MacDon R85 User manual

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

Rotary Disc 16-Foot Self-Propelled Windrower Header
Published: December, 2013

Introduction
This instructional manual describes the operating and maintenance procedures for the MacDon Model R85 Rotary
Disc 16-foot Self-Propelled Windrower Header.
Your new MacDon rotary header is designed to cut, condition, and lay a wide variety of grasses and hay crops
in windrows.
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, a technical
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 in the manual storage case in the windrower cab.
169457 iRev. F

Serial Number(s)
Record the serial number of the header in the
space provided.
Header Serial No: ____________
Serial Number Plate (A) is located on the top surface at the
right hand end of the header.
Figure 1
169457 iiRev. F

TABLE OF CONTENTS
Introduction ...................................................................................................................................... i
Serial Number(s) ..............................................................................................................................ii
1 Safety .................................................................................................................................................... 1
1.1 Safety Alert Symbols........................................................................................................................ 1
1.2 Signal Words................................................................................................................................... 2
1.3 General Safety ................................................................................................................................ 3
1.4 Maintenance Safety ......................................................................................................................... 5
1.5 Hydraulic Safety .............................................................................................................................. 6
1.6 Tire Safety....................................................................................................................................... 7
1.7 Safety Signs.................................................................................................................................... 8
1.7.1 Installing Safety Decals ............................................................................................................ 8
1.8 Safety Decal Location ...................................................................................................................... 9
1.9 Interpreting Safety Signs ................................................................................................................ 12
2Definitions........................................................................................................................................... 17
3 Component Identification.................................................................................................................... 19
4 Specifications ..................................................................................................................................... 21
5 Operation ............................................................................................................................................ 23
5.1 Owner/Operator Responsibilities..................................................................................................... 23
5.2 Operational Safety......................................................................................................................... 24
5.3 Header Safety Props...................................................................................................................... 26
5.4 Driveshields .................................................................................................................................. 28
5.4.1 Opening the Driveshield: North American Header .................................................................... 28
5.4.2 Closing the Driveshield: North American Header...................................................................... 28
5.4.3 Removing Right End Shield: North American Headers.............................................................. 29
5.4.4 Installing Right End Shield: North American Headers ............................................................... 29
5.4.5 Opening the Driveshield: Export Header.................................................................................. 30
5.4.6 Closing the Driveshield: Export Header ................................................................................... 30
5.5 Cutterbar Doors............................................................................................................................. 31
5.5.1 Opening the Cutterbar Doors: North American Header ............................................................. 31
5.5.2 Closing the Cutterbar Doors: North American Header............................................................... 32
5.5.3 Opening the Cutterbar Doors: Export Header........................................................................... 34
5.5.4 Closing the Cutterbar Doors: Export Header ............................................................................ 36
5.6 Daily Start-Up Check ..................................................................................................................... 38
5.7 Attaching the Header ..................................................................................................................... 40
5.7.1 Attaching the Forming Shield ..................................................................................................40
5.7.2 Attaching the Header (M205 Windrowers)................................................................................ 42
5.7.3 Attaching the Header (M200 Windrowers)................................................................................ 46
5.8 Detaching the Header .................................................................................................................... 53
5.8.1 Detaching the Header (M205 Windrowers)............................................................................... 53
5.8.2 Detaching the Header (M200 Windrowers)............................................................................... 57
5.9 Break-In Period ............................................................................................................................. 60
5.10 Shutting Down the Windrower ........................................................................................................ 61
5.11 Transporting the Header................................................................................................................. 62
5.12 Lights............................................................................................................................................ 63
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 iii Rev. F

