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R80 Rotary Disc Self-Propelled Windrower Header

1. 250 HOURS Cutterbar Lube gt gt Bevel Gearbox Lube Form 169089 92 Model Year 2009 TROUBLESHOOTING 8 TROUBLESHOOTING 8 1 MOWER PERFORMANCE SYMPTOM PROBLEM SOLUTION SECTION Cutterbar Plugging Dull bent or badly worn blades Replace blades 7 8 4 3 Build up of dirt between rock Decrease header angle and guards increase flotation In some conditions it may be necessary to carry header slightly with header lift cylinders Lift roll drive belt slipping Change belts 7 HEN 5 1 Conditioner drive belt slipping Adjust conditioner drive belt 79 31 tension Ragged Or Uneven Cutting Of Header angle too flat for guards Increase header angle 6 12 3 Crop to pick up down crop Mx Header flotation too light Adjust to heavier float setting 6 124 causing bouncing dui Excessive ground speed Reduce ground speed 6 12 8 Downed crop Adjust header angle to cut 6 12 3 closer to ground ak Strips Of Uncut Crop Left On Bent cutter blades Replace blades 7843 Field DS Build up of dirt between rock Decrease header angle and 6 12 3 amp guards increase flotation 6 12 4 Ground speed too slow Increase ground speed 6 12 8 Excessive header speed Reduce header disc speed 6 12 1 Foreign object on cutterbar Disengage header and stop engine When all moving 6 10 part
2. MER Install caps on connectors and hose end if he we p NiD equipped Ls A i br IN Rotate lever A clockwise and push to engage bracket continued next page T or e T Form 169089 18 Model Year 2009 OPERATION f Atthe header disconnect electrical connector by turning collar counterclockwise and pulling 6 5 TRANSPORTING WINDROWER connector to disengage Refer to M150 amp M200 Self Propelled M hw h Windrower Operators Manual for transporting headers when attached to the M150 M200 windrower tractor 6 6 LIGHTS The turn signal lights and hazard lights which are mounted on both ends of the header are activated by switches in the M Series windrower tractor cab Only the g Disconnect the two drive couplers and case 16 ft model is drain coupler on header equipped with lights h Move hose bundle from header and locate on tractor LH side with hoses in support D d Q a Drm mu ll gt A aV d v p _ r ey A amp y Er adis i Rotate lever A clockwise and push to engage bracket j Locate electrical harness through support D and attach cap to electrical connector E k Move tractor platform back to closed position I Detach header from tractor Refer to the M150 amp M200 Self Propelled Windrower Operator s Manual for procedures for mechanically detaching the header from the self prop
3. A CAUTION To ensure gauge is not forcibly ejected from rolls when machine is started ensure gauge is securely re attached to frame LH SHOWN c To increase the roll tension loosen jam nut D and turn the spring draw bolt E clockwise to tighten the spring F 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 D after adjusting tension f Close drive shields f Store gauge B inside RH panel with bolt A and nut Form 169089 26 Model Year 2009 OPERATION 6 12 7 Forming Shields 6 12 7 1 Side Deflectors The position of the side forming shields controls A WARNING the width and placement of the windrow Keep everyone several hundred feet away from your operation Ensure bystanders A DANGER are never in line with the front or rear of the Stop engine and remove key from ignition machine Stones or other foreign objects before leaving operator s seat for any can be ejected from either end with force reason A child or even a pet could engage The position of the forming shields controls the an idling machine width and placement of the windrow The X decision on forming shield position should be based on the following factors e weather conditions rain sun humidity wind e type and yield of crop e drying time available e method of processing bales silage green feed A wider windrow will
4. d Slip forward end of skid plate B into forward end of rock guard D al a Locate forward end of rock guard D onto i i M a gi cutterbar and engage tabs F onto cutterbar NH e Lift aft end and install two bolts A and nuts Tighten bolts from topside of cutterbar b Raise aft end and install bolt E and nut Form 169089 48 Model Year 2009 7 8 2 1 a b MAINTENANCE SERVICE 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 A 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 CAUTION Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades Draining Park the machine on level ground raise header fully stop engine and remove key A 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 Engage header lift cylinder locks Open RH cutterbar door To gain access to t
5. F on middle valve block as shown i Remove caps and plugs from hoses and lines RETURN a Disengage and rotate lever A counter clockwise to fully up position b Remove cap B securing electrical connector to frame 1 CASE DRAIN ELECTRICAL j Connect the three hoses from tractor to the fittings on the header as shown k Connect harness from tractor to electrical connector I Move tractor platform to closed position c Move hose bundle C from tractor through hose support D on header d Route header pressure hose E from header through hose support D to tractor and locate it above existing hose bundle C as shown e Lower and lock lever A f Secure with existing cinch straps g Move tractor left side platform to open position Form 169089 16 Model Year 2009 OPERATION 6 4 HEADER DETACHMENT Refer to the M150 amp M200 Self Propelled Windrower Operator s Manual for procedures for mechanically detaching the header from the self propelled windrower Refer to the following procedures for disconnecting electrical harness and hydraulic hoses A CAUTION To prevent accidental movement of tractor shut off engine engage parking brake and remove key 6 4 1 M200 13 FT amp 16 FT a Move LH cab forward platform to rear of tractor b Disconnect the two hydraulic couplers from tractor valve Form 169089 17 FWD VALVE BLOCK If grass seed heade
6. 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 e 13 ft Header Exactly 7 pints 3 25 litres e 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 f Replace filler plugs g Start engine and raise header h Stop engine and engage header lift cylinder lock outs i Remove blocks j Re install skid plate Refer to Section 7 8 1 Skid Plates and Rock Guards Form 169089 50 Model Year 2009 MAINTENANCE SERVICE 7 8 3 Disc Maintenance c Remove four bolts A on disc cover B and remove cover and disc C d If removing 2 disc Check daily that discs are not damaged by rocks or worn excessively from abrasive working conditions They are interchangeable and a disc Standard Header 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 Stop engine and remove key from ignition 16FT SHOWN 13 FT SIMI
7. Conditioner The conditioner drive belt is located inside the Drive Belt drive compartment at the left hand side of the a Lower header to ground turn off engine and remove key header and is tensioned with a spring tensioner A 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 Open LH drive shield A a r MENU c Loosen jam nut B A d Turn adjuster bolt C clockwise to tighten belt or counterclockwise to loosen continued next page Form 169089 65 Model Year 2009 MAINTENANCE SERVICE e Adjust belt tension by adjusting the length of the spring to the values in the following table NUMBER OF VISIBLE COILS MEASUREMENT X 197 207 mm 206 216 mm E Eoo po ili lll L 21 ci S E 90 mm ERU f Tighten jam nut B Form 169089 66 Model Year 2009 MAINTENANCE SERVICE 7 9 3 2 Conditioner Drive Belt Removal 16 FT A 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 c Loosen jam nut B and loosen belt C with adjuster bolt D so that belt can be slipped off pulley E and drive pulley F Form 169089 d Remove nut and bolt G and pull U jo
8. Place ground speed control in N DETENT Stop engine and remove key from ignition Wait for all movement to stop 6 11 UNPLUGGING THE HEADER A DANGER Stop tractor engine and remove key before removing plugged material from header A child or even a pet could engage the drive a Stop forward movement of the tractor and disengage the header Raise header fully shut off engine remove key Engage header lift cylinder locks A WARNING Wear heavy gloves when working around cutterbar d Open header doors and clean off cutterbar by hand Form 169089 21 Model Year 2009 OPERATION 6 12 HEADER OPERATION Satisfactory operation of the header in all situations requires making proper adjustments to suit various crops and conditions Correct operation reduces crop loss and increases productivity 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 header You will quickly become adept at adjusting the machine to give you the desired results VARIABLE SECTION Disc Speed 6 12 1 Cutting Height 6 12 2 Header Angle 6 12 3 Header Flotation 6 12 4 Roll Gap Timing Alignment 6 12 5 Roll Tension 6 12 6 Forming Shields 6 12 7 Ground Speed 6 12 8 Windrow Forming Rods Grass Seed 6 12 9 Converging Drums Grass Seed 6 12 10 Double W
9. e Tighten bolts M to 75 ft lbf 102 N m continued next page dao b Ensure woodruff key is in shaft keyway and slide yoke Q onto gearbox shaft Tighten bolt P on U joint Form 169089 82 Model Year 2009 MAINTENANCE SERVICE f Re install belt on pulley L and tighten idler U with adjuster bolt K See 7 9 3 1 Tension Adjustment Conditioner Drive Belt Tighten jam nut H 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 169089 83 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 Adjust roll timing Refer to Section 6 12 5 2 Roll Timing Close drive shield A Model Year 2009 MAINTENANCE SERVICE 7 9 11 Conditioner Gearbox 16 Foot 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 b Open LH drive shield lower door A Fara c Remove nut B bolt C and washers D and l pin E Remove LH drive shield EN ee 9 a um AS 9 Ea d Remove nuts and bolts F and remove panel 7 9 11 1 Conditioner Gearbox Removal 16 G Foot Nor gt
10. zm _ I i 2 Stop engine and remove key from ignition ES e 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 _ Ni L 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 169089 84 Model Year 2009 MAINTENANCE SERVICE f Remove bolts M Slide pulley L off gearbox and slide pulley over timing flange yoke onto driveshaft N i Loosen bolt Q on lower U joint and slide yoke R off gearbox g Remove bolts O and swivel driveshaft N so that pulley can be slipped off driveline h Position driveline clear of work area j Remove eight bolts S attaching gearbox T to frame and lift gearbox out of drive compartment Form 169089 85 Model Year 2009 MAINTENANCE SERVICE 7 9 11 2 Conditioner Gearbox Installation 16 LO d Foot j E x 2 N A EM Aso NN 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 s 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 f
11. 0 12 9 eo AA SA RU QU E set octo seduto s pau casu oa apR OS i 23 6 124 Header Flotation X 23 om o ROGA AAA S E a a OE ea 24 O 12 D ROITEnS OM ii i aiar 26 6 12 f A dade aut Mot Md oM aad 27 oM PEE CIO Peel oM T Tum 29 6 12 9 Converging Drum Assemblies Grass Seed Header e 30 6 12 10 Windrow Forming ROdS elia pd ir ii Coats Qu t C vA aov ele bial 30 5 12 13 DouE WNA ONNO dieci bacia 30 PAN RO ella 31 6 12 13 Tall Crop Transition Shield Grass Seed ii 31 A 0S LEN ce PCR du E E te er er ee Eu ee ee qi ee eer ere 32 61ST CQ Lr 32 6d 0G A e E e a a E 32 6 19 39 Weather ana LopodraDIYVa ia 32 6 194 Windrow Ghafacieristi s LL 32 6 13 57 Diving OD VARO Wi dies 32 6130 Rakng and edad sais da 32 6197 Chemical DIAN AGS eE AS AS 32 0314 STORAGE nia A A ae eee a ee 33 7 MAINTENANCESERVICE ili lilla 34 7 1 PREPARATION POR SERVICING heel ola 34 7 2 REGOMMENDED SAFETY PROCEDURES c iaia 34 7 3 MAINTENANCE SPECIFICATIONS aici aa 35 Form 169089 2 Model Year 2009 TABLE OF CONTENTS 7 3 1 Recommended Torques stable bebiendo dle 35 7 3 2 Recommended LUBICAN Sueras delta 37 F33 ConversionChiiaLissra ili 38 7 4 AEBEADER LIFFEYLINDERLOCKS sa ilaria io 39 7 5 DRIVE SHIELDS either 39 7 6 GUFIERBARDOORS lilla 39 T T LUBRICATION ec 40 Tod PIOGGOMI TTE STET 40 1 7 2 ARA o AA A E A ia 40 5S X eB m 21216 2 rali 41 i pfmac 43
12. 9 9 3 Removal Bevel Gearbox Form 169089 7 9 9 1 Checking Oil The bevel gearbox oil level should be checked every 100 hours or once per year A 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 ms 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 Clean up any spilled oil 14 Model Year 2009 MAINTENANCE SERVICE k Properly dispose of used oil and clean up any 7 9 9 2 Changing Oil spilled oil Y DANGER I Lower drive shield A 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 header lift cylinder locks Stop engine and remove key Open LH drive shield A d Place a suitable container under drain plug C O 1 m eS 16 FT SHOWN 13 FT SIMILAR Remove plugs B and C Allow sufficient time for oil to drain Replace plug C and tighten Disengage header lift cylinder locks start engine and lower header so that it is level i Add 0 86 pints 0 4 litres of 75
13. DRIVELINE UNIVERSALS 2 PLCS DRIVELINE SHAFT 2 PLCS ROLL SHAFT BEARINGS 3 PLCS Form 169089 41 Model Year 2009 MAINTENANCE SERVICE 13 FT HEADER cont d High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base A A 508 LIFTING ROLL SHAFT BEARING un 9 sl 490 7 ROLL SHAFT BEARINGS 2 PLCS 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY i DRIVELINE UNIVERSALS amp SHAFT 3 PLCS ONE SIDE Form 169089 42 Model Year 2009 MAINTENANCE SERVICE ll 16 FT HEADER High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide CHECK PLUG Oil should slightly run out when removed NLGI Grade 2 Lithium Base a 1004 GEARBOX OIL LEVEL e rd DRIVELINE UNIVERSALS 2 PLCS 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY DRIVELINE UNIVERSALS 2 PLCS DRIVELINE SHAFT 2 PLCS Form 169089 ROLL SHAF BEARINGS 3 PLCS 43 Model Year 2009 MAINTENANCE SERVICE 16 FT HEADER cont d High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base OPTIONAL GAUGE ROLL BEARINGS 2 PLCS BOTH SIDES 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY NB Ff a BEES B25 H DRIVELINE UNIVERSALS 2 PLCS DRIVESHAFT 1 PLC BOTH SIDES Form 169089 44 Model Ye
14. F7 Evidence of interference with adjacent A parts ul J A b Check nuts for wear or damage and replace nut if 1 Worn height is less than half total height ud H 2 Cracked pa 3 Nut has been removed and installed five times Form 169089 56 Model Year 2009 MAINTENANCE SERVICE 7 8 5 Accelerators 7 8 5 2 Installation a 7 8 5 1 Removal C Stop engine and remove key from ignition d 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 f key b Engage lift cylinder lock out valves g C Open cutterbar doors A 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 bolt and nut A and nut B and remove accelerator C from disc D Do not remove cutterblade bolt unless it or the blade are being replaced Repeat for other accelerator Form 169089 57 A DANGER Locate accelerator on disc onto existing cutterblade bolt and install nut B Install hex bolt A and nut at inboard hole Bolt head faces up Tighten both nuts to 100 ft Ibf 135 N m Repeat for other accelerator Reinstall disc D on spindle Refer to Paragraph 7 8 3 2 Disc Installation Remove block o
15. OWNER OPERATOR RESPONSIBILITIES A CAUTION It is your responsibility to read and understand this manual completely before operating the windrower Contact your dealer if an instruction is not clear to you 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 windrower 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 header This may include adding ballast according to Tractor Operator s Manual requirements for attachments of this size and mass Form 169089 12 Follow all safety and operational instructions given in your tractor Operator s Manual If you do not have a tractor manual get one
16. To prolong belt and drive life do not over tighten belts Manually turn drive system and re check tension Adjust as required Tighten nuts B and jam nut C Re install hourglass deflector Refer to Section 7 8 6 1 Driveline Deflector Form 169089 follows 1 Loosen nuts G 2 Loosen jam nut H on adjuster bolt J 3 Turn adjuster bolt J to loosen belts F so they can be slipped off both pulleys Remove nuts K and bolts and lift drive assembly L out of driveline and free of belts IMPORTANT Belts are a matched set Replace both drive belts even if only one needs replacing Locate new belts over driveline opening Re install drive assembly L onto driveline and install bolts and nuts K and tighten Position belts on pulleys and tension the belts with adjuster bolt J Apply force of 51 Ibf 22 N to each deflector drive belt at mid span Deflection of each belt should be 0 12 in 3 mm IMPORTANT To prolong belt and drive life do not over tighten belts Manually turn drive system and re check tension Adjust as required Tighten nuts G and jam nut H Close drive shields and cutterbar doors Re check belt tension after 5 hours of operation Model Year 2009 MAINTENANCE SERVICE 7 9 9 Bevel Gearbox 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 See 7
17. b Open cutterbar doors c Open RH side drive compartment shield Form 169089 Remove nuts A securing nut guards and feed plates to side of compartment and remove shields and plates A CAUTION Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades Place a block of wood between discs to prevent deflector from turning Remove four bolts B and remove inboard cage driven deflector C from cutterbar continued next page Model Year 2009 MAINTENANCE SERVICE g Locate feed plate D on the disc ensuring that hole in feed plate registers on disc Position plate approximately as shown and align holes IMPORTANT Feed plate should be located so that when holes are aligned it is closer to the cutter blade 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 Ibf 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 169089 63 Model Year 2009 MAINTENANCE SERVICE 7 9 HEADER DRIVE 7 9 1 The main drive hydraulic motor does not require normal maintenance or servicing If repairs are required it should be removed and serviced at your dealer Hydraulic Motor 7 9 1 1 Removal A DANGER Stop engine and remove key from ignition before leaving opera
18. best 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 When relative humidity is high the evaporation rate is low and hay dries slower If there is no wind saturated air becomes trapped around the windrow Raking or tedding will expose the hay to fresher less saturated air Cutting hay perpendicular to the direction of the prevailing winds is also recommended Form 169089 32 6 13 4 Windrow Characteristics It is recommended that a windrow with the following characteristics be produced Refer to Operating Variables Section 6 12 for instructions on adjusting the header CHARACTERISTIC ADVANTAGE High And Fluffy The movement of air through the windrow is more important to the curing process than direct sunlight Consistent Permits an even flow of Formation Not material into the baler chopper Bunchy etc Even Distribution Results in even and consistent of Material Across bales to minimize handling and Windrow stacking problems Properly Prevents excessive leaf Conditioned damage 6 13 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 u
19. clockwise to fully up position G b Remove cap B securing electrical connector to h Move tractor left side platform to open position frame Pres PRESSURE MY sai i i w c Move hose bundle C from tractor through hose valve block as shown support D on header continued next page d Route header return and pressure hose bundle E through header support D to tractor and locate bundle above existing hose bundle C as shown i Connect two hose bundle from header to middle Form 169089 14 Model Year 2009 OPERATION ein a di mar mi RETURN MA PRESSURE CONVERGING DRUM CYLINDER HOSE 9 ml a i FWD VALVE BLOCK j If grass seed header is being attached connect converging drum three hose bundle to forward and aft valve blocks as shown k Move tractor platform to closed position Form 169089 15 HEADER CONNECTIONS 6 3 1 2 RETURN WS ES i Li AC i 1 PRESSURE E a T a amp i d calo Li F a f L m ig LI 1 E CASE DRAIN 1 i tal Lid hl E p osi i d 1 cat a Remove caps and plugs from hoses and lines b Connect the three hoses from tractor to the fittings on the header as shown c Assemble electrical connector as shown Model Year 2009 OPERATION 6 3 2 M150 13 FT 1 LU y di Lb A 3 q JT u f E HE NIIT arti Il h Connect single hose E from header to coupler
20. configuration instructions and are intended for tall crops A rod assembly is installed on either side of header opening The kit includes all hardware and installation instructions 9 8 11 DEGREE BEVEL UP CUTTERBLADES 1 ROTATION DIRECTION 11 bevel up cutter blades provide good cutting performance for general cutting conditions where the occurrence of hitting a stone and bending the blade downward is minimal Form 169089 98 Model Year 2009 UNLOADING AND ASSEMBLY 10 UNLOADING AND ASSEMBLY Refer to R80 Rotary Disc Self Propelled Windrower Header Unloading amp Assembly Instructions 169079 and Pre Delivery Checklist that is included with your shipment Form 169089 99 Model Year 2009 ADD VIANON Stein eil ela 9 AGCElerdiors salici DI ASS MDI carrillo 99 Attachmenf naa en la adi 97 EIU SCRAP 28 Bearing sealed IrisralldtlOlis caesos See seucun ers ir dna 46 Belts Conditioner dive turale 65 hourglass deflectors 72 Bevel GedfDbOX art 74 e AAA TE MET ORIENT IC PETENS 75 co ie eli 78 A A ian 74 cs 76 speed SEnNSor i 88 Break in Inspection i 90 BreaksIniPerloG vs hall re ani 20 Component Identication 10 Conditioner Bellotto anatra 68 Del TO ER TER 67 DOIFIGIG E aita coe O EA ES 69 belElensioniz a esaet la etes ai bre oed A ken Oda Ut 65 Conditioner Drive Belt Spalle 66 Conditioner
21. cutting height The kit includes dividers and attachment hardware two roller assemblies and attachment hardware It is available only for the 16 foot 95 CUTTERBAR REPAIR TOOL KIT header 9 2 SKID SHOE KIT wey f t i te MAA O The cutterbar repair tool kit contains the The skid shoe kit installs at either end of the necessary tools for replacement of the cutterbar cutterbar and the shoes can be adjusted for idler gears Refer to the Technical Service varying cutting height The kit includes two Manual for instructions skid shoe assemblies and attachment hardware It is available only for the 16 foot 9 6 DOUBLE WINDROW ATTACHMENT header 9 3 SKID PLATE LIFT KIT The double windrow attachment DWA can be The skid plate lift kit consists of spacer attached to the M Series Windrower Tractor to assemblies that attach to the existing skid enable double windrowing The kit includes all plates to increase the ground clearance by the necessary fittings and instructions approximately 2 inches 51 mm The kit includes four assemblies and attachment hardware Form 169089 97 Model Year 2009 OPTIONS 9 7 WINDROW FORMING RODS 9 9 TALL CROP TRANSITION SHIELD The tall crop transition shield deflects the grass seed heads down and into the cutterbar area i while minimizing head shattering and seed loss Windrow forming rods which assist in The kit includes all hardware and installation forming the desired windrow
22. deflector A base and slide lower end of deflector off disc H Installation A 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 a Slide driveline G upward onto shaft locate deflector A over driveline and_ position deflector on disc H b Align cut outs in base of deflector with cutter blades c Install four bolts F and torque to 92 ft Ibf 125 N m Form 169089 59 ao a Position guard E and tighten bolts D Position guard C and attach with two bolts B Remove block of wood if used Close doors 7 8 6 2 Driven Deflector 13 FT Removal a Place a block of wood between two discs to prevent deflector from turning b Remove four bolts J and remove deflector K Installation a Position deflector K on disc with cut outs in base of deflector lined up with cutter blades b Install bolts J and torque to 92 ft Ibf 125 N m c Remove block of wood if used d Close doors Model Year 2009 MAINTENANCE SERVICE 7 8 6 3 Driven and Suspended Deflectors 16 Ft Standard Header A 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 CAUTION Exercise caution when working around the blades Blades are sharp and can cause serious inju
23. generally dry faster and more evenly resulting in less protein loss Fast MEM s drying is especially important in areas where the a Set forming shield side deflectors to desired 7 ha g c dea PU da E n a E mo weather allows only a few days to cut and bale width by repositioning adjuster bars A in holes Refer to Section 6 13 Haying Tips for more in forming shield cover To ensure windrow information placement is centered adjust both side deflectors to the same position 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 NOTE The forming shields are not required when using a grass seed header b If forming shield attachment is too tight or too loose tighten or loosen nut B as required Form 169089 27 Model Year 2009 a C OPERATION 6 12 7 2 Rear Deflector Fluffer Shield The rear deflector slows the crop exiting the conditioner rolls directs the flow downward and fluffs the material Adjust the deflector as follows A 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 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 NOTE Locking handles D are located at eithe
24. jam nut B on adjuster bolt C Turn adjuster bolt to adjust tension Tighten nuts A and jam nut B e Re adjust tension of a new belt after a short run in period about 5 hours DONA 7 9 8 2 Belt Replacement a Lower header fully shut off engine and remove key Open cutterbar door s c Open LH and RH drive shields A CAUTION Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades continued next page Model Year 2009 MAINTENANCE SERVICE Driven Side RH a Loosen hourglass deflector drive belts F as Driveline LH Side I a T E m Y E dem gi Remove outboard hourglass deflector and driveline Refer to Section 7 8 6 1 Driveline Deflector Loosen hourglass deflector drive belts A as follows 1 Loosen nuts B 2 Loosen jam nut C on adjuster bolt D 3 Turn adjuster bolt D to loosen belts A so they can be slipped off both pulleys Feed belts through opening E to disengage from gearbox drive shaft IMPORTANT Belts are a matched set Replace both drive belts even if only one needs replacing Feed new belts through opening E and onto gearbox drive shaft Position belts on pulleys and tension the belts with adjuster bolt D Apply force of 51 Ibf 22 N to each deflector drive belt at mid span Deflection of each belt should be 0 12 in 3 mm IMPORTANT
25. lil 16 FT Header Grass Seed iHeadef a i idilliaca 45 7 1 3 Sealed Bearing InstallationN iii 46 7 8 CUTTER BAP m RETI OD oe ene ee ee Oe ee aia 47 7 8 1 Skid Flates arid Rock GUA istas ir idea Raves eee 47 7 8 2 SuUtterBarbubicaldo nasca 49 7 8 3 DISC IIR ARIES REUTERS altas 51 7 8 4 Cutter Blade Suit thai adds iota Ae ut cupa c tA EDI cadet eie 54 7 8 5 ACES lO Saca a ai Sota Dafa 57 7 8 6 BIS RP leto 58 1 8 1 Tall Crop Feed Plates iio lalla 62 7 9 HEADERPRNE elica 64 7 9 1 Hydraul Motol as M 64 7 9 2 Converging Drum Motors Grass Seed Header nennen nnns 64 7 9 3 Conditioner Dive Bellas ears ous tian reed ail 65 7 9 4 Conditioner brive BeltIdlefs areata NED 69 7 9 5 Tt FROM DRIVE Bolitas dai 70 7 9 6 EiftingRell Bslbldier ancola hier 71 7 9 7 Eifing Roll Iidier Beannigisa sartoria ilaele 71 7 9 8 Hourglass Deflector Drive Belts 16 FLO iii A AA 72 7 9 9 Bevel GearboXka fichi 74 7 910 CondtionerGearboe 139 FOo0tssli aa A uvae Uu OR 80 79 11 CondionerGearbor 16 FOot4 0 vini 84 TOAZ Gearboxopeed SENSO get EE 88 7 10 FVD RAW Mg Sii ina des soi tunted Ut 89 7 10 THOSCS AMG Ginestra 89 7 11 ELECTRICAL atletici alia 89 7 12 MAINTENANCE SCHEDULE vrai ia e a iii 90 FAZ Break ASPE CIN ER 90 22 erva Mamen O 5 ardid delia ist 91 7 12 95 Maintenance Recortar dl ndo oe 92 8 TROUBLESHOOTING lella aliena 93 8 1 MOWER PERFORMANCE iii hmnemem reme sese ense iense ense
26. roll timing 6 12 5 2 Excessive Heat In Cutterbar Too much oll in cutterbar Drain oil and refill with 782 specified amount i Frequent Blade Damage Mud on cutterbar Remove mud from cutterbar Do not allow mud to dry on cutterbar opindle bearing failure Replace spindle bearing See MacDon Dealer Material wrapped around Remove disc and remove 7834 spindle material dE Cutting too low in rocky field Decrease header angle 6 12 3 amp conditions Increase flotation 6 12 4 Header Header float set too heavy set too Header float set too heavy Increase Increase flotation 674 12 4 Ground speed too high in rocky field conditions Note high ground speed tends to dig rocks from ground instead of floating over them e ground speed 6 12 8 Blade incorrectly mounted Check all blade mounting hardware ensure blades are 7 8 4 3 free to move Bevel up blades more Switch to bevel down blades 7843 susceptible to damage mE Excessive Wear Of Cutting Header angle too steep Reduce header angle 6 12 3 Components DES Crop residue and dirt deposits Clean cutterbar 6 10 on cutterbar l Mud on cutterbar Remove mud from cutterbar Do not allow mud to dry on 6 10 cutterbar Form 169089 95 Model Year 2009 TROUBLESHOOTING Drive Belt tension Foreign object between rolls Disengage header and stop engine When all moving parts are completely stopped remove foreign object Belt pull
27. show cracking but no more than 5 of a Lower header fully the leaves are damaged Set enough roll gap to achieve this result 0 25 in 6 mm b Loosen and back off upper jam nut A both A larger gap up to 1 inch 25 mm may be sides of conditioner desirable in thick stemmed cane type crops i c To increase roll gap turn both lower nuts B however too large a gap may cause feeding clockwise problems NOTE Grass type CIOPS may deque less gap for The amount of thread protruding through proper feeding and conditioning jam nut indicates roll gap Factory setting is 0 25 in 6 mm NOTE When adjusting roll gap be sure that the thread protruding is the same on both sides of the conditioner roll to achieve a consistent gap across the rolls d To decrease the roll gap turn lower nuts B counter clockwise e Tighten jam nuts A both sides continued next page Form 169089 24 Model Year 2009 OPERATION a Lower header to ground shut down tractor and remove key f Inspect roll gap at both ends of the rolls at access port IMPORTANT Roll timing is critical when the roll gap is decreased because e Conditioning is affected and e The bars may contact each other e c Remove bolt A and nut and remove gauge B Refer to Section 6 12 5 2 Roll Timing from inside panel at RH end of header 6 12 5 2 Roll Timing For proper conditioning the rolls must be properly timed with
28. 7 9 3 1 Tension Adjustment Lower drive shield A Model Year 2009 7 9 4 MAINTENANCE SERVICE Conditioner Drive Belt Idler A 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 Lower header to ground turn off engine and remove key inni iz hal gt sli o hs CN AN wm cin d EJ Loosen jam nut B Turn adjuster bolt C counter clockwise to release tension on spring until idler D and belt E are loose Form 169089 69 Remove nut F from idler shaft and remove idler D IMPORTANT Note locations of washers on shaft They centre idler on the drive belt and must be re installed the same location Install idler D onto shaft with washers in same locations Install nut F and torque to 150 ft Ibf 203 N m Tension the drive belt E See Section 7 9 3 1 Tension Adjustment Close drive shield A Model Year 2009 MAINTENANCE SERVICE 7 9 5 Lifting Roll Drive Belt c Remove five bolts C and nuts and remove rear shield D The two lifting roll drive belts A are located inside the drive compartment at the right hand side of the header Belt tension is set at the factory and doe
29. CORD THE SERIAL NUMBER OF THE HEADER Serial Number plate is located on the top surface at the right hand end of the header Form 169089 1 Model Year 2009 TABLE OF CONTENTS Section Title Page 1 INCRODUGION 1 2 SAFETY atada tc 4 2 1 SAFETYAEERTSIMBOL rallo 4 2 2 SIGNAL WORDS curra 4 2 3 SAFETY SIGNS E 4 2 3 1 saletysigh Installalio Em 4 2 3 2 erii elle nMmeeeg c A TEN 5 2 4 GENERAL o cl TTE 7 3 JAAGORONYMS AND ABBREVIATIONS oo oia A Uns gU eve gU E 9 4 COMPONENT IDENTIFICA TON reoni aaia enaa Ebay ro Fux Rita FL ER x rC9g aaa Aa Aaaa a 10 5 SPECIFICATIONS esna E e r 11 6 OPERATION 12 6 1 OWNER OPERATOR RESPONSIBILITIES lari 12 6 2 OPERATIONAL SAFETY ia hill du BERE 12 6 3 HEADERATTACHMENT rule iaia 14 6 3 1 M200 13FT amp 160 Fisc 14 6 3 2 MIO ea ei a e 16 6 4 HEADER DELDACPBIVEDNT oa do lalo en 17 6 4 1 AO A EH NS MEER 17 6 4 2 hog T9 pl uUi Me DM pL EEUU 18 6 5 TRANSPORTING WINDROWEBENR 2 5 quoi e teo sea a ta tees 19 6 6 EAG ciu mA MM MEM S MU 19 6 7 BREAKIN PERIOD M M 20 6 8 PRE SEASON CHECK e Ee Ce ene arado 20 6 9 DAILY START UP CORE coc 20 0 10 SHUTDOWN PROCEDURE serrio e aa a aae 21 6 11 UNPLUGGING THE HEADER T 21 6012 HEABEROPERANON glande 22 eu P o e UL Mem 22 0122 CUUIIMG CI GING uou rale 22
30. DAILY START UP CHECK A CAUTION Be sure tractor and header are properly attached all controls are in neutral and tractor brake is engaged e Clear the area of other persons pets etc Keep children away from machinery Walk around the windrower to be sure no one is under on or close to it e Wear close fitting clothing and protective shoes with slip resistant soles e Remove foreign objects from the machine and surrounding area e As well carry with you any protective clothing and personal safety devices that COULD be necessary through the day Don t take chances o 25 e You may need a hard hat protective glasses or goggles heavy gloves respirator or filter mask wet weather gear e 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 Hydraulics b Clean all lights and reflective surfaces on the machine Check lights for proper operation c Perform all Daily maintenance Refer to Section 7 12 Maintenance Schedule Model Year 2009 OPERATION 6 10 SHUTDOWN PROCEDURE A CAUTION Before leaving the tractor seat for any reason Park on level ground if possible Lower the header fully
31. Form 169089 5 awoad inju salis a SEEST OE EER ua nbn tu eparation Fiii Pi mom Manual and Boro all safety brat ff you do noi have a manal g sin one from your doser 2 Do nat allow untrained perse lo operato the machine LI 1 Rave safety instructoce with all operators anralk 4 Erto that all aate aigna are levata liad and legible 5 Malo certain enone bs char of machina before starting angie and during operation Reap ridera of the machina T Hosp all ahiskhi in place sel sia cheer of mori parta Pe epena sorio fur Pa a Le Veil ir al mira I to atop betes berri operator a peailion A e e E O iabricaling Carra oF plu a a pura header es el beleresaedeing bn the eh tr ET Uci sia mesa veh cha em biem and Has bin sing lag hos whee arg oat reaiways unkaa penhibisd bey hirer 109843 To avoid injury stop engine before opening Keep all shields in pisca 32738 BOTH SIDES e Sop engine and remove bey before openireg shiekl Keep all shields and guards serviced amd In placa Failur to comply vill result in death or serious injury 170281 Model Year 2009 SAFETY Safety Sign Locations continued A DANGER SHIELD MISSING DO NOT OPERATE 1 PLC BOTH SIDES 036651 GUARD MISSING DO NOT OPERATE GUARD MISSING DO NOT OPERATE MDANGER 1 PLC 036651 Form 169089 6 Model Year 2009 SAFETY 2 4 GENERAL SAFETY A CAUTION The following a
