R80 Rotary Disc Self-Propelled Windrower Header Unloading & Assembly Instructions

Transcription

1 R80 Rotary Disc Self-Propelled Windrower Header Unloading & ssembly Instructions Form #

2 MDON R80 SELF PROPELLED ROTRY DIS HEDER Form #

3 INTRODUTION This instruction describes the unloading, set-up and pre-delivery requirements for the MacDon Model R80 Rotary Disc Self-Propelled Windrower Header. Use the table of contents to guide you to specific areas. REFULLY RED LL THE MTERIL PROVIDED EFORE TTEMPTING TO UNLOD, SSEMLE, OR USE THE MHINE. TLE OF ONTENTS INTRODUTION... 1 GENERL SFETY... 2 REOMMENDED TORQUES GENERL SE OLTS METRI OLTS... 4 D. HYDRULI FITTINGS... 5 ONVERSION HRT... 6 STEP 1. UNLOD HEDER... 7 STEP 2. REMOVE UNDERSIDE SHIPPING STND... 8 STEP 3. INSTLL GUGE ROLLERS OR SKID SHOES 16 FT ONLY GUGE ROLLERS SKID SHOES... 9 STEP 4. LOWER HEDER STEP 5. REMOVE SHIPPING STNDS...11 STEP 6. INSTLL MOTOR 13 FT ONLY...13 STEP 7. INSTLL HOSE SUPPORT STEP 8. SSEMLE FORMING SHIELD...14 STEP 9. INSTLL FORMING SHIELD STEP 10. INSTLL TLL ROP FEED PLTES STEP 11. TTH HEDER TO TRTOR STEP 12. ONNET HYDRULIS M FT & 16 FT I. TRTOR ONNETIONS II. HEDER ONNETIONS III. GRSS SEED HEDER HYDRULIS IV. GRSS SEED HEDER HOSE ONNETIONS M FT I. TRTOR ONNETIONS II. HEDER ONNETIONS STEP 13. INSTLL ROTRY SWITH STEP 14. INSTLL OPTIONS TLL ROP DIVIDER KIT SHOE LIFT KIT DOULE WINDROW TTHMENT D. TLL ROP TRNSITION SHIELD GRSS SEED HEDER STEP 15. LURITE THE HEDER STEP 16. PERFORM PRE-DELIVERY HEKS DRIVE ELTS HEDER FLOTTION HEK LEVEL OF HEDER D. ONDITIONER ROLLS I. ROLL GP II. ROLL TIMING E. MNULS F. GUGE ROLLERS OR SKID SHOES G. LIGHTS 16 FT ONLY H. HEK ONVERGING DRUM OPERTION GRSS SEED I. RUN-UP THE HEDER Form #

4 GENERL SFETY UTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Provide a first-aid kit for use in case of emergencies. Keep a fire extinguisher on the machine. e sure the extinguisher is properly maintained and be familiar with its proper use. Protect yourself. When assembling, operating and servicing machinery, wear all the protective clothing and personal safety devices that OULD be necessary for the job at hand. Don't take chances. You may need: a hard hat. protective shoes with slip resistant soles. protective glasses or goggles. heavy gloves. wet weather gear. respirator or filter mask. hearing protection. e aware that prolonged exposure to loud noise can cause impairment or loss of hearing. Wearing a suitable hearing protective device such as ear muffs () or ear plugs () protects against objectionable or loud noises. Keep young children away from machinery at all times. e aware that accidents often happen when the operator is tired or in a hurry to get finished. Take the time to consider the safest way. Never ignore warning signs of fatigue. Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets. Keep hands, feet, clothing and hair away from moving parts. Never attempt to clear obstructions or objects from a machine while the engine is running. Keep all shields in place. Never alter or remove safety equipment. Make sure driveline guards can rotate independently of the shaft and can telescope freely. Use only service and repair parts made or approved by the equipment manufacturer. Substituted parts may not meet strength, design, or safety requirements. Do not modify the machine. Unauthorized modifications may impair the function and/or safety and affect machine life. (continued next page) Form #

5 Stop engine and remove key from ignition before leaving operator's seat for any reason. child or even a pet could engage an idling machine. Keep the area used for servicing machinery clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment. e sure all electrical outlets and tools are properly grounded. Use adequate light for the job at hand. Keep machinery clean. Do not allow oil or grease to accumulate on service platforms, ladders or controls. 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. Form #

6 REOMMENDED TORQUES. GENERL The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specified in chart unless otherwise noted throughout this manual. heck tightness of bolts periodically, using bolt torque chart as a guide. Replace hardware with the same strength bolt. Torque figures are valid for non-greased or non-oiled threads and heads unless otherwise specified. Do not grease or oil bolts or capscrews unless specified in this manual. When using locking elements, increase torque values by 5%.. SE OLTS N OLT TORQUE* OLT DI. "" SE 5 SE 8 in. lbf ft N m lbf ft N m. METRI OLTS OLT DI. "" N OLT TORQUE* lbf ft N m lbf ft N m M M M M M M M M M M M M M * Torque categories for bolts and capscrews are identified by their head markings. 1/ / / / / / / / / * Torque categories for bolts and capscrews are identified by their head markings. SE-5 SE-8 Form #

7 D. HYDRULI FITTINGS FLRE TYPE FLRE NUT O-RING TYPE FITTING SET LOKNUT WSHER O-RING GROOVE FLRESET ODY a. heck flare and flare seat for defects that might cause leakage. b. lign tube with fitting before tightening. c. Lubricate connection and hand tighten swivel nut until snug. d. To prevent twisting the tube(s), use two wrenches. Place one wrench on the connector body and with the second tighten the swivel nut to the torque shown. TUE SIZE O.D. (in.) NUT SIZE ROSS FLTS (in.) TORQUE VLUE* REOMMENDED TURNS TO TIGHTEN (FTER FINGER TIGHTENING) lbf ft N m Flats Turns 3/16 7/ /6 1/4 9/ /6 5/16 5/ /6 3/8 11/ /6 1/2 7/ /6 5/ /6 3/4 1-1/ /4 1/8 7/8 1-3/ /4 1/8 * The torque values shown are based on lubricated connections as in reassembly. a. Inspect O-ring and seat for dirt or obvious defects. b. On angle fittings, back off the lock nut until washer () bottoms out at top of groove () in fitting. c. Hand tighten fitting until back up washer () or washer face (if straight fitting) bottoms on part face () and O-ring is seated. d. Position angle fittings by unscrewing no more than one turn. e. Tighten straight fittings to torque shown. f. Tighten angle fittings to torque shown in the following table while holding body of fitting with a wrench. THD SIZE (in.) NUT SIZE ROSS FLTS (in.) TORQUE VLUE* REOMMENDED TURNS TO TIGHTEN (FTER FINGER TIGHTENING) lbf ft N m Flats Turns 3/8 1/ /3 7/16 9/ /3 1/2 5/ /3 9/16 11/ /3 3/4 7/ /3 7/ /2 1/4 1-1/16 1-1/ /6 1-3/16 1-3/ /6 1-5/16 1-1/ /4 1/8 1-5/8 1-7/ /4 1/8 1-7/8 2-1/ /2 1/12 * The torque values shown are based on lubricated connections as in reassembly. Form #

8 ONVERSION HRT QUNTITY INH-POUND UNITS FTOR SI UNITS (METRI) UNIT NME R. UNIT NME R. rea acres acres x = hectares ha Flow US gallons per minute (gpm) x = liters per min L/min Force pounds force lbf x = Newtons N Length inch in. x 25.4 = millimeters mm foot ft x = meters m Power horsepower hp x = kilowatts kw Pressure pounds per square inch psi x = kilopascals kpa x = megapascals MPa Torque pound feet or foot pounds lbf ft or ft lbf x = newton meters N m pound inches or inch pounds lbf in. or in lbf x = newton meters N m Temperature degrees Fahrenheit F (F- 32) x 0.56 = elsius feet per minute ft/min x = meters per min m/min Velocity feet per second ft/s x = meters per sec m/s miles per hour mph x = kilometers per hour km/h US gallons US gal. x = liters L Volume ounces oz. x = milliliters ml cubic inches in. 3 x = cubic centimeters cm 3 or cc Weight pounds lb x = kilograms kg Form #

9 UNLODING ND SSEMLY STEP 1. UNLOD HEDER UTION To avoid injury to bystanders from being struck by machinery, do not allow persons to stand in unloading area. IMPORTNT Take care not to contact the other machine if load is two-wide. c. Raise header off deck. d. ack up until unit clears trailer and slowly lower to 6 inches (150 mm) from ground. e. Take to storage or set-up area. UTION Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping or machine damage. LIFTING VEHILE Min. Lifting apacity * 8000 lb. (3630 kg) Min. Fork Length 78 inches (1981 mm) * t 48 inches (1220 mm) from back end of forks. IMPORTNT Forklifts are normally rated for a load located 24 inches (610 mm) ahead of back end of the forks. To obtain the forklift capacity at 48 inches (1220 mm), check with your forklift distributor. f. Set machine down securely on level ground. g. If hydraulic motor and hoses are shipped separately on pallet, unload pallet. h. heck for shipping damage and missing parts. WRNING e sure forks are secure before moving away from load. Stand clear when lifting. a. Remove hauler's tie down straps and chains. b. pproach header from its "underside" and slide forks in underneath lifting framework as far as possible. Form #

10 UNLODING ND SSEMLY STEP 2. REMOVE UNDERSIDE SHIPPING STND UTION Keep feet clear when removing final bolts. STEP 3. INSTLL GUGE ROLLERS OR SKID SHOES 16 FT ONLY If kits not supplied proceed to STEP 4, LOWER HEDER, otherwise install kit as follows: NOTE These kits may be installed later in the header assembly sequence but it may be easier prior to laying the header down.. GUGE ROLLERS a. Unpack gauge roller bundle. b. Remove four clevis pins from roller assembly. a. Remove two bolts () on each end of stand and remove shipping stand (). Discard stand and hardware. c. Position gauge roller assembly on frame and secure with two clevis pins (). Secure pins with lynch pins. (continued next page) Form #

11 UNLODING ND SSEMLY D d. djust roller assembly to desired height and install two clevis pins (D). Secure with lynch pins. e. Repeat above steps for opposite side. Set both gauge rollers to same position.. SKID SHOES a. Unpack skid shoe bundle. b. Remove four clevis pins from skid shoe. E F c. Position skid shoe on frame and secure with two clevis pins (E). Secure pins with lynch pins. d. djust skid shoe to desired height and install two clevis pins (F). Secure with lynch pins. e. Repeat above steps for opposite side. Set both skid shoes to same position. Form #

12 UNLODING ND SSEMLY STEP 4. LOWER HEDER a. ttach either a spreader bar or chain to forks. UTION Ensure spreader bar or chain is secured to the forks so that it cannot slide off the forks or towards the mast as the header is lowered to the ground. hain Type Min. Working Load Overhead Lifting Quality (1/2 Inch) 5000 lb. (2270 kg) 1 2 b. Drive lifting vehicle to approach header from its "underside". e. ack up SLOWLY while simultaneously lowering machine until cutterbar rests on ground. f. Remove chain from header. 3 c. ttach chain hooks to hooks on either side of header. UTION Stand clear when lowering the header. NOTE Do not lift at hooks when unloading from trailer. This procedure is only for laying the machine over into working position. IMPORTNT hain length must be sufficient to provide a minimum 4 feet (1.2 m) vertical chain height. d. Raise forks until lift chains are fully tensioned. Form #

13 UNLODING ND SSEMLY STEP 5. REMOVE SHIPPING STNDS NOTE Step a. is only applicable to 16 ft header. 13 ft headers are shipped without the motor installed. d. Remove hairpin from pin (). e. Hold shipping stand (), remove pin (), and remove stand. Re-insert pin () in header boot. Discard stand and hardware. f. Repeat above steps for opposite shipping stand. a. Untie hose bundle and relocate on top of header. b. Remove bag of Velcro straps from hose end and set aside for installation in STEP 12. ONNET HYDRULIS. D E g. Remove four bolts (D) in angle (E) and remove angle. c. Remove four bolts () from shipping stand. h. ut all banding at cutterbar doors. (continued next page) Form #

14 UNLODING ND SSEMLY EPTLE NOT EPTLE F k. lose cutterbar doors. Ensure that curtains hang properly and completely enclose cutterbar area. Minor creases in curtains will eventually straighten out. i. Remove five bolts and nuts on each door and remove front angles and lift hooks. Retain lower bolt (F) for re-installation at same location after hook is removed. WRNING Ensure cutterbar completely clear of foreign objects. These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage. l. ut shipping wire and plastic cable ties securing crop deflector lever and drive shield latches. G H J j. Open cutterbar doors and check cutterbar area for debris and foreign objects. Ensure all material is removed. m. Move crop deflector lever (G) upward from shipping position and pull lever slightly away from bracket (H) so that pin engages slots in bracket. Release it at the center position to lock crop deflector (J) in desired position. Form #

15 UNLODING ND SSEMLY STEP 6. INSTLL MOTOR 13 FT ONLY STEP 7. INSTLL HOSE SUPPORT a. Retrieve hose support from header center mast. G a. Remove four bolts () and remove plate () from gearbox. Retain bolts for re-installation and discard plate. b. ttach a sling to motor and the other end to lifting device. Motor and lines weigh approximately 150 lb (68 kg). IMPORTNT Do not lift motor with hydraulic lines. E b. Remove carriage bolts in support (G). c. ttach support (G) to header with the two carriage bolts (H) and nuts. H F D c. Position motor () onto gearbox opening as shown and remove sling. NOTE Hydraulic lines may require repositioning to clear bracket (D). Loosen bolts (E) and move lines as required. Tighten bolts (E) to 32 ft lbf (43 N m). d. Install four bolts () to secure motor to gearbox. Torque bolts to 103 ft lbf (140 N m). e. Install case drain hose (F) into bracket (D). Form #

16 UNLODING ND SSEMLY STEP 8. SSEMLE FORMING SHIELD For Grass Seed headers go to STEP 11. TTH HEDER TO TRTOR. To assemble forming shield, proceed as follows: d. ssemble side deflectors () to cover () with bolts (), jam-nut (D), washer (E), and nut (F) from previous step. e. Tighten flange nut (F) enough to hold deflectors () in position, but still allow deflectors to move. f. Tighten jam nut (D) against cover while holding bolt (). H G a. Unpack and remove shipping material. g. Remove lynch pin (G) from adjuster rod (H) and locate rod in hole in side deflector (). Secure with lynch pin (G). h. Repeat for other deflector. b. Lay cover () upside down on a flat surface. c. Remove bolts () from side deflectors (). i. Invert forming shield to installation position as shown. D E F Form #

17 UNLODING ND SSEMLY STEP 9. INSTLL FORMING SHIELD For Grass Seed headers go to STEP 11. TTH HEDER TO TRTOR. To install forming shield, proceed as follows: a. Remove the header from the tractor if attached for ease of installation of the forming shield. b. Retrieve plate () and hardware from forming shield bundle. D E D g. Locate forming shield onto spacers (D) on tractor leg and secure with clevis pins (E) and lynch pin. F G c. ttach plate () to tractor leg with two ½ x 5.0 hex bolts () and nuts. Repeat for opposite leg. Hardware is supplied with forming shield bundle. d. Install a ½ x 3.25 hex bolt () with spacer (D), and nut on each plate. Hardware is supplied with forming shield kit. E h. Lift the aft end of the forming shield and attach straps (F) to pins (G) on tractor frame. Install washer and hairpin to secure strap. Use the middle hole and adjust height to suit the crop. OTH SIDES K e. Remove the two clevis pins (E) from forming shield forward end. J H i. Set forming shield side deflectors to desired width by repositioning adjuster bars (H). Use same hole location on both sides. j. djust fluffer shield (J) to middle position. Loosen handles (K) if required. f. Position forming shield under the tractor frame. Form #

18 UNLODING ND SSEMLY STEP 10. INSTLL TLL ROP FEED PLTES The tall crop feed plates assist the feeding of tall crops into the conditioner by encouraging material flow from behind the hourglass deflectors. They will degrade the cutting performance of the cutterbar if they are used in medium to light alfalfa, and so should not be installed in those types of crops. The feed plates are designed for installation on the two inboard hourglass deflectors and only on 16 ft headers. They are stored inside the RH side drive compartment, except for grass seed headers, which have them factory installed. For Grass Seed headers go to STEP 11. TTH HEDER TO TRTOR. To install feed plates, proceed as follows: c. Remove nuts () securing two feed plates to side of compartment and remove plates. UTION Exercise caution when working around the blades. lades are sharp and can cause serious injury. Wear gloves when handling blades. d. Place a block of wood between discs to prevent deflector from turning. a. Open cutterbar doors. b. Open RH side drive compartment shield. D e. Remove four bolts () and remove inboard hourglass driven deflector () and disc assembly (D) from cutterbar. (continued next page) Form #

19 UNLODING ND SSEMLY g. Manually rotate discs to check for interference of feed plate and adjacent parts. D E h. Locate feed plate (D) on the disc ensuring that hole in feed plate registers on disc. Position plate approximately as shown and align holes. IMPORTNT Feed plate should be located so that when holes are aligned, it is closer to the cutter blade leading edge (E) than the trailing edge. i. Re-position deflector () and align holes. j. Re-install bolts () and tighten to 92 ft lbf (125 N m). k. Manually rotate discs to check for interference of feed plate and adjacent parts. l. Repeat above steps for opposite side. m. Manually rotate discs to check for interference of feed plate and adjacent parts. Form #

20 UNLODING ND SSEMLY STEP 11. TTH HEDER TO TRTOR Refer to M Series Unloading & ssembly Instructions, Form #169018, or M150 & M200 Self-Propelled Windrower Operator s Manual, Form # for tractor operating instructions. c. Slowly drive tractor forward so that feet () on tractor enter boots () on the header. ontinue to drive slowly forward until feet engage the boots, and header nudges forward. d. onnect center link as follows: MEHNIL LINK M150 a. Remove hairpin from pin (), and remove pin from left and right header boots (). UTION heck to be sure all bystanders have cleared the area. DNGER Stop engine and remove key from ignition before leaving operator's seat for any reason. child or even a pet could engage an idling machine. 1. Stop engine and remove key. D HEDER UP HEDER TILT DOWN HEDER TILT UP E HEDER DOWN 2. Loosen nut (D) and rotate barrel (E) to adjust length so that other end lines up with mounting hole in center mast (F). b. Start the engine and activate header down button on the GSL to fully retract header lift cylinders. F E G 3. Install clevis pin (G) and secure with cotter pin. (continued next page) Form #

21 UNLODING ND SSEMLY 4. djust link to required length for proper header angle by rotating barrel (E). Tighten nut (D) against barrel. slight tap with a hammer is sufficient. 5. Proceed to step e. HYDRULI LINK M200 STD, M150 OPTION J HEDER UP HEDER TILT DOWN HEDER TILT UP 3. Push down on rod end of center link until hook engages pin (J) in center mast and is locked. UTION HEDER DOWN heck to be sure all bystanders have cleared the area. e. Start engine. f. Raise the header fully with the header up switch on the GSL. Stop engine and remove key. H DNGER J To avoid bodily injury from fall of raised header, always engage header lift cylinder stops when working on or around raised header. g. Engage lift cylinder stops on both lift cylinders. 1. ctivate header tilt cylinder switches on GSL to position center link hook (H) so that it can connect to pin (J) in center mast. NOTE If optional auto-connect system is installed, activate link lift cylinder from in the cab to lower center link onto header and proceed to step f. DNGER Stop engine and remove key from ignition before leaving operator's seat for any reason. child or even a pet could engage an idling machine. 2. Stop engine and remove key. h. Install pin () through each boot and foot and secure with hairpin. IMPORTNT Ensure pin () is fully inserted and hairpin is installed behind bracket on boot. (continued next page) Form #

22 UNLODING ND SSEMLY K L i. Remove pin (K) from storage position in linkages on both sides and insert in hole (L) to engage float springs. Secure with hairpin. j. Disengage lift cylinder stops. UTION heck to be sure all bystanders have cleared the area. k. Start engine, and activate header lift cylinder switch on GSL to lower header fully. Stop engine and remove key. Form #

23 UNLODING ND SSEMLY STEP 12. ONNET HYDRULIS. M FT & 16 FT E I. TRTOR ONNETIONS F G 2. Locate cinch strap (E) through slot and under bracket (F) on tractor hose support. 3. ttach strap to bracket with ½ inch carriage bolt (G) and locking nut. Install bolt from under bracket. H a. Disengage and rotate lever () counterclockwise to fully up position. b. Remove cap () securing electrical connector to frame. c. Move hose bundle () from tractor through hose support (D) on header. d. Move tractor left side platform to open position. e. Install cinch straps as follows if not already installed. 1. Retrieve package of three cinch straps from shipping bundle. D f. Route header return and pressure hose bundle (H) through support (D) on header, to tractor, and locate bundle above existing hose bundle () as shown. g. Secure with three straps (E). h. Lower and lock lever (). i. Open left side (cab-forward) platform. j. Route header hose bundle (H) to valve block (J). k. Disconnect fittings at bundle (H) hose ends. X l. Remove fittings at ports (X) and (Y) on valve (J). (continued next page) J E Y Form #

24 UNLODING ND SSEMLY L II. HEDER ONNETIONS a. Remove caps and plugs from hoses and lines. K RETURN m. Install male 45 degree fitting (K) from hose in port (X), and female straight fitting (L) from hose in port (Y). NOTE Male fitting (K) may need to be disassembled prior to installing on valve block. PRESSURE RETURN SE DRIN PRESSURE ELETRIL n. onnect hoses from header to fittings as shown. b. onnect the three hoses from tractor to the fittings on the header as shown. c. If a 16 ft grass seed header is being set up, proceed to III GRSS SEED HEDER HYDRULIS, otherwise close maintenance platform and proceed to STEP 14. INSTLL OPTIONS. Form #

25 UNLODING ND SSEMLY III. GRSS SEED HEDER HYDRULIS onverging Drum Drive Valve Installation; E a. Obtain drive valve block () from grass seed completion package (4911). b. Install 3/4 tube x 1 1/16 OR male connector () from package in port R2 of new valve block (). c. Install 5/8 tube x 7/8 OR male connector () from package in port P. E D e. Disconnect existing hose (E) from tractor manifold and re-connect to new valve block fitting (). H d. ttach valve block () to support on tractor as shown with two 3/8 in.x0.75 hex bolts (D). F f. ttach new hydraulic hose (F) to fitting () on backside of valve block () but do not tighten. Form #

26 UNLODING ND SSEMLY g. ttach other end of new hose (F) to tractor manifold at (H). U J M J K b. Install the following fittings in this port to suit existing hydraulic configuration. 9/16 OR X 3/8 TUE (O) 90 SWIVEL ELOW 3/8 TUE (P) 3/4 MLE OR X 9/16 FEMLE TUE (Q) 3/4 OR MLE OUPLER (R) 3/8 TUE X STR THD RUN TEE (S) 3/8 TUE SWIVEL RNH TEE (T) c. ttach existing hose(s) to new fittings as required. P O K L h. Install 7/8 OR x 1/2 Tube Swivel, (J), 1/2 Tube 45 Elbow with O-ring (K), and 3/4 OR Male oupling (L) into port DW as shown. i. Install 1 1/16 OR x 7/8 OR Female (M), 7/8 OR x 1/2 Tube Swivel, (J), 1/2 Tube 45 Elbow with O-ring (K), and 3/4 OR Female oupling (N) fittings into port R1 of new valve block and orientate as shown. j. ttach existing harness connector P74 to valve block receptacle (U). onverging Drum ontrol ylinder onnection; N R Q WITHOUT DRPER HEDER OR ENTER LINK SSIST P S R Q WITH DRPER HEDER OR ENTER LINK SSIST T S Q R a. Remove existing hose fittings, if installed, from port D on forward valve block. P WITH DRPER HEDER & ENTER LINK SSIST d. Tighten all connections. Form #

27 UNLODING ND SSEMLY IV. GRSS SEED HEDER HOSE ONNETIONS F E a. Disengage and rotate lever () counterclockwise to fully up position. d. Route the short hose (E) in converging drum bundle with the female coupler to the forward valve block and connect it to male coupler (F). H D G b. Route converging drum hose bundle () through hose support () on header to the tractor hose support (D). e. Route the two longer hoses to the aft valve block and connect them to couplers (G) and (H). f. Proceed to STEP 14. INSTLL OPTIONS. D c. Lower lever () and secure it in hook. Secure hose bundles with existing cinch straps. Form #

28 UNLODING ND SSEMLY. M FT I. TRTOR ONNETIONS E F G 2. Locate cinch strap (E) through slot and under bracket (F) on hose support. 3. ttach strap to bracket with ½ inch carriage bolt (G) and locking nut. Install bolt from under bracket. H a. Disengage and rotate lever () counterclockwise to fully up position. b. Remove cap () securing electrical connector to frame. E D f. Route header pressure hose (H) from header through hose support (D) to tractor, and locate bundle above existing hose bundle () as shown. g. Secure with three straps (E). h. Lower and lock lever (). (continued next page) c. Move hose bundle () from tractor through hose support (D) to header. d. Move tractor left side platform to open position. e. Install cinch straps as follows if not already installed. 1. Retrieve package of three cinch straps from shipping bundle. Form #

29 UNLODING ND SSEMLY EXISTING O NEW J m. Install fitting assembly (O) onto valve block (J) at this location. NOTE djacent hoses may need to be loosened and moved to allow installation of fitting. If necessary, disassemble quick disconnect and 45 degree fitting, and then reassemble after fitting is installed onto valve block. i. Install valve block (J) that is supplied with the tractor (ref. 4657). Refer to installation instructions supplied in the kit. M L O j. Disconnect quick-disconnect (K) at end of header hose (L). k. Remove cap (M) on fitting assembly. K L n. onnect hose (L) from header to fitting (O). II. HEDER ONNETIONS a. Remove caps and plugs from hoses and lines. RETURN PRESSURE N J l. Remove plug (N) from valve (J). SE DRIN ELETRIL b. onnect the three hoses from tractor to the fittings on the header as shown. c. onnect harness from tractor to electrical connector. d. Move tractor platform to closed position. Form #

30 UNLODING ND SSEMLY STEP 13. INSTLL ROTRY SWITH H d. onnect plug P52 (F) to rotary switch. Plug is inside the console. a. Inside tractor cab, remove cover () from console by removing 5 screws (). e. Re-install cover () with five screws (). f. Program the tractor monitor as follows to recognize the onverging Drums: PROGRM RROWS SELET b. ut hole in decal and install rotary switch () as shown. The hole is already present in the mounting plate and the switch is supplied with the grass seed bundle. D c. Install knob (D) on rotary switch (). Tighten set screw in knob with llen wrench (E). E 1. Turn the key on. 2. Press PROGRM and SELET at the same time to go into program menu. 3. Press right arrow switch (YES) for Tractor Setup. 4. Scroll through menu with SELET switch to DW VLVE INSTLLED. 5. Press right arrow switch (YES). 6. Press SELET switch to lock in selection. 7. Press PROGRM switch to exit menu and return to main screen. Form #

31 UNLODING ND SSEMLY STEP 14. INSTLL OPTIONS Install options, if supplied with shipment, in accordance with the instructions supplied with each kit, or as follows:. TLL ROP DIVIDER KIT a. Unpack kit. D E 1. Remove two bolts (), pivot the skid shoe (D), and remove from slot (E) in rock guard. b. Open cutterbar doors. F G D c. Locate LH divider () on header LH front corner and install with three bolts () and nuts supplied with kit in existing holes. Tighten hardware. d. Repeat for RH side. e. Lower cutterbar doors.. SHOE LIFT KIT a. Unpack kit. 2. ttach shoe lift (F) to skid shoe as shown with hardware (G) supplied in kit. Tighten bolts. 3. Position skid shoe (D) joggled end in rock guard slot (E) and locate aft end with lift (F) against rock guard. Secure with existing bolts ().. DOULE WINDROW TTHMENT WRNING To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key and engage lift cylinder stops before going under machine to adjust skid shoes or for any reason. b. Start tractor and raise header fully. c. Stop engine, remove key, and engage lift cylinder stops. d. Install a lift on each of the two end skid shoes, and on two additional shoes at equi-distant locations as follows: Refer to instructions supplied with kit. Form #

32 UNLODING ND SSEMLY D. TLL ROP TRNSITION SHIELD GRSS SEED HEDER Refer to instructions supplied with kit. Form #

33 UNLODING ND SSEMLY STEP 15. LURITE THE HEDER WRNING To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key and engage lift cylinder stops before going under machine for any reason. a. Wipe grease fitting with a clean cloth before greasing, to avoid injecting dirt and grit. b. Inject grease through fitting with grease gun until grease overflows fitting, except where noted. c. Leave excess grease on fitting to keep out dirt. d. Replace any loose or broken fittings immediately. e. If fitting will not take grease, remove and clean thoroughly. lso clean lubricant passageway. Replace fitting if necessary. f. Refer to the illustrations on following pages for lubrication points. 13 FT High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium ase ROLL SHFT ERINGS (3 PLS) 10% MOLY GRESE IS REOMMENDED FOR DRIVELINE SHFT SLIP JOINT ONLY DRIVELINE UNIVERSLS (2 PLS) DRIVESHFT (1 PL) Form #

34 LURITE HEDER 13 FT (ont d) UNLODING ND SSEMLY GEROX OIL LEVEL DRIVELINE UNIVERSLS (2 PLS) ELT TENSIONER PIVOT (1 PL) 10% MOLY GRESE IS REOMMENDED FOR DRIVELINE SHFT SLIP JOINT ONLY DRIVELINE UNIVERSLS (2 PLS) DRIVELINE SHFT (2 PLS) ROLL SHFT ERINGS (3 PLS) Form #

35 UNLODING ND SSEMLY LURITE HEDER 16 FT High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium ase HEK PLUG Oil should slightly run out when removed. GEROX OIL LEVEL DRIVELINE UNIVERSLS (2 PLS) ELT TENSIONER PIVOT (1 PL) 10% MOLY GRESE IS REOMMENDED FOR DRIVELINE SHFT SLIP JOINT ONLY DRIVELINE UNIVERSLS (2 PLS) DRIVELINE SHFT (2 PLS) ROLL SHFT ERINGS (3 PLS) Form #

36 LURITE HEDER 16 FT (ont d) UNLODING ND SSEMLY High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium ase ROLL SHFT ERINGS (3 PLS) OPTIONL GUGE ROLL ERINGS (2 PLS) OTH SIDES 10% MOLY GRESE IS REOMMENDED FOR DRIVELINE SHFT SLIP JOINT ONLY DRIVELINE UNIVERSLS (2 PLS) DRIVESHFT (1 PL) (OTH SIDES) Form #

37 LURITE HEDER 16 FT GRSS SEED (ont d) PRE-DELIVERY HEKS 10% MOLY GRESE IS REOMMENDED FOR DRIVELINE SHFT SLIP JOINT ONLY HEK PLUG Oil should slightly run out when removed. DRIVELINE UNIVERSLS (2 PLS) DRIVESHFT (1 PL) (OTH SIDES) GEROX OIL LEVEL OPTIONL GUGE ROLL ERINGS (2 PLS) OTH SIDES ONVERGING DRUMS (2 PLS) - OTH SIDES Form #

38 PRE-DELIVERY HEKS STEP 16. PERFORM PRE- DELIVERY HEKS WRNING Stop windrower engine and remove key before making adjustments to machine. child or even a pet could engage the drive. IMPORTNT To avoid machine damage, check that no shipping dunnage has fallen down between auger and pans. a. Perform the final checks and adjustments as listed on the "Pre-Delivery hecklist" (yellow sheet) to ensure the machine is field-ready. Refer to the following pages for detailed instructions as indicated on the checklist. b. The completed checklist should be retained either by the operator or the dealer.. DRIVE ELTS Drive belt tensions have been properly set at the factory and should not require any further adjustment. heck as follows: c. pply force of 51 lbf (22 N) to each deflector drive belt at mid-span. Deflection of each belt should be 0.12 in. (3 mm). d. Open LH drive shield. 16 FT ONLY a. Open RH drive shield. X e. Measure the length X of the spring () as shown. It should be within the dimensions in the following table. b. Lifting roll drive belt tension is factory adjusted. Hole in tensioner member should be visible. NUMER OF VISILE OILS MESUREMENT X inches ( mm) inches ( mm) (continued next page) Form #

39 PRE-DELIVERY HEKS f. pply force of 51 lbf (22 N) to each deflector drive belt at mid-span. Deflection of each belt should be 0.12 in. (3 mm).. HEDER FLOTTION a. Set the float fine adjustment to mid-range with the tractor float adjustment system in the cab. Refer to the M Series Self-Propelled Windrower Operator s Manual, Form # b. heck float by grasping the front corner of header and lifting. The force to lift should be ( N) and should be approximately the same at both ends. c. Perform the following steps to adjust the float if necessary: DNGER Stop engine and remove key from ignition before leaving operator's seat for any reason. child or even a pet could engage an idling machine. 1. Raise the header fully, shut down the engine, and remove the key. 16 FT ONLY 2. Loosen nut () on linkage spring drawbolt. 3. Turn drawbolt () clockwise to increase float (makes header lighter) or counterclockwise to decrease float (makes header heavier). 4. Tighten nut () to lock drawbolt. 5. Recheck the float.. HEK LEVEL OF HEDER a. Park windrower on level ground and raise header approximately 6 inches (150 mm) off ground. b. heck that clearances between header and ground at each end of the header are approximately the same. IMPORTNT The header float springs are not used to level the header. c. If header needs levelling, proceed as follows: 1. Place wooden blocks under header cutterbar and legs. D E 2. Lower header onto blocks so that linkage () lifts at tractor leg and off of shims (E). DNGER Stop engine and remove key from ignition before leaving operator's seat for any reason. child or even a pet could engage an idling machine. 3. Shut down the engine and remove the key. 4. On the high side linkage, remove nut, washer and bolt (D) that attaches shims (E) to link. 5. Remove one or both shims (E) and reinstall the hardware (D). 6. heck level of header. 7. If additional levelling is required, install the removed shim on the opposite linkage. NOTE Float does not require adjustment after levelling header. Form #

40 PRE-DELIVERY HEKS D. ONDITIONER ROLLS I. ROLL GP ROLL GP II. ROLL TIMING DNGER Stop engine and remove key from ignition before leaving operator's seat for any reason. child or even a pet could engage an idling machine. ROP ROP TIMING GP a. Lower header to ground, shut down tractor and remove key. b. Open drive shields. a. The amount of thread protruding through jam nut should equal roll gap. Factory setting should be 0.25 in. (6 mm). c. Remove bolt () and nut, and remove gauge () from inside panel at RH end of header. (continued next page) Form #

41 PRE-DELIVERY HEKS STRT POSITION GUGE POSITION d. From the rear of the header, locate gauge at centre of rolls as shown and manually turn rolls to limits of gauge. Rolls will engage the gauge if timing is correct. e. Manually turn rolls to release gauge. g. heck timing flange bolts () are tight. h. lose drive shields. E. MNULS The following manuals should be stored in the manual storage case in the tractor cab: R80 Rotary Disc Header PRTS TLOG. Form # R80 Rotary Disc Self-Propelled Windrower Header OPERTOR S MNUL. Form # WRNING Remove gauge from rolls and return it to storage location before starting machine. f. Replace gauge in header with bolt () and nut. Form #

42 PRE-DELIVERY HEKS F. GUGE ROLLERS OR SKID SHOES G. LIGHTS 16 FT ONLY WRNING To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key and engage lift cylinder stops before going under machine to adjust skid shoes or for any reason. a. Raise header and engage lift cylinder stops. b. oth gauge rollers or skid shoes should be set at the same position. The hazard lights, which are mounted on both ends of the header (and on Grass Seed transition shield), are activated by a switch in the M Series tractor cab. a. heck for operation during run-up. b. heck light mountings for security and check lights for damage. SKID SHOE GUGE ROLLER Form #

43 PRE-DELIVERY HEKS H. HEK ONVERGING DRUM OPERTION GRSS SEED heck operation as follows during run-up: REEL DOWN REEL UP a. Press REEL UP or REEL DOWN switches on GSL to move converging drums. Drum movement can be observed from the cab. I. RUN-UP THE HEDER UTION Never start or move the machine until you are sure all bystanders have cleared the area. UTION lear the area of other persons, pets etc. Keep children away from machinery. Walk around the machine to be sure no one is under, on or close to it. UTION efore investigating an unusual sound or attempting to correct a problem, shut off engine, engage parking brake and remove key. Refer to M Series Unloading & ssembly Instructions, Form #169018, or M150 & M200 Self-Propelled Windrower Operator s Manual, Form # for tractor operating instructions. a. Start windrower and run the machine for 15 minutes. b. Listen for any unusual sounds or abnormal vibration. c. Perform the run-up check as listed on the "Pre- Delivery hecklist" (yellow sheet attached to this instruction) to ensure the machine is field-ready. b. Rotate DW knob on console to change drum rotational speed. Form #

44 NOTES Form #

45 Form #

46 MacDon Industries Ltd. 680 Moray Street Winnipeg, Manitoba anada R3J 3S3 t. (204) f. (204) MacDon Inc N. Pomona venue Kansas ity, Missouri United States, t. (816) f. (816) MacDon ustralia Pty. Ltd...N P.O. ox 243 Suite 3, 143 Main Street Greensborough, Victoria ustralia 3088 t f USTOMERS DELERS Trademarks of products are the marks of their respective manufacturers and/or distributors. Printed in anada Form #

47 R80 Rotary Disc Header Pre-Delivery hecklist Perform these checks and adjustments prior to delivery to your customer. See the Unloading and ssembly Instructions for details. The completed checklist should be retained either by the operator or the dealer. UTION: arefully follow the instructions given. e alert for safety related messages which bring your attention to hazards and unsafe practices. WRNING: Do not operate the machine with the drive shields open. High speed rotating components may throw debris and could result in death or serious injury. Header Serial Number: ITEM PGE heck for shipping damage or missing parts. e sure all shipping dunnage is removed. - heck for loose hardware. Tighten to required torque. 4 heck main drive belt tension (not applicable to grass seed header). 36 heck hourglass deflector drive belts tension (16 ft. only). 36 heck lift roll drive belt tension (not applicable to grass seed header). 36 heck header angle to middle of adjustment range. 18 heck header flotation. ( lbf ( N)). 37 heck header is level. 37 heck side forming shields evenly set to desired position (not applicable to grass seed header). 15 heck rear fluffer deflector about half way down (not applicable to grass seed header). 15 heck crop deflector set about half way. 12 heck gauge rollers/skid shoes evenly set (16 ft. only). 40 heck bevel gearbox lube level. 32, 33 Grease all bearings and drivelines heck conditioner roll gap and timing (not applicable to grass seed header). 38 heck roll intermesh hardware is securely tightened (not applicable to grass seed header). 38 heck cutterbar curtains hanging properly. 12 heck hydraulic hose and wiring harness routing. -- heck cutterbar area carefully for loose parts and hardware on the cutterbar. WRNING: These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage. RUN-UP PROEDURE 41 heck hydraulic hose and wiring harness routing for clearance when raising or lowering header. heck converging drum operation (grass seed header). 41 heck hazard lights are functional (16 ft. only). 40 POST RUN-UP HEKS. STOP ENGINE. heck belt drives for idler alignment and heated bearings. 36 heck for hydraulic leaks. -- heck header manuals in tractor cab storage compartment Date hecked: hecked by: Form #