MacDon R80 User manual

Form # 169080 Issue - April 2007
R80 Pull-Type
Rotary Disc Mower Conditioner
Unloading & Assembly Instructions

Form # 169080 Issue - April 2007
PULL-TYPE ROTARY DISC MOWER CONDITIONER

Form # 169080 Issue – April 2007
1
TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................................................... 1
GENERAL SAFETY................................................................................................................................................. 2
RECOMMENDED TORQUES ................................................................................................................................. 4
ENGLISH/METRIC EQUIVALENTS ........................................................................................................................ 6
STEP 1. UNLOAD HITCH................................................................................................................................. 7
STEP 2. UNLOAD HEADER............................................................................................................................. 8
STEP 3. LOWER HEADER .............................................................................................................................. 9
STEP 4. REMOVE SHIPPING CHANNELS AND BLOCKING ....................................................................... 10
STEP 5. REMOVE CUTTERBAR COMPONENTS......................................................................................... 12
STEP 6. UNPACK HITCH............................................................................................................................... 13
STEP 7. ATTACH HITCH ............................................................................................................................... 15
STEP 8. CONNECT LIFT HOSE .................................................................................................................... 16
STEP 9. INSTALL HYDRAULIC MOTOR ....................................................................................................... 17
STEP 10. INSTALL WHEELS........................................................................................................................... 18
STEP 11. INSTALL CENTER LINK .................................................................................................................. 19
STEP 12. REMOVE FLOAT SPRINGS ............................................................................................................ 20
STEP 13. ATTACH TRACTOR......................................................................................................................... 21
STEP 14. INSTALL STEERING CYLINDER..................................................................................................... 24
STEP 15. FILL LIFT CYLINDERS .................................................................................................................... 25
STEP 16. INSTALL CROP DEFLECTOR ......................................................................................................... 26
STEP 17. INSTALL FORMING SHIELD ........................................................................................................... 27
STEP 18. INSTALL FLOAT SPRINGS ............................................................................................................. 31
STEP 19. INSTALL OPTIONS.......................................................................................................................... 32
STEP 20. PERFORM PRE-DELIVERY CHECKS ............................................................................................ 33
INTRODUCTION
This instruction describes the unloading, set-up and pre-delivery requirements for the Model R80 Pull-Type
Rotary Disc Mower Conditioner. Use the table of contents to guide you to specific areas.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE,
OR USE THE MACHINE.

Form # 169080 Issue – April 2007
2
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.
A
B

Form # 169080 Issue – April 2007
3
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.
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.

Form # 169080 Issue – April 2007
4
RECOMMENDED TORQUES
I. GENERAL
The tables shown below give correct torque
values for various bolts and capscrews.
•Tighten all bolts to the torques specified in
chart unless otherwise noted throughout
this manual.
•Check tightness of bolts periodically, using
bolt torque chart as a guide.
•Replace hardware with the same strength
bolt.
•Torque figures are valid for non-greased or
non-oiled threads and heads unless
otherwise specified. Do not grease or oil
bolts or capscrews unless specified in this
manual. When using locking elements,
increase torque values by 5%.
II. SAE BOLTS
Bolt
Dia.
"A"
NC Bolt Torque*
SAE 5
SAE 8
lb-ft
N·m
lb-ft
N·m
1/4"
9
12
11
15
5/16"
18
24
25
34
3/8"
32
43
41
56
7/16"
50
68
70
95
1/2"
75
102
105
142
9/16"
110
149
149
202
5/8"
150
203
200
271
3/4"
265
359
365
495
7/8"
420
569
600
813
1"
640
867
890
1205
* Torque categories for bolts and capscrews are
identified by their head markings.
III. METRIC BOLTS
BOLT
DIA.
"A"
NC BOLT TORQUE*
8.8 10.9
lb-ft N·m lb-ft N·m
M3
0.4
0.5
1.3
1.8
M4 2.2 3 3.3 4.5
M5
4
6
7
9
M6 7 10 11 15
M8 18 25 26 35
M10
37
50
52
70
M12 66 90 92 125
M14
103
140
148
200
M16 166 225 229 310
M20 321 435 450 610
M24
553
750
774
1050
M30 1103 1495 1550 2100
M36
1917
2600
2710
3675
* Torque categories for bolts and capscrews are
identified by their head markings.
SAE-5
SAE-8
8.8
10.9

