812A COMBINE HEADER ADAPTER Operator Manual Includes operating, adjustment, maintenance, technical, repair parts, and safety instructions for the 812A Combine Header Adapter Attachment. Please retain this document for future reference. Keep this manual available for reference to the operator at all times. RCI Engineering LLC RC071429 Rev B 24Oct17 www.rciengineering.com Copyright 2017 by RCI Engineering LLC 0
RCI New Agricultural Attachments and Implements Warranty Statement RCI Engineering LLC, hereinafter referred to as RCI, warrants new RCI attachments and implements, to the Original Retail Purchaser to be free from defects in material and workmanship for a period of one (1) year from the date of sale. RCI warranty includes: Genuine RCI parts costs and labor required to repair or replace equipment at the selling dealer s business location. RCI MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT. RCI WARRANTY DOES NOT INCLUDE: 1. Transportation to the selling dealer s business location or, at the option of the Original Retail Purchaser, the cost of a service call. 2. Freight costs above standard shipping costs for the replacement parts. 3. Used equipment. 4. Components covered by their own non-rci warranties, such as tires and trade accessories. 5. Normal maintenance service and expendable, high-wear items. 6. Sacrificial components designed to fail to prevent damage to other components when obstructions are encountered (i.e. shear bolts, pickup teeth) 7. Repairs or adjustments caused by: improper use; non-intended use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty. 8. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment or damage to machines to which the attachment is installed. No agent, employee, or representative of RCI has any authority to bind RCI to any warranty except as specifically set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty; all other terms will continue to apply. 1
812A Combine Header Adapter Marketing Bulletin 12 October 2017 The 812A Combine Header Adapter is now available from RCI Engineering for the John Deere 8000-Series Self-Propelled Forage Harvesters. Intended Use: The 812A is intended to be used to adapt John Deere C-Series, 40-Series, and 90- Series corn headers. This adapter is intended for non-chopping and chopping headers of up to 12 rows in size. (12-Row Chopping Heads are approved for use with the heavy-duty drive on the SPFH starting in 2017.) Product Highlights: Mechanical Drive for reliable operation. Dual gearboxes are used to power the headers in demanding conditions. A cross drive shaft is standard equipment for dual drive headers. Feed roll allows for installation of replaceable paddles for long life. Extra plates and plastic filler pieces are standard equipment so each adapter can be used with both standard and wide forage harvesters. Filler plates provide for the lateral tilt of the forage harvester to operate normally. Jack stands allow for the adapter to be removed independently or retained on the corn head on a trailer for transport. No modifications of the corn head are needed for use on the forage harvester with the exception of older corn headers. Older corn headers need to be updated to use PTO driveshafts (Contour Master Style) to fit the adapter. Contact your John Deere dealer for more information. Adapter is compatible with the quick-attach system of the 8000-Series SPFH. Adapter is compatible with all tire configurations and spacings of the 8000-Series SPFH. 2
Ordering Information: RC071285 Adapter, 812A Combine Header* Order Through RCI * All product features are now standard equipment. Starting in 2016, this product includes parts for both standard and wide body machines and this product is shipped with Feed Roll Bars installed. Additional Deere parts are no longer needed, except if the quick-attach driveline option is used. For compatibility with the quick-attach driveline option on the SPFH, also order the following parts through John Deere parts: Deere Part Number Description Qty LCA113522 Bundle, Quick Attach Drive Coupler 1 F39010175 Ring, 1-3/4 External Snap 1 o Install all parts on the input shaft of the Adapter. See latest Operator Manual for 812A Adapter for more information. For this update bundle and for new machines, these parts are NOT included, and must be ordered separately through the Deere parts system. IMPORTANT All 8000-Series Forage Harvesters need to be ordered with the Feedroll Sealing Kit from John Deere. For machines ordered without this sealing kit, please contact DTAC. Also, all North American 8000-Series Forage Harvesters are equipped with grain pans. For 8000-Series Forage Harvesters in other markets, verify that grain pans are installed. Contact DTAC for more information. Starting in MY2016, all 8000-Series Forage Harvesters need to be ordered with the Heavy-Duty Header Drive option. The code for this is 8424. This option is also available to be retrofitted to MY2015 machines. Contact John Deere DTAC for more information. A recutter screen bundle is available from RCI for the 8000-Series Forage Harvesters to provide for improved cut quality, and is recommended for use with the 812A Combine Header Adapter. Contact RCI for more information. 3
Setup Time: Approximately 1 hour of setup time is required from shipping configuration to set up to attach to the combine header. Approximately 1/2 hour of time is required to install the header and adapter on the 8000-Series Forage Harvester. Warranty: Standard 1 (one) year warranty on all new units from date of sale. All parts, service and warranty matters are handled by RCI Engineering LLC. RCI Engineering LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously manufactured or sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice. Visit www.rciengineering.com for more product information, ordering, and pictures of this bundle. RCI Engineering LLC P: 920-387-9804 208 River Knoll Drive P: 888-472-4552 (Toll Free) Mayville, WI 53050 F: 920-387-9806 info@rciengineering.com www.rciengineering.com RCI Engineering LLC also offers an assortment of attachments for other John Deere hay and forage equipment to improve performance, increase efficiency and to increase machine capabilities in different crop and field conditions. 4
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Table of Contents Section Page Warranty Statement 1 Marketing Bulletin 2 Table of Contents 6 Pre-delivery Checklist 7 Delivery Checklist 8 Safe Operation of Machine 10 Safety Warning Signs 11 Safety Sign Locations 12 Setup Instructions 14 Adjustments 24 Maintenance 26 Service 27 Troubleshooting 30 Bolt Torque Values 31 Repair Parts 34 Pre-delivery Checklist (return copy) 62 Delivery Checklist (return copy) 64 Feedback for RCI 66 6
Pre-delivery Checklist (Copy for Return to RCI at back of this manual) After the unit has been assembled and lubricated and prior to delivery to customer, the adapter needs to be inspected thoroughly to ensure it is in proper working order. The following checklist must be reviewed and each item found to be satisfactorily completed. Adapter has been setup according to the instructions included in this manual. All grease fittings have been lubricated. All guards, shields and safety decals are in place, securely fastened, and operate correctly. All nuts and bolts have been tightened and inspected. Adjustments have been made as described in the Adjustments section of this manual Plastic insert centered on adapter at feed roll housing area, undamaged, and in working order. All moving parts operate freely. Spare shear bolts in place. Feed roll locked in the raised position and spring tension set properly. All applicable warranty information recorded. I acknowledge that the pre-delivery service was performed and the unit is ready for delivery to the customer. Dealership s Name Representative Date Model Number Serial Number Date Sold Owner s Name and Address Name Address City, State, Zip Original: Enclose in manual and give to customer at time of delivery. Copy: Dealership Copy: RCI Engineering LLC RCI Engineering LLC Fax: 920-387-9804 Email: info@rciengineering.com Mail: 208 River Knoll Drive, Mayville, WI 53050 7
Delivery Checklist (Copy for Return to RCI at back of this manual) The following items must be performed when delivering the attachment to the customer. Check off each item as it is performed. Provide the customer with the Operator's Manual and instruct them to read prior to operating the unit. Review and explain all safety information and operating adjustments. Review and explain maintenance and lubrication schedule that is required to ensure proper operation and long life. Show how to properly adjust the spring tension as instructed in the Adjustments section. Make it be known that if the customer can visit or call the dealership to discuss any questions or problems they may encounter. Complete the Owner s Registration with the customer, ensure it is completely filled out, and return it to RCI Engineering. Date Delivered Signature Original: Enclose in manual and give to customer at time of delivery. Copy: Dealership Copy: RCI Engineering LLC RCI Engineering LLC Fax: 920-387-9804 Email: info@rciengineering.com Mail: 208 River Knoll Drive, Mayville, WI 53050 8
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Safe Operation of Machine Operator Authorization The machine owner must provide the operator of the machine this manual and ensure that the operator reads and understands the contents. This must be performed before the machine is put into operation. Safety Alert Symbol This safety alert symbol is used to alert the operator to the potential for personal injury. Whenever this symbol is noticed in this manual or on the machine, be alert to the situation and read the message near the symbol shown in graphical format. Always be alert for the potential for personal injury. General Safety Precautions / Accident Prevention Before operation of the machine each time, check the entire machine for operational safety. 1. BEFORE unclogging, removing material, cleaning, adjusting, servicing, or lubricating, the operator must: a. Disengage harvester, put the machine in park, shut off the engine, and remove the key from the ignition. b. Wait until all parts have stopped moving. 2. The warning and safety decals on the attachment provide important information to ensure safe operation of the machine. Follow these instructions at all times to remain safe. Replace all such decals if they should become illegible or be missing. 3. Avoid loose fitting clothing while operating this implement. The operator should always wear close-fitting clothing and sturdy footwear. 4. Before operation of this attachment, become familiar with all controls of the harvester and attachment and understand the function of this implement. 5. Check all guards and shields to make sure they are in place and functional. Replace any defective or missing guards, shields, or components before operation. 6. To transport the unit on the road, follow all guidelines in the Operator Manual for the harvester. 7. Keep clear of the working and danger area of the machine. 8. Use proper personal protection for eyes, ears, and head to protect against projected objects and noise. 9. Do not modify the machine. Unauthorized modifications may affect the safety and longevity of the machine and voids warranty. 10
