MacDon R80 User Manual

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R80 Rotary Disc

Pull-Type Windrowe

OPERATOR’S MANUAL

Model Year 2009

Part #169053 $15

This Manual contains instructions for “SAFETY”, “OPERATION”, and “MAINTENANCE/SERVICE” for your new

MacDon Model R80 Rotary Disc Pull-Type Mower Conditioner.

R80 PULL-TYPE ROTARY DISC MOWER CONDITIONER

1 INTRODUCTION

This manual describes the operating and maintenance procedures for the MacDon Model R80 Pull-Type Rotary Disc Mower Conditioner. Your new MacDon rotary disc mower conditioner is designed to cut, condition, and lay in windrows a wide variety of grasses and hay crops.

CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR USE THE MACHINE. . Use this manual as your first source of information about the machine. If you follow the instructions given in this manual, your mower conditioner will work well for many years. A Parts Catalog is also supplied with your new header. If you require more detailed service information, a Service Manual is available from your dealer.

Use the Table of Contents and the Index to guide you to specific areas. Study the Table 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 assistance, information, or additional copies of this manual. Store the Operator’s Manual and the Parts Catalog in the plastic manual case inside the header right hand side drive compartment.

RECORD THE SERIAL NUMBERS OF THE HEADER AND ARTICULATING POWER TONGUE (APT) IN THE SPACES BELOW.

HEADER SERIAL NUMBER: ____________________________________

Serial Number plate is located on the top surface at the right hand end of the header.

APT SERIAL NUMBER: ___________________________________

Serial Number plate is located at the left front side of the APT.

Form # 169053 1 Model Year - 2009

TABLE OF CONTENTS

Section/Title Page 1

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

2 SAFETY ............................................................................................................................................................ 5

2.1 SAFETY ALERT SYMBOL ....................................................................................................................... 5

2.2 SIGNAL WORDS......................................................................................................................................5

2.3 SAFETY SIGNS........................................................................................................................................ 5

2.3.1 Safety Sign Installation ......................................................................................................................... 5

2.3.2 Safety Sign Locations ........................................................................................................................... 6

2.4 GENERAL SAFETY................................................................................................................................ 10

3 ACCRONYMS AND ABBREVIATIONS ......................................................................................................... 11

4 COMPONENT IDENTIFICATION ................................................................................................................... 12

5 SPECIFICATIONS .......................................................................................................................................... 15

6 OPERATION ................................................................................................................................................... 17

6.1 OWNER/OPERATOR RESPONSIBILITIES........................................................................................... 17

6.2 OPERATIONAL SAFETY ....................................................................................................................... 17

6.3 TRACTOR SETUP .................................................................................................................................19

6.3.1 Tractor Requirements ......................................................................................................................... 19

6.3.2 Drawbar Adjustment ...........................................................................................................................19

6.3.3 Drawbar Hitch Set-Up ......................................................................................................................... 19

6.3.4 3 Point Hitch (Cat. II, III, or IIIN) Set-Up ............................................................................................. 20

6.4 MOWER CONDITIONER/ TRACTOR HOOK-UP.................................................................................. 22

6.4.1 Drawbar Hook-Up ............................................................................................................................... 22

6.4.2 3 Point Hitch (Cat. II, III, or IIIN) Hook-Up .......................................................................................... 23

6.4.3 Hydraulic Connections ........................................................................................................................ 25

6.5 MOWER CONDITIONER/ TRACTOR UNHOOK................................................................................... 26

6.5.1 Drawbar Unhook ................................................................................................................................. 26

6.5.2 3-Point Hitch Unhook .......................................................................................................................... 27

6.6 BREAK-IN PERIOD ................................................................................................................................ 29

6.7 PRE-SEASON CHECK........................................................................................................................... 29

6.8 DAILY START-UP CHECK..................................................................................................................... 29

6.9 SHUTDOWN PROCEDURE................................................................................................................... 30

6.10 ENGAGING THE PTO............................................................................................................................ 30

6.11 STEERING.............................................................................................................................................. 31

6.11.1 Right Side Operation........................................................................................................................... 31

6.11.2 Left Side Operation ............................................................................................................................. 31

6.11.3 Avoiding Obstacles ............................................................................................................................. 32

6.11.4 Square Corners................................................................................................................................... 32

6.11.5 180 Degree Turn.................................................................................................................................33

6.12 TRANSPORTING MOWER CONDITIONER.......................................................................................... 34

6.12.1 Transporting With A Tractor................................................................................................................ 34

6.12.2 Transporting With a Truck................................................................................................................... 34

6.12.3 Preparing Windrower for Transport..................................................................................................... 36

6.12.4 Flatbed ................................................................................................................................................ 37

6.13 HEADER OPERATION........................................................................................................................... 41

6.13.1 Cutting Height .....................................................................................................................................41

6.13.2 Header Angle ...................................................................................................................................... 42

6.13.3 Header Flotation .................................................................................................................................43

6.13.4 Roll Gap and Timing ........................................................................................................................... 44

6.13.5 Roll Tension ........................................................................................................................................ 46

6.13.6 Forming Shields .................................................................................................................................. 47

6.13.7 Ground Speed..................................................................................................................................... 49

6.14 UNPLUGGING THE MOWER CONDITIONER...................................................................................... 50

6.15 HAYING TIPS ......................................................................................................................................... 50

6.15.1 Curing.................................................................................................................................................. 50

6.15.2 Topsoil Moisture.................................................................................................................................. 50

6.15.3 Weather and Topography ................................................................................................................... 50

6.15.4 Windrow Characteristics ..................................................................................................................... 51

Form # 169053 2 Model Year - 2009

TABLE OF CONTENTS

6.15.5 Driving On Windrow ............................................................................................................................ 51

6.15.6 Raking And Tedding ...........................................................................................................................51

6.15.7 Chemical Drying Agents ..................................................................................................................... 51

6.16 STORAGE .............................................................................................................................................. 51

7 MAINTENANCE/SERVICE ............................................................................................................................. 52

7.1 PREPARATION FOR SERVICING ........................................................................................................ 52

7.2 RECOMMENDED SAFETY PROCEDURES ......................................................................................... 52

7.3 MAINTENANCE SPECIFICATIONS ......................................................................................................53

7.3.1 Recommended Torques .....................................................................................................................53

7.3.2 Recommended Lubricants.................................................................................................................. 55

7.3.3 Conversion Chart................................................................................................................................ 56

7.4 LIFT CYLINDER LOCK-0UT VALVES ...................................................................................................57

7.5 DRIVE SHIELDS ....................................................................................................................................57

7.6 CUTTERBAR DOORS............................................................................................................................ 58

7.7 LUBRICATING THE WINDROWER.......................................................................................................59

7.7.1 Procedure............................................................................................................................................ 59

7.7.2 Lubrication Points ...............................................................................................................................59

I. 13 FT Header................................................................................................................................. 60

II. 16 FT Header................................................................................................................................. 62

III. Carrier Frame................................................................................................................................. 64

IV. Driveline ......................................................................................................................................... 65

7.8 CUTTERBAR.......................................................................................................................................... 66

7.8.1 Skid Plates and Rock Guards............................................................................................................. 66

7.8.2 Cutter Bar Lubrication......................................................................................................................... 68

7.8.3 Disc Maintenance ............................................................................................................................... 69

7.8.4 Cutter Blades ...................................................................................................................................... 72

7.8.5 Accelerators ........................................................................................................................................ 75

7.8.6 Hourglass Deflectors........................................................................................................................... 76

7.8.7 Tall Crop Feed Plates ......................................................................................................................... 79

7.9 HEADER DRIVE..................................................................................................................................... 81

7.9.1 Pump Gearbox.................................................................................................................................... 81

7.9.2 Bevel Gearbox .................................................................................................................................... 81

7.9.3 Conditioner Gearbox – 13 Ft............................................................................................................... 87

7.9.4 Conditioner Gearbox – 16 Ft............................................................................................................... 91

7.9.5 Conditioner Drive Belt......................................................................................................................... 95

7.9.6 Conditioner Drive Belt Idler................................................................................................................. 97

7.9.7 Lifting Roll Drive Belt........................................................................................................................... 98

7.9.8 Lifting Roll Belt Idler ............................................................................................................................ 99

7.9.9 Lifting Roll Idler Bearing...................................................................................................................... 99

7.9.10 Hourglass Deflector Drive Belts – 16 Ft............................................................................................ 100

7.10 HYDRAULIC DRIVE SYSTEM ............................................................................................................. 102

7.10.1 Reservoir........................................................................................................................................... 102

7.10.2 Hydraulic Oil Filter............................................................................................................................. 103

7.10.3 Pressure Relief Valve .......................................................................................................................103

7.10.4 Pump................................................................................................................................................. 104

7.10.5 Hydraulic Motor................................................................................................................................. 106

7.10.6 Hoses and Lines ............................................................................................................................... 106

7.11 ELECTRICAL........................................................................................................................................ 107

7.11.1 Light Bulb Replacement.................................................................................................................... 107

7.11.2 Fixture Replacement......................................................................................................................... 107

7.12 WHEELS AND TIRES ..........................................................................................................................109

7.12.1 Wheel Bolts....................................................................................................................................... 109

7.12.2 Wheel - Removal/Installation ............................................................................................................ 109

7.12.3 Tire Inflation ...................................................................................................................................... 111

7.13 MAINTENANCE SCHEDULE............................................................................................................... 112

7.13.1 Break-In Inspection ........................................................................................................................... 112

7.13.2 Interval Maintenance......................................................................................................................... 113

8 TROUBLESHOOTING.................................................................................................................................. 115

Form # 169053 3 Model Year - 2009

TABLE OF CONTENTS

8.1

MOWER PERFORMANCE................................................................................................................... 115

8.2 MECHANICAL ......................................................................................................................................117

9 OPTIONS AND ATTACHMENTS................................................................................................................. 119

9.1 GAUGE ROLLER KIT........................................................................................................................... 119

9.2 SKID SHOE KIT.................................................................................................................................... 119

9.3 SKID PLATE LIFT KIT .......................................................................................................................... 119

9.4 TALL CROP DIVIDER KIT.................................................................................................................... 119

9.5 CUTTERBAR REPAIR TOOL KIT........................................................................................................ 119

9.6 HYDRAULIC CENTER LINK KIT.......................................................................................................... 119

10 UNLOADING AND ASSEMBLY................................................................................................................... 120

INDEX ....................................................................................................................................................................121

Form # 169053 4 Model Year - 2009

SAFETY

2 SAFETY

2.1 SAFETY ALERT SYMBOL

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.

2.2 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, may result in minor or moderate injury. It is also used as a reminder of good safety practices.

WHY IS SAFETY IMPORTANT TO YOU?

ACCIDENTS DISABLE AND KILL ACCIDENTS COST ACCIDENTS CAN BE AVOIDED

2.3 SAFETY SIGNS

• 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.

2.3.1 Safety Sign Installation

a. Be sure the installation area is clean and dry. b. Decide on the exact location before you remove

the decal backing paper.

c. Remove the smaller portion of the split backing

paper.

d. Place the sign in position and slowly peel back

the remaining paper, smoothing the sign as it is applied.

e. Small air pockets can be smoothed out or

pricked with a pin.

Form # 169053 5 Model Year - 2009

SAFETY

2.3.2 Safety Sign Locations

(BOTH SIDES) #115100

#148829

(BOTH SIDES) #32738

#109843

#134070

Form # 169053 6 Model Year - 2009

#170281

SAFETY

Safety Sign Locations

(cont’d)

#115148

#109843

#44944

Form # 169053 7 Model Year - 2009

BOTH SIDES #142677

SAFETY

Safety Sign Locations (cont’d)

#142909

#36651

Form # 169053 8 Model Year - 2009

SAFETY

Safety Sign Locations

(cont’d)

#44944

#142752

#142912

Form # 169053 9 Model Year - 2009

SAFETY

• Provide a first-aid kit for use in case of

2.4 GENERAL SAFETY

CAUTION

The following are general farm safety precautions that should be part of your operating procedure for all types of machinery.

• 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:

o a hard hat. o protective shoes with slip resistant

soles.

o protective glasses or goggles. o heavy gloves. o wet weather gear. o respirator or filter mask. o 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 muffs (A) or ear plugs (B) protects against objectionable or loud noises.

• Keep a fire extinguisher on the machine. Be

• Keep young children away from machinery at

• Be aware that accidents often happen when

• Wear close-fitting clothing

• Keep hands, feet, clothing

• Keep all shields in place. Never alter or

• Stop engine and remove key from ignition

• Keep machinery clean. Do not allow oil or

• When storing machinery, cover sharp or

emergencies.

sure the extinguisher is properly maintained and be familiar with its proper use.

all times.

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.

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

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

remove safety equipment. Make sure driveline guards can rotate independently of the shaft and can telescope freely.

