MacDon R85 User manual

The harvesting specialists.
R85
Rotary Disc 16-Foot Self-Propelled
Windrower Header
Operator’s Manual
169457 Revision G
Original Instruction

Rotary Disc 16-Foot Self-Propelled Windrower Header
Published: September, 2014

Introduction
This manual describes operating and maintenance procedures for the MacDon R85 16-Foot Rotary Disc
Self-Propelled Windrower Header.
Your new 16-foot rotary header can be attached to MacDon M200 and M205 Self-propelled Windrowers and is
designed to cut, condition, and lay in windrows a wide variety of grasses and hay crops.
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 header will work well for many years.
A parts catalog is also supplied with your new header. If you require more detailed service information, contact your
MacDon 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.
NOTE: Keep your MacDon publications up-to-date. The most current version can be downloaded from our website
www.macdon.com or from our Dealer-only site (https://portal.macdon.com) (login required).
Store the operator’s manual and the parts catalog in the
plastic manual case (A) at the header right-hand side.
Figure 1: Manual Storage Case
169457 iRevision G

Serial Number(s)
Record the serial number of the header in the
space provided.
Header Serial No: ____________
Serial Number Plate (A) is located on the top surface at the
right hand end of the header.
Figure 2: Serial Number Location
169457 iiRevision G

List of Revisions
At MacDon, we’re continuously making improvements: occasionally these improvements impact product
documentation. The following list provides an account of major changes from the previous version of this document.
Summary of Change Location
Added a note about keep MacDon publications
up-to-date
Added new image showing the instruction manual
storage case
Introduction, page i
Replaced the gauge roller image 6.7.1 Adjusting Gauge Roller Height , page 78
Updated the procedure for inspecting the cutterblades Inspecting Cutter Blade Hardware, page 136
Modified images to update the header drive speed
sensor wire routing
Adjusting the Header Drive Speed Sensor, page 152
Updated the instruction and images to improve clarity Removing the Hydraulic Motor, page 158
Updated the instruction and images to improve clarity Installing the Hydraulic Motor, page 159
Updated the cutterbar tool kit image 9.1.2 Cutterbar Repair Tool Kit, page 169
Added figure titles to all illustrations Throughout
169457 iii Revision G

TABLE OF CONTENTS
Introduction ...................................................................................................................................... i
Serial Number(s) ..............................................................................................................................ii
List of Revisions .............................................................................................................................. iii
1 Safety .................................................................................................................................................... 1
1.1 Safety Alert Symbols........................................................................................................................ 1
1.2 Signal Words................................................................................................................................... 2
1.3 General Safety ................................................................................................................................ 3
1.4 Maintenance Safety ......................................................................................................................... 6
1.5 Hydraulic Safety .............................................................................................................................. 7
1.6 Safety Signs.................................................................................................................................... 8
1.6.1 Installing Safety Decals ............................................................................................................ 8
1.7 Safety Decal Location ...................................................................................................................... 9
1.8 Interpreting Safety Signs ................................................................................................................ 12
2Definitions........................................................................................................................................... 19
3 Component Identification.................................................................................................................... 21
4 Specifications ..................................................................................................................................... 23
5 Operation ............................................................................................................................................ 25
5.1 Owner/Operator Responsibilities..................................................................................................... 25
5.2 Operational Safety......................................................................................................................... 26
5.3 Header Safety Props...................................................................................................................... 28
5.4 Driveshields .................................................................................................................................. 30
5.4.1 Opening the Driveshield: North American Header .................................................................... 30
5.4.2 Closing the Driveshield: North American Header...................................................................... 30
5.4.3 Removing Right Endshield...................................................................................................... 31
5.4.4 Installing Right Endshield........................................................................................................ 31
5.4.5 Opening the Driveshield: Export Header.................................................................................. 32
5.4.6 Closing the Driveshield: Export Header ................................................................................... 32
5.5 Cutterbar Doors............................................................................................................................. 33
5.5.1 Opening the Cutterbar Doors: North American Header ............................................................. 33
5.5.2 Closing the Cutterbar Doors: North American Header............................................................... 34
5.5.3 Opening the Cutterbar Doors: Export Header........................................................................... 36
5.5.4 Closing the Cutterbar Doors: Export Header ............................................................................ 37
5.6 Daily Start-Up Check ..................................................................................................................... 39
5.7 Attaching the Header ..................................................................................................................... 41
5.7.1 Attaching the Forming Shield ..................................................................................................41
5.7.2 Attaching the Header (M205 Windrowers)................................................................................ 43
5.7.3 Attaching the Header (M200 Windrowers)................................................................................ 47
5.8 Detaching the Header .................................................................................................................... 54
5.8.1 Detaching the Header (M205 Windrowers)............................................................................... 54
5.8.2 Detaching the Header (M200 Windrowers)............................................................................... 58
5.9 Break-In Period ............................................................................................................................. 61
5.10 Shutting Down the Windrower ........................................................................................................ 62
5.11 Transporting the Header................................................................................................................. 63
5.12 Lights............................................................................................................................................ 64
6 Operating the Header .......................................................................................................................... 65
6.1 Header Float ................................................................................................................................. 65
6.1.1 Adjusting Header Float ........................................................................................................... 66
6.2 Roll Gap........................................................................................................................................ 67
6.2.1 Checking Roll Gap ................................................................................................................. 67
6.2.2 Adjusting Roll Gap ................................................................................................................. 68
6.3 Roll Tension .................................................................................................................................. 70
6.3.1 Adjusting Roll Tension ............................................................................................................ 70
169457 vRevision G

