Geringhoff-Operating Manual Rota Disc Rigid

Operating Manual
9000167-01_en
ROTA DISC
Corn Header
Carl Geringhoff Vertriebsgesellschaft mbH & Co. KG Telefon +49 (0) 2382 9814-0
Porschestrae 8 Telefax +49 (0) 2382 9814-40
D-59227 Ahlen E-Mail info@geringhoff.de
www.geringhoff.de
Copyright
Copyright by
Carl Geringhoff Vertriebsgesellschaft mbH & Co. KG
Porschestrae 8
D-59227 Ahlen
Federal Republic of Germany
3
4
1. General information .....................................................................................................7
1.1. Introduction .................................................................................................................... 7
1.2. Pollution control information ...........................................................................................10
2. Safety .........................................................................................................................11
2.1. Intended use .................................................................................................................11
2.2. Basic safety instructions .................................................................................................11
2.3. General accident prevention regulations ..........................................................................13
2.4. Header hazard symbol locations and descriptions (ISO 11684) ..........................................15
2.5. Hydraulic safety instructions ...........................................................................................19
3. Prior to start-up ..........................................................................................................20
3.1. Hydraulics - Fluid cleanliness and oil specification.............................................................20
3.2. Preparing and hooking up the header ..............................................................................21
3.3. Connecting the hook-up adapter (John Deere) .................................................................24
3.4. Connecting the hydraulic multi-coupler (John Deere) ........................................................26
3.5. Adjusting the combine feeder house (Case AFX models) ...................................................27
3.6. Connecting the hook-up adapter (Case AF models) ..........................................................28
3.7. Connecting the hook-up adapter (Case AFX models) ........................................................30
3.8. Connecting the hydraulic multi-coupler (Case AFX) ...........................................................32
3.9. Connecting the hydraulics without a multi-coupler (Case AF) ............................................33
3.10. Connecting the hook-up adapter (Claas Lexion, Tucano, Avero models) ...........................34
3.11. Connecting the hydraulic multi-coupler (Claas Lexion, Tucano, and Avero models) ............37
3.12. Connecting the hook-up adapter (Acros/Vektor/Torum) ....................................................39
3.13. Connecting the hydraulics (Acros/Vektor/Torum) .............................................................41
3.14. Connecting the hook-up adapter (Deutz) .........................................................................42
3.15. Connecting the hydraulic multi-coupler (Deutz) ................................................................44
3.16. Connecting the hook-up adapter (Massey Ferguson) ........................................................45
3.17. Connecting the hydraulic multi-coupler (Massey Ferguson) ...............................................47
3.18. Adjusting the combine feeder house (New Holland CR/CX models) ...................................48
3.19. Connecting the hook-up adapter (New Holland) ...............................................................49
3.20. Connecting the hydraulic multi-coupler (New Holland) ......................................................51
3.21. Connecting the hook-up adapter (Fendt) .........................................................................53
3.22. Connecting the hydraulic multi-coupler (Fendt) ................................................................55
3.23. Installing the transmission shaft ......................................................................................57
3.24. Installing the terminal ....................................................................................................59
3.25. Turning on and reading the terminal ...............................................................................61
3.26. Installing the divider tips ................................................................................................62
3.27. Installing the ground sensors option ................................................................................67
3.28. Adjusting the stalk breakers ............................................................................................69
3.29. Installing the cob catcher option .....................................................................................70
3.30. Installing the body raiser ................................................................................................71
3.31. Installing the optional down corn auger ...........................................................................72
3.32. Header rated speed ........................................................................................................73
3.33. Conducting a test run / Checking the rated speed ............................................................74
3.34. Preparing the header for road transport ..........................................................................76
5
4. Operation and set-up .................................................................................................78
4.1. Adjusting the auger cover ...............................................................................................78
4.2. Installing conveying elements to the transverse auger ......................................................79
4.3. Removing and installing the center hoods ........................................................................80
4.4. Removing and installing the outer hoods .........................................................................81
4.5. Changing the header speed ............................................................................................82
4.6. Adjusting the speed with a manual speed selector ...........................................................85
5. Service and maintenance ...........................................................................................87
5.1. Tensioning the auger drive chain ....................................................................................87
5.2. Re-adjusting the transverse auger ...................................................................................89
5.3. Transverse auger slip clutch............................................................................................90
5.4. Checking the split transverse auger dog coupling .............................................................91
5.5. Using the chain key for chain removal .............................................................................92
5.6. Removing the front gathering chain sprockets .................................................................94
5.7. Removing the gathering chains .......................................................................................96
5.8. Changing the rear gathering chain sprockets (nut-type mounting) ....................................98
5.9. Changing the rear gathering chain sprockets (split-pin type locking) .................................99
5.10. Re-adjusting the deck plate standard setting ................................................................. 100
5.11. Checking the row unit frame ......................................................................................... 102
5.12. Row unit overload protection ........................................................................................ 104
5.13. Replacing the slip clutch / Disassembling the gearbox .................................................... 105
5.14. Re-adjusting the picking gap end plate .......................................................................... 106
5.15. Adjusting or replacing the stalk cutters .......................................................................... 107
5.16. Adjusting the scrapers .................................................................................................. 108
5.17. Replacing the rotary knives ........................................................................................... 109
5.18. Checking or replacing the rotor knives ........................................................................... 114
5.19. Removing the rotors ..................................................................................................... 115
5.20. Using special tools........................................................................................................ 118
5.21. Checking the Centaflex couplings (without connecting shaft) .......................................... 119
5.22. Checking the Centaflex couplings (with connecting shaft) ............................................... 119
5.23. Checking the deck plate speed sensor and slide resistor ................................................. 120
5.24. Lubrication and maintenance ........................................................................................ 121
5.25. Lubrication chart .......................................................................................................... 122
5.26. Gearbox maintenance advice ........................................................................................ 129
5.27. Maintaining the crown wheel gearbox............................................................................ 130
5.28. Maintaining the manual speed selector (optional two-speed or four-speed) ..................... 133
5.29. Maintaining the angular gearbox ................................................................................... 136
5.30. Maintaining the row unit gearbox (RD) .......................................................................... 139
6. Malfunctions and troubleshooting ...........................................................................141
6.1. Fault assistance ........................................................................................................... 141
7. Appendix ...................................................................................................................145
7.1. Bolt tightening torques ................................................................................................. 146
7.2. Specifications ............................................................................................................... 147
EC declaration of conformity
6
General information
1. General information
1.1. Introduction
Dear customer,
Thank you for your trust in our products.
Periodical servicing and maintenance help conserve your equipment's high value
and provide for many years of trouble-free operation.
We highly appreciate your professional experience and know-how. All feedback

provided by you will contribute to the continuous development and improvement
of our products.
This operator manual was handed to you at the time of delivery of your
equipment. Please keep this operator manual in a safe place. Should you ever
decide to sell your equipment, please pass this operator manual on to the new
owner.
Important information on the operator manual
Any person operating this header should carefully read the operator manual
before commissioning the equipment. Commissioning describes the initial,
purpose-bound operation of the header by the operator.
Make sure to comply with the regulations for work safety and accident prevention,
see pages from 11, as well as the information on intended use, see pages from 11.
Keep the operator manual accessible at all times. Make sure to read the sections
on operating the header from the combine operator manual. The transmission
shaft operator manual will be supplied separately and attached to the transmission
shaft. We also recommend consulting the parts book.
Dimensions are expressed using the internationally standardized SI (metric)
units.
All references to left and right in this manual are as viewed in the direction of
travel.
Row units are numbered from left to right as viewed in the direction of travel
(corn headers only).
Dimension and weight specifications are approximate and refer to the relevant
standard header versions.
For instructions with no specified tightening torque please refer to the Bolt
Tightening Torques chart, see pages from 146, in the Appendix.
All efforts have been made to assure the accuracy of the contents of this manual.
However, should any errors be detected, we would greatly appreciate being
informed of them.
7
General information
Symbols and instructions
All important instructions and information in this operator manual are identified by
specific symbols and phrases. Follow all safety instructions. Use caution to avoid
accidents, injury, or damage to property. Also comply with all local accident
prevention regulations and general safety regulations. The following symbols and
instructions notify the reader of potential injury or damage or provide other
important information.
DANGER
Identifies a risk which may lead to death, severe/moderate/minor injury, or
damage to property. The level of risk is described in the safety information text.
Always observe any hazard information and use particular caution and care.
Important note
This information is used to ensure the trouble-free performance of the work at hand or the
trouble-free operation of the equipment. Do not ignore this information.
Note:
This information is useful to facilitate operation and handling of the equipment.
Tip:
This information contains helpful hints and additional information.
Example figures and text
Some pictures in this manual may not depict the actual components as found on
the equipment at the time of delivery. This, however, does not affect the
truthfulness of the information which is applicable to all models.
Safety-related information is essential for the safe and trouble-free operation of

the equipment and always refers to the product as delivered.
8
General information
Prior to start-up
Use the fields provided to make a note of the required header data. This way the
supplier will know exactly what header you are referring to. Locate the information
on the header type plate (1). See below for the type plate position.
Type plate position Type plate
Machine type:
Machine number:
Key code:
Weight (kg):
Year of manufacture:
Row spacing:
Work width / number of row units:
Combine harvester type:
For spare parts please contact your specialist retailer and make sure to have the
required information at hand.
Use Geringhoff genuine spare parts only.
Do not modify any structural and/or safety-related machine components. The
manufacturer is not liable for any damage resulting from the use of the header
other than that intended.
(Errors and technical changes excluded.)
9
General information
1.2. Pollution control information

Ensure that consumables, auxiliary materials and equipment parts are disposed of in a
proper and environmentally friendly manner. Adhere to all regulations and all environmental
or disposal standards applicable in your country.
General information
1. Avoid skin contact with liquid fuels, oils, lubricants, acids, solvents, etc.
Always wear appropriate protective clothing when disposing of such
substances.
2. Never put fire to oils or similar substances.
3. Never allow groundwater-hazardous operating fluids (oils, grease, etc.) to
penetrate the soil or enter the groundwater system.
4. When changing oil, collect all used oil in appropriate containers and never
allow it to penetrate the soil. Ensure the oil is properly disposed of in
accordance with all applicable environmental standards.
5. Immediately repair any damage or leaks in the hydraulic system. Periodically
check all hydraulic hoses for damage.
6. For information regarding proper substance disposal consult a certified waste
management company.
10
Safety
2. Safety
2.1. Intended use

This header is intended solely for the purpose of harvesting dry corn and sunflower
seeds.
Always operate lifting devices according to their intended use. Any modification or
use with other machines is prohibited.
Any use beyond the intended use will be considered improper. The manufacturer
does not assume liability for damage arising from such use. The operator bears the
sole risk instead.
Adhering to the intended use includes complying with the manufacturer's

operating, maintenance, and repair specifications.
The header must only be used, maintained, and repaired by qualified specialists or
personnel familiar with the header and its implied hazards.
Always observe and adhere to all applicable Accident Prevention Regulations and
any applicable general regulations regarding safety, occupational health and road
traffic laws.
The manufacturer is not liable for any damage arising from unauthorized
modifications to the header.
2.2. Basic safety instructions

1. Carefully read the header operator manual.
2. Follow the safety instructions in this operator manual and comply with all
general regulations for work safety and accident prevention.
3. Read the combine operator manual.
4. The warning labels on the header contain important information related to the
safe operation of the header.
5. Do not exceed the maximum permissible lift load when lifting the header. Use
appropriate lifting devices only. The header weight is specified on the type
plate.
6. Install the transport lock for road transport. If necessary, have additional
headlights installed by qualified personnel (see road homologation
requirements).
7. Check the vehicle's driving, steering, and braking performance.
8. Do not exceed the permissible axle loads and/or the gross vehicle weight and
follow all relevant regulations.
9. Never allow passengers to ride on vehicle parts other than those provided for
seating.
11
Safety
10. Follow all applicable legal requirements when traveling on public roads.
Always move the header into transport position before traveling on public
roads or ways.
11. Check the header for operational safety and roadworthiness before operating.
12. Familiarize yourself with the header functions and learn how to operate the
header before harvesting.
13. Always re-install guards or protective devices and close the service hatches
before operating the header. Check the header for loose parts.
14. Before performing any repair, maintenance, cleaning, troubleshooting, or
similar work on the header, turn off the combine engine and engage the
header safety stop. To do this, remove the ignition key and disengage the
battery disconnect switch. Relieve the pressure from all hydraulic lines and
move all control levers to the neutral position. Always secure work equipment
against unauthorized use.
15. Always disengage the battery disconnect switch before working on the
electrical system.
16. Always use the provided header supports when working on the header.
17. Do not actuate the header fold sequence until the vehicle has come to a
complete halt and has been secured against rolling off. Stay clear of the pivot
area (folding headers only).
18. Stay clear of the hazard area when the header is running.
19. Changing the knives involves an increased risk of personal injury.
20. The header design does not provide sufficient protection from hazards
associated with the header auger and other moving parts. Therefore, stay
clear of all moving parts while the header is operating.
21. Never run transmission shafts without their appropriate protective guards.
22. Use caution when mounting the header to the combine. This procedure
involves an increased risk of personal injury.
23. Test-run the header in fully lowered position only.
24. Immediately replace any damaged or missing safety decals on the header.
12
Safety
2.3. General accident prevention regulations

The following general accident prevention regulations apply to the general
operation and handling of all types of equipment.
DANGER
Protect yourself.
Always wear the required protective clothing when preparing for work,
performing work, or servicing the equipment.
This includes:
Safety helmet and

Safety boots
safety goggles
Overalls/
Protective gloves
rain protection
Respirator Ear protection
13
Safety
Safety precautions
1. Always keep a First Aid kit within reach.

2. Always keep a working fire extinguisher within reach. Check its functionality
and make yourself familiar with its operation before proceeding.
3. Never allow children or animals to go near your equipment.
4. Accidents are often caused by fatigue and/or time pressure. Always be calm
and focus on your work. Never ignore signs of fatigue.
5. Always wear skin-tight clothing. Cover long hair. Do not wear any loose
jewelry (necklaces etc.).
6. Keep hands, feet, clothing, and hair away from moving parts. Never attempt
to remove blockages or objects from the equipment while the engine is
running.
7. Never modify or remove any safety installations. Leave all parts in place.
Ensure the trouble-free operation of all drive assemblies.
8. Only use service and spare parts approved or supplied by the manufacturer.
Non-approved spare parts may vary in size, design, or safety standards and
can result in warranty claims being denied.
9. Never modify any part of the equipment. Unauthorized modifications may
adversely affect the functionality, safety, or service life of the equipment.
10. Always stop the engine and remove the key before leaving the driver's seat.
Secure the equipment against unintentional starting.
11. The area used for servicing and maintaining the equipment should always be
clean and dry. Avoid slip hazards caused by moisture or oil on the ground.
Avoid hazards caused by moisture on the ground while operating electric
tools. Always ensure electric tools are grounded.
12. Ensure sufficient illumination at work.
13. Keep the equipment clean at all times. Straw, chaff, or other material may
catch fire from hot equipment parts. Never allow oil or grease to accumulate
near service stations, ladders, or inspection structures. Thoroughly clean the
equipment before storage.
14. Never use gasoline, solvents, or similar substances for cleaning. These
substances may be toxic or flammable.
15. When storing the equipment, ensure to avoid any risk of injury caused by
sharp or protruding parts.
14
Safety
2.4. Header hazard symbol locations and descriptions

(ISO 11684)
All safety-related header locations are identified by hazard symbols, known as pictograms, to point out
specific hazards. In these symbols, the hazardous situation is depicted on the left, whereas the
relevant hazard prevention measure is depicted on the right. Any damaged or lost hazard decals
should be replaced immediately. Ensure to fit all replacement parts and accessories with the relevant
hazard decals. The decals can be ordered using the specified part numbers.
Below is a description of the header hazard symbol locations and their relevant meaning.
Stop the engine and remove the key before 1.

performing maintenance or repair work. Secure
against unauthorized use.
(P/N 510889)
Never stand between the header and the 2.

harvester.
(P/N 510891)
Never open or remove protective devices or 3.

guards while the engine is running.
(P/N 510893)
Keep a safe distance from the header. Disengage 4.

the header, stop the engine, and remove the key
before performing maintenance work or removing
blockages.
(P/N 510895)
15
Safety
Engage the safety stop before entering the hazard 5.

area.
(P/N 510890)
Keep hands clear of the rotating auger. 6.

(P/N 510892)
Stay clear of rotating components. 7.

(P/N 519917)
Stand clear of moving equipment. 8.

(P/N 510896)
Keep a safe distance to the cutter bar when the 9.

drive is engaged and the diesel engine is running.
(P/N 510905)
16
Safety
Beware of flying objects while the engine is 10.

running. Keep a safe distance.
(P/N 510904)
Do not open or remove protective devices or 11.

guards while the engine is running.
(P/N 510894)
Header decal locations
Right-hand side or right-hand and left-hand sides. Right-hand side or right-hand and left-hand sides.
17
Safety
Two front decal locations (6).
One rear decal location (6).
18
Safety
2.5. Hydraulic safety instructions
DANGER
Risk of death.
The oil in the hydraulic system is under high pressure. Any work on the
hydraulic system should always be performed by qualified personnel.
Physical contact with pressurized hydraulic oil may cause severe personal
injury or death.
Never use your bare hands to detect leaks.
Always wear protective gloves, long-sleeved clothing, and safety goggles
when working in the vicinity of hydraulic system components.
Immediately replace any faulty hydraulic components or brittle hoses.
Fluids escaping under high pressure (e.g.,

hydraulic oil) may penetrate the skin and
cause severe injuries.
To avoid injuries always release the pressure
from the hydraulic system before performing
repair or adjustment work or before
disconnecting any hydraulic components. Do
not pressurize the hydraulic system until all
components have been correctly installed
and tightened.
Never use your bare hands to detect leaks.
Always wear protective gloves and safety
goggles when working in the vicinity of
hydraulic system components.
Frequently check the condition of all
hydraulic components and have them
replaced as necessary.
In the event of an accident make sure to
seek medical attention as severe infections
may occur.
Replace hose assemblies no later than
6 years after their date of manufacture.
19
Prior to start-up
3. Prior to start-up
3.1. Hydraulics - Fluid cleanliness and oil specification

Fluid cleanliness
The hydraulic system fluid cleanliness complies with the ISO 4406 cleanliness level 18/16/13. This
level of cleanliness should always be maintained. If the system fails to achieve this level, take
appropriate measures to restore the required level of cleanliness.
DANGER
Personal injury or damage to equipment may occur.
If the required level of fluid cleanliness cannot be achieved the hydraulic
system components may suffer reduced lifetime, damage, or defects.
Damage or defects may cause accidents.
Always make sure the required level of fluid cleanliness is achieved.
Some work may involve a high risk of fluid contamination, including:

Changing the hydraulic oil
Connecting the hydraulic multi-coupler
Installing/removing hydraulically driven accessories (including vertical knives, Sweeper, or down
corn augers)
Work performed on the hydraulic valve block (e. g. when adjusting the hydraulic system)
Opening or unscrewing hydraulic connections
Cleaning
Repair work
Oil specification
The hydraulic system uses HLP 46 oil to DIN 51524-2. Always use this oil specification when changing
or adding oil.
20
Prior to start-up
3.2. Preparing and hooking up the header
DANGER
Personal injury may occur.
Turn off the engine. Prevent unintentional starting.
Stay clear of the hazard area.
Use suitable lifting devices and load-handling equipment only. Follow all safety
instructions related to the use of lifting devices and load-handling equipment.
Observe the combine load capacity and the tire load index.
Ensure the header is in a stable position.
Depending on type and model, the header

will be supplied in a vertical or horizontal
position. If the header is supplied in a
vertical position, use appropriate load-
handling equipment to move it to the
horizontal position before proceeding.
Hooking up is easy as the header is
configured according to the owner's
specifications.
After changing the hook-up adapter as well
as hydraulic or driveline components the
header may be mounted to different types of Hook-up adapter example.
combine.
Important note
The exact header weight is specified on the type plate. Make sure the lifting device has
sufficient capacity for the header weight.
21
Prior to start-up
A detailed, type-specific packing list is supplied

with each header.
1. Remove the packing items fastened to the
header.
2. Thoroughly check the shipment for
completeness.
3. Check that the row unit spacing is as
ordered.
4. Before placing the header on the ground,
attach the stands and, if applicable, the stalk
breakers. The stalk breakers are adjustable, Stalk breaker in mounted position.
see page 69.
When initally mounting the stands, it may be
necessary to rotate them by 180 degrees.
MS Collect only:
This model has no stands and may be
placed directly on the ground.
Stands in transport position. Example of stands in mounted position.
Suggestion:
For ease of folding the header, support one side of the transport frame with an angled
wooden block or a similar device.
22
Prior to start-up
5. Attach the lifting device to the header lifting

eyes (1) and tension it by lifting up slightly.
6. Slowly move the lifting device away from the
header. While observing the tilt angle
(harvesting position), carefully tilt rearward
and support the header so the front beam
can be removed (use a suitable support).
Important note!
Personal injury can occur. Always secure the transport frame prior to disassembly.
7. First remove the two top M16 bolts (2) from

the transport frame and fold down the
frame. Then remove the bottom bolts and
remove the transport frame.
Remove top and bottom bolts (example)
Note:
Retain the transport frame (and, if necessary, the transport lock bolt) for future use to save
space when storing the header. Post-season service work will be easier to perform with the
header standing upright.
Preparing for hook-up

Afterwards, place the combine in the correct
hook-up position relative to the header.
23
Prior to start-up
3.3. Connecting the hook-up adapter (John Deere)
DANGER
Engage the safety stop before working on the header.
Follow the combine manufacturer's guidelines.
The main crop elevator locking device is

automatically controlled by the multi-coupler.
With the multi-coupler connected, the
header will be locked; with the multi-coupler
disconnected, the header will be unlocked.
1. Ensure the multi-coupler is disconnected so
the main crop elevator lock pins retract.
Lock pin holder.
2. Slightly raise the header until the safety stop

can be engaged. The main crop elevator
should engage in the top adapter.
24
Prior to start-up
3. Engage the safety stop.
Engage the safety stop.
4. Connect the multi-coupler. The pins will lock.

If necessary, align the locking device
position.
Ensure the pins engage correctly.
25
Prior to start-up
3.4. Connecting the hydraulic multi-coupler (John Deere)
DANGER
Avoid leakages to protect the environment.
Check all connection lines for damage.
Follow the instructions on oil purity and oil specifications in the relevant
section. Comply with all applicable rules and regulations.
Important note!
Upon delivery, the multi-coupler connector is

attached to its bracket using an R-type clip.
Multi-coupler attached to the header.
1. Remove the multi-coupler connector from its

bracket.
2. Check that the male and female connections
are clean.
Remove the multi-coupler.
26
Prior to start-up
3. Connect the multi-coupler to the combine

and move the latch lever to the fully locked
position.
Connect and lock the lever.
3.5. Adjusting the combine feeder house

(Case AFX models)
Important note
Before initially mounting a header to a Case AFX type combine, be sure to remove the
angled guide plates.
Remove the angled guide plates (1).
Remove the angled guide plates.
27
Prior to start-up
3.6. Connecting the hook-up adapter (Case AF models)
DANGER
1. Loosen the bolts (1) at the main crop

elevator locking device.
2. Move the locking lever (2) forward.
Move the locking lever forward.

should precisely engage in the top adapter
to ensure the header will hook up correctly.
28
Prior to start-up
5. Move the header lock pin (3) upward into

the locking notch.
Then move the locking lever rearward and
re-tighten the bolts.
Move the lock pin upward.
29
Prior to start-up
3.7. Connecting the hook-up adapter (Case AFX models)
DANGER
1. Ensure that the locking levers on the main

crop elevator are unlocked.
Unlocked position.

can be engaged. Ensure the main crop
elevator engages in the top adapter and the
locking lever engages in the opening
provided.
Header state before hooking up.
30
Prior to start-up
4. Move the main crop elevator locking lever to

securely engage it in the hook provided on
the header. The locking lever should be
slightly pre-loaded when engaged in the
hook.
Engage the locking lever in the hook.
5. If necessary, remove the eccentric

connection bolt and adjust the eccentric
shaft to secure the connection between the
locking hook and the header and remove
any free play. Then lock the eccentric
connection using the bolt.
Engaged locking device and eccentric bolt (arrow).
31
Prior to start-up
3.8. Connecting the hydraulic multi-coupler (Case AFX)
DANGER
Important note!
Upon delivery, the multi-coupler (mobile

part) is attached to the combine's bracket.
1. Remove the multi-coupler from its bracket.
are clean.
3. Connect the multi-coupler to the header and

lock the lever (1).
32
Prior to start-up
3.9. Connecting the hydraulics without a multi-coupler

(Case AF)
DANGER

Connect the combine hydraulic lines to the

header as follows:
Paired-up hydraulic lines. Left - deck plate adjustment. Right - Combine hydraulic lines. Left - deck plate adjustment. Right
down corn auger, Sweeper. (reel drive) - down corn auger, Sweeper.
Note:
The male and female couplers are different in shape to avoid confusion.
33
Prior to start-up
3.10. Connecting the hook-up adapter

(Claas Lexion, Tucano, Avero models)
DANGER

1. Loosen the left-hand and right-hand hook-up

adapter bolts (1) and move the locking lever
(2) upward.
Move the locking lever upward. Locking lever in released position.
2. Loosen the left-hand and right-hand hook-up

adapter R-clips (1) and retract the lock pin
(2).
34
Prior to start-up
Loosen the R-clip (1). Retract the lock pin.

should precisely engage in the top adapter
so the hook-up dog engages correctly.
Attach the header. Ensure the hook-up dog engages correctly.
35
Prior to start-up
5. Push in the lock pin and secure it using the

R-clip.
Lock pin in locked position.
6. Move the left-hand and right-hand hook-up

adapter locking levers (2) downward and
tighten the bolt (1) (17mm wrench).
Locking lever in locked position.
36
Prior to start-up
3.11. Connecting the hydraulic multi-coupler

(Claas Lexion, Tucano, and Avero models)
DANGER

Important note!

part) is attached to the combine's bracket.
Multi-coupler attached to the combine.
1. Remove the multi-coupler (mobile part) from

its bracket.
are clean.
37
Prior to start-up

tighten the knob bolt.
Attach the multi-coupler and tighten the knob bolt.
38
Prior to start-up
3.12. Connecting the hook-up adapter (Acros/Vektor/Torum)
DANGER
Personal injury can occur.
Keep personnel away from the hazard area.
1. Remove the bolt (1).

2. Remove the lock pin (2).
Remove the lock pin.

should attach directly to the top adapter.
Header at the attachment point.
39
Prior to start-up
5. Install and secure the lock pin and the bolts.
Install the lock pin.
40
Prior to start-up
3.13. Connecting the hydraulics (Acros/Vektor/Torum)
DANGER
The hydraulic connections are located on the

left-hand side of the machine (as viewed in
the direction of travel).
To connect the deck plate adjustment
system (double-acting cylinders), attach the
two combine hydraulic lines to the header.
Protect the hydraulic lines from damage and,
if necessary, secure the lines.
Deck plate adjustment hydraulic lines.
Connector locations.
41
Prior to start-up
3.14. Connecting the hook-up adapter (Deutz)
DANGER
1. Ensure that the locking lever on the main

crop elevator is unlocked.
Locking lever in released position.

can be engaged. To ensure the locking hook
will engage in the relevant slot, the main
crop elevator should be precisely aligned
with the top adapter.
Attach the header.
42
Prior to start-up
4. Moving the locking lever to the front, push it

over-center to lock the hook-up adapter.
43
Prior to start-up
3.15. Connecting the hydraulic multi-coupler (Deutz)
DANGER
Important note!

part) is attached to its bracket on the
header.
are clean.

and lock the lever.
44
Prior to start-up
3.16. Connecting the hook-up adapter (Massey Ferguson)
DANGER

Locking lever in released position.

can be engaged. Ensure the locking hook (1)
correctly engages in the opening provided.
Attach the header.
45
Prior to start-up
4. Move the locking lever forward to lock the

hook-up adapter.
46
Prior to start-up
3.17. Connecting the hydraulic multi-coupler

(Massey Ferguson)
DANGER

Important note!

part) is attached to its bracket using an R-
type clip.

its bracket.
are clean.
47
Prior to start-up

position.
3.18. Adjusting the combine feeder house

(New Holland CR/CX models)
Important note
Before initially mounting a header to a CNH combine, be sure to remove the angled guide
plates (1).
Remove the angled guide plates (1).
Remove the angled guide plates.
48
Prior to start-up
3.19. Connecting the hook-up adapter (New Holland)
DANGER
1. Ensure that the locking levers on the main

crop elevator are unlocked.
Unlocked position.

can be engaged. To ensure the locking lever
will engage in the relevant slot, the main
crop elevator should be precisely aligned
with the top adapter.
Attach the header.
49
Prior to start-up
4. Tilt the feeder house locking lever to the

front and secure it to the header's hook.
Moving the locking lever to the front, push it
over-center to lock the hook-up adapter.
Engage the locking lever in the hook.
5. If necessary, remove the eccentric

connection bolt and adjust the eccentric
shaft to secure the connection between the
locking device and the header and remove
any free play. Then lock the eccentric
connection using the bolt.
Engaged locking device and eccentric bolt (arrow).
50
Prior to start-up
3.20. Connecting the hydraulic multi-coupler (New Holland)
DANGER
Important note!
Upon delivery the multi-coupler connector

(mobile part) is attached to the combine's
bracket.
Multi-coupler attached to the combine.

are clean.
51
Prior to start-up

lock the lever (1).
52
Prior to start-up
3.21. Connecting the hook-up adapter (Fendt)
DANGER

Unlocked locking levers.

can be engaged. Ensure the main crop
elevator engages in the top adapter and the
locking lever (1) engages in the opening
provided.
Attach the header.
53
Prior to start-up
4. Move the locking lever forward to lock the

hook-up adapter.
54
Prior to start-up
3.22. Connecting the hydraulic multi-coupler (Fendt)
DANGER
Important note!

part) is attached to its bracket using an R-
type clip.

its bracket.
are clean.
55
Prior to start-up

position.
56
Prior to start-up
3.23. Installing the transmission shaft
DANGER
Prior to installing the transmission shaft make sure to read the operating
manual supplied by the relevant manufacturer.
Never open or remove protection devices/guards during operation. Never
operate the header without the protective devices/guards installed.
Check the transmission shaft guards. Replace defective transmission shaft
protection guards as necessary.
Install the transmission shaft guard attachment chain (anti-rotation device) in
its original location.
The headers are equipped with different

transmission shaft drives depending on the
model. Drive comes from the right-hand
and/or left-hand sides.
1. Clean and grease the drive shaft prior to
connecting it to the transmission shaft.
2. Fit the transmission shaft onto the drive
shaft and make sure it engages as shown
(1).
Check the transmission shaft guard (2) for
damage and push it over the joint.
Ensure that the guard on the combine side is
also installed.
Example of a guard. Prevent the guard from rotating using the attachment chain
(example).
57
Prior to start-up
3. Hook the attachment chain (3) to the eyelet

to prevent it from rotating.
4. Ensure that the collar shield (4) is
undamaged and correctly positioned over
the transmission shaft guard (2).
5. Check that the transmission shaft is properly
covered.
Locking mechanism for transmission and drive shafts (1),

transmission shaft guard (2), attachment chain (3), collar
shield (4).
58
Prior to start-up
3.24. Installing the terminal

Installing the terminal and the distribution box
DANGER
Ensure that the terminal does not limit the driver's field of vision.
Attach the terminal so the driver's field of vision is not limited and the display
is easilyreadable.
1. Attach the terminal using the suction holder

above the dashboard on the right-hand side
of the cab. Alternative mounting options are
available.
Terminal and holder.
Note:
Ensure that the front window is free of dust and grease and that the terminal is not attached
to the curved section of the glass.
Routing the harnesses
1. When routing the terminal harness (1) to the

header check that it cannot be damaged.
2. Route the connection harness from the
terminal through a suitable opening on the
right-hand side into the cab floor. (If
necessary, drill a 15mm (.59") diameter
hole.)
Important note!
Make sure to seal the harness exit location.
The harness should be long enough to compensate for the lifting and lowering
movements of the feeder house.
59
Prior to start-up
1 = Harness routing. Magnifier = terminal connection to Connection diagram.

header.
Connecting the power supply and the terminal
DANGER
Short-circuits may occur.
1. Connect the power plug as required for the

relevant ignition system (12 volts, max. 10
amps fuse rating).
2. Securely connect the electrical terminal
connection to the header.
60
Prior to start-up
3.25. Turning on and reading the terminal

Turning on the terminal
The terminal will boot up automatically each time the ignition is turned on. The
current operating hours will be shown for approx. 35 seconds.
The system automatically detects the connected header model. The terminal
displays the current RPM and deck plate spacing values.
Important note!
The deck plate spacing is displayed as an indicator value between 0 and 10.
Terminal functions
1 Status display: RPM example.

