Page 1 Rotary Disc 4.9-Meter (16-Foot) Self-Propelled Windrower Header Unload and Assembly Instructions 214367 Revision A 2018 Model Year Original Instruction The harvesting specialists.
Page 2 R85 Rotary Disc 4.9-Meter (16-Foot) Self-Propelled Windrower Header Published: August 2017...
Page 3 Carefully read all the material provided before attempting to use or service the machine. When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous situation.
Page 4 List of Revisions The following list provides an account of major changes from the previous version of this document. Location Summary of Changes Changed measurement format so that metric values Throughout the book appear first followed by imperial in parentheses. Added conventions to Introduction.
Page 5 Location Summary of Changes Updated figure title/description. 3.14.5 Installing Tall Crop Feed Plates, page 74 4.2 Checking Header Float: M200 and M205 Updated topic title. Windrowers, page 83 4.3 Checking Header Float: M1240 Windrowers, page Added topic to manual. Added topic to manual. 4.3.1 Setting the Float: M1240 Windrower, page 84 Updated procedure illustrations.
Page 7: Table Of Contents
TABLE OF CONTENTS Introduction..............................i List of Revisions ............................ii Chapter 1: Safety ............................ 1 1.1 Signal Words ............................1 1.2 General Safety.............................2 1.3 Safety Signs ............................4 Chapter 2: Unloading the Header ....................... 5 Chapter 3: Assembling the Header ....................7 3.1 Removing Underside Shipping Support and Installing Auger Pan ............7 3.2 Installing Skid Shoes (Optional) ......................9 3.3 Installing Gauge Rollers (Optional) ......................10 3.4 Lowering Header ..........................
Page 8 TABLE OF CONTENTS 3.14.6 Installing Nut Protectors (for Blade Hardware on Discs)..............74 3.15 Lubricating the Header ........................75 3.15.1 Driveshields ..........................75 Opening the Driveshield: North American Headers..............75 Closing the Driveshield: North American Headers ...............75 Opening the Driveshield: Export Headers ...................76 Closing the Driveshield: Export Headers..................76 3.15.2 Greasing Procedure ........................77 3.15.3 Lubrication Points........................77 Chapter 4: Performing Predelivery Checks ...................
Page 9: Chapter 1: Safety
1 Safety 1.1 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.
Page 10: General Safety
SAFETY 1.2 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 protective clothing and personal safety devices that could be necessary for job at hand.
Page 11 SAFETY • Wear close-fitting 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 shaft and can telescope freely. •...
Page 12: Safety Signs
Replace safety signs that are missing or become illegible. • If original parts on which a safety sign was installed are replaced, be sure repair part also bears current safety sign. • Safety signs are available from your MacDon Dealer. Figure 1.7: Operator’s Manual Decal 214367 Revision A...
Page 13: Chapter 2: Unloading The Header
2 Unloading the Header CAUTION To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area. CAUTION Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping, or machine damage. IMPORTANT: Forklifts are normally rated for a load located 610 mm (24 in.) ahead of the back end of the forks.
Page 14 UNLOADING THE HEADER 4. Back up until the unit clears trailer, and slowly lower to 150 mm (6 in.) from the ground. 5. Take to storage or setup area. 6. Set machine down on secure, level ground. 7. If hydraulic motor and hoses are shipped separately on pallet, unload pallet.
Page 15: Chapter 3: Assembling The Header
3 Assembling the Header 3.1 Removing Underside Shipping Support and Installing Auger Pan CAUTION Keep feet clear when removing final bolts. 1. Use a forklift to support stand. 2. Remove two bolts (A) on each end of support and remove shipping support (B). Lay support on ground. Figure 3.1: Shipping Support 3.
Page 16 ASSEMBLING THE HEADER 5. Position auger pan (A) against cutterbar lugs and install four 1/2 x 3.5 in. long bolts (B) and lock nuts. Do NOT fully tighten. 6. Check and make sure that auger pan is oriented as shown. 7.
Page 17: Installing Skid Shoes (Optional)
ASSEMBLING THE HEADER 3.2 Installing Skid Shoes (Optional) NOTE: This kit may be installed later in the assembly sequence, but installation may be easier prior to laying the header down. DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 18: Installing Gauge Rollers (Optional)
ASSEMBLING THE HEADER 3.3 Installing Gauge Rollers (Optional) NOTE: This kit may be installed later in the assembly sequence, but installation may be easier prior to laying the header down. 1. Unpack gauge roller bundle and install gauge rollers. Refer to instruction supplied with kit. Figure 3.5: Gauge Roller (Right Side Shown –...
Page 19: Lowering Header
ASSEMBLING THE HEADER 3.4 Lowering Header CAUTION Equipment used for lowering the header must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping, or machine damage. Table 3.1 Lifting Vehicle Chain Type Overhead lifting quality 12.7 mm (1/2 in.) Minimum Working Load 2270 kg (5000 lb.)
Page 20 ASSEMBLING THE HEADER CAUTION Stand clear when lowering the header. 5. Back up SLOWLY, while simultaneously lowering header until cutterbar rests on ground. 6. Remove chains from header. Figure 3.7: Lowering Header to the Ground 214367 Revision A...
Page 21: Removing Shipping Stands
ASSEMBLING THE HEADER 3.5 Removing Shipping Stands 1. Cut and remove banding (A) from baffle. Figure 3.8: Banding on Baffle 2. Remove plate (A) from left shipping stand (B) and set aside with hardware for reinstallation. Figure 3.9: Shipping Stand (Left Side Shown – Right Side Opposite) 214367 Revision A...
Page 22 ASSEMBLING THE HEADER 3. Remove the three bolts (A) securing left stand (B) to shipping channel plate and shield. Figure 3.10: Shipping Stand (Left Side Shown – Right Side Opposite) 4. Remove bolt (A) securing shipping stand to header lifting arm. 5.
Page 23 ASSEMBLING THE HEADER 10. Remove two bolts (A) attaching shipping channel (B) to frame. Retain hardware. Figure 3.13: Shipping Stand (Left Side Shown – Right Side Opposite), Baffle Not Shown for Clarity 11. Remove the two bolts (A) attaching shipping channel (B) to frame.
Page 24 ASSEMBLING THE HEADER 15. Reinstall two bolts (A) and lock nuts into cover support and tighten. 1009213 Figure 3.16: Frame with Shipping Stand Removed 16. Remove hooks (A) at front corners. Reinstall hardware. NOTE: If tall crop divider option will be installed, do not reinstall hardware.
Page 25: Installing Swath Baffle Lever
ASSEMBLING THE HEADER 3.6 Installing Swath Baffle Lever 1. Retrieve adjuster plate and hardware previously removed from shipping stand (in 3.5 Removing Shipping Stands, page 13). 2. Position adjuster plate (A) over holes on side deflector, and install bolts (E) and nuts. Do NOT tighten. 3.
Page 26: Unpacking Curtains
ASSEMBLING THE HEADER 3.7 Unpacking Curtains 1. Remove two bolts (A) securing cutterbar doors to frame. 2. Remove shipping wire (B) from around curtains. WARNING Ensure cutterbar is completely clear of foreign objects. These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage.
Page 27 ASSEMBLING THE HEADER 4. Lift at front of door to open position. 5. Check cutterbar area for debris and foreign objects. Ensure all material is removed. Figure 3.23: Cutterbar Doors Open 6. Close cutterbar doors. Ensure that curtains hang properly and completely enclose cutterbar area. Minor creases in curtains will eventually straighten out.
Page 28 ASSEMBLING THE HEADER 7. For export headers, ensure latches (A) engage cutterbar doors. Figure 3.26: Cutterbar Door Latch 8. Fasten latches (A) at corners of curtains. Figure 3.27: Curtain Latches 214367 Revision A...
Page 29 ASSEMBLING THE HEADER 9. Remove shipping edge trim (A). 10. Close the shields (B) over the two shipping tie-down holes and tighten nuts (C). Figure 3.28: Top Shield Cover 11. Remove shipping wire banding and protective packing (A) from hydraulic hoses. Figure 3.29: Shipping Material around Hoses 214367 Revision A...
Page 30: Attaching Conditioner Cover
ASSEMBLING THE HEADER 3.8 Attaching Conditioner Cover 1. Remove bolts (A) and remove cover (B) from shipping position. 2. Replace bolts (A) into existing holes. Figure 3.30: Cover in Shipping Configuration 3. Remove six carriage bolts (A) along aft edge. 1009255 Figure 3.31: Hardware on Edge of Hood 214367...
Page 31 ASSEMBLING THE HEADER 4. Position cover (A) on hood as shown and secure with six carriage bolts (B) and lock nuts. Figure 3.32: Cover Installed 214367 Revision A...
Page 32: Assembling Forming Shield
ASSEMBLING THE HEADER 3.9 Assembling Forming Shield 1. Unpack and remove shipping material from side deflectors (A). 2. Remove hardware bag (B). 3. Open the hardware bag. Figure 3.33: Forming Shield in Shipping Configuration 4. Install rubber strap (A) to the side bracket (B) using bolt (C), washer (D), and nut (E).
Page 33 ASSEMBLING THE HEADER 8. Assemble side deflectors (C) to cover with 5/8 x 10 in. bolt (B), jam nut (E), washer (D), and nut (A). 9. Tighten flange nut (A) enough to hold deflectors (C) in position, but still allow deflectors to move. 10.
Page 34 ASSEMBLING THE HEADER 13. Invert forming shield to installation position as shown. Figure 3.38: Forming Shield Right Side Up 14. For M205 and M1240 Self-Propelled Windrowers: Install hose support (A) to the left side of the top shield (B) and channel (C) using two bolts and nuts (D). Figure 3.39: Hose Support 15.
Page 35 ASSEMBLING THE HEADER NOTE: If there are no mounting slots for the hose support, drill two 11 mm (7/16 in.) holes (A) through top shield (B) and channel (C). Figure 3.41: Forming Shield Top View A - Two 11 mm (7/16 in.) Holes B - Top Shield C - Channel D - Header Forward...
Page 36: Installing Forming Shield
ASSEMBLING THE HEADER 3.10 Installing Forming Shield To install the forming shield, follow these steps: 1. To ease forming shield installation, remove header from windrower (if attached). Refer to your windrower operator’s manual for instructions. 2. Retrieve plate (A) and attachment hardware from forming shield bundle.
Page 37 ASSEMBLING THE HEADER 6. Position the forming shield (A) under the windrower frame. Figure 3.44: Forming Shield under Windrower Frame 7. Position the forming shield onto spacers (B) on windrower legs. Secure with clevis pins (A) and lynch pin. Figure 3.45: Attaching Forming Shield to Windrower Legs 214367 Revision A...
Page 38 ASSEMBLING THE HEADER 8. Lift the aft end of the forming shield and attach straps (B) to pins (A) on windrower frame. Install washer and hairpin to secure strap. Use the middle hole and adjust height to suit the crop. Figure 3.46: Attaching Forming Shield to Windrower Frame 9.
Page 39: Attaching Header To An M Series Windrower
ASSEMBLING THE HEADER 3.11 Attaching Header to an M Series Windrower The procedure for attaching the header to an M Series windrower varies depending on the type of center-link installed. The center-link consists of either a hydraulic cylinder that adjusts the header tilt or angle and is controlled with switches in the windrower cab, or a manually adjusted mechanical link.
Page 40 ASSEMBLING THE HEADER CAUTION Check to be sure all bystanders have cleared the area. 2. Start the engine and activate the HEADER DOWN button (A) on the ground speed lever (GSL) to fully retract header lift cylinders. IMPORTANT: If the center-link is too low, it may contact the header as the windrower approaches the header for hookup.
Page 41 ASSEMBLING THE HEADER 5. Use the following GSL functions to position the center-link hook above the header attachment pin: • REEL UP (A) to raise the center-link • REEL DOWN (B) to lower the center-link • HEADER TILT UP (C) to retract the center-link •...
Page 42 ASSEMBLING THE HEADER 11. Engage safety props on both lift cylinders as follows: a. Stop engine and remove key from ignition. b. Pull lever (A) and rotate towards the header to release and lower safety prop (B) onto the lift cylinder.
Page 43 ASSEMBLING THE HEADER 13. Remove clevis pin from storage position (B) in linkage and insert into hole (A) to engage float springs. Secure with hairpin. Figure 3.58: Header Float Linkage 14. Disengage safety prop by turning lever (A) downwards to release and lower stop until lever locks into vertical position.
Page 44: Attaching Header To An M200 Or M205 Windrower: Hydraulic Center-Link Without Optional Self-Alignment
ASSEMBLING THE HEADER 3.11.2 Attaching Header to an M200 or M205 Windrower: Hydraulic Center-Link without Optional Self-Alignment DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 45 ASSEMBLING THE HEADER CAUTION Check to be sure all bystanders have cleared the area. 2. Start the engine and activate HEADER DOWN button (A) on the ground speed lever (GSL) to fully retract header lift cylinders. Figure 3.63: Ground Speed Lever 3.
Page 46 ASSEMBLING THE HEADER 5. Use the following GSL functions to position the center-link hook above the header attachment pin: • HEADER TILT UP (A) to retract the center-link • HEADER TILT DOWN (B) to extend the center-link 6. Stop engine and remove key from ignition. Figure 3.66: Ground Speed Lever 7.
Page 47 ASSEMBLING THE HEADER 12. Engage safety props on both lift cylinders as follows: a. Stop engine and remove key from ignition. b. Pull lever (A) and rotate towards the header to release and lower safety prop (B) onto the lift cylinder.
Page 48 ASSEMBLING THE HEADER 14. Remove clevis pin from storage position (B) in linkage and insert into hole (A) to engage float springs. Secure with hairpin. Figure 3.71: Header Float Linkage 15. Disengage safety prop by turning lever (A) downwards to release and lower stop until lever locks into vertical position.
Page 49: Attaching Header To An M200 Windrower: Mechanical Center-Link
ASSEMBLING THE HEADER 3.11.3 Attaching Header to an M200 Windrower: Mechanical Center-Link DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 50 ASSEMBLING THE HEADER 3. Drive the windrower slowly forward until the windrower feet (A) enter the header supports (B). Continue driving slowly forward until the feet engage the supports and the header nudges forward. Figure 3.77: Header Support 4. Stop engine and remove key from ignition. 5.
Page 51 ASSEMBLING THE HEADER 11. Engage safety props on both lift cylinders as follows: a. Stop engine and remove key from ignition. b. Pull lever (A) and rotate towards the header to release and lower safety prop (B) onto the lift cylinder.
Page 52 ASSEMBLING THE HEADER 13. Remove clevis pin from storage position (B) in linkage and insert into hole (A) to engage float springs. Secure with hairpin. Figure 3.82: Header Float Linkage 14. Disengage safety prop by turning lever (A) downwards to release and lower stop until lever locks into vertical position.
Page 53: Attaching Header To An M1 Series Windrower
ASSEMBLING THE HEADER 3.12 Attaching Header to an M1 Series Windrower The procedure for attaching the header to an M1 Series windrower varies depending on the type of center-link installed. Follow the appropriate procedure: • 3.12.1 Attaching Header to an M1240 Windrower: Hydraulic Center-Link with Optional Self-Alignment, page 45 •...
Page 54 ASSEMBLING THE HEADER NOTE: If not prompted by the HPT display to remove header float, remove header float manually by doing the following: 3. Press rotary scroll knob (A) on Harvest Performance Tracker (HPT) to highlight QuickMenu options. 4. Rotate scroll knob (A) to highlight HEADER FLOAT symbol (B), and press scroll knob to select.
Page 55 ASSEMBLING THE HEADER 8. Drive the windrower slowly forward until the windrower feet (A) enter the header supports (B). Continue to drive slowly forward until feet engage the supports and header nudges forward. 9. Ensure that lift linkages are properly engaged in header legs.
Page 56 ASSEMBLING THE HEADER 17. Engage safety prop on lift cylinder as follows: a. Pull lever (A) and rotate toward header to release, and lower safety prop onto cylinder. b. Repeat for opposite lift cylinder. IMPORTANT: Ensure the safety props engage over the cylinder piston rods.
Page 57 ASSEMBLING THE HEADER 21. Start engine and press HEADER DOWN switch (A) on GSL to fully lower header. Figure 3.96: GSL 22. Press rotary scroll knob (A) on Harvest Performance Tracker (HPT) to highlight QuickMenu options. 23. Rotate scroll knob (A) to highlight HEADER FLOAT symbol (B), and press scroll knob to select.
Page 58: Attaching Header To An M1240 Windrower: Hydraulic Center-Link Without Optional Self-Alignment
ASSEMBLING THE HEADER 3.12.2 Attaching Header to an M1240 Windrower: Hydraulic Center-Link without Optional Self-Alignment DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 59 ASSEMBLING THE HEADER CAUTION To prevent damage to the header lift linkages when lowering header lift legs without a header or weight box attached to the windrower, ensure the float springs tension is fully released. Figure 3.101: Header Float Spring NOTE: If not prompted by the HPT display to remove header float, remove header float manually by doing the...
Page 60 ASSEMBLING THE HEADER 7. Press HEADER DOWN button (A) on the ground speed lever (GSL) to fully retract header lift cylinders. Figure 3.104: Ground Speed Lever 8. Drive the windrower slowly forward until the windrower feet (A) enter the header supports (B). Continue driving slowly forward until the feet engage the supports and the header nudges forward.
Page 61 ASSEMBLING THE HEADER 12. Push down on rod end of link cylinder (B) until hook engages and locks onto header pin. IMPORTANT: Hook release must be down to enable self-locking mechanism. If the release is open (up), manually push it down after hook engages header pin.
Page 62 ASSEMBLING THE HEADER 17. Install clevis pin (A) through support and windrower lift member, and secure with hairpin (B). Repeat for opposite side. IMPORTANT: Ensure clevis pin (A) is fully inserted and hairpin is installed behind bracket. Figure 3.110: Header Support 18.
Page 63 ASSEMBLING THE HEADER NOTE: If not prompted by the HPT display to restore float, restore float manually by doing the following: 21. Press rotary scroll knob (A) on Harvest Performance Tracker (HPT) to highlight QUICK MENU options. 22. Rotate scroll knob (A) to highlight the HEADER FLOAT symbol (B) and press to select.
Page 64: Attaching Hydraulics And Electrical Connections
NOTE: Factory-installed hard plumb connections are ideal for attaching an R85 disc header’s hydraulics on an M205 windrower. If an auger header or draper header will also be used on a disc header-ready M205 windrower, quick...
Page 65 3. Place hoses on support (C) and on the hose support on the forming shield (not shown). Figure 3.116: Hydraulic Hoses 4. Remove protective plugs (A) from ends of hydraulic hoses. Figure 3.117: Protective Shipping Plugs on R85 Hydraulic Hoses 214367 Revision A...
Page 66 ASSEMBLING THE HEADER Attaching hydraulics using quick coupler connections: 1. Remove coupler lock as follows: a. Remove lynch pin (A) and open up coupler lock (B). b. Remove lock from coupler. Figure 3.118: Hydraulic Couplers with Coupler Lock 2. Connect rear pump hose (A) to outboard line (D) on windrower using coupler (C).
Page 67 ASSEMBLING THE HEADER 4. Position the lock onto the couplers so that retainer (A) rests under the fitting next to the sleeve on each coupler. NOTE: The retainer can be adjusted by loosening bolts (B). Tighten bolts after adjusting. Figure 3.120: Hydraulic Couplers with Coupler Lock 5.
Page 68 5. Connect the electrical harness to connector HC-2A (A) (located beside the forward valve block on the windrower). NOTE: The R85 disc header ships with a factory-installed electrical harness extension for compatibility with M1240 windrowers. Remove the extension from the electrical harness before connecting to the M205 windrower.
Page 69: Attaching Hydraulic And Electrical Components: M200 Windrowers
ASSEMBLING THE HEADER 6. Move windrower platform (A) to the CLOSED position. For instructions, refer to the windrower operator’s manual. Figure 3.125: Windrower with Left Platform in Closed Position 3.13.2 Attaching Hydraulic and Electrical Components: M200 Windrowers DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 70 ASSEMBLING THE HEADER 1. Disengage and rotate lever (A) counterclockwise to the UP position. 2. Remove cap (B) securing the electrical connector to the frame. Figure 3.127: Hose Bundle 3. Move hose bundle (A) from the windrower, and rest the bundle on the header.
Page 71 ASSEMBLING THE HEADER 4. Position the hose support with lower bolt (A) in the forward hole, as shown. Loosen both bolts and adjust as required. Figure 3.129: Hose Support 5. Route hose bundle (A) from the windrower through support (B) on header. 6.
Page 72 ASSEMBLING THE HEADER 9. Move the windrower’s left side (cab-forward) platform (A) to the OPEN position to access the valve blocks. Figure 3.132: Windrower with Left Platform in Open Position 10. Remove caps from pressure (M2) and return (R2) ports on the header drive manifold (A) and discard.
Page 73 ASSEMBLING THE HEADER 12. Disconnect fittings at end of hose bundle (A). Discard caps. Figure 3.134: Hose Bundle 13. Remove O-ring from cap (A) and install over JIC threads on fitting at return port (R2) on header drive manifold. 14. Install female coupler (B) from hose in return port (R2) on header drive manifold.
Page 74 ASSEMBLING THE HEADER 16. Connect pressure hose (A) to male coupler in port (M2) on header drive manifold. 17. Connect return hose (B) to female coupler in port (R2) on header drive manifold. NOTE: If the windrower is equipped with a reverser valve for an auger header, replace the 90°...
Page 75: Attaching Hydraulics And Electrical: M1240 Windrowers
3.13.3 Attaching Hydraulics and Electrical: M1240 Windrowers NOTE: Factory-installed hard plumb connections are ideal for attaching an R85 disc header’s hydraulics on an M1240 windrower. If an auger header or draper header will also be used on a disc header-ready M1240 windrower, quick couplers can be ordered and installed to make switching between these headers easier 1.
Page 76 (C) on multicoupler. Figure 3.142: Knife Drive Hose NOTE: R85 hoses can be connected with either quick-disconnect or hard plumbed fittings. Refer to Step 8, page 69 quick-disconnect hydraulic connections, and to Step 9, page 69 for hard plumbed hydraulic connections.
Page 77 ASSEMBLING THE HEADER 8. Refer to the following to connect hydraulic hoses with quick-disconnect fittings to the windrower: NOTE: If hoses are not equipped with quick-disconnect fittings, they can be attached directly to the windrower fittings as described in Step 9, page a.
Page 78 ASSEMBLING THE HEADER 10. Push latch (B) to unlock the platform (A). 11. Pull platform (A) towards the cab until it stops and latch (B) engages. 1015479 Figure 3.145: Left Cab-Forward Platform 214367 Revision A...
Page 79: Installing Other Options
ASSEMBLING THE HEADER 3.14 Installing Other Options Install options (if supplied with shipment) in accordance with the instructions supplied with each kit. 3.14.1 Installing Tall Crop Divider To install the tall crop divider kit (MD #B5509), follow these steps: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 80: Installing Double Windrow Attachment (Dwa)
ASSEMBLING THE HEADER 6. Position left divider (B) on header left front corner, and install with four bolts (A) and nuts in existing holes. Tighten hardware. 7. Repeat for right side. 8. Lower cutterbar doors. Figure 3.148: Tall Crop Divider Installed 3.14.2 Installing Double Windrow Attachment (DWA) Refer to instructions supplied with kit.
Page 81: Installing Skid Shoes (Optional)
ASSEMBLING THE HEADER 3.14.3 Installing Skid Shoes (Optional) DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 82: Installing Tall Crop Feed Plates
ASSEMBLING THE HEADER 3.14.5 Installing Tall Crop Feed Plates Two plates (A) are supplied with each header and can be installed if required. They are stored behind the right side driveshield. Installation instructions are included in the operator’s manual. Figure 3.152: Tall Crop Feed Plates Storage Location (Driveshield Removed for Clarity) 3.14.6 Installing Nut Protectors (for Blade Hardware on Discs) Twelve nut protector caps (A) are supplied as standard...
Page 83: Lubricating The Header
ASSEMBLING THE HEADER 3.15 Lubricating the Header The header has been lubricated at the factory. However, you should lubricate the header prior to delivery to offset the effects of weather during outside storage and transport, and to familiarize yourself with the header. 3.15.1 Driveshields WARNING Do NOT operate the machine with the driveshields open.
Page 84: Opening The Driveshield: Export Headers
ASSEMBLING THE HEADER Opening the Driveshield: Export Headers Follow these steps to open the driveshield on export headers: 1. Release rubber latches (A). 2. Insert a screwdriver (or equivalent) through hole in shield (B) and into the notch in latch (C) and disengage latch.
Page 85: Greasing Procedure
ASSEMBLING THE HEADER 3.15.2 Greasing Procedure DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. The greasing points are marked on the machine by decals showing a grease gun and grease interval in hours of operation.
Page 86 ASSEMBLING THE HEADER Figure 3.159: Lubrication Points A - Driveline Universals (Two Places) B - Roll Shaft Bearings (Two Places) C - Driveline Universals (Two Places) D - Driveline Shaft 3 (Two Places) E - Driveline Universals 3 (Two Places) F - Driveshaft (One Place) 3.
Page 87 ASSEMBLING THE HEADER Figure 3.160: Lubrication Points B - Optional Gauge Roll Bearings (Two Places) – Both Sides A - Roll Shaft Bearings (Two Places) C - Belt Tensioner Pivot (One Place) D - Auger Bearing (One Place) 214367 Revision A...
Page 89: Chapter 4: Performing Predelivery Checks
4 Performing Predelivery Checks DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. IMPORTANT: To avoid machine damage, check that no shipping dunnage has fallen down between auger and pans. 1.
Page 90 PERFORMING PREDELIVERY CHECKS 2. Check that adjuster nut (A) is tight and that conditioner drive belt (B) is tensioned. 3. Check that end of slots (C) are aligned with plate (D). Figure 4.2: Conditioner Drive Belt Tension CAUTION Check to be sure all bystanders have cleared the area. 4.
Page 91: Checking Header Float: M200 And M205 Windrowers
PERFORMING PREDELIVERY CHECKS 4.2 Checking Header Float: M200 and M205 Windrowers CAUTION Check to be sure all bystanders have cleared the area. 1. Start engine and lower header to ground, and ensure header lift cylinders are fully retracted. 2. Adjust the header angle/tilt to mid-range position with the switches (A) and (B) on the windrower ground speed lever (GSL).
Page 92: Checking Header Float: M1240 Windrowers
PERFORMING PREDELIVERY CHECKS 4.3 Checking Header Float: M1240 Windrowers DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 93 PERFORMING PREDELIVERY CHECKS 3. Press rotary scroll knob (A) on HPT to display the QuickMenu system. 4. Rotate scroll knob (A) to highlight header float icon (B) and press scroll knob to select. Figure 4.8: HPT Run Screen 5. Turn scroll knob (A) to highlight left (B) or right (C) float and press knob (A) to activate selection.
Page 94: Checking Header Level
PERFORMING PREDELIVERY CHECKS 4.4 Checking Header Level To check and adjust header level, follow these steps: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 95 PERFORMING PREDELIVERY CHECKS 8. Place wooden blocks (A) under header cutterbar and header support. 9. Disengage header safety props. CAUTION Check to be sure all bystanders have cleared the area. Figure 4.12: Wooden Block Under Header Support 10. Start engine, and lower header onto blocks so that header lift linkage (A) lifts at windrower leg and off of shims.
Page 96: Checking Conditioner Rolls
PERFORMING PREDELIVERY CHECKS 4.5 Checking Conditioner Rolls 4.5.1 Checking Conditioner Roll Gap DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. NOTE: If roll gap is not set correctly, refer to the header operator’s manual for adjustment procedure.
Page 97: Checking Conditioner Roll Timing
PERFORMING PREDELIVERY CHECKS 4.5.2 Checking Conditioner Roll Timing DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 98 PERFORMING PREDELIVERY CHECKS 6. From the rear of the header, position gauge at center of rolls as shown, and manually turn rolls to limits of gauge. Rolls will engage the gauge if timing is correct. 7. Manually turn rolls to release gauge. WARNING Remove gauge from rolls and return it to storage location before starting machine.
Page 99: Checking Gauge Rollers Or Skid Shoes
PERFORMING PREDELIVERY CHECKS 4.6 Checking Gauge Rollers or Skid Shoes DANGER To avoid bodily injury or death from unexpected startup of the windrower, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 100: Preparing The Bevel Gearbox
PERFORMING PREDELIVERY CHECKS 4.7 Preparing the Bevel Gearbox To prepare the bevel gearbox and check the oil level, follow these steps: 1. Adjust header height and angle so that top of header is horizontal. 2. Open the driveshield. Figure 4.24: Driveshield 3.
Page 101: Preparing The Conditioner Roll Timing Gearbox
PERFORMING PREDELIVERY CHECKS 4.8 Preparing the Conditioner Roll Timing Gearbox To prepare the conditioner gearbox and check the oil level, follow these steps: 1. Open the driveshield. 2. Adjust the header height and angle until the top of the conditioner gearbox (A) is level with the ground (B). Figure 4.27: Conditioner Gearbox 3.
Page 102: Checking Lights
PERFORMING PREDELIVERY CHECKS 4.9 Checking Lights The hazard lights are mounted on both ends of the header, and activated by a switch in the windrower cab. 1. Check for operation during run-up. 2. Ensure light mountings (A) are secure and check lights (B) for damage.
Page 103: Checking Manuals
4.10 Checking Manuals The following manuals should be stored in the manual storage case (A) on the right side of the header: • R85 Rotary Disc 4.9-Meter (16-Foot) Header for Self-Propelled Windrower Operator’s Manual Figure 4.31: Manual Storage Case 214367...
Page 104: Running Up The Header
PERFORMING PREDELIVERY CHECKS 4.11 Running up the Header DANGER • Keep everyone several hundred feet away from your operation. Ensure bystanders are never in line with the front or rear of the machine. Stones or other foreign objects can be ejected from either end with force.
Page 105: Chapter 5: Reference
5 Reference 5.1 Torque Specifications The following tables provide correct torque values for various bolts, cap screws, and hydraulic fittings. • Tighten all bolts to torque values specified in charts (unless otherwise noted throughout this manual). • Replace hardware with same strength and grade of bolt. •...
Page 106 REFERENCE Table 5.2 SAE Grade 5 Bolt and Grade F Distorted Thread Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) Size (A) Min. Max. Min. Max. 1/4-20 5/16-18 16.7 18.5 *149 *164 3/8-16 7/16-14 1/2-13 9/16-12 Figure 5.2: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
Page 107: Metric Bolt Specifications
REFERENCE Table 5.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) Size (A) Min. Max. Min. Max. 1/4-20 16.8 18.6 *150 *165 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 Figure 5.4: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
Page 108 REFERENCE Table 5.6 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 18.8 20.8 *167 *185 Figure 5.6: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...
Page 109: Metric Bolt Specifications Bolting Into Cast Aluminum
REFERENCE Table 5.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 10.7 11.8 *105 8-1.25 Figure 5.8: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...
Page 110: Flare-Type Hydraulic Fittings
REFERENCE 5.1.4 Flare-Type Hydraulic Fittings 1. Check flare (A) and flare seat (B) for defects that might cause leakage. 2. Align tube (C) with fitting (D) and thread nut (E) onto fitting without lubrication until contact has been made between flared surfaces. 3.
Page 111: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)
REFERENCE 5.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off lock nut (C) as far as possible. Ensure that washer (D) is loose and is pushed toward lock nut (C) as far as possible.
Page 112 REFERENCE Table 5.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque Value SAE Dash Size Thread Size (in.) lbf·ft (*lbf·in) 5/16–24 6–7 *53–62 3/8–24 12–13 *106–115 7/16–20 19–21 14–15 1/2–20 21–33 15–24 9/16–18 26–29 19–21 3/4–16 46–50 34–37 7/8–14 75–82 55–60 1-1/16–12 120–132 88–97...
Page 113: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)
REFERENCE 5.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Check that O-ring (A) is NOT on threads and adjust if necessary. 3. Apply hydraulic system oil to O-ring. 4.
Page 114: O-Ring Face Seal (Orfs) Hydraulic Fittings
REFERENCE 5.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings 1. Check components to ensure that sealing surfaces and fitting threads are free of burrs, nicks, scratches, or any foreign material. Figure 5.14: Hydraulic Fitting 2. Apply hydraulic system oil to O-ring (B). 3.
Page 115: Tapered Pipe Thread Fittings
REFERENCE Table 5.13 O-Ring Face Seal (ORFS) Hydraulic Fittings (continued) Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) lbf·ft – – Note 1-7/16 150–165 111–122 1-11/16 1-1/4 205–226 151–167 1–2 1-1/2 315–347 232–256 2-1/2 510–561 376–414 5.1.8 Tapered Pipe Thread Fittings Assemble pipe fittings as follows: 1.
Page 116: Conversion Chart
REFERENCE 5.2 Conversion Chart Table 5.15 Conversion Chart SI Units (Metric) Inch-Pound Units (Imperial) Factor Quantity Unit Name Abbreviation Unit Name Abbreviation acres acres Area hectares x 2.4710 = US gallons per minute gpm Flow liters per minute L/min x 0.2642 = Force Newtons x 0.2248 =...
Page 117: Definitions
Joint Industrial Council: A standards body that developed standard sizing and shape for original 37° flared fitting M Series windrower MacDon M100, M105, M150, M155, M155E4, M200, and M205 windrowers M1 Series windrower MacDon M1170 and M1240 windrowers Not applicable An internally threaded fastener that is designed to be paired with a bolt The slot opposite the NEUTRAL position on operator’s console of M Series...
Page 118 This style of fitting is also commonly called ORS, which stands for O-ring seal Revolutions per minute R Series header MacDon R80 and R85 disc headers RoHS (Reduction of A directive by the European Union to restrict use of certain hazardous substances...
Page 119: Predelivery Checklist
Predelivery Checklist Perform these checks and adjustments before delivering the machine to your Customer. If adjustments are required, refer to the appropriate page number in this manual. The completed Checklist should be retained by either the Operator or the Dealer. WARNING Do NOT operate the machine with the driveshields open.
Page 120 REFERENCE Table .16 Predelivery Checklist (continued) ü ü Item Reference 3.15 Lubricating the Header, page 75 Grease all bearings and drivelines. 4.5 Checking Conditioner Rolls, page 88 Check conditioner roll gap and timing. 4.5 Checking Conditioner Rolls, page 88 Check if roll intermesh hardware is securely tightened. 3.7 Unpacking Curtains, page 18 Check if cutterbar curtains are hanging properly.
Page 122 10708 N. Pomona Avenue Kansas City, Missouri United States 64153-1924 t. (816) 891-7313 f. (816) 891-7323 MacDon Australia Pty. Ltd. A.C.N. 079 393 721 P.O. Box 243, Suite 3, 143 Main Street Greensborough, Victoria, Australia 3088 t. 03 9432 9982 f.

MacDon R85 Assembly Instructions Manual

Chapter 1: Safety

Chapter 2: Unloading the Header

Chapter 3: Assembling the Header

Chapter 4: Performing Predelivery Checks

Chapter 5: Reference

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