MacDon R85 User manual

R85 Rotary Disc 13 Foot
Self-Propelled Windrower Heade
r
OPERATOR’S MANUAL
Revision
A
Part #169455 $15

R85 ROTARY DISC 13 FOOT SELF-PROPELLED WINDROWER HEADER

Form # 169455 1Revision A
1 INTRODUCTION
This manual describes the operating and maintenance procedures for the MacDon Model R85 Self-Propelled
13 Foot Rotary Disc Header. Your new MacDon rotary header is designed to cut, condition, and lay in windrows
a wide variety of grasses and hay crops.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR
USE THE MACHINE.
Use this manual as your first source of information about the machine. If you follow the instructions given in this
manual, your Mower will work well for many years. A Parts Catalog is also supplied with your new header. If you
require more detailed service information, a Service Manual is available from your dealer.
Use the Table of Contents and the Index to guide you to specific areas. Study the Table of Contents to familiarize
yourself with how the material is organized.
Keep this manual handy for frequent reference and to pass on to new operators or owners. Call your dealer if you
need assistance, information, or additional copies of this manual. Store this Operator’s Manual and the Parts
Catalog in the manual storage case located at the right end of the header.
RECORD THE SERIAL NUMBER OF THE HEADER.
____________________________________
Serial Number plate is located on the top surface at the right end
of the header.
Published: Jujy, 2010

TABLE OF CONTENTS
Form # 169455 2Revision A
Section/Title Page
1INTRODUCTION...............................................................................................................................................1
2SAFETY ............................................................................................................................................................4
2.1 SAFETY ALERT SYMBOL.......................................................................................................................4
2.2 SIGNAL WORDS......................................................................................................................................4
2.3 SAFETY SIGNS........................................................................................................................................4
2.3.1 Safety Sign Installation.......................................................................................................................4
2.3.2 Safety Sign Location...........................................................................................................................5
2.4 GENERAL SAFETY..................................................................................................................................7
3DEFINITIONS....................................................................................................................................................9
3.1 ACRONYMS AND ABBREVIATIONS ......................................................................................................9
3.2 TERMS .....................................................................................................................................................9
4COMPONENT IDENTIFICATION ...................................................................................................................10
5SPECIFICATIONS ..........................................................................................................................................11
6OPERATION...................................................................................................................................................12
6.1 OWNER/OPERATOR RESPONSIBILITIES...........................................................................................12
6.2 OPERATIONAL SAFETY.......................................................................................................................12
6.3 PRE-SEASON CHECK...........................................................................................................................14
6.4 DAILY START-UP CHECK.....................................................................................................................14
6.5 HEADER ATTACHMENT.......................................................................................................................15
6.5.1 M205 Windrower...............................................................................................................................16
6.5.2 M200 WINDROWER ........................................................................................................................17
6.5.3 M150 WINDROWER ........................................................................................................................19
6.6 HEADER DETACHMENT.......................................................................................................................21
6.6.1 M205 Windrower...............................................................................................................................21
6.6.2 M200 WINDROWER ........................................................................................................................22
6.6.3 M150 WINDROWER ........................................................................................................................24
6.7 BREAK-IN PERIOD................................................................................................................................25
6.8 SHUTDOWN PROCEDURE...................................................................................................................25
6.9 TRANSPORTING HEADER...................................................................................................................25
6.10 HEADER OPERATION...........................................................................................................................26
6.10.1 Header Flotation...............................................................................................................................26
6.10.2 Roll Gap............................................................................................................................................27
6.10.3 Roll Tension......................................................................................................................................29
6.10.3 Roll Tension......................................................................................................................................29
6.10.4 Roll Timing........................................................................................................................................30
6.10.5 Forming Shields................................................................................................................................31
6.10.6 Header Angle....................................................................................................................................33
6.10.7 Cutting Height...................................................................................................................................34
6.10.8 Disc Speed .......................................................................................................................................35
6.10.9 Ground Speed ..................................................................................................................................35
6.10.10 Double Windrowing...........................................................................................................................36
6.10.11 Tall Crop Dividers.............................................................................................................................36
6.11 HAYING TIPS.........................................................................................................................................37
6.11.1 Curing ...............................................................................................................................................37
6.11.2 Topsoil Moisture ...............................................................................................................................37
6.11.3 Weather and Topography.................................................................................................................37
6.11.4 Windrow Characteristics...................................................................................................................37
6.11.5 Driving On Windrow..........................................................................................................................37
6.11.6 Raking and Tedding..........................................................................................................................37
6.11.7 Chemical Drying Agents...................................................................................................................37
6.12 UNPLUGGING THE HEADER ...............................................................................................................38
6.13 STORAGE ..............................................................................................................................................38
7MAINTENANCE AND SERVICE....................................................................................................................39
7.1 PREPARATION FOR SERVICING.........................................................................................................39

