186M Windrow Merger. Operator Manual

Transcription

1 186M Windrow Merger Operator Manual Includes operating, adjustment, maintenance, technical, repair parts and safety instructions for the 186M Windrow Merger. Please retain this document for future reference. Keep this manual available for reference to the operator at all times. Do not allow anyone to operate this implement without reading and fully understanding this operator manual. Never allow children to operate on or near any equipment at any time. RCI Engineering LLC RC Rev B 1Nov Copyright 2017 by RCI Engineering LLC 0

2 New Agricultural Implements Warranty Statement RCI Engineering LLC, hereinafter referred to as RCI, warrants new RCI attachments, to the Original Retail Purchaser to be free from defects in material and workmanship for a period of one (1) year from the date of sale. RCI warranty includes: Genuine RCI parts costs and labor required to repair or replace equipment at the selling dealer s business location. RCI MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT. RCI WARRANTY DOES NOT INCLUDE: 1. Transportation to the selling dealer s business location or, at the option of the Original Retail Purchaser, the cost of a service call. 2. Freight costs above standard shipping costs for the replacement parts. 3. Used equipment. 4. Components covered by their own non-rci warranties, such as tires and trade accessories. 5. Normal maintenance service and expendable, high-wear items. 6. Sacrificial components designed to fail to prevent damage to other components when obstructions are encountered (i.e. shear bolts, pickup teeth) 7. Repairs or adjustments caused by: improper use; non-intended use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty. 8. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment or damage to machines to which the attachment is installed. No agent, employee, or representative of RCI has any authority to bind RCI to any warranty except as specifically set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty; all other terms will continue to apply. 1

3 186M Windrow Merger The 186M Windrow Merger from RCI Engineering is a simple, cost-effective solution to merging windrows together while minimizing dirt and foreign material in the windrow as can be experienced in raking operations. Intended Use: For merging two or three windrows from up to 18' wide cut widths into a single windrow. The 186M can also function as a very effective windrow inverter for improved crop drying in some conditions. Product Highlights: Effective pickup width is 8 6 wide. Tine bar assembly features six tine bars with center support. Extension with 3 feet of length is standard equipment. A bundle to increase the extension length to 5 is available and recommended when tripling 16 or 18 cut widths to a windrow of less than 8 wide. If tripling windrows from a 16 cut width and a final windrow width of under 9 is needed, the standard extension is sufficient. The longer extension option is recommended for all cut widths of greater than 16. Windguard is standard equipment. Pickup and belts are driven hydraulically in series. Gauge wheels are adjustable. Conveyor extension shut-off valve is standard equipment such that the merger can be used with the extension in the transport position. Can be used with virtually any 50+ hp tractor with a drawbar, self-contained oil cooler, and two remote hydraulic valves Unit discharges at the right side with the extension in the raised or lowered position. Reversible belt direction is standard equipment. 2

4 Product Limitations: The 186M is not recommended at this time for use with tractors without integrated oil coolers. When used on a tractor with open-center hydraulics and no flow control from the tractor, a pair of plugs must be removed from the manifold to allow for flow control at the manifold. Refer to the 186M Operator Manual for more information. The maximum transport speed for the unit is 25 mph. Additional safety lighting may need to be added if pulled behind any vehicle besides a tractor. See local DOT regulations regarding lighting requirements for road transport when not using a tractor. Ordering Information: Part Number Description Comments RC M Merger, Base Unit RC Bundle, 2-Foot Extension Addition Total of 5 extension length Setup Time: Approximately 2 hours of setup time is required from shipping configuration to field operation when shipped on a skid. When shipped via flatbed trailer, the unit requires approximately 30 minutes of setup time for preparation to the field. RCI Engineering LLC also offers an assortment of attachments for John Deere hay and forage equipment to improve performance, increase efficiency and to increase machine capabilities in different crop and field conditions. The 186M Merger is not an Allied Product for John Deere, but is available through any John Deere dealer. RCI Engineering LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously manufactured or sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice. 3

5 Table of Contents Section Page Warranty Statement... 1 Intended Use... 2 Table of Contents Specifications. 5 Pre-Delivery Checklist... 6, 68 Delivery Checklist... 8, 70 Safe Operation of Machine Safety Warning Signs 11 Safety Sign Locations Safety Sign Definitions Setup Instructions Field Operation Adjustments.. 20 Maintenance Service Troubleshooting Hydraulic Functional Schematic.. 34 Bolt and Screw Torque Values Repair Parts Parts Index

6 186M Merger Specifications Pickup Pickup Working Width 8' 6 Type Cam w/tine bar reel Number of Cams 2 Number of Tine Bars 6 w/ center support Wind Guard Yes Pickup Drive Hydraulic Stripper Guard Type Metal Float System Spring Conveyor Belt Width, in. 35 1/4" Lug Height, in. 3/4" Lug Width, in. 32 1/2" Extension Yes Length 36" Standard; 60 Optional Extension Folding Hydraulic Belt Drive Hydraulic Tractor Hyd. Drive System Yes GPM/PSI Required 12 / 2000 Hydraulic Remotes Needed 2 Tractor Size Minimum 50 hp Dimensions & other Specifications Base Weight, lbs 2,200 approx Transport Width 10' 11" Transport Length 12' Tire Size (Frame) 26 x Gauge Wheel Size 18.5 x Operating Speed 2 to 12 mph Transport Speed Up to 25 mph Merging Width Cuts Up to 18' (with optional extension) 5

7 Pre-delivery Checklist (Copy for Return to RCI at back of this manual) After the unit has been assembled and lubricated and prior to delivery to customer, the merger needs to be inspected thoroughly to ensure it is in proper working order. The following checklist must be reviewed and each item found to be satisfactorily completed. Windrow merger has been setup according to the instructions included in this manual. All grease fittings have been lubricated. All guards, shields and safety decals are in place, securely fastened, and operate correctly. All nuts and bolts have been tightened and inspected. Adjustments have been made as described in the Adjustments section of this manual Crop guides at belt installed properly. Gauge wheels installed and inflated properly. All moving parts operate freely. Belt tension set properly. Extension belt tension set properly. All applicable warranty information recorded. I acknowledge that the pre-delivery service was performed and the unit is ready for delivery to the customer. Dealership s Name Representative Date Model Number Serial Number Date Sold Owner s Name and Address Name Address City, State, Zip Original: Enclose in manual and give to customer at time of delivery. Copy: Dealership Copy: RCI Engineering LLC RCI Engineering LLC Fax: info@rciengineering.com Mail: 208 River Knoll Drive, Mayville, WI

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9 Delivery Checklist (Copy for Return to RCI at back of this manual) The following items must be performed when delivering the attachment to the customer. Check off each item as it is performed. Provide the customer with the Operator's Manual and instruct them to read prior to operating the unit. Review and explain all safety information and operating adjustments. Review and explain maintenance and lubrication schedule that is required to ensure proper operation and long life. Show how to properly adjust the belt tension as instructed in the Adjustments section. Make it be known that if the customer can visit or call the dealership to discuss any questions or problems they may encounter. Complete the Owner s Registration with the customer, ensure it is completely filled out, and return it to RCI Engineering. Date Delivered Signature Original: Enclose in manual and give to customer at time of delivery. Copy: Dealership Copy: RCI Engineering LLC RCI Engineering LLC Fax: info@rciengineering.com Mail: 208 River Knoll Drive, Mayville, WI

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11 Safe Operation of Machine Operator Authorization The machine owner must provide the operator of the machine this manual and ensure that the operator reads and understands the contents. This must be performed before the machine is put into operation. Safety Alert Symbol This safety alert symbol is used to alert the operator to the potential for personal injury. Whenever this symbol is noticed in this manual or on the machine, be alert to the situation and read the message near the symbol shown in graphical format. Always be alert for the potential for personal injury. General Safety Precautions / Accident Prevention Before operation of the machine each time, check the entire machine for operational safety. 1. BEFORE unclogging, removing material, cleaning, adjusting, servicing, or lubricating, the operator must: a. Disengage tractor, put the tractor in park, shut off the engine, and remove the key from the ignition. b. Wait until all parts have stopped moving. 2. The warning and safety decals on the attachment provide important information to ensure safe operation of the machine. Follow these instructions at all times to remain safe. Replace all such decals if they should become illegible or be missing. 3. Avoid loose fitting clothing while operating this implement. The operator should always wear close-fitting clothing and sturdy footwear. 4. Before operation of this implement, become familiar with all controls of the prime mover and implement and understand the function of this implement. 5. Check all guards and shields to make sure they are in place and functional. Replace any defective or missing guards, shields, or components before operation. 6. To transport the merger on the road, raise the unit to its highest position and fold the extension to its transport position. Engage the hand valve for the extension to prevent unintentional opening. Engage the pickup lift lock arm to prevent unintentional lowering of the unit. Disengage the main drive clutch. 7. Keep clear of the working and danger area of the machine. 8. Use proper personal protection for eyes, ears, and head to protect against projected objects and noise. 9. Do not modify the machine. Unauthorized modifications may affect the safety and longevity of the machine and voids warranty. 10. Check with local authorities for regulations regarding transportation of the unit on public roads. Ensure that all unit markings are clearly visible before transporting the unit. 11. Restrict on-road towing of unit to 25 mph (40 kmph). 12. Use the safety chain when transporting the unit. 10

12 Safety Warning Signs The safety warning signs feature a hazard description panel without text. It is important to properly identify any hazards when working around the attachment. The signs have a black border and yellow background. Each decal has two boxes of information regarding the hazard. The top or left box of the decal indicates a warning for the hazard. The triangle indicates WARNING. The symbol inside the triangle indicates what the warning pertains to. In some cases, a simple explanation mark is used. The right or bottom box of the decal indicates an instruction on how to respond to the hazard. Reference each decal to the operator manual for further explanation of the meaning of the decal and respond accordingly. 11

13 Safety Sign Locations Decal locations are identified in the figures below and referenced on the following pages. 12

14 Safety Sign Definitions Safety Sign 1 This safety sign is a general warning sign instructing the operator to read the Operator's Manual for an explanation of safety signs applicable to the machine. The Operator's Manual is located in a tube holder at the left rear corner of the machine. Figure 1. Safety Sign 1 Safety Sign 2, 3, and 7 These reflective decals are for proper machine marking for transport. Ensure that these decals are clearly visible and clear of debris before transporting unit. Safety Sign 4 This safety sign is a warning of injury due to escaping hydraulic fluid under pressure. Keep away from this area when the hoses have hydraulic pressure to avoid the hazard. Failure to do so may result in serious injury. Figure 2. Safety Sign 4 Safety Sign 5 This safety sign is a warning of entanglement of moving parts. Keep all body parts away from moving parts. Failure to do so may result in serious injury. Figure 3. Safety Sign 5 13

15 Safety Sign 6 This safety sign is a warning of a pinch point. Keep clear of this area and do not place any body parts in this area due to the risk of the pinch point. Failure to do so may result in serious injury. Figure 4. Safety Sign 6 Safety Sign 8 This safety sign is an indication that tire pressure is critical to proper machine operation and reliability. This decal is located on the tongue of the unit near the jack stand storage position. Figure 5. Safety Sign 8 Safety Sign 9 This safety sign is a Slow Moving Vehicle Sign and is provided to meet the requirements of on-road transportation. Always make sure this decal is complete, clean, and visible to the rear of the implement whenever transporting the machine on public roads. Figure 6. Safety Sign 9 14

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17 Setup Instructions Convert from Shipping to Field Setup Each unit is shipped with the tongue in a raised position. See Figure 7. Perform the following actions to prepare the machine from shipping configuration to field configuration: 1) Release unit from shipping skid by cutting shipping straps. 2) Remove the hitch from the skid. See Key 1 Figure 7. Release the shipping strap from the hitch. See Key 1 Figure 8. Retain hardware and Strap. Figure 7. Shipping Configuration Key 1 - Hitch 3) Using a lift or other device, safely lower the tongue until the Latch can fit the pin in the rear hook point of the latch. See Key 2 Figure 8. 4) Install the hitch into the tongue and replace the ¾ bolts provided. Torque bolts to 280 lb-ft (380 Nm). See Figure 9. Figure 8. Shipping Lock Key 1 Shipping Strap Key 2 - Latch 5) Install Jack Stand and Hydraulic Hoses as indicated in Figure 9. Slots are provided for hose storage when not in use. 6) Lift the unit with a forklift from the rear through the fork pockets in the main frame. Take care to not damage any tine bars or tines. Secure the merger to the forklift in a safe manner. Do not move the merger fore/aft with the forklift. 7) Place the merger on blocks for safety. Install spindles and tires. Tighten all hardware properly. Remove shipping skid, remove safety blocks and lower unit to the ground. Figure 9. Htich Installation Key 1 Hitch Key 2 Bolts Key 3 Jack Stand Key 4 Hoses Key 5 Hose Mounts 16

18 8) Install the shipping strap from the hitch as a stop on the lower side of the tongue frame. See Figure 10. IMPORTANT: Ensure that the plate is arranged with the hook slot towards the front of the merger and the wide area extended under the frame of the merger. 9) Install pin at hydraulic cylinder. Install spring at pivot link. See Figure ) Grease unit. See Maintenance Section of this manual. 11) Verify tire pressures are set correctly. See Service section of this manual. Figure 10. Lift Cylinder Assembly Key 1 Cylinder Key 2 Spring Key 3 Pin Key 4 - Stop 12) Use the shipping blocks to create a ramp in front of the skid at the tires. Connect the unit to a tractor and pull from the shipping skid. See Attach Merger to Tractor in the next section. 17

19 Attach Merger To Tractor Perform the following actions when connecting the merger to a tractor. 1) Disengage tractor, put the tractor in park, shut off the engine, and remove the key from the ignition. 2) Install hitch pin and hitch pin clip. 3) Install safety chain. 4) Install hydraulic hoses. 5) Lower jack stand and move to storage position at the top of the tongue. Place in a horizontal position. Field Operation The 186M Windrow Merger is capable of merging windrows from cut widths up to 16' with the standard extension. With the longer extension, merging of cut widths up to 18 can be accomplished. In some configurations, three windrows can be put together into one windrow. The unit is also capable of merging windrows with or without the extension in the lowered position. However, in heavier crops, it may be necessary to use the extension due to limited clearance beneath the extension. To prepare the 186M for field operation, perform the following: 1) Raise the pickup to the highest position to relieve pressure on the transport lock. WARNING: Hydraulic systems at rest may contain hydraulic pressure. Do not disconnect or service hydraulic systems with pressure in the system. Relieve all pressure before performing any service work. Beware of components that may move when changing selections with valves or removing locking mechanisms. Failure to do so may result in serious injury. 2) Disengage tractor, put the tractor in park, shut off the engine, and remove the key from the ignition. 3) Disengage the transport lock. See "Engage / Disengage Transport Lock" in the next section. 4) Return to the tractor and slowly release all hydraulic pressure on all circuits to lower the pickup to the ground. IMPORTANT If required to start the engine or tractor electrical circuit to relieve hydraulic pressure, be sure to repeat Step 2 before proceeding to Step 5. 5) If it is desired to use the extension, slowly switch hydraulic valve near jack storage position to the OPEN position. "See Engage/Disengage Extension Folding" in the next section. If use of the extension is not desired, proceed to Step 12. 6) Return to the tractor and start the unit while following the General Safety Precautions on Page 8 of this manual. 7) Lower the extension by activating the hydraulic function to lower the pickup to the ground. The extension will move to a lowered position. Be 18

20 sure to lower extension completely before proceeding. 8) Disengage tractor, release all hydraulic pressure, put the tractor in park, shut off the engine, and remove the key from the ignition. 9) Slowly switch hydraulic valve near jack storage position to the CLOSED position. "See Engage/Disengage Extension Folding" in the next section. 10) Engage the extension belt motor by selecting the "Motor Engaged Position" at the hydraulic manifold. See "Extension Motor Engage / Disengage" in the next section. IMPORTANT When the extension is not in use, be sure the extension motor is disengaged. Failure to do so may result in belt damage. 11) Return to the tractor and start the unit while following the General Safety Precautions on Page 8 of this manual. 12) Proceed to merging operation. To prepare the 186M for transport from the field, perform the following: 1) Engage the transport lock. See "Engage / Disengage Transport Lock" in the next section. Folding" in the next section. If the extension was not used, proceed to next step but skip Steps 5 and 6. 3) Raise the pickup to the highest position to allow the transport lock to fall into place. Continue to raise the pickup to raise the extension to transport position. Verify the transport lock is engaged. 4) Disengage tractor, release all hydraulic pressure, put the tractor in park, shut off the engine, and remove the key from the ignition. 5) Slowly switch hydraulic valve near jack storage position to the CLOSED position. "See Engage/Disengage Extension Folding" in the next section. 6) Disengage the extension belt motor by selecting the "Motor Disengaged Position" at the hydraulic manifold. See "Extension Motor Engage / Disengage" in the next section. 7) With the tractor still shut off, disengage the main clutch at the rear axle. See "Engage/Disengage Main Clutch" in the next section. 8) Return to the tractor and start the unit while following the General Safety Precautions on Page 8 of this manual. 9) Proceed to transporting of unit. 2) If the extension was used, slowly switch hydraulic valve near jack storage position to the OPEN position. "See Engage/Disengage Extension 19

21 Adjustments IMPORTANT: Before making any adjustments to the windrow merger, lower pickup to ground or lock the pickup in transport position. (See "Engage / Disengage Transport Lock in this section.) Set the park brake of the tractor and shut off the engine. Remove the key from the ignition. Float Pressure The 186M Merger is preset to operate under full spring load in normal operation. To reduce float pressure, tension must be adjusted on the spring. Loosen jam nut (Key 2, Figure 11) and turn adjustment rod (Key 3, Figure 11). Counterclockwise will decrease spring tension and result in higher ground pressure. Figure 11. Float Adjustment Key 1 - Spring Key 2 - Jam Nut (Hidden) Key 3 - Adjustment Rod Gauge Wheel Adjustment To adjust the gauge wheels, the unit must be raised to transport position and the transport lock must be engaged. See "Engage / Disengage Transport Lock in this section. With the tractor disengaged, in park and engine off with the key removed, remove adjustment bolt, (Key 1, Figure 12). Move gauge wheel support bracket (Key 2, Figure 12) up or down to desired location (minimum recommended ground clearance for tines is 1" (25 mm)) and reinstall adjustment bolt. Tighten bolt properly. Figure 12. Gauge Wheel Adjustment Key 1 - Adjustment Bolt Key 2 - Spring Repeat operation at opposite side of unit. 20

22 Engage / Disengage Transport Lock The transport lock is located at the left side of the implement. Before disengaging the transport lock, disengage tractor, release all hydraulic pressure, put the tractor in park, shut off the engine, and remove the key from the ignition. Disengage the transport lock (Key 1, Figure 13) by moving the lock to a raised position. To engage the transport lock, first disengage tractor, release all hydraulic pressure, put the tractor in park, shut off the engine, and remove the key from the ignition. Move the transport lock (Key 1, Figure 13) to a lowered position. before performing any service work. Beware of components that may move when changing selections with valves or removing locking mechanisms. Failure to do so may result in serious injury. Turn the hydraulic valve to the OPEN position. See Figure 14. When in the OPEN position, the extension will fold up when the pickup is raised. The extension will also fold down once the pickup is lowered completely and the operator continues to operate the pickup lower function. IMPORTANT Close the hydraulic valve when it is not desired to have the extension raise or lower. Return to the tractor and start the unit while following the General Safety Precautions on Page 8 of this manual. Raise the pickup to the highest position to allow the transport lock to fall into place. Verify the transport lock is engaged. Raise / Lower Extension The extension is raised and lowered using the same hydraulic circuit as the pickup raise / lower circuit. Figure 13. Transport Lock Key 1 - Transport Lock (Lowered Position) The extension raise / lower function is enabled or disabled by use of a handcontrolled hydraulic valve located on the tongue near the jack stand storage location. To raise the extension, first ensure there is no hydraulic pressure in the system. WARNING: Hydraulic systems at rest may contain hydraulic pressure. Do not disconnect or service hydraulic systems with pressure in the system. Relieve all pressure Figure 14. Hydraulic Valve Key 1 - Valve OPEN 21

23 Engage / Disengage Extension Motor The extension motor is engaged and disengaged manually. IMPORTANT When the extension is not in use, be sure the extension motor is disengaged. Failure to do so may result in belt damage. Always release all hydraulic pressure, lower unit to ground or transport stop, engage park brake, turn off tractor, and remove key before making any adjustments. To engage the extension motor, first release the lock ring of the manual valve for the extension. Then turn the manual valve on the manifold clockwise completely to engage the extension. Turn the lock ring tight to lock. See Key 1, Figure 15. Figure 15. Valve for Extension Motor Key 1 - Valve (Engaged) IMPORTANT Do not use tools to turn the hand valve as component damage may result. To disengage the extension motor, push the manual valve on the manifold in slightly, turn counterclockwise, and pull the valve out. Windguard Adjustment The windguard is adjustable for stop positions in a raised and lowered position. The default position is such that the windguard tines are positioned directly above the pickup tines such that no pickup tines extend above the windguard. The end tine of the windguard is bent higher than the others to allow for more flow at the corner of the extension mount to help prevent any accumulation in this area. To adjust the windguard, loosen the stop bolts (Key 2, Figure 16) and move to the desired location. Retighten properly. Figure 16. Windguard Adjustment Key 1 - Windguard Key 2 - Stops (qty 2) 22

24 Pickup Speed Adjustment Closed Center Systems The tine speed is adjustable in series with the belt speed by adjusting hydraulic oil flow. IMPORTANT: For closed-center hydraulic-type tractors, always leave the hand valves of the merger manifold completely open (turned out fully). See Figure 17. For closed-center tractors, adjust the flow of the tractor to control the pickup speed. To set the maximum speed, first, start with a slow oil flow and increase the hydraulic flow slowly until the pickup speed no longer increases or a pulse develops in the pickup speed, whichever occurs first. Then decrease the hydraulic flow slightly to make sure that oil is not pushing over relief in the tractor. Note: A new manifold is used starting with serial number RCIX Units built prior to this serial number break do not feature the ability to switch between open-center and closed-center tractors and do not have flow control built into the manifold. For units with earlier serial numbers, the belt motor circuit is equipped with a fuse to prevent over speed and implement damage. If hydraulic flow exceeds 11 gpm (42 lpm), the fuse will trip. To reset the fuse, release all hydraulic pressure on the motor circuit through the float position of the tractor hydraulic function. Resume operation once reset. To set a slower speed, decrease the tractor oil flow. IMPORTANT: It is important to limit the tractor output to less than 12 GPM to avoid pushing oil over the relief in the tractor which can cause the tractor hydraulic system to overheat. The manifold on the merger protects the motors from over speed, but not from overheating. Figure 17. Pickup Speed Adjustment Key 1 Forward Flow Control (Fully CCW) Key 2 Lock Ring Key 3 Reverse Flow Control (Fully CCW) IMPORTANT: Depending on tractor make and model, engine speed can impact the hydraulic oil flow to the merger during this process. Always set the tractor engine rpm to desired operating speed before setting merger hydraulic speeds. 23

25 Changing Between Closed- and Open- Center Hydraulics The default configuration for the hydraulic manifold is for Closed-Center Hydraulics. Note: A different manifold is used starting with serial number RCIX Units built prior to this serial number break do not feature the ability to switch between opencenter and closed-center tractors and do not have flow control built into the manifold. For units with earlier serial numbers, the belt motor circuit is equipped with a fuse to prevent over speed and implement damage. If hydraulic flow exceeds 11 gpm (42 lpm), the fuse will trip. To reset the fuse, release all hydraulic pressure on the motor circuit through the float position of the tractor hydraulic function. Resume operation once reset. There are two flow control valves on the manifold. The third, silver handle is the valve used to engage/disengage the extension motor. Each valve is also labeled on the manifold with engraved letters. There is one valve for belt forward speed and one for belt reverse speed. See Fig. 19. To adjust the pickup and belt speed, first loosen the lock collar at the speed control valve of the manifold. Turn the valve clockwise (in) to decrease speed and counterclockwise (out) to increase speed. IMPORTANT: The valves are to be only adjusted by hand. Do not use tools as implement damage may result. On units with serial number 835 and above, change from closed- to open-center by removing the plugs inside the PLG ports and store them in the machined ports in the manifold as indicated in Figure 18. Reinstall outer plugs when complete. To revert back to closed-center hydraulics, reinstall the plugs under the cartridges. Pickup Speed Adjustment Open Center Systems The tine speed is adjustable in series with the belt speed by adjusting hydraulic oil flow. WARNING: Only adjust the belt speed when the tractor is turned off, park brake is set, key is removed, and all pressure is relieved from the system and unit is lowered to the ground. IMPORTANT: For open-center tractors, see previous section. Figure 18. Plug Locations Key 1 -PLG1 Port Key 2 PLG2 Port Key 3 Plug 1 Storage Key 4 Plug 2 Storage Figure 19. Pickup Speed Adjustment Key 1 Forward Flow Control Key 2 Lock Ring Key 3 Reverse Flow Control 24

26 Maintenance Perform general lubrication every 10 hours of operation or before and after intermediate use (before and after seasonal harvests) unless otherwise specified. Severe or unusual conditions may require more frequent lubrication. The following illustrations show the lubrication points on the unit. Prior to using grease gun, clean the grease fitting. Replace lost and broken grease fittings immediately. Grease fitting locations: Figure 20. Gauge Wheel Grease Fitting Key 1 - Fitting Location 1. Gauge wheels adjusters at 1 place on each end. See Figure Pickup raise / lower pivot pins at 1 place on each end. See Figure Wheel clutches at outer housings within wheel well on each side. See Figure 22. Inspect pickup/cylinder tines and tine bar guards daily for damage. Replace damaged tines immediately to prevent further damage to other tines and the tine bar assembly. Figure 21. Pickup Raise / Lower Pivot Key 1 - Fitting Location (Each End) Figure 22. Wheel Clutch Key 1 - Wheel Clutch Fitting (qty 2) 25

27 Service Cam Bearing Replacement Right end pickup cam bearing replacement. 1. Remove the cover from the cam track. 2. Remove the first tine bar guard from the end for clearance to work. 3. Loosen the bolt retaining the cover tab and move the tab for clearance to the access hole for removal of the bearing retaining bolt. See Figure Remove the cam bearing bolt. 5. Replace the cam bearing. 6. Reassemble components using red loctite on the cam bearing bolt. SPECIFICATION: Cam bearing bolt torque: 46 lb-ft (63 N-m)* *MUST USE RED LOCTITE Figure 23. Access Hole Location Key 1 - Access Hole Cover (1 each end) Straightening Bent Tines There should be approximately 6 (150 mm) gap between the point of tine disappearance and the end of the slot. If the distance is different, bend the tine back to the original position of 6 (150 mm). See Figure 24. Figure 24. Tine Gap Key 1 - Tip of Tine Key 2 - Gap of 6 (150 mm) 26

28 Broken Tine Replacement Broken tines must be replaced immediately to prevent damage to other components. To replace a broken tine: 1. Remove the tine guard covering the broken tine. 2. Remove the 3/8 x 1¼ bolt and tine clip holding the broken tine in place. 3. Replace the broken tine with a new part. 4. Secure the tine using the 3/8 x 1¼ bolt, tine clip, and lock nut. SPECIFICATION: Tine bolt torque: 28 lb-ft (38 N-m) Figure 25. Tine installation Key 1 - Tine Key 2 - Tine Bar Key 3 - Bolt Key 4 - Tine Clip Key 5 - Lock Nut Key 6 - Radius Edge IMPORTANT: Radius edge towards tine IMPORTANT: Install tine clip with cup side towards bolt head (round edge towards tine). Failure to do so may result in premature failure of tine. See Figure Replace the tine guard. Tine Bar Guard Replacement Damaged tine bar guards must be replaced immediately to prevent damage to other components. To replace a damaged tine bar guard, remove all four retaining bolts. The guard will now slide forward for removal. See Figure 26. Figure 26. Tine Bar Guard Key 1 - Guard Key 2 - Lifter Key 3 - Front Bolt Key 4 Rear Bolt 27

29 Tire Pressures Inspect tire pressures and adjust appropriately. SPECIFICATION Gauge Wheel Pressure: Max 20 psi (140 kpa) Drive Wheel Pressure Max 20 psi (140 kpa) Main Belt Tension The main belt of the merger is automatically adjusting, but requires occasional maintenance to reset the spring. Adjust the spring tension such that the black bushing over the spring is loose so that it can be turned but not moved laterally along the spring. Use the jam nut to prevent the adjustment nut from loosening during operation. Adjust both sides of the belt as required. See Figure 27. Verify the main belt is clean and in proper alignment on grooves and the frame before and after tensioning. Figure 27. Main Belt Tension Adjustment Key 1 - Adjustment Nut Key 2 - Jam Nut Key 3 - Bushing Extension Belt Tension The extension belt is adjusted manually and must be adjusted regularly so the belt does not sag more than 3/4" (19 mm) at the bottom between the rollers. To adjust the extension belt, first loosen the four carriage bolts (Key 1, Figure 28) that hold each adjuster plate in place. Adjust the adjuster bolt (Key 2, Figure 28) to move the roller in the desired direction for belt tension. When the proper belt tension is gained, tighten all hardware properly. Figure 28. Extension Belt Tension Adjustment Key 1 - Carriage Bolt (qty 4 per side) Key 2 - Adjustment Bolt 28

30 Implement Plugging Should the unit encounter an obstruction of crop at the pickup, use the following procedure to remove the restriction. 1. Stop the forward motion of the tractor. 2. Continue to run the hydraulics for the pickup. 3. Slowly reverse the direction of the tractor with the pickup in the lowered position. 4. If the obstruction does not clear within 5 seconds, raise the pickup while continuing to reverse the tractor. 5. If the obstruction does not clear within 5 seconds of raising the pickup, reverse the direction of the belt by reversing the hydraulic flow. 6. If the obstruction still does not clear, stop the oil flow to the merger, lower unit to the ground, remove all hydraulic pressure, turn off the tractor, and remove the key. 7. Remove obstruction manually. Belt Care The belt compound includes polyesterreinforced-rubber. Although designed for durability, the following is important to consider to maximize the life of the belt. 1. Always store the unit out of direct sunlight in a cool, dry place free of rodents. 2. Always keep the belt and rollers free of debris, moisture (when not in use), oil, grease, and any other chemicals that may affect the belt. 3. Do not treat the belt with any belt dressing of any kind. 4. Prevent damage to the belt by avoiding foreign objects that may cause cuts or damage to the belt. 5. Make any necessary repairs to the edges of the belt if they are damaged by improper adjustment or any other outside force. 6. Use the lowest belt speed allowable for the crop conditions. Higher belt speeds typically result in lower belt life. 7. Keep the area under the crop guides clear of crop build-up. Over time, crop debris can accumulate and cause heavy wear on the belt. 8. Regularly inspect and adjust belt tension as needed. Improperly tensioned belts can result in belt slippage on the drive roller or excessive wear. 29

31 Preparation for Storage At the end of the season, the following should be done before putting the windrow pickup attachment into storage. 1. Clean the merger of all chaff, dirt, excess grease, and any other material that will draw moisture and cause rust. 2. Thoroughly lubricate the merger as described in the Maintenance section. 4. Store merger with transport lock in place and extension in the transport position. 5. Store in a dry place out of the elements, if possible. 6. Order and replace any parts needed for next season. 3. Paint all parts where the paint has been removed. 30

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33 Troubleshooting Problem Cause Remedy Belt will not move. Obstruction to belt. Clear obstruction. Hydraulic valve closed. Open hydraulic valve. Will not float freely. Float spring is too tight. Loosen float springs Hydraulics not functioning properly. Inspect for proper connection of hoses. Crop is left in the field Gauge wheels are too low. Adjust gauge wheels up to make the tines lower. Ground speed too slow. Adjust flow to pickup. Pickup tines are bent or Straighten / replace tines. missing. Tines dig into the ground. Gauge wheels are too high. Adjust gauge wheels. Float improperly adjusted. Adjust float. Tines do not revolve. Obstruction to pickup. Clear obstruction. Broken cam. Replace cam. Tines bend / break Ground clearance too low. Adjust float or gauge wheels. Foreign material inside tine Remove material. guides. Crop is blown out of Windguard is in raised Adjust windguard. pickup tines by the wind. position. Crop does not feed Tines missing or broken. Straighten or replace tines. smoothly to belt. Tine bar guards are worn or Replace tine bar guards. missing. Large windrows* or fast ground speed Reduce windrow size and/or ground speed.* * This unit is not designed to pick up windrows that are already merged. 32

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35 Hydraulic Functional Schematic 34

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37 Bolt and Screw Torque Values 36

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39 Repair Parts General Comments The following pages include information regarding parts for the 186M Windrow Merger. Right or left hand parts are determined by sitting in the operator s seat facing forward. The abbreviation A.R. in the USED column indicates As Required. This is because a different number of the specific component may be needed for proper assembly depending on the tolerance of the individual implement. All parts listed for the 186M Windrow Merger are available from your local John Deere dealer. Attention: Dealer Contact RCI directly for all part orders for this attachment. Please include a serial number and model of the attachment when placing a parts order. The serial number plate is attached to the rear of the unit along the frame rail. Replacement Hardware All bolts, cap screws, washers and machine screws are standard grade 5 and zinc plated unless markings on the part indicate otherwise. The use of improper hardware in any location can result in the failure of the component fastened with the hardware or related structures, and can cause personal injury, further damage to the product, or loss of property. Replacement Parts Replacement parts may have occasional differences to the parts being replaced. This difference is typically providing the benefit of a design change made after the release of this publication. Recommended Spare Parts Listing - Dealer The following spare parts are recommended for stocking purposes and include common wear items for this attachment. Part Number Description Qty. RC Guard, Tine Bar 5 RC Assembly, Bearing 1 RC Bearing (Cam) 5 RC Clip, Tine 5 RC Tine, Pickup 10 RC Belt, Conveyor 1 RC Belt, Extension 1 38

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41 Parts Index Section Page Hitch and Wheel Components Hitch Pivot Components Pickup Components Conveyor Components Extension Components Long Extension Components Windguard Components Motor and Manifold Components Hydraulic Components Decals Left Decals Right Decals Back

42 Hitch And Wheel Components 41

43 Hitch and Wheel Components Key Part Number Description Qty Comments 1 RC Pivot 2 2 RC Takeup 2 3 RC Plug, Lower Spring 2 4 RC Spring 2 5 RC Plug, Upper Spring 2 6 RC Axle, Adjustable 2 7 RC Pin, Pivot 2 8 RC Stand, Jack 1 9 RC Bushing, 1.00 Machine 2 10 RC Sprindle 2 11 RC Valve, Ball 1 12 RC Cushion, Hose 4 13 RC Cushion, Hose 4 14 RC Plate, Cushion 4 15 RC Clamp, Hose 3 16 RC Chain, 3/8" x 40" 1 17 RC Hook 1 18 RC Assembly, Tongue 1 19 RC Tongue 1 20 RC0188 Spindle 2 21 RC Assembly, Rear 2 22 RC Assembly, Gauge Wheel and Tire 2 23 RC Nut, 1/2-13 YZ Nylock 1 24 RC Washer, 3/4 SAE YZ Flat 4 25 RC Washer, 1/2 SAE YZ Flat 4 26 RC Pin, 1/4 X 1-1/2 Spring 2 27 RC Nut, 5/8-11 YZ Hex Jam 2 28 RC Screw, 1/4-20 x 5/8 Thread Cutting 3 29 RC Screw, 1/4-20 x 2 Thread Cutting 2 30 RC Bolt, 3/8-16 x 2.5 Gr 5 YZ Hex 2 31 RC Washer, 5/8 SAE YZ Flat RC Bolt, 1/2-13 x 1-3/4 CZ Carriage 1 33 RC Bolt, 5/16-18 x 1 Gr5 YZ Hex 2 34 RC Washer, 5/16 SAE YZ Flat 6 35 RC Washer, 5/16 YZ Lock 6 36 RC Nut, 3/8-16 YZ Nylock 4 37 RC Bolt, 3/8-16 x 3 Gr 8 YZ Hex 2 38 RC Washer, 5/8 YZ Lock 2 39 RC Bolt, 5/16-18 x 3-1/2 Gr5 YZ Hex 4 40 RC Nut, 3/4-10 Gr 8 YZ Nylock 2 41 RC Bolt, 3/4-10 x 6 Gr 8 YZ Hex 2 42 RC Pin, 1/8 x 1 YZ Cotter 2 43 RC Bolt, 5/8-11 X 1-1/2 Gr8 YZ Hex 2 44 RC Pin, 5/8 x 2-1/2 Clevis 2 45 RC Bolt, 1/2" NF Lug 20 42

44 Hitch Pivot Components 43

45 Hitch Pivot Components Key Part Number Description Qty Comments 1 RC Latch 1 2 RC Cylinder, Lift 1 3 RC Spring, Cylinder 1 4 RC Link, Cylinder 1 5 RC Fitting, Orifice 1 6 RC Stop 1 7 RC Tongue 1 8 RC Pin, 5/8 X 4 CZ Clevis 1 9 RC Nut, 1/2-13 YZ Nylock 1 10 RC Bolt, 1/2-13 x 1-1/2 Gr 8 YZ Hex 1 11 RC Washer, 3/4 SAE YZ Flat 1 12 RC Washer, 1/2 SAE YZ Flat 2 13 RC Washer, 1/2 Belleville 1 14 RC Washer, 3/8 SAE YZ Hard Flat 4 15 RC Bolt, 3/8-16 x 1-1/2 Gr 5 YZ Hex 2 16 RC Pin, 3/16 X 1 CZ Cotter 1 17 RC Zerk, 1/8 NPT Straight Grease 1 18 RC Bolt, 3/8-16 x 2.5 Gr 5 YZ Hex 1 19 RC Washer, 5/8 SAE YZ Flat 3 20 RC Nut, 3/8-16 YZ Nylock 2 21 RC Nut, 3/8-16 YZ Hex 2 22 RC Washer, 1/4 YZ Flat 1 23 RC Pin, 1/4 X 2-1/4 CZ Clevis 1 24 RC Pin, 5/64 X 1/2 Cotter 1 25 RC Pin, 1/8 x 1 YZ Cotter 3 26 RC Pin, 5/8 x 2-1/2 Clevis 2 44

46 Pickup Components 45

47 Pickup Components Key Part Number Description Qty Comments 1 RC Guard, Tine Bar 31 2 RC Reel 1 3 RC Assembly, Bearing 18 4 RC Bar, Tine 6 5 RC Tine, Pickup 96 6 RC Arm, RH Cam 6 7 RC Arm, LH Cam 6 8 RC Bushing 12 9 RC Bearing, Ball RC Shaft, Center Support 6 11 RC Bar, Tine Long 6 12 RC Clip,Tine RC Bolt, 5/16-18 x 1 CZ Carriage 36 Red Loctite - RC RC Nut, Nylock 3/ RC Bolt, 3/8-16 x 2.5 Gr 5 YZ Hex RC Bolt, 3/8-16 x 1-1/4 Gr 5 YZ Hex RC Coupling, Motor 2 18 RC Shaft, Idler 1 19 RC Washer, 5/16 SAE YZ Flat RC Nut, 5/16-18 YZ Nylock RC Bolt, 1/2-20 x 1.75 Gr 5 CZ Hex 12 Red Loctite - RC RC Cam, Inner 4 23 RC Cam, Outer 4 24 RC Guard, RH End Tine Bar 1 25 RC Cover 2 26 RC Guard RC Assembly, Bearing 1 28 RC Hub, Motor 1 29 RC Motor, Hydraulic 1 30 RC Assembly, Tube 1 31 RC Nut, 1/2-13 YZ Nylock RC Screw, 1/2-13 x 1-3/4 Countersunk Allen 2 33 RC Screw, 3/8-24 x 1/2 BO Button Socket Cap 2 34 RC Spacer 3 35 RC Stripper, Left End 1 36 RC Washer, Cup RC Plate, Motor 1 38 RC Screw, 3/8-16 X 3/4 Thread Forming RC Washer, 1/2 SAE YZ Flat RC Screw, 1/4-20 X 5/8 Thread Cutting RC Bolt, 1/2-13 x 1-3/4 CZ Carriage 3 42 RC Washer, 3/8 SAE 2 43 RC Washer, Lock, 1/ RC Screw, 3/8-16 x 1 Gr 5 Thread Rolling 5 45 RC Bolt, Carriage, 1/2-13 x 2-1/4 G RC Bolt, 3/8-16 x 1-1/4 CZ Carriage 2 46

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49 Pickup Components - continued Key Part Number Description Qty Comments 47 RC Adapter, -10 MORB -8 FORB Reducer 2 48 RC Bolt, 1/2-20 x 1-1/4 Gr 8 YZ Hex RC Pin, 1/8 x 2 SS Cotter 2 50 RC Nut, 1-20 Castle 1 51 RC Bolt, 5/16-18 x 2-1/2 Gr5 YZ Hex RC Screw, 3/8-24 X 3/8 BO Button Socket Cap 4 53 RC Key, SQ 5/16 x RC Adapter, -8 MORB -8 MFS 90 Elbow 2 48

50 Conveyor Components 49

51 Conveyor Components Key Part Number Description Qty Comments 1 RC Frame, Main 1 2 RC Channel, Conveyor 2 3 RC Holder, OM 1 4 RC Stop 1 5 RC Scraper 2 6 RC Belt, Conveyor 1 7 RC Assembly, Bearing 4 8 RC Takeup 1 9 RC0347 Spring 2 10 RC Rode, Takeup 2 11 RC0416 Spacer 2 12 RC Roller 1 13 RC Roller, Idler 1 14 RC Deflector 1 15 RC Bolt, 5/16-18 x 1 CZ Carriage RC Washer, 1/2 SAE YZ Flat 2 18 RC Washer, M12 Fender 4 19 RC Nut, 1/4-20 YZ Serated Flange 2 20 RC Washer, 3/8 SAE RC Washer, 5/16 SAE YZ Flat RC Nut, 5/16-18 YZ Nylock RC Bolt, 3/8-16 x 1-1/4 CZ Carriage RC Nut, Nylock 3/ RC Nut, 1/2-13 YZ Hex Jam 8 26 RC Bolt, 1/4-20 x 5/8 CZ Carriage 2 27 RC Pin, Belt 1 28 RC Manual, 186M Operator 1 50

52 Extension Components 51

53 Extension Components Key Part Number Description Qty Comments 1 RC Extension 1 2 RC Pivot, Rear 1 3 RC Pin, Pivot 2 4 RC Brg, Polymer 2 5 RC Bushing, 1.00 Machine 8 6 RC Cylinder 1 7 RC Gear, Laminate 1 8 RC Plate, Brg 2 9 RC Washer 1 10 RC Scraper 1 11 RC Assembly, Bearing 2 12 RC Bearing, Sleeve 1 13 RC Bearing, FHSPFTZ RC Belt, Converyor Ext 1 15 RC Roller 1 16 RC Roller, Idler 1 17 RC Fitting, Orifice 2 18 RC Nut, 1/2-13 YZ Nylock 4 19 RC Bolt, 1/2-13 x 1-1/2 Gr 8 YZ Hex 1 20 RC Washer, Lock, 1/ RC Bolt, 1/2-13 x 4 Gr5 CZ Tap 2 22 RC Bolt, 5/16-18 x 1 CZ Carriage RC Washer, 1/2 SAE YZ Flat 5 24 RC Washer, 3/8 SAE RC Washer, 5/16 SAE YZ Flat RC Washer, Lock, 5/ RC Nut, 5/16-18 YZ Nylock 3 28 RC Bolt, 3/8-16 x 1-1/4 CZ Carriage RC Nut, Nylock 3/ RC Bolt, 1/2-13 X 1-1/4 CZ Carriage 4 31 RC Nut, 5/16-18 YZ Hex 8 32 RC Nut, 1/2-13 YZ Hex 4 33 RC Ring, 1" External Snap 4 34 RC Pin, Belt 1 52

54 Long Extension Components Optional 53

55 Long Extension Components Optional Key Part Number Description Qty Comments 1 RC Extension 1 2 RC Belt, Extension 1 3 RC Seal 2 4 RC Bolt, 5/16-18 X 1 CZ Carriage 16 5 RC Washer, 5/16 SAE YZ Flat 16 6 RC Nut, 5/16-18 YZ Nylock 16 7 RC Belt, Pin 1 8 RC Manual, Operator 1 54

56 Windguard Components 55

57 Windguard Components Key Part Number Description Qty Comments 1 RC Spacer 2 2 RC Bracket, RH Pivot 1 3 RC Windguard 1 4 RC Washer 2 5 RC Bracket, LH Pivot 1 6 RC Bushing, Pivot 4 7 RC Retainer 2 8 RC Nut, 1/2-13 YZ Nylock 4 9 RC Washer, 1/2 SAE YZ Flat 8 10 RC Washer, 3/8 SAE YZ Hard Flat 4 11 RC Bolt, 3/8-16 x 1-1/2 Gr 5 YZ Hex 2 12 RC Pin, 3/16 x 2" Cotter 2 13 RC Bolt, 1/2-13 x 2 Gr 5 YZ Hex 4 14 RC Nut, 3/8-16 YZ Nylock 2 56

58 Motor and Manifold Components 57

59 Motor and Manifold Components Key Part Number Description Qty Comments 1 RC Mount, Motor 1 2 RC Key, SQ.25 X RC Coupler 2 4 RC Motor, Hydraulic 2 5 RC Mount, Motor 1 6 RC Manifold, 186M Hydraulic 1 *1 7 RC Bolt, 1/4-20 x 3/4 YZ Hex 2 8 RC Washer, 3/8 SAE 8 9 RC Washer, 7/16 SAE YZ Flat 4 10 RC Washer, 7/16 YZ Lock 4 11 RC Bolt, 7/16-14 x 1 Gr 5 YZ Hex 4 12 RC Washer, 3/8 YZ Lock 8 13 RC Bolt, 3/8-16 x 1 Gr 5 YZ Hex 8 14 RC Nut, 1/4-20 YZ Nylock 2 15 RC Adapter, -8 MFS, -10 MORB Straight RC Adapter, -8 MFS -10 MORB 90 Elbow 2 *1 For implement s/n RCIX00834 and higher. Replaces previous versions. If replacing on implement s/n RCIX00833 and below, contact RCI for update instructions. 58

60 59

61 Hydraulic Components Key Part Number Description Qty Comments F1 RC COUPLER, QUICK, MALE, -8 FORB 4 F2 RC ADAPTER, Straight, -6 MFS, -6 MORB 1 F3 RC ADAPTER, 90 deg, Elbow, -8 MFS, -10 MORB 2 F4 RC ADAPTER, 90 deg. Elbow, -6 MFS, -8 MORB 2 F5 RC ADAPTER, TEE, -6 MFS, -6 MORB 1 F6 RC ADAPTER, Straight, -8 MFS, -10 MORB 10 F9 RC ADAPTER, 90 deg. Elbow, -6 MFS, -6 MORB 1 F10 RC ADAPTER, -10 MORB REDUCER, -8 FORB 2 F11 RC ADAPTER, ELBOW, 90 DEG, -8 MORB, -8 MFS 2 *1 For other hydraulic components, see previous page. *2 This layout effective for implement s/n RCIX00834 and higher. For units up to s/n RCX00833, components are the same except for the manifold and hose lengths to the pickup reel and main belt motor. 60