Page 1 R113/R116 Pull-Type Rotary Disc Mower Conditioner Operator’s Manual 169820 Revision A Original Instruction The harvesting specialists.
Page 2 R113 13-Foot Rotary Disc Pull-Type Mower Conditioner Published November, 2014...
Page 3 Introduction This instructional manual contains operating and maintenance procedures for the MacDon R113 13-Foot And R116 16-Foot Rotary Disc Pull-Type Mower Conditioners. Your new mower conditioner is designed to cut, condition, and lay a wide variety of grasses and hay crops in windrows.
Page 4 Serial Numbers Record the serial number of the mower conditioner in the space provided below. Mower Conditioner Serial Number Year of Manufacture Figure 2: Mower Conditioner Serial Number Location Swivel Hitch Year of Manufacture Figure 3: Swivel Hitch Identiﬁcation Plate Location 169820 Revision A...
Page 5: Table Of Contents
TABLE OF CONTENTS Introduction ............................i Serial Numbers..........................ii Safety ..............................1 Safety Alert Symbols........................1 Signal Words........................... 2 General Safety ..........................3 Maintenance Safety ......................... 5 Hydraulic Safety ..........................6 Tire Safety............................7 Safety Signs ............................ 8 1.7.1 Installing Safety Decals ......................8 Locating Safety Sign Decals ......................
Page 6 TABLE OF CONTENTS 3.14.1 Right-Side Operation ......................61 3.14.2 Left-Side Operation ........................ 61 3.14.3 Avoiding Obstacles......................... 62 3.14.4 Square Corners........................63 3.14.5 180-Degree Turn ........................63 3.15 Transporting the Mower Conditioner....................65 3.15.1 Preparing Mower Conditioner for Transport ................65 3.15.2 Transporting with a Tractor......................
Page 7 TABLE OF CONTENTS 4.3.1 Recommended Lubricants .....................106 4.3.2 Torque Speciﬁcations ......................106 SAE Bolt Torque Speciﬁcations..................107 Metric Bolt Speciﬁcations ....................109 Metric Bolt Speciﬁcations Bolting into Cast Aluminum ............112 Flare-Type Hydraulic Fittings ..................112 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) ............114 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ...........
Page 8 TABLE OF CONTENTS Installing Rock Guards ....................172 4.5.9 Rotary Deﬂectors ........................173 Inspecting Rotary Deﬂectors...................173 Removing Driven Rotary Deﬂectors and Driveline ............174 Installing Driven Rotary Deﬂectors and Driveline ..............177 Removing Non-Driven Rotary Deﬂectors .................181 Installing Non-Driven Rotary Deﬂectors ................182 4.5.10 Cutterbar Spindle Shear Pin....................184 Removing Cutterbar Spindle Shear Pin ................185 Installing Cutterbar Spindle Shear Pin ................186 Drive Systems ..........................190...
Page 9 TABLE OF CONTENTS 4.9.3 Replacing Driveshield Latch....................229 4.10 Roll Conditioner ..........................231 4.10.1 Inspecting Roll Conditioner ....................231 4.11 Finger Conditioner ........................233 4.11.1 Inspecting Finger Conditioner....................233 4.12 Changing the Conditioner......................235 4.12.1 Separating Header from Carrier .....................235 4.12.2 Removing the Conditioner......................239 4.12.3 Installing the Conditioner .......................240 4.12.4 Assembling Header and Carrier .....................241 4.13...
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 . 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: Tire Safety
SAFETY 1.6 Tire Safety • Follow proper procedures when mounting a tire on a wheel or rim. Failure to do so can produce an explosion that may result in serious injury or death. Figure 1.14: Overinﬂated Tire • Do NOT attempt to mount a tire unless you have the proper training and equipment.
Page 18: Safety Signs
SAFETY 1.7 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 19: Locating Safety Sign Decals
SAFETY 1.8 Locating Safety Sign Decals Figure 1.17: Safety Sign Decal Locations A - MD #194466 B - MD #247167 C - MD #194465 D - MD #190546 E - MD #247166 F - MD #113482 G - MD #174474 Figure 1.18: Safety Sign Decals 169820 Revision A...
Page 20 SAFETY Figure 1.19: Safety Sign Decal Location A - MD #171287 Figure 1.20: Safety Sign Decal Locations A - MD #113482 B - MD #171287 C - MD #174436 169820 Revision A...
Page 21: Understanding Safety Signs
SAFETY 1.9 Understanding Safety Signs NOTE: This is a general list of safety sign deﬁnitions, and every decal may not necessarily be applied to your machine. MD #113482 General hazard pertaining machine operation and servicing. CAUTION • Read the operator’s manual, and follow all safety instructions.
Page 22 SAFETY MD #171280 Lock pull-type (PT) hydraulic for transport WARNING • Charge cylinder with oil before towing. • Rotate valve handle to lock in transport position. • Maximum towing speed 20 mph (32 km/h). • Failure to comply could result in death or serious injury. Figure 1.23: MD #171280 MD #171281 Hot ﬂuid under pressure...
Page 23 SAFETY MD #174434 Raised mower conditioner hazard DANGER • Rest mower conditioner on ground or engage mechanical locks before going under unit. Figure 1.26: MD #174434 MD #174436 High pressure oil hazard CAUTION • High pressure oil easily punctures skin causing serious injury, gangrene, or death.
Page 24 SAFETY MD #184385 Entanglement hazard CAUTION • To avoid injury from entanglement with rotating auger, stand clear of while machine is running. Figure 1.29: MD #184385 MD #184386 Pinch hazard WARNING—KEEP AWAY • Failure to comply could result in death or serious injury. Figure 1.30: MD #184386 MD #190546 Slippery surface...
Page 25 SAFETY MD #194462 Engage lock WARNING • Engage safety lock before going under unit. • Failure to comply could result in death or serious injury. Figure 1.32: MD #194462 MD #194464 Shut down for service WARNING • Remove key from ignition. •...
Page 26 SAFETY MD #194466 Rotating ﬁngers under hood 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 1.35: MD #194466 MD #194521 Shield missing...
Page 27 SAFETY MD #247166 Moving implement hazard WARNING • To avoid injury, do not mount or ride machine while the machine is in motion. Figure 1.38: MD #247166 MD #247167 Rotating blades WARNING • Disengage power take-off, shut off tractor, and remove key before opening covers.
Page 29: Reference
• It is your responsibility to read and understand this manual completely before operating the mower conditioner. 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 30: Operational Safety
REFERENCE 2.2 Operational Safety CAUTION Follow these safety precautions: • Follow all safety and operational instructions provided in your operator's manuals. • Never attempt to start the engine or operate the machine except from the seat. • Check the operation of all controls in a safe and clear area before starting work. •...
Page 31: Definitions
REFERENCE 2.3 Deﬁnitions The following terms and abbreviations may be used in this manual: Term Deﬁnition American Petroleum Institute ASTM American Society of Testing and Materials A headed and externally threaded fastener that is designed to be Bolt paired with a nut. A hydraulic cylinder or turnbuckle type link between the mower Center-link conditioner and the carrier frame that tilts the mower conditioner.
Page 32 REFERENCE The product of a force X lever arm length, usually measured in Torque foot-pounds (ft·lbf) or Newton-meters (N·m). A tightening procedure where the ﬁtting is assembled to a Torque angle precondition (ﬁnger tight) and then the nut is turned further a number of degrees or a number of ﬂats to achieve its ﬁnal position.
Page 33: Component Identification
REFERENCE 2.4 Component Identiﬁcation Figure 2.2: Mower with Finger Conditioner A - Cutterbar Door B - Rear Swivel Gearbox C - Center-Link D - Amber Hazard/Turn Signal Light E - Red Tail/Brake Light F - Red Tail/Brake Light G - Front Curtains H - Amber Hazard/Turn Signal Light J - Carrier Frame K - Optional Endwise Transport System...
Page 34 REFERENCE Figure 2.3: Mower with Finger Conditioner A - Side Deﬂector B - Steering Cylinder C - Transport Latch D - Articulated Power Turn (APT) Hitch E - Driveline F - Lift Cylinder G - Float Spring H - Optional Endwise Transport Deployed 169820 Revision A...
Page 35 REFERENCE Figure 2.4: Mower with Finger Conditioner A - Rear Swivel Gearbox B - Forward Bafﬂe Control C - Hydraulic Center-Link D - Rear Deﬂector Control E - Driveshield 169820 Revision A...
Page 36 REFERENCE Figure 2.5: Mower with Finger Conditioner A - Optional Endwise Transport B - Forming Shield Cover C - Transport Latch D - Skid Shoe E - Side Deﬂector F - Rear Curtain Figure 2.6: Hitch and Driveline A - Control Hoses B - Primary Driveline C - Hose Support D - Rear Swivel Gearbox...
Page 37 REFERENCE Figure 2.7: Hitch Options A - Tractor Two-Point Hitch Adapter B - Tractor Drawbar Hitch Adapter C - Truck Transport Hitch Adapter 169820 Revision A...
Page 38: Product Specifications
REFERENCE 2.5 Product Speciﬁcations NOTE: Speciﬁcations and design are subject to change without notice or obligation to revise previously sold units. Table 2.1 Mower Conditioner Speciﬁcations Components 13-Foot 16-Foot Frame and Structure without ETO 13 ft.-4 in. (4063 mm) 16 ft.-6 in. (5027 mm) Transport Width with ETO 8 ft.-9 in.
Page 39 REFERENCE Components 13-Foot 16-Foot Conditioner System Intermeshing rolls (steel or polyurethane) Conditioner Speed 900 rpm Length of Rolls 10 ft.–9 in. (3275 mm) Roll Diameter Intermeshing Steel Bars 9 in. (229 mm) / 7 in. (179 mm) tube Intermeshing Polyurethane Bars 10 in..
Page 41: Operation
3 Operation 3.1 Lift Cylinder Lock-Out Valves Engaging lift cylinder lock-out valves before servicing, repairing, or unplugging your machine will prevent unintentional raising or lowering of the mower conditioner. 3.1.1 Engaging Locks 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.
Page 42: Disengaging Locks
OPERATION 3.1.2 Disengaging Locks 1. Open the lock-out valve (A) on each lift cylinder by turning the handle to the vertical position. Figure 3.3: Cylinder Lock-Out Valve 2. Move cylinder control lever (A) forward to position (B) to lower machine. Figure 3.4: Tractor Cylinder Control Lever 169820 Revision A...
Page 43: Driveshields
OPERATION 3.2 Driveshields 3.2.1 Opening Driveshields CAUTION Do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown are for left side driveshield—right side driveshield is similar. 1. Remove lynch pin (A) and tool (B) from pin (C). Figure 3.5: Driveshield 2.
Page 44: Closing Driveshields
OPERATION 3. Pull top of driveshield (A) away from mower conditioner to open. NOTE: For improved access, lift driveshield off the pins at the base of the shield, and lay the shield on the mower conditioner. Figure 3.7: Driveshield 3.2.2 Closing Driveshields CAUTION Do NOT operate the machine without the driveshields in place and secured.
Page 45 OPERATION 4. Replace tool (B) and lynch pin (A) on pin (C). Figure 3.9: Tool to Unlock Driveshield 169820 Revision A...
Page 46: Driveline Shield Cone
OPERATION 3.3 Driveline Shield Cone 3.3.1 Removing Driveline Shield Cone WARNING Do NOT operate the machine without the driveline shield cones in place and the lever clamps securely fastened. 1. Release two lever clamps (A) using a screwdriver or similar prying tool. 2.
Page 47 OPERATION 1. Slide shield cone along drive shaft until it is seated in metal plate (A). Figure 3.12: Driveline Shield Cone Removed from Metal Plate 2. Securely fasten two lever clamps (A) to metal plate (B). 3. Attach safety chain (C) to hitch, and ensure that chain is secured to the shield cone and metal plate.
Page 48: Cutterbar Doors
OPERATION 3.4 Cutterbar Doors WARNING Do NOT operate the machine without all the cutterbar doors down or without curtains installed and in good condition. There are two doors (A) that provide access to the cutterbar area. Rubber outboard curtains (B) are attached to each front corner, and an inboard curtain (C) is installed at the center ﬁxed cover location.
Page 49 OPERATION 1. Pull door at top to move to closed position. Figure 3.16: Cutterbar Door 2. Ensure that curtains hang properly and completely enclose cutterbar area. Figure 3.17: Cutterbar Doors in Closed Position 169820 Revision A...
Page 50: Daily Startup Check
OPERATION 3.5 Daily Startup Check Perform the following checks each day before startup: CAUTION • Ensure tractor and mower conditioner are properly attached, all controls are in neutral, and tractor brakes are engaged. • Clear the area of other persons, pets etc. Keep children away from machinery. Walk around the mower conditioner to make sure no one is under, on, or close to it.
Page 51 OPERATION 2. Clean all lights and reﬂective surfaces on the machine, and check lights for proper operation. 3. Perform all daily maintenance. Refer to 4.4.1 Maintenance Schedule/Record, page 121. 169820 Revision A...
Page 52: Preparing Tractor For Mower Conditioner
OPERATION 3.6 Preparing Tractor for Mower Conditioner 3.6.1 Tractor Requirements Table 3.1 Tractor Requirements Minimum Drawbar Mower Width Minimum Power Minimum Hydraulics Capacity 13-Foot 100 hp (75 kW) In accordance with ASAE 2000 psi (13.7 MPa) 16-Foot 125 hp (93 kW) NOTE: Tractor must be equipped with a seven-terminal outlet to supply power to the mower conditioner's hazard lights.
Page 53: Setting Up The Mower Conditioner Hitch
3.7 Setting Up the Mower Conditioner Hitch MacDon R113 and R116 mower conditioners are shipped from the factory ﬁtted for either a drawbar or two-point hitch, and your Dealer will have installed the proper hitch adapter for your tractor. The procedure for installing the drawbar hitch adapter onto the tractor drawbar is described in the following section.
Page 54: Attaching Mower Conditioner To The Tractor
OPERATION 3.8 Attaching Mower Conditioner to the Tractor 3.8.1 Attaching with Drawbar Hitch CAUTION Shut off tractor, engage parking brake, and remove key before working around hitch. 1. Remove lynch pin (A) from clevis pin (B), and remove clevis pin from mower conditioner hitch. Figure 3.22: Mower Conditioner Hitch 2.
Page 55: Attaching With Two-Point Hitch
OPERATION 6. Position driveline (A) onto tractor power take-off (PTO). 7. Pull back collar (B) on driveline (A), and push driveline until it locks. Release collar. 8. Route safety chain (C) from mower conditioner through chain support (D) on drawbar hitch adapter and around tractor drawbar support.
Page 56 NOTE: If tractor is equipped with a Category III hitch, use a bushing (MacDon #224322) on each hitch pin. 3. Secure arms (A) onto adapter pins (C) with lynch pins (springs not shown). 4. Install anti-sway bars (not shown) on tractor hitch to stabilize lateral movement of hitch arms (A).
Page 57 OPERATION 9. Start tractor and raise hitch so that stand (A) is off the ground. Shut down tractor and remove key from ignition. 10. Remove inner hairpin (B) and pull lock (C) to release stand. Figure 3.31: Hitch Stand 11. Raise stand (A), rotate lock (B) clockwise to vertical position, and re-engage lock (B) to hold the stand in the storage location.
Page 59: Connecting Hydraulics
OPERATION 3.8.3 Connecting Hydraulics WARNING Do NOT use remote hydraulic system pressures over 3000 psi (20,684 kPa). Check your tractor operator’s manual for remote system pressure. NOTE: Refer to colored bands on hoses to identify lift, steering/transport, and tilt hose sets. Table 3.4 Hydraulic System Hoses Tractor System...
Page 60: Connecting Electrical Wiring Harness
OPERATION 3. Connect two mower conditioner TILT cylinder hoses (C) to activate the following tractor hydraulic controls: (Not required with mechanical center-link.) Table 3.7 Mower Conditioner Tilt System Mower Control Lever Cylinder Conditioner Position Movement Movement Forward Retract Lower Backward Extend Raise 3.8.4 Connecting Electrical Wiring Harness...
Page 61: Detaching Mower Conditioner From Tractor
OPERATION 3.9 Detaching Mower Conditioner from Tractor 3.9.1 Detaching from Drawbar 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 62 OPERATION 7. Move jack (A) to working position at front of hitch and secure with pin (B). 8. Lower jack to take weight off tractor drawbar. 9. Disconnect safety chain (C) from drawbar and store on mower conditioner hitch. 10. Pull back collar (D) on driveline, slide coupler off tractor power take-off shaft, and rest driveline on hook (not shown).
Page 63: Detaching From Two-Point Hitch
OPERATION 3.9.2 Detaching from Two-Point Hitch 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. 1.
Page 64 OPERATION 7. Remove inboard hairpin (A) from lock (B). Figure 3.43: Inboard Hairpin 8. Hold stand (A), and pull lock (B) to disengage stand. Figure 3.44: Hitch Stand and Lock 9. Lower stand (A), rotate lock (C) counterclockwise to horizontal position, and push to engage stand. 10.
Page 65 OPERATION 14. Remove lynch pins (A) and washers and swing tractor arms (B) away from hitch adapter. NOTE: If tractor is equipped with a quick hitch system, it is NOT necessary to remove pins (A). 15. Replace lynch pins (A) and washers in mower conditioner hitch.
Page 66: Breaking-In The Mower Conditioner
OPERATION 3.10 Breaking-In the Mower Conditioner After attaching the mower conditioner to the tractor for the ﬁrst time, operate the machine at low speed for ﬁve minutes while watching and listening from the operator’s seat for binding or interfering parts. NOTE: Be especially alert and attentive until you become familiar with the sound and feel of your new mower conditioner.
Page 67: Engaging The Power Take-Off (Pto)
OPERATION 3.11 Engaging the Power Take-Off (PTO) DANGER Be sure all bystanders are clear of the machine before engaging the PTO. Never leave tractor seat with the PTO engaged. 1. Move the mower conditioner up to the standing crop, and slowly engage the PTO. 2.
Page 68: Raising And Lowering Mower Conditioner
OPERATION 3.12 Raising and Lowering Mower Conditioner 3.12.1 Lift Cylinders Two hydraulic cylinders (A), one at each end of the carrier, raise or lower the mower conditioner when the tractor’s cylinder control lever in the cab is activated. The lift system is equipped with a lock-out valve (B) at each cylinder which prevents the cylinder from extending or retracting due to inadvertent movement of the lift control.
Page 69: Shutdown Procedure
OPERATION 3.13 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 the power take-off. • Engage the park brake. •...
Page 70: Maneuvering/Steering The Mower Conditioner
OPERATION 3.14 Maneuvering/Steering the Mower Conditioner IMPORTANT: The valve on the steering line must be in the working, or open position (handle in line with hose), for the steering system to operate. Steering is controlled by the tractor’s remote hydraulic system.
Page 71: Right-Side Operation
OPERATION 3.14.1 Right-Side Operation Figure 3.51: Right-Side Operation 1. Move steering control lever (A) forward to position (B) until the mower conditioner reaches the desired path of travel on the right side of the tractor. Figure 3.52: Tractor Steering Control Lever 3.14.2 Left-Side Operation Figure 3.53: Left-Side Operation 169820...
Page 72: Avoiding Obstacles
OPERATION 1. Move steering control lever (A) backward to position (B) until the mower conditioner reaches the desired path of travel on the left side of the tractor. Figure 3.54: Tractor Steering Control Lever 3.14.3 Avoiding Obstacles Figure 3.55: Mower Conditioner Steered around Obstacle 1.
Page 73: Square Corners
OPERATION 3.14.4 Square Corners The following procedure is intended only as a guide for developing a turning procedure for your tractor and mower conditioner. Speciﬁc distances are not given due to the differing maneuverability of various tractors. 1. Guide the tractor sharply away from the crop when approaching a corner.
Page 74 OPERATION Figure 3.58: 180-Degree Turn 1. Guide the tractor away from the uncut crop beginning at position (A) while steering the mower conditioner in a straight line until it cuts through the end of the row. 2. Ensure the mower conditioner cuts past the end of the row, and immediately raise the mower conditioner until the skid shoes clear the ground.
Page 75: Transporting The Mower Conditioner
OPERATION 3.15 Transporting the Mower Conditioner The mower conditioner in normal ﬁeld mode or in endwise transport mode can be transported on public roads by towing with a tractor or a truck. Refer to 3.15.2 Transporting with a Tractor, page 66 3.15.3 Transporting with a Truck, page Endwise towing requires the optional endwise transport system.
Page 76: Transporting With A Tractor
OPERATION 3. Close the steering lock-out valve by turning the handle to the vertical position. Figure 3.60: Steering Lock-Out Valve in Open Position 4. Raise the mower conditioner fully, and close the cylinder lock-out valve (A) on each lift cylinder by turning the handle to the horizontal position.
Page 77: Transporting With A Truck
OPERATION 1. Hook-up mower conditioner to tractor (refer to Attaching Mower Conditioner to the Tractor, page 44). NOTE: The hydraulic hoses (A) do not need to be attached to the tractor for towing. Ensure they are securely stored on the hitch. NOTE: The power take-off (PTO) driveline (B) does not need to be attached for towing purposes.
Page 78 OPERATION 1. Store hydraulic hoses (A) on the hitch. 2. Place driveline (C) in hook (D). 3. Remove the forward half (B) of driveline and store in truck for transport. Figure 3.65: Mower Conditioner Hitch 4. Remove pins (A) from transport hitch (B). Figure 3.66: Transport Hitch 5.
Page 79: Transport Lighting
OPERATION 7. Wrap safety chain around hitch and attach to truck frame (A). 8. Connect electrical harness (B). 9. Check local laws for width regulations and lighting or marking requirements before transporting on roads. 10. Do not exceed 20 mph (32 km/h). Figure 3.68: Safety Chain and Electrical Harness 3.15.4 Transport Lighting Without Endwise Transport System Option...
Page 80: With Endwise Transport System Option
OPERATION With Endwise Transport System Option The mower conditioner is equipped with two bidirectional amber lights (A) located on the outboard edges of the carrier frame that function as ﬂashing hazard lights and turn signals. The red lights (B) located on the inboard side of the amber lights function as both tail and brake lights.
Page 81: Endwise Transport System Option
OPERATION 4. Open the lock-out valve (A) on each lift cylinder by turning the handle to the vertical position. Figure 3.72: Cylinder Lock-Out Valve 3.15.6 Endwise Transport System Option The optional endwise transport system allows the mower conditioner to be towed on roadways while remaining within the legal width restrictions on most roads and highways.
Page 82 OPERATION 1. Start tractor if not running. Do NOT operate the mower conditioner. 2. Raise the mower conditioner fully. 3. Align the hitch to the tractor. 4. Operate the steering control lever to swing the mower conditioner clockwise until the mower moves to the right of center.
Page 83: Converting From Transport To Field Mode
OPERATION 7. Hold the swing cylinder control lever until the transport assembly (A) has lifted the carrier frame (B) off the ground and has rotated the right side of the carrier frame towards hitch (C). 8. Release the swing cylinder control lever when the carrier frame (B) has stopped rotating.
Page 84 OPERATION 1. Operate the lift cylinder control lever (as if raising the mower conditioner) to fully extend the lift cylinders (A) and raise the cutterbar off the transport assembly support pad (B). The carrier frame latch (C) will automatically open. Figure 3.79: Lift Cylinders and Carrier Frame Latch 2.
Page 85: Operating The Mower Conditioner
OPERATION 3.16 Operating the Mower Conditioner Satisfactory operation of the mower conditioner in all situations requires making proper adjustments to suit various crops 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 your machine.
Page 86 OPERATION 1. Center mower conditioner directly behind the tractor. WARNING To avoid bodily injury or death from unexpected start-up or fall of raised machine: stop engine, remove key, and engage lift cylinder lock-out valves before going under machine. 2. Raise mower conditioner fully, shut off engine, and remove key.
Page 87: Mower Conditioner Angle
OPERATION 3.16.2 Mower Conditioner Angle Mower conditioner (or cutterbar) angle adjustment can range from 0–5° below horizontal using the mechanical center-link and from 0–7° below horizontal using the hydraulic center-link. Choose an angle that maximizes performance for your crop and ﬁeld conditions. A ﬂatter angle provides better clearance in stony conditions, whereas a steeper angle is required in down crops for better lifting action.
Page 88: Cutting Height
OPERATION 3.16.3 Cutting Height Cutting height is determined by a combination of the cutterbar/mower conditioner angle and skid shoe settings. Adjust cutting height for optimum cutting performance while preventing excessive build-up of mud and soil inside the mower conditioner that can lead to poor crop ﬂow and increased wear on cutting components. To choose an angle that maximizes performance for your crop and ﬁeld conditions, refer to 3.16.2 Mower Conditioner Angle, page...
Page 89 OPERATION 1. Raise mower conditioner fully, stop engine, and remove key. 2. Loosen bolts (C) and remove bolts, nuts, and washers (D). 3. Raise (A) or lower (B) skid shoe. NOTE: Skid shoes have two adjustment settings: Fully raised (A) or fully lowered (B). 4.
Page 90: Ground Speed
OPERATION 3.16.4 Ground Speed CAUTION Reduce speed when turning, crossing slopes, or 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 mower conditioner speed and ground speed to suit your speciﬁc crop. Refer to your tractor operator’s manual for changing ground speed.
Page 91: Roll Gap
OPERATION Roll Gap The degree to which the crop is conditioned as it passes through the rolls is controlled by the roll gap which is factory set at 1/4 in. (6 mm) for steel rolls and approximately 1/8 in. (3 mm) for polyurethane (poly) rolls. Correct conditioning of alfalfa, clover, and other legumes is achieved when 90% of the stems show cracking, but no more than 5% of the leaves are damaged.
Page 92 OPERATION Adjusting Roll Gap: Steel Rolls 1. Lower mower conditioner fully. 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. 2. Stop engine and remove key. 3.
Page 93: Roll Tension
OPERATION 3. Loosen and back off upper jam nut (A) on both sides of conditioner. 4. Turn stop nut (B) counterclockwise until upper roll rests on lower roll. Ensure both rolls intermesh. 5. Turn stop nut (B) one full turn clockwise to raise the upper roll and achieve a 3 mm roll gap..
Page 94: Roll Timing
OPERATION 2. Loosen jam nut (A) on both sides of conditioner. 3. Turn the spring drawbolt (B) clockwise to tighten spring (C) and increase roll tension. 4. Turn the spring drawbolt (B) counterclockwise to loosen spring (C) and decrease roll tension. 5.
Page 95 OPERATION 1. Lower mower conditioner fully, stop engine, and remove key from ignition. 2. Open the right side driveshield (refer to 3.2.1 Opening Driveshields, page 33). Figure 3.93: Right Side Driveshield 3. Examine the four bolts (A) in slots of yoke plate (B) on upper roll universal shaft.
Page 96: Forming Shields: Roll Conditioner
OPERATION Forming Shields: Roll Conditioner WARNING 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. The position of the forming shields controls the width and placement of the windrow.
Page 97: Conditioning: Finger Type
OPERATION Positioning Rear Bafﬂe: Roll Conditioner The rear bafﬂe primarily determines the height of the windrow but can also affect the width. It is located immediately behind and above the conditioning rolls and can be positioned to do the following: •...
Page 98: Internal Intensity Baffle
OPERATION Internal Intensity Bafﬂe Conditioning intensity is controlled by adjusting clearance ‘X’ between the rotor and the bafﬂe. There are seven clearance positions from 5/16—2-3/4 in. (8–71 mm). The setting chosen depends on crop volume and the desired level of conditioning. The highest clearance setting is recommended for heavy crops, and the lowest clearance setting should be used for maximum conditioning in average crops.
Page 99 OPERATION Changing Finger Rotor Speed The following outlines the procedure for changing ﬁnger speed change by changing the pulleys: 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. NOTE: •...
Page 100 OPERATION 4. Measure and record the distance from the shaft end to the taper lock bushing face (A) on both pulleys. 5. Remove three bolts (B) and insert them into the three threaded bores. 6. Apply uniform pressure to the taper lock bushing by slightly tightening each bolt in a circular pattern until the taper lock bushing comes free.
Page 101 OPERATION 15. Measure the length of tensioner spring (A), and turn adjuster nut (B) to adjust spring length to 14-3/8 in. to conform with spring tension decal (C). Figure 3.104: Spring Tension Decal 16. Install jam nut (A). 17. Hold a wrench on adjuster nut (B) and turn jam nut (A) clockwise into adjuster nut to lock tension adjustment.
Page 102: Forming Shields: Finger Conditioner
OPERATION Forming Shields: Finger Conditioner The position of the forming shields controls the width and placement of the windrow. Deciding which forming shield position to use is based on the following factors: • Weather conditions (rain, sun, humidity, wind) • Type and yield of crop •...
Page 103 OPERATION Positioning Rear Bafﬂe: Finger Conditioner The rear bafﬂe determines the width and height of the windrow. It is located immediately behind and above the conditioner and can be positioned to do the following: • Direct the crop ﬂow into the forming shield for narrow and moderate width windrows.
Page 104: Cutterbar Deflector
OPERATION 3.16.7 Cutterbar Deﬂector Cutterbar deﬂectors attach to the cutterbar just below the conditioner rolls and provide improved feeding into the conditioner rollers by preventing crop from feeding under the rolls when cutting heavy crops with long stems. Cutterbar deﬂectors may not be well-suited for are all environments, such as sandy conditions, and and are easily removed or installed in the ﬁeld.
Page 105: Tall Crop Divider Option
OPERATION 6. Repeat Step to Step to install 3., page 94 5., page 94 right deﬂector (A). 7. Align deﬂectors at position (B) and tighten bolts (C) to speciﬁed torque with a 16 mm socket and an 8 mm hex key. Figure 3.111: Right Cutterbar Deﬂector Viewed from Underside of Cutterbar 3.16.8 Tall Crop Divider Option...
Page 106 OPERATION 3. Remove three bolts (A), and remove deﬂector (B). 4. Reinstall three bolts (A). 5. Repeat for opposite side. 6. Close cutterbar doors. Figure 3.113: Deﬂector and Hardware 169820 Revision A...
Page 107: Installing Tall Crop Divider
OPERATION Installing Tall Crop Divider 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. Lower mower conditioner fully, shut down tractor and mower conditioner, and remove key.
Page 108: Haying Tips
OPERATION 3.17 Haying Tips 3.17.1 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 109: Driving On Windrow
OPERATION Table 3.10 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 110: Leveling The Mower Conditioner
If the mower conditioner is NOT level, check the tire pressure and ensure proper inﬂation. Refer to Inﬂating Tires, page 222. Component damage in the mower conditioner support system may occur if the mower conditioner cannot be leveled. See your MacDon Dealer. 169820 Revision A...
Page 111: Unplugging The Mower Conditioner
OPERATION 3.19 Unplugging the Mower Conditioner DANGER Stop tractor engine and remove key before removing plugged material from mower conditioner. A child or even a pet could engage the drive. 1. Stop forward movement of the tractor and stop the power take-off (PTO).
Page 113: Maintenance And Servicing
4 Maintenance and Servicing The following instructions provide information about routine mower conditioner service. Detailed maintenance and service information is contained in the technical service manual that is available from your Dealer. A parts catalog is located in a plastic case at the right end of the mower conditioner. Log hours of operation and use the maintenance record provided (refer to 4.4.1 Maintenance Schedule/Record, 121) to keep track of your scheduled maintenance.
Page 114: Recommended Safety Procedures
MAINTENANCE AND SERVICING 4.2 Recommended Safety Procedures • Park on level surface when possible. Securely block wheels if mower conditioner is parked on an incline. Follow all recommendations in your tractor operator's manual. • Wear close-ﬁtting clothing and cover long hair. Never wear dangling items such as scarves or bracelets.
Page 115 MAINTENANCE AND SERVICING • Be prepared if an accident should occur. Know where the ﬁrst aid kits and ﬁre extinguishers are located, and know how to use them. Figure 4.4: Safety Equipment • Keep the service area clean and dry. Wet or oily ﬂoors are slippery.
Page 116: Maintenance Specifications
MAINTENANCE AND SERVICING 4.3 Maintenance Speciﬁcations 4.3.1 Recommended Lubricants Keep your machine operating at top efﬁciency by using only clean lubricants and by ensuring the following: • Use clean containers to handle all lubricants. • Store lubricants in an area protected from dust, moisture, and other contaminants. IMPORTANT: Do NOT overﬁll the cutterbar when adding lubricant.
Page 117: Sae Bolt Torque Specifications
MAINTENANCE AND SERVICING SAE Bolt Torque Speciﬁcations Torque values shown in the following tables are valid for non-greased, or non-oiled threads and heads; therefore, do NOT grease or oil bolts or cap screws unless otherwise speciﬁed in this manual. Table 4.2 SAE Grade 5 Bolt and Grade 5 Free Spinning Nut Torque (ft·lbf) Torque (N·m)
Page 118 MAINTENANCE AND SERVICING Table 4.3 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 4.7: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8...
Page 119: Metric Bolt Specifications
MAINTENANCE AND SERVICING Table 4.5 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 4.9: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8...
Page 120 MAINTENANCE AND SERVICING Table 4.7 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 4.11: Bolt Grades 10-1.5 12-1.75 14-2.0...
Page 121 MAINTENANCE AND SERVICING Table 4.9 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 4.13: Bolt Grades 10-1.5 12-1.75 14-2.0...
Page 122: Metric Bolt Specifications Bolting Into Cast Aluminum
MAINTENANCE AND SERVICING Metric Bolt Speciﬁcations Bolting into Cast Aluminum Table 4.10 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 4.14: Bolt Grades –...
Page 123 MAINTENANCE AND SERVICING Table 4.11 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 124: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)
MAINTENANCE AND SERVICING 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 loose and is pushed toward the lock nut (C) as far as possible.
Page 125 MAINTENANCE AND SERVICING Table 4.12 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 126: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)
MAINTENANCE AND SERVICING 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 127: O-Ring Face Seal (Orfs) Hydraulic Fittings
MAINTENANCE AND SERVICING 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 4.19: Hydraulic Fitting 2. Apply hydraulic system oil to the O-ring (B). 3.
Page 128 MAINTENANCE AND SERVICING Table 4.14 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 41–45 55–61 13/16-16 1–14 59–65 80–88 1-3/16-12 85–94 115–127...
Page 129: Conversion Chart
MAINTENANCE AND SERVICING 4.3.3 Conversion Chart Table 4.15 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 130: Maintenance Requirements
MAINTENANCE AND SERVICING 4.4 Maintenance Requirements Periodic maintenance requirements are organized according to service intervals. Regular maintenance is the best insurance against early wear and untimely breakdowns. Following the maintenance schedule will increase your machine’s life. When servicing the machine, refer to the speciﬁc headings in this section and use only ﬂuids and lubricants speciﬁed 4.3.1 Recommended Lubricants, page 106.
Page 131: Maintenance Schedule/Record
Hydraulic Hoses and Lines - Refer to 4.7.1  Hydraulic Hoses and Lines, page 224. NOTE: MacDon recommends keeping a record of daily Cutter Blades, Deﬂectors and Discs - Refer to maintenance as evidence of a properly maintained  4.5 Cutterbar, page 136.
Page 132 MAINTENANCE AND SERVICING 50 HOURS Cutterbar Lube (First 50 and 250 hours) - Refer  Checking Lubricant Level, page 136. Roll Universal Shafts - Refer to 4.4.5  Lubricating the Mower Conditioner, page 125. Hitch Driveline Universals - Refer to 4.4.5 ...
Page 133: Break-In Inspections
MAINTENANCE AND SERVICING 4.4.2 Break-In Inspections Table 4.16 Break-In Inspection Schedule Inspection Item Refer to Interval Wheel bolts Checking Wheel Bolts, page 220 Hour Check for loose hardware and 4.3.2 Torque Speciﬁcations, page 106 tighten to required torque. Hours Check drive belt tension. Inspecting Conditioner Drive Belt, page 207 Check drive belt tension.
Page 134: End-Of-Season Servicing
MAINTENANCE AND SERVICING 4.4.4 End-of-Season Servicing Perform the following procedures at the end of each operating season: CAUTION Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or ﬂammable. CAUTION Cover cutterbar to prevent injury from accidental contact. 1.
Page 135: Lubricating The Mower Conditioner
MAINTENANCE AND SERVICING 4.4.5 Lubricating the Mower Conditioner WARNING To avoid personal injury, before servicing mower conditioner or opening drive covers, refer to 4.1 Preparing Machine for Servicing, page 103. Greasing points are marked on the machine by decals showing a grease gun and the grease interval in hours of operation.
Page 136: Greasing Procedure
MAINTENANCE AND SERVICING Greasing Procedure CAUTION 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. Open driveshields at ends of mower conditioner to access greasing points. Refer to 3.2.1 Opening Driveshields, page 2.
Page 137: Service Intervals
MAINTENANCE AND SERVICING Service Intervals Every 25 Hours NOTE: Use High Temperature Extreme Pressure (EP2) Performance with 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base unless otherwise speciﬁed. Figure 4.22: Every 25 Hours A - Conditioner Drive Idler B - Bearing for Finger-Type Conditioner 169820 Revision A...
Page 138 MAINTENANCE AND SERVICING NOTE: Use High Temperature Extreme Pressure (EP2) Performance with 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base unless otherwise speciﬁed. Figure 4.23: Every 25 Hours A - Hitch Steering Pivot B - Tractor Hitch Pivot 169820 Revision A...
Page 139 MAINTENANCE AND SERVICING NOTE: It may be necessary to remove and replace the driveline shield cones during the greasing procedure. Refer to for more information. Driveline Shield Cone, page 36 NOTE: Use High Temperature Extreme Pressure (EP2) Performance with 10% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base unless otherwise speciﬁed.
Page 140 MAINTENANCE AND SERVICING NOTE: Use High Temperature Extreme Pressure (EP2) Performance with 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base unless otherwise speciﬁed. Figure 4.25: Every 25 Hours A - Endwise Transport Casting Pivot B - Endwise Transport Wheel Frame Pivot NOTE: Use High Temperature Extreme Pressure (EP2) Performance with 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base unless otherwise speciﬁed.
Page 141 MAINTENANCE AND SERVICING Every 50 Hours NOTE: Use High Temperature Extreme Pressure (EP2) Performance with 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base unless otherwise speciﬁed. Figure 4.27: Every 50 Hours 169820 Revision A...
Page 142 MAINTENANCE AND SERVICING Every 100 Hours 1. Ensure top of hitch and mower conditioner are horizontal, remove check plug from swivel gearbox, and verify that oil slightly runs out when removed. Figure 4.28: Every 100 Hours A - Check Plug - Swivel Gearbox B - Check Plug - Swivel Gearbox C - Check Plug - Swivel Gearbox D - Check Plug - Swivel Gearbox...
Page 143 MAINTENANCE AND SERVICING Figure 4.29: Every 100 Hours B - Bearing - Field Wheel (2 Places) 12 A - Check Plug - Mower Conditioner C -Bearing - Endwise Transport Option (2 Places) Drive Gearbox 11 11. Remove check plug from conditioner drive gearbox as shown and check oil level. 12.
Page 144 MAINTENANCE AND SERVICING Every 250 Hours 1. Change lubricant in locations (A), (B), and (C). Refer to the following sections for more information: • 4.5.1 Cutterbar Lubrication, page 136. • Checking and Changing Conditioner Gearbox Oil, page 211. • Lubricating Mower Conditioner Drive Gearbox, page 214.
Page 145 MAINTENANCE AND SERVICING 2. Change lubricant in hitch swivel gearboxes (A), (B), (C), and (D). Refer to 4.6.8 Forward and Rear Swivel Gearboxes, page 219. Figure 4.31: Every 250 Hours A - Upper Forward Gearbox B - Lower Forward Gearbox C - Upper Rear Gearbox D - Lower Rear Gearbox 169820...
Page 146: Cutterbar
MAINTENANCE AND SERVICING 4.5 Cutterbar The cutterbar does not require regular maintenance other than checking and changing the lubricant at regular intervals. Refer to 4.4.1 Maintenance Schedule/Record, page 121. IMPORTANT: Check the lubricant level when the lubricant is warm. If the lubricant is cold, idle the machine for about 10 minutes prior to checking.
Page 147 MAINTENANCE AND SERVICING CAUTION Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 5. Use a spirit level to ensure the cutterbar is level in both directions. Raise or lower mower conditioner accordingly.
Page 148: Draining Cutterbar
MAINTENANCE AND SERVICING Draining Cutterbar 1. Park the mower conditioner on level ground. 2. Place a block under each end of the mower conditioner. NOTE: Block mower conditioner so one end is higher than the opposite end. 3. Clean around cutterbar end plate (B). 4.
Page 149: Filling Cutterbar
MAINTENANCE AND SERVICING Filling Cutterbar 1. Add exactly 10-1/2 quarts (US) (10 liters) of SAE 90 lubricant through ﬁller hole (A) at high end of cutterbar for ten disc cutterbar, and add exactly 8-1/2 quarts (US) (8 liters) of SAE 90 lubricant for eight disc cutterbar. IMPORTANT: Do NOT overﬁll the cutterbar.
Page 150: Removing Cutterbar Discs
MAINTENANCE AND SERVICING CAUTION Damaged blades may damage the cutterbar and result in poor cutting performance. Replace damaged blades at earliest possible opportunity. 1. Ensure that the cutter blade fasteners (A) are securely attached to the cutterbar disc and that nut shields (B) are present and undamaged.
Page 151: Installing Cutterbar Discs
MAINTENANCE AND SERVICING 4. Place a pin (or equivalent) in the front hole of the rock guard (B) to prevent disc rotation while loosening bolts. 5. Remove four M12 bolts (A) and washers. Figure 4.40: Cutterbar Disc Bolts 6. Remove cutterbar disc cap (A). 7.
Page 152 MAINTENANCE AND SERVICING 1. Place a pin (or equivalent) in the front hole of the rock guard (D) to prevent disc rotation while tightening bolts. 2. Position new disc (A) on spindle ensuring that it is positioned at a 90° angle in relation to the adjacent discs.
Page 153: Cutterbar Spindles
MAINTENANCE AND SERVICING 4.5.3 Cutterbar Spindles Discs are factory installed to produce three crop-streams, but disc rotation patterns can be changed to suit crop conditions. To prevent damage to the cutterbar and drive systems, each disc is attached to a spindle containing a shear pin (A).
Page 154 MAINTENANCE AND SERVICING Figure 4.46: 13-Foot (8 Disc) Spindle Rotation Pattern and Crop Streams A - One Crop-Stream B - Two Crop-Streams C - Three Crop-Streams D - Four Crop-Streams 13-Foot (8 Disc) Spindle Rotation Patterns Changing from three crop-streams (C) to one crop-stream (A): •...
Page 155 MAINTENANCE AND SERVICING Figure 4.47: 16-Foot (10 Disc) Spindle Rotation Pattern and Crop Streams A - One Crop-Stream B - Two Crop-Streams C - Three Crop-Streams D - Four Crop-Streams 16-Foot (10 Disc) Spindle Rotation Patterns Changing from three crop-streams (C) to one crop-stream (A): •...
Page 156: Removing Cutterbar Spindles
MAINTENANCE AND SERVICING Removing Cutterbar Spindles DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage header lift cylinder lock-out valves before going under machine for any reason. CAUTION Cutter blades have two cutting edges.
Page 157 MAINTENANCE AND SERVICING 5. Remove cutterbar disc cap (A). 6. Remove cutterbar disc (B). IMPORTANT: Blades are rotation speciﬁc. It is necessary to switch entire disc when swapping spindles. Figure 4.50: Cutterbar Disc and Cap 7. Remove spacer plate (A). Figure 4.51: Spacer Plate 8.
Page 158: Installing Cutterbar Spindles
MAINTENANCE AND SERVICING 9. Remove spindle (A) from cutterbar. Figure 4.53: Left-Hand Spindle Installing Cutterbar Spindles DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage header lift cylinder lock-out valves before going under machine for any reason. CAUTION Cutter blades have two cutting edges.
Page 159 MAINTENANCE AND SERVICING Figure 4.54: Underside of Cutterbar Spindles Installed in Cutterbar IMPORTANT: Right-hand discs (A) and left-hand discs (B) are timed and must be at 90° when reinstalled. Misaligned discs could result in the following: • Cutter blades of co-rotating discs hitting each other. •...
Page 160 MAINTENANCE AND SERVICING 1. Lower mower conditioner fully, shut off engine, and remove key. NOTE: Ensure mower conditioner is on a ﬂat, level surface and is tilted all the way back while installing spindles to prevent oil from spilling from the cutterbar.
Page 161 MAINTENANCE AND SERVICING 5. Insert spindle (A) into cutterbar. Figure 4.58: Left-Hand Spindle 6. Insert studs (A) into spindle as shown. NOTE: Plugs are factory installed as shown in position (B) but may come loose over time. Ensure studs are inserted into proper location. IMPORTANT: Ensure clockwise spindles rotate clockwise and counterclockwise spindles (with machined...
Page 162 MAINTENANCE AND SERVICING 8. Install spacer plate (A). Figure 4.61: Spacer Plate 9. Place a pin (or equivalent) in the front hole of the rock guard (D) to prevent disc rotation while tightening bolts. IMPORTANT: Blades are rotation speciﬁc. It is necessary to switch entire disc when swapping spindles.
Page 163: Cutter Blades
MAINTENANCE AND SERVICING 4.5.4 Cutter Blades Each disc has two cutter blades (A) attached at opposite ends that are free to rotate horizontally on a specially designed shoulder bolt. The blade has two cutting edges and can be ﬂipped over so that the blade does not need replacing as often.
Page 164 MAINTENANCE AND SERVICING IMPORTANT: The cutter blades 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. If you are unsure which direction the spindles rotate, refer to 4.5.3 Cutterbar Spindles, page...
Page 165: Inspecting Cutter Blade Hardware
MAINTENANCE AND SERVICING Inspecting Cutter Blade Hardware 1. Inspect blade attachment hardware each time blades are changed. 2. Check and replace bolts under the following conditions: a. Bolt has been removed and reinstalled ﬁve times. b. Head (A) is worn ﬂush with bearing surface of blade.
Page 166: Removing Cutter Blades
MAINTENANCE AND SERVICING 3. Check and replace nuts under the following conditions: a. Nut has been previously installed—nuts are one-time-use only. b. Nut shows signs of wear (A) that is more than half the original height (B). c. Nut is cracked. Figure 4.69: Cutter Blade Nut Removing Cutter Blades DANGER...
Page 167: Installing Cutter Blades
MAINTENANCE AND SERVICING 4. Rotate disc (A) so that blade (B) faces forward and lines up with hole (C) in rock guard. Figure 4.71: Cutter Blade Aligned with Hole in Rock Guard 5. Place a pin (or equivalent) in the front hole of the rock guard to prevent disc rotation while loosening blade bolts.
Page 168: Cutterbar Doors
MAINTENANCE AND SERVICING 1. Place a pin (or equivalent) in the front hole of the rock guard to prevent disc rotation while tightening blade bolts. 2. Install new or reversed blade (A) with shoulder bolt (B) onto disc (C). IMPORTANT: Nuts are one-time-use only.
Page 169: Inspecting Cutterbar Doors
MAINTENANCE AND SERVICING Inspecting Cutterbar Doors 1. Ensure that door operates smoothly and lies ﬂat when closed. Adjust if necessary. 2. Inspect hinge pin bolts (A) and tighten if loose. 3. Check door for cracks and repair if required. 4. Check for exposed metal surfaces and surface rust. Repair and repaint if necessary.
Page 170: Curtains
MAINTENANCE AND SERVICING 1. Pull door at top to move to closed position. Figure 4.78: Cutterbar Door 2. Ensure that curtains hang properly and completely enclose cutterbar area. Figure 4.79: Cutterbar Doors in Closed Position 4.5.6 Curtains Rubber curtains are installed at the following locations: •...
Page 171: Inspecting Curtains
MAINTENANCE AND SERVICING Inspecting Curtains WARNING Do NOT operate the machine without all the cutterbar doors down or without curtains installed and in good condition. CAUTION To avoid injury, keep hands and ﬁngers away from corners of doors when closing. Rubber curtains are attached to each door and at the front corners and center ﬁxed cover.
Page 172: Installing Cutterbar Door Curtains
MAINTENANCE AND SERVICING 2. Remove ﬁve nuts (A) from the bolt studs. 3. Remove shield panel (B). 4. Remove curtain (C). Figure 4.83: Nuts Securing Shield Panel and Curtain to Cutterbar Door Installing Cutterbar Door Curtains The procedure for installing cutterbar door curtains is the same for both sides. 1.
Page 173: Removing Cutterbar Inboard Curtain
MAINTENANCE AND SERVICING 4. Close cutterbar door. Refer to Closing Cutterbar Doors, page 159. Figure 4.86: Cutterbar Doors in Closed Position Removing Cutterbar Inboard Curtain 1. Open cutterbar doors to gain access to inboard curtain nuts. Refer to Opening Cutterbar Doors, page 159.
Page 174: Installing Cutterbar Inboard Curtain
MAINTENANCE AND SERVICING 3. Remove four nuts (A) from weld studs on center shield, remove two curtain brackets (B), and remove curtain. Figure 4.89: Inboard Curtain, Nuts, and Brackets Installing Cutterbar Inboard Curtain 1. Open cutterbar doors to gain access to inboard curtain nuts.
Page 175: Removing Outboard Curtains
MAINTENANCE AND SERVICING 3. Secure two curtain brackets (A) to center shield using two M10 carriage head bolts (B) and nuts. 4. Torque bolts (A) to 30 ft·lbf (40 N·m). Figure 4.92: Inboard Curtain Attached to Mower Conditioner Removing Outboard Curtains The procedure for removing outboard curtains is the same for both sides.
Page 176: Installing Outboard Curtains
MAINTENANCE AND SERVICING 3. Remove two nuts (A) from bolt studs. 4. Remove the square neck carriage head bolt (B), slide out the bracket, and remove curtain (C). Figure 4.95: Outboard Curtain Installing Outboard Curtains The procedure for installing outboard curtains is the same for both sides. 1.
Page 177 MAINTENANCE AND SERVICING 2. Install curtain (A) into bracket (B). 3. Install two nuts (D) and tighten. 4. Slide bracket (B) into position, and install the square neck carriage head bolt and ﬂange nut (C). 5. Torque ﬂange nut (C) to 30 ft·lbf (40 N·m). Figure 4.97: Outboard Curtain 6.
Page 178: Accelerators
MAINTENANCE AND SERVICING 4.5.7 Accelerators Accelerators (A) are mounted on each outboard disc and are designed to quickly move cut material off the disc and into the conditioner. One pair of accelerators is installed at each outboard end of a 13-foot mower conditioner, whereas a 16-foot mower conditioner has two pairs.
Page 179: Removing Accelerators
MAINTENANCE AND SERVICING Removing Accelerators 1. Raise mower conditioner fully, shut off engine, and remove key. 2. Engage lift cylinder lock-out valves (refer to 3.1.1 Engaging Locks, page 31). 3. Remove nut (A), ﬂange bolt (B), and cutter blade (C) from disc.
Page 180: Installing Accelerators
MAINTENANCE AND SERVICING Installing Accelerators 1. Place a wooden block between two cutterbar discs to prevent disc rotation while tightening blade bolts. IMPORTANT: Accelerators can operate in a clockwise or counterclockwise direction. Verify the direction of the disc before installing accelerators. If you are unsure which direction the spindle rotates, refer to 4.5.3 Cutterbar Spindles, page...
Page 181: Rock Guards
MAINTENANCE AND SERVICING 4.5.8 Rock Guards The machine is equipped with rock guards at each cutting disc location. Rock guards prevent the cutterbar from digging into the ground and protect the disc from coming in contact with stones and other debris. Inspecting Rock Guards DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove...
Page 182: Installing Rock Guards
MAINTENANCE AND SERVICING 2. Slide rock guard (A) forward in the direction of arrow (B) and remove. Figure 4.109: Rock Guard Removed from Cutterbar Installing Rock Guards 1. Guide rock guard onto cutterbar until tabs (A) sit on top of the cutterbar while bottom back bolt holes line up. Figure 4.110: Rock Guard Installed on Cutterbar 2.
Page 183: Rotary Deflectors
MAINTENANCE AND SERVICING 4.5.9 Rotary Deﬂectors The rotary deﬂectors are designed to deliver cut material from the ends of the cutterbar and help maintain an even ﬂow of crop into the conditioner. Rotary deﬂectors are attached to only the two outboard discs at each end of the cutterbar.
Page 184: Removing Driven Rotary Deflectors And Driveline
MAINTENANCE AND SERVICING 3. Inspect deﬂectors (A) and (B) for damage and wear, and replace if deﬂectors are worn at the center to 50% or more of their original thickness. Do NOT repair deﬂectors. 4. Examine drums for signiﬁcantly sized dents. Replace dented drums to prevent an imbalance in the cutterbar.
Page 185 MAINTENANCE AND SERVICING 2. Remove four M10 hex ﬂange head bolts (A) and remove vertical drive shield (B). Figure 4.116: Vertical Drive Shield 3. Remove two M10 hex ﬂange head bolts (A) and remove cover plate (B). Figure 4.117: Cover Plate 4.
Page 186 MAINTENANCE AND SERVICING 5. Remove M10 hex ﬂange head bolt (A) and remove vertical shield (B). Figure 4.119: Vertical Shield 6. Remove eight M8 hex ﬂange head bolts (A), and remove two drum shields (B). Figure 4.120: Drum Shields 7. Remove four M12 hex ﬂange head bolts (A) and spacers securing driveline assembly (B) to hub drive (C).
Page 187: Installing Driven Rotary Deflectors And Driveline
MAINTENANCE AND SERVICING 8. Slide driveline (A) downwards, tilt to the side, and pull driveline up and out of drum (cut away view of drum and tube shield shown for improved clarity). Figure 4.122: Vertical Driveline (Cut Away View Shown) 9.
Page 188 MAINTENANCE AND SERVICING NOTE: Arrow indicates forward direction. 1. Position the rotary deﬂector disc assembly as shown. 2. Use a 12 in. extension and 16 mm deep socket to install the four M12 bolts (A) and washers that hold the deﬂector disc in place.
Page 189 MAINTENANCE AND SERVICING 7. Position two drum shields (B) as shown, and secure with eight M8 hex ﬂange head bolts (A). Figure 4.127: Drum Shields 8. Position vertical shield (B) as shown, and install M10 hex ﬂange head bolt (A). Figure 4.128: Vertical Shield 9.
Page 190 MAINTENANCE AND SERVICING 10. Install cover plate (A), insert top M10 hex ﬂange head bolt (B) through cover plate and top plate (C), and install lower M10 hex ﬂange head bolt (D) through cover plate and vertical shield (E). Tighten bolts. Figure 4.130: Cover Plate 11.
Page 191: Removing Non-Driven Rotary Deflectors
MAINTENANCE AND SERVICING WARNING Ensure cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage. 12. Close cutterbar doors (refer to Closing Cutterbar Doors, page 159).
Page 192: Installing Non-Driven Rotary Deflectors
MAINTENANCE AND SERVICING NOTE: Arrow indicates forward direction. 2. Place a wooden block between two cutterbar discs to prevent disc rotation while loosening blade bolts. 3. Remove eight M8 bolts (A) and washers securing the cover to the non-driven rotary deﬂector. Figure 4.134: 16-Foot Mower Conditioner Shown 4.
Page 193 MAINTENANCE AND SERVICING NOTE: Arrow indicates forward direction. 1. Orient each disc at a 90° angle relative to the neighboring discs. NOTE: Discs are direction speciﬁc. It is important to ensure proper disc orientation. Figure 4.136: Cutterbar Discs (Top View) 2.
Page 194: Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING WARNING Ensure cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage. 5. Close cutterbar doors (refer to Closing Cutterbar Doors, page 159).
Page 195: Removing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING Removing Cutterbar Spindle Shear Pin 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 mower conditioner fully, shut off engine, and remove key.
Page 196: Installing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING Installing Cutterbar Spindle Shear Pin 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. Remove two M10 bolts (A) and washers. NOTE: Do NOT damage the nuts or threads during disassembly.
Page 197 MAINTENANCE AND SERVICING 4. Use safecut spindle-nut wrench removed in Step to torque spindle nut (A) to 221 ft·lbf 2., page 186 (300 N·m). NOTE: Turn left-hand threads clockwise to tighten, and turn right-hand threads counterclockwise to tighten. 5. Return safecut spindle-nut wrench to left side shield plate.
Page 198 MAINTENANCE AND SERVICING 8. Use a pin punch and hammer to install one shear pin (A) so that the outermost end is ﬂush with hub landing (B). IMPORTANT: Proper shear pin orientation during installation is critical. Shear pin grooves must be facing the same direction and oriented on a horizontal plane parallel to the cutterbar.
Page 199 MAINTENANCE AND SERVICING WARNING Ensure cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage. 12. Close cutterbar doors (refer to Closing Cutterbar Doors, page 159).
Page 200: Drive Systems
MAINTENANCE AND SERVICING 4.6 Drive Systems 4.6.1 Primary Driveline The primary driveline transfers power from the tractor’s power take-off (PTO) to the mower conditioner’s forward swivel gearbox. No maintenance is required other than regular lubrication. Refer to 4.4.5 Lubricating the Mower Conditioner, page 125.
Page 201: Installing Primary Driveline
MAINTENANCE AND SERVICING 4. Slide driveline shield cone away from gearbox. 5. Loosen nut (A) and use a hammer to release yoke from taper pin lock. 6. Pull driveline off gearbox. 7. Remove driveline guard if necessary. Refer to Removing Driveline Guard, page 204.
Page 202: Hitch Driveline
MAINTENANCE AND SERVICING 4. Attach the male half (A) of driveline to the female half, and position onto storage hook (B) or connect to tractor power take-off (PTO). To attach unit to tractor, refer to 3.8 Attaching Mower Conditioner to the Tractor, page Figure 4.159: Primary Driveline 4.6.2 Hitch Driveline The hitch driveline is a solid shaft that connects the forward...
Page 203 MAINTENANCE AND SERVICING 1. Stop engine, and remove key from ignition. 2. Disconnect clutch driveline (A) at the center support. Do not remove entire driveline. Refer to Removing Clutch Driveline, page 199. Figure 4.161: Clutch Driveline 3. Remove three screws (A) from driveshield cover, and slide driveline away from center support.
Page 204 MAINTENANCE AND SERVICING 5. Remove two bolts (A) that secure metal plate (B) to the center support. Figure 4.163: Metal Plate 6. Remove spacer (A). Figure 4.164: Spacer 7. Support driveline and remove ﬁve nuts (A), ﬂange with grease ﬁtting (B), ball bearing (C), ﬂange (D), and unlock bearing lock collar.
Page 205: Installing Hitch Driveline
MAINTENANCE AND SERVICING 8. Lower driveline from center support. NOTE: Bolts may or may not be removed. If removing bolts, note position of the long (A) and short (B) bolts. Figure 4.166: Long and Short Bolts Installed at Center Support 9.
Page 206 MAINTENANCE AND SERVICING 2. Position forward end of hitch driveline (A) onto forward swivel gearbox shaft and push onto shaft. Figure 4.168: Forward End of Hitch 3. Position shaft hitch driveline onto center support. 4. Install two long bolts (A) and three short bolts (B) exactly as shown.
Page 207 MAINTENANCE AND SERVICING 7. Ensure bearing lock collar is on the backside of the support bracket, and install ball bearing (C), ﬂange (B) with grease ﬁtting (D), and ﬁve nuts (A). IMPORTANT: Grease ﬁtting (D) must be positioned 90° from long bolts as shown.
Page 208 MAINTENANCE AND SERVICING 12. Position driveshield cover on center support and secure with three screws (A). 13. Install metal shield (B) with two bolts. NOTE: There are two hitch drivelines for installation on 16-foot mower conditioners. Figure 4.174: Driveline Cover and Shield Installed at Center Support 14.
Page 209: Clutch Driveline
MAINTENANCE AND SERVICING 4.6.3 Clutch Driveline The clutch driveline (A) transfers power from the hitch driveline to the rear swivel gearbox through a clutch mechanism. Replace the driveline if there are signs of damage, vibration, excessive noise, or if the clutch needs replacing. No maintenance is required other than regular lubrication.
Page 210 MAINTENANCE AND SERVICING 4. Remove driveline shield cone from metal plate, and slide driveline shield cone (A) away from center support. 5. Loosen nut (B) and use a hammer to release yoke from taper pin lock. Figure 4.178: U-Joint 6. Slide clutch driveline (A) off hitch driveline. 7.
Page 211: Installing Clutch Driveline
MAINTENANCE AND SERVICING 9. Slide shield away from gearbox. 10. Loosen nut (A), use a hammer to release driveline from taper pin lock, and pull driveline off gearbox shaft. Figure 4.181: Driveline and Gearbox 11. Remove driveline guard if necessary. Refer to Removing Driveline Guard, page 204.
Page 212 MAINTENANCE AND SERVICING 4. Slide the shield cone to the gearbox and secure with the two lever clamps (A). Figure 4.183: Driveline Shield Cone 5. Assemble forward half (A) of clutch driveline onto female half, and attach to shaft on hitch driveline (B). Figure 4.184: Clutch Driveline Attached to Hitch Driveline 6.
Page 213 MAINTENANCE AND SERVICING 7. Slide shield cone onto metal plate (C) attached to center support, secure with two lever clamps (A), and hook safety chain (B) to hitch. Figure 4.186: Driveline Shield Cone 169820 Revision A...
Page 214: Driveline Guard
MAINTENANCE AND SERVICING 4.6.4 Driveline Guard Removing Driveline Guard WARNING Do NOT operate the machine without the driveline guards in place and securely fastened. 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 215: Installing Driveline Guard
MAINTENANCE AND SERVICING 5. Remove base cone (A) and shield tube (B) from driveline (not shown) and outer cone (C). Figure 4.189: Base Cone and Shield Tube Removed from Outer Cone 6. Remove shield support (A) from outer cone (B). Figure 4.190: Shield Support Removed from Outer Cone Installing Driveline Guard...
Page 216 MAINTENANCE AND SERVICING 1. Stop engine, and remove key from ignition. 2. Grease the bearing groove (A) on the inner yokes. NOTE: Use High Temperature Extreme Pressure (EP2) Performance with 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base unless otherwise speciﬁed.
Page 217: Conditioner Drive Belt
MAINTENANCE AND SERVICING 6. Install three self-tapping Phillips head screws (A) into base cone (B). NOTE: Hand tighten only using an appropriate screw driver. Do NOT use a powered tool to tighten screws. Figure 4.194: Phillips Head Screws Installed in Base Cone 7.
Page 218: Removing Conditioner Drive Belt
MAINTENANCE AND SERVICING 1. Lower mower conditioner fully, turn off engine, and remove key. 2. Open the left side driveshield (A) (refer to 3.2.1 Opening Driveshields, page 33). Figure 4.196: Left Side Driveshield 3. Inspect drive belt (A) and replace if damaged or cracked.
Page 219: Installing Conditioner Drive Belt
MAINTENANCE AND SERVICING 1. Lower mower conditioner fully, turn off engine, and remove key. 2. Remove the left driveshield (A) (refer to 4.9.1 Removing Driveshields, page 227). Figure 4.199: Left Driveshield 3. Turn jam nut (A) counterclockwise to unlock tension adjustment. 4.
Page 220 MAINTENANCE AND SERVICING 1. Lower mower conditioner fully, turn off engine, and remove key. 2. Install drive belt (A) onto driven pulley (C) ﬁrst, and then onto drive pulley (B) ensuring that the belt is in the pulley grooves. NOTE: If necessary, loosen jam nut and adjuster nut to relieve spring tension.
Page 221: Conditioner Drive Gearbox
The gearbox does not require routine maintenance or service other than checking and changing the oil. If repairs are required, however, remove it and have it serviced by your MacDon Dealer. Figure 4.204: Conditioner Drive Gearbox Checking and Changing Conditioner Gearbox Oil Change oil after the ﬁrst 50 hours of operation.
Page 222 MAINTENANCE AND SERVICING 1. Lower mower conditioner fully, turn off engine, and remove key. 2. Remove the right driveshield (A) (refer to 4.9.1 Removing Driveshields, page 227). Figure 4.205: Right Driveshield Checking Conditioner Gearbox Oil Level 3. Clean around oil level plug (A) on inboard side of gearbox.
Page 223: Mower Conditioner Drive Gearbox
If the gearbox requires repair, remove it and have it serviced at your MacDon Dealer. For service intervals, refer to 4.4.1 Maintenance Schedule/Record, page 121.
Page 224: Lubricating Mower Conditioner Drive Gearbox
MAINTENANCE AND SERVICING Lubricating Mower Conditioner Drive Gearbox Checking 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. 1. Stop engine and remove key from ignition. 2.
Page 225 MAINTENANCE AND SERVICING 3. Remove four M10 hex ﬂange head bolts (A) and remove vertical drive shield (B). Figure 4.211: Vertical Drive Shield 4. Remove two M10 hex ﬂange head bolts (A) and remove cover plate (B). Figure 4.212: Cover Plate 5.
Page 226 MAINTENANCE AND SERVICING 6. Remove M10 hex ﬂange head bolt (A) and remove vertical shield (B). Figure 4.214: Vertical Shield 7. Place a suitably sized container under drain plug (A), and remove plug using a 17 mm socket. 8. Allow sufﬁcient time for lubricant to drain, replace drain plug (A), and tighten.
Page 227 MAINTENANCE AND SERVICING 11. Position top plate (B) and drum top (C) onto drum as shown, and secure with four M10 hex ﬂange head bolts (A). Figure 4.217: Top Plate and Drum Top 12. Install cover plate (A), insert top M10 hex ﬂange head bolt (B) through cover plate and top plate (C), and install lower M10 hex ﬂange head bolt (D) through cover plate and vertical shield (E).
Page 228 MAINTENANCE AND SERVICING 13. Install vertical drive shield (B) using four M10 hex ﬂange head bolts (A). Figure 4.219: Vertical Drive Shield WARNING Ensure cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage.
Page 229: Forward And Rear Swivel Gearboxes
The rear swivel gearbox transfers power from the clutch driveline to the mower conditioner drive gearbox. The gearbox consists of an upper and lower gearbox. If the gearbox requires repair, remove it and have it serviced at your MacDon Dealer. For service intervals, refer to 4.4.1 Maintenance Schedule/Record, page...
Page 230: Draining Lubricant: Forward And Rear Swivel Gearboxes
MAINTENANCE AND SERVICING Draining Lubricant: Forward and Rear Swivel Gearboxes 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. Place a suitably sized container under drain plug (A), and remove plug using a 17 mm socket.
Page 231: Removing Wheels
MAINTENANCE AND SERVICING 1. Torque wheel bolts to 120 ft·lbf (160 N·m) using the tightening sequence shown. NOTE: Whenever a wheel is installed, check torque after one hour of operation. Figure 4.226: Tightening Sequence Removing Wheels 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 232: Installing Wheels
MAINTENANCE AND SERVICING Installing Wheels CAUTION When installing wheel, be sure to match countersunk holes with bolt head proﬁles. Holes that are not countersunk do NOT correctly seat the bolts. 1. Position wheel on spindle, install bolts, partially tighten. IMPORTANT: Be sure valve stem points away from wheel support.
Page 233 MAINTENANCE AND SERVICING WARNING • Do NOT stand over tire. Use a clip-on chuck and extension hose. • Never exceed air pressure of 35 psi (241 kPa) for ﬁeld tires and 40 psi (276 kPa) for transport tires when seating the bead on the rim. •...
Page 234: Hydraulics
4.7.2 Hydraulic Cylinders The hydraulic cylinders do not require routine maintenance or service. Occasionally visually inspect cylinders for signs of leaks or damage and if repairs are required, remove them and have them serviced by your MacDon Dealer. 169820 Revision A...
Page 235: Electrical
MAINTENANCE AND SERVICING 4.8 Electrical 4.8.1 Maintaining Electrical System 1. Use electrical tape and cable ties as required to prevent wires from dragging or rubbing. 2. Keep lights clean and replace defective bulbs. 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 236: Servicing Red Brake/Tail Lights
MAINTENANCE AND SERVICING 4.8.3 Servicing Red Brake/Tail Lights Replacing Red Brake/Tail Light Bulb 1. Remove two Phillips screws from ﬁxture, and remove the plastic lens. 2. Replace bulb, and reinstall plastic lens and screws. Bulb—Trade #1157. Figure 4.236: Plastic Lens and Screws Replacing Red Brake/Tail Light Fixture 1.
Page 237: Driveshields
MAINTENANCE AND SERVICING 4.9 Driveshields 4.9.1 Removing Driveshields CAUTION Do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown are for left side driveshield—right side driveshield is similar. 1. Remove lynch pin (A) and tool (B) from pin (C). Figure 4.238: Tool to Unlock Driveshield 2.
Page 238: Installing Driveshields
MAINTENANCE AND SERVICING 3. Pull top of driveshield (A) away from mower conditioner and lift off the pins at the base of the shield to remove. Figure 4.240: Driveshield 4.9.2 Installing Driveshields CAUTION Do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown are for left side driveshield—right side driveshield is similar.
Page 239: Replacing Driveshield Latch
MAINTENANCE AND SERVICING 4. Replace tool (B) and lynch pin (A) on pin (C). Figure 4.242: Tool to Unlock Driveshield 4.9.3 Replacing Driveshield Latch CAUTION Do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown are for left side driveshield—right side driveshield is similar. 1.
Page 240 MAINTENANCE AND SERVICING 2. Remove hex nut (A) and ﬂat washer securing latch to backside of driveshield, replace latch if worn or damaged, and reinstall nut and washer. Figure 4.244: Backside of Driveshield 3. Remove two carriage bolts (A), replace stud and clip assembly (B) if worn or damaged, and reinstall carriage bolts.
Page 241: Roll Conditioner
MAINTENANCE AND SERVICING 4.10 Roll Conditioner 4.10.1 Inspecting Roll Conditioner DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage header lift cylinder lock-out valves before going under machine for any reason. CAUTION Exercise caution when working around the blades.
Page 242 MAINTENANCE AND SERVICING 5. Inspect right side roll conditioner U-joints (A) for signs of wear or damage. Figure 4.248: Right Side Roll Conditioner U-Joints 6. Inspect right side roll conditioner gearbox bearings (A) for signs of wear or damage. Figure 4.249: Right Side Roll Conditioner Gearbox Bearings 169820 Revision A...
Page 243: Finger Conditioner
MAINTENANCE AND SERVICING 4.11 Finger Conditioner 4.11.1 Inspecting Finger Conditioner DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage header lift cylinder lock-out valves before going under machine for any reason. CAUTION Exercise caution when working around the blades.
Page 244 MAINTENANCE AND SERVICING 5. Check rotor ﬁngers (A) for damage and replace any bent ﬁngers to prevent rotor imbalance. Figure 4.252: Rotor Fingers 6. Remove the left driveshield (refer to 4.9.1 Removing Driveshields, page 227). 7. Inspect left side rotor bearing (A) for signs of wear or damage.
Page 245: Changing The Conditioner
4.12 Changing the Conditioner The R113 and R116 Pull-Type Mower Conditioners are factory equipped with either a ﬁnger conditioner or one of two types of roll conditioners. Conditioners can be changed before or after delivery, and this instruction describes the procedure.
Page 246 MAINTENANCE AND SERVICING 6. Open lift cylinder lock-out valves (A) (handle is vertical). 7. Start tractor and fully lower header. 8. Shutdown tractor and remove key from ignition. 9. Check that ﬂoat adjuster bolts (B) are loose. Back off adjuster bolts as required. 10.
Page 247 MAINTENANCE AND SERVICING 13. Remove the M20 nut (A), washers, and hex head bolt (B) securing carrier leg (C) and ﬂoat spring arm (D) to header at right end of header. 14. Move ﬂoat spring arm (D) clear of conditioner and remove bolt (B).
Page 248 MAINTENANCE AND SERVICING 19. Remove two hex head bolts (A) and spacers (B) securing steering arm (C) to gearbox. 20. Lift steering arm (C) off gearbox and secure arm to hitch (D) with a strap or wire. 21. Reinstall hex head bolts (A) and spacers (B) into gearbox.
Page 249: Removing The Conditioner
MAINTENANCE AND SERVICING 4.12.2 Removing the Conditioner CAUTION Ensure spreader bar is secured to the forks so that it cannot slide off the forks or towards the mast while detaching the conditioner from the header. 1. Attach a spreader bar (A) to a forklift or equivalent, and attach chains to lugs (B) on conditioner.
Page 250: Installing The Conditioner
MAINTENANCE AND SERVICING CAUTION Stand clear when detaching the conditioner. 4. Lift conditioner (A) off header (B), and move it away from work area. Figure 4.269: Conditioner 4.12.3 Installing the Conditioner CAUTION Ensure spreader bar is secured to the forks so that it cannot slide off the forks or towards the mast while detaching the conditioner from the header.
Page 251: Assembling Header And Carrier
MAINTENANCE AND SERVICING 4. Align mounting holes and install four M16x40 hex head bolts (A) with heads facing inboard towards conditioner (two per side). Secure with M16 center lock ﬂanged nuts and torque to 126 lbf·ft (170 N·m). 5. Remove lifting chains from conditioner and move lifting device clear of work area.
Page 252 MAINTENANCE AND SERVICING 6. Align right side carrier leg (A) with header brackets, and install M20x40 bolt (B) with hardened washer (C). 7. Install hardened washer (D), spacer (E), ﬂoat tension arm (F), and ﬂanged lock nut (G) on bolt (B). 8.
Page 253 MAINTENANCE AND SERVICING NOTE: Ensure proper pulley conﬁguration installation—large pulley installed onto gearbox for roll conditioner, and small pulley installed onto gearbox for ﬁnger conditioner. 17. Install conditioner drive belts (A) onto pulleys. 18. Check that tensioner spring installed correct location: •...
Page 254 MAINTENANCE AND SERVICING 28. If endwise transport system is installed, reconnect electrical harness (A) to the lights (B) and secure harness to shielding using existing clips (C) and (D). 29. Secure harness to light bracket with plastic tie wraps (E). Figure 4.281: Electrical Harness 169820 Revision A...
Page 255: Shield (No Conditioner)
MAINTENANCE AND SERVICING 4.13 Shield (No Conditioner) 4.13.1 Removing Shield (No Conditioner) 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. Lower mower conditioner fully, turn off engine, and remove key.
Page 256: Installing Shield (No Conditioner)
MAINTENANCE AND SERVICING 4. Lift shield (A) until pins (B) disengage from slots in support (C) and shield on panel (D). NOTE: Remove ﬁeld wheels and spindles (or ﬂip them around) if they are in the way. Figure 4.284: Shield (No Conditioner) 5.
Page 257 MAINTENANCE AND SERVICING 1. Lower mower conditioner fully, turn off engine, and remove key. 2. Position shield (A) on mower conditioner. Figure 4.286: Shield (No Conditioner) Removed from Mower Conditioner 3. Lift shield (A) until pins (B) engage in slots in cutterbar support (C) and shield on panel (D).
Page 258 MAINTENANCE AND SERVICING 5. Install driveshields (A) (refer to 4.9.2 Installing Driveshields, page 228). Figure 4.289: Left Driveshield 169820 Revision A...
Page 259: Troubleshooting
5 Troubleshooting 5.1 Troubleshooting Mower Performance Problem Symptom Solution Refer to Dull, bent, or badly Replace blades. 4.5.4 Cutter Blades, page 153 worn blades Decrease mower conditioner angle and increase ﬂotation. Cutterbar Build-up of dirt In some conditions, it may 3.16.3 Cutting Height, page 78 be necessary to carry mower plugging...
Page 260 TROUBLESHOOTING Symptom Problem Solution Refer to Ground speed too fast Reduce ground speed. 3.16.4 Ground Speed, page 80 Roll gap too large for Decrease roll gap. Roll Gap, page 81 proper feeding Roll gap too small in thick-stemmed Increase roll gap. Roll Gap, page 81 cane-type crops Bafﬂe set too low...
Page 261 TROUBLESHOOTING Symptom Problem Solution Refer to Rolls not crimping Decrease roll gap. Roll Gap, page 81 crop sufﬁciently Forming Shields: Roll Conditioner, page Slow crop drying Crop is bunched Forming Shields: Finger Adjust forming shields/bafﬂe. in windrow 92, and Conditioner, page Internal Intensity Bafﬂe, page Excessive crimping Increase roll gap.
Page 262: Troubleshooting Mechanical Issues
TROUBLESHOOTING 5.2 Troubleshooting Mechanical Issues Symptom Problem Solution Refer to 4.5.4 Cutter Blades, page Bent cutter blade Replace blade. Check roll timing, and Excessive noise Conditioner roll timing off Roll Timing, page 84 adjust if necessary. Conditioner roll gap Check roll gap, and adjust Roll Gap, page 81 too small if necessary.
Page 263 TROUBLESHOOTING Symptom Problem Solution Refer to Mower conditioner angle Reduce mower 3.16.2 Mower Conditioner too steep conditioner angle. Angle, page 77 3.19 Unplugging the Crop residue and dirt Excessive wear of Clean cutterbar. Mower Conditioner, page deposits on cutterbar cutting components Remove mud from 3.19 Unplugging the Mud on cutterbar...
Page 265: Options And Attachments
6 Options and Attachments 6.1 Tall Crop Divider Kit Tall crop dividers attach to the ends of the mower conditioner for clean crop dividing and cutterbar entry in tall crops. The kit includes left and right dividers and attachment hardware. MD #B5800 Figure 6.1: Right Side Tall Crop Divider 169820...
Page 266: Hydraulic Center-Link Kit
OPTIONS AND ATTACHMENTS 6.2 Hydraulic Center-Link Kit The hydraulic center-link kit replaces the standard mechanical link and uses a hydraulic cylinder and separate tractor hydraulic circuit to adjust mower conditioner angle. The kit includes installation instructions. MD #B5760 Figure 6.2: Hydraulic Center-Link 169820 Revision A...
Page 267: Truck Transport Hitch
OPTIONS AND ATTACHMENTS 6.3 Truck Transport Hitch The truck transport hitch connects the mower conditioner to a truck for towing on the road. The kit includes the transport hitch, attachment hardware, and safety chain. MD #B5802 Figure 6.3: Truck Transport Hitch 169820 Revision A...
Page 268: Endwise Transport System
OPTIONS AND ATTACHMENTS 6.4 Endwise Transport System The endwise transport system allows the mower conditioner to be towed on roadways while remaining within the legal width restrictions on most roads and highways. The kit is available as a Dealer-installed option and includes all hardware and installation instructions MD #B5759 and MD #B5949...
Page 269: Index
Index 180-degree turns ..........63 installing ............. 162 removing ............ 161 inboard curtains installing ............. 164 removing ............ 163 accelerators inspecting curtains.......... 161 inspecting ............168 outboard curtains installing ............170 installing ............. 166 maintaining ............ 168 removing ............ 165 removing ............
Page 270 INDEX installing ............. 141 amber hazard/signal lights ......225 removing ............ 140 replacing bulbs ........225 drawbars replacing light ﬁxtures ......225 adjusting drawbar ..........42 red brake/tail lights ........226 installing drawbar hitch adapter ......43 replacing bulbs ........226 drive systems ............
Page 271 INDEX setting up mower conditioner hitch..... 43 unplugging mower conditioner......101 inspections greasing accelerators ........... 168 decals............125 break-in inspections........123 every 100 hours ..........132 conditioner drive belt ........207 every 25 hours ..........127 cutter blade hardware ........155 every 250 hours ..........
Page 272 INDEX detaching two-point hitch ....... 53 leveling ............100 maintenance maintaining/servicing ........103 conversion charts ..........119 mower conditioner speciﬁcations ....... 28 metric bolts operating ............75 torque when bolting onto cast aluminum ..112 raising and lowering mower conditioner ..... 58 torque speciﬁcations........
Page 273 INDEX See also roll bearings positioning ..........86, 92 inspecting roll conditioner........ 231 speciﬁcations roll gaps .............. 81 maintenance ..........106 adjusting roll gap mower conditioner speciﬁcations ....... 28 poly rolls............82 tractor requirements ......... 42 steel rolls............82 spindle shear pins..........184 checking roll gap installing ............
Page 274 INDEX endwise transport systems........ 71 detaching from tractor........53 lighting............. 69 preparing mower conditioners for transport..65 with a truck ............67 with endwise transport system unplugging mower conditioners ......101 converting from ﬁeld to transport mode... 71 converting from transport to ﬁeld mode... 73 with tractors .............
Page 276 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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