Page 1 Rotary Disc 16-Foot Self-Propelled Windrower Header Operator’s Manual 169457 Rev. F Original Instruction The harvesting specialists worldwide.
Page 2 Rotary Disc 16-Foot Self-Propelled Windrower Header Published: December, 2013...
Page 3 This instructional manual describes the operating and maintenance procedures for the MacDon Model R85 Rotary Disc 16-foot Self-Propelled Windrower Header. Your new MacDon rotary header is designed to cut, condition, and lay a wide variety of grasses and hay crops in windrows.
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 1 169457 Rev. F...
Page 5: Table Of Contents
TABLE OF CONTENTS Introduction ............................i Serial Number(s) ..........................ii Safety ..............................1 Safety Alert Symbols........................1 Signal Words........................... 2 General Safety ..........................3 Maintenance Safety ......................... 5 Hydraulic Safety ..........................6 Tire Safety............................7 Safety Signs ............................ 8 1.7.1 Installing Safety Decals ......................8 Safety Decal Location ........................
Page 6 TABLE OF CONTENTS Roll Timing ............................ 71 6.4.1 Checking Roll Timing......................71 6.4.2 Adjusting the Roll Timing ......................72 Forming Shields ..........................74 6.5.1 Adjusting the Side Deﬂectors ....................74 6.5.2 Adjusting the Rear Deﬂector (Fluffer Shield)................76 6.5.3 Adjusting the Swath Bafﬂe ...................... 76 Header Angle ..........................
Page 7 TABLE OF CONTENTS 7.5.6 Greasing Procedure ......................116 7.5.7 Lubrication and Servicing Intervals ..................117 7.5.8 Lubricating the Cutterbar .......................121 Draining the Cutterbar Lubricant ..................121 Filling the Cutterbar Lubricant ..................123 7.5.9 Rock Guards.........................125 Inspecting the Rock Guards ...................125 Cutterbar Disc Maintenance ......................126 7.6.1 Inspecting the Cutterbar Discs ....................126 7.6.2...
Page 8 TABLE OF CONTENTS Options and Attachments ........................165 Kits ..............................165 9.1.1 Adjustable Skid Shoe Kit......................165 9.1.2 Cutterbar Repair Tool Kit......................165 9.1.3 Double Windrow Attachment (DWA) ..................166 9.1.4 Gauge Roller ........................166 9.1.5 Hydraulic Drive - 16-Ft. for M200 Self-Propelled..............166 9.1.6 Tall Crop Divider Kit .......................167 9.1.7 Tall Crop Feed Plate Kit ......................167 Index ..............................169...
Page 9: 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 10: 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 11: 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 12 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 13: 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 14: Hydraulic Safety
SAFETY 1.5 Hydraulic Safety • Always place all hydraulic controls in Neutral before dismounting. • Make sure that all components in the hydraulic system are kept in good condition and clean. • Replace any worn, cut, abraded, ﬂattened, or crimped hoses and steel lines.
Page 15: Tire Safety
SAFETY 1.6 Tire Safety • Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion that may result in serious injury or death. Figure 1.14: Lower All Safety Stops • Do NOT attempt to mount a tire unless you have the proper training and equipment.
Page 16: Safety Signs
SAFETY 1.7 Safety Signs • Keep safety signs clean and legible at all times. • Replace safety signs that missing become illegible. • If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the current safety sign.
Page 17: Safety Decal Location
SAFETY 1.8 Safety Decal Location Figure 1.18 A - MD #166466 B - MD #113482 C - MD #194464 D - MD #194521 E - MD #184385 Figure 1.19 169457 Rev. F...
Page 18 SAFETY Figure 1.20 A - MD #190546 B - MD #184371 C - MD #184385 D - MD #194466 E - MD #194463 F - MD #194465 Figure 1.21 169457 Rev. F...
Page 19 SAFETY Figure 1.22 A - MD #184386 169457 Rev. F...
Page 20: Interpreting Safety Signs
SAFETY 1.9 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 21 SAFETY 2. MD #166466 a. High pressure oil hazard. b. WARNING Do not go near leaks. • High pressure oil easily punctures skin causing serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. •...
Page 22 SAFETY 5. MD #184386 a. Pinch hazard. b. WARNING Keep away. • Failure to comply could result in death or serious injury. Figure 1.27: MD #184386 6. MD #190546 a. Slippery surface. b. WARNING Do not place foot. • Do not use this area as a step or platform. •...
