MacDon R85 Operator's Manual
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MacDon R85 Operator's Manual

MacDon R85 Operator's Manual

Rotary disc 16-foot header for self-propelled windrower
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R85
Rotary Disc 16-Foot Header for
Self-Propelled Windrower
Operator's Manual
214366 Revision A
2018 Model Year
Original Instruction

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Summary of Contents for MacDon R85

  • Page 1 Rotary Disc 16-Foot Header for Self-Propelled Windrower Operator’s Manual 214366 Revision A 2018 Model Year Original Instruction...
  • Page 2 R85 Rotary Disc 4.9-Meter (16-Foot) Self-Propelled Windrower Header Published: August 2017...
  • Page 3 Recommended Fluids and Lubricants Your machine can operate at top efficiency only if clean lubricants are used. • Use clean containers to handle all lubricants. • Store in an area protected from dust, moisture, and other contaminants. Table .16 Fluids and Capacities Capacities Lubricant Location...
  • Page 4 Declaration of Conformity Figure 1. EC Declaration of Conformity, Page 1 214366 Revision A...
  • Page 5 Figure 2. EC Declaration of Conformity, Page 2 214366 Revision A...
  • Page 6 The A-weighted sound pressure level inside the operator’s station of a typical self-propelled vehicle (e.g., M205), when operated in conjunction with this R85 rotary disc header, is 79 dBA. This measurement was taken in accordance with ISO 5131. The sound pressure level depends upon the rotary disc speed, crop conditions, as well the exact type of self-propelled vehicle used to power the R85.

  • Page 7: List Of Revisions

    List of Revisions At MacDon, we’re continuously making improvements: occasionally these improvements affect product documentation. The following list provides an account of major changes from the previous version of this document. Summary of Change Location Updated Declaration of Conformity. Declaration of Conformity, page i Added conventions used in this document.

  • Page 8: Introduction

    MacDon Dealer. 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 9 Store the operator’s manual and the parts catalog in the plastic manual case (A) located at the right side of the header. Figure 3. Manual Storage Case 214366 Revision A...

  • Page 10: Serial Number(S)

    Serial Number(s) Record the serial number of the header in the space provided. Header Serial No: ____________ The serial number plate (A) is located on the top cover at the right side of the header. Figure 4. Serial Number Location – Self-Propelled 214366 Revision A...

  • Page 12: Table Of Contents

    TABLE OF CONTENTS Declaration of Conformity..........................i Noise Levels ............................iii List of Revisions ............................iv Introduction...............................v Serial Number(s) ............................. vii Chapter 1: Safety ............................ 1 1.1 Safety Alert Symbols ..........................1 1.2 Signal Words ............................2 1.3 General Safety.............................3 1.4 Maintenance Safety ..........................5 1.5 Hydraulic Safety...........................6 1.6 Safety Signs ............................7 1.6.1 Installing Safety Decals .......................7...
  • Page 13 TABLE OF CONTENTS 3.7.2 Attaching Header to an M200 and M205 Self-Propelled Windrower..........44 3.7.3 Attaching Hydraulic and Electrical Components: M205 Windrowers ..........45 3.7.4 Attaching Hydraulic and Electrical Components: M200 Windrowers ..........51 3.7.5 Attaching Hydraulic Center-Link with Optional Self-Alignment: M1240 Windrowers ......57 3.7.6 Attaching Hydraulic and Electrical Components: M1240 Windrowers ..........62 Routing Hydraulic Hoses and Electrical Components to M1240 Windrowers .........63 Connecting Header Hydraulics Using Quick Couplers: M1240 Windrowers ........64...
  • Page 14 TABLE OF CONTENTS 4.11 Tall Crop Feed Plates ........................103 4.11.1 Removing the Tall Crop Feed Plates from Storage ..............103 Installing Tall Crop Feed Plates under Driven Deflector.............. 104 Installing Tall Crop Feed Plates under Driveline Deflector ............105 4.11.2 Removing Tall Crop Feed Plates .....................
  • Page 15 TABLE OF CONTENTS 5.3.5 Cutterblades ........................... 140 Inspecting Discblades ......................141 Inspecting Cutterblade Hardware..................... 142 Replacing the Cutterblades ..................... 144 5.3.6 Accelerators ........................... 145 Inspecting Accelerators......................146 Replacing Accelerators ......................147 5.3.7 Nut Shield..........................148 Inspecting Nut Shield ......................148 Replacing Nut Shield ......................
  • Page 16 TABLE OF CONTENTS Chapter 6: Options and Attachments ....................175 6.1 Options and Attachments: Kits ......................175 6.1.1 Adjustable Skid Shoe Kit......................175 6.1.2 Cutterbar Repair Tool Kit......................175 6.1.3 Double Windrow Attachment (DWA) ..................176 6.1.4 Gauge Roller .......................... 176 6.1.5 Hydraulic Drive: 16-Foot for M200 Self-Propelled ..............

  • Page 18: Chapter 1: Safety

    1 Safety 1.1 Safety Alert Symbols This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read and follow the safety message accompanying this symbol.

  • Page 19: Signal Words

    SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The appropriate signal word for each situation has been selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

  • Page 20: General Safety

    SAFETY 1.3 General Safety CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself. • When assembling, operating, and servicing machinery, wear all protective clothing and personal safety devices that could be necessary for job at hand.
  • Page 21 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 22: Maintenance Safety

    SAFETY 1.4 Maintenance Safety To ensure your safety while maintaining machine: • Review operator’s manual and all safety items before operation and/or maintenance of machine. • Place all controls in Neutral, stop the engine, set the park brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing.

  • Page 23: Hydraulic Safety

    SAFETY 1.5 Hydraulic Safety • Always place all hydraulic controls in Neutral before dismounting. • Make sure that all components in hydraulic system are kept clean and in good condition. • Replace any worn, cut, abraded, flattened, or crimped hoses and steel lines. •...

  • Page 24: Safety Signs

    SAFETY 1.6 Safety Signs • Keep safety signs clean and legible at all times. • 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.

  • Page 25: Safety Decal Locations

    SAFETY 1.7 Safety Decal Locations Figure 1.15: Safety Decal Locations A - MD #174436 B - MD #113482 C - MD #194464 D - MD #194521 E - MD #184385 Figure 1.16: Safety Decals 214366 Revision A...
  • Page 26 SAFETY Figure 1.17: Safety Decal Locations A - MD #190546 B - MD #247166 C - MD #184371 D - MD #184385 E - MD #194466 F - MD #194463 G - MD #194465 Figure 1.18: Safety Decals 214366 Revision A...
  • Page 27 SAFETY Figure 1.19: Safety Decal Locations A - MD #184386 214366 Revision A...

  • Page 28: Understanding Safety Signs

    SAFETY 1.8 Understanding Safety Signs MD #113482 General hazard pertaining to machine operation and servicing CAUTION To avoid injury or death from improper or unsafe machine operation: • Read the operator’s manual and follow all safety instructions. • Do not allow untrained persons to operate the machine. •...
  • Page 29 SAFETY MD #174434 Header hazard DANGER • Rest header on ground or engage mechanical locks before going under unit. Figure 1.22: MD #174434 MD #184371 Hand entanglement hazard WARNING • Do not operate without shields in place. • To avoid injury, stop engine and remove key before opening shield.
  • Page 30 SAFETY MD #184386 Pinch hazard WARNING • Keep away. • Never reach into pinch area. • Failure to comply could result in death or serious injury. Figure 1.25: MD #184386 MD #184422 Keep shields in place hazard WARNING • Do not place hand. •...
  • Page 31 SAFETY MD #194462 Header crushing hazard WARNING • Install lock before going under unit. Figure 1.28: MD #194462 MD #194463 Rotating blades WARNING • Stop the engine and remove the key before opening the header covers. • Listen and look for evidence of rotation before lifting cover.
  • Page 32 SAFETY MD #194465 Rotating blades WARNING • Stand clear. • Stop the engine and remove the key. • Listen and look for evidence of rotation before lifting cover. • Rotating cutters may continue to rotate after power is shut off. •...
  • Page 33 SAFETY MD #194521 Auger entanglement hazard CAUTION • To avoid injury from entanglement with rotating auger, stand clear of header/mower while machine is running. General hazard pertaining to machine operation and servicing. CAUTION • Read the operator’s manual and follow safety instructions.
  • Page 34 SAFETY MD #247167 Rotating blades WARNING • Stop the engine and remove the key. • Listen and look for evidence of rotation before lifting cover. • Rotating blades may continue to rotate after power is shut off due to inertia. Figure 1.35: MD #247167 214366 Revision A...

  • Page 36: Chapter 2: Product Overview

    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...
  • Page 37 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 38: Component Identification

    PRODUCT OVERVIEW 2.2 Component Identification Figure 2.1: Component Identification A - Driveshield B - Tower C - Door D - Gauge Rollers (Optional) E - Baffle F - Hydraulic Hoses to Windrower G - Baffle Control H - Header Boot Figure 2.2: Component Identification A - Transport Light B - Conditioner Rolls...

  • Page 39: Specifications

    Specifications and design are subject to change without notice or obligation to revise previously sold units. S: standard / O: optional / O : optional (dealer installed) / -: not available 4.9-Meter (16-Foot) R85 Cutterbar Effective cutting width 4827 mm (15.83 ft.)
  • Page 40 PRODUCT OVERVIEW 4.9-Meter (16-Foot) R85 Hay Conditioner Drive: Bevel gearbox to 5 HA banded belt drive to enclosed timing gearbox and driveline Roll type: Intermeshing steel bars Roll length: 300 mm (118 in.) Roll diameter 229 mm (9.0 in.) outside diameter on (179 mm) 7.0 in. O.D. tube Roll diameter 233 mm (9.17 in.) outside diameter on 168.4 mm (6.63 in.) O.D.

  • Page 42: Chapter 3: Operation

    • It is your responsibility to read and understand this manual completely before operating the header. Contact your MacDon Dealer if an instruction is not clear to you. • Follow all safety messages in the manual and on safety decals on the machine.

  • Page 43: Operational Safety

    OPERATION 3.2 Operational Safety CAUTION Follow these safety precautions: • Follow all safety and operational instructions given in your windrower operator’s manuals. If you do not have an operator’s manual, get one from your Dealer and read it thoroughly. • Never attempt to start the windrower’s engine or operate the machine except from the windrower seat. •...
  • Page 44 OPERATION CAUTION • Operate only in daylight or good artificial light. • 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 with force from either end.

  • Page 45: Engaging And Disengaging Header Safety Props

    OPERATION 3.3 Engaging and Disengaging Header Safety Props Safety props are located on both header lift cylinders on the windrower. Follow these steps to engage or disengage the header safety props: DANGER To avoid bodily injury from fall of raised header, always engage safety props when working on or around raised header, and before going under header for any reason.
  • Page 46 OPERATION Disengage safety props as follows: 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. Turn lever (A) away from header to raise safety prop until lever locks into vertical position.

  • Page 47: Driveshields

    OPERATION 3.4 Driveshields WARNING Do NOT operate the machine with the driveshields open. High-speed rotating components may throw debris and could result in death or serious injury. The Rotary Disc 4.9-Meter (16-Foot) Header for Self-Propelled Windrowers comes in two configurations: one for use in North America and one for use outside of North America.

  • Page 48: Opening The Driveshield: Export Headers

    OPERATION 3.4.3 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 49: Removing Right Endshield

    OPERATION 3.4.5 Removing Right Endshield 1. Remove three bolts (A) and remove right endshield (B). NOTE: Tall crop feed plates are supplied from the factory and stored behind the right endshield. Figure 3.9: Right Endshield 3.4.6 Installing Right Endshield 1. Install right endshield (B) using three bolts (A). Figure 3.10: Right Endshield 214366 Revision A...

  • Page 50: Cutterbar Doors

    OPERATION 3.5 Cutterbar Doors The Rotary Disc 4.9-Meter (16-Foot) Header for Self-Propelled Windrowers comes in two configurations: one for use in North American and one for use outside of North America. Headers configured for use outside of North America are referred to as export headers. The configuration is specified in the title when necessary. CAUTION Do NOT operate the machine without all the cutterbar doors down.

  • Page 51: Opening The Cutterbar Doors: North America

    OPERATION 3.5.1 Opening the Cutterbar Doors: North America Follow these steps to open the cutterbar doors on a North American header: 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 52: Closing The Cutterbar Doors: North American Header

    OPERATION 3.5.2 Closing the Cutterbar Doors: North American Header Follow these steps to close the cutterbar doors on a North American header: CAUTION To avoid injury, keep hands and fingers away from corners of doors when closing. 1. Holding the door open, lift safety door latch (A) to disengage its lock, then move the door down to its closed position over the cutterbar.

  • Page 53: Opening The Cutterbar Doors: Export Header

    OPERATION 3.5.3 Opening the Cutterbar Doors: Export Header Follow these steps to open the cutterbar doors on an export header: 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 54: Closing The Cutterbar Doors: Export Header

    OPERATION 2. Insert a screwdriver (or equivalent) through hole (A) in door into notch in latch (B) and push latch to disengage. 3. Lift at front of door to open. Figure 3.17: Cutterbar Door Latch 3.5.4 Closing the Cutterbar Doors: Export Header To close the cutterbar doors on an export header follow these steps: CAUTION To avoid injury, keep hands and fingers away from corners of doors when closing.
  • Page 55 OPERATION 1. Pull at top and move to closed position. Ensure latch (A) has engaged the door. Figure 3.18: Cutterbar Door Latch 2. Hook curtain latches (A). Figure 3.19: Curtain Latches 214366 Revision A...

  • Page 56: Daily Start-Up Check

    OPERATION 3.6 Daily Start-Up Check CAUTION • Be sure windrower and header are properly attached, all controls are in NEUTRAL, and windrower brake is engaged. • Clear the area of other persons, pets etc. Keep children away from machinery. Walk around the header to be sure no one is under, on or close to it.
  • Page 57 OPERATION Do the following each day before start-up: 1. Check the machine for leaks or any parts that are missing, broken, or not working correctly. NOTE: Use proper procedure when searching for pressurized fluid leaks. Refer to 5.5.2 Hydraulic Hoses and Lines, page 172.

  • Page 58: Attaching The Header

    OPERATION 3.7 Attaching the Header 3.7.1 Attaching the Forming Shield 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 OPERATION 4. Position the forming shield onto spacers (B) on windrower legs. Secure with clevis pins (A) and lynch pin. Figure 3.24: Attaching Forming Shield to Windrower Legs IMPORTANT: Forming shield plate (A) is shown in standard position. If installing double windrow attachment (DWA), install plate in inverted position.
  • Page 60 9. Adjust rear fluffer deflector (C) to the middle position. Loosen handles (B) if required. 10. Attach the R85 header to the windrower. Refer to the windrower operator’s manual for instructions, and then return to this manual to complete the attachment.

  • Page 61: Attaching Header To An M200 And M205 Self-Propelled Windrower

    OPERATION 3.7.2 Attaching Header to an M200 and M205 Self-Propelled Windrower To attach the header to a self-propelled windrower, follow these steps: 1. Remove hairpin from pin (A) and remove pin from left and right header boots (B). CAUTION Ensure all bystanders have cleared the area. 2.

  • Page 62: Attaching Hydraulic And Electrical Components: M205 Windrowers

    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 couplers can be ordered and installed to make switching between these headers easier Refer to your windrower operator’s manual for procedures to mechanically attach the header to the windrower.
  • Page 63 OPERATION Routing hydraulic hose bundle from header to windrower: 1. Move windrower left (cab-forward) platform (A) to OPEN position. For instructions, refer to the windrower operator’s manual. Figure 3.33: Windrower with Left Platform in Open Position 2. Route hose bundle (A) from the header under the windrower frame, and insert pin (B) into hole in windrower frame.
  • Page 64 OPERATION 4. Remove protective plugs (A) from ends of hydraulic hoses. Figure 3.35: Protective Shipping Plugs on R85 Hydraulic Hoses Attaching hydraulics using quick coupler connections: 1. Remove coupler lock as follows: a. Remove lynch pin (A) and open up coupler lock (B).
  • Page 65 OPERATION 2. Connect rear pump hose (A) to outboard line (D) on windrower using coupler (C). 3. Connect front pump hose (B) to inboard line (E) on windrower using coupler (C). Figure 3.37: Hose Routing and Connections 4. Position the lock onto the couplers so that retainer (A) rests under the fitting next to the sleeve on each coupler.
  • Page 66 OPERATION 5. Lower holder (A) onto sleeves (B) so that the flats are positioned on the holder. NOTE: Holder can be adjusted by loosening bolts (C). Tighten bolts after adjusting. Figure 3.39: Hydraulic Couplers with Coupler Lock 6. Insert lynch pin (A) to secure the lock. 7.
  • Page 67 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 68: Attaching Hydraulic And Electrical Components: M200 Windrowers

    OPERATION 6. Move windrower platform (A) to the CLOSED position. For instructions, refer to the windrower operator’s manual. Figure 3.43: Windrower with Left Platform in Closed Position 3.7.4 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 69 OPERATION 1. Disengage and rotate lever (A) counterclockwise to the UP position. 2. Remove cap (B) securing the electrical connector to the frame. Figure 3.45: Hose Bundle 3. Move hose bundle (A) from the windrower, and rest the bundle on the header. Figure 3.46: Hose Bundle 214366 Revision A...
  • Page 70 OPERATION 4. Position the hose support with lower bolt (A) in the forward hole, as shown. Loosen both bolts and adjust as required. Figure 3.47: Hose Support 5. Route hose bundle (A) from the windrower through support (B) on header. 6.
  • Page 71 OPERATION 9. Move the windrower’s left side (cab-forward) platform (A) to the OPEN position to access the valve blocks. Figure 3.50: Windrower with Left Platform in Open Position 10. Remove caps from pressure (A) and return (B) ports on valve (C) and discard. IMPORTANT: Keep open lines and ports clean.
  • Page 72 OPERATION 12. Disconnect fittings at end of hose bundle (A). Discard caps. Figure 3.52: Hose Bundle 13. Remove O-ring (A) from cap and install over JIC threads on fitting at return port (B). 14. Install female coupler (C) from hose in return port (B). 15.
  • Page 73 OPERATION 16. Connect hoses from header to fittings as shown. NOTE: If the windrower is equipped with a reverser valve for an auger header, replace the 90° fitting on hose (C) with a 45° fitting. Figure 3.54: Hydraulic Connections A - Middle Valve Block B - Pressure C - Return 17.

  • Page 74: Attaching Hydraulic Center-Link With Optional Self-Alignment: M1240 Windrowers

    Figure 3.56: Top View of Windrower 3.7.5 Attaching Hydraulic Center-Link with Optional Self-Alignment: M1240 Windrowers To attach an R85 header to a windrower, 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 75 OPERATION 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. NOTE: If not prompted by the harvest performance tracker (HPT) display to remove float, remove float manually by doing the following: Figure 3.58: Header Float Spring...
  • Page 76 OPERATION 6. Press HEADER DOWN switch (E) on the ground speed lever (GSL) to fully retract header lift cylinders. 7. Press REEL UP switch (B) on the GSL to raise the center-link until the hook is above the attachment pin on the header.
  • Page 77 OPERATION 13. Start engine. 14. Press HEADER UP switch (A) to raise header to maximum height. 15. If one end of the header does NOT fully raise, rephase the lift cylinders as follows: a. Press and hold HEADER UP switch (A) until both cylinders stop moving.
  • Page 78 OPERATION 19. Disengage safety prop by turning lever (A) downward to raise safety prop until lever locks into vertical position. NOTE: If safety prop will not disengage, raise header slightly. 20. Repeat for opposite side. Figure 3.67: Cylinder Safety Prop 21.

  • Page 79: Attaching Hydraulic And Electrical Components: M1240 Windrowers

    Your M1240 Self-Propelled Windrower may be configured with either quick coupler or hard plumb connections for the R85 Header. Refer to the following procedures for routing and connecting M1240 and R85 hydraulic and electrical components: • Routing Hydraulic Hoses and Electrical Components to M1240 Windrowers, page 63 •...

  • Page 80: Routing Hydraulic Hoses And Electrical Components To M1240 Windrowers

    OPERATION Routing Hydraulic Hoses and Electrical Components to M1240 Windrowers To route the R85 Header hydraulic hoses and electrical harness to the M1240 Windrower, follow these steps. 1. Move windrower left (cab-forward) platform (A) to the OPEN position. For instructions, refer to the windrower operator’s manual.

  • Page 81: Connecting Header Hydraulics Using Quick Couplers: M1240 Windrowers

    OPERATION Connecting Header Hydraulics Using Quick Couplers: M1240 Windrowers To connect the R85 Header hydraulic hoses and electrical cords to the M1240 Self-Propelled Windrower, follow these steps. 1. Use a clean rag to remove dirt and moisture from the couplers.

  • Page 82: Connecting Header Hydraulics Using Hard Plumbing: M1240 Windrowers

    Hard plumbing helps reduce the potential for leaks at the hydraulic connection sites and helps the header drive run more efficiently. To connect the R85 Header to the M1240 Windrower with hard plumbing, follow these steps. 1. Remove protective plugs (A) from ends of hydraulic hoses.
  • Page 83 OPERATION 2. Use a clean rag to remove dirt and moisture from the couplers on the windrower and remove protective plugs (A) from hard plumbing (B). NOTE: Hard plumbing should be factory-set to 30° to allow hoses to pass by the multicoupler. Figure 3.76: Protective Shipping Plugs on M1240 Hard Plumbing Connections (Parts Removed for Clarity)
  • Page 84 OPERATION 4. Move windrower platform (A) to the CLOSED position. For instructions, refer to the windrower operator’s manual. Figure 3.78: Windrower with Left Platform in Closed Position 214366 Revision A...

  • Page 85: Detaching The Header

    OPERATION 3.8 Detaching the Header 3.8.1 Detaching the Header: 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. CAUTION Check to be sure all bystanders have cleared the area.
  • Page 86 OPERATION 5. Remove hairpin (B) from clevis pin (A) and remove clevis pin from header support (C) on both sides of header. Figure 3.81: Header Supports 6. For windrowers with self-aligning center-link: Release center-link latch (A) before returning to the cab. Figure 3.82: Center-Link 7.
  • Page 87 OPERATION 11. For windrowers with self-aligning center-link: Use HEADER TILT cylinder switches (A) on GSL to release load on center-link cylinder. 12. Operate the link lift cylinder with the REEL UP switch (B) to disengage the center-link from the header. Figure 3.84: GSL 13.

  • Page 88: Detaching The Header: M205 Windrowers

    OPERATION 3.8.2 Detaching the Header: M205 Windrowers Refer to your windrower operator’s manual for the procedure to mechanically detach the header from a windrower. Refer to the following procedure to disconnect electrical and hydraulic systems: 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 89 OPERATION 6. Disconnect 12.7 mm (1/2 in.) hose (B) from windrower coupler and remove lynch pin (A). Figure 3.89: Hydraulic Connections 7. Open coupler lock (A). 8. Remove lock from couplers (B). Figure 3.90: Hydraulic Connections 9. Unscrew sleeves (A) on couplers and separate couplers.
  • Page 90 OPERATION 11. Attach coupler lock (B) to hoses and secure with lynch pin (A). 12. Proceed to Step 14, page Figure 3.92: Hydraulic Connections 13. Disconnect hoses from lines (A), (B), and (C) on windrower. Install caps and plugs on open lines. Figure 3.93: Hydraulic Connections 214366 Revision A...
  • Page 91 OPERATION 14. Remove hose support (A) from the windrower frame. 15. Route hoses (B) and electrical harness onto the header. Figure 3.94: Hose Bundle 16. Move maintenance platform (A) to the CLOSED position. For instructions, refer to the windrower operator’s manual. 17.

  • Page 92: Detaching The Header: M200 Windrowers

    OPERATION 3.8.3 Detaching the Header: M200 Windrowers Refer to your windrower operator’s manual for procedure to mechanically detach the header from a windrower. Refer to the following procedure to disconnect electrical and hydraulic systems: 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 93 OPERATION 7. Raise and unlock lever (A) and undo the three cinch straps (B). 8. Move hose bundle to store on header. Figure 3.98: Hose Bundle 9. At the header, disconnect electrical connector (D) by turning the collar counterclockwise and pulling connector to disengage.
  • Page 94 OPERATION 14. Move windrower platform (A) back to the CLOSED position. For instructions, refer to the windrower operator’s manual. 15. For instructions on mechanically detaching the header from the windrower, refer to the windrower operator's manual. Figure 3.101: Windrower Left Platform 214366 Revision A...

  • Page 95: Break-In Period

    OPERATION 3.9 Break-In Period After attaching the header to the windrower for the first time, operate the machine slowly for five minutes, watching and listening from the windrower seat for binding or interfering parts. NOTE: Until you become familiar with the sound and feel of your new header, be extra alert and attentive. CAUTION Before investigating an unusual sound or attempting to correct a problem, stop the engine, engage parking brake, and remove the key.

  • Page 96: Shutting Down The Windrower

    OPERATION 3.10 Shutting down the Windrower CAUTION Before leaving the windrower seat for any reason: 1. Park on level ground (if possible). 2. Lower the header fully. 3. Place ground speed control in N-DETENT. 4. Stop the engine and remove the key. 5.

  • Page 97: Transporting The Header

    OPERATION 3.11 Transporting the Header For information on transporting the header when attached to the windrower, refer to your windrower operator’s manual. IMPORTANT: For cab-forward road travel the windrower must have the lighting and marking bundle installed (MD #B5412). 214366 Revision A...

  • Page 98: Chapter 4: Operating The Header

    4 Operating the Header Your header will provide the best performance when it is properly adjusted to suit the crop and conditions. Correct operation reduces crop loss and increases productivity. As well, proper adjustments and timely maintenance will increase the length of service you receive from the machine. The variables listed below and detailed on the following pages will affect the performance of the header.

  • Page 99: Adjusting Float - M200 And M205 Windrowers

    OPERATING THE HEADER – M200 and M205 Windrowers, page 82 4.1.5 Removing and Restoring Float – M1240 Windrowers, or refer to page 4.1.2 Adjusting Float – M200 and M205 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 100: Checking Float - M1240 Windrower

    OPERATING THE HEADER 4.1.3 Checking Float – M1240 Windrower 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 101: Removing And Restoring Float - M1240 Windrowers

    OPERATING THE HEADER 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 4.4: HPT Run Screen 5. Turn scroll knob (A) to highlight left (B) or right (C) float and press knob (A) to activate selection.
  • Page 102 OPERATING THE HEADER 3. Press soft key 3 (A) to remove or restore the header float. NOTE: If the header float is active, the icon at soft key 3 will say REMOVE FLOAT; if header float has been removed, the icon will say RESTORE FLOAT.

  • Page 103: Roll Gap

    OPERATING THE HEADER 4.2 Roll Gap Steel rolls condition the crop by crimping and crushing the stem in several places. This allows moisture to release for quicker drying. The degree to which the crop is conditioned as it passes through the rolls is controlled by roll gap.

  • Page 104: Adjusting Roll Gap

    OPERATING THE HEADER 5. Inspect roll gap at both ends of the rolls. At factory setting, roll gap (B) should be 25.4 mm (1 in.). IMPORTANT: Roll timing is critical when the roll gap is decreased because the bars may contact each other if the timing is wrong.
  • Page 105 OPERATING THE HEADER 4. Loosen upper jam nut (B) on both sides of conditioner adjustment bolts. 5. To increase roll gap, turn lower nut (A) clockwise. 6. To decrease roll gap, turn lower nut (A) counterclockwise. 7. Measurement at (C) should be 35 mm (1.4 in.). This equates to 25.4 mm (1 in.) of roll gap.

  • Page 106: Roll Tension

    OPERATING THE HEADER 4.3 Roll Tension Roll tension (the force holding the rolls together) is factory set with a spring-type adjustable linkage. The roll tension factory setting is the spring fully tensioned. Heavy crops or tough forage tend to separate the rolls and require more tension to ensure material is sufficiently crimped.

  • Page 107: Roll Timing

    OPERATING THE HEADER 4.4 Roll Timing For proper conditioning, the rolls must be properly timed. Each steel bar on one of the rolls should be centered between two bars of the other roll. The factory setting should be suitable for most crop conditions. IMPORTANT: Roll timing is especially critical when roll gap is decreased because the bars can contact each other if the timing is wrong.

  • Page 108: Adjusting Roll Timing

    OPERATING THE HEADER 4.4.2 Adjusting Roll Timing Follow these steps to adjust the roll timing (if necessary): 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 109 OPERATING THE HEADER 5. Position gauge (MD #150572) (A) at left end of rolls, and manually turn the rolls to engage. The rolls will automatically adjust to the correct timing. This will provide for a roll gap of 11 mm (7/16 in.) and a roll timing setting of 4 mm (3/16 in.).

  • Page 110: Forming Shields

    OPERATING THE HEADER 4.5 Forming Shields WARNING Keep hands and feet away from discharge opening. Keep everyone several hundred feet away from your operation. Never direct the discharge toward anyone. Stones or other foreign objects can be ejected with force. The position of the forming shields controls the width and placement of the windrow.
  • Page 111 OPERATING THE HEADER 2. If side deflector attachment is too tight or too loose, tighten or loosen nut (A) as required. Figure 4.19: Forming Shield 214366 Revision A...

  • Page 112: Adjusting The Rear Deflector (Fluffer Shield)

    OPERATING THE HEADER 4.5.2 Adjusting the Rear Deflector (Fluffer Shield) 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 rear deflector (fluffer shield) slows the crop exiting the conditioner rolls, directs the flow downward, and fluffs the material.
  • Page 113 OPERATING THE HEADER 1. Remove lynch pin from pin (B) and remove pin from lever (C). 2. Move lever to middle hole in bracket and reinstall pin (B) through lever and bracket. 3. Secure with lynch pin. Figure 4.21: Swath Baffle Lever NOTE: Swath baffle position may need to be adjusted for proper pin engagement.

  • Page 114: Header Angle

    OPERATING THE HEADER 4.6 Header Angle Header (or cutterbar) angle can be varied from 0–8° below horizontal. Choose an angle that maximizes performance for your crop and field conditions. A flatter angle provides better clearance in stony conditions while a steeper angle provides better lifting action in down crops.

  • Page 115: Cutting Height

    OPERATING THE HEADER 4.7 Cutting Height Cutting height is determined by a combination of the angle of the cutterbar/header and the optional gauge roller or skid shoe settings if installed. Cutting height should be adjusted for optimum cutting performance without excessive mud build-up inside the header that can lead to poor crop flow and increased wear on cutting components.

  • Page 116: Adjusting The Skid Shoe Height

    OPERATING THE HEADER 4.7.2 Adjusting the Skid Shoe Height Optional adjustable skid shoes are available to provide different cutting heights. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key, and engage header safety props before going under machine for any reason. To adjust skid shoe height, follow these steps: 1.

  • Page 117: Disc Speed

    OPERATING THE HEADER 4.8 Disc Speed The disc header can be used to cut a variety of crops. For the best cutting results, a range of disc speeds is recommended for each type of crop and condition. Refer to table below. Table 4.2 Disc Speed Recommendations Condition Disc rpm...

  • Page 118: Ground Speed

    OPERATING THE HEADER 4.9 Ground Speed CAUTION Reduce speed when turning, crossing slopes, or when travelling over rough ground. 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. In tough cutting conditions, such as native grasses, the disc speed will need to be increased.

  • Page 119: Double Windrowing

    OPERATING THE HEADER 4.10 Double Windrowing If your windrower is equipped with the Double Windrow Attachment (DWA [A]), refer to the MacDon DWA Manual for operating and maintenance instructions. The manual is shipped with the DWA Kit. Figure 4.27: DWA...

  • Page 120: Tall Crop Feed Plates

    OPERATING THE HEADER 4.11 Tall Crop Feed Plates The tall crop feed plates (A) assist in feeding tall crops into the conditioner by aiding material flow from behind cage deflectors (B). The feed plates are designed for installation under the two cage deflectors.

  • Page 121: Installing Tall Crop Feed Plates Under Driven Deflector

    OPERATING THE HEADER Installing Tall Crop Feed Plates under Driven Deflector 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 122: Installing Tall Crop Feed Plates Under Driveline Deflector

    OPERATING THE HEADER Installing Tall Crop Feed Plates under Driveline Deflector 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 123: Removing Tall Crop Feed Plates

    OPERATING THE HEADER 4.11.2 Removing Tall Crop Feed Plates Follow these steps to remove the tall crop feed plates: 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 124: Removing Tall Crop Feed Plates From Under Driveline Deflector

    OPERATING THE HEADER Removing Tall Crop Feed Plates from under Driveline Deflector 1. Open cutterbar doors. Refer to 3.5 Cutterbar Doors, page 2. Remove the deflector. Refer to Removing the Driveline Deflector, page 151. 3. Remove feed plate (A). 4. Return feed plates to storage. Refer to 4.11.3 Returning Tall Crop Feed Plates to Storage, page 107.

  • Page 125: Tall Crop Divider Option

    OPERATING THE HEADER 4.12 Tall Crop Divider Option Tall crop dividers (one on each end of the header) assist in clean crop dividing and cutterbar entry in tall crops. Tall crop dividers are not adjustable, but they are removable. 4.12.1 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...

  • Page 126: Removing Tall Crop Divider

    OPERATING 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 4.40: Tall Crop Divider Installed 4.12.2 Removing Tall Crop Divider DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and...
  • Page 127 OPERATING THE HEADER 5. Reinstall two bolts and nuts at location shown (A). 6. Repeat Steps 4, page 109 5, page 110 at the other end of the header. 7. Close the cutterbar doors. Refer to 3.5 Cutterbar Doors, page Figure 4.42: Crop Divider Mounting Holes 214366 Revision A...

  • Page 128: Overshot Auger

    OPERATING THE HEADER 4.13 Overshot Auger The overshot auger is designed to feed the cut crop from the cutterbar into the conditioner rolls. The auger position has been factory set and should not normally require adjustment. However, if adjustment is required the vertical and fore-aft positions of the auger can be adjusted for crop conditions.
  • Page 129 OPERATING THE HEADER 5. Loosen jam nuts (A) to relieve tension on auger drive belts (B). 6. Loosen three jam nuts (C). 7. To adjust vertical position, loosen upper nuts on adjuster bolts (D). Hold lower nut and turn adjuster bolts (D) to set auger vertical position from bottom of pan.
  • Page 130 OPERATING THE HEADER 14. To tighten auger drive belts (C), adjust eye bolt (A) and secure with jam nut (B). Refer to Inspecting and Adjusting the Auger Drive Belts, page 166. Figure 4.47: Drive Belts 214366 Revision A...

  • Page 131: Stripper Bars

    OPERATING THE HEADER 4.14 Stripper Bars There are two adjustable stripper bars installed on the pan at both ends of the auger that minimize wrapping of material around the auger. The factory position should be satisfactory for most crops, but bars can be adjusted for specific conditions.
  • Page 132 OPERATING THE HEADER Figure 4.50: Right End 6. Position stripper bar (A) as close as possible to auger flighting without contacting it. 7. Repeat Steps 5, page 114 6, page 115 opposite side. 8. Manually rotate auger to check that auger does NOT contact stripper bars.
  • Page 133 OPERATING THE HEADER Figure 4.53: Right End 214366 Revision A...

  • Page 134: Haying

    OPERATING THE HEADER 4.15 Haying 4.15.1 Curing Curing crops quickly helps maintain the highest quality of crop material as 5% of protein is lost from hay for each day that it lays on the ground after cutting. Leaving the windrow as wide and fluffy as possible results in the quickest curing. Cured hay should be baled as soon as possible.

  • Page 135: Windrow Characteristics

    OPERATING THE HEADER 4.15.4 Windrow Characteristics Producing windrows with the recommended characteristics will achieve the greatest results. Refer to 4 Operating the Header, page 81 for instructions on adjusting the header. Table 4.4 Recommended Windrow Characteristics Characteristic Advantage Enables airflow through windrow, which is more important to the curing High and fluffy process than direct sunlight Consistent formation (not bunching)

  • Page 136: Unplugging The Header

    OPERATING THE HEADER 4.16 Unplugging the Header Follow these steps to remove plugged material from the header: DANGER To avoid bodily injury or death from unexpected startup of machine, always stop the engine and remove the key before removing plugged material from header. 1.

  • Page 138: Chapter 5: Maintenance And Servicing

    5 Maintenance and Servicing Use the following instructions as your first source of information for servicing the header. A parts catalog is located in a plastic case at the right end of the header. If more detailed maintenance and service information is required, contact your Dealer.

  • Page 139: Maintenance Requirements

    MAINTENANCE AND SERVICING 5.2 Maintenance Requirements In this manual, periodic maintenance requirements are organized by service intervals. For detailed instructions, refer to the specific headings in this section. Regular maintenance is the best insurance against early wear and breakdowns. Use the following schedule and recommendations to increase machine life.
  • Page 140 MAINTENANCE AND SERVICING ü ü Check S S Lubricate ▲ Change Action First 25 hours Check drive belt tension. Refer to Inspecting the Conditioner ü Drive Belt, page 159 Inspecting and Adjusting the Auger Drive Belts, page 166. Every 25 hours Lube roll universal joints.
  • Page 141 MAINTENANCE AND SERVICING ü ü C C h h e e c c k S S L L u u b b r r i i c c a a t t e e ▲ Change Action Check auger drive belt. ü...

  • Page 142: Preseason/Annual Service

    MAINTENANCE AND SERVICING 5.2.2 Preseason/Annual Service CAUTION • Review the operator’s manual to refresh your memory on safety and operating recommendations. • Review all safety signs and other decals on the header and note hazard areas. • Be sure all shields and guards are properly installed and secured. Never alter or remove safety equipment.

  • Page 143: Lubrication And Servicing

    MAINTENANCE AND SERVICING 5.2.4 Lubrication and Servicing WARNING To avoid personal injury, before servicing the header or opening drive covers, follow procedures in Preparation for Servicing, page 121. Log hours of operation and use the Maintenance Checklist provided to keep a record of scheduled maintenance. Refer to 5.2.1 Maintenance Schedule/Record, page 122.

  • Page 144: Greasing Procedure

    MAINTENANCE AND SERVICING 5.2.5 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 145 MAINTENANCE AND SERVICING Every 25 Hours C - Driveline Shaft 5 (2 Places) A - Driveline Universals (2 Places) B - Driveline Universals (2 Places) E - Driveline Shaft 5 D - Driveline Universals (2 Places) NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2) lithium base except where noted.
  • Page 146 MAINTENANCE AND SERVICING Every 50 Hours A - Roll Shaft Bearings (2 Places) B - Roll Shaft Bearings (2 Places) C - Optional Gauge Roll Bearings (2 Places Each) D - Auger Bearing (1 Place) E - Auger Bearing (1 Place) F - Belt Tensioner Pivot (1 Place) NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2)
  • Page 147 MAINTENANCE AND SERVICING Every 100 Hours or Annually A - Conditioner Gearbox Oil Level (Check with Top of Header Horizontal) B - Bevel Gearbox Oil Level (Check with Top of Header Horizontal) 214366 Revision A...
  • Page 148 MAINTENANCE AND SERVICING Every 250 Hours A - Drain and Refill Bevel Gearbox Lube 6 B - Drain and Refill Conditioner Gearbox Lube 6 C - Drain and Refill Cutterbar Lube 7 6. Refer to Changing the Bevel Gearbox Lubricant, page 158.

  • Page 149: Lubricating The Cutterbar

    MAINTENANCE AND SERVICING 5.2.7 Lubricating the Cutterbar The lubricant level in the cutterbar CANNOT be checked. If the cutterbar lubricant quantity is in doubt, do NOT add lubricant. Drain the cutterbar and refill with new clean lubricant. Draining the Cutterbar Lubricant IMPORTANT: Drain the cutterbar when the lubricant is warm.
  • Page 150 MAINTENANCE AND SERVICING Figure 5.4: Cutterbar Filler Plug Locations 7. Clean around either filler plug (A) and remove one plug with an 8 mm hex key. NOTE: Rotate disc to expose filler plug if necessary. 8. Place a suitably sized container under the cutterbar drain hole (A).

  • Page 151: Filling The Cutterbar Lubricant

    MAINTENANCE AND SERVICING Filling the Cutterbar Lubricant DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key, and engage header safety props before going under machine for any reason. 1. Park the machine on level ground. 2.
  • Page 152 MAINTENANCE AND SERVICING Figure 5.8: Cutterbar Filler Plug Locations 11. Clean around and remove filler plugs (A) and (B) with an 8 mm hex key. NOTE: Opening two fill plugs allows air to escape while adding oil to the cutterbar and prevents oil from blowing back through the fill hole.

  • Page 153: Rock Guards

    The guards should be replaced if severely damaged or worn. 6. Check for loose or missing fasteners and tighten or replace fastener if missing. 7. Contact your MacDon Dealer for replacement procedures. Figure 5.9: Rock Guards 214366 Revision A...

  • Page 154: Cutterbar Discs

    MAINTENANCE AND SERVICING 5.3 Cutterbar Discs Perform daily inspections to ensure that cutterbar discs have not suffered damage from rocks, or experienced excessive wear from abrasive working conditions. Cutterbar discs are interchangeable and can be moved to a spindle that rotates in the opposite direction as long as it is in usable condition and the blades are oriented to cut in the correct direction.

  • Page 155: Inspecting The Cutterbar Discs

    MAINTENANCE AND SERVICING 5.3.2 Inspecting the Cutterbar Discs Perform the following cutterbar disc inspection daily: 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 156: Installing A Cutterbar Disc

    MAINTENANCE AND SERVICING 5. Remove four bolts (A) on disc cover (B) and remove cover and disc (C). NOTE: If removing multiple discs, mark the position of each disc to assist in reinstallation. The blades on each disc are direction-specific. Refer to 5.3.1 Direction of Spindle Rotation, page 137.

  • Page 157: Cutterblades

    Since each blade has two cutting edges, they can be flipped over to extend the life of the blades. The blades are NOT repairable and must be replaced if damaged or worn. IMPORTANT: Always use MacDon factory replacement parts. Figure 5.15: Cutterblades 214366 Revision A...

  • Page 158: Inspecting Discblades

    MAINTENANCE AND SERVICING Inspecting Discblades DANGER To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. CAUTION Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades.

  • Page 159: Inspecting Cutterblade Hardware

    MAINTENANCE AND SERVICING IMPORTANT: The discblades have cutting edges on both sides so the blades can be turned over and reused. The twist in each blade determines the cutting direction. If you are unsure which direction the spindles rotate, refer to 5.3.1 Direction of Spindle Rotation, page 137.
  • Page 160 MAINTENANCE AND SERVICING Check blade attachment hardware each time blades are changed. Refer to Replacing the Cutterblades, page 144 hardware replacement procedure. Check bolts and replace bolt if: • Bolt has been removed and installed five times • Head (A) is worn flush with bearing surface of blade •...

  • Page 161: Replacing The Cutterblades

    MAINTENANCE AND SERVICING Check nuts and replace nut if: • Nut has been removed and installed five times • Worn height (A) is less than half original height (B) • Nut is cracked Figure 5.20: Cutterblade Nut Replacing the Cutterblades Follow these steps to replace the cutterblades: DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove...

  • Page 162: Accelerators

    MAINTENANCE AND SERVICING 8. Remove nut (A). 9. Remove shoulder bolt (B) and blade (C). 10. Install new or reversed blade (C) with shoulder bolt (B) onto disc. NOTE: Ensure shoulder bolt is fully engaged into blade before tightening nut. NOTE: Ensure blade is installed correctly to suit rotation of disc.

  • Page 163: Inspecting Accelerators

    MAINTENANCE AND SERVICING Inspecting Accelerators Follow these steps to inspect accelerators: 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 164: Replacing Accelerators

    MAINTENANCE AND SERVICING Replacing Accelerators Follow these steps to replace the accelerators: 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 165: Nut Shield

    MAINTENANCE AND SERVICING 5.3.7 Nut Shield If accelerators are not used, nut shields will be required to protect the cutterblade nuts. Nut shields (A) are mounted on each outboard disc. Nut shields are replaceable and should be inspected periodically for damage and loose or missing fasteners. Figure 5.27: Inspecting Nut Shield Inspecting Nut Shield DANGER...

  • Page 166: Replacing Nut Shield

    MAINTENANCE AND SERVICING Replacing Nut Shield 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. Raise the header fully. 2.

  • Page 167: Removing The Driven Deflector

    MAINTENANCE AND SERVICING 3. Open the cutterbar doors. Refer to 3.5 Cutterbar Doors, page 4. Check that deflectors (A) are not damaged or bent, also check for loose hardware. 5. Replace deflectors (A) if they are severely damaged or worn. Do NOT repair. Refer to: •...

  • Page 168: Installing The Driven Deflector

    MAINTENANCE AND SERVICING Installing the Driven Deflector Follow these steps to replace the driven rotary deflector: 1. Position new deflector (C) on spindle so that it clears accelerators (D). 2. Install cover (B) and secure with four bolts (A). 3. Tighten bolts. 4.

  • Page 169: Installing The Driveline Deflector

    MAINTENANCE AND SERVICING 8. Loosen four bolts (A) in the two plates (B) that hold upper driveline shield (C) in place. 9. Move plates (B) so that shield (C) can be lowered into deflector (D). 10. Remove deflector (D). Figure 5.34: Driveline Deflector Installing the Driveline Deflector Follow these steps to install the driveline deflector: 1.

  • Page 170: Disc Spindles

    MAINTENANCE AND SERVICING 6. Tighten bolts (A) on shield plates (B). 7. Remove block of wood (if used). 8. Manually rotate discs to check for interference of adjacent parts. 9. Close the cutterbar doors. Refer to 3.5 Cutterbar Doors, page WARNING Ensure cutterbar is completely clear of foreign objects.
  • Page 171 MAINTENANCE AND SERVICING 4. Remove cutter disc (A) from failed spindle. Refer to 5.3.3 Removing a Cutterbar Disc, page 138. Figure 5.38: Cutter Disc 5. Using a 34 mm socket wrench, remove nut (A) and washer (B) from spindle. Figure 5.39: Cutterbar Spindle Assembly (Short Spindle Shown) 6.
  • Page 172 10. Inspect flange (C) and spindle shaft (E) for damage. If seriously damaged, replace entire spindle assembly. Contact your MacDon Dealer. 11. Install new key (D) into gear (E) keyway as shown. 12. Align keyway in disc (C) with key in gear (E) and install disc (C) onto gear until sufficient threads are exposed to install washer (B) and nut (A).

  • Page 173: Cutterbar Doors

    MAINTENANCE AND SERVICING 5.3.10 Cutterbar Doors Inspecting Curtains Replace the curtains if they should become worn or damaged. Contact your Dealer for replacement instructions. Inspecting Door Latches: North American Header The cutterbar door latches should operate smoothly and remain engaged when the doors are open. The door latch should pivot on its hinge bolt and should engage the securing pin when the cutterbar doors are opened.

  • Page 174: Replacing Door Latches: Export Header

    MAINTENANCE AND SERVICING Replacing Door Latches: Export Header To replace cutterbar door latches, 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 175: Drive Systems

    MAINTENANCE AND SERVICING 5.4 Drive Systems 5.4.1 Bevel Gearbox The bevel gearbox (A), which transfers power from the hydraulic motor to the header drives, is located inside the drive compartment at the left end of the header. If repairs are required, the gearbox should be removed and serviced at your Dealer.

  • Page 176: Conditioner Drive Belt

    MAINTENANCE AND SERVICING 6. Place a suitablly sized container under drain plug (B). Refer to the inside back cover for gearbox capacity. 7. Remove plugs (A) and (B). 8. Allow sufficient time for lubricant to drain. 9. Disengage header safety props. Refer to 3.3 Engaging and Disengaging Header Safety Props, page 10.

  • Page 177: Replacing The Conditioner Drive Belt

    MAINTENANCE AND SERVICING 4. Inspect condition of belt (A). Replace if damaged or showing signs of cracking or separation. 5. Check that adjuster nut (B) is tight. 6. Check that end of slots (C) are aligned with plate (D). 7. If necessary, adjust tension as follows: a.
  • Page 178 MAINTENANCE AND SERVICING 5. Turn adjuster nut (A) counterclockwise until springs are loose and there is no tension on belt (B). Figure 5.51: Drive Belts (Left Side) 6. Remove conditioner drive belt (A). 7. Install new conditioner drive belt (A) onto pulleys ensuring it is in the pulley grooves.

  • Page 179: Conditioner Gearbox

    If repairs are required, the conditioner gearbox should be removed and serviced at your MacDon Dealer. The only regular servicing required is maintaining the lubricant level and changing the lubricant according to the intervals specified in this manual.
  • Page 180 MAINTENANCE AND SERVICING 5. Open the driveshield. Refer to 3.4 Driveshields, page Figure 5.55: Driveshield 6. Place a suitable container under drain plug (A). Refer to the inside back cover for conditioner gearbox lubricant capacity. 7. Remove plugs (A) and (B). 8.

  • Page 181: Header Drive Speed Sensor

    MAINTENANCE AND SERVICING 5.4.4 Header Drive Speed Sensor The header drive speed sensor monitors the rotational speed of the bevel gearbox pulley and sends a signal to the system monitor in the windrower cab to display disc speed. The sensor does not require regular maintenance; if it malfunctions or is damaged, it can be easily adjusted or replaced.

  • Page 182: Replacing The Header Drive Speed Sensor

    MAINTENANCE AND SERVICING Replacing the Header Drive Speed Sensor 1. Loosen bolts (A) and remove cover (B). Figure 5.60: Header Drive Cover 2. Cut and remove cable tie securing harness to bracket (C). 3. Unplug sensor wire from connector (A). 4.

  • Page 183: Auger Drive Belt

    MAINTENANCE AND SERVICING 5.4.5 Auger Drive Belt The auger drive belts are located inside the drive compartment at the lower left end of the header. Check the belt tension and inspect for damage or wear every 100 hours or annually, preferably before the start of the cutting season.

  • Page 184: Replacing The Auger Drive Belts

    MAINTENANCE AND SERVICING 7. To check the belt tension, spring (A) length should measure 262 mm (10.3 in.) (B). If necessary, adjust belt tension as follows: a. Loosen jam nut (C). b. Adjust eye bolt with adjuster bolt (D) until spring length (B) is achieved.
  • Page 185 9. Check alignment of belts on pulleys. Belts must not overhang the edge of idler pulley (B). Contact your MacDon Dealer if pulleys need realigning. Figure 5.68: Auger Drive Belts 10. Tension the belts (B) with adjuster nuts (A). Refer to Inspecting and Adjusting the Auger Drive Belts, page 166.

  • Page 186: Installing Sealed Bearings

    MAINTENANCE AND SERVICING 11. Reinstall cover (B) with bolts (A). 12. Close the driveshield. Refer to 3.4 Driveshields, page 13. Adjust the tension of new belts after a short break-in period (about 5 hours). Figure 5.70: Drive Cover – SP 5.4.6 Installing Sealed Bearings Follow these steps to install sealed bearings: 1.

  • Page 187: Hydraulics

    MAINTENANCE AND SERVICING 5.5 Hydraulics Refer to your windrower operator’s manual for hydraulic system maintenance procedures. 5.5.1 Hydraulic Motor The hydraulic motor does not require regular maintenance or servicing. If repairs are required, it should be serviced by your Dealer. Figure 5.72: Hydraulic Motor Removing the Hydraulic Motor Follow these steps to remove the hydraulic motor:...

  • Page 188: Installing The Hydraulic Motor

    MAINTENANCE AND SERVICING 7. Cover gearbox opening (A) with a rag or plastic. Figure 5.74: Hydraulic Motor Removed Installing the Hydraulic Motor Follow these steps to install the hydraulic motor: 1. Remove covering from gearbox opening (A). 2. Attach a sling to the motor with the opposite end to a lifting device.

  • Page 189: Hydraulic Hoses And Lines

    MAINTENANCE AND SERVICING 5.5.2 Hydraulic Hoses and Lines Check hydraulic hoses and lines daily for signs of leaks. WARNING • Avoid high-pressure fluids. Escaping fluid can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes and nozzles which eject fluids under high pressure.

  • Page 190: Electrical System

    MAINTENANCE AND SERVICING 5.6 Electrical System Use electrical tape and wire clips as required to prevent wires from dragging or rubbing. Keep lights clean and replace defective bulbs. 5.6.1 Hazard Lights Replacing Amber Hazard/Signal Bulb 1. Remove two Phillips screws (A) from fixture, and remove the plastic lens.

  • Page 192: Chapter 6: Options And Attachments

    6 Options and Attachments 6.1 Options and Attachments: Kits The following kits are available through your MacDon Dealer. The Dealer will require the “B” number for pricing and availability. 6.1.1 Adjustable Skid Shoe Kit The skid shoe kit installs at either end of the cutterbar. The shoes can be adjusted for varying cutting height. The kit includes two skid shoe assemblies, attachment hardware, and installation instructions.

  • Page 193: Double Windrow Attachment (Dwa)

    OPTIONS AND ATTACHMENTS 6.1.3 Double Windrow Attachment (DWA) Allows headers to lay a double windrow when installed on a self-propelled windrower. The kit includes a draper deck, linkage assembly, hydraulics, and installation instructions. M205 MD #C1987 consists of: • MD #B4655 Deck •...

  • Page 194: Tall Crop Divider Kit

    OPTIONS AND ATTACHMENTS 6.1.6 Tall Crop Divider Kit The tall crop dividers attach to the ends of the header for clean crop dividing and cutterbar entry in tall crops. The kit includes left and right dividers and attachment hardware. MD #B5509 Instruction part number: MD #169485 Figure 6.4: MD #B5509 6.1.7 Tall Crop Feed Plate Kit...

  • Page 195: Solid Drums And Shields Kit

    OPTIONS AND ATTACHMENTS 6.1.8 Solid Drums and Shields Kit The Solid Drums and Shields kit reduces crop wrapping of the vertical shaft and improves crop feeding into the conditioners. MD #268223 Instruction part number: MD #214191 Figure 6.6: MD #268223 214366 Revision A...

  • Page 196: Chapter 7: Troubleshooting

    7 Troubleshooting 7.1 Header Performance Symptom Problem Solution Refer to Dull, bent, or badly Replacing the Cutterblades, Cutterbar plugging Replace blades. worn blades page 144 5.4.5 Auger Drive Belt, page 166 Auger drive belt Adjust tension or change Cutterbar plugging 5.4.2 Conditioner Drive Belt, slipping belts.
  • Page 197 TROUBLESHOOTING Symptom Problem Solution Refer to Ground speed too 4.9 Ground Speed, page 101 Conditioner rolls plugging Reduce ground speed. fast Roll gap too large 4.2.2 Adjusting Roll Gap, page Conditioner rolls plugging Decrease roll gap. for proper feeding 4.2.2 Adjusting Roll Gap, page Roll gap too small Conditioner rolls plugging in thick stemmed...
  • Page 198 TROUBLESHOOTING Symptom Problem Solution Refer to Replacing the Cutterblades, Not cutting short enough in Broken, bent, or Replace blades or turn page 144 down crop dull blades blades over. Adjust header angle to Not cutting short enough in Cutting height too lower cutting height if field 4.6 Header Angle, page 97 down crop...

  • Page 199: Mechanical Problems

    Mud on cutterbar cutterbar: do not allow mud to dry on cutterbar. Frequent blade damage Spindle bearing failure Replace spindle bearing. See MacDon Dealer Material wrapped around Remove disc and remove 5.3 Cutterbar Discs, page Frequent blade damage spindle material.
  • Page 200 Breakage of conditioner Belt pulleys and idlers Align pulleys and idler. See MacDon Dealer drive belt misaligned Remove mud from Discs don’t turn when — Mud on cutterbar cutterbar: do not allow engaging header mud to dry on cutterbar.

  • Page 202: Chapter 8: Reference

    8 Reference 8.1 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 203 REFERENCE Table 8.2 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 8.2: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...

  • Page 204: Metric Bolt Specifications

    REFERENCE Table 8.4 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 8.4: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
  • Page 205 REFERENCE Table 8.6 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 8.6: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...

  • Page 206: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE Table 8.8 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 8.8: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...

  • Page 207: Flare-Type Hydraulic Fittings

    REFERENCE 8.1.4 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 208: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)

    REFERENCE 8.1.5 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 209 REFERENCE Table 8.11 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 210: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)

    REFERENCE 8.1.6 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 211: O-Ring Face Seal (Orfs) Hydraulic Fittings

    REFERENCE 8.1.7 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 8.14: Hydraulic Fitting 2. Apply hydraulic system oil to O-ring (B). 3.

  • Page 212: Tapered Pipe Thread Fittings

    REFERENCE Table 8.13 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 8.1.8 Tapered Pipe Thread Fittings Assemble pipe fittings as follows: 1.

  • Page 213: Conversion Chart

    REFERENCE 8.2 Conversion Chart Table 8.15 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 214: Index

    Index cutterbar doors..........33, 156 adjusting ............156 accelerators ..........145–146 closing replacing ............147 export headers ..........37 North American headers ........35 definitions............19 inspecting latches export headers ..........156 definitions............19 latch brackets ASTM replacing ............. 157 definitions............19 latches ............156 attaching replacing .............
  • Page 215 INDEX spindle keys adjusting ............95 replacing ............. 153 spindles............153 doors, See cutterbar doors double windrowing..........102 gauge rollers ............176 drive systems............. 158 gearbox speed sensors........164 auger drive belts ..........166 adjusting ............164 inspect/adjust ..........166 replacing ............165 replacing .............
  • Page 216 INDEX hydraulic motors, See motors hydraulics M1240 windrowers fittings attaching header ..........57 flare-type............. 190 detaching header ..........68 O-ring boss (ORB) adjustable ....... 191 M200 windrowers O-ring boss (ORB) non-adjustable ....193 attaching header ..........44 O-ring face seal (ORFS)....... 194 detaching header ..........75 tapered pipe thread fittings ......
  • Page 217 INDEX gauge roller ............ 176 general safety .............3 hydraulic drive - 16-foot for M200 ..... 176 header safety props ..........28 solid drums and shields ........178 hydraulic safety...........6 tall crop divider..........177 maintenance and servicing ........5 tall crop feed plate........... 177 operational safety..........26 preparing for service........
  • Page 218 INDEX torque angles definitions............19 torque specifications........... 185 flare-type hydraulic fittings ....... 190 metric bolt specifications........187 bolting into cast aluminum ......189 O-ring boss (ORB) hydraulic fittings (adjustable)........... 191 O-ring boss (ORB) hydraulic fittings (non- adjustable)............ 193 O-ring face seal (ORFS) fittings......194 SAE bolt torque specifications......
  • Page 220 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.

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