9352c SELF-PROPELLED WINDROWER OPERATOR’S MANUAL Form 147459 Issue 11/06 Web Rev_01 Sugg. Retail: $25.
CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
INTRODUCTION Your new Self-Propelled Windrower is designed to cut and lay in windrows, a wide variety of grain, hay and specialty crops. Windrowing allows starting the harvest earlier, protects the crop from wind damage, and gives you more flexibility in scheduling combine time.
TABLE OF CONTENTS PAGE INTRODUCTION...........................................................................................................................................1 SERIAL NUMBER LOCATIONS ...................................................................................................................5 SAFETY Safety Alert Symbol ................................................................................................................................6 Signal Words .........................
TABLE OF CONTENTS OPERATION PAGE Transporting the Windrower (continued) Towing With a Trailer ...............................................................................................................52, 53 Towing without a Trailer...........................................................................................................54, 55 Storage Procedure ......................................................................................................................................
TABLE OF CONTENTS PAGE MAINTENANCE/SERVICE (continued) Hydraulic System: Header & Reel Lift Cylinder Control Valve Relief Pressure .........................................................................................90 Header & Reel Lift Hydraulic Schematic....................................................................... back of book Header Drive: Hydraulics Flow Control Block .........................................................................................................................
SERIAL NUMBER LOCATIONS Record the serial numbers in the space provided. Tractor: Plate is located on left side of main frame, near rear corner. TRACTOR SERIAL PLATE LOCATION Diesel Engine: Plate is located on right side of block, beside injection pump. NOTE: When ordering parts and service, be sure to give your dealer the complete and proper serial number. For engine parts, see your local Cummins engine dealer.
SAFETY SAFETY ALERT SYMBOL This safety alert symbol indicates important safety messages in this manual and on safety signs on the header. 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 reproduced below appear on the windrower at the locations listed. • Keep safety signs clear 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. The part number is printed in the lower R/H corner of each safety sign. To install safety signs: 1.
SAFETY SAFETY SIGNS (continued) Form # 147459 8 Issue 11/06 Web Rev_01
SAFETY GENERAL SAFETY The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. 1. Protect yourself. When assembling, operating and servicing machinery, wear all the protective clothing and personal safety devices that COULD 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.
SAFETY GENERAL SAFETY (continued) 6. Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets. 7. 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. 8. 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. NEVER WEAR LOOSE OR DANGLING CLOTHES 9.
SPECIFICATIONS TRACTOR DIMENSIONS: Weight (varies with tire size): e.g. With 16.5L-16.1 forked casters & 500-70R24 radial bar tread drive tires.........................................................8516 lbs. (3863 kg) Drive Tire 500-70R24 Tread Width A 117" (2972 mm) 540 - 65R24 117" (2972 mm) 560 - 65D24 117" (2972 mm) Front Width B 136” (3455 mm) 137” (3480 mm) 139.3” (3538 mm) Clearance C 43.4” (1102 mm) 42.1” (1070 mm) 43.0” (1092 mm) 127.6” (3240 mm) 126.3” (3210 mm) 127.
SPECIFICATIONS TRANSMISSION: Type ............................................................................................................................................ Hydrostatic Displacement..................................................................................................................3.0 cu.in. (49.16 cc) Fluid......................................................See "Fuels, Fluids and Lubricants" in Maintenance/Service section FINAL DRIVE: Type ..................................
DIESEL ENGINES: Type ...................................................................................................... Cummins B 4.5NA, 4 Cylinder, 4-stroke cycle - Turbocharged Displacement ..............................................................................................................................................................275 cu. in. (4.5 L) Power: ...................................................................................................................................
TORQUE SPECIFICATIONS TIGHTENING HYDRAULIC O-RING FITTINGS* 1. Inspect O-ring and seat for dirt or obvious defects. Thread Size (in.) 2. On angle fittings, back the lock nut off until washer bottoms out at top of groove. 3. Hand tighten fitting until back-up washer or washer face (if straight fitting) bottoms on face and O-ring is seated. 4. Position angle fittings by unscrewing no more than one turn. 5. Tighten straight fittings to torque shown. 6.
OPERATOR'S STATION Symbol Definitions The following symbols are used to depict functions or reactions at the various instruments and controls. Learn the meaning of these symbols before operating the Windrower. - Engine oil pressure - Turn signals - Transmission oil pressure - Temperature control: heater - Parking brake on – NOT USED with this model. - Temperature control: Air conditioning - Engine hours - Turn to increase output: Heater or air conditioner - Header hours - Blower - Engine R.P.M.
OPERATOR'S STATION Symbol Definitions (continued) - Header tilt up - Conveyor speed - Header tilt down - Engaged - Header drive - Reel forward - Disengaged - Reel aft - Header height - Seatback angle - Increase - Seat fore-aft - Decrease - Reel height - Seat height - Deck shift - Seat fore-aft isolator lockout - Speed range control High Low - Cigarette lighter - On - Header express down option - Bypass Form # 147459 16 Issue 11/06 Web Rev_01
OPERATOR'S STATION CAUTION: Learn and practice safe use of controls before operating. IMPORTANT: See your Dealer if there are any instrument malfunctions. Operate windrower only if all instruments work properly. B Mac-Monitor D C The LCD display allows the operator to monitor various machine systems, while the warning lights and audible tones are provided to alert the operator that continued operation will cause serious machine damage.
OPERATOR'S STATION Mac-Monitor Machine Warning System: Consists of individual lights to indicate low engine oil pressure, low transmission oil pressure (and park brake) on. An audible tone will sound whenever one of the indicator lights is on. In addition, the tone will sound when a high engine coolant temperature is indicated. Mac-Monitor: PROGRAMMING (continued) 4. Once the desired programming mode is displayed, enter the selection mode by pressing and holding switch (A) for more than 5 seconds.
OPERATOR'S STATION Operator Presence System Speedometer Requires the operator to be seated in the seat in order to engage the header drive. Should the operator leave the seat with the header drive engaged, power is maintained to the header drive for 5 seconds, after which the header is shut off. NOTE: If the operator leaves the seat for more than 5 seconds and then sits down again, the operator must move the header engage switch to “OFF” position and back to the “ON” position again to restart the header.
OPERATOR'S STATION Ignition Switch A The ignition switch (A) has three positions; OFF, RUN and START. The furthest counter-clockwise position of the key is OFF. Turn key fully clockwise to START. Holding key in this position will cause engine to crank. Release of key will return to the vertical RUN position. C B Lights LIGHT SWITCH (B) - The light switch has four positions: IGNITION SWITCH AND LIGHTS 1. OFF - Furthest counter-clockwise position. To turn off all lamps. 2.
OPERATOR'S STATION Cab Temperature Controls NOTE: For access to circuit breakers, relays, fuses and other electrical components in cab side console, remove panel on window side of console. F BLOWER SPEED SWITCH (A) - Controls operation of blower. Four positions are: OFF, LOW, MEDIUM and HIGH. The blower recirculates cab air as well as drawing in outside air to pressurize the cab. With door and window closed and blower on, dust and dirt will be filtered out to keep cab interior clean.
OPERATOR'S STATION Windrower Controls VARIABLE GROUND SPEED CONTROL LEVER (A) Controls windrower direction of movement and rate of speed. A neutral start switch prevents the starter from engaging unless this lever is in the neutral detent as shown and the steering is locked in the straight-ahead position. For forward motion: Push lever forward. The further the lever is moved from neutral the faster the speed. Release lever at desired speed and lever will engage friction device to secure the position.
OPERATOR'S STATION Header Controls NOTE: Some of these controls are not used for all types of headers. Some are optional equipment and may not be present in your unit. For others, while the switch may be installed, it will be non-functional for certain headers. HEADER DRIVE SWITCH (A) - Lift the guard to expose toggle switch. Push toggle switch forward to engage all header mechanical and hydraulic drives. Push guard down to disengage drives. Starter will not engage if switch is in the engaged position.