Form # 169080 Issue – April 2007
5
IV.HYDRAULIC FITTINGS
O-RING TYPE
Refer to illustration and proceed as follows:
a. Inspect O-ring and seat for dirt or obvious
defects.
b. On angle fittings, back off the lock nut until
washer bottoms out at top of groove.
c. Hand tighten fitting until back up washer or
washer face (if straight fitting) bottoms on face
and O-ring is seated.
d. Position angle fittings by unscrewing no more
than one turn.
e. Tighten straight fittings to torque shown.
f. Tighten angle fittings to torque shown in the
following table while holding body of fitting with
a wrench.
THD
SIZE
(in.)
NUT SIZE
ACROSS
FLATS
(in.)
TORQUE
VALUE*
RECOMMENDED
TURNS TO
TIGHTEN (AFTER
FINGER
TIGHTENING)
lb-ft N·m Flats Turns
3/8
1/2
6
8
2
1/3
7/16 9/16 9 12 2 1/3
1/2
5/8
12
16
2
1/3
9/16 11/16 18 24 2 1/3
3/4 7/8 34 46 2 1/3
7/8
1
46
62
1-1/2
1/4
1-1/16 1-1/4 75 102 1 1/6
1-3/16
1-3/8
90
122
1
1/6
1-5/16 1-1/2 105 142 3/4 1/8
1-5/8 1-7/8 140 190 3/4 1/8
1-7/8
2-1/8
160
217
1/2
1/12
* The torque values shown are based on lubricated
connections as in reassembly.
FLARE TYPE
Refer to illustration and proceed as follows:
a. Check flare and flare seat for defects that
might cause leakage.
b. Align tube with fitting before tightening.
c. Lubricate connection and hand tighten swivel
nut until snug.
d. To prevent twisting the tube(s), use two
wrenches. Place one wrench on the connector
body and with the second tighten the swivel
nut to the torque shown.
TUBE
SIZE
O.D.
(in.)
NUT
SIZE
ACROSS
FLATS
(in.)
TORQUE
VALUE*
RECOMMENDED
TURNS TO
TIGHTEN
(AFTER FINGER
TIGHTENING)
lb-ft N·m Flats Turns
3/16
7/16
6
8
1
1/6
1/4
9/16
9
12
1
1/6
5/16
5/8
12
16
1
1/6
3/8
11/16
18
24
1
1/6
1/2
7/8
34
46
1
1/6
5/8
1
46
62
1
1/6
3/4
1-1/4
75
102
3/4
1/8
7/8
1-3/8
90
122
3/4
1/8
* The torque values shown are based on
lubricated connections as in reassembly.
LOCKNUT
WASHER
GROOVE
FITTING
O-RING
SEAT
FLARE
FLARESEAT
BODY
C

Form # 169080 Issue – April 2007
6
ENGLISH/METRIC
EQUIVALENTS
ENGLISH
FACTOR
SI UNITS (METRIC)
acres x 0.4047 hectares (ha)
ft/min x 0.3048 = meters/min (m/min)
ft/s x 0.3048 = meters/sec (m/s)
US gal x 3.7854 = liters (L)
US
gal/min
(gpm)
x 3.7854 = liters/min (L/min)
hp x 0.7457 = kilowatts (kW)
in3x 16.3871
= cubic centimeters (cm3
or cc)
lbf. x 4.4482 = newtons (N)
lbf.ft or
ft-lb x 1.3558 = newton meters (N·m)
lbf.in or
in-lb x 0.1129 = newton meters (N·m)
mph x 1.6063 = kilometers/hour (km/h)
oz.
x 29.5735
= milliliters (ml)
psi
x 6.8948
= kilopascals (kPa)
psi x .00689 = megapascals (MPa).

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
7
STEP 1. UNLOAD HITCH
CAUTION
To avoid injury to bystanders from being
struck by machinery, do not allow persons
to stand in unloading area.
CAUTION
Equipment used for unloading must meet
or exceed the requirements specified
below. Using inadequate equipment may
result in chain breakage, vehicle tipping or
machine damage.
LIFTING VEHICLE
MIN. LIFTING
CAPACITY
8000 LB. (3630 KG)
MIN. LIFTING HEIGHT
15 FT. (4.5 M)
CHAIN
TYPE OVERHEAD LIFTING
QUALITY (1/2 INCH)
MIN. WORKING LOAD
5000 LB. (2270 KG)
a. Remove hauler's tie down straps and chains.
b. Attach chain to two brackets on top of hitch as
shown.
c. Adjust chain lengths so hitch is lifted evenly.
d. Raise hitch off deck, back up until unit clears
trailer and slowly lower to 6 inches (150 mm)
from ground.
IMPORTANT
Take care not to contact the other
machine if load is two-wide.
e. Take to storage or set-up area and set hitch
down securely on level ground.
f. Repeat for second hitch if required.
g. Check for shipping damage and missing parts.

