New Holland H7460 H7560 Discbine Disc Mower Conditoner Service Repair Manual (84207371) - NH - PDF D by www.heydownloads.com

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SECTION 00 - GENERAL INFORMATION - CHAPTER 1

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

Description

Page

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Model H7460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Model H7560 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Recommended Lubricants and Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation of Adjustable Fittings in Straight Thread O-Ring Bosses . . . . . . . . . . . . . . . . 9 Standard Torque Data for Hydraulic Tubes and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pipe Thread Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation of ORFS (O-ring Flat Faced) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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 H7460

Standard Tongue

Swivel Hitch Tongue

Overall Width Transport position . . . . . . . . . . . . . . . . . 4801 mm (15 ft 9 in) Field position . . . . . . . . . . . . . . . . . . . . . 7087 mm (23 ft 3 in)

4801 mm (15 ft 9 in) 7595 mm (24 ft 11 in)

Overall Length Transport position . . . . . . . . . . . . . . . . . 8966 mm (29 ft 5 in) Field position . . . . . . . . . . . . . . . . . . . . . 7366 mm (24 ft 2 in)

9271 mm (30 ft 5 in) 7670 mm (25 ft 2 in)

Height

Transport position . . . . . . . . . . . . . . . . . 2032 mm (6 ft 8 in) Field position . . . . . . . . . . . . . . . . . . . . . 1727 mm (5 ft 8 in)

2032 mm (6 ft 8 in) 1727 mm (5 ft 8 in)

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

457 mm (18 in)

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

3772 mm (148.5 in)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2948 kg (6500 lb)

2948 kg (6500 lb)

00-2

SECTION 00 - GENERAL INFORMATION - CHAPTER 1 Driveline

Header

Tractor Requirement . . . . . . . . . . . . . . . 75 kW (100 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 . . . . . . . . . . . . . . . . . . . . . . .

Cutter Bar Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. of Discs . . . . . . . . . . . . . . . . . . . . . . Knives per Disc . . . . . . . . . . . . . . . . . . . Disc Cutting Diameter . . . . . . . . . . . . . Disc Drive . . . . . . . . . . . . . . . . . . . . . . . . Disc Speed . . . . . . . . . . . . . . . . . . . . . . Cutting Height, Approximate . . . . . . . . Cutting Bar Angle . . . . . . . . . . . . . . . . .

4699 mm (15 ft 7 in) Vertical & radial 914 mm to 2438 mm (3 ft to 8 ft) Hydraulic (master-slave system) Modular 8 counter-rotating, 4 co-rotating 2 500 mm (19.7 in) Bevel gears in sealed modules 3000 RPM 24 mm - 81 mm (0.95 in - 3.20 in) -2Â° to -10Â°

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 in) 264 mm (10.38 in) 740 rpm

Operating Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 14 km/h (0 to 9 mph) Transport Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 32 km/h (20 mph) maximum Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36 H/hr (8.97 A/hr) @ 10 km/h (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 H7560

Standard Tongue

Swivel Hitch Tongue

Overall Width Transport position . . . . . . . . . . . . . . . . . 4801 mm (15 ft 9 in) Field position . . . . . . . . . . . . . . . . . . . . . 7087 mm (23 ft 3 in)

4801 mm (15 ft 9 in) 7595 mm (24 ft 11 in)

Overall Length Transport position . . . . . . . . . . . . . . . . . 8966 mm (29 ft 5 in) Field position . . . . . . . . . . . . . . . . . . . . . 7366 mm (24 ft 2 in)

9271 mm (30 ft 5 in) 7670 mm (25 ft 2 in)

Height

Transport position . . . . . . . . . . . . . . . . . 2032 mm (6 ft 8 in) Field position . . . . . . . . . . . . . . . . . . . . . 1727 mm (5 ft 8 in)

2032 mm (6 ft 8 in) 1727 mm (5 ft 8 in)

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

457 mm (18 in)

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

3772 mm (148.5 in)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2894 kg (6380 lb)

2894 kg (6380 lb)

Driveline

Header

Tractor Requirement . . . . . . . . . . . . . . . 74 kW (100 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 . . . . . . . . . . . . . . . . . . . . . . .

4750 mm (15 ft 7 in) Vertical & radial 914 mm to 2438 mm (3 ft to 8 ft) Hydraulic (master-slave system) Modular 8 counter-rotating, 4 co-rotating 2 500 mm (19.7 in) Bevel gears in sealed modules 3000 rpm 24 mm - 81 mm (0.95 in - 3.20 in) -2° to -10°

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

00-4

SECTION 00 - GENERAL INFORMATION - CHAPTER 1 Rolls

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 2591 mm (102 in) Diameter . . . . . . . . . . . . . . . . . . . . . . . . . 560 mm (22 in) Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 1011 rpm (726 rpm optional)

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

Type and Description

Part Number

Container Size

Engine Oil

AMBRA SUPER GOLD SSL ENGINE OIL SAE 10W-40

86994335

2.5G / 9.46L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W

86641050

5G / 18.93L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W-30

9613313

1QT / .946L

86641052

1G / 3.785L

9613314

2.5G / 9.46L

9673508DS

5G / 18.93L

9613286

1QT / .946L

86641043

1G / 3.785L

9613289

2.5G / 9.46L

86641044

5G / 18.93L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 40

9624812DS

55G / 208.2L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 15W-40

86641081

1QT / .946L

86641082

1G / 3.785L

86641084

2.5G / 9.46L

86641083

5G / 18.93L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 20W-50

86994337

5G / 18.93L

AMBRA AUTO SUPREME SAE 5W-30

9673589DS

1QT / .946L

AMBRA AUTO SUPREME SAE 10W-30

86641101

1QT / .946L

AMBRA MULTI TRAN

86639558

1G / 3.785L

86639559

2.5G / 9.46L

86639560

5G / 18.93L

AMBRA MULTI TRAN SSL

86994339

2.5G / 9.46L

AMBRA MULTI BIO S

86994341

2.5G / 9.46L

AMBRA MULTI G 134

9624655DS

1QT / .946L

9624656DS

1G / 3.785L

9624450

2.5G / 9.46L

9624451

5G / 18.93L

AMBRA HYDROSYSTEM 46 HYD FLUID

86109085

5G / 18.93L

AMBRA HYDROSYSTEM 68 HYD FLUID

86994331

5G / 18.93L

AMBRA HYDROSYSTEM 100 HYD FLUID

86994343

5G / 18.93L

AMBRA HYDRODEX 3 ATF

9613304

1QT / .946L

9613312

2.5G / 9.46L

9613295

1QT / .946L

9613294

2.5G / 9.46L

86994348

16G / 60.6L

87027134*

1QT / .946L

87027135

2.5G / 9.46L

86994351

16G / 60.6L

AMBRA TRANSAXLE FLUID

86994352

5G / 18.93L

AMBRA HYPOIDE SSL GEAR LUBE

86994354

1QT / .946L

AMBRA GR-9 MULTI-PURPOSE GREASE

9613310

TUBE - 14 OZ

AMBRA HI-TEMP GREASE

9861804DS

TUBE - 14 OZ

AMBRA CORN HEAD GREASE

94107DS

TUBE - 14 OZ

AMBRA GR 75 MD GREASE

87400001

TUBE - 14 OZ

AMBRA GR 1000 SYNTHETIC GREASE

86994355

TUBE - 14 OZ

LIMITED SLIP ADDITIVE

B96606

Brake Fluid

BRAKE LHM FLUID ( Mineral Based Oil)

86541699DS

1QT / .946L

Coolant

ESE-M97B18-D, Ethylene Glycol Coolant Concentrate

FGCC2701DS

1G / 3.785L

Propylene Glycol Concentrate

FGCC2711DS

1G / 3.785L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 30

Transmission Oil

Hydraulic Oil

ATF Oil Gear Oil

AMBRA HYPOIDE 90 GEAR LUBE

AMBRA HYPOIDE 140 GEAR LUBE

Grease

00-6

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

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

METRIC NON-FLANGED HARDWARE AND LOCKNUTS CLASS 5.8

CLASS 8.8

CLASS 10.9

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL.8 W/CL8.8 BOLT

2.6 (23)*

3.4 (30)*

3.7 (33)*

4.8 (42)*

2.3 (20)*

7.6 (67)*

8.9 (79)*

12 (102)*

13 (115)*

17 (150)*

7.8 (69)*

14 (124)*

18 (159)*

22 (195)*

28 (248)*

31 (274)*

40 (354)*

19 (169)*

M10

28 (21)

36 (27)

43 (32)

56 (41)

61 (45)

79 (58)

38 (28)

M12

49 (36)

63 (46)

75 (55)

97 (72)

107 (79)

138 (102)

66 (49)

M16

121 (89)

158 (117)

186 (137)

240 (177)

266 (196)

344 (254)

164 (121)

M20

237 (175)

307 (226)

375 (277)

485 (358)

519 (383)

671 (495)

330 (243)

M24

411 (303)

531 (392)

648 (478)

839 (619)

897 (662)

1160 (855)

572 (422)

NOMINAL SIZE

UNPLATED

PLATED W/ZnCr

1.7 (15)*

2.2 (19)*

5.8 (51)*

UNPLATED

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

86529681 REV F 5.1

PROPERTY CLASS

00-7

CLOCK MARKING

SECTION 00 - GENERAL INFORMATION - CHAPTER 1

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

INCH NON-FLANGED 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

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

SAE GRADE 5

PLATED W/ZnCr

SAE GRADE 8

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

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

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

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

GOLD

UNPLATED or PLATED SILVER

LOCKNUTS

PLATED W/ZnCr GOLD

GR.B w/GR5 BOLT

14 (121)* 18 (157)* 8.5 (75)* 28 (250)* 37 (324)* 17.5 (155)* 50 (37) 65 (48) 31 (23) 80 (59) 104 (77) 50 (37) 123 (91) 159 (117) 76 (56) 176 (130) 229 (169) 111 (82) 244 (180) 316 (233) 153 (113) 432 (319) 560 (413) 271 (200) 698 (515) 904 (667) 437 (323) 1048 (773) 1356 (1000) 654 (483)

GR.C w/GR8 BOLT

NOMINAL SIZE

12.2 (109)* 25 (220)* 44 (33) 71 (53) 108 (80) 156 (115) 215 (159) 383 (282) 617 (455) 924 (681)

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 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

86529681 REV F 5.2

GRADE A NO MARK GRADE B LETTER B GRADE C LETTER C GRADE IDENTIFICATION

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.

3. Position the fitting by turning out (counter-clockwise) 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

1/4

6.4

7/16-20

TORQUE POUND NEWTON FOOT 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

25.4

1-5/16-12

110

120

149

163

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

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 inch (12.7 mm) OD and larger with wall thickness of 0.035 inch (0.889 mm) or less. The torque is specified for 0.035 inch (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 POUND NEWTON FOOT 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 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. Thread Size

Torque (Maximum)

1/8 inch - 27

13 N⋅m (10 lb ft)

1/4 inch - 18

16 N⋅m (12 lb ft)

3/8 inch - 14

22 N⋅m (16 lb ft)

1/2 inch - 14

41 N⋅m (30 lb ft)

3/4 inch - 14

54 N⋅m (40 lb ft)

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

50011183

1 2

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

00-10

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

H7460/H7560 Swivel Hitch Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Primary PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Front Half Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Front Half Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear Half Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear Half Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Intermediate PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front Half Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front Half Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear Half Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rear Half Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Secondary PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front Half Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front Half Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear Half Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear Half Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Slide Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Auto-Lok Slide Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Auto-Lok Slide Lock - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Auto-Lok Slide Lock - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Standard Driveline Guards - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Secondary Driveline Guards - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Standard Driveline Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

31-1

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

Description

Page

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 U-Joints: Swivel Hitch Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

31-2

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

H7460/H7560 SWIVEL HITCH DRIVELINE INTRODUCTION The primary PTO, 1, on the swivel hitch models uses a pair of U-joints to transfer power from the tractor to the lower swivel hitch gearbox. The U-joints are located at the tractor end of the primary PTO shaft, 2, and lower gearbox end, 3, allowing the tractor to turn the driveline during PTO operation.

The lower swivel hitch gearbox turns the upper gearbox, which transfers power to the intermediate PTO.

1 3

19985235

1 The intermediate PTO, 1, runs from the upper gearbox, 2, to a point midway along the tongue. The intermediate PTO uses a clamp yoke, 3, at the gearbox end and attaches to the jackshaft, 4, using a slip clutch assembly, 5.

4 19994422

2 The secondary PTO shaft, 1, attaches to the rear of the jackshaft, 2, using an Auto-Lok yoke, 3, and attaches to the center gearbox, 4, using a clamp hub assembly, 5.

2 19994458

3 1

4 3

31-3

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

Front Half Removal 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.

1. To service the front half of the primary PTO, 1, pull the front half from the rear half, 2, of the primary PTO. Refer to the Slide Lok, Driveline Guards, and U-joints sections in this manual to service the front half of the primary PTO.

19985198

Front Half Installation Align the female splines on the front half of the primary PTO with the male splines on the rear half of the primary PTO and slide the two shafts together. NOTE: Ensure the shields fit together properly and the two halves telescope freely. Rear Half Removal 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.

2 3

1. To service the rear half of the primary PTO, 1, pull the front half, 2, from the rear half of the primary PTO. 2. Remove the protective shielding by squeezing the sides together until they release from the retaining pins.

19985235

3. Pull back the slide lock, 3, and slide the primary PTO off the lower swivel gearbox.

1 5

4. Refer to the Slide Lok, Driveline Guards, and U-joints sections in this manual to service the rear half of the primary PTO.

31-4

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 Rear Half Installation 1. Pull back the slide lock, 1, and slide the primary PTO on the lower swivel gearbox.

2. Install the protective shielding by squeezing the sides together until the mounting holes align with the retaining pins, and release the shield.

3. Align the female splines on the front half, 2, of the primary PTO with the male splines on the rear half, 3, of the primary PTO and slide the two shafts together. NOTE: Ensure the shields fit together properly and the two halves telescope freely.

19985235

INTERMEDIATE PTO Front Half Removal 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. 1. Remove the protective shielding, 1, by squeezing the sides together until they release from the retaining pins. Slide the shield rearward on the shaft to gain access to the retaining bolts.

1 19994437

7 2. Remove the two 1/2 inch x 3 inch yoke bolts, 1, and lock nuts from the clamp yoke, 2, and slide the intermediate PTO off the upper swivel gearbox output shaft.

3. To service the front half, 3, of the intermediate PTO pull the front half from the rear half of the primary PTO. 4. Refer to the Slide Lok, Driveline Guards, and U-joints sections in this manual to service the rear half of the primary PTO.

2 19994433

3 8

31-5

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 Front Half Installation 1. Align the male yoke shaft on the front half, 1, of the intermediate PTO with the female yoke tube on the rear half of the intermediate PTO and slide the two shafts together.

NOTE: In the female yoke tube of the intermediate PTO there is a phase, the male yoke shaft will only fit in two positions. 2. Install the intermediate PTO, shield and position over the PTO with the small end of the shield facing the gearboxes.

19994433

9 NOTE: Ensure the shields fit together properly and the two halves telescope freely. 3. Slide the intermediate PTO onto the upper gearbox output shaft until the clamp yoke bolt holes align with the groove in the output shaft. 4. Install the two 1/2 inch x 3 yoke bolts, 2, and lock nuts. Torque to 159 Nâ&#x2039;&#x2026;m (117 lb ft). 5. Install the protective shielding by squeezing the sides together until the mounting holes align with the retaining pins, and release the shield.

31-6

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 Rear Half Removal 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. 1. Remove the protective shielding by pulling one side of shield from the retaining pin, then pull the other side from the retaining pin. Slide the shield rearward on the shaft to gain access to the retaining bolts.

2 3

2. Remove the two 1/2 inch x 2 inch yoke bolts, 1, and lock nuts form the slip clutch shaft, 2, and slide the intermediate PTO off the splined shaft. NOTE: Use caution not to loose the spacer, 3, and shims when removing the rear half of the PTO. 3. Pull the rear half of the intermediate PTO from the front half. 4. Refer to the Driveline Guards, U-joints sections, and the Slip Clutch sections in this manual to service the rear half of the intermediate PTO. Rear Half Installation 1. Align the male yoke shaft on the front half of the intermediate PTO with the female yoke tube on the rear half of the intermediate PTO and slide the two shafts together. NOTE: In the female yoke tube of the intermediate PTO there is a phase, the male yoke shaft will only fit in two positions. 2. Slide the intermediate PTO onto the splined shaft until the clamp yoke bolt holes align with the groove in the shaft. 3. Install the two 1/2 inch x 2 inch yoke bolts, 1, Figure 10, and lock nuts form the slip clutch shaft. Torque to 159 Nâ&#x2039;&#x2026;m (117 lb ft). 4. Install the protective shielding by pulling one side of shield on the retaining pin, and then pull the other side on the retaining pin.

31-7

1 19994455

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

Removal

1. Remove the intermediate PTO, 1, from the jackshaft, as described earlier in this section.

2. Remove the five 1/2 inch-13 carriage bolts and one 1/2 inch-13 cap screw, 2, and nuts, 3, from the flangettes, 4, and bracket, 5.

2 10001655

11 3. Remove the protective shielding by pulling one side of shield from the retaining pin, then pull the other side from the retaining pin. Slide the shield rearward on the shaft to gain access to the retaining bolts.

3 2

4. Pull back on the auto lock collar, 1, and pull the secondary PTO, 2, from the jackshaft. 5. Remove the six 1/2 inch-13 carriage bolts and nuts, 3, from the flangettes, 4. NOTE: There are two 1/2 inch flat washers installed between the shield bracket and flangette at the slot in the support.

10001659

1 12

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. 6. Support the entire jackshaft and shift the jackshaft towards the cutter bar, then lower the jackshaft to the ground.

31-8

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

1. Loosen the setscrews, 1, from the bearing, 2, on the rear half of the shaft assembly, 3.

2 4

2. Remove the bearing and inside flangette, 4, from the shaft assembly. 3. Remove the bracket, 5, from the shaft assembly. 4. Slide the protective tube, 6, from the shaft assembly.

10001657

13 5. Loosen the setscrews, 1, from the bearing, 2, on the front half of the shaft assembly.

6. Remove the bearing and inside flangette, 3, from the shaft assembly, 4.

10001658

14 Inspection 1. Clean and check the splines on the shaft for wear or distortion. If necessary, replace the shaft. 2. Check the flange bearing for heat discoloration. A blue discoloring indicates overheating and possible damage to the bearing. Make sure that the flange bearing rotates smoothly with no binding or roughness. Assembly

1. Install the inside flangette, 3, on the shaft assembly, 4.

2 4

2. Install the bearing, 3, on the front half of the shaft assembly until bearing touches the welded spacer. 3. Tighten the setscrews, 1, securely. 4. Slide the protective tube, 6, on the shaft assembly. 5. Install the bracket, 5, on the rear half of the shaft assembly. 6. Install the inside flangette, 4, on the shaft assembly. 7. Install the bearing, 2, on the shaft assembly, tighten the setscrews securely.

31-9

10001657

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 Installation 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. 1. Support the entire jackshaft and raise it into position so the flangettes rest in the bracket openings. NOTE: There are two 1/2 inch flat washers installed between the shield bracket and flangette at the slot in the support.

3 2

2. Install the outside flangette, 4, and six 1/2 inch-13 carriage bolts and nuts. Torque the bolts to 113 N⋅m (83 lb ft).

3. Pull back on the auto lock collar, 1, and push the secondary PTO, 2, on the jackshaft. 4. Install the protective shielding by pulling one side of shield on the retaining pin, then pull the other side on the retaining pin.

10001659

5. Install the five 1/2 inch-13 carriage bolts and nuts, 3, from the flangettes, 4, and bracket. Torque the bolts to 113 N⋅m (83 lb ft).

6. Install the one 1/2 inch-13 cap screw, 2, in the bottom hole of the bracket. Torque the bolts to 113 N⋅m (83 lb ft).

7. Install the intermediate PTO, 1, on the jackshaft, as described earlier in this section.

2 10001655

31-10

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 SECONDARY PTO Front Half Removal 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. 1. Remove the protective shielding by squeezing the sides together until they release from the retaining pins. Slide the shield rearward on the shaft to gain access to the auto lock collar. 2. Slide the auto lock collar, 1, rearward and pull the secondary PTO, 2, from the jackshaft. 3. To service the front half of the secondary PTO pull the front half from the rear half of the secondary PTO. 4. Refer to the Auto Lok, Driveline Guards, and U-joints sections in this manual to service the rear half of the secondary PTO.

10001659

1 18

Front Half Installation 1. Align the male yoke shaft on the rear half of the secondary PTO with the female yoke tube on the front half of the secondary PTO and slide the two shafts together. 2. Install the secondary PTO, shield and position over the PTO with the small end of the shield facing the gearboxes. NOTE: Ensure the shields fit together properly and the two halves telescope freely. 3. Slide the secondary PTO onto the jackshaft until the auto lock slips into position. 4. Install the protective shielding by squeezing the sides together until the mounting holes align with the retaining pins, and release the shield.

31-11

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 Rear Half Removal 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. 1. Remove the secondary PTO front half from the secondary rear half as described earlier in this section. 2. Remove the four retaining bolts, 1, from the shield, Remove the shield.

1 2

10001660

19 3. Remove the two 1/2 inch-13 cap screws, 1, from the clamp hub assembly, 2.

4. Remove the clamp hub assembly. Turn out the center cap screw, 3, about 9.5 mm (3/8 in).

5. Pull the rear half of the secondary PTO from the center gearbox.

NOTE: It may be necessary to heat the clamp yoke to break the shaft loose from the gearbox. 6. Refer to the Driveline Guards and U-joints sections in this manual to service the rear half of the secondary PTO.

10001661

31-12

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 Rear Half Installation 1. Clean the center gearbox spline shaft of rust and dirt. Lubricate the shaft with corrosion inhibiting compound. 2. Slide the clamp yoke end of the drive shaft onto the center gearbox spline shaft.

3. Use a soft faced hammer or mallet and strike the tractor end of the shaft and seat the shaft completely on the gearbox spline.

4. Turn in the center cap screw, 1, and tighten as much as possible to pull the clamp yoke securely onto the tapered end of the gearbox shaft.

5. Install the shaft clamp. Torque the two cap screws, 3, to 87 Nâ&#x2039;&#x2026;m (64 lb ft). 10001661

21 6. Install the shield, Install the four retaining bolts, 1, and tighten securely. 7. Install the secondary PTO front half on the secondary rear half as described earlier in this section.

1 10001660

2 22

31-13

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

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

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

19990039

24 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.

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

31-14

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

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

19990039

26 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

31-15

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

19990039

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

19990038

31-16

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 1 AUTO-LOK SLIDE LOCK

The H7460 and H7560 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

30 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.

1 3

1431-3-19

31 AUTO-LOK Slide Lock - Disassembly

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

31-17

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.

1431-3-19

33 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

34 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.

1431-3-19

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.

31-18

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.

1431-3-18

36 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

37 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

31-19

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

39 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.

A3657-06

5. Check that the retaining ring and nylon bushing have seated properly in the guard, and that the guard rotates freely. 6. Reinstall the grease zerk, 1, on the end of the female secondary PTO shaft, as shown.

1411/3-21

31-20

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

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

42 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

43 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

31-21

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

45 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.

19990046

46 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

31-22

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

48 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.

IMPORTANT: Support the yoke properly to prevent bending and damage. IMPORTANT: Keep the opposite yoke upright to prevent binding and damage. 19990048

49 IMPORTANT: Pressing the bearing more than about 9.5 mm (3/8 in) will bottom out the cross against the yoke. Do not push any farther once the cross has bottomed out.

19990050

31-23

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

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

19990051

52 9. Inspect the rubber grease seals on the bearings, replacing any that show wear or damage.

19990052

31-24

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

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

19990044

55 3. Remove the yoke from the vise and start the opposite bearing cup into the yoke from the outside.

19990049

31-25

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

57 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

31-26

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

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 2 - Slip Clutch CONTENTS Section

Description

Page

H7460/H7560 Swivel Hitch Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Slip Clutch Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

31-1

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

H7460/H7560 SWIVEL HITCH DRIVELINE INTRODUCTION

The slip clutch, 1, on the H7460 and H7560 disc mower-conditioner is part of the intermediate PTO drive shaft and is mounted on the jackshaft. It is set to slip in the event an overload occurs during machine operation. 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. 10001652

1 Slip Clutch Run-In To burnish the slip clutch: 1. Remove the protective shielding by pulling one side of shield from the retaining pin, then pull the other side from the retaining pin. Slide the shield rearward on the shaft to gain access to the retaining bolts. 2. Loosen the six cap screws, 1, one half turn at a time until the cap screws are just loose, then retighten all six cap screws one half turn. 3. Attach a tractor to the disc mower-conditioner as outlined in the “General Information” section of the manual, if not already connected.

1 19994455

4. 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.

5. After slipping the clutch, retighten the six cap screws one half turn at a time until the compression plate, 1, contacts the clutch housing, 2.

IMPORTANT: the slip clutch is set at 2034 N⋅m (18,000 lb in) [static] of breakaway torque. Do not attempt to alter the slip clutch setting or damage to the machine may result. 6. Install the protective shielding by pulling one side of shield on the retaining pin, and then pull the other side on the retaining pin.

19994455

31-2

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 Wear Inspection The amount of wear on the slip clutch friction discs can be determined without disassembling the clutch.

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

19994455

4 Removal 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. 1. Remove the protective shielding by pulling one side of shield from the retaining pin, then pull the other side from the retaining pin. Slide the shield rearward on the shaft to gain access to the retaining bolts.

31-3

1 19994455

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 Disassembly 1. Loosen the six 5/16 inch-18 x 2-1/2 inch cap screws, 1, around the clutch housing, one half turn at a time until the six cap screws are loose. Carefully remove and discard the six cap screws and nuts from the clutch.

10001662

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

10001665

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

3. Discard the friction discs, 4, and 6.

50006843

2 8

31-4

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 Inspection 1. Inspect the separator plate, 1, for distortion, warpage or cracking, replace if any damage is found.

2. Both faces of the separator plate should have a rough surface, replace if either surface is smooth. 3. Inspect the inner drive tangs for excessive wear, replace the plate if drive tangs are rounded off or worn more than 1/3 through. 4. Inspect the ribbed pressure plate, 2, for discoloration or cracking, replace if necessary.

10001664

5. Lay a straight edge across the face of the pressure plate, replace if warped more than 1.6 mm (1/16 in). 6. Inspect the disc spring, 1, for discoloration or cracking, replace if necessary.

7. Place the disc spring on a flat surface; use a depth micrometer or calipers to measure the height of the disc spring. The height should be between 10.2 - 10.7 mm (0.400 in - 0.420 in). Replace the spring if the measurement is less than the specified range.

50006843

31-5

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

2. Install the pressure plate, 4, 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.

3. Install the disc spring, 5, over the clutch hub so the inside diameter of the disc spring contacts the ribs on the pressure plate.

50006843

5 11

4. Install the compression plate, 1, over the clutch hub and against the outer diameter of the clutch spring.

5. Install six new six 5/16 inch-18 x 2-1/2 inch cap screws, 2, through the compression plate and grooves in the housing. Insert new 5/16 inch-18 nuts in the pockets on the front of the clutch housing and thread the bolts into the nuts until snug.

6. Tighten the six cap screw, 2, an additional one half turn, to hold the clutch components securely, and to provide the setting for running in the clutch.

10001662

7. The slip clutch must be installed on the unit and â&#x20AC;&#x153;Run-Inâ&#x20AC;? before use.

31-6

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

1. Align the male yoke shaft on the front half of the intermediate PTO with the female yoke tube on the rear half of the intermediate PTO and slide the two shafts together.

NOTE: In the female yoke tube of the intermediate PTO there is a phase, the male yoke shaft will only fit in two positions. 2. Slide the intermediate PTO onto the splined shaft until the clamp yoke bolt holes align with the groove in the shaft.

1 19994455

3. Install the two 1/2 inch x 2 inch yoke bolts, 1, and lock nuts form the slip clutch shaft. Torque to 159 N⋅m (117 lb ft). 4. Attach a tractor to the disc mower-conditioner as outlined in the “General Information” section of the manual, if not already connected. 5. 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. 6. After slipping the clutch, retighten the six cap screws one half turn at a time until the compression plate, 1, contacts the clutch housing, 2.

IMPORTANT: the slip clutch is set at 2034 N⋅m (18,000 lb in) [static] of breakaway torque. Do not attempt to alter the slip clutch setting or damage to the machine may result. 7. Install the protective shielding by pulling one side of shield on the retaining pin, and then pull the other side on the retaining pin.

19994455

31-7

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 OVERRUNNING CLUTCH Disassembly 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 a described earlier in this section. It is possible to repair the overrunning clutch without disassembling the slip clutch. 1. Remove the four 5/16 inch-18 x 1 inch cap screws, 1, holding the overrunning clutch to the slip clutch housing.

10001668

15 2. Remove the snap ring, 1, and washer, 2, from the hub, 3, of the overrunning clutch.

10001669

16 3. Slowly remove the hub, 1, from the inner hub, 2, and retain the keys, 3, and leaf springs, 4, while removing the hub from the inner hub.

4. Remove the wave spring, 5, from the inner hub.

10001671

31-8

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 5. Remove the 5/16 inch-18 set screw, 1, from the inner hub, 2.

1 10001672

18 6. Rotate the inner hub while holding the hole down until the 31 ball bearings fall out. NOTE: It may be necessary to apply a small amount of penetrating fluid to assist in the removing of the ball bearings

10001673

19 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 necessary. 2. Inspect the overrunning hub and yoke bearing grooves and mating surfaces for galling or other damage, replace as necessary. 3. Discard the ball bearings and replace with new parts.

10001674

31-9

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 Assembly 1. Apply a film of grease to the inner and outer race of the ball bearing cavity. 2. Install the inner hub onto the yoke. 3. Install the ball bearings until all 31 are in place.

10001673

21 4. Install the set screw and tighten securely. 5. Apply grease through the zerk while rotating the overrunning hub to distribute the lubricant evenly. Wipe away any excess grease.

10001672

22 6. Install the wave spring, 1, in place over the yoke.

7. Apply grease to the spring recesses, 2, in the inner hub. 8. Install the leaf springs into place with the curved in side facing toward the center.

50006853

1 23

31-10

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 2 9. Apply a film of grease to the keys and set each in place on top of the leaf springs.

10. Install the outer hub, 1, on the inner hub.

11. Install the washer, 2, and snap ring, 3.

10001669

2 24

12. Install the overrunning clutch assembly into the slip clutch assembly.

13. Install the four 5/16 inch-18 x 1 inch cap screws, 1, holding the overrunning clutch to the slip clutch housing, tighten securely 14. Install the slip clutch on the unit a described earlier in this section.

10001668

1 25

31-11

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

31-12

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

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 3 - Gearbox (Swivel Hitch) CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Swivel Hitch Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Neck Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Neck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Upper Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Upper Gearbox and Neck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Gear Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Lower Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lower Gearbox and Neck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Gear Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Lower Gearbox, Neck Assembly, and Upper Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Swivel Hitch Gearbox Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

31-1

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

2 5

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.

A4898-06

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 3

31-3

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

31-4

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

31-5

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

SWIVEL HITCH GEARBOXES

OVERHAUL

Description 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.

The Swivel Hitch Gearbox on H7460/H7560 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

31-6

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

1. 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.

36092372

1 6

2. 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

WARNING Properly block and support the hitch and trunnion assemblies. Failure to do so could result in them becoming unstable and falling off lifting or supporting devices. Failure to comply could result in death or serious injury.

10001626

3 7

M1503

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

50013379

31-7

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 3. Remove the 5/16 x 1 inch 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 4. Using a punch and hammer, drive the 5/16 x 2-1/2 inch pin, 1, out from the coupling and shaft.

1 10001627

10 5. 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 inch cap screws, 3, that hold the upper gearbox to the tongue.

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

10001628

31-8

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 6. 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 7. 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 1-1/2 inch 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 13

8. 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.

10001631

31-9

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

1. Prior to disassembly, drain the oil from the upper and lower gearboxes by removing the oil drain plugs, 1. 2. Remove the breathers, 2, in the upper and lower gearboxes to prevent them from being damaged during disassembly.

10992721

2 15

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

10992728

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

10001632

31-10

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 5. Remove the remaining eight hex socket head M10 x 22 mm cap screws that secure the neck collar to the upper gearbox.

10992727

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

10001633

31-11

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

1. Remove the cotter pin, 1, from the castellated nut.

10992651

20 2. Remove the castellated nut, 1.

10992652

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

10992720

1 22

31-12

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 4. 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 5. 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 6. 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

31-13

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 7. Turn over the neck assembly and remove the bearing race, 1, from the outer neck assembly.

1 10992657

26 8. 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 9. Remove the lock nut, 1, from the outer neck assembly. Use the special lock nut tool (local manufacture). 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 Loctiteâ&#x201E;˘. Use heat if necessary to loosen the lock nut.

1 10992659

31-14

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 10. Press the inner neck out of the outer neck, removing the bearings and thrush washers in the process.

10992660

29 11. 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 12. Inspect all parts from the neck assembly. Replace any worn or damaged parts. Replace all seals during assembly.

10992661

31-15

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 Neck Assembly NOTE: Assembly requires special tools, both purchased and of local manufacture. See â&#x20AC;&#x153;Special Toolsâ&#x20AC;? for instructions regarding special tool availability and dimensions for manufacture. 1. Coat the O-ring with petroleum jelly and install it in the groove in the inner neck assembly,1. 2. 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

3. Install the seal and bearing race in the outer neck case. IMPORTANT: 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 4. 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 3 5. Press the outer neck bearing onto the inner neck.

10992667

35 6. Install the lock nut with Loctite 242 sealant.

10992668

36 7. 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 3 8. Use the special tightening tool, 1, to tighten the lock nut. Torque the locknut to 490 to 540 Nâ&#x2039;&#x2026;m (363 to 399 lb ft). 9. 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 10. 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&#x2039;&#x2026;m (87 - 109 lb in). Retorque the locknut and reseat the bearings as required to obtain the proper rolling torque.

10992670

1 39

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

10001646

31-18

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 12. 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 13. 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 14. Place previously removed shims over the outer bearing and press the gear onto the shaft (beveled end up).

10992673

31-19

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 15. 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&#x2039;&#x2026;m (4 - 10 lb in). Set the preload by striking the shaft and turning it approximately ten revolutions.

10992674

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

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. Then tighten the castle nut slowly to obtain the correct preload.

10992674

45 17. Install the cotter pin to retain the castellated nut.

10992651

31-20

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

Disassembly 1. Remove the eight M10 x 22 cap screws securing the cover, 1, to the housing, 2.

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.

10001636

31-21

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

1 10986527

31-22

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 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 M10 x 22 bolts, 2, and torque to 41 Nâ&#x2039;&#x2026;m (30 lb ft).

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 in) of endplay on the shaft.

50013374

NOTE: The shims used are available in 0.012 inch, 0.016 inch, and 0.020 inch thicknesses. The shim pack thickness can be changed in 0.004 inch increments by removing a shim and installing the next size thicker shim to increase or decrease endplay. 8. When the proper end play has been obtained the shaft rolling torque needs to be calculated. 9. Install a 1/2 inch 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 Nâ&#x2039;&#x2026;m (2 - 6 lb in).

A4834-4

31-23

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

2. Install the eight M10 x 22 hex bolts to attach the neck to the upper gear box. Torque the bolts to 78 N⋅m (58 lb ft) 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 in to 0.004 in); this indicates a true backlash of 0.21 to 0.57 mm (0.008 in to 0.022 in).

50013376

31-24

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 Backlash Adjustment If the backlash reading is less than the required measurement. 1. Remove the eight M10 x 22 hex bolts to attach the neck to the upper gear box using special tool, 1.

2. Remove the neck assembly from the upper gearbox.

10996523

57 3. Remove the eight M10 x 22 cap screws, 1, securing the cover to the housing.

10992723

58 4. Remove the cover from the housing.

5. Remove the shaft and gear assembly, 1, from the housing.

10001635

31-25

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

10001636

50013380

31-26

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 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 inch, 0.016 inch, and 0.020 inch thicknesses. The shim pack thickness can be changed in 0.004 inch increments by removing a shim and installing the next size thicker shim to increase or decrease backlash. 8. Assemble the shaft as described earlier in this section.

10001636

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. 11. Install the eight M10 x 22 cap screws securing the cover to the housing. Torque the bolts to 78 N⋅m (58 lb ft). 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.

13. Install the eight M10 x 22 hex bolts to attach the neck to the upper gear box. Torque the bolts to 78 N⋅m (58 lb ft) using special tool, 1. 14. Check for proper backlash reading at the input shaft as described earlier in this section.

10996523

31-27

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

1. Remove the eight M10 x 22 hex bolts that attach the neck assembly to the upper gear box using special tool, 1. 2. Remove the neck assembly from the upper gearbox.

10996523

65 3. Remove the eight M10 x 22 cap screws, 1, securing the cover to the housing, 2.

10992723

66 4. Remove the cover from the housing.

5. Remove the shaft and gear assembly, 1, 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 LoctiteÂŽ 270 to the gearbox at this time. 8. Install the cover on the housing.

10001635

31-28

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 9. Install the eight M10 x 22 cap screws securing the cover, 1, to the housing, 2. Torque the bolts to 78 Nâ&#x2039;&#x2026;m (58 lb ft).

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

10992723

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

11. Install the eight M10 x 22 hex bolts to attach the neck assembly to the upper gear box. Torque the bolts to 78 Nâ&#x2039;&#x2026;m (58 lb ft) 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

69 13. Remove the eight M10 x 22 hex bolts that attach the neck assembly to the upper gear box using special tool, 1.

14. Remove the neck assembly from the upper gearbox.

10996523

31-29

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 15. Remove the eight M10 x 22 cap screws, 1, securing the cover to the housing.

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

10992723

71 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

31-30

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

50013380

73 20. Remove shims at A, between the inner bearing and bevel gear. NOTE: The shims used are available in 0.012 inch, 0.016 inch, and 0.020 inch thicknesses. The shim pack thickness can be changed in 0.004 inch 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; 22. Disassemble the neck assembly as describe earlier in this section.

31-31

A 10001646

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

50013380

75 23. Add shims at A, between the inner bearing and bevel gear. NOTE: The shims used are available in 0.012 inch, 0.016 inch, and 0.020 inch thicknesses. The shim pack thickness can be changed in 0.004 inch 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

31-32

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

Disassembly 1. Remove the eight M10 x 22 cap screws securing the cover, 1, to the housing, 2.

10992723

77 2. Remove the cover from the housing, and slide the shaft and gear assembly, 1, from the housing.

10001635

78 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.

10001636

31-33

10992722

80 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

1 10986527

31-34

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 5. Install the shaft and gear assembly in the case.

10992723

82 6. Apply a bead of RTV silicone sealant to the mating surfaces and install the cap, 1, over the shaft. Install the eight M10 x 22 x 8.8 bolts, 2, and torque to 41 Nâ&#x2039;&#x2026;m (30 lb ft).

3 1

50013374

NOTE: Make two complete revolutions of the shaft to seat the bearing rollers before measuring rolling torque. 8. When the proper end play has been obtained the shaft rolling torque needs to be calculated. 9. Install a 1/2 inch 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 Nâ&#x2039;&#x2026;m (2 - 6 lb in).

A4834-4

31-35

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

2. Install the eight M10 x 22 hex bolts to attach the neck to the lower gear box. Torque the bolts to 78 N⋅m (58 lb ft) using special tool, 1.

10996523

85 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 in to 0.004 in); this indicates a true backlash of 0.21 to 0.57 mm (0.008 in to 0.022 in).

50013376

31-36

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 Backlash Adjustment If the backlash reading is less than the required measurement;

1. Remove the eight M10 x 22 hex bolts to attach the neck to the lower gear box using special tool, 1. 2. Remove the neck assembly from the lower gearbox.

10996523

87 3. Remove the eight M10 x 22 cap screws, 1, securing the cover to the housing.

10992723

88 4. Remove the cover from the housing. 5. Remove the shaft and gear assembly, 1, from the housing.

10001635

31-37

10001636

50013380

31-38

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

10001636

10. Install the cover on the housing.

92 11. Install the eight M10 x 22 cap screws, 1, securing the cover to the housing. Torque the bolts to 78 N⋅m (58 lb ft).

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

10992723

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

10996523

31-39

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

1. Remove the eight M10 x 22 hex bolts that attach the neck assembly to the lower gear box using special tool, 1. 2. Remove the neck assembly from the lower gearbox.

10996523

95 3. Remove the eight M10 x 22 cap screws, 1, securing the cover to the housing.

10992723

96 4. Remove the cover from the housing. 5. Remove the shaft and gear assembly, 1, from the housing.

10001635

31-40

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

98 9. Install the eight M10 x 22 cap screws, 1, securing the cover to the housing. Torque the bolts to 78 N⋅m (58 lb ft).

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

10992723

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

11. Install the eight M10 x 22 hex bolts to attach the neck assembly to the lower gear box. Torque the bolts to 78 N⋅m (58 lb ft) 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

100

31-41

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 13. Remove the eight M10 x 22 hex bolts that attach the neck assembly to the lower gear box using special tool, 1.

14. Remove the neck assembly from the lower gearbox.

10996523

101 15. Remove the eight M10 x 22 cap screws, 1, securing the cover to the housing.

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

10992723

102 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

103

31-42

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

50013380

104 20. Remove shims at A, between the outer bearing and bevel gear. NOTE: The shims used are available in 0.012 inch, 0.016 inch, and 0.020 inch thicknesses. The shim pack thickness can be changed in 0.004 inch 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.

31-43

A 10001646

105

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

50013380

106 24. Add shims at A, between the inner bearing and bevel gear. NOTE: The shims used are available in 0.012 inch, 0.016 inch, and 0.020 inch thicknesses. The shim pack thickness can be changed in 0.004 inch 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. 26. Repeat the addition or removal of the shims until the contact pattern reaches 40% central-toe.

A 10001646

107

31-44

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

108

3. Install the neck assembly on the lower gearbox. 4. Apply Loctite 270 to the threads of the eight M10 X 22 hex bolts. 5. Install the eight M10 x 22 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 lb ft) 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 M10 X 22 hex bolts. 12. Install the eight M10 x 22 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

109

31-45

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 14. Torque the bolts to 78 Nâ&#x2039;&#x2026;m (58 lb ft) using special tool, 1. 15. If necessary, install the oil filler fittings on each gearbox.

1 10992728

110 Swivel Hitch Gearbox Installation 1. Lower the swivel hitch gearbox into the trunnion assembly. Install four hardened flat washers and the 5/8 x 1-1/2 inch 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

111

31-46

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 2. 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

112 3. Install the plate, 1, two hardened washers, and the 5/8 x1-1 /2 inch 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 40 mm cap screws were used. Replace these with class 10.9 plated M16 x 40 mm cap screws and torque to 344 Nâ&#x2039;&#x2026;m (254 lb ft). On tongue serial number 619310 and above, grade 5 plated 5/8 x 1-1/2 inch cap screws were used in production. Replace these sixteen cap screws with grade 8 plated 5/8 x 1-1/2 inch cap screws and torque to 315 Nâ&#x2039;&#x2026;m (232 lb ft).

10001628

113

NOTE: Start the cap screws by hand. Make sure they are fully started before tightening. 4. 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.

2 10001627

114

31-47

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) - CHAPTER 3 5. Reinstall the top shield over the driveline by install the 5/16 x 1 inch flanged cap screws, 1.

10001626

115 6. 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. 7. Reinstall the PTO shield, primary PTO, and the support.

8. Fill the gearbox with 80W90 oil. Lubricate all grease fittings before using the disc mower/conditioner. 19985198

116

31-48

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

SECTION 35 - HYDRAULIC SYSTEM Chapter 1 - Cylinders CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bleeding Air from the Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Header Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Tongue Swing Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

35-1

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 INTRODUCTION

Four different cylinders are used on the Model H7460 and H7560 disc mower-conditioners to control the unit during operation.

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 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) 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.

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.

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

20002690

35-2

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.

2 A4833-8

3 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

35-3

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 HYDRAULIC DIAGRAM

0.093 inch

TILT CYLINDER

1431-8-8

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. Failure to comply could result in death or serious injury. M1184

35-4

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 BLEEDING AIR FROM THE LIFT CYLINDERS

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. 1. Loosen the hose swivel fitting, 1, at the upper end of the slave cylinder. NOTE: Use a shop rag or other shielding means for protection from seeping oil at loosened fittings. 2. 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. 3. Raise and lower the header several times until all air is purged from the system. Repeat the previous steps if necessary.

