Page 1 Rotary Disc 16-Foot Header for Self-Propelled Windrower Operator’s Manual 214014 Revision B Model Year 2017 Original Instruction The harvesting specialists.
Page 2 R85 Rotary Disc 16-Foot Self-Propelled Windrower Header Published: October 2016...
Page 3 Declaration of Conformity Figure 1: EC Declaration of Conformity, Page 1 214014 Revision B...
Page 4 Figure 2: EC Declaration of Conformity, Page 2 214014 Revision B...
Page 5 The A-weighted sound pressure level inside the operator’s station of a typical self-propelled vehicle (e.g., M205), when operated in conjunction with this R85 rotary disc header, is 79 dBA. This measurement was taken in accordance with ISO 5131. The sound pressure level depends upon the rotary disc speed, crop conditions, as well the exact type of self-propelled vehicle used to power the R85.
Page 6 MacDon Dealer. When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous situation.
Page 7: Serial Number(S)
Serial Number(s) Record the serial number of the header in the space provided. Header Serial No: ____________ The serial number plate (A) is located on the top cover at the right side of the header. Figure 4: Serial Number Location – Self-Propelled 214014 Revision B...
Page 8: List Of Revisions
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 Updated ﬂuids and capacities table.
Page 9: Table Of Contents
TABLE OF CONTENTS Declaration of Conformity ........................i Noise Levels ........................... iii Introduction .............................iv Serial Number(s) ..........................v List of Revisions ..........................vi Safety ..............................1 Safety Alert Symbols........................1 Signal Words........................... 2 General Safety ..........................3 Maintenance Safety ......................... 5 Hydraulic Safety ..........................
Page 10 TABLE OF CONTENTS 3.12 Adjusting the Transport Lights ......................82 Operating the Header .......................... 83 Header Float ..........................83 4.1.1 Checking Float ........................83 4.1.2 Adjusting Float for M200 and M205 Self-Propelled Windrowers ..........84 4.1.3 Removing and Restoring Float for M1240 Self-Propelled Windrowers........84 Roll Gap............................
Page 11 TABLE OF CONTENTS 5.3.1 Maintenance Schedule/Record....................121 5.3.2 Preseason/Annual Service .....................124 5.3.3 End-of-Season Service ......................124 5.3.4 Lubrication and Servicing.......................125 5.3.5 Greasing Procedure ......................125 5.3.6 Lubrication and Servicing Intervals ..................126 5.3.7 Lubricating the Cutterbar .......................131 Draining the Cutterbar Lubricant ..................131 Filling the Cutterbar Lubricant ..................133 5.3.8 Rock Guards.........................135 Inspecting the Rock Guards ...................135...
Page 12 TABLE OF CONTENTS Replacing the Auger Drive Belts ..................166 5.5.6 Installing Sealed Bearings......................169 Hydraulics ............................170 5.6.1 Hydraulic Motor........................170 Removing the Hydraulic Motor..................170 Installing the Hydraulic Motor..................171 5.6.2 Hydraulic Hoses and Lines ....................172 Electrical System ..........................173 5.7.1 Hazard Lights........................173 Hazard Lights: Replacing Bulbs and Lenses..............173 Hazard Lights: Replacing the Lamp Assembly ..............173 Hazard Lights: Replacing the Lamp Bracket ..............174 Options and Attachments ........................175...
Page 13: Safety
1 Safety 1.1 Safety Alert Symbols This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read follow safety message accompanying this symbol.
Page 14: 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 15: 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 16 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 17: 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 18: 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 19: 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 20: Safety Decal Locations
SAFETY 1.7 Safety Decal Locations Figure 1.15: Safety Decal Locations A - MD #174436 B - MD #113482 C - MD #194464 D - MD #194521 E - MD #184385 Figure 1.16: Safety Decals 214014 Revision B...
Page 21 SAFETY Figure 1.17: Safety Decal Locations A - MD #190546 B - MD #247166 C - MD #184371 D - MD #184385 E - MD #194466 F - MD #194463 G - MD #194465 Figure 1.18: Safety Decals 214014 Revision B...
Page 22 SAFETY Figure 1.19: Safety Decal Locations A - MD #184386 214014 Revision B...
Page 23: Understanding Safety Signs
SAFETY 1.8 Understanding Safety Signs MD #113482 General hazard pertaining machine operation and servicing CAUTION To avoid injury or death from improper or unsafe machine operation: • Read the operator’s manual and follow all safety instructions. If you do not have a manual, obtain one from your Dealer.
Page 24 SAFETY MD #174434 Header hazard DANGER • Rest header on ground or engage mechanical locks before going under unit. Figure 1.22: MD #174434 MD #184371 Open drive hazard WARNING • Guard missing. Do not operate. • Keep all shields in place. Figure 1.23: MD #184371 MD #184385 Pinch hazard...
Page 25 SAFETY MD #184386 Pinch hazard WARNING • Failure to comply could result in death or serious injury. Figure 1.25: MD #184386 MD #184422 Keep shields in place hazard WARNING • Do not place hand. • To avoid injury, stop the engine and remove the key before opening power drive system shield.
Page 26 SAFETY MD #194462 Header crushing hazard WARNING • Install lock before going under unit. Figure 1.28: MD #194462 MD #194463 Rotating blades WARNING • Stop engine and remove the key before opening the header covers. • Listen and look for evidence of rotation before lifting cover.
Page 27 SAFETY MD #194465 Rotating cutters WARNING • Stand clear. • Stop the engine and remove the key. • • Listen and look for evidence of rotation before lifting cover. • Rotating cutters may continue to rotate after power is shut off. Figure 1.31: MD #194465 •...
Page 28 SAFETY MD #194521 Auger entanglement hazard CAUTION • To avoid injury from entanglement with rotating auger, stand clear of header/mower while machine is running. General hazard pertaining machine operation and servicing. CAUTION • Read the operator’s manual and follow safety instructions.
Page 29 SAFETY MD #247167 Rotating blades WARNING • Stop the engine and remove the key. • Listen and look for evidence of rotation before lifting cover. • Rotating cutters may continue to rotate after power is shut off due to inertia. Figure 1.35: MD #247167 214014 Revision B...
Page 31: Product Overview
Intermediate Speed Control Joint Industrial Council: A standards body that developed standard sizing and shape for original 37° ﬂared ﬁtting M-Series windrower MacDon M100, M105, M150, M155, M155E4, M200, and M205 windrowers M1–Series windrower MacDon M1240 windrowers Not applicable 214014...
Page 32 This style of ﬁtting is also commonly called ORS, which stands for O-ring seal Revolutions per minute R-Series header MacDon R80 and R85 rotary disc headers RoHS (Reduction of A directive by the European Union to restrict use of certain hazardous substances...
Page 33: Component Identification
PRODUCT OVERVIEW 2.2 Component Identiﬁcation Figure 2.1: Component Identiﬁcation A - Driveshield B - Tower C - Door D - Gauge Rollers (Optional) E - Bafﬂe F - Hydraulic Hoses to SP Windrower G - Bafﬂe Control H - Header Boot Figure 2.2: Component Identiﬁcation A - Transport Light B - Conditioner Rolls...
Page 34: Specifications
Speciﬁcations and design are subject to change without notice or obligation to revise previously sold units. S: standard / O : optional (factory installed) / O : optional (dealer installed) / -: not available 16–Foot R85 Cutterbar Effective cutting width 4827 mm (15.83 ft.)
Page 35 PRODUCT OVERVIEW 16–Foot R85 Overshot Auger Peripheral diameter 229 mm (9.0 in.) Center tube diameter 152 mm (6.0 in.) Rpm range: 720–1040 Three HB belt drive (with spring loaded idler) Universal joint in auger center Hay Conditioner Drive: Bevel gearbox to 5 HA banded belt drive to enclosed timing gearbox and...
Page 36 PRODUCT OVERVIEW 16–Foot R85 Attachments and Accessories Double windrow attachment Tall crop divider kit Cutterbar repair tool kit 214014 Revision B...
Page 37: 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 38: Operational Safety
OPERATION 3.2 Operational Safety CAUTION Follow these safety precautions: • Follow all safety and operational instructions given in your windrower operator’s manuals. If you do not have an operator’s manual, get one from your Dealer and read it thoroughly • Never attempt to start the windrower’s engine or operate the machine except from the windrower seat •...
Page 39 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 40: Engaging And Disengaging The Header Safety Props
OPERATION 3.3 Engaging and Disengaging the 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.
Page 41 OPERATION Disengage safety props as follows: 1. Turn lever (A) away from header to raise safety prop until lever locks into vertical position. Repeat for opposite cylinder. 2. Start engine, choose a level area, and lower header to the ground. 3.
Page 42: Driveshields
OPERATION 3.4 Driveshields WARNING Do NOT operate the machine with the driveshields open. High-speed rotating components may throw debris and could result in death or serious injury. The Rotary Disc 16-Foot Header for Self-Propelled Windrowers comes in two conﬁgurations: one for use in North America and one for use outside of North America.
Page 43: Opening The Driveshield: Export Headers
OPERATION 3.4.3 Opening the Driveshield: Export Headers Follow these steps to open the driveshield on export headers: 1. Release rubber latches (A). 2. Insert a screwdriver (or equivalent) through hole in shield (B) and into the notch in latch (C) and disengage latch.
Page 44: Removing Right Endshield
OPERATION 3.4.5 Removing Right Endshield 1. Remove three bolts (A) and remove right endshield (B). NOTE: Tall crop feed plates are supplied from the factory and stored behind the right endshield. Figure 3.9: Right Endshield 3.4.6 Installing Right Endshield 1. Install right endshield (B) using three bolts (A). Figure 3.10: Right Endshield 214014 Revision B...
Page 45: Cutterbar Doors
OPERATION 3.5 Cutterbar Doors The Rotary Disc 16–Foot Header for Self-Propelled Windrowers comes in two conﬁgurations: one for use in North American and one for use outside of North America. Headers conﬁgured for use outside of North America are referred to as export headers. The conﬁguration is speciﬁed in the title when necessary. CAUTION Do NOT operate the machine without all the cutterbar doors down.
Page 46: Opening The Cutterbar Doors: North America
OPERATION 3.5.1 Opening the Cutterbar Doors: North America Follow these steps to open the cutterbar doors on a North American header: 1. Unhook the curtain latches (A). Figure 3.12: Curtain Latches 2. Lift front of door to the open position. The front cover safety latch (A) will automatically drop into position and keep the cover from falling closed again during maintenance.
Page 47: Closing The Cutterbar Doors: North American Header
OPERATION 3.5.2 Closing the Cutterbar Doors: North American Header Follow these steps to close the cutterbar doors on a North American header: CAUTION To avoid injury, keep hands and ﬁngers away from corners of doors when closing. 1. Holding the door open, lift the safety door latch (A) to disengage its lock, then move the door down to its closed position over the cutterbar.
Page 48: Opening The Cutterbar Doors: Export Header
OPERATION 3.5.3 Opening the Cutterbar Doors: Export Header Follow these steps to open the cutterbar doors on an export header: 1. Unhook curtain latches (A). Figure 3.16: Curtain Latches 214014 Revision B...
Page 49: Closing The Cutterbar Doors: Export Header
OPERATION 2. Insert a screwdriver (or equivalent) through hole (A) in door into notch in latch (B) and push latch to disengage. 3. Lift at front of door to open. Figure 3.17: Cutterbar Door Latch 3.5.4 Closing the Cutterbar Doors: Export Header To close the cutterbar doors on an export header follow these steps: CAUTION To avoid injury, keep hands and ﬁngers away from corners of doors when closing.
Page 50 OPERATION 1. Pull at top and move to closed position. Ensure latch (A) has engaged the door. Figure 3.18: Cutterbar Door Latch 2. Hook curtain latches (A). Figure 3.19: Curtain Latches 214014 Revision B...
Page 51: Daily Start-Up Check
OPERATION 3.6 Daily Start-Up Check CAUTION • Be sure windrower and header are properly attached, all controls are in NEUTRAL, and windrower brake is engaged. • Clear the area of other persons, pets etc. Keep children away from machinery. Walk around the header to be sure no one is under, on or close to it.
Page 52 OPERATION Do the following each day before start-up: 1. Check the machine for leaks or any parts that are missing, broken, or not working correctly. NOTE: Use proper procedure when searching for pressurized ﬂuid leaks. Refer to 5.6.2 Hydraulic Hoses and Lines, page 172.
Page 53: Attaching The Header
OPERATION 3.7 Attaching the Header 3.7.1 Attaching the Forming Shield DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 54 OPERATION 4. Position the forming shield onto spacers (B) on windrower legs. Secure with clevis pins (A) and lynch pin. Figure 3.24: Attaching Forming Shield to Windrower Legs IMPORTANT: Forming shield plate (A) is shown in standard position. If installing double windrow attachment (DWA), install plate in inverted position.
Page 55 8. Adjust the rear ﬂuffer deﬂector (C) to the middle position. Loosen handles (B) if required. 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 56: Attaching Header To An M200 And M205 Self-Propelled Windrower
OPERATION 3.7.2 Attaching Header to an M200 and M205 Self-Propelled Windrower To attach the header to a self-propelled windrower, follow these steps: 1. Remove hairpin from pin (A) and remove pin from the left and right header boots (B). CAUTION Ensure all bystanders have cleared the area.
Page 57 OPERATION 6. If the hydraulic center-link is installed, use the HEADER TILT cylinder switches on the GSL to position center-link cylinder (A) so it can connect to the header. 7. Push down on the rod end of the link cylinder until the hook engages pin (B) on header.
Page 58: Attaching Hydraulic Center-Link: M1240 Windrowers
OPERATION 3.7.3 Attaching Hydraulic Center-Link: M1240 Windrowers To attach an R85 header to a windrower, follow these steps: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 59 OPERATION CAUTION To prevent damage to the header lift linkages when lowering header lift legs without a header or weight box attached to the windrower, ensure the ﬂoat springs tension is fully released. NOTE: If not prompted by the harvest performance tracker (HPT) display to remove ﬂoat, remove ﬂoat manually.
Page 60 OPERATION 8. For hydraulic center-link with optional self-alignment: a. Adjust position of the center-link cylinder (A) with the switches on the GSL until the hook (B) is above the header attachment pin. IMPORTANT: Hook release (C) must be down to enable self-locking mechanism.
Page 61 OPERATION CAUTION Check to be sure all bystanders have cleared the area. 10. Press the HEADER UP switch (A) to raise header to maximum height. NOTE: If one end of the header does NOT fully raise, rephase the lift cylinders as follows: a.
Page 62: Attaching Hydraulic And Electrical Components: M1240 Windrowers
Your M1240 Self-Propelled Windrower may be conﬁgured with either quick coupler or hard plumb connections for the R85 Header. Refer to the following procedures for routing and connecting M1240 and R85 hydraulic and electrical components: • Routing Hydraulic Hoses and Electrical Components to M1240 Windrowers, page 51 •...
Page 63: Routing Hydraulic Hoses And Electrical Components To M1240 Windrowers
OPERATION Routing Hydraulic Hoses and Electrical Components to M1240 Windrowers To route the R85 Header hydraulic hoses and electrical harness to the M1240 Self-Propelled Windrower, follow these steps. 1. Move windrower left-hand (cab-forward) platform (A) to the OPEN position. For instructions, refer to the windrower operator’s manual.
Page 64: Connecting Header Hydraulics Using Quick Couplers: M1240 Windrowers
OPERATION Connecting Header Hydraulics Using Quick Couplers: M1240 Windrowers To connect the M1240 Self-Propelled Windrower hydraulic hoses and electrical cords to the R85 Header, follow these steps. 1. Use a clean rag to remove dirt and moisture from the couplers.
Page 65: Connecting Header Hydraulics Using Hard Plumbing: M1240 Windrowers
Connecting Header Hydraulics Using Hard Plumbing: M1240 Windrowers Hard plumbing helps reduce the potential for leaks at the hydraulic connection sites and helps the header drive run more efﬁciently. To connect the M1240 Self-Propelled Windrower to the R85 Header with hard plumbing, follow these steps.
Page 66 OPERATION 2. Use a clean rag to remove dirt and moisture from the couplers on the windrower and remove protective plugs (A) from the hard plumbing (B). NOTE: Hard plumbing should be factory-set to 30° to allow hoses to pass by the multicoupler. Figure 3.50: Protective Shipping Plugs on M1240 Hard Plumbing Connections (Parts Removed for Clarity)
Page 67: Attaching Hydraulic And Electrical Components: M205 Windrowers
OPERATION 4. Move the windrower platform (A) to the CLOSED position. For instructions, refer to the windrower operator’s manual. Figure 3.52: Windrower with LH Platform in Closed Position 3.7.5 Attaching Hydraulic and Electrical Components: M205 Windrowers DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 68 OPERATION 1. Move windrower left-hand (cab-forward) platform (A) to OPEN position. For instructions, refer to the windrower operator’s manual. Figure 3.53: Windrower with LH Platform in Open Position 2. Route the hose bundle (A) from the header under the windrower frame, and insert pin (B) into hole in windrower frame.
Page 69 OPERATION 5. Remove coupler lock as follows: a. Remove lynch pin (A) and open up coupler lock (B). b. Remove lock from coupler. Figure 3.55: Hydraulic Couplers with Coupler Lock 6. Connect the rear pump hose (A) to outboard line (D) on windrower using coupler (C).
Page 70 OPERATION 8. Position the lock onto the couplers so that retainer (A) rests under the ﬁtting next to the sleeve on each coupler. NOTE: The retainer can be adjusted by loosening bolts (B). Tighten bolts after adjusting. Figure 3.57: Hydraulic Couplers with Coupler Lock 9.
Page 71 OPERATION 13. Connect the rear pump hose (A) to outboard line (F) on windrower using ﬁtting (D). 14. Connect the front pump hose (B) to the inboard line (G) on windrower using ﬁtting (D). 15. Torque ﬁttings to 183 N·m (135 ft·lbf). 16.
Page 72: Attaching Hydraulic And Electrical Components: M200 Windrowers
To operate the 16-foot header on an M200 windrower, installation of a motor/hose kit (MD #B5455) is required. If required, obtain the kit through your MacDon Dealer. Install kit in accordance with the supplied instructions. Figure 3.63: MD #B5455 Hydraulic Drive Kit...
Page 73 OPERATION 1. Disengage and rotate lever (A) counterclockwise to the UP position. 2. Remove the cap (B) securing the electrical connector to the frame. Figure 3.64: Hose Bundle 3. Move hose bundle (A) from the windrower and rest the bundle on the header. Figure 3.65: Hose Bundle 214014 Revision B...
Page 74 OPERATION 4. Position the hose support with the lower bolt (A) in the forward hole, as shown. Loosen both bolts and adjust as required. Figure 3.66: Hose Support 5. Route hose bundle (A) from the windrower through the support (B) on header. 6.
Page 75 OPERATION 9. Move the windrower’s left-hand side (cab-forward) platform (A) to the OPEN position to access the valve blocks. Figure 3.69: Windrower with LH Platform in Open Position 10. Remove caps from pressure (A) and return (B) ports on valve (C) and discard. IMPORTANT: Keep open lines and ports clean.
Page 76 OPERATION 12. Disconnect ﬁttings at end of hose bundle (A). Discard caps. Figure 3.71: Hose Bundle 13. Remove O-ring (A) from cap and install over JIC threads on ﬁtting at return port (B). 14. Install female coupler (C) from hose in return port (B). 15.
Page 77 OPERATION 16. Connect hoses from header to ﬁttings as shown. NOTE: If the windrower is equipped with a reverser valve for an auger header, replace the 90° ﬁtting on hose (C) with a 45° ﬁtting. Figure 3.73: Hydraulic Connections A - Middle Valve Block B - Pressure C - Return 17.
Page 78 OPERATION 20. Move platform (A) to the CLOSED position. instructions, refer to the windrower operator’s manual. Figure 3.75: Top View of Windrower 214014 Revision B...
Page 79: Detaching The Header
OPERATION 3.8 Detaching the Header 3.8.1 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 To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 80 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 3.77: Hydraulic Connections 6.
Page 81 OPERATION 9. Unscrew sleeves couplers separate couplers. 10. Install caps and plugs on open lines. Figure 3.80: Hydraulic Connections 11. Attach coupler lock (B) to hoses and secure with lynch pin (A). 12. Proceed to Step 14., page Figure 3.81: Hydraulic Connections 13.
Page 82 OPERATION 14. Remove hose support (A) from the windrower frame. 15. Route hoses (B) and electrical harness onto the header. Figure 3.83: Hose Bundle 16. Move maintenance platform CLOSED position. For instructions, refer to the windrower operator’s manual. 17. Refer to the windrower operator’s manual to mechanically detach the header from the windrower.
Page 83: Detaching The Header: M200 Windrowers
OPERATION 3.8.2 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 To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 84 OPERATION 7. Raise and unlock lever (A) and undo the three cinch straps (B). 8. Move hose bundle to store on header. Figure 3.87: Hose Bundle 9. Disconnect the electrical connector (A) at the header by turning the collar counterclockwise and pulling the connector to disengage.
Page 85: Detaching The Header: M1240 Windrowers
OPERATION 12. Move the hose bundle from header to the left-side (cab-forward) hose support (B). 13. Rotate lever (A) clockwise and push to engage bracket. 14. Route the electrical harness through the hose support (B) and attach cap to electrical connector (C). Figure 3.90: Hose Bundle 15.
Page 86 OPERATION CAUTION Check to be sure all bystanders have cleared the area. 1. Start the windrower and press switch (A) to raise the header to the maximum height. 2. Stop engine and remove key from ignition. Figure 3.92: Ground Speed Lever 3.
Page 87 OPERATION 6. Remove hairpin from clevis pin (A) and remove clevis pin from header boot (B) on both sides of header. Figure 3.95: Header Boots 7. Engage safety prop on the windrower’s lift cylinder as follows: a. Pull lever (A) and rotate toward header to release, and lower safety prop onto cylinder.
Page 88 OPERATION 9. Disengage safety prop by turning lever (A) downwards until lever locks into the vertical position. 10. Repeat for the opposite side. Figure 3.98: Safety Props CAUTION Check to be sure all bystanders have cleared the area. 11. Start engine and remove header ﬂoat when prompted by the Harvest Performance Tracker (HPT).
Page 89 OPERATION Windrowers with center-link self-alignment kit only: 13. Activate the HEADER TILT cylinder switches (A) on the GSL to release load on center-link cylinder and unlatch the center-link. 14. Operate the link lift cylinder with the REEL UP switch (B) to disengage the center-link from the header. Figure 3.99: GSL Windrowers WITHOUT...
Page 90 OPERATION 18. Back the windrower slowly away from header. 19. Reinstall clevis pin (A) through boot (C) and secure with hairpin (B). Repeat for opposite side. Figure 3.101: Header Boot 214014 Revision B...
Page 91: Break-In Period
OPERATION 3.9 Break-In Period After attaching the header to the windrower for the ﬁrst time, operate the machine slowly for ﬁve minutes, watching and listening from the windrower seat for binding or interfering parts. NOTE: Until you become familiar with the sound and feel of your new header, be extra alert and attentive. CAUTION Before investigating an unusual sound or attempting to correct a problem, stop the engine, engage parking brake, and remove the key.
Page 92: Shutting Down The Windrower
OPERATION 3.10 Shutting down the Windrower CAUTION Before leaving the windrower seat for any reason: 1. Park on level ground (if possible). 2. Lower the header fully. 3. Place ground speed control in N-DETENT. 4. Stop the engine and remove the key. 5.
Page 93: Transporting The Header
OPERATION 3.11 Transporting the Header For information on transporting the header when attached to the windrower, refer to your windrower operator’s manual. IMPORTANT: For cab-forward road travel the windrower must have the lighting and marking bundle installed (MD #B5412). IMPORTANT: Lights are factory assembled to meet road travel lighting requirements with windrower in ENGINE-FORWARD transport mode.
Page 94: Adjusting The Transport Lights
OPERATION 3.12 Adjusting the Transport Lights The transport lights, which are mounted on both ends of the header, are activated by switches in the M-Series and M1-Series windrower cab. Refer to your windrower operator’s manual on when to use them. The reﬂectors can be reversed, depending on the direction of travel.
Page 95: Operating The Header
4 Operating the Header Your header will provide the best performance when it is properly adjusted to suit the crop and conditions. Correct operation reduces crop loss and increases productivity. As well, proper adjustments and timely maintenance will increase the length of service you receive from the machine. The variables listed below and detailed on the following pages will affect the performance of the header.
Page 96: Adjusting Float For M200 And M205 Self-Propelled Windrowers
OPERATING THE HEADER 4.1.2 Adjusting Float for M200 and M205 Self-Propelled Windrowers DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. Set the ﬂoat ﬁne adjustment to MID-RANGE with the windrower ﬂoat adjustment system in the cab (refer to your windrower operator’s manual).
Page 97 OPERATING THE HEADER 3. Press soft key 3 (A) to remove or restore the header ﬂoat. NOTE: If the header ﬂoat is active, the icon at soft key 3 will say REMOVE FLOAT; if header ﬂoat has been removed, the icon will say RESTORE FLOAT.
Page 98: Roll Gap
OPERATING THE HEADER 4.2 Roll Gap Steel rolls condition the crop by crimping and crushing the stem in several places. This allows moisture to release for quicker drying. The degree to which the crop is conditioned as it passes through the rolls is controlled by roll gap.
Page 99: Adjusting Roll Gap
OPERATING THE HEADER 5. Inspect roll gap at both ends of the rolls. At factory setting, the roll gap (B) should be 25.4 mm (1 in.). IMPORTANT: Roll timing is critical when the roll gap is decreased because the bars may contact each other if the timing is wrong.
Page 100 OPERATING THE HEADER 4. Loosen upper jam nut (B) on both sides of conditioner adjustment bolts. 5. To increase roll gap, turn lower nut (A) clockwise. 6. To decrease roll gap, turn lower counterclockwise. 7. Measurement at (C) should be 35 mm (1.4 in.). This equates to 25.4 mm (1 in.) of roll gap.
Page 101: Roll Tension
OPERATING THE HEADER 4.3 Roll Tension Roll tension (the force holding the rolls together) is factory set with a spring-type adjustable linkage. The roll tension factory setting is the spring fully tensioned. Heavy crops or tough forage tend to separate the rolls and require more tension to ensure material is sufﬁciently crimped.
Page 102: Roll Timing
OPERATING THE HEADER 4.4 Roll Timing For proper conditioning, the rolls must be properly timed. Each steel bar on one of the rolls should be centered between two bars of the other roll. The factory setting should be suitable for most crop conditions. IMPORTANT: Roll timing is especially critical when roll gap is decreased because the bars can contact each other if the timing is wrong.
Page 103: Adjusting Roll Timing
OPERATING THE HEADER 4.4.2 Adjusting 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. Figure 4.11: Conditioner Gearbox 2. Locate roll timing gauge (MD #150572) (B) on frame member under the ﬂange.
Page 104: Forming Shields
OPERATING THE HEADER 4.5 Forming Shields WARNING Keep hands and feet away from discharge opening. Keep everyone several hundred feet away from your operation. Never direct the discharge toward anyone. Stones or other foreign objects can be ejected with force. The position of the forming shields controls the width and placement of the windrow.
Page 105 OPERATING THE HEADER 2. If side deﬂector attachment is too tight or too loose, tighten or loosen nut (A) as required. Figure 4.15: Forming Shield 214014 Revision B...
Page 106: Adjusting The Rear Deflector (Fluffer Shield)
OPERATING THE HEADER 4.5.2 Adjusting the Rear Deﬂector (Fluffer Shield) DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. The rear deﬂector (ﬂuffer shield) slows the crop exiting the conditioner rolls, directs the ﬂow downward, and ﬂuffs the material.
Page 107 OPERATING THE HEADER The swath bafﬂe (A) 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 • Direct crop downward to form a wide swath 1.
Page 108: Header Angle
OPERATING THE HEADER 4.6 Header Angle Header (or cutterbar) angle can be varied from 0–8° below horizontal. Choose an angle that maximizes performance for your crop and ﬁeld conditions. A ﬂatter angle provides better clearance in stony conditions while a steeper angle provides better lifting action in down crops.
Page 109: Cutting Height
OPERATING THE HEADER 4.7 Cutting Height Cutting height is determined by a combination of the angle of the cutterbar/header and the optional gauge roller or skid shoe settings if installed. Cutting height should be adjusted for optimum cutting performance without excessive mud build-up inside the header that can lead to poor crop ﬂow and increased wear on cutting components.
Page 110 OPERATING THE HEADER 1. Raise header fully. 2. Stop the engine and remove the key. 3. Engage header safety props. Refer to 3.3 Engaging and Disengaging the Header Safety Props, page 4. Remove lynch pin and remove adjuster pin (A) from one side of skid shoe (B).
Page 111: Disc Speed
OPERATING THE HEADER 4.8 Disc Speed The disc header can be used to cut a variety of crops. For the best cutting results, a range of disc speeds is recommended for each type of crop and condition. Refer to table below. Table 4.2 Disc Speed Recommendations Crop Condition...
Page 112: Ground Speed
OPERATING THE HEADER 4.9 Ground Speed CAUTION Reduce speed when turning, crossing slopes, or when travelling over rough ground. Choose a ground speed that allows the cutterbar and conditioner to cut the crop smoothly and evenly. Try different combinations of header speed and ground speed to suit your speciﬁc crop. In tough cutting conditions, such as native grasses, the disc speed will need to be increased.
Page 113: Double Windrowing
OPERATING THE HEADER 4.10 Double Windrowing If your windrower is equipped with the Double Windrow Attachment (DWA [A]), refer to the MacDon DWA Manual for operating and maintenance instructions. The manual is shipped with the DWA Kit. Figure 4.23: DWA...
Page 114: Tall Crop Feed Plates
OPERATING THE HEADER 4.11 Tall Crop Feed Plates The tall crop feed plates (A) assist in feeding tall crops into the conditioner by aiding material ﬂow from behind the cage deﬂectors (B). The feed plates are designed for installation under the two cage deﬂectors.
Page 115: Installing Tall Crop Feed Plates Under Driven Deflector
OPERATING THE HEADER Installing Tall Crop Feed Plates under Driven Deﬂector 1. Lower header fully. 2. Stop the engine and remove the key. 3. Open the cutterbar doors. Refer to 3.5 Cutterbar Doors, page 4. Remove driven deﬂector. Refer to Removing the Driven Deﬂector, page 149.
Page 116: Removing Tall Crop Feed Plates
OPERATING THE HEADER 1. Locate the feed plates. Refer to 4.11.1 Removing the Tall Crop Feed Plates from Storage, page 102. 2. Lower the header fully. 3. Stop the engine and remove the key. 4. Open the cutterbar door(s). Refer to 3.5 Cutterbar Doors, page 5.
Page 117: Removing Tall Crop Feed Plates From Under Driven Deflector
OPERATING THE HEADER 1. Lower the header fully. 2. Stop the engine and remove the key. 3. Open cutterbar doors. Refer to 3.5 Cutterbar Doors, page CAUTION Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.
Page 118: Returning Tall Crop Feed Plates To Storage
OPERATING THE HEADER 3. Remove feed plate (A). 4. Return feed plates to storage. Refer to 4.11.3 Returning Tall Crop Feed Plates to Storage, page 106. 5. Install the deﬂector. Refer to Installing the Driveline Deﬂector, page 151. 6. Close the cutterbar doors. Refer to 3.5 Cutterbar Doors, page...
Page 119: Tall Crop Divider Option
OPERATING THE HEADER 4.12 Tall Crop Divider Option Tall crop dividers (one on each end of the header) assist in clean crop dividing and cutterbar entry in tall crops. Tall crop dividers are not adjustable, but they are removable. 4.12.1 Installing Tall Crop Divider To install the tall crop divider kit (MD #B5509), follow these steps: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove...
Page 120: Removing Tall Crop Divider
OPERATING THE HEADER 6. Position left-hand divider (B) on header left front corner, and install with four bolts (A) and nuts in existing holes. Tighten hardware. 7. Repeat for right-hand side. 8. Lower cutterbar doors. Figure 4.36: Tall Crop Divider Installed 4.12.2 Removing Tall Crop Divider DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove...
Page 121 OPERATING THE HEADER 5. Reinstall two bolts and nuts at location shown (A). 6. Repeat Steps at the 4., page 108 5., page 109 other end of the header. 7. Close the cutterbar doors. Refer to 3.5 Cutterbar Doors, page Figure 4.38: Crop Divider Mounting Holes 214014 Revision B...
Page 122: Overshot Auger
OPERATING THE HEADER 4.13 Overshot Auger The overshot auger is designed to feed the cut crop from the cutterbar into the conditioner rolls. The auger position has been factory set and should not normally require adjustment. However, if adjustment is required the vertical and fore-aft positions of the auger can be adjusted for crop conditions.
Page 123 OPERATING THE HEADER 5. Loosen jam nuts (A) to relieve tension on auger drive belts (B). 6. Loosen three jam nuts (C). 7. To adjust vertical position, loosen upper nuts on adjuster bolts (D). Hold lower nut and turn adjuster bolts (D) to set auger vertical position from bottom of pan.
Page 124 OPERATING THE HEADER 14. To tighten auger drive belts (C), adjust eye bolt (A) and secure with jam nut (B). Refer to Inspecting and Adjusting the Auger Drive Belts, page 165. Figure 4.43: Drive Belts 214014 Revision B...
Page 125: Stripper Bars
OPERATING THE HEADER 4.14 Stripper Bars There are two adjustable stripper bars installed on the pan at both ends of the auger that minimize wrapping of material around the auger. The factory position should be satisfactory for most crops, but bars can be adjusted for speciﬁc conditions.
Page 126 OPERATING THE HEADER 5. Loosen nuts (A) on the two bolts securing stripper bar to the pan sufﬁciently so that stripper bar can be moved. Figure 4.45: Left End Drives Figure 4.46: Right End 6. Position stripper bar (A) as close as possible to auger ﬂighting without contacting it.
Page 127 OPERATING THE HEADER 9. Tighten nuts (A). NOTE: Right side and left side stripper bars are interchangeable. Each stripper bar can be ﬂipped when one bar wears out or becomes damaged. Figure 4.48: Left End Figure 4.49: Right End 214014 Revision B...
Page 128: Haying
OPERATING THE HEADER 4.15 Haying 4.15.1 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 129: Driving On Windrow
OPERATING THE HEADER Table 4.4 Recommended Windrow Characteristics Characteristic Advantage Enables airﬂow through windrow which is more important to the curing High and ﬂuffy process than direct sunlight Consistent formation (not bunching) 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 130: Unplugging The Header
OPERATING THE HEADER 4.16 Unplugging the Header Follow these steps to remove plugged material from the header: DANGER To avoid bodily injury or death from unexpected startup of machine, always stop the engine and remove the key before removing plugged material from header. 1.
Page 131: Maintenance And Servicing
5 Maintenance and Servicing Use the following instructions as your ﬁrst source of information for servicing the header. A parts catalog is located in a plastic case at the right end of the header. If more detailed maintenance and service information is required, contact your Dealer.
Page 132: Recommended Fluids And Lubricants
MAINTENANCE AND SERVICING 5.2 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 5.1 Fluids and Capacities Lubricant Location...
Page 133: Maintenance Requirements
MAINTENANCE AND SERVICING 5.3 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 134 MAINTENANCE AND SERVICING Action  Check  Lubricate ▲ Change First 25 hours Check drive belt tension. Refer to Inspecting the Conditioner  Drive Belt, page 158 Inspecting and Adjusting the Auger Drive Belts, page 165. Every 25 hours Lube roll universal joints. ...
Page 135 MAINTENANCE AND SERVICING Action  Check  Lubricate ▲ Change Check auger drive belt. Refer to  Inspecting and Adjusting the Auger Drive Belts, page 165. Check conditioner gearbox lubricant.  Refer to 5.5.3 Conditioner Gearbox, page 161. Check bevel gearbox lubricant. ...
Page 136: Preseason/Annual Service
MAINTENANCE AND SERVICING 5.3.2 Preseason/Annual Service CAUTION • Review the operator’s manual to refresh your memory on safety and operating recommendations. • Review all safety signs and other decals on the header and note hazard areas. • Be sure all shields and guards are properly installed and secured. Never alter or remove safety equipment.
Page 137: Lubrication And Servicing
MAINTENANCE AND SERVICING 5.3.4 Lubrication and Servicing WARNING To avoid personal injury, before servicing the header or opening drive covers, follow procedures in Preparation for Servicing, page 119. Log hours of operation and use the Maintenance Checklist provided to keep a record of scheduled maintenance. Refer to 5.3.1 Maintenance Schedule/Record, page 121.
Page 138: Lubrication And Servicing Intervals
MAINTENANCE AND SERVICING The greasing points are marked on the machine by decals showing a grease gun and grease interval in hours of operation. Use the recommended lubricants speciﬁed in this manual. Refer to 5.2 Recommended Fluids and Lubricants, page 120.
Page 139 MAINTENANCE AND SERVICING Every 25 Hours Figure 5.3 A - Driveline Universals (2 Places) B - Driveline Universals (2 Places) C - Driveline Shaft 4 (2 Places) D - Driveline Universals (2 Places) E - Driveline Shaft 4 NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2) lithium base except where noted.
Page 140 MAINTENANCE AND SERVICING Every 50 Hours Figure 5.4 A - Roll Shaft Bearings (2 Places) B - Roll Shaft Bearings (2 Places) C - Optional Gauge Roll Bearings(2 Places Each) D - Auger Bearing (1 Place) E - Auger Bearing (1 Place) F - Belt Tensioner Pivot (1 Place) NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI...
Page 141 MAINTENANCE AND SERVICING Every 100 Hours or Annually Figure 5.5 A - Conditioner Gearbox Oil Level (Check with Top of Header Horizontal) B - Bevel Gearbox Oil Level (Check with Top of Header Horizontal) 4. 10% moly grease is recommended for driveline shaft slip joint only 214014 Revision B...
Page 142 MAINTENANCE AND SERVICING Every 250 Hours Figure 5.6 A - Drain and Reﬁll Bevel Gearbox Lube 5 B - Drain and Reﬁll Conditioner Gearbox Lube 5 C - Drain and Reﬁll Cutterbar Lube 6 5. Refer to Changing the Bevel Gearbox Lubricant, page 157.
Page 143: Lubricating The Cutterbar
MAINTENANCE AND SERVICING 5.3.7 Lubricating the Cutterbar The lubricant level in the cutterbar CANNOT be checked. If the cutterbar lubricant quantity is in doubt, do NOT add lubricant. Drain the cutterbar and reﬁll with new clean lubricant. Draining the Cutterbar Lubricant IMPORTANT: Drain the cutterbar when the lubricant is warm.
Page 144 MAINTENANCE AND SERVICING 6. Locate one of the three ﬁller plugs along the top of the cutterbar. Refer to 5.8: 16 ft.: Cutterbar Filler Plug Locations, page 132. Figure 5.8: Cutterbar Filler Plug Locations 7. Clean around either ﬁller plug (A) and remove one plug with an 8 mm hex key.
Page 145: Filling The Cutterbar Lubricant
MAINTENANCE AND SERVICING Filling the Cutterbar Lubricant DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key, and engage header safety props before going under machine for any reason. 1. Park the machine on level ground. 2.
Page 146 MAINTENANCE AND SERVICING 10. Locate the ﬁller plugs (A) and (B) along the top of the cutterbar. Refer to Figure 5.12: Cutterbar Filler Plug Locations, page 134. Figure 5.12: Cutterbar Filler Plug Locations 11. Clean around and remove ﬁller plugs (A) and (B) with an 8 mm hex key. NOTE: Opening two ﬁll plugs allows air to escape while adding oil to the cutterbar and prevents oil from blowing back through the ﬁll hole.
Page 147: Rock Guards
4. Inspect rock guards (A) for severe damage, wear, and distortion. The guards should be replaced if severely damaged or worn. 5. Check for loose or missing fasteners and tighten or replace fastener if missing. 6. Contact your MacDon Dealer replacement procedures. Figure 5.13: Rock Guards 214014 Revision B...
Page 148: Cutterbar Disc Maintenance
MAINTENANCE AND SERVICING 5.4 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 149: Inspecting The Cutterbar Discs
MAINTENANCE AND SERVICING 5.4.2 Inspecting the Cutterbar Discs Perform the following cutterbar disc inspection daily: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 150: Installing A Cutterbar Disc
MAINTENANCE AND SERVICING 5. Remove four bolts (A) on disc cover (B) and remove cover and disc (C). NOTE: If removing multiple discs, mark the position of each disc to assist in reinstallation. The blades on each disc are direction-speciﬁc. Refer to 5.4.1 Direction of Spindle Rotation, page 136.
Page 151: Cutterblades
ﬂipped over to extend the life of the blades. The blades are NOT repairable and must be replaced if damaged or worn. IMPORTANT: Always use MacDon factory replacement parts. Figure 5.19: Cutterblades Inspecting Cutterblades DANGER To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 152 MAINTENANCE AND SERVICING 1. Check daily that the cutterblades are securely attached to the disc. 2. Inspect blades for cracks, wear beyond safe operating limits (C), and distortion. 3. Replace blades immediately if any problems occur. IMPORTANT: Blades should be replaced in pairs, or the disc may become unbalanced and cause damage to the cutterbar.
Page 153: Inspecting Cutterblade Hardware
MAINTENANCE AND SERVICING Inspecting Cutterblade Hardware CAUTION Damaged or loose cutterblades or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage. 214014 Revision B...
Page 154 MAINTENANCE AND SERVICING Check blade attachment hardware each time blades are changed. Refer to Replacing the Cutterblades, page 143 for hardware replacement procedure. Check bolts and replace bolt if: • Bolt has been removed and installed ﬁve times • Head (A) is worn ﬂush with bearing surface of blade •...
Page 155: Replacing The Cutterblades
MAINTENANCE AND SERVICING Check nuts and replace nut if: • Nut has been removed and installed ﬁve times • Worn height (A) is less than half original height (B) • Nut is cracked Figure 5.24: 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 156: 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 157: Inspecting Accelerators
MAINTENANCE AND SERVICING Inspecting Accelerators Follow these steps to inspect accelerators: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 158 MAINTENANCE AND SERVICING 4. Remove disc (D). Refer to 5.4.3 Removing a Cutterbar Disc, page 137. 5. Remove bolt and nut (A) and nut (B). 6. Remove accelerator (C) from disc (D). IMPORTANT: Do NOT remove cutterblade bolt unless it or the blade is being replaced.
Page 159: Nut Shield
MAINTENANCE AND SERVICING 5.4.7 Nut Shield If accelerators are not used, nut shields will be required to protect the cutterblade nuts. Nut shields are mounted on each outboard disc. Nut shields are replaceable and should be inspected periodically for damage and loose or missing fasteners. Figure 5.31: Inspecting Nut Shield Inspecting Nut Shield 1.
Page 160: Replacing Nut Shield
MAINTENANCE AND SERVICING Replacing Nut Shield 1. Raise the header fully. 2. Stop the engine and remove the key. 3. Engage header safety props. Refer to 3.3 Engaging and Disengaging the Header Safety Props, page 4. Open the cutterbar doors. Refer to 3.5 Cutterbar Doors, page...
Page 161: Removing The Driven Deflector
MAINTENANCE AND SERVICING 3. Open the cutterbar doors. Refer to 3.5 Cutterbar Doors, page 4. Check that deﬂectors (A) are not damaged or bent, also check for loose hardware. 5. Replace deﬂectors (A) if they are severely damaged or worn. Do NOT repair. Refer to: •...
Page 162: 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 163: Installing The Driveline Deflector
MAINTENANCE AND SERVICING 8. Loosen the four bolts (A) in the two plates (B) that hold the upper driveline shield (C) in place. 9. Move the plates (B) so that shield (C) can be lowered into deﬂector (D). 10. Remove the deﬂector (D). Figure 5.38: Driveline Deﬂector Installing the Driveline Deﬂector Follow these steps to replace the driveline deﬂector:...
Page 164: Disc Spindles
MAINTENANCE AND SERVICING 6. Tighten bolts (A) on shield plates (B). 7. Remove block of wood (if used). 8. Manually rotate discs to check for interference of adjacent parts. 9. Close the cutterbar doors. Refer to 3.5 Cutterbar Doors, page WARNING Ensure cutterbar is completely clear of foreign objects.
Page 165 MAINTENANCE AND SERVICING 5. Using a 34 mm socket wrench, remove nut (A) and washer (B) from spindle. Figure 5.43: Cutterbar Spindle Assembly (Short Spindle Shown) 6. Install four M12 mm x 60 mm long bolts (A) into holes in disc (B). 7.
Page 166: Cutterbar Doors
10. Inspect ﬂange (C) and spindle shaft (E) for damage. If seriously damaged, replace entire spindle assembly. Contact your MacDon Dealer. 11. Install new key (D) into gear (E) keyway as shown. 12. Align keyway in disc (C) with key in gear (E) and install disc (C) onto gear until sufﬁcient threads are exposed...
Page 167: Adjusting Door Latches: Export Header
MAINTENANCE AND SERVICING Adjusting Door Latches: Export Header Follow these steps to adjust the door latches: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
Page 168: Replacing Door Latch Brackets: Export Header
MAINTENANCE AND SERVICING 3. Remove bolts (A) and remove latch assembly from frame. 4. Locate new latch assembly on frame and reinstall bolts (A). 5. Adjust to position shown and tighten bolts (A). Figure 5.49: Cutterbar Door Latch Replacing Door Latch Brackets: Export Header To replace the cutterbar door latch brackets, follow these steps: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove...
Page 169: Drive Systems
MAINTENANCE AND SERVICING 5.5 Drive Systems 5.5.1 Bevel Gearbox The bevel gearbox (A), which transfers power from the hydraulic motor to the header drives, is located inside the drive compartment at the left end of the header. If repairs are required, the gearbox should be removed and serviced at your Dealer.
Page 170: Conditioner Drive Belt
MAINTENANCE AND SERVICING 6. Place a suitablly sized container under drain plug (B). Refer to 5.2 Recommended Fluids and Lubricants, for gearbox capacity. page 120 7. Remove plugs (A) and (B). 8. Allow sufﬁcient time for lubricant to drain. 9. Disengage header safety props. Refer to 3.3 Engaging and Disengaging the Header Safety Props, page 10.
Page 171: Replacing The Conditioner Drive Belt
MAINTENANCE AND SERVICING 4. Inspect the condition of belt (A). Replace if damaged or showing signs of cracking or separation. 5. Check that adjuster nut (B) is tight. 6. Check that end of slots (C) are aligned with plate (D). 7.
Page 172 MAINTENANCE AND SERVICING 4. Remove the auger drive belts (A). Refer to Replacing the Auger Drive Belts, page 166. Figure 5.54: Drive Belts (Left Side) 5. Turn adjuster nut (A) counterclockwise until springs are loose and there is no tension on belt (B). Figure 5.55: Drive Belts (Left Side) 6.
Page 173: Conditioner Gearbox
If repairs are required, the conditioner gearbox should be removed and serviced at your MacDon Dealer. The only regular servicing required is maintaining the lubricant level and changing the lubricant according to the intervals speciﬁed in this manual.
Page 174 MAINTENANCE AND SERVICING 5. Open the driveshield. Refer to 3.4 Driveshields, page Figure 5.59: Driveshield 6. Place a suitable container under drain plug (A). Refer 5.2 Recommended Fluids and Lubricants, page 120 for conditioner gearbox lubricant capacity. 7. Remove plugs (A) and (B). 8.
Page 175: Header Drive Speed Sensor
MAINTENANCE AND SERVICING 5.5.4 Header Drive Speed Sensor The header drive speed sensor monitors the rotational speed of the bevel gearbox pulley and sends a signal to the system monitor in the windrower cab to display disc speed. The sensor does not require regular maintenance; if it malfunctions or is damaged, it can be easily adjusted or replaced.
Page 176: Replacing The Header Drive Speed Sensor
MAINTENANCE AND SERVICING Replacing the Header Drive Speed Sensor 1. Loosen bolts (A) and remove the cover (B). Figure 5.64: Header Drive Cover 2. Cut and remove cable tie securing harness to bracket (C). 3. Unplug sensor wire from connector (A). 4.
Page 177: Auger Drive Belt
MAINTENANCE AND SERVICING 5.5.5 Auger Drive Belt The auger drive belts are located inside the drive compartment at the lower left end of the header. Check the belt tension and inspect for damage or wear every 100 hours or annually, preferably before the start of the cutting season.
Page 178: Replacing The Auger Drive Belts
MAINTENANCE AND SERVICING Belt Tension Spring (Eye Bolt Style) 7. To check the belt tension, spring (A) length should measure 262 mm (10.3 in.) (B). If necessary, adjust belt tension as follows: a. Loosen jam nut (C). b. Adjust eye bolt with adjuster bolt (D) until spring length (B) is achieved.
Page 179 MAINTENANCE AND SERVICING 4. Open the driveshield. Refer to 3.4 Driveshields, page 5. Remove/loosen four bolts (A) and remove cover (B). Figure 5.70: Drive Cover – SP 6. Loosen jam nut (A) to release tension on auger drive belts (B). 7.
Page 180 9. Check alignment of belts on pulleys. Belts must not overhang the edge of idler pulley (B). Contact your MacDon Dealer if pulleys need realigning. Figure 5.72: Auger Drive Belts 10. Tension the belts with adjuster nuts (A). Refer to Inspecting and Adjusting the Auger Drive Belts, page 165.
Page 181: Installing Sealed Bearings
MAINTENANCE AND SERVICING 11. Reinstall cover (B) with bolts (A). 12. Close the driveshield. Refer to 3.4 Driveshields, page 13. Adjust the tension of new belts after a short break-in period (about 5 hours). Figure 5.74: Drive Cover – SP 5.5.6 Installing Sealed Bearings Follow these steps to install sealed bearings: 1.
Page 182: Hydraulics
MAINTENANCE AND SERVICING 5.6 Hydraulics Refer to your windrower operator’s manual for hydraulic system maintenance procedures. 5.6.1 Hydraulic Motor The hydraulic motor does not require regular maintenance or servicing. If repairs are required, it should be serviced by your Dealer. Figure 5.76: Hydraulic Motor Removing the Hydraulic Motor Follow these steps to remove the hydraulic motor:...
Page 183: Installing The Hydraulic Motor
MAINTENANCE AND SERVICING 7. Cover gearbox opening (A) with a rag or plastic. Figure 5.78: 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 184: Hydraulic Hoses And Lines
MAINTENANCE AND SERVICING 5.6.2 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 185: Electrical System
MAINTENANCE AND SERVICING 5.7 Electrical System Use electrical tape and wire clips as required to prevent wires from dragging or rubbing. Keep lights clean and replace defective bulbs. 5.7.1 Hazard Lights Hazard Lights: Replacing Bulbs and Lenses Follow these steps to replace a hazard light bulb or lens: 1.
Page 186: Hazard Lights: Replacing The Lamp Bracket
MAINTENANCE AND SERVICING Hazard Lights: Replacing the Lamp Bracket Follow these steps to replace the lamp bracket: 1. Disconnect lamp wires from wiring harness at connectors (A). 2. Remove four bolts (B) and remove lamp assembly (C) from header. 3. Place new lamp assembly (C) on header and secure with four bolts (B).
Page 187: Options And Attachments
6 Options and Attachments 6.1 Options and Attachments: Kits The following kits are available through your MacDon Dealer. The Dealer will require the “B” number for pricing and availability. 6.1.1 Adjustable Skid Shoe Kit The skid shoe kit installs at either end of the cutterbar. The shoes can be adjusted for varying cutting height. The kit includes two skid shoe assemblies, attachment hardware, and installation instructions.
Page 188: Double Windrow Attachment (Dwa)Double Windrow Attachment - Self Propelled
OPTIONS AND ATTACHMENTS 6.1.3 Double Windrow Attachment (DWA)Double Windrow Attachment - Self Propelled 6.1.4 Gauge Roller MD #B5650 Instruction Part Number: MD #169467 Figure 6.3: MD #B5650 6.1.5 Hydraulic Drive: 16-Foot for M200 Self-Propelled MD #B5455 Instruction Part Number: MD #169483 6.1.6 Tall Crop Divider Kit The tall crop dividers attach to the ends of the header for clean crop dividing and cutterbar entry in tall crops.
Page 189: Tall Crop Feed Plate Kit
OPTIONS AND ATTACHMENTS 6.1.7 Tall Crop Feed Plate Kit The tall crop feed plates (A) assist the feeding of tall crops into the conditioner by encouraging material ﬂow from behind the cage deﬂectors (B). MD #B4903 NOTE: One set is supplied standard. Figure 6.5: MD #B4903 214014 Revision B...
Page 191: Troubleshooting
7 Troubleshooting 7.1 Header Performance Symptom Problem Solution Refer to Dull, bent, or badly Replacing the Cutterblades, Replace blades. worn blades page 143 Auger drive belt 5.5.5 Auger Drive Belt, page slipping Adjust tension or change belts. 5.5.2 Conditioner Drive Conditioner drive belt Cutterbar Belt, page 158...
Page 192 TROUBLESHOOTING Symptom Problem Solution Refer to Ground speed too fast Reduce ground speed. 4.9 Ground Speed, page 100 Roll gap too large for Decrease roll gap. proper feeding 4.2.2 Adjusting Roll Gap, page Roll gap too small in thick stemmed Increase roll gap.
Page 193 TROUBLESHOOTING Symptom Problem Solution Refer to Material being pulled out by roots Crop in conditioner when cutting tall 4.2.2 Adjusting Roll Gap, page rolls before crop is cut Increase roll gap. crop leaning into machine Insufﬁcient roll gap Damaged leaves Check roll timing and adjust if and broken stems Roll timing off...
Page 194: 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 5.4 Cutterbar Disc spindle material. Maintenance, page 136 4.6 Header Angle, page...
Page 195 – 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. Discs don’t turn when 5.5.2 Conditioner Drive...
Page 197: Reference
8 Reference 8.1 Torque Speciﬁcations The following tables provide the correct torque values for various bolts, cap screws, and hydraulic ﬁttings. • Tighten all bolts to torque values speciﬁed in charts (unless otherwise noted throughout this manual). • Replace hardware with same strength and grade of bolt. •...
Page 198 REFERENCE Table 8.2 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 5/16-18 16.7 18.5 *149 *164 3/8-16 7/16-14 1/2-13 9/16-12 Figure 8.2: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
Page 199: Metric Bolt Specifications
REFERENCE Table 8.4 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 16.8 18.6 *150 *165 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 Figure 8.4: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
Page 200 REFERENCE Table 8.6 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 18.8 20.8 *167 *185 Figure 8.6: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...
Page 201 REFERENCE Table 8.8 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 8.8: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...
Page 202: Metric Bolt Specifications Bolting Into Cast Aluminum
REFERENCE 8.1.3 Metric Bolt Speciﬁcations Bolting into Cast Aluminum Table 8.9 Metric Bolt Bolting into Cast Aluminum Bolt Torque Nominal 10.9 Size (A) (Cast Aluminum) (Cast Aluminum) N·m N·m ft·lbf ft·lbf – – – – – – – Figure 8.9: Bolt Grades –...
Page 203 REFERENCE Table 8.10 Flare-Type Hydraulic Tube Fittings Torque Value Flats from Finger Tight (FFFT) SAE Dash Size Thread Size (in.) Swivel Nut or N·m ft·lbf Tube Hose — — 5/16–24 4–5 3–4 7–8 5–6 — — 3/8–24 7/16–20 18–19 13–14 2-1/2 1/2–20 19–21...
Page 204: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)
REFERENCE 8.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off lock nut (C) as far as possible. Ensure that washer (D) is loose and is pushed toward lock nut (C) as far as possible.
Page 205 REFERENCE Table 8.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque Value SAE Dash Size Thread Size (in.) N·m ft·lbf (*in·lbf) 5/16–24 6–7 *53–62 3/8–24 12–13 *106–115 7/16–20 19–21 14–15 1/2–20 21–33 15–24 9/16–18 26–29 19–21 3/4–16 46–50 34–37 7/8–14 75–82 55–60 1-1/16–12 120–132...
Page 206: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)
REFERENCE 8.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Check that O-ring (A) is NOT on threads and adjust if necessary. 3. Apply hydraulic system oil to O-ring. 4.
Page 207: O-Ring Face Seal (Orfs) Hydraulic Fittings
REFERENCE 8.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings 1. Check components to ensure that sealing surfaces and ﬁtting threads are free of burrs, nicks, scratches, or any foreign material. Figure 8.14: Hydraulic Fitting 2. Apply hydraulic system oil to O-ring (B). 3.
Page 208 REFERENCE Table 8.13 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) N·m ft·lbf – – Note 3/16 9/16 25–28 18–21 Note 5/16 – – 11/16 40–44 29–32 13/16 55–61 41–45 80–88 59–65 1-3/16 115–127...
Page 209: Tapered Pipe Thread Fittings
REFERENCE 8.1.8 Tapered Pipe Thread Fittings Assemble pipe ﬁttings as follows: 1. Check components to ensure that ﬁtting and port threads are free of burrs, nicks and scratches, or any form of contamination. 2. Apply pipe thread sealant (paste type) to external pipe threads. 3.
Page 210: Conversion Chart
REFERENCE 8.2 Conversion Chart Table 8.15 Conversion Chart SI Units (Metric) Inch-Pound Units Quantity Factor Unit Name Abbreviation Unit Name Abbreviation Area hectares x 2.4710 = acres acres US gallons Flow liters per minute L/min x 0.2642 = per minute Force Newtons x 0.2248 =...
Page 211: Index
Index latches............155 replacing ............ 155 accelerators ............144 opening See also cutterbars export headers..........36 replacing............145 North American headers........ 34 cutterbars deﬁnitions ............19 accelerators ASTM inspecting ........... 145 deﬁnitions ............19 replacing ............ 145 attaching cutterblades ........... 139 windrowers ............
Page 212 INDEX bevel gearbox ..........157 changing lubricant........157 haying tips............116 conditioner drive belts........158 curing .............116 replacing ............ 159 driving on windrows .........117 conditioner gearbox ........161 raking and tedding...........117 changing lubricant........161 topsoil moisture ..........116 hydraulic motor weather and topography ........116 installing .............
Page 213 INDEX replacing............148 kits adjustable skid shoes ........175 cutterbar repair tool ........175 operation............. 83 gauge roller............ 176 operator responsibilities ........25 hydraulic drive - 16-foot for M200 ....176 options and attachments ........175 tall crop divider..........176 adjustable skid shoes ........
Page 214 INDEX alert symbols............1 removing ............108 daily start-up checks......... 39 tall crop feed plates..........102 decal location............. 8 installing plates general safety ............ 3 under driveline deﬂector ......103 header safety props.......... 28 under driven deﬂector........103 hydraulic safety ..........6 removing ............
Page 216 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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