R80 Rotary Disc Windrower

Transcription

R80 Rotary Disc
Self-Propelled Windrower Header
Unloading & Assembly Instructions
Form # 169079
Model Year - 2009
MACDON R80 SELF PROPELLED ROTARY DISC HEADER
Form # 169079
Model Year - 2009
INTRODUCTION
This instruction describes the unloading, set-up and pre-delivery requirements for the MacDon Model R80
Rotary Disc Self-Propelled Windrower Header. Use the table of contents to guide you to specific areas.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE,
OR USE THE MACHINE.
TABLE OF CONTENTS
INTRODUCTION........................................................................................................................................................ 1
GENERAL SAFETY ................................................................................................................................................... 2
RECOMMENDED TORQUES ................................................................................................................................... 4
A.
GENERAL ..................................................................................................................................................... 4
B.
SAE BOLTS .................................................................................................................................................. 4
C.
METRIC BOLTS............................................................................................................................................ 4
D.
HYDRAULIC FITTINGS ................................................................................................................................ 5
CONVERSION CHART.............................................................................................................................................. 6
STEP 1.
UNLOAD HEADER .............................................................................................................................. 7
STEP 2.
REMOVE UNDERSIDE SHIPPING STAND ........................................................................................ 8
STEP 3.
INSTALL GAUGE ROLLERS OR SKID SHOES – 16 FT ONLY ......................................................... 8
A.
GAUGE ROLLERS ....................................................................................................................................... 8
B.
SKID SHOES ................................................................................................................................................ 9
STEP 4.
LOWER HEADER .............................................................................................................................. 10
STEP 5.
REMOVE SHIPPING STANDS .......................................................................................................... 11
STEP 6.
INSTALL MOTOR – 13 FT ONLY ...................................................................................................... 13
STEP 7.
INSTALL HOSE SUPPORT ............................................................................................................... 13
STEP 8.
ASSEMBLE FORMING SHIELD ........................................................................................................ 14
STEP 9.
INSTALL FORMING SHIELD............................................................................................................. 15
STEP 10.
INSTALL TALL CROP FEED PLATES .............................................................................................. 16
STEP 11.
ATTACH HEADER TO TRACTOR..................................................................................................... 18
STEP 12.
CONNECT HYDRAULICS ................................................................................................................. 21
A.
M200 – 13 FT & 16 FT ................................................................................................................................ 21
I.
TRACTOR CONNECTIONS................................................................................................................... 21
II.
HEADER CONNECTIONS ..................................................................................................................... 22
III.
GRASS SEED HEADER HYDRAULICS ................................................................................................ 23
IV.
GRASS SEED HEADER HOSE CONNECTIONS ................................................................................. 25
B.
M150 - 13 FT............................................................................................................................................... 26
I.
TRACTOR CONNECTIONS................................................................................................................... 26
II.
HEADER CONNECTIONS ..................................................................................................................... 27
STEP 13.
INSTALL ROTARY SWITCH.............................................................................................................. 28
STEP 14.
INSTALL OPTIONS............................................................................................................................ 29
A.
TALL CROP DIVIDER KIT .......................................................................................................................... 29
B.
SHOE LIFT KIT ........................................................................................................................................... 29
C.
DOUBLE WINDROW ATTACHMENT ........................................................................................................ 29
D.
TALL CROP TRANSITION SHIELD – GRASS SEED HEADER................................................................ 30
STEP 15.
LUBRICATE THE HEADER ............................................................................................................... 31
STEP 16.
PERFORM PRE-DELIVERY CHECKS.............................................................................................. 36
A.
DRIVE BELTS............................................................................................................................................. 36
B.
HEADER FLOTATION ................................................................................................................................ 37
C.
CHECK LEVEL OF HEADER ..................................................................................................................... 37
D.
CONDITIONER ROLLS .............................................................................................................................. 38
I.
ROLL GAP .............................................................................................................................................. 38
II.
ROLL TIMING ......................................................................................................................................... 38
E.
MANUALS................................................................................................................................................... 39
F.
GAUGE ROLLERS OR SKID SHOES........................................................................................................ 40
G.
LIGHTS – 16 FT ONLY ............................................................................................................................... 40
H.
CHECK CONVERGING DRUM OPERATION – GRASS SEED ................................................................ 41
I.
RUN-UP THE HEADER .............................................................................................................................. 41
Form # 169079
1
Model Year - 2009
GENERAL SAFETY
•
Provide a first-aid kit for use in case of
emergencies.
•
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 attempt 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.
(continued next page)
CAUTION
The following are general farm safety
precautions that should be part of your
operating procedure for all types of machinery.
•
•
•
Protect yourself.
When assembling, operating and servicing
machinery, wear all the protective clothing
and personal safety devices that COULD be
necessary for the job at hand. Don't take
chances.
You may need:
• a hard hat.
• protective shoes with slip resistant
soles.
• protective glasses or goggles.
• heavy gloves.
• wet weather gear.
• respirator or filter mask.
• hearing protection. Be aware that
prolonged exposure to loud noise
can cause impairment or loss of
hearing. Wearing a suitable hearing
protective device such as ear muffs
(A) or ear plugs (B) protects against
objectionable or loud noises.
A
B
Form # 169079
2
Model Year - 2009
•
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.
•
Keep the area used for servicing machinery
clean and dry. Wet
or oily floors are
slippery. Wet spots
can be dangerous
when working with
electrical
equipment.
Be
sure all electrical
outlets and tools
are
properly
grounded.
•
Use adequate light
for the job at hand.
•
Keep machinery clean. Do not allow oil or
grease to accumulate on service platforms,
ladders or controls. Clean machines before
storage.
•
Never use gasoline, naphtha or any volatile
material for cleaning purposes. These
materials may be toxic and/or flammable.
•
When storing machinery, cover sharp or
extending components to prevent injury
from accidental contact.
Form # 169079
3
Model Year - 2009
RECOMMENDED TORQUES
C. METRIC BOLTS
A. GENERAL
The tables shown below give correct torque
values for various bolts and capscrews.
•
•
•
•
Tighten all bolts to the torques specified in
chart unless otherwise noted throughout this
manual.
Check tightness of bolts periodically, using
bolt torque chart as a guide.
Replace hardware with the same strength
bolt.
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%.
B. SAE BOLTS
NC BOLT TORQUE*
BOLT DIA.
"A"
in.
SAE 5
NC BOLT TORQUE*
BOLT
DIA.
"A"
8.8
10.9
lbf·ft
N·m
lbf·ft
N·m
M3
0.4
0.5
1.3
1.8
M4
2.2
3
3.3
4.5
M5
4
6
7
9
M6
7
10
11
15
M8
18
25
26
35
M10
37
50
52
70
M12
66
90
92
125
M14
103
140
148
200
M16
166
225
229
310
M20
321
435
450
610
M24
553
750
774
1050
M30
1103
1495
1550
2100
M36
1917
2600
2710
3675
* Torque categories for bolts and capscrews are identified by
their head markings.
SAE 8
lbf·ft
N·m
lbf·ft
N·m
1/4
9
12
11
15
5/16
18
24
25
34
3/8
32
43
41
56
7/16
50
68
70
95
1/2
75
102
105
142
9/16
110
149
149
202
5/8
150
203
200
271
3/4
265
359
365
495
7/8
420
569
600
813
1
640
867
890
1205
* Torque categories for bolts and capscrews are identified by
their head markings.
SAE-5
Form # 169079
SAE-8
4
Model Year - 2009
O-RING TYPE
D. HYDRAULIC FITTINGS
FITTING
LOCKNUT
FLARE TYPE
WASHER
O-RING
NUT
FLARE
GROOVE
SEAT
BODY
FLARESEAT
a. Check flare and flare seat for defects that might
cause leakage.
b. Align tube with fitting before tightening.
c. Lubricate connection and hand tighten swivel
nut until snug.
d. To prevent twisting the tube(s), use two
wrenches. Place one wrench on the connector
body and with the second tighten the swivel nut
to the torque shown.
TUBE
SIZE
O.D.
(in.)
NUT
SIZE
ACROSS
FLATS
(in.)
3/16
7/16
TORQUE
VALUE*
a. Inspect O-ring and seat for dirt or obvious
defects.
A
B
RECOMMENDED
TURNS TO
TIGHTEN
(AFTER FINGER
TIGHTENING)
lbf·ft
N·m
Flats
Turns
6
8
1
1/6
1/4
9/16
9
12
1
1/6
5/16
5/8
12
16
1
1/6
3/8
11/16
18
24
1
1/6
1/2
7/8
34
46
1
1/6
5/8
1
46
62
1
1/6
3/4
1-1/4
75
102
3/4
1/8
7/8
1-3/8
90
122
3/4
1/8
C
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.
THD
SIZE
(in.)
* The torque values shown are based on lubricated connections
as in reassembly.
NUT SIZE
ACROSS
FLATS
(in.)
TORQUE
VALUE*
RECOMMENDED
TURNS TO
TIGHTEN (AFTER
FINGER
TIGHTENING)
lbf·ft
N·m
Flats
Turns
3/8
1/2
6
8
2
1/3
7/16
9/16
9
12
2
1/3
1/2
5/8
12
16
2
1/3
9/16
11/16
18
24
2
1/3
3/4
7/8
34
46
2
1/3
7/8
1
46
62
1-1/2
1/4
1-1/16
1-1/4
75
102
1
1/6
1-3/16
1-3/8
90
122
1
1/6
1-5/16
1-1/2
105
142
3/4
1/8
1-5/8
1-7/8
140
190
3/4
1/8
1-7/8
2-1/8
160
217
1/2
1/12
* The torque values shown are based on lubricated connections
as in reassembly.
Form # 169079
5
Model Year - 2009
CONVERSION CHART
INCH-POUND UNITS
QUANTITY
UNIT NAME
SI UNITS (METRIC)
FACTOR
ABBR.
UNIT NAME
ABBR.
Area
acres
acres
x 0.4047 =
hectares
ha
Flow
US gallons per minute
(gpm)
x 3.7854 =
liters per min
L/min
Force
pounds force
lbf
x 4.4482 =
Newtons
N
inch
in.
x 25.4 =
millimeters
mm
foot
ft
x 0.305 =
meters
m
Power
horsepower
hp
x 0.7457 =
kilowatts
kW
Pressure
pounds per square inch
psi
x 6.8948 =
kilopascals
kPa
x .00689 =
megapascals
MPa
pound feet or foot pounds
lbf·ft or ft·lbf
x 1.3558 =
newton meters
N·m
pound inches or inch pounds
lbf·in. or in·lbf
x 0.1129 =
newton meters
N·m
degrees Fahrenheit
˚F
(F- 32) x 0.56 =
Celsius
˚C
feet per minute
ft/min
x 0.3048 =
meters per min
m/min
feet per second
ft/s
x 0.3048 =
meters per sec
m/s
miles per hour
mph
x 1.6063 =
kilometers per hour
km/h
US gallons
US gal.
x 3.7854 =
liters
L
ounces
oz.
x 29.5735 =
milliliters
ml
cubic inches
in.3
x 16.3871 =
cubic centimeters
cm3 or cc
pounds
lb
x 0.4536 =
kilograms
kg
Length
Torque
Temperature
Velocity
Volume
Weight
Form # 169079
6
Model Year - 2009
UNLOADING AND ASSEMBLY
IMPORTANT
STEP 1. UNLOAD HEADER
Take care not to contact the other
machine if load is two-wide.
