New Holland CornMaster 9208-22 User manual

Part number 51510606
1st edition English
July 2018
SERVICE MANUAL
CornMaster™9208-22
CornMaster™9212-20
CornMaster™9212-22
CornMaster™9216-20
CornMaster™9216-22
CornMaster™9218-20
CornMaster™9218-22
Corn Header
Printedin U.S.A.
© 2018 CNH Industrial America LLC. All Rights Reserved.
NewHolland is a trademark registered in the United States and many other countries,
owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

SERVICEMANUAL
CornMaster™9208-22,CornMaster™9212-20,CornMaster™9212-22,
CornMaster™9216-20,CornMaster™9216-22,CornMaster™9218-20,
CornMaster™9218-22
5151060627/07/2018
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Contents
INTRODUCTION
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.603]Deckplatehydraulicsystem.......................................................35.2
[35.910]Headandheaderhydraulicdrive..................................................35.3
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.100]Harnessesandconnectors.........................................................55.2
[55.404]Externallighting....................................................................55.3
[55.421]Feedingcontrolsystem............................................................55.4
[55.662]Headerheightcontrol..............................................................55.5
[55.785]Precisionfarmingsystem..........................................................55.6
[55.995]Chopperslipclutchmonitoringsystem.............................................55.7
Attachments/Headers..................................................................58
[58.100]Attachment/Headersupportanddrives............................................58.1
[58.120]Attachment/Headerfeedauger....................................................58.2
[58.130]Attachment/Headerframe..........................................................58.3
[58.208]Cornheadershieldsandguards...................................................58.4
[58.210]Cornheaderfeedchainandrollers................................................58.5
[58.218]Cornheaderfeederstructure......................................................58.6
[58.220]Cornheaderstructure..............................................................58.7
[58.224]Headerdrive.......................................................................58.8
[58.228]Rotatingdividers...................................................................58.9
[58.230]Stalkchoppers...................................................................58.10
[58.414]Row-independentheadergearboxes............................................58.11
Lubricationsystem......................................................................71
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[71.480]Oilersystem........................................................................71.1
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INTRODUCTION
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Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing....................................3
Personalsafety.................................................................................4
Safetyrules.....................................................................................7
Safetyrules-Ecologyandtheenvironment....................................................8
Safetysigns.....................................................................................9
Basicinstructions-Shopandassembly......................................................24
Torque-Minimumtighteningtorquesfornormalassembly...................................26
Torque-Standardtorquedataforhydraulics.................................................31
Hydrauliccontamination......................................................................33
Basicinstructions-ChainWearT ables-RollerChains......................................34
Attachments/Headers-Basicinstructions....................................................36
Generalspecication.........................................................................38
Capacities.....................................................................................39
Productidentication..........................................................................44
Productoverview-Machineorientation......................................................45
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INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecicationsatanytimewithout
noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specications,descriptions,and
illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
Incaseofquestions,refertoyourNEWHOLLANDSalesandServiceNetworks.
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INTRODUCTION
Personalsafety
Yourmachinemaybeequippedwithspecialguardingorotherdevicesincompliancewithlocallegislation.Someof
theserequireactiveusebytheoperator.
Therefore,checklocallegislationontheusageofthismachine.
Hydraulicsystemsafety
•Hydraulicoilleakingunderpressurecanpenetratetheskinandcauseinfectionorotherinjury.Toprevent
personalinjury:
•Relieveallpressurebeforedisconnectinguidlines.
•Beforeapplyingpressure,makesureallconnectionsaretightandcomponentsareingoodcondition.
•Neveruseyourhandtocheckforsuspectedleaksunderpressure.Useapieceofcardboardorwoodforthis
purpose.
•Ifinjuredbyleakinguid,seekmedicalattentionimmediately.
•Thehydraulichosesandttingsonyourmachinemeetengineeringspecicationsfortheparticularfunction.When
replacingdamaged,blownorwornhosesorttings,useonlymanufactureauthorizedserviceparts.
•Careinhydraulichoseinstallationisamust:
•Makesurepressureisrelievedbeforestartinginstallationprocedure.
•DONOTkinkortwistahose,failuremayoccur.
•Properlyroutethehose.
•Haveacertiedhydraulictechnicianinstallthehose.
•Removeairfromthehydraulicsystemafterinstallinganyhydrauliccomponent.
•Periodicallycheckhydraulicsystemforleaksordamage.checkfor:
•Leaksathosettingorinhose.
•Damagedhosesand/orttings.
•Kinked,crushed,attened,hardblistered,heatcracked,charred,twisted,softorloosecoveredhoses.
•Corrodedordamagedttings.
•Leakingports.
•Excessivedirtanddebrisaroundhosesand/orttings.
•Damagedormissinghoseretainingclamps,guards,shields,etc.
•DONOTstandonoruseahoseasastep.DONOTpullorapplyexternalforcestothehose.Thehosemayfail
andcauseinjury.
•Keepallpersonsawayfromtheworkingarea.Mechanismscontrolledbyuidpowercanbecomehazardousifa
hosefails.Liftedmechanismscanfalltotheground,machinesteeringmayfail,etc.
•Stayclearofapressurizedhoseassemblythathasblownapart.Hosettingscanbethrownoffathighspeedand
aloosehosecanwhiparoundwithgreatforce.
•Hydraulicuidcanreachhightemperatures.Allowuidtocoolbeforeservicingthesystem.
•Escapinguidunderpressuremayformamistornespraywhichcanashorexplodeuponcontactwithanignition
source.
•Vibrationcanreducehoseservicelife.Makesureallretainingclampsand/ordevicesaresecured.
•Environmentalconditionscancausehoseandttingstodeteriorate.Inspecthydraulichosesperiodically.Replace
wornordamagedhosesandttings.
Safetyrequirementsforuidpowersystemsandcomponents-hydraulics(EUROPEAN
STANDARDPREN982)
•Flexiblehoseassembliesmustnotbeconstructedfromhoseswhichhavebeenpreviouslyusedaspartofahose
assembly.
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INTRODUCTION
•Donotweldhydraulicpiping.
•Whenexiblehosesorpipingaredamaged,replacethemimmediately.
•Itisforbiddentomodifyahydraulicaccumulatorbymachining,weldingoranyothermeans.
•Beforeremovinghydraulicaccumulatorsforservicing,theliquidpressureintheaccumulatormustbereducedto
zero.
•Pressurecheckonhydraulicaccumulatorsshallbecarriedoutbymethodrecommendedbytheaccumulatorman-
ufacturer.
•Caremustbetakennottoexceedthemaximumallowablepressureoftheaccumulator.Afteranycheckofadjust-
menttheremustbenoleakageofgas.
Safetyprecautions
Farmaccidentscanbepreventedwithyourhelp.
Noaccidentpreventionprogramcanbesuccessfulwithoutthewholeheartedcooperationofthepersonwhoisdirectly
responsiblefortheoperationoftheequipment.
Toreadaccidentreportsfromalloverthecountryistobeconvincedthatalargenumberofaccidentscanbeprevented
onlybytheoperatoranticipatingtheresultbeforetheaccidentiscausedanddoingsomethingaboutit.
Itissaidthat"Thebestkindofsafetydeviceisacarefuloperatorwhowithcareandmatureconsiderationcansave
morelivesandlimbsthananyaccidentpreventionprogramwhichisnotadheredto".
Furtherinthischapteryouwillndalistofthemostimportantsafetyprecautions.
Taketimetoreadandfollowtheinstructionsandfurthermore,becareful!
Somepicturesinthismanualmayshowthesafetyguardingopenorremovedtobetterillustrateaparticularfeature
oradjustment.
Ensuretocloseorreplaceallguardsbeforeoperatingthemachine.
Generalandoperatingsafety
Mostfarmmachineryaccidentscanbeavoidedbytheobservanceofafewsimplesafetyprecautions.
•Themachinemustonlybeusedbyaskilledoperatorfamiliarwithallthecontrolsandharvestingtechniqueson
cultivatedlandwithslopesuptomaximum26%(15°)uphillanddownhill.
•Keepchildrenawayfromandoffthemachineatalltimes.
•Whendrivingonpublicroads,observetrafcregulations,adaptyourspeedtoroadandtrafcconditionsandensure
thatalllightsandothersafetymechanismsonthemachine(iftheyarerequired)arettedandworkproperly.
•Beforeoperatingthemachineensurethatallsafetyguardsareinstalled.
•Donotenterthegraintankwhilethemachineengineisrunning.Withenginestopped,useawoodenclearingclub
shouldthegraintankunloadingaugerbecomebridged.Takeutmostcarenottobepulledintothegraintankin
caseunbridgingisrequired.
•Donotattempttoclean,lubricateorcarryoutanyadjustmentsonthemachinewhileitisinmotionorwhilethe
engineisrunning.
•Neverleavetheoperator'splatformwithoutrstdisengagingthemachinedrivemechanism,loweringtheheader,
stoppingtheengine,applyingtheparkbrakeandremovingtheignitionkey.
•Donotworkunderthemachineheaderunlessitissecurelyblockedand/ortheheadersafetylatchisengaged.
•Donotworkaroundthemachineinlooseclothingthatmightcatchinanyofthemovingparts.
•Keephandsawayfrommovingpartsofthemachine.
•Keepthereextinguisherwithineasyreachoftheoperator.Ensuretoreplaceitbyasimilartypeofextinguisher
orhaveitcheckedorrelledaftereveryusageand/ordateofexpiry.
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INTRODUCTION
Dangerofdeathbyelectrocution!
Payspecialattentiontotheoverheadpowerlines.Makesurethemachinehassufcientclearancetopassinall
directions(alsowithraisedoropenedmachinecomponents).Alsothinkoftheradioaerial(s)oranyotherfactory-
ttedaccessoryorpartswhichmayhavebeenaddedafterwards.
Shouldacontactbetweenthemachineandanelectricpowerlineoccur,thenthefollowingprecautionsmustbetaken:
Stopthemachinemovementimmediately,stoptheengineandapplythehandbrake.
Checkifyoucansafelyleavethecaboryouractualpositionwithoutdirectcontactwithelectricwires.Ifnot,stay
inyourpositionandcallforhelp.Ifyoucanleaveyourpositionwithouttouchingthelines,jumpoffthelaststepor
supportpositiontoensurethatthereisnocontactbetweenanypartofyourbodyandthegroundatanytime.Donot
touchthemachineafterwardsuntilpowertothelineshasbeenshutoff.Whenpeopleapproachthemachine,warn
themnottotouchthemachinebuttoasktheelectricpowersupplycompanytoshutoffthepowertothelines.
Fireandexplosionprevention
•Duetotheammablenatureofthecropmaterialsencountered,rerisksarehigh.Thisriskcanbeminimizedby
frequentremovalofaccumulatedcropmaterialfromthemachineandcheckingforoverheatedmachinecompo-
nents.Ifoilleaksappear,re-torqueboltsorreplacegasketsasnecessary.
•Removealltrashordebrisfromthemachineeachday.Especiallychecktheengineareaandexhaustsystem.
•Sparksoramecancausethehydrogengasinabatterytoexplode.T opreventanexplosiondothefollowing:
•Donotweld,grindorsmokenearabattery.
•Sparksfromtheelectricalsystemorengineexhaustcancauseanexplosionandre.Beforeyouoperatethis
machineinanareawithammabledustorvapors,usegoodventilationtoremovetheammabledustorvapors.
•Usenonammablecleaningsolventtocleanparts.
•Arecancausedeathorinjury.Alwayshavereextinguishernearoronthemachine.Makesurethereextin-
guishersareservicedaccordingtothemanufacturersinstructions.
•Ifareextinguisherhasbeenused,alwaysrechargeorreplacethereextinguisherbeforeoperatingthemachine.
•MakesurethatyouDONOTstoreoilyragsorotherammablematerialsonthemachine.
•Ifthemachinehasanoil,fuelorhydraulicleak,alwaysrepairtheleakandcleantheareabeforeoperating.
•Checktheelectricalsystemforlooseconnectionsorfrayedinsulation.Repairorreplacethelooseordamaged
parts.
•Beforeweldingorusingatorchonthemachine,cleantheareatoberepaired.
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY .
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Safetyrules-Ecologyandtheenvironment
Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe
treatmentofsomeofthesubstancesthatadvancedtechnologyrequires,soundjudgmentshouldgoverntheuseand
disposalofproductsofachemicalandpetrochemicalnature.
Familiarizeyourselfwiththerelativelegislationapplicabletoyourcountry,andmakesurethatyouunderstandthis
legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,anti-freeze,
cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use,
anddisposeofthesesubstances.
Helpfulhints
•Avoidtheuseofcansorotherinappropriatepressurizedfueldeliverysystemstolltanks.Suchdeliverysystems
maycauseconsiderablespillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostoftheseproductscontainsubstances
thatmaybeharmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhenyoudrainuidssuchasusedenginecoolantmixtures,engineoil,hydraulicuid,brakeuid,
etc.Donotmixdrainedbrakeuidsorfuelswithlubricants.Storealldraineduidssafelyuntilyoucandisposeof
theuidsinaproperwaythatcomplieswithalllocallegislationandavailableresources.
•Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly.
•Theair-conditioningsystemcontainsgasesthatshouldnotbereleasedintotheatmosphere.Consultanair-condi-
tioningspecialistoruseaspecialextractortorechargethesystemproperly.
•Repairanyleaksordefectsintheenginecoolingsystemorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringwelding.Penetratingweldsplattermayburnaholeorweakenhoses,allowingthelossofoils,
coolant,etc.
Batteryrecycling
Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful
effectontheenvironmentifthebatteriesarenotproperlyrecycledafteruse.Improper
disposalofbatteriescancontaminatethesoil,groundwater,andwaterways.NEW
HOLLANDstronglyrecommendsthatyoureturnallusedbatteriestoaNEWHOLLAND
dealer,whowilldisposeoftheusedbatteriesorrecycletheusedbatteriesproperly.In
somecountries,thisisalegalrequirement.
Mandatorybatteryrecycling
NOTE:ThefollowingrequirementsaremandatoryinBrazil.
Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead,
CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany
batteries.Donotdisposeofbatteriesinyourhouseholdgarbage.
Pointsofsaleareobligedto:
•Acceptthereturnofyourusedbatteries
•Storethereturnedbatteriesinasuitablelocation
•Sendthereturnedbatteriestothebatterymanufacturerforrecycling
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INTRODUCTION
Safetysigns
RowUnitDriveandChopperDrive
Signsshownareforacornheaderwitharowunitdrivesystem.
Thefollowingsafetysignsareonyourmachineasaguideforyoursafetyandforthesafetyofthoseworkingwithyou.
Walkaroundthemachineandnotethecontentandthelocationofallsafetysignsbeforeyouoperateyourmachine.
Keepsafetysignscleanandlegible.Cleansafetysignswithasoftcloth,water,andagentledetergent.
NOTICE:Donotusesolvent,gasoline,orotherharshchemicals.Solvents,gasoline,andotherharshchemicalsmay
damageorremovesafetysigns.
Replaceallsafetysignsthataredamaged,missing,paintedover,orillegible.Ifasafetysignisonapartyouoryour
dealerreplaces,makesurethatyouoryourNEWHOLLANDNEWHOLLANDdealerinstallthesafetysignonthenew
part.SeeyourNEWHOLLANDdealerforreplacementsafetysigns.
Safetysignsthatdisplaythe“ReadOperator’sManual”symbolareintendedtodirect
theoperatortotheoperator’smanualforfurtherinformationregardingmaintenance,
adjustments,orproceduresforparticularareasofthemachine.Whenasafetysign
displaysthissymbol,refertotheappropriatepageoftheoperator’smanual.
Safetysignsthatdisplaythe“Readservicemanual”symboldirectyoutotheservice
manual.Ifyoudoubtyourabilitytoperformserviceoperations,contactyourdealer.
NOTE:Calloutsonthispagerefertodecalsasnumberedonthefollowingpages.
NHIL17MH00166AA1
Rear–Non-chopping
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INTRODUCTION
NOTE:Calloutsonthispagerefertodecalsasnumberedonthefollowingpages.
NHIL17MH00164AA2
Rear–Chopping
NHIL16GH00061AA3NHIL16GH00069AA4
LeftRight
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INTRODUCTION
NOTE:Calloutsonthispagerefertodecalsasnumberedonthefollowingpages.
NHIL17MH00038AA5
Front
NHIL17MH00150AA6
Top
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INTRODUCTION
WARNING
Overheadliftinghazard.
Liftandhandleheavycomponentsusinglifting
equipmentwithappropriateliftingcapacity.
Ensurethatunitsaresupportedbysuitableslings
andhooks.
Ensurethatnopersonsorpetsareinthevicinityof
theloadbeinglifted.
Failuretocomplycouldresultindeathorserious
injury.
Quantity:2
84593097
845930977
(1)Left-Hand(LH)sideofthefeederhouseopeningtop
beam.
NHIL17MH00167AA8
(1)Right-Hand(RH)sideofthefeederhouseopening
topbeam.
NHIL17MH00159AA9
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INTRODUCTION
WARNING
Slipperysurface.
Donotusetheareaofthetopbeamoutboardof
thesesafetysignsasasteporplatform.
Failuretocomplycouldresultindeathorserious
injury.
Quantity:2
87026533
87026533_B10
(2)LHsideofthefeederopeningontopofthetopbeam.
NHIL13GH00420AA11
(2)RHsideofthefeederopeningontopofthetopbeam.
NHIL13GH00419AA12
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INTRODUCTION
WARNING
Hiddenknife.
Flyingdebris.
Stayclearofthemachinewhilerunning.
Failuretocomplycouldresultindeathorserious
injury.
Quantity:4
Onlyusedonchopperequippedcornheaders.
84586899
8458689913
(3)LHsiderearbacksheet(Chopperequippedunits
only).
NHIL17MH00080AA14
(3)RHsiderearbacksheet(Chopperequippedunits
only).
NHIL17MH00081AA15
(3)OntheRHouterhood.
NHIL16GH00069AA16
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INTRODUCTION
WARNING
Hiddenknife.
Flyingdebris.
Stayclearofthemachinewhilerunning.
Failuretocomplycouldresultindeathorserious
injury.
Quantity:4
Onlyusedonchopperequippedcornheaders.
84586899
8458689913
(3)OntheLHouterhood.
NHIL16GH00061AA17
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