Page 1 R80 Rotary Disc Self-Propelled Windrower Header OPERATOR’S MANUAL Model Year - 2010 Part #169089 $15...
Page 2 R80 ROTARY DISC SELF-PROPELLED WINDROWER HEADER...
Page 3: Introduction
1 INTRODUCTION This manual describes the operating and maintenance procedures for the MacDon Model R80 Self-Propelled Rotary Disc Header. Your new MacDon rotary header is designed to cut, condition, and lay in windrows a wide variety of grasses and hay crops.
Page 4: Table Of Contents
TABLE OF CONTENTS Section/Title Page INTRODUCTION ............................... 1 SAFETY ................................4 SAFETY ALERT SYMBOL ........................4 SIGNAL WORDS............................4 SAFETY SIGNS............................4 2.3.1 Safety Sign Installation ........................4 2.3.2 Safety Sign Locations ......................... 5 GENERAL SAFETY..........................7 ACCRONYMS AND ABBREVIATIONS ......................9 COMPONENT IDENTIFICATION ........................
Page 5 TABLE OF CONTENTS 7.3.1 Recommended Torques ........................36 7.3.2 Recommended Lubricants........................ 38 7.3.3 Conversion Chart..........................39 HEADER LIFT CYLINDER LOCKS......................40 DRIVE SHIELDS ............................ 40 CUTTERBAR DOORS..........................40 LUBRICATION............................41 7.7.1 Procedure ............................41 7.7.2 Lubrication Points ..........................41 13 FT Header ............................42 16 FT Header ............................
Page 6: Safety
SAFETY 2 SAFETY WARNING 2.1 SAFETY ALERT SYMBOL Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It is also used to alert against unsafe practices. CAUTION Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.
Page 7: Safety Sign Locations
SAFETY 2.3.2 Safety Sign Locations 2 PLCS #148829 #109843 #32738 (BOTH SIDES) #134070 #170281 Form # 169089 Model Year - 2010...
Page 8 SAFETY Safety Sign Locations (continued) 1 PLC – BOTH SIDES #142909 1 PLC #36651 Form # 169089 Model Year - 2010...
Page 9: General Safety
SAFETY Provide a first-aid kit for use in case of 2.4 GENERAL SAFETY emergencies. CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself. Keep a fire extinguisher on the machine. Be sure the extinguisher is properly maintained and be familiar with its proper use.
Page 10 SAFETY Keep area used servicing machinery clean and dry. oily floors slippery. spots can be dangerous when working with electrical equipment. Be sure electrical outlets and tools are properly grounded. Use adequate light for the job at hand. Keep machinery clean. Do not allow oil or grease accumulate service...
Page 11: Accronyms And Abbreviations
GENERAL 3 ACCRONYMS AND ABBREVIATIONS TERM DEFINITION American Petroleum Institute American Society Of Testing And ASTM Materials Celsius Fahrenheit ft/min feet per minute ft/s feet per second U.S. gallons per minute horsepower cubic inches kilopascals pounds force pound feet or foot pounds lbf·ft or ft·lbf lbf·in or in·lbf pound inches or inch pounds...
Page 12: Component Identification
GENERAL 4 COMPONENT IDENTIFICATION DOOR DRIVE SHIELD CENTER LINK DRIVE MOTOR BAFFLE CONTROL FRONT CURTAIN STANDARD HEADER HAZARD LIGHTS – 16 FT ONLY TALL CROP TRANSITION SHIELD HOSE SUPPORT FRONT CURTAIN GRASS SEED HEADER Form # 169089 Model Year - 2010...
Page 13: Specifications
16 ft-3 in. (4957 mm) Weight (estimated) 3500 lb (1590 kg) 4300 lb (1955 kg) Carrier MacDon M150 & M200 SP Windrowers MacDon M200 SP Windrower Lighting Two Amber Transport, Four On Grass Seed Manual Storage Windrower Cab Manual Storage Compartment...
Page 14: Operation
OPERATION 6.2 OPERATIONAL SAFETY 6 OPERATION Follow these safety precautions: 6.1 OWNER/OPERATOR CAUTION RESPONSIBILITIES Follow safety operational CAUTION instructions given in your windrower Operator's Manual. If you do not have a It is your responsibility to read and windrower manual, get one from your understand this manual...
Page 15 OPERATION 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. Extreme care must be exercised to avoid injury from thrown objects.
Page 16: Header Attachment
OPERATION 6.3 HEADER ATTACHMENT Refer to the M150 & M200 Self-Propelled Windrower Operator’s Manual for procedures for mechanically attaching the disc header to the self-propelled windrower. Refer to the following procedures electrical hydraulic connections. The header drive hydraulic hoses and electrical harness are located on the left cab-forward side of the windrower.
Page 17 OPERATION Move windrower left side platform to open 6.3.1.2 HEADER CONNECTIONS position. RETURN RETURN PRESSURE PRESSURE k. Connect two hose bundle from header to middle valve block as shown. RETURN PRESSURE CASE DRAIN ELECTRICAL a. Remove caps and plugs from hoses and lines. b.
Page 18: M150 - 13 Ft
OPERATION 6.3.2 M150 - 13 FT 16 FT SHOWN – 13 FT SIMILAR e. Route hose bundle (C) from windrower through support (D) on header. Route header return and pressure hose bundle (E) through support (D) on header, to windrower. a.
Page 19 OPERATION Remove caps and plugs from hoses and lines. RETURN PRESSURE CASE DRAIN ELECTRICAL k. Connect the three hoses from windrower to the fittings on the header as shown. Connect harness from windrower to electrical connector. m. Move windrower platform to closed position. Form # 169089 Model Year - 2010...
Page 20: Header Detachment
OPERATION 6.4 HEADER DETACHMENT Refer to the M150 & M200 Self-Propelled Windrower Operator’s Manual for procedures for mechanically detaching the header from the self- propelled windrower. Refer to the following procedures for disconnecting electrical harness and hydraulic hoses. CAUTION prevent accidental movement windrower, shut off engine, engage parking...
Page 21: M150 - 13 Ft
OPERATION 6.4.2 M150 – 13 FT RETURN a. Move LH (cab forward) platform to rear of windrower. PRESSURE CASE DRAIN b. Disconnect the hydraulic coupler from windrower valve. ELECTRICAL g. At the header, disconnect electrical connector by turning collar counterclockwise and pulling connector to disengage.
Page 22: Transporting Windrower
OPERATION g. Disconnect the two drive couplers, and case 6.5 TRANSPORTING WINDROWER drain coupler on header. Refer M150 & M200 Self-Propelled Windrower Operator’s Manual for transporting headers when attached to the M150/M200 windrower. 6.6 LIGHTS The turn signal lights hazard lights, which are mounted on both...
Page 23: Break-In Period
OPERATION 6.7 BREAK-IN PERIOD 6.9 DAILY START-UP CHECK a. After attaching header to windrower for the first time, operate the machine slowly for 5 minutes, CAUTION watching listening FROM WINDROWER SEAT for binding or interfering Be sure windrower and header are parts.
Page 24: Shutdown Procedure
OPERATION 6.10 SHUTDOWN PROCEDURE CAUTION Before leaving the windrower seat for any reason: - Park on level ground if possible. - Lower the header fully. - Place ground speed control in N- DETENT. - Stop engine and remove key from ignition.
Page 25: Header Operation
OPERATION 6.12.2 Cutting Height 6.12 HEADER OPERATION Cutting height is determined by the angle of the Satisfactory operation of the header in all cutterbar/header which can be adjusted with the situations requires making proper adjustments to center link, either hydraulically or mechanically. suit various crops and conditions.
Page 26: Header Angle
OPERATION c. Hold roller and remove lynch pin and adjuster 6.12.3 Header Angle pin (A) from other side. Position roller at desired position and reinstall adjuster pins (A). Secure Header (or cutterbar) angle can be varied from with lynch pins. 0-8°...
Page 27: Roll Gap
OPERATION 6.12.5 Roll Gap 6.12.5.1 Roll Gap Adjustment To adjust the roll gap, refer to following Steel rolls "condition" the crop by crimping and illustration and proceed as follows: crushing the stem in several places. This allows moisture release for quicker drying. The degree to which the crop is conditioned as it passes DANGER through the rolls is controlled by roll gap.
Page 28 OPERATION b. Lower header to ground, shut down windrower and remove key. ROLL GAP c. Open both rear drive shields. Inspect roll gap at both ends of the rolls at access port. IMPORTANT Roll timing is critical when the roll gap is decreased because: Conditioning is affected, and d.
Page 29: Roll Tension
OPERATION To adjust roll timing, refer to illustrations and 6.12.6 Roll Tension proceed as follows: The roll tension (the force holding the rolls together) is factory set to maximum and is adjustable. DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason.
Page 30: Forming Shields
OPERATION 6.12.7.1 Side Deflectors 6.12.7 Forming Shields The position of the side forming shields controls WARNING the width and placement of the windrow. DANGER Keep everyone several hundred feet away from your operation. Ensure bystanders are never in line with the front or rear of the Stop engine and remove key from ignition machine.
Page 31 OPERATION 6.12.7.2 Rear Deflector (Fluffer Shield) 6.12.7.3 Baffle The rear deflector slows the crop exiting the The baffle (E) determines the width and height conditioner rolls, directs the flow downward, and of the windrow. It is located immediately behind "fluffs" the material. and above the conditioning rolls, and can be positioned to;...
Page 32: Ground Speed
OPERATION 6.12.8 Ground Speed CAUTION Reduce speed when turning, crossing slopes, or when travelling over rough ground. a. Choose a ground speed that allows the cutterbar and conditioner to cut the crop smoothly and evenly. Try different combinations of header speed and ground speed to suit your specific crop.
Page 33: Converging Drum Assemblies - Grass Seed Header
The position can be controlled from the d. Re-install hairpin (C). windrower cab with the REEL UP and REEL DOWN switches on the GSL. 6.12.11 Double Windrowing Refer to MacDon M Series Windrower Double The drums are hydraulically driven and the Windrow Attachment Manual...
Page 34: Tall Crop Dividers
OPERATION 6.12.12 Tall Crop Dividers The tall crop dividers (one on each end of header) assist in clean crop dividing and cutterbar entry in tall crops (except grass seed). They are not adjustable but can easily be removed when operating the header with the tall crop transition shield in grass seed.
Page 35: Haying Tips
OPERATION 6.13.4 Windrow Characteristics 6.13 HAYING TIPS It is recommended that a windrow with the following characteristics be produced. Refer to 6.13.1 Curing Header Operation, Section 6.12 for instructions a. A quick cure will maintain top quality because: on adjusting the header. Protein is lost for each day hay lies on the CHARACTERISTIC ADVANTAGE...
Page 36: Storage
OPERATION 6.14 STORAGE Do the following at the end of each operating season: a. Clean the windrower thoroughly. CAUTION Never use gasoline, naphtha or any volatile material for cleaning purposes. These materials may be toxic and/or flammable. b. Store in a dry, protected place if possible. If stored outside, always cover windrower with a waterproof canvas or other protective material.
Page 37: Maintenance/Service
MAINTENANCE/SERVICE extinguishers are located and how to use them. 7 MAINTENANCE/SERVICE Keep the service area clean and dry. The following instructions are provided to assist Wet or oily floors are slippery. Wet the operator in the use of the disc header. spots can be dangerous when working Detailed maintenance,...
Page 38: Maintenance Specifications
MAINTENANCE/SERVICE 7.3 MAINTENANCE SPECIFICATIONS 7.3.1.2 Metric Bolts NC BOLT TORQUE* 7.3.1 Recommended Torques BOLT DIA. 10.9 Tighten all bolts to the torques specified in "A" chart unless otherwise noted throughout this lbf·ft N·m lbf·ft N·m manual. Check tightness of bolts periodically, using bolt torque chart as a guide.
Page 39 MAINTENANCE/SERVICE 7.3.1.3 Flare-Type Hydraulic Fittings 7.3.1.4 O-Ring Type Hydraulic Fittings FITTING LOCKNUT FLARE WASHER O-RING GROOVE BODY SEAT FLARESEAT a. Check flare and flare seat for defects that might cause leakage. b. Align tube with fitting before tightening. a. Inspect O-ring and seat for dirt or obvious c.
Page 40: Recommended Lubricants
MAINTENANCE/SERVICE IMPORTANT Do not overfill the cutterbar when 7.3.2 Recommended Lubricants adding lubricant. Overheating and Your machine can operate at top efficiency failure of cutterbar components may occur only if clean lubricants are used. if overfilled clean containers handle lubricants. Store in an area protected from dust, moisture, and other contaminants.
Page 41: Conversion Chart
MAINTENANCE/SERVICE 7.3.3 Conversion Chart INCH-POUND UNITS SI UNITS (METRIC) QUANTITY FACTOR UNIT NAME ABBR. UNIT NAME ABBR. Area acres acres x 0.4047 = hectares Flow US gallons per minute (gpm) x 3.7854 = liters per min L/min Force pounds force x 4.4482 = Newtons inch...
Page 42: Header Lift Cylinder Locks
MAINTENANCE/SERVICE 7.6 CUTTERBAR DOORS 7.4 HEADER LIFT CYLINDER LOCKS Refer to M150/M200 Self-Propelled Windrower WARNING Operator’s Manual for details on the header lift cylinder locks. Do not operate the machine without all the cutterbar doors down, curtains installed and 7.5 DRIVE SHIELDS in good condition.
Page 43: Lubrication
MAINTENANCE/SERVICE 7.7 LUBRICATION 7.7.2 Lubrication Points Refer to the illustrations on the following pages WARNING for identifying the various locations that require lubrication. To avoid personal injury, before servicing windrower or opening drive covers, follow procedures in Section 7.1, Preparation for Servicing.
Page 44: 13 Ft Header
MAINTENANCE/SERVICE I. 13 FT HEADER GEARBOX OIL LEVEL DRIVELINE UNIVERSALS (2 PLCS) BELT TENSIONER PIVOT (1 PLC) 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY DRIVELINE UNIVERSALS (2 PLCS) DRIVELINE SHAFT (2 PLCS) ROLL SHAFT BEARINGS (3 PLCS) Form # 169089 Model Year - 2010...
Page 45 MAINTENANCE/SERVICE 13 FT HEADER (cont’d) High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium Base LIFTING ROLL SHAFT BEARING ROLL SHAFT BEARINGS (2 PLCS) 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY DRIVELINE UNIVERSALS &...
Page 46: 16 Ft Header
MAINTENANCE/SERVICE II. 16 FT HEADER High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium Base CHECK PLUG Oil should slightly run out when removed. GEARBOX OIL LEVEL DRIVELINE UNIVERSALS (2 PLCS) BELT TENSIONER PIVOT (1 PLC) 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY DRIVELINE UNIVERSALS (2 PLCS)
Page 47 MAINTENANCE/SERVICE 16 FT HEADER (cont’d) High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium Base ROLL SHAFT BEARINGS (3 PLCS) OPTIONAL GAUGE ROLL BEARINGS (2 PLCS) BOTH SIDES 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY DRIVELINE UNIVERSALS (2 PLCS) DRIVESHAFT (1 PLC) (BOTH SIDES)
Page 48: 16 Ft Header - Grass Seed Header
MAINTENANCE/SERVICE III. 16 FT HEADER – GRASS SEED HEADER 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY CHECK PLUG Oil should slightly run out when removed. DRIVELINE UNIVERSALS (2 PLCS) DRIVESHAFT (1 PLC) GEARBOX OIL LEVEL (BOTH SIDES) OPTIONAL GAUGE ROLL BEARINGS (2 PLCS) BOTH SIDES CONVERGING DRUMS (2 PLCS) - BOTH SIDES...
Page 49: Sealed Bearing Installation
MAINTENANCE/SERVICE 7.7.3 Sealed Bearing Installation a. Clean shaft and coat with rust preventative. b. Install flangette (A), bearing (B), second flangette (C) and lock collar (D). NOTE The locking cam is only on one side of the bearing. c. Install (but do not tighten) the flangette bolts (E). d.
Page 50: Cutterbar
MAINTENANCE/SERVICE CUTTERBAR 7.8.1 Skid Plates and Rock Guards DANGER 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. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine;...
Page 51 MAINTENANCE/SERVICE NOTE 7.8.1.2 Installation Longer bolt (E) is required for rock guards at ends of cutterbar. DANGER c. Install the two forward bolts (C) and nuts. Tighten bolts. Stop engine and remove key from ignition before leaving operator's seat for any reason.
Page 52: Cutter Bar Lubrication
MAINTENANCE/SERVICE NOTE 7.8.2 Cutter Bar Lubrication The block under the LH end of the header should be higher than the RH end. The oil level in the cutterbar cannot be checked. If in doubt as to the quantity of oil in the Disengage the header lift cylinder locks, start cutterbar, do not add oil.
Page 53 MAINTENANCE/SERVICE 7.8.2.2 Filling DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engine, remove key and engage header lift cylinder stops before going under machine for any reason. a. Start engine and raise header. Stop engine and engage header lift cylinder lock-outs.
Page 54: Disc Maintenance
MAINTENANCE/SERVICE 7.8.3 Disc Maintenance c. Remove four bolts (A) on disc cover (B) and remove cover and disc (C). Check daily that discs are not damaged by rocks d. If removing #2 disc; or worn excessively from abrasive working Standard Header conditions.
Page 55 MAINTENANCE/SERVICE e. If removing driveline disc; 7.8.3.2 Disc Installation DANGER 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. CAUTION Exercise caution when working around the blades.
Page 56 MAINTENANCE/SERVICE Grass Seed Header – 16 Ft Only. 1. Position new disc (M) on spindle ensuring it is 90 degrees to adjacent discs. 2. Install plate (L), drum (K) and secure with four bolts (J). 3. Tighten bolts to 92 ft·lbf (125 N·m). 4.
Page 57: Cutter Blades
MAINTENANCE/SERVICE a. Check daily that the cutter blades are securely 7.8.4 Cutter Blades attached to the disc. BLADE WEAR 7.8.4.1 Cutter Blade Types TO CENTERLINE a. 18 DEGREE BEVEL DOWN 0.81 in. (20.6 mm) Higher Lift for Certain Crop Conditions / Better in Stony Soil ELONGATED ROTATION DIRECTION...
Page 58 MAINTENANCE/SERVICE 7.8.4.3 Replacement CAUTION Cutter blades have two cutting edges. DISC ROTATION Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine;...
Page 59 MAINTENANCE/SERVICE 7.8.4.4 Cutter Blade Hardware Check blade attachment hardware each time blades are changed. Refer to previous section for hardware replacement procedure. a. Check bolts for wear or damage and replace bolt 1. Bolt has been removed and installed five times.
Page 60: Accelerators
MAINTENANCE/SERVICE 7.8.5.2 Installation 7.8.5 Accelerators a. Locate accelerator disc onto existing 7.8.5.1 Removal cutterblade bolt and install nut (B). NOTE DANGER Accelerators are handed for clockwise or counterclockwise operation. Verify the direction disc before installing Stop engine and remove key from ignition accelerators.
Page 61: Deflectors
MAINTENANCE/SERVICE 7.8.6 Deflectors 7.8.6.1 Driveline Deflector NOTE Check daily that hourglass deflectors are not Procedure is the same for both 13 and 16 damaged or bent by rocks. The deflectors are ft headers. 16 ft is shown. not repairable and must be replaced if severely damaged or worn.
Page 62 MAINTENANCE/SERVICE e. Remove four bolts (F). d. Position guard (E) and tighten bolts (D). Lift driveline (G) off deflector (A) base and slide e. Position guard (C) and attach with two bolts (B). lower end of deflector off disc (H). Remove block of wood if used.
Page 63 MAINTENANCE/SERVICE 7.8.6.3 Driven and Suspended Deflectors - 16 7.8.6.3.2 Suspended Deflector Ft - Standard Header DANGER 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. CAUTION Exercise caution when working around the blades.
Page 64 MAINTENANCE/SERVICE 7.8.6.4 Driven and Suspended Deflectors - 16 7.8.6.4.2 Suspended Deflector Ft – Grass Seed Header DANGER 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. CAUTION Exercise caution when working around the blades.
Page 65: Tall Crop Feed Plates
MAINTENANCE/SERVICE 7.8.7 Tall Crop Feed Plates The tall crop feed plates assist the feeding of tall crops into the conditioner by encouraging material flow from behind the cage deflectors. They will degrade the cutting performance of the cutterbar if they are used in medium to light d.
Page 66 MAINTENANCE/SERVICE LEADING EDGE LEADING EDGE COUNTERCLOCKWISE ROTATION CLOCKWISE ROTATION RH INBOARD DISC LH INBOARD DISC g. Locate feed plate (D) on the disc ensuring that NOTE hole in feed plate registers on disc. Position Older type feed plates may required plate approximately as shown and align holes.
Page 67: Header Drive
MAINTENANCE/SERVICE 7.9.1.2 Installation 7.9 HEADER DRIVE a. Remove covering from gearbox (F) opening. 7.9.1 Hydraulic Motor b. Place motor (E) on gearbox (F) flange. c. Install four bolts (D). Torque to 103 ft·lbf (140 The main drive hydraulic motor does not require N·m).
Page 68: Conditioner Drive Belt
MAINTENANCE/SERVICE 7.9.3 Conditioner Drive Belt 7.9.3.1 Tension Adjustment – Conditioner Drive Belt The conditioner drive belt is located inside the a. Lower header to ground, turn off engine, and drive compartment at the left hand side of the remove key. header and is tensioned with a spring tensioner.
Page 69 MAINTENANCE/SERVICE e. Adjust belt tension by adjusting the length of the spring to the values in the following table: NUMBER OF VISIBLE COILS MEASUREMENT ‘X’ 7.75-8.15 inches (197-207 mm) 8.11-8.5 inches (206-216 mm) Tighten jam-nut (B). Form # 169089 Model Year - 2010...
Page 70 MAINTENANCE/SERVICE 7.9.3.2 Conditioner Drive Belt Removal – 16 FT DANGER 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. a. Lower header to ground, turn off engine, and remove key.
Page 71 MAINTENANCE/SERVICE 7.9.3.4 Conditioner Drive Belt Removal – 13 FT 7.9.3.5 Conditioner Drive Belt Installation– 13 a. Lower header to ground, turn off engine, and remove key. b. Open LH drive shield (A). 13 FT a. Slip belt (D) between pulley (G) and driveline (F).
Page 72: Conditioner Drive Belt Idler
MAINTENANCE/SERVICE 7.9.4 Conditioner Drive Belt Idler DANGER 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. The conditioner drive belt idler does not require normal maintenance or servicing but may eventually require replacing.
Page 73: Lifting Roll Drive Belt
MAINTENANCE/SERVICE 7.9.5 Lifting Roll Drive Belt c. Remove five bolts (C) and nuts and remove rear shield (D). The two lifting roll drive belts (A) are located inside the drive compartment at the right hand side of the header. Belt tension is set at the factory and does not require adjustment.
Page 74: Lifting Roll Belt Idler
MAINTENANCE/SERVICE 7.9.6 Lifting Roll Belt Idler 7.9.7 Lifting Roll Idler Bearing DANGER DANGER Stop engine and remove key from ignition Stop engine and remove key from ignition before leaving operator's seat for any before leaving operator's seat for any reason. A child or even a pet could engage reason.
Page 75: Hourglass Deflector Drive Belts - 16 Ft Only
MAINTENANCE/SERVICE d. If necessary, adjust as follows: 7.9.8 Hourglass Deflector Drive Belts – 16 Ft Only DANGER 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. 7.9.8.1 Belt Tension a.
Page 76 MAINTENANCE/SERVICE Driveline (LH) Side Driven Side (RH) a. Loosen hourglass deflector drive belts (F) as follows: a. Remove outboard hourglass deflector and driveline. Refer to Section 7.8.6.1 Driveline Deflector. b. Loosen hourglass deflector drive belts (A) as follows: 1. Loosen nuts (G). 2.
Page 77: Bevel Gearbox
MAINTENANCE/SERVICE 7.9.9.1 Checking Oil 7.9.9 Bevel Gearbox The bevel gearbox oil level should be checked every 100 hours or once per year: DANGER 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.
Page 78 MAINTENANCE/SERVICE k. Properly dispose of used oil and clean up any 7.9.9.2 Changing Oil spilled oil. Lower drive shield (A). DANGER 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.
Page 79 MAINTENANCE/SERVICE 7.9.9.3 Removal – Bevel Gearbox DANGER 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. a. Lower header to ground, turn off engine, and remove key.
Page 80 MAINTENANCE/SERVICE Remove two bolts (P) and remove guard (Q). Loosen two bolts (R) and remove guard (S). 13 FT 16 FT o. Lift gearbox (Y) and manoeuvre from drive area, top end first. k. Rotate drum (T) so that wider space between bars face forward.
Page 81 MAINTENANCE/SERVICE 7.9.9.4 Installation – Bevel Gearbox DANGER 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. b. Install four bolts (X). Torque to 106 ft·lbf (144 N·m).
Page 82 MAINTENANCE/SERVICE NOTE Steps g. to i. applicable to 16 ft header only. 16 FT m. Position speed sensor bracket (E) onto gearbox and install bolts (D). Adjust gap (Z) between g. Install hourglass deflector drive belts (N) onto speed sensor and pulley (J) to 0.08 in (2 mm). drive pulley (O).
Page 83: Conditioner Gearbox - 13 Foot
MAINTENANCE/SERVICE 7.9.10 Conditioner Gearbox – 13 Foot The conditioner gearbox is located inside the drive compartment at the left hand side of the header. The conditioner gearbox does not require normal maintenance or servicing, and if repairs are required, it should be removed and serviced at your dealer.
Page 84 MAINTENANCE/SERVICE Remove bolts (M). Slide pulley (L) off gearbox onto driveline. h. Loosen bolt (P) on lower U-joint and slide yoke (Q) off gearbox. g. Remove bolts (N) and swivel driveline so that pulley and driveshaft (O) can be slipped off driveline.
Page 85 MAINTENANCE/SERVICE 7.9.10.2 Conditioner Gearbox Installation – 13 Foot DANGER 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. a. Slide upper driveshaft (O) with pulley (L) and belt into yoke (T).
Page 86 MAINTENANCE/SERVICE h. Adjust roll timing. Refer to Section 6.12.5.2, Roll Timing. Close drive shield (A). d. Re-install belt on pulley (L) and tighten idler (U) with adjuster bolt (K). See 7.9.3.1 Tension Adjustment – Conditioner Drive Belt. Tighten jam-nut (H). e.
Page 87: Conditioner Gearbox - 16 Foot
MAINTENANCE/SERVICE 7.9.11 Conditioner Gearbox – 16 Foot The conditioner gearbox is located inside the drive compartment at the left hand side of the header. The conditioner gearbox does not require normal maintenance or servicing, and if repairs are required, it should be removed and serviced at your dealer.
Page 88 MAINTENANCE/SERVICE Remove bolts (M). Slide pulley (L) off gearbox Loosen bolt (Q) on lower U-joint and slide yoke and slide pulley over timing flange yoke onto (R) off gearbox. driveshaft (N). g. Remove bolts (O) and swivel driveshaft (N) so Remove eight bolts (S) attaching gearbox (T) to that pulley can be slipped off driveline.
Page 89 MAINTENANCE/SERVICE 7.9.11.2 Conditioner Gearbox Installation – 16 Foot DANGER 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. c. Slide pulley and belt onto upper driveshaft (N) and position driveshaft on gearbox.
Page 90 MAINTENANCE/SERVICE Position belt (J) on pulley (L) and tighten idler with adjuster bolt (K). See 7.9.3.1 Tension Adjustment – Conditioner Drive Belt. Tighten jam-nut (H). g. Re-install panel (G) with five bolts (F) and nuts. Install bolts from inside. h. Position LH drive shield on header and locate on existing pin (U).
Page 91: Gearbox Speed Sensor
MAINTENANCE/SERVICE 7.9.12 Gearbox Speed Sensor DANGER 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. a. Lower header to ground, turn off engine, and remove key.
Page 92: Hydraulics
MAINTENANCE/SERVICE 7.11 ELECTRICAL 7.10 HYDRAULICS NOTE Refer to M150/M200 Self-Propelled Windrower Only the 16 foot header is equipped with Operator’s Manual hydraulic system lights. maintenance procedures self-propelled windrowers. DANGER 7.10.1 Hoses And Lines Stop engine and remove key from ignition Check hydraulic hoses and lines daily for signs before leaving operator's seat for any of leaks.
Page 93: Maintenance Schedule
MAINTENANCE/SERVICE Service Intervals: The recommended service 7.12 MAINTENANCE SCHEDULE intervals are in hours of operation. Where a service interval is given in more than one time The following maintenance schedule lists the frame, e.g. "100 hours or Annually", service the periodic maintenance procedures, organized by machine at whichever interval is reached first.
Page 94: Interval Maintenance
MAINTENANCE/SERVICE 7.12.2 Interval Maintenance INTERVAL SERVICE FIRST USE Refer To BREAK-IN INSPECTIONS (previous page). 1. Check Bevel Gearbox Lubricant Level. 100 HOURS OR 2. Check Conditioner Drive Belt Tension. Except Grass Seed Header. See Section ANNUALLY * 7.9.3.1. 3. Check Hourglass Deflector Belt Tension – 16 Ft Only. See Section 7.9.8.1. END OF Refer To Section 6.14, STORAGE.
Page 95: Maintenance Record
MAINTENANCE/SERVICE 7.12.3 Maintenance Record 9 - Check 6 - Lubricate S - Change ACTION: Hour Meter Reading Date Serviced By FIRST USE Refer To Section 7.12.1, BREAK-IN PERIOD 100 HOURS OR ANNUALLY Bevel Gearbox Lubricant Level END OF SEASON Refer To Section 6.14, STORAGE 10 HOURS OR DAILY Hydraulic Hoses &...
Page 96: Troubleshooting
TROUBLESHOOTING 8 TROUBLESHOOTING 8.1 MOWER PERFORMANCE SYMPTOM PROBLEM SOLUTION SECTION Cutterbar Plugging Dull, bent, or badly worn blades. Replace blades. 7.8.4.3 Build-up of dirt between rock Decrease header angle and guards. increase flotation. In some conditions, it may be 6.12.3 & necessary to carry header 6.12.4 slightly with header lift...
Page 97 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Conditioner Rolls Plugging Cutting height too low. Decrease header angle to 6.12.3 (cont’d) raise cutting height. Backing into windrow. Raise header before backing Rolls improperly timed. Adjust roll timing. 6.12.5.2 Uneven Formation And Rear deflector bypassing or Adjust rear deflector for 6.12.7.2 Bunching Of Windrow...
Page 98: Mechanical
Mud on cutterbar. Remove mud from cutterbar. Do not allow mud to dry on 6.11 cutterbar. Spindle bearing failure. Replace spindle bearing. MacDon Dealer. Material wrapped around Remove disc and remove 7.8.3.1 spindle. material. Cutting too low in rocky field Decrease header angle.
Page 99 When all moving parts are completely stopped, remove foreign object. Belt pulleys and idlers Align pulleys and idler. misaligned. MacDon Dealer. Machine Pulling To One Side Header dragging on one end Adjust header flotation on 6.12.4 and pulling to that side.
Page 100: Options And Attachments
OPTIONS 9 OPTIONS AND 9.4 TALL CROP DIVIDER KIT ATTACHMENTS 9.1 GAUGE ROLLER KIT The tall crop dividers attach to the ends of the The gauge roller kit installs at either end of header for clean crop dividing and cutterbar entry the cutterbar and the rollers can be adjusted in tall crops.
Page 101: Windrow Forming Rods
OPTIONS 9.7 WINDROW FORMING RODS 9.9 TALL CROP TRANSITION SHIELD The tall crop transition shield deflects the grass seed heads down and into the cutterbar area while minimizing head shattering and seed loss. Windrow forming rods which assist in The kit includes all hardware and installation forming the desired windrow configuration instructions.
Page 102: Unloading And Assembly
UNLOADING AND ASSEMBLY 10 UNLOADING AND ASSEMBLY Refer to R80 Rotary Disc Self-Propelled Windrower Header Unloading & Assembly Instructions, #169079 and Pre-Delivery Checklist that is included with your shipment. Form # 169089 Model Year - 2010...
Page 103: Index
INDEX Abbreviations ..............9 Float................24 Accelerators..............58 Forming Shields.............. 28 Assembly ..............100 rear deflector............... 29 Attachments..............98 side deflectors............. 28 Baffle................29 Gauge Roller Kit ............. 98 Bearing, sealed Gauge Rollers..............23 installation..............47 Grass Seed Header Belts hydraulics..............
Page 104 INDEX timing................26 maintenance..............36 Safety Speed Sensor..............89 general ................7 Storage................34 operating ..............12 Tall Crop Divider Kit ............98 owner ................12 Tall Crop Feed Plates............63 procedures ..............35 Tall Crop Transition Shield ........32, 99 shut-down..............22 Tedding ................33 signal words ..............4 Topography ..............33 signs ................4 Torques ................36 symbols .................4 Transporting ..............20...

MacDon R80 Operator's Manual

1 Introduction

2 Safety

3 Accronyms and Abbreviations

4 Component Identification

5 Specifications

6 Operation

7 Maintenance/Service

8 Troubleshooting

9 Options and Attachments

10 Unloading and Assembly

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