Westward DUPLEX 3000 User manual

DUPLEX
MODEL
3000
Pull-Type
Windrower
Westward Parts Services Ud.
6517-67 Street
Red Deer, Alberta T4P 1A3
Canada

INTRODUCTION
This manual is provided to assist you in the Operation and Maintenance
of your swather. Assembly Instructions are also included towards the
rear of the manual to guide you in initial set-up.
The manual contains idformation on both the single unit swather and
the duplex swather (made up of front and rear units). Any information
not pertaining to all units (single, duplex front and duplex rear) will
be designated as such. Be sure the information you are using is correct
for your machine.
We recommend that you read this manual carefully to become completely
familiar with your machine. Please pay special attention to the CAUTION
notes throughout the manual and on the machine. They are for your
SAFETY 1
Repair or replacement parts may be ordered from your nearest dealer.
When ordering parts be sure to include the proper serial number. For
serial number plate locations, see Figures 2 and 4
NOTE:
For assembly and parts description purposes, right and left
hand are determined by standing behind the machine and facing
forward (in the direction of travel). These may be abbreviated
using R/H and L/H.
2 4
1

TABLE OF CONTENTS PAGE
Introduction ................................................................................................... 1
Serial Plate Locations ........................................................................................ .. 1
Safety ... ............................................................................................ . ......... 3
Safety Decals ............................................................................................... 4,5
Specifications ............................................................................................... 6,7
Operation
At First Use- Electrical Hook-Up ............................................................................. 8,9
-
PTO Adjustment ............................................. .... ............................... 10
-Optional Hitch Plate ......................... ....... ............................................ 11
-Duplex Initial Field Adjustments .............................................................. 11,12
-Hydraulic Oil Filter
.............................................................................. 12
-
Wheel Bolts ........................................... ............ ................... .......... 12
Switch Box ................................................................................................... 13
Pre-Season Check
............................................................................................ 14
End of Season Check
.......................................................................................... 14
Transporting-General
........................................................................................ 15
-Single Unit -Field to Transport
................................. .......... ........................ 16
-Single Unit -Transport to Field
................................................................ 17,18
-Duplex Unit -Field to Transport
........................... ... ................................. 19-22
-Duplex Unit -Transport to Field
............ .. ................................................. 23-26
Changing Modes of Delivery -Description of Modes
.............................................................. 26
-Center to
End ...•................................................................ 27
-Conveyor Extension Package (Option)
.............................................. 28
To Separate and Re-Connect Duplex Units ........................................................................ 29
Duplex Operating Tips ............................................. ........ ................. ............ ..... 30,31
Trouble Shooting
Swath Formation: Center Delivery .............................................................................. 32
Crop Loss at Cutter Bar ....................................................................................... 33
Crop Loss at Drapers .......................................................................................... 33
Transport
..................................................................................................... 34
Drives .............................................. . . . ..................... ... ............................ 35,36
Duplex Tracking .............................................................................................. 37
Duplex Cornering .......................................................................................... 38,39
Duplex Swath Formation: End Delivery ......................................................................... 40
Duplex Hydraulic System ...................................................................................... 41
Duplex Electrical System ...................................................................................... 42
Duplex Transport & Conversion ................................................................................ 43
Duplex Center Deck ........................................................................................... 43
Adjustment & Maintenance
Main Drives -Idler Alignment ............................................................................... 44
-Belt Tension ......... ............... .......... ................................. ............... 44
-Rear Unit Main Drive Belt Tension .............................................................. 45
-Rear Unit Clutch Drive Belt Tension ............................................................ 45
Knife -Drive Belt Tension ........................................ .............. ............... . ............. 46
-Maintenance ........................................................... ...... ..... ... ............... 47
Reel -Horizontal Position ................................................................................... 48
-Safety Props ......................................................................................... 48
-Clearance From Cutterbar ................................................ ......... ............... ... . 49
-Centering ........................................................................................... 49
-Drive Idler Position ................................................................................... 50
-Primary Drive Belt Tension ........................................................................... 50
-Final Drive Belt Tension ...................................................... . ............... ........ 51
-Speed ................................................................ ........ ....................... 52
Drapers -Tracking
....................................................................................... 53,54
-Tension
............................................. .. ........ ........... ........................ 54
-Speed ............................................................................................ 55
-Drive Belt Travel
.................................................................................. 55
-Delivery Opening
.................................................................................. 56
Head Lift Cylinder Stop ........................................................................................ 57
Header Float .................................................................................................. 57
Wheel Alignment .............................................................. ...... ......................... 58
Trail Width .................................................................... ........................... .... 59
Telescoping Hitch Shear Bolt .................................................................................. 59
Duplex Hitch -Rear Machine Overlap ...................................................................... 60,61
-Hitch Spring .................................................................................. 62
Front Wheel Steering Spring
................................................................................... 62
Front Wheel Support Dis-assembly
............................................................................. 63
Hydraulic System-Maintenance .............................................................................. 64
-Single Unit Schematic ..................................................................... 64
-Duplex Unit Schematic
.................................................................... 65
Electrical System -Schematic ................................................................................ 66
Lubrication & Periodic Maintenance-
10 Hour ................................................................. 67
-
50 Hour ................................................................. 68
-
End of Season ........................................................ 69-71
A~~~~~I~harts ............................................................................................. 72-75
Single Unit or Front Duplex Unit ............................................................................ 76-95
Rear Duplex
Unit ........................................................................................ 96-117

SAFETY
WATCH FOR THIS SYMBOL to bring
your attention to important
safety precautions. Safety
messages are located through--
out this manual, as well as
on the machine. Be certain
that EVERYONE operating this
machine is familiar with the
procedures recommended and
follows safety precautions.
REMEMBER, most accidents can
be prevented. DO NOT RISK
INJURY
OR DEATH.
BEFORE RUNNING MACHINE
- Read the Operator's Manual
- Ensure all safety shields are
properly installed.
- Check that all observers are
clear of machine.
WHEN OPERATING MACHINE
- Keep all riders off the machine
- Never wear loose fitting
clothing.
- Keep hands, feet, clothing and
hair away from moving parts.
- Keep all safety shields in
place.
- Keep a charged fire extinguisher
in tra c tor at all times.
WHEN SERVICING MACHINE
- Always stop the machine, dis-
engage the drive, and stop
tractor engine before per-
forming checks, adjustments
or lubrication.
- Engage header and reel
safety locks before servic-
ing header or reel in raised
position.
3
WHEN TRANSPORTING MACHINE
- Check local laws regarding
the lighting and marking of
vehicles before travelling
on public roads.
Be sure safety chain is
attached to tractor.
- The gross weight of the
trailed equipment (without
brakes) should not exceed
the weight of the towing
vehicle.
WHEN STORING ~mCHINE
- Clean thoroughly to remove
flammable suhstances.
- Cover cutter bar and knife
guards to prevent accidents
while unit is in storage.

SAFETY DECALS
PLEASE
PAY HEED TO THESE
SAFETY MESSAGES,
LOCATED ON THE MACHINE,
TO MAKE SAFETY A HABIT.
A CAUTION
- Maximum transport speed 20 mph (30 km/h).
-Minimum weight of towing vehicle 5000 Ibs. (2300 kg)
- Reduce speed for corners and slippery conditions.
- Ensure all safety pins and chain are in transport
position.
-And obey all highway traffic regulations in your area
when transporting this equipment on public roads.
-Read opera~or's manual before transporting.
SINGLE UNIT
located on front hitch.
- Maximum transport speed 15 mph (25 km/h).
-Minimum weight of towing vehicle 8000 Ibs. (3600 kg).
- Reduce speed for corners and slippery conditions.
- Ensure all safety pins and chains are in transport
position.
- And obey all highway traffic regulations in your area
when transporting this equipment on public roads.
- Read operator's manual before transporting.
DUPLEX UNIT
hitch.
4
A CAUTION
Belt drive inside frame.
located on main drive frame
(duplex rear unit) .
AWARNING
To avoid bodily injury, keep all
power drive system safety shields
in place.
Operate
only with 1000 rpm PTO.
Adjust tractor drawbar to 16.0 in.
(406mm).
~ appropriate decal located c
\front hitch.
AWARNING
To avoid bodily injury, keep all
power drive system safety shields
in place.
Operate only with
540 rpm PTO.
Adjust tractor drawbar to 14.0 in.
(356mm).
:\It---_ -~--1
PTO shaft c:;::::::
Tractor d~awbar
K-31912-1
K·31104·1

SAFETY DECALS
A CAUTION
LEARN TO OPERATE THIS MACHINE SAFELY.
DO NOT RISK INJURY OR DEATH.
Before operating this machine, READ THE
OPERATOR'S MANUAL and all safety instruc-
tions. If you do not have a manual, obtain one
from your nearest dealer.
1. Make certain everyone 5. Never adjust, lubricate,
Is clear
of machine be- clean or unplug ma-
fore starting engine or chine with the engine
operation. running.
See owner's
2. Stop the engine, remove manuaJ for all adjust-
the key and wait for all ment and lubrication
movement to stop before procedures.
leaving operator's posi- 6. Use slow moving ve-
tlon for any reason. hicle identification
3. Keep all shields In place. emblem and flashing
Keep hands, feet, cloth- warning lights when
Ing and hair away from operating on highway
moving parts. except when pro-
4. Keep all riders off the hibited by law.
machine.
K23438-1
located on main drives shield.
A WARNING
To avoid injury from fall of raised reel, completely
raise reel, stop engine, remove ignition key, and set
safety prop
on or under reel. Safety prop is located on
each reel arm behind top cylinder pin.
To avoid Injury from fall of raised header, completely
raise header, stop engine, remove ignition key,
and install header lock. Header lock is located behind
header
lift cylinder. K-31903-1
located on knife drive cover
(single and duplex front unit)
and on front wheel support
(duplex rear unit) .
A CAUTION
Transport lock position
install pin in
storage hole
for field
5
hairpin
AOANGER
DO NOT RIDE
ON MACHINE K-31910-1
located on duplex hitch.
AOANGER
Lower cutter bar to ground and
unload springs before removing
pins for repairs.
SEE OPERATORS MANUAL
K-31911-1
located on front wheel
support (duplex rear unit) .
A CAUTION
FIELD
TRANSPORT
located on back tube rear R/H
wheel (duplex front unit) .
located on back tube near L/H
end (single and duplex front
unit), back tube near R/H
wheel (single and both duplex
units) and on front wheel
support upper link (duplex
rear unit.

SPECI FICATIONS
DIMENSIONS:
Overall Width
Cutting Position
Transport Position
Overall Length
Cutting Position
Transport Position
SINGLE UNIT
30'
34'4" (10450mm)
11'2"
(3400mm)
13'4"
(4070mm)
41'
(12500mm)
Overall Height - header
and reel down
Main Frame to Ground
Clearance
45'
12'
37'
61'
DUPLEX
UNIT
42' 50'
4"
(13818 mm) 53'4" (16550mm)
4"
(
3760
mm)
13'2"
(4000mm)
4"
(11370
rom)
37'4"
(11370mm)
8"
(18796 rom)
69'5"
(21170mm)
Mass 3200 lbs.
(1450 kg )
57" (1450mm)
34" (87 Omm )
6690 lbs.
(3035 kg)
7210 lbs ..
(3270 kg )
KNIFE
Drive
Cutting Height Range
Stroke Length
Speed
Crank Wheel - Pitman System
o - 45" (0 -1150mm)
3" (76mm)
1250 strokes/minute
Width of Cut (nominal) 30'
Header Lift
(9150mm) 42' (12800 mm) 50' (l5240mm)
REEL:
Diameter
Lift Range - above cutter bar
Speed
Lift
DRAPERS:
Width
Speed
Angle - at 6" (150mm)
cutting height
Delivery Opening
Adjustable to
TIRES:
44.1"
51.6"
59.1"
Hydraulic (from tractor)
54 1/2" (1384mm)
1" to 28 1/ 2" (25 - 72 5mm)
26.8 RPM to 50 RPM
Hydraulic (from tractor)
41 1/2" (1054mm)
I .
275 to 479 ft/min. (84 to 275m/min.)
(1120mm)
(1310mm)
(1500mm)
Front Unit Rear Unit
44.1" (1120mm)
51. 6" (l310mm)
59.1" (1500mm) 59.1"(1500mm)
Size
8.5L x 14 (2 tires) 8.5L x 14 (5 tires)
Pressure 24 to 28 psi (165 to 190 kPa)
6

DRIVES:
Knife
Reel
Drapers
HYDRAULICS:
System Capacity - lines
full
Pump Pressure
DELIVERY MODES:
TRACTOR REQUIREMENTS:
Minimum
Weight
Minimum Power
PTO Speed
Hydraulics: Type
Minimum
SPECIFICATIONS
SINGLE UNIT
Mechanical
Mechanical
Mechanical
Center Delivery
5000 lbs. (2250 kg )
40 hp. (30 kw)
540 or 1000 RPM
Dual
Pressure 1800 psi (12400 kPa)
7
DUPLEX UNIT
Front Unit
Mechanical
Mechanical
Mechanical
Rear Unit
Hydraulic to
Mechanical
Hydraulic to
Mechanical
Hydraulic to
Mechanical
10 Imp.gal, (45 L) ,12 US gal.
2800 psi (19300 kPa)
Two Center Delivery
Swaths or
Two Side by Side Swaths
with 41" (1040rnrn) center
to centre of swath (with
standard conveyor) .
or
Two Side by Side Swaths
with 58" (1470rnrn) center
to center of swath (with
optional short conveyor) .
or
Two Swaths Stacked with
rear directly on top of
front (with standard conveyor
plus optional short conveyor)
10,000 lbs. (4500 kg )
80 hp. (60 kw)
1000 RPM
Dual
1800 psi (12400 kPa)

OPERATION
AT FIRST USE: ELECTRICAL
FOR TRACTORS WITHOUT SEVEN POLE
RECEPTACLE, Figure 50
1. Mount a seven pole receptacle
(available from your dealer) on
the tractor cab rear wall as
close as possible to the
hydraulic couplings.
2. Connect the tractor wiring
harness to the receptacle as
shown.
NOTE: ! The tractor must have
a 20 amp supply connected to
receptacle terminal 7. The
circuit should de-energize when
the key is turned off to prevent
the windrower's electric clutch
from draining the battery.
GREEN-R/H TURN SIGNAL ~ _
YELLOW-L/H TURN SIGNAL 3-
BLACK-WORK LAMPS 2 _
BROWN-TAIL LAMPS
4
__ ~B~LU~E~~U~X~. ________ 7-
WHITE-GROUND·
8
50

OPERATION
ELECTRICAL CONNECTIONS
When attaching windrower to tractor:
1. Connect seven pole plug on the
windrower wiring harness to the
seven pole receptacle on the
tractor.
2. Place switch box in tractor cab
and connect switch box wiring
harness to windrower wiring
harness at four-way connector.
9

OPERATION
AT FIRST USE (continued)
TRACTOR PTO (SINGLE UNIT)
The single unit can be operated
with 540 or 1000 RPM PTO.
If the machine is not equipped
to match the tractor to be used,
an adapter kit must first be
installed. (Installation
instructions included wi th kit) .
If tractor PTO RPM is 1000,
set tractor drawbar to 16 inches
(406 rom) as shown in Figure 56.
If tractor PTO RPM is 540,
set tractor drawbar to 14 inches
(356 rom) as shown in Figure 58.
TRACTOR PTO (DUPLEX)
The duplex unit must be
operated with a 1000 RPM PTO.
Set tractor drawbar as shown
in Figure 56.
IMPORTANT: The telescoping
PTO shaft should slide under
hand pressure. DO NOT let
shaft pull loose from tractor
or the swather. The p'ro
shaft must always be operated in
as straight a line as possible
and may be adjusted vertically
as shown in Figure 60.
When the tractor is equipped
with a swinging drawbar, be
sure to lock it directly
beneath the PTO shaft.
CAUTION: When attaching the
yoke of the universal to the
tractor PTO, it is important
that the yoke is secured to
the PTO shaft with the spring
loaded collar. Be sure the
collar slides fully forward to
lock the P.T.O. shaft to the
tractor.
FOR 1000 RPM PTO
tractor
PTO~
~16"~
(406 mm) I
I
c:::=:=::::::' ~Z =====r==~,b
I J ~ hitch
tractor point
drawbar
FOR 540 RPM PTO
tractor
PTO~
k14"~
(356 mm) I
':
tr~ctorJ
drawbar
10
hitch
point
60
56
58

OPERATION
AT FIRST USE (continued)
OPTIONAL HITCH PLATE, Figure 61
An optional hitch plate is
available to provide a clevis-
type hitch.
To install:
a) Remove pin securing
telescoping hitch member.
b) Replace pin with 3/4 x 6~"
bolt through hitch and
additional plate.
Secure with locknut.
c) Remove nut on bolt securing
safety chain and re-install
through additional plate.
DUPLEX ONLY: DUPLEX INITIAL
FIELD ADJUSTMENT
At first use the operator
should perform the following
initial field checks and
adjustments:
1. Align front wheel- rear machine.
The front wheel should lead to
the right (3° to 5° off
parallel with the other wheels)
when the roller is positioned
in the bend of the cam as shown
in Figure 62.
To Adjust Wheel Alignment:
1. Raise rear header fully
up and install header lock.
2. Loose nut "A", Figure 62.
3. Position roller with nuts
Band C.
4. Tighten nut A.
11
~ .
roller
centered in
bend
61
62

OPERATION
AT FIRST USE (continued)
DUPLEX INITIAL FIELD
ADJUSTMENT (continued)
2. Adjust rear machine overlap
to reduce material missed
on corners and hills. See
Adjustments Section: Duplex
Hitch for details.
3. Adjust front wheel spring
pressure - rear machine.
Spring pressure should be
such that wheel is steered
by cam, but does not skid
excessively in corners.
See Adjustments Section:
Front Wheel Spring Pressure
for adjustment detail.
4. Adjust hitch spring force.
See Adjustments Section:
Duplex Hitch for details.
NOTE: Adjustments 3 and 4 work
together to prevent the
rear machine from rolling
forward when going down
hills. The springs
should be operated with
the minimum pressure
required to give satis-
factory operation to
minimize wear on pins
and other parts.
HYDRAULIC OIL FILTER
Change oil filter after the
first 5 hours' of operation with
the spare filter provided.
WHEEL BOLTS
Check wheel bolt torque after
first 5 hours operation. Re-
torque to 80-90 ft.lbs. (110-
120 N.m).
12

OPERATION
SWITCH BOX, FIGURE 64 - DUPLEX
ONLY.
The switch box, positioned at
the operator's feet provides
the following:
1. Draper Clutch Control Switch -
Pressed once, this switch
will stop the drapers on the
rear machine only. Pressed
again drapers will resume
motion.
Stopping the rear drapers in
corners prevents accumulation
of large piles of crop. The
operator has the option of
having the rear reel stop
with the drapers, or having
the reel turn continuously.
See Figure 66 for details on
controlling rear reel operation.
2. Hydraulic Valve Switch -
Solenoid valves are set so
that hydraulic lift controls
will normally lift the reels
for front and rear machines.
Pressing and holding this
switch will divert hydraulic
flow to the header lift
cylinders, allowing raising
and lowering of both headers.
Releasing the switch reverts
flow back to the reel lift
cylinders.
3. Rear Machine Function Light -
Light will be on when rear
draper clutch is engaged,
and off when clutch is
disengaged.
4. Circuit Breaker:Manual
Re-Set - Electrical system
is protected by a 20 amp
circuit breaker. Should
this breaker be tripped, it
must be manually re-set by
pushing the button shown.
13
rear machine
function light
hydraulic
valve switch
ci rcuit breaker
re-set button
tighten bolts
to 20-25 ft. Ibs.
(27-34 N-m)
draper clutch
control switch
(rear unit)
64
66

OPERATION
PRE-SEASON CHECK
1. Install drapers. See Assembly
Section - Drapers.
2. Adjust tension on drapers and
belts. See Adjustments Section
for details.
3. Inflate tires to 24 to 28 psi
( 16 5 - 190 kP a) .
4. Lubricate machine. See
Lubrication Section for details.
5. Ensure all shields are in place.
6. Run machine, check for belt
interference. Stop machine,
check for heated bearings.
END OF SEASON CHECK
1. Remove drapers and store in a
dark, dry place.
NOTE: If the drapers are not
removed, release tension and
position header so water/snow will
not accumulate on the drapers.
This accumulation of weight can
stretch draper material and put
excessive stress on draper slats
and draper tracks.
2. Clean the machine thoroughly and
store in a dry place if possible.
3. Grease all fittings, leaving
excess grease to keep moisture
away from bearings.
4. Oil knife and guards and cover
to prevent accidents while unit
is stored.
14
5. Connect plugs in wiring
harness to ensure auxilIary
circuits are live and to
prevent plugs from corrosion.
Store switch box inside.
(DUPLEX ONLY) .

OPERATION
TRANSPORTING THE WINDROWER
Instructions follow for
converting to transport from
field position and vice-versa
for both the single and
duplex units.
CAUTION: Lights have been
installed to make transportation
on public roadways safer. Check
local laws regarding the lighting
and marking of vehicles before
travelling on public roadways.
CAUTION:: Maximum transport
speed is 15 MPH (25 km/h) for
the duplex unit and 20 MPH (30
km/h) for the single unit.
Reduce speed before corners and
in slippery conditions. Ensure
all safety pins and chains are
in transport position and
safety chain is properly
attached to tractor.
See Figure 98.
Ensure R/H wheel (both units if
duplex) is adjusted to provide
minimum transport width. See
Adjustments Section: Trail
width.
DUPLEX ONLY -Be especially
careful when transporting the
duplex machines. In transport
the rear machine is steered by
the rear wheel of the front
machine. Excessive speed may
cause this wheel to skid on
loose gravel or slippery roads.
Applying tractor brakes during
a corner at excessive speed may
result in a loss of control,
machine damage and personal
injury. See Figure 99.
To reduce tendancy to skid,
ensure both headers are fully
raised and wheel casters are
well lubricated.
The gross weight of the trailed
equipment (without brakes)
should not exceed the weight of
the towing vehicle.
15
Allow no riders.
Chain should be as
tight as possible
without affecting
maneuverability.
Rear wheel of front
machine may skid.
Front wheels of rear
machine will roll in
direction of skid.
----
98
99

OPERATION
TO CONVERT SINGLE UNIT FROM
FIELD POSITION TO TRANSPORT
1. RAISE HEADER to full up
position.
2. MOVE LEVERS FROM FIELD TO
TRANSPORT POSITIONS:
a) Move lever on hitch to
transport position. See
Figure 100 ..
b) Move lever on L/H wheel
lock to transport position.
See Figure 102.
3. DRIVE FORWARD, holding
header lift valve in UP
position, until telescoping
hitch locks and R/H wheel
moves into transport
position.
4. INSTALL LOCK PINS:
a) Install lock pin in
transport safety position
on hitch. See Figure 104.
b) Install pin to secure
header lock to lug on main
hitch.
See Figure 106. The
header lock should be
adjusted to the minimum
length required to
permit installation.
c) Install lock pin in
transport safety position
at R/H wheel. See Figure
108 .
16
wheel lock
transport position
100
102
104
106

OPERATION
TO CONVERT SINGLE UNIT FROM
TRANSPORT TO FIELD POSITION
1. RAISE HEADER to full up
position.
2. PLACE LEVERS AND PINS IN
FIELD
POSITION:
a) Remove lock pin at
telescoping hitch and
place in storage position.
Move hitch lever to field
position. See Figure 110.
b) Remove pin securing header
lock to main hitch. Place
pin in storage position
shown. See Figure 112.
c) Move lever on LIH wheel
lock to field position.
See Figure 114.
d) Remove lock pin from R/H
wheel assembly and place
in storage position. See
Figure 116.
116
17
header lock pin
storage position
110
112
114

TO CONVERT SINGLE UNIT FROM
TRANSPORT TO FIELD POSITION
(continued)
3. Back tractor up so that
L/H wheel casters to field
position and locks, and
front hitch pivots to field
position and locks.
OPERATION
4. Lower header about 12 inches
(300 rom) and drive forward
until R/H wheel casters into
field position.
5. P.T.O. may be engaged when
angle "A" is 45° or less. See
Figure 120.
hitch lock
lever &
pin
-n- ---
II
I
header
lock LlH wheel lock
18
120