OPERATOR'S STATION Header Controls (continued) REEL HEIGHT SWITCH (E) - Press top of switch to raise reel and bottom to lower. Hold switch until reel reaches desired position. NOTE: For Auger Headers with Hay Conditioners equipped with Hydraulic Roll Opener cylinders, switch (E) controls the operation of these cylinders. E H K HEADER HEIGHT SWITCH (F) - Press top of switch to raise header and bottom to lower. Hold switch until header reaches desired position. (See "Cut Height Indicator").
OPERATOR'S STATION Header Controls (continued) CUT HEIGHT INDICATOR (G) - The gauge on the lift linkage can be used to identify desired cut heights. G With the center link (between tractor and header) in a mid-range position, the numbers on the gauge indicate approximate cut (stubble) height in inches. Adjusting center link length will affect the starting point; eg. gauge reading 4 may indicate a 3" (longer center link) or 5" (shorter center link) cut height.
OPERATOR'S STATION Seat Adjustments OPERATOR WEIGHT & SEAT HEIGHT ADJUSTMENT - Press knob (A) in to increase suspension stiffness and seat height. Pull knob out to decrease. SEAT-BACK ANGLE - Pull up on lever (B), position seat back as desired, and release lever. A LUMBAR SUPPORT - Rotate knob (C) to position lumbar support as desired. SEAT FORE-AFT POSITION - To adjust, pull out on lever (D), move seat forward or rearward to desired position and release lever.
OPERATOR'S STATION Operator Amenities CUP HOLDER (A) – Provided at side console. A CIGARETTE LIGHTER (B) CUP HOLDER ASHTRAY (C) B C LIGHTER & ASHTRAY AUXILIARY POWER POINTS (D) - Two 12 volt power outlets are provided on backside of console.
OPERATION Your Responsibilities as an Owner/Operator CAUTION: 1. It is your responsibility to read and understand this manual and the Header Operator's Manual completely before operating the windrower. Contact your dealer if an instruction is not clear to you. 2. Follow all safety messages in the manuals and on safety signs on the windrower. 3. Remember that YOU are the key to safety. Good safety practices protect you and the people around you. 4.
OPERATION Break-in Period The windrower is ready for normal operation. However there are several items to check and watch out for during the first 100 hours, as follows: ENGINE BREAK-IN: 1. Operate engine at moderate load, avoid extremely heavy or light loading for longer than 5 minutes. 2. Avoid unnecessary idling. If engine will be idling for longer than 5 minutes after reaching operating temperature, turn key OFF to stop engine. 3. Check engine oil level frequently. Watch for any signs of leakage.
OPERATION Pre-Starting Checks: Annual Do the following at the start of each operating season: CAUTION: 1. Review the Operator's Manual to refresh your memory on safety and operating recommendations. 2. Review all safety signs and other decals on the windrower and note hazard areas. 3. Be sure all shields and guards are properly installed and secured. Never alter or remove safety equipment. 4. Re-acquaint yourself with the controls before beginning operation. 5.
OPERATION Pre-Starting Checks: Daily Do the following each day before starting the engine: CAUTION: 1. Clear the area of other persons, pets, etc. Keep children away form machinery. Walk around the windrower to be sure no one is under, on or close to it. 2. Remove foreign objects from windrower and surrounding area. the 3. Wear close-fitting clothing and protective shoes with slip resistant soles.
OPERATION Start-Up Procedure DANGER: Avoid possible injury or death from a runaway machine. Do not start engine by shorting across starter terminals. Machine will start in gear and move if normal starting circuitry is bypassed. This machine has two safety devices which prevent the engine from starting unless the variable speed lever is in neutral, the steering wheel is locked in the neutral position, and the header drive switch is in the OFF position.
OPERATION Start-Up Procedure (continued) STARTING ENGINE A CAUTION: Be sure the area is clear of other persons, pets etc. before proceeding. Temperature above 16° C (60° F): Turn ignition key to START position until engine starts. Release key. If engine does not start within 5 seconds of cranking, follow the start procedure that suits outside temperature as below. Temperature between 5° - 16° C (40° - 60° F): Move throttle lever (A) fully forward after turning ignition key to START position.
OPERATION Driving the Windrower WARNING: · Avoid driving the machine with header removed. Removing header decreases the weight on drive wheels, reducing steering control. · If necessary to drive machine with header removed, use transmission "field speed" range, do not exceed half maximum engine speed and avoid loose gravel and slopes. · Never use windrower as a towing vehicle when header is removed. There is insufficient weight on the drive wheels to provide steering control.
OPERATION Driving the Windrower (continued) TO DRIVE FORWARD: 1. For field operation, set speed-range switch (A) to position L. For road speeds, set control to position H. A 2. Slowly push throttle lever (C) to full forward (operating speed). IMPORTANT: • Return throttle lever (C) to low idle position before engaging header drives. • For field operation, always operate windrower with speed-range control in field position and throttle lever fully forward (maximum engine RPM).
OPERATION Driving the Windrower (continued) TO DRIVE REARWARD: WARNING: Back up slowly. Steering is opposite to normal when reversing. Hold steering wheel at the bottom and turn wheel in direction you want the rear of the machine to travel. 1. Move speed-range switch (A) to field position L. 2. Move throttle lever to a mid-range position (B). NOTE: Reversing in low speed-range and at reduced engine speed is recommended since steering will be less sensitive than at higher speed settings.
OPERATION Driving the Windrower (continued) MAKING A SPIN TURN: Hydrostatic steering gives the operator significantly more maneuverability than mechanical steering. CAUTION: Be sure area is clear before making turns. Although tractor pivots "on the spot", ends of header travel in a large arc. To make a spin turn: A 1. Move the variable speed lever (A) out of its neutral detent (towards the seat, not forward or rearward). 2. Slowly turn the steering wheel in the desired direction of turn.
OPERATION Stopping Procedure TO STOP WINDROWER: WARNING: Do not move variable speed lever rapidly back to neutral. Operator may be thrown forward by sudden stop. Always wear seat belt when operating windrower. B C 1. To slow down and stop the windrower, SLOWLY return the variable speed lever (A) to neutral. 2. Turn steering wheel until it locks. 3. Move throttle lever (B) to low idle position. NOTE: Avoid unnecessary idling. Stop engine if it will be idling for longer than 5 minutes. A 4.
OPERATION Leaving the Windrower CAUTION: Before leaving operator's seat for any reason: the 1. Park on level ground if possible. 2. Be sure variable ground speed lever is in the neutral detent and steering wheel is locked in the straight-ahead position. 3. Fully lower header and reel. 4. Disengage header drives. 5. Stop engine and remove key from ignition. A child or even a pet could engage an idling machine. 6. Turn off all lights (and wiper). 7. Release seat belt. 8.
OPERATION Attaching the Header NOTE: For Harvest Headers with gauge wheels, instructions under "Attaching" and "Detaching the Header" which refer to the "header stand" do not apply. Use the "stand" position of the gauge wheels to support rear of header. All gauge wheel positions are identified on a decal located at each gauge wheel. Be sure to reposition gauge wheel to field position before operating. 1. Choose an area that is as level as possible and set header stand (A) in the down position.
OPERATION Attaching the Header (continued) 6. Connect driveline to header drive shaft as follows: • Open hinged shield at header drive shaft. • Pull back spring loaded collar (G) on driveline yoke and slide yoke onto header shaft. Release collar, ensuring yoke locks in position on shaft. • Attach chain hook (if present) to hinged shield at (H). • Close hinged shield. NOTE: For 962/963 Header only, attach chain hook (if present) to shield (J) on connector shaft as below.
OPERATION Attaching the Header (continued) 9. Start engine. Activate header lift cylinders (switch on ground speed lever) to raise header fully. Stop engine and remove key. 10. DANGER: To avoid bodily injury from fall of raised header, always engage header lift cylinder stops (A) when working on or around raised header. A 11. Attach float springs to front of linkage, both sides. Secure with "L" pin (B) and hair pin. NOTE: For 12’ & 15’ 972 headers, connect pin at second hole (F) to ensure proper float.