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 ............................................................................................................................ 74
6.5.1 Adjusting the Side Deflectors .................................................................................................. 74
6.5.2 Adjusting the Rear Deflector (Fluffer Shield)............................................................................. 76
6.5.3 Adjusting the Swath Baffle ...................................................................................................... 76
6.6 Header Angle ................................................................................................................................ 78
6.7 Cutting Height ............................................................................................................................... 79
6.7.1 Adjusting Gauge Roller Height ............................................................................................... 79
6.7.2 Adjusting the Skid Shoe Height ............................................................................................... 80
6.7.3 Disc Speed ............................................................................................................................ 80
6.8 Ground Speed............................................................................................................................... 81
6.9 Double Windrowing........................................................................................................................ 82
6.10 Tall Crop Feed Plates..................................................................................................................... 83
6.10.1 Locating Tall Crop Feed Plates for Installation .......................................................................... 83
Installing Tall Crop Feed Plates: Under Driven Deflector.................................................... 84
Installing Tall Crop Feed Plates: Under Driveline Deflector ................................................ 84
6.10.2 Removing Tall Crop Feed Plates ............................................................................................. 85
Removing Tall Crop Feed Plates: Under Driven Deflector.................................................. 85
Removing Tall Crop Feed Plates: Under Driveline Deflector .............................................. 86
6.10.3 Returning Tall Crop Feed Plates to Storage.............................................................................. 87
6.11 Tall Crop Dividers .......................................................................................................................... 88
6.11.1 Removing Tall Crop Divider..................................................................................................... 88
6.12 The Overshot Auger....................................................................................................................... 90
6.12.1 Adjusting the Overshot Auger.................................................................................................. 90
6.13 Stripper Bars ................................................................................................................................. 93
6.13.1 Adjusting the Stripper Bar ....................................................................................................... 93
6.14 Haying Tips ................................................................................................................................... 96
6.14.1 Curing ................................................................................................................................... 96
6.14.2 Topsoil Moisture ..................................................................................................................... 96
6.14.3 Weather and Topography........................................................................................................ 96
6.14.4 Windrow Characteristics ......................................................................................................... 97
6.14.5 Driving On Windrow ............................................................................................................... 97
6.14.6 Raking and Tedding................................................................................................................ 97
6.14.7 Using Chemical Drying Agents................................................................................................ 97
6.15 Unplugging the Header .................................................................................................................. 98
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 ....................................................................................106
7.2.6 O-Ring Face Seal (ORFS) Hydraulic Fittings...........................................................................107
7.3 Conversion Chart..........................................................................................................................109
7.4 Recommended Fluids and Lubricants ............................................................................................110
7.5 Maintenance Requirements........................................................................................................... 111
7.5.1 Maintenance Schedule/Record...............................................................................................112
7.5.2 Break-In Inspections..............................................................................................................114
7.5.3 Preseason/Annual Service.....................................................................................................114
7.5.4 End-of-Season Service..........................................................................................................115
7.5.5 Lubrication and Servicing.......................................................................................................115
169457 ivRev. F