Safety Warning Signs The safety warning signs feature a hazard description panel without text. It is important to properly identify any hazards when working around the attachment. The signs have a black border and yellow background. Each decal has two boxes of information regarding the hazard. The top or left box of the decal indicates a warning for the hazard. The triangle indicates WARNING. The symbol inside the triangle indicates what the warning pertains to. In some cases, a simple explanation mark is used. The right or bottom box of the decal indicates an instruction on how to respond to the hazard. Reference each decal to the operator manual for further explanation of the meaning of the decal and respond accordingly. Note A feedback form is provided at the end of this manual. Please share any recommendations for improvements to this manual or to the product using this form. 11
Safety Sign Locations Decal locations are identified in the figures below and referenced on the following pages. Figure 1. Left Side Decals Figure 2. Right Side Decals (If equipped with RH Drive Bundle) 12
Safety Sign Definitions Safety Sign 1 This safety sign is a general warning sign instructing the operator to read the Operator's Manual for an explanation of safety signs applicable to the machine. The Operator's Manual is to be placed in the cab of the harvester when not in use. Figure 3. Safety Sign 1 Safety Sign 5 This safety sign is a warning of entanglement of moving parts. Keep all body parts away from moving parts. Failure to do so may result in serious injury. Figure 4. Safety Sign 2 13
Setup Instructions Convert from Shipping to Field Setup Starting with MY2017, each unit is shipped on a shipping stand that can be used for off-season storage of the unit. The unit may be wrapped with plastic for shipping, depending on shipping methods. The unit may be moved with a forklift from front, rear, or drive end. Fork pockets are provided for ease of handling. Units are shipped in the Wide-Body SPFH Configuration. The parts used for conversion for Standard-Body SPFH machines are mounted to the shipping stand. See Figure 5. Figure 5. Shipping Configuration Key 1 Shipping Stand Key 2 Adapter Key 3 Standard-Body Parts Storage Key 4 Fork Hole Locations To prepare for field use, first remove plastic wrap and other shipping material from the unit. Remove the LH PTO shaft guard from the storage location at the front of the unit. Install at the LH (Drive End) PTO hinge location using the mounting hardware provided. See Figure 6. Remove the RH PTO shaft guard from the rear of the unit. Install at the RH PTO location using the mounting hardware provided. If the unit will not be using the Quick Adapter for the driveline, remove the shield at the input shaft. The shield can be retained at one of the bolts for the Standard-Body Parts on the shipping stand. For more information regarding the Quick Adapter, refer to the Marketing Bulletin at the beginning of this manual. See Figure 7. Figure 6. LH PTO Shaft Guard Key 1 Guard Key 2 Hardware Key 3 Hinge Installation Location Figure 7. RH PTO Shaft Guard Key 1 Guard Key 2 Hardware Key 3 Hinge Installation Location 14
Standard Body Configuration Proceed with these instructions only if setting up the unit for use on a Standard- Body SPFH. Remove the Standard-Body components from the shipping stand. See Figure 8. Remove the filler plate and seal from the rear of the adapter. Retain hardware. Install the new filler plate and seal. Reuse existing hardware. Figure 8. Standard-Body Components Key 1 Storage Location Tighten all hardware properly. Ensure that the plastic sheet can slide freely within the slot when completed. See Figure 9. Center the plastic sheet on the frame of the unit. Install the Wide-Body components on the shipping stand where the parts were previously stored. Figure 9. Standard Body Component Installation Key 12 Floor, Throat (ref) Key 15 Plate, Filler Key 14 Seal Key 3 Bolt, 5/16 x 1 Hex Key 4 Washer, 5/16 Flat Key 1 - Washer, 5/16 Lock 15
Install Driveline Quick Adapter If a Quick Adapter is desired, order the following parts through the John Deere parts system. Part Number Description Qty LCA113522 Bundle, QA Drive 1 F39010175 Ring, 1-3/4 Snap 1 From the bundle, discard the guard and clamp. See John Deere parts catalog for breakdown of the bundle. See Figure 10. Figure 10. Quick Adapt Bundle Install the F3901017 Snap Ring on the input shaft of the adapter. Install the remainder of the bundle on the input shaft. Keep the RCI shield (yellow) on the adapter. Check for clearance to the Bundle and adjust as needed to prevent contact during rotation. Tighten all hardware properly. If the Quick Adapter is not desired, remove the shield over the input shaft. Reinstall hardware in the original holes for storage. Figure 11. Quick Adapt Shield Key 1 Quick Adapt Bundle Key 2 Shield Key 3 Hardware (qty 4) See Figure 11. Install the shield on the shipping stand using one of the bolts for the Narrow- Body Parts. See Figure 12. Figure 12. Storage Location Key 1 Bolt Hole Location 16
