Case IH TerraFlex 3020 Auger Header OEM Service & Repair Manual

Part number 47627573 2 nd edition English October 2013 Replaces part number 84405004 SERVICE MANUAL TerraFlex ™ 3020 Auger Header

Contents INTRODUCTION Main gearbox and drive ............................................................... 14 [14.100] Main gearbox and drive ............................................................ 14.1 Clutch ....................................................................................... 18 [18.112] Slip clutch or ﬂywheel damper ..................................................... 18.1 Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems .................................................................. 35.1 [35.420] Reel vertical positioning system.................................................... 35.2 [35.430] Reel fore-and-aft positioning system ............................................... 35.3 Electrical systems ....................................................................... 55 [55.000] Electrical system ................................................................... 55.1 [55.036] Hydraulic system control ........................................................... 55.2 [55.100] Harnesses and connectors ......................................................... 55.3 [55.404] External lighting .................................................................... 55.4 [55.421] Feeding control system ............................................................ 55.5 [55.661] Cab header controls................................................................ 55.6 [55.675] Reel speed and position control.................................................... 55.7 Attachments/Headers .................................................................. 58 [58.101] Attachment/Header reel ............................................................ 58.1 [58.105] Attachment/Header reel control system ............................................ 58.2 [58.110] Attachment/Header cutting mechanism ............................................ 58.3 [58.120] Attachment/Header feed auger .................................................... 58.4 [58.130] Attachment/Header frame .......................................................... 58.5 Platform, cab, bodywork, and decals ............................................. 90 [90.105] Machine shields and guards ....................................................... 90.1 [90.108] Decals and plates .................................................................. 90.2 47627573 27/10/2013

[90.116] Fenders and guards ................................................................ 90.3 47627573 27/10/2013

47627573 27/10/2013

INTRODUCTION 47627573 27/10/2013 1

Contents INTRODUCTION Basic instructions - Important notice regarding equipment servicing ........................... 3 Personal safety ................................................................................. 4 Safety rules - Ecology and the environment .................................................... 7 Safety rules ..................................................................................... 8 Safety rules - Precautionary statements ........................................................ 9 Safety signs - Single drive .................................................................... 12 Safety signs - Double drive ................................................................... 20 Personal safety ............................................................................... 28 Basic instructions - Shop and assembly ...................................................... 29 Torque - Minimum tightening torques for normal assembly ................................... 31 Torque - Standard torque data for hydraulics ................................................. 36 Basic instructions - Chain Wear Tables - Roller Chains ...................................... 38 General specification - General Welding ..................................................... 40 General specification - Machine specifications ............................................... 41 Product identification .......................................................................... 44 Frame - Product identification ................................................................ 45 3020, 3000 Series Grain Header 47627573 27/10/2013 2

INTRODUCTION Basic instructions - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualiﬁed dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer. The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modiﬁcations of a technical or commercial type, or changes to the laws and regulations of different countries. In case of questions, refer to your CASE IH Sales and Service Networks. 47627573 27/10/2013 3

INTRODUCTION Personal safety Your machine may be equipped with special guarding or other devices in compliance with local legislation. Some of these require active use by the operator. Therefore, check local legislation on the usage of this machine. Hydraulic system safety • Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: • Relieve all pressure before disconnecting fluid lines. • Before applying pressure, make sure all connections are tight and components are in good condition. • Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. • If injured by leaking fluid, seek medical attention immediately. • The hydraulic hoses and fittings on your machine meet engineering specifications for the particular function. When replacing damaged, blown or worn hoses or fittings, use only manufacture authorized service parts. • Care in hydraulic hose installation is a must: • Make sure pressure is relieved before starting installation procedure. • DO NOT kink or twist a hose, failure may occur. • Properly route the hose. • Have a certified hydraulic technician install the hose. • Remove air from the hydraulic system after installing any hydraulic component. • Periodically check hydraulic system for leaks or damage. check for: • Leaks at hose fitting or in hose. • Damaged hoses and/or fittings. • Kinked, crushed, flattened, hard blistered, heat cracked, charred, twisted, soft or loose covered hoses. • Corroded or damaged fittings. • Leaking ports. • Excessive dirt and debris around hoses and/or fittings. • Damaged or missing hose retaining clamps, guards, shields, etc. • DO NOT stand on or use a hose as a step. DO NOT pull or apply external forces to the hose. The hose may fail and cause injury. • Keep all persons away from the working area. Mechanisms controlled by fluid power can become hazardous if a hose fails. Lifted mechanisms can fall to the ground, machine steering may fail, etc. • Stay clear of a pressurized hose assembly that has blown apart. Hose fittings can be thrown off at high speed and a loose hose can whip around with great force. • Hydraulic fluid can reach high temperatures. Allow fluid to cool before servicing the system. • Escaping fluid under pressure may form a mist or fine spray which can flash or explode upon contact with an ignition source. • Vibration can reduce hose service life. Make sure all retaining clamps and/or devices are secured. • Environmental conditions can cause hose and fittings to deteriorate. Inspect hydraulic hoses periodically. Replace worn or damaged hoses and fittings. Safety requirements for fluid power systems and components - hydraulics (EUROPEAN STANDARD PR EN 982) • Flexible hose assemblies must not be constructed from hoses which have been previously used as part of a hose assembly. 47627573 27/10/2013 4

