattering of grain heads or crop loss over the header back tube may be indications that reel speed is too fast Excessive reel speed causes undue wear of reel components and Refer to Section 8 12 5 Reel Drive Sprocket for unnecessary load on reel drive resulting in installation details uneven reel motion Generally 9 bat reels can effectively operate at lower reel speed while minimizing crop loss in shatter prone crops Refer to Section 7 8 1 Header Settings for recommended reel speeds in specific crops and crop conditions The reel speed is adjustable with the controls in the combine cab Refer to your Combine Operator s Manual for adjustment details 169593 70 Revision B SECTION 7 OPERATION 7 9 5 Ground Speed Ground speed should be such that the sickle can cut crop smoothly and cleanly while giving the desired delivery of material to the opening Excessive ground speed results in ragged cutting In tough to cut crops reduce ground speed to reduce loads on cutting components and drives When cutting very light crops e g short soybeans ground speed may have to be reduced to allow reel to pull in small and short plants
64. searching for pressurized fluid leaks Refer to Section 8 5 HYDRAULICS Clean all lights and reflective surfaces on the machine Perform all Daily maintenance Refer to Section 8 4 1 Maintenance Schedule Record Revision B SECTION 7 OPERATION 7 3 1 1 Flighting Extensions Flighting extension kits may have been supplied 7 3 HEADER ATTACHMENT with your header to improve feeding in certain DETACHMENT crops such as rice Installation instructions are included with the kits The header adapter is configured to each particular model of combine at the factory They are not recommended in cereal crops These combines are APPLICABLE COMBINES except New COMBINE SECTION Holland CR960 9060 970 9070 and 9080 If necessary remove auger flighting extensions Case IH 7010 8010 7120 732 8120 5088 6088 7088 John Deere 60 70 and 733 5 Series CAT Lexion 500 700 i 7 3 4 R Series New Holland CR CX 7 3 5 AGCO Gleaner R S Series Challenger 660 670 680B 7 3 6 Massey 9690 9790 9895 This section includes instructions on setting up attaching and detaching the header to the combines listed above IMPORTANT Ensure applicable functions AHHC a Remove access cover A Draper Header Option Hydraulic b Remove eight bolts B washers and nuts that Center Link Option Hydraulic Reel Drive etc are enabled on the remove exes ior combine and in the combine mE l computer Failure to do so may c Repeat f
65. shaft from U joint f Remove six bolts G attaching U joint flange to driven sprocket J continued next page Revision B SECTION 8 MAINTENANCE AND SERVICING g Remove U joint NOTE Right hand reel may need to be moved sideways for U joint to clear reel tube h Position U joint flange H onto driven sprocket J shown Install six bolts G and hand tighten Do not torque at this time i Position RH reel tube against reel drive and engage stub shaft into U joint pilot hole j Rotate reel until holes in end of reel tube and U joint flange F line up Install four bolts C and torque to 70 80 ft Ibf 95 108 N m Torque bolts E to 70 80 95 108 N m m Remove temporary reel support n Re attach reel drive covers 169593 168 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 7 Reel Drive Motor The reel drive motor does not require regular maintenance servicing problems develop with the motor it should be removed and serviced at your MacDon dealer 8 12 7 1 Drive Motor Replacement High Torque a Lower header and reel shut down combine and remove key from ignition b Remove reel drive cover s 1 Double Reel Remove six screws A and remove upper cover B screws C and remove cover D 169593 169 C Loosen chain Refer to Section 8 12 4 1 Tension Adjustment High Torque Drive If STANDARD TORQU
66. shoes are available as an optional header to bounce and result in uneven cutting attachment They are recommended for cutting height on the ground Installation and adjustment instructions are 10 2 STUB GUARD CONVERSION KIT 10 4 STABILIZER TRANSPORT WHEELS Sea see 6 7 Stub guards complete with top guides and adjuster shoes are designed to cut tough crops Available as an attachment stabilizer transport Installation and adjustment instructions are whee stabilize the header i oe included wih theca conditions that would otherwise cause the header to bounce and result in uneven cutting height The wheels convert to Transport mode to allow the header to be towed behind the combine or pick up at slow speed 169593 196 Revision B SECTION 10 OPTIONS AND ATTACHMENTS 10 5 LODGED CROP REEL FINGER 10 7 UPPER CROSS AUGER The cross auger helps deliver very bulky crops across the header onto the windrow or into the combine Installation and adjustment instructions are The steel fingers attach to ends of every other tine bar and help in clearing material in heavy lodged rice 10 8 REEL ENDSHIELD KIT Two kits are required for modifying each bar of a 6 bat reel Installation and adjustment instructions are included with the kit 10 6 VERTICAL KNIFE MOUNTS The steel shields attach to ends of the reel and help in clearing
67. shut off engine and remove key Adjust skid shoes to achieve desired cutting height as follows Outer Skid Shoes d 1 Remove lynch pin at each skid shoe B 2 Hold shoe and remove pin C by disengaging frame and then pulling away from shoe 3 Raise or lower skid shoe to desired position using holes in support as a guide 4 Re install C engage in frame and secure with lynch pin A Inner Skid Shoes 1 Remove lynch pin D 2 Hold shoe E and remove pin F by pulling down to disengage frame and then pulling away from shoe 3 Raise or lower skid shoe E to desired position using holes in support G as a guide 4 Re insert pin F engage in frame and secure with lynch pin D Check that skid shoes are adjusted to the same position Adjust header angle to desired working position using the machine s header angle controls lf angle is not critical set it to mid position Check header float as described in the following Section 7 9 2 Header Float Revision B SECTION 7 OPERATION 792 Header Float 7 9 2 2 Checking and Adjusting Float Park bi level surface D65 combine headers perform best with Ex da minimum extra weight on the header under normal conditions 7 9 2 1 Header Float Locks The function of the header float locks is to lock and unlock the header float system There are two locks one on each side of the adapter IMPORTANT The float
68. small screwdriver to separate the serrations Pull clamp off tine tube 169593 179 3 Rotate arm B clear of disc and slide arm inboard off bushing and remove bushing halves D Remove bolt from tine next to arm or remove plastic finger if required so that arm can slide off bushing b Remove cam end bushings as follows 1 Remove bolt E at on cam linkage so that tine tube F is free to rotate 2 If required remove securing the first tine to the left of the support so that tine is free to move inboard to the right If plastic finger is installed refer to previous section for removal procedure continued next page Revision B SECTION 8 MAINTENANCE AND SERVICING g Install bushing clamps as follows 3 Slide tine tube to expose bushing Remove bushing halves H 8 12 10 2 Bushing Installation 6 and 9 Bat Pick Up Reels IMPORTANT Ensure tine tube is supported at all 1 times to prevent damage the tube or other components Spread clamp J and slip over tine tube adjacent to flangeless end of bushing 2 Locate clamp on bushings D so that edges of clamp and bushing are flush when clamp fits into groove on bushing and lock i PANT A tabs are engaged eh ee a At cam end position bushing halves on tine tube so that lug in each bushing half locates in hole in tine tube b Slide tine tube to the left side of header to locate bushings
69. so adjust skid shoes or header angle to compensate Adjust reel rearward to get reel further away from ground when tilting header forward Header Tilt can be increased to get reel closer to ground or decreased to get reel further away from ground while keeping material flowing onto drapers To leave maximum amount of stubble behind in lodged crop raise header but increase header tilt to keep reel close to ground Position the reel fully forward Reel may have to be moved back to prevent lumps or plugging on cutterbar in thinner crops Minimum crop carrying capacity minimum area of exposed draper between reel and header backsheet occurs with the reel in the furthest aft position Maximum crop carrying capacity maximum area of exposed draper between reel and header backsheet occurs with the reel in the furthest forward position The tip speed of the fingers tines at the cutterbar becomes higher than the reel speed at higher cam settings due the nature of the cam action Refer to Reel Settings Chart on previous page 62 Revision B 169593 SECTION 7 OPERATION 7 9 HEADER OPERATING VARIABLES Satisfactory function of the header in all situations requires making proper adjustments to suit various crops and conditions Correct operation reduces crop loss and allows cutting of more acres As well proper adjustments and timely maintenance will increase the length of service you receive from the machine The variables listed below
70. the combine adapter and the header Refer to your Combine Operators Manual for Steeper angles are recommended in downed adjusting the header angle crops for better lifting action or for cutting close to the ground in soybeans for example Refer to Section 7 8 1 Header Settings for recommended header angle in specific crops and crop conditions 169593 69 Revision B SECTION 7 OPERATION 7 9 4 1 Optional Reel Drive Sprockets 7 9 4 Reel Speed Reel speed affects feeding of crop into the MACHINE DRIVE COMBINE APPLICATION sickle and onto the drapers as well as the HYDRAULICS SPROCKET smoothness and evenness of the delivered crop ais Operating the reel too fast too slow relative to ground speed will cause bunching At the proper speed the reel discs should appear to MS d be being driven by the ground e they look like they are skidding relative to CAT 500 ground the reel is turning too slow 2500 psi 700 Series Combining NS f they look like they are spinning iE E udin excessively relative to the ground reel speed may be too fast NH CR CX Case IH In standing crop reel speed should be just 7010 8010 14 Tooth faster than or equal to ground speed sweeping 7120 8120 crop across the sickle 88 Series Flattened crop or a crop that is leaning away Combining from the cutterbar requires a higher reel speed Low Flow Light Crops 21 Tooth in
71. with the reel being fully forward to leave maximum amount of stubble in lodged crops This setting gives finger tip speed approximately 30 faster than the reel speed e Cam Position 4 Header Angle At Maximum and Reel Fully Forward provides maximum amount of reel reach below cutterbar to pick up lodged crops and gives a finger tip speed approximately 35 faster than the reel speed Cutting height is set to approximately 8 inches 203 mm to leave a significant amount of stubble In damp materials such as rice it is possible to double ground speed because the amount of material that is being cut is less NOTE High cam settings with the reel fore aft position at 4 5 severely decrease the draper capacity because the reel disrupts crop flow across the drapers The fingers are still engaged in the crop that is moving on the drapers High cam settings are recommended only with the reel at or close to full forward settings IMPORTANT The reel to cutterbar clearance should always be checked following adjustments to reel tine pitch and reel fore aft position Refer to Section 8 12 1 Reel Clearance to Cutterbar Refer to Section 7 8 1 Header Settings for recommended reel tine pitch in specific crops and crop conditions Revision B SECTION 7 OPERATION 7 9 10 3 Cam Adjustment A WARNING Stop combine engine and remove key before making adjustments to machine A child or even a pet could engage the drive
72. 0 4 Pulley Installation a Remove any rust or paint from shaft and pulley splines For replacement parts remove oil grease with degreasing agent b Apply Loctite 243 adhesive or equivalent to spline Apply in two bands around shaft as shown with one band at end of spline and one band approximately mid way c Install pulley on shaft until flush with end of shaft and secure with bolt and nut Torque bolt to 160 ft Ibf 217 N m Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 10 5 Sickle Drive Box Installation mar ith locating tab at d Slide pitman arm D onto output shaft a Position sickle drive box with locating ta a original position and install four bolts B e Slide arm up or down on shaft until it just Torque side bolts and then bottom bolts to knifehead 0 010 In 0 25 200 ft Ibf 270 N m f Rotate pulley to ensure drive arm just clears frame to ensure proper placement on splines Position pitman arm at furthest outboard position g Install bolt A and nut and torque to 160 ft lbf 217 N m h Install sickle head pin Refer to Section 8 9 4 Sickle Installation i Install drive belt onto sickle drive box pulley and tighten Refer to Section 8 9 8 Sickle Drive Belts Non Timed Drive b Apply Loctite 243 adhesive or equivalent to spline Apply in two bands around shaft as shown with one band at end of spline and one band approximat
73. A WARNING Stand to rear of sickle during installation to reduce risk of injury from cutting edges Wear heavy gloves when handling sickle 8 9 5 Spare Sickle IMPORTANT Align guards and re set sickle hold downs while replacing sickle Ensure sickle is secured in place a If sickle head pin A is installed in sickle head remove pin b Slide sickle into place and align sickle head B with pitman arm C c Install sickle head pin A in pitman arm and tap it down into sickle head ensuring pin is bottomed out in sickle head d Tap underside of sickle head B until the pin is flush with upper face D of pitman arm and until it just contacts pitman arm 0 010 in 0 25 mm Re install bolt and nut F Tighten nut to 160 ft Ibf 220 N m Re install grease zerk in pin Grease bearing 20 29 169593 132 A spare sickle may be stored in the header frame tube at the left end as shown above Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 6 Sickle Guards 8 9 6 2 Guard Replacement Check daily that guards are aligned to obtain proper shear cut between sickle section and A CAUTION guard Sickle sections should contact shear surface of each guard Always engage reel props before working 8 9 6 1 Guard Adjustment under reel To align guards proceed as follows The guard Pointed Guards Single Knife Straightening tool MD 140135 is available from your MacDon Dealer a Stroke
74. ANCE AND SERVICING 8 12 4 4 Drive Chain Replacement Double Method 1 Disconnecting the Reel Drive Reel Lower header and reel shut down combine and remove key from ignition Remove reel drive upper cover Refer to previous section 1 Support inboard end of right reel with a front end loader and nylon slings or equivalent set up IMPORTANT To avoid damaging or denting center tube support reel as close as possible to the end disc UNRELATED PARTS HIDDEN FOR CLARITY Remove three screws A and remove lower cover B Release tension on chain C Refer to previous section The endless chain C can be replaced by e Method 1 Disconnecting the Reel Drive OR e Method 2 Breaking the Chain 2 Remove four bolts D attaching reel tube to U joint E Method 1 is preferred because the chain integrity is not affected 169593 160 Revision 9 SECTION 8 MAINTENANCE AND SERVICING Move RH reel sideways to separate the reel tube F and U joint E Remove the chain C Route new chain C over U joint E and locate on sprockets Adjust the chain tension Refer to Section 8 12 4 1 Tension Adjustment High Torque Drive Position RH reel tube F against reel drive and engage stub shaft into U joint E pilot hole Hotate reel until holes in end of reel tube and U joint line up Apply Loctite 243 or equivalent to four 1 2 in bolts G and install with lock washers
75. Dealer 7 15 2 1 A CAUTION Attaching Header To Towing Vehicle To avoid bodily injury and or machine damage caused by loss of control Weight of towing vehicle must exceed header weight to ensure adequate braking performance and control Do NOT tow with any highway capable vehicle Use only an agricultural tractor agricultural combine properly configured MacDon windrower Ensure that reel is down and fully back on support arms to increase header stability in transport For headers with hydraulic reel fore aft never connect the fore aft couplers to each other This would complete the circuit and allow the reel to creep forward in transport resulting in instability Check that all pins are properly secured in Transport position at wheel supports hitch and cutterbar support Check tire condition and pressure prior to transporting Connect hitch to towing vehicle with a proper hitch pin with a spring locking pin or other suitable fastener Attach safety hitch chain to towing vehicle Adjust safety chain length to remove all slack except what is needed for turns Connect header wiring harness 7 pole plug to mating receptacle on towing vehicle The 7 pole receptacle is available from your MacDon Dealer Parts Department Ensure lights are functioning properly and clean the slow moving vehicle emblem and other reflectors Use flashing warning lights unless prohibited by law Revision B SECTION 7 OP
76. E drive 1 Remove bolt F lock washer and flat washer G 2 Remove speed sensor disc H if installed If HIGH TORQUE drive 1 Remove cotter pin J and slotted nut K 2 Remove speed sensor disc H if installed continued next page Revision B SECTION 8 MAINTENANCE AND SERVICING f Slip chain E off drive sprocket L g Remove sprocket from shaft IMPORTANT Do NOT use pry bar and or hammer to remove sprocket This will damage the motor If sprocket does not come off by hand use a puller h Disconnect hydraulic lines M at motor N Cap or plug open ports and lines 169593 170 Slide motor N and motor mount O up or down so that attachment bolts P are exposed in holes and slots in back plate Remove four nuts Q and bolts P and remove motor N Position new hydraulic motor N on motor mount O and install four countersunk bolts P through holes and slots in chain case to secure motor to motor mount Install nuts and torque to 75 102 N m continued next page Revision B SECTION 8 MAINTENANCE AND SERVICING m Align keyway in sprocket L with key R in shaft and slide new sprocket onto shaft n Slip chain over drive sprocket Install soeed sensor disc H if applicable onto shaft If HIGH TORQUE drive and torque to slotted nut 10 20 in Ibf 1 1 2 2 N m 1 Install K 2 Install cotter pin J