TABLE OF CONTENTS
Form # 169455 3Revision A
7.2 RECOMMENDED SAFETY PROCEDURES.........................................................................................39
7.3 MAINTENANCE SPECIFICATIONS ......................................................................................................40
7.3.1 Recommended Torques...................................................................................................................40
7.3.2 Recommended Lubricants................................................................................................................42
7.3.3 Conversion Chart..............................................................................................................................43
7.4 HEADER LIFT CYLINDER LOCKS........................................................................................................44
7.5 DRIVE SHIELD.......................................................................................................................................44
7.6 CUTTERBAR DOORS............................................................................................................................44
7.7 LUBRICATION........................................................................................................................................45
7.7.1 Greasing Procedure..........................................................................................................................45
7.7.2 Greasing Points................................................................................................................................45
7.7.3 Lubricant Level .................................................................................................................................48
7.7.4 Sealed Bearing Installation...............................................................................................................49
7.8 CUTTERBAR..........................................................................................................................................50
7.8.1 Cutter Bar Lubrication.......................................................................................................................50
7.8.2 Rock Guards.....................................................................................................................................52
7.8.3 Disc Maintenance.............................................................................................................................52
7.8.4 Cutter Blades....................................................................................................................................54
7.8.5 Cage Deflectors................................................................................................................................57
7.9 DRIVES...................................................................................................................................................58
7.9.1 Conditioner Drive Belt.......................................................................................................................58
7.9.2 Conditioner Gearbox.........................................................................................................................60
7.9.3 Bevel Gearbox..................................................................................................................................62
7.9.4 Gearbox Speed Sensor....................................................................................................................63
7.10 HYDRAULICS.........................................................................................................................................65
7.10.1 Hoses and Lines...............................................................................................................................65
7.10.2 Hydraulic Motor.................................................................................................................................65
7.11 MAINTENANCE SCHEDULE.................................................................................................................66
7.11.1 Break-In Inspection...........................................................................................................................66
7.11.2 Interval Maintenance ........................................................................................................................67
7.11.3 Maintenance Record.........................................................................................................................68
8TROUBLESHOOTING....................................................................................................................................69
8.1 MOWER PERFORMANCE.....................................................................................................................69
8.2 MECHANICAL........................................................................................................................................71
9OPTIONS AND ATTACHMENTS...................................................................................................................73
9.1 TALL CROP DIVIDER KIT......................................................................................................................73
9.2 CUTTERBAR REPAIR TOOL KIT..........................................................................................................73
9.3 DOUBLE WINDROW ATTACHMENT....................................................................................................73
9.1 SKID SHOE KIT......................................................................................................................................73
10 UNLOADING AND ASSEMBLY.....................................................................................................................74
INDEX ......................................................................................................................................................................75

SAFETY
Form # 169455 4Revision A
2 SAFETY
2.1 SAFETY ALERT SYMBOL
This safety alert symbol indicates important
safety messages in this manual and on safety
signs on the machine.
This symbol means:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Carefully read and follow the safety message
accompanying this symbol.
WHY IS SAFETY IMPORTANT TO YOU?
ACCIDENTS DISABLE AND KILL.
ACCIDENTS COST.
ACCIDENTS CAN BE AVOIDED.
2.2 SIGNAL WORDS
Note the use of the signal words DANGER,
WARNING, and CAUTION with safety
messages. The appropriate signal word for each
message has been selected using the following
guidelines:
DANGER
Indicates an imminently hazardous
situation that, if not avoided, will result in
death or serious injury.
WARNING
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious injury. It is also used to alert
against unsafe practices.
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor or
moderate injury. It is also used as a
reminder of good safety practices.
2.3 SAFETY SIGNS
•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.
2.3.1 Safety Sign Installation
a. Be sure the installation area is clean and dry.
b. Decide on the exact location before you remove
the decal backing paper.
c. Remove the smaller portion of the split backing
paper.
d. Place the sign in position and slowly peel back
the remaining paper, smoothing the sign as it is
applied.
e. Small air pockets can be smoothed out or
pricked with a pin. .

SAFETY
Form # 169455 5Revision A
2.3.2 Safety Sign Location
2 PLCS #148829
#32738
#170281
#109843
#134070

SAFETY
Form # 169455 6Revision A
1 PLC #36651
1 PLC – BOTH SIDES
#142909

SAFETY
Form # 169455 7Revision A
2.4 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 shoes with slip resistant
soles.
•protective glasses or goggles.
•heavy gloves.
•wet weather gear.
•respirator or filter mask.
•hearing protection. Be aware that
prolonged exposure to loud noise
can cause impairment or loss of
hearing. Wearing a suitable hearing
protective device such as ear muffs
(A) or ear plugs (B) protects against
objectionable or loud noises.
•Provide a first-aid kit for use in case of
emergencies.
•Keep a fire extinguisher on the machine.
Be sure the extinguisher is properly
maintained and be familiar with its proper
use.
•Keep young children away from
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.
•Wear close-fitting
clothing and cover long
hair. Never wear
dangling items such as
scarves or bracelets.
•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.
•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.
•Do not modify the machine. Unauthorized
modifications may impair the function
and/or safety and affect machine 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.
(continued next page)
A B

GENERAL
Form # 169455 8Revision A
•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.
•Use adequate light for the job at hand.
•Keep machinery clean. 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.

SAFETY
Form # 169455 9Revision A
3 DEFINITIONS
3.1 ACRONYMS AND ABBREVIATIONS
TERM DEFINITION
API American Petroleum Institute
APT Articulating Power Tongue
ASTM American Society Of Testing And
Materials
C Celsius
F Fahrenheit
ft/min feet per minute
ft/s feet per second
gpm U.S. gallons per minute
hp horsepower
in.3cubic inches
kPa kilopascals
lbf pounds force
lbf·ft or ft·lbf pound feet or foot pounds
lbf·in. or
in·lbf pound inches or inch pounds
MPa megapascals
mph miles per hour
N newtons
N·m newton meters
oz. ounces
psi pounds per square inch
PTO Power Take-Off
rpm Revolutions Per Minute
SAE Society Of Automotive Engineers
3.2 TERMS
The following terms may be used in this manual:
TERM DEFINITION
Cab-
Forward
Windrower operation with the
operator and cab facing in the
direction of travel.
Center Link A hydraulic cylinder or turnbuckle type link between the header and
the machine that tilts the header.
Engine-
Forward
Windrower operation with the
operator and engine facing in the
direction of travel.
Header or
Rotary
Header
A machine that cuts and conditions
hay, and is attached to a
windrower.
Mower
Conditioner A machine that cuts and conditions hay, and is pulled by an ag tractor.
Self-
propelled
Windrower
Self-propelled machine consisting
of a power unit with a header and
conditioner.
Tractor Ag type tractor.
Truck A four-wheel highway/road vehicle weighing no less than 7500 lb
(3400 kg).
Windrower Power unit of a self-propelled rotary
header.

GENERAL
Form # 169455 10 Revision A
4 COMPONENT
IDENTIFICATION
HOSE SUPPORT DRIVE MOTOR
CONDITIONER ROLLS
FRONT CURTAINS 8 DISC CUTTERBAR
CAGE DEFLECTOR
HYDRAULIC HOSES
TO SP WINDROWER
DRIVE SHIELD
BAFFLE CONTROL HEADER BOOT
HEADER BOOT
DOORS
BAFFLE
MANUAL STORAGE
CASE

SPECIFICATIONS
Form # 169455 11 Revision A
5 SPECIFICATIONS
NOTES: 1. Specifications and design are subject to change without notice or obligation to revise previously sold units.
HEADER MODEL R85 – 13 FT
FRAME & STRUCTURE
Transport Width 13 ft-0 in. (3952 mm)
Weight (estimated) 3000 lb (1360 kg)
Carrier MacDon M150, M205 SP Windrowers
Lighting None
Manual Storage Header Mounted Storage Case
CUTTERBAR
Qty Of Cutting Discs 8
Blades Per Disc Two 18 Deg. Bevel Down Reversible
Disc Speed 1800-2600 rpm
Blade Tip Speed Range 131-189 mph (59.2-85.5 m/s)
Effective Cutting Width 12 ft-9.5 in. (3895 mm)
Cutting Height 1 to 3 in. (25-75 mm)
Lubricant Capacity (Maximum) 7 Pints (3.25 litres)
Cutting Angle Range 0-8 Deg Below Horizontal
Geartrain Protection Shearable Disc Spindles
Deflectors Two Hourglass Converging
Shoes Two Adjustable
DRIVE
Type M200&M205 6.4 cu in. (106 cc) Heavy Duty Hydraulic Motor
M150 4.6 cu in. (75 cc) Heavy Duty Hydraulic Motor
Max. Power
Developed
M205 231 hp (174 kW)
M200 195 hp (146 kW)
M150 130 hp (97 kW)
Connections Direct Coupled (Optional Quick Coupler Connection)
Normal Operating Pressure 4000 psi (27.58 MPa)
CONDITIONER
Drive Bevel Gearbox To Belt Driven Enclosed Conditioner Timing Gearbox And Driveline.
Bevel Gearbox Lub. Capacity 21 oz. (620 ml)
Conditioner Gearbox Lub. Cap. 12 oz. (350 ml)
Roll Type Intermeshing Steel Bars
Roll Diameter 9.0 in. (229 mm) / 7.0 in. (179 mm) OD Tube
Roll Length 118 in. (3000 mm)
Roll Speed 730-1040 rpm
Swath Width 36-102 in. (915-2540 mm)
Forming Shields Windrower Mounted Adjustable Forming Shield System
GROUND SPEED 16 mph (25.7 km/h)

OPERATION
Form # 169455 12 Revision A
6 OPERATION
6.1 OWNER/OPERATOR
RESPONSIBILITIES
CAUTION
•It is your responsibility to read and
understand this manual completely
before operating the windrower. Contact
your dealer if an instruction is not clear
to you.
•Follow all safety messages in the
manual and on safety signs on the
machine.
•Remember that YOU are the key to
safety. Good safety practices protect
you and the people around you.
•Before allowing anyone to operate the
windrower, for however short a time or
distance, make sure they have been
instructed in its safe and proper use.
•Review the manual and all safety related
items with all operators annually.
•Be alert for other operators not using
recommended procedures or not
following safety precautions. Correct
these mistakes immediately, before an
accident occurs.
•Do not modify the machine.
Unauthorized modifications may impair
the function and/or safety and affect
machine life.
•The safety information given in this
manual does not replace safety codes,
insurance needs, or laws governing
your area. Be sure your machine meets
the standards set by these regulations.
•Ensure that the windrower is properly
equipped to safely operate the header.
This may include adding ballast
according to Windrower Operator’s
Manual requirements for attachments of
this size and mass.
6.2 OPERATIONAL SAFETY
Follow these safety precautions:
CAUTION
•Follow all safety and operational
instructions given in your windrower
Operator's Manual. If you do not have a
windrower manual, get one from your
dealer and read it thoroughly.
•Never attempt to start the windrower
engine or operate the windrower except
from the operator’s seat.
•Check the operation of all controls in a
safe clear area before starting work.
•Do not allow riders on windrower.
•Never start or move the machine until
you are sure all bystanders have cleared
the area.
•Avoid travelling over loose fill, rocks,
ditches or holes.
•Drive slowly through gates and
doorways.
•If cutting ditch banks, use extreme
caution. If the header hits an
obstruction, the front of the windrower
will usually swerve towards the ditch.
•When working on inclines, travel uphill
or downhill when possible.
•Never attempt to get on or off a moving
windrower.
•Do not get off the windrower while the
header is in operation.
•Stop windrower engine and remove key
before adjusting or removing plugged
material from the machine. A child or
even a pet could engage the drive.
•Check for excessive vibration and
unusual noises. If there is any indication
of trouble, shut down and inspect the
machine. Follow proper shutdown
procedure:
- engage windrower brake
- turn off engine and remove key
- wait for all movement to stop
- dismount and engage lift cylinder stops
before inspecting raised machine.
•Operate only in daylight or good
artificial light. (continued next page)

OPERATION
Form # 169455 13 Revision A
•Keep everyone several hundred feet
away from your operation. Ensure
bystanders are never in line with the
front or rear of the machine. Stones or
other foreign objects can be ejected
from either end with force.
•Extreme care must be exercised to
avoid injury from thrown objects. Do
not, under any circumstances, operate
the mower-conditioner when other
people are in the vicinity. Stones and
other objects can be thrown great
distances by the rotating cutting blades.
•The cutterbar curtains are very
important to reduce the potential for
thrown objects. Always keep these
curtains down when operating the
mower-conditioner. Replace the
curtains if they should become worn or
damaged.

