MacDon FlexDraper FD1 Series User manual

Featuring MacDon FLEX-FLOAT Technology
™
The harvesting specialists.
FD1-Series
FlexDraper®Combine Header
Operator’s Manual
147831 Revision A
2016 Model Year
Original Instruction
IMPORTANT: PAGE 29 HAS
BEEN UPDATED SINCE THIS
MANUAL WAS PUBLISHED.

FD1-Series FlexDraper®Header for Combines
Published: April 2016

Declaration of Conformity
147831 iRevision A

147831 iiRevision A

147831 iii Revision A

147831 ivRevision A

Introduction
This instructional manual contains information on the FD1-Series FlexDraper®and the FM100 Combine Float
Module. It must be used in conjunction with your combine operator's manual.
The FD1-Series FlexDraper®is specially designed 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 use the machine.
Use this manual as your first source of information about the machine. If you follow the instructions provided, 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 manual storage case is
located inside the header left endshield.
Call your MacDon Dealer if you need assistance,
information, or additional copies of this manual.
Figure 1: Manual Storage Location
147831 vRevision A

Model and Serial Number
Record the model number, serial number, and model year of the header, combine float module, and
transport/stabilizer wheel option (if installed) in the spaces provided.
NOTE:
Right-hand (RH) and left-hand (LH) designations are determined from the operator’s position, facing forward.
FlexDraper®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 Float Module
Float Module
Model:
Serial Number:
Year:
The serial number plate (A) is located on the underside
of the reservoir at the right end.
Figure 3: Float Module
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
147831 vii Revision A

TABLE OF CONTENTS
Declaration of Conformity .................................................................................................................. i
Introduction ..................................................................................................................................... v
Model and Serial Number................................................................................................................ vii
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 ............................................................................................................11
2 Product Overview................................................................................................................................17
2.1 Definitions ..................................................................................................................................... 17
2.2 Specifications ................................................................................................................................ 19
2.3 Component Identification................................................................................................................ 24
2.3.1 FD1-Series FlexDraper®......................................................................................................... 24
2.3.2 FM100 Float Module............................................................................................................... 25
3 Operation ............................................................................................................................................ 27
3.1 Owner/Operator Responsibilities..................................................................................................... 27
3.2 Operational Safety ......................................................................................................................... 28
3.2.1 Header Safety Props .............................................................................................................. 29
3.2.2 Reel Safety Props .................................................................................................................. 29
Engaging Reel Safety Props............................................................................................ 29
Disengaging Reel Safety Props ....................................................................................... 30
3.2.3 Endshields............................................................................................................................. 31
Opening Endshields........................................................................................................ 31
Closing Endshields ......................................................................................................... 32
Removing Endshields ..................................................................................................... 33
Installing Endshields ....................................................................................................... 33
Checking and Adjusting Endshields ................................................................................. 34
3.2.4 Linkage Covers...................................................................................................................... 37
Removing Linkage Covers............................................................................................... 37
Installing Linkage Covers ................................................................................................ 38
3.2.5 Daily Start-Up Check .............................................................................................................. 39
3.3 Break-in Period.............................................................................................................................. 40
3.4 Shutting down the Machine ............................................................................................................ 41
3.5 Cab Controls ................................................................................................................................. 42
3.6 Header Setup ................................................................................................................................ 43
3.6.1 Header Attachments............................................................................................................... 43
3.6.2 Header Settings ..................................................................................................................... 43
3.6.3 Optimizing Header for Straight Combining Canola.................................................................... 45
Checking and Adjusting Feed Auger Spring Tension ......................................................... 46
3.6.4 Reel Settings ......................................................................................................................... 47
3.7 Header Operating Variables ........................................................................................................... 49
3.7.1 Cutting Height ........................................................................................................................ 49
Cutting off the Ground..................................................................................................... 49
Cutting on the Ground..................................................................................................... 53
3.7.2 Header Float.......................................................................................................................... 55
Checking and Adjusting Header Float .............................................................................. 56
Locking/Unlocking Header Float ...................................................................................... 61
Locking/Unlocking Header Wings..................................................................................... 62
147831 ixRevision A

TABLE OF CONTENTS
Operating in Flex Mode................................................................................................... 62
Operating in Rigid Mode.................................................................................................. 63
3.7.3 Checking and Adjusting Header Wing Balance......................................................................... 64
Checking Wing Balance .................................................................................................. 65
Adjusting Wing Balance .................................................................................................. 70
3.7.4 Header Angle......................................................................................................................... 72
Adjusting Header Angle................................................................................................... 73
3.7.5 Reel Speed............................................................................................................................ 73
Optional Reel Drive Sprockets ......................................................................................... 73
3.7.6 Ground Speed ....................................................................................................................... 74
3.7.7 Draper Speed ........................................................................................................................ 75
Adjusting Header Draper Speed ...................................................................................... 75
Feed Draper Speed ........................................................................................................ 76
3.7.8 Knife Speed........................................................................................................................... 77
Checking Knife Speed..................................................................................................... 77
3.7.9 Reel Height............................................................................................................................ 78
Manually Checking Voltage Range................................................................................... 79
Adjusting Reel Height Sensor .......................................................................................... 80
3.7.10 Reel Fore-Aft Position ............................................................................................................ 82
Adjusting Reel Fore-Aft Position ...................................................................................... 82
Repositioning Fore-Aft Cylinders...................................................................................... 84
Repositioning Fore-Aft Cylinders with Multi-Crop Rapid Reel Conversion Option................. 87
3.7.11 Reel Tine Pitch....................................................................................................................... 89
Reel Cam Settings.......................................................................................................... 89
Adjusting Reel Cam ........................................................................................................ 91
3.7.12 Crop Dividers......................................................................................................................... 92
Removing Crop Dividers with Latch Option from Header ................................................... 92
Removing Crop Dividers without Latch Option from Header............................................... 93
Installing Crop Dividers with Latch Option onto Header ..................................................... 93
Installing Crop Dividers without Latch Option onto Header................................................. 95
3.7.13 Crop Divider Rods.................................................................................................................. 96
Removing Crop Divider Rods .......................................................................................... 97
Installing Crop Divider Rods ............................................................................................ 97
Rice Divider Rods ........................................................................................................... 98
3.8 Auto Header Height Control (AHHC) ............................................................................................... 99
3.8.1 Sensor Output Voltage Range – Combine Requirements .........................................................101
Manually Checking Voltage Range (One-Sensor System).................................................101
Manually Checking Voltage Range (Two-Sensor System).................................................104
Adjusting Voltage Limits (One-Sensor System) ................................................................106
Adjusting Voltage Limits (Two-Sensor System) ................................................................108
3.8.2 Case IH 2500 and 5088/6088/7088 Combines ........................................................................110
Calibrating the Auto Header Height Control (Case IH 2500 and 5088/6088/7088) ..............110
Setting the Sensitivity of the Auto Header Height (Case IH 2500 and
5088/6088/7088) ........................................................................................................ 111
3.8.3 Case IH 5130/6130/7130, 7010/8010, 7120/8120/9120, and 7230/8230/9230 Combines ...........112
Checking Voltage Range from the Combine Cab (Case 8010) ..........................................112
Checking Voltage Range from the Combine Cab (Case IH 5130/6130/7130, 7010/8010;
7120/8120/9120; 7230/8230/9230) ..............................................................................115
Calibrating the Auto Header Height Control (Case IH 5130/6130/7130, 7010/8010;
7120/8120/9120; 7230/8230/9230) ..............................................................................118
Calibrating the Auto Header Height Control (Case Combines with Version 28.00 or
Higher Software) ........................................................................................................120
Setting Preset Cutting Height (Case 7010/8010, 7120/8120/9120, 7230/8230/9230) ...........122
3.8.4 Challenger and Massey Ferguson Combines ..........................................................................124
147831 xRevision A

TABLE OF CONTENTS
Checking Voltage Range from the Combine Cab (Challenger and Massey
Ferguson) ..................................................................................................................124
Engaging the Auto Header Height Control (Challenger and Massey Ferguson)..................126
Calibrating the Auto Header Height Control (Challenger and Massey Ferguson) ................126
Adjusting the Header Height (Challenger and Massey Ferguson)......................................128
Adjusting the Header Raise/Lower Rate (Challenger and Massey Ferguson).....................129
Setting the Sensitivity of the Auto Header Height Control (Challenger and Massey
Ferguson) ..................................................................................................................130
3.8.5 Gleaner R65/R66/R75/R76 and S Series Combines ................................................................132
Checking Voltage Range from the Combine Cab (Gleaner R65/R66/R75/R76 and S
Series).......................................................................................................................132
Engaging the Auto Header Height Control (Gleaner R65/R66/R75/R76 and S
Series).......................................................................................................................133
Calibrating the Auto Header Height Control (Gleaner R65/R66/R75/R76 and S
Series).......................................................................................................................135
Turning off the Accumulator (Gleaner R65/R66/R75/R76 and S Series).............................136
Adjusting the Header Raise/Lower Rate (Gleaner R65/R66/R75/R76 and S Series) ...........136
Adjusting Ground Pressure (Gleaner R65/R66/R75/R76 and S Series) .............................137
Adjusting the Sensitivity of the Auto Header Height Control (Gleaner R65/R66/R75/R76
and S Series) .............................................................................................................138
Troubleshooting Alarms and Diagnostic Faults (Gleaner R65/R66/R75/R76 and S
Series).......................................................................................................................139
3.8.6 John Deere 60 Series Combines............................................................................................142
Checking Voltage Range from the Combine Cab (John Deere 60 Series) ..........................142
Calibrating the Auto Header Height Control (John Deere 60 Series) ..................................143
Turning the Accumulator Off (John Deere 60 Series)........................................................145
Setting the Sensing Grain Header Height to 50 (John Deere 60 Series).............................145
Setting the Sensitivity of the Auto Header Height Control (John Deere 60 Series) ..............146
Adjusting the Threshold for the Drop Rate Valve (John Deere 60 Series)...........................147
3.8.7 John Deere 70 Series Combines............................................................................................149
Checking Voltage Range from the Combine Cab (John Deere 70 Series) ..........................149
Calibrating Feeder House Speed (John Deere 70 Series).................................................152
Calibrating the Auto Header Height Control (John Deere 70 Series) ..................................152
Setting the Sensitivity of the Auto Header Height Control (John Deere 70 Series) ..............154
Adjusting the Manual Header Raise/Lower Rate (John Deere 70 Series)...........................154
3.8.8 John Deere S and T Series Combines....................................................................................156
Checking Voltage Range from the Combine Cab (John Deere S and T Series) ..................156
Calibrating the Auto Header Height Control (John Deere S and T Series)..........................159
Setting the Sensitivity of the Auto Header Height Control (John Deere S and T
Series).......................................................................................................................161
Adjusting the Manual Header Raise/Lower Rate (John Deere S and T Series)...................161
Calibrating Feeder House Fore/Aft Tilt Range (John Deere S and T Series).......................163
3.8.9 Lexion 500 Series Combines .................................................................................................166
Calibrating the Auto Header Height Control (Lexion 500 Series) .......................................166
Setting Cutting Height (Lexion 500 Series) ......................................................................168
Setting the Sensitivity of the Auto Header Height Control (Lexion 500 Series)....................170
Adjusting Auto Reel Speed (Lexion 500 Series) ...............................................................172
3.8.10 Lexion 600 and 700 Series Combines.....................................................................................175
Calibrating the Auto Header Height Control (Lexion 600 and 700 Series) ..........................175
Setting Cutting Height (Lexion 600 and 700 Series) .........................................................177
Setting the Sensitivity of the Auto Header Height Control (Lexion 600 and
700 Series) ................................................................................................................177
Adjusting Auto Reel Speed (Lexion 600 and 700 Series)..................................................179
3.8.11 New Holland Combines .........................................................................................................181
147831 xiRevision A

