MacDon FD75 User manual

Featuring MacDon FLEX-FLOAT Technology
™
The harvesting specialists.
FD75
FlexDraper®Combine Header
Operator’s Manual
147695 Revision A
2016 Model Year
Original Instruction
IMPORTANT: PAGE 31 HAS BEEN
UPDATED SINCE THIS MANUAL WAS
PUBLISHED.

FD75 FlexDraper®Header for Combines
Published: May 2015

Declaration of Conformity
147695 iRevision A

147695 iiRevision A

Introduction
This instructional manual contains information on the FD75 FlexDraper®and the CA25 Combine Adapter. It must
be used in conjunction with your combine operator's manual.
The FD75 FlexDraper®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, using a three-piece flexible frame to closely follow
ground contours.
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 technical manual is
available from your MacDon Dealer.
The Table of Contents and Index will guide you to specific areas of this manual. Study the Table of Contents to
familiarize yourself with how the information 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 header left endshield.
Call your MacDon Dealer if you need assistance,
information, or additional copies of this manual.
NOTE:
Keep your MacDon publications up-to-date. The
most current version can be downloaded from our
website (www.macdon.com) or from our Dealer-only site
(https://portal.macdon.com) (login required).
This manual is also available in the following languages:
•French
•Russia
n
•Portug
uese
• Spanish
They can be ordered from MacDon, downloaded from
the Dealer Portal (https://portal.macdon.com)orfromour
International website (http://www.macdon.com/world).
Figure 1: Manual Storage Location
147695 iii Revision A

List of Revisions
The following lists the changes from the previous version (169894 Revision A) of this document.
Summary of Change Refer To
New Book Part Number •FD75FlexDraper
®Header Operator’s Manual from
MD #196894_A to MD #147695_A
•8.3 Unloading and Assembly, page 446
New Declaration of Conformity Declaration of Conformity, page i
Added a step in Calibrating the Auto Header Height
Control
•Calibrating the Auto Header Height Control
(Challenger 6 Series), page 97
•Calibrating the Auto Header Height Control
(Case IH 2300/2500 and 5088/6088/7088), page 103
•Calibrating the Auto Header Height Control (Case
IH 5130/6130/7130, 7010/8010; 7120/8120/9120;
7230/8230/9230), page 110
•Calibrating the Auto Header Height Control System
(Case Combines with Version 28.00 Software), page
112
•Calibrating the Auto Header Height Control (Gleaner
R62/R72), page 114
•Calibrating the Auto Header Height Control (Gleaner
R65/R75), page 120
•Calibrating the Auto Header Height Control (John
Deere 50 Series), page 129
•Calibrating the Auto Header Height Control (John
Deere 60 Series), page 132
•Calibrating the Auto Header Height Control (John
Deere 70 Series), page 141
•Calibrating the Auto Header Height Control (John
Deere S Series), page 146
•Calibrating the Auto Header Height Control (Lexion
500 Series), page 150
•Calibrating the Auto Header Height Control (Lexion
700 Series), page 157
•Calibrating the Auto Header Height Control (New
Holland CR/CX Series), page 167
Added new kit 6.1.1 Multi-Crop Rapid Reel Conversion Kit, page 407
Revised Header Settings 3.6.2 Header Settings, page 44
147695 ivRevision A

Model and Serial Number
Record the model number, serial number, and model year of the header, combine adapter, and transport/stabilizer
wheel option (if installed) on the lines below.
NOTE:
Right-hand (RH) and left-hand (LH) designations are determined from the operator’s position, facing forward.
Draper Header
Header Model:
Serial Number:
Year:
The serial number plate (A) is located beside the knife
drive motor on the left-hand endsheet.
Figure 2: Header
Combine Adapter
AdapterModel:
Serial Number:
Year:
The serial number plate (A) is located on the underside
of the reservoir at the right end.
Figure 3: Adapter
Slow Speed Transport/Stabilizer Wheel Option
Serial Number:
Year:
The serial number plate (A) is located on the right-hand
axle assembly.
Figure 4: Transport/Stabilizer Option
147695 vRevision A