Page 23 SAFETY 8. MD #194464 a. Shut down for service. b. WARNING • Remove key from ignition. • Read tractor mower manufacturer’s manuals for inspection and maintenance instructions. Figure 1.30: MD #194464 9. MD #194465 a. Rotating cutters. b. WARNING Stand clear •...
Page 24 SAFETY 11. MD #194521 a. Auger entanglement hazard. b. CAUTION • To avoid injury from entanglement with rotating auger, stand clear of header while machine is running. c. General hazard pertaining to machine operation and servicing d. CAUTION • Read the operator’s manual and follow safety instructions.
Page 25: Definitions
2 Deﬁnitions The following terms and acronyms may be used in this manual. Term Deﬁnition American Petroleum Institute. Articulating 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 Display Module on a self-propelled windrower.
Page 26 DEFINITIONS Term Deﬁnition 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. A headed and externally threaded fastener that threads into preformed threads or Screw forms its own thread in one of the mating parts.
Page 27: Component Identification
3 Component Identiﬁcation Figure 3.1 A - Driveshield B - Tower C - Door D - Gauge Rollers (Optional) E - Bafﬂe F - Hydraulic Hoses to SP Windrower G - Bafﬂe Control H - Header Arm Figure 3.2 A - Transport Light B - Conditioner Rolls C - Hose Support D - Drive Motor...
Page 29: Specifications
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 30 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 31: Operation
• It is your responsibility to read and understand this manual completely before operating the header. Contact your MacDon Dealer if an instruction is not clear to you. • Follow all safety messages in the manual and on safety decals on the machine.
Page 32: Operational Safety
OPERATION 5.2 Operational Safety CAUTION Follow these safety precautions: • Follow all safety and operational instructions given in your windrower operator’s manuals. If you do not have an operator’s manual, get one from your Dealer and read it thoroughly • Never attempt to start the windrower’s engine or operate the machine except from the windrower seat •...
Page 33 OPERATION CAUTION • Operate only in daylight or good artiﬁcial light • Keep everyone several hundred feet away from your operation • Ensure bystanders are never in line with the front or rear of the machine. Stones or other foreign objects can be ejected with force from either end •...
Page 34: Header Safety Props
OPERATION 5.3 Header Safety Props Safety props are located on both header lift cylinders on the windrower. DANGER To avoid bodily injury from fall of raised header, always engage safety props when working on or around raised header. 1. Start engine, and press HEADER UP (B) switch to raise header to maximum height.
Page 35 OPERATION 4. To disengage safety props, turn lever (A) away from header to raise safety prop until lever locks into vertical position. Repeat for opposite cylinder. Figure 5.4 5. Start engine, choose a level area, and lower header to the ground. Stop engine and remove key. 169457 Rev.
Page 36: Driveshields
OPERATION 5.4 Driveshields The R85 16-foot self-propelled header 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. WARNING Do NOT operate the machine with the driveshields open. High speed rotating components may throw debris and could result in death or serious injury.
Page 37: Removing Right End Shield: North American Headers
OPERATION 5.4.3 Removing Right End Shield: North American Headers 1. Remove three bolts (A) and remove right endshield (B). Figure 5.7 5.4.4 Installing Right End Shield: North American Headers 1. Install right end shield (B) using three bolts (A). Figure 5.8 169457 Rev.
Page 38: 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 39: 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. There are two doors to provide access to the cutterbar area. Rubber curtains are attached to each door, at the front corners, and center ﬁxed cover.
Page 40: Closing The Cutterbar Doors: North American Header
OPERATION 2. Lift front of door to the open position. Figure 5.13 5.5.2 Closing the Cutterbar Doors: North American Header Follow these steps to close the cutterbar doors on North American header: CAUTION To avoid injury, keep hands and ﬁngers away from corners of doors when closing.
Page 41 OPERATION 2. Hook curtain latches (A). NOTE: Ensure that curtains hang properly and completely enclose cutterbar area. Figure 5.15 169457 Rev. F...
Page 42: 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 export header: 1. Unhook curtain latches (A). Figure 5.16 169457 Rev. F...
Page 43 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 169457 Rev. F...
Page 44: Closing The Cutterbar Doors: Export Header
OPERATION 5.5.4 Closing the Cutterbar Doors: Export Header To close the cutterbar doors on export header: CAUTION To avoid injury, keep hands and ﬁngers away from corners of doors when closing. 1. Pull at top and move to closed position. Ensure latch (A) has engaged the door.
Page 45 OPERATION 2. Hook curtain latches (A). Figure 5.19 169457 Rev. F...
Page 46: 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 47 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. See Section 7.8.2 Hydraulic Hoses and Lines, page 156.
Page 48: Attaching The Header
OPERATION 5.7 Attaching the Header 5.7.1 Attaching the Forming Shield To attach the forming shield to the windrower, follow these steps. 1. Remove the two clevis pins (A) from forming shield forward end. Figure 5.22 DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason.
Page 49 OPERATION 4. Position the forming shield onto spacers (B) on windrower legs. Secure with clevis pins (A) and lynch pin. Figure 5.24 5. Lift the aft end of the forming shield and attach straps (B) to pins (A) on windrower frame. Install washer and hairpin to secure strap.
Page 50: Attaching The Header (M205 Windrowers)
7. Adjust rear ﬂuffer deﬂector (C) to middle position. Loosen handles (B) if required. Figure 5.26 8. Attach the R85 header to the windrower. Refer to the MacDon self-propelled windrower operator’s manual, and then return to this manual to complete the attachment.
Page 51 OPERATION 1. Move windrower left side (cab-forward) platform (A) to OPEN position. Figure 5.27 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 52 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 6. Position hose couplers against mating couplers on windrower and screw sleeves (A) onto mating receptacles. Use wrench to tighten couplers. Figure 5.30 7.
Page 53 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 9. Insert lynch pin (A) to secure lock. 10. Attach case drain hose coupler at (B). 11.
Page 54: Attaching The Header (M200 Windrowers)
15. Move windrower platform (A) to CLOSED position. Figure 5.35 5.7.3 Attaching the Header (M200 Windrowers) The R85 16-foot header requires kit MD #B5455 installed to enable operation on an M200 windrower. If required, obtain the kit through your MacDon Dealer.
Page 55 OPERATION 1. Disengage and rotate lever (A) counterclockwise to FULLY UP position. 2. Remove cap (B) securing electrical connector to frame. Figure 5.37 3. Move hose bundle (A) from windrower and rest the bundle on the header. Figure 5.38 169457 Rev.
Page 56 OPERATION 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 5.39 5. Route hose bundle (A) from windrower through support (B) on header. 6.
Page 57 OPERATION 9. Move windrower left side (cab-forward) platform (A) to OPEN position to access valve blocks. Figure 5.42 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.
Page 58 OPERATION 12. Disconnect ﬁttings at end of hose bundle (A). Discard caps. Figure 5.44 13. Remove O-ring (A) from cap and install over JIC threads on ﬁtting at return port (B). 14. Install female coupler (C) from hose in return port (B). 15.
Page 59 OPERATION 16. Connect hoses from header to ﬁttings as shown. Figure 5.46 A - Middle Valve Block B - Pressure C - Return 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.
Page 60 OPERATION 20. Move platform (A) to the CLOSED position. Figure 5.48 169457 Rev. F...
Page 61: Detaching The Header
OPERATION 5.8 Detaching the Header 5.8.1 Detaching the Header (M205 Windrowers) 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 detach the header from an M205 windrower, follow these steps: 1.
Page 62 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., Detaching the Header (M205 Windrowers), page Figure 5.50 6. Disconnect 1/2 in. (12.7 mm) hose (B) from windrower coupler and remove lynch pin (A).
Page 63 OPERATION 9. Unscrew sleeves couplers separate couplers. 10. Install caps and plugs on open lines. Figure 5.53 11. Attach coupler lock (B) to hoses and secure with lynch pin (A). 12. Proceed to step 14., Detaching the Header (M205 Windrowers), page Figure 5.54 13.
Page 64 14. Remove hose support (A) from windrower frame. 15. Route hoses (B) and electrical harness onto header. Figure 5.56 16. Move maintenance platform (A) to CLOSED position. 17. Detach the header from the windrower. Refer to the MacDon self-propelled windrower operator’s manual. Figure 5.57 169457 Rev. F...
Page 65: Detaching The Header (M200 Windrowers)
OPERATION 5.8.2 Detaching the Header (M200 Windrowers) 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 detach a header from an M200 windrower, follow these steps: 1.
