MacDon FM100 User manual

FM100
Float Module
Dual Sensor Auto Header Height Control (AHHC) Kit
(MD #B6211) Installation Instructions
214143 Revision F
Original Instruction
The Harvesting Specialists.

FM100 Float Module
1017434
Published August 2019
© 2019 MacDon Industries, Ltd.
The information in this publication is based on the information available and in effect at the time of printing. MacDon
Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the
information in this publication. MacDon Industries, Ltd. reserves the right to make changes at any time without notice.

Introduction
The Dual Sensor Auto Header Height Control (AHHC) kit (MD #B6211) for the FM100 Float Module is designed for use with
combines that have lateral tilt capability. This kit allows lateral tilt to work with auto header height control.
IMPORTANT:
The Dual Sensor AHHC kit is NOT compatible with New Holland combines with a 10 volt system.
A list of parts included in the kit is provided in Chapter 2 Parts List, page 5.
Installation time
The approximate installation time for this kit is 1.5 hours.
Conventions
The following conventions are used in this document:
•Right and left are determined from the operator’s position. The front of the float module is the side that faces the crop;
the back of the float module is the side that connects to the combine.
•Unless otherwise noted, use the standard torque values provided in the header operator’s manual and technical
manual.
NOTE:
Keep your MacDon publications up-to-date. The most current version of this instruction can be downloaded from our
Dealer-only site (https://portal.macdon.com) (login required).
NOTE:
This document is currently available in English only.
214143 iRevision F

Summary of Changes
At MacDon, we’re continuously making improvements, and occasionally these improvements affect product
documentation. The following list provides an account of major changes from the previous version of this document.
Section Summary of Change Internal Use Only
—Revised instruction format to include front and back covers, and
safety section.
Tech Pubs
2 Parts List, page 5 Revised parts illustration to make it easier to distinguish between
the left and the right sensor assemblies.
Support
3 Installation Instructions, page 7 •Added steps and illustration for identifying the left and right
sensor assemblies.
•Added note to ensure the connector is facing down and the
sensor arm arrow is facing the combine.
•Added step to ensure the rubber boot is attached to the cable
adjuster nut.
•Reordered steps so that the harness gets fully installed before
securing. After the harness is installed, and it gets secured
from the float indicator box and working down to the sensor.
•Added step to set the float and wing balance before calibrating
the AHHC system.
•Added note that if the combine sees the center sensor (except
John Deere), then connector C40 on the FM100 main harness
is not connected.
•Added photos taken during an install to help clarify the
procedure.
Support
•4.1 Manually Checking
Voltage Range –Two-Sensor
System, page 17
•4.2 Adjusting Voltage Limits
–Two-Sensor System, page
21
•4.3 Sensor Output Voltage
Range –Combine
Requirements, page 24
Added Troubleshooting topics. Support
214143 ii Revision F

214143 iii Revision F
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Signal Words .........................................................................................................................................1
1.2 General Safety .......................................................................................................................................2
Chapter 2: Parts List.................................................................................................................................... 5
Chapter 3: Installation Instructions ........................................................................................................... 7
Chapter 4: Troubleshooting...................................................................................................................... 17
4.1 Manually Checking Voltage Range –Two-Sensor System ............................................................................. 17
4.2 Adjusting Voltage Limits –Two-Sensor System........................................................................................... 21
4.3 Sensor Output Voltage Range –Combine Requirements.............................................................................. 24
TABLE OF CONTENTS

214143 1Revision F
Chapter 1: Safety
1.1 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words,
IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be
used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may be used
to alert against unsafe practices.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.

214143 2Revision F
1.2 General Safety
1000004
Figure 1.1: Safety Equipment
CAUTION
The following general farm safety precautions should be part of
your operating procedure for all types of machinery.
Protect yourself.
•When assembling, operating, and servicing machinery, wear
all protective clothing and personal safety devices that could
be necessary for the job at hand. Do NOT take chances. You
may need the following:
•Hard hat
•Protective footwear with slip-resistant soles
•Protective glasses or goggles
•Heavy gloves
•Wet weather gear
•Respirator or filter mask
1000005
Figure 1.2: Safety Equipment
•Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection devices
such as earmuffs or earplugs to help protect against loud
noises.
1010391
Figure 1.3: Safety Equipment
•Provide a first aid kit in case of emergencies.
•Keep a properly maintained fire extinguisher on the machine.
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. Take time to consider safest way. NEVER
ignore warning signs of fatigue.
SAFETY

214143 3Revision F
1000007
Figure 1.4: Safety around Equipment
•Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as scarves or bracelets.
•Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate
independently of shaft and can telescope freely.
•Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.
1000008
Figure 1.5: Safety around Equipment
•Keep hands, feet, clothing, and hair away from moving parts.
NEVER attempt to clear obstructions or objects from a
machine while the engine is running.
•Do NOT modify the machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten the machine’s life.
•To avoid injury or death from unexpected startup of the
machine, ALWAYS stop the engine and remove the key from
the ignition before leaving the operator’s seat for any reason.
1000009
Figure 1.6: Safety around Equipment
•Keep service area clean and dry. Wet and/or oily floors are
slippery. Wet spots can be dangerous when working with
electrical equipment. Be sure all electrical outlets and tools
are properly grounded.
•Keep work area well lit.
•Keep machinery clean. Straw and chaff on a hot engine are
fire hazards. Do NOT allow oil or grease to accumulate on
service platforms, ladders, or controls. Clean machines before
storage.
•NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
•When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
SAFETY

214143 5Revision F
Chapter 2: Parts List
The following parts are included in this kit:
1030485
12
3
4
5
6
7
ABC
D
Ref
Part
Number Description Quantity
1 NSS1AHHC SENSOR ASSEMBLY, LH 1
2NSS1AHHC SENSOR ASSEMBLY, RH 1
3295179 BRACKET –SENSOR LINK 2
4276201 HARNESS –LH HEIGHT SENSOR 1
5 276871 HARNESS –RH HEIGHT SENSOR 1
6136410 CLAMP –INSULATED 3/8 IN. 2
7 136655 FASTENER –FIR TREE MT W/ TIE 4
A 135671 BOLT –HEX HD TFL M6 X 1 X 40-8.8-A2L 2
B 152668 NUT –HEX FLG CTR LOC M6 X 1-8-A2L 2
C 184705 WASHER –FLAT M6-200HV-A2L 2
D 136151 BOLT –HEX FLG HD TFL M10 X 1.5 X 16-8.8-A3L 2
1. Not sold separately. Refer to the parts catalog if ordering replacement components for sensor assemblies.

214143 7Revision F
Chapter 3: Installation Instructions
DANGER
To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop engine and remove
key before leaving the operator’s seat, and always engage safety props before going under the machine for any reason.
To install the Dual Sensor AHHC kit (MD #B6211), follow these steps:
NOTE:
Unless otherwise stated, all parts are provided in the kit.
1. Raise the reel to full height, and engage the safety props.
NOTE:
The header is removed from the illustrations for clarity. The kit is installed with the float module attached to the
header.
2. Shut down the combine, and remove the key from the ignition.
IMPORTANT:
Before installing the sensor assemblies, make sure you correctly identify which assembly is for the left side and which
assembly is for the right side. The sensor assemblies MUST be installed in the correct locations for the dual sensor
system to work correctly.
1030503
A
B
C
L
R
C
A
B
Figure 3.1: Left and Right Sensor Assemblies
3. Hold up the assembly so that the sensor connector (A) is
pointing down and the mounting bolt heads (B) are facing
away from you.
•The left sensor assembly (L) has the linkage (C) to the
left of the sensor.
•The right sensor assembly (R) has the linkage (C) to the
right of the sensor.

214143 8Revision F
1020839
AB
C
Figure 3.2: Float Indicator Cable
4. Remove the nut from bolt (A), and leave the bolt, washer,
and float indicator cable (B) attached to float lever (C).
NOTE:
Unless otherwise stated, illustrations in this procedure
show the installation of the right side sensor assembly (not
sold separately).
1030467
A
B
C
A
Figure 3.3: Installing Sensor Link Bracket
5. Install sensor link bracket (A) (MD #295179) arms into
hole (B) at the top of the float lever, with the indented end
of the bracket facing up.
NOTE:
The sensor link bracket arms fit snugly inside the hole of
the float lever. If required, use a mallet to tap brackets
into place.
6. Align hole (C) in the bottom of the bracket with the hole in
the float lever where the nut was removed in Step 4, page
8.
INSTALLATION INSTRUCTIONS