77. ERATION 7 15 2 2 Towing The Header A CAUTION THIS IS INTENDED AS SLOW SPEED TRANSPORT 169593 A CAUTION To avoid bodily injury and or machine damage caused by loss of control Do NOT exceed 25 mph 40 km h Reduce transport speed to less than 5 mph 8 km h for corners and slippery or rough conditions Do NOT accelerate when making or coming out of a turn Obey all highway traffic regulations in your area when transporting on public roads Use flashing amber lights unless prohibited by law 88 7 15 3 Converting from Transport to Field a b Position Block the tires to prevent header rolling and unhook from towing vehicle Remove tow bar as follows Disconnect wiring connector A on tow bar Remove pin B tow bar and disassemble forward section C from aft section D 3 Disconnect wiring connector E at front wheel continued next page Revision B SECTION 7 OPERATION 2 For clevis or pintle end of tow bar secure in support L on endsheet with hitch pin M Secure with lynch pin Install rubber strap on cradle 4 Similarly locate other section of tow bar in cradle at other end of header 5 Secure tube end in support O with clevis pin P Secure with hairpin 6 Install rubber strap N on cradle d Attach header to combine Refer to Section 7 3 HEADER ATTACHMENT DETACHMENT IMPORTANT Carrying the tow bar on the header 4 R
78. Push handle to closed position until lock button J snaps out Remove cover on adapter electrical receptacle N Remove electrical connector M from storage cup on combine and route to adapter receptacle Align lugs on connector with slots in receptacle push connector onto receptacle and turn collar on connector to lock it in place Rotate disc O on adapter driveline storage hook and remove driveline from hook 32 Pull back collar P on end of driveline and push onto combine output shaft Q until collar locks Disengage both adapter float locks by moving latch R away from adapter and moving lever S at each lock to lowest position Revision B SECTION 7 OPERATION CASE IH IMPORTANT C If stabilizer wheels are installed set wheels to storage or uppermost working position Otherwise header may so that re attachment will be difficult Refer to Section 7 9 1 Cutting Height p 7 3 2 2 Detachment a Choose a level area Position header slightly above ground Stop engine and remove key A DANGER To avoid bodily injury or death from fall of raised machine always engage lift cylinder stops before going under header for any reason See your Combine Operator s Manual for instructions for use and storage of header lift cylinder stops A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engag
79. R To avoid bodily injury or death from unexpected start up or fall of raised header stop engine remove key and engage header lift cylinder stops before going under header for any reason 7 15 4 1 Left Wheels To Transport Position A CAUTION Stand clear of wheels and release linkage carefully as wheels will drop once the mechanism is released FIELD TO TRANSPORT LH SIDE a Remove clevis pin A b Pull latch handle B and disengage link C from lug D to lower wheels FIELD TO TRANSPORT LH SIDE l 93 169593 Place suspension assembly in full upward position E in leg and lower handle F to lock Remove pin G from storage at top of leg move and swivel wheels clockwise so that lug D faces forward Insert pin G and turn pin to lock FIELD TO TRANSPORT LH SIDE Locate tow bar H onto axle and push against latch J until tow bar pins drop into hooks K Check that latch J has engaged tow bar Install clevis pin A and secure with hairpin Connect plug L for lights Revision B SECTION 7 OPERATION 7 15 4 2 Right Side Wheels To Transport Position FIELD TO TRANSPORT LH WHEEL h Left wheel is now in Transport position as FIELD TO TRANSPORT RH SIDE At wheels at the right of header remove hairpin A from latch b Lift latch B disengage right axle and lower to ground A CAUTION Stand clear of wheels and release linkage
80. Revision B SECTION 7 OPERATION a Lower header to ground shut down combine 7 14 UPPER CROSS AUGER and remove key DOUBLE REEL HEADERS The cross auger helps deliver very bulky crops across the header onto the windrow or into the combine Removable beater bars assist in delivering material through the header opening but if wrapping occurs the beater bars can be removed as follows A WARNING Stop engine and remove key before SINGLE REEL HEADERS removing plugged material from header A child or even a pet could engage the drive b Remove bolts A securing bars B and clamps C to auger tubes and remove bars and clamps To re install the beater bars a Locate one beater bar B with one clamp set C on auger tube and loosely secure with carriage bolt A and nut Bolt head must face direction of auger rotation b Locate remaining clamp sets on tube and loosely attach to beater bar with carriage bolts and nuts Bolt heads must face direction of auger rotation c Position second beater bar in clamps and secure with carriage bolts and nuts d Tighten bolts 169593 86 Revision B SECTION 7 OPERATION 7 15 TRANSPORTING HEADER A WARNING Do NOT drive combine with header attached on a road or highway at night or in conditions which reduce visibility such as fog or rain The width of the header may not be apparent under these conditions 7 15 1 Combine A CAUTION Check loc
81. a Using a 3 4 in wrench turn the cam latch pin A counterclockwise to release the cam disc IMPORTANT Secure cam position before operating machine b Use the wrench on bolt B to rotate cam disc and align latch pin A with desired hole 1 to 4 at C in cam disc NOTE Bolt B is through cam disc Some parts shown transparent for visibility c Turn latch pin A clockwise to engage and lock cam disc d Repeat above procedure for the other reel 169593 79 Revision SECTION 7 7 9 11 Crop Divider Rods Divider rods are removable The removable divider rods are suitable when crop is down while the crop divider without rods is better in standing crops oee chart below for recommended rod use for various crops and Section 7 8 1 Header Settings for recommended reel height in specific crops and crop conditions WITH WITHOUT DIVIDER RODS DIVIDER RODS Lodged Cereal Peas Lentils Canola Rice Winter Forage Milo Sudan Grass Flax Alfalfa Grass Seed Soybeans Standing Cereal Edible Beans Soybeans Remove divider rods as follows b Store both rods on the inboard side of the right endsheet 169593 60 OPERATION 7 9 12 Crop Dividers The crop dividers are removable to suit installation of vertical knives and to decrease transport width DANGER To avoid bodily injury or death from unexpected start up or fall of raised machine stop engine remove key and engage lift cylin
82. a 3 4 inch socket 3 Close endshield and adjust position to achieve the gap X between the front end of shield and header frame on previous page 4 Open endshield and tighten nut A 5 To achieve a snug fit between top of shield and header frame and to ensure that endshield is fully engaged on pin B loosen bolts on catch C and adjust catch as required to re position shield 6 Tighten bolts on catch C 7 Close endshield 7 2 4 Daily Start Up Check Do the following each day before start up A CAUTION e Clear the area of other persons pets etc Keep children away from machinery Walk around the machine to be sure no one is under on or close to it e Wear close fitting clothing and protective shoes with slip resistant soles e Remove foreign objects from the machine and surrounding area 27 e As well carry with you any protective clothing and personal safety devices that COULD be necessary through the day Don t take chances e You may need cA A YP u in an o LB a hard hat protective glasses or goggles heavy gloves respirator or filter mask wet weather gear O O O OO o Protect against noise Wear a suitable hearing protective device such as ear muffs or ear plugs to protect against objectionable or uncomfortable loud noises Check the machine for leaks or any parts that are missing broken or not working correctly NOTE Use proper procedure when
83. afety signs are installed and legible Make certain everyone is clear of machine before starting engine and during operation Keep riders off the machine Keep all shields in place and stay clear of moving parts Disengage header drive put transmission in neutral and wait for all movement to stop before leaving operator s position 113482 Shut off engine and remove key from ignition before servicing adjusting lubricating cleaning or unplugging machine Engage locks to prevent lowering of header or reel before servicing in the raised position Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law Reel Hazard WARNING To avoid injury from fall of raised reel fully raise reel stop engine remove key and engage mechanical lock on each reel support arm before working on or under reel See Manual 174432 Header Hazard DANGER e Rest header on ground or engage mechanical locks before going under unit 174434 169593 13 Revision B SECTION 3 SAFETY High Pressure Oil Hazard WARNING Do not go near leaks High pressure oil easily punctures skin causing serious injury gangrene or death If injured seek emergency medical help Immediate surgery is required to remove oil Do not use finger or skin to check for leaks Lower load or relieve hydraulic pressure before loosening fittings 174436 Hydraulic Oil Pressu
84. al in position and slowly peel back the remaining paper smoothing the decal as it is applied Small air pockets can be smoothed out or pricked with a pin Revision B SECTION 3 SAFETY 3 3 2 Safety Decal Locations BOTH ENDS 113482 BACKTUBE 174432 169593 7 Revision SECTION 3 SAFETY Safety Decal Locations cont d BACK TUBE BOTH ENDS 174474 Tea sa LT NL o 3 DONC CNN VM BACK TUBE DOUBLE REEL ONLY BACK TUBE BOTH ENDS 11174432 11174434 169593 8 Revision B SECTION 3 SAFETY Safety Decal Locations cont d M 3 m BOTH ENDS DOUBLE KNIFE LEFT END SINGLE KNIFE 220238 DRIVELINE 194521 LEFT END 174436 169593 9 Revision B SECTION 3 SAFETY Safety Decal Locations cont d BOTH ENDS DOUBLE KNIFE LEFT END SINGLE KNIFE 220238 REEL ARMS LH amp RH REEL ARMS 174432 174632 169593 10 Revision B SECTION 3 SAFETY Safety Decal Locations cont d This is a SLOW SPEED Header Transport System To aod injury endfor machine damage caused by ics of conte Reed Opemio s Manua baloe transporting gb afl highway imbs requiagons in your aned when inaia on public roads Secure at pins ane hitch chain in transport postion See Opermiors Manual Move ree down and folly back do increase header stability Useslow moving vehide emblem and flashing waning lights unless prohi bibed by lave
85. al laws for width regulations and lighting or marking requirements before transporting on roads Follow all recommended procedures in your Combine Operator s Manual for transporting towing etc Disengage header drive clutch when travelling to and from the field Before driving combine on a roadway be sure flashing amber lamps red tail lamps and head lamps are clean and working properly Pivot amber lamps for best visibility by approaching traffic Always use these lamps on roads to provide adequate warning 10 other vehicles Do NOT use field lamps on roads they may confuse other drivers Before driving on a roadway clean slow moving vehicle emblem and reflectors Adjust rear view mirror and clean windows Lower the reel fully and raise header unless transporting in hills Maintain adequate visibility and be alert for roadside obstructions oncoming traffic and bridges When travelling downhill reduce speed and keep header at a minimum height This provides maximum stability if forward motion is stopped for any reason Raise header completely at bottom of grade to avoid contacting ground Travel speed should be such that complete control and machine stability are maintained at all times 169593 87 7 15 2 Towing The header can be towed behind the combine or with the Slow Speed Transport Stabilizer Wheel option or on an approved header transporter Refer to your Combine Operator s Manual or see your MacDon
86. alling optional stub guards Cutterbar Guards Breaking Excessive amount of rocks in Tip Experiment with a few field guards on a section of cutterbar to compare the performance of the two different styles of guards Reel running too fast Reduce reel speed Reel Shattering Pods Cut at night with heavy dew Bean pods are too dry once pods have softened See your MacDon Dealer Refer to your Combine Operator s Manual continued next page Refer to your Technical Service Manual 169593 194 Revision B SECTION 9 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Reel Shattering Pods cont d Cutterbar Pushing Too Much Trash And Dirt Cutterbar Pushing Too Much Dirt In Certain Locations For Length Of Field Cutterbar Fills Up With Dirt Reel Carries Over Odd Plants In Same Location Reel Carries Over Excessive Amounts Of Plants Or Wads See your MacDon Dealer Reel finger pitch not aggressive enough Reel too far forward of cutterbar C section Header angle too steep Regular guards push dirt and plug up with trash or plug up with trash and then push dirt Tire tracks or row crop ridges caused by seeding or spraying operations Rolling land along length of field due to cultivating Excessive gap between top of front of draper and cutterbar Reel fingers steel bent and hook plants out of the crop flow on drapers Dirt accumulation on end of fingers
87. and slide new sprocket onto shaft Install soeed sensor disc H if applicable onto shaft and secure with flat washer G lockwasher and bolt F Torque bolt to 18 24 N m Position chain J around sprockets Slide motor D and motor mount E upward until tension on chain D is such that hand force deflects the chain 1 8 inch 8 mm at mid span Tighten nuts C and re check tension Re install drive cover Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 6 Reel Drive U joint Double Reel Lubricate the U joint in accordance with the requirements in Section 8 4 5 Lubrication and Servicing If the U joint is severely worn or damaged it should be replaced 8 12 61 U joint Replacement a Lower header and reel shut down combine and remove key from ignition b Remove six screws A and remove upper cover B UNRELATED PARTS HIDDEN FOR CLARITY c Remove three screws C and remove lower cover D 169593 167 hee tee WN ee SV 2 4 1 UIT u emm d Support inboard end of right reel with a front end loader and nylon slings or equivalent set up IMPORTANT To avoid damaging or denting center tube support reel as close as possible to the end disc e Remove four bolts E attaching reel tube to U joint flange F and move reel sideways to disengage sub
88. approximately nine inches further aft by re positioning the cylinders on the reel arms This may be desirable when straight combining canola a Position reel fully aft with support arms horizontal Stop engine and remove key A WARNING Stop combine engine and remove key before making adjustments to machine A child or even a pet could engage the drive b Re position center arm cylinder as follows NOTE Reel components are not shown for Clarity gt a Ir n M REARWARD POSITION 1 Remove four bolts A securing cylinder bracket B to reel arm 2 Push reel back until bracket B lines up with the aft set of holes C HRe install the four bolts A to secure bracket to reel arm at new position 169593 15 Re position right arm cylinder as follows NOTE Reel components are not shown for Clarity LJ E 4 s tes ail x Rn 5 ay oe D REARWARD POSITION Remove four bolts D securing cylinder bracket E to reel arm Push reel back until bracket E lines up with the aft set of holes F Re install the four bolts D to secure bracket to reel arm at new position continued next page Revision B SECTION 7 d left arm cylinder as follows NOTE Heel components are not shown for clarity OPERATION 1 Remove pin A securing cylinder B to bracket
89. ar operating too low in Raise cutterbar using skid 7912 stony conditions shoes Excessive Breakage Of Sickle Sections Or Guards Float is set too heavy springs for Bent or broken guard Straighten or replace Header angle too steep Flatten header angle Bent or broken guard Straighten or replace Sickle Back Breakage sickle head pin sickle head sickle head pin 893 9 3 eplace Dull sickle Pra 9 3 REEL DELIVERY SYMPTOM PROBLEM SOLUTION SECTION Heel speed too fast Reduce reel speed in Normal Standing Crop Reel tines too aggressive Reduce cam setting 7 9 10 Reel too far back Move reel forward Reel tines too aggressive for standing crop Reel tines too aggressive Reduce cam setting Wrapping On Reel End Reel speed too fast Reduce reel speed 7 794 4 Crop conditions Install optional endshields Ew 10 8 Heel not centered in header Center reel in header 8123 123 Reel Not Releasing Material in Lodged and Standing Crop Reduce cam setting 1 or 2 Reel Fully Lowered See your MacDon Dealer Refer to your Combine Operator s Manual continued next page Refer to your Technical Service Manual 169593 188 Revision B SECTION 9 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Reel tines not aggressive Quickly Reel too far forward Move reel back Reel lift couplers are Reel Will Not Lift incompatible or defective Change q
90. ccess to the endsheet area 15 required the shield can be removed See Section 7 2 3 3 Removing below Closing shield towards header b Lift shield and engage pin C on top of frame endsheet c Pushin shield to engage lower latch D d Use tool B to lock lower latch D e Replace tool B and lynch pin A on top pin 7 2 3 3 a Open endshield See Section 7 2 3 1 Opening in previous column Removing b Remove acorn nut F and lift endshield off support Revision B 7 2 3 4 SECTION 7 OPERATION Installing a Position endshield on endshield support G and locate hole on the stud H b Secure endshield with acorn nut F c Close endshield See Section 7 2 3 2 Closing previous page 169593 NOTE Plastic endshields are subject to expansion or contraction depending on large temperature variations Top pin and lower latch bracket positions can be adjusted to compensate for dimensional changes Refer to next section 26 7 2 3 5 Adjustment a Check X between the front end of shield and header frame and compare to chart below TEMPERATURE GAP X Degrees Inches mm 25 4 1 1 8 28 continued next page Revision B 169593 SECTION 7 OPERATION If adjustments are required proceed as follows 1 Open endshield See Section 7 2 3 1 Opening 2 From inside endsheet loosen nut A on pin B with
91. cedures in Section 8 1 PREPARATION FOR SERVICING Tension Adjustment Timing Belt IMPORTANT To prolong belt and drive life do NOT over tighten belt Refer to 8 9 9 1 Left End Drive Tension Adjustment Timing Belt Removal Right End Timing Belt a Open right endshield b Loosen two nuts A on belt idler bracket to relieve tension on belt c Loosen nut B on idler pulley and slide idler down to loosen belt d Remove bolt in plate C in right endsheet at sickle drive box and remove plate This provides clearance between pulley and endsheet for when it is removed e Slip timing belt off sickle drive box pulley and route belt between sickle drive box pulley and endsheet f Remove belt from drive pulley 169593 140 a Installation Right End Timing Belt Route timing belt D between sickle drive box pulley E and endsheet and locate on sickle drive box pulley and over idler F NOTE When installing new belt never pry belt over pulley Be sure adjusting device is fully loosened then tension belt Position timing belt on drive pulley G Adjust timing belt tension and check belt clearance to belt guide Refer to 8 9 9 1 Left End Drive Tension Adjustment Timing Belt Re install plate C in endsheet Close left endshield Re adjust tension of a new belt after a short run in period about 5 hours Revision B SECTION 8 MAINTENANCE AND
