New Holland 1431,1432 Disc Mower-conditioner Service Manual (86592631) - PDF Download

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1431 1432

REPAIR MANUAL

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86592631

10/01

1431, 1432 REPAIR MANUAL CONTENTS SECTION 00 SECTION 31 SECTION 35 SECTION 39 SECTION 55 SECTION 58 SECTION 90

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GENERAL INFORMATION IMPLEMENT POWER TAKE OFF (PTO) HYDRAULIC SYSTEM FRAMES/TONGUE AND HITCHES ELECTRICAL SYSTEM ATTACHMENTS/HEADERS DECALS

The sections used through out all New Holland product Repair manuals may not be used for each product. Each Repair manual will be made up of one or several books.

The sections listed above are the sections utilized for the 1431, 1432 Disc Mower-Conditioners.

358

ã 2001 NEW HOLLAND NORTH AMERICA, INC.

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

SECTION 00 - GENERAL INFORMATION Chapter 1 - General Information CONTENTS Section

Description

Page

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 Model 1431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 Model 1432 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11

00-1

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

SPECIAL TOOLS Tool Number

Description/Use

Section 31 NHO1386

Pivot tongue gearbox neck cap screws

610R

Snap ring remover

Local Manufacture

Neck lock nut removal

Local Manufacture

Holding tool for neck housing

Local Manufacture

Neck rolling torque measurement

Section 58 FNH23ET95

Top cap bearing cover

FNH01221-2

Cutter bar tie bolt holding tool

FNH01221-3

Cutter bar wrench

SPECIFICATIONS MODEL 1431

Standard Tongue

Swivel Hitch Tongue

Overall Width Transport position . . . . . . . . . . . . . . . . . 4000 mm (13′3″) Field position . . . . . . . . . . . . . . . . . . . . . 5791 mm (19′0″)

4000 mm (13′3″) 6274 mm (20′7″)

Overall Length Transport position . . . . . . . . . . . . . . . . . 7925 mm (26′0″) Field position . . . . . . . . . . . . . . . . . . . . . 6375 mm (20′11″)

8484 mm (27′10″) 6934 mm (22′9″)

Height

Transport position . . . . . . . . . . . . . . . . . 2032 mm (6′8″) Field position . . . . . . . . . . . . . . . . . . . . . 1676 mm (5′6″)

2032 mm (6′8″) 1676 mm (5′6″)

Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 457 mm (18″)

457 mm (18″)

Wheel Tread Width . . . . . . . . . . . . . . . . . . . . . . . . 3772 mm (148.5″)

3772 mm (148.5″)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2557 kg (5600 lbs.)

2694 kg (5900 lbs.)

00-2

SECTION 00 - GENERAL INFORMATION - CHAPTER 1 Driveline

Header

Tractor Requirement . . . . . . . . . . . . . . . 67 KW (90 HP) or greater with standard category 2 or 3 ASAE hitch and PTO locations. Two remote hydraulic circuits capable of 104 bar (1500 PSI).

Input Speed . . . . . . . . . . . . . . . . . . . . . . 1000 RPM only Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 RPM PTO with slip clutch/overrunning clutch, enclosed gears and (3) HB banded belts with spring loaded idlers.

Cutting Width . . . . . . . . . . . . . . . . . . . . .

Flotation . . . . . . . . . . . . . . . . . . . . . . . . .

Windrow Width . . . . . . . . . . . . . . . . . . .

Header Lift . . . . . . . . . . . . . . . . . . . . . . .

3906 mm (13′0″) Vertical & radial 914 mm to 2438 mm (3′ to 8′) Hydraulic (master-slave system)

Cutter Bar Type . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No. of Discs . . . . . . . . . . . . . . . . . . . . . .

Knives per Disc . . . . . . . . . . . . . . . . . . .

Disc Cutting Diameter . . . . . . . . . . . . .

Disc Drive . . . . . . . . . . . . . . . . . . . . . . . .

Disc Speed . . . . . . . . . . . . . . . . . . . . . .

Cutting Height, Approximate . . . . . . . .

Modular 8 counter-rotating, 2 co-rotating 2 500 mm (19.7″) Bevel gears in sealed modules 3000 RPM 32 mm to 83 mm (1.25″ to 3.25″)

Conditioner Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermeshing rolls Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4HB V-belt, enclosed gears with u-joint drives to upper & lower rolls.

Rolls

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Length . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter . . . . . . . . . . . . . . . . . . . . . . . . .

Speed . . . . . . . . . . . . . . . . . . . . . . . . . . .

Molded rubber with intermeshing chevron design.

2591 mm (102″) 264 mm (10.38″) 640 RPM

Operating Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 14 KPH (0 to 9 MPH) Transport Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 40 KPH (25 MPH) maximum Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.06 H/hr (7.56 A/hr) @ 10 KPH (6 MPH) & 80% field efficiency.

Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.5 x 13.5L x 15, 6 ply tubeless agricultural rib implement tire Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa or 2.07 bar (30 PSI).

Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 lb. capacity side-wind Tongue Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic

00-3

SECTION 00 - GENERAL INFORMATION - CHAPTER 1 MODEL 1432

Standard Tongue

Swivel Hitch Tongue

Overall Width Transport position . . . . . . . . . . . . . . . . . 4000 mm (13′3″) Field position . . . . . . . . . . . . . . . . . . . . . 5791 mm (19′0″)

4000 mm (13′3″) 6274 mm (20′7″)

Overall Length Transport position . . . . . . . . . . . . . . . . . 8052 mm (26′5″) Field position . . . . . . . . . . . . . . . . . . . . . 6502 mm (21′′4″)

8611 mm (28′″) 7061 mm (23′2″)

Height

Transport position . . . . . . . . . . . . . . . . . 2184 mm (7′2″) Field position . . . . . . . . . . . . . . . . . . . . . 1829 mm (6′0″)

2184 mm (7′2″) 1803 mm (5′11″)

Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 406 mm (16″)

406 mm (16″)

Wheel Tread Width . . . . . . . . . . . . . . . . . . . . . . . . 3772 mm (148.5″)

3772 mm (148.5″)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2582 kg (5655 lbs.)

2719 kg (5955 lbs.)

Driveline

Header

Tractor Requirement . . . . . . . . . . . . . . . 67 KW (90 HP) or greater with standard category 2 or 3 ASAE hitch and PTO locations. Two remote hydraulic circuits capable of 104 bar (1500 PSI).

Input Speed . . . . . . . . . . . . . . . . . . . . . . 1000 RPM only Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 RPM PTO with slip clutch/overrunning clutch, enclosed gears and (3) HB banded belts with spring loaded idlers.

Cutting Width . . . . . . . . . . . . . . . . . . . . .

Flotation . . . . . . . . . . . . . . . . . . . . . . . . .

Windrow Width . . . . . . . . . . . . . . . . . . .

Header Lift . . . . . . . . . . . . . . . . . . . . . . .

3906 mm (13′0″) Vertical & radial 914 mm to 2438 mm (3′ to 8′) Hydraulic (master-slave system)

Cutter Bar Type . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No. of Discs . . . . . . . . . . . . . . . . . . . . . .

Knives per Disc . . . . . . . . . . . . . . . . . . .

Disc Cutting Diameter . . . . . . . . . . . . .

Disc Drive . . . . . . . . . . . . . . . . . . . . . . . .

Disc Speed . . . . . . . . . . . . . . . . . . . . . .

Cutting Height, Approximate . . . . . . . .

Modular 8 counter-rotating, 2 co-rotating 2 500 mm (19.7″) Bevel gears in sealed modules 3000 RPM 32 mm to 83 mm (1.25″ to 3.25″)

Conditioner Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flail Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4HB V-belt, enclosed gears with u-joint drives to rotor.

Rotor

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 2591 mm (102″) Diameter . . . . . . . . . . . . . . . . . . . . . . . . . 560 mm (22″) Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 1011 RPM (726 RPM optional)

00-4

SECTION 00 - GENERAL INFORMATION - CHAPTER 1 Operating Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 14 KPH (0 to 9 MPH) Transport Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 40 KPH (25 MPH) maximum Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.06 H/hr (7.56 A/hr) @ 10 KPH (6 MPH) & 80% field efficiency.

Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.5 x 13.5L x 15, 6 ply tubeless agricultural rib implement tire Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa or 2.07 bar (30 PSI).

Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 lb. capacity side-wind Tongue Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic

00-5

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

LUBRICATION Adequate lubrication and maintenance on a regular schedule is vital to maintaining your equipment. To ensure long service and efficient operation, follow the lubrication and maintenance schedules outlined in this manual.

The use of proper fuels, oils, grease and filters, as well as keeping the systems clean, will also extend machine and component life.

IMPORTANT: Always use genuine New Holland replacement parts, oils and filters to ensure proper operation, filtration of engine and hydraulic systems. See your New Holland dealer for additional oil quantities.

RECOMMENDED LUBRICANTS AND COOLANTS Lubricant

Location Used

Type and Description

Part Number

Quart or Gallon Liter or Tube

Oil

Engine and Pivot Points without Grease Fittings, Chains

SAE 30 API CF--2SJ

9613286

1Qt.

SAE 30 API CF--2SJ

9613289

SAE 30 API CF--2SJ

9613366*

4L

5W--30 API SG/CD

9673589DS

1 Qt.

5W--30 API SG/CD

9624590*

4L

10W--30 API SG/CD

9613313

1 Qt.

10W--30 API SG/CD

9613314

2.5 Gal.

10W--30 API SG/CD

9673508DS

5 Gal.

10W--30 API SG/CD

9613358*

1L

10W--30 API SG/CD

9613359*

4L

15W--40 API CF--4

9613290

1 Qt.

15W--40 API CF--4

9673730DS

1 Gal.

15W--40 API CF--4

9613303

2.5 Gal.

15W--40 API CF--4

9613292

15W--40 API CF--4

9613350*

1L

15W--40 API CF--4

9613351*

4L

Coolant

Engine

Hydraulic Oil

Hydraulic System, Hydrostatic System Front Axle Oil

Hydraulic Oil

Gear Oil

Grease Brake Fluid

2.5 Gal.

5 Gal.

ESE--M97B18--D, Ethylene Glycol New Hol- FGCC2701DS land Spec. Coolant Concentrate

1 Gal.

Propylene Glycol Concentrate

FGCC2711DS

1 Gal.

134D – ESN--M2C134--D New Holland Spec. Hydraulic oil

9624450

2.5 Gal.

134D – ESN--M2C134--D

9624451

134D – ESN--M2C134--D

9613367*

4L

134D – ESN--M2C134--D

5 Gal.

9624785*

10 L

Optional, Multi-Seasonal F200 Use, Recommended for Low Temperatures

86523625DS

1 Qt.

F200

86523626DS

F200

86509446*

20 L

80W90 EP Gear Oil API GL5

9613295

1 Qt.

80W90 EP Gear Oil API GL5

9613294

80W90 EP Gear Oil API GL5

9613375*

5L

85W140 EP Gear Oil API GL5

9613297

1 Qt.

85W140 EP Gear Oil API GL5

9613296

85W140 EP Gear Oil API GL5

9613376*

Lithium base EP high temperature

9861804DS

Lithium base EP high temperature

9861804CDS*

Mineral Based Oil

1QM6C34A 86541699DS

Gearboxes

All Grease Fittings

* NOTE: Canada Part Numbers ONLY.

00-6

5 Gal.

2.5 Gal.

2.5 Gal. 4L Tube Tube or 1 Qt.

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS

INCH HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL UNPLATED SIZE or PLATED SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

55* (6.2) 115* (13) 17 (23) 27 (37) 42 (57) 60 (81) 83 (112) 146 (198) 142 (193) 213 (289)

SAE GRADE 5

PLATED W/ZnCr

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

72* (8.1) 149* (17) 22 (30) 35 (47) 54 (73) 77 (104) 107 (145) 189 (256) 183 (248) 275 (373)

86* (9.7) 178* (20) 26 (35) 42 (57) 64 (87) 92 (125) 128 (174) 226 (306) 365 (495) 547 (742)

112* (13) 229* (26) 34 (46) 54 (73) 83 (113) 120 (163) 165 (224) 293 (397) 473 (641) 708 (960)

GOLD

SAE GRADE 8 UNPLATED or PLATED SILVER

LOCKNUTS

PLATED W/ZnCr GOLD

121* (14) 157* (18) 250* (28) 324* (37) 37 (50) 48 (65) 59 (80) 77 (104) 91 (123) 117 (159) 130 (176) 169 (229) 180 (244) 233 (316) 319 (432) 413 (560) 515 (698) 667 (904) 773 (1048) 1000 (1356)

GR.B w/GR5 BOLT

GR.C w/GR8 BOLT

NOMINAL SIZE

61* (6.9) 125* (14) 19 (26) 30 (41) 45 (61) 65 (88) 90 (122) 160 (217) 258 (350) 386 (523)

86* (9.8) 176* (20) 26 (35) 42 (57) 64 (88) 92 (125) 127 (172) 226 (306) 364 (494) 545 (739)

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS

SAE GRADE 2

SAE GRADE 5

SAE GRADE 8 REGULAR NUTS

SAE GRADE 5 HEX NUTS

SAE GRADE 8 HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION

GRADE IDENTIFICATION

GRADE A NO NOTCHES

GRADE A NO MARKS

GRADE B ONE CIRCUMFERENTIAL NOTCH

GRADE B THREE MARKS

GRADE C TWO CIRCUMFERENTIAL NOTCHES

GRADE C SIX MARKS MARKS NEED NOT BE LOCATED AT CORNERS GRADE A NO MARK GRADE B LETTER B GRADE C LETTER C

GRADE IDENTIFICATION

00-7

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC HARDWARE AND LOCKNUTS PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL.8 W/CL8.8 BOLT

23* (2.6)

30* (3.4)

33* (3.7)

42* (4.8)

16* (1.8)

67* (7.6)

79* (8.9)

102* (12)

115* (13)

150* (17)

56* (6.3)

124* (14)

159* (18)

195* (22)

248* (28)

274* (31)

354* (40)

133* (15)

M10

21 (28)

27 (36)

32 (43)

41 (56)

45 (61)

58 (79)

22 (30)

M12

36 (49)

46 (63)

55 (75)

72 (97)

79 (107)

102 (138)

39 (53)

M16

89 (121)

117 (158)

137 (186)

177 (240)

196 (266)

254 (344)

97 (131)

M20

175 (237)

226 (307)

277 (375)

358 (485)

383 (519)

495 (671)

195 (265)

M24

303 (411)

392 (531)

478 (648)

619 (839)

662 (897)

855 (1160)

338 (458)

CLASS 5.8

CLASS 8.8

NOMINAL SIZE

UNPLATED

PLATED W/ZnCr

M4

15* (1.7)

19* (2.2)

M6

51* (5.8)

M8

UNPLATED

CLASS 10.9

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

CLOCK MARKING

00-8

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

INSTALLATION OF ADJUSTABLE FITTINGS IN STRAIGHT THREAD O RING BOSSES 1. Lubricate the O ring by coating it with a light oil or petroleum. Install the O ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove, 4.

2. Install the fitting into the SAE straight thread boss until the metal backup washer contacts the face of the boss, 5.

NOTE: Do not over tighten and distort the metal backup washer.

1

3. Position the fitting by turning out (counterclockwise) up to a maximum of one turn. Holding the pad of the fitting with a wrench, tighten the locknut and washer against the face of the boss, 6.

STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS O RING BOSS PLUGS ADJUSTABLE FITTING LOCKNUTS, SWIVEL JIC - 37° SEATS

TUBE NUTS FOR 37° FLARED FITTINGS

4

1/4

6.4

7/16-20

TORQUE FOOT NEWTON POUNDS METERS Min. Max. Min. Max. 9 12 12 16

5 6

5/16 3/8

7.9 9.5

1/2-20 9/16-18

12 21

15 24

16 29

20 33

10 15

15 20

14 20

20 27

8 10

1/2 5/8

12.7 15.9

3/4-18 7/8-14

35 53

40 53

47 72

54 79

25 35

30 40

34 47

41 54

12 14

3/4 7/8

19.1 22.2

1-1/16-12 1-3/16-12

77 90

82 100

104 122

111 136

60 70

70 80

81 95

95 109

16

1

25.4

1-5/16-12

110

120

149

163

80

90

108

122

20 24

1-1/4 1-1/2

31.8 38.1

1-5/8-12 1-7/8-12

140 160

150 175

190 217

204 237

95 120

115 140

129 163

158 190

32

2

50.8

2-1/2-12

225

240

305

325

250

300

339

407

SIZE

TUBING OD In. mm

THREAD SIZE

These torques are not recommended for tubes of 1/2″ (12.7 mm) OD and larger with wall thickness of 0.035″ (0.889 mm) or less. The torque is specified for 0.035″ (0.889 mm) wall tubes on each application individually.

Before installing and torquing 37° flared fittings, clean the face of the flare and threads with a clean

00-9

TORQUE FOOT NEWTON POUNDS METERS Min. Max. Min. Max. 6 10 8 14

solvent or Loctite cleaner and apply hydraulic sealant Loctite no. 569 to the 37° flare and the threads.

Install fitting and torque to specified torque, loosen fitting and retorque to specifications.

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

PIPE THREAD FITTING TORQUE

Thread Size

Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant Loctite no. 567 for all fittings including stainless steel or no. 565 for most metal fittings. For high filtration/zero contamination systems use no. 545.

1/8″ -- 27

13 N⋅m (10 ft. lbs.)

1/4″ -- 18

16 N⋅m (12 ft. lbs.)

3/8″ -- 14

22 N⋅m (16 ft. lbs.)

1/2″ -- 14

41 N⋅m (30 ft. lbs.)

3/4″ -- 14

54 N⋅m (40 ft. lbs.)

Torque (Maximum)

INSTALLATION OF ORFS (O-RING FLAT FACED) FITTINGS When installing ORFS fittings thoroughly clean both flat surfaces of the fittings, 1, and lubricate the O-ring, 2, with light oil. Make sure both surfaces are aligned properly. Torque the fitting to specified torque listed throughout the repair manual.

IMPORTANT: If the fitting surfaces are not properly cleaned, the O-ring will not seal properly. If the fitting surfaces are not properly aligned, the fittings may be damaged and will not seal properly.

50011183

IMPORTANT: Always use genuine New Holland replacement oils and filters to ensure proper lubrication and filtration of engine and hydraulic system oils.

1

2

1 2

The use of proper oils, grease, and keeping the hydraulic system clean will extend machine and component life.

00-10

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

LABOR GUIDE The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job.

SECTION 31 - Implement Power Take-off (PTO) Job Description

Hours

Auto-Lok Slide Lock, Rbld

0.25

U-joints, replace cross; Standard

0.3

50° CV

0.7

80° CV

0.75

Guards, R & R

0.25

Burnishing Clutch

0.33

Slip Clutch, R & R

0.50

Slip Clutch, Rbld

0.75

Center Pivoting Gearbox Gearbox, R & R

1.50

Gearbox, Rbld

2.25

Guidance Link, R & R and Shim

0.50

Right Hand Gearbox Gearbox, R & R (Includes removing and replacing conditioner drive belt)

1.75

Gearbox Rebuild

3.00

Conditioner Drive belt, R & R

0.50

Conditioner Drive Gearbox Gearbox, R & R 2.00 (Includes removing and replacing the conditioner roll drive shafts) Gearbox, Rbld

2.00

SECTION 35 - Hydraulic System Job Description Swing Cylinder, R&R Master Cylinder, Slave Cylinder, Tilt Cylinder,

Hours 0.50

Rbld

0.75

R&R

0.

Rbld

0.50

R&R

0.

Rbld

0.50

R&R Rbld

0.3 0.50

00-11

SECTION 00 - GENERAL INFORMATION - CHAPTER 1 SECTION 39 - Frames/Tongue and Hitches Job Description Hood Liner R&R (both sides) Hood

Hours 1.0

R&R

1.5

SECTION 58 - Cutter Bar Job Description Failure Diagnosis

Hours 0.50

Top Cap, R & R

0.50

Cutter Bar Drive Shaft, R & R

0.33

Cutter Bar Drive Shaft, Rbld 1 U-joint

0.33

Cutter Bar Assembly, R & R

1.25

Disc Module, R & R

0.75

Disc Module, Rbld

1.00

Lower conditioner roll, R&R

2.00

Lower drive shaft R&R (includes retiming rolls)

0.50

Replace 1 universal joint

0.25

Upper drive shaft R&R

0.30

Replace 1 universal joint

0.25

Upper conditioner roll (lower roll R&R not included)

2.50

Conditioner belt R&R

0.30

Left side torsion bar R&R

0.75

Left side tension arm R&R (includes left torsion bar R&R)

1.25

Right side torsion bar R&R (includes left torsion bar R&R)

2.00

Right side tension arm R&R (includes right torsion bar R&R)

2.50

Conditioner Belt R & R (with adjustment)

0.50

Flai l R&R (each group of six, w/shaft)

0.50

Rotor R&R (without repairs to rotor)

2.0

00-12

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 1 - Drive Lines (Standard Tongue) CONTENTS Section

Description

Page

Standard Tongue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2 Auto-lok Slide Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-4 Auto-lok Slide Lock - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-4 Drive Shaft Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-6 Tongue Jackshaft - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-16 Tongue Jackshaft - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-18

31-1

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1

1431/1432 STANDARD TONGUE INTRODUCTION

1

The 1431/1432 disc mower-conditioners utilize constant velocity U-joint drivelines for smooth operation, and to provide the ability to swing the tongue during PTO operation. The primary PTO shaft is equipped with an 80° CV U-joint, 1, at the tractor end, and a 50° CV U-joint, 2, at the mower end of the shaft. The primary PTO shaft attaches to the front of the tongue jackshaft; the tongue jackshaft then transfers power back to a point midway along the tongue.

2

A4832-7

1 The secondary PTO shaft attaches to the rear of the tongue jackshaft and uses conventional U-joints, 1, at both ends of the shaft. The 1431 and 1432 are available as a 1000 RPM PTO units only.

1

1

A4897-11

2

31-2

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 A CV joint consists of a double U-joint assembly, with both the front, 1, and rear, 2, yokes connected together with a mechanical connection; this ensures that both the front U-joint and the rear U-joint in the assembly are operating at the same angles. By operating at equal angles, the CV joint provides a constant velocity output (hence the name, CV joint) at all operating angles, and eliminates the vibration that can result when turning sharp in the field.

The CV joint degree rating indicates the maximum allowable operating angle of the CV U-joint; operation at angles exceeding that value will result in CV joint failure. The 80° CV joint consists of a front and rear joint, which have a spherical ball joint, 3, in the strap of the yokes. The center housing of the joint assembly contains a floating intermediate plate, 4, with a pin protruding from the center of each side.

With the CV joint assembled, the spherical ball joint, 3, on the yokes fit over the pin on the intermediate plate, 4. As one yoke moves, it shifts the intermediate plate, and the opposite yoke as well, to maintain the same operating angles of both U-joints. The maximum operating angle occurs when the intermediate plate pin contacts the edge of the center housing opening.

1

4

2

3 1431-3-22

3

The 50° CV joint differs in that there is no intermediate plate; the one yoke has a ball, 1, on the strap of the yoke, while the opposing yoke has a socket, 2; when the joint is assembled, the ball on the one yoke is engaged in the socket of the other; in this way, the two joints are connected, and one yoke moves the other to maintain equal angles. While the 50° CV joint has fewer parts to wear, the maximum operating angle is less, as the yokes will contact the center housing sooner.

1

2

1431-3-23

4

31-3

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1

AUTO-LOK SLIDE LOCK

1

The 1431 and 1432 are equipped with an Auto-Lok slide lock, 1, which automatically latches in the rearward position when pulled back. The primary PTO shaft may then be held with both hands to guide it onto the tractor shaft; as the yoke slides onto the tractor shaft, the slide lock collar springs forward to latch the PTO shaft to the tractor shaft.

1431-3-18

5 The Auto-Lok slide lock works as follows; as the collar is slid rearward, it tends to twist or cock slightly sideways, allowing a shoulder in the collar, 1, to catch on a ridge on the yoke, 2. As the yoke is slid onto the tractor shaft, and the pawls, 3, line up with the groove on the tractor shaft, four balls, 4, in the yoke are pushed outward by the end of the shaft. These four balls center the collar, causing the shoulder to disengage from the ridge, and the collar springs forward to lock the pawls in the tractor PTO shaft groove.

2

1 3

4

1431-3-19

6

AUTO-LOK SLIDE LOCK - DISASSEMBLY 1

1. Pull the slide lock collar rearward until it latches in place. Use a screwdriver or spring pick to remove the retaining ring, 1, from the end of the yoke.

1431-3-18

7

31-4

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 2. Slide the collar, 1, off the yoke, and remove the spring, 2, from the yoke barrel.

2 3

NOTE: The spring is an interference fit, and will have to be worked off the yoke barrel.

3. Remove the pawls, 3, by reaching into the yoke bore and pushing the pawls outwards, so that they can be grabbed and removed. Remove the four centering balls, 4, from the yoke using the same process.

1

4

1431-3-19

8 4. Thoroughly clean all slide lock components.

Clean the yoke bore and pawl holes. Replace the yoke if damage or excessive wear is found.

1431-3-20

9 AUTO-LOK Slide Lock - Assembly 1. Coat the outer surface of the yoke barrel, 1, with grease; push grease into the centering ball bores and the pawl holes in the yoke. Apply grease to the four centering balls, 2, and insert them into their bores; the grease will hold them in place.

Apply grease to the sides of the pawls, 3, and insert them into the square holes, positioning them so that the lip of the pawl faces into the groove in the yoke barrel. The pawls must slide freely up and down, and must be flush with the top of the yoke barrel.

2. Push a new spring over the yoke barrel up to the shoulder.

NOTE: One end of the spring has a smaller diameter than the other. Be sure the small diameter of spring is up against the shoulder on the yoke barrel.

31-5

3

1

2

1431-3-19

10

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 3. Fill the inside of the collar cavity with grease.

Slide the collar, 1, over the yoke barrel, ensuring the large diameter end of the spring stays inside the collar against the front lip. Pull the collar rearward past the retaining ring groove until it latches in place. Install the retaining ring, 2, in the groove. Grab the collar and manually center it on the yoke so that it springs forward; the collar must slide freely and the pawls must move up and down after assembly.

1

2

1431-3-18

11

DRIVE SHAFT REMOVAL AND INSTALLATION

1

The front half of the primary PTO shaft, 1, may be serviced by sliding it off of the rear half of the primary PTO shaft; use caution to prevent the rear half of the primary PTO shaft from dropping onto the tongue, as damage to the shielding may result. To reinstall the front half of the primary PTO shaft, align the blank female spline on the front half-shaft with the two crimped male splines on the rear half-shaft, and slide the two shafts together. Ensure that the shields fit together properly, and the two half-shafts telescope freely.

A4832-07

12

The rear half of the primary PTO shaft, and the secondary drive shaft must be removed from the machine in order to repair the U-joints or guards. The drive shafts are retained using one clamp bolt (front of the secondary shaft) or two clamp bolts and a center retaining bolt (rear of primary shaft and secondary shaft/slip clutch).

31-6

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 A. To remove the rear half of the primary PTO shaft, remove the shield by removing the four cap screws and flange nuts. Remove the two cap screws, 1, and locknuts from the rear of the yoke, cap screw, 2, and the hardened flat washer from the end of the tongue jackshaft. Slide the primary PTO shaft off of the tongue jackshaft.

1

IMPORTANT: The PTO shafts are very heavy and awkward; use caution not to drop the shaft assemblies as personal injury or damage to the components may result.

To reinstall the rear half of the primary PTO shaft, slide it over the tongue jackshaft as far as possible. Install the cap screw, 2, and hardened flat washer inside the rear yoke and into the end of the tongue jackshaft; tighten the cap screw securely to seat the PTO shaft rear yoke against tongue jackshaft front bearing. Install the two clamp bolts, 1, and locknuts in the rear yoke; torque to 87 N⋅m (64 ft.-lbs.).

NOTE: Do not overtorque; the locknut is Class C, and is limited to 87 N⋅m (64 ft. lbs.).

2 1431-1-25

13

Reinstall the front shield over the PTO shaft using the four previously removed bolts and nuts.

B. To remove the front half of the secondary drive shaft, remove the protective shielding by squeezing the top and bottom of the shield together until the sides pop off the retaining pins.

Slide the shield rearward on the shaft to gain access to the clamp bolt. Remove the clamp bolt, 1, and slide the drive shaft off the tongue jackshaft.

IMPORTANT: The PTO shafts are very heavy and awkward; use caution not to drop the shaft assemblies as personal injury or damage to the components may result.

To reinstall the drive shaft, ensure the shield is positioned over the shaft with the small end facing the end of the shaft. Slide the drive shaft onto the tongue jackshaft until the clamp bolt hole aligns with the groove in the jackshaft. Reinstall the clamp bolt, 1, and locknut; torque to 87 N⋅m (64 ft.-lbs.).

31-7

1

1431-1-24

14

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 NOTE: Do not overtorque; the locknut is Class C, and is limited to 87 Nâ‹…m (64 ft. lbs.).

Reinstall the shield by squeezing the top and bottom together and aligning the mounting holes with the retaining pins. Release the shield, ensuring it fits over the retaining pins.

C. To remove the slip clutch end of the secondary drive shaft, remove the shield over the clutch by removing the four retaining bolts, 1.

1

1431-2-36

15 Loosen the two cap screws, 1, and locknuts at the rear of the clutch assembly. Loosen the cap screw, 2, inside the slip clutch yoke, but do not remove it. Tap the rear of the slip clutch housing with a soft faced hammer to remove it from the taper on the gearbox input shaft; the center retaining bolt will prevent the clutch from falling off the shaft.

1

Remove the center retaining bolt, 2, and hardened flat washer. Slide the clutch assembly off of the gearbox input shaft. With both sections of the secondary drive shaft supported, slip the drive shaft apart to remove the slip clutch and rear section of the drive shaft.

2

1431-1-43

16

IMPORTANT: The PTO shafts are very heavy and awkward; use caution not to drop the shaft assemblies as personal injury or damage to the components may result.

31-8

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 To reinstall the slip clutch end of the secondary shaft, slide it onto the center pivoting gearbox input shaft as far as possible. Install the cap screw, 2, and hardened flat washer into the slip clutch yoke, and thread it into the end of the shaft.

Tighten the cap screw as much as possible to pull the slip clutch hub securely onto the tapered end of the gearbox shaft. Reinstall the two cap screws, 1, and lock nuts at the rear of the slip clutch assembly; torque to 87 Nâ‹…m (64 ft.-lbs.).

NOTE: Do not overtorque; the locknut is Class C, and is limited to 87 Nâ‹…m (64 ft. lbs.).

1

2

1431-1-43

17

IMPORTANT: The PTO shafts are very heavy and awkward; use caution not to drop the shaft assemblies as personal injury or damage to the components may result.

Reinstall the shielding over the slip clutch, and secure using the four previously removed bolts.

Position the shield so that the access hole is forward.

Standard Driveline Guards - Disassembly 1. Insert a screwdriver into the slot, 1, in the driveline bell, and push down and forward to snap the retaining ring out of its groove. Reach in the end of the bell to finish popping the retaining ring out of its groove.

2. Slide the driveline guard off of the drive shaft. It may be necessary to tap the guard lightly with a rubber mallet to unseat the guard bushings from the shaft.

A3657-06

18

31-9

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 3. Remove the overlap section grease zerk, 1, on the female secondary PTO shaft prior to removing the driveline guard.

IMPORTANT: The internal bushings in the driveline guard will be pulled out of the tube if the grease zerk is not removed.

1411/3-21

19 Primary Driveline Guards - Disassembly 1. Insert screwdriver into slot, 1, in the driveline bell, and push down and forward to snap retaining ring out of groove. It may be easier to try different slots until the end of the retaining ring is found. Push down and forward to snap the retaining ring out of its groove, and then continue the process at each slot to fully remove the retaining ring.

1411/3-10

20 2. Slide the driveline guard off of the drive shaft. It may be necessary to tap the guard lightly with a rubber mallet to unseat the guard bushings from the shaft, or from the center housing, 1, on the CV joint shielding.

1411/3-11

21

31-10

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 Driveline Guards - Inspection The driveline guards, 1, should be inspected for any signs of physical damage such as dents or bends; if any damage is found, the guards should be replaced.

Inspect the driveline guards bushings, 2. Replace the bushings if they are worn enough to allow guard movement when mounted on the shaft.

1411/3-11

22 Secondary Driveline Guards - Assembly 1. Install the nylon bushing, 1, in yoke groove, and position the retaining ring in between yoke and nylon bushing.

1411/3-12

23 2. Slide the guard onto the shaft, making sure the bushing on the end of the guard slips over the end of the shaft, and turn the guard to seat the nylon bushing properly in the guard.

3. Rotate the guard so that the opening of the retaining ring is positioned close to the slot, 1,in the guard. Insert a screwdriver into the slot and use it to hold the end of the retaining ring securely against the guard.

4. Reach in through the front of the guard with a second screwdriver, and pry the opposite end of the retaining ring into the groove in the guard.

Continue to hold the ring with the first screwdriver, and use the second screwdriver to work around the guard until the retaining ring is fully seated in the groove in the guard.

5. Check that the retaining ring and nylon bushing have seated properly in the guard, and that the guard rotates freely.

31-11

A3657-06

24

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 6. Reinstall the grease zerk, 1, on the end of the female secondary PTO shaft, as shown.

1411/3-21

25 80°° CV Front Guard Assembly 1. Install the nylon bushing, 1, in yoke groove. The retaining ring, 2, should be positioned between the CV joint and nylon bushing.

2. Slip guard over the shaft and onto the nylon bushing; it will be necessary to align the front portion of the guard with the CV joint center housing, and firmly push the guard on to seat the nylon sleeve in the guard over the center housing of the CV joint.

3. Rotate the guard to ensure the nylon bushing is seated properly, and rotates with the guard.

1411/3-11

26 4. Position the opening of retaining ring between two slots in the guard. Insert a screwdriver into a slot, 1, in guard near the end of the retaining ring, and use it to hold the retaining ring securely.

Insert a second screwdriver into the adjacent slot, 2, away from the open end of the retaining ring, and push down and rearward to seat the retaining ring into the groove in the guard.

5. Keep the #2 screwdriver in place to hold the ring and move #1 screwdriver to the remaining slots to finish prying the retaining ring into groove.

6. Check that the retaining ring and nylon bushing have seated properly in the guard, and that the guard rotates freely.

1411/3-10

27

31-12

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 CV/U-JOINTS - Disassembly 1. Remove the PTO shaft from the unit, and remove the shielding as previously described.

2. To disassemble a Weasler universal joint, remove the snap rings. Use pliers or a spring pick to remove internal snap rings, 1. External snap rings, 2, may be removed by using two flat blade screwdrivers. Use a screwdriver to hold one end of the snap ring, while prying the other end out of the groove with the other screwdriver.

50° CV U-joints, rear of Primary shaft - snap rings are internal 80° CV U-joints, front of Primary shaft, shown in Figure 1-28 - outer yokes use internal snap rings - CV yokes use external snap rings Standard U-joints, secondary shaft - snap rings are external

1411/3-5

28

Remove the grease zerk, 3, from the bearing cup on the U-joint to be disassembled.

3. A press, or a large bench vise should be used to remove the bearing cups from the Weasler yokes. The bearing cups are a very tight fit in the yokes, and are not easily disassembled by conventional methods using a hammer. Position the joint in a press, or vise as shown, using a piece of keystock, 1, to support one yoke ear.

With a socket or bushing driver, 2, positioned against the opposite bearing, press the bearing cup, 3, out of the yoke. The bearing may be pushed out approximately 10 mm (3/8″) before the cross will bottom out on the yoke.

1411/3-17

29

31-13

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 4. Grip the loosened bearing in vise, and drive the yoke off the bearing by striking the yoke with a soft-faced hammer or mallet.

5. This same procedure should be followed to remove the bearing directly opposite the one just removed, after which the yoke itself may be removed.

6. Remove the remaining two bearing cups from the yoke using the same process described above.

1411/3-5

30 CV/U-JOINTS - Inspection NOTE: The U-joint cross and bearings must be replaced anytime the U-joint is disassembled, even if the cross and bearings were not the source of failure.

1. Inspect the yoke ears, 1, for wear in the bearing area. Replace the yoke if there is any evidence of wear, or if the bearing area is distorted. The bearing cups must be a tight fit in the yoke ear.

1411/3-17

31 2. On the CV U-joints, it is necessary to inspect the intermediate connection between the yokes. On the 50° CV U-joints, inspect the ball, 1, and socket, 2, connection between the yokes for excessive wear or galling. On the 80° CV U-joint, inspect the conical bushings, 2, Figure 1-31, in the yokes for wear or excessive play. Inspect the intermediate plate, 3, Figure 1-31, for wear or damage on the attaching pins, and excessive wear between the plate and housing. Replace components as necessary.

1411/3-17

32

31-14

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 CV/U-JOINTS - Assembly 1. To reassemble the U-joint, start one bearing cup into the yoke ear, and position the center cross through the yoke.

NOTE: When assembling a CV U-joint, install the cross into the outer yoke first, and then assemble the yoke and cross assembly into the intermediate housing.

Position the yoke in a vise or press, and use a bushing driver or socket, 1, to press the bearing cup into the yoke, 2, until the snap ring may be installed. Remove the yoke from the vise, and start the second bearing cup into the opposite yoke ear. Reposition the assembly in the vise or press, and press the second bearing cup in until it seats. Install the snap ring to retain it.

NOTE: It may be difficult to rotate the cross after seating the second bearing. This condition will be corrected after complete assembly of the U-joint.

1411/3-5

33

2. Position the yoke and cross assembly into the shaft and yoke. On the CV joints, it is also necessary to connect the yoke to the opposing yoke or intermediate plate.

On the 80° CV joint, slide the conical bushing in the end yoke over the pin on the intermediate plate to establish the proper connection.

On the 50° CV joint, slide the ball end, 1, of the end yoke into the socket end on the opposing yoke (or vice versa), as shown, to establish the proper connection.

Install the remaining bearing cups using the same process described in step 1.

3. After complete assembly of the U-joint, strike the forged surfaces of all yoke ears with a sharp blow from a hammer. This will ensure proper seating of the bearing cups, and eliminate any tightness to ensure a free flexing joint.

IMPORTANT: Use caution not to strike the bearing bore area of the yoke, as this will damage the bore and may cause premature cross bearing failure.

4. Reinstall the shielding as previously described.

31-15

1411/3-17

34

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1

TONGUE JACKSHAFT - DISASSEMBLY 1. Remove the shield over the rear primary PTO shaft by removing the four cap screws and flange nuts at 1. Remove the rear half of the primary PTO shaft by loosening the two cap screws, 2, and locknuts at the rear of the yoke, and remove the cap screw, 3, and hardened flat washer from the end of the tongue jackshaft. Slide the primary PTO shaft off of the tongue jackshaft.

2

1

3

IMPORTANT: The PTO shaft is very heavy and awkward; use caution not to drop the shaft assembly as personal injury or damage to the components may result.

1

1431-1-25

35

2. Remove the protective shielding over the secondary PTO shaft U-joint at the rear of the tongue jackshaft by squeezing the top and bottom of the shield together until the sides pop off the retaining pins. Slide the shield rearward on the shaft to gain access to the retaining bolt.

Remove the clamp bolt, 1, and slide the drive shaft off the tongue jackshaft.

1

IMPORTANT: The PTO shaft is very heavy and awkward; use caution not to drop the shaft assembly as personal injury or damage to the components may result.

1431-1-24

36 3. Remove the plastic shields, 4, over the jackshaft by spreading them apart along the split seam until they can be slid off the shield brackets.

Remove the shield brackets, 1, by removing the two carriage bolts, 2, and flange nuts, and slide them out of the way along the shaft.

2

NOTE: There are two 1/2″ flat washers installed between the shield bracket and the flangette at the slot in the support, 3, as spacers.

4

4 1

1431-3-24

2

3 37

31-16

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 4. Remove the bearing lock collars, 1, by loosening the setscrews. Use a hammer and punch to drive the lock collar in the direction opposite shaft rotation until it becomes loose. Slide the lock collar off the bearing flange. Repeat for the other bearing assembly.

1

1431-3-25

38 5. Loosen the bearing hanger pivot bolt and nut, 1, so that the hanger bracket is loose. Remove the four carriage bolts and flange nuts, 2, securing the bearing flangettes to the hanger bracket.

Repeat for the remaining bearing hanger.

Lower the shaft down through the slots in the bearing hangers, and slide the shaft rearward out of the front bearing.

1

2

2

1431-3-26

39 6. Clean the shaft using emery cloth, so that the bearings and other components may be slid off the shaft.

1431-3-27

40

31-17

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 7. Unbolt the front bearing housing from the tongue by removing the four cap screws, 1, and remove the bearing housing and spacer plate.

1

1 1431-3-28

41

TONGUE JACKSHAFT - ASSEMBLY

1

1. Install the front bearing housing and spacer plate in the tongue, and secure with four 1/2″ x 1-1/2″ cap screws, 1.

1 1431-3-28

42 2. Preassemble the bearing components for the center bearing hanger on the shaft by sliding on a shield bracket, 1, with the bolt flange facing towards the rear, bearing flangette, 2, bearing, 3, bearing flangette, 4, lock collar, 5, and shield bracket, 6, with the bolt flange facing the front of the shaft.

6

5

4

3

2

1

1431-3-29

43

31-18

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 Install the bearing components for the rear bearing hanger on the shaft by sliding on a shield bracket, 1, with the bolt flange facing towards the rear, lock collar, 2, bearing flangette, 3, bearing, 4, and bearing flangette, 5.

5

3

4

2

1

1431-3-27

44 3. Insert the end of the shaft with the heat shrink collar in through the back of the tongue and into the bearing until the collar contacts the bearing inner race.

1431-3-30

45 Install the primary PTO shaft onto the front of the input shaft. Install a 1/2 x 1-1/2″ cap screw, 1, and hardened flat washer inside the rear yoke and into the end of the jackshaft. Tighten securely to seat the PTO shaft against bearing inner race.

Install two 1/2 x 3″ Grade 8 cap screws, 2, and locknuts in the rear of the yoke, and torque to 87 N⋅m (64 ft.-lbs.).

NOTE: Do not overtorque PTO yoke clamp bolts; locknuts are Class C, and are limited to 87 N⋅m (64 ft.-lbs.).

Reinstall the front PTO shield using the four flange bolts and nuts previously removed.

31-19

2

1

1431-1-25

46

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 4. Loosen the support pivot bolts, 1, so that the center and rear bearing supports are free to pivot fore and aft. Position the bearing components so that a shield support will be positioned on the front face of each bearing support; all other components mount to the rear side of the bearing hangers. Lift the shaft upwards so that it fits through the slots in the bearing supports, and loosely bolt the rear bearing and flangettes, 3, to the rear side of the rear bearing support using four 1/2 x 1″ carriage bolts and flange nuts, 2.

1 3

2

2

1431-3-26

47 Use a square to align the support perpendicular to the shaft. Install the lock collar onto the bearing, and use a hammer and punch to tighten it in the direction of rotation (clockwise, as viewed from the rear), to hold the support in place.

Tighten the bearing flangette mounting bolts, 2, Figure 1-47, to 113 N⋅m (83 ft.-lbs.), and the bearing hanger pivot bolt, 1, Figure 1-47, to 224 N⋅m (165 ft.-lbs.).

1

1431-3-31

48 5. Install the center bearing and flangettes, 1, to the rear side of the center support using 1/2 x 1″ carriage bolts and flange nuts, 2; leave the bolts loose. Use a square to align the support perpendicular to the shaft. Install the lock collar over the bearing flange, and use a hammer and punch to tighten it in the direction of rotation (clockwise, as viewed from the rear), to hold the support in place. Tighten the bearing flangette mounting bolts, 2, to 113 N⋅m (83 ft.-lbs.), and the bearing hanger pivot bolt, 3, to 224 N⋅m (165 ft.-lbs.).

3

1 2 2

1431-3-25

49

31-20

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 6. Secure the shield brackets, 1, to the bearing supports using two 1/2 x 1″ carriage bolts and flange nuts, 2; insert two 1/2″ flat washers between the shield bracket and the flangette at the slot in the support, 3, to prevent bending the shield bracket when tightening the bolts.

Install the shaft shields, 4, by spreading the shields apart until they can be slipped over the shaft and shield brackets.

2 4

4 1

1431-3-24

2

3 50

7. Ensure the third joint shield is installed over the secondary PTO shaft, and slide the yoke end onto the end of the jackshaft until the bolt hole lines up with the groove in the shaft. Install a 1/2 x 3″ Grade 8 cap screw, 1, and locknut; torque to 87 N⋅m (64 ft.-lbs.).

1

NOTE: Do not overtorque; locknut is Class C, and is limited to 87 N⋅m (64 ft.-lbs.).

NOTE: Secondary PTO shaft is very heavy and awkward; use caution not to drop shaft assembly as damage to slip clutch will result.

Reinstall the shield by squeezing the top and bottom together and aligning the mounting holes with the retaining pins. Release the shield, ensuring it fits over the retaining pins.

31-21

1431-1-24

51

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1

31-22

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 2 - Drive Lines (Swivel Hitch Tongue) CONTENTS Section

Description

Page

3-Point/Drawbar Swivel Hitch Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2 Slide Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-4 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-6 Standard Driveline Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-9 U-joints: Swivel Hitch Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-10 Tongue Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-15

31-1

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2

1431/1432 SWIVEL HITCH DRIVELINE INTRODUCTION

1

The drivelines on swivel hitch models use a pair of U-joints to transfer power from the tractor to the lower swivel hitch gearbox via the primary PTO shaft, 2.

The U-joints, one each at the tractor end of the primary PTO shaft, 1, and lower gearbox end, 3, of the shaft allow the tractor to turn the driveline during PTO operation.

The lower swivel hitch gearbox turns the upper swivel hitch gearbox, which transfers power to the tongue jackshaft.

2 19985235

3 1

The tongue jackshaft, 1, runs from the upper gearbox, 2, to a point midway along the tongue. The jackshaft uses a coupler at the gearbox end and attaches to a U-joint on the secondary PTO at the other end.

2

1

19990094

2 The secondary PTO shaft, 2, attaches to the rear of the jackshaft and uses U-joints at both ends, 1 and 3.

3

1

2

4897-11

3

31-2

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2

SLIDE LOCK Both ends of the primary PTO shaft feature a quick slide lock. The primary PTO shaft can be removed and attached quickly at either end.

DISASSEMBLY 1

1. Pull the collar rearward and hold it in place. Use a screwdriver or spring pick to remove the retaining ring, 1, from the end of the yoke.

19990038

4 2. Slide the collar, 1, off the yoke, and remove the spring from the yoke barrel.

1

NOTE: The spring is an interference fit, and will have to be worked off the yoke barrel.

19990039

5 3. Remove the pawls, 1, by reaching into the yoke bore and pushing them out from the inside. Once they protrude to the outside of the yoke, grab and remove them.

1

4. Thoroughly clean all parts. Clean the yoke bore and pawl holes. Inspect the yoke for damage or excessive wear, and replace if necessary.

19990040

6

31-3

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2

ASSEMBLY

2

1. Coat the outer surface of the yoke barrel, 1, with grease. Push grease into the pawl holes, 2.

1

19990039

7 2. Apply grease to the sides of the pawls and insert them into the square holes. The lip of the pawl should face into the groove in the yoke barrel.

The pawls must slide freely up and down, and must be flush with the top of the yoke barrel.

3. Push a new spring over the yoke barrel up to the shoulder.

NOTE: One end of the spring has a smaller diameter than the other. Place the small diameter against the shoulder on the yoke barrel.

19990040

8

31-4

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 4. Fill the inside of the collar cavity with grease.

Slide the collar, 1, over the yoke barrel. Keep the large diameter end of the spring inside the collar against the front lip. Pull the collar past the retaining ring groove and hold it in place.

1

19990039

9 5. Install the retaining ring, 1, in the groove. The collar must slide freely and the pawls must move up and down after assembly.

1

19990038

10

31-5

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2

DRIVE SHAFT REMOVAL

1

The front half of the primary PTO shaft, 1, may be serviced by sliding it off of the rear half of the primary PTO shaft; use caution to prevent the rear half of the primary PTO shaft from dropping onto the tongue, as damage to the shielding may result. To reinstall the front half of the primary PTO shaft, align the blank female spline on the front half-shaft with the two crimped male spline on the rear half-shaft, and slide the two shafts together. Ensure that the shields fit together properly, and the two half-shafts telescope freely.

19985198

The rear half of the primary PTO shaft (retained by a slide lock), and the secondary drive shaft must be removed from the machine in order to repair the U-joints or guards. The secondary drive shaft is retained using one clamp bolt (front of the secondary shaft) or two clamp bolts and a center retaining bolt (secondary shaft/slip clutch).

11

The 3-point swivel hitch is shown in Figure 11 and the drawbar swivel hitch is shown in Figure 12.

19996817

12 A. To remove the rear half of the primary PTO shaft, remove the shield by squeezing the sides together until they pop off the retaining pins. Pull back on the slide collar, 1, and slide the primary PTO shaft off of the lower swivel gearbox.

IMPORTANT: The PTO shafts are very heavy and awkward; use caution not to drop the shaft assemblies as personal injury or damage to the components may result.

To reinstall the rear half of the primary PTO shaft, pull back on the slide collar, 1, and slide the PTO onto the gearbox shaft until the pins engage in the groove.

The collar will slide forward automatically locking the PTO shaft on the gearbox shaft.

19985234

1 13

Slide the shield over the PTO shaft, and squeeze the sides together. Align the mounting holes with the retaining pins, and release the shield.

31-6

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 B. To remove the front half of the secondary drive shaft, remove the protective shielding, by squeezing the top and bottom of the shield together until the sides pop off the retaining pins.

Slide the shield rearward on the shaft to gain access to the retaining bolt. Remove the clamp bolt, 1, and slide the drive shaft off the tongue jackshaft.

IMPORTANT: The PTO shafts are very heavy and awkward; use caution not to drop the shaft assemblies as personal injury or damage to the components may result.

To reinstall the drive shaft, ensure the shield is positioned over the shaft with the small end facing the end of the shaft. Slide the drive shaft onto the tongue jackshaft until the clamp bolt hole aligns with the groove in the jackshaft. Reinstall the clamp bolt, 1, and lock nut; torque to 87 Nâ‹…m (64 ft.-lbs.).

NOTE: Do not over-torque; the lock nut is Class C, and is limited to 87 Nâ‹…m (64 ft.-lbs.).

Reinstall the shield by squeezing the top and bottom together and aligning the mounting holes with the retaining pins. Release the shield, ensuring it fits over the retaining pins.

31-7

1

1431-1-24

14

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 C. To remove the slip clutch end of the secondary drive shaft, remove the shield over the clutch by removing the four retaining bolts, 1.

1 1431-2-36

15 Loosen the two cap screws, 1, and lock nuts at the rear of the clutch assembly. Loosen the cap screw, 2, inside the slip clutch yoke, but do not remove it. Tap the rear of the slip clutch housing with a soft faced hammer to remove it from the taper on the gearbox input shaft; the center retaining bolt will prevent the clutch from falling off the shaft.

1

Remove the center retaining bolt, 2, and hardened flat washer, and slide the clutch assembly off of the gearbox input shaft. With both sections of the secondary drive shaft supported, slip the drive shaft apart to remove the slip clutch and rear section of the drive shaft.

2

1431-1-43

16

IMPORTANT: The PTO shafts are very heavy and awkward; use caution not to drop the shaft assemblies as personal injury or damage tot the components may result.

31-8

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 To reinstall the slip clutch end of the secondary shaft, slide it onto the center pivoting gearbox input shaft as far as possible. Install the cap screw, 2, and hardened flat washer into the slip clutch yoke, and thread it into the end of the shaft. Tighten the cap screw as much as possible to pull the slip clutch hub securely onto the tapered end of the gearbox shaft.

Reinstall the two cap screws, 1, and lock nuts at the rear of the slip clutch assembly; torque to 87 Nâ‹…m (64 ft.-lbs.).

NOTE: Do not over-torque; the lock nut is Class C, and is limited to 87 Nâ‹…m (64 ft.-lbs.).

1

2

1431-1-43

17

IMPORTANT: The PTO shafts are very heavy and awkward; use caution not to drop the shaft assemblies as personal injury or damage to the components may result.

Reinstall the shielding over the slip clutch, and secure using the four previously removed bolts.

Position the shield so that the access hole is forward.

STANDARD DRIVELINE GUARDS

1

Disassembly 1. Insert a screwdriver into the slot, 1, in the bell end of the guard. Push down and forward to snap the retaining ring out of its groove. Repeat this procedure at each slot. Reach into the end of the shielding with a screwdriver to finish popping the retaining ring out of its groove.

19990046

18 2. Slide the shielding off of the drive shaft. If necessary, tap the guard lightly with a soft mallet to unseat the guard bushings from the shaft.

IMPORTANT: Remove grease fittings as needed to allow the guard to slide off the shaft. If the grease fittings are not removed, the internal bushings may be pulled out during disassembly.

19990047

19

31-9

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 Reassembly 1. Slide the guard onto the shaft. Using two screwdrivers, work around the bell opening pressing the retaining clip in its slot. Press the clip into place with one screwdriver while holding the already-seated portion in place with the other.

2. Reinstall the grease fitting(s) as needed.

Lubricate the U-joint and shaft before operating the disc mower.

19990042

20

U-JOINTS: SWIVEL HITCH UNITS Disassembly The swivel-hitch units use standard U-joints with internal retaining clips in the driveline. Disassembly is as follows: 1. Remove the primary PTO shaft from the unit.

Slide the shaft apart, separating the front and rear sections of the shaft.

19990045

21 2. Insert a screwdriver into the slot, 1. Push down and forward to snap the retaining ring out of its groove. Repeat this procedure at each slot.

Reach into the end of the shielding with a screwdriver to finish popping the retaining ring out of its groove.

1

19990046

22

31-10

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 3. Slide the shielding off of the drive shaft. If necessary, tap the guard lightly with a soft mallet to unseat the guard bushings from the shaft.

19990047

23 4. Remove the internal retaining clips. Use a pair of flat blade screwdrivers, holding one end of the clip with the first and pressing out the other end with the second.

19990043

24 5. Press the bearing cups out of the U-joint using an arbor press or large bench vise (shown). Press one bearing inward with a small socket, 1, or suitable keystock. Use a large socket, 2, or bushing driver on the opposite side to hold the yoke while pressing out the bearing.

2

1

IMPORTANT: Support the yoke properly to prevent bending and damage.

IMPORTANT: Keep the opposite yoke upright to prevent binding and damage.

19990048

25

31-11

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 IMPORTANT: Pressing the bearing more than about 3/8″ will bottom out the cross against the yoke. Do not push any farther once the cross has bottomed out.

19990050

26 6. Remove the bearing. If necessary, grip the bearing in a vise and drive the yoke off using a soft mallet.

7. Repeat the process in the opposite direction, driving the opposite bearing out of the yoke.

Separate the yokes and follow the same procedure to remove the bearings from the other yoke.

19990049

27 8. Clean and inspect all parts, replacing any that show wear or damage.

19990051

28

31-12

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 9. Inspect the rubber grease seals on the bearings, replacing any that show wear or damage.

19990052

29 Reassembly Start one bearing cup into the yoke ear from the outside, and place the center cross through the yoke.

1. Place the yoke with the bearing cup in a press or vise using a small and large socket or key stock and bushing driver.

IMPORTANT: Support the yoke properly to avoiding bending or damaging it.

19990048

30 2. Press the bearing cup into the yoke until the snap ring can be installed.

19990044

31

31-13

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 3. Remove the yoke from the vise and start the opposite bearing cup into the yoke from the outside.

19990049

32 4. Press the second bearing cup into place using the same procedure. Place the snap ring on the bearing cup to retain it.

5. Repeat the process to install the remaining bearing cups until the U-joint is fully assembled.

6. After complete assembly, strike the forged surfaces of all yoke ears with a sharp blow from a hammer. This ensures proper seating of the bearing cups and eliminates tightness to allow the joint to flex freely.

19990044

33 7. Slide the guard onto the shaft. Using two screwdrivers, work around the bell opening pressing the retaining clip in its slot. Press the clip into place with one screwdriver while holding the already-seated portion in place with the other.

8. Reinstall the grease fitting(s) as needed.

Lubricate the U-joint and shaft before operating the disc mower.

19990042

34

31-14

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2

TONGUE JACKSHAFT Disassembly 1. Remove the metal shield covering the jackshaft.

The shield is in two halves held together by metal screws in anchor clips. A pair of bolts at each end holds the halves on the tongue brackets.

19990097

35 2. Remove the plastic shield from the rear half of the jackshaft. The shield wraps around the brackets at either end. Free one end and work toward the other end until the shield is completely removed.

19990093

36 3. Remove the guard from the front of the secondary PTO shaft. Press the top and bottom together and slide the guard off of its mounting pins.

19990041

37

31-15

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 4. Remove the clamp bolt, 1, and slide apart the two halves of the secondary PTO shaft. Remove the bolts, 2, securing the bearing flangette and the bracket. Lower the jackshaft out of the support brackets.

2

NOTE: Swivel hitch units have two sets of bearings on the jackshaft. Remove both from the tongue support brackets to remove the jackshaft.

1 1431-1-24

38 5. Clean the jackshaft with fine emery cloth or other abrasive cloth and then lubricate it to ease removal and replacement of the bearing assemblies.

1431-3-27

39 Installation 1. With the bearings and hardware on the shaft, raise the shaft into place beneath the tongue.

Slide the front end into the coupler, 1, at the upper swivel gearbox.

1 19990095

40

31-16

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 2. Raise the shaft into the support brackets. Bolt the bearing flangettes onto the support bracket.

Tighten the flangette bolts to 113 N∙m (83 ft.-lbs.).

3. Be sure to secure the shaft guard brackets into place at the same time using the bolts in the 12 o’clock and 6 o’clock positions.

1431-3-24

41 4. Inspect the support, making sure it is perpendicular to the shaft. Adjust it as needed. Tighten the hanger pivot bolt, 1, to 224 N∙m (165 ft.-lbs.).

1

1431-3-31

42 5. Reattach the secondary PTO, installing the clamp bolt, 1, and tighten it to 87 N∙m (64 ft. lbs.).

NOTE: Do not overtighten the clamp bolt. The locknut is class C and is limited to 87 N∙m (67 ft.-lbs.).

1431-1-24

1 43

31-17

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 6. Place the large guard onto the secondary PTO before reattaching it to the jackshaft. After reattachment, slide the guard forward and, pressing the top and bottom together, install it on the mounting pins.

7. Replace the metal guard and plastic shield on the jackshaft.

CAUTION Always install all safety shields before operating the machine.

19990041

IMPORTANT: Lubricate all fittings following reassembly, and before operating the machine.

44

31-18

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 3 - Slip Clutch CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2 Slip Clutch - Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2 Slip Clutch - Wear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-3 Slip Clutch - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-3 Slip Clutch - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-4 Slip Clutch - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-5 Slip Clutch - Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-5

31-1

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3

INTRODUCTION

1

The slip clutch, 1, on the 1431 and 1432 disc mower-conditioner is part of the secondary PTO drive shaft, and is mounted on the input shaft of the center pivoting gearbox. It is set to slip in the event an overload occurs during machine operation.

2

Prior to the start of each season and after long periods of non-use, the slip clutch should be burnished to insure it is not locked up.

1431-1-43

1

SLIP CLUTCH - RUN-IN To burnish the slip clutch: 1. Ensure the tractor is shut off, if connected to unit.

Remove the shielding over the slip clutch by removing the four retaining bolts, 1, and lifting the shield off the center gearbox channel. Loosen the six cap screws, 2, Figure 2-1, 1/2 turn at a time until cap screws are just loose, then retighten all six cap screws one half turn.

1

2. Attach a tractor to the disc mower-conditioner as outlined in the “General Information� section of this manual, if not already connected.

1431-2-36

2

3. Operate the tractor at 1/3 throttle, and engage the tractor PTO for several seconds, or until the slip clutch visibly smokes, at which time, disengage the tractor PTO. Turn the tractor off.

If the clutch does not slip, the clutch must be disassembled to unlock the friction discs.

31-2

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 4. After slipping the clutch, retighten the six cap screws 1/2 turn at a time until the compression plate, 1, contacts the clutch housing, 2.

2

1

NOTE: The slip clutch is set at 1356 Nâ‹…m (12,000 in. lbs.) [static] of breakaway torque. Do not attempt to alter the slip clutch setting or damage to the machine could result.

5. Reinstall the shield over the slip clutch and secure using the four bolts previously removed.

Position the shield so that the access hole is forward.

1431-2-34

3

SLIP CLUTCH - WEAR INSPECTION

1

The amount of wear on the slip clutch friction discs can be determined without disassembling the clutch.

2

Remove the shielding over the slip clutch by removing the four retaining bolts and lifting the shield off the center gearbox channel.

Inspect the clearance between the pressure plate tangs, 1, and the housing, 2; if the clearance is less than 1.6 mm (1/16″), the friction discs are worn out and require replacement.

1431-1-43

4

SLIP CLUTCH - REMOVAL NOTE: Removal of both styles of slip clutches is identical. Only one will be discussed.

1

1. Remove the shielding, 1, over the slip clutch by removing the four retaining bolts, 2. Lift the shielding off the center gearbox channel.

2 1431-2-36

5

31-3

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 2. Loosen the two cap screws, 1, and locknuts on the clamp hub at the rear of the slip clutch.

Loosen the cap screw, 2, inside the slip clutch yoke, but do not remove it from the shaft. Tap the rear of the clutch housing with a soft faced hammer to remove it from the taper on the gearbox shaft; the center retaining bolt will prevent the clutch from falling off the shaft.

1

3. Remove the center retaining bolt, 2, and slide the clutch assembly off the center gearbox input shaft. With both sections of the secondary drive shaft supported, slip the drive shaft apart to remove the slip clutch and rear section of the drive shaft.

2

1431-1-43

6

IMPORTANT: The slip clutch end of the secondary PTO shaft is very heavy and awkward; use caution not to drop the shaft assembly as personal injury or damage to the clutch may result.

SLIP CLUTCH - DISASSEMBLY 1

NOTE: Figures show slip clutch removed from secondary PTO shaft for clarity.

2

NOTE: The disassembly of both styles of slip clutches is nearly identical. Only one will be discussed.

1. Remove the two cap screws and locknuts from the clamp hub, 1, at the rear of the clutch.

2

2. Loosen the six cap screws, 2, around the clutch housing, one half turn at a time until all six cap screws are loose. Carefully remove the six cap screws and nuts from the clutch, and discard them.

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7

Remove the internal components one at a time over the clamp hub at the rear of the clutch.

The clutch contains a compression plate, 1, disc spring, 2, ribbed pressure plate, 3, friction disc, 4, separator plate, 5, and friction disc, 6.

Discard the friction discs, 4 and 6.

5

6 50006843

4

3

2

1 8

31-4

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3

SLIP CLUTCH - INSPECTION

2

1. Inspect the separator plate, 1, for discoloration, warpage or cracking; replace if any damage is found. Both faces of the separator plate should have a rough surface; replace the plate if either face is worn smooth. Inspect the inner drive tangs for excessive wear; replace the plate if drive tangs are rounded off or worn more than 1/3 through.

2. Inspect the ribbed pressure plate, 2, for discoloration or cracking; replace if any damage is found. Lay a straight edge across the face of the pressure plate; replace if warped more than 1.6 mm (1/16″).

1

1431-4-3

9

3. Inspect the disc spring, 1, for discoloration or cracking; replace if any damage is found. Use a depth micrometer or calipers to measure the height of the disc spring when placed on a flat surface; it should be between 10.2 -10.7 mm (0.400″ - 0.420″). Replace spring if it is less than specified range.

1

20006843

10

SLIP CLUTCH - REASSEMBLY NOTE: The first step is applicable only to 1431 on and below SN 650203; 1432 on and below SN 641954.

2 1

1. A spacer, 1, is used on the outer overrunning clutch hub, 2, to prevent the hub from shifting rearward during use. Ensure this spacer is installed over the outer overrunning clutch hub before rebuilding the slip clutch.

1431-4-4

11

31-5

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 2. Install a new friction disc, 1, into the clutch housing, followed by the separator plate, 2, and another friction disc, 3.

1

2

3

50006844

12 3. Install the pressure plate, 1, in the housing with the flat surface facing the friction disc; align the tabs on the pressure plate with the relief notches in the housing.

1

20006845

13 4. Position the disc spring, 1, over the clutch hub so that the inside diameter of the disc spring contacts the ribs on the pressure plate.

1

20006846

14

31-6

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 5. Position the compression plate, 1, over the clutch hub against the outer diameter of the disc spring, and install six new cap screws, 2, through the compression plate and the grooves in the housing. Insert new nuts, 3, into the pockets on the front of the clutch housing and thread the bolts into the nuts until snug to hold the assembly together.

6. Tighten all six cap screws, 2, evenly until snug, and then one additional one half turn each, to hold the clutch components securely, and to provide the setting for running in the clutch.

2

2

3

3 1

50006847

15 7. The slip clutch must be installed on the unit and run in before use. Install the two cap screws, 1, and locknuts into the clamp hub.

1 2

8. Install the drive shaft and slip clutch assembly so that the two crimped splines align with the slot in the front of the secondary drive shaft. Slide the two drive shaft halves together.

9. Slide the slip clutch onto the center gearbox input shaft as far as possible. Thread the bolt, 2, inside the slip clutch hub into the end of the shaft, and tighten as much as possible to pull the slip clutch hub securely onto the tapered end of the gearbox shaft. Tighten the two 1/2″ x 3″ Grade 8 cap screws, 1, and locknuts at the rear of the clutch to 87 N⋅m (64 ft.-lbs.).

NOTE: Do not overtorque; locknuts are Class C, and are limited to 87 N⋅m (64 ft.-lbs.).

10. Attach a tractor to the disc mower-conditioner as outlined in the “General Information” section of this manual, if not already connected.

11. Operate the tractor at 1/3 throttle, and engage the tractor PTO for several seconds, or until the slip clutch visibly smokes, at which time, disengage the tractor PTO. Turn the tractor off.

If the clutch does not slip, disassemble the clutch and check for proper assembly.

31-7

1431-1-43

16

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 12. After slipping the clutch, tighten the six cap screws 1/2 turn at a time until the compression plate, 1, contacts the clutch housing, 2.

1

NOTE: The slip clutch is set at 1356 Nâ‹…m (12,000 in. lbs.) [static] of breakaway torque. Do not attempt to alter the slip clutch setting or damage to the machine could result.

2

1431-3-34

17 13. Reinstall the shield, 1, over the slip clutch and secure using the four bolts previously removed.

Position the shield so that the access hole is forward.

1

1431-2-36

18

31-8

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 4 - Overrunning Clutch CONTENTS Section

Description

Page

Overrunning Clutch - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2 Overrunning Clutch - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-3 Overrunning Clutch - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-4 Overrunning Clutch – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-6 Overrunning Clutch - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-7 Overrunning Clutch – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-7 Slip Clutch - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-9

31-1

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4

OVERRUNNING CLUTCH DISASSEMBLY 1431 SN on and below 650203 1432 SN on and below 641954 1. If the overrunning clutch does not operate when the tractor PTO is disengaged, the overrunning clutch must be disassembled for inspection.

Remove the slip clutch from the unit as previously described. It is possible to repair the overrunning clutch without disassembling the slip clutch.

1

2. Remove the two cap screws and locknuts from the clamp hub, 1, at the rear of the clutch.

1431-4-8

2

1

3. To disassemble the overrunning clutch hub, the bearing between the inner overrunning clutch hub and the yoke assembly must be disassembled. Remove the hex socket head cap screw, 2, from the yoke assembly, and spray penetrating fluid into the hole to remove the grease.

4. Rotate the hub, 1, in the yoke, 2, while holding the hole down until all the balls, 3, fall out; there are 20 balls in the overrunning clutch bearing. It may be necessary to remove the grease zerk, 4, on the yoke and spray penetrating fluid in the grease passage to assist in removing the balls.

2

1

4

1431-4-9

3 2

31-2

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4 5. Slide the inner overrunning hub, 1, out of the yoke. Remove and clean the two overrunning clutch pawls, 2, and leaf springs, 3, from the inner hub.

1

2

3

1431-4-10

3 6. Remove the four cap screws retaining the slip clutch assembly, 1, to the yoke, and remove it.

Slide the outer overrunning clutch hub, 2, and spacer, 3, out the front of the slip clutch assembly. Remove the grease seal, 4, from the front of the overrunning clutch hub and discard it.

1 3

2

4

1431-4-11

4

OVERRUNNING CLUTCH - INSPECTION 1. Inspect the overrunning pawls and ramps on the inner diameter of the outer overrunning clutch hub for wear or damage; replace the components as required.

2. Inspect the overrunning hub and yoke bearing grooves and mating surfaces for galling or other damage; replace as necessary. Discard the overrunning bearing balls and replace with new parts.

31-3

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4

OVERRUNNING CLUTCH - ASSEMBLY

1

1431 SN on and below 650203 1432 SN on and below 641954 1. Remove and discard the O ring seal, 1, in the yoke plate. Install a new O ring into the groove in the yoke plate.

1431-4-12

5 2. Install a new grease seal, 1, on the end of the outer overrunning clutch hub. Slide the spacer, 2, over the outside of the clutch hub, and position the assembly into the slip clutch assembly, 3.

1

3

2 1431-4-13

6 3. Position the slip clutch assembly, 1, against the yoke plate, 2, and loosely install the four cap screws, 3, to retain the clutch assembly.

3 2

1 1431-4-14

3 7

31-4

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4 4. Install the leaf springs and pawls, 1, into the inner overrunning clutch hub, oriented as shown.

The leaf spring should be installed with the ends down on the hub, and the curve facing up. Install the pawls so that the step is down on the spring, and is facing the direction of rotation (clockwise as viewed from the bearing end of the inner hub).

Apply a thin film of grease to the overrunning clutch hub and pawls.

Slide the inner overrunning clutch hub assembly through the outer clutch hub, 2, and into the yoke so that the hole in the yoke aligns with the bearing groove in the hub.

1 2

1

1431-4-15

8 5. Drop the new ball bearings in through the hole into the bearing groove,1; there are 20 balls used. Install the hex socket head cap screw, and tighten it securely. Reinstall the grease zerk, 2, in the yoke, and pump grease into the bearing while rotating the overrunning hub to distribute grease in the bearing. Wipe away any excess grease.

2

1

1431-4-16

9 6. After rotating the overrunning clutch several revolutions to center all components, securely tighten the four cap screws, 1, retaining the slip clutch assembly to the yoke plate. Install the two cap screws and locknuts through the clamp hub, 2, on the rear of the slip clutch.

1

2

1431-4-8

1 10

31-5

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4

OVERRUNNING CLUTCH – DISASSEMBLY 1431 on and above SN 650204 1432 on and above SN 641955 If the overrunning clutch does not operate when the tractor PTO is disengaged, the overrunning clutch must be disassembled for inspection. Remove the slip clutch from the unit as previously described. It is possible to repair the overrunning clutch without disassembling the slip clutch.

1

Turn out the four cap screws, 1, holding the overrunning clutch to the slip clutch housing.

1

50006847

11

Pry out the snap ring, 1, and lift off the washer, 2, from the hub of the overrunning clutch.

1

2 50006848

12 Slide the hub, 1, from the yoke shaft, 2. Capture the pawls and leaf springs as the hub is slid from the shaft.

2

1 50006849

13

31-6

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4 Turn the set screw, 1, from the ball bearing cavity.

Rotate the yoke shaft while holding the hole down until all the bearings fall out; there are thirty balls in the overrunning clutch bearing cavity. It may be necessary to apply a small amount of penetrating fluid to assist in removing the ball bearings.

1

OVERRUNNING CLUTCH - INSPECTION Inspect the overrunning pawls and ramps on the inner diameter of the outer overrunning clutch hub for wear or damage; replace the components as required.

50006850

Inspect the overrunning hub and yoke bearing grooves and mating surfaces for galling or other damage; replace as necessary. Discard the overrunning bearing balls and replace with new parts.

14

OVERRUNNING CLUTCH – ASSEMBLY

2

1

1431 on and above SN 650204 1432 on and above SN 641955 Apply a film of grease to the inner, 1, and outer, 2, race of the ball bearing cavity.

50006851

15 Set the outer yoke shaft onto the inner shaft. Insert the ball bearings, 1, into the cavity, 2, until all thirty are in place. Turn in the set screw, 3, and tighten it securely. Apply grease through the zerk while rotating the overrunning hub to distribute the lubricant evenly. Wipe away and excess grease.

2

1 3

50006852

16

31-7

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4 Slide the spring washer, 1, in place over the yoke shaft. Apply grease to the spring recesses in the shaft, and set the leaf springs, 2, into place with the concave side facing toward the center.

1

2

50006853

17 Apply a film of grease to the pawls, 1, and set each in place on top of the leaf springs. Slide the hub, 2, over the pawls. Secure the hub in place with the washer, 3, and snap ring, 4.

1 2

3

4

50006854

18

31-8

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4

SLIP CLUTCH - INSTALLATION NOTE: Installation of both styles of slip clutches is identical. Only one will be discussed.

2

1

1. Install the drive shaft and slip clutch assembly so that the two crimped splines align with the slot in the front of the secondary drive shaft. Slide the two drive shaft halves together.

IMPORTANT: The PTO shafts are very heavy and awkward; use caution not to drop the shaft assemblies as personal injury or damage to the components may result.

1431-1-43

19

2. Slide the slip clutch onto the center gearbox input shaft as far as possible. Thread the bolt, 1, inside the slip clutch hub into the end of the shaft, and tighten as much as possible to pull the slip clutch hub securely onto the tapered end of the gearbox shaft. Tighten the two 1/2″ x 3″ Grade 8 cap screws, 2, and locknuts to 87 N⋅m (64 ft.-lbs.).

NOTE: Do not overtorque; locknuts are Class C, and are limited to 87 N⋅m (64 ft.-lbs.).

3. Reinstall the shield, 1, over the slip clutch and secure using the four bolts previously removed.

Position the shield so that the access hole is forward.

1

1431-2-36

20

31-9

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 4

31-10

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 5 - Gearbox (Swivel Hitch) CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2 Swivel Hitch Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-6 Upper Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-21 Upper Gearbox and Neck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-24 Lower Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-36 Lower Gearbox and Neck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-39 Lower Gearbox, Neck Assembly, and Upper Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-51

31-1

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

INTRODUCTION

2

Three gearboxes and a pedestal shaft assembly are used to power the cutter bar and the conditioner rolls.

The driveline on the tongue connects to the center pivoting gearbox, 1, on the header; the center gearbox pivots with the tongue through a mechanical sliding linkage, 6, to minimize U-joint angles on the secondary drive shaft. The center bevel gearbox drives two 2HB banded, kevlar cord v-belts, 2, to power the header. The left side belt drives a pedestal shaft, 3, which is connected to the #2 disc on the cutter bar with a U-joint drive shaft.

5

1

2

3

6

4

A4898-06

The right side belt drive powers a bevel gearbox, 4, which drives the #9 cutter bar disc module through a U-joint drive shaft, and also drives the conditioner rolls. The dual cutter bar drives reduces the loading experienced by the #2 & #9 disc modules; the cutter bar is completely connected with intermodule shafts for power transmittal and disc timing. The right side bevel gearbox also drives a 4HB banded, kevlar cord v-belt, 5, to the conditioner drive gearbox which powers the rolls using two multispline telescoping u-joint drive shafts.

1

SPECIAL TOOLS Tool Number

Description/Use

NHO1386

Pivot tongue gearbox neck cap screws

Local Manufacture

Neck lock nut removal (Figure 3)

Local Manufacture

Holding tool for neck housing (Figure 4)

Local Manufacture

Neck rolling torque measurement (Figure 2)

31-2

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

2

31-3

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

3

31-4

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

4

31-5

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

SWIVEL HITCH GEARBOXES

The inner neck casing is held to the outer neck casing by the use of a center joint lock nut. Motion between the two gearboxes occurs when the tractor initiates a turn. Bearings installed in the neck permit unrestricted horizontal movement between the upper and lower gearboxes. The neck shaft rotates within the assembly maintaining a constant PTO speed without regard to the direction each gearbox is facing. An O ring is installed between the inner and outer neck casings to prevent leakage from the swivel hitch gearbox at the point of relative motion.

Description The Swivel Hitch Gearbox on 1431/1432 Pivot Tongue Disc Mower Conditioners, allows a smaller angle between the tractor and mower without damaging either the tractor PTO or mower PTO shaft.

The lower gearbox directs the torque from the tractor PTO, through the swivel neck gear, into the upper gearbox, to the disc mower PTO shaft, and pivot tongue gearbox. The upper and lower gearboxes are nearly identical. Four beveled gears are used in the construction of the swivel hitch gearbox, and are interchangeable. The lower PTO input gearbox is coupled to the tractor using a six-spline shaft. The upper PTO output gearbox contains a twenty-one spline shaft.

To maintain a visible oil level in the lower gearbox, a set of two seals is installed on the neck shaft. Oil leaking out the lower gearbox breather is a possible indication of worn neck shaft seals, and should be investigated to prevent damage to either assembly.

20005569

5

31-6

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Swivel Hitch Gearbox - Removal Lower the header onto two blocks, 1, under the #2 and #9 disc. Using a lifting device, lift up on the tongue, 2, enough to support the tongue and remove the weight from the jack stand. Remove the jack stand and place it in its storage position.

2

10001625

1 6

Remove the primary PTO, shield, and support.

Position a pallet mover or other suitable lifting device under the swivel hitch. Support the hitch by installing blocking at the front, 1, and rear, 2, of the trunnion assembly. Place a wooden block, 3, on the top of the hitch frame assembly and under the trunnion assembly. Secure these two blocks with wire around the hitch frame.

1 2

CAUTION Failure to properly block and support the hitch and trunnion assemblies can result in them becoming unstable and falling off lifting or supporting devices.

10001626

3 7

The 3-point swivel hitch is shown in Figure 7 and the drawbar swivel hitch is shown in Figure 8.

50013379

8

31-7

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Remove the 5/16 x 1″ flanged cap screws, 1, that secures the top shield, 2, to the bottom shield.

Remove the top shield and set it aside.

2 1

10001626

9 Using a punch and hammer, drive the 5/16 x 2 ½″ pin, 1, out from the coupling and shaft.

1 10001627

10 Slide the coupling, 1, on the shaft, 2. With the weight of the tongue being supported by an overhead lifting device, and the hitch assembly being supported by blocks on a pallet mover, remove the eight 5/8 x 1-1/2″ cap screws, 3, that hold the upper gearbox to the tongue.

3

NOTE: If the bolts are difficult to remove, adjust the lifting device holding the tongue or the device supporting the hitch and gearbox assemblies.

1

2

10001628

11

31-8

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Using the lifting device that is supporting the tongue, slowly raise the tongue up and pull the gearbox and hitch assembly forward out of the tongue.

10001629

12 Place a block, 1, on the pallet mover or lifting device to support the front of the hitch assembly. The hitch assembly and trunnion assembly will go forward on the block when the gearbox is removed from the trunnion assembly. Attach a lifting chain, 2, to the upper gearbox and remove the eight 5/8 x 1 ½″ cap screws, 3, and hardened washers securing the lower gearbox to the trunnion assembly. Lift the gearbox up out of the trunnion and hitch assembly.

2 1

10001630

3

3 13

While the swivel hitch gearbox is attached to overhead lifting device drain the oil from both the upper and lower gearboxes prior to disassembly by removing the drain plugs, 1, on the gearboxes.

1

10001631

14

31-9

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Swivel Hitch Gearbox - Disassembly Prior to disassembly, drain the oil from the upper and lower gearboxes by removing the oil drain plugs, 1.

1

Remove the breathers, 2, in the upper and lower gearboxes to prevent them from being damaged during disassembly.

10992721

2 15

Use special tool NHO1386 to remove the eight hex socket head M10 x 22 cap screws that secure the neck collar to the lower gearbox.

10992728

16 Use a chisel or other suitable tool as needed to pry apart the gearbox and neck.

10001632

17

31-10

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Remove the remaining eight hex socket head M10 x 22 cap screws that secure the neck collar to the upper gearbox.

10992727

18 Separate the neck from the upper gear box by using a chisel.

10001633

19

31-11

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Neck Disassembly Remove the cotter pin, 1, from the castellated nut.

1

10992651

20 Remove the castellated nut, 1.

1

10992652

21 Use a splitter to press the gear, 1, off the shaft.

10992720

1 22

31-12

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Remove the shims and press the bearing out of the neck.

IMPORTANT: Do not attempt to press the shaft out of the neck without first removing the gear and key.

Pressing the shaft with the key installed will damage the shaft, shims, keys and other parts in the neck assembly.

10992654

23 Remove the bearing race, 1, from the inner neck. Tap evenly around the race from the rear with a soft punch until the race is free of the neck.

1 10992655

24 Remove the seal, 1, from the inner neck.

NOTE: Removing the seal will damage it. Replace all seals that are removed from the gearbox.

1 10992656

25

31-13

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Turn over the neck assembly and remove the bearing race, 1, from the outer neck assembly.

1 10992657

26 Remove the seal from the outer neck assembly.

NOTE: Removing the seal will damage it. Replace all seals that are removed from the gearbox.

10992658

27 Remove the lock nut, 1, from the outer neck assembly. Use the special lock nut tool (local manufacture) shown in Figure 4. Leave two or more of the eight neck bolts and nuts assembled to hold the inner neck in place during lock nut removal.

NOTE: The lock nut is assembled with Loctite. Use heat if necessary to loosen the lock nut.

1 10992659

28

31-14

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Press the inner neck out of the outer neck, removing the bearings and thrush washers in the process.

10992660

29 Use a splitter or equivalent tool to press the inner neck bearing off the neck. Remove the O ring from the lower neck.

10992665

30 Inspect all parts from the neck assembly. Replace any worn or damaged parts. Replace all seals during assembly.

10992661

31

31-15

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Neck Assembly NOTE: Assembly requires special tools, both purchased and of local manufacture. See “Special Tools� for instructions regarding special tool availability and dimensions for manufacture.

Coat the O ring with petroleum jelly and install it in the groove in the inner neck assembly,1.

1

Install the inner neck thrust washer and bearing, 2, using a press with suitable tools to prevent damage to the neck or bearing during installation.

10992663

2 32

Install the seal and bearing race in the outer neck case.

CAUTION Make sure the seal is installed as shown with the groove facing the upper gearbox. Oil will leak from the upper gearbox if not installed correctly and part failure may result.

10992664

33 Press the inner neck assembly into the outer neck assembly. Install the bearing race, 1, in the outer neck case.

10992666

1 34

31-16

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Press the outer neck bearing onto the inner neck.

10992667

35 Install the lock nut with Loctite 242 sealant.

10992668

36 Bolt the assembly, inner neck down, onto the special platform, 1. See “Special Tools” for dimensions to manufacture the special tools needed for this section.

10992669

1 37

31-17

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Use the special tightening tool, 1, to tighten the lock nut. Torque the locknut to 490 to 540 Nâ‹…m (363 to 399 ft.-lbs.).

Using a soft-faced hammer, strike the outer neck flange several times around its circumference, while rotating the outer neck. This will assist in seating the bearings.

1 10998189

38 Install the special tool, 1, onto the neck and check the rolling torque. The neck should have a rolling torque of 9.8 - 12.2 Nâ‹…m (87 - 109 in lbs). Retorque the locknut and reseat the bearings as required to obtain the proper rolling torque.

10992670

1 39

Clean and inspect the shaft and parts. Replace any worn or damaged parts.

10001646

40

31-18

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Set the shaft in a press with the threaded end up.

Press on the gear, (beveled end down), shim, and inner bearing, (beveled end up).

10992671

41 Place the shaft through the neck assembly, ensuring that oil seals are in place on both sides of the neck assembly opening. Press the outer bearing onto the shaft (beveled end down).

10992672

42 Place previously removed shims over the outer bearing and press the gear onto the shaft (beveled end up).

10992673

43

31-19

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Install the castellated nut to retain the gear. Use the special tool to apply a preload on the bearings equal to a rolling torque of 0.452 - 1.130 Nâ‹…m (4 - 10 in.-lbs.).

Set the preload by striking the shaft and turning it approximately ten revolutions.

10992674

44 Check the preload with the special torque wrench, 1, and adjust as needed.

1

To increase the rolling torque, tighten the castle nut.

To decrease the rolling torque, support the neck flange and strike the end of the shaft to slightly back off the press ft. Then tighten the castle nut slowly to obtain the correct preload.

10992674

45 Install the cotter pin to retain the castellated nut.

10992651

46

31-20

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

UPPER GEAR BOX

2

Disassembly 1. Remove the eight M10x22 cap screws securing the cover, 1, to the housing, 2.

1

10992723

47 2. Remove the cover from the housing, and slide the shaft and gear assembly from the housing.

10001635

48 3. Press off the bearing, 1. Remove the shims, 2, from the shaft, 3. Remove the snap ring, 4, and press the bearing 5, shims, 6, and gear, 7, from the shaft.

3

5

6

7

4

2

1

10001636

49

31-21

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Inspection Discard all used seals and gaskets. Replace with new seals and gaskets.

Replace all worn and pitted bearing cups and cones.

Replace all bearings if gearbox is contaminated with debris from an internal failure.

Inspect all key ways and splines for damage or wear.

Replace any damaged or worn assemblies.

Inspect all gears and gear teeth for wear and damage. Replace any damaged or worn parts.

Inspect the gearbox housing and all bearing caps for cracks. Replace any damaged or worn parts.

Assembly 1. Clean all parts thoroughly.

2. Remove any remaining gasket material or sealer from the case and end cap mating surfaces.

3. Press the gear and bearing onto the shaft using the previously removes shims between the gear and bearing.

10992722

50 4. Install the snap ring, 1, and previously removed shims, 3, on the shaft. Press the bearing, 2, on the opposite end of the shaft.

2 3

3

1 10986527

51

31-22

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 5. Install the shaft and gear assembly in the case.

10992723

52 6. Apply a bead of RTV silicone sealant to the mating surfaces and install the cap, 1, over the shaft. Install the eight M10x22x8.8 bolts, 2, and torque to 41 N⋅m (56 ft.-lbs.).

3 1

NOTE: Make two complete revolutions of the shaft to seat the bearing rollers before measuring end play.

7. Install a dial indicator, 3, on the end of the shaft, and pull on the shaft to measure end play. If necessary add or remove shims between the gear and the bearing at the end cap to obtain 0-0.05 mm (0-0.002″) of endplay on the shaft.

2

50013374

NOTE: The shims used are available in 0.012″, 0.016″, and 0.020″ thicknesses. The shim pack thickness can be changed in 0.004″ increments by removing a shim and installing the next size thicker shim to increase or decrease endplay.

53

8. When the proper end play has been obtained the shaft rolling torque needs to be calculated.

9. Install a 1/2″ screw in the end of the shaft and use an inch pound torque wrench to measure the shaft rolling torque. The rolling torque should be 0.23 - 0.68 N⋅m (2 - 6 in.-lbs.).

1

A4834-4

54

31-23

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

UPPER GEARBOX AND NECK ASSEMBLY The following tests must be performed on the upper gearbox with the neck assembly attached before the gearboxes can be installed on the machine.

• • • •

Upper gearbox input shaft end play Upper gearbox input shaft rolling torque Upper gearbox backlash Upper gearbox contact pattern.

Assembly NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearboxes at this time.

1. Install the neck assembly on the upper gearbox.

1

2. Install the eight M10x22 hex bolts to attach the neck to the upper gear box. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

10996523

55 3. Install a dial indicator on the gearbox so the indicator stem is engaged against a spline on the input shaft.

4. Rotate the input shaft back and forth to measure the backlash between the gears. The proper backlash reading at the input shaft splines is 0.05 to 0.10 mm (0.002″ to 0.004″); this indicates a true backlash of 0.21 to 0.57 mm (0.008″ to 0.018″).

50013376

56

31-24

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Backlash Adjustment If the backlash reading is less than the required measurement.

1. Remove the eight M10x22 hex bolts to attach the neck to the upper gear box.

1

2. Remove the neck assembly from the upper gearbox.

10996523

57 3. Remove the eight M10x22 cap screws securing the cover to the housing.

10992723

58 4. Remove the cover from the housing.

5. Remove the shaft and gear assembly from the housing.

10001635

59

31-25

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 6. Press off the bearing, 1. Remove the shims, 2, from the shaft, 3. Remove the snap ring, 4, and press the bearing 5, shims, 6, and gear, 7, from the shaft.

3

5

6

7

4

2

1

10001636

60

50013380

61

31-26

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 7. Move the shims from A, between the outer bearing and gear, to B, between the inner bearing and the snap ring.

NOTE: The shims used are available in 0.012″, 0.016″, and 0.020″ thicknesses. The shim pack thickness can be changed in 0.004″ increments by removing a shim and installing the next size thicker shim to increase or decrease backlash.

A

8. Assemble the shaft as described earlier in this section.

9. Install the shaft and gear assembly in the housing.

B

10001636

62

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10. Install the cover on the housing.

11. Install the eight M10x22 cap screws securing the cover to the housing. Torque the bolts to 78 N⋅m (58 ft.-lbs.).

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10992723

63 12. Install the neck assembly on the upper gearbox.

1

13. Install the eight M10x22 hex bolts to attach the neck to the upper gear box. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

14. Check for proper backlash reading at the input shaft as described earlier in this section.

10996523

64

31-27

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Backlash Adjustment If the backlash reading is greater than the required measurement;

1

1. Remove the eight M10x22 hex bolts to attach the neck to the upper gear box.

2. Remove the neck assembly from the upper gearbox.

10996523

65 3. Remove the eight M10x22 cap screws securing the cover to the housing.

10992723

66 4. Remove the cover from the housing.

5. Remove the shaft and gear assembly from the housing.

10001635

67

31-28

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 6. Press off the bearing, 1. Remove the shims, 2, from the shaft, 3. Remove the snap ring, 4, and press the bearing 5, shims, 6, and gear, 7, from the shaft.

3

5

6

7

4

2

1

10001636

68

50013380

69

31-29

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 7. Move the shims from B, between the inner bearing and the snap ring, to, A, between the outer bearing and gear.

NOTE: The shims used are available in 0.012″, 0.016″, and 0.020″ thicknesses. The shim pack thickness can be changed in 0.004″ increments by removing a shim and installing the next size thicker shim to increase or decrease backlash.

A

8. Assemble the shaft as described earlier in this section.

9. Install the shaft and gear assembly in the housing.

B

10001636

70

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10. Install the cover on the housing.

11. Install the eight M10x22 cap screws securing the cover, 1, to the housing, 2. Torque the bolts to 78 N⋅m (58 ft.-lbs.).

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10992723

71 12. Install the neck assembly on the upper gearbox.

1

13. Install the eight M10x22 hex bolts to attach the neck to the upper gear box. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

14. Check for the proper backlash reading at the input shaft as described earlier in this section.

10996523

72

31-30

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Gear Contact Pattern 1. Remove the eight M10x22 hex bolts that attach the neck assembly to the upper gear box.

1

2. Remove the neck assembly from the upper gearbox.

10996523

73 3. Remove the eight M10x22 cap screws securing the cover, 1, to the housing, 2.

10992723

74 4. Remove the cover from the housing.

5. Remove the shaft and gear assembly from the housing.

6. Apply a bluing compound to the beveled gear teeth on the neck assembly and on the beveled gear teeth in the upper gearbox assembly.

7. Install the shaft and gear assembly in the housing.

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10001635

8. Install the cover on the housing.

75

31-31

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 9. Install the eight M10x22 cap screws securing the cover, 1, to the housing, 2. Torque the bolts to 78 N⋅m (58 ft.-lbs.).

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10992723

76 10. Install the neck assembly on the upper gearbox.

1

11. Install the eight M10x22 hex bolts to attach the neck assembly to the upper gear box. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

12. Rotate the input shaft on the gearbox assembly counterclockwise several revolutions. This will mark the gear contact pattern in the bluing compound on the gear teeth.

10996523

77 13. Remove the eight M10x22 hex bolts that attach the neck assembly to the upper gear box.

1

14. Remove the neck assembly from the upper gearbox.

10996523

78

31-32

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 15. Remove the eight M10x22 cap screws securing the cover to the housing.

16. Remove the cover from the housing.

17. Remove the shaft and gear assembly from the housing.

10992723

79 18. Inspect the gear contact pattern on the gears made from the bluing compound on the gear teeth. The pattern should be 40% central-toe.

If the contact pattern is high (towards the top of the tooth) on the shaft assembly, and low (toward the root of the tooth) on the neck assembly gear; 19. Disassemble the neck assembly as describe earlier in this section.

1431-5-5

80

31-33

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

50013380

81 20. Remove shims at A, between the inner bearing and bevel gear.

NOTE: The shims used are available in 0.012″, 0.016″, and 0.020″ thicknesses. The shim pack thickness can be changed in 0.004″ increments by removing a shim and installing the next size thicker shim to increase contact mesh.

21. Assemble the neck assembly as described earlier in this section.

If the contact pattern is low on the shaft assembly and high on the neck assembly gear;

A 10001646

82

22. Disassemble the neck assembly as describe earlier in this section.

31-34

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

50013380

83 23. Add shims at A, between the inner bearing and bevel gear.

NOTE: The shims used are available in 0.012″, 0.016″, and 0.020″ thicknesses. The shim pack thickness can be changed in 0.004″ increments by removing a shim and installing the next size thicker shim to increase contact mesh.

24. Assemble the neck assembly as described earlier in this section.

25. Repeat the addition or removal of the shims until the contact pattern reaches 40% central-toe.

A 10001646

84

31-35

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

LOWER GEAR BOX Disassembly 1. Remove the eight M10x22 cap screws securing the cover, 1, to the housing, 2.

10992723

85 2. Remove the cover from the housing, and slide the shaft and gear assembly from the housing.

10001635

86 3. Press off the bearing, 1. Remove the shims, 2, from the shaft, 3. Remove the snap ring, 4, and press the bearing 5, shims, 6, and gear, 7, from the shaft.

3

5

6

7

4

2

1

10001636

87

31-36

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Inspection Discard all used seals and gaskets. Replace with new seals and gaskets.

Replace all worn and pitted bearing cups and cones.

Replace all bearings if gearbox is contaminated with debris from an internal failure.

Inspect all key ways and splines for damage or wear.

Replace any damaged or worn assemblies.

Inspect all gears and gear teeth for wear and damage. Replace any damaged or worn parts.

Inspect the gearbox housing and all bearing caps for cracks. Replace any damaged or worn parts.

Assembly 1. Clean all parts thoroughly.

2. Remove any remaining gasket material or sealer from the case and end cap mating surfaces.

3. Press the gear and bearing onto the shaft using the previously removes shims between the gear and bearing.

10992722

88 4. Install the snap ring, 1, and previously removed shims, 3, on the shaft. Press the bearing, 2, on the opposite end of the shaft.

2 3

3

1 10986527

89

31-37

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 5. Install the shaft and gear assembly in the case.

10992723

90 6. Apply a bead of RTV silicone sealant to the mating surfaces and install the cap, 1, over the shaft. Install the eight M10x22x8.8 bolts, 2, and torque to 41 N⋅m (56 ft.-lbs.).

3 1

NOTE: Make two complete revolutions of the shaft to seat the bearing rollers before measuring end play.

2

7. Install a dial indicator, 3, on the end of the shaft, and pull on the shaft to measure end play. If necessary add or remove shims between the gear and the bearing at the end cap to obtain 0-0.05 mm (0-0.002″) of endplay on the shaft.

50013374

NOTE: Make two complete revolutions of the shaft to seat the bearing rollers before measuring rolling torque.

91

8. When the proper end play has been obtained the shaft rolling torque needs to be calculated.

9. Install a 1/2″ screw in the end of the shaft and use an inch pound torque wrench to measure the shaft rolling torque. The rolling torque should be 0.23 - 0.68 N⋅m (2 - 6 in.-lbs.).

1

A4834-4

92

31-38

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

LOWER GEARBOX AND NECK ASSEMBLY The following tests must be performed on the lower gearbox with the neck assembly attached before the gearboxes can be installed on the machine.

• • • •

Lower gearbox input shaft end play Lower gearbox input shaft rolling torque Lower gearbox backlash Lower gearbox contact pattern.

Assembly NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearboxes at this time.

1. Install the neck assembly on the lower gearbox.

1

2. Install the eight M10x22 hex bolts to attach the neck to the lower gear box. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

10996523

93 3. Install a dial indicator on the gearbox so the indicator stem is engaged against a spline on the input shaft.

4. Rotate the input shaft back and forth to measure the backlash between the gears. The proper backlash reading at the input shaft splines is 0.05 to 0.10 mm (0.002″ to 0.004″); this indicates a true backlash of 0.21 to 0.57 mm (0.008″ to 0.018″).

50013376

94

31-39

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Backlash Adjustment If the backlash reading is less than the required measurement;

1

1. Remove the eight M10x22 hex bolts to attach the neck to the lower gear box.

2. Remove the neck assembly from the lower gearbox.

10996523

95 3. Remove the eight M10x22 cap screws securing the cover to the housing.

10992723

96 4. Remove the cover from the housing.

5. Remove the shaft and gear assembly from the housing.

10001635

97

31-40

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 6. Press off the bearing, 1. Remove the shims, 2, from the shaft, 3. Remove the snap ring, 4, and press the bearing 5, shims, 6, and gear, 7, from the shaft.

3

5

6

7

4

2

1

10001636

98

50013380

99

31-41

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 7. Move the shims from A, between the outer bearing and gear, to B, between the inner bearing and the snap ring.

8. Assemble the shaft as described earlier in this section.

9. Install the shaft and gear assembly in the housing.

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

A

10. Install the cover on the housing.

B

10001636

100 11. Install the eight M10x22 cap screws securing the cover to the housing. Torque the bolts to 78 N⋅m (58 ft.-lbs.).

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10992723

101 12. Install the neck assembly on the lower gearbox.

1

13. Install the eight M10x22 hex bolts to attach the neck to the upper gear box. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

14. Check for proper backlash reading at the input shaft as described earlier in this section.

10996523

102

31-42

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Backlash Adjustment If the backlash reading is greater than the required measurement;

1

1. Remove the eight M10x22 hex bolts to attach the neck to the lower gear box.

2. Remove the neck assembly from the lower gearbox.

10996523

103 3. Remove the eight M10x22 cap screws securing the cover to the housing.

10992723

104 4. Remove the cover from the housing.

5. Remove the shaft and gear assembly from the housing.

10001635

105

31-43

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 6. Press off the bearing, 1. Remove the shims, 2, from the shaft, 3. Remove the snap ring, 4, and press the bearing 5, shims, 6, and gear, 7, from the shaft.

3

5

6

7

4

2

1

10001636

106

50013380

107

31-44

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 7. Move the shims from B, between the inner bearing and the snap ring, to, A, between the outer bearing and gear.

8. Assemble the shaft as described earlier in this section.

9. Install the shaft and gear assembly in the housing.

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10. Install the cover on the housing.

A

B

10001636

108 11. Install the eight M10x22 cap screws securing the cover to the housing. Torque the bolts to 78 N⋅m (58 ft.-lbs.).

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10992723

109 12. Install the neck assembly on the lower gearbox.

1

13. Install the eight M10x22 hex bolts to attach the neck to the lower gear box. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

14. Check for the proper backlash reading at the input shaft as described earlier in this section.

10996523

110

31-45

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Gear Contact Pattern 1. Remove the eight M10x22 hex bolts that attach the neck assembly to the lower gear box.

1

2. Remove the neck assembly from the lower gearbox.

10996523

111 3. Remove the eight M10x22 cap screws securing the cover to the housing.

10992723

112 4. Remove the cover from the housing.

5. Remove the shaft and gear assembly from the housing.

10001635

113

31-46

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 6. Apply a bluing compound to the beveled gear teeth on the neck assembly and on the beveled gear teeth in the lower gearbox assembly.

7. Install the shaft and gear assembly in the housing.

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

8. Install the cover on the housing.

10992651

114 9. Install the eight M10x22 cap screws securing the cover to the housing. Torque the bolts to 78 N⋅m (58 ft.-lbs.).

NOTE: Do not apply RTV silicone sealant or Loctite 270 to the gearbox at this time.

10992723

115 10. Install the neck assembly on the lower gearbox.

1

11. Install the eight M10x22 hex bolts to attach the neck assembly to the lower gear box. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

12. Rotate the input shaft on the gearbox assembly counterclockwise several revolutions. This will mark the gear contact pattern in the bluing compound on the gear teeth.

10996523

116

31-47

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 13. Remove the eight M10x22 hex bolts that attach the neck assembly to the lower gear box.

1

14. Remove the neck assembly from the lower gearbox.

10996523

117 15. Remove the eight M10x22 cap screws securing the cover to the housing.

16. Remove the cover from the housing.

17. Remove the shaft and gear assembly from the housing.

10992723

118 18. Inspect the gear contact pattern on the gears made from the bluing compound on the gear teeth. The pattern should be 40% central-toe.

If the contact pattern is high (towards the top of the tooth) on the shaft assembly, and low (toward the root of the tooth) on the neck assembly gear; 19. Disassemble the neck assembly as describe earlier in this section.

1431-5-5

119

31-48

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

50013380

120 20. Remove shims at A, between the outer bearing and bevel gear.

NOTE: The shims used are available in 0.012″, 0.016″, and 0.020″ thicknesses. The shim pack thickness can be changed in 0.004″ increments by removing a shim and installing the next size thicker shim to increase contact mesh.

21. Assemble the neck assembly as described earlier in this section.

22. If the contact pattern is low on the shaft assembly and high on the neck assembly gear; 23. Disassemble the neck assembly as describe earlier in this section.

31-49

A 10001646

121

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

50013380

122 24. Add shims at A, between the inner bearing and bevel gear.

NOTE: The shims used are available in 0.012″, 0.016″, and 0.020″ thicknesses. The shim pack thickness can be changed in 0.004″ increments by removing a shim and installing the next size thicker shim to increase contact mesh.

25. Assemble the neck assembly as described earlier in this section.

A

26. Repeat the addition or removal of the shims until the contact pattern reaches 40% central-toe.

10001646

123

31-50

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5

LOWER GEARBOX, NECK ASSEMBLY, AND UPPER GEARBOX Assembly 1. Apply silicone sealant to the mating surfaces of the neck assembly and lower gearbox assembly.

NOTE: Do not cover the area of the mating surfaces where the attaching hardware will be installed. The spacers prevent silicone from entering into the bolt holes and inactivating the Loctite.

2. Install spacers or washers on the mating surface of the lower gearbox.

50013377

124

3. Install the neck assembly on the lower gearbox.

4. Apply Loctite 270 to the threads of the eight M10X22 hex bolts.

5. Install the eight M10x22 hex bolts that attach the neck to the lower gearbox. Hand tighten at this time.

6. Remove the spacers or washers from the mating surfaces of the lower gearbox and neck assembly.

7. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

8. Apply silicone sealant to the mating surfaces of the neck assembly and upper gearbox assembly.

NOTE: Do not cover the area of the mating surfaces where the attaching hardware will be installed. The spacers prevent silicone from entering into the bolt holes and inactivating the Loctite.

9. Install spacers or washers on the mating surface of the upper gearbox.

10. Install the neck assembly on the upper gearbox.

11. Apply Loctite 270 to the threads of the eight M10X22 hex bolts.

12. Install the eight M10x22 hex bolts that attach the neck to the upper gearbox. Hand tighten at this time.

13. Remove the spacers or washers from the mating surfaces of the lower gearbox and neck assembly.

50013378

125

31-51

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 14. Torque the bolts to 78 N⋅m (58 ft.-lbs.) using special tool, 1.

15. If necessary, install the oil filler fittings on each gearbox.

10992728

126 Swivel Hitch Gearbox Installation Lower the swivel hitch gearbox into the trunnion assembly. Install four hardened flat washers and the 5/8 x 1 ½″ cap screws that secure the lower gearbox to the trunnion and hitch assembly.

NOTE: The gearboxes should always be installed so the inner neck is attached to the lower gearbox.

10986519

127

31-52

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Remove the lifting chain from the upper gearbox.

Attach a lifting devise to the tongue of the mower-conditioner. Raise the tongue up enough to slide the upper gearbox into the tongue.

10001630

128 Install the plate, 1, two hardened washers, and the 5/8 x1-1 /2″ cap screw, 2, to secure the plate, 3, to the upper gearbox.

NOTE: On tongue serial number 619301 to 619309 class 8.8 plated M16 x 40mm cap screws were used.