CAUTION
c. Raise header off deck.
d. Back up until unit clears trailer and slowly lower
to 6 inches (150 mm) from ground.
e. Take to storage or set-up area.
To avoid injury to bystanders from being
struck by machinery, do not allow persons
to stand in unloading area.
CAUTION
Equipment used for unloading must meet
or exceed the requirements specified
below. Using inadequate equipment may
result in chain breakage, vehicle tipping or
machine damage.
LIFTING VEHICLE
Min. Lifting Capacity *
8000 lb. (3630 kg)
Min. Fork Length
78 inches (1981 mm)
* At 48 inches (1220 mm) from back end of
forks.
IMPORTANT
f. Set machine down securely on level ground.
g. If hydraulic motor and hoses are shipped
separately on pallet, unload pallet.
h. Check for shipping damage and missing parts.
Forklifts are normally rated for a load
located 24 inches (610 mm) ahead of
back end of the forks. To obtain the
forklift capacity at 48 inches (1220 mm),
check with your forklift distributor.
WARNING
Be sure forks are secure before moving
away from load. Stand clear when lifting.
a. Remove hauler's tie down straps and chains.
b. Approach header from its "underside" and slide
forks in underneath lifting framework as far as
possible.
Form # 169079
7
Model Year - 2009
STEP 2. REMOVE UNDERSIDE
SHIPPING STAND
STEP 3. INSTALL GAUGE
ROLLERS OR SKID
SHOES – 16 FT ONLY
CAUTION
If kits not supplied proceed to STEP 4, LOWER
HEADER, otherwise install kit as follows:
Keep feet clear when removing final bolts.
NOTE
These kits may be installed later in the
header assembly sequence but it may be
easier prior to laying the header down.
A. GAUGE ROLLERS
a. Unpack gauge roller bundle.
B
b. Remove four clevis pins from roller assembly.
A
a. Remove two bolts (A) on each end of stand and
remove shipping stand (B). Discard stand and
hardware.
C
c.
Form # 169079
8
Position gauge roller assembly on frame and
secure with two clevis pins (C). Secure pins
with lynch pins.
Model Year - 2009
D
d. Adjust roller assembly to desired height and
install two clevis pins (D). Secure with lynch
pins.
e. Repeat above steps for opposite side. Set both
gauge rollers to same position.
B. SKID SHOES
a. Unpack skid shoe bundle.
b. Remove four clevis pins from skid shoe.
E
F
c.
Position skid shoe on frame and secure with two
clevis pins (E). Secure pins with lynch pins.
d. Adjust skid shoe to desired height and install two
clevis pins (F). Secure with lynch pins.
e. Repeat above steps for opposite side. Set both
skid shoes to same position.
Form # 169079
9
Model Year - 2009
STEP 4. LOWER HEADER
a. Attach either a spreader bar or chain to forks.
CAUTION
1
Ensure spreader bar or chain is secured to
the forks so that it cannot slide off the
forks or towards the mast as the header is
lowered to the ground.
Chain Type
Overhead Lifting Quality
(1/2 Inch)
Min. Working Load
5000 lb. (2270 kg)
2
3
b. Drive lifting vehicle to approach header from its
"underside".
c.
e. Back up SLOWLY while simultaneously lowering
machine until cutterbar rests on ground.
f. Remove chain from header.
Attach chain hooks to hooks on either side of
header.
CAUTION
Stand clear when lowering the header.
NOTE
Do not lift at hooks when unloading from
trailer. This procedure is only for laying the
machine over into working position.
IMPORTANT
Chain length must be sufficient to provide
a minimum 4 feet (1.2 m) vertical chain
height.
d. Raise forks until lift chains are fully tensioned.
Form # 169079
10
Model Year - 2009
STEP 5. REMOVE SHIPPING
STANDS
NOTE
Step a. is only applicable to 16 ft header.
13 ft headers are shipped without the
motor installed.
C
B
d. Remove hairpin from pin (B).
e. Hold shipping stand (C), remove pin (B), and
remove stand. Re-insert pin (B) in header boot.
Discard stand and hardware.
f. Repeat above steps for opposite shipping stand.
D
a. Untie hose bundle and relocate on top of
header.
b. Remove bag of Velcro straps from hose end and
set aside for installation in STEP 12. CONNECT
HYDRAULICS.
E
g. Remove four bolts (D) in angle (E) and remove
angle.
A
A
c.
Remove four bolts (A) from shipping stand.
Form # 169079
h. Cut all banding at cutterbar doors.
11
Model Year - 2009
ACCEPTABLE
NOT ACCEPTABLE
k.
Close cutterbar doors. Ensure that curtains
hang properly and completely enclose cutterbar
area. Minor creases in curtains will eventually
straighten out.
l.
Cut shipping wire and plastic cable ties securing
crop deflector lever and drive shield latches.
F
i.
Remove five bolts and nuts on each door and
remove front angles and lift hooks. Retain lower
bolt (F) for re-installation at same location after
hook is removed.
WARNING
Ensure cutterbar 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
H
j.
m. Move crop deflector lever (G) upward from
shipping position and pull lever slightly away
from bracket (H) so that pin engages slots in
bracket. Release it at the center position to lock
crop deflector (J) in desired position.
Open cutterbar doors and check cutterbar area
for debris and foreign objects.
Ensure all
material is removed.
Form # 169079
J
12
Model Year - 2009
STEP 6. INSTALL MOTOR – 13 FT
ONLY
STEP 7. INSTALL HOSE
SUPPORT
a. Retrieve hose support from header center mast.
G
A
B
a. Remove four bolts (A) and remove plate (B)
from gearbox. Retain bolts for re-installation
and discard plate.
b. Attach a sling to motor and the other end to
lifting device.
Motor and lines weigh
approximately 150 lb (68 kg).
H
IMPORTANT
Do not lift motor with hydraulic lines.
b. Remove carriage bolts in support (G).
c. Attach support (G) to header with the two
carriage bolts (H) and nuts.
E
C
F
A
D
c.
Position motor (C) onto gearbox opening as
shown and remove sling.
NOTE
Hydraulic lines may require repositioning
to clear bracket (D). Loosen bolts (E) and
move lines as required. Tighten bolts (E)
to 32 ft·lbf (43 N·m).
d. Install four bolts (A) to secure motor to gearbox.
Torque bolts to 103 ft·lbf (140 N·m).
e. Install case drain hose (F) into bracket (D).
Form # 169079
13
Model Year - 2009
d. Assemble side deflectors (C) to cover (A) with
bolts (B), jam-nut (D), washer (E), and nut (F)
from previous step.
e. Tighten flange nut (F) enough to hold deflectors
(C) in position, but still allow deflectors to move.
f. Tighten jam nut (D) against cover while holding
bolt (B).
STEP 8. ASSEMBLE FORMING
SHIELD
For Grass Seed headers go to STEP 11.
ATTACH HEADER TO TRACTOR.
To
assemble forming shield, proceed as follows:
C
C
H
G
B
a. Unpack and remove shipping material.
g. Remove lynch pin (G) from adjuster rod (H) and
locate rod in hole in side deflector (C). Secure
with lynch pin (G).
h. Repeat for other deflector.
A
b. Lay cover (A) upside down on a flat surface.
c. Remove bolts (B) from side deflectors (C).
C
C
B
i.
D
Invert forming shield to installation position as
shown.
E
F
Form # 169079
14
Model Year - 2009
STEP 9. INSTALL FORMING
SHIELD
D
ATTACH HEADER TO TRACTOR. To install
forming shield, proceed as follows:
E
a. Remove the header from the tractor if attached
for ease of installation of the forming shield.
b. Retrieve plate (A) and hardware from forming
shield bundle.
g. Locate forming shield onto spacers (D) on
tractor leg and secure with clevis pins (E) and
lynch pin.
A
D
B
G
F
C
c.
Attach plate (A) to tractor leg with two ½ x 5.0
hex bolts (B) and nuts. Repeat for opposite leg.
Hardware is supplied with forming shield bundle.
d. Install a ½ x 3.25 hex bolt (C) with spacer (D),
and nut on each plate. Hardware is supplied
with forming shield kit.
h. Lift the aft end of the forming shield and attach
straps (F) to pins (G) on tractor frame. Install
washer and hairpin to secure strap. Use the
middle hole and adjust height to suit the crop.
BOTH SIDES
E
K
e. Remove the two clevis pins (E) from forming
shield forward end.
J
i.
j.
f.
H
Set forming shield side deflectors to desired
width by repositioning adjuster bars (H). Use
same hole location on both sides.
Adjust fluffer shield (J) to middle position.
Loosen handles (K) if required.
Position forming shield under the tractor frame.
Form # 169079
15
Model Year - 2009
STEP 10. INSTALL 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 hourglass
deflectors.
They will degrade the cutting
performance of the cutterbar if they are used in
medium to light alfalfa, and so should not be
installed in those types of crops. The feed
plates are designed for installation on the two
inboard hourglass deflectors and only on 16 ft
headers. They are stored inside the RH side
drive compartment, except for grass seed
headers, which have them factory installed.
A
ATTACH HEADER TO TRACTOR. To install
feed plates, proceed as follows:
c.
Remove nuts (A) securing two feed plates to
side of compartment and remove plates.
CAUTION
Exercise caution when working around the
blades. Blades are sharp and can cause
serious injury. Wear gloves when handling
blades.
d. Place a block of wood between discs to prevent
deflector from turning.
a. Open cutterbar doors.
C
B
b. Open RH side drive compartment shield.
D
e. Remove four bolts (B) and remove inboard
hourglass driven deflector (C) and disc
assembly (D) from cutterbar.
Form # 169079
16
Model Year - 2009
g. Manually rotate discs to check for interference of
feed plate and adjacent parts.
C
D
B
E
h. 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.
i.
j.
Re-position deflector (C) and align holes.
Re-install bolts (B) and tighten to 92 ft·lbf (125
N·m).
k. Manually rotate discs to check for interference of
l. Repeat above steps for opposite side.
m. Manually rotate discs to check for interference of
Form # 169079
17
Model Year - 2009
STEP 11. ATTACH HEADER TO
TRACTOR
Refer to M Series Unloading & Assembly
Instructions, Form #169018, or M150 & M200
Self-Propelled Windrower Operator’s Manual,
Form #169017 for tractor operating instructions.
C
c.
Slowly drive tractor forward so that feet (C) on
tractor enter boots (B) on the header. Continue
to drive slowly forward until feet engage the
boots, and header nudges forward.
d. Connect center link as follows:
MECHANICAL LINK – M150
B
A
DANGER
a. Remove hairpin from pin (A), and remove pin
from left and right header boots (B).
an idling machine.
1. Stop engine and remove key.
CAUTION
Check to be sure all bystanders have
cleared the area.
D
HEADER UP
HEADER
TILT DOWN
HEADER TILT UP
E
2. Loosen nut (D) and rotate barrel (E) to
adjust length so that other end lines up with
mounting hole in center mast (F).
HEADER DOWN
E
F
b. Start the engine and activate header down
button on the GSL to fully retract header lift
cylinders.
G
3. Install clevis pin (G) and secure with cotter
pin.
Form # 169079
18
Model Year - 2009
4. Adjust link to required length for proper
header angle by rotating barrel (E). Tighten
nut (D) against barrel. A slight tap with a
hammer is sufficient.
5. Proceed to step e.
HYDRAULIC LINK – M200 STD, M150 OPTION
J
HEADER UP
3. Push down on rod end of center link until
hook engages pin (J) in center mast and is
locked.
HEADER
TILT DOWN
HEADER TILT UP
CAUTION
cleared the area.
e. Start engine.
f. Raise the header fully with the header up switch
on the GSL. Stop engine and remove key.
HEADER DOWN
DANGER
H
To avoid bodily injury from fall of raised
header, always engage header lift cylinder
stops when working on or around raised
header.
g. Engage lift cylinder stops on both lift cylinders.
J
1. Activate header tilt cylinder switches on GSL
to position center link hook (H) so that it can
connect to pin (J) in center mast.
NOTE
If optional auto-connect system is
installed, activate link lift cylinder from in
the cab to lower center link onto header
and proceed to step f.
A
DANGER
an idling machine.
2. Stop engine and remove key.
h. Install pin (A) through each boot and foot and
secure with hairpin.
IMPORTANT
Ensure pin (A) is fully inserted and hairpin
is installed behind bracket on boot.
Form # 169079
19
Model Year - 2009
K
L
i.
j.
Remove pin (K) from storage position in linkages
on both sides and insert in hole (L) to engage
float springs. Secure with hairpin.
Disengage lift cylinder stops.
CAUTION
k.
cleared the area.
Start engine, and activate header lift cylinder
switch on GSL to lower header fully. Stop
engine and remove key.
Form # 169079
20
Model Year - 2009
STEP 12. CONNECT HYDRAULICS
E
A. M200 – 13 FT & 16 FT
I. TRACTOR CONNECTIONS
F
G
2. Locate cinch strap (E) through slot and
under bracket (F) on tractor hose support.
3. Attach strap to bracket with ½ inch carriage
bolt (G) and locking nut. Install bolt from
under bracket.
C
A
H
B
A
E
C
a. Disengage and rotate lever (A) counterclockwise to fully up position.
b. Remove cap (B) securing electrical connector to
frame.
f.
Route header return and pressure hose bundle
(H) through support (D) on header, to tractor,
and locate bundle above existing hose bundle
(C) as shown.
g. Secure with three straps (E).
h. Lower and lock lever (A).
i. Open left side (cab-forward) platform.
j. Route header hose bundle (H) to valve block (J).
k. Disconnect fittings at bundle (H) hose ends.
D
J
C
X
Move hose bundle (C) from tractor through hose
support (D) on header.
d. Move tractor left side platform to open position.
e. Install cinch straps as follows if not already
installed.
1. Retrieve package of three cinch straps from
shipping bundle.
Y
c.
Form # 169079
l.
21
Remove fittings at ports (X) and (Y) on valve (J).
Model Year - 2009
II. HEADER CONNECTIONS
L
a. Remove caps and plugs from hoses and lines.
K
RETURN
m. Install male 45 degree fitting (K) from hose in
port (X), and female straight fitting (L) from hose
in port (Y).
PRESSURE
NOTE
Male fitting (K) may need to be
disassembled prior to installing on valve
block.
RETURN
CASE DRAIN
PRESSURE
ELECTRICAL
b. Connect the three hoses from tractor to the
fittings on the header as shown.
c. If a 16 ft grass seed header is being set up,
proceed to III GRASS SEED HEADER
HYDRAULICS, otherwise close maintenance
platform and proceed to STEP 14. INSTALL
OPTIONS.
n. Connect hoses from header to fittings as shown.
Form # 169079
22
Model Year - 2009
III. GRASS SEED HEADER HYDRAULICS
Converging Drum Drive Valve Installation;
E
A
C
B
a. Obtain drive valve block (A) from grass seed
completion package (B4911).
b. Install 3/4 tube x 1 1/16 ORB male connector (B)
from package in port “R2” of new valve block
(A).
c. Install 5/8 tube x 7/8 ORB male connector (C)
from package in port “P”.
C
E
A
e. Disconnect existing hose (E) from tractor
manifold and re-connect to new valve block
fitting (C).
D
H
d. Attach valve block (A) to support on tractor as
shown with two 3/8 in.x0.75 hex bolts (D).
F
f.
Form # 169079
23
B
Attach new hydraulic hose (F) to fitting (B) on
backside of valve block (A) but do not tighten.
Model Year - 2009
b. Install the following fittings in this port to suit
existing hydraulic configuration.
g. Attach other end of new hose (F) to tractor
manifold at (H).
9/16 ORB X 3/8 TUBE
90˚ SWIVEL ELBOW – 3/8 TUBE
3/4 MALE ORB X 9/16 FEMALE TUBE
3/4 ORB MALE COUPLER
3/8 TUBE X STR THD RUN TEE
3/8 TUBE SWIVEL BRANCH TEE
U
M
c.
J
K
Attach existing hose(s) to new fittings as
required.
J
O
P
R
K
L
(O)
(P)
(Q)
(R)
(S)
(T)
Q
N
WITHOUT DRAPER HEADER OR CENTER LINK ASSIST
h. Install 7/8 ORB x 1/2 Tube Swivel, (J), 1/2 Tube
45 Elbow with O-ring (K), and 3/4 ORB Male
Coupling (L) into port “DWA” as shown.
i. Install 1 1/16 ORB x 7/8 ORB Female (M), 7/8
ORB x 1/2 Tube Swivel, (J), 1/2 Tube 45 Elbow
with O-ring (K), and 3/4 ORB Female Coupling
(N) fittings into port “R1” of new valve block and
orientate as shown.
j. Attach existing harness connector P74 to valve
block receptacle (U).
Converging Drum Control Cylinder Connection;
P
S
R
Q
WITH DRAPER HEADER OR CENTER LINK ASSIST
T
S
Q
R
P
a. Remove existing hose fittings, if installed, from
port “D“ on forward valve block.
WITH DRAPER HEADER & CENTER LINK ASSIST
d. Tighten all connections.
