Page 3: Table Of Contents
COMPLETE CONTENTS SECTION 00 - - GENERAL INFORMATION Chapter 1 - - General Information CONTENTS Section Description Page Foreword ..............Precautionary Statements .
Page 4: Description Page
SECTION 00 - - GENERAL INFORMATION Chapter 2 - - Adjustments CONTENTS Section Description Page Conditioning (Roll Pressure) ..........Unplugging The Conditioner Rolls .
Page 5 SECTION 00 - - GENERAL INFORMATION Chapter 3 - - Lubrication (Continued) CONTENTS Section Description Page Cutter Bar Drive Shaft ............Upper Roll Pivot Arms .
Page 6 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 1 - - PTO CONTENTS Section Description Page Description of Operation ............Slide Lock -- Disassembly .
Page 7 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 2 - - Slip Clutch CONTENTS Section Description Page Slip Clutch ..............Slip Clutch - Removal .
Page 8 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 4 - - Step-up Gearbox CONTENTS Section Description Page Step-Up Gearbox ............To Convert Step-up Gearbox for Different PTO Speed .
Page 9 SECTION 39 - - FRAMES Chapter 1 - - Floatation Springs CONTENTS Section Description Page Adjustment ..............Removal .
Page 10 SECTION 58 - - ATTACHMENTS / HEADERS Chapter 1 - - Cutter Bar CONTENTS Section Description Page Introduction ..............Discs .
Page 11 SECTION 58 - - ATTACHMENTS / HEADERS Chapter 3 - - Conditioner Rolls and Drive System CONTENTS Section Description Page Introduction ..............Conditioner Belt .
Page 12 SECTION 88 - - ACCESSORIES Chapter 1 - - Optional Equipment CONTENTS Section Description Page High Stubble Kit ............SECTION 90 - - SAFETY DECALS Chapter 1 - Safety Decals CONTENTS...
Page 13 SECTION 00 - GENERAL INFORMATION - CHAPTER 1 SECTION 00 - - GENERAL INFORMATION Chapter 1 - - General Information CONTENTS Section Description Page Foreword ..............Precautionary Statements .
Page 14: Foreword
All data and illustrations in this manual are subject to variations in build specification. This information was correct at the time of issue, but Case IH policy is one of continuous improvement, and the right to change specifications, equipment, or design at any time, without notice, is reserved.
Page 15: Precautionary Statements
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 PRECAUTIONARY STATEMENTS PERSONAL SAFETY Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”, “WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them. DANGER This word “DANGER”...
Page 16: Safety
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 SAFETY PRECAUTIONARY STATEMENTS A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. To help prevent accidents, read the following precautions before operating this equipment. Equipment should be operated only by those who are responsible and instructed to do so.
Page 17 SECTION 00 - GENERAL INFORMATION - CHAPTER 1 14. The header should be resting on the ground 19. Before disconnecting the lift cylinder hose, or suspended in the transport position by the be sure the header is resting on the ground or header lift locks during lubrication or on the header lift locks.
Page 18: Product Identification Number
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 On this equipment, left and right are determined by standing behind the unit, looking in the direction of travel. PRODUCT IDENTIFICATION NUMBER The product identification number plate, 1, for the mower-conditioner is located on the left side of the trailframe.
Page 19: Hardware Torque Values
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 HARDWARE TORQUE VALUES Check the tightness of hardware periodically. Make sure fastener threads are clean and not damaged. Use the following charts to determine the correct torque when checking, adjusting or replacing NOTE: A torque wrench is necessary to properly hardware on the tractor.
Page 20 SECTION 00 - GENERAL INFORMATION - CHAPTER 1 MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS METRIC NON-FLANGED HARDWARE AND LOCKNUTS CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT NOMINAL CL.8 SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8 W/ZnCr...
Page 21 SECTION 00 - GENERAL INFORMATION - CHAPTER 1 MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS INCH NON-FLANGED HARDWARE AND LOCKNUTS SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B...
Page 22: Installation Of Adjustable Fittings In Straight Thread O-Ring Bosses
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 INSTALLATION OF ADJUSTABLE FITTINGS IN STRAIGHT THREAD O-RING BOSSES 1. Lubricate the O-ring by coating it with a light oil or petroleum. Install the O-ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove, 4.
Page 23: Pipe Thread Fitting Torque
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 PIPE THREAD FITTING TORQUE THREAD SIZE TORQUE (MAXIMUM) Before installing and tightening pipe fittings, clean 1/8″ - 27 13 N m (10 ft-Ib) ⋅ the threads with a clean solvent or Loctite cleaner 1/4″...
Page 24: Ecology And The Environment
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 ECOLOGY AND THE ENVIRONMENT Soil, air, and water are vital factors of agriculture and 3. Modern oils contain additives. Do not burn life in general. When legislation does not yet rule the contaminated fuels and or waste oils in ordinary treatment of some of the substances which are heating systems.
Page 25: Universal Symbols
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 UNIVERSAL SYMBOLS As a guide to the operation of your tractor, various universal symbols have been utilized on the instruments, con- trols, switches, and fuse box. The symbols are shown below with an indication of their meaning. Thermostart Position Radio...
Page 26: Tractor Requirements
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 TRACTOR REQUIREMENTS 1. 540 or 1000 RPM PTO. 2. 80 HP (60 kw) minimum PTO HP. 3. ASAE standard hitch and PTO dimensions conforming to category 1 or 2 specifications. (See Figure 1 and 2). NOTE: For tractors with a stepped, or bent drawbar, the bend must be positioned to met ASAE hitch and PTO specifications.
Page 27: Tractor Drawbar Dimensions
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 TRACTOR DRAWBAR DIMENSIONS 540 RPM 356 mm (14 in) FOR 540 RPM Be sure the drawbar is adjusted to meet the ASAE standard specifications as shown here. On 540 RPM machines, the distance from the end of 152 - - 305 mm (6 - - 12 in) (203 mm (8 in) Recommended) the tractor PTO shaft to the center of the drawbar...
Page 28: Attaching The Mower-Conditioner To The Tractor
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 ATTACHING THE MOWER-CONDITIONER TO THE TRACTOR Attach the mower-conditioner to the tractor with a 19 mm (3/4 in) minimum diameter hitch pin that can be securely fastened as shown, 1. The pin should also be smaller than the hitch holes to prevent binding when operating over rough terrain.
Page 29: Hydraulic Cylinders
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 HYDRAULIC CYLINDERS NOTE: If this valve is adjustable, set it for slow hydraulic flow. Release all the pressure from the hydraulic lines before making any repairs. Replace or repair 3. Attach the single lift cylinder hose to a remote damaged hoses immediately.
Page 30: Bleeding Air From The Lift Cylinders
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 BLEEDING AIR FROM THE LIFT CYLINDERS WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running.
Page 31: Transporting The Mower-Conditioner
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 TRANSPORTING THE MOWER-CONDITIONER SLOW-MOVING VEHICLE EMBLEM Some states and provinces require Slow-Moving Vehicle (SMV) emblems on machines traveling at speeds under 40 km/hr (25 MPH). Consult local regulations for information and mounting require- ments.
Page 32: Trailing Lights
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 Attach the safety chain to the unit at the bottom hitch clevis on the tongue, as shown. Install the large round washer, 2, and the 1″ long spacer, 3, over the 5/8″ x 2-3/4″ cap screw, 1. Position the large angled link, 4, on the end of the safety chain over the spacer, and install this assembly through the hole in the bottom hitch plate on the tongue.
Page 33: Towing With A Tractor
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 TOWING WITH A TRACTOR 1. Refer to “Hitching to the Tractor” section of this manual. 2. Raise the header. Engage the header lift locks by pivoting lock levers, 1, forward. Lower the header onto the stop blocks.
Page 34: Towing With A Truck
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 TOWING WITH A TRUCK 1. Raise the header. Engage the header lift locks by pivoting lock levers, 1, forward. Lower the header onto the stop blocks. A3657-29 2. Shift the machine into the transport position. Lock the swing cylinder by pivoting handle, 1, forward.
Page 35: Parking The Machine
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 PARKING THE MACHINE STORING THE MOWER-CONDITIONER When cutting is finished: When preparing the mower-conditioner for storage: 1. Disengage the tractor PTO. Park the machine on 1. Clean the mower-conditioner. Remove any a level area. buildup of debris and any wrappage from the cutter bar components.
Page 36: Specifications
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 SPECIFICATIONS Overall Width Transport position ..........3429 mm (11 ft 3 in) Field position .
Page 37: Special Tools
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 Rolls Type ............Steel or rubber with intermeshing spirals Length...
Page 38 SECTION 00 - GENERAL INFORMATION - CHAPTER 1 00-26...
Page 39 SECTION 00 - GENERAL INFORMATION - CHAPTER 2 SECTION 00 - - GENERAL INFORMATION Chapter 2 - - Adjustments CONTENTS Section Description Page Conditioning (Roll Pressure) ..........Unplugging The Conditioner Rolls .
Page 40: Conditioning (Roll Pressure)
SECTION 00 - GENERAL INFORMATION - CHAPTER 2 CONDITIONING (ROLL PRESSURE) Adjust the roll pressure with crank, 1. Turn crank clockwise to increase the roll pressure. Apply only sufficient pressure to crack the stems, with minimal damage to the leaves. Overconditioning will result in leaves overdrying and shattering, increased power requirements, and increased driveline wear.
Page 41: Roll Timing
SECTION 00 - GENERAL INFORMATION - CHAPTER 2 5. Rotate the machine in the opposite direction by using a bar, 1, in the right hand cutter bar tower, 6. Clear all crop from in front of the conditioner rolls. Make sure no foreign objects are in the conditioner.
Page 42: Rubber Rolls
SECTION 00 - GENERAL INFORMATION - CHAPTER 2 Rubber Rolls Where the rubber rolls mesh, all the lugs should be evenly spaced between the lugs of the opposing roll. 50020722 Steel Rolls When the steel rolls mesh, the rail of one roll should be centered between two rails of the opposing roll.
Page 43: Roll Gap
SECTION 00 - GENERAL INFORMATION - CHAPTER 2 ROLL GAP WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running.
Page 44: Steel Rolls
SECTION 00 - GENERAL INFORMATION - CHAPTER 2 Steel Rolls Under most crop conditions, maintain a gap of 5 -- 7 mm (3/16 -- 1/4 in) at the closest point. 5 - - 7 mm (3/16 - - 1/4 in) NOTE: In certain cane-type crops like Sorghum, Sudex or Sudan grass, it may be necessary to increase the roll gap in order to feed the crop through...
Page 45: Cutter Bar Flotation
SECTION 00 - GENERAL INFORMATION - CHAPTER 2 CUTTER BAR FLOTATION WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running.
Page 46: Cutting Height
SECTION 00 - GENERAL INFORMATION - CHAPTER 2 CUTTING HEIGHT WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running.
Page 47 SECTION 00 - GENERAL INFORMATION - CHAPTER 2 For 10 degree header tilt, store pin in the lower plate holes, 1, as shown. This position does not restrict the tilt cylinder stroke, and allows the header to tilt forward to the lowest cutting height. If a stone or obstacle is seen when the machine is being operated in the 5 degree or 10 degree position the header angle can be retracted to 2 degrees...
Page 48 SECTION 00 - GENERAL INFORMATION - CHAPTER 2 00-10...
Page 49: Section 00 - - General Information
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 SECTION 00 - - GENERAL INFORMATION Chapter 3 - - Lubrication CONTENTS Section Description Page Lubrication ..............Recommended Lubricants .
Page 50: Lubrication
The use of proper fuels, oils, grease and filters, as well as keeping the systems clean, will also extend machine and component life. IMPORTANT: Always use genuine Case IH replacement parts, oils and filters to ensure proper operation, filtration of engine and hydraulic systems. See your Case IH dealer for additional quantities.
Page 51: Lubrication Schedule
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 LUBRICATION SCHEDULE NOTE: The items listed at the first 50 hours are very important. If they are not performed, it could cause early failures of components and severely lower the life expectancy of the disc mower-conditioner. Every After First Every...
Page 52: Pto Slide Collar
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 Different types of grease guns provide a different amount of grease per pump of the handle. In general, a pistol grip style grease gun, 1, provides half the amount of grease per pump as a lever style grease gun, 2.
Page 53: Every 50 Hours
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 EVERY 50 HOURS Lubricate the slide collar, 2, as required with oil to prevent rust from seizing the components. BONDIOLI PRIMARY PTO - - EVERY 50 HOURS Fittings, 1, universal joints (2 fittings) (4 -- 6 pumps) 540 and 1000 rpm.
Page 54: Secondary Pto
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 SECONDARY PTO - - EVERY 50 HOURS There are three areas on the secondary PTO shaft which require lubrication: the front CV joint, 1; telescoping section, 2; and the rear CV joint and slip clutch assembly, 3.
Page 55: Telescoping Section
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 Telescoping Section Fitting, 1, sliding PTO shaft (16 -- 20 pumps) WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running.
Page 56: Roll Drive
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 ROLL DRIVE Fittings, 1, 2, and 3, top roll drive shaft (4 -- 6 pumps) Fitting, 4, belt tightener pivot (4 -- 6 pumps) NOTE: Figure shows conditioner drive belt and idler removed for clarity.
Page 57: Tongue Pivot Pin
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 TONGUE PIVOT PIN Fitting, 1, (4 -- 6 pumps) 20011825 WHEEL BEARINGS Repack the wheel bearings every 400 hours or each season with premium grease EP-2. 19982129 CUTTER BAR MOUNTING BOLTS Fittings, 1, left and right cutter bar mounting bolts (one fitting on each bolt, four bolts total.) (4 -- 6 pumps) WARNING Disengage the PTO, turn off the tractor engine...
Page 58: After First 50 Hours
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 AFTER FIRST 50 HOURS STEP UP GEARBOX 540 rpm drive -- Fill to oil level plug, 1. (50 hours) The step up gearbox oil should be changed after the first 50 hours of use to remove any contaminants from the break-in process.
Page 59: Every 100 Hours
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 EVERY 100 HOURS ROLL PRESSURE CRANK Fitting, 1, (4 -- 6 pumps) A3659-15 BEVEL GEARBOX Fill to oil level plug, 1. (50 hours) Oil may be added through the level plug, or through the breather plug, 1, Figure 23.
Page 60 SECTION 00 - GENERAL INFORMATION - CHAPTER 3 The bevel gearbox oil should be changed after the first 50 hours of use to remove any contaminants from the break-in process. After this, change the oil every 200 hours or yearly, whichever occurs first. Drain oil by removing plug, 1.
Page 61: Every 200 Hours
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 EVERY 200 HOURS ROLL DRIVE GEARBOX Fill to oil level plug, 1. (50 hours) Add oil by removing breather plug, 3. The roll drive gearbox oil should be changed after the first 50 hours of use to remove any contaminants from the break-in process.
Page 62: Every 400 Hours
SECTION 00 - GENERAL INFORMATION - CHAPTER 3 Module oil should be changed after the first 50 hours of use to remove any contaminants from the break-in process. After this, change the oil every 200 hours or yearly, whichever occurs first. Raise the header and engage the header transport locks.
Page 63 SECTION 00 - GENERAL INFORMATION - CHAPTER 4 SECTION 00 - - GENERAL INFORMATION Chapter 4 - - Troubleshooting CONTENTS Section Description Page Troubleshooting ..............00-1...
Page 64 SECTION 00 - GENERAL INFORMATION - CHAPTER 4 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE CORRECTION Leaves damaged or Too much pressure on the rolls. Reduce the pressure until the leaves stripped off stems. are not damaged. Leaving ragged or long Ground speed too fast. Reduce the ground speed.
Page 65 SECTION 00 - GENERAL INFORMATION - CHAPTER 4 PROBLEM POSSIBLE CAUSE CORRECTION Forming poor or bunchy Tractor PTO speed too slow. Maintain RPM on the tractor PTO. windrow (Do not overspeed.) Incorrect swath gate adjustment. Adjust the swath gate to even discharge flow.
Page 66 SECTION 00 - GENERAL INFORMATION - CHAPTER 4 00-4...
Page 67: Description Page
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 1 - - PTO CONTENTS Section Description Page Description of Operation ............Slide Lock -- Disassembly .
Page 68: Description Of Operation
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 DESCRIPTION OF OPERATION The mower-conditioners utilize constant velocity U-joint drivelines for smooth operation, and to provide the ability to swing the tongue during PTO operation. The primary PTO shaft on both 540 RPM and 1000 RPM units is equipped with an 80 degree CV U-joint, 1, at the tractor end, and a conventional U-joint, 2, at the rear.
Page 69 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 Slide Lock - - Disassembly 1. Pull back the collar to expose the retaining ring, 1. Use a screwdriver or spring pick to remove the retaining ring from the barrel. 1411/3-1 2.
Page 70: Drive Shaft Removal/Installation
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 3. Fill inside of collar cavity with grease. Apply grease to yoke bore, spring and pawls. 4. Slide collar, 1, over bore, ensuring the large diameter end of spring stays inside the collar against the front lip.
Page 71: 1000 Rpm Pto Units
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 1000 RPM PTO Units Remove the front PTO shield by removing two 5/16″ x 3/4″ cap screws and cupped lock washers at, 1. 3657-7 Remove the tapered pin, 1, washer, and lock nut, 2. Slide the PTO off of the gearbox shaft.
Page 72: Secondary Pto Assembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 Secondary PTO Assembly Unhook the anti-rotating chain (if equipped). Remove the shield from the rear side of the step-up gearbox by squeezing the sides together off the retaining pins. Slide shield over the secondary PTO shaft.
Page 73: 540 Rpm Ptos
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 540 RPM PTOs Standard Drivelines Guards - - Disassembly 1. Insert a screw driver into the slot, 1, in the driveline bell, and push down and forward to snap the retaining ring out of its groove. Reach in the end of the bell to finish popping the retaining ring out of its groove.
Page 74: Driveline Guards -- Inspection
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 3. Slide the driveline guard off of the drive shaft. It may be necessary to tap the guard lightly with a rubber mallet to unseat the guard bushings from the shaft, or from the center housing, 1, on the 80°...
Page 75: Standard Driveline Guards -- Assembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 Standard Driveline Guards - - Assembly 1. Install the nylon bushing, 1, in yoke groove, and position the retaining ring in between yoke and nylon bushing. 1411/3-12 2. Slide the guard onto the shaft, making sure the bushing on the end of the guard slips over the end of the shaft, and turn the guard to seat the nylon bushing properly in the guard.
Page 76: Front Guard Assembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 Front Guard Assembly 1. Install the nylon bushing, 1, in yoke groove; the retaining ring, 2, should be positioned between the CV joint and nylon bushing. 2. Slip guard over the shaft and onto the nylon bushing;...
Page 77: 1000 Rpm Ptos
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 1000 RPM PTOs 1. Unscrew the shield cone screws, 1, on the rear yoke. 86065244 2. Slide the drive shaft, 1, out of the shield, 2, shown above. Spread apart the support ring, 3, and remove from the groove.
Page 78: 1000 Rpm Assembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 4. Slide the shield off of the drive shaft. 86065241 5. Remove the cone, 1, by sliding it off of the shaft, 2, as shown above. Spread apart the support rings, 3, and remove from the grooves.
Page 79 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 2. At the front yoke, grease the grooves, 1. Place 86065243 support rings, 2, around the grooves. Place the smaller support ring so that the grease fitting faces the rear yoke. 86065242 3.
Page 80 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 5. Slide the guard over the PTO shaft, with the tractor image toward the slide lock. 86065254 6. Align the grease fitting, 1, with the square notch cut into the guard. Secure the cone guard and guard to the support rings with the screws.
Page 81: Secondary Pto Disassembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 8. Slide the female shaft over the male shaft. 86065260 9. Align the grease fitting, 1, with the square notch cut out of the guard. Secure the guard to the support ring with screws.
Page 82 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 At this point, you can now slide the two shafts apart. 2. Slide the cone shield, 1, off of the support ring. 86065256 3. Spread apart the support ring, 1, and remove it 86065257 from the groove.
Page 83 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 5. Slide the shield off of the PTO shaft. 86065263 6. Remove the cone shield. 86065264 7. Spread apart the support ring, and remove from the groove. 86065265 31-17...
Page 84: Secondary Pto Assembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 Secondary PTO Assembly At the clutch end of the PTO. 1. Lubricate the support ring groove, 1, with grease. 2. Lubricate the male PTO shaft, 2, with grease. 86065258 3. Place the support ring back on to the groove. 86065257 4.
Page 85 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 5. Slide the two guards together. 6. Place the guards onto the female PTO shaft. NOTE: The end with the tractor image, 1, goes opposite the end with the clutch. 86065254 7.
Page 86: U-Joints -- Disassembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 U-Joints - - Disassembly 1. Remove the PTO shaft from the unit, and remove the shielding, as previously described. 2. To disassemble a Weasler universal joint, the first step is to remove the snap rings. Use pliers or a spring pick to remove internal snap rings, 1.
Page 87: U-Joints -- Inspection
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 U-Joints - - Inspection NOTE: The U-joint cross and bearings must be replaced anytime the U-joint is disassembled, even if the cross and bearings were not the source of failure. 1.
Page 88: U-Joints -- Assembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 U-Joints - - Assembly 1. To reassemble the U-joint, start one bearing cup into the yoke ear, and position the center cross through the yoke. NOTE: When assembling a CV U-joint, install the cross into the outer yoke first, and then assemble the yoke and cross assembly into the intermediate housing.
Page 89: Repair Time Schedule
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 REPAIR TIME SCHEDULE Procedure Time Slide Lock, Rbld 0.25 U-Joints, replace cross: Standard 0.33 50° CV 0.75 80° CV 0.75 Guards, R & R 0.25 31-23...
Page 90 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 1 31-24...
Page 91: Description
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 2 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 2 - - Slip Clutch CONTENTS Section Description Page Slip Clutch ..............Slip Clutch - Removal .
Page 92: Slip Clutch
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 2 SLIP CLUTCH WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running.
Page 93: Slip Clutch - Removal
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 2 WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running.
Page 94: Slip Clutch - Inspection
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 2 Slip Clutch - Inspection 1. Inspect the separator plate, 1, for discoloration, warpage or cracking, replace if any damage is found. Both faces of the plate should have a rough surface. Replace the plate if either face is worn smooth.
Page 95 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 2 Slip Clutch - Assembly 1. Set a new friction disc, 1, into the clutch housing, followed by the separator plate, 2, and another friction disc, 3. 50006844 2. Slide the pressure plate, 1, into the housing with the flat surface facing the friction disc.
Page 96 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 2 4. Set the compression plate, 1 over the hub against the outer diameter of the disc spring, and install six new cap screws, 2, through the compression plate. Insert new nuts, 3, into the pockets on the front of the clutch housing and thread the bolts into the nuts until snug to hold the assembly together.
Page 97: Slip Clutch - Run In
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 2 Slip Clutch - Run In 1. If applicable: Loosen the six cap screws, 1, (three shown), 1/2 turn at a time until all are just loose. Tighten the cap screws 1/2 turn. 2.
Page 98 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 2 31-8...
Page 99: Section 31 - - Implement Power Take-Off (Pto)
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 3 - - Overrunning Clutch CONTENTS Section Description Page Overrunning Clutch ............Overrunning Clutch - Disassembly .
Page 100: Overrunning Clutch
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 OVERRUNNING CLUTCH Overrunning Clutch - Disassembly If the overrunning clutch does not operate when the tractor PTO is disengaged, the overrunning clutch must be disassembled for inspection. Remove the slip clutch from the unit as previously described. It is possible to repair the overrunning clutch without disassembling the slip clutch.
Page 101: Overrunning Clutch - Inspection
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 3. Slide the hub, 1, from the yoke shaft, 2. Capture the pawls and leaf springs, 3, as the hub is slid from the shaft. 50006849 4. Turn the set screw, 1, from the ball bearing cavity. Rotate the yoke shaft with the hole down until all the bearings fall out.
Page 102: Overrunning Clutch - Assembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 Overrunning Clutch - Assembly 1. Apply a film of grease to the inner, 1, and outer, 2, race of the ball bearing cavity. 50006851 2. Set the outer yoke shaft, 1, onto the inner shaft. Insert the ball bearings, 2, into the cavity until all thirty are in place.
Page 103 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 4. Apply a film of grease to the pawls, 1, and set each in place on top of the leaf springs. 50006854 5. Slide the hub, 1, over the pawls. Secure the hub in place with the washer, 2, and snap ring, 3.
Page 104 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 Exploded view of the Slip with Overrunning Clutch Assembly. 1. Bolt 2. Flange Yoke 3. Adjustment Band 4. Friction Lining 5. Driving Plate 6. Inner Plate 7. Locking Plate 8. Allen Bolt 9.
Page 105: Slip With Overrunning Clutch
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 SLIP WITH OVERRUNNING CLUTCH Disassembly 1. Remove the grease fitting, 1. 2. Break loose the eight nuts, 2. Loosen and remove the nuts. 86065269 3. Remove the Belleville Spring, 1. 86065269 4.
Page 106 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 5. Remove the adjustment band, 1, pressure plate, 86065271 2, and friction lining, 3. 86065290 6. Grab hold of the overrunning clutch housing with hub, rotate clockwise, and counterclockwise swiftly to work loose. Remove. 86065269 7.
Page 107 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 8. Place assembly, hub up, in a vice. Knock out the locking plate, 1 (as shown above), with a punch and hammer. 86065269 9. Flip the assembly over and tighten vice. Place a punch through the tapered pin hole, 1, and push against the vice.
Page 108 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 11. Place assembly hub down on workbench, remove bolts. 12. With your fingers, remove the overrunning clutch plug. 86065269 13. Lift housing off of the hub. 86065269 14. Remove the keys, 1, and spring, 2, from the hub. 86065269 31-10...
Page 109: Assembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 Assembly 1. Lubricate the hub with grease. Insert the springs, 86065282 2. Squeeze two of the keys, 1, tighten against the hub pushing back the springs. Place a C-clamp on the keys, near the bottom of the hub. Tighten C-clamp to hold the keys.
Page 110 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 4. Slide the overrunning clutch housing over the hub, with the keys in sync with the key way grooves in the housing. 86065269 5. Remove the C-clamp. 86065269 6. Insert the Overrunning Clutch Plug and secure with the Allen bolts.
Page 111 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 8. Tap the locking plate, 1, back into position. 86065277 9. Place the friction linings, inner plate, and driving plate back on the hub assembly. 86065275 10. Slide the assembly back into the flange yoke. 86065273 31-13...
Page 112 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 11. Place the friction lining and pressure plate back on to the assembly. Align the bolt holes, and insert the bolts. 86065290 12. Place the adjustment band back on. 86065271 13.
Page 113 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 14. Tighten the nuts so that the Belleville spring, 1, just touches the adjustment band, 2. 15. Back off the nuts 1/4 turn, so that the Belleville spring, 1, is only applying pressure to the pressure plate, and not the adjustment band, 2.
Page 114 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 3 31-16...
Page 115: Description
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 4 - - Step-up Gearbox CONTENTS Section Description Page Step-Up Gearbox ............To Convert Step-up Gearbox for Different PTO Speed .
Page 116 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 SET-UP GEARBOX The units are shipped from the factory with the PTO driveline configured for 540 PTO operation. In this mode, the 540 RPM primary PTO shaft, 1, connects to the 21 spline gearbox shaft, 2, and power flows through the gearbox to step up the output to the secondary PTO shaft to 1000 RPM.
Page 117 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 5. Remove the four cap screws and flat washers at 1, which attach the gearbox to the tongue. Tip gearbox forward, and remove it from the tongue. IMPORTANT: The step-up gearbox is heavy and awkward;...
Page 118 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 7. Tip the step-up gearbox so that the breather is positioned upwards and lift it back into the tongue; for 1000 RPM operation, it will be necessary to install top of gearbox first, and then swing bottom of gearbox into frame to avoid damaging breather.
Page 119: Step-Up Gearbox - Disassembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 Step-up Gearbox - Disassembly Remove the gearbox from the tongue, following the steps described in previous section; “To Convert Step-Up Gearbox for Different PTO Speed”. 1. Drain the oil from the gearbox. 2.
Page 120 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 5. Position the gearbox in a press with the back side of the gearbox facing down, and push the shafts out of the gearbox, starting with the output shaft. The shafts must be pushed out of the upper bearings only, as the shafts are a slip fit in the gears.
Page 121 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 CUTAWAYS OF STEP-UP GEARBOX 31-7...
Page 122: Step-Up Gearbox - Assembly
SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 Step-up Gearbox - Assembly Clean and inspect all parts. Inspect shafts for excessive wear or damage to splined surfaces, and for damage on bearing shoulders. Check gear teeth for chipping or cracks, and the mating splines for wear.
Page 123 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 2. Position the gearbox housing in a press with the front of the gearbox facing down. Apply oil to the bearing cone, and install it into the bearing cup in the housing.
Page 124 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 7. Install the intermediate shaft bearing cap and original shim pack using three cap screws and lock washers. If the original shim pack is destroyed, or if all new parts are being used, use a starting shim pack thickness of 1.02 -- 1.27 mm (0.040 -- 0.050 in).
Page 125 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 10. Apply a thin coat of silicone sealant to the edge of the expansion plug, 1, and insert it into the bore of the intermediate shaft until it contacts the shoulder.
Page 126 SECTION 31 - IMPLEMENT POWER TAKE-OFF (PTO) - CHAPTER 4 31-12...
Page 127: Description
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 SECTION 35 - - HYDRAULIC SYSTEMS Chapter 1 - - Hydraulic Cylinders CONTENTS Section Description Page Hydraulic Diagram ............. Bleeding Air from the Lift Cylinders .
Page 128 SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 Four different cylinders are used on the disc mower-conditioners. The tongue shift cylinder, 1, is a double-acting cylinder, with a screw-in orifice to control the speed of stroke. A mechanical transport latch, 2, is used to prevent accidental actuation of the cylinder.
Page 129: Hydraulic Diagram
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 HYDRAULIC DIAGRAM 0.0785″ TILT CYLINDER 1431-8-8 35-3...
Page 130 SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 WARNING Fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Always protect the skin and eyes from escaping fluid under pressure. Before disconnecting lines or fittings, be sure to release all pressure by operating the tractor control valves.
Page 131: Bleeding Air From The Lift Cylinders
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 BLEEDING AIR FROM THE LIFT CYLINDERS If the lift cylinders do not lift the frame evenly or if one side lifts higher than the other, rephase the cylinders by lowering the mower-conditioner and hold the tractor valve in the lower position for 10 to 15 seconds or by raising the mower-conditioner and hold the tractor valve for 10 to 15 seconds.
Page 132: Lift Cylinder Removal
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 LIFT CYLINDER REMOVAL WARNING Before attempting to remove the lift cylinders: 1. Raise the header with the tractor hydraulics. 2. Engage the header transport locks, 1. Install the pin, 2, figure 3, to lock the header tilt cylinder in the 2 degree position.
Page 133: Master Cylinder
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 MASTER CYLINDER Disassembly 1. Remove setscrew, 1. A1411/9-6 2. Tap the cylinder head, 1, into the cylinder far enough to remove retaining ring, 2, with a screwdriver. A1411/9-7 3. Pull the complete piston rod assembly out of the cylinder barrel.
Page 134: Assembly
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 Assembly 1. Lubricate all seals, O-rings, and sliding surfaces before assembly. 2. Install a new rod seal inside the cylinder head, 1. Drive a new wiper seal, 2, in place in the face of the cylinder head.
Page 135: Slave Cylinder
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 SLAVE CYLINDER Disassembly 1. Remove setscrew, 1. A1411/9-13 2. Tap the cylinder head, 1, into the cylinder far enough to remove retaining ring, 2. A1411/9-13 3. Pull the complete piston rod assembly out of the cylinder barrel.
Page 136: Assembly
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 Assembly 1. Lubricate all seals and sliding surfaces before assembly. 2. Install a new back-up washer and O-ring in the inner bore of the cylinder head, 3, with the back-up washer towards the outer face. Drive a new wiper seal, 4, into the outer face of the cylinder head.
Page 137: Header Tilt Cylinder
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 HEADER TILT CYLINDER Removal 1. Place the header tilt position pin in the 10 degree position. Position jackstands, 1, or blocking at the front of the header to support it in a horizontal position when it is lowered.
Page 138: Inspection
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 2. Remove setscrew, 1. 3. Tap the cylinder head, 2, into the cylinder far enough to remove retaining ring, 3, with a screwdriver. 1411/9-3 4. Pull the complete piston rod assembly out of the cylinder barrel.
Page 139: Swing Cylinder
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 5. Lubricate the cylinder barrel with oil, and carefully insert the complete piston rod assembly into the barrel, using caution not to damage the seals on the retaining ring groove. Push the cylinder head into the cylinder barrel far enough to expose the retaining ring groove, and install retaining ring, 3.
Page 140: Inspection
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 3. Pull the complete piston rod assembly out of the barrel. NOTE: The O-rings and seals should be replaced. 4. Capture the piston rod using a bar through the clevis, and remove the rod nut, 1. Slide the piston, 2, cylinder head, 3, and nut, 4, off of the piston rod.
Page 141 SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 6. Lubricate the cylinder barrel with oil, and carefully insert the complete piston rod assembly into the barrel, 1, using caution not to damage the seals on the retaining ring groove. Push the cylinder head into the cylinder barrel far enough to expose the retaining ring groove, and install retaining ring, 2.
Page 142 SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 1 35-16...
Page 143 SECTION 39 - FRAMES - CHAPTER 1 SECTION 39 - - FRAMES Chapter 1 - - Floatation Springs CONTENTS Section Description Page Adjustment ..............Removal .
Page 144: Adjustment
SECTION 39 - FRAMES - CHAPTER 1 ADJUSTMENT WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running. Failure to comply could result in death or serious injury.
Page 145: Removal
SECTION 39 - FRAMES - CHAPTER 1 REMOVAL WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running. Failure to comply could result in death or serious injury.
Page 146: Installation
SECTION 39 - FRAMES - CHAPTER 1 INSTALLATION 1. Place the bushing, spring assembly and spacer on the lower hub. 2. Install the anchor and cotter pin, 1. 19992632 3. Slide the long adjusting bolt through the washer, 1, and pivot, 2, and insert it through the anchor plate on the frame.
Page 147: Disassembly: Flotation Spring Wrench
SECTION 39 - FRAMES - CHAPTER 1 DISASSEMBLY: FLOTATION SPRING WRENCH Separating the spring nuts from the springs requires a special tool for holding the spring. Use the specifications provided to manufacture the proper tool for your machine using common metal pipe stock.
Page 148: Disassembly
SECTION 39 - FRAMES - CHAPTER 1 DISASSEMBLY 1. Clamp the spring assembly firmly in a vise. 2. Slide the flotation spring wrench onto the spring, 1, with the metal nib facing out. Use the metal nib to catch the end of the spring coil, and rotate the tool clockwise.
Page 149: Assembly
SECTION 39 - FRAMES - CHAPTER 1 ASSEMBLY 1. Clamp the spring firmly in a vise. 2. Clean the spring nuts thoroughly with emery cloth to remove rust and rough areas. Apply lubricant, such as light oil, to the spring nuts to ease assembly.
Page 150 SECTION 39 - FRAMES - CHAPTER 1 39-8...
Page 151 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 SECTION 55 - - ELECTRICAL SYSTEM Chapter 1 - - Implement Lights CONTENTS Section Description Page Trailing Lights ............. . Installing the Wire Harness .
Page 152: Trailing Lights
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 TRAILING LIGHTS The trailing lights, 1, improve machine visibility and warn operators of other vehicles. The optional trailing light kit should be used when towing the mower-conditioner on a public road, and conforms to ASAE S279.13.
Page 153 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 2. Route the left side portion of the harness through the hose clamp on the flotation spring mount. 3. The remaining portion of the wire harness to the right side lights must be routed through the frame.
Page 154 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 NOTE: On this equipment, left and right are determined by standing behind the unit, looking in the direction of travel. 20011816 Mower Left Left Red Left Red Right Red Right Red Right Conditioner’s Amber Inner...
Page 155 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 The mower-conditioner trailing light harness uses a 7-pin trailer connector to connect the mower-condi- tioner to a tractor electrical outlet, which conforms to SAE J560. For proper light function, this unit must be connected to a tractor incorporating an SAE standard 7-pin conductor electrical socket which conforms to SAE J560.
Page 156 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 If you have one of these tractors, the brake light circuit can be disabled by disconnecting the bullet connector, 1, located in the wire harness where it attaches to the lighting control box, 2. IMPORTANT: When you later reattach the machine to a standard electrical socket on propelling vehicle, the brake light circuit must be reconnected to...
Page 157: Description Page
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 SECTION 58 - - ATTACHMENTS / HEADERS Chapter 1 - - Cutter Bar CONTENTS Section Description Page Introduction ..............Discs .
Page 158: Introduction
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 INTRODUCTION The disc mower-conditioners use an 8-disc, counter-rotating disc cutter bar to provide a 10 ft 4 in. cutting width. All eight discs are counter-rotating. The outer two discs are each equipped with an open feed drum to help feed crop into the conditioner rolls.
Page 159 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 Each disc module is a separate gear case with its own oil sump, and utilizes precision forged gears for strength. Each module consists of a top cap assembly and a lower module assembly. The top cap assembly consists of the top cap housing, a bevel gear shaft, a matched bearing set and a disc hub.
Page 160 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 Each disc module is protected by a hardened ductile iron rock guard, 1, and a skid shoe, 2. Skid shoes are 1/4 inches thick and 8 inches wide; they extend behind the module several inches for optimum flotation and extended wear life of the shoe.
Page 161: Discs
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 DISCS Each time knives are replaced or turned, check the discs for damage and wear. If a disc is bent or cracked, replace it. When the leading edge, 1, of the disc wears thin, it can be used on an opposite rotating module to utilize the second face.
Page 162: Knife And Bolt Inspection
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 KNIFE AND BOLT INSPECTION is found or if it can be threaded into the knife nut by hand. Inspect the cutter bar daily for damaged compo- nents. The quality of cut and safety of operation Replace the knife nut if the shoulder or threads show depends on regular inspection of the cutter bar.
Page 163: Knife Replacement
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 KNIFE REPLACEMENT NOTE: Inspect the cutter bar for leaks or other needed repairs whenever performing service work on the bar. If a leak is found repair it immediately to prevent possible future failures. IMPORTANT: Always replace both knives on a disc to maintain balance.
Page 164 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 7. Install the nut through the knife and insert the nut, 1, into the bottom of the discs aligning it with the slot in the disc. NOTE: Crop lifter removed for clarity. 2--46 8.
Page 165: Crop Lifter Replacement
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 CROP LIFTER REPLACEMENT WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running.
Page 166: Cutter Bar Inspection/Failure Analysis
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 CUTTER BAR INSPECTION/FAILURE ANALYSIS In the event of a failure of the modular disc cutter bar, it is important to properly inspect the unit to determine the extent of the damage. A thorough examination will help to locate all the damaged components, and minimize unnecessary repair labour.
Page 167 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 C. Starting at the left end of the cutter bar, grab both the #1 and #2 discs, and slowly rotate both discs while applying pressure to one of the discs against the direction of rotation. If one disc suddenly moves, it may indicate damage to the gear teeth in that module.
Page 168 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 E. The cutter bar should only be removed from the machine and disassembled if it has been determined that the lower module compo- nents or the intermodule shafts are damaged. Ensure that all disc modules were checked as per steps B, C, and D to determine which modules require removal for repair or replace- ment.
Page 169: Top Cap Removal
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 TOP CAP REMOVAL 1. Block the cutter bar discs in place with a hardwood block, or install a bar through the right end tower to lock up the cutter bar, and remove the disc of the affected module by removing the four retaining bolts, 1, securing the disc and cover to the disc hub.
Page 170: Inspection
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 5. Remove the four retaining bolts, 1, and pry the top cap assembly off the lower module. 50012157 INSPECTION 1. Inspect the top cap assembly, 1, for excessive play in bearings, bearing damage, and gear tooth damage.
Page 171: Top Cap Installation
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 TOP CAP INSTALLATION 1. Apply a thin bead of silicone sealant to the sealing flange of the new top cap assembly, 1, and position it on the lower module assembly with the breather, 2, facing to the right. 19985741 2.
Page 172 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 Apply a thin coating of grease to the seal lip and surface on disc hub. Slide the disc hub onto the top cap shaft; if it is not perfectly timed to the adjacent discs, remove the disc hub, rotate it 90°...
Page 173: Cutter Bar Removal
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 CUTTER BAR REMOVAL The cutter bar must be removed if a lower module assembly requires replacement or repair. 1. Raise the header and engage the transport locks. Install the pin, 1, to lock the hydraulic header tilt cylinder in the 2 degree position.
Page 174 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 4. The tie bolts clamping the spacers to the disc modules are extremely tight, and are easier to loosen while the cutter bar is still clamped in the header frame. To gain access to the tie bolts, remove the rock guard and skid shoe from the module to be removed.
Page 175 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 6. Remove the two special bolts, 1, and nuts from each end of the cutter bar attaching arms. Drive the bushings out of the arms with a punch. WARNING Disengage the PTO, turn off the tractor engine and remove the key.
Page 176: Cutter Bar Installation
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 CUTTER BAR INSTALLATION 1. Support the cutter bar with floor jacks positioned under each end. 2. Roll the cutter bar under the header, positioning the attaching arms so that they line up with the slots in the header frame.
Page 177 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 CUTTER BAR BAYONET BUSHING - REPLACEMENT 1. To replace the cutter bar bayonet bushings, the cutter bar must first be removed from the unit (refer to “Cutter Bar Removal”). 2. Remove the snap ring, 1, from the bayonet arm. 19991333 3.
Page 178: Cutter Bar Disassembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 CUTTER BAR DISASSEMBLY 1. If not already removed, remove the disc, rock guard and skid shoe from the module to be removed in order to gain access to the tie bolts. Loosen the tie bolts by installing the special holding tools, 1, on one end of each tie bolt.
Page 179: Cutter Bar Reassembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 CUTTER BAR REASSEMBLY 1. Prior to reassembly, remove the connecting shafts, 1, from both spacers, and apply special lubricant to both ends of the shafts. Reinstall the connecting shafts. A3997-10 2. It is necessary to time the cutter bar discs on either side of the replacement module during reassembly to eliminate interference between the knives.
Page 180 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 It is necessary to determine the direction of rotation of a replacement module prior to installing it in the cutter bar. Note that the pinion end of the lower module shaft has a groove, 1, in it to determine which side of the module the pinion gear is on;...
Page 181 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 Slide the disc hub, 1, onto the top cap shaft; if it is not perfectly timed to the adjacent discs, remove the disc hub, rotate it 90° and reinstall it. Continue to do this until the disc hub is properly timed;...
Page 182: Disc Module - Disassembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 DISC MODULE - DISASSEMBLY 1. Remove the disc hub by removing the center retaining bolt, 1. It will be easier to remove the disc hub if the bolt is loosened prior to removing the module from the cutter bar.
Page 183 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 4. Use a pair of snap ring pliers to carefully remove the slingers, 1, on each end of the lower module shaft. IMPORTANT: Use caution to prevent the tips of the slingers from contacting the sealing surface on the end of the shaft, or seal failure will occur.
Page 184: Disc Module - Assembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 50021984 DISC MODULE - ASSEMBLY on the left side, and a clockwise module will have the pinion gear on the right side. Disc modules can be assembled for clockwise or counterclockwise rotation of the disc. Before The direction of rotation of an assembled module can assembling a disc module it must be determined at be determined by looking at the ends of the lower...
Page 185 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 The backlash of the assembled disc module is controlled by precision machining of the disc module and top cap housings, the use of precision forged gears, and the use of low tolerance bearings, which are manufactured to provide a specific “stack height,”...
Page 186 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 4. Check the end play of the pinion shaft with the pinion side facing down, to ensure an accurate measurement. Rotate the shaft two complete revolutions to seat all components (bearing rollers in cage), and install a dial indicator to measure shaft end play.
Page 187 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 7. Apply silicone sealant to the threads of the drain plug and check plug, and install them into the housing. Pour 300 ml (10 fl. oz.) of Case 135H EP (API GL5 80W90) gear oil or Case Gear Lube SSL (75W90 synthetic) through the top opening into the lower module.
Page 188 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 CUTTER BAR DRIVE SHAFT - DISASSEMBLY 1. Remove the four cap screws retaining the cutter bar drive shaft, tower and disc to the disc hub at 1. Lift the tower and drive shaft slightly to clear the disc hub bolt, and pull them forward so the upper end of the drive shaft slides off the splined shaft.
Page 189 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 4. Position the joint in an open vise, with each ear of one yoke supported by a vise jaw. With a soft hammer of mallet, strike the top ear of the unsupported yoke at 1.
Page 190 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 1 CUTTER BAR DRIVE SHAFT - ASSEMBLY 1. To reassemble the U-joint, position the cross, 1, in the yoke so that the bearing journals are positioned in each yoke ear. Insert the bearings in the outside of the yoke ears, and position the assembly in a vise.
Page 191 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 SECTION 58 - - ATTACHMENTS / HEADERS Chapter 2 - - Bevel Gearbox CONTENTS Section Description Page Bevel Gearbox - Removal ........... . Bevel Gearbox - Disassembly .
Page 192: Bevel Gearbox - Removal
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 BEVEL GEARBOX - REMOVAL WARNING Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving operator’s position. Never adjust, lubricate, clean or unplug machine with the engine running.
Page 193 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 6. Remove the upper shielding by removing four carriage bolts, flat washers and flange nuts at 1 and four carriage bolts, flat washers and flange nuts at 2. It may be necessary to loosen two or three bolts between the lower shield and header frame if shield is sandwiched between these components.
Page 194 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 10. Remove the tension on the conditioner roll drive belt by loosening the nuts, 2, on the spring tension rod until the belt can be removed from the upper sheave. Remove the spring, 1, from the idler arm.
Page 195: Bevel Gearbox - Disassembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 BEVEL GEARBOX - DISASSEMBLY 1. Remove the belt idler pulley by removing the cotter pin, 1, and washers; slide pivot shaft out of the mount. 2. To disassemble the conditioner drive shaft assembly, the drive pulley must be removed.
Page 196 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 7. Tip the gearbox over, and remove the four cap screws, 1, and lock washers retaining the anti-wrap shield and bearing cap on the output shaft. Remove the anti-wrap shield, and pry off the bearing cap, being careful not to damage the shims.
Page 197 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 CUTAWAYS OF BEVEL GEARBOX 58-7...
Page 198: Bevel Gearbox - Reassembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 BEVEL GEARBOX - REASSEMBLY During assembly of the bevel gearbox, it is important to be aware that all bearings, except for the bottom bearing, 1, Figure 15, on the cutter bar drive shaft, consists of carefully manufactured cups and cones to provide a specific “stack height,”...
Page 199 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 4. Install the flat washer and castellated nut onto the shaft, and tighten the castellated nut as required to obtain 0.23 -- 0.68 N⋅m (2 -- 6 in-lb) rolling torque on the conditioner drive shaft assembly. After adjusting the rolling torque, tighten or loosen the nut as required in order to align it with the hole in the shaft.
Page 200 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 7. Install a 24T gear onto the front of the input shaft, and press a bearing cone onto shaft until it seats against shoulder on shaft. Install the 54T gear onto the end of the shaft and press a bearing cone onto shaft until the gear seats against the collar on the shaft.
Page 201 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 10. Apply oil to the input shaft bearing cones, and install the input shaft assembly into the housing by inserting the input end through the front opening in housing until the 54T gear can be lowered into the housing.
Page 202 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 12. Remove the output shaft bearing cap, 1, and apply a thin coat of silicone sealant to the shoulder of the cap; reinstall the cap on the housing, install the anti-wrap shield, 2, and retain with the previously removed hardware.
Page 203: Bevel Gearbox - Installation
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 BEVEL GEARBOX - INSTALLATION 1. Set the gearbox onto the header frame, inserting the output shaft through the hole in the frame. IMPORTANT: The bevel gearbox is heavy and awkward; use caution not to drop the gearbox as personal injury or damage to the gearbox may result.
Page 204 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 3. Reinstall the shielding, 1, by sliding the edge between the lower shield and header frame until the bolt holes line up. Retain the shield using four 5/16″ x 1″ carriage bolts, flat washers and flange nuts at 2 and four 3/8″...
Page 205 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 6. Reinstall the left end shield if previously removed by positioning it over the mounting bosses and retaining with two cap screws and lock nuts at 1. 7. Secure the PTO shielding anti-rotation chain, 2, to the slot in the shielding.
Page 206 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 2 58-16...
Page 207 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 SECTION 58 - - ATTACHMENTS / HEADERS Chapter 3 - - Conditioner Rolls and Drive System CONTENTS Section Description Page Introduction ..............Conditioner Belt .
Page 208: Introduction
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 INTRODUCTION The disc mower-conditioner is equipped with two 2.6 m (102″-long) steel or rubber conditioner rolls, 1, to condition the crop thoroughly, yet gently, for fast drying without leaf loss or crop damage. Cut crop is fed directly from the cutter bar into the conditioner rolls.
Page 209: Conditioner Belt
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 CONDITIONER BELT The conditioner belt must be properly tensioned at all times to prevent excessive slipping. A loose belt may cause conditioner rolls to wrap or plug. Check the belt tension each day for the first few days. Check weekly thereafter.
Page 210: Conditioner Belt Replacement
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 CONDITIONER BELT REPLACEMENT To remove the conditioner roll drive belt, remove the tension on the belt by loosening the nuts, 1, on the spring tension rod until the belt can be removed from the upper sheave.
Page 211: Conditioner Roll Gearbox - Removal
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 CONDITIONER ROLL GEARBOX - REMOVAL 1. Drain oil by removing the bottom plug, 1, on conditioner roll gearbox. The oil may drain faster if the top plug is removed from the gearbox also. NOTE: Figure shows shielding removed for clarity.
Page 212 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 4. Remove the four cap screws, 1, and washers that retain the gearbox shaft flange to the lower sheave. NOTE: Leave one cap screw partially threaded in to support bottom of gearbox. A3662-4 5.
Page 213: Conditioner Roll Gearbox - Disassembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 CONDITIONER ROLL GEARBOX - DISASSEMBLY 1. Clean off gearbox prior to disassembly. 2. Place gearbox on a large flat surface with the cover side upwards. Remove sixteen cap screws and cupped lock washers, and pry off cover. Note the positions of the supports, 1, before removing the cover.
Page 214: Conditioner Roll Gearbox - Assembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 CONDITIONER ROLL GEARBOX - ASSEMBLY 1. Thoroughly clean the gearbox housing, taking care to remove all old sealant on cover mounting flange. Install bearing cups into housing with the cups facing outwards from bore. Firmly seat bearing cups against shoulders in housing.
Page 215: Conditioner Roll Gearbox - Installation
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 7. Clean and degrease the mating surfaces of the gearbox housing and cover to provide proper sealant adhesion. Apply a thin bead of silicone sealant to the mating surface of the gearbox housing;...
Page 216 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 3. Reconnect the upper roll drive shaft by aligning the master splines and sliding the two half shafts together. Position the yoke flange to the upper shaft in the gearbox, and reinstall the cap screws, 1, and washers;...
Page 217: Upper Conditioner Roll Drive Shaft - Disassembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 5. Reinstall the divider sheet assembly using a cap screw and locknut at 1, and six carriage bolts, lock washers and nuts at 2. If the left side swing out shield was removed, reinstall it on the unit using two cap screws and locknuts at 3.
Page 218 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 2. The drive shaft can be slid apart, and each end serviced separately. 1411/8-5 3. Remove the internal snap rings, 1, from the U-joint using pliers. Remove the grease zerk, 2, from one bearing cup before the snap ring may be removed.
Page 219: U-Joints - Assembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 8. To remove the remaining two bearings, support the cross in the vise, making certain the vise jaws are covered with brass protectors or the previously removed bearings are reinstalled on the cross.
Page 220: Lower Conditioner Roll - Removal
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 4. Assemble the second yoke repeating steps 1-3. NOTE: The grease zerk, 1, is oriented to line up with other grease zerks, 2, on the driveline. Note the positioning of the bearing for the grease zerk during reassembly.
Page 221 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 3. Remove the tension on the conditioner roll drive belt by loosening the nuts, 1, on the spring tension rod until the belt is loose on the sheaves. 10045453 4. Remove the divider sheet assembly from the unit by removing the cap screw and locknut, 1, and six carriage bolts, lock washers, and nuts, 2.
Page 222 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 6. Remove the cap screw, 1, three flat washers, and locknut from the upper gearbox mount. Carefully support gearbox, 2, and remove the remaining lower flange cap screw. Pull the gearbox straight away from unit. The upper roll drive shaft will slide apart allowing gearbox removal.
Page 223 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 9. Clean the shaft thoroughly using emery cloth. Loosen the setscrew, 1, and remove the lock collar by driving it in the opposite direction of rotation using a hammer and punch. Use a file to remove any marks on the shaft from the lock collar setscrew.
Page 224: Lower Conditioner Roll - Installation
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 14. Using a suitable lift or floor jack to support the conditioner roll, slide the right end of the roll to the rear, out of the slot in header frame, and lower to the ground.
Page 225 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 4. The lower conditioner roll must be properly aligned with the upper conditioner roll so that the conditioner rolls can be timed. Slide the lower conditioner roll in the bearings until the edges of the upper and lower conditioning rolls, 1, are even.
Page 226 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 7. Reinstall the flotation spring by aligning the lower spring mount with the brackets on the lift arm. Insert the clevis pin, flat washer, 1, and retain using a cotter pin, 2. Retighten the flotation spring as required to provide correct header flotation on the right side of the header.
Page 227 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 10. Rotate the lower roll until the holes in the sheave line up with the holes in the lower shaft flange on the gearbox, and reinstall the four cap screws, 1, and washers.
Page 228 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 12. Check the conditioner rolls for proper timing. The lug of one roll should be centered between the two lugs of the opposite roll, as shown. The lugs must not touch. Steel Rolls 50011826 Rubber Rolls...
Page 229 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 NOTE: The figure at right shows the slotted yoke flange, 1, on the upper gearbox shaft removed from the machine. 19992645 14. Position the conditioner drive belt on the sheaves and tighten the nuts, 1, on the spring tension rod to tension spring to a length of 279 mm (11 in) between the hooks.
Page 230: Upper Conditioner Roll - Removal
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 UPPER CONDITIONER ROLL - REMOVAL NOTE: The lower conditioner roll must be removed before the upper conditioner roll can be removed (refer to “Lower Conditioner Roll - Removal”). 1. Remove the drive shaft from the left side of the upper conditioner roll by removing the two clamp bolts, 1, and nuts at the end of the drive shaft.
Page 231 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 4. Completely loosen the roll pressure tension by rotating the roll pressure handle, 1, counterclock- wise until loose. A3658-3 5. Remove the cap screw, 1, and spacer that connect the roll tension arm straps, 2, to the pivot arm.
Page 232 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 8. Lower the right side of roll through slots, 1, in header frame and out of frame. 19992647 Slide the left end out of the bearing. Back the roll out of the frame and lower it to the ground. 50012162 58-26...
Page 233: Upper Conditioner Roll - Installation
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 UPPER CONDITIONER ROLL - INSTALLATION 1. Position the upper conditioner roll behind the unit, with the hex shaft on the left side. Using a suitable lift or floor jack to support the conditioner roll, lift the left end of the conditioner roll up and slide the hex shaft through the bearing in the left side pivot arm.
Page 234 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 4. Install the roll gap bolt, 1, down through the header frame and through the pivot arm. Install the locknut, 2, on the roll gap bolt, threading it on as far as possible to ensure the pivot arm is securely engaged on the square shank of the roll gap bolt.
Page 235: Conditioner Roll Tension System
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 7. Install the upper conditioner roll drive shaft, 1, by sliding the clamp yokes over the conditioner roll shaft and gearbox shaft. Install the two bolts and nuts in each yoke, 2, and torque to 46 Nám (34 ft-lb).
Page 236 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 3. If the bushing remains, remove to free torsion bar, 1. 19992649 4. Grip the left side torsion bar tightly. Use a pair of locking pliers to shift the torsion rod out of the center adjusting tube and the tension arm.
Page 237: Right Side Torsion Arm, Torsion Bar And Adjusting Tube Disassembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 Right Side Torsion Arm, Torsion Bar and Adjusting Tube Disassembly 1. In order to remove the right side roll tension system components, the left side torsion bar must be removed. Refer to steps 1 to 4 from “Left Side Torsion Arm and Bar Disassembly”.
Page 238 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 5. Remove the cotter pin and washers at each end of the swathgate where it fits through the header frame, 1. Slide the swathgate to the right so that the swathgate handle disengages from the adjusting quadrant and the left end slips out of the header frame.
Page 239: Conditioner Roll Tension System - Assembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 9. The right side tension arm may now be removed. Remove the snap ring, 1, and washer, 2, on the inner end of the tension arm hub, and slide the tension arm out of the header frame. If the bushing in the header frame is worn or galled, use a hammer and punch to drive the bushing out of the header frame.
Page 240 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 3. Slide the washer, 1, against the swathgate quadrant bracket, and drive a groove pin, 2, through the adjusting tube to secure it in position. Drive the roll pin slowly to ensure it exits through the hole in the opposite side of the adjusting tube.
Page 241: Left Side Torsion Arm And Bar Assembly
SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 6. Reinstall the swathgate by inserting the right end through the header frame. Lift the left end up to align with the hole in the header frame, and slide the swathgate to the left until the adjusting handle clip engages a notch in the quadrant bracket, 1.
Page 242 SECTION 58 - ATTACHMENTS / HEADERS - CHAPTER 3 2. Apply a permanent lubricant to the hex bores of the adjusting tube and the tension arm, 1. Apply permanent lubricant to the ends of the torsion bar, and slide it through the tension arm until the inner end engages in the adjusting tube.
Page 243 SECTION 88 - - ACCESSORIES - CHAPTER 1 SECTION 88 - - ACCESSORIES Chapter 1 - - Optional Equipment CONTENTS Section Description Page High Stubble Kit ............88-1...
Page 244 SECTION 88 - - ACCESSORIES - CHAPTER 1 HIGH STUBBLE KIT The high stubble kit is intended to provide a higher cutting height for clipping pastures, or for crops where a higher stubble height is desirable. Cutting height is approximately 127 mm (5 in) at 2 degrees cutter bar tilt to approximately 89 mm (3-1/2 in) at 10 degrees cutter bar tilt.
Page 245 SECTION 90 - SAFETY DECALS - CHAPTER 1 SECTION 90 - - SAFETY DECALS Chapter 1 - Safety Decals CONTENTS Section Description Page Safety Decals ..............90-1...
Page 246 SECTION 90 - SAFETY DECALS - CHAPTER 1 SAFETY DECALS The following safety decals have been placed on and the operating instructions detailed in this manual your machine in the areas indicated. They are with your machine operators. intended for your personal safety and for those Keep the decals legible.
Page 247 SECTION 90 - SAFETY DECALS - CHAPTER 1 Part #86611825E Part #86624774B WARNING: The surface is not intended as DANGER: To avoid injury, DO NOT work a personnel platform. Individuals may slip under a raised header without cylinder locks and fall causing serious injury or machine in place.
Page 248 SECTION 90 - SAFETY DECALS - CHAPTER 1 Part #80772110C WARNING: While the equipment is in operation, stand clear of the knife path. Part #849471 DANGER: Rotating driveline can cause death. Part #849472 DANGER: The shield has been removed, do not operate this unit. 90-4...
Page 249 SECTION 90 - SAFETY DECALS - CHAPTER 1 Part # 87041061 WARNING: Tractor, PTO and component shielding MUST be in place when PTO is engaged. Failure to comply could result in death or Part # 87041060 serious injury. WARNING: 32 kph (20 mph) - - MAX road speed. Part # 86547781 Part # 86547782 Reflective Tape, Red...
Page 250 SECTION 90 - SAFETY DECALS - CHAPTER 1 90-6...
Page 251 COMPLETE CONTENTS SECTION 00 - - GENERAL INFORMATION Chapter 1 - - General Information CONTENTS Section Description Page Foreword ..............Precautionary Statements .
Page 252 SECTION 00 - - GENERAL INFORMATION Chapter 2 - - Adjustments CONTENTS Section Description Page Conditioning (Roll Pressure) ..........Unplugging The Conditioner Rolls .
Page 253 SECTION 00 - - GENERAL INFORMATION Chapter 3 - - Lubrication (Continued) CONTENTS Section Description Page Cutter Bar Drive Shaft ............Upper Roll Pivot Arms .
Page 254 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 1 - - PTO CONTENTS Section Description Page Description of Operation ............Slide Lock -- Disassembly .
Page 255 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 2 - - Slip Clutch CONTENTS Section Description Page Slip Clutch ..............Slip Clutch - Removal .
Page 256 SECTION 31 - - IMPLEMENT POWER TAKE-OFF (PTO) Chapter 4 - - Step-up Gearbox CONTENTS Section Description Page Step-Up Gearbox ............To Convert Step-up Gearbox for Different PTO Speed .
Page 257 SECTION 39 - - FRAMES Chapter 1 - - Floatation Springs CONTENTS Section Description Page Adjustment ..............Removal .
Page 258 SECTION 58 - - ATTACHMENTS / HEADERS Chapter 1 - - Cutter Bar CONTENTS Section Description Page Introduction ..............Discs .
Page 259 SECTION 58 - - ATTACHMENTS / HEADERS Chapter 3 - - Conditioner Rolls and Drive System CONTENTS Section Description Page Introduction ..............Conditioner Belt .
Page 260 SECTION 88 - - ACCESSORIES Chapter 1 - - Optional Equipment CONTENTS Section Description Page High Stubble Kit ............SECTION 90 - - SAFETY DECALS Chapter 1 - Safety Decals CONTENTS...

Case IH DCX101 Repair Manual

Chapter 3 - - Lubrication

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