MacDon 5020 User Manual

INTRODUCTION Your new MacDon Model 5020 Power-Tongue Windrower is designed to cut, condition and lay in

windrows, a wide variety of grasses and hay crops. Use this manual as your f irst sour ce of inf ormation about th e mac hine. If you foll ow the instruc tions give n

in this manual, your Windrower will work well for many years. The manual contains instructions for "Safety", "Operation", and "Maintenance/Service". In addition,

"Unloading and Assembly" information is given towards the back of this book. CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD,

ASSEMBLE, OR USE THE MACHINE. Use the Table of Contents and the Index to guide you to s pecific areas. Study the T able of Contents to

familiarize yourself with how the material is organized. Keep this manual handy for frequent reference and to pass on to new operators or owners. Call your

Dealer if you need ass istance, infor mation, or add itional cop ies of this m anual. A manual s torage case is provided on the primary drive shield at rear of main frame.

NOTE: Right ha nd (R/H) and left hand (L/H) designations are determined from the operator’s position, facing forward.

TABLE OF CONTENTS

PAGE

INTRODUCTION ..................................................................................................................................1

SERIAL NUMBER LOCATION.............................................................................................................4

SAFETY

Safety Alert Symbol .........................................................................................................................5

Signal Words ...................................................................................................................................5

Safety Signs................................................................................................................... ................6, 7

General Farm Safety .......................................................................................................................8

SPECIFICATIONS

Windrower..................................................................................................................................... 9,10

Tractor Requirements.....................................................................................................................10

Hardware Torque Specifications ....................................................................................................11

Hydraulic Fitting Torque Specifications..........................................................................................12

OPERATION

Your Responsibilities as an Owner/Operator .................................................................................13

To the New Operator ......................................................................................................................13

Preparing the Tractor......................................................................................................................14

Preparing the Windrower................................................................................................................15

Attaching Windrower to Tractor................................................................................................... 16,17

Detaching Windrower from Tractor.................................................................................................17

Break-In Period...............................................................................................................................18

Pre-Starting Checks: Annual ..........................................................................................................19

Pre-Starting Checks: Daily..............................................................................................................20

Operate Correctly ...........................................................................................................................21

Engaging the PTO ..........................................................................................................................21

Lift Cylinder Stop (Raising and Lowering the Machine) .................................................................22

Steering...........................................................................................................................................23

180

° Turn........................................................................................................................................24

Turning Square Corners.................................................................................................................25

Operating Variables..................................................................................................................... 25-33

Lean Bar Position .........................................................................................................................26

Ground Speed ..............................................................................................................................26

Reel Speed...................................................................................................................................27

Reel Position.............................................................................................................................. 27,28

Cutting Height (Skid Plates) .........................................................................................................29

Header Angle................................................................................................................................30

Header Flotation ...........................................................................................................................31

Feed Pan / Rock Drop Tine Position ............................................................................................31

Roll Gap........................................................................................................................................32

Forming Shields............................................................................................................................33

Rear Deflector.............................................................................................................................33

Haying Tips:................................................................................................................................. 34,35

Topsoil Moisture ...........................................................................................................................34

Climate and Topography ..............................................................................................................34

Windrow Characteristics...............................................................................................................35

Running Tractor Tire on Previously Cut Windrow ........................................................................35

Raking and Tedding......................................................................................................................35

Chemical Drying Agents...............................................................................................................35

Unplugging the Windrower: Sickle..................................................................................................36

Unplugging the Windrower: Rolls ...................................................................................................36

Shut-Down Procedure ....................................................................................................................37

Transporting the Windrower: Towing..............................................................................................37

Transporting the Windrower: Flatbed .............................................................................................38

Storage Procedure..........................................................................................................................39

TABLE OF CONTENTS PAGE MAINTENANCE/SERVICE

Service Procedures.........................................................................................................................39

Recommended Fluids and Lubricants............................................................................................40

Capacities of Enclosed Drives and Reservoir.................................................................................40

Bearing Installation .........................................................................................................................40

Closing Drive Shields......................................................................................................................41

Greasing the Windrower.............................................................................................................. 41-44

Center Link Ball Joints ....................................................................................................................44

Spring Pivots...................................................................................................................................44

Hitch Pin Lock Nut ..........................................................................................................................44

Hydraulics................................................................................................................................... 45,46

System Safety...............................................................................................................................45

Hoses and Lines...........................................................................................................................45

Hydraulic Reservoir.................................................................................................................... 45,46

Hydraulic Oil Filter.........................................................................................................................46

Electrical........................................................................................................................................46

Sickle and Sickle Drive..............................................................................................................47-51

Sickle Lubrication..........................................................................................................................47

Sickle Sections..............................................................................................................................47

Sickle Removal.............................................................................................................................47

Sickle Head Needle Bearing Installation.......................................................................................48

Sickle Installation..........................................................................................................................48

Guards..........................................................................................................................................49

Excessive Breakage .....................................................................................................................49

Sickle Hold-Downs........................................................................................................................49

Sickle Drive Belt Tension..............................................................................................................50

Sickle Drive Belt Replacement .....................................................................................................50

Wobble Box Maintenance.............................................................................................................51

Reel and Reel Drive ......................................................................................................................52

Reel Drive Chain Lubrication........................................................................................................52

Reel Drive Chain Tension.............................................................................................................52

Reel Drive Belt Tension................................................................................................................52

Reel Tines.....................................................................................................................................52

Auger and Auger Drive..............................................................................................................53-55

Auger Position...............................................................................................................................53

Stripper Bars.................................................................................................................................54

Auger Drive Chain Lubrication......................................................................................................55

Auger Drive Chain Tension...........................................................................................................55

Rolls and Roll Drive................................................................................................................... 56,57

Roll Drive Chain Tension..............................................................................................................56

Roll Drive Chain Case Lubricant...................................................................................................56

Roll Timing....................................................................................................................................57

Roll Drive Chain Removal & Installation .................................................................................... 58,59

Wheels and Tires ..........................................................................................................................60

Wheel Bolts...................................................................................................................................60

Wheel Removal ............................................................................................................................60

Tire Inflation..................................................................................................................................60

Maintenance Schedule ...................................................................................................................61

Maintenance Record.......................................................................................................................62

TROUBLE SHOOTING..................................................................................................................... 63-66

OPTIONS AND ATTACHMENTS

Additional Skid Plates .....................................................................................................................67

PTO Conversion Kits ......................................................................................................................67

Tall Crop Kit....................................................................................................................................67

Stub Guard Conversion Kit.............................................................................................................68

Hydraulic Header Angle Kits...........................................................................................................68

Reel Bat Replacement Kits.............................................................................................................68

UNLOADING & ASSEMBLY............................................................................................................. 69-77

INDEX............................................................................................................................................... 78,79

SERIAL NUMBER LOCATIONS

Record the serial number in the space provided. Windrower:

Serial number plate (A) is located on the s ide of the left hand end frame.

Tongue:

Serial number plate (B) is located at rear of tongue.

NOTE: When ordering parts and service, be sure to give your dealer the complete and proper serial number.

SERIAL PLATE LOCATION: WINDROWER

SERIAL PLATE LOCATION: TONGUE

SAFETY

SAFETY ALERT SYMBOL

Why is SAFETY important to you?

3 BIG REASONS · ACCIDENTS COST

SIGNAL WORDS

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

DANGER – Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING – Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It is also used to alert against unsafe practices.

CAUTION – Indicates a potentially hazardous situation that, if not avoided, m ay result in m inor or moderate injury. It is also used as a reminder of good safety practices.

This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine.

This symbol means: ATTENTION!

BECOME ALERT! YOUR SAFETY IS INVOLVED!

Carefully read and follow the safety message accompanying this symbol.

· ACCIDENTS DISABLE AND KILL

· ACCIDENTS CAN BE AVOIDED

SAFETY

SAFETY SIGNS

• The safety signs reproduced below appear on the windrower at the locations shown on page 7.

• Keep safety signs clean and legible at all times

• Replace safety signs that are missing or become illegible.

• If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the

current safety sign.

• Safety signs are available from your Dealer Parts Department.

To install safety signs

1. Be sure the installation area is clean and dry.

2. Decide on the exact location before you remove the decal backing paper.

3. Remove the smaller portion of the split backing paper.

4. Place the sign in position and slowly peel back the remaining paper, smoothing the sign as it is applied.

5. Small air pockets can be smoothed out or pricked with a pin.

A - # 44611

D - # 28403

E - # 140311

B - # 32738

C - # 32009

G - # 115100

F - # 44944

H - # 140290

J - # 32008

SAFETY

SAFETY SIGN LOCATIONS

TONGUE & FRAME BACK TUBE

LEFT ONLY

LEFT & RIGHT (14’ & 16’)

LEFT & RIGHT (12’)

LEFT & RIGHT

BACK SIDE OF

LEG FOR 12’

MAIN FRAME

HEADER END FRAMES

12’ UNIT 14’ & 16’ UNITS

PRIMARY DRIVE SHIELD

SAFETY

GENERAL SAFETY

The following are genera l farm safet y precautions that should be part of your operating procedure for all types of machinery.

1. Protect yourself.

When assembling, operating and servicing

machinery, wear all the protective clothing

and personal safety devices that COULD be

necessary for the job at hand. Don’t take

chances.

You may need:

· a hard hat.

· protective shoes with slip resistant soles.

· protective glasses or goggles.

· heavy gloves.

· wet weather gear.

· respirator or filter mask.

· hearing protection. Be aware that

prolonged exposure to loud noise can

cause impairment or loss of hearing.

Wearing a suitable hearing protective

device such as ear muff s (A) or ear plugs

(B) protects against objectionable or loud

noises.

2. Provide a first-aid

kit for use in case

of emergencies.

3. Keep a fire

extinguisher on the

machine. Be sure

the extinguisher is properly mai ntain ed an d

be familiar with its proper use.

4. Keep young children away from machinery

at all times.

5. Be aware that accidents often happen whe n

the operator is tired or in a hurry to get finished. Take the time to consider the safest way. Never ignore warning signs of fatigue.

6. Wear close-fitting clothing

7. Keep hands, feet,

8. Keep all shields in

9. Use only service and repair parts mad e or

10. Do not modify the machine. Unauthorized

11. Stop engine and remove key from ignition

12. Keep the area used for

13. Use adequate light for the job at hand.

14. Keep machinery clean. Straw and chaff on a

15. Never use gasoline, naphtha or any volatile

16. When storing machinery, cover sharp or

and cover long hair. Never wear dangling items such as scarves or bracelets.

clothing and hair away from moving parts. Never attempt to clear obstructions or objects from a machine while the engine is running.

place. Never alter or remove safety equipment. Make sure driveline guards can rotate independently of the shaft and can telescope freely.

approved by the equipment manufacturer. Substituted parts may not meet strength, design, or safety requirements.

modifications may impair the function and/or safety and affect machine life.

before leaving operator's seat for any reason. A child or even a pet c ould engage an idling machine.

servicing machinery clean and dry. Wet or oily floors are slippery . Wet spots can be dangerous when working with electrical equipment. Be sure all electrical outlets and tools are properly grounded.

hot engine are a fire hazard. Do no t all ow oi l or grease to accumulate on service platforms, ladders or controls. Clean machines before storage.

material for cleaning purposes. These materials may be toxic and/or flammable.

extending components to prevent injury from accidental contact.

SPECIFICATIONS

DIMENSIONS Overall Width:

Transport Position 13.5 ft. (4103 mm) 15.5 ft. (4713 mm) 17.5 ft. (5323 mm)

Field Position 18.1 ft. (5531 mm) 21.1 ft. (6446 mm) 24.1 ft. (7360 mm) Overall Length:

Transport Position 20.7 ft. (6320 mm) 22.1 ft. (6740 mm) 24.9 ft. (7573 mm)

Field Position 15.8 ft. (4816 mm) 16.3 ft. (4975 mm) 18.2 ft. (5557 mm) Overall Height

Transport Position 6.2 ft. (1896 mm)

Field Position 6.2 ft. (1896 mm) Weight 5900 lbs. (2675 kg) 6250 lbs. (2835 kg) 6623 lbs. (3005 kg)

CUTTERBAR Cutterbar Width 12.25 ft. (3734 mm) 14.25 ft. (4343 mm) 16.25 ft. (4953 mm) Cutting Height (on skids) 1.5 to 4 in. (38 to 100 mm)

at 8° guard angle Guard (Header) Angle (adjustable) 6° to 11.5° below horizontal Cutterbar Range 2.0 in. below ground to 21 in. above ground

at 8° guard angle (to guard tip) (-50 mm to +533 mm)

MAIN DRIVE Rear Countershaft Speed 1156 RPM *

SICKLE Drive Type Belt driven wobble box (enclosed oil bath ) Speed 1560 strokes or 780 cycles per minute * Stroke 3 in. (76 mm) Sections Over-serrated, low shoulder Guards Double heat treated, forged steel

REEL Drive Type V-belt drive from R/H auger shaft

Reel Type 5 bats (4 or 6 bats optional),

Radius 22 in. (1560 mm) to finger tip Speed 72 RPM as assembled / 59 RPM with

NOTE: Specifications listed only under 14 ft. column are common to all sizes. * All speeds are in no-load condition at rated tractor RPM.

12 FT. 14 FT. 16 FT.

540 or 1000 RPM PTO tractor driven pump

to hydraulic motor driving primary shaft

to chain final drive

replaceable steel pick-up tines, cam action, polymer tine tube bearings

pulley exchange / 66 RPM optional *

SPECIFICATIONS

AUGER Drive Type Chain final drive Overload Protection Hydraulic motor Auger Type 20 in. (508 mm) diameter

Auger Speed 245 RPM *

CONDITIONER ROLLS Drive Type Drivelines from enclosed oil bath chain dri ve Roll Type Helical intermeshing steel “V” bars Roll Diameter 8.75 in. (222 mm) Roll Length 93 in. (2360 mm) Roll Speed 827 RPM *

WHEELS Tread Width 119 in. (3030 mm) 143 in. (3640 mm) 143 in. (3640 mm) Tires 31 x 13.5 - 15 NHS 8 ply Terra-Rib Tire Pressure 30 psi (207 kPa)

MATERIAL DISCHARGE Minimum Width 30 in. (760 mm) Maximum Width 92 in. (2346 mm) Rear Fluffing Shield Adjustable

OPERATING SPEED Recommended Field Speed 5 mph (8 km/h) Recommended Transport Speed 20 mph (30 km/h)

TRACTOR REQUIREMENTS Minimum Power 60 hp (45 kw) 75 hp (56 kw) 90 hp (68 kw)

Drawbar Capacity Must Exceed 1300 lbs. (5785 N) 1030 lbs. (4580 N) 1100 lbs. (4895 N) PTO 540 or 1000 RPM - ASAE standard location Hydraulic Capacity 1750 psi (12000 kPa), two hy drauli c circuits

* All speeds are in no-load condition at rated tractor RPM. (SPECIFICATIONS AND DESIGN ARE SU BJECT TO CHANGE WITHOUT NOTICE OR OBLIGATION TO

REVISE UNITS PREVIOUSLY SOLD.)

