Swath Compressor for M Series Windrowers

Transcription

1 Swath ompressor for M Series Windrowers Setup, Operation, and Parts Manual Revision Original Instruction The harvesting specialists.

2 Swath ompressor for M Series Windrowers Published: June 2018

3 Introduction The MacDon Swath ompressor is a large, formed polyethylene sheet which is designed to mount to the underside of a MacDon M155, M155E4, or M205 Windrower. The MacDon Swath ompressor is designed for use with D Series Draper Headers cutting canola. The swath compressor is compatible with M155, M155E4, or M205 Windrowers equipped with DM5 (MD #183920) with the following minimum software requirements: DM5 version 512 or newer WM2 version 236 or newer WM3 version 116 or newer The swath compressor shapes the windrow and anchors it into the stubble behind the header to help prevent shelling in ripe conditions and wind damage. Excessive compression by a swath compressor or roller can increase losses from crop shelling, and may increase drying time; inadequate compression can leave a windrow prone to wind damage. The swath compressor height can be adjusted and monitored with the cab display. Height can be adjusted for crop ripeness, yield, and the amount of compression required. The swath compressor will automatically lift up if an Operator stops and reverses the windrower. When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous situation. MacDon provides warranty for ustomers who operate and maintain their equipment as described in this manual. copy of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided to you by your Dealer. Damage resulting from any of the following conditions will void the warranty: ccident Misuse buse Improper maintenance or neglect bnormal or extraordinary use of the machine Failure to use the machine, equipment, component, or part in accordance with the manufacturer s instructions This manual is currently available in English only. onventions M155, M155E4, and M205 Windrowers are Dual Direction, meaning the windrower can be driven in cabforward or engine-forward modes. When referencing specific locations on the machine, this manual always assumes a cab-forward direction when using the terms right and left. Unless otherwise noted, use the standard torque values provided in hapter 6 Reference, page 59 of this document. NOTE: Keep your MacDon publications up-to-date. The most current version can be downloaded from our website or from our Dealer-only site ( (login required) i Revision

4 List of Revisions t MacDon, we re continuously making improvements, and occasionally these improvements affect product documentation. The following list provides an account of major changes from the previous version of this document. Summary of hange General grammar and formatting revisions. dded hazard statements. dded compatibility information. Location Throughout Throughout Introduction, page i Updated procedure Installing Reverse Switch and Harness, page 21 Updated procedure Installing Valve lock, page 24 dded new procedure Installing Rocker Switch, page 27 dded compatibility information. Revised last step and illustration to reference correct callouts. 3.1 ctivating the Swath ompressor, page 35 Updated descriptions for clarity. 5 Illustrated Parts Lists, page 45 dded seal kit as a service part to 3/8 inch hydraulic coupler. Removed incorrect model from list of applicable windrowers. dded rocker switch to parts list and illustration. 5.2 Swath ompressor Hydraulics and Supports, page M Series Swath ompressor ompletion, page 54 Updated illustration to show new safety decal locations. 5.3 Decals, page ii Revision

5 TLE OF ONTENTS Introduction...i List of Revisions... ii hapter 1: Safety Safety lert Symbols Signal Words General Safety Maintenance Safety Hydraulic Safety Tire Safety attery Safety Welding Precautions Engine Safety High-Pressure Rail Engine Electronics Safety Signs Installing Safety Decals Safety Sign Decals...13 hapter 2: Installation Instructions Removing Swath ompressor from Shipping rate Installing Swath ompressor Installing Frame Installing Reverse Switch and Harness Installing Valve lock onnecting Hydraulics Installing Rocker Switch Installing Shield ssembly...29 hapter 3: Operation ctivating the Swath ompressor Using the Swath ompressor Setting up the Swath ompressor djusting ompression djusting Side Deflectors Locking the Swath ompressor...41 hapter 4: Maintenance Removing Swath ompressor Shield...43 hapter 5: Illustrated Parts Lists Swath ompressor Frame iii Revision

6 TLE OF ONTENTS 5.2 Swath ompressor Hydraulics and Supports M Series Swath ompressor ompletion Decals...56 hapter 6: Reference Torque Specifications SE olt Torque Specifications Metric olt Specifications Metric olt Specifications olting into ast luminum Flare-Type Hydraulic Fittings O-Ring oss (OR) Hydraulic Fittings (djustable) O-Ring oss (OR) Hydraulic Fittings (Non-djustable) O-Ring Face Seal (ORFS) Hydraulic Fittings Tapered Pipe Thread Fittings onversion hart...70 Index Predelivery hecklist iv Revision

7 1 Safety 1.1 Safety lert Symbols This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: TTENTION! EOME LERT! YOUR SFETY IS INVOLVED! arefully read and follow the safety message accompanying this symbol. Why is safety important to you? ccidents disable and kill ccidents cost ccidents can be avoided Figure 1.1: Safety Symbol Revision

8 SFETY 1.2 Signal Words Three signal words, DNGER, WRNING, and UTION, are used to alert you to hazardous situations. Signal words are selected using the following guidelines: DNGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WRNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be used to alert against unsafe practices. UTION Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may be used to alert against unsafe practices Revision

9 SFETY 1.3 General Safety UTION 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 protective clothing and personal safety devices that could be necessary for job at hand. Do NOT take chances. You may need the following: Hard hat Protective footwear with slip-resistant soles Protective glasses or goggles Heavy gloves Wet weather gear Respirator or filter mask e aware that exposure to loud noises can cause hearing impairment or loss. Wear suitable hearing protection devices such as earmuffs or earplugs to help protect against loud noises. Figure 1.2: Safety Equipment Provide a first aid kit for use in case of emergencies. Keep a fire extinguisher on the machine. e sure fire extinguisher is properly maintained. e familiar with its proper use. Keep young children away from machinery at all times. e aware that accidents often happen when Operator is tired or in a hurry. Take time to consider safest way. Never ignore warning signs of fatigue. Figure 1.3: Safety Equipment Figure 1.4: Safety Equipment Revision

10 SFETY Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets. Keep all shields in place. NEVER alter or remove safety equipment. Make sure driveline guards can rotate independently of shaft and can telescope freely. Use only service and repair parts made or approved by equipment manufacturer. Substituted parts may not meet strength, design, or safety requirements Figure 1.5: Safety around Equipment Keep hands, feet, clothing, and hair away from moving parts. NEVER attempt to clear obstructions or objects from a machine while engine is running. Do NOT modify machine. Unauthorized modifications may impair machine function and/or safety. It may also shorten machine s life. To avoid bodily injury or death from unexpected startup of machine, LWYS stop the engine and remove the key from the ignition before leaving the operator s seat for any reason Figure 1.6: Safety around Equipment Keep service area clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment. e sure all electrical outlets and tools are properly grounded. Keep work area well lit. Keep machinery clean. Straw and chaff on a hot engine is a fire hazard. Do NOT allow oil or grease to accumulate on service platforms, ladders, or controls. lean 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. Figure 1.7: Safety around Equipment Revision

11 SFETY 1.4 Maintenance Safety To ensure your safety while maintaining machine: Review operator s manual and all safety items before operation and/or maintenance of machine. Place all controls in Neutral, stop the engine, set the park brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing. Follow good shop practices: Keep service areas clean and dry e sure electrical outlets and tools are properly grounded Keep work area well lit Figure 1.8: Safety around Equipment Relieve pressure from hydraulic circuits before servicing and/or disconnecting machine. Make sure all components are tight and that steel lines, hoses, and couplings are in good condition before applying pressure to hydraulic systems. Keep hands, feet, clothing, and hair away from all moving and/or rotating parts. lear area of bystanders, especially children, when carrying out any maintenance, repairs, or adjustments. Install transport lock or place safety stands under frame before working under machine. If more than one person is servicing machine at same time, be aware that rotating a driveline or other mechanically-driven component by hand (for example, accessing a lubricant fitting) will cause drive components in other areas (belts, pulleys, and knives) to move. Stay clear of driven components at all times. Wear protective gear when working on machine. Wear heavy gloves when working on knife components. Figure 1.9: Equipment NOT Safe for hildren Figure 1.10: Safety Equipment Revision

12 SFETY 1.5 Hydraulic Safety lways place all hydraulic controls in Neutral before dismounting. Make sure that all components in hydraulic system are kept clean and in good condition. Replace any worn, cut, abraded, flattened, or crimped hoses and steel lines. Do NOT attempt any makeshift repairs to hydraulic lines, fittings, or hoses by using tapes, clamps, cements, or welding. The hydraulic system operates under extremely high-pressure. Makeshift repairs will fail suddenly and create hazardous and unsafe conditions Figure 1.11: Testing for Hydraulic Leaks Wear proper hand and eye protection when searching for high-pressure hydraulic leaks. Use a piece of cardboard as a backstop instead of hands to isolate and identify a leak. If injured by a concentrated high-pressure stream of hydraulic fluid, seek medical attention immediately. Serious infection or toxic reaction can develop from hydraulic fluid piercing the skin Figure 1.12: Hydraulic Pressure Hazard Make sure all components are tight and steel lines, hoses, and couplings are in good condition before applying pressure to a hydraulic system Figure 1.13: Safety around Equipment Revision

13 SFETY 1.6 Tire Safety WRNING Service tires safely. tire can explode during inflation which could cause serious injury or death. Follow proper procedures when mounting a tire on a wheel or rim. Failure to do so can produce an explosion that may result in serious injury or death Figure 1.14: Overinflated Tire WRNING Do NOT stand over tire. Use a clip-on chuck and extension hose. Do NOT exceed maximum inflation pressure indicated on tire label. Replace tires that have defects. Replace wheel rims that are cracked, worn, or severely rusted. Never weld a wheel rim. Never use force on an inflated or partially inflated tire. Make sure tire is correctly seated before inflating to Figure 1.15: Safely Inflating Tire operating pressure. If tire is not correctly positioned on rim or is overinflated, tire bead can loosen on one side causing air to escape at high speed and with great force. n air leak of this nature can thrust tire in any direction endangering anyone in area. Make sure all air is removed from tire before removing tire from rim. Do NOT remove, install, or repair a tire on a rim unless you have proper equipment and experience to perform job. Take tire and rim to a qualified tire repair shop Revision

14 SFETY 1.7 attery Safety WRNING Keep all sparks and flames away from batteries, as a gas given off by electrolyte is explosive. Ventilate when charging in enclosed space Figure 1.16: Safety around atteries WRNING Wear safety glasses when working near batteries. Do NOT tip batteries more than 45 to avoid electrolyte loss. attery electrolyte causes severe burns. void contact with skin, eyes, or clothing. Electrolyte splashed into eyes is extremely dangerous. Should this occur, force eye open, and flood with cool, clean water for 5 minutes. all a doctor immediately. If electrolyte is spilled or splashed on clothing or body, neutralize it immediately with a solution of baking soda and water, then rinse with clear water. WRNING To avoid injury from spark or short circuit, disconnect battery ground cable before servicing any part of electrical system. Do NOT operate engine with alternator or battery disconnected. With battery cables disconnected and engine running, a high voltage can be built up if terminals touch frame. nyone touching frame under these conditions would be severely shocked. When working around storage batteries, remember that all of the exposed metal parts are live. Never lay a metal object across terminals because a spark or short circuit will result. Keep batteries out of reach of children. Figure 1.17: Safety around atteries Figure 1.18: Safety around atteries Revision

15 SFETY 1.8 Welding Precautions High currents and voltage spikes associated with welding can cause damage to electronic components. efore welding on any part of windrower or an attached header, disconnect all electronic module harness connections as well as battery cables. Refer to your Dealer for proper procedures Revision

16 SFETY 1.9 Engine Safety WRNING Do NOT use aerosol starting aids such as ether. Such use could result in an explosion and personal injury. UTION On initial start-up of a new, serviced, or repaired engine, always be ready to stop the engine in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine. Do NOT bypass or disable automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage. ontact your Dealer for repairs and adjustments. Inspect the engine for potential hazards. efore starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that people clear the area. ll protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around parts carefully. If a warning tag is attached to engine start switch or to controls, do NOT start engine or move controls. onsult with person who attached warning tag before engine is started. Start engine from operator s compartment. lways start engine according to procedure that is described in Starting Engine section of operator s manual. Knowing correct procedure will help to prevent major damage to engine components and prevent personal injury. To ensure that the jacket water heater (if equipped) and/or lubricant oil heater (if equipped) is working correctly, check the water temperature gauge and/or oil temperature gauge during heater operation. Engine exhaust contains products of combustion, which can be harmful to your health. lways start the engine and operate the engine in a well-ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside. Engine exhaust gases become very hot during operation and can burn people and common materials. Stay clear of the rear of machine and avoid exhaust gases when engine is running. NOTE: The engine may be equipped with a device for cold starting. If the engine will be operated in very cold conditions, then an additional cold starting aid may be required High-Pressure Rail UTION ontact with high-pressure fuel may cause fluid penetration and burn hazards. High-pressure fuel spray may cause a fire hazard. Failure to follow these instructions may cause personal injury or death. efore disconnecting fuel lines or any other components under high-pressure between the fuel pump and high-pressure common rail fuel system, confirm that the fuel pressure is relieved Revision

17 SFETY Engine Electronics WRNING Tampering with electronic system installation or original equipment manufacturer (OEM) wiring installation can be dangerous and could result in personal injury or death and/or engine damage. WRNING Electrical Shock Hazard. The electronic unit injectors use D voltage. The engine control module (EM) sends this voltage to the electronic unit injectors. Do NOT come in contact with the harness connector for the electronic unit injectors while engine is operating. Failure to follow this instruction could result in personal injury or death. This engine has a comprehensive, programmable engine monitoring system. The EM has the ability to monitor engine operating conditions. If conditions exceed the allowable range, the EM will initiate immediate action. The following actions are available for engine monitoring control: Warning Derate Shut down The following monitored engine operating conditions have the ability to limit engine speed and/or engine power: Engine coolant temperature Engine oil pressure Engine speed Intake manifold air temperature The engine monitoring package can vary for different engine models and different engine applications. However, monitoring system and engine monitoring control will be similar for all engines. Together, two controls provide engine monitoring function for specific engine application Revision

18 SFETY 1.10 Safety Signs Keep safety signs clean and legible at all times. Replace safety signs that are missing or illegible. If original part on which a safety sign was installed is replaced, be sure repair part also bears current safety sign. Replacement safety signs are available from your MacDon Dealer Parts Department Figure 1.19: Operator s Manual Decal Installing Safety Decals 1. lean and dry installation area. 2. Decide on exact location before you remove decal backing paper. 3. Remove smaller portion of split backing paper. 4. Place decal in position and slowly peel back remaining paper, smoothing decal as it is applied. 5. Prick small air pockets with a pin and smooth out Revision

19 SFETY 1.11 Safety Sign Decals MD # General hazard pertaining to machine operation and servicing. UTION Read the operator s manual and follow all safety instructions. If you do not have a manual, obtain one from your Dealer. Do not allow untrained persons to operate the machine. Review safety instructions with all Operators every year. Ensure that all safety signs are installed and legible. Make certain everyone is clear of machine before starting engine and during operation. Keep riders off the machine. Keep all shields in place and stay clear of moving parts. Disengage header drive, put transmission in Neutral, and wait for all movement to stop before leaving operator s position. Stop the engine and remove the key from ignition before servicing, adjusting, lubricating, cleaning, or unplugging machine. Engage locks to prevent lowering of header or reel before servicing in the raised position. Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law. MD # HIGH PRESSURE HYDRULIS DO NOT GO NER LEKS High pressure oil easily punctures skin causing serious injury, gangrene, or death. If injured, seek emergency medical help. Immediate surgery is required to remove oil. Do not use finger or skin to check for leaks. Lower load or relieve hydraulic pressure before loosening fittings. Figure 1.20: MD # Figure 1.21: MD # Revision

20 SFETY MD # PINH POINT - MOVING PRTS STND LER Figure 1.22: MD # MD # LOK - SWTH OMPRESSOR DEK Engage lock when swath compressor is not in use. Lock compressor shield before servicing or working under the windrower. Lock compressor shield before operating in engineforward mode Figure 1.23: MD # Revision

21 2 Installation Instructions 2.1 Removing Swath ompressor from Shipping rate Follow these steps to unpack the swath compressor from the shipping crate. Retain all parts for installation unless instructed to discard. 1. Remove the top cross members () from shipping crate and discard Figure 2.1: Shipping onfiguration - ross Members - Front - Rear 2. Remove four bolts () securing deflector () to left and right supports, and remove deflector (). Retain hardware for reinstallation Figure 2.2: Front Deflector Revision

22 INSTLLTION INSTRUTIONS 3. Remove four bolts and nuts () and remove two bar clamps () from front pivot support () Remove bolts and nuts () securing front support () to the left and right supports. 5. Remove hairpins () from pivot pins (D) and pull pivot pins to disengage from side supports. Remove front pivot support (). Figure 2.3: Front Pivot Support D Remove nut and bolt () and remove pivot pin () from the left support. NOTE: If necessary, loosen handle () and adjust deflector so pin () can be removed. Figure 2.4: Front Pivot Support Figure 2.5: Left Support Revision

23 INSTLLTION INSTRUTIONS 7. Remove lynch pin () and washer () from pivot pin (). 8. Remove pin () securing cylinder rod end to rock shaft. NOTE: If necessary, lift left support (E) out of frame so pin () can slide out. E 9. Release latch (D) and remove left support (E) complete with cylinder and hydraulic hoses. 10. Remove shipping wire securing hoses to support. D Figure 2.6: Left Support 11. Remove nut and bolt () and remove pivot pin () from right support. D NOTE: If necessary, loosen handle () and adjust deflector so pin () can be removed. 12. Remove the right support (D) Remove rock shaft (). 14. Remove four lag screws () securing swath compressor to shipping crate. Discard lag screws and washers. 15. Leave swath compressor on shipping pallet. Figure 2.7: Right Support Figure 2.8: Rock Shaft Revision

24 INSTLLTION INSTRUTIONS 2.2 Installing Swath ompressor Follow these steps to install the swath compressor onto a M155, M155E4, or M205 Self-Propelled Windrower. The swath compressor weighs approximately 180 kg (400 lb.) Installing Frame 1. Loosely attach bar clamps () to each side of front support with two M10 bolts and nuts () Position front support () below the windrower frame at the cab end and adjust bar clamps () to hold support in place. 3. Tighten two bolts () on bar clamps () to hold front support in place, do NOT fully tighten. Figure 2.9: Front Support Figure 2.10: Front Support on Windrower Frame 4. Locate left support () onto the left side of windrower frame as shown, and temporarily clamp in position. 5. Install M10 x 35 mm bolt () and nut through bar clamp () and M10 x 20 mm bolt (D) and nut through front support (E). Do NOT fully tighten bolts. E D Figure 2.11: Left Support (Front) Revision

25 INSTLLTION INSTRUTIONS 6. Secure rear of left support with M10 x 35 mm bolt () and nut through existing hole in windrower frame. Do NOT fully tighten. 7. t rear of left support, pick up hole in bracket () and drill hole through frame with a 10 mm (13/32 in.) drill. 8. Install M10 x 35 mm bolt () and nut through bracket () and frame Figure 2.12: Left Support (Rear) 9. Remove clamp at aft end of right support and discard. Retain hardware. 10. Remove and discard hardware at aft inboard bracket location. 11. Locate right support () onto the right side of windrower frame as shown, and temporarily clamp in position. 12. Install M10 x 35 mm bolt () and nut through bar clamp () and M10 x 20 mm bolt (D) and nut through front support (E). Do NOT fully tighten bolts. E D Secure rear of right support with M10 x 35 mm bolt () and nut through existing hole in windrower frame. Do NOT fully tighten. 14. t rear of right support, pick up hole in bracket () and drill hole through frame with a 10 mm (13/32 in.) drill. 15. Install M10 x 35 mm bolt () and nut through bracket () and existing hole in windrower frame. Do NOT fully tighten. Figure 2.13: Right Support (Front) Figure 2.14: Right Support (Rear) Revision

26 INSTLLTION INSTRUTIONS 16. Position rock shaft lift () inside left and right support channels. Insert pivot pins () on both sides, and secure them with M10 x 20 mm bolts and nuts (). Tighten bolts Figure 2.15: Rock Shaft 17. Ensure sensor arm () engages bolt () on left rock shaft lift support, and ensure it is not bent or damaged Figure 2.16: Sensor on Left Support Revision

27 INSTLLTION INSTRUTIONS 18. Tighten six bolts () and torque to 39 Nm (29 lbf ft). 19. Ensure front clamps () engage windrower frame as much as possible and torque four bolts () to 39 Nm (29 lbf ft) Figure 2.17: View from below Windrower Installing Reverse Switch and Harness 1. Install reverse switch () onto existing bracket as shown with two M6 x 16 mm bolts and flanged lock nuts (). lign switch support () with existing bracket before tightening nuts Figure 2.18: Reverse Switch (View From Top) Revision

28 INSTLLTION INSTRUTIONS 2. Open left cab-forward side platform. 3. Locate harness bundle that contains three-pin plug P97 (). If plug is attached to a pressure sensor, remove the plug. Otherwise cut cable tie securing P97 () to wire bundle Figure 2.19: Windrower hassis Harness NOTE: P97 () may be in use on a windrower equipped with a reel circuit pressure transducer. If so, disable the reel circuit pressure transducer in the DM Figure 2.20: Location of P97 on Windrower hassis Harness (View from Left) 4. Route swath compressor completion harness () along forward cross-member. onnect swath compressor connector P97 () to plug P97 on the chassis harness shown in Figure 2.20, page 22. E NOTE: P97 may need to be repositioned underneath the windrower. D 5. onnect swath compressor height sensor plug P97 () to existing connector P560 on the swath compressor harness. 6. onnect swath compressor reverse switch plug P108 (D) to reverse switch connector DTM04-2P. 7. Route single wire (E) to main system harness and into cab at the left rear corner. Figure 2.21: Swath ompressor ompletion Harness Revision

29 INSTLLTION INSTRUTIONS 8. Enter cab and locate the manual holder () beneath the trainer s seat. The WM () is just above the manual holder Figure 2.22: Manual Holder and WM 9. Gently move the upholstery () on both sides of the manual holder (). Remove the two nuts () and remove manual holder Figure 2.23: Upholstery and Hardware 10. Remove P35 plug () from the WM Figure 2.24: WM and Wiring Harnesses Revision

30 INSTLLTION INSTRUTIONS 11. Retrieve single wire () from swath compressor and insert into position 24 () on harness side of P35 plug. Secure wire () to existing harness () with plastic cable tie. 12. ttach plug P35 to WM Figure 2.25: P35 Plug 13. Reposition manual storage () and secure with two nuts (). Replace upholstery (). 14. Secure swath compressor harness to existing harness above forward cross member Figure 2.26: Upholstery and Hardware Installing Valve lock 1. Remove fitting () and plug () from the lift manifold block, and retain for reinstallation. 2. pply grease to O-rings (supplied with valve block) and install them in the countersunk port holes where the plug and fitting were removed Figure 2.27: Lift Manifold lock Revision

31 INSTLLTION INSTRUTIONS 3. ssemble smooth side of new valve block () to existing valve bock with four 3/8 in. bolts (D) provided. Use the longer bolts if there are two existing valve blocks. NOTE: If installing onto a windrower paired with a draper header with reel fore-aft, the windrower will already have an auxiliary valve block. The new valve block () is mounted next to the existing one. 4. Torque bolts to 34 Nm (25 lbf ft). 5. Install fitting () and plug () (removed in Step 1, page 24) into new valve block. If plug () is damaged on removal, an extra plug is provided in the kit. D Figure 2.28: New Valve lock Install the 90 elbow fitting () into port K on the new valve block (). K 7. onnect plugs P55 () and P59 () from the windrower chassis harness to the solenoids on the new valve block () as shown in the illustration at right. Figure 2.29: New Valve lock Figure 2.30: New Valve lock Revision

32 INSTLLTION INSTRUTIONS onnecting Hydraulics 1. Remove quick disconnect couplers () and elbows from the three hoses on swath compressor, and discard Figure 2.31: Quick Disconnects 2. Remove hose () and fitting () from charge pump () Figure 2.32: M Series Hydraulics 3. Install tee () in its place. Reconnect existing hose () to tee (). 4. Retrieve new hose () from shipment and connect to tee () and to hose (D) from pressure-reducing valve forward fitting. D Figure 2.33: Hose onnections (View from under Windrower) Revision

33 INSTLLTION INSTRUTIONS 5. onnect hose () from barrel end of cylinder () to elbow () on valve block. E D 6. Remove and discard plug from tank at location (D). Install elbow (E). 7. onnect hose (F) from pressure reducing valve (G) to elbow (E) on tank. F G Figure 2.34: Hose onnections Installing Rocker Switch 1. Inside the windrower cab, remove cover () from the console by removing five screws () Figure 2.35: onsole ontrol Plate 2. Remove the knockout in cover () for the rocker switch and file down the burrs Figure 2.36: onsole ontrol Plate Revision

34 INSTLLTION INSTRUTIONS 3. Install rocker switch () (MD #109575) into the cover. The side with the prongs should be next to the operator s seat Figure 2.37: Rocker Switch 4. Install the rocker switch into plug (). The plug comes prewired into the windrower console Figure 2.38: Rocker Switch 5. Reinstall the cover () with five screws (). NOTE: Refer to 3.1 ctivating the Swath ompressor, page 35 to program the cab display module for control of swath compressor functions Figure 2.39: onsole ontrol Plate Revision

35 INSTLLTION INSTRUTIONS Installing Shield ssembly UTION To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator s seat for any reason. 1. Start engine and raise header legs. Press SWTH OMPRESSOR LOWER switch () to fully retract swath compressor cylinder. 2. Shut off engine and remove key Figure 2.40: Windrower onsole switches 3. Position forklift with forks over front of compressor shield, and attach lifting straps () through front and back of shield frame. Lift swath compressor shield out of shipping crate Figure 2.41: Lifting Swath ompressor Shield Revision

36 INSTLLTION INSTRUTIONS 4. pproach windrower from front and move shield () under windrower. Lower to ground. Remove lifting straps and back forklift clear of windrower. Figure 2.42: ompressor Shield under Windrower To make connecting lowering arms easier, turn lock handle () counterclockwise and rotate rock shaft () so that supports are vertical Figure 2.43: Rock Shaft and Lock Revision

37 INSTLLTION INSTRUTIONS 6. Ensure bushings () are installed onto pins () on both sides of rock shaft. 7. Position floor jack or equivalent under swath compressor shield cross member (). G 8. Raise shield sufficiently to connect lowering arm (D) to pin () on rock shaft (G). 9. Secure lowering arm (D) to rock shaft (G) with washer (E) and lynch pin (F). Repeat on opposite side. D D F E Figure 2.44: Shield Installation 10. Loosen handle () and remove three bolts and nuts () from side deflector (). Retain bolts and nuts Figure 2.45: Side Deflector Shipping Position Revision

38 INSTLLTION INSTRUTIONS 11. Rotate side deflector () to working position, and secure it to compressor shield with three bolts and nuts () from previous step. Install bolts with heads facing the crop. 12. Torque nuts to 22 Nm (15 lbf ft). 13. Position the side deflector and tighten the adjustment handle (). Repeat on opposite side Figure 2.46: Side Deflector Working Position 14. Push down on rear () of shield and another installer lifts the front (D). 15. lign ball joints () with pins () at front of shield, and insert pins (). Use a rubber mallet if pins are difficult to install. D Figure 2.47: Front Pivot Pins 16. Install hairpin () to secure pivot pin (). Repeat on opposite side Figure 2.48: Front Pivot Pins Revision

39 INSTLLTION INSTRUTIONS 17. lign rod end of hydraulic cylinder () with holes in rock shaft and secure with pin (). Ensure plate on pin engages slot (E) in rock shaft support. 18. Secure pin with washer () and lynch pin (D). D E Figure 2.49: Rock Shaft 19. Position front deflector () onto front support () and remove the two existing bolts () that interfere with the deflector. Do NOT discard. 20. Secure deflector () to support with two M10 hex head bolts () removed in previous step and four M10 hex head bolts (D) that secured deflector to frame for shipping purposes. enter deflector with main shield before tightening bolts. D D Figure 2.50: Front Deflector (View from under Shield) Revision

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41 3 Operation 3.1 ctivating the Swath ompressor n optional swath compressor (MD #2061) is available through your MacDon Dealer. NOTE: DM5 (version 512 or later) and WM2 (version 237 or later), or WM3 (version 116 or later), are required to operate the swath compressor. The Double Windrow ttachment (DW) system must be disabled in the DM when setting up the swath compressor. Users can activate and set up the swath compressor via in-cab controls without a header attached to the windrower. Use the following procedure when installing and setting up the swath compressor. UTION heck to be sure all bystanders have cleared the area. 1. Turn ignition key to RUN, or start the engine. 2. Press PROGRM () and SELET () on cab display module (DM) to enter programming mode. WINDROWER SETUP? is displayed on the upper line. NO/YES is displayed on the lower line. 3. Press right arrow () to select YES. Press SELET (). SET KNIFE SPEED? is displayed on the upper line. XXX MXXX WINDROWER SETUP? NO/YES Press SELET () until SWTH OMPR INSTLL? is displayed on the upper line. Figure 3.1: DM Programming uttons NO/YES is displayed on the lower line. 5. Press right arrow () to select YES. Press SELET (). 6. Press SELET () until LIRTE SENSORS is displayed on upper line. NO/YES is displayed on lower line. 7. Press right arrow () to select YES. Press SELET (). TO LIRTE SELET is displayed on upper line. HEDER HEIGHT is displayed on lower line. 8. Press right arrow () to scroll through choices until SWTH OMPR HT is displayed. Press SELET (). SWTH SENSOR L is displayed on upper line. XXX MXXX SWTH OMPR INSTLL? NO/YES Figure 3.2: Swath ompressor ontrols Revision

42 OPERTION SWTH UP TO STRT is displayed on lower line. 9. Press switch () on console to raise swath compressor. LIRTING SWTH is displayed on upper line. FORM UP and flashing HOLD is displayed on lower line until system has completed reading signal with swath compressor fully raised. SWTH FORM UP and DONE (with buzzer) is displayed on lower line when complete. SWTH SENSOR L is displayed on upper line. PRESS SWTH DOWN is displayed on lower line. 10. Press switch () on console to lower swath compressor. LIRTING SWTH is displayed on upper line. FORM DOWN and HOLD is displayed on lower line. SWTH FORM OMPLETE flashes for 2 seconds on lower line (with buzzer) when calibration is finished. 11. Press PROGRM () to exit programming mode or press SELET () to proceed to next windrower setup action. Figure 3.3: Swath ompressor Switch XXX MXXX WINDROWER SETUP? NO/YES Figure 3.4: DM Programming uttons Revision

43 OPERTION 3.2 Using the Swath ompressor The following topic explains how to use the swath compressor, and describes the automated raise/lower functions. UTION To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator s seat for any reason. 1. Rotate handle () on the left rear support counterclockwise to disengage lock. IMPORTNT: Lock prevents swath compressor from lowering inadvertently when not in use, either due to operator error or loss of hydraulic pressure. Engage lock when operating in engineforward mode. Disengage lock before using swath compressor Figure 3.5: Swath ompressor Lock UTION heck to be sure all bystanders have cleared the area. 2. Start the windrower in cab-forward mode. 3. Press SELET switch () on DM to show SWTH OMPR HT () on display. Height is displayed using an arbitrary scale from 0 to 10. Fully raised is 0. XXX MXXX # SWTH OMPR HT Figure 3.6: DM Display Revision

44 OPERTION 4. Lower swath compressor by pressing button () on the operator s console, and raise it by pressing button (). The DM display indicates the position of the swath compressor. Release the switch to stop movement at the desired height. NOTE: The last position set with the console buttons becomes the target height. When an adjustment is made, the display shows the target value. The system immediately adjusts to attain the target position. fter the last adjustment, the display shows target value for 5 seconds then the display reverts to the previous screen Figure 3.7: Operator s onsole Swath compressor automated functions: header engaged, cab-forward When ground speed higher than 2.5 km/h (1.6 mph) is detected, the swath compressor lowers to target height. When ground speed transitions through 1.6 km/h (1 mph) during deceleration, the swath compressor is fully raised. When ground speed is faster than 1.6 km/h (1 mph) and the HEDER ENGGE switch is OFF, the swath compressor will fully raise. The swath compressor remains inactive in engine-forward mode Setting up the Swath ompressor Operate windrower in the crop and use the following procedure to determine the settings for the crop and crop conditions. UTION To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator s seat for any reason. 1. Rotate handle () counterclockwise to disengage lock on the left rear support. UTION Park on a flat, level surface with the ground speed lever in N-DETENT position and the steering wheel in locked position (centered). Wait for the DM to beep and display an In Park message to confirm the park brakes have engaged. 2. Start the engine, set ground speed lever (GSL) in N-DETENT, and ensure that the header is disengaged Figure 3.8: Swath ompressor Lock Revision

45 OPERTION 3. djust swath compressor position with controls () and () on the console to the target (preferred) operating height. Set to 6 () if there is no preferred operating height. 4. Engage and then disengage the header. The swath compressor will raise fully. 5. Engage header and begin cutting crop. When ground speed exceeds 2.5 km/h (1.6 mph), the swath compressor will lower to the target (preferred) height (). 6. Stop the windrower and check the formation of the windrow. If necessary, adjust the target height (). If the edges of the windrow are not sufficiently pressed into the stubble, adjust side deflectors. Refer to djusting Side Deflectors, page 40. If swath compressor shield raises too easily in dense windrows, adjust compression. Refer to djusting ompression, page 40. Figure 3.9: Operator s onsole XXX MXXX 6 SWTH OMPR HT Figure 3.10: Display Revision

46 OPERTION djusting ompression The swath compressor automatically raises when the load on the shield exceeds the compression setting. When load decreases, the compressor deck automatically returns to the target height. The compression setting is set at the factory to suit most crop conditions and can be adjusted as follows: 1. Loosen jam nut () to allow the adjustment knob () to turn. Do NOT remove nut. Turn adjuster knob () clockwise to increase compression for a more compact windrow and higher wind resistance. Turn the adjuster knob () counterclockwise to decrease compression and minimize crop shelling. NOTE: Start with lowest compression (adjuster knob fully counterclockwise) and increase setting in 1/2 turn increments as required. 2. Tighten jam nut () sufficiently to maintain setting Figure 3.11: ompression djustment djusting Side Deflectors To reduce wind damage to the windrow, adjust side deflectors to ensure edges are tucked in and anchored to the stubble. 1. To adjust swath compressor side deflectors (), loosen handles () and move deflectors to the desired position. To ensure windrow placement is centered, set both side deflectors to the same position. 2. Tighten handles () when adjustment is complete Figure 3.12: Swath ompressor Side Deflectors Revision

47 OPERTION Locking the Swath ompressor The swath compressor lock is located on the left cab-forward side of the swath compressor frame. When engaged, the lock prevents the compressor shield from lowering. 1. Turn lock handle () clockwise to engage the swath compressor lock under the following conditions: Swath compressor is not in use Windrower is being serviced Windrower is in engine-forward mode 2. Turn handle () counterclockwise to disengage the lock before operating the swath compressor Figure 3.13: Swath ompressor Lock Revision

48

49 4 Maintenance The swath compressor does not require any scheduled maintenance or servicing. If necessary to replace components, refer to 5 Illustrated Parts Lists, page 45 in this manual. 4.1 Removing Swath ompressor Shield Windrower service or maintenance procedures may require access under the machine. Do NOT sit on swath compressor shield to service the windrower. Remove the shield as follows: UTION To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator s seat for any reason. 1. Disengage swath compressor lock (). 2. Start windrower, fully lower swath compressor, turn off windrower, and remove key t front of swath compressor, remove hairpin () from pivot pin () on both sides of frame. Figure 4.1: Swath ompressor Lock Figure 4.2: Forward Pivot Pin Revision

50 MINTENNE 4. Push down on rear () of shield and another person supports the front (D). Pull pivot pins () from ball joints () on both sides of frame. To avoid misplacing parts, reinstall hairpins into pivot pins. 5. Lower forward end of shield to ground. D Figure 4.3: Front Pivot Pins 6. Support shield under support () at back end with a floor jack (or equivalent). 7. Remove lynch pins (F) and washers (E) from pins () on both ends of rock shaft. G 8. Remove lowering arms (D) from rock shaft (G). 9. Store bushings (), washers (E) and lynch pins (F) on pins (). D 10. Lower back end of shield to ground and move jack away from work area. 11. Start windrower and fully raise swath compressor lift mechanism. Slowly drive windrower away from shield. D F E Figure 4.4: Disconnecting Lowering rms Revision

51 5 Illustrated Parts Lists This section lists the replacement parts for the M Series windrower swath compressor Revision

52 ILLUSTRTED PRTS LISTS 5.1 Swath ompressor Frame 7 1 J E F 7 5 E D E D E 6 D J F 9 G E H 10 F E Revision

53 ILLUSTRTED PRTS LISTS Ref Part Number Description Qty SWTH OMPRESSOR FRME SUPPORT DEFLETORS, WELD'T DEFLETOR LH WELD'T DEFLETOR RH WELD'T SHEET SWTH OMPRESSOR DIS RETINER USHING FLNGE RM LOWER UMPER RUER NGLE RER TOP SSEMLY HNDLE SUPPORT RER DEFLETOR, LH SUPPORT RER DEFLETOR, RH STRP JOINING 2 Serial Number Revision

54 ILLUSTRTED PRTS LISTS 7 1 J E F 7 5 E D E D E 6 D J F 9 G E H 10 F E Revision

55 ILLUSTRTED PRTS LISTS Ref Part Number Description Qty SWTH OMPRESSOR FRME (ONTINUED) OLT HEX SO M6 X 1 X R NUT HEX FLG TR LO M6 X 1-8-2L SREW FLG TN HD M10 X J 49 D WSHER FLT 31 E NUT HEX NYLO M10 X L 51 F WSHER FLT REG M10-200HV-3L 20 G OLT RHSSN M12 X 1.75 X L 2 H WSHER FLT 2 J NUT HEX FLG TR LO M8 X L 2 Serial Number Revision

56 ILLUSTRTED PRTS LISTS 5.2 Swath ompressor Hydraulics and Supports P P 30 M P N R Q P P Q R N 13 P M M P 4 36 P R P R J H 5 G 6 P S N R K N P R F P E D N R 4 P L R 27 4 P Revision

57 ILLUSTRTED PRTS LISTS Ref Part Number Description Qty HYDRULIS ND SUPPORTS SUPPORT LH WELD T YLINDER LEVER LOK PIN WELD T PIN PIVOT, WELD'T ROTRY SENSOR HV RM SENSOR VLVE PRESSURE REDUING FITTING ELOW 90 HYD FITTING DPTER GROMMET PIN YLINDER, WELD'T PIN LYNH USHING FLNGE SLEEVE HOSE HYD,.25 IN. I.D., 1400 MM LG, 100R17, METL REIN HOSE HYD,.25 IN. I.D., 1220 MM LG, 100R17, METL REIN HOSE HYD,.25 IN. I.D., 1200 MM LG, 100R17, METL REIN HOSE HYD,.25 IN. I.D., 490 MM LG, 100R17 METL REIN OUPLER MLE HYD. 3/8 IN. FLT FE SEL KIT OUPLER FEMLE HYD. 3/8 IN. FLT FE OUPLER HYDRULI, 1/2 IN FEMLE FF FITTING ELOW 90 HYD W O-RING FITTING DPTER FSTENER FIR TREE MT W/ TIE HRNESS SWTH OMPRESSOR DEL DOWN FORE DEL UP LOK SUPPORT RH WELD'T SUPPORT FRONT PIVOT, WELD'T 1 Serial Number Revision

58 Revision D E F G H J K L M M M N N N N P P P P P P P P P Q Q P N R R R R R R R R S 13 P P P P ILLUSTRTED PRTS LISTS

59 ILLUSTRTED PRTS LISTS Ref Part Number Description Qty HYDRULIS ND SUPPORTS (ONTINUED) R LMP PIN PIVOT PIN HIR PIN OTTER 3/16 DI X 1.25 ZP ROKSHFT LIFT, WELD'T DEFLETOR FRONT R LMP FITTING ELOW 45 HYD FSTENER LE TIE, LK, 305 MM LG FSTENER LE TIE, LK, 160 MM LG 1 Serial Number OLT HEX FLG HD TFL M10 X 1.5 X L NUT HEX M10 X L OLT HEX HD M10 X 1.5 X L 1 D WSHER ONIL SPRING 1/2 IN. 1 E WSHER FLT REG M12-300HV-3L 1 F NUT HEX M12 X L 2 G OLT RHSN TFL M5 X 0.8 X L 2 H WSHER FLT SE 7/32 I.D. X 7/16 IN. O.D. ZP 2 J NUT HEX NYLO M5 X L 2 K OLT RHSN M6 X 1 X L 2 L NUT HEX FLG TR LO M6 X 1-8-2L 2 M WSHER SE FLT 13/16 I.D. X 1.5 IN. O.D. ZP 3 N OLT RHSN M10 X 1.5 X L 4 P NUT HEX FLG TR LO M10 X L 12 Q OLT RHSN M10 X 1.5 X L 2 R OLT RHSN TFL M10 X 1.5 X L 8 S SREW PN HD M6 X 1 X L 2 1. Shipped in manual bag Revision

60 ILLUSTRTED PRTS LISTS M Series Swath ompressor ompletion This supplemental parts list is applicable only to M155, M155E4, and M205 Windrowers. 9 F 1 D E Revision

61 ILLUSTRTED PRTS LISTS Ref Part Number Description Qty SWTH OMPRESSOR OMPLETION PKGE SWITH PROXIMITY SUPPORT F/R SWITH HRNESS 5-SERIES SWTH OMP HOSE HYD,.375 IN. I.D., 200 MM LG, 100R17, METL REIN VLVE LOK UX LIFT (REEL FORE FT-DW) PLUG HEX W O-RING FITTING ELOW 90 HYD FITTING TEE HYD STR THD RUN TEE W O-RING FITTING ELOW 90 HYD FSTENER LE TIE, LK, 160 MM LG SWITH ROKER, ON-OFF-ON 1 Serial Number OLT HEX HD M5 X 0.8 X L NUT HEX NYLO M5 X L OLT RHSN M6 X 1 X L 2 D NUT HEX FLG TR LO M6 X 1-8-2L 2 E OLT HH 3/8 N X 5.5 LG GR 5 ZP 4 F WSHER FLT LRGE M5-200HV-2L Revision

62 ILLUSTRTED PRTS LISTS 5.3 Decals x Revision

63 ILLUSTRTED PRTS LISTS Ref Part Number Description Qty DEL HIGH PRESSURE FLUID DEL DOWN FORE DEL DEK LOWER LOK (may not be exactly as shown) DEL PINH POINT DEL RED MNUL 1 Serial Number Revision

64

65 6 Reference 6.1 Torque Specifications The following tables provide correct torque values for various bolts, cap screws, and hydraulic fittings. Tighten all bolts to torque values specified in charts (unless otherwise noted throughout this manual). Replace hardware with same strength and grade of bolt. Use torque value tables as a guide and periodically check tightness of bolts. Understand torque categories for bolts and cap screws by using their identifying head markings. Jam nuts When applying torque to finished jam nuts, multiply the torque applied to regular nuts by f=0.65. Self-tapping screws Standard torque is to be used (NOT to be used on critical or structurally important joints) SE olt Torque Specifications Torque values shown in following tables are valid for non-greased, or non-oiled threads and heads; therefore, do NOT grease or oil bolts or cap screws unless otherwise specified in this manual. Table 6.1 SE Grade 5 olt and Grade 5 Free Spinning Nut Nominal Size () Torque (lbf ft) Torque (Nm) (*lbf in) Min. Max. Min. Max. 1/ *106 *117 5/ *218 *241 3/ / / / / / / Figure 6.1: olt Grades - Nominal Size - SE-5 D - SE-8 D - SE Revision

66 REFERENE Table 6.2 SE Grade 5 olt and Grade F Distorted Thread Nut Nominal Size () Torque (lbf ft) Torque (Nm) (*lbf in) Min. Max. Min. Max. 1/ *72 *80 5/ *149 *164 3/ / / / / / Figure 6.2: olt Grades - Nominal Size - SE-5 D - SE-8 D - SE / Table 6.3 SE Grade 8 olt and Grade G Distorted Thread Nut Nominal Size () Torque (lbf ft) Torque (Nm) (*lbf in) Min. Max. Min. Max. 1/ *150 *165 5/ / / D 1/ / / / Figure 6.3: olt Grades - Nominal Size - SE-5 - SE-8 D - SE / Revision

67 REFERENE Table 6.4 SE Grade 8 olt and Grade 8 Free Spinning Nut Nominal Size () Torque (lbf ft) Torque (Nm) (*lbf in) Min. Max. Min. Max. 1/ *150 *165 5/ / / / / / / / Metric olt Specifications Table 6.5 Metric lass 8.8 olts and lass 9 Free Spinning Nut Figure 6.4: olt Grades - Nominal Size - SE-5 D - SE-8 D - SE Nominal Size () Torque (Nm) Torque (lbf ft) (*lbf in) Min. Max. Min. Max *13 * *20 * *29 * *59 * *101 * Figure 6.5: olt Grades Revision

68 REFERENE Table 6.6 Metric lass 8.8 olts and lass 9 Distorted Thread Nut Nominal Size () Torque (Nm) Torque (lbf ft) (*lbf in) Min. Max. Min. Max *9 * *14 * *20 * *40 * *69 * *167 * Table 6.7 Metric lass 10.9 olts and lass 10 Free Spinning Nut Nominal Size () Torque (Nm) Torque (lbf ft) (*lbf in) Min. Max. Min. Max *18 * *27 * *41 * *82 * *140 * Figure 6.6: olt Grades Figure 6.7: olt Grades Revision

69 REFERENE Table 6.8 Metric lass 10.9 olts and lass 10 Distorted Thread Nut Nominal Size () Torque (Nm) Torque (lbf ft) (*lbf in) Min. Max. Min. Max *12 * *19 * *28 * *56 * *95 * Figure 6.8: olt Grades Metric olt Specifications olting into ast luminum Table 6.9 Metric olt olting into ast luminum olt Torque Nominal Size () 8.8 (ast luminum) 10.9 (ast luminum) Nm lbf ft Nm lbf ft M3 1 M M M M M M M14 M16 Figure 6.9: olt Grades Revision

70 REFERENE Flare-Type Hydraulic Fittings 1. heck flare () and flare seat () for defects that might cause leakage. 2. lign tube () with fitting (D) and thread nut (E) onto fitting without lubrication until contact has been made between flared surfaces. 3. Torque fitting nut (E) to specified number of flats from finger tight (FFFT) or to a given torque value in Table 6.10, page Use two wrenches to prevent fitting (D) from rotating. Place one wrench on fitting body (D), and tighten nut (E) with other wrench to torque shown. 5. ssess final condition of connection. E Figure 6.10: Hydraulic Fitting D Table 6.10 Flare-Type Hydraulic Tube Fittings Torque Value 2 Flats from Finger Tight (FFFT) SE Dash Size Thread Size (in.) Swivel Nut or Nm lbf ft Tube Hose -2 5/ / / / / / /2-8 3/ /2-10 7/ /2 1-1/ / /2 1-1/ / /2 1-1/ / / / / / Torque values shown are based on lubricated connections as in reassembly Revision

71 REFERENE O-Ring oss (OR) Hydraulic Fittings (djustable) 1. Inspect O-ring () and seat () for dirt or obvious defects. 2. ack off lock nut () as far as possible. Ensure that washer (D) is loose and is pushed toward lock nut () as far as possible. 3. heck that O-ring () is NOT on threads and adjust if necessary. 4. pply hydraulic system oil to O-ring (). D Figure 6.11: Hydraulic Fitting 5. Install fitting () into port until back up washer (D) and O-ring () contact part face (E). 6. Position angle fittings by unscrewing no more than one turn. 7. Turn lock nut () down to washer (D) and tighten to torque shown. Use two wrenches, one on fitting () and other on lock nut (). 8. heck final condition of fitting. D E Figure 6.12: Hydraulic Fitting Revision

72 REFERENE Table 6.11 O-Ring oss (OR) Hydraulic Fittings (djustable) Torque Value 3 SE Dash Size Thread Size (in.) Nm lbf ft (*lbf in) -2 5/ * / * / / / / / / / / / / / Torque values shown are based on lubricated connections as in reassembly Revision

73 REFERENE O-Ring oss (OR) Hydraulic Fittings (Non-djustable) 1. Inspect O-ring () and seat () for dirt or obvious defects. 2. heck that O-ring () is NOT on threads and adjust if necessary. 3. pply hydraulic system oil to O-ring. 4. Install fitting () into port until fitting is hand-tight. 5. Torque fitting () according to values in Table 6.12, page heck final condition of fitting. Figure 6.13: Hydraulic Fitting Table 6.12 O-Ring oss (OR) Hydraulic Fittings (Non-djustable) SE Dash Size Thread Size (in.) Torque Value 4 Nm lbf ft (*lbf in) -2 5/ * / * / / / / / / / / / / / Torque values shown are based on lubricated connections as in reassembly Revision

74 REFERENE O-Ring Face Seal (ORFS) Hydraulic Fittings 1. heck components to ensure that sealing surfaces and fitting threads are free of burrs, nicks, scratches, or any foreign material Figure 6.14: Hydraulic Fitting 2. pply hydraulic system oil to O-ring (). 3. lign tube or hose assembly so that flat face of sleeve () or () comes in full contact with O-ring (). D 4. Thread tube or hose nut (D) until hand-tight. The nut should turn freely until it is bottomed out. 5. Torque fittings according to values in Table 6.13, page 68. NOTE: If applicable, hold hex on fitting body (E) to prevent rotation of fitting body and hose when tightening fitting nut (D). 6. Use three wrenches when assembling unions or joining two hoses together. Figure 6.15: Hydraulic Fitting E heck final condition of fitting. Table 6.13 O-Ring Face Seal (ORFS) Hydraulic Fittings SE Dash Size Thread Size (in.) Tube O.D. (in.) Torque Value 5 Nm lbf ft -3 Note 6 3/16-4 9/16 1/ Note 6 5/ /16 3/ /16 1/ / /16 3/ Torque values and angles shown are based on lubricated connection as in reassembly. 6. O-ring face seal type end not defined for this tube size Revision