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

grease to accumulate on service platforms, ladders or controls. Clean machines before storage.

extending components to prevent injury from accidental contact.

Form # 169053 10 Model Year - 2009

3 ACCRONYMS AND

ABBREVIATIONS

TERM DEFINITION

API APT

ASTM

C F ft/min feet per minute

ft/s feet per second gpm U.S. gallons per minute hp horsepower

in. kPa lbf lbf·ft or ft·lbf lbf·in or in·lbf mPa mph N N·m oz. psi PTO rpm SAE

American Petroleum Institute Articulating Power Tongue

American Society Of Testing And Materials

Celsius Fahrenheit

cubic inches kilopascals pounds force pound feet or foot pounds pound inches or inch pounds megapascals miles per hour newtons newton meters ounces pounds per square inch Power Take-Off Revolutions Per Minute Society Of Automotive Engineers

GENERAL

Form # 169053 11 Model Year - 2009

4 COMPONENT

IDENTIFICATION

MANUAL CASE

STEERING CYLINDER

GENERAL

DRIVE MOTOR CENTER LINK CARRIER FRAME

ARTICULATING

POWER TONGUE (APT)

DOOR

BAFFLE CONTROL

FRONT CURTAIN HEADER

13 FT MODEL

TAIL-LIGHT

HAZARD LIGHT

FLOAT SPRING

DRIVE SHIELD CUTTERBAR

Form # 169053 12 Model Year - 2009

LIFT CYLINDER

LOCK VALVE

FLUFFER SIDE DEFLECTOR

GENERAL

HAZARD LIGHT

MANUAL CASE

ARTICULATING

POWER TONGUE

STEERING

CYLINDER

FRONT CURTAIN HEADER

CENTER LINK CARRIER FRAME

DRIVE MOTOR

16 FT MODEL

HAZARD LIGHT FLOAT SPRING

DOOR

BAFFLE CONTROL

TAIL-LIGHT

DRIVE SHIELD CUTTERBAR GAUGE ROLLER

Form # 169053 13 Model Year - 2009

LIFT CYLINDER

LOCK VALVE

FLUFFER SIDE DEFLECTOR

GENERAL

ARTICULATING POWER TONGUE (APT)

STEERING CYLINDER LOCKOUT VALVE

CONTROL HOSES

DRIVELINE

PUMP AND GEARBOX

3-POINT HITCH YOKE TOWING ADAPTER

JACK

SAFETY CHAIN

DRAWBAR HITCH

13 & 16 FT MODELS

Form # 169053 14 Model Year - 2009

SPECIFICATIONS

5 SPECIFICATIONS

HEADER MODEL

FRAME & STRUCTURE

Width

Weight (estimated) 6200 lb (2818 kg) 7130 lb (3240 kg)

Carrier

Lighting

Wheels/Tires

Tread Width

Manual Storage

CUTTERBAR

Qty Of Cutting Discs

Knives Per Disc Disc Speed 2530 rpm

Knife Tip Speed Range

Effective Cutting Width

Cutting Height

Oil Capacity (Maximum)

Cutting Angle Range

Geartrain Protection

Deflectors 2 Hourglass Converging 6 Hourglass Converging

DRIVES Tractor PTO 1.375 in. (35 mm) Dia. 21 Spline or 1.75 in. (44 mm) Dia. 20 Spline

Connections Quick Attachment Coupling

Hydraulic Pump Step-Up Gearbox to 4.9 cu in. (80 cc) Pump

Hydraulic Motor

Power Developed (max) 143 hp (107 kW)

Normal Operating Pressure 2000 psi (13.71 MPa)

CONDITIONER

Drive Bevel Gearbox To Belt Driven Enclosed Timing Gearbox And Driveline. Bevel Gearbox Lub.

Capacity

Roll Type Intermeshing Steel Bars

Roll Diameter

Roll Length

Roll Speed

Swath Width 36-102 in. (915-2540 mm)

Forming Shields

R80 – 13 FT R80 – 16 FT

13 ft-0 in. (3952 mm) 16 ft-3 in. (4957 mm)

Pull-Type

Two Amber Transport and Two Red Tail-Lights

16 in. / 10.00x16 – 4 Rib 16 in. / 14Lx16.1 8 Ply

143 in. (3265 mm) 150 in. (3800 mm)

Plastic Case In Header RH Drive Compartment

8 10

Two 18 Deg. Bevel Down Reversible (11 Deg. Optional)

184 mph (82.9 m/s)

12 ft-9.37 in. (3895 mm) 16 ft-0.87 in. (4899 mm)

1 to 3 in. (25-75 mm) Without Lift Kit 1 to 3 in. (25-75 mm) Without Lift Kit

7 Pints (3.25 Litres) 9 Pints (4.25 litres)

0-8 Deg Below Horizontal

Shearable Disc Spindles

3.7 cu in. (60 cc) To Gearbox

0.9 Pints (0.4 Litres)

Main 9.17 in. (233 mm)/6.62 in. (168 mm) OD Tube

Lifting 9.21 in. (234 mm)/6.62 in. (168 mm) OD Tube

Main 118 in. (3000 mm)

Lifting 118 in. (3000 mm)

Main 1035 rpm

Lifting 690 rpm

Header Mounted Adjustable Baffle, Fixed Side Deflectors, and Header Mounted Adjustable Forming

Shield System.

(continued next page)

Form # 169053 15 Model Year - 2009

SPECIFICATIONS

HEADER MODEL

GROUND SPEED

Recommended Cutting

Recommended Transport

TRACTOR REQUIREMENTS

PTO Power - Minimum

Hydraulics

R80 – 13 FT R80 – 16 FT

8-11 mph (13-18 km/h)

20 mph (30 km/h)

120 hp (90 kW) 150 hp (112 kW) Pressure Controls

Two Double-Acting / One Single-Acting

2000 psi (13.71 MPa)

NOTES: 1. Specifications and design are subject to change without notice or obligation to revise previously

sold units.

2. Tractor must be equipped with a cab.

Form # 169053 16 Model Year - 2009

OPERATION

6 OPERATION

6.1 OWNER/OPERATOR RESPONSIBILITIES

CAUTION

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

• Follow all safety messages in the manual and on safety signs on the machine.

• Remember that YOU are the key to safety. Good safety practices protect you and the people around you.

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

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

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

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

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

• Ensure that the tractor is properly equipped to safely operate the mower conditioner. This may include adding ballast according to Tractor Operator’s Manual requirements for attachments of this size and mass.

6.2 OPERATIONAL SAFETY

Follow these safety precautions:

CAUTION

• 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.

• Never attempt to start the tractor engine or operate the mower conditioner except from the tractor seat.

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

• Do not allow riders on tractor or mower conditioner.

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

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

• Drive slowly through gates and doorways.

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

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

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

• Do not get off the tractor while the mower conditioner is in operation.

• 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.

• Check for excessive vibration and unusual noises. If there is any indication of trouble, shut down and inspect the machine. Follow proper shutdown procedure:

o engage tractor brake o disengage PTO o turn off engine and remove key o wait for all movement to stop o dismount and close lift cylinder

valves before inspecting raised machine.

(continued next page)

Form # 169053 17 Model Year - 2009

OPERATION

• Operate only in daylight or good artificial light.

• Keep everyone several hundred feet away from your operation. Ensure bystanders are never in line with the front or rear of the machine. Stones or other foreign objects can be ejected from either end with force.

• Extreme care must be exercised to avoid injury from thrown objects. Do not, under any circumstances, operate the mower-conditioner when other people are in the vicinity. Stones and other objects can be thrown great distances by the rotating cutting blades.

• The cutterbar curtains are very important to reduce the potential for thrown objects. Always keep these curtains down when operating the mowerconditioner. Replace the curtains if they should become worn or damaged.

Form # 169053 18 Model Year - 2009

OPERATION

6.3 TRACTOR SETUP

6.3.1 Tractor Requirements

R80

MODEL

13 FT 120 (90) As per ASAE 2000 (13.7) 16 FT 150 (112) As per ASAE 2000 (13.7)

MIN POWER

HP (kW)

MINIMUM DRAWBAR

CAPACITY

NOTE

Tractor must be equipped with a seven terminal outlet to supply power to the mower conditioner's hazard lights.

MINIMUM

HYDRAULICS

psi (MPa)

6.3.2 Drawbar Adjustment

CAUTION

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

Adjust tractor drawbar to meet ASAE Standard specifications as listed below.

DIMENSION 1000 RPM PTO

1.75 INCH DIA.

20 in. (508 mm)

1.37 INCH DIA.

16 in. (406 mm)

6-12 in. (152-305 mm)

8 in. (203 mm) Recommended

13-17 in. (330-432 mm)

16 in. (406 mm) Recommended

6.3.3 Drawbar Hitch Set-Up

CAUTION

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

a. Secure the tractor drawbar so the hitch-pin hole

is directly below the driveline.

b. Loosen bolts (B) on extension assembly (A) and

slide onto drawbar.

c. Install pin (C) through drawbar and extension

from underside and secure with hairpin.

d. Gradually tighten the four bolts to 265 ft·lbf (359

N·m).

PTO

TRACTOR

DRAWBAR

e. Attach the swivel APT member (D) with pin (E)

onto the APT.

GROUND

(continued next page)

Form # 169053 19 Model Year - 2009

OPERATION

6.3.4 3 Point Hitch (Cat. II, III, or IIIN) SetUp

f. Secure pin with clevis pin (F), washers, and

cotter pin.

g. Assemble PTO driveline male half (G) onto PTO

shaft (H) on APT. Push male half so that PTO shaft is at its fully compressed length.

h. Locate PTO shaft in hook (J).

a. Attach the 3 point hitch yoke (K) to the APT with

pin (L). The installation is similar to that described in the previous section.

b. Secure pin (L) with clevis pin (M), washers, and

cotter pin.

c. The arms (N) on APT yoke can be set up to suit

the tractor hitch arms:

CATEGORY II or IIIN

CATEGORY III

1. Remove pins (O) from arms.

2. Remove arms (N) from APT yoke.

3. Re-install arms on opposite ends of yoke as shown.

4. Re-install pins (O) in arms.

(continued next page)

Form # 169053 20 Model Year - 2009

OPERATION

NOTE

Bushings (P) on pins can be removed to suit hole size in tractor hitch arms.

d. Assemble PTO driveline male half (Q) onto PTO

shaft (R) on APT. Push male half so that PTO shaft is at its fully compressed length.

e. Locate PTO shaft in hook (S).

Form # 169053 21 Model Year - 2009

OPERATION

e. Attach driveline (E) to tractor PTO shaft as

6.4 MOWER CONDITIONER/ TRACTOR HOOK-UP

follows:

6.4.1 Drawbar Hook-Up

CAUTION

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

a. Remove pin (A).

5. Position driveline onto tractor PTO shaft (F).

6. Pull back collar on driveshaft and push driveshaft until it locks. Release collar.

f. Route safety chain from mower conditioner

through chain support (G), around drawbar support and lock the hook (H) on chain.

IMPORTANT

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

b. Position tractor to align drawbar extension (B)

with arm (C) on mower conditioner.

c. Lower jack (D) to engage arm (C) on drawbar

extension (B).

d. Install hitch-pin (A) and secure with hairpin.

IMPORTANT

If the tractor has a three-point hitch, lower the lower links as low as possible to prevent damage to articulating power tongue (APT).

g. Raise jack (D), pull pin (J) and move jack to

storage position on side of APT.

h. Secure jack with pin (J). i. Proceed to Step 6.4.3 Hydraulic Connections

Form # 169053 22 Model Year - 2009

OPERATION

6.4.2 3 Point Hitch (Cat. II, III, or IIIN) HookUp

CAUTION

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

CAT. II & IIIN CONFIGURATION

a. Position tractor and align tractor hitch arms (A)

with windrower arms (B). Use the jack to adjust

height of windrower APT. b. Secure arms with lynch pins (C). c. Install anti-sway bars on tractor hitch to stabilize

lateral movement of hitch arms (A). Refer to

your tractor operator’s manual.

TRACTOR AXLE

R80 WINDROWER

f. Change locations of pins (F) in APT arms to hole

(G) to locate implement closer to tractor if necessary.

g. Position driveshaft (H) onto tractor PTO shaft.

Driveline should be approximately level.

h. Pull back collar on driveshaft and push

driveshaft until it locks. Release collar.

i. Rotate driveline storage hook (J) to upward

position.

d. Check distance ‘X’ between tractor PTO shaft

K (D) and implement input shaft (E) (without the front half of the driveline attached).

e. The measurement must not exceed the

following:

DRIVELINE SHAFT SIZE DISTANCE ‘X’

1.375 in. (34 mm) 14 in. (356 mm)

1.75 in. (43 mm) 17 in. (432 mm)

j. Attach down-stop chains (K) to pin (L) on tractor.

