Page 1 Rotary Disc 16-Foot Self-Propelled Windrower Header Operator’s Manual 169457 Revision G Original Instruction The harvesting specialists.
Page 2 Rotary Disc 16-Foot Self-Propelled Windrower Header Published: September, 2014...
Page 3 This manual describes operating and maintenance procedures for the MacDon R85 16-Foot Rotary Disc Self-Propelled Windrower Header. Your new 16-foot rotary header can be attached to MacDon M200 and M205 Self-propelled Windrowers and is designed to cut, condition, and lay in windrows a wide variety of grasses and hay crops.
Page 4 Serial Number(s) Record the serial number of the header in the space provided. Header Serial No: ____________ Serial Number Plate (A) is located on the top surface at the right hand end of the header. Figure 2: Serial Number Location 169457 Revision G...
Page 5 List of Revisions At MacDon, we’re continuously making improvements: occasionally these improvements impact product documentation. The following list provides an account of major changes from the previous version of this document. Summary of Change Location Added a note about keep MacDon publications...
Page 7: Table Of Contents
TABLE OF CONTENTS Introduction ............................i Serial Number(s) ..........................ii List of Revisions ..........................iii Safety ..............................1 Safety Alert Symbols........................1 Signal Words........................... 2 General Safety ..........................3 Maintenance Safety ......................... 6 Hydraulic Safety ..........................7 Safety Signs ............................ 8 1.6.1 Installing Safety Decals ......................
Page 8 TABLE OF CONTENTS Roll Timing ............................ 71 6.4.1 Checking Roll Timing......................71 6.4.2 Adjusting the Roll Timing ......................72 Forming Shields ..........................73 6.5.1 Adjusting the Side Deﬂectors ....................73 6.5.2 Adjusting the Rear Deﬂector (Fluffer Shield)................75 6.5.3 Adjusting the Swath Bafﬂe ...................... 75 Header Angle ..........................
Page 9 TABLE OF CONTENTS 7.5.5 Lubrication and Servicing....................... 118 7.5.6 Greasing Procedure ......................119 7.5.7 Lubrication and Servicing Intervals ..................120 7.5.8 Lubricating the Cutterbar .......................124 Draining the Cutterbar Lubricant ..................124 Filling the Cutterbar Lubricant ..................126 7.5.9 Rock Guards.........................129 Inspecting the Rock Guards ...................129 Cutterbar Disc Maintenance ......................130 7.6.1 Inspecting the Cutterbar Discs ....................130...
Page 10 TABLE OF CONTENTS Mechanical Problems........................166 Options and Attachments ........................169 Kits ..............................169 9.1.1 Adjustable Skid Shoe Kit......................169 9.1.2 Cutterbar Repair Tool Kit......................169 9.1.3 Double Windrow Attachment (DWA) ..................170 9.1.4 Gauge Roller ........................170 9.1.5 Hydraulic Drive - 16-ft. for M200 Self-Propelled...............170 9.1.6 Tall Crop Divider Kit .......................171 9.1.7 Tall Crop Feed Plate Kit ......................171...
Page 11: Safety
1 Safety 1.1 Safety Alert Symbols This safety alert symbol indicates important safety messages in this manual and on safety signs on the header. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read follow safety message accompanying this symbol.
Page 12: Signal Words
SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The appropriate signal word for each situation has been selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
Page 13: General Safety
SAFETY 1.3 General Safety CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself • When assembling, operating, and servicing machinery, wear all the protective clothing and personal safety devices that COULD be necessary for the job at hand.
Page 14 SAFETY • Provide a ﬁrst aid kit for use in case of emergencies. • Keep a ﬁre extinguisher on the machine. Be sure the ﬁre extinguisher is properly maintained. Be familiar with its proper use. • Keep young children away from the machinery at all times.
Page 15 SAFETY • Keep the service area clean and dry. Wet or oily ﬂoors are slippery. Wet spots can be dangerous when working with electrical equipment. Be sure all electrical outlets and tools are properly grounded. • Keep work area well lit. •...
Page 16: 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 17: 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 18: 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 19: Safety Decal Location
SAFETY 1.7 Safety Decal Location Figure 1.15: Safety Decal Locations A - MD #166466 B - MD #113482 C - MD #194464 D - MD #194521 E - MD #184385 Figure 1.16: Safety Decals 169457 Revision G...
Page 20 SAFETY Figure 1.17: Safety Decal Locations A - MD #190546 B - MD #184371 C - MD #184385 D - MD #194466 E - MD #194463 F - MD #194465 Figure 1.18: Safety Decals 169457 Revision G...
Page 21 SAFETY Figure 1.19: Safety Decal Locations A - MD #184386 169457 Revision G...
Page 22: Interpreting Safety Signs
SAFETY 1.8 Interpreting Safety Signs In the safety sign explanations below, (a) refers to the top or left position panel, (b) refers to the bottom or right position of the safety decal depending on decal orientation. NOTE: If there are more than two panels in a decal, the lettering will continue downward or to the right, depending on decal orientation.
Page 23 SAFETY 2. MD #166466 a. High pressure oil hazard b. WARNING Do not go near leaks. • High pressure oil easily punctures skin causing serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. •...
Page 24 SAFETY 5. MD #184386 a. Pinch hazard b. WARNING Keep away • Failure to comply could result in death or serious injury Figure 1.24: MD #184386 6. MD #184422 a. Keep shields in place hazard b. WARNING • To avoid injury, stop the engine and remove the key before opening power drive system shield •...
Page 25 SAFETY 8. MD #194463 a. Rotating blades b. WARNING • Disengage PTO, shut off the engine, and remove the key before opening covers • Listen and look for evidence of rotation before lifting cover • Rotating cutters may continue to rotate after power is shut off Figure 1.26: MD #194463 9.
Page 26 SAFETY 11. MD #194466 a. Rotating ﬂails under hood b. WARNING Stand clear • Crop materials exiting at high speed • Stop machine, look, listen, and wait for all movement to stop before approaching • Failure to comply could result in death or serious injury Figure 1.29: MD #194466 169457...
Page 27 SAFETY 12. MD #194521 a. Auger entanglement hazard b. CAUTION • To avoid injury from entanglement with rotating auger, stand clear of header while machine is running c. General hazard pertaining to machine operation and servicing d. CAUTION • Read the operator’s manual and follow safety instructions.
Page 29: Definitions
2 Deﬁnitions The following terms and acronyms may be used in this manual. Term Deﬁnition American Petroleum Institute Articulated Power Turn ASTM American Society of Testing and Materials Bolt A headed and externally threaded fastener that is designed to be paired with a nut Cab-forward Windrower operation with the Operator and cab facing in the direction of travel Cab display module on a self-propelled windrower...
Page 30 DEFINITIONS Term Deﬁnition O-ring face seal: a style of ﬁtting commonly used for connecting hoses and tubes. ORFS This style of ﬁtting is also commonly called ORS, which stands for O-ring seal Power Take-Off RoHS (Reduction of A directive by the European Union to restrict the use of certain hazardous Hazardous Substances) substances (such as hexavalent chromium used in some yellow zinc platings) Society of Automotive Engineers...
Page 31: Component Identification
3 Component Identiﬁcation Figure 3.1: 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 3.2: Component Identiﬁcation A - Transport Light D - Drive Motor B - Conditioner Rolls...
Page 33: Specifications
Speciﬁcations and design are subject to change without notice or obligation to revise previously sold units. Frame and Structure Transport width 16 ft.-0 in. (4879 mm) Weight (estimated) 4300 lb. (1955 kg) Carrier MacDon M200 and M205 Self-Propelled Windrowers Lighting Two amber transport Manual storage Windrower cab manual storage compartment Cutterbar Quantity of cutting discs Blades per disc Two 11°...
Page 34 SPECIFICATIONS Frame and Structure Conditioner gearbox lube 11.8 oz. (350 ml) capacity Roll type Intermeshing steel bars Roll diameter 9-5/32 in. (233 mm) / 6-5/8 in. (168.4 mm) OD tube Roll length 118 in. (3000 mm) Roll speed 730–1040 rpm Swath width 36–102 in.
Page 35: 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 36: Operational Safety
OPERATION 5.2 Operational Safety CAUTION Follow these safety precautions: • Follow all safety and operational instructions given in your windrower operator’s manuals. If you do not have an operator’s manual, get one from your Dealer and read it thoroughly • Never attempt to start the windrower’s engine or operate the machine except from the windrower seat •...
Page 37 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 38: Header Safety Props
OPERATION 5.3 Header Safety Props Safety props are located on both header lift cylinders on the windrower. DANGER To avoid bodily injury from fall of raised header, always engage safety props when working on or around raised header, and before going under header for any reason. Engage safety props as follows: 1.
Page 39 OPERATION 4. To disengage safety props and for storage, turn lever (A) away from header to raise safety prop until lever locks into vertical position. Repeat for opposite cylinder. Figure 5.4: Safety Prop 5. Start engine, choose a level area, and lower header to the ground.
Page 40: Driveshields
The R85 16-foot header for Self-Propelled Windrower comes in two conﬁgurations—one conﬁgured for use in North America and one conﬁgured for use outside of North America. The conﬁguration is speciﬁed in the title when necessary.
Page 41: Removing Right Endshield
OPERATION 5.4.3 Removing Right Endshield 1. Remove three bolts (A) and remove right endshield (B). Figure 5.7: Right Endshield 5.4.4 Installing Right Endshield 1. Install right endshield (B) using three bolts (A). Figure 5.8: Right Endshield 169457 Revision G...
Page 42: Opening The Driveshield: Export Header
OPERATION 5.4.5 Opening the Driveshield: Export Header Follow these steps to open the driveshield on export header: 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 43: Cutterbar Doors
OPERATION 5.5 Cutterbar Doors CAUTION Do NOT operate the machine without all the cutterbar doors down, curtains installed and in good condition. Two doors provide access to the cutterbar area. Rubber curtains are attached to each door, at the front corners, and center ﬁxed cover.
Page 44: Closing The Cutterbar Doors: North American Header
OPERATION 2. Lift front of door to the open position. Figure 5.13: Cutterbar Doors 5.5.2 Closing the Cutterbar Doors: North American Header Follow these steps to close the cutterbar doors on a North American header: CAUTION To avoid injury, keep hands and ﬁngers away from corners of doors when closing. 1.
Page 45 OPERATION 2. Hook curtain latches (A). NOTE: Ensure that curtains hang properly and completely enclose cutterbar area. Figure 5.15: Curtain Latches 169457 Revision G...
Page 46: Opening The Cutterbar Doors: Export Header
OPERATION 5.5.3 Opening the Cutterbar Doors: Export Header Follow these steps to open the cutterbar doors on an export header: 1. Unhook curtain latches (A). Figure 5.16: Curtain Latches 169457 Revision G...
Page 47: Closing The Cutterbar Doors: Export Header
OPERATION 2. Insert a screwdriver (or equivalent) through hole (A) in door into notch in latch (B) and push latch to disengage. 3. Lift at front of door to open. Figure 5.17: Cutterbar Door Latch 5.5.4 Closing the Cutterbar Doors: Export Header To close the cutterbar doors on an export header follow these steps: CAUTION To avoid injury, keep hands and ﬁngers away from corners of doors when closing.
Page 48 OPERATION 1. Pull at top and move to closed position. Ensure latch (A) has engaged the door. Figure 5.18: Cutterbar Door Latch 2. Hook curtain latches (A). Figure 5.19: Curtain Latches 169457 Revision G...
Page 49: Daily Start-Up Check
OPERATION 5.6 Daily Start-Up Check CAUTION • Be sure windrower and header are properly attached, all controls are in NEUTRAL, and windrower brake is engaged. • Clear the area of other persons, pets etc. Keep children away from machinery. Walk around the header to be sure no one is under, on or close to it.
Page 50 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 7.8.2 Hydraulic Hoses and Lines, page 160.
Page 51: Attaching The Header
OPERATION 5.7 Attaching the Header 5.7.1 Attaching the Forming Shield DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason. A child or even a pet could engage an idling machine. To attach the forming shield to the windrower, follow these steps: 1.
Page 52 OPERATION 4. Position the forming shield onto spacers (B) on windrower legs. Secure with clevis pins (A) and lynch pin. Figure 5.24: Forming Shield under Windrower 5. Lift the aft end of the forming shield and attach straps (B) to pins (A) on windrower frame. 6.
Page 53: Attaching The Header (M205 Windrowers)
8. Adjust rear ﬂuffer deﬂector (C) to middle position. Loosen handles (B) if required. Figure 5.26: Forming Shield Adjuster Bar 9. Attach the R85 header to the windrower. Refer to the windrower operator’s manual, and then return to this manual to complete the attachment.
Page 54 OPERATION 1. Move windrower left-hand (cab-forward) platform (A) to OPEN position. Figure 5.27: Windrower LH Platform 2. Route the hose bundle (A) from the header, under the windrower frame and insert pin (B) into hole in windrower frame. 3. Place hoses on support (C). 4.
Page 55 OPERATION Remove coupler lock as follows: a. Remove lynch pin (A) and open up coupler lock (B). b. Remove lock from coupler. Figure 5.29: Hydraulic Couplers 6. Position hose couplers against mating couplers on windrower and screw sleeves (A) onto mating receptacles.
Page 56 OPERATION 8. Lower holder (A) onto sleeves (B) so that ﬂats locate on holder. Holder can be adjusted by loosening bolts (C). Tighten bolts after adjusting. Figure 5.32: Hydraulic Couplers 9. Insert lynch pin (A) to secure lock. 10. Attach case drain hose coupler at (B). 11.
Page 57: Attaching The Header (M200 Windrowers)
OPERATION 14. Connect the electrical harness to connector (A) (located beside the forward valve block on the windrower). Figure 5.35: Hydraulic Couplers 15. Move windrower platform (A) to CLOSED position. Figure 5.36: Windrower LH Platform 5.7.3 Attaching the Header (M200 Windrowers) DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 58 OPERATION The 16-foot header requires kit MD #B5455 installed to enable operation on an M200 windrower. If required, obtain the kit through your MacDon Dealer. Install kit in accordance with the supplied instructions. Figure 5.37: MD #B5455 1. Disengage and rotate lever (A) counterclockwise to the UP position.
Page 59 OPERATION 3. Move hose bundle (A) from windrower and rest the bundle on the header. Figure 5.39: Hose Bundle 4. Check that hose support is positioned with lower bolt (A) in forward hole and support positioned as shown. Loosen both bolts and adjust as required. Figure 5.40: Hose Support 5.
Page 60 OPERATION 7. Secure hose bundles with three cinch straps (B). 8. Lower and lock lever (A). Figure 5.42: Hose Bundle 9. Move windrower left side (cab-forward) platform (A) to OPEN position to access valve blocks. Figure 5.43: Windrower LH Platform 169457 Revision G...
Page 61 OPERATION 10. Remove caps from pressure (A) and return (B) ports on valve (C) and discard. IMPORTANT: Maintain cleanliness of all open lines and ports. 11. Remove ﬁtting at pressure port (A) and discard. Figure 5.44: Hydraulic Connections 12. Disconnect ﬁttings at end of hose bundle (A). Discard caps.
Page 62 OPERATION 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. Install male 45° ﬁtting (D) and male coupler (E) from hose in pressure port (F).
Page 63 OPERATION 17. Remove caps and plugs from hoses and lines. 18. Connect the pressure (A), return (B), and case drain (C) hoses from windrower to ﬁttings on header as shown. 19. Connect electrical harness (D) from windrower to connector on header. Figure 5.48: Header Connections 20.
Page 64: Detaching The Header
OPERATION 5.8 Detaching the Header 5.8.1 Detaching the Header (M205 Windrowers) Refer to your windrower operator’s manual for procedure to mechanically detach the header from a self-propelled windrower. Refer to the following procedure to disconnect electrical and hydraulic systems: DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 65 OPERATION 4. Disconnect electrical harness at connector (A). 5. If couplers and coupler lock are installed on lines, proceed as follows. Otherwise, proceed to step 13., page Figure 5.51: Hydraulic Connections 6. Disconnect 1/2 in. (12.7 mm) hose (B) from windrower coupler and remove lynch pin (A).
Page 66 OPERATION 9. Unscrew sleeves couplers separate couplers. 10. Install caps and plugs on open lines. Figure 5.54: Hydraulic Connections 11. Attach coupler lock (B) to hoses and secure with lynch pin (A). 12. Proceed to step 14., page Figure 5.55: Hydraulic Connections 13.
Page 67 OPERATION 14. Remove hose support (A) from windrower frame. 15. Route hoses (B) and electrical harness onto header. Figure 5.57: Hose Bundle 16. Move maintenance platform (A) to CLOSED position. 17. Detach the header from the windrower. Refer to the windrower operator’s manual.
Page 68: Detaching The Header (M200 Windrowers)
OPERATION 5.8.2 Detaching the Header (M200 Windrowers) Refer to your windrower operator’s manual for procedure to mechanically detach the header from a self-propelled windrower. Refer to the following procedure to disconnect electrical and hydraulic systems: DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason. A child or even a pet could engage an idling machine.
Page 69 OPERATION 6. Raise and unlock lever (A) and undo cinch straps (B). 7. Move hose bundle to store on header. Figure 5.61: Hose Bundle 8. At the header, disconnect electrical connector (D) by turning collar counterclockwise and pull connector to disengage. 9.
Page 70 OPERATION 13. Move windrower platform back CLOSED position. 14. Detach header from windrower. Refer to the windrower operator’s manual. Figure 5.64: Windrower LH Platform 169457 Revision G...
Page 71: Break-In Period
OPERATION 5.9 Break-In Period After attaching the header to the windrower for the ﬁrst time, operate the machine slowly for 5 minutes, watching and listening from the windrower seat for binding or interfering parts. NOTE: Until you become familiar with the sound and feel of your new header, be extra alert and attentive. CAUTION Before investigating an unusual sound or attempting to correct a problem, shut off windrower, engage parking brake, and remove key.
Page 72: Shutting Down The Windrower
OPERATION 5.10 Shutting Down the Windrower CAUTION Before leaving the windrower seat for any reason: • Park on level ground (if possible) • Lower the header fully • Place ground speed control in N-DETENT • Stop engine and remove key from ignition •...
Page 73: Transporting The Header
OPERATION 5.11 Transporting the Header Refer to your windrower operator’s manual for transporting headers when attached to the windrower. IMPORTANT: Lights are factory assembled to meet road travel lighting requirements with windrower in ENGINE-FORWARD transport mode. If transporting header with header forward, light assemblies MUST be reversed.
Page 74: Lights
OPERATION 5.12 Lights The transport lights, which are mounted on both ends of the header, are activated by switches in the M-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 75: Operating The Header
6 Operating the Header Satisfactory operation of the header 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 the machine. The variables listed below and detailed on the following pages will affect the performance of the header.
Page 76: Adjusting Header Float
OPERATING THE HEADER 6.1.1 Adjusting Header Float Set the Float Fine Adjustment to MID-RANGE with the windrower ﬂoat adjustment system in the cab. Refer to your windrower operator’s manual. 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 77: Roll Gap
OPERATING THE HEADER 6.2 Roll Gap When crop enters the conditioner, steel "N" bar rolls crimp and crush the stems in several places. This conditioning releases moisture for quick drying. The roll gap controls the degree of conditioning. Correct conditioning of alfalfa, clover, and other legumes is indicated when 90% of the stems show cracking with no more than 5% leaf damage.
Page 78: Adjusting Roll Gap
OPERATING THE HEADER 5. Inspect roll gap at both ends of the rolls. Gap (B) should be 1 in. (25.4 mm). This is the factory setting. IMPORTANT: Roll timing is critical when the roll gap is decreased because the bars may contact each other if the timing is wrong.
Page 79 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 1-3/16 in. (30 mm). 8.
Page 80: Roll Tension
OPERATING THE HEADER 6.3 Roll Tension Roll tension (the force holding the rolls together) is factory set with a spring type adjustable linkage. Heavy crops or tough forage tend to separate the rolls and require more tension to ensure material is sufﬁciently crimped.
Page 81: Roll Timing
OPERATING THE HEADER 6.4 Roll Timing For proper conditioning, the rolls must be properly timed with each steel bar on one roll centered between two bars of the other roll. The factory setting should be suitable for most crop conditions. IMPORTANT: Roll timing is critical when the roll gap is decreased because the bars may contact each other if the timing is wrong.
Page 82: Adjusting The Roll Timing
OPERATING THE HEADER 6.4.2 Adjusting the Roll Timing Follow these steps to adjust the roll timing (if necessary): 1. Loosen four bolts (A) in slots of yoke plate (B) on upper roll universal shaft. Figure 6.9: Conditioner Gearbox 2. Locate roll timing gauge (MD #150572) (B) on frame member under the ﬂange.
Page 83: Forming Shields
OPERATING THE HEADER 6.5 Forming Shields WARNING Keep hands and feet away from discharge opening. Keep everyone several hundred feet away from your operation. Never direct the discharge toward anyone. Stones or other foreign objects can be ejected with force. The position of the forming shields controls the width and placement of the windrow.
Page 84 OPERATING THE HEADER 2. If side deﬂector attachment is too tight or too loose, tighten or loosen nut (A) as required. Figure 6.13: Forming Shield 169457 Revision G...
Page 85: Adjusting The Rear Deflector (Fluffer Shield)
OPERATING THE HEADER 6.5.2 Adjusting the Rear Deﬂector (Fluffer Shield) DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason. A child or even a pet could engage an idling machine. The rear deﬂector (ﬂuffer shield) slows the crop exiting the conditioner rolls, directs the ﬂow downward, and ﬂuffs the material.
Page 86 OPERATING THE HEADER The swath bafﬂe (A) determines the width and height of the windrow. It is located immediately behind and above the conditioning rolls and can be positioned to • direct the crop ﬂow into the forming shield for narrow and moderate width windrows •...
Page 87: Header Angle
OPERATING THE HEADER 6.6 Header Angle Header (or cutterbar) angle can be varied from 0–8° below horizontal. Choose an angle that maximizes performance for your crop and ﬁeld conditions. A ﬂatter angle provides better clearance in stony conditions while a steeper angle provides better lifting action in down crops.
Page 88: Cutting Height
OPERATING THE HEADER 6.7 Cutting Height Cutting height is determined by a combination of the angle of the cutterbar/header and the gauge roller or skid shoe settings. Cutting height should be adjusted for optimum cutting performance without excessive mud build-up inside the header that can lead to poor crop ﬂow and increased wear on cutting components.
Page 89: Disc Speed
OPERATING THE HEADER 3. Remove lynch pin and remove adjuster pin (A) from one side of skid shoe (B). 4. Hold skid shoe and remove lynch pin and adjuster pin (A) from other side. Position shoe at desired position, and reinstall adjuster pins (A). Secure with lynch pins.
Page 90: Ground Speed
OPERATING THE HEADER 6.8 Ground Speed CAUTION Reduce speed when turning, crossing slopes, or when travelling over rough ground. Choose a ground speed that allows the cutterbar and conditioner to cut the crop smoothly and evenly. Try different combinations of header speed and ground speed to suit your speciﬁc crop. Refer to your windrower operator’s manual for changing ground speed.
Page 91: Double Windrowing
OPERATING THE HEADER 6.9 Double Windrowing If your windrower is equipped with the Double Windrow Attachment (DWA [A]), refer to the MacDon DWA Manual for operating and maintenance instructions. The manual is shipped with the DWA Kit. Figure 6.21: DWA...
Page 92: Tall Crop Feed Plates
OPERATING THE HEADER 6.10 Tall Crop Feed Plates 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). They will degrade the cutting performance of the cutterbar if they are used in medium to light alfalfa and so should not be installed in those types of crops.
Page 93: Installing Tall Crop Feed Plates: Under Driven Deflector
OPERATING THE HEADER Installing Tall Crop Feed Plates: Under Driven Deﬂector 1. Remove driven deﬂector. Refer to Removing the Driven Deﬂector, page 141. 2. Locate tall crop feed plates from storage. Refer to 6.10.1 Locating Tall Crop Feed Plates for Installation, page 3.
Page 94: Removing Tall Crop Feed Plates
OPERATING THE HEADER IMPORTANT: Depending on disc (B) rotation, feed plate (A) should be located so that when holes are aligned, the leading edge of the feed plate is further from the accelerator (B) than the trailing edge. 6. Install the deﬂector. Refer to Installing the Driveline Deﬂector, page 143.
Page 95: Removing Tall Crop Feed Plates: Under Driveline Deflector
OPERATING THE HEADER 2. Remove feed plate (A). 3. Return the tall crop feed plates to the storage location. Refer to 6.10.3 Returning Tall Crop Feed Plates to Storage, page 4. Install the deﬂector. Refer to Installing the Driven Deﬂector, page 142.
Page 96 OPERATING THE HEADER 4. Remove nuts (A) and secure the feed plates (B) to side of compartment and remove plates. Reinstall nuts (A). 5. Install RH shield. Refer to 5.4.4 Installing Right Endshield, page Figure 6.31: Feed Plate Storage 169457 Revision G...
Page 97: Tall Crop Dividers
OPERATING THE HEADER 6.11 Tall Crop Dividers Tall crop dividers (one on each end of the header) assist in clean crop dividing and cutterbar entry in tall crops. Tall crop dividers are not adjustable, but they are removable. 6.11.1 Removing Tall Crop Divider DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason.
Page 98 OPERATING THE HEADER 4. Reinstall two bolts and nuts at location shown (A). 5. Repeat steps at the other 3., page 87 4., page 88 end of the header. 6. Close cutterbar doors. Figure 6.34: Crop Divider Mounting Holes 169457 Revision G...
Page 99: The Overshot Auger
OPERATING THE HEADER 6.12 The 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 100 OPERATING THE HEADER 4. Loosen jam nuts (A) to relieve tension on auger drive belts (B). 5. Loosen three jam nuts (C). 6. 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 101 OPERATING THE HEADER 13. Adjust eye bolt (A) and secure with jam nut (B) to tighten auger drive belts (C). Refer to Inspecting the Auger Drive Belts, page 154. Figure 6.39: Drive Belts 169457 Revision G...
Page 102: Stripper Bars
OPERATING THE HEADER 6.13 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 103 OPERATING THE HEADER Figure 6.42: Right End 6. Position stripper bar (A) as close as possible to auger ﬂighting, without contacting it. 7. Repeat above steps 5., page 92 6., page 93 opposite side. 8. Manually rotate auger to check that auger does NOT contact stripper bars.
Page 104 OPERATING THE HEADER Figure 6.45: Right End 169457 Revision G...
Page 105: Haying Tips
OPERATING THE HEADER 6.14 Haying Tips 6.14.1 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 106: Driving On Windrow
OPERATING THE HEADER Table 6.4 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 107: Unplugging The Header
OPERATING THE HEADER 6.15 Unplugging the Header Follow these steps to remove plugged material from the header: DANGER Stop windrower engine and remove key before removing plugged material from header. A child or even a pet could engage the drive. 1.
Page 109: Maintenance And Servicing
7 Maintenance and Servicing Use the following instructions as your ﬁrst source of information for servicing the header. A parts catalog is located in a plastic case at the right end of the header. If more detailed maintenance and service information is required, contact your Dealer.
Page 110: Torque Specifications
MAINTENANCE AND SERVICING 7.2 Torque Speciﬁcations The following tables provide the correct torque values for various bolts, cap screws, and hydraulic ﬁttings. • Tighten all bolts to the torque values speciﬁed in the charts (unless otherwise noted throughout this manual). •...
Page 111 MAINTENANCE AND SERVICING Table 7.2 SAE Grade 5 Bolt and Grade 5 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 3/8-16 7/16-14 1/2-13 9/16-12 Figure 7.2: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
Page 112: Metric Bolt Specifications
MAINTENANCE AND SERVICING Table 7.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 1/4-20 16.8 18.6 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 Figure 7.4: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
Page 113 MAINTENANCE AND SERVICING Table 7.6 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 18.8 20.8 Figure 7.6: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...
Page 114 MAINTENANCE AND SERVICING Table 7.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 10.7 11.8 8-1.25 Figure 7.8: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...
Page 115: Metric Bolt Specifications Bolting Into Cast Aluminum
MAINTENANCE AND SERVICING 7.2.3 Metric Bolt Speciﬁcations Bolting into Cast Aluminum Table 7.9 Metric Bolt Bolting into Cast Aluminum Bolt Torque Nominal 10.9 Size (A) (Cast Aluminum) (Cast Aluminum) N·m N·m ft·lbf ft·lbf – – – – – – – Figure 7.9: Bolt Grades –...
Page 116 MAINTENANCE AND SERVICING Table 7.10 Flare-Type Hydraulic Tube Fittings Flats from Finger Nut Size Torque Value Tube Size Thread Tight (FFFT) SAE No. acrossFlats 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 1-3/8...
Page 117: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)
MAINTENANCE AND SERVICING 7.2.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off the lock nut (C) as far as possible. Ensure that washer (D) is not loose and is pushed toward the lock nut (C) as far as possible.
Page 118 MAINTENANCE AND SERVICING Table 7.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque Value SAE Dash Size Thread Size (in.) ft·lbf (*in·lbf) N·m 3/8-24 106–115 12–13 7/16–20 14–15 19–21 1/2–20 15–24 21–33 9/16–18 19–21 26–29 3/4–16 34–37 46–50 7/8–14 55–60 75–82 1-1/16-12 88–97 120–132...
Page 119: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)
MAINTENANCE AND SERVICING 7.2.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Check that O-ring (A) is NOT on the threads and adjust if necessary. 3. Apply hydraulic system oil to the O-ring. 4.
Page 120: O-Ring Face Seal (Orfs) Hydraulic Fittings
MAINTENANCE AND SERVICING 7.2.7 O-Ring Face Seal (ORFS) Hydraulic Fittings 1. Check components to ensure that the sealing surfaces and ﬁtting threads are free of burrs, nicks, scratches, or any foreign material. Figure 7.14: Hydraulic Fitting 2. Apply hydraulic system oil to the O-ring (B). 3.
Page 121 MAINTENANCE AND SERVICING Table 7.13 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value SAE Dash Thread ft·lbf Size Size (in.) N·m (*in·lbf) Note – – 9/16–18 18–21 25–28 Note – – 11/16-16 29–32 40–44 41–45 55–61 13/16-16 1–14 59–65 80–88 1-3/16-12 85–94 115–127...
Page 122: Conversion Chart
MAINTENANCE AND SERVICING 7.3 Conversion Chart Table 7.14 Conversion Chart Inch-Pound Units SI Units (Metric) Quantity Factor 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 123: Recommended Fluids And Lubricants
MAINTENANCE AND SERVICING 7.4 Recommended Fluids and Lubricants Your machine can operate at top efﬁciency only if clean lubricants are used. • Use clean containers to handle all lubricants. • Store in an area protected from dust, moisture, and other contaminants. Table 7.15 Fluids and Capacities Lubricant Speciﬁcation...
Page 124: Maintenance Requirements
MAINTENANCE AND SERVICING 7.5 Maintenance Requirements In this manual, periodic maintenance requirements are organized by service intervals. For detailed instructions, refer to the speciﬁc headings in this section. Regular maintenance is the best insurance against early wear and breakdowns. Use the following schedule and recommendations to increase machine life.
Page 125: Maintenance Schedule/Record
MAINTENANCE AND SERVICING 7.5.1 Maintenance Schedule/Record Action:  - Check  - Lubricate ▲ - Change Hour meter reading  Service date  Serviced by  First use Refer to 7.5.2 Break-In Inspections, page 117. 100 hours or annually Refer to 7.5.3 Preseason/Annual Service, page 117.
Page 126 MAINTENANCE AND SERVICING Action:  - Check  - Lubricate ▲ - Change Conditioner gearbox lubeﬁrst 50 and 150 hours  Refer to 7.7.3 Conditioner Gearbox, page 150. Drive belt tensioner  Refer to 7.5.5 Lubrication and Servicing, page 118. Roll shaft bearings ...
Page 127: Break-In Inspections
MAINTENANCE AND SERVICING 7.5.2 Break-In Inspections Timing Item Refer to Section Check for loose hardware. Tighten 7.2 Torque Speciﬁcations, page 100. to required torque. At 5 hours Check drive belt tension. Inspecting the Conditioner Drive Belt, page 146 At 25 hours Check drive belt tension.
Page 128: End-Of-Season Service
MAINTENANCE AND SERVICING 7.5.4 End-of-Season Service CAUTION Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or ﬂammable. Do the following at the end of each operating season: • Clean the header thoroughly. •...
Page 129: Greasing Procedure
MAINTENANCE AND SERVICING To access the drive systems, open the driveshield and cutterbar doors. Refer to: • 5.4 Driveshields, page 30 • 5.5 Cutterbar Doors, page 33 Figure 7.16: Driveshield 7.5.6 Greasing Procedure DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason. A child or even a pet could engage an idling machine.
Page 130: Lubrication And Servicing Intervals
MAINTENANCE AND SERVICING 7.5.7 Lubrication and Servicing Intervals To identify the various locations that require lubrication and servicing, refer to the following illustrations (organized by the frequency of service that is required). Every 25 Hours Figure 7.18 C - Driveline Shaft 7 (2 Places) A - Driveline Universals (2 Places) B - Driveline Universals (2 Places) E - Driveline Shaft 7...
Page 131 MAINTENANCE AND SERVICING Every 50 Hours Figure 7.19 A - Roll Shaft Bearings (2 Places) B - Roll Shaft Bearings (2 Places) C - Optional Gauge Roll Bearings (2 Places Each) D - Auger Bearing (1 Place) E - Auger Bearing (1 Place) F - Belt Tensioner Pivot (1 Place) NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2)
Page 132 MAINTENANCE AND SERVICING Every 100 Hours or Annually Figure 7.20 A - Conditioner Gearbox Oil Level (Check with Top of Header Horizontal) B - Bevel Gearbox Oil Level (Check with Top of Header Horizontal) NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2) lithium base except where noted.
Page 133 MAINTENANCE AND SERVICING Every 250 Hours Figure 7.21 A - Drain and Reﬁll Bevel Gearbox Lube. Refer to B - Drain and Reﬁll Conditioner Gearbox Lube. Refer to Changing the Bevel Changing the Gearbox Lubricant, page 145 Conditioner Gearbox Lubricant, page 150 C - Drain and Reﬁll Cutterbar Lube.
Page 134: Lubricating The Cutterbar
MAINTENANCE AND SERVICING 7.5.8 Lubricating the Cutterbar The lubricant level in the cutterbar CANNOT be checked. If in doubt as to the quantity of lubricant in the cutterbar, 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 135 MAINTENANCE AND SERVICING Figure 7.23: Cutterbar Filler Plug Locations 10. Locate one of the three ﬁller plugs along the top of the cutterbar. Refer to 7.23: Cutterbar Filler Plug Locations, page 125. 11. Clean around either ﬁller plug (A) and remove one plug with an 8 mm hex key.
Page 136: 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 safety props before going under machine for any reason. CAUTION Never start or move the machine until you are sure all bystanders have cleared the area. 1.
Page 137 MAINTENANCE AND SERVICING 10. Verify that drain plug (A) has been installed, before adding new lubricant. Figure 7.26: Cutterbar Drain Plug Figure 7.27: Cutterbar Filler Plug Locations 11. Locate one of the three ﬁller plugs along the top of the cutterbar. Refer to 7.27: Cutterbar Filler Plug Locations, page...
Page 138 MAINTENANCE AND SERVICING 13. Add lubricant to cutterbar through ﬁller hole (A). Refer 7.4 Recommended Fluids and Lubricants, page 113. IMPORTANT: DO NOT overﬁll the cutterbar. Overﬁlling can cause overheating and damage to or failure of the cutterbar will occur. 14.
Page 139: Rock Guards
3. Inspect rock guards (A) for severe damage, wear, and distortion. The guards should be replaced if severely damaged or worn. 4. Check for loose or missing fasteners and tighten or replace fastener if missing. 5. Contact your MacDon Dealer replacement procedures. Figure 7.28: Rock Gaurds 169457 Revision G...
Page 140: Cutterbar Disc Maintenance
MAINTENANCE AND SERVICING 7.6 Cutterbar Disc Maintenance Perform daily inspections to ensure that cutterbar discs have not suffered damage from rocks or experienced excessive wear from abrasive working conditions. Cutterbar discs are interchangeable and can be moved to a spindle that rotates in the opposite direction as long as it is in usable condition and the blades are oriented to cut in the correct direction.
Page 141: Discs
MAINTENANCE AND SERVICING 3. Check discs (A) for damage or loose fasteners. 4. Replace damaged discs. Refer to: • Removing a Disc, page 131 • Installing a Disc, page 132 5. Replace damaged fasteners. Tighten loose fasteners. 6. Close cutterbar doors. Figure 7.30: Cutterbar Disc 7.6.2 Discs Removing a Disc...
Page 142: Installing A Disc
MAINTENANCE AND SERVICING Installing a Disc CAUTION Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 1. Position new disc on spindle ensuring it is 90° to the adjacent discs. Figure 7.32: Cutterbar Discs 2.
Page 143: Direction Of Spindle Rotation
MAINTENANCE AND SERVICING 7.6.3 Direction of Spindle Rotation Figure 7.34: Spindle Rotation C - Disc 1 8 A - Front of Header B - 16 ft. Cutterbar D - Disc 8 9 7.6.4 Cutter Blades Each disc has two cutter blades (A) attached to each end and are free to swivel horizontally on a specially designed shoulder bolt.
Page 144: Inspecting Cutter Blades
MAINTENANCE AND SERVICING Inspecting Cutter Blades DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason. A child or even a pet could engage an idling machine. CAUTION Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp and can cause serious injury.
Page 145 MAINTENANCE AND SERVICING IMPORTANT: Blades should be replaced in pairs or the disc may become unbalanced and cause damage to the cutterbar. 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.
Page 146: Inspecting Cutter Blade Hardware
MAINTENANCE AND SERVICING Inspecting Cutter Blade Hardware Check blade attachment hardware each time blades are changed. Refer to Replacing the Cutter Blades, page 137 for hardware replacement procedure. Check bolts and replace bolt if: • Bolt has been removed and installed ﬁve times •...
Page 147: Replacing The Cutter Blades
MAINTENANCE AND SERVICING Check nuts and replace nut if: • Nut has been removed and installed ﬁve times • Worn height (A) is less than half original height (B) • Nut is cracked Figure 7.40: Cutter Blade Nut Replacing the Cutter Blades Follow these steps to replace the cutter blades: DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine: stop engine, remove...
Page 148: 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 149: Inspecting Accelerators
MAINTENANCE AND SERVICING Inspecting Accelerators Follow these steps to inspect accelerators: DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason. A child or even a pet could engage an idling machine. 1. Raise header fully, stop engine, and remove key. 2.
Page 150: Rotary Deflectors
MAINTENANCE AND SERVICING 4. Remove bolt and nut (A) and nut (B) and remove accelerator (C) from disc (D). IMPORTANT: Do NOT remove cutter blade bolt unless it or the blade are being replaced. Repeat for other accelerator. 5. Locate new accelerator on disc onto existing cutter blade bolt.
Page 151: Removing The Driven Deflector
MAINTENANCE AND SERVICING 4. Check that deﬂectors (A) are not damaged or bent by rocks and for loose fasteners. 5. Replace deﬂectors (A) if they are severely damaged or worn. Do NOT repair. Refer to: • Removing the Driven Deﬂector, page 141 •...
Page 152: 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 153: 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 7.50: Driveline Deﬂector Installing the Driveline Deﬂector Follow these steps to replace the driveline deﬂector:...
Page 154 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 cutterbar doors. Refer to 5.5 Cutterbar Doors, page WARNING Ensure cutterbar is completely clear of foreign objects.
Page 155: Drive Systems
MAINTENANCE AND SERVICING 7.7 Drive Systems 7.7.1 Bevel Gearbox The bevel gearbox (A), which transfers power from the hydraulic motor to the header drives, is located inside the drive compartment at the left end of the header. If repairs are required, it should be removed and serviced at your Dealer.
Page 156: Conditioner Drive Belt
MAINTENANCE AND SERVICING 4. Open the driveshield. Refer to 5.4 Driveshields, page Figure 7.55: Driveshield 5. Place a suitable container under drain plug (A). 6. Remove plugs (A) and (B). 7. Allow sufﬁcient time for lubricant to drain. 8. Disengage header safety props, start engine, and lower header so that it is level.
Page 157 MAINTENANCE AND SERVICING 2. Open the driveshield. Refer to 5.4 Driveshields, page Figure 7.57: Driveshield 3. Inspect the condition of belt (A). Replace if damaged or showing signs of cracking or separation. 4. Check that adjuster nuts (B) is tight. 5.
Page 158: Replacing The Conditioner Drive Belt
MAINTENANCE AND SERVICING Replacing the Conditioner Drive Belt Follow these steps to replace the conditioner drive belt: 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.
Page 159 MAINTENANCE AND SERVICING 4. Turn adjuster nut (A) counterclockwise until springs are loose and there is no tension on belt (B). Figure 7.61 5. Remove conditioner drive belt (A). 6. Install new conditioner drive belt (A) onto pulleys, ensuring it is in the pulley grooves. 7.
Page 160: Conditioner Gearbox
7.5.1 Maintenance Schedule/Record, page 115. If repairs are required, the conditioner gearbox should be removed and serviced at your MacDon Dealer. Figure 7.63: Conditioner Gearbox Changing the Conditioner Gearbox Lubricant Follow these steps to change the conditioner gearbox lubricant: DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 161 MAINTENANCE AND SERVICING 3. Open driveshield. Refer to 5.4 Driveshields, page Figure 7.64: Driveshield 4. Place a suitable container under drain plug (A). 5. Remove plugs (A) and (B). 6. Allow sufﬁcient time for lubricant to drain. 7. Replace plug (A) and tighten. Figure 7.65: Conditioner Gearbox 8.
Page 162: Header Drive Speed Sensor
MAINTENANCE AND SERVICING 7.7.4 Header Drive Speed Sensor The header drive speed sensor monitors the rotational speed of the bevel gearbox pulley and sends a signal to the systems monitor in the operator’s station to display disc speed. The sensor does not require regular maintenance, and if it malfunctions or is damaged, it can be easily adjusted or replaced.
Page 163 MAINTENANCE AND SERVICING 1. Loosen bolts (A) and remove cover (B). Figure 7.69: Header Drive Cover 2. Cut and remove plastic tie (A) securing harness to bracket. 3. Unplug sensor wire from connector (B). 4. Remove nut and bolt (C) securing sensor (D) to bracket and remove sensor.
Page 164: Auger Drive Belt
MAINTENANCE AND SERVICING 7.7.5 Auger Drive Belt The auger drive belts are located inside the drive compartment at the lower left end. Check the belt tension and inspect for damage or wear every 100 hours or annually, preferably before the start of the cutting season.
Page 165: Replacing The Auger Drive Belts
MAINTENANCE AND SERVICING 6. To check the belt tension, spring (A) length should measure 10.3 in. (262 mm) (B). If necessary, adjust belt tension as follows: a. Loosen jam nuts (C). b. Adjust eye bolt (D) until spring length (B) is achieved.
Page 166: Sealed Bearing Installation
NOTE: All three belts must be replaced. NOTE: Check alignment of pulleys. Contact your MacDon Dealer if pulleys need realigning. 7. Install belts (B) on pulleys ensuring they are in the pulley grooves. Figure 7.76: Auger Drive Belts 8. Tension the belts. Refer to...
Page 167 MAINTENANCE AND SERVICING 2. Install ﬂangette (A), bearing (B), second ﬂangette (C), and lock collar (D). NOTE: The locking cam is only on one side of the bearing. 3. Install (but do NOT tighten) the ﬂangette bolts (E). 4. When the shaft is correctly located, lock the lock collar with a punch.
Page 168: Hydraulics
MAINTENANCE AND SERVICING 7.8 Hydraulics Refer to your windrower operator’s manual for hydraulic system maintenance procedures for self-propelled windrowers. 7.8.1 Hydraulic Motor The hydraulic motor does not require regular maintenance or servicing. If repairs are required, it should be serviced by your Dealer.
Page 169: Installing The Hydraulic Motor
MAINTENANCE AND SERVICING 5. Cover gearbox opening (A) with a rag or plastic. Figure 7.81: Hydraulic Motor Removed Installing the Hydraulic Motor Follow these steps to install the hydraulic motor: 1. Remove covering from gearbox (A) opening. Figure 7.82: Hydraulic Motor Removed 2.
Page 170: Hydraulic Hoses And Lines
MAINTENANCE AND SERVICING 7.8.2 Hydraulic Hoses and Lines Check hydraulic hoses and lines daily for signs of leaks. WARNING • Avoid high-pressure ﬂuids. Escaping ﬂuid can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes and nozzles which eject ﬂuids under high pressure.
Page 171: Electrical
MAINTENANCE AND SERVICING 7.9 Electrical Use electrical tape and wire clips as required to prevent wires from dragging or rubbing. 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 172: 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 173: Troubleshooting
8 Troubleshooting 8.1 Mower Performance Symptom Problem Solution Section Dull, bent, or badly Replacing the Cutter Blades, Replace blades. worn blades page 137 Auger drive belt 7.7.5 Auger Drive Belt, page slipping Adjust Tension. Change belts. 7.7.2 Conditioner Drive Conditioner drive belt Cutterbar Belt, page 146 slipping...
Page 174 TROUBLESHOOTING Symptom Problem Solution Section Ground speed too fast Reduce ground speed. 6.8 Ground Speed, page 80 Roll gap too large for Decrease roll gap. proper feeding 6.2 Roll Gap, page 67 Roll gap too small in thick stemmed Increase roll gap. cane-type crops 6.5.3 Adjusting the Swath Bafﬂe, Bafﬂe set too low...
Page 175 TROUBLESHOOTING Symptom Problem Solution Section Material being pulled out by roots Crop in conditioner when cutting tall rolls before crop is cut Increase roll gap. 6.2 Roll Gap, page 67 crop leaning into machine Insufﬁcient roll gap Damaged leaves Check roll timing and adjust if and broken stems Roll timing off 6.4 Roll Timing, page 71...
Page 176: 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 7.6 Cutterbar Disc spindle material. Maintenance, page 130 6.6 Header Angle, page...
Page 177 – 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 7.7.2 Conditioner Drive...
Page 179: Options And Attachments
9 Options and Attachments 9.1 Kits The following kits are available through your MacDon Dealer. The Dealer will require the B number for pricing and availability. 9.1.1 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 180: Double Windrow Attachment (Dwa)
OPTIONS AND ATTACHMENTS 9.1.3 Double Windrow Attachment (DWA) Allows auger header windrower to lay a double windrow. The kit includes a draper deck, linkage assembly, hydraulics, and installation instructions. MD #C1987 consists of: • MD #B4655 Deck • MD #B5270 Linkage assembly •...
Page 181: Tall Crop Divider Kit
OPTIONS AND ATTACHMENTS 9.1.6 Tall Crop Divider Kit The tall crop dividers attach to the ends of the header for clean crop dividing and cutterbar entry in tall crops. The kit includes left and right dividers and attachment hardware. MD #B5509 Instruction Part Number: MD #169485 Figure 9.4: MD #B5509 9.1.7 Tall Crop Feed Plate Kit...
Page 183: Index
Index blades replacing ..........137 direction of spindle rotation ......133 accelerator ............138 disc inspecting ............139 inspecting ........... 130 replacing............139 installing ............. 132 removing ............ 131 deﬁnition ............19 disc maintenance ASTM accelerators..........138 deﬁnition ............19 door ..............
Page 184 INDEX removing ............ 158 topsoil moisture ..........95 driveshield............30 weather and topography ........95 closing windrow characteristics........95 export header ..........32 header North American header ......... 30 angle ............... 77 installing right endshield........31 attaching............41 opening M200 windrower ........... 47 export header ..........
Page 185 INDEX overshot auger adjusting ............89 light ..............161 stripper bar amber reﬂector..........64 adjusting ............92 hazard lights owner responsibility ..........25 replacing bulbs and lenses ......161 replacing lamp assembly ......161 replacing lamp bracket ........ 162 lubrication preseason service ..........117 ﬂuids and lubricants.........113 lubrication and servicing........118...
Page 186 INDEX sealed bearing returning to storage .......... 85 installing ............156 tedding..............96 serial number ............ii topography............95 shield, See forming shield torque speciﬁcation skid shoe ............78 ﬂare-type hydraulic ﬁttings ......105 adjusting ............78 torque speciﬁcations .......... 100 skid shoe kit ...........
Page 188 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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