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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