OPERATION Adding Rear Weight IMPORTANT: The stability of the machine varies with different attachments, tractor options, terrain and operator’s driving technique. Install weight at rear of tractor to provide adequate machine stability. To determine the additional rear weight required, pick the tractor model, header model and size to find your “base machine”. Add up the values for the base machine plus options/conditions to obtain a score for a particular application.
OPERATION Adding Rear Weight (continued) To install weight bundle B2266 in rear tractor frame: 1. Install bolt (A) through welded nut in existing tractor weight (B) and start jam nut on bolt (A). 2. Insert weights (C) forward of welded pin (D) as shown, then move weight back towards rear of tractor. 3. After weights are in position, tighten bolt (A) against the new weight (C), then tighten jam nut against weight (B).
OPERATION Detaching the Header 1. Activate header lift cylinders (switch on ground speed lever) to raise header fully. For units with Header Express Down option, use switch on side console to bypass the feature. Lower the reel (second switch on lever). Stop engine and remove key. 2. DANGER: To avoid bodily injury from fall of raised header, always engage header lift cylinder stops (A) when working on or around raised header. A ENGAGE LIFT CYLINDER STOPS 3.
OPERATION Detaching the Header (continued) DANGER: Wait for all movement to stop. A rotating driveline can cause entanglement resulting in serious personal injury or death. 8. Disconnect driveline from header shaft as follows: • Pull back spring-loaded collar on driveline yoke and remove yoke from header shaft. • Detach chain (if present) from header hinged shield. • Pull back spring-loaded collar and store driveline on pin welded to tractor frame at (E). E 9.
OPERATION Operating the Header Correct operation reduces crop loss and allows cutting of more acres. The length of service you receive from your windrower depends upon thorough lubrication, and proper maintenance and adjustments. CAUTION: Do not mount anything on the windrower tractor except the headers and attachments designed for use with it. Unapproved attachments may change the stability and controllability of the machine.
OPERATION Header Angle Header angle is adjustable by changing the length of the center link between header and tractor. HEADER TILT HYDRAULIC ADJUSTMENT Header angle adjustment ranges: 910, 920, 930 Series Headers: 8° to 16° 940 Series Headers: 6° to 13° 960 Series Headers: 13° to 21° 970 Series Headers: 9.5° to 21° An optional kit is available which allows adjustment of header angle from the cab by means of a hydraulic cylinder. See “Options and Attachments” section for order numbers.
OPERATION Header Levelling A 1/4 inch (6 mm) shim (A) is located on both sides of windrower lift linkage. If header is not level, adjust as follows: 1. Lower header onto a block so back of linkage lifts. B A 2. Remove hardware (B) on the high side of the header and remove shim (A). Replace hardware (B). 3. Check header level. If more levelling is required, install the removed shim on opposite side of linkage, adding it to the existing shim. 4.
OPERATION Header Flotation The following suggested header float settings are a starting point for normal conditions. Your specific requirements and conditions may require heavier or lighter float. Force required to lift the cutterbar off ground at each end of the header (with lift cylinders fully retracted): 910/920/932 Auger Headers: 100 to 120 lbs. (445 - 535 N) 912/922/933 Auger Headers & 942 Multi-Crop Header: 75 to 85 lbs. (335 - 380 N) Draper Headers: 50 to 70 lbs.
OPERATION Transporting the Windrower C WARNING: Do not drive windrower on a road or highway at night, or in conditions which reduce visibility, such as fog or rain. The width of the windrower may not be apparent under these conditions. WARNING: Avoid driving the tractor with header removed. Removing header decreases the weight on drive wheels, reducing steering control.
OPERATION Transporting the Windrower TOWING THE WINDROWER ON A TRAILER For transporting the windrower other than under its own power, a side mount trailer (A) carrying all four windrower wheels is recommended. Also acceptable are side mount trailers (B) where the windrower tail wheels remain on the ground. For this type, tighten caster set screws, step 7, below. For narrower headers, front or rear mount trailers may be used, providing local laws regarding width regulations are adhered to.
OPERATION Transporting the Windrower TOWING THE WINDROWER ON A TRAILER (continued) WARNING: When towing the windrower on a trailer (continued): 8. When towing on a front or rear mount trailer, lock casters in a straight-ahead or straight-back position with L-pin (F). Secure L-pin with hairpin in lock or storage position. (See storage position, lower right photo on page 52.) F 9. Do not tow at speeds over 25 mph (40 km/h).
OPERATION Transporting the Windrower TOWING WINDROWER WITHOUT TRAILER The best method for transporting a disabled windrower is to haul it on a suitable trailer or flatbed. (See Towing Windrower on a Trailer.) In emergency situations, for example, towing out of a field or into a shop, windrower may be towed without a trailer, providing the following precautions are followed: 1. Attach windrower to towing vehicle. WARNING: A proper towing apparatus is critical to safe towing.
OPERATION Transporting the Windrower TOWING WINDROWER WITHOUT TRAILER (continued) WARNING: When towing windrower without a trailer: the F 3. Lock casters in a straight-ahead or straightback position with L-pin (F). Secure L-pin with hairpin in lock or storage position. (See storage position, lower right photo on page 52.) 4. Be sure the towing vehicle is heavier than the windrower. NOTE: Windrower weighs 8000 to 10000 lbs. (3600 to 4500 kg) depending on header size.
OPERATION Storage Procedure Do the following at the end of each operating season: CAUTION: 1. Clean the windrower thoroughly. Never use gasoline, naphtha or any volatile material for cleaning purposes. These materials may be toxic and/or flammable. 2. Store windrower in a dry protected place. Never operate engine in a closed building. Proper ventilation is required to avoid exhaust gas hazards. 3. Remove the battery. Bring to full charge and store in a cool, dry place not subject to freezing.
MAINTENANCE/SERVICE Service Procedures CAUTION: To avoid personal injury, before servicing machine or opening drive covers: 1. Move variable speed lever to neutral and turn steering wheel until it locks to engage park brake. 2. Fully lower header and reel. 3. Disengage header drive clutch. STAY CLEAR OF DRIVELINE AND ALL MOVING PARTS 4. Stop engine and remove key. 5. Wait for all moving parts to stop. Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets.
MAINTENANCE/SERVICE Seat Belt Inspection and Maintenance R/H Step Ladder – Use & Storage Keep the operator and trainer seat belts in good condition as follows: A storable ladder is provided on the right hand side of the tractor for access to the maintenance platform. 1. Keep sharp edges and items that can cause damage away from the belts. For storage, swing ladder up and pivot arm (A) down as shown. 2.
MAINTENANCE/SERVICE Fuels, Fluids and Lubricants DIESEL FUEL Use Grade No. 2 - D fuel, as defined by ASTM Designation: D 975 for diesel fuels. NOTE: When temperature is very cold, the use of a mixture of No. 1 and No. 2 Diesel Fuel is permitted for a short period of time, providing the following specifications are met: Sulphur Content - less than 1% by weight, preferably less than .5%. Water and Sediment - for maximum filter life, should not exceed .1% by weight. Cetane Number - 40 minimum.
MAINTENANCE/SERVICE Fuels, Fluids and Lubricants (continued) ENGINE OIL SAE 15W40 complying with SAE specs for API Class SJ and CH-4 engine oil minimum. High grade oil would be API CI-4SK or API CI-4.
MAINTENANCE/SERVICE Greasing the Windrower Tractor See "Fuels, Fluids and Lubricants" for recommended greases. The following greasing points are marked on the windrower by decals showing a grease gun (A), and grease interval (B) in hours of operation. Use the engine hour meter in the cab and the "Maintenance Checklist" provided to keep a record of scheduled maintenance. SAMPLE GREASE DECAL Procedure: 1. Wipe grease fitting with a clean cloth before greasing, to avoid injecting dirt and grit. 2.
MAINTENANCE/SERVICE Greasing the Windrower Tractor: 50 Hours (continued) J CASTER PIVOTS: (J) – FOUR FITTINGS IMPORTANT: Pump until grease pushes out top of caster B HEADER DRIVE PULLEY (B) - ONE FITTING E WALKING BEAM PIVOT (E) - ONE FITTING F C HEADER CLUTCH PIVOT (C) - ONE FITTING TOP LIFT LINK REAR PIVOT (F) - TWO FITTINGS G D TRANSMISSION DRIVELINE U-JOINTS (D) THREE FITTINGS FORKED CASTER SPINDLE BEARINGS (G) FOUR FITTINGS (16.
MAINTENANCE/SERVICE Greasing the Windrower Tractor: 200 Hours or Annually H CASTER WHEEL HUB BEARINGS (H) TWO FITTINGS Form # 147459 63 Issue 11/06 Web Rev_01
MAINTENANCE/SERVICE OPENING & CLOSING HOOD Engine For access to the engine compartment: 1. Pull hood release handle (B). 2. Lift hood to raised position. CAUTION: Never operate engine in a closed building. Proper ventilation is required to avoid exhaust gas hazards. B AVOID EXHAUST GAS HAZARDS Keep the engine clean. Straw and chaff on a hot engine are a fire hazard. HOOD RELEASE HANDLE Never use gasoline, naphtha or any other volatile material for cleaning purposes.
MAINTENANCE/SERVICE Diesel Engine LUBRICATING OIL Check engine oil level daily on dipstick. See "Fuels, Fluids and Lubricants" section for recommended oil type. IMPORTANT: Never operate the engine with the oil level below the "L" (LOW) mark or above the "H" (HIGH) mark. CAPACITY - LOW MARK TO HIGH: 2 U.S. qt. (2 litres) Change engine oil and filter after the FIRST 50 HOURS OF OPERATION and every 500 hours (or beginning of each operating season) thereafter. To change: MAINTAIN ENGINE OIL LEVEL 1.
MAINTENANCE/SERVICE Diesel Engine LUBRICATING OIL Changing engine oil and filter (continued) 6. Install the new filter. Turn the filter onto the mount until the gasket contacts the filter head. Tighten the filter an additional 1/2 to 3/4 turn by hand. IMPORTANT: Do not use a filter wrench to install the oil filter. Over-tightening can damage the gasket and the filter. 7. Install the oil pan drain plug. A 8. Fill the engine at (A) with the proper amount of oil.
MAINTENANCE/SERVICE Diesel Engine ENGINE SPEED: Turbocharged units have an electronic throttle. No adjustment required. Engine maximum and low idle speeds are factory set to specifications listed on page 13. IMPORTANT: Do not remove any seals from injector pump; removal of seals will void engine warranty. If specified speeds can not be maintained, see your Windrower dealer. NOTE: In addition to in-cab tachometer, hand held tach can be attached at bevel gear box output shaft.
MAINTENANCE/SERVICE Diesel Engine: Air Intake System AIR CLEANER IMPORTANT: Do not run engine with air cleaner disconnected or disassembled. The air cleaner is equipped with a vacuator valve which removes dust continuously from the air cleaner housing. A Check daily that system is functioning properly: 1. Remove air cleaner end cap (A). 2. Check for dust inside the canister. 3. If dust or debris is present, clean canister and check for the source of the contamination. Possibilities are: a.
MAINTENANCE/SERVICE Diesel Engine: Air Intake System AIR CLEANER CLEANING FILTER ELEMENTS (continued) 5. Using a Dry Element Cleaner Gun, clean element with compressed air. Hold nozzle next to inner surface, and move up and down pleats. IMPORTANT: Air pressure must not exceed 100 psi (700 kPa). Do not direct air against outside of element, as dirt might be forced through to inside. 6. Repeat steps 4 and 5 to remove additional dirt. 7.
MAINTENANCE/SERVICE Diesel Engine: Fuel System STORING FUEL • • • • Buy good quality, clean fuel from a reputable dealer. Proper fuel storage is critically important. Keep all dirt, water and other contaminants away from fuel. Avoid storing fuel over long periods of time. If you have a slow turnover of fuel in windrower tank or supply tank, add fuel conditioner to avoid condensation problems. Store fuel in a convenient place away from buildings.
MAINTENANCE/SERVICE Diesel Engine: Fuel System FUEL SEDIMENT BOWL Inspect fuel sediment bowl daily for water or other contaminants. Bowl is located under tank. Clean as required. To clean: 1. Close valve (A) to shut off fuel. A 2. Loosen nut (B) and remove bowl. 3. Clean bowl and mesh screen in head. B 4. Replace bowl and open valve (A). FUEL SEDIMENT BOWL FUEL/WATER SEPARATOR Drain the water and sediment from the separator at the fuel filter daily, as follows: 1. Shut off engine. 2.
MAINTENANCE/SERVICE Diesel Engine: Fuel System FUEL FILTERS - DIESEL ENGINE Change fuel filters every 500 hours of operation. NOTE: 2004 and earlier models have two fuel filters, 2005 units have only one. To change: 1. Close valve (A) under fuel tank to shut off fuel. A FUEL SHUT-OFF VALVE 2. Clean the filter head, filter (B) and the engine area next to the filters. B 3. Remove the filter using a filter wrench. REMOVE FILTER (Naturally Aspirated Tractor Shown) 4.
MAINTENANCE/SERVICE Diesel Engine: Fuel System FUEL SYSTEM AIR REMOVAL - DIESEL ENGINE Controlled venting of air is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing filters or injection pump supply line will be vented automatically, if the fuel filter is changed in accordance with instructions. (See "Fuel Filters".) However, manual venting ("bleeding") may be required if: 1. 2. 3. 4. The fuel filter is not filled prior to installation.
MAINTENANCE/SERVICE Diesel Engine: Fuel System FUEL SYSTEM AIR REMOVAL - DIESEL ENGINE (continued) To bleed high pressure lines: WARNING: Escaping fluid under pressure can penetrate the skin causing serious injury. When disconnecting diesel lines, have engine stopped and loosen fittings slowly to relieve pressure. Tighten all connections before applying pressure. Keep hands and body away from pin-holes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks.
Engine Exhaust System MUFFLER CAUTION: To avoid burns, do not touch muffler when engine is running or before allowing sufficient cooling time after shut-down.
MAINTENANCE/SERVICE Engine Cooling System COOLANT LEVEL Check coolant level daily at reserve tank (A). Check level when engine is cold. If tank is less than half full, add coolant to reserve tank (A), not to radiator. IMPORTANT: Use a 50/50 mix of clean, soft water and anti-freeze. This ratio will protect engine to temperatures of -30°F (-34°C).
MAINTENANCE/SERVICE Engine Cooling System CHANGING COOLANT Coolant should be removed, and the system flushed and filled with new coolant every 2000 hours or 2 years. Procedure: CAUTION: To avoid personal injury from hot coolant, do not turn radiator cap until engine cools. Turn the cap to the first notch to relieve pressure before removing cap completely. Use a ladder as shown on previous page to access radiator. D 1. With engine cool and approximately level, remove radiator cap.
MAINTENANCE/SERVICE Engine Cooling System SCREENS AND COOLERS RADIATOR SCREEN The radiator screen may be equipped with an automatic cleaning device which "vacuums" the screen by means of two rotors (A). A If rotors fail to clean the screen adequately, remove plastic arm and check for obstructions in ducting from screen to fan shroud. For units not equipped with cleaning device, manually clean the screen periodically during a day's operation. Do not allow excessive trash build-up.
MAINTENANCE/SERVICE Electrical System BATTERY WARNING: · Gas given off by battery electrolyte is explosive. Keep all smoking materials, sparks and flames away from batteries. · Follow proper charging and boosting procedures given in this section. · Ventilate when charging in enclosed space. · Always wear protective eye-wear when working near batteries. · Do not tip batteries more than 45° to avoid electrolyte loss. · Battery electrolyte causes severe burns. Avoid contact with skin, eyes or clothing.