92. cement Stub Guards Single Knife The guard near center of double knife header where the two sickles overlap requires a Stub guards complete with top guides and slightly different replacement procedure adjuster plates are designed to cut tough crops Some configurations of the D65 header come ee center guard or center top guide as equipped with stub guards at the outer ends ollows Replace stub guards as follows a Remove two nuts A and bolts that attach guard B and top guide C to cutterbar b Remove guard poly wear plate if installed top guide C and adjuster bar D a Remove the two nuts E and bolts that attach guard F and top guide G to cutterbar b Remove guard poly wear plate if installed top guide and adjuster bar H c Position poly wear plate if applicable replacement guard F adjuster bar H top guide G and install bolts Do not tighten IMPORTANT Note position of mitre on adjuster bar H Bar should be re installed in same position Mitres should not be adjacent to each other p IMPORTANT The first four outboard guards on drive side s of the header do NOT l have a ledger plate Ensure that the c Position poly wear plate if applicable proper replacement is installed replacement guard B adjuster bar D top guide C Install bolts but do not tighten IMPORTANT Ensure center guard B right of cutterbar split has offset cutting sur
93. crews A Torque set screws to 20 ft lbf 27 N m e Torque bolt C to 70 ft Ibf 95 N m f Re attach draper Refer to Section 8 11 2 Replacing Split Draper g Adjust draper tension Refer to Section 8 11 1 Header Draper Tension Adjustment h Re adjust hydraulic motor hoses if required and tighten hose clamps i Run machine and adjust tracking if required Section 8 11 3 Header Draper Alignment Revision B SECTION 8 MAINTENANCE AND SERVICING 8 11 4 3 Idler Roller Removal A DANGER Engage header lift cylinder stops and reel props before working under header or reel a Raise header and reel and engage cylinder and reel stops b On deck shift headers position deck so idler roller is easily accessible c Loosen and uncouple draper Refer to Section 8 11 2 1 Draper Removal d Remove bolts A and washer at ends of idler roller e Spread roller arms B and C and remove roller 169593 151 8 11 4 4 See illustration opposite Idler Roller Installation a Position stub shaft in idler roller in forward arm B on deck b Push on roller to deflect forward arm slightly so that stub shaft at rear of roller can be slipped into rear arm C c Install bolts A with washers and torque to 70 ft Ibf 93 N m d He attach draper Refer to Section 8 11 2 Replacing Split Draper e Adjust draper tension Refer to Section 8 11 1 Header Draper Tension Adjustment f Run machine and
94. ctions for details NOTE Header angle adjustments or AHHC ground pressure control may be used for on the go cut height adjustments Revision B 7 9 1 2 169593 SECTION 7 OPERATION Cutting On The Ground Cutting on the ground is controlled with a combination of skid shoes header angle and float adjustment and not with the header lift cylinders NOTE Skid shoes are standard equipment on the D65 header Having the header ride on the skid shoes allows the float linkage to float the header over obstacles and follow ground contours rather than supporting the header with the cylinders Lowering the skid shoes or decreasing the header angle increases the cutting height This may be desirable in stony conditions to reduce damage to cutting components Also a longer stubble length helps material dry faster Raising the skid shoes and increasing the header angle allows the crop to be shaved Refer to Section 7 8 1 Header Settings for recommended skid shoe positions in specific crops and crop conditions Set up the header as follows Fully raise the stabilizer wheels or slow speed transport wheels if installed Refer to previous section A DANGER To avoid bodily injury or death from unexpected start up or fall of raised machine stop engine remove key and engage lift cylinder stops before going under machine to adjust skid shoes or for any reason b Fully raise header engage lift cylinder stops
95. d MN E d Li p UPPER CROSS AUGER U JOINT amp BEARING REEL U JOINT 1 PLC DOUBLE REEL UPPER CROSS AUGER BEARING 1 PLC 169593 113 Revision B SECTION 8 MAINTENANCE AND SERVICING EVERY 250 HOURS cont d High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base a FRAME WHEEL PIVOT 1 PLC BOTH SIDES in j 00000000 AUGER PIVOT Revision B 169593 114 SECTION 8 MAINTENANCE AND SERVICING EVERY 500 HOURS REEL SHAFT RH BEARING 1 PLC REEL CENTER BEARING 1 PLC High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base ax j AL WHEEL BEARINGS 4 PLCS A REEL SHAFT LH BEARING 1 PLC 169593 115 Revision B 8 4 5 3 169593 SECTION 8 MAINTENANCE AND SERVICING Auger Drive Chain Lubrication Lubricate auger drive chain every 100 hours This can be done with the adapter attached to the combine but is easier if the adapter is detached The auger drive cover consists of an upper and a lower half Only the upper half needs to be removed to grease the chain Remove six bolts A securing the upper half Loosen three bolts B at the rear of cover Rotate upper half C forward to r
96. d or attempting to correct a problem shut off engine and remove key NOTE Until you become familiar with the sound and feel of your new header be extra alert and attentive Perform the items specified in to Section 8 4 2 Break In Inspections 7 6 SHUTDOWN PROCEDURE A CAUTION Before leaving the combine seat for any reason e Park on level ground if possible e Lower the header fully e Place all controls in NEUTRAL or PARK e Disengage header drive e Stop engine and remove key from ignition e Wait for all movement to stop 169593 59 7 7 HEADER CONTROLS A CAUTION Be sure all bystanders are clear of machine before starting engine or engaging any header drives See your Combine Operator s Manual for identification of in cab controls for e Header Drive Clutch e Header Height e Header Angle e Ground Speed e Reel Speed e Reel Height Reel Fore Aft Position Revision B SECTION 7 OPERATION 7 8 HEADER SET UP 7 8 1 Header Settings This table is a guideline for setting up the 065 Harvest Header Settings other than those suggested can be made to suit various crops and conditions not covered here See also Section 7 8 2 Pickup Reel Settings Draper Knife Divider Speed Header Angle Speed Reel Cam S 2 Reel P Suc d Upper Cross Notes Type g Condition Rods Setting Notes 1 and 4 Setting Setting peed Position 22 190 Note ee
97. d remove chain Install new chain as follows 1 Grind off the head from one of the link rivets on the new chain and punch out rivet to separate the chain 2 Feed new chain D around drive and driven sprockets and under idler sprocket Position chain ends so that connection can be made on driven sprocket E 3 Install connector link at F Refer to Section 8 3 2 Roller Chain Installation Tighten chain Refer to Section 8 8 2 Auger Drive Chain Adjustment Lubricate the chain with SAE Multi Purpose High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Re install chain case See step j on previous page Revision B SECTION 8 MAINTENANCE AND SERVICING 8 8 4 Auger Tine Replacement CA25 Combine Adapters are fitted with tines to accommodate a wide variety and sizes of combines Some conditions may require the removal or addition of tines for optimal feeding of the crop In addition tines that become worn or damaged should be replaced To simplify the procedure detach header from combine NOTE Refer to Section 7 3 HEADER ATTACHMENT If the sixth tine D opposite drive side DETACHMENT is being replaced it also must be slipped off drive tube G This 8 8 41 Tine Removal particular tine cannot be removed for normal operation d If tine is not re installed proceed to next step Otherwise proceed to Section 8 8 4 2 Tine Installation e R
98. d so that reason A child or even a pet could engage universals are aligned Align weld F an idling machine with missing spline when a Lower header stop engine and remove key assembling g Slide driveshaft in hook H so that disc J drops to secure driveshaft or connect to combine V VE Mp nomm b Remove chain adjusting cover Be sure gasket B is not damaged c Remove retainer plate C d Tighten bolt D to 60 in lbf 6 8 N m Then back off bolt 1 2 3 turns e Re install retainer plate C f Re install chain adjusting cover A and gasket B Torque hardware to 84 in Ibf 9 5 N m 169593 124 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 8 AUGER 8 8 1 Auger Pan Clearance a Adapters are factory set to the proper auger clearances to the pan and feed draper led r 3 16 3 8 5 10 mm PAN CLEARANCE STEEPEST HEADER ANGLE b FEED DRAPER CLEARANCE AT FLATEST HEADER ANGLE IMPORTANT is important that these clearances are maintained Too little clearance may result in the tines or flighting contacting and damaging the draper or feed under certain orientations of the header Look for evidence of contact when greasing the adapter d e f g 169593 125 Should adjustment to the auger be necessary proceed as follows Extend center link to maximum for steepest
99. d up on a Reel Ends Wrap Up With Uncut crop interfering on reel Crop ends Reel Wraps Up With Crop Ree too low Lower header to ground and run on skid shoes and or 7 9 1 2 cutterbar Header being carried off ground Float set too light rides on Set float for high spots and does not get Dry ground 100 150 Ibf 7 9 2 back down soon enough Wet ground 50 100 Ibf Reel being operated too high Fully retract reel cylinders Reel too high with cylinders fully retracted Adjust reel height 8 12 1 Finger pitch not aggressive Move reel forward until the Reel too far back on reel fingertips skim the soil surface 799 support arms with header on ground and HS center link properly adjusted Plants Being Stripped and Complete Or Partial Plants Left Behind Lengthen center link Header angle too shallow If cutting on ground header 7 9 3 angle can be increased by fully retracting lift cylinders Adjust reel speed to be Reel too slow Mi faster than ground 7 9 4 speed Ground speed too fast Lower ground speed Header skid shoes adjusted Raise skid shoes to maximum 7912 too low Up position Dirt packs on bottom of Install plastic wear strips on cutterbar and raises cutterbar bottom of cutterbar and skid off the ground shoes Replace sections or complete knife Worn damaged knife sections See your MacDon Dealer Refer to your Combine Operator s Manual
100. dapter and header This kit is NOT recommended for use if there are rocks present 10 13 KNIFE HEAD SHIELD The shields attach to the endsheets and reduce the knife head opening to prevent cut crop from accumulating over the knife head They are slightly different depending on header size See Parts Catalog for details 10 14 DRAPER WIDE DEFLECTOR KIT iu 4 L 4 iP 53 3 o3 14 3 EG iie E 1 4 gt E Rubber deflectors that attach to the inboard side of the endsheets prevent material from falling through the gap between the endsheet and draper Revision B SECTION 11 UNLOADING AND ASSEMBLY 11 UNLOADING AND ASSEMBLY Refer to header specific instruction for the unloading assembly and set up procedures that are included with your shipment according to the following table SHIPPING INSTRUCTION DESTINATION HEADER DESCRIPTION PART NUMBER NORTH AMERICA D65 HARVEST HEADER AND CA25 ADAPTER MD 169602 EXPORT D65 HARVEST HEADER AND CA25 ADAPTER MD 169604 169593 199 Revision B PDDICVIALIONS 18 Adapter COMPONEN Ec 20 feed draper 145 TET DH 85 Adjustable Skid Shoes with Poly Cover 196 Attachment PAG CO 47 Case IH 7010 8010 8120 5088 6088 7088 31 CAT Lexon D00700 rua aiiis emer ooo Stine od tu 39 John Deere 60 70 and S
101. der stops before going under machine to remove crop dividers or for any reason 7 9 12 1 Headers with Latch Option Removal a Raise header and engage header lift cylinder lockouts Refer to your Combine Operator s Manual Stop engine and remove key b Open header endshields See 7 2 3 Endshields c Lift safety lever d Hold onto divider D push lever E to open latch and lower divider e Lift divider off endsheet and store as follows 1 Locate pin F on divider in in endsheet at location shown 2 Lift divider and locate lugs G on divider into bracket on endsheet Ensure lugs engage bracket f Close header endshield continued next page Revision B SECTION 7 OPERATION Headers Without Latch Option a Raise header and engage lift cylinder lockouts Refer to combine operating manual b Open header endshield Refer to Section 7 2 3 Endshields c Remove bolt A c Position crop divider as shown by locating lugs C in holes in endsheet d Lower divider B e Lift divider off endsheet Close header endshield d Lift forward end of divider until pin D at top of divider engages and closes latch E 7 9 12 2 Installation e Push safety lever F down to lock pin in latch Headers with Latch Option a Open header endshield ET ag eal f Check that divider does not move laterally b At divider storage location lift divid
102. ders A CAUTION Wear heavy gloves when working around or handling sickles 169593 83 Revision B SECTION 7 7 11 HEADER LEVELLING The adapter is factory set to provide the proper level for the header and should not normally require adjustment If the header is not level perform the following checks prior to adjusting the leveling linkages IMPORTANT The adapter float springs are not used to level the header e Check combine tire pressures e Check that the combine feeder house is level Refer to your Combine Operator s Manual Check that of adapter is level with combine axle Make fine adjustments to header leveling as follows a Park combine on level ground b Check float lock is disengaged so header can float c Check and set float adjustment Section 7 9 2 Header Float Refer to d Set header approximately 6 inches 150 mm off ground and check that float linkage is against down stops Note high and low end of header e Adjust level with nut A at each float lock as follows Use small adjustments 1 4 1 2 turn and adjust each side equally but in opposite directions NOTE Set screw B does not require loosening for adjustments up to one half turn of nut A 64 169593 OPERATION 1 Turn low side nut clockwise to raise header 2 Turn high side nut counterclockwise to lower header NOTE Adjustment of more than two turns in either direction may adversely aff
103. do not let plants slide off fingers over drapers Excessive accumulation of crop on drapers up to height of reel center tube Finger pitch too retarded Refer to your Combine Operator s Manual Refer to your Technical Service Manual 169593 195 Increase finger aggressiveness cam position 7910 Re position reel Header too heavy to make Decrease header angle with lift cylinders 7 9 3 Shorten the center link Install stub guard kit Improper support for header e skid shoes on Cut at angle to ridges or crop rows to allow knife and guards to clean out better Cut at 90 to undulations provided knife floats across without digging in Adjust front deck hooks to obtain proper clearance between cutterbar and draper 8 11 5 Raise header fully at each end of field or as required and shift decks back and forth to help clean out cutterbar Straighten fingers steel Haise reel Adjust reel fore and aft location to move fingers out of 7 9 9 the ground Increase draper speed 7 9 6 Increase finger pitch 7 9 10 Revision B SECTION 10 OPTIONS AND ATTACHMENTS 10 OPTIONS AND 10 3 STABILIZER WHEELS ATTACHMENTS see your MacDon Dealer for availability and ordering information 10 1 ADJUSTABLE SKID SHOES WITH POLY COVER Available as an attachment stabilizer wheels help stabilize the header in field conditions that would otherwise cause the Inner skid
104. e an idling machine c Disconnect driveshaft B from combine and slide driveshaft in hook so that disc D drops to secure driveshaft b Engage both adapter float locks by lifting lever A at each lock until it latches into lock position IMPORTANT If slow speed transport wheels are installed header may be detached in either Transport or Field mode If detaching with wheel in Field mode set wheels to storage or uppermost working position Refer to Section 7 9 1 Cutting Height continued next page d Remove electrical connector E and replace cover 169593 33 Revision B SECTION 7 OPERATION CASE IH e Push in lock button F and pull handle G to release coupler H Position coupler H onto storage plate J on combine f Place electrical connector E in storage cup on plate on combine J g Push handle G to closed position until lock button F snaps out Close cover 169593 34 Lift lever L pull and lower handle M to disengage feeder house adapter lock N Lower feeder house until it disengages adapter support Slowly back combine away from adapter Revision B SECTION 7 OPERATION JOHN DEERE 60 70 and S SERIES 7 3 3 John Deere 60 70 and S Series p Contour Master Level Land f Check that bolts E on adapter brackets are tight g If pins B do not fully engage adapter brackets loosen bolts E and adjust bracket as requir
105. e is directly under the adapter top cross member f Lower handle A to engage adapter pins B into feeder house Re insert locking pin E and secure with hairpin continued next page c Raise feeder house to lift adapter ensuring feeder house posts C are properly engaged in adapter frame D d Position header slightly off the ground 169593 39 Revision B SECTION 7 OPERATION CAT LEXION g Connect hydraulic hoses as follows 1 Unscrew knob F on combine coupler G h Place cover J on combine receptacle to release coupler from combine receptacle i Rotate disc N on adapter driveline storage hook and remove driveline from hook 3 Clean mating surface of coupler G and locate onto adapter receptacle 4 Turn knob F to secure coupler to receptacle 5 Connect combine harness L to reel fore aft header tilt selector receptacle M Attach driveline to combine output shaft O continued next page 169593 40 Revision B SECTION 7 OPERATION CAT LEXION b Engage the adapter float locks by lifting lever A at both locks until it latches into the lock position IMPORTANT If slow speed transport wheels are installed header may be detached in either Transport or Field mode If detaching with wheel in Field mode set wheels to storage or uppermost working position Otherwise header may tilt forward so that re attachment will be difficult Refer
106. ect header float d uw h h b ii 181 2 3 mm Always be sure there is a minimum 1 8 inch 2 to 3 mm clearance between frame and back of bellcrank lever as shown NOTE Float does not require adjustment after levelling header Revision B SECTION 7 OPERATION 7 12 UNPLUGGING CUTTERBAR a b Stop forward movement of machine and disengage header drives With header on ground back up several feet and engage header drive clutch A CAUTION Lowering rotating reel on plugged cutterbar will damage reel components c If plug does not clear disengage header drive clutch and raise header fully A WARNING Stop engine and remove key before removing plugged material from header A child or even a pet could engage the drive d Shut off engine remove key and engage park brake e Engage header lift cylinder locks A WARNING Wear heavy gloves when working around sickle f Clean off cutterbar by hand NOTE If sickle plugging persists see Section 9 TROUBLESHOOTING 169593 85 7 13 UNPLUGGING ADAPTER a b Stop forward movement of the machine and disengage header drives Raise header slightly off the ground and raise the reel Activate the header reverse drive control on combine and engage the header drive When plug clears disengage header drive and deactivate the reverse switch Re engage header drive