32. Gearbox 13 ft installations aaa 82 temoval tail e iii 80 Conditioner Gearbox 16 ft cl T T 86 A O A E O TES 84 Converging DIM sala 30 GHtenbBlade Sonica daa alude 54 hardware damage i 56 A lisa 54 A nm 98 FEDIACCING IW isernia roei ini riani a ia ani 55 Cutterbar A nda dei diri 47 detlectol Sida la 58 deflectors Ariven ei 60 61 deflectors suspended 60 61 NA A A A II DETE TET 39 UDACA IO y ERROR RERO 49 CUTING Het lai 22 BEST m 20 Deflector A A a 58 A TM 59 60 dass Sn D LN 61 suspende da callo cdta lille 60 DIMENSIONS tulle 11 Disc IristellatlOl A A delete 52 Manent a criado 51 CN iii 51 DISC SO CCC e dio bale a 22 Double Windrowing ii 30 Driving on VVIDGIEOW sica las cid 32 DIN AGED aa ie 32 Electrical lights and WIFI cional orali 89 Fabia oa le eo na ee dado lei 23 Forming ohields tele 27 Form 169089 100 rear dele nai iaa 28 side derleclolS ori oa ie sea 27 Gauge Roller Kit 97 Gauge Rollers 0 ll ora 22 Grass Seed Header Yara lOs id rollos 14 Greasing 1S FENeaderascnan A 41 42 A eee eet ade 43 44 Grass Seed header uu tease cose lalla 45 Ej glo eeje i o Mte e EE 29 PLAYING TIDS RIP ERES NNTEUPTO ii 32 Header ONO na ao cols do EMEN 64 Header Angle A A 23 Header Attachment A ON 14 MiS tradi caia 16 Header Detachment A TA 18 M200 LL a 17 He
33. LAR 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 Ibf 125 N m continued next page Form 169089 52 Model Year 2009 MAINTENANCE SERVICE Grass Seed Header 16 Ft Only 1 Position new disc M on spindle ensuring it is 90 degrees to adjacent discs 2 Install plate L drum K and secure with four bolts J 3 Tighten bolts to 92 ft Ibf 125 N m 4 Install cover H with two bolts G e If driveline disc is being installed 1 Lift deflector N and driveline and slide disc O onto spindle 2 Locate deflector N and driveline onto disc O 3 Install bolts P and torque to 92 ft lbf 125 N m f Remove block of wood if used A 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 doors Form 169089 53 Model Year 2009 MAINTENANCE SERVICE 7 8 4 Cutter Blades 7 8 4 1 Cutter Blade Types a 18 DEGREE BEVEL DOWN ES Higher Lift for Certain Crop Conditions Better in Stony Soil ROTATION DIRECTION b 11 DEGREE BEVEL UP Optional Di General Purpose Cutting Longer Life ROTATION DIRECTION 7 8 4 2 Inspection A CAUTION Cutter blades have two cutting edges Exercise cau
34. LAR before leaving operator s seat for any 1 Remove bolts D and remove deflector E reason A child or even a pet could engage an idling machine 2 Removedisc F Grass Seed Header 16 Ft Onl a Open cutterbar door s A CAUTION Exercise caution when working around the blades Blades are sharp and can cause cpm serious injury Wear gloves when handling 1 Remove bolts G and remove cover H blades 2 Remove four bolts J and remove drum K b Place a block of wood between two discs to and plate L prevent disc rotation while loosening blade bolts 3 Remove disc M continued next page Form 169089 51 Model Year 2009 MAINTENANCE SERVICE e If removing driveline disc 7 8 3 2 Disc Installation A 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 1 Remove bolts N a Position new disc C on spindle ensuring it is 90 2 Lift deflector O and driveline and slide disc degrees to the adjacent discs P off spindle Install cover B and secure with four bolts A c Tighten bolts to 92 ft Ibf 125 N m d If installing disc with converging drum 3 Clean spindle G Standard Header 16 FT SHOWN 13 FT SIMI
35. R80 Rotary Disc Self Propelled Windrower Header OPERATOR S MANUAL Model Year 2009 Part 44169089 15 This Manual contains instructions for SAFETY OPERATION and MAINTENANCE SERVICE for your new MacDon Model R80 Rotary Disc Self Propelled Windrower Header R80 ROTARY DISC SELF PROPELLED WINDROWER HEADER 1 INTRODUCTION This manual describes the operating and maintenance procedures for the MacDon Model R80 Self Propelled Rotary Disc Header Your new MacDon rotary header 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 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 this Operators Manual and the Parts Catalog with the windrower manuals in the cab storage compartment RE
36. REVIATIONS Materials F mPa megapascals Form 169089 9 Model Year 2009 GENERAL 4 COMPONENT IDENTIFICATION DOOR DRIVE SHIELD CENTER LINK By FRONT CURTAIN DRIVE MOTOR BAFFLE CONTROL STANDARD HEADER HAZARD LIGHTS 16 FT ONLY TALL CROP TRANSITION SHIELD HOSE SUPPORT GRASS SEED HEADER Form 169089 10 Model Year 2009 SPECIFICATIONS 9 SPECIFICATIONS COC IE 3500 159019 MacDon M150 ca SP Windrower MacDon M200 SP Windrower Tractor Lighting Two Amber Transport CCC I T 2 Hourglass Converging PORES O M150 4 6 cu in 75 cc Heavy Duty Hydraulic Motor Bm M200 6 4 cu in 106 cc Heavy Duty Hydraulic Motor M150 130 hp 97 kw 9 17 in 233 mm 6 63 in 168 4 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 737 1064 rpm Lifting 492 709 rpm 36 102 in 915 2540 mm Header Mounted Adjustable Baffle Fixed Side Deflectors and Tractor Mounted Adjustable Forming Shield System 11 mph 17 7 km h GROUND SPEED 16 mph 25 7 km h NOTES 1 Specifications and design are subject to change without notice or obligation to revise previously sold units Max Power Roll Diameter dh Roll Length Roll Speed Swath Width Forming Shields Form 169089 11 Model Year 2009 OPERATION 6 2 OPERATIONAL SAFETY Follow these safety precautions A CAUTION 6 OPERATION 6 1
37. S TO TIGHTEN AFTER FINGER TIGHTENING TORQUE VALUE 1 4 9 16 12 5 8 3 8 5 8 75 718 The torque values shown are based on lubricated connections as in reassembly DN O Nm M EUN O EN uM 8 EN Lasi 75 90 N N Form 169089 7 3 1 4 O ring Type Hydraulic Fittings FITTING a LOCKNUT WASHER E O RING te GROOVE SEAT a Inspect O ring and seat for dirt or obvious defects Mh SS Ta Ss OS S RY Yj 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 NUT SIZE ACROSS FLATS THD SIZE in 4 rens The torque values shown are based on lubricated connections as in reassembly 3 1 8 34 78 a 4 m a 1 1 2 6 1 1 16 75 10 12 4 9 2 6 4 2 2 2 2 0 17 36 Model Year 2009 MAINTENANCE SERVICE 7 3 2 Recommended Lubricants e Your machine can operate at top efficiency IMPORTANT only if clean lubricants are used Do not ove
38. Universal Shafts Except Grass Seed Header E Grease Roll Shaft Bearings Except Grass Seed Header 3 Grease Drive Belt Tensioner Except Grass Seed Header 4 Grease Gauge Roller Bearings 5 Grease Converging Drum Bearings Grass Seed Header Change Bevel Gearbox Lubricant Change Cutterbar Lubricant Use only specified amount Do not overfill IT IS RECOMMENDED THAT ANNUAL MAINTENANCE BE DONE PRIOR TO START OF OPERATING SEASON Form 169089 91 Model Year 2009 MAINTENANCE SERVICE 7 12 3 Maintenance Record ACTION v Check Lubricate A Change Hour Meter Reading MAINTENANCE RECORD Date Serviced By FIRST USE Refer To Section 7 12 1 BREAK IN PERIOD 100 HOURS OR ANNUALLY y Bevel Gearbox Lubricant Level END OF SEASON Refer To Section 6 14 STORAGE 10 HOURS OR DAILY Hydraulic Hoses amp Lines Cutter Blades Deflectors amp Discs 25 HOURS e Roll Universal Shafts e Cutterbar Driveline Bearings NOTE A RECORD OF DAILY MAINTENANCE IS NOT NORMALLY REQUIRED BUT IS AT THE OWNER OPERATOR S DISCRETION 50 HOURS Cutterbar Lube First 50 amp 150 H Bevel Gearbox Oil First 50 amp 150 H Roll Universal Shafts Drive Belt Tensioner Converging Drum Bearings Roll Shaft Bearings gt e gt o o opp Gauge Roller Bearings
39. W 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 2079 Form 169089 15 Model Year 2009 MAINTENANCE SERVICE 7 9 9 3 Removal Bevel Gearbox A 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 e Remove three bolts A1 and lift off panel A2 A 16 FT SHOWN 13 FT SIMILAR f Remove bolts D securing sensor bracket E to gearbox and move sensor clear of work area g Loosen jam nut F and loosen belt G with adjuster bolt H so that belt can be slipped off pulley J NOTE Following step h is only applicable to 16 ft header c Remove clamp B securing hydraulic lines to header No clamp on 13 ft d Remove four bolts C and lift motor D off gearbox Move motor and hoses clear of work area h 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 Form 169089 76 Model Year 2009 MAINTENANCE SERVICE i Remove two bolts P and remove guard Q j Loosen two bolts R and remove guard S o Lift gearbox Y and manoeuvre from dr
40. Wait for all moving parts to stop 7 2 RECOMMENDED SAFETY PROCEDURES e Park on level surface when possible Block wheels securely if windrower is parked on an incline Follow all recommendations in your Tractor Operator s Manual e Wear close fitting clothing and cover long hair Never wear dangling items such as scarves or bracelets e Wear protective shoes with slip resistant soles a hard hat protective glasses or goggles and heavy gloves e f 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 disc to move Stay clear of driven components at all times e Be prepared if an accident should occur Know where the first aid kit and fire extinguishers are located and how to use them Form 169089 34 Keep the service area clean and dry Wet or oily floors are slippery Wet spots can be dangerous when working with electrical equipment Be sure all electrical outlets and tools are properly grounded Use adequate light for the job at hand Replace all shields removed or opened for service Use only service and repair parts made or approved by the equipment manufacturer Substituted parts may not meet strength design or safety requirements Keep the machine clean Never use gasoline naphtha or any volatile
41. ader Operation i 22 Hourglass Deflectors A RETI 72 PY OV AUIS andina 89 ING Assalti 36 hoses amd lines aas eerte bett dd a ore Uode 89 EA EMEN 89 MIB Es Rc e A RARE 16 A RR RO eae 14 Lift Roll drive belt replacemeEnt ii 70 Lift Roll A slice ia T1 A E A E A E AE E 19 DUID TE DIACE dii prece s 89 LUBACAN ES DRE 37 L UBDTICATION rt 40 Maintenance ChecKS Rm 91 Maintenance Record 92 Maintenance Schedule 90 Maintenance Service mee 34 Manuals o Nh ae o 1 Darts catalog uiua o ir data 1 SONICO ille ile ra 1 Metric CONVEFSIONS Hmm 38 MOIStUFS TOPSOIL ue id 32 Motor converging OU 64 header are iia 64 ODIONS aln ee is 97 Owner Operator Responsibilities 12 Pre Season CNOC aor aa ada di 20 A i ia 32 FROCK GUA SS ica id intona 47 Roll Drive Belt iie dnd See Conditioner Rolls ero f E 24 tens IO esate arctic cyan erect rc 26 RI RIE e RE ER EE EE 25 Safety generales dada aaa T Model Year 2009 OP STALIN cick cca aaa alata 12 A 12 POCO US Sian 34 AULA a le et ace 21 signal WOFGS siasi dec aa 4 SIGNS alal 4 O A A situa onda dress 4 Salte ela gf 5 sSerial NUMDEt irene 1 EE o E EERE A E 39 A A 21 Skid Plate Lift Kit ooocccoccccccccncococcocnocononoconnnnncnnnos 97 SKId A ect acta aa 23 47 SPpecific
42. al is reached first IMPORTANT Recommended intervals are for average conditions Service the machine more often if operated under adverse conditions severe dust extra heavy loads etc A CAUTION Carefully follow safety messages given under Section 7 2 Recommended Safety Procedures REFER TO SECTION 7 9 3 7 9 5 and 7 9 8 Check For Loose Hardware Tighten To Required 7 3 1 Hardware Torque Drive Belts Check Tension 7 9 3 7 9 5 and 7 9 8 7 9 3 7 9 5 and 7 9 8 Cutterbar Lubricant iii Use Only Specified Amount Do Not 7 8 2 Bevel Gearbox Lubricant Change Bevel Gearbox Lubricant Change H Drive Belts Check Tension 7 9 9 7 9 9 Cutterbar Lubricant abs Use Only Specified Amount Do Not 7 8 2 Form 169089 90 Model Year 2009 MAINTENANCE SERVICE 7 12 2 Interval Maintenance INTERVAL SERVICE FIRST USE Refer To BREAK IN INSPECTIONS previous page 1 Check Bevel Gearbox Lubricant Level 100 HOURS OR 2 Check Conditioner Drive Belt Tension Except Grass Seed Header See Section ANNUALLY 7 9 3 1 3 Check Hourglass Deflector Belt Tension 16 Ft Only See Section 7 9 2 1 END OF SEASON Refer To Section 6 14 STORAGE 1 Check Hydraulic Hoses And Lines For Leaks 10 HOURS OR DAILY 2 Check Cutter Blades For Security And Condition 3 Check Hourglass Deflectors For Security And Condition aroos 1 ee Grease Roll Universal Shafts Except Grass Seed Header Grease Roll