12 FT. 14 FT. 16 FT.

variable pitch, center feed

TORQUE SPECIFICATIONS

8.8

10.9

N·m

[lb-ft]

N·m

[lb-ft]

0.5

[.4]

1.8

[1.3]

[2.2]

4.5

[3.3]

[4]

[7]

[11]

[18]

[26]

M10

[37]

[52]

M12

[66]

125

[92]

M14

140

[103]

200

[148]

M16

225

[166]

310

[

229]

M20

435

[321]

610

[450]

M24

750

[553]

1050

[774]

M30

1495

[1103]

2100

[1550]

CHECKING BOLT TORQUE

The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specified in chart unless otherwise noted throughout this manual. Check tightness of bolts periodically, using bolt torque chart as a guide. Replace hardware with the same strength bolt.

ENGLISH TORQUE SPECIFICATION

Bolt Dia.

"A"

1/4" 12 [9] 15 [11]

5/16" 24 [18] 34 [25]

3/8" 43 [32] 56 [41]

7/16" 68 [50] 95 [70]

1/2" 102 [75] 142 [105]

9/16" 149 [110] 202 [149]

5/8" 203 [150] 271 [200] 3/4" 7/8" 569 [420] 813 [600]

1" 867 [640] 1205 [890]

METRIC TORQUE SPECIFICATIONS

Bolt Dia.

"A"

NC Bolt Torque*

SAE 5 SAE 8

N·m [lb-ft] N·m [lb-ft]

359 [265]

Bolt Torque*

495 [365]

M36 2600 [1917] 3675 [2710]

Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise specified. Do not grease or oil bolts or capscrews unless specified in this manual. W hen using locking elements, increase torque values by 5%.

* Torque value for bolts and capscrews are identified by their head markings.

TORQUE SPECIFICATIONS

TIGHTENING HYDRAULIC O-RING FITTINGS*

1. Inspect O-ring and seat for dirt or obvious

defects.

2. On angle fittings, back the lock nut off until

washer bottoms out at top of groove.

3. Hand tighten fitting until back up washer or

washer face (if straight fitting) bottoms on face and O-ring is seated.

4. Position angle fittings by unscrewing no more

than one turn.

5. Tighten straight fittings to torque shown.

6. Tighten angle fittings to torque shown while

holding body of fitting with a wrench.

* The torque values shown are based on

lubricated connections as in reassembly

Size (in.)

3/8

Nut Size

Across

Flats

(in.)

1/2

Thread

7/16 9/16 12

1/2

5/8

9/16 11/16

3/4

7/8

7/8 1-1/16 1-3/16

1-1/4 102 [75] 1-3/8 122 [90]

Torque Value*

Recommended

Turns to Tighten

(after finger

tightening)

N·m [lb-ft] Flats Turns

[6]

[9] 16 [12] 24 [18] 46 [34]

1/3 1/3 1/3 1/3 1/3

62 [46] 1-1/2 1/4

1/6 1/6

TIGHTENING HYDRAULIC FLARE-TYPE TUBE FITTINGS*

1. Check flare and flare seat for defects that might cause leakage.

2. Align tube with fitting before tightening.

3. Lubricate connection and hand tighten swivel nut until snug.

4. To prevent twisting the tube(s), use two wrenches. Place one wrench on the connector body and with the second tighten the swivel nut to the torque shown.

* The torque values shown are based on

lubricated connections as in reassembly.

1-5/16

1-1/2 142 [105] 3/4 1/8 1-5/8 1-7/8 190 [140] 3/4 1/8 1-7/8 2-1/8 217 [160] 1/2 1/12

Tube

O.D.

Size (in.)

Nut Size

Across

Flats

(in.)

Torque Value*

Recommended

Turns to Tighten

(after finger

tightening)

N·m [lb-ft] Flats Turns

3/16 7/16

1/4 9/16 12

5/16 5/8

3/8 11/16

16 [12] 24 [18]

[6] [9]

1/6 1/6 1/6

1/6 1/2 5/8

7/8

46 [34] 62 [46]

1/6

1/6 3/4 1-1/4 102 [75] 3/4 1/8 7/8 1-3/8 122 [90] 3/4 1/8

OPERATION

YOUR RESPONSIBILITIES AS AN OWNER/OPERATOR

CAUTION:

1. It is your responsibility to read and understand this manual completely before operating the windrower. Contact your dealer if an instruction is not clear to you.

2. Fo llow all safety messages in the manual and on safety signs on the machine.

3. Remember that YOU Good safety practices protect you and the people around you.

4. Before allowing anyone to operate the windrower, for however short a time or distance, make sure they have been instructed in its safe and proper use.

5. Review the manual and all safety related items with all operators annually.

6. Be alert for other operators not using recommended procedures or not following safety precautions. Correct these mistakes immediately, before an accident occurs.

7. Do not modify the machine. Unauthorized modifications may impair the function and/or safety and affect machine life.

8. The safety information given in this manual does not replace safet y codes, insurance needs, or laws governing your area. Be sure your machine meets the standards set by these regulations.

9. Ensure that the tractor is properly equipped

to safely operate the windrow er. This may include adding ballast according to Tractor Operator’s Manual requirements for attachments of this size and mass.

TO THE NEW OPERATOR

It’s natural for an operator to be anxious to get started with a new machine. Please take the time to familiarize yourself with the windrower by reading the Operator’s Manual and safety signs before attempting operation.

are the key to safety.

OPERATION

STANDARD DRAWBAR SPECIFICATIONS

PREPARING THE TR ACTOR

1. Select proper tractor size. The minimum po wer required is: 12 ft. - 60 hp (45 kw)

14 ft. - 75 hp (56 kw) 16 ft. - 90 hp (68 kw)

Tractor drawbar capacity must exceed:

12 ft. – 1300 lb. (5785 N) 14 ft. – 1030 lb. (4580 N)

16 ft. – 1100 lb. (4895 N) Also, minimum hydraulics required are 1750 psi (12000 kPa) pr essure with double acting, dual remote capability.

2. Adjust tractor drawbar to meet ASAE Standard specifications as listed below. An im properly located drawbar may affect header flotation and guard angle.

(A) 14 in. (356 mm) for 540 rpm. 16 in. (406 mm) for 1000 rpm.

(B) 6 to 12 in. (152 to 305 mm) with 8 in. (203 mm) recommended.

with 16 in. (406 mm) recommended.

3. Secure the drawbar so the hitch pinhole is directly below the driveline.

NOTE: If the tractor has a three-point hitch, raise the lower links as high as possible to prevent damage.

4. Attach the drawbar extension (D) to the tractor drawbar.

IMPORTANT: To prevent damage to the pump and hose assembly, do not operate the machine without the drawbar extension. Use washers (E) as required depending on drawbar thickness.

Tighten 5/8 nut (F) to 160 ft.lbs. (215 N·m) torque.

Tighten 1 inch slotted nut (G) to 630 ft.lbs. (850 N·m) torque. Further tighten nut (G) to align slot with hole and install cotter pin.

Back off nuts (J) and turn in four bolts (K) until snug against tractor drawbar. Tighten nuts (J) to secure the position.

5. Use proper PTO speed (540 or 1000) depending on windrower options.

6. Tractor must be equipped with a seven terminal outlet (H) to supply power to the windrower's warning lights.

ATTACH DRAWBAR EXTENSION

SEVEN TERMINAL ELECTRICAL OUTLET

OPERATION

CHECK REEL DRIVE BELT TENSION

CHECK HYDRAULIC OIL LEVEL

CHECK SICKL

E DRIVE BELT TENSION,

AND DRIVE BOX LUBRICANT

PREPARING THE WINDROWER

1. Check the tires and inflate if necessary. Recommended pressure is 30 psi (207 kPa).

CAUTION: When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and not facing the tire.

2. Check for proper assembly and adjustment and make sure all bolts are tightened securely.

3. Check the tension of the reel drive belt and the sickle drive belt. Adjust if required. See Maintenance/Service section.

4. Lubricate the machine completely and check the oil level of the sickle drive box. See Maintenance/Service section.

5. Check hydraulic oil level at dipstick. Add oil if required. See Maintenance/Service section.

6. Install quick coupler tips (m atc hing the tractor to be used) on the remote hydraulic hoses.

STAND TO ONE SIDE WHEN INFLATING TIRES

OPERATION

ATTACHING WINDROWER TO TRACTOR

CAUTION: Shut off tractor, engage parking brake and remove key before working around hitch.

CAUTION: Never attach windrowe r to tractor rear axle or three-point hitch arms.

1. Using the jack, raise windrower tongue to clear the hitch pin in drawbar extension. Position tractor to align ball joint on tongue with hitch pin and lower tongue. Secure with lock pin (A).

2. Route hitch chain from windrower through chain support (B), around drawbar support and lock hook (C) on chain.

IMPORTANT: Adjust chain length to remove all slack except what is needed for turns.

3. Remove weight from jack. Pull pin securing jack and move to storage position (D) on top of frame tube.

4. NOTE: Pump attachm ent is easier if hitch is angled to tractor, not straight on.

Slide the hydraulic pump assembly onto the PTO shaft of the tractor. Adjust the torque arm (E) so that it rests on the right side of the drawbar.

IMPORTANT:

• Pump outlets must remain vertical. Loop the

torque arm c hain (F) around the drawbar and lock the chain in keyhole slot in torque arm mounting plate.

• To prevent hose damage, route hoses through

guide (G) to provide proper hose arc as shown.

• Full engagement of PTO shaft into pump is

required to prevent damage to pump spline. Pump should slide 2-1/2" (64 mm) onto shaft.

• The pump must never be keyed or fastened to

the PTO shaft. If the drawbar pin should become disengaged, the pump must be free to slip off.

SECURE HITCH PIN AND CHAIN

JACK STORAGE

ATTACH PUMP ASSEMBLY

OPERATION

CONNECT REMOTE HYDRAULICS

ATTACHING WINDROWER TO TRACTOR (cont’d)

5. Connect remote hydraulic hoses as follows:

a. Connect the two tongue swing hoses (H) s o

that when the tractor control is moved forward, the swing cylinder will extend, mov ing th e wi ndrower to the right. When the tractor control handle is moved back, the swing cylinder will retract, moving the windrower to the left.

b. Connect the two lift cylinder hoses (J) so that

when the tractor control is moved back, the lift cylinder will extend, raising the header. W hen the tractor control is moved forward, the lift cylinder will retract, lowering the header.

6. Connect the windrower wiring harness plug (K) to outlet on tractor.

DETACHING WINDROWER FROM TRACTOR

CAUTION: To prevent accidental movement of tractor, shut off engine, engage parking brake, and remove key.

To maintain stability, always lower the machine completely. Block windrower wheels before detaching from tractor.

Park machine on flat level surface with hitch at an angle to tractor drawbar (to facilitate pump detachment).

Move remote cylinder control valve lever back and forth to relieve stored hydraulic pressure.

1. Pull pin securing jack and move to working position (A) at front of tongue.

2. Lower jack to take weight off tractor drawbar.

3. Unlock torque arm chain fr om keyhole slot in torque arm mounting plate. Remove hydraulic pump assembly and store at (B).

4. Disconnect hydraulic hoses and electrical harness. Store with ends off ground.

5. Remove hitch pin lock (C) and unhook chain (D) from tractor. Wrap chain around windrowe r tongue for storage. Raise windrower tongue with jack to clear hitch pin.

6. Slowly drive tractor away from windrower.

AND ELECTRICAL

MOVE JACK TO WORKING POSITION

STORE PUMP ASSEMBLY

REMOVE HITCH PIN LOCK AND CHAIN

OPERATION

AUGER DRIVE BELT & CHAIN TENSION

CHECK REEL DRIVE BELT & CHAIN

BREAK-IN PERIOD

1. After attaching windrower to tractor for the first time, operate the machine slowly for 5 minut es, watching and listening FROM THE TRACTOR SEAT for binding or interfering parts.

CAUTION: Before investigating an unusual sound or attempting to correct a problem, shut off tractor,

engage parking brake and remove key.

2. Check wheel bolt torque after 1 hour

operation and periodically thereafter (at least ever y 100 hours). Torque to 120 ft.lbs. (160 N

⋅m).

3. Check sickle drive belt (A), auger primary driv e belt (H) and reel drive belt (G) after 5 hours operation for initial stretch. Tighten as necessary. (See Maintenance/Service section). Continue to check the belts periodically for the first 50 hours.

4. Check hitch pin nut (B) after 5 hours

operation and every 50 hours thereafter. T orque to 350 ft.lbs. (475 N

⋅m).

5. Check hardware after 5 hours

CHECK HITCH PIN LOCK NUT

operation. Tighten as necessary. See Specifications section for recommended torques.

6. Tighten the four wobble box mounting bolts (C) after 10 hours thereafter. Torque to 200 ft.lbs. (270 N

operation and every 100 hours

⋅m),

starting with the side mounting bolts.

7. Check reel drive chain (D), auger drive chain (E) and roll drive chain (F) after 10 hours operation for proper tension and lubrication. See Maintenance/Service section.

CONTINUED NEXT PAGE…..

CHECK SICKLE DRIVE BELT AND

CHECK WOBBLE BOX MOUNTING BOLTS

CHECK ROLL DRIVE CHAIN TENSION

OPERATION

BREAK-IN PERIOD

8. Change wobble box lubricant after 50 hours Maintenance/Service section.

9. Change hydraulic oil filter after 100 hours Maintenance/Service section.

10. Until you become familiar with the sound and feel of your new windrower, be extra alert and attentive.

PRE-STARTING CHECKS

Do the following at the start of each operating season:

CAUTION:

1. Review the Operator’s Manual to refresh

your memory on safety and operating recommendations.

2. Review all safety signs and other decals on the windrower and note hazard areas.

3. Be sure all shields and guards are properly installed and secured. Never alter or remove safety equipment.

4. Be sure you understand and have prac tice d safe use of all controls. Know the capacity and operating characteristics of the machine.

5. Check the first aid kit and fire extinguisher. Know where they are and how to use them.

Also:

6. Adjust tension on drive belts. See Maintenance/ Service section.

7. Perform all annual maintenance. See Maintenance/ Service section.

(continued)

operation and every 1000 hours (or 3 years) thereafter. See

operation and every 250 hours thereafter. See Hydraulics in

OPERATION

PRE-STARTING CHECKS

Do the following each day before start-up:

CAUTION:

1. Clear the area of other persons, pets etc. Keep children away from machinery. Walk around the windrower to be sure no one is under, on or close to it.

2. Remove foreign objects f rom the machine and surrounding area.

3. Wear close fitting clothing and protective shoes with slip resistant soles.

As well, carry with you any protective clothing and personal safety dev ices that COULD be necessary through the day. Don’t take chances.

You may need:

- a hard hat

- protective glasses or goggles

- heavy gloves

- respirator or filter mask

- wet weather gear.

4. Protect against noise. Wear a suitable hearing protective device such as ear muffs or ear plugs to protect against objectionable or uncomfortable loud noises.

5. Check t he machine for leaks or any parts that are missing, broken, or not working correctly.

NOTE: Use proper procedure when searching for pressurized fluid leaks. See "Hydraulics" in Maintenance/Service section.

6. Be sure tractor and windrower are properl y attached, all controls are in neutral and tractor brake is engaged.

7. Clean all lights and reflective surfaces on the machine. Check lights for proper operation.

8. Perform all Daily maintenance. See Maintenance/Service section.

PROTECT YOURSELF

PROTECT AGAINST NOISE

OPERATION

OPERATE CORRECTLY

CAUTION:

1. Follow all safety and operational instructions given in your tractor Operator’ s Manual. If you do not have a tractor manual, get one from your dealer and read it thoroughly.