Page 66 OPERATION 6. Raise and unlock lever (A) and undo cinch straps (B). 7. Move hose bundle to store on header. Figure 5.60 8. At the header, disconnect electrical connector (D) by turning collar counterclockwise and pull connector to disengage. 9. Disconnect the pressure (A), return (B), and case drain (C) hoses.
Page 67 OPERATION 13. Move windrower platform back CLOSED position. 14. Detach header from windrower. Refer to the self-propelled windrower operator’s manual. Figure 5.63 169457 Rev. F...
Page 68: 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 69: 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 70: Transporting The Header
OPERATION 5.11 Transporting the Header Refer to your MacDon self-propelled 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. transporting header with header forward, light assemblies MUST be reversed.
Page 71: 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. See your self-propelled windrower operator’s manual on when to use them. The reﬂectors can be reversed, depending on the direction of travel.
Page 73: 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 74: 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 75: Roll Gap
OPERATING THE HEADER 6.2 Roll Gap Steel "n" bar 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.
Page 76: 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 77 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 78: Roll Tension
OPERATING THE HEADER 6.3 Roll Tension The roll tension (the force holding the rolls together) is achieved with a spring type adjustable linkage that is preset to maximum at the factory. Heavy crops or tough forage that tend to separate the rolls require the maximum roll tension to ensure that material is sufﬁciently crimped.
Page 79: 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 as shown. 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...
Page 80: Adjusting The Roll Timing
OPERATING THE HEADER 4. Measure the clearance (B) between the ﬂats of the conditioner roll bars at both end of the conditioner rolls. Dimension (B) should be set to 0.35–0.51 in. (9–13 mm). If adjustment is required, see Section 6.4.2 Adjusting the Roll Timing, page 72 NOTE: There should be less than 0.08 in.
Page 81 OPERATING THE HEADER 3. Position gauge (A) at left end of rolls and manually turn the rolls to engage the gauge. The rolls will automatically adjust to the correct timing. Using the roll gap adjustment bolt, reduce the roll gap until the roll sits lightly on the gauge.
Page 82: 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 83 OPERATING THE HEADER 2. If side deﬂector attachment is too tight or too loose, tighten or loosen nut (A) as required. Figure 6.13 169457 Rev. F...
Page 84: 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 ﬂuffer shield or rear deﬂector slows the crop exiting the conditioner rolls, directs the ﬂow downward, and ﬂuffs the material.
Page 85 OPERATING THE HEADER NOTE: Swath bafﬂe position may need to be adjusted for proper pin engagement. Loosen bolts (A) and adjust bracket (B) and bafﬂe as required. Tighten bolts (A). Figure 6.16 169457 Rev. F...
Page 86: Header Angle
A ﬂatter angle provides better clearance in stony conditions while a steeper angle is required in down crops for better lifting action. The header angle may be hydraulically adjusted from the windrower cab using the hydraulic cylinder (A) without shutting down the windrower. Refer your MacDon self-propelled windrower operator’s manual. Figure 6.17 169457 Rev. F...
Page 87: 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 roller gauge or skid shoe settings. Cutting height should be adjusted for optimum cutting performance without allowing excessive build-up of mud and soil inside the header that can lead to poor crop ﬂow and increased wear on cutting components.
Page 88: Adjusting The Skid Shoe Height
Sudan, Sorghum, Haygrazer, Tall and stemmy 2300–2500 Timothy Dense 2500 Short grass Thin 1800–2000 Disc speeds are set and adjusted from the cab using system controls, without shutting down the windrower. Refer to your MacDon self-propelled windrower operator’s manual. 169457 Rev. F...
Page 89: Ground Speed
Refer to your MacDon self-propelled windrower operator’s manual for changing ground speed. In tough cutting conditions, such as native grasses, the disc speed will need to be increased.
Page 90: 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 (MD #169216) for operating and maintenance instructions. The manual is shipped with the DWA Kit. Figure 6.21 169457 Rev.
Page 91: 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 92: Installing Tall Crop Feed Plates: Under Driven Deflector
OPERATING THE HEADER Installing Tall Crop Feed Plates: Under Driven Deﬂector 1. Remove driveline deﬂector. See Removing the Driven Deﬂector, page 137. 2. Locate tall crop feed plates from storage. See Section 6.10.1 Locating Tall Crop Feed Plates for Installation, page 3.
Page 93: 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 deﬂectors. See •...