TABLE OF CONTENTS
7.5.6 Greasing Procedure ..............................................................................................................116
7.5.7 Lubrication and Servicing Intervals .........................................................................................117
7.5.8 Lubricating the Cutterbar .......................................................................................................121
Draining the Cutterbar Lubricant .....................................................................................121
Filling the Cutterbar Lubricant .........................................................................................123
7.5.9 Rock Guards.........................................................................................................................125
Inspecting the Rock Guards ...........................................................................................125
7.6 Cutterbar Disc Maintenance ..........................................................................................................126
7.6.1 Inspecting the Cutterbar Discs ...............................................................................................126
7.6.2 Disc......................................................................................................................................127
Removing a Disc ...........................................................................................................127
Installing a Disc .............................................................................................................128
7.6.3 Direction of Spindle Rotation..................................................................................................129
7.6.4 Cutter Blades........................................................................................................................129
Inspecting Cutter Blades ................................................................................................130
Replacing the Cutter Blades ...........................................................................................132
Inspecting Cutterbar Hardware .......................................................................................133
7.6.5 Accelerators..........................................................................................................................134
Inspecting Accelerators ..................................................................................................135
Replacing Accelerators ..................................................................................................135
7.6.6 Rotary Deflectors ..................................................................................................................136
Inspecting Rotary Deflectors...........................................................................................137
Removing the Driven Deflector .......................................................................................137
Installing the Driven Deflector .........................................................................................138
Removing the Driveline Deflector....................................................................................138
Installing the Driveline Deflector......................................................................................139
7.7 Drive Systems ..............................................................................................................................141
7.7.1 Bevel Gearbox ......................................................................................................................141
Changing the Bevel Gearbox Lubricant ...........................................................................141
7.7.2 Conditioner Drive Belt............................................................................................................142
Inspecting the Conditioner Drive Belt...............................................................................142
Replacing the Conditioner Drive Belt...............................................................................144
7.7.3 Conditioner Gearbox .............................................................................................................146
Changing the Conditioner Gearbox Lubricant ..................................................................146
7.7.4 Header Drive Speed Sensor ..................................................................................................148
Adjusting the Header Drive Speed Sensor.......................................................................148
Replacing the Header Drive Speed Sensor......................................................................149
7.7.5 Auger Drive Belt....................................................................................................................150
Inspecting the Auger Drive Belts .....................................................................................150
Replacing the Auger Drive Belts .....................................................................................151
7.7.6 Sealed Bearing Installation ....................................................................................................152
7.8 Hydraulics ....................................................................................................................................154
7.8.1 Hydraulic Motor.....................................................................................................................154
Removing the Hydraulic Motor........................................................................................154
Installing the Hydraulic Motor..........................................................................................155
7.8.2 Hydraulic Hoses and Lines ....................................................................................................156
7.9 Electrical ......................................................................................................................................157
7.9.1 Hazard Lights........................................................................................................................157
Hazard Lights: Replacing Bulbs and Lenses....................................................................157
Hazard Lights: Replacing the Lamp Assembly.................................................................157
Hazard Lights: Replacing the Lamp Bracket ....................................................................158
8 Troubleshooting .................................................................................................................................159
8.1 Mower Performance......................................................................................................................159
8.2 Mechanical...................................................................................................................................162
169457 vRev. F

TABLE OF CONTENTS
9 Options and Attachments ..................................................................................................................165
9.1 Kits ..............................................................................................................................................165
9.1.1 Adjustable Skid Shoe Kit........................................................................................................165
9.1.2 Cutterbar Repair Tool Kit........................................................................................................165
9.1.3 Double Windrow Attachment (DWA) .......................................................................................166
9.1.4 Gauge Roller ........................................................................................................................166
9.1.5 Hydraulic Drive - 16-Ft. for M200 Self-Propelled......................................................................166
9.1.6 Tall Crop Divider Kit...............................................................................................................167
9.1.7 Tall Crop Feed Plate Kit .........................................................................................................167
Index ..................................................................................................................................................169
169457 viRev. F

1 Safety
1.1 Safety Alert Symbols
This safety alert symbol indicates important safety
messages in this manual and on safety signs on
the header.
This symbol means:
•ATTENTION!
•BECOME ALERT!
•YOUR SAFETY IS INVOLVED!
Carefully read 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: Read Operator’s Manual Before
Operating
169457 1Rev. F

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 may also be used to 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.
169457 2Rev. F

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.
Figure 1.2
• 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
– Hearing protection
Be aware that exposure to loud noise can cause
impairment or loss of hearing. Wearing suitable
hearing protection devices such as ear muffs or ear
plugs. These will help protect against objectionable
or loud noises.
Figure 1.3
•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
istiredorinahurrytogetfinished. Takethetimeto
consider the safest way. Never ignore warning signs
of fatigue.
Figure 1.4
169457 3Rev. F

SAFETY
•Wearclosefitting 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
• 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.
•Do NOT modify the machine. Non-authorized
modifications may impair machine function and/or safety.
It may also shorten the machine’s life.
• Stop engine and remove key from ignition before leaving
operator’s seat for any reason. A child or even a pet
could engage an idling machine.
Figure 1.6
• Keep 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.
• 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
169457 4Rev. F