(continued next page)

Form # 169053 23 Model Year - 2009

OPERATION

CAUTION

The downstop chains limit the downward travel of the 3-point hitch lifting arms to prevent damaging the PTO driveline on the mower-conditioner. Ensure chains are attached when operating the mowerconditioner.

k. Adjust chain length as required by relocating

end link at tractor end of chain as follows:

1. Remove cotter pin and clevis pin (M) to disconnect open link (N) and end link (O).

2. Relocate open link (N) to new location on chain and re-attach to end link (O) with clevis pin (M). Chains do not need to be tight.

3. Secure clevis pin with cotter pin.

m. Secure jack with pin (Q).

l. Raise jack (P), pull pin (Q), and move jack to

storage position on side of APT.

Form # 169053 24 Model Year - 2009

OPERATION

b. Connect two steering cylinder hoses (A) as

6.4.3 Hydraulic Connections

WARNING

Do not use remote hydraulic system pressures over 3000 psi (20684 kPa). Check your tractor manual for remote system pressure.

SYSTEM HOSE

Steering

Lift

Header Tilt

A (2 Hoses) Control 1

B (1 Hose) Control 2

C (2 Hoses) Control 3

NOTE

TRACTOR

HYDRAULICS

Arrows cut into plate indicate system for hoses. LIFT STEERING

c. Connect one lift cylinder hose (B) as follows:

d. Connect two header tilt cylinder hoses (C) as

e. Connect the mower-conditioner wiring harness

follows:

CONTROL

LEVER

POSITION

Forward

Backward

CONTROL

LEVER

POSITION

Forward

Backward

CYLINDER

MOVEMENT

Extend Right Retract Left

CYLINDER

MOVEMENT

Retract Lower Extend Raise

MOWER-

CONDITIONER

DIRECTION

HEADER

MOVEMENT

follows: (Not required with mechanical center link).

CONTROL

LEVER

POSITION

Forward

Backward

CYLINDER

MOVEMENT

Retract Lower Extend Raise

HEADER

MOVEMENT

connector (D) to tractor. The connector is designed to fit tractors equipped with a round 7pin receptacle (SAE J560).

IMPORTANT

Older model tractors will have Pin #4 (F)

a. Ensure hoses are routed through guide (E) to

provide proper hose arc as shown.

energized as an accessory circuit. The R80 mower conditioner uses this pin position (G) for brake lights. Check that Pin #4 in the tractor receptacle is not

constantly energized – see tractor’s operator’s manual and remove the

appropriate fuse if required.

Form # 169053 25 Model Year - 2009

OPERATION

6.5 MOWER CONDITIONER/ TRACTOR UNHOOK

6.5.1 Drawbar Unhook

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 mower conditioner wheels before detaching from tractor.

a. Park machine on flat level surface. b. Lower header onto blocks or leave header

raised. Engage lift cylinder lock-out valves if leaving in raised position.

c. Move remote cylinder control valve lever back

and forth to relieve stored hydraulic pressure.

g. Rotate hook (C) to lower position and position

driveline in hook.

h. Pull pin (D) securing jack (E) and move to

working position at front of APT. Secure jack with pin (D).

d. Disconnect hydraulic hoses and electrical

harness. Store hose ends in holes at front of APT as shown.

i. Lower jack to take weight off tractor drawbar

e. Remove pin (A). f. Pull back collar on driveline (B) and slide coupler

off tractor PTO shaft and rest driveline on drawbar.

Form # 169053 26 Model Year - 2009

(continued next page)

OPERATION

6.5.2 3-Point Hitch Unhook

a. Park machine on flat level surface. b. Lower header onto blocks or leave header

c. If necessary, raise 3-point hitch arms to release

raised. Engage lift cylinder lock-out valves if leaving in raised position.

tension on downstop chains.

CAUTION

j. Remove chain lock (E) and unhook safety chain

from tractor. Wrap chain around APT for

storage. k. Lower jack to raise APT clear of drawbar. l. Slowly drive tractor away from mower

conditioner.

m. Replace hitch pin (G) and secure with hairpin.

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

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

d. Shut off engine and remove key. e. Move remote cylinder control valve lever back

and forth to relieve stored hydraulic pressure.

f. Disconnect hydraulic hoses and electrical

harness. Store hose ends in holes at front of APT as shown.

g. Remove pin (A), and remove down-stop chains

(B) from tractor and store on APT yoke.

(continued next page)

Form # 169053 27 Model Year - 2009

OPERATION

k. Lower jack to raise APT and take weight off

hitch arms.

h. Pull pin (C) securing jack (D) and move to

working position at front of APT. Secure jack with pin (C).

l. Remove lynch pins (G) and swing hitch arms (H)

clear of APT.

m. Slowly drive tractor away from mower

conditioner.

i. Pull back collar on driveline (E) and slide coupler

off tractor PTO shaft.

j. Rotate hook (F) to lower position and place

driveline in hook.

Form # 169053 28 Model Year - 2009

OPERATION

6.6 BREAK-IN PERIOD

a. After attaching mower conditioner to tractor for

the first time, operate the machine slowly for 5

minutes, watching and listening FROM THE

TRACTOR SEAT for binding or interfering parts.

NOTE

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

CAUTION

Before investigating an unusual sound or

attempting to correct a problem, shut off

tractor, engage parking brake and remove

key.

b. Perform the items specified in to paragraph

7.13.1 Break-In Inspection Requirements.

6.7 PRE-SEASON CHECK

Perform the following the beginning of each

operating season:

CAUTION

6.8 DAILY START-UP CHECK

Do the following each day before start-up:

CAUTION

• Be sure tractor and mower conditioner are properly attached, all controls are in neutral and tractor brake is engaged.

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

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

• Remove foreign objects from the machine and surrounding area.

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

• Review the Operator's Manual to refresh your memory on safety and operating recommendations.

• Review all safety signs and other decals on the mower conditioner and note hazard areas.

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

• Be sure you understand and have practiced safe use of all controls. Know the capacity and operating characteristics of the machine.

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

a. Check tension on conditioner drive belt and

adjust if required. Refer to Section 7.9.5 Conditioner Drive Belt.

b. Check tension on hourglass deflector drive belts

and adjust if required. Refer to Section 7.9.10 Hourglass Deflector Drive Belts – 16 Ft.

c. Lubricate machine completely. Refer to Section

7.7 Lubrication.

d. Check tire pressure and adjust as required. See

Section 7.12.3 Tire Inflation.

e. Perform all annual maintenance. See Section

7.13 Maintenance Schedule.

• You may need:

- a hard hat

- protective glasses or goggles

- heavy gloves

- respirator or filter mask

- wet weather gear

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

a. Check the machine for leaks or any parts that

are missing, broken, or not working correctly.

NOTE:

Use proper procedure when searching for pressurized fluid leaks. Refer to Section

7.10 Hydraulic Drive System.

b. Clean all lights and reflective surfaces on the

machine. Check lights for proper operation.

c. Perform all Daily maintenance. Refer to Section

7.13, Maintenance Schedule.

(continued next page)

Form # 169053 29 Model Year - 2009

OPERATION

6.9 SHUTDOWN PROCEDURE

CAUTION

Before leaving the tractor seat for any reason:

• Park on level ground if possible.

• Lower the mower conditioner fully.

• Place all controls in NEUTRAL or PARK.

• Disengage PTO.

• Engage the park brake.

• Stop engine and remove key from

ignition.

• Wait for all movement to stop.

• Lock tractor anti-vandalism covers and

closures when leaving the machine unattended.

6.10 ENGAGING THE PTO

DANGER

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

a. Engage the PTO slowly, just before the mower

conditioner is moved up to the standing crop.

b. Be sure tractor PTO is running at 1000 rpm

before starting to cut.

c. Disengage the PTO when not operating the

mower conditioner.

d. To prevent pump cavitation, run machine at low

tractor idle for approximately 10 minutes when ambient temperature is 50°F (10°C) or less.

Form # 169053 30 Model Year - 2009

OPERATION

6.11 STEERING

IMPORTANT

The valve on the APT must be in the working or open position (handle in line with APT) for the steering system to be operational.

Steering is controlled by the tractor remote hydraulic system. The APT provides the operator the ability to move the mower conditioner into field position easily, allows right angle turns in either direction, steering around objects on both sides and straight line field cutting on either side of the tractor.

IMPORTANT

Hoses should be connected so that moving tractor control lever (A) forward steers the machine to the right and moving the lever (A) backward steers the mower conditioner left.

The control (A) is operated momentarily for steering and must be returned to OFF or NEUTRAL position as soon as the mower conditioner reaches the desired path of travel.

6.11.1 Right Side Operation

Move steering lever forward to achieve desired position of mower conditioner on right side of tractor.

6.11.2 Left Side Operation

Move steering lever backward to achieve desired position of mower conditioner on left side of tractor.

Form # 169053 31 Model Year - 2009

OPERATION

6.11.3 Avoiding Obstacles

Move steering lever as required to avoid obstacles.

6.11.4 Square Corners

c. As the tractor passes the corner, steer it sharply

d. Guide the tractor to straddle the last cut

back towards the uncut crop, taking care that the inside tractor tire does not contact the APT.

windrow. As the mower conditioner finishes turning, steer it back towards the uncut crop, align the header with the crop edge and lower header to cutting height.

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 manoeuvrability.

a. As the tractor approaches the corner, guide the

tractor sharply away from the crop. Steer the mower conditioner to maintain a straight cut ahead as the tractor moves away from the crop.

b. As soon as the header cuts past where the new

corner will be, raise the header sufficiently for skid shoes to clear the ground, then steer the mower conditioner to the extreme direction away from the uncut crop.

Form # 169053 32 Model Year - 2009

OPERATION

6.11.5 180 Degree Turn

NOTE

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

turn-around.

180

a. Beginning at position (A), the tractor is guided

away from the uncut crop while the mower conditioner is guided straight ahead until cutting through the end.

b. As soon as the header cuts through, raise the

header to lift the skid shoes clear of the ground, and steer the mower conditioner to the extreme direction away from the uncut crop.

NOTE

For ease of operation, both levers can be activated with one hand and held until steering cylinder completes its stroke.

c. At position (B), start turning the tractor back

towards the uncut crop.

d. In positions (C) and (D), continue turning

e. At position (E), the tractor completes the circle

f. At position (F), lower header to cutting height

IMPORTANT

When turning, take care that the inside tractor tire does not contact APT of mower conditioner.

towards the uncut crop, (with the mower conditioner steered towards the outside of the turning circle), being aware of APT-to-tire clearance.

and the front wheels are turned to straddle the last cut windrow. At this point, steer the mower conditioner to line up with the edge of the uncut crop.

and begin a new cut through the field.

Form # 169053 33 Model Year - 2009

OPERATION

6.12 TRANSPORTING MOWER CONDITIONER

The R80 Windrower can be transported on public roads by towing with a tractor or a truck. Proceed to 6.12.1 Transporting With A Tractor. or, 6.12.2 Transporting With A Truck.

CAUTION

• Be aware of roadside obstructions, oncoming traffic and bridges.

• Travel speed should be such that complete control and machine stability are maintained at all times. Do not exceed 20 mph (32 km/h). Reduce speed for corners and slippery conditions.

• When transporting on roads, use tractor lights and mower conditioner flashing amber and red tail-lights to provide adequate warning to operators of other vehicles.

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

b. Ensure that APT safety chain is properly

c. Check local laws for width regulations and

d. Do not exceed 20 mph (32 km/h).

6.12.2 Transporting With a Truck

NOTE

The PTO does not need to be attached for towing purposes. If not attached, lower hook (A), store driveline (B) on hook, and remove forward half of driveline. Store forward half in cab for transport.

attached to towing vehicle. Provide only enough slack in chain to permit turning.

lighting or marking requirements before transporting on roads.

CAUTION

Do not tow with a vehicle weighing less than 7500 lb (3400 kg). Ensure that the capacity of the towing vehicle is sufficient to maintain control.

If the windrower is in transport mode, proceed as follows. Otherwise, see 6.12.3 Preparing Windrower for Transport.

6.12.1 Transporting With A Tractor

If the windrower is in transport mode, proceed as follows. Otherwise, see 6.12.3 Preparing Windrower for Transport.

a. Hook-up mower conditioner to tractor. See 6.4

Mower Conditioner/Tractor Hook-up, for details on attaching the mower conditioner to the tractor.

NOTE

The hydraulic hoses do not need to be attached to the tractor for towing. Ensure they are securely stored on the APT.

a. Store hydraulic hoses on the APT as shown

opposite. b. Lower hook (A) and place driveline in hook. c. Remove the forward half (B) of driveline and

store in truck for transport.

(continued next page)

Form # 169053 34 Model Year - 2009

OPERATION

d. Position towing adapter (C) on APT and secure

with pins (D). e. Attach mower conditioner to truck. f. Remove jack from working position and store on

APT. Secure with pin.

g. Wrap safety chain around APT and attach to

truck frame (E). h. Connect electrical harness (F). i. Check local laws for width regulations and

lighting or marking requirements before

transporting on roads. j. Do not exceed 20 mph (32 km/h).