TABLE OF CONTENTS
Declaration of Conformity.................................................................................................................. i
Introduction.....................................................................................................................................iii
List of Revisions ..............................................................................................................................iv
Model and Serial Number................................................................................................................. v
1 Safety.................................................................................................................................................... 1
1.1 Safety Alert Symbols........................................................................................................................ 1
1.2 Signal Words................................................................................................................................... 2
1.3 General Safety ................................................................................................................................ 3
1.4 Maintenance Safety......................................................................................................................... 5
1.5 Hydraulic Safety .............................................................................................................................. 6
1.6 Safety Signs.................................................................................................................................... 7
1.6.1 Installing Safety Decals ............................................................................................................ 7
1.7 Safety Decal Locations .................................................................................................................... 8
1.8 Understanding Safety Signs ........................................................................................................... 12
2 Product Overview................................................................................................................................21
2.1 Definitions..................................................................................................................................... 21
2.2 Specifications................................................................................................................................ 23
2.3 Component Identification................................................................................................................ 26
2.3.1 FD75 FlexDraper®.................................................................................................................. 26
2.3.2 CA25 Combine Adapter.......................................................................................................... 27
3 Operation ............................................................................................................................................ 29
3.1 Owner/Operator Responsibilities..................................................................................................... 29
3.2 Operational Safety......................................................................................................................... 30
3.2.1 Header Safety Props.............................................................................................................. 30
3.2.2 Reel Safety Props.................................................................................................................. 31
Engaging Reel Safety Props............................................................................................ 31
Disengaging Reel Safety Props ....................................................................................... 32
3.2.3 Endshields............................................................................................................................. 33
Opening Endshields........................................................................................................ 33
Closing Endshields ......................................................................................................... 34
Removing Endshields ..................................................................................................... 35
Installing Endshields ....................................................................................................... 36
Adjusting Endshields....................................................................................................... 37
3.2.4 Linkage Covers...................................................................................................................... 38
Removing Linkage Covers............................................................................................... 38
Installing Linkage Covers ................................................................................................ 39
3.2.5 Daily Start-Up Check.............................................................................................................. 40
3.3 Break-in Period.............................................................................................................................. 41
3.4 Shutting Down the Machine............................................................................................................ 42
3.5 Cab Controls................................................................................................................................. 43
3.6 Header Setup................................................................................................................................ 44
3.6.1 Header Attachments............................................................................................................... 44
3.6.2 Header Settings..................................................................................................................... 44
3.6.3 Optimizing Header for Straight Combining Canola.................................................................... 48
Adjusting Feed Auger Springs ......................................................................................... 49
3.6.4 Reel Settings ......................................................................................................................... 50
3.7 Header Operating Variables ........................................................................................................... 52
3.7.1 Cutting Height........................................................................................................................ 52
Cutting Off the Ground.................................................................................................... 52
Cutting On the Ground.................................................................................................... 56
3.7.2 Header Float.......................................................................................................................... 58
Checking and Adjusting Header Float .............................................................................. 58
Locking/Unlocking Header Float ...................................................................................... 63
147695 vii Revision A

