Page 1 R80 Rotary Disc Pull-Type Windrower OPERATOR’S MANUAL Model Year 2010 Part #169053 $15...
Page 2 This Manual contains instructions for “SAFETY”, “OPERATION”, and “MAINTENANCE/SERVICE” for your new MacDon Model R80 Rotary Disc Pull-Type Mower Conditioner. R80 PULL-TYPE ROTARY DISC MOWER CONDITIONER...
Page 3: Introduction
This manual describes the operating and maintenance procedures for the MacDon Model R80 Pull-Type Rotary Disc Mower Conditioner. Your new MacDon rotary disc mower conditioner 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 ................................5 SAFETY ALERT SYMBOL ........................5 SIGNAL WORDS............................5 SAFETY SIGNS............................5 2.3.1 Safety Sign Installation ......................... 5 2.3.2 Safety Sign Locations ........................... 6 GENERAL SAFETY..........................10 ACCRONYMS AND ABBREVIATIONS ......................11 COMPONENT IDENTIFICATION ........................
Page 5 TABLE OF CONTENTS 6.15.5 Driving On Windrow ..........................51 6.15.6 Raking And Tedding ........................... 51 6.15.7 Chemical Drying Agents ........................51 6.16 STORAGE .............................. 51 MAINTENANCE/SERVICE ..........................52 PREPARATION FOR SERVICING ......................52 RECOMMENDED SAFETY PROCEDURES ..................52 MAINTENANCE SPECIFICATIONS ...................... 53 7.3.1 Recommended Torques ........................
Page 6 TABLE OF CONTENTS MOWER PERFORMANCE........................114 MECHANICAL ............................116 OPTIONS AND ATTACHMENTS ......................... 118 GAUGE ROLLER KIT........................... 118 SKID SHOE KIT............................ 118 SKID PLATE LIFT KIT .......................... 118 TALL CROP DIVIDER KIT........................118 CUTTERBAR REPAIR TOOL KIT ......................118 HYDRAULIC CENTER LINK KIT......................118 PRESSURE GAUGE KIT ........................
Page 7: Safety
SAFETY 2 SAFETY 2.2 SIGNAL WORDS Note the use of the signal words DANGER, 2.1 SAFETY ALERT SYMBOL WARNING, CAUTION with safety messages. The appropriate signal word for each message has been selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
Page 8: Safety Sign Locations
SAFETY 2.3.2 Safety Sign Locations (BOTH SIDES) #115100 #148829 (BOTH SIDES) #32738 ON MANUAL CASE #184390 #134070 #170281 Form # 169053 Model Year - 2010...
Page 9 SAFETY Safety Sign Locations (cont’d) #115148 #109843 BOTH SIDES #171029 #44944 Form # 169053 Model Year - 2010...
Page 10 SAFETY Safety Sign Locations (cont’d) #30316 #36651 #142909 Form # 169053 Model Year - 2010...
Page 11 SAFETY Safety Sign Locations (cont’d) #142908 #44944 #142912 Form # 169053 Model Year - 2010...
Page 12: General Safety
SAFETY • 2.4 GENERAL SAFETY Provide a first-aid kit for use in case of emergencies. CAUTION following general farm safety precautions that should part 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 13: Accronyms And Abbreviations
GENERAL 3 ACCRONYMS AND ABBREVIATIONS TERM DEFINITION American Petroleum Institute Articulating Power Tongue 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 lbf·ft or ft·lbf pound feet or foot pounds lbf·in or in·lbf...
Page 14: Component Identification
GENERAL 4 COMPONENT IDENTIFICATION STEERING MANUAL CASE CENTER LINK DRIVE MOTOR CARRIER FRAME CYLINDER FRONT CURTAIN HEADER ARTICULATING POWER TONGUE (APT) 13 FT MODEL DOOR BAFFLE CONTROL TAIL-LIGHT FLOAT SPRING HAZARD LIGHT CUTTERBAR DRIVE SHIELD LIFT CYLINDER SIDE DEFLECTOR FLUFFER LOCK VALVE Form # 169053 Model Year - 2010...
Page 15 GENERAL STEERING MANUAL CASE CENTER LINK DRIVE MOTOR CARRIER FRAME HAZARD LIGHT CYLINDER FRONT CURTAIN HEADER ARTICULATING POWER TONGUE 16 FT MODEL DOOR BAFFLE CONTROL HAZARD LIGHT TAIL-LIGHT FLOAT SPRING CUTTERBAR DRIVE SHIELD GAUGE ROLLER LIFT CYLINDER SIDE DEFLECTOR FLUFFER LOCK VALVE Form # 169053 Model Year - 2010...
Page 16 GENERAL ARTICULATING POWER TONGUE (APT) STEERING CYLINDER LOCKOUT VALVE CONTROL HOSES DRIVELINE PUMP AND GEARBOX SAFETY CHAIN DRAWBAR HITCH JACK 3-POINT HITCH YOKE TOWING ADAPTER 13 & 16 FT MODELS Form # 169053 Model Year - 2010...
Page 17: Specifications
SPECIFICATIONS 5 SPECIFICATIONS HEADER MODEL R80 – 13 FT R80 – 16 FT FRAME & STRUCTURE Width 13 ft-0 in. (3952 mm) 16 ft-3 in. (4957 mm) Weight (estimated) 6200 lb (2818 kg) 7130 lb (3240 kg) Carrier Pull-Type Lighting...
Page 18 SPECIFICATIONS HEADER MODEL R80 – 13 FT R80 – 16 FT GROUND SPEED Recommended Cutting 8-11 mph (13-18 km/h) Recommended Transport 20 mph (30 km/h) TRACTOR REQUIREMENTS PTO Power - Minimum 120 hp (90 kW) 150 hp (112 kW) Pressure 2000 psi (13.71 MPa)
Page 19: Operation
OPERATION 6.2 OPERATIONAL SAFETY 6 OPERATION Follow these safety precautions: 6.1 OWNER/OPERATOR CAUTION RESPONSIBILITIES • Follow safety operational CAUTION instructions given your tractor Operator's Manual. If you do not have a • It is your responsibility to read and tractor manual, get one from your dealer understand this manual...
Page 20 OPERATION • 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 from either end with force.
Page 21: Tractor Setup
OPERATION 6.3 TRACTOR SETUP 6.3.3 Drawbar Hitch Set-Up CAUTION 6.3.1 Tractor Requirements MINIMUM MIN POWER MINIMUM DRAWBAR HYDRAULICS Shut off tractor, engage parking brake and MODEL HP (kW) CAPACITY psi (MPa) remove key before working around hitch. 13 FT 120 (90) As per ASAE 2000 (13.7) a.
Page 22: Point Hitch (Cat. Ii, Iii, Or Iiin) Set-Up
OPERATION 6.3.4 3 Point Hitch (Cat. II, III, or IIIN) Set- Secure pin with clevis pin (F), washers, and cotter pin. a. Attach the 3 point hitch yoke (K) to the APT with pin (L). The installation is similar to that described in the previous section.
Page 23 OPERATION NOTE Bushings (P) on pins can be removed to suit hole size in tractor hitch arms. d. Assemble PTO driveline male half (Q) onto PTO shaft (R) on APT. Push male half so that PTO shaft is at its fully compressed length. e.
Page 24: Mower Conditioner/ Tractor Hook-Up
OPERATION 6.4 MOWER CONDITIONER/ TRACTOR HOOK-UP 6.4.1 Drawbar Hook-Up CAUTION Shut off tractor, engage parking brake and remove key before working around hitch. e. Attach driveline (E) to tractor PTO shaft as follows: 1. Position driveline onto tractor PTO shaft (F). 1.
Page 25: Point Hitch (Cat. Ii, Iii, Or Iiin) Hook-Up
Install anti-sway bars on tractor hitch to stabilize lateral movement of hitch arms (A). Refer to your tractor operator’s manual. g. Position driveshaft (H) onto tractor PTO shaft. R80 WINDROWER TRACTOR AXLE Driveline should be approximately level. h. Pull back collar on driveshaft and push driveshaft until it locks.
Page 26 OPERATION CAUTION The downstop chains limit the downward travel of the 3-point hitch lifting arms to prevent damaging the PTO driveline on the mower-conditioner. Ensure chains attached when operating mower- conditioner. k. Adjust chain length as required by relocating end link at tractor end of chain as follows: m.
Page 27: Hydraulic Connections
Older model tractors will have Pin #4 (F) energized as an accessory circuit. a. Ensure hoses are routed through guide (E) to R80 mower conditioner uses this pin provide proper hose arc as shown. position (G) for brake lights. Check that...
Page 28: Mower Conditioner/ Tractor Unhook
OPERATION 6.5 MOWER CONDITIONER/ TRACTOR UNHOOK 6.5.1 Drawbar Unhook CAUTION To prevent accidental movement of tractor, shut off engine, engage parking brake, and remove key. To maintain stability, always lower the machine completely. Block mower conditioner wheels before detaching from tractor.
Page 29: 3-Point Hitch Unhook
OPERATION 6.5.2 3-Point Hitch Unhook a. Park machine on flat level surface. b. Lower header onto blocks or leave header raised. Engage lift cylinder lock-out valves if leaving in raised position. c. If necessary, raise 3-point hitch arms to release tension on downstop chains.
Page 30 OPERATION k. Lower jack to raise APT and take weight off hitch arms. Remove lynch pins (G) and swing hitch arms (H) clear of APT. m. Slowly drive tractor away from mower conditioner. h. Pull pin (C) securing jack (D) and move to working position at front of APT.
Page 31: Break-In Period
OPERATION 6.6 BREAK-IN PERIOD 6.8 DAILY START-UP CHECK a. After attaching mower conditioner to tractor for Do the following each day before start-up: the first time, operate the machine slowly for 5 minutes, watching and listening FROM THE CAUTION TRACTOR SEAT for binding or interfering parts. NOTE •...
Page 32: Shutdown Procedure
OPERATION 6.9 SHUTDOWN PROCEDURE CAUTION Before leaving the tractor seat for any reason: • Park on level ground if possible. • Lower the mower conditioner fully. • Place all controls in NEUTRAL or PARK. • Disengage PTO. • Engage the park brake. •...
Page 33: Steering
OPERATION The control (A) is operated momentarily for 6.11 STEERING steering and must be returned to OFF or NEUTRAL position as soon as the mower conditioner reaches the desired path of travel. 6.11.1 Right Side Operation IMPORTANT The valve on the APT must be in the working or open position (handle in line with APT) for the steering system to be Move steering lever forward to achieve desired...
Page 34: Avoiding Obstacles
OPERATION c. As the tractor passes the corner, steer it sharply 6.11.3 Avoiding Obstacles back towards the uncut crop, taking care that the inside tractor tire does not contact the APT. d. Guide the tractor to straddle the last cut windrow.
Page 35: Degree Turn
OPERATION IMPORTANT When turning, take care that the inside 6.11.5 180 Degree Turn tractor tire does not contact APT of mower NOTE conditioner. When cutting back and forth on one side of the field, approximately 50 ft. (15 m) is d.
Page 36: Transporting Mower Conditioner
(A), store driveline (B) on hook, and remove forward half of driveline. Store The R80 Windrower can be transported on forward half in cab for transport. public roads by towing with a tractor or a truck. Proceed to 6.12.1 Transporting With A Tractor.
Page 37 OPERATION d. Position towing adapter (C) on APT and secure with pins (D). e. Attach mower conditioner to truck. Remove jack from working position and store on APT. Secure with pin. g. Wrap safety chain around APT and attach to truck frame (E).
Page 38: Preparing Windrower For Transport
OPERATION e. If steering cylinder is not fully charged, install 6.12.3 Preparing Windrower for Transport temporary transport lock follows: Otherwise, proceed to step f. a. Charge the steering circuit as follows: 1. Connect the two APT steering cylinder hoses to a tractor hydraulic circuit. 2.
Page 39: Flatbed
OPERATION 6.12.4 Flatbed CAUTION following procedure when transporting the mower conditioner on a flatbed trailer. 6.12.4.1 Loading d. Remove pin (C) attaching steering cylinder (D) at frame and swing cylinder under APT. Store pin in barrel end of cylinder. a. Lower the header to the ground and engage lift cylinder lock-out valves (A).
Page 40 OPERATION Locate two lifting slings (E) around APT and frame approximately as shown and attach to fork lift with chains. NOTE Adjust position of slings so that mower conditioner is lifted evenly. CAUTION Attach a chain to front of APT and other end to a fork lift or equivalent.
Page 41 OPERATION Slowly drive to flatbed and raise mower 6.12.4.2 Unloading conditioner. a. Remove tie downs. b. Approach mower conditioner from backside with forklift. m. Lower mower conditioner onto flatbed. Blocking is not required. Remove slings from mower conditioner. c. Locate two lifting slings (A) around APT and frame approximately as shown and attach to fork lift with chains.
Page 42 OPERATION d. Lift mower conditioner off flatbed and back away slowly. e. Lower mower conditioner to slightly above ground. Attach a chain to front of APT and other end to a fork lift or equivalent. IMPORTANT Ensure hoses on carrier frame are not pinched when APT is moved to working position.
Page 43: Header Operation
OPERATION 6.13 HEADER OPERATION Satisfactory operation of the mower conditioner situations requires making proper adjustments to suit various crops and conditions. Correct operation reduces crop loss and allows cutting more acres. well, proper adjustments timely maintenance will increase the length of service you receive from the machine.
Page 44: Header Angle
OPERATION 6.13.2 Header Angle 6.13.1.2 Skid Shoe Height Adjustment – 16 Ft Header (or cutterbar) angle can be varied from 0 DANGER to 5° below horizontal with the mechanical center link and 0-8° below horizontal with the hydraulic center link. Choose an angle that To avoid bodily injury or death from maximizes performance for your crop and field unexpected start-up or fall of raised...
Page 45: Header Flotation
OPERATION c. Engage lift cylinder lock-out valves. 6.13.2.2 Hydraulic Adjustment (if equipped) The header angle can be adjusted from the tractor without shutting down mower conditioner. GREEN ZONE RED ZONE d. Back jam nut (A) away from spring. a. To decrease (flatten) header angle, operate e.
Page 46: Roll Gap And Timing
OPERATION 6.13.4 Roll Gap and Timing 6.13.4.1 Roll Gap Adjustment Steel rolls "condition" the crop by crimping and DANGER crushing the stem in several places. This allows moisture release for quicker drying. The degree Stop engine and remove key from ignition to which the crop is conditioned as it passes before leaving operator's seat for any through the rolls is controlled by roll gap.
Page 47 OPERATION 6.13.4.2 Roll Timing For proper conditioning, the rolls must be properly timed with each steel bar on one roll centered between two bars of the other roll as shown. The factory setting should be suitable for most crop conditions. DANGER Stop engine and remove key from ignition before leaving operator's seat for any...
Page 48: Roll Tension
OPERATION e. If required, adjust roll timing as follows: 6.13.5 Roll Tension The roll tension (the force holding the rolls together) is factory set and is adjustable. required, adjust as follows: 1. Open LH drive shield. a. Open LH and RH drive shields. 2.
Page 49: Forming Shields
OPERATION 6.13.6 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 50 OPERATION 6.13.6.3 Baffle 6.13.6.2 Rear Deflector (Fluffer Shield) The baffle (E) determines the width and height of the windrow. It is located immediately behind and above the conditioning rolls, and can be positioned to direct the crop flow from the The rear deflector (C) slows the crop exiting the conditioner downward to form a wide swath.
Page 51: Ground Speed
OPERATION 6.13.7 Ground Speed CAUTION Reduce speed when turning, crossing slopes, or when travelling over rough ground. a. Operate the PTO at rated speed. b. Choose a ground speed that allows the cutterbar and conditioner to cut the crop smoothly and evenly.
Page 52: Unplugging The Mower Conditioner
OPERATION 6.15 HAYING TIPS 6.14 UNPLUGGING THE MOWER CONDITIONER 6.15.1 Curing a. A quick cure will maintain top quality because: WARNING • 5% of the protein is lost for each day hay lies on the ground, Stop tractor engine and remove key before •...
Page 53: Windrow Characteristics
OPERATION 6.15.4 Windrow Characteristics 6.16 STORAGE It is recommended that a windrow with the Do the following at the end of each operating following characteristics be produced. Refer to season: Section 6.13 Header Operation for instructions a. Clean the mower conditioner thoroughly. on adjusting the mower conditioner.
Page 54: Maintenance/Service
MAINTENANCE/SERVICE • Use adequate light for the job at hand. • 7 MAINTENANCE/SERVICE Replace all shields removed or opened for service. The following instructions are provided to assist • Use only service and repair parts made the operator for servicing the mower conditioner. approved equipment Detailed maintenance and service information...
Page 55: Maintenance Specifications
MAINTENANCE/SERVICE 7.3 MAINTENANCE SPECIFICATIONS 7.3.1.2 Metric Bolts NC BOLT TORQUE* BOLT 7.3.1 Recommended Torques 10.9 DIA. • Tighten all bolts to the torques specified in "A" lbf·ft N·m lbf·ft N·m chart unless otherwise noted throughout this manual. • Check tightness of bolts periodically, using bolt torque chart as a guide.
Page 56 MAINTENANCE/SERVICE 7.3.1.3 Flare-Type Hydraulic Fittings 7.3.1.4 O-ring Type Hydraulic Fittings a. Check flare and flare seat for defects that might FITTING LOCKNUT WASHER FLARE O-RING GROOVE SEAT BODY FLARESEAT cause leakage. b. Align tube with fitting before tightening. a. Inspect O-ring and seat for dirt or obvious c.
Page 57: 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 only failure of cutterbar components may occur if clean lubricants are used. if overfilled. • clean containers handle lubricants.
Page 58: 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 59: Lift Cylinder Lock-0Ut Valves
MAINTENANCE/SERVICE Return to normal operation as follows: 7.4 LIFT CYLINDER LOCK-0UT VALVES WARNING To avoid bodily injury or death from fall of raised machine, always lock-out lift cylinders before going under mower conditioner for any reason. Lockout the lift cylinders as follows: a.
Page 60: Cutterbar Doors
MAINTENANCE/SERVICE 7.6 CUTTERBAR DOORS 7.7 LUBRICATING THE WINDROWER CAUTION WARNING • To avoid personal injury, before servicing Do not operate the machine without all windrower or opening drive covers, follow cutterbar doors down, curtains procedures in Section 7.1, Preparation for installed and in good condition.
Page 61: 13 Ft Header
MAINTENANCE/SERVICE I. 13 FT HEADER High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium Base ROLL SHAFT BEARINGS (3 PLCS) 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY DRIVELINE UNIVERSALS & SHAFT (3 PLCS) Form # 169053 Model Year - 2010...
Page 62 MAINTENANCE/SERVICE 13 FT HEADER (cont’d) 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. ROLL SHAFT BEARINGS (3 PLCS) GEARBOX OIL LEVEL DRIVELINE UNIVERSALS (2 PLCS) 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY BELT TENSIONER PIVOT (1 PLC)
Page 63: 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 64 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 65: Carrier Frame
MAINTENANCE/SERVICE III. CARRIER FRAME High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium Base TONGUE PIVOT & STEERING CYLINDER WHEEL BEARING – BOTH WHEELS LIFT LINK 1PLC – BOTH SIDES CYLINDER PIVOT 1 PLC Form # 169053 Model Year - 2010...
Page 66: Driveline
MAINTENANCE/SERVICE IV. DRIVELINE High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).Lithium Base APT SWIVEL 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY APT DRIVELINE Form # 169053 Model Year - 2010...
Page 67: Cutterbar
MAINTENANCE/SERVICE 7.8 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 fall...
Page 68 MAINTENANCE/SERVICE 7.8.1.2 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. DANGER To avoid bodily injury or death from unexpected start-up fall raised machine;...
Page 69: Cutter Bar Lubrication
MAINTENANCE/SERVICE e. Place a suitably sized container under the 7.8.2 Cutter Bar Lubrication cutterbar drain hole and a block under each end of the header. The oil level in the cutterbar cannot be checked. NOTE If in doubt as to the quantity of oil in the The block under the LH end of the header cutterbar, do not add oil.
Page 70: Disc Maintenance
MAINTENANCE/SERVICE 7.8.2.2 Filling 7.8.3 Disc Maintenance DANGER To avoid bodily injury or death from unexpected start-up fall raised machine; stop engine, remove key and engage lift cylinder lock-out valves before going under machine for any reason. a. Start engine and raise header. Stop engine and engage lift cylinder lock-out valves.
Page 71 MAINTENANCE/SERVICE b. Place a block of wood between two discs to prevent disc rotation while loosening blade bolts. c. Remove four bolts (A) on disc cover (B) and remove cover and disc (C). Clean spindle (G). d. If end disc is being removed; 7.8.3.2 Disc Installation DANGER...
Page 72 MAINTENANCE/SERVICE d. If installing end disc; 1. Position new disc (F) on spindle ensuring it is 90 degrees to adjacent discs. 2. Install deflector (E) and secure with four bolts (D). 3. Tighten bolts to 92 ft·lbf (125 N·m). e. If driveline disc is being installed; 1.
Page 73: 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 HOLE...
Page 74 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 fall...
Page 75 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 76: Accelerators
MAINTENANCE/SERVICE 7.8.5.2 Installation 7.8.5 Accelerators a. Locate accelerator (C) on disc onto existing cutter blade bolt and install nut (B). 7.8.5.1 Removal NOTE Accelerators are handed for clockwise and DANGER counterclockwise operation. Verify the direction disc before installing Stop engine and remove key from ignition accelerators.
Page 77: Hourglass Deflectors
MAINTENANCE/SERVICE 7.8.6 Hourglass Deflectors 7.8.6.1 Driveline Deflector – 13 & 16 Ft a. Remove driveline deflector (A) as follows: Check daily that hourglass deflectors are not damaged or bent by rocks. The deflectors are not repairable and must be replaced if severely damaged or worn.
Page 78 MAINTENANCE/SERVICE b. Install driveline deflector as follows: WARNING CAUTION Ensure cutterbar is completely clear of foreign objects. These objects can be Cutter blades have two cutting edges. ejected with considerable force when the Exercise caution when working around the machine is started and may result in serious blades.
Page 79 MAINTENANCE/SERVICE Suspended Deflector (D) 7.8.6.3 Driven and Suspended Deflectors - 16 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 80: Tall Crop Feed Plates
MAINTENANCE/SERVICE c. Open RH side drive compartment shield. 7.8.7 Tall Crop Feed Plates d. Remove nuts (A) securing feed plates to side of compartment and remove plates. The tall crop feed plates assist the feeding of tall crops into the conditioner by encouraging CAUTION material flow...
Page 81 MAINTENANCE/SERVICE LEADING EDGE LEADING EDGE COUNTERCLOCKWISE ROTATION CLOCKWISE ROTATION RH INBOARD DISC LH INBOARD DISC g. Locate feed pate (D) on the disc ensuring that NOTE hole in feed plate registers on disc. Position Older type feed plates may require plate as shown and align holes.
Page 82: Header Drive
MAINTENANCE/SERVICE 7.9.2 Bevel Gearbox 7.9 HEADER DRIVE 7.9.1 Pump Gearbox 7.9.1.1 Checking Oil Level a. Park mower conditioner on level ground. 16 FT b. Check oil level in sight gauge (A) on lower left side of gearbox. The oil must be even with the sight glass when at the proper level.
Page 83 MAINTENANCE/SERVICE 7.9.2.1 Checking Oil 7.9.2.2 Changing Oil The bevel gearbox oil level should be checked DANGER 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 Stop engine and remove key from ignition an idling machine.
Page 84 MAINTENANCE/SERVICE 7.9.2.3 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 85 MAINTENANCE/SERVICE g. Remove two bolts (P) and remove guard (Q). 13 FT 16 FT m. Lift gearbox (Y) and manoeuvre from drive area, top end first. h. Loosen two bolts (R) and remove guard (S). Rotate deflector (T) so that wider space between bars face forward.
Page 86 MAINTENANCE/SERVICE 7.9.2.4 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 87 MAINTENANCE/SERVICE NOTE Steps g to i. applicable to 16 ft header only. 16 FT g. Install hourglass deflector drive belts (N) onto n. Position hydraulic motor (B) on gearbox and drive pulley (O) and driven pulley. install four bolts (A). Torque bolts to 103 ft·lbf h.
Page 88: Conditioner Gearbox - 13 Ft
MAINTENANCE/SERVICE 7.9.3 Conditioner Gearbox – 13 Ft c. Remove nut (B), bolt (C), and washers (D), and pin (E). Remove LH drive shield. 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...
Page 89 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 Remove eight bolts (S) holding gearbox (R) to driveline.
Page 90 MAINTENANCE/SERVICE 7.9.3.2 Conditioner Gearbox Installation – 13 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 upper driveshaft (O) with pulley (L) and belt into yoke (T).
Page 91 MAINTENANCE/SERVICE Position pin (E) in shield and attach to frame with two washers (D), bolt (C), and nut (B). Washers are under the pin. Tighten nut (B). Adjust roll timing. Refer to Section 6.13.4.2 Roll Timing. k. Close drive shield (A). Re-install belt on pulley (L) and tighten idler (U) with adjuster bolt (K).
Page 92: Conditioner Gearbox - 16 Ft
MAINTENANCE/SERVICE 7.9.4 Conditioner Gearbox – 16 Ft d. Remove nut (B), bolt (C), and washers (D), and pin (E). Remove LH drive shield. 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...
Page 93 MAINTENANCE/SERVICE g. 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). h. Remove bolts (O) and swivel driveshaft (N) so k.
Page 94 MAINTENANCE/SERVICE 7.9.4.2 Conditioner Gearbox Installation – 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. c. Slide pulley and belt onto upper driveshaft (N) and position driveshaft on gearbox.
Page 95 MAINTENANCE/SERVICE Position belt (J) on pulley (L) and tighten idler with adjuster bolt (K). See 7.9.5.1 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 96: Conditioner Drive Belt
MAINTENANCE/SERVICE 7.9.5 Conditioner Drive Belt NUMBER OF VISIBLE COILS MEASUREMENT ‘X’ The conditioner drive belt is located inside the 7.75-8.15 inches drive compartment at the left hand side of the (197-207 mm) header. 8.11-8.5 inches (206-216 mm) DANGER 7.9.5.2 Tension Adjustment Stop engine and remove key from ignition before leaving operator's seat for any reason.
Page 97 MAINTENANCE/SERVICE 7.9.5.3 Conditioner Drive Belt Removal 7.9.5.4 Conditioner Drive Belt 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. a. Raise header fully, shut off engine and remove key.
Page 98: Conditioner Drive Belt Idler
MAINTENANCE/SERVICE 7.9.6 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 99: Lifting Roll Drive Belt
MAINTENANCE/SERVICE 7.9.7 Lifting Roll Drive Belt The two lifting roll drive belts 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. Replace the belts if they are slipping.
Page 100: Lifting Roll Belt Idler
MAINTENANCE/SERVICE 7.9.8 Lifting Roll Belt Idler The lifting roll belt idler does not require normal maintenance or servicing but may eventually require replacing. 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 101: Hourglass Deflector Drive Belts - 16 Ft
MAINTENANCE/SERVICE 7.9.10 Hourglass Deflector Drive Belts – 16 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. 7.9.10.1 Belt Tension a. Raise header fully, shut off engine and remove key.
Page 102 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 103: Hydraulic Drive System
MAINTENANCE/SERVICE 7.10.1.2 Adding Hydraulic Oil 7.10 HYDRAULIC DRIVE SYSTEM The pull-type mower conditioner is hydraulically WARNING powered using the following systems: • To avoid injury from contact with hot oil, do A self-contained hydraulic system to operate not remove cap when system is hot. When the header functions.
Page 104: Hydraulic Oil Filter
MAINTENANCE/SERVICE 7.10.2 Hydraulic Oil Filter NOTE Change hydraulic oil filter after the first 100 hours operation and every 250 hours thereafter. b. Place drain pan under pump (B). c. Lower APT as low as possible with jack. d. Loosen hose clamp (C) on the pump suction a.
Page 105: Pump
MAINTENANCE/SERVICE 7.10.4 Pump The main drive pump does not require normal maintenance or servicing. If repairs are required, it should be removed and serviced at your dealer. 7.10.4.1 Removal DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason.
Page 106 MAINTENANCE/SERVICE h. Fill pump case with clean hydraulic oil at fitting (F). Attach case drain hose (A) and tighten. Install hose ties. k. Check reservoir oil level and add oil if required. See Section 7.10.1 Reservoir. Form # 169053 Model Year - 2010...
Page 107: Hydraulic Motor
MAINTENANCE/SERVICE 7.10.5.2 Installation 7.10.5 Hydraulic Motor a. Remove covering from gearbox (E) opening. The main drive hydraulic motor does not require b. Place motor (B) on gearbox (E) flange. normal maintenance or servicing. If repairs are illustration opposite. required, it should be removed and serviced at your dealer.
Page 108: Electrical
MAINTENANCE/SERVICE 7.11 ELECTRICAL 7.11.2 Fixture Replacement a. Use electrical tape and wire clips as required to prevent wires from dragging or rubbing. b. Keep lights clean and replace burnt bulbs. 7.11.1 Light Bulb Replacement a. Using a phillips screwdriver, remove screws from fixture and remove plastic lens.
Page 109 MAINTENANCE/SERVICE 7.11.2.2 Tail/Brake Lights a. Cut plastic cable tie (E) securing harness covering to light (F). b. Retrieve connections (G) from inside harness covering approximately 6 inches (150 mm) from light and disconnect wires. Remove tape if necessary. c. Remove nut (H) securing light to frame and remove light.
Page 110: Wheels And Tires
MAINTENANCE/SERVICE 7.12.2 Wheel - Removal/Installation 7.12 WHEELS AND TIRES 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 111 MAINTENANCE/SERVICE Bottle Jack (Field or Road Application): 7.12.2.2 Installation 1. Raise header to full height if in working position. CAUTION When installing wheel be sure to use the holes that are countersunk to match bolt head profile. The uncountersunk holes do not seat the bolts correctly.
Page 112: Tire Inflation
MAINTENANCE/SERVICE 7.12.3 Tire Inflation Check tire pressure daily. Maintain pressure at 30 psi (207 kPa). WARNING • Service tires safely. • A tire can explode during inflation and cause serious injury or death. • Do not stand over tire. Use a clip-on chuck and extension hose.
Page 113: Maintenance Schedule
MAINTENANCE/SERVICE 7.13 MAINTENANCE SCHEDULE IMPORTANT The following maintenance schedule is a listing Recommended intervals are for average of periodic maintenance procedures, organized conditions. Service the machine more by service intervals. Regular maintenance is the often if operated under adverse conditions best insurance against early wear and untimely (severe dust, extra heavy loads, etc.).
Page 114: Interval Maintenance
MAINTENANCE/SERVICE 7.13.2 Interval Maintenance INTERVAL SERVICE FIRST USE Refer To BREAK-IN INSPECTIONS (previous page). 4. Check Hourglass Deflector Belt Tension – 1. Check Bevel Gearbox Lubricant Level. 100 HOURS OR 16 Ft. 2. Check Wheel Bolt Torques. ANNUALLY * 5. Grease Wheel Hub Bearings. 3.
Page 115 MAINTENANCE/SERVICE ACTION: - Check - Lubricate - Change Hour Meter Reading Date Serviced By FIRST USE Refer To BREAK-IN INSPECTIONS (previous page). 100 HOURS OR ANNUALLY Hydraulic Oil Filter - First 100 H Only Conditioner Drive Belt Tension Hourglass Drive Belt Tension – 16 Ft Wheel Bolt Torque Wheel Hub Bearings Bevel Gearbox Lubricant Level...
Page 116: 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 6.13.2 & necessary to carry header 6.13.3 slightly with header lift...
Page 117 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Strips Of Uncut Crop Left On Foreign object on cutterbar. Disengage header and stop Field. engine. When all moving 6.14 parts are completely stopped, remove foreign object. Uneven Formation And Rear deflector bypassing or Adjust rear deflector for 6.13.6.2 Bunching Of Windrow.
Page 118: Mechanical
Mud on cutterbar. Remove mud from cutterbar. Do not allow mud to dry on 6.14 cutterbar. Spindle bearing failure. Replace spindle bearing. MacDon Dealer. Material wrapped around Remove disc and remove 7.8.3.4 spindle. material. Cutting too low in rocky field Decrease header angle.
Page 119 SOLUTION SECTION Breakage Of Conditioner Belt pulleys and idlers Align pulleys and idler. Drive Belt. misaligned. MacDon Dealer. Machine Pulling To One Side. Header dragging on one end Adjust header flotation on 6.13.3 and pulling to that side. both ends.
Page 120: Options And Attachments
OPTIONS AND ATTACHMENTS 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 header for clean crop dividing and reel entry in tall crops. The kit includes left and right dividers and attachment hardware.
Page 121: Pressure Gauge Kit
OPTIONS AND ATTACHMENTS 9.7 PRESSURE GAUGE KIT This kit allows the operator to monitor the header operating load on the machine with the installation of a pressure gauge on the Articulated Power Tongue. Installation instructions are included with the kit. Form # 169053 Model Year - 2010...
Page 122: Unloading And Assembly
UNLOADING AND ASSSEMBLY 10 UNLOADING AND ASSEMBLY Refer to R80 Pull-Type Rotary Disc Mower Conditioner Unloading & Assembly Instructions, #169080 and Pre-Delivery Checklist that is included with your shipment for unloading and set-up procedures. Form # 169053 Model Year - 2010...
Page 123: Index
INDEX 3 Point Hitch..............20, 23 Hazard Lights Abbreviations ..............11 bulbs ................. 106 Accelerators ..............74 Header Angle Articulating Power Tongue ..........14 adjustment ..............42 Assembly ..............120 Header Flotation ............. 43 Baffle................48 adjustment ..............43 Belts Header Operation ............41 conditioner drive............94 Hook-Up hourglass deflectors ............99 3 point hitch..............
Page 124 INDEX oil level ................80 Storage................51 Raking ................51 Tall Crop Divider Kit ............118 Reservoir Tall Crop Feed Plates............78 hydraulic ..............101 Tedding ................51 oil level ..............101 Tire inflation..............110 Rock Guards ..............65 Torques ................53 Rolls Tractor gap ................44 drawbar adjust.............19 tension.................46 set-up ................19 timing................45 Transporting Safety...

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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