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262150

Revision A

Chapter 1:

Safety

Understanding and consistently following these safety procedures will help to ensure the safety of those operating the
machine and of bystanders.

1.1

Safety Alert Symbols

The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine.

1000915

Figure 1.1: Safety Symbol

This symbol means:

•

ATTENTION!

•

BECOME ALERT!

•

YOUR SAFETY IS INVOLVED!

Carefully read and follow the safety message accompanying this
symbol.

Why is safety important to you?

•

Accidents disable and kill

•

Accidents cost

•

Accidents can be avoided

Summary of Contents for TM100

Page 1: ...TM100 Tractor Mount Float Module for D1 Series Draper Headers Setup Operation and Parts Manual 262150 Revision A Original Instruction The Harvesting Specialists...

Page 2: ...ember 2022 2022 MacDon Industries Ltd The information in this publication is based on the information available and in effect at the time of printing MacDon Industries Ltd makes no representation or w...

Page 3: ...5 6 d D D D dD E E t D d E D E E K E K W E Z D D t K E K E K D t s D E K E K E K E Z D t d t W D E D s Z E K E K K E h W E W h Z D D t E d E E E K E K E Z D t d D E m E K E K d Z W D t D W d E E K E K...

Page 4: ...s E t s D E Z E K E K W E E Z D t WK D K d E E t E K E K Z D t E ZK E d E E K E K E Z D D t s s D E E K E K W E Z D t d D s h E K E K Z D t E D d E s W E K E K D D D Z D t E d E d E E h E K E K E E Z...

Page 5: ...t D d E D E D Z E K E K W h 0DF RQ QGXVWULHV WG 0RUD 6WUHHW LQQLSHJ 0DQLWRED DQDGD 5 6 d D D D dD E E D Z hE Zz Z KZK K Y 262150 iii Revision A...

Page 6: ...l the material provided before attempting to use the machine Use this manual as your first source of information about the machine If you follow the instructions provided your tractor mount float modu...

Page 7: ...le in English French and German These manuals can be ordered from MacDon downloaded from our Dealer only site https portal macdon com login required or downloaded from the MacDon website www macdon co...

Page 8: ...ity page i Updated the Declaration of Conformity documents Technical Publications 3 3 Unpacking the Tractor Mount Float Module page 24 Removed SAE hardware from hose guide hardware bag Engineering Eng...

Page 9: ...cDon for Product Support or Parts 1034134 A Figure 1 Serial Number Location Record the serial number of the TM100 Tractor Mount Float Module in the space provided TM100 serial number _________________...

Page 10: ......

Page 11: ...Mount Float Module 21 3 2 Moving Tractor Mount Float Module to Assembly Area 23 3 3 Unpacking the Tractor Mount Float Module 24 3 4 Removing Shipping Stands 29 3 5 Installing Hose Guide 32 3 6 Instal...

Page 12: ...Topsoil Moisture 96 5 8 3 Weather and Topography 96 5 8 4 Windrow Characteristics 97 5 8 5 Driving on Windrow 97 5 8 6 Raking and Tedding 97 5 8 7 Chemical Drying Agents 97 Chapter 6 Maintenance and S...

Page 13: ...embly 140 7 11 Integrated Pump Service Parts 142 7 12 Electrical 144 7 13 Electrical TM100 to Tractor Cab 146 7 14 Hydraulics Multicoupler and Hoses 148 7 15 TM100 to Three Point Hitch 150 7 16 Drivel...

Page 14: ......

Page 15: ...y Alert Symbols The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine 1000915 Figure 1 1 Safety Symbol This symbol means ATTENTION BECOME ALERT...

Page 16: ...l result in death or serious injury WARNING Indicates a potentially hazardous situation that if it is not prevented could result in death or serious injury It may also be used to alert you to unsafe p...

Page 17: ...e footwear with slip resistant soles Protective glasses or goggles Heavy gloves Wet weather gear Respirator or filter mask 1000005 Figure 1 3 Safety Equipment In addition take the following precaution...

Page 18: ...the functionality and or safety of the machine It may also shorten the machine s service life To avoid injury or death from the unexpected startup of the machine ALWAYS stop the engine and remove the...

Page 19: ...ep the work area well lit 1008958 Figure 1 9 Equipment is NOT Safe for Children Relieve pressure from hydraulic circuits before servicing and or disconnecting the machine Ensure that all components ar...

Page 20: ...262150 6 Revision A 1000004 Figure 1 10 Personal Protective Equipment Wear protective gear when working on the machine Wear heavy gloves when working on knife components SAFETY...

Page 21: ...fittings or hoses by using tapes clamps cements or welding The hydraulic system operates under extremely high pressure Makeshift repairs can fail suddenly and create hazardous conditions 1001207 Figu...

Page 22: ...have with regard to future malfunctions or shorter lifespan It is very important that welding on the header is not attempted while the header is connected to the tractor If you need to do any welding...

Page 23: ...part on which a safety sign was installed is replaced ensure that the repair part displays the current safety sign Replacement safety signs are available from your Dealer 1 7 1 Installing Safety Decal...

Page 24: ...aced on the machine where there is a risk of personal injury or where the operator has to take extra precaution before operating controls 1035016 A B A B Figure 1 15 TM100 Safety Decal Locations A MD...

Page 25: ...ou do not have a manual obtain one from your Dealer Making certain everyone is clear of the machine before starting engine and during operation 1000706 Figure 1 17 MD 166832 MD 166832 High pressure hy...

Page 26: ...ydraulic safety lock before going under the pull type Alternatively rest the pull type on the ground stop the engine and remove the key before servicing the machine Figure 1 19 MD 247130 MD 247130 Dri...

Page 27: ...ng operation Keep riders off of the machine Keep all shields in place and stay clear of moving parts Disengage the header drive put the transmission in Neutral and wait for all movement to stop before...

Page 28: ......

Page 29: ...cross section used to drive bolts and screws that have a hexagonal socket in the head internal wrenching hexagon drive also known as an Allen key JIC Joint Industrial Council A standards body that de...

Page 30: ...n the nut is turned farther by a specified number of degrees until it achieves its final position Torque tension The relationship between the assembly torque applied to a piece of hardware and the axi...

Page 31: ...in Z6 1 3 8 in Z21 or 1 3 4 in Z20 Oil capacity 12 6 L 3 3 US gallons Oil type Single grade transmission hydraulic fluid THF THF viscosity at 40 C 104 F 60 1 cSt THF viscosity at 100 C 212 F 9 5 cSt...

Page 32: ...A 2 3 Dimensions When transporting or operating a TM100 it is important to know the dimensions of the machine 1034209 A B C Figure 2 1 TM100 Dimensions A 2991 mm 118 in B 1306 mm 51 in C 1186 mm 47 i...

Page 33: ...e 2 2 Header Side of TM100 A Float Springs 2 Per Side B Lift Cylinder Slave C Lift Cylinder Master D Drive Gearbox1 E Driveline Gearbox to Pump F Header Drive and Draper Drive Pump G Float Spring Adju...

Page 34: ...M100 A Cooling Fan B Header Tilt Cylinder C Hydraulic Reservoir D Float Links 2 per side E PTO Driveline2 F Tractor Pick Up Categories 2 3N 3 G PTO Driveline Holder Shown in Storage Position PRODUCT O...

Page 35: ...cle tipping machine damage or bodily harm to operators or bystanders IMPORTANT Two forklifts or suitable lifting vehicles are required for this procedure one to hold the lifting platform and the other...

Page 36: ...around float module leg A and float links B Connect the chain to the forks on a the second lifting vehicle 7 Pull the float module from the container onto the platform 8 Repeat Steps 6 page 22 and 7 p...

Page 37: ...roach the rear of the float module with the lifting vehicle 2 Attach chains to lift hooks A and the forklift forks If chains are not available slide the forklift forks into shipping channels B IMPORTA...

Page 38: ...s three separate parts bags 1034240 A A B Figure 3 5 Shipping Foam 2 Remove shipping wire and foam padding A securing the hydraulic hoses at both sides of the float module Do NOT remove the shipping w...

Page 39: ...Brackets and Hardware Bag Two locking brackets A MD 333522 Four retaining rings B MD 135385 Two pins C MD 333536 Four M20 x 30 mm hex bolts D MD 252891 Eight hardened washers E MD 21540 Four flat wash...

Page 40: ...Multicoupler with fittings C MD 333422 Four 8 ORB fittings D MD 135563 Suction cup base E MD 287859 Harness TM100 power F MD 333266 Harness TM100 power G MD 333265 Harness TM100 to cab H MD 333569 UNL...

Page 41: ...262150 27 Revision A A B C D E F G H Figure 3 9 Parts in Electrical and Hydraulic Connections Bag UNLOADING AND ASSEMBLING TRACTOR MOUNT FLOAT MODULE...

Page 42: ...262150 28 Revision A A Figure 3 10 Parts in Hydraulic Hoses Bag Hydraulic Hoses Bag Four 9000 mm hoses A MD 333420 UNLOADING AND ASSEMBLING TRACTOR MOUNT FLOAT MODULE...

Page 43: ...C can be removed after the TM100 is attached to the tractor If attached to a tractor raise the tractor s three point linkage sufficiently to remove the shipping channels located under the TM100 lift...

Page 44: ...ng channel C under the lift arm Remove nail B Remove shipping channel C and block of wood D Repeat Step page 30 to Step page 30 for shipping channel on opposite lift arm 1034322 B A Figure 3 15 Lift L...

Page 45: ...rm Right Side Remove shipping wire and wood block A that secure rubber block B in place Repeat this step on the opposite lift arm NOTE To attach the TM100 to a header rubber block B must pivot freely...

Page 46: ...of the TM100 1034601 A B C Figure 3 17 Hose Guides A New Hose Guide MD 333378 Install in Place of Existing Hose Guide B B Existing Hose Guide Remove from Header and Install at Location C on the TM100...

Page 47: ...and center lock flange nuts MD 135799 B 1034612 A B Figure 3 20 New Hose Guide installed on Header D115 and D120 Double Knife 1034616 A B Figure 3 21 New Hose Guide installed on Header All D1 Headers...

Page 48: ...staller and damage to the driveline hold the driveline so that it doesn t fall to the floor or ground To install the PTO driveline onto the float module follow these steps 1034374 A B Figure 3 22 PTO...

Page 49: ...pin C 1034367 A Figure 3 24 Driveline Cover 3 Unlatch driveline cover A from the gearbox 1034368 A B Figure 3 25 Driveline Gearbox End 4 Slide the cover over the driveline Align the splines on drivel...

Page 50: ...ghtening the nut the pin MUST be recessed into the yoke 2 4 mm otherwise driveline and gearbox damage may occur A B Figure 3 28 Driveline Cover 7 Latch driveline cover A back onto the gearbox 8 Attach...

Page 51: ...e Remove only the lynch pin and washer to access the storage bracket 10 Reinstall pin A 1035241 A B C Figure 3 30 Driveline Storage Bracket 11 Slide storage bracket A onto driveline yoke B IMPORTANT E...

Page 52: ...d slide out hitch pin B enough to allow room to install the storage bracket at location C 1035022 A B Figure 3 33 Driveline in Storage Position 14 Secure storage bracket B to the frame using three poi...

Page 53: ...ion the tractor PTO rotates Looking in direction B at the pump input shaft driveline C rotation must be clockwise The correct rotation is indicated by an arrow on the mounting bracket You may need to...

Page 54: ...ack plate B on the gearbox 1034449 B A Figure 3 37 TM100 Driveline Pin 2 Remove nut B and washer 3 Tap out the pin retaining the driveline yoke onto the gearbox shaft NOTE There isn t enough room to s...

Page 55: ...stalled in their original orientation to minimize the chain length hanging below the gearbox 1035008 A B Figure 3 40 Back Plate 7 Remove and retain four bolts A and back plate B from the gearbox A B C...

Page 56: ...to the rear of the gearbox 1034967 A B Figure 3 43 Gearbox on the Ground 11 Remove breather A and swap it with plug B at the opposite side of the gearbox Apply Teflon tape or pipe thread sealant and...

Page 57: ...bolts B Ensure tab A where the chain attaches is positioned as shown Apply medium strength threadlocker Loctite 243 or equivalent to the bolt threads and tighten the bolts to 20 Nm 15 lbf ft A Figure...

Page 58: ...the chain attaches is positioned as shown Apply medium strength threadlocker Loctite 243 or equivalent to the bolt threads and tighten the bolts to 20 Nm 15 lbf ft C 1035244 A B Figure 3 49 Gearbox M...

Page 59: ...igure 3 51 Taper Pin 22 Install washer and nut A Tighten the nut to 150 Nm 111 lbf ft When tightened pin B will draw into the yoke a few millimeters IMPORTANT After tightening the pin MUST be recessed...

Page 60: ......

Page 61: ...Float Module to a Tractor The TM100 allows attachment of D1 Series Draper Headers to three point hitch categories 2 3N and 3 1 Attach the float module to the tractor s three point linkage Refer to th...

Page 62: ...loat module height is set to 400 mm 15 3 4 in 1034423 A Figure 4 3 Tractor PTO 3 Confirm the power take off PTO s direction of rotation as indicated by arrow A near the PTO shaft The TM100 gearbox is...

Page 63: ...e lynch pin and washer to install the storage bracket on pin B and then reinstall the washer and lynch pin IMPORTANT If connecting this driveline to the tractor s PTO for this first time the driveline...

Page 64: ...e fitting A on the sliding element is accessible 9 If the grease fitting is not accessible cut a 25 4 mm 1 in access hole in the driveline s outer shield 1034420 A B Figure 4 8 Tractor PTO 10 Find a s...

Page 65: ...ctor s PTO shaft A until it locks in place Release the collar and ensure the yoke is locked onto the shaft 5 Fully raise the tractor s three point linkage 1035064 L A Figure 4 11 PTO Driveline Halves...

Page 66: ...g Shielding 10 Remove shield tube A from driveline shaft B 1035232 A Figure 4 14 Grease Collar 11 Remove grease collar A by using a large punch and gently tapping around the circumference IMPORTANT Th...

Page 67: ...sed for cutting the driveline shaft NOTE This will ensure the shaft extends out of the shield tube as it did previously If the shield tube is flush with the shaft it will be difficult to align the dri...

Page 68: ...om the TM100 gearbox as follows a Remove nut C and washer B b Tap out pin A retaining the yoke onto the shaft c Pull the driveline off the gearbox shaft 18 Cut the inner half of the driveline using th...

Page 69: ...e chain to avoid damage to the shield when the three point linkage is lowered or raised Ensure the slack in the chain does not allow for the chain to wrap around the shield during operation 4 1 2 Conn...

Page 70: ...e eight hoses are required Choose the correct hose length for each connection depending on which end of the tractor the SCV is located IMPORTANT The hoses for each function need to be connected to the...

Page 71: ...actor along the left side of the three point hitch toward the multicoupler receptacle IMPORTANT When routing the hoses avoid pinch points on the tractor Consider any points that could lengthen shorten...

Page 72: ...D no ties 1034870 A B C Figure 4 30 Multicoupler Receptacle 10 Open the cover on receptacle A located on the left side of the float module 11 Press lock button B and pull handle C to the fully open po...

Page 73: ...up base B are provided with the TM100 1034760 A B C Figure 4 33 Control Console and Base 1 Attach suction cup base B to ball mount A on the back of the control console Tighten using knob C 1034763 A B...

Page 74: ...C85A TM Unused3 E C471B TM Connects to C471A TM of MD 333568 Optional Foot Pedal Harness F C471A TM Connects to C471B TM of MD 333568 Optional Foot Pedal Harness 1034639 A B Figure 4 36 Connector C20...

Page 75: ...if the float module moves up or down relative to the tractor and allow for extra extension to avoid damage to the harness IMPORTANT Ensure the harness isn t hanging below the frame because stubble ca...

Page 76: ...A Figure 4 40 Routing Harness into Cab 6 Route harness A around the rear of the cab and then inside the cab toward the console 1034658 A B Figure 4 41 Control Box 7 Connect 12 pin connector C84A TM A...

Page 77: ...stalled plug C471B TM A to C471A TM B of electrical harness MD 333569 10 Coil excess harness C inside the cab and secure it in place 4 1 5 Installing Electrical Harness Cab Power An electrical harness...

Page 78: ...source instead of a battery power source to avoid draining the battery when not in use IMPORTANT The tractor end of the circuit must be capable of handling the 25 amp draw requirement and must be fus...

Page 79: ...he safety props before going under the machine for any reason 1034469 A B C B C Figure 4 46 Float Springs 1 Fully loosen the float springs as follows a Loosen bolts B and rotate spring locks C out of...

Page 80: ...ed with the TM100 1005040 A Figure 4 49 Header Stand 4 Remove header stand A from the header leg C B A Figure 4 50 Header Leg 5 Place 203 mm 8 in blocks A under each lift leg When the lift legs are 20...

Page 81: ...locking bracket A into position and secure with two M20 bolts B and four hardened washers C two washers per bolt as shown Apply medium strength threadlocker Loctite 243 or equivalent to the bolt threa...

Page 82: ...rs have cleared the area 15 Start the engine and slowly raise the float module using the tractor SCV controls while ensuring the float module arms engage the header legs 16 Raise the header to its ful...

Page 83: ...the right side of the float module route hose bundle A over hose support B 20 Matching the colored ties connect the reel drive and reel position hoses to header hoses C 1034957 A B C Figure 4 58 Knif...

Page 84: ...r to lock it in place 1034996 A B Figure 4 60 Harness MD 333181 27 Remove the cover from the receptacle on header bulkhead B Ensure the receptacle is clean and not damaged 28 Connect C20E TM A to the...

Page 85: ...der weight turn both adjustment bolts A counterclockwise Repeat the adjustment at the opposite side of the float module 1034467 A A B Figure 4 63 Float Spring Locks 32 Lock the adjustment bolts with s...

Page 86: ...E The pump may be louder but it should clear after 10 15 minutes of running 5 Shut down the engine and remove the key from the ignition 6 Check the oil level during the initial run up and fill it as n...

Page 87: ...son 1 Park the tractor on a level surface 2 Lower the header to the ground 3 Lower the reel fully 4 Shut down the engine and remove the key from the ignition 1034639 A B Figure 4 64 Connector C20A TM...

Page 88: ...re the multicoupler and hoses with the tractor 1035109 A A A Figure 4 67 Three Point Hitch Attachment Points 9 Detach the three point linkage from the float module Ensure all pins A are replaced and s...

Page 89: ...me Remove only the lynch pin and washer to access the storage bracket 13 Reinstall pin A 1035241 A B C Figure 4 70 Driveline Storage Bracket 14 Slide storage bracket A onto driveline yoke B IMPORTANT...

Page 90: ...de out three point hitch pin B enough to allow room to install the storage bracket at location C 1035022 A B Figure 4 73 Driveline in Storage Position 17 Secure storage bracket B to the frame using th...

Page 91: ...the safety props before going under the header for any reason 1001215 Figure 4 74 Cutterbar Hazard WARNING Keep hands clear of the area between the guards and knife at all times WARNING Wear heavy glo...

Page 92: ...Figure 4 77 TM100 Lift Cylinder Lockout Valve Left Side 7 Engage both safety props on the float module lift cylinders The lift cylinders are locked when handle A is oriented 90 degrees to valve B and...

Page 93: ...Figure 4 80 Disconnecting Harness 10 Disconnect electrical connector A from bulkhead B by turning the collar counterclockwise and pulling on the connector to disengage 1034957 A B C Figure 4 81 Knife...

Page 94: ...hoses A from header hoses C 14 Remove the hoses from support B and store the hoses on the float module DANGER Ensure that all bystanders have cleared the area 15 Start the engine and slowly back away...

Page 95: ...the people around you Before allowing anyone to operate the header for however short a time or distance make sure they have been instructed in its safe and proper use Review the manual and all safety...

Page 96: ...ible Be sure to keep transmission in gear when travelling downhill Never attempt to get on or off a moving machine Do NOT leave the operator s station while the engine is running To avoid bodily injur...

Page 97: ...en engaged the reel safety props prevent the reel from falling unexpectedly IMPORTANT To prevent damage to the reel support arms do NOT transport the header with the reel safety props engaged Engaging...

Page 98: ...engagement NOTE Keep pivot bolt C sufficiently tight so that the prop remains in the stored position when not in use but can still be engaged using hand force 4 Repeat Step 3 page 84 on the opposite...

Page 99: ...m the ignition before making adjustments to the machine 1 Raise the reel to the maximum height 2 Shut down the engine and remove the key from the ignition 1004154 A Figure 5 6 Reel Safety Prop Left Ar...

Page 100: ...ces Personal safety devices that may be needed include a hard hat protective glasses or goggles heavy gloves a respirator or filter mask or wet weather gear Protect against noise Wear a suitable heari...

Page 101: ...r with the sound and feel of your new header be extra attentive After attaching the float module and header to the tractor for the first time follow these steps 1 Operate the machine with the reels dr...

Page 102: ...tion before leaving the operator s seat for any reason To shut down the tractor follow these steps 1 Park on level ground whenever possible 2 Lower the header fully 3 Place all controls in PARK 4 Dise...

Page 103: ...PTO rpm Front three point linkage height Header height Reel speed selective control valve SCV flow IMPORTANT Take care not to overspeed the reel Ensure reel speed is slow when starting and then incre...

Page 104: ...itch to header angle operation B Use the tractor SCV to operate the header tilt function C Reel Fore Aft Set switch to fore aft operation C Use the tractor SCV to adjust the fore aft position D Reel H...

Page 105: ...1034657 A B Figure 5 10 Float Springs Header float can be gauged by the length of threaded portion A of the spring adjustment bolts The maximum force is determined by the tension on the float module s...

Page 106: ...tment at the opposite side of the float module To decrease float increase header weight turn both adjustment bolts A counterclockwise Repeat the adjustment at the opposite side of the float module 3 A...

Page 107: ...criptions Windrow Type Windrow Descriptions Herringbone 1004222 Description The most desirable form of windrow stalks are crossed and interwoven Heads are distributed across full width of windrow This...

Page 108: ...Distribution Poor Curing Fair Weatherability Poor Machine Setting Guidelines High draper speed High header angle Center delivery Parallel 1004533 Description The stalks are parallel to windrow and he...

Page 109: ...or Machine Setting Guidelines Low reel speed Less aggressive tine pitch End delivery or center delivery if crop is leaning 75 Diagonal 1004220 Description The stalks are closer to parallel than the 45...

Page 110: ...sing the table below Level Moisture Condition Wet Over 45 Soil is muddy Damp 25 45 Shows footprints Dry Under 25 Surface is dusty If the ground is wet due to irrigation wait until soil moisture drops...

Page 111: ...drying time by a full day in hay that will not be raked If practical set the opening width of the draper decks for a narrower windrow that can be straddled NOTE Driving on the windrow in high yieldin...

Page 112: ......

Page 113: ...ent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props befo...

Page 114: ...ntervals are for average conditions Service the machine more often if operating under adverse conditions severe dust extra heavy loads etc CAUTION Carefully follow safety messages Refer to 6 1 Prepari...

Page 115: ...dware and tighten to required torque 8 2 Torque Specifications page 165 50 Hours Change gearbox oil 6 5 2 Changing Oil in Header Drive Gearbox page 112 50 Hours Change hydraulic oil filter 6 4 4 Chang...

Page 116: ...dboard or paper to search for leaks IMPORTANT Keep hydraulic coupler tips and connectors clean The introduction of dust dirt water or foreign material into a hydraulic system is the major cause of dam...

Page 117: ...keep a record of scheduled maintenance 6 3 1 Service Intervals Refer to the illustrations on the following pages to identify the various locations that require lubrication and servicing Illustrations...

Page 118: ...refer to 6 4 4 Changing Oil Filter page 110 Every 50 hours Apply grease every 50 hours of operation to the grease points shown in Figure 6 6 page 105 Use high temperature extreme pressure EP2 performa...

Page 119: ...e 6 6 Grease Points Every 50 Hours A Lift Arm Pivot x2 B Lift Arm Pivot x2 C PTO Driveline Universal x2 D PTO Driveline Slip Joint E PTO Driveline Guard x2 F Driveline Universal x2 G Driveline Slip Jo...

Page 120: ...e Gearbox page 112 A 1034920 Figure 6 8 TM100 Oil Filter Every 250 hours Change hydraulic oil filter A For instructions refer to 6 4 4 Changing Oil Filter page 110 1034673 A B Figure 6 9 Header Drive...

Page 121: ...The grease point location decal is located on the back of the tractor mount float module DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine an...

Page 122: ...enum disulphide NLGI Grade 2 lithium base unless otherwise specified 2 Inject grease through the fitting with the grease gun until the grease overflows the fitting except where noted 3 Leave excess gr...

Page 123: ...oil level using sight glass A with the float module set to operating height and angle 10 degrees forward and 400 mm 15 3 4 in above the ground NOTE Check the level when the oil is cold 3 Ensure the hy...

Page 124: ...e leaving the operator s seat for any reason 1 Engage the header to warm up the oil 2 Shut down the engine and remove the key from the ignition 1034691 A B Figure 6 15 Hydraulic Reservoir 3 Place a su...

Page 125: ...in off filter A and clean the exposed filter port in the pump 4 Apply a thin film of clean oil to the O ring provided with the new filter IMPORTANT Do NOT use a filter wrench to install the new filter...

Page 126: ...oil level plug A and check that the oil level is up to the bottom of the hole 4 If required add oil through the level plug hole A until the oil level is up to the bottom of the hole Use SAE 85W 140 ge...

Page 127: ...ain to collect the oil 6 Remove oil drain plug A and oil level plug B and allow the oil to drain 7 Replace oil drain plug A and tighten to 25 Nm 18 lbf ft 1034675 B A Figure 6 19 Linkage Position A 10...

Page 128: ...oil through level plug hole B until oil level is up to the bottom of the hole Use SAE 85W 140 gear lubricant NOTE The header drive gearbox holds approximately 0 8 liters 0 83 quarts of oil 10 Replace...

Page 129: ...l Connections In order to aid with the service or repair of the selector manifold this topic describes the electrical components connections and their functions 1035139 A C D B Figure 6 21 Selector Va...

Page 130: ...hydraulic ports and their functions E G C 1035138 A D F B Figure 6 22 Selector Valve Manifold Hydraulic Connections Table 6 3 Selector Valve Manifold Hydraulic Connections Ref Port Function Cable Tie...

Page 131: ...he knife and side draper drives are powered by a hydraulic pump The required relief and flow settings are integrated within the pump 1035133 A B Figure 6 23 Integrated Pump MD 333086 A Knife Drive B S...

Page 132: ...2 K L J Figure 6 24 Integrated Pump MD 333086 A Port SDP B Port KP C Port T D Port KR E Port SDR F Port D G Port KS H Filter J Flow Control Valve K Knife Drive Pressure Compensator L Draper Flow and P...

Page 133: ...F national fine thread NSS not sold separately NT narrow transport O D outside diameter OPT optional PO pilot operated PT pull type mower conditioner RC roller chain REF reference part number called u...

Page 134: ...erial number on which the dash appears determines whether the part is used up to or after the serial number given Example 451189 Used on machines up to and including serial number 451189 451190 Used o...

Page 135: ......

Page 136: ...262150 122 Revision A 7 3 Lift Arms and Center Link 1035105 1 2 3 4 5 6 7 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21 11 A B C D D 14 9 20 D D D D E 22...

Page 137: ...N 1 4 28 UNF 2 14 333488 PLATE FLOAT LINK 4 15 258703 ASSEMBLY RUBBER BLOCK 2 16 258318 PIN PIVOT 2 17 247801 PIN WELDMENT WHEEL ARM 2 18 247111 RING EXT RETAINING PLATED 2 19 163921 PIN CLEVIS 1 20 4...

Page 138: ...262150 124 Revision A 7 4 Float Springs 1035141 1 2 3 4 5 6 A B C D E F F...

Page 139: ...N CLEVIS 4 5 18609 PIN COTTER 1 4 DIA X 2 ZP 4 6 18608 PIN COTTER 3 16 DIA X 1 5 ZP 4 A 136088 BOLT HEX HD TFL M20 X 2 5 X 450 X SPCL 8 8 AA1J B 136506 BOLT RHSSN M10 X 1 5 X 25 8 8 AA1J C 135799 NUT...

Page 140: ...262150 126 Revision A 7 5 Header Drive 1 2 3 4 5 6 7 8 9 3 3 A B B C D E F G H J K K L M N F 10...

Page 141: ...RING EXTERNAL 247084 SHIM M72 OD 247091 SHIM M45 OD 333549 RETAINING RING EXTERNAL 333550 CAP B P GEARBOX 333551 SEAL 333552 PLUG 7 333540 COVER SHAFT 1 8 202986 ELEMENT HYDRAULIC FILTER 1 9 REF DRIVE...

Page 142: ...262150 128 Revision A 1 2 3 4 5 6 7 8 9 3 3 A B B C D E F G H J K K L M N F 10 REPAIR PARTS...

Page 143: ...29 Revision A Ref Part Number Description Qty Serial Number L 135369 WASHER HARDENED ASTM F436 1 2 M 50155 BOLT HEX HD TFL M12 X 1 75 X 25 8 8 AA1J N 50139 BOLT HEX HD TFL M8 X 1 25 X 16 8 8 AA1J REPA...

Page 144: ...262150 130 Revision A 7 6 Hydraulics Header Lift and Reel Drive 1 2 3 6 7 5 4 8 9 10 11 12 13 14 15 16 17 18 19 19 20 20 20 21 22 22 23 A B C 24 24 24 25 25 25 25 12 13 26 27 11 11 3...

Page 145: ...15 135704 SEAL EDGE TRIM 4 16 333499 SEAL EDGE TRIM 2 17 333257 SEAL EDGE TRIM 2 18 172877 GROMMET 2 38 IN I D 2 19 247875 VALVE BALL 2 20 136154 FITTING ELBOW 45 HYD 3 44209 O RING 2 21 X 16 36 13586...

Page 146: ...262150 132 Revision A 1 2 3 6 7 5 4 8 9 10 11 12 13 14 15 16 17 18 19 19 20 20 20 21 22 22 23 A B C 24 24 24 25 25 25 25 12 13 26 27 11 11 3 REPAIR PARTS...

Page 147: ...133 Revision A Ref Part Number Description Qty Serial Number A 167307 SCREW HEX SOC HD M8 X 1 25 X 20 8 8 AA1J B 320181 RIVNUT M8 X 1 25 HEX 3 8 7 9 C 135337 NUT HEX FLG CTR LK M8 X 1 25 8 AA1J REPAIR...

Page 148: ...262150 134 Revision A 7 7 Hydraulics Knife Drive and Draper Drive 15 1 2 3 4 5 7 8 9 10 11 12 13 6 7 8 8 8 14...

Page 149: ...X 9 25 6 135788 FITTING ADAPTER 1 30971 O RING 2 95 X 23 47 135868 O RING 1 78 X 18 77 7 135791 FITTING ADAPTER 2 50220 O RING 2 95 X 29 74 135554 O RING 1 78 X 23 52 8 293184 CINCH STRAP 8 IN LG HEA...

Page 150: ...262150 136 Revision A 7 8 Hydraulics Reel Positioning and Header Tilt B A C D E D 1 2 3 4 5 6 8 8 7 9 10 10 11 11 12 13 14 15 16 16 16 16 16 13 13 13 13 14 15 17 18 2...

Page 151: ...1 135563 FITTING COUPLING HYD 2 12 135234 CLAMP DOUBLE HOSE INSULATED 1 13 49227 FASTENER CABLE TIE GREEN 14 40704 FASTENER CABLE TIE ORANGE 15 40703 FASTENER CABLE TIE BLUE 16 40702 FASTENER CABLE TI...

Page 152: ...262150 138 Revision A 7 9 Hydraulic Reservoir A B C D E C 1 2 3 4 5 6 7 8 9 A B 9 10 11...

Page 153: ...252814 FITTING ELBOW 45 HYD 1 9 136106 FLANGE HALF SPLIT 1 5 IN 2 10 REF PUMP INTEGRATED 16 1 11 135400 O RING 3 53 X 47 22 A 30627 BOLT HEX HD TFL M10 X 1 5 X 25 8 8 A3L B 184711 WASHER FLAT REG M10...

Page 154: ...262150 140 Revision A 7 10 Selector Valve Assembly 1035189 A B 2 3 4 4 5 5 6 6 7 1 8 9 10 9 10 11 12 13 13 13 13 14 14 15 16 16 17 18 19 19...

Page 155: ...FITTING ELBOW 90 HYD 4 135865 O RING 1 78 X 9 25 50219 O RING 1 98 X 11 89 14 135778 FITTING ADAPTER 2 135865 O RING 1 78 X 9 25 50219 O RING 1 98 X 11 89 15 252693 RESTRICTOR 6 ORB X 052 IN 1 16 4922...

Page 156: ...262150 142 Revision A 7 11 Integrated Pump Service Parts 1035179 1 2 3 4 5 6 7 A B C C A A A D D D D...

Page 157: ...ING HOSE AND HARDWARE 1 3 322142 SEAL SHAFT 1 4 328178 RING RETAINING INTERNAL 1 5 136900 CAP DUST 1 6 328307 KIT COMPENSATOR LOAD SENSING 1 7 328306 KIT COMPENSATOR 1 A 337430 BOLT SOC HD M10 X 40 GR...

Page 158: ...262150 144 Revision A 7 12 Electrical 1 2 3 4 5 6 7 8 9 9 10 10 A B C D D E E 11 11...

Page 159: ...OUNT 21 1 9 21763 FASTENER CABLE TIE BLACK 4 10 134442 SPACER DUAL SWIVEL SADDLE 2 11 136655 FASTENER FIR TREE MT W TIE 2 A 136324 BOLT HEX FLG HD TFLM6 X 1 X 20 10 9 AA1J B 184705 WASHER FLAT M6 200H...

Page 160: ...262150 146 Revision A 7 13 Electrical TM100 to Tractor Cab 1 2 3 4 5 6 7 8 9 10 11 A B C D...

Page 161: ...H ROCKER ON OFF ON 1 10 333265 HARNESS POWER TM100 1 11 333266 HARNESS POWER TM100 HELLA 1 A 252247 SCREW PAN HD 12 14 X 1 2 RC45 AF0C B 197230 NUT HEX NYLOC M5 X 0 8 8 AA1J C 197225 BOLT RHSN M5 X 0...

Page 162: ...262150 148 Revision A 7 14 Hydraulics Multicoupler and Hoses 1035222 1 2 3 4 5 6 7 4 3 8 9 10 11 12 13 1 1 1 13 13 13...

Page 163: ...LLOW 1 6 49232 FASTENER CABLE TIE WHITE 1 7 30994 FITTING PLUG HYD 6 ORB HEX HD 1 8 111985 COUPLER 3 8 IN 1 9 294350 COUPLER 3 8 IN 1 10 111984 KIT DOWEL 2 11 111986 COUPLER 1 4 IN 3 12 111983 KIT SCR...

Page 164: ...262150 150 Revision A 7 15 TM100 to Three Point Hitch 1035223 2 4 1 5 6 7 8 9 5 1 A 3 3 3...

Page 165: ...6 IN 1 7 333543 DRIVELINE Z21 PTO TO GEARBOX 26 1 333544 DRIVELINE Z20 PTO TO GEARBOX 26 1 333542 DRIVELINE Z6 PTO TO GEARBOX 26 1 8 333506 PLATE PTO DRIVELINE HOLDER 27 1 9 176334 SEAL EDGE TRIM 2 A...

Page 166: ...262150 152 Revision A 7 16 Driveline Power Take Off to Gearbox Service Parts A 11 2 3 4 5 6 7 8 9 10 1...

Page 167: ...EMBLY 28 1 4 333555 PIN ROLL B AND P 8 X 60 1 5 333556 PIN ROLL B AND P 8 X 55 1 6 333557 YOKE 1 3 8 IN Z6 TAPERED PIN 1 7 333558 SUPPORT OUTER SHIELD G3 G4 1 8 333559 SUPPORT INNER SHIELD G3 G4 1 9 3...

Page 168: ...262150 154 Revision A 7 17 TM100 to Header Attaching Parts 1035226 1 2 A B C D D C D D A B...

Page 169: ...ty Serial Number 1 333536 PIN LOCK 2 2 333522 BRACKET D1 LOCK WELDMENT 2 A 18601 WASHER FLAT SAE B 135385 RING EXT RETAINING FOR 0 750 IN SHAFT C 252891 BOLT HEX HD TFL M20 X 2 5 X 35 8 8 AA1J D 21540...

Page 170: ...262150 156 Revision A 7 18 Decals 1 2 3 4 5 6 7 8...

Page 171: ...mber 1 166832 DECAL HIGH PRESSURE FLUID 1 2 313728 DECAL READ MANUAL FLUID SPRAY 1 3 333263 DECAL CONTROLS 1 4 333225 DECAL SERVICE GREASE 1 5 132898 STRIP ANTI SLIP 1 6 247130 DECAL DANGER 1 7 158289...

Page 172: ......

Page 173: ...chapter provides additional information such as lubricants fluids and system capacities fuel and torque specifications a unit conversion chart and a list of acronyms abbreviations and terms used in t...

Page 174: ......

Page 175: ...FMA2135 P16 FMA4010 U16 FMA4020 U16 FMA4401 U16 FMA2514 N16 FMA2214 Y16 FMA2134 P16 FMA0504 B16 FMA2135 P16 FMA4010 U16 FMA4020 U16 FMA4401 U16 FM0707 R12 FM4402 U16 FM4401 U16 FM4020 U16 FM4010 U16...

Page 176: ......

Page 177: ...4 5 6 7 8 9 10 2 1 PRESSURE RETURN Side Draper Pressure Case Drain Knife Pressure Knife Return Side Draper Return Reel Return Reel Pressure Reel Lower Reel Lift Reel Aft Reel Fore Blue Tie Orange Tie...

Page 178: ......

Page 179: ...screws Refer to the standard torque values when installing the self tapping screws Do NOT install the self tapping screws on structural or otherwise critical joints 8 2 1 Metric Bolt Specifications Sp...

Page 180: ...65 72 48 53 14 2 0 104 115 77 85 16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 1001370 1001370 A Figure 8 3 Bolt Grades Table 8 3 Metric Class 10 9 Bolts and Class 10 Free Spin...

Page 181: ...num Specifications are provided for the appropriate final torque values for various sizes of metric bolts in cast aluminum NOTE The torque values provided in the following metric bolt torque tables ap...

Page 182: ...g A is NOT on the threads Adjust O ring A if necessary 4 Apply hydraulic system oil to O ring A 1003432 D A E B C Figure 8 7 Hydraulic Fitting 5 Install fitting B into the port until backup washer D a...

Page 183: ...ame type and size of fitting found in this topic use the value specified in the procedure instead 1004663 A B C Figure 8 8 Hydraulic Fitting 1 Inspect O ring A and seat B for dirt or defects 2 Ensure...

Page 184: ...cedure instead Torque values are shown in the Table 8 8 page 171 1001376 Figure 8 9 Hydraulic Fitting 1 Ensure that the sealing surfaces and the fitting threads are free of burrs nicks scratches and a...

Page 185: ...contamination 2 Apply paste type pipe thread sealant to the external pipe threads 3 Thread the fitting into the port until it is hand tight 4 Torque the connector to the appropriate torque angle The t...

Page 186: ...ead Tapered Pipe Thread Size Recommended TFFT Recommended FFFT 1 8 27 2 3 12 18 1 4 18 2 3 12 18 3 8 18 2 3 12 18 1 2 14 2 3 12 18 3 4 14 1 5 2 5 12 18 1 11 1 2 1 5 2 5 9 15 1 1 4 11 1 2 1 5 2 5 9 15...

Page 187: ...er m x 3 2808 foot ft Power kilowatt kW x 1 341 horsepower hp Pressure kilopascal kPa x 0 145 pounds per square inch psi Pressure megapascal MPa x 145 038 pounds per square inch psi Pressure bar Non S...

Page 188: ......

Page 189: ...451 123 132898 157 134442 145 134728 145 134730 145 135234 137 135238 149 135337 133 135369 129 135385 155 135400 139 135444 131 137 135554 135 135563 137 149 135704 131 135778 131 141 135779 149 1357...

Page 190: ...14537 139 320181 133 320284 141 320308 151 320309 151 322142 143 327600 123 328178 143 328261 143 328306 143 328307 143 328411 145 333081 125 333086 127 333128 127 333181 145 333183 145 333189 131 333...

Page 191: ...rol console functions 89 installing 59 conversion chart 173 D daily start up checks 86 definition of terms 15 detaching from tractor 73 dimensions 18 drivelines installing 34 shortening 51 E electrica...

Page 192: ...drive gearbox adding oil 112 changing oil 112 checking oil level 112 M maintenance and servicing 99 preparing machine for servicing 99 requirements 100 safety 5 schedule record 100 service intervals...

Page 193: ...ing shipping stands removing 29 shutdown procedures 88 soft joints definition 15 specifications product specifications 17 torque specifications 165 start up daily checks 86 T tension definition 15 TFF...

Page 194: ...types 93 weather and topography 96 INDEX...

Page 195: ...shipping damage or missing parts Be sure all shipping dunnage is removed Check for loose hardware Tighten to required torque 8 2 Torque Specifications page 165 Check gearbox oil level 6 5 1 Checking O...

Page 196: ......

Page 197: ...rease SAE multi purpose High temperature extreme pressure EP performance with 10 max molybdenum disulphide NLGI Grade 2 lithium base Driveline slip joints Gear Lubricant SAE 85W 140 API service class...

Page 198: ...STOMERS M Ma ac cD Do on n c co om m DEALERS P Po or rt ta al l M Ma ac cD Do on n c co om m Trademarks of products are the marks of their respective manufacturers and or distributors Printed in Canad...

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