TABLE OF CONTENTS
Locking/Unlocking Header Wings..................................................................................... 64
Operating in Flex Mode................................................................................................... 64
Operating in Rigid Mode.................................................................................................. 65
3.7.3 Header Angle......................................................................................................................... 66
Controlling Header Angle ................................................................................................ 67
3.7.4 Reel Speed............................................................................................................................ 67
Optional Reel Drive Sprockets......................................................................................... 68
3.7.5 Ground Speed ....................................................................................................................... 68
3.7.6 Draper Speed ........................................................................................................................ 69
Adjusting Side Draper Speed........................................................................................... 70
Adjusting Feed Draper Speed.......................................................................................... 71
3.7.7 Knife Speed........................................................................................................................... 71
Checking Knife Speed..................................................................................................... 72
3.7.8 Reel Height............................................................................................................................ 73
3.7.9 Reel Fore-Aft Position ............................................................................................................ 73
Adjusting Reel Fore-Aft Position ...................................................................................... 74
Repositioning Fore-Aft Cylinders...................................................................................... 75
3.7.10 Repositioning Fore-Aft Cylinders with Multi-Crop Rapid Reel Conversion Option........................ 78
3.7.11 Reel Tine Pitch....................................................................................................................... 80
Reel Cam Settings.......................................................................................................... 80
Adjusting Reel Cam........................................................................................................ 82
3.7.12 Crop Dividers......................................................................................................................... 83
Removing Crop Dividers from Header with Latch Option ................................................... 83
Removing Crop Dividers from Header without Latch Option............................................... 84
Installing Crop Dividers on Header with Latch Option ........................................................ 84
Installing Crop Dividers on Header without Latch Option.................................................... 86
3.7.13 Crop Divider Rods.................................................................................................................. 87
Removing Crop Divider Rods .......................................................................................... 88
Rice Dividers.................................................................................................................. 88
3.8 Auto Header Height Control (AHHC)............................................................................................... 89
3.8.1 Auto Header Height Control Sensor Output Voltage Range – Combine Requirements ................ 91
Manually Checking Voltage Range................................................................................... 91
Adjusting Voltage Limits .................................................................................................. 93
3.8.2 Challenger 6 and 7 Series Combines....................................................................................... 94
Checking Voltage Range from the Combine Cab (Challenger 6 and 7 Series)..................... 94
Engaging the Auto Header Height Control (Challenger 6 Series)........................................ 96
Calibrating the Auto Header Height Control (Challenger 6 Series)...................................... 97
Adjusting the Header Height (Challenger 6 Series)............................................................ 99
Adjusting the Header Raise/Lower Rate (Challenger 6 Series)........................................... 99
Setting the Sensitivity of the Auto Header Height Control (Challenger 6 Series).................100
3.8.3 Case IH 2300/2500 and 5088/6088/7088 Combines................................................................101
Engaging the Auto Header Height Control (Case IH 2300)................................................101
Calibrating the Auto Header Height Control (Case IH 2300/2500 and
5088/6088/7088)........................................................................................................103
Setting the Sensitivity of the Auto Header Height (Case IH 2300/2500 and
5088/6088/7088)........................................................................................................104
3.8.4 Case IH 5130/6130/7130, 7010/8010, 7120/8120/9120, and 7230/8230/9230 Combines ...........105
Checking Voltage Range from the Combine Cab (Case 8010) ..........................................105
Checking Voltage Range from the Combine Cab (Case IH 5130/6130/7130, 7010/8010;
7120/8120/9120; 7230/8230/9230)..............................................................................108
Calibrating the Auto Header Height Control (Case IH 5130/6130/7130, 7010/8010;
7120/8120/9120; 7230/8230/9230)..............................................................................110
Calibrating the Auto Header Height Control System (Case Combines with Version
28.00 Software)..........................................................................................................112
147695 viii Revision A

TABLE OF CONTENTS
3.8.5 Gleaner R62/R72 Combines..................................................................................................114
Determining System Requirements (Gleaner R62/R72)....................................................114
Calibrating the Auto Header Height Control (Gleaner R62/R72)........................................114
Setting the Sensitivity of the Auto Header Height Control (Gleaner R62/R72 Series)...........114
3.8.6 Gleaner R65/R75 Combines..................................................................................................117
Checking Voltage Range from the Combine Cab (Gleaner R65/R75) ................................117
Engaging the Auto Header Height Control (Gleaner R65/R75)..........................................118
Calibrating the Auto Header Height Control (Gleaner R65/R75)........................................120
Turning the Accumulator Off (Gleaner R65/R75)..............................................................121
Adjusting the Header Raise/Lower Rate (Gleaner R65/R75).............................................122
Adjusting Ground Pressure (Gleaner R65/R75)................................................................122
Adjusting the Sensitivity of the Auto Header Height Control (Gleaner R65/R75).................123
Troubleshooting Alarms and Diagnostic Faults (Gleaner R65/R75) ...................................124
3.8.7 John Deere 50 Series Combines............................................................................................127
Checking Voltage Range from the Combine Cab (John Deere 50 Series)..........................127
Calibrating the Auto Header Height Control (John Deere 50 Series)..................................129
3.8.8 John Deere 60 Series Combines............................................................................................131
Checking Voltage Range from the Combine Cab (John Deere 60 Series)..........................131
Calibrating the Auto Header Height Control (John Deere 60 Series)..................................132
Turning the Accumulator Off (John Deere 60 Series)........................................................134
Setting the Sensing Grain Header Height to 50 (John Deere 60 Series).............................134
Setting the Sensitivity of the Auto Header Height Control (John Deere 60 Series)..............135
Adjusting the Threshold for the Drop Rate Valve (John Deere 60 Series)...........................136
3.8.9 John Deere 70 Series Combines............................................................................................137
Checking Voltage Range from the Combine Cab (John Deere 70 Series)..........................137
Calibrating Feeder House Speed (John Deere 70 Series).................................................141
Calibrating the Auto Header Height Control (John Deere 70 Series)..................................141
Setting the Sensitivity of the Auto Header Height Control (John Deere 70 Series)..............142
Adjusting the Manual Header Raise/Lower Rate (John Deere 70 Series)...........................142
3.8.10 John Deere S Series Combines .............................................................................................143
Checking Voltage Range from the Combine Cab (John Deere S Series)............................143
Calibrating the Auto Header Height Control (John Deere S Series) ...................................146
Setting the Sensitivity of the Auto Header Height Control (John Deere S Series)................148
Adjusting the Manual Header Raise/Lower Rate (John Deere S Series) ............................149
3.8.11 Lexion 500 Series Combines .................................................................................................150
Calibrating the Auto Header Height Control (Lexion 500 Series) .......................................150
Setting Cutting Height (Lexion 500 Series) ......................................................................152
3.8.12 Lexion 700 Series Combines .................................................................................................157
Calibrating the Auto Header Height Control (Lexion 700 Series) .......................................157
Setting Cutting Height (Lexion 700 Series) ......................................................................160
Setting the Sensitivity of the Auto Header Height Control (Lexion 700 Series)....................160
Adjusting Auto Reel Speed (Lexion 700 Series)...............................................................162
3.8.13 New Holland Combines .........................................................................................................163
Checking Voltage Range from the Combine Cab (New Holland) .......................................163
Engaging the Auto Header Height Control (New Holland CR/CX Series) ...........................166
Calibrating the Auto Header Height Control (New Holland CR/CX Series)..........................167
Adjusting Header Raise Rate (New Holland CR/CX Series)..............................................169
Setting the Header Lower Rate to 50 (New Holland CR/CX Series)...................................170
Setting the Sensitivity of the Auto Header Height Control to 200 (New Holland CR/CX
Series).......................................................................................................................170
3.8.14 Sensor Operation..................................................................................................................171
3.9 Levelling the Header.....................................................................................................................173
3.10 Unplugging Cutterbar....................................................................................................................175
3.11 Unplugging Adapter......................................................................................................................176
147695 ixRevision A