Page 94: 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. See Section 6.10.3 Returning Tall Crop Feed Plates to Storage, page Figure 6.29: RH End Removing Tall Crop Feed Plates: Under Driveline Deﬂector 1.
Page 95: Returning Tall Crop Feed Plates To Storage
OPERATING THE HEADER 6.10.3 Returning Tall Crop Feed Plates to Storage Follow these steps to install the tall crop feed plates: 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 96: Tall Crop Dividers
OPERATING THE HEADER 6.11 Tall Crop Dividers The 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 can be removed easily. 6.11.1 Removing Tall Crop Divider DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason.
Page 97 OPERATING THE HEADER 4. Reinstall two bolts and nuts at location shown (A). 5. Repeat steps 3., Removing Tall Crop Divider, page 88 4., Removing Tall Crop Divider, page 89 at other end. 6. Close cutterbar doors. Figure 6.34 169457 Rev.
Page 98: 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 vertical and fore-aft positions of the auger can be adjusted to suit the crop conditions for optimal movement of the crop, minimized wrapping, and to keep the cutterbar clear.
Page 99 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 100 OPERATING THE HEADER 13. Adjust eye bolt (A) and secure with jam nut (B) to tighten auger drive belts (C). See Inspecting the Auger Drive Belts, page 150. Figure 6.39 169457 Rev. F...
Page 101: 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 102 OPERATING THE HEADER Figure 6.42: Right End 5. Position stripper bar (A) as close as possible to auger ﬂighting, without contacting it. 6. Repeat above steps 4., Adjusting the Stripper Bar, 5., Adjusting the Stripper Bar, page 94 page 93 for opposite side.
Page 103 OPERATING THE HEADER 8. Tighten nuts (A). NOTE: Right side and left side stripper bars are interchangeable. Each stripper bar can be ﬂipped when one bar wears out or becomes damaged. Figure 6.44: Both Ends Shown 169457 Rev. F...
Page 104: Haying Tips
OPERATING THE HEADER 6.14 Haying Tips 6.14.1 Curing A quick cure will maintain top quality because • 5% of the protein is lost for each day hay lies on the ground. • The sooner the cut hay is harvested, the earlier the start for next growth. Leaving the windrow as wide and thin as possible makes for the quickest curing.
Page 105: Windrow Characteristics
OPERATING THE HEADER 6.14.4 Windrow Characteristics Refer to Section 6 Operating the Header, page 65 for instructions on adjusting the header. For best results, a windrow should have the following characteristics: Characteristic Advantage High and ﬂuffy Movement of air through windrow is more important to the curing process than direct sunlight.
Page 106: 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 107: Maintenance And Servicing
7 Maintenance and Servicing The following instructions are provided to assist the Operator in servicing the header. Detailed maintenance and service information is available from your Dealer. A parts catalog is located in a plastic case at the right end of the header.
Page 108: Torque Specifications
MAINTENANCE AND SERVICING 7.2 Torque Speciﬁcations The following tables give correct torque values for various bolts, cap screws, and hydraulic ﬁttings. • Tighten all bolts to the torques speciﬁed in chart (unless otherwise noted throughout this manual). • Replace hardware with the same strength and grade bolt. •...
Page 109 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 *149 *164 16.7 18.5 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 Table 7.3 SAE Grade 8 Bolt and Grade 8 Distorted Thread Nut Torque (ft·lbf)
Page 110: Metric Bolt Specifications
MAINTENANCE AND SERVICING Table 7.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 1/4-20 *150 *165 16.8 18.6 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1165 1288 7.2.2 Metric Bolt Speciﬁcations...
Page 111 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 Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 *167 *185 18.8 20.8 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5 24-3.0 Table 7.7 Metric Class 10.9 Bolts and Class 10 Free...
Page 112 MAINTENANCE AND SERVICING Table 7.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque Torque (N·m) Nominal (ft·lbf)(*in·lbf) Size Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 *105 10.7 11.8 8-1.25 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5 24-3.0 169457 Rev.
Page 113: 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 (Cast Aluminum) (Cast Aluminum) ft·lbf N·m ft·lbf N·m Figure 7.4 A - Nominal Size 7.2.4 Flare-Type Hydraulic Fittings 1.
Page 114: O-Ring Boss (Orb) Hydraulic Fittings
MAINTENANCE AND SERVICING Table 7.10 Flare-Type Hydraulic Tube Fittings Flats From Finger Nut Size Torque Value Tube Size Thread Tight (FFFT) SAE No. Across O.D. (in.) Size (in.) Flats (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...
Page 115: O-Ring Face Seal (Orfs) Hydraulic Fittings
MAINTENANCE AND SERVICING Table 7.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque Value Flats From Finger Tight (FFFT) Thread Nut Size Across SAE No. Size (in.) Flats (in.) ft·lbf N·m Flats Turns 7/16 9/16 9/16 11/16 1-1/2 1-1/16 1-1/4 1-5/16 1-1/2 1-5/8 1-7/8...
Page 116 MAINTENANCE AND SERVICING 2. Apply hydraulic system oil to the O-ring. 3. Align the tube or hose assembly. Ensure that ﬂat face of the mating ﬂange comes in full contact with O-ring. 4. Thread tube or hose nut until hand-tight. The nut should turn freely until it is bottomed out.
Page 117: Conversion Chart
MAINTENANCE AND SERVICING 7.3 Conversion Chart Inch-Pound Units SI Units (Metric) Factor Quantity Unit Name Abbreviation Unit Name Abbreviation Area acres acres x 0.4047 = hectares US gallons per Flow x 3.7854 = liters per minute L/min minute Force pounds force x 4.4482 = Newtons inch...
Page 118: 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. Lubricant Speciﬁcation Description...
Page 119: Maintenance Requirements
MAINTENANCE AND SERVICING 7.5 Maintenance Requirements In this manual, periodic maintenance requirements are organized by service intervals. Regular maintenance is the best insurance against early wear and untimely breakdowns. Following this schedule will increase machine life. For detailed instructions, refer to the speciﬁc headings in this section. Use the ﬂuids and lubricants speciﬁed in Section 7.4 Recommended Fluids and Lubricants, page 110.
Page 120: Maintenance Schedule/Record
MAINTENANCE AND SERVICING 7.5.1 Maintenance Schedule/Record Action:  - Lubricate ▲ - Change  - Check Hour meter reading  Service date  Serviced by  First use Refer to Section 7.5.2 Break-In Inspections, page 114. 100 hours or annually Refer to Section 7.5.3 Preseason/Annual Service, page 114.
Page 121 MAINTENANCE AND SERVICING Action:  - Check  - Lubricate ▲ - Change Conditioner gearbox lubeﬁrst 50 and 150 hours  Section 7.7.3 Conditioner Gearbox, page 146. Drive belt tensioner See Section 7.5.5 Lubrication and  Servicing, page 115. Roll shaft bearings ...
Page 122: Break-In Inspections
MAINTENANCE AND SERVICING 7.5.2 Break-In Inspections Timing Item Refer to Check for loose hardware. Tighten Section 7.2 Torque Speciﬁcations, page 100. to required torque. At 5 hours Check drive belt tension. Inspecting the Conditioner Drive Belt, page 142 At 25 hours Check drive belt tension.
Page 123: 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 124: Greasing Procedure
MAINTENANCE AND SERVICING Access to the drive systems requires opening the driveshield and cutterbar doors. Refer to Sections • 5.4 Driveshields, page 28 • 5.5 Cutterbar Doors, page 31 Figure 7.9 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 125: 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 7.11 C - Driveline Shaft 8 (2 Places) A - Driveline Universals (2 Places) B - Driveline Universals (2 Places) E - Driveline Shaft 8 (1 Place)
Page 126 MAINTENANCE AND SERVICING Every 50 Hours Figure 7.12 A - Roll Shaft Bearings (2 Places) B - Roll Shaft Bearings (2 Places) C - Optional Gauge Roll Bearings (2 Places) Both Sides 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) lithium base except where noted.
Page 127 MAINTENANCE AND SERVICING Every 100 Hours or Annually Figure 7.13 A - Conditioner Gearbox Oil 9 Level (Check With Top of Header Horizontal). B - Bevel Gearbox Oil 9 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 128 MAINTENANCE AND SERVICING Every 250 Hours Figure 7.14 A - Drain and Reﬁll Bevel Gearbox Lube. See B - Drain and Reﬁll Conditioner Gearbox C - Drain and Reﬁll Cutterbar Lube. See Section Changing the Bevel Gearbox Lubricant, page 141 Lube.