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.
•Placeallcon
trols 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 area clean and dry.
–Be sure ele
ctrical outlets and tools are
properly grounded.
– Use adequate light for the job at hand.
Figure 1.8: Slip On Puddle
• Relieve pressure from hydraulic circuits before servicing
and/or disconnecting the machine.
• Before applying pressure to a hydraulic system, make
sure all components are tight and that steel lines, hoses,
and couplings are in good condition.
• Keep hands, feet, clothing, and hair away from all moving
and/or rotating parts.
•Clearth
e area of bystanders especially children when
carrying out any maintenance and repairs or when
making any adjustments.
•Instal
l transport lock or place safety stands under the
frame before working under the header.
•Ifmore
than one person is servicing the machine at the
same time,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: Keep Away
• Wear protective gear when working on the machine.
• Wear heavy gloves when working on knife components.
Figure 1.10: Safety Gear
169457 5Rev. F

SAFETY
1.5 Hydraulic Safety
• Always place all hydraulic controls in Neutral before
dismounting.
• Makesurethatall components in the hydraulic system
are kept in good condition and clean.
•Replaceanyw
orn, cut, abraded, flattened, or crimped
hoses and steel lines.
• Do not 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. Such makeshift repairs will fail
suddenly and create a hazardous and unsafe condition.
Figure 1.11: Checking 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
aleak.
• 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
• Before applying pressure to a hydraulic system, make
sure all components are tight and that steel lines, hoses,
and couplings are in good condition.
Figure 1.13: Wear Safety Glasses
169457 6Rev. F

SAFETY
1.6 Tire Safety
• Failure to follow proper procedures when mounting a tire
on a wheel or rim can produce an explosion that may
result in serious injury or death.
Figure 1.14: Lower All Safety Stops
•DoNOT attempt to mount a tire unless you have the
proper training and equipment.
Figure 1.15: Safely Filling a Tire With Air
• Haveaq
ualified tire dealer or repair service perform
required tire maintenance.
Figure 1.16: Over-Inflation Of Tire
169457 7Rev. F

SAFETY
1.7 Safety Signs
• Keep safety signs clean and legible at all times.
•Replace safet
y 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 1.17: Read Operator’s Manual Before
Operating
1.7.1 Installing Safety Decals
To install a safety decal, follow these steps:
1. Be sure the installation area is clean and dry.
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. Small air pockets can be smoothed out or pricked with a pin.
169457 8Rev. F

SAFETY
1.8 Safety Decal Location
Figure 1.18
A - MD #166466 B - MD #113482 C - MD #194464
D - MD #194521 E - MD #184385
Figure 1.19
169457 9Rev. F

SAFETY
Figure 1.20
A - MD #190546 B - MD #184371 C - MD #184385
D - MD #194466 E - MD #194463 F - MD #194465
Figure 1.21
169457 10Rev. F

SAFETY
Figure 1.22
A - MD #184386
169457 11Rev. F

SAFETY
1.9 Interpreting Safety Signs
In the safety sign explanations below, (a) refers to the top or
left position panel, (b) refers to the bottom or right position
of the safety decal depending on decal orientation.
NOTE: If there are more than two panels
in a decal, the lettering will continue
downward or to the right, depending on
decal orientation.
1. MD #113482
a. General hazard pertaining to machine operation
and servicing.
b. CAUTION
To avoid injury or death from improper or unsafe
machine operation:
• Read the operator’s manual and follow all safety
instructions. If you do not have a manual, obtain
one from your Dealer.
• Do not allow untrained persons to operate
the machine.
• Review safety instructions with all
operators annually.
• Ensure that all safety signs are installed
and legible.
• Make certain everyone is clear of machine
before starting engine and during operation.
• Keep riders off the machine.
• Keep all shields in place and stay clear of
moving parts.
• Disengage header drive, put transmission in
neutral, and wait for all movement to stop before
leaving operator’s position.
• Shut down the engine and remove the key from
ignition before servicing, adjusting, lubricating,
cleaning, or unplugging machine.
• Engage locks to prevent lowering of header or
reel before servicing in the raised position.
• Use slow moving vehicle emblem and flashing
warning lights when operating on roadways
unless prohibited by law.
Figure 1.23: MD #113482
169457 12Rev. F