TABLE OF CONTENTS
3.12 Upper Cross Auger (UCA).............................................................................................................177
3.12.1 Removing Beater Bars...........................................................................................................177
3.12.2 Installing Beater Bars ............................................................................................................178
3.13 Transporting Header ....................................................................................................................179
3.13.1 Transporting Header on Combine...........................................................................................179
3.13.2 Towing..................................................................................................................................179
Attaching Header to Towing Vehicle................................................................................180
Towing the Header.........................................................................................................180
3.13.3 Converting from Transport to Field Position.............................................................................181
Removing Tow-Bar ........................................................................................................181
Storing Tow-Bar.............................................................................................................182
Moving Front (Left) Wheels into Field Position.................................................................183
Moving Rear (Right) Wheels into Field Position................................................................185
3.13.4 Converting from Field to Transport Position.............................................................................187
Moving Front (Left) Wheels into Transport Position..........................................................187
Moving Rear (Right) Wheels into Transport Position.........................................................190
Attaching Tow-Bar..........................................................................................................192
3.14 Storing Header.............................................................................................................................196
4 Header Attachment/Detachment ........................................................................................................197
4.1 Adapter Setup ..............................................................................................................................197
4.1.1 Using Flighting Extensions.....................................................................................................197
4.1.2 Using Stripper Bars...............................................................................................................197
4.1.3 Adjusting Auger Speed..........................................................................................................198
4.2 Case IH Combines........................................................................................................................199
4.2.1 Attaching Header to Case IH Combine ...................................................................................199
4.2.2 Detaching Header from Case IH Combine ..............................................................................203
4.3 John Deere Combines ..................................................................................................................207
4.3.1 Attaching Header to John Deere Combine..............................................................................207
4.3.2 Detaching Header from John Deere Combine.........................................................................210
4.4 Lexion Combines..........................................................................................................................214
4.4.1 Attaching Header to Lexion Combine......................................................................................214
4.4.2 Detaching Header from Lexion Combine.................................................................................218
4.5 New Holland Combines.................................................................................................................222
4.5.1 Attaching Header to New Holland CR/CX Combine .................................................................222
4.5.2 Detaching Header from New Holland Combine........................................................................225
4.5.3 CR Feeder Deflectors............................................................................................................230
4.6 Challenger, Gleaner, and Massey Ferguson Combines ...................................................................231
4.6.1 Attaching Header to Challenger, Gleaner, or Massey Ferguson Combine..................................231
4.6.2 Detaching Header from Challenger, Gleaner, or Massey Ferguson Combine.............................236
4.7 Attaching and Detaching Header from Adapter and Combine ..........................................................240
4.7.1 Detaching Header from Adapter and Combine ........................................................................240
4.7.2 Attaching Header to Adapter and Combine.............................................................................245
5Main
tenance and Servicing................................................................................................................251
5.1 Preparation for Servicing...............................................................................................................251
5.2 Maintenance Specifications...........................................................................................................252
5.2.1 Recommended Fluids and Lubricants.....................................................................................252
5.2.2 Installing a Roller Chain.........................................................................................................252
5.2.3 Installing a Sealed Bearing ....................................................................................................253
5.3 Maintenance Requirements...........................................................................................................254
5.3.1 Maintenance Schedule/Record...............................................................................................255
5.3.2 Break-In Inspection ...............................................................................................................257
5.3.3 Preseason/Annual Service.....................................................................................................257
5.3.4 End-of-Season Service..........................................................................................................257
147695 xRevision A

TABLE OF CONTENTS
5.3.5 Checking Hydraulic Hoses and Lines......................................................................................259
5.3.6 Lubrication and Servicing.......................................................................................................259
Service Intervals............................................................................................................260
Greasing Procedure.......................................................................................................268
Lubricating Reel Drive Chain ..........................................................................................269
Lubricating Auger Drive Chain........................................................................................270
Lubricating Header Drive Gearbox..................................................................................271
5.4 Hydraulics....................................................................................................................................273
5.4.1 Reservoir..............................................................................................................................273
Checking Oil Level in Hydraulic Reservoir.......................................................................273
Adding Oil.....................................................................................................................273
Changing Oil .................................................................................................................274
5.4.2 Changing Oil Filter ................................................................................................................275
5.5 Electrical......................................................................................................................................277
5.5.1 Replacing Light Bulbs............................................................................................................277
5.6 Header Drive................................................................................................................................278
5.6.1 Removing Driveline ...............................................................................................................278
5.6.2 Installing Driveline.................................................................................................................279
5.6.3 Removing Driveline Guard.....................................................................................................280
5.6.4 Installing Driveline Guard.......................................................................................................282
5.6.5 Adjusting Tension on Gearbox Drive Chain .............................................................................284
5.7 Auger...........................................................................................................................................285
5.7.1 Adjusting Auger to Pan Clearance..........................................................................................285
5.7.2 Adjusting Auger Drive Chain Tension......................................................................................286
5.7.3 Removing Auger Drive Chain.................................................................................................287
5.7.4 Installing Auger Drive Chain...................................................................................................291
5.7.5 Auger Tines ..........................................................................................................................293
Removing Feed Auger Tines ..........................................................................................293
Installing Feed Auger Tines............................................................................................295
Replacing Auger Tine Guides.........................................................................................296
5.7.6 Flighting Extensions ..............................................................................................................297
Installing Flighting Extensions.........................................................................................297
Removing Flighting Extensions.......................................................................................298
5.8 Knife............................................................................................................................................299
5.8.1 Replacing Knife Section.........................................................................................................299
5.8.2 Removing Knife.....................................................................................................................301
5.8.3 Removing Knifehead Bearing.................................................................................................301
5.8.4 Installing Knifehead Bearing...................................................................................................302
5.8.5 Installing Knife ......................................................................................................................302
5.8.6 Spare Knife...........................................................................................................................303
5.8.7 Knife Guards.........................................................................................................................303
Adjusting Knife Guards...................................................................................................304
Replacing Pointed Guards on a Single-Knife Header........................................................305
Replacing Pointed Guards on a Double-Knife Header......................................................305
Replacing Stub Guards on a Single-Knife Header............................................................306
Replacing Stub Guards on a Double-Knife Header...........................................................307
Checking Knife Hold-Downs...........................................................................................308
5.8.8 Knifehead Shield...................................................................................................................310
Installing Knifehead Shield .............................................................................................310
5.9 Knife and Knife Drive....................................................................................................................312
5.9.1 Knife Drive Box.....................................................................................................................312
Checking Mounting Bolts................................................................................................312
Removing Knife Drive Box..............................................................................................312
Removing Knife Drive Box Pulley....................................................................................314
147695 xiRevision A

