Case IH DC92 Disc Mower Conditioner Service Manual

Remove the damaged disc and inspect the drive hub for cracked or sheared splines. Check axial movement on each hub: normal clearance is 1.5 mm (0.060 in) per page 147. If movement exceeds this or you find spline damage, replace the hub. When reinstalling, torque the retaining bolt to 183 N·m (135 lb ft). Inspect the shock hub bolts at the same time and torque those to 183 N·m (135 lb ft) as well, per page 175.

Check the conditioner gearbox oil level first: capacity is 200 mL (7 US fl oz) per page 25. Then verify roll gap is set between 0.4 and 3 mm (1/64 to 1/8 in); each full turn of the adjustment bolt changes the gap by 2 mm (0.060 in), per page 243. If the rolls still slip after adjusting, measure gearbox rolling torque: first shaft must fall between 0.45 and 1.13 N·m (4 to 10 lb in), second shaft adds that value on top, per page 256. Worn bearings outside this range need replacement.

Start with the troubleshooting chart to rule out PTO speed and windrow issues. Then inspect all 7 discs per for bending or cracking. Pull the knife hardware on each of the 14 knives and check for elongated bolt holes and worn threads per . Verify disc alignment and check for gaps between modules; spline wear and dowel pin failure show up here. Replace any bent disc or damaged knife set before returning the machine to field speed at 540 RPM PTO.

With PTO disengaged and machine stopped, remove the clutch cover and inspect separator plates and ribbed pressure plates per page 62. Discoloration or blue heat marks mean the clutch overheated and warped. Replace any disc spring showing cracking or permanent set. The breakaway torque specification is 1450 N·m (1069 lb ft) per page 58. A clutch that trips below that value under normal draft needs new friction plates, not just reassembly.

Shut down and check the tongue jackshaft for wear per page 39. Then inspect both universal joint yoke ears and conical bushings for play and pitting per page 43. A worn U-joint will amplify vibration at 540 RPM and accelerate gearbox damage fast. When reinstalling, torque the clamp bolt locknut on the rear half shaft to 87 N·m (64 lb ft) per page 41, and the front half to the same spec per page 52. Replace the full shaft assembly if bearing journals are pitted or the cross shows any galling.

Drain and measure oil volume against the 1000 mL (34 US fl oz) capacity on page 25. Inspect the input shaft bearings and cones per ; scoring on the shaft journal means the bearing spun in the housing. Check input crown wheel to cross shaft pinion gear backlash: acceptable range is 0.160 to 0.430 mm (0.006 to 0.017 in) per page 200. After reassembly, verify input shaft bearing preload with a torque wrench: specification is 0 to 1 kg/cm (0 to 1.87 lb/in) per page 224. Fill with fresh oil before testing.