INTRODUCTION • Do not weld hydraulic piping. • When flexible hoses or piping are damaged, replace them immediately. • It is forbidden to modify a hydraulic accumulator by machining, welding or any other means. • Before removing hydraulic accumulators for servicing, the liquid pressure in the accumulator must be reduced to zero. • Pressure check on hydraulic accumulators shall be carried out by method recommended by the accumulator manufacturer. • Care must be taken not to exceed the maximum allowable pressure of the accumulator. After any check of adjustment there must be no leakage of gas. Safety precautions Farm accidents can be prevented with your help. No accident prevention program can be successful without the wholehearted cooperation of the person who is directly responsible for the operation of the equipment. To read accident reports from all over the country is to be convinced that a large number of accidents can be prevented only by the operator anticipating the result before the accident is caused and doing something about it. It is said that "The best kind of safety device is a careful operator who with care and mature consideration can save more lives and limbs than any accident prevention program which is not adhered to". Further in this chapter you will find a list of the most important safety precautions. Take time to read and follow the instructions and furthermore, be careful! Some pictures in this manual may show the safety guarding open or removed to better illustrate a particular feature or adjustment. Ensure to close or replace all guards before operating the machine. General and operating safety Most farm machinery accidents can be avoided by the observance of a few simple safety precautions. • The machine must only be used by a skilled operator familiar with all the controls and harvesting techniques on cultivated land with slopes up to maximum 26 % ( 15 °) uphill and downhill. • Keep children away from and off the machine at all times. • When driving on public roads, observe traffic regulations, adapt your speed to road and traffic conditions and ensure that all lights and other safety mechanisms on the machine (if they are required) are fitted and work properly. • Before operating the machine ensure that all safety guards are installed. • Do not enter the grain tank while the machine engine is running. With engine stopped, use a wooden clearing club should the grain tank unloading auger become bridged. Take utmost care not to be pulled into the grain tank in case unbridging is required. • Do not attempt to clean, lubricate or carry out any adjustments on the machine while it is in motion or while the engine is running. • Never leave the operator's platform without first disengaging the machine drive mechanism, lowering the header, stopping the engine, applying the park brake and removing the ignition key. • Do not work under the machine header unless it is securely blocked and/or the header safety latch is engaged. • Do not work around the machine in loose clothing that might catch in any of the moving parts. • Keep hands away from moving parts of the machine. • Keep the fire extinguisher within easy reach of the operator. Ensure to replace it by a similar type of extinguisher or have it checked or refilled after every usage and/or date of expiry. 47627573 27/10/2013 5

INTRODUCTION Danger of death by electrocution! Pay special attention to the overhead power lines. Make sure the machine has sufficient clearance to pass in all directions (also with raised or opened machine components). Also think of the radio aerial(s) or any other factory- fitted accessory or parts which may have been added afterwards. Should a contact between the machine and an electric power line occur, then the following precautions must be taken: Stop the machine movement immediately, stop the engine and apply the hand brake. Check if you can safely leave the cab or your actual position without direct contact with electric wires. If not, stay in your position and call for help. If you can leave your position without touching the lines, jump off the last step or support position to ensure that there is no contact between any part of your body and the ground at any time. Do not touch the machine afterwards until power to the lines has been shut off. When people approach the machine, warn them not to touch the machine but to ask the electric power supply company to shut off the power to the lines. Fire and explosion prevention • Due to the flammable nature of the crop materials encountered, fire risks are high. This risk can be minimized by frequent removal of accumulated crop material from the machine and checking for overheated machine components. If oil leaks appear, re-torque bolts or replace gaskets as necessary. • Remove all trash or debris from the machine each day. Especially check the engine area and exhaust system. • Sparks or flame can cause the hydrogen gas in a battery to explode. To prevent an explosion do the following: • Do not weld, grind or smoke near a battery. • Sparks from the electrical system or engine exhaust can cause an explosion and fire. Before you operate this machine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust or vapors. • Use nonflammable cleaning solvent to clean parts. • A fire can cause death or injury. Always have fire extinguisher near or on the machine. Make sure the fire extin- guishers are serviced according to the manufacturers instructions. • If a fire extinguisher has been used, always recharge or replace the fire extinguisher before operating the machine. • Make sure that you DO NOT store oily rags or other flammable materials on the machine. • If the machine has an oil, fuel or hydraulic leak, always repair the leak and clean the area before operating. • Check the electrical system for loose connections or frayed insulation. Repair or replace the loose or damaged parts. • Before welding or using a torch on the machine, clean the area to be repaired. 47627573 27/10/2013 6

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Case IH TerraFlex 3020 Auger Header OEM Service & Repair Manual

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