Form # 169053 35 Model Year - 2009

OPERATION

e. If steering cylinder is not fully charged, install

6.12.3 Preparing Windrower for Transport

a. Charge the steering circuit as follows:

1. Connect the two APT steering cylinder hoses to a tractor hydraulic circuit.

2. Steer the header completely to the left, then right. Repeat three or four times.

b. Steer the mower conditioner so that it is

centered behind the towing vehicle.

temporary transport lock pin as follows: Otherwise, proceed to step f.

1. Remove pin from storage at aft end of APT.

c. Close the lock-out valve on the APT.

d. Raise the header fully and engage both header

lift cylinder lock-out valves.

WARNING

Do not tow unless the steering cylinder is fully charged. If steering cylinder is not fully charged loss of control can result in injury or death. Use the temporary transport lock pin if machine must be towed without a fully charged steering cylinder.

2. Line up holes in APT and frame and install transport lock pin as shown.

3. Secure with lynch pin.

f. Check that jack is properly attached in storage

position on APT.

g. Keep SMV sign, reflectors and lights clean and

visible at rear of mower conditioner.

Form # 169053 36 Model Year - 2009

OPERATION

6.12.4 Flatbed

CAUTION

Use the following procedure when transporting the mower conditioner on a flatbed trailer.

6.12.4.1 Loading

d. Remove pin (C) attaching steering cylinder (D)

at frame and swing cylinder under APT. Store pin in barrel end of cylinder.

a. Lower the header to the ground and engage lift

cylinder lock-out valves (A).

b. Retract header angle control link (B) to minimum

length.

c. Unhook tractor from mower conditioner. See

Section 6.5 Mower Conditioner/Tractor Unhook.

e. Secure cylinder (D) to APT with shipping wire or

equivalent.

IMPORTANT

Ensure shipping wire is not over hydraulic lines.

(continued next page)

Form # 169053 37 Model Year - 2009

OPERATION

i. Locate two lifting slings (E) around APT and

frame approximately as shown and attach to fork lift with chains.

NOTE

Adjust position of slings so that mower conditioner is lifted evenly.

f. Attach a chain to front of APT and other end to a

fork lift or equivalent.

g. Lift front of APT and slowly swing APT aft until it

is approximately parallel with carrier frame. Lower APT and remove chain.

IMPORTANT

Ensure hoses on carrier frame are free to move when APT is moved to transport position.

h. Tie APT to frame back tube with shipping wire or

equivalent.

CAUTION

To avoid injury to bystanders from being struck by machinery, do not allow persons to stand in loading area.

CAUTION

Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping or machine damage.

LIFTING VEHICLE

Min. Lifting Capacity 8000 lb. (3630 kg)

Min. Lifting Height 15 ft. (4.5 m)

CHAIN

Overhead Lifting

Quality (1/2 Inch)

j. Lift mower conditioner slightly to take weight off

APT.

5000 lb. (2270 kg) Min. Working Load

IMPORTANT

Ensure shipping wire is not over hydraulic lines.

k. Remove jack from forward end of APT and

move to storage location (G) on APT. Secure with pin.

(continued next page)

Form # 169053 38 Model Year - 2009

OPERATION

l. Slowly drive to flatbed and raise mower

conditioner.

m. Lower mower conditioner onto flatbed. Blocking

is not required. Remove slings from mower conditioner.

n. Secure mower conditioner to flatbed with straps.

6.12.4.2 Unloading

a. Remove tie downs. b. Approach mower conditioner from backside with

forklift.

c. Locate two lifting slings (A) around APT and

frame approximately as shown and attach to fork lift with chains.

NOTE

Adjust position of slings so that mower conditioner is lifted evenly.

CAUTION

To avoid injury to bystanders from being struck by machinery, do not allow persons to stand in loading area.

CAUTION

Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping or machine damage.

LIFTING VEHICLE

Min. Lifting Capacity 8000 lb. (3630 kg)

Min. Lifting Height 15 ft. (4.5 m)

CHAIN

Overhead Lifting

Quality (1/2 Inch)

5000 lb. (2270 kg) Min. Working Load

(continued next page)

Form # 169053 39 Model Year - 2009

OPERATION

d. Lift mower conditioner off flatbed and back away

slowly.

e. Lower mower conditioner to slightly above

ground.

j. Attach a chain to front of APT and other end to a

fork lift or equivalent.

IMPORTANT

Ensure hoses on carrier frame are not pinched when APT is moved to working position.

f. Remove jack (B) from storage location on APT.

g. Install jack at working position (C) at front of

APT.

h. Lower mower conditioner to ground and remove

slings.

k. Lift front of APT and slowly swing APT forward

until it is approximately perpendicular with carrier frame. Lower APT and remove chain.

l. Cut shipping wire securing steering cylinder (D)

to APT. Swing cylinder to attachment bracket (E) on frame.

m. Remove pin (F) from cylinder. n. Align yoke on cylinder with bracket (E) and

install pin (F). Secure with cotter pin.

o. Attach mower conditioner to tractor or towing

i. Cut shipping wire securing APT to carrier frame.

Form # 169053 40 Model Year - 2009

vehicle.

OPERATION

6.13 HEADER OPERATION

Satisfactory operation of the mower conditioner in all situations requires making proper adjustments 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 variables listed below and detailed on the following pages will affect the performance of the mower conditioner. You will quickly become adept at adjusting the machine to give you the desired results.

VARIABLE SECTION

Cutting Height 6.13.1 Header Angle 6.13.2 Header Flotation 6.13.3 Roll Gap/Timing/Alignment 6.13.4 Roll Tension 6.13.5 Forming Shields 6.13.6 Ground Speed 6.13.7

6.13.1 Cutting Height

Cutting height is determined by the angle of the cutterbar/header which can be adjusted with the center link, either hydraulically or mechanically. Optional adjustable gauge rollers or skid shoes are available for 16 ft headers to also provide different cutting heights. Refer to Section 8, Options and Attachments.

Cutting height should be adjusted for optimum cutting performance without allowing excessive build-up of mud and soil inside the header which can lead to poor crop flow and increased wear on cutting components.

6.13.1.1 Gauge Roller Height Adjustment – 16 Ft

DANGER

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

a. Raise header fully, stop engine, and remove

key.

b. Remove lynch pin and remove adjuster pin (A)

from one side of roller.

c. Hold roller and remove lynch pin and adjuster

pin (A) from other side. Position roller at desired position and reinstall adjuster pins (A). Secure

with lynch pins. d. Repeat for roller at opposite end of header. e. Adjust mud bar (B) by loosening nuts (C) and

then re-tighten to maintain minimum clearance

between mud bar and roller.

(continued next page)

Form # 169053 41 Model Year - 2009

OPERATION

6.13.1.2 Skid Shoe Height Adjustment – 16 Ft

DANGER

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

a. Raise header fully, stop engine, and remove

key.

6.13.2 Header Angle

Header (or cutterbar) angle can be varied from 0 to 5° below horizontal with the mechanical center link and 0-8° below horizontal with the hydraulic center link. Choose an angle that maximizes 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.

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

6.13.2.1 Mechanical Adjustment (if equipped)

a. Lower header so that cutter bar is resting on the

ground.

b. Remove lynch pin and remove adjuster pin (D)

from one side of skid shoe.

c. Hold skid shoe and remove lynch pin and

adjuster pin (D) from other side. Position shoe at desired position and reinstall adjuster pins (D). Secure with lynch pins.

b. Loosen nut (A. c. To decrease (flatten) header angle, rotate the

turnbuckle sleeve (B) so that the turnbuckle decreases in length.

d. To increase (steepen) header angle, rotate the

turnbuckle sleeve (B) so that the turnbuckle increases in length.

e. Snug up nut (A) but do not over tighten. A slight

tap with a small hammer is sufficient. f. Check cutting height and adjust if required. g. Check header float and adjust if required. Refer

to Section 6.13.3, Header Flotation.

Repeat for skid shoe at opposite end of header. Cutting height is determined by the angle of the cutterbar/header to the ground which can be adjusted with the center link, either hydraulically or mechanically.

Form # 169053 42 Model Year - 2009

OPERATION

6.13.2.2 Hydraulic Adjustment (if equipped)

The header angle can be adjusted from the tractor without shutting down the mower conditioner.

RED ZONE GREEN ZONE

a. To decrease (flatten) header angle, operate

tractor hydraulic control so that cylinder (C) retracts, moving the gauge (D) toward the green zone.

b. To increase (steepen) header angle, operate

tractor hydraulic control so that cylinder (C) extends, moving the gauge (D) toward the red zone.

6.13.3 Header Flotation

Header flotation springs are normally set so 95105 lbf (426-471 N) is required to lift either end of the header just off the ground. In rough or stony conditions, it may be desirable to maintain a lower force to protect cutting components.

NOTE

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

6.13.3.1 Flotation Adjustment

IMPORTANT

Float setting (or lifting force) must be equal on both ends of the header. Left and right ends require different spring lengths to achieve equal float at both ends.

c. Engage lift cylinder lock-out valves.

d. Back jam nut (A) away from spring. e. To increase flotation, turn adjuster bolt (B)

clockwise (further into spring).

f. To decrease flotation, turn adjuster bolt (B)

counterclockwise (out of spring).

g. Tighten jam nut (A) against spring insert to

secure the setting.

h. Lower header and check header flotation at

each end.

NOTE

Other operating variable adjustments may affect float setting. Check the float and readjust if necessary after adjusting 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.

WARNING

To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engine, remove key and engage lift cylinder lockout valves before going under machine.

a. Center header directly behind the tractor. b. Raise header fully, shut off engine and remove

key.

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

Form # 169053 43 Model Year - 2009

OPERATION

6.13.4 Roll Gap and Timing

Steel rolls "condition" the crop by crimping and crushing 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 is controlled by roll gap. See illustration. The gap is factory set at 1/4 inch (6 mm).

ROLL GAP

CROP

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 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 a smaller gap for proper feeding and conditioning.

IMPORTANT

When the roll gap is decreased, the roll timing is critical because:

• conditioning is affected, and

• the bars may contact each other.

6.13.4.1 Roll Gap Adjustment

DANGER

Stop engine and remove key from ignition

before leaving operator's seat for any

reason. A child or even a pet could engage

an idling machine.

a. Lower header fully.

0.25 in. (6 mm) A

b. Loosen and back-off upper jam nut (A), both

sides of conditioner.

c. To increase roll gap, turn lower nut (B) clockwise

which raises the upper roll.

NOTE

The amount of thread protruding through jam nut should equal roll gap. Factory setting is 1/4 in. (6 mm).

NOTE

When adjusting roll gap, be sure that the thread protrusion is the same on both sides of the conditioner roll to achieve consistent intermesh across the rolls.

d. To decrease roll gap, turn lower nut (B)

counterclockwise which lowers the upper roll.

e. Tighten jam nuts (A), both sides.

ROLL GAP

f. Inspect roll gap at both ends of the rolls at

access port (C).

Form # 169053 44 Model Year - 2009

OPERATION

6.13.4.2 Roll Timing

For proper conditioning, the rolls must be properly timed with each steel bar on one roll centered between two bars of the other roll as shown. The factory setting should be suitable for most crop conditions.

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

c. Remove bolt (D) and nut, and remove gauge (E)

from inside panel at RH end of header.

CROP

Check roll timing (distance ‘X’) as follows:

a. Lower header to ground, shut down tractor and

remove key.

b. Open RH drive shield.

START POSITION

d. Locate gauge at center of rolls as shown and

turn rolls to limits of gauge. Rolls will engage the gauge if timing is correct.

GAUGE POSITION

(continued next page)

Form # 169053 45 Model Year - 2009

OPERATION

e. If required, adjust roll timing as follows:

6.13.5 Roll Tension

1. Open LH drive shield.

The roll tension (the force holding the rolls together) is factory set and is adjustable. If required, adjust as follows:

2. Loosen four bolts (F) in slots of yoke plate on lower roll universal shaft.

3. Position gauge at center of rolls and manually turn the rolls to engage the gauge. The rolls will automatically adjust to the correct timing.

4. Tighten bolts (F) to secure the position.

5. Turn the rolls to release gauge.

WARNING

Remove gauge from rolls and return it to storage location before starting machine.

f. Store gauge inside RH panel with bolt (D) and

nut.

g. Close drive shields.

a. Open LH and RH drive shields.

b. Loosen jam nut (A). c. To increase the roll tension, turn the spring

draw-bolt (B) clockwise to tighten the spring (C) at each end of the roll.

d. To decrease the roll tension, turn the spring

draw-bolts counterclockwise to loosen the

springs. e. Tighten jam-nut (A) after adjusting tension. f. Close drive shields.

Form # 169053 46 Model Year - 2009

OPERATION

6.13.6 Forming Shields

WARNING

Keep hands and feet away from discharge opening. Keep everyone several hundred feet away from your operation. Never direct the discharge 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 should be based on the following factors:

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

• type and yield of crop

• drying time available

• method of processing (bales, silage, "green-

feed")

A wider windrow will generally dry faster and more evenly, resulting in less protein loss. Fast drying is especially important in areas where the weather allows only a few days to cut and bale. Refer to Section 6.15 Haying Tips, for more information.

a. Loosen locking handle (A). b. Move deflector (B to desired position and tighten

handle.

c. Repeat for other side.

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

6.13.6.1 Side Deflectors

The position of the side forming shields controls the width and placement of the windrow.

To ensure windrow placement is centered with respect to carrier wheels, adjust both side deflectors to the same position.

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

Form # 169053 47 Model Year - 2009

OPERATION

6.13.6.2 Rear Deflector (Fluffer Shield)

The rear deflector (C) slows the crop exiting the conditioner rolls, directs the flow downward, and "fluffs" the material.

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

6.13.6.3 Baffle

The baffle (E) determines the width and height of the windrow. It is located immediately behind and above the conditioning rolls, and can be positioned to direct the crop flow from the conditioner downward to form a wide swath.

Adjust the baffle as follows:

Adjust the deflector as follows:

a. For more crop control in light material, lower the

deflector (C) by pushing down on one side of the deflector and then on the other side. Locking handles (D) are located at either end of the deflector and may be loosened slightly.

b. For heavier crops, raise the deflector by pulling

up on one side and then on the other side.

NOTE

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

a. Pull lever (F) to disengage from bracket (G) and

move lever forward to raise baffle and backward to lower baffle.

b. Release lever into bracket.

Form # 169053 48 Model Year - 2009

OPERATION

6.13.7 Ground Speed

CAUTION

Reduce speed when turning, crossing slopes, or when travelling over rough ground.

a. Operate the PTO at rated speed. b. Choose a ground speed that allows the cutterbar

and conditioner to cut the crop smoothly and evenly. Try different combinations of PTO and ground speed to suit your specific crop.

c. In tough cutting conditions, such as native

grasses, the PTO speed will need to be maintained and ground speed decreased.

d. In light crops the PTO can be reduced (reduce

engine rpm) and shifting into a higher gear to maintain ground speed.

NOTE

Operating the header at the minimum PTO speed will extend the wear life of components, and save fuel.

e. The chart below indicates the relationship

between ground speed and area cut for a 13 ft header.

Example: At ground speed of 13 mph (21 km/h) with a 16 ft. windrower, the area cut would be approximately 25 acres (10 hectares) per hour.

kilometers/hour

1.6 3.2 4.8 6.4 8.0 9.7 11.3 12.9 14.5 16.1 17.7 19.3 20.9 22.5 24.1 25.7

acres/hour

1 2 3 4 5 6 7 8 9 10111213141516

16 FT 13 FT

hectares/hour

miles/hour

Form # 169053 49 Model Year - 2009

OPERATION

6.14 UNPLUGGING THE MOWER CONDITIONER

WARNING

Stop tractor engine and remove key before removing conditioner. A child or even a pet could engage the drive.

a. Stop forward movement of the tractor and stop

the PTO.

b. Raise the header fully, shut down the tractor

engine, and remove the key.

c. Engage lift cylinder lock-out valves.

plugged material from mower

WARNING

Wear heavy gloves when working around cutterbar.

d. Open cutterbar doors and clean off cutterbar or

rolls by hand.

6.15 HAYING TIPS

6.15.1 Curing

a. A quick cure will maintain top quality because:

• 5% of the protein is lost for each day hay lies on the ground,

• The sooner the cut hay is off, the earlier the start for next growth.

b. Leaving the windrow as wide and thin as

possible makes for the quickest curing.

c. The cured hay should be baled as soon as

possible.

6.15.2 Topsoil Moisture

a. 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.

b. When the ground is wetter than the hay,

moisture from the soil is absorbed by the hay above it. Determine topsoil moisture level before cutting. Use a moisture tester or estimate level:

LEVEL

Wet Over 45 Soil is Muddy

Damp 25 – 45 Shows Footprints

Dry Under 25 Surface is Dusty

c. If ground is wet due to irrigation, wait until soil

moisture drops below 45%.

d. If 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.

e. The cut hay will dry no more until the ground

under it dries, so consider moving the windrow to drier ground.

% MOISTURE CONDITION

6.15.3 Weather and Topography

a. Cut as much hay 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 hay is baled and chopped, 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.

d. If there is no wind, saturated air becomes

trapped around the windrow. Raking or tedding will expose the hay to fresher, less saturated air.

e. Cut hay perpendicular to the direction of the

prevailing winds is also recommended.

Form # 169053 50 Model Year - 2009

OPERATION

6.15.4 Windrow Characteristics

It is recommended that a windrow with the following characteristics be produced. Refer to Section 6.13 Header Operation for instructions on adjusting the mower conditioner.

CHARACTERISTIC ADVANTAGE

The movement of air through

High And Fluffy

Consistent

Formation, Not

Bunchy

Even Distribution

of Material Across

Windrow

Properly

Conditioned

the windrow is more important to the curing process than direct sunlight.

Permits an even flow of material into the baler, chopper etc.

Results in even and consistent bales to minimize handling and stacking problems.

Prevents excessive leaf damage.

6.15.5 Driving On Windrow

Driving on previously cut windrows 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.

NOTE

Driving on the windrow in high yielding crops may be unavoidable if a full width windrow is necessary.

6.15.6 Raking And Tedding

Raking or tedding speeds up drying, however the benefits must be weighted against the additional leaf losses which will result. There is little or no advantage to raking or tedding if the ground beneath the windrow is dry.

Large 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.

6.15.7 Chemical Drying Agents

6.16 STORAGE

Do the following at the end of each operating season:

a. Clean the mower conditioner thoroughly.

CAUTION

Never use gasoline, naphtha or any volatile material for cleaning purposes. These materials may be toxic and/or flammable.

CAUTION

Cover cutterbar to prevent injury from accidental contact.

b. Store in a dry, protected place if possible. If

stored outside, always cover mower conditioner with a waterproof canvas or other protective

material. c. Raise header and engage lift cylinder lock-outs. d. If possible, block up the mower conditioner to

take weight off tires. e. Repaint all worn or chipped painted surfaces to

prevent rust. f. Loosen drive belts. g. Lubricate the mower conditioner 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 cutterbar

components to prevent rust. h. Check for worn components and repair as

necessary. i. 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. j. Replace or tighten any missing or loose

hardware. Refer to Section 7.3.1 Recommended

Torques. k. Remove divider rods (if equipped) to reduce

space required for inside storage.

Hay drying agents work by removing wax from legume surfaces, 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.

Form # 169053 51 Model Year - 2009

MAINTENANCE/SERVICE

7 MAINTENANCE/SERVICE

The following instructions are provided to assist the operator for servicing the mower conditioner. Detailed maintenance and service information are contained in the Service Instruction Manual that is available from your dealer. A Parts Catalog is located in a plastic case inside the RH drive compartment.

Log hours of operation and use the "Maintenance Checklist" provided to keep a record of scheduled maintenance. Refer to Section 7.13, Maintenance Schedule.

7.1 PREPARATION FOR SERVICING

CAUTION

To avoid personal injury, before servicing mower conditioner or opening drive covers, perform the following:

a. Fully lower the mower conditioner. If

necessary to service in the raised position,

always close lift cylinder valves. b. Disengage PTO. c. Stop engine and remove key. d. Engage park brake. e. Wait for all moving parts to stop.

• 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 toxic and/or flammable.

• Keep the area used for 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.

7.2 RECOMMENDED SAFETY PROCEDURES

• Review Section 2.4 GENERAL SAFETY.

• Park on level surface when possible.

Block wheels securely if mower conditioner is parked on an incline. Follow all recommendations in your Tractor Operator's Manual.

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

• If more than one person is servicing the machine at the same time, be aware that rotating a driveline or other mechanically driven component by hand (for example, accessing a lube fitting) will cause drive components in other areas (belts, pulleys, and sickle) to move. Stay clear of driven components at all times.

• 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.

Form # 169053 52 Model Year - 2009

MAINTENANCE/SERVICE

7.3 MAINTENANCE SPECIFICATIONS

7.3.1 Recommended Torques

• 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.

• Torque figures 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. When using locking elements, increase torque values by 5%.

7.3.1.1 SAE Bolts

BOLT

DIA. "A"

in.

1/4 9 12 11 15

5/16 18 24 25 34

3/8 32 43 41 56

lbf·ft N·m lbf·ft N·m

NC BOLT TORQUE*

SAE 5 SAE 8

7.3.1.2 Metric Bolts

BOLT

DIA.

"A"

M3 0.4 0.5 1.3 1.8

M4 2.2 3 3.3 4.5

M5 4 6 7 9

M6 7 10 11 15

M8 18 25 26 35

M10 37 50 52 70

M12 66 90 92 125

M14 103 140 148 200

M16 166 225 229 310

M20 321 435 450 610

M24 553 750 774 1050

M30 1103 1495 1550 2100

M36 1917 2600 2710 3675

* Torque categories for bolts and capscrews are identified by their

head markings.

lbf·ft N·m lbf·ft N·m

NC BOLT TORQUE*

8.8 10.9

7/16 50 68 70 95

1/2 75 102 105 142

9/16 110 149 149 202

5/8 150 203 200 271

3/4

7/8 420 569 600 813

1 640 867 890 1205

* Torque categories for bolts and capscrews are identified by their

head markings.

265 359

SAE-5 SAE-8

365 495

Form # 169053 53 Model Year - 2009

MAINTENANCE/SERVICE

7.3.1.4 O-ring Type Hydraulic Fittings

7.3.1.3 Flare Type Hydraulic Fittings

FLARE

FLARESEAT

NUT

BODY

a. Check flare and flare seat for defects that might

cause leakage. b. Align tube with fitting before tightening. c. Lubricate connection and hand tighten swivel

nut until snug. d. 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.

TUBE

SIZE

O.D.

(in.)

NUT SIZE

ACROSS

FLATS

(in.)

TORQUE

VALUE*

lbf·ft N·m Flats Turns

3/16 7/16 6 8 1 1/6

1/4 9/16 9 12 1 1/6

5/16 5/8 12 16 1 1/6

3/8 11/16 18 24 1 1/6 1/2 7/8 34 46 1 1/6 5/8 1 46 62 1 1/6 3/4 1-1/4 75 102 3/4 1/8 7/8 1-3/8 90 122 3/4 1/8

* The torque values shown are based on lubricated connections

as in reassembly.

RECOMMENDED

TURNS TO TIGHTEN

(AFTER FINGER

TIGHTENING)

FITTING

SEAT

LOCKNUT

WASHER

O-RING

GROOVE

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

defects.

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

washer (A) bottoms out at top of groove (B) in fitting.

c. Hand tighten fitting until back up washer (A) or

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

d. Position angle fittings by unscrewing no more

than one turn. e. Tighten straight fittings to torque shown. f. Tighten angle fittings to torque shown in the

following table while holding body of fitting with a

wrench.

RECOMMENDED

TURNS TO TIGHTEN

(AFTER FINGER

TIGHTENING)

THD

SIZE

(in.)

NUT SIZE

ACROSS

FLATS

(in.)

TORQUE

VALUE*

lbf·ft N·m Flats Turns

3/8 1/2 6 8 2 1/3

7/16 9/16 9 12 2 1/3

1/2 5/8 12 16 2 1/3

9/16 11/16 18 24 2 1/3

3/4 7/8 34 46 2 1/3

7/8 1 46 62 1-1/2 1/4 1-1/16 1-1/4 75 102 1 1/6 1-3/16 1-3/8 90 122 1 1/6 1-5/16 1-1/2 105 142 3/4 1/8

1-5/8 1-7/8 140 190 3/4 1/8 1-7/8 2-1/8 160 217 1/2 1/12

* The torque values shown are based on lubricated connections

as in reassembly.

Form # 169053 54 Model Year - 2009

MAINTENANCE/SERVICE

IMPORTANT

7.3.2 Recommended Lubricants

Your machine can operate at top efficiency only if clean lubricants are used.

• Use clean containers to handle all lubricants.

• Store in an area protected from dust, moisture, and other contaminants.

LUBRICANT SPEC DESCRIPTION USE

High Temp. Extreme Pressure (EP2)

Performance With 1% Max Molybdenum

Disulphide (NLGI Grade 2).

Grease

SAE Multi-

Purpose

Traxon SAE

80W90

High Temp. Extreme Pressure (EP)

Performance With 10% Max Molybdenum

High Thermal & Oxidation Stability.

Lithium Base

Disulphide (NLGI Grade 2).

Lithium Base

API Service Class GL-5

Do not overfill the cutterbar when adding lubricant. Overheating and

failure of cutterbar components may occur if overfilled.