TABLE OF CONTENTS
Checking Voltage Range from the Combine Cab (New Holland) .......................................181
Engaging the Auto Header Height Control (New Holland CR/CX Series) ...........................183
Calibrating the Auto Header Height Control (New Holland CR/CX Series)..........................184
Adjusting Header Raise Rate (New Holland CR/CX Series)..............................................186
Setting the Header Lower Rate (New Holland CR/CX Series) ...........................................187
Setting the Sensitivity of the Auto Header Height Control (New Holland CR/CX
Series).......................................................................................................................188
3.8.12 New Holland Combines (CR Series—Model Year 2015 and Later)............................................191
Checking Voltage Range from the Combine Cab (New Holland CR Series) .......................191
Engaging the Auto Header Height Control (New Holland CR Series) .................................194
Calibrating the Auto Header Height Control (New Holland CR Series) ...............................197
Setting Auto Height (New Holland CR Series)..................................................................199
Setting Maximum Work Height (New Holland CR Series)..................................................200
3.8.13 Sensor Operation ..................................................................................................................201
3.9 Levelling the Header .....................................................................................................................202
3.10 Unplugging the Cutterbar ..............................................................................................................204
3.11 Unplugging the Float Module.........................................................................................................205
3.12 Upper Cross Auger (UCA).............................................................................................................206
3.12.1 Removing Beater Bars...........................................................................................................206
3.12.2 Installing Beater Bars ............................................................................................................206
3.13 Transporting Header ....................................................................................................................208
3.13.1 Transporting Header on Combine...........................................................................................208
3.13.2 Towing..................................................................................................................................208
Attaching Header to Towing Vehicle ................................................................................209
Towing the Header.........................................................................................................209
3.13.3 Converting from Transport to Field Position.............................................................................210
Removing Tow-Bar ........................................................................................................210
Storing the Tow-Bar .......................................................................................................211
Moving Front (Left) Wheels into Field Position .................................................................212
Moving Rear (Right) Wheels into Field Position................................................................214
3.13.4 Converting from Field to Transport Position.............................................................................217
Moving Front (Left) Wheels into Transport Position ..........................................................217
Moving Rear (Right) Wheels into Transport Position.........................................................218
Attaching Tow-Bar..........................................................................................................221
3.14 Storing the Header........................................................................................................................224
4 Header Attachment/Detachment ........................................................................................................225
4.1 Float Module Feed Auger Configurations........................................................................................225
4.1.1 Converting from Configuration B or D to Configuration A..........................................................227
4.1.2 Converting from Configuration C to Configuration A.................................................................229
4.1.3 Converting from Configuration A or C to Configuration B..........................................................230
4.1.4 Converting from Configuration D to Configuration B.................................................................232
4.1.5 Converting from Configuration A to Configuration C.................................................................233
4.1.6 Converting from Configuration B or D to Configuration C .........................................................234
4.1.7 Optional Modification to Configuration C .................................................................................235
4.1.8 Converting from Configuration A or C to Configuration D .........................................................236
4.1.9 Converting from Configuration B to Configuration D.................................................................240
4.2 Float Module Setup.......................................................................................................................243
4.2.1 Using Auger Flighting ............................................................................................................243
4.2.2 Using Stripper Bars ...............................................................................................................243
4.2.3 Adjusting Auger Speed ..........................................................................................................243
4.3 Case IH Combines........................................................................................................................244
4.3.1 Attaching Header to Case IH Combine ...................................................................................244
4.3.2 Detaching Header from Case IH Combine ..............................................................................249
4.4 AGCO (Challenger, Gleaner, and Massey Ferguson) Combines ......................................................252
147831 xii Revision A

TABLE OF CONTENTS
4.4.1 Attaching Header to a Challenger, Gleaner, or Massey Ferguson Combine...............................252
4.4.2 Detaching Header from a Challenger, Gleaner, or Massey Ferguson Combine ..........................257
4.5 John Deere Combines ..................................................................................................................260
4.5.1 Attaching Header to John Deere Combine ..............................................................................260
4.5.2 Detaching Header from John Deere Combine .........................................................................264
4.6 Lexion Combines..........................................................................................................................267
4.6.1 Attaching Header to Lexion Combine......................................................................................267
4.6.2 Detaching Header from Lexion Combine.................................................................................272
4.7 New Holland Combines.................................................................................................................276
4.7.1 Attaching Header to New Holland CR/CX Combine .................................................................276
4.7.2 Detaching Header from New Holland CR/CX Combine ............................................................280
4.7.3 CR Feeder Deflectors............................................................................................................284
4.8 Attaching and Detaching Header from Float Module........................................................................285
4.8.1 Detaching Header from Float Module .....................................................................................285
4.8.2 Attaching Header to Float Module ..........................................................................................290
5 Maintenance and Servicing................................................................................................................295
5.1 Preparing Machine for Servicing ....................................................................................................295
5.2 Maintenance Specifications ...........................................................................................................296
5.2.1 Recommended Fluids and Lubricants.....................................................................................296
5.2.2 Installing a Sealed Bearing ....................................................................................................297
5.3 Maintenance Requirements...........................................................................................................298
5.3.1 Maintenance Schedule/Record...............................................................................................299
5.3.2 Break-In Inspection ...............................................................................................................301
5.3.3 Preseason Servicing..............................................................................................................302
5.3.4 End-of-Season Service..........................................................................................................302
5.3.5 Checking Hydraulic Hoses and Lines......................................................................................303
5.3.6 Lubrication and Servicing.......................................................................................................303
Service Intervals ............................................................................................................304
Greasing Procedure.......................................................................................................313
Lubricating Reel Drive Chain ..........................................................................................314
Lubricating Auger Drive Chain ........................................................................................315
Lubricating Header Drive Gearbox ..................................................................................318
5.4 Hydraulics ....................................................................................................................................320
5.4.1 Checking Oil Level in Hydraulic Reservoir...............................................................................320
5.4.2 Adding Oil to Hydraulic Reservoir...........................................................................................320
5.4.3 Changing Oil in Hydraulic Reservoir .......................................................................................321
5.4.4 Changing Oil Filter ................................................................................................................322
5.5 Electrical System ..........................................................................................................................323
5.5.1 Replacing Light Bulbs............................................................................................................323
5.6 Header Drive................................................................................................................................324
5.6.1 Removing Driveline ...............................................................................................................324
5.6.2 Installing Driveline .................................................................................................................325
5.6.3 Removing Driveline Guard .....................................................................................................326
5.6.4 Installing Driveline Guard.......................................................................................................328
5.6.5 Adjusting Tension on Gearbox Drive Chain .............................................................................330
5.7 Auger...........................................................................................................................................331
5.7.1 Adjusting Auger to Pan Clearance..........................................................................................331
5.7.2 Adjusting Auger Drive Chain Tension......................................................................................333
5.7.3 Removing Auger Drive Chain.................................................................................................335
5.7.4 Installing Auger Drive Chain...................................................................................................338
5.7.5 Using Auger Flighting ............................................................................................................339
5.7.6 Auger Fingers .......................................................................................................................340
Removing Feed Auger Fingers .......................................................................................340
Installing Feed Auger Fingers .........................................................................................341
147831 xiii Revision A

TABLE OF CONTENTS
Replacing Feed Auger Finger Guides..............................................................................343
5.8 Knives..........................................................................................................................................345
5.8.1 Replacing Knife Section.........................................................................................................345
5.8.2 Removing Knife.....................................................................................................................347
5.8.3 Removing Knifehead Bearing.................................................................................................347
5.8.4 Installing Knifehead Bearing...................................................................................................348
5.8.5 Installing Knife ......................................................................................................................348
5.8.6 Spare Knife...........................................................................................................................349
5.8.7 Knife Guards.........................................................................................................................349
Adjusting Knife Guards...................................................................................................350
Replacing Pointed Guards..............................................................................................350
Replacing Stub Guards ..................................................................................................352
Checking Knife Hold-Downs ...........................................................................................354
5.8.8 Knifehead Shield...................................................................................................................356
Installing Knifehead Shield .............................................................................................357
5.9 Knife Drive ...................................................................................................................................358
5.9.1 Knife Drive Box .....................................................................................................................358
Checking Knife Drive Box...............................................................................................359
Checking Mounting Bolts................................................................................................360
Removing Knife Drive Box..............................................................................................360
Removing Knife Drive Box Pulley....................................................................................362
Installing Knife Drive Box Pulley......................................................................................363
Installing Knife Drive Box................................................................................................363
Changing Oil in Knife Drive Box ......................................................................................367
5.9.2 Knife Drive Belts ...................................................................................................................367
Knife Drive Belts ............................................................................................................367
5.10 Feed Draper.................................................................................................................................371
5.10.1 Replacing Feed Draper..........................................................................................................371
5.10.2 Adjusting Feed Draper Tension ..............................................................................................372
5.10.3 Feed Draper Drive Roller .......................................................................................................373
Removing Feed Draper Drive Roller – FM100..................................................................373
Installing Feed Draper Drive Roller – FM100 ...................................................................375
Replacing Feed Draper Drive Roller Bearing – FM100 .....................................................376
5.10.4 Feed Draper Idler Roller ........................................................................................................379
Removing Feed Draper Idler Roller – FM100...................................................................379
Replacing Feed Draper Idler Roller Bearing – FM100.......................................................380
Installing Feed Draper Idler Roller – FM100.....................................................................381
5.11 Float Module Stripper Bars and Feed Deflectors .............................................................................383
5.11.1 Removing Stripper Bars.........................................................................................................383
5.11.2 Installing Stripper Bars...........................................................................................................384
5.11.3 Replacing Feed Deflectors on New Holland CR Combines.......................................................385
5.12 Header Drapers............................................................................................................................386
5.12.1 Removing Drapers ................................................................................................................386
5.12.2 Installing Header Drapers ......................................................................................................386
5.12.3 Adjusting Draper Tension.......................................................................................................388
5.12.4 Adjusting Header Draper Tracking..........................................................................................390
5.12.5 Adjusting Deck Height ...........................................................................................................391
5.12.6 Header Draper Roller Maintenance ........................................................................................394
Inspecting Draper Roller Bearing ....................................................................................394
Draper Deck Idler Roller.................................................................................................394
Draper Deck Drive Roller................................................................................................397
5.12.7 Replacing Draper Deflectors ..................................................................................................401
Removing Narrow Draper Deflectors...............................................................................401
Installing Narrow Draper Deflectors.................................................................................402
147831 xiv Revision A

TABLE OF CONTENTS
5.13 Reel.............................................................................................................................................404
5.13.1 Reel Clearance to Cutterbar...................................................................................................404
Measuring Reel Clearance .............................................................................................404
Adjusting Reel Clearance ...............................................................................................407
5.13.2 Reel Frown ...........................................................................................................................407
Adjusting Reel Frown.....................................................................................................407
5.13.3 Centering Double Reels.........................................................................................................408
5.13.4 Reel Fingers .........................................................................................................................409
Removing Steel Fingers .................................................................................................409
Installing Steel Fingers ...................................................................................................409
Removing Plastic Fingers...............................................................................................410
Installing Plastic Fingers.................................................................................................411
5.13.5 Tine Tube Bushings...............................................................................................................411
Removing Bushings from Five-, Six-, or Nine-Bat Reels ...................................................411
Installing Bushings on Five-, Six-, or Nine-Bat Reels ........................................................416
5.13.6 Reel Endshields ....................................................................................................................423
Replacing Reel Endshields.............................................................................................423
Replacing Reel Endshield Supports ................................................................................424
5.14 Reel Drive ....................................................................................................................................426
5.14.1 Replacing Reel Drive Cover ...................................................................................................426
Removing Reel Drive Cover ...........................................................................................426
Installing Reel Drive Cover .............................................................................................426
5.14.2 Adjusting Reel Drive Chain Tension........................................................................................427
Loosening Reel Drive Chain ...........................................................................................427
Tightening Reel Drive Chain ...........................................................................................428
5.14.3 Replacing Reel Drive Sprocket...............................................................................................429
Removing Reel Drive Sprocket .......................................................................................430
Installing Reel Drive Sprocket .........................................................................................430
5.14.4 Replacing Double-Reel U-Joint ..............................................................................................431
Removing Double-Reel U-Joint.......................................................................................431
Installing Double-Reel U-Joint.........................................................................................432
5.14.5 Replacing Reel Drive Motor ...................................................................................................433
Removing Reel Drive Motor............................................................................................433
Installing Reel Drive Motor..............................................................................................434
5.14.6 Replacing Drive Chain on Double Reel...................................................................................435
5.14.7 Replacing Reel Speed Sensor ...............................................................................................437
Replacing AGCO Sensor................................................................................................437
Replacing John Deere Sensor ........................................................................................438
Replacing Lexion 400 Series Sensor...............................................................................439
Replacing Lexion 500/700 Series Sensor ........................................................................439
5.15 Transport System (Optional)..........................................................................................................441
5.15.1 Checking Wheel Bolt Torque ..................................................................................................441
5.15.2 Checking Axle Bolt Torque .....................................................................................................442
5.15.3 Checking Tire Pressure .........................................................................................................443
6 Options and Attachments ..................................................................................................................445
6.1 Reel.............................................................................................................................................445
6.1.1 Multi-Crop Rapid Reel Conversion Kit.....................................................................................445
6.1.2 Lodged Crop Reel Finger Kit..................................................................................................445
6.1.3 PR15 Tine Tube Reel Conversion Kit......................................................................................446
6.1.4 Reel Endshield Kit.................................................................................................................446
6.1.5 Tine Tube Reinforcing Kit.......................................................................................................446
6.2 Cutterbar......................................................................................................................................447
6.2.1 Cutterbar Wearplate ..............................................................................................................447
6.2.2 Knifehead Shield...................................................................................................................447
147831 xvRevision A

TABLE OF CONTENTS
6.2.3 Stub Guard Conversion Kit ....................................................................................................448
6.2.4 Vertical Knife Mounts.............................................................................................................448
6.3 Header.........................................................................................................................................449
6.3.1 Divider Latch Kit....................................................................................................................449
6.3.2 Stabilizer Wheels ..................................................................................................................449
6.3.3 Stabilizer/Slow Speed Transport Wheels.................................................................................449
6.4 Crop Delivery ...............................................................................................................................450
6.4.1 FM100 Feed Auger Flighting..................................................................................................450
6.4.2 Draper Deflector (Narrow)......................................................................................................450
6.4.3 Draper Deflector (Wide).........................................................................................................451
6.4.4 Stripper Bars.........................................................................................................................451
6.4.5 Upper Cross Auger (UCA) .....................................................................................................451
6.4.6 Rice Divider Rods .................................................................................................................452
7 Troubleshooting.................................................................................................................................453
7.1 Crop Loss at Cutterbar..................................................................................................................453
7.2 Cutting Action and Knife Components ............................................................................................455
7.3 Reel Delivery................................................................................................................................458
7.4 Header and Drapers .....................................................................................................................460
7.5 Cutting Edible Beans ....................................................................................................................462
8 Reference...........................................................................................................................................467
8.1 Torque Specifications ....................................................................................................................467
8.1.1 Metric Bolt Specifications.......................................................................................................467
8.1.2 Metric Bolt Specifications Bolting into Cast Aluminum..............................................................470
8.1.3 Flare-Type Hydraulic Fittings..................................................................................................470
8.1.4 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)..................................................................472
8.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ..........................................................474
8.1.6 O-Ring Face Seal (ORFS) Hydraulic Fittings...........................................................................475
8.2 Conversion Chart..........................................................................................................................477
8.3 Unloading and Assembly...............................................................................................................478
Index ..................................................................................................................................................479
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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 machine.
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
147831 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.
147831 2Revision A