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UNLOADING AND ASSEMBLY

Form # 169089

100

Model Year - 2010

10 UNLOADING AND ASSEMBLY

Refer to R80 Rotary Disc Self-Propelled Windrower Header Unloading & Assembly Instructions,
#169079 and Pre-Delivery Checklist that is included with your shipment.

Summary of Contents for R80

Page 1: ...R80 Rotary Disc Self Propelled Windrower Header OPERATOR S MANUAL Model Year 2010 Part 169089 15...

Page 2: ...R80 ROTARY DISC SELF PROPELLED WINDROWER HEADER...

Page 3: ...atalog 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 spe...

Page 4: ...TART UP CHECK 21 6 10 SHUTDOWN PROCEDURE 22 6 11 UNPLUGGING THE HEADER 22 6 12 HEADER OPERATION 23 6 12 1 Disc Speed 23 6 12 2 Cutting Height 23 6 12 3 Header Angle 24 6 12 4 Header Flotation 24 6 12...

Page 5: ...e Belt 66 7 9 4 Conditioner Drive Belt Idler 70 7 9 5 Lifting Roll Drive Belt 71 7 9 6 Lifting Roll Belt Idler 72 7 9 7 Lifting Roll Idler Bearing 72 7 9 8 Hourglass Deflector Drive Belts 16 Ft Only 7...

Page 6: ...at 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...

Page 7: ...SAFETY Form 169089 5 Model Year 2010 2 3 2 Safety Sign Locations 2 PLCS 148829 32738 BOTH SIDES 134070 170281 109843...

Page 8: ...SAFETY Form 169089 6 Model Year 2010 Safety Sign Locations continued 1 PLC 36651 1 PLC BOTH SIDES 142909...

Page 9: ...maintained and be familiar with its proper use x Keep young children away from machinery at all times x Be aware that accidents often happen when the operator is tired or in a hurry to get finished Ta...

Page 10: ...tools are properly grounded x Use adequate light for the job at hand x Keep machinery clean Do not allow oil or grease to accumulate on service platforms ladders or controls Clean machines before stor...

Page 11: ...et per minute ft s feet per second gpm U S gallons per minute hp horsepower in 3 cubic inches kPa kilopascals lbf pounds force lbf ft or ft lbf pound feet or foot pounds lbf in or in lbf pound inches...

Page 12: ...del Year 2010 4 COMPONENT IDENTIFICATION GRASS SEED HEADER STANDARD HEADER FRONT CURTAIN TALL CROP TRANSITION SHIELD HOSE SUPPORT FRONT CURTAIN CENTER LINK BAFFLE CONTROL DRIVE MOTOR DOOR DRIVE SHIELD...

Page 13: ...Cutting Angle Range 0 8 Deg Below Horizontal Geartrain Protection Shearable Disc Spindles Deflectors 2 Hourglass Converging 6 Hourglass Converging Grass Seed Deflectors 4 Converging Drums 1000 rpm Ma...

Page 14: ...ize and mass 6 2 OPERATIONