Challenger EU Harvesting 5200 DHW Draper Header Service Manual 79035580A – PDF DOWNLOAD

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Challenger EU Harvesting 5200 DHW Draper Header Service Manual 79035580A – PDF DOWNLOAD

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CHALLENGER EU HARVESTING 5200 DHW DRAPER HEADER SERVICE MANUAL 79035580A – PDF DOWNLOAD:

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Challenger EU Harvesting 5200 DHW Draper Header Service Manual 79035580A – PDF DOWNLOAD

SIN: xxxxxxxxxCHDW1999 and prior

A WORD TO THE OPERATOR :

It is YOUR responsibility to read and understand the safety section in this manual and the manual for all attachments before operating this machine. Remember YOU are the key to safety. Good safety practices not only protect you, but also the people around you. Study the features in this manual and make them a working part of your safety program. Keep in mind that this safety section is written only for this type of machine.

• Practice all other usual and customary safe working precautions, and above all REMEMBER – SAFETY IS YOUR RESPONSIBILITY. YOU CAN PREVENT SERIOUS INJURY OR DEATH. This safety section is intended to point out some of the basic safety situations that may be encountered during FIG. 3 the normal operation and maintenance of your machine. This section also suggests possible ways of dealing with these situations.
• This section is NOT a replacement for other safety practices featured in other sections of this manual. Personal injury or death may result if these precautions are not followed. Learn how to operate the machine and how to use the controls properly.
• Do not let anyone operate the machine without instruction and training. For your personal safety and the personal safety of others, follow all safety precautions and instructions found in the manuals and on safety signs affixed to the machine and all attachments. Use only approved attachments and equipment. Make sure your machine has the correct equipment needed by the local regulations.

OPERATOR MANUAL :

• This manual covers general safety practices for this machine. The Operator Manual must always be kept with the machine. Right-hand and left-hand, as used in this manual, are determined by facing the direction the machine will travel when in use.
• The photos, illustrations, and data used in this manual were current at the time of printing, but due to possible in-line production changes, your machine can vary slightly in detail. The manufacturer reserves the right to redesign and change the machine as necessary without notification.

TABLE OF CONTENTS:

Challenger EU Harvesting 5200 DHW Draper Header Service Manual 79035580A – PDF DOWNLOAD