OPERATION
Form # 169455 14 Revision A
6.3 PRE-SEASON CHECK
Perform the following the beginning of each
operating season:
CAUTION
•Review the Operator's Manual to refresh
your memory on safety and operating
recommendations.
•Review all safety signs and other decals
on the header and note hazard areas.
•Be sure all shields and guards are
properly installed and secured. Never
alter or remove safety equipment.
•Be sure you understand and have
practiced safe use of all controls. Know
the capacity and operating
characteristics of the machine.
•Check the first aid kit and fire
extinguisher. Know where they are and
how to use them.
a. Lubricate machine completely. Refer to Section
7.7, Lubrication.
b. Perform all annual maintenance. See Section
7.11, Maintenance Schedule.
6.4 DAILY START-UP CHECK
CAUTION
•Be sure windrower and header are
properly attached, all controls are in
neutral and windrower brake is
engaged.
•Clear the area of other persons, pets
etc. Keep children away from
machinery. Walk around the windrower
to be sure no one is under, on or close
to it.
•Wear close fitting clothing and
protective shoes with slip resistant
soles.
•Remove foreign objects from the
machine and surrounding area.
•As well, carry with you any protective
clothing and personal safety devices
that COULD be necessary through the
day. Don't take chances.
•You may need:
- a hard hat
- protective glasses or goggles
- heavy gloves
- respirator or filter mask
- wet weather gear
•Protect against noise. Wear
a suitable hearing protective
device such as ear muffs or
ear plugs to protect against
objectionable or
uncomfortable loud noises.
a. Check the machine for leaks or any parts that
are missing, broken, or not working correctly.
NOTE:
Use proper procedure when searching for
pressurized fluid leaks. Refer to Section
7.10 Hydraulics.
b. Clean all reflective surfaces on the machine.
c. Perform all Daily maintenance. Refer to Section
7.11 Maintenance Schedule.

OPERATION
Form # 169455 15 Revision A
6.5 HEADER ATTACHMENT
a. If not installed, attach the forming shield to the
windrower:
1. Remove the two clevis pins (A) from forming
shield forward end.
2. Position forming shield under the windrower
frame.
3. Locate forming shield onto spacers (B) on
windrower legs and secure with clevis pins
(A) and lynch pin.
4. Lift the aft end of the forming shield and
attach straps (C) to pins (D) on windrower
frame. Install washer and hairpin to secure
strap. Use the middle hole and adjust height
to suit the crop.
5. Set forming shield side deflectors to desired
width by repositioning adjuster bars (E).
Use same hole location on both sides.
6. Adjust fluffer shield (F) to middle position.
Loosen handles (G) if required.
b. Attach the R85 header to the Windrower. Refer
to the MacDon Self-Propelled Windrower
Operator’s Manual, and then return to this
manual to complete the attachment.
c. Connect the hydraulics and electrical harness.
See applicable section in the following pages for
your windrower model.
A
A
B
CD
F
G
E
BOTH SIDES

OPERATION
Form # 169455 16 Revision A
6.5.1 M205 Windrower
DANGER
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.
a. Move windrower left side platform to open
position.
b. Route the hose bundle (A) from the header,
under the windrower frame and attach hose
support (B) to bracket on windrower frame.
c. Remove caps and plugs from the two large
hoses and lines.
d. Connect large hoses to the lines at (C) and (D)
as shown. Torque fittings to 135 ft·lbf (183
N·m).
e. Attach case drain hose coupler at (E).
f. Connect electrical harness to connector (F)
located beside the forward valve block on the
windrower.
g. Move windrower platform to closed position.
A
B
C
D
E
F

OPERATION
Form # 169455 17 Revision A
6.5.2 M200 WINDROWER
DANGER
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.
a. Disengage and rotate lever (A) counter-
clockwise to fu lly up position.
b. Remove cap (B) securing electrical connector to
frame.
c. Move hose bundle (C) from windrower, and rest
bundle on to header.
d. Check that hose support is positioned so that
lower bolt is in forward hole and support is
positioned as shown. Loosen bolts and adjust
as required.
e. Route hose bundle (C) from windrower through
support (D) on header.
f. Route header return and pressure hose bundle
(E) through support (D) on header, to windrower.
g. Lower and lock lever (A) .
h. Secure hose bundles with three cinch straps (F).
(continued next page)
A
C
B
C
F
A
E
C
D

OPERATION
Form # 169455 18 Revision A
i. Move windrower left side platform to open
position.
j. Connect two hose bundle from header to middle
valve block as shown.
k. Remove caps and plugs on hoses from
windrower and lines on header
l. Connect the three hoses from windrower to the
fittings on the header as shown.
m. Assemble electrical connector as shown.
n. Move platform to closed position.
ELECTRICAL
CASE DRAIN
PRESSURE
RETURN
MIDDLE VALVE BLOCK
RETURN
PRESSURE