Feed Roll Stop Bolts For optimum feeding in most conditions, the feed roll is retained in a fixed position to allow for proper feeding of ears to the feedrolls. See Figure 13. This is achieved with a Stop Bolt at the end of the feed roll through the pivot arms of the top shaft. See Figure 14. Starting with MY2017, one bolt is used per side. Prior to this, only the RH end used a feed roll stop bolt. This was part of an update available for all units not equipped with this feature from the factory. Figure 13. Raised Feed Roll Key 1 Feed Roll Key 2 Gap It is important to keep the feed roll stop bolts in their position and the feed roll raised for most conditions. In extremely light conditions, or in drought conditions with small ears, the bolts may be removed to allow the feed roll to float. When the feed roll stop bolts are removed, it is important to remove the cover plates at the inside of the frame. These covers limit crop from escaping out the shaft slot in the frame. Figure 14. Stop Bolt Location (RH Side) Key 1 Top Shaft Key 2 Bolt Location Key 3 Feed roll shaft Key 4 Spring Key 5 Stop Key 6 Strap Key 7-Arm These plates are adjustable to allow adjustment to keep clear of the rotating shaft. See Figure 15. To remove the stop bolts and cover plates, use a ratchet strap to hold the feedrolls up to relieve pressure on the bolts. Use a wood block under the feed roll for safety. Remove the bolts and covers. Remove the wood block and lower the feed roll with the ratchet strap until the rubber stops of the pivot arms reaches the frame below. Figure 15. Cover Plate Adjustment Key 1 Plate Key 2 Clearance Key 3 Adjustment Bolts 17
Attach Adapter to SPFH To attach the adapter to the SPFH, first ensure that the adapter is set up on a flat, level and firm surface. Center the plastic seal and filler plate on the adapter so that it will fit into the feed roll housing of the forage harvester. See Figure 16. Check to ensure that all shields are installed and tightened properly. Align the SPFH with the adapter. Lower the feed roll housing and approach the adapter slowly. See Figure 17. Figure 16. Attachment Preparation Key 1 Center Plastic Seal The unit may remain in the shipping stand for loading and unloading on the machine. IMPORTANT Make sure there are no bystanders near the adapter during installation. Be careful to not push the adapter forward as it may become unstable on the stands. FAILURE TO DO SO MAY RESULT IN SEVERE INJURY. Figure 17. SPFH Alignment Key 1 SPFH Pins Key 2 Adapter Holes Key 3 - Driveshaft Pick up the adapter with the SPFH through the holes in the top of the adapter. Allow the adapter to slide into position on the SPFH. See Figure 18. Secure the adapter to the SPFH using the header lock mechanism of the SPFH (lower hooks). Figure 18. Adapter on SPFH Key 1 Hole Locations Key 2 Header Latch Location 18
If the Quick Adapter is used for the driveline, the couplers should seat properly and engage. If they do not engage properly, investigate the issue. Note New SPFH drives may be tight with paint causing misalignment. Investigate and correct any misalignment as needed. See Figure 19. Figure 19. Quick Attach Coupler Key 1 Checkpoint for Alignment If the Quick Adapter is not used, attach the SPFH Header Driveshaft and secure to the input shaft of the adapter. See Figure 20. Figure 20. Driveshaft Install Key 1 Gearbox Key 2 Driveshaft Key 3 Jack Stand Key 4 - Pin The large diameter hole of the bracket at the gearbox is provided for securing and centering the shield of the PTO shaft. A chain hole is provided for attaching the anti-rotation chain of the shield. See Figure 21. Figure 21. PTO Guard Securing Key 1 Ring Key 2 Chain Hole 19
Remove Shipping / Storage Stand The simplest method for removing the stands is to keep the feet of the stand in the shipping stand. Raise the feedrolls of the machine to take all weight off of the shipping stand. Remove the pins at the stands. See Figure 22. Note The stands are offset for balance of the adapter in storage. The LH side is always placed in the rear hole of the stand. The RH side is always placed in the forward hole. Holes are labeled for reference. Figure 22. Jack Stand Pins Key 1 LH Side Pin Key 2 RH Side Pin Remove the upper pins and slide the stand tubes to the highest position. Install the pins in either the original frame holes or 90 degrees to the holes. See Figure 23. Figure 23. Jack Tube Pins Key 1 LH Pin Key 2 RH Pin Alternatively, the stands can be removed from the shipping bracket by removing two bolts at the shipping stand. See Figure 24. The shipping stands can be stored in the machine storage area or can be mounted on the adapter jack stands as desired. Figure 24. Storage Positions Key 1 - Upper LH Pin Key 2 Upper RH Pin Key 3 Retaining Bolts. 20
Attach Header to Adapter Refer to the Operator Manual for the header as well as the SPFH for safe procedures for connecting and disconnecting headers. Depending on header, a header stand extension or blocks under header may be required to raise the header for the attachment. Perform the following to attach the header to the adapter. Lower SPFH feedrolls to a height appropriate for connection to the header. Remove the latch pin and open the hand latch mechanism of the adapter to retract the locking pins and allow the header to fit on the adapter. See Figure 25. Figure 25. Header Latch Open Key 1 Latch Arm Key 2 Pin Key 3 Header Pin (retracted) Center the machine on the header. Hook into the header at the lift pockets of the adapter and lift the header off of the ground or trailer. Move the hand latch mechanism lever of the adapter to engage the locking pins and secure the header to the adapter. Verify the pins are properly engaged with the header. If not properly engaged, adjust the cable mounting at the frame to properly position the pins in the extended position. See Figure 26. Install the latch pin at the handle to lock into latched position. Figure 26. Header Latch Closed (Header removed for clarity) Key 1 Latch Arm Key 2 Pin Key 3 Header Pin (extended) NOTE Depending on header, adjustments may be needed at the retaining pin for proper attachment to the adapter. Refer to the Operator Manual for the header for more information. 21