43. and remove adjuster pin A from one side of roller continued next page 22 Model Year 2009 C OPERATION 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 Repeat for roller at opposite end of header Adjust mud bar B by loosening nuts C and then re tighten to maintain minimum clearance between mud bar and roller 6 12 2 2 Skid Shoe Height Adjustment a A 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 Raise header fully stop engine and remove key b Remove lynch pin and remove adjuster pin D d from one side of skid shoe 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 Repeat for skid shoe at opposite end of header Form 169089 23 6 12 3 Header Angle Header or cutterbar angle can be varied from 0 8 below horizontal 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 The header angle can be hydraulically adjusted from the cab using hydr
44. ar 2009 MAINTENANCE SERVICE III 16 FT HEADER GRASS SEED HEADER 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY LI _ A CHECK PLUG AAA Oil should slightly run L n out when removed DRIVELINE UNIVERSALS 2 PLCS DRIVESHAFT 1 PLC BOTH SIDES 90H OPTIONAL GAUGE ROLL BEARINGS 2 PLCS BOTH SIDES P 50n CONVERGING DRUMS 2 PLCS BOTH SIDES Form 169089 45 Model Year 2009 MAINTENANCE SERVICE 7 7 3 Sealed Bearing Installation a Clean shaft and coat with rust preventative Install flangette A bearing B second flangette C and lock collar D NOTE The locking cam is only on one side of the bearing Install but do not tighten the flangette bolts E When the shaft is correctly located lock the lock collar with a punch NOTE The collar should be locked in the same direction the shaft rotates Tighten the set screw in the collar Tighten the flangette bolts Loosen the flangette bolts on the mating bearing one turn and re tighten This will allow the bearing to line up Form 169089 46 Model Year 2009 MAINTENANCE SERVICE 7 8 CUTTERBAR 7 8 1 Skid Plates and Rock Guards A 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 DANGER To avoid bodily injury or death from unexpected start up or fall of ra
45. 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 e 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 FA p Pet com e The cutterbar curtains are very important to reduce the potential for thrown objects Always keep these curtains down when operating the mower conditioner Replace the curtains if they should become worn or damaged Form 169089 13 Model Year 2009 OPERATION 6 3 HEADER ATTACHMENT Refer to the M150 amp M200 Self Propelled Windrower Operator s Manual for procedures for mechanically attaching the disc header to the self propelled windrower Refer to the following procedures for electrical and hydraulic connections The header drive hydraulic hoses and electrical harness are located on the left cab forward side of the tractor 6 3 1 M200 13 FT amp 16 FT 6 3 1 1 TRACTOR CONNECTIONS e If grass seed header is being attached route converging drum hose bundle F through header support D to tractor and locate bundle above existing hose bundles as shown i a AD f Lower and lock lever A a Disengage and rotate lever A counter g Secure hose bundles with three cinch straps
46. atonS sica id inici 11 Speed AA arcos 88 o ee eR oer ene ee meee Rates een Sca 33 Form 169089 INDEX 101 Tall Crop Divider Kirscosts aia rio ents 97 Tall Crop Feed Plates 62 Tall Crop Transition Shield 31 98 O OS 32 ToDOGFSDhVy Le ote irit eor a 32 d ru ET 35 dc A OPES rer erp 19 Troubleshooting mechanical a PROC 95 windrower performance 93 A O E 99 UNDIUGGINO A aria iaia 21 e en sera ence POR 32 Windrow Characteristics 32 Windrow Forming Rods 30 98 Model Year 2009
47. aulic cylinder without shutting down the windrower To adjust the angle refer to M150 amp M200 Self Propelled Windrower Operator s Manual 6 12 4 Header Flotation Header flotation springs are normally set so 95 105 Ibf 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 lighter setting 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 The header float can be hydraulically fine tuned from the cab without shutting down the windrower To adjust the float refer to M150 amp M200 Self Propelled Windrower Operator s Manual Model Year 2009 OPERATION 6 12 5 Roll Gap 6 12 5 1 Roll Gap Adjustment Steel rolls condition the crop by crimping and To adjust the roll gap refer to following crushing the stem in several places This allows illustration and proceed as follows 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 A DANGER Stop engine and remove key from ignition mm before leaving operator s seat for any Correct conditioning of alfalfa clover and other reason A child or even a pet could engage legumes is usually indicated when 90 of the an idling machine stems
48. deflector drive belts N onto and install bolts D Adjust gap Z between drive pulley O speed sensor and pulley J to 0 08 in 2 mm Turn adjuster bolt M to tighten belts N Apply Tighten bolts a force of 51 Ibf 22 N to each deflector drive belt at mid span Deflection of each belt should be 0 12 in 3 mm Tighten nuts K and jam nut L E ar 3 i e si a i O A i E 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 Tension drive belt G Refer to Section 7 9 3 1 Tension Adjustment o Position hydraulic motor A on gearbox and install four bolts W Torque bolts to 103 ft lbf 140 N m p Secure hydraulic lines to header with clamp Y bolt and nut q Close shield 79 Model Year 2009 Form 169089 MAINTENANCE SERVICE 7 9 10 Conditioner Gearbox 13 Foot 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 d Remove five nuts and bolts F and remove panel G 7 9 10 1 Conditioner Gearbox Removal 13 Foot A DANGER Stop engine and remove key from ignition e Loosen jam nut H and loosen belt J with before
49. e increased In light crops the header speed can be reduced while maintaining ground speed NOTE Operating the header at the minimum disc speed will extend the wear life of cutting components d The chart below indicates the between ground speed and area cut for two header sizes Example At ground speed of 13 mph 21 km h with a 16 ft header the area cut would be approximately 25 acres 10 hectares per hour relationship acres hour kilometers hour 16 32 48 64 80 97 113 12 9 145 16 1 17 7 19 3 20 9 22 5 24 1 25 7 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 miles hour hectares hour 16 FT 13FT Form 169089 29 Model Year 2009 OPERATION 6 12 9 Converging Drum Assemblies Grass Seed Header TOP VIEW OF HEADER SOME PARTS NOT SHOWN FOR CLARITY The twin converging drum assemblies are designed specifically for grass seed and similar crops where conditioning is not a requirement The hydraulically adjustable drum assemblies are used to form the desired type and shape of windrow depending on crop density dryness and maturity Refer to Section 6 13 Haying Tips for more information GEO REEL DOWN The position can be controlled from the windrower cab with the REEL UP and REEL DOWN switches on the GSL The drums are hydraulically driven and the rotational speed can be varied from 0 to 1000 rpm from t
50. 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 A 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 Check roll timing distance X at each end of the rolls with the header fully lowered using the gauge located inside the RH end panel of header GAUGE POSITION d From the rear of the header locate gauge B at X centre of rolls as shown and manually turn rolls to limits of gauge Rolls will engage the gauge if timing is correct continued next page Form 169089 25 Model Year 2009 OPERATION e To adjust roll timing refer to illustrations and l proceed as follows 6 12 6 Roll Tension The roll tension the force holding the rolls together is factory set to maximum and is adjustable A 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 shut down tractor and remove key 1 Loosen four bolts C in slots of yoke plate on upper roll universal shaft 2 Position gauge at centre of rolls and manually turn the rolls to engage the gauge The rolls will automatically adjust to the correct timing Tighten bolts C to secure the position Turn the rolls manually to release gauge
51. ed machine stop engine remove key and engage lift cylinder lock out valves before going under machine for any reason Replace cutter blade as follows Raise header fully shut off engine and remove key Engage lift cylinder lock out valves Rotate disc A so that blade B faces forward and lines up with hole C in rock guard Place a block of wood between two discs to prevent disc rotation while loosening blade bolts Clean debris from blade attachment area Form 169089 Remove nut D Remove shoulder bolt E and blade F Install new or reversed blade F with shoulder bolt E onto disc Install nut D Tighten nut to 100 ft lbf 135 N m Remove block of wood if used A 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 Close doors 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 2 Bolt has been removed and installed five times Head is worn flush with bearing surface of blade Diameter of bolt neck 0 13 in is worn out of 3 mm specification Fa Bolt is cracked ee Bolt is visibly distorted
52. elled windrower Form 169089 19 Model Year 2009 OPERATION 6 7 BREAK IN PERIOD a After attaching header 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 header be extra alert and attentive A WARNING 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 12 1 Break In Inspection Requirements 6 8 PRE SEASON CHECK a Perform the following the beginning of each operating season A CAUTION Review the Operator s Manual to refresh your memory on safety and operating recommendations Review all safety signs and other decals on the header 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 Adjust tension on drive belt Refer to Section 7 9 3 Lubricate machine completely Refer to Section 7 7 Lubrication Perform all annual maintenance 7 12 Maintenance Schedule Form 169089 See Section 20 6 9
53. eys and idlers Align pulleys and idler See misaligned MacDon Dealer Machine Pulling To One Side Header dragging on one end Adjust header flotation on 6 124 and pulling to that side both ends in Discs Don t Turn When Mud on cutterbar Remove mud from cutterbar Do not allow mud to dry on 6 10 cutterbar Poor connection at valve Check connection at tractor See tractor manual Engaging Cutterbar Header runs while unloaded Hydraulic oil level in tractor is Add oil to tractor reservoir See but slows or stops when low tractor starting to cut manual Defective hydraulic motor Repair replace hydraulic See motor tractor manual Defective hydraulic pump in Repair replace pump See tractor tractor manual Defective relief valve in tractor Repair replace relief valve See tractor manual Cold oil in hydraulic drive Reduce ground speed until system oil reaches operating temperature Header slows when going Hydraulic oil level in tractor is Add oil to tractor reservoir See uphill low tractor manual Form 169089 96 Model Year 2009 OPTIONS 9 OPTIONS AND ATTACHMENTS 9 4 TALL CROP RIDER KIT 9 1 GAUGE ROLLER KIT E i j dij A S The tall crop dividers attach to the ends of the The gauge roller kit installs at either end of header for clean crop dividing and cutterbar entry the cutterbar and the rollers can be adjusted in tall crops The kit includes left and right for varying
54. f wood if used A 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 Close cutterbar doors Model Year 2009 MAINTENANCE SERVICE 7 8 6 Deflectors 7 8 6 1 Driveline Deflector NOTE Procedure is the same for both 13 and 16 ft headers 16 ft is shown 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 A CAUTION A DANGER 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 Removal Stop engine and remove key from ignition before leaving operators 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 header lift cylinder lock outs C Open door s LH SHOWN RH OPPOSITE a Remove two bolts B and remove guard C Loosen two bolts D and remove guard E c Rotate deflector A so that wider space between bars face forward d Place a block of wood between two discs to prevent deflector from turning continued next page Form 169089 58 Model Year 2009 MAINTENANCE SERVICE e Remove four bolts F f Lift driveline G off
55. from your dealer and read it thoroughly Never attempt to start the tractor engine or operate the windrower except from the operator s seat Check the operation of all controls in a safe clear area before starting work Do not allow riders on windrower 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 header hits an obstruction the front of the tractor will usually swerve towards the ditch When working on inclines travel uphill or downhill when possible Never attempt to get on or off a moving tractor Do not get off the tractor while the header 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 engage tractor brake turn off engine and remove key wait for all movement to stop dismount and engage lift cylinder stops before inspecting raised machine Operate only in daylight or good artificial light continued next page Model Year 2009 OPERATION e Keep everyone several hundred feet away from your operation Ensure bystanders
56. he cutterbar drain plug the RH skid plate needs to be removed Refer to Section 7 8 1 Skid Plates And Rock Guards Place a suitably sized container under the cutterbar drain hole and a block under each end of the header Form 169089 49 f NOTE The block under the LH end of the header should be higher than the RH end Disengage the header lift cylinder locks start windrower and lower header onto blocks Shut down windrower and remove key 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 for oil to drain IMPORTANT Do not flush the cutterbar Replace drain plug G and tighten Model Year 2009 MAINTENANCE SERVICE 7 8 2 2 Filling A 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 Start engine and raise header Stop engine and engage header lift cylinder lock outs b Move higher block to RH end of header and remove used oil container NOTE Having the fil end higher allows for quicker filling of cutterbar c Disengage header lift cylinder lock outs A 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 A DANGER
57. he windrower cab with the rotary knob on the operator s console Form 169089 6 12 10 Windrow Forming Rods Grass seed headers are equipped with windrow forming rods which assist in forming the narrow windrows preferred for this application A rod assembly is installed on the windrower tractor at either side of header opening Adjust the rods as follows to modify the windrow shape Use the forming rods in conjunction with the converging drum deflectors to achieve the width and shape of windrows you desire Loosen clamp bolts A and move rod assembly B inboard or outboard to achieve desired swath width Tighten clamp bolts A To adjust height of rods remove hairpin C from lug and re position link on lug Re install hairpin C Refer to MacDon M Series Windrower Tractor Double Windrow Attachment Manual 169216 for operating and maintenance instructions The manual is shipped with the DWA Kit Model Year 2009 OPERATION 6 12 12 Tall Crop Dividers The tall crop dividers one on each end of header assist in clean crop dividing and cutterbar entry in tall crops except grass seed They are not adjustable but can easily be removed when operating the header with the tall crop transition shield in grass seed 6 12 13 Tall Crop Transition Shield Grass Seed The tall crop transition shield deflects the grass seed heads down and into the cutterbar area while minimizing head shattering and seed l
58. idler C Install new idler C with bolt and nut B Tighten nut to 150 ft Ibf 203 N m Reinstall belts See previous section Re install rear shield See previous section Close drive shield Form 169089 7 9 7 Lifting Roll Idler Bearing A 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 lifting roll belt idler bearing does not require normal maintenance or servicing but may eventually require replacing Replace the idler bearing as follows Remove lifting roll idler C Refer to previous section Remove C clip D and remove bearing E from idler Install new bearing E and secure with C clip D Re install idler Refer to previous section Model Year 2009 MAINTENANCE SERVICE 7 9 8 Hourglass Deflector Drive Belts 16 Ft Only A DANGER e 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 8 1 Belt Tension a Lower header fully shut off engine and remove key o Open LH and RH drive shields Apply force of 51 Ibf 22 N to each deflector drive belt at mid span Deflection of each belt should be 0 12 in 3 mm E IMPORTANT To prolong belt and drive life do not over tighten belts Form 169089 72 d If necessary adjust as follows Loosen nuts A Loosen
59. inches pounds x 1 6063 kilometers per hour US gal 38 x 29 5735 milliliters t hp psi F 32 x 0 56 mph Z n 3 Model Year 2009 MAINTENANCE SERVICE 7 4 HEADER LIFT CYLINDER LOCKS Refer to M150 M200 Self Propelled Windrower Operator s Manual for details on the header lift cylinder locks 7 5 DRIVE SHIELDS A WARNING Do not operate the machine with the drive shields open High speed rotating components may throw debris and could result in death or serious injury To open the left and right drive shields on the header pull rubber latch A off hook and lift cover B to open position To close lower shield and engage pin C in frame Place rubber latch A in hook Form 169089 39 7 6 CUTTERBAR DOORS A WARNING Do not operate the machine without all the cutterbar doors down curtains installed and in good condition The cutterbar curtains are very important to reduce the potential for thrown objects Always keep these curtains down when operating the mower conditioner Replace the curtains if they should become worn or damaged There are two doors to provide access to the cutterbar area To open door lift at front of door To close door pull at top and move to closed position A CAUTION To avoid injury keep hands and finger away from corners of doors when closing Model Year 2009 MAINTENANCE SERVICE 7 7 LUBRICATION A WARNING To av
60. indrowing 6 12 11 6 12 1 Disc Speed The disc header can be used to cut a variety of crops and for the best cutting results a range of disc speeds is recommended for each type of crop and condition See table below CROP CONDITION DISC RPM Light 1600 2000 Alfalfa Sudan Sorghum Tall amp Stemmy 2300 2500 Haygrazer Timothy 1005000 Short Grass Disc speeds are set and adjusted from the cab using without shutting down the windrower Refer to M150 M200 Self Propelled Windrower Operator s Manual Form 169089 6 12 2 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 following paragraphs 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 12 2 1 Gauge Roller Height Adjustment A 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 Engage header lift cylinder stops Pe TD HO b Remove lynch pin
61. int off shaft e Slip belt off driveline H 7 9 3 3 Conditioner Drive Belt Installation 16 FT F J i t y T F Y I a Slip belt C over driveshaft H at inboard end b Locate belt onto drive pulley F See illustration opposite c Route belt over idler and onto driven pulley E NOTE Check alignment of pulleys E and F d Attach U joint to shaft and secure with bolt G and nut Tighten bolt See illustration above e Adjust roll timing See Section 6 12 5 2 Roll Timing f Tension drive belt See Section 7 9 3 1 Tension Adjustment g Lower drive shield A Model Year 2009 MAINTENANCE SERVICE 7 9 3 4 Conditioner Drive Belt Removal 13 FT Lower header to ground turn off engine and remove key a C Loosen jam nut B and turn bolt C counter clockwise to release belt tension Remove four bolts E and slide driveline F fully inboard Slip belt D between pulley G and driveline Slip belt off drive pulley to remove it Form 169089 7 9 3 5 Conditioner Drive Belt Installation 13 i ia i Slip belt D between pulley G and driveline F Locate belt onto drive pulley J Install four bolts E but do not tighten Route belt over idler H and onto driven pulley G NOTE Check alignment of pulleys G and J Adjust roll timing Refer to Section 6 12 5 2 Roll Timing Tension the drive belt See Section
62. ised machine stop engine remove key and engage header lift cylinder stops before going under machine for any reason A 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 header lift cylinder locks ij 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 c Open cutterbar doors 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 169089 47 Model Year 2009 MAINTENANCE SERVICE NOTE 7 8 1 2 Installation Longer bolt E is required for rock guards at ends of cutterbar A DANGER c Install the two forward bolts C and nuts Tighten bolts Stop engine and remove key from ignition before leaving operators seat for any reason A child or even a pet could engage an idling machine A 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 CAUTION ij Ma Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades
63. ive area top end first k Rotate drum T so that wider space between bars face forward I Remove four bolts U m Pull driveline V through cage and slide U joint W off drive shaft n Remove four bolts U Support gearbox Y when removing last bolt Form 169089 TT Model Year 2009 MAINTENANCE SERVICE 7 9 9 4 Installation Bevel Gearbox A 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 AELA b Install four bolts X Torque to 106 ft Ibf 144 E E ar FALSI us m A ti c Position driveline V in drum and slide U joint W onto drive shaft d Install four bolts U and torque to 92 ft Ibf 125 N m a Lower gearbox Y into position through top opening NOTE On 16 ft header ensure hourglass deflector drive belts are engaged onto gearbox shaft ri i _ L3 r z E ca 1 F P n 1 F 3 f i at 4 ae j 1 i i 3 i u i 1 i E ry Fi e Position guard S and tighten bolts R f Position guard Q and attach with two bolts P continued next page Form 169089 78 Model Year 2009 MAINTENANCE SERVICE NOTE Steps g to i applicable to 16 ft header only UN z K 16 FT o PES T n m Position speed sensor bracket E onto gearbox Install hourglass
64. ld Precision fits require WHITE ROOM CARE during overhaul Form 169089 89 7 11 ELECTRICAL NOTE Only the 16 foot header is equipped with lights A 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 electrical tape and wire clips as required to prevent wires from dragging or rubbing Keep lights clean and replace burnt bulbs To replace light bulbs 1 Using a phillips screwdriver remove screws from fixture and remove plastic lens 2 Replace bulb and reinstall plastic lens and screws NOTE Bulb Part No Trade 1156 Model Year 2009 7 12 1 MAINTENANCE SERVICE 7 12 MAINTENANCE SCHEDULE The following maintenance schedule lists the periodic maintenance procedures organized by service intervals Regular maintenance is the best insurance against early wear and untimely breakdowns Following this schedule will increase machine life For detailed instructions refer to the specific headings in Section 7 Maintenance Service Use the fluids and lubricants specified in Section 7 3 Recommended Fluids and Lubricants Break In Inspection ITEM Drive Belts Check Tension INSPECTION Service Intervals The recommended service intervals are in hours of operation Where a service interval is given in more than one time frame e g 100 hours or Annually service the machine at whichever interv
65. leaving operator s seat for any adjuster bolt K so that belt can be slipped off reason A child or even a pet could engage pulley L an idling machine a Lower header to ground turn off engine and remove key continued next page b Open LH drive shield lower door A c Remove nut B bolt C and washers D and pin E Remove LH drive shield Form 169089 80 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 i Remove eight bolts S holding gearbox R to frame j Lift gearbox out of drive compartment Form 169089 81 Model Year 2009 MAINTENANCE SERVICE 7 9 10 2 Conditioner Gearbox Installation 13 Foot A 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 Ibf 125 N m 1 _ j E FAT A d Position pulley L on gearbox and install four bolts M with lockwashers
66. material for cleaning purposes These materials may be toxic and or flammable Model Year 2009 MAINTENANCE SERVICE 7 3 MAINTENANCE SPECIFICATIONS 7 3 1 2 Metric Bolts 7 3 1 Recommended Torques e Tighten all bolts to the torques specified in chart unless otherwise noted throughout this manual e Check tightness of bolts periodically using bolt torque chart as a guide e Replace hardware with the same strength bolt e 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 ee Torque categories for bolts and capscrews are identified by their head markings Y 0 N 8 87 N 4 KEIRA SEE 58 190 zs 200 zi 34 265 39 005 005 7 8 420 569 Torque categories for bolts and capscrews are identified by their head markings SAE 5 SAE 8 de OG Form 169089 35 Model Year 2009 MAINTENANCE SERVICE 7 3 1 3 Flare Type Hydraulic Fittings FLARE FLARESEAT a Check flare and flare seat for defects that might cause leakage Align tube with fitting before tightening 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 RECOMMENDED TURN
67. navoidable if a full width windrow is necessary 6 13 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 13 7 Chemical Drying Agents 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 Model Year 2009 OPERATION 6 14 STORAGE Do the following at the end of each operating season a Clean the windrower thoroughly A CAUTION Never use gasoline naphtha or any volatile material for cleaning purposes These materials may be toxic and or flammable b Store in a dry protected place if possible If stored outside always cover windrower with a waterproof canvas or other protective material c Raise header and engage header lift cylinder lock outs d If possible block up the windrower to take weight off tires e Repaint all worn or chipped painted surfaces to prevent rust f Loo
68. ngle to lower cutting height if field conditions allow Not Cutting Short Enough In Down Crop 6 12 3 Material Being Pulled Out By Crop in conditioner rolls before Increase roll gap Roots When Cutting Tall crop is cut 6 12 5 Crop Leaning Into Machine Damaged Leaves And Broken Stems Insufficient roll gap Adjust roll spacing 6 12 5 Roll timing off Check roll timing and adjust if pe Rolls not crimping crop Decrease roll gap 6 12 5 sufficiently E Crop is bunched in windrow Adjust forming shields baffle 6 12 7 Excessive Drying Or Increase roll gap 6 12 5 Bleaching Of Crop Crop is spread too wide in Adjust forming shields 6 127 windrow 2 Plugging Behind End Ground speed too slow Increase ground speed 6 12 8 Hourglass Deflectors Material not moving Install optional feed plate Poorly Formed Or Bunchy Forming shields not properly Adjust forming shields 6127 Windrows adjusted bg Form 169089 94 Model Year 2009 Slow Crop Drying TROUBLESHOOTING 8 2 MECHANICAL SYMPTOM PROBLEM SOLUTION SECTION Excessive Noises Bent cutter blade Replace blade 7 8 4 3 Conditioner roll timing off Check roll timing and adjust if 6 1252 necessary mE Conditioner roll gap too small Check gap and adjust if 6 12 5 necessary m Excessive Vibration Or Noise Mud deposits on conditioner Clean rolls 6 10 In Header rolls Conditioner rolls contacting each Increase roll gap 6 12 5 other o A Check
69. nnect sensor to wiring harness h Close shield A b Open LH drive shield door A c Gap B between speed sensor and pulley should be 0 08 in 2 mm d To adjust gap loosen bolts C and move bracket D to achieve gap Tighten bolts e Toreplace speed sensor 1 Remove bolts C and remove bracket D and sensor from gearbox 2 Disconnect sensor wire from wiring harness Form 169089 88 Model Year 2009 MAINTENANCE SERVICE 7 10 HYDRAULICS Refer to M150 M200 Self Propelled Windrower Operators Manual for hydraulic system maintenance procedures for self propelled windrowers 7 10 1 Hoses And Lines Check hydraulic hoses and lines daily for signs of leaks A WARNING e Avoid high pressure fluids Escaping fluid can penetrate the skin causing disconnecting serious injury Relieve pressure before Z hydraulic lines Tighten all connections before applying pressure Keep hands and body away from pin holes and nozzles which eject fluids under high pressure e f ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Use a piece of cardboard or paper to search for leaks IMPORTANT Keep hydraulic coupler tips and connectors clean Dust dirt water and foreign material are the major causes of hydraulic system damage DO NOT attempt to service hydraulic system in the fie
70. oid 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 200 H Log hours of operation and use the Maintenance Checklist provided to keep a record of scheduled maintenance Refer to Section 7 12 Maintenance Schedule 7 7 1 Procedure A 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 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 Form 169089 40 7 7 2 Refer to the illustrations on the following pages for identifying the various locations that require lubrication Lubrication Points Model Year 2009 MAINTENANCE SERVICE I 13 FT HEADER BELT TENSIONER PIVOT 1 PLC 0 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE E SLIP JOINT ONLY
71. osition drum J and secure with four bolts H Tighten bolts to 92 ft Ibf 125 N m Install cover G with two bolts F Remove block of wood if used Close doors o ooo Removal a Place a block of wood between two discs to prevent deflector from turning b Remove bolts A and remove cover B c Remove four bolts C and remove drum D Installation a Install drum D and secure with four bolts C Ensure plate E is correctly positioned Tighten bolts to 92 ft Ibf 125 N m Install cover B with two bolts A d Remove block of wood if used Form 169089 61 Model Year 2009 MAINTENANCE SERVICE 7 8 7 Tall Crop Feed Plates The tall crop feed plates assist the feeding of tall crops into the conditioner by encouraging material flow from behind the cage 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 on the two inboard cage deflectors and only on 16 ft headers They are stored inside the RH side drive compartment Feed plates are factory installed on grass seed headers A 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
72. oss There are no adjustments necessary for its required operation Ensure the hazard lights on it are in working properly when transporting the header on the road See Section 6 6 Lights Form 169089 31 Model Year 2009 OPERATION 6 13 HAYING TIPS 6 13 1 a Curing A quick cure will maintain top quality because e Protein is lost for each day hay lies on the ground e The sooner the cut hay is harvested the earlier the start for next growth Leaving the windrow as wide and thin as possible makes for the quickest curing The cured hay should be baled as soon as possible 6 13 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 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 25 45 Shows Footprints Under 25 Surface is Dusty If ground is wet due to irrigation wait until soil moisture drops below 45 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 The cut hay will dry no more until the ground under it dries so consider moving the windrow to drier ground 6 13 3 Weather and Topography a Cut as much hay as possible by midday when drying conditions are
73. r end of the deflector and may be loosened slightly 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 Tighten handles D to secure deflector position Form 169089 28 6 12 7 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 e Direct the crop flow into the forming shield for narrow and moderate width windrows e Direct crop downward to form a wide swath Adjust the baffle as follows A 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 Pull lever F to disengage from bracket G and move lever forward to raise baffle E and backward to lower baffle Release lever into bracket Model Year 2009 OPERATION 6 12 8 Ground Speed A CAUTION Reduce speed when turning crossing slopes or when travelling over rough ground Choose a ground speed that allows the cutterbar and conditioner to cut the crop smoothly and evenly Try different combinations of header speed and ground speed to suit your specific crop Refer to M150 M200 Self Propelled Windrower Operators Manual for changing ground speed In tough cutting conditions such as native grasses the disc speed will need to b
74. r is being detached disconnect two couplers at the aft valve and the single coupler at the forward valve Raise lever A and undo Velcro straps B Move hose bundle C to store on header f grass seed header is being detached there are two hose bundles to store on the header Install caps on connectors and hose ends if equipped continued next page Model Year 2009 OPERATION k Locate electrical harness through support D and attach cap to electrical connector E I Move tractor platform back to closed position m Detach header from tractor Refer to the M150 amp M200 Self Propelled Windrower Operator s Manual for procedures for mechanically detaching the header from the self propelled windrower 6 4 2 M150 13 FT a Move LH cab forward platform to rear of tractor g Atthe header disconnect electrical connector by turning collar counterclockwise and pulling connector to disengage h Disconnect the two drive couplers and case drain coupler on header b Disconnect the hydraulic coupler from tractor valve Wa 498983 i r TE etr T Le 3j mm Ve i l i 6 PU 4 la i Ba hac a a ip a Th i Move hose bundle from header and locate on tractor LH side with hoses in support D SRL ATH Ia eges TT RR mE M A c Raise lever A and undo Velcro straps B i Wa Semi ja d Move hose C to store on header J E
75. re general farm safety precautions that should be part of your operating procedure for all types of machinery e Protect yourself y a A d a A e 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 ed FIDO D Lam e You may need e ahardhat e protective shoes with slip resistant soles e protective glasses or goggles e heavy gloves e wet weather gear e respirator or filter mask e 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 Form 169089 Provide a first aid kit for use in case of emergencies A ni di ELLIT ili PELE pa reba Keep a fire extinguisher on the machine Be sure the extinguisher is properly maintained and be familiar with its proper use Keep young children away from machinery at all times Be aware that accidents often happen when 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 Wear close fitting clothing and cover long hair Never wear dangling items such as scarves or bracelets Keep hands feet clothing and hair away from moving parts Never attemp
76. rfill the cutterbar when e Use clean containers to handle all adding lubricant Overheating and lubricants failure of cutterbar components may occur if overfilled e Store in an area protected from dust moisture and other contaminants LUBRICANT SPEC DESCRIPTION CAPACITIES High Temp Extreme Pressure EP2 As Performance With 1 Max VaR ee Required Disulphide NLGI Grade 2 Unless i Lithium Base Otherwise SAE Multi Specified Grease Purpose High Temp Extreme Pressure EP Performance With 10 Max Driveline Molybdenum Disulphide NLGI Grade 2 Slip Joints Lithium Base Traxon SAE High Thermal amp Oxidation Stability 3 43 qts U S 4 5 gts U S Cutterbar 80W90 API Service Class GL 5 3 25 liters 4 25 liters SAE 75W90 Gear API Service i Bevel E E Lubaeant Class GL 5 Fully Synthetic Gear Lubricant Gearbox 0 86 pints U S 0 4 liters SAE J2360 Preferred NLGI 00 Synthetic EP Condon Lubricated For Life Gearbox or equivalent Form 169089 37 Model Year 2009 MAINTENANCE SERVICE 73 Conversion Chart 3 3 INCH POUND UNITS UNIT NAME ABBR FACTOR SI UNITS METRIC UNIT NAME ABBR Length Power Pressure Torque Velocity Volume Weight Form 169089 inch foot horsepower pounds per square inch pound feet or foot pounds pound inches or inch pounds degrees Fahrenheit feet per minute feet per second miles per hour US gallons ounces cubic