214143 9Revision F
CDE
1030522
A
B
Figure 3.4: Installing Sensor Link Bracket
7. Hold cable (E) in place, and replace bolt (C) and washer (D)
with bolt (MD #135671) and washer (MD #184705)
supplied in the kit.
8. Install nut (A) (MD #152668) to secure the sensor link
bracket (B) to the float lever. Ensure washer (D) is between
bolt (C) and cable (E).
9. Ensure cable eye (E) is not twisted, and then fully tighten
bolt (C).
1024211
A
B
Figure 3.5: Right Sensor Assembly
10. Check if jam nuts (A) are tight against the two ball joints of
the right sensor assembly. If jam nuts are not secured,
tighten to 12 Nm (9 lbf·ft).
IMPORTANT:
Measurement (B) should be 50.4 mm (1 31/32 in.).
Incorrect measurement will lead to equipment damage.
1030471
A
B
Figure 3.6: Right Sensor Assembly
IMPORTANT:
The sensor is to be installed with electrical connector (A)
facing down and sensor arm arrow (the pointed end) (B)
facing the combine.
INSTALLATION INSTRUCTIONS

214143 10 Revision F
1030472
A
B
B
C
D
Figure 3.7: Installing Right Sensor Assembly
11. With the sensor assembly positioned inside the right side of
the frame, route sensor assembly linkage (C) through frame
opening (D) and out toward the front of the header.
IMPORTANT:
The sensor assemblies must be installed on the back side of
the float module.
12. Install the right sensor assembly (A) onto the rear of the
float module frame as shown, with bolts (B) on the
assembly slotted into place on the frame. Make sure the
sensor connector faces down.
1030474
A
B
C
Figure 3.8: Installing Right Sensor Assembly
13. Remove nut (A) from the sensor assembly ball joint, then
attach sensor linkage (B) to the top of sensor link
bracket (C) and reinstall nut (A). Tighten to 12 Nm (9 lbf·ft).
1030478
A
B
Figure 3.9: Installing Right Sensor Assembly
14. Ensure rubber boot (A) is attached to the cable adjuster
nut (B).
INSTALLATION INSTRUCTIONS

214143 11 Revision F
1030521
A
Figure 3.10: Left Sensor Assembly Installed
15. Repeat Step 3, page 7 to Step 14, page 10 to install the left
sensor assembly (A).
1030479
A
Figure 3.11: Installing Right Sensor Harness
16. Connect right sensor harness (A) (MD #276871) to the right
sensor.
17. Route the right sensor harness up inside the frame as
shown.
1030480
A
B
C
Figure 3.12: Installing Right Sensor Harness
18. Continue routing right sensor harness (A) along the front of
frame toward the float indicator box (B) and connect to
connector P539 (C) on the FM100 main harness.
INSTALLATION INSTRUCTIONS

214143 12 Revision F
1030481
A
CB
Figure 3.13: Installing Right Sensor Harness
19. Secure harness (A) to the front of the frame using two
clamps (MD #136410) and bolts (MD #136151). Install
clamp at location (B) first, then at location (C).
NOTE:
Clamp (C) attaches to existing clamp that secures the float
indicator cable to the frame.
NOTE:
Do NOT route the float indicator cable through clamp (B).
1030542
A
B
Figure 3.14: Securing Right Sensor Harness
20. Secure the right sensor harness (A) to the inside frame
using fastener (B) (MD #136655).
1030543
A
Figure 3.15: Securing Right Sensor Harness
21. Near the sensor connection, secure the right sensor
harness to the inside frame using fastener (A)
(MD #136655).
INSTALLATION INSTRUCTIONS

214143 13 Revision F
1030532
A
B
Figure 3.16: Installing Left Sensor Harness
22. Connect left sensor harness (A) (MD #276201) to left
sensor (B).
1030533
A
B
Figure 3.17: Installing Left Sensor Harness
23. Route left sensor harness (A) up inside the frame as shown,
between the frame and hydraulic hoses (B).
1030534
A
B
Figure 3.18: FM100 Main Harness P537
24. Near the inner float spring (B) on the left side of the float
module, locate plug P537 (A) on the FM100 main harness,
and remove the cap.
INSTALLATION INSTRUCTIONS

214143 14 Revision F
A
B
1030537
Figure 3.19: FM100 Harness P537 and Left Sensor
Harness Connector
25. Connect left sensor harness connector (B) to plug P537 (A)
on the FM100 main harness.
1030538
A
Figure 3.20: Securing Left Sensor Harness
26. Secure the top end of the left sensor harness to the inside
frame using fastener (A) (MD #136655).
1030539
A
B
Figure 3.21: Securing Left Sensor Harness
27. Near the sensor connection (A), secure the left sensor
harness to the inside frame using fastener (B)
(MD #136655).
INSTALLATION INSTRUCTIONS