TABLE OF CONTENTS
6.4 Roll Timing .................................................................................................................................... 71
6.4.1 Checking Roll Timing.............................................................................................................. 71
6.4.2 Adjusting the Roll Timing ........................................................................................................ 72
6.5 Forming Shields ............................................................................................................................ 73
6.5.1 Adjusting the Side Deflectors .................................................................................................. 73
6.5.2 Adjusting the Rear Deflector (Fluffer Shield)............................................................................. 75
6.5.3 Adjusting the Swath Baffle ...................................................................................................... 75
6.6 Header Angle ................................................................................................................................ 77
6.7 Cutting Height ............................................................................................................................... 78
6.7.1 Adjusting Gauge Roller Height ............................................................................................... 78
6.7.2 Adjusting the Skid Shoe Height ............................................................................................... 78
6.7.3 Disc Speed ............................................................................................................................ 79
6.8 Ground Speed............................................................................................................................... 80
6.9 Double Windrowing........................................................................................................................ 81
6.10 Tall Crop Feed Plates..................................................................................................................... 82
6.10.1 Locating Tall Crop Feed Plates for Installation .......................................................................... 82
Installing Tall Crop Feed Plates: Under Driven Deflector.................................................... 83
Installing Tall Crop Feed Plates: Under Driveline Deflector ................................................ 83
6.10.2 Removing Tall Crop Feed Plates ............................................................................................. 84
Removing Tall Crop Feed Plates: Under Driven Deflector.................................................. 84
Removing Tall Crop Feed Plates: Under Driveline Deflector .............................................. 85
6.10.3 Returning Tall Crop Feed Plates to Storage.............................................................................. 85
6.11 Tall Crop Dividers .......................................................................................................................... 87
6.11.1 Removing Tall Crop Divider..................................................................................................... 87
6.12 The Overshot Auger....................................................................................................................... 89
6.12.1 Adjusting the Overshot Auger.................................................................................................. 89
6.13 Stripper Bars ................................................................................................................................. 92
6.13.1 Adjusting the Stripper Bar ....................................................................................................... 92
6.14 Haying Tips ................................................................................................................................... 95
6.14.1 Curing ................................................................................................................................... 95
6.14.2 Topsoil Moisture ..................................................................................................................... 95
6.14.3 Weather and Topography........................................................................................................ 95
6.14.4 Windrow Characteristics ......................................................................................................... 95
6.14.5 Driving On Windrow ............................................................................................................... 96
6.14.6 Raking and Tedding................................................................................................................ 96
6.14.7 Using Chemical Drying Agents................................................................................................ 96
6.15 Unplugging the Header .................................................................................................................. 97
7 Maintenance and Servicing ................................................................................................................. 99
7.1 Preparation for Servicing................................................................................................................ 99
7.2 Torque Specifications....................................................................................................................100
7.2.1 SAE Bolt Torque Specifications ..............................................................................................100
7.2.2 Metric Bolt Specifications.......................................................................................................102
7.2.3 Metric Bolt Specifications Bolting into Cast Aluminum..............................................................105
7.2.4 Flare-Type Hydraulic Fittings..................................................................................................105
7.2.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)..................................................................107
7.2.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ..........................................................109
7.2.7 O-Ring Face Seal (ORFS) Hydraulic Fittings...........................................................................110
7.3 Conversion Chart..........................................................................................................................112
7.4 Recommended Fluids and Lubricants ............................................................................................113
7.5 Maintenance Requirements...........................................................................................................114
7.5.1 Maintenance Schedule/Record...............................................................................................115
7.5.2 Break-In Inspections..............................................................................................................117
7.5.3 Preseason/Annual Service.....................................................................................................117
7.5.4 End-of-Season Service..........................................................................................................118
169457 viRevision G

TABLE OF CONTENTS
7.5.5 Lubrication and Servicing.......................................................................................................118
7.5.6 Greasing Procedure ..............................................................................................................119
7.5.7 Lubrication and Servicing Intervals .........................................................................................120
7.5.8 Lubricating the Cutterbar .......................................................................................................124
Draining the Cutterbar Lubricant .....................................................................................124
Filling the Cutterbar Lubricant .........................................................................................126
7.5.9 Rock Guards.........................................................................................................................129
Inspecting the Rock Guards ...........................................................................................129
7.6 Cutterbar Disc Maintenance ..........................................................................................................130
7.6.1 Inspecting the Cutterbar Discs ...............................................................................................130
7.6.2 Discs....................................................................................................................................131
Removing a Disc ...........................................................................................................131
Installing a Disc .............................................................................................................132
7.6.3 Direction of Spindle Rotation..................................................................................................133
7.6.4 Cutter Blades........................................................................................................................133
Inspecting Cutter Blades ................................................................................................134
Inspecting Cutter Blade Hardware...................................................................................136
Replacing the Cutter Blades ...........................................................................................137
7.6.5 Accelerators..........................................................................................................................138
Inspecting Accelerators ..................................................................................................139
Replacing Accelerators ..................................................................................................139
7.6.6 Rotary Deflectors ..................................................................................................................140
Inspecting Rotary Deflectors...........................................................................................140
Removing the Driven Deflector .......................................................................................141
Installing the Driven Deflector .........................................................................................142
Removing the Driveline Deflector....................................................................................142
Installing the Driveline Deflector......................................................................................143
7.7 Drive Systems ..............................................................................................................................145
7.7.1 Bevel Gearbox ......................................................................................................................145
Changing the Bevel Gearbox Lubricant ...........................................................................145
7.7.2 Conditioner Drive Belt............................................................................................................146
Inspecting the Conditioner Drive Belt...............................................................................146
Replacing the Conditioner Drive Belt...............................................................................148
7.7.3 Conditioner Gearbox .............................................................................................................150
Changing the Conditioner Gearbox Lubricant ..................................................................150
7.7.4 Header Drive Speed Sensor ..................................................................................................152
Adjusting the Header Drive Speed Sensor.......................................................................152
Replacing the Header Drive Speed Sensor......................................................................152
7.7.5 Auger Drive Belt....................................................................................................................154
Inspecting the Auger Drive Belts .....................................................................................154
Replacing the Auger Drive Belts .....................................................................................155
7.7.6 Sealed Bearing Installation ....................................................................................................156
7.8 Hydraulics ....................................................................................................................................158
7.8.1 Hydraulic Motor.....................................................................................................................158
Removing the Hydraulic Motor........................................................................................158
Installing the Hydraulic Motor..........................................................................................159
7.8.2 Hydraulic Hoses and Lines ....................................................................................................160
7.9 Electrical ......................................................................................................................................161
7.9.1 Hazard Lights........................................................................................................................161
Hazard Lights: Replacing Bulbs and Lenses....................................................................161
Hazard Lights: Replacing the Lamp Assembly.................................................................161
Hazard Lights: Replacing the Lamp Bracket ....................................................................162
8 Troubleshooting .................................................................................................................................163
8.1 Mower Performance......................................................................................................................163
169457 vii Revision G

TABLE OF CONTENTS
8.2 Mechanical Problems....................................................................................................................166
9 Options and Attachments ..................................................................................................................169
9.1 Kits ..............................................................................................................................................169
9.1.1 Adjustable Skid Shoe Kit........................................................................................................169
9.1.2 Cutterbar Repair Tool Kit........................................................................................................169
9.1.3 Double Windrow Attachment (DWA) .......................................................................................170
9.1.4 Gauge Roller ........................................................................................................................170
9.1.5 Hydraulic Drive - 16-ft. for M200 Self-Propelled.......................................................................170
9.1.6 Tall Crop Divider Kit...............................................................................................................171
9.1.7 Tall Crop Feed Plate Kit .........................................................................................................171
Index ..................................................................................................................................................173
169457 viii Revision G