SAFETY
Challenger®
5200/DHW
Draper Header
SERVICE MANUAL
79035580 A Rev
SIN: XXXXXXXXXCHDW1999 AND PRIOR
CONTENTS
Safety Alert Symbol 1
Safety Messages 1
Informational Messages1
Safety Signs 2
A Word To The Operator 2
Operator Manual 3
Prepare For Operation 4
Operation 5
General Information 5
PPE (Personal Protection Equipment) 6
Seat Instructions6
Shield and Guards 6
Exhaust Warning 7
Flying Debris 7
Handrails 8
Agricultural Chemicals 8
Travel On Public Roads 9
Maintenance 10
General Information 10
Fire Prevention and First Aid 12
Checking for High Pressure Leaks 13
Tire Safety 13
Cylinder Stops – If Equipped 14
Late Production Tractors 14
Early Production Tractors14
GENERAL INFORMATION
Introduction 15
Units of Measurement 15
Replacement Parts15
Machine Identification15
Serial Number Description (2009 and prior) 16
Serial Number Description (2010 and up) 16
Description 17
Header 17
Reel 17
Drapers 17
Component Location 18
Component Access19
End Shield 19
Reel Drive Shield 19
Rear Shields 19
General Maintenance Information 20
79035580 A Rev
Bolt Torque Values 20
Bearing Replacement 21
DRAPER
General Draper Maintenance 23
Draper Removal and Installation 23
Draper Removal 23
Draper Installation 24
Draper Tension 25
Roller Alignment25
Drive Roller 25
Idler Roller 26
Draper Tracking 27
Idler Roller – Early Production28
Disassembly28
Assembly 29
Idler Roller – Late Production 30
Disassembly30
Assembly 30
Drive Roller – Early Production 32
Disassembly32
Assembly 33
Drive Roller – Late Production 34
Disassembly34
Assembly 35
CUTTING COMPONENTS
General Sickle Maintenance 37
Sickle Removal and Replacement 37
Standard Sickle and Guards 38
Sickle to Holddown Adjustment 38
Sickle Guard Replacement 39
Sickle Section Replacement39
SCH Sickle and Guards (Schumacher Manufacturing Co) 39
Sickle Guard Replacement 40
Sickle Section Replacement40
Sickle Drive Gearbox 41
Gearbox Alignment 41
Removal 44
Installation 46
Components 48
Disassembly50
Assembly 54
Head Assembly 61
ELECTRICAL
ii
Tools 63
Electrical Schematic 64
General Testing Information 66
Multimeter 66
Basic Checks 66
Continuity and Resistance Check 66
Voltage Check 67
Connectors 68
Checking A Connector 68
Terminal Numbers 68
Dielectric Grease 68
Pin and Socket Replacement 69
Lighting 72
Header Speed Sensor Adjustments 73
Adjustment 73
Testing 74
79035580 A Rev
HYDRAULICS
Hydraulic Schematic 75
Serial Number HU and Prior 75
Serial Number xxxxxxxxxAHDW1101 and up 77
Sickle Drive Motor 81
Removal 81
Installation 84
Disassembly89
Assembly 93
Reel Drive Motor (SN HT10296 and Prior) 98
Removal 98
Installation 101
Disassembly 106
Assembly 109
Reel Drive Motor (SN HT10297 and Up) 113
Removal113
Installation 116
Disassembly 121
Inspection of Motor Components 126
Assembly 129
Conveyor Drive Motor (Eaton) 138
Removal138
Installation 140
Disassembly 143
Assembly 146
Conveyor Drive Motor (Parker)150
Removal150
Installation 152
Disassembly 155
Inspection of Motor Components 160
Assembly 163
Relief Valve manifolds (HU and Prior) 172
Removal172
Installation 173
Disassembly 173
Inspection 174
Assembly 174
Relief Valve manifold (xxxxxxxxxAHDW1101 and up) 175
Removal175
Installation 175
Disassembly 176
Inspection 176
Assembly 176
Flow Control Valve 177
Removal177
Installation 177
Disassembly 178
Inspection 178
Assembly 179
Draper Control Valve – Double Swath Headers Only 180
Removal180
Installation 180
Valve Adjustment 181
Disassembly 182
Inspection 182
Assembly 182
Reel Lift Master Cylinder 183
Removal183
Installation 183
Components 184
Disassembly 185
Inspection 185
Assembly 185
79035580 A Rev iii
Reel Lift Slave Cylinder 186
Removal186
Installation 186
Components 187
Disassembly 187
Inspection 187
Assembly 188
Reel Lift Cylinder Phase 189
Reel Leveling 189
Deck Shift Cylinder – Double Swath Headers Only190
Removal190
Installation 190
Components 191
Disassembly 192
Inspection 192
Assembly 192
REEL
Reel Drive Chain 193
Shield 193
Reel Drive Chain Replacement 193
Reel Drive Chain Alignment and Tension 194
Reel Drive195
Disassembly 195
Assembly 195
UHC Reel196
General Information 196
Maintenance 196
Roller Adjustment196
Tine Pitch 197
Inspection 197
Reel Tine Replacement 198
Reel Bats 198
Control Arms, Reel Arms, and Control Plate Components 202
TROUBLESHOOTING
Cutterbar 205
Reel 207
Draper 208
SPECI Fl CATIONS
Dimensions and Weights 209
Header 209
Sickle 210
Reel 210
Gauge Wheel Tires 210
Draper 210
Lubrication 210
INDEX 211

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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