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
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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
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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
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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
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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

1Safety
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 and follow the safety message
accompanying this symbol.
Why is safety important to you?
• Accidents disable and kill
• Accidents cost
• Accidents can be avoided
Figure 1.1: Safety Symbol
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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. It
mayalsobeusedto alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It
may be used to alert against unsafe practices.
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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.
Don’t take chances.
You may need:
• A hard hat
• Protective footwear with slip resistant soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• A respirator or filter mask
Figure 1.2: Safety Equipment
Hearing protection
• Be aware that exposure to loud noise can cause
impairment or loss of hearing. Wear suitable hearing
protection devices such as ear muffs or ear plugs to
help protect against objectionable or loud noises.
Figure 1.3: Safety Equipment
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SAFETY
•Provideafirst aid kit for use in case of emergencies.
•Keepafire extinguisher on the machine. Be sure the
fire extinguisher is properly maintained. Be familiar with
its proper use.
• Keep young children away from the machinery at
all times.
• Be 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.
Figure 1.4: Safety Equipment
•Wearclose-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.
• Use only service and repair parts made or approved by
the equipment manufacturer. Substituted parts may not
meet strength, design, or safety requirements.
Figure 1.5: Safety Around Equipment
• Keep hands, feet, clothing, and hair away from moving
parts. Never attempt to clear obstructions or objects
from a machine while the engine is running.
•DoNOT modify the machine. Non-authorized
modifications may impair machine function and/or
safety. It may also shorten the machine’s life.
• Stop the engine and remove the key from ignition before
leaving operator’s seat for any reason. A child or even
a pet could engage an idling machine.
Figure 1.6: Safety Around Equipment
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SAFETY
• Keep the service area 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.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff, on a hot
engine, are a fire hazard. Do NOT allow oil or grease to
accumulate on service platforms, ladders, or controls.
Clean machines before storage.
• Never use gasoline, naphtha, or any volatile material
for cleaning purposes. These materials may be toxic
and/or flammable.
• When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
Figure 1.7: Safety Around Equipment
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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.
• Follow good shop practices:
– Keep service areas clean and dry
– Be sure electrical outlets and tools are
properly grounded
– Use adequate lighting for the job at hand Figure 1.8: Safety Around Equipment
• Relieve pressure from hydraulic circuits before servicing
and/or disconnecting the machine.
• Make sure all components are tight and that steel lines,
hoses, and couplings are in good condition before
applying pressure to a hydraulic system..
• Keep hands, feet, clothing, and hair away from all
moving and/or rotating parts.
• Clear the area of bystanders, especially children, when
carrying out any maintenance and repairs or when
making any adjustments.
• Install transport lock or place safety stands under the
frame before working under the header.
• If more than one person is servicing the machine at the
sametime,beawarethatrotatingadrivelineorother
mechanically driven component by hand (for example,
accessing a lube fitting) will cause drive components in
other areas (belts, pulleys, and knife) to move. Stay
clear of driven components at all times.
Figure 1.9: Equipment NOT Safe for Children
•Wearprotectivegea
r when working on the machine.
• Wearheavyglovesw
hen working on knife components.
Figure 1.10: Safety Equipment
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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 clean and in good condition.
• Replace any worn, cut, abraded, flattened, or crimped
hoses and steel lines.
•DoNOT attempt any makeshift repairs to the hydraulic
lines, fittings, or hoses by using tapes, clamps, cements,
or welding. The hydraulic system operates under
extremely high pressure. Makeshift repairs will fail
suddenly and create a hazardous and unsafe condition.
Figure 1.11: Testing for Hydraulic Leaks
• Wear proper hand and eye protection when searching
for a high-pressure hydraulic leak. Use a piece of
cardboard as a backstop instead of hands to isolate
and identify a leak.
• If injured by a concentrated high-pressure stream of
hydraulicfluid, seek medical attention immediately.
Serious infection or toxic reaction can develop from
hydraulic fluid piercing the skin.
Figure 1.12: Hydraulic Pressure Hazard
• Make sure all components are tight and that steel lines,
hoses, and couplings are in good condition before
applying pressure to a hydraulic system.
Figure 1.13: Safety Around Equipment
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SAFETY
1.6 Safety Signs
• Keep safety signs clean and legible at all times.
• Replace safety signs that are missing or
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.
• Safety signs are available from your Dealer
Parts Department.
Figure 1.14: Operator’s Manual Decal
1.6.1 Installing Safety Decals
To in st all a safety decal, follow these steps:
1. Clean and dry the installation area.
2. Decide on the exact location before you remove the decal backing paper.
3. Remove the smaller portion of the split backing paper.
4. Place the sign in position and slowly peel back the remaining paper, smoothing the sign as it is applied.
5. Prick small air pockets with a pin and smooth out.
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SAFETY
1.7 Safety Decal Location
Figure 1.15: Safety Decal Locations
A - MD #166466 B - MD #113482 C - MD #194464
D - MD #194521 E - MD #184385
Figure 1.16: Safety Decals
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SAFETY
Figure 1.17: Safety Decal Locations
A - MD #190546 B - MD #184371 C - MD #184385
D - MD #194466 E - MD #194463 F - MD #194465
Figure 1.18: Safety Decals
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