107. ect on gearbox Do NOT disconnect tether C Pull quick disconnect collar to release driveline yoke and pull driveline off shaft Slide shield B off driveline Rotate disc D on adapter driveline storage Ll hook and remove the NB 4 driveline from hook N p Revision B SECTION 8 MAINTENANCE AND SERVICING 8 7 2 Driveline Installation 8 73 Guard Removal IMPORTANT The main driveline guard normally remains If combine output shaft splines attached to the driveline match adapter input shaft splines ensure driveline is installed with longer guard at adapter gearbox A CAUTION A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine If removal is required for maintenance proceed as follows Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine NOTE 7 The driveline does not need to be removed from the adapter in order to remove the driveline guard a Rotate disc D on adapter driveline storage hook E and remove driveline from hook a Slide driveshaft in hook E so that disc D drops to secure driveshaft b Lift combine end of driveline F from hook and extend driveline until it separates Hold adapter end of driveline to prevent it from dropping and hitting the
108. ed Re tighten bolts h Remove blocks from under cutterbar i Start engine and lower header a Push handle A on combine coupler toward feeder house to retract pins B at bottom corners of feeder house b Slowly drive combine up to adapter until feeder house saddle C is directly under the adapter top cross member D c Haise feeder house to lift adapter ensuring feeder saddle is properly engaged in adapter frame d Raise or lower header until slightly off the ground j Pull handle F on adapter to release coupler G from storage position Remove coupler CAUTION and push handle back into adapter to store k Attach coupler C Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine 1 Handle A should be in the nearly up position Clean receptacle e Pull handle A to engage pins B in adapter continued next page 169593 35 Revision B SECTION 7 OPERATION JOHN DEERE 60 70 and S SERIES 2 Locate coupler G onto receptacle and pull handle A so that lugs on coupler are engaged into handle 3 Pull handle to full horizontal position as shown n Disengage both adapter float locks by moving 4 Slide latch H to lock handle in position latch P away from adapter and moving lever and secure with lynch pin J Q at each lock to lowest position 5 If adapter is equipped with reel
109. ely mid way c Hemove any rust or paint from pitman arm splines For replacement parts remove oil grease with degreasing agent 169593 143 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 10 6 Changing Oil NOTE Change sickle drive box lubricant after the first 50 hours of operation and every 1000 hours or 3 years thereafter a Raise header to allow a suitable container to be placed under sickle drive box drain to collect oil b Open endshield s c Remove breather dipstick and drain plug d Re install drain plug and add 2 3 U S quarts 2 2 liters SAE 85W 140 oil to required level e Close endshield s 169593 144 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 10 ADAPTER FEED DRAPER A CAUTION To avoid personal injury before servicing machine or opening drive covers follow procedures in Section 8 1 PREPARATION FOR SERVICING 8 10 1 Draper Tension Adjustment Draper tension should be just enough to prevent slipping and keep draper from sagging below cutterbar Set draper tension as follows A DANGER To avoid bodily injury or death from fall of raised machine always engage lift cylinder stops before going under header for any reason See your Combine Operator s Manual for instructions for use and storage of header lift cylinder stops A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage
110. emove E Liberally apply grease to chain D f Re install upper half C by positioning the inboard lip into the auger tube and rotating back to engage the rear support g Replace and tighten bolts A and B 8 4 5 4 Main Drive Gearbox Lubrication Oil Level Check oil level every 100 hours as follows A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine a Set cutterbar to working position Remove oil level plug E bottom of hole Re install plug E Add oil if required See next section Adding Oil Level should be to Lower cutterbar to ground Gearbox must be in working position Remove oil level plug E and filler plug F Add SAE 85W 140 oil at F until it runs out of hole E Replace oil level plug E and filler plug F Revision B SECTION 8 MAINTENANCE AND SERVICING Changing Gearbox Lubricant NOTE Change main drive gearbox lubricant after the first 50 hours of operation and every 1000 hours or 3 years thereafter a Raise or lower header to position oil drain plug A at its lowest point b Place a suitable container approximately one US gallon 4 liters under gearbox drain to collect oil c Remove drain plug A and filler plug B and allow oil to drain d Replace drain plug A and remove oil level plug C e
111. emove clevis pin F and set aside for will affect the main header float later installation Refer to Section 7 9 2 Header Float 5 Push latch G and lift tow bar H from for adjustment procedures hook Release latch c Store tow bar on header as follows 1 Locate larger end of one section of tow bar in cradle K on header back tube 169593 89 Revision SECTION 7 OPERATION 7 15 31 Front Wheels To Field Position A DANGER To avoid bodily injury or death from unexpected start up or fall of raised header stop engine remove key and engage header lift cylinder stops before going under header for any reason a Raise header fully b Swivel wheel assembly so that wheels are aligned with lower frame TRANSPORT TO FIELD FRONT WHEELS c Remove pin A and pull wheel assembly towards rear of header Store pin A in hole at top of leg 169593 90 TRANSPORT TO FIELD FRONT WHEELS d Pull handle C to release and lower the linkage TRANSPORT TO FIELD FRONT WHEELS e Align lift hook D with lug E and lift wheel assembly to engage pin in hook Ensure latch F is engaged f Install clevis pin B and secure with hairpin etree E ETC 8 pre eee E M c TRANSPORT TO FIELD FRONT WHEELS g Lift wheel assembly to desired height and slide linkage F into appropriate slot in vertical support h
112. emove screws H securing plastic guide F to auger and remove guide from inside auger b From inside the auger remove hairpin C and pull tine D out of bushing E f Position cover J from inside auger over hole c From inside the auger swivel tine away from and secure with screws K Coat screws with bushing pull from plastic guide F and remove Loctite 243 or equivalent and torque to from auger 75 in lbf 8 5 N m 169593 128 Revision SECTION 8 MAINTENANCE AND SERVICING 8 8 4 2 Tine Installation If replacing tine proceed to step d Otherwise proceed to step a a Remove access cover if applicable b Remove cover at tine location if applicable c Install plastic guide g Replace access cover B and secure with screws A Coat screws with Loctite 243 or equivalent and torque to 75 in lbf 8 5 N m d Insert tine D through plastic guide F from inside the auger e Insert tine into bushing E NOTE The 6 tine D must also be inserted through the square tube G f Secure tine in bushing with hairpin C Install hairpin with closed end leading with respect to auger forward rotation 169593 129 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 SICKLE AND SICKLE DRIVE A CAUTION To avoid personal injury before servicing machine or opening drive covers follow procedures in Section 8 1 PREPARATION FOR SERVICING A WARNING Keep hands c
113. en torque value in the table shown in the opposite column NOTE If available always hold the hex on the fitting body to prevent unwanted rotation of fitting body and hose when tightening the fitting nut When assembling unions or two hoses together three wrenches will be required Revision B SECTION 8 MAINTENANCE AND SERVICING 8 3 2 Roller Chain Installation a 169593 A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine Locate ends of chain on sprocket Install pin connector A into chain preferably from the sprocket backside Install connector B onto pins Install spring clip C onto front pin D with closed end of clip in direction of sprocket rotation Locate one leg of clip in groove of aft pin E Press other leg of spring clip over face of aft pin E until it slips into groove Do not press clip lengthwise from closed end Ensure clip is seated in grooves of pins 100 8 3 3 Sealed Bearing Installation a Clean shaft and coat with rust preventative Install flangette F bearing second flangette H and lock collar J NOTE The locking cam is only on one side of the bearing Install but do not tighten flangette bolts When the shaft is correctly located lock the lock collar with a punch NOTE The collar should be locked in the same direction the shaft r
114. er is level with combine axle continued next page 169593 66 Revision B SECTION 7 OPERATION UNLOCK g Move both header float lock levers B down UNLOCK h If header is equipped with stabilizer wheels or slow speed transport wheels place them in storage position i Remove special torque wrench D from storage position at RH side of adapter frame Pull slightly in direction shown to disengage wrench from hook A y 67 169593 RIGHT SIDE Place torque wrench D onto float lock at E Note position of wrench for checking RH or LH side Push down on wrench to rotate bell crank F forward Continue pushing down on the wrench until indicator G reaches a maximum reading and begins to decrease Note the maximum reading Repeat for opposite side Use the table below as a guide for float settings TORQUE SETTINGS HEADER SIZE FT CUTTING ON CUTTING OFF THE GROUND THE GROUND 1 1 2 to 2 2 to 2 1 2 continued next page Revision B 169593 SECTION 7 OPERATION If reading on wrench is high header is heavy If reading on wrench is low header is light LI Te gt LEFT SIDE FLOAT RIGHT SIDE FLOAT To increase float lighten header turn bolts H and J clockwise NOTE Loosen jam nuts on adjuster bolts before adjusting and re tighten once complete To decrease float increase header weight turn bolts H and
115. er stops on combine remove prop from under center link A 2 Install pin B through center link A and bracket and secure with lynch pin Replace pin D in header legs and secure with ring C p Remove lift cylinder locks start engine and lower header to ground Adjust header angle to the shallowest setting shortest center link continued next page k Connect reel hydraulics at right end of adapter matching colored plastic ties 169593 56 Revision B SECTION 7 OPERATION ADAPTER q Raise reel fully shut down engine and remove 4 Repeat for other side of feed draper deck key from ignition r Engage reel props A WARNING Keep hands clear of the area between guards and sickle at all times s Attach adapter feed deck E e E P eT e E i E ie P E E p eT ETT I n a d mt Install fillers N at each front corner of feed deck with two 3 8 inch x 0 75 long hex head bolts O at each location M gt an rs ge 1 a MAE eese sen s 1 Remove bolts at either side of opening to allow attachment of adapter deck 2 Rotate latches E forward and down engage transition pan tube L u Connect knife and draper drive hydraulics as shown above matching colored plastic cab
116. er to Adjust bolts G as required to tighten divider disengage lugs C at lower end and then lower and remove lateral play when pulling at divider it slightly to disengage pin D from endsheet tip g Close endshield continued next page 169593 81 Revision B SECTION 7 OPERATION Headers Without Latch Option a Open endshield b Remove from storage 7 9 13 Rice Dividers Optional special rice dividers can be installed and used when required See Section 10 10 c Position crop divider as shown by locating lugs RICE DIVIDER RODS A in holes in endsheet The installation and removal procedures are the same as for the standard crop dividers d Lift forward end of divider and install bolt B and special stepped washer C step towards divider Tighten bolt e Check that divider does not move laterally Adjust bolts D as required to tighten divider and remove lateral play when pulling at divider tip f Close endshield 169593 82 Revision B SECTION 7 OPERATION 7 10 KNIFE HEAD SHIELD The shield attaches to the endsheet and reduces the knife head opening to prevent cut crop from accumulating in knife head cut out creating plugging lt is recommended that the shield s be installed when harvesting severely lodged crop or any crop condition where plugging occurs at knife head cut out The shield s and mounting hardware available from your MacDon Dealer and are instal
117. es not have to be removed from arm e Seal bearing in sickle head with plastic or tape f Wrap a chain around sickle head and pull sickle out NOTE For single drive sickles with splice plate remove bolts from splice plate and pull sickle out from both ends 8 9 3 Sickle Head Bearing Replacement 8 9 3 1 Bearing Removal a Remove sickle Refer to previous section b Using a flat ended tool D with approximately the same diameter as the plug E tap out the seal F bearing G and plug from the underside of the head NOTE The seal can be replaced without removing the bearing When changing seal check pin and needle bearing for wear Replace if necessary 169593 131 8 9 3 2 Bearing Installation a REMOVAL Place O ring C and plug E in sickle head IMPORTANT Install the bearing with the stamped end the end with identification markings against the tool Using a flat ended tool D with approximately the same diameter as the bearing G push the bearing into the sickle head until the top of the bearing is flush with the step H in sickle head Install seal F in top of sickle head with lip facing outwards IMPORTANT To avoid premature sickle head or sickle drive box failure be sure there is no looseness in e fit of sickle head pin and needle bearing and e fit of sickle head pin and pitman arm Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 4 Sickle Installation
118. es travel uphill or downhill when possible Be sure to keep transmission in gear when travelling downhill Never attempt to get on or off a moving machine Do NOT leave Operator s station while the engine is running continued next page Revision B SECTION 7 OPERATION e Stop engine and remove key before adjusting or removing plugged material from the machine A child or even a pet could engage the drive e Check for excessive vibration and unusual noises If there is any indication of trouble shut down and inspect the machine Follow proper shutdown procedure Refer to Section 7 6 SHUTDOWN PROCEDURE e Operate only in daylight or good artificial light 7 2 1 Header Lift Cylinder Locks A DANGER To avoid bodily injury or death from fall of raised machine always engage lift cylinder stops before going under header for any reason See your Combine Operator s Manual for instructions for use and storage of header lift cylinder stops 7 2 2 Reel Props A WARNING To avoid bodily injury from fall of raised reel always engage reel props before going under raised reel for any reason IMPORTANT To prevent damage to reel support arms do not transport header with reel props engaged Reel props are located at the reel support arms Engage Props Raise reel to maximum height b At outer arms move props A to engaged position shown 169593 24 NOTE Keep pivot bolt B properly tightened
119. es not come off by hand 1 Install flat washer G lock washer and bolt F 2 Torque bolt to 18 24 N m WLS Vie od M m Tighten chain E Refer to Section 8 12 4 1 h Align keyway H in new sprocket with key J in Tension Adjustment High Torque Drive shaft and slide new sprocket onto shaft continued next page i Slip chain over drive sprocket j Install speed sensor disc if applicable onto shaft 169593 164 Revision B SECTION 8 MAINTENANCE AND SERVICING n Re install drive cover s 1 Double Reel Position upper cover B onto drive and secure with six screws A 2 Single Reel High Torque Position cover D onto drive and secure with four screws C 169593 165 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 5 2 Sprocket Replacement Single Reel Standard Torque Drive a Lower header and reel shut down combine and remove key from ignition b Remove four screws A and remove reel drive cover B C Loosen bolts C d Slide motor D and motor mount E down towards reel shaft e Remove bolt F lock washer and flat washer G f Remove speed sensor disc H if installed 169593 Remove sprocket K from shaft IMPORTANT Do NOT use pry bar and or hammer to remove sprocket This will damage the motor Use a puller if sprocket does not come off by hand Align keyway L in new sprocket with key M in shaft
120. faces NORMAL DRIVE SIDE Top guide C must accommodate the two overlapping knifes at center guard d Check and adjust clearance between top guide location on Double Knife header and sickle Refer to Section 8 9 7 Sickle Ensure replacement is correct part Hold Downs 169593 134 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 7 Sickle Hold Downs Check daily that sickle hold downs are set to prevent sickle sections from lifting off guards but still permit sickle to slide without binding NOTE Guards should be aligned prior to adjusting hold downs 8 9 7 1 Pointed Guard Adjustment a To adjust the clearance between hold down and sickle for typical pointed guards 0 1 0 6 mm 1 Turn the adjuster bolts A Using a feeler gauge clearance from hold down to sickle section should be 0 004 0 024 in 0 1 0 6 mm NOTE For larger adjustments it may be necessary to loosen nuts B turn adjuster bolt A then re tighten nuts B b To adjust clearance between hold down and sickle 0 004 0 040 in 9 TL 0 1 1 0 mm g lt LO 1 Torque nuts C to 35 ft lbf 46 N m 2 Turn the adjuster bolts D Using a feeler gauge clearance from hold down to sickle section should be e 0 004 0 016 in 0 1 0 4 at guide tip and e 0 004 0 040 in 0 1 1 0 mm at rear of guide Torque nuts C to 53 ft lbf 72 N m 169593 135 0 004 0 016 in 0 1 0 4 mm
121. follows p Store and secure hoses to adapter frame q Ensure header is on ground or is supported by wheels in Transport mode 1 Line up slot N in collar with pin on connector Start engine and slowly back combine away from header 2 Push collar toward pin and pull connector to disengage 5 Stop engine and remove key Install plugs or caps on hose ends if equipped m Disconnect electrical connector P by turning collar counterclockwise and pulling connector to disengage n Store and secure hoses electrical connector on adapter t Replace pin J in header legs and secure with ring H 169593 54 Revision B SECTION 7 OPERATION ADAPTER 7 4 2 Attaching The D65 Harvest Header can be attached to the adapter from either Field configuration or Transport configuration NOTE Stabilizer Transport wheels can be used to support header Refer to Section 7 9 1 Cutting Height a Prop up hydraulic center link A with pin or equivalent tool at B A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine b Remove ring C from pin D and remove pins from header legs at delivery opening 169593 55 Ensure latches E at front corners of adapter are rotated towards the rear of adapter A CAUTION Be sure all bystanders are clear of machine before starting e
