MacDon R80 User manual

R80 Rotary Disc
Self-Propelled Windrowe
r
Heade
r
OPERATOR’S MANUAL
Model Year - 2010
Part #169089 $15

R80 ROTARY DISC SELF-PROPELLED WINDROWER HEADER

Form # 169089 1Model Year - 2010
1 INTRODUCTION
This manual describes the operating and maintenance procedures for the MacDon Model R80 Self-Propelled
Rotary Disc Header. Your new MacDon rotary header is designed to cut, condition, and lay in windrows a wide
variety of grasses and hay crops.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR
USE THE MACHINE.
Use this manual as your first source of information about the machine. If you follow the instructions given in this
manual, your Mower will work well for many years. A Parts Catalog is also supplied with your new header. If you
require more detailed service information, a Service Manual is available from your dealer.
Use the Table of Contents and the Index to guide you to specific areas. Study the Table of Contents to familiarize
yourself with how the material is organized.
Keep this manual handy for frequent reference and to pass on to new operators or owners. Call your dealer if you
need assistance, information, or additional copies of this manual. Store this Operator’s Manual and the Parts
Catalog with the windrower manuals in the windrower cab storage compartment.
RECORD THE SERIAL NUMBER OF THE HEADER.
____________________________________
Serial Number plate is located on the top surface
at the right hand end of the header.

TABLE OF CONTENTS
Form # 169089 2Model Year - 2010
Section/Title Page
1INTRODUCTION ............................................................................................................................................... 1
2SAFETY ............................................................................................................................................................ 4
2.1 SAFETY ALERT SYMBOL ....................................................................................................................... 4
2.2 SIGNAL WORDS...................................................................................................................................... 4
2.3 SAFETY SIGNS........................................................................................................................................ 4
2.3.1 Safety Sign Installation ....................................................................................................................... 4
2.3.2 Safety Sign Locations ......................................................................................................................... 5
2.4 GENERAL SAFETY.................................................................................................................................. 7
3ACCRONYMS AND ABBREVIATIONS ........................................................................................................... 9
4COMPONENT IDENTIFICATION ................................................................................................................... 10
5SPECIFICATIONS .......................................................................................................................................... 11
6OPERATION ................................................................................................................................................... 12
6.1 OWNER/OPERATOR RESPONSIBILITIES........................................................................................... 12
6.2 OPERATIONAL SAFETY ....................................................................................................................... 12
6.3 HEADER ATTACHMENT ....................................................................................................................... 14
6.3.1 M200 – 13 FT & 16 FT...................................................................................................................... 14
6.3.2 M150 - 13 FT .................................................................................................................................... 16
6.4 HEADER DETACHMENT....................................................................................................................... 18
6.4.1 M200 – 13 FT & 16 FT...................................................................................................................... 18
6.4.2 M150 – 13 FT ................................................................................................................................... 19
6.5 TRANSPORTING WINDROWER........................................................................................................... 20
6.6 LIGHTS ................................................................................................................................................... 20
6.7 BREAK-IN PERIOD ................................................................................................................................ 21
6.8 PRE-SEASON CHECK........................................................................................................................... 21
6.9 DAILY START-UP CHECK..................................................................................................................... 21
6.10 SHUTDOWN PROCEDURE................................................................................................................... 22
6.11 UNPLUGGING THE HEADER ............................................................................................................... 22
6.12 HEADER OPERATION........................................................................................................................... 23
6.12.1 Disc Speed ....................................................................................................................................... 23
6.12.2 Cutting Height ................................................................................................................................... 23
6.12.3 Header Angle.................................................................................................................................... 24
6.12.4 Header Flotation ............................................................................................................................... 24
6.12.5 Roll Gap............................................................................................................................................ 25
6.12.6 Roll Tension...................................................................................................................................... 27
6.12.7 Forming Shields................................................................................................................................ 28
6.12.8 Ground Speed .................................................................................................................................. 30
6.12.9 Converging Drum Assemblies – Grass Seed Header ...................................................................... 31
6.12.10 Windrow Forming Rods .................................................................................................................... 31
6.12.11 Double Windrowing........................................................................................................................... 31
6.12.12 Tall Crop Dividers ............................................................................................................................. 32
6.12.13 Tall Crop Transition Shield – Grass Seed ........................................................................................32
6.13 HAYING TIPS ......................................................................................................................................... 33
6.13.1 Curing ............................................................................................................................................... 33
6.13.2 Topsoil Moisture ............................................................................................................................... 33
6.13.3 Weather and Topography................................................................................................................. 33
6.13.4 Windrow Characteristics ................................................................................................................... 33
6.13.5 Driving On Windrow.......................................................................................................................... 33
6.13.6 Raking and Tedding.......................................................................................................................... 33
6.13.7 Chemical Drying Agents ................................................................................................................... 33
6.14 STORAGE .............................................................................................................................................. 34
7MAINTENANCE/SERVICE ............................................................................................................................. 35
7.1 PREPARATION FOR SERVICING......................................................................................................... 35
7.2 RECOMMENDED SAFETY PROCEDURES ......................................................................................... 35
7.3 MAINTENANCE SPECIFICATIONS....................................................................................................... 36

TABLE OF CONTENTS
Form # 169089 3Model Year - 2010
7.3.1 Recommended Torques ................................................................................................................... 36
7.3.2 Recommended Lubricants................................................................................................................ 38
7.3.3 Conversion Chart.............................................................................................................................. 39
7.4 HEADER LIFT CYLINDER LOCKS........................................................................................................ 40
7.5 DRIVE SHIELDS .................................................................................................................................... 40
7.6 CUTTERBAR DOORS............................................................................................................................ 40
7.7 LUBRICATION........................................................................................................................................ 41
7.7.1 Procedure ......................................................................................................................................... 41
7.7.2 Lubrication Points ............................................................................................................................. 41
I. 13 FT Header...................................................................................................................................... 42
II. 16 FT Header...................................................................................................................................... 44
III. 16 FT Header – Grass Seed Header.................................................................................................. 46
7.7.3 Sealed Bearing Installation............................................................................................................... 47
7.8 CUTTERBAR.......................................................................................................................................... 48
7.8.1 Skid Plates and Rock Guards........................................................................................................... 48
7.8.2 Cutter Bar Lubrication....................................................................................................................... 50
7.8.3 Disc Maintenance ............................................................................................................................. 52
7.8.4 Cutter Blades .................................................................................................................................... 55
7.8.5 Accelerators...................................................................................................................................... 58
7.8.6 Deflectors.......................................................................................................................................... 59
7.8.7 Tall Crop Feed Plates....................................................................................................................... 63
7.9 HEADER DRIVE..................................................................................................................................... 65
7.9.1 Hydraulic Motor................................................................................................................................. 65
7.9.2 Converging Drum Motors – Grass Seed Header ............................................................................. 65
7.9.3 Conditioner Drive Belt....................................................................................................................... 66
7.9.4 Conditioner Drive Belt Idler............................................................................................................... 70
7.9.5 Lifting Roll Drive Belt ........................................................................................................................ 71
7.9.6 Lifting Roll Belt Idler.......................................................................................................................... 72
7.9.7 Lifting Roll Idler Bearing ................................................................................................................... 72
7.9.8 Hourglass Deflector Drive Belts – 16 Ft Only................................................................................... 73
7.9.9 Bevel Gearbox .................................................................................................................................. 75
7.9.10 Conditioner Gearbox – 13 Foot ........................................................................................................ 81
7.9.11 Conditioner Gearbox – 16 Foot ........................................................................................................ 85
7.9.12 Gearbox Speed Sensor .................................................................................................................... 89
7.10 HYDRAULICS......................................................................................................................................... 90
7.10.1 Hoses And Lines............................................................................................................................... 90
7.11 ELECTRICAL.......................................................................................................................................... 90
7.12 MAINTENANCE SCHEDULE................................................................................................................. 91
7.12.1 Break-In Inspection........................................................................................................................... 91
7.12.2 Interval Maintenance ........................................................................................................................ 92
7.12.3 Maintenance Record......................................................................................................................... 93
8TROUBLESHOOTING.................................................................................................................................... 94
8.1 MOWER PERFORMANCE..................................................................................................................... 94
8.2 MECHANICAL ........................................................................................................................................ 96
9OPTIONS AND ATTACHMENTS ................................................................................................................... 98
9.1 GAUGE ROLLER KIT............................................................................................................................. 98
9.2 SKID SHOE KIT...................................................................................................................................... 98
9.3 SKID PLATE LIFT KIT ............................................................................................................................ 98
9.4 TALL CROP DIVIDER KIT...................................................................................................................... 98
9.5 CUTTERBAR REPAIR TOOL KIT.......................................................................................................... 98
9.6 DOUBLE WINDROW ATTACHMENT.................................................................................................... 98
9.7 WINDROW FORMING RODS................................................................................................................ 99
9.8 11 DEGREE BEVEL UP CUTTERBLADES ........................................................................................... 99
9.9 TALL CROP TRANSITION SHIELD....................................................................................................... 99
10 UNLOADING AND ASSEMBLY................................................................................................................... 100
INDEX .................................................................................................................................................................... 101

SAFETY
Form # 169089 4Model Year - 2010
2 SAFETY
2.1 SAFETY ALERT SYMBOL
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 and follow the safety message
accompanying this symbol.
WHY IS SAFETY IMPORTANT TO YOU?
ACCIDENTS DISABLE AND KILL
ACCIDENTS COST
ACCIDENTS CAN BE AVOIDED
2.2 SIGNAL WORDS
Note the use of the signal words DANGER,
WARNING, and CAUTION with safety
messages. The appropriate signal word for each
message 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. It is also used to alert
against unsafe practices.
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor or
moderate injury. It is also used as a
reminder of good safety practices.
2.3 SAFETY SIGNS
xKeep safety signs clean and legible at all
times.
xReplace safety signs that are missing or
become illegible.
xIf original parts on which a safety sign was
installed are replaced, be sure the repair
part also bears the current safety sign.
xSafety signs are available from your Dealer
Parts Department.
2.3.1 Safety Sign Installation
a. Be sure the installation area is clean and dry.
b. Decide on the exact location before you remove
the decal backing paper.
c. Remove the smaller portion of the split backing
paper.
d. Place the sign in position and slowly peel back
the remaining paper, smoothing the sign as it is
applied.
e. Small air pockets can be smoothed out or
pricked with a pin.

SAFETY
Form # 169089 5Model Year - 2010
2.3.2 Safety Sign Locations
2 PLCS #148829
#32738
(BOTH SIDES)
#134070
#170281
#109843

SAFETY
Form # 169089 6Model Year - 2010
Safety Sign Locations (continued)
1 PLC #36651
1 PLC – BOTH SIDES
#142909

SAFETY
Form # 169089 7Model Year - 2010
2.4 GENERAL SAFETY
CAUTION
xThe following are general farm safety
precautions that should be part of your
operating procedure for all types of
machinery.
xProtect yourself.
xWhen assembling, operating and
servicing machinery, wear all the
protective clothing and personal safety
devices that COULD be necessary for the
job at hand. Don't take chances.
xYou may need:
xa hard hat.
xprotective shoes with slip resistant
soles.
xprotective glasses or goggles.
xheavy gloves.
xwet weather gear.
xrespirator or filter mask.
xhearing protection. Be aware that
prolonged exposure to loud noise
can cause impairment or loss of
hearing. Wearing a suitable hearing
protective device such as ear muffs
(A) or ear plugs (B) protects against
objectionable or loud noises.
xProvide a first-aid kit for use in case of
emergencies.
xKeep a fire extinguisher on the machine.
Be sure the extinguisher is properly
maintained and be familiar with its proper
use.
xKeep young children away from
machinery at all times.
xBe aware that accidents often happen
when the operator is tired or in a hurry to
get finished. Take the
time to consider the
safest way. Never ignore
warning signs of fatigue.
xWear close-fitting
clothing and cover long
hair. Never wear
dangling items such as
scarves or bracelets.
xKeep hands, feet, clothing and hair away
from moving parts. Never attempt to
clear obstructions or objects from a
machine while the engine is running.
xKeep all shields in place. Never alter or
remove safety equipment. Make sure
driveline guards can rotate
independently of the shaft and can
telescope freely.
xUse only service and repair parts made
or approved by the equipment
manufacturer. Substituted parts may not
meet strength, design, or safety
requirements.
xDo not modify the machine. Unauthorized
modifications may impair the function
and/or safety and affect machine life.
xStop 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.
(continued next page)
A
B

SAFETY
Form # 169089 8Model Year - 2010
xKeep the area used for servicing
machinery
clean and dry.
Wet or oily
floors are
slippery. Wet
spots can be
dangerous
when working
with electrical
equipment. Be
sure all
electrical
outlets and tools are properly grounded.
xUse adequate light for the job at hand.
xKeep machinery clean. Do not allow oil or
grease to accumulate on service
platforms, ladders or controls. Clean
machines before storage.
xNever use gasoline, naphtha or any
volatile material for cleaning purposes.
These materials may be toxic and/or
flammable.
xWhen storing machinery, cover sharp or
extending components to prevent injury
from accidental contact.