MacDon HC10 Guide

The harvesting specialists worldwide.
HC10
Hay Conditioner for D-Series
Draper Headers
Setup, Operation, and Parts Manual
169254 Rev. D
Original Instruction

MacDon Model HC10 Hay Conditioner
Published on January, 2014.

Introduction
This manual contains safety information, set-up instructions, operating and maintenance procedures, and parts
information for the ModelHC10 Hay Conditioner. This hayconditioner, when teamedwith an M-Series Self-Propelled
Windrower power unit and a D-Series Draper Header, will cut and lay crop into uniform, fluffy windrows. Conditioning
or crimping the cut hay allows moisture release for quicker drying and earlier processing.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR USE
THE MACHINE.
Use this manual as your first source of information about the machine. If you follow the instructions given in this
manual, your hay conditioner will work well for many years. Use this manual in conjunction with your M-Series
Self-Propelled Windrower and D-Series Draper Header manuals.
Use the Table of Contents to guide you to specific topics. Review the Table of Contents to familiarize yourself with
how the material is organized.
Keep this manual handy for frequent reference and to pass on to new Operators or Owners. Call your Dealer if you
need assistance, information, or additional copies of this manual.
169254 iRev. D

Serial Numbers
Record the serial number of the hay conditioner in the space below.
HAY CONDITIONER SERIAL NO: ____________
Serial Number Plate (A) is located on the rear cover of the conditioner frame as shown below.
Figure 1: Serial Number Plate
169254 iiRev. D

TABLE OF CONTENTS
Introduction...................................................................................................................................... i
Serial Numbers.................................................................................................................................ii
1 Safety.................................................................................................................................................... 1
1.1 Safety Alert Symbols........................................................................................................................ 1
1.2 Signal Words................................................................................................................................... 2
1.3 General Safety ................................................................................................................................ 3
1.4 Maintenance Safety......................................................................................................................... 5
1.5 Hydraulic Safety .............................................................................................................................. 6
1.6 Tire Safety....................................................................................................................................... 7
1.7 Battery Safety.................................................................................................................................. 8
1.8 Welding Precaution........................................................................................................................ 10
1.9 Engine Safety.................................................................................................................................11
1.9.1 High Pressure Rails.................................................................................................................11
1.9.2 Engine Electronics ................................................................................................................. 12
1.10 Safety Signs.................................................................................................................................. 13
1.10.1 Installing Safety Decals .......................................................................................................... 13
2 General Information ............................................................................................................................ 15
2.1 Torque Specifications..................................................................................................................... 15
2.1.1 SAE Bolt Torque Specifications............................................................................................... 15
2.1.2 Metric Bolt Specifications........................................................................................................ 17
2.1.3 Metric Bolt Specifications Bolting into Cast Aluminum............................................................... 20
2.1.4 Flare-Type Hydraulic Fittings................................................................................................... 20
2.1.5 O-Ring Boss (ORB) Hydraulic Fittings ..................................................................................... 21
2.1.6 O-Ring Face Seal (ORFS) Hydraulic Fittings............................................................................ 22
2.2 Specifications................................................................................................................................ 24
2.3 Conversion Chart........................................................................................................................... 25
2.4 Component Identification................................................................................................................ 26
3 Unloading and Assembly .................................................................................................................... 29
3.1 Unloading the Hay Conditioner....................................................................................................... 29
3.2 Preparing the Header..................................................................................................................... 31
3.3 Installing the Rock Grate................................................................................................................ 32
3.4 Installing Deck Brackets................................................................................................................. 33
3.5 Installing the Feed Deck................................................................................................................. 35
3.6 Installing the Conditioner................................................................................................................ 37
3.6.1 Installing Conditioner: Lifting Method....................................................................................... 37
3.6.2 Installing Conditioner: Windrower Method................................................................................ 39
3.7 Attaching Hydraulics...................................................................................................................... 45
3.7.1 Attaching Hydraulics: 15-Foot Headers.................................................................................... 45
3.7.2 Attaching Hydraulics: All Headers Except 15-Foot.................................................................... 47
3.8 Assembling the Forming Shield ...................................................................................................... 50
3.9 Installing the Forming Shield........................................................................................................... 53
3.10 Attaching to a Windrower ............................................................................................................... 55
3.11 Lubricating the Conditioner............................................................................................................. 56
3.11.1 Greasing Procedure ............................................................................................................... 56
3.11.2 Lubrication Points................................................................................................................... 57
3.12 Performing Predelivery Checks....................................................................................................... 59
3.12.1 Checking Roll Drive Belt Tension............................................................................................. 59
3.12.2 Checking Roll Gap ................................................................................................................. 60
3.12.3 Checking Roll Timing.............................................................................................................. 60
3.12.4 Running Up the Conditioner.................................................................................................... 61
3.12.5 Storing Manuals..................................................................................................................... 62
4 Operation ............................................................................................................................................ 63
4.1 Owner/Operator Responsibilities..................................................................................................... 63
169254 iii Rev. D

TABLE OF CONTENTS
4.2 Operational Safety......................................................................................................................... 64
4.2.1 Shutting Down the Machine .................................................................................................... 64
4.3 Attaching Hay Conditioner to Header..............................................................................................65
4.4 Detaching Hay Conditioner from Header ......................................................................................... 66
4.4.1 Detaching Hay Conditioner: Windrower Method....................................................................... 66
4.4.2 Detaching Hay Conditioner: Lifting Method.............................................................................. 70
4.5 Detaching Feed Deck and Rock Grate............................................................................................ 74
4.6 Break-in Period.............................................................................................................................. 77
4.7 Preseason Check .......................................................................................................................... 78
4.8 Daily Startup Check....................................................................................................................... 79
4.9 Conditioner Operation.................................................................................................................... 80
4.9.1 Roll and Feed Draper Speed................................................................................................... 80
4.9.2 Adjusting Roll Gap ................................................................................................................. 80
4.9.3 Checking and Adjusting Roll Timing......................................................................................... 81
4.9.4 Adjusting Conditioner Roll Tension ......................................................................................... 83
4.9.5 Forming Shields..................................................................................................................... 83
Adjusting Forming Shield Height...................................................................................... 84
Adjusting Side Deflectors ................................................................................................ 84
Adjusting Rear Deflector (Fluffer Shield)........................................................................... 85
Adjusting Deflector Fins .................................................................................................. 85
4.9.6 Unplugging the Conditioner..................................................................................................... 85
4.10 Storage......................................................................................................................................... 86
5 Maintenance........................................................................................................................................ 87
5.1 Preparation for Servicing................................................................................................................ 87
5.2 Recommended Safety Procedures..................................................................................................88
5.3 Drive Shields................................................................................................................................. 89
5.4 Lubrication .................................................................................................................................... 90
5.4.1 Lubricants.............................................................................................................................. 90
5.4.2 Greasing Procedure ............................................................................................................... 90
5.4.3 Lubrication Points................................................................................................................... 91
5.5 Hydraulics..................................................................................................................................... 94
5.5.1 Hydraulic Hoses and Lines .....................................................................................................94
5.6 Feed Draper.................................................................................................................................. 95
5.6.1 Adjusting Feed Draper Tension ............................................................................................... 95
5.7 Drive Belt...................................................................................................................................... 96
5.7.1 Adjusting Drive Belt Tension.................................................................................................... 96
5.7.2 Adjusting Drive Belt Pulley Alignment ...................................................................................... 97
5.7.3 Checking and Adjusting Drive Belt Tracking............................................................................. 98
5.7.4 Removing Drive Belt .............................................................................................................100
5.7.5 Installing Drive Belt ...............................................................................................................100
5.8 Maintenance Schedule..................................................................................................................102
5.9 Troubleshooting............................................................................................................................104
6Repa
ir Parts .......................................................................................................................................107
6.1 Abbreviations ...............................................................................................................................107
6.1.1 Serial Number Breaks ...........................................................................................................107
6.2 Lower Roll and Frame Assembly ...................................................................................................108
6.3 Upper Roll Assembly ....................................................................................................................110
6.4 Cover and Supports......................................................................................................................112
6.5 Hydraulic Motor, Mounts, and Tensioner.........................................................................................116
6.6Belt Drive and Shield ....................................................................................................................120
6.7Hydraulic Completion Package......................................................................................................122
6.8Gears and Roll Coupling Assembly................................................................................................126
6.9Forming Shields ...........................................................................................................................128
169254 ivRev. D

TABLE OF CONTENTS
6.10 Feed Deck and Pan......................................................................................................................130
6.11 Mounting Brackets........................................................................................................................134
Index ..................................................................................................................................................137
Model HC10 Hay Conditioner Predelivery Checklist........................................................................143
169254 vRev. D

1 Safety
1.1 Safety Alert Symbols
This safety alert symbol indicates important safety
messages in this manual and on safety signs on
the hay conditioner.
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.
Figure 1.1: Read Operator’s Manual Before
Operating
169254 1Rev. D

SAFETY
1.2 Signal Words
Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The
appropriate signal word for each situation has been selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death, or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death, or serious injury.
It may also be used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor, or moderate injury.
It may be used to alert against unsafe practices.
169254 2Rev. D

SAFETY
1.3 General Safety
CAUTION
The following are general farm safety precautions
that should be part of your operating procedure
for all types of machinery.
Protect yourself
• When assembling, operating, and servicing machinery,
wear all the protective clothing and personal safety
devices that COULD be necessary for the job at hand.
Don’t take chances.
Figure 1.2
• You may need:
– A hard hat
– Protective footwear with slip resistant soles
– Protective glasses or goggles
– Heavy gloves
– Wet weather gear
– A respirator or filter mask
– Hearing protection
Be aware that exposure to loud noise can cause
impairment or loss of hearing. Wearing suitable
hearing protection devices such as ear muffs or ear
plugs. These will help protect against objectionable
or loud noises.
Figure 1.3
•Provideafirst aid kit for use in case of emergencies.
•Keepafire extinguisher on the machine. Be sure the fire
extinguisher is properly maintained. Be familiar with its
proper use.
• Keep young children away from the machinery at
all times.
• BeawarethataccidentsoftenhappenwhentheOperator
istiredorinahurrytogetfinished. Takethetimeto
consider the safest way. Never ignore warning signs
of fatigue.
Figure 1.4
169254 3Rev. D

SAFETY
•Wearclosefitting clothing and cover long hair. Never
wear dangling items such as scarves or bracelets.
• Keep all shields in place. Never alter or remove safety
equipment. Make sure driveline guards can rotate
independently of the shaft and can telescope freely.
• Use only service and repair parts, made, or approved by
the equipment manufacturer. Substituted parts may not
meet strength, design, or safety requirements.
Figure 1.5
• Keep hands, feet, clothing, and hair away from moving
parts. Never attempt to clear obstructions or objects,
from a machine while the engine is running.
•Do NOT modify the machine. Non-authorized
modificationsmayimpairmachine functionand/orsafety.
It may also shorten the machine’s life.
• Stop engine and remove key from ignition before leaving
operator’s seat for any reason. A child or even a pet
could engage an idling machine.
Figure 1.6
• Keep the area used for servicing machinery clean
and dry. Wet or oily floors are slippery. Wet spots
can be dangerous when working with electrical
equipment. Be sure all electrical outlets and tools are
properly grounded.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff, on a hot
engine, are a fire hazard. Do NOT allow oil or grease to
accumulate on service platforms, ladders, or controls.
Clean machines before storage.
• Never use gasoline, naphtha, or any volatile material
for cleaning purposes. These materials may be toxic
and/or flammable.
• When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
Figure 1.7
169254 4Rev. D

SAFETY
1.4 Maintenance Safety
To ensure your safety while maintaining the machine:
• Review the operator’s manualand all safety items before
operation and/or maintenance of the machine.
•Placeallcon
trols in Neutral, stop the engine, set the park
brake, remove the ignition key, and wait for all moving
partsto stopbeforeservicing,adjusting,and/orrepairing.
• Follow good shop practices:
– Keep service area clean and dry.
–Besureele
ctrical outlets and tools are properly
grounded.
– Use adequate light for the job at hand. Figure 1.8: Slip on Puddle
• Relieve pressure from hydraulic circuits before servicing
and/or disconnecting the machine.
• Before applying pressure to a hydraulic system, make
sure all components are tight and that steel lines, hoses,
and couplings are in good condition.
• Keephands,feet, clothing, andhairawayfrom allmoving
and/or rotating parts.
•Clearth
e area of bystanders especially children when
carrying out any maintenance and repairs or when
making any adjustments.
•Instal
l transport lock or place safety stands under the
frame before working under the hay conditioner.
•Ifmore
than one person is servicing the machine at the
same time,beawarethatrotatingadrivelineorother
mechanically driven component by hand (for example,
accessing a lube fitting) will cause drive components in
otherareas (belts, pulleys, and knife) to move. Stay clear
of driven components at all times.
Figure 1.9: Keep Away
• Wear protective gear when working on the machine.
• Wear heavy gloves when working on knife components.
Figure 1.10: Safety Gear
169254 5Rev. D

SAFETY
1.5 Hydraulic Safety
• Always place all hydraulic controls in Neutral before
dismounting.
• Makesurethatall components in the hydraulic system
are kept in good condition and clean.
•Replaceanyw
orn, cut, abraded, flattened, or crimped
hoses and steel lines.
• Do not attempt any makeshift repairs to the hydraulic
lines, fittings, or hoses by using tapes, clamps, cements,
or welding. The hydraulic system operates under
extremely high pressure. Such makeshift repairs will fail
suddenly and create a hazardous and unsafe condition.
Figure 1.11: Checking Hydraulic Leaks
• Wearproperhandandeye protectionwhensearchingfor
a high-pressure hydraulicleak. Use a piece of cardboard
as a backstop instead of hands to isolate and identify
aleak.
• If injured by a concentrated high-pressure stream of
hydraulicfluid, seek medical attention immediately.
Serious infection or toxic reaction can develop from
hydraulic fluid piercing the skin.
Figure 1.12: Hydraulic Pressure Hazard
• Before applying pressure to a hydraulic system, make
sure all components are tight and that steel lines, hoses,
and couplings are in good condition.
Figure 1.13: Wear Safety Glasses
169254 6Rev. D

SAFETY
1.6 Tire Safety
• Failure to follow proper procedures when mounting a tire
on a wheel or rim can produce an explosion that may
result in serious injury or death.
Figure 1.14: Lower All Safety Stops
•DoNOT attempt to mount a tire unless you have the
proper training and equipment.
Figure 1.15: Safely Filling a Tire with Air
•Haveaq
ualified tire dealer or repair service perform
required tire maintenance.
Figure 1.16: Over-Inflation of Tire
169254 7Rev. D

SAFETY
1.7 Battery Safety
WARNING
• Keep all sparksandflames away from the
batteries, as a gas given off by electrolyte is
explosive.
•Ventilatewh
en charging in enclosed space.
Figure 1.17
169254 8Rev. D

SAFETY
WARNING
• Wear safety glasses when working near
batteries.
• Do not tip batteries more than 45° to avoid
electrolyte loss.
• Battery electrolyte causes severe burns. Avoid
contact with skin, eyes, or clothing.
• Electrolyte splashed into the eyes is extremely
dangerous. Should this occur, force the eye
open, and floodwithcool,cleanwaterforfive
minutes. Call a doctor immediately.
• If electrolyte is spilled or splashed on clothing
or the body, neutralize it immediately with a
solution of baking soda and water, then rinse
with clear water.
Figure 1.18
WARNING
• To avoid injury from spark or short circuit,
disconnect battery ground cable before
servicing and part of electrical system.
• Do not operate the engine with alternator or
battery disconnected. With battery cables
disconnected and engine running, a high
voltage can be built up if terminals touch the
frame. Anyone touching the frame under these
conditions would be severely shocked.
• When working around storage batteries,
remember that all of the exposed metal parts
are live. Never lay a metal object across the
terminals because a spark or short circuit will
result.
• Keep batteries out of reach of children.
Figure 1.19
169254 9Rev. D

SAFETY
1.8 Welding Precaution
High currents and voltage spikes associated with welding can cause damage to electronic components. Before
welding on any part of the windrower or an attached header, disconnect all electronic module harness connections
as well as the battery cables. Refer to your technical manual or MacDon Dealer for proper procedures.
169254 10Rev. D

SAFETY
1.9 Engine Safety
WARNING
Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and
personal injury.
CAUTION
• In the initial start-up of a new, serviced, or repaired engine always make provision to shut the
engine off, in order to stop an over-speed. This may be accomplished by shutting off the air and/or
fuel supply to the engine. Over-speed shut down should occur automatically for engines that are
controlled electronically.
• Do not bypass or disable the automatic shutoff circuits. The circuits are provided in order to help
prevent personal injury. The circuits are also provided in order to help prevent engine damage. See
the technical manual for repairs and adjustments.
• Inspect the engine for potential hazards.
• Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that
theareaisfreeofpersonnel.
• All protective guards and all protective covers must be installed if the engine mustbe started in order
to perform service procedures.
• To help prevent an accident that is caused by parts in rotation, work around the parts carefully.
• If a warning tag is attached to the engine start switch or to the controls, do NOT start the engine
or move the controls. Consult with the person who attached the warning tag before the engine is
started.
• Start the engine from the operator’s compartment. Always start the engine according to the
procedure that is described in the Engine Starting section of the operator’s manual. Knowing
the correct procedure will help to prevent major damage to the engine components and prevent
personal injury.
• To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working
correctly, check the water temperature gauge and/or the oil temperature gauge during the heater
operation. Engine exhaust contains products of combustion which can be harmful to your health.
Always start the engine and operate the engine in a well ventilated area. If the engine is started in an
enclosed area, vent the engine exhaust to the outside.
NOTE: The engine may be equipped with a device for cold starting. If the engine will be operated in very
cold conditions, then an additional cold starting aid may be required. Normally, the engine will be
equipped with the correct type of starting aid for your region of operation.
1.9.1 High Pressure Rails
CAUTION
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray
may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may
cause personal injury or death.
169254 11Rev. D

SAFETY
1.9.2 Engine Electronics
WARNING
Tampering with the electronic system installation or the Original Equipment Manufacturer (OEM) wiring
installation can be dangerous and could result in personal injury or death and/or engine damage.
WARNING
Electrical Shock Hazard. The electronic unit injectors use DC voltage. The Electronic Control Module
(ECM) sends this voltage to the electronic unit injectors. Do not come in contact with the harness
connector for the electronic unit injectors while the engine is operating. Failure to follow this instruction
could result in personal injury or death.
This engine has a comprehensive, programmable engine monitoring system. The ECM has the ability to monitor
the engine operating conditions. If any of the engine parameters extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine monitoring control:
• Warning
• Derate
• Shutdown
The following monitored engine operating conditions have the ability to limit engine speed and/or the engine power:
• Engine Coolant Temperature
• Engine Oil Pressure
• Engine Speed
• Intake Manifold Air Temperature
The engine monitoring package can vary for different engine models and different engine applications. However,
the monitoring system and the engine monitoring control will be similar for all engines. Together, the two controls
will provide the engine monitoring function for the specific engine application.
169254 12Rev. D