35-5

86080761

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 LIFT CYLINDER Removal

WARNING Before disconnecting the lift cylinder hose, be sure the header is resting on the ground or on the Header lift locks. Failure to comply could result in death or serious injury.

M1190

1. Engage the header transport stops by pivoting lever, 1, forward. Install the pin, 2, Figure 8, to lock the header tilt cylinder in the 2 degree position.

50051189

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

1431-2-19

8 3. Remove the hose(s), 1, at the cylinder port(s) to remove either of the two cylinders. 4. Remove pins, 2, and 3, to remove the lift cylinder.

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

2 3 86080761

35-6

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 MASTER CYLINDER Disassembly 1. Remove setscrew, 1.

A1411/9-6

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

A1411/9-7

11 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

35-7

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. 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, 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

13 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&#x2039;&#x2026;m (155 lb ft).

4. Install the piston seal, 3.

A1411/9-8

35-8

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

SLAVE CYLINDER Disassembly 1. Remove setscrew, 1.

A1411/9-13

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

A1411/9-13

35-9

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

18 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. Assembly 1. Lubricate all seals and sliding surfaces before assembly.

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&#x2039;&#x2026;m (155 lb ft).

35-10

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

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. 2. Engage the travel locks on the disc mower. Lower the mower so that it is resting on the locks.

20002675

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.

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

3 22

35-11

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Disassembly

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

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

20002683

24 4. Remove the retaining ring, 1, from the cylinder. 5. Withdraw the piston rod assembly sharply to remove it from the cylinder.

1 20002680

35-12

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

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

1 20002678

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

20002677

3 27

35-13

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Assembly 1. Lubricate the flange, piston and seals with clean hydraulic oil before assembling.

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

20002676

28 3. Apply Loctiteâ&#x201E;˘ 242 onto the threads of the outer half of the piston rod.

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

20002677

29 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.

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

20001727

35-14

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

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

11. Slide the piston, 2, onto the end of the piston rod and secure it with a lock nut, 3. Torque the lock nut onto the piston rod to 210-251 Nâ&#x2039;&#x2026;m (155-185 lb ft). Allow the inner piston rod to rotate on the outer piston rod. The torque between the two rods is also 210-251 Nâ&#x2039;&#x2026;m (155-185 lb ft).

1 20002678

31 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

32 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

35-15

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.

20002681

34 17. Install the self locking set screw, 1, into the side of the cylinder.

18. Remove the cylinder from the vise.

20002682

35-16

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Installation 1. Insert the enclosed bushings, 1, into the rod, 2, and barrel end clevis.

2 1 20002657

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

20002658

37 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.

1 20002659

35-17

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.

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

20002660

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

7. Attach the hydraulic hose, 2, to the cylinder port. 8. Install the nut, 3, and bolt, 4, into the limit channel.

20002661

3 40

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

20002661

35-18

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 TONGUE SWING CYLINDER

Removal 1. Remove the hydraulic hoses, 1, and cap the hose ends.

2 20002656

42 2. Remove clevis pin, 1, cap screw, 2, lock washer, 3, flat washer, 4, and spacer, 5.

3. Remove cylinder port plugs, 6.

4. Remove the cylinder from the disc mower.

20002654

35-19

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Disassembly 1. Clamp the swing cylinder in a vise.

20002684

44 2. Unscrew the flange from the cylinder.

20002685

45 3. Remove the piston rod assembly from the cylinder.

20002689

35-20

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Assembly 1. Lubricate the flange, piston and seals with clean hydraulic oil before assembling.

4. Install the o-ring, 3, and backup ring, 4, on the flange.

2. Install the 3 piece seal, 1, on the piston as shown.

5. Install the inner flange seal, 5, into the flange.

3. Install the wear ring, 2, on the piston.

6. Install the oil seal, 6, into the end of the flange.

1 4

20002690

35-21

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 7. Clamp the piston rod into a vise.

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. NOTE: On new production models the clevis is welded to the piston rod.

20002691

48 10. Slide the piston over the end of the rod. Install the lock nut, 2, and torque to 339-366 Nâ&#x2039;&#x2026;m (250-270 lb ft).

2 20002692

35-22

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 11. Remove the piston rod assembly from the vise. 12. Clamp the swing cylinder in a vise.

20002686

50 13. Lubricate the piston and inside of cylinder with clean hydraulic oil. 14. Slide the piston rod assembly carefully into the cylinder.

20002687

51 15. Screw the flange, 1, into the cylinder and torque to 373-407 Nâ&#x2039;&#x2026;m (275-300 lb ft).

20002688

35-23

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Installation

1. Align the hole of the barrel end clevis with frame mount.

2. Insert the clevis pin, 1, to attach the cylinder to the frame.

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. NOTE: On new production models the clevis is welded to the piston rod.

20002654

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.

7. Insert the clevis pin, 3, to attach the cylinder to the tongue.

20002655

35-24

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.

1 2 3 4

20002655

55 9. Install the 90Â° elbows, 1, into the cylinder ports.

10. Attach the hydraulic hoses, 2, to the cylinder ports.

2 20002656

35-25

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

35-26

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1

SECTION 39 - FRAMES/TONGUE AND HITCHES Chapter 1 - Hood and Hood Liner (H7560 Only) CONTENTS Section

Description

Page

Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hood Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

39-1

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1 HOOD 1

Removal 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. Raise the hood by turning the crank, 1, clockwise.

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

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.

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. Use caution when installing, removing or handling. Failure to comply may result in minor or moderate injury. M1448

19990085

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

39-4

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1 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. Use caution when installing, removing or handling. Failure to comply may result in minor or moderate injury. M1448

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

39-5

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1 4. Install the down stop bolts and spacers, 1.

19985249

13 5. Reattach the hood to the adjustment arm, 1, using the hardware taken off during removal at 2.

19990083

14 6. Raise the hood to the desired conditioning level by turning the crank, 1, counter-clockwise. 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.

19985216

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.

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 is heavy. Use caution when installing, removing or handling. Failure to comply may result in minor or moderate injury. M1448

4. Remove the liner sections from the machine. 19985249

1 18

39-7

SECTION 39 - FRAMES/TONGUE AND HITCHES - CHAPTER 1 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 specification.

19985249

1 20

3. Lower the hood to the desired conditioning level and resume operation.

19985216

39-8

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

SECTION 55 - ELECTRICAL SYSTEM Chapter 1 - Implement Lights CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Trailing Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installing #9603575 Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Trailer Connector Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lighting Control Box - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Model H7460/H7560 Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

55-1

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 INTRODUCTION The H7460/H7560 pivot-tongue disc mowerconditioner is equipped with flashing amber lights, 1, and red tail/brake lights, 2, to improve machine visibility and to warn operators of other vehicles.

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.

1431-1-28

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.

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

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 DESCRIPTION

The H7460/H7560 pivot-tongue disc mowerconditioner 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. Left

Right

19985205

Mower Conditionerâ&#x20AC;&#x2122;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

Lights On

Off

Brakes Only

Off

Hazards/No Brakes

Flashing

Off

Flashing

Hazards with Brakes

Flashing

Off

Flashing

Left Turn/No Brakes

Flashing

Off

Left Turn with Brakes

Flashing

Off

Right Turn/No Brakes

Off

Flashing

Off

Flashing

Right Turn with Brakes

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 H7460/H7560 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

White (WHT)

Ground wire, all lights

Black (BLK)

Not Used

Yellow (YEL)

Left side amber light

Red (RED)

Brake lights

Green (GRN)

Right side amber light

Brown (BRN)

Taillights

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 tractors are wired to provide the brake light signal through the number 4 pin in the connector socket. Some model 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 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. IMPORTANT: When you later reattach the machine to a standard electrical socket on propelling vehicle, the brake light circuit must be reconnected to function.

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.

19994424

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.

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.

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 inch of the wire. Insert the bare end of the wire fully into the connector, and tighten the screw securely to retain the wire.

1431-9-3

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 in) for identification. The end plug on the connector is labeled to assist in assembly.

LIGHTING CONTROL BOX REMOVAL AND INSTALLATION

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. 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 11

6. Secure the control box guard in place with four cap screws, 1, and nuts.

55-8

MODEL H7460/H7560 WIRING SCHEMATIC

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

55-9

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

55-10

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

SECTION 58 - ATTACHMENTS/HEADERS Chapter 1 - Cutter Bar CONTENTS Section

Description

Page

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Knife And Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disc Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7 Degree Twist Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 14 Degree Twist Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 V Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Knife Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crop Lifter Replacement (Model H7460 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rock Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Skid Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cutter Bar Inspection/Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Top Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Cutter Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Cutter Bar Bayonet Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cutter Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Disc Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 Section

Description

Page

Cutter Bar Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

58-2

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 H7460 and H7560 DiscbineÂŽ disc mower-conditioners use a 12 disc cutter bar to provide a 15 foot 7 inch cutting width. The two end discs, 1, 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). Each end of the cutter bar is equipped with open feed towers to help feed crop into the conditioner. The cutter bar is driven from both ends through drive shafts, 2, connected to the #3 and #10 discs.

1 19994436

3 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.

36092371

58-3

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

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 counter-clockwise. 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 in) thick and hardened for long wear. The profile of the discs, combined with bolt-on lifters (H7460 only), 2, provides aggressive feeding to the conditioner in difficult crop conditions.

1441-2-48

The discs are equipped with 50.8 mm (2 in) wide knives, 3, which are retained with 1/2 inch 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.

3 4

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 Each disc module is protected by a ductile iron rock guard, 1, and a skid shoe, 2.

Skid shoes are 6.4 mm (1/4 in) thick and 203 mm (8 in) 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, H7460, H7560, and 2355 DiscbineÂŽ disc mowerconditioners, 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.

5000-11

2 5

The H7460 and H7560 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

36092373

58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 Model H7460 and H7560 disc mower-conditioners use a smaller diameter drum, 1, around each cutter bar drive shaft. The two halves of the drive are bolted together at, 2, and to the drive shafts at, 3. The drum can be removed from the drive shaft without removing the shaft from the drive module.

2 1

19994432

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. 1. Remove discs by removing four bolts at 2. 4896-10

8 2. 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 inch cap screws cupped lock washers

#2 & #9 discs & towers

1/2 x 1-1/4 inch cap screws thick hardened washers

#3 & #10 discs, towers & drive shafts

1/2 x 1-3/4 inch cap screws thick hardened washers

19994432

IMPORTANT: Use of incorrect disc retaining hardware may cause cutter bar lock-up and potential damage, or may prevent proper retention of discs. 3. Torque retaining bolts to 113 Nâ&#x2039;&#x2026;m (83 lb ft). 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

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. Failure to comply could result in death or serious injury. M1260

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

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.

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 DiscbineÂŽ disc mower-conditioners and disc mowers are shipped with these knives from the plant. Clockwise Knife counter-clockwise Knife

19986850

9847684 9847683

14 DEGREE TWIST KNIVES The 14 degree twist knives, 2, are recommended in lighter crop conditions. A greater knife twist angle enables the knifeâ&#x20AC;&#x2122;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 Knife counter-clockwise Knife

86561093 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

13 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

1441-2-45

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

19994377

15 6. The leading edge of the knives must be lower than the rear edge. On the Model H7460 and H7560 mower-conditioners, the three 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&#x2039;&#x2026;m (117 lb ft). 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. 1441-2-46

CROP LIFTER REPLACEMENT (MODEL H7460 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. 1. 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. 2. Torque the bolts to 159 Nâ&#x2039;&#x2026;m (117 lb ft).

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

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 ROCK GUARDS Rock guards, 1, can be removed by removing bolts, 2.

Broken rock guards should be replaced immediately. Rock guards which are worn thin should be replaced before they break.

2 5000-11

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.

NOTE: It may be easier to install the skid shoe by first loosening the rock guard mounting bolts, 2, Figure 18. Broken skid shoes should be replaced immediately. Skid shoes which are worn thin should be replaced before they break.

5000-09

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: 1. 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 1

19994432

3 20

2. 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 in) 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 Nám (83 lb ft) and disc hub bolt, 203 Nám (150 lb ft), 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.

CAUTION The bottom leading edge of worn discs can become very sharp . Wear gloves when handling worn discs to prevent injury. Failure to comply could result in injury. M1261

58-13

1441-2-60

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 3. 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 in) between adjacent discs is normal, as a result of the backlash in both gear sets. 1441-2-44

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.

4. 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.

58-14

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 5. 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

19994436

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 TOP CAP

Removal 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.

1441-2-48

25 2. Clean any material buildup from around the disc hub and top cap assembly.

3. With the cutter bar blocking still in place, remove the disc hub retaining bolt, 1.

19986023

26 4. Remove the hub, and remove any remaining material buildup on top of module and 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. 5. Remove the four retaining bolts, 1, and pry the top cap assembly off the lower module.

1 19991335

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.

28 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 29

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

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 lb ft).

19985745

31 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.

19994432

32 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. 4. If the module has a hex head cap screw, discard this bolt and install a new 12-point bolt with lock patch. Apply a small amount of silicone sealant to the end of the disc hub retaining bolt, 1, and torque it to 203 Nám (150 lb ft), or turn the bolt 90 degrees after it has contacted the washer.

19986023

58-18

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 5. Install the disc assembly and cover. Torque retaining bolts, 1, to 113 Nâ&#x2039;&#x2026;m (83 lb ft).

1 1

1441-2-48

34 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.

50015477

2 35

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 3 mm (1/8 in) of the clearance measured at the front.

If the clearance is more than 5 mm (3/16 in) 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.

1 50015478

58-19

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 CUTTER BAR Removal On the H7460/H7560, 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. 1441-2-19r

37 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.

1441-2-48

38 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.

19986023

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 inch breaker bar to loosen the tie bolts 1/2 turn total by turning the front and rear nuts alternating one flat at a time.

40 5. Place a floor jack under each end of the cutter bar.

4896-14

41 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.

50015479

1 42

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

43 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

44 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.

10001682

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. 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 Nám (200 lb ft).

50015479

2 46

CUTTER BAR BAYONET BUSHING Replacement 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

47 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.

NOTE: Do not drive against the inner ball of the bushing to remove it, or the bayonet arm will fracture and break.

19991334

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.

5. Reinstall the snap ring, 1, to retain the bushing.

19991333

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 inch 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.

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

51 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

52 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 90Â° apart, as shown. Rotate the discs of the modules on either side of the replacement module so that they are timed to each other.

50015480

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

54 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

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.

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

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 Nâ&#x2039;&#x2026;m (50 lb ft). 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 inch 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 Nâ&#x2039;&#x2026;m (50 lb ft) plus 1 turn, for a clamping force of 15870 to 16780 kg (35,000 to 37,000 Ib). 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

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.

50015480

58 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.

2 1

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. 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 lb ft), or turn the bolt 90 degrees after the bolt has contacted the washer.

19986023

10. Reinstall the rock guard, skid shoe and disc on the replacement module.

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

2. Remove the four retaining bolts and pry the top cap assembly, 1, off the lower module.

19985741

61 3. Pry the seals, 1, from each side of the lower module, using caution not to damage the shaft surface.

A3655-2

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

63 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

58-30

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1

65 Assembly Disc modules can be assembled for clockwise or counter-clockwise 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 counter-clockwise 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 in - 0.011 in) 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

66 2. Support the module housing approximately 1/2 inch 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.

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.

A3654-10

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 in - 0.008 in). 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

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

69 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

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

71 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 Nâ&#x2039;&#x2026;m (83 lb ft). 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 Nâ&#x2039;&#x2026;m (165 lb ft) to seat bevel shaft against bearings and housing. Acceptable backlash is 0.13 - 0.28 mm (0.005 in - 0.011 in). If backlash is unacceptable, recheck assembly of the disc module.

19985741

58-34

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 CUTTER BAR DRIVE SHAFT Removal 1. Remove the six cap screws, 1, retaining the tower to the cutter bar drive shaft.

19994432

73 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.

19991337

2 74

58-35

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 Disassembly 1. The drive shaft contains two U-joints, which may be serviced individually.

1441-6-6

75 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.

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.

1441-6-7

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 in).

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.

1441-6-8

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.

1441-6-9

58-37

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 1 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, 2, is exposed on the inside of the yoke ear. Install the snap ring over the bearing cup.

2 1441-6-10

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.

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.

1441-6-6

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 2 LEFT PEDESTAL SHAFT

Disassembly

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.

1431-3-2

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 â&#x20AC;&#x153;popâ&#x20AC;? 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

58-3

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 2 Assembly

1. Loosely install the upper and lower bearings in the header frame, as follows:

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 8, 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.

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

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 Nâ&#x2039;&#x2026;m (150 lb ft). 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.

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).

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 in). 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

305 mm (12 in)

1431-3-14

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.

1431-2-22

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

SECTION 58 - ATTACHMENTS/HEADERS Chapter 3 - Gearbox (Center Pivot) CONTENTS Section

Description

Page

Center Pivoting Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Gear Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Gearbox Support Plate Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Center Pivoting Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Guidance Link Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 CENTER PIVOTING GEARBOX

Removal 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 inch x 2-1/4 inch bolts, 1. The guidance link can then be slid out of the channel on the tongue.

Remove the shielding, 2, by removing the four retaining bolts, 3. Lift the shielding off the center gearbox channel.

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2. Remove the two 1/2 inch-13 cap screws, 1, from the clamp hub assembly, 2. 3. Remove the clamp hub assembly. Turn out the center cap screw, 3, about 9.5 mm (3/8 in).

4. Pull the rear half of the secondary PTO from the center gearbox. NOTE: It may be necessary to heat the clamp yoke to break the shaft loose from the gearbox.

1 10001661

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 5. 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 inch x 1 inch 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.

1431-G26

3 6. 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.

1431-2-22

4 7. 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.

1431-G24

58-3

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 8. Remove the woodruff key, 1, from the output shaft of the gearbox. Remove the four 1/2 inch x 1-1/2 inch 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.

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.

2 2 4 1431-G9

6 9. 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.

1431-G6

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 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.

2. Remove the input shaft from the gearbox.

A4836-5

8 3. 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.

1 3

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9 4. 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.

2 1431-G19

58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 5. 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. 6. Remove the retaining ring, 2, and shims, 3, from the gearbox housing.

7. 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.

A4833-1

8. 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.

A4835-15

12 9. 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.

A4833-2

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 16

13 12 10

4 6

4 1

3 18

11 3

8 2

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14 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.

58-7

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 3 and 4. 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. Assembly 1. Assemble the input shaft: •

•

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.

1 3

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NOTE: Failure to securely seat all components together may result in gearbox failure. •

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.

1431-G22

58-8

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 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 lb ft). 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 inch 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 lb in). NOTE: Make two complete revolutions of the input shaft to seat the bearing rollers before measuring the rolling torque.

A4834-4

3. Adjust input shaft rolling torque: •

•

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 inch, 0.016 inch, and 0.020 inch thicknesses. The shim pack thickness can be changed in 0.004 inch 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.

58-9

20001697

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.

1431-G20

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.

A4833-2

58-10

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. 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

21 7. Install the snap ring, 1, and original shim pack, 2, in the housing.

2 1 1431-G17

58-11

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 Nâ&#x2039;&#x2026;m (44 - 52 lb ft). 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 22, as necessary to obtain 0 - 0.05 mm (0 - 0.002 in) of end play on the shaft.

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. 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 Nâ&#x2039;&#x2026;m (44 - 52 lb ft).

While holding the output shaft to apply a load to it, rotate the input shaft counter-clockwise 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

24 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 inch to 0.004 inch; this indicates a true backlash of 0.008 inch to 0.018 inch 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 27.

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If the backlash was found to be incorrect, or if the contact pattern is not located properly, the gearbox will need to be reshimmed.

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SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3

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D 26

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 inch, 0.016 inch and 0.020 inch thicknessâ&#x20AC;&#x2122;; shifting the input shaft 0.004 inch will change the backlash between the gears approximately 0.0024 inch. To shift the shaft 0.004 inch inwards (to decrease backlash), remove a 0.020 inch or 0.016 inch shim at B, and substitute the next size smaller shim, and then remove a 0.012 inch or 0.016 inch 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.

58-13

1431-5-5

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, Figure 26, 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.

1431-5-5

28 If the contact pattern is low on the pinion, 1, and high on the gear, 2, remove shims from D, Figure 26, 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 inch, 0.016 inch and 0.020 inch thicknesses. To shift the pinion 0.004 inch inwards (to increase mesh), remove a 0.020 inch or 0.016 inch shim at D and position it at C, and move the next size smaller shim (0.016 inch or 0.012 inch) 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.

1431-5-5

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 Nâ&#x2039;&#x2026;m (44 - 52 lb ft).

4 1

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.

3 2 A5038-11

58-14

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.

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D 31

58-15

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. 2. 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

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. 3. 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.

1431-5-1

58-16

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 CENTER PIVOTING GEARBOX

Installation 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

34 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 inch x 1-3/4 inch cap screws, and torque to 113 N⋅m (83 lb ft). The gearbox must be free to pivot with a force of 14 - 68 N⋅m (10 - 50 lb ft) 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

When there is no end play detected, install a 1/2 inch 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 lb ft). If the force required to rotate the gearbox is excessive, shims must be added between the upper and lower support plates.

1 A5033-12

58-17

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 lb ft). 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.

1431-2-33

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 inch x 1 inch Grade 8 cap screws; torque the cap screws, 2, to 159 N⋅m (117 lb ft). 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.

1 A5032-9

38 6. Slide the clamp yoke end of the drive shaft onto the center gearbox spline shaft.

7. Use a soft faced hammer or mallet and strike the tractor end of the shaft and seat the shaft completely on the gearbox spline.

8. Turn in the center cap screw, 1, and tighten as much as possible to pull the clamp yoke securely onto the tapered end of the gearbox shaft. 9. Install the shaft clamp, 2. Torque the two cap screws, 3, to 87 N⋅m (64 lb ft).

3 10001661

58-18

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 10. Install the shield, 2. Install the four retaining bolts, 1, and tighten securely.

11. Install the secondary PTO front half on the secondary rear half as described earlier in this section.

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1 40

12. 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, 3, Figure 40, over the end of the center pivoting gearbox channel, and install two 1/2 inch x 2-1/4 inch bolts, 4, hardened washers and spacer bushings through the clevis, channel and U-bracket. Secure with flange nuts and torque to 113 Nâ&#x2039;&#x2026;m (83 lb ft). The bolts should tighten down on the spacer bushings, leaving the guidance link clevis free to pivot. NOTE: Ensure the 5/16 inch x 1 inch bolt and locknut, 4, Figure 38, are installed and secure, as this prevents brace, 5, from pivoting against the drive shaft.

58-19

1431-G10

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 3 GUIDANCE LINK SHIMMING

Slide the front of the guidance link, 1, in the plastic slides, 2. There should be no more than 1.5 mm (0.060 in) 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 inch 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.

1431-G10

58-20

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

SECTION 58 - ATTACHMENTS/HEADERS Chapter 4 - Gearbox (Right Hand) CONTENTS Section

Description

Page

Right-hand Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Gear Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 RIGHT-HAND GEARBOX

Removal 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.

1431-2-15

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.

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

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.

1431-G79

7 8. Detach the inner gearbox shroud, 1, by taking out carriage bolt and nut, 2.

50006857

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 9. Detach the outer gearbox shroud, 1, by turning out cap screws, 2.

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. 1431-G94

3 10

11. As the gearbox is raised out of the frame, the gearbox shaft will slide out of the cutter bar drive shaft, 1.

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58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 Disassembly 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.

1431-G56

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.

Remove the straight key from the keyway in the shaft after removing the gear.

1431-G55

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.

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.

1431-G51

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

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.

1431-G50

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.

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

2 1

3 20

12 17

25 27

14 18

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 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.

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&#x2039;&#x2026;m (38 - 46 lb ft).

NOTE: Do not install the shaft seal into the bearing cap at this time.

1 A5035-11

58-12

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 4. Rotate the shaft two full revolutions to seat the bearings. Thread a 5/8 inch x 1 inch 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 lb in) 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

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

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.

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 lb in) 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.

1431-G51

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.

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 lb in) 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&#x2039;&#x2026;m (38 - 46 lb in).

A5035-14

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 inch to 0.004 inch; this indicates a true backlash of 0.008 inch to 0.018 inch between the gears.

1431-5-4

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

58-16

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4

B C

1431-G66

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 inch, 0.016 inch and 0.020 inch thicknesses; shifting the conditioner drive shaft 0.004 inch will change the backlash between the gears approximately 0.0027 inch. To shift the shaft 0.004 inch inwards (to decrease backlash), remove a 0.020 inch or 0.016 inch shim at B and position it at A, and move the next size smaller shim (0.016 in or 0.012 in) 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 inch, 0.016 inch and 0.020 inch thicknesses. To shift the pinion 0.004 inch inwards (to increase mesh), remove a 0.020 inch or 0.016 inch shim at D and position it at C, and move the next size smaller shim (0.016 in or 0.012 in) 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

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.

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° counter-clockwise 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 lb ft).

A5036-2

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 lb ft). 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

3 A5036-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 Installation

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.

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 inch x 1-1/4 inch cap screws and lock washers, 3, Figure 44. Torque the gearbox retaining bolts to 224 Nâ&#x2039;&#x2026;m (165 lb ft). Remove the lifting sling and hoist.

1 1 2

10001683

45 3. Attach the outer gearbox shroud, 1, by turning in cap screws, 2.

50006858

58-20

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 4 4. Attach the inner gearbox shroud, 1, using a carriage bolt and nut, 2.

50006857

47 5. Install the right side support bearing and flangettes using four 1/2 inch x 1-1/4 inch cap screws, 1. Tighten the bolts evenly to 113 Nâ&#x2039;&#x2026;m (83 lb ft).

NOTE: Do not tighten bearing flangette bolts until gearbox mounting bolts are tightened.

1431-G79

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).

Install the snap ring onto the shaft by positioning the flat face of the spacer against the snap ring. Use a 5/8 inch x 1-1/2 inch 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 inch x 1-3/4 inch 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 Nâ&#x2039;&#x2026;m (165 lb ft).

1431-G84

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&#x2039;&#x2026;m (150 lb ft). Install the conditioner drive belt over the gearbox sheaves, and adjust the idler spring length to 279 mm (11 in). 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.

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.

1431-G76

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 H7460) CONTENTS Section

Description

Page

Gearbox Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Pivot Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Right-Hand Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conditioner Drive Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Model H7460 Conditioner Drive Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 For Machines with Rubber Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 For Machines with Steel Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 GEARBOX SPECIFICATIONS Pivot Gearbox Input shaft gear cap screw torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 to 70 N⋅m (45 to 50 lb ft) Bearing cap retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 to 70 N⋅m (45 to 50 lb ft) Output pulley retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 N⋅m (150 lb ft) Input shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 to 9 kg/cm (5 to 8 lb in) Output shaft end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 0.05 mm (0 to 0.002 in) Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W-90 GL5 Right-Hand Gearbox Input pulley retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 N⋅m (150 lb ft) Cutter bar output shaft end cap cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N⋅m (248 lb in) Conditioner roll drive shaft end cap cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 N⋅m (41 lb ft) Input shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 to 5.5 kg/cm (2 to 5 lb in) Cutter bar drive shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 3.5 kg/cm (0 to 3 lb in) Conditioner drive shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 3.5 kg/cm (0 to 3 lb in) Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W-90 GL5 Conditioner Drive Gearbox Input shaft drive pulley cap screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 N⋅m (128 lb ft) Gearbox mounting cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 N⋅m (83 lb ft) Conditioning roll drive shaft clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 N⋅m (83 lb ft) Input shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 5.5 kg/cm (0 to 5 lb in) Intermediate shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 x torque on input shaft plus 5.5 to 11 kg/cm (5 to 10 lb in) Lower output shaft rolling torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque on intermediate shaft plus 4.5 to 11 kg/cm (4 to 10 lb in) Sealant for bolt threads and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTV Silicone sealer Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W-90 GL5

58-2

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 MODEL H7460 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.

WARNING Always engage header lift lock rods or channels when working around or under a raised header and when transporting machine on a public road. Failure to comply could result in death or serious injury.

50051189

DMC002

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.

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.

1441-G29

2 3. Detach anti-wrap shield, 1, by turning out four cap screws, 2.

2 1

50006856

58-3

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 1441-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

1441-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

58-4

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 Disassembly 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.

1441-G63

7 2. Remove the snap ring, 1, from the input shaft.

1441-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.

1441-G64

58-5

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. 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

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.

58-6

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 Assembly

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.

3 A5039-5

11 2. Install a 5/8 inch x 1 inch 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 Nâ&#x2039;&#x2026;m (0 - 5 lb in) 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. 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.

58-7

3 4 1 5 A5039-10

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 lb in

5 - 10 lb in

1 lb in

7 - 12 lb in

2 lb in

9 - 14 lb in

3 lb in

11 - 16 lb in

4 lb in

13 - 18 lb in

5 lb in

15 - 20 lb in

A5039-9

5. Install a bearing cup, 1, Figure 14, into the housing so that it is seated against the shoulder. Install a shaft seal, 2, Figure 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.

2 3 4

5 A5039-15

58-8

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 lb in. 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.

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

58-9

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.

1441-G63

18 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.

1441-G60

19 2. Raise the gearbox up into the header frame, and install the five retaining bolts, 1. Torque the bolts to 113 Nâ&#x2039;&#x2026;m (83 lb ft).

1 1

A5040-3

58-10

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&#x2039;&#x2026;m (83 lb ft).

2 1

1441-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 1441-G75

58-11

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

58-12

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 5 5. Attach the anti-wrap shield, 1, by turning in the four cap screws, 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 in) from inside hook to inside hook. 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 Nâ&#x2039;&#x2026;m (165 lb ft).

2 (279 mm) 11â&#x20AC;ł

1 1441-G29

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 (H7460) CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conditioner Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Conditioner Roll Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 For Machines with Rubber Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 For Machines with Steel Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Lower Conditioner Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 For Machines with Rubber Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 For Machines with Steel Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Upper Conditioner Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Conditioner Roll Tension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Left Side Torsion Arm and Bar Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Right Side Torsion Arm, Torsion Bar and Adjusting Tube Disassembly . . . . . . . . . 24 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Right Side Torsion Arm, Torsion Bar and Adjusting Tube Assembly . . . . . . . . . . . 26 Left Side Torsion Arm and Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 INTRODUCTION The H7460 disc mower-conditioner is equipped with two long (102 in x 10-3/8 in) 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 H7460. 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.

1441-1-36

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.

A4835-8

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 in)

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 in) from inside hook to inside hook.

A4835-13

Loosen nuts, 1, and tighten the inner nut to stretch the spring to the correct length; tighten the jam nut to secure.

A4835-8

58-3

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 Replacement 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.

279 mm (11 in)

Install the new belt onto the sheaves, and tighten nuts on spring tension rod to adjust spring to a length of 279 mm (11 in) from inside hook to inside hook.

A4835-13

CONDITIONER ROLL DRIVE SHAFT

Removal 1. Detach anti-wrap shield, 1, by turning out four cap screws, 2.

1 2

50006856

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.

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.

A5000-1

58-5

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 Disassembly 1. The drive shafts can be slid apart, and each U-joint serviced separately.

1441-7-8

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.

3. 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.

1441-6-7

12 4. Position the joint in an open vise, with each ear of one yoke supported by a vise jaw. With a soft hammer or mallet, strike the top ear of the unsupported yoke at 1. This will drive the top bearing outward approximately 8 mm (1/4 in).

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

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

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

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.

1441-7-8

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. 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&#x2039;&#x2026;m (83 lb ft).

A4835-8

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&#x2039;&#x2026;m (83 lb ft).

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.

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

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

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.

50051189

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.

1441-2-19

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.

1441-7-1

27 6. Remove the plates, 1, on the removal slot at the right side of header by removing the two cap screws, 2.

1441-7-2

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.

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.

1441-7-3

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. Repeat the process on the left side of the conditioner roll.

1441-7-4

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.

1441-7-9

58-13

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 6 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. 1441-7-9

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.

1441-7-6

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.

2 2

1441-7-36

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.

1441-7-23

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.

1441-7-3

36 6. Install the plates, 1, to cover the slot in the header frame using the two previously removed bolts, 2; tighten securely.

1441-7-2

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&#x2039;&#x2026;m (83 lb ft).

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.

1411-8-12

58-16

20001730

40 9. Attach the anti-wrap shield, 1, by turning in four cap screws, 2.

2 1 2

50006856

UPPER CONDITIONER ROLL Removal

NOTE: The lower conditioner roll must be removed before the upper conditioner roll may be removed; refer to â&#x20AC;&#x153;Lower Conditioner Roll - Removal.â&#x20AC;? 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.

1441-7-10

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.

1441-7-12

43 3. Raise the lock plate, 1, and swing it to the side. Lift the adjusting nut, 2, and bolt out of the header.

1441-1-36

44 4. Completely loosen the roll pressure tension by rotating the roll pressure handle, 1, counterclockwise until loose.

4833-12

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

1441-7-13

46 6. Loosen the setscrew and rotate the lock collar, 1, opposite direction of roll rotation. Remove lock collar. Repeat for opposite side.

1441-7-15

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.

1441-7-18

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.

1441-7-16

49 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.

1441-7-16

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.

1441-7-17

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.

2 1441-7-18

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.

1441-7-21

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

1441-7-20

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.

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.

1441-7-12

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 lb ft).

Install the lower conditioner roll; refer to “Lower Conditioner Roll - Installation” in this section.

A5000-1

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. 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

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

1441-7-25

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

1441-7-26

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.

1441-7-27

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.

1441-7-28

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. 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.

1441-7-22

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

1441-7-29

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.

1441-7-32

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

1441-7-30

65 6. Remove the groove pin, 1, at the inner end of the adjusting tube by driving it out of the tube.

1441-7-33

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.

8. Slide the torsion bar out of the adjusting tube. 1441-7-34

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 1441-7-35

68 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 1441-7-35

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 69. 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

1441-7-34

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.

1441-7-33

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.

1441-7-13

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

1441-7-29

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.

1441-2-25

74 7. Reinstall the swathgate baffle, 1, on the right end of the swathgate using the four previously removed carriage bolts and nuts, 2.

1441-7-32

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.

1441-7-28

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

1441-7-27

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

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 (H7560) CONTENTS Section

Description

Page

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conditioner Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Flail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Conditioner Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Drive Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

58-1

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 The H7560 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.

The H7560 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 H7560. The conditioner hood is adjustable to provide a greater or lesser degree of conditioning as needed.

19985249

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 in) from inside hook to inside hook.

305 mm (12 in)

30000982

3 1. Loosen the jam nut, 1, and tighten the adjusting nut to stretch the spring to the correct length; tighten the jam nut to secure.

Replacement 1. 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.

2. Remove the six hub cap screws, 2, and slide the hub, 3, away from the lower sheave. 3. Remove the belt.

2 19985727

4 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 in) from inside hook to inside hook. 5. Slide the hub onto the lower sheave and attach with six cap screws. 305 mm (12 in)

30000982

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.

19990055

6 2. Drive the second roll pin, 1, out of the flail shaft, freeing it from the rotor.

19990090

7 3. Slide the flails, 1, and spacers, 2, off the shaft.

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 3 mm (1/8 in) from the edge of the flail.

CAUTION The flail rotor turns at high speeds . Failure to replace worn or damaged flail castings can result in the flail casting separating from the rotor. Failure to comply could result in death or serious injury. M1180

IMPORTANT: If flails are replaced, the used flail shafts should be rotated one-half turn, or 180Â°. Replace the flail shaft if a 3 mm (1/8 in) or greater wear groove is in the shaft.

58-5

19982138

3 mm (1/8 in)

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Installation 1. Set the flail shaft, 1, in the rotor as shown. NOTE: Rotate the flail shaft 180Â° 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.

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.

19990090

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 NOTE: The rotor can be removed and reinstalled without removing the conditioner hood.

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.

19990060

15 3. Remove the right extender plate from the swathgate, 1.

19990058

58-7

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 4. Remove the adjustment arm, 2, and springs, 1, from the swathgate.

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.

19990063

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.

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.

19990070

21 9. Remove the locking eccentric collars from both sides of the rotor shaft. Loosen the set screw and drive the collars counter-clockwise 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

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.

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 DANGER Verify the area around the rotor is free from people and obstacles. Rotors are very heavy and must be handled properly with an adequate removal or lifting device. Failure to comply will result in death or serious injury. M1227

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

58-11

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Installation 1. Assemble the rotor and flails (see â&#x20AC;&#x153;Flail Installationâ&#x20AC;?). Clean the shafts, 1, on both ends of the rotor with emery cloth. Wipe them clean and apply a lubricant to ease bearing installation.

19990075

27 2. Using a suitable hoist or lift, place the left shaft of the rotor through the opening in the frame.

DANGER Verify the area around the rotor is free from people and obstacles. Rotors are very heavy and must be handled properly with an adequate removal or lifting device. Failure to comply will result in death or serious injury. M1227

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

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.

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

7. Install the block plate and shield on the right side of the frame, 2.

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

58-13

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 8. Install the side shields. If the small windrow deflectors, 1, were removed, reinstall them.

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.

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.

19990058

35 12. Install the springs, 1, on the swathgate.

19990059

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.

2 19990062

37 14. Reinstall the retaining bolts, 1, on either end of the swathgate.

19990060

38 15. Reinstall the windrow shields, 1, holding them onto the pivot post with the retaining collar, 2, and bolt, 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 1. Remove the clamp bolt, 1, from the rotor shaft.

19990070

40 2. Release belt tension by loosening the jam nut and nut on the spring tension rod, 1. 3. Remove the five drive shaft hub cap screws, 2, from the rotor drive sheave. 4. 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. 5. Slide the drive shaft from the conditioning rotor stub shaft.

58-17

1 19985728

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 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.

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.

10005554

42 1. 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 2. 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.

3. 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

58-18

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 4. Rotate the U-joint over and lift out the bearing cup, 1, if it has not fallen free from the yoke arm.

10005557

45 5. 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. 6. Lift out the bearing cup if it has not fallen free from the yoke arm.

10005558

46 7. Rotate the U-joint free from the yoke arm. Repeat this procedure to remove the cross from the other yoke arm.

10005559

58-19

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 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.

10005554

48 1. 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 2. Install the snap rings, 1, and grease zerks, 2, (if equipped), into the U-joint. 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 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

58-20

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 Installation

1. Attach the conditioner rotor drive shaft to the drive sheave using five 3/8 inch x 2-1/4 inch cap screws, 1.

1 19990092

51 2. Slide the drive shaft onto the flail conditioner rotor. Install clamp bolt, 1, and tighten.

19990070

52 3. Tighten the nuts on spring tension rod to adjust spring length to 305 mm (12 in) from inside hook to inside hook. Tighten the jam nut to secure.

30000982

58-21

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 DRIVE SHAFT BEARING Removal 1. Remove the guard from the right front corner of the machine to access the drive belt.

10005566

54 2. Loosen the jam and adjusting nuts, 1, until the drive belt can be removed from the machine.

3. 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.

1 3

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 4. 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

5. 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 Disassembly 1. Hold the drive shaft bearing assembly in a vise.

10005510

57 2. 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.

3. 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

58-23

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 4. 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.

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.

10005515

58-24

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 5. 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 6. 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 7. Using a punch, remove the two bearing cups, 1, from the housing.

1 10005518

58-25

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 8. Install tool 610R, 1, onto the cup spacer. Using a snap ring pliers, remove the spacer from the housing.

9. Clean all parts to be reused, of all rust, dirt, and old lubricant.

10005519

66 Assembly

1. Using tool 610R, 1, insert the bearing cup spacer ring into the shaft housing. 2. 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 3. Pack each bearing with standard bearing grease.

IMPORTANT: Proper initial packing of the bearings is very important to prevent bearing failure. 4. 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

58-26

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 5. 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.

10005550

69 6. Press the inner bearing, 1, onto the shaft until inward travel stops. The bearing spacer is sized to ensure the proper bearing clearance.

10005551

70 7. 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.

10005552

58-27

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 8. 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.

10005553

72 Installation

1. Apply a thin film of silicon sealant to the seating area of the bearing cover, 1, and housing, 2.

10005561

73 2. 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.

NOTE: Seal must be on drive pulley side of housing.

2 2 2 10005562

58-28

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 3. Apply a thin film of anti-corrosion lubricant to the bearing assembly hub at 1. 4. Slide the sheave onto the bearing hub.

1 10005563

75 5. Slide the conditioner drive shaft onto the stub shaft spline. Install cap screw and nut, 1. Tighten to standard torque.

10005565

58-29

SECTION 58 - ATTACHMENTS/HEADERS - CHAPTER 7 6. Install the drive shaft hub, 1, onto the bearing hub with the sheave, 2, between them.

7. Secure the shaft hub with five cap screws and washers at 3.

3 10005567

77 8. Install the drive belt, 1, as shown. Tighten the idler spring until it is 305 mm (12 in) from inside hook to inside hook.

9. Install the guard at 2, using four cap screws, washers, and nuts.

10005566

2 78

58-30

SECTION 90 - DECALS - CHAPTER 1

SECTION 90 - DECALS Chapter 1 - Decals CONTENTS Section

Description

Page

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

90-1

SECTION 90 - DECALS - CHAPTER 1

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. Keep the decals legible. If they are not, obtain replacements from your authorized dealer. The decal replacement part numbers are listed with each decal.

16 2 5

3 6 13

12 2 16

12 1

14 12 2

1 2 8 5 15 50051171

5 9 2 6

90-2

SECTION 90 - DECALS - CHAPTER 1 8

3 4

8 50052111

12 10

3 4

50052856

90-3

SECTION 90 - DECALS - CHAPTER 1 1

Part #86624774 (2)

Part #86611825 (3)

Part #86624775 (2) Part #86622073

Part #86628571 (3)

90-4

SECTION 90 - DECALS - CHAPTER 1 6

Part #80772110 (2)

Part #770033

Part #849472 (2)

Part #86629148 (2)

Part # 87049205

90-5

SECTION 90 - DECALS - CHAPTER 1

Part # 87041060

Part # 86547782 (10) Reflective Tape, Yellow

Part # 86547781 (3) Reflective Tape, Red

Part # 849471 (2)

Part # 86547710 Slow-Moving Vehicle Sign

Part # 86547783 (3) Reflective Tape, Red-Orange

90-6

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

Description

Page

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

Description

Page

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

Description

Page

Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Secondary PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front Half Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front Half Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear Half Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear Half Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Slide Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Auto-Lok Slide Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Auto-Lok Slide Lock - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Auto-Lok Slide Lock - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Standard Driveline Guards - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Secondary Driveline Guards - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Standard Driveline Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 U-Joints: Swivel Hitch Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 2 - Slip Clutch CONTENTS Section

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SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 3 - Gearbox (Swivel Hitch) CONTENTS Section

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SECTION 31 - IMPLEMENT POWER TAKE OFF (PTO) Chapter 3 - Gearbox (Swivel Hitch) (Continued) CONTENTS Section

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Upper Gearbox and Neck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Gear Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Lower Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lower Gearbox and Neck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Gear Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Lower Gearbox, Neck Assembly, and Upper Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Swivel Hitch Gearbox Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SECTION 35 - HYDRAULIC SYSTEM Chapter 1 - Cylinders CONTENTS Section

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SECTION 39 - FRAMES/TONGUE AND HITCHES Chapter 1 - Hood and Hood Liner (H7560 Only) CONTENTS Section

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SECTION 55 - ELECTRICAL SYSTEM Chapter 1 - Implement Lights CONTENTS Section

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SECTION 58 - ATTACHMENTS/HEADERS Chapter 1 - Cutter Bar CONTENTS Section

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SECTION 58 - ATTACHMENTS/HEADERS Chapter 2 - Left Pedestal Shaft CONTENTS Section

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SECTION 58 - ATTACHMENTS/HEADERS Chapter 3 - Gearbox (Center Pivot) CONTENTS Section

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SECTION 58 - ATTACHMENTS/HEADERS Chapter 4 - Gearbox (Right Hand) CONTENTS Section

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SECTION 58 - ATTACHMENTS/HEADERS Chapter 5 - Gearbox (Conditioner Drive H7460) CONTENTS Section

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SECTION 58 - ATTACHMENTS/HEADERS Chapter 6 - Conditioner Rolls and Drive (H7460) CONTENTS Section

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SECTION 58 - ATTACHMENTS/HEADERS Chapter 7 - Conditioner Flail and Drive (H7560) CONTENTS Section

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SECTION 90 - DECALS Chapter 1 - Decals CONTENTS Section

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Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2