Adjust the stop plates at the top of the adapter as needed. The stop plates should be adjusted to be up to the cross tube of the frame of the header. See Figure 27. Figure 27. Stop Plate Key 1 Stop Plate Location Install header drive shaft(s) and multicoupler to adapter and base machine. See Figure 28. Figure 28. Multi-Coupler Installation Key 1 SPFH Coupler Key 2 Header Coupler The side shields over the output shafts of the adapter have a feature to be retained in the open position for ease of shaft connection. Once the shafts are installed, raise the latch to allow the shield to lower into operating position. See Figure 29. Figure 29. Shield Latch Key 1 Shield Key 2 - Latch 22
Remove Header From Adapter To remove the header from the adapter, reverse the steps of the previous section. Alternatively, it is permissible to leave the adapter connected to the header and remove it from the SPFH. If this operation is desired, make sure the header is secured properly to a trailer or positioned on flat, solid ground and follow the removal process of the header outlined in the Operator Manual for the header. Figure 30. Adapter Left on Header Key 1 Header Key 2 Adapter See Figure 30. 23
Adjustments Feed Roll Spring Tension The tension of the spring that provides for pressure on the feed roll is adjustable. The feed roll should be retained in a fixed position for most conditions. Therefore, once the feed roll is fixed, spring tension is not critical. A spring is located at each end of the feed roll to provide equal tension at each end. The default setting for this tension is set from the factory at 0 (none) inches of rod exposure. Figure 31. Spring Tension RH Side Key 1 Spring Location Key 2 Adjustment Location The max setting for spring tension is 1.5 (32 mm) of rod exposure. Adjust both sides equally. Spring tension should only need to be adjusted in conditions where the feed roll is lifted to the highest position during operation in extreme conditions of light, dry material (i.e. extremely small crops but high trash). Note Consult with RCI before adjusting the spring tension beyond the default setting. See Figure 31. 24
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Maintenance Maintenance Schedule The chart shown in Figure 32 indicates all maintenance items for the adapter. Notes: Fluids in the gearboxes are determined by volume, not level, due to configuration. If a leak is observed, drain the appropriate gearbox, repair the leak, and refill with the specified volume of fluid. Chain Lubrication Lubricate chain daily. Greasing Grease the yokes at both drive shafts daily (2 driveshafts with RH Drive). The same grease used for the header and base machine can be used with the adapter. Use a general chain lubricant for the drive chain of the feed roll. If a chain lubricant is not provided, a heavy oil can be used. IMPORTANT: ONLY PERFORM LUBRICATION WHEN MACHINE IS OFF AND HEADER IS LOWERED TO THE GROUND. Figure 32. Maintenance Schedule Item Interval Qty Specification Comments Greasing 10 2 or 4 Same as base hours locations machine 2 Driveshafts Drive Chain Lube 10 hours AR Common Main Gearbox Oil <200 Or annually, 85 oz* 80w90 (ISO EP) hours whichever occurs first Vertical Gearbox Oil <200 Or annually, 50 oz* John Deere Hygard hours whichever occurs first * Fill by volume only 26
Service Shear Bolt Replacement The feed roll driveline is protected by a shear bolt located on the output shaft hub at the vertical gearbox. In the event of a shear bolt failure, perform the following: Stop the machine. Put in park. Shut off engine. Remove key. Remove obstruction from feed roll. Remove failed shear bolt from shear hub. Install spare shear bolt (provided). Install with head towards feedrolls. Tighten hardware properly. See Figures 33 and 34. Figure 33. Shear Bolt Replacement Key 1 Shear Bolt Location Key 2 Spare Shear Bolts (MY15-16) Specification Shear bolt 1/4 x 1-1/2 Grade 5 Hex Note Do not use a bolt of greater hardness than Grade 5. Machine damage may result. Chain Tension The feed roll is driven by drive chain from the output shaft of the vertical gearbox. Adjust chain tension after the first 10 hours of operation, and again as needed. Figure 34. Shear Bolt Storage Key 1 ¼ x 1-1/2 Shear Bolt (MY2017+) SPECIFICATION: Chain Tension: 1/8 to 1/4" (3-6 mm) of slack at back side Loosen the tensioner bolt and adjust the adjustment nuts (2) to set the proper tension. Tighten all hardware properly. See Figure 35. Figure 35. Chain Tension Adjustment Key 1- Tensioner Bolt Key 2 Adjustment Bolt 27
Main Gearbox Fluid Due to orientation of the gearbox, the fluid level cannot be inspected properly. If any leaks develop, drain the gearbox and repair the leak. Then refill the gearbox with the appropriate volume of oil. The gearbox is equipped with a breather at the top. This breather is positioned inside the frame of the adapter and cannot be removed without removing the gearbox. To change the fluid in the gearbox, perform the following: Figure 36. Drain Plug Location (Gearbox removed from machine for clarity) Key 1 Gearbox Key 2 Drain Plug Tilt the feedrolls of the SPFH such that the main 90-degree gearbox of the adapter is placed in a level position. Remove the skid shoe of the gearbox. Remove the drain plug of the gearbox and drain all oil. Remove the adapter from the SPFH. Using a lifting device, move the adapter to a horizontal position taking care with blocks to prevent damage to the crop guide mounted on the front of the adapter. Figure 37. Skid Plate Removal Key 1 Gearbox Key 2 Skid Plate Refill the gearbox through the drain hole to specification. Install drain plug when complete. SPECIFICATION Main Gearbox Fluid Volume: 85 ounces (2,500 ml) Weight: 80W90 Spec: ISO EP Reinstall the skid shoe and install the adapter on the machine. See Figures 36 through 38. Figure 38. Lifting Process Key 1 Adapter Key 2 Lifting Holes Key 3 Lifting Straps Key 4 Locking Device at Lifting Device 28
