MacDon FlexDraper FD1 Series User manual

FD1 Series
FlexDraper®® Combine Header with
FM100 Float Module
Unloading and Assembly Instructions (North America)
214685 Revision A
Original Instruction
Featuring MacDon FLEX-FLOAT Technology™
The harvesting specialists.

FD1 Series FlexDraper®Header
Published: June 2018

Introduction
This instruction manual describes the unloading, setup, and predelivery requirements for the MacDon FD1 Series
FlexDraper®Combine Header with FM100 Float Module.
To ensure the best performance of this product and the safety of your customers, carefully follow the unload and
assembly procedure from the beginning through to completion.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Retain this instruction for future reference.
NOTE:
Keep your MacDon publications up-to-date. The latest version can be downloaded from our website
(www.macdon.com) or from our Dealer portal (https://portal.macdon.com) (login required).
214685 iRevision A

List of Revisions
Summary of Change Refer To
Added procedures.
•2.4 Removing Endshields from Shipping Position –
FD145 Headers, page 14
•Replacing Float Indicator Cable, page 166
•Calibrating Reel Height Sensor (CLAAS 600 and
700 Series), page 219
•Adjusting Auto Reel Height (CLAAS 600 and 700
Series), page 221
•9.1.3 Adjusting Feed Draper Tension, page 323
Revised illustrations of the auger drum.
•4.2.1 Converting from Ultra Narrow Configuration or
Narrow Configuration to Medium Configuration,
page 36
•4.2.2 Converting from Wide Configuration to
Medium Configuration, page 38
•4.2.3 Converting from Medium Configuration or
Wide Configuration to Narrow Configuration, page
40
•4.2.4 Converting from Ultra Narrow Configuration to
Narrow Configuration, page 42
•4.2.5 Converting from Medium Configuration to
Wide Configuration, page 43
•4.2.6 Converting from Ultra Narrow or Narrow
Configuration to Wide Configuration, page 45
•4.2.7 Optional Modification to Wide Configuration,
page 46
•4.2.8 Converting from Medium Configuration or
Wide Configuration to Ultra Narrow Configuration,
page 47
•4.2.9 Converting from Narrow Configuration to Ultra
Narrow Configuration, page 51
Removed bundle B6215 from flighting kit options.
•4.2.1 Converting from Ultra Narrow Configuration or
Narrow Configuration to Medium Configuration,
page 36
•4.2.2 Converting from Wide Configuration to
Medium Configuration, page 38
•4.2.6 Converting from Ultra Narrow or Narrow
Configuration to Wide Configuration, page 45
Removed bundle B6216 from flighting kit options.
•4.2.3 Converting from Medium Configuration or
Wide Configuration to Narrow Configuration, page
40
214685 ii Revision A

•4.2.8 Converting from Medium Configuration or
Wide Configuration to Ultra Narrow Configuration,
page 47
•4.2.9 Converting from Narrow Configuration to Ultra
Narrow Configuration, page 51
Updated center reel image and updated torque value. 6.9 Centering Reel, page 116
Revised the high voltage limit adjustment instruction. Adjusting Voltage Limits: One-Sensor System, page
162
Added note at the beginning of each procedure.
•Calibrating the Auto Header Height Control (Case
IH 5088/6088/7088), page 170
•Calibrating the Auto Header Height Control (Case
Combines with Version 28.00 or Higher Software),
page 191
•Calibrating the Auto Header Height Control (New
Holland CR/CX Series), page 294
•Calibrating the Auto Header Height Control (New
Holland CR Series), page 306
Added settings specific to the two-sensor system.
•Setting up the Header on the Combine Display
(Case IH 5130/6130/7130; 5140/6140/7140), page
173
•Calibrating the Auto Header Height Control
(Case IH 7010/8010, 7120/8120/9120,
7230/8230/9230, 7240/8240/9240), page 187
•Calibrating the Auto Header Height Control (Case
Combines with Version 28.00 or Higher Software),
page 191
Added note at the start and end of each procedure
about setting float.
•Calibrating Auto Header Height Control (Case IH
5130/6130/7130, 5140/6140/7140), page 177
•Calibrating the Auto Header Height Control
(Case IH 7010/8010, 7120/8120/9120,
7230/8230/9230, 7240/8240/9240), page 187
•Calibrating the Auto Header Height Control
(Challenger and Massey Ferguson), page 200
•Calibrating the Auto Header Height Control
(Gleaner R65/R66/R75/R76 and Pre-2016
S Series), page 226
•Calibrating the Auto Header Height Control (John
Deere 60 Series), page 248
•Calibrating the Auto Header Height Control (John
Deere 70 Series), page 257
214685 iii Revision A

•Calibrating the Auto Header Height Control (John
Deere S and T Series), page 264
•Calibrating the Auto Header Height Control (CLAAS
500 Series), page 205
Added settings for HEIGHT/TILT RESPONSE and
AUTO HEIGHT OVERRIDE.
Calibrating the Auto Header Height Control (Case
Combines with Version 28.00 or Higher Software),
page 191
Removed topic Attaching Reel Height Sensor as this is
already attached.
—
214685 iv Revision A

214685 vRevision A
Introduction................................................................................................................................................i
Chapter 1: Safety .................................................................................................................................... 1
1.1 Signal Words .......................................................................................................................................1
1.2 General Safety.....................................................................................................................................2
1.3 Safety Signs ........................................................................................................................................4
Chapter 2: Unloading............................................................................................................................. 5
2.1 Unloading Header and Float Module from Trailer ....................................................................................5
2.2 Lowering Header .................................................................................................................................7
2.3 Removing Shipping Stands.................................................................................................................10
2.4 Removing Endshields from Shipping Position –FD145 Headers............................................................14
Chapter 3: Assembling Header and Float Module ....................................................................... 17
3.1 Attaching Reel Lift Cylinders ...............................................................................................................17
3.2 Attaching Cam Arms ..........................................................................................................................24
3.3 Repositioning Gearbox.......................................................................................................................26
3.4 Installing Driveline..............................................................................................................................28
Chapter 4: Setting up Float Module ................................................................................................. 31
4.1 Installing Filler Cap.............................................................................................................................31
4.2 Float Module Feed Auger Configurations .............................................................................................34
4.2.1 Converting from Ultra Narrow Configuration or Narrow Configuration to Medium
Configuration......................................................................................................................36
4.2.2 Converting from Wide Configuration to Medium Configuration ......................................................38
4.2.3 Converting from Medium Configuration or Wide Configuration to Narrow Configuration ..................40
4.2.4 Converting from Ultra Narrow Configuration to Narrow Configuration ............................................42
4.2.5 Converting from Medium Configuration to Wide Configuration ......................................................43
4.2.6 Converting from Ultra Narrow or Narrow Configuration to Wide Configuration ................................45
4.2.7 Optional Modification to Wide Configuration ................................................................................46
4.2.8 Converting from Medium Configuration or Wide Configuration to Ultra Narrow
Configuration......................................................................................................................47
4.2.9 Converting from Narrow Configuration to Ultra Narrow Configuration ............................................51
4.2.10 Installing Feed Auger Fingers...................................................................................................54
4.2.11 Removing Feed Auger Fingers .................................................................................................56
4.3 Float Module Stripper Bars and Feed Deflectors...................................................................................58
4.3.1 Removing Stripper Bars.............................................................................................................58
4.3.2 CR Feeder Deflectors ................................................................................................................58
4.3.3 Replacing Feed Deflectors on New Holland CR Combines ...........................................................59
Chapter 5: Attaching Header to Combine ...................................................................................... 61
5.1 AGCO (Challenger, Gleaner, and Massey Ferguson) Combines ............................................................61
5.1.1 Installing Reel Fore-Aft / Header Tilt Selector Switch and Harness ................................................61
5.1.2 Attaching Header to a Challenger, Gleaner, or Massey Ferguson Combine....................................64
TABLE OF CONTENTS

214685 vi Revision A
5.2 Case IH Combines .............................................................................................................................69
5.2.1 Attaching Header to Case IH Combine........................................................................................69
5.3 John Deere Combines........................................................................................................................75
5.3.1 Installing Reel Fore-Aft / Header Tilt Switch: S and T Series Combines .........................................75
5.3.2 Installing Reel Fore-Aft / Header Tilt Switch: 60 and 70 Series Combines ......................................79
5.3.3 Attaching Header to John Deere Combine ..................................................................................83
5.4 CLAAS Combines ..............................................................................................................................87
5.4.1 Attaching Header to CLAAS Combine.........................................................................................87
5.5 New Holland Combines ......................................................................................................................92
5.5.1 Attaching Header to New Holland CR/CX Combine......................................................................92
5.6 Completing the Header Assembly .......................................................................................................97
5.6.1 Removing Shipping Supports .....................................................................................................97
5.6.2 Positioning Transport Lights .......................................................................................................98
5.6.3 Crop Dividers............................................................................................................................98
Removing Crop Dividers from Storage .......................................................................................98
Opening Endshields..................................................................................................................99
Installing Crop Divider without Latch Option................................................................................99
Installing Crop Divider with Latch Option ..................................................................................101
Closing Endshields .................................................................................................................102
Installing Crop Divider Rods ....................................................................................................102
5.6.4 Installing Options ....................................................................................................................103
Chapter 6: Performing Predelivery Checks .................................................................................105
6.1 Recording Model and Serial Number .................................................................................................105
6.2 Checking Tire Pressure: Transport and Stabilizer Wheels ...................................................................107
6.3 Checking Wheel Bolt Torque .............................................................................................................108
6.4 Checking Knife Drive Box .................................................................................................................109
6.5 Checking Oil Level in Header Drive Gearbox...................................................................................... 111
6.6 Checking Oil Level in Hydraulic Reservoir .......................................................................................... 112
6.7 Checking Knife Drive Belt Tension..................................................................................................... 113
6.8 Checking Pointed Guard Hold-Downs................................................................................................ 114
6.8.1 Adjusting Pointed Guard Hold-Downs ....................................................................................... 115
6.8.2 Adjusting Hold-Down at Double-Knife Center Pointed Guard ...................................................... 115
6.9 Centering Reel.................................................................................................................................116
6.10 Checking and Adjusting Header Float .............................................................................................. 117
6.11 Checking and Adjusting Header Wing Balance .................................................................................122
6.11.1 Checking Wing Balance .........................................................................................................122
6.11.2 Adjusting Wing Balance .........................................................................................................128
6.12 Measuring and Adjusting Reel Clearance to Cutterbar ......................................................................131
6.12.1 Measuring Reel Clearance.....................................................................................................131
6.12.2 Adjusting Reel Clearance.......................................................................................................133
6.13 Adjusting Auger to Pan Clearance ...................................................................................................135
6.14 Adjusting Draper Tension................................................................................................................138
TABLE OF CONTENTS

214685 vii Revision A
6.15 Checking Draper Seal ....................................................................................................................140
6.16 Lubricating the Header ...................................................................................................................142
6.16.1 Greasing Procedure ..............................................................................................................142
6.16.2 Lubrication Points..................................................................................................................143
6.17 Checking and Adjusting Endshields .................................................................................................149
6.18 Checking Manuals..........................................................................................................................153
Chapter 7: Setting up Auto Header Height Control....................................................................155
7.1 Auto Header Height Control (AHHC)..................................................................................................155
7.1.1 Sensor Operation....................................................................................................................156
7.1.2 Sensor Output Voltage Range –Combine Requirements ...........................................................157
10 Volt Adapter (MD #B6421) –New Holland Combines Only ....................................................157
Manually Checking Voltage Range: One-Sensor System ...........................................................158
Manually Checking Voltage Range: Two-Sensor System ...........................................................160
Adjusting Voltage Limits: One-Sensor System ..........................................................................162
Adjusting Voltage Limits: Two-Sensor System...........................................................................163
Replacing the Auto Header Height Control (AHHC) Sensor (One-Sensor System).......................165
Replacing Float Indicator Cable ...............................................................................................166
7.1.3 Case IH 5088/6088/7088 Combines .........................................................................................170
Calibrating the Auto Header Height Control (Case IH 5088/6088/7088) ......................................170
Setting the Sensitivity of the Auto Header Height (Case IH 5088/6088/7088)...............................171
7.1.4 Case IH 5130/6130/7130 and 5140/6140/7140 Mid-Range Combines.........................................173
Setting up the Header on the Combine Display (Case IH 5130/6130/7130;
5140/6140/7140)........................................................................................................173
Checking Voltage Range from Combine Cab (Case IH 5130/6130/7130;
5140/6140/7140)........................................................................................................175
Calibrating Auto Header Height Control (Case IH 5130/6130/7130, 5140/6140/7140) ..................177
Setting Preset Cutting Height (Case 5130/6130/7130, 5140/6140/7140) .....................................178
7.1.5 Case IH 7010/8010, 7120/8120/9120, 7230/8230/9230 and 7240/8240/9240 Combines ..............181
Checking Voltage Range from the Combine Cab (Case 8010)....................................................181
Setting Header Controls (Case 8010).......................................................................................183
Checking Voltage Range from the Combine Cab (Case IH 7010/8010, 7120/8120/9120,
7230/8230/9230, 7240/8240/9240)..............................................................................185
Calibrating the Auto Header Height Control (Case IH 7010/8010, 7120/8120/9120,
7230/8230/9230, 7240/8240/9240)..............................................................................187
Calibrating the Auto Header Height Control (Case Combines with Version 28.00 or Higher
Software)...................................................................................................................191
Checking Reel Height Sensor Voltages (Case IH) .....................................................................195
Setting Preset Cutting Height (Case 7010/8010, 7120/8120/9120, 7230/8230/9230,
7240/8240/9240)........................................................................................................196
7.1.6 Challenger and Massey Ferguson 6 and 7 Series Combines ......................................................197
Checking Voltage Range from the Combine Cab (Challenger and Massey Ferguson) ..................197
Engaging the Auto Header Height Control (Challenger and Massey Ferguson) ...........................199
Calibrating the Auto Header Height Control (Challenger and Massey Ferguson)..........................200
Adjusting the Header Height (Challenger and Massey Ferguson) ...............................................202
Adjusting the Header Raise/Lower Rate (Challenger and Massey Ferguson) ..............................202
Setting the Sensitivity of the Auto Header Height Control (Challenger and
Massey Ferguson) .....................................................................................................204
7.1.7 CLAAS 500 Series Combines ..................................................................................................205
Calibrating the Auto Header Height Control (CLAAS 500 Series)................................................205
Setting Cutting Height (CLAAS 500 Series) ..............................................................................207
TABLE OF CONTENTS

214685 viii Revision A
Setting the Sensitivity of the Auto Header Height Control (CLAAS 500 Series) ............................209
Adjusting Auto Reel Speed (CLAAS 500 Series) ....................................................................... 211
7.1.8 CLAAS 600 and 700 Series Combines......................................................................................213
Calibrating the Auto Header Height Control (CLAAS 600 and 700 Series) ...................................213
Setting Cutting Height (CLAAS 600 and 700 Series)..................................................................216
Setting the Sensitivity of the Auto Header Height Control (CLAAS 600 and 700 Series)................216
Adjusting Auto Reel Speed (CLAAS 600 and 700 Series) ..........................................................218
Calibrating Reel Height Sensor (CLAAS 600 and 700 Series) ....................................................219
Adjusting Auto Reel Height (CLAAS 600 and 700 Series) ..........................................................221
7.1.9 Gleaner R65/R66/R75/R76 and S Series Combines ..................................................................223
Checking Voltage Range from the Combine Cab (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ...................................................................................................................223
Engaging the Auto Header Height Control (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ...................................................................................................................224
Calibrating the Auto Header Height Control (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ...................................................................................................................226
Turning off the Accumulator (Gleaner R65/R66/R75/R76 and Pre-2016 S Series) .......................227
Adjusting the Header Raise/Lower Rate (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ...................................................................................................................228
Adjusting Ground Pressure (Gleaner R65/R66/R75/R76 and Pre-2016 S Series) ........................228
Adjusting the Sensitivity of the Auto Header Height Control (AHHC) (Gleaner
R65/R66/R75/R76 and Pre-2016 S Series) ..................................................................229
Troubleshooting Alarms and Diagnostic Faults (Gleaner R65/R66/R75/R76 and Pre-2016
S Series) ...................................................................................................................230
7.1.10 Gleaner S9 Series Combines .................................................................................................232
Setting up the Header (Gleaner S9 Series) ...............................................................................232
Setting up Reel Settings (Gleaner S9 Series)............................................................................237
Setting up Automatic Header Controls (Gleaner S9 Series)........................................................239
Calibrating the Header (Gleaner S9 Series) ..............................................................................241
Operating Header (Gleaner S9 Series).....................................................................................244
Header In-Field Settings .........................................................................................................245
7.1.11 John Deere 60 Series Combines ............................................................................................246
Checking Voltage Range from the Combine Cab (John Deere 60 Series)....................................246
Calibrating the Auto Header Height Control (John Deere 60 Series) ...........................................248
Turning the Accumulator Off (John Deere 60 Series) .................................................................251
Setting the Sensing Grain Header Height to 50 (John Deere 60 Series) ......................................251
Setting the Sensitivity of the Auto Header Height Control (John Deere 60 Series) ........................252
Adjusting the Threshold for the Drop Rate Valve (John Deere 60 Series) ....................................253
7.1.12 John Deere 70 Series Combines ............................................................................................254
Checking Voltage Range from the Combine Cab (John Deere 70 Series)....................................254
Calibrating Feeder House Speed (John Deere 70 Series) ..........................................................257
Calibrating the Auto Header Height Control (John Deere 70 Series) ...........................................257
Setting the Sensitivity of the Auto Header Height Control (John Deere 70 Series) ........................259
Adjusting the Manual Header Raise/Lower Rate (John Deere 70 Series) ....................................260
7.1.13 John Deere S and T Series Combines ....................................................................................261
Checking Voltage Range from the Combine Cab (John Deere S and T Series)............................261
Calibrating the Auto Header Height Control (John Deere S and T Series)....................................264
Setting the Sensitivity of the Auto Header Height Control (John Deere S and T Series) ................267
Adjusting the Manual Header Raise/Lower Rate (John Deere S and T Series).............................268
Setting Preset Cutting Height (John Deere S and T Series)........................................................269
Calibrating Feeder House Fore-Aft Tilt Range (John Deere S and T Series) ................................271
Checking Reel Height Sensor Voltages (John Deere S and T Series) .........................................274
Calibrating Reel Height Sensor (John Deere S and T Series) .....................................................276
TABLE OF CONTENTS