Page 1 Rotary Disc 13-Foot Header for Self-Propelled Windrower Operator’s Manual 147757 Revision B Model Year 2016 Original Instruction The harvesting specialists.
Page 2 R85 Rotary Disc 13-Foot Header for Self-Propelled Windrower Published: June 2016...
Page 3 Declaration of Conformity Figure 1: EC Declaration of Conformity, Page 1 147757 Revision B...
Page 4 Figure 2: EC Declaration of Conformity, Page 2 147757 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 This manual describes operating and maintenance procedures for the MacDon R85 Rotary Disc 13-Foot Self-Propelled Windrower Header. Your new 13-foot rotary header can be attached to MacDon M150, M155, M155E4, 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 7: Serial Number(S)
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 cover at the right side of the header. Figure 4: Serial Number Location – Self Propelled 147757 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 Inserted EC Declaration of Conformity document.
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 Roll Tension ..........................78 4.3.1 Adjusting Roll Tension ......................78 Roll Timing ............................ 79 4.4.1 Checking Roll Timing......................79 4.4.2 Adjusting Roll Timing ......................80 Forming Shields ..........................81 4.5.1 Adjusting the Side Deﬂectors ....................81 4.5.2 Adjusting the Rear Deﬂector (Fluffer Shield)................
Page 11 TABLE OF CONTENTS Replacing the Cutterblades ....................123 5.4.6 Accelerators..........................124 Inspecting Accelerators ....................125 Replacing Accelerators ....................126 5.4.7 Nut Shield..........................127 Inspecting Nut Shield .....................127 Replacing Nut Shield......................128 5.4.8 Rotary Deﬂectors ........................128 Inspecting Rotary Deﬂectors...................128 Removing the Driven Deﬂector ..................129 Installing the Driven Deﬂector ..................130 Removing the Driveline Deﬂector ..................130 Installing the Driveline Deﬂector..................131 5.4.9...
Page 12 TABLE OF CONTENTS 8.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings................167 8.1.8 Tapered Pipe Thread Fittings ....................169 Conversion Chart..........................170 Index ..............................171 147757 Revision B...
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 #194465 B - MD #194463 C - MD #194466 D - MD #194464 E - MD #113482 F - MD #174436 G - MD #184385 H - MD #184371 J - MD #247166 Figure 1.16: Safety Decals 147757...
Page 21 SAFETY Figure 1.17: Safety Decal Locations A - MD #184385 147757 Revision B...
Page 22: 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 23 SAFETY MD #174432 Reel hazard WARNING • To avoid injury from fall of raised reel; fully raise reel, stop the engine, remove the key, and engage mechanical lock on each reel support arm before working on or under reel. • Refer to operator’s manual. Figure 1.20: MD #174432 MD #174434 Header hazard...
Page 24 SAFETY 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. • Keep all shields in place. Figure 1.23: MD #184422 MD #190546 Slippery surface WARNING...
Page 25 SAFETY MD #194464 Shut down for service WARNING • Stop the engine and remove the key. • Read tractor and mower manufacturer’s manuals for inspection and maintenance instructions. • Read the windrower and header manuals for inspection and maintenance instructions. Figure 1.26: MD #194464 MD #194465 Rotating cutters...
Page 26 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 27 SAFETY MD #247167 Rotating blades WARNING • Disengage power take-off, stop engine, and remove 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 due to inertia. Figure 1.31: MD #247167 147757 Revision B...
Page 29: Product Overview
2 Product Overview 2.1 Deﬁnitions The following terms and acronyms may be used in this manual. Term Deﬁnition American Petroleum Institute ASTM American Society of Testing and Materials Bolt A headed and externally threaded fastener that is designed to be paired with a nut Cab-forward Windrower operation with Operator and cab facing in direction of travel Cab display module on a self-propelled windrower...
Page 30 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 31: Component Identification
PRODUCT OVERVIEW 2.2 Component Identiﬁcation Figure 2.1: Component Identiﬁcation M205 A - Doors B - Driveshield C - Swath Bafﬂe Control D - Swath Bafﬂe E - Header Boot Figure 2.2: Component Identiﬁcation M205 A - Hydraulic Hoses to SP Windrower B - Hose Supports C - Drive Motor D - Rotary Deﬂector...
Page 32: 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 13-Foot R85 Cutterbar Effective cutting width 3895 mm (12.78 ft.)