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
8
STEP 2. UNLOAD HEADER
CAUTION
To avoid injury to bystanders from being
struck by machinery, do not allow persons
to stand in unloading area.
CAUTION
Equipment used for unloading must meet
or exceed the requirements specified
below. Using inadequate equipment may
result in chain breakage, vehicle tipping or
machine damage.
LIFTING VEHICLE
MIN. LIFTING
CAPACITY
8000 LB. (3630 KG)
MIN. LIFTING HEIGHT
15 FT. (4.5 M)
CHAIN
TYPE OVERHEAD LIFTING
QUALITY (1/2 INCH)
MIN. WORKING LOAD
5000 LB. (2270 KG)
WARNING
Be sure forks are secure before moving
away from load. Stand clear when lifting.
a. Remove hauler's tie down straps and chains.
b. Approach windrower from either its "underside"
or "topside" and slide forks in underneath lifting
framework as far as possible.
NOTE
When possible, approach from the
underside to minimize potential for
scratching the unit.
c. Raise windrower off deck.
IMPORTANT
Take care not to contact the other
machine if load is two-wide.
d. Back up until unit clears trailer and slowly
lower to 6 inches (150 mm) from ground.
e. Take to storage or set-up area set machine
down securely on level ground.
f. Repeat for other header if required.
g. Check for shipping damage and missing parts.
FORKS

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
9
STEP 3. LOWER HEADER
a. Drive lifting vehicle to approach windrower
from its "underside".
b. Attach chain hooks to hooks on either side of
header.
CHAIN
TYPE OVERHEAD LIFTING
QUALITY (1/2 INCH)
MIN. WORKING LOAD
5000 LB. (2270 KG)
CAUTION
Stand clear when lowering, as machine
may swing.
NOTE
Do not lift at hooks when unloading from
trailer. This procedure is only for laying
the machine over into working position.
IMPORTANT
Chain length must be sufficient to
provide a minimum 4 feet (1.2 m) vertical
chain height.
c. Raise forks until lift chains are fully tensioned.
d. Back up SLOWLY while simultaneously
lowering machine until cutterbar rests on
ground.
NOTE
The front face of the carrier mast should
be approximately vertical for easier
assembly of the hitch.
e. Remove chain from windrower.
1
2
3
MAST PERPENDICULAR
TO GROUND
ADJUST HEIGHT
AS REQUIRED

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
10
STEP 4. REMOVE SHIPPING
CHANNELS AND BLOCKING
a. Cut the banding on the shipping beam at the
rear of carrier frame and remove components
from inside the shipping beam. Set these
components aside for a later assembly step
b. Place blocks under the shipping beam at the
rear of the carrier frame.
c. Loosen the shipping stand bolt at the lower
end of each carrier frame leg.
d. Remove the bolt that secure shipping stand at
each float spring anchor.
e. Remove the support blocks and lower the
shipping stand to the ground.
f. Remove bolts at carrier frame legs and remove
shipping stand frame.
g. Cut banding that secures angles to carrier
frame tube and remove angles.

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
11
h. Cut all banding at header front covers.The
two center bands also secure the forming
shield top cover inside the header.
i. Remove five bolts and nuts on each door and
remove front angles and lift hooks. Retain
lower side bolt (A) for re-installation at same
location after hook is removed.
j. Open cutterbar doors fully.
k. Remove shipping wire holding forming shield
top cover to header.
l. Slide top cover out from front of header and
set aside for later installation.
A

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
12
STEP 5. REMOVE CUTTERBAR
COMPONENTS
a. Cut banding securing forming shield side
deflectors to cutterbar and remove
components from cutterbar. Set aside for later
installation.
WARNING
Ensure cutterbar is completely clear of
foreign objects. These objects can be
ejected with considerable force when the
machine is started and may result in
serious injury or machine damage.
b. Thoroughly check cutterbar area for wooden
blocking, banding, and hardware that may
have fallen between discs.
c. Close cutterbar doors. Ensure that curtains
hang properly and completely enclose
cutterbar area. Minor creases in curtains will
eventually straighten out.
NOT ACCEPTABLE
ACCEPTABLE

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
13
STEP 6. UNPACK HITCH
a. Attach chain from lifting vehicle or hoist to hitch
hooks, and raise it two feet off ground.
b. Cut banding securing hydraulic motor and
hoses to underside of hitch.
CAUTION
Hold motor to keep it from dropping to the
ground when cutting band around motor.
c. Route motor and hoses to the left side of the
hitch.
d. Secure the motor to the steering cylinder with
shipping wire.
e. Remove the two bolts securing wooden stand
to hitch pin.
NOTE
Bolt and washer at top of pin keeps pin
in hitch when bolts are removed.
f. Cut banding securing wooden stand to hitch
and remove wooden stand.