77. ry Wear gloves when handling blades 7 8 6 3 1 Driven Deflector RH SHOWN LH OPPOSITE Removal a Place a block of wood between two discs to prevent deflector from turning b Remove four bolts A and remove deflector B Installation a Position deflector B on disc C and install bolts A and torque to 92 ft Ibf 125 N m b Remove block of wood if used Form 169089 60 I RH SHOWN LH OPPOSITE Removal a Place a block of wood between two discs to prevent deflector from turning b Remove four bolts D and nuts and remove deflector E Installation a Position deflector E on flange and install bolts D and nuts Tighten to 92 ft Ibf 125 N m Remove block of wood if used c Close doors Model Year 2009 MAINTENANCE SERVICE 7 8 6 4 Driven and Suspended Deflectors 16 7 8 6 4 2 Suspended Deflector Ft Grass Seed Header A 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 CAUTION Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades 7 8 6 4 1 Driven Deflector Removal a Place a block of wood between two discs to prevent deflector from turning b Remove bolts F and remove cover G c Remove four bolts H and remove drum J Installation a P
78. s are completely stopped remove foreign object Conditioners Plugging Ground speed too fast Ground speed too fast too fast Slowdown down 6128 12 8 Roll gap too large for proper roll gap 6 12 5 feeding Roll gap too small in thick Increase roll gap 6 12 5 stemmed cane type crops Baffle set too low Raise baffle 6427 12 7 Roll speed too low Increase disc speed Ed Foreign object between rolls Disengage header and stop engine When all moving parts are completely stopped remove foreign object Form 169089 93 Model Year 2009 TROUBLESHOOTING raise cutting height Se dan EA up Rolls improperly timed Adjust roll timing 6 12 5 2 Uneven Formation And Rear deflector bypassing or Adjust rear deflector for 61272 Bunching Of Windrow dragging crop proper crop control VOTE Forming shields improperly Adjust forming shields 6 127 adjusted die Roll gap too large Adjust roll gap 6 12 5 Crop lifter roll belts slipping Replace belts 7 9 5 1 Conditioner rolls running too Maintain rated header speed 6 12 1 slow Uneven Windrow Formation Uneven feeding Reduce header speed 6 122 In Light Crop Cutting Height Varies From Flotation not properly balanced Adjust header flotation 6 124 One Side To The Other Mk Broken bent or dull blades Replace blades or turn 7843 blades over sala Ground speed too fast Reduce ground speed 6 12 8 Cutting height too high Adjust header a
79. s not require adjustment a E Mod de E e NOTE d Insert the end of a inch drive socket wrench in Rear shield not shown for clarity the square hole on the idler arm E 7 9 5 1 Replacement e Rotate idler arm until belts A are loose f Insert a bolt in hole F to hold idler A DANGER g Remove belts A NOTE Stop engine and remove key from ignition Belts must be replaced in pairs before leaving operator s seat for any NOTE reason A child or even a pet could engage Check alignment of pulleys an idling machine h Install belts on pulleys ensuring they are in the pulley grooves i Rotate idler arm E so that bolt in F can be removed j Release load on idler and remove wrench k Re install rear shield D with bolts C and nuts I Close drive shield a Lower header to ground turn off engine and remove key b Open RH drive shield B Form 169089 70 Model Year 2009 MAINTENANCE SERVICE 7 9 6 Lifting Roll Belt Idler 207292 A 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 lifting roll belt idler does not require normal maintenance or servicing but may eventually require replacing Replace the idler as follows Lower header to ground turn off engine and remove key Open RH drive shield A Remove belts See previous section Remove nut and bolt B and remove
80. safety sign e Safety signs are available from your Dealer Parts Department Carefully read and follow the safety message accompanying this symbol 2 3 1 Safety Sign Installation a Be sure the installation area is clean and dry WHY IS SAFETY IMPORTANT TO YOU b Decide on the exact location before you remove the decal backing paper ACCIDENTS DISABLE AND KILL c Remove the smaller portion of the split backing ACCIDENTS COST io NN ACCIDENTS CAN BE AVOIDED d Place the sign in position and slowly peel back the remaining paper smoothing the sign as it is 22 SIGNAL WORDS de e Small air pockets can be smoothed out or Note the use of the signal words DANGER pricked with a pin WARNING and CAUTION with safety messages The appropriate signal word for each message has been selected using the following guidelines A DANGER Indicates an imminently hazardous situation that if not avoided will result in death or serious injury Form 169089 4 Model Year 2009 SAFETY 2 3 2 Safety Sign Locations A DANGER STAY CLEAR ROTATING BLADES Contact with blades or thrown objects can result in serious injury or death Do not stand on or near machine when in operation Do not operate with covers or curtains open or removed Shut off tractor and remove key before opening covers 2 PLCS 148829 xd fi c Dare as Pr dr A LP Farisha a Lamm bed d ESSE era nari erar bo eer y Be gm 134070
81. sen drive belts g Lubricate the header 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 91 9 Recommended Torques k Remove tall crop dividers if equipped to reduce space required for inside storage Form 169089 33 Model Year 2009 MAINTENANCE SERVICE 7 MAINTENANCE SERVICE The following instructions are provided to assist the operator in the use of the disc header Detailed maintenance service and parts information are contained in the Service Instruction Manual and Parts Catalogue that are available from your dealer Log hours of operation and use the Maintenance Checklist provided to keep a record of scheduled maintenance Refer to Section 7 12 Maintenance Schedule 7 1 PREPARATION FOR SERVICING 9 A CAUTION avoid personal injury before ion header or opening drive covers perform the following Fully lower the header If necessary to service in the raised position always engage header lift cylinder stops Stop engine and remove key Engage park brake
82. sens ses se eese ten se sense senses anann 93 8 2 NECHANICAL ll Li i sii ii e bi e ie iii 95 9 OPTIONS AND A FTACHME NT S l a a O a E aaa 97 9 1 GAUGE ROLLER Kire arr 97 9 2 SKIDSHOEKEE eater ria 97 9 3 SKIb PEATEMFEKNT ct a A i i al 97 9 4 TALL CROP DINAD ER ARK Doc elia lil era 97 9 5 CUTTERBAR REPAIR TOOL KIT ia ila 97 9 6 DOUBLE WINDROW ATTACHMENT sti i ia 97 9 7 WINDROW FORMING RODS siglati 98 9 8 1 DEGREE BEVEL UP CUTTER BLADE Sui Ara ia lid De musa dee di ani 98 9 9 TALECGROP TRANSITION SHIEL D earn 98 10 UNLOADING AND ASSEMBLY nnt ie eee iene iene 99 INDEX ell 100 Form 169089 3 Model Year 2009 SAFETY 2 SAFETY A WARNING 2 1 SAFETY ALERT SYMBOL 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 A 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 This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine 2 3 SAFETY SIGNS e Keep safety signs clean and legible at all times This symbol means e Replace safety signs that are missing or become illegible ATTENTION e f original parts on which a safety sign was BECOME ALERT installed are replaced be sure the repair YOUR SAFETY IS INVOLVED part also bears the current
83. t Ibf 125 N m EN e Attach pulley L to gearbox with bolts M Torque to 75 ft Ibf 102 N m continued next page b Ensure woodruff key is in shaft keyway and slide yoke R onto gearbox shaft Tighten bolt Q on U joint Form 169089 86 Model Year 2009 MAINTENANCE SERVICE 1 y f Position belt J on pulley L and tighten idler with adjuster bolt K See 7 9 3 1 Tension Adjustment Conditioner Drive Belt Tighten jam nut H LO 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 12 5 2 Roll Timing k Close drive shield A Form 169089 87 Model Year 2009 MAINTENANCE SERVICE 7 9 12 Gearbox Speed Sensor A 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 3 Remove nut and bolt E securing sensor F to bracket and remove sensor 4 Install new sensor onto bracket with bolt E and nut f Install bracket D onto gearbox and adjust gap B between sensor and pulley to 0 08 in 2 mm Tighten bolts C g Co
84. t to clear obstructions or objects from a machine while the engine is running Keep all shields in place Never alter or remove safety equipment Make sure driveline guards can rotate independently of the shaft and can telescope freely Use only service and repair parts made or approved by the equipment manufacturer Substituted parts may not meet strength design or safety requirements Do not modify the machine Unauthorized modifications may impair the function and or safety and affect machine life 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 continued next page Model Year 2009 SAFETY e 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 7 equipment Be sure all 3T T electrical outlets and tools are properly grounded e Use adequate light for the job at hand e Keep machinery clean Do not allow oil or grease to accumulate on service platforms ladders or controls Clean machines before storage e Never use gasoline naphtha or any volatile material for cleaning purposes These materials may be toxic and or flammable e When storing machinery cover sharp or extending components to prevent injury from accidental contact Form 169089 8 Model Year 2009 GENERAL 3 ACCRONYMS AND ABB
85. tion when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades A CAUTION Damaged blades may damage the cutterbar and result in poor cutting performance Replace damaged blades at earliest possible opportunity A 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 169089 BLADE WEAR TO CENTERLINE 0 81 in 20 6 mm ELONGATED HOLE Check daily that the cutter blades are securely attached to the disc Check blades for cracks or wear beyond safe operating limits and distortion 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 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 Model Year 2009 MAINTENANCE SERVICE 7 8 4 3 Replacement a b d e f A 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 A DANGER To avoid bodily injury or death from unexpected start up or fall of rais
86. tor 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 b Remove nut bolt and bracket A Open shield to access nut c Remove bolts on split flange fittings and disconnect supply and return hoses at B Install plugs on motor and cap off hydraulic lines d Disconnect case drain hose C from fitting and install caps on tube end and motor fitting e Remove four bolts D and remove motor E W m Qu NE ELI a m o e f Cover gearbox opening F with a rag or plastic Form 169089 64 7 9 1 2 a Installation Remove covering from gearbox F opening b Place motor E on gearbox F flange c Install four bolts D Torque to 103 ft Ibf 140 N m d Remove caps from motor fitting and case drain line and re connect to motor at C e Remove plugs from motor and caps from supply and return lines and re connect lines to motor at B Torque bolts to 32 ft Ibf 43 N m f Secure hydraulic lines with bracket A bolt and nut 7 9 2 Converging Drum Motors Grass Seed Header The converging drum hydraulic motors do not require normal maintenance or servicing If repairs are required they should be removed and serviced at your dealer Refer to the Technical Service Manual available through your dealer Model Year 2009 MAINTENANCE SERVICE 7 9 3 Conditioner Drive Belt 7 9 3 1 Tension Adjustment

R80 Rotary Disc Self-Propelled Windrower Header

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