Page 33 PRODUCT OVERVIEW 13-Foot R85 Frame and Structure Mounts to self-propelled windrower tractor Easy access doors to access cutterbar components Transport width 3952 mm (156 in.) Total weight complete with lift arms (estimated) 1360 kg (3000 lb.) Drives M150/M155/M155E4 Windrower tractor to 75 CC (4.6 cu in.) Eaton heavy duty hydraulic motor M205 Windrower tractor to 106 cc (6.4 cu in.) Eaton heavy duty hydraulic motor...
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 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 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: Engaging/Disengaging The Header Safety Props
OPERATION 3.3 Engaging/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. Engage safety props as follows: 1.
Page 39 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 40: Driveshields
The R85 13-Foot Header for Self-Propelled Windrowers 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: 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 latch (A). 2. Insert a screwdriver (or equivalent) through hole (B) in driveshield and into the notch in latch (C) and disengage latch.
Page 42: Cutterbar Doors
OPERATION 3.5 Cutterbar Doors The R85 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. CAUTION Do NOT operate the machine without all the cutterbar doors down. The curtains should be installed and in good condition.
Page 43: 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 3.10: Curtain Latches 2. Lift front of door to the open position. Figure 3.11: Cutterbar Doors 147757 Revision B...
Page 44: 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. Pull at top of the cutterbar door and move to the closed position.
Page 45: 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 3.14: Curtain Latches 147757 Revision B...
Page 46: 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 3.15: 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 47 OPERATION 1. Pull at top and move to closed position. Ensure latch (A) has engaged the door. Figure 3.16: Cutterbar Door Latch 2. Hook curtain latches (A). Figure 3.17: Curtain Latches 147757 Revision B...
Page 48: 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 49: 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 50 OPERATION 4. Position the forming shield onto spacers (B) on windrower legs. Secure with clevis pins (A) and lynch pin. Figure 3.22: Forming Shield under Windrower 5. Lift the aft end of the forming shield and attach straps (B) to pins (A) on windrower frame. 6.
Page 51: Attaching The Header: M205 Windrowers
8. Adjust rear ﬂuffer deﬂector (C) to 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 52 OPERATION 1. Move windrower left-hand (cab-forward) platform (A) to OPEN position. Figure 3.26: 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 53 OPERATION 5. Remove coupler lock as follows: a. Remove lynch pin (A) and open up coupler lock (B). b. Remove lock from coupler. Figure 3.28: Hydraulic Couplers with Coupler Lock 6. Connect the rear pump hose (A) to outboard line (D) on windrower using coupler (C).
Page 54 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 3.30: Hydraulic Couplers with Coupler Lock 9.
Page 55 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 56: Attaching The Header: M200 Windrowers
To operate the 13-foot header on an M200 windrower, installation of a motor/hose kit (MD #B5511) is required. If required, obtain the kit through your MacDon Dealer. Install kit in accordance with the supplied instructions. Figure 3.36: MD #B5511 Hydraulic Drive Kit...
Page 57 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 3.37: Hose Bundle 3. Move hose bundle (A) from the windrower and rest the bundle on the header. Figure 3.38: Hose Bundle 147757 Revision B...
Page 58 OPERATION 4. Position the hose support with the lower bolt (A) in the forward hole and the support positioned as shown. Loosen both bolts and adjust as required. Figure 3.39: Hose Support 5. Route hose bundle (A) from the windrower through the support (B) on header.
Page 59 OPERATION 9. Move the windrower’s left-hand side (cab-forward) platform (A) to the OPEN position to access the valve blocks. Figure 3.42: Windrower with LH Platform in Open Position IMPORTANT: Keep open lines and ports clean. 10. Connect the pressure hose (C) from port (A) on the header motor to port (M2) on the header drive valve block.
Page 60 OPERATION 12. Connect the return hose (A) from the header drive valve block port (R1) to the steel line attached to motor port (B). Figure 3.44: Windrower Connections 13. Connect the pressure hose (B) from the header drive valve block port (M1) to the steel line attached to motor port (A).
Page 61 OPERATION NOTE: Final hose conﬁguration shown for an M200 Self-Propelled Windrower equipped with a reverser valve. Figure 3.46: M200 Windrower Hose Connections with Reverser 14. Connect the case drain hose (A) from the header lift valve block port (T3) to the hose attached to motor port (D).