122. fore aft header tilt selector connect harness K to combine connector L Rotate disc M on adapter driveline storage hook and remove driveline from hook m Pull back collar N on end of driveline and push onto combine output shaft O until collar locks 169593 36 Revision B SECTION 7 OPERATION JOHN DEERE 60 70 and S SERIES IMPORTANT If stabilizer wheels are installed set wheels to storage or uppermost working position Otherwise header may so that re attachment will be difficult Refer to Section 7 9 1 Cutting Height 7 3 3 2 Detachment a Choose a level area Position header slightly above ground Stop engine and remove key A DANGER To avoid bodily injury or death from fall of raised machine always engage lift cylinder stops before going under header for any reason See your Combine Operator s Manual for instructions for use and storage of header lift cylinder stops A CAUTION Stop engine and remove key from ignition c Open shield B on combine Pull back collar before leaving Operator s seat for any on driveline and pull driveline C off combine reason A child or even a pet could engage output shaft an idling machine d Slide driveline in hook D so that disc E drops b Engage both adapter float locks by lifting lever to secure driveline A at each lock until it latches into the lock position IMPORTANT If slow speed transport wheels are instal
123. g Type Hydraulic Fittings 8 3 1 3 Flare Type Hydraulic Fittings FITTING WASHER O RING GROOVE SEAT FLARESEAT BODY a Check flare and flare seat for defects that might cause leakage b Align tube with fitting before tightening Lubricate connection and hand tighten swivel nut until snug d To prevent twisting the tube s use two wrenches Place one wrench on the connector body and with the second tighten the swivel nut to the torque shown a Inspect O ring and seat for dirt or obvious defects KG 524 RECOMMENDED TURNS TO TIGHTEN AFTER FINGER b On angle fittings back off the lock nut until TIGHTENING washer A bottoms out at top of groove B in fitting c Hand tighten fitting until back up washer washer face if straight fitting bottoms on part Tae me 5 3 8 7 16 9 16 12 mne 916 face C and O ring is seated d Position angle fittings by unscrewing no more one turn 9 e Tighten straight fittings to torque shown 2 f Tighten angle fittings to torque shown the 102 following table while holding body of fitting with COREEA a wrench 1 156 1 1 105 142 3 4 RECOMMENDED E NUT SIZE TURNS TO TIGHTEN Torque values shown are based on lubricated connections as ACROSS AFTER FINGER in re assembly in TIGHTENING Cms ns 8 O 8 1 2 Pans ne 16 rio ve 1 Torque values shown are based o
124. ge adapter pins K from feeder house Replace locking pin J in adapter pin and secure with hairpin Remove cover H from combine receptacle h Lower feeder house to ground until feeder house posts M disengage adapter N i Slowly back combine away from adapter 4 Locate coupler G onto combine receptacle and turn knob F to secure coupler to receptacle 169593 42 Revision B SECTION 7 OPERATION NEW HOLLAND CR CX 7 3 5 New Holland CR CX 7 3 5 1 a gi oe Attachment Ensure handle A is positioned so that hooks B can engage adapter Slowly drive combine up to adapter until feeder house saddle C is directly under the adapter top cross member D c Raise feeder house to lift adapter ensuring feeder saddle is properly engaged in adapter frame A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine 169593 43 E Lift lever E on adapter at left side of feeder house and push handle A on combine so that hooks B engage pins F on both sides of the feeder house Push down on lever E so that slot in lever engages handle to lock handle in place If hook B does not fully engage pin on adapter when A and E are engaged loosen bolts G and adjust lock as required X Re tighten bolts Open cover J Push in lock button K and pull handle L
125. ground Slide shield B over driveline c Locate driveline quick disconnect onto adapter gearbox shaft pull back collar and slide onto shaft until yoke locks onto shaft Release collar d Position shield B on gearbox and secure with c Release grease zerk lock with a nuts A screwdriver e Re connect other end to combine if necessary continued next page 169593 122 Revision B SECTION 8 MAINTENANCE AND SERVICING b Push guard onto ring until locking ring is visible in slots C b d Rotate guard locking ring counterclockwise with a screwdriver until lugs J line up with slots in guard e Pull guard off driveline f Repeat above steps c to e for the other driveline guard c Rotate ring D clockwise with a screwdriver to lock ring in guard 8 7 4 Guard Installation d Push grease zerk E back into guard e Repeat steps a to d for the other guard continued next page a Slide guard onto driveline and line up slotted lug on locking ring A with arrow B on guard 169593 123 Revision B SECTION 8 MAINTENANCE AND SERVICING f Re assemble driveline 8 7 5 Gearbox Drive Chain Adjustment A sprocket on main drive input shaft from combine drives another shaft to auger To adjust tension on chain in main gearbox proceed as follows CAUTION Stop engine and remove key from ignition NOTE before leaving Operator s seat for any The splines are keye
126. h are available from your MacDon Dealer 8 1 PREPARATION FOR SERVICING Ay aution To avoid personal injury before servicing header or opening drive covers 1 Fully lower the header If necessary to service in the raised position always engage lift cylinder stops Stop engine and remove key Engage park brake Wait for all moving parts to stop 8 2 RECOMMENDED SAFETY PROCEDURES e Park on level surface when possible Block wheels securely if combine is parked on an incline Follow all recommendations in your Combine Operator s Manual e Wear close fitting clothing and cover long hair Never wear dangling items such as scarves or bracelets e Wear protective shoes with slip resistant soles a hard hat protective glasses or goggles and heavy gloves e If more than one person is servicing the machine at the same time be aware that rotating a driveline or other mechanically driven component by hand for example accessing a lube fitting will cause drive components in other areas belts pulleys and sickle to move Stay clear of driven components at all times 169593 96 Be prepared if an accident should occur Know where the first aid kit and fire extinguishers are located and how to use them 22 2t 2255 Keep the service area clean and Wet or oily floors are slippery Wet spots can be dangerous when working with electrical equipment Be sure electrical outlets and tools are pro
127. i REARWARD POSITION 1 Remove four bolts D securing cylinder bracket E to reel arm 2 Push reel back until bracket E lines up with the aft set of holes F Re install the four bolts D to secure bracket to reel arm at new position 77 Re position left arm cylinder as per Section 7 9 9 2 Fore Aft Cylinder Position Double Reel step d Check reel clearance to back sheet upper cross auger if installed and reel braces Adjust reel tine pitch if required Refer to Section 7 9 10 Reel Tine Pitch or Section 8 12 1 Reel Clearance to Cutterbar adjustment procedures Revision B 169593 SECTION 7 OPERATION 7 9 10 Reel Tine Pitch IMPORTANT The following describes the concept and operational guidelines of the pickup reel Please read carefully before operating the machine 7 9 10 1 Concept The pickup reel is designed to pick up flattened and severely lodged crops lt is not always necessary to increase the tine pitch higher cam setting to pick up crops that are lodged but rather the cam settings are mainly used to determine how the crop will get delivered to the drapers The position of the fingers relative to ground tine pitch is not significantly affected by the cam setting For example the cam position range is 33 degrees but the corresponding finger pitch range is only 5 degrees at the lowest point of reel rotation For best performance use the minimum cam setting that
128. in reel arm Tighten clamp with modified channel lock pliers K so that finger pressure will not c the center and left side disc position bushing 3 halves D on tine tube so that lug in each bushing half locates in hole in tine tube move clamp d Slide reel arm B onto bushing and position IMPORTANT onoma Over tightening clamp result in e Install bolts A in original holes and tighten breakage f Re install any fingers or tines that were removed 169593 180 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 10 3 Bushing Removal 5 Bat Pick Up Reels a Remove bushings at cam end disc as follows 4 169593 Remove bolts A securing arm B to disc IMPORTANT Ensure tine tube is supported at all times to prevent damage to the tube or other components IMPORTANT Note the hole locations in arm and disc and ensure bolts re installed at original locations Remove bushing clamp previously described Rotate arm B clear of disc and slide arm off bushing Remove bolt from tine next to arm or remove plastic finger if required so that arm can slide off bushing Remove bushing halves C 181 Remove bushings at center disc and left end disc as follows Disconnect reel arm at cam end so that tine tube is free to move See step a 1 Remove bolt D at on cam linkage so that tine tube 1 free to rotate Slide tine tube outboard to expose bu
129. ine Operator s Manual for instructions for use and storage of header lift cylinder stops c Disengage reel props start engine lower reel and raise header fully Stop engine remove key and engage combine lift cylinder locks d Remove ring H from pin J and remove pins from header legs at delivery opening GROUND e Place two 6 inch 150 mm blocks K under header legs at delivery opening 169593 53 NOTE Stabilizer Transport wheels can be used to support header Disengage lift cylinder locks Start engine and lower header until it rests on blocks K or stabilizer wheels and the ground NOTE Length of hydraulic center link may need to be adjusted to relieve load on link A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine h Stop engine and remove key from ignition Disconnect hydraulic center link Remove lynch pin and clevis pin L then lift center link M clear of bracket 2 Replace pin L and secure with lynch pin continued next page Revision B SECTION 7 OPERATION ADAPTER Disconnect knife and draper drive hydraulic Disconnect reel hydraulics Cap off end hoses at bracket Cap off ends immediately to immediately to avoid loss of oil avoid loss of oil k Store and secure hoses on adapter frame If quick disconnects are installed disconnect as
130. ions sickle sections Broken sickle sections Excessive Bouncing At Normal Field Speed Float set too light Adjust header float E Divider Rod Running Down v Standing Crop Divider rods too long Remove divider rod 7 9 11 See your MacDon Dealer Refer to your Combine Manual continued next page Refer to your Technical Service Manual 169593 185 Revision B SECTION 9 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Bushy or Tangled Crop Flows Over Divider Rod Divider rods providing Install long divider rods or 7911 Builds Up On Endsheets insufficient separation floating dividers Reel not frowning or not Adjust reel frown or reel 7 9 9 amp centered in header horizontal position 8 12 2 Adjust hold downs so sickle Sickle hold downs not adjusted works freely but still keep properly sections from lifting off guards Sickle sections or guards are Replace all worn and broken Crop Not Being Cut At Ends worn or broken cutting parts Header is not level Level header Reel fingers not lifting crop Adjust reel position finger 7 9 9 amp properly ahead of sickle pitch 7 9 10 Divider runs down thick crop at ends preventing proper feeding Replace 3 or 4 end guards due to material bridging the with stub guards cutter guards 9 2 CUTTING ACTION AND SICKLE COMPONENTS SYMPTOM PROBLEM SOLUTION SECTION Sickle hold downs not adjusted properly Adjust ho
131. just tension Refer to Section 8 11 1 Header Draper Tension Adjustment 169593 148 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 11 3 Header Draper Alignment Each draper deck has one fixed roller and one spring loaded roller The spring loaded roller is located at the same end of the deck as the draper tensioner Both rollers can be aligned by adjuster rods so that the draper tracks properly on the rollers A CAUTION To avoid personal injury before servicing machine or opening drive covers follow procedures in Section 8 1 PREPARATION FOR SERVICING If the draper is tracking incorrectly make the following adjustments to the rollers LH DRIVE ROLLER ADJUST RH OPPOSITE a Adjust the drive roller X by loosening nuts jam nut B on adjuster rod and turning the adjusting nut C LH IDLER ROLLER ADJUST RH OPPOSITE TRACKING NEN Aon METHOD b Adjust the idler roller Y by loosening nut D Backward INCREASE Tighten Nut jam nut E on adjuster rod and turning rive Roller P DECREASE xli adjusting nut F draper will not track the idler roller end Backward INCREASE Y Y Tighten Nut F Tighten Nut F P the drive roller is likely not square to the deck idler Roller Adjust the drive roller and then re adjust the Forward rward 169593 149 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 11 4 Draper Roller Maintenance
132. k height so that draper runs just below cutterbar with maximum 1 32 in 1 mm gap or with draper deflected down slightly up to 1 16 in 1 5 mm to create a seal The illustration shows the adjustment without the draper NOTE 152 Measurement is at supports with header in working position and decks slid fully ahead Adjust as follows A DANGER Engage header lift cylinder stops and reel props before working under header or reel A DANGER To avoid bodily injury or death from unexpected start up or fall of raised machine stop engine remove key and engage lift cylinder locks before going under machine for any reason Loosen tension on draper Refer to Section 8 11 1 Header Draper Tension Adjustment Lift draper up at front edge past cutterbar Loosen two lock nuts A four if it is an endless draper one half turn only on deck support B There are two to four supports per deck depending on header size Tap deck C to lower deck relative to supports to achieve setting recommended above Tap support B using a punch to raise deck relative to support Tighten deck support hardware A Tension draper Refer to Section 8 11 1 Header Draper Tension Adjustment Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 REEL AND REEL DRIVE 8 12 1 1 Clearance Measurement A CAUTION Engage header lift cylinder stops before working under header A CAUTION To avoid personal injury before servici
133. l Plastic Fingers 8 12 9 4 Installation Plastic Fingers a Position finger on rear of finger tube and engage lug at bottom of finger in lower hole in finger tube INSTALLATION a Remove screw A with a Torx 27 IP socket wrench b Gently lift top flange and rotate finger until lug in top flange engages upper hole in finger tube IMPORTANT Do NOT apply force to finger prior to tightening mounting screw Applying force to finger without screw tightened will break finger or shear off locating pins REMOVAL b Push finger top clip back toward reel tube and remove from finger tube c Install screw A and torque to 75 80 in lbf 8 5 9 0 N m with a Torx Plus 27 IP socket wrench 169593 178 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 10 Tine Tube Bushings A CAUTION To avoid bodily injury from fall of raised reel always engage reel props before going under raised reel for any reason Lower header raise reel fully and engage reel stops 8 12 10 1 Bushing Removal 6 and 9 Bat Pick Up Reels a Remove bushings at center disc and left end disc as follows 1 Remove bolts A securing arm B to disc at both locations IMPORTANT Ensure tine tube is supported at all times to prevent damage to the tube or other components IMPORTANT Note the hole locations in arm and disc and ensure bolts are re installed at original locations 2 Release bushing clamps C using a
134. ld downs Sickle sections or guards are Replace all worn and broken worn or broken cutting parts Sickle is not operating at Check engine speed of recommended speed combine Ground speed too fast for reel Reduce ground speed or speed increase reel speed a Or Uneven Cutting Reel fingers not lifting crop Adjust reel position finger properly ahead of sickle pitch Cutterbar too high Lower cutting height Header angle too flat Steepen header angle Bent sickle causing binding of Straighten a bent sickle cutting parts Align guards Cutting edge of guards not close enough or parallel to Align guards sickle sections See your MacDon Dealer Refer to your Combine Operator s Manual continued next page Refer to your Technical Service Manual 169593 186 Revision B SECTION 9 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Tangled tough to cut crop Install stub guards Ragged Or Uneven Cutting Of Crop cont d Reel too far back Move reel forward Loose sickle drive belt Adjust drive belt tension Lower reel or move reel 7 9 8 amp Ground speed too slow Ground speed too slow too slow Increase ground speed Increase ground speed speed 795 795 5 Loose sickle drive belt sickle drive belt Loose sickle drive belt Adjust drive belt tension Improper sickle hold down adjustment Adjust hold down Dull or broken sickle sections Dull or br
135. le ties v Attach electrical connector P 1 Remove cover on receptacle 2 Align lugs on connector with slots in receptacle push connector onto receptacle and turn collar on connector to lock it in place 3 Attach cover to mating cover on combine wiring harness 3 Rotate latches E down with a 15 16 in continued next page wrench on hex M to raise feed deck so that bolt K can be re installed to lock the latch position 169593 57 Revision SECTION 7 OPERATION ADAPTER w quick disconnects are installed connect as follows 1 Remove covers if installed from receptacles and hose ends 2 Check connectors and clean if required Push hose connector onto mating receptacle until collar on receptacle snaps into lock position NOTE Ensure hoses are clear of driveline and adjacent structure NOTE It is not necessary to bleed the system by loosening fittings x Check float and if the header is level Refer to Section 7 9 2 Header Float and Section 7 11 HEADER LEVELLING 169593 58 Revision B SECTION 7 OPERATION 7 5 BREAK IN PERIOD a After attaching header to combine for the first time operate the machine with reel drapers and sickle running slowly for 5 minutes watching and listening FROM THE OPERATOR S SEAT for binding or interfering parts NOTE Reel and side drapers will not operate until oil flow fills the lines A CAUTION Before investigating an unusual soun