As Required

Unless

Otherwise

Specified.

Driveline

Slip-Joints

Cutterbar

Pump Drive

Gearbox

CAPACITIES

13 Ft 16 Ft

7 pints

(3.25 liters)

2.1 qts (2.0 liters)

9 pints

(4.25 liters)

Gear

Lubricant

Hydraulic

Oil

* For Australian Units – Use SAE 15W40 complying with SAE specs for API Class SJ and CH-4 engine oil.

** The following oil company and equipment manufacturer brand names are recommended:

Petro Canada Duratran Case IH Hy-Tran Plus® John Deere Quatrol® J20C Agco Power Fluid 821XL

** The following oil company and equipment manufacturer brand names are acceptable:

New Holland Hydraul Esso/Exxon Hydraul 56 Shell Donax TD

SAE 75W90

API Service Class GL-5. (SAE J2360

Preferred)

NLGI 00 Synthetic EP

Single Grade

Trans-

Hydraulic Oil *

Fully Synthetic Gear Lubricant

** See Below For List of Recommended

Brand Names.

Bevel

Gearbox

Conditioner

Drive

Gearbox

Hydraulic

Drive

Systems

0.86 pints US (0.4 liters)

Lubricated For Life

39 gal. US (147 liters)

48 gal. US (180 liters)

Form # 169053 55 Model Year - 2009

MAINTENANCE/SERVICE

7.3.3 Conversion Chart

QUANTITY

INCH-POUND UNITS SI UNITS (METRIC)

UNIT NAME ABBR.

FACTOR

UNIT NAME ABBR.

Area acres acres x 0.4047 = hectares ha Flow US gallons per minute (gpm) x 3.7854 = liters per min L/min Force pounds force lbf x 4.4482 = Newtons N

Length

inch in. x 25.4 = millimeters mm foot ft x 0.305 = meters m

Power horsepower hp x 0.7457 = kilowatts kW

Pressure pounds per square inch psi

Torque

pound feet or foot pounds lbf·ft or ft·lbf x 1.3558 = newton meters N·m pound inches or inch pounds lbf·in. or in·lbf x 0.1129 = newton meters N·m

x 6.8948 = kilopascals kPa x .00689 = megapascals MPa

Temperature degrees Fahrenheit ˚F (F- 32) x 0.56 = Celsius ˚C

feet per minute ft/min x 0.3048 = meters per min m/min

Velocity

feet per second ft/s x 0.3048 = meters per sec m/s miles per hour mph x 1.6063 = kilometers per hour km/h US gallons US gal. x 3.7854 = liters L

Volume

ounces oz. x 29.5735 = milliliters ml

cubic inches in.

x 16.3871 = cubic centimeters cm3 or cc

Weight pounds lb x 0.4536 = kilograms kg

Form # 169053 56 Model Year - 2009

MAINTENANCE/SERVICE

7.4 LIFT CYLINDER LOCK-0UT

Return to normal operation as follows:

VALVES

WARNING

To avoid bodily injury or death from fall of raised machine, always lock-out lift cylinders before going under mower conditioner for any reason.

Lockout the lift cylinders as follows:

a. Raise machine to maximum height by activating

remote cylinder control valve in tractor.

a. Turn the handle on the lock-out valves to the

vertical position.

b. Lower machine by activating the remote cylinder

control in tractor.

IMPORTANT

Hoses should be connected so that moving control lever (A) backward raises the header. See Section 6.4.3 Hydraulic Connections for more information.

b. Close the lock-out valve on each lift cylinder by

turning the handle to the horizontal position.

7.5 DRIVE SHIELDS

a. To open the left and right drive shields on the

header, pull rubber latch (B) off hook and lift cover (C) to open position.

b. To close, lower shield and engage bolt (D) in

frame.

c. Place rubber latch (B) in hook.

Form # 169053 57 Model Year - 2009

MAINTENANCE/SERVICE

7.6 CUTTERBAR DOORS

CAUTION

• Do not operate the machine without all the cutterbar doors down, curtains installed and in good condition.

a. To open doors, lift each door at arrow. b. To close door pull at top and move to closed

position. Ensure that curtains hang properly and completely enclose cutterbar area.

Form # 169053 58 Model Year - 2009

MAINTENANCE/SERVICE

7.7 LUBRICATING THE WINDROWER

WARNING

To avoid personal injury, before servicing windrower or opening drive covers, follow procedures in Section 7.1, Preparation for Servicing.

The greasing points are marked on the machine by decals showing a grease gun and grease interval in hours of operation. See illustration below.

Log hours of operation and use the "Maintenance Checklist" provided to keep a record of scheduled maintenance. Refer to Section 7.13, Maintenance Schedule.

7.7.1 Procedure

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Use the recommended lubricants specified in

this manual. See 7.3.2 Recommended Lubricants.

b. Wipe grease fitting with a clean cloth before

greasing, to avoid injecting dirt and grit.

c. Inject grease through fitting with grease gun until

grease overflows fitting, except where noted. d. Leave excess grease on fitting to keep out dirt. e. Replace any loose or broken fittings

immediately. f. If fitting will not take grease, remove and clean

thoroughly. Also clean lubricant passageway.

Replace fitting if necessary.

7.7.2 Lubrication Points

Refer to the illustrations on the following pages

for identifying the various locations that require

lubrication.

Form # 169053 59 Model Year - 2009

MAINTENANCE/SERVICE

I. 13 FT HEADER

High Temp. Extreme Pressure

(EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium Base

ROLL SHAFT BEARINGS (3 PLCS)

10% MOLY GREASE IS RECOMMENDED

FOR DRIVELINE SHAFT SLIP JOINT ONLY

DRIVELINE UNIVERSALS & SHAFT (3 PLCS)

Form # 169053 60 Model Year - 2009

MAINTENANCE/SERVICE

13 FT HEADER (cont’d)

CHECK PLUG

Oil should slightly run

out when removed.

GEARBOX OIL LEVEL

High Temp. Extreme Pressure

(EP2) Performance With 1% Max Molybdenum Disulphide

(NLGI Grade 2).Lithium Base

ROLL SHAFT BEARINGS (3 PLCS)

DRIVELINE UNIVERSALS (2 PLCS)

BELT TENSIONER PIVOT (1 PLC)

10% MOLY GREASE IS RECOMMENDED

FOR DRIVELINE

DRIVELINE UNIVERSALS (2 PLCS)

SHAFT SLIP JOINT ONLY

DRIVELINE SHAFT (2 PLCS)

Form # 169053 61 Model Year - 2009

MAINTENANCE/SERVICE

II. 16 FT HEADER

High Temp. Extreme Pressure

(EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium Base

CHECK PLUG

Oil should slightly run

out when removed.

GEARBOX OIL LEVEL

DRIVELINE UNIVERSALS (2 PLCS)

BELT TENSIONER PIVOT (1 PLC)

10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY

DRIVELINE UNIVERSALS (2 PLCS)

DRIVELINE SHAFT (2 PLCS)

Form # 169053 62 Model Year - 2009

ROLL SHAFT BEARINGS (3 PLCS)

MAINTENANCE/SERVICE

16 FT HEADER (cont’d)

High Temp. Extreme Pressure

(EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium Base

ROLL SHAFT BEARINGS (3 PLCS)

OPTIONAL GAUGE ROLL BEARINGS (2 PLCS)

BOTH SIDES

10% MOLY GREASE IS RECOMMENDED

FOR DRIVELINE SHAFT SLIP JOINT ONLY

DRIVELINE UNIVERSALS (2 PLCS)

DRIVESHAFT (1 PLC)

(BOTH SIDES)

Form # 169053 63 Model Year - 2009

MAINTENANCE/SERVICE

III. CARRIER FRAME

TONGUE PIVOT & STEERING CYLINDER

High Temp. Extreme Pressure

(EP2) Performance With 1%

Max Molybdenum Disulphide

(NLGI Grade 2).Lithium Base

WHEEL BEARING – BOTH SIDES

CYLINDER PIVOT 1 PLC

Form # 169053 64 Model Year - 2009

LIFT LINK 1PLC – BOTH SIDES

MAINTENANCE/SERVICE

IV. DRIVELINE

High Temp. Extreme Pressure

(EP2) Performance With 1%

Max Molybdenum Disulphide

(NLGI Grade 2).Lithium Base

APT SWIVEL

10% MOLY GREASE IS RECOMMENDED

FOR DRIVELINE SHAFT SLIP JOINT ONLY

APT DRIVELINE

Form # 169053 65 Model Year - 2009

MAINTENANCE/SERVICE

7.8 CUTTERBAR

7.8.1 Skid Plates and Rock Guards

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

DANGER

To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engine, remove key and engage lift cylinder lock-out valves before going under machine for any reason.

CAUTION

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

7.8.1.1 Removal

a. Raise header fully, stop engine, and remove

key.

b. Engage lift cylinder lock-out valves.

c. Open cutterbar doors.

d. Remove two bolts (A) from the skid plate (B) and

remove skid plate by lowering the aft end and dropping forward end from rock guard (D).

e. Remove nuts and bolts (C) from rock guard (D). f. Remove nut and bolt (E), slightly lower aft end of

rock guard (D) and slide rock guard forward off cutterbar.

Form # 169053 66 Model Year - 2009

MAINTENANCE/SERVICE

7.8.1.2 Installation

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

DANGER

To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engine, remove key and engage lift cylinder lock-out valves before going under machine for any reason.

CAUTION

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

b. Raise aft end of rock guard (D) and install the

long bolt (E) and nut.

c. Install the two shorter forward bolts (C) and nuts.

Tighten bolts.

a. Locate forward end of rock guard (D) onto

cutterbar and engage tabs (F) onto cutterbar.

Form # 169053 67 Model Year - 2009

d. Slip forward end of skid shoe (B) into forward

end of rock guard (D).

e. Lift aft end and install two bolts (A) and nuts.

Tighten bolts from topside of cutterbar.

MAINTENANCE/SERVICE

e. Place a suitably sized container under the

7.8.2 Cutter Bar Lubrication

The oil level in the cutterbar cannot be checked. If in doubt as to the quantity of oil in the cutterbar, do not add oil. Drain the cutterbar and refill with new clean oil as follows:

IMPORTANT

Drain the cutterbar when the oil is warm. If the oil is cold, idle the machine for about 10 minutes prior to draining.

cutterbar drain hole and a block under each end of the header.

The block under the LH end of the header should be higher than the RH end to improve draining.

f. Disengage the lift cylinder lock-out valves, start

mower conditioner, and lower header onto blocks. Shut down mower conditioner and remove key.

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

CAUTION

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

NOTE

7.8.2.1 Draining

a. Park the machine on level ground, raise header

fully, stop engine, and remove key.

DANGER

To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engine, remove key and engage lift cylinder lock-out valves before going under machine for any reason.

b. Engage lift cylinder lock-out valves.

g. Clean around either filler (A) and remove plug.

NOTE

Rotate disc to expose filler if necessary.

h. Remove drain plug (B) and allow sufficient time

c. Open RH cutterbar door. d. To gain access to the cutterbar drain plug, the

RH skid shoe needs to be removed. Refer to Section 7.8.1, Skid Shoes and Rock Guards.

Form # 169053 68 Model Year - 2009

for oil to drain.

IMPORTANT

Do not flush the cutterbar.

i. Replace drain plug (B) and tighten.

MAINTENANCE/SERVICE

7.8.2.2 Filling

DANGER

To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engine, remove key and engage lift cylinder lock-out valves before going under machine for any reason.

a. Start engine and raise header. Stop engine and

engage lift cylinder lock-out valves.

b. Move higher block to RH end of header and

remove used oil container.

NOTE

Having the fill end higher allows for quicker filling of cutterbar.

c. Disengage lift cylinder lock-out valves.

CAUTION

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

d. Start engine and lower header onto blocks.

Stop engine and remove key.

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

e. Add Traxon SAE 80W-90 lubricant through filler

hole (A). See illustration on previous page.

• 13 ft. Header – Exactly 7 pints (3.25 litres).

• 16 ft. Header – Exactly 9 pints (4.25 litres)

IMPORTANT

Do not overfill the cutterbar. Overfilling can cause overheating, and damage to or failure of cutterbar will occur.

7.8.3 Disc Maintenance

Check daily that discs are not damaged by rocks or worn excessively from abrasive working conditions. They are interchangeable and a disc can be moved to a spindle that rotates in the opposite direction, as long as it is in a useable condition. The discs are not repairable and must be replaced if severely damaged or worn.

IMPORTANT

If holes appear in a disc, replace the disc immediately. Do not attempt to repair the discs. Always use factory replacement parts.

7.8.3.1 Disc Removal

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

f. Replace filler plugs. g. Start engine and raise header. h. Stop engine and engage lift cylinder lock-out

valves. i. Remove blocks. j. Reinstall skid shoe that was previously removed.

