D60 FD70 CA20 Harvest Header Flex Draper Combine Adapter: Technical Manual

D60 FD70 CA20
Harvest Header
Flex Draper
Combine Adapter
TECHNICAL MANUAL
Revision E
Part #169046
Published 04/19/18
D60/FD70/CA20 TOC
Section 1: Safety
1.1 Important Safety Notice ..................................................................................... 1-1
1.2 Safety Alert Symbols ......................................................................................... 1-1
1.2.1 Why is Safety Important to You?............................................................... 1-1
1.3 Signal Words ..................................................................................................... 1-2
1.4 Safety Signs ...................................................................................................... 1-3
1.4.1 Safety Sign Installation.............................................................................. 1-3
A30-S Pull-Type............................................................................................ 1-4
A40 SP Auger Header .................................................................................. 1-7
D60 & FD70 Draper Header ......................................................................... 1-8
M100 Self Propelled Unit .............................................................................. 1-9
M150/M200 Self Propelled Unit .................................................................. 1-12
CA20 Adapter ............................................................................................. 1-14
R85 Disc PT................................................................................................ 1-15
R85 Disc SP ............................................................................................... 1-18
1.5 General Safety................................................................................................. 1-20
1.6 Engine Safety .................................................................................................. 1-22
High Pressure Rails .................................................................................... 1-22
Engine Electronics ...................................................................................... 1-23
1.7 Maintenance Safety......................................................................................... 1-24
1.8 Hydraulic Safety .............................................................................................. 1-25
1.9 Refueling Safety .............................................................................................. 1-26
1.10 Battery Safety ................................................................................................ 1-26
1.11 Tire Safety ..................................................................................................... 1-27
Section 2: Specifications
2.1 Torque Specifications ........................................................................................ 2-1
2.1.1 English Bolt Torque Specifications............................................................ 2-1
2.1.2 Metric Bolt Specifications .......................................................................... 2-1
2.1.3 Tightening Tube Flare Type Fittings ......................................................... 2-2
2.1.4 Tightening O-ring Fittings* ........................................................................ 2-3
2.1.5 Metric Bolt Specifications Bolting into Cast Aluminum.............................. 2-4
2.2 Recommended Fluids and Lubricants ............................................................... 2-4
Capacities ..................................................................................................... 2-4
Capacities ..................................................................................................... 2-4
2.3 Acronyms and Abbreviations............................................................................. 2-5
2.4 English/Metric Equivalents ................................................................................ 2-5
2.5 Draper Header Specifications............................................................................ 2-6
Design Features ........................................................................................... 2-6
Engineering Specifications ........................................................................... 2-7
Section 3: Trouble Shooting
3.1 Troubleshooting................................................................................................. 3-1
Feeding......................................................................................................... 3-1
Auto Header Height Control (AHHC) ............................................................ 3-4
Vibration........................................................................................................ 3-5
Cut Quality / Crop loss.................................................................................. 3-6
Cutting Action & Sickle Components .......................................................... 3-10
Reel Delivery .............................................................................................. 3-11
Header Lift .................................................................................................. 3-12
Drapers & Decks......................................................................................... 3-13
D60/FD70/CA20 TOC
Section 4: General Procedures

4.1 Taper Lock Hub ................................................................................................. 4-1
The way it works ........................................................................................... 4-1
4.1.1 Removal and Installation ........................................................................... 4-1
4.2 Lock Collar......................................................................................................... 4-4
The way it works ........................................................................................... 4-4
4.2.1 Removal and Installation ........................................................................... 4-4
4.3 Universal Joint ................................................................................................... 4-5
The Way it Works.......................................................................................... 4-5
4.3.1 Universal Joint Rebuild.............................................................................. 4-5
4.4 Guards ............................................................................................................... 4-9
The Way it Works.......................................................................................... 4-9
Stub Guard Header:...................................................................................... 4-9
Pointed Guard Header: ............................................................................... 4-10
Double Knife Headers Pointed Guards Only: ............................................. 4-10
Double Knife Headers Forged Stub Guards Only:...................................... 4-11
4.4.1 Important Guard Information ................................................................... 4-12
4.4.2 Guard Adjustments.................................................................................. 4-13
Regular Guard: ........................................................................................... 4-13
Stub Guards & Center Guards:................................................................... 4-13
4.5 Blades (Disc Only) ........................................................................................... 4-14
4.5.1 Cutting Hardware Inspection ................................................................... 4-16
4.5.2 Cutterbar Hardware................................................................................. 4-17
4.5.3 Blade Replacement ................................................................................. 4-18
4.5.4 Disc Removal .......................................................................................... 4-19
4.5.5 Disc Installation ....................................................................................... 4-20
Section 5: Knife Drive System
5.1 Knife Drive System ............................................................................................ 5-1
Single Knife................................................................................................... 5-1
Double Knife: D60 40’ & Smaller (Timed) ..................................................... 5-2
Double Knife: FD70 40’ & D60 45’ (Un-Timed)............................................. 5-3
5.2 Wobble Box Removal ........................................................................................ 5-4
Single & Un-Timed Double Knife .................................................................. 5-4
Double Knife: Timed ..................................................................................... 5-6
Left Side Wobble Box Removal .................................................................... 5-6
Right Side Wobble Box Removal.................................................................. 5-9
5.3 Knife Drive Wobble Box................................................................................... 5-11
5.3.1 Wobble Box Rebuild Tools ...................................................................... 5-12
Wobble Box Kit Items.................................................................................. 5-12
5.3.2 Wobble Box Disassembly........................................................................ 5-13
5.3.3 Wobble Box Re-Assembly....................................................................... 5-19
5.3.4 Wobble Box Installation........................................................................... 5-29
Wobble box Squareness............................................................................. 5-31
5.3.5 Double Knife Drive Timing (D60 40’ & Smaller) ...................................... 5-32
5.3.6 Knife Drive Belt Tensioning ..................................................................... 5-33
Single Knife................................................................................................. 5-33
Double Knife ............................................................................................... 5-34
D60/FD70/CA20 TOC
Section 6: Adapter Drive

6.1 Adapter Gearbox ............................................................................................... 6-1
6.1.1 2011 and Prior........................................................................................... 6-1
Prepare to Remove Gearbox:....................................................................... 6-1
Disassembly ................................................................................................. 6-5
Reassembly: ................................................................................................. 6-9
6.1.2 2012 and newer ...................................................................................... 6-18
Prepare to Remove Gearbox...................................................................... 6-18
Disassembly ............................................................................................... 6-22
Reassembly ................................................................................................ 6-29
Cover: ......................................................................................................... 6-32
Housing:...................................................................................................... 6-33
6.2 Feed Auger...................................................................................................... 6-38
Removal:..................................................................................................... 6-38
Reinstallation .............................................................................................. 6-43
Feed Auger Repair ..................................................................................... 6-44
Feed Auger Internal Repair ........................................................................ 6-47
Disassembly ............................................................................................... 6-47
RH Finger Assembly Support Repair.......................................................... 6-49
RH Finger Assembly Support Reassembly ................................................ 6-51
Feed Auger Clutch Repair .......................................................................... 6-53
Clutch Reassembly..................................................................................... 6-55
Section 7: Draper Drive System
7.1 Draper Drive System ......................................................................................... 7-1
7.2 Side Draper Deck .............................................................................................. 7-2
Removal:....................................................................................................... 7-2
Installation:.................................................................................................... 7-4
7.2.1 Idler Roller Bearing Replacement ............................................................. 7-6
Removal........................................................................................................ 7-6
Installation..................................................................................................... 7-7
7.2.2 Drive Roller Bearing Replacement............................................................ 7-8
Removal........................................................................................................ 7-8
Installation................................................................................................... 7-10
7.3 Adapter Feed Deck.......................................................................................... 7-11
Removal:..................................................................................................... 7-11
Installation................................................................................................... 7-13
7.3.1 Adapter Idler Roller Bearing Replacement.............................................. 7-15
Removal:..................................................................................................... 7-15
Installation:.................................................................................................. 7-17
7.3.2 Feed Draper Drive Roller Bearing Replacement..................................... 7-19
Removal:..................................................................................................... 7-19
Installation:.................................................................................................. 7-21
Section 8: Reel Drive System
8.1 Reel Drive System............................................................................................. 8-1
8.1.1 PR15 Reel Configuration (FD70/D60/D50) ............................................... 8-2
8.1.2 Reel Speed Sprocket Change................................................................... 8-3
8.2 Single Span Reel Removal................................................................................ 8-4
D60/FD70/CA20 TOC
8.3 Double Reel (Split) Removal ............................................................................. 8-8

Right-hand Side Removal: ............................................................................ 8-8
Left-hand Side Removal: ............................................................................ 8-11
8.3.1 Reel Drive Repair .................................................................................... 8-15
8.3.2 Single Reel Drive Disassembly ............................................................... 8-15
Single Reel Reassembly:............................................................................ 8-19
8.3.3 Split Reel Drive Disassembly .................................................................. 8-23
Double Reel Drive Reassembly .................................................................. 8-28
Section 9: Hydraulic System
9.1 Adapter Hydraulics System ............................................................................... 9-1
9.1.1 Manifold (MD #133318) .................................................................................. 9-3
9.2 Forward Operation............................................................................................. 9-4
9.2.1 Forward Operation Schematic................................................................... 9-5
9.2.2 Forward Operation - Feed Draper Over Relief .......................................... 9-6
9.2.3 Forward Operation - Side Draper Over Relief ........................................... 9-7
9.2.4 Forward Operation with Knife Reverser .................................................... 9-8
9.3 Reverse Operation............................................................................................. 9-9
9.3.1 Reverse Operation Schematic ................................................................ 9-10
9.3.2 Reverse Operation - Over Relief ............................................................. 9-11
9.3.3 Reverse Operation with Knife Reverser .................................................. 9-12
9.3.4 CA20 Hydraulic Pressure Test ................................................................ 9-13
9.4 Flushing the Hydraulic System ........................................................................ 9-16
9.4.1 Feed Draper Motor Failure ...................................................................... 9-16
9.5 Selector Valve Block........................................................................................ 9-18
9.5.1 Hydraforce Selector Valve (Prior to 2007)............................................... 9-18
9.5.2 Selector Valve Schematic (CASE 7010/8010 & NH CR/CX) .................. 9-19
9.5.3 Selector Valve Schematic (All, Except CASE 7010/8010, NH CR/CX)... 9-20
9.5.4 Hydraforce Selector Valve (2007 & Newer) ............................................ 9-21
9.5.5 Selector Valve Schematic For All Combines (2007 & Newer)................. 9-22
9.6 Combine Data: Output Shaft Speeds on Headers........................................... 9-23
9.7 Hydraulic Testing & Repair .............................................................................. 9-24
9.7.1 Minimum Test equipment ........................................................................ 9-24
9.7.2 Checking Knife Drive Flow & Pressure Compensator............................. 9-25
Checking Flow & Pressure Compensation ................................................. 9-25
9.7.3 Setting The Unloading Valve "V7"........................................................... 9-29
9.7.4 Testing Gear Pump Efficiency................................................................. 9-30
9.7.5 Testing Piston Pump Efficiency............................................................... 9-31
9.8 Hydraulic Oil Specifications ............................................................................. 9-32
9.9 Adapter Oil Temperature ................................................................................. 9-32
9.10 Oil Change Procedure ................................................................................... 9-33
9.11 Reel Lift Cylinders.......................................................................................... 9-34
9.11.1 Reel Lift Theory ..................................................................................... 9-34
9.11.2 Reel Drive, Lift & Fore-Aft Schematics.................................................. 9-35
9.11.3 Diagnostic Test - Static ......................................................................... 9-36
Split Reel..................................................................................................... 9-36
9.11.4 Diagnostic Test - Dynamic .................................................................... 9-36
D60/FD70/CA20 TOC
9.11.5 Static and Dynamic Test Diagnostic Chart: Cylinder vs. Symptom....... 9-37
Solutions (Single Span Reel):..................................................................... 9-38
Solutions (Split Reel): ................................................................................. 9-38
9.12 Component Repair ........................................................................................ 9-39
9.12.1 Single Reel Header Cylinders ............................................................... 9-39
Reel lift (L/H) Cylinder (145237) Repair...................................................... 9-39
Reel Lift (R/H) Cylinder (145395) Repair.................................................... 9-40
Fore-Aft Cylinders (137458 & 113434) Repair ........................................... 9-41
9.12.2 Double Reel Headers Cylinders............................................................ 9-43
Center Reel Lift Cylinder (145386) Repair.................................................. 9-43
Reel Lift (L/H) Cylinder (145395) Repair .................................................... 9-45
9.13 Hydraulic Motors ...................................................................................... 9-48
9.13.1 Side Drapers ......................................................................................... 9-48
Removal Side Draper Motor ....................................................................... 9-48
Disassembly (MD# 172471/120930) .......................................................... 9-49
Repair (MD# 172471/120930) .................................................................... 9-52
Reassembly (MD# 172471/120930) ........................................................... 9-52
Disasemble (MD #220891) ......................................................................... 9-55
Reassemble (MD #220891)........................................................................ 9-55
Repair (MD #220891) ................................................................................. 9-55
Disasemble (MD #220936) ......................................................................... 9-56
Reassemble (MD #220936)........................................................................ 9-58
Disassemble (MD# 174369) ....................................................................... 9-60
9.13.2 Deck Shift (# 120374) Swathing Application Only................................. 9-63
Removal...................................................................................................... 9-63
Eaton Motor Disassembly........................................................................... 9-64
Reassembly (Shaft End)............................................................................. 9-66
Reassembly (Gerotor End) ......................................................................... 9-69
Timing Procedure ....................................................................................... 9-69
Parker Motor Disassembly MD# 120374 .................................................... 9-70
Repair ......................................................................................................... 9-73
Reassembly ................................................................................................ 9-74
9.13.3 Reel (MD# 143088)............................................................................... 9-78
Removal (White Hydraulics) ....................................................................... 9-78
Disassembly ............................................................................................... 9-79
Repair ......................................................................................................... 9-84
Reassembly ................................................................................................ 9-84
9.13.4 Feed Draper (MD# 151981) .................................................................. 9-89
Disassembly (Parker Hannifin) ................................................................... 9-89
Repair ......................................................................................................... 9-92
Reassembly ................................................................................................ 9-93
D60/FD70/CA20 TOC
9.14 Knife Drive Motor...................................................................................... 9-97

9.14.1 Single Knife & Untimed Double Knife.................................................... 9-97
Seal Kit Installation MD #174217................................................................ 9-98
9.14.2 Double Knife (Timed) ............................................................................ 9-99
9.15 Multi-Coupler ............................................................................................... 9-101
9.15.1 Lexion 400 Series Multi-Coupler ......................................................... 9-101
9.15.2 Lexion 500 Series Multi-Coupler ......................................................... 9-102
9.15.3 Lexion Multi-Link Valve Block.............................................................. 9-103
9.15.4 MacDon, Case 7010/8010 & NH CR/CX Multi-Coupler ...................... 9-104
9.15.5 John Deere 60 Series Multi-Coupler ................................................... 9-105
9.15.6 Agco Multi-Coupler.............................................................................. 9-106
Section 10: Electrical System
10.1 Header Electrical Harnesses ......................................................................... 10-1
10.2 Lighting .......................................................................................................... 10-1
Single Span 15’ - 30’ D60 Reel Wiring Schematic...................................... 10-1
Single Span Reel 30’, 35’ D60 & Split Reel 30’, 40’ Wiring Schematic....... 10-2
Split Reel 45’ Wiring Schematic.................................................................. 10-2
10.2.1 Electrical Harness Combine Specific .................................................... 10-4
Case 2100/2300/2500 Series: .................................................................... 10-4
Case 7010/8010, NH CR/CX: ..................................................................... 10-4
Lexion 400 (R) Series: ................................................................................ 10-5
Lexion 500 (R) Series: ................................................................................ 10-6
John Deere 50 Series: ................................................................................ 10-7
John Deere 60 Series ................................................................................. 10-8
Agco............................................................................................................ 10-9
10.2.2 Transport Wiring Harnesses................................................................ 10-11
10.3 Selector Valve Standard FD70 (Optional D60 & D50)................................. 10-14
Hydraforce Coil Resistance: ..................................................................... 10-14
10.4 Combine Electrical Harness for the Selector Valve ..................................... 10-15
10.4.1 Case 23XX/25XX Series ..................................................................... 10-15
10.4.2 Case 7010/8010, New Holland CR/CX ............................................... 10-17
10.4.3 Agco .................................................................................................... 10-19
10.4.4 John Deere 50/60/70 Series................................................................ 10-20
10.4.5 Lexion 400 series ................................................................................ 10-21
10.4.6 Lexion 500 Series................................................................................ 10-22
10.5 2006 & Prior Selector Valve Standard FD70 (Optional D60)....................... 10-23
10.6 Combine Electrical Harness for the Selector Valve ..................................... 10-24
10.6.1 Case 23XX Series ............................................................................... 10-24
10.6.2 Case AFX, New Holland CR/CX ......................................................... 10-25
10.6.3 Agco .................................................................................................... 10-27
10.6.4 John Deere Pre 50 Series ................................................................... 10-28
10.6.5 John Deere 50/60 series ..................................................................... 10-29
10.6.6 Lexion 400 series ................................................................................ 10-30
10.6.7 Lexion 500 Series................................................................................ 10-31
D60/FD70/CA20 TOC
10.7 Automatic Header Height Control (AHHC) .................................................. 10-32

10.7.2 Case 7010/8010 & 21XX/23XX/25XX ................................................. 10-32
10.7.3 Agco/Massey/Challenger/JD 50/60/70................................................ 10-34
10.8 AHHC Calibration ........................................................................................ 10-35
10.8.1 Case 21XX/23XX/25XX ...................................................................... 10-35
10.8.2 Case 7010/8010.................................................................................. 10-37
10.9 JD 50/60/70 Series, Agco AHHC ........................................................... 10-43
10.9.1 JD 70 Series........................................................................................ 10-51
10.9.2 Gleaner R62/72................................................................................... 10-56
10.9.3 Gleaner R65 & R75............................................................................. 10-58
Adjusting the Sensors Range (Case, JD, Agco, Massey, Challenger) ..... 10-67
Diagnostic of Potentiometer (Case, JD Agco, Massey, Challenger) ........ 10-68
10.9.4 New Holland CR/CX AHHC ................................................................ 10-69
Adjustment and Operation ........................................................................ 10-71
Autofloat Mode.......................................................................................... 10-72
Check Sensor Range................................................................................ 10-72
Combine configuration.............................................................................. 10-73
10.9.5 Calibration of the header..................................................................... 10-74
Intelliview .................................................................................................. 10-74
Intelliview II ............................................................................................... 10-78
Combine Configuration ............................................................................. 10-82
Set the Maximum Stubble Height ............................................................. 10-83
Set the Header Lower Rate ...................................................................... 10-84
Set the Header Lateral Float..................................................................... 10-84
Set the Header Autofloat .......................................................................... 10-84
Set Header raise rate................................................................................ 10-85
Adjusting the Sensors Range (New Holland CR/CX) ............................... 10-86
Diagnostic of Potentiometer (New Holland CR/CX).................................. 10-87
10.9.6 Lexion AHHC ...................................................................................... 10-88
10.9.7 AHHC Calibration (Lexion).................................................................. 10-90
500 Series................................................................................................. 10-90
Automatic Header Functions .................................................................... 10-91
Header Height Limits ................................................................................ 10-91
Auto Contour Sensitivity (Auto Header).................................................... 10-93
Reel Settings ............................................................................................ 10-95
Cutting Height ........................................................................................... 10-98
Setting Cut Height Manually ..................................................................... 10-99
Adjusting the Sensors Range (Lexion) ................................................... 10-102
Diagnostic of Potentiometer (Lexion)...................................................... 10-103
10.10 Potentiometer Replacement .................................................................... 10-104
10.11 Reel Speed.............................................................................................. 10-105
10.11.1 John Deere 50/60/70 Series ........................................................... 10-105
10.11.2 Lexion 400 Series ........................................................................... 10-105
10.11.3 Lexion 500 Series ........................................................................... 10-106
10.11.4 Agco ................................................................................................ 10-107
D60/FD70/CA20 TOC
10.12 Header Recognition ................................................................................. 10-108

10.12.1 Case 7010/8010 & NH CR/CX ........................................................ 10-108
Section 11: Combine Electrical Schematics
11.1 Electrical Schematics..................................................................................... 11-1
11.1.1 John Deere 50 Series............................................................................ 11-1
11.1.2 John Deere 60 & 70 Series ................................................................... 11-2
11.1.3 Agco ...................................................................................................... 11-3
11.1.4 Gleaner “R” & “S” Series ....................................................................... 11-4
11.1.5 CaseIH 2300 & 2500 Series.................................................................. 11-5
11.1.6 CaseIH 10 & 20 Series.......................................................................... 11-6
11.1.7 Lexion 400............................................................................................. 11-7
11.1.8 Lexion 500 Series.................................................................................. 11-8
11.1.9 New Holland .......................................................................................... 11-9
11.1.9 New Holland Legend ............................................................................. 11-9
11.1.10 Transport 179759 & Below................................................................ 11-10
11.1.11 Transport 179760 & Up ..................................................................... 11-11
Section 11A: Electrical Schematic Legend
11A.1 Header Legend............................................................................................ 11-1
11A.2 Agco Legend ............................................................................................... 11-2
11A.3 Case IH Legend .......................................................................................... 11-3
11A.4 John Deere Legend..................................................................................... 11-4
11A.5 Lexion 400 Lexion ....................................................................................... 11-5
11A.6 Lexion 500 Lexion ....................................................................................... 11-6
11A.7 New Holland Legend ................................................................................... 11-7
11A.8 Transport Option Legend ............................................................................ 11-8
Section 12: Flex Linkage
12.1 Flex Linkage .................................................................................................. 12-1
Disassembly................................................................................................ 12-2
Reassembly ................................................................................................ 12-5
12.2 FD70 Wing Adjustments ................................................................................ 12-7
12.2.1 Cutterbar Straightness .......................................................................... 12-7
12.2.2 Cutter Bar Stringing............................................................................... 12-8
12.2.2 CutterBar Stringing................................................................................ 12-8
12.2.3 Cutterbar Straightness ........................................................................ 12-10
12.2.3 Cutterbar Fore-Aft ............................................................................... 12-10
12.2.4 Header Levelling ................................................................................. 12-11
12.2.5 Header Float........................................................................................ 12-13
12.2.6 Float Locks .......................................................................................... 12-13
12.2.7 Header Float Check ............................................................................ 12-14
12.2.8 Header Float Adjustment..................................................................... 12-16
12.2.9 Toplink/Bellcrank Alignment ................................................................ 12-17
12.2.10 Compression Link Check .................................................................. 12-18
12.2.11 Compression Link Adjustment........................................................... 12-18
12.2.12 Wing Balance .................................................................................... 12-19
SECTION 1: SAFETY
D60/FD70/CA20 TOC
Section 1: Safety
1.1 Important Safety Notice ..................................................................................... 1-1
1.2 Safety Alert Symbols ......................................................................................... 1-1
1.2.1 Why is Safety Important to You?............................................................... 1-1
1.3 Signal Words ..................................................................................................... 1-2
1.4 Safety Signs ...................................................................................................... 1-3
1.4.1 Safety Sign Installation.............................................................................. 1-3
A30-S Pull-Type............................................................................................ 1-4
A40 SP Auger Header .................................................................................. 1-7
D60 & FD70 Draper Header ......................................................................... 1-8
M100 Self Propelled Unit .............................................................................. 1-9
M150/M200 Self Propelled Unit .................................................................. 1-12
CA20 Adapter ............................................................................................. 1-14
R85 Disc PT................................................................................................ 1-15
R85 Disc SP ............................................................................................... 1-18
1.5 General Safety................................................................................................. 1-20
1.6 Engine Safety .................................................................................................. 1-22
High Pressure Rails .................................................................................... 1-22
Engine Electronics ...................................................................................... 1-23
1.7 Maintenance Safety......................................................................................... 1-24
1.8 Hydraulic Safety .............................................................................................. 1-25
1.9 Refueling Safety .............................................................................................. 1-26
1.10 Battery Safety ................................................................................................ 1-26
1.11 Tire Safety ..................................................................................................... 1-27
D60/FD70/CA20 Section 1: Safety PAGE 1-1
1.1 IMPORTANT SAFETY NOTICE

Appropriate service and repair procedures are
essential for safe, reliable machine operation and
the safety of the individuals doing the work.
There are various tools, techniques and
procedures for servicing machines. This manual
cannot possibly anticipate all variations and
provide cautions or warnings to each. The
product has been designed with built in safety
features however one has not been include:
Figure 1-1: Caution Sign
• THE INDIVIDUAL'S SAFETY HABITS.

1.2 SAFETY ALERT SYMBOLS
This safety alert symbol indicates important
safety messages in this manual and on safety
signs on the header.
This symbol means:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
1.2.1 WHY IS SAFETY IMPORTANT TO

YOU? Figure 1-2: Warning Sign
Three Big Reasons:
• Accidents disable and kill
• Accidents cost
• Accidents can be avoided
169046 ISSUE DATE 05/01/14

1.3 SIGNAL WORDS

Three signal words DANGER, WARNING and
CAUTION are used to alert of 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
DANGER
death or serious injury.
Figure 1-3: Danger Banner
WARNING: Indicates a potentially hazardous

situation that, if not avoided, could result in WARNING
death or serious injury. It may also be used to
alert against unsafe practices.
Figure 1-4: Warning Banner
CAUTION: Indicates a potentially hazardous

situation that, if not avoided, may result in
CAUTION
minor or moderate injury. It may be used to
alert against unsafe practices. Figure 1-5: Caution Banner
169046 ISSUE DATE 05/01/14

1.4 SAFETY SIGNS

• Keep safety signs clean and legible at all
times.
• Replace safety signs that are missing or
become illegible.
• If original parts on which a safety sign
was installed are replaced, be sure the
repair part also bears the current safety
sign.
• Safety signs are available from your
Dealer Parts Department.
1.4.1 SAFETY SIGN INSTALLATION

a. Be sure the installation area is clean and
dry.
b. Decide on the exact location before you
remove the decal backing paper.
c. Remove the smaller portion of the split
backing paper.
d. Place the sign in position and slowly peel
back the remaining paper, smoothing the
sign as it is applied. Figure 1-6: Read Operators manual before operating
e. Small air pockets can be smoothed out or
pricked with a pin.
Figure 1-7: Rotating Driveline Hazard
169046 ISSUE DATE 05/01/14

A30-S Pull-Type
Figure 1-10: MD#142909
Figure 1-8: MD#124763
Figure 1-11: MD#3009
Figure 1-9: MD#36651
169046 ISSUE DATE 05/01/14

Figure 1-14: MD#142908
Figure 1-12: MD#44944
Figure 1-15: MD#142912
Figure 1-13: MD#171029
Figure 1-16: MD#28403
169046 ISSUE DATE 05/01/14

Figure 1-17: MD#32738
Figure 1-18: MD#140311
Figure 1-19: MD#115100
169046 ISSUE DATE 05/01/14

A40 SP Auger Header
Figure 1-20: MD#30316 Driveline Figure 1-23: MD#34093 Conditioner Top Sheet
Figure 1-21: MD#44944 Left End Sheet
Figure 1-24: MD#28403 L/H & R/H Reel Ends
Figure 1-22: MD#32738 End Sheets
169046 ISSUE DATE 05/01/14

D60 & FD70 Draper Header
Figure 1-28: MD#32738 Keep Shields in Place
Figure 1-25: MD#44611 Back Tube
Figure 1-26: 42122 Reel Hazard
Figure 1-29: MD#174436 High Pressure Oil
Figure 1-27: MD#32009 General Caution
169046 ISSUE DATE 05/01/14

M100 Self Propelled Unit
Figure 1-30: 110986
Figure 1-34: 32743
Figure 1-31: 134068
Figure 1-32: 160351
Figure 1-33: 110989
Figure 1-35: 42130
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Figure 1-38: 109844
Figure 1-36: 44611
Figure 1-39: 109868

Figure 1-37: 109843
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Figure 1-40: 163561
Figure 1-44: 183096
Figure 1-41: 163562
Figure 1-42: 160350 Figure 1-45: 160400
Figure 1-43: 44944
169046 ISSUE DATE 05/01/14

M150/M200 Self Propelled Unit
Figure 1-46: MD#32744
Figure 1-47: MD#110989

Figure 1-50: MD#42130
Figure 1-48: MD#163561
Figure 1-51: MD#134068
Figure 1-49: MD#109868
Figure 1-52: MD#109844
169046 ISSUE DATE 05/01/14

Figure 1-57: MD#163562

Figure 1-53: MD#109843
Figure 1-54: MD#110986

Figure 1-58: 134070
Figure 1-55: MD#109866
Figure 1-56: MD#32743
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CA20 Adapter
Figure 1-59: 44944 Back of Adapter
Figure 1-60: 44611 Left side of Adapter
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R85 Disc PT
Figure 1-64: 142912
Figure 1-61: 148829
Figure 1-62: 44944
Figure 1-65: 36651
Figure 1-63: 32738
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Figure 1-69: 109843
Figure 1-66: 142909
Figure 1-67: 142908
Figure 1-70: 170281
Figure 1-71: 134070

Figure 1-68: 115100
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Figure 1-72: 171029
Figure 1-73: 142909
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R85 Disc SP
Figure 1-74: 148829
Figure 1-77: 36651
Figure 1-75: 134070
Figure 1-78: 109843
Figure 1-76: 32738
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Figure 1-81: 184390
Figure 1-79: 170281
Figure 1-80: 142909
169046 ISSUE DATE 05/01/14

1.5 GENERAL SAFETY

The following are general farm safety
precautions that should be part of your operating
procedure for all types of machinery
1. Protect Yourself:
When assembling, operating and servicing

machinery wear all the protective clothing and
personal safety devices that COULD be
necessary for the job at hand. Don't take
Chances.
Figure 1-82: Safety Gear
You may need:
• A hard hat
• Protective footwear with slip resistant
soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• Respirator or filter mask
• Hearing protection.
Be aware that exposure to loud noise can

cause impairment or loss of hearing. Wearing
suitable hearing protection devices such as ear Figure 1-83: Hearing Protection
muffs (A) or ear plugs (B) protects against
objectionable or loud noises.
2. Provide a First Aid Kit for use in case of

emergencies.
3. Keep a Fire Extinguisher on the machine. Be

sure the fire extinguisher is properly
maintained and be familiar with its proper
use.
4. Keep young children away from the Figure 1-84: First Aid Kit
machinery at all times.
5. Wear close fitting clothing and cover long

hair. Never wear dangling items such as
scarves or bracelets.
169046 ISSUE DATE 05/01/14

6. Keep hands, feet, clothing and hair away

from moving parts. Never attempt to clear
obstructions or objects from a machine while
the engine is running.
7. Keep all shields in place. Never alter or

remove safety equipment.
8. Do not substitute parts, especially safety

related items, that may not meet strength or
design requirements of the manufacturer.
9. Stop engine and remove the key from the

ignition before leaving the operators seat for
any reason. A child or even a pet could
engage an idling machine.
Figure 1-85: Loose Clothing
10. Keep the area used for servicing machinery

clean and dry. Wet or oily floors are very
slippery. Wet spots can be dangerous when
working with electrical equipment. Be sure all
electrical outlets and tools are properly
grounded.
11. Make sure lighting is adequate for the job at

hand.
12. Keep machinery clean. Straw and chaff on a

hot engine are a fire hazard. Do not allow oil
or grease to accumulate on service platforms,
ladders or controls. Clean machines before
storage. Figure 1-86: Fingers caught in Objects
13. Never use Gasoline, Naptha or any volatile

material cleaning purposes. These materials
may be toxic and/or flammable.
14. When storing machinery cover sharp or

extending components to prevent injury from
accidental contact.
Figure 1-87: Slip on Puddle
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1.6 ENGINE SAFETY If a warning tag is attached to the engine start

switch or to the controls DO NOT start the engine
WARNING or move the controls. Consult with the person
that attached the warning tag before the engine is
Do not use aerosol types of starting aids such started.
as ether. Such use could result in an explo-
sion and personal injury. All protective guards and all protective covers
must be installed if the engine must be started in
WARNING order to perform service procedures. To help
prevent an accident that is caused by parts in
High Pressure Rails rotation, work around the parts carefully.
Contact with high pressure fuel may cause Start the engine from the operator’s compartment
fluid penetration and burn hazards. High or from the engine start switch.
pressure fuel spray may cause a fire hazard.
Failure to follow these inspection, mainte- Always start the engine according to the
nance and service instructions may cause procedure that is described in the Operation and
personal injury or death. Maintenance Manual, “Engine Starting” topic in
the Operation Section. Knowing the correct
The initial start-up of an engine that is new, procedure will help to prevent major damage to
serviced or repaired make provision to shut the the engine components.
engine off, in order to stop an over speed. This
may be accomplished by shutting off the air and/ Knowing the procedure will also help to prevent
or fuel supply to the engine. personal injury.
Over speed shutdown should occur automatically To ensure that the jacket water heater (if
for engines that are controlled electronically. If equipped) and/or the lube oil heater (if equipped)
automatic shutdown does not occur, press the is working correctly, check the water temperature
emergency stop button in order to cut the fuel gauge and/or the oil temperature gauge during
and/or air to the engine. the heater operation.
Inspect the engine for potential hazards. Engine exhaust contains products of combustion
which can be harmful to your health. Always start
Before starting the engine, ensure that no one is the engine and operate the engine in a well
on, underneath, or close to the engine. Ensure ventilated area. If the engine is started in an
that the area is free of personnel. enclosed area, vent the engine exhaust to the
If equipped, ensure that the lighting system for outside.
the engine is suitable for the conditions. Ensure NOTE:
that all lights work correctly, if equipped. The engine may be equipped with a device
All protective guards and all protective covers for cold starting. If the engine will be operated
must be installed if the engine must be started in in very cold conditions, then an extra cold
order to perform service procedures. To help starting aid may be required. Normally, the
prevent an accident that is caused by parts in engine will be equipped with the correct type
rotation, work around the parts carefully. of starting aid for your region of operation.
Do not bypass the automatic shutoff circuits. Do
not disable the automatic shutoff circuits. The
circuits are provided in order to help prevent
personal injury. The circuits are also provided in
order to help prevent engine damage.
See the Service Manual for repairs and for
adjustments.
169046 ISSUE DATE 05/01/14

Engine Electronics
WARNING
Tampering with the electronic system installa-
tion or the OEM wiring installation can be
dangerous and could result in personal injury
or death and/or engine damage.
WARNING
Electrical Shock Hazard. The electronic unit
injectors use DC voltage. The ECM sends this
voltage to the electronic unit injectors. Do not
come in contact with the harness connector
for the electronic unit injectors while the
engine is operating. Failure to follow this
instruction could result in personal injury or
death.
This engine has a comprehensive,
programmable Engine Monitoring System. The
Electronic Control Module (ECM) has the ability
to monitor the engine operating conditions. If any
of the engine parameters extend outside an
allowable range, the ECM will initiate an
immediate action.
The following actions are available for engine
monitoring control:
• Warning
• Derate
• Shutdown
The following monitored engine operating
conditions have the ability to limit engine speed
and/or the engine power:
• Engine Coolant Temperature
• Engine Oil Pressure
• Engine Speed
• Intake Manifold Air Temperature
The Engine Monitoring package can vary for
different engine models and different engine
applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Together, the two controls will provide the engine
monitoring function for the specific engine
application.
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1.7 MAINTENANCE SAFETY
1. Review the operators manual and all safety

items before working with, maintaining or
operating the header.
2. Place all controls in neutral, stop the engine,

set the park brake, remove the ignition key
and wait for all moving parts to stop before
servicing, adjusting or repairing.
3. Follow good shop practices:
• Keep service area clean and dry.

• Be sure electrical outlets and tools are
properly grounded.
• Use adequate light for the job at hand.
Figure 1-88: Slip on Puddle

4. Before applying pressure to a hydraulic
system, make sure all components are tight
and that steel lines, hoses and couplings are
in good condition.
5. Relieve pressure from hydraulic circuits

before servicing or disconnecting from wind-
rower.
6. Keep hands, feet clothing and hair away from

all moving and/or rotating parts.
7. Clear the area of bystanders, especially

children when carrying out any maintenance
and repairs or making any adjustments.
Figure 1-89: Keep Away
8. Install transport lock or place safety stands

under the frame before working under the
header.
9. Wear protective gear when working on the

machine.
10. Wear heavy gloves when working on sickle

components.
Figure 1-90: Safety Gear
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1.8 HYDRAULIC SAFETY
1. Always place all windrower hydraulic controls

in neutral before dismounting.
2. Make sure that all components in the

hydraulic system are kept in good condition
and clean.
3. Replace any worn, cut, abraded, flattened or

crimped hoses and steel lines.
4. Do not attempt any makeshift repairs to the

hydraulic lines, fittings or hoses by using
tapes, clamps cements or welding. The
hydraulic system operates under extremely
high pressure. Such makeshift repairs will fail
suddenly and create a hazardous and unsafe
condition. Figure 1-91: Checking Hydraulic Leaks
5. Wear proper hand and eye protection when

searching for a high-pressure hydraulic leak.
Use a piece of cardboard as a backstop
instead of hands to isolate and identify a leak.
6. If injured by a concentrated high-pressure

stream of hydraulic fluid, seek medical
attention immediately. Serious infection or
toxic reaction can develop from hydraulic fluid
piercing the skin.
7. Before applying pressure to a hydraulic

system, make sure all components are tight Figure 1-92: Hydraulic Pressure Hazard
and that steel lines, hoses and couplings are
in good condition.
Figure 1-93: Wear safety glasses
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1.9 REFUELING SAFETY
1. Handle fuel with care. It is highly flammable.
2. Allow engine to cool for 5 minutes before

refueling. Clean up spilled fuel before
restarting engine.
3. Do not refuel the machine while smoking or

when near open flame or sparks.
4. Fill fuel tank outdoors. Figure 1-94: Refueling Safety
5. Prevent fires by keeping machine clean of

accumulated trash, grease and debris.
1.10 BATTERY SAFETY
1. Keep all sparks and flames away from the

batteries, as a gas given off by electrolyte is
explosive.
2. Avoid contact with battery electrolyte: wash

off any spilled electrolyte immediately.
3. Wear safety glasses when working near bat-

teries.
4. Do not tip batteries more than 45° degrees, to

avoid electrolyte loss.
5. To avoid injury from spark or short circuit,

disconnect battery ground cable before
servicing and part of electrical system.
Figure 1-95: Battery Safety
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1.11 TIRE SAFETY
1. Failure to follow proper procedures when

mounting a tire on a wheel or rim can
produce an explosion which may result in
serious injury or death.
2. Do no attempt to mount a tire unless you

have the proper equipment and experience to
do the job.
3. Have a qualified tire dealer or repair service

perform required tire maintenance.
Figure 1-96: Lower All Safety Stops
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Figure 1-97: Safely Filling Air in a Tire
Figure 1-98: Over inflation of Tire
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SECTION 2: SPECIFICATIONS
D60/FD70/CA20 TOC
Section 2: Specifications
2.1 Torque Specifications ........................................................................................ 2-1
2.1.1 English Bolt Torque Specifications............................................................ 2-1
2.1.2 Metric Bolt Specifications .......................................................................... 2-1
2.1.3 Tightening Tube Flare Type Fittings ......................................................... 2-2
2.1.4 Tightening O-ring Fittings* ........................................................................ 2-3
2.1.5 Metric Bolt Specifications Bolting into Cast Aluminum.............................. 2-4
2.2 Recommended Fluids and Lubricants ............................................................... 2-4
Capacities ..................................................................................................... 2-4
Capacities ..................................................................................................... 2-4
2.3 Acronyms and Abbreviations............................................................................. 2-5
2.4 English/Metric Equivalents ................................................................................ 2-5
2.5 Draper Header Specifications............................................................................ 2-6
Design Features ........................................................................................... 2-6
Engineering Specifications ........................................................................... 2-7
D60/FD70/CA20 Section 2: Specifications PAGE 2-1
2.1 TORQUE SPECIFICATIONS

The tables shown below give correct torque valves for various bolts and capscrews
1. Tighten all bolts to the torque specified in charge unless otherwise noted.
2. Check tightness of bolts periodically, using bolt torque chart as a guide.
3. Replace hardware with the same grade bolt
• Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise
specified.
• Therefore, do not grease or oil bolts or capscrews unless otherwise specified in this manual.
• When using locking elements, increase torque values by 5%.
* Torque value for bolts and capscrews are identified by their head markings.
2.1.1 ENGLISH BOLT TORQUE SPECIFICATIONS

Bolt Bolt Torque *
Diameter SAE 2 SAE 5 SAE 8
“A” (Nm) (lbf.-ft.) (Nm) (Lbf-ft.) (Nm) (lbf-ft.)
1/4” 8 6 12 9 15 11
5/16” 13 10 24 18 34 25
3/8” 27 20 43 32 56 41
7/16” 41 30 68 50 95 70
1/2” 61 45 102 75 142 105
9/16” 95 60 149 110 202 149
5/8” 128 95 203 150 271 200
3/4” 225 165 359 265 495 365
7/8” 230 170 569 420 813 600
1” 345 225 867 640 1205 890
2.1.2 METRIC BOLT SPECIFICATIONS

Bolt Bolt Torque *
Diameter 8.8 10.9
“A” (Nm) (lbf-ft.) (Nm) (lbf-ft.)
M3 0.5 0.4 1.8 1.3
M4 3 2.2 4.5 3.3
M5 6 4 9 7
M6 10 7 15 11
M8 25 18 35 26
M10 50 37 70 52
M12 90 66 125 92
M14 140 103 200 148
M16 225 166 310 229
M20 435 321 610 450
M24 750 553 1050 774
M30 1495 1103 2100 1550
M36 2600 1917 3675 2710
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2.1.3 TIGHTENING TUBE FLARE TYPE FITTINGS

Tube Nut Size Torque Value* Recommended
Size Across Turns to tighten
OD Flats (After finger tight- Flare Nut
ening)
(in.) (in.) (Nm) (lb.-ft.) (Flats) (Turn)
3/16 7/16 8 6 1 1/6
1/4 9/16 12 9 1 1/6
5/16 5/8 16 12 1 1/6
3/8 11/16 24 18 1 1/6
1/2 7/8 46 34 1 1/6
5/8 1 62 46 1 1/6
3/4 1-1/4 102 75 3/4 1/8
7/8 1-3/8 122 90 3/4 1/8
Flare seat
Body
*The torque values shown are based on lubricated connections as in reassembly.
Instructions for tightening flare type tube fittings*

1. Check flare and flare seat for defects that might cause leakage.
2. Align tube with fitting before tightening.
3. Lubricate connection and hand tighten swivel nut until snug.
4. To prevent twisting the tube(s), use two wrenches. Place one wrench on the connector body and with the
second, tighten the swivel nut to the torque shown.
169046 ISSUE DATE 05/01/14

2.1.4 TIGHTENING O-RING FITTINGS*

Tube Nut Size Torque Value* Recommended
Size Across Turns To tighten Fitting Locknut
OD Flats (After finger tight-
ening)
Washer
O-Ring
(in.) (in.) (Nm) (lb.-ft.) (Flats) (Turn)
3/8 1/2 8 6 2 1/3 Groove
7/16 9/16 12 9 2 1/3
1/2 5/8 16 12 2 1/3 Seat
9/16 11/16 24 18 2 1/3
3/4 7/8 46 34 2 1/3
7/8 1 62 46 1-1/2 1/4
1-1/16 1-1/4 102 75 1 1/6
1-3/16 1-3/8 122 90 1 1/6
1-5/16 1-1/2 142 105 3/4 1/8
1-5/8 1-7/8 190 140 3/4 1/8
1-7/8 2-1/8 217 160 1/2 1/12
* The torque values shown are based on lubricated connections as in reassembly.
Instructions for tightening O-ring fittings*:

1. Inspect O-ring and seat for dirt or obvious defects.
2. On angle fittings, back the lock nut off until washer bottoms out at top of groove.
3. Hand tighten fitting until back-up washer or washer face (if straight fitting) bottoms on face and O-ring is
seated.
4. Position angle fittings by unscrewing no more than one turn.
5. Tighten straight fittings to torque shown.
6. Tighten angle fitting to torque shown while holding body of fitting with a wrench.
* The torque values shown are based on lubricated connections as in reassembly.
169046 ISSUE DATE 05/01/14

2.1.5 METRIC BOLT SPECIFICATIONS BOLTING INTO CAST ALUMINUM

Bolt Bolt Torque
Diameter 8.8 8.8 (cast alum) 10.9 10.9 (cast alum)
Nm Ft.-lbs. Nm Ft.-lbs. Nm Ft.-lbs. Nm Ft.-lbs.
M3 0.5 0.4 1.8 1.3 1
M4 3 2.2 4.5 3.3 4 2.6
M5 6 4 9 7 8 5.5
M6 10 7 9 6 15 11 12 9
M8 25 18 20 14 35 26 28 20
M10 50 37 40 28 70 52 55 40
M12 90 66 70 52 125 92 100 73
M14 140 103 200 148
M16 225 166 310 229
2.2 RECOMMENDED FLUIDS AND LUBRICANTS
LUBRICANT SPEC DESCRIPTION USE Capacities

High Temp. Extreme Pressure As Required Unless Oth-
(EP). 0-1% Max Molybdenum erwise Specified.
Disulphide
(NLGI Grade 2).
Lithium Complex Base.
Grease SAE Multi- High Temp. Extreme Pressure
Purpose. (EP)
Performance With 10% Max
Molybdenum
Disulphide (NLGI Grade 2).
Lithium Base
Gear Lubricant SAE 85W-140 API Service Class GL-5. Wobble Box 2.3 qts (2.2 Liters)
Main Drive Gearbox 5 Pints (2.5 Liters)
Hydraulic Oil SAE 15W40 Compliant With SAE Specs For Header Drive systems 16 gal. US (60
API Class SJ And CH-4 Engine Reservoir Liters)
Oil.
Figure 2-1: Lubricant Chart
Capacities
ITEM CAPACITY
Wobble Box 2.2 liters (2.3 qts)
Main Gearbox 5 Pints (2.5 Liters)
Hydraulic Tank 16 Gallons U.S. (60 Litres)
Figure 2-2: System Capacities
169046 ISSUE DATE 05/01/14

2.3 ACRONYMS AND ABBREVIATIONS
TERM DEFINITION
API American Petroleum Institute
ASTM American Society Of Testing And Materials
DKD Double Knife Drive
F Fahrenheit
ft/min feet per minute
ft/s feet per second
gpm U.S. gallons per minute
hp Horsepower
in³ cubic inches
lbf. pounds force
lbf.ft or ft-lb pound feet or foot pounds
lbf.in or in-lb pound inches or inch pounds
mph miles per hour
n/a not applicable
oz. ounces
psi pounds per square inch
rpm revolutions per minute
spm strokes per minute
SAE Society Of Automotive Engineers
SKD Single Knife Drive
AHHC Auto Header Height Control
RTD Feed Auger
Figure 2-3: Definitions
2.4 ENGLISH/METRIC EQUIVALENTS
ENGLISH FACTOR SI UNITS (METRIC)

acres x 0.4047 hectares (ha)
ft/min x 0.3048 = meters/min (m/min)
ft/s x 0.3048 = meters/sec (m/s)
US gal x 3.7854 = liters (L)
US gal/min (gpm) x 3.7854 = liters/min (L/min)
hp x 0.7457 = kilowatts (kW)
in3 x 16.3871 = cubic centimeters (cm3 or cc)
lbf. x 4.4482 = newtons (N)
lbf.ft or ft-lb x 1.3558 = newton meters (Nm)
lbf.in or in-lb x 0.1129 = newton meters (Nm)
mph x 1.6063 = kilometers/hour (km/h)
oz. x 29.5735 = milliliters (ml)
psi x 6.8948 = kilo pascals (kPa)
psi x 0.00689 = mega pascals (MPa).
Figure 2-4:
169046 ISSUE DATE 05/01/14

2.5 DRAPER HEADER SPECIFICATIONS
Design Features
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Engineering Specifications
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SECTION 3: TROUBLE SHOOTING
D60/FD70/CA20 TOC
Section 3: Trouble Shooting

3.1 Troubleshooting................................................................................................. 3-1
Feeding......................................................................................................... 3-1
Auto Header Height Control (AHHC) ............................................................ 3-4
Vibration........................................................................................................ 3-5
Cut Quality / Crop loss.................................................................................. 3-6
Cutting Action & Sickle Components .......................................................... 3-10
Reel Delivery .............................................................................................. 3-11
Header Lift .................................................................................................. 3-12
Drapers & Decks......................................................................................... 3-13
D60/FD70/CA20 Section 3: Trouble Shooting PAGE 3-1
3.1 TROUBLESHOOTING
NOTE: Legend REF material.
* See your MacDon Dealer.
** See your combine adapter operators manual
*** See your combine header operators manual
**** See your CA20/D60/FD70 Technical Manual
***** See Section 9 Hydraulics
Feeding
SYMPTOM PROBLEM SOLUTION REF
Feed Auger back-feeds or Feed Auger set too high therefore not Set auger to recommended **
wraps effectively feeding the crop to the feed- clearance.
erhouse.
Feeder house speed too slow Increase feeder house speed ---
On John Deere combines it is ---
recommended to run the feeder
house on the high speed
sprocket
Feed chain not taking crop up into Move feeder house drum to ---
feeder house corn position
extend feed chain, if required ---
install additional links to further
extend feed chain.
Feed auger reversing mechanism not Check to ensure the feed auger ****
shifting out of reverse fingers are fully extended at the
front of the drum and fully
retracted at the rear of drum
when in forward operation.
Feed auger reverser tube not installed Install reverser tube to ensure ****
feed auger shifts back to for-
ward position.
Case: Stone retarding drum installed, or Install standard drum or fill slots ---
smooth feeder chain bars installed in stone retarding drum, or
install serrated feed chain bars
Lexion: Stone ejection roll set too low Adjust roll position ---
Hesitation in crop flow Reel too far back disturbing the crop Move reel forward on support ***
mat feeding across side drapers arms far enough to not disturb
the crop on the side drapers.
Side drapers running too fast, piling Reduce header side draper **
material in center of feed draper speed
Side drapers running too slow, piling Increase header side draper **
crop up at the sides of the feed draper. speed
Feed auger set too high therefore not Set auger to recommended **
effectively feeding the crop to the feed- clearance.
erhouse.
Feed chain not taking crop up into Increase feeder house speed *
feeder house
Move feeder house drum to ---
corn position
169046 ISSUE DATE 01/01/10


extend feed chain, if required *
install additional links to further
extend feed chain.
Feed draper speed too slow See Hydraulic Trouble shooting ****
section
Feed auger speed too slow Incorrect drive sprocket. ****
Ensure you have the correct
sprocket size based on the
combine make
Standard drive sprocket incor- ****
rect for application. Install
larger drive sprocket to
increase drum speed
Crop being fed too wide for the feeder Remove feed auger fingers to ****
house opening narrow crop flow into the feeder
house
Install stripper bar and/or **
flighting extension options to
help feed correct width. Note
these kits are recommended as
standard equipment on New
Holland CR 920/940/960/9040/
9060 combines
Crop is being feed down the center of Add fingers to the feed auger to ****
the feeder house widen flow of crop into the
feeder house
Crop is very bulky and is catching on Install an optional Upper Cross ***
the backsheet and center reel arm Auger
Crop being carried under feed Feed auger set too high therefore not Set auger to recommended **
draper. effectively feeding the crop to the clearance.
feeder house.
side drapers back feed Side drapers running at incorrect speed Open flow control valve 4 full ***
turns as a starting point. Adjust
speed by opening valve (coun-
terclockwise) to increase and
closing valve (clockwise) to
decrease speed.
Hesitation of crop flow into feeder See Hesitation in crop flow in ****
house troubleshooting section
Crop is thrown across opening Side drapers running too fast in light Reduce side draper speed. **
and under opposite side draper crop.
Crop accumulating at guards Reel position not set correctly Check reel clearance to knife **
and not moving rearward onto and cutterbar
drapers
-Check reel finger clearance to **
ground
-Reel too far forward of cut- **
terbar C-section
Reel finger pitch not aggressive enough Increase finger aggressive- **
ness (cam position)
169046 ISSUE DATE 01/01/10

Ground Following / Float & Wing Balance

Cutterbar pushes dirt across Main float locked out Unlock main float **
entire length
Main Float set too heavy Adjust main float ***
To much ground pressure Reduce ground pressure with ****
the AHHC (Auto Header Height
Control).
AHHC not functioning See AHHC not functioning in ****
troubleshooting section
Header angle too steep Adjust header to optimum ***
angle
Cutterbar poly not installed Install cutterbar poly option ***
Cutterbar poly worn or damaged replace worn and damaged ---
poly
Cutterbar pushing too much Ridges caused by seeding or spraying Cut at angle to ridges to allow ---
dirt in certain locations for operations knife and guards to clean out
length of field better. When cutting in line with
tracks, or ridges the same
guards and sections have to cut
in dirt for the whole length of
the field.
Stubble longer at center than Wing balance is set too heavy (wings Adjust wing balance to make ***
at dividers, or cutterbar pushes are frowning) wings lighter. (FD70 ONLY)
dirt at dividers, not at center
Stubble longer at dividers than Stabilizer wheels lifting on wings Stabilizer wheels are intended ***
at center, or cutterbar pushes for off the ground cutting only.
dirt at center, not at ends Place stabilizer wheels into the
storage position for cutting on
the ground. (FD70 ONLY)
Wing balance is set too light (wings are Adjust wing balance to make ***
smiling) wings heavier.
Pushing dirt at combine Stabilizer wheels floating header Stabilizer wheels are intended ***
adapter lower beam to allow the header to follow the
contours of the ground when
cutting off the ground. Place
stabilizer wheels in the storage
position for cutting on the
ground.
Running too much ground pressure Reduce the amount of ground ***
causing header to float off adapter pressure.
Main float too light, header is floating off Ensure float rests back on **
of adapter downstop when header is 6” off
the ground.
Combine faceplate angle set too Adjust combine faceplate angle ---
shallow to get optimum guard angle
range for your applications.
Header angle too shallow Increasing the header angle will ***
increase the ground clearance
to the adapter
169046 ISSUE DATE 01/01/10

Auto Header Height Control (AHHC)

AHHC not functioning AHHC not calibrated in combine Calibrate AHHC as per combine ****
operators manual or AHHC sec-
tion in Technical manual
AHHC will not calibrate Voltage range not set correctly. Set ****
AHHC voltage range and re cali-
brate
Combine not receiving reading from Harness not connected or break in
AHHC the harness. Connect or repair as
necessary
Failed potentiometer Test potentiometer and replace if ****
faulty. Voltage range will need to be
set when replacing the potentiom-
eter
AHHC reacting too slowly Accumulator slowing down Turn off accumulator in combine.
response time of combine See combine operators manual
AHHC lift and/or lower rates too Adjust AHHC lift and/or lower rates ****
slow on combine. See combine opera-
tors manual or AHHC section in
technical manual
AHHC sensitivity too low which Increase AHHC sensitivity in com- ****
requires more movement of the bine. See combine operators
header before the combine will manual or AHHC section in tech-
react. nical manual
Lateral tilt is not responding to AHHC on FD70/D60 does not work Disable the lateral tilt feature in the
the contours of the field. with the lateral tilt feature. The combine and use the AHHC com-
CA20 float system allows the bined with the float system to follow
header to follow the contours of the the contours of the ground.
ground
169046 ISSUE DATE 01/01/10

Vibration

Excessive vibration of adapter Sickle hold-downs not adjusted Adjust hold-downs so sickle works ***
and header. properly freely, but keeps sections from
lifting off guards
Guards and sections worn causing replace guards and sections as ****
excessive sickle loads. required.
Less than 4 special guards (Guards Make sure there are four special
w/o ledger plate) at knife drive end. guards at the knife drive
Loose or worn sickle head pin or Tighten or replace parts ***
drive arm
Wobble box pitman arm position Make sure there is proper clear- ****
To much grease in the pitman arm ance between the pitman arm and
knifehead the knife head
Vibration dampers worn (D60 only) Replace rubber in dampers *
Vibration dampers not installed Install vibration dampers onto **

(D60 only). adapter legs.
Knife speed set too fast Adjust knife speed to match recom- ****
mended setting listed in knife drive
section based on header size and
configuration
Double knife headers running with Time knives as per Knife drive sec- ****
the knives un-timed (excludes 40’ tion in technical manual
and 45’ sizes as these units run un-
timed)
Vibration from driveline U-joints in driveline worn replace u-joints as required ---
Bent driveline Replace or repair driveline ****
Bent jackshaft on combine Replace or repair jackshaft ---
169046 ISSUE DATE 01/01/10