136. lear of the area between guards and sickle at all times A CAUTION Wear heavy gloves when working around or handling sickles 8 9 1 Sickle Sections Check daily that sections are firmly bolted to the sickle back and are not worn or broken Damaged or worn sections leave behind uncut plants Coarse serrated sections last longer than fine serrated sections in dirty or sandy conditions Fine serrated sections perform better in fine stemmed grasses and plants that contain more fibrous stems A worn or broken sickle section can be replaced without removing sickle from cutterbar 169593 130 Replace sickle section as follows NOTE Stroke sickle as required to expose sickle Remove lock nuts A Remove bars B and lift sickle section off knife IMPORTANT Do NOT mix heavy and light sickle sections on same sickle Clean any dirt off of sickle back and position n new sickle section on knife Re position bars B and install lock nuts A Torque nuts to 7 9 5 N m Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 2 Sickle Removal A WARNING Stand to rear of sickle during removal to reduce risk of injury from cutting edges Wear heavy gloves when handling sickle a Stroke sickle to its outer limit and clean area around sickle head Remove zerk from pin A c Remove nut and bolt B d Insert screwdriver in groove of pin A and pry up on sickle head pin to free sickle Pin do
137. lector or replace End Deflectors And End deflectors too wide with narrow deflector Releasing In Bunches MacDon part 172381 Raise header height with Header height too low float optimizer control EN Cutterbar Pushes Dirt Float locked Unlock float Across Entire Length Float set too heavy Adjust float Header angle too steep Adjust header to optimum angle Combine face plate incorrectly Remove adapter and check installed combine faceplate Pushing Dirt At Combine Adapter Lower Beam Header angle too flat Increase header angle Float too light header legs do not rest on Stops Adjust to heavier float Float locked out A S adapter float Wing Float Assembly Binding Float set too heavy fl springs to Reel Contacts Endsheet Reel not centered in header Center reel in header m 8 12 3 Especially In Smile Center reel in header and Adjust reel clearance to EN 12 4 Reel Fingers Being Cut At cutterbar Adjust reel frown at finger tubes 8 12 2 See your MacDon Dealer Refer to your Combine Operator s Manual continued next page Refer to your Technical Service Manual Header Hinge Points In Reel clearance inadequate Frown Condition 169593 192 Revision B SECTION 9 TROUBLESHOOTING 9 5 CUTTING EDIBLE BEANS SYMPTOM PROBLEM SOLUTION SECTION Divider rod running down crop emove divider rod Excessive Losses At poss 7911 Dividers idi Vines and plants buil
138. led header may be detached in either Transport or Field mode If detaching with wheel in Field mode set wheels to storage or uppermost working position Otherwise header may tilt forward so that re attachment will be difficult Refer to Section 7 9 1 Cutting Height Lift handle F on adapter continued next page 169593 37 Revision SECTION 7 OPERATION JOHN DEERE 60 70 and S SERIES f Disconnect hydraulic electrical coupler from combine as follows 1 Disconnect harness P from combine harness 2 Remove lynch pin H and slide lock J to release handle K 5 Push handle K on combine toward feeder house to disengage feeder house pin L from adapter g Lower feeder house until saddle disengages and clears adapter support N release coupler G from combine h Slowly back combine away from adapter 4 Position coupler G on adapter receptacle and lower handle F to lock coupler 169593 38 Revision B SECTION 7 OPERATION CAT LEXION 7 3 4 Lexion 500 700 Series A CAUTION Stop engine and remove key from ignition L before leaving Operator s seat for any reason A child or even a pet could engage kgs an idling machine 7 3 4 1 Attachment Handle on the 25 adapter should be in raised position and pins B at bottom corners of adapter retracted b Slowly drive combine up to adapter until feeder hous
139. led as follows IMPORTANT Shields should be removed when c Locate knife head shield A against endsheet cutting with cutterbar on ground in muddy conditions Mud may pack d Orient the shield so that cutout matches profile into cavity behind shield and cause of knife head and or hold downs sickle drive box failures e Bend shield along slit to conform to endsheet NOTE f Place shield on endsheet align mounting holes Shields are slightly different depending and install two 3 8 in x 1 2 Torx head bolts on header size and guard B configuration Ensure proper shield is g Snug up bolts just enough so that shield can be used See Parts Catalog for proper adjusted as close as possible to knife head replacement parts h Manually rotate sickle drive box pulley to move a Raise reel fully lower header to ground shut knife and check for areas of contact between down combine and remove key the knife head and shield i If required adjust shield to avoid interference A CAUTION with the knife Tighten bolts Always engage reel props before working under reel b Engage reel arm locks A DANGER To avoid bodily injury or death from unexpected start up or fall of raised machine stop engine remove key and engage lift cylinder stops before going under machine NOTE The knife head shield is supplied in flattened form and can be bent to suit installation on pointed or stub guard cutterbars and on double knife hea
140. locks must be engaged when the header is being transported with the adapter attached so there is no relative movement between the adapter and header during transport b Fully lower the reel and adjust the fore aft position between 5 and 6 on decal on the right side reel arm The float locks must also be locked during detachment from _ the combine to allow the feeder house to release the adapter c Adjust center link to mid range between B and C on cylinder indicator d Position cutterbar 8 12 in 200 300 mm off the ground A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine e Stop engine and remove key from ignition f Check that adapter is level If the adapter is not UNLOCK a Disengage float locks by moving latch A level perform the following checks prior to downward and moving lever B at each lock to adjusting the leveling linkages lowest position In this position the header is IMPORTANT unlocked and can float with respect to the The adapter float springs are not adapter used to level the header b Engage the float locks by moving lever B up to its highest position In this position the e Check combine tire pressures header cannot move with respect to the e Check that the combine feeder house is adapter level Refer to combine operator s manual Check that of adapt
141. lt A 2 Turn cylinder rod B counterclockwise to raise reel and increase clearance to cutterbar or clockwise to decrease 3 Tighten bolt A 4 Repeat at opposite side 169593 154 Double Reel Only Adjust center arm to change clearance at center of cutterbar as follows 1 Ll Es clockwise LOOKING UP AT ARM UNDERSIDE Loosen nut Turn nut D counterclockwise to raise reel and increase clearance to cutterbar or clockwise to decrease Tighten nut C Revision B 169593 SECTION 8 MAINTENANCE AND SERVICING 8 12 2 Reel Frown Adjustment The reel has been adjusted at the factory to provide more clearance at the center of the reel than at the ends frown to compensate for reel flexing The frown is adjusted by re positioning the hardware connecting reel finger tube arms to reel discs The frown adjustment compensates for reel flexing IMPORTANT The frown profile should be measured prior to reel disassembly for servicing so that the profile can be maintained after re assembly Position the reel over the cutterbar 4 5 on gauge This position provides adequate clearance at all reel fore aft positions Refer to Section 7 9 9 Reel Fore Aft Position Take a measurement at each reel disc location for each reel tube Adjust the profile as follows Start with the reel disc set closest to center of header and proceed to the ends CERO 1 Remove bolts A 2
142. n applies to 35 ft and smaller Double Knife headers with timed drives For Single Knife headers and non timed Double Knife headers refer to Section 8 9 8 Sickle Drive Belts Non Timed Drive 8 9 9 1 Left End Drive Remove endshield at left end of header Refer to Section 7 2 3 Endshields A CAUTION To avoid personal injury before servicing machine or opening drive covers follow procedures in Section 8 1 PREPARATION FOR SERVICING Tension Adjustment Timing Belt IMPORTANT To prolong belt and drive life do NOT over tighten belt Loosen two nuts A on sickle drive belt idler a bracket b Insert a long punch or equivalent into hole B in idler bracket and pry downward until a force of 6 27 N deflects timing belt 1 2 in 13 mm at mid span C c Tighten nuts A on idler mounting bracket 169593 137 0 02 0 04 in 0 5 1 0 mm GAP haz 1 DAC nv KARMEA AANA oor Check clearance between belt and belt guide D The measurement should be 0 02 0 04 in 0 5 1 0 mm Adjust as follows 1 Ensure belt is properly tensioned 2 Loosen bolts E and adjust position of guide as required 3 Tighten bolts Re adjust tension of a new belt after a short run in period about 5 hours Removal Left End Timing Belt Loosen two nuts A on belt idler bracket to relieve tension on belt Loosen nut F on idler pulley and slide idler down to loo
143. n lubricated connections as in re assembly oO Oo RIP K I Mm oO N 169593 98 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 3 1 5 O ring Face Seal ORFS Hydraulic Fittings Brazed Slee dk Two Place RECOMMENDED TURNS TO TORQUE VALUE TIGHTEN AFTER FINGER oe TIGHTENING I i I 9 16 11 12 14 16 uo oue dm uoc as 242 xs 32 35 43 47 1 2 3 4 assi 1 4 1 2 en 98 en wm pee oo pee 1 3 1 2 148 167 200 205 Torque values and angles shown are based on lubricated connection as in re assembly Always default to the torque value for evaluation of adequate torque O ring face seal type end not defined for this tube size 169593 99 Check components to ensure that the sealing surfaces and fitting threads are free of burrs nicks and scratches or any foreign material Apply lubricant typically Petroleum Jelly to O ring and threads If O ring is not already installed install O ring Align the tube or hose assembly Ensure that flat face of the mating flange comes in full contact with O ring Thread tube or hose nut until hand tight The nut should turn freely until it is bottomed out Torque fitting further to the specified number of F F F T Flats From Finger Tight or to a giv
144. nditions 20T 22T and 26T sprockets are available to change adapter feed auger speed Consult with your MacDon Dealer Revision B SECTION 7 OPERATION 7 3 1 4 CR Feeder Deflectors For New Holland CR 960 9070 and 9080 combines feeder kits have been installed on the adapter at the factory to improve feeding into the feeder house They may also have been installed as an option on older machines If necessary they can be removed CA25 adapters for the CR Models listed have short feeder kits installed at the factory Long feeder kits are provided for narrow feeder house combines and are dealer installed to replace the short feeder kits COMBINE FEEDER MODEL HOUSE size FEEDER KIT SIZE CR970 Short 7 7 8 in 9070 9080 200 mm CR960 M 9060 940 Narrow Long 12 13 16 in 9040 325 mm If required replace the feeder deflectors as follows E Tv X d afar 5 IMMS Ss t CY Em zr Determine position of existing deflector A by measuring gap X between deflector forward edge and pan 169593 30 LH SHOWN RH OPPOSITE Remove two bolts B and nuts securing deflector A to adapter frame and remove deflector Position replacement deflector and secure with bolts B and nuts Maintain dimension X from existing deflector for replacement deflector Repeat for opposite deflector After attaching header to combine extend center link fully
145. ne e Remove electrical connector K from adapter and connect to combine at L Replace cover M on adapter receptacle f Lift lever N and pull and lower handle O to disengage feeder house adapter lock P 169593 46 Revision B SECTION 7 OPERATON AGCO 7 3 6 AGCO ALL EXCEPT GLEANER amp S SERIES and LL MODEL Gleaner R and S Series EN Challenger 660 670 680B Massey 9690 9790 9895 git p 7 3 6 1 Attachment ALL EXCEPT GLEANER R amp S SERIES a HRetract lugs A at base of feeder house with lock handle B b Slowly drive combine up to adapter until feeder house is directly under the adapter top cross member C and alignment pins D are aligned with holes E in adapter frame continued next page 169593 47 Revision B SECTION 7 OPERATION AGCO f Connect adapter hydraulic quick coupler to combine receptacle as follows c Raise feeder house to lift adapter ensuring feeder house saddle F and alignment pins are properly engaged in adapter frame d Raise header slightly off the ground 1 Raise handle G to release coupler H from adapter A CAUTION d Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine ALL ALL EXCEPT GLEANER S SERIES GLEANER R amp S SERIES ta 2 Push handle J on combine
146. ng header or opening drive covers follow procedures in Section 8 1 PREPARATION FOR SERVICING 8 12 1 Reel Clearance to Cutterbar The finger to guard cutterbar clearances with reel fully lowered varies with header width and are as follows See illustration opposite X 12 in 3 mm REEL ENDS HEADER FT SINGLE REEL DOUBLE REEL TAKE MEASUREMENTS 2 PLACES 3 4 in 20 mm 169593 153 a b 6 INCH BLOCKS LEVEL GROUND DOUBLE REEL Raise header and place a 6 in 150 mm block under each inboard header leg Lower header onto blocks Fully lower the reel cam disc is approximately between 4 and 5 on the arm decal Shut down combine Remove key from ignition Measure clearance at ends of each reel NOTE The reel has been adjusted at the factory to provide more clearance at the center of the reel than at the ends frown to compensate for reel flexing Check all possible points of contact between points Y and Z Depending on reel fore aft position minimum clearance can occur at guard tine hold down or cutterbar continued next page Revision B SECTION 8 MAINTENANCE AND SERVICING g Refer to following section for adjustment procedure 8 12 1 2 Reel Clearance Adjustment A DANGER Engage header lift cylinder stops before working under header a Adjust outside arms to change clearance at ends of cutterbar as follows 1 Loosen bo
147. ng with a clean cloth before greasing to avoid injecting dirt and grit d Inject grease through fitting with grease gun until grease overflows fitting except where noted e Leave excess grease on fitting to keep out dirt f Replace any loose broken fittings immediately ADAPTER g If fitting will not take grease remove and clean thoroughly Also clean lubricant passageway Replace fitting if necessary 169593 108 Revision B SECTION 8 MAINTENANCE AND SERVICING EVERY 10 HOURS OR DAILY EXCEPT IN SANDY CONDITIONS EVERY 25 HOURS High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base SICKLE HEAD To prevent binding and or excessive wear SINGLE KNIFE 1 PLC caused by sickle pressing on guards do NOT DOUBLE KNIFE 2 PLCS over grease If more than 6 to 8 pumps of the grease gun are required to fill the cavity replace the seal in the sickle head Check for signs of excessive heating on first few guards after greasing If required relieve pressure by depressing check ball in grease fitting 169593 109 Revision B SECTION 8 MAINTENANCE AND SERVICING EVERY 50 HOURS High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base IDLER ROLLER BOTH SIDES 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY DRIVE UNIVERSAL 2 PLCS DRIVELINE SLIP JOINT
148. ngine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine UNLOCK b Engage the adapter float locks by lifting lever A at each lock until it latches into the lock position IMPORTANT If slow speed transport wheels are installed header may be detached in either Transport or Field mode If detaching with wheel in Field mode set wheels to storage or uppermost working position Otherwise header may tilt forward so that re attachment will be difficult Refer to Section 7 9 1 Cutting Height 45 d IMPORTANT If stabilizer wheels are installed set wheels to storage or uppermost working position Otherwise header may forward so that re attachment will be difficult Refer to Section 7 9 1 Cutting Height Disconnect driveshaft B from combine and slide driveshaft in hook C so that disc D drops to secure driveshaft Remove hydraulic quick coupler receptacle on adapter as follows E from 1 Push in lock button F and pull handle G to release coupler E continued next page Revision B SECTION 7 OPERATON NEW HOLLAND CR CX 2 Push handle G to closed position until g Lower feeder house until feeder house Q lock button F snaps out Close cover H disengages adapter support h Slowly back combine away from adapter 3 Position coupler E onto storage plate J on combi
149. ngine or engaging any header drives Start engine and lower combine feeder house so that adapter arms F are aligned with header legs G Drive slowly forward maintaining alignment between adapter arms F and header legs G Keep adapter arms F just under the legs G to ensure adapter legs seat properly in the header linkage supports at H IMPORTANT Keep hydraulic hoses clear to prevent damage when driving into header Continue forward until adapter arms F contact stops in legs G continued next page Revision B SECTION 7 OPERATION ADAPTER A CAUTION Always connect center link before fully raising header A CAUTION Be sure all bystanders are clear of machine before starting engine or engaging any header drives Start engine and raise adapter slowly making sure adapter legs engage in header legs m Raise header fully stop engine and remove key A DANGER To avoid bodily injury or death from fall of h Adjust length of center link A with header angle hydraulics to approximately align eye J on center link with hole in header bracket i Shut down engine and remove key raised machine always engage lift Connect center link cylinder stops before going under header for any reason See your Combine 1 Pull pin part way out of bracket and Operator s Manual for instructions for use and storage of header lift cylinder stops n Engage header lift cylind
150. o slow Install auger speed up kit Side drapers manning too slow Side Drapers Back Feed Increase side draper speed Side running too fast in Crop Is Thrown Across Reduce side Reduce side draper speed speed Opening And Under Center side draper drive Opposite Side Draper overlap of feeder rollers over feed draper side deflectors Add flighting extensions Crop Feeding Into Feeder e House At Sides More Than Auger not dellvering crop At Center properly Remove auger outer tines Install auger speed up kit See your MacDon Dealer Refer to your Combine Manual continued next page Refer to your Technical Service Manual 169593 191 Revision B SECTION 9 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Add auger outer tines recaer Auger not delivering cro ahti i House At Center More Than 9 Remove flighting extensions 7 3 1 1 At Sides Remove auger stripper bars auger Remove auger stripper bars bars 7 1 2 anol bana fap Crop heads leaning away from Add shields except in Endsheet and Knife Head knife head hole in endsheet damp sticky Soils Material Accumulates Inside moroner Or Under Front Edge Of 9 pp Adjust deck height 8 11 5 Draper adjusted Material Wrapping At Upper Crop conditions do not require Cross Auger Beater Bars beater bars Hemove beater bars Material Accumulating On Trim def
151. oken sickle sections broken sickle sections Replace sickle section Replace sickle section section 891 9 1 Bent or broken guards Align or replace guards Reel fingers not lifting crop Adjust reel position finger 7 9 9 amp roperly ahead of sickle itch 9 Sickle Plugging P odas Steel pick up fingers contacting Increase reel clearance to 8 12 1 amp sickle cutterbar or adjust frown 8 12 2 Float too heavy et springs for lighter Raise cutterbar by lowering skid shoes Mud or dirt build up on cutterbar Install cut out sections Flatten header angle E Sickle is not operating at Check engine speed of recommended speed combine Sickle hold downs not adjusted properly Sickles on double knife drive Excessive Header Vibration Sickle not operating at Check engine speed of recommended speed combine Loose or worn sickle head pin Adjust hold downs See your MacDon Dealer Refer to your Combine Manual continued next page Refer to your Technical Service Manual 169593 187 Revision B SECTION 9 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Incorrect knife speed Adjust knife speed Excessive Vibration Of Adapter And Header Driveline U joints worn Replace U joints ni Bent cutterbar cutterbar Bent cutterbar Straighten cutterbar Straighten cutterbar Sickle hold downs not adjusted properly Adjust hold downs ES Cutterb
152. or other flighting extension result in improper header operation d Re install access cover secure flighting extension C to auger and 7 3 1 Adapter Set up The following sections outline recommended adapter set up guidelines depending on your combine and crop The recommendations cannot cover all conditions If feeding problems develop with adapter operation For detailed information refer to Section 9 TROUBLESHOOTING 169593 28 Revision B 169593 SECTION 7 OPERATION 7 3 1 2 Stripper Bars Stripper bar kits may have been supplied with your header to improve feeding in certain crops such as rice Installation instructions are included with the kits They are not recommended in cereal crops APPLICABLE COMBINES All except New Holland CR960 9060 970 9070 and 9080 If necessary remove auger stripper bars as follows Remove four bolts A and nuts securing bars B to adapter frame and remove bars b Repeat for opposite set of stripper bars 29 7 3 1 3 Auger Drive The adapter auger is chain driven from a sprocket that is mounted on the input shaft from the combine and which is enclosed in the drive gearbox The speed is determined by the combine input shaft and is matched to each particular combine so no adjustment is necessary However optional drive sprockets are available to change the auger speed to optimize auger performance See your MacDon Dealer NOTE For special co
153. orque to 215 ft lbf 290 N m If necessary lubricate the chain with SAE Multi Purpose High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 To re install covers C and D engage inboard of cover into auger tube and rotate cover back to engage rear support Replace and tighten bolts A and B Revision B SECTION 8 MAINTENANCE AND SERVICING 8 8 8 Auger Drive Chain Replacement a The chain tensioner can only take up slack for a single pitch When the chain has worn or stretched beyond the limits of the tensioner the chain should be replaced or removed to replace the connector link with an offset half link A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine Detach header from combine Refer to Section 7 3 HEADER ATTACHMENT DETACHMENT Remove auger chain case See previous page Remove chain as follows IS N m o m t lt gi CS hs E d 1 Loosen idler sprocket bolt A and raise to uppermost position to release tension on chain B Snug up bolt A to hold sprocket 169593 127 o 2 Grind off head of a link rivet C on chain B punch out the rivet an
154. otates Tighten the set screw in the collar Tighten flangette bolts Loosen flangette bolts on mating bearing one turn and re tighten This will allow bearing to line up Revision B SECTION 8 MAINTENANCE AND SERVICING 8 3 4 Recommended Fluids and Lubricants Your machine can operate at top efficiency only if clean lubricants are used Use clean containers to handle lubricants e Store in an area protected from dust moisture and other contaminants LUBRICANT SPEC DESCRIPTION USE CAPACITIES High Temperature Extreme Pressure As Required EP2 Performance With 1 Max Unless Molybdenum Disulphide NLGI Grade 2 Otherwise SAE Multi Lithium Base Specified Grease Purpose High Temperature Extreme Pressure EP Performance With 10 Max Driveline Molybdenum Disulphide NLGI Grade 2 Slip Joints Lithium Base Gear Lubricant Main Drive Gearbox Header Drive Systems Reservoir Compliant With SAE Specs For DM API Class SJ And CH 4 Engine Oil 169593 101 2 3 US quarts 2 2 liters SAE 85W 140 API Service Class GL 5 5 pints 2 5 liters 16 US gallons 60 liters Revision B SECTION 8 MAINTENANCE AND SERVICING 8 3 5 Conversion Chart INCH POUND UNITS SI UNITS METRIC QUANTITY FACTOR UNIT NAME ABBR UNIT NAME ABBR US gallons per minute X 3 7854 liters per minute Length 6 8948 kilopascals Pressure pounds per square inch psi pound feet or foot pounds
155. ove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine Turn filler cap C counterclockwise until loose and remove cap Add warm room temperature SAE 15W 40 oil to required level Refer to Section 8 3 4 Recommended Fluids and Lubricants for proper oil IMPORTANT Warm room temperature oil will flow through the screen better than cold oil DO NOT REMOVE THE SCREEN Re install filler cap Hand tighten Revision B SECTION 8 MAINTENANCE AND SERVICING 8 5 1 3 Changing Hydraulic Oil in Reservoir NOTE Change hydraulic oil every 1000 hours or 3 years There is a drain plug at the bottom of each side frame a Detach header from adapter Refer to Section 7 3 HEADER ATTACHMENT DETACHMENT b Detach adapter from combine Support adapter on blocks Refer to Section 7 3 HEADER ATTACHMENT DETACHMENT c Place a suitable container at least 16 US gallons 60 liters under the two drains A to collect oil d Using a 1 1 2 inch hex socket with extension remove drain plugs A e Replace drain plugs when reservoir is empty f Fill with 16 US gallons 60 liters of clean SAE 15W 40 oil Refer to previous section for filling procedures 169593 119 Revision B 169593 SECTION 8 MAINTENANCE AND SERVICING 8 5 2 Hydraulic Oil Filter NOTE Change hydraulic oil filter after the first 50 hours of operation and every 250 hours thereaf
156. p hydraulic coupler tips and connectors clean Dust dirt water and foreign material are the major causes of hydraulic system damage DO attempt 10 service hydraulic system in the field Precision fits require WHITE ROOM CARE during overhaul Revision B SECTION 8 MAINTENANCE AND SERVICING 8 6 ELECTRICAL a Use electrical tape and wire clips as required to prevent wires from dragging or rubbing b Keep lights clean and replace defective bulbs replace light bulbs 169593 Using a Phillips screwdriver remove screws from fixture and remove plastic lens Replace bulb and re install plastic lens and SCrews NOTE Bulb Part Numbers Use Bulb Trade 1156 for amber clearance lights and 1157 for red tail light Slow Speed Transport option 1156 is 21W 12V 1157 is 21 5W 12V 121 8 7 MAIN DRIVE 8 7 1 Driveline Removal a 2 i The main driveline normally remains attached to the adapter and is stored on the hook provided when not in use A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine If adapter is attached to combine remove driveline from combine by pulling the quick disconnect collar to release driveline yoke at combine shaft Remove two nuts A attaching shield B to gearbox Slide shield over poly driveline shield to expose quick disconn
157. perly grounded Use adequate light for the job at hand Replace all shields removed or opened for service Use only service and repair parts made or approved by the equipment manufacturer Substituted parts may not meet strength design or safety requirements Keep the machine clean Never use gasoline naphtha or volatile material for cleaning purposes These materials be toxic and or flammable Revision B SECTION 8 MAINTENANCE AND SERVICING 8 3 MAINTENANCE SPECIFICATIONS B4 8 3 1 Recommended Torques m e Tighten all bolts to the torques specified in s chart unless otherwise noted throughout Nm this manual e Check tightness of bolts periodically using bolt torque chart as a guide M4 e Replace hardware with the same strength bolt pales e Torque figures are valid for non greased or M6 non oiled threads and heads unless otherwise specified i e Do not grease or oil bolts or capscrews M10 unless specified in this manual e When using locking elements increase 6 90 torque values by 5 M14 8 3 1 1 SAE Bolts M16 225 E Moo 321 435 pia SAES sss 750 M30 1103 1495 M36 1917 2600 Torque categories for bolts and capscrews are identified by their head markings Torque categories for bolts and capscrews are identified by their head markings 169593 97 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 3 1 4 O rin
158. ppropriate when e detaching the header for use on a windrower e changing headers or e performing certain maintenance tasks The procedure is the same for all makes and models of combines The headers can be attached to the adapter from either Field configuration or Transport configuration 7 4 1 Detaching a Disconnect adapter deck from cutterbar as follows 1 Start engine and tilt header to almost full forward position to increase clearance under adapter feed draper 2 Stop engine and remove key A WARNING oN EAN Keep hands clear of the area between guards and sickle at all times A CAUTION Wear heavy gloves when working around or handling sickles 169593 52 Remove two hex head bolts A attaching filler B to transition pan at front corners and fold back filler B for access to latch C Rotate latch C down with a 15 16 wrench on hex D so that bolt E can be removed Rotate latch C up and back to lower adapter deck and disengage transition pan tube F Re install bolt E Repeat for other side of the feed draper deck continued next page Revision B SECTION 7 OPERATION ADAPTER UNLOCK b Engage the adapter float locks by lifting lever G until it latches into the lock position A DANGER To avoid bodily injury or death from fall of raised machine always engage lift cylinder stops before going under header for any reason See your Comb
159. r Auger in Note 3 4 4 and 5 Note 7 Note 2 gh 600 60 3 1 15 Normal a ERE NN B C ss 2 Not Required Note 1 Up or Center Set header angle 7 Lodged Off 525 600 304 5 10 Not Required as shallow as tight s 6055 4 s Not Required Not Required with center link and Normal ee G00 Center or Down i RE LER Skid shoes while lodged on 525 600 sora 510 405 Dow Not Required it eae Maintaining cutting eight oW 600 6509 15 10 Normal 550 600 Not Applicable Not Required Lodged Off 525 600 304 5 10 Note 2 Minimum knife Center or Down drive pulley rpm 3 gt o 2 Recommended Applicable only to single knife Down Center or Down headers oo MEN 550 600 fae Not Applicable Recommended 7 D j 525 600 Note 3 600_650 Percentage above TS ground speed Note 6 seso 50500 Up or Center Storage Not Required D 525 800 oc D 600 650 Note 4 T B C 550 600 Center Down Not Required Cutting height i Cus eh controlled with a 525 600 x combination of skid 600_650 shoes ae header angle Whisker Note 5 B EN EN sso ES Not Applicable Not Required EA 525 600 510 b
160. r all the protective clothing and personal safety devices that COULD be necessary for the job at hand Don t take chances You may need D hard hat protective shoes with slip resistant soles protective glasses or goggles heavy gloves wet weather gear respirator or filter mask hearing protection Be aware that prolonged exposure to loud noise can cause impairment or loss of hearing Wearing a suitable hearing protective device such as ear muffs A or ear plugs B protects against objectionable or loud noises 16 Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the extinguisher is properly maintained and be familiar with its proper use Keep young children away from machinery at all times Be aware that accidents often happen when the Operator is tired or in a hurry to get finished Take the time to consider the safest way Never warning signs of fatigue Wear close fitting clothing and cover long hair Never wear dangling items such as scarves or bracelets Keep hands feet clothing and h from moving parts Never attempt to clear obstructions or objects from a machine while the engine is running Keep all shields in place Never alter or remove safety equipment Make sure driveline guards can rotate independently of the shaft and can telescope f
161. raulic compartment cover to set the desired draper speed a he draper speed control is factory set to 6 This setting should satisfy normal crop feeding b Ifa different draper speed is desired shut down the combine and adjust the control accordingly 169593 72 Revision SECTION 7 OPERATION a Stop combine engine and remove key from ignition 7 9 7 Knife Speed The header knife drive is driven by the adapter mounted hydraulic pump The knife drive speed is factory set for a feeder house speed of 5 5 rpm for CNH and John Deere CA25 Adapters 780 rom for AGCO and Lexion CA25 Adapters IMPORTANT For variable speed feeder houses this will be the minimum speed setting b Open the LH endshield IMPORTANT To operate variable speed feeder A WARNING house at greater than minimum speed flow to the knife drive motor Ensure bystanders are clear before must reduced to prevent starting excessive speeds which could result 1 in premature knife failure c Start combine engine engage the header drive and run the combine at operating rom IMPORTANT Check that the knife speed is in the range shown in the chart below using the procedure that follows If adjustment is required contact your MacDon Dealer or refer to the Header Technical Manual RECOMMENDED KNIFE DRIVE HEADER SIZE SPEED RANGE RPM FT FT SINGLE KNIFE DOUBLE KNIVE DRIVE SKD DRIVE DKD
162. rbar Refer to Section 7 8 1 Header Settings for recommended reel height in specific crops and crop conditions 169593 74 7 9 9 Reel Fore Aft Position 7 9 9 1 h Reel position has been found to be a critical factor in achieving good results in adverse conditions The reel position is factory set for average straight standing crop and can be adjusted forward and backward for different crop conditions A decal is provided on the reel right support arm for identifying a preferred position The back edge of the reel cam disc is the gauge indicator Refer to Section 7 8 1 Header Settings for recommended reel positions in specific crops and crop conditions Hydraulic Adjustment Fore Aft Select the fore aft adjust mode on the selector switch in the cab Operate the hydraulics to move the reel to the desired position again using the gauge as a reference Check reel clearance to cutterbar after making changes to cam setting Refer to Section 8 12 1 Reel Clearance to Cutterbar measurements and adjustment procedures IMPORTANT Operating with the reel too far forward can cause the fingers to contact the ground before the cutterbar Lower the skid shoes or adjust header tilt as required when operating with the reel this position otherwise damage to the fingers will occur continued next page Revision B SECTION 7 OPERATION 7 9 9 2 Fore Aft Cylinder Position Double Reel The reel can be moved
163. re Hazard CAUTION Do not go near leaks High pressure oil easily punctures skin Causing serious injury gangrene or death If injured seek emergency medical help Immediate surgery is required to remove oil Do not use finger or skin to check for leaks Lower load or relieve pressure before loosening fittings Reel Entanglement Hazard CAUTION To avoid injury from entanglement with rotating reel stand clear of header while machine is running 174632 Auger Entanglement Hazard CAUTION e To avoid injury from entanglement with rotating auger stand clear of header while machine is running 174682 169593 14 Revision B SECTION 3 SAFETY Sharp Component Hazard CAUTION Knife Sections are Sharp Wear heavy canvas or leather gloves when working with knife Be sure no one 1 near the vertical knife when removing or rotating knife 174684 Transport Roading Hazard WARNING Before Transporting e Ensure tow bar lock mechanism is locked 193147 Keep Shields in Place Hazard WARNING To avoid injury stop engine before opening power drive system shield Keep all shields in place 220238 220238 169593 15 Revision B SECTION 3 SAFETY 3 4 GENERAL SAFETY A CAUTION 169593 The following are general farm safety precautions that should be part of your Operating procedure for all types of machinery Protect yourself When assembling operating and servicing machinery wea
164. reely continued next page Revision B 169593 SECTION 3 SAFETY Use only service and repair parts made approved the equipment manufacturer Substituted parts may not meet strength design safety requirements Do modify the machine Unauthorized modifications may impair the function and or safety and affect machine life Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine 72 5 7 Keep the area used for servicing machinery clean and dry Wet or oily floors are slippery Wet spots can be dangerous when working with electrical equipment Be sure all electrical outlets and tools are properly grounded Use adequate light for the job at hand Keep machinery clean Straw and chaff on a hot engine are a fire hazard Do NOT allow oil or grease to accumulate on service platforms ladders controls Clean machines before storage Never use gasoline naphtha or any volatile material for cleaning purposes These materials may be toxic and or flammable When storing machinery cover sharp or extending components to prevent injury from accidental contact 17 Revision B SECTION 4 DEFINITIONS 4 DEFINITIONS The following terms abbreviations may be used in this manual TERM DEFINITION Automatic Header Height Control American Petroleum Institute ASTM ASTM American American Society Of
165. rews c Loosen chain C Refer to Section 8 12 4 1 Tension Adjustment High Torque Drive d Remove speed sensor disc D and drive sprocket Refer to Section 8 12 5 2 Sprocket Replacement Single Reel Standard Torque Drive e Disconnect hydraulic lines E at motor Cap or plug open ports and lines 169593 173 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 8 Reel Speed Sensor 8 12 8 1 John Deere A WARNING Stop combine engine and remove key before making adjustments to machine A child or even a pet could engage the drive a Lower header and reel shut down combine and remove key from ignition b Remove reel drive cover a Maintain a 1 8 in 8 mm gap between sensor disc G and sensor H Adjust with nuts F as required b Replace sensor as follows 1 Disconnect connector E 1 Double Reel Remove six screws A and 2 Remove top nut F and remove sensor remove upper cover B 3 Remove top nut from new sensor and locate in support 4 Secure with top nut F 5 Adjust gap between sensor disc G and sensor H to 1 8 in 3 mm 6 Connect to harness E to sensor IMPORTANT Ensure sensor electrical harness does contact chain or sprocket 2 Single Reel High Torque Remove four screws C and remove cover D 169593 174 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 8 2 Lexion 500 a Maintain a 1 8 in 8 mm gap bet