Vertical Gearbox Fluid Due to gearbox orientation, the fluid level cannot be inspected properly. If any leaks develop, drain the gearbox and repair the leak. Then refill the gearbox with the appropriate volume of oil. The gearbox is equipped with a breather at the top. The gearbox can be refilled through the port the breather is attached to. To change the fluid in the gearbox, perform the following: Tilt the feedrolls of the SPFH such that the vertical gearbox of the adapter is placed in a vertical position. Remove the drain plug of the gearbox and drain the oil. Figure 39. Vertical Gearbox Key 1 Gearbox Key 2 Drain Plug Key 3 Breather / Fill Port Reinstall the drain plug. Remove the breather from the top of the gearbox. Refill the gearbox to specification. Install breather when complete. SPECIFICATION Vertical Gearbox Fluid Volume: 50 ounces (1,500 ml) Fluid: John Deere Hygard Alternative Oil Spec: ISO EP 220 See Figure 39. 29
Troubleshooting In the event of an issue with the unit, refer to the troubleshooting chart shown in Figure 40. Always work from top to bottom in the chart for best results. For additional troubleshooting assistance, contact your local John Deere dealer. Dealers, contact RCI directly for more assistance. Figure 40. Troubleshooting Chart Issue Recommendation Feed roll does not turn. Check shear bolt, drive chain, and input shaft. Check to ensure the Feed roll sealing kit is installed on the SPFH. This is critical to performance. Unit is pushing crop over the top of the feedroll, feeding unevenly or feeding with poor performance. Header stalls under load. Check to ensure the feed roll of the adapter is in the fixed position. Install lock bolts if needed. Check inside seals of side sheets of frame. Check wear of the bars on the feed roll of the adapter. Replace if needed. If harvesting large diameter ears, consider taking off every other bar on the feed roll. Adjust length of cut. Ideal length of cut is 13mm (1/2") for adapter performance, but shorter cuts will work. Adjustment to length of cut can be changed to verify adapter performance is optimal. A recutter screen from RCI may be desired for proper sizing of material. If harvesting small diameter ears or extremely light volume, consider removing lock bolts and filler plates at side sheets of inside of frame. Ensure that heavy duty drive kit / option is installed on SPFH. Contact your local dealer for more information. 30
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Standard Bolt and Screw Torque Values 32
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REPAIR PARTS General Comments The following includes information regarding parts for the 812A Combine Adapter. Right or left hand parts are determined by sitting in the operator s seat facing forward. The abbreviation A.R. in the USED column indicates As Required. This is because a different number of the specific component may be needed for proper assembly depending on the tolerance of the individual machine. Figure 41. S/N Location Key 1 S/N Tag All parts listed are available through your local dealer. Dealer Contact RCI directly for all part orders for this attachment. Please include a serial number and model of the attachment when placing a parts order. The serial number plate is attached to the main frame of the adapter at the RH side. See Figure 41. Replacement Hardware The use of improper hardware in any location can result in the failure of the component fastened with the hardware or related structures, and can cause personal injury, further damage to the product, or loss of property. Replacement Parts Replacement parts may have occasional differences to the parts being replaced. This difference is typically providing the benefit of a design change made after the release of this publication. 34
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Repair Parts Index Section Page Drive Assembly 38 Feed Roll Suspension 41 Feed Roll 43 Wide-Body SPFH Components 45 Standard-Body SPFH Components 47 Push Pull Cable 49 Right Side Drive 51 Shields and Bumpers 53 Shipping Stands 55 Right Angle Gearbox RC071357 57 Vertical Gearbox RC071107 59 36
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Drive Assembly 38
Drive Assembly Key Part No. Description Qty Comments 1 RC071024 Shaft, Hex 1 2 RC071373 Flangette, Bearing 4 3 RC071316 Bearing, Hex 1-1/4 2 4 RC071342 Spacer 1 5 RC071169 Plate, Bearing Adjustment 1 6 RC071025 Flangette 2 7 RC071330 Frame, Adapter 1 8 RC071159 Bearing, Ball 1 10 RC071306 Assembly, Take up 1 11 RC071357 Gearbox, Right Angle 1 12 RC071107 Gearbox, Vertical 1 13 RC071452 Bundle, Quick Attach 1 14 RC071376 Assembly, Skid Shoe 1 15 RC071384 Shaft, Lower Drive 1 16 RC071171 Washer, Hex 1-1/4 2 17 RC071247 Shaft, Drive 35E 1 18 RC071301 Assembly, Sprocket 1 19 RC071313 Hub, Shear 1 20 RC024403 Sprocket, Bearing 1 21 RC071352 Chain, #80 Roller 1 22 RC071448 Mount, Guard 1 23 RC071449 Cover 1 24 RC071450 Guard 1 25 RC900560 Nut, 1/2-13 gr 9 YZ Top Lock 4 26 RC901669 Bolt, 1/2-13 x 2-3/4 Gr 8 YZ Hex 4 27 RC900084 Bolt, 5/16-18 x 3/4 Gr5 YZ Hex 4 28 RC900726 Washer, Lock, 5/16 4 29 RC900672 Washer, 5/16 SAE YZ Flat 8 30 RC900520 Nut, 5/16-18 YZ Hex 4 31 RC901885 Ring, Crescent 2 32 RC901791 Washer, M14 Flat 4 33 RC901295 Washer, Lock M14 4 34 RC900588 Nut, 1/2-13 YZ Nylock 4 35 RC900703 Washer, 3/4 SAE YZ Flat 15 36 RC900529 Nut, 1/2-13 YZ Hex 2 37 RC900402 Bolt, 3/8-16 x 1 CZ Carriage 7 38 RC900426 Bolt, 1/2-13 X 1-1/4 CZ Carriage 4 39 RC900583 Nut, 3/8-16 YZ Nylock 9 Drive Assembly - Continued 39