TABLE OF CONTENTS
Installing Knife Drive Box Pulley......................................................................................315
Installing Knife Drive Box................................................................................................315
Changing Oil in Knife Drive Box......................................................................................318
5.9.2 Knife Drive Belts ...................................................................................................................318
Removing Knife Drive Belt..............................................................................................318
Installing Knife Drive Belts..............................................................................................319
Tensioning Knife Drive Belts...........................................................................................320
5.10 Adapter Feed Draper ....................................................................................................................322
5.10.1 Replacing Adapter Feed Draper.............................................................................................322
5.10.2 Adjusting Feed Draper Tension ..............................................................................................323
5.10.3 Adapter Drive Roller..............................................................................................................324
Removing Adapter Feed Draper Drive Roller...................................................................324
Installing Adapter Feed Draper Drive Roller.....................................................................326
Replacing Adapter Feed Draper Drive Roller Bearing.......................................................327
5.10.4 Adapter Idler Roller ...............................................................................................................328
Removing Adapter Feed Draper Idler Roller ....................................................................328
Replacing Adapter Feed Draper Idler Roller Bearing........................................................329
Installing Adapter Feed Draper Idler Roller ......................................................................331
5.11 Adapter Stripper Bars and Feed Deflectors.....................................................................................332
5.11.1 Installing Stripper Bars...........................................................................................................332
5.11.2 Removing Stripper Bars.........................................................................................................332
5.11.3 Replacing Feed Deflectors.....................................................................................................332
5.12 Header Drapers............................................................................................................................334
5.12.1 Removing Drapers ................................................................................................................334
5.12.2 Installing Drapers ..................................................................................................................334
5.12.3 Adjusting Side Draper Tension...............................................................................................335
5.12.4 Adjusting Header Draper Tracking..........................................................................................337
5.12.5 Adjusting Deck Height ...........................................................................................................339
5.12.6 Draper Roller Maintenance ....................................................................................................340
Inspecting Side Draper Roller Bearing.............................................................................340
Side Draper Idler Roller..................................................................................................341
Side Draper Deck Drive Roller........................................................................................343
5.12.7 Replacing Draper Deflectors..................................................................................................347
Removing Narrow Draper Deflectors...............................................................................347
Installing Narrow Draper Deflectors.................................................................................348
5.13 Reel.............................................................................................................................................350
5.13.1 Reel Clearance to Cutterbar...................................................................................................350
Measuring Reel Clearance.............................................................................................350
Adjusting Reel Clearance...............................................................................................352
5.13.2 Reel Frown...........................................................................................................................353
Adjusting Reel Frown.....................................................................................................353
5.13.3 Centering the Reel ................................................................................................................354
5.13.4 Reel Tines ............................................................................................................................355
Removing Steel Tines....................................................................................................355
Installing Steel Tines......................................................................................................356
Removing Plastic Fingers...............................................................................................356
Installing Plastic Fingers.................................................................................................357
5.13.5 Tine Tube Bushings...............................................................................................................358
Removing Bushings from 5-, 6- or 9-Bat Reels ................................................................358
Installing Bushings on 5-, 6- or 9-Bat Reels .....................................................................362
5.13.6 Reel Endshields....................................................................................................................369
Replacing Endshield......................................................................................................369
Replacing Support .........................................................................................................370
5.14 Reel Drive....................................................................................................................................372
147695 xii Revision A

TABLE OF CONTENTS
5.14.1 Replacing Reel Drive Sprocket...............................................................................................372
Removing Drive Cover...................................................................................................372
Loosening Drive Chain...................................................................................................372
Removing Drive Sprocket...............................................................................................373
Installing Drive Sprocket.................................................................................................373
Tightening Drive Chain...................................................................................................374
Installing Drive Cover.....................................................................................................374
5.14.2 Replacing Double Reel U-Joint...............................................................................................375
Removing Drive Cover...................................................................................................375
Removing Double Reel U-Joint.......................................................................................375
Installing Double Reel U-Joint.........................................................................................376
Installing Drive Cover.....................................................................................................377
5.14.3 Replacing Reel Drive Motor ...................................................................................................378
Removing Drive Cover...................................................................................................378
Loosening Drive Chain...................................................................................................378
Removing Drive Sprocket...............................................................................................379
Removing Reel Drive Motor............................................................................................380
Installing Reel Drive Motor..............................................................................................380
Installing Drive Sprocket.................................................................................................382
Tightening Drive Chain...................................................................................................382
Installing Drive Cover.....................................................................................................383
5.14.4 Replacing Drive Chain...........................................................................................................383
Removing Drive Cover...................................................................................................383
Loosening Drive Chain...................................................................................................384
Disconnecting the Reel Drive Method..............................................................................384
Breaking the Chain Method............................................................................................386
Tightening Drive Chain...................................................................................................386
Installing Drive Cover.....................................................................................................387
5.14.5 Adjusting Reel Drive Chain Tension........................................................................................387
Removing Drive Cover...................................................................................................387
Tightening Drive Chain...................................................................................................388
Installing Drive Cover.....................................................................................................388
5.14.6 Replacing Reel Speed Sensor ...............................................................................................389
Removing Drive Cover...................................................................................................389
Replacing AGCO Sensor................................................................................................389
Replacing John Deere Sensor........................................................................................390
Replacing Lexion 400 Series Sensor...............................................................................391
Replacing Lexion 500/700 Series Sensor ........................................................................391
Installing Drive Cover.....................................................................................................392
5.15 Transport System (Optional)..........................................................................................................393
5.15.1 Checking Wheel Bolt Torque..................................................................................................393
5.15.2 Checking Axle Bolt Torque.....................................................................................................394
5.15.3 Checking Tire Pressure .........................................................................................................395
5.16 Checking and Adjusting Header Wing Balance...............................................................................396
5.16.1 Checking Wing Balance.........................................................................................................396
5.16.2 Adjusting Wing Balance.........................................................................................................401
6 Options and Attachments ..................................................................................................................407
6.1 Reel.............................................................................................................................................407
6.1.1 Multi-Crop Rapid Reel Conversion Kit.....................................................................................407
6.1.2 Lodged Crop Reel Finger Kit..................................................................................................407
6.1.3 PR15 Tine Tube Reel Conversion Kit......................................................................................408
6.1.4 Reel Endshield Kit.................................................................................................................408
6.1.5 Reel Tine Tube Reinforcing Kit...............................................................................................408
6.2 Cutterbar......................................................................................................................................409
147695 xiii Revision A

