MacDon R85 Installation Instructions Manual
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MacDon R85 Installation Instructions Manual

MacDon R85 Installation Instructions Manual

16-foot rotary disc self-propelled windrower header and pull-type mower conditioner, bevel gearbox kit
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R85
16-Foot Rotary Disc Self-Propelled
Windrower Header and Pull-Type
Mower Conditioner
Bevel Gearbox Kit (MD #268040) Installation Instructions
147974 Revision B
Original Instruction
The harvesting specialists.

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Summary of Contents for MacDon R85

  • Page 1 16-Foot Rotary Disc Self-Propelled Windrower Header and Pull-Type Mower Conditioner Bevel Gearbox Kit (MD #268040) Installation Instructions 147974 Revision B Original Instruction The harvesting specialists.
  • Page 2 R85 16-Foot Rotary Disc Self-Propelled Windrower Header and Pull-Type Mower Conditioner Published in November 2016...
  • Page 3 The Bevel Gearbox kit (MD #268040) is used to replace the cutterbar drive gearbox (also known as the bevel gearbox) on R85 16-Foot Rotary Disc Self-Propelled Windrower Headers and Pull-Type Mower Conditioners built in model year 2015 or earlier. The new gearbox is factory-installed on headers built in model year 2016 and later.
  • Page 4 List of Revisions At MacDon, we’re continuously making improvements, and occasionally these improvements affect product documentation. The following list provides an account of major changes from the previous version (MD #147974 revision A) of this document. Summary of Change Location Revised installation time.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ............................i List of Revisions ..........................ii Safety ..............................1 Signal Words........................... 1 General Safety ..........................2 Parts List ............................... 5 Installation Instructions ........................9 Removing Hazard Light........................9 Removing Header Drive Motor......................10 Opening the Driveshield ........................11 3.3.1 Opening the Driveshield North American ..................11 3.3.2...

  • Page 7: Safety

    1 Safety 1.1 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 8: General Safety

    SAFETY 1.2 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 protective clothing and personal safety devices that could be necessary for job at hand.
  • Page 9 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 shaft and can telescope freely. •...

  • Page 11: Parts List

    2 Parts List The following parts are included in this kit. 147974 Revision B...
  • Page 12 PARTS LIST Figure 2.1: Parts Included in R85 Cutterbar Drive Gearbox Kit 147974 Revision B...
  • Page 13 PARTS LIST Part Number Description Quantity 236983 DRIVE GEARBOX – 90 DEG 115074 BUSHING – SPLIT TAPER 11142 KEY – WOODRUFF (5/16 X 1 1/8 NOM) 268122 IDLER BRACKET 268129 PULLEY 268023 BRACKET – SPEED SENSOR 236985 GEARBOX PLATE 268049 HARNESS –...

  • Page 15: Installation Instructions

    3 Installation Instructions To install the Bevel Gearbox kit, follow these steps: CAUTION 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. 1. Lower the header/mower conditioner fully. 2.

  • Page 16: Removing Header Drive Motor

    INSTALLATION INSTRUCTIONS 3.2 Removing Header Drive Motor To remove the header drive motor, follow these steps: 1. Loosen the access panel bolts and remove panel (A). Retain for reinstallation. 2. Remove the four bolts (B) securing the header drive motor (C) to the gearbox. 3.

  • Page 17: Opening The Driveshield

    INSTALLATION INSTRUCTIONS 3.3 Opening the Driveshield The procedure for opening the driveshield varies depending on whether the header or mower conditioner was sold in North America or not. Refer to the relevant procedure: • 3.3.1 Opening the Driveshield North American , page 11 •...

  • Page 18: Opening The Driveshield Export

    INSTALLATION INSTRUCTIONS 3.3.2 Opening the Driveshield Export Follow these steps to open the driveshield on export mowers/headers: 1. Release rubber latches (A). 2. Insert a screwdriver (or equivalent) through hole in shield (B) and into the notch in latch (C) and disengage latch.

  • Page 19: Removing Existing Cutterbar Drive Gearbox

    INSTALLATION INSTRUCTIONS 3.4 Removing Existing Cutterbar Drive Gearbox The existing cutterbar drive gearbox is located below the header drive motor. To remove the existing gearbox, follow these steps: 1. Loosen jam nut (A) and adjust nut (B) until belt tension is released fully.
  • Page 20 INSTALLATION INSTRUCTIONS 4. Unhook the curtain latches (A) on the left side of the header/mower conditioner. Figure 3.9: Curtain Latches 5. North American headers/mower conditioners: Lift the front of the left-hand cutterbar door to the open position. Figure 3.10: Cutterbar Doors Open 147974 Revision B...
  • Page 21 INSTALLATION INSTRUCTIONS 6. For export headers/mower conditioners: Insert a screwdriver (or equivalent) through hole (A) in door into notch in latch (B) and push latch to disengage. 7. Lift the front of the left-hand cutterbar door to the open position. Figure 3.11: Cutterbar Door Latch on Export Header 8.
  • Page 22 INSTALLATION INSTRUCTIONS 9. Using a suitable lifting device, lift the gearbox, gearbox plate, and pulley out of the header. IMPORTANT: Use an appropriate lifting device. The gearbox weighs approximately 68 kg (150 lb.). Figure 3.13: Gearbox and Pulley 147974 Revision B...

  • Page 23: Removing Left-Hand Endshield And Frame Channel

    INSTALLATION INSTRUCTIONS 3.5 Removing Left-Hand Endshield and Frame Channel The new gearbox will not fit through the access panel in the top cover of the header/mower conditioner, so the top cover must be lifted or removed. In order to do that, the left-hand endshield and frame channel must be removed.

  • Page 24: Installing New Cutterbar Drive Gearbox

    INSTALLATION INSTRUCTIONS 3.6 Installing New Cutterbar Drive Gearbox To install the new gearbox (MD #236983) provided in the kit, follow these steps: 1. Attach gearbox mounting plate (A) (MD #236985) to frame with ten each of the following: • 1.25 in. long grade 5 hex head bolts (MD #21491) •...
  • Page 25 INSTALLATION INSTRUCTIONS 5. Attach gearbox to the mounting plate (A) with four 1-1/4 in. long grade 8 hex head bolts (MD #136067) and USS hardened flat washers (B) (MD #137699). ® Use Loctite 262 on the threads. Torque bolts to 87 N·m (64 ft·lbf).
  • Page 26 INSTALLATION INSTRUCTIONS 9. Slide pulley (B) (MD #268129) onto gearbox shaft (A) with notches facing outboard. The pulley is provided in the kit. 10. Slide split taper bushing (C) (MD #115074) onto gearbox shaft (A). The bushing is provided in the kit. Figure 3.22: Gearbox Components A - Gearbox Shaft B - Pulley...
  • Page 27 INSTALLATION INSTRUCTIONS 13. Windrower headers only: Attach speed sensor bracket (A) (MD #268122) to idler bracket (B) with two 1 in. carriage bolts (MD #19965) and two flange nuts (C) (MD #30228). Speed sensor bracket, bolts, and nuts are provided in kit. 14.
  • Page 28 INSTALLATION INSTRUCTIONS 18. Adjust nut (B) to tension the gearbox drive belt. Tension the belt until plate (C) is just past the slot (D). 19. Lock jam nut (A). Figure 3.28: Belt Tensioner 20. Windrower headers only: Attach the speed sender to the P88A branch of the main wiring harness (A).

  • Page 29: Reinstalling Left-Hand Endshield And Frame Channel

    INSTALLATION INSTRUCTIONS 3.7 Reinstalling Left-Hand Endshield and Frame Channel To reinstall the left-hand endshield and frame channel, follow these steps. Unless damaged, reuse the original hardware. Replacements are not included in the kit. 1. Position left-hand frame channel (A) over front edge of top cover with left-hand corner shield (B) hanging down.

  • Page 30: Reinstalling Header Drive Motor

    INSTALLATION INSTRUCTIONS 3.8 Reinstalling Header Drive Motor To reinstall the header drive motor, follow these steps: IMPORTANT: Do NOT lift motor by the hydraulic lines. The motor weighs approximately 68 kg (150 lb.). Use a sling or chain and hoist to lift. 1.

  • Page 31: Adding Oil To Cutterbar Drive Gearbox

    INSTALLATION INSTRUCTIONS 3.9 Adding Oil to Cutterbar Drive Gearbox CAUTION 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. 1. Position header/mower conditioner so that the gearbox is level with the ground.

  • Page 32: Closing The Driveshield

    INSTALLATION INSTRUCTIONS 3.10 Closing the Driveshield The procedure for closing the driveshield varies depending on whether the header or mower conditioner was sold in North America or not. Follow the relevant procedure: • 3.10.1 Closing the Driveshield North American , page 26 •...

  • Page 33: Closing The Driveshield Export

    INSTALLATION INSTRUCTIONS 3.10.2 Closing the Driveshield Export Follow these steps to close the driveshield on export mowers/headers: 1. Lower the shield (C) so that pins at lower end of shield engage holes in the lower panel, and latch (B) re-engages the driveshield. 2.

  • Page 34: Closing Cutterbar Doors

    INSTALLATION INSTRUCTIONS 3.11 Closing Cutterbar Doors The procedure for closing cutterbar doors varies depending on whether the header/mower conditioner was sold in North America or not. Refer to the relevant procedure: • 3.11.1 Closing the Cutterbar Doors: North American Header or Mower Conditioner, page 28 •...
  • Page 35 INSTALLATION INSTRUCTIONS 2. Hook curtain latches (A). NOTE: Ensure that curtains hang properly and completely enclose cutterbar area. Figure 3.39: Curtain Latches: 16-Ft. PT Figure 3.40: Curtain Latches: 16-Ft. SP 147974 Revision B...

  • Page 36: Closing The Cutterbar Doors: Export Header Or Mower Conditioner

    INSTALLATION INSTRUCTIONS 3.11.2 Closing the Cutterbar Doors: Export Header or Mower Conditioner To close the cutterbar doors on an export header or mower conditioner follow these steps: CAUTION To avoid injury, keep hands and fingers away from corners of doors when closing. 1.
  • Page 37 INSTALLATION INSTRUCTIONS Figure 3.42: Cutterbar Door Latch: 16-Ft. SP 2. Hook curtain latches (A). Figure 3.43: Curtain Latches: 16-Ft. PT 147974 Revision B...
  • Page 38 INSTALLATION INSTRUCTIONS Figure 3.44: Curtain Latches: 16-Ft. SP 147974 Revision B...

  • Page 39: Replacing Left-Hand Hazard Light

    INSTALLATION INSTRUCTIONS 3.12 Replacing Left-Hand Hazard Light To replace the left-hand hazard light and lamp bracket, follow these steps: 1. Place lamp assembly (C) on header/mower conditioner and secure with four bolts (B). NOTE: Ensure amber reflector (D) faces the front of the machine.
  • Page 42 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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268040

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