Cut Quality / Crop Loss

Header not picking up down Cutterbar too high Lower cutterbar ***
crop
Header angle too flat Steepen header angle ***
Skid shoes adjusted for higher cutting Adjust skid shoes to the highest ***
height position for the lowest cutting
position
Reel too high Lower reel. ***
Reel too far back Move reel forward ***
Ground speed too fast for reel speed Reduce ground speed or ***
increased reel speed
Reel fingers not lifting crop sufficiently Increase finger pitch aggres- ***
siveness
Heads shattering or breaking Reel speed too fast Reduce reel speed, Reel speed ***
off stem should only be slightly (10%)
faster than ground speed in
most applications
Reel too low Raise reel ***
Crop too ripe Operate at night when humidity ---
is higher
Cut grain falling ahead of Ground speed too slow Increase ground speed ***
cutterbar
Reel speed too slow Increase reel speed ***
Reel too high Lower reel ***
Cutterbar too high Lower cutterbar ***
Reel too far forward Move reel back on arms ***
Header angle too steep allowing crop to Decrease header angle. ***
roll off
Unable to get fast enough reel speed. Confirm size of drive and driven **
(May have high torque sprocket installed sprockets in your reel drive.
Consult the header parts book
for higher speed reel drive
options.
Strips of uncut material. Divider laying down crop on previous Leave more space of empty c- ---
pass. bar, so reel can pick up crop
pressed down by divider.
Broken/worn sickle components Replace ***
Sickle not cutting clean as sickle sec- Make sure hold downs are ***
tion is lifting off guard. adjusted correctly
Reel not lifting down crop Lower reel and adjust for-aft to ***
allow fingers to pick up down
crop.
Check and adjust reel finger ***
pitch
Crop flows over divider rod, Divider rods providing insufficient sepa- Refer to header OM for recom- ***
builds up on endsheets ration mended divider rod for your
condition.
169046 ISSUE DATE 01/01/10


Poor cut quality at ends of Reel not cleaning cutterbar sufficiently Adjust reel height to ensure reel ***
header fingers keep cutterbar clear of
crop.
Adjust reel position / finger ***
pitch
Sickle sections or guards are worn or Check and replace all worn and ***
broken broken cutting parts
Crop laid down by divider hanging up Replace 3 or 4 end guards with ***
on guard tips. stub guards which will help with
crop hanging up on guard tips.
Ragged or uneven cutting of Sickle hold-downs not adjusted properly Adjust hold-downs so sickle ***
crop works freely, but still keep sec-
tions from lifting off guards
Sickle sections or guards are worn or Check and replace all worn and ***
broken broken cutting parts
Sickle stroke not centered with guard Align sickle stroke so that the ****
tang sickle section is centered with a
guard tang at the end of the
stroke.
Cutterbar too high Lower cutting height ***
Header angle too flat Steepen header angle ***
Sickle is not operating at recommended Run Combine Jackshaft at rec- *
speed ommended speeds.
Ensure sickle speed is running *****

in the recommended range.
May need to increase sickle
speed in tough cutting condi-
tions.
Loose sickle drive belt Adjust drive belt tension ***
Ground speed too fast for reel speed. Reduce ground speed or ***
increase reel speed. Reel
speed should generally be run
10% faster than ground speed.
Reel is not lifting crop effectively Ensure the reel is far enough ***
enough for the sickle to cut it off. forward to effectively lift the
crop ahead of the sickle
Ensure reel finger pitch is set **
so that the fingers pick up the
crop ahead of the sickle
Tangled/tough to cut crop Install stub guards ---
Header stripping plants - Com- Header being carried off ground Lower header to ground and ***
plete or partial plants left run on skid shoes and/or cut-
behind terbar
Float set too light or running too little Check float setting as per oper- **
ground pressure. Header is bouncing ators manual. Then adjustment
over crop. ground pressure to ensure
header follows the contours of
the ground.
169046 ISSUE DATE 01/01/10


Reel being operated too high Position reel height to effec- ***
tively convey the crop without
leaving stems behind.
Reel speed too slow Adjust reel speed to be margin- **
ally faster than ground speed
Tip: Look at perimeter of reel **
discs. they should appear to be
being driven by the ground
Reel too high with cylinders fully Adjust reel height with cylinders ***
retracted fully retracted to obtain min-
imum clearance to knife
IMPORTANT - Maintain ade-
quate clearance to prevent
finger from getting in knife
Finger pitch not aggressive enough Move finger pitch adjustment to ***
a higher number to make finger
path more aggressive.
Reel too far back on reel support arms Move reel forward until the fin- ***
gertips skim the soil surface
with header on ground and
center link properly adjusted
Header angle too shallow Lengthen center link to max. **
length to start with. Decrease
center link length if header
pushes too much dirt
Header skid shoes adjusted for higher Raise skid shoes to max. up ***
cutting height. position
Dirt packs on bottom of cutterbar and Install plastic wear strips on ***
raises cutterbar off the ground bottom of cutterbar and skid
shoes
Dirt still packing on bottom of cutterbar Decrease amount of ground **
with poly wear strips on cutterbar and pressure on cutterbar.
raises cutterbar off the ground
Header not level Level Header - See adapter **
Operators Manual
Knife sections worn out and have no Replace sections or complete ***
serrations left causing plants to slip out knife
of guards and sections
Tip: - Coarse serrated sections ---
last longer when operating in
dirty conditions.
Parts of vines get caught in regular Install stub guard kit. Reel has ***
guard tip while reel is trying to lift the a better chance of lifting the
vines above the knife and end up get- crop mat above the knife
ting cut off. (This is more prevalent without any pods being cut by
when cutting row-cropped beans that the knife
have been hilled due to cultivating -Stub guards not recommended
for Soybeans.
169046 ISSUE DATE 01/01/10


Excessive losses at dividers Divider rod running down crop and Remove divider rod ***
shattering pods
Excessive amount of vines and plants Install divider rod ***
run up divider and endsheet up to cyl-
inder and either fall into or outside
header in lumps
169046 ISSUE DATE 01/01/10

Cutting Action & Sickle Components

Sickle plugging Reel is not clearing crop from cutterbar Adjust reel fore-aft, height and/ ***
or pitch to effectively clean the
cutterbar.
Loose sickle drive belt Adjust drive belt tension ***
Improper sickle hold-down adjustment Adjust hold-down so sickle is ***
held against guard cutting sur-
face
Dull or broken sickle sections Replace ***
Bent or broken guards Align or replace ***
Mud or dirt build-up on cutterbar Raise cutterbar by lowering ***
skid shoes
Decrease amount of ground ****
pressure when running in
muddy conditions.
Sickle is not operating at recommended Run Combine Jackshaft at rec- ****
speed ommended speeds.
High Pressure standby set too low Ensure sickle speed is running *****
in the recommended range.
May need to increase sickle
speed in tough cutting condi-
tions.
Excessive breakage of sickle Sickle hold-downs not adjusted prop- Adjust hold-downs so sickle ***
sections or guards erly. This allows sickle to raise up and works freely, but still keep sec-
could contact guard tang and damage tions from lifting off guards
either or both.
Header angle too steep Flatten header angle ***
In stony conditions rocks get stuck Reduce guard angle and/or ***
between sickle section and guard tang lower skid shoes to reduce the
or contact with rocks breaks compo- number of rocks being picked
nent. up.
Reduce number of rocks in field ---
by picking or rolling land
Main float is set too heavy therefore Adjust float and wing balance to ***
increased pressure is required to float ensure header floats properly.
header (If applicable)
Operating header with too much ground Decrease amount of ground ****
pressure pressure.
Sickle back breakage Worn sickle sections and/or guards replace worn components ***
Bent or broken guard Straighten or replace ***
Worn sickle head pin Replace ***
Over greasing the knifehead pin will Only put 1-2 pumps of grease ***
force the knifehead down putting extra every 25hrs for the knifehead
stress on the sickle back pin
Wobble box pitman arm height not set Set wobble box pitman arm ****
correctly height.as per knife drive section
Guard bar bent causing excessive knife Straighten guard bar ---
loading
169046 ISSUE DATE 01/01/10

Reel Delivery
Reel not releasing crop In heavy crop, fingers starting to flip Move to a less aggressive finger ***
over before releasing crop pitch position
Reel speed too fast Reduce speed of reel to allow ***
crop to fall onto drapers prop-
erly. Reel speed should be
slightly faster than ground
speed
Reel too far back Move reel forward ***
Wrapping on reel end Reel tines too aggressive Reduce cam setting ***
Reel speed too fast Reduce reel speed ***
Reel not centered in header Center reel in header ***
Reel endsheets not installed or end- Install reel endsheets or repair
sheets are damaged damaged endsheets
Crop dividers not dividing crop properly See OM for recommended ***
divider configuration for your
conditions.
Reel releases crop too quickly Reel tines not aggressive enough Increase cam setting ***
Reel too far forward Move reel back ***
Reel will not lift Hydraulic couplers not connected prop- Check coupler connection **
erly
Insufficient hydraulic flow or pressure Check hydraulic flow and pres- ---
from combine sure on combine lift circuit
Reel will not turn Control set at 0 Activate reel speed control *
Quick couplers not properly connected Connect couplers *
Final drive chain disconnected Connect chain ***
Combine not suppling enough oil Check combine oil level ---
Insufficient hydraulic flow or pressure Check hydraulic flow and pres- ---
from combine sure on combine reel drive cir-
cuit
Reel speed is uneven or stalls Reel speed too fast Reduce reel speed ***
in heavy crop
Reel fingers not aggressive enough Move to a more aggressive ***
finger pitch notch
Low oil reservoir level on combine. Fill to proper level ---
(NOTE: Sometimes more than one res-
ervoir.)
Reel drive circuit on combine providing Check combine reel drive circuit ---
insufficient flow or pressure to run reel flow and pressure
Cutting tough crops with high-speed reel Replace with high torque reel See
drive sprocket drive sprocket parts
cat
Reel contacts header endsheet Reel not centered in header Center reel in header. ***
Reel centering hardware loose Center reel and torque cen- ***
tering hardware
169046 ISSUE DATE 01/01/10


Reel fingers being cut by sickle Reel height adjustment set too low Adjust reel clearance to cut- ***
terbar
Reel carries over odd plants in Reel fingers (steel) bent and hook Straighten fingers (steel) ---
same location plants out of the crop flow on drapers
Dirt accumulation on end of fingers do Reel too low relative to the ***
not let plants slide off fingers ground
-Adjust reel fore and aft location ***
to move fingers out of the
ground
Reel carries over excessive Too much accumulation of crop on Speed up drapers to thin out **
amounts of plants or wads drapers (up to height of reel center amount of material on drapers.
tube)
Finger pitch too aggressive Decrease finger pitch to move ***
finger flip-over point out of the
crop flow.
Reel fore-aft too far back reducing Move reel forward to increase ***
available space for crop flow crop flow area.
Excessive amount of vines and plants Raise reel a slight amount ---
or weeds cause reel to wrap up when getting into a patch of
viney weeds or green viney
crop
Header Lift

Header lift insufficient Low combine relief pressure Increase relief pressure ---
Combine lift cylinders are to small Install large lift cylinders **
Third lift cylinder is required on
some combines for larger
headers.
169046 ISSUE DATE 01/01/10

Drapers & Decks

Draper will not drive Drapers are loose Tighten drapers ***
Drive or idler roller wrapped with Loosen draper and clean rollers ***
material
Slat or connector bar jammed by frame clear obstruction ***
or material
Roller bearing seized Replace ***
Low hydraulic oil Fill reservoir to full level *
Incorrect relief setting at flow control Adjust relief setting ****
valve
Draper stalling Material not feeding evenly off sickle Lower reel ***
Crop is hanging up on guard tips when Install stub guards (not recom- ---
using standard guards mended for soybeans)
Relief valve setting to low Adjust relief pressure **
Relief valve bad Replace relief valve **
Insufficient side draper speed Mechanical failure in draper turn drapers over by hand to
ensure no obstruction is
present and to check bearings.
Insufficient draper tension Tension draper to recom- ***
mended settings
Speed control set too low Increase flow control setting *****
Relief pressure too low Increase relief pressure to rec- ****
ommended setting
Insufficient feed draper speed Mechanical failure in draper turn draper over by hand to
ensure no obstruction is
present and to check for
bearing failure.
Insufficient draper tension Tension draper to recom- **
mended settings
Relief pressure too low Increase relief pressure to rec- *****
ommended setting
Insufficient side and feed Combine feeder house speed too slow Run feeder house at recom- ****
draper speed mended speed.
Incorrect pump size Ensure correct displacement *****
pump is being used based on
the combine make.
poor pump efficiency Test pump efficiency *****
Material accumulates inside or Deck height improperly adjusted Adjust deck height ***
under front edge of side draper
Crop entering draper at outer ends due Shift decks to ensure cover is ***
to gap between cover and draper over draper or extend cover.
Cutterbar has filled up with trash with Raise header fully at each end ---
draper to cutterbar gap properly of the field or as required to
adjusted help clean out the cutterbar
169046 ISSUE DATE 01/01/10

SECTION 4: GENERAL PROCEDURES
D60/FD70/CA20 TOC
Section 4: General Procedures

4.1 Taper Lock Hub ................................................................................................. 4-1
The way it works ........................................................................................... 4-1
4.1.1 Removal and Installation........................................................................... 4-1
4.2 Lock Collar......................................................................................................... 4-4
The way it works ........................................................................................... 4-4
4.2.1 Removal and Installation........................................................................... 4-4
4.3 Universal Joint ................................................................................................... 4-5
The Way it Works ......................................................................................... 4-5
4.3.1 Universal Joint Rebuild ............................................................................. 4-5
4.4 Guards............................................................................................................... 4-9
The Way it Works ......................................................................................... 4-9
Stub Guard Header:...................................................................................... 4-9
Pointed Guard Header:............................................................................... 4-10
Double Knife Headers Pointed Guards Only: ............................................. 4-10
Double Knife Headers Forged Stub Guards Only:...................................... 4-11
4.4.1 Important Guard Information ................................................................... 4-12
4.4.2 Guard Adjustments ................................................................................. 4-13
Regular Guard: ........................................................................................... 4-13
Stub Guards & Center Guards:................................................................... 4-13
4.5 Blades (Disc Only)........................................................................................... 4-14
4.5.1 Cutting Hardware Inspection................................................................... 4-16
4.5.2 Cutterbar Hardware................................................................................. 4-17
4.5.3 Blade Replacement................................................................................. 4-18
4.5.4 Disc Removal .......................................................................................... 4-19
4.5.5 Disc Installation ....................................................................................... 4-20
D60/FD70/CA20 Section 4: General Procedures PAGE 4-1
4.1 TAPER LOCK HUB

The Way it Works
The taper lock hub is a mechanism designed to
lock rotating parts such as pulleys and sprockets
to the rotating shaft without the need of a press
fit. As the pulley or sprocket is drawn onto the
hub the clamping force increases. Using a taper
lock hub allows the parts to be separated easier
and more frequently.
Figure 4-1: Drive and idler pulley
4.1.1 REMOVAL AND INSTALLATION

A typical pulley is shown here, but the same
steps apply to any taper hub.
1. If removing the pulley or taper-lock only and

not moving the shaft measure position as
shown. If replacing bearing and or shaft mea-
sure end of shaft from end frame after taper
lock and pulley have been removed before
undoing lock collars.
2. Remove 3 bolts (A). (Figure 4-3) Figure 4-2: Shaft Measurement
Figure 4-3: Taper Lock hub bolts
169046 ISSUE DATE 01/01/11

3. Install 2 of the 3 bolts into holes (B) and

tighten evenly. This will push the pulley off the
hub. (Figure 4-4)
Figure 4-4: Splitting hub and pulley
4. Use emery cloth and clean the paint off the

shaft before removing the hub. (Figure 4-5)
Figure 4-5: Clean shaft for assembly
5. Remove the taper hub. Use a puller if

necessary. (Figure 4-6)
6. Then remove the pulley
Figure 4-6: Pulling hub off shaft
169046 ISSUE DATE 01/01/11

7. Place pulley on the shaft and tap taper lock

hub to the pre-measured position that was
taken upon its removal. (Figure 4-7)
HINT: Remember pulley or sprocket will draw

onto the hub and move as much as 1/8” (2-3
mm)
8. Tighten 3 bolts evenly at (A) until tight. Once

tight use a mallet or block of wood and tap
the hub. Torque 1/4” bolt to 55 in.lbs (6.2
Nm). 3/8” Bolt to 175 in.lbs (19.77 Nm).
(Figure 4-8) Figure 4-7: Hub and Pulley Reinstallation
NOTE:
The hub does not move when bolts are tight-
ened, pulley is pulled onto the hub.
NOTE:
If the original problem was poor alignment,
align belt from pulley to pulley using a straight
edge. On a long span ensure belt rotation
oncoming should be as straight as possible.
Belt leaving pulley need not be as straight in
some circumstances. A
Figure 4-8: Taper Lock hub bolts
169046 ISSUE DATE 01/01/11

4.2 LOCK COLLAR

PUNCH HOLE
The Way it Works
The lock collar is designed to hold bearings from
moving on the shaft. By rotating the collar onto
the eccentric shoulder of the bearing the bearing
is secured to the shaft.
4.2.1 REMOVAL AND INSTALLATION

C
There are several lock collars on the D60, FD70
and CA20. Always determine rotation of shaft
prior to beginning disassembly.
Figure 4-9: Lock Collar
Direction of Rotation
1. Loosen setscrew (C). (Figure 4-9)
2. The lock collar must be rotated to remove it.

The direction to rotate the collar depends on
the direction the shaft rotates that it is locked
onto. To unlock the collar tap in the opposite
direction of rotation. To lock it, tap it in the
same direction as rotation. Once complete Lock Unlock
retighten set screw. (Figure 4-10)
Figure 4-10: UnLocking Collar Shown

NOTE:
In some applications shaft may turn in both
directions. In this case lock the collar in the
most frequently used direction.
169046 ISSUE DATE 01/01/11

4.3 UNIVERSAL JOINT
The Way it Works

The universal joint is designed to transfer a spin-
ning force in different directions. It makes a rigid
shaft flexible, which is useful, for conditions
where the driven component moves independent
of the driving component (header on a combine).
Figure 4-11: U-Joint assembly
4.3.1 UNIVERSAL JOINT REBUILD

1. To maintain the balance of the U-joint, mark
the U-joint's yolks so when re-assembling you
position the yolks to their initial orientation.
(Figure 4-12)
Figure 4-12: Marking U-Joint

2. Remove all four retaining clips. (Figure 4-13)
Figure 4-13: Retaining Clip removal
169046 ISSUE DATE 01/01/11

3. Place U-joint on wood blocks or in a vise as

shown and tap (X) until bearing can be
removed. (Figure 4-14) X
NOTE:
By tapping the yolk at (X) as shown the yolk
will slide down the cross exposing the
bearing and allowing it to be removed
4. Flip U-joint 180° and repeat step 3. One yolk
can now be removed from the cross.
Figure 4-14: Tap at (X)

5. Place remaining part of U-joint in wood blocks
as shown, again tapping at (X) to remove
bearing. (Figure 4-15)
X
6. Flip part 180° and repeat step 5.
7. Once the last bearing has been removed, the

cross can now be removed from the
remaining yolk. You are now ready to install
new cross and bearing kit. (Figure 4-16)
Figure 4-15: Tap at (X)
Figure 4-16: Cross
169046 ISSUE DATE 01/01/11

8. For 1st bearing cup install, align the cross

with the yolk and tap bearing in using a
socket and hammer until retaining clip can be
installed.
NOTE:
If a new cross is installed, do not install the
grease fitting at this time, doing so will create
a pressure build-up and make assembly diffi-
cult.
Figure 4-17: 1st bearing installation
9. Install 1st clip. (Figure 4-18)
Figure 4-18: Retaining clip installation
10. Install 2nd bearing cup as shown. Be sure to

align cross to avoid bearing damage.
11. Install 2nd retaining clip.
Figure 4-19: 2nd bearing installation
169046 ISSUE DATE 01/01/11

12. For 3rd bearing, align cross and press the

bearing in using a socket until retaining clip
can be installed. (Figure 4-20)
13. Install 3rd retaining clip.
Figure 4-20: 3rd & 4th Bearing Installation

14. Install 4th bearing. Be sure to align cross to
avoid bearing damage. (Figure 4-20)
15. Install 4th retaining clip.
16. Install grease fitting into bearing cross and into

the bearing cup (if applicable). (Figure 4-21) Figure 4-21: Grease Zerk Installation
17. As a final step, tap all 4 sides to insure all

bearings are tight against retaining clips. This
step is also necessary to free up joint if
excessive stiffness in joint is felt. (Figure 4-
22)
Figure 4-22: Tight U-joint prevention
169046 ISSUE DATE 01/01/11

4.4 GUARDS Stub Guard Header:
The Way it Works

Guards are designed for a dual purpose. The first
purpose of the knife guard is to protect the knife
against damage due to rocks and other contours
of the land that the cutter bar encounters. The
second function of the guards is to provide a
surface for the knife to cut against. Much the way
a pair of scissors works. This is why it is
important for your guards to be adjusted properly.
There are three types of guards on MacDon Figure 4-23: 118346 Stub Guard With Ledger Plate
header, the regular guard, the stub guard, and
the center guard for double knife drive headers.
Figure 4-24: 118347 Stub Guard No Ledger Plate
Figure 4-25: 118351 Stub Guard Hold Down
169046 ISSUE DATE 01/01/11

Pointed Guard Header: Double Knife Headers Pointed Guards Only:
Figure 4-30: 124338 Bottom Center Guard Double Knife

Figure 4-26: 118301 Outboard L/H Side
Figure 4-27: 118302 Outboard R/H Side
Figure 4-31: 124344 Top Center Guard Double Knife
Figure 4-28: 118345 Guard No Ledger Plate
Figure 4-29: 118344 Guard With Ledger Plate
169046 ISSUE DATE 01/01/11

Double Knife Headers Forged Stub Guards

Only:
Figure 4-35: 34359 Stub Guard
Figure 4-32: 118346 Top Stub Guard
Figure 4-33: 124775 Stub Guard Special (Overlap)
Figure 4-34: 118347 Stub Guard
169046 ISSUE DATE 01/01/11

4.4.1 IMPORTANT GUARD INFORMATION

The first four guards closest to the wobble box on
every MacDon header are different than the rest
of the guards on the header. The first three
guards do not have a ledger to guide the knife.
Guard With Ledger Plate
The reason for this to allow for some front to back
movement generated by the wobble box.
Guard Without Ledger Plate

Figure 4-36: Important Guard Information
169046 ISSUE DATE 01/01/11

4.4.2 GUARD ADJUSTMENTS

The first thing is to identify which type of guards
the machine has.
Regular Guard: A
1. Section must not contact guard at (A)
Figure 4-37: Contact Location
(Figure 4-37), and knife must move freely
fore and aft. Tap guard tips up and down to
adjust guards. Align adjacent guards as
required.
2. The clearance of the hold down to the knife at

(B) (Figure 4-38), should be 0.0015-0.0025”
(0.3-0.6 mm). This dimension can be B
adjusted by an adjustment bolt at the back of
the hold-down. Figure 4-38: Hold down spacing
Stub Guards & Center Guards:

Both the stub guards and center guards can be
adjusted the same. The center guard is for
double knife drive machines, where the two
knives overlap.
1. Adjust the three adjustment bolts on the

guard until the clearances are met across the
whole span of the guard. (Figure 4-39) The
clearances for these guards are: At the tip
0.004-0.015” (0.1-0.4 mm), and at the rear of
the guard 0.015-0.04” (0.4-1.0 mm)
Figure 4-39: Stub Guard Spacing
For information on adjustment, see

Operator's Manual for D60/FD70.
169046 ISSUE DATE 01/01/11

4.5 BLADES (DISC ONLY)

The R85 uses specially formed blades for cutting
the crop.
There are two different sets of blades, an 11° and

an 18° beveled version.
The 11° bevel is used for general purpose cutting
and longer life expectancy and is optional. Rotation Direction
Figure 4-40: End View of the 11° Bevel Down
CW
Figure 4-41: MD#149436 11° Bevel Up (13’ & 16’)
CCW
Figure 4-42: MD#149437 11° Bevel Up (13’ & 16’)
169046 ISSUE DATE 01/01/11

The 18° bevel is used for higher lift in certain crop

conditions and performs better in stony soil.
NOTE:
Blades have a tendency to bend up.
Rotation Direction
Figure 4-43: End View of the 18° Bevel Down
CW
Figure 4-44: MD#149438 18° Bevel Down (13’ & 16’)
CCW
Figure 4-45: MD#149439 18° Bevel Down (13’ & 16’)
169046 ISSUE DATE 01/01/11

4.5.1 CUTTING HARDWARE INSPECTION

BLADE CENTER LINE
CAUTION Max
Wear
Cutter blades have two cutting edges. Exer-
cise caution when working around the
blades. Blades are sharp and can cause Max
serious injury. Wear gloves when handling Elongation
blades. 0.81”
(20.6 MM)
CAUTION
Damaged blades may damage the cutterbar, Elongated
Hole
and result in poor cutting performance.
Replace damaged blades immediately. Figure 4-46: Knife Wear Check
DANGER
Stop engine and remove key from ignition
before leaving operator's seat for any reason.
A child or even a pet could engage an idling
machine.
a. Check daily that the cutter blades are
securely attached to the disc. (Figure 4-46)
b. Check blades for cracks or wear beyond
safe operating limits, and distortion.
(Figure 4-46)
c. Replace blades immediately if any of Figure 4-47: Counter Clockwise Disc
these problems occur. (Figure 4-46)
IMPORTANT
Blades should be replaced in pairs, otherwise
the disc may be unbalanced and damage the
cutterbar.
IMPORTANT
The cutter blades have cutting edges on both
edges so that the blade can be turned over
and reused. The twist in each blade deter-
mines if its cutting direction is clockwise or
counterclockwise. Figure 4-48: Clockwise Disc
169046 ISSUE DATE 01/01/11

4.5.2 CUTTERBAR HARDWARE

Check blade attachment hardware each time Bolt head worn
blades are changed. Refer to See “Blade
Replacement” on page 4-18. for hardware
replacement procedure.
4.0 - 0.00
(0.16 - 0.00”)
Check bolts for wear or damage and replace Bolt neck worn
bolt if: 0.13”
(3mm)
1. Bolt has been removed and installed five
times.
2. Head is worn flush with bearing surface of Bolt neck Cracked
blade.(Figure 4-49)
3. Diameter of bolt neck is worn out of specifica-
tion. (Figure 4-49)
4. Bolt is cracked. (Figure 4-49)
5. Bolt is visibly distorted. (Figure 4-49)
Bolt distorted
6. Evidence of interference with adjacent parts.
(Figure 4-49)
Check nuts for wear or damage and replace

nut if:
1. Worn height is less than half total height. Bolt Interference
(Figure 4-49)
2. Cracked.
3. Nut has been removed and installed five
times. (Figure 4-49)
Nut wear
12.8 -13.0
6.0 - 0.00 (0.5 - 0.512”)
Check nut guards for wear or damage replace (0.24 - 0.00”)
nut guard if:
Figure 4-49: Bolt & Nut Wear
1. Nut guard is cracked or broken. (Figure 4-50)
2. Guard is worn flush with bearing surface of
nut. (Figure 4-50)
Figure 4-50: Nut Guard Wear
169046 ISSUE DATE 01/01/11

4.5.3 BLADE REPLACEMENT
CAUTION B A
Cutter blades have two cutting edges. Exer-
cise caution when working around the blades.
Blades are sharp and can cause serious injury.
Wear gloves when handling blades.
DANGER
To avoid bodily injury or death from unex- C
pected start-up or fall of raised machine; stop
engine, remove key and engage lift cylinder
lock-out valves before going under machine for Figure 4-51: Lining up Bolt For Removal
any reason.
Replace cutter blade as follows: D
E
1. Raise header fully, shut off engine and
remove key.
2. Engage lift cylinder lock-out valves (PT only)
or mechanical stops. (SP only)
B
3. Open cutterbar door(s).
4. Rotate disc (A) so that blade (B) faces for-
ward, and lines up with hole (C) in rock F
guard. (Figure 4-51)
5. Place a block of wood between two discs to pre- Figure 4-52: Blade Removal and Installation
vent disc rotation while loosening blade bolts.
6. Clean debris from blade attachment area.
7. Remove nut (D), and nut guard (E).
(Figure 4-52)
8. Remove shoulder bolt (F), and blade (B).
(Figure 4-52)
9. Install new or reversed blade (B) with
shoulder bolt (F) onto disc. (Figure 4-52)
10. Install nut guard (E) and nut (D). Tighten nut
to 100 ft.lbs. (135 Nm). (Figure 4-52)
11. Remove block of wood if used.
12. Close doors.
WARNING
Ensure cutterbar is completely clear of for-
eign objects. These objects can be ejected
with considerable force when the machine is
started and may result in serious injury or
machine damage.
169046 ISSUE DATE 01/01/11

4.5.4 DISC REMOVAL

NOTE:
For disc removal on outer cage you will be
required to remove the cutterbar driveline.
See “Outer Cage Deflectors” on page 6-1.
DANGER
A child or even a pet could engage an idling Figure 4-53: Cutterbar Door Opening
machine.
CAUTION C
Exercise caution when working around the
blades. Blades are sharp and can cause
serious injury. Wear gloves when handling
blades.
1. Open cutterbar doors. (Figure 4-53)
2. Remove four bolts (A) on the disc cover, A
remove cover and disc (C). (Figure 4-54)
Figure 4-54: Disc Removal
NOTE:
If feed assist plates are installed, remove
them along with the cover and disc.
3. If end disc is being removed:
a. Remove bolts (D) and remove cage E F
deflector (E). (Figure 4-55)
b. Remove disc (F). (Figure 4-55)
NOTE:
For drive end you will need to remove the D
drive line first before removing the cage Figure 4-55: Cage Deflector and Disc Removal
deflector and disc.
169046 ISSUE DATE 01/01/11

4.5.5 DISC INSTALLATION

NOTE:
For disc installation on outer cage you will be C
required to re install the cutterbar driveline.
See “Outer Cage Deflectors” on page 6-1.
DANGER
A
machine. Figure 4-56: Disc Installation
CAUTION
Exercise caution when working around the
blades. Blades are sharp and can cause
serious injury. Wear gloves when handling
blades.
E F
1. Position new disc (C) on spindle ensuring it is
90° to the adjacent discs. (Figure 4-56)
2. Install disc cover and secure with four bolts
(A). (Figure 4-56)
3. Tighten bolts to 92 ft.lbs. (125 Nm). D
4. If installing end disc: Figure 4-57: Cage Deflector and Disc Installation
a. Position new disc (F) on spindle ensuring it
is 90° to adjacent discs. (Figure 4-57)
b. Install cage deflector (E) and secure with
four bolts (D). (Figure 4-57)
NOTE:
Make sure that the cage deflectors notched
area lines up with the blades.
c. Tighten bolts to 92 ft.lbs. (125 Nm).
5. Remove block of wood if used.
WARNING
Ensure cutterbar is completely clear of for-
eign objects. These objects can be ejected
with considerable force when the machine is
started and may result in serious injury or
machine damage.
6. Close cutterbar doors.
169046 ISSUE DATE 01/01/11

SECTION 5: KNIFE DRIVE
D60/FD70/CA20 TOC
Section 5: Knife Drive System

5.1 Knife Drive System ............................................................................................ 5-1
Single Knife................................................................................................... 5-1
Double Knife: D60 40’ & Smaller (Timed)..................................................... 5-2
Double Knife: FD70 40’ & D60 45’ (Un-Timed)............................................. 5-3
5.2 Wobble Box Removal ........................................................................................ 5-4
Single & Un-Timed Double Knife .................................................................. 5-4
Double Knife: Timed ..................................................................................... 5-6
Left Side Wobble Box Removal .................................................................... 5-6
Right Side Wobble Box Removal.................................................................. 5-9
5.3 Knife Drive Wobble Box................................................................................... 5-11
5.3.1 Wobble Box Rebuild Tools...................................................................... 5-12
Wobble Box Kit Items ................................................................................. 5-12
5.3.2 Wobble Box Disassembly ....................................................................... 5-13
5.3.3 Wobble Box Re-Assembly ...................................................................... 5-19
5.3.4 Wobble Box Installation........................................................................... 5-29
Wobble box Squareness............................................................................. 5-31
5.3.5 Double Knife Drive Timing (D60 40’ & Smaller) ...................................... 5-32
5.3.6 Knife Drive Belt Tensioning..................................................................... 5-33
Single Knife................................................................................................. 5-33
Double Knife ............................................................................................... 5-34
D60/FD70/CA20 Section 5: Knife Drive System PAGE 5-1
5.1 KNIFE DRIVE SYSTEM
Single Knife:
The knife on the D60 & FD70 is hydraulically
driven. The hydraulic motor turns a pulley which
drives a belt that is attached to the pulley on the
wobble box.
Figure 5-1: Single Knife & Un-Timed Double Knife
169046 ISSUE DATE 06/06/11

Double Knife: D60 40’ & Smaller (Timed) the pulley on the wobble box. The cross shaft
rides in a grease filled tube to prevent shaft whip
The double knife on the D60 is hydraulically
and provides bearing support of bearing less
driven. The hydraulic motor turns two pulleys.
mid-span section.
One pulley drives a cogged belt that is attached
to a pulley on the wobble box. The second pulley Double knife machines must be timed to prevent
drives a cross shaft. The cross shaft reaches to excessive vibration. If a belt is removed or
the to the other side of the header, it then drives a replaced please follow the timing procedure later
pulley that drives a cogged belt that attaches to in this section.
Figure 5-2: Double Knife D60 40’ and Smaller
169046 ISSUE DATE 06/06/11

Double Knife: FD70 40’ & D60 45’ (Un-Timed)

The double knife on FD70 40’ and D60 45’ is There is no cross shaft on these headers and the
hydraulically driven. There are two hydraulic double knife on these headers does not need to
motors, one on either side of the header. The be timed.
hydraulic motors turn a pulley which drives a belt
that is attached to the pulley on the wobble box.
Figure 5-3: Single Knife & Un-Timed Double Knife
169046 ISSUE DATE 06/06/11

5.2 WOBBLE BOX REMOVAL
Single & Un-Timed Double Knife:

NOTE: A
Procedure will be the same for the RH side of
the un-timed double knife header.
1. Loosen the two (2) bolts (A) that hold the

motor assembly tight to the header end
sheet. (Figure 5-4)
Figure 5-4: Motor Assembly Support
2. Loosen the tension on the belt by turning the

tensioning bolt (B) counterclockwise, this will
loosen the belt that is attached to the wobble
box. (Figure 5-5) When reinstalling the belt,
tighten it so at mid span there is a minimum B
of 0.8” (20mm) deflection using 18lbs.ft C
(24Nm) of force.
Figure 5-5: Belt Tensioning Bolt
3. Once the belt is loose, open the access panel

(C) inside the draper opening, just behind the W
cutterbar. (Figure 5-5)
4. There is a notch (W) cast into the wobble box

pulley, line the belt up with the notch to ease
Figure 5-6: Notched Pulley
with belt removal. Remove the belt. (Figure 5-6)
169046 ISSUE DATE 06/06/11

5. Clean area around the sickle head. Stroke

sickle to its outer limit and remove bolt (E).
(Figure 5-14) When reinstalling the bolt, F
torque to 160 lbf (217 N)
G
6. Remove the grease zerk (F) in the pin. Use a
screwdriver or a chisel in slot (G) to spread
clamp apart to remove sickle head pin.
NOTE:
Groove in pin may be used to pry up on pin.
(Figure 5-14) E
7. By pushing on the end of the sickle head
bearing cup push the sickle in until it is clear
of the drive arm. Figure 5-7: Knife Head Pin Removal
8. Mark drive arm and wobble box shaft to

facilitate re-assembly. L
9. Loosen and remove the bolt (H) clamping the
knife drive arm to the wobble box output shaft.
(Figure 5-15)
10. Remove the knife drive arm from the wobble
box output shaft. X
11. Loosen and remove the four wobble box
mounting bolts (K). (Figure 5-15)
K
NOTE:
Do not remove bolt (X) this is used to position
the knife back clearance in between the H
K
guards.
12. Remove wobble box c/w pulley and place on Figure 5-8: Wobble Box Mounting Bolt Removal
a bench for disassembly.
CAUTION
Wobble box with pulley weighs over 65 lbs
(35 kg). Use care when removing or use an
appropriate lifting device. Lug at (L) can be
used to lift.
Loctite must be used when re-installing drive arm

and/or wobble box pulley, See “Wobble Box
Installation” on page 29. for instructions.
Repeat above steps for R/H side on a 40’ & 45’

D60D and 40’ FD70 with double knife.
169046 ISSUE DATE 06/06/11

Double Knife: Timed

Left Side Wobble Box Removal:
A
1. Loosen the two (2) bolts (A) that hold the
motor assembly tight to the header end
sheet. (Figure 5-9)
Figure 5-9:
2. Release tension on the double belt by turning

the tensioning bolt (B) counterclockwise, this
will loosen the belts that drive the cross shaft.
(Figure 5-10) B
NOTE:
When reinstalling and tensioning the belts,
tighten the timing belt so at mid span there is
a deflection of 1/2” (13mm) using 6lbs.ft (27 Figure 5-10:
Nm), once this is achieved tighten nut (C1).
The tension for the double V belts is 1/8”
(3mm) using 12lbs.ft (53Nm) of force, once
this is achieved tighten two nuts (C2).
C1
3. Loosen the three (3) bolts (C1 & C2) that ten- C2
sion the knife drive pulley belt, then turn the
adjusting screw counterclockwise to release
the tension. (Figure 5-11)
NOTE:
Remember that timing the knives is required Figure 5-11:
for double knife drive headers. See “Double
Knife Drive Timing (D60 40’ & Smaller)” on
page 32.
169046 ISSUE DATE 06/06/11

4. Once the belt is loose, open the access panel

inside the draper opening, just behind the D
5. There is a notch (W) machined into the

wobble box pulley line the belt up with the
notch to ease with belt removal. Remove the
belt. (Figure 5-13)

Figure 5-12: Access Panel
(Figure 5-14) When reinstalling the bolt,
torque to 160 lbf (217 N) W
7. Remove the grease zerk (F) in the pin. Use a

screwdriver or a chisel in slot (G) to spread
NOTE:
Groove in pin may be used to pry up on pin. Figure 5-13: Notched Pulley
(Figure 5-14)
F
8. By pushing on the end of the sickle head

bearing cup push the sickle in until it is clear G
of the drive arm.
9. Mark drive arm and wobble box shaft to

facilitate re-assembly. E
Figure 5-14: Knife Head Pin Removal
169046 ISSUE DATE 06/06/11

10. Loosen and remove the bolt (H) clamping the

(Figure 5-15) L
box output shaft.
mounting bolts (K). (Figure 5-15)
NOTE: X
Do not remove bolt (X) this is used to position
the knife back clearance in between the
guards.
13. Remove wobble box c/w pulley and place on
a bench for disassembly.
K K
CAUTION H
Wobble box c/w pulley weighs over 65 lbs (35 Figure 5-15: Wobble Box Mounting Bolt Removal
kg). Use care when removing or use an
used to lift.
Loctite must be used when re-installing drive arm

and/or wobble box pulley, See “Wobble Box
Installation” on page 29. for instructions.
169046 ISSUE DATE 06/06/11

Right Side Wobble Box Removal:

1. Loosen the two bolts (A) that hold the right hand
side bearing support in place. (Figure 5-17)
Figure 5-16: Right hand Side Double Knife
2. Turn the belt tensioning bolt (B) counterclock-

wise to loosen. (Figure 5-17)
Figure 5-17:
3. Once the belt is loose, open the access panel C

(C) inside the draper opening, just behind the
4. There is a notch machined into the wobble

box pulley line the belt up with the notch to
ease with belt removal. Remove the belt.
Figure 5-18: Access Panel
169046 ISSUE DATE 06/06/11


(Figure 5-14) When reinstalling the bolt, F
torque to 160 lbf (217 N)
6. Remove the grease zerk (F) from the pin. Use
a screwdriver or chisel in slot (G) to spread G
NOTE:
Groove in pin may be used to pry up on pin.
(Figure 5-19)
7. By pushing on the end of the sickle head E
bearing cup push the sickle in until it is clear
of the drive arm.
8. Mark drive arm and wobble box shaft to Figure 5-19: Knife Head Pin Removal
facilitate re-assembly.
9. Loosen and remove the bolt (H) clamping the Z
Remove the pitman arm.
10. Remove the four (4) bolts that hold in the
wobble box to the frame. (Figure 5-20)
11. Using a lifting device, lift the wobble box out
of the header and place it on a work bench.
box output shaft.
mounting bolts (I).(Figure 5-20) X
I
NOTE:
When reinstalling the wobble box bolts (I), H
snug them up first, then tighten the side two Figure 5-20: Wobble Box Mounting Bolt Removal
bolts first, then the bottom two. Torque them
to 200 lbf (270 N)
NOTE:
Do not remove bolt (X) this is used to align
the wobble box.
14. Remove wobble box and place on a bench
for disassembly.
NOTE:
Wobble box c/w pulley weighs over 65 lbs
(35 kg). Use care when removing or use an
appropriate lifting device. Lug at (Z) can
be used to lift.
169046 ISSUE DATE 06/06/11

5.3 KNIFE DRIVE WOBBLE BOX
The Way it Works

The heavy duty oil bath, wobble box uses
tapered roller bearing on the input shaft and yoke
for increased durability. The pulley and drive arm
connections are straight splines with clamping
bolts to insure a tight fit.
The oil level in the wobble box is easily checked
with the dipstick incorporated into the breather.
The function of the wobble box is to convert the Figure 5-21: MacDon Wobble Box
rotational force from the power unit to side to side
cyclical motion. This is done simply by a camshaft.
1. Output Yoke
2. Output Shaft Seal
3. Bronze Bushing
4. Plug
5. Steel Bushing
7. Special Nut
6. Input Shaft
7. 60mm OD Spacer
8. O-ring
9. 60mm Input Shaft Seal
10. Bearing Assembly
11. Oil Drain Plug
12. Nut (M55 x 2) Figure 5-22: Box Assembly (Side View)
13. Breather Plug with Dipstick

15. Nut (M30 X 1.5)
16. Dust Cap
17. Input Shaft Shim
19. Pivot
20. Internal Retaining Ring
21. Bronze Bushing
22. Bolt (M10 X 50mm)
Figure 5-23: Box Assembly (Top View)
169046 ISSUE DATE 06/06/11

5.3.1 WOBBLE BOX REBUILD TOOLS

The MacDon wobble box requires special tools
designed specifically to aid in the tear down and
rebuild of the wobble box. This kit can be obtained
through MacDon parts department, MD # 139003.
The kit consists of:
Kit Items: Quantity:

Special 2
Wrenches
2-Sizes
Threaded Rods 2
3/4” Nuts 18
Pusher Bolts 2
Flat iron 4
supports
169046 ISSUE DATE 06/06/11

5.3.2 WOBBLE BOX DISASSEMBLY

NOTE: B B
Before attempting to rebuild the wobble box
the wobble box rebuild kit MD# 139003 B
should be ordered from MacDon Parts B
Department. B B
1. Mount the wobble box in vise as shown.
B B
2. Loosen and remove the wobble box pulley-
clamping bolt, and remove the wobble box
pulley.
C
3. Remove one of two plugs (13) located at (A) C
and drain oil. (Figure 5-24) (Figure 5-25)
4. Using a 8mm hex key wrench or socket, A
remove the eight hex socket head bolts (B)
A
securing the top half of the wobble box
housing to the bottom half. (Figure 5-24)
5. Separate the top housing from the bottom Figure 5-24: Remove Top Housing
housing, use a hammer chisel and/or screw-
driver to separate the two halves being
careful not to damage the mating surfaces.
Two areas to start are located on each side of
the input shaft opening (C). (Figure 5-24)
6. Remove the dust cap (18) from the housing.
(Figure 5-25)
7. Using a screwdriver or other suitable tool
eliminate the locking deformations from the
input shaft carrier bearing stake nuts (Items 7
and 17). (Figure 5-25)
NOTE:
You may need to drill out the locking nut
deformations. See step 8.
Figure 5-25: Side View
169046 ISSUE DATE 06/06/11

8. It is acceptable to drill out the dimple that is

used to lock the stake nuts in place. Do this to
stake nuts (7 and 17) (Figure 5-26)
9. Place a block of wood into the housing to pre-

vent yoke movement. (Figure 5-28)
10. Remove the two stake nuts (7 and 17) using

the wrenches provided in the kit. (Figure 5-
26) (Figure 5-28)
Figure 5-27: Remove 2 Stake Nuts

11. Remove the input shaft seal (11). (Figure 5-29)
Figure 5-28: Remove 2 Stake Nuts
Figure 5-26: Box Assembly (Side View)
Figure 5-29: Remove Input Shaft Seal
169046 ISSUE DATE 06/06/11

12. Remove the spacer plate and O-ring (9 and

10). (Figure 5-30)
13. Clamp the output yoke into the vice, so that

the output shaft is aimed down. (Figure 5-31)
14. Using a bearing puller, remove the input shaft

Figure 5-31: Input Shaft Bearing Removal

15. Now remove the bearing on the opposite side
of the input shaft. (Figure 5-32)
Figure 5-32: Input shaft Bearing
169046 ISSUE DATE 06/06/11

16. Remove retaining rings (22) which retains the

bronze yoke bushings (23). Do this to both
sides of the yoke. (Figure 5-33) (Figure 5-34)
Figure 5-34: Removal of the Retaining Ring
Figure 5-33: Box Assembly (Top)
17. Tap out the pivot pins (21), using a hammer

and a brass drift, push bushing (23) as far as
possible (approximately 1/2 way out). Repeat
at opposite side. (Figure 5-33) (Figure 5-35)
18. Remove both of the bushings completely. Be
care not to damage pivot pin or yoke.
Figure 5-35: Tap Out Pivot Pins
(Figure 5-36)
19. Separate the output shaft (1) from the input
shaft assembly.
Figure 5-36: Separate Shafts
169046 ISSUE DATE 06/06/11

20. Drill out the dimple that locks the stake nut in
place. (14). (Figure 5-37) (Figure 5-38)
Figure 5-38: Eliminate Deformations
21. Remove the stake nut using a hammer and

chisel. (Figure 5-39)
22. Remove the bearing cone and pivot ring (21)
from the input shaft. (Figure 5-33) (Figure 5-40)
23. Remove the remaining bearing cone (20) from
the input shaft. (Figure 5-33) (Figure 5-40)
Figure 5-39: Remove Stake Nut
Figure 5-40: Remove Bearings
169046 ISSUE DATE 06/06/11

24. Use a chisel or punch and push the bearing

races out of the pivot ring. (Figure 5-41)
Figure 5-41: Bearing Race Removal
25. Remove the output shaft seal (2) from the lower
half of the wobble box case, and using a 2 1/8 in
(54 MM.) outside diameter sleeve press the
output shaft bushings (3 and 5) out of the case.
(Figure 5-42)
NOTE:
It is recommended to replace all bearings,
races, & bushings upon reassembly.
169046 ISSUE DATE 06/06/11

5.3.3 WOBBLE BOX RE-ASSEMBLY

1. Heat bearing cones (20) to around 80°C
(176°F) in oil.
2. Using a 2 1/8 in (54 MM.) OD shaft or pipe, push
the bottom bushing (3) into the housing, making
certain to orientate the mark on the bushing as
shown. Push bushing in till flush with seal stop.
Figure 5-45: Cut out on the Lower Bushing

3. Using a sleeve, push the upper bushing (5)

into the housing, making certain to orientate
the mark on the bushing as shown. The
bushing must be pushed 13/64 in (5 MM.)
below the surface of the casting. (Figure 5-43)
Figure 5-44: Box Assembly (Top) Figure 5-46: Cut out in the Upper Bushing
169046 ISSUE DATE 06/06/11

4. Install two bearing races (20) into the pivot

ring (21). (Figure 5-47)
Figure 5-48: Install Bearing Cone
5. Install shims (19) at (F) onto shaft (8). Install

bearing cone (20). (Figure 5-47) G
6. Install the pivot ring (G) onto the input shaft
(8) making certain the face marked with a
machined groove is towards the shoulder
(facing shims) of the shaft. Install the second
bearing onto the shaft. (Figure 5-43)
(Figure 5-49)
7. Install nut (14) onto shaft using Loctite® 270 Figure 5-49: Install Second Bearing
or 271, tighten nut to achieve a pre-load
which produces a rolling torque of 9-13lbf.in
(1-1.5Nm). (Figure 5-43) (Figure 5-50)
NOTE:
See step 8 to check rolling torque/rolling
torque.
Figure 5-50: Install Nut
169046 ISSUE DATE 06/06/11

8. To determine pre-load place a small key (H)

in shaft cut out. (Figure 5-52)
Figure 5-52: Place Key into Keyway
9. Use a 1 3/16 socket on a torque wrench

(lbf.in) and place the key so that it will enter
one of the points of the socket. This method
will be adequate for testing this very low
torque.
Figure 5-53: Test Rolling Torque
10. Mount in vise as shown and test rolling

torque. It should be 9-13lbf.in (1-1.5Nm)
(Figure 5-53)
169046 ISSUE DATE 06/06/11

11. When the rolling torque requirement has

been satisfied, use a punch and deform the
nut as shown. This will lock the bearing in
place. (Figure 5-55)
Figure 5-55: Deform Nut
12. Lubricate the outer diameter of the bushings

(23) with Molykote grease (I), position pivot
ring (21) into the yoke of the output shaft (1),
then using a sleeve or socket insert bushings
(23) into the yoke arms until the snap ring
groove is visible. Install retaining clips (22).
Figure 5-56: Lubricate Bushings
Using brass drift tap the pivot pins to set
bushings against retaining clips. (Figure 5-
56)
13. Install the input shaft carrier bearing assem-

blies, cups and cones (12 & 16) onto the input
shaft (8). Do not slide all the way on as they
will need to be set into the housing.
Figure 5-57: Install Shaft Assembly
169046 ISSUE DATE 06/06/11

14. Position the lower housing in a vice or other

suitable support for further assembly.
(Figure 5-58)
15. Lubricate the two bushing contact surfaces
on the output shaft using Molykote grease,
then insert the shaft assembly into the
lower housing.
Figure 5-58: Position Housing On Vise
16. Push the bearing races on the input shaft car-

rier bearings in contact with the shoulder on
the housing, then push the cones in contact
with the bearing races.
17. Install the O-ring (10) and spacer (9) onto the
shaft, use adhesive tape over the threads to
prevent damage to the O-ring. (Figure 5-59)
Figure 5-59: Install The O-ring

18. Install top housing onto the lower housing
aligning the dowel pins. This is to make sure
everything lines up before applying silicone.
IMPORTANT
Do not use the bolts to pull the two halves of
the wobble box together if it does not fit
together easily disassemble to find the cause
of interference before proceeding.
169046 ISSUE DATE 06/06/11

19. Seal box mating surface as shown using a

RTV sealing compound such as Silastic RTV
732 or General Electric Silimate RTV.
No.1437 (Figure 5-61)
Figure 5-61: Silicone Mating Surface
20. Install the eight housing bolts finger tight, Use

Loctite® 270 or 271.
21. Check that bearing cups (12 & 16) are fully
seated. (Figure 5-60)
22. Torque housing bolts to 85-95 lbf.in (9.5-11Nm). Figure 5-62: Bolt Down Housing
23. Set up jig as shown and clamp to wobble box.
(Figure 5-63)
Figure 5-63: Set Up Jig
169046 ISSUE DATE 06/06/11

24. Use wobble box drive arm (A) to hold the

splined shaft from turning when tightening
nuts in the following steps. (Figure 5-64)
IMPORTANT
Steps 25-30 must be completed before Loctite®
sets.
25. Install nuts (7 and 17) using Loctite® 270 or
262. Finger tight only, do not allow nut to
contact the cone bearing at this time.
(Figure 5-60)
Figure 5-64: Wobble Box Arm Installed
169046 ISSUE DATE 06/06/11

26. It is critical that both pressure bolts (K) contact

the shaft at the center (J). (Figure 5-66)
27. Grease threads and tip of bolt (K).
(Figure 5-66)
K
J
Figure 5-66: Contact Shaft At Center
28. Place both wrenches provided in kit on nuts

(7 and 17). (Figure 5-65)
29. Apply 200lbf.in (22.8Nm) torque to bolt (K),
pushing on input shaft (8) at (J). Mount dial Figure 5-67: Tighten Bolts
indicator and zero in on face of the input
shaft (8). (Figure 5-65) (Figure 5-66)
30. Remove the thrust load from the input end of
the shaft (8) and apply the same load 200lbf.in
(22.8Nm) to the backside of the shaft, take a
reading on the dial gauge. (Figure 5-65)
IMPORTANT
Take care not to disturb dial indicator with
wrench while tightening nut (7).
169046 ISSUE DATE 06/06/11

31. Turn the nut (7) using wrench provided until

half of the play is taken up, then take up an
additional 0.001 in (0.04 MM.). (Figure 5-68)
(Figure 5-69)
32. Maintaining the load on the input shaft turn the
nut (17) until the additional 0.001 in (0.04 MM.)
is taken up, this will insure that the pivot yoke
is centered perfectly in the yoke. Deform the
stake nuts (7 & 17), using a punch, at the
slotted area of the shaft. (Figure 5-68)
33. Grease the lips of the shaft seal and install
the input and output shaft seals use adhesive
tape on the output shaft to prevent damage to
the seal. (Figure 5-70)
Figure 5-69: Tightening Stake Nuts
Figure 5-70: Install Seals
34. Grease and install dust cap (18) into the

housing. (Figure 5-68) (Figure 5-71)
Figure 5-71: Install Dust Cap
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35. Install the oil drain plug into the lower housing
and fill the box with the correct amount of oil
SAE 85W-140 (API Service Classification GL-
5) (2.3 qt. (US) (2.2L)) checking with the dip-
stick (15). (Figure 5-74)
Figure 5-73: Install Dipstick
IMPORTANT
When checking the oil level make certain the Figure 5-74: Complete Wobble Box
base of the box is level and that the level of
the oil is between the two holes on the dip-
stick.
36. Install the dipstick/breather into the housing, make
sure the oil level is between the holes on the dip-
stick before tightening. (Figure 5-73)
169046 ISSUE DATE 06/06/11

5.3.4 WOBBLE BOX INSTALLATION

Before installing the wobble box onto the header
install the pulley onto the wobble box. If the
pulley was not removed, then proceed to step 4.
1. Ensure splines and bores in pulley or drive
arm are free of paint oil and solvents.
2. Apply 2 bands of Loctite® #243 (C) on pulley
shaft. (Figure 5-75)
3. Push pulley on until flush with end of shaft and
insert 5/8 X 3 in. hex head bolt with distorted
thread NC locknut and torque to 160 lbf (217
N). (Figure 5-75)
CAUTION
Wobble box c/w pulley weighs over 65 lbs Figure 5-75: Pulley Location
(35 kg). Use care when installing or use an
used to lift. (Figure 5-76) L
4. Place wobble box into position on header
mount, placing belt around pulley and install
5/8 X 1.5" grade 8 hex head bolts to mount
wobble box to frame.
5. Tighten the four (4) mounting bolts (M) gradu- X
ally to ensure proper contact with vertical and M
horizontal mounting surfaces. Leave the bolts
loose enough to adjust the wobble box fore-
aft in step 10.
6. Apply Loctite® #243 to the output shaft in 2
bands as shown at (C) and slide arm onto
shaft. Rotate pulley to ensure drive arm just
clears frame on inboard stroke to ensure
proper placement on splines. (Figure 5-76)
Figure 5-76: Add Loctite®
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7. Position drive arm at furthest outboard posi-

tion. Move drive arm up or down on splined
shaft until it almost contacts knife head at (A) L
(0.010" or 0.254 MM. gap) while making sure
knife is laying flat on ledger surface of first
few guards. Torque 5/8 X 3 in. hex head bolt
to 160 lbf (217 N). at (B) to secure arm on
spline. (Figure 5-76)
X
8. Install knifehead pin and align groove in knife- M
head pin just above top of casting. Install 5/8
X 3 in. hex head bolt and torque to 160 lbf
(217 N).
9. If (X) has been removed shims can be added
to adjust wobble box squareness, align
wobble box pulley with drive pulley.
10. Adjust wobble box fore-aft bolt (X) to center
knife back within guard.
11. Position the pitman arm in mid stroke, check
the gap (N) between the front of the guard
and the knife back. Make sure they are not Figure 5-77: Add Loctite®
contacting each other. If they do, adjust the
wobble box rearward.
12. Torque side bolts first and then bolts through
the bottom to 200 lbf (271 N).
13. Then tighten up the wobble box locating tab
(X). (Figure 5-77)
NOTE:
Remove grease zerk when removing or N
installing knifehead pin.
Figure 5-78: Gap between Guard and Knife Back.
IMPORTANT
Grease knifehead just enough to start a slight
downward movement of knifehead. Over
greasing will cause knife to heat at guards
and cause undue loading.
14. Install the knife drive belt and the double belts
onto the pulleys. Leave them loose. See
“Knife Drive Belt Tensioning” on page 33.
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Wobble box Squareness

1. Using a straight edge along the face of the
wobble box pulley. Measure point “A” & point Straight Edge
“B”. Points to be measured can be around
39.4” (1000mm) apart. See if they are the X
same within 0.12” (3mm) of each other.
NOTE: X
There could be some deformation in the end “Point B”
panel, if difference seems too large.
“Point A”
2. If the dimensions are more than 0.2” (5mm)

apart, you may need to shim the wobble box.
(Figure 5-79)
3. Remove the four bolts that secure the wobble Figure 5-79: Check Pulley Alignment
box to the frame.
4. Shim the wobble box accordingly to align the

pulley. Manufacture a shim that is shaped like
the letter “n”, so it will fit over the bolt that
secures the wobble box to the frame.
(Figure 5-80)
5. See “Knife Drive Belt Tensioning” on page 33.

for bolt reinstallation instructions.
6. Once bolts are tight check squareness again.
7. See “Knife Drive Belt Tensioning” on page 33. Figure 5-80: Shim Installation Location
169046 ISSUE DATE 06/06/11

5.3.5 DOUBLE KNIFE DRIVE TIMING (D60 40’ & SMALLER)

Double knife D60 harvest headers require that
the sickles are properly timed to move in
opposite directions. To adjust the sickle timing,
refer to following illustrations and proceed as
follows:
NOTE:
Remove the belt on the R/H side, this must A
be done in order to properly time the knives.
1. Rotate the left wobble box driven pulley (A)
clockwise until the left sickle (B) is at the
centre of the inboard stoke (moving towards
centre of header). (Figure 5-81) (Figure 5-83)
NOTE:
Centre stroke is when the sickle sections are
centered between guard points as shown.
(Figure 5-83) Figure 5-81: Rotating Wobble Box Pulley on LH Side
2. Rotate the right wobble box pulley (C)

counterclockwise until the right sickle (D) is at
the centre of the inboard stroke.
3. Install the R/H Belt and apply some tension,
so the belt does not slip. C
IMPORTANT
To maintain timing, wobble box driver and
driven pulleys must not rotate as the belt is
tightened.
4. Check that the timing belts are properly
seated in the grooves on both driver and
driven pulleys.
Figure 5-82: Rotating Wobble Box Pulley on R/H Side
5. Check for correct sickle timing by rotating the
drive slowly by hand and observe sickles
where they overlap at the centre of the
header.
NOTE:
If right sickle “leads” left sickle, rotate RIGHT
SIDE driven pulley (C) clockwise. If right
sickle “lags” left sickle, rotate RIGHT SIDE
B D
driven pulley (C) counterclockwise.
6. Once the knives are lined up, tension the
belts according to the notes in the double Figure 5-83: Timing of the Knives
knife wobble box removal section.
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5.3.6 KNIFE DRIVE BELT TENSIONING
Single Knife:
IMPORTANT
To prolong belt and drive life, do not over-
tighten belt.
1. Loosen two bolts (E) on sickle drive mounting E

bracket.
G F
2. Turn adjuster bolt (F) to move drive motor
until a force of 20 lbf (80 N) deflects belt (G)
3/4” (18mm) at mid-span. Figure 5-84:
3. Tighten jam-nut at (F) and bolts (E) on drive

mounting bracket. (Figure 5-84)
H
4. Check clearance between belt (G) and belt

guide (H). The measurement should be 0.04”
(1mm). (Figure 5-85) G
5. Loosen bolts (J) and adjust position of guide

(H) as required. (Figure 5-85) J
6. Tighten bolts (J). (Figure 5-85) Figure 5-85:
7. Re-adjust tension of a new belt after a short

run in period, (about 5 hours).
169046 ISSUE DATE 06/06/11

Double Knife:
LH Side: O
8. Locate the grease zerk (O) on the back tube,
that greases the cross shaft tube, there is one
per side. Check the location of the bolt in the
slot. The LH bolt should be near the centre of
the slot and the RH bolt should be near the
front of the slot. Torque the nuts to 230-
250lbs.ft (312-339Nm) (Figure 5-86)
Figure 5-86: Check Grease Zerk Bolt Location
9. Adjust bolt (P) to move the knife drive pulley.

The pulley may need to be pushed forward
manually. (Figure 5-88)
NOTE: P
The following is important to belt alignment.
Follow instructions carefully.
Figure 5-87: Knife Drive Belt Tensioning Bolt
This adjustment will “toe in” the knife drive

pulley, so the pulley will be aligned after the
belts are tensioned. Use a straight edge
across the face of the double pulley bolted to
the knife drive pulley. (Figure 5-88)
Measure the difference between point “A”

and “B”. Point “B” should be 0.16” (4mm)
less than point “A”. (Dimension is measured
from straight edge to end panel.)
Figure 5-88: Measure “Toe In” Setting
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10. Tighten nut (Q) to retain the initial pulley set-

ting. (Figure 5-89)
Figure 5-89: Tighten Nut on Pulley Setting
11. Tighten bolt (P) to tension double v belts.

Correct tension is checked at mid span of the S
belts. They should deflect 0.12” (3mm) with
12lbs.ft (53Nm) of force.
12. Tighten bolts (S) and (T) to lock in the double T

v belt setting. (Figure 5-90) P
13. Locate the knife drive belt idler pulley, rotate Figure 5-90: Tighten Nut on Pulley Setting
the bracket down and slide the idler pulley up
by hand to remove most of the belt slack. W
Tighten nut (V). (Figure 5-91)
Slot
14. Rotate the bracket up using a long punch in for
punch
the slot to obtain the proper tension. Belt ten-
sion is checked at mid span of the belt. It
should deflect 0.51” (13mm) at 6 lbs.ft V
(24Nm). (Figure 5-91)
15. Tighten bolts (W), that secure the idler Figure 5-91: Idler Pulley Alignment
bracket to the end frame. (Figure 5-91)
169046 ISSUE DATE 06/06/11

16. Check idler pulley alignment. Place a 12”

(300mm) straight edge on the idler pulley hor-
izontally & vertically. Measure from the
straight edge to the frame. Pulley should be
parallel to the frame in both directions within Align
0.08” (2mm). If pulley adjustment is required,
use a deep socket and extension on nut “V”
to do the adjustment. (Figure 5-92)
V
Align
Figure 5-92: Idler Pulley Alignment Using Straight Edge
17. After the double V and timing belts are ten-

sioned re-check drive pulley alignment with a
straight edge. Dimensions at points “A” and
“B” should be the same within 0.12” (3mm). If
not go back to step 9 and re-adjust the fore
aft position of the drive pulley, this will change
the “toe in/toe out” dimension of the pulley.
(Figure 5-90) (Figure 5-93)
18. Loosen bolts (X) and adjust belt guide

bracket (M). It should set so there is 0.02-
0.06” (0.5-1.5mm) between the belt and the
guide. (Figure 5-94)
Figure 5-93: Check Pulley Setting
19. Run up the header and ensure belt is tracking
correctly. If not shut down the header and
adjust pulleys as required.
NOTE: M
Belt should run completely on wobble box
sprocket and should not tend to ride up on
flanges of driving sprocket or idler pulley. If it
does not then, you may need to adjust the X
idler pulley or the driving pulley. Use a deep
socket and extension on nut “V” to do the Figure 5-94: Belt Guide Adjustment
adjustment. (Figure 5-92)
169046 ISSUE DATE 06/06/11

RH Side:
NOTE:
If you have removed the belt, ensure the
knifes are timed. See “Double Knife Drive
Timing (D60 40’ & Smaller)” on page 32
20. Locate the grease zerk (O) on the back tube,
that greases the cross shaft tube, there is one
per side. Check the location of the bolt in the
slot. The LH bolt should be near the centre of
the slot and the RH bolt should be near the O
front of the slot. Torque the nuts to 230-
250lbs.ft (312-339Nm) (Figure 5-95) Figure 5-95: RH Grease Zerk Bolt Location
21. Adjust bolt (B) to move the knife drive pulley.

The pulley may need to be pushed forward
manually.
NOTE:
The following is important to belt alignment
follow instructions carefully.
B
This adjustment will “toe out” the knife drive
pulley. so the pulley will be aligned after the
belts are tensioned. Use a straight edge Figure 5-96: Tighten Knife Drive Tensioning Bolt
across the face of the double pulley bolted to
the knife drive pulley. (Figure 5-97)
Measure the difference between point “A”

and “B”. Point “B” should be 0.12” (3mm)
greater than point “A”. (Dimension is mea-
sured from straight edge to end panel.)
Figure 5-97: Measure “Toe Out” Setting
169046 ISSUE DATE 06/06/11

22. Tighten nuts (Y) to retain the pulley setting.

(Figure 5-98)
23. Locate the knife drive belt idler pulley, rotate it Figure 5-98: Tighten Nut on Pulley Setting
down and slide the idler pulley up by hand to
remove most of the belt slack. (Figure 5-99)
A
24. Rotate the bracket up using a long punch in Slot

the slot to obtain the proper tension. Tighten for
punch
bolt (Z). Belt tension is checked at mid span
of the belt. It should deflect 0.51” (13mm) at
6lbs.ft (24Nm). (Figure 5-99)
Z
Figure 5-99: Tighten Idler Pulley Setting
25. Tighten bolts (A) that secure the idler bracket

to the end frame. (Figure 5-99)
Align
26. Check idler pulley alignment. Place a 12”
(300mm) straight edge on the idler pulley hor-
izontally & vertically. Measure from the
straight edge to the frame. Pulley should be
parallel to the frame in both directions within Align
0.08” (2mm). If pulley adjustment is required,
use a deep socket and extension on nut “Z” Figure 5-100: Idler Pulley Alignment
to do the adjustment. (Figure 5-100)
169046 ISSUE DATE 06/06/11

27. Re-check pulley alignment with a straight

edge. Dimensions at points “A” and “B” should
be the same within 0.12” (3mm). If not go back
to step 21 and re-adjust bolt (B), this will
change the “toe in/toe out” dimension of the
pulley. (Figure 5-96) (Figure 5-101)
Figure 5-101: Re check “Toe Out” Setting
28. Loosen bolts (X) and adjust belt guide

bracket (M). It should set so there is 0.02-
0.06” (0.5-1.5mm) between the belt and the
guide. (Figure 5-102) M
29. Run up the header and ensure belt is tracking X

correctly. If not shut down the header and
adjust pulleys as required. Figure 5-102: Belt Guide Adjustment
30. Re-adjust tension of a new belt after a short

run in period, (about 5 hours).
NOTE:
Belt should run completely on wobble box
sprocket and should not tend to ride up on V
flanges of driving sprocket or idler pulley. If it
does not then, you may need to adjust the
idler pulley or the driving pulley. Use a deep
socket and extension on nut “V” to do the
adjustment. Figure 5-103: Idler Pulley Adjustment
169046 ISSUE DATE 06/06/11

SECTION 6: ADAPTER DRIVE
D60/FD70/CA20 TOC
Section 6: Adapter Drive

6.1 Adapter Gearbox ............................................................................................... 6-1
6.1.1 2011 and Prior........................................................................................... 6-1
Prepare to Remove Gearbox:....................................................................... 6-1
Disassembly ................................................................................................. 6-5
Reassembly: ................................................................................................. 6-9
6.1.2 2012 and newer ...................................................................................... 6-18
Prepare to Remove Gearbox...................................................................... 6-18
Disassembly ............................................................................................... 6-22
Reassembly ................................................................................................ 6-29
Cover: ......................................................................................................... 6-32
Housing:...................................................................................................... 6-33
6.2 Feed Auger...................................................................................................... 6-38
Removal:..................................................................................................... 6-38
Reinstallation .............................................................................................. 6-43
Feed Auger Repair ..................................................................................... 6-44
Feed Auger Internal Repair ........................................................................ 6-47
Disassembly ............................................................................................... 6-47
RH Finger Assembly Support Repair.......................................................... 6-49
RH Finger Assembly Support Reassembly ................................................ 6-51
Feed Auger Clutch Repair .......................................................................... 6-53
Clutch Reassembly..................................................................................... 6-55
D60/FD70/CA20 Section 6: Adapter Drive PAGE 6-1
6.1 ADAPTER GEARBOX

6.1.1 2011 AND PRIOR
Prepare to Remove Gearbox:
1. Remove the CA20 from the D series header; Q

refer to Combine Header Operators manual
for this procedure.
2. Loosen nut (Q) and move bolt out of working

position slot. Rotate gearbox down until drain
Figure 6-1:
(A) is at lowest point. (Figure 6-1)
3. Place a suitable container underneath the

gearbox, this should collect any grease or oil
from the gearbox. Remove bolt (A) and drain
gearbox. (Figure 6-2)
Figure 6-2:
B
4. Remove, mark and cap the hoses (B) from
the knife drive pump and the draper pump cir-
cuit both front and back sides. (Figure 6-3)
Figure 6-3:
169046 ISSUE DATE 04/03/18

5. Remove the driveline from the gearbox.
6. Remove bolt (X) securing brace (Z) to

gearbox and lower brace away from gearbox.
Figure 6-4: Gearbox Support Removal
7. Attach a lifting strap to the gearbox to assist

in lifting the gear box safely from the adapter.
Figure 6-5:
8. Locate the drive cover, remove the upper
cover to gain access to the idler sprocket.
D
Loosen nut (D) to remove the tension from
the chain and auger drive sprocket.
9. Remove the sprocket. Pay close attention on

how the sprocket was installed. The shoulder
of the sprocket is facing the flighting on the
retractable tine drum. (Figure 6-6)
Figure 6-6:
169046 ISSUE DATE 04/03/18

10. Loosen hardware (E) from clamp plate that

secures drive shaft into the retractable tine
drum drive case and rotate upward.
(Figure 6-7)
E
NOTE:
Float springs have been removed for clarity.
Figure 6-7:
11. Undo spring tension (G) on both sides of the

retractable tine drum. This will make it easier
to pull out the driveline/gear case from the
Figure 6-8:
12. Secure retractable tine drum with a strap (H)

around the back of the adapter frame.
(Figure 6-9)
Figure 6-9:
169046 ISSUE DATE 04/03/18

13. Remove clamp (J) two places, that secures

the drive shaft tube to the adapter. (Figure 6-
10) (Figure 6-11)
Figure 6-10: RH Clamp Removal

14. Slide gearbox assembly out from adapter.
Figure 6-11: LH Clamp Removal
169046 ISSUE DATE 04/03/18

Disassembly:
1. Before working on the adapter gearbox,
remove the drain plug (A) and drain all the oil.
(Figure 6-12)
2. Remove the 12 bolts (C) that hold the

clamping plate and cover to the gearbox
housing. (Figure 6-13)
Figure 6-12: Draining Oil from Gearbox
3. Remove the clamping plate, cover and rubber

gasket from the gearbox housing.
Figure 6-13: Removing Cover and Rubber Seal

4. Remove the fill plug (D) from the gearbox
housing to access the chain tensioning bolt. E
(Figure 6-14)
D
5. Remove compression spring (E) and lock (F) F

from the head of the chain tensioning bolt.
(Figure 6-14) Figure 6-14: Removing Fill Plug and Locking Mecha-
nism
169046 ISSUE DATE 04/03/18

6. Loosen bolt (I) this will remove any tension

that is on the chain.
I
NOTE:
If you are only replacing the chain, go to step
9. Z
J
7. To remove the chain tensioner (Z), remove

bolt (J) (the nut is located on the outside of
the housing). Remove the chain tensioner
bolt (I). The chain tensioner assembly (Z) c/w
sprocket, should now slide off the spacer
tube. (Figure 6-15)
Figure 6-15: Chain Tensioner Parts Removal
8. There should be enough slack in the chain to

remove it now. There is no connecting link in K
the chain as it is an endless chain. (Figure 6-
16)
9. Loosen the jam nuts and set screws (K) that

secures the clutch assembly. (Figure 6-16)
Figure 6-16: Chain & Clutch Removal
10. Remove the clutch assembly. (Figure 6-17)

NOTE:
Clutch assembly is not serviceable. The
assembly must be replaced.
Figure 6-17: Clutch Removal
169046 ISSUE DATE 04/03/18

11. If removing the shaft, loosen the locking

collar. Unlock the collar by turning it in the
opposite direction of the shaft rotation.
(Figure 6-18)
NOTE:
If removing the driveline input shaft, you
should remove the input driveline from the Figure 6-18: Loosening Locking Collar
shaft.
12. Remove the nut (L) that holds the pinion in M

place. Then slide the pinion off the motor
13. If removing the pump also, loosen the two

bolts that hold it to the outside of the gearbox
housing.
Figure 6-19: Pinion and Gear Removal

14. Remove the two nuts (M) that secure the
gear to the shaft. Then slide the gear off the
shaft. (Figure 6-19) O
N
15. Remove the key (N) and washer (O) from the P
shaft. Remove the shaft (P) by sliding it out of
the housing. (Figure 6-20)
Shaft Removal Direction
Figure 6-20: Remove the Gear Shaft and Key
169046 ISSUE DATE 04/03/18

16. Remove bearing from the housing. Check

bearing races for wear, replace as required.
(Figure 6-21)
OUTER
Figure 6-21: Bearing Removal
17. Remove the feed auger drive shaft, check

bearings for wear, replace as required.
Figure 6-22: Drive Shaft Removal
169046 ISSUE DATE 04/03/18

Reassembly:
Figure 6-23: Complete Gearbox Break Down
169046 ISSUE DATE 04/03/18

Figure 6-24: Gearbox Parts Listing
169046 ISSUE DATE 04/03/18

1. Clamp the gearbox housing onto a table or

stand. Clean off any paint or debris that might
still be on the housing (A) with a suitable
cleaner. (Figure 6-26)
2. If installing a new housing (1), you will need

to grease the feed auger drive tube. Do this
by tieing wire to a rag and coating it in
grease. Then pull it through the clutch tube to
get a layer of grease in there. (Figure 6-25)
Figure 6-25: Greasing Clutch Tube

3. Check the two bearing cups (5). Replace
cups if either cone bearings are being
replaced. (Figure 6-26)
A
INNER
OUTER
Figure 6-26: Gearbox Housing Clamped
4. Install the cone bearings into the bearing

cups. Outer cone bearing (6) c/w seals.
(Figure 6-27)
OUTER
Figure 6-27: Installing Grease
169046 ISSUE DATE 04/03/18

5. Insert the gear shaft (B) into the gearbox

housing, the threaded end should be towards
the inside of the gearbox. Then install the C
washer (C), then the key (D). (Figure 6-28) D
Figure 6-28: Install Gear Shaft and Key
E
6. Install the gear (E) onto the shaft. (Figure 6-29)
7. Install the sprocket (F) onto the gear. Torque

the bolts to 35 lbs.ft (48 Nm). (Figure 6-29)
NOTE:
Ensure you are installing the correct sprocket
required for your particular model of combine.
Figure 6-29: Install Sprocket
See the CA20 parts catalog for sprocket
options.
F
G
8. Thread nut (G) onto the threaded shaft. Make
sure that the nut threads on easily. Torque the
nut to 70-75 lbs.ft (94.5-101.7 Nm). Back it off H
one turn, then re-torque to 2-5 lbs.ft (2.7-6.8
Nm).
9. Check the rolling resistance on shaft (B). If

drag is greater than 5lbs.in (0.56Nm) tap the
splined end of the shaft to reseat the bearings.
Then re-torque as in step 8. (Figure 6-28) Figure 6-30: Installing Nuts
10. If rolling resistance is less than 5lb.in

(0.56Nm) then install locking nut (H), holding
the first nut (G) and shaft, torque the locking
nut to 110-140 lbs.ft (149-190 Nm). (Figure 6-
30)
169046 ISSUE DATE 04/03/18

11. Remove the gearbox housing from the clamp,

lay it on a table so the tube sticks straight up
in the air. Re-clamp it to the table. Run a bead
of silicone (I) around the pump mount hole.
(Figure 6-31)
Figure 6-31: Apply Silicone to Motor Mount
12. Install the pump. Apply silicone to the bolts (J)

and torque bolts to 80-90lbs.ft (108-122Nm)
(Figure 6-32)
J
Figure 6-32: Install Motor Mount Bolts
13. Install the pinion gear (12). Brush oil onto the
threads, tighten nut and lock washer (K) to K
140lbs.ft (190Nm). (Figure 6-33)
Figure 6-33: Install Pinion Gear
169046 ISSUE DATE 04/03/18

14. Install the bearings into the feed auger drive

shaft tube. Use a pry bar to align the bearing
in the tube. Do this to both ends of the tube.
(Figure 6-34)
NOTE:
Locking collar is only required for inner
bearing.
Figure 6-34: Bearing Alignment
15. Apply a thin film of grease to the feed auger

drive shaft, then insert it into the tube, so that
the splined end is away from the gearbox.
(Figure 6-35)
Figure 6-35: Drive Shaft Installation
16. Measure the amount of splined shaft sticking

out the end of the feed auger drive tube. Set
this measurement to 2.02” (51.4 mm)
Figure 6-36: Measuring Shaft
169046 ISSUE DATE 04/03/18

17. Install the locking collar on the inner bearing

of the feed auger drive shaft. Lock the collar
in the direction of forward rotation, then
tighten the set screws. (Figure 6-37)
Figure 6-37: Tightening Locking Collar
18. Install the key (L) onto the shaft, then install the M
clutch assembly (M). If you replaced the L
sprocket on the clutch, torque the bolts to 35
lbs.ft (47 Nm). (Figure 6-32)
NOTE:
Clutch rated at 370-425lbs.ft (4500-5100
lbs.in)
19. Line up the two sprockets and add loctite®

243 to the set screws. Torque the set screws Figure 6-38: Clutch Installation
(N) to 35lbs.ft (47Nm). Then tighten the jam
nuts. (Figure 6-38)
NOTE:
Sprockets must be lined up within ±1mm. It
would be recommended to turn the sprockets
and take an average as the sprockets may N
not be true.
20. Install the chain over the two sprockets, there

is no connecting link as the chain is endless.
(Figure 6-39)
Figure 6-39: Chain Installation
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21. Install the chain tensioner pivot tube (O), then

the chain tensioner (P), then the tension
adjustment shaft and bolt (Q). P
22. Install the tensioner retaining bolt (R), then

install the idler sprocket (S) onto the tension
adjustment shaft. Tighten the chain, so it has Figure 6-40: Chain Tensioner Parts Installation
0.24” (6 mm) of play. (Figure 6-41)
R
NOTE:
Before installing the nut on the tensioner
retaining bolt, make sure to use silicone
S
around the threads to prevent leaks.
23. Insert the chain tensioner bolt lock (T), then

the spring (U), and then install the plug Figure 6-41: Chain Idler and Pin Installation
complete with o-ring. (Figure 6-42)
NOTE:
When installing the chain tensioner bolt lock,
you will need to align the bolt head with the
T
pattern that has been cut into the lock
Figure 6-42: Installing Locking Hardware
169046 ISSUE DATE 04/03/18

24. Clean the gearbox flange on the gearbox and

plastic cover with isopropyl alcohol. Wait for
isopropyl alcohol to dry before assembling.
25. Lightly sand area “A” to remove paint gloss.

Place a 5-8 mm bead of silicone around the
filler spout as shown. Apply silicone to
gearbox flange and to plastic cover.
(Figure 6-44).
Figure 6-43: Area to be Sanded and Siliconed
26. Place the clamping plate around the plastic

cover. Lay the rubber gasket on the plastic
gearbox cover with the holes aligned. Lift the
clamping plate and push the bolts through the
plate, plastic cover and rubber gasket.
(Figure 6-45)
27. Install the cover onto the gearbox install the two Figure 6-44: Silicone Application
bolts around the filler spout first. Then install the
rest of the bolts and nuts around the gearbox.
Tighten plastic cover hardware until the gasket Rubber Seal
just begins to squeeze out. (Figure 6-45)
IMPORTANT
Allow 2 hour to cure at room temperature. Plastic Cover
28. Fill with 2.5 liters of 85W 140 oil. Clamping Plate
Figure 6-45: Sub Assembling the Cover
169046 ISSUE DATE 04/03/18

6.1.2 2012 AND NEWER
Prepare to Remove Gearbox:
1. Remove the CA20 from the D series header;

refer to Combine Header Operators manual
for this procedure. Q
2. Loosen nut (Q) and move bolt out of working

position slot. Rotate gearbox down until drain
(A) is at lowest point. (Figure 6-1)
Figure 6-46:
3. Place a suitable container underneath the

gearbox, this should collect any grease or oil
from the gearbox. Remove bolt (A) and drain
Figure 6-47:
4. Remove, mark and cap the hoses (B) from B

the knife drive pump and the draper pump cir-
cuit both front and back sides. (Figure 6-3)
Figure 6-48:
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5. Remove the driveline from the gearbox.
6. Remove bolt (X) securing brace (Z) to

gearbox and lower brace away from gearbox.
Figure 6-49: Gearbox Support Removal
7. Attach a lifting strap to the gearbox to assist

in lifting the gear box safely from the adapter.
Figure 6-50:
8. Locate the drive cover, remove the upper
cover to gain access to the idler sprocket.
D
Loosen nut (D) to remove the tension from
the chain and auger drive sprocket.
9. Remove the sprocket. Pay close attention on

how the sprocket was installed. The shoulder
of the sprocket is facing the flighting on the
Figure 6-51:
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10. Loosen hardware (E) from clamp plate that

secures drive shaft into the retractable tine
drum drive case and rotate upward.
(Figure 6-7)
E
NOTE:
Float springs have been removed for clarity.
Figure 6-52:
11. Undo spring tension (G) on both sides of the

retractable tine drum. This will make it easier
to pull out the driveline/gear case from the
Figure 6-53:
12. Secure retractable tine drum with a strap (H)

around the back of the adapter frame.
(Figure 6-9)
Figure 6-54:
169046 ISSUE DATE 04/03/18

13. Remove clamp (J) two places, that secures

the drive shaft tube to the adapter. (Figure 6-
10) (Figure 6-11)
Figure 6-55: RH Clamp Removal

14. Slide gearbox assembly out from adapter.
Figure 6-56: LH Clamp Removal
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Disassembly:
1. Drain oil from the gear case, remove drain
plug (A). (Figure 6-57)
Figure 6-57: Drain Plug Removal
2. Remove circular cover plate (B) to access the

bottom sprocket/gear assembly. Remove the
nine bolts (C) that secure it. (Figure 6-58) B
Figure 6-58: Gearbox Cover Removal
3. Remove PTO shield (D) by loosening the two

3/8” bolts (E) that retain it and rotate the E
shield, then pull it away from the gear case.
(Figure 6-59)
Figure 6-59:
169046 ISSUE DATE 04/03/18

4. Remove chain tension adjustment cover (F).

Remove two bolts (G) that secure it.
(Figure 6-60)
F
G
Figure 6-60:
5. Bend over locking tab (H) in order to loosen

off chain tensioning adjustment bolt. H
(Figure 6-61)
Figure 6-61:
6. Using a ¾" socket, loosen off chain tension

adjusting bolt until chain is slack. (Figure 6-
62)
Figure 6-62:
169046 ISSUE DATE 04/03/18

7. Remove the cotterpin (I) and castellated nut

(J). (Figure 6-63)
8. Remove the six socket head cap screws (K) I J

that retain the bottom sprocket. (Figure 6-63)
Figure 6-63:
9. Remove the sprocket from the gearbox and

pull the sprocket from the chain and out the
gear case.(Figure 6-63)
L
10. Remove all sixteen bolts (L) that retain the

gear case cover to the gearbox. (Figure 6-64)
11. Remove the cover complete with slip clutch,

top sprocket and chain. Place it on a work
bench. (Figure 6-64) Figure 6-64:
12. Remove the 97 tooth gear (M) from the input

shaft. Tap input shaft lightly with a rubber
M
mallet to push shaft through the gear to
remove gear. (Figure 6-65)
Figure 6-65:
169046 ISSUE DATE 04/03/18

13. Remove input shaft from housing. (Figure 6-

66)
14. Using a seal puller, remove the seal from the

bottom outer bearing housing.
15. Remove the inner and outer bottom bearing M

of housing.
16. To remove the inner and outer bearing races

use a brass drift and tap the races out of the
housing. Figure 6-66: Remove Input Shaft
17. Remove chain tension idler sprocket (N) by

removing 3/8”-16 socket head shoulder bolt.
This bolt is installed with Loctite® 271.
Removal may be difficult and may require the
use of heat.
NOTE:
If removal can not be done without using
heat, it is recommended that the idler block N
be removed prior to applying heat. (Figure 6-
67)
Figure 6-67: Idler Sprocket Removal
18. Remove six 1/4”-20 bolts (O) to remove the

plate (P) that secures the idler block to the
gearbox housing. (Figure 6-68)
Figure 6-68: Idler Sprocket Removed
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19. Idler assembly removed. (Figure 6-69)
Figure 6-69:
20. Remove the bolt (Q) holding gear box brace
to the gear box. Swing the brace (R) out of
the way. (Figure 6-70)
Q
R
Figure 6-70:
21. Use wire to tie up the hydraulic pump
attached to the gear box. Remove two bolts
(S) that attach the pump to the gearbox and
push the pump out of the way. (Figure 6-70)
(Figure 6-71)
Figure 6-71:
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22. Mark the position of the gear box where it is

attached on the adapter drive shaft.
(Figure 6-72)
23. Remove the six bolts retaining the gearbox to

the adapter and remove the gear box.
Figure 6-72:
24. In the gearbox cover, remove six 5/16”- 24

socket head cap screws (T). The clutch may
now be removed from the sprocket hub
assembly. (Figure 6-73)
T
Figure 6-73:
25. If you need to replace the bearing in the
clutch. You will need to dismantle the clutch
assembly.
NOTE:
Bearing will need to be pressed into the
clutch. Endplay to 0.001-0.008” (0.025-
0.203mm), if more shimming is required use
shim kit MD#187487.
Figure 6-74:
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26. Remove the snap ring (U) retaining the

sprocket onto the hub. Remove shims and
sprocket (A) from the pinion support. A
(Figure 6-74)
NOTE:
The edge of the hub shaft may need to be U
filed in order for the sprocket to be removed
from the hub without binding.
Figure 6-75:
27. Remove the pinion support (V) from the gear

case cover. Remove the six bolts (W) that
W
secure it to the housing. The gear case cover
is now fully disassembled. (Figure 6-76)
V
Figure 6-76: Pinion Removal
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Reassembly:
Figure 6-77:
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Figure 6-78:
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Figure 6-79:
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Cover:
1. Install the pinion support (A) to the gear case
cover. Secure it with six bolts (B). Torque B
pinion bolts to 6-8ft.lbs (8-11Nm) (Figure 6-
80)
A
Figure 6-80: Pinion Installation
2. Install the shims if removed, and sprocket (C) C

onto the pinion. Install the snap ring (D).
(Figure 6-81)
NOTE:
Alignment to input sprocket to be within
0.040" (1.02mm). D
Figure 6-81:
3. Install the clutch to the sprocket. Secure it
with six 5/16”- 24 socket head cap screws
(E). Torque to 20-25 ft.lbs (27-34Nm).
(Figure 6-82)
Figure 6-82:
169046 ISSUE DATE 04/03/18

Housing:
1. Using a press, install bearing races into the
bottom housing, if removed, before installing
housing onto adapter frame. F
NOTE:
Ensure mating surface are clean. G
2. Line up your markings and install the gearbox

housing to the adapter frame. Add silicon (GE
RTV-103) to the face of the connection point
(F). Torque the six bolts (G) to 30-35 ft.lbs
Figure 6-83:
(41-47Nm). (Figure 6-83)
3. Swing the brace (H) into position and secure

it with bolt (I) holding gearbox brace to the
J
4. Add silicon (GE RTV-103) to the face of the
connection point for the motor. Install the
motor onto the housing and secure it with two
bolts (J). Torque to 55-65 ft.lbs (75-88Nm). I
(Figure 6-84) H
Figure 6-84:
5. Install the plate (K) complete with idler block
(L). Secure it with six 1/4”-20 bolts (M).
Torque to 6-8 ft.lbs (8-11Nm). (Figure 6-85)
6. Install the chain tension bolt (N) and tab K

retainer. Apply grease to last 1" of thread of
adjustment bolt. (Figure 6-85) N
NOTE:
The grease is to prevent the Loctite® applied
later from adhering to the adjustment bolt M
L
Figure 6-85:
169046 ISSUE DATE 04/03/18

7. Install the bolt (O) through the idler sprocket,

then apply a small amount of loctite ® 271 on
the bolt used to secure the idler sprocket.
(Figure 6-86)
NOTE:
Ensure Loctite® does not get between the
screw and the pulley. O
8. Torque bolt (O) to 20-25 ft.lbs (27-34Nm).

(Figure 6-86)
Figure 6-86:
9. Install the inner and outer bearings (P) into R Q

the bottom bearing of housing. (Figure 6-87)
10. Install input shaft (Q). Install key onto shaft.

(Figure 6-87)
11. Install a dial Indicator, to inspect bearing end- P

play, once the large gear is installed.
Figure 6-87:
12. Install the large gear (S). Install washer (T). U T

Torque castle nut to 90ft.lbs (122Nm). Back
off castle nut and tap with a rubber mallet, S
until bearing endplay is 0.001-0.003”.
(Figure 6-88)
13. Install cotter pin.

NOTE:
Tighten castle nut (U) in order to align cotter
pin hole in shaft to line up with castle nut.
Shaft should rotate freely by hand and end- Figure 6-88:
play should not exceed 0.003".
14. Install seal to the bottom outer bearing

housing.
169046 ISSUE DATE 04/03/18

15. Install the sprocket (V) onto the large gear.

Torque bolts to 35-40ft.lbs (47-54Nm).
V
W
Figure 6-89:
16. Install gearbox cover complete with clutch

and chain. Install sixteen bolts (X) and torque
X
to 6-8ft.lbs (8-11Nm). Route chain beneath
idler sprocket and around bottom sprocket
inside gearbox.
NOTE:
Check seal around cover and replace if dam-
aged.
NOTE:
Sprockets should be aligned within 0.040"
(1.02mm).
Figure 6-90:
17. Install the guard weldment (Y). Secure it with

bolts (Z). Torque to 22-25ft.lbs (30-34Nm)
(Figure 6-91) Z
Figure 6-91:
169046 ISSUE DATE 04/03/18

18. Tighten chain (B) with tension bolt (A).

Torque bolt to 6.8Nm (60 lbf in) . (Figure 6-
92) A
• For Case New Holland/John Deere
gearbox (MD #187475): Back off bolt 1-2/
3 turns after tensioning.
• For Lexion/AGCO gearbox (MD
#187502): Back off bolt 1/2 turn after ten-
sioning.
NOTE:
A properly tensioned chain should have 10–
14 mm (3/8–9/16 in.) of deflection in midpoint B
of chain.
Figure 6-92:
19. Bend over locking tab to secure bolt location.

(Figure 6-93)
Figure 6-93:
20. Install chain idler cover. Secure it with nine

bolts (C). Torque to 6-8ft.lbs (8-11Nm)
(Figure 6-94)
NOTE:
C
Check seal around cover and replace if dam-
aged.
Figure 6-94:
169046 ISSUE DATE 04/03/18

21. At the chain tension location, fill the gearbox

with 2.5L (2.6us quart) of extreme pressure
gear lubricant 85W-140. (Figure 6-95)
Figure 6-95:
22. Install the adjusting cover and gasket (E).

Secure with two bolts (E). Torque to 6-8ft.lbs
(8-11Nm). (Figure 6-96)
D
Figure 6-96:
169046 ISSUE DATE 04/03/18

6.2 FEED AUGER
Removal:
1. Remove adapter from header. Consult the
operators manual for procedure on how to
remove the adapter from the header.
Figure 6-97: Disconnecting Adapter from Combine
2. Disconnect the driveline, hydraulic lines and

electrical lines that attach the adapter to the
combine. (Figure 6-97)
3. Place blocks under the legs of the adapter.

Lower the adapter and back the combine
away. (Figure 6-98)
Figure 6-98: Adapter Disconnected from Combine
4. Adapter should now be removed from the

combine. (Figure 6-99)
Figure 6-99: Adapter Completely Removed
169046 ISSUE DATE 04/03/18

5. Remove the deflector poly (A) on the R/H

side of the feed auger. (Figure 6-100)
6. Remove the three bolts holding the auger’s Figure 6-100: Poly Removal
front chain cover on the L/H side of the drum.
(Figure 6-101)
Figure 6-101: Cover Removal
7. Turn the chain by rotating the driveline, do Z

this until the connecting link (C) is found.
Remove the chain after the connecting link
has been removed. (Figure 6-102) C
NOTE:
You may need to loosen the tension on the
chain by loosening nut (Z)
Figure 6-102: Connecting Link
169046 ISSUE DATE 04/03/18

8. Using a ratcheting tie strap (D), wrap it

around the main back tube of the adapter and
the drum and connect the ends together, do E
this to both sides of the drum. (Figure 6-103) D
9. Loosen both float springs on the RH side until

all the tension is gone, then completely remove
the inner spring (E) from the adapter.
(Figure 6-103)
10. Remove tension from the auger spring by loos-

Figure 6-103: R/H Side Shown
ening the nut (Z) that secures the eyebolt to
the deck. (Figure 6-104)
NOTE:
The auger spring is found on 2010 model
adapters and any combines adapters that
have had SB0908 performed.
Z
11. Tighten the straps, so that the auger float

limiter bars (F) are loose on both sides of the
auger. (Figure 6-105)
12. Remove the float limiter bars (X) on both sides

of the adapter. Do this by removing pins
(G).(Figure 6-105) Figure 6-104: Auger Spring removal
NOTE:
When reinstalling pins (G) use cotter pins X
instead of the circle-clips.
NOTE:
Take note of orientation and locations of float
limiter bars before removal. Outside bars go G
to the front (they are also marked with a “F”,
inside go to the back.
Figure 6-105: Float Limiter Bar Removal
169046 ISSUE DATE 04/03/18

13. Loosen nut (X) that secures the idler

sprocket. Lower the sprocket to remove ten-
sion on the chain.
Figure 6-106:
14. Remove the nut (K) holding the clip that holds
down the auger’s rear chain cover (L) on the
L/H side of the drum. (Figure 6-107)
Figure 6-107:
15. Locate the connecting link (A) and remove it

from the chain. (Figure 6-108)
16. Slide the drive sprocket (B) off the input shaft.
(Figure 6-108)
A
NOTE:
Pay close attention on how the sprocket was B
installed. The shoulder of the sprocket is
facing the flighting on the retractable tine Figure 6-108:
drum.
169046 ISSUE DATE 04/03/18

17. Remove the two (2) bolts (H) that hold the
feed auger to the drive shaft. (Figure 6-109)
X
J
18. Remove clamp plate (J) (Figure 6-109)

H
Figure 6-109:
19. Remove the four (4) bolts (M) that hold the R/H
feed auger support to the adapter frame.
(Figure 6-110)
20. Shift the drum to the right, this will allow the L/H
side feed auger mount to slide off the feed
auger drive shaft tube. (Figure 6-111)
Figure 6-110: R/H Drum Support Removal
NOTE:
Make sure to remove the drive sprocket from
the feed auger drive shaft, when sliding the
drum over. When reinstalling make sure to
install the sprocket when pushing the drum Shift this
onto the drive shaft. Direction
21. Place 4X4 blocks (N) along the center draper N

deck. This will protect the deck from cuts.
(Figure 6-111) Figure 6-111: Shifting Drum Over For Removal
22. Loosen the ratcheting tie straps until drum is

lowered onto wood blocks. Then remove the
straps.
169046 ISSUE DATE 04/03/18

23. Roll the drum down the 4X4 blocks.

(Figure 6-112)
NOTE:
Make sure to use a least two people to
remove the drum or use a suitable lifting
device.
For Auger Internal Repair, See “Feed

Auger Internal Repair” on page 47.
Reinstallation:
1. Follow the removal procedure in reverse for Figure 6-112: Auger Removed
installation.
Q
2. Once the adapter is reinstalled on the com-
bine and the adapter is installed into the
header. Make sure to check the height of the
auger flighting to the feed pan. It should be
0.2 - 0.6 in. (5-15 mm) above the feed pan at
the steepest header angle. At the shallowest
angle make sure the flighting is 1.0 - 1.5 in
(25-40 mm) away from the feed draper. Do
this by adjusting nuts (Q) on both sides of the
auger. (Figure 6-113)
Figure 6-113: Auger Spring removal
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Feed Auger Repair:
Figure 6-114: Auger Parts Graphic
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Figure 6-115: Auger Parts List
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Figure 6-116: Auger Parts list
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Feed Auger Internal Repair
Disassembly: A
1. Place the auger on a work bench.
2. On the R/H side of the feed auger, remove

the three (3) bolts (A) that holds the feed
auger support to the drum. Once the support
is removed, remove the plastic cover (Z).
(Figure 6-117) Z
Figure 6-117: R/H Support Removal
3. Open the five (5) drum access covers (B). B

(Figure 6-118)
4. Remove the fingers in the drum, do this by

removing the hair pin clip and then pull fin-
Figure 6-118: Auger Cover Removal
gers out Take note of which fingers are not
installed as this is important for reinstallation.
D
NOTE:
Take note of the orientation of the hair pin clip
that hold the finger to the plastic. Loop in pin
should be in the forward direction of the feed
auger.
5. Remove the square reverser tube (D) from
inside the drum. (Figure 6-119)
Figure 6-119: Reverser Tube Removal
6. Remove the six (6) bolts (E) that holds the

finger assembly to the R/H side of the drum.
(Figure 6-120)
Figure 6-120: Auger End Cover Removal
169046 ISSUE DATE 04/03/18

7. Remove the R/H side of the feed auger finger

assembly support (F) complete with bushing.
F
(Figure 6-121)
Bushing
NOTE:
Make sure not to loose or damage the
bushing on the drum stop as it may slide out
of the casting upon removal. (Figure 6-121)
Figure 6-121: Finger Assembly Support

8. Remove the complete feed auger finger
NOTE:
If you are only repairing the clutch mecha-
nism, you do not need to loosen the lock
collar.
9. Loosen the lock collar (H) that holds the spring

tension against the clutch. (Figure 6-123)
Figure 6-122: Finger Assembly Removal
H
J
10. Remove the auger block off the R/H side by
removing bolts (J). (Figure 6-123)
11. Slide the clutch assembly off the finger shaft.

Replace any finger holders that may be dam-
aged or missing.
Figure 6-123: Auger Block Removal
169046 ISSUE DATE 04/03/18

RH Finger Assembly Support Repair
1. Remove the two bolts (A) that hold the

machined stop to the spindle weldment.
(Figure 6-125)
Figure 6-124: RH Finger Support Breakdown
2. Remove the machined stop (B). (Figure 6-

126)
Figure 6-125: RH Finger Assembly Support Disas-

sembly
3. Remove the nut retainer (C), then remove the
nut (D). (Figure 6-126)
169046 ISSUE DATE 04/03/18

4. Remove the thrust washer (E) and hub

assembly (F) from the spindle weldment.
(Figure 6-127)
Figure 6-127:
5. Remove the two bearings (G) from the hub

NOTE: H
There are two snap rings (H) between the two
G
bearings. (Figure 6-128)
Figure 6-128: RH Finger Support Bearing Removal
169046 ISSUE DATE 04/03/18

RH Finger Assembly Support Reassembly

1. Install snap rings (H), then install new bear-
ings (G) into hub assembly. (Figure 6-129)
H
G
2. Install hub assembly (F) onto spindle weld- Figure 6-129: RH Finger Support Bearing Removal
ment, then install the thrust washer (E).
(Figure 6-130)
Figure 6-130:
3. Install nut (D), torque the nut to 70-75 lbs.ft

(95-102Nm) to seat the bearing. Back nut off
one full turn, then retighten to 2-5lbs.ft (3-
7Nm). (Figure 6-131) C
4. Install the nut retainer (C), so it lines up with

the hole in the shaft. (Figure 6-131)
D
169046 ISSUE DATE 04/03/18

5. Install the drum stop (B) and install the bolts.

Make sure the nut retainer is also secured at
this time. (Figure 6-132) Forward
Figure 6-132: Disc Spindle
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Feed Auger Clutch Repair

6. Remove the three bolts (K) that holds the K
clutch assembly together. This will allow the
brake disc to be removed. (Figure 6-133)
Figure 6-133: Clutch Bolt Removal
L
7. Remove the brake disc (L). (Figure 6-134)
NOTE:
There will be two (2) washers (M) per bolt
beneath the brake disc that held the clutch
assembly together, make sure not to lose
them.
M
Figure 6-134: Brake Disc Removal
8. Remove the disc brake assembly (N). N

(Figure 6-135)
Figure 6-135: Brake Disc Assembly Removal
169046 ISSUE DATE 04/03/18

9. Remove the friction plate (P), plastic washer

(Q), clutch activator arm (R) and the ball cage
plate (S). (Figure 6-136)
P
NOTE:
Q
Make sure not to loose the three (3) metal
balls. R
Balls
Figure 6-136:
169046 ISSUE DATE 04/03/18

Clutch Reassembly:
1. Place the three (3) metal balls (T) on the
groove (U) that is machined into the clutch
housing. (Figure 6-137) N
2. Place the ball cage (S) plate over the three
(3) balls. (Figure 6-137)
NOTE:
If ball cage or metal balls have been
changed, make sure the metal balls pass
P
through the holes in the ball cage plate.
Q
3. Place the clutch activator arm (R) on top of
the ball cage plate and balls. (Figure 6-137) R
NOTE: S
Make sure that the diamond shaped hole cut
into the clutch activator arm and the ball cage T
are lined up. U
4. Install the plastic washer (Q), and friction

plate (P). (Figure 6-137)
Figure 6-137:
5. Install the disc brake assembly (N). (Figure 6-
137)
6. Install two (2) washers (M) per bolt. Then

install the brake disc (L). (Figure 6-138)
Figure 6-138:
169046 ISSUE DATE 04/03/18

7. Install nuts (K) and torque to 35 ft./lb. (48 Nm).

(Figure 6-139)
K
Figure 6-139: Torque Clutch Bolts
8. Install nuts (J) and torque to 4 ft./lb. (5 Nm).

(Figure 6-140) J
9. Turn clutch activator arm (I) and ball cage F

(H) until they lock. Turn the clutch assembly I
retainer bar (F) to ensure clutch is fully
engaged. Measure the distance between the H
outside edge of the activator arm (I) and ball
cage (H). The dimension at “X” should
between 12-16 mm (0.47-0.63”). If separation
is greater that 16 mm (0.63”), remove one
washer from each of the three bolts (K). Then
repeat procedure.
“X”
169046 ISSUE DATE 04/03/18

10. Hold the activator arm (I) and ball cage (H)
aligned in the neutral position, turn clutch
assembly retainer bar (F). It should be able to
spin freely (no clutch drag). (Figure 6-142) F
11. Install the clutch and auger block on to the feed

auger finger assembly shaft. (Figure 6-143)
H
I
Figure 6-142: Algin Clutch Arms
12. When you install the clutch and auger block,

line up the blocks on both ends of the finger
shaft. On the clutch end, line up the stub shaft
with the opposite sides hole with the bushing.
(Figure 6-144)
NOTE: Figure 6-143: Clutch installed on Finger Shaft

Take note of the orientation, the block can
easily be installed 180° from the correct way. Bushing End
Clutch End: Stub Shaft
IMPORTANT
If you loosened the lock collar that held the
spring tension. Tension it at this time setting
the gap between the clutch assembly and the Line Up
lock to 9/16” (15 mm). (Figure 6-145)
Figure 6-144: Alignment of Auger Blocks
Figure 6-145:
169046 ISSUE DATE 04/03/18

13. Make sure the drum stop is mounted cor-

rectly. (Figure 6-146) Forward
14. Install the RH side of the feed auger finger

assembly support.
Figure 6-146: Drum Stop
NOTE:
Make sure to reinstall the bushing (V) on the
drum stop as it may have slide out of the V
casting upon removal.
Figure 6-147: Bushing Installation
169046 ISSUE DATE 04/03/18

15. Install the six (6) bolts (E) that holds the
finger assembly to the R/H side of the drum.
(Figure 6-148)
Figure 6-148:
16. Install 15 fingers into center 15 guides where
fingers were installed before, if this in not done Drum Rotation
fingers could contact the side drapers.
NOTE:
Make sure to install the hair pin clips, so the
rounded end leads the rotation.
Hair Pin
Figure 6-149:
17. Install the reverser tube. Insert one end in the

square hole of the clutch mechanism. The other
end is held in place by the finger (D) in the sixth
holder. (Figure 6-150)
Figure 6-150: Reverser Tube Installation
169046 ISSUE DATE 04/03/18

18. Install the five (5) drum access covers (B).

(Figure 6-151)
Figure 6-151: Drum Cover Installation
19. On the R/H side of the feed auger, install the

plastic cover (Z), then put the feed auger sup-
port on with three (3) bolts (A). (Figure 6-152) A
20. Grease the bearing on both ends of the drum

and you are now ready to reinstall the drum
into the adapter.
Z
See “Reinstallation:” on page 43
Figure 6-152:
169046 ISSUE DATE 04/03/18

SECTION 7: DRAPER DRIVE SYSTEM
D60/FD70/CA20 TOC
Section 7: Draper Drive System

7.1 Draper Drive System ......................................................................................... 7-1
7.2 Side Draper Deck .............................................................................................. 7-2
Removal:....................................................................................................... 7-2
Installation:.................................................................................................... 7-4
7.2.1 Idler Roller Bearing Replacement ............................................................. 7-6
Removal........................................................................................................ 7-6
Installation..................................................................................................... 7-7
7.2.2 Drive Roller Bearing Replacement............................................................ 7-8
Removal........................................................................................................ 7-8
Installation................................................................................................... 7-10
7.3 Adapter Feed Deck.......................................................................................... 7-11
Removal:..................................................................................................... 7-11
Installation................................................................................................... 7-13
7.3.1 Adapter Idler Roller Bearing Replacement.............................................. 7-15
Removal:..................................................................................................... 7-15
Installation:.................................................................................................. 7-17
7.3.2 Feed Draper Drive Roller Bearing Replacement..................................... 7-19
Removal:..................................................................................................... 7-19
Installation:.................................................................................................. 7-21
D60/FD70/CA20 Section 7: Draper Drive System PAGE 7-1
7.1 DRAPER DRIVE SYSTEM

The drapers are supplied oil by a flow control block which is located on the combine adapter. See
section 9 for diagnostics. If header is on a swather tractor please see your windrower tractor technical
manual.
Figure 7-1: Hydraulic Schematic for CA20 adapter and Draper Header
169046 ISSUE DATE 01/01/11

7.2 SIDE DRAPER DECK
Removal:
(RH side is Shown)
NOTE: A
Header may be originally configured for
swathing and may have deck shift installed. If
so you will need to loosen the chain, so it will
bypass the sprocket that drives the deck side
to side.
1. Raise the reel and engage the reel supports.
Figure 7-2: Disconnect Hydraulic Hoses

2. Once you have determined which deck needs
to be removed, measure the delivery opening
size as you will need to set this measurement
upon reinstallation of the deck.
B
3. Loosen the draper and remove it from the
deck requiring removal.
4. Disconnect the hydraulic hoses (A) from the

hydraulic draper drive motor on the deck that
is being removed. (Figure 7-2)
5. Remove the bolts (B) that hold the deck Figure 7-3: Loosen the Deck Casting Supports
casting supports at the cutterbar side of the
deck. There are 2 supports for headers that
are 25’ or less, and 3 supports for headers
that are 30’ or greater. (Figure 7-3)
NOTE:
The bolts holding the deck casting supports
D
may have been removed already, when
removing the endless draper from the deck.
6. Remove the two (2) deck locks (D). They are

located on either side of the back sheet close
to the ends. (Figure 7-4)
Figure 7-4: Deck Lock Removal
169046 ISSUE DATE 01/01/11

7. Remove the bolts (E) from the deck support

straps. Do this to both straps located on the
backsheet. (Figure 7-5)
NOTE: Figure 7-5: Deck Support Strap Removal

You will require two people to support the
deck.
8. Lift the deck from both ends as you will need

help to support it from twisting when lifting it
out. (Figure 7-6)
Figure 7-6: Deck Being Removed

NOTE:
On 30’ & larger headers, you will need to tilt
the backsheet as you lift the deck, in order to Q
pass by the plastic guides (Q) that are
mounted to the backsheet. (Figure 7-7)
Figure 7-7: Plastic Guide
169046 ISSUE DATE 01/01/11

Installation:
(RH side will be Shown)
1. Lift the deck from both ends as you will need
help to support it from twisting when lifting it
in. You will need to tilt the backsheet as you
lift the deck, in order to pass by the plastic
guides that are mounted to the backsheet.
(Figure 7-8)
NOTE:
You will require two people to support the
deck.
Figure 7-8: Deck Being Installed
2. Run a bead of silicon along the deck support

strap location, do this to both straps located
on the backsheet. (Figure 7-9)
3. Install the bolts and the deck support straps.
Figure 7-9: Silicon Installation
4. Install the bolts (F) (do not tighten fully) that

hold the deck casting supports at the cut-
F
terbar side of the deck. There are 2 supports
for headers that are 25’ or less, and 3 sup-
ports for headers that are 30’ or greater.
(Figure 7-10)
Figure 7-10: Loosen the Deck Casting Supports
169046 ISSUE DATE 01/01/11

5. Install the two (2) deck locks (D). They are

located on either side of the back sheet close
to the ends. (Figure 7-11)
NOTE:
Make sure to leave them loose as you will D
position the deck once you are finished.
6. Reconnect the hydraulic hoses (B) from the

hydraulic draper drive motor on the deck that
you just repaired or replaced. (Figure 7-12)
Figure 7-11: Deck Lock Installation
7. Using a 8 mm shim (G), set the draper seal

gap between top of the draper deck and cut-
terbar. (Figure 7-13)
B
NOTE:
Tighten the outside two (2) outer deck casting
supports first, if the middle support is installed
tighten that one last.
8. Install the draper and tension it.

Figure 7-12: Disconnect Hydraulic Hoses
9. Reset the draper opening according to your

initial measurement. If you are not sure,
check your operators manual for opening
sizes.
10. Tighten the two (2) deck locks (D), once the
deck is set into position. (Figure 7-11)
NOTE: G
Header may be originally configured for
swathing and may have deck shift installed. If
you loosened the chain, reinstall it beneath
the sprocket that drives the deck side to side. Figure 7-13: Shimming the Deck
Set the chain so the midpoint is 0.98 to 1.97”
(25 to 50mm) lower than the ends.
169046 ISSUE DATE 01/01/11

7.2.1 IDLER ROLLER BEARING REPLACEMENT
Removal:
1. Shut the header off, raise it until the combine
safety prop can be engaged. Raise the reel
until the safety props can be engaged.
A
NOTE:
If the draper connector is not visible on the
header, engage the header until the con-
nector on the side you are working on comes
to the top.
2. At the back of the header on either side, there Figure 7-14: Draper Tensioner Location
is a bolt for tensioning the draper, locate bolt
(A) on the side you will be changing, turn it to
loosen the draper. Once the bolt is loose
push the roller assembly inboard, this will
ensure the draper is loose. (Figure 7-14)
3. Undo the connector slat that joins the draper

together.
4. Locate the idler roller (B). Remove the two B

end bolts that hold the roller to the idler arms.
(Figure 7-15)
Figure 7-15: Idler Roller Location

5. Use a slide hammer to remove the bad
bearing from in the roller.
6. Install new bearing by pressing on the outer

race of the bearing into the tube. From the out-
side edge of the tube bearing must be pressed
in 0.51”- 0.55”(13-14 mm). (Figure 7-16)
7. Install the new seal by pressing on the inner

and outer race of the seal. From the outside
edge of the tube the seal must be pressed in
0.47-0.51 (12-13 mm). (Figure 7-16)
Fill with 8 CC of Grease
NOTE: before installing the seal
Before installing new seal, fill area with 8cc of Figure 7-16: Idler Roller Bearing Installation
grease.
169046 ISSUE DATE 01/01/11

Installation:
1. Install the idler roller (B) between the idler

arms. Install the two bolts that hold the roller
to the arms. Torque bolts to 70 lbs.ft (95Nm).
(Figure 7-17)
2. Connect the ends of the draper together with

the connector slat. Figure 7-17: Idler Roller Installation
3. Tension the draper, locate bolt (A) follow the

directions on the decal for proper draper ten- A
sioning. (Figure 7-18)
4. Disengage the reel safety props and header

safety props. Lower header to the ground and
verify that the draper tracks correctly.
Figure 7-18: Draper Tensioner
169046 ISSUE DATE 01/01/11

7.2.2 DRIVE ROLLER BEARING REPLACEMENT
Removal:
NOTE:
Motor with two bolts shown during disas-
sembly, may have 4 bolts
A
1. Shut the header off, raise it until the combine
safety prop can be engaged. Raise the reel
until the safety props can be engaged.
NOTE:
Figure 7-19: Draper Tensioner Location
If draper connectors are not visible on the
header engage the header until the connector
on the side you are working on comes to the
top.
B
2. At the back of the header on either side of the

header is a bolt for tensioning the draper,
locate the bolt (A) on the side you will be
changing and loosen the draper. (Figure 7-19)
Figure 7-20: Drive Roller Location

3. Undo the connector slat that joins the draper
together.
4. Locate the drive roller (B), line up the set

screws with the hole (C) in the guard.
Remove the two set screws that hold the
motor onto the drive roller. (Figure 7-20)
(Figure 7-21)
C
NOTE: Figure 7-21: Hole in Guard to Line up Set Screws
The set screws are a 1/4 turn apart.
169046 ISSUE DATE 01/01/11

5. Remove the two bolts (D) that hold the motor

to the drive roller arm. (Figure 7-22)
D
NOTE:
You may need to remove the plastic shield in E
order to get access to the top bolt.
6. Remove the bolt that secures the other end of

the drive roller to the support arm.
7. Remove the drive roller.

