4-3-2012

8E000005,Rev. AE

Combine Grain Tank Extension

CASE IH SERIES
OPERATORS / ASSEMBLY MANUAL

PLACE IN COMBINE CAB AFTER ASSEMBLY

FOR FUTURE REFERENCE.

ASSEMBLY
OPERATION
REPLACEMENT PARTS

Maurer Manufacturing • 1300 38th Ave. West • P.O. Box 160 • Spencer, IA 51301
PH: (712) 262-2992 • FAX: (712) 262-1022 • www.maurermfg.com
 INTRODUCTION
Thank you for purchasing a Maurer grain tank extension. Proper care and use will result in
many years of service.

WARNING: TO AVOID PERSONAL INJURY OR DEATH, OBSERVE THE FOLLOWING

INSTRUCTIONS:

Ensure that anyone present is clear before applying power to any machinery
used in conjunction with a Maurer grain tank extension.

Never allow anyone in or near the grain tank of a combine during loading or
unloading of grain. The accumulation of grain is dangerous and can cause
entrapment, resulting in serious injury or death by suffocation.

Adding a Maurer Bin Extension or Tip-Up increases the overall height of your
combine. Use caution when operating around trees, buildings, power lines, and
when approaching bridges and over passes. Pay attention to height restric-
tions.

Do not exceed advertised maximum capacity of a Maurer grain tank extension.

GENERAL INFORMATION
1. Read assembly instructions carefully. Study as-
sembly procedures and all illustrations before you
begin assembly. Note which parts are used in each
step. This unit must be assembled in proper se-
quence or complications will result.

2. Whenever terms "LEFT" and "RIGHT" are used in

this manual it means from a position behind com-
bine and facing forward.

3. When placing a parts order, refer to this manual for

proper part numbers and place order by PART NO.
and DESCRIPTION.

TABLE OF CONTENTS
General Information ............................................................................................................... 2
Safety, Signal Words ............................................................................................................ 3
Product Safety Guidelines .................................................................................................... 4
Safety Sign Locations ........................................................................................................... 5
Safety Sign Care ................................................................................................................... 5
Product Disclaimer ............................................................................................................... 5
Parts Breakdown .................................................................................................................. 6
Parts List .............................................................................................................................. 7
Frame Assembly ................................................................................................................... 8
Panel Assembly .................................................................................................................. 8-9
Misc. Bracket Assembly/Complete Assembly ..................................................................... 10
Mounting Instructions/Internal Cover Plate/Tank Cap ........................................................... 11
Tank Cap cont., Wiring ........................................................................................................ 12

Page 2
 SAFETY
TAKE NOTE! THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS MANUAL IS USED
TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY AND
SAFETY OF OTHERS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY
OR DEATH!

THIS SYMBOL MEANS

ATTENTION
BECOME ALERT
YOUR SAFETY IS INVOLVED!

SIGNAL WORDS
Note use of following signal words DANGER, WARNING, and CAUTION with safety messages.
The appropriate signal word for each has been selected using the following guidelines:

DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or
serious injury. This signal word is to be limited to most extreme situations typically for machine
components which, for functional purposes, cannot be guarded.

WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or
serious injury, and includes hazards that are exposed when guards are removed. It may also be
used to alert against unsafe practices.

CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices.

If you have questions not answered in this manual, require additional copies, or if your manual is damaged,
please contact your dealer or Maurer Manufacturing, P.O. Box 160, 1300 38th Ave. West, Spencer, Iowa
51301, Ph: (712) 262-2992 Fax: (712) 262-1022 www.maurermfg.com

Page 3
 PRODUCT SAFETY GUIDELINES

Every year many accidents occur which could have been avoided by a few seconds of thought
and a more careful approach to handling equipment. You, the operator, can avoid many accidents
by observing the following precautions in this section. To avoid personal injury, study the following
precautions and insist those working with you, or you yourself, follow them.

Replace any caution, warning, danger or instruction safety decal that is not readable or is
missing. Location of such decals is indicated in this booklet.

Review safety instructions with all users annually.

Operator should be a responsible adult. DO NOT ALLOW PERSONS TO OPERATE OR

ASSEMBLE THIS UNIT UNTIL THEY HAVE DEVELOPED A THOROUGH
UNDERSTANDING OF SAFETY PRECAUTIONS AND HOW IT WORKS.

Do not paint over, remove, or deface any safety signs or warning decals on your equipment.
Observe all safety signs and practice instructions on them.

Never exceed limits of a piece of machinery. If it's ability to do a job, or to do so safely is in

question DON'T TRY IT.

Adding a Maurer Bin Extension or Tip-Up increases the overall height of your combine. Use
caution when operating around trees, buildings, power lines, and when approaching bridges
and over passes. Pay attention to height restrictions.

Fold and secure (if needed) the grain tank extension panels when transporting the combine to
avoid contact with low power lines and other obstructions.

Use the panel safety step to safely enter and exit the grain tank.

Ensure that any additional bracing and safety equipment have been installed according to this
manual. (Some models do not require additional bracing or safety equipment)

Ensure that the grain tank extension frame has been properly mounted to the combine according
to this manual.

Never exceed the maximum advertised capacity of the grain tank extension. By doing so you
risk damage to the grain tank extension.

Page 4
 SAFETY SIGN LOCATIONS
Types of safety sign and locations on equipment are shown in illustration below. Good safety
requires that you familiarize yourself with various safety signs, type of warning, and area or
particular function related to that area, that requires your SAFETY AWARENESS.

SAFETY SIGN CARE

• Keep safety signs clean and legible at all times.

• Replace safety signs that are missing or have become illegible.

• Replacement parts that displayed a safety sign should also display current sign.

• Safety signs are available from the Spencer plant.

PRODUCT DISCLAIMER

Increasing the grain tank capacity of any combine by use of this product is at the discretion of
the owner. Increasing the grain holding capacity of any combine may affect the structural as-
pects of the combine as well as drive line components and tires. Although Maurer Mfg. has
included additional support bracing on selected models, it does not assume liabilities, or make
any warranties pertaining to the structural stability or performance of any combine. See the
combine owners/operators manual for additional combine specifications and safety informa-
tion not listed in this manual.

Page 5
Grain Tank Extension Breakdown

Case IH Series Grain Tank Extension

13 20-Seal
21-Window

11 1
8
12
13 4
6

3 10 Fig.3 Fig.2
22 2

9 5
9

22 10

7 9
4

Figure 1

16

17
15

14 18

Figure 2 Figure 3

Page 6
 8
5

18

18 17
17
17 18

18 18 17
18
17

Figure 4 Figure 5

PARTS LIST
Please order replacement parts by PART NO. and DESCRIPTION.
REF. PART
NO. NO. QTY. DESCRIPTION
1. R5E000011_0 1 Front Left Corner Panel Tank Caps for Case IH 88 Series
2. R5E000003_0 1 Front Right Corner Panel
3. R5E000005_0 2 Rear Corner Panel
4. R5E000020_0 2 Side Panel (Case IH/9000 Series)
5. R5E000006_0 1 Extension Safety Step
25
6. R5E000028_0 1 Front Panel (Case IH Series)
7. R5E000029_0 1 Rear Panel (Case IH Series)
8. R3E000015_0 1 Base Sensor Bracket
9. R5E000007_0 4 Frame Corner Assembly
27
10. R5E000024_0 2 Frame Splice Side Assembly
11. 1AF032D0000 8 Press Rivet 24 26
12. 1AF031DKA00 16 Nylon Lanyard
13. 1AF034CAAI0 16 3/16” x 1-9/16” Lynch Pin
14. 1AFC12FFA05 16 3/8” x 6” Hex Bolt
15. 1AF009E000C 32 3/8” SAE Flat Washer
16. 1AFC18F0000 16 3/8” Nylon Lock Nut 28
17. 1AFC37E00L0 40 5/16” x 3/4” Serrated Flange Bolt
18. 1AFC08E0000 40 5/16” Serrated Flange Nut
19. *1AEX0015242 1 Case IH Wire Harness Figure 6
20. R3E000026_0 2 Window Seal
21. 1AWALACKAMC 2 Window
22. R5E000030_0 2 Frame Splice Front & Rear Assembly Tank Caps for Case IH 66 Series
23. *1AFC35CAA00 26 #12 x 1” Self Tapping Screw
24. R3E000060_0 1 Case IH Internal Cover Plate
27
25. R3E000061_0 1 Case IH Left Front Tank Cap (88)
26. R3E000062_0 1 Case IH Right Front Tank Cap
27. R3E000063_0 2 Case IH Left Rear (Front 66) Tank Cap 24
28. R3E000064_0 1 Case IH Right Rear Tank Cap
29. R3E000067_0 1 Case IH Right Front Tank Cap (66)
30. R3E000089_0 1 Case IH Internal Cover Plate, Small (66)
30 29
27
_ Substitute “S” for Red or “L” for Black
* Indicates items not shown in illustrations

28

Figure 7
Page 7
NOTE: In order to simplify the assembly process, we recommend that the grain tank extension be
assembled on the ground and hoisted to the top of the combine.

FRAME ASSEMBLY
Arrange the frame components as shown in figure 8. The frame corner with the serial number decal is
the left front frame corner. Fasten the frame joints together with two 5/16” x 3/4” serrated flange bolts
and two 5/16” serrated flange nuts per joint. See figure 8A.

REAR

FRONT

Figure 8A

Figure 8
PANEL ASSEMBLY

STEP 1:
Using one 3/8” x 6” hex bolt, two 3/8” washers and one 3/8” nylon lock nut per hinge point, attach the
extension corner panels to the frame of the grain tank extension. See figure 9A.

STEP 2:
Assemble all four corner panels to the frame (panels with windows are to be fastened to the front)
and slowly fold the panels outward to accept the front, rear, and side panels. The corner panel with
the Maurer logo on the back side is the left front corner. See figure 9.

NOTE: DO NOT over tighten nuts and distort hinge component, but ensure nylon lock nut fully
engages bolt threads.

Page 8
 ATTENTION: DAMAGE TO CORNER PANEL CAN OCCUR IF NOT FOLDED OUTWARD SLOWLY!

SPENCER, IOWA 712-262-2992

Figure 9A
Figure 9

STEP 3:
Assemble the front, rear, and side panels the same
as the corner panels. Please ensure that the panel
with DANGER decal is the rear panel. This panel
will also receive the safety step.

STEP 4:
Remove the partial cut slugs near the bottom of the
rear panel, and fasten the safety step to the rear panel REAR PANEL
using 5/16” x 3/4” serrated flange bolts and 5/16”
serrated flange nuts. When mounting, place the nuts
to the inside. See figure 10.

Figure 10

ATTENTION: DANGER decal must be facing the rear of the combine!

Page 9
STEP 5:
Remove the partial cut slugs near the top of the
front panel and fasten the tank full sensor bracket
to the front panel using two 5/16” x 3/4” serrated
flange bolts and two 5/16” serrated flange nuts.
See figure 11.

NOTE: If installing Tip-Up unit with base

extension unit, do not remove slugs. Sensor
will be located on Tip-Up unit.

STEP 6:
Align two nylon lanyards with one press rivet and
fasten together. Loop and lock the ends of the lan-
yards around one lynch pin each. Fasten the com- Figure 11
plete assembly to the two small holes located on
the corner panels. See figure 12.

Completed Grain Tank Extension Assembly

Figure 12

Page 10
MOUNTING INSTRUCTIONS

STEP 1:
Hoist the assembled grain tank extension to the top of the combine. Position over the grain tank and
carefully lower into place with the window panels facing front.

STEP 2:
Position the extension frame as far to the right as possible without creating a gap in which grain could
leak from. Once positioned square the unit front to rear.

STEP 3:
Secure the extension frame to the top of the grain tank using four 5/16” x 3/4” serrated bolts and four
5/16” serrated nuts. (Two holes in both the front and rear of the tank will align with slots in the frame)

INTERNAL COVER PLATE / TANK CAPS

STEP 1: (88 & 66 series)

Using four 5/16” x 3/4” serrated flange bolts and four 5/16” serrated flange nuts fasten the internal
cover plate to the inside bottom lip of the of the extension frame. Once the cover plate is secured to
the frame, complete by screwing the plate to the tank using #12 x 1” self tapping screws. See figure
13.

#12 x 1” Self Tapping Screws

5/16” x 3/4” Bolts

Figure 13

NOTE: When installing a grain tank extension on 66 series combine the internal cover plate and
tank caps will fasten to the previously installed Maurer Riser unit. You can use two 5/16” x 3/4” ser-
rated flange bolts and two 5/16” serrated flange nuts to fasten the internal cover plate to the riser unit
as well near the frame.

Page 11
STEP 2: (66 series only)
Using three 5/16” x 3/4” serrated flange bolts and three
5/16” serrated flange nuts fasten the small internal cover
plate to the inside bottom lip of the of the extension frame
over the large cut-out of the riser. Once the cover plate
is secured to the frame , complete by screwing the plate
to the tank using #12 x 1” self tapping screws. See
figure 14.
5/16” x 3/4”
Bolts
#12 x 1” Self
Tapping Screws

Figure 14

STEP 3:
Fasten the Tank Caps to the extension frame corners using 5/16” x 3/4” serrated flange bolts and 5/16”
serrated nuts. (Tabs will be on the under side of the frame) Complete by screwing the Tank Caps to the outer
rim of the tank using #12 x 1” screws. See figure 15. If installing on 66 series combine Tank Caps will screw
to Maurer Riser Unit. See figure 16.

Top View Top View

Case IH 66 Series Grain Tank

Case IH 88 Series Grain Tank with Maurer Riser Unit Installed
Figure 15 Figure 16

NOTE: Not all parts will be used depending on the model of combine. (Also see page 7, fig. 6 & 7)

TANK FULL SENSOR

Mount the sensor to the slots in the bracket using the original hardware. Use the provided wire harness to
connect the sensor to the OEM wiring.