MAINTENANCE/SERVICE Electrical System BATTERY (continued) PREVENTING BATTERY DAMAGE 1. Be sure alternator connections are correct before cables are connected to battery. See "Preventing Alternator and Regulator Damage" in this section. 2. Carefully observe polarity when attaching booster battery. 3. Do not operate the engine with alternator or battery disconnected. WARNING: With battery cables disconnected and engine running, a high voltage can be built up if terminals touch the frame.
MAINTENANCE/SERVICE Electrical System BATTERY (continued) CHARGING BATTERY CAUTION: · Ventilate the area where batteries are being charged. · Do not charge a frozen battery. Warm to 60°F (16°C) before charging. · Do not connect or disconnect live circuits. To prevent sparks, turn off charger and connect positive cable first. If charging battery in windrower, disconnect positive battery cable before connecting charger cable, then connect ground cable last, away from battery.
MAINTENANCE/SERVICE Electrical System PREVENTING ALTERNATOR AND REGULATOR DAMAGE 1. Always disconnect battery ground cable when working with the alternator or regulator. 2. Never attempt regulator. to polarize alternator or C 3. If wires are disconnected from the alternator (B) or regulator (C), use the photo at right to ensure proper reconnection. 4. Never ground the alternator field terminal or field circuit. 5.
MAINTENANCE/SERVICE Electrical System LIGHTS AND BULBS A ADJUSTABLE HEADLIGHTS The two front headlights can be adjusted up or down and to the right or left with adjustment screws (A). Adjust for maximum illumination while ensuring oncoming traffic cannot be blinded by the lights. The recommended setting is: • Light beams laterally centered on the “direction of travel” line from the headlights (i.e. not skewed left or right).
MAINTENANCE/SERVICE Electrical System LIGHTS AND BULBS (continued) CAUTION: To avoid a slip and fall injury when replacing lamps at front of machine, remove header and use a step ladder, unless header has a traction surface across the back tube. REPLACING HEAD LIGHT BULBS 1. Turn light switch and ignition key to OFF. A 2. Remove two screws from lamp bezel (A) and remove light assembly from roof. IMPORTANT: Do not remove the three adjusting screws. 3.
MAINTENANCE/SERVICE Electrical System LIGHTS AND BULBS (continued) REPLACING RED TAIL LIGHT BULBS A 1. Remove two screws (A). Remove plastic lens. 2. Replace bulb and reinstall plastic lens. NOTE: Bulb trade #1157. RED LIGHTS REPLACING AMBER LIGHT BULBS 1. Remove light (B) from rubber bezel. 2. Replace bulb and reinstall light. NOTE: Bulb trade #1156. IMPORTANT: For proper lighting pattern, be sure lights are installed right side up. B AMBER LIGHTS REPLACING GAUGE LIGHT BULBS 1.
MAINTENANCE/SERVICE Electrical System E LIGHTS AND BULBS (continued) REPLACING DOME LIGHT BULB 1. Remove two screws (D) from plastic lens. 2. Replace bulb and reinstall plastic lens. NOTE: Festoon Bulb 12V-21 CP D REPLACING TURN SIGNAL INDICATORS F 1. Remove six screws around outer edge of cover (F). Lower cover to expose inner wiring. 2. Push out entire unit (E), detach wiring and replace. 3. Reinstall cover (F).
MAINTENANCE/SERVICE Electrical System CIRCUIT BREAKERS CHECKING IN-CAB CIRCUIT BREAKERS For access to breakers, remove panel (G) on window side of right hand side console. These breakers will reset automatically after approximately one minute. See your dealer if circuits do not operate correctly.
MAINTENANCE/SERVICE Hydraulic System WARNING: Avoid high pressure fluids. Escaping fluid can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin-holes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks.
MAINTENANCE/SERVICE Hydraulic System HYDRAULIC OIL Change hydraulic oil every 2000 hours. CAPACITY: Reservoir only: 15.2 US gal. (57 litres) Total system: approximately 17 US gal. (65 litres)(varies with options) NOTE FOR FLEET OWNERS: If you also operate an older MacDon built windrower tractor with a production year ’99 or earlier, that unit’s hydraulic system will be filled with 10W30 engine oil.
MAINTENANCE/SERVICE Hydraulic System: Header & Reel Lift CYLINDER CONTROL VALVE RELIEF PRESSURE Control valve (A), located under the R/H tractor floorboard, directs hydraulic flow to the header lift cylinders, reel lift cylinders and the cylinder used to engage the clutch for the sickle drive. The control valve relief pressure is pre-set to be sufficient for all header sizes and options. Should lift capacity problems develop, check and adjust cylinder control valve relief pressure as follows: 1.
MAINTENANCE/SERVICE Header Drive: Hydraulics FLOW CONTROL BLOCK Flow control block (A), located under cab near ground speed linkage, provides hydraulic power to the header. The block divides pump output of 19 gallons per minute (gpm) and controls the flow of oil into two circuits. Flow is used by the various headers as follows: Auger Header Both circuits combine to supply oil to the reel drive. Flow can be varied from 6 to 19 gpm with either reel or conveyor speed control knob on cab console.
MAINTENANCE/SERVICE Header Drive BEVEL GEAR BOX LUBRICANT The bevel gear box directs power from the main drive train to the header drive at the right side of the tractor. See “Fuels, Fluids and recommended lubricant. Lubricants” A for Check lubricant level as follows: 1. Check level with engine stopped. 2. Loosen level plug (B) (13 mm wrench required) located on extension tube of gear box. 3. Add lubricant at filler location (A) to level plug (B). 4. Replace plugs.
MAINTENANCE/SERVICE Header Drive HEADER DRIVE BELT: PULLEY FORE-AFT ALIGNMENT Fore-aft misalignment of pulleys can cause a belt failure where the backing band splits between Vbelt sections, as shown at (A). Check and correct the pulley fore-aft alignment in the following order: BELT FAILURE DUE TO FORE-AFT MISALIGNMENT 1. Rear pulley must be square to frame as shown. To check, place a straight edge along side of rear pulley and check that clearance to frame at (L) and (M) is equal.
MAINTENANCE/SERVICE Header Drive HEADER DRIVE BELT: PULLEY VERTICAL ALIGNMENT Vertical misalignment of front pulley can cause a belt failure where sections of the backing band are missing, as shown at (T). The missing sections will vary from 1/2 inch to 5 feet long. Failure starts with cracks across the backing band from one side to the other, followed by pieces falling off.
MAINTENANCE/SERVICE Header Drive HEADER DRIVE BELT GUIDES (continued) To adjust: 1. Stop engine and remove key from ignition. F 2. Loosen hardware securing top guide (A), belt keeper (B) and lower guide (C). E 3. Hold rear idler (D) down with 15/16 wrench to tighten belt. A B 4. Adjust belt guides and keepers: • Adjust top guide (A) to clear belt by 1/4 inch (6 mm) at front. At the back, center the belt between top guide (A) and retainer (E). Adjust hardware (F), both sides, to clear sides of belt.
MAINTENANCE/SERVICE Traction Drive: Hydraulics TRANSMISSION OIL PRESSURE Warning light and buzzer in cab will be activated when ignition switch is turned ON if transmission oil pressure is below approximately 150 psi (1035 kPa). Do not drive the windrower until light and buzzer go off. If light and buzzer stay on after engine starts, or if they activate during operation, shut engine off and check hydraulic oil level at reservoir. If oil level is adequate, measure charge pump pressure as described below.
MAINTENANCE/SERVICE Traction Drive: Neutral Lock and Steering Checks DANGER: To prevent machine runaway: • STOP ENGINE before adjusting steering linkage or neutral interlock. • Never rewire or misadjust neutral interlock so engine can be started with controls out of neutral. • Never start engine by shorting across starter terminals. Machine will start with drive engaged and move if normal starting circuitry is bypassed. • Start engine only from operator's seat.
MAINTENANCE/SERVICE Traction Drive: Neutral Lock and Steering Checks (continued) 3. Neutral Lock Adjustment Bolts Engagement: Check the depth of engagement of the neutral lock adjustment bolts (B) on pintle arms (C). Minimum engagement is 3/8 inch (10 mm), that is, the full diameter of the bolt must contact pintle arms. To adjust: a. Loosen cable as described in check 4, below. b. Adjust neutral start switch to obtain proper engagement depth. c. Readjust cable as described in check 4.
MAINTENANCE/SERVICE Traction Drive: Neutral Lock and Steering Checks (continued) 6. Radius Arm Pivots: Check the two pivots (A) and (C). At each pivot, torque inner nut (D) to 7 ft.lbs. (10 N⋅m). Hold inner nut (D) with a wrench and tighten outer nut (E) against nut (D). Torque nut (E) to 60 to 70 ft.lbs. (80 to 90 N⋅m). B D IMPORTANT: Be sure to hold inner nut (D) while tightening outer nut (E). Nut (D) MUST NOT TURN. G At ball joint connection (B), torque both nuts to 60 to 70 ft.lbs. (80 to 90 N⋅m).
MAINTENANCE/SERVICE Traction Drive: Neutral Lock and Steering Troubleshooting Any problem with the neutral lock and steering controls could be caused by loose, worn, or improperly adjusted parts as described in the preceding nine checks. IMPORTANT: When servicing this area, it is important to perform all of the nine checks to avoid missing the problem and providing only a temporary fix. PROBLEM: Steering wheel will not lock in neutral.
MAINTENANCE/SERVICE Traction Drive: Neutral Set-Up Procedure This procedure should be performed only after the nine preceding checks and adjustments have failed to solve the neutral lock/steering problem. This procedure will eliminate machine movement in neutral and will improve neutral locking ability. CAUTION: Use jack-stands with a minimum capacity of 3 tons (2720 kg) to provide adequate support for machine.
MAINTENANCE/SERVICE Traction Drive: Neutral Set-Up Procedure (continued) 7. The following adjustment is designed to give the maximum clearance between the neutral lock adjustment bolts and the pintle arms without having the wheels turn. This results in easy locking of the steering wheel into the neutral position. F Perform this adjustment for each of the four neutral lock adjustment bolts, starting at the rear bolt and working towards the front.
MAINTENANCE/SERVICE Traction Drive: Ground Speed Lever Friction Device Adjustment The ground speed lever friction device maintains lever position at the point in the forward/reverse slot where it was released by the operator. The friction device is located at the bottom of the ground speed lever (A), under the cab. It has been factory set as shown, where lock nut (B) is 0 to 1/8 inch (0 to 3 mm) from the end of the carriage bolt.
MAINTENANCE/SERVICE Traction Drive: Wheels and Tires POWER HUBS Check lubricant level every 200 hours or annually. See "Fuels, Fluids and Lubricants" for recommended lubricant. Plugs (D) are located at 90° around wheel. To check level, position wheel so plugs (D) are at the 12 o’clock (fill) and 3 o’clock (level) positions. Lubricant should be level with plug at 3 o’clock. D Change power hub lubricant after the first 50 hours operation and every 2000 hours (or annually) thereafter.
MAINTENANCE/SERVICE Traction Drive: Wheels and Tires (continued) DRIVE WHEEL BOLTS At first use, or when a wheel is removed, check drive wheel bolt torque according to the following schedule: • Every 15 minutes on the road or 60 minutes in the field until torque stabilizes, then • Daily (10 hours) until no change is recorded for 3 consecutive days (30 hours), then • Every 200 hours or annually thereafter. Torque Specification for drive wheels: 180 ft.lbs. (245 N·m).
MAINTENANCE/SERVICE Traction Drive: Wheels and Tires TIRE INFLATION Make a visual check daily that tires have not lost pressure. Under-inflation of drive tires can cause side wall cracks. Once a year, measure tire pressure with a gauge. Maintain the pressures recommended on page 12 (Specifications Section). SERVICE TIRES SAFELY WARNING: Service tires safely. A tire can explode during inflation and cause serious injury or death.
MAINTENANCE/SERVICE Cab Air System WARNING: The air conditioning system is pressurized. Improper servicing may cause refrigerant to penetrate eyes and skin or cause burns. Special equipment and procedures are required to service the air conditioning system. See your Windrower dealer for service. If an accident involving refrigerant should occur, see a doctor familiar with this type of injury immediately. NOTE: 1. The refrigerant utilized in this machine is R134a. Total system refrigerant capacity is 1.
MAINTENANCE/SERVICE Cab Air System RETURN AIR FILTERS Clean return air filters every 100 hours, more often in dusty conditions. A To clean: 1. Remove filter covers at both sides of cab rear wall by removing two nuts (A). 2. Remove foam filter elements and clean with compressed air. 3. Replace filter elements and covers. REMOVE FOR ACCESS TO RETURN AIR FILTER EVAPORATOR CORE If air conditioning system produces insufficient cooling, a possible cause is clogged evaporator fins.
MAINTENANCE/SERVICE Cab Air System COMPRESSOR PROTECTION The compressor is protected from excessively low suction and high discharge pressures by two switches: To prevent damage to the compressor, if the air conditioning system is shut down by either switch, locate the source of the problem and correct it before operating the system. • Low suction pressure switch is located at the outlet of the evaporator (under seat in cab).
MAINTENANCE/SERVICE Maintenance Schedule The following maintenance schedule is a listing of periodic maintenance procedures, organized by service intervals. For detailed instruction, see the specific heading in Maintenance/Service section. Use "Fuels, Fluids and Lubricants as specified under that heading. SERVICE INTERVALS The recommended service intervals are in hours of operation. Use the hour meter in the cab to indicate when the next service interval has been reached.
MAINTENANCE/SERVICE Maintenance Schedule 100 HOURS OR ANNUALLY * 500 HOURS 1. Clean cab return air filters. 1. Change engine oil and filter. 2. Change fuel filters. 3. Clean fuel feed pump strainer. 200 HOURS OR ANNUALLY* 1000 HOURS OR 3 YEARS 1. Change bevel gear box oil. 1. Change engine air cleaner filter element. 2. Check power hub lubricant level. 2. Check engine valve tappet clearance. 3. Grease caster wheel hub bearings. 4. Check wheel bolt/nut torque. ANNUALLY* 2000 HOURS 1.
MAINTENANCE RECORD Windrower Tractor Serial No. __________________ Combine this record with Header Maintenance Record for complete unit service. See Maintenance/Service section for details on each procedure. Copy these pages to continue record. 9- Check ACTION: 6 - Lubricate S- Change - Clean + - Add Engine Hour Meter Reading: Serviced By: Maintenance Procedure BREAK-IN 6 10 HOURS OR DAILY Trans.
MAINTENANCE RECORD (continued) 9- Check ACTION: 6 - Lubricate S- Change - Clean + - Add Engine Hour Meter Reading: Serviced By: S Maintenance Procedure 300 HOURS Hydraulic Oil Filters S 500 HOURS Engine Oil & Filter S Fuel Filters Fuel Feed Pump Strainer S 1000 HOURS OR 3 YEARS Air Cleaner Element 9 Valve Tappets S 2000 HOURS Hydraulic Oil S Power Hub Oil (or yearly) S Engine Coolant 9 General Engine Inspection Form # 147459 113 Issue 11/06 Web Rev_01
TROUBLE SHOOTING SYMPTOM Cab Air System PROBLEM SOLUTION REF. See page 109 for possible causes of abnormal high side / low side pressure. Blower fan will not run. Blower fan operating but no air coming into cab. Heater not heating. Odour from air louvers. Air conditioning not cooling. Burned out motor. Replace motor. * Burned out switch. Replace switch. * Motor shaft tight or bearings worn. Repair motor. * Faulty wiring - loose or broken. Repair or replace wiring.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. Air conditioning not cooling. (continued) Loose or broken drive belt. Replace drive belt and/ or tighten to specs. 66 Compressor partially or completely seized. Remove compressor for service or replacement. * Dirty filters. Clean fresh air and recirculation filters. 107, 108 Broken or disconnected electrical wire. Check all terminals for loose connections; check wiring for hidden breaks. --- Broken or disconnected ground wire.
TROUBLE SHOOTING SYMPTOM Air conditioning not producing sufficient cooling (continued). Air conditioning system too noisy. PROBLEM Clogged expansion valve. SOLUTION Recover system refrigerant and replace valve. Then, evacuate and charge system. REF. * Clogged receiver-drier. Recover system refrigerant and replace receiver-drier. Then evacuate and charge system. * Excessive moisture in system. Recover system refrigerant and replace receiver-drier. Then evacuate and charge system. * Air in system.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. Air conditioning system too noisy. (continued) Excessive moisture in system. Replace receiver-drier, evacuate & charge system. * Air conditioning cools intermittently. Compressor clutch slipping. Slippage over a prolonged period will require removing clutch for service. May require adjustment for proper spacing. * Unit icing up due to: · thermostat adjusted too low. · excessive moisture in system.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. Engine hard to start or will not start. (cont'd) Water, dirt or air in fuel system. Drain, flush, fill and bleed system. 73 Improper type of fuel. Use proper fuel for operating conditions. 59 Crankcase oil too heavy. Use recommended oil. 60 Low battery output. Have battery tested. Check battery electrolyte level. 80 Poor battery connection. Clean and tighten loose connections. 80 Faulty starter. Repair or replace.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. Engine runs irregularly or stalls frequently. Unsteady fuel supply. Change filter on fuel tank vent line. Replace clogged fuel filter. 70 Water, dirt or air in fuel system. Drain, flush, fill and bleed system. 73 Low coolant temperature. Remove and check thermostat. * Dirty or faulty injectors. Clean or replace injectors. * Engine electrical faults Check fuses and electrical connections at engine Incorrect timing. Time injection pump.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. Warning alarm sounds. Engine overheated. Check coolant level and thermostat. 76 Low engine oil pressure. Check oil level. 65 Low transmission oil pressure. Check oil level. 88 Low coolant level. Fill reserve tank to proper level. Check system for leaks. 76 Engine overloaded. Reduce ground speed. 35 Defective radiator cap. Replace cap. 76 Defective fan belt. Replace belt.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. High fuel consumption (continued). Engine out of time. Time injection pump. * Low engine temperature. Check thermostat. * Injection nozzles dirty. Clean or replace injectors. * Improper type of fuel. Consult your fuel supplier and use proper type fuel for conditions. 59 Engine overloaded. Reduce ground speed. 35 Clogged or dirty air cleaner. Service air cleaner. 68 Defective muffler.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. Starter cranks slowly or will not operate (cont'd) Relay not functioning. Check relay and wire connections. * Loose or corroded battery connections. Clean and tighten loose connections. 80 Key switch worn or terminals loose. Check switch and terminals. * Crankcase oil too high viscosity. Use recommended oil. 60 Main circuit breaker tripped. Reset main circuit breaker. 87 Main circuit breaker defective. Replace circuit breaker.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. Lights do not light. Defective light switch. Replace switch. * Broken wiring; open or defective circuit breaker. Check wiring for broken wire or shorts, check circuit breaker. 87 Defective relay. Replace relay. * Poor ground on lights. Clean and tighten ground wires. --- Turn signals or indicators showing wrong direction. Reversed wires. Connect properly. * No current to cab. Main circuit breaker tripped. Reset main breaker.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. Both wheels will not pull in forward or reverse. Low oil level. Check oil reservoir level. Engage power hubs. 88 Damaged hydraulic lines preventing proper oil flow. Replace damaged lines. * Steering controls worn or defective. Check variable speed lever and steering for loose, worn or damaged ball joints and connecting rods. * Speed-range control not working. Check speed-range wiring. Check for faulty servo or blockage in hose.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. One wheel does not pull in forward or reverse (continued). Speed-range control not working. Check for faulty servo or blockage in hose. * High pressure relief valve stuck open, damaged seat. Check valve and clean or replace. * Failed pump, motor or power hub. Repair or replace failed component. * Leakage at pump or motor. Repair pump or motor. * Faulty relief valve. Repair or replace valve. * Hydraulic line clamps loose. Tighten clamps.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF. Contaminant in relief valve. Clean relief valve at cylinder control valve. 90 Appropriate solenoids not being energized by activating switch. Check electrical connections; repair or replace solenoid(s). * Header or reel lifts but lacks power. Relief pressure too low, or contaminant in relief valve. Check/adjust/clean relief valve at cylinder control valve. 90 Reel and/or conveyor not turning. Header drive switch not engaged. Engage switch.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF Appropriate solenoid not being energized by activating switch. Check electrical connections; repair or replace solenoid. * Header drive belt tension too low. Check hydraulic pressure at tensioning cylinder. Should be between 150 & 250 psi. --- Check for plugged orifice at cylinder. --- Header Drive Sickle drive not engaging (continued) If pressure is below 150: 1) Check charge pressure 2) Repair/replace pump Sickle drive engages but lacks power.
TROUBLE SHOOTING SYMPTOM PROBLEM SOLUTION REF Adjust pulley shield. 95 Adjust belt guides and keepers 95 Adjust belt guides and keepers. 95 Header Drive (continued) Belt band frayed and separated from V-belt at one side. Belt bands or sides of belt prematurely worn. Burnt paint on shields or guides. Belt has jumped one groove at front pulley: Belt shield too far from pulley. Belt guides and shields not properly adjusted. Belt guides and keepers too close to belt.
OPTIONS AND ATTACHMENTS Consult your Windrower dealer for details on the following Options & Attachments. NOTE: If not factory ordered, installation of these kits is to be done by Windrower dealer. Forked Tail-Wheel Casters Tractor Models 9352c, 4952c, 2952c, 8152c: WholeGoods order number: B2995 – 11-16 tires B2996 – 16.5L-16.1 tires Air Intake Screen Cleaner WholeGoods order number: B2972 This automatic screen cleaning device "vacuums" the screen by means of two rotors.
UNLOADING WARNING: To avoid personal injury or death do not attempt to drive the windrower off the carrier. It must be lifted or towed. When starting the windrower, slight movement of the steering wheel could cause fast and hard-to-correct movement on a small surface such as a trailer bed. This could cause the machine to fall from the carrier onto the ground. Prepare to Unload CAUTION: To avoid injury to bystanders from being struck by machinery, do not allow persons to stand in the unloading area. 1.
UNLOADING One Forklift Method FORKLIFT REQUIREMENT: One forklift with a 5,000 lb. (2270 kg) capacity. CHAIN REQUIREMENTS: Overhead lifting quality chain with a minimum 5000 lb. (2270 kg) working load limit. 1. Back rear of truck bed up to an unloading dock which is the same height or slightly lower than the trailer bed. Remove miscellaneous parts shipped under tractor frame. 2. Set forklift tines to the widest possible setting. 3.
ASSEMBLY NOTE: The purpose of shipping preparations such as having no battery is to better adapt the unit for an extended non-active period. If the machine is to remain non-active for a long period of time, do not perform the following assembly work until necessary. Also, further prepare the unit for storage as instructed in this manual. Install Tires 16.5, 11-16 or 7.5 REAR TIRES 1. Lift rear end of windrower with forklift and remove yellow shipping support (B) from walking beam.
ASSEMBLY Install Tires DRIVE TIRES Install tires on a hard, level surface as follows: 1. Lift front end of windrower using a forklift and place 14” (35 cm) blocks under yellow skid shoes (S) on front frame legs. 2. Install drive tires onto power hubs ensuring tire tread points forward and air valve stems are on the outside. NOTE: For "Turf and Field" tires (diamond or rectangular tread), be sure arrow on sidewall points in forward rotation. 3. Torque drive wheel bolts to 180 ft. lbs.
ASSEMBLY Battery The windrower is shipped without battery. BATTERY RECOMMENDATIONS Battery should meet the following specs: • 640 amps cold cranking at 0°F (-18°C) • Reserve Capacity: 180 minutes • Size: approximately 13 x 6.8 x 9.4 inches (331 x 173 x 238 mm). • Battery must be vibration proof hybrid type with top posts. FILL BATTERY (if required) WARNING: Keep all smoking materials, sparks and flames away from electrolyte container and battery, as gas given off by electrolyte is explosive.
ASSEMBLY Battery INSTALL BATTERY NOTE: For easier installation, position a low platform on which to stand when placing battery. 1. Lower battery from above onto battery tray located at left rear corner of frame. Position + post towards rear of machine. A 2. Install battery holder (A). CONNECT BATTERY CABLES B 1. Connect starter cable (B) to positive (+) terminal on battery. 2. Connect ground cable (C) to negative (-) terminal on battery. 3. Be sure connections are clean and tight.
ASSEMBLY Preparing the Tractor for 962/963 & 972 Headers 1. Remove plastic blocks (A) on tractor lift legs and reinstall as shown with 1/2 x 5 inch bolts provided. NOTE: For 12’ 972 Header only, install extensions (D) with 1/2 x 1 inch hex head bolts and lock nuts. A D REPOSITION LIFT LINKAGE BLOCKS LINKAGE BLOCK EXTENSIONS – 12’ 972 2. For 972 Hydraulic Deck Shift Harvest Header, install deck shift switch (B) (shipped with header) in side console as follows: • Cut decal to expose switch hole punch-out.
ASSEMBLY Preparing 962/963 Harvest Header for Windrower Tractor 1. Attach lift linkage supports to lower header legs with 5/8 locknut at (A). NOTE: For 963 Header, remove existing linkage supports first. ATTACH LINKAGE SUPPORTS TO HEADER LEGS – 962/963 HEADER 2. Attach connector shaft assembly to header frame tube as follows: • With carriage bolt and nut installed loosely in plate (C) of shaft assembly, engage head of carriage bolt in key-hole slot in header frame tube near left leg.
ASSEMBLY Preparing 962/963 Harvest Header for Windrower Tractor (continued) 5. Attach reel lift hose and coupler (supplied in adapter kit) as follows: 30': Attach to hydraulic line (F) at header left leg. 36': Attach to hose (G) at header left leg.
ASSEMBLY Preparing 972 Harvest Header (21' to 36') for Windrower Tractor 1. Attach lift linkage supports (A) inside lower header legs with 5/8 x 6-1/2 carriage bolt, lockwasher and nut. Use the top hole in the leg as shown. 2. For 21’ & 25’ Headers, attach center section of wear plate (D) to cutterbar at delivery opening. Longer guard bolts are positioned at the correct locations. 3. Attach skid shoes (B) at header legs with 5/8 x 1-1/2 carriage bolts and flange nuts. 4.
ASSEMBLY Radio Installation Provision has been made for easy installation of a radio: B • Remove six screws around outer edge of panel (A). Panel hangs on wiper motor with a plastic tie. If it is desired to work at a bench, unplug turn signal lights and slip tie off motor to release panel. • Remove decal (B) and remove radio cut-out piece from panel (A) by cutting through four tabs. A • Install radio in cut-out. • Secure rear of radio body to support (F).
ASSEMBLY Two-Way Radio Installation At the rear of the side console (D), you will find two auxiliary power points provided for accessories such as a two-way radio. To mount antenna to cab roof: • Remove console lower panel (to right of operator's seat) and route antenna cable (E) from the radio into the console. • Remove instrument panel on cab right post. Follow cab wiring harness into headliner. • Remove wiper motor cover and/or right radio speaker for access to inside of headliner.
ASSEMBLY Swath Roller A hitch for a pull-behind swath roller can be attached at two bottom bolts (A) on walking beam pivot plate. A ATTACH SWATH ROLLER HITCH HERE A direct mounted swath roller can be installed at holes provided in frame at (B).
INDEX A E PAGE PAGE Air Cleaner – Engine ....................................... 68 Air Conditioning System Maintenance .......... 107 Air Intake Screen Cleaner (Attachment)........ 129 Air Removal - Fuel System.............................. 73 Alarms - System Malfunction........................... 18 Alternator/Regulator ........................................ 82 Anti-freeze Concentration................................ 76 Assembly.......................................................
INDEX Power Hubs................................................... 104 Power Hub Gear Lubricant.............................. 60 Pre-Starting Checks: Annual ........................... 30 Pre-Starting Checks: Daily .............................. 31 Pulley Shield Adjustment (Header Drive) ........ 95 S PAGE Safety: Alert Symbol................................................... 6 Battery.......................................................... 79 Driving the Windrower..................................
INDEX T cont'd. PAGE Trouble Shooting ........................................... 114 Trouble Shooting: A/C Diagnostics ............... 109 Two-Way Radio Installation........................... 141 U Unloading Preparations................................. 130 Unloading With One Forklift .......................... 131 Unloading With Two Forklifts......................... 130 V Valve Tappets - Engine ................................... 67 W Warning Lights - System Malfunction..............
Self-Propelled Windrower Pre-Delivery Checklist Perform these checks and make adjustments as required prior to delivery to your customer. See the Operator's Manual for adjustment details. CAUTION: Carefully follow the instructions given. Be alert for safety related messages which bring your attention to hazards and unsafe practices. Serial Numbers: ENGINE: ____________________ WINDROWER: Check for damage or missing parts.
Roof Wiring Schematic CONNECTOR TO RADIO 315 306 LEFT SPEAKER INTERIOR LIGHT 10 BLK 315 12 DK BLUE 418 14 DK BLUE 431 10 BLK 315 18 BLK 315 14 BLK 315 14 BLK 315 14 BLK 315 18 BLK 315 RADIO MEMORY 18 DK BLUE 431 18 PINK 702 18 BLK 306 18 RED 503 18 BLK 315 10 BLK 315 RADIO BODY GROUND RIGHT FRONT RIGHT FRONT AMBER WORKLIGHT 18 TAN 302 18 BLK 315 18 BLK 305 18 DK BLUE 430 RIGHT IND RIGHT FRONT LIGHT HEADLIGHT RIGHT SPEAKER 18 TAN 301 P 8 BLK 315 12 DK BLUE 505 LEFT IND LIGHT 18
702 506 505 503 CONNECTOR TO ROOF 430 431 418 702 506 505 503 Cab Wiring Schematic 431 430 418 12 RED 416 FUEL GAUGE I 18 BLK 415 18 DK BLUE 514 FLASHER/TURN SIGNAL SWITCH VOLTMETER 18 BLACK 415 HEADLIGHT RELAY 5 10 RED 416 4 S I 87a 30 87 2 G 18 ORANGE 507 30 CONNECTOR TO BLOWER MOTOR 18 BLK 415 85 86 BLOWER SWITCH L A/C LO PRESS.
Tractor Wiring Schematic AUX POWER -----2 SPD SHIFT SW ---------------FUEL LEVEL TEMP SENDER TACH SIGNAL OIL PRESS SW -----PARK BRAKE LIGHT ECM IGNITION PWR TRANS OIL PRESS TEMP SWITCH SENSOR POWER SPD SENSOR SIG.
Header & Reel Lift: Hydraulic Schematic (includes brake circuit) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Pump Reservoir Filter Cylinder Control Valve – Relief Pressure: 2400 to 2650psi measured as described on pg.
Header Drive: Hydraulic Schematic Traction Drive: Hydraulic Schematic 12345678910 11 12 13 14 - Form 147141/147459 Pump Left Wheel Motor Right Wheel Motor Reservoir Oil Cooler Filter (500 psi) Charge Pump Relief Valve (cracking pressure): 250 psi Oil Pressure Switch (remove to attach pressure gauge) Filler / Dipstick To Cylinder Control Valve (12 gpm) To Header Drive Control Block (19 gpm) Return from Cylinder Control Valve (see Header & Reel Lift Schematic) To Header Clutch Cylinder 2 Speed Motor Contr
