Combine harvesters are prone to various clogging issues during operation, which can significantly affect efficiency and performance. These problems typically occur in several key areas, including the knife, header, conveyor system, roller, and re-cleaning unit. Understanding the causes and implementing proper preventive measures is essential for smooth and efficient harvesting.
1. **Knife Clogging Failure**
a. **Causes**:
- Operators often neglect to adjust the cutting speed before entering the field, leading to immediate blockage when starting the cut.
- Failure to raise the header while crossing the field may result in the knife getting stuck on stones or mud.
b. **Preventive Measures**:
- Increase engine speed before entering the cutting area to ensure the knife operates at an optimal rate.
- Raise the header in time when moving across the field and clear any blockages promptly.
- Maintain sharp knives and replace worn ones regularly.
- Ensure the knife clearance is less than 0.5mm for efficient cutting.
2. **Header Jamming Failure**
a. **Causes**:
- Improper adjustment of the header auger can create excessive gaps between the auger and base plates.
- Incorrect reel speed or height can lead to a large "dead zone" between the reel and header.
- Poor alignment between the cutter and the pull-out wheel can cause crops to accumulate at the front of the header.
b. **Preventive Measures**:
- Adjust the header and auger position as needed, repairing or replacing worn parts to maintain proper spacing.
- Properly set the reel speed and height based on crop density and machine speed.
- Avoid harvesting overly wet crops to prevent jamming.
- Reduce cutting width and slow down when dealing with fallen crops to avoid blockages.
- Keep all chains (abutment, claw, stem, spike) properly tensioned and replace them if worn.
- If the header becomes blocked, do not force the throttle; instead, stop and clear the blockage immediately.
3. **Conveyor Blockage Fault**
- Excessive feed can cause the trough to become clogged even if the header is working fine.
- If grass starts turning in the cutting head, stop the machine and allow it to run for a while to clear the issue.
- Loose conveyor belts or drive belts can also lead to blockages. Regular checks on belt tension and rake teeth are necessary.
- Loose or damaged rake teeth can cause uneven grain flow, leading to blockages. In severe cases, they may damage the threshing mechanism.
4. **Roller Jamming Failure**
a. **Causes**:
- Insufficient throttle may not provide enough power to overcome the threshing resistance.
- High machine speed can exceed the feeding capacity of the harvester.
- Belt slippage due to wear, looseness, oil contamination, or improper tensioning.
- Clutch slippage caused by dirt, worn friction plates, or incorrect clearance settings.
- Improper roller speed or gap adjustment between the roller and concave plate.
- Incorrect positioning of the upper and lower bars can reduce the space for material passage, causing frequent jams.
- Failure to clear blockages in the concave plate can gradually reduce the gap, leading to full blockage.
b. **Preventive Measures**:
- Adjust drum speed according to crop type and growing conditions.
- Ensure proper clearance between the roller and concave plate.
- Maintain medium to high throttle during operation to minimize blockage risks.
- When harvesting fallen crops, control the machine speed and use the header lift handle to ensure even feeding.
- Regularly inspect and maintain the clutch and drive belt to prevent slippage.
5. **Recombinator Blockage Fault**
- The recombinator is responsible for re-threshing unspilled grains and returning them to the cleaning screen.
- If the tail screen opening is too large, more broken stalks may enter the recombinator, causing blockages.
- When a blockage occurs, stop the machine and adjust the tail screen opening to restore normal operation.
By understanding these common issues and taking proactive steps, operators can significantly reduce downtime and improve the overall performance of their combine harvesters. Regular maintenance, proper adjustments, and careful operation are key to preventing clogging failures.
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