Refer to Section 7.8.1 Skid Shoes and Rock

Guards.

Form # 169053 69 Model Year - 2009

a. Open cutterbar door(s).

CAUTION

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

(continued next page)

MAINTENANCE/SERVICE

b. Place a block of wood between two discs to

prevent disc rotation while loosening blade bolts.

c. Remove four bolts (A) on disc cover (B) and

remove cover and disc (C).

d. If end disc is being removed;

1. Remove bolts (D) and remove deflector (E).

2. Remove disc (F).

e. If driveline disc is being removed;

f. Clean spindle (G).

7.8.3.2 Disc Installation

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

CAUTION

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

a. Position new disc (C) on spindle ensuring it is 90

b. Install cover (B) and secure with four bolts (A). c. Tighten bolts to 92 ft·lbf (125 N·m).

1. Remove bolts (G).

2. Lift deflector (H) and driveline, and slide disc (J) off spindle.

Form # 169053 70 Model Year - 2009

degrees to the adjacent discs.

(continued next page)

MAINTENANCE/SERVICE

d. If installing end disc;

1. Position new disc (F) on spindle ensuring it is 90 degrees to adjacent discs.

2. Install deflector (E) and secure with four bolts (D).

3. Tighten bolts to 92 ft·lbf (125 N·m).

e. If driveline disc is being installed;

1. Lift deflector (H) and driveline and slide disc (J) onto spindle.

2. Locate deflector (H) and driveline onto disc (J).

3. Install bolts (G) and torque to 92 ft·lbf (125 N·m).

f. Remove block of wood if used.

WARNING

Ensure cutterbar is completely clear of foreign objects. These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage.

g. Close cutterbar doors.

Form # 169053 71 Model Year - 2009

MAINTENANCE/SERVICE

(

)

7.8.4 Cutter Blades

7.8.4.1 Cutter Blade Types

a. 18 DEGREE BEVEL DOWN

Higher Lift for Certain Crop Conditions /

Better in Stony Soil

b. 11 DEGREE BEVEL UP (Optional)

General Purpose Cutting / Longer Life

BLADE WEAR

TO CENTERLINE

0.81 in

20.6 mm

ELONGATED

HOLE

a. Check daily that the cutter blades are securely

attached to the disc.

b. Check blades for cracks or wear beyond safe

operating limits, and distortion.

c. Replace blades immediately if any of these

problems occur.

IMPORTANT

Blades should be replaced in pairs, otherwise the disc may be unbalanced and damage the cutterbar.

ROTATION DIRECTION

7.8.4.2 Inspection

CAUTION

Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

CAUTION

Damaged blades may damage the cutterbar, and result in poor cutting performance. Replace damaged blades at earliest possible opportunity.

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

ROTATION

CLOCKWISE DISC

ROTATION

COUNTERCLOCKWISE DISC

IMPORTANT

The cutter blades have cutting edges on both edges so that the blade can be turned over and reused. The twist in each blade determines if its cutting direction is clockwise or counterclockwise.

Form # 169053 72 Model Year - 2009

MAINTENANCE/SERVICE

7.8.4.3 Replacement

CAUTION

Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

DANGER

To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engine, remove key and engage lift cylinder lock-out valves before going under machine for any reason.

Replace cutter blade as follows:

a. Raise header fully, shut off engine and remove

key.

b. Engage lift cylinder lock-out valves.

g. Remove nut (D). h. Remove shoulder bolt (E), and blade (F). i. Install new or reversed blade (F) with shoulder

bolt (E) onto disc.

j. Install nut (D). Tighten nut to 100 ft·lbf (135

N·m).

k. Remove block of wood if used.

c. Open cutterbar door(s).

WARNING

Ensure cutterbar is completely clear of foreign objects. These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage.

l. Close doors.

d. Rotate disc (A) so that blade (B) faces forward,

and lines up with hole (C) in rock guard.

e. Place a block of wood between two discs to

prevent disc rotation while loosening blade bolts.

f. Clean debris from blade attachment area.

Form # 169053 73 Model Year - 2009

MAINTENANCE/SERVICE

7.8.4.4 Cutter Blade Hardware

Check blade attachment hardware each time blades are changed. Refer to previous section for hardware replacement procedure.

a. Check bolts for wear or damage and replace bolt

if:

1. Bolt has been removed and installed five times.

2. Head is worn flush with bearing surface of blade.

3. Diameter of bolt neck is worn out of

0.13 in. (3 mm)

specification.

4. Bolt is cracked.

5. Bolt is visibly distorted.

6. Evidence of interference with adjacent parts.

b. Check nuts for wear or damage and replace nut

if:

1. Worn height is less than half total height.

H/2

2. Cracked.

3. Nut has been removed and installed five times.

Form # 169053 74 Model Year - 2009

MAINTENANCE/SERVICE

7.8.5 Accelerators

7.8.5.1 Removal

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Raise header fully, shut off engine and remove

key.

b. Engage lift cylinder lock-out valves.

7.8.5.2 Installation

a. Locate accelerator (C) on disc onto existing

cutter blade bolt and install nut (B).

b. Install hex bolt (A) and nut at inboard hole. Bolt

head faces up. c. Tighten both nuts to 100 ft·lbf (135 N·m). d. Repeat for other accelerator. e. Reinstall disc on spindle. Refer to Paragraph

7.8.3.2 Disc Installation.

f. Remove block of wood if used.

Ensure cutterbar is completely clear of

foreign objects. These objects can be

ejected with considerable force when the

machine is started and may result in serious

injury or machine damage.

g. Close cutterbar doors.

WARNING

c. Open cutterbar doors.

CAUTION

Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

d. Remove disc. Refer to Paragraph 7.8.3.1 Disc

Removal.

e. Remove nut and bolt (A), nut (B), and remove

accelerator (C) from disc. Do not remove cutter blade bolt unless it or the blade are being replaced. Repeat for other accelerator.

Form # 169053 75 Model Year - 2009

MAINTENANCE/SERVICE

7.8.6 Hourglass Deflectors

Check daily that hourglass deflectors are not damaged or bent by rocks. The deflectors are not repairable and must be replaced if severely damaged or worn.

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Raise header fully, shut off engine and remove

key.

b. Engage lift cylinder lock-out valves.

7.8.6.1 Driveline Deflector – 13 & 16 Ft

a. Remove driveline deflector (A) as follows:

c. Open cutterbar door(s) and inspect deflectors.

CAUTION

Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

1. Remove two bolts (B) and remove guard (C).

2. Loosen two bolts (D) and remove guard (E).

3. Rotate deflector (A) so that wider space between bars faces forward.

4. Place a block of wood between two discs to prevent deflector from turning.

5. Remove four bolts (F).

6. Lift driveline (G) off deflector (A) base and slide lower end of deflector off disc (H).

(continued next page)

Form # 169053 76 Model Year - 2009

MAINTENANCE/SERVICE

b. Install driveline deflector as follows:

CAUTION

Ensure cutterbar is completely clear of

Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

foreign objects. These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage.

7. Close cutterbar doors.

WARNING

1. Slide driveline (G) upward onto shaft, locate deflector (A) over driveline, and position deflector on disc (H).

2. Align cut-outs in base of deflector with cutter blades.

3. Install four bolts (F), and torque to 92 ft·lbf (125 N·m).

7.8.6.2 Driven Deflector – 13 Ft

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

CAUTION

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

a. Remove driven deflector as follows:

1. Place a block of wood between two discs to prevent deflector from turning.

4. Position guard (E) and tighten bolts (D).

5. Position guard (C) and attach with two bolts (B).

6. Remove block of wood if used.

Form # 169053 77 Model Year - 2009

b. Install deflector as follows:

2. Remove four bolts (K) attaching deflector (J) to disc and remove deflector.

1. Position deflector (J) on disc and install bolts (K) and torque to 92 ft·lbf (125 N·m).

2. Remove block of wood if used.

3. Close cutterbar doors.

MAINTENANCE/SERVICE

7.8.6.3 Driven and Suspended Deflectors - 16 Ft

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

CAUTION

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

Driven Deflector (A) a. Place a block of wood between two discs to

prevent deflector from turning.

Suspended Deflector (D)

RH SHOWN – LH OPPOSITE

b. To remove driven deflector (A), remove four

bolts (B) and remove deflector.

c. To install deflector (A), position deflector on disc

d. Remove block of wood if used.

a. Place a block of wood between two discs to

prevent deflector from turning.

b. To remove suspended deflector (D), remove

four bolts (E) and nuts, and remove deflector.

c. To install deflector (D), position deflector on

flange (F) and install bolts (E) and nuts. Tighten

to 92 ft·lbf (125 N·m). d. Remove block of wood if used. e. Close doors.

Form # 169053 78 Model Year - 2009

MAINTENANCE/SERVICE

c. Open RH side drive compartment shield.

7.8.7 Tall Crop Feed Plates

d. Remove nuts (A) securing feed plates to side of

The tall crop feed plates assist the feeding of tall crops into the conditioner by encouraging material flow from behind the hourglass deflectors. They will degrade the cutting performance of the cutterbar if they are used in medium to light alfalfa, and so should not be installed in those types of crops. The feed plates are designed for installation under the two inboard hourglass deflectors and only on 16 ft headers. They are stored inside the RH side drive compartment.

compartment and remove plates.

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

e. Place a block of wood between discs to prevent

deflector from turning.

CAUTION

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

7.8.7.1 Installation

a. Lower header to the ground, shut off engine and

remove key from ignition.

b. Open cutterbar doors.

f. Remove four bolts (B) and remove inboard

hourglass driven deflector (C) from cutterbar.

(continued next page)

Form # 169053 79 Model Year - 2009

MAINTENANCE/SERVICE

g. Locate feed pate (D) on the disc ensuring that

hole in feed plate registers on disc. Position plate as shown and align holes.

IMPORTANT

Feed plate should be located so that when holes are aligned, it is closer to the accelerator leading edge (E) than the trailing edge.

h. Re-position deflector (C) and align holes. i. Re-install bolts (B) and tighten to 92 ft·lbf (125

N·m). j. Repeat above steps for opposite side. k. Manually rotate discs to check for interference of

feed plate and adjacent parts.

Form # 169053 80 Model Year - 2009

MAINTENANCE/SERVICE

7.9 HEADER DRIVE

7.9.1 Pump Gearbox

7.9.1.1 Checking Oil Level

a. Park mower conditioner on level ground.

7.9.2 Bevel Gearbox

16 FT

b. Check oil level in sight gauge (A) on lower left

side of gearbox. The oil must be even with the sight glass when at the proper level.

7.9.1.2 Changing Oil

a. Drain the gearbox when the oil is warm. If the

oil is cold, idle the machine for about 10 minutes prior to draining.

b. Place a suitable container under drain plug (B)

and remove the plug. c. Allow sufficient time for oil to drain. d. Replace plug and tighten. e. Remove filler/breather plug (C). f. Add 2.1 qts (2.0 litres) SAE 80W-90 gear

lubricant to gearbox through port (C). g. Check sight glass (A) for proper level. h. Properly dispose of used oil and clean up any

spilled oil.

13 FT

The bevel gearbox is located inside the drive compartment at the left hand side of the header. If repairs are required, it should be removed and serviced at your dealer. Refer to Section 7.9.2.3 Removal – Bevel Gearbox.

Form # 169053 81 Model Year - 2009

MAINTENANCE/SERVICE

7.9.2.1 Checking Oil

The bevel gearbox oil level should be checked every 100 hours or once per year:

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Rest header onto blocks so that it is level.

7.9.2.2 Changing Oil

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Drain the gearbox when the oil is warm. If the

oil is cold, idle the machine for about 10 minutes prior to draining.

b. Raise header to full height and engage

windrower lift cylinder locks. Stop engine and remove key.

c. Open up LH drive shield (A).

b. Open up LH drive shield (A).

16 FT SHOWN – 13 FT SIMILAR

c. Remove plug (B) and verify that the oil slightly

runs from the hole. d. Replace plug and tighten. e. Clean up any spilled oil.

16 FT SHOWN – 13 FT SIMILAR

d. Place a suitable container under drain plug (C). e. Remove plugs (B) and (C). f. Allow sufficient time for oil to drain. g. Replace plug (C) and tighten. h. Disengage windrower lift cylinder locks, start

engine and lower header so that it is level.

i. Add 0.86 pints (0.4 litres) of 75W-90 Synthetic

gear oil to gearbox through port (B). Oil should

slightly run out of port (B) when full. j. Replace plug (B) and tighten. k. Properly dispose of used oil and clean up any

spilled oil. l. Lower drive shield (A).

Form # 169053 82 Model Year - 2009

MAINTENANCE/SERVICE

7.9.2.3 Removal – Bevel Gearbox

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Lower header to ground, turn off engine, and

remove key.

16 FT SHOWN – 13 FT SIMILAR

d. Open LH drive shield door (E).

e. Loosen jam-nut (F) and loosen belt (G) with

adjuster bolt (H) so that belt can be slipped off pulley (J).