Key Part No. Description Qty Comments 40 RC900677 Washer, 3/8 SAE YZ Hard Flat 7 41 RC900213 Bolt, 3/4-10 x 4.5 1 42 RC900595 Nut, 3/4-10 Gr 5 YZ Nylock 1 43 RC901963 Washer, 1-3/8 8 44 RC901211 Bolt, M14-2 X 30mm YZ Hex 4 45 RC900689 Washer, 1/2 YZ USS Flat 8 46 RC900137 Bolt, 1/2-13 x 2 Gr 5 YZ Hex 4 47 RC900731 Washer, Lock, 1/2 12 48 RC900133 Bolt, 1/2-13 x 1-1/4 Gr 5 YZ Hex 4 49 RC900686 Washer, 1/2 SAE YZ Flat 2 50 RC900136 Bolt, 1/2-13 x 1 3/4 Gr 5 YZ Hex 4 51 RC900099 Bolt, 3/8-16 x 2 Gr5 YZ Hex 2 52 RC901810 Washer, 1-3/8 Thin 1 53 RC024404 Bearing 1 54 RC901887 Snap Ring, 1-5/8 Bore Internal 1 55 RC071312 Sprocket, Drive 1 56 RC071293 Bearing, Flanged 1 57 RC071298 Bearing, Sleeve 1 58 RC900575 Nut, 1/4-20 YZ Nylock 1 59 RC900045 Bolt, 1/4-20 x 1-1/2 Gr 5 YZ Hex 1 60 RC901892 Ring, Retaining 1 40
Feed Roll Suspension 41
Feed Roll Suspension Key Part No. Description Qty Comments 1 RC071306 Assembly, Take Up 2 2 RC071110 Flangette, Bearing 4 3 RC071086 Bearing, 7/8 Hex 2 4 RC071087 Shaft, Hex 1 5 RC071088 Arm, Stabilizer 1 6 RC071089 Strap 4 7 RC071090 Washer, 7/8 Hex 6 8 RC071309 Spring 2 9 RC071318 Weldment, Feed Roll Arm 2 10 RC071370 Assembly, Feed Roll 1 11 RC071171 Washer, 1-1/4 Hex 2 12 RC071436 Arm, Stablizer Lockout 1 13 RC900672 Washer, 5/16 SAE YZ Flat 4 14 RC901885 Ring, Crescent 2 15 RC900140 Bolt, 1/2-13 x 2-1/2 Gr5 YZ Hex 1 16 RC900588 Nut, 1/2-13 YZ Nylock 1 17 RC900529 Nut, 1/2-13 YZ Hex 4 18 RC900579 Nut, 5/16-18 YZ Nylock 4 19 RC900864 Pin, 5/32" x 1-1/4" Roll 2 20 RC901685 Pin, 5/32 x 1 YZ Cotter 6 21 RC900686 Washer, 1/2 SAE YZ Flat 6 22 RC901558 Bolt, 5/16-18 x 1 CZ Carriage 4 23 RC900303 Bolt, 5/8-11 x 3-1/2 YZ Gr8 Hex 2 24 RC900593 Nut, 5/8-11 YZ Nylock 2 25 RC071094 Pin, 1/2 x 1-1/4 Clevis 6 26 RC071316 Bearing, 1-1/4 Hex 2 27 RC071245 Bumper 2 28 RC901735 Screw, 1/4-20 x 5/8 Socket Cap 4 42
Feed Roll 43
Feed Roll Key Part No. Description Qty Comments 1 RC071304 Assembly, Header Feed Roll 2 2 RC071372 Weldment, Deep Paddle 6 3 RC071319 Shaft, Feed Roll 1 4 RC901942 Bolt, 5/16-18 x 3/4 Gr 5 Serrated Flange 12 5 RC900100 Bolt, 3/8-16 x 2-1/4 Gr 5 YZ Hex 4 6 RC900583 Nut, Nylock 3/8-16 4 7 RC902177 Bolt, 3/8-16 x 1 Gr5 Serrated Flange 30 8 RC900661 Nut, Flange, 3/8-16, YZ 30 9 RC071178 Bar, Feeding 6 44
Wide-Body SPFH Components 45
Wide-Body SPFH Components Key Part No. Description Qty Comments 1 RC071330 Frame, Adapter 1 2 RC071176 Support, Floor 2 3 RC071427 Floor, Throat 1 4 RC071256 Spacer 3 5 RC071276 Seal, Wide Floor 1 6 RC900726 Washer, Lock, 5/16 6 7 RC900672 Washer, 5/16 SAE YZ Flat 21 8 RC900579 Nut, 5/16-18 YZ Nylock 12 9 RC900063 Bolt, 5/16-18 x 1 Gr5 YZ Hex 6 10 RC900064 Bolt, 5/16-18 x 1-1/4 Gr5 YZ Hex 3 11 RC901558 Bolt, 5/16-18 x 1 CZ Carriage 6 12 RC901747 Screw, 5/16-18 x 1-1/4 CZ Button Socket 3 13 RC900668 Washer, 1/4 YZ Flat 4 14 RC900575 Nut, 1/4-20 YZ Nylock 2 15 RC901956 Bolt, 1/4-20 x 3/4 Hex 2 16 RC071277 Plate, Filler 1 46
Standard-Body SPFH Components 47
Standard-Body SPFH Components Key Part No. Description Qty Comments 1 RC900579 Nut, 5/16-18 YZ Nylock 12 2 RC900063 Bolt, 5/16-18 x 1 Gr5 YZ Hex 10 3 RC900064 Bolt, 5/16-18 x 1-1/4 Gr5 YZ Hex 3 4 RC900672 Washer, 5/16 SAE YZ Flat 25 5 RC900726 Washer, Lock, 5/16 10 6 RC901558 Bolt, 5/16-18 x 1 CZ Carriage 6 7 RC901747 Screw, 5/16-18 x 1-1/4 CZ Button Socket Cap 3 8 RC900668 Washer, 1/4 YZ Flat 4 9 RC900575 Nut, 1/4-20 YZ Nylock 2 10 RC901956 Bolt, 1/4-20 x 3/4 Gr 5 YZ Hex 2 11 RC071176 Support, Floor 2 12 RC071168 Floor, Throat 1 13 RC071256 Spacer 6 14 RC071275 Seal, Floor Narrow 1 15 RC071279 Plate, Filler 1 16 RC071260 Block, Merging 2 See Notes* *Part is no longer used and is not needed. 48
Push-Pull Cable 49
Push Pull Cable Key Part No. Description QTY Comments 1 RC071280 Cable, Push-Pull 1 2 RC071195 Clevis 2 3 RC071197 Assembly, Handle 1 4 RC071256 Spacer 2 5 RC071366 Pin, Locking 1 6 RC071184 Pin, Locking 2 7 RC071185 Bar, Pull 2 8 RC071204 Assembly, Lever 1 9 RC900726 Washer, Lock, 5/16 4 10 RC900672 Washer, 5/16 SAE YZ Flat 5 11 RC900675 Washer, 5/16 USS Flat 4 12 RC900072 Bolt, 5/16-18 x 2-3/4 Gr5 YZ Hex 2 13 RC900579 Nut, 5/16-18 YZ Nylock 4 14 RC901915 P-Clamp 4 15 RC900063 Bolt, 5/16-18 x 1 Gr5 YZ Hex 6 16 RC900064 Bolt, 5/16-18 x 1-1/4 Gr5 YZ Hex 2 50
Right Side Drive 51
Ride Side Drive Key Part No. Description Qty Comments 1 RC071124 Weldment, Bearing Bracket 1 2 RC071025 Flangette 4 3 RC071159 Bearing, Ball 2 4 RC071006 Shaft, Drive 1 5 RC071231 Shield, PTO 1 6 RC071213 Shield 1 7 RC071266 Driveshaft, 44E 1 8 RC071433 Hinge, Stainless 1 9 RC071216 Shield, PTO 1 10 RC071451 Latch 1 11 RC900726 Washer, 5/16 YZ Lock 5 12 RC900084 Bolt, 5/16-18 x 3/4 Gr5 YZ Hex 5 13 RC900677 Washer, 3/8 SAE YZ Hard Flat 6 14 RC900686 Washer, 1/2 SAE YZ Flat 4 15 RC900672 Washer, 5/16 SAE YZ Flat 5 16 RC900731 Washer, 1/2 YZ Lock 4 17 RC900402 Bolt, 3/8-16 x 1 CZ Carriage 6 18 RC900583 Nut, 3/8-16 YZ Nylock 6 19 RC901817 Nut, 8-32 YZ Nylock 3 20 RC900453 Machine Screw, 8-32 x 3/4 SI Rd Head 6 21 RC900666 Washer, #8 SAE YZ Flat 9 22 RC900133 Bolt, 1/2-13 x 1-1/4 Gr 5 YZ Hex 4 23 RC902050 Bolt, M14-2 x 25mm YZ Hex 2 24 RC901295 Washer, M14 Lock 2 25 RC901791 Washer, M14 Flat 2 26 RC071330 Frame, Adapter 1 52
Shields and Bumpers 53
Shields and Bumpers Key Part No. Description Qty Comments 1 RC071330 Frame, Adapter 1 2 RC071328 Shield, PTO 1 3 RC071210 Pad, Wear 2 4 RC071220 Shield, RH Feeder 1 5 RC071219 Shield, LH Feeder 1 6 RC071218 Strip, Wear 3 7 RC071215 Shield, Intake 1 8 RC071365 Shield, Chain 1 9 RC071208 Weldment, Stop Block 2 10 RC071209 Pad, Bumper 2 11 RC071433 Hinge, Stainless 1 12 RC071451 Latch 1 13 RC900084 Bolt, 5/16-18 x 3/4 Gr5 YZ Hex 11 14 RC900726 Washer, Lock, 5/16 11 15 RC900672 Washer, 5/16 SAE YZ Flat 15 16 RC900453 Screw, 8-32 x 3/4 SI Rd Head Machine 6 17 RC900666 Washer, #8 SAE YZ 9 18 RC900579 Nut, 5/16-18 YZ Nylock 4 19 RC900119 Bolt, 3/8-16 x 3/4 Gr 5 YZ Hex 4 20 RC900728 Washer, 3/8 YZ Lock 4 21 RC901817 Nut, 8-32 YZ Nylock 3 22 RC901950 Screw, 5/16-18 x 3/4 CZ Flat Head Socket 10 23 RC901746 Screw, 5/16-18 x 3/4 CZ Button Socket Cap 7 24 RC901744 Screw, 5/16-18 x 1-1/4 CZ Flat Head Socket 4 25 RC901742 Screw, 1/2-13 x 1-1/4 CZ Flat Head Socket 4 26 RC900575 Nut, 1/4-20 YZ Nylock 4 Spares 27 RC900045 Bolt, 1/4-20 x 1-1/2 Gr5 YZ Hex 4 Spares 54
Shipping Stands 55
Shipping Stands Key Part No. Description Qty Comments 1 RC071446 Stand, Shipping 1 2 RC071292 Stand, Jack 2 3 RC071443 Tube 2 4 RC901585 Pin, 1/2 x 2-1/2 Bent Pull Hitch 4 Supplied with clip 5 RC902177 Bolt, 3/8-16 x 1 Gr5 Serrated Flange 4 56
Right Angle Gearbox - RC071357 57
Right Angle Gearbox - RC071357 Key Part No. Description Qty Comments 1 RC071459 Casting, Mach 600 Tap 1 2 RC071389 Casting, Mach 600 Thru 1 3 RC071390 Suba, Stub Shaft/Gear 1 4 RC071391 Suba, Cross Shaft/Gear 1 5 RC071392 Bearing, Cone #3782 1.750 1 6 RC071393 Bearing, Cup #3720 3.6718 1 7 RC071394 Bearing, Cone TK#25581 1.750 1 8 RC071395 Bearing, Cone TK#25580 1.750 2 9 RC071396 Bearing, Cup TK#25520 3.265 3 10 RC071397 Retaining Ring, Ext 1.750 Shft 1 11 RC071398 Seal, 1.75-2.437-.312 (R) TC 2 12 RC071399 Seal, End Cap, 2.45-.312 1 13 RC071400 Bolt, 3/8-16 x 2.25 SHCS 1 14 RC071401 Plug, 1/2-14 NPT SCHD W/3M 1 15 RC071402 Bushing, 1/2 NPT to 1/8 NPT 1 16 RC071403 Plug, 1/8-27 NPT Vent 5PSI 1 17 RC071404 Lube/EP 80W90 AR 58
Vertical Gearbox - RC071107 59
Vertical Gearbox - RC071107 Key Part No. Description Qty Comments 1 RC071405 Sleeve 2 2 RC071406 Seal, Double Lip 4 50X90X10 3 RC071407 Ring, Snap 4 90 UNI7437 4 RC071408 Elbow, 90 3/8" Gas 1 5 RC071409 Plug, 3/8" Gas Oil Filler 1 6 RC071410 Bearing 4 6210 7 RC071411 Wheel, Crown 3 8 RC071412 Pin, Spring 2 A8X50 U6364 9 RC071413 Key, Parallel 3 B 16X10X30 10 RC071414 Shim 2 11 RC071415 Cap 2 80X10 12 RC071416 Shaft 1 13 RC071417 Ring, Snap 2 80 UNI7437 14 RC071418 Bearing 2 NJ 208 15 RC901975 Bolt, M8X75 16 16 RC071420 Casing 1 17 RC071421 Casing 1 18 RC901274 Nut, M8 Hex 16 19 RC071423 Plug, 3/8" Gas 2 20 RC071424 Shim 1 79.9 60
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Pre-delivery Checklist (Return this copy to RCI) After the unit has been assembled and lubricated and prior to delivery to customer, the adapter needs to be inspected thoroughly to ensure it is in proper working order. The following checklist must be reviewed and each item found to be satisfactorily completed. Adapter has been setup according to the instructions included in this manual. All grease fittings have been lubricated. All guards, shields and safety decals are in place, securely fastened, and operate correctly. All nuts and bolts have been tightened and inspected. Adjustments have been made as described in the Adjustments section of this manual Plastic insert centered on adapter at feed roll housing area, undamaged, and in working order. All moving parts operate freely. Spare shear bolts in place. Feed roll locked in the raised position and spring tension set properly. All applicable warranty information recorded. I acknowledge that the pre-delivery service was performed and the unit is ready for delivery to the customer. Dealership s Name Representative Date Model Number Serial Number Date Sold Owner s Name and Address Name Address City, State, Zip Original: Enclose in manual and give to customer at time of delivery. Copy: Dealership Copy: RCI Engineering LLC Fax: 920-387-9804 Email: info@rciengineering.com Mail: 208 River Knoll Drive, Mayville, WI 53050 62
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Delivery Checklist (Copy for Return to RCI) The following items must be performed when delivering the attachment to the customer. Check off each item as it is performed. Provide the customer with the Operator's Manual and instruct them to read prior to operating the unit. Review and explain all safety information and operating adjustments. Review and explain maintenance and lubrication schedule that is required to ensure proper operation and long life. Show how to properly adjust the spring tension as instructed in the Adjustments section. Make it be known that if the customer can visit or call the dealership to discuss any questions or problems they may encounter. Complete the Owner s Registration with the customer, ensure it is completely filled out, and return it to RCI Engineering. Date Delivered Signature Original: Enclose in manual and give to customer at time of delivery. Copy: Dealership Copy: RCI Engineering LLC RCI Engineering LLC Fax: 920-387-9804 Email: info@rciengineering.com Mail: 208 River Knoll Drive, Mayville, WI 53050 64
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Feedback for RCI Use this page to provide feedback to RCI regarding this product, manual, or other ways for RCI to improve in the future. Product: Recutter Screen Bundle for 8000-Series SPFH Dealership Name: Dealership City: Dealership Phone: Technician: S/N: Date: Installation Time (hours): Comments: Send to RCI Engineering: RCI Engineering LLC Fax: 920-387-9804 Email: info@rciengineering.com Mail: 208 River Knoll Drive, Mayville, WI 53050 66
208 River Knoll Drive Mayville, WI 53050 920-387-9804 Fax 920-387-9806 www.rciengineering.com 67