Form # 169079
24
Model Year - 2009
IV. GRASS SEED HEADER HOSE
CONNECTIONS
A
F
E
a. Disengage and rotate lever
clockwise to fully up position.
B
(A)
d. Route the short hose (E) in converging drum
bundle with the female coupler to the forward
valve block and connect it to male coupler (F).
counter-
C
H
D
G
b. Route converging drum hose bundle (B) through
hose support (C) on header to the tractor hose
support (D).
e. Route the two longer hoses to the aft valve block
and connect them to couplers (G) and (H).
f. Proceed to STEP 14. INSTALL OPTIONS.
A
B
D
c.
Lower lever (A) and secure it in hook. Secure
hose bundles with existing cinch straps.
Form # 169079
25
Model Year - 2009
B. M150 - 13 FT
E
I. TRACTOR CONNECTIONS
F
G
2. Locate cinch strap (E) through slot and
under bracket (F) on hose support.
3. Attach strap to bracket with ½ inch carriage
bolt (G) and locking nut. Install bolt from
under bracket.
C
A
H
B
A
a. Disengage and rotate lever (A) counterclockwise to fully up position.
b. Remove cap (B) securing electrical connector to
frame.
C
E
f.
Route header pressure hose (H) from header
through hose support (D) to tractor, and locate
bundle above existing hose bundle (C) as
shown.
g. Secure with three straps (E).
h. Lower and lock lever (A).
D
C
c.
Move hose bundle (C) from tractor through hose
support (D) to header.
d. Move tractor left side platform to open position.
e. Install cinch straps as follows if not already
installed.
1. Retrieve package of three cinch straps from
shipping bundle.
Form # 169079
26
Model Year - 2009
EXISTING
O
m. Install fitting assembly (O) onto valve block (J) at
this location.
NEW
NOTE
Adjacent hoses may need to be loosened
and moved to allow installation of fitting. If
necessary, disassemble quick disconnect
and 45 degree fitting, and then
reassemble after fitting is installed onto
valve block.
J
i.
Install valve block (J) that is supplied with the
tractor (ref. B4657).
Refer to installation
instructions supplied in the kit.
L
O
M
L
n. Connect hose (L) from header to fitting (O).
K
j.
k.
II. HEADER CONNECTIONS
Disconnect quick-disconnect (K) at end of
header hose (L).
Remove cap (M) on fitting assembly.
a. Remove caps and plugs from hoses and lines.
RETURN
PRESSURE
N
J
l.
CASE DRAIN
Remove plug (N) from valve (J).
ELECTRICAL
b. Connect the three hoses from tractor to the
fittings on the header as shown.
c. Connect harness from tractor to electrical
connector.
d. Move tractor platform to closed position.
Form # 169079
27
Model Year - 2009
STEP 13. INSTALL ROTARY
SWITCH
H
B
d. Connect plug P52 (F) to rotary switch. Plug is
inside the console.
A
a. Inside tractor cab, remove cover (A) from
console by removing 5 screws (B).
A
B
e. Re-install cover (A) with five screws (B).
f. Program the tractor monitor as follows to
recognize the Converging Drums:
C
PROGRAM
ARROWS
SELECT
b. Cut hole in decal and install rotary switch (C) as
shown. The hole is already present in the
mounting plate and the switch is supplied with
the grass seed bundle.
1. Turn the key on.
2. Press PROGRAM and SELECT at the same
time to go into program menu.
3. Press right arrow switch (YES) for Tractor
Setup.
4. Scroll through menu with SELECT switch to
“DWA VALVE INSTALLED”.
5. Press right arrow switch (YES).
6. Press SELECT switch to lock in selection.
7. Press PROGRAM switch to exit menu and
return to main screen.
D
E
c.
Install knob (D) on rotary switch (C). Tighten set
screw in knob with Allen wrench (E).
Form # 169079
28
Model Year - 2009
E
STEP 14. INSTALL OPTIONS
D
Install options, if supplied with shipment, in
accordance with the instructions supplied with
each kit, or as follows:
A. TALL CROP DIVIDER KIT
a. Unpack kit.
C
1. Remove two bolts (C), pivot the skid shoe
(D), and remove from slot (E) in rock guard.
b. Open cutterbar doors.
F
B
A
D
G
2. Attach shoe lift (F) to skid shoe as shown
with hardware (G) supplied in kit. Tighten
bolts.
3. Position skid shoe (D) joggled end in rock
guard slot (E) and locate aft end with lift (F)
against rock guard. Secure with existing
bolts (C).
c.
Locate LH divider (A) on header LH front corner
and install with three bolts (B) and nuts supplied
with kit in existing holes. Tighten hardware.
d. Repeat for RH side.
e. Lower cutterbar doors.
C. DOUBLE WINDROW
ATTACHMENT
B. SHOE LIFT KIT
a. Unpack kit.
WARNING
To avoid bodily injury or death from
unexpected start-up or fall of raised
machine, stop engine, remove key and
engage lift cylinder stops before going
under machine to adjust skid shoes or for
any reason.
b. Start tractor and raise header fully.
c. Stop engine, remove key, and engage lift
cylinder stops.
d. Install a lift on each of the two end skid shoes,
and on two additional shoes at equi-distant
locations as follows:
Form # 169079
Refer to instructions supplied with kit.
29
Model Year - 2009
D. TALL CROP TRANSITION
SHIELD – GRASS SEED
HEADER
Refer to instructions supplied with kit.
Form # 169079
30
Model Year - 2009
d. Replace any loose or broken fittings
immediately.
e. If fitting will not take grease, remove and clean
thoroughly. Also clean lubricant passageway.
Replace fitting if necessary.
f. Refer to the illustrations on following pages for
lubrication points.
STEP 15. LUBRICATE THE
HEADER
WARNING
under machine for any reason.
a. Wipe grease fitting with a clean cloth before
greasing, to avoid injecting dirt and grit.
b. Inject grease through fitting with grease gun until
grease overflows fitting, except where noted.
c. Leave excess grease on fitting to keep out dirt.
13 FT
High Temp. Extreme Pressure
(EP2) Performance With 1%
Max Molybdenum Disulphide
(NLGI Grade 2).Lithium Base
ROLL SHAFT BEARINGS (3 PLCS)
10% MOLY GREASE IS RECOMMENDED
FOR DRIVELINE SHAFT SLIP JOINT ONLY
DRIVELINE UNIVERSALS (2 PLCS)
DRIVESHAFT (1 PLC)
Form # 169079
31
Model Year - 2009
LUBRICATE HEADER – 13 FT
(Cont’d)
GEARBOX OIL LEVEL
BELT TENSIONER PIVOT (1 PLC)
DRIVELINE SHAFT (2 PLCS)
Form # 169079
32
Model Year - 2009
CHECK PLUG
Oil should slightly run
out when removed.
GEARBOX OIL LEVEL
BELT TENSIONER PIVOT (1 PLC)
DRIVELINE SHAFT (2 PLCS)
Form # 169079
33
Model Year - 2009
(Cont’d)
OPTIONAL GAUGE ROLL BEARINGS (2 PLCS)
BOTH SIDES
DRIVESHAFT (1 PLC)
(BOTH SIDES)
Form # 169079
34
Model Year - 2009
PRE-DELIVERY CHECKS
GRASS SEED (Cont’d)
CHECK PLUG
Oil should slightly run
out when removed.
DRIVESHAFT (1 PLC)
(BOTH SIDES)
GEARBOX OIL LEVEL
OPTIONAL GAUGE ROLL BEARINGS (2 PLCS)
BOTH SIDES
CONVERGING DRUMS (2 PLCS) - BOTH SIDES
Form # 169079
35
Model Year - 2009
PRE-DELIVERY CHECKS
STEP 16. PERFORM PREDELIVERY CHECKS
WARNING
Stop windrower engine and remove key
before making adjustments to machine. A
child or even a pet could engage the drive.
16 FT ONLY
IMPORTANT
To avoid machine damage, check that no
shipping dunnage has fallen down
between auger and pans.
c.
Apply force of 51 lbf (22 N) to each deflector
drive belt at mid-span. Deflection of each belt
should be 0.12 in. (3 mm).
a. Perform the final checks and adjustments as
listed on the "Pre-Delivery Checklist" (yellow
sheet) to ensure the machine is field-ready.
Refer to the following pages for detailed
instructions as indicated on the checklist.
b. The completed checklist should be retained
either by the operator or the dealer.
A. DRIVE BELTS
Drive belt tensions have been properly set at the
factory and should not require any further
adjustment. Check as follows:
d. Open LH drive shield.
A
X
a. Open RH drive shield.
e. Measure the length ‘X’ of the spring (A) as
shown. It should be within the dimensions in the
following table.
NUMBER OF VISIBLE COILS
23
b. Lifting roll drive belt tension is factory adjusted.
Hole in tensioner member should be visible.
Form # 169079
24
36
MEASUREMENT ‘X’
7.75-8.15 inches
(197-207 mm)
8.11-8.5 inches
(206-216 mm)
Model Year - 2009
PRE-DELIVERY CHECKS
C. CHECK LEVEL OF HEADER
a. Park windrower on level ground and raise
header approximately 6 inches (150 mm) off
ground.
b. Check that clearances between header and
ground at each end of the header are
approximately the same.
IMPORTANT
16 FT ONLY
f.
The header float springs are not used to
level the header.
Apply force of 51 lbf (22 N) to each deflector
drive belt at mid-span. Deflection of each belt
should be 0.12 in. (3 mm).
c.
B. HEADER FLOTATION
a. Set the float fine adjustment to mid-range with
the tractor float adjustment system in the cab.
Refer to the M Series Self-Propelled Windrower
Operator’s Manual, Form #169017.
b. Check float by grasping the front corner of
header and lifting. The force to lift should be 95105 (426-471 N) and should be approximately
the same at both ends.
c. Perform the following steps to adjust the float if
necessary:
If header needs levelling, proceed as follows:
1. Place wooden blocks under header
cutterbar and legs.
C
D
DANGER
E
an idling machine.
1. Raise the header fully, shut down the
engine, and remove the key.
2. Lower header onto blocks so that linkage
(C) lifts at tractor leg and off of shims (E).
DANGER
an idling machine.
3. Shut down the engine and remove the key.
4. On the high side linkage, remove nut,
washer and bolt (D) that attaches shims (E)
to link.
5. Remove one or both shims (E) and reinstall
the hardware (D).
6. Check level of header.
7. If additional levelling is required, install the
removed shim on the opposite linkage.
B
A
2. Loosen nut (A) on linkage spring drawbolt.
3. Turn drawbolt (B) clockwise to increase float
(makes header lighter) or counterclockwise
to decrease float (makes header heavier).
4. Tighten nut (A) to lock drawbolt.
5. Recheck the float.
Form # 169079
NOTE
Float does not require adjustment after
levelling header.
37
Model Year - 2009
PRE-DELIVERY CHECKS
D. CONDITIONER ROLLS
II. ROLL TIMING
DANGER
I. ROLL GAP
an idling machine.
ROLL GAP
CROP
CROP
TIMING GAP
a. Lower header to ground, shut down tractor and
remove key.
b. Open drive shields.
a. The amount of thread protruding through jam nut
should equal roll gap. Factory setting should be
0.25 in. (6 mm).
A
B
c.
Form # 169079
38
Remove bolt (A) and nut, and remove gauge (B)
from inside panel at RH end of header.