Figure 7-22: Motor Support Bolts
NOTE:
There may not be enough clearance to
remove the roller, if not loosen bolt (E).
(Figure 7-22)
8. Use a slide hammer to remove the bad

bearing from in the roller.
9. Install new bearing by pressing on the outer

race of the bearing into the tube. From the out-
side edge of the tube bearing must be pressed Figure 7-23: Bearing Installation
in 0.51”- 0.55” (13-14 mm). (Figure 7-23)
10. Install the new seal by pressing on the inner

and outer race of the seal. From the outside
edge of the tube the seal must be pressed in
0.12-0.16” (3-4 mm). (Figure 7-24)
NOTE:
Before installing new seal, fill area with 8cc of
grease.
Figure 7-24: Seal Installation
169046 ISSUE DATE 01/01/11

Installation:
NOTE:
Motor with two bolts shown during installa-
tion, may have 4 bolts. B
1. Install the drive roller (B) between the roller

support arms. Install the bolt that holds the
drive roller to the arm closest to the cutterbar.
Torque the bolt to 70 lbs.ft (95Nm). (Figure 7-
25)
Figure 7-25: Drive Roller Location
2. Place grease on the motor shaft, then insert it

into the end of the drive roller.
D
E
3. Install the two bolts (D) that hold the motor to
the roller support. (Figure 7-26)
4. Tighten both set screws, then torque them to

20 lbs.ft (27 Nm).
NOTE:
If you loosened bolt (E) tighten it at this point. Figure 7-26: Motor Support Bolts
(Figure 7-26)
NOTE:
If you removed the plastic shield, re-install it A
now.
5. Connect the ends of the draper together with

the connector slat.
6. Tension the draper, locate bolt (A) follow the Figure 7-27: Draper Tensioner Location
directions on the decal for proper draper ten-
sioning. (Figure 7-27)
7. Disengage the reel safety props and header

safety props. Lower header to the ground and
verify that the draper tracks correctly.
169046 ISSUE DATE 01/01/11

7.3 ADAPTER FEED DECK

RIGHT SIDE
Removal:
1. Remove the header from the adapter. Con-
sult operators manual for procedure.
2. Leave adapter attached to combine. Engage

the feeder house manual safety locks.
C
3. Use a ratcheting strap and loop it around the

auger to support it.
NOTE:
Remove the spring if installed. Figure 7-28: Auger Support Arm Removal (RH Side)
4. Remove the auger support arms (C), two (2)
on each side of the adapter. (Figure 7-28)
(Figure 7-29)
LEFT SIDE
NOTE:
Make sure to install the supports correctly as
they are different lengths, outside supports go
to the front, inside supports go to the rear.
5. Remove the hose clamps (D) and hoses (E)

that go to the motor on the feed deck. C
(Figure 7-30)
NOTE: Figure 7-29: Auger Support Arm Removal (LH Side)

Make sure to plug all ports and hoses, this
will avoid contaminating the system, also be
sure to mark where the hoses attach to. This
will help with reassembly. D
Figure 7-30: Hose Clamp and Hose Removal
169046 ISSUE DATE 01/01/11

6. Loosen the bolts (F) that secure the deck

retaining pins. There is one per side.
(Figure 7-31)
Figure 7-31: Retaining Pin Bolt Removal

7. Use a fork lift to support the deck, remove
pins (G) from the sides of the adapter and
slowly back the deck away from the adapter.
Figure 7-32: Supporting the Deck for Removal
169046 ISSUE DATE 01/01/11

Installation
1. Use a fork lift to support the deck, slowly drive
the deck forward into the adapter frame.
Figure 7-33: Deck Supported
2. Install pins (A) from the sides of the adapter,

then install the bolts (B) that secure the deck A
retaining pins. Do this to both sides.
(Figure 7-34)
B
Figure 7-34: Retaining Pin Bolt Installation
3. Install the hose hoses (C) and clamps (D)

that go to the motor on the feed deck. M1 on D
the valve block should connect to the bottom
port on the motor. M2 should connect the top
port on the motor. (Figure 7-35) C
NOTE:
Make sure to hook up hoses correctly or
center draper will turn the wrong direction.
Figure 7-35: Hose Clamp and Hose Installation
169046 ISSUE DATE 01/01/11

4. Install the auger support arms (E), two (2) on

each side of the adapter. Secure them in
place with a cotter pin. (Figure 7-36)
(Figure 7-36)
NOTE:
Make sure to install the supports correctly as
they are different lengths, outside supports go
to the front, inside supports go to the rear.
Figure 7-36: Auger Support Arm Installation (Right Side)
5. Remove the ratcheting nylon strap from

around the auger.
6. Adapter is ready to be reinserted into the

header. See operators manual for procedure.
Figure 7-37: Auger Support Arm Installation (Left Side)
169046 ISSUE DATE 01/01/11

7.3.1 ADAPTER IDLER ROLLER BEARING REPLACEMENT
Removal:
Procedure shown for removal of right hand side.
1. Remove the dust cap. (Figure 7-38)
Figure 7-38: Dust Cap Removal
2. Completely loosen the draper tensioning

bolt. (Figure 7-39)
Figure 7-39: Draper Tensioner Removal
3. Flip up the deck seal weldment along the side

of the adapter and remove the two bolts that
hold it to the idler roller bearing casting.
(Figure 7-40)
Figure 7-40: Draper Seal Removal
169046 ISSUE DATE 01/01/11

4. Remove the nut that holds the bearing

casting to the idler roller. (Figure 7-41)
Figure 7-41: Casting Securing Nut Removal
5. Using a hammer, tap the casting until it slides

off the shaft. (Figure 7-42)
Figure 7-42: Bearing Casting Removal
6. Secure the casting and remove the internal G

retaining ring (E), then the bearing (F) and
two seals (G). (Figure 7-43)
F E
Figure 7-43: Bearing and Seal Removal
169046 ISSUE DATE 01/01/11

Installation:
NOTE: G
Make sure to install seals in the correct direc-
tion.
1. Install the seals (G), then the bearing (F) and

then the retaining ring (E). (Figure 7-44)
Seal Installation F E
Direction
Figure 7-44: Bearing and Seal Installation
2. Lubricate the shaft then install the casting

complete with bearings onto the idler roller,
secure it with the 5/8” nut. (Figure 7-45)
NOTE:
Install the casting carefully to avoid damaging
the seals.
Figure 7-45: Casting Securing Nut Removal
3. Install the deck seal support onto the idler

roller casting along the side of the adapter.
Snug the bolts up, and squeeze the plates
together. Do not over tighten. (Figure 7-46)
Figure 7-46: Draper Seal Installation
169046 ISSUE DATE 01/01/11

4. Tension the center draper until the spring

retainer (H) is flush with in 0.06” (1.5mm) with
the outside housing, also make sure that the
bolt (J) also turns freely. Once properly ten-
sioned, use the inside most nut (K) to lock the K
position of the tension bolt. (Figure 7-47)
H
J
5. Install the dust cap (L) and pump the casting

full of grease through the grease zerk. (M). M
(Figure 7-48)
Figure 7-48: Dust Cap Installation
169046 ISSUE DATE 01/01/11

7.3.2 FEED DRAPER DRIVE ROLLER BEARING REPLACEMENT
Removal:
1. Remove the header from the adapter. Con-
sult operators manual for procedure.
2. Leave adapter attached to combine. Engage

the feeder house manual safety locks.

3. Loosen the tension off the center draper, do
this to both sides. (Figure 7-49) F
4. Remove the lock collar (E) from the RH side

Shaft Rotation
of the drive roller shaft. (Figure 7-50) E
5. Remove the bolts (F) from the bearing flan- Figure 7-50: Lock Collar & Bolt Removal
gettes. Remove and inspect or replace the
H G
If replacing the drive roller continue following the
remaining steps.
6. Loosen the hose clamp (G) and bolts (H) that

hold the motor to the frame. (Figure 7-51)
Figure 7-51:
169046 ISSUE DATE 01/01/11

7. Loosen the setscrews (J) that hold the drive

roller to the hydraulic motor shaft. (Figure 7-52)
NOTE:
There are two set screws per hole. J
8. Slide the motor out of the end of the drive

roller.
NOTE:
Figure 7-52: Loosen Setscrews on Drive Roller
9. Lift the drive roller out of the deck assembly.
169046 ISSUE DATE 01/01/11

Installation:
If you only replaced the bearing start at step 4.
1. Install the drive roller, push the motor shaft J

into the drive roller until it is fully engaged.
(Figure 7-53)
2. Install the setscrews (J) that hold the drive

roller to the hydraulic motor shaft. (Figure 7-
53)
Figure 7-53: Install Setscrews into Drive Roller

NOTE:
There are two set screws per hole.
H G
3. Tighten the bolts (H) and hose clamp (G) that
holds the motor to the frame. (Figure 7-51)
4. Install the bearing (N) and flangettes, then

install the retaining bolts (O). (Figure 7-55)
5. Install the lock collar (P) onto the drive roller

shaft. Tighten the collar in the direction of
rotation. (Figure 7-55) Figure 7-54:
O
N
Shaft Rotation
P
Figure 7-55: Drive Roller Bearing Installation
169046 ISSUE DATE 01/01/11

6. Tension the center draper until the spring

retainer (Q) is flush or within 0.06” (1.5mm) of
the outside housing, also make sure that the
bolt (R) also turns freely. Once properly ten-
sioned, use the inside most nut (S) to lock the S
position of the tension bolt. (Figure 7-56)
7. Install the adapter into the header. Consult

operators manual for procedure.
Q
R
Figure 7-56: Draper Tensioner Installation
169046 ISSUE DATE 01/01/11

SECTION 8: REEL DRIVE
D60/FD70/CA20 TOC
Section 8: Reel Drive System

8.1 Reel Drive System............................................................................................. 8-1
8.1.1 PR15 Reel Configuration (FD70/D60/D50) ............................................... 8-2
8.1.2 Reel Speed Sprocket Change................................................................... 8-3
8.2 Single Span Reel Removal................................................................................ 8-4
8.3 Double Reel (Split) Removal ............................................................................. 8-8
Right-hand Side Removal:............................................................................ 8-8
Left-hand Side Removal: ............................................................................ 8-11
8.3.1 Reel Drive Repair.................................................................................... 8-15
8.3.2 Single Reel Drive Disassembly ............................................................... 8-15
Single Reel Reassembly:............................................................................ 8-19
8.3.3 Split Reel Drive Disassembly .................................................................. 8-23
Double Reel Drive Reassembly.................................................................. 8-28
D60/FD70/CA20 Section 8: Reel Drive System PAGE 8-1
8.1 REEL DRIVE SYSTEM

The reel drive system is hydraulically driven by the combine or windrower tractor hydraulic system.
The hydraulic motor is coupled to a chain drive reduction that varies slightly depending on size of the
header. All 25’ and smaller headers are single span reels (2-arm), 30’-35’ headers are available in
either: single span (2-arm) or split reel (3-arm) versions. All headers larger than 35’ are only available
in split reel (3-arm) configurations. Single span reels are driven from the R/H arm and split reels are
driven from the centre arm.
Figure 8-1: Reel Drive System for 2 and 3 arm Headers
169046 ISSUE DATE 01/01/11

8.1.1 PR15 REEL CONFIGURATION (FD70/D60/D50)
Reel Reel Drive MPH/Cam #

Combine Reel Drive Reel Sprocket Reel High torque
Flow Ratio 3&4 Finger
Model Pressure Configuration RPM Reel RPM
GPM Drive/Driven tip
Case
2300/2500 13 2000 Standard 19-56 56.2 9
Series 5088/
6088/7088
21-56 62.1 10
Export - 40 + 19-48 65.5 10.5
High Torque 10-56 29.6
7010/8010 13 2000 Standard 19-56 67.2 10.8
7120/8120/
9120
21-56 74.3 12
Export - 40 + 19-48 78.4 12.7
New Holland
CR/CX Series 13 3000 Standard 19-56 67.2 10.8
21-56 74.3 12
Export - 40 + 19-48 78.4 12.7
Lexion
400 Series 11 2030 Standard 19-56 56 9
Export - 40 + 19-48 65 10.5
500 Series 11 2500 Standard 19-56 56 9

Export - 40 + 19-48 65 10
John Deere
50/60/70 11 2190 Standard 19-56 56 9
Series
Export - 40 + 21-48 75.6 12.2
Agco
R Series 14 2000 Standard 19-56 73 11.9
A Series/ 9.5 2600 Standard 19-56 51 8.2

Challenger
/Massey
Export - 40 + 21-48 65.6 10.5
NOTE:
Reel Drive Ratios 19-48, 21-48 are factory set for high speed Export
21-56 are optional high speed for North America
169046 ISSUE DATE 01/01/11

8.1.2 REEL SPEED SPROCKET CHANGE
CaseIH 50/60/70 88 Series Combines.

When changing reel speed sprockets on
headers, the combine needs to be configured for
reel speed sprocket size to optimize the auto reel
to ground speed control.
1. Press Header Setting Key (12) to enter the

Header Sensitivity Change Screen.
2. Press Header Setting Key (12) until Grain
Header Type Screen (D) is highlighted.
3. Press Enter Key (4) and display will change
to Grain Header Screen. Figure 8-2: Main Screen
4. Press Header Setting Key (12) until Reel
Configuration Screen (H) is highlighted.
5. Use the Up Key (5) or the Down Key (8) until
the correct drive type is displayed for your
configuration as outlined in chart below.
Header Drive
Sprocket Description
Type Type
D50/D60/ 4 19 Tooth
FD70
5 14 Tooth
ALL 6 17 Tooth or 10 tooth
7 11 Tooth
6. Press Enter Key (4) to save setting and
return to Header Sensitivity Change Figure 8-3: Header Sensitivity Change Screen
Screen.
7. To exit Header Sensitivity Change Screen
wait 5 seconds or press Cancel Key (6).
Figure 8-4: Grain Header Change Screen
169046 ISSUE DATE 01/01/11

8.2 SINGLE SPAN REEL REMOVAL

This section will detail the procedure required to
remove the reel from a single reel header. This
will work on all configurations of a single reel.
1. Lower header to the ground and raise the reel

all the way up until the safety stands can be
engaged. (Figure 8-5)
A
NOTE:
Use an appropriate lifting device that can
support approximately 1000 lbs.
2. Position the lifting device in the middle of the Figure 8-5: Header Lowered, Reel Raised
reel, using slings, or using a cradle lift from
underneath the reel tube. Support the reel so
that it will be lifted out as straight as possible.
(Figure 8-6)
3. Using the lifting device, lift the reel enough to

take the weight off the reel arms.
4. Detach the wiring harness (D) from the

hazard light assembly. Make sure to mark the
wires for reassembly.
Figure 8-6: Lifting Device Positioned
5. Remove the transport light bracket option
from the end of the reel arms by removing the
two (2) bolts (E) that hold it in place (If
installed). D
Figure 8-7: Electrical Bracket Removed
169046 ISSUE DATE 01/01/11

6. Remove the two hoses (F) from the reel drive

motor. Make sure to mark the hoses as to
which ports they were removed from.
(Figure 8-8)
NOTE:
Plug the hydraulic lines and ports on the
motor to avoid any possible contamination of
the hydraulics system. F
7. Disconnect the reel speed sensor from the

wiring harness (G). (If installed). If it is not
installed cut the zip tie that holds it to the reel
drive plate. (Figure 8-9) Figure 8-8: Hydraulic Motor Hoses Removed
NOTE: G
If you have a mechanical reel fore-aft adjust-
ment go to step 12.
8. If hydraulic reel fore aft is installed, discon-

nect the pins (H) that hold the cylinder rods to
the reel support mount, do this to both sides
of the reel. (Figure 8-10)
Figure 8-9: Reel Speed Harness Disconnection
Figure 8-10: Cylinder Pin Removal (2 Arm Shown)
169046 ISSUE DATE 01/01/11

9. Remove the reel arm shield (L) by removing

the three (3) bolts that hold it on. (Figure 8-
11) L
10. Once the shield is off, remove the support

plates (M) that hold the cylinder in place on
the reel drive support. (Figure 8-11)
11. Move the right-hand cylinder, so that it will not

get caught when removing the reel. M
Figure 8-11: Shield Removal (2 Arm Shown)
12. If your reel has mechanical fore aft you will Q P

R
need to remove the one bolt (P) that holds
the mechanical fore aft adjuster bar in place.
Do this to both sides. (Figure 8-12)
13. Remove the two pins (Q) that hold the

adjuster bar (R) to the reel arm then remove
the bar (R) from the header. Do this to both
sides. (Figure 8-12)
Figure 8-12: Bolt Removal (LH Shown)
14. Remove the end plates (S) on both sides of

the header that stop the reel from falling off
the ends of the reel arms. (Figure 8-13)
X
NOTE:
Make sure to take note of the orientation of
the reel drive support (X) and the tail end sup- Z
port (Z), this will help with reassembly.
Figure 8-13: Reel Stop Plate Removal
169046 ISSUE DATE 01/01/11

15. Back up the lifting device, making sure that

the reel does not catch on anything. Once
removed from the reel arms place the reel on
the ground using blocks underneath it.
(Figure 8-14)
NOTE:
Make sure to support the reel drive assembly,
as the weight of the assembly may want to
turn the cam arms.
Figure 8-14: Reel Removal
169046 ISSUE DATE 01/01/11

8.3 DOUBLE REEL (SPLIT) REMOVAL

This section will detail the procedure required to
remove the reels from a double reel header. This
will work on all configurations of a double reel
header, rigid and flex.
Right-hand Side Removal:
1. Lower header to the ground and raise the reel

D
all the way up until the safety stands (D) can
be engaged. (Figure 8-15)
NOTE:
Use an appropriate lifting device that can
support approximately 1000lbs.
Figure 8-15: Header Lowered
2. Position the lifting device in the middle of the

right-hand reel, using slings or use a cradle
underneath the reel tube. Support the reel
tube in a way, so that it will be lifted out as
straight as possible. (Figure 8-16)
3. Using the lifting device, lift the reel enough to

take the weight off the reel arms.
4. Detach the wiring harness (E) from the

hazard light assembly. Make sure to mark the
wires for reassembly. Figure 8-16: Positioning the Lifting Device
5. Remove the transport light bracket from the

end of the reel arms by removing the two (2)
bolts (F) that hold it in place. E
Figure 8-17: Electrical Bracket Removed
169046 ISSUE DATE 01/01/11

6. Remove the two (2) plastic covers (G) that

cover the center reel arm u-joint. (Figure 8-18)
Figure 8-18: Center Reel Cover
7. Remove the four (4) bolts (H) that hold the reel
tube to the reel drive at the center of the
header. (Figure 8-19)
Figure 8-19: Center Reel Tube Bolt Removal
8. Remove the two (2) horse shoe shaped

brackets (J) that hold the cylinder to the reel
arm on the right hand side. (Figure 8-20)
Figure 8-20: Cylinder Retention Removal
169046 ISSUE DATE 01/01/11

9. Remove the pin (K), that holds the rod end of

the cylinder to the reel arm. Then remove end
plate (L) on the RH reel arm. (Figure 8-21)

the right-hand reel does not catch on any-
thing.
11. Once removed from the reel arms, place the

reel on the ground using blocks underneath L
it, this will avoid breaking or bending any reel K
fingers. (Figure 8-21)
Figure 8-21: PIn and Plate Removal
Figure 8-22: Lift Reel out of Header
169046 ISSUE DATE 01/01/11

Left-hand Side Removal:

1. Line up the lifting device with the left-hand
side of the reel tube. Make sure to be closer
to the reel drive, as it adds extra weight to
that end of the reel. (Figure 8-23)
2. Using the lifting device, lift the reel high

enough to take the weight of the reel, off the
reel arms.
Figure 8-23: L/H Side Reel Removal

3. Remove the two hoses (D) from the reel drive
motor. Make sure to mark the hoses as to
which ports they were removed from.
(Figure 8-24)
Figure 8-24: Hose Removal
169046 ISSUE DATE 01/01/11

4. Plug the hydraulic lines and ports on the

motor to avoid any possible contamination of
the hydraulics system.
5. On the center arm disconnect the reel speed

sensor (E) from the wiring harness. (If
installed). If it is not installed cut the zip tie that
holds it to the reel drive plate. (Figure 8-26)
NOTE: Figure 8-25: Reel Speed Harness Disconnection

If you have a mechanical reel adjustment go
to step 10.
6. If hydraulic fore aft is installed, disconnect the

pins that hold the cylinder rods to the reel
support arm, do this to the center and the left
side of the reel. (Figure 8-26)
Figure 8-26: PIn Removal
169046 ISSUE DATE 01/01/11

7. Remove the three (3) bolts that holds the

shield (G) on the center reel drive assembly.
(Figure 8-27) G
8. Once the shield is off, remove the support H

plates (H) that hold the cylinder in place on
the reel drive support. (Figure 8-27)
9. Move the center cylinder, so that it will not get

caught when removing the reel.
Figure 8-27: Shield Removal (3 Arm Shown)
K J
L
10. If your reel has mechanical fore aft you will
need to remove the one bolt (J) that holds the
fore aft adjuster bar (L) in place. Do this to
both arms. (Figure 8-28)
11. Remove the two pins (K) that hold the adjuster
bar to the reel arm then remove the bar (L)
from the header. Do this to both sides.
(Figure 8-28)
Figure 8-28: Bolt Removal (RH Shown)
12. Remove the end plates (M) that are mounted Z

to the ends of the reel arms, they stop the
reel from falling off. (Figure 8-29)
X
M
NOTE:
Make sure to take note of the orientation of
the reel drive support (Z) and the tail end sup-
Figure 8-29: Reel Stop Plate Removal
ports (X), this will help with reassembly.
169046 ISSUE DATE 01/01/11


the reel does not catch on anything. Once
removed from the reel arms place the reel on
the ground using blocks underneath it.
(Figure 8-30)
NOTE:
Make sure to support the reel drive assembly,
as the weight of the assembly may want to
turn the cam arms.
Figure 8-30: L/H Reel Lifted Out
169046 ISSUE DATE 01/01/11

8.3.1 REEL DRIVE REPAIR
Reel has been removed for clarity of pictures.
CAUTION
This procedure is written assuming the reel A
removed off the header and either sitting on
the ground or on stands.
8.3.2 SINGLE REEL DRIVE DISASSEMBLY
1. Remove the four (4) bolts (A) from the plastic

Figure 8-31: Reel Drive Plastic Cover Removal
cover and remove it off the reel drive.
(Figure 8-31)
2. Loosen the six (6) bolts (B) that hold the

hydraulic motor, then slide the assembly Reel
down. (Figure 8-32) Rotation
Figure 8-32: Chain Removal

3. Remove the chain.
NOTE: Z
There is no connecting link in the chain.
NOTE:
You may need to remove the reel speed
toning wheel, if installed.
4. Remove the cotter pin (Z) from the motor

shaft, then remove the nut. (Figure 8-33)
Figure 8-33: Cotter Pin Removal
169046 ISSUE DATE 01/01/11

5. Remove the sprocket from the motor shaft,

make sure not to lose the key in the shaft.
6. Line up the four (4) bolts (C) that hold the

motor in place with the four holes in the sup- C C
port plate and then remove them. (Figure 8-34)
Figure 8-34: Sprocket Removal
7. If applicable, remove the speed sensor and

bracket by removing the two (2) bolts (D) that
hold it in place. (Figure 8-35)
Figure 8-35: Speed Sensor Removal
8. Remove the cotter pin (E) and nut from the

bottom reel drive shaft. (Figure 8-36)
169046 ISSUE DATE 01/01/11

9. Remove the bottom sprocket, make sure not

to lose the keys in the shaft.
10. Remove the six (6) bolts (F) that hold the reel
drive plate and adjustment plate to the reel
drive assembly. (Figure 8-37)
F F
Figure 8-37: Sprockets Removed
11. Remove the two keys (G) installed on the

REEL
G
Figure 8-38: Removing the key
12. Use a bearing puller, pull the remaining reel

drive assembly (H) off the reel shaft.
(Figure 8-39)
NOTE:
Outer bearing (X) may be removed with the
housing. Inner bearing (Z) may stay on the
REEL
shaft or may stay in the housing. You may
also remove the bearing races at this time, if
required.
X Z
Figure 8-39: Reel Assembly Removal
169046 ISSUE DATE 01/01/11

13. Remove the four (4) bolts (J) that hold the
reel drive hub to the cam track plate.
(Figure 8-40)
Figure 8-40: Cam Track Support Removed

14. Remove the one (1) bolt (K) and support that
holds the casting in place. (Figure 8-41) Support
Figure 8-41: Casting Support Removal
15. Remove casting from assembly. (Figure 8-42)
Figure 8-42: Casting Removed
169046 ISSUE DATE 01/01/11

Single Reel Reassembly:

Support
NOTE:
Before reassembling check to make sure the
bearings and races that are pressed into the
casting are still good, if not replace them.
1. Insert casting and support into the reel sup-

port. Lock it in place by tightening bolt (K)
(Figure 8-43)
Figure 8-43: Casting Support installation
2. Install the four (4) bolts (J) that hold the reel
drive hub to the cam track plate. (Figure 8-44)
Figure 8-44: Cam Track Support Installation
169046 ISSUE DATE 01/01/11

NOTE:
Take care when installing assembly onto the
reel shaft. Make sure the bearings (I) do not
get damaged on installation. (Figure 8-45)
REEL
I
Figure 8-45: Reel Assembly Installation
3. Install the two keys (G) into the keyway

machined on the shaft. (Figure 8-46)
REEL
G
Figure 8-46: Installing the keys

4. Install the adjustment plate with six (6) bolts
(F) to the reel drive assembly. Leave the bolts
loose for ease of adjustment. (Figure 8-47)
F F
Figure 8-47: Adjustment Plate Install
169046 ISSUE DATE 01/01/11

5. Line up the motor mounting holes with the

four (4) holes that hold the motor in place on
the adjustment plate. Once lined up, install
the bolts (C). Make sure to use a thread
locking compound (Loctite 243) on the bolts.
(Figure 8-48)
C C
Figure 8-48: Motor Install
6. Install the bottom sprocket on the reel shaft,

make sure not to forget the keys in the shaft.
7. Tighten the slotted nut to 40 lbs.ft (54Nm), E

while turning the reel assembly to seat the
bearings. Loosen the nut, then re-tighten to
18-20 in.lbs (2-2.3Nm). Install the cotter pin
(E), If required tighten nut to next cotter pin
hole. (Figure 8-49)
Figure 8-49: Bottom Sprocket Installation
8. Install the speed sensor and bracket by

installing the two (2) bolts (D) that hold it in
D
NOTE:
Make sure the sensor gap is set to 3mm (± 1mm).
Figure 8-50: Speed Sensor Installation
169046 ISSUE DATE 01/01/11

9. Install the sprocket onto the motor, make sure

not to forget the key.
10. Tighten the slotted nut to 40 lbs.ft (54Nm),

bearings. Loosen the nut, then re-tighten to 18-
20 in.lbs (2-2.3Nm). Install the cotter pin (C). If
required tighten nut to next cotter pin hole.
(Figure 8-51)
11. Install the chain. (Figure 8-52)

Figure 8-51: Cotter Pin Installation
NOTE:
There is no connecting link in the chain. B1
B3
12. Push on the motor assembly until you have
tension on the chain. Tighten the two bolts (B1)
B2
closest to the motor first, then tighten the two
bolts (B2) farthest away from the motor, then
tighten the two bolts (B3) in the middle. Torque
bolts to 70-80 ft.lbs (95-108 Nm). (Figure 8-52)
13. Install the plastic cover and four (4) bolts (A)
that hold it on. (Figure 8-53)
A
Figure 8-53: Reel Drive Plastic Cover Installation
169046 ISSUE DATE 01/01/11

8.3.3 SPLIT REEL DRIVE DISASSEMBLY
CAUTION
This procedure is written assuming the reel is
removed off the header and either sitting on A
the ground or on stands.
1. Remove the nine (9) bolts (A) from the plastic
cover and remove it off the reel drive.
(Figure 8-54)
Figure 8-54: Reel Drive Plastic Cover Removal
B
2. Loosen the six (6) bolts (B) that hold the
hydraulic motor, then slide the assembly
down. (Figure 8-55)
3. Remove the chain.
NOTE:
These is no connecting link in the chain.
NOTE:
You may need to also remove the reel speed
toning wheel.
Figure 8-55: Chain Removal
C
4. Remove the cotter pin (C) from the motor
shaft, then remove the nut. (Figure 8-56)
169046 ISSUE DATE 01/01/11

5. Remove the sprocket from the motor shaft,

make sure not to lose the key in the shaft.
6. Line up the four (4) bolts (C) that hold the

motor in place with the four holes in the sup- C C
port plate and then remove them. (Figure 8-57)
Figure 8-57: Sprocket Removal
7. If applicable, remove the speed sensor and

bracket by removing the two (2) bolts (D) that
hold it in place. (Figure 8-58)
Figure 8-58: Speed Sensor Removal
8. Remove the u-joint assembly that is bolted to Q

the bottom pulley with six (6) bolts (Q).
(Figure 8-59)
Figure 8-59: U-Joint Removal
169046 ISSUE DATE 01/01/11

9. Remove the cotter pin (E) and nut from the

bottom reel drive shaft. (Figure 8-60)
E
10. Remove the bottom sprocket, make sure not
to lose the keys in the shaft.
11. Remove the six (6) bolts that hold the reel
drive plate and adjustment plate to the reel
drive assembly. (Figure 8-61)
F F
Figure 8-61: Sprockets Removed
12. Remove the two keys (G) installed on the

REEL
G
Figure 8-62: Removing the key
169046 ISSUE DATE 01/01/11

13. Use a bearing puller, pull the remaining reel

drive assembly (H) off the reel shaft.
(Figure 8-63)
H
NOTE:
Outer bearing (X) may be removed with the
housing. Inner bearing (Z) may stay on the
shaft or may stay in the housing. You may REEL
also remove the bearing races at this time, if
required.
X Z
Figure 8-63: Reel Assembly Removal
14. Remove the four (4) bolts (J) that hold the
reel drive hub to the cam track plate. J
(Figure 8-64)
Figure 8-64: Cam Track Support Removed
Support
15. Remove the one (1) bolt (K) and support that
holds the casting (Y) in place. (Figure 8-65)
K
Y
Figure 8-65: Casting Support Removal
169046 ISSUE DATE 01/01/11

16. Remove casting from assembly. (Figure 8-66)
Figure 8-66: Casting Removed
169046 ISSUE DATE 01/01/11

Double Reel Drive Reassembly:

Support
NOTE:
Before reassembling check to make sure the
cone bearings and races that are pressed
into the casting are still good, if not replace
them.
1. Insert casting and support into the reel sup-

port. Lock it in place by tightening bolt (K)
(Figure 8-67)
K
Figure 8-67: Casting Support installation
2. Install the four (4) bolts (J) that hold the reel
drive hub to the cam track plate. (Figure 8-68)
Figure 8-68: Cam Track Support Installation
169046 ISSUE DATE 01/01/11

NOTE:
Take care when installing assembly onto the
reel shaft. Make sure the bearings (I) do not
get damaged during installation. (Figure 8-
69)
REEL
I
Figure 8-69: Reel Assembly Installation
3. Install the two keys (G) into the machined

keyway on the shaft. (Figure 8-70)
REEL
G
Figure 8-70: Installing the keys
4. Install the adjustment plate with six (6) bolts

(F) to the reel drive assembly. Leave the bolts
loose for ease of adjustment. (Figure 8-71)
F F
Figure 8-71: Adjustment Plate Install
169046 ISSUE DATE 01/01/11

5. Line up the motor mounting holes with the

four (4) holes that hold the motor in place on
the adjustment plate. Once lined up, install
the bolts (C). Make sure to use a thread
locking compound (loctite 243) on the bolts.
(Figure 8-72)
C C
Figure 8-72: Motor Install
6. Install the sprocket on the reel drive shaft,

make sure not to forget the keys in the shaft.
7. Tighten the slotted nut to 40 lbs.ft (54Nm), E

bearings. Loosen the nut, then re-tighten to
18-20 in.lbs (2-2.3Nm). Install the cotter pin
(E), If required tighten nut to next cotter pin
hole. (Figure 8-73)
Figure 8-73: Bottom Sprocket Installation
8. Install the speed sensor and bracket by

installing the two (2) bolts (D) that hold it in
D
NOTE:
Make sure the sensor gap is set to 3mm (± 1mm).
Figure 8-74: Speed Sensor Installation
169046 ISSUE DATE 01/01/11

9. Install the top sprocket onto the motor, make

sure not to forget the key.
10. Tighten the slotted nut to 40 lbs.ft (54Nm),

bearings. Loosen the nut, then re-tighten to 18-
20 lbs.in (2-2.3Nm). Install the cotter pin (R). If
required tighten nut to next cotter pin hole.
(Figure 8-75)
Figure 8-75: Cotter Pin Installation

11. Install the chain. (Figure 8-76)
NOTE: B1
There is no connecting link in the chain.
B3
12. Push up on the motor assembly until you B2

have tension on the chain. Tighten the two
bolts (B1) closest to the motor first, then
tighten the two bolts (B2) farthest away from
the motor, then tighten the two bolts (B3) in
the middle. Torque the bolts to 70-80 lbs.ft
(95-108 Nm.). (Figure 8-76)
13. Install the u-joint assembly (Q) onto the

bottom pulley. It is secured with six (6) bolts.
Use loctite® 243 on the threads, torque bolts
to 75-85 lbs.ft (102-115Nm.) (Figure 8-77)
Figure 8-77: U-joint Assembly Installation
169046 ISSUE DATE 01/01/11

NOTE:
Before installing the split plastic cover, install
the reel onto the header, as you need to
install the bolts into the RH reel. Use loctite®
243, torque bolts to 75-85 lbs.ft (102-115 Nm) A
14. Install the bottom plastic cover first, then

install the top half, then install bolts (A).
(Figure 8-78)
15. Tighten bolts that attach the LH reel to reel Figure 8-78: Reel Drive Plastic Cover Installation
drive shaft. Use loctite® 243, torque bolts to
75-85 ft/lbs (102-115 N.m.)
169046 ISSUE DATE 01/01/11

SECTION 9: HYDRAULICS
D60/FD70/CA20 TOC
Section 9: Hydraulic System

9.1 Adapter Hydraulics System ............................................................................... 9-1
9.2 Forward Operation............................................................................................. 9-3
9.2.1 Forward Operation Schematic .................................................................. 9-4
9.2.2 Forward Operation - Feed Draper Over Relief.......................................... 9-5
9.2.3 Forward Operation - Side Draper Over Relief........................................... 9-6
9.2.4 Forward Operation with Knife Reverser .................................................... 9-7
9.3 Reverse Operation ............................................................................................ 9-8
9.3.1 Reverse Operation Schematic .................................................................. 9-9
9.3.2 Reverse Operation - Over Relief............................................................. 9-10
9.3.3 Reverse Operation with Knife Reverser.................................................. 9-11
9.3.4 CA20 Hydraulic Pressure Test................................................................ 9-12
9.4 Selector Valve Block........................................................................................ 9-14
9.4.1 Hydraforce Selector Valve (Prior to 2007) .............................................. 9-14
9.4.2 Selector Valve Schematic (CASE 7010/8010 & NH CR/CX) .................. 9-15
9.4.3 Selector Valve Schematic (All, Except CASE 7010/8010, NH CR/CX)... 9-16
9.4.4 Hydraforce Selector Valve (2007 & Newer) ............................................ 9-17
9.4.5 Selector Valve Schematic For All Combines (2007 & Newer) ................ 9-18
9.6 Hydraulic Testing & Repair.............................................................................. 9-20
9.6.1 Minimum Test equipment........................................................................ 9-20
9.6.2 Checking Knife Drive Flow & Pressure Compensator............................. 9-21
Checking Flow & Pressure Compensation ................................................. 9-21
9.6.3 Setting The Unloading Valve "V7"........................................................... 9-25
9.6.4 Testing Gear Pump Efficiency................................................................. 9-26
9.6.5 Testing Piston Pump Efficiency............................................................... 9-27
9.7 Hydraulic Oil Specifications ............................................................................. 9-28
9.8 Adapter Oil Temperature ................................................................................. 9-28
9.9 Oil Change Procedure ..................................................................................... 9-29
9.10 Reel Lift Cylinders ......................................................................................... 9-30
9.10.1 Reel Lift Theory..................................................................................... 9-30
9.10.2 Reel Drive, Lift & Fore-Aft Schematics.................................................. 9-31
9.10.3 Diagnostic Test - Static ......................................................................... 9-32
Split Reel .................................................................................................... 9-32
9.10.4 Diagnostic Test - Dynamic .................................................................... 9-32
9.10.5 Static and Dynamic Test Diagnostic Chart: Cylinder vs. Symptom....... 9-33
Solutions (Single Span Reel):..................................................................... 9-34
Solutions (Split Reel): ................................................................................. 9-34
9.11 Component Repair ........................................................................................ 9-35
9.11.1 Single Reel Header Cylinders ............................................................... 9-35
Reel lift (L/H) Cylinder (145237) Repair...................................................... 9-35
D60/FD70/CA20 TOC
9.11.2 Double Reel Headers Cylinders ............................................................ 9-38

Center Reel Lift Cylinder (145386) Repair.................................................. 9-38
Reel Lift (R/H) Cylinder (145237) Repair .................................................... 9-39
Reel Lift (L/H) Cylinder (145395) Repair..................................................... 9-40
Fore-Aft Cylinders (137458 & 113434) Repair............................................ 9-41
9.12 Hydraulic Motors ...................................................................................... 9-42
9.12.1 D50 & D60 Side Drapers....................................................................... 9-42
Disassembly................................................................................................ 9-43
Repair ......................................................................................................... 9-46
Reassembly ................................................................................................ 9-46
9.12.2 FD70 Side Drapers................................................................................ 9-49
Repair ......................................................................................................... 9-50
9.12.3 Deck Shift (# 120374) Swathing Application Only................................. 9-52
Removal...................................................................................................... 9-52
Eaton Motor Disassembly ........................................................................... 9-53
Reassembly (Shaft End) ............................................................................. 9-55
Reassembly (Gerotor End) ......................................................................... 9-58
Timing Procedure........................................................................................ 9-58
Parker Motor Disassembly MD# 120374 .................................................... 9-59
Repair ......................................................................................................... 9-62
Reassembly ................................................................................................ 9-63
9.12.4 Reel (MD# 143088) ............................................................................... 9-67
Removal (White Hydraulics) ....................................................................... 9-67
Disassembly................................................................................................ 9-68
Repair ......................................................................................................... 9-73
Reassembly ................................................................................................ 9-73
9.12.5 Feed Draper (MD# 151981) .................................................................. 9-78
Disassembly (Parker Hannifin) ................................................................... 9-78
Repair ......................................................................................................... 9-81
Reassembly ................................................................................................ 9-82
9.13.2 Double Knife (Timed) ............................................................................ 9-87
9.14 Multi-Coupler ................................................................................................. 9-88
9.14.1 Lexion 400 Series Multi-Coupler ........................................................... 9-88
9.14.2 Lexion 500 Series Multi-Coupler ........................................................... 9-89
9.14.3 Lexion Multi-Link Valve Block................................................................ 9-90
9.14.4 MacDon, Case 7010/8010 & NH CR/CX Multi-Coupler ........................ 9-91
9.14.5 John Deere 60 Series Multi-Coupler ..................................................... 9-92
9.14.6 Agco Multi-Coupler................................................................................ 9-93
D60/FD70/CA20 Section 9: Hydraulic System PAGE 9-1
9.1 ADAPTER HYDRAULICS SYSTEM

The Way It Works
The CA20 combine adapter is designed to supply
enough hydraulic power to drive the knife as well
as the draper drive motors on both the header
and adapter.
NOTE:
All volume measurements are in U.S. GPM.
A drive shaft which runs off of the left hand side
of the combine jackshaft drives a gear box (A)
which powers a double pump assembly (B). The
first pump (C) is a variable displacement piston
pump (set to 23.8 cc/rev for Lexion & Agco
combines and 31 cc/rev for all other combines) Figure 9-1: CA20 Combine Adapter
which powers a 6.1 CU IN (100 cc) displacement
hydraulic motor on the header which drives the E
knife. B
NOTE:
On the FD70 40’ + 45’ and D60-D 45’ double A
knife headers, there are two knife drive
motors.
The piston pump displacement is factory set so
that an appropriate knife speed is achieved for
the specific combine in use. It may be fine tuned
to increase knife speed. Especially for double
knife drive headers.
The second pump (D) is a gear pump which
supplies 7-9 GPM (27-34 lpm) (relative to feeder- C D
house jackshaft speed) (Lexion & Agco Figure 9-2: Hydraulic Plumbing Schematic
combines are equipped with an 11 cc gear
pump while all other combines are equipped
with a 16cc gear pump) of hydraulic oil to the
hydraulic valve block (E) located on the left side
of the adapter. This oil then powers the center
feed draper followed by the left and right side
drapers on the header.
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The speed of the side drapers is controlled using

a flow valve which is typically set to a mid range
position. Any excess oil flow which is not being
used is then drained back to tank through an
unloading valve.
The reel on the header is not powered by the
hydraulic system on the adapter and relies on the
combine’s reel drive hydraulics. This info must be
supplied by the combine manufacturer.
NOTE:
If an obvious system problem such as a
draper or auger not turning is indicated,
check all bearings or mechanical couplings
such as set screws, and or key ways before
beginning to diagnose a hydraulic system
problem.
Figure 9-3: Flow Valve
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9.1.1 MANIFOLD (MD #133318)
Figure 9-4: Valve Manifold MD #133318

Port Part Number Description Torque
V1 MD #133557 Check Valve CVFP-12-N-0-015 68-75 Nm (50-55 lbf ft)
V2 MD #133558 Check Valve CVFP-08-N-0-015 34-41 Nm (25-30 lbf ft)
V3 MD #133559 Relief Valve 243140 RVDA-1455-12 34-41 Nm (25-30 lbf ft)
V4 MD #133560 Logic Valve LCEF-10-N-F-F-0-70 47-54 Nm (35-40 lbf ft)
V5 MD #133561 Relief Valve 243141-RVDA-1455-25 34-41 Nm (25-30 lbf ft)
V6 MD #133562 Flow control Valve NFCV-10-N-K-0 47-54 Nm (35-40 lbf ft)
V7 MD #133563 Compensator Valve PCEB-10-N-S-0-80 47-54 Nm (35-40 lbf ft)
V8 MD #133564 Check Valve Insert VUB1-916-00-000 15 Nm (11 lbf ft)
V9 MD #156904 Check Valve Fitting 8 psi
Seal Kit MD #133556
NOTE:
V9 is located on the return hose on the right
side of the reservoir.
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9.2 FORWARD OPERATION Feed Draper Relief (1200 psi above draper
pressure)
When the jackshaft on the combine feeder house
is engaged both the piston pump and the gear If the hydraulic pressure on the feed draper motor
pump are engaged. should exceed 1200 psi above side draper drive
pressure, “V3” will open and all the oil will by-pass
The variable displacement piston pump then draws
the feed draper motor. This means that the feed
oil from the reservoir tank and pumps it to the knife
draper will stop turning, however both side drapers
drive motors. This pump has been factory set to
will continue to operate normally.
deliver 16 gpm (61 lpm) minimum based on
recommended combine jackshaft speed per set-up To test the relief pressure of “V3” refer to Section
instructions. The return oil from the knife is 9.3.4.
combined with the return oil flow from the draper
circuit, it then passes through the filter (at a rate of Side Draper Relief
23-29 gpm (87-110 lpm)) after which the flow is split If the hydraulic pressure on the side draper motors
into two different directions. Approximately 30% of should exceed 2500 psi “V5” will open and all the
the flow is used as supply oil for the gear pump oil will by-pass the side draper motors and return
(draper drive) the other 70% of the oil flows through to tank. This means that the side drapers will stop
an integral cooling line, which runs through the turning however, the feed draper will continue to
upper beam of the reservoir tank, through the oil operate normally.
reservoir and into the R/H adapter leg. Then it exits To test the relief pressure of “V5” refer to Section
through a line at the bottom of the R/H leg of the 9.3.4.
reservoir which contains an 8 psi check valve (V9)
before returning to mix with the oil in the reservoir.
The check valve (V9) supercharges the supply oil to
the gear pump to 8 psi. V6
The supercharged (8 psi) supply oil enters the
S2T
valve block at port “S1”. Valve “V1” must be open
to allow supply oil to reach the gear pump. At the
same time valve “V2” must be closed as this valve V5
is only used in reverse operation. If “V2” is not fully S1 S2 V1
closed, the header side drapers and the center
draper will slow down or stop completely. V7
P
The oil then flows out port “S2” and supplies the R
gear pump with oil. The gear pump delivers oil (at
7-9 gpm; combine jackshaft speed dependant) to Figure 9-5: Valve Block - View 1
the valve block entering through port “P”. The oil
exits the valve block at port “M1” powering the feed V3
draper motor. It then re-enters the valve block at SD
port “M2”. Pilot pressure above 70 psi activates the PT
logic valve “V4” via a pilot line at internal port 3.
Once “V4” is activated the oil continues through SDT
the valve block to the flow control “V6” and M1
unloading valve “V7”, it then exits the valve block V4 T
at port “SD”. This oil then drives the left and right
side drapers and the upper cross auger (option if M2 V2
present). Finally the return oil tees into the return
line from the knife drive motor and makes it’s way
through the filter and back to tank.
Figure 9-6: Valve Block - View 2
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9.2.1 FORWARD OPERATION SCHEMATIC
Figure 9-7: Schematic - Forward Operation
Port “S2” Suction from valve block to gear Port “M1” Flow to Feed Draper Drive Motor
pump Port “S1” Suction from tank return line into valve
Port “S2T*” Test port for “S2” block
Port “P” Flow from gear pump into valve V1 Check Valve CVFP-12-N-0-015
block V2 Check Valve CVFP-08-N-0-015
Port “R*” Suction from tank for make-up oil in V3 Relief Valve 243140 RVDA-1455-12
reverse operation V4 Logic Valve LCEF-10-N-F-F-0-70
Port “SDT*” Test port for “SD” V5 Relief Valve 243141-RVDA-1455-25
Port “SD” Flow to side draper motors V6 Flow control Valve NFCV-10-N-K-0
Port “T” Return line to tank V7 Unloading Valve PCEB-10-N-S-0-80
Port “M2” Flow from Feed Draper motor into V8 Check Valve Insert VUB1-916-00-000
valve block V9 Check Valve Fitting
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9.2.2 FORWARD OPERATION - FEED DRAPER OVER RELIEF
Figure 9-8: Forward Operation - Feed Deck Over Relief
Port “S2” Suction from valve block to gear Port “M1” Flow to Draper Drive Motor
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9.2.3 FORWARD OPERATION - SIDE DRAPER OVER RELIEF
Figure 9-9: Forward Operation - Side Drapers Over Relief
Port “S2” Suction from valve block to gear Port “M1” Flow to Draper Drive Motor
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9.2.4 FORWARD OPERATION WITH KNIFE REVERSER
Figure 9-10:
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9.3 REVERSE OPERATION

When the combine’s feeder house is engaged in
reverse operation, the jackshaft will operate in
reverse. This will run both the piston pump and
gear pump in reverse.
V6
NOTE:
Although the piston pump can run in reverse
from 180 to 500 rpm it does not pump any oil
in reverse.
The gear pump will supply oil (at 2 gpm) to the V1 V5
valve block at port “S2”. The oil will then enter the
valve block and pressurize “V1”, closing it S2
completely. If valve “V1” is not fully closed, oil will
be allowed into the reservoir tank before
P V7
travelling through the adapter and will not
develop sufficient pressure to operate the feed
draper in reverse.
With “V1” closed oil will be forced through “V2”
and up towards the “V4” and “V5” valves. When Figure 9-11: Valve Block - View 1
operating in reverse the logic valve “V4” takes it’s
pilot pressure from the return line which only
operates at approximately 10 psi. Since “V4”
requires 70 psi of pressure to open it will remain
closed while the CA20 operates in reverse.
With both “V4” and “V1” closed the hydraulic oil
will be forced out port “M2” through the draper
drive motor and will then re-enter the block at
port “M1”. The oil will flow directly through the
block and will exit at port “P” and supply the gear M1
pump with oil. V4
To ensure there is sufficient oil in the hydraulic V2
system a supply line runs from the reservoir to
port R which allows the gear pump to draw in M2
make up oil while operating in reverse. This
prevents the pump from cavitating.
Relief Pressure
If the system pressure exceeds 2500 psi the Figure 9-12: Valve Block - View 2
relief valve “V5” will open and oil will flow back to
tank by-passing the feed draper motor. This
means the feed draper motor will not turn when
the system pressure exceeds 2500 psi.
To test the relief pressure of “V5” refer to Section
9.3.4
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9.3.1 REVERSE OPERATION SCHEMATIC
Figure 9-13: Schematic - Reverse Operation
Port “S2” Flow from gear pump into valve Port “T” Return line to tank
block Port “M2” Flow to Draper Drive Motor
Port “S2T*” Test port for “S2” V1 Check Valve CVFP-12-N-0-015
Port “P” Flow from valve block to gear pump V2 Check Valve CVFP-08-N-0-015
Port “SDT*” Test port for “S2” V5 Relief Valve 243141-RVDA-1455-25
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9.3.2 REVERSE OPERATION - OVER RELIEF
Figure 9-14: Schematic - Forward Operation
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9.3.3 REVERSE OPERATION WITH KNIFE REVERSER
Figure 9-15: Schematic - Reverse with Knife Reverse Operation
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9.3.4 CA20 HYDRAULIC PRESSURE TEST

Follow the procedure below to test draper
V3
pressures on CA20.
NOTE:
Test should be completed in forward operta-
tion. PT
1. Remove the steel cover off the back of the
adapter exposing the hydraulic filter and
valve block.
2. Run adapter and/or header for 10 minutes to

warm up oil. Figure 9-16: Port SD Location
3. Lower header to the ground and extend

center link as far as possible. Shut machine
off and remove the key.
4. Install a shut off valve at side draper port (A).

(Figure 9-17)
5. Remove plug and install 5000 psi pressure

gauge into port “PT” on front on valve block.
(This will be the feed draper relief pressure in
forward operation). (Figure 9-16) Figure 9-17: Port SD Location
6. Remove plug and install 5000 psi pressure SDT

gauge into port “SDT” on top of block. (This
will be the side draper operating and relief
pressure in forward operation). (Figure 9-18)
V5
7. Install a shut off valve at port “M1” (A).

(Figure 9-19)
8. Engage header in forward operaration at low

idle.
Figure 9-18:
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9. Install a shut off valve at port “M1” (A).