NOTE

Following step f. is only applicable to 16 ft. header.

b. Remove four bolts (A) and remove hydraulic

motor (B). Locate motor and hoses clear of work area.

NOTE

On 16 ft header, cut plastic ties securing wiring harness to hose bundle as required.

c. Remove three bolts (C) and lift off panel (D).

Form # 169053 83 Model Year - 2009

f. Loosen hourglass deflector drive belts (K) as

follows:

1. Loosen nuts (L).

2. Loosen jam-nut (M) on adjuster bolt (N).

3. Turn adjuster bolt (N) to loosen belts (K) so they can be slipped off drive pulley (O).

(continued next page)

16 FT

MAINTENANCE/SERVICE

g. Remove two bolts (P) and remove guard (Q). h. Loosen two bolts (R) and remove guard (S).

i. Rotate deflector (T) so that wider space between

bars face forward. j. Remove four bolts (U). k. Pull driveline (V) through deflector and slide U-

joint (W) off drive shaft.

13 FT

16 FT

m. Lift gearbox (Y) and manoeuvre from drive area,

top end first.

l. Remove four bolts (X). Support gearbox (Y)

when removing last bolt.

Form # 169053 84 Model Year - 2009

MAINTENANCE/SERVICE

7.9.2.4 Installation – Bevel Gearbox

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

b. Install four bolts (X). Torque to 106 ft·lbf (144

N·m).

13 FT

16 FT

a. Lower gearbox (Y) into position through top

opening.

NOTE

On 16 ft header, ensure hourglass deflector drive belts are engaged onto gearbox shaft.

c. Position driveline (V) in deflector, and slide U-

joint (W) onto drive shaft.

d. Install four bolts (U) and torque to 92 ft·lbf (125

N·m).

e. Position guard (S) and tighten bolts (R). f. Position guard (Q) and attach with two bolts (P).

(continued next page)

Form # 169053 85 Model Year - 2009

MAINTENANCE/SERVICE

NOTE

Steps g to i. applicable to 16 ft header only.

16 FT

g. Install hourglass deflector drive belts (N) onto

drive pulley (O) and driven pulley. h. Turn adjuster bolt (M) to tighten belts (N). i. Tighten nuts (K) and jam-nut (L).

n. Position hydraulic motor (B) on gearbox and

install four bolts (A). Torque bolts to 103 ft·lbf (140 N·m).

o. On 16 ft header, re-attach wiring harness to

hose bundle with plastic ties as required.

p. Close shield.

j. Locate conditioner drive belt (G) onto forward

pulley (J). k. Route belt over idler (F) ensuring it is properly

located on pulley (H).

NOTE

Check alignment of pulleys (H) and (J).

l. Tension drive belt (G). Refer to Section 7.9.4.2

Tension Adjustment.

16 FT SHOWN – 13 FT SIMILAR

m. Re-install cover (D) with three bolts (C).

Form # 169053 86 Model Year - 2009

MAINTENANCE/SERVICE

7.9.3 Conditioner Gearbox – 13 Ft

The conditioner gearbox is located inside the drive compartment at the left hand side of the header. The conditioner gearbox does not require normal maintenance or servicing, and if repairs are required, it should be removed and serviced at your dealer.

c. Remove nut (B), bolt (C), and washers (D), and

pin (E). Remove LH drive shield.

7.9.3.1 Conditioner Gearbox Removal – 13 Ft

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Raise header fully, shut off tractor engine and

remove key. Close lift cylinder shut-off valves.

b. Open LH drive shield lower door (A).

d. Remove five nuts and bolts (F), and remove

panel (G).

e. Loosen jam-nut (H) and loosen belt (J) with

adjuster bolt (K) so that belt can be slipped off pulley (L).

(continued next page

Form # 169053 87 Model Year - 2009

MAINTENANCE/SERVICE

f. Remove bolts (M). Slide pulley (L) off gearbox

onto driveline.

h. Loosen bolt (P) on lower U-joint and slide yoke

(Q) off gearbox.

g. Remove bolts (N) and swivel driveline so that

pulley and driveshaft (O) can be slipped off

driveline.

Form # 169053 88 Model Year - 2009

i. Remove eight bolts (S) holding gearbox (R) to

frame.

j. Lift gearbox out of drive compartment.

MAINTENANCE/SERVICE

7.9.3.2 Conditioner Gearbox Installation – 13 Ft

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

c. Slide upper driveshaft (O) with pulley (L) and

belt into yoke (T). Attach timing flange to gearbox with bolts (N), washers, and lockwashers. Do not tighten.

a. Position conditioner gearbox (R) in drive

compartment and secure with eight bolts (S). Torque to 92 ft·lbf (125 N·m).

b. Ensure woodruff key is in shaft keyway and slide

yoke (Q) onto gearbox shaft. Tighten bolt (P) on U-joint.

d. Position pulley (L) on gearbox and install four

bolts (M) with lockwashers.

e. Tighten bolts (M) to 75 ft·lbf (102 N·m).

(continued next page)

Form # 169053 89 Model Year - 2009

MAINTENANCE/SERVICE

f. Re-install belt on pulley (L) and tighten idler (U)

with adjuster bolt (K). See 7.9.5.1 Tension Adjustment – Conditioner Drive Belt. Tighten jam-nut (H).

i. Position pin (E) in shield and attach to frame

with two washers (D), bolt (C), and nut (B). Washers are under the pin. Tighten nut (B).

j. Adjust roll timing. Refer to Section 6.13.4.2 Roll

Timing.

k. Close drive shield (A).

g. Re-install panel (G) with five bolts and nuts (F).

Install bolts from inside.

h. Position LH drive shield on header and locate on

existing pin (S).

Form # 169053 90 Model Year - 2009

MAINTENANCE/SERVICE

7.9.4 Conditioner Gearbox – 16 Ft

7.9.4.1 Conditioner Gearbox Removal – 16 Ft

DANGER

d. Remove nut (B), bolt (C), and washers (D), and

pin (E). Remove LH drive shield.

e. Remove nuts and bolts (F), and remove panel

(G).

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Raise header fully, shut off engine and remove

key. b. Engage lift cylinder lock-out valves. c. Open LH drive shield lower door (A).

f. Loosen jam-nut (H) and loosen belt (J) with

Form # 169053 91 Model Year - 2009

adjuster bolt (K) so that belt can be slipped off pulley (L).

MAINTENANCE/SERVICE

g. Remove bolts (M). Slide pulley (L) off gearbox

and slide pulley over timing flange yoke onto driveshaft (N).

j. Loosen bolt (Q) on lower U-joint and slide yoke

(R) off gearbox.

h. Remove bolts (O) and swivel driveshaft (N) so

that pulley can be slipped off driveline.

i. Position driveline clear of work area.

k. Remove eight bolts (S) attaching gearbox (T) to

frame and lift gearbox out of drive compartment.

Form # 169053 92 Model Year - 2009

MAINTENANCE/SERVICE

7.9.4.2 Conditioner Gearbox Installation –

16 Ft

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

c. Slide pulley and belt onto upper driveshaft (N)

and position driveshaft on gearbox.

d. Install four bolts (O) with lockwashers but do not

tighten.

a. Position conditioner gearbox (T) in drive

compartment and secure with eight bolts (S).

Torque to 92 ft·lbf (125 N·m).

b. Ensure woodruff key is in shaft keyway and slide

yoke (R) onto gearbox shaft. Tighten bolt (Q) on

U-joint.

e. Attach pulley (L) to gearbox with bolts (M).

Torque to 75 ft·lbf (102 N·m).

(continued next page)

Form # 169053 93 Model Year - 2009

MAINTENANCE/SERVICE

f. Position belt (J) on pulley (L) and tighten idler

with adjuster bolt (K). See 7.9.5.1 Tension Adjustment – Conditioner Drive Belt. Tighten jam-nut (H).

g. Re-install panel (G) with five bolts (F) and nuts.

Install bolts from inside.

h. Position LH drive shield on header and locate on

existing pin (U).

i. Position pin (E) in shield and attach to frame

with two washers (D), bolt (C), and nut (B). Washers are under the pin. Tighten bolt.

j. Adjust roll timing. Refer to Section 6.13.4.2 Roll

Timing.

k. Close drive shield (A).

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MAINTENANCE/SERVICE

7.9.5 Conditioner Drive Belt

The conditioner drive belt is located inside the

drive compartment at the left hand side of the

header.

DANGER

NUMBER OF VISIBLE COILS MEASUREMENT ‘X’

7.75-8.15 inches (197-207 mm)

8.11-8.5 inches (206-216 mm)

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

7.9.5.1 Checking Belt Tension

IMPORTANT

Belt tension acts as an overload protection mechanism to prevent damage to the gearboxes or roll drivelines in the event the rolls reach peak load. Check tension at beginning of each operating season.

a. Raise header fully, shut off engine and remove

key.

b. Engage lift cylinder lock-out valves.

7.9.5.2 Tension Adjustment

a. Loosen jam-nut (B). b. Turn adjuster bolt (C) to fully release spring (A)

tension.

c. Turn adjuster bolt (C) by hand to take up all belt

(D) slack and clearance at hook end of the spring. Spring must be snug but not stretched.

c. Open LH drive shield. d. Measure the length of

the spring (A) as shown. It should be within the dimensions in the following table. If required, adjust tension as per the following section.

Form # 169053 95 Model Year - 2009

d. Back off jam-nut (B) 13/16 inch (20 mm) from

the end of the spring insert (E).

e. Tighten adjuster bolt (C) with a wrench to stretch

spring until jam-nut (B) contacts the spring insert

(E). f. Tighten jam-nut (B) against spring insert. g. Close drive shield.

MAINTENANCE/SERVICE

7.9.5.3 Conditioner Drive Belt Removal

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Raise header fully, shut off engine and remove

key. b. Engage lift cylinder lock-out valves. c. Open LH drive shield.

7.9.5.4 Conditioner Drive Belt Installation

a. Slip belt (C) between pulley (F) and driveline

(H).

d. Loosen jam-nut (A). e. Turn adjuster bolt (B) to fully release tension on

belt (C). f. Slip belt (C) off forward pulley (D), idler (E), and

driven pulley (F).

g. Remove four bolts (G) and slide driveline (H)

fully inboard. h. Slip belt between pulley (F) and driveline flange

to remove it.

b. Locate belt onto forward pulley (D). c. Route belt over idler (E) and onto driven pulley

(F).

d. Attach driveline flange to gearbox with four bolts

(G) but do not tighten.

NOTE

Check alignment of pulleys (D) and (F).

e. Tension belt (C). Refer to Section 7.9.5.2

Tension Adjustment.

f. Adjust roll timing. Refer to Section 6.13.4.2, Roll

Timing.

g. Lower drive shield.

Form # 169053 96 Model Year - 2009

MAINTENANCE/SERVICE

7.9.6 Conditioner Drive Belt Idler

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

The conditioner drive belt idler does not require normal maintenance or servicing but may eventually require replacing.

Replace the idler as follows:

a. Raise header fully, shut off engine and remove

key.

b. Engage lift cylinder lock-out valves.

c. Open LH drive shield.

f. Remove nut (E), washers, and remove idler (C).

IMPORTANT

Note locations of washers on bolt. They center the idler on the drive belt and must be re-installed the same location.

g. Install idler (C) onto bolt with washers in same

locations. h. Install nut (E) and torque to 150 ft·lbf (203 N·m). i. Tension belt (D). Refer to Section 7.9.5.2

Tension Adjustment. j. Close drive shield.

d. Loosen jam-nut (A). e. Turn adjuster bolt (B) counter-clockwise to

release tension on spring until idler (C) and belt (D) are loose.

Form # 169053 97 Model Year - 2009

MAINTENANCE/SERVICE

7.9.7 Lifting Roll Drive Belt

The two lifting roll drive belts are located inside the drive compartment at the right hand side of the header. Belt tension is set at the factory and does not require adjustment. Replace the belts if they are slipping.

7.9.7.1 Replacement

DANGER

Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.

a. Raise header fully, shut off engine and remove

key.

b. Engage lift cylinder lock-out valves.

e. Insert the end of a ½ inch drive socket wrench in

the square hole on the idler arm (C). f. Rotate idler arm until belts (D) are loose. g. Insert a bolt in hole (E) to hold idler. h. Remove belts (D).

Belts must be replaced in pairs.

Check alignment of pulleys.

NOTE

c. Open RH drive shield.

d. Remove five bolts (A) and nuts and remove rear

shield (B).

i. Install belts (D) on pulleys ensuring they are in

the pulley grooves. j. Rotate idler arm (C) so that bolt in (E) can be

removed. k. Release tension on spring and remove wrench. l. Re-install rear shield (B) with bolts (A) and nuts. m. Close drive shield.

Form # 169053 98 Model Year - 2009

MacDon R80 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual