Page 1 Rotary Disc 13-Foot Self-Propelled Windrower Header Operator’s Manual 169455 Revision F Original Instruction The harvesting specialists.
Page 2 13-Foot Rotary Disc Self-Propelled Windrower Header Published: October, 2014...
Page 3 This manual describes operating and maintenance procedures for the MacDon R85 13-Foot Rotary Disc Self-Propelled Windrower Header. Your new 13-foot rotary header can be attached to MacDon M150, M155, M200 and M205 Self-Propelled Windrowers and is designed to cut, condition, and lay in windrows a wide variety of grasses and hay crops.
Page 4 Serial Number(s) Record the serial number of the header in the space provided. Header Serial No: ____________ Serial Number Plate (A) is located on the top surface at the right-hand end of the header. Figure 2: Serial Number Location 169455 Revision F...
Page 5 List of Revisions At MacDon, we’re continuously making improvements; occasionally these improvements impact product documentation. The following list provides an account of major changes from the previous version of this document. Summary of Change Location Added a note about keeping MacDon publications...
Page 7: Table Of Contents
TABLE OF CONTENTS Introduction ............................i Serial Number(s) ..........................ii List of Revisions ..........................iii Safety ..............................1 Safety Alert Symbols........................1 Signal Words........................... 2 General Safety ..........................3 Maintenance Safety ......................... 5 Hydraulic Safety ..........................6 Safety Signs ............................ 7 1.6.1 Installing Safety Decals ......................
Page 8 TABLE OF CONTENTS 6.4.1 Checking Roll Timing......................77 6.4.2 Adjusting the Roll Timing ......................78 Forming Shields ..........................79 6.5.1 Adjusting the Side Deﬂectors ....................79 6.5.2 Adjusting the Rear Deﬂector (Fluffer Shield)................81 6.5.3 Adjusting the Swath Bafﬂe ...................... 81 Header Angle ..........................
Page 9 TABLE OF CONTENTS 7.6.2 Cutterbar Discs ........................127 Removing a Cutterbar Disc.....................127 Installing a Cutterbar Disc ....................128 7.6.3 Direction of Spindle Rotation ....................129 7.6.4 Cutterblades .........................129 Inspecting Cutterblades....................130 Inspecting Cutterblade Hardware ..................132 Replacing the Cutterblades ....................133 7.6.5 Accelerators..........................134 Inspecting Accelerators ....................135 Replacing Accelerators ....................135 7.6.6 Rotary Deﬂectors ........................136...
Page 11: 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 header. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read follow safety message accompanying this symbol.
Page 12: 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 13: 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 the protective clothing and personal safety devices that COULD be necessary for the job at hand.
Page 14 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 the shaft and can telescope freely. •...
Page 15: Maintenance Safety
SAFETY 1.4 Maintenance Safety To ensure your safety while maintaining the machine: • Review the operator’s manual and all safety items before operation and/or maintenance of the 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 16: Hydraulic Safety
SAFETY 1.5 Hydraulic Safety • Always place hydraulic controls Neutral before dismounting. • Make sure that all components in the hydraulic system are kept clean and in good condition. • Replace any worn, cut, abraded, ﬂattened, or crimped hoses and steel lines. •...
Page 17: Safety Signs
SAFETY 1.6 Safety Signs • Keep safety signs clean and legible at all times. • Replace safety signs that missing become illegible. • If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the current safety sign.
Page 18: Safety Decal Locations
SAFETY 1.7 Safety Decal Locations Figure 1.15: Safety Decal Locations A - MD #194465 B - MD #194463 C - MD #194466 D - MD #194464 E - MD #113482 F - MD #166466 G - MD #184385 H - MD #184371 Figure 1.16: Safety Decals 169455 Revision F...
Page 19 SAFETY Figure 1.17: Safety Decal Locations A - MD #184385 169455 Revision F...
Page 20: Understanding Safety Signs
SAFETY 1.8 Understanding Safety Signs In the safety sign explanations below, (a) refers to the top or left position panel, (b) refers to the bottom or right position of the safety decal depending on decal orientation. NOTE: If there are more than two panels in a decal, the lettering will continue downward or to the right, depending on decal orientation.
Page 21 SAFETY 2. MD #166466 a. High pressure oil hazard b. WARNING Do not go near leaks. • High pressure oil easily punctures skin causing serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. •...
Page 22 SAFETY 5. MD #194463 a. Rotating blades b. WARNING • Shut down the windrower and remove the key before opening the header covers • Listen and look for evidence of rotation before lifting cover • Rotating cutters may continue to rotate after power is shut off Figure 1.22: MD #194463 6.
Page 23 SAFETY 8. MD #194466 a. Rotating parts under hood b. WARNING Stand clear • Crop materials exiting at high speed • Stop machine, look, listen, and wait for all movement to stop before approaching • Failure to comply could result in death or serious injury Figure 1.25: MD #194466 169455...
Page 24 SAFETY 9. MD #194521 a. Auger entanglement hazard b. CAUTION • To avoid injury from entanglement with rotating auger, stand clear of header while machine is running c. General hazard pertaining to machine operation and servicing d. CAUTION • Read the operator’s manual and follow safety instructions.
Page 25: Definitions
2 Deﬁnitions The following terms and acronyms may be used in this manual. Term Deﬁnition American Petroleum Institute ASTM American Society of Testing and Materials Bolt A headed and externally threaded fastener that is designed to be paired with a nut Cab-forward Windrower operation with the Operator and cab facing in the direction of travel Cab display module on a self-propelled windrower...
Page 26 DEFINITIONS Term Deﬁnition O-ring face seal: a style of ﬁtting commonly used for connecting hoses and tubes. ORFS This style of ﬁtting is also commonly called ORS, which stands for O-ring seal Power take-Off RoHS (Reduction of A directive by the European Union to restrict the use of certain hazardous Hazardous Substances) substances (such as hexavalent chromium used in some yellow zinc platings) Society of Automotive Engineers...
Page 27: Component Identification
3 Component Identiﬁcation Figure 3.1: Component Identiﬁcation A - Doors B - Driveshield C - Swath Bafﬂe Control E - Header Boot D - Swath Bafﬂe Figure 3.2: Component Identiﬁcation A - Hydraulic Hoses to SP Windrower B - Hose Supports C - Drive Motor D - Rotary Deﬂector E - 8 Disc Cutterbar...
Page 29: Specifications
Frame and Structure Width (transport) 13-ft.-0 in. (3952 mm) Weight (estimated) 3000 lb (1360 kg) Compatible windrower MacDon M150, M155, M200, M205 Self-Propelled Windrowers Lighting None Manual storage Plastic case on header right drive shield Cutterbar Number of cutting discs...
Page 30 SPECIFICATIONS Frame and Structure Swath width 36–102 in. (915–2540 mm) Forming shields Windrower mounted adjustable forming shield system 0–16 mph (25.7 km/h) Ground speed 169455 Revision F...
Page 31: 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 32: Operational Safety
OPERATION 5.2 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 33 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 34: Header Safety Props
OPERATION 5.3 Header Safety Props Safety props are located on both header lift cylinders on the windrower. 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. Engage safety props as follows: 1.
Page 35 OPERATION 4. To disengage safety props and for storage, turn lever (A) away from header to raise safety prop until lever locks into vertical position. Repeat for opposite cylinder. Figure 5.4: Safety Prop 5. Start engine, choose a level area, and lower header to the ground.
Page 36: Driveshields
The R85 13-Foot Header for Self-Propelled Windrower comes in two conﬁgurations—one conﬁgured for use in North America and one conﬁgured for use outside of North America. The conﬁguration is speciﬁed in the title when necessary.
Page 37: Opening The Driveshield: Export Headers
OPERATION 5.4.3 Opening the Driveshield: Export Headers Follow these steps to open the driveshield on export headers: 1. Release rubber latch (A). 2. Insert a screwdriver (or equivalent) through hole (B) in driveshield and into the notch in latch (C) and disengage latch.
Page 38: Cutterbar Doors
OPERATION 5.5 Cutterbar Doors CAUTION Do NOT operate the machine without all the cutterbar doors down, curtains installed and in good condition. Two doors provide access to the cutterbar area. Rubber curtains are attached to each door, at the front corners, and center ﬁxed cover.
Page 39: Closing The Cutterbar Doors: North American Header
OPERATION 2. Lift front of door to the open position. Figure 5.11: Cutterbar Doors 5.5.2 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.
Page 40 OPERATION 2. Hook curtain latches (A). NOTE: Ensure that curtains hang properly and completely enclose cutterbar area. Figure 5.13: Curtain Latches 169455 Revision F...
Page 41: Opening The Cutterbar Doors: Export Header
OPERATION 5.5.3 Opening the Cutterbar Doors: Export Header Follow these steps to open the cutterbar doors on an export header: 1. Unhook curtain latches (A). Figure 5.14: Curtain Latches 169455 Revision F...
Page 42: 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 5.15: Cutterbar Door Latch 5.5.4 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 43 OPERATION 1. Pull at top and move to closed position. Ensure latch (A) has engaged the door. Figure 5.16: Cutterbar Door Latch 2. Hook curtain latches (A). Figure 5.17: Curtain Latches 169455 Revision F...
Page 44: Daily Start-Up Check
OPERATION 5.6 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 45: Attaching The Header
OPERATION 5.7 Attaching the Header 5.7.1 Attaching the Forming Shield 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. To attach the forming shield to the windrower, follow these steps: 1.
Page 46 OPERATION 4. Position the forming shield onto spacers (B) on windrower legs. Secure with clevis pins (A) and lynch pin. Figure 5.22: Forming Shield under Windrower 5. Lift the aft end of the forming shield and attach straps (B) to pins (A) on windrower frame. 6.
Page 47: Attaching The Header (M205 Windrowers)
8. Adjust rear ﬂuffer deﬂector (C) to middle position. Loosen handles (B) if required. Figure 5.24: Forming Shield Adjuster Bar 9. Attach the R85 header to the windrower. Refer to the windrower operator’s manual, and then return to this manual to complete the attachment.
Page 48 OPERATION 1. Move windrower left-hand (cab-forward) platform (A) to OPEN position. Figure 5.26: Windrower LH Platform 2. Route the hose bundle (A) from the header, under the windrower frame and insert pin (B) into hole in windrower frame. 3. Place hoses on support (C). 4.
Page 49 OPERATION Remove coupler lock as follows: a. Remove lynch pin (A) and open up coupler lock (B). b. Remove lock from coupler. Figure 5.28: Hydraulic Couplers 6. Position hose couplers against mating couplers on windrower and screw sleeves (A) onto mating receptacles.
Page 50 OPERATION 8. Lower holder (A) onto sleeves (B) so that ﬂats locate on holder. Holder can be adjusted by loosening bolts (C). Tighten bolts after adjusting. Figure 5.31: Hydraulic Couplers 9. Insert lynch pin (A) to secure lock. 10. Attach case drain hose coupler at (B). 11.
Page 51: Attaching The Header (M200 Windrowers)
OPERATION 14. Connect the electrical harness to connector (A) (located beside the forward valve block on the windrower). NOTE: Valve block hidden to show the electrical connector. Figure 5.34: Electrical Connection 15. Move the windrower platform (A) to the CLOSED position.
Page 52 OPERATION The 13-foot header requires kit MD #B5511 installed to operate on an M200 windrower. If required, obtain the kit through your MacDon Dealer. Install kit in accordance with the supplied instructions. Figure 5.36: MD #B5511 1. Disengage and rotate lever (A) counterclockwise to the UP position.
Page 53 OPERATION 3. Move hose bundle (A) from the windrower and rest the bundle on the header. Figure 5.38: Hose Bundle 4. Position the hose support with the lower bolt (A) in the forward hole and the support positioned as shown. Loosen both bolts and adjust as required.
Page 54 OPERATION 7. Secure hose bundles with three cinch straps (B). 8. Lower and lock lever (A). Figure 5.41: Hose Bundle 9. Move the windrower’s left side (cab-forward) platform (A) to the OPEN position to access the valve blocks. Figure 5.42: Windrower LH Platform 169455 Revision F...
Page 55 OPERATION 10. Connect the pressure hose (C) from port (A) on the header motor to port (M2) on the header drive valve block. 11. Connect the return hose (D) coming from port (B) on the header motor to port (R2) on the header drive valve block.
Page 56 OPERATION 13. Connect the pressure hose (B) from the header drive valve block port (M1) to the steel line attached to motor port (A). Figure 5.45: Windrower Connections 14. Connect the case drain hose (A) from the header lift valve block port (T3) to the hose attached to motor port (D).
Page 57: Attaching The Header (M150/M155 Windrowers)
OPERATION 15. Connect the electrical harness (A) from windrower to the electrical connector on the header. NOTE: Hydraulic lines and hoses hidden on illustration to show the electrical connection. Figure 5.47: Windrower Connections 16. Move platform (A) to the CLOSED position. Figure 5.48: Windrower LH Platform 5.7.4 Attaching the Header (M150/M155 Windrowers) DANGER...
Page 58 MD #B5510 installed to enable operation on an M150 or M155 windrower. If required, obtain the kit through your MacDon Dealer. Install kit in accordance with the supplied instructions. Figure 5.49: MD #B5510 1. Disengage and rotate lever (A) counterclockwise to FULLY UP position.
Page 59 OPERATION 3. Move hose bundle (A) from the windrower and rest the bundle on the header. Figure 5.51: Hose Bundle 4. Position the hose support with lower bolt (A) in the forward hole and support positioned as shown. Loosen both bolts and adjust as required. Figure 5.52: Hose Support 169455 Revision F...
Page 60 OPERATION 5. Move the windrower’s left side (cab forward) platform (A) to the OPEN position. Figure 5.53: Windrower LH Platform 6. Route the windrower hose bundle (A) through hose support (B) on the header. 7. Route hose (C) from the header through support (B), to the windrower.
Page 61 OPERATION 8. Connect the single pressure hose (A) routed from the header to port (M2) on the disc drive valve (middle block). Figure 5.55: Hydraulic Connections 9. Remove caps and plugs on hoses from windrower and lines on header. 10. Connect the pressure hose (B) from the drive manifold port (M1) to the steel line attached to motor port (A).
Page 62 OPERATION 11. Connect the return hose (A) from the drive manifold port (R1) to the steel line attached to motor port (B). Figure 5.57: Hydraulic Connections 12. Connect the case drain hose (A) from the lift manifold port (T3) to the ﬁtting attached to motor port (D). Figure 5.58: Hydraulic Connections 169455 Revision F...
Page 63 OPERATION 13. Connect the electrical harness (A) from windrower to the electrical connector on the header. NOTE: Hydraulic hoses removed from the illustration to improve clarity. Figure 5.59: Electrical Connection 14. Lower and lock lever (A). Secure hose (B) with three cinch straps (C).
Page 64 OPERATION 15. Move platform (A) to the CLOSED position. Figure 5.61: Windrower LH Platform 169455 Revision F...
Page 65: Detaching The Header
OPERATION 5.8 Detaching the Header 5.8.1 Detaching the Header (M205 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 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 66 OPERATION 4. Disconnect the electrical harness at connector (A). NOTE: Valve block hidden to show the electrical connector. 5. If couplers and coupler lock are installed on lines, proceed as follows. Otherwise, proceed to Step 13., page Figure 5.63: Hydraulic Connections 6.
Page 67 OPERATION 9. Unscrew sleeves couplers separate couplers. 10. Install caps and plugs on open lines. Figure 5.66: Hydraulic Connections 11. Attach coupler lock (B) to hoses and secure with lynch pin (A). 12. Proceed to Step 14., page Figure 5.67: Hydraulic Connections 13.
Page 68 OPERATION 14. Remove hose support (A) from the windrower frame. 15. Route hoses (B) and electrical harness onto the header. Figure 5.69: Hose Bundle 16. Move maintenance platform (A) to the CLOSED position. 17. Refer to the windrower operator’s manual to mechanically detach the header from the windrower.
Page 69: Detaching The Header (M200 Windrowers)
OPERATION 5.8.2 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 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 70 OPERATION 7. Raise and unlock lever (A) and undo the three cinch straps (B). 8. Move hose bundle to store on header. Figure 5.73: Hose Bundle 9. Disconnect the electrical connector (A) at the header by turning the collar counterclockwise and pulling the connector to disengage.
Page 71 OPERATION 10. Disconnect following hoses from hydraulic motor: • Pressure hose (A) • Return hose (B) • Case drain hose (C) 11. Install caps on the connectors and hose ends (if equipped). NOTE: Hydraulic hoses from the header hidden on illustration for clarity.
Page 72: Detaching The Header (M150/M155 Windrowers)
OPERATION 15. Move the windrower platform (A) back to the CLOSED position. 16. Refer to the windrower operator’s manual to mechanically detach header from the windrower. Figure 5.77: Windrower LH Platform 5.8.3 Detaching the Header (M150/M155 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.
Page 73 OPERATION 3. Move the left side (cab-forward) platform (A) to the open position. Figure 5.78: Windrower LH Platform 4. Disconnect hose (A) from port (M2) on the disc drive valve. Figure 5.79: Hydraulic Connections 169455 Revision F...
Page 74 OPERATION 5. Raise lever (A) and undo the three cinch straps (C). 6. Move hose (B) to store on header. Figure 5.80: Hose Bundle 7. Disconnect following hoses from hydraulic motor: • Pressure hose (A) • Return hose (B) • Case drain hose (C) 8.
Page 75 OPERATION 9. Disconnect the electrical connector (A) by turning the collar counterclockwise and pulling connector to disengage. NOTE: Hydraulic lines and hoses hidden on illustration to show the electrical connection. Figure 5.82: Electrical Connection 10. Move the hose bundle from header to the left-side (cab forward) hose support (B).
Page 76 OPERATION 13. Move windrower platform CLOSED position. 14. Refer to the windrower operator’s manual to mechanically detach the header from the windrower. Figure 5.84: Windrower LH Platform 169455 Revision F...
Page 77: Break-In Period
OPERATION 5.9 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, shut off windrower, engage parking brake, and remove key.
Page 78: Shutting Down The Windrower
OPERATION 5.10 Shutting Down the Windrower CAUTION Before leaving the windrower seat for any reason: • Park on level ground (if possible). • Lower the header fully. • Place ground speed control in N-DETENT. • Stop engine and remove key from ignition. •...
Page 79: Transporting The Header
OPERATION 5.11 Transporting the Header Refer to your windrower operator’s manual for transporting headers when attached to the windrower. 169455 Revision F...
Page 81: Operating The Header
6 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 82: Adjusting Header Float
OPERATING THE HEADER 6.1.1 Adjusting Header Float 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. Check the ﬂoat by grasping the front corner of the header and lifting. The force to lift should be 95–105 lbf (426–471 N), and should be approximately the same at both ends.
Page 83: Roll Gap
OPERATING THE HEADER 6.2 Roll Gap When crop enters the conditioner, steel “N-bar” rolls crimp and crush the stems in several places. This conditioning releases moisture for quick drying. The roll gap controls the degree of conditioning. Correct conditioning of alfalfa, clover, and other legumes is indicated when 90% of the stems show cracking with no more than 5% leaf damage.
Page 84: Adjusting The Roll Gap
OPERATING THE HEADER 5. Inspect roll gap at both ends of the rolls. Gap (B) should be 0.5 in. (12.7 mm). IMPORTANT: Roll timing is critical when the roll gap is decreased because the bars may contact each other if the timing is wrong. 6.
Page 85 OPERATING THE HEADER 4. Loosen upper jam nut (A) on both sides of conditioner. 5. To increase roll gap (increase conditioning action), turn lower nut (B) clockwise. 6. To decrease roll gap (reduce conditioning action), turn lower nut (B) counterclockwise. 7.
Page 86: Roll Tension
OPERATING THE HEADER 6.3 Roll Tension Roll tension (the force holding the rolls together) is factory set with a spring type adjustable linkage. Heavy crops or tough forage tend to separate the rolls and require more tension to ensure material is sufﬁciently crimped.
Page 87: Roll Timing
OPERATING THE HEADER 6.4 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. The factory setting should be suitable for most crop conditions. IMPORTANT: Roll timing is critical when the roll gap is decreased because the bars may contact each other if the timing is wrong.
Page 88: Adjusting The Roll Timing
OPERATING THE HEADER 6.4.2 Adjusting the Roll Timing Follow these steps to adjust the roll timing (if necessary): 1. Loosen four bolts (A) in slots of yoke plate (B) on upper roll universal shaft. 2. Manually rotate upper roll until it stops. Make a mark on yoke ﬂange to align with the center of one of the bolt heads (A).
Page 89: Forming Shields
OPERATING THE HEADER 6.5 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 90 OPERATING THE HEADER 2. If side deﬂector attachment is too tight or too loose, tighten or loosen nut (A) as required. Figure 6.11: Forming Shield 169455 Revision F...
Page 91: Adjusting The Rear Deflector (Fluffer Shield)
OPERATING THE HEADER 6.5.2 Adjusting the Rear Deﬂector (Fluffer Shield) 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 rear deﬂector (ﬂuffer shield) slows the crop exiting the conditioner rolls, directs the ﬂow downward, and ﬂuffs the material.
Page 92 OPERATING THE HEADER The swath bafﬂe (A) 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 into the forming shield for narrow and moderate width windrows •...
Page 93: Header Angle
OPERATING THE HEADER 6.6 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 94: Cutting Height
OPERATING THE HEADER 6.7 Cutting Height Cutting height is determined by a combination of the angle of the cutterbar/header and the skid shoe settings. 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 95: Disc Speed
OPERATING THE HEADER 6.7.2 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 6.2 Disc Speed Recommendations Disc rpm Crop...
Page 96: Ground Speed
OPERATING THE HEADER 6.8 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. Refer to your windrower operator’s manual for changing ground speed.
Page 97: Double Windrowing
OPERATING THE HEADER 6.9 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 6.18: DWA...
Page 98: Tall Crop Divider Option
OPERATING THE HEADER 6.10 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. 6.10.1 Removing Tall Crop Divider DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason.
Page 99: The Header Pan
OPERATING THE HEADER 6.11 The Header Pan The header pan is located behind the cutterbar and helps prevent material loss and wrapping in certain crops, such as grass seed, oats, and tall stalky crops. In conditions where more soil and stones are being picked up by the cutterbar, it may be desirable to remove the pan to allow the debris to fall out before being fed into the conditioner.
Page 100: Installing The Header Pan
OPERATING THE HEADER 6.11.2 Installing the Header Pan To install the header pan, follow these steps: 1. Locate pan (B) under header frame and hold in place. 2. Install six 1/2 in. x 1 carriage bolts (A) and ﬂanged lock nuts.
Page 101: Haying Tips
OPERATING THE HEADER 6.12 Haying Tips 6.12.1 Curing Curing crops quickly helps maintain the highest quality because for each day that hay lies on the ground, 5% of the protein is lost. Leaving the windrow as wide and ﬂuffy as possible results in the quickest curing. Cured hay should be baled as soon as possible.
Page 102: Driving On Windrow
OPERATING THE HEADER Table 6.4 Recommended Windrow Characteristics Advantage Characteristic Enables airﬂow through windrow which is more important to the curing High and ﬂuffy process than direct sunlight Consistent formation (not bunching) Permits an even ﬂow of material into the baler, chopper, etc. Even distribution of material Results in even and consistent bales to minimize handling and across windrow...
Page 103: Levelling The Header
OPERATING THE HEADER 6.13 Levelling the Header Windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. The ﬂoat springs are NOT used to level the header. If the header is not level, check the tire pressures on the windrower ensuring they are properly inﬂated. Refer to your windrower operator’s manual.
Page 104: Unplugging The Header
OPERATING THE HEADER 6.14 Unplugging the Header Follow these steps to remove plugged material from the header: DANGER Stop windrower engine and remove key before removing plugged material from header. A child or even a pet could engage the drive. 1.
Page 105: Maintenance And Servicing
7 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 106: Torque Specifications
MAINTENANCE AND SERVICING 7.2 Torque Speciﬁcations The following tables provide the correct torque values for various bolts, cap screws, and hydraulic ﬁttings. • Tighten all bolts to the torque values speciﬁed in the charts (unless otherwise noted throughout this manual). •...
Page 107 MAINTENANCE AND SERVICING Table 7.2 SAE Grade 5 Bolt and Grade F Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 1/4-20 16.7 18.5 5/16-18 *149 *164 3/8-16 7/16-14 1/2-13 9/16-12 Figure 7.2: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8...
Page 108: Metric Bolt Specifications
MAINTENANCE AND SERVICING Table 7.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 1/4-20 *150 *165 16.8 18.6 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 Figure 7.4: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8...
Page 109 MAINTENANCE AND SERVICING Table 7.6 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) 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 *167 *185 18.8 20.8 Figure 7.6: Bolt Grades 10-1.5 12-1.75 14-2.0...
Page 110 MAINTENANCE AND SERVICING Table 7.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) 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 7.8: Bolt Grades 10-1.5 12-1.75 14-2.0...
Page 111: Metric Bolt Specifications Bolting Into Cast Aluminum
MAINTENANCE AND SERVICING 7.2.3 Metric Bolt Speciﬁcations Bolting into Cast Aluminum Table 7.9 Metric Bolt Bolting into Cast Aluminum Bolt Torque Nominal 10.9 Size (A) (Cast Aluminum) (Cast Aluminum) ft·lbf N·m ft·lbf N·m – – – – – – – Figure 7.9: Bolt Grades –...
Page 112 MAINTENANCE AND SERVICING Table 7.10 Flare-Type Hydraulic Tube Fittings Flats from Finger Nut Size Torque Value Tube Size Thread Tight (FFFT) SAE No. Across Flats O.D.(in.) Size (in.) (in.) ft·lbf N·m Flats Turns 3/16 7/16 7/16 9/16 5/16 9/16 11/16 1-1/16 1-1/4 1-3/8...
Page 113: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)
MAINTENANCE AND SERVICING 7.2.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off the lock nut (C) as far as possible. Ensure that washer (D) is not loose and is pushed toward the lock nut (C) as far as possible.
Page 114 MAINTENANCE AND SERVICING Table 7.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque Value SAE Dash Size Thread Size (in.) ft·lbf (*in·lbf) N·m 3/8-24 *106–115 12–13 7/16–20 14–15 19–21 1/2–20 15–24 21–33 9/16–18 19–21 26–29 3/4–16 34–37 46–50 7/8–14 55–60 75–82 1-1/16-12 88–97 120–132...
Page 115: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)
MAINTENANCE AND SERVICING 7.2.6 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 the threads and adjust if necessary. 3. Apply hydraulic system oil to the O-ring. 4.
Page 116: O-Ring Face Seal (Orfs) Hydraulic Fittings
MAINTENANCE AND SERVICING 7.2.7 O-Ring Face Seal (ORFS) Hydraulic Fittings 1. Check components to ensure that the sealing surfaces and ﬁtting threads are free of burrs, nicks, scratches, or any foreign material. Figure 7.14: Hydraulic Fitting 2. Apply hydraulic system oil to the O-ring (B). 3.
Page 117 MAINTENANCE AND SERVICING Table 7.13 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value SAE Dash Thread ft·lbf Size Size (in.) N·m (*in·lbf) – – Note 9/16–18 18–21 25–28 Note – – 11/16-16 29–32 40–44 13/16-16 41–45 55–61 1–14 59–65 80–88 1-3/16-12 85–94 115–127...
Page 118: Conversion Chart
MAINTENANCE AND SERVICING 7.3 Conversion Chart Table 7.14 Conversion Chart Inch-Pound Units SI Units (Metric) Factor Quantity Unit Name Abbreviation Unit Name Abbreviation Area Acres acres x 0.4047 = Hectares Us gallons Flow x 3.7854 = Liters per Minute L/min per minute Force Pounds force...
Page 119: Recommended Fluids And Lubricants
MAINTENANCE AND SERVICING 7.4 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 7.15 Fluids and Capacities Lubricant Speciﬁcation...
Page 120: Maintenance Requirements
MAINTENANCE AND SERVICING 7.5 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 121: Maintenance Schedule/Record
Cutter blades, deﬂectors, and discs NOTE:  - refer to 7.6.1 Inspecting the MacDon recommends keeping a record of daily maintenance Cutterbar Discs, page 126. as evidence of a properly maintained machine, however daily maintenance records are not required to meet normal warranty 25 hours conditions.
Page 122 Cutterbar lube - refer to 7.5.8 ▲ Lubricating the Cutterbar, page 120. Bevel gearbox lube - refer to ▲ Changing the Bevel Gearbox Lubricant, page 145. NOTE: MacDon recommends performing annual maintenance before the start of each operating season. 169455 Revision F...
Page 123: Break-In Inspections
MAINTENANCE AND SERVICING 7.5.2 Break-In Inspections Timing Item Refer to Section Check for loose hardware, tighten to 7.2 Torque Speciﬁcations, page 96 required torque At 5 hours Check drive belt tension Check drive belt tension At 25 hours Inspecting the Conditioner Drive Belt, page 146 Check drivebelt tension 120.
Page 124: End-Of-Season Service
MAINTENANCE AND SERVICING 7.5.4 End-of-Season Service CAUTION Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or ﬂammable. Do the following at the end of each operating season: • Clean the header thoroughly •...
Page 125: Greasing Procedure
MAINTENANCE AND SERVICING To access the drive systems, open the driveshield and cutterbar doors. Refer to: • 5.4 Driveshields, page 26 • 5.5 Cutterbar Doors, page 28 Figure 7.16: Driveshield 7.5.6 Greasing Procedure 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 126: Lubrication And Servicing Intervals
MAINTENANCE AND SERVICING 7.5.7 Lubrication and Servicing Intervals To identify the various locations that require lubrication and servicing, refer to the following illustrations (organized by the frequency of service that is required). Every 25 Hours Figure 7.18 B - Driveshaft 7 A - Cutterbar Driveline Universals (2 Places) D - Driveline Shaft 7 C - Conditioner Driveline Universals (4 Places)
Page 127 MAINTENANCE AND SERVICING Every 50 Hours Figure 7.19 A - Roll Shaft Bearing (2 Places) B - Belt Tensioner Pivot (1 Place) C - Roll Shaft Bearing (2 Places) NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2) lithium base except where noted.
Page 128 MAINTENANCE AND SERVICING Every 100 Hours or Annually Figure 7.20 A - Gearbox Lubricant Level (Check with Top of Header Horizontal) B - Conditioner Drive Belt Tension NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2) lithium base except where noted.
Page 129 MAINTENANCE AND SERVICING Every 250 Hours Figure 7.21 A - Change Bevel Gearbox Oil B - Change Cutterbar Lube NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2) lithium base except where noted. 169455 Revision F...
Page 130: Lubricating The Cutterbar
MAINTENANCE AND SERVICING 7.5.8 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 131 MAINTENANCE AND SERVICING Figure 7.23: Cutterbar Filler Plug Locations 10. Locate one of the two ﬁller plugs along the top of the cutterbar. Refer to 7.23: Cutterbar Filler Plug Locations, page 121. 11. Clean around either ﬁller plug (A) and remove one plug with an 8 mm hex key.
Page 132: Filling The Cutterbar Lubricant
MAINTENANCE AND SERVICING Filling the Cutterbar Lubricant DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason. A child or even a pet could engage an idling machine. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine: stop engine, remove key, and engage safety props before going under machine for any reason.
Page 133 MAINTENANCE AND SERVICING 10. Verify that drain plug (A) has been installed, before adding new lubricant. Figure 7.26: Cutterbar Drain Plug Figure 7.27: Cutterbar Filler Plug Locations 11. Locate one of the two ﬁller plugs along the top of the cutterbar. Refer to 7.27: Cutterbar Filler Plug Locations, page...
Page 134 MAINTENANCE AND SERVICING 13. Add lubricant to cutterbar through ﬁller hole (A). Refer 7.4 Recommended Fluids and Lubricants, page 109. IMPORTANT: DO NOT overﬁll the cutterbar. Overﬁlling can cause overheating and damage to or failure of the cutterbar will occur. 14.
Page 135: Rock Guards
3. Inspect rock guards (A) for severe damage, wear, and distortion. The guards should be replaced if severely damaged or worn. 4. Check for loose or missing fasteners and tighten or replace fastener if missing. 5. Contact your MacDon Dealer replacement procedures. Figure 7.28: Rock Guards 169455 Revision F...
Page 136: Cutterbar Disc Maintenance
MAINTENANCE AND SERVICING 7.6 Cutterbar Disc Maintenance 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 137: Cutterbar Discs
MAINTENANCE AND SERVICING 3. Check discs (A) for damage or loose fasteners. 4. Replace damaged discs. Refer to: • Removing a Cutterbar Disc, page 127 • Installing a Cutterbar Disc, page 128 5. Replace damaged fasteners. Tighten loose fasteners. 6. Close cutterbar doors. Figure 7.30: Cutterbar Disc 7.6.2 Cutterbar Discs Removing a Cutterbar Disc...
Page 138: Installing A Cutterbar Disc
MAINTENANCE AND SERVICING Installing a Cutterbar Disc CAUTION Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 1. Position new disc on spindle ensuring it is 90° to the adjacent discs.
Page 139: Direction Of Spindle Rotation
MAINTENANCE AND SERVICING 7.6.3 Direction of Spindle Rotation When installing cutterblades or disc accelerators, the direction of rotation determines proper positioning. Reference the following illustration to determine the direction of spindle rotation. Figure 7.34: Spindle Rotation C - Disc 1 8 A - Front of Header B - 13-ft.
Page 140: Inspecting Cutterblades
MAINTENANCE AND SERVICING Inspecting Cutterblades 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 Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp and can cause serious injury.
Page 141 MAINTENANCE AND SERVICING IMPORTANT: Blades should be replaced in pairs or the disc may become unbalanced and cause damage to the cutterbar. IMPORTANT: The cutterblades have cutting edges on both sides so the blades can be turned over and reused. The twist in each blade determines if the cutting direction is clockwise or counterclockwise.
Page 142: Inspecting Cutterblade Hardware
MAINTENANCE AND SERVICING Inspecting Cutterblade Hardware Check blade attachment hardware each time blades are changed. Refer to Replacing the Cutterblades, page 133 for hardware replacement procedure. Check bolts and replace bolt if: • Bolt has been removed and installed ﬁve times •...
Page 143: 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 7.40: 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 144: 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 145: Inspecting Accelerators
MAINTENANCE AND SERVICING Inspecting Accelerators Follow these steps to inspect accelerators: 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. 1. Raise header fully, stop engine, and remove key. 2.
Page 146: Rotary Deflectors
MAINTENANCE AND SERVICING 4. Remove bolt and nut (A) and nut (B) and remove accelerator (C) from disc (D). IMPORTANT: Do NOT remove cutterblade bolt unless it or the blade are being replaced. Repeat for other accelerator. 5. Locate new accelerator on disc onto existing cutterblade bolt.
Page 147: Removing The Driven Deflector
MAINTENANCE AND SERVICING 4. Check that deﬂectors (A) are not damaged or bent by rocks and for loose fasteners. 5. Replace deﬂectors (A) if they are severely damaged or worn. Do NOT repair. Refer to: • Removing the Driven Deﬂector, page 137 •...
Page 148: 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 149: Installing The Driveline Deflector
MAINTENANCE AND SERVICING 9. Loosen the four bolts (A) in the two plates (B) that hold the upper driveline shield (C) in place. 10. Move the plates (B) so that shield (C) can be lowered into deﬂector (D). 11. Remove the deﬂector (D). Figure 7.50: Driveline Deﬂector Installing the Driveline Deﬂector Follow these steps to replace the driveline deﬂector:...
Page 150: Disc Spindles
MAINTENANCE AND SERVICING 7. Tighten bolts (A) on shield plates (B). 8. Remove block of wood (if used). 9. Manually rotate discs to check for interference of adjacent parts. 10. Close cutterbar doors. Refer to 5.5 Cutterbar Doors, page WARNING Ensure cutterbar is completely clear of foreign objects.
Page 151 MAINTENANCE AND SERVICING CAUTION Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 3. Remove disc (A) from failed spindle. Refer to Removing a Cutterbar Disc, page 127.
Page 152: Cutterbar Doors
9. Inspect plate (C) and gear shaft (E) for damage. If seriously damaged, replace entire spindle assembly. Contact your MacDon Dealer. 10. Install new key (D) into gear (E) keyway as shown. 11. Align keyway in plate (C) with key in gear (E) and install plate (C) onto gear until sufﬁcient threads are exposed...
Page 153: Inspecting Door Latches: Export Header
MAINTENANCE AND SERVICING Inspecting Door Latches: Export Header The cutterbar door latches should operate smoothly and remain engaged when the doors are down. Tighten latch hardware if loose. If the rubber bushing is damaged or does not allow the latch to operate properly, the latch should be replaced.
Page 154: Replacing Latch Brackets
MAINTENANCE AND SERVICING Replacing Latch Brackets To replace the cutterbar door latch brackets, follow these steps: 1. Open cutterbar door. 2. Remove bolts (A), washers, and nuts, and remove latch bracket (B) from door. 3. Locate new latch bracket (B) on door and reinstall bolts (A), washers and nuts.
Page 155: Drive Systems
MAINTENANCE AND SERVICING 7.7 Drive Systems 7.7.1 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, it should be removed and serviced at your Dealer.
Page 156: Conditioner Drive Belt
MAINTENANCE AND SERVICING 3. Open the driveshield. Refer to 5.4 Driveshields, page Figure 7.65: Driveshield 4. Place a suitable container under drain plug (A). 5. Remove plug (A). 6. Allow sufﬁcient time for lubricant to drain. 7. Disengage header safety props, start engine, and lower header so that it is level.
Page 157 MAINTENANCE AND SERVICING 1. Lower header to ground, turn off engine, and remove key. 2. Open the driveshield. Refer to 5.4 Driveshields, page Figure 7.67: Driveshield 3. Check that adjuster nuts (A) and (B) are tight. Figure 7.68: Conditioner Drive Belts 4.
Page 158: Replacing The Conditioner Drive Belt
MAINTENANCE AND SERVICING 5. If necessary, adjust tension as follows: a. Loosen jam nut (B). b. Turn nut (A) clockwise to increase spring length (increase tension). c. Turn nut (A) counterclockwise to decrease spring length (decrease tension). 6. Tighten jam nut (B). 7.
Page 159 MAINTENANCE AND SERVICING 3. Release tension on conditioner drive belt (A). Refer to Inspecting the Conditioner Drive Belt, page 146. 4. Remove conditioner drive belt (A) from drive pulley (B). Tensioner (C) can be forced away from belt to ease removal. Figure 7.72: Conditioner Drive Belt 5.
Page 160: Conditioner Gearbox
The gearbox does not require normal maintenance or servicing. If repairs are required, the conditioner gearbox should be removed and serviced at your MacDon Dealer. Figure 7.76: Conditioner Gearbox 169455 Revision F...
Page 161: Gearbox Speed Sensor
MAINTENANCE AND SERVICING 7.7.4 Gearbox Speed Sensor The gearbox speed sensor monitors the rotational speed of the gearbox output shaft and sends a signal to the systems monitor in the operator’s station that is displayed as disc speed. The sensor does not require regular maintenance, and if it malfunctions or is damaged, it can be easily adjusted or replaced.
Page 162 MAINTENANCE AND SERVICING 1. Loosen bolts (A) and remove the cover (B). Figure 7.79: Gearbox Cover 2. Disconnect the sensor wire from the header wiring harness at connector (A). 3. Remove bolt through clip (B). 4. Pull the harness through grommet and into the drive compartment.
Page 163: Hydraulics
MAINTENANCE AND SERVICING 7.8 Hydraulics Refer to your windrower operator’s manual for hydraulic system maintenance procedures. 7.8.1 Hydraulic Motor The hydraulic motor does not require regular maintenance or servicing. If repairs are required, it should be serviced by your Dealer. Figure 7.82: Hydraulic Motor Removing the Hydraulic Motor Follow these steps to remove the hydraulic motor:...
Page 164: Installing The Hydraulic Motor
MAINTENANCE AND SERVICING 6. Cover gearbox opening (A) with a rag or plastic. Figure 7.84: 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 165: Hydraulic Hoses And Lines
MAINTENANCE AND SERVICING 7.8.2 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 167: Troubleshooting
8 Troubleshooting 8.1 Mower Performance Problem Symptom Solution Refer to Dull, bent, or badly Replacing the Cutterblades, Replace blades. worn blades page 133 Decrease header angle and increase ﬂotation. In some Build-up of dirt 6.6 Header Angle, page 83 Cutterbar plugging conditions, it may be necessary between rock guards 6.1 Header Float, page 71...
Page 168 TROUBLESHOOTING Symptom Problem Solution Refer to Ground speed too fast Reduce ground speed. 6.8 Ground Speed, page 86 Roll gap too large for Decrease roll gap. proper feeding 6.2.2 Adjusting the Roll Gap, Roll gap too small page 74 in thick-stemmed Increase roll gap.
Page 169 TROUBLESHOOTING Symptom Problem Solution Refer to Material being pulled out by roots Crop in conditioner when cutting. Tall 6.2.2 Adjusting the Roll Gap, rolls before crop is cut Increase roll gap. crop leaning into page 74 machine Insufﬁcient roll gap Damaged leaves 6.4 Roll Timing, page 77 Check roll timing and adjust if...
Page 170: Mechanical Problems
Remove mud from Mud on cutterbar cutterbar: do NOT allow — mud to dry on cutterbar. Spindle bearing failure Replace spindle bearing. See MacDon Dealer Material wrapped around Remove disc and remove Removing a Cutterbar spindle material. Disc, page 127 6.6 Header Angle, page...
Page 171 — drive belt rolls completely stopped, remove foreign object. Belt pulleys and idlers Align pulleys and idler. See MacDon Dealer misaligned Remove mud from Mud on cutterbar cutterbar: do NOT allow — mud to dry on cutterbar. 5.7 Attaching the Header, Hoses not connected Connect hoses.
Page 173: Options And Attachments
9 Options and Attachments 9.1 Options and Attachments – Kits The following kits are available through your MacDon Dealer. The Dealer will require the “B” number for pricing and availability. 9.1.1 Cutterbar Repair Tool Kit The cutterbar repair tool kit contains the tools required to replace the cutterbar idler gears.
Page 174: Shoes
OPTIONS AND ATTACHMENTS 9.1.3 Shoes MD #B5457 Instruction Part Number: MD #169465 Figure 9.2: MD #B5457 9.1.4 Tall Crop Divider 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 175: Index
Index North American headers........ 29 inspecting latches accelerators ............134 export headers..........143 inspecting ............135 latch brackets replacing............135 replacing ............ 144 latches............143 deﬁnition ............15 replacing ............ 143 ASTM opening deﬁnition ............15 export headers..........31 attaching North American headers........
Page 176 INDEX installing ............. 154 windrow characteristics........91 removing ............ 153 header drivelines angle ............... 83 conditioner drive belts........146 unplugging ............94 driveshields ............26 header ﬂoat, See ﬂoat closing header pan............89 13-ft. North American headers ....... 26 installing ............90 export headers..........
Page 177 INDEX tall crop divider kit .......... 164 raking ..............92 recommended ﬂuids and lubricants..... 109 revisions list ............iii lubrication rock guards ............125 draining cutterbar lubricant......120 inspecting ............125 ﬁlling the cutterbar lubricant ......122 roll gap..............73 ﬂuids and lubricants........
Page 178 INDEX replacing............151 metric bolts ............98 spindle keys O-ring boss (ORB) hydraulic ﬁttings replacing............140 adjustable........... 103 spindles non-adjustable ..........105 direction of spindle rotation ......129 O-ring face seal (ORFS) hydraulic ﬁttings..106 SAE bolts............96 deﬁnition ............15 tractors start-up procedures..........
Page 180 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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