Page 129: 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 130 MAINTENANCE AND SERVICING Figure 7.16: Cutterbar Filler Plug Locations 9. Locate one of the three ﬁller plugs along the top of the cutterbar. Refer to Figure 7.16: Cutterbar Filler Plug Locations, page 122. 10. Clean around either ﬁller plug (A) and remove one plug with an 8 mm hex Allen L-key.
Page 131: 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. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine: stop engine, remove key, and engage lift cylinder lock-out valves before going under machine for any reason.
Page 132 MAINTENANCE AND SERVICING Figure 7.20: Cutterbar Filler Plug Locations 9. Locate one of the three ﬁller plugs along the top of the cutterbar. Refer to Figure 7.20: Cutterbar Filler Plug Locations, page 124. 10. Clean around either ﬁller plug (A) and remove one plug with an 8 mm hex Allen L-key.
Page 133: 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 7.21 169457 Rev. F...
Page 134: Cutterbar Disc Maintenance
MAINTENANCE AND SERVICING 7.6 Cutterbar Disc Maintenance Check daily that discs are not damaged by rocks or worn excessively from abrasive working conditions. They are interchangeable and a disc can be moved to a spindle that rotates in the opposite direction, as long as it is in a usable condition and the blades are oriented to cut in the correct direction.
Page 135: Disc
MAINTENANCE AND SERVICING 3. Check discs (A) for damage or loose fasteners. 4. Replace damaged discs. Refer to • Removing a Disc, page 127 • Installing a Disc, page 128 5. Replace damaged fasteners. Tighten loose fasteners. 6. Close cutterbar doors. Figure 7.23 7.6.2 Disc Removing a Disc...
Page 136: 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 (C) on spindle ensuring it is 90° to the adjacent discs. 2.
Page 137: Direction Of Spindle Rotation
MAINTENANCE AND SERVICING 7.6.3 Direction of Spindle Rotation Figure 7.26 A - Front of Header B - 16-Foot Cutterbar 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 138: Inspecting Cutter Blades
MAINTENANCE AND SERVICING Inspecting Cutter Blades CAUTION Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. CAUTION Damaged blades may damage the cutterbar and result in poor cutting performance.
Page 139 MAINTENANCE AND SERVICING IMPORTANT Blades should be replaced in pairs, otherwise the disc may be unbalanced and damage the cutterbar. IMPORTANT The cutter blades have cutting edges on both edges so that the blade can be turned over and reused. The twist in each blade determines if its cutting direction is clockwise or counterclockwise.
Page 140: Replacing The Cutter Blades
MAINTENANCE AND SERVICING Replacing the Cutter Blades Follow these steps to replace the cutter blades: CAUTION Cutter blades have two cutting edges. Exercise caution when working around the blades. Blades are sharp, and can cause serious injury. Wear gloves when handling blades. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine: stop engine,...
Page 141: Inspecting Cutterbar Hardware
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 142: Accelerators
MAINTENANCE AND SERVICING Figure 7.33 A - Bolt Head Worn B - 0.0–0.16 in. (0.0–4 mm) C - Bolt Neck Worn D - 0.13 in. (3 mm) E - Bolt Distorted F - Bolt Neck Cracked G - Bolt Interference H - Nut Wear J - 0.00–0.24 in.
Page 143: 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 144: 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 145: Inspecting Rotary Deflectors
MAINTENANCE AND SERVICING Inspecting Rotary Deﬂectors DANGER Stop engine and remove key from ignition before leaving operator’s seat for any reason. A child or even a pet could engage an idling machine. 1. Lower header to ground. 2. Shut off the engine and remove the key. 3.
Page 146: Installing The Driven Deflector
MAINTENANCE AND SERVICING 4. Remove four bolts (A). 5. Remove cover (B) and deﬂector (C). Figure 7.38 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).
Page 147: Installing The Driveline Deflector
MAINTENANCE AND SERVICING 4. Locate the deﬂector (C) with the driveline in the center of it. 5. Remove the four bolts (A) that secure the driveline (B) and disc to the spindle. 6. Rotate the deﬂector (C) as required so that large opening in deﬂector faces you.
Page 148 MAINTENANCE AND SERVICING 3. Insert driveline (B) into deﬂector (C) and install onto shaft. Ensure that driveline (B) grease zerks will be accessible through large opening in deﬂector. 4. Align mounting holes in deﬂector (C), spindle, and driveline (B) and reinstall four bolts (A). Tighten bolts. 5.
Page 149: Drive Systems
If repairs are required, it should be removed and serviced at your Dealer. Contact your MacDon Dealer. The only regular servicing required is maintaining the lubricant level and changing the lubricant according to the intervals speciﬁed in this manual.
Page 150: Conditioner Drive Belt
MAINTENANCE AND SERVICING 4. Open the driveshield. See Section 5.4 Driveshields, page Figure 7.46 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 151 MAINTENANCE AND SERVICING 2. Open the driveshield. See Section 5.4 Driveshields, page Figure 7.48 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. Check that end of slots (C) are aligned with plate (D). 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 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 153 MAINTENANCE AND SERVICING 4. Turn adjuster nut (A) counterclockwise until springs are loose and there is no tension on belt (B). Figure 7.52 5. Remove conditioner drive belt (A). 6. Install new conditioner drive belt (A) onto pulleys, ensuring it is in the pulley grooves. 7.
Page 154: Conditioner Gearbox
See Section 7.5.1 Maintenance Schedule/Record, page 112. If repairs are required, the conditioner gearbox should be removed and serviced at your MacDon Dealer. Figure 7.54 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 155 MAINTENANCE AND SERVICING 3. Open driveshield. See Section 5.4 Driveshields, page Figure 7.55 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 7.56 8.
Page 156: 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 157: Replacing The Header Drive Speed Sensor
MAINTENANCE AND SERVICING Replacing the Header Drive Speed Sensor To replace the gearbox speed sensor, follow these steps: 1. Loosen bolts (A) and remove cover (B). Figure 7.60 2. Cut and remove plastic tie (A) securing harness to bracket. 3. Unplug sensor wire from connector (B). 4.
Page 158: 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 159: 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 160: Sealed Bearing Installation
6. Remove the belts. 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. 8. Tension the belts. See...
Page 161 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 162: Hydraulics
MAINTENANCE AND SERVICING 7.8 Hydraulics Refer to your MacDon self-propelled 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 163: Installing The Hydraulic Motor
MAINTENANCE AND SERVICING 5. Cover gearbox opening (A) with a rag or plastic. Figure 7.71 Installing the Hydraulic Motor Follow these steps to install the hydraulic motor: 1. Remove covering from gearbox (A) opening. Figure 7.72 2. Place motor (B) on gearbox opening. 3.
Page 164: 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 penetrate skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure.
Page 165: 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 166: 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 167: Troubleshooting
8 Troubleshooting 8.1 Mower Performance Symptom Problem Solution Section Dull, bent, or badly Replacing the Cutter Blades, Replace blades. worn blades page 132 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 142 slipping...
Page 168 TROUBLESHOOTING Symptom Problem Solution Section Ground speed too fast Reduce ground speed. 6.8 Ground Speed, page 81 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 169 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 170: Mechanical
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 126 6.6 Header Angle, page...
Page 171 – 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 173: 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 174: 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 — This collector consists of: • MD #46555 Deck •...
Page 175: 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 177: Index
Index blades ............ 129–130 blades replacing ..........132 accelerator ............134 direction of spindle rotation ......129 inspecting ............135 disc replacing............135 inspecting ........... 126 installing ............. 128 deﬁnition ............17 removing ............ 127 ASTM disc maintenance ........... 126 deﬁnition ............
Page 178 INDEX conditioner gearbox chemical drying agents ........97 changing the lubricant ......... 146 curing .............. 96 conditioner gearbox lubricant driving on windrow..........97 changing ............ 146 raking and tedding..........97 hydraulic motor topsoil moisture ..........96 installing ............. 155 weather and topography ........96 removing ............
Page 179 INDEX replacing lamp assembly ......157 adjusting ............90 replacing lamp bracket ........ 158 owner responsibility ..........23 lights amber reﬂector..........63 lubrication ﬂuids and lubricants.........110 preseason service ..........114 lubrication and servicing........115 raking ..............97 maintenance and servicing ........99 recommended ﬂuids and lubricants......110 break-in inspections.........114 rock guard............
Page 180 INDEX deﬁnition ............17 returning to storage .......... 87 skid shoe ............79 tedding..............97 adjusting ............80 topography............96 speciﬁcation torque speciﬁcation..........100 torque speciﬁcation ........100 ﬂare-type hydraulic ﬁttings ......105 speciﬁcations ............21 metric bolt............102 speed sensor ............ 148 metric bolt bolting into cast aluminum ....
Page 182 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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