166. s Fa y 7 HA THU eee 3M 22 0 E 150 ftllbf 203 N m BA 180 f Ibf 244 amp a Check and tighten axle bolts daily until torque is maintained as shown Revision B SECTION 8 MAINTENANCE AND SERVICING 8 13 3 Tire Inflation Check tire pressure daily Maintain pressures recommended in following table ST205 75 R15 A WARNING e Service tires safely e A tire can explode during inflation and cause serious injury or death e Do NOT stand over tire Use a clip on chuck and extension hose e Never increase air pressure beyond pressure specified on tire side wall to seat the bead on the rim 169593 184 Replace the tire if it has a defect Replace a wheel rim which has cracks wear or severe rust Never weld a wheel rim Never use force on an inflated or partially inflated tire Make sure the tire is correctly seated before inflating to operating pressure If the tire is not in correct position on the rim or is too full of air the tire bead can loosen on one side causing air to leak at high speed and with great force An air leak of this nature can thrust the tire in direction endangering anyone in the area Make sure all the air is removed from a tire before removing the tire from a rim Do NOT remove install or make repairs to a tire on a rim unless you have the proper
167. s belt C 3 4 in 18 mm at mid span Tighten jam nut at B and bolts A on drive mounting bracket Re adjust tension of a new belt after a short run in period about 5 hours 136 8 9 8 2 Removal Loosen sickle drive belt using procedure in previous section so that belt C can be slipped off drive pulley Remove bolt in plate D in endsheet sickle drive box and remove plate This provides clearance between pulley and endsheet for the belt when it is removed Slip belt over and behind sickle drive box pulley E and remove belt Utilize the notch in pulley to assist in removing the belt 8 9 8 3 Installation Route sickle drive belt C around sickle drive box pulley E and sickle drive pulley Utilize the notch in the pulley to assist in installing the belt NOTE When installing new belt never pry belt over pulley Be sure drive motor is fully forward and then tension the belt Tighten belt Refer to Section 8 9 8 1 Tension Adjustment in previous column Check clearance between belt C and belt guide F The measurement should be 0 04 in 1 mm Adjust as follows 1 Ensure belt is properly tensioned 2 Loosen bolts G and adjust position of guide F as required 3 Tighten bolts Re install plate D and secure with bolt and nut Close endshield Revision B SECTION 8 MAINTENANCE AND SERVICING 8 9 9 Double Knife Drive Belts Timed Drive This sectio
168. s rt Rv dni tun 7 GO RPM POE 6 genera eR TI PI 16 signal e 6 6 Serial NUMDE 2 Servicing a een eee 96 59 Sickle bearing 131 eiii P 133 135 132 removal ene Dite 131 SECORS 130 gt Gane buo terre EE CHR 132 Sickle Drive Belt ante costes 137 installation eee 136 140 FEIMOVAN 136 140 SING E 136 136 137 139 140 141 HAING 137 ASIN NU m TT T 139 Sickle Double Tp 141 Skid SUB 65 Stabilizer Wheels enne 63 196 Stabilizer Transport Wheels 196 lt gt ucc oput 29 Stub Guard Conversion 196 cec See Guards stub Tine Tube Bushings II STANAM OM etm 180 replacement 179 E 128 octies 178 ssl E 177 zi P L 177 ATI ATO mete mer 184 iio cte rH 97 Transport System
169. safety practices protect you and the people around you Before allowing anyone to operate the header for however short a time or distance make sure they have been instructed in its safe and proper use Review the manual and all safety related items with all Operators annually Be alert for other Operators not using recommended procedures following safety precautions Correct these mistakes immediately before an accident occurs Do modify the machine Unauthorized modifications may impair the function and or safety and affect machine life The safety information given in this manual does not replace safety codes insurance needs or laws governing your area Be sure your machine meets the standards set by these regulations 23 Me 7 2 OPERATIONAL SAFETY Follow these safety precautions CAUTION Follow all safety and operational instructions given in your Operator s Manuals If you do not have a combine manual get one from your MacDon Dealer and read it thoroughly Never attempt to start the engine or operate the machine except from the combine seat Check the operation of all controls in a safe clear area before starting work Do NOT allow riders on combine Never start or move the machine until you are sure all bystanders have cleared the area Avoid travelling over loose fill rocks ditches or holes Drive slowly through gates and doorways When working on inclin
170. sen belt Loosen two bolts G on endsheet continued next page Revision B SECTION 8 MAINTENANCE AND SERVICING Installation Left End Timing Belt d Loosen two bolts H on sickle drive mounting bracket e Turn adjuster bolt J to loosen the two V belts K and remove belts f Remove bolt in plate L in left endsheet at sickle drive box and remove plate This provides clearance between pulley and 3 endsheet for the belt when it is removed g Slip timing belt off sickle drive box pulley lt 1 and route belt between _ b Route belt between sickle drive box pulley O sickle drive box pulley and endsheet and endsheet and locate on sickle drive box pulley and over idler P h Remove belt from drive pulley NOTE When installing new belt never pry belt over pulley Be sure adjusting device is fully loosened then tension belt c Position V belts K onto drive pulleys d Turn adjuster bolt J to move drive motor until a force of 12 Ibf 53 deflects V belts 1 8 in 3 mm at mid span e Tighten two bolts on drive mounting brackets continued next page 169593 138 Revision B 169593 SECTION 8 MAINTENANCE AND SERVICING Slide idler P up until most of the belt slack is taken up Tighten idler nut F Adjust the timing belt tension and check belt clearance to belt guide See 8 9 9 1 Tension Adjustment Timing
171. shings Remove bolt F from tine or remove plastic finger next to arm if required so that tube can slide through arm Remove bushing halves G continued next page Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 10 4 Bushing Installation 5 Bat Pick Up Reels a At center disc and left end disc position bushing halves G on tine tube so that lug in each bushing half locates in hole in tine tube b Slide tine tube inboard towards cam end to locate bushing in reel arm c At the cam end disc position bushing halves C on tine tube so that lug in each bushing half locates in hole in tine tube d Slide reel arm B onto bushing and position against disc at original location e Install bolts A in original holes and tighten f Re install any fingers or tines that were removed g HRe install bolt D at on cam linkage h Install bushing clamps as previously described 169593 182 Revision B SECTION 8 MAINTENANCE AND SERVICING 8 13 TRANSPORT SYSTEM Optional 8 13 1 Wheel Bolt Torque IMPORTANT Whenever a wheel is removed and re installed check torque after one hour of operation Maintain 80 90 ft Ibf 110 120 N m torque a Check and tighten wheel bolts after the first hour of operation and every 100 hours thereafter Maintain 80 90 ft Ibf 110 120 N m torque IMPORTANT Follow proper bolt sequence shown tightening 169593 183 8 13 2 Axle Bolt
172. sickle so that sickle sections are spaced midway between the guards UPWARD ADJUSTMENT b Remove two nuts A and bolts that attach guard B and hold down C if applicable to cutterbar c Remove guard hold down and poly wear plate if installed d Position new guard and poly wear plate if applicable on cutterbar and install carriage bolts a adjust guard tips upward position tool as shown and pull up IMPORTANT The first four outboard guards on drive side s of header do not have a ledger plate Ensure that proper replacement is installed Install hold down and secure with nuts Tighten nuts to 50 ft lbf 68 N m D DOWNWARD ADJUSTMENT b To adjust tips downward position tool as shown and push down TIP If trouble is encountered cutting tangled or fine stemmed material replace lower guards with stub guards and install a sickle hold down on every guard f Check and adjust clearance between hold c If material is tough to cut install stub guards down and sickle Refer to Section 8 9 7 Sickle with top guard and adjuster plate A kit is Hold Downs available from your MacDon Dealer Refer to Section 10 2 STUB GUARD CONVERSION KIT 169593 133 Revision B SECTION 8 MAINTENANCE AND SERVICING Pointed Guards Double Knife d Check and adjust clearance between hold down and sickle Refer to Section 8 9 7 Sickle Refer to previous section for typical guard Hold Downs repla
173. t mid span g Tighten nuts A and re check tension h Re install drive cover c Loosen bolts C Slide motor D and motor mount E down towards reel shaft 169593 162 Revision B SECTION 8 MAINTENANCE AND SERVICING d If STANDARD TORQUE drive 8 12 5 Reel Drive Sprocket 8 12 5 1 Sprocket Replacement Double Reel Standard Torque and Single Reel High Torque Drive a Lower header and reel shut down combine and remove key from ignition b Remove reel drive cover s 1 Remove bolt F lock washer and flat washer 2 Remove speed sensor disc H if installed e If HIGH TORQUE drive 1 Double Reel Remove six screws A and remove upper cover B 1 Remove cotter pin J and slotted nut K 2 Remove speed sensor disc H if installed continued next page 2 Single Reel High Torque Remove four screws C and remove cover D c Release tension on chain E Refer to Section 8 12 4 1 Tension Adjustment High Torque Drive 169593 163 Revision B SECTION 8 MAINTENANCE AND SERVICING If HIGH TORQUE drive f Slip chain E off drive sprocket L g Remove sprocket L from shaft 1 Install slotted nut K and torque to IMPORTANT 10 20 1 1 2 2 N m Do NOT use pry bar and or hammer 2 Install cotter pin J Tighten nut to next slot to remove sprocket This will if required damage the motor Use a puller if If STANDARD TORQUE drive sprocket do
174. ter MD 123989 can be obtained from your MacDon Dealer To change hydraulic oil filter proceed as follows A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine Remove five screws A and remove panel B Clean around mating surfaces of filter and valve block C Remove spin off filter D and clean the exposed filter port in valve block Apply a thin film of clean oil to the O ring provided with the new filter Turn filter into the valve block until O ring contacts mating surface Tighten filter additional 1 2 to 3 4 turn by hand 120 IMPORTANT Do NOT use a filter wrench to install filter Over tightening can damage O ring and filter Re install panel B with screws A 8 5 3 Hoses and Lines Check hydraulic hoses and lines daily for signs of leaks A WARNING Avoid high pressure fluids Escaping fluid can penetrate the skin causing serious injury Relieve pressure before disconnecting hydraulic lines Tighten connections before applying pressure Keep hands and body away from pin holes and nozzles which eject fluids under high pressure e If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result e Use a piece of cardboard or paper to search for leaks IMPORTANT Kee
175. tinguisher Know where they are and how to use them Adjust tension on drive belts Refer to Section 8 9 8 Sickle Drive Belts Non Timed Drive Perform all annual maintenance See Section 8 4 1 Maintenance Schedule Record 107 Do the following at the end of each operating season Clean the header thoroughly A CAUTION Never use gasoline naphtha or any volatile material for cleaning purposes These materials may toxic and or flammable A CAUTION Cover cutterbar and sickle guards to prevent injury from accidental contact Store the machine in a dry protected place if possible If stored outside always cover with a waterproof canvas or other protective material If machine is stored outside remove drapers and store in a dark dry place NOTE If drapers are not removed store header with cutterbar lowered so water snow will not accumulate on drapers This accumulation of weight puts excessive stress on drapers and header Lower header onto blocks to keep cutterbar off the ground Lower reel completely If stored outside tie reel to frame to prevent rotation caused by wind Re paint all worn or chipped painted surfaces to prevent rust Loosen drive belts Lubricate the header thoroughly leaving excess grease on fittings to keep moisture out of bearings Apply grease to exposed threads cylinder rods and sliding surfaces of components Oil sickle components to prevent rust Check for worn or
176. to Section 7 9 1 Cutting Height k Disengage both adapter float locks by moving 7 IMPORTANT latch P away from adapter and moving lever If stabilizer wheels are installed set Q at each lock to lowest position wheels to storage or uppermost working position Otherwise header 7 3 4 2 Detachment may tilt forward so that re attachment will be difficult Refer to Section 7 9 1 Cutting Height a Choose a level area Position header slightly off the ground Stop engine and remove key A DANGER To avoid bodily injury or death from fall of raised machine always engage lift cylinder stops before going under header for any reason See your Combine Operator s Manual for instructions for use and storage of header lift cylinder stops A CAUTION c Disconnect driveline B from combine Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine d Slide driveline in hook C so that disc D drops to secure driveline continued next page 169593 41 Revision B SECTION 7 OPERATION CAT LEXION e Disconnect hydraulics electrical from adapter as follows 5 Place cover H on adapter receptacle 1 Unplug electrical connector from adapter receptacle 2 Unscrew knob F on coupler G to release coupler from adapter f Remove locking pin J from adapter pin g Raise handle L to disenga
177. to full open position 3 Clean mating surfaces of coupler and receptacle if necessary 4 Position coupler H onto combine receptacle K and pull handle J to fully engage coupler into receptacle 5 Connect reel fore aft header tilt selector e Engage lugs A with adapter using lock handle BY ge lugs A 9 harness L to combine harness continued next page 169593 48 Revision B SECTION 7 OPERATON AGCO g Rotate disc N on adapter driveline storage hook and remove driveline from hook h Pull back collar O on end of driveline and push onto combine output shaft P until collar locks UNLOCK i both adapter float locks by moving latch Q away from adapter and moving lever R at each lock to lowest position 169593 49 Revision B SECTION 7 OPERATION AGCO 43 p 7 3 6 2 Detachment a Choose a level area Position header slightly off the ground Stop engine and remove key A DANGER To avoid bodily injury or death from fall of raised machine always engage lift cylinder stops before going under header for any reason See your Combine Operator s Manual for instructions for use and storage of header lift cylinder stops A CAUTION Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine UNLOCK b Engage the adapter float locks by lifting lever
178. uick coupler EN Quick couplers not properly connected Reel Will Not Turn Reel drive chain disconnected drive chain disconnected Connect ohan chain 8 12 4 Reel Motion Uneven Under Excessive slack in reel drive No Load chain Tighten chain Reel speed too fast Reduce reel speed 794 Heel not aggressive Move to a more aggressive 7910 enough finger pitch notch Reel Motion Is Uneven or Stalls In Heavy Crops Reel too low too low Raise reel reel Relief valve on combine LI on relief pressure to combine adapter has low relief manufacturer s pressure setting recommendations Low oil reservoir level on combine NOTE Fill to proper level more than one reservoir nec MOUOn As Unever Or Relief valve malfunction Replace relief valve Stalls In Heavy Crop Cutting tough crops with high Replace with high torque speed 19 tooth reel drive 10 tooth or 14 tooth reel 8 12 5 sprocket drive sprocket Plastic Fingers Cut at Tip Insufficient reel to cutterbar clearance Reel digging into ground with T reel speed slower than ground Decrease header tilt x speed Move reel aft at Tip opposite of Reel digging into ground with US reel speed faster than ground Decrease header tilt gs S speed AD Move reel aft 7 9 9 Increase clearance 8 12 1 See your MacDon Dealer Refer to your Combine Operator s Manual
179. ween sensor disc G and sensor H Adjust by bending support J b Replace sensor as follows 1 Disconnect connector 2 Remove screw L attaching sensor and remove sensor H 3 Locate new sensor in support and secure with screw L 4 Adjust gap between sensor disc G and sensor H to 1 8 in 8 mm by bending support J 3 Connect to harness at IMPORTANT Ensure sensor electrical harness does contact chain or sprocket 169593 175 8 12 8 3 Lexion 400 a Maintain a 1 8 in 8 mm gap between sensor disc G and sensor H Adjust with nuts J as required b Replace sensor as follows 1 Disconnect connector K 2 Hemove top nut J and remove sensor H 3 Remove top nut from new sensor and locate in support 4 Secure with top nut J 5 Adjust gap between sensor disc G and sensor H to 1 8 in 3 mm with nuts J 6 Connect to harness at IMPORTANT Ensure sensor electrical harness does contact chain or sprocket Revision B SECTION 8 MAINTENANCE AND SERVICING 8 12 8 5 AGCO a Maintain a 02 in 0 5 mm gap between sensor disc A and sensor B Adjust by bending support C b Replace sensor as follows DUAL REE SINGLE REEL 1 Disconnect connector D 2 Cut plastic tie E securing harness to cover 3 Remove screws F and remove sensor B and harness Bend cover G if necessary to remove harness 4 Feed wire of
180. will deliver the crop past the rear edge of the cutterbar and onto the drapers 7 9 10 2 Operating Guidelines The following outlines the function of each cam setting and includes guidelines for set up in various crop conditions The setting numbers are visible above the slots on the cam disc Refer to Section 7 9 10 3 Cam Adjustment e Cam Position 1 Delivers the most even crop flow onto the drapers without fluffing up or disturbing the material The crop is released quite close to the cutterbar and works best with the cutterbar on the ground Some crops will not be delivered past the cutterbar when the cutterbar is raised off the ground and the reel is pushed forward Initially have the reel speed set about equal to the ground speed e Cam Position 2 Recommended starting position for most crops and conditions This setting gives fingertip speed approximately 20 faster than the reel speed o df crops tend to stall on the cutterbar with the reel in a forward position the cam setting should be increased to push the crop past the rear edge of the cutterbar 78 If the crop getting fluffed or the flow across the drapers is disrupted the cam setting should be decreased e Cam Positions 3 and 4 Mainly used to leave long stubble Allows the reel to reach forward and lift the crop aross the knife and onto the drapers The further forward the reel the higher the cam setting should be e Cam Position 4 would be used

D65 Harvest Header for Combines

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