CHAPTER 14 SET-UP & ASSEMBLY

Handling Crated Unit

The DC2340 and DC2360 Disc Conditioners are shipped from the factory in three separate shipping bundles consisting of the Main Frame package, the Drawbar package and the Completing Parts box. The Main Frame is packaged at the factory in such a way that the front of the Header is next to the ground and Windrow-forming Chamber is pointed upwards. Discardable shipping crate is secured to the front of the Header for additional stability during warehousing.

Depending on facilities, the unit can either be handled with a forklift truck (capable of carrying at least 4000 lb) or, with a 2 ton overhead hoist, using lifting points on each Spring Tower or on each Axle. In either case, handle the machine carefully, so as NOT to damage it. If a forklift is going to be used, BE SURE to spread the forks as far apart as possible and insert them under the shipping frame.

Warning

BEFORE attempting to lift the unit with a forklift, securely attach chains from the shipping mounts to the forklift, on both ends of the unit, to prevent the unit from swinging away, when the unit is picked up. Also, BE SURE that nobody is close to the unit while unit is being transported in the shipping position.

UNCRATING UNIT (Fig. 34)

After the machine is placed on a solid level surface in its uncrating location, use the following steps and the drawing provided to properly uncrate it:

1.Remove all items that are banded to the unit.

2.Securely attach a long heavy chain to the Wheel Axles. Then, securely attach the chain, with a spreader bar, to the forklift carriage or hoist. MAKE SURE to leave the Shipping Wires from the Axles to the Spring Towers installed while letting the unit down from the shipping position. NOTE: The chain(s) being used MUST be equipped with safety lock clevises to assure that the chain does NOT disconnect as the Conditioner is being lowered. A spreader bar, capable of lifting at least 4000 lb (1820 kg) and that is at least as wide as the distance between the Disc Conditioner legs, MUST be used. The spreader bar used MUST have a reach of 95″ (242 cm) for the DC2340 and 110″ (280 cm) for the DC2360. The bar will keep the chain apart and prevent the chain from crushing the sides of the Windrow Forming Chamber. In addition, BE SURE that the chain is long enough so that the Forming Chamber will clear the spreader bar as unit is being pivoted down.

Danger

Do NOT allow anyone near the unit, while it is being lowered. Also, BE SURE that the chains are long enough and strong enough to do the job.

3.Keeping tension on the chain at all times, raise the forklift carriage to a point approximately 2 feet higher than the end of the Windrow Forming Chamber. Then, as shown in the drawing provided (Figure 34), slowly pull and lift on the Mower Conditioner to rotate it around and rest it on the floor.

NOTE: When rotating the unit down from the shipping position, the hydraulic Lift Cylinders may extend slightly.

NOTE: Block both Tires, front and back, to prevent the unit from moving.

1.Install the Drawbar (Tongue), which was shipped separately, using the Pivot Pin to attach it to the Frame. Secure the Pivot Pin with the attaching hardware provided. See Figure 35 for details.

NOTE: It may be necessary to raise and block the front of the Header (using the shipping mounts), to obtain the correct alignment for installing the Pivot Pin.

2.Install Hydraulic Drawbar Hitch Positioner Cylinder with rod end attached to the Trailer Frame and secure with Pins and Roll Pins. See Figure 35 for details.

3.Install 125347 90° Female Elbow to rod end port in Positioner Cylinder. See Figure 35 for details.

4.Install 068938 90° Male Elbow to anchor end port in Positioner Cylinder. See Figure 35 for details.

1 – Drawbar

2 – Positioner Cylinder

3 – Female Elbow Fitting

4 – Positioner Cylinder Hoses

5 – Lift Cylinder Hose

6 – Hose Clamps

Fig. 35

5.Install 125348 Hydraulic Ball Valve to 90° Female Elbow in rod end port of Positioner Cylinder. MAKE SURE to position Valve such that the Valve Lever is pointing up in a vertical direction when the Valve is closed and the Lever is positioned on the Drawbar side of the Valve Body. See Figure 35 for details.

6.Install and lock Hitchjack onto the Drawbar Hub. Raise the Drawbar with the Jack until the shipping crate is off the ground. Slide blocks under the shipping crate and let the Header rest on blocks.

7. Remove and discard the two shipping links that connect the Header to the Trailer Frame. MAKE SURE to install a 1/2 x 1″ Carriage Bolt and Lock Nut to the Header where the Shipping Straps were removed. To prevent oil leakage, MAKE SURE to apply silicone sealer to the hole in Frame on the back of the Chain Case BEFORE installing the Carriage Bolt.

8.Check that the Wheel lugs are torqued to 90 ft-lb (124 Nm).

7 – Cylinder Pins

8 – Roll Pins

9 – Transport Lock Valve

10 – Tie Straps

11 – Male Elbow Fitting

12 – Pivot Pin

NOTE: BEFORE routing the Hoses, MAKE SURE that the holes in and out of the Tongue are free of all burrs and sharp edges and the factory installed edging is properly in place. Also MAKE SURE to position the Tongue so that the Positioner Cylinder is fully extended before installing Hoses.

9.Route the Header Lift Hose through the Tongue and out the Tower. Use a Tie Strap near Female Elbow to secure Hose to bottom of Swing Cylinder. See Figure 35 for details.

10.Route the Swing Cylinder Hoses through the Tongue. Attach Hoses to the Swing Cylinder Elbow and Valve. Use a Tie Strap around all 3 Hoses near Drawbar. See Figure 35 for details.

11.Attach the Tower Cover to the Tower on the Tongue securing with 4 carriage bolts, Washers, Lock Washers and Nuts. MAKE SURE the heads of the bolts face out.

12.Install the 2 Hose Clamps to the Tower Cover Securing with 5/16 x 1-1/2 Carriage Bolts and Lock Nuts. See Figure 35 for details.

13.Install the Telescoping Drive Retaining Spring to the Tower Cover. Secure the Spring to the Tower by crimping the end of the Spring.

Warning

MAKE SURE that the Shipping Straps have been removed as instructed in Step 7. BEFORE the Hydraulics System is energized or charged. Failure to heed can result in death or serious injury.

Warning

When raising the Header, the Tongue will be free to change positions. MAKE SURE the immediate area is clear of personnel and obstructions. Failure to heed can result in death or serious injury.

14.Connect the Header Lift Hose to the tractor and raise the Header. Refer to the Operator’s Manual Service chapter for proper procedures for bleeding the Lift Cylinders. Engage the Header Lift Transport Lock on each Trailing Leg.

15.With the Positioner Cylinder Valve in the “open” position, connect the Drawbar Positioner Hoses to the tractor and cycle the Drawbar Cylinder several times to fill the Cylinder and Hoses completely with hydraulic fluid. Place the Drawbar in the operating position (Cylinder extended). Engage the Drawbar Lock by placing the Positioner Cylinder Valve in the “closed” position. See Figure 35 for details. Securely block the unit. Disconnect the tractor from the Disc Conditioner.

16.Remove the Shipping Crate from the Header. Discard Shipping Crate mounting bolts and retain Washers, Lock Washers and Nuts.

NOTE: To prevent damage to the Disc Conditioner, the use of a forklift or overhead crane is recommended to assist in the removal of the Shipping Crate.

17.Install (4) 1/2 x 1-1/2 Carriage Bolts, Washers, Lock Washers and Nuts to the rear of the Skid Shoes where the Shipping Mounts were installed. Position Carriage Bolt heads to the outside of the Shoes in all locations EXCEPT the left end Shoe below the Drive Disc.

18.Remove the wires that are retaining the Curtains on the unit in the rolled-up position. MAKE SURE to re-tighten the hardware that holds the Curtains in place.

19.Remove the top Roller Chain Cover on the right side of the Conditioner. There is a protective paper film between the Cover Seal and the Header Frame. Remove the paper film. Reinstall the Cover. Apply silicone sealer to the top area of the Lower Cover to insure a positive seal between Covers and Frame.

20.Add 3 quarts (2.84 L) of SAE 80W90EP Gear Lube to the Chain Case through the 90° Elbow that is located on the inside of the Roll Pressure Spring Compartment.

21.Remove the cylindrical Clutch Shield from the front of the Gearbox on the Header Assembly by removing and retaining the 3 Flanged Head Screws from outside of the Clutch Shield. MAKE SURE to leave the Inner Mounting Plate secured to the nose of the Gearbox.

22.Slide the cylindrical Clutch Shield over the Clutch end of the Tower to Transmission Driveline Assembly.

23.Clean and lightly grease the Spline on the Transmission Shaft. Apply Loctite 271 or equivalent to the Cap Screw in the end of the Clutch Assembly. Install the Tower to Transmission Driveline and Overrunning Clutch Assembly securing Driveline Clutch End to Transmission with Cap Screw torqued to 65 ft lb (88 Nm). Reinstall the cylindrical Clutch Shield securing with the 3 retained Flanged Head Screws.

24.Slide one of the Tower Shields (flared end first) over the Tower end of the Tower to Transmission Driveline Assembly.

25.Clean and lightly grease the Splines on the Tower Shaft. Install the other end of the Tower to Transmission Driveline and Overrunning Clutch assembly to the Tower Shaft. Secure with 2 Cap Screws, Lock Washers and Nuts. Torque Screws to 80 ft lb (108 Nm). MAKE SURE to properly align the phasing notch as the Driveline is installed. See Figure 36 for details.

27.In a similar manner, secure the remaining Tower Shield to the front of the Tower Assembly with 4 Flanged Head Screws supplied.

28.Install the tractor to Tower Driveline by depressing the Safety Lock Ring on Rear Drive Yoke and slide the Yoke onto the Tower Shaft. MAKE SURE to properly align the phasing notch as the Driveline is installed. See Figure 36 for details. Move the Yoke back and forth until the Safety Lock Ring pops out and locks into the groove in the Tower Shaft. Support tractor end of Driveline with Telescoping Drive Retaining Spring by wrapping Spring around Driveline and hooking end of Spring into hole on top of Tower Cover. The Driveline is also stored in this position. The Driveline will be attached to the tractor following completion of instructions contained in the Preparing for Field Operation chapter in this manual.

NOTE: When transporting unit without PTO Driveline attached to tractor PTO shaft, the tractor to Tower Driveline should be removed and carried separately from the Disc Conditioner.

26.Position the base end of the Tower Shield with flap on top against the rear of the Tower Assembly and align the holes in the tabs on the Shield with the tapped holes in the Tower Assembly. Secure the Tower Shield to the Tower Assembly with 4 Flanged Head Screws supplied.

29.Refer to the topics, Tractor and Drawbar Requirements and Attachment To Tractor, in the Preparing for Field Operation chapter of the Operator’s Manual, for additional details on connecting the Disc Conditioner to the tractor. This additional information will be required to properly complete the installation of the remaining Hitch and Drawbar parts with regards to 540 RPM and 1000 RPM tractor PTOs.