2 Status display: Deck plate spacing example.
Note:
During operation the terminal will display the current header speed.
This means the driver can continuously monitor the speed value for combine drive slip or
overload conditions.
The terminal displays the following functions:
RPM.
Deck plate spacing.
Set the deck plate spacing using the Reel Fore/Aft function on the combine's control lever.
61
Prior to start-up
3.26. Installing the divider tips
DANGER
The gas spring can cause the row unit hood to snap upward when opening.
Crushing hazard when assembling the hoods and divider tips.
Do not carry out any assembly work unless the system is locked and the
safety stop is engaged.
Use extreme care.
1. Unlock the lever (1). Push down on the hood

and release the locking hooks (2).
2. Then carefully tilt up the hood.
Unlock the lever and release the locking hook.
3. Remove the lynch pin (1) and extract the pin

(2).
Remove the lynch pin (1) and pull out the pin (2).
62
Prior to start-up
4. Remove the bolt (3) on one side. Hold the

locking lever and pull out the tube (4).
Loosen the bolt (3) and pull out the tube.
Important note!
Lower the header until the divider tips can be easily installed.
Engage the safety stop or, if necessary, use an alternative protective device.
If the setting spindle is equipped with compression springs, release the springs until
they can be connected to the eyelet.
5. Raise the divider tip as shown and insert the

tube in the existing hood and divider tip
openings. Then attach using bolts and lock
the bolt with a thread-lock compound. Refer
to the torque table in the Appendix for the
required tightening torque (Nm).
Insert the tube with the divider tip hanging down.
63
Prior to start-up
6. Hook the divider tip setting spindle (1) into

the existing hood eyelet.
Connect the setting spindle (shown here with a compression

spring).
Important note!
In certain countries the connection may not be equipped with compression springs.
7. Install the safety pin and secure with the

lynch pin.
Install and secure the pin.
8. Close the hood. Ensure that the locking hook

engages.
9. Lock the locking lever with moderate pre-
load. Adjust as necessary by screwing the
hook in or out.
Lock and close.
64
Prior to start-up
Installing the outer divider tip
The outer divider tips are installed in the same way as the inner divider tips.
Adjusting the divider tips
DANGER
Important note
Avoid interference between the divider tips and the gathering chains.
Raise the tips if the combine wheels sink too deep into the ground.
Lower the tips when harvesting down corn.
1. Begin by engaging the safety stop.

2. Park the combine on a flat, even surface and
lower the header until the sensor skids are
approx.
10cm (3.94") from the ground.
3. Adjust the bolt (1) so the divider tips are
approx. 2cm (.79") from the ground
(standard setting).
4. Raise the header, engage the safety stop
and align the remaining divider tips.
5. Set the two outside divider tips to be approx.
Set the ground clearance to 2cm (.79") using the bolt (1).
50mm above the center tips.
Note:
It is recommended to set the two outer divider tips to be approx. 50mm (2") above the
center tips.
Unload the compression spring of the setting spindle until it can be hooked up.
65
Prior to start-up
Set the ground clearances to specification.
66
Prior to start-up
3.27. Installing the ground sensors option
DANGER
Use extreme care.
The header may be equipped with optional

ground sensors for precise float control.
Depending on the option, the ground
sensors will mount to two or three divider
tips (see opposite picture).
Divider tip with ground sensor system.
1. Position the divider tips on the outer right

(1) and left (2).
With the three-sensor option, the third
ground sensor is installed to one of the
center divider tips (3).
The position of the third ground sensor is
determined by the connection harness
routing (X) inside of one of the center hoods.
The header comes pre-wired with the
required connection harnesses.
Positioning the divider tips equipped with ground sensors.
67
Prior to start-up
2. After installing the divider tips pull the

harness from the opening (X) and connect it
to the divider tip connection harness.
3. Use the pre-installed clips to fasten the
harnesses inside the divider tips.
Pull the harness out from the opening (X).
No adjustment is required as the ground

sensors are set in the factory. If, however,
the ground sensors require adjustment,
change the length of the spindle (1, 3) and
re-position the hole (2, 4).
Adjust the hole location.
Important note!
Never allow the potentiometer (5) to reach the end stop. If necessary, choose a
different hole position on the potentiometer lever.
The combine manufacturer specifies a certain voltage for adjustment of the
potentiometer, refer to the combine manual.
Calibration
After assembly, calibrate the ground sensor

function according to the combine
manufacturer's specifications to synchronize
the header functions with the combine.
68
Prior to start-up
3.28. Adjusting the stalk breakers
DANGER
Models with a horizontal chopper come with

standard stalk breakers which need to be
installed after delivery. For all other models
they are offered as an option.
Stalk breakers flatten the corn stalks directly
behind the row unit to protect the machine
tires from damage. The tension spring pre-
load (1) ensures the tilting plate (2) will
flatten the stalk, even with the header raised
above normal harvesting position.
Make sure to install the stalk breaker after
connecting the header to the combine. Make sure to install the stalk breaker.
Setting the height

Loosen the bolts (3) on the attachment tube
(4) and move the assembly up or down until
the required height is achieved. Then re-
tighten the bolts.
Stalk breaker lateral and vertical adjustment.
69
Prior to start-up
Lateral adjustment
The stalk breakers can be moved to the right
or left to adjust them to the combine's
overall width or tire size and the resulting
track gauge.
Loosen the 6 bolts (5) and move the stalk
breaker to the right or left. Then re-tighten
the bolts.
3.29. Installing the cob catcher option
As an option the headers can be supplied

with cob catcher skirts (1) mounted to the
divider tips. Cob catcher skirts may be
retrofitted at any time.
When harvesting down corn we recommend
removing the cob catcher skirts.
Cob catcher skirt (1).
Lateral cob catcher skirts
Lateral cob catcher skirts (1) can restrict

crop feed to the machine when harvesting
low-volume crops. In this case, remove the
lateral cob catcher skirts.
The gap (2) can be adjusted.
70
Prior to start-up
3.30. Installing the body raiser
1. Remove the outside bolts from the

rectangular tube (1).
Rectangular tube attached to the body.
2. Fasten the body raiser (2) as shown using

four M8x16 bolts on the inside and four
M8x40 bolts on the outside.
Install the body raiser.
71
Prior to start-up
3.31. Installing the optional down corn auger
DANGER
Note:
The down corn auger has three hydraulic connections on the left-hand side and two
hydraulic connections on the right-hand side.
1. Loosen the bolts from the rectangular tube

and remove the rectangular tube.
Remove the rectangular tube from the body.
2. Install the down corn auger to the body and

fasten with two M8x45 bolts at the top and
two M8x40 bolts at the bottom.
Fasten the down corn auger to the rectangular tube.
72
Prior to start-up
Connecting the hydraulics

3. Connect as identified: V = supply line, T =
tank return line. There is an additional case
drain (not identified) on the left-hand side
for installing down corn augers on both
sides.
Down corn auger speed adjustment

The down corn auger speed can be adjusted
using the combine's Reel Speed Adjustment
function. V = Supply line, T = return line, center = case drain.
Speed reduction valve (Case/New

Holland)
On the control valve (2), set the down corn
auger speed to leave sufficient room for
adjustment using the combine's Reel Speed
Adjustment function.
Case/New Holland speed reduction valve.
3.32. Header rated speed
Important note!
See the Specifications in the Appendix for information on the header rated speed.
Models using a manual speed selector (option) require a different rated speed, see
"Adjusting the speed with a manual speed selector".
73
Prior to start-up
3.33. Conducting a test run / Checking the rated speed
DANGER
Personal injury may occur due to moving parts and knives. Keep a safe
distance.
Ensure that the protective devices are securely installed.
When not harvesting, always operate the header close to the ground.
Operate the header at rated speed.
1. After completing the required assembly work

check that all protective devices are correctly
installed.
Transmission shaft guard for folding headers. Transmission shaft guard for non-folding headers.
2. Check the lift area of the folding lift wings:

Ensure that the transmission drive shafts are
relieved of any axial pressure in the
retracted position. Ensure that there is
sufficient overlap in the extended position.
Check the lift area of the folding lift wings.
74
Prior to start-up
DANGER
Personal injury may occur due to moving parts and knives. Keep a safe
distance.
3. Lower the header until it is close to the

ground and then slowly start it up. Carry out
a visual and acoustic inspection.
4. Accelerate the header to rated speed. Check
the current speed from the terminal and
compare the RPM value with the
specifications, see page 147.
5. If the header is not in use, always lower it to
the ground, avoiding shock loads to the
frame.
Important note!
Do not go below or exceed the specified rated speed (see Specifications in the
Appendix).
If the speed is below the specified range, the torque decreases too much and the
reliable operation can no longer be guaranteed. Exceeding the speed range causes an
unwanted change of the slip clutch torque (any warranty claims are rendered null and
void).
75
Prior to start-up
3.34. Preparing the header for road transport
DANGER
Install the roading protection frame before roading.
Consider the combine load capacity and the tire load index.
Consider the combine's minimum steering axle load and the legally required
maximum drive axle load when driving on public roads.
Note the combine manufacturer's specifications regarding road transport.
Headers with a total width of up to 3.3m

(10.8ft) come with an illuminated roading
protection frame.
Headers with a greater working width should
be transported on public roads using special
transport vehicles only.
Installing the roading protection

frame
The holes for engaging the roading
protection frame mounting are located on
the outer center tips.
1. Drill an 18mm (.71") diameter hole into the
top plastic cover just behind the tip
attachment.
2. Install the roading protection frame.
3. Check that the protection frame is securely
engaged.
Insert the center tips into the roading protection frame. Roading protection frame mounting.
76
Prior to start-up
Connecting the lighting

1. Connect the roading protection frame to the
header connector (or, as in some exceptions,
the combine connector).
2. During road transport the bottom edge of
the transport front protector allows a
maximum ground clearance of 45cm (17.7")
(underride protection).
Do not exceed the maximum transport speed
of 25km/hr (15.5mph).
7-pin connector at the rear of the header (example).
77
Operation and set-up
4. Operation and set-up
4.1. Adjusting the auger cover
DANGER
The auger cover can be adjusted steplessly

to individual requirements.
Manually adjust the auger cover up or down
until the desired position is reached.
Auger cover open.
Auger cover fully closed.
78
4.2. Installing conveying elements to the transverse auger
DANGER
Depending on model and harvest conditions,

the header comes with different conveying
elements (rubber paddles, fingers).
The auger tube has bolt locations for
attaching the conveying elements.
Center the conveying element in front of the
feeder house opening. Keep a minimum
distance of 100mm on either side. Refer to
the torque table in the Appendix for the
required tightening torque (Nm). Use the
following as a guideline: feeder house
opening - 200mm = maximum total width of (1) = Hardware, (2) and (3) = rubber paddles,
(4) = fingers.
conveyor assembly.
Important note!
Install the conveying elements against the direction of rotation.
79
4.3. Removing and installing the center hoods
DANGER
High pressure gas. Crushing hazard.
Use extreme care.
The hoods and divider tips offer easy, tool-

less removal for cleaning and maintenance.
1. Open and lift up on the center hood.
2. Remove the spring clip with the pin (1) at
the top end of the gas spring.
Spring clip and pin.
3. Tilt the gas spring to the rear.
Tilt the gas spring to the rear.
80
4. Manually lower the hood far enough to pull it

off toward the front. Remove the hood.
Carry out the assembly in reverse order.
Pull the hood toward the front.
4.4. Removing and installing the outer hoods
DANGER
High pressure gas. Crushing hazard.
The gas spring can cause the row unit hood to snap upward when
opening.
Use extreme care.
1. Remove the lynch pin (1).

2. Open the outer hood.
3. Remove the spring clip from the gas spring
and tilt the cylinder rearward.
4. Pull off the hood toward the side and put it
aside.
The assembly procedure is the same as
above.
Lynch pin on the outer hood.
81
4.5. Changing the header speed
DANGER
Risk of environmental pollution.
Follow all instructions regarding environmental protection in this user manual.
Avoid skin contact with oil.
Never operate the machine with low oil.
If the specified rated speed cannot be

achieved, the ring gear inside the crown
wheel gearbox may need to be replaced (for
models with left-hand and right-hand drives
the change must be made on both sides).
The specifications on the type plate attached
to the crown wheel gearbox include the
number of teeth (z). For information on
alternative ring gears please consult your
dealer.
Type plate on the crown wheel gearbox, z = number of teeth.
1. Remove the guard (1).

2. Loosen the clamp (2) and disconnect the
transmission shaft (3) from the crown wheel
gearbox.
Remove the guard and loosen the transmission shaft.
82
3. Remove the crown-wheel drive transmission

shaft (4).
4. Remove the auger drive chain.
5. Loosen the four M12 bolts and remove the
gearbox.
Remove the drive shaft.
6. Drain the oil from the drain plug breather

which must be removed.
7. Place the crown wheel gearbox on the
workbench with the cover pointing up.
Marked crown wheel gearbox.
Important note!
Always mark the position of the cover in relation to the gear housing to facilitate
assembly.
83
8. Remove the M10 Allen bolts and remove the

cover with the crown wheel and the shaft
from the housing. Take care not to damage
the sealing faces.
9. Remove the M8 hex bolts used to install the
crown wheel and remove the ring gear.
Install a new crown wheel. Apply a medium
strength thread-lock compound to the bolts
and tighten to 22Nm.
10. Reassembly: Clean the sealing faces, apply a
suitable sealant and reassemble the unit.
11. Reassemble the gearbox and tighten the Change the crown wheel.
bolts (see tightening torque table in the

Appendix). Make sure to align the marks.
12. Use marking punches to change the current
number-of-teeth information on the gear
housing type plate to the new number of
teeth.
13. Reassemble.
Aligning the gearbox drive

1. After completing the reassembly, align the
crown wheel gearbox with the line (y). If
necessary, also re-adjust the angular
gearbox using the M10x8mm Allen bolts
using an Allen key.
2. Then check the oil level.
Align the crown wheel gearbox with the line (y).
84
4.6. Adjusting the speed with a manual speed selector
DANGER
Damage to equipment may occur.
Do not use the sunflower harvest speed for harvesting corn.
Before shifting speeds wait for the header to come to a complete stop.
Two different manual speed selectors (1) are

available as options.
Depending on the harvest and crop conditions,
the header may require different speeds:
Corn and sunflower harvest 2-speed
selector.
selector.
(1) = Gearbox, (2) = selector shaft.

selector
Use a 24mm (.94") combination wrench to
engage the desired speed.
Drawing shows 4th speed selected. Corn and sunflower harvest speeds.
85

selector
The two-speed selector (3) has a fixed speed
for harvesting corn and a fixed speed for
harvesting sunflower seeds.
Select the required speed using the lever
(2 1) as shown.
2-speed selector. Corn and sunflower harvest speeds.
86
Service and maintenance
5. Service and maintenance
5.1. Tensioning the auger drive chain
DANGER
Never open or remove protection devices/guards during operation. Never
operate the header without the protective devices/guards installed.
Ensure that the protective devices are securely installed.
The chain tensioner design varies depending on the model.
Drive from the header shaft

The auger is driven from the side opposite the
main drive. The speed is determined by the
header main shaft and cannot be changed.
1. Frequently lubricate the chains.

2. Frequently clean the protective housing.
3. Frequently check the chain tension. If
necessary, use the tensioner sprocket to
tension the chain (adhere to general
guidelines). Use the tensioner sprocket to tension the chain.
87
Drive from the crown wheel gearbox

The auger is driven by the crown wheel gearbox
input shaft.
1. Open the panel (1) when performing

maintenance.
2. Regularly lubricate the chains.
3. Regularly check the chain tension. If
necessary, move the tensioner lever (2) to
tension the chain (adhere to general
guidelines). Use the tensioner sprocket to tension the chain.
88
5.2. Re-adjusting the transverse auger
DANGER
Before re-adjusting the transverse auger make sure to slacken the drive chain.
The optimum gap between the transverse auger

and the auger trough is set in the factory. In
certain harvest conditions a different gap may be
required (e.g. to avoid kernel damage caused by
the auger panels, or for improved conveying
performance).
The transverse auger can be adjusted up or
down. See opposite picture.
(1) Sprocket.
Important note!
Do not forget to re-tension the chain after all work has been completed.
On folding headers check the adjustment of all auger brackets. Ensure the auger
brackets are fully aligned.
Adjusting the outer gap

1. Slacken the drive chain before changing the
auger position.
2. Loosen the bolts (2) on the right and left by
two turns. Do not loosen the pivot bolt (3).
3. Use a suitable tool (19mm (.75") wrench
size) to evenly adjust the sprocket (1) to the
required height.
4. Use a suitable device as a distance gauge for
adjusting the height.
5. Re-tighten the bolts. Loosen the bolts.
6. Tension the chain, see page 87.
89
Adjusting the gap on a split auger

1. Loosen the bolts (6).
2. Use the adjuster bolt (5) to set the auger
parallel with the auger trough.
3. Tighten the bolts (6) according to the torque
table in the Appendix.
Adjust the height using the adjuster bolt (5).
5.3. Transverse auger slip clutch
The auger drives are equipped with a

maintenance-free, non-adjustable slip clutch.
1. Grease the slip clutch with no more than 1
shot from the grease gun (see Lubrication
Chart).
Caution: Excessive greasing can cause
malfunctions.
2. Regularly grease and tension the chain drive.
3. If the slip clutch opens, immediately stop the
engine and rectify the issue.
4. If the header plugs up, use the combine's
Grease fitting (1).
reversing function to clear the obstruction.
5. Slowly re-start the engine.
90
5.4. Checking the split transverse auger dog coupling
Split transverse auger

Ensure that the bearing supports (1) bolt
together tightly.
Removing the dog coupling

1. Remove the center bearing bolt joint.
2. Loosen the outside bearing at the short half-
auger (right-hand side).
3. Remove the right-hand half-auger.
4. Mark the position of the half-couplings in
relation to the tube.
5. Remove the bolt (4) and the washer (5).
Remove the dog ring (1) and the spring (6).
6. Do not swap the half-couplings.
7. Replace any worn parts.
8. Clean and grease the shaft and the coupling.
9. Then insert and tighten the bolts while
observing the mark (see tightening torque
table in the Appendix).
10. Grease the dogs.
91
5.5. Using the chain key for chain removal
DANGER
The chain key lever can snap upward.
Always engage the lever after putting it under tension. Use extreme care.
The gathering chains and the gathering

chain sprockets can be easily removed using
the supplied chain key. The chain key is
attached on the rear of the header, see
figure to the right. The chain key has two
operating positions:
Long position (1), short position (2).
The chain key is located at the rear of the header.
Short position:
Used to slacken or tension the chain.
Used to remove the chain.
Chain key in short position.
92
Long position:
Used to remove the sprocket.
Chain key in long position.
93
5.6. Removing the front gathering chain sprockets
DANGER
Spring-loaded parts can fly off when removing the chain guide.
The chain key can snap back.
Use extreme care.
Note:
At the end of the harvest season make sure to remove and clean the deck plates, the
gathering chains and the gathering chain tensioner.
1. Remove the gathering chain.
2. For ease of re-assembly, mark the chain

guide factory setting on the row unit or
measure the chain spacing.
Mark the narrow and wide chain spacings.
94
3. Remove the bolts (1) and (2) and remove

the chain guide. The drill holes are oblong in
shape.
4. Remove and clean the deck plates as
necessary.
5. Fasten the chain guide.

6. Assemble the chain key in the long position
and tension it.
7. Remove the fastening bolts (1) and washers
(2) and the cover (3) from the chain guide.
Ensure that the chain tensioner sprocket
remains parallel with the chain guide and
does not give way. Use appropriate tooling if
necessary.
8. Remove the guide piece (4).
9. Relieve tension from the chain key.
10. The chain tensioner can now be

disassembled. Pull the spring out of the
chain tensioner and clean the spring.
Replace any worn or damaged parts.
95
11. Reassemble the chain tensioner.

12. To reassemble follow the disassembly steps
in reverse order. During reassembly, ensure
that the chain tensioner is installed in its
original narrow (1) or wide (2) position. Note
the mark.
Narrow chain guide (1) = aggressive intake.
Wide chain guide (2) = less aggressive.
Important note!
When harvesting sunflower seeds use the wide setting, see the instructions for the sunflower
harvest.
5.7. Removing the gathering chains
Note:
Swap the right hand chains with the left-hand chains at yearly intervals and make sure to
flip them over in the process. This ensures even wear on the link plates. If the chain tends
to slip excessively, check the function of the chain tensioner. Replace chains when
lengthened excessively.
1. Assemble the chain key in short position as

shown and slacken the chains by moving the
lever. Make sure the lever engages in the
chain key safety hook.
2. Remove the chain.
3. Replace the chain or turn it over.
4. Unlock the chain key and move the lever
back to tension the chain.
Chain key.
96
The gathering chains are protected from

contamination by slip rollers (1). The chain
tension cannot be adjusted. Any overload
condition will cause the slip rollers to slip, which
provides sufficient protection for the system.
Important note!
Never change the automatically adjusted chain tension.
The relative position of the chain slats is

irrelevant. During normal harvesting it changes
each time the slip protection is triggered.
5. If the slip clutch opens, immediately stop
the header and rectify the issue.
6. If the header plugs up, use the combine's
reversing function to clear the obstruction.
7. Slowly re-start the header.
Arrow points in driving direction.
97
5.8. Changing the rear gathering chain sprockets

(nut-type mounting)
DANGER
Personal injury may occur if the special tool slips off the sprockets.
Ensure the special tool will not slip off the sprockets when loosening and
tightening the sprocket nut.
Important note
Before installing a new sprocket make sure the sprocket conical bore, the sprocket
shaft cone and threads, and the sprocket nut threads are clean and free of oil or
grease.
Observe the sprocket nut torque specification.
1. Block the sprocket to be changed by

positioning the spline bore (2) on the special
tool (1) over the sprocket so the special tool
spline engages in the sprocket teeth.
Position the ring bore (3) on the opposite
tool side over the other sprocket.
2. Loosen and remove the sprocket nut (4).
3. Remove the special tool.
4. Use an appropriate puller to pull the sprocket
off the sprocket shaft. Remove the sprocket.
5. Degrease the new sprocket bore, the shaft
Geringhoff special tool.
cone, and both threads.
6. Apply Loctite 601 or 263 to the bore and the
cone.
7. Place the new sprocket onto the sprocket
shaft.
8. Apply a medium strength thread-lock
compound (e. g., EURO-LOCK A 24.20) to
the threads.
9. Position the sprocket nut.
10. Use the special tool to block the new
sprocket (see step 1).
11. Torque the sprocket nut to 200 lbf ft
Special tool in position.
(270 Nm).
12. Remove the special tool.
98
5.9. Changing the rear gathering chain sprockets

(split-pin type locking)
1. Drive out the split pin (1). Replace the split

pin as necessary.
2. Pull the sprocket (2) off the sprocket shaft
and remove the sprocket.
3. Replace the key (3) as necessary.
4. Place the new sprocket onto the sprocket
shaft.
5. Install the split pin.
Split pin (1), sprocket (2) Split pin (1), sprocket (2), key (3).
99
5.10. Re-adjusting the deck plate standard setting
DANGER
The deck plate setting may need to be re-

adjusted for locally different crop types or upon
impact by foreign objects.
The deck plate standard setting can be adjusted
on one side using the lever (1).
1. Hydraulically move the deck plates to the
narrowest position.
2. Slide the lever on the tube (2) to the right to
open the deck plate.
3. Slide the lever on the tube to the left to
close the deck plate. Deck plate spacing is adjustable on both sides.
100
Important note!
Always center the gap above the
deck plates.
Ensure that the deck plate spacing
and centering are identical for all
deck plates. If necessary use
suitable tools.
Check that the deck plate spacing
on the gearbox side is at least 3mm
(.12") wider than on the intake side
(taper opens toward the rear).
X = 3mm (.12") wider on gearbox side.
Deck plate gap not centered. Deck plate gap centered.
101
5.11. Checking the row unit frame
DANGER
Sharp edges can be a hazard. Use extreme care.
Important note!
Deformation on the row unit is always caused by external impact. The normal
operating load is controlled by both the rotor slip clutch and the gathering chains safety
device.
After hitting large foreign objects (bumping into

obstacles, severe impact of metal parts, etc.) the
frame may be deformed, especially on the left-
hand and right-hand outer rows. Usually such
deformation leads to a visibly increased deck
plate gap. (On the Rota Disc header, a good
indication of this problem is when the newly
installed rotary knives do not extend far enough
into the rotor groove). Always check the affected
row after a collision.
Outer row unit support.
Identifying deformation to the

frame
Frame gap: 317.50.5mm (12.5"0.02")
1. Loosen the two bolts (1) on the right-hand
and left-hand sides until free of any torque.
2. On the outer rows also release the row unit
support by loosening the nut (2) at the tube
(3) using a suitable tool (17mm (.67")
wrench size) and rotating the tube until free
of tension. Rotate the header by hand.
3. If there is any difference in spacing at the Frame gap: 317.50.5mm (12.5"0.02")
arrow position between the fixing bracket
and the frame, take appropriate measures.
102
Compensating for varying frame

gaps
1. Variations of up to 3mm (.12") in the
horizontal gaps (arrow) between the fixing
bracket and the frame can be corrected by
inserting U-shaped shims.
2. Variations of up to 3mm in the vertical frame
gaps can be corrected by vertically moving
the fixing bracket.
3. When installed, the front rotor bearing must
be free of any tension.
4. If the difference in the gaps is too large, the
frame should be replaced or horizontally and
vertically aligned using suitable tooling.
5. Manually check for run-out.
6. Adjust the outer row unit support without
preload and counter-tighten.
103
5.12. Row unit overload protection
Important note!
Before removing the gearbox make sure to read the information in "Gearbox repair".
Stop the header immediately after the slip clutch has opened. Rectify the cause.
Each row unit is equipped with an overload

protection device for the rotors, gears, and
gathering chains.
For securing the gathering chains see see
page 96.
The non-adjustable slip clutch inside the
gearbox is virtually maintenance-free and
wear-proof.
After overloading the clutch, reverse and
clean the header.
Then slowly start up the header again.
Rota Disc row unit (partial view).
104
5.13. Replacing the slip clutch / Disassembling the gearbox
DANGER
Important note!
All work on the gearbox should be carried out by authorized expert personnel using the
repair manual as a guide.
105
5.14. Re-adjusting the picking gap end plate
DANGER
The picking gap end plate (1) is located

below the deck plates in front of the gearbox
housing. It is fastened with two bolts (2).
If necessary, set the distance to the rotors to
1mm (.04") maximum by inserting shims
between the plate and the row unit gearbox.
If the gap exceeds 1mm (.04"), there is a
risk of the rotors wrapping with material in
this area (especially in wet conditions).
Picking gap end plate.
Add shims as necessary.
106
5.15. Adjusting or replacing the stalk cutters
DANGER
Always wear protective gloves when replacing the knives.
Important note!
Frequently re-adjusting the stalk cutters reduces the header's power requirements and
improves work quality.
If wear occurs it may be necessary to re-

adjust the stalk cutter or to replace the stalk
cutter and the cutting knives. The self-
sharpening cutting edges are carbide-coated
and must not be reground.
Adjusting the spacing
1. Loosen the three fastening bolts (1).
2. Push back the knife support (2).
3. Push the stalk cutter toward the rotor knife.
Gap, < 1mm (.04").
4. Lightly tighten the center bolt. Stalk cutter location.
5. Rotate the rotor by hand (if necessary, use
multigrip pliers to turn the rotary knife
shaft). Check and adjust the gap at all the
rotating rotary knives. Check for smooth
running.
6. Tighten the center and the outside bolt to
150Nm.
7. Drive the knife support in until it contacts
the stalk cutter. Tighten the knife support
bolt to 150Nm.
<1mm (.04") gap.
107
5.16. Adjusting the scrapers
DANGER
Adjusting the spacing

Move the scraper to <0.5mm (.02") from the
rotor surface.
Scraper <0.5mm (.02").
108
5.17. Replacing the rotary knives
DANGER
Rotary knives
Ensure that the rotary knives extend far into the
rotor grooves to leverage the header rotor's self-
cleaning effect for clean material delivery.
The knives are designed to be self-sharpening,
which ensures consistently high cutting
performance over long periods.
The front rotary knives may require replacement
due to normal wear. The self-sharpening cutting
edges are carbide-coated and must not be
reground. The rotary knives should extend far into the rotor grooves.
The first ten rotary knives are subject to the

highest stress loads and therefore are a different
design than the remaining rotary knives. Please
consider this when ordering spare parts.
Replace rotary knives in due time to avoid
continuing wear on the rotor counter-edges. We
recommend replacing the rotary knives worn
down to a diameter of 110mm (4.33") and below.
Do not sharpen the rotary knives.
It is not possible to compensate for rotary knife
wear by re-adjusting the rotors. Replace all rotary knives worn down to a diameter of 110mm
(4.33") and below.
109
Important note!
Frequently re-adjusting the rotary knives reduces the header's power requirements and
Remove the stalk cutters

Remove the stalk cutters, see page 107.
Replacing the rotary knives

1. Remove the four bolts (1) from the knife
shaft flange.
Remove the four bolts.
110
2. Remove the four Allen bolts (1).

3. Remove the bearing cap (2) (= bearing cup).
4. Support the rotor front by hand to extract
and remove the rotary knife shaft on the
gearbox side using a crowbar.
Take care not to damage the gearbox.
Remove the Allen bolts.
(2) Bearing cup
Important note!
Make sure to pair up each bearing cup (2) with its bearing retainer. Never swap bearing
cups between row units.
111
5. Vertically position the rotary knife shaft in a

vise. Where possible, use the nut (1) as a
clamping surface.
6. Remove the nut (2).
7. Remove the bearing.
8. Remove and replace the affected rotary
knives. Replace any damaged spacers (4).
Important note!
Note the correct mounting direction for the angular-contact ball bearing.
We recommend replacing the complete seal kit (3) including the bearing.
9. Re-install the bearing. Ensure the angular-

contact ball bearing is mounted with its open
side facing the nut (2) as shown in the
opposite picture.
10. Tighten the top nut (2) to 150Nm.
11. In case the rear rotary knives are also to be
replaced, make sure to check the bottom nut
(1) pre-load (180Nm).
Mount the bearing with its open side facing the nut.
112
Installing the rotary knife shaft

1. Clean and apply a thin layer of grease to the
flange surfaces.
2. Clean the front bearing housing.
3. Position the rotary knife shaft on the flange
and in the bearing housing.
4. Loosely install the front bearing cap.
5. Attach the rear flange using four bolts.
6. Install the front bearing cap.
7. Check the rotary knife shaft for smooth
running. If the rotor interferes with the
knives, loosen the relevant hardware and
move the rotor until it runs smoothly.
8. Immediately grease the bearing.
113
5.18. Checking or replacing the rotor knives
DANGER
The rotor knives may require replacement due to normal wear. The self-sharpening cutting edges
are carbide-coated and must not be reground.
Important note!
Frequently re-adjusting the rotor knives reduces the header's power requirements and
Replacing the rotor knives

Whenever possible, replace all three rotor
knives at the same time.
1. Remove the bolts (1) and the knife (2).
2. Carefully clean the contact faces. The
contact face should be perfectly smooth.
3. Install the new knives and tighten the bolts
(see torque chart in the Appendix).
Whenever possible, replace all three rotor knives at the same

time.
Important note!
Use M8x14, grade 8.8 bolts with serrated lock washers. If longer bolts are used the rotor can
wrap with material.
4. Then install the stalk cutters, also see

"Adjusting the stalk cutters".
114
5.19. Removing the rotors
DANGER
Removal of the large and small rotors is

identical.
1. Loosen the three bolts (1) and remove the
skid.
2. Remove the stalk cutter (2).
3. Remove the rotary knife shaft (see
"Replacing the front rotary knives").
4. Remove the scraper (large rotor only).
5. Remove the bolt (3) from the fixing bracket.
6. Use a suitable tool to push the rotor shaft
toward the gearbox side and pull it straight Loosen the skid and the fixing bracket.
out. Take care not to damage the gearbox
housing.
115
Removing/replacing the rotor

bearing
7. Remove the Allen bolt (1) from the bore (2).
8. Turn the bearing support (3) until another
Allen bolt (2) becomes visible in the bearing
housing bore. Loosen the Allen bolt by two
revolutions, do not unscrew completely.
9. Turn the bearing support by 180 degrees
until the hole becomes visible. Insert the
punch and block the internal nut.
10. Turn the bearing support counter-clockwise Removed rotor shaft.
(right-handed thread) until the nut is free.
Use suitable tools to drive the bearing
support out of the bearing. The bearing
support ring (4) should remain installed on
the bearing support shaft.
Removing the bearing

11. Remove the circlip (5).
12. Remove the sealing ring (6).
Important note!
Use the special tool (see relevant section in the manual).
13. Use special tools to extract the angular ball

bearing (7).
14. Remove the rotor bearing nut (8) (note the
mounting direction).
15. Remove the second circlip (9).
16. Extract the grooved ball bearing (10).
17. Remove the cover (11).
18. Replace any damaged parts.
19. To re-assemble, follow the disassembly
instructions in reverse order. Ensure that the
bearing support ring is present and
undamaged.
116
Important note!
Grease the rotor splines prior to re-assembly.
Install the sealing ring (6) with the groove towards the outside.
Ensure that the right-hand and left-hand rotors are installed correctly (when installed
the auger should guide the crop toward the gearbox).
20. Use a mandrel to fasten the rotor bearing

nut (8) to the bearing support and turn the
bearing support clockwise until the nut is
tightened. Use a suitable tool to increase the
tightening torque to 90+10Nm. For the
remaining re-assembly, follow the
disassembly procedure in reverse order.
21. When re-assembling the rotors ensure that

the counter-edges are installed as shown.
22. Fit the small rotor onto the shaft so the
rotor counter-edge is just centered between
the counter-edges of the large rotors and
the rotor head auger flights mesh smoothly.
23. Install the front bearing support assembly
without pre-loading. Insert shims as
necessary.
The small-rotor counter-edge is centered between the large-

rotor counter-edges.
24. When no tension is applied the front bearing

support bolt hole (3) should be precisely
aligned with the hole in the fixing bracket.
If the bolt holes are not parallel the tension-
free installation of the rotor bearing is no
longer possible (refer to the section
"Checking the row unit frame").
117
5.20. Using special tools

Use the disassembly tool to remove the front bearing from the rotor.
Installing the tool

1. Screw the hex nut (5) onto the hex bolt (6).
2. Install the washer (4) to the hex bolt (6).
3. Apply medium-strength Loctite to the hex
nut and hex bolt threads.
4. Use the extension nut (2) to securely tighten
the hex nut (1) and the hex bolt (6).
Disassembly tool.
Removing the bearing

1. Install the puller (1) to the ball bearing.
2. Put the puller sleeve (7) over the rotor auger
head.
3. Install the grooved plate (3).
4. Secure the hex bolt against turning.
5. Pull off the ball bearing using the hex nut.
118
5.21. Checking the Centaflex couplings (without connecting

shaft)
1. Regularly check the damper (1) and the

drive dogs (2) on the Centaflex coupling.
2. Replace any worn parts in good time.
3. Always ensure that the damper has 1mm
(.04") axial play between the hubs (3).
4. Apply a thread lock compound to the Allen
bolt (4) and tighten to 140Nm.
Centaflex coupling.
5.22. Checking the Centaflex couplings (with connecting shaft)
1. Regularly check the dampers (1) and the

drive dogs (2) on the Centaflex coupling.
2. Replace any worn parts in good time.
3. Ensure that the connecting shaft (3) has an
axial clearance of 2mm (.08").
4. Apply a thread lock compound to the Allen
bolt (5) and tighten to 140Nm.
Centaflex coupling.
119
5.23. Checking the deck plate speed sensor and slide resistor
DANGER
Never reach into the snapping rolls.
Checking the speed

The speed sensor (opposite picture) is
located between two row units on the
Centaflex coupling drive dog.
Ensure that the sensor gap to the signal
transducer and/or the dog is 23mm (.91").
Speed sensor underneath the header.
Checking the slide resistor

Regularly clean the slide resistor (1) and the
slide (2).
The diode display can be individually adjusted:
by axially adjusting the spindle (3)
by changing the position of the slide resistor
Regularly check all electrical supply lines.
Regularly clean the slide resistor and the slide.
120
5.24. Lubrication and maintenance
DANGER
To prevent damage caused by water ingress, ensure that all hydraulic
connectors, multi-couplers and electrical connectors are connected or tightly
capped prior to cleaning.
1. Lubricate all moving parts at standard

intervals. See the Lubrication Chart.
2. Regularly clean the header and remove crop
residue.
3. After the harvest apply an anti-corrosive coat
to all shiny metal parts.
Lubricants:
Gearbox: SAE 90 API-GL-4.
Hydraulics: HLP 46.
Grease fittings: KP2 anti-friction bearing
grease.
Important note!
In difficult conditions make sure to adapt the maintenance intervals specified in the
Lubrication Chart as necessary.
121
5.25. Lubrication chart

Lubricate every ten operating hours:
All rotor bearings.
Three grease fittings per row

unit.
122
Lubricate every 25 operating hours:
Transmission shafts.
After cleaning and greasing, ensure that the

unit runs smoothly.
123
Lubricate 50 hours after commissioning and subsequently before each

harvest or every 500 hours:
Crown wheel gearbox, angular

gearbox, manual speed selector.
Also applies to the manual speed

selector (option, not shown).
Refer to the respective section(s)

in this operating manual.
All row unit gearboxes.

124
All deck plate adjustment units.
Transmission shafts.
See separate transmission shaft

operating manual.
125
Chain.

Top picture: Model with eight or more rows.

Bottom picture: Model with six or less rows.
126
Transmission shaft(s).
One grease fitting per

transmission shaft.
127
Transverse auger slip clutch

(behind sprocket).

One grease fitting.
Top picture: Model with eight or more rows.

Bottom picture: Model with six or less rows.
128
5.26. Gearbox maintenance advice

Change the gearbox oil at the specified intervals. Frequently check the gearbox oil levels in between
oil changes.
DANGER
Gearbox and oil may be very hot and can cause burns.
Ensure that consumables, auxiliary materials and machine components are disposed of
in a proper and environmentally friendly manner. Adhere to all regulations and any
environmental or disposal standards applicable in your country.
Also observe all other environmentally related instructions in this operating manual.
Important note!
After loosening a bolt always replace the pertinent seal by a new seal.
Note the tightening torques specified in each chapter.
Frequently check the oil levels in between oil changes.
During gearbox maintenance the combine should be abolutely level.
Suggestion:
Warm the oil to operating temperature before the change.
Jammed bolts, plugs or dipsticks can be released by means of hammer blows to
facilitate removal. Proceed calmly and use suitable tools (e.g. a hammer and a drift).
129
5.27. Maintaining the crown wheel gearbox
DANGER
Follow the instructions in the section on maintaining the gearbox.
Important note!
Depending on the header model the crown wheel gear is located on the right-hand or
left-hand side or on both sides of the header.
The crown wheel gearbox oil capacity varies depending on the number of gear teeth
(z). Check the number of teeth information on the gearbox type plate or on the housing
surface (1).
See the Lubrication Chart for oil change

intervals.
Oil specification: SAE 90 API GL-4 (or higher)
Capacity:
z = 32 or 34: 2.0l.
z = 37 to 64: 1.6l.
1. Raise the header.

2. Engage the combine safety stop.
3. Turn off the combine engine. Prevent
unintentional starting. Right-hand crown wheel gearbox. Number of teeth, z (1).
Left-hand crown wheel gearbox. Number of teeth, z (1).
130
Changing the oil

4. Drain and collect the gearbox oil. To do this,
unscrew the drain plug (3). Clean the drain
plug magnet.
5. Unscrew the fill plug (4) (17mm (.67")
wrench size). (Do not unscrew the breather
(12mm (.47") wrench size).)
6. Replace the sealing rings by new ones.
7. Screw in the drain plug (3) and tighten to
the specified torque.
8. Fill the gearbox with new oil. Capacity: Right-hand crown wheel gearbox. Drain plug (3), fill plug (4),
z (1) = 32 or 34: 2.0l. number of teeth (z) (1).
z (1) = 37 to 64: 1.6l.

9. Screw in the fill plug (4) and tighten to the
specified torque.
Tightening torques
Drain plug (3):
50Nm (37lbf ft).
Fill plug (4)
(17mm (.67") wrench size):
50Nm (37lbf ft).
Left-hand crown wheel gearbox. Drain plug (3), fill plug (4),
number of teeth (z) (1).
131
Checking the oil level

4. Unscrew the check plug (2) (bottom plug).
5. The oil level should reach the bottom edge
of the hole (2). Correct the oil level as
necessary. To do this, unscrew the fill plug
(4) (17mm (.67") wrench size). (Do not
unscrew the breather (12mm (.47") wrench
size).)
7. Screw in the check plug (2) and, if removed,
the fill plug (4) and tighten to the specified Right-hand crown wheel gearbox. Check plug (2), fill plug (4).
torque.
Tightening torques
Check plug (2):
20-25Nm (15-18lbf ft).
Fill plug (4)
50Nm (37lbf ft).
Left-hand crown wheel gearbox. Check plug (2), fill plug (4).
Note:
The breather is located in the fill plug (4) and requires a 12mm (.47") wrench. If the
breather has been replaced (not part of the scheduled maintenance routine):
The specified torque is 15Nm (11lbf ft).
132
5.28. Maintaining the manual speed selector (optional two-

speed or four-speed)
DANGER
Important note!
As an option, the header may be fitted with one or more manual speed selector(s).
Depending on the header model the manual speed selector is located on the right-hand
or left-hand side or on both sides of the header.

intervals.
Oil specification: SAE 90 API GL-4 (or
higher).
Capacity: 1.5 l.

unintentional starting.
133
Changing the oil

plug magnet.
6. Replace the seals by new seals.
8. Fill the gearbox with new oil. Capacity: 1.5 l. Right-hand header side. Drain plug (2), fill plug (3).
specified torque.
Tightening torques
Drain plug (2):
30Nm (22lbf ft).
Fill plug (3)
30Nm (22lbf ft).
Left-hand header side. Drain plug (2), fill plug (3).
134

4. Unscrew the check plug (1).
size).)
the fill plug (3) and tighten to the specified Right-hand header side. Check plug (1), fill plug (3).
torque.
Tightening torques
Check plug (1):
20-25Nm (15-18lbf ft).
Fill plug (3)
30Nm (22lbf ft).
Left-hand header side. Check plug (1), fill plug (3).
Note:
135
5.29. Maintaining the angular gearbox
DANGER
Important note!
Depending on the header model the angular gearbox is located on the right-hand or
left-hand side or on both sides of the header.

intervals.
Oil specification: SAE 90 API GL-4 (or
higher).
Capacity: 1.5 l.

136
Changing the oil

plug magnet.
8. Fill the gearbox with new oil. Capacity: 1.5 l. Right-hand angular gearbox. Drain plug (2), fill plug (3).
specified torque.
Tightening torques
Drain plug (2):
50Nm (37lbf ft).
Fill plug (3)
50Nm (37lbf ft).
Left-hand angular gearbox. Drain plug (2), fill plug (3).
137

4. Unscrew the check plug (1).
size).)
the fill plug (3) and tighten to the specified Right-hand angular gearbox. Check plug (1), fill plug (3).
torque.
Tightening torques
Check plug (1):
30Nm (22lbf ft).
Fill plug (3)
50Nm (37lbf ft).
Left-hand angular gearbox. Check plug (1)., Fill plug (3).
Note:
138
5.30. Maintaining the row unit gearbox (RD)
DANGER

intervals.
Oil specification: SAE 90 API GL-4 (or higher)
Capacity: 1.5l.

Changing the oil

plug magnet.
5. Unscrew the dipstick (1). (Jammed nuts or
bolts can be released by means of hammer
blows.)
8. Fill the gearbox with new oil. Capacity: 1.5l. Drain plug (2), dipstick (1).
9. Screw in the dipstick (1) and tighten to the
specified torque.
Tightening torques
Dipstick (1):
50Nm (37lbf ft)
Drain plug (2):
35Nm (22lbf ft)
139

4. Unscrew the dipstick (1). (Jammed nuts or
bolts can be released by means of hammer
blows.)
5. Replace the sealing ring by a new one.
6. Put the dipstick (1) into the gearbox housing
(do not screw in). Pull the dipstick back out.
The oil level should reach the bottom
dipstick mark. Correct the oil level as
necessary.
7. Screw in the dipstick (1) and tighten to the Dipstick (1).
specified torque.
Tightening torque
Dipstick (1):
50Nm (37lbf ft)
Note:
If the breather (3) has been replaced
(not part of the scheduled maintenance
routine):
The specified torque is

15Nm (11lbf ft).
Breather (3).
140
Malfunctions and troubleshooting
6. Malfunctions and troubleshooting
6.1. Fault assistance

Hydraulics
Fault Cause Remedy Page
Header cannot be raised Insufficient hydraulic oil Add oil Combine manual
quantity
Insufficient lifting force Additional lifting cylinder Combine manual

required
Hydraulic header No flow through the Check connections/ see pages from 24
functions do not work hydraulic connections couplings/bolt joints
Option: Control valve Check control valve see pages from 34

does not work
Poor hydraulic oil quantity Add oil Combine manual
Header control valve Multi-coupler incorrectly Check multi-couplers and see pages from 34
(option) does not work connected electrical connections
Drive system
Drive system is engaged, Transmission shaft Check the transmission see page 57
header does not rotate. shaft
Header locks up during Insufficient V-belt tension Check the drive system Combine manual
harvest
Overload Forward speed Combine manual
141
Row unit
Header locks up during Sluggish drive Stalk cutter knife gap too see page 107
harvest wide
Blunt stalk cutter edge Replace the parts see page 107
Forward speed too high Adjust Combine manual
Poor combine drive belt Tension or replace belt Combine manual

tension
Rotors wrap with material Scraper Adjust the scrapers see page 107
Rotor knife bolts too long Use original bolts see page 108
Rotary knives worn Replace rotary knives see page 108
Row unit slip clutch opens Foreign material Remove foreign material, see page 114
check condition of the
rotors and rotary knives
Overload Reduce forward speed or Combine manual

raise RPM
Too much straw Deck plates Open the deck plates as see page 109
widely as possible
Forward speed Adapt the forward speed Combine manual

to the conditions
Obstruction inside the row Deck plates not parallel Adjust the deck plates see page 104
unit
Gathering chains slipping Replace the chains see page 100
Foreign material inside or Remove foreign material see page 100

underneath the row unit and stuck corn straw see page 100
RPM too low Check the terminal see page 100
Picking gap end plate. Plate missing or gap too see page 96
large
Cob loss RPM too high Reduce as necessary see page 147
see page 147
Cob catcher skirt Missing or broken see page 147
Cob catcher Retrofit as necessary see page 106
Forward speed Increase significantly Combine manual
Row spacing Adapt the header to the

conditions
142
Kernel loss Deck plates Use a narrower gap see page 85
RPM Reduce as necessary see page 70
Feeder house chain expels Lower the cover above see page 70
material the transverse auger
Forward speed Raise until the header fills Combine manual

with crop
Corn stalks too long Working height Lower the header and Combine manual
retrofit a float system, if
necessary
Stalk cutter worn or blunt Replace parts as see page 70

necessary
RPM too low Check RPM see page 70
Divider tips Set the tips to a flatter see page 61

angle and move the
header closer to the
ground
Row spacing Incorrect
Forward speed Slow down Combine manual
Deck plates plug up Dirt or contamination Clean the mechanism, see page 82
open and close the plates
several times a day
Hydraulic supply line Check see page 78
Standard setting Check see page 62
Lateral dividers plugged Lateral extension impedes Remove the extension see page 121
with crop material material flow and install the side augers
Divider tips plugged with Cob catchers restrict crop Remove the cob catchers see page 24
crop material flow from the center hoods
Cob catcher skirts restrict Remove the cob catcher see page 72
the crop flow skirt
143
Transverse auger
Transverse auger stops Overload condition Reduce crop volume, too Combine manual
much straw
Slip clutch opens Remove the foreign see page 89

object.
Drive system Check the chain and the see page 89

coupling
Half-auger does not Dog coupling Check adjustment and see page 91
rotate meshing, check the
function of the axially
spring-loaded half-
coupling (lubrication)
Auger expels corn cobs RPM Check header speed and see page 147
reduce as necessary
Conveying element Check position and/or see page 79

positions remove
Crop volume too low Increase feed rate
Poor transverse auger Transverse auger blocked Raise transverse auger see page 89
performance
144
Appendix
7. Appendix
145
Appendix
7.1. Bolt tightening torques
Important note
Use appropriate tools to achieve the specified bolt torque values.
This table applies to solid bolts.
Dimension Torque rating (Nm)
Grade 8.8 Grade 10.9 Grade 12.9
M4 2.7 3.8 4.6
M5 5.4 7.6 9.1
M6 9.2 13.0 15.5
M8 22.0 31.0 37.5
M8 x 1 24.0 33.5 40.0
M10 43.5 61.0 73.5
M10 x 1.25 46.0 65.0 77.5
M10 x 1 50.0 70.0 84.0
M12 76.0 106.0 127.0
M12 x 1.5 79.0 111.0 133.0
M12 x 1.25 82.5 116.0 139.0
M14 120.0 168.5 202.0
M14 x 1.5 130.0 183.0 219.0
M16 187.0 262.0 314.0
M16 x 1.5 198.0 278.0 333.0
M18 257.5 362.0 433.0
M18 x 2 272.0 382.0 457.5
M18 x 1.5 287.0 403.0 483.0
M20 362.5 509.0 610.0
M20 x 2 381.0 535.0 641.0
M20 x 1.5 400.0 562.0 673.0
146
Appendix
7.2. Specifications
Specifications Rota Disc, non-folding
Electronic speed display Standard feature
Rated speed 720-750rpm

(w/o optional manual speed
selector)
Manual speed selector Option
Hydraulic deck plate adjustment Standard feature
Sunflower harvesting device Option
Down corn augers Option
Picking system Two snapping rolls and one straw

chopper rotor
Straw chopper 15 actively-driven, rotating knives
Straw chopper working width Approx. 5500mm (216.54") per

row unit
Stalk cutter Active radial cutter above the

snapping rolls
Body (row unit hoods and divider Imbued, double-walled plastic

tips)
Hydraulic oil to DIN 51524-2 HLP 46
Hydraulic oil purity to ISO 4406 18/16/13
147
Appendix
Type No. of rows Row width Transport width Weight
cm / inch mm ft kg (approx.) lbs (approx.)
RD 470 4 70cm 3109 10.20 1300 2860
RD 475 4 75cm 3150 10.33 1310 2882
RD 430 4 30" 3186 10.45 1320 2904
RD 480 4 80cm 3250 10.66 1330 2926
RD 436 4 36" 3754 12.32 1440 3168
RD 438 4 38" 3795 12.45 1470 3234
RD 440 4 40" 3897 12.79 1500 3300
RD 570 5 70cm 3759 12.33 1500 3300
RD 575 5 75cm 3900 12.80 1550 3410
RD 580 5 80cm 4100 13.45 1600 3520
RD 670 6 70cm 4400 14.44 1800 3960
RD 675 6 75cm 4692 15.39 1850 4070
RD 630 6 30" 4710 15.45 1850 4070
RD 680 6 80cm 4900 16.08 1900 4180
RD 636 6 36" 5475 17.96 1980 4356
RD 638 6 38" 5785 18.98 2030 4466
RD 640 6 40" 6039 19.81 2080 4576
RD 820 B 8 20" 4470 14.67 2220 4884
RD 822 B 8 22" 4813 15.79 2255 4961
RD 870 B 8 70cm 5800 19.03 2375 5225
RD 875 B 8 75cm 6209 20.37 2450 5390
RD 830 B 8 30" 6227 20.43 2450 5390
RD 880 B 8 80cm 6500 21.33 2525 5555
RD 836 B 8 36" 7305 23.97 2680 5896
RD 838 B 8 38" 7655 25.11 2730 6006
RD 840 B 8 40" 8012 26.29 2780 6116
Continued on the next page
148
Appendix
Continued from the previous page
Type No. of rows Row width Transport width Weight
cm / inch mm ft kg (approx.) lbs (approx.)
RD 920 B 9 20" 4980 16.34 2400 5280
RD 922 B 9 22" 5372 17.62 2500 5500
RD 970 B 9 70cm 6500 21.33 2780 6116
RD 975 B 9 75cm 6900 22.64 2830 6226
RD 930 B 9 30" 6996 22.95 2830 6226
RD 1220 B 12 20" 6510 21.36 3320 7304
RD 1222 B 12 22" 7049 23.13 3420 7524
RD 1270 B 12 70cm 8600 28.22 3710 8162
RD 1275 B 12 75cm 9250 30.35 3770 8294
RD 1230 B 12 30" 9282 30.45 3770 8294
RD 1620 B 16 20" 8550 28.05 4210 9262
RD 1622 B 16 22" 9285 30.46 4375 9625
RD 1630 B 16 30" 12330 40.45 4635 10197
RD 1820 B 18 20" 9570 31.40 4730 10406
RD 1822 B 18 22" 10403 34.13 4950 10890

Subject to change.
149
Appendix
150
Appendix
EC declaration of conformity
according to the EC machinery directive
2006/42/EC Annex II A and
EMC guidelines 2004/108/EC.
Hereby the manufacturer

Carl Geringhoff Produktions GmbH & Co. KG
Gersteinstrae 18
D59227 Ahlen
declares that the machines listed below comply with the basic safety and health
requirements of the EC guideline 2006/42/EC, concerning their design and build as well
as the version introduced by us. In case of a machine modification not authorised by us,
this declaration becomes null and void.
Rota Disc
RD 200, RD 300, RD 400, RD 500, RD 600, RD 600 F, RD 800 B, RD 800 FB, RD 900,
RD 900 FB, RD 1200 B, RD 1200 FB
series 110
Applied harmonised standards:

DIN EN ISO 12100:2011 (Safety of machines - general design guidelines -
risk assessment and risk reduction)
EN 60204-1 (Safety of machines - electrical equipment)
DIN EN 953 (Design and construction of fixed and movable protective devices/guards)
DIN EN 349 (Safety of machines, minimum spacing in order to avoid
crushing body parts)
DIN EN 632 (1995-08 agricultural machines, combine harvesters and
forage harvesters)
ISO 4413 (Fluid technology - design guidelines - hydraulics)
Applied national and technical specifications

VDI guideline 0113, safety of machines, displays, markings and operation -
Part 1: Requirements of visible, audible and tactile signals
(IEC 1310-1: 1995 and correction 1995) German version EN 61310-1: 1995
Person authorised to compile the technical documents:

Carl Geringhoff Vertriebsgesellschaft mbH & Co. KG, J. Kolter, Porschestr. 8, D-59227 Ahlen
Ahlen, 2015-2-3 Daniel Hansmeier

CEO
151

Geringhoff-Operating Manual Rota Disc Rigid

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Geringhoff-Operating Manual Rota Disc Rigid

Caricato da

Copyright:

Formati disponibili

Operating Manual

We highly appreciate your professional experience and know-how. All feedback

Important information on the operator manual

Symbols and instructions

Example figures and text

Safety-related information is essential for the safe and trouble-free operation of

Type plate position Type plate

Combine harvester type:

1.2. Pollution control information

2.1. Intended use

Adhering to the intended use includes complying with the manufacturer's

2.2. Basic safety instructions

2.3. General accident prevention regulations

Safety helmet and

Respirator Ear protection

1. Always keep a First Aid kit within reach.

2.4. Header hazard symbol locations and descriptions

Stop the engine and remove the key before 1.

Never stand between the header and the 2.

Never open or remove protective devices or 3.

Keep a safe distance from the header. Disengage 4.

Engage the safety stop before entering the hazard 5.

Keep hands clear of the rotating auger. 6.

Stay clear of rotating components. 7.

Stand clear of moving equipment. 8.

Keep a safe distance to the cutter bar when the 9.

Beware of flying objects while the engine is 10.

Do not open or remove protective devices or 11.

Header decal locations

Two front decal locations (6).

One rear decal location (6).

2.5. Hydraulic safety instructions

Fluids escaping under high pressure (e.g.,

3.1. Hydraulics - Fluid cleanliness and oil specification

Some work may involve a high risk of fluid contamination, including:

3.2. Preparing and hooking up the header

Depending on type and model, the header

A detailed, type-specific packing list is supplied

Stands in transport position. Example of stands in mounted position.

5. Attach the lifting device to the header lifting

7. First remove the two top M16 bolts (2) from

Remove top and bottom bolts (example)

Preparing for hook-up

3.3. Connecting the hook-up adapter (John Deere)

The main crop elevator locking device is

Lock pin holder.

2. Slightly raise the header until the safety stop

3. Engage the safety stop.

Engage the safety stop.

4. Connect the multi-coupler. The pins will lock.

Ensure the pins engage correctly.

3.4. Connecting the hydraulic multi-coupler (John Deere)

Upon delivery, the multi-coupler connector is

Multi-coupler attached to the header.

1. Remove the multi-coupler connector from its

Remove the multi-coupler.

3. Connect the multi-coupler to the combine

Connect and lock the lever.

3.5. Adjusting the combine feeder house

Remove the angled guide plates (1).

Remove the angled guide plates.

3.6. Connecting the hook-up adapter (Case AF models)

1. Loosen the bolts (1) at the main crop