Combine harvesters are prone to various clogging issues during operation, which can significantly affect efficiency and performance. These problems typically fall into several key categories, each with specific causes and preventive measures.
1. **Knife Clogging Failure**
a. **Causes**: One common issue is improper cutting speed management. Some operators fail to increase the throttle before entering the field, leading to immediate blockage of the knife. Additionally, failing to raise the header when crossing fields can cause the knife to get stuck on stones or mud.
b. **Preventive Measures**: To avoid this, operators should pre-adjust the throttle before starting to cut. Raising the header in time when moving across fields is essential. Regular sharpening of the knife and maintaining proper clearance (less than 0.5mm) are also important. Replacing worn blades promptly helps prevent frequent blockages.
2. **Header Jamming Failure**
a. **Causes**: Header jamming often results from incorrect adjustment of the auger gap or reel speed. A large "dead zone" between the reel and header can lead to crop accumulation. Poor coordination between the cutter and pull-out wheel can also cause crops to pile up at the front of the header.
b. **Preventive Measures**: Properly adjusting the auger position and ensuring the blade is in good condition can reduce jams. The reel speed and height should be adjusted according to crop density and machine speed. Avoid harvesting overly wet crops, and when dealing with fallen crops, reduce cutting width and speed. Maintaining tension in chains and belts is crucial, and any signs of wear should be addressed immediately.
3. **Conveyor Blockage Fault**
When the feeding rate is too high, even if the header is clear, the conveyor can become blocked. If grass starts to turn in the head area, the machine should be stopped, and the system should be cleared. Loose conveyor belts or power transmission belts can also contribute to blockages. Ensuring that rakes and other components are properly tightened prevents uneven grain flow and potential damage.
4. **Roller Jamming Failure**
a. **Causes**: Insufficient throttle can lead to the drum being unable to overcome threshing resistance. High operating speed may result in excessive feed, overwhelming the machine’s capacity. Belt slippage due to wear, looseness, or oil contamination is another common issue. Improper roller speed or concave plate gap settings can also cause jams.
b. **Prevention and Fix**: Adjusting the drum speed based on crop type and conditions is essential. Proper clearance between the roller and concave plate must be maintained. Keeping the throttle at medium to high levels during operation reduces blockage risk. When harvesting fallen crops, controlling the speed and using lifting handles ensures even feeding. Preventing clutch and belt slippage is also critical.
5. **Recombinator Blockage Fault**
The recombinator is responsible for re-threshing unspilled spikes and returning them to the cleaning screen. If the tail screen opening is too large, more broken stalks enter the recombinator, causing blockage. In such cases, the machine should be stopped, and the tail screen opening should be adjusted appropriately to restore normal operation.
By understanding these common failure points and following the recommended preventive measures, operators can significantly improve the efficiency and reliability of their combine harvesters. Regular maintenance, proper adjustments, and attentive operation are key to minimizing downtime and maximizing productivity.
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