Replace these with class 10.9 plated M16 x 40mm cap screws and torque to 344 N⋅m (254 ft lbs). On tongue serial number 619310 and above, grade 5 plated 5/8 x 1 ½″ cap screws were used in production. Replace these sixteen cap screws with grade 8 plated 5/8 x 1 ½″ cap screws and torque to 315 N⋅m (233 ft lbs).

10001628

129

NOTE: Start the cap screws by hand. Make sure they are fully started before tightening.

Slide the coupling, 1, over the twenty-one spline output shaft of the upper gearbox. Drive the pin, 2, in until it is extended out the other side of the coupling.

1

2 10001627

130

31-53

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 5 Reinstall the top shield over the driveline by install the 5/16 x 1″ flanged cap screws, 1.

10001626

131 Using the lifting device, raise the tongue up to remove the blocking that secured the trunnion and hitch assembly. Reinstall the jack stand, 1, by inserting two pins through the trunnion and jack stand assembly, and secure with a hairpin cotter.

Reinstall the PTO shield, primary PTO, and the support.

1

Fill the gearbox with 80W90 oil. Lubricate all grease fittings before using the disc mower/conditioner.

19985198

132

31-54

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

SECTION 35 - HYDRAULIC SYSTEM Chapter 1 - Cylinders CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-2 Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-5 Bleeding Air from the Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6 Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-7 Master Cylinder - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-8 Master Cylinder - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9 Master Cylinder - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9 Slave Cylinder - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-10 Slave Cylinder - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-11 Header Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12 Header Tilt Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-15 Header Tilt Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-16 Header Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-18 Header Tilt Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-21 Tongue Swing Cylinder - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-23 Tongue Swing Cylinder - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-24 Tongue Swing Cylinder - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-25 Tongue Swing Cylinder - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-25 Tongue Swing Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-28 Tongue Swing Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-29 Tongue Swing Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-30 Tongue Swing Cylinder - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-33

35-1

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

INTRODUCTION

2

Four different cylinders are used on the Model 1431 and 1432 disc mower-conditioners to control the unit during operation.

1

The tongue swing cylinder, 1, is a double-acting cylinder which pivots the tongue relative to the header and trail frame. A mechanical transport latch, 2, is used to prevent accidental actuation of the cylinder.

A4897-9

1

On Model 1431 below SN 638805 and Model 1432 below SN 636431, the tongue swing cylinder has a screw-in style orifice plate, 1, to control the speed of swing during use; the orifice is 2.36 mm (0.093″) in diameter. In addition, the tongue swing cylinder has a metering pin, 2, and a metering sleeve, 3, to control the speed of the cylinder at the end of stroke.

1

3

When retracting, the cylinder moves at a speed controlled by the flow rate from the tractor and the orifice plate, until the metering pin, 2, enters a counterbore at the end of the cylinder barrel; this further restricts the flow of oil out of the cylinder, to “cushion” the end of stroke.

1431-8-7

2 2

When extending, the cylinder moves at a speed controlled by the flow rate from the tractor and the orifice plate, until the metering sleeve, 3, enters a counterbore in the cylinder head; this further restricts the flow of oil out of the cylinder, to “cushion” the end of stroke.

35-2

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 On Model 1431 above SN 638804 and Model 1432 above SN 636430, the tongue swing cylinder has a screw-in style orifice plate, 1, to control the speed of swing during use; the orifice is 2.36 mm (0.093″) in diameter. In addition, the tongue swing cylinder piston is tapered toward the barrel end to control the speed of the cylinder at the end of the stroke.

When retracting, the cylinder moves at a speed controlled by the flow rate from the tractor and the orifice plate. As the leading edge of the piston covers

the barrel end port, the flow rate is reduced by the taper of the cylinder to “cushion” the end of the stroke. The piston will continue to move until it gently bottoms out in the cylinder bore.

When extending, the cylinder moves at a speed controlled by the flow rate from the tractor and the orifice plate. As the piston reaches the cylinder head, the metering sleeve, 2, enters a counterbore, 3, in the cylinder head; this further restricts the flow of oil out of the cylinder, to “cushion” the end of the stroke.

2

3

1

20002690

3

35-3

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 The right side lift cylinder, 1, is a master cylinder that supplies oil to the left side lift cylinder. The left cylinder, 2, operates as a slave cylinder. Mechanical transport locks are used to prevent accidental lowering of the header.

NOTE: Figure 4 shows the 1431.

1

2 A4833-8

4 The header tilt cylinder, 1, is teed into the pressure line between the tractor and the master lift cylinder, and is a single-acting cylinder. The header tilt cylinder operates in sequence with the header lift cylinders, based on their relative pressure requirements.

When the unit is lowered, the header will drop until it rests on the ground, and the tilt cylinder will then extend to the position determined by the location of the pin, 2. When the header is raised, the header tilt cylinder will first retract, and the header will then raise.

2 1 1431-2-19

5

NOTE: Figure 5 shows the 1431.

35-4

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

HYDRAULIC DIAGRAM

0.093″

TILT CYLINDER

1431-8-8

6

WARNING Fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Always protect the skin and eyes from escaping fluid under pressure.

Before disconnecting lines or fittings, be sure to release all pressure by operating the tractor control valves. Before applying pressure to the system, be sure all connections are tight and that hoses and connections are not damaged.

If injured by escaping fluid, obtain medical assistance at once. Serious infection or reaction can develop if medical treatment is not administered immediately.

35-5

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

BLEEDING AIR FROM THE LIFT CYLINDERS

1

If the lift cylinders do not lift the frame evenly or if one side lifts higher than the other, rephase the cylinders by lowering the mower-conditioner and hold the tractor valve in the lower position for 10 to 15 seconds or by raising the mower-conditioner and hold the tractor valve for 10 to 15 seconds. If the cylinders do not extend far enough to release the transport stops, there may be air in the hydraulic system that must be purged.

4831-14r

Loosen the hose swivel fitting, 1, at the upper end of the slave cylinder.

7

NOTE: Use a shop rag or other shielding means for protection from seeping oil at loosened fittings.

With the tractor engine at a low idle, actuate the tractor hydraulic lever and extend the master lift cylinder until oil flow from the loosened fitting is free of air. Then tighten the fitting.

IMPORTANT: If the cylinders do not extend far enough to release the transport stops, air remains in the hydraulic system and must be purged. If the transport stop on the master cylinder side does not release, excessive oil may be in the slave cylinder circuit. Bleed this oil until both stop blocks are engaged on their respective transport stops.

Raise and lower the header several times until all air is purged from the system. Repeat the previous steps if necessary.

35-6

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

LIFT CYLINDER REMOVAL

2

WARNING Before attempting to remove the lift cylinders: • Raise the header with the tractor hydraulics.

• Engage the header transport stops by pivoting lever, 1, forward. Install the pin, 2, Figure 9, to lock the header tilt cylinder in the 2 degree position.

• Lower the header so that the weight is carried on the transport lock, 2, Figure 8.

1 1431-2-04

8

2

1431-2-19

9 1. Remove the hose(s), 1, at the cylinder port(s) to remove either of the two cylinders.

2

2. Remove pins, 2 and 3, to remove the lift cylinder.

1

NOTE: The left side is shown. The right side is similar.

1431-2-04

3 10

35-7

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

MASTER CYLINDER - DISASSEMBLY 1. Remove setscrew, 1.

A1411/9-6

11 2. Tap the head, 1, into the cylinder far enough to remove retaining ring, 2, with a screwdriver.

A1411/9-7

12 3. Pull the complete piston rod assembly out of the cylinder barrel.

NOTE: All O rings and seals should be replaced.

4. Capture the piston rod using a bar through the hole in the end, and remove rod nut, 1. Slide off the piston, 2, and cylinder head, 3.

A1411/9-8

13

35-8

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

MASTER CYLINDER - INSPECTION 1. Examine the parts for wear or nicks. Remove any burrs inside the cylinder.

2. Remove all seals and O rings, carefully noting the lip position on the seals.

MASTER CYLINDER - ASSEMBLY 2

1. Lubricate all seals, O rings, and sliding surfaces before assembly.

1

2. Install a new rod seal inside the cylinder head.

Drive a new wiper seal, 1, in place in the face of the cylinder head. Install an O ring, 3, and back-up washer in the outer groove on the cylinder head, with the back- up washer, 2, towards the outer face of the cylinder head. Slide a new retaining ring and the cylinder head assembly over the piston rod.

A1411/9-9

14 3. Capture the piston rod using a bar through the hole in the end. Install piston, 2, with the recessed end facing out. Install the locknut, 1, and torque it to 210 Nâ‹…m (155 ft.-lbs.).

3

4. Install the piston seal, 3.

A1411/9-8

15

35-9

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 5. Lubricate the cylinder barrel with oil, and carefully insert the complete piston rod assembly into the barrel, using caution not to damage the seals on the retaining ring groove. Push the cylinder head into the cylinder barrel far enough to expose the retaining ring groove, and install retaining ring, 2. Pull the piston rod outwards to seat the cylinder head, 1, against the retaining ring.

6. Install setscrew, aligning it with the groove in cylinder head.

A1411/9-7

16

SLAVE CYLINDER - DISASSEMBLY 1. Remove setscrew, 1.

A1411/9-13

17 2. Tap the cylinder head, 1, into the cylinder far enough to remove retaining ring, 2.

A1411/9-13

18

35-10

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 3. Pull the complete piston rod assembly out of the cylinder barrel.

NOTE: All O rings and seals should be replaced.

4. Capture the piston rod using a bar through the hole in the end, and remove rod nut, 1. Slide the piston, 2, and the cylinder head, 3, off the cylinder rod.

A1411/9-14

19

SLAVE CYLINDER - INSPECTION 1. Examine the parts for wear or nicks. Remove any burrs inside the cylinder.

2. Remove all seals, carefully noting the lip position on the seals.

SLAVE CYLINDER - ASSEMBLY 1. Lubricate all seals and sliding surfaces before assembly.

3

2. Install a new back-up washer and O ring in the inner bore of the cylinder head with the back-up washer towards the outer face. Drive a new wiper seal, 4, into the outer face of the cylinder head.

Install a back-up washer and O ring into the outer groove, 5, in the cylinder head, with the back-up washer towards the outer face. Slide a new retaining ring and the cylinder head assembly over the piston rod.

A1411/9-14

3. Install a new seal, 3, on the piston. Install the piston with the recessed end facing outwards.

Install the locknut, 1, and torque it to 210 Nâ‹…m (155 ft.-lbs.).

35-11

20

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 4. Lubricate the cylinder barrel with oil, and carefully insert the complete piston rod assembly into the barrel, using caution not to damage the seals on the retaining ring groove. Push the cylinder head into the cylinder barrel far enough to expose the retaining ring groove, and install retaining ring, 2. Pull the piston rod outwards to seat the cylinder head, 1, against the retaining ring.

5. Install setscrew, aligning it with the groove in cylinder head.

A1411/9-13

21 Model 1431 Serial Number 638805 and below Model 1432 Serial Number 636431 and below

HEADER TILT CYLINDER Removal 1. Place the header tilt position pin in the 10 degree position. Position jack stands, 1, or blocking at the front of the header to support it in a horizontal position when it is lowered. Lower the header fully to the ground, and allow the header to roll forward onto the jack stands to relieve the pressure on the tilt cylinder mounting pins.

1

1431-G36

22

2. Disconnect the hydraulic hose, 1, from the tilt cylinder.

1

3. Remove the cap screws and nuts, 2, and take the tilt cylinder from the unit. Note the positioning of the spacers and washers used on the rear mounting pin to center the cylinder rod.

2

1431-G38

23

35-12

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Disassembly 1. Take out the 90° elbow, 1, from the cylinder port, if not already removed. This will allow removal of the limit channel.

A1411/9-2

24 2. Remove setscrew, 1.

3. Tap the cylinder head, 2, into the cylinder far enough to remove retaining ring, 3, with a screwdriver.

A1411/9-3

25 4. Pull the complete piston rod assembly out of the cylinder barrel.

NOTE: All O rings and seals should be replaced.

5. Capture the piston rod using a bar through the one of the holes in the rod, and remove rod nut, 1 . Slide off the piston, 2, and cylinder head, 3.

A1411/9-4

26

35-13

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Inspection 1. Examine the parts for wear or nicks. Remove any burrs inside the cylinder.

2. Remove all seals and O rings, carefully noting the lip position on the seals.

3. Remove and clean the breather on the cylinder barrel.

Assembly 1. Lubricate all seals, O rings, and sliding surfaces before assembly.

2. Install a new rod seal inside the cylinder head.

Drive a new wiper seal, 4, in place in the face of the cylinder head. Install an O ring in the outer groove on the cylinder head. Slide the cylinder head assembly over the piston rod.

3

3. Capture the piston rod using a bar through one of the holes in the rod. Install piston, 2, and the locknut, 1. Torque the locknut to 210 Nâ‹…m (155 ft.-lbs.).

A1411/9-4

4. Install the piston seal, 3.

27

5. Lubricate the cylinder barrel with oil, and carefully insert the complete piston rod assembly into the barrel, using caution not to damage the seals on the retaining ring groove. Push the cylinder head into the cylinder barrel far enough to expose the retaining ring groove, and install retaining ring, 3. Pull the piston rod outwards to seat the cylinder head against the retaining ring.

Install setscrew, 1, aligning it with the groove in cylinder head, 2.

A1411/9-3

28

35-14

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Model 1431 Serial Number 638806 and above Model 1432 Serial Number 636432 and above

HEADER TILT CYLINDER REMOVAL 1. Position adequate blocks under the front skirt frame of the disc mower.

IMPORTANT: Ensure that the support blocks are positioned under an area of the skirt which will support the weight of the disc mower.

20002675

2. Engage the travel locks on the disc mower.

Lower the mower so that it is resting on the locks.

29

3. Tilt the head down until the front frame is resting on the blocks. Hold the switch in the tilt down position for a couple of seconds to ensure that the hydraulic pressure on the cylinder has been released.

4. Remove the hydraulic hose, 1, and cap the end of the hose.

1

2

5. Remove cap screws, 2, and nuts, 3, from the cylinder mounts. Capture the spacers as the cap screws are being removed.

6. Remove the hydraulic line adapter fitting.

7. Remove the limit channel, 4, from the cylinder.

20002661

4

3 30

35-15

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

HEADER TILT CYLINDER DISASSEMBLY

1

1. Clamp the barrel end of the hydraulic cylinder in a vise.

2. Remove the self locking set screw, 1, from the side of the cylinder.

20002682

31 3. Lightly tap the flange into the cylinder until it is 1-2 inches from the top.

1

20002683

32 4. Remove the retaining ring from the cylinder.

5. Withdraw the piston rod assembly sharply to remove it from the cylinder.

1 20002680

33

35-16

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 6. Clamp the piston rod assembly in a vise.

3

7. Remove the piston lock nut, 3, piston, 2, and cylinder flange, 1, from the rod.

2

1 20002678

34 8. Remove the inner half of the rod, 1, from the outer half of the rod, 2.

1

2

20002677

3 35

35-17

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

HEADER TILT CYLINDER ASSEMBLY 1. Lubricate the flange, piston and seals with clean hydraulic oil before assembling.

1

2. Clamp the outer half of the piston rod, 1, in a vise.

20002676

36 3. Apply Loctite 242 onto the threads of the outer half of the piston rod.

1

4. Turn the inner half of the piston rod, 1, onto the outer half, 2.

2

3

20002677

37 5. Lubricate the flange, piston and seals with clean hydraulic oil before assembling.

6. Assembly the three piece piston seal, 1, as shown.

7. Install the 2 piece seal, 2, onto the cylinder flange.

3

2

1

8. Install the flange to rod seal, 3, into the cylinder flange.

20001727

38

35-18

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 9. Lubricate the piston rod and cylinder flange with clean hydraulic oil.

3

10. Slide the cylinder flange, 1, onto the piston rod with the 2 piece seal closest to the piston end.

2

11. Slide the piston onto the end of the piston rod and secure it with a lock nut. Torque the lock nut onto the piston rod to 210-251 Nâ‹…m (155-185 ft.-lbs.).

Allow the inner piston rod to rotate on the outer piston rod. The torque between the two rods is also 210-251 Nâ‹…m (155-185 ft.-lbs.).

1 20002678

39 12. Remove the assembled piston rod from the vise.

Clamp the cylinder into the vise.

13. Lubricate the inside of the cylinder and cylinder flange with clean hydraulic oil.

14. Slide the piston rod into the cylinder. Lightly tap the piston rod until it has been fully inserted into the cylinder. Push the cylinder flange 25-51 mm (1-2 inches) deeper into the cylinder.

20002679

40 15. Insert the retaining ring, 1, into the cylinder. Once in the bore, navigate the retaining ring until it is seated firmly in the groove provided near the end of the cylinder.

1 20002680

41

35-19

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 16. Withdraw the piston rod from the cylinder sharply to draw the flange, 1, to the top of the cylinder and mate the retaining ring with the flange.

1

20002681

42 17. Install the self locking set screw into the side of the cylinder.

1

18. Remove the cylinder from the vise.

20002682

43

35-20

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

HEADER TILT CYLINDER INSTALLATION 1. Insert the enclosed bushings, 1, into the rod, 2, and barrel end clevis.

2 1 20002657

44 2. Remove the cylinder port plug and install the straight through adapter, 1.

1

20002658

45 3. Align the barrel end clevis with the head mounting bracket, 1. Ensure that the cylinder is installed so that the hydraulic port, 2, is on top.

2

1 20002659

46

35-21

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 4. Insert the mounting bolt, 1, through holes attaching the cylinder to the mounting bracket using a lock washer, 2, and spacers, 3, on each side.

2

1

5. Extend or retract the cylinder as required and attach the rod end clevis in the same manner as the barrel end.

3

20002660

47 6. Install the tilt cylinder limit channel, 1, with the flanged end toward the barrel end of the cylinder.

1

2

7. Attach the hydraulic hose, 2, to the cylinder port.

8. Install the nut, 3, and bolt, 4, into the limit channel.

20002661

4

3 48

9. Install the adjusting pin, 1, into the appropriate adjustment hole from the cylinder of the cylinder and limit channel.

1

20002661

49

35-22

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Model 1431 Serial Number 638804 and below Model 1432 Serial Number 6364310and below

TONGUE SWING CYLINDER REMOVAL 1. Engage the tongue transport lock by rotating the transport lock bracket up and over (one half turn) so that the transport lock pin is spring loaded downwards. Shift the machine into the transport (center) position so that the transport lock pin engages in the trail frame.

1431-2-7

50

CAUTION Before shifting the tongue, be sure the machine will clear any obstructions. Be sure bystanders are clear of the machine when shifting the tongue. Air in the system or high hydraulic flow rate can cause erratic operation.

2. Cycle the tractor hydraulic valve into the float position to relieve all pressure in the tongue swing cylinder. Loosen and remove the hoses, 1, from the 90° elbows on the cylinder barrel.

Remove the cotter pins and the clevis pins, 2, and lift the cylinder off the unit.

2

1

2

A4897-9

51

35-23

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

TONGUE SWING CYLINDER DISASSEMBLY 1. Thoroughly drain all oil out of the cylinder prior to disassembly. Remove the three cap screws, 1, retaining the seal plate to the cylinder head. Slide the seal plate down the cylinder rod.

1 1

1431-8-1

52 2. Tap the cylinder head, 1, into the cylinder far enough to remove the snap ring, 2, with a screwdriver. It will be easier to remove the snap ring by pushing one end further into the cylinder barrel, then wedge a screwdriver under the end of the snap ring and pop it out past the groove.

1

2 1431-8-2

53 3. Pull the complete piston rod assembly out of the barrel.

5

NOTE: The O rings and seals must be replaced, as they will be damaged during removal from the cylinder barrel.

3

4

2

4. Remove the metering pin, 1, and retaining screw from the end of the cylinder rod. Capture the piston rod using a bar through the clevis and remove the rod nut, 2. Slide the piston, 3, metering sleeve, 4, cylinder head, 5, and seal plate off of the piston rod.

1

1431-8-4

54

35-24

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

TONGUE SWING CYLINDER INSPECTION 1. Examine the parts for wear or nicks. Remove any burrs inside the cylinder.

2. Remove all O rings and seals, carefully noting the positioning of the components, and the lip position of the seals.

TONGUE SWING CYLINDER ASSEMBLY

4 3

1. Lubricate all O rings, seals and sliding surfaces before assembly.

2. Drive a new wiper seal, 1, into the seal plate, with the lip facing outwards.

Install a new rod seal inside the cylinder head at 2. Install a back-up washer and O ring in the outer groove, 3, of the cylinder head, with the back-up washer positioned towards the outer face. Install an O ring and two back-up washers in the inner groove, 4, of the cylinder head, with the O ring sandwiched between the two back-up washers.

Install a new seal, 5, onto the piston.

2 1

55

3. Slide the seal plate, 1, retaining ring, 2, and cylinder head, 3, onto the piston rod. Ensure the cylinder head is installed with the bolt holes facing towards the seal plate. Install the metering sleeve, 4, over the end of the piston rod with the tapered end facing the cylinder head. Position the piston, 5, on the end of the piston rod with the recessed end facing the threaded end of the rod, and install the locknut, 6.

Capture the piston rod using a bar through the clevis and torque the locknut to 339 - 380 Nâ‹…m (250 - 280 ft.-lbs.).

5

1431-8-6

3 5

2

1

4

6 1431-8-5

56

35-25

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 4. Apply a locking agent to the threads of the retaining screw, and install the screw and metering pin, 1. The stepped end of the metering pin should be towards the piston rod, with the tapered end facing the screw head. Tighten the screw securely to eliminate any movement of the metering pin.

1

1431-8-4

57 5. Ensure the 0.093″ orifice plate, 1, is installed in the base end port of the cylinder barrel.

1

1431-8-3

58

35-26

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 6. Lubricate the cylinder barrel with oil, and carefully insert the complete piston rod assembly into the barrel, using caution not to damage the seals on the retaining ring groove. Push the cylinder head, 1, into the cylinder barrel far enough to expose the retaining ring groove, and install the retaining ring, 2. Pull the piston rod outwards to seat the cylinder head against the retaining ring.

1

2 1431-8-2

59 7. Install the three cap screws, 1, and torque to 18 - 20 Nâ‹…m (13 - 15 ft.-lbs.).

1 1

1431-8-1

60

35-27

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Model 1431 Serial Number 638805 and above

1

Model 1432 Serial Number 6364311and above

TONGUE SWING CYLINDER REMOVAL 1. Remove the hydraulic hoses, 1, and cap the hose ends.

2 20002656

61 2. Remove the cap screws, 1, washers, 2, spacers, 3, and clevis pins, 4, from both ends of the swing cylinder.

1

2

3

6

4

3. Remove the cylinder from the disc mower.

5

20002654

62

35-28

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

TONGUE SWING CYLINDER DISASSEMBLY 1. Clamp the swing cylinder in a vise.

20002684

63 2. Unscrew the flange from the cylinder.

20002685

64 3. Remove the piston rod assembly from the cylinder.

20002689

65

35-29

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

TONGUE SWING CYLINDER ASSEMBLY 1. Lubricate the flange, piston and seals with clean hydraulic oil before assembling.

2. Install the 3 piece seal, 1, on the piston as shown.

4. Install the o-ring, 3, and backup ring, 4, on the flange.

5. Install the inner flange seal, 5, into the flange.

6. Install the oil seal, 6, into the end of the flange.

3. Install the wear ring, 2, on the piston.

1 4

3

6

2

5

20002690

66

35-30

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 7. Clamp the piston rod into a vise.

1

8. Lubricate the piston rod with clean hydraulic oil.

9. Slide the flange, 1, onto the rod with the oil seal end toward the clevis.

20002691

67 10. Slide the piston over the end of the rod. Install the lock nut, 2, and torque to 339-366 Nâ‹…m (250-270 ft.-lbs.).

1

2 20002692

68

35-31

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 11. Remove the piston rod assembly from the vise.

12. Clamp the swing cylinder in a vise.

20002686

69 13. Lubricate the piston and inside of cylinder with clean hydraulic oil.

14. Slide the piston rod assembly carefully into the cylinder.

20002687

70 15. Screw the flange, 1, into the cylinder and torque to 373-407 Nâ‹…m (275-300 ft.-lbs.).

1

20002688

71

35-32

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

TONGUE SWING CYLINDER – INSTALLATION

1

2

3

1. Align the hole of the barrel end clevis with frame mount.

4

2. Insert the clevis pin, 1, to attach the cylinder to the frame.

5

6

3. Secure the clevis pin to the cylinder by installing the cap screw, 2, lock washer, 3, flat washer, 4, and spacer, 5.

4. Remove the cylinder port plugs, 6.

20002654

72 5. Rotate the rod end clevis, 1, so that the securing bolts, 2, are toward the rear of the disc cutter.

6. Align the hole of the rod end clevis with the tongue mount.

2

1

3

7. Insert the clevis pin, 3, to attach the cylinder to the tongue.

20002655

73

35-33

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 8. Secure the clevis pin to the cylinder by installing the cap screw, 1, lock washer, 2, flat washer, 3, and spacer, 4.

2

1

3

20002655

74 9. Install the 90° elbows into the cylinder ports.

1

10. Attach the hydraulic hoses to the cylinder ports.

2 20002656

75

35-34

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1

SECTION 39 - FRAMES/TONGUE AND HITCHES Chapter 1 - Hood and Hood Liner CONTENTS Section

Description

Page

Hood Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-2 Hood Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-5 Hood Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-7 Hood Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-8

39-1

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1

HOOD REMOVAL 1

1. Remove or raise the rear curtain, and remove the side windrow shields.

2. Remove the upper half of the rotor shields, 1, from both ends of the rotor.

19990063

1 3. aise the hood by turning the crank, 1, clockwise.

1

19985216

2 4. Use one or more wood blocks, 1, to hold the hood above the rotor. Take the pressure off of the hood-retaining hardware by lowering the hood until it is resting on the wood block(s).

1 19990089

3

39-2

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1 5. Remove the down stop bolt and spacer, 1, at either end of the hood.

1

19985249

4 6. Remove the bolts, 1, that secure the hood to the adjustment shaft, 2.

2 1

19990083

5 7. Attach a lift to the hood using available hardware.

Raise the lift until it is snug to prevent the hood from sliding out of the front of the disc mower.

Remove the wood block.

CAUTION The hood is heavy. Do not attempt to lift it out of the machine alone. Use a lift or adequate manpower to prevent injury during removal and replacement.

19990085

6

39-3

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1 8. Remove the pivot bolt, washer and nut at 1, from both ends of the hood.

1 50005509

7 9. Using the lift and/or additional manpower, slide the hood over the flail rotor and out the rear of the machine.

10. Inspect the hood for wear or damage and repair or replace it as needed.

19990088

8 11. Inspect the hood liners for wear or damage. If necessary, replace the liners with the hood off the machine. This will ease liner installation.

19990082

9

39-4

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1

HOOD INSTALLATION 1. With the liners installed, lift the hood into the disc mower from the rear. The pivot end of the hood goes toward the front of the header.

CAUTION The hood is heavy. Do not attempt to lift it into the machine alone. Use a lift or adequate manpower to prevent injury during removal and replacement.

19990085

10 2. Line up the pivot bolt holes in the hood and frame, and install the pivot bolts, 1, with nuts and washers.

50005509

1 11

3. Block up the rear of the hood to line up the down stop bolt holes.

19990089

12

39-5

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1 4. Install the down stop bolts and spacers, 1.

1

19985249

13 5. Reattach the hood to the adjustment arm, 1, using the hardware taken off during removal at 2.

1

2

19990083

14 6. Raise the hood to the desired conditioning level by turning the crank, 1, counterclockwise.

Remove the wood block(s).

IMPORTANT: Do not allow the flails to strike the hood liner during operation. Adjust or repair the hood and/or liner if this occurs.

1

19985216

15

39-6

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1

HOOD LINER REMOVAL NOTE: The hood need not be removed to change the liners. However, the liners can be removed and reinstalled with the hood on or off the machine.

1. Turn the hood crank, 1, clockwise to set the hood in its highest position.

1

19985216

16 2. The hood liner comes in two sections. Each section is held in place with 12 bolts, six in the front and six in the rear. Remove the six bolts in the front of each section, 1.

19990091

1 17

3. Remove the six bolts from the rear of each section, 1.

CAUTION The hood liners are heavy. Use care in handling them to prevent injury.

4. Remove the liner sections from the machine.

19985249

1 18

39-7

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1

HOOD LINER INSTALLATION NOTE: The hood need not be removed to change the liners. However, the liners can be removed and reinstalled with the hood on or off the machine.

1. Secure the front of each hood liner section to front of the hood using six bolts with washers and flange nuts, 1.

19990091

1 19

2. Install the six bolts, 1, in the rear of each section.

Tighten all hood liner fasteners to specificaiton.

19985249

1 20

3. Lower the hood to the desired conditioning level and resume operation.

19985216

21

39-8

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

SECTION 55 - ELECTRICAL SYSTEM Chapter 1 - Implement Lights CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2 Trailing Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-4 Installing #9603575 Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-5 Trailer Connector Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-7 Lighting Control Box - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-8

55-1

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

INTRODUCTION The 1431/1432 pivot-tongue disc mower- conditioner is equipped with flashing amber lights, and red tail/brake lights to improve machine visibility and to warn operators of other vehicles.

1

2

2

1

A4899-12

1 The wire harness uses a 7-pin trailer connector, 1, which conforms to SAE J560 standard. A storage mount, 2, for the trailer connector is provided on the top of the tongue; press the connector into the mount and rotate the connector 1/4 turn to latch it in the mount.

2

1

1431-1-28

2

55-2

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

TRAILING LIGHTS The trailing lights as shown should be used when towing the mower-conditioner on a public road.

1

2

3

2

1

The trailing lights consist of two amber flashing lights, 1, attached to the trailframe spring towers, red tail/brake lights, 2, attached to the inside trailframe locations, and a lighting control box, 3, positioned on the tongue that controls the signals from the tractor to the mower-conditioner.

This lighting system is intended to improve the machine visibility on public roads and warn operators of other vehicles of your actions. This machine is equipped with a lighting system which conforms to ASAE S279.10.

NOTE: Left and right are determined by standing behind the unit, looking in the direction of travel.

55-3

19985205

3

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

DESCRIPTION

1

The 1431/1432 pivot-tongue disc mower- conditioner, (1431 -- Serial Number 638669 and above, 1432 -- Serial Number 634006 and above), uses a control box to manage the installed lighting system.

The lighting control box receives inputs of left and right turn signals, and brake lights from the tractor.

The red tail lamps are controlled directly by the tractor electrical system. The amber flashing lights and red brakes are controlled by the lighting control box.

2

3

Left

4

Right

19985205

4

Mower Conditioner’s Lights

Left Amber Outer Lamp, 1

Left Red Inner Brake Lamp, 2

Left Red Inner Tail Lamp, 2

Right Red Inner Brake Lamp, 3

Right Red Inner Tail Lamp, 3

Right Amber Outer Lamp, 4

Lights Off

Off

Off

Off

Off

Off

Off

Lights On

Off

Off

On

Off

On

Off

Brakes Only

Off

On

Off

On

Off

Off

Hazards/No Brakes

Flashing

Off

Off

Off

Off

Flashing

Hazards with Brakes

Flashing

On

Off

On

Off

Flashing

Left Turn/No Brakes

Flashing

Flashing

Off

Off

Off

On

Left Turn with Brakes

Flashing

Flashing

Off

On

Off

On

Right Turn/No Brakes

On

Off

Off

Flashing

Off

Flashing

Right Turn with Brakes

On

On

Off

Flashing

Off

Flashing

NOTE: The lighting control box is used to control the brake light and amber lamps circuits. The tail lamps are on only when the tractor park or road lights are on.

55-4

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 The 1431/1432 mower-conditioner trailing light wire harness uses a 7-pin trailer connector to connect the mower-conditioner to a tractor electrical socket which conforms to SAE J560.

For proper light function, this unit must be connected to a tractor incorporating an SAE standard 7-pin conductor electrical socket which conforms to SAE J560. If your tractor does not have a 7-pin conductor electrical socket, obtain a #9603575 connector socket from your New Holland Dealer.

INSTALLING #9603575 SOCKET Use the tractor wiring diagram or, if necessary, use a test light to identify the tractor wires. Connect the wires to the socket as follows: Pin

Connector ID

Attached To

1

White (WHT)

Ground wire, all lights

2

Black (BLK)

Not Used

3

Yellow (YEL)

Left side amber light

4

Red (RED)

Brake lights

5

Green (GRN)

Right side amber light

6

Brown (BRN)

Taillights

7

Blue (BLU)

Not used 19987865

5 Standard SAE J560 provides that the number 4 conductor (red wire) socket of the propelling vehicle is connected to the brake light circuit so that the brake lights activate when the brake pedal is depressed.

Most newer model New Holland tractors are wired to provide the brake light signal through the number 4 pin in the connector socket. Older model New Holland tractors and most competitive tractors do not provide this capability. On these tractors, the brake lights on trailing implements will not function; however, hazard, turn, and tail lamps will function.

55-5

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 NOTE: On some competitive tractors, the number 4 pin in the socket is utilized for other functions.

Therefore, this circuit may be on all the time or any time the key switch is on. This will cause the trailing implement brake lights to be on all the time.

If you have one of these tractors, the brake light circuit can be disabled by disconnecting the bullet connector located in the wire harness where it attaches to the lighting control box, 1.

CAUTION When you later reattach the machine to a standard electrical socket on propelling vehicle, the brake light circuit must be reconnected to function.

1 19994424

IMPORTANT: If this machine is to be transported on the highway, the propelling vehicle must be equipped with the appropriate electrical socket so that the brake lights function.

6

55-6

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

TRAILER CONNECTOR REPAIR 1. The trailer connector may be disassembled to service the electrical connections inside the connector. To disassemble the connector, loosen the clamping screw, 1, and remove the screw, 2.

1

2

1431-9-1

7 2. Grasp the end plug, 1, of the connector, and carefully pull it away from the body of the connector to expose the connections inside the connector. If the end plug does not pull easily away from the end of the connector, check the clamping screw, 2, to ensure it is loose enough, and push the clamping block away from the harness sheathing.

1

2 1431-9-2

8 3. The wires are held in the end plug by a clamp and screw, 1. To remove the wire from the end plug, loosen the screw, 1, until the wire can be slid out of the connector. To install a wire into the connector, ensure that the wire insulation is stripped off to expose approximately 1/4″ of the wire. Insert the bare end of the wire fully into the connector, and tighten the screw securely to retain the wire.

1

1431-9-3

9

55-7

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

1431-1-50

10 4. When installing the wires into the connector, ensure that they are properly positioned to provide correct functioning of the lights. The trailer connector is wired to conform to SAE J560 standard. Each wire is color coded and, in addition, has the circuit number printed on the insulation every 50 mm (2″) for identification. The end plug on the connector is labeled to assist in assembly.

LIGHTING CONTROL BOX REMOVAL AND INSTALLATION

2

1. Remove the four cap screws, 1, and nuts holding the guard to the frame.

2. Unplug the electrical connector, 2, from the control box.

3

3. Remove the two control box mounting cap screws, 3.

4. Set the control box against the mount and install the two mounting cap screws, 3.

20005568

5. Plug the electrical connector, 2, into the control box.

1

1 11

6. Secure the control box guard in place with four cap screws, 1, and nuts.

55-8

1431 -- Serial Numbers 638668 and below.

1432 - Serial Numbers 634005 and below.

MODEL 1431/1432 WIRING SCHEMATIC

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

12

55-9

1431 -- Serial Numbers 638669 and above.

1432 - Serial Numbers 634006 and above.

MODEL 1431/1432 WIRING SCHEMATIC

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

13

55-10

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

SECTION 58 - ATTACHMENTS/HEADERS Chapter 1 - Cutter Bar CONTENTS Section

Description

Page

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-2 Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-6 Knife and Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-7 Disc Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-8 7 Degree Twist Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-8 14 Degree Twist Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-8 V Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-8 Knife Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-9 Crop Lifter Replacement (Model 1431 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-11 Rock Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-12 Skid Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-12 Cutter Bar Inspection/Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-13 Top Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-16 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-17 Top Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-17 Cutter Bar Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-20 Cutter Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-22 Cutter Bar Bayonet Bushing - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-23 Cutter Bar Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-24 Cutter Bar Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-25 Disc Module - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-29 Disc Module - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-31 Cutter Bar Drive Shaft - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-35 Cutter Bar Drive Shaft - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-36 Cutter Bar Drive Shaft - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-38

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

SPECIAL TOOLS Tool Number

Description/Use

FNH23ET95

Top cap bearing cover

FNH01221-2

Cutter bar tie bolt holding tool

FNH01221-3

Cutter bar wrench

INTRODUCTION The Models 1431 and 1432 Discbine disc mower-conditioners use a 10 disc cutter bar to provide a 13′ cutting width. Discs #2 through #9 (numbered from left to right, as viewed from the rear) counter-rotate, while the outer two discs, 1, on each end of the cutter bar co-rotate (both spin in the same direction), and are each equipped with an open feed drum to help feed crop into the conditioner. The cutter bar is driven from both ends through drive shafts, 2, connected to the #2 & #9 discs.

2

2

A4896-5

1

1 1

The disc cutter bar is New Holland designed and produced, and is a true modular design. Gearbox modules, 1, are connected by independent, hardened alloy steel drive shafts, 3, running through spacer modules, 2, and the entire cutter bar is assembled using high strength tie bolts, 4, to clamp the disc modules between the spacers. In the unlikely event of catastrophic failure, damage is contained to one module, which can be easily replaced without disturbing other modules.

A3663-08

2

58-2

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 Each disc module is a separate gear case with its own oil sump, and utilizes precision forged gears for strength. Each module consists of a top cap assembly and a lower module assembly.

The top cap assembly consists of the top cap housing, a bevel gear shaft, a matched bearing set and a disc hub. The top cap assembly can be removed from the module for servicing, without disassembling the cutter bar.

The lower module assembly consists of the lower module housing and the pinion shaft and bearing assembly. Because the pinion shaft runs at 5400 RPM, steel slingers are mounted at each end to splash oil on the shaft seals for lubrication and cooling.

CBAR

3

The direction of rotation of the disc module is determined by the installation of the pinion shaft; if the pinion shaft is installed with the gear positioned on the right side of the housing, the disc will rotate clockwise. Installing the pinion shaft with the gear to the left will rotate the disc counterclockwise.

If a problem is found with a specific module, the extent of the damage can be quickly determined by removing the disc and the top cap assembly of the affected module. If damage is limited to the top cap assembly components, the lower module can be flushed out to remove contaminants, and a new top cap assembly installed to complete the repair.

The cutter bar uses small diameter, high profile discs, 1, which are 4.7 mm (3/16″) thick and hardened for long wear. The profile of the discs, combined with bolt-on lifters (1431 only), 2, provides aggressive feeding to the conditioner in difficult crop conditions.

The discs are equipped with 50.8 mm (2″) wide knives, 3, which are retained with 1/2″ bolts and hardened knife nuts. The knives are reversible for long life, and always have the beveled edge up. An arrow is stamped on both sides of the knife to show the direction of rotation. The knives can be easily changed in any position on the cutter bar.

58-3

1

2

2

1431-2-48

3 4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 Each disc module is protected by a ductile iron rock guard, 1, and a skid shoe, 2.

1

Skid shoes are 6.4 mm (1/4″) thick and 203 mm (8″) wide; they extend behind the module several inches for optimum flotation and extended wear life of the shoe.

All cutter bar components are interchangeable between the 600 Series disc mowers, 1411, 1412, 1431, 1432, and 2355 Discbine disc mower-conditioners, with two exceptions. The 615 and 617 disc mowers, because of the odd number of discs and the need for the end discs to be spinning inwards, have the #1 and #2 discs co-rotating; that is, they both spin in the same direction. This requires a slightly longer spacer and drive shaft between the #1 and #2 disc modules to eliminate interference between the knives on these two discs.

2

5000-11

5

The 1431 and 1432 use a longer drive shaft between the two end discs on each end of the cutter bar, which also co-rotate, and use a special spacer, 1, which is longer to accommodate the longer drive shaft. These longer spacers contain the bayonet arms, 2, for mounting the cutter bar to the header.

2

1

1431-6-1

6

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 The Model 1431 disc mower-conditioners, serial number 638668 and below, utilizes a large diameter drum, 1, around each drive shaft. The drum is mounted to the cutter bar drive module between the disc, 2, and drive shaft flange, 3. To remove the drum, the drive shaft must be unbolted from the drive module.

1

3

4896-12

2 7

Model 1431, serial number 638669 and above, and Model 1432 disc mower-conditioners use a smaller diameter drum, 1, around each drive shaft. The two halves of the drive are bolted together at 2, and to the drive shaft at 3. The drum can be removed from the drive shaft without removing the shaft from the drive module.

2

3

1

2

19991336

8

58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

DISCS Each time knives are replaced or turned, check the discs for damage and wear. If a disc is bent or cracked, replace it. When the leading edge, 1, of the disc wears thin, it can be used on an opposite rotating module to utilize the second face.

IMPORTANT: Do not make weld repairs to the discs, as this will affect disc strength and balance.

Remove discs by removing four bolts at 2.

4896-10

9 Reinstall discs at right angles to each other as shown. Position the notches in the towers to align with the slots in the disc. Be sure the correct hardware is installed as follows: Discs w/caps

1/2 x 1″ cap screws cupped lock washers

End discs & towers

1/2 x 1-1/4″ cap screws thick hardened washers

#2 & #9 discs, towers & drive shafts

1/2 x 1-3/4″ cap screws thick hardened washers

4896-11

10

IMPORTANT: Use of incorrect disc retaining hardware may cause cutter bar lock-up and potential damage, or may prevent proper retention of discs.

Torque retaining bolts to 113 N⋅m (83 ft.-lbs.).

NOTE: Do not over-tighten as bolts may yield.

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

KNIFE AND BOLT INSPECTION Inspect the cutter bar daily for damaged components. The quality of cut and safety of operation depends on regular inspection of the cutter bar.

Check the discs, knives, and hardware systematically for wear, damage or loose components.

Operating over rough terrain and rocky conditions can cause the knives to crack or deform leading to cutting problems, increase of safety risks, and possible cutter bar damage.

NOTE: Striking an object can cause knife hardware to loosen. If an obstacle is struck, STOP, check all hardware and retighten.

4896--10

11

The knives must be replaced or turned over to a new cutting edge on a timely basis to maintain good cutting performance. Dull knives will require more horsepower to cut the crop and will leave a ragged stubble.

Replace the knives if they are bent, severely worn, or if the hole is elongated. Replace the knife bolt if wear is found or the nut can be installed by hand.

Replace the knife nut if the shoulder or threads show wear.

NOTE: The knife bolts have a lock patch on them. If the knife nuts can be installed by hand, replace the bolt.

When a knife or securing hardware is in question, replace it.

WARNING Replace cracked or severely deformed knives immediately to prevent an accident.

If the cutter bar cannot be turned by hand due to crop buildup under the discs, start the tractor and operate the PTO at 1/3 rated speed for 30 seconds. Shut the tractor off and recheck. If the cutter bar still cannot be turned by hand, it will be necessary to remove the discs and clean out the material build-up.

58-7

19991314

12

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

DISC KNIVES New Holland has several disc mower and disc mower-conditioner knives available through Service Parts. Each type of knife is designed to function well in specific crop and field conditions. Contact your New Holland Dealer for the disc mower/mower-conditioner knife that will work best in your conditions.

1

2

3

7 DEGREE TWIST KNIVES The 7 degree twist knives, 1, are recommended for most cutting conditions. These knives function well in a wide range of field and cutting conditions. All Discbine disc mower-conditioners and disc mowers are shipped with these knives from the plant.

Clockwise Knife9847684 Counterclockwise Knife

19986850

13

9847683

14 DEGREE TWIST KNIVES The 14 degree twist knives, 2, are recommended in lighter crop conditions. A greater knife twist angle enables the knife’s cutting edge to cut closer to the ground while providing more lifting action to move the crop over the cutter bar into the conditioner, producing a cleaner cut in most light crop conditions.

However, because of the greater twist angle of the knife, these knives are more susceptible to rock damage.

Clockwise Knife86561093 Counterclockwise Knife

86561092

V KNIVES The V knives, 3, are recommended in rocky conditions where excessive knife bending is a concern. The V knife is to be installed with the concave side facing downward. This style knife has a greater resistance to bending when coming in contact with a foreign object. The cutting quality of this knife is not as good as with the twisted knives and will deteriorate with knife wear. However, they are more resistant to bending in rocky field conditions.

V Knife

86532078

58-8

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

KNIFE REPLACEMENT NOTE: Inspect the cutter bar for leaks or other needed repairs whenever performing service work on the bar. If a leak is found repair it immediately to prevent possible future failures.

IMPORTANT: Always replace both knives on a disc to maintain balance. Do not intermix old and new knives on a disc.

1. Remove the dirt around the knife bolt, 1.

4896-10

14 2. Block the discs in place with a hardwood block, 1, or install a bar through an end tower.

3. Remove the bolt with a socket as shown. If necessary hold the nut in place from the bottom with your hand. This will keep the nut from turning.

NOTE: If you are using an impact wrench use a bar to hold the nut in place, not your hand.

4. The knife and the nut can be removed from under the disc after the bolt is removed.

5. Knives can be turned over to use the opposite cutting edge after they become dull or nicked. All knives are angled. Knives are referred to as clockwise or counter- clockwise depending on which disc they are attached to.

58-9

1431-2-45

15

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

1431-CBAR

16 6. The leading edge of the knives must be lower than the rear edge. On the Model 1431 and 1432 mower-conditioners, the two end discs on each end of the cutter bar rotate in the same direction (co-rotate); all other cutter bar discs rotate in opposite directions (counter-rotate). Refer to the accompanying drawing as to which way the discs turn.

58-10

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 7. Install the nut through the knife and insert the nut, 1, into the bottom of the discs aligning it with the slot in the disc.

8. Reinstall the knife bolt and torque it to 159 Nâ‹…m (117 ft.-lbs.).

NOTE: After all knives are installed, turn the cutter bar by hand and check to be sure all knives are installed in the right direction and there is no interference.

1431-2-46

17

CROP LIFTER REPLACEMENT (MODEL 1431 ONLY) The crop lifters should be inspected daily for wear or damage. Replace the lifters, 1, when the sloping surfaces wear thin or wear through, or if the lifter is bent or cracked.

Replace the lifter by removing the knife bolt, 2, and the lifter bolt, 3. It will be necessary to slide a wrench under the disc to hold the flange nut on the lifter bolt.

Torque the bolts to 159 Nâ‹…m (117 ft.-lbs.).

4896-10

IMPORTANT: Replace both lifters on a disc to maintain balance. Do not make weld repairs to the lifters, as this will affect lifter strength and balance.

58-11

18

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

ROCK GUARDS Rock guards, 1, can be removed by removing bolts, 2.

1

Broken rock guards should be replaced immediately.

Rock guards which are worn thin should be replaced before they break.

2 5000-11

19

SKID SHOES Skid shoes can be removed by removing bolts, 1.

Reinstall the skid shoe by inserting the forward edge up into the rock guard, and lift the rear up to align the bolt holes.

1

NOTE: It may be easier to install the skid shoe by first loosening the rock guard mounting bolts, 2, Figure 4-19.

Broken skid shoes should be replaced immediately.

Skid shoes which are worn thin should be replaced before they break.

5000-09

20

58-12

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

CUTTER BAR INSPECTION/FAILURE ANALYSIS In the event of a failure of the New Holland modular disc cutter bar, it is important to properly inspect the unit to determine the extent of the damage. A thorough examination will help to locate all the damaged components, and minimize unnecessary repair labor. Often, it may not be necessary to remove and disassemble the cutter bar to repair or replace the failed components.

If a cutter bar failure is experienced, check the cutter bar components in the following sequence: A. Inspect the external components for damage, paying particular attention to the knives, 1, lifters, 2, and discs, 3. Broken knives and bent or cracked discs and lifters are a result of contact with solid foreign objects, and may indicate possible internal damage. A disc out of time may also indicate internal damage; the discs are properly timed when they are positioned 90° to each other as shown.

Misalignment or gaps between the disc modules and spacers may indicate the tie bolts are loose or broken, or the dowel pins between the components have failed or are missing.

2

A4896-11

3

1

3 21

B. Carefully grab both ends of each disc, and try to “rock” the disc up and down. A small amount of movement 1.52 mm (0.060″) is normal. An excessive amount of movement may be the result of a loose disc hub retaining bolt, or could indicate a worn top cap housing or bearings. Disc modules with excessive disc movement should have the disc retaining bolts, 113 N∙m (83 ft.-lbs.) and disc hub bolt, 203 N∙m (150 ft.-lbs.), or turn the bolt 90° after it has contacted the washer, checked for proper torque. Replace the disc hub retaining bolt if it has loosened. The bolt is equipped with a locking agent. If the bolts are tight, and movement still exists, the top cap assembly may need to be replaced.

WARNING The bottom leading edge of worn discs can become very sharp; wear gloves to prevent injury.

58-13

1431-2-60

22

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 C. Starting at the left end of the cutter bar, grab both the #1 and #2 discs, and slowly rotate both discs while applying pressure to one of the discs against the direction of rotation. If one disc suddenly moves, it may indicate damage to the gear teeth in that module.

Excessive free play between discs, or if one disc may be turned freely without the other disc moving, may indicate excessive wear or failure of the intermodule shaft. Some rotational free play 5 mm (3/16″) between adjacent discs is normal, as a result of the backlash in both gear sets.

1431-2-44

Check all disc modules by working gradually across the cutter bar, checking each disc to the next disc. In some cases, two adjacent modules may sustain damage from the same event, or there may be two separate failures on the cutter bar, involving modules in different locations.

23

D. After checking all disc modules for evidence of internal failure, remove the discs and top cap assemblies of any module with suspected damage. Inspect both the top cap assembly and the lower module assembly for bearing play or damage, and gear tooth damage.

Grab the pinion shaft, and rotate the adjacent discs to check for play in the intermodule shaft splines. If only the top cap assembly components are damaged, it is not necessary to disassemble the cutter bar further. Before installing the replacement top cap assembly, drain the oil, flush the lower module with a cleaning solvent to remove contaminants and install fresh API GL5 80W90 oil.

24

58-14

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 E. The cutter bar should only be removed from the machine and disassembled if it has been determined that the lower module components or the intermodule shafts are damaged.

Ensure that all disc modules were checked as per steps B, C, and D to determine which modules require removal for repair or replacement. Check the intermodule shafts on both sides of a failed disc module for worn or twisted splines.

The cutter bar should also be removed and disassembled if misalignment or gaps between the modules and spacers was noted in step A. Check the intermodule shafts and pinions shafts for excessive spline wear at any connection where the tie bolts were found to be loose or failed, or where misalignment occurred due to missing or failed dowel pins. Note that dirt will tend to work its way inside spacers where the tie bolts are loose.

NOTE: Following all of the above listed steps when inspecting a failed cutter bar, ensure all components are checked. Any worn or failed components should be identified prior to disassembly and repair of the cutter bar.

58-15

A4896-14

25

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

TOP CAP REMOVAL

1

1. Block the cutter bar discs in place with a hardwood block, or install a bar through an end tower to lock up the cutter bar, and remove the disc of the affected module by removing the four retaining bolts, 1, securing the disc and cover to the disc hub.

1

1431-2-48

26 2. Clean any material buildup from around the disc hub and top cap assembly.

1

3. With the cutter bar blocking still in place, remove the disc hub retaining bolt, 1.

19986023

27 4. Remove the hub, and remove any remaining material buildup on top of module and top cap assembly.

1

NOTE: Removing the disc hub will expose the upper bearing in the top cap assembly. Cover this area with a cloth, or use special tool #FNH23ET95 to prevent contamination from entering the bearing.

5. Remove the four retaining bolts, 1, and pry the top cap assembly off the lower module.

1 19991335

28

58-16

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

INSPECTION 1. Inspect the top cap assembly, 1, for excessive play in bearings, bearing damage, and gear tooth damage.

2. Inspect the lower module assembly, 2, for evidence of damage to pinion gear teeth or excessive shaft movement in any direction.

If the top cap assembly is damaged, but the lower module assembly is not, the lower module should be flushed out to remove any contaminants.

29 a. Drain the oil out of the module by removing the drain plug, 1, through access hole in skid shoe. After the oil has drained, flush out the lower module with a cleaning solvent. Use a magnet to remove any large pieces of debris from the lower module assembly. b. Apply sealant to the drain plug, and reinstall it in the lower module. Pour 300 ml (10 oz.) of API GL5 80W90 oil through the top opening into the lower module.

5000-9

1 30

TOP CAP INSTALLATION 1. Apply a thin bead of silicone sealant to the sealing flange of the new top cap assembly, 1, and position it on the lower module assembly with the breather facing to the right.

1 19985741

31

58-17

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 2. Apply silicone sealant to the end of the threads of the top cap retaining bolts, install them, and torque to 113 N⋅m (83 ft.-lbs.).

19985745

32 3. It is necessary to time the cutter bar discs during reassembly to eliminate interference between the knives. The discs are properly timed when they are 90° apart, as shown. The disc hub and top cap shaft splines are randomly cut, with no index marks.

1431-2-8

33 Apply a thin coating of grease to the seal lip and surface on disc hub. Slide the disc hub onto the top cap shaft; if it is not perfectly timed to the adjacent discs, remove the disc hub, rotate it 90° and reinstall it. Continue to do this until the disc hub is properly timed; one of the four positions will provide correct timing.

NOTE: With the adjacent discs positioned at 90°, the breather should be completely visible through the disc hub bolt hole, 2, when the hub is properly timed.

2

4. If the module has a hex head cap screw, discard this bolt and install a new 12-point bolt. Apply a small amount of silicone sealant to the end of the disc hub retaining bolt, 1, and torque it to 203 N∙m (150 ft.-lbs.), or turn the bolt 90 degrees after it has contacted the washer.

1

19986023

34

58-18

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 5. Install the disc assembly and cover. Torque retaining bolts, 1, to 113 N⋅m (83 ft.-lbs.).

1 1

1431-2-48

35 6. The disc timing is critical on the co-rotating end discs to prevent the knives from contacting each other during normal operation, and should be checked again after the discs are installed to ensure it is correct. Position the knives, 1, straight out from the discs, and rotate the discs by turning the inner disc, 2, in the direction of rotation until the knives are at their closest position at the front of the cutter bar. Measure the clearance, 3, between the knives.

1

1

3

1431-6-2

2 36

7. Continue to rotate the inner disc in the direction of rotation until the knives, 1, are at their closest position at the rear of the cutter bar. Measure the clearance, 2, between the knives; it should be within 3mm (1/8″) of the clearance measured at the front.

1

2

1

If the clearance is more than 5 mm (3/16″) different from the clearance measured at the front, the end disc and tower should be removed, and the end disc module retimed to the inner disc.

1431-6-3

37

58-19

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

CUTTER BAR REMOVAL On the 1431/1432, the cutter bar must be removed if a lower module assembly requires replacement or repair.

1. Raise the header and engage the transport locks. Install the pin, 1, to lock the hydraulic header tilt cylinder in the 2 degree position.

1

1431--2--19r

38 2. Block the cutter bar discs in place with a hardwood block, or install a bar through the right end tower to lock up the cutter bar. Remove the four retaining bolts, 1, securing the disc and cover to the disc hub of the defective module.

1

1

1431-2-48

39 3. Clean any material buildup from around the disc hub and top cap assembly as possible. With the cutter bar blocking still in place, loosen the disc hub retaining bolt, 1.

1

19986023

40

58-20

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 4. The tie bolts clamping the spacers to the disc modules are extremely tight, and are easier to loosen while the cutter bar is still clamped in the header frame. To gain access to the tie bolts, remove the rock guard and skid shoe from the defective module. Loosen the tie bolts by using the holding tools #FNH01221-2, 1, on one end of each tie bolt. Use wrench #FNH01221-3, 2, with a 3/4″ breaker bar to loosen the tie bolts 1/2 turn total by turning the front and rear nuts alternating one flat at a time.

41 5. Place a floor jack under each end of the cutter bar.

4896-14

42 6. Special nuts and bolts are used to retain the cutter bar on each end of the cutter bar. Remove the two nuts and slide the bolts, 1, out of the bayonet arms.

NOTE: If the bolts do not slide out easily, slightly raise or lower the cutter bar using the floor jacks.

1 A4896-16

43

58-21

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 7. Lower the floor jacks and roll the cutter bar out from under the header.

NOTE: The drive shafts will slide off and stay with the cutter bar.

A4831-16

44

CUTTER BAR INSTALLATION 1. Support the cutter bar with floor jacks positioned under each end.

2. Roll the cutter bar under the header, positioning the bayonet arms so that they line up with the slots in the header frame.

3. Raise the cutter bar with the floor jacks until the top of the drive shafts are even with the gearbox output and pedestal shaft.

4896-14

45 4. Line up the drive shaft splines with the gearbox output and pedestal shaft. Raise the cutter bar until the bayonet arms line up with the header frame mounts.

NOTE: It may be necessary to loosen one header drive belt so that the gearbox output shaft and pedestal shaft may be turned individually to align with the drive shaft yokes.

A4896-13

46

58-22

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 5. Position the cutter bar so that the rear bolt holes are lined up. Install the rear bolt, 1, through the mount and bayonet arm, and secure with the nut.

Install the nut with the tapered side facing towards the mount.

1

Raise or lower the front of the cutter bar as required to install the front bolt/nut, 2.

After all four mounting bolts are installed, torque the hardware to 271 N∙m (200 ft.-lbs.).

2

A4831-16

47

CUTTER BAR BAYONET BUSHING REPLACEMENT

1

1

1. To replace the cutter bar bayonet bushings, the cutter bar must first be removed from the unit; refer to “Cutter Bar Removal.”

2. Remove the snap ring, 1, from the bayonet arm.

19991333

48 3. Using a hammer and punch, evenly drive the bushing out of the bayonet arm by striking the outer race, 1, of the bushing. On older units, it may be necessary to grind two small notches, 2, in the bayonet arm using a die grinder to provide access to the outer race of the bushing. Drive the bushing out slowly to prevent damaging the bayonet arm.

1

2

NOTE: Do not drive against the inner ball of the bushing to remove it, or the bayonet arm will fracture and break.

2

19991334

49

58-23

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 4. Install the new bushing into the bayonet arm by driving against the outer race of the bushing.

Drive the bushing in slowly, ensuring that it does not cock sideways in the bayonet arm.

1

1

5. Reinstall the snap ring, 1, to retain the bushing.

19991333

50

CUTTER BAR DISASSEMBLY 1. If not already removed, remove the disc, rock guard and skid shoe from the defective module in order to gain access to the tie bolts. Loosen the tie bolts by using the holding tools #FNH01221-2, 1, on one end of each tie bolt. Use wrench #FNH01221-3, 2, with a 3/4″ breaker bar to loosen the front and rear nuts alternately a flat at a time until nuts can be turned freely by hand.

IMPORTANT: Do not loosen one nut completely as this will cause cutter bar to bow and may cause failure of the opposite tie bolt.

51

NOTE: If the tie bolts were not previously loosened with the cutter bar on the machine, it will be necessary to secure the cutter bar in some manner prior to attempting to loosen the tie bolts.

58-24

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 2. Slide the cutter bar apart far enough to allow removal of the disc module, 1.

A3997-10

52

CUTTER BAR REASSEMBLY 1. Prior to reassembly, remove the connecting shafts, 1, from both spacers, and apply special lubricant part# 9861804 to both ends of the shafts. Reinstall the connecting shafts.

A3997-10

53 2. It is necessary to time the cutter bar discs on either side of the replacement module during reassembly to eliminate interference between the knives. The discs are properly timed when they are 90° apart, as shown. Rotate the discs of the modules on either side of the replacement module so that they are timed to each other.

1431-2-8

54

58-25

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 3. Install the replacement module, 1, on one end of the cutter bar so that the connecting shaft splines into the pinion shaft, the tie bolts are properly positioned and the module housing fits onto the aligning dowels on the spacer.

A3997-11

55 It may be necessary to determine the direction of rotation of a replacement module prior to installing it in the cutter bar. Note that the pinion end of the lower module shaft has a groove, 1, in it to indicate which side of the module the pinion gear is on, which indicates the direction of rotation. If the groove (pinion) is on the right side of assembled module, module will rotate clockwise, while a module with the groove (pinion) on the left will rotate counter- clockwise.

A3655-2

56

1

4. Slide the cutter bar together so that the other connecting shaft splines into the pinion shaft, and the spacer aligning dowels engage the holes in the disc module. Ensure that the discs on either side of the replacement module remain timed to each other.

1

5. Install the nuts, 1, onto the tie bolts, and tighten finger tight, ensuring that the tie bolt threads protrude out of the nuts on both ends for full thread engagement in the nuts.

19991332

57

58-26

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 6. The tie bolts which connect the cutter bar together are torqued using the degree method of torquing, which requires a special procedure.

Install holding tools #FNH01221- 2, 1, onto the nuts on one end of each tie bolt. Then, using tool #FNH01221-3, 2, with a torque wrench, torque both tie bolts to 68 N⋅m (50 ft.-lbs.).

NOTE: Always torque or turn the rear tie bolt first.

7. Use a marker or scribe to mark the front and rear nut positions relative to the spacer. Using wrench #FNH01221-3 and a 3/4″ breaker bar, turn each nut 1/2 turn at a time to achieve one full turn on each tie bolt, starting with the rear tie bolt first.

This will give a total torque on the tie bolt of 68 N⋅m (50 ft.-lbs.) plus 1 turn, for a clamping force of 15870 to 16780 kg (35,000 to 37,000 Ibs.).

NOTE: It may be necessary to partially torque the tie bolts, mount the cutter bar assembly back onto the unit, and use a cheater bar to obtain enough leverage to complete tightening the tie bolts.

8. Remove special tools from the cutter bar; it may be necessary to use a hammer to knock the holding tools #FNH01221-2 off of the nuts.

58-27

58

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 9. The replacement module must be timed to the rest of the cutter bar by properly positioning the disc hub on the top cap assembly. The discs are properly timed when they are 90° apart, as shown. The disc hub and top cap shaft splines are randomly cut, with no index marks.

1431-2-8

59 Slide the disc hub, 1, onto the top cap shaft. If it is not perfectly timed to the adjacent discs, remove the disc hub, rotate it 90° and reinstall it.

Continue to do this until the disc hub is properly timed; one of the four positions will provide correct timing.

NOTE: With the adjacent discs positioned at 90°, the breather should be completely visible through the disc hub bolt hole, 3, when the hub is properly timed.

3

2 1

After determining the correct position, apply a thin coating of grease to the seal lip and sealing surface on disc hub, and carefully slide disc hub onto shaft past seal. Install a new disc hub retaining bolt, 2, and torque it to 203 N⋅m (150 ft.-lbs.), or turn the bolt 90 degrees after the bolt has contacted the washer.

10. Reinstall the rock guard, skid shoe and disc on the replacement module.

19986023

60

58-28

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

DISC MODULE - DISASSEMBLY 1. Remove the disc hub by removing the center retaining bolt, 1. It will be easier to remove the disc hub if the bolt is loosened prior to removing the module from the cutter bar. Clean off any material buildup on top of the module and the top cap assembly.

NOTE: Removing the disc hub will expose the upper bearing in the top cap assembly. Cover this area with a cloth, or use special tool #FNH23ET95 to prevent contamination from entering the bearing.

A3663-3

61 2. Remove the four retaining bolts and pry the top cap assembly, 1, off the lower module.

1

19985741

62 3. Pry the seals, 1, from each side of the lower module, using caution not to damage the shaft surface.

A3655-2

63

58-29

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 4. Use a pair of snap ring pliers to carefully remove the slingers, 1, on each end of the lower module shaft.

IMPORTANT: Use caution to prevent the tips of the slingers from contacting the sealing surface on the end of the shaft, or seal failure will occur.

5. Remove the snap rings from each side of the module.

A3654-13

64 6. Slide the lower module shaft, bearings and spacer washers out of the module housing. Note the orientation of the shaft in the housing prior to removing it, as this determines the direction of rotation of the disc module.

If module has not been previously repaired, a compression shim washer, 1, will be on the lower module shaft instead of individual shims.

NOTE: If the lower module shaft is to be reused, use a non-metallic abrasive pad to clean any dirt or corrosion from the sealing surfaces. Do not use emery cloth or steel wool as this will damage the sealing surface.

A3654-5

65

58-30

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

66

DISC MODULE - ASSEMBLY Disc modules can be assembled for clockwise or counterclockwise rotation of the disc. Before assembling a disc module it must be determined at which cutter bar location the disc module will be used to ensure it is assembled for proper rotation.

58-31

When looking at a disc module from the rear, a counterclockwise module will have the pinion gear on the left side, and a clockwise module will have the pinion gear on the right side. The direction of rotation of an assembled module can be determined by looking at the ends of the lower module shaft; the pinion end of the shaft has a shallow groove in the end to identify it.

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 The backlash of the assembled disc module is controlled by precision machining of the disc module and top cap housings, the use of precision forged gears, and the use of low tolerance bearings, which are manufactured to provide a specific “stack height,” or combined thickness. The backlash in the gear set should be 0.13 - 0.28 mm (0.005″ - 0.011″) after the module has been assembled.

If the back lash is found to be incorrect after module repair with new parts, recheck the module for correct assembly of all components.

NOTE: Each bearing for the pinion shaft is manufactured for a specific “stack height”. Do not mix old and new bearing components or substitute with “jobber” bearings.

1. Install a snap ring, 1, on the pinion side of module casting. Slide the bearing cup for the pinion side bearing into the housing bore against snap ring.

Note that the direction of rotation desired will affect which side of housing you start on. For example, install snap ring on right side of housing for clockwise rotation, and on the left side of housing for counter-clockwise rotation.

A3654-11

67 2. Support the module housing approximately 1/2″ above the work surface on blocks, a large piece of pipe as shown, or in an open vise. Position the snap ring and bearing cup down. Slide the assembled lower module shaft, 1, into housing, making sure pinion side is down against snap ring to orient properly for desired direction of rotation.

1

2

3. Install the bearing cup, 2, for the upper bearing cone into the housing. Place the two spacer washers, 3, on top of the bearing cup, and install the snap ring, 4, into the groove in the housing.

3

3

4

A3654-10

68

58-32

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 4. Check the end play of the pinion shaft with the pinion side facing down, to ensure an accurate measurement. Rotate the shaft two complete revolutions to seat all components (bearing rollers in cage), and install a dial indicator to measure shaft end play. Use a screwdriver or punch to pry upwards on the pinion gear to obtain an end play reading; allowable end play is 0.05 - 0.20 mm (0.002″ - 0.008″). Remove the snap ring and add the required thickness of shims between the spacer washers to achieve the correct end play.

NOTE: The shims must be sandwiched between two hardened washers to protect them from the bearing and the snap ring groove.

A3654-16

69

Recheck the end play as described above to ensure the assembled end play is correct.

5. Install an oil slinger, 1, into the groove on each end of the pinion shaft. Be careful not to scratch the sealing surface on the shaft as this will cause the shaft seal to leak, causing module failure.

The slingers are bidirectional in nature, and may be installed in either direction on the shaft.

IMPORTANT: Use caution to prevent the tips of the slingers from contacting the sealing surface on the end of the shaft, or seal failure will occur.

A3654-13

70 6. Apply grease to the sealing lip on the shaft seal, 1, and press them into place on each side of the housing.

NOTE: The seal must be pressed into place with a seal installing tool or suitable substitute. The seals must be flush with the side of the housing, and square to the shaft. If the seal is driven in with a hammer, it will be distorted and leak, causing disc module failure.

1 A3655-2

71

58-33

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 7. Apply silicone sealant to the threads of the drain plug and check plug, 1. Install them into the housing and pour 300 ml (10 oz.) of API GL5 80W90 gear oil through the top opening into the lower module.

A3655-1

72 8. Apply a thin bead of silicone sealant to the sealing flange of the new top cap assembly, and position it on the lower module assembly with the breather facing to the right. Apply silicone sealant to the end of the threads of the top cap retaining bolts, install them and torque to 113 N⋅m (83 ft.-lbs.).

Do not install the disc hub onto the top cap at this time, unless it is desired to check backlash. To check backlash, the disc hub must be installed and torqued to 203 N⋅m (165 ft.-lbs.) to seat bevel shaft against bearings and housing.

Acceptable backlash is 0.13 - 0.28 mm (.005″ .011″). If backlash is unacceptable, recheck assembly of the disc module.

19985741

73

58-34

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

CUTTER BAR DRIVE SHAFT - REMOVAL This Step Model 1431 (Below SN 638668) 1. Remove the four cap screws retaining the cutter bar drive shaft, tower and disc to the disc hub at 1. Lift the tower and drive shaft slightly to clear the disc hub bolt, and pull them forward so the upper end of the drive shaft slides off the splined shaft.

A4896-12

74 This Step Model 1432 and 1431 (Above SN 638668) 1. Remove the six cap screws, 1, retaining the tower to the cutter bar drive shaft.

1 1 1 1

19991336

75 2. Remove the four cap screws, 1, retaining the cutter bar drive shaft to the disc. Lift the drive shaft slightly to clear the star wheel, 2, and the disc hub bolt. Pull the drive shaft forward to allow the drive shaft to slide off the splined shaft.

1

19991337

1

2 76

58-35

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

CUTTER BAR DRIVE SHAFT DISASSEMBLY 1. The drive shaft contains two U-joints, which may be serviced individually.

1431-6-6

77 2. The U-joint bearing cups are retained with external-type snap rings, 1, positioned on the inner side of the yoke ears. Remove the snap rings by positioning a screwdriver against the open end of the snap ring, and give a light blow to the screwdriver to pop the snap ring off the bearing cup.

1

1

Remove the grease zerk, 2, from the one bearing cup.

NOTE: The grease zerk is oriented to line up with other grease zerks on the drive shaft. Note the positioning of the grease zerk prior to removal.

1 1431-6-7

78

58-36

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 3. Position the joint in an open vise, with each ear of one yoke supported by a vise jaw. With a soft hammer or mallet, strike the top ear of the unsupported yoke at 1. This will drive the top bearing outward approximately 8 mm (1/4″).

1

IMPORTANT: Do not use a hard faced hammer, as this may damage the edge of the bearing cup bore in the yoke, causing the bearing cup to hang up or seize in the yoke.

4. Pull the bearing out of the yoke ear. If necessary, grip the loosened bearing in a vise, and drive the yoke off the bearing by striking the yoke ear with the soft faced hammer or mallet.

1431-6-8

79

5. This same procedure should be followed to remove the bearing directly opposite the one just removed, after which the yoke itself may be removed.

6. To remove the remaining two bearings, support the cross in the vise, making certain the vise jaws are covered with brass protectors or the previously removed bearings are reinstalled on the cross. By striking the yoke ear, the bearings can be removed as per steps 4 & 5.

1431-6-9

80

58-37

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

CUTTER BAR DRIVE SHAFT ASSEMBLY 1. To reassemble the U-joint, position the cross, 1, in the yoke so that the bearing journals are positioned in each yoke ear. Insert the bearings in the outside of the yoke ears, and position the assembly in a vise. Press the bearings in until they are flush with the edge of the yoke.

1

2. Using a socket of the same diameter as the bearing, press the bearing into the yoke ear until the snap ring groove, 2, is exposed on the inside of the yoke ear. Install the snap ring over the bearing cup.

2 1431-6-10

81

3. Reposition the yoke and cross in the vise, and use the socket to press the opposite bearing fully into the yoke ear while rotating the cross to ensure it does not bind up. Continue to press the bearing into the yoke ear until the snap ring can be installed. It may be necessary to push the bearing in as far as possible with the vise, and then remove the yoke assembly and strike the yoke ears with a sharp blow from a hammer to spring the yoke enough to install the snap ring.

4. Assemble the second yoke to the cross repeating steps 1 to 3.

1

NOTE: The grease zerk, 1, should be oriented to line up with the other grease zerks, 2, on the drive shaft for ease of lubrication. Note the positioning of the bearing cup for the grease zerk during reassembly to ensure it aligns with the other grease zerks.

2

2

5. After complete assembly of the U-joint, strike the forged surfaces of all yoke ears with a sharp blow from a hammer. This will ensure proper seating of the bearings, and eliminate any possible tightness to ensure a free flexing joint.

1431-6-6

82

IMPORTANT: Use caution not to strike the bearing bore area of the yoke, as this will damage the bore and may cause premature cross bearing failure.

58-38

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 2

SECTION 58 - ATTACHMENTS/HEADERS Chapter 2 - Left Pedestal Shaft CONTENTS Section

Description

Page

Left Pedestal Shaft - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-2 Left Pedestal Shaft - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-4

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 2

LEFT PEDESTAL SHAFT DISASSEMBLY

1

2

1. Remove the hardware retaining the center, 1, and two left side shields, 2, and lift the shields off the unit.

1431-3-1

1 2. Remove the tension on the belt by loosening the jam nut and adjusting nut, 1, on the spring tension rod until the belt can be removed from the left side driven sheave.

1 1431-2-22

2 3. Remove the cotter pin securing the nut, 1, on the shaft. Block the cutter bar by inserting a bar through the cutter bar end tower and rotating the cutter bar until the bar contacts the side sheet.

Remove the nut from the shaft.

1

1431-3-2

3

58-2

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 2 4. The sheave is keyed to the shaft using a woodruff key, and is seated on a straight taper on the shaft.

Install a three jaw puller so that the legs of the puller are engaged on the center hub of the sheave. Tighten the puller, and hit the underside of the sheave with a hammer to “pop� it off the shaft.

1431-3-4

4 5. Remove the three flange nuts, 1, and carriage bolts at the lower bearing, and the four flange nuts, 2, and bolts retaining the upper bearing plate. Lift the pedestal shaft and bearing assembly up out of the header frame; the shaft will lift out of the cutter bar drive shaft.

2 2

1 1431-3-6

5 6. Disassemble the shaft and bearing assembly on the bench by cleaning any paint and crop residue from the ends of the shaft. Remove the bearing lock collars, 1, by loosening the set screws, and driving the lock collars away from the direction of rotation until they loosen up. Remove the lower bearing, 2, lock collar and remaining flangette by sliding them off the bottom of the shaft.

Remove the woodruff key from the keyway in the top of the shaft. Slide the upper bearing lock collar off the top of the shaft. Remove the three flange bolts and nuts, 3; remove the flangettes, bearing and bearing plate from the shaft.

2 3

1 1 1431-3-9

6

58-3

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 2

LEFT PEDESTAL SHAFT - ASSEMBLY

4

1. Loosely install the upper and lower bearings in the header frame, as follows:

2

Position the lower bearing in the flangettes with the locking flange of the bearing facing up, and the flangette with the grease zerk positioned on top. Place the bearing and flangette assembly, 1, in the header frame, and install three carriage bolts through the flangettes and header. Position the antiwrap shield, 1, Figure 3-9, over the carriage bolts under the header, and install the nuts snugly. Do not tighten the hardware, as it will allow the bearing to easily align when installing the shaft.

Position the flangette with the grease zerk onto the mount plate, 2, so that the mounting holes align. Position the mount and flangette on the header frame so that the grease zerk faces the forward outside corner, 3, and it is accessible with the shielding installed. Install the mounting plate hardware snugly; do not tighten.

Install the bearing with the locking flange facing upwards, position the remaining flangette and secure loosely with three flange bolts and nuts, 4.

3

1431-3-10

1 7

2. Insert the splined end of the shaft, 2, down through the top bearing, slide the locking collar for the lower bearing over the shaft, and continue sliding the shaft down through the lower bearing.

Align the splines with the cutter bar drive shaft, and allow the shaft to drop down until it contacts the bearing cross, 3. Install the upper bearing lock collar over the shaft onto the bearing flange.

Lift the shaft up until it is flush with inside of drive shaft yoke bore and seat the upper bearing lock collar snug enough to hold the shaft in place. This will provide a starting point for sheave alignment.

1 2 3

1431-3-12

8

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 2 3. Install the woodruff key into the keyway in the shaft, and drop the driven sheave, 1, on the shaft; ensure both the taper on the shaft and the bore in the sheave are clean of paint or debris. Install the retaining washer and nut, and torque the nut to 203 N⋅m (150 ft.-lbs.). After torquing the nut, continue turning the nut until it lines up with the hole in the shaft. Install the cotter pin to secure the nut.

1

1431-3-3

9 4. Adjust the shaft so the center rib of pulley, 1, is the same height from the deck as the center pulley.

Check this dimension at four different locations to make certain the pulley is square with the deck.

Seat both lock collars on the bearing lock flanges and tighten the collars in the direction of rotation (clockwise as viewed from the top of the shaft).

1

19986003

10 To double-check the sheave alignment, tie a string to the right side idler bracket, and stretch it over the drive, 1, and left side driven, 2, sheaves; use the string to check the alignment of the sheaves. Raise or lower the left pedestal shaft in the bearings if necessary until the sheave is aligned within 1.6 mm (1/16″).

Recheck the shaft spline engagement in the cutter bar drive shaft yoke; the shaft splines should be fully engaged in the yoke. If not, recheck for correct shaft assembly, or for wear in the cutter bar attaching arm bushings.

Tighten all bearing mounting hardware; ensure the anti-wrap shield is not contacting the shaft when tightening the lower bearing hardware.

58-5

1

2

(305 mm) 12″

1431-3-14

11

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 2 5. Slide the belt under the shielding supports, and install it on the sheaves. Tighten the belt tensioner adjusting nut, 1, until the spring length matches the length of the gauge, 2. Tighten the jam nut to secure.

6. Reinstall the shielding on the unit; position the center shield under the left and right middle shields, and the left end shield under the middle left shield. Install all hardware loosely to ensure a proper fit-up before tightening retaining bolts.

2

1

1431-2-22

12

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

SECTION 58 - ATTACHMENTS/HEADERS Chapter 3 - Gearbox (Center Pivot) CONTENTS Section

Description

Page

Center Pivoting Gearbox - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-2 Center Pivoting Gearbox - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-10 Center Pivoting Gearbox - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-10 Gearbox Support Plate Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-21 Center Pivoting Gearbox - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-22 Guidance Link Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-25

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

CENTER PIVOTING GEARBOX REMOVAL

2

NOTE: It is easier to remove the gearbox with the tongue positioned on the right side of the header and the header lowered .

1. Remove the steering linkage by removing the two 1/2″ x 2-1/4″ bolts, 1. The guidance link can then be slid out of the channel on the tongue.

3 1

Remove the shielding, 2, over the slip clutch by removing the four retaining bolts, 3. Lift the shielding off the center gearbox channel.

1431-1-41

1 2. Loosen the two cap screws, 1, and locknuts on the clamp hub at the rear of the slip clutch.

Loosen the cap screw, 2, inside the slip clutch yoke, but do not remove it from the shaft. Tap the rear of the clutch housing with a soft faced hammer to remove it from the taper on the gearbox shaft; the center retaining bolt will prevent the clutch from falling off the shaft.

1

3. Remove the center retaining bolt, 2, and slide the clutch assembly off the center gearbox input shaft. With both sections of the secondary drive shaft supported, slip the drive shaft apart to remove the slip clutch and rear section of the drive shaft.

2

1431-1-43

2

IMPORTANT: The slip clutch end of the secondary PTO shaft is very heavy and awkward; use caution not to drop the shaft assembly as personal injury or damage to the clutch may result.

58-2

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 4. Remove the hardware retaining the center and middle left shields, and remove the shielding from the unit.

Remove the channel, 1, from the gearbox by removing the four 1/2″ x 1″ G8 retaining bolts at 2.

NOTE: Do not mix the channel mounting bolts with other hardware; the channel mounting bolts are Grade 8 bolts, and must be reinstalled with the channel.

2 1

1431-G26

3 5. Remove the tension on the left side belt by loosening the jam nut and adjusting nut, 1, on the spring tension rod until the belt can be removed from the center sheave. Repeat the process on the right side belt spring tension rod so that the right side belt may be removed from the center sheave.

1

1431-2-22

4 6. The belts can be removed by rolling them off the center pulley assembly. Remove the cotter pin and nut at, 1, that retain the sheave to the gearbox shaft. Use a puller to remove the pulley assembly, 2.

1

2

1431-G24

5

58-3

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 7. Remove the woodruff key, 1, from the output shaft of the gearbox. Remove the four 1/2″ x 1 1/2″ flange bolts at 2, that hold the gearbox support, 3, in place, and carefully lift the support off the gearbox. Remove the plastic thrust washer from the neck of the gearbox.

3

NOTE: There are shims used between the upper and lower support plates for the gearbox at 4; note the location and quantity of these shims for reassembly.

1

2 2 4 1431-G9

6 8. The gearbox assembly, 1, can now be lifted from the lower support plate; remove the plastic thrust washer from the lower neck of the gearbox, and set it aside.

1

1431-G6

7

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

CENTER PIVOTING GEARBOX DISASSEMBLY NOTE: During disassembly keep track of location and number of all shim packs. Use the same shim packs during re-assembly.

1. Remove the input shaft bearing cap, 1, by removing the eight cap screws; pry the cover off the gearbox.

1

A4836-5

8 2. Remove the input shaft from the gearbox.

1431 -- SN 650152 and below 1432 -- SN 639638 and below • Remove the M10 x 22 cap screw, 1, and washer that retains the bearings and gear to the shaft. After the cap screw is removed, use a hydraulic press to push off the gear, 2, and the bearing, 3. Remove the key in the shaft and push off the bearing, 4, shims, and washer.

2 3

4

1 A4834-2

9

58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 1431 -- SN 650153 and above 1432 -- SN 639639 and above • Set the shaft in a hydraulic press and remove gear, 1, and bearing, 2. Capture all shims behind the bearing. Turn the shaft over, and remove bearing, 3. Capture all shims behind the bearing.

2

1 3

20001699

10 3. Remove the eight bolts retaining the output shaft bearing cap, 1. Pry the bearing cap off the gearbox. Lift the output shaft out of the gearbox until the lower bearing, 2, is pulled completely out of its bore in the gearbox.

1

2 1431-G19

11 4. Slide a long punch through the gearbox past the output shaft lower bearing, and use a hammer to drive the plug, 1, from the bottom of the gearbox housing.

NOTE: Use caution to prevent damage to the shims when driving the plug out of the gearbox.

Remove the retaining ring, 2, and shims, 3, from the gearbox housing.

Position the output shaft against the inner structure of the gearbox, and use a hammer and punch to drive output shaft out of the lower bearing, 4. The output shaft may now be removed from the gearbox.

4

3

2

1

A4833-1

12

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 5. Position the output shaft assembly in a press, supporting it under the gear.

Press the gear, 1, spacer, 2, and the bearing, 3, off the end of the shaft.

NOTE: The gear, spacer and the bearing are pressed off in the direction of the arrow.

3

1

2

A4835-15

13 6. Remove oil seal ,1, from output shaft bearing cap, 2. Remove snap ring, 3, and shim pack, 4.

The bearing cup can then be removed from the output shaft cover, 2. The remaining bearing cup can now be removed from the gearbox assembly.

1

2

3

4

5

A4833-2

14

58-7

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 1431 -- SN 650152 and below 1432 -- SN 639638 and below

22

10

25

3

23 18

20

9

5 22

1 7

5

8

11

16

3

12 21 6

9

24

4 17

13

11

4 2

14

19

12

12

15

50005572

15 Parts identification 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

Shaft Seal Snap Ring Bearing Key Pinion Cover Crown Wheel Shim Kit Breather Washer Bolt

58-8

Bearing Shim Kit Seal Shaft Cover Bearing Cap Elbow Blank Washer Pipe Plug Casing Shim Kit Plate

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 1431 -- SN 650153 and above 1432 -- SN 639639 and above

16

3

15

20

13 12 10

16

14

7

19

4 6

10

8

4 1

5

3 18

17

11 3

8 2

4

9

9

2

50005570

16 Parts identification

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Shaft Seal Snap Ring Shim Kit Cover Crown Wheel Cover Bearing Bolt Key

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

58-9

Pinion Breather Elbow Shaft Casing Plug Shim Kit Bearing Cap Bearing

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

INSPECTION 1. Discard the shaft seals and plug, 19, Figures 15 and 16. Replace any worn or pitted bearings.

Replace all bearings if gearbox is contaminated with debris from an internal failure.

2. Clean all parts thoroughly.

3. Inspect all keyways and splines for damage.

Replace any damaged or worn shafts.

4. Inspect all gears and gear teeth for damage and wear. Replace any worn or damaged gears.

5. Inspect the gearbox housing and all bearing end caps for wear or cracks. Replace any worn or damaged parts.

CENTER PIVOTING GEARBOX ASSEMBLY

2

1. Assemble the input shaft: 1431 -- SN 650152 and below 1432 -- SN 639638 and below • Install the straight key, 1, into the keyway on the input shaft, and press the large gear, 2, onto the shaft over the key; orient the gear so the gear teeth face the shouldered end, 3, of the shaft after it is installed. Push the gear onto the shaft until it is just past the shoulder on the shaft.

3

A5036-9

1 17

Install the washer, 1, and original shim pack, 2, over the end of the shaft against the shoulder. Press the bearing, 3, onto the shaft until it is tight against the shim pack, washer and shoulder on the shaft.

NOTE: It will be necessary to use a pusher pipe of appropriate size to press the bearing onto the shaft, as the shaft will protrude out past the seated bearing. •

3

2

1

A5036-14

18

58-10

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 •

Install the spacer, 1, and original shim pack, 2, for the outer bearing over the shaft against the gear. Slide the outer bearing, 3, over the end of the shaft.

1

3

2 A5037-4

19 Support the shaft and gear assembly in a press on the pusher pipe, 1, used to press on the inner bearing. Use a long piece of pipe to press the outer bearing cone, 2, onto the shaft against the gear, 3. Continue to press the outer bearing cone and gear downwards until they are securely seated against the inner bearing cone, shim pack and washer.

NOTE: Failure to securely seat all components together may result in gearbox failure.

•

2 3

A5037-3

1 20

Install the cap screw, 1, and washer into the inner end of the shaft, and torque to 60 - 70 N⋅m (44 - 52 ft.-lbs.).

NOTE: The cap screw and washer will seat against the end of the shaft, and not the bearing cone. The cap screw and washer simply guard against the possibility of the shaft being removed from the assembled gearbox.

•

1

A4834-2

21

58-11

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 1431 -- SN 650153 and above 1432 -- SN 639639 and above

2

Set the key into the keyway of the input shaft.

Orient the gear so the gear teeth face away from the spline end of the shaft. Press the large gear onto the shaft over the key until it is seated against the shoulder.

• Slide the original shim pack, 1, over the end of the shaft against the gear. Press the inner bearing, 2, onto the shaft until it is tight against the shim pack.

• Slide the washer over the shaft, and set against the shoulder. Press the outer bearing, 3, onto the shaft until it is tight against the washer.

NOTE: Failure to securely seat all components together may result in gearbox failure.

1

•

3

20001699

22

Install the bearing cup, 1, into the gearbox housing inner web, and into the input shaft bearing cap.

NOTE: Do not install a shaft seal in the bearing cap at this time.

•

1

1431-G22

23 2. Install the input shaft assembly into the gearbox housing, and install the bearing cap, 1, using four cap screws equally spaced around the cap; torque the cap screws to 60 - 70 N⋅m (44 - 52 ft.-lbs.). Rotate the shaft assembly a minimum of two full turns to seat the bearing rollers, and then push and pull on the shaft to determine if the shaft has any end play. If no end play is detected, install a 1/2″ cap screw into the end of the input shaft, and use an inch pound torque wrench to measure the input shaft rolling torque. The rolling torque should be 6 - 9 kg. cm. (5 - 8 in. lbs.).

1

A4834-4

NOTE: Make two complete revolutions of the input shaft to seat the bearing rollers before measuring the rolling torque.

24

58-12

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 3. Adjust input shaft rolling torque: 1431 -- SN 650152 and below 1432 -- SN 639638 and below • If the input shaft assembly is determined to have end play or insufficient rolling torque, it will be necessary to disassemble the input shaft, and add shims between the inner bearing, 1, and the shoulder on the shaft.

• If the input shaft was determined to have an excessive amount of rolling torque, it will be necessary to disassemble the input shaft, and remove shims between the inner bearing, 1, and the shoulder on the shaft.

NOTE: Do not add or remove shims between the outer bearing, 2, and spacer, as this will affect the gear position in the gearbox.

2 1 A4834-2

25

1431 -- SN 650153 and above 1432 -- SN 639639 and above •

•

•

•

If the input shaft assembly is determined to have end play or insufficient rolling torque, it will be necessary to add shims between the snap ring and bearing cup in the input shaft housing.

If the input shaft was determined to have an excessive amount of rolling torque, it will be necessary to remove shims between the snap ring and bearing cup in the input shaft housing.

The shims used in the gearbox are available in 0.012″, 0.016″, and 0.020″ thicknesses.

The shim pack thickness can be changed in 0.004″ increments by removing a shim and installing the next size thicker shim to increase rolling torque or next size thinner shim to decrease rolling torque.

Repeat steps 2 and 3 until the input shaft is properly adjusted. Once adjusted, remove the bearing cap and input shaft, and set aside.

58-13

20001697

26

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 4. Assemble the output shaft by installing the key into the keyway in the shaft; press the pinion gear, 1, onto the shaft over the key until it is seated against the shoulder on the shaft. Pack the upper output shaft bearing with grease prior to installation. Install the spacer, 2, over the shaft against the gear, and press the bearing, 3, onto the shaft against the spacer.

1

2

3

1431-G20

27

5. Install the snap ring, 1, into the output shaft bearing cap. Position the original shim pack, 2, against the snap ring, and install the bearing cup, 3, in the bearing cap.

NOTE: Do not install a shaft seal in the bearing cap at this time.

1

2

3

A4833-2

28

58-14

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 6. Insert the output shaft assembly into the gearbox housing, and support the entire assembly on the pusher pipe, 1, used to press the bearing and pinion gear onto the output shaft. Position the lower output shaft bearing, 2, into the housing, and drive the bearing over the end of the output shaft. Ensure the bearing is seated against the shoulder on the shaft.

2

NOTE: The lower output shaft bearing is a slip fit in the housing, and a press fit on the output shaft. Drive against the inner race of the bearing to prevent damage to the bearing.

1 A5037-10

29 7. Install the snap ring, 1, and original shim pack, 2, in the housing.

2 1 1431-G17

30

58-15

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 8. Apply sealant to the flange of the output shaft bearing cap, 1, and install it onto the gearbox over the output shaft. Install the 8 cap screws, and torque to 60 - 70 N⋅m (44 - 52 ft.-lbs.). Rotate the output shaft two full revolutions to seat the bearing rollers. Install a dial indicator on the end of the output shaft, and pull on the shaft to measure the end play. Add or remove shims, 2, Figure 30, as necessary to obtain 0 - 0.05 mm (0 - 0.002″) of end play on the shaft.

1

NOTE: Make certain the shaft does not have any preload on it, or bearing failure may result.

1431-5-2

NOTE: Do not add or remove shims between the bearing cup and snap ring in the output shaft bearing cap, as this will affect the gear position in the gearbox.

31

9. Apply a bluing compound to the gear teeth of the pinion gear, 1, and the input gear, 2. Install the input shaft assembly into the gearbox, and retain the bearing cap using four cap screws, torqued to 60 - 70 N⋅m (44 - 52 ft.-lbs.).

1

While holding the output shaft to apply a load to it, rotate the input shaft counterclockwise several revolutions, as viewed from the end of the shaft.

This will seat the bearing rollers, and will also mark the gear contact pattern in the bluing compound on the gear teeth.

2 A5038-5

32 10. Install a dial indicator onto the gearbox, so that the indicator stem is engaged against a spline on the input shaft. While holding the output shaft securely against rotation, rotate the input shaft back and forth to measure the backlash between the gears. The proper backlash reading at the input shaft splines is 0.002″ to 0.004″; this indicates a true backlash of 0.008″ to 0.018″ between the gears.

11. Remove the input shaft from the gearbox, and check the gear contact pattern on the gears; the contact pattern should be 40% central-toe, as shown in Figure 36.

1431-5-3

33

If the backlash was found to be incorrect, or if the contact pattern is not located properly, the gearbox will need to be reshimmed.

58-16

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 1431 -- SN 650152 and below 1432 -- SN 639638 and below

OUTPUT

B

C

A

INPUT

D 1431-G70

34 Backlash Adjustment To adjust backlash, move shims from one end of the input shaft to the other. To increase backlash, move shims from A, between the outer bearing cone and gear, to B, between the inner bearing cone and the shoulder. To decrease backlash, remove shims from B, and install them at A. The shims used in the gearbox are available in 0.012″, 0.016″ and 0.020″ thickness’; shifting the input shaft 0.004″ will change the backlash between the gears approximately 0.0024″. To shift the shaft 0.004″ inwards (to decrease backlash), remove a 0.020″ or 0.016″ shim at B, and substitute the next size smaller shim, and then remove a 0.012″ or 0.016″ shim at A, and substitute the next size larger shim.

NOTE: Because the shims used at each end of the input shaft are different in diameter, use caution to keep track of the shims used, so that the shaft preload adjustment does not change.

58-17

1431-5-5

35

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 1431 -- SN 650153 and above 1432 -- SN 639639 and above

A

C

B

20005571

D 36

Backlash Adjustment To adjust backlash, move shims from one end of the input shaft to the other. To increase backlash, move shims from A, between the outer bearing cone and snap ring, to B, between the inner bearing cone and the gear. To decrease backlash, remove shims from B, and install them at A. The shims used in the gearbox are available in 0.012″, 0.016″ and 0.020″ thickness’; shifting the input shaft 0.004″ will change the backlash between the gears approximately 0.0024″. To shift the shaft 0.004″ inwards (to decrease backlash), remove a 0.020″ or 0.016″ shim at B, and substitute the next size smaller shim, and then remove a 0.012″ or 0.016″ shim at A, and substitute the next size larger shim.

1431-5-5

37

NOTE: Because the shims used at each end of the input shaft are different in diameter, use caution to keep track of the shims used, so that the shaft preload adjustment does not change.

58-18

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 Gear Contact Pattern To adjust the gear contact pattern, move shims from one end of the output shaft to the other, to reposition the pinion gear.

If the contact pattern is high (towards the top of the tooth) on the pinion, 1, and low (towards the root of the tooth) on the gear, 2, remove shims from C, Figures 35 or 36, between the snap ring and bearing cup, and add them at D, between the ball bearing and the snap ring, to move the pinion out of mesh with the gear.

1

2

1431-5-5

38 If the contact pattern is low on the pinion, 1, and high on the gear, 2, remove shims from D, Figures 35 or 37, between the ball bearing and snap ring, and add them at C, between the snap ring and the bearing cup, to move the pinion further into mesh with the gear.

The shims used on the output shaft are the same on both ends, and are available in 0.012″, 0.016″ and 0.020″ thicknesses. To shift the pinion 0.004″ inwards (to increase mesh), remove a 0.020″ or 0.016″ shim at D and position it at C, and move the next size smaller shim (0.016″ or 0.012″) from C to position D. Use the opposite of this process to move the pinion out of mesh.

Repeat as necessary until the back lash and gear contact patterns are correct.

12. Remove the input shaft bearing cap, 1, from the gearbox, and drive a new shaft seal, 2, in flush with the outer face of the bearing cap. Apply sealant to the flange of the bearing cap, and reinstall it over the input shaft on the gearbox.

Install the eight cap screws, and torque them to 60 - 70 N⋅m (44 - 52 ft.-lbs.).

Slide the output shaft seal, 3, over the output shaft, using caution to prevent rolling the seal lip outwards; carefully drive the seal into the bearing cap until flush with the outer face.

Drive a new plug, 4, into the bottom of the gearbox until flush with the housing.

Apply sealant to the drain plug, and install it in the gearbox housing, if previously removed.

58-19

2

1

1431-5-5

39

4 1 3 2 A5038-11

40

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 13. Fill the gearbox with fresh API GL5 80W90 gear oil to the level plug. Add oil through the breather.

Model 1431 SN 650152 and below Model 1432 SN 639638 and below 2000 ml (68 oz.)

Model 1431 SN 650153 and above Model 1432 SN 639639 and above 2200 ml (75 oz.)

A

C

B

20005571

D 41

58-20

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

GEARBOX SUPPORT PLATE BUSHING REPLACEMENT

1

Prior to installation of the center pivoting gearbox, inspect the condition of the bushings, 1, in the upper and lower support plates. If the bushings are worn excessively, or are a loose fit on the hubs of the gearbox, they must be replaced.

On the lower support, pull the bushing out of the hub on the support plate. Install the new bushing so that two of the grease holes are positioned an equal distance away from the grease zerk hole; drive the bushing in flush with the top of the hub. The bushing holes should be lined up with the grease groove in the hub.

1431-G14

42

NOTE: Do not position a bushing hole over the grease zerk hole, as this will prevent grease from being evenly distributed around the diameter of the gearbox hub.

On the upper support, pull the bushing, 1, and the seal plate, 2, out the bottom of the hub on the support plate. Inspect the seal plate for wear or damage to the inner diameter; replace it if any wear is noticed.

Position the seal plate, 2, in the hub against the shoulder, and install the new bushing so that two of the grease holes are positioned an equal distance away from the grease zerk hole. Drive the bushing in flush with the bottom face of the hub. The bushing holes should be lined up with the grease groove in the hub.

NOTE: Do not position a bushing hole over the grease zerk hole, as this will prevent grease from being evenly distributed around the diameter of the gearbox hub.

58-21

2

1

1431-5-1

43

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

CENTER PIVOTING GEARBOX INSTALLATION

2

1. Position the gearbox lower support plate, 1, over the weld nuts in the header frame, and install the original shim packs, 2, on the lower support plate.

It may be necessary to apply a small amount of sealant to the shims to keep them in place during gearbox installation.

1 A5033-10

44 2. Install a plastic thrust washer over the lower neck on the gearbox, and set the gearbox in place on the lower support plate. Install another plastic thrust washer over the upper neck on the gearbox, and position the upper support plate over the gearbox. Install the four 1/2″ x 1-3/4″ cap screws, and torque to 113 N⋅m (83 ft.-lbs.).

The gearbox must be free to pivot with a force of 14 - 68 N⋅m (10 - 50 ft.-lbs.) applied against the end of the input shaft, but the gearbox must have no end play between the upper and lower support plates. Use a pry bar under the gearbox to determine if any end play exists; if so, shims must be removed between the upper and lower support plates.

A5033-6

45

When there is no end play detected, install a 1/2″ cap screw, 1, partially into the end of the input shaft. Hook a spring scale over the cap screw, and measure the force required to rotate the gearbox; it should be between 14 - 68 N⋅m (10 50 ft.-lbs.). If the force required to rotate the gearbox is excessive, shims must be added between the upper and lower support plates.

1 A5033-12

46

58-22

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 3. Install the woodruff key into the keyway on the output shaft, and apply a permanent lubricant to the end of the shaft. Position the pulley, 1, down over the shaft and key, and install the washer and castellated nut, 2, on the end of the shaft. Tighten the nut to 203 N⋅m (150 ft.-lbs.). Hit the sheave inner hub with a sharp blow from a soft faced or dead-blow hammer to ensure the sheave is fully seated on the taper on the shaft, and retorque the nut. Install the cotter pin to secure the nut.

4. Install the right side drive belt, 3, in the lower set of grooves on the center sheave; tighten the right side belt tensioner adjusting nut until the spring length matches the length of the gauge. Tighten the jam nut to secure.

5

1

2

1431-2-33

4

3

47

Reinstall the left side belt, 4, on the center sheave. Tighten the left side belt tensioner adjusting nut, 5, until the spring length matches the length of the gauge. Tighten the jam nut to secure.

5. Reinstall the channel, 1, to the gearbox using four 1/2″ x 1″ Grade 8 cap screws; torque the cap screws, 2, to 159 N⋅m (117 ft.-lbs.). Reinstall the center and left side shielding on the unit using the previously removed hardware; position the center shield under the left and right middle shields. Install all hardware loosely to ensure a proper fitup before tightening retaining bolts.

2

1 A5032-9

48

58-23

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 6. Slide the slip clutch onto the center gearbox input shaft as far as possible. Thread the bolt, 1, inside the slip clutch hub into the end of the shaft, and tighten as much as possible to pull the slip clutch hub securely onto the tapered end of the gearbox shaft. Tighten the two 1/2″ x 3″ Grade 8 cap screws, 2, and locknuts to 87 N⋅m (64 ft.-lbs.).

2

1

NOTE: Do not overtorque; locknuts are Class C, and are limited to 87 N⋅m (64 ft.-lbs.).

1431-1-43

49 7. Reinstall the shield, 1, over the slip clutch and secure using the four bolts previously removed.

Position the shield so that the access hole is forward.

1 5

3 4 1431-1-41

2 50

8. Slide the plate, 1, on the end of the guidance link into the plastic slides on the tongue. Position the clevis end of the guidance link, 2, Figure 51, over the end of the center pivoting gearbox channel, and install two 1/2″ x 2-1/4″ bolts, 3, hardened washers and spacer bushings through the clevis, channel and U-bracket. Secure with flange nuts and torque to 113 N⋅m (83 ft.-lbs.). The bolts should tighten down on the spacer bushings, leaving the guidance link clevis free to pivot.

1

NOTE: Ensure the 5/16″ x 1″ bolt and locknut, 4, Figure 50, are installed and secure, as this prevents brace, 5, from pivoting against the drive shaft.

1431-G10

51

58-24

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

GUIDANCE LINK SHIMMING

1

Slide the front of the guidance link, 1, in the plastic slides, 2. There should be no more than 1.5 mm (0.060″) clearance between the plate and the slides at any point, but the plate should not bind in the slides. Add or remove shims between the slides and the frame on both sides to achieve the appropriate clearance. Tighten the 1/4″ cap screws and locknuts to remove all play between the plastic slides and the mount, and then turn each locknut one full turn.

NOTE: Do not overtighten, or plastic slides will be damaged.

2

1431-G10

52

58-25

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

58-26

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

SECTION 58 - ATTACHMENTS/HEADERS Chapter 4 - Gearbox (Right Hand) CONTENTS Section

Description

Page

Right-hand Gearbox - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-2 Right-hand Gearbox - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-10 Right-hand Gearbox - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-12 Right-hand Gearbox - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-20

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

RIGHT-HAND GEARBOX - REMOVAL

1

1. Remove the hardware retaining the two right side shields, 1, and lift the shields off the unit.

1431-G76

1 2. If the gearbox is being removed for disassembly, drain the oil out of the gearbox by removing the plug, 1, on the lower neck of the gearbox.

1

1431-2-15

2

58-2

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 3. Remove the tension on the belt by loosening the jam nut and adjusting nut, 1, on the spring tension rod until the belt, 2, can be removed from the gearbox sheave.

1 2

1431-G85

3 4. Loosen the spring, 1, for the conditioner drive belt, 2, by loosening the jam nut and adjusting nut; remove the drive belt from the sheaves.

2

1

1431-2-42

4 5. Block the cutter bar using wood blocking between the discs, or a bar through the right end tower. Remove drive pulley retaining bolt, 1, and pull the drive pulley, 2, off the conditioner drive shaft.

2 1

1431-G84

5

58-3

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 6. Remove the washers, 1, spacer, 2, and snap ring, 3, off the end of the shaft. Remove the lock collar, 4, using a hammer and punch to drive the lock collar opposite the direction of rotation (clockwise as viewed from the end of the shaft) until it loosens up. Remove the lock collar from the shaft.

3 1

2 4

A5034-15

6 7. Remove the four bolts, 1, retaining the bearing flangettes, and remove the outer flangette. Clean the shaft using emery cloth, and slide the bearing off the shaft.

1

1

1431-G79

7 8. Detach the inner gearbox shroud, 1, by taking out carriage bolt and nut, 2.

1

2

50006857

8

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 9. Detach the outer gearbox shroud, 1, by turning out cap screws, 2.

2

1

50006858

9 10. Remove the cotter pin retaining the castellated nut. With the cutter bar blocking or bar in the right end tower in place, break the drive sheave retaining nut, 1, loose; leave the nut snug against the sheave. Wrap a chain under the drive sheave, 2, and use a hoist to support the gearbox. Remove the eight bolts, 3, retaining the gearbox. Use the hoist to lift the gearbox out of the header frame.

1 2 4

NOTE: As the gearbox is removed the conditioner drive shaft, 4, will need to be tipped out of the frame.

3

1431-G94

10 11. As the gearbox is raised out of the frame, the gearbox shaft will slide out of the cutter bar drive shaft, 1.

1

1431-G77

11

58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

RIGHT-HAND GEARBOX DISASSEMBLY

1

NOTE: Keep track of the number and location of all shim packs. During assembly, the shim packs will be installed in their original location.

1. Place the gearbox on a table. Pull the drive sheave off the input shaft of the gearbox.

Remove the woodruff key from the keyway, 1, on the input shaft.

1431-G58

12 2. Remove the eight cap screws securing the conditioner drive shaft bearing cap, 1. Pry the bearing cap off, and lift the shaft assembly out of the gearbox.

1

1431-G56

13

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 3. Remove the rear plug, 1, from the gearbox using a hammer and long punch to drive the plug out of the housing.

1 1431-G58

14 4. Remove the snap ring and the shim pack at 1, from the rear of the gearbox.

1 1431-G57

15 5. Disassemble the conditioner drive shaft by pressing off the ball bearing, 1; remove the washer, 2, from the end of the shaft. Clean all the paint and dirt off the shaft and press the gear, 3, and bearing, 4, off the shaft.

1

2

3

4

Remove the straight key from the keyway in the shaft after removing the gear.

1431-G55

16

58-7

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 6. Remove the snap ring and dust cover at, 1, at the input shaft end of the gearbox housing.

1 1431-G53

17 7. Remove the snap ring, 1, shim pack, 2, and the spacer, 3. Press the input shaft (in the direction of the arrow) through the outer bearing into the housing. Remove the input shaft from the gearbox housing through the right side opening, 4.

2

3

4

1

NOTE: The input shaft must be removed from the gearbox before the lower output shaft may be removed.

1431-G43

18 8. Use a split bearing puller to remove the bearing from the input shaft. Press the bearing, 1, off the end of the shaft. Remove the shim pack that was installed between the bearing and the gear, and set it aside.

NOTE: Keep track of the number and location of all shim packs. During assembly, the shim packs will be installed in their original location.

1

1431-G51

19

58-8

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 9. Remove the four cap screws securing the lower output shaft end cap, 1, and remove the end cap.

1 1431-G54

20 10. Remove the snap ring, 1, shim pack, 2, and spacer from the lower output shaft. Press the shaft (in the direction of the arrow) through the bearing into the housing. Remove the shaft from the gearbox housing through the right side opening, 3.

3 1

2

NOTE: The input shaft must be removed from the gearbox before the lower output shaft may be removed.

1431-G40

21 11. Use a split bearing puller to remove the ball bearing on the lower output shaft, and press the ball bearing, 1, off the shaft. Remove the shim pack that was installed between the bearing and the gear, and set it aside.

NOTE: Keep track of the number and location of all shim packs. During assembly, the shim packs will be installed in their original location.

1

1431-G50

22

58-9

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 12. Remove the bearing cup from the conditioner drive shaft bearing cap, and from the input shaft position, 1, in the gearbox housing.

1

1431-G49

23

INSPECTION 1. Discard the shaft seals and plug, 23, Figure 24.

Replace any worn or pitted bearings. Replace all bearings if gearbox is contaminated with debris from an internal failure.

2. Inspect all keyways and splines for wear.

Replace and damaged or worn assemblies.

3. Inspect all gears and gear teeth for wear and damage. Replace any worn or damaged parts.

4. Inspect the gearbox housing and all bearing caps for wear and cracks. Replace any worn or damaged parts.

58-10

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

10 8

6 4

9

2 1

7

5

19

21

3 20

22

24

12 17

15

23

13

26

28

11

30

25 27

14 18

16

29

31

32

1431-G67

24 Parts Identification 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

Gearbox housing Input shaft Shim kit Bearing cup and cone Sealed ball bearing Washer Shim kit Snap ring Cover Snap ring Conditioner drive shaft Key Gear Bearing cup and cone Shim kit Snap ring

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

58-11

Seal Conditioner drive shaft bearing cap Washer Ball bearing (conditioner drive shaft) Shim kit Snap ring Plug Lower output shaft Shim kit Ball bearing Ball bearing Washer Shim kit Snap ring Seal Lower output shaft end cap

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

RIGHT-HAND GEARBOX - ASSEMBLY 1. Install the straight key into the keyway on the conditioner drive shaft, and press the gear, 1, onto the shaft over the key until the gear is seated against the collar on the shaft. Press the bearing, 2, onto the shaft against the gear.

4

3

1

2

Position the washer, 3, over the end of the shaft, and press the ball bearing, 4, onto the shaft until it is seated against the washer and shoulder in the shaft.

1431-G55

25 2. Install the snap ring into the rear of the housing at 1, and position the original shim pack inside the housing against the snap ring. Insert the conditioner drive shaft into the housing so that the ball bearing is seated against the shim pack and snap ring.

1 1431-G57

26 3. Install the snap ring, 1, into the conditioner drive shaft bearing cap, 2. Position the original shim pack, 3, against the snap ring, and install the bearing cup, 4. Carefully lower the bearing cap assembly over the conditioner drive shaft, and bolt it to the housing using four cap screws, evenly spaced, and torqued to 51 - 62 Nâ‹…m (38 46 ft.-lbs.).

2

3

4

NOTE: Do not install the shaft seal into the bearing cap at this time.

1 A5035-11

27

58-12

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 4. Rotate the shaft two full revolutions to seat the bearings. Thread a 5/8″ x 1″ cap screw into the end of the conditioner drive shaft, and use an inch-pound torque wrench to check the rolling torque on the shaft. The conditioner drive shaft must have zero end play, and 0 - 3.5 kg. cm. (0 - 3 in. lbs.) of rolling torque. Add or remove shims between the ball bearing and the snap ring at 1, Figure 27, to adjust the shaft.

NOTE: Do not add or remove shims between the bearing cup and snap ring in the bearing cap to adjust rolling torque, as this will affect the gear position in the gearbox.

1431-G48

28

Once the shaft is properly adjusted, remove the bearing cap assembly and conditioner drive shaft assembly from the gearbox and set aside.

Remove the shims at the snap ring in the housing, and set aside with the shaft, so they do not become lost during reassembly.

5. Install the previously removed shim pack, 1, over the lower output shaft, and press the ball bearing, 2, onto the shaft until it is seated against the shim pack and gear.

2 1

A5035-1

29

58-13

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 6. Install the lower output shaft assembly into the gearbox until the ball bearing is seated against the shoulder in the housing. Insert the outer ball bearing, 1, over the shaft and into the gearbox until it is also seated against its shoulder in the housing. Install the washer, 2, original shim pack, 3, and snap ring, 4, to retain the shaft.

1 2

NOTE: Make certain the snap ring is properly seated in the groove in the shaft.

4

3

A5035-9

30 7. Select a socket that just fits over the shaft, and lock it to the shaft by sliding a hex key between the shaft and the socket. Attach an inch-pound torque to the socket, and check the rolling torque of the shaft. Add or remove shims behind the snap ring, 4, Figure 30, as necessary to obtain 0 - 3.5 kg. cm. (0 - 3 in. lbs.) of rolling torque.

1431-G41

31 8. Install the original shim pack over the input shaft, and press a new bearing, 1, over the shaft against the shim pack and gear.

1

1431-G51

32

58-14

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 9. Install the bearing cup into the gearbox housing, and insert the input shaft into the gearbox. Hold the input shaft in place while inserting the sealed ball bearing, 1, over the input shaft and into the housing until it is seated against the shoulder in the housing. Install the washer, 2, and original shim pack, 3, over the shaft, and retain using a snap ring, 4.

1 2

NOTE: Make certain the snap ring is properly seated in the groove in the shaft.

3

4

A5035-5

33 10. Thread the castellated nut onto the end of the input shaft; use a socket and inch-pound torque wrench to check the rolling torque of the input shaft. Add or remove shims behind the snap ring, 4, Figure 33, in order to obtain 2 - 5.5 kg. cm. (2 - 5 in. lbs.) of rolling torque.

1431-G44

34 11. Applying bluing compound to both the input shaft pinion, 1, and lower output shaft pinion, 2, gears.

Install the shim pack, 3, into the rear of the housing, and lower the conditioner drive shaft assembly into the gearbox. Install the conditioner drive shaft bearing cap and retain using four cap screws, equally spaced, and torqued to 51 - 62 Nâ‹…m (38 - 46 ft.-lbs.).

2

A5035-14

1

3 35

58-15

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 12. Hold the lower output shaft to apply a load to the gearbox, and rotate the input shaft several times in order to mark the gear contact patterns into the bluing on the pinion gears.

A5036-4

36 13. Install a dial indicator onto the gearbox, so that the indicator stem is engaged against the keyway on the conditioner drive shaft. Check the backlash between the conditioner drive gear and each pinion separately; while holding the lower output shaft securely against rotation, rotate the conditioner drive shaft back and forth to measure the backlash between the gears. Repeat the process by holding the input shaft, and recheck the backlash; it should be a similar amount. The proper backlash reading at the conditioner drive shaft keyway is 0.002″ to 0.004″; this indicates a true backlash of 0.008″ to 0.018″ between the gears.

1431-5-4

37

Remove the conditioner drive shaft bearing cap and shaft assemblies from the gearbox, and inspect the gear contact pattern on the pinion gears; the pattern should be 40% central-toe.

1431-5-5

38

58-16

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

D

C

A

B C

D

1431-G66

39 Backlash Adjustment 14. If the backlash was found to be incorrect, or if the contact pattern is not located properly on one or both pinions, the gearbox will need to be reshimmed.

58-17

To adjust backlash, move shims from one end of the conditioner drive shaft to the other. To increase backlash, move shims from A, between the snap ring and bearing cone in the bearing cap, to B, between the ball bearing and snap ring in the housing. To decrease backlash, move shims from B, and install them at A.

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 The shims used in the gearbox are available in 0.012″, 0.016″ and 0.020″ thicknesses; shifting the conditioner drive shaft 0.004″ will change the backlash between the gears approximately 0.0027″. To shift the shaft 0.004″ inwards (to decrease backlash), remove a 0.020″ or 0.016″ shim at B and position it at A, and move the next size smaller shim (0.016″ or 0.012″) from A to position B. Gear Contact Pattern To adjust the gear contact pattern, move shims from one end of the appropriate shaft to the other, to reposition the pinion gear.

If the contact pattern is high (towards the top of the tooth) on the pinion, and low (towards the root of the tooth) on the gear, remove shims from C, between the bearing and pinion, and add them at D, between the ball bearing and the snap ring, to move the pinion out of mesh with the gear.

1431-5-5

40 If the contact pattern is low on the pinion, and high on the gear, remove shims from D, between the ball bearing and snap ring, and add them at C, between the bearing and the pinion, to move the pinion further into mesh with the gear.

The shims used on the input and lower output shafts are the same on both ends, and are available in 0.012″, 0.016″ and 0.020″ thicknesses. To shift the pinion 0.004″ inwards (to increase mesh), remove a 0.020″ or 0.016″ shim at D and position it at C, and move the next size smaller shim (0.016″ or 0.012″) from C to position D. Use the opposite of this process to move the pinion out of mesh.

Repeat steps 11 through 14 as necessary until the back lash and gear contact patterns are correct.

1431-5-5

41

58-18

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 15. Remove the conditioner drive shaft bearing cap, 1, from the gearbox, and install a new shaft seal, 2, in bearing cap, flush with the outer surface.

Lubricate the seal lip liberally with grease.

4

NOTE: Gearbox seals are special high temperature seals; do not substitute with “jobber” seals.

Apply a thin bead of silicone sealant around the inner flange of the bearing cap, and carefully lower the cap over the conditioner drive shaft, use caution not to roll or damage the seal lip.

Orient the check plug, 3, so that it is 90° counterclockwise from the fill plug, 4, and install the eight cap screws to retain the bearing cap; torque the cap screws to 51 - 62 N⋅m (38 - 46 ft.-lbs.).

1

2

3

A5036-2

42

16. Install the dust plate, 1, over the input shaft, and secure using the snap ring, 2.

Drive a new plug, 3, into the rear of the housing until it is flush with the outer surface.

Install the lower output shaft seal, 4, into the housing using a seal driver until the seal is flush with the face of the housing. Install the cover, 5, and tighten the four cap screws evenly to push the seal into the housing the remaining distance.

Torque the cap screws to 28 - 30 N⋅m (21 - 23 ft.-lbs.).

Fill the gearbox with fresh oil; the gearbox holds approximately 2000 ml (68 oz.) of oil. Use only API GL5 80W90 gear oil.

NOTE: Gearbox seals are special high temperature seals; do not substitute with “jobber” seals.

58-19

5

1

4

2

3 A5036-5

43

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

RIGHT-HAND GEARBOX INSTALLATION

1

1. Install a woodruff key in the keyway of the input shaft, and apply a permanent lubricant to the shaft and key. Slide the drive sheave, 1, over the shaft, and secure with the washer and castellated nut, 2. Using a hoist and lifting sling, lower the right-hand gearbox into the frame, tipping the conditioner drive shaft through the opening in the header frame.

2

3

3 1431-G94

44 2. Line up the splines on the lower output shaft, 1, with the splines on the cutter bar drive shaft, 2, as the gearbox is lowered into the frame. Secure the right-hand gearbox to the main frame using eight 5/8″ x 1-1/4″ cap screws and lock washers, 3, Figure 44. Torque the gearbox retaining bolts to 224 N⋅m (165 ft lbs). Remove the lifting sling and hoist.

1 2

1431-G93

45 3. Attach the outer gearbox shroud, 1, by turning in cap screws, 2.

2

1

50006858

46

58-20

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 4. Attach the inner gearbox shroud, 1, using a carriage bolt and nut, 2.

1

2

50006857

47 5. Install the right side support bearing and flangettes using four 1/2″ x 1-1/4″ cap screws, 1.

Tighten the bolts evenly to 113 N⋅m (83 ft.-lbs.).

1

NOTE: Do not tighten bearing flangette bolts until gearbox mounting bolts are tightened.

1

1431-G79

48

58-21

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 6. Slide the lock collar, 1, over the shaft and onto the right side bearing flange. Use a hammer and punch to tighten the lock collar in the direction of rotation (counterclockwise, as viewed from the end of the shaft).

1

Install the snap ring onto the shaft by positioning the flat face of the spacer against the snap ring.

Use a 5/8″ x 1-1/2″ cap screw and flat washer threaded into the shaft to push the snap ring onto the shaft. Use a screwdriver or punch to slide the snap ring into the groove on the output shaft.

A5034-14

49 7. Install the spacer, 1, on the output shaft, with the chamfered edge against the snap ring.

NOTE: Make certain that the chamfer on the spacer is against the snap ring to prevent the snap ring from being pushed out of its groove.

1 2 A5034-15

50 8. Install any shim washers, 2, Figure 50, removed at disassembly on the shaft. Place the square key in the keyway on the shaft and install the conditioner roll drive pulley, 1, on the output shaft. Install the 5/8″ x 1-3/4″ center bolt, 2, and washer to retain the sheave. Position wood blocking between the cutter bar discs, or insert a bar in the right end tower to lock up the driveline.

Torque the bolt to 224 N⋅m (165 ft.-lbs.).

1

2

1431-G84

51

58-22

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 9. With the blocking still in place, torque the castellated nut, 1, retaining the drive sheave to 224 Nâ‹…m (150 ft.-lbs.).

Install the conditioner drive belt over the gearbox sheaves, and adjust the idler spring length to 279 mm (11″). Check the alignment of the drive pulley, 2 and the driven pulley, 3. If the pulleys are not in alignment add or remove shim washers as needed behind the drive pulley, 2.

1

3

2 1431-G83

52 10. Install the right side header drive belt, 1, on the drive sheave. Tighten the adjusting nut, 2, on the spring tension rod until the spring length matches the length of the gauge. Tighten the jam nut to secure.

2 1

1431-G85

53 11. Reinstall the right side shielding, 1, on the unit; position the end and center shields under the right middle shield. Install all hardware loosely to ensure a proper fitup before tightening retaining bolts.

1

1431-G76

54

58-23

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

58-24

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5

SECTION 58 - ATTACHMENTS/HEADERS Chapter 5 - Gearbox (Conditioner Drive 1431) CONTENTS Section

Description

Page

Model 1431 Conditioner Drive Gearbox - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-2 Model 1431 Conditioner Drive Gearbox - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-5 Model 1431 Conditioner Drive Gearbox - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-6 Model 1431 Conditioner Drive Gearbox - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-9 Gearbox Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-13

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5

MODEL 1431 CONDITIONER DRIVE GEARBOX - REMOVAL 1. Raise the header, and engage the transport stops by pivoting both the right and left lock levers, 1, forward. Lower the header onto the stops.

DANGER Always engage the transport stops when working around a raised header.

1 1431-2-4

1 2. Lift the right-hand end shield. Install wood blocking between the cutter bar discs, or install a bar through the right end tower; loosen the conditioner gearbox drive sheave retaining bolt, 1.

2

1

Remove the spring, 2, from the conditioning roll drive idler by loosening the jam nut and adjusting nut on the spring tension rod. Remove the drive belt, 3, from the unit.

3

1431-G29

2 3. Detach anti-wrap shield, 1, by turning out four cap screws, 2.

2

2 1

50006856

3

58-2

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 4. Remove the four bolts, 1, retaining the lower conditioner drive shaft, 2, to the gearbox shaft; lower the drive shaft out of the way.

1

2

1 1431-G75

4 5. Remove the two clamp bolts, 1, retaining the top conditioning roll drive shaft, 2, to the upper gearbox shaft. Slide the drive shaft off the gearbox shaft, and lower it out of the way.

1 2

1431-G61

5 6. Position a hoist or other lifting mechanism above the gearbox, and attach a chain around the gearbox sheave; make sure to use a long enough span of chain to allow the gearbox to be fully lowered to the floor.

Remove the five gearbox retaining bolts, 1, from the header side sheet. Lower the gearbox to the floor, remove the lifting chain, and slide the gearbox from under the header.

1 1

A5040-3

6

58-3

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5

MODEL 1431 CONDITIONER DRIVE GEARBOX - DISASSEMBLY

1

1. Place the gearbox on a table and remove the previously loosened sheave retaining bolt, 1.

The drive pulley, 2, and the key can be removed from the input shaft.

2

1431-G63

7 2. Remove the snap ring, 1, from the input shaft.

1

1431-G65

8 3. Remove the bolts retaining the cover, 1, and the bearing end caps, 2 and 3. Pry the cover and end caps away from the housing.

3

2

1

1431-G64

9

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 4. Remove the cotter pin and nut, 1, from the lower output shaft. Remove the gear, 2, from the shaft.

Press the shaft, 3, out of the bearing assemblies.

Press the center shaft, 4, out of the gear and the gearbox housing in the direction of the arrow. The intermediate gear can now be removed though the lower gearbox access opening, 5. Press the input shaft and gear, 6, out of the gearbox housing.

3 5 2

6 4

1

A5039-3

10

INSPECTION 1. Discard all seals and gaskets.

2. Replace all worn or pitted bearing cups and cones. Replace all bearings if gearbox is contaminated with debris from an internal failure.

3. Inspect all keyways and splines for damage or wear. Replace any damaged or worn assemblies.

4. Inspect all gears and gear teeth for wear and damage. Replace worn and damaged parts.

5. Inspect the gearbox housing and all bearing caps for wear or cracks. Replace all worn or damaged parts.

58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5

MODEL 1431 CONDITIONER DRIVE GEARBOX - ASSEMBLY

2

1. Press new bearing cones onto the input shaft and gear assembly, 1. Install new bearing cups in the gearbox housing, 2, and the bearing cap, 3.

Install the input shaft into the housing, and install the bearing cap, using the original shims.

1

3 A5039-5

11 2. Install a 5/8″ x 1″ cap screw in the end of the input shaft, and use a socket and inch-pound torque wrench to measure the rolling torque of the input shaft. Add or remove shims between the bearing cap and housing as necessary to obtain 0 - 0.56 N⋅m (0 - 5 in.-lbs.) of rolling torque.

Record the amount of rolling torque obtained when properly adjusted, as this will affect set-up of the remaining shafts.

A5039-11

12 3. Press the bearing cone onto the short end of the center shaft, 1, so that the bearing cone is seated against the shoulder on the shaft.

2

Install a bearing cup into the gearbox housing at 2, and position the bearing cone, 3, into the cup in the housing. Insert the gear, 4, through the large opening in the housing, and slide it into position over the bearing cup and cone, 3.

Insert the splined end of the center shaft through the gear and bearing assembly, and continue to press the shaft through until the shoulder on the shaft seats against the bearing cone, 3.

Slide the bearing cup, 5, into the housing over the bearing cone on the end of the shaft, and install the bearing cap with the original shim pack.

3 4 1 5 A5039-10

13

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 4. Select a socket that just fits over the splined end of the center shaft, and lock it to the shaft using a hex wrench. Attach an inch-pound torque wrench to the socket, and measure the rolling torque of the shaft. Add or remove shims between the bearing cap and the housing as required to adjust the rolling torque to the appropriate range, based on the input shaft rolling torque measured earlier.

Input Shaft Rolling Torque

Center Shaft Rolling Torque Range

0 in.-lbs.

5 - 10 in.-lbs.

1 in.-lbs.

7 - 12 in. lbs

2 in.-lbs.

9 - 14 in.-lbs.

3 in.-lbs.

11 - 16 in.-lbs.

4 in.-lbs.

13 - 18 in.-lbs.

5 in.-lbs.

15 - 20 in.-lbs.

2

1

A5039-9

14

5. Install a bearing cup, 1, Figure 3-14, into the housing so that it is seated against the shoulder.

Install a shaft seal, 2, Figure 3-14, flush with the housing. Apply grease to the seal lip.

6. Install the remaining bearing cup, 1, into the inside of the gearbox housing, seated against the shoulder. Press a bearing cone onto the lower shaft, 2, and insert the lower shaft through the gearbox. Install the other bearing cone, 3, over the shaft. Slide the gear, 4, over the shaft, and install the washer and castellated nut, 5.

1

2 3 4

5 A5039-15

15

58-7

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 7. Install a socket and inch-pound torque wrench to measure the rolling torque of the lower shaft; tighten the castellated nut as required to adjust the lower shaft rolling torque. Set the rolling torque to the total rolling torque found on the center shaft, plus 4 - 10 in.-lbs.

After the rolling torque is properly adjusted, secure the castellated nut on the lower shaft using a cotter pin, 1.

Apply sealant to the plate, 2, and install it on the gearbox housing using eight cap screws.

Remove the input shaft bearing cap, 3, and apply sealant to the inner flange; reinstall the bearing cap.

Remove the center shaft end cap, 4, and install a shaft seal flush with the cap. Apply sealant to the inner flange, and reinstall the end cap.

3

4 1

A5039-14

2 16

8. Install new shaft seals, 1 and 2, on the center shaft and input shaft; lubricate the seal lips liberally prior to installation.

Install the snap ring into the groove, 3, on the input shaft.

3 2 A5039-13

1 17

58-8

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 9. Install the square key in the keyway on the input shaft, and slide the drive pulley, 1, over the shaft until it is seated against the snap ring. Install the center washer and cap screw, 2, to retain the sheave.

1

2

1431-G63

18

MODEL 1431 CONDITIONER DRIVE GEARBOX - INSTALLATION 1. Carefully slide the gearbox under the header frame, and attach a chain around the drive sheave. Run the chain up through the header frame, and attach it to a hoist or other lifting device, as shown.

1431-G60

19 2. Raise the gearbox up into the header frame, and install the five retaining bolts, 1. Torque the bolts to 113 Nâ‹…m (83 ft.-lbs.).

1 1

A5040-3

20

58-9

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 3. Slide the upper conditioning roll drive shaft, 1, over the top output shaft of the gearbox. Install the two cap screws, 2, and nuts; torque the bolts to 113 Nâ‹…m (83 ft.-lbs.).

2 1

1431-G61

21 4. Attach the lower conditioner roll drive shaft yoke plate to the gearbox shaft using the four bolts, 1, and washers; leave the bolts loose.

1

1 1431-G75

22

58-10

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 For Machines with Rubber Rolls To reset the timing of the lower conditioner roll to the upper roll, center the bottom roll lug in the upper roll lug gap while applying hand force on the upper roll in the direction opposite the normal rotation. Tighten the four bolts and washers between the lower drive shaft yoke flange and the gearbox shaft, then recheck the timing by applying reverse rotational force on both rolls.

1411-8-12

23 For Machines with Steel Rolls Center the lower roll lug in the upper roll valley, while applying hand force on the upper roll in the direction opposite the normal rotation. Tighten the four bolts and washers at the lower drive shaft yoke flange, and recheck the timing by applying reverse rotational force on both rolls.

20001730

24

58-11

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 5. Attach the anti-wrap shield, 1, by turning in the four cap screws, 2.

2

2 1

50006856

25 6. Install the conditioner drive belt, 1, over the sheaves, and tighten the nuts on the spring tension rod to adjust the spring to a length of 279 mm (11″) from inside hook to inside hook.

2 (279 mm) 11″

Install wood blocking between the cutter bar discs, or insert a bar through the right end tower, and tighten the conditioner gearbox drive sheave retaining bolt, 2, to 224 N⋅m (165 ft.-lbs.).

1 1431-G29

26

58-12

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5

GEARBOX SPECIFICATIONS Pivot Gearbox Input shaft gear cap screw torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 to 70 N⋅m (45 to 50 ft.-lbs.)

Bearing cap retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 to 70 N⋅m (45 to 50 ft.-lbs.)

Output pulley retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 N⋅m (150 ft.-lbs.)

Input shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 to 9 kg/cm (5 to 8 in.-lbs.)

Output shaft end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 0.05 mm (0 to 0.002″) Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W-90 GL5 Right-Hand Gearbox Input pulley retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 N⋅m (150 ft.-lbs.)

Cutter bar output shaft end cap cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N⋅m (248 in.-lbs.)

Conditioner roll drive shaft end cap cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 N⋅m (41 ft.-lbs.)

Input shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 to 5.5 kg/cm (2 to 5 in.-lbs.)

Cutter bar drive shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 3.5 kg/cm (0 to 3 in.-lbs.)

Conditioner drive shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 3.5 kg/cm (0 to 3 in.-lbs.)

Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W-90 GL5 Conditioner Drive Gearbox Input shaft drive pulley cap screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 N⋅m (128 ft.-lbs.)

Gearbox mounting cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 N⋅m (83 ft.-lbs.)

Conditioning roll drive shaft clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 N⋅m (83 ft.-lbs.)

Input shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 5.5 kg/cm (0 to 5 in.-lbs.)

Intermediate shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 x torque on input shaft plus 5.5 to 11 kg/cm (5 to 10 in.-lbs.)

Lower output shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque on intermediate shaft plus 4.5 to 11 kg/cm (4 to 10 in.-lbs.)

Sealant for bolt threads and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTV Silicone sealer Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W-90 GL5

58-13

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5

58-14

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6

SECTION 58 - ATTACHMENTS/HEADERS Chapter 6 - Conditioner Rolls and Drive (1431) CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-2 Conditioner Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-3 Conditioner Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-4 Conditioner Roll Drive Shaft - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-4 Conditioner Roll Drive Shaft - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-6 Conditioner Roll Drive Shaft - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-7 Conditioner Roll Drive Shaft - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-8 Lower Conditioner Roll - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-10 Lower Conditioner Roll - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-14 Upper Conditioner Roll - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-17 Upper Conditioner Roll - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-20 Conditioner Roll Tension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-22 Conditioner Roll Tension System - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-26

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6

INTRODUCTION The 1431 disc mower-conditioner is equipped with two long (102″ x 10-3/8″) chevron, intermeshing rubber conditioner rolls, 1, to condition the crop thoroughly, yet gently, for fast drying without leaf loss or crop damage. Cut crop is fed directly from the cutter bar into the conditioner rolls. The conditioner rolls are adjustable for clearance, pressure and timing.

1 A4831-7

1 Optional steel conditioning can be installed on the 1431. The replacement steel rolls provide improved wear characteristics during heavy or high yield crop conditions.

10003721

2 The conditioner rolls are driven from the right side bevel gearbox, 1, through a 4HB banded belt, 2, to the conditioner drive gearbox.

1

1431-1-36

2 3

58-2

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 The conditioner drive gearbox, 1, drives the conditioner rolls through two telescoping U-joint drive shafts, 2. The bottom drive shaft is equipped with a slotted flange to provide for the roll timing adjustment.

2

1

A4835-8

4

CONDITIONER BELT ADJUSTMENT The conditioner belt must be properly tensioned at all times to prevent excessive slipping. A loose belt may cause conditioner rolls to wrap.

(279 mm) 11″

Check the belt tension each day for the first few days of service with a new belt. Check the belt tension weekly thereafter.

The conditioner belt is tensioned by a spring. The belt is properly tensioned when the spring, 1, is tightened to a length of 279 mm (11″) from inside hook to inside hook.

1

A4835-13

5 Loosen nuts, 1, and tighten the inner nut to stretch the spring to the correct length; tighten the jam nut to secure.

1

A4835-8

6

58-3

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6

CONDITIONER BELT REPLACEMENT

(279 mm) 11″

Remove the tension on the belt by loosening the nuts, 1, on the spring tension rod until the belt can be removed from the upper sheave. Slide the belt off between the sheaves.

Install the new belt onto the sheaves, and tighten nuts on spring tension rod to adjust spring to a length of 279 mm (11″) from inside hook to inside hook.

1

A4835-13

7

CONDITIONER ROLL DRIVE SHAFT REMOVAL

2

1. Detach anti-wrap shield, 1, by turning out four cap screws, 2.

1 2

50006856

8

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 2. To remove the lower conditioner roll drive shaft, remove the two clamp bolts, 1, and nuts retaining the yoke end to the lower conditioner roll.

Remove the four bolts, 2, and washers attaching the yoke plate to the conditioner gearbox, and remove the drive shaft from the unit.

1

2

A4835-8

9 3. To remove the upper conditioner roll drive shaft, remove the two clamp bolts, 1, and nuts at each end of the drive shaft. Slide the yokes off of the upper conditioner roll shaft and gearbox shaft, and remove the drive shaft from the unit.

1

1

A5000-1

10

58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6

CONDITIONER ROLL DRIVE SHAFT DISASSEMBLY 1. The drive shafts can be slid apart, and each U-joint serviced separately.

1431-7-8

11 2. The U-joint bearing cups are retained with external-type snap rings, 1, positioned on the inner side of the yoke ears. Remove the snap rings by positioning a screwdriver against the open end of the snap ring, and give a light blow to the screwdriver to pop the snap ring off the bearing cup.

1

2

3. Remove the grease zerk, 2, from the one bearing cup.

1

NOTE: The grease zerk is oriented to line up with other grease zerks on the drive shaft. Note the positioning of the grease zerk prior to removal.

1431-6-7

12 4. Position the joint in an open vise, with each ear of one yoke supported by a vise jaw. With a soft hammer of mallet, strike the top ear of the unsupported yoke at 1. This will drive the top bearing outward approximately 8 mm (1/4″).

1

IMPORTANT: Do not use a hard faced hammer, as this may damage the edge of the bearing cup bore in the yoke, causing the bearing cup to hang up or seize in the yoke.

1411/8-7

13

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 5. Pull the bearing out of the yoke ear. If necessary, grip the loosened bearing in a vise, and drive the yoke off the bearing by striking the yoke ear with the soft faced hammer or mallet.

6. This same procedure should be followed to remove the bearing directly opposite the one just removed, after which the yoke itself may be removed.

7. To remove the remaining two bearings, support the cross in the vise, making certain the vise jaws are covered with brass protectors or the previously removed bearings are reinstalled on the cross. By striking the yoke ear, the bearings can be removed as per steps 4 & 5.

1411/8-8

14

CONDITIONER ROLL DRIVE SHAFT ASSEMBLY 1. To reassemble the U-joint, position the cross, 1, in the yoke so that the bearing journals are positioned in each yoke ear. Insert the bearings in the outside of the yoke ears, and position the assembly in a vise. Press the bearings in until they are flush with the edge of the yoke.

2. Using a socket of the same diameter as the bearing, press the bearing into the yoke ear until the snap ring groove is exposed on the inside of the yoke ear. Install the snap ring over the bearing cup.

3. Reposition the yoke and cross in the vise, and use the socket to press the opposite bearing fully into the yoke ear while rotating the cross to ensure it does not bind up. Continue to press the bearing into the yoke ear until the snap ring can be installed. It may be necessary to push the bearing in as far as possible with the vise, and then remove the yoke assembly and strike the yoke ears with a sharp blow from a hammer to spring the yoke enough to install the snap ring.

58-7

1 1411/8-9

15

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 4. Assemble the second yoke to the cross repeating steps 1 to 3.

NOTE: The grease zerk, 1, should be oriented to line up with the other grease zerks, 2, on the drive shaft for ease of lubrication. Note the positioning of the bearing cup for the grease zerk during reassembly to ensure it aligns with the other grease zerks.

5. After complete assembly of the U-joint, strike the forged surfaces of all yoke ears with a sharp blow from a hammer. This will ensure proper seating of the bearings, and eliminate any possible tightness to ensure a free flexing joint.

1

2

1431-7-8

16

IMPORTANT: Use caution not to strike the bearing bore area of the yoke, as this will damage the bore and may cause premature cross bearing failure.

CONDITIONER ROLL DRIVE SHAFT INSTALLATION 1. Before installing the lower drive shaft, rotate the machine over by hand until the upper roll drive shaft is positioned with the grease zerks facing to the rear. Install the lower conditioner roll drive shaft with the grease zerks facing rearwards also, by sliding the clamp yoke over the lower conditioner roll shaft. Attach the yoke plate to the gearbox shaft using the four bolts, 2, and washers; leave the bolts loose. Install the two clamp bolts, 1, and nuts, and torque to 113 Nâ‹…m (83 ft.-lbs.).

1

2

A4835-8

17

58-8

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 2. Before installing the upper drive shaft, rotate the machine over by hand until the lower roll drive shaft is positioned with the grease zerks facing to the rear. Install the upper conditioner roll drive shaft with the grease zerks facing rearwards also, by sliding the clamp yokes over the conditioner roll shaft and gearbox shaft. Install the two bolts, 1, and nuts in each yoke, and torque to 113 Nâ‹…m (83 ft.-lbs.).

1

1

A5000-1

18 3. Check the conditioner roll timing by applying reverse rotational force on both rolls, and ensure the lug of the lower roll is centered in the valley of the upper roll. To reset the timing, loosen the four bolts, 1, and washers at the lower drive shaft yoke flange.

1

A4835-7

19 For Machines with Rubber Rolls Center the lower roll lug in the upper roll valley while applying hand force on the upper roll in the direction opposite the normal rotation. Tighten the four bolts and washers at the lower drive shaft yoke flange, and recheck the timing by applying reverse rotational force on both rolls.

1411-8-12

20

58-9

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 For Machines with Steel Rolls To reset the timing, center the lower roll lug in the upper roll valley while applying hand force on the upper roll in the direction opposite the normal rotation. Tighten the four bolts and washers at the lower drive shaft yoke flange, and recheck the timing by applying reverse rotational force on both rolls.

20001730

21 4. Attach the anti-wrap shield, 1, by turning in four cap screws, 2.

2 1 2

50006856

22

LOWER CONDITIONER ROLL REMOVAL 1. Raise the header fully, and engage the header lift transport locks by pivoting both right and left lock levers, 1, forward.

1 1431-2-4

23

58-10

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 2. Install the header tilt cylinder pin, 1, through the channel slot and the rear hole of the cylinder rod to lock the header in the level position. Lower the header onto the transport locks.

1

1431-2-19

24 3. Detach anti-wrap shield, 1, by turning out four cap screws, 2.

2 1 2

50006856

25 4. Loosen the adjusting bolt to relieve all tension on the right side flotation spring. Remove the cotter pin, 1, and washer, and slide the attaching straps, 2, and spacer off of the post on the header. Allow the flotation spring and straps to lay back against the right side tire.

NOTE: Removing the flotation spring will provide improved access to the right side of the lower conditioner roll to facilitate removal.

1 A4835-8

2 26

58-11

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 5. Remove the lower conditioner roll drive shaft by removing the two cap screws, 1, and nuts from the yoke attached to the conditioner roll, and the four cap screws at the yoke flange attached to the conditioner drive gearbox. Slide the yoke off of the lower conditioner roll shaft and lift the drive shaft off the unit.

1

1431-7-1

27 6. Remove the plates, 1, on the removal slot at the right side of header by removing the two cap screws, 2.

1

2

1431-7-2

28

58-12

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 7. Loosen the setscrew and remove the lock collar, 1, by driving it in the opposite direction of rotation using a hammer and punch.

1

Repeat the process on the left side of the conditioner roll.

8. Clean any rust, dirt or corrosion off the shaft using emery cloth, and file down any marks from the locking collar setscrew. Support the lower conditioner roll using a floor jack and appropriate blocking. Remove the four flange nuts, 2, and slide the bearing and housing off the shaft.

2

2

1431-7-3

29 Note that the top rear bolt,1, on the right side of header is loose (not welded to header) and should be removed also.

NOTE: The top rear bolt on the right side of the header is removable to facilitate removal of the upper roll pivot arm.

1

Repeat the process on the left side of the conditioner roll.

1431-7-4

30 9. Using the floor jack to support the conditioner roll, slide the right end of the roll to the rear out of the slot in header frame, and lower to the ground.

While supporting the left end of the conditioner roll, slide the roll to the right, until the left end of the conditioner roll is clear of the header frame, and lower it to the ground.

1431-7-9

31

58-13

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6

LOWER CONDITIONER ROLL INSTALLATION 1. Position the lower conditioner roll under the unit, with the splined shaft on the right side. Using a floor jack to support the conditioner roll, lift the left end of the conditioner roll up, and slide the stub shaft through the bearing hole on the left side of the header frame.

2. Lift the right end of the conditioner roll up, and slide it through the slot in the frame into the bearing mount area.

1431-7-9

32 3. Slide the bearing housing, 1, onto the left side stub shaft; lift the roll using the floor jack and blocking until the bearing housing can be slid over the four bolts, 2, in the header frame. Install lock washers and nuts to retain the housing, and tighten securely.

1

2

2

1431-7-6

33 Install the bearing housing, 1, on the right side by sliding it over the shaft; lift the roll using the floor jack and blocking until the housing can be slid over the three bolts in the header. Reach in through the slot in the header frame, and install the fourth bolt through the frame and housing.

Install lock washers and nuts, 2, on all four mounting bolts, and tighten securely to retain the bearing housing.

1

2 2

1431-7-36

34

58-14

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 4. The lower conditioner roll must be properly aligned with the upper conditioner roll so that the conditioner rolls can be timed. Slide the lower conditioner roll in the bearings until the “V’s” at the center of the rolls are perfectly aligned. Once the rolls are aligned, check at both ends of the lower conditioner rolls to ensure there is a relatively even amount of clearance between the roll and header frame at both sides.

1431-7-23

35 5. Install the lock collar, 1, onto the shaft, and seat it over the bearing flange; tighten the lock collar in the direction of rotation using a hammer and punch, and tighten the setscrew to secure the lock collar. Repeat for the opposite end of the conditioner roll.

1

1431-7-3

36 6. Install the plates, 1, to cover the slot in the header frame using the two previously removed bolts, 2; tighten securely.

1

2

1431-7-2

37

58-15

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 7. Before installing the lower drive shaft, rotate the machine over by hand until the upper roll drive shaft is positioned with the grease zerks facing to the rear. Install the lower conditioner roll drive shaft with the grease zerks facing rearwards also, by sliding the clamp yoke over the lower conditioner roll shaft. Attach the yoke plate to the gearbox shaft using the four bolts, 1, and washers. Leave the bolts loose. Install the two clamp bolts, 2, and nuts, and torque to 113 Nâ‹…m (83 ft.-lbs.).

2

1

A4835-8

38 For Machines with Rubber Rolls 8. To reset the timing of the lower conditioner roll to the upper roll, center the bottom roll lug in the upper roll lug gap while applying hand force on the upper roll in the direction opposite the normal rotation. Tighten the four bolts and washers between the lower drive shaft yoke flange and the gearbox shaft, then recheck the timing by applying reverse rotational force on both rolls.

50006856

39

58-16

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 For Machines with Steel Rolls To reset the timing, center the lower roll lug in the upper roll valley while applying hand force on the upper roll in the direction opposite the normal rotation. Tighten the four bolts and washers at the lower drive shaft yoke flange, and recheck the timing by applying reverse rotational force on both rolls.

20001730

40 9. Attach the anti-wrap shield, 1, by turning in four cap screws, 2.

2 1 2

50006856

41

UPPER CONDITIONER ROLL REMOVAL NOTE: The lower conditioner roll must be removed before the upper conditioner roll may be removed; refer to “Lower Conditioner Roll - Removal.�

1. Remove the drive shaft from the right side of the upper conditioner roll by removing the two clamp bolts, 1, and nuts at each end of the drive shaft.

Slide the yokes off of the upper conditioner roll shaft and gearbox shaft, and remove the drive shaft from the unit.

1

1

1431-7-10

42

58-17

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 2. The right side pivot arm, 1, must be removed in order to remove the roll. Remove the roll gap bolt, 2, by removing the nut, 3, on the bottom of the bolt.

2

1

3

1431-7-12

43 3. Raise the lock plate, 1, and swing it to the side.

Lift the adjusting nut, 2, and bolt out of the header.

1

2

1431-1-36

44 4. Completely loosen the roll pressure tension by rotating the roll pressure handle, 1, counterclockwise until loose.

1

4833-12

45

58-18

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 5. Remove the cap screw, 1, and spacer that connect the roll tension arm straps, 2, to the pivot arm.

1 2

1431-7-13

46 6. Loosen the setscrew and rotate the lock collar, 1, opposite direction of roll rotation. Remove lock collar. Repeat for opposite side.

1

1431-7-15

47 7. Support the roll using a floor jack and appropriate blocking. Remove the pivot nut and bolt from 1 at the rear of the right side pivot plate, and swing plate, 2, downwards so that it is clear of the pivot mount. Slide the pivot plate and bearing off the end of the roll.

1 2

NOTE: The top rear bolt that retains the right side lower conditioner roll bearing is removable to allow removal of the upper roll right side pivot arm.

1431-7-18

48

58-19

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 8. Lower the right side of roll through slots in header frame and out of frame. Slide the left end out of the bearing and lower it to the ground.

1431-7-16

49

UPPER CONDITIONER ROLL INSTALLATION 1. Position the upper conditioner roll under the unit, with the splined shaft on the right side. Using a floor jack to support the conditioner roll, lift the left end of the conditioner roll up, and slide the stub shaft through the bearing in the left side pivot arm.

1431-7-16

50 2. Use the floor jack and blocking to lift the right end of the upper conditioner roll up, and slide it through the slot in the frame into the bearing mount area. Lift the roll up into position in the header frame.

1431-7-17

51

58-20

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 3. Slide the pivot arm and bearing assembly, 1, far enough over the right end of the conditioner roll, so that it may be pivoted up into its mounting bracket. Ensure the pivot bushing, 2, is installed in the pivot arm, and swing the pivot arm up in place. Install the carriage bolt and nut at 3 to retain the pivot arm.

3

1

2 1431-7-18

52 4. Install the roll gap bolt by inserting the roll gap bolt, 1, and adjusting nut down through the header frame, and through the pivot arm. Install the locknut on the roll gap bolt, threading it on as far as possible to ensure the pivot arm is securely engaged on the square shank of the roll gap bolt.

1

1431-7-21

53 5. Center the upper conditioner roll evenly in the header frame, so that there is an equal amount of clearance between the ends of the conditioner roll, 1, and header side sheets, 2, by sliding the roll in the bearings as required.

2 1

1431-7-20

54

58-21

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 6. Install the lock collar, 1, onto the shaft, and seat it over the bearing flange. Tighten the lock collar in the direction of rotation using a hammer and punch, and tighten the setscrew to secure the lock collar.

2

Reinstall the cap screw, 2, and spacer that connect the roll tension arm straps to the pivot arm.

Repeat for the opposite end of the conditioner roll.

1

1431-7-12

55 7. Install the upper conditioner roll drive shaft by sliding the clamp yokes over the conditioner roll shaft and gearbox shaft. Install the two bolts, 1, and nuts in each yoke, and torque to 113 N⋅m (83 ft.-lbs.).

1 1

Install the lower conditioner roll; refer to “Lower Conditioner Roll - Installation” in this section.

A5000-1

56

CONDITIONER ROLL TENSION SYSTEM Left Side Torsion Arm and Bar Disassembly 1. Completely loosen the roll pressure tension by rotating the roll pressure handle, 1, counterclockwise until loose.

1

IMPORTANT: Failure to loosen the roll pressure may result in sudden movement of the roll tension system components or the upper conditioner roll, causing injury or component damage.

A4833-12

57

58-22

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 2. Loosen and remove the bolt, 1, and spacer from the left side roll tension arm straps to the upper roll left side pivot arm. Lower the tension arm, 2, down onto the roll pivot arm.

1 2

1431-7-25

58 3. Loosen the retaining cap screw, 1, and pivot the plate, 2, at the rear of the left side roll tension arm downwards.

1 2

1431-7-26

59 4. Grip the left side torsion rod tightly using a pair of locking pliers, and tap the pliers to shift the torsion rod, 1 out of the center adjusting tube and the tension arm. It may be necessary to apply penetrating fluid to loosen the hex ends of the torsion arms.

1

1431-7-27

60

58-23

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 5. The left side tension arm may now be removed.

Remove the snap ring, 1, and washer, 2, on the inner end of the tension arm hub, and slide the tension arm out of the header frame. If the bushing in the header frame is worn or galled, use a hammer and punch to drive the bushing out of the header frame.

2

1

1431-7-28

61 Right Side Torsion Arm, Torsion Bar and Adjusting Tube Disassembly 1. In order to remove the right side roll tension system components, the left side torsion bar must be removed; refer to steps 1 to 4 above.

1

2. Loosen and remove the bolt, 1, and spacer from the right side roll tension arm straps to the upper roll pivot arm. Lower the tension arm down onto the roll pivot arm.

1431-7-22

62 3. Loosen the bolt and locknut, 1, that pinches the two mount straps against the adjusting handle assembly, and remove the handle assembly, 2.

1 2

1431-7-29

63

58-24

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 4. To remove the right side roll tension system components, the swathgate must be removed.

Remove the baffle, 1, at the right end of the swathgate by removing the four carriage bolts and nuts, 2.

2

1

1431-7-32

64 5. Remove the cotter pin, 1, and washers, 2, at each end of the swathgate where it fits through the header frame. Slide the swathgate to the right so that the swathgate handle disengages from the adjusting quadrant, and the left end slips out of the header frame. Lower the left end down so that the swathgate can be slid to the left to remove the right end from the header. Set the swathgate aside.

1 2

1431-7-30

65 6. Remove the groove pin, 1, at the inner end of the adjusting tube by driving it out of the tube.

1

1431-7-33

66

58-25

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 7. Slide the adjusting tube, 1, inwards until the outer end comes off the right side tension arm hub. If the torsion bar does not fully slide out of the right side tension arm, loosen the retaining cap screw on the right side pivot arm, and pivot the plate downwards. Use a hammer and punch to drive the torsion bar inwards out of the tension arm. Tip the outer ends of the adjusting tube and torsion bar assembly down and to the rear of the machine until it can be slid outwards and out of the inside mount on the header frame.

1

8. Slide the torsion bar out of the adjusting tube.

1431-7-34

67 9. The right side tension arm may now be removed.

Remove the snap ring, 1, and washer, 2, on the inner end of the tension arm hub, and slide the tension arm out of the header frame. If the bushing in the header frame is worn or galled, use a hammer and punch to drive the bushing out of the header frame.

1 2 1431-7-35

68

CONDITIONER ROLL TENSION SYSTEM - ASSEMBLY Right Side Torsion Arm, Torsion Bar and Adjusting Tube Assembly 1. Install a new bushing in the header frame by driving it in flush with the tube. Apply permanent lubricant to the bushing inner surface and the tension arm shaft, and insert the tension arm through the frame. Retain with a washer, 1, and snap ring, 2.

3 2 1 1431-7-35

69

58-26

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 2. Install a washer over the inner end, 2, of the adjusting tube. Apply a permanent lubricant to the hex bores of the adjusting tube, 1, and the right side tension arm, 3, Figure 5-63. Apply permanent lubricant to the ends of the torsion bar, and slide it into the adjusting tube. Insert the inner end of the adjusting tube through the swathgate quadrant bracket and lift it up in line with the tension arm. Carefully slide the adjusting tube and torsion bar against the tension arm, so that the torsion bar is seated in the tension arm hex bore, and the adjusting tube is seated over the tube in the header frame.

2 1

1431-7-34

70 3. Slide the washer, 1, against the swathgate quadrant bracket, and drive a groove pin, 2, through the adjusting tube to secure it in position.

Drive the roll pin slowly to ensure it exits through the hole in the opposite side of the adjusting tube.

1

2

1431-7-33

71 4. Swing the retaining clip up over the end of the torsion bar, and tighten the cap screw. Lift the tension arm up until the tension straps, 1, are aligned with the bushing in the upper roll pivot arm; install the cap screw and tighten securely.

1

1431-7-13

72

58-27

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 5. Attach the adjusting handle assembly to the adjusting tube by inserting the pivot nut, 1, between the straps on the tube so that it engages in the holes. Install the cap screw and locknut, 2, and tighten the locknut to draw the straps up enough to capture the pivot nut.

1 2

1431-7-29

73 6. Reinstall the swathgate by inserting the right end through the header frame; lift the left end up to align with the hole in the header frame, and slide the swathgate to the left until the adjusting handle clip engages a notch in the quadrant bracket.

Install washers, 1, on the left end of the swathgate tube so that with the cotter pin installed, the swathgate cannot move to the right allowing the adjusting handle to disengage from the quadrant. Once the washers and cotter pin are installed on the left side, install washers to take up the clearance on the right side, and install a cotter pin to secure.

1

1431-2-25

74 7. Reinstall the swathgate baffle, 1, on the right end of the swathgate using the four previously removed carriage bolts and nuts, 2.

2

1

1431-7-32

75

58-28

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 Left Side Torsion Arm and Bar Assembly 1. Install a new bushing in the header frame by driving it in flush with the tube. Apply permanent lubricant to the bushing inner surface and the tension arm shaft, and insert the tension arm through the frame. Retain with a washer, 1, and snap ring, 2.

2

1

1431-7-28

76 2. Apply a permanent lubricant to the hex bores of the adjusting tube and the tension arm, 1. Apply permanent lubricant to the ends of the torsion bar, and slide it through the tension arm until the inner end engages in the adjusting tube.

Continue to slide the torsion bar in until it is fully seated in the tension arm. Swing the retaining clip, 2, up over the end of the torsion bar, and tighten the cap screw. Lift the tension arm up until the tension straps, 3, are aligned with the bushing, 4, in the upper roll pivot arm; install the cap screw and tighten securely.

1 4 3

2

1431-7-27

77 3. Adjust the roll tension to a starting point by rotating the adjusting handle, 1, clockwise until all slack is taken up, and then apply 8 additional turns. Reengage the retaining clip in the notch, 2, in the header frame.

1 2

A4833-12

78

58-29

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6

58-30

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7

SECTION 58 - ATTACHMENTS/HEADERS Chapter 7 - Conditioner Flail and Drive (1432) CONTENTS Section

Description

Page

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-2 Conditioner Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-3 Conditioner Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-3 Flail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-4 Flail Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-6 Rotor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-7 Rotor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-12

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 The 1432 disc mower uses a flail conditioner, 1. The cutterbar feeds the crop into the conditioner, where a cylindrical rotor with free-swinging flails condition the crop and feed it out the rear of the unit through the windrow shields.

1

The 1432 uses 20 sets of six flails each, placed evenly in a spiral pattern around the rotor. The flails are mounted on flail shafts, which are in turn held onto the rotor with roll pins.

19985731

1 The crop is forced against the spinning flails by a conditioner hood. Both flat and textured conditioner hood plates are available on the 1432. The conditioner hood is adjustable to provide a greater or lesser degree of conditioning as needed.

19985249

2

SPECIAL TOOLS Tool Number

Description/Use

610R

Snap ring remover

58-2

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7

CONDITIONER BELT The conditioner belt must be properly tensioned at all times to prevent excessive slipping. A loose belt may cause conditioner rotor to slip.

Check the belt tension each day for the first few days of service with a new belt. Check the belt tension weekly thereafter.

The conditioner belt is tensioned by a spring. The belt is properly tensioned when the spring, 1, is tightened to a length of 305 mm (12″) from inside hook to inside hook.

305 mm (12″)

30000982

3 Loosen the jam nut, 1, and tighten the adjusting nut to stretch the spring to the correct length; tighten the jam nut to secure.

2

1

CONDITIONER BELT REPLACEMENT

3

Remove the tension on the belt by loosening the jam nut and adjusting nut, 1, on the spring tension rod until the belt can be removed from the upper sheave.

Remove the six hub cap screws, 2, and slide the hub, 3, away from the lower sheave.

Remove the belt.

2 19985727

4 Install the new belt onto the sheaves, and tighten nuts on spring tension rod to adjust spring to a length of 305 mm (12″) from inside hook to inside hook.

Slide the hub onto the lower sheave and attach with six cap screws.

305 mm (12″)

30000982

5

58-3

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7

FLAIL REMOVAL 1. Drive the roll pin, 1, out of the free end of the flail shaft.

1

19990055

6 2. Drive the second roll pin, 1, out of the flail shaft, freeing it from the rotor.

1

19990090

7 3. Slide the flails, 1, and spacers, 2, off the shaft.

2

19990054

1 8

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 4. Inspect the shaft, spacers and flails and replace any damaged or worn parts.

19982139

9 5. Replace any flails in which the edge of the mounting hole is less than 3mm (1/8″) from the edge of the flail.

CAUTION The flail rotor turns at high speed. Failure to replace worn or damaged flails can result in the flails separating from the rotor, causing personal injury or damage to the disc mower.

If flails are replaced, the used flail shafts should be rotated one-half turn, or 180°°. Replace the flail shaft if a 3 mm (1/8″″) or greater wear groove is in the shaft.

19982138

3 mm (1/8″″)

10

58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7

FLAIL INSTALLATION 1. Set the flail shaft, 1, in the rotor as shown.

NOTE: Rotate the flail shaft 180° when replacing the flails.

1 19990053

11 2. Slide the shaft to the right, installing a spacer, 1, then a flail, 2, and alternating until all seven spacers and six flails are on the shaft and the shaft is seated in the holes at both ends.

1

IMPORTANT: Install the flails properly and in position as shown. Failure to do so can cause rotor imbalance, vibration and failure.

19990054

2 12

3. Drive the roll pin into the left side, 1.

1

19990090

13

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 4. Drive the roll pin into the right side, 1.

5. The flails should pivot freely. If they do not, inspect the rotor for a bent or damaged disc, 2, or flail shaft and repair or replace as needed.

ROTOR REMOVAL

2

NOTE: The rotor can be removed and reinstalled without removing the conditioner hood.

1

1. Raise or remove the rear curtain and remove the side windrow shields.

19990055

14 2. Remove the two retaining bolts, 1, from both ends of the swathgate.

1

19990060

15 3. Remove the right extender plate from the swathgate, 1.

1

19990058

16

58-7

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 4. Remove the adjustment arm, 2, and springs, 1, from the swathgate.

2

1

19990059

17 5. Slide the swathgate to the right, freeing it from the left side of the machine. Slide it back to the left to free the right side. Set the swathgate aside.

19990061

18 6. Remove the four anti-wrap shields from inside the ends of the frame, 1. Two are shown.

1

19990063

19

58-8

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 7. Remove the plates, 1, from the rear of the frame on both sides of the rotor.

1

19990064

20 8. Remove the drive shaft from the right side of the rotor by removing the clamp bolt, 1, from the rotor drive shaft. The shaft telescopes, allowing it to be freed from the rotor without removing it from the disc mower.

1

19990070

21 9. Remove the locking eccentric collars from both sides of the rotor shaft. Loosen the set screw and drive the collars counterclockwise to loosen them from the shaft.

If necessary, heat the collars and/or apply penetrating oil to loosen them.

NOTE: Clean the rotor shaft on both sides with fine grit emery paper or equivalent and apply penetrating oil to ease removal and reinstallation of the collars and bearings.

19990067

22

58-9

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 10. Remove the bearing housing retaining nuts and pull the bearing and housing assemblies, 1, off both sides of the rotor shaft.

1

19990073

23 11. Use an appropriate puller, 1, if necessary to remove the bearing assemblies.

19990072

1 24

58-10

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7

CAUTION The rotor is heavy. Support the rotor with a suitable hoist or lift during removal.

12. With a suitable lift or hoist, swing the right side of the rotor out of the frame. Hold the rotor against the left side of the frame while lowering until the right side clears the bottom frame member.

19990076

25 13. Carefully remove the left rotor shaft from the frame.

14. Inspect the rotor and replace any worn or damaged parts. For instructions on removing the flails, see “Flail Removal” and “Flail Installation” earlier in this section.

The rotor and discs should be straight. Bent discs can cause the rotor to be unbalanced, resulting in vibration or damage to the conditioner hood and rotor components Bent discs also may prevent the flails from moving freely once installed.

19990077

26

58-11

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7

ROTOR INSTALLATION 1. Assemble the rotor and flails (see “Flail Installation�). Clean the shafts, 1, on both ends of the rotor with emery cloth. Wipe them clean and apply a lubricant to ease bearing installation.

1

19990075

27 2. Using a suitable hoist or lift, place the left shaft of the rotor through the opening in the frame.

CAUTION The rotor is heavy. Always support it with blocks or a suitable lift when removing or installing it.

19990076

28 3. Move the right side of the rotor into place on the right side of the frame. Hold the rotor against the left side while lifting it past the lower frame member and into place.

19990077

29

58-12

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 4. Install the bearing assemblies on both sides.

Slide the bearings fully onto the shaft, 1, and mount the bearing housing on the four bolts, 2, as shown.

2

IMPORTANT: Center the rotor carefully so that the gap between rotor and frame is the same on both ends. Then tighten the retaining collars.

5. With the rotor centered between the frame members, install the retaining collars, 3, on both sides.

Tighten each retaining collar in the direction of rotation on the bearing flangette, then tighten the setscrew to hold it in place.

6. Install the rotor drive shaft on the spline shaft, 1, on the right side of the rotor.

1 3 19990068

2 30

2

7. Install the block plate and shield on the right side of the frame, 2.

1

NOTE: Two of the shield mounting bolts are common to the block plate on the right side. The left side block plate is welded into place.

19990070

31

58-13

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 8. Install the side shields. If the small windrow deflectors, 1, were removed, reinstall them.

1

19990057

32 9. Install the four rotor anti-wrap shields, 1, two are shown. Use cap screws with the nut and washer facing out to hold them in place.

1

19990063

1 33

58-14

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 10. Place the swathgate, 1, on the machine. Install the retaining bolts on both sides to keep the swathgate centered.

19985216

1 34

11. Install the right extender plate, 1, on the swathgate.

1

19990058

35 12. Install the springs, 1, on the swathgate.

1

19990059

36

58-15

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 13. Install the adjustment lever, 1, on the swathgate.

The adjustment lever bolts to the outside of the bracket, 2.

1

2 19990062

37 14. Reinstall the retaining bolts, 1, on either end of the swathgate.

1

19990060

38 15. Reinstall the windrow shields, 1, holding them onto the pivot post with the retaining collar, 2, and bolt, 3.

3

16. Reinstall or lower the rear curtain into place.

17. Inspect all attachment points and moving parts to make sure they are tightened to specification and function properly. Lubricate any joints that were disassembled or otherwise disturbed before operating the disc mower.

2 19990056

1 39

58-16

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Conditioner Drive Shaft – Removal Remove the clamp bolt, 1, from the rotor shaft.

1

19990070

40 Release belt tension by loosening the jam nut and nut on the spring tension rod, 1.

Remove the five drive shaft hub cap screws, 2, from the rotor drive sheave.

Slide the drive shaft hub from the bearing assembly hub.

NOTE: Due to the tight clearances between the drive shaft hub and the bearing assembly hub, the drive shaft may not be easily removed. If the drive shaft hub will not detach from the sheave, removal of the bearing assembly may be required.

Slide the drive shaft from the conditioning rotor stub shaft.

58-17

2

1 19985728

41

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Conditioner Drive Shaft – Disassembly The drive shaft contains two U-joints, which may be serviced individually. The U-joint bearing cups are retained with external snap rings, 1, positioned on the outer side of the yoke ears.

1

1

1

2

1

2

NOTE: The grease zerks, 2, are oriented to line up on the drive shaft to allow ease of lubrication. Note the positioning of the zerk fittings prior to removal.

1

2

1

10005554

42 Remove the snap rings, 1, for the bearing cups to be pressed out. Take out the grease zerk, 2, and store in a suitable location.

2 1

10005555

43 Set the U-joint up in a press. Use a piece of pipe, 1, with an ID slightly larger than the OD of the bearing cup on the bottom of the joint. A socket or short metal rod, 2, with an OD slightly smaller that the OD of the bearing cup can be used to force the cup from the yoke.

2

Apply pressure to the top cup forcing the lower cup to move out the bottom. Stop applying force to the top bearing cup when the cross has bottomed out on the yoke arm.

1 10005556

44

58-18

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Rotate the U-joint over and lift out the bearing cup, 1, if it has not fallen free from the yoke arm.

1

10005557

45 Set the U-joint in the press with the opposite cup facing down. Apply pressure to the cross through the yoke arm forcing the lower cup to move out the bottom. Stop applying force to the cross when it has bottomed out on the yoke arm.

Lift out the bearing cup if it has not fallen free from the yoke arm.

10005558

46 Rotate the U-joint free from the yoke arm. Repeat this procedure to remove the cross from the other yoke arm.

10005559

47

58-19

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Conditioner Drive Shaft – Assembly NOTE: The grease zerk should be oriented to line up with the other grease zerks on the drive shaft for ease of lubrication. Note the positioning of the bearing cup for the grease zerk during reassembly to ensure it aligns with the other grease zerks.

1

1

1

2

1

2

1

2

1

10005554

48 Rotate the cross into the yoke arms. Slide a grease cup into the yoke arm, and raise the cross so that the end is inside the cup. Press the cup in until it clears the snap ring groove. Rotate the U-joint over and follow the same procedure to install the opposite grease cup.

10005560

49 Install the snap rings, 1, and grease zerks, 2, (if equipped), into the U-joint.

After complete assembly of the U-joint, strike the forged surfaces of all yoke ears with a sharp blow from a hammer. This will ensure proper seating of the bearings, eliminate tightness, and produce a free flexing joint.

2 1

IMPORTANT: Use caution not to strike the bearing bore area of the yoke as this will damage the bore, and may cause premature cross bearing failure.

10005555

50

58-20

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Conditioner Drive Shaft – Installation Attach the conditioner rotor drive shaft to the drive sheave using five 3/8″ x 2 ¼″ cap screws, 1.

1 1

1 19990092

51 Slide the drive shaft onto the flail conditioner rotor.

Install clamp bolt, 1, and tighten.

1

19990070

52 Tighten the nuts on spring tension rod to adjust spring length to 305 mm (12″) from inside hook to inside hook. Tighten the jam nut to secure.

30000982

53

58-21

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Drive Shaft Bearing – Removal Remove the guard from the right front corner of the machine to access the drive belt.

10005566

54 Loosen the jam and adjusting nuts, 1, until the drive belt can be removed from the machine.

2 1

Remove the drive shaft hub cap screws, 2, and washers. Slide the drive shaft hub, 3, off of the bearing assembly hub. Slide the sheave from the hub.

3

1

NOTE: Due to the tight clearances between the drive shaft hub and the bearing assembly hub, the drive shaft may not be easily removed. If the drive shaft hub will not detach from the sheave, remove the bearing assembly at the same time as the drive shaft.

2 19990092

55 Remove the four cap screws, 1, and outside bearing cover, 2. As the outside bearing cover comes off, the bearing assembly will also come off on the inside.

Remove the bearing assembly from the machine.

1 2

Clean both sides of the bearing mounting area of all dirt, grease, and sealant.

10005562

1 56

58-22

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Drive Shaft Bearing – Disassembly Hold the drive shaft bearing assembly in a vise.

10005510

57 Use one wrench to hold the shaft stationary and the other wrench to apply force to the cap screws. Turn one of the cap screws from the bearing assembly, only one of them will become loose in this step.

10005508

58 IMPORTANT: Do not use the stud already installed in the hub. This stud is for sheave alignment purposes only and is not designed to withstand the force that may be required to remove the remaining cap screw.

1

Slide a bolt, 1, through the unthreaded hole in the hub. Prevent the hub from rotating by using a pry bar as shown. Loosen and remove the remaining cap screw from the shaft.

10005512

59

58-23

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Rotate the assembly in the vise so that the shaft is vertical. Use a gear puller to remove the hub, 1, from the shaft assembly. It may be necessary to use penetrating fluid or apply heat to the outside of the hub to remove it.

1

10005513

60 NOTE: The bearing assembly is a matched set. If one bearing has failed, the entire assembly must be replaced.

10005511

61 IMPORTANT: The shaft has a integral shoulder, 1.

Care must be taken to ensure that the shoulder is not damaged during removal of the bearings.

1

10005515

62

58-24

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Remove the bearing housing from the vise and set it up on a press with the tapered shaft end pointing down. Press the shaft and inner bearing from the housing.

10005516

63 Remove the bearing spacer from the shaft. Set the shaft and bearing up on a press with the tapered end pointing down. Press the shaft from the bearing.

10005517

64 Using a punch, remove the two bearing cups, 1, from the housing.

1 10005518

65

58-25

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7

1

Install tool 610R, 1, onto the cup spacer. Using a snap ring pliers, remove the spacer from the housing.

Clean all parts to be reused, of all rust, dirt, and old lubricant.

10005519

66 Drive Shaft Bearing – Assembly Using tool 610R, 1, insert the bearing cup spacer ring into the shaft housing.

1

Set the bearing cups into the housing with the tapered ends facing out. Drive the cups in until they have been seated against the spacer ring. The bearing cup spacer is sized to ensure the proper clearance.

10005519

67 Pack each bearing with standard bearing grease.

1

IMPORTANT: Proper initial packing of the bearings is very important to prevent bearing failure.

Set the shaft up in a hydraulic press with the tapered end down. Press on the bearing, 1, (with the integral seal), until it is seated against the shoulder.

10005549

68

58-26

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Slide the bearing spacer, 1, onto the shaft. Set the shaft housing, 2, onto the installed bearing in the orientation shown. Check the opposite side of the housing to ensure that the integral seal has been seated into the seal recess of the housing.

2

1

10005550

69 Press the inner bearing, 1, onto the shaft until inward travel stops. The bearing spacer is sized to ensure the proper bearing clearance.

1

10005551

70 Hold the bearing assembly in a vise. Apply a thin layer of anti-corrosion lubricant to the tapered end of the shaft, 1, keyway, and inside surface of the hub.

Insert the key, 2, into the keyway.

2

1

10005552

71

58-27

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Slide the hub, 1, onto the tapered end of the shaft.

Turn the two cap screws into either end of the shaft.

Using two wrenches, tighten the cap screws to standard torque.

1

10005553

72 Drive Shaft Bearing – Installation Apply a thin film of silicon sealant to the seating area of the bearing cover, 1, and housing, 2.

1 2

10005561

73 Install the bearing cover on the outside with the grease fitting, 1, in the top position. Mate the housing on the inside with the cover, and attach with four cap screws, 2, and nuts.

1

2 2 2 10005562

74

58-28

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Apply a thin film of anti-corrosion lubricant to the bearing assembly hub at 1.

Slide the sheave onto the bearing hub.

1 10005563

75 Slide the conditioner drive shaft onto the stub shaft spline. Install cap screw and nut, 1. Tighten to standard torque.

1

10005565

76

58-29

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Install the drive shaft hub, 1, onto the bearing hub with the sheave, 2, between them.

2

3

1

Secure the shaft hub with five cap screws and washers at 3.

3

3 10005567

77 Install the drive belt, 1, as shown. Tighten the idler spring until it is 305mm (12″) from inside hook to inside hook.

1

Install the guard at 2, using four cap screws, washers, and nuts.

10005566

2

2 78

58-30

SECTION 90 - DECALS - CHAPTER 1

SECTION 90 - DECALS Chapter 1 - Decals CONTENTS Section

Description

Page

Model 1431 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2 Model 1432 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-6

90-1

SECTION 90 - DECALS - CHAPTER 1

MODEL 1431 SAFETY DECALS The following safety decals have been placed on your machine in the areas indicated. They are intended for your personal safety and for those working with you. Please take this manual and walk

around your machine to note the content and location of these warning signs. Review these warning signs and the operating instructions detailed in this manual with your machine operators.

2

2

5 6

2

7 2

9

5 10

5 2

90-2

6

SECTION 90 - DECALS - CHAPTER 1

3 4

19988730

7

9 3 4

19988731

90-3

SECTION 90 - DECALS - CHAPTER 1

4

1

2

3

5

6

90-4

SECTION 90 - DECALS - CHAPTER 1

7

9

8

10

90-5

SECTION 90 - DECALS - CHAPTER 1

MODEL 1432 SAFETY DECALS The following safety decals have been placed on your machine in the areas indicated. They are intended for your personal safety and for those working with you. Please take this manual and walk

around your machine to note the content and location of these warning signs. Review these warning signs and the operating instructions detailed in this manual with your machine operators.

2

2

5

6

7 2

1 2

9 5 10

5 2

6

19988729

90-6

SECTION 90 - DECALS - CHAPTER 1

3 4

19988730

7

9 3 4

19988731

90-7

SECTION 90 - DECALS - CHAPTER 1

1

4

2

5

3

6

90-8

SECTION 90 - DECALS - CHAPTER 1

9

7

8

10

90-9

SECTION 90 - DECALS - CHAPTER 1

90-10

blank

New Holland North America, Inc., New Holland, PA Printed in U.S.A.