Combine harvesters are prone to various clogging issues during operation, which can significantly affect efficiency and performance. These problems typically occur in different parts of the machine and can be attributed to improper operation, maintenance, or adjustment. Below is a detailed overview of common clogging faults and their causes, along with preventive measures.
1. **Knife Clogging Failure**
a. **Causes**: One common issue is when operators fail to adjust the cutting speed before entering the field, leading to immediate blockage. Additionally, not raising the header while crossing fields can result in stones or mud getting caught in the knife.
b. **Preventive Measures**: Ensure the throttle is increased before starting the cut to maintain optimal knife speed. Raise the header before moving between fields and clear any obstructions promptly. Regularly sharpen the knife and replace worn blades. Maintain proper clearance (less than 0.5mm) between the knife and the base plate.
2. **Header Jamming Failure**
a. **Causes**: Improper adjustment of the header auger, excessive gaps, or incorrect reel speed and height can create a "dead zone" where crops accumulate. Poor coordination between the cutter and pull-out wheel may also cause blockage.
b. **Preventive Measures**: Adjust the header and auger position regularly. Repair or replace worn auger blades. Properly set the reel speed and height according to crop conditions. Avoid harvesting overly wet crops. Reduce cutting width and speed when dealing with fallen crops. Keep all chains and belts properly tensioned and replace them if worn out. Never force the machine through a blockage.
3. **Conveyor Blockage Fault**
When the feed rate is too high, the conveyor can become blocked even if the header is clear. If grass starts turning in the cutting station, stop the machine and let it run for a while to clear the issue. Loose conveyor belts or power transmission belts can also cause blockages. Check and tighten the conveyor rake teeth regularly. Worn or loose teeth can lead to uneven grain flow and potential damage to the threshing mechanism.
4. **Roller Jamming Failure**
a. **Causes**: Low throttle, excessive operating speed, belt slippage, clutch slippage, improper roller speed, or incorrect gap settings between the roller and concave plate can all lead to jamming. Misaligned upper and lower bars can also cause blockage.
b. **Preventive Measures**: Adjust drum speed based on crop type and field conditions. Maintain proper clearance between the roller and concave plate. Operate at medium to high throttle to avoid overloading. Control speed when harvesting fallen crops and use the header lift to ensure even feeding. Prevent clutch and belt slippage by regular inspection and maintenance.
5. **Recombiner Blockage Fault**
The recombiner is responsible for re-threshing unspilled grains from the tail screen and returning them for further cleaning. If the tail screen opening is too large, more stalks may enter the recombiner, causing blockage. In such cases, stop the machine and adjust the tail screen opening to prevent further issues.
By understanding these common clogging faults and following the recommended preventive measures, operators can significantly reduce downtime and improve the overall performance of the combine harvester. Regular maintenance, proper adjustments, and careful operation are key to ensuring smooth and efficient harvesting.
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