Model Year - 2009
PRE-DELIVERY CHECKS
B
C
START POSITION
B
g. Check timing flange bolts (C) are tight.
h. Close drive shields.
E. MANUALS
The following manuals should be stored in the
manual storage case in the tractor cab:
•
GAUGE POSITION
•
d. From the rear of the header, locate gauge at
centre of rolls as shown and manually turn rolls
to limits of gauge. Rolls will engage the gauge if
timing is correct.
e. Manually turn rolls to release gauge.
R80 Rotary Disc Header PARTS CATALOG.
Form #169054.
R80 Rotary Disc Self-Propelled Windrower
Header OPERATOR’S MANUAL.
Form #169089.
WARNING
Remove gauge from rolls and return it to
storage location before starting machine.
A
B
f.
Replace gauge in header with bolt (A) and nut.
Form # 169079
39
Model Year - 2009
PRE-DELIVERY CHECKS
G. LIGHTS – 16 FT ONLY
F. GAUGE ROLLERS OR SKID
SHOES
WARNING
under machine to adjust skid shoes or for
any reason.
a. Raise header and engage lift cylinder stops.
b. Both gauge rollers or skid shoes should be set
at the same position.
The hazard lights, which are mounted on both
ends of the header (and on Grass Seed
transition shield), are activated by a switch in the
M Series tractor cab.
a. Check for operation during run-up.
b. Check light mountings for security and check
lights for damage.
SKID SHOE
GAUGE ROLLER
Form # 169079
40
Model Year - 2009
PRE-DELIVERY CHECKS
H. CHECK CONVERGING DRUM
OPERATION – GRASS SEED
I. RUN-UP THE HEADER
CAUTION
Check operation as follows during run-up:
Never start or move the machine until you
are sure all bystanders have cleared the
area.
REEL UP
CAUTION
Clear the area of other persons, pets etc.
Keep children away from machinery. Walk
around the machine to be sure no one is
under, on or close to it.
REEL DOWN
CAUTION
a. Press REEL UP or REEL DOWN switches on
GSL to move converging drums.
Drum
movement can be observed from the cab.
Before investigating an unusual sound or
attempting to correct a problem, shut off
engine, engage parking brake and remove
key.
Refer to M Series Unloading & Assembly
Instructions, Form #169018, or M150 & M200
Self-Propelled Windrower Operator’s Manual,
Form #169017 for tractor operating instructions.
a. Start windrower and run the machine for 15
minutes.
b. Listen for any unusual sounds or abnormal
vibration.
c. Perform the run-up check as listed on the "PreDelivery Checklist" (yellow sheet attached to this
instruction) to ensure the machine is field-ready.
b. Rotate DWA knob on console to change drum
rotational speed.
Form # 169079
41
Model Year - 2009
NOTES
Form # 169079
Model Year - 2009
Form # 169079
Model Year - 2009
MacDon Industries Ltd.
680 Moray Street
Winnipeg, Manitoba
Canada R3J 3S3
t. (204) 885-5590
f. (204) 832-7749
MacDon Inc.
10708 N. Pomona Avenue
Kansas City, Missouri
United States, 64153-1924
t. (816) 891-7313
f. (816) 891-7323
MacDon Australia Pty. Ltd.
A.C.N. 079 393 721
P.O. Box 243
Suite 3, 143 Main Street
Greensborough, Victoria
Australia 3088
t. 03 9432 9982
f. 03 9432 9972
CUSTOMERS
www.macdon.com
DEALERS
www.macdondealers.com
Trademarks of products are the marks of their
respective manufacturers and/or distributors.
Printed in Canada
Form # 169079
Model Year - 2009
R80 Rotary Disc Header Pre-Delivery Checklist
Perform these checks and adjustments prior to delivery to your customer. See the Unloading and Assembly
Instructions for details. The completed checklist should be retained either by the operator or the dealer.
CAUTION: Carefully follow the instructions given. Be alert for safety related messages which
bring your attention to hazards and unsafe practices.
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.
Header Serial Number: _____________________
9
ITEM
PAGE
Check for shipping damage or missing parts. Be sure all shipping dunnage is removed.
-
Check for loose hardware. Tighten to required torque.
4
Check main drive belt tension (not applicable to grass seed header).
36
Check hourglass deflector drive belts tension (16 ft. only).
36
Check lift roll drive belt tension (not applicable to grass seed header).
36
Check header angle to middle of adjustment range.
18
Check header flotation. (95-105 lbf (426-471 N)).
37
Check header is level.
37
Check side forming shields evenly set to desired position (not applicable to grass seed header).
15
Check rear fluffer deflector about half way down (not applicable to grass seed header).
15
Check crop deflector set about half way.
12
Check gauge rollers/skid shoes evenly set (16 ft. only).
40
Check bevel gearbox lube level.
32, 33
Grease all bearings and drivelines.
31-35
Check conditioner roll gap and timing (not applicable to grass seed header).
38
Check roll intermesh hardware is securely tightened (not applicable to grass seed header).
38
Check cutterbar curtains hanging properly.
12
Check hydraulic hose and wiring harness routing.
--
Check cutterbar area carefully for loose parts and hardware on the cutterbar.
WARNING: These objects can be ejected with considerable force when the machine is
started and may result in serious injury or machine damage.
--
RUN-UP PROCEDURE
41
Check hydraulic hose and wiring harness routing for clearance when raising or lowering
header.
--
Check converging drum operation (grass seed header).
41
Check hazard lights are functional (16 ft. only).
40
POST RUN-UP CHECKS. STOP ENGINE.
Check belt drives for idler alignment and heated bearings.
36
Check for hydraulic leaks.
--
Check header manuals in tractor cab storage compartment.
39
Date Checked: _________________________
Form # 169079
Checked by: ________________________
Model Year - 2009

R80 Rotary Disc Windrower

Transcription

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