(Figure 9-19)
10. Engage header in forward operaration at low

idle.
Side Draper Relief:
11. Slowly close shut off valve installed on Port
SD. Check pressure on pressure gauge
plumbed in at port “SDT”. When valve is fully
closed, pressure should read 2500 psi +/-
200 psi. Adjust relief valve as follows: Figure 9-19: Port M1 location
a. Locate “V5” and loosen jam nut (B) using
an 11/16” open end wrench. (Figure 9-20) SDT
b. Turn valve adjusting screw (C) using a 5/
16” Allen wrench in 1/4 to 1/2 turn
intervals until the correct pressure is
V5
achieved.
c. Retest until necessary pressure is
achieved.
d. Tighten the jam nut once complete. Open
shut off valve.
NOTE:
Clockwise rotation of the relief screw will
increase the pressure and a counter-clock-
wise rotation of the relief screw will reduce
the pressure.
Figure 9-20:
12. Disengage header and engage in forward
operation.
C
B
Figure 9-21: Relief Valve Adjustment
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Feed Draper Relief:

13. Slowly close shut off valve installed on Port
V3
M1. Check pressure on pressure gauge
plumbed in at port “PT”. Pressure should
read 1200 psi +/- 150 psi above pressure
reading on port “SDT“. If it is not adjust relief
valve as follows: PT
a. Locate “V3” and loosen jam nut (B) using
an 11/16” open end wrench. (Figure 9-22)
b. Turn valve adjusting screw (C) using a
5\16” Allen wrench in 1/4 to 1/2 turn
intervals until the correct pressure is
achieved. Figure 9-22:
c. Retest until necessary pressure is

achieved. SDT
d. Tighten the jam nut once complete.
NOTE:
Clockwise rotation of the relief screw will V5
increase the pressure and a counter-clock-
wise rotation of the relief screw will reduce
the pressure.
14. Remove gauges and reinstall plugs.
15. Reinstall rear cover on adapter.
Figure 9-23:
C
B
Figure 9-24: Relief Valve Adjustment
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9.4 FLUSHING THE HYDRAULIC SYSTEM

Flushing the hydraulic system is required if debris
is found. If a motor has failed, holding the
housing of the motor, see if the shaft of the motor
can move along its axis of rotation (in and out of
the motor housing). If the shaft can move, the
thrust bearing has failed and has contaminated
the system.
9.4.1 FEED DRAPER MOTOR FAILURE
When diagnosing a feed draper motor, watch for
the following symptoms:
• Hydraulic oil leaking from the left hand
end of the feed draper drive roller: Oil
leaking from this connection indicates that
the shaft seal of the motor has failed.
• The side drapers or upper cross auger
moving slower than expected or a high
pitched noise originating from the
CA20 hydraulic manifold when the
side drapers are operating empty: The
noise is a sign that the side draper relief
valve (V5) is opening and closing repeat-
edly or being held open thus allowing oil
flow to bypass the side draper motors and
return to tank.
If either of the symptoms above is noticed, check
valves 3, 5, 6, and 7 for debris. If debris is found,
remove the feed draper motor.
1. Mark the M1 hose (A) from the feed draper
motor with tape to make it easy to identify
later. (Figure 9-25)
2. Disconnect all hoses from the manifold using
hose caps to minimize oil spillage.
3. Remove the manifold from the CA25 frame
and disconnect the following hoses from the
feed draper motor and side draper motors:
• Hoses connecting ports M1 and M2 to the
feed draper motor.
• Hose connecting port SD to the left hand
side draper motor.
Figure 9-25:
• Hose connecting the left hand motor to
the right hand motor.
• Hose connecting the right hand motor to
the return circuit run-tee fitting.
169046 ISSUE DATE 04/03/18

4. Flush all the hoses using a solvent and com-

pressed air. Check the ports of the motors for
debris.
5. Replace the failed feed draper motor. Ensure
that extreme pressure grease is applied to
the motor shaft when the motor is installed
into the draper drive roller.
6. Remove all the valves, filter, and port plugs
from the manifold housing. Ensure that the
valves are marked according to their location.
7. Flush the manifold using solvent and com-
pressed air. Visually check all the ports for
signs of debris.
8. Visually check all the valve cartridges for
signs of debris stuck inside the parts. Clean
using solvent and compressed air.
9. Once all the valves have been cleaned and
checked, reinstall into the manifold ensuring
the valves are torqued.
10. Reinstall the manifold and reconnect all the
hydraulic hoses.
11. Install a new oil filter (MD #151975).
12. Test hydraulic system, See “CA20 Hydraulic
Pressure Test” on page 9-13.
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9.5 SELECTOR VALVE BLOCK

9.5.1 HYDRAFORCE SELECTOR VALVE (PRIOR TO 2007)
• Standard Equipment - FD70
• Optional - D50 & D60
The selector valve will direct the flow from the combines reel fore-aft circuit to either the reel fore-aft of
the hydraulic center link circuit. This allows the operator to adjust either setting from the combine cab.
Figure 9-26: Hydraforce Selector Valve
IMPORTANT
Hoses must be connected as stated below to ensure cab monitor will display the proper func-
tion, for CASE 7010/8010 and NH CR/CX.
Barrel end tilt

Rod end tilt cylinder
cylinder port (at R/H Fore-aft cylinder L/H Fore-aft cylinder
port (at header)
adapter) (green) connects to: (red) connects to:
connects to:
connects to:
Case 7010/8010 &
Valve Port “A2” Valve Port “B2” Valve port “A1” Valve port “B1”
NH CR/CX
All other combines Valve Port “A1” Valve Port “B1” Valve Port “A2” Valve Port “B2”
Figure 9-27: Port Routing Chart for all Combines
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9.5.2 SELECTOR VALVE SCHEMATIC (CASE 7010/8010 & NH CR/CX)
Figure 9-28: Selector Valve NON-ENERGIZED - 3 Arm Reel (Reel Fore-Aft Selected)
169046 ISSUE DATE 04/03/18

9.5.3 SELECTOR VALVE SCHEMATIC (ALL, EXCEPT CASE 7010/8010, NH CR/CX)
169046 ISSUE DATE 04/03/18

9.5.4 HYDRAFORCE SELECTOR VALVE (2007 & NEWER)

This selector valve gives the operator the ability
to use hydraulic fore-aft option and the header tilt
option from the combine reel fore-aft circuit.
The 2007 and newer Hydraforce Selector Valves
consist of only two electronically activated
solenoid valves (as opposed to the three on the
previous model) and one pilot operated check
valve. The pilot operated check valve receives a
pilot pressure reading from the line at port “A2”
and opens whenever the pressure in this line
exceeds 25 PSI.
IMPORTANT
Hoses must be connected as stated below to
ensure the proper operation of the selector
valve for all combine models. Figure 9-32: Hydraforce Selector Valve (2007 &
Newer)
Identify hydraulic lines from where they are

coming from (barrel or rod end of cylinder).
Connect hoses to tilt and fore-aft cylinders as
follows:
• Barrel end tilt cylinder line to Valve Port “A2”
• Rod end tilt cylinder port to Valve Port “B2”
• Fore-Aft “fore” (Green) hose from Valve
Port “A1” to (See chart)
Fore-Aft “aft” (Red) hose from Valve Port “B1” to
(see chart)
Fore-Aft “fore” (green) hose

Fore-Aft “aft” (red) hose from
Header Model: from Valve Port “A1”
Valve Port “B1” connects to:
connects to:
D60 (Double Reel) R/H Fore-Aft cylinder (green) Center Fore-Aft cylinder (red) Barrel
FD70 Rod End End
D50 L/H Fore-Aft cylinder (green) R/H Fore-Aft cylinder (red)
D60 (Single Reel) Barrel End Barrel End
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9.5.5 SELECTOR VALVE SCHEMATIC FOR ALL COMBINES (2007 & NEWER)
Figure 9-33: Selector Valve NON-ENERGIZED D-Series 2 Arm Reel (Reel Fore-Aft Priority)
Figure 9-34: Selector Valve NON-ENERGIZED D-Series 3 Arm Reel (Reel Fore-Aft Priority)
169046 ISSUE DATE 04/03/18

9.6 COMBINE DATA: OUTPUT SHAFT SPEEDS ON HEADERS

Feeder
House
Combine
Speed
(RPM)
John Deere 520

CIH 44/66/77/88 series 525
CIH 570
Gleaner 624
Massey 624
Challenger 624
New Holland 570
Lexion1 420
IMPORTANT
Knife drive speed is determined by size of the
header and if the header is a single knife drive
or double knife drive (see chart on section
9.6.2). For combines with variable output do
not exceed recommended speeds (see chart)
as this can cause excessive header vibration.
NOTE:
1- 420 is the rear shaft speed on Lexion com-
bines (speed shown on cab monitor will also
be 420). The output shaft speed is actually
750 RPM.
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9.7 HYDRAULIC TESTING & REPAIR

9.7.1 MINIMUM TEST EQUIPMENT Needle Valve
The minimum testing equipment required is
shown in Figure 9-35 & Figure 9-36. The
equipment can be assembled from common Flow Meter
hydraulic components available at any local
hydraulic shop.
Required Equipment:
• A flow meter capable of handling 0-30
GPM.
• Needle Valve
• A 5/8” JIC 37 flare (tube) male/male 0 - 5000 PSI
straight fitting. Pressure Gauge
• A 7/8” JIC 37 flare (tube) male/male
straight fitting. Figure 9-35: Test Equipment
• Two 3ft. (1m) 1” diameter hydraulic hoses
with a minimum 4000 psi working pres-
sure. The ends of the hoses must be
adaptable to both 5/8” and 7/8” female
tube fittings. Female JIC
• 0-5000 PSI (0-345 bar) pressure gauge. Swivel Head
• A set of 1/2” pioneer flat couplers.
(MD # 135206 (female) & (male))
• A set of 3/4” pioneer flat couplers.
(MD # 135205 (male) & 135204 (female))
• 0-5000 PSI (0-345 bar) pressure gauge
NOTE:
Hydraulic couplers are only good on units
with quick couplers (05 & 06) with optional kit. Male/Male
NOTE: JIC Fitting
You will also require an additional pressure
gauge for doing the feed draper relief test. Figure 9-36: JIC 37° Flared Fittings
Assemble the above components so that the flow Male

gauge is at the output end of the circuit, the
pressure gauge is at the input end of the circuit
and the needle valve is in the middle (refer to
Figure 9-35).
Female
Figure 9-37: Pioneer Flat Couplers
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9.7.2 CHECKING KNIFE DRIVE FLOW & PRESSURE COMPENSATOR

The piston (knife drive) pump on CA20 combine Wobble Box Pulley Speed
adapter has variable displacement of 1.8 to 2.7
Knife Drive Speed (RPM)
cu in. This allows the output flow of the pump to
SKD DKD
be adjusted in order to achieve the appropriate
knife speed for a specific combine model. Factory Recommended Factory Recommended
Setting Range Setting Range
The piston pump on the CA20 combine adapter 600 550 - 650 660 550 - 690
also has an internal adjustable pressure
compensator valve which is set at 3500 psi. NOTE:
For SK, knife speed can be measured at
If the output flow or compensating pressure wobble box pulley or at driven pulley.
should need to be adjusted the following
procedures should be followed. For DK knife speed must be measured at
wobble box pulley.
NOTE:
May have quick couplers. NOTE:
Knife speed is factory set but will vary by
Checking Flow & Pressure Compensation: combine make and model (jackshaft speed).
1. Plumb in the test equipment into the pressure Ensure on variable speed feederhouses at
line to the knife drive motor. max feederhouse speed that the knife does
2. Connect the input line of the test equipment not exceed above recommended speed.
to the pressure line coming from the adapter Changing knife speed from factory setting is
(marked with orange tag) and connect the not recommended unless speed is lower than
output line of the test equipment. that indicated in the above chart. In some
applications such as: green weeds, green
CAUTION straw or very high ground speeds, the knife
speed may need to be increased. Increasing
Before starting the combine be sure that the the knife speed can cause higher cutting
needle valve on the test equipment is all the component wear or overall machine vibration.
way open. In all cases do not exceed the recommended
3. Run combine at low idle, engage separator & maximum speed for your header size and
feeder house. Increase engine RPM to max- type (SKD or DKD). If knife speed is adjusted
imum, the flow meter should read between ensure knife compensation is checked as
15-17 GPM depending on combine make and well. Follow all steps 5 through 10.
model (feederhouse jackshaft speed).
NOTE:
A jackshaft speed of 520 RPM is desired for
variable speed feederhouses (except Lexion:
420 RPM), some fixed speed feederhouse
combines may run slower or faster then rec-
ommended speed. Do not exceed maximum
knife speed listed on the chart in step 4.
4. The RPM of the wobble box pulley varies with

combine make and model. Use the following
table to determine the appropriate range.
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NOTE:
There are tow different piston pumps avail-
able for the CA20. One pump is a Sauer
(MD# 187229), the other pump is a Bosch
(MD# 187517 Note: there are two revisions
of this pump). It will say on the pump serial
tag, which one is installed, follow the proce-
dure below accordingly.
5. If the knife speed requires adjustment turn off

the header and combine:
Bosch:
Figure 9-38: Bosch Piston Pump (MD# 187517)
• Remove the cap nut and loosen the
locking nut on the piston pump displace-
ment valve using a 19 mm wrench. This is
the valve on the piston pump which is at a
30 degree angle (refer to Figure 9-40).
• Using a 5mm Allen wrench turn the

adjustment bolt clockwise to decrease the
flow and pulley speed, and counter-clock-
wise to increase the flow and pulley
speed. Tighten locking nut and replace
cap.
Sauer: Figure 9-39: Sauer Piston Pump (MD# 187229)
• Loosen the locking nut, using a wrench
turn the adjustment bolt clockwise to
decrease the flow and pulley speed, and
counter-clockwise to increase the flow
and pulley speed. Tighten locking nut.
6. Run the combine and header at full throttle

and tach the wobble box pulley again. Repeat
this procedure until the correct knife speed is
achieved. Figure 9-40: Bosch Piston Pump DIsplacement Valve
7. Once the knife speed is set (output flow) the

pressure compensation setting will need to
be checked.
8. While the test equipment is still plumbed in
the same direction and location, run the com-
bine and header at full throttle.
Figure 9-41: Sauer Piston Pump DIsplacement Valve
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9. Close the needle until the flow meter reads 0

GPM. The reading on the pressure gauge
should be 3500 psi (+/- 150 psi). If it does not
read 3350-3650 psi the pressure compen-
sator valve will need to be adjusted.
WARNING
Do not leave the needle valve completely
closed for more then 10 seconds at a time as
it will cause undo stress on the hydraulic
system. Do not continue to close needle valve
if pressure exceeds 3500 psi.
Figure 9-42: 3500 PSI Relief Pressure

10. Locate the pressure compensator valve on
the piston pump. Knife Motor
Bosch: Revision 1
Flow Gauge
NOTE: Needle Valve
This is the straight valve located on the back
Pres. Gauge
side of the pump (refer to Figure 9-44). Pump Filter
11. Remove the steel cap and loosen the jam nut
using a 17 mm open end wrench.
Reservoir
12. Turn the compensator screw using a 5 mm
Figure 9-43: Plumbing Schematic
Allen wrench until the compensator pressure
is correct (3500 psi).
NOTE:
Clockwise rotation of the compensator screw
will increase the pressure and a counter-
clockwise rotation of the screw will reduce the
pressure.
13. Once the compensation pressure is set

tighten the jam nut and replace the cap.
NOTE: Figure 9-44: Bosch Pressure Compensator Valve

Ensure on variable speed feederhouses, at
maximum feederhouse speed, that the knife
does not exceed recommended speed. See
“Wobble Box Pulley Speed” on page 9-25.
169046 ISSUE DATE 04/03/18

Bosch: Revision 2
14. Loosen set screw (A).
A
Turn the compensator screw (B) using an allen
wrench until the compensator pressure is correct
(3500 psi). (Figure 9-46)
B
Sauer:
15. Loosen set screw (F).
Figure 9-45: Bosch Pressure Compensator Valve
16. Turn the compensator screw (G) using an

allen wrench until the compensator pressure
G
is correct (3500 psi). (Figure 9-46)
NOTE:
Clockwise rotation of the compensator screw
will increase the pressure and a counter-
clockwise rotation of the screw will reduce the F
pressure.
17. Once the compensation pressure is set

tighten the set screw. Figure 9-46: Sauer Pressure Compensator Valve
NOTE:
Ensure on variable speed feederhouses, at
maximum feederhouse speed, that the knife
does not exceed recommended speed. See
“Wobble Box Pulley Speed” on page 9-25.
169046 ISSUE DATE 04/03/18

9.7.3 SETTING THE UNLOADING VALVE “V7”

The unloading valve “V7” on the CA20 combine
adapter dumps off excess oil flow which is not
used by the side drapers. This oil is then drained
back to tank. If the unloading valve should need
to be adjusted the following procedure should be
followed.
V7
Checking Unloading Valve “V7”:
1. Plumb in the test equipment along the 1/2”
hydraulic line running from port “SD” on the
valve block, to the header hydraulics. Plug
the output end of the test equipment into the
1/2” female flat coupler on the header and
plug the input end of the test equipment into
the 1/2’ male flat coupler on the adapter.
CAUTION Figure 9-47: Unloading Valve “V7”
Before starting the combine be sure that the

needle valve on the test equipment is all the
way open. C
B
2. Run combine at low idle, engage separator
and feederhouse. Increase engine RPM to
maximum, the flow meter should read the
same (+/-0.5 GPM) output flow as was
recorded in section 9.3.4 (between 7-9
GPM). If the flow is not within this range then
the unloading valve “V7” will need to be
adjusted.
Adjusting Unloading Valve “V7”: Figure 9-48: Unloading Valve - “V7”
1. Turn off the header and combine and remove

the steel cover off the back of the adapter
exposing the hydraulic filter and valve block.
2. Locate “V7” (refer to Figure 9-47) and loosen
jam nut (B) using a 3/4” open end wrench.
Turn valve adjusting screw (C) using a 5\16”
Allen wrench. Be sure and turn the adjusting
screw in 1/2 turn increments. Tighten the jam
nut once complete.
3. Run unit up and check flow again. Repeat if
necessary.
NOTE:
Clockwise rotation of the adjusting screw (C)
will increase the flow and a counter-clockwise
rotation of the relief screw will reduce the
flow.
169046 ISSUE DATE 04/03/18

9.7.4 TESTING GEAR PUMP EFFICIENCY

This test will provide an accurate reading of the
CA20’s gear pump (draper system) efficiency.
NOTE:
If a hydraulic component failure is suspect it
is important to check the relief pressures prior
to performing a gear pump efficiency test.
Specifications:
“X”
Gear Pump
• Lexion & Agco: MD# 156853 or 187253 -
0.67 cubic inch (11cc) displacement gear
pump. Gear Pump
• All Other Combines: MD# 156852 or
187252 - 0.98 cubic inch (16cc) displace- Figure 9-49: Gear Pump
ment gear pump.
NOTE:
The two gear pumps are identical in looks, Insert Test
the only difference is that the bodies are dif-
ferent lengths. (Figure 9-49) Equipment Here
• Lexion & Agco: MD# 156853 or 187253
“X” = 2-5/16” (59 mm)
• All Other Combines: MD# 156852 or
187252 “X” = 2-1/2” (63.5 mm)
Seal Kit: MD #133568 - Same for both models.

Checking Pump Efficiency: Figure 9-50: Gear Pump - Output
1. Install test equipment as shown in Figure 9-50.
Make sure the input end of the test equipment Flow Gauge
is the end closest to the pump.
2. The system must be tested hot. In order to Hyd. System
accomplish this run up the system to oper-
ating speed and close the needle valve until
the pressure gauge reads 1000 psi. Run the Needle Valve
system at this pressure for 10 to 15 minutes.
3. With the system hot record the hydraulic flow Pressure Gauge
at 1000 psi (should be between 7-9 GPM). Pump Filter
4. Increase the system pressure to 2000 psi, the
hydraulic flow should not drop more than 2
GPM. If the pump’s output flow drops more
than 2 GPM the pump efficiency is low and
the pump will need to be repaired or
replaced. Reservoir
Figure 9-51: Gear Pump Test Schematic
169046 ISSUE DATE 04/03/18

9.7.5 TESTING PISTON PUMP EFFICIENCY

CA20’s knife drive piston pump efficiency.
Specifications:
NOTE:
There are two different piston pumps avail-
able for the CA20. One pump is a Sauer
(MD# 187229), the other pump is a Bosch
(MD# 156033 Note: There are two revi-
sions of this pump). See which one is
installed and follow the following procedure
accordingly.
Piston Pump:
Variable displacement piston pump: Piston Pump
• Lexion & Agco (MD# 187229): - Factory
Figure 9-52: Piston Pump
set at 16 to 20 GPM @ jackshaft RPM of
750 ± 10). Flow Gauge
• All Other Combines (MD# 156033): - Knife Drive Motor
Factory set at 16 to 20 GPM @ jackshaft
RPM of 580 ± 10).
Seal Kit: MD #133569
Needle Valve
Checking Pump Efficiency:
1. Plumb in the test equipment into the pressure Pressure Gauge
line to the knife drive motor at the line on the Pump
header marked with an orange tag. Filter
2. The system must be tested hot. In order to
accomplish this run up the system to oper-
ating speed and close the needle valve until
the pressure gauge reads 1000 psi. Run the Reservoir
system at his pressure for 10 to 15 minutes.
Figure 9-53: Piston Pump Test Schematic
3. With the system hot record the hydraulic flow
at 1000 psi. Oil flow should be between 16-20
GPM depending on feederhouse jackshaft
speed.
hydraulic flow should not drop more than 2
GPM. If the pump’s output flow drops more
than 2 GPM the pump efficiency is low and
the pump will need to be repaired or
replaced.
169046 ISSUE DATE 04/03/18

9.8 HYDRAULIC OIL SPECIFICATIONS

The CA20 combine adapter is produced using
15W-40 Multi Grade oil.
The following is a recommended and acceptable
oil specification:
Recommended:
• Any 15W-40 Multi Grade oil compliant
with SAE specifications for API class SJ
and CH-4 engine oil.
IMPORTANT
Mixing of different viscosity oils can cause
hydraulic problems. Make sure when
changing to a different type of oil that all the
existing oil is drained completely (refer to
Section 9.10).
Figure 9-54: Oil Specifications
9.9 ADAPTER OIL TEMPERATURE
Check using a digital temperature reader.

Recommend testing just above the piston pump
suction line. (Figure 9-55)
If the oil temp in the field is 80ºF (27°C) or less

over ambient – all is normal.
If the oil temp in the field is 80°F to 100°F (27°C

to 38°C) over ambient – look for a reason. There Figure 9-55: Check Temperature Location
may be a problem or machine is operating in
exceptional conditions.
If the oil temp in the field is more than 100ºF

(38°C) over ambient – unit requires hydraulic
testing as there is an issue causing excessive oil
temp.
Examples: Plugged filters, low fluid, restric-
tion in the lines, etc...
169046 ISSUE DATE 04/03/18

9.10 OIL CHANGE PROCEDURE

It is recommended that the oil is changed every
1000 hours and the filter is changed after the first
50 hours and 250 hours there after. The oil and
filter should also be changed after any hydraulic
component failure.
To change the oil in the CA20 combine adapter
use the following procedure:
1. Properly mount the adapter to the combine
and raise the feeder house up high enough to
place an oil bucket under both the left and
right hand adapter leg (tanks).
Drain Plugs
IMPORTANT
Be sure to use the safety props or block the
Figure 9-56: Drain Plug Locations (Front of Adapter)
feeder house in order to prevent the adapter
and feeder house from falling in the event of a
hydraulic line failure.
2. Remove the filler cap from the top of the reser-
voir. Using 1-1/2” wrench remove the two drain
plugs located at the bottom of the left and right
hand tank (Figure 9-56) (Figure 9-57).
3. Allow oil to drain completely from both the left
and right hand tank. Replace plugs and
tighten to standard torques.
NOTE:
Make sure the O-rings on the plugs are
present and in good condition otherwise
replace them accordingly.
4. Remove the pails from under the adapter and
Figure 9-57: O-ring Drain Plug
lower the adapter until the oil gauge is ver-
tical.
5. Fill the reservoir through the filler cap, until
the oil level is slightly below the mid point on
the oil gauge. (Figure 9-58)
NOTE:
Do not fill the reservoir any more then indi-
cated as the oil will expand when the unit is
brought up to full operating temperature. 2007
&
Prior
Figure 9-58: Oil Gauge (2008 & Later)
169046 ISSUE DATE 04/03/18

9.11 REEL LIFT CYLINDERS

9.11.1 REEL LIFT THEORY
In a static state the pressure (P1, P2, & P3) are
relative to each other and in general can be used
to help diagnose in which direction oil will flow if a
given seal is defective. Oil will flow from the high
pressure side to the low pressure side.
On a split reel the center reel arm cylinder carries

3.5 times more weight than the L/H cylinder due
to the reel drive and cam being at the center of
the reel. Also there is more weight on the center
cylinder due to it being mounted farther back.
This fact also accounts for the shorter stroke
length on the center cylinder. The R/H cylinder
carries 1.4 times more weight than the L/H
cylinder due to the cam being on the R/H side.
Figure 9-59: Three Cylinder Circuit

F varies as the reel is moved up and down.
P1 > (is greater than) P2

P2 > (is greater than) P3
On a single span reel, the L/H cylinder is the

slave and the R/H cylinder is the master. The R/H
cylinder carries 1.2 times more weight than the L/
H cylinder. The pressure is higher in the master
than the slave.
Consider header bouncing around over the field

at any time if downward F reduces dramatically
as the center reel momentarily bounces up then
P2 can increase great enough to force oil back to
the area at P1 through a leaky seal.
Figure 9-60: Two Cylinder Circuit
169046 ISSUE DATE 04/03/18

9.11.2 REEL DRIVE, LIFT & FORE-AFT SCHEMATICS
Figure 9-61: Single Span Reel
Figure 9-62: Split Reel
169046 ISSUE DATE 04/03/18

9.11.3 DIAGNOSTIC TEST - STATIC 9.11.4 DIAGNOSTIC TEST - DYNAMIC

1. Lower reel all the way down and hold to re-
phase the cylinders. IMPORTANT
2. Raise the reel at least 1/2 way up, or at Care must be taken when reporting symp-
normal operating height. (Reel should toms observed while machine is in operation.
move at each arm at the same time if one For example, if reel appears to be dropping
arm moves significantly ahead of another on one end confirm that the reel is dropping
refer to dynamic tests). on that end and also report what is happening
to the other end, and middle. The problem
3. Measure the shiny exposed portion of the cyl- can be quite different if the other end is
inder rod at each cylinder and record mea- raising or staying at the same level. If the
surement. middle of the reel appears to be lifting make
4. After a minimum of ten minutes re-measure sure you also report whether the ends of the
as in step 3 and note any changes up or reel are falling, or staying at the same level.
down. Changes of 1/16” (2 mm) or less The following is a list of pointers on the
should be recorded as “no change”. Recheck observations required when trying to accu-
in 5-10 minutes to confirm results. (Refer to rately diagnose reel lift problems.
solutions on the following page)
If reel is tested overnight remember that thermal 1. Run the header in the field to determine the
expansion can cause some unexpected results. optimal reel height for dynamic tests. Lower
Especially when air is in hydraulic lines. reel all the way down and hold to re-phase
5. IF STATIC TEST CANNOT DIAGNOSE the cylinders. Raise the reel to operating
PROBLEM PROCEED TO DYNAMIC height, stop machine. Measure the shiny
TESTS. exposed portion of the cylinder rod at each
cylinder and record measurement. Alterna-
NOTE:
Static tests are 90% reliable diagnosing tively, mark one bat and position vertically
severe problems. Seals do leak normally and over c-bar and measure to the same point on
the severity of the leak will depend on the c-bar and bat as close to reel support arm as
length of rod exposed (i.e. reel height is off possible, continue to operate in field.
the cutter bar when cutting). Concentricity of 2. After a period of time, or when symptoms
the barrel is another concern (has it been become obvious recheck measurements and
squeezed in a vice). Weight of the reel and refer to the solutions on the following page.
roughness of the ground are other concerns.
Re-phasing of the reel is to be expected 4-5
times an hour, depending on ground condi-
tions, and if static tests pass cylinder should IMPORTANT
be considered acceptable. Welding distortion Dynamic tests are to verify the symptoms that
on the barrel can effect the squeeze of the are observed, and to confirm symptoms
cylinder and leakage can increase as cylinder reported that could not be verified by a static
is tested closer to the lower end near the port. test.
169046 ISSUE DATE 04/03/18

9.11.5 STATIC AND DYNAMIC TEST DIAGNOSTIC CHART: CYLINDER VS. SYMPTOM
Problem/
Slave Cylinder Center Master Master Cylinder
Solution
Down Up 1
Down No Change 2,3, or 4
Down Down 5
Up No Change 4
No Change Up No Change 9
Down No Change Up 1
Up Down Up 6
Down Down Down 7
Down Down Up 1 and 6
Up No Change Up 4
Up No Change No Change 4
Down No Change Down 8
Down No Change No Change 4 or 3
No Change No Change No Change ok
Figure 9-63: Static and Dynamic Test Diagnostic Chart: Cylinder vs. Symptom
6. Internal leaks at centre master cylinder seals.
Identify the type of cylinder by the number
Problem/Solution:
stamped on it.
1. Internal leak at Master Cylinder most likely
7. Leaks between base of centre master cyl-
poor seal. Check the seal's condition If good
inder and hydraulic source (traction unit).
inspect cylinder bore for scratches or over-
Repair as in solution 5.
size bore. Do not hone cylinder bore, but
replace cylinder (honing may reduce seal 8. Leak in line between center cylinder and sec-
contact pressure). ondary master cylinder.
2. External leak at Slave Cylinder. Replace 9. May be insufficient tension at compression
slave cylinder seal kit. spring in poppet valve. This symptom may
occur when operating at high speeds on
3. Leak at a line between Master and Slave cyl-
rough ground. Slower ground speeds recom-
inders. Locate leak in line, or connection
mended.
(Check inside Back-tube) and repair.
4. Air in system. Bleed air from slave cylinder.
Loosen bleed screw and allow air to escape
tighten bleed screw, cycle reel up and down
several times and repeat until no air is
present.
5. Leak between base of master cylinder and
hydraulic source (traction unit). Locate leak
and repair.
HINT: Try disconnecting reel lift line from

hydraulic source to confirm whether problem
with header or traction unit.
169046 ISSUE DATE 04/03/18

Solutions (Single Span Reel):

If a problem is present the reel will always sag at
the slave cylinder, if the testing procedures
described on the previous page are used. In
order to determine which cylinder is faulty use
the following guide lines:
• Slave cylinder sags but no seal leaks are

present on the slave cylinder - Master
Cylinder no good
• Slave cylinder sags and a seal leak is
present on the slave cylinder - Slave Cyl-
inder no good
Solutions (Split Reel):
1. Center Master cylinder sags, others do not

move - Center Master no good.
Figure 9-64: Center Master Sags
2. Slave cylinder sags while all others remain

constant - Slave cylinder no good (oil will be
leaking from the top seal of cylinder)
Figure 9-65: Slave Cylinder Sags
3. Slave cylinder sags and Secondary Master

raised - Secondary master no good.
Figure 9-66: Slave Sags & Secondary Master Raised
169046 ISSUE DATE 04/03/18

9.12 COMPONENT REPAIR NOTE:

Honing of the cylinder barrel is not recom-
9.12.1 SINGLE REEL HEADER CYLINDERS mended as it will decrease the seal to wall
Reel Lift (L/H) Cylinder (145237) Repair contact pressure.
NOTE: 7. Replace seals on head plate and thread
Cylinders re-phases at both ends of the securely into cylinder barrel. Re-install cyl-
stroke through a re-phasing port. inder into header.
The table below refers to cylinder MD #145237
specifically. Items listed below are found in the
seal repair kit MD #132474.
ITEM # DESCRIPTION
1 W-Ring 1.75 OD x 0.125 x 0.19
3
2 W-Ring 1.00 ID x 0.625 x 0.375
3 O-Ring BN 1.250 x 1.00
4
4 Wiper Snap 1.00 x 1.28 x 0.104
5 U Cup Rod 1.00 x 1.25 x 0.250 9
6 O-Ring P 1.75 x 1.50 x 0.187
7 BU Washer 1.750 x 1.500 5
8 O-Ring BN 1.750 x 1.500 2
9 O-Ring BN 1.938 x 1.750
10 O-Ring BN 0.625 x 0.500 7
1. Raise reel up and engage reel support props, 8
then lower reel onto props. Stroked
593 MM.
2. Remove pin at top of cylinder. Be careful not
to lose the spacer bushings when removing Closed
378 MM.
the pin.
3. Disconnect hoses and remove lower cylinder 10
pin, remove cylinder.
4. Clamp cylinder in a vise at base end to pre- 6
vent deforming the barrel of the cylinder.
Remove head plate with pipe wrench.
Remove rod assembly. Clamp hex nut in vice
1
and turn rod out of nut. Pull piston off rod to
replace O-ring (10).
5. With the new O-ring installed push piston
back onto rod and thread piston back into nut
until piston is firmly seated against the
shoulder of the rod.
6. Replace piston seal (6) and flat expander ring
(1) using oil or grease as a lubricant. Prior to
re-insertion of piston examine barrel for nicks Figure 9-67: Reel Lift Cylinder L/H (145237)
and scratches and hone if necessary. Use
caution not to damage the seal on the
threads when reinstalling.
169046 ISSUE DATE 04/03/18

Reel Lift (R/H) Cylinder (145395) Repair NOTE:

NOTE:
mended as it will decrease the seal to wall
Cylinders re-phases at both ends of the
contact pressure.
stroke through a re-phasing port.
7. Replace seals on head plate and thread
securely into cylinder barrel. Re-install cyl-
inder into header.
ITEM # DESCRIPTION
1 W-Ring 1.00 ID x 0.625 x.375
2 O-Ring BN 1.25 x 1.00
3 Wiper Snap 1.00 x 1.28 x 1.04 2
4 U Cup Rod 1.00 x 1.25 x 0.250 3
5 O-Ring P 2.00 x 1.625 8
6 BU Washer 2.00 x 1.750
7 O-Ring BN 2.00 x 1.750 4
8 O-Ring BN 2.188 x 2.00
1
9 O-Ring BN 0.750 x 0.625 6
1. Raise reel up and engage reel support props,
then lower reel onto props.
7
to lose the spacer bushings when removing Stroked
598 MM.
the pin.
Closed
3. Disconnect hoses and remove lower cylinder 378 MM.
4. Clamp cylinder in a vise at base end to pre-
vent deforming the barrel of the cylinder. 9
replace O-ring (9).
back onto rod and thread piston back into nut 5
6. Replace piston seal (5) using oil or grease as
a lubricant. Prior to re-insertion of piston
examine barrel for nicks and scratches and
hone if necessary or replace the cylinder. Use
Figure 9-68: Reel Lift Cylinder R/H (145395)
169046 ISSUE DATE 04/03/18

Fore-Aft Cylinders (137458 & 113434) Repair

Table below refers to cylinder MD #137458 &
#113434 specifically. Items listed below are found
in the seal repair kit MD #113435.
NOTE:
The only difference between cylinders
137458 & 113434 is a blank port which is
welded to the side of cylinder 113434. This
port is strictly for mounting purposes.
ITEM # DESCRIPTION
2 O-ring (Buna N) 1 3/8” x 1 5/8” x 1/8
3 Rod Seal (Poly) 7/8” ID x 1-1/8” OD x 1/
4”
4 Rod Wiper Seal (Poly) 7/8” ID x 1-1/8”
OD x 3/16”
5 Wear Ring (Nylon Glass filled) 7/8” ID 1-
1/8” OD x 3/16”
7 Piston Seal 1-1/4” ID X 1-1/2” OD x 1/8”
8 O-ring 5/8” ID x 11/16” OD x 3/32”
1. Ensure reel arms are level or lock reel for-aft

out with bolts to keep reel from moving.
2. Disconnect hoses and remove cylinder pins,
remove cylinder.
3. Clamp cylinder in vice at base end to prevent
deforming barrel of cylinder. Remove head
plate with pipe wrench.
4. Remove piston and rod assembly. Clamp hex
nut in vice and turn rod out of nut. Pull piston
off rod to replace O-ring (8) and replace with
new one.
5. Push piston back onto rod and thread piston
back into nut until piston firmly seated against
shoulder and rod sticks out slightly past nut.
6. Insert piston rod assembly back into barrel,
be careful not to damage seal on the threads.
7. Replace seals on head plate and thread back
into barrel and tighten.
Figure 9-69: Fore-Aft Cylinder (137458)
169046 ISSUE DATE 04/03/18


#164934 specifically. Items listed below are
found in the seal repair kit MD #113435.
NOTE:
The only difference between cylinders MD
#164933 & MD #164934 is a blank port which
is welded to the side of cylinder MD #164933.
This port is strictly for mounting purposes.
1 9/16-18UNF-2A
2 7/8 ID x 1 1/8 OD x 3/161
3 1 3/8 ID x 1 5/8 OD x 1/82
4 7/8 ID x 1 1/8 OD x 1/43
5 7/8 ID x 1/16 Thk x 3/8 Wide
6 5/8 ID x 11/16 OD x 3/322
7 1 1/4 ID x 1 1/2 OD x 1/83
1. Polyurethane
2. Buna-N
3. Poly / Buna
remove cylinder.
new one.
169046 ISSUE DATE 04/03/18

9.12.2 DOUBLE REEL HEADERS CYLINDERS

Center Master Reel Lift Cylinder (145386) Repair
NOTE: NOTE:
Cylinders re-phases at both ends of the Honing of the cylinder barrel is not recom-
stroke through a re-phasing port. mended as it will decrease the seal to wall
The table below refers to cylinder MD #145386 contact pressure.
specifically. Items listed below are found in the 7. Replace seals on head plate and thread
seal repair kit MD #132476. securely into cylinder barrel. Re-install cyl-
ITEM # DESCRIPTION
inder into header.
1 W-Ring 1.25 OD x 0.625 x.375
2 O-Ring BN 1.375 x 1.125
3 Wiper Snap 1.13 x 1.50 x 1.87
4 U Cup Rod 1.13 x 1.38 x 0.250
2
5 O-Ring P 2.50 x 2.125
3
6 BU Washer 2.50 x 2.250
7 O-Ring BN 2.50 x 2.250
8 O-Ring BN 2.688 x 2.50 8
9 O-Ring BN 0.750 x 0.625
4
then lower reel onto props. 1
2. Remove pin at top of cylinder. Be careful not 6
to lose the spacer bushings when removing
the pin.
7
3. Disconnect hoses and remove lower cylinder
pin, remove cylinder. Stroked
520 MM.
vent deforming the barrel of the cylinder. Closed
344 MM.
5
replace O-ring (9).
a lubricant. Prior to re-insertion of piston 9
hone if necessary or replace cylinder. Use
Figure 9-71: Center Reel Lift Cylinder (145386)
169046 ISSUE DATE 04/03/18

Reel Lift (R/H) Cylinder (145237) Repair

NOTE: NOTE:
Cylinders re-phases at both ends of the Honing of the cylinder barrel is not recom-
stroke through a re-phasing port. mended as it will decrease the seal to wall
The table below refers to cylinder MD #145237 contact pressure.
specifically. Items listed below are found in the 7. Replace seals on head plate and thread
seal repair kit MD #132474. securely into cylinder barrel. Re-install cyl-
inder into header.
ITEM # DESCRIPTION
1 W-Ring 1.75 OD x 0.125 x 0.19
2 W-Ring 1.00 ID x 0.625 x 0.375
3 O-Ring BN 1.250 x 1.000
4 Wiper Snap 1.00 x 1.28 x 0.104
5 U Cup Rod 1.00 x 1.25 x 0.250
3
6 Piston Seal 1.750 x 1.50 x 0.187
7 BU Washer 1.750 x 1.500 4
8 O-Ring BN 1.750 x 1.500
9 O-Ring BN 1.938 x 1.750 9
10 O-Ring BN 0.625 x 0.500
5
then lower reel onto props. 2
to lose the spacer bushings when removing 7
the pin.
8
3. Disconnect hoses and remove lower cylinder Stroked
593 MM.
Closed
4. Clamp cylinder in a vise at base end to pre- 378 MM.
Remove head plate with pipe wrench. 10
replace O-ring (10). 6
back onto rod and thread piston back into nut 1
6. Replace piston seal (6) and flat expander ring
(1) using oil or grease as a lubricant. Prior to
re-insertion of piston examine barrel for nicks
and scratches and hone if necessary or
replace cylinder. Use caution not to damage
the seal on the threads when reinstalling.
Figure 9-72: Reel Lift Cylinder R/H (145237)
169046 ISSUE DATE 04/03/18

Reel Lift (L/H) Cylinder (145395) Repair

NOTE: 7. Replace seals on head plate and thread
Cylinders re-phases at both ends of the securely into cylinder barrel. Re-install cyl-
stroke through a re-phasing port. inder into header.
ITEM # DESCRIPTION
1 W-Ring 1.00 ID x 0.625 x.375 2
2 O-Ring BN 1.25 x 1.00 3
3 Wiper Snap 1.00 x 1.28 x 1.04 8
4 U Cup Rod 1.00 x 1.25 x 0.250
5 O-Ring P 2.00 x 1.625 4
6 BU Washer 2.00 x 1.750
1
7 O-Ring BN 2.00 x 1.750
6
8 O-Ring BN 2.188 x 2.00
9 O-Ring BN 0.750 x 0.625
1. Raise reel up and engage reel support props, 7
then lower reel onto props. Stroked
598 MM.
Closed
to lose the spacer bushings when removing 378 MM.
the pin.
3. Disconnect hoses and remove lower cylinder
pin, remove cylinder. 9
replace O-ring (9). 5
a lubricant. Prior to re-insertion of piston
hone if necessary or replace cylinder. Use
caution not to damage the seal on the Figure 9-73: Reel Lift Cylinder L/H (145395)
NOTE:
mended as it will decrease the seal to wall
contact pressure.
169046 ISSUE DATE 04/03/18


#113434 specifically. Items listed below are found
in the seal repair kit MD #113435.
NOTE:
ITEM # DESCRIPTION
2 O-ring (Buna N) 1 3/8” x 1 5/8” x 1/8
3 Rod Seal (Poly) 7/8” ID x 1-1/8” OD x 1/
4”
4 Rod Wiper Seal (Poly) 7/8” ID x 1-1/8”
OD x 3/16”
5 Wear Ring (Nylon Glass filled) 7/8” ID 1-
1/8” OD x 3/16”
7 Piston Seal 1-1/4” ID X 1-1/2” OD x 1/8”
8 O-ring 5/8” ID x 11/16” OD x 3/32”

remove cylinder.
new one.
169046 ISSUE DATE 04/03/18


#164934 specifically. Items listed below are
found in the seal repair kit MD #113435.
NOTE:
ITEM # DESCRIPTION
1 9/16-18UNF-2A
2 7/8 ID x 1 1/8 OD x 3/161
3 1 3/8 ID x 1 5/8 OD x 1/82
4 7/8 ID x 1 1/8 OD x 1/43
5 7/8 ID x 1/16 Thk x 3/8 Wide
6 5/8 ID x 11/16 OD x 3/322
7 1 1/4 ID x 1 1/2 OD x 1/83
1. Polyurethane
2. Buna-N
3. Poly / Buna

remove cylinder.
new one.
169046 ISSUE DATE 04/03/18

9.13 HYDRAULIC MOTOR

9.13.1 SIDE DRAPERS
D50 MD# 172471 or MD# 220891
D60 MD# 120930 or 220936
A
FD70 MD#172471 or 220891
B
Removal Side Draper Motor
1. Release the tension from the draper. Turn the

draper drive roller until the hex headed set
screw in the drive roller lines up with hole (A)
in the mounting bracket, then remove the set Figure 9-76: Draper Drive Motor
screw. Turn the roller another quarter turn,
there should be another set screw in the
roller. Once this is complete remove the
hydraulic lines from the motor and cap them
off, as well as the motor ports. Remove the
the mounting hardware at (B) and slide the
motor out of the draper drive roller.
169046 ISSUE DATE 04/03/18

Disassemble (MD# 172471/120930):

NOTE:
The D50 & D60 motors are almost identical.
The difference in procedure will be noted at
the appropriate time.
Cleanliness is extremely important when

repairing these motors. Work in a clean area.
Before disconnecting lines, clean port area of
motor. Remove key when used. Check shaft and
key slot. Remove burrs, nicks and sharp edges.
Before disassembly, drain oil from motor. Then
plug ports and thoroughly clean exterior of motor. Figure 9-77: Remove End Cover Bolts
Although not all drawings show the motor in a
vise, we recommend that you keep the motor in a
vise during disassembly. Follow the clamping
procedures explained throughout the manual.
1. Place motor in vice and clamp across edge of

flange with output shaft down. When
clamping, use protective device on vise such C
as special soft jaws, pieces of hard rubber or
board. Using a marker pen drawn two refer-
ence lines, in the shape of a V down the side
of the motor as shown in (Figure 9-77). This
will insure that the motor is reassembled cor-
rectly. Once the reference lines are marked
remove the 7 end cover bolts using a 1/2” (13
mm) wrench.
Figure 9-78: Remove End Cover & Seal
IMPORTANT
Once the end cover bolts are removed use a
sliding motion to remove the end cover. This
will insure that the gear wheel set “C” will not
come apart upon disassembly.
DO NOT DISASSEMBLE THE GEAR WHEEL SET!
2. Remove and discard the end cover seal

using a seal pick and place the end cover in a
clean location on the work bench.
169046 ISSUE DATE 04/03/18

3. Once the end cover is remove wipe the gear

set clean with a shop towel. Using a paint
marker draw two or three reference marks on
the gear set, refer to (Figure 9-79). This will
ensure that the gear set will go back together
the exact same way should it accidently
come apart.
Figure 9-79: Rotor Reference Marks

4. Remove the gear set being careful not to sep-
arate the rotor from the main wheel, refer to
(Figure 9-80). Once this is complete carefully
remove and discard the seal from the base of
the gear set, then remove the channel plate D
from the motor housing. Place the gear set
and the channel plate in a clean location on
the work bench.
Figure 9-80: Remove Gear Set
5. Remove and discard the seal from slot E,

then remove the cardan shaft from the motor
and place it in a clean location on the work
bench.
E
Figure 9-81: Remove Cardan Shaft
169046 ISSUE DATE 04/03/18

6. Remove the motor from the vise, flip it upside

down and drain the excess oil contained in
the pump into a drain pan.
7. Mount the motor in the vise with the output

shaft pointing upwards. Remove the six hex
head bolts using a 7/32” (4 mm) Alan wrench,
then remove the spigot flange using a pair of
needle nose pliers.
Figure 9-82: Remove Spigot Flange
8. With the spigot flange separated from the

H
motor body, remove the inner and outer shaft
seals; F and G as well as the spigot flange
seal H and discard. F
Figure 9-83: Remove Flange Seals
9. Using a seal pick remove the inner and outer

race as well as the thrust bearing and place
them in a clean location on the work bench.
Note the order in which each component was
removed.
NOTE:
The thrust bearing and its races can also be
removed by turning motor upside down and
gently taping on the backside of the motor.
Figure 9-84: Remove Thrust Bearing
169046 ISSUE DATE 04/03/18

10. With the thrust bearing and all the seals

removed turn the output shaft back and forth
in both directions and determine if there are
any ruff spots or binding occurring in the
needle bearings. If the rotation of the shaft in
both directions is smooth the motor can be
rebuilt otherwise it will need to be replaced.
Repair MD# 172471/120930:

There is a seal kit available through MacDon
parts MD# 132759 is used for both motors.
Figure 9-85: Turn Shaft

Inspect motor housing, thrust bearing, gear set
and all other components for any scoring,
damage or excessive wear. If there is any
damage to any of these components the motor
will need to be replaced. If all the components
are undamaged they should be cleaned using in
an oil-base solvent and dried with compressed
air (for safety observe all OSHA safety
guidelines).
It is also important that all new seals be lightly
coated in oil or grease prior to installation.
If the order of assembly is lost or becomes

confusing at any point during the reassembly,
refer to (Figure 9-86) for the exploded parts view.
Figure 9-86: Exploded View
Reassembly (MD# 172471/120930):
NOTE:
On motor MD# 172471, there is a bushing
instead of the thrust bearings.
1. Install the races and thrust bearing back on to

the output shaft remembering that the thinner
race goes on before the bearing while the
thicker race goes on after.
Figure 9-87: Install Thrust Bearing
169046 ISSUE DATE 04/03/18

2. Install the new lightly oiled/greased outer

shaft seal, inner shaft seal and spigot flange
seal into the spigot flange. Make sure to
press in the inner and outer shaft seals as
attempting to pry or hammer them into place
will cause damage to the seals.
Figure 9-88: Install New Shaft Seals
1
3. Install the spigot flange, washers and hex 4 5
headed bolts. Torque the hex head bolts to 2 3
4.5 to 6 ft-lbs. (6 to 8 Nm). When torquing the 6
bolts do not follow a circular pattern but
torque the bolts in a diagonal order (never
torque the bolt directly beside the one which
was just torqued), follow this pattern till all six
bolts are tight.
Figure 9-89: Torque Hex Head Bolts
4. Loosen the vise holding the motor and flip the

motor 180 degrees so that the output shaft is
pointing downwards; tighten the vise with the
motor in this position.
I
5. Install the new o-ring I into the grove in the
motor body then place the channel plate on
top so that the V shaped reference marks are
aligned.
Figure 9-90: Install Channel Plate
169046 ISSUE DATE 04/03/18

6. Place a magnet J on the gear set in order to

hold it together as it is placed into position,
refer to (Figure 9-91) (make sure all refer- J
ence marks are aligned). Slide the cardan
shaft through the rotor in the gear set and
then through the hole in the channel in shown
in (Figure 9-91). Once this is done carefully
place the gear set against the channel plate
and make sure the V shaped reference
marks are aligned. Once complete remove
the magnet.
NOTE:
The gear set and cardan shaft must be
assembled by the way described in step 6,
otherwise the pump body, channel plate and
gear set will not align properly.
Figure 9-91: Install Cardan Shaft
7. Once the gear set and cardan shaft are

assembled correctly remove the paint marks
from the gear.
8. Insert the new o-ring seal into the grove in the

end cover and place the end cover in position
making that the reference marks are aligned.
Figure 9-92: Install End Cover
9. Insert and hand tighten the six end cover

bolts. Torque the bolt to 22-26 ft-lbs (30-35 1 6
Nm) using the bolt torque sequence dis-
played in (Figure 9-93).
3 4
5 2
7
Figure 9-93: Torque Sequence
169046 ISSUE DATE 04/03/18

Disasemble (MD #220891)
Reassemble (MD #220891)
Repair(MD #220891)
169046 ISSUE DATE 04/03/18

Disasemble (MD #220936)
Figure 9-94: MD# 174369 Parts Breakdown
169046 ISSUE DATE 04/03/18

1. Remove the draper drive motor from the

deck. See “Removal Side Draper Motor” on
page 9-48.
NOTE:
Do not disassemble both ends at the same
time.
Shaft End
2. Remove the six M6 screws (A), that secure
the pilot flange (B). (Figure 9-95)
3. Remove pilot flange (B). Remove the dust
seal (C), oil seal (D) and O-ring (E). (Figure
9-95)
Figure 9-95:
Cap End
4. Remove the seven bolts (A) that secure the
end cap (B) to the motor. (Figure 9-96)
5. Remove the end cap (B). (Figure 9-96)
6. Remove the gearwheel set (D) and two seals
(C). (Figure 9-96)
NOTE:
Hold the gearwheel set together to prevent
parts from falling out.
7. Remove the distributor plate (E) and seal (C).
(Figure 9-96)
Figure 9-96:
169046 ISSUE DATE 04/03/18

Reassemble (MD #220936)
Item Qty Description Dimensions

A 1 Dust Seal 35 X 28.5 X 4 mm1
B 1 Shaft Seal 42 x 28.6 x 5.5 mm1
C 1 O-ring 48 x 2.0 mm1
D 3 O-ring 75.9 x 1 8 mm1
E 7 Washer 11.9 x 8.2 x 1 mm
F 1 Washer 17.5 x 13.5 x 1.5 mm
Figure 9-97:
1. Buna N, Perbunan
Figure 9-98:
Shaft End
1. Replace the dust seal (C), oil seal (D) and O-
ring (E) into the pilot flange (B). (Figure 9-99)
2. Install the pilot flange (B) onto the motor
housing and secure with six M6 screws (A),
torque to 45-70 in lbf (5-8 N m). (Figure 9-99)
Figure 9-99:
Cap End
1. Lubricate seal (C) and install, then install the
distributor plate (E). Turn the distributor plate
so that the holes line up. (Figure 9-100)
Figure 9-100:
169046 ISSUE DATE 04/03/18

2. Mark the cardan shaft, between the end

splines (A) that align with the key way that is
in the shaft. (Figure 9-101)
3. Lubricate seals (C) and install into gearwheel
set (D). Place the gearwheel set on the
cardan shaft so that the top of a tooth in the
external teeth of the gearwheel is vertically
above the mark on the cardan shaft. Turn the
gearwheel set counter clockwise until the
cardan shaft and the gearwheel start to mesh
(15°). Turn the gearwheel rim so that the
holes made for the screws line up. (Figure 9-
101)
Figure 9-101:
4. Install the end cap (B).(Figure 9-102)

NOTE:
If you removed the drain plug in the center of
the end cap, reinstall using a new washer
from the seal kit. Torque plug to 270-315 in lbf
(30-36 N m).
5. Use new washers included with seal kit and
install seven bolts (A) to secure the end cap
to the motor. Torque to 265-310 in lbf (30-35
N m). (Figure 9-102)
Figure 9-102:
169046 ISSUE DATE 04/03/18

Disassemble (MD# 174369)
Seal Orientation Motor Timing
Figure 9-103: MD# 174369 Parts Breakdown
IMPORTANT highly recommended that paint or a marker

be used to make a “V” shaped set of lines
The RS (255/256) Series Motors depend on from the end cover to the housing. This will
the correct orientation of parts as well as cor- aid in reassembling the motor components
rect internal timing for proper motor opera- properly. It is also important that the steps
tion. Before disassembling the motor, it is
169046 ISSUE DATE 04/03/18

involving internal parts timing be followed should be timed using the “255” series and
carefully to insure proper motor operation. motors that are to have the shafts turning
1. Remove all shaft related components from counterclockwise (as viewed from shaft end)
shaft (15) (i.e. keys, nuts). To aid in reas- should be timed using the “256” series.
sembly of the motor, make a “V” shaped set 5. Turn shaft (15) over so that output end of the
of lines from the end cover (11) to the housing shaft faces down. Lower drive link (7) into
using either paint or a marker. With shaft shaft making sure that the timing mark end of
facing down, secure motor in vise by drive link faces up and that the timing mark
clamping on to the housing (5). on the end of the drive link (7) is aligned to
2. Loosen and remove seven bolts (14) holding the left of any short, open cutter slot on shaft
motor assembly together. Remove end cover (15).
(11). Remove body seal (4) and discard seal. 6. Turn housing (5) over so that the pilot of
Remove rotor set assembly (9), & wear plate housing faces down and secure housing (5)
(8). Remove body seals (4) from rotor in vise. Without disturbing the shaft seal (2),
assembly (9) and housing (5) and discard and drive link (7), carefully lower shaft
seals. Remove drive link pin (10) and drive assembly into housing. Apply pressure using
link (7) from motor and lay aside. an arbor press or a rubber mallet to make
3. Gently tap shaft (15) upward through housing sure that the shaft end is flush or slightly
(5) and remove through rear of housing. lower than the housing bolt hole surface.
Remove housing (5) from vise. Collect thrust 7. Place a body seal (4) in groove in the rear
bearing and thrust washer from the rear of surface of the housing (5). Place wear plate
the housing while turning the housing over. (8) on housing. Make sure that the seven
Secure the housing in the vise with the flange valving slots on the wear plate line up with the
end facing up. Gently pry dust seal (1) from seven bolt holes on the housing (5).
housing using a small screwdriver and a 8. Place a body seal (4) in the groove in the face
hammer. Gently remove shaft seal (2) with a of the rotor assembly (9). With the seal
small screwdriver and discard it. groove surface on the rotor assembly facing
At this point, all parts should be cleaned in an oil- wear plate, lower rotor assembly (9) onto
based solvent and dried using compressed air drive link (7) making sure that the timing mark
(For safety, observe all OSHA safety guidelines). on drive link is aligned with a peak on the
All new seals should be lightly coated in clean oil rotor (9) for 256 series, or with a valley on the
prior to installation. rotor (9) for 255 series (See Figure (2)). After
4. Place shaft (15) on a clean flat surface with assembling the rotor assembly on the drive
output end facing up. Place thrust bearing (6) link rotate the rotor assembly to line up the
then thrust washer (3) on the shaft. Install assembly bolt holes. Insert drive link pin (10)
into end of drive link (7) making sure that con-
shaft seal (2) down onto shaft (15) making sure cave or the indented end faces up.
that lip on seal faces down. (See Figure (1) for
shaft component orientation). 9. Place remaining body seal (4) in groove in
end cover (11). Place end cover (11) onto
NOTE: motor making sure that end of drive link pin
To turn the WR Series Motors to proper oper- (10) is in hole in center of end cover (11).
ation, the rotation code of the motor must be There is no specific orientation to assemble
known. The rotation code of the motor is 255 the end cover on the motor.
(standard) 256 (reverse timed) – the first 3
digits of the model code. If the rotational code 10. Install one washer (13) on each bolt (14) from
is not known, and if port ‘A’ is pressurized , the threaded end side. Insert seven assembly
motors that are to have the shafts turning bolts (14) with washers (13) into bolt holes
clockwise (as viewed from the shaft end) and pre-torque to 13.6 Nm [10 ft. lb.]. Using a
169046 ISSUE DATE 04/03/18

crisscross pattern, final torque bolts to 60 Nm

[44 ft. lb.].
11. Remove motor from vise and place on work
surface with shaft (15) facing up. Making sure
that lip on dust seal (1) faces up, place dust
seal (1) over shaft (15). Using a sleeve and
hammer, carefully drive dust seal (1) into
place.
169046 ISSUE DATE 04/03/18

9.13.2 DECK SHIFT (MD# 120374) SWATHING APPLICATION ONLY

Removal:
There are two seal kits available through
MacDon parts, before ordering make sure you
identify which motor you are working on.
Eaton Motor MD# 132758
Parker Motor MD# 37181
A
R/H Motor:
If repairing the right hand motor remove the two
hydraulic lines and plug both the lines as well as
the ports on the motor to avoid contamination.
Once this is complete remove the four bolts A on
the inside of the header leg. These are the bolts
which secure the motor to header leg.
Figure 9-104: R/H Deck Shift Motor
NOTE:
It may be necessary to remove the tension
from the deck chain in order to remove the
deck shift motor. For information on how to do A
this refer to the operators manual.
L/H Motor
If repairing the left hand motor remove all eight
hoses from the hydraulic manifold attached to the
motor. Plug the hydraulic lines as well as the
ports on the manifold to avoid contamination.
Once this is complete remove the four bolts A on
the inside of the header leg. These are the bolts
which secure the motor to header leg.
NOTE:
Figure 9-105: L/H Deck Shift Motor
It may be necessary to remove the tension
from the deck chain in order to remove the
deck shift motor. For information on how to do
this refer to the operators manual.
Once the motor is removed the hydraulic

manifold will need to be removed from the motor.
In order to do this remove the four hex head bolts
B from the top of the manifold. This will separate B
the manifold from the motor. Be careful not to
lose or damage the o-rings between the manifold
and the motor. Replacement o-rings are available
through the MacDon parts system MD #16605.
Figure 9-106: Deck Shift Valve Block
169046 ISSUE DATE 04/03/18

Eaton Motor Disassembly:

plug ports and thoroughly clean exterior of motor.
vise during disassembly. Follow the clamping
procedures explained throughout the manual.

clamping, use protective device on vise such
board. See (Figure 9-107).
Figure 9-107: Motor In Vise
2. Remove cap screws and seal washers (when
applicable). See (Figure 9-108).
3. Remove end cap.
4. Remove seal from end cap.
5. Remove gerotor.
6. Remove seal from gerotor (Figure 9-108).
7. Remove drive spacer if applicable.
8. Remove drive. See (Figure 9-108).
9. Remove spacer plate.
10. Remove seal from housing.
11. Remove output shaft from housing.
12. Remove needle thrust bearing from shaft or

housing.
Figure 9-108: Gerotor Assembly
169046 ISSUE DATE 04/03/18

13. Reposition motor in vise. Clamp across ports When heated, Loctite partially melts. This
as shown in (Figure 9-109). Do not clamp on reduces torque required to remove screw. Use
side of housing. Excessive clamping pres- small flame propane torch to heat small area of
sure on side of housing causes distortion. housing where screw enters. See (Figure 9-110).
14. Remove cap screws from mounting flange. Be careful not to overheat housing and damage
These screws are assembled with Loctite to motor. Gradually apply torque to screw with
hold them in place. socket wrench as heat is applied for 8-10 sec-
onds. As soon as screw breaks loose, remove
heat from housing. Continue turning screw until it
is completely removed.
15. Carefully remove flange from housing.
IMPORTANT
Some motors may have a quad seal and back-
up ring in place of the pressure seal. The
quad seal and back-up ring are no longer
available and are replaced by the pressure
seal. They are interchangeable, but some pre-
cautions must be taken to insure proper
installation.
Follow the reassembly instructions.
Figure 9-109: Cap Screw Removal 16. Exclusive seal, back-up ring, pressure seal
The screws will require 300-400 lb.-in [35-45 Nm] and seal will come off with flange. Use seal
of toque to break loose and 100 lb.-in [11 Nm] removal tool, shown in (Figure 9-111), to
torque to remove. Do not use impact wrench on remove exclusion and pressure seals.
Loctite screws. This could result in rounded
heads or broken sockets.
NOTE: If torque higher than given above is
required to break screws loose, apply
heat according to following instructions:
Figure 9-110: Mounting Flange Removal

Figure 9-111: Screwdriver Modification
169046 ISSUE DATE 04/03/18

IMPORTANT IMPORTANT
Be careful not to scratch seal cavity O.D. This Do not stretch seals before installing them.
could create a leak path.
Figure 9-112: Plug Removal Figure 9-113: Seal Installation

17. A metal plug, with seal, plugs a machining Cleanliness is extremely important in the suc-
hole in the housing. It is not necessary to cessful application of Loctite. Before Loctite can
remove plug and replace seal unless leakage be applied, the parts should be cleaned as fol-
occurs around plug. To remove plug, insert 3/ lows:
16 in. [5 mm] hex key through port opening
and push it out. See (Figure 9-112). The 009 NOTE:
plug is not interchangeable with 007 and 008 Fully cured Loctite resists most solvents, oil,
plugs. gasoline and kerosene and is not affected by
cleaning operations. It is not necessary to
Reassembly (Shaft End): remove cured Loctite that is securely bonded
NOTE: in tapped holes; however, any loose particles
Check all mating surfaces. Replace any parts of cured Loctite should be removed.
with scratches or burrs that could cause a. Wash the housing with solvent to remove
leakage or damaged. Clean all metal parts in oil, grease and debris. Pay particular
clean solvent. Blow dry with air. Do not wipe attention to four tapped holes on flange
parts with cloth or paper towel because lint or end.
other matter could get into the hydraulic
system and cause damage. b. Blow dry with compressed air. Clean and
dry tapped holes.
Check around key slot and chamfered area of
shaft for burrs, nicks or sharp edges that could c. Wire brush screw threads to remove
damage seals during reassembly. Remove nicks cured Loctite and other debris. Discard
or burrs with a hard smooth stone (such as an any screws that have damaged threads
Arkansas stone). Do not file or grind motor parts. or rounded heads.
NOTE: d. Wash screws with non-petroleum base

Lubricate all seals with petroleum jelly. Use solvent. Blow dry with compressed air.
new seals when reassembling motor. Order 18. If you remove plug and seal, lubricate new
seal kit #101670. seal and install on plug. Some plugs have two
o-ring grooves but require only one o-ring.
Install o-ring in groove closest to outside end
of plug. Push plug into housing so plug and
housing are flush. Be careful not to damage
seal.
169046 ISSUE DATE 04/03/18

19. Install exclusion seal in flange. See (Figure excess Loctite from housing face, using a
9-113). Carefully press exclusion seal into non-petroleum base solvent.
place.
20. Visually check seal seat in mounting flange
for scratches or other marks that might
damage the pressure seal. Check for cracks
in flange that could cause leakage.
Figure 9-115: Loctite Application

NOTE:
Do not apply Loctite to threads more than 15
minutes before installing screws. If housing
stands for more than 15 minutes, repeat
application. No additional cleaning or removal
of previously applied Loctite is necessary.
23. Before installing the flange and seal
assembly over the shaft, place protective
sleeve or bullet over the shaft. Then lubricate
space between exclusion seal and pressure
seal, as well as lips of both seals. See (Figure
9-116).
Figure 9-114: Exclusion Seal Installation
21. Lubricate I.D. of seal tube and O.D. of shaft
pressure seal with light film of clean petro-
leum jelly. Align small I.D. end of seal tube
with seal seat in mounting flange. Install
back-up ring and pressure seal in tube with
lips of seal face up. See (Figure 9-114).
Insert seal driver in tube and firmly push seal
seat with a rotating action.
NOTE:
Use of primer is optional. With primer, Loctite
curing time is approximately 15 minutes. Figure 9-116: Flange and Seal Assembly
Without primer, curing time is approximately 6
hours.
22. Apply 3 or 4 drops of Loctite sealant at top of
thread for each of four holes in housing. See
(Figure 9-115). Do no allow parts with Loctite
applied to come in contact with any metal
parts other than those for assembly. Wipe off
169046 ISSUE DATE 04/03/18

24. Install flange. Rotate flange slowly while

pushing down over shaft. Be careful not to
invert or damage seals.
25. After removing bullet, clamp motor in vise as
shown in (Figure 9-117). Make sure shaft
cannot fall out. Install dry screws and alter-
nately torque them immediately to 250 lb.-in
[28 N-m]. If you use primer, allow to cure for
10 to 15 minutes. Without primer allow 6
hours curing time before subjecting motor to
high torque reversals. On all other applica-
tions, you can run motor immediately.
Figure 9-117: Clamp Motor In Vise

NOTE:
If you use new screws, make sure they are
the correct length: 7/8 in. [22 mm] under head
length. See parts list for correct part number.
169046 ISSUE DATE 04/03/18

Reassembly (Gerotor End)

1. Reposition motor with gerotor end up, then
clamp across ports. Do no clamp on side of
housing.
IMPORTANT
To aid installation of seals, apply light coat of
clean petroleum jelly to seals. Do not stretch
seals before installing them in groove.
2. Pour approximately 35 cc of clean hydraulic
oil in output shaft cavity.
3. Install 2 7/8 in. [73 mm] I.D. seal in housing
seal groove. Avoid twisting seal.
Timing Procedure
1. Install drive. Use felt tip marker to mark one
drive tooth. Align this tooth with timing dot on
shaft.
NOTE:
If drive is not symmetrical, install larger Figure 9-118: Align Gerotor With Drive
splined end into shaft.
2. Install spacer plate.
3. Install 2 7/8 in. [73 mm] I.D. seal in gerotor
seal groove. Carefully place gerotor on
spacer plate, seal side toward spacer plate.
4. Rotate gerotor to line up with bolt holes. Be
careful not to disengage star from drive or
disturb gerotor seal.
5. Install drive spacer if applicable.
6. Install 2 7/8 in. [73 mm] seal in end cap.
Carefully place end cap on gerotor.
7. Install cap screws and seal washers (if appli-
cable) in end cap. Pre tighten screws to 40 lb.-in
[7, 4 Nm]. Make sure seal are properly seated.
Then torque screws 235-250 lb.-in [27-28 Nm] Figure 9-119: Bolt Torquing Sequence
in sequence, as shown in (Figure 9-119).
169046 ISSUE DATE 04/03/18

Parker Motor Disassembly MD# 120374

parts #37181.
1. Place the hydraulic motor in a soft jaw vise so

that the output shaft is pointing down. Using a
paint marker drawn two reference lines, in the
shape of a V down the side of the motor as
shown in (Figure 9-171). This will ensure that
the motor is reassembled correctly. Loosen
and remove the six bolts holding the motor
assembly together using a 1/2 inch socket.
Figure 9-120: V Shaped Reference Mark
2. Remove the end cover (B) and commutator

ring (C) from the top of the motor assembly. C
Remove and discard the old end cover seal.
It may be necessary to use a seal pick or
small screwdriver in order to remove the seal
from the cover.
Figure 9-121: Remove End Cover

3. Remove the commutator from the end of the
drive link and place on a clean workbench.
Be sure to remove and discard the clear seal
(D) from the recess (E) in the commutator.
169046 ISSUE DATE 04/03/18

4. Remove the manifold from the motor body

assembly. Remove and discard both the top
and bottom seal from the manifold. Place F
manifold on a clean workbench.
Figure 9-122: Remove Commutator
5. Check the rotor set for any scoring or

damage. Check the rotor lobe to rotor vane
clearance (using a feller gauge) at (F), where
the rotor lobe and the rotor vane are tip to tip.
If there is more than 0.005” (0.13 mm) of
clearance the motor must be replaced.
Figure 9-123: Remove Manifold
Figure 9-124: Check Rotor Set
169046 ISSUE DATE 04/03/18

6. Remove the rotor set from the motor body

assembly being very careful not to loose any
of the internal components within the rotor set
as they may fall out upon removal.
IMPORTANT
When removing the rotor set from the motor
assembly be very careful not to displace any
of the components within the rotor set as this
will disrupt the timing of the motor.
Make sure to remove and discard the seal on
the bottom side of the rotor set. Place the
rotor set in a safe and clean location where it
will not be disturbed until reassembly.
Figure 9-125: Remove Rotor Set
7. Remove the drive link from the motor

assembly, once this is done remove the wear
plate making sure to remove and discard the G
seal (G) from the motor body.
IMPORTANT Figure 9-126: Remove Wear Plate

In steps 8 and 9 it is important to note the
order and position in which the components
are removed as it will be necessary to reas-
semble these components in the same order.
8. Remove the coupling shaft by pushing

upwards on the output end of the shaft and
pulling the shaft out of the housing. With the
coupling shaft removed pull the thrust bearing
and washer from the motor body and place
on a clean workbench.
Figure 9-127: Remove Thrust Bearing & Washer
169046 ISSUE DATE 04/03/18

9. Remove the seal (H), washer (J) and small

backup washer (K) from the housing using a
seal pick or small screwdriver. Discard all K
three components.
J H
Figure 9-128: Remove Seal & Backup Washer
10. With the internal seal and backup washer

removed from the motor housing flip the
motor upsidedown in the vise so that the
shaft end of the housing is pointing up. Using
a small screwdriver pry up on the dirt and
water seal until it pops out of the housing.
Discard this seal once it is removed.
Figure 9-129: Remove Dirt & Water Seal

Repair:
Order seal kit MD #37181
Inspect the motor housing, both inner needle

bearings and all other components for any
scoring or damage. If there is any damage to any
of the components discard and replace the
motor. If all the components check out OK they
should be cleaned in an oil-base solvent and
dried using compressed air (For safety observe
all OSHA safety guidelines). All new seals should
be lightly coated in grease (provided in kit) prior
to installation.
Figure 9-130: Motor Assembly
169046 ISSUE DATE 04/03/18

Reassembly:
1. Place motor body in a soft jaw vise with shaft
end facing up. Using the grease supplied in
the kit, repack the front bearing. This is easily
done by applying some grease to the tip of
the finger and working the grease in between
the needle bearings (Refer to (Figure 9-
182)).
2. Once the front bearing is greased the new dirt Figure 9-131: Pack Front Bearing
and water seal must be pressed into the
motor housing. Place the housing in a vise
with a board between the backside of the
housing and the jaw of the vise, as shown in
(Figure 9-183). Place the new dirt and water
seal in the recess of the motor housing. Using
a large socket (the same diameter as the
seal) as a collar between the jaw of the vise
and the seal, tighten the vise until the seal is
pressed into the housing.
IMPORTANT
Do not over tighten the vise as it will damage
the dirt and water seal. Simply tighten until
the flange of the seal sits flush against the Figure 9-132: Press In Front Seal
face of the motor housing.
3. Reposition the housing in the vise so that the L
shaft end of the housing faces down. Insert
the new backup washer first followed by the
new seal. Work the seal into its respective
counter bore until it is seated properly in the
housing. Be sure to apply a small amount of
grease to the seal before installing.
NOTE:
With the new seal kit there is no washer
between the seal and the backup washer as
there was originally. This washer is replaced
by a red plastic backup ring (L) which is part
of the new seal. Seal must be installed with
the red ring facing down towards the backup Figure 9-133: Insert Seal & Backup Washer
washer (Refer to (Figure 9-184)).
169046 ISSUE DATE 04/03/18

4. Insert the thrust washer and thrust bearing

into the housing making sure that the thrust
washer (M) goes in first. Once this is done M
the coupling shaft can be reinstalled. Make
sure to clean the output end of the shaft with
some fine emery cloth and apply masking
tape to the keyway on the shaft prior to
installing.
It is important to remove any rust or
debris from the output end of the coupling
shaft prior to installing it. If any rust or
debris is present on the shaft or if the
keyway is exposed, seal damage may
occur upon reassembly.
Figure 9-134: Insert Thrust Bearing & Washer

IMPORTANT
Be sure to apply a small amount of grease
(provided in kit) to all new seal rings prior to
installing.
P
5. Once the coupling shaft is installed and prop-
erly seated against the thrust bearing, the top
edge of the shaft should be flush or just
slightly below the edge of the housing. It may
be necessary to tap on the top edge of the
coupling shaft with a rubber mallet in order to
seat the shaft against the thrust bearing.
Install seal ring (P) into the groove in the
housing. Install the wear plate making sure all
reference marks line up.
Figure 9-135: Install Wear Plate
6. Insert the drive link into the coupling shaft.

Install seal ring into the groove on the bottom
side of the rotor set. Install rotor set so that
the reference marks line up, be careful not to
displace any of the components within the
rotor set when engaging the drive link into the
rotor.
Figure 9-136: Install Rotor Set
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7. Install seal rings into the seal grooves on both

the top and bottom side of the manifold.
Place manifold on top of the rotor set making
sure the reference marks line up.
Figure 9-137: Install Manifold
8. Install the commutator seal (R) into the seal

bore in the commutator. The seal is tapered
at one end and must be inserted into the seal
bore with the tapered end facing down (Refer
to (Figure 9-189)).
R
Figure 9-138: Install Commutator Seal
9. Install commutator on the top of the drive link

with the seal facing up (Refer to (Figure 9-
190)). Once this is done install the commu-
tator ring on top of the manifold making sure
the reference marks line up.
Figure 9-139: Install Communtator Ring
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10. Insert ring seal into the end cover and place
end cover on top of the commutator ring
making sure the reference marks line up.
Once all the reference lines line up insert the
6 bolts into the motor and turn finger tight.
NOTE:
If pump was rebuilt correctly there will be one
extra ring seal remaining (from kit MD #37181).
11. Torque each bolt to 24 ft. lbs (33 Nm) in the

sequence specified in (Figure 9-192).
1
3 6
12. Refer to Section 7 “Draper Drive System” for
proper instructions on reinstalling the motor
into the drive roller.
13. Once the motor is properly installed start the 5 4

windrower or combine and run at low idle.
Check for any leaks or abnormal operation.
2
Figure 9-141: Bolt Torque Sequence
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9.13.3 REEL (MD# 143088)

Removal (White Hydraulics)
parts. MD# 47277.
1. Remove hydraulic lines A from the hydraulic A
motor and plug hydraulic lines as well as the
ports on the hydraulic motor in order to avoid
contamination. Refer to See “Reel Drive
Repair” on page 8-15. for instructions on how
remove the hydraulic motor from the reel
drive gearbox.
Figure 9-142: Reel Drive Motor
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Disassembly
plug ports and thoroughly clean exterior of motor.
vise during disassembly.
1. Place the hydraulic motor on a clean work Figure 9-143: V Shaped Reference Mark
bench. Using a paint marker, draw two refer-
ence lines, in the shape of a V down the side
of the motor as shown in (Figure 9-143). This
will insure that the motor is reassembled cor-
rectly.

clamping, use protective device on vise such
board. Loosen and remove the seven bolts
holding the motor assembly together using a
14mm socket.
Figure 9-144: Remove 7 Bolts
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3. Remove end cover from top of motor.

Remove and discard old end cover seal using
a pick or small screwdriver.
IMPORTANT
Be sure to make note of the dimensions of all
the seals removed during the disassembly
process so that the correct seal is installed in
the correct location during the reassembly
process as the seal kit contains various sizes,
all of which are unmarked.
4. Remove balance plate from motor being sure

not to lose the three steel balls B located in
the three holes in the top of the balance plate.
Figure 9-146: Remove Balance Plate
5. Remove drive link spacer C from the pump

body and place on clean workbench. C
Figure 9-147: Remove Drive Link Spacer
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6. Remove and discard old rotor seals (one on

each side of the rotor) using a pick or small
screwdriver. Remove rotor from housing and
place on clean workbench.
Figure 9-148: Remove Rotor Seals
7. Remove the drive link D and manifold E from D

the motor housing and place on workbench.
Figure 9-149: Remove Drive Link
8. Remove and discard the old body seal using

a pick or small screwdriver. It is also neces-
sary to remove the thrust bearing F from the F
pump body and place on the workbench.
Figure 9-150: Remove Body Seals
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9. With the motor still in the vise push up on the

drive shaft from the bottom side till the shaft
pops out of the top of the pump body.
Remove the drive shaft and place on the
workbench.
NOTE:
If the shaft will not pop out of the top of the
motor by pushing upwards, it may be neces-
sary to tap upwards on the end of the shaft
with a rubber mallet in order to free the shaft
from the body.
Figure 9-151: Remove Drive Shaft
10. Loosen vise and turn motor body over so that

the output end of the motor faces upwards.
Pry dust seal from housing.
Figure 9-152: Remove Dust Seal
11. Push the seal carrier G down to gain access

to the retaining ring. Using a small flat screw- G
driver remove the retaining ring form the
housing as shown in (Figure 9-153).
Figure 9-153: Remove Retaining Ring
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12. Once the retaining ring has been removed,

remove the high pressure seal H and the
I
steel backup shim I.
Figure 9-154: Remove High Pressure Seal

13. Remove the seal carrier assembly from the
motor housing. This includes three compo-
nents: the seal carrier, thrust washer and
thrust bearing.
Figure 9-155: Remove Seal Carrier Assembly

14. Using a pick or small screwdriver, carefully
remove shaft seal, backup seal and metal
backup shim from seal carrier and discard.
Lay seal carrier aside.
Figure 9-156: Disassemble Seal Carrier
169046 ISSUE DATE 04/03/18

Repair
Order seal repair kit #47277.

Inspect motor housing, both inner needle bear-
ings and all other components for any scoring or
damage. If there is any damage to any of the
components discard and replace motor. If all the
components check out OK all parts should be
cleaned in an oil-base solvent and dried using
compressed air (For safety observe all OSHA
safety guidelines). All new seals should be lightly
coated in oil prior to installation.
Reassembly Figure 9-157: Motor Assembly
1. Place shaft on a clean flat surface with output N M

end facing up. Place thrust bearing J then
thrust washer K onto the shaft. Lightly coat
L K
seal area of shaft with clean oil. Slide new
shaft seal L down onto shaft (making sure
that lip on seal faces down) until it contacts
the thrust washer. Carefully install the new
backup seal M onto the shaft with the flat side
up and the seal lip facing the shaft seal. Place
the metal backup shim N onto the shaft and
against the backup seal. (Figure 9-158) J
Figure 9-158: Install Seal Carrier Assembly
2. Place the seal carrier onto the shaft and care-

fully press the seal carrier down onto the seal
assembly.
Figure 9-159: Install Seal Carrier
169046 ISSUE DATE 04/03/18

3. With output side of motor facing up, place

housing in vise leaving about 1/2” of clear-
ance between the bottom of the housing and
the vise (this will allow the drive shaft to slide
out the bottom of the housing slightly leaving
enough clearance at the top of the housing to
install the high pressure seal and metal
backup shim). Place shaft/seal carrier
assembly into housing. Using a 1 1/4” deep
socket and a rubber mallet tap the seal car-
rier assembly into the housing until the thrust
bearing is seated against the needle bearing
inside the motor housing.
Figure 9-160: Install Shaft/Seal Assembly
O P
4. Install high pressure seal O into grove in

housing. Install metal backup shim P against
high pressure seal in groove in housing bore
by squeezing the shim between thumb and
forefinger to bow shim. While maintaining bow
in shim, start the shim into the grove and use
a small screwdriver to push the shim into the Q
groove. Install wire retaining ring Q into the
groove making sure that the ends are butted.
Refer to (Figure 9-161).
Figure 9-161: Install Retaining Ring
5. While holding the shaft in the housing, place

the housing/shaft assembly in the vise with
the shaft end down. Make sure that the end of
the drive link with the crowned splines goes
into shaft. Install drive link into shaft and tap
lightly (with a rubber mallet) to seat the seal
carrier against the wire ring.
Figure 9-162: Install Drive Link
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6. Place thrust bearing over drive link. If seal

carrier is seated properly against the wire
retaining ring, thrust bearing will be flush with
rear surface of housing. Install new housing R
seal into groove in housing R. Refer to
(Figure 9-163).
Figure 9-163: Install Thrust Bearing
7. Place manifold onto housing making sure that

the reference marks made during the disas-
sembly process line up properly.
NOTE:
The side of the manifold with only seven
holes should be facing the housing.
8. Place body seals in grooves S in both sides

of rotor. Place rotor onto manifold with side of
rotor with chamfer in splines facing the mani-
fold. Again making sure that the reference
lines match up. Place the drive link spacer on
top of the drive link at opening T at center of
rotor. T
S
NOTE:
Make sure that the splines on the drive link
and the splines on the rotor are properly
engaged. If properly engaged the top of the
drive link spacer should sit flush with the top
of the rotor. Figure 9-165: Install Rotor
169046 ISSUE DATE 04/03/18

9. Install the balance plate onto the rotor with

holes for steel balls facing up making sure
that the reference lines match up. Install three
steel balls in holes in balance plate.
Figure 9-166: Install Balance Plate
10. Install end cover seal in groove in end cover.

Place the end cover on the balance plate so
that the reference lines match up.
NOTE:
Before proceeding to the next step ensure
that all reference marks on the side of the
motor line up correctly.
Figure 9-167: Install End Cover Seal
1
11. Install the seven assembly bolts and pre-
torque each one to 10 ft. lbs. (14 Nm) using a 4 6
torque wrench with a 14 mm socket. Follow
the bolt torque sequence shown in (Figure 9-
168). Finally torque all bolts to 50 ft. lbs (68
Nm) using the same bolt torque sequence.
5 3
2 7
169046 ISSUE DATE 04/03/18

12. Remove motor from vise and place on work-

bench with output shaft facing up. Making
sure that the lip on the seal is facing up, place
dust seal over shaft. Using a rubber mallet
tap the seal into place.
NOTE:
It may be necessary to use a sleeve in order
to seat the seal properly. A 1 1/4” deep socket
usually works well for this.
13. Refer to Section 8 “Reel Drive” for proper

instructions on reinstalling the motor into the
reel drive gearbox.
14. Once the motor is properly installed start the

combine and run at low idle. Check for any
leaks or abnormal operation. Figure 9-169: Install Dust Seal
169046 ISSUE DATE 04/03/18

9.13.4 FEED DRAPER (MD# 151981)

Disassembly (Parker Hannifin):
parts #37181.
1. Remove hydraulic lines (A) from the hydraulic

motor and plug hydraulic lines as well as the
ports on the hydraulic motor in order to avoid
contamination. Refer to Section 7 “Draper
Drive System” for instructions on how to
remove the hydraulic motor from the drive
roller. A
Figure 9-170: Feed Draper Motor
2. Place the hydraulic motor in a soft jaw vise so

that the output shaft is pointing down. Using a
paint marker drawn two reference lines, in the
shape of a V down the side of the motor as
shown in (Figure 9-171). This will ensure that
the motor is reassembled correctly. Loosen
and remove the six bolts holding the motor
assembly together using a 1/2 inch socket.
Figure 9-171: V Shaped Reference Mark
B
3. Remove the end cover (B) and commutator
ring (C) from the top of the motor assembly.
Remove and discard the old end cover seal.
It may be necessary to use a seal pick or
small screwdriver in order to remove the seal C
from the cover.
169046 ISSUE DATE 04/03/18

4. Remove the commutator from the end of the

drive link and place on a clean workbench.
Be sure to remove and discard the clear seal F
(D) from the recess (E) in the commutator.
Figure 9-173: Remove Commutator
5. Remove the manifold from the motor body

assembly. Remove and discard both the top
and bottom seal from the manifold. Place
manifold on a clean workbench.
Figure 9-174: Remove Manifold
6. Check the rotor set for any scoring or

damage. Check the rotor lobe to rotor vane
clearance (using a feller gauge) at (F), where
the rotor lobe and the rotor vane are tip to tip.
If there is more than 0.005” (0.13mm) of
clearance the motor must be replaced.
Figure 9-175: Check Rotor Set
169046 ISSUE DATE 04/03/18

7. Remove the rotor set from the motor body

assembly being very careful not to loose any
of the internal components within the rotor set
as they may fall out upon removal.
IMPORTANT
When removing the rotor set from the motor
assembly be very careful not to displace any
of the components within the rotor set as this
will disrupt the timing of the motor.
Make sure to remove and discard the seal on
the bottom side of the rotor set. Place the
rotor set in a safe and clean location where it
will not be disturbed until reassembly.
Figure 9-176: Remove Rotor Set
8. Remove the drive link from the motor

assembly, once this is done remove the wear
plate making sure to remove and discard the G
seal (G) from the motor body.
IMPORTANT Figure 9-177: Remove Wear Plate

In steps 8 and 9 it is important to note the
order and position in which the components
are removed as it will be necessary to reas-
semble these components in the same order.
9. Remove the coupling shaft by pushing

upwards on the output end of the shaft and
pulling the shaft out of the housing. With the
coupling shaft removed pull the thrust bearing
and washer from the motor body and place
on a clean workbench.
Figure 9-178: Remove Thrust Bearing & Washer
169046 ISSUE DATE 04/03/18

10. Remove the seal (H), washer (J) and small

backup washer (K) from the housing using a
seal pick or small screwdriver. Discard all K
three components.
J H
Figure 9-179: Remove Seal & Backup Washer
11. With the internal seal and backup washer

removed from the motor housing flip the
motor upsidedown in the vise so that the
shaft end of the housing is pointing up. Using
a small screwdriver pry up on the dirt and
water seal until it pops out of the housing.
Discard this seal once it is removed.
Figure 9-180: Remove Dirt & Water Seal

Repair:
Order seal kit MD #37181
Inspect the motor housing, both inner needle

bearings and all other components for any
scoring or damage. If there is any damage to any
of the components discard and replace the
motor. If all the components check out OK they
should be cleaned in an oil-base solvent and
dried using compressed air (For safety observe
all OSHA safety guidelines). All new seals should
be lightly coated in grease (provided in kit) prior
to installation.
Figure 9-181: Motor Assembly
169046 ISSUE DATE 04/03/18

Reassembly:
1. Place motor body in a soft jaw vise with shaft
end facing up. Using the grease supplied in
the kit, repack the front bearing. This is easily
done by applying some grease to the tip of
the finger and working the grease in between
the needle bearings (Refer to (Figure 9-
182)).
2. Once the front bearing is greased the new dirt Figure 9-182: Pack Front Bearing
and water seal must be pressed into the
motor housing. Place the housing in a vise
with a board between the backside of the
housing and the jaw of the vise, as shown in
(Figure 9-183). Place the new dirt and water
seal in the recess of the motor housing. Using
a large socket (the same diameter as the
seal) as a collar between the jaw of the vise
and the seal, tighten the vise until the seal is
pressed into the housing.
IMPORTANT
Do not over tighten the vise as it will damage
the dirt and water seal. Simply tighten until
the flange of the seal sits flush against the Figure 9-183: Press In Front Seal
face of the motor housing.
3. Reposition the housing in the vise so that the L
shaft end of the housing faces down. Insert
the new backup washer first followed by the
new seal. Work the seal into its respective
counter bore until it is seated properly in the
housing. Be sure to apply a small amount of
grease to the seal before installing.
NOTE:
With the new seal kit there is no washer
between the seal and the backup washer as
there was originally. This washer is replaced
by a red plastic backup ring (L) which is part
of the new seal. Seal must be installed with
the red ring facing down towards the backup Figure 9-184: Insert Seal & Backup Washer
washer (Refer to (Figure 9-184)).
169046 ISSUE DATE 04/03/18

4. Insert the thrust washer and thrust bearing

into the housing making sure that the thrust
washer (M) goes in first. Once this is done M
the coupling shaft can be reinstalled. Make
sure to clean the output end of the shaft with
some fine emery cloth and apply masking
tape to the keyway on the shaft prior to
installing.
It is important to remove any rust or
debris from the output end of the coupling
shaft prior to installing it. If any rust or
debris is present on the shaft or if the
keyway is exposed, seal damage may
occur upon reassembly.
Figure 9-185: Insert Thrust Bearing & Washer

IMPORTANT
Be sure to apply a small amount of grease
(provided in kit) to all new seal rings prior to
installing.
P
5. Once the coupling shaft is installed and prop-
erly seated against the thrust bearing, the top
edge of the shaft should be flush or just
slightly below the edge of the housing. It may
be necessary to tap on the top edge of the
coupling shaft with a rubber mallet in order to
seat the shaft against the thrust bearing.
Install seal ring (P) into the groove in the
housing. Install the wear plate making sure all
reference marks line up.
Figure 9-186: Install Wear Plate
6. Insert the drive link into the coupling shaft.

Install seal ring into the groove on the bottom
side of the rotor set. Install rotor set so that
the reference marks line up, be careful not to
displace any of the components within the
rotor set when engaging the drive link into the
rotor.
Figure 9-187: Install Rotor Set
169046 ISSUE DATE 04/03/18

7. Install seal rings into the seal grooves on both

the top and bottom side of the manifold.
Place manifold on top of the rotor set making
sure the reference marks line up.
8. Install the commutator seal (R) into the seal

bore in the commutator. The seal is tapered
at one end and must be inserted into the seal
bore with the tapered end facing down (Refer
to (Figure 9-189)).
R
Figure 9-189: Install Commutator Seal
9. Install commutator on the top of the drive link

with the seal facing up (Refer to (Figure 9-
190)). Once this is done install the commu-
tator ring on top of the manifold making sure
the reference marks line up.
Figure 9-190: Install Communtator Ring
169046 ISSUE DATE 04/03/18

10. Insert ring seal into the end cover and place
end cover on top of the commutator ring
making sure the reference marks line up.
Once all the reference lines line up insert the
6 bolts into the motor and turn finger tight.
NOTE:
If pump was rebuilt correctly there will be one
extra ring seal remaining (from kit MD #37181).
11. Torque each bolt to 24 ft. lbs (33 Nm) in the

sequence specified in (Figure 9-192).
1
3 6
12. Refer to Section 7 “Draper Drive System” for
proper instructions on reinstalling the motor
into the drive roller.
13. Once the motor is properly installed start the 5 4

combine and run at low idle. Check for any
leaks or abnormal operation.
2
9.14 KNIFE DRIVE MOTOR

9.14.1 SINGLE KNIFE & UNTIMED B
DOUBLE KNIFE
MD #174217 - 6.2 cubic inch displacement (1000cc)
Seal Kit: MD# 174304
knife drive hydraulic motor efficiency.
A
NOTE:
is important to check the relief pressure and
pump efficiency prior to performing a motor
efficiency test. Figure 9-193: MD# 174217 (LH Side Single Knife)
Checking Motor Efficiency:

B
1. Install test equipment at the return port of the
hydraulic drive motor. Make sure the input
end of the test equipment is closest to the
pump. Plumb input into port ”B” for single
knife. If you are checking the RH motor on a
double knife, plump into port “A”. Once
installed run the system up and check for A
leaks.
NOTE:
System must be tested hot at standard oper-
ating speeds. If the system is cold refer to Figure 9-194: MD# 174217 (RH side DK only)
step 2 of the pump efficiency test.
2. With the system hot and running at standard Pressure
operating speeds record the hydraulic flow at F

B (Orange)
1500 psi (should be around 16-20 GPM).
3. Increase the system pressure to 3000 psi, the Flow Gauge
Motor
hydraulic flow should not drop more then 2-3
GPM. If the motor’s output flow drops more
then 2-3 GPM to much oil is flowing through M
the case drain when the motor is under load. A (Blue)
This means the motor efficiency is low and Return

the motor will need to be repaired or Needle Pressure
Valve Gauge
replaced.
Figure 9-195: Knife Drive Schematic
NOTE:
The motors efficiency can also be measure
through case drain loses. Standard case
drain loses should not exceed 1.5 GPM even
under load. If the case drain loses are above
and beyond this specification the motor’s effi-
ciency is low and will likely need to be
replaced.
169046 ISSUE DATE 04/03/18

Seal Kit Installation MD #174217

Figure 9-196:
Procedure
169046 ISSUE DATE 04/03/18

9.14.2 DOUBLE KNIFE (TIMED)

knife drive hydraulic motor efficiency.
NOTE:
is important to check the relief pressure and
pump efficiency prior to performing a motor
efficiency test.
Specifications:
Hydraulic Motor: C
• MD #145392 - 2.65 cubic inch displace-
ment (44cc) Figure 9-197: MD# 145392
• Seal kit 124495
Checking Motor Efficiency: Pressure
F
1. Install test equipment at (C) the top port of the B (Orange)
hydraulic drive motor. Make sure the input Flow Gauge

end of the test equipment is closest to the Motor
pump. Once installed run the system up and
check for leaks.
M
NOTE: A (Blue)
System must be tested hot at standard oper- Return
ating speeds. If the system is cold refer to Needle Pressure
step 2 of the pump efficiency test. Valve Gauge
2. With the system hot and running a standard Figure 9-198: Knife Drive Schematic
operating speeds record the hydraulic flow at
???? psi (should be around ?? GPM).
hydraulic flow should not drop more then 2-3
GPM. If the motor’s output flow drops more
then 2-3 GPM to much oil is flowing through
the case drain when the motor is under load.
This means the motor efficiency is low and
the motor will need to be repaired or
replaced.
NOTE:
The motors efficiency can also be measure
through case drain loses. Standard case
drain loses should not exceed 1.5 GPM even
under load. If the case drain loses are above
and beyond this specification the motor’s effi-
ciency is low and will likely need to be
replaced.
169046 ISSUE DATE 04/03/18

Seal Kit Installation MD #145392

Procedure
169046 ISSUE DATE 04/03/18

9.15 MULTI-COUPLER
The Way It Works Yellow
The purpose of the any multi-coupler system is to White

allow you to hook up the combine to the adapter
while making only one connection. Some multi-
coupler connectors incorporate both the
Black
hydraulic and electrical connections in one
simple connections while others separate these
two systems into separate connections. This sec-
tion will explore the orientation and functionality
of the various multi-coupler systems.
Red
9.15.1 LEXION 400 SERIES MULTI-COU- Green

PLER
Figure 9-199: Rear View
The Lexion 400 series multi-coupler is present on
all 400 series Lexion combines. It incorporates
the reel lift and fore-aft hydraulics as well as all E
the electrical connections into one multi-coupler,
however the reel drive hoses remain separate A
connections. The Lexion multi-coupler is unique
because it also includes a hydraulic valve block.
This valve block is used to control the hydraulic
flow to the various reel functions. For further
information regarding this valve block refer to
Section 9.15.3.
B
Use the following table in conjunction with C
(Figure 9-199) in order to properly identify the
hydraulic porting. D
Figure 9-200: Front View
Tag Color Function
Yellow Reel Drive Return
White Reel Drive Pressure
Red Reel Fore (port “B2”)
Green Reel Aft (port “A2”)
Black Reel Lift (port “A1”)
Use the following table in conjunction with

hydraulic porting.
Call Out
Function
Letter
A Reel Drive Pressure
B Reel Drive Return
C Reel Lift & Fore-Aft Return
D Reel Lift & Fore-Aft Pressure
E Electrical
169046 ISSUE DATE 04/03/18

9.15.2 LEXION 500 SERIES MULTI-COUPLER

The Lexion 500 series multi-coupler is present on all 500 series Lexion combines. It incorporates the
reel lift, fore-aft and drive hydraulics as well as all the electrical connections into one coupler. The
Lexion multi-coupler is unique because it also includes a hydraulic valve block. This valve block is
used to control the hydraulic flow to the various reel functions. For further information regarding this
valve block refer to Section 9.15.3.

(Figure 9-201) in order to properly identify the Yellow
hydraulic porting.
White
NOTE:
Ensure that line P1 from the multi-coupler
connects to port “P” on the multi-coupler
block, and that line T1 from the multi-coupler Black
connects to port “T” on the multi-coupler
block.
Tag Color Function
White Reel Drive Pressure

Green
Red Reel Fore (port “B2”) Red
Green Reel Aft (port “A2”)

Black Reel Lift (port “A1”)
E
A
B
hydraulic porting.
Call Out
Function
Letter
A Reel Drive Pressure

C
B Reel Drive Return
D
Reel Lift & Fore-Aft
C
Return
Reel Lift & Fore-Aft
D
Pressure
E Electrical
169046 ISSUE DATE 04/03/18

9.15.3 LEXION MULTI-COUPLER VALVE BLOCK

The Lexion multi-coupler valve block is included
on all Lexion configured harvest headers. It’s
purpose is to direct oil flow to the appropriate reel
function such as reel raise/lower and fore/aft.
The Way It Works
V4
When the button on the hydrostatic lever for reel
raise or reel fore/aft is depressed it activates the
master solenoid on the combine. This then sends V3 V1
oil down from the combine through the hydraulic
lines to the multi coupler and into the valve block V2
at port “P”. Once inside the valve block the
appropriate solenoid valve is activated
electronically and oil is diverted to the
appropriate function. When the reel lower button
is depressed only valve “V2” is activated (master
solenoid not activated) allowing the reel raise/ Figure 9-203: Lexion Valve Block
lower cylinders to drain directly to tank. This is to
say that the reel lower function is gravity powered
and not pump down by the combine hydraulics.

(Figure 9-203) and (Figure 9-204).
Valve Function Electrical Connection
V1 Reel Raise X2 (Marked on Harness)
V2 Reel Lower X5 (Marked on Harness)
V3 Reel Fore X4 (Marked on Harness)
V4 Reel Aft X3 (Marked on Harness)
Figure 9-204: Hydraulic Schematic
169046 ISSUE DATE 04/03/18

9.15.4 MACDON, CASE 7010/8010 & NH CR/CX MULTI-COUPLER

The CIH multi-coupler is present on all Case 7010/8010 and New Holland CR/CX combines. This
multi-coupler system is also an option on all MacDon CA20 combine adapters (located on the right
hand side of the adapter) to allow the adapter’s reel hydraulics to connect to the header’s reel hydrau-
lics.
The multi-coupler incorporates the reel lift, fore-aft and drive hydraulics into one connection however
the electrical connections remain separate.

(Figure 9-205) in order to properly identify the B A
hydraulic porting.
Tag Color Function
A Reel Drive Return
B Reel Drive Pressure
C Reel Fore/Aft
D Reel Lift D E
E Electrical
Use the following table in conjunction with Black

hydraulic porting.
White
Tag Color Function
White Reel Drive Pressure Yellow

Red Reel Fore
Green Reel Aft
Black Reel Lift Green
Red
169046 ISSUE DATE 04/03/18

9.15.5 JOHN DEERE 60/70 SERIES MULTI-COUPLER

The John Deere 60 series multi-coupler is present on all 60/70 series John Deere combines. It incorpo-
rates the reel lift, fore-aft and drive hydraulics as well as all the electrical connections into one multi-
coupler coupler. There are two different options available in order to accommodate the functions avail-
able on the particular header in use. One multi-coupler option includes the electrical, reel lift and reel
fore/aft while the other cheaper option does not include the reel fore/aft connections.
John Deere Multi-Coupler

MD# 129120 [C/W All 5 Couplers]
Figure 9-207: JD 60 Series Multi-Coupler
Remove Fittings For Combines or Headers Without Reel Fore-aft Option
With a screwdriver remove retaining ring at base

of reel aft fitting (LT Blue disk) and reel fore fitting
(DK Blue). Fitting can then be removed from
multi coupler (refer to Figure 9-208).
Figure 9-208: Removing Retaining Clip
169046 ISSUE DATE 04/03/18

9.15.6 AGCO MULTI-COUPLER

Use the following table in conjunction with E C
B
hydraulic porting.
Tag Color Function
A Reel Drive Return
B Reel Drive Pressure

A C
C Reel Fore/Aft D
D Reel Lift Figure 9-209: Agco Multi-Coupler (Front)

E Electrical (MD#187019)
RED NO TIE
YELLOW
hydraulic porting.
BLACK
Tag Color Function
GREEN
Figure 9-210: Agco Multi-Coupler (Back)
No Tie Reel Drive Pressure
Red Reel Fore
Green Reel Aft
Black Reel Lift
169046 ISSUE DATE 04/03/18

SECTION 10: ELECTRICAL
D60/FD70/CA20 TOC
Section 10: Electrical System

10.1 Header Electrical Harnesses ......................................................................... 10-1
10.2 Lighting .......................................................................................................... 10-1
Single Span 15’ - 30’ D60 Reel Wiring Schematic...................................... 10-1
Single Span Reel 30’, 35’ D60 & Split Reel 30’, 40’ Wiring Schematic....... 10-2
Split Reel 45’ Wiring Schematic.................................................................. 10-2
10.2.1 Electrical Harness Combine Specific .................................................... 10-4
Case 2100/2300/2500 Series: .................................................................... 10-4
Case 7010/8010, NH CR/CX: ..................................................................... 10-4
Lexion 400 (R) Series: ................................................................................ 10-5
Lexion 500 (R) Series: ................................................................................ 10-6
John Deere 50 Series: ................................................................................ 10-7
John Deere 60 Series ................................................................................. 10-8
Agco............................................................................................................ 10-9
10.2.2 Transport Wiring Harnesses ............................................................... 10-11
10.3 Selector Valve Standard FD70 (Optional D60 & D50)................................. 10-14
10.4 Combine Electrical Harness for the Selector Valve..................................... 10-15
10.4.1 Case 23XX/25XX Series ..................................................................... 10-15
10.4.2 Case 7010/8010, New Holland CR/CX ............................................... 10-17
10.4.3 Agco .................................................................................................... 10-19
10.4.4 John Deere 50/60/70 Series ............................................................... 10-20
10.4.5 Lexion 400 series ................................................................................ 10-21
10.4.6 Lexion 500 Series ............................................................................... 10-22
10.5 2006 & Prior Selector Valve Standard FD70 (Optional D60)....................... 10-23
10.6 Combine Electrical Harness for the Selector Valve..................................... 10-24
10.6.1 Case 23XX Series............................................................................... 10-24
10.6.2 Case AFX, New Holland CR/CX ......................................................... 10-25
10.6.3 Agco .................................................................................................... 10-27
10.6.4 John Deere Pre 50 Series................................................................... 10-28
10.6.5 John Deere 50/60 series ..................................................................... 10-29
10.6.6 Lexion 400 series ................................................................................ 10-30
10.6.7 Lexion 500 Series ............................................................................... 10-31
10.7 Automatic Header Height Control (AHHC) .................................................. 10-32
10.7.2 Case 7010/8010 & 21XX/23XX/25XX ................................................. 10-32
10.7.3 Agco/Massey/Challenger/JD 50/60/70................................................ 10-34
10.8 AHHC Calibration ........................................................................................ 10-35
10.8.1 Case 21XX/23XX/25XX ...................................................................... 10-35
10.8.2 Case 7010/8010.................................................................................. 10-37
10.9 JD 50/60/70 Series, Agco AHHC ........................................................... 10-43
10.9.1 JD 70 Series........................................................................................ 10-51
10.9.2 Gleaner R62/72................................................................................... 10-56
10.9.3 Gleaner R65 & R75............................................................................. 10-58
D60/FD70/CA20 TOC
Adjusting the Sensors Range (Case, JD, Agco, Massey, Challenger) ..... 10-67
Diagnostic of Potentiometer (Case, JD Agco, Massey, Challenger)......... 10-68
10.9.4 New Holland CR/CX AHHC................................................................. 10-69
Adjustment and Operation ........................................................................ 10-71
Autofloat Mode.......................................................................................... 10-72
Check Sensor Range................................................................................ 10-72
Combine configuration .............................................................................. 10-73
10.9.5 Calibration of the header ..................................................................... 10-74
Intelliview .................................................................................................. 10-74
Intelliview II ............................................................................................... 10-78
Combine Configuration ............................................................................. 10-82
Set the Maximum Stubble Height.............................................................. 10-83
Set the Header Lower Rate ...................................................................... 10-84
Set the Header Lateral Float..................................................................... 10-84
Set the Header Autofloat........................................................................... 10-84
Set Header raise rate................................................................................ 10-85
Adjusting the Sensors Range (New Holland CR/CX) ............................... 10-86
Diagnostic of Potentiometer (New Holland CR/CX).................................. 10-87
10.9.6 Lexion AHHC....................................................................................... 10-88
10.9.7 AHHC Calibration (Lexion) .................................................................. 10-90
500 Series................................................................................................. 10-90
Automatic Header Functions..................................................................... 10-91
Header Height Limits ................................................................................ 10-91
Auto Contour Sensitivity (Auto Header) .................................................... 10-93
Reel Settings............................................................................................. 10-95
Cutting Height ........................................................................................... 10-98
Setting Cut Height Manually ..................................................................... 10-99
Adjusting the Sensors Range (Lexion) ................................................... 10-102
Diagnostic of Potentiometer (Lexion)...................................................... 10-103
10.10 Potentiometer Replacement .................................................................... 10-104
10.11 Reel Speed .............................................................................................. 10-105
10.11.1 John Deere 50/60/70 Series............................................................ 10-105
10.11.2 Lexion 400 Series............................................................................ 10-105
10.11.3 Lexion 500 Series............................................................................ 10-106
10.11.4 Agco ................................................................................................ 10-107
10.12 Header Recognition ................................................................................. 10-108
10.12.1 Case 7010/8010 & NH CR/CX ........................................................ 10-108
D60/FD70/CA20 Section 10: Electrical PAGE 10-1
10.1 HEADER ELECTRICAL HARNESSES

The D60 and FD70 headers come equipped with standard amber turn signal / hazard lights. To adapt
these lights to the combine lighting system there are electrical adapters that come with the CA20
combine adapter to adapt the signal light wiring harness connector of a particular make of combine to
the header harness connector. The adapters are generally kept current with combines of the same
production year as the adapters older combines may require some adaptation at the dealer level.
10.2 LIGHTING
MacDon Single Span 15’ - 25’ D60 Reel Wiring schematic
This is the standard wiring harness that is attached to a MacDon D60 harvest headers. This connector
attaches to a combine specific wiring harness adapter that mates to the combine wiring harness at the
feeder house.
Not used on 15’ SR
Figure 10-1: MD#172766 Single Span Reel 15’-25’ & 35’ Split Reel Wiring Schematic
169046 ISSUE DATE 01/01/11

Single Span Reel 30’, 35’ D60 & Split Reel 30’,35’ 40’ D60D Wiring Schematic
This is the standard wiring harness that is attached to a single span reel D60 header that is either 30’
or 35’. It also is on the 30’, 35’ and 40’ double knife drive headers. It comes complete with transport
connector built into the harness. This harness attaches to a combine specific wiring harness adapter
that mates to the combine wiring harness at the feeder house.
Figure 10-2: MD#172761 Single Span Reel 30’, 35’ D60 & Double Reel 30’, 35’ & 40’ D60D Wiring Schematic
Split Reel 45’ Wiring Schematic
This is the standard wiring harness that is attached to a Split Reel 45’ header. This harness attaches to
a combine specific wiring harness adapter that mates to the combine wiring harness at the feeder
house.
169046 ISSUE DATE 01/01/11

Figure 10-3: MD#172765 Split Reel 45’ Wiring Schematic
169046 ISSUE DATE 01/01/11

10.2.1 ELECTRICAL HARNESS COMBINE SPECIFIC

These are the harnesses sent with the Hydro/Electric completion package. Each combine specific
harness is detailed below.
Case 2100/2300 Series:
Figure 10-4: MD # 156612_B Combine Completion Harness

Case 7010/8010, NH CR/CX:
Figure 10-5: MD# 156613_E Combine Completion Harness Possible need 153698 also
169046 ISSUE DATE 01/01/11

Only used on units without

AHHC on Header
Figure 10-6: MD# 158974_A Combine Completion Harness
Only used on units without

AHHC on Header
Figure 10-7: MD# 153933_F Header Recognition Module
Lexion 400 (R) Series:
Figure 10-8: MD# 156615_D Combine Completion Harness
169046 ISSUE DATE 01/01/11

Figure 10-9: MD# 133888_A Reel Speed Harness

Lexion 500 (R) Series:
Figure 10-10: MD# 156990_C Combine Completion Harness
169046 ISSUE DATE 01/01/11

John Deere 50 Series:
169046 ISSUE DATE 01/01/11

John Deere 60 Series:
Figure 10-14: MD# 187033_B
Figure 10-15: MD# 156617_C Reel Speed Harness
169046 ISSUE DATE 01/01/11

Agco: All models Gleaner R and A Series, MF 9690/9790/9895, CHLG 660/670/680B
Figure 10-16: MD# 187019_E Combine Completion Harness
2007 & Older
169046 ISSUE DATE 01/01/11

Figure 10-18: MD# 133137_D Reel Speed Harness
169046 ISSUE DATE 01/01/11

10.2.2 TRANSPORT WIRING HARNESSES
This is the hitch adapter that plugs into a hitch harness that is wired to match the agricultural standard.
Figure 10-19: MD # 144737_C Transport Hitch Adapter
This is the standard wiring harness that is attached to the hitch. This harness connects the header
wiring harness to the hitch adapter.
Figure 10-20: MD # 144736_B Transport Hitch: Header End
169046 ISSUE DATE 01/01/11

Figure 10-21: MD#193080_B Part of MD#113524 Lighting Kit
Figure 10-22: MD#187033_B Part of MD#113524 Lighting Kit
169046 ISSUE DATE 01/01/11

Figure 10-23: MD# 113579_E Transport Light Module Relay

Normal driving mode:
• Red tail light (low filament) steady burn (if turned on)
• Amber warning lights flashing in unison with towing vehicle at 60 to 85 flashes per minute.
• Brake lamps (high filament) becomes steady burning if brake signal is received on the input
side of module (NOTE: Any harness prior to revision E will not react to input brake signal).
Turning Mode:
• Amber flashing warning light and red light opposite the direction of turn shall become steady
burning. The red light is on high filament.
• Amber flashing warning light in the direction of turn shall increase in flashing a minimum of 20
flashes per minute. In addition the red lamp in the direction of turning shall change from steady
burn (on low filament) to flashing in unison with the amber turning light and will flash from high
red to low red filament.
169046 ISSUE DATE 01/01/11

10.3 SELECTOR VALVE STANDARD FD70 (OPTIONAL D60 & D50)

The Way It Works
The selector valve gives the operator in the cab the ability to use the hydraulic fore-aft option and the
header tilt option from the combines reel fore-aft circuit. Solenoids are energized by a switch mounted
in the combine cab, diverting flow through the valve block to the header. Certain combines have
functionality built in to the universal display to toggle back and forth between reel fore-aft and header
fore-aft tilt. (See header controls in combine OP manual for details. These combines do not require
switch to be mounted)
Figure 10-24: Hydra Force Block (MD#133985)

See section 9 for the hydraulic schematic of the selector valve.
The main valve block is wired the same for all the combines except the CASE AFX & NH CR/CX. It
then attaches to the combine by specialized harnesses designed for each combine in specific.
Hydraforce coil resistance:
• Large coil 8.0 - 8.1 Ohm. 1.3 - 1.4 amp draw.
All valves are energized for header tilt and non energized for reel fore-aft. 1 black (ground)
and 1 white (power) lead to each coil.
169046 ISSUE DATE 01/01/11

10.4 COMBINE ELECTRICAL HARNESS FOR THE SELECTOR VALVE

10.4.1 CASE 23XX/25XX SERIES
Here are illustrations of the wiring harnesses required for the Case 23XX & 25XX series combines to
operate the selector valve.
Hydra Force
MD# 133985
Figure 10-25: MD# 129566_A connects to MD# 133985_A
Figure 10-26: MD#153989_D from header to 31 pin connector
169046 ISSUE DATE 01/01/11

Figure 10-27: MD#153990_A from 31 pin Connector to MD#109064 electrical switch in cab
Figure 10-28: MD#109064_C Electrical Switch
169046 ISSUE DATE 01/01/11

10.4.2 CASE 7010/8010, NEW HOLLAND CR/CX

Here are illustrations of the wiring harnesses required for the Case 7010/8010, New Holland CR/ CX
series combines to operate the selector valve.
Hydra Force
MD# 133985
Figure 10-29: MD#129566_A connects to MD# 133985_A
Connects to:
MacDon # 109064
Connects to:
MacDon # 158349
Figure 10-30: MD# 158326_C Connects to MD#129566_A for New Holland CR/CX or Case without Intergral control
Figure 10-31: MD# 109064_C Electrical Switch MD#158349_B Cigar Lighter Adapter
169046 ISSUE DATE 01/01/11

Figure 10-32: MD#153157_E for Case 7010/8010 & NH CR CX with Intergral control
169046 ISSUE DATE 01/01/11

10.4.3 AGCO: ALL MODELS GLEANER R AND A SERIES, MF 9690/9790/9895, CHLG

660/670/680B
Here are illustrations of the wiring harnesses required for the AGCO combines to operate the selector
valve.
Hydra Force
MD# 133985
Connects to:
MD# 109064
Connects to:
MD# 158349
Figure 10-34: MD#158326_C from MD#129566_A to combine cab
Figure 10-35: MD#109064_C Electrical Switch MD#158349_B Cigar Lighter Adapter
169046 ISSUE DATE 01/01/11

10.4.4 JOHN DEERE 50/60/70 SERIES
Hydra Force
MD# 133985
Connects to:
MD# 109064
Connects to:
MD# 158349
Figure 10-37: MD# 158326_C from MD# 129566_A to combine cab
169046 ISSUE DATE 01/01/11

10.4.5 LEXION 400 SERIES
Hydra Force
MD# 133985
Figure 10-39: MD#129566_A connects to MD#133985_A
Connects to:
MD# 109064
Connects to:
MD# 158349
Figure 10-40: 158326_C from MD#129566_A to Combine Cab
169046 ISSUE DATE 01/01/11

Hydra Force
MD# 133985
Figure 10-42: MD#129566_A connects to MD#133985_A
Connects to:
MacDon # 109064
Connects to:
MacDon # 158349
Figure 10-43: MD#158326_C from MD#129566_A to Combine Cab
169046 ISSUE DATE 01/01/11

10.5 2006 & PRIOR SELECTOR VALVE STANDARD FD70 (OPTIONAL D60)
The Way It Works
The selector valve gives the operator in the cab the ability to use the hydraulic fore-aft option and the
header tilt option from the combines reel fore-aft circuit. Solenoids are energized by a switch mounted
in the combine cab, diverting flow through the valve block to the header. Certain combines have
functionality built in to the universal display to toggle back and forth between reel fore-aft and header
fore-aft tilt. (See header controls in combine OP manual for details. These combines do not require
switch to be mounted)
Figure 10-45: HydraForce Block

See section 9 for the hydraulic schematic of the selector valve.
The main valve block is wired the same for all the combines except the CASE AFX & NH CR/CX. It
then attaches to the combine by specialized harnesses designed for each combine in specific.
Hydraforce Coil Resistance:
• Small coil 9.0 - 9.1 Ohm current draw, 1.2 amp draw.
• Large coil 8.0 - 8.1 Ohm. 1.3 - 1.4 amp draw.
All valves are energized for header tilt and non energized for reel fore-aft. 1 black (ground)
and 1 white (power) lead to each coil.
NOTE:
For 2007 production there is a new selector valve. See SB 0727 for technical info. Info not avail-
able until April 2007.
169046 ISSUE DATE 01/01/11

10.6 COMBINE ELECTRICAL HARNESS FOR THE SELECTOR VALVE

10.6.1 CASE 23XX SERIES
Here are illustrations of the wiring harnesses required for the Case 23XX series combines to operate
the selector valve.
Hydra Force
MD# 129564
Figure 10-46: MD#129566_A connects to MD#129564_D
Figure 10-47: MD#109064_C Electrical Switch
169046 ISSUE DATE 01/01/11

10.6.2 CASE AFX, NEW HOLLAND CR/CX

Here are illustrations of the wiring harnesses required for the Case AFX, New Holland CR/ CX series
combines to operate the selector valve.
Hydra Force
MD# 129564
Figure 10-48: MD#129566_A
Connects to:
MacDon # 109064
Connects to:
MacDon # 158349
Figure 10-49: MD#158326_B MD#153988_B to combine cab for New Holland CR/CX or Case without header tilt
169046 ISSUE DATE 01/01/11

Figure 10-50: MD# 153157_E for Case AFX with Header fore-aft option on universal display
169046 ISSUE DATE 01/01/11

10.6.3 AGCO
Here are illustrations of the wiring harnesses required for the AGCO combines to operate the selector
valve.
Hydra Force
MD# 129564
Figure 10-51: MD#129566_A connects to MD#129564_D
Connects to:
MD# 109064
Connects to:
MD# 158349
Figure 10-52: MD# 158326_C from MD# 129566_A to Combine Cab
169046 ISSUE DATE 01/01/11

10.6.4 JOHN DEERE PRE 50 SERIES
Hydra Force
MD# 129564
Figure 10-54: MD# 129566_A connects to MD# 129564_D
Connects to:
MD# 109064
Connects to:
MD# 158349
169046 ISSUE DATE 01/01/11

10.6.5 JOHN DEERE 50/60 SERIES
Hydra Force
MD# 129564
Connects to:
MD# 109064
Connects to:
MD# 158349
169046 ISSUE DATE 01/01/11

Hydra Force
MD# 129564
Connects to:
MD# 109064
Connects to:
MD# 158349
Figure 10-61: 158326_C from MD#129566_A to Combine Cab
169046 ISSUE DATE 01/01/11

Hydra Force
MD# 129564
Figure 10-63: MD#129566_A Connects to MD#129564
Connects to:
MacDon # 109064
Connects to:
MacDon # 158349
Figure 10-64: MD#158326_C from MD#129566_A to Combine Cab
169046 ISSUE DATE 01/01/11

10.7 AUTOMATIC HEADER HEIGHT CONTROL (AHHC)

10.7.1 THE WAY IT WORKS
The AHHC automatically adjusts the feeder house relative to ground conditions to optimize flotation
with changes of ground contour. It allows you to cut closer to the ground than ever before with less
operator input required. It accomplishes this by a sensor that is mounted between the adapter and
header. This sensor reads any changes in positioning of the header in comparison to the adapter as a
result of cutter bar or stabilizer wheel pressure (when cutting above ground) lifting header away from
adapter and automatically adjusts feeder house. This allows the header to cut as close to the ground
as possible.
NOTE:
AHHC does not work if cutterbar or stabilizer wheels are not in contact with the ground.
For best operation of the AHHC while cutting on the ground, place stabilizer wheels in top (highest)
position.
10.7.2 CASE 7010/8010 & 21XX/23XX/25XX
Figure 10-66: Base AHHC

This is a sketch for the base AHHC for the Case 7010/8010 & 21XX/23XX/25XX. The diagrams below
will give you a break down of each harness used on the combine.
Figure 10-67: MD# 133133_B

This part is only for 21XX/23XX/25XX series combines.
169046 ISSUE DATE 01/01/11

Figure 10-68: MD# 153698_D

This part is only for 7010/8010 series combines
Figure 10-69: MD# 158069_A Diagram of sensor

This is the sensor used for Case 7010/8010 & 21XX/23XX/25XX combines. The voltage range that the
sensor should be within is 0.5 to 4.5 volts for Case 7010/8010, 2.8 to 7.2 volts for 21XX/23XX/25XX. If
you are not getting a reading in this range then you will need to diagnose whether the sensor is out of
range or if it is non functioning. See “Adjusting the Sensors Range (Case, JD Agco, Massey,
Challenger)” on page 10-67. if sensor is out of range. If it is not functioning, See “Diagnostic of
Potentiometer (Case, JD, Agco, Massey, Challenger)” on page 10-68.
NOTE:
Make sure that you have at least 2.5 volts difference from the bottom reading to the top reading for
the Case 7010/8010 and at least 4 volts difference for the 21XX/23XX/25XX.
169046 ISSUE DATE 01/01/11

10.7.3 AGCO/MASSEY/CHALLENGER/JD 50/60/70 SERIES COMBINES
Figure 10-70: Base AHHC

This is a sketch for the base AHHC for the Agco/
Massey/Challenger & JD 50/60/70 combines. There is no additional harness required for Agco/
The diagrams below will give you a break down Massey/Challenger & JD 50/60/70 Combines to
of each harness used for the different models of operate the AHHC. The main header harness
combines. connects directly to the potentiometer.
Figure 10-71: MD# 158069_A Diagram of sensor

This sensor is used on Agco/Massey/Challenger out of range. If it is not functioning, See
& JD 50/60/70 combines. “Diagnostic of Potentiometer (Case, JD, Agco,
The voltage range that the sensor should be: 0.5 Massey, Challenger)” on page 10-68.
to 4.5 volts for Agco & John Deere Combines. If NOTE:
you are not getting a reading in this range then Make sure that you have at least 2.5 volts dif-
you will need to diagnose whether the sensor is ference from the bottom reading to the top
out of range or if it is non functioning. See reading.
“Adjusting the Sensors Range (Case, JD Agco,
Massey, Challenger)” on page 10-67. if sensor is
169046 ISSUE DATE 01/01/11

10.8 AHHC CALIBRATION NOTE:

As soon as operator functions height switch
After installing the float optimizer on the header in HT when unit is functioning, this disen-
these are the procedures to follow in order to cal- gages HT mode. Simply press switch down to
ibrate, operate and increase the sensitivity of the re-engage.
float optimizer.
10.8.1 CASE 21XX, 23XX, 25XX
1. Set the flotation on the header and adapter
package (see OP manual for instructions).
Position fore aft and center link in mid span.
2. Combine engine running, there is no need to
have separator or feeder house engaged.
3. On RH console switch header control switch
(17) to “HT” (This is Auto Header height
Mode).
4. On the propulsion lever, engage the header
raise/lower switch (6). Hold the lower switch Figure 10-72:
down until the adapter and header are
lowered. Remain holding the switch down for
5 seconds.
5. Engage header raise/lower switch (6). Hold
the header raise switch up. The header
should stop at about the half way point. Keep
holding the header raise switch and header
will automatically raise until the feeder
reaches the top of its limitations.
6. The F.O. is now calibrated.
NOTE:
If “S1” appears on the monitor, it means that
the potentiometer is out of range.
OPERATION
Figure 10-73:
1. HT is auto header height mode.
2. Ground pressure and sensitivity are
controlled by the sensitivity control (18) and
response control (19)knobs on the RH
console.
3. HT is activated as soon as the down switch
on the propulsion lever is held for 1 second.
4. Header will always lower to desired height.
5. Height and or cutter bar pressure can be
adjusted by the operator on the go as
conditions change with sensitivity control
knob (18).
169046 ISSUE DATE 01/01/11

Automatic Header Height Control (If Equipped)
Figure 1-74:
1. The Automatic Header Height Control mode

can be entered if the mode select switch (1)
is in “HT”, the feeder is ON and the header
LOWER switch is momentarily pushed.
2. In Automatic Header Height Control, the
system raises and lowers the header to
maintain a fixed distance from the ground. 6
The POSITION CONTROL (2) sets the height
to maintain the header from the ground.
3. The rate at which the header raises or lowers
to maintain the ground height is controlled by
the HEADER RAISE RATE (3) and HEADER
LOWER RATE (4) control settings.
4. In this mode the SENSITIVITY CONTROL (5)
sets how sensitive the header control is to Figure 10-75:
changing ground conditions.
NOTE:
When using HT control and MacDon AHHC,
the accumulator (6) must be turned off.
169046 ISSUE DATE 01/01/11

10.8.2 CASE 7010/8010 between the ground height sensors and the
working setting, the higher the sensitivity setting,
After installing the float optimizer on the header
the quicker the raise or lower speed will reach
these are the procedures to follow in order to
maximum. See Height Sensitivity for setting
calibrate, operate and increase the sensitivity of
information.
the float optimizer.
Auto Height Mode
Before Auto Height can be enabled, the correct
header type identified via the display and a
ground calibration must have been performed for
that header.
See Ground Height Calibration and Header Con-
figuration for details. See “Ground Calibration” on
page 10-38.
When the RESUME switch is momentarily Figure 10-76:

actuated, the header is raised or lowered to the
feeder position setting. If the Settings call for The actual ground height position is shown on
AUTO HEIGHT mode, AUTO HEIGHT mode will the display, 1, as a numeric relative to the zeroed
be enabled when the actual feeder position feeder position (header fully on the ground).
matches the feeder position setting. The height Along with the ground height, Auto Height., 2, is
system raises or lowers the feeder to maintain shown.
the header ground height at the working setting.
If the ground height decreases, the feeder is If the operator actuates the RAISE or LOWER
raised to lift the header to increase the ground switch, the system will go into Manual mode. To
height back to the working setting. If the ground return to Auto Height mode, the operator
height increases, the feeder is lowered to lower momentarily selects the RESUME switch.
the header to decrease the ground height back to If ground height sensor or sensors are detected
the working setting. on the header and then no ground height sensors
The operator can fine adjust the working setting are detected, the operator will get the momentary
with the INCREASE, 1, and DE-CREASE, 2, warning alarm, Auto Header Height., on the
switches. When the operator actuates the display.
INCREASE switch, the working setting is
increased and the feeder is raised until the
header reaches the new working setting. The
new working setting is saved to the Setting being
used, with the appropriate header type. When the
operator actuates the DECREASE switch, the
working setting is decreased and the feeder is
lowered until the header reaches the new
working setting. The new working setting is
saved to the Setting being used, Setting#1 or
Setting#2 with the appropriate header type. The
working setting can be set between 93%, Figure 10-77:
highest, to 13%, lowest, of the ground height
sensor or sensors range.
The Height Sensitivity control sets the gain of the
raise and lower signals. For a given correction
169046 ISSUE DATE 01/01/11

HEADER CALIBRATION The operator will again be asked to initiate a

momentary RAISE command to continue
Height Calibration
calibration.
Feeder house calibration is done at the factory
When the height system receives this command,
and should only be needed if the CCM1, Feeder
the feeder will automatically raise (slow con-
Position Angle Sensor, Raise Solenoid, Lower
trolled raise) to the full up position and save this
Solenoid or the Feeder Lift Valve is changed. The
feeder position sensor value. Then the feeder will
control is located on the screen CAL >COMBINE,
be lowered slightly to calculate the lower current
then HEADER HEIGHT.
threshold and save this value. This completes the
DANGER calibration.
If a RAISE, LOWER, LEFT TILT or RIGHT TILT
The header calibration is an automatic command occurs during any time the height
process. No one should be in the area of the system is automatically raising or lowering the
header while calibrating. feeder, the height system stops any feeder move-
The height system will only run in Calibration, if ment and exits Calibration state immediately.
the feeder drive is off, the combine is not moving
Ground Calibration
and the display requests calibration. During cali-
bration, the feeder position sensor limits and If the combine is stopped and the feeder drive is
raise and lower solenoid threshold currents are not on, the operator can zero the feeder position
measured. display relative to the header type. If the operator
continues to actuate the LOWER switch for 2
NOTE:
seconds after the header reaches the ground, the
The full range of feeder travel needs to be
feeder position for zeroing the display will be
measured. Since the feeder range goes
measured.
below ground level, the combine must be
positioned over a depression at least 300 mm If ground height sensors are on the header, the
(11.8 in) lower than the tire ground level. The ground height sensors fully on the ground limits
combine can also be driven up ramps so that will be measured. The feeder position and
the feeder can travel below the tire ground ground height sensors fully on the ground limits
level. are saved relative to the header type.
NOTE: If ground height sensors are on the header and if
It is strongly recommended that calibration the operator zeroed the feeder position display,
occur without a header attached. the header needs to be raised to complete the
ground calibration. Press the raise switch until
The operator is directed to.Ensure the header is
the header is momentarily stopped partway from
removed & feeder can be lowered below ground
the top for 1.5 seconds. The ground height sen-
level. Press START to begin.
sors off the ground limits will be measured and
NOTE: saved relative to the type of header.
The feeder will automatically move during
NOTE:
this procedure.
If a new header type is detected or a new
The operator will be asked to initiate a default header is defined (see HEADER
momentary RAISE command to start calibration. CONFIGURATION), the operator will get a
When the height system receives this command, momentary warning alarm “Calibrate Header
the feeder will automatically lower (slow Ground Height Sensors”.
controlled lower if not already fully down) to the
full down position and save this feeder position
sensor value. Then the feeder will be raised
slightly to calculate the raise current threshold
and save this value.
169046 ISSUE DATE 01/01/11

RAISE & LOWER SENSITIVITY

Manual Header Height Control
In Manual, when the lower switch, 1 is pressed
the header lower solenoid is energized until the
lower switch is released. The speed the header
lowers is limited with the lower rate setting, con-
trolled on the Display. The lower rate is adjust-
able from 3.5 to 4.5 seconds fastest to 9 to 11
seconds for a full up to full down travel.
Likewise, when raise switch, 2 is pressed the
header raise solenoid is energized until the raise
switch is released.
The speed the header raises is limited with the Figure 10-78:
raise rate setting. The raise rate setting range is
adjustable from 4 to 5 seconds fastest to 9 to 11
seconds for a full down to full up travel. This set-
ting is adjustable using the adjustable readout
display, 1, on the Display (location on the
USER>HARV or USER>ADJUST screen user
defined). The control.s range is from 0, slowest,
to 250, fastest by steps of 10. The header lower
rate is similarly controlled.
When the feeder gets close to the top, the speed
the header raises starts to slow down. The closer
the header gets to the top, the slower the speed
of the header.
The actual position of the feeder, 2, is shown on
the display as a numeric relative to the zeroed
feeder position. Along with the feeder position,
Manual is displayed, 3.
Figure 10-79:
Height and Tilt Sensitivity

In addition to setting the header raise and lower
rates as previously described in this section, the
operator can adjust how sensitive the header is
when maintaining ground height in Auto Height
mode or ground pressure in Pressure Float mode
and ground height in Auto Tilt mode. These set-
tings are adjustable using the adjustable read out
display, 1, on the display (location on the
USER>HARV or USER>ADJUST screens user
defined). The control.s range is from 0, least sen-
sitive, to 250, most sensitive by steps of 10.
169046 ISSUE DATE 01/01/11

Setting the working setting and operating

mode
To set the working setting and operating mode,
with the feeder running, the operator manually
raises or lowers the header to the cutting height
wanted. Once at the cutting height wanted, the
operator actuates the SET #1 switch, 1.
The system determines the mode by the position
of the header. If the ground height sensors are off
the ground, the mode will be RTC and the
working setting will be the feeder position. If the
ground height sensors are in contact with the
ground but the header is still off the ground, the
mode will be Auto Height and the working setting Figure 10-80:
will be the ground height. If the header is on the
ground and the header is a grain head, the mode
will be Pressure Float and the working setting will
be the ground pressure. The mode, the feeder
position and the working setting will be saved rel-
ative to the header type.
NOTE:
If the grain head is a flex header, the auto
height and pressure float modes occupy the
same effective range on the header. There-
fore, to set pressure float, the operator needs
to lower the header all the way to the ground,
then actuate the SET #1 or SET #2 switch.
See pressure float mode for adjusting the
working setting.
Figure 10-81:
169046 ISSUE DATE 01/01/11

The mode, the feeder position and the working

setting will be saved to Settings #1 relative to the
header type If the operator has selected the SET
#1, 1, switch. If the operator has selected the
SET #2 switch, 2, instead of the SET #1 switch,
then the mode, the feeder position and the
working setting will be saved to Settings #2
relative to the header type. SET #2 switch
otherwise operates the same as the SET #1
switch.
When the system is using Settings #1, the
Header Height Mode Lamp, 3, next to the SET #1
switch is turned on. Likewise, when the system is
using Settings #2, the Header Height Mode Figure 10-82:
Lamp, 4, next to the SET #2 switch is turned on.
Each header type can have two different settings
(Settings #1 and Settings #2). four
different header types are accommodated.
NOTE:
If the header is near or at the top of travel
and the operator actuates one of the SET
switches, the mode saved to the settings will
be Manual. This effectively disables this Set-
tings and toggle capability of the RESUME
switch (see RESUME below). If both SET
switches are actuated when the header is at
or near the top of travel, this effectively dis-
ables the RESUME switch functionality in the
Auto state.
169046 ISSUE DATE 01/01/11

HEADER CONTROLS
Reel Position Switch
This is a four position switch which operates
grain heads as follows:
• Raise, 1 - Press the (+) symbol on the
switch to raise the reel.
• Lower, 2. Press the (-) symbol on the
switch to lower the reel.
• Forward, 3. Press the () symbol on the
switch to move the reel forward (if
equipped with the reel fore/aft option).
• Aft, 4. Press the () symbol on the switch
to move the reel to the rear. Figure 10-83:
NOTE:
For draper headers equipped with Fore/Aft
Tilt the reel fore and aft switches also control
Fore/Aft Tilt.
To be able to swap between using the Reel Fore /
Aft switches to position the reel or header fore
and aft, the Fore / AFT CNTL, 1, needs to be
selected and placed on one of the operator
configurable screens; HARV1, HARV2, HARV3
or ADJUST under the RUN menu. If “Header” is
selected with the Fore / Aft Control, press the reel
aft switch, on the propulsion handle, to tilt the
header rearward. or press the reel fore switch, on
the propulsion handle, to tilt the header forward.
H F/A, 2, is displayed on the status bar on the
right side of the operator configurable screens
when “Header” is selected with the Fore / Aft
Control.
Figure 10-84:
169046 ISSUE DATE 01/01/11

10.9 JD 50/60 SERIES, AGCO

NOTE:
For best performance of the Auto Header
Height system, perform these procedures
with the center link adjusted as long as pos-
sible. When setup & calibration is complete,
adjust the center link back to desired header
angle. See “Header Angle” in Operation sec-
tion of the CA20 adapter Operators Manual.
• Ensure header is on Down Stops with
adaptor float unlocked.
• FD70 units should have wings in locked
position. Figure 10-85:
Checking the sensor reading (Voltage) from
the cab:
Push the diagnostic button on the (HHS) monitor
(this is the button with the open book with the
wrench on top of it; marked “C”) “DIA” will appear
on the monitor. Push the up button (A) until
“EO1” appears on the monitor (these are all your
header adjustments). Then hit enter (B). A C
Now push the up or down button (A) until “24” is
displayed on the top portion of the monitor. This
is the voltage reading of the sensor.
Start the combine and lower the feeder house
until the header is on the ground and the adapter
is completely separated from the header.
B
NOTE: Figure 10-86:
You may need to hold the header down
switch for a few seconds to ensure the feeder
house is entirely down.
The sensor reading on the monitor should be
above 0.5 volts.
Next raise the header so it is just off the ground.
The reading on the monitor should read below
4.5 volts.
NOTE:
If the reading is outside these ranges, See
Massey, Challenger)” on page 10-67.
169046 ISSUE DATE 01/01/11

Calibration:
To calibrate the header, start the combine. Push
the diagnostic button on the monitor (this is the
button with the open book with the wrench on top
of it; marked (“C”) “DIA” will appear on the
monitor.
Then push the “CAL” button (D) “DIA - CAL” will A C
appear on the monitor. Push the up or down
buttons until “HDR” appears on the monitor.
Push enter button (B), “HDR - DWN” will appear
on the monitor. Lower the feeder house all the
way (after the header hits the ground you will
D
have to continue to hold the header lower button B
for about 5 to 8 seconds in order to accomplish
this). Figure 10-87:
Once the feeder house is all the way down push
the “CAL” button (D). This will save the lower
calibration in the computer. “HDR -UP” will now
appear on the monitor.
Raise the header 3' off the ground and again
push the “CAL” (D), “EOC” should appear on the
screen. Press the enter button (B) to save the
calibration of the header.
Your Auto Header Height is now calibrated.
NOTE: Figure 10-88:

If an error code comes up on the screen the
sensor is not in the correct working range. Go
back to “Checking the Sensor Reading from
the Cab” on the previous page to check and
adjust the range.
D
After the calibration is complete specific combine

operation settings need to be made to ensure
proper field operation.
Figure 10-89:
169046 ISSUE DATE 01/01/11

Operation Settings:
50 Series John Deere: For proper performance Figure 10-90: 50 Series Accumulator Shut Off Location
deactivate the accumulator as described in
combine's operator's manual. Once this is done
proceed to the “Operation” section later in this
document.
John Deere 60 Series Combines Only:

A C
1. Turn the accumulator off:
Push the diagnostic button on the “VisionTrak
Display” monitor (this is the button with the
open book with the wrench on top of it;
marked (C) “DIA” will appear on the monitor. D
Push the up button (A) until “EO1” appears
on the monitor (these are all your header
B
adjustments). Then hit enter (B). Figure 10-91:
Now push the up or down button (A) until
“132” is displayed on the top portion of the
monitor. This is the reading of the accumu-
lator.
Once you have “132” displayed at the top of
the monitor, press enter (B). This will now
allow you to change the display to a 3-digit
number so it has a “0” in it. Example: “x0x”.
Push the up or down button (A) until the
desired number is displayed, then press the E G
cal (D) button.
The accumulator is now deactivated. Press F
enter (B) to save the changes.
2. Set the Sensing Grain Header Height to “50”.
Figure 10-92:
Push the diagnostic button on the “Vision
Trak Display” monitor (this is the button with
the open book with the wrench on top of it;
marked (C) “DIA” will appear on the monitor.
Push the up button (A) until “EO1” appears
on the monitor (this is all your header adjust-
ments). Then hit enter (B).
Now push the up or down button (A) until
“128” is displayed on the top portion of the
monitor. This is the reading of the sensor.
Once you have “128” displayed at the top of
the monitor, press enter. This will now allow
you to change the display so it has a “50” in it.
169046 ISSUE DATE 01/01/11

3. Push the up or down button (A) until the

desired number is displayed, then press the
cal (D) button.
4. The height is now set, press enter (B) to save

the changes. A C
D
B
Figure 10-93:
5. Do not use the active header float function

(G) in combination with the MacDon Auto
Header Height as the two systems will
counter-act one another. Header symbol on G
display should not have wavy line under it
E
and should appear exactly as shown on the
“Active Header Control Display” illustration. F
Figure 10-94:
169046 ISSUE DATE 01/01/11

Operation:
To operate your Auto Header Height, ensure the
header height resume and active header control
functions are on. Do this by pressing the buttons
on the top monitor. Header height resume is
indicated with a header diagram with a curved
arrow in front of it (F) and active header height is
indicated with an arrow going up and down in E G
front of it (E). Icons will appear on the monitor
with same picture that is displayed on the
buttons. This indicates that your auto header F
height, resume and active header control is
turned on.
Once the header height resume and auto header Figure 10-95:
control is turned on, use buttons 2 and 3 on your
hydrostatic lever for active header control.
NOTE:
Button 1 is reserved for auto height resume
which will return the header to a certain
height but will not automatically compensate
for ground variation.
NOTE:
In order to do this the combine must be run-
ning, the auto header height sensing must be
turned on, the header switch and feeder
house must also be engaged.
Once you choose which button you are going to
Figure 10-96:
use push it and the header will position itself at a
default height.
From this position adjust the header to the H
desired ground pressure by turning your “AHC”
dial (auto header control dial) located at the
upper right hand corner of the console (H).
NOTE:
Desired ground pressure is in most cases 1
number separation of the Auto Header Height
from having the header fully suspended off
the ground to just sitting on the ground.
Figure 10-97:
169046 ISSUE DATE 01/01/11

Once you have set your desired ground pressure

the Auto Header Height will now maintain
constant float at this ground pressure (it will lower H
or raise the feeder house to compensate for the
changes in ground height).
The additional buttons (2 or 3) on the hydrostatic
lever are use for two different ground pressure
settings. The dial (H) will work for the specific
button that was pushed to activate auto header
control. Each time the button is pushed the
header will return to that specific ground
pressure.
NOTE:
The Auto Header Height is designed to “opti-
mize” your float when cutting on the ground. It Figure 10-98:
will not function if the cutterbar is off the
ground.
169046 ISSUE DATE 01/01/11

Increasing the sensitivity of the Auto Header

Height (Dead Band Adjustment)
To increase the sensitivity of the float optimizer
push the diagnostic button on the monitor (this is
the button with the open book with the wrench on A C
top of it; marked “C”) “DIA” will appear on the
monitor. Push the up button (A) until “EO1”
appears on the monitor (this is all your header
adjustments) then push the enter button (B).
Now push the up or down button until “112” is D B
displayed on the monitor. This is your sensitivity
setting. The default setting is 105 and the Figure 10-99:
maximum sensitivity is 50. You are most likely
going to operate in the 60 to 80 range. To adjust,
once you have “112” displayed at the top of the
monitor enter. This will now allow you to change
the first digit of the number sequence.
Push the up or down button (A) until the desired
number is displayed. Then push the button (D)
marked “CAL”. This will bring you to the second
digit. Repeat this procedure until the desired
setting is achieved. Push enter (B) to save
changes.
Figure 10-100:
NOTE:
For 60 series combines only, you will need to
go back into the E01 setting. This time push
the up or down button to get to “128”. There is
a range from 50-250. By lowering the number
you increase the sensitivity and therefore
speed up the response time.
NOTE:
The numbers under this display are simply
reference numbers they do not represent any
particular value.
169046 ISSUE DATE 01/01/11

Adjust the threshold for the drop rate valve

This adjusts the point at which the restrictor valve
opens allowing full flow to the lift cylinders.
To increase the flow rate sooner push the A C
diagnostic button on the monitor (this is the
button with the open book with the wrench on top
of it; marked (C) “DIA” will appear on the monitor.
Push the up button (A) until “EO1” appears on
the monitor (these are all your header
adjustments) then push the enter button (B). D B
Now push the up or down button until “114” is Figure 10-101:
displayed on the monitor. This is the setting that
adjusts when the fast drop rate starts with
respect to the dead band. You should operate in
the 60 to 85 range to adjust, once you have “114”
displayed at the top of the monitor, press enter.
This will now allow you to change the first digit of
the number sequence.
Push the up or down button (A) until the desired
number is displayed. Then push the button (D)
marked “CAL”. This will bring you to the second
digit. Repeat this procedure until the desired
setting is achieved. Push Enter (B) to save
Figure 10-102: Triple Display Tachometer
changes.
NOTE:
particular value.
169046 ISSUE DATE 01/01/11

10.9.1 JD 70 SERIES
CHECKING THE SENSOR READING
(VOLTAGE) FROM THE CAB
From the main page of the Command Center
push the Home Page button (A) to view the 3
icons (B). (Figure 10-104) (Figure 10-105)
Figure 10-103: Command Center - Main Page
Scroll down using the Scroll knob (E) until you

reach the middle icon, (green circle with a yellow A
“i”). Once the middle icon is selected, push the
enter button (D). (Figure 10-104) (Figure 10-105)
E
D
Figure 10-104:
This will bring up the Message Center. Highlight
the Diagnostic Addresses from the right hand
column, the second icon from the top (J), using
the Scroll knob (E). Push the enter button (D) to
select. (Figure 10-104) (Figure 10-105)
(Figure 10-106)
Figure 10-105:
169046 ISSUE DATE 01/01/11

Scroll over to the drop down box (H) and hit enter
(D). Scroll down, using the Scroll knob (E), until
LC 1.001 Vehicle (Q) is highlighted. Push enter
(D) to select. (Figure 10-104) (Figure 10-106)
Scroll to the small bottom arrow (S) and hit enter

to scroll down the list until 029 Data (T) is
displayed, this is where the voltage reading is H J
located.
Start the combine and lower the feeder house

until the header is on the ground and the adapter
is completely separated from the header.
NOTE:
You may need to hold the header down Figure 10-106:
switch for a few seconds to ensure the feeder
house is entirely down.
The sensor reading on the monitor should be
above 0.5 volts.
Next raise the header so it is just off the ground.
The reading on the monitor should read below
4.5 volts.
NOTE:
If the reading is outside these ranges, See Q
Massey, Challenger)” on page 10-67.
Figure 10-107:
Voltage
Figure 10-108:
169046 ISSUE DATE 01/01/11

CALIBRATION
Feeder house raise/lower speed
To calibrate the feeder house raise/lower speed,
start the combine. From the main page the 4th
icon from the left (K), the book with the wrench
L
on it, needs to be selected. To select press top
button (L). K
Top button (L) needs to be pushed a second time
to enter diagnostics and calibration mode. Select
the option Header in the box (C) by scrolling
down to the box using the scroll knob (E) and
hitting enter (D).
Scroll, using knob (E), to the option Feeder Figure 10-109: Command Center - Main Page
house Speed (M) and select it by pressing the
enter key (D). Next, scroll down, using the scroll
knob (E), to the R/H corner icon (N), the arrow in
the diamond, and again hit the enter key (D) to
select.
Follow the steps listed on the screen to perform
the calibration.
NOTE:
back to “Checking the Sensor Reading from M
adjust the range.
After the calibration is complete specific combine
Figure 10-110:
E
D
Figure 10-111:
169046 ISSUE DATE 01/01/11

Header
To calibrate the header, start the combine. From
the main page the 4th icon from the left (K), the
book with the wrench on it, needs to be selected.
To select press top button (L). L
Top button (L) needs to be pushed a second time
to enter diagnostics and calibration mode. Select K
the option Header in the box (C) by scrolling
down to the box using the scroll knob (E) and
hitting enter (D).
Scroll, using knob (E), to the option Header (Z)
and select it by pressing the enter key (D). Next,
scroll down, using the scroll knob (E), to the R/H
corner icon (N), the arrow in the diamond, and Figure 10-112: Command Center - Main Page
again hit the enter key (D) to select.
Follow the steps listed on the screen to perform
the calibration.
NOTE:
back to “Checking the Sensor Reading from
adjust the range.
After the calibration is complete specific combine Z
Figure 10-113:
E
D
Figure 10-114:
169046 ISSUE DATE 01/01/11

INCREASING THE SENSITIVITY OF THE

AUTO HEADER HEIGHT:
To adjust the sensitivity of the Auto Header
Height push button (D), found on the R/H
console, twice. On the Command Center the
screen will display the current setting. To adjust
use Scroll knob (E). This is your sensitivity
setting, the lower the reading the lower the
sensitivity.
E
The adjustment will be automatically saved. If the
D F
screen remains idle for a short period of time it
will return to its previous screen or the enter
button (F) can be pushed to return to the Figure 10-115:
previous screen.
NOTE:
particular value.
ADJUST THE MANUAL HEADER RAISE/

LOWER RATE
To adjust the Raise/Lower rate push button (D),
found on the R/H console, once. On the
Command Center the screen will display the
current setting. To adjust use Scroll knob (E).
This is your Raise/Lower rate setting, the lower
the reading the slow the rate.
The adjustment will be automatically saved. If the Figure 10-116: Header Height Sensitivity
screen remains idle for a short period of time it
will return to its previous screen or the enter
button (F) can be pushed to return to the
previous screen.
NOTE:
particular value.
Figure 10-117: Manual Raise Lower Speed
169046 ISSUE DATE 01/01/11

10.9.2 GLEANER R62/72

CALIBRATION & OPERATION PROCEDURE
Once the header is installed on the combine and H
the Auto Header Height is setup correctly and
plugged in it will need to be calibrated.
G
1. Ensure the center link is as short as possible,
and that the adapter float is unlocked.
2. To calibrate the Auto Header Height turn on
the combine, press and hold the hidden “C1” P
button (M) until the LED light (K) flashes
momentarily.
3. Lower the feeder house as far as it will go. K
Press and hold the hidden “L2” button (P) M
until the LED light (K) flashes momentarily.
N
4. The header is now calibrated.
OPERATION SETTINGS Figure 10-118:
Engage the Main Threshing Clutch (2) and
Header Clutch (1). Speed the throttle (3) to over
2000 rpm’s.
Push the Auto Header Height button (N) and the
LED light (K) should flash continuously, indicating
it is in standby mode and waiting for a response
from the operator.
Momentarily push the header down button (4)
and the header should lower automatically and
the LED light (K) should stay illuminated
indicating the auto height system is engaged and
working. Figure 10-119:
To control the ground pressure turn the Height
Dial (G) to increase or decrease ground
pressure.
3
To control the sensitivity or how quickly the auto
header height reacts to varying ground
conditions, turn the Sensitivity Dial (H).
4
Figure 10-120:
169046 ISSUE DATE 01/01/11

NOTE:
Desired ground pressure is in most cases 1
number separation of the Auto Header Height
from having the header fully suspended off
the ground to just sitting on the ground.
Figure 10-121:
169046 ISSUE DATE 01/01/11

10.9.3 GLEANER R65 & R75

These instructions are designed to be used with,
the combine operator's manual; header height
sensing section, to simplify final adjustment.
NOTE:
Height, perform all the following steps with
center link adjusted as short as possible.
When the procedure is complete, adjust the
center link back to desired header angle. See
“Adaptor Mounting Instructions” in Operation
section of CA20 Adapter Operators Manual.
System components required for the Auto
Header Height to operate:
• Main module (PCB board) and header Figure 10-122: AHHC PCB Board
driver module (PCB board) mounted in
card box (1) in Fuse Panel Module (FP)
NOTE:
• Multi Function Control Handle operator
In addition to the above components the
inputs
electro hydraulic header lift control valve
• Operator inputs mounted in the control
must also be considered an integral part of
console module (CC) panel.
the A.H.H.C.system.
CHECKING THE SENSOR READINGS
(VOLTAGE) FROM THE CAB (AGCO COM-
BINES)
1. Press and hold button (1) on the heads up
display for three seconds to enter the com-
bine diagnostic mode.
2. Scroll down using button (2) until “LEFT” is
displayed in the LCD screen.
3. Press the (3) “OK” button
1
2
Figure 10-123: Gleaner display
169046 ISSUE DATE 01/01/11

The number indicated on the LCD screen (2) is

the voltage reading from the sensor of the Auto
Header Height.
The voltage range should read over 0.5 volts
when the feeder house is all the way to down.
(adapter should be completely separated from
the header)
It should read below 4.5 when the header is

suspended off the ground.
Rotate Sensor to Achieve Range

NOTE: Figure 10-124:
If the reading is below 0.5 volts or above 4.5
volts the auto sensing circuit will not work. If
this is the case rotate the sensor on the Auto
Header Height to set the specific working
range between 0.5 and 4.5 volts. If you
cannot read the voltage see troubleshooting
section later in this document for sensor diag-
nostics.
SENSOR CALIBRATION
Sensor calibration will be required when a new
header is installed or when sensors or linkage
have been modified or adjusted. The calibration
procedure determines the limits of the sensors
and compensates for adjustments or linkage
changes between the header sensors.
NOTE:
Calibration should be done on flat, level
ground without the header clutches engaged.
Header height and header tilt must not be in
auto or standby modes. The engine rpm must
also be above 2000 rpm. The Header Tilt
option on 2004 and prior combines does not
work with MacDon Headers. This system will
have to be removed and disabled in order to
calibrate the Auto Header Height. Refer to
combine operators manual.
169046 ISSUE DATE 01/01/11

To Calibrate Header: 7. Wait for the header tilt left light to start
1. Press AUTO MODE button (A) until the flashing and then tilt header to the maximum
AHHC light (H) is illuminated left position.
2. Press and hold CAL1 button (D) until you see 8. Press CAL2 button (E) until the tilt header left
the following lights flash: header (G) (F), tilt light stops flashing (not present in picture)
auto mode, (J) and AHHC.(H) and release button when the right header tilt
light (not present in picture) starts to flash.
3. Lower header all the way down and continue
to hold for 5-8 seconds to ensure adapter has 9. Tilt the header to the maximum right position.
separated from header. 10. Press CAL2 button (E) until all of the fol-
4. Press CAL2 button (E) until lower header lowing lights flash: Raise header (G), lower
light (F) stops flashing, and release it when header (H), height auto mode (A), right
the raise header light (G) starts to flash. header, left header (not present) and tilt auto
mode (J). Center the header.
5. Raise header to its maximum height (ensure
the header is resting on the down-stop pads). 11. Press CAL1 button (D) to exit calibration and
save all values to the memory.
6. Press CAL2 button (E) until the raise header
light (G) turns off. NOTE:
All lights should stop flashing
NOTE:
The following steps are only applicable to
2005 and newer combines with the Smartrac
feeder house.
C D B A
I
G H J
F E
Figure 10-125:
169046 ISSUE DATE 01/01/11

OPERATION SETTINGS
Header Raise and Lower Speeds:
Header height control system stability is affected
by hydraulic flow rates. Ensure that the header
raise (4) and lower (5) adjustable restrictors in
the hydraulic valve, are adjusted so it takes
approximately six seconds to raise the header
from ground level to maximum height (hydraulic
cylinders fully extended) and approximately six
seconds to lower the header from maximum
height to ground level.
4 5
NOTE:
Make this adjustment with the hydraulic
system at normal operating temperature
(130°F / 54.4°C) and the engine running at Figure 10-126:
full throttle.
Turn Accumulator Off

Refer to Combine Operator Manual for proper
procedure when turning accumulator Off and On.
For best performance turn the feeder house Accumulator Lever
accumulator off. The accumulator will affect the (Off Position)
combines' reaction time and greatly inhibit the
Auto Header Heights' performance.
Figure 10-127: Accumulator Shut Off
NOTE:
The accumulator is located in front of the
front left axle beam
169046 ISSUE DATE 01/01/11

Engaging the System

To engage the Auto Header Height Control push
the “AUTO MODE” (A) button until the “AHHC”
LED light (D) is flashing. If the “RTC” light is
flashing push the “AUTO MODE” (A) button
again until it switches to “AHHC”.
Momentarily push the down button (E) on the

control handle and the “AHHC” light (D) should
change from flashing to solid. The header should E
also drop toward the ground.
The Auto Header Height control is now working

and active and can be adjusted for height and
sensitivity
Figure 10-128:
C B
A
D
Figure 10-129:
169046 ISSUE DATE 01/01/11

Ground Pressure
To adjust height of header, be sure the header is
in Auto Header Height Control (AHHC) mode
indicated by the LED (3) being solid. The header
will lower to the height (ground pressure)
corresponding to the position selected with the
height control knob (2). Turn the knob counter
clockwise for minimum ground pressure and
clockwise for maximum ground pressure.
NOTE:
NOTE: Desired ground pressure is in most
cases 1 number separation of the Auto
Header Height from having the header fully
suspended off the ground to just sitting on the Figure 10-130:
ground.
Automatic Header Sensitivity 2 1

The sensitivity adjustment dial (1) is used to
control the distance the cutterbar travels (moves
up or down) in relation to the header frame (flex
head) or header in relation to ground (rigid or
corn head) before the control module activates
the hydraulic valve to raise or lower the header
frame.
Example - When the sensitivity adjustment dial Figure 10-131:

(1) is turned completely CLOCKWISE, the
control module is set to the “MOST” sensitive
position. In this position the cutterbar typically
only moves up and down a distance of
approximately 3/4” (19 mm) before the control
module activates the hydraulic control valve to
raise or lower the header frame. When the
sensitivity adjustment dial is turned completely
COUNTERCLOCKWISE, the control module is 3
set to the “LEAST” sensitive position. In this
position the flex head cutterbar can move up and
down approximately 2” (51 mm) before the
control module activates the hydraulic control Figure 10-132:
valve to raise or lower the header frame. The
“HEADER SENSE LINE” input changes the
range of the sensitivity sensor as well.
Connected to a draper, the counterclockwise
position (least sensitive) allows for approximately
4” of vertical travel before correction is initiated.
169046 ISSUE DATE 01/01/11

DIAGNOSTICS:
Display Type: 3
Displayed on LCD (2) as “XX in” or “XXX cm”.
Displayed on tachometer (3) as “XX” or “XXX”.
Alarm Conditions:
If an error is indicated in message received from
the fuse panel, and audible alarm will be set. The
LCD on the EIP will indicate the header system in
error as “HDR CTRL” followed by “HGT ERR” for
height, and “HDR CTRL” followed by “TILT ERR”
from tilt.
The header height LED will flash yellow 2 times
every second.
The alarm is also noted by the buzzer sounding 5
times every 10 seconds. Figure 10-133:
NOTE:
If the header height switch (1) is depressed
for five seconds or longer, the EIP will go into
auto header height/tile (HTC) control diag-
nostic mode.
When an alarm condition occurs, switch green
LED will start flashing on and off (green, yellow,
or red depending on the input).
In addition, a message will be displayed on the
LCD to identify the nature of the alarm, example
“HYD TEMP”, “OPEN”, “SHrt” will be flashed
alternately.
1
2
4 5 7 6
Figure 10-134: Gleaner display
169046 ISSUE DATE 01/01/11

DIAGNOSTIC FAULT FAILURES:

Pressing the header height switch (1) for a min-
1
imum of five seconds will put Electronic Instrument
Panel (EIP) in header diagnostic mode.
The LCD (shown on previous page) will display the
message “HDR DIAG” when the EIP has entered
header diagnostic mode.
Figure 10-135: Header height switch
In this mode, after three seconds, header fault
parameter labels are displayed on the EIP LCD. 4
NOTE:
All the information displayed is read only.
The “OK” (6) and “CLEAR” (7) buttons allow the
operator to scroll through the list of parameters.
If there are no “Active fault codes”. The EIP
LCD will display “NO CODE”. 5
When a parameter is displayed, its label is dis-
played for three seconds, after which its value is
automatically displayed.
Pressing “OK” button (6) at this point when the
value is displayed will advance to the next param-
Figure 10-137:
eter and display its label.
When a parameter label is displayed and the “OK”
button (6) is pressed before three seconds, the 6
parameters value will be displayed.
Press “AREA” (4) will cycle through the options.
NOTE:
When “LEFT” is displayed in LCD, hit the
“OK” button (6) and the Auto Header Height Figure 10-138:
voltage will be shown in display.
Proceed with the “Checking the Sensor Settings” 7
page 10.
Press “DIST” (5) to cycle back through the table.
Press “CLEAR” button (7) to exit header
diagnostics and return to normal mode. Figure 10-139:
169046 ISSUE DATE 01/01/11

SENSOR OPERATION
NOTE:
When checking voltage on the Agco potenti-
ometer. The low voltage is measured 6”
(150MM) off the ground. The high voltage is
measured with feeder house fully lowered
and header fully floated.
All position sensors are (5K) 5000 ohm industrial
series potentiometers containing sealed
connectors. Normal operating signal voltages for
the sensors fall between 10% (0.5VDC) and 90%
(4.5VDC). Below 5%, a sensor is considered to
be shorted; above 95%, open. An increase in Figure 10-140:
sensor voltage correlates to an increase in
header height. Each sensor is constructed with a
power wire and a ground wire. Inside the sensor,
these two wires are connected by a high
resistance filament band (3). The resistance
measured across the power (1) and ground (2)
wires, should read a constant value between
4,000 and 6,000 ohms (4-6k) with the nominal
reading being 5,000 ohms (5k).
In addition to the power (1) and ground (2) wires,

a signal wire (3) is connected internally to a
movable wiper that sweeps the high resistance
filament band. This wiper is attached to an Figure 10-141:
external arm. As the external arm is rotated and
the wiper is moved toward or further away from
the power wire connection, the measure of
resistance at the signal wire (3) changes. The
resistance measured across the signal and
ground wires should show a uniform progressive
increase from a low (350-500 ohms) to a high
(4,000-6,000 ohms). This can be observed if an
ohmmeter is connected across the signal and
power wires and the sensor shaft rotated.
When an input voltage is applied to the high
resistance filament band through the power wire
(1) the output (or “measured”) voltage in the
signal wire (3) is changed by this variable
resistance
The sensor must be in the range of 0.5 to 4.5V,
but it is preferred to be above 1.0V and below
4.0V.
169046 ISSUE DATE 01/01/11

ADJUSTING THE SENSORS RANGE (CASE, JD AGCO, MASSEY, CHALLENGER)

If optimizer function is not acceptable at the initial
settings, it may be necessary to adjust sensor
angle. The sensor voltage output must change at
least 3 volts in order to calibrate successfully. If
the difference between the high and low voltage
readings is not 3 volts you will need to adjust the Z Y
high and low limits.
Check the sensor voltage output in the combine
cab. It must be within the range of 0.5 to 4.5 volts
(or as specified in your Combine Operator's/
Service Manual).
Check high voltage limit with header 150 mm (6") X
off ground and resting on down stops
Figure 10-142: Potentiometer Adjustments
NOTE:
If header is not on down stops, the voltage
may go out of range during operation,
causing a malfunction of the Auto Header
Height. Be sure to take high limit voltage
readings with header on down stops.
Check low voltage limit for with header lowered
all the way to the ground and the adapter
completely separated from the header.
To adjust high voltage limit:
1. Loosen both sensor mounting bolts (X).
2. Rotate sensor (Y) clockwise to increase
voltage and counter-clockwise to decrease
voltage.
3. Tighten sensor mounting bolts.
To adjust low voltage limit:

1. Loosen mounting bolts (Z).
2. Slide sensor mount fwd to raise and back-
ward to lower.
IMPORTANT
To prevent damage to sensor: When
replacing sensor, See “Potentiometer
Replacement” on page 10-104.
169046 ISSUE DATE 01/01/11

DIAGNOSTIC OF POTENTIOMETER
(CASE, JD, AGCO, MASSEY,
CHALLENGER)
Test the potentiometer by reading the resistance
across terminals 1 & 2. The range may vary from
approximately 100 -1000 Ohms.
Figure 10-143: Potentiometer Testing

Potentiometer Test Procedure:
Set multi-meter to Ohms. Place black lead on ground and red lead on signal. Rotate potentiometer,
watch for the numbers on the multi-meter to fluctuate between 100-1000 Ohms.
NOTE:
At full extent of rotation Ohms reading may be 70 to 1020 Ohms. But when mounted to AHHC
bracket, it will be limited to a reading between 100 to 1000 Ohms. When mounted, range is set to
read the correct voltage range recommended for the combine in the instructions. If the Ohms range
cannot be achieved, the potentiometer may be considered defective.
NOTE:
Ground and power supply maybe switched, depending on combine. In order to determine this refer
to AHHC wiring diagram.
169046 ISSUE DATE 01/01/11

10.9.4 NEW HOLLAND CR/CX AHHC
Figure 10-144: Basic AHHC

This is a picture for the base AHHC for the New Holland CR/CX. The diagrams below will give you a
break down of each harness used for the different models of combines.
Figure 10-145: MD# 153769_D

This harness is for both New Holland CR/CX combines.
169046 ISSUE DATE 01/01/11

Figure 10-146: MD# 153692_D Potentiometer for AHHC on NH Combines

The graph indicates the signal output relative to the sensor position. i.e. 25% of Supply Voltage at -
41°, 50% Supply Voltage at 0°. and 75% of supply voltage at +41°.
Figure 10-147: Sensor alignment for New Holland CR / CX

The voltage range that the sensor should be should be 2.8 to 7.2 for New Holland CR/CX combines. If
you are not getting a reading in this range then you will need to diagnose of the problem is that the
sensor is out of range or if it is non functioning. See “Adjusting the Sensors Range (New Holland CR/
CX)” on page 10-86. if sensor is out of range. If it is not functioning, See “Diagnostic of Potentiometer
(New Holland CR/CX)” on page 10-87.
NOTE:
Make sure that you have at least 4 volts difference from the bottom reading to the top reading.
169046 ISSUE DATE 01/01/11

ADJUSTMENT AND OPERATION:

NOTE:
Height, perform ground calibration with
center link adjusted as long as possible.
When calibration is complete, adjust the
center link back to desired header angle. See
“Header Angle” in Operation section of
adapter Operators Manual.
1. Complete the header calibration procedure
for the combine after initial header installation
and after replacement or adjustment of any
component of the Auto Header Height
system. (See Calibration or Combine Opera-
tors Manual). If the unit does not function, see
the Troubleshooting section in the CA20
Technical Manual.
2. Response time may be improved by
increasing sensitivity of Auto Header Height
sensor (See Calibration). Re calibrate after
making this adjustment.
3. To reduce raise and lower time, press
“RESUME” button twice when raising header.
(See Combine Operators Manual.)
4. Ground pressure at the cutterbar can be
adjusted from the combine cab (See Com-
bine Operators Manual.) A good starting point
is to adjust the ground pressure so the float
indicator on the adapter reads one number
higher when cutting on the ground than when
cutterbar is 150 mm (6") off the ground. This
difference may have to be increased (to up to
three numbers higher) to hold the cutterbar
on the ground on side hills or when ground
speed is increased.
169046 ISSUE DATE 01/01/11

AUTOFLOAT MODE:
NOTE:
The status bar on the monitor shows in which
mode the header works: There are three dif-
ferent modes.
1. Stubble height mode
2. Autofloat mode (Must be in this mode for
Auto Header Height to work). Stubble Height Mode
3. Compensation mode
CHECK SENSOR RANGE

Check the sensor voltage output. It must be
within the range of 2.5 to 7.5 volts. The voltage Auto Float Mode
output range (difference between high and low
voltage limits) must be 3 volts or higher.
For Intelliview Display

From Main screen:
Scroll down to magnifying glass and press right
arrow.
Compensation Mode
Scroll to header profile and press right arrow.
Figure 10-148: Combine Modes
Scroll to left stubble height and press enter.
For Intelliview II Display

From Main screen:
Press Diagnostics
Select Settings
In the Group window, select Header Height/Tilt
In the Parameter window, select Left Skid Plate.
Touch Graph at bottom of screen.
Exact voltage is displayed at top of screen.
169046 ISSUE DATE 01/01/11

COMBINE CONFIGURATION
1. Ensure all header and adapter electrical and
hydraulic connections are made and the fol-
lowing header settings are as follows:
2. Select the Header Settings submenu.
3. Scroll down to Header Autofloat.
4. Press “enter” when this item is selected, a
pop-up screen appears, showing the possibil-
ities “Installed” or “Not installed”.
5. Using the “up” or “down” navigation keys to
select, press “enter” to confirm the installed
option.
6. Select Height sensitivity. Figure 10-149:
7. Engage threshing and feeder house.
8. Use the “+” or “-” buttons to change the set-
ting. Recommended starting setting is 200.
9. Press “enter” to save the setting.
NOTE:
Values are changed in increments of 10 from
0 to 250. Factory setting = 100.
Figure 10-150:
169046 ISSUE DATE 01/01/11

10.9.5 CALIBRATION OF THE HEADER

INTELLIVIEW
Check following conditions before starting the
header calibration procedure:
• The header is attached to the combine.
• Place the combine on level ground, with
the engine running and put the header
level to the ground
• No faults received from the Header
Height Controller (HHC) module.
• Header/Feeder disengaged.
• The combine is not moving.
• Header is on down stops and center link
is fully extended. Figure 10-151:
1. Select the calibration sub-menu and press

the “right” navigation key to enter the informa-
tion box.
2. Use the “up” and/or “down” navigation keys to
select the item you want to calibrate.
3. Press “enter”.
4. The calibration window will appear on the
screen.
Follow the steps as described in the window. The
display will automatically show the next step.
Pressing the “esc” key in one of the following
steps will cause the calibration procedure to stop.
Not reacting to the system within three minutes, Figure 10-152:
will cause the calibration procedure to stop.
Proceed to the end, which is when “calibration
successful” is displayed. Leave the calibration by
pressing the “enter” or “esc” key.
169046 ISSUE DATE 01/01/11

Calibration Procedure
1. Select the “Header” calibration window.
Message: “Park the combine with the engine
running and header level to the ground”
Message: “CAUTION”: “header will move

automatically -stand clear of header”.
Message: “First press enter, then pulse the

header down switch”.
2. First press enter, then press the header down
key.
CAUTION Figure 10-153:

The header will lower until it is on the ground.
If the header was already on the ground, it will
raise a little bit.
Message: “Calibration initiated”
Message: “Calibration started”
Message: “Determining ground height”
3. Wait a few seconds until the next message.
Figure 10-154:
169046 ISSUE DATE 01/01/11

Message: “Pulse header switch up”

4. Press the header up key.
CAUTION
The header raises slowly to the maximum cal-
ibrated position and moves fast until max-
imum position.
Message: “Determining maximum height”.
Message: “Pulse header down switch”.
Figure 10-155:
6. Press the header down key.
CAUTION
The header lowers to a position just above
the ground
Message: “Determining header weight”
Message: “Pulse header up switch”.
Figure 10-156:
Figure 10-157:
169046 ISSUE DATE 01/01/11

Message: “Determining pressure difference”
Message: “Calibration successful”
10. Press “enter” or “esc” to close the calibration

window.
Figure 10-158:
See Combine operator's manual for error codes.
Figure 10-159:
169046 ISSUE DATE 01/01/11

INTELLIVIEW II
Check following conditions before starting the
header calibration procedure:
• The header is attached to the combine.
• Place the combine on level ground, with
the engine running and put the header
level to the ground
• No faults received from the Header
Height Controller (HHC) module.
• Header/Feeder disengaged.
• The combine is not moving.
• Header is on down stops and center link Figure 10-160:
is fully extended.
1. Ensure all header and adapter electrical and

hydraulic connections are made.
2. At Home screen go to Tool Box and scroll to

Header screen.
3. Cutting type should be set to Platform.

Figure 10-161:
4. Set appropriate Header Style by pressing

Enter and selecting from list and pressing
Enter again.
5. Install Autofloat and set Reel drive to

hydraulic.
6. Install Reel fore-back if applicable.
Figure 10-162:
169046 ISSUE DATE 01/01/11

7. Install Hdr foreaft tilt if applicable.
Figure 10-163:
8. Once complete select the Head2 screen.
9. Ensure Header type is Draper.

NOTE:
Note: If recognition resistor is plugged into
header harness, you will not be able to
change this.
10. Set Header width and appropriate Header

usage. Typical usage is 0.2 to 0.5 ft less than
header width. Figure 10-164:
11. Once complete return to Home screen.
169046 ISSUE DATE 01/01/11

Calibration Procedure
1. From the Home screen, select Calibrations.
Figure 10-165:
2. Select Header from the list and press Enter.
3. Follow on screen prompts to complete cali- Figure 10-166:

bration.
CAUTION
The header will lower until it is on the ground.
If the header was already on the ground, it
will raise a little bit.
4. Press enter.
Message: “Calibration initiated”

Figure 10-167:
Message: “Calibration started”
Message: “Determining ground height”
169046 ISSUE DATE 01/01/11


Figure 10-168:
Message: “Pulse header switch up” Figure 10-169:
6. Press the header up key. Figure 10-170:
CAUTION
The header raises slowly to the maximum cal-
ibrated position and moves fast until max-
imum position.
Message: “Determining maximum height”
Message: “Pulse header down switch”
8. Press the header down key.
CAUTION
The header lowers to a position just above
the ground
Message: “Determining header weight”
Message: “Pulse header up switch”
Message: “Determining pressure difference”
Message: “Calibration successful”
12. Press “enter” or “esc” to close the calibration
window.
See Combine operator's manual for error codes.
169046 ISSUE DATE 01/01/11

COMBINE CONFIGURATION
Set the Header type: PICK-UP or DRAPER/
VARIFEED
TM
To obtain correct information on the Infoview ,
the correct header type should be selected.
To select the correct header type, proceed as

follows:
1. Select the item “Header type”.
2. Press “enter”.
3. Pop up screen 1 appears on the screen
showing the different header types.
4. Select the pick-up or draper/varifeed Figure 10-171:
header using the “up” or “down” navigation
keys.
5. Press “enter” to store.
IMPORTANT
After changing this item it is recommended to
select first another sub-menu, after return
back to the “header” sub-menu. All the items
of the selected “header type” are now viewed
on the display.
Figure 10-172:
169046 ISSUE DATE 01/01/11

SET THE MAXIMUM STUBBLE HEIGHT
This is necessary to know from which height the

area counter should stop or start counting. When
the header is raised above the level the combine
assumes you are not cutting any crop. So you
have to put the header at a certain height you will
always exceed when not cutting crop and always
stay below when cutting crop.
1. Select the item “Maximum stubble height”.
2. Use the “+” or “-” buttons to change the
setting to 250.
The value can be changed between 0 and
250 in steps of 1.
169046 ISSUE DATE 01/01/11

SET THE HEADER LOWER RATE

The fast lower speed (the automatic header
height control button or second speed on the
header height rocker switch of the multi-function
handle) can be changed
Proceed as follows:
1. Select the item “header Lower rate”.
ting to 58.
NOTE:
The setting can be changed between 2 and
247% in steps of 7. Figure 10-174:
SET THE HEADER LATERAL FLOAT

If press “enter” when this item is selected, a pop-
up screen appears, showing the possibilities
“Installed” or “Not installed”.
Using the “up” or “down” navigation keys to

select and press “enter” to confirm the installed
option.
SET THE HEADER AUTOFLOAT

If press “enter” when this item is selected, a pop-
up screen appears, showing the possibilities
“Installed” or “Not installed”.
Figure 10-175:
Using the “up” or “down” navigation keys to

select and press “enter” to confirm the installed
option.
Figure 10-176:
169046 ISSUE DATE 01/01/11

SET HEADER RAISE RATE

The manual slow raise (first speed on the header
height rocker switch of the multifunction handle)
can be changed.
Proceed as follows:
1. Select the item “Header raise rate”.
ting. Set to operators preference.
NOTE:
The settings can be changed between 32
and 236% in steps of 34.
Figure 10-177:
Once combine configuration values have been

set, proceed to combine header calibration
procedure.
NOTE:
If float was set heavier to complete ground calibration procedure, adjust to recommended oper-
ating float after the calibration is complete.
• Response time may be improved by increasing sensitivity of float optimizer sensor (See Step 5
on page 2 of these instructions).
• To reduce raise and lower time, press “RESUME” button twice when raising header. (See Com-
bine Operators Manual.)
• Ground pressure at the cutter bar can be adjusted from the combine cab. With the threshing
mechanism and header engaged, lower the header to the desired setting on the float indicator
(L) and press the “Set Position” on the header control selector. (See Combine Operators
Manual.) A good starting point is to adjust the ground pressure so the float indicator on the
adapter reads one number higher when cutting on the ground than when cutter bar is 150 mm
(6") off the ground. This difference may have to be increased (to up to three numbers higher) to
hold the cutter bar on the ground on side hills or when ground speed is increased
169046 ISSUE DATE 01/01/11

ADJUSTING THE SENSORS RANGE (NEW HOLLAND CR/CX)

least 3 volts in order to calibrate successfully. If
readings is not 3 volts you will need to adjust the Z Y
high and low limits.
Service Manual).
NOTE:
Check low voltage limit with header lowered all
the way to the ground and the adapter
voltage.
ward to lower.
NOTE:
Error code 08 indicates that the voltage range
is too wide. Error code 15 indicates that
voltage is too low or too high.
IMPORTANT
169046 ISSUE DATE 01/01/11

DIAGNOSTIC OF POTENTIOMETER (NEW HOLLAND CR/CX)

NOTE:
Ground and power supply maybe switched, depending on combine. In order to determine this refer
to AHHC wiring diagram.
169046 ISSUE DATE 01/01/11

10.9.6 LEXION AHHC
Figure 10-180: Basic AHHC without Sensor
Figure 10-181: MD# 133220_A Harness

This harness is for S/N 174610 & above
169046 ISSUE DATE 01/01/11

Figure 10-182: MD# 158666_B 12 Volt Sensor
The voltage range that the sensor should be

should be 0.5 to 4.5 for Lexion combines. If you
are not getting a reading in this range then you
will need to diagnose of the problem is that the
sensor is out of range or if it is non functioning.
See “Adjusting the Sensors Range (Lexion)” on
page 10-102. if sensor is out of range. If it is not
functioning, See “Diagnostic of Potentiometer
(Lexion)” on page 10-103.
NOTE:
Make sure that you have at least 2.5 volts dif-
ference from the bottom reading to the top
reading.
169046 ISSUE DATE 01/01/11

10.9.7 LEXION
500 Series
After installing the AHHC on the header these are
the procedures to follow in order to calibrate,
operate and increase the sensitivity of the AHHC.
Setting Cebis
Initial Operation Settings - CEBIS

SMCS Code: 5900; 6900; 7000
Before you operate CEBIS for the first time, the
following system parameters must be set:
• Select the language, Refer to Operation
and Maintenance Manual, “CEBIS Menu Figure 10-183:
Settings”.
• Select the units of measure, Refer to
Operation and Maintenance Manual,
“CEBIS Menu Settings”.
• Learn the speeds, Refer to Operation and
Maintenance Manual, “Speed Adjustment
- CEBIS”.
• Set the tachometer, Refer to Operation
and Maintenance Manual, “Tachometer
Adjustment - CEBIS”.
• Program the various settings of the
header, Refer to Operation and Mainte-
nance Manual, “Header Adjustment -
CEBIS”.
• If a yield meter (Quantimeter) is installed,
reset the zero angle, Refer to Operation
and Maintenance Manual, “Yield
Measurement - CEBIS”.
169046 ISSUE DATE 01/01/11

Automatic Header Functions

You can turn on and off the functions of the auto-
matic header height system at any time. To use
the automatic header height you must first set the
upper and lower limits of the header.
Using the “<“ key or use the “>” key, to select

“Auto header”. Once selected press the “OK” Key
to confirm your selection. Window (E5) displays
whether the automatic header height is on or off.
Use the “-” key (A) or use the “+” key (B) in order
to turn the automatic header height on or off.
Press the “OK” key (C) in order to confirm the Figure 10-184:
setting.
C
A
Header Height Limits

CEBIS must learn the upper limit and the lower
limit of the header. Ensure that the threshing
mechanism and the header are engaged for this.
Use the “<“ key or use the “>” key in order to
select “Cutt.height limits”. Press the “OK” key (C) Figure 10-185:
in order to confirm the selection. Follow the pro-
cedure that is displayed on the screen.
NOTE:
The threshing mechanism and header must
be engaged for calibration to start.
Figure 10-186:
169046 ISSUE DATE 01/01/11

Figure 10-187:
169046 ISSUE DATE 01/01/11

Auto Contour Sensitivity (Auto Header)

Use the “<“ key or use the “>” key in order to
select “Sensitivity CAC”. Press the “OK” key in
order to confirm the selection.
Setting the sensitivity of the AHHC system

influences the reaction speed of the AHHC on
the header.
NOTE:
CEBIS must learn the upper limits and the
lower limits of the header before you adjust
the sensitivity of the AHHC system. The set-
Figure 10-188:
ting can be adjusted from 0 percent to 100
percent. When sensitivity is adjusted to 0 per-
cent, the signals from the sensing bands
have no effect. When set to 100 percent, F
sensing bands have maximum effect on the
automatic cutting height adjustment. 50% is a
D E
recommended starting point
Use the “-” key (D) or use the “+” key (E) in order
to change the setting of the reaction speed.
Press the “OK” key (F) in order to confirm the
setting.
Figure 10-189:
E4 2
Line (1) indicates the setting of the sensitivity.

Window (E4) displays the (1). Also value (2)
indicates the sensitivity. Window (E5) displays
value (2).
1
E5
Figure 10-190:
169046 ISSUE DATE 01/01/11

Figure 10-191:
NOTE:
Use 50 as a starting point.
169046 ISSUE DATE 01/01/11

Reel Settings
Preset Reel Speed
The preset reel speed can be set when the auto-
matic header functions are activated.
Use the “<” key or use the “>” key in order to

select reel window. When reel window is
selected, window (E15) will display the current
advance or retard speed of the reel relation to the
ground speed.
Figure 10-192:
Press the “OK” key (C) in order to select the reel
speed window.
C
A B
to set the reel speed in relation to the current
ground speed. Window (E15) will display the
selected reel speed.
Figure 10-193:
Also, you can manually adjust the reel speed.

Rotate the rotary switch to the reel position (F). D E
Then, use the “-” key (D) or the “+” key (E) in
order to set the reel speed.
Figure 10-194:
169046 ISSUE DATE 01/01/11

Press button (H) or button or button (J) for three

V
seconds in order to store the setting into CEBIS.
NOTE:
The alarm will sound when the new setting is
stored.
NOTE: J
Whenever button (H) or button (J) is pressed
for three seconds, the current positions for
the following functions are stored: reel speed H
and cutting height
Figure 10-195:

select the reel window. When the reel window is
selected, window (E15) will display the current
advance or retard speed of the reel in relation to
the ground speed.
E15
Figure 10-196:
Figure 10-197:
169046 ISSUE DATE 01/01/11

Press the “OK” button (C1). Use the “<“ key or

use the “>” key in order to select the reel fore &
aft window. Figure 1-15 C
A B
to set the fore-aft position of the reel.
Also, you can use button (P) or button (Q) in

order to set the fore-aft position of the reel.
Figure 10-198:
Press button (H) or button (J) for three seconds
in order to store the setting into CEBIS.
P
NOTE:
The alarm will sound when the new setting is
stored.
NOTE:
Whenever button (H) or button (J) is pressed Q
for three seconds, the current positions for
the following functions are stored: reel speed
and cutting height. Figure 10-199:
Figure 10-200:
169046 ISSUE DATE 01/01/11

Cutting Height
The cutting heights can be programmed into the
preset cutting height and into the auto contour
system. use the preset cutting height for cutting
heights above 150 mm (5.9”) (J). Use the auto Z
contour system for cutting heights below 150mm
(5.9”) (H).
J
H X
select the Cutting height window. Press the “OK”
key in order to open the respective sub menu. Figure 10-201:
An active value is indicated by a solid arrow. An

inactive value is indicated by an empty arrow.
Setting Auto Header Height for 500 Series A B

Use the following procedure in order to program
the settings of the preset cutting height.
NOTE:
In order to use the auto contour system, the
CEBIS must first learn the upper and lower
limit of the header. Figure 10-202:
1. Start the engine.
2. Activate the machine enable switch.
3. Engage the threshing mechanism.
4. Engage the header.
5. Briefly press button (H) in order to activate
the auto contour system or briefly press
button (J) in order to activate the preset cut-
ting height.
NOTE:
Button (H) is used only with AHHC function.
Button (J) is used only with the return to cut
function.
6. Use the “-” key (A) or use the “+” key (B) in
order to set the desired cutting height. An
arrow indicates the selected cutting height on
the scale.
7. Briefly press button (H) or button (J) in order
to select the set point.
8. Repeat step 6 for the set point.
169046 ISSUE DATE 01/01/11

Setting cut height manually:

1. When you enter the crop use button (X) or
use button (Z) in order to set the cutting
height. Then press button (H) or press button
(J) for three seconds. This stores the cutting
height into the CEBIS. The alarm will sound
when the new setting is stored.
2. Briefly press button (H) or button (J) in order

to select the second setpoint
3. Repeat step 1 for the second setpoint.
Setting the Auto Header Height 400

series. Figure 10-204:
The cutting heights can be programmed into the An active value is indicated by a solid arrow (3).
AHHC system. Use the AHHC system for cutting An inactive value is indicated by an empty arrow
on the ground. (4).
Use the following steps in order to program the
AHHC system.
NOTE: In order to use the AHHC system, the
CEBIS must first learn the upper limit of the
header and the lower limit of the header.
See Operation and Maintenance Manual,
“Header Adjustments”.
1. Start the engine.
2. Activate the machine enable switch.
3. Engage the threshing mechanism.
Figure 10-203: 4. Engage the header.
The display for the cutting height is located in
window (E4). Scale (1) indicates the setting of
the AHHC system.
Figure 10-205:
169046 ISSUE DATE 01/01/11

5. Briefly press button (M10) in order to activate

the AHHC system.
6. Use the “-” key (C6) or use the “+” key (C7) in
order to set desired cutting height. An arrow
indicates the selected cutting height on the
scale.
7. Briefly press button (M10) in order to select
the second setpoint.
8. Repeat Step 6 for the second setpoint.
Figure 10-206:
169046 ISSUE DATE 01/01/11

Figure 10-207:
169046 ISSUE DATE 01/01/11

ADJUSTING THE SENSORS RANGE (LEXION)

least 2.5 volts in order to calibrate successfully. If
readings is not 2.5 volts you will need to adjust Z Y
the high and low limits.
Service Manual).
NOTE:
Check low voltage limit with header lowered all
the way to the ground and the adapter
voltage.

ward to lower.
IMPORTANT
169046 ISSUE DATE 01/01/11

DIAGNOSTIC OF POTENTIOMETER (LEXION)

Test the potentiometer by reading the resistance across terminals 1 & 2. The range may vary from
approximately 100 -1000 Ohms.
IMPORTANT
Testing of a Lexion potentiometer requires that the potentiometer has power from the combine
in order to test it.

To check and see if the potentiometer is defective. Leave key turned to the run position with combine
turned off. Lower the feeder house all the way to the ground. Move the indicator from 4 to 0 and record
the readings. A defective potentiometer will not display volts incrementally i.e. 1.2, 1.4, 1.6, 1.8, 2.0
etc. If potentiometer is defective, replace it. See “Potentiometer Replacement” on page 10-104.
169046 ISSUE DATE 01/01/11

10.10 POTENTIOMETER REPLACEMENT

Follow the instructions bellow for potentiometer
replacement. If done incorrectly you will damage
the new potentiometer.
IMPORTANT
When replacing a sensor, it is critical to avoid
immediate damage caused by incorrect
assembly of the sensor to linkage arm.
Figure 10-210:
1. When installing a new sensor, linkage arm (B)

must be in the forward position against stop.
The wiring plug (A) on sensor must face back
as shown.
Figure 10-211:
Figure 10-212:
2. When installed properly, linkage should

operate freely in range (A to B) as shown.
Figure 10-213:
169046 ISSUE DATE 01/01/11

10.11 REEL SPEED

10.11.1 JOHN DEERE 50/60/70 SERIES
The Way it Works:
The reel speed sensor is used to indicate how fast the reel is rotating. It uses a sensor that is mounted
to a bracket that passes through the reel drive shield. The sensor then takes reading off of a second
sprocket that is mounted to the reel drive sprocket.
10,14,19, & 21 Tooth

Options Available
See Parts Catalog
Figure 10-214: MD# 156617_C Reel Speed Harness

Sensor for the reel speed is included in the JD completion package.

The way it works
to a bracket that is passes through the reel drive shield. The sensor then takes reading off of a second
10,14,19, & 21 Tooth

Options Available
See Parts Catalog
169046 ISSUE DATE 01/01/11


The way it works
to a bracket that is passes through the reel drive shield. The sensor then takes reading off of a second
10,14,19, & 21 Tooth

Options Available
See Parts Catalog
169046 ISSUE DATE 01/01/11

10.11.4 AGCO
The way it works
The reel speed sensor is used to indicate how
fast the reel is rotating. It uses a sensor that is
mounted to a bracket that is passes through the
reel drive shield. The sensor then takes reading
off of a second sprocket that is mounted to the
reel drive sprocket.
10,14,19, & 21 Tooth

Options Available
See Parts Catalog
Figure 10-217: MD# 133137_D Reel Speed Harness (3 pin)
169046 ISSUE DATE 01/01/11

10.12 HEADER RECOGNITION

10.12.1 CASE IH & NH CR/CX
These combines use a module that plugs into the
harness. The module tells the combine what type
of header is on the combine when you are not
using the AHHC.
Figure 10-218: 153933 Header Recognition Module
169046 ISSUE DATE 01/01/11

SECTION 11: COMBINE ELECTRICAL
SCHEMATICS
D60/FD70/CA20 TOC
Section 11: Combine Electrical Schematics

11.1 Electrical Schematics .................................................................................... 11-1
11.1.1 John Deere 50 Series ........................................................................... 11-1
11.1.2 John Deere 60 & 70 Series ................................................................... 11-2
11.1.3 Agco ...................................................................................................... 11-3
11.1.4 Gleaner “R” & “S” Series ....................................................................... 11-4
11.1.5 CaseIH 2300 & 2500 Series.................................................................. 11-5
11.1.6 CaseIH 10 & 20 Series.......................................................................... 11-6
11.1.7 Lexion 400............................................................................................. 11-7
11.1.8 Lexion 500 Series ................................................................................. 11-8
11.1.9 New Holland.......................................................................................... 11-9
11.1.9 New Holland Legend............................................................................. 11-9
11.1.10 Transport 179759 & Below................................................................ 11-10
11.1.11 Transport 179760 & Up..................................................................... 11-11
11.1 ELECTRICAL SCHEMATICS
11.1.1 JOHN DEERE 50 SERIES
11.1.2 JOHN DEERE 60 & 70 SERIES
11.1.3 AGCO
11.1.4 GLEANER “R” & “S” SERIES
11.1.5 CASEIH 2300 & 2500 SERIES
11.1.6 CASEIH 10 & 20 SERIES
11.1.7 LEXION 400
11.1.9 NEW HOLLAND
11.1.10 TRANSPORT 179759 & BELOW
11.1.11 TRANSPORT 179760 & UP
SECTION 11A: COMBINE ELECTRICAL
SCHEMATICS LEGEND
D60/FD70/CA20 TOC
Section 11A: Electrical Schematic Legend

11A.1 Header Legend ......................................................................................... 11A-1
11A.2 Agco Legend .............................................................................................11A-2
11A.3 Case IH Legend ........................................................................................ 11A-3
11A.4 John Deere Legend................................................................................... 11A-4
11A.5 Lexion 400 Lexion ..................................................................................... 11A-5
11A.6 Lexion 500 Lexion ..................................................................................... 11A-6
11A.7 New Holland Legend................................................................................. 11A-7
11A.8 Transport Option Legend .......................................................................... 11A-8
D60/FD70/CA20 Section 11A: Electrical Schematic Legend PAGE 11A-1
11A.1 HEADER LEGEND
169046 ISSUE DATE 01/01/11

11A.2 AGCO LEGEND
169046 ISSUE DATE 01/01/11

11A.3 CASE IH LEGEND
169046 ISSUE DATE 01/01/11

11A.4 JOHN DEERE LEGEND
169046 ISSUE DATE 01/01/11

11A.5 LEXION 400 LEGEND
169046 ISSUE DATE 01/01/11

11A.6 LEXION 500 LEGEND
169046 ISSUE DATE 01/01/11

11A.7 NEW HOLLAND LEGEND
169046 ISSUE DATE 01/01/11

11A.8 TRANSPORT OPTION LEGEND
169046 ISSUE DATE 01/01/11

SECTION 12: FLEX LINKAGE
D60/FD70/CA20 TOC
Section 12: Flex Linkage

12.1 Flex Linkage .................................................................................................. 12-1
Disassembly ............................................................................................... 12-2
Reassembly ................................................................................................ 12-5
12.2 FD70 Wing Adjustments................................................................................ 12-7
12.2.1 Cutterbar Straightness .......................................................................... 12-7
12.2.2 Cutter Bar Stringing............................................................................... 12-8
12.2.2 CutterBar Stringing................................................................................ 12-8
12.2.3 Cutterbar Straightness ........................................................................ 12-10
12.2.3 Cutterbar Fore-Aft ............................................................................... 12-10
12.2.4 Header Levelling ................................................................................. 12-11
12.2.5 Header Float ....................................................................................... 12-13
12.2.6 Float Locks.......................................................................................... 12-13
12.2.7 Header Float Check ............................................................................ 12-14
12.2.8 Header Float Adjustment .................................................................... 12-16
12.2.9 Toplink/Bellcrank Alignment................................................................ 12-17
12.2.10 Compression Link Check .................................................................. 12-18
12.2.11 Compression Link Adjustment .......................................................... 12-18
12.2.12 Wing Balance .................................................................................... 12-19
D60/FD70/CA20 Section 12: Flex Linkage PAGE 12-1
12.1 FLEX LINKAGE:
How It works:
The flex linkage on the FD70 is designed to allow
the wings of the header to pivot off of the main
frame.
Figure 12-1: Balance Linkage
169046 ISSUE DATE 01/15/18

Disassembly:
NOTE:
Support the reel at the end of the header.
1. Engage the flex linkage lockout (A). Place 2 x

2 blocks under the skid shoes. Lower the
header and adapter to the ground.
2. Remove the adapter from the header, consult Figure 12-2: Flex Wing Lockout
the CA20 operators manual for the proce-
dure.
C
3. Remove the plastic cover (C) from the flex

linkage by removing the self taping bolt (D).
(Figure 12-3) D
Figure 12-3: Plastic Cover Removal
4. Check linkages (E) to see if they are loose. If

they are not, use an appropriate jack and
raise/lower the wing from one of the outboard
ends. Once the linkages are loose, add
enough blocking to secure the wing of the
Figure 12-4: Checking Linkages
169046 ISSUE DATE 01/15/18

5. Remove bolt (F) that holds the top link in

Figure 12-5: Toplink Removal

6. Remove bolt (G) that holds the compression
link to the bellcrank. (Figure 12-6)
Figure 12-6: Bellcrank Removal
7. Remove the bolt (J) that holds the compres-

sion link tube (H) to the header. (Figure 12-7)
NOTE:
Take care when removing the compression
link as the length of the link is critical.
H
Figure 12-7: Compression Link Removal
169046 ISSUE DATE 01/15/18

NOTE:
Make sure there is no load on the stoplink
before removing the bolts
8. Measure the stoplink bar nut locations before

removing the nuts, upon reassembly you will
need to set the stoplink back to its original
dimension.
K
9. Remove the two nuts and one bolt (K) that
hold the stoplink bar in place. (Figure 12-8)
Figure 12-8: StopLink Bar Removal

10. Once the stoplink has been removed you can
now repair or replace any of the parts. (Figure
12-9)
Figure 12-9: Stop Link Removed
169046 ISSUE DATE 01/15/18

Reassembly:
1. With the reel, wing and center section sup-
O N
ported. Install the stoplink c/w nuts (M), then
install the stop bar pieces and securing bolt
(L). (Figure 12-12)
2. Ensure the wings are supported higher than
the center section. See chart for required dif-
ference.
M
Header Size Wings Above Center Section
30’ 1-1.8” (25-30mm) L
35’ 1.7-2.1” (43-53mm)
40’ 2.8-3.1” (70-80mm) Figure 12-12: Stop Link Bar Installation
45’ 4-4.3” (100-110mm)
Figure 12-10: “X” “X”
3. Using the previously recorded dimension, (in
Top Bottom
step 8 of disassembly) tighten nuts (N) against
the spacer to 150 lbs.ft (203 Nm). Then using
the jam nuts, lock the stoplink nuts, torque to
150 lbs.ft (203 Nm). (Figure 12-12)
Figure 12-13: Compression Link Dimensions
NOTE:
If you adjusted the compression link or did
not take down the measurements, please use
the following dimensions below as a starting
point. See (Figure 12-13) for dimension loca-
tions.
Hdr Length Dimension “X”

30’ 1.8” (30mm)
35’ 1.8” (30mm)
40’ 1.8” (30mm)
45’ 1.8” (30mm) P
Figure 12-11: Compression Link Thread Dimension
NOTE:
The above dimensions are a starting point
only. Adjustment will be required from these S
dimensions.
4. Install the compression link tube (P) and
secure it with a bolt (S). (Figure 12-14)
NOTE: Figure 12-14: Compression Link Installation
Make sure that the locking nut for the com-
pression link tube is at the top and locked.
169046 ISSUE DATE 01/15/18

5. Raise the bell crank assembly, install the bolt

(U) that secures the bell crank to the com-
pression link. (Figure 12-15)
NOTE: U
Make sure the bolt (U) that connects the com-
pression link to the bell crank is orientated, so
that the nut is faced away from the header
back tube (towards combine). (Figure 12-15)
6. Install the adapter back into the header. See

Figure 12-15: Bellcrank Removal
CA20 Operators Manual for Procedure.
7. Raise the header and adapter 6” (152mm) off

the ground.
169046 ISSUE DATE 01/15/18

12.2 FD70 WING ADJUSTMENTS

NOTE:
The following instructions must be performed
in order to properly adjust the header.
Before beginning Adjustments:
1. Extend the header angle hydraulic cylinder to
B 1/2 on indicator.
2. Raise header until cutterbar is 6 to 10 inches Q
(152-254 mm) off the ground.
3. Stop engine and remove key.
4. Check that trim springs (Q) are connected to Figure 12-16: Trim Spring Bracket
the combine CA20 adapter. (Figure 12-16)
5. Move transport/stabilizer wheels so that they A
are in storage position.
12.2.1 CUTTERBAR STRAIGHTNESS
If the cutterbar is not straight when the wings are
in LOCK mode, refer to illustrations and proceed
as follows:
1. Remove linkage cover (A) by removing bolt B
(B). (Figure 12-17)
2. Unlock the wing float by moving handle (C) to
lower UNLOCK position (D). (Figure 12-18)
NOTE: Figure 12-17: Plastic Cover Removal
FD70 headers should frown 0.50" (12.7mm)
from end to end. That means that both wings C E
of the header should be 0.50" (12.7mm)
lower at the ends than in the center.
3. Support the header so that the cutterbar is
straight by either lowering on level ground or H
F G
on blocks that are even.
4. Lock the wing float by moving handle (C) to D
the upper LOCK position (E). (Figure 12-18)
5. Loosen nut (F) and (G) and adjust so that
stop link (H) freely moves out of and into the
upper LOCK position. (Figure 12-18)
Figure 12-18: Toplink Adjustment
6. Tighten nuts (F) & (G) against the spacer to
150 lbs.ft (203 Nm). Then using the thinner
nuts, lock the stop link nuts, also torque these
to 150 lbs.ft (203 Nm). (Figure 12-18)
7. If cutterbar is straight within tolerance, con-
tinue on, See “Header Levelling” on page 12-
11. If cutterbar requires further straightening
See “CutterBar Stringing” on page 12-8.
169046 ISSUE DATE 01/15/18

12.2.2 CUTTERBAR STRINGING

The cutter bar would need to be strung to
determine if the cutter bar has been deformed or
damaged. After cutter bar has been strung,
contact MacDon Product Support so that it can
be determined if the cutter bar is bent
excessively.
NOTE:
To accurately measure a cutter bar, it is crit-
ical that the header be suspended on either a
MacDon built Adapter for Combine, or Wind-
rower.
NOTE:
If you are stringing a FD70 flexing draper,
make sure to lock the wings rigid before Figure 12-19:
starting.
1. Raise the reel fully up and engage the safety
props to prevent reel from dropping. Raise
header full up and engage safety stops to
prevent header from dropping. Remove keys
from drive unit to prevent unexpected start
up.
2. Remove the 2nd guard at each end of the
header.
3. On either side of the header place at least a
3-inch bolt through one of the cutter bar holes
left by the guard bolts (Figure 12-21).
4. Secure the bolt into place using two opposing
nuts on either side of the cutter bar. Tie a
string to one of the bolts, then the other so Figure 12-20:
the string spans the whole distance of the
header. Adjust the string so that is the exact
same height above the guard bar on both
ends. (Figure 12-20)
169046 ISSUE DATE 01/15/18

NOTE:
Be sure the string is tight so it has very little
deflection. It will allow for more accurate
measurements.
5. Take measurements every 6’. Measure from

the surface of the guard bar to the string. Be
careful to measure only to the surface of the
guard bar and not to guards or hold-downs.
(Guards or hold-downs will give inconsistent
measurements). Use the measurements to
get an idea of the profile of the cutter bar.
NOTE:
D50 and D60 cutter bars are designed to
have some deflection from the ends to the Figure 12-21:
center so the center should be slightly lower
than the outside. As the machine ages this
deflection will become less and less.
NOTE:
FD70 headers should frown 0.50" (12.7mm)
from end to end. That means that both wings
of the header should be 0.50" (12.7mm)
lower at the ends than in the center.
169046 ISSUE DATE 01/15/18

12.2.3 CUTTERBAR FORE-AFT

1. Extend the header angle hydraulic cylinder to
B 1/2 on indicator.
2. Raise header until cutterbar is 6 to 10 inches
(152-254 mm) off the ground.
4. Check that trim springs (Q) are connected to
the combine CA20 adapter. (Figure 12-16) Q
5. Move transport/stabilizer wheels so that they
are in storage position. .
6. With no load at hinges, place a string that is
Figure 12-23: Trim Spring Bracket
parallel to the front edge of the centre section
of the guard bar. Adjust the rear hinges until
the wings are ahead of the center section.
See dimensions listed below for specific J
headers.
Hdr Length Wing Ahead of Center Section

30’ 0.2-0.6” (5-15mm)
35’ 0.6-1” (15-25mm)
40’ 1”-1.4” (25-35mm)
45’ 1.6-2” (40-50mm) K
Figure 12-22: Wing Fore-aft Chart
Adjust rear hinge as follows: Figure 12-24:
NOTE:
LH side shown, procedure for the RH side is
the same.
M
7. Loosen bolts (J) and (K). (Figure 12-24)
8. Loosen jam nut (L) and adjust bolt (M) until

the correct fore-aft dimension is achieved.
L
9. Tighten jam nut (L). (Figure 12-25) Figure 12-25:
10. Tighten bolt (J) first, then (K). Torque to

269ft.lbs (365Nm). (Figure 12-24)
169046 ISSUE DATE 01/15/18

12.2.4 HEADER LEVELLING

The adapter is factory set to provide the proper
level for the header and should not normally
require adjustment. If the header is not level,
perform the following checks prior to adjusting
the leveling linkages.
IMPORTANT
The adapter float springs are not used to level A
the header.
Before beginning Adjustments:

• Check combine tire pressures. Figure 12-26:
• Check that combine feeder house is level.
Refer to combine Operator’s Manual.
• Check that top of adapter is level with
combine axle.
• Lock header wings rigid.
Make fine adjustments to header leveling as
follows:
1. Park combine on level ground.
2. Check float lock is disengaged (header can B
float).
3. Set header approximately 6 inches (150 mm)
off ground and check that float linkage is Figure 12-27:
against down stops. Note high and low end of
header.
4. Adjust level with nut (A) at each float lock as
follows. Use small adjustments (1/4 -1/2 turn)
and adjust each side equally but in opposite
directions: (Figure 12-26)
NOTE:
Set screw (B) does not require loosening for
adjustments up to ½ turn of nut (A). (Figure
12-27)
Figure 12-28:
169046 ISSUE DATE 01/15/18

5. Turn low-side nut clockwise to raise header.

(Figure 12-29)
6. Turn high-side nut counter-clockwise to lower
Raise Lower
NOTE: Header Header
Adjustment of more than two turns in either
direction may adversely affect header float.
Always be sure there is a minimum 2 to 3 mm
(1/8”) clearance between frame and back of
bellcrank lever. Ensure that there is not too
many threads sticking past the nut on one
side as compared to the other. (Figure 12-30)
Figure 12-29:
NOTE:
Float does not require adjustment after level-
ling header.
0.12” (2-3mm)
Figure 12-30:
169046 ISSUE DATE 01/15/18

12.2.5 HEADER FLOAT

The machine will perform best with minimum
extra weight on the header. Under normal
conditions, approximately 75 lbf (337 N) force is
required to lift the header at the diagonal brace.
IMPORTANT
To avoid frequent breakage of sickle compo-
nents, scooping soil, or soil buildup at cut-
terbar in wet conditions, header float should
be set as light as possible without causing
excessive bouncing. When float setting is
light, it may be necessary to use a slower Figure 12-31:
ground speed to avoid excessive bouncing
and leaving a ragged cut.
X
IMPORTANT
The stabilizer wheels may be used in con-
junction with main float to minimize bouncing Z
at the header ends and control cut height.
Lock
Refer to the D50 and D60 Harvest Header /
FD70 FlexDraper Operator’s Manual for
details.
Unlock
12.2.6 FLOAT LOCKS
Figure 12-32:
The header main float locks, lock and unlock the
header float system.
The main float locks must be engaged when the
header is being transported with the adapter
attached so there is no relative movement
between the adapter and header during
transport. Both on trailer and during field to field
travel attached to a combine. The float locks
must also be locked during detachment from the
combine to allow the feeder house to release the
adapter. There are two locks, one on each side of
the adapter.
1. Disengage main float locks by moving latch
(X) away from adapter and moving lever (Z)
at each lock to lowest position. In this posi-
tion, the header is unlocked and can float with
respect to the adapter. (Figure 12-32)
2. Engage the main float locks by moving lever
(Z) up to its highest position. In this position,
the header cannot move with respect to the
adapter. (Figure 12-32)
169046 ISSUE DATE 01/15/18

12.2.7 HEADER FLOAT CHECK
CAUTION Lock
before leaving operator's seat for any reason. Unlock
machine.
1. If adjusting FD70 FlexDraper header float,

ensure both wing float locks are engaged
(LOCKED). (Figure 12-33)
Figure 12-33:
2. Ensure both header float lock levers are

down (UNLOCKED). (Figure 12-34)
Lock
Unlock
Figure 12-34:
3. Set center link to mid-range (B to C on the

float/angle indicator). Raise the feeder house,
so cutterbar is 6 to 10” (150-250mm) above
the ground. (Figure 12-35)
4. Lower the reel completely and set the fore-aft

adjustment to 5.
5. If header is equipped with stabilizer wheels or

slow speed transport wheels, raise them off
the ground so they are supported by the Figure 12-35:
header. Refer to D50 and D60 Harvest
Header/FD70 FlexDraper Operator’s Manual.
169046 ISSUE DATE 01/15/18

6. Remove special torque wrench (A) from

storage position at RH side of adapter frame.
Pull slightly in direction shown to disengage
wrench from hook. (Figure 12-36)
Figure 12-36: Special Torque Wrench Location
7. Place torque wrench (A) onto float setting

indicator (B). Note position of wrench for
checking RH or LH side.
8. Push down on wrench until bell crank (C) C

rotates forward. Check the position of the A
wrench indicator (D) near the handle. Repeat
for opposite side. B
Figure 12-37: LH Side Shown
D
Use the table below as a guide for float settings:
HEADER TORQUE SETTINGS

WIDTH CUTTING ON CUTTING OFF THE
THE GROUND GROUND
20, 25, 30 2 2 1/2
and 35 FT
40, 45 FT 2 1/2 3
Figure 12-38: Special Torque Wrench Settings
169046 ISSUE DATE 01/15/18

12.2.8 HEADER FLOAT ADJUSTMENT

(
NOTE:
See “Header Float Check” on page 12-14.
before making adjustments.
1. Adjust float with the adjuster bolts (P) so that
the washer (Q) behind the down-stop nut is
loose, then back off the adjuster bolts (P) two P
to five turns. While setting the float, make
small adjustments, then rock the header side
to side then let settle and continue to adjust.
IMPORTANT
Turn each bolt pair eqaul amounts. Figure 12-39:
2. If excessive force is required to lift, or the
header does not return to its original position,
the float requires more adjusting.
The float is properly adjusted when: Q
• both sides of the header are adjusted to
the same setting on the special torque
Lock
wrench
IMPORTANT
Proper float adjustment in accordance with
the above is critical for maintaining proper Unlock
wing balance when cutting on the ground. Figure 12-40:
3. When cutting on ground, adjust header angle

to achieve desired stubble height. AHHC indi-
cates A for shallowest angle/higher stubble,
D for steepest angle/lower stubble.
4. In rocky fields, adjust skid shoes down to
raise guards when operating at flattest
header angle to minimize scooping rocks.
5. Increase header height or decrease header
angle to minimize pushing soil.
NOTE:
Header angle and reel fore-aft position Figure 12-41:
changes do not significantly affect header flo-
tation (down force).
169046 ISSUE DATE 01/15/18

12.2.9 TOPLINK/BELLCRANK ALIGNMENT
WARNING
Stop combine engine and remove key before
making adjustments to machine. A child or
even a pet could engage the drive. If the wing
vertical movement up or down is not equal,
adjust the wing linkage as follows, referring
to following illustrations.\
A
IMPORTANT
Only attempt to make the following adjust-
ments once the cutter bar is straight, header Figure 12-42: LH Cover Removal
level, float is set and wings are locked.
B
Procedure:
1. Remove screw (A) and remove linkage cover
on the side that needs adjustment. (Figure
12-42)
C
2. Make sure that the bottom edge of the top
link (B), and the bottom edge of the bellcrank
(C) are parallel to each other. If not, you need
to adjust the 1" bolt (F) clockwise to move the Figure 12-43: LH Parallelism Adjustment
bell crank down or counterclockwise to move
the bell crank up. (Figure 12-43)
3. Loosen jam nuts (E) and turn bolt (F) until the
bottom edges of the toplink and bellcrank are
parallel. Tighten jam nuts (E). (Figure 12-44) F
Figure 12-44: LH Toplink Bolt Adjustment
169046 ISSUE DATE 01/15/18

12.2.10 COMPRESSION LINK CHECK

1. Ensure that the top of the bottom link C D
channel (C), lines up with white decal (D)
inside of the leg. (Figure 12-45)
2. If decal is missing, check that the bottom link 3.1”
channel (C) dimension in (Figure 12-45) is (80mm)
set correctly to 3.1” (80mm).
NOTE:
Making this adjustment may affect top-link/
bell crank alignment. Make small adjustments
and monitor the top-link/bell crank alignment.
Adjust the top-link/bell crank and compres-
sion link as nessesary. Figure 12-45:
12.2.11 COMPRESSION LINK ADJUSTMENT G
1. If adjustment is required. Loosen jam-nut (G)

and turn compression link (H) until bottom
link channel (C) and decal (D) are lined up, or H
the dimension 3.1” (80mm) is met. Lock the
nut (G). (Figure 12-46)
Figure 12-46:
NOTE:
By making this adjustment, you may affect
toplink/bellcrank alignment. Make small
adjustments and monitor toplink/bellcrank
alignment. Make adjustments to both com-
pression link and toplink/bellcrank as neces-
sary.
2. Replace linkage cover.
169046 ISSUE DATE 01/15/18

12.2.12 WING BALANCE

If a wing has a tendency to be in a ‘smile’ or
‘frown’ position, wing balance may require A
adjusting.
Check and balance the header wings as follows:
WARNING
Stop combine engine and remove key before
making adjustments to machine. A child or
even a pet could engage the drive.
1. Extend the header angle hydraulic cylinder

to B 1/2 on indicator.
Figure 12-47: Trim Springs Connected
2. Raise header until cutterbar is 6 to 10 inches

(152-254 mm) off the ground. C
4. Check that trim springs (A) are connected to

the combine CA20 adapter. (Figure 12-47) B
D
5. Move transport/stabilizer wheels all the way

up, so that they are supported by the header
and not touching the ground. Figure 12-48: Plastic Cover Removal
6. Move spring handle (B) to lower position to

unlock the wing float of the wing you are
checking. (Figure 12-48)
7. Remove linkage cover (C) by removing bolt

(D). (Figure 12-48) E
8. Retrieve wrench (E) from RH adapter leg.

(Figure 12-49)
Figure 12-49: Special Torque Wrench Location
169046 ISSUE DATE 01/15/18

9. Place torque wrench (F) on bolt (G). (Figure

12-50)
Full Smile
10. Move each wing up and down with the F
wrench (F) to determine tendency of wing to
“smile” or “frown”. (Figure 12-50) Straight
G
HINT: In most conditions it is desirable to
have the wings (more effort to move up).
Full Frown
11. Balance is set when the supplied torque

wrench measures the same setting with the
bellcrank (wing) up or down, or the wing
tends to align itself with the center cutterbar.
Figure 12-50:
12. If wing tends to “smile” (stay up), loosen
clamp-bolt (H) and turn draw-bolt (I) counter- H
clockwise to move clevis (J) inboard to
reduce teh “smile”. (Figure 12-51)
I
13. If wing tends to “frown” (stay down), loosen
J
clamp-bolt (H) and turn draw-bolt (I) clock-
wise to move clevis (J) outboard to reduce
“frown”. (Figure 12-51)
Figure 12-51: Balance Adjustment
14. Tighten clamp bolt (H). (Figure 12-51)
A
Lock
15. Move spring handle (A) to upper position to
LOCK the wing float. (Figure 12-52)
Unlock
NOTE:
If the cutterbar is not straight when wings are
in lock mode, then further adjustments are
required. See “Cutterbar Fore-Aft” on
page 12-10.
Figure 12-52:
NOTE:
Decals are located on the top link for each
wing to indicate adjustments.
16. Replace linkage cover and wrench.
169046 ISSUE DATE 01/15/18

INDEX
D60/FD70/CA20 INDEX
A
Acronyms and Abbreviations ..................................................................................................... 2-5
Adapter
Gearbox ................................................................................................................................. 6-1
Oil Temperature .................................................................................................................. 9-32
Adjustment
Compression Link Adjustment ......................................................................................... 12-18
Compression Link Check .................................................................................................. 12-18
Cutterbar Stringing ............................................................................................................. 12-8
FD70 Wing ......................................................................................................................... 12-7
Float Locks ....................................................................................................................... 12-13
Header Float ...................................................................................................................... 12-13
Header Float Adjustment .................................................................................................. 12-16
Header Float Check .......................................................................................................... 12-14
Header Levelling ............................................................................................................... 12-11
Toplink/Bellcrank Alignment ........................................................................................... 12-17
Wing Balance .................................................................................................................... 12-19
AHHC
Adjusting the Sensors Range (Case, JD, Agco, Massey, Challenger) .............................. 10-67
Adjusting the Sensors Range (Lexion) ........................................................................... 10-102
Adjusting the Sensors Range (New Holland CR/CX) ...................................................... 10-86
Agco/Massey/Challenger/JD 50/60 Series Combines ...................................................... 10-34
Automatic Header Height Control .................................................................................... 10-32
Case 21XX/23XX/25XX .................................................................................................. 10-35
Case 7010/8010 ................................................................................................................. 10-37
Case 7010/8010 & 21XX/23XX/25XX ............................................................................ 10-32
Diagnostic of Potentiometer (Case, JD Agco, Massey, Challenger) ................................ 10-68
Diagnostic of Potentiometer (Lexion) ............................................................................ 10-103
Diagnostic of Potentiometer (New Holland CR/CX) ....................................................... 10-87
Gleaner R62 & R72 .......................................................................................................... 10-56
Gleaner R65 & R75 .......................................................................................................... 10-58
JD 50/60/70 Series, Agco ................................................................................................. 10-43
JD 70 Series ...................................................................................................................... 10-51
Lexion ............................................................................................................................... 10-88
New Holland CR/CX ........................................................................................................ 10-69
Auger
Clutch Reassembly ............................................................................................................. 6-55
Disassembly ........................................................................................................................ 6-47
Internal Repair .................................................................................................................... 6-47
Reinstallation ...................................................................................................................... 6-43
Removal .............................................................................................................................. 6-38
Repair .................................................................................................................................. 6-44
Automatic Header Height Control
See AHHC ........................................................................................................................ 10-32
D60/FD70/CA20 INDEX
B
Bearing
Idler Roller Replacement ..............................................................................................7-6, 7-8
C
Configuration
PR15 Reel (FD70/D60/D50) ................................................................................................. 8-2
Cutterbar
Straightness ......................................................................................................................... 12-7
Cylinders
Center Reel Lift Cylinder (145386) Repair (Split Reel) ..................................................... 9-43
Double Reel Headers .......................................................................................................... 9-43
Fore-Aft Cylinders (137458 & 113434) Repair ........................................................9-41, 9-46
Reel Lift .............................................................................................................................. 9-34
Reel Lift (L/H) Cylinder (145237) Repair .......................................................................... 9-39
Reel Lift (R/H) Cylinder (145395) Repair .......................................................................... 9-40
Reel Lift Secondary Master (R/H) Cylinder (145237) Repair ............................................ 9-44
Reel Lift Theory .................................................................................................................. 9-34
Single Reel Header Cylinders ............................................................................................. 9-39
D
Deck
Adapter Feed ....................................................................................................................... 7-11
Adapter Feed Deck Removal .............................................................................................. 7-11
Adapter Feed Installation .................................................................................................... 7-13
Feed Deck Idler Roller Bearing Replacement .................................................................... 7-15
Feed Deck Removal ............................................................................................................ 7-15
Feed Draper Bearing Installation ........................................................................................ 7-17
Draper
Deck ...................................................................................................................................... 7-2
Deck Installation ................................................................................................................... 7-4
Deck Removal ....................................................................................................................... 7-2
E
Electrical
Agco .................................................................................................................................... 10-9
Case 2100/2300/2500 Harnesses ........................................................................................ 10-4
Case 7010/8010, NH CR/CX .............................................................................................. 10-4
Harness’ Combine Specific ................................................................................................. 10-4
Header Electrical Harnesses ................................................................................................ 10-1
Header Recognition ......................................................................................................... 10-108
Hydraforce Coil Resistance ..................................................................................10-14, 10-23
John Deere 50 Series ........................................................................................................... 10-7
John Deere 50/60 Series .................................................................................................... 10-29
John Deere 50/60/70 Series ............................................................................................... 10-20
D60/FD70/CA20 INDEX
John Deere Pre 50 Series .................................................................................................. 10-28

Lexion 400 (R) Series ......................................................................................................... 10-5
Lexion 400 Series ................................................................................................. 10-21, 10-30
Lexion 500 Series .......................................................................................10-6, 10-22, 10-31
Lighting ............................................................................................................................... 10-1
Potentiometer Replacement ............................................................................................ 10-104
Raise & Lower Sensitivity ................................................................................................ 10-39
Selector Valve - Agco ........................................................................................... 10-19, 10-27
Selector Valve - Case 23XX ............................................................................................. 10-24
Selector Valve - Case 23XX/25XX .................................................................................. 10-15
Selector Valve - Case 7010/8010, New Holland CR/CX ................................................. 10-17
Selector Valve - Case AFX, New Holland CR/CX .......................................................... 10-25
Single Span 15’ - 30’ D60 Reel Wiring .............................................................................. 10-1
Single Span Reel 30’, 35’ D60 & Split Reel 30’, 40’ Wiring Schematic ........................... 10-2
Transport Wiring Harnesses ............................................................................................. 10-11
Engine
Electronics .......................................................................................................................... 1-23
High Pressure Rails ............................................................................................................. 1-22
Safety .................................................................................................................................. 1-22
F
Feed Auger
Clutch Repair ...................................................................................................................... 6-53
Feed Auger .......................................................................................................................... 6-38
Flex Linkage ............................................................................................................................. 12-1
Disassembly ........................................................................................................................ 12-2
Reassembly ......................................................................................................................... 12-5
G
Gearbox
2012 and Newer Disassembly ............................................................................................. 6-22
2012 and Newer Reassembly .............................................................................................. 6-29
Adapter .................................................................................................................................. 6-1
2011 and prior ................................................................................................................. 6-1
2012 and newer ............................................................................................................. 6-18
Disassembly .......................................................................................................................... 6-5
Reassembly ........................................................................................................................... 6-9
General Procedure
Blades
Inspection
Cutting Hardware 4-16
Blades (Disc Only) .............................................................................................................. 4-14
Cutterbar
Blade
Replacement 4-18
Disc Installation ............................................................................................................ 4-20
Disc Removal ................................................................................................................ 4-19
Hardware Inspection ..................................................................................................... 4-17
D60/FD70/CA20 INDEX
Guards
Adjustments .................................................................................................................. 4-13
Regular Guard 4-13
Stub & Center 4-13
Taper lock Hub
Removal and Installation ................................................................................................ 4-1
Universal Joint
Rebuild ............................................................................................................................ 4-5
Guards
Double Knife Headers Forged Stub Guards Only .............................................................. 4-11
Double Knife Headers Pointed Guards Only ...................................................................... 4-10
Important Guard Information .............................................................................................. 4-12
Pointed Guard Header ......................................................................................................... 4-10
Stub Guard Header ................................................................................................................ 4-9
H
Hydraulic
Flushing the Hydraulic System ........................................................................................... 9-16
Hydraulics
Adapter Forward Operation .................................................................................................. 9-4
Adapter Forward Operation - Feed Draper Over Relief ....................................................... 9-6
Adapter Forward Operation - Side Draper Over Relief ................................................9-7, 9-8
Adapter Forward Operation Schematic ................................................................................. 9-5
Adapter Reverse Operation ................................................................................................... 9-9
Adapter Reverse Operation - Over Relief ........................................................................... 9-11
Adapter Reverse Operation Schematic ............................................................................... 9-10
Adapter Reverse Operation with Knife Reverser ............................................................... 9-12
Agco Multi-Coupler .......................................................................................................... 9-106
Center Reel Lift Cylinder (145386) Repair (Split Reel) ..................................................... 9-43
Checking Flow & Pressure Compensation ......................................................................... 9-25
Checking Knife Drive Flow & Pressure Compensator ....................................................... 9-25
Component Repair .............................................................................................................. 9-39
Diagnostic Test - Dynamic ................................................................................................. 9-36
Diagnostic Test - Static ....................................................................................................... 9-36
Disassembly (Parker Hannifin) ........................................................................................... 9-89
Disassembly Eaton Motor ................................................................................................... 9-64
Hydraulic Oil Specifications ............................................................................................... 9-32
John Deere 60 Series Multi-Coupler ................................................................................. 9-105
Lexion 400 Series Multi-Coupler ..................................................................................... 9-101
Lexion 500 Series Multi-Coupler ..................................................................................... 9-102
Lexion Multi-Coupler Valve Block .................................................................................. 9-103
MacDon, Case 7010/8010 & NH CR/CX Multi-Coupler ................................................. 9-104
Manifold (MD #133318) ....................................................................................................... 9-3
Minimum Test equipment ................................................................................................... 9-24
Multi-Coupler ................................................................................................................... 9-101
D60/FD70/CA20 INDEX
Oil Change Procedure ......................................................................................................... 9-33

Reassembly (Parker Hannifin) .................................................................................. 9-74, 9-93
Reassembly (White Hydraulics) ......................................................................................... 9-84
Reassembly Gerotor End (Eaton Motor) ............................................................................ 9-69
Reassembly Shaft End (Eaton Motor) ................................................................................ 9-66
Reel Drive, Lift & Fore-Aft Schematics ............................................................................. 9-35
Reel Lift (R/H) Cylinder (145395) Repair ......................................................................... 9-40
Reel Lift Cylinders .............................................................................................................. 9-34
Reel Lift Secondary Master (R/H) Cylinder (145237) Repair ........................................... 9-44
Reel Lift Theory .................................................................................................................. 9-34
Removal .............................................................................................................................. 9-63
Removal (White Hydraulics) .............................................................................................. 9-78
Repair (Parker Hannifin) .......................................................................................... 9-73, 9-92
Repair (White Hydraulics) .................................................................................................. 9-84
Setting The Unloading Valve "V7" .................................................................................... 9-29
Solutions (Single Span Reel) .............................................................................................. 9-38
Solutions (Split Reel) .......................................................................................................... 9-38
Testing & Repair ................................................................................................................. 9-24
Testing Gear Pump Efficiency ............................................................................................ 9-30
Testing Piston Pump Efficiency ......................................................................................... 9-31
Timing Procedure (Eaton Motor) ....................................................................................... 9-69
Hydraulics, Motor, Side Drapers .............................................................................................. 9-48
Hydraulics, Motor, Side Drapers (MD# 174369) ..................................................................... 9-60
Hydraulics, Motor, Side Drapers, Disasemble (MD #220891) ................................................ 9-55
Hydraulics, Motor, Side Drapers, Disasemble (MD #220936) ................................................ 9-56
Hydraulics, Motor, Side Drapers, Disassembly (MD# 172471/120930) ................................. 9-49
Hydraulics, Motor, Side Drapers, Reassemble (MD #220936) ................................................ 9-58
Hydraulics, Motor, Side Drapers, Reassembly MD# 172471/120930 ..................................... 9-52
Hydraulics, Motor, Side Drapers, Removal .............................................................................. 9-48
Hydraulics, Motor, Side Drapers, Repair (MD #220891) ........................................................ 9-55
Hydraulics, Motor, Side Drapers, Repair (MD# 172471/120930) ........................................... 9-52
I
Installation
Drive Roller Bearing ........................................................................................................... 7-21
K
Knife Drive
Double Knife D60 40’ & Smaller (Timed) ........................................................................... 5-2
Double Knife FD70 40’ & D60 45’ (Un-Timed) ................................................................. 5-3
Single Knife .......................................................................................................................... 5-1
Knife Drive Belt Tensioning ..................................................................................................... 5-33
L
Lock Collar
Removal and Installation ...................................................................................................... 4-4
D60/FD70/CA20 INDEX
M
Motor
Deck Shift (MD# 120374) Swathing Application Only ..................................................... 9-63
Failure, flushing system ...................................................................................................... 9-16
Feed Draper Motor (MD# 151981) ..................................................................................... 9-89
Hydraulic ............................................................................................................................. 9-48
Knife Drive Motor .............................................................................................................. 9-97
Parker Disassembly MD# 120374 ...................................................................................... 9-70
Reel (MD# 143088) ............................................................................................................ 9-78
Single Knife & Untimed Double Knife .............................................................................. 9-97
R
Reassembly
Double Reel Drive Reassembly .......................................................................................... 8-28
Single Reel Drive ................................................................................................................ 8-19
Reel
Settings .............................................................................................................................. 10-95
Sprocket Change ................................................................................................................... 8-3
Reel Speed ............................................................................................................................. 10-105
Agco ................................................................................................................................ 10-107
John Deere Pre 50, 50/60 Series ..................................................................................... 10-105
Lexion 500 Series ..............................................................................................10-105, 10-106
Removal
Double Reel (Split) ............................................................................................................... 8-8
Double Reel Left-hand Side ................................................................................................ 8-11
Double Reel Right-hand Side ............................................................................................... 8-8
Drive Roller Bearing ........................................................................................................... 7-19
Single Span Reel ................................................................................................................... 8-4
Repair
Reel Drive ........................................................................................................................... 8-15
Single Reel Drive Disassembly ........................................................................................... 8-15
Split Reel Drive Disassembly ............................................................................................. 8-23
Replacement
Feed Draper Drive Roller Bearing ...................................................................................... 7-19
S
Safety
Battery ................................................................................................................................. 1-26
General ................................................................................................................................ 1-20
Hydraulic ............................................................................................................................. 1-25
Important Safety Notice ........................................................................................................ 1-1
Maintenance ........................................................................................................................ 1-24
Refueling ............................................................................................................................. 1-26
Safety Alert Symbols ............................................................................................................ 1-1
Sign Installation .................................................................................................................... 1-3
Signal Words ......................................................................................................................... 1-2
Signs
D60/FD70/CA20 INDEX
A30-S Pull-Type ............................................................................................................. 1-4

A40 SP Auger Header ..................................................................................................... 1-7
CA20 Adapter ............................................................................................................... 1-14
D60 & FD70 Draper Header ........................................................................................... 1-8
Disc PT ......................................................................................................................... 1-15
M100 Self Propelled Unit ............................................................................................... 1-9
M150/M200 Self Propelled Unit .................................................................................. 1-12
R85 Disc SP .................................................................................................................. 1-18
Tire ...................................................................................................................................... 1-27
Schematics
Agco .......................................................................................................................... 10-9, 11-2
Agco Complete ................................................................................................................... 11-3
Case 2100/2300/2500 Series ............................................................................................... 10-4
Case 7010/8010, NH CR/CX .............................................................................................. 10-4
Case IH ............................................................................................................................... 11-3
Case IH 10 & 20 Series Complete ...................................................................................... 11-6
Case IH 2300 & 2500 Series Complete .............................................................................. 11-5
Electrical (Color) (2009 & Prior) ........................................................................................ 11-1
Electrical Harness Combine Specific ................................................................................. 10-4
Feed Draper Over Relief ....................................................................................................... 9-6
Forward Operation ................................................................................................................ 9-5
Forward Operation - Side Draper Over Relief .............................................................. 9-7, 9-8
Gleaner "R" & "S" Series Complete ................................................................................... 11-4
Header Legend .................................................................................................................... 11-1
John Deere 50 Series Complete .......................................................................................... 11-1
John Deere 60 & 70 Series Complete ................................................................................. 11-2
John Deere Legend ............................................................................................................. 11-4
Lexion 400 .......................................................................................................................... 11-5
Lexion 400 (R) Series ......................................................................................................... 10-5
Lexion 400 Complete .......................................................................................................... 11-7
Lexion 500 .......................................................................................................................... 11-6
Lexion 500 Series ............................................................................................................... 10-6
Lexion 500 Series Complete ............................................................................................... 11-8
Lighting ............................................................................................................................... 10-1
New Holland Complete ...................................................................................................... 11-9
Newholland Legend ............................................................................................................ 11-7
Reel Drive, Lift & Fore-Aft ................................................................................................ 9-35
Reverse Operation ............................................................................................................... 9-10
Reverse Operation - Over Relief ........................................................................................ 9-11
Reverse Operation with Knife Reverser ............................................................................. 9-12
Selector Valve - Agco ........................................................................................... 10-19, 10-27
Selector Valve - Case 23XX Series .................................................................................. 10-24
Selector Valve - Case 23XX/25XX Series ....................................................................... 10-15
Selector Valve - Case 7010/8010, New Holland CR/CX ................................................. 10-17
D60/FD70/CA20 INDEX
Selector Valve - Case AFX, New Holland CR/CX .......................................................... 10-25

Selector Valve - John Deere 50/60 Series ......................................................................... 10-29
Selector Valve - John Deere 50/60/70 Series .................................................................... 10-20
Selector Valve - John Deere Pre 50 Series ....................................................................... 10-28
Selector Valve - Lexion 400 Series .......................................................................10-21, 10-30
Selector Valve - Lexion 500 Series .......................................................................10-22, 10-31
Selector Valve (All, Except CASE 7010/8010, NH CR/CX) ............................................. 9-20
Selector Valve (CASE 7010/8010 & NH CR/CX) ............................................................. 9-19
Selector Valve For All Combines (2007 & Newer) ............................................................ 9-22
Single Span 15’ - 30’ D60 Reel Wiring .............................................................................. 10-1
Single Span Reel 30’, 35’ D60 & Split Reel 30’, 40’ Wiring Schematic ........................... 10-2
Split Reel 45’ Wiring Schematic ........................................................................................ 10-2
Transport 176760 & up Complete .................................................................................... 11-11
Transport 179759 & Below ............................................................................................... 11-10
Transport Option Legend .................................................................................................... 11-8
Transport Wiring Harnesses .............................................................................................. 10-11
Selector Valve
Hydraforce (2007 & Newer) ............................................................................................... 9-21
Standard FD70 (Optional D60 & D50) ............................................................................. 10-14
Standard FD70 (Optional D60) ......................................................................................... 10-23
Specifications
Design Features ..................................................................................................................... 2-6
Draper Header ....................................................................................................................... 2-6
Engineering ........................................................................................................................... 2-7
English Bolt Torque .............................................................................................................. 2-1
English/Metric Equivalents ................................................................................................... 2-5
Fluids and Lubricant Capacities ............................................................................................ 2-4
Fluids and Lubricants ............................................................................................................ 2-4
Metric Bolt ............................................................................................................................ 2-1
Metric Bolt, Bolting into Cast Aluminum ............................................................................ 2-4
Output Shaft Speeds on Headers ......................................................................................... 9-23
Tightening O-ring Fittings* .................................................................................................. 2-3
Tightening Tube Flare Type Fittings .................................................................................... 2-2
Torque ................................................................................................................................... 2-1
System
Adapter Hydraulics ............................................................................................................... 9-1
Draper Drive ......................................................................................................................... 7-1
Knife Drive ........................................................................................................................... 5-1
Reel Drive ............................................................................................................................. 8-1
T
Timing
Double Knife Drive (D60 40’ & Smaller) .......................................................................... 5-32
Troubleshooting .......................................................................................................................... 3-1
Auto Header Height Control (AHHC) .................................................................................. 3-4
D60/FD70/CA20 INDEX
CA20 Hydraulic Pressure Test, Hydraulic

CA20 Hydraulic Pressure Test ..................................................................................... 9-13
Cut Quality / Crop loss ......................................................................................................... 3-6
Cutting Action & Sickle Components ................................................................................ 3-10
Drapers & Decks ................................................................................................................. 3-13
Feeding .................................................................................................................................. 3-1
Gleaner R62 & R72 .......................................................................................................... 10-56
Gleaner R65 & R75 .......................................................................................................... 10-58
Ground Following / Float & Wing Balance .......................................................................... 3-3
Header Lift .......................................................................................................................... 3-12
JD 50/60/70 Series Agco .................................................................................................. 10-43
JD 70 Series ...................................................................................................................... 10-51
Lexion ............................................................................................................................... 10-90
Reel Delivery ...................................................................................................................... 3-11
Static and Dynamic Test Diagnostic Chart, Cylinder vs. Symptom ................................... 9-37
Vibration ............................................................................................................................... 3-5
V
Valve
Hydraforce Selector (Prior to 2007) ................................................................................... 9-18
Selector Block ..................................................................................................................... 9-18
W
Wobble Box
Disassembly ........................................................................................................................ 5-13
DKD, Left Side Wobble Box Removal ................................................................................ 5-6
DKD, Right Side Wobble Box Removal .............................................................................. 5-9
Double Knife (Timed) Removal ........................................................................................... 5-6
Installation .......................................................................................................................... 5-29
Kit Items ............................................................................................................................. 5-12
Re-Assembly ....................................................................................................................... 5-19
Rebuild Tools ...................................................................................................................... 5-12
Removal ................................................................................................................................ 5-4
Repair .................................................................................................................................. 5-11
Single & Un-Timed Double Knife Removal ........................................................................ 5-4
Wobble box Squareness ............................................................................................................ 5-31

D60 FD70 CA20 Harvest Header Flex Draper Combine Adapter: Technical Manual

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D60 FD70 CA20 Harvest Header Flex Draper Combine Adapter: Technical Manual

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D60 FD70 CA20

Section 4: General Procedures

Section 6: Adapter Drive

8.3 Double Reel (Split) Removal ............................................................................. 8-8

9.14 Knife Drive Motor...................................................................................... 9-97

10.7 Automatic Header Height Control (AHHC) .................................................. 10-32

10.12 Header Recognition ................................................................................. 10-108

1.1 IMPORTANT SAFETY NOTICE

• THE INDIVIDUAL'S SAFETY HABITS.

1.2.1 WHY IS SAFETY IMPORTANT TO

169046 ISSUE DATE 05/01/14

1.3 SIGNAL WORDS

DANGER: Indicates an imminently hazardous

WARNING: Indicates a potentially hazardous

CAUTION: Indicates a potentially hazardous

169046 ISSUE DATE 05/01/14

1.4 SAFETY SIGNS

1.4.1 SAFETY SIGN INSTALLATION

Figure 1-7: Rotating Driveline Hazard

169046 ISSUE DATE 05/01/14

Figure 1-10: MD#142909

Figure 1-8: MD#124763

Figure 1-11: MD#3009

Figure 1-9: MD#36651

169046 ISSUE DATE 05/01/14

Figure 1-14: MD#142908

Figure 1-12: MD#44944

Figure 1-15: MD#142912

Figure 1-13: MD#171029

Figure 1-16: MD#28403

169046 ISSUE DATE 05/01/14

Figure 1-17: MD#32738

Figure 1-18: MD#140311

Figure 1-19: MD#115100

169046 ISSUE DATE 05/01/14

A40 SP Auger Header

Figure 1-21: MD#44944 Left End Sheet

Figure 1-24: MD#28403 L/H & R/H Reel Ends

Figure 1-22: MD#32738 End Sheets

169046 ISSUE DATE 05/01/14

D60 & FD70 Draper Header

Figure 1-28: MD#32738 Keep Shields in Place

Figure 1-25: MD#44611 Back Tube

Figure 1-26: 42122 Reel Hazard

Figure 1-29: MD#174436 High Pressure Oil

Figure 1-27: MD#32009 General Caution

169046 ISSUE DATE 05/01/14

M100 Self Propelled Unit

Figure 1-30: 110986

Figure 1-34: 32743

Figure 1-31: 134068

Figure 1-32: 160351

Figure 1-33: 110989

Figure 1-35: 42130

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Figure 1-38: 109844

Figure 1-36: 44611

Figure 1-39: 109868

169046 ISSUE DATE 05/01/14

Figure 1-40: 163561

Figure 1-44: 183096

Figure 1-41: 163562

Figure 1-42: 160350 Figure 1-45: 160400