TABLE OF CONTENTS
6.2.1 Cutterbar Wearplate..............................................................................................................409
6.2.2 Knifehead Shield...................................................................................................................409
6.2.3 Stub Guard Conversion Kit ....................................................................................................410
6.2.4 Vertical Knife Mounts.............................................................................................................410
6.3 Header.........................................................................................................................................411
6.3.1 Divider Latch Kit....................................................................................................................411
6.3.2 Stabilizer Wheels ..................................................................................................................411
6.3.3 Rice Divider Rods .................................................................................................................412
6.3.4 Stabilizer/Slow Speed Transport Wheels.................................................................................412
6.4 Crop Delivery ...............................................................................................................................413
6.4.1 CA25 Feed Auger Flighting....................................................................................................413
6.4.2 European Adapter Seal Kit.....................................................................................................413
6.4.3 Draper Deflector (Narrow)......................................................................................................414
6.4.4 Stripper Bars.........................................................................................................................414
6.4.5 Upper Cross Auger (UCA) .....................................................................................................415
7 Troubleshooting.................................................................................................................................417
7.1 Crop Loss at Cutterbar..................................................................................................................417
7.2 Cutting Action and Knife Components............................................................................................419
7.3 Reel Delivery................................................................................................................................422
7.4 Header and Drapers .....................................................................................................................424
7.5 Cutting Edible Beans ....................................................................................................................428
8 Reference...........................................................................................................................................433
8.1 Torque Specifications....................................................................................................................433
8.1.1 SAE Bolt Torque Specifications..............................................................................................433
8.1.2 Metric Bolt Specifications.......................................................................................................435
8.1.3 Metric Bolt Specifications Bolting into Cast Aluminum..............................................................438
8.1.4 Flare-Type Hydraulic Fittings..................................................................................................438
8.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)..................................................................440
8.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ..........................................................442
8.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings...........................................................................443
8.2 Conversion Chart..........................................................................................................................445
8.3 Unloading and Assembly...............................................................................................................446
Index ..................................................................................................................................................447
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1Safety
1.1 Safety Alert Symbols
This safety alert symbol indicates important safety
messages in this manual and on safety signs on
the header.
This symbol means:
•ATTENTION!
•BECOME ALERT!
•YOUR SAFETY IS INVOLVED!
Carefully read and follow the safety message
accompanying this symbol.
Why is safety important to you?
• Accidents disable and kill
• Accidents cost
• Accidents can be avoided
Figure 1.1: Safety Symbol
147695 1Revision A

SAFETY
1.2 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. The
appropriate signal word for each situation has been selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. 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.
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SAFETY
1.3 General Safety
CAUTION
The following are general farm safety precautions
that should be part of your operating procedure for
all types of machinery.
Protect yourself.
• When assembling, operating, and servicing machinery,
wear all the protective clothing and personal safety
devices that could be necessary for the job at hand.
Don’t 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
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 ear muffs or ear plugs to
help protect against objectionable or loud noises.
Figure 1.3: Safety Equipment
•Provideafirst aid kit for use in case of emergencies.
• Keep a fire extinguisher on the machine. Be sure the
fire extinguisher is properly maintained. Be familiar with
its proper use.
• Keep young children away from the machinery at
all times.
• Be aware that accidents often happen when the
Operator is tired or in a hurry. Take the time to
consider the safest way. Never ignore the warning
signs of fatigue.
Figure 1.4: Safety Equipment
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SAFETY
•Wearclose-fitting clothing and cover long hair. Never
wear dangling items such as scarves or bracelets.
• Keep all shields in place. Never alter or remove safety
equipment. Make sure driveline guards can rotate
independently of the shaft and can telescope freely.
• Use only service and repair parts made or approved by
the equipment manufacturer. Substituted parts may not
meet strength, design, or safety requirements.
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.
•DoNOT modify the machine. Non-authorized
modifications may impair machine function and/or
safety. It may also shorten the machine’s life.
• To avoid bodily injury or death from unexpected startup
of machine, always stop engine and remove key from
ignition before leaving operator’s seat for any reason.
Figure 1.6: Safety Around Equipment
• Keep the service area 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.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff on a hot
engine is a fire hazard. 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. Figure 1.7: Safety Around Equipment
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