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
14
g. Remove bolt and washer securing pin to hitch.
CAUTION
Hold pin from falling to the ground when
bolt is removed.
h. Remove pin and reinsert pin in hitch from top.
i. Remove four bolts securing shipping bracket at
front of hitch, and remove bracket.
j. Remove banding from jack.
k. Remove pin (A) securing jack to hitch and
remove jack from shipping position.
l. Install at jack location at front of hitch and
secure with pin (A).
IMPORTANT
Ensure articulated hitch lock pin (B) is
installed and secured with lynch pin.
A
A
B

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
15
STEP 7. ATTACH HITCH
CAUTION
Keep hands clear when lowering hitch.
a. Remove the six bolts and nuts from frame and
retain for reinstallation.
b. Using a forklift or equivalent, manoeuvre hitch
into position and install pivot pin (A) into
windrower frame.
NOTE
Use the jack to adjust the pitch of the
hitch for proper alignment when
installing pivot pin.
NOTE
Pin may need to be tapped into final
position with a hammer due to the tight
clearances.
c. Secure pivot pin to frame by installing six 5/8 x
1.75 long Gr. 8 bolts (C) with lock nuts
removed at step a. Install bolts with heads
facing aft.
d. Torque to 250 ft-lb (339 N∙m).
e. Install bolt (B), lockwasher, and flatwasher
removed at STEP 6g. at lower end of pivot pin
and tighten bolt.
f. Position hitch with jack so that rear span of
hitch is approximately horizontal. Remove
lifting chain from hitch.
g. Check oil level in site glass (D) on the left side
of the tongue, is between ADD and FULL.
C
B
A
A
D

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
16
STEP 8. CONNECT LIFT HOSE
IMPORTANT
Hoses should be routed so there are no
twists or sharp bends and no locations
where contact with the frame is likely.
Ensure that there is sufficient length of
hose and wiring in span to
accommodate full swing of hitch in both
directions. Relocate plastic ties if
necessary to provide suitable slack in
hoses and wiring.
IMPORTANT
To prevent contamination of the
hydraulic system, extreme care must be
taken to avoid dirt entering at connection
points. To minimize exposure to
contamination, remove cap from one
hose and its mating connection and
connect before removing other caps and
plugs.
a. Connect the lift cylinder hose (A) to the fitting
on the hitch.
b. Connect electrical wiring harness (B) at rear of
hitch as shown.
A
B

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
17
STEP 9. INSTALL HYDRAULIC
MOTOR
a. Remove shipping wire that holds motor to
steering cylinder.
b. Route the motor and main drive hoses from
the hitch to the left side of the carrier frame.
c. Route hoses through hose guides.
d. Remove four bolts (A) securing plate (B) to
gearbox and remove plate. Retain bolts.
e. Position motor on gearbox as shown and re-
install the four bolts (A). If required, loosen the
hose swivel fittings at the motor ports to
remove any twist in the hose routing from the
hitch. Re-tighten fittings.
A
B
A

UNLOADING AND ASSEMBLY
Form # 169080 Issue – April 2007
18
STEP 10. INSTALL WHEELS
a. Attach a lifting chain to the hook at one end of
the carrier frame. Attach the other end to a
forklift or equivalent.
b. Lift frame so that the cutterbar is slightly off the
ground.
c. Remove bolt (A) securing shipping wedge (B)
at the lower lift link and remove wedge.
CAUTION
Do not drive out this bolt. If carrier frame
is lifted high enough, bolt becomes free to
remove.
d. Remove wheel bolts from wheel hub.
CAUTION
When installing wheel be sure to use the
holes that are countersunk to match bolt
head profile. The uncountersunk holes do
not seat the bolts correctly.
e. Install wheel with existing bolts. Be sure valve
stem points away from wheel support.
f. Torque bolts to 120 ft lb (160 N·m) following
tightening sequence shown.
IMPORTANT
Follow proper bolt tightening sequence
shown.
g. Lower carrier frame and repeat steps a. to f.
for other end of carrier frame.
h. Check tires inflated to 30 psi (207 kPa).
5
4
3
2
1
6
A
B