2. Never attempt to start the tractor engine or operate the windrower except from the tractor seat.

3. Check the operation of all controls in a safe clear area before starting work.

4. Do not allow riders on tractor or windrower.

5. Never start or move the machine until you are sure all bystanders have cleared the area.

6. Avoid travelling over loose fill, rocks, ditches or holes.

7. Drive slowly through gates and doorways.

8. If cutting ditch banks, use extreme caution. If the windrower hits an obstruction, the front of the tractor will usually swerve towards the ditch.

9. When working on inclines, travel uphill or downhill when possible. Be sure to keep tractor transmission in gear when travelling downhill.

10. Never attempt to get on or off a moving tractor.

11. Do not get off the tractor while the windrower is in operation.

12. Stop tractor engine and remove key before adjusting or removing plugged material from the

machine. A child or even a pet could engage the drive.

13. Check for excessive vibration and unusual noises. If there is any indication of trouble, shut down

and inspect the machine. Follow proper shutdown procedure:

- engage tractor brake

- disengage PTO

- turn off engine and remove key

- wait for all movement to stop

- dismount and engage cylinder stops before inspecting raised machine.

14. Operate only in daylight or good artificial light.

ENGAGING THE P TO

DANGER: Be sure all bystanders are clear of the machine before engaging the PTO. Never leave tractor seat with the PTO engaged.

• Engage the PTO slowly, just before the windrower is moved up to the standing crop.

• Be sure tractor PTO is running at correct rpm before starting to cut. (540 or 1000, as equipped.)

• Disengage the PTO when not operating the windrower.

OPERATION

LIFT CYLINDER STOP (RAISING AND LOWERING WINDROWER)

WARNING: To avoid bodily inju ry or death from fall of raised machine, always engage lift cylinder stops before going under windrower for any reason.

To engage cylinder stops:

1. Raise machine to maximum height by activating remote cylinder control valve in tractor. NOTE: Hoses should be connected so that moving control lever (A) back header.

2. Remove cylinder stops from storage pos ition and install in engaged position (B). Secure with clevis pin and hair pin.

3. Lower machine slightly so stops take some weight.

To lower windrower:

1. Raise machine to maximum height to take weight off stops.

2. Remove stops from cylinders and store in position (C). Secure with clevis pin and hair pin.

3. Lower m achine by activating remote cylinder control valve in tractor.

raises the

TRACTOR CONTROL LEVER (TYPICAL)

LIFT CYLINDER STOPS - ENGAGED

LIFT CYLINDER STOPS - STORAGE

OPERATION

STEERING

Steering the windrower is controlled by the tractor remote hydraulic system. This steering system allows the windrower to follow directly behind the tractor, make a full cut to either side, or any position in between. NOTE: To allow hitch to swing, latch rod must be in field position (D). If rod is in transport position (A), pivot rod retainer (C) up to allow moving rod from (A) to (D).

NOTE: Hoses should be connected so that moving tractor control lever (E) forward steers the machine to the right and moving the lever back steer s the windrower left.

The control is operated m omentarily for steering and must be returned to OFF or NEUTRAL position as soon as the windrower reaches the desired path of travel.

The center pivot provides the operator the opportunity to move the windrower into field position easily, allows right angle turns in either direction, steering around obj ects on both sides and straight line field cutting on either side of the tractor. NOTE: Before steering the windrower, the header should be raised enough that the skid shoes clear the ground.

OPERATING ON LEFT SIDE

MOVE LATCH ROD TO FIELD POSITION (D)

TRACTOR CONTROL LEVER - TYPICAL

STEERING AROUND AN OBSTRUCTION

OPERATING ON RIGHT SIDE

OPERATION

180q TURN

When cutting back and forth on one side of the field, approximately 50 ft. (15 m) is required at each end of the field to make a 180

Proceed as follows:

1. Beginning at position (A), the tractor is guided away from the uncut crop while the windrower is guided straight ahead until cutting through the end.

2. As soon as the sickle cuts through, raise the header to lift the skid shoes clear of the ground, and steer the windrower to the extreme direction away from the uncut crop.

NOTE: For ease of operation, both lever s can be ac tivated with one hand and held until steering cylinder completes its stroke.

3. At position (B), start turning the tractor back towards the uncut crop.

IMPORTANT: When turning, take care that the inside tractor tire does not contact tongue of windrower.

4. In positions (C) and (D), continue turning towards the uncut crop, (with the windrower steered towards the outside of the turning circle), being aware of tongue-to-tire clearance.

5. At position (E), the tractor com pletes the cir cle and the front wheels are turned to s traddle the last cut windrow. At this point, steer the windrower to line up with the edge of the uncut crop.

6. At position (F), lower header to cutting height and begin a new cut through the field.

° turn-around.

OPERATION

TURNING SQUARE CORNERS

The following procedure is intended only as a guide to developing a turning procedure for the tractor being used. Specific distances are not given due to the variances in tractor maneuverability.

1. As the tractor approaches the corner, guid e the tractor sharply away from the crop. Steer the windrower to maintain a straight cut ahead as the tractor moves away from the crop.

2. As soon as the sickle cuts past where the new corner will be, raise the header sufficiently for skid shoes to clear the ground, then steer the windrower to the extreme direc tion away from the uncut crop.

3. As the tractor passes the corner, steer it sharply back towards the uncut crop, taking care that the inside tractor tire does not contact the windrower tongue.

4. Guide the tractor to straddle the last cut windrow. As the windrower finishes turning, steer it back towards the unc ut cr op, align the header with the crop edge and lower header to cutting height.

OPERATING VARIABLES

Satisfactory function of the windrower in all situations requires m ak ing pr oper adj us tments to suit various crops and conditions.

Correct operation reduces crop loss and allows cutting of more acres. As well, proper adjustments and timely maintenance will increase the length of service you receive from the machine.

The ten variables listed here and detailed on the following pages will affect the performance of the windrower. You will quickly become adept at adjusting the machine to give you the desired results.

1. Lean Bar Position

2. Ground Speed

3. Reel Speed

4. Reel Pos ition

5. Cutting Height

6. Header Angle

7. Header Flotation

8. Feed Pan / Rock Drop Tine Position

9. Roll G ap

10. Forming Shields

TURNING A SQUARE CORNER

OPERATING VARIABLES

OPERATION

LEAN BAR POSITION IMPORTANT: To prevent structural damage to the

header, do not operate with lean bar removed. Use the lean bar adjustment to accommodate

different crop heights. The lean bar should strike the upper portion of the

crop, leaning it away from the header and exposing the stalks to the sickle.

To extend or retract lean bar, re-position hardw are (A) in adjustment holes as required.

GROUND SPEED

CAUTION: Reduce speed when turning, crossing slopes, or when traveling over rough ground.

Tractor ground speed should not exceed 8 mph (13 km/h). For most crop conditio ns a g round speed of 5 mph (8 km/h) has been found satisfactory.

Choose a ground speed that allows the sickle to cut the crop smoothly and evenly. The chart below indicates the relationship between ground speed and area cut for three header sizes.

Example: At ground speed of 5 mph (8 km/h) with a 14 ft. windrower, the area cut would be approximately 9 acres (3.7 hectares) per hour.

LEAN BAR ADJUSTMENT

OPERATION

CHANGING REEL SPEED

REEL SPEED

For best feeding of the crop into the auger, reel speed should be just faster than ground s peed. This gently sweeps material across the sickle into the auger.

The reel speed is fac tory set at 72 rpm . (No-load at rated tractor RPM.)

With a pulley position exchange, other reel speeds are possible. (See chart.) A slower reel speed will reduce excessive crop carry-over, while a faster reel speed will result in a more even stubble height in down and tangled crops.

To change reel speed:

a. Loos en jam nut (C) on adjuster bolt and two

flange nuts (D) at reel drive arm. Loosen adjuster bolt (E) to slacken belt. Remove belt.

b. Remove three flange locknuts at position (A). c. Remove three bolts and lockwashers at

position (B).

d. Position pulleys to achieve desired reel speed,

(see chart). Replace pulley hardware. NOTE: For 66 rpm reel speed it will be

necessary to purchase an additional 10 O.D. pulley from your Dealer.

e. Replace reel drive belt and tighten. Check reel

drive chain tension. See Maintenance /Service section for recommended belt and chain tension.

REEL POSITION

Reel position has been found to be a critical position is factory set for average str aight standing crop. It c an be adjusted both vertically and horizontally (fore-aft) for differ ent crop conditions. See the c hart below for rec omm ended reel position in unus ual crop conditions. (Continued next page.)

9 ½" OD Pulley Position

10 ½" OD Pulley Position

Reel

Speed B A 59 rpm A B 72 rpm none A & B

66 rpm

REEL SPEED CHART (for positions (A) & (B) see photo below)

1/2 inch

66 rpm CONFIGURATION SHOWN

factor in achieving good results in adverse conditions. The reel

· Crop down or lodged Forward & down (also increase reel speed)

· Wet or dead material collects Back & down (close to guards) on cutterbar, plugging sickle.

· Short crop. Back

· Thick stemmed or heavy standing crop. Up and forward

REEL POSITION CHART

Unusual Crop Condition Reel Position

OPERATION

RIGHT SIDE

REEL POSITION NOTE: The reel must be adjusted equally on both

sides, both horizontally and vertically.

To adjust reel horizontal (fore-aft) position:

a. Loos en jam nut (A) on adjuster bolt and two

flange nuts (B) at reel drive arm. Loosen adjuster bolt (C) to slacken belt

b. Loosen nut (D) and back of f nut (E). T urn nut

(F) to move idler sprocket upward until reel drive chain is loose.

c. Loosen nuts (G), three on left side, four on right

side.

d. Loosen jam nut on bolt (H), both sides, and

turn adjuster nuts to move reel f ore or aft to

desired position. Tighten jam nut. e. Tighten nuts (G). f. Tighten belt first, then tighten chain. See

recommended tensions in Maintenance/

Service section.

To adjust reel vertical position:

a. Loos en jam nut (A) on adjuster bolt and two

flange nuts (B) at reel drive arm. Loosen

adjuster bolt (C) to slacken belt b. Loosen nut (D) and back of f nut (E). T urn nut

(F) to move idler sprocket upward until reel

drive chain is loose. c. Loosen nuts (G), three on left side, four on right

side. d. Loos en jam nuts (J) (left side only), and use

push bolts (K), two per side, to move reel up or

down to desired position. Tighten nuts (J). e. Tighten nuts (G) f. Tighten belt first, then tighten chain. See

recommended tensions in Maintenance/

Service section.

To adjust tine aggressiveness:

a. At right side of reel (cam end) only, loosen four

nuts (G). b. Use push bolts (K) to rotate cam to desired

position. Viewed from right side, rotate cam

clockwise to obtain more aggressive tine

action. c. Tighten nuts (G), then check that chain and/or

belt have not become over tight. Adjust to

recommended tension if required. See

Maintenance/ Service section.

After adjusting reel position:

a. Check that the reel rotates freely. Tines m ust

not contact auger, guards or ground. b. Check that the reel is adjusted to the same

position on both sides. Reel tube should

appear parallel to header beam from both side

and front. c. Check header float and adjust if required. See

"Header Flotation" in this section.

(continued)

REEL POSITION ADJUSTMENTS - RIGHT SIDE

LOOSENING REEL DRIVE BELT –

REEL POSITION ADJUSTMENTS - LEFT SIDE

OPERATION

CUTTING HEIGHT

Control cutting height with skid plates, not with the hydraulic cylinder. Having the header "ride" on the skid plates allows the float linkage to float header over obstacles and follow ground contours, rather than supporting the header with the cylinder.

NOTE: Lowering the skid plates raises the cutting height. This may be desirable in stony conditions, to reduce damage to cutting components. Also, a longer stubble length helps material dry faster.

To adjust cutting height:

WARNING: To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key and engage lift cylinder stop before going under machine to adjust skid plates or for any reason.

a. Remove pin (A) at each skid plate. b. Raise or lower skid plate (B) to desired

position. c. Replace pin (A).

After adjusting cutting height:

a. Check that skid plates are adjusted to the

same position. b. Check header float and adjust if required. See

"Header Flotation" in this section. NOTE: Left and right skid plates are standard

equipment. An additional two inner skid plates may be added if required.

WARNING: Stones or other foreign objects carried into the conditioner rolls can be ejected with force in ANY direction. Keep everyone several hundred feet away fr om your operation and be sure you are adequately protected. See "General Safety" in Safety section for recommended protective wear.

CUTTING HEIGHT ADJUSTMENT

OPERATION

HEADER ANGLE

Header (or guard) angle can be var ied f rom 6° to 11.5° below horizontal. Choose an angle that maximises performance for your crop and field conditions. A flatter angle provides better clearance in stony conditions while a steeper angle is required in down crops for better lifting action.

To adjust header angle

a. Loosen nut (A). b. To decrease (flatten) header angle, turn nut (B) clockwise. c. To increase (steepen) header angle, turn nut (B) counter-clockwise. d. Tighten nut (A) to 200 ft.lbs. (270 N.m)

After adjusting header angle

a. Check cutting height and adjust if required. See "Cutting Height" in this section. b. Check header float and adjust if required. See "Header Flotation" in this section.

NOTE: Two optional kits are available which allow header angle to be adjusted hydraulically with a cylinder replacing the mechanical link shown above. One kit (B 4257) requires a separate hydraulic circuit from the tractor. The other (B 4256) uses the existing tongue steering cylinder hydraulic circuit, and a remote switch-operated selector valve controls which circuit is currently active. Installation instruc tions are included with the kits.

HEADER ANGLE ADJUSTMENT

OPTIONAL HYDRAULIC HEADER ANGLE KIT

OPERATION

HEADER FLOTATION

Header flotation springs are normally set so 70 lbs. force (311 N) is required to lift either end of the header just off the ground.

In rough or stony conditions, it may be desirable to change setting to 35-50 lbs. (156-222 N) to protect cutting components.

NOTE: When f loat setting is light, it may be necessary to use a slower ground speed to avoid excessive bouncing and leaving a ragged cut.

To increase header flotation a. Raise header fully. b. Back jam nut (A) away from spring. c. Turn adjuster bolt (B) further into spring to

increase flotation. d. Tighten jam nut (A) against spr ing insert

at each end. IMPORTANT: Float setting (or lifting force)

must be equal on both springs. Weight difference between left and right ends requires differ ent spring lengths to achieve equal float at both ends. Note that other operating variable adjustments may affect float setting. Check the f loat and readjust if necessary after adjusting reel position, cutting height, or header angle. Also, if using a tractor with drawbar height different than 16 inches (406 mm) flotation will be affected. Adjust as required.

FEED PAN / ROCK DROP TINE POSITION

The rear of the feed pan is adjustable up and down to raise or lower the feed pan and rock drop tines.

• Move down in heavy crop to prevent plugging of

bulky material.

• Move up in light crop for even windrow

formation.

• To adjust, loosen hardware (D) both sides and

position rock drop tine support as required.

• Align pointer at each side of rock drop tine

support with slot to match crop condition: Light Crop – Upper slot Normal Crop – Center slot Heavy Crop – Lower slot

NOTE: Use pointer to align with slot, not tines

which are aligned above the pointer as shown.

• Tighten hardware (D) both sides.

, which decreases the force required to lift header:

HEADER FLOTATION ADJUSTMENT

ROCK DROP TINE HEIGHT ADJUSTMENT

OPERATION

ROLL GAP

Steel rolls "condition" the crop by crimping the stem in several places. This allows moisture release for quicker drying. The degree to which the crop is conditioned as it passes through the rolls i s controlled by roll gap (A), measured from bar to roll tube. The gap is factory set at 3/4 inch (20 mm) for normal operation.

Correct conditioning of alfalfa, clover and other legumes is usually indicated when 90% of the stems show cracking, but no more than 5% of the leaves are damaged. Use only enough roll gap to achieve this result.

A slightly larger gap (up to 1 inch [25 mm]) may be desirable in thick stemmed cane-type crops; however, too large a gap may cause feeding problems.

Grass type crops may require less gap for proper feeding and conditioning.

To adjust roll gap NOTE: The top face of nut (B) is used as the

indicator for the gauge decal on the threaded rod. Each division on the roll gap decal represents a change of approximately 1/8 inch (3mm) in roll gap. The factory setting of 3/4 inch (20mm ) roll gap is mark 5 on the dec al. When adjusting roll gap, be sure that the decal reading is the same on both sides of the conditioner roll to achieve consistent intermesh across the rolls.

a. Raise header fully. b. Loosen jam nut (B), both sides. c. To increase roll gap, turn nut (C) clockwise. d. To decrease roll gap, turn nut (C) counter-

clockwise. e. Tighten jam nut (B), both sides. f. Lower header and inspect roll gap along the

length of the rolls. NOTE: Roll tension (the force holding the rolls

together) is factory set and non-adjustable.

WARNING: To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engine, remove key and engage lift cylinder stop before going under machine to examine rolls or for any other reason.

ROLL GAP

= APPROX. 1/8” (3 mm) ROLL GAP CHANGE

ROLL GAP DECAL

ROLL GAP ADJUSTMENT

OPERATION

FORMING SHIELDS

WARNING: Keep hands and feet away from discharge opening. Keep everyone several hundred feet away from your oper ation. Never direct the dis charge toward anyone. Stones or other foreign objects can be ejected with force.

The position of the forming shields controls the width and placement of the windrow. The decision on forming shield position (infinite settings between 30 and 92 inches [760 - 2346 mm]) should be based on the follow ing factors:

- weather conditions (rain, sun, humidity, wind)

- type and yield of crop

- drying time available

- method of processing (bales, silage, "green-feed")

A wide windrow will generally dry faster and more evenly, re sultin g in l ess prot ein l oss. Fast dry ing i s especi ally important in areas where the weather allows only a few days to cut and bale. See "Haying Tips" in this sectio n for more information.

Where weather conditions permit or when drying is not critical, for example, when cutting for silage or "greenfeed", a narrower windrow may be preferred for ease of pick-up.

To adjust windrow width and placement IMPORTANT:

Set forming shield side deflectors to desired width by repositioning adjuster rods (A) in holes. To ensure windrow placement is centered with respect to tractor wheels, rear edge of left and right side deflectors m ust be equal distance from tongue center pivot, as shown on decal (E) on the top shield. To achieve this setting, adjus ter rods must be in the corresponding hole both sides. Count holes from inner-most hole (B).

NOTE: If forming shield side deflectors are too loose, or too difficult to m ove with adjuster rods: Back off nut (D) and adjust lower nut (C) as required. Then, holding nut (C) with a wrench, tighten top nut (D) securely against nut (C).

Rear Deflector

The rear deflector (F ) slows the crop exiting the conditioner rolls, direc ts the flow downward, and "fluffs" the material.

The rear deflector can be adjusted down for more crop control in light material, and up for clearance in heavier crops.

To adjust rear deflector, pull up or push down one side of deflector (F), then repeat at the other side. There is no hardware to be loosened.

NOTE: For even windrow formation, be sure the deflector is not twisted.

FORMING SHIELD ADJUSTMENTS

OPERATION

HAYING TIPS

There is one certainty when making hay - a quick cure will maintain top quality. It is critical to have the cured hay baled as quickly as possible, for two reasons:

1. Every day hay lies on the ground, 5% of the protein is lost.

2. The sooner the cut hay is off, the earlier the start for next growth. Generally, leaving the windrow as wide and thin as possible makes for the quickest curing, however th ere ar e

other factors which affect curing time:

1. TOPSOIL MOISTURE When the ground is wetter than the hay, moistur e f r om the soil is absorbed by the hay above it. Determine

topsoil moisture level before cutting. Use a moisture tester or estimate level: Over 45% - WET - Soil will be muddy

25 - 45% - DAMP - Walking on soil leaves tracks Under 25% - DRY - Soil will be dusty on top

When ground is wet due to irr igation, wait until soil moisture drops below 45%. When ground is wet due to frequent rains, cut when weather allows and let the forage lie on wet ground until it dries to the moisture level of the ground. At this point, the cut hay will dry no more until the ground under it dries, so consider moving the windrow to drier ground.

On wet soil, the general rule of "wide and thin" does not apply. A narrower windrow will dry faster than hay left flat on wet ground.

2. CLIMATE AND TOPOGRAPHY a. Try to have as much hay cut as possible by midday, when drying conditions are best. b. Fields sloping south get up to 100% more exposure to the sun’s heat than do north sloping fields. If you

bale and chop, consider baling the south facing fields and chopping those facing north. c. When relative humidity is high, the evaporation rate is low and hay dries slower. If there is no wind,

saturated air becomes trapped around the win drow, furth er hindering the dry ing process. Raking or tedding

will expose the hay to fresher, less saturated air. Cutting hay perpendicular to the direction of the prevailing

winds may also help.

OPERATION

HAYING TIPS

3. WINDROW CHARACTERISTICS

See "Operating Variables" in this section. Control the f ac tor s lis ted to pr oduc e a windrow with the following characteristics:

a. High and fluffy for good air flow.

process than direct sunlight. b. Consistent formation, not bunchy.

chopper etc. c. Even distribution, not piled in the middle or higher on one side.

side could cause stacks to lean, round bales to have one end smaller and loose, or small square bales to

be heavy on one side, causing handling and stacking problems. d. Properly conditioned without excessive leaf damage.

4. RUNNING TRACTOR ON PREVIOUSLY CUT WINDROW: This can lengthen drying time by a full day in hay that will not be raked. If practical, set forming shields for a

narrower windrow that can be straddled. However, in high-yielding alfalfa, driving on the hay may be unavoidable if a full width windrow is necessary,

5. RAKING AND TEDDING Raking or tedding will speed up drying, however the benefits must be weighted against the additional leaf

losses which will result. W hen the ground beneath the down hay is dry, raking or tedding is probably not worthwhile.

Big windrows on damp or wet ground should be turned over when they reach 40-50% moisture. Hay should not be raked or tedded at less than 25% moisture, or excessive yield losses will result.

6. CHEMICAL DRYING AGENTS Hay drying agents work by removing wax from legum e surfac es, enabling water to escape and evaporate

faster. However, treated hay lying on wet ground will also absorb ground moisture faster. Before deciding to use a drying agent, costs and benefits relative to your area should be carefully compared.

(continued)

The movement of air through the windrow is more important to the curing

A uniform windrow permits an even flow of material into the baler,

A windrow that is higher or heavier on one

OPERATION

UNPLUGGING THE WINDROWER

WARNING: Stop tractor engine and remove key before removing plugged material from windrower. A child or even a pet could engage the drive.

If the sickle plugs

1. Stop forward movement of the tractor and stop the PTO.

2. Lift the cutterbar about 12 inches (300 mm).

3. Back up about 3 feet (1 metre) while slowly engaging the PTO.

4. If the plug does not clear; raise machine, shut off engine, remove key and lock tractor brakes.

5. Engage lift cylinder stop.

WARNING: Wear heavy gloves when working around sickle.

6. Clean off cutterbar by hand. If sickle plugging persis ts, see Trouble Shooting

section.

If the rolls plug

1. Stop forward movement of the tractor and stop

the PTO.

2. Raise the machine and slowly engage the

PTO. NOTE: Raising the windrower automatically

reduces roll tension, to ease plug removal.

3. If plug does not clear: with machine still raised,

shut off engine, remove k ey and lock tractor brakes.

4. Engage lift cylinder stop.

WARNING: Wear heavy gloves when working around sickle.

5. Clean off cutterbar and area under reel by

hand.

6. Use wrench on left-hand end of prim ary drive

shaft (A) to turn rolls forward until plug clears. NOTE: Store wrench in header fram e tube at left

end, secured with hairpin (B) as shown. If roll plugging persists, see Trouble Shooting

section.

CLEARING PLUGGED ROLLS

WRENCH STORAGE

OPERATION

SHUT-DOWN PROCEDURE

CAUTION: Before leaving the tractor seat for any reason:

1. Park on level ground if possible.

2. Lower the windrower fully.

3. Place all controls in NEUTRAL or PARK.

4. Disengage PTO.

5. Engage the park brake.

TRANSPORTING THE WINDROWER: TOWING

WARNING: To avoid injury or death from los s of c ontrol, enga ge tr anspor t lock pin be fore transporting machine. Use correct transport procedure as detailed:

1. The hitch steering cylinder and hoses must

be full of oil before towing the windrower. If

not previously done, fill steering circuit as

follows:

• Connect the two hitch steering cylinder

hoses to a tractor hydraulic circuit.

• Steer the header completely to the left, then

right. Repeat three or four times.

2. Place transport latch rod in transport

position (A) and engage r od retainer (C).

3. Slowly shift hitch into transport position s o

the machine is centered directly behind the

tractor. See "Steering" in this section. Hitch

will lock when it reaches center position.

Oscillate the header left and right a small

amount to ensure transport lock pin (B) is

properly engaged in the plate on carrier

frame.

WARNING: The transport lock pin locks the machine to tow directly behind the tractor and prevents inadvertent movement to either side due to accidental operation of the remote hydraulic control levers or to a malfunctioning hydraulic system.

4. Raise the w indrower fully and engage lift

cylinder stop. See "Lift Cylinder Stop".

5. Do not tow with a vehicle weighing less

than 5000 lbs. (2300 kg).

6. Be sure hitch chain is properly attached to

towing vehicle. Provide only enough slack

in chain to permit turning . See "Attaching

Windrower to Tractor" in this section.

7. Be sure jack is properly attached in storage

position on frame tube.

6. Stop engine and remove key from ignition.

7. Wait for all movement to stop.

8. Lock tractor anti-vandalism covers and closures when leaving the machine unattended.

8. Check local laws for width regulations and

9. Keep Slow Moving Vehicle emblem, reflectors and lights clean and visible at rear of windrower.

10. Be aware of roadside obstructions,

oncoming traffic and bridges.

11. Travel speed should be such that complete control and machine stability are maintained at all times. Do no t exceed 20 mph (30 km/h). Reduce speed for corners and slippery conditions.

12. When transporting on roads, use tractor lights and windrower flashing amber and red taillights to provide adequate warning to operators of other vehicles.

13. Do not transport the windrower on a road or highway at night, or in conditions, which reduce visibility, such as fog or rain.

TRANSPORT LATCH ROD & LOCK

lighting or marking requirements before transporting on roads.

OPERATION

LOWER AND TIE DOWN UNIT

TRANSPORTING THE WINDROWER: FLATBED

CAUTION: Use the following procedure when shipping the windrower on a flatbed trailer.

1. Raise header with tractor hydraulics and install lift cylinder stops.

2. Position lean bar to hang vertically downward. Install only one bolt per side. (Remove divider rods, if equipped.)

3. Remove complete rear forming shield group, in whole.

4. At tongue pivot, back off two 5/8 nuts (B) approximately 3/4 inch (20 mm ). This clears the stop to allow pivoting the tongue past the normal travel range.

NOTE: If tongue does not raise up as nuts (B)

are loosened, lift rear of tongue with fork lift to clear stops.

5. Detach rod end of tongue shift cylinder from frame and swing tongue to the right until no part of tongue extends forward of header R/H end panel (that is, the tongue m ust not widen the shipping package). Secure the cylinder to the tongue for shipping. Tie tongue to frame at float arm (C) to prevent movement. (Use cardboard or suitable material under the tie to protect paint.)

CAUTION: Be sure forklifts are large enough to lift the windrower safely. See Specifications section for weight of the unit.

6. Position two forklifts as shown, lift windrower and back the flatbed trailer under the unit.

IMPORTANT: To allow windrower to rest

securely on header panels, hitch end of tongue must extend over rear of flatbed by approximately 2 feet (0.6 m).

7. Lower windrower onto flatbed so its weight rests on the tires and sloped edge (D) of header end panels.

8. Block wheels and tie the unit down securely.

NOTE: TONGUE DO E S NOT WIDEN SHIPPING PACKAGE AND HITCH END OF TONGUE EXTENDS APPROX. 2 FT. OVER END OF FLATBED

LOOSEN NUTS TO RAISE TONGUE

RAISE UNIT - POSITION FLATBED

OPERATION

STORAGE PROCEDURE

Do the following at the end of each operating season:

CAUTION:

1. Clean the windrower thoroughly. Neve r us e gasoline, naphtha or any volatile material for cleaning purposes. These materials may be toxic and/or flammable.

2. Cover cutterbar and sickle guards to prevent injury from accidental contact.

Also:

3. Store in a dry, protected place if possible. If stored outside, always cover windrower with a waterproof canvas or other protective material.

4. Raise header and engage lift cylinder stops.

5. If possible, block up the windrower to take weight off tires.

6. Repaint all worn or chipped painted surfaces to prevent rust.

7. Loosen drive belts.

8. Lubricate the windrower thoroughly, leaving excess grease on fittings to keep moisture out of bearings. Apply grease to exposed threads, cylinder rods and sliding surfaces of components. Oil sickle components to prevent rust.

9. Check for worn components and repair.

10. Check for broken components and order replacement from your dealer. Attention to these items right away will save time and effort at beginning of next season.

11. Replace or tighten any missing or loose hardware. See Specifications section for torque charts.

12. Remove divider rods (if equipped) to reduce space required for inside storage.

MAINTENANCE/SERVICE

SERVICE PROCEDURES

CAUTION: To avoid personal injury, before servicing windrower or opening drive covers:

1. Fully lower the windro wer. If necessary to service in the raised position, always engage lift cylinder stops.

2. Disengage PTO.

3. Stop engine and remove key.

4. Engage park brake.

5. Wait for all

Park on level surface when possible. Block wheels securely if w ind rower is p arked on an incline. Follow all recommendations in your Tractor Operator’s Manual.

Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets.

Wear protective shoes with slip-resistant soles, a hard hat, protective glasses or goggles and heavy gloves.

Be prepared if an accident should occur. Know where the first aid kit and fire extinguishers a re located and how to use them.

Keep the service area clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment. Be sure all electrical outlets and tools are properly grounded.

Use adequate light for the job at hand. Replace all shields removed or opened for

service. Use only service and repair parts made or

approved by the equipment manufacturer. Substituted parts may not meet strength, design or safety requirements.

Keep the machine clean. Never use gasoline, naphtha or any volatile material for cleaning purposes. These materials may be t oxic and /or flammable.

moving parts to stop.

MAINTENANCE/SERVICE

TIGHTEN COLLAR IN DIRECTION

RECOMMENDED FLUIDS AND LUBRICANTS GREASE

Use an SAE Multi-Purpose High Temperature Grease with Extreme Pressure (EP) Performance and containing at least 1.5% molybdenum disulphide. (NLGI Grade 2)

Also acceptable is an SAE Multi-Purpose Lithium Base Grease.

HYDRAULIC OIL

Use SAE 15W40 complying with SAE specs for API Class SJ and CH-4 engine oil.

WOBBLE BOX LUBRICANT

In sickle drive wobble box, use SAE 85W-140 gear lubricant (API Service Classification GL-5)

ROLL DRIVE CHAIN CASE See "Grease", above.

CAPACITIES Wobble Box (Sickle Drive) - 2.2 litres (2.3 U.S. quarts) Roll Drive Chain Case - 2000 grams (5 tubes) Hydraulic Reservoir - 12 ft. windrower

14 ft. windrower 16 ft. windrower

STORING LUBRICANTS Your machine can operate at top efficiency only if clean lubrican ts are used. Use clean containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contaminants.

SEALED BEARING INSTALLATION

1. Clean shaft and coat with rust preventative.

2. Install flangette, bearing, second flangette and lock collar. NOTE: The locking cam is only on one side of the bearing.

3. Install (but do not tighten) the flangette bolts.

4. W hen the shaft is correctly located, lock the lock collar with a punch. The c ollar should be locked in the sam e dir ect ion the shaf t r otates . Tighten the set screw in the collar.

5. Tighten the flangette bolts.

6. Loosen the flangette bolts on the mating bearing one turn and re-tighten. This will allow the bearing to line up.

: 93 litres (25 U.S. gallons) : 104 litres (27 U.S. gallons) : 126 litres (33 U.S. gallons)

SHAFT ROTATES

MAINTENANCE/SERVICE

DRIVE SHIELDS

Press a screwdriver against latch in opening at (A ) to open the left and right drive shields on the header.

CAUTION: Ensure shield lock engages in the open position as shown at (B) before letting go of shield.

To close, push shield slightly farther open and move loc k out of engagement slot. Lower shield by hand and release about 12” from fully closed position. Shield will self-latch.

GREASING THE WINDROWER

See "Recommended Lubricants" in this secti on for recommended greases.

The following greasing points are m arked on the machine by decals showing a grease gun (A), and grease interval (B) in hours of operation. Log your hours of operation and use the "Maintenance Checklist" provided to keep a record of scheduled maintenance.

Procedure:

1. Wipe grease fitting with a clean cloth before greasing, to avoid injecting dirt and grit.

2. Inject grease through fitting with grease gun until grease overflows fitting, except where noted.

3. Leave excess grease on fitting to keep out dirt.

4. Replace any loose or broken fittings immediately.

5. If fitting will not take grease, r emove and clean thoroughly. Also clean lubricant passageway. Replace fitting if necessary.

10 Hours or Daily

1. Upper Roll Universal Shaft (C) - three fittings

2. Lower Roll Universal Shaft (D) - three fittings

MAIN DRIVE SHIELDS

25 Hours

1. Sickle Head (E) - one fitting NOTE: To prevent binding and/or excessive wear caused by sickle pressing on guards, do not over grease. If m ore than 6 to 8 pum ps of the grease gun are required to fill the cavity, replace the seal in the sickle head. When changing seal, check pin and needle bearing for wear. R eplace i f necessary . See page

SAMPLE GREASE DECAL

48.

ROLL UNIVERSALS

SICKLE HEAD

MAINTENANCE/SERVICE

LEFT SIDE

RIGHT SIDE

ROLL SHAFT BEARINGS

(continued)

4. Roll Shaft Bearings (G) & (H) - four fittings

REEL AND AUGER BEARINGS - RIGHT SIDE

GREASING THE WINDROWER 50 Hours

1. Main Drive Shaft Bearings (A) & (B)

- two fittings

MAIN DRIVE SHAFT BEARINGS

2. Reel Shaft Bearings (C) & (D) - two fittings

REEL SHAFT BEARING - LEFT SIDE

3. Auger Shaft Bearings (E) & (F) - two fittings

AUGER SHAFT BEARING - LEFT SIDE

MAINTENANCE/SERVICE

LOWER FLOAT LINK BUSHINGS

GREASING THE WINDROWER 50 Hours:

(continued)

5. Frame-to-Header Pivot (J) - two fittings

FRAME-TO-HEADER PIVOT

6. Lower Float Link Bushings (K) - two fittings

7. Tongue Pivot (L) - one fitting

8. Transport Lock Pin (M) - one fitting

TONGUE PIVOT & TRANSPORT LOCK PIN

9. Auger Drive Jackshaft Bearings (N)

- one fitting (on sprocket hub)

AUGER DRIVE JACKSHAFT BEARINGS

MAINTENANCE/SERVICE

WHEEL HUB BEARINGS

GREASING THE WINDROWER 100 Hours:

1. Wheel Hub Bearings (D) - two fittings

CENTER LINK BALL JOINTS

Apply SAE 30 or equivalent lightweight oil to the center link ball joints (A) every 50 hours

(continued)

HITCH PIN LOCK NUT

Check hitch pin nut (C) every 50 hours. 350 ft. lbs. (475 N

CHECK HITCH PIN LOCK NUT

Maintain

⋅m) torque.

OIL CENTER LINK BALL JOINTS

SPRING PIVOTS

Apply SAE 30 or equivalent lightweight oil to the spring pivots (B) every 50 hours.

OIL SPRING PIVOTS

MAINTENANCE/SERVICE

HYDRAULICS

The windrower is hydraulically powered using:

1. A s elf-contained hydraulic system to operate the header functions.

2. The tractor remote system to operate the header lift cylinder and steering cylinder.

Hydraulic Hoses and Lines

Check hydraulic hoses and lines daily leaks.

Relieve pressure before disconnecting hydraulic lines. Tighten all connections b efor e applying pressure. Keep hands and body away from pin- holes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result.

IMPORTANT: Keep hydraulic coupler tips and

connectors clean. Dust, dirt, water and foreign material are the major causes of hydraulic system damage. DO NOT attempt to service hydraulic system in the field. Precision f its require W HITE ROOM CARE during overhaul.

Hydraulic Reservoir

The windrower’s self-contained hydraulic system uses the tongue of the machine f or the hydraulic oil reservoir. See “Recommended Fluids and Lubricants” on page 40 for proper oil type and capacity.

Check oil level daily (A) at rear of tongue. Oil level should be between ADD and FULL mark s on the dipstick when top surface (C) of tongue is level and oil is cold.

removing dipstick (A), unscrew it slowly to vent the build-up of air pressure in the reservoir.

To add hydraulic oil:

1. Loosen hydraulic fitting (B) to vent reservoir, making adding oil easier.

2. Slowly unscrew dipstick (A) from filler tube.

3. Add oil until level is between ADD and FULL marks on dipstick (A). (See page 40 for oil specs).

4. Replace dipstick and tighten fitting (B).

for signs of

WARNING: Avoid high-pressure fluids. Escaping fluid can penetrate the skin causing serious injury.

(before start-up) at dipstic k

WARNING: To avoid injury from contact with hot oil, do not remove dipstick when system is hot. When

AVOID HIGH-PRESSURE FLUIDS

SEARCH PROPERLY FOR LEAKS

HYDRAULIC RESERVOIR

MAINTENANCE/SERVICE

OIL FILTER & RELIEF VALVE

Pump & Gearbox Matching

– Pump (P) and

gearbox (G) must be properly matched for 540 or

rpm. If problems arise related to RPM (sickle

plugging, vibration etc.), check that components

Model numbers are stamped on the pump

HYDRAULICS: Hydraulic Reservoir

Change hydraulic oil every 600 hours or 3 years To drain the reservoir:

1. Loosen hydraulic fitting and remove dipstick as described under "To add hydraulic oil", previous page.

2. Disconnect the pump supply hose (A) from the pump. NOTE: A drain pan with a capacity of 130 litres (35 U.S. gallons) will be required.

Hydraulic Oil Filter

Change hydraulic oil filter (B) after the first 100 hours operation and every 250 hours thereafter. To change:

1. Clean around the filter head.

2. Remove the filter and clean the gasket surface of the filter head.

3. Apply a thin film of clean oil to the gask et on the new filter.

4. Install new filter. Turn the filter onto the mount until the gasket contacts the filter head. Tighten the filter an additional 1/2 to 3/4 turn by hand.

IMPORTANT: Do not use a filter wrench to install the filter. Over-tightening can damage gasket and filter.

Hydraulic Relief Pressure

A possible cause of poor cutting performance and/or excessive heating of hydraulic oil is low relief pressur e. Relief valve (D) is factory set at 4000 psi (27.6 MPa). See your dealer for adjustment or s ervice. A pressure gauge can be installed at tapped elbow (C).

ELECTRICAL

Use electrical tape and wire clips as required to prevent wires from dragging or rubbing.

Keep lights clean and replace burnt bulbs. To replace light bulbs

1. Using a phillips screwdriv er, remove screws (B ) from fixture, freeing amber cover.

2. Replace bulb, plastic lens, and reinstall screws.

NOTE: Bulb trade #1156.

Wiring Harness:

White - ground Yellow - L/H amber Brown - red tail light Green - R/H amber

(continued)

1000 are matched as follows:

540 RPM: Pump 73428 LA_ with Box 77020_ _ 1000 RPM: Pump 73424 LA_ with Box 77030_ _

mounting flange and the gearbox front plate.

• ENSURE RPM MATCH AT PUMP/GEARBOX

• DRAIN RESERVOIR AT PUMP SUPPLY HOSE

REPLACING LIGHT BULBS

MAINTENANCE/SERVICE

OIL KNIFE DAILY EXCEPT IN SANDY SOIL

SICKLE AND SICKLE DRIVE

WARNING: Keep hands clear of the area between guards and sickle at all times.

CAUTION: Wear heavy gloves when working around or handling sickles.

Sickle Lubrication

Apply SAE 10 or equivalent light weight oil daily (one or two drops per section) along entire length of sickle.

NOTE: Do not oil sickle if operating in sandy conditions. Oil will cause sand to adhere to sickle components, resulting in excessive wear.

Sickle Sections

Check daily sickle back and are not worn or broken. Replace as required.

To replace sickle section:

1. A worn or broken sickle section (C) can be replaced without removing sickle from cutterbar.

2. Remove lock nuts and lift section off of bolts. IMPORTANT: Do not mix heavy and light sickle sections o n same sickle.

3. Clean any dirt off of sic kle back and position new sickle section on bolts. Secur e with locknuts.

To Remove Sickle

1. Clean area around sickle head. Stroke sickle to its outer limit and remove bolt (A).

2. Insert screwdriver in slot (B) and pry up on sickle head pin to free sickle.

3. Pull sickle out.

4. Cover sickle head to shield bear ing from dirt.

that sections are firm ly bolted to the

WARNING: Always stand to rear of sickle during removal to reduce risk of injury from cutting edges. Wear heavy gloves when handling sickle.

KEEP HANDS AWAY FROM SICKLE

BOLT-ON SECTIONS

REMOVING SICKLE

MAINTENANCE/SERVICE

SICKLE AND SICKLE DRIVE

(continued)

Sickle Head Needle Bearing Installation

Using a flat-ended tool (A) with approximately the same diam eter as the bearing, push the bearing into the sickle head until the top of the bearing is flush with the step (B) in sickle head. IMPORTANT: O-ring and plug must be in place in sickle head before installing bearing. Assemble the bearing with the stamped end (the end with identification markings) against the tool.

Install seal (C) in top of sickle head with lip facing outwards.

IMPORTANT: To avoid premature sickle head or wobble box failure, be sure there is no looseness in: a) Fit of sickle head pin and needle bearing. b) Fit of sickle head pin and pitman arm.

To Install Sickle

WARNING: Always stand to rear an d grasp rear edge of sickle during installation to reduce risk of injury from cutting edges. Wear heavy gloves when handling sickle.

IMPORTANT: Always align guards and re-set

sickle hold-downs while replacing sickle.

1. Slide sickle into plac e, install sickle head pin

and replace bolt (D). To ease assembly, remove lube fitting from pin. Replace when installation is complete. NOTE: Bottom of groove in sickle head pin must be flush with top face (E) of pitman arm.

2. Tighten bolt (D) to 160 ft.lbs. (220 N.m).

Spare Sickle Storage

A spare sickle (F) may be stored in header frame tube at left end, as shown below. Ensure guard tool/wrench (G) and hairpin are in place as shown to secure the spare sickle.

NEEDLE BEARING INSTALLATION

INSTALLING SICKLE

INSTALLING SICKLE – FRONT VIEW

MAINTENANCE/SERVICE

SICKLE AND SICKLE DRIVE Guards

Check daily proper shear cut between sickle section and guard. Sickle sections should contact shear surface of each guard.

Align guards with guard straighte ning tool provi ded as shown:

To bend guard tips up, position tool as s hown at (A) and pull up.

To bend tips down, position tool as at (B) and push down.

NOTE: Tool is stored in header frame tube at left end. See (G) in photo on page 48 (bottom left).

TIP: If trouble is encountered cutting tangled, but easy to cut material (canola, peas, grain) r eplace guards with stub guards or install a sic kle holddown on every guard. If material is tough to cut, install stub guards with top guard and adjuster plate. A stub guard conversion kit for the Windrower is available from your dealer.

Excessive Breakage

Excessive breakage of sickle sections and guards can be controlled by several factors. See "Cutting Height", "Header Angle" and "Header Flotation" in Operation section for recommendations.

Sickle Hold-Downs

Check daily prevent sickle s ections from lifting of f guards but still permit sickle to slide without binding. Set holddowns after guards are aligned.

To set hold-downs:

1. Use the unplug wrench (A) with the flattened

2. After adjusting all hold-downs, run header at a

that guards are aligned to obtain

that sickle hold-downs are set to

end against the front edge of hold down. Str ike wrench with a hammer. This allows adjustment of hold-down arch (B) without "pinching" sickle. Clearance from hold-down to sickle section should be .020 inch (0.5 mm).

low engine speed and listen for noise due to insufficient clearance. Re-adjust as necessary by placing a .020 inch (0.5 mm) shim between hold-down and section, then striking the holddown arch (B) with a hammer.

(continued)

BENDING GUARD TIPS UP

BENDING GUARD TIPS DOWN

SETTING SICKLE HOLD-DOWNS

MAINTENANCE/SERVICE

SICKLE AND SICKLE DRIVE Sickle Drive Belt Tension IMPORTANT: To prolong belt and drive life, do not

over-tighten belt. To adjust:

1. Loosen nut (A) securing idler pulley.

2. Using a punch or s cr ewdriver in pry holes (B), raise idler until a force of 12 lbs. (55 N) deflects belt 1/2 inch (13 mm) at mid-span.

3. Tighten nut (A).

4. Re- adjust tension of a new belt after a short run-in period, (about 5 hours).

Sickle Drive Belt Replacement

To remove belt:

1. Loosen chain idler sprocket (C) and remove chain from drive sprocket behind pulley (D).

2. Loosen and remove auger drive belt as fol lows:

• Loosen nuts (E).

• Back off nut (F) and back bolt out of adjuster

bracket until belt can be removed. (Access bolt head under end panel.)

3. Loosen sickle drive belt idler pulley (A).

4. Remove belt from sickle drive pulley.

5. Remove bolt-in plate in left end sheet at wobble box (G), and route belt through this hole.

When installing new belt, never pry belt over pulley. Be sure idler is fully loosened, then tension belt as above.

(continued)

SICKLE DRIVE BELT TENSION ADJUST.

SICKLE DRIVE BELT REMOVAL

MAINTENANCE/SERVICE

WOBBLE BOX MOUNTING

BOLTS

SICKLE AND SICKLE DRIVE Wobble Box Maintenance Mounting Bolts - Check four wobble box

mounting bolts (B) torque after the first 10 hours operation and every 100 hours thereafter. Torque should be 200 ft.lbs. (270 N start with the side mounting bolts.

Lubricant - Check wobble box lubricant level before first operation and every 100 hours thereafter. To check:

1. Raise header to a point where the wobble box base is approximately level.

2. Remove breather/dipstick ( A). Oil level must be between end of dipstick and bottom hole (or groove) in dipstick.

3. Add as requir ed. See "Recommended Lubricants" for specified gear lube and capacity of box.

4. Replace breather/dipstick.

Change wobble box lubricant after the first 50 hours operation and every 1000 hours (or 3 year s) thereafter.

To drain wobble box, raise header fully and engage header lift cylinder stops. Remove breather/dipstick (A) and drain plug (D).

Assembly/Disassembly

If removing wobble box pulley, a 3-jaw puller is recommended.

When reinstalling drive arm or pulley:

1. Remove any rust or paint from inner spline. For

replacement parts, remove oil/grease with degreasing agent.

2. Before assembly, apply Loctite® #243 adhesive

(or equivalent) to spline. Apply in two bands (C) as shown, with one band at end of spline and one band approximately mid-way.

(continued)

⋅m). When tightening,

USE ADHESIVE FOR ASSEMBLY

& LUBRICANT

MAINTENANCE/SERVICE

REEL AND REEL DRIVE Reel Drive Chain Lubrication

Lubricate chain daily Apply oil to upper edge of lower chain span (A).

Reel Drive Belt Tension IMPORTANT: T o prolong drive life, do not over -

tighten belt. Belt slippage is used to protect the reel in an overload situation.

To adjust reel drive belt tension:

1. Loos en jam nut (A) on adjuster bolt and two

flange nuts (B) at reel drive arm.

2. To tighten belt, tighten adjus ter bolt (C) until a

force of: NEW BELT - 20 lbs. (80 N) USED BELT - 12 lbs. (55 N) deflects belt 1/4 in. (6 mm) at mid-span (F).

3. Tighten jam nut (A) and two flange nuts (B).

4. Re-adjust tension of a new belt after about 5 hours of operation to used belt specifications.

5. Check reel drive chain tension and adjust if necessary. See below.

Reel Drive Chain Tension NOTE: For major adjustments, like after

repositioning reel or auger, adjust belt tension before

chain tension.

To adjust reel drive chain tension:

1. Loosen nut (D) and back off nut (E).

2. To increase tension, turn nut (F) to move idler sprocket downward until total chain slac k at (G) is 1/2 in. (13 mm).

3. Tighten nuts (D) and (E).

Reel Tines

Keep reel tines in good condition. Straighten or replace as required.

with a light weight oil (SAE 30).

OIL REEL DRIVE CHAIN

REEL DRIVE BELT TENSION ADJUSTMENT

REEL DRIVE CHAIN ADJUSTMENT

MAINTENANCE/SERVICE

AUGER AND AUGER DRIVE Auger Position

The auger position has been factory set and should not normally require adjustment. For nearly all conditions, the auger performs best when set as close as poss ible to the stripper bars without rubbing. This is espec ially important in gr as s and other crops which have a tendency to wrap. Component wear may cause clearances to become excessive, r esulting in feeding problem s and uneven windrows.

NOTE: In heavier crops it may be necessary to remove the front stripper for smoother crop flow across the auger.

Should adjustment be required:

1. Loosen nut (A), lef t s ide, sec uring auger drive chain idler sprocket.

2. Loosen reel drive belt and chain. See page 52 for adjustment details

3. Loosen bolts (B), four per side.

4. To adjust auger fore-aft

a. Loosen jam nut on bolt (C), both sides. b. Turn adjuster nuts to move auger fore or aft to

desired position.

c. Tighten jam nut on bolt (C).

5. To adjust auger vertical position:

a. Loosen jam nuts (D), two per side. b. Turn push bolts ( E), two per side, to lower or

raise auger.

c. Tighten jam nuts (D).

NOTE: The auger should clear the stripper bars on the auger pan by approximately 1/32” – 5/32” (1 - 4 mm).

AUGER POSITION ADJUSTMENTS

See next page for stripper adjustment.

6. Tighten bolts (B) to secure the position.

7. Adjust tension of auger drive chain, reel drive belt, and reel drive chain. Tighten hardware.

MAINTENANCE/SERVICE

AUGER AND AUGER DRIVE

Stripper Bars

To adjust:

1. Position auger for clearance to strippers (A)

and (B), as shown. Use shims as required at stripper bars (A) and (B). See Parts Catalog.

2. Loosen bolts (H) along upper stripper bar.

3. Slide extension bars (J) in or out to obtain

approximately 1/32 – 5/32” (1 – 4 mm) clearance to auger flighting (K) along entire auger length.

4. Tighten bolts (H).

NOTE: In heavier crops it may be necessary to remove the front stripper (A) for smoother crop flow across the auger.

1 – 4 mm (1/32 – 5/32”) CLEARANCE

1 – 4 mm

(1/32 – 5/32”)

CLEARANCE

STRIPPER BAR ADJUSTMENT

MAINTENANCE/SERVICE

AUGER DRIVE CHAIN

AUGER DRIVE BELT

AUGER AND AUGER DRIVE

(continued)

Auger Drive Chain Lubrication

Lubricate auger drive chain daily oil (SAE 30).

Auger Drive Chain Tension

To tighten auger drive chain:

with lightweight

1. Loosen idler sprocket mounting bolt (K).

2. Using a punch or scr ewdriver in pry holes (L),

move sprocket upward until deflection at (M) is 1/4 inch (6 mm).

3. Tighten bolt (K).

Auger Drive Belt Tension IMPORTANT: T o prolong drive life, do not over -

tighten belt. Belt slippage is used to protect the auger in an overload situation.

NOTE: Minor belt tension adjustments may be made without affecting chain tension. F or major adjustments, like after repositioning reel or auger, adjust chain tension before

belt tension.

To adjust auger drive belt tension:

1. Loosen nuts (P) at auger drive arm.

2. Back off jam nut (R), then turn adjuster bolt

(access under end panel) until a force of:

NEW BELT - 20 lbs. (80 N) USED BELT - 12 lbs. (55 N)

deflects belt 1/4 in. (6 mm) at mid-span.

3. Tighten jam nut (R) against frame t o secure the

position, then tighten nuts (P).

TENSION ADJUSTMENT

4. Re-adjust tension of a new belt after about 5

hours of operation to used belt specifications.

TENSION ADJUSTMENT

MAINTENANCE/SERVICE

ROLLS AND ROLL DRIVE Roll Drive Chain Tension

Check chain tension after the first 10 hours operation and every 100 hours or annually thereafter, as follows:

1. Remove rubber plug at left side of chain case.

(See "Roll Drive Chain Case Lubricant" bel ow.)

2. Chain s hould deflect a maximum 1/4 inc h (6

mm) each way.

3. If adjustment is required:

a. Loosen nut (B). b. Loosen two bolts (C). c. To tighten chain, rotate cam clockwise,

using a 15/16 wrench on welded nut (D). (To loosen chain, rotate cam counterclockwise.)

d. Tighten nut (B) and bolts (C).

4. Check chain deflection as in step 2, and

replace plug (A).

Roll Drive Chain Case Lubricant

Check chain lubrication after the first 10 hours operation and every 100 hours or annually thereafter, as follows:

1. Remove rubber plug (A) from chain case.

2. Chain should be coated with grease.

3. If required, add one complete tube (400 g) of

SAE Multi-Purpose (EP) Lithium Base Grease (NLGI Grade 2) to the chain case. Case capacity is 2000 grams (5 tubes).

4. Replace plug (A).

CHAIN TENSION ADJUSTMENT

CHECK CHAIN CASE LUBE LEVEL

MAINTENANCE/SERVICE

ROLLS AND ROLL DRIVE Roll Timing

For proper conditioning, the rolls must be timed with each steel bar on one roll centered between two bars of the other roll as shown.

Examine roll tim ing along the length of the rolls and adjust to desired position as follows:

1. Adjust roll drive chain tension (previous page).

2. Loosen two bolts (A) in slots

either upper or lower roll universal shaft.

3. Remove bolt (B) from one of the series of holes

in yoke plate.

4. Turn rolls to achieve best timing.

5. When roll timing is satisfactory, align any o f the

holes in yoke plate with a hole in mating plate at drive case and install and tighten bolt (B). Tighten bolts (A) to secure the position.

NOTE: This adjustment should be made in conjunction with the "Roll Gap" adjustment, detailed in Operation section.

WARNING: To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engin e, remove key and engage lift cylinder stops before going under machine to examine roll timing, or for any reason.

(continued)

of yoke plate on

ROLL TIMING

ROLL TIMING ADJUSTMENT

MAINTENANCE/SERVICE

ROLLS AND ROLL DRIVE Roll Drive Chain Removal

1. Raise header. Stop engine, rem ove key and

engage lift cylinder stops.

2. Remove bolts securing upper cover (A) to

chain case. Loosen clamp bolt (B) and slide the cover down the drive shaft shield.

3. Remove bolts securing lower cover (C) and

remove cover.

4. Loosen two bolts (D) and nut (L) at chain

tensioner.

5. Rotate tensioner cam counter-clockwise , usin g

a 15/16 wrench on welded nut (E).

6. Remove the chain tensioner sprocket from

inside chain case.

NOTE: Be careful not to lose the three washers

between the sprocket and inner cam disc.

7. Rotate upper or lower roll universal joint to

position chain connector link (F) as shown.

8. Remove connector link (F).

9. Turn lower roll u-joint to r otate lower sprocket

(G) counter-clockwise until chain is free of the lower sprocket.

10. Lift excess chain up and bring it out of the

chain case through the top opening.

11. Turn sickle drive pulley at left end of header to

rotate driver sprocket (H) clockwise until chain is free of driver sprocket.

(continued)

RELEASE CHAIN TENSION

REMOVE COVERS

REMOVE CHAIN

MAINTENANCE/SERVICE

CONNECT CHAIN AND

ROLLS AND ROLL DRIVE Roll Drive Chain Installation IMPORTANT: To ensure proper chain quality,

service with original equipment part only.

1. Feed the chain into chain case.

2. Lift chain up to driver sprocket (H) and engage

on first few teeth.

3. Turn sickle drive pulley at left end of header to

rotate driver sprock et counter-clockwise until chain engages upper roll sprocket (J) as shown.

4. Turn upper roll u-joint to rotate upper sprocket

(J) clockwise until chain engages lower roll sprocket (G) as shown.

5. Turn the lower roll u-joint to rotate lower

sprocket (G ) counter-clockwise while holding the first link of the c hain against s pr ocket (G). Continue turning until chain is engaged sufficiently to install connector link.

6. Install connector link (F ) and install the chain

tensioner sprocket (K).

7. Tension c hain as desc ribed on page 56, "Roll

Drive Chain Tension".

8. Scrape old silicone off of chain case and

covers, and clean these surfaces with solvent.

9. Apply new silicone to mating surfaces of chain

case, upper and lower covers, and drive shaf t shield.

10. Bolt covers to chain case and tighten bolt which

clamps upper cover to drive shaft shield.

11. Replace chain case grease to capacity shown

on page 56, "Roll Drive Chain Case Lubricant".

(continued)

ENGAGE DRIVER AND UPPER SPROCKETS

ENGAGE LOWER SPROCKET

INSTALL TENSIONER SPROCKET

MAINTENANCE/SERVICE

WHEELS AND TIRES Wheel Bolts

Check and tighten wheel bolts after the first 1 hour operation and every 100 hours thereafter.

Whenever a wheel is rem oved and re-installed, check torque after one hour of operation. Maintain 120 ft. lbs. (160 N.m) torque.

Follow proper bolt tightening sequence shown. Be sure valve stem (A) points away from wheel support.

CAUTION: When installing wheel be sure to use the holes that are countersunk to match bolt head profile. The second set of "straightthrough" holes do not seat the bolts correctly.

Wheel Removal

1. Raise header fully and engage lift

cylinder stops.

2. Position 5000 lb. capacity jack on mount

provided on frame leg and raise tire just off the ground. Place block under frame leg at (A).

3. Remove wheel bolts

4. NOTE: To remove either wheel on 12

foot windrower, or left wheel on 14 and 16 foot windrower – Remove spindle retaining bolt (B) and slide spindle outboard until clearance to vertical float spring and chain drive housing is adequate for wheel removal.

5. Remove wheel.

6. When replacing spindle retaining bolt

(B), torque nut to 80 ft.lbs. (110 N

Tire Inflation

Check tire pressure daily

WARNING: Service tires safely. A tire can explode during inflation and cause serious injury or death. Do not stand over tire. Use a clip-on chuck and extension

hose. Never increase air pressure beyond 35 psi (241 kPa) to seat the bead on the rim. Replace the tire if it has a de fect. Replace a wheel rim, which has cracks, wear or severe rust. Never weld a wheel rim. Make sure all the air is removed from a tire before removing t he tire from a rim. Never use f orce on an inflated or partially inflated tire. M ake sure the tire is correctly seated before inflating to operating pressure.

Do not remove, install or make repairs to a tire on a rim unless you have the proper equipment and experience to perform the job. Take the tire and rim to a qualified tire repair shop. If the tire is not in correct position on the rim, or is too full of air, the tire bead can loosen on one side, causing air to leak at high speed and with great force. An air leak of this nature can thrust the tire in any direction, endangering anyone in the area.

WHEEL BOLT TIGHTENING SEQUENCE

⋅m).

12’ - REMOVING WHEEL - 14’ & 16’

. Maintain pressures recommended in Specifications section.

SERVICE TIRES SAFELY

MAINTENANCE/SERVICE

MAINTENANCE SCHEDULE

procedures, organized by service intervals. For detailed instructions, see the specific headings in Maintenance/Service section. Use "Recommended Fluids and Lubricants" as specified under that heading.

Service Intervals IMPORTANT: Recommended intervals are for average conditions. Service the machine more often if

operated under adverse conditions (severe dust, extra heavy loads, etc.). Regular maintenance is the best insur ance against early wear and untimely breakdowns. Following this

schedule will increase machine life. Where a service interval is given in more than one time frame, eg. "100 hours or Annually", service the machine at whichever interval is reached first.

CAUTION: Carefully follow safety messages given under "Service Procedures".

AT FIRST USE: See "Preparing the Windrower" and "Break-In Period" in Operation section.

10 HOURS OR DAILY

1. Grease roll universal shafts.

2. Check hydraulic oil level.

3. Check hydraulic hoses and lines for leaks.

4. Oil sickle (except in sandy conditions).

25 HOURS

1. Grease sickle head.

50 HOURS

1. Grease tongue pivot and transport lock pin.

2. Grease main drive shaft bearing.

3. Grease reel shaft bearings.

4. Grease auger shaft bearings.

5. Grease roll shaft bearings.

6. Grease frame-to-header pivot.

7. Grease lower float link bushings.

100 HOURS OR ANNUALLY

1. Check roll drive chain tension.

2. Check roll drive chain case lubricant level.

3. Check wobble box mounting bolt torques.

4. Check wobble box lubricant level.

5. Check wheel bolt torques. * It is recommended that Annual Maintenance be done prior to start of operating season.

END OF SEASON: See "Storage Procedure" in Operation section.

250 HOURS

1. Change hydraulic oil filter.

600 HOURS or 3 YEARS

1. Change hydraulic oil.

1000 HOURS or 3 YEARS

1. Change wobble box lubricant.

The recommended service intervals are in hours of operation.

The following maintenance sc hedule is a listing of periodic maintenance

5. Check sickle sections, guards, & hold-downs.

6. Oil reel drive chain.

7. Oil auger drive chain.

8. Check tire pressure.

8. Grease auger drive jackshaft bearings.

9. Oil center link ball joints.

10. Oil spring pivots.

11. Check hitch pin lock nut torque.

12. Change wobble box lubricant. (First 50

hours only, every 1000 hours thereafter)

6. Grease wheel hub bearings.

7. Change hydraulic oil filter. (First 100 hours

only, every 250 hours thereafter)

MAINTENANCE RECORD

ACTION:

Hour Meter Reading:

Serviced By: Maintenance

Procedure

BREAK-IN

10 HOURS OR DAILY

Roll Universal Shafts

✳

Hydraulic Oil Level

Hydraulic Hoses & Lines Sickle Assembly

✳

Sections, Guards, Hold-downs

✳

Reel Drive Chain

✳

Auger Drive Chain

Tire Pressure

25 HOURS

Sickle Head

✳

50 HOURS

Wobble Box Oil - First 50 H only

✳

Tongue Pivot, Transport Lock

✳

Main Drive Shaft Bearings

✳

Reel Shaft Bearings

✳

Auger Shaft Bearings

✳

Roll Shaft Bearings

✳

Frame-to-Header Pivot

✳

Lower Float Link Bushings

✳

Auger Drive Jackshaft Brngs.

✳

Center Link Ball Joints

✳

Spring Pivots

Hitch Pin Nut Torque

100 HOURS OR ANNUALLY

Hydraulic Oil Filter - First 100 H only

Wheel Hub Bearings

✳

Roll Drive Chain Tension

Roll Drive Case Lube Level

Wobble Box Bolt Torque

Wobble Box Lubricant Level

Wheel Bolt Torque

250 HOURS

S Hydraulic Oil Filter

600 HOURS OR 3 YEARS

S Hydraulic Oil

1000 HOURS OR 3 YEARS

S Wobble Box Lubricant

9 - Check

See “Preparing the Windrower” and “Break-In Period” (Pages 15 & 18) for checklist.

✳ - Lubricate

S - Change

TROUBLE SHOOTING

Cutting height too low in

Raise cutting height with

tain proper RPM on

Header angle too flat for

Replace worn or broken

Straighten a bent sickle.

SYMPTOM

Excessive breakage of sickle sections o r guards.

Sickle back breakage.

Ragged or uneven cutting of crop.

PROBLEM

stony conditions.

Header angle too steep in stony conditions.

Header flotation too heavy in stony conditions

Guards, sickle and holddowns misaligned.

Ground speed too high in stony conditions.

Sickle speed too slow.

Bent or broken guard. Worn sickle head pin. Dull sickle.

guards to pick up down crop.

Reel position incorrect.

PTO speed too slow.

Relief valve pressure too low.

Sickle sections or guards are worn or broken.

Bent sickle causing binding.

Sickle hold-downs improperly adjusted.

SOLUTION

skid plates.

Decrease header angle

Adjust to lighter float setting.

Straighten guards, align hold-downs.

Reduce ground speed.

Main PTO. Check for proper match of pump & geardrive at PTO.

Straighten or replace. Replace. Replace.

Increase header angle.

Move reel forward and down.

Maintain proper RPM on PTO. Check for proper match of pump & geardrive at PTO.

Replace valve.

parts.

Check alignment and adjust if necessary.

Adjust hold-downs so sickle works freely, but still keep sections from lifting off guards.

REF.

--46

49 48 48

--46

TROUBLE SHOOTING

for more aggressive tine

Header angle too flat for

Maintain proper RPM on

cutting components and

SYMPTOM

Ragged or uneven cutting of crop. (continued)

Long stubble in down crop.

Rotate cam clockwise

PROBLEM

Bent or misaligned guards causing poor shearing action.

Header flotation too light, causing bouncing.

Ground speed too fast.

Sickle drive belt too loose.

Reel drive chain too loose.

Reel position incorrect.

SOLUTION

Align guards for proper shearing action.

Adjust to heavier float setting.

Slow down. Ground speed should not exceed 8 mph (13 km/h).

Increase belt tension.

Increase chain tension.

Move reel forward and down.

(viewed from R/H end)

REF. 49

action.

Excessive vibration of cutting parts.

Knocking in sickle drive.

Pulling material by the roots or tall material leaning into machine.

guards to pick up down crop.

Ground speed too fast. Cutting height too high.

Incorrect PTO speed.

Excessive looseness of sickle and sickle drive parts.

Worn sickle head pin. Worn needle bearing in

sickle head. Reel position incorrect.

Ground speed too slow. Reel speed too fast.

Increase header angle.

Slow down. Lower cutting height

with skid plates.

PTO. Check for proper match of pump & geardrive at PTO.

Remove all excessive play from cutterbar and sickle drive to reduce vibration, then adjust

drive. Replace.

Replace.

Move reel forward and down.

Increase ground speed. Reduce reel speed.

26 29

--46

48 48

26 27

TROUBLE SHOOTING

Replace worn or broken

Maintain proper RPM on

SYMPTOM

Leaving small strip of flattened, uncut material.

Sickle plugging

Header turns while unloaded but slows or stops when starting to cut.

Defective O-ring inside

(* - See your Dealer)

PROBLEM

Ground speed too fast. Crowding of the uncut

material. Reel position incorrect.

Sickle sections or guards are worn or broken.

Extremely thick or wet undergrowth.

Sickle sections or guards are worn or broken.

Bent or misaligned guards.

Sickle hold-downs improperly adjusted.

Sickle drive belt too loose.

Header flotation too heavy.

PTO speed too slow.

Cold oil in system.

Low reservoir oil level.

relief valve. Defective relief valve. Defective motor Defective pump. PTO slipping on tractor.

Replace relief valve. *

SOLUTION

Slow down. Steer tractor slightly

away from uncut crop. Move reel forward and

down.

parts.

Raise cutting height to clear undergrowth.

Move reel back and down (close to guards).

Cut when undergrowth is dry.

parts.

Align guards.

Adjust hold-downs so sickle works freely.

Adjust belt tension.

Adjust to lighter float setting.

PTO. Check for proper match of pump & geardrive at PTO.

Reduce ground speed until oil reaches operating temperature.

Add oil to reservoir.

Repair relief valve. Repair motor. Repair pump. Repair tractor PTO

system.

REF. 26

---

--46

* * * *

TROUBLE SHOOTING

ap too small in thick

extremely tall, heavy crop

Reel not feeding properly

SYMPTOM

PROBLEM

SOLUTION

REF.

Excessive heating of hydraulic oil.

Rolls plugging.

Header stalling in (6+ tons per acre)

Install tall crop divider. 67 Insufficient crop

Leaves damaged, crushed or stripped off stems.

Insufficient conditioning of stems.

Uneven formation and bunching of windrow.

Uneven crop flow across

Uneven windrow formation in light crop.

Windrower side drift.

Auger and/or conditioner rolls damaged by stones.

Relief pressure too low.

Roll gap too large for proper feeding.

Roll g stemmed cane-type crops.

Ground speed too fast. Rolls improperly timed. Feeding aids for shorter,

lighter crop impede flow of heavy or thick stemmed crops (cane, sudan grass etc.).

clearance at rear of feed pan.

Roll gap too small. Rolls improperly timed.

Reel speed too fast.

Roll gap too large.

Rear deflector bypassing or dragging crop.

Auger to stripper clearance too wide.

auger.

in heavy crops. Rear of feed pan too low.

Low tire pressure on one side.

Header is dragging on one end and pulling to that side.

Feed pan doesn’t allow stones to fall through.

Lower rock drop tines 31

Remove front stripper. 54

Replace relief valve. (* - See your Dealer)

Decrease roll gap.

Increase roll gap.

Slow down. Adjust roll timing. Remove front set of

stripper bars. Remove rubber fingers from auger at delivery opening. Increase roll gap.

Increase roll gap. Adjust roll timing.

Reduce reel speed.

Decrease roll gap.

Adjust rear deflector for proper crop control.

Adjust auger to stripper bars clearance.

Decrease ground speed.

Raise rock drop tine bar.

Check and correct tire pressure (30 psi, 207 kPa).

Adjust header flotation. Adjust skid plates to

prevent cutterbar dragging.

Modify feed pan, install fingers.

26 57 54

32 57

31 29

OPTIONS & ATTACHMENTS

The following attachments and optional equipment are available from your Dealer:

ADDITIONAL SKID PLATES

WholeGoods order number: B2149 In addition to the standard two outer skid plates, two inner plates m ay be added for extra control of cutting height and protection of cutting components. See "Cutting Height" in Operation section.

PTO CONVERSION KITS

Parts order number: 540 rpm PTO pump kit – 36909 (converts 1000 rpm to 540 rpm) 1000 rpm PTO pump kit – 36859 (converts 540 rpm to 1000 rpm) Kits are for converting from 540 to 1000 RPM or vice-versa.

TALL CROP KIT

WholeGoods order number: B2539 Kit includes crop dividers and lean bar extensions. IMPORTANT: Lean bar extensions provided in

this kit are not for use in this application, as they will cause crop dividers to contact the swing tongue. These extensions are for use with SelfPropelled Windrower Auger Headers only.

Crop dividers mount to lean bar for clean crop dividing and reel entry in tall crops. Lef t and right dividers are included in the kit. The amount of crop "gathered" by the divider is adjustable. For the most aggressive gathering, mount the divider at the two forward holes (A) and position the U-bolt (B) farther inboard on the lean bar. For the least aggressive gathering, mount the divider at the two rearward holes (C) and position the U-bolt (B) farther outboard on the lean bar. Use minor adjustments of U-bolt position to achieve best results in specific conditions. Crop dividers should be removed for flat-bed transport or for storage.

MOST AGGRESSIVE

LEAST AGGRESSIVE

CROP DIVIDERS

OPTIONS & ATTACHMENTS

STUB GUARD CONVERSION KIT

WholeGoods order number: 12’ – B2515 14’ – B2516 16’ – B2517 Stub guards, complete with top guides and adjuster plates are designed to cut tough crops.

Installation and adjustment instructions are included with the kit.

HYDRAULIC HEADER ANGLE KITS

WholeGoods order number: With Selector Valve – B4256 Without Selector Valve – B4257

These kits allow header angle to be adjusted hydraulically with a cy linder replacing the standard mechanical link. Kit B4257 requires a separate hydraulic circuit from the tractor . Kit B4256 uses the existing tongue steering cylinder hydraulic circuit, and a remote switch-operated selector valve controls which circuit is currently active. Installation instructions are included with the kits.

REPLACEMENT REEL BAT KITS

Wholegoods order number: 12’ – B2890 14’ – B2891 16’ – B2892

Consists of one complete bat assembly for ease of replacement.

HYDRAULIC HEADER ANGLE KIT

STUB GUARDS

UNLOADING & ASSEMBLY

PREPARE TO UNLOAD

CAUTION: To avoid injury to

bystanders from being struck by

machinery, do not allow persons to

stand in unloading area.

1. Move trailer into position and block trailer

wheels.

2. Lower trailer storage stands.

CAUTION: Unloading equipment

must meet or exceed the specified

requirements. Using inadequate

equipment may result in chain

breakage, vehicle tipping or mach ine

damage.

LIFTING VEHICLE REQUIREMENTS

Use a lifting vehicle with a minim um 8000 lb. (3630 kg) lif ting capacity and minimum 15 ft. (4.5 m) lifting height.

CHAIN REQUIREMENTS

Use overhead lifting quality chain (1/2 inch) with minimum 5000 lb. (2270 kg) working load limit.

UNLOAD WINDROWER

WARNING: Be sure forks are secure before moving away from load. Stand clear when lifting.

IMPORTANT: Do not unload using lean bar for

lifting. Chain hook slots in lean bar are only for laying the machine over into working position after it is on the ground.

1. Approach windrower from either its "underside"

as in (A) or "topside" (B) and slide forks in underneath lifting framework as far as p ossible. Take care not to bend parts on back tube.

When poss ible, approach from the underside as in (A) to minim ize potential for scratching the unit.

2. Remove hauler’s tie down straps and chains.

3. Raise windrower off deck.

IMPORTANT: Take care not to contact the other machine if load is two-wide.

4. Back up until unit clears trailer and slowly lowe r

to 6 inches (150 mm) from ground.

5. Take to storage or set-up area.

6. Set machine down securely on level ground.

Check for shipping damage and missing parts.

UNLOADING WINDROWER FROM "UNDERSIDE"

UNLOADING WINDROWER FROM "TOPSIDE"

PREPARE TO UNLOAD

UNLOADING & ASSEMBLY

UNLOAD TONGUE

Attach chain to two brackets (A) on top of tongue. Adjust chain lengths so tongue is lifted evenly.

LOWER WINDROWER TO WORKING POSITION

1. Choose an area with level ground. Rest each

tire on two 2x4’s (side by side) or one 2x6 (B) to provide ground clearance and prevent damage to conditioner shield when windrower is lowered.

2. Block wheels at (C) and set 14 inch (350 mm)

blocks (D) for support at rear of skid plates.

3. Remove deflectors (E). Remove lights from

shipping position (F) at fr am e legs. Set aside. Leave the lifting framework in place to support the top cover as windrower is lowered.

4. Drive lifting vehicle to approach windrower from

its "underside". Attach chain hooks to lean bar at slots (G).

NOTE: Do not lift at lean bar when unloading from trailer. T his procedure is only for laying the machine over into working position.

IMPORTANT: See "Chain Requirements" in this section for m inimum chain spec ifications. Also, chain length must be sufficient to provide a minimum 4 feet (1.2 m) vertical chain height.

5. Raise forks to take most of the weight off

windrower frame and back up SLOWLY to lower machine onto blocks (D).

CAUTION: Stand clear when

lowering, as machine may swing.

6. Check that frame is sitting at proper angle, wit h

tongue pivot pin perpendicular to ground. Remove chain hooks.

ATTACH CHAIN TO TONGUE BRACKETS

PLACE BLOCKS & REMOVE DEFLECTORS

ATTACH CHAIN & LOWER ONTO BLOCKS

UNLOADING & ASSEMBLY

INSTALL TONGUE IMPORTANT: If ther e is m ore than one m ac hine

to be assembled, and they are different sizes (12 ft., 14 ft., 16 ft.) and/or different PTO speeds (540 or 1000), be sure the proper tongue is matched to each unit. Tongues are identified on a plas tic tag tied to the hose support near the front end. Should this tag be missing, tongues can be identified by length as follows:

HEADER SIZE

12 ft. 17’ 7" (5360 mm) 14 ft. 19’ (5780 mm) 16 ft. 21’ 7

* Tongue length is measured from center o f pivot

hole at back end to center of hitch pin hole at front end.

1. Ens ure plastic bushings are installed in pivot

hole at back end of tongue. Remove the shipping wire that secured the bushings. NOTE: The two shorter bushings (A) install from top of tongue, the longer one (F) from the bottom.

2. Install jack in working position at front of

tongue.

3. Cut the banding that secures the hydraulic

cylinder to the tongue, allowing cylinder to move away from frame as tongue is lowered.

WARNING: Keep hands clear when

lowering tongue.

4. Attach chain from lifting vehicle or hoist to

tongue as described on page 70. Lowe r tongue (B) onto pivot pin. NOTE: Use the jack to adjust the pitch of the tongue for proper alignment when installing onto pivot pin.

5. Before tongue is lowered com pletely, position

retainer (C) on top of tongue, over pivot pin bolts (D) and start 5/8 lock nuts (E). Clearance to hydraulic lines will prevent installing this retainer and nuts once the tongue is fully lowered.

6. If tongue is not fully seated on pivot pin, use

nuts (E) to draw the tongue down completely. Torque two 5/8 lock nuts (E) to 160 ft.lbs. (215 N

⋅m).

7. Remove lifting brackets from tongue when

complete.

POSITION LEAN BAR

1. Remove hardware and ins tall lean bar in field

position at height appropriate for crop.

TONGUE LENGTH *

1/2" (6590 mm)

ADJUST LEAN BAR TO SUIT CROP

INSTALL TONGUE

UNLOADING & ASSEMBLY

INSTALL WHEELS IN FIELD POSITION

1. Attach front of tongue to tractor drawbar. See “Attaching Windrower to Tractor” in Operation section. If

tractor is not available, block front of tongue securely.

WARNING: Ensure block at front of tongue is wide and stable enough to prevent tipping off

of block when rear of unit is jacked up to install wheels.

2. Remove jack from working position on tongue.

WARNING: Ensure jack is 5000 lb. capacity before using it to lift frame for wheel

repositioning. Jack label must indicate 5000 lb. maximum capacity. Production units prior to

2003 are equipped with a 2000 lb. capacity jack intended for tongue only. The 2000 lb.

capacity jack is not adequate for lifting frame.

3. Position jack on mount provided on f rame leg and r aise enough to place a 12” (300 mm) block under

frame leg at (A).

4. Remove spindle retaining bolt and nut (B) and move wheels fr om shipping position (C) to field position

(D). NOTE: Shipping position for wheels on 12’ units is outboard of the frame legs. Field pos ition fo r all un its is inboard of frame leg.

5. For both wheels on 12 ft. unit, and left wheel only on 14 and 16 ft. units

achieve enough clearance to vertical float spring and chain drive housing to allow installing the wheels in field position:

• Remove wheel and tire from spindle/hub assembly.

• Install spindle/hub assembly in field position (D).

• Slide spindle outboard until clearance to vertical float spring and/or chain drive housing is adequate for

wheel installation on spindle.

• Reinstall wheel and tire. Tighten wheel bolts.

6. Install spindle retaining bolt and nut (B). Torque the 1/2 inch lock nut (B) to 80 ft.lbs. (110 N·m).

7. Raise jack, remove block and lower machine onto the tire. Torque wheel bolts to 120 ft.lbs. (160 N

8. Repeat steps 2 to 6 at other side.

9. Check tire inflation pressure. Adjust to 30 psi (207 kPa).

, use the following procedure to

⋅m)

12’ 14’ & 16’

INSTALL WHEELS IN FIELD POSITION

UNLOADING & ASSEMBLY

ATTACH LIFT HOSES

CASE DRAIN

ATTACH HYDRAULICS AND ELECTRICAL

1. Attach barrel end (A) of shift cylinder to

bracket on hitch. Attach rod end (B) to bracket on frame tube. Secure pins with cotter pins (installed below brackets).

NOTE: It m ay be necessary to loosen a hose fitting to allow extension of cylinder rod. Be sure to retighten fitting after cylinder installation.

2. Remove lift cylinder hoses and electrical

harness from shipping position in the upright hose support near motor. Route hoses and harness through top clamp (Y) at tongue (see Step 7). Attach lift cylinder hoses to open hydraulic lines at (N) and (P) on top of tongue.

NOTE: Connect hose from left lift cylinder (master) to left hydraulic line, and hose from right lift cylinder (slave) to right hydraulic line. Loosen clamp on top of tongue to ease installation of hoses. Retighten clamp after attaching hoses.

3. Connect electrical wiring harness at (R).

4. Attach hoses to header drive motor:

NOTE: For additional clearance when installing hoses, first lower the header if raised.

a. Remove cotter pin s ecuring bottom of m otor

shield and open shield.

b. IMPORTANT: To prevent contamination of the

hydraulic system, extreme care must be taken to avoid dirt entering at hose ends and motor ports. To minimize exposure to contamination, remove cap from one hos e and its mating motor port plug and connect before removing other caps and plugs. Install hoses in sequence from front to rear of motor (pressure – case drain – return).

PRESSURE FROM

RELIEF VALVE TO

FRONT MOTOR PORT

Ensure that pressure and return hoses are connected to the proper fitting as shown in photo at right. Tighten all hoses securely.

c. Close motor shield and

secure with cotter pin.

INSTALL SHIFT CYLINDER

AND ELECTRICAL HARNESS

RETURN FROM REAR MOTOR PORT TO FILTER

ATTACH HOSES TO MOTOR

UNLOADING & ASSEMBLY

ATTACH HYDRAULICS AND ELECTRICAL

5. Attach lights to left and right frame legs as

follows:

a) Insert light support tube through welded tube on

header frame. NOTE: Left and right lights are different. Ensure light support tube angles towards rear of unit with light outboard, as shown.

b) Install one 3/8 NC x ¾ long hex head bolt (B)

and one 3/8 NC hex nut (C). NOTE: Tighten bolt (B) to secure light firm ly. Do not overtighten bolt. Light must be able to be turned with minimal force. Lock jam nut (C) against tube to secure the position.

c) Secure ground wire to frame at (D) with one ¼

NC x 5/8 long hex head bolt, one ¼ external tooth lock washer (against f rame) and one ¼ NC lock nut.

d) Attach wiring harness to light wiring and cover

with plastic harness sheath.

6. Route motor hoses between holders (M) at

support. To avoid damage to hoses, do not over-tighten holder hardware.

7. Remove top clamp (Y) and place two lift

cylinder hoses and electrical harness across holder. Replace top clamp (Y) to captu re ho ses and harness.

ATTACHING LIGHTS – L/H SHOWN

HOSE ROUTING

UNLOADING & ASSEMBLY

ATTACH HYDRAULICS AND ELECTRICAL

8. Remove shipping material (strapping, wood blocks

and foam wrap) that secures the components at the front of the tongue. Mount pump (S) in storage position at front of tongue.

9. Install quick coupler tips (m atching the tractor to

be used) on the remote hydraulic hoses.

INSTALL SMV SIGN

Install Slow Moving Vehicle sign at rear of unit wi th hardware provided.

REMOVE LIFTING FRAMEWORK & SHIPPING MATERIAL

Remove the yellow lifting framework and any remaining shipping material. Retain the hardware used to secure the lifting framework. Some of this hardware will be reused to install hood and deflectors, next page.

ATTACH WINDROWER TO TRACTOR

See "Attaching Windrower to Tractor" in Operation section for details.

MOUNT PUMP IN STORAGE POSITION

ATTACH SMV SIGN

UNLOADING & ASSEMBLY

INSTALL HOOD A ND DEFLECTORS

1. Loosen 5/8 nut (A) at center link adj usting bolt .

2. Loosen three ½ x 1 inch carriage bolts

securing hood to frame at left, right and center. Swing top hood assembly into field position and fasten to main f rame with ½ x 1 inch carriage bolts and serrated flange nuts at (B), seven places. NOTE: If necessary, temporarily remove top support angle hardware (C) should it interfere with swinging the hood into field position.

3. Attach top support angles to m ain fame with

3/8 x ¾ carriage bolts and smooth flange lock nuts at (C), both sides.

4. Install side deflectors as follows: Insert deflector adjuster rod (E) through opening in hood side shield at

(J), then insert threaded rod of deflector into frame bracket and secure with two ¾ nuts at (D), both sides. Hardware (D) must be tight enough to hold deflectors in position, but still allow positioning with adjuster rods. If forming shield side deflectors are too loose, or if they bind when moved with adjuster rods, back off top nut and adjust lower nut as required. T hen, holding lower nut with a wrench, tighten top nut securely against lower nut.

5. Set forming shield side deflectors to desired width by repositioning adjuster rods (E) in holes. To ensure

windrow placement is centered with respect to tractor wheels, rear edge of left and right side deflectors must be equal distance from tongue center pivot, as shown on decal (F) on the top shield . To a chiev e thi s setting, adjuster rods must be in the corresponding hole both sides. Count holes from inner-most hole (G).

6. Adjust the rear deflector (H) to suit c r op conditions . Adj us t down for more crop control in light material,

and up for clearance in heavier crops. To adjust rear deflector, pull up or push down one side of deflector, then repeat at the other side. There is no hardware to be loosened. For even windrow formation, be sure the deflector is not twisted.

REPEAT AT LEFT

SIDE AND CENTER

SUPPORTS

LOOSEN THREE BOLTS – SWING HOOD UP

UNLOADING & ASSEMBLY

ADJUST HEADER ANGLE AND FLOAT Mechanical Center Link – Adjust header angle by

adjusting center float link to center of slot (A). Hydraulic Header Angle – Adjust header angle by

positioning hydraulic cylinder near center of gauge (B).

Adjust header float. See "Header Angle" and "Header Flotation" in Operation section for adjustment details.

HYDRAULIC HEADER ANGLE KIT

ADJUSTMENTS AND CHECKS

Perform the final checks and adjustments as listed on the "Pre- Deliv ery Checkli st" (y el low sheet) to ensure the machine is field-ready.

IMPORTANT: To avoid machine damage, check that no shipping dunnage has fallen down between auger and pans.

Place Operator’s Manual and Parts Catalog in storage case (C) provided on primary drive shield.

ADJUST LINK TO CENTER OF SLOT

12’ UNITS 14’ & 16’ UNITS

MANUAL STORAGE CASE

INDEX

A PAGE

Assembly....................................................... 69

Attaching the Windrower............................... 16

Attachments.................................................. 67

Auger Drive Chain Lubrication ...................... 55

Auger Drive Chain Tension........................... 55

Auger Position............................................... 53

Ball Joints, center link ................................... 44

Bearing Installation........................................ 40

Break-In Period............................................. 18

Capacities, Enclosed drives & reservoir........ 40

Chemical Drying Agents................................ 35

Climate and Topography Effects................... 34

Corners, square ............................................25

Cutting Height ............................................... 29

Cylinder Stop................................................. 22

Detaching the Windrower.............................. 17

Divider, crop (Tall Crop Attachment)............. 67

Deflector, rear ............................................... 33

Electrical........................................................ 46

Feed Pan / Rock Drop Tine Position............. 31

Forming Shields............................................ 33

Greasing the Windrower............................... 41

Ground Speed............................................... 26

Guards, sickle ............................................... 49

Guard Straightening Tool.............................. 49

Haying Tips................................................... 34

Header Angle................................................ 30

Header Flotation............................................ 31

Hitch Pin Lock Nut......................................... 44

Hydraulic Header Angle Kits (Option) ........... 68

Hydraulic Hoses and Lines ........................... 45

Hydraulic Oil Filter......................................... 46

Hydraulic Oil, recommended......................... 40

Hydraulic Reservoir....................................... 45

Hydraulic System Safety............................... 45

PAGE

Lean Bar Position...........................................26

Lubricants, recommended.............................40

Maintenance Record......................................62

Maintenance Schedule ..................................61

New Operator ................................................13

Operate Correctly...........................................21

Operating Variables.......................................25

Owner/Operator Responsibility......................13

Preparing the Tractor.....................................14

Preparing the Windrower...............................15

Pre-Starting Checks: Annual .........................19

Pre-Starting Checks: Daily.............................20

PTO Conversion Kits .....................................67

PTO Engagement..........................................21

Raising and Lowering the Machine................22

Raking and Tedding.......................................35

Reel Bat Replacement Kits............................68

Reel Drive Belt Tension.................................52

Reel Drive Chain Lubrication.........................52

Reel Drive Chain Tension..............................52

Reel Position..................................................27

Reel Speed....................................................27

Reel Tines......................................................52

Rock Drop Tine Position................................31

Roll Drive Chain Case Lubricant....................56

Roll Drive Chain Removal & Installation........58

Roll Drive Chain Tension...............................56

Roll Gap.........................................................32

Roll Timing.....................................................57

Rolls, unplugging ...........................................36

Safety - Alert Symbol.......................................5

- Cylinder Stop............................................22

- General Farm .............................................8

- Hydraulic System......................................45

- Operating..................................................21

- Pre-Starting Checks: Annual ....................19

- Pre-Starting Checks: Daily .......................20

- PTO ..........................................................21

- Service Procedures ..................................39

- Shut-Down Procedure ..............................37

- Signal Words..............................................5

INDEX

S PAGE

Safety (continued)

- Signs.......................................................... 6

- Storage Procedure................................... 39

- Transporting............................................. 37

- Your Responsibilities ............................... 13

Serial Number Locations................................. 4

Service Procedures....................................... 39

Shields, closing............................................. 41

Shut-Down Procedure................................... 37

Sickle Drive Belt Replacement...................... 50

Sickle Drive Belt Tension .............................. 50

Sickle Guards and Hold-Downs.................... 49

Sickle Head Needle Bearing Installation....... 48

Sickle Installation .......................................... 48

Sickle Lubrication.......................................... 47

Sickle Removal ............................................. 47

Sickle Sections.............................................. 47

Sickle Stub Guard Kit.................................... 68

Sickle, unplugging......................................... 36

Skid Plates.................................................... 29

Skid Plates, additional (Attachment) ............. 67

Specifications: Hardware Torque.................. 11

Specifications: Hydraulic Fitting Torque........ 12

Specifications: Tractor Requirements........... 10

Specifications: Windrower............................... 9

Spring Pivots................................................. 44

Steering the Windrower ................................ 23

Storage Procedure........................................ 39

Stripper Bars................................................. 54

Tall Crop Kit (Attachment)............................. 67

Tire Inflation and Maintenance...................... 60

Topsoil Moisture............................................ 34

Tractor - Preparation..................................... 14

Tractor - Requirements................................. 10

Transporting the Windrower: Flatbed............ 38

Transporting the Windrower: Towing............ 37

Trouble Shooting........................................... 63

Turning, 180

Turning Square Corners ............................... 25

Unloading the Windrower.............................. 69

Unplugging the Rolls..................................... 36

Unplugging the Sickle ................................... 36

Wheel Bolts................................................... 60

Wheel Removal............................................. 60

Windrow Characteristics............................... 35

Windrow, running on previously cut.............. 35

Wobble Box Maintenance............................. 51

°................................................. 24

MacDon 5020 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual