Model 802 CENTER MOUNT ADAPTER for New Holland 9030 & TV140 Bi-Directional Tractors OPERATOR’S MANUAL Form 46488 Issue 06/02 Sugg. Retail: $10.
INTRODUCTION This manual contains information on the Model 802 adapter which is required to allow attachment of MacDon Headers to the New Holland 9030 and TV140 Bi-Directional Tractors. NOTE: This supplement does not provide all the information required to operate the header. It must be used in conjunction with your Harvest Header and Tractor Operator's Manuals. CAREFULLY READ ALL MANUALS TO BECOME FAMILIAR WITH RECOMMENDED PROCEDURES BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE OR USE THE MACHINE.
TABLE OF CONTENTS INTRODUCTION.........................................................................................................................................1 SERIAL NUMBER LOCATION ...................................................................................................................3 SAFETY Safety Alert Symbol................................................................................................................................4 Signal Words...................................
SERIAL NUMBER LOCATION Record the serial number in the space provided. 802 Adapter: Plate (A) is located on flow control mounting plate. A 802 ADAPTER SERIAL PLATE NOTE: When ordering parts and service, be sure to give your dealer the complete and proper serial number.
SAFETY SAFETY ALERT SYMBOL This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: ATTENTION ! BECOME ALERT ! YOUR SAFETY IS INVOLVED ! Carefully read and follow the safety message accompanying this symbol. Why is SAFETY important to you? 3 BIG REASONS • ACCIDENTS DISABLE AND KILL • ACCIDENTS COST • ACCIDENTS CAN BE AVOIDED SIGNAL WORDS Note the use of the signal words DANGER, WARNING, and CAUTION with safety messages.
SAFETY SAFETY SIGNS • • • • The safety signs below appear on the adapter. Keep safety signs clean and legible at all times. Replace safety signs that are missing or become illegible. If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the current safety sign. • Safety signs are available from your Dealer Parts Department. To install safety signs: 1. Be sure the installation area is clean and dry. 2.
INITIAL SET-UP PREPARING THE TRACTOR 1. TRACTOR REQUIREMENTS AND SETTINGS: • For 9030 tractor & TV140 tractor without auxiliary pump: 1000 rpm PTO at cab end to operate header drive pump. • For TV140 tractor with auxiliary pump (Factory order NH #720827033)(Field order NH #86019713): One hydraulic circuit with ¾” SAE female hydraulic quick couplers with 25 GPM flow and 4000 psi for header drive. If a flow meter is not available, see Header Controls, page 31 for alternate method.
INITIAL SET-UP PREPARING THE TRACTOR (continued) 3. Install the header control panel in cab: 9030 TRACTOR • Pull the floor mat back. Remove the "knock-out" plug from the 1 3/4" (45 mm) hole (D) in the floorboard. Hole is located 7" (180 mm) forward of floor bend-line, and 13" (330 mm) from the side of the console. • Route the harness plug down through the hole. Pull the plug down between the hoses to the GREEN hydraulic couplers. • Disassemble controller panel (E) from its mounting bracket and cover.
INITIAL SET-UP PREPARING THE TRACTOR (continued) 3. Install the header control panel in cab: A C TV140 TRACTOR • Attach panel mount to left post using existing hardware at (A). Drill a 1/8” (3 mm) hole and install a #10 x ½ self-tapping screw at (B). • Hang control panel on mount by engaging screw heads in slots (C). • Remove rubber grommet (D) near windshield and slit it on the side to allow inserting panel wiring harness.
INITIAL SET-UP PREPARING THE ADAPTER 1. Check that pin (A) is in working position and pin (B) in float lockout position as shown. Repeat at other side. NOTE: At L/H side, pin (B) goes through round hole instead of slot. Loosen float springs to line up slot/hole for pin installation. IMPORTANT: Damage to float may occur if pin (B) is not under frame on both sides. A A B A B INSTALL PINS - BOTH SIDES B 2. Move crop deflector (C) to correct position for the application as shown below.
INITIAL SET-UP PREPARING THE ADAPTER (continued) ADJUSTING OR REMOVING THE CROP DEFLECTOR: Tractor Attached To Adapter: 1. If the tractor is attached to the adapter, partially detach adapter from tractor by following steps 3 through 7 on page 20 of this manual. 2. Proceed with steps 3 through 7 given below. A Tractor Not Attached To Adapter: POSITION TRACTOR FOR HOOK-UP To adjust or remove crop deflector: 1.
INITIAL SET-UP PREPARING THE HEADER Tractor is positioned at header center delivery opening. A center delivered windrow goes under the tractor. Windrow width and height are limited by tractor tire tread width and tractor frame height. Headers with hay conditioner: Cab end tire tread width must be 88” (2235 mm) center to center to clear hay conditioner shield. Headers with Reel Lift: Extend reel lift hose by removing existing coupler and replacing it with hose and coupler supplied with adapter.
INITIAL SET-UP PREPARING THE 721/722 HAY CONDITIONER This conditioner is used with 910 Series and 920/922 Auger Headers. For Model 942 and 970 Series Headers, see page 15. 1. Remove two flange nuts, front hinge support (F), two more flange nuts and bar (J) from rear of conditioner top cover, both sides. DISASSEMBLE FRONT HINGE SUPPORTS 2. 3.
INITIAL SET-UP PREPARING THE 721/722 HAY CONDITIONER (continued) 5. Move rear forming shield support brackets (D) to second bolt from each end. D ATTACH REAR SUPPORTS 6. Remove crop deflector (C) from under adapter to allow conditioner forming shield installation. See page 10 for removal instructions. Remove L-bracket from top of rubber strap and attach rubber strap (E) to adapter frame with 3/8 flange nut and washer supplied with hay conditioner shield.
INITIAL SET-UP PREPARING THE 721/722 HAY CONDITIONER (continued) 7. Remove spacers (G) from shield and install in brackets on adapter frame legs at location shown in Step 8 below. Ensure that bolt head and spacer are positioned on inboard side of frame bracket and lockwasher and nut are positioned outboard. G REMOVE SPACERS H 8. Install front supports (H) supplied with completion package onto spacers installed in Step 7. Bolt to forming shield with ½ x 1 flange bolts and flange nuts at (J) as shown.
INITIAL SET-UP PREPARING THE 741/742 HAY CONDITIONER 3. This conditioner is used with Model 942 Multi-Crop and Model 970 series Harvest Headers. For Model 910 and 920 Series Headers, see page 12. 1. Remove crop deflector from under adapter to allow conditioner forming shield installation. See page 10 for removal instructions. Remove L-bracket from top of rubber strap and attach rubber strap (E) to adapter frame with 3/8 flange nut and washer supplied with hay conditioner shield.
INITIAL SET-UP PREPARING THE 741/742 HAY CONDITIONER (continued) 4. Attach conditioner float spring to left side of conditioner at pin (D), using the third chain link from the end of the chain. Leave top of spring unattached until hook-up to adapter. NOTE: When header is in steep angle position, it may be necessary to move to first or second link. See header Operator’s Manual for conditioner adjustments. IMPORTANT: Damage to pump or hay conditioner shield may occur if chain is too short.
ATTACHING & DETACHING ATTACHING ADAPTER TO TRACTOR 3. Raise or lower cylinders as required to drive tractor into adapter frame. NOTE: Turning slightly from side to side will aide in engaging 4x4 tubes on tractor. The adapter should be disconnected from the header; standing on level ground, with both adapter stands down. See decal on adapter frame for stand adjustment for various tractor/tire combinations. On softer ground, 2x4 blocks under stand pad may be required. 4. Drive partially into adapter.
ATTACHING & DETACHING ATTACHING ADAPTER TO TRACTOR (continued) 7. For 9030 Tractor & TV140 Tractor with MacDon Header Drive Pump: Lock pump torque arm to channel with clevis pin and lynch pin at (F). NOTE: For 9030 Tractor, turn pump torque arm 180° to reverse offset as shown at right. F LOCK PUMP TORQUE ARM - 9030 9.
ATTACHING & DETACHING ATTACHING ADAPTER TO TRACTOR (continued) 12. Remove pin from hole (A) and place in storage position (B) on top of frame leg. Place adapter stands in storage position (G). Retract the telescoping foot into the stand to minimize storage length. NOTE: For adapters with hay conditioner top forming shield attached, stands must be rotated 180° (inside edge to outside) as shown.
ATTACHING & DETACHING DETACHING ADAPTER FROM TRACTOR The adapter should be attached to tractor with the header removed. For instruction on detaching adapter and header from tractor, see page 28. 1. Raise the adapter. Stop engine and remove key. 2. Swing the two adapter stands into support position and install clevis pins, washers and lynch pins at (A). Pin (A) is stored on top of frame leg, each side. Extend foot and secure with clevis pin, washer and lynch pin at (B). Lower adapter onto stands. 3.
ATTACHING & DETACHING DETACHING ADAPTER FROM TRACTOR 6. Remove bolt (E) from frame, both sides and back partially away from adapter (enough room to stand between tractor and adapter). Stop engine and remove key. E 7. DETACH 4 X 4’S FROM TRACTOR For 9030 Tractor & TV140 Tractor with MacDon Header Drive Pump: Disconnect pump from tractor PTO and store on torque arm support (K). K 8. Back away from adapter until tractor is just clear of 4 x 4 tubes.
ATTACHING & DETACHING ATTACHING HEADER TO TRACTOR AND ADAPTER The adapter should be attached to the tractor. The header should be in stand position on level ground with the pins removed from header legs. 1. CAUTION: Be sure area is clear of bystanders, then start engine. 2. 3. 4. Slowly drive tractor forward so that adapter lift linkage enters header legs. Continue to drive slowly forward until linkage contacts support plate in the lower header leg, and header nudges forward. Stop engine and remove key.
ATTACHING & DETACHING ATTACHING HEADER TO TRACTOR AND ADAPTER 5. Header with 741/742 Hay Conditioner a. Attach chain at right side of conditioner to adapter frame at middle hole (H) as shown. NOTE: For steeper header angles, lower hole may give better conditioner ground clearance. See Header Operator’s Manual for ground clearance adjustment. To avoid damage to conditioner drive, do not install chain in top inboard hole (K) in this application. If highest setting is required, use outboard hole (L).
ATTACHING & DETACHING ATTACHING HEADER TO TRACTOR AND ADAPTER (continued) DANGER: To avoid bodily injury from fall of raised header, always set adapter stands in prop position when working under raised header. 7. Remove lynch pin at foot of adapter stand and swing adapter stands into prop position. Replace lynch pin at (B) to lock the position. Repeat at other side. B ADAPTER STANDS – PROP POSITION 8.
ATTACHING & DETACHING ATTACHING HEADER TO TRACTOR AND ADAPTER (continued) 11. Depending on header type, connect from zero to five hydraulic hoses between header and adapter/tractor: 942 and 970 Series Headers - 5 hoses: - reel drive pressure and return near right header leg (R). - reel lift (S) to TAN-EXTEND coupler at TV140 tractor. (To TAN-RETRACT on 9030 tractor.) NOTE: Wrap reel lift hose (S) around adapter hoses a couple of times to take up slack as shown.
ATTACHING & DETACHING DETACHING HEADER FROM TRACTOR AND ADAPTER Using this procedure, adapter will remain attached to the tractor. This would be appropriate when header is to be used on another power unit. Instructions for detaching both header and adapter from tractor are given on page 28. A 1. Choose a level area. 2. Disconnect adapter wiring harness(es) at the header. 3. Depending on header type, disconnect from zero to five hydraulic hoses between header and tractor/adapter.
ATTACHING & DETACHING DETACHING HEADER FROM TRACTOR AND ADAPTER (continued) 9. Remove pins (E) from header legs. (When detaching procedure is complete, replace pins in header legs for storage. E 10. Swing adapter stands back to the storage position (F). 11. Lower header. Stop engine and remove key. REMOVE PINS FROM HEADER LEGS 942 HEADER SHOWN 12. Disconnect center link at header and raise to storage position (G). F G ADAPTER STANDS – STORAGE POSITION K DISCONNECT CENTER LINK 13.
ATTACHING & DETACHING DETACHING HEADER AND ADAPTER FROM TRACTOR Using this procedure, adapter will remain attached to the header. This would be appropriate when tractor is required for other use. Instructions for detaching header only from adapter and tractor are given beginning on page 26. 1. Choose a level area. Lower the reel and raise the header. Stop engine and remove key. 5. For TV140 Tractor with NH Auxiliary Pump: Disconnect sickle drive ¾” couplers (L). 2.
ATTACHING & DETACHING DETACHING HEADER AND ADAPTER FROM TRACTOR (continued) 8. Swing the two adapter stands into support position and install clevis pins, washers and lynch pins at (A). (Retrieve pin A from storage position on top of frame leg.) Extend foot and secure with clevis pin, washer and lynch pin at (B). If the ground is soft, place a piece of wood under stands. NOTE: For units with hay conditioner, stand position is as shown at (C). Be sure that frame is resting on pin at (D).
ATTACHING & DETACHING ATTACHING HEADER AND ADAPTER TO TRACTOR The adapter should be connected to the header, with float lock-out pins in engaged position. 1. Choose a level area. 2. Follow the procedure for connecting adapter to tractor on pages 17 to 19. 3. For 942 and 970 Series headers, when connecting hydraulics, also connect reel lift coupler (A) to TAN-EXTEND port on TV140 tractor or to TAN-RETRACT port on 9030 tractor. A HYDRAULIC & ELECTRICAL CONNECTIONS TV140 without AUX. PUMP SHOWN 4.
OPERATION HEADER CONTROLS WARNING: To avoid injury caused by unexpected movement of reel and/or conveyor, always disengage the blue hydraulic circuit before shutting the engine off. Reel and conveyor will move if engine is started with blue circuit engaged. Blue Hydraulic Control Lever – Engage blue hydraulic circuit before engaging the PTO or auxiliary pump. The blue circuit provides oil for the reel and conveyor drives and supercharges the PTO mounted MacDon pump if equipped.
OPERATION HEADER LEVELLING NOTE: Adjust header level before adjusting header flotation. To level header: 1. Ensure pins (G) are at the top of slots in bars (F) on both sides. 2. Loosen off jam nut on header levelling bolt (E). Access to nut is through slot (D). 3. Adjust bolt (E) until header is level. 4. Tighten jam nut to secure the position.
OPERATION HEADER ANGLE Header angle is adjustable by changing the length of the center link between header and adapter. See header Operator’s Manual for header angle adjustment ranges. IMPORTANT: A flatter header angle is recommended for normal conditions. A flatter angle reduces sickle section breakage and reduces soil build-up at the cutterbar in wet conditions.
MAINTENANCE/SERVICE SERVICE PROCEDURES CAUTION: To avoid personal injury, before servicing machine or opening drive covers: 1. Fully lower header and adapter. If it is necessary to service header in the raised position, first engage lift cylinder stop. 2. Disengage header drive clutch. 3. Stop engine and remove key. 4. Engage park brake. 5. Wait for all moving parts to stop. Park on level surface when possible. Follow all recommendations in your Tractor Operator's Manual.
MAINTENANCE/SERVICE GREASING THE ADAPTER Use an SAE Multi-Purpose High Temperature Grease with Extreme Pressure (EP) Performance and containing at least 1.5% molybdenum disulphide. Also acceptable is an SAE MultiPurpose Lithium Base Grease. The following greasing points are marked on the adapter by decals showing a grease gun (A), and grease interval (B) in hours of operation.
MAINTENANCE/SERVICE FLOAT SPRING HARDWARE B To prevent premature wear, apply an anti-seize/ lubricating compound to header float spring adjustment bolt threads (A) and washers (B) (four of each) before adjusting header floatation. A LUBRICATE FLOAT SPRING HARDWARE HYDRAULIC SYSTEM Hydraulic Hoses - Check daily for leakage. WARNING: Avoid high-pressure fluids. Escaping fluid can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines.
MAINTENANCE/SERVICE HYDRAULIC SYSTEM (continued) FLOW CONTROL BLOCK: Flow control block provides hydraulic power to the reel and conveyor drives with flow variable from 5 to 8 gallons per minute (gpm) to each circuit. Header Drive Relief Valve: Overload protection for the reel and conveyor drives is provided by an internal relief valve (A) in the flow control block.
MAINTENANCE/SERVICE HYDRAULIC SYSTEM (continued) NOTE: Available flow from tractor for the above circuit is 22 GPM.
MAINTENANCE/SERVICE HYDRAULIC SYSTEM (continued) MAINTENANCE/SERVICE NOTE: Available flow from tractor for circuits other than auxillary circuit is 22 GPM. Available flow from tractor for Auxillary circuit is up to 33 GPM.
MAINTENANCE/SERVICE ELECTRICAL SYSTEM 802 ADAPTER - ELECTRICAL SCHEMATIC 40
TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION REF. Reel does not operate smoothly. Improper hydraulic flow. Ensure that ¾” hoses to reel/draper flow valve are attached to BLUE hydraulic circuit with 18 GPM flow and open return to tank on tractor. 18 Ensure that ¾” hoses to reel/draper flow valve are attached to BLUE hydraulic circuit with 18 GPM flow and open return to tank on tractor. 18 Header improperly adjusted. Adjust header as recommended. * Relief pressure too low.
TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION REF. Sickle drive motor vibrates. Improper hydraulic flow. Reduce or increase oil flow/PTO rpm until vibration stops. Flow should be 25 gpm. 31 Float cannot be adjusted to heavy enough setting. Light header. Remove inner coil springs from float. 32 Tires running over crop. Tractor wheels improperly set. Adjust wheels. * For TV140 Tractor: Install 4” wheel spacers (supplied by New Holland). 6 Crop fanning out excessively. Adjust header opening.
INDEX A P PAGE Attaching Adapter to Tractor ......................... 17 Attaching Header and Adapter to Tractor...... 30 Attaching Header to Tractor and Adapter...... 22 PAGE Preparing the Adapter ......................................9 Preparing the 721/722 Hay Conditioner.........12 Preparing the 741/742 Hay Conditioner.........15 Preparing the Header.....................................11 Preparing the Tractor .......................................6 PTO Clutch .......................................