Page 62: Attaching The Header: M150, M155, Or M155E4 Windrowers
Refer to your windrower operator’s manual for procedures to mechanically attach the header to the windrower. Refer to the following procedures for electrical and hydraulic connections. NOTE: The M150, M155, and M155E4 Self-Propelled Windrowers require the disc drive manifold kit (MD #B4657) to hydraulically connect the R85 13-foot header. 147757 Revision B...
Page 63 (MD #B5510) installed to enable operation on an M150, M155, or M155E4 Self-Propelled Windrower. If required, obtain the kit through your MacDon Dealer. Install kit in accordance with the supplied instructions. Figure 3.50: Hydraulic Drive Kit (MD #B5510) 1. Disengage and rotate lever (A) counterclockwise to FULLY UP position.
Page 64 OPERATION 3. Move hose bundle (A) from the windrower and rest the bundle on the header. Figure 3.52: Hose Bundle 4. Position the hose support with lower bolt (A) in the forward hole and support positioned as shown. Loosen both bolts and adjust as required. Figure 3.53: Hose Support 147757 Revision B...
Page 65 OPERATION 5. Move the windrower’s left side (cab forward) platform (A) to the OPEN position. Figure 3.54: Windrower LH Platform in Open Position 6. Route the windrower hose bundle (A) through hose support (B) on the header. 7. Route the hose (C) from the header through support (B) to the windrower.
Page 66 OPERATION IMPORTANT: Keep open lines and ports clean. 8. Connect the single pressure hose (A) routed from the header to port M2 on the disc drive valve (middle block). Figure 3.56: Hydraulic Connections 9. Remove caps and plugs on hoses from windrower and lines on header.
Page 67 OPERATION 11. Connect the return hose (A) from the drive manifold port R1 to the steel line attached to motor port (B). Figure 3.58: Hydraulic Connections NOTE: If the windrower is equipped with a reverser valve (A) for an auger header, route the return hose (B) from port R1 on the reverser valve to the steel line attached to motor port (C).
Page 68 OPERATION 12. Connect the case drain hose (A) from the lift manifold port T3 to the ﬁtting attached to motor port (D). Figure 3.60: Hydraulic Connections 13. Connect the electrical harness (A) from windrower to the electrical connector on the header. NOTE: Hydraulic hoses removed from the illustration to improve clarity.
Page 69 OPERATION 14. Lower and lock lever (A). Secure hose (B) with three cinch straps (C). Figure 3.62: Hose Bundle 15. Move platform (A) to the CLOSED position. Figure 3.63: Top View of Windrower 147757 Revision B...
Page 70: 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 71 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 3.65: Hydraulic Connections 6.
Page 72 OPERATION 9. Unscrew sleeves couplers separate couplers. 10. Install caps and plugs on open lines. Figure 3.68: Hydraulic Connections 11. Attach coupler lock (B) to hoses and secure with lynch pin (A). 12. Proceed to Step 14., page Figure 3.69: Hydraulic Connections 13.
Page 73 OPERATION 14. Remove hose support (A) from the windrower frame. 15. Route hoses (B) and electrical harness onto the header. Figure 3.71: Hose Bundle 16. Move maintenance platform CLOSED position. 17. Refer to the windrower operator’s manual to mechanically detach the header from the windrower. Figure 3.72: Windrower LH Platform 147757 Revision B...
Page 74: 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 75 OPERATION 7. Raise and unlock lever (A) and undo the three cinch straps (B). 8. Move hose bundle to store on header. Figure 3.75: Hose Bundle 9. Disconnect the electrical connector (A) at the header by turning the collar counterclockwise and pulling the connector to disengage.
Page 76 OPERATION 10. Disconnect following hoses from hydraulic motor: • Pressure hose (A) • Return hose (B) • Case drain hose (C) 11. Install caps on the connectors and hose ends (if equipped). NOTE: Hydraulic hoses from the header hidden on illustration for clarity.
Page 77: Detaching The Header: M150, M155, Or M155E4 Windrowers
OPERATION 15. Move the windrower platform (A) back to the CLOSED position. 16. Refer to the windrower operator’s manual to mechanically detach header from the windrower. Figure 3.79: Windrower LH Platform 3.8.3 Detaching the Header: M150, M155, or M155E4 Windrowers Refer to your windrower operator’s manual for the procedure to mechanically detach the header from a windrower.
Page 78 OPERATION 3. Move the left side (cab-forward) platform (A) to the open position. Figure 3.80: Windrower LH Platform 4. Disconnect hose (A) from port (M2) on the disc drive valve. Figure 3.81: Hydraulic Connections 147757 Revision B...
Page 79 OPERATION 5. Raise lever (A) and undo the three cinch straps (C). 6. Move hose (B) to store on header. Figure 3.82: Hose Bundle 7. Disconnect following hoses from hydraulic motor: • Pressure hose (A) • Return hose (B) • Case drain hose (C) 8.
Page 80 OPERATION 9. Disconnect the electrical connector (A) by turning the collar counterclockwise and pulling connector to disengage. NOTE: Hydraulic lines and hoses hidden on illustration to show the electrical connection. Figure 3.84: Electrical Connection 10. Move the hose bundle from header to the left-side (cab forward) hose support (B).
Page 81 OPERATION 13. Move windrower platform CLOSED position. 14. Refer to the windrower operator’s manual to mechanically detach the header from the windrower. Figure 3.86: Windrower LH Platform 147757 Revision B...
Page 82: 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 83: 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 84: 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). 147757 Revision B...
Page 85: 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 86: Adjusting Float
OPERATING THE HEADER 4.1.2 Adjusting Float 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 87: 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 release for quicker drying. The degree to which the crop is conditioned as it passes through the rolls is controlled by roll gap, which is factory set at 13 mm (1/2 in.).
Page 88: Adjusting Roll Gap
OPERATING THE HEADER 6. Center the upper roll bar (B) between two lower roll bars. 7. Inspect roll gap at both ends of the rolls. Gap (C) should be 12.7 mm (0.5 in.). NOTE: Factory setting is 12.7 mm (1/2 in.). A gap of 16 mm (5/8 in.) is strongly recommended for heavier crop conditions.
Page 89 OPERATING THE HEADER 4. Loosen upper jam nut (A) on both sides of conditioner. 5. To increase roll gap (increase conditioning action), turn lower nut (B) clockwise. 6. To decrease roll gap (reduce conditioning action), turn lower nut (B) counterclockwise. 7.
Page 90: 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 91: 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 92: Adjusting Roll Timing
OPERATING THE HEADER 4.4.2 Adjusting Roll Timing Follow these steps to adjust the roll timing (if necessary): 1. Lower the header fully. 2. Stop the engine and remove the key. 3. Open the driveshield. Refer to 3.4 Driveshields, page 4. Loosen four bolts (A) in slots of yoke plate (B) on upper roll universal shaft.
Page 93: 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 94 OPERATING THE HEADER 2. If side deﬂector attachment is too tight or too loose, tighten or loosen nut (A) as required. Figure 4.11: Forming Shield 147757 Revision B...
Page 95: 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 96 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 97: 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 98: 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 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 99: 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 100: 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. Refer to your windrower operator’s manual for changing ground speed.
Page 101: 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 4.18: DWA...
Page 102: Tall Crop Divider Option
OPERATING THE HEADER 4.11 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. 4.11.1 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 103: 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 4.21: Tall Crop Divider Installed 4.11.2 Removing Tall Crop Divider DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove...
Page 104: Header Pan
OPERATING THE HEADER 4.12 Header Pan The header pan is located behind the cutterbar and helps prevent material loss and wrapping in certain crops, such as grass seed, oats, and tall stalky crops. In conditions where more soil and stones are being picked up by the cutterbar, it may be desirable to remove the pan to allow the debris to fall out before being fed into the conditioner.
Page 105: Installing Header Pan
OPERATING THE HEADER 4.12.2 Installing Header Pan To install the header pan, follow these steps: 1. Locate pan (B) under header frame and hold in place. 2. Install six 1/2 x 1 in. carriage bolts (A) and ﬂanged lock nuts. Tighten hardware. 3.
Page 106: Haying
OPERATING THE HEADER 4.13 Haying 4.13.1 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 107: 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 108: Levelling The Header
OPERATING THE HEADER 4.14 Levelling the Header Windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. The ﬂoat springs are NOT used to level the header. If the header is not level, check the tire pressures on the windrower ensuring they are properly inﬂated. Refer to your windrower operator’s manual.
Page 109: Unplugging The Header
OPERATING THE HEADER 4.15 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 111: 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 112: 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 113: 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 114 MAINTENANCE AND SERVICING Action  Check  Lubricate ▲ Change First 25 hours Check drive belt tension.  Refer to Inspecting the Conditioner Drive Belt, page 138. Every 25 hours Lube roll universal joints.  Refer to 5.3.4 Lubrication and Servicing, page 104.
Page 115: Preseason/Annual Service
MAINTENANCE AND SERVICING Action  Check  Lubricate ▲ Change Check bevel gearbox lubricant. Refer to  5.5.1 Bevel Gearbox, page 137. First 150 hours Change cutterbar lubricant. ▲ Refer to 5.3.7 Lubricating the Cutterbar, page 111 Change bevel gearbox lubricant. ▲...
Page 116: End-Of-Season Service
MAINTENANCE AND SERVICING 5.3.3 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 117: Greasing Procedure
MAINTENANCE AND SERVICING To access the drive systems, open the driveshield and cutterbar doors. Refer to: • 3.4 Driveshields, page 28 • 3.5 Cutterbar Doors, page 30 Figure 5.1: Driveshield 5.3.5 Greasing Procedure 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 118: Lubrication And Servicing Intervals
MAINTENANCE AND SERVICING 5.3.6 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). 147757 Revision B...
Page 119 MAINTENANCE AND SERVICING Every 25 Hours Figure 5.3 B - Driveshaft 4 A - Cutterbar Driveline Universals (2 Places) D - Driveline Shaft 4 C - Conditioner Driveline Universals (4 Places) NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2) lithium base except where noted.
Page 120 MAINTENANCE AND SERVICING Every 50 Hours Figure 5.4 A - Roll Shaft Bearing (2 Places) B - Belt Tensioner Pivot (1 Place) C - Roll Shaft Bearing (2 Places) NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI grade 2) lithium base except where noted.
Page 121 MAINTENANCE AND SERVICING Every 100 Hours or Annually Figure 5.5 A - Conditioner Drive Belt Tension B - Gearbox Lubricant Level (Check with Top of Header Horizontal) 147757 Revision B...
Page 122 MAINTENANCE AND SERVICING Every 250 Hours Figure 5.6 A - Change Bevel Gearbox Oil B - Change Cutterbar Lube 147757 Revision B...
Page 123: 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 124 MAINTENANCE AND SERVICING 6. Locate one of the two ﬁller plugs along the top of the cutterbar. Refer to 5.8: Cutterbar Filler Plug Locations, page 112. 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 125: 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 126 MAINTENANCE AND SERVICING 11. Locate one of the two ﬁller plugs along the top of the cutterbar. Refer to Figure 5.12: Cutterbar Filler Plug Locations, page 114. Figure 5.12: Cutterbar Filler Plug Locations 12. Clean around either ﬁller plug (A) and remove one plug with an 8 mm hex key. NOTE: Rotate disc to expose ﬁller plug if necessary.
Page 127: Rock Guards
5. Inspect rock guards (A) for severe damage, wear, and distortion. The guards should be replaced if severely damaged or worn. 6. Check for loose or missing fasteners and tighten or replace fastener if missing. 7. Contact your MacDon Dealer replacement procedures. Figure 5.13: Rock Guards 147757 Revision B...
Page 128: 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 129: 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 130: 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 116.
Page 131: 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 132 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 133: 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. 147757 Revision B...
Page 134 MAINTENANCE AND SERVICING Check blade attachment hardware each time blades are changed. Refer to Replacing the Cutterblades, page 123 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 135: 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 136: 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 137: 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 138: Replacing Accelerators
MAINTENANCE AND SERVICING Replacing Accelerators Follow these steps to replace the accelerators: 1. Raise the header fully. 2. Stop the engine and remove the key. 3. Engage header safety props. Refer to Engaging/Disengaging the Header Safety Props, page 4. Remove disc (D). Refer to 5.4.3 Removing a Cutterbar Disc, page 117.
Page 139: Nut Shield
MAINTENANCE AND SERVICING 5.4.7 Nut Shield If accelerators are not used, nut shields will be required to protect the cutter blade 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 140: 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 Engaging/Disengaging the Header Safety Props, page 4. Open the cutterbar doors. Refer to 3.5 Cutterbar Doors, page 5.
Page 141: Removing The Driven Deflector
MAINTENANCE AND SERVICING 2. Stop the engine and remove the key. 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.
Page 142: 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 143: Installing The Driveline Deflector
MAINTENANCE AND SERVICING 9. Loosen the four bolts (A) in the two plates (B) that hold the upper driveline shield (C) in place. 10. Move the plates (B) so that shield (C) can be lowered into deﬂector (D). 11. Remove the deﬂector (D). Figure 5.38: Driveline Deﬂector Installing the Driveline Deﬂector Follow these steps to replace the driveline deﬂector:...
Page 144: Disc Spindles
MAINTENANCE AND SERVICING 7. Tighten bolts (A) on shield plates (B). 8. Remove block of wood (if used). 9. Manually rotate discs to check for interference of adjacent parts. 10. Close the cutterbar doors. Refer to 3.5 Cutterbar Doors, page WARNING Ensure cutterbar is completely clear of foreign objects.
Page 145 MAINTENANCE AND SERVICING 5. Using a 34 mm socket wrench, remove nut (A) and washer (B) from spindle. Figure 5.43: Cutterbar Spindle 6. Install four M12 mm x 60 mm long bolts (A) into holes in plate (B). 7. Use bolts (A) as jacking screws to remove plate (B) from gear.
Page 146: Cutterbar Doors
10. Inspect plate (C) and gear 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 plate (C) with key in gear (E) and install plate (C) onto gear until sufﬁcient threads are exposed...
Page 147: Replacing Latches
MAINTENANCE AND SERVICING 2. Loosen bolts (A) and move latch assembly to position as shown so that latch (B) engages pin. 3. Tighten bolts (A). 4. If necessary, loosen nut (C) and rotate latch (B) to position as shown. 5. Tighten nut (C). Figure 5.48: Cutterbar Door Latch Replacing Latches To replace cutterbar door latches, follow these steps:...
Page 148: Replacing Latch Brackets
MAINTENANCE AND SERVICING Replacing Latch Brackets To replace the cutterbar door latch brackets, follow these steps: 1. Open cutterbar door. 2. Remove bolts (A), washers, and nuts, and remove latch bracket (B) from door. 3. Locate new latch bracket (B) on door and reinstall bolts (A), washers, and nuts.
Page 149: 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, it should be removed and serviced at your Dealer.
Page 150: Conditioner Drive Belt
MAINTENANCE AND SERVICING 6. Place a suitable container under drain plug (A). 7. Remove plug (A). 8. Allow sufﬁcient time for lubricant to drain. 9. Disengage header safety props. Refer to Engaging/Disengaging the Header Safety Props, page 10. Start engine, and lower the header until the gearbox is level with the ground.
Page 151 MAINTENANCE AND SERVICING 4. Check that adjuster nuts (A) and (B) are tight. Figure 5.53: Conditioner Drive Belt Adjuster 5. When properly tensioned, tensioner spring (A) should measure approximately 141–151 mm (5-9/16 to 5-15/16 in.) in length. Figure 5.54: Drive Belt Tensioner Spring 6.
Page 152: Replacing The Conditioner Drive Belt
MAINTENANCE AND SERVICING Replacing the Conditioner Drive Belt Follow these steps to replace the conditioner drive belt: 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. IMPORTANT: Change all three belts when replacing as they are a matched set.
Page 153 MAINTENANCE AND SERVICING 7. Remove the four bolts (A) and washers attaching upper driveline to driven pulley (B) and slide driveline away from pulley. 8. Remove drive belt (C) from driven pulley. Figure 5.58: Conditioner Drive Belt 9. Install new belts (A) onto driven pulley (B) ﬁrst and then onto drive pulley (D), ensure belts are in the pulley grooves.
Page 154: Conditioner Gearbox
Maintenance Schedule/Record, page 101. If repairs are required, the conditioner gearbox should be removed and serviced at your MacDon Dealer. Figure 5.62: Conditioner Gearbox 5.5.4 Gearbox Speed Sensor The gearbox speed sensor monitors the rotational speed of the gearbox output shaft and sends a signal to the system monitor in the operator’s station that is displayed as disc speed.
Page 155: Replacing The Gearbox Speed Sensor
MAINTENANCE AND SERVICING 2. Loosen bolts (A) and slide cover (B) off opening. Figure 5.63: Gearbox 3. Check gap (E) between sensor (A) and pulley. required, adjust gap by loosening bolts (B) and moving bracket (C) to achieve 2 mm (0.08 in.) gap (E). When correct gap is achieved, tighten bolts (B).
Page 156 MAINTENANCE AND SERVICING 2. Disconnect the sensor wire from the header wiring harness at connector (A). 3. Remove bolt through clip (B). 4. Pull the harness through grommet and into the drive compartment. 5. Remove nut and bolt (C) securing sensor (D) to bracket and remove the sensor.
Page 157: 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 at your Dealer. Figure 5.68: Hydraulic Motor Removing the Hydraulic Motor Follow these steps to remove the hydraulic motor:...
Page 158: Installing The Hydraulic Motor
MAINTENANCE AND SERVICING 7. Cover gearbox opening (A) with a rag or plastic. Figure 5.70: 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 159: 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 161: 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 Cutterbar Repair Tool Kit The cutterbar repair tool kit contains the tools required to replace the cutterbar idler gears.
Page 162: Skid Shoes
OPTIONS AND ATTACHMENTS 6.1.3 Skid Shoes MD #B5457 Instruction Part Number: MD #169465 Figure 6.2: MD #B5457 6.1.4 Tall Crop Divider Kit The tall crop dividers attach to the ends of the header for clean crop dividing and reel entry in tall crops. The kit includes left and right dividers and attachment hardware.
Page 163: Troubleshooting
7 Troubleshooting 7.1 HeaderPerformance Symptom Problem Solution Refer to Dull, bent, or badly Replacing the Cutterblades, Replace blades. worn blades page 123 Decrease header angle and increase ﬂotation. In some Build-up of dirt 4.6 Header Angle, page 85 Cutterbar plugging conditions, it may be necessary between rock guards 4.1 Header Float, page 73...
Page 164 TROUBLESHOOTING Symptom Problem Solution Refer to Ground speed too fast Reduce ground speed. 4.9 Ground Speed, page 88 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. cane-type crops Swath bafﬂe set too 4.5.3 Adjusting the Swath Bafﬂe,...
Page 165 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 4.4 Roll Timing, page 79 Check roll timing and adjust if and broken stems...
Page 166: 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 5.4.3 Removing a Material wrapped around Remove disc and remove Cutterbar Disc, page spindle material.
Page 167 — drive belt rolls completely stopped, remove foreign object. Belt pulleys and idlers Align pulleys and idler. See MacDon Dealer misaligned Remove mud from Mud on cutterbar cutterbar: do NOT allow — mud to dry on cutterbar. 3.7 Attaching the Header, Hoses not connected Connect hoses.
Page 169: 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 170 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 171: 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 172 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 173 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 174: 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 175 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 176: 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 177 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 178: 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 179: 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 180 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 181: 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 182: 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 0.4047 = acres acres US gallons Flow liters per minute L/min x 3.7854 = per minute Force Newtons x 4.4482 =...
Page 183: Index
Index spindles direction of rotation ........116 accelerators ............124 cutterbar doors ..........30, 134 See also cutterbar adjusting ............134 replacing............126 closing export headers..........34 deﬁnitions ............17 North American headers........ 32 ASTM inspecting latches deﬁnitions ............17 export headers..........134 attaching latch brackets windrowers ............
Page 184 INDEX closing M150/155/155E4 windrowers......50 13-foot North American headers ....28 M200 windrowers.......... 44 export headers..........29 M205 windrowers.......... 39 opening deﬁnitions ............17 13-foot North American headers ....28 detaching............58 export headers..........29 M150, M155 or M155E4 windrowers ....65 drying agents ............
Page 185 INDEX revisions list ............vi rock guards maintenance and servicing ........99 inspecting ............115 cutterbar lubrication ......... 111 roll gap end of season service........104 adjusting ............76 greasing procedure ........105 checking ............75 lubrication and servicing ......... 104 roll tension ............78 maintaining cutterbar discs.......116 adjusting ............
Page 186 INDEX spindle keys O-ring boss (ORB) ﬁttings replacing............132 (non-adjustable) ........... 166 spindles O-ring boss (ORB) hydraulic ﬁttings direction of spindle rotation ......116 (adjustable) ..........164 O-ring face seal (ORFS) ﬁttings....167, 169 deﬁnitions ............17 SAE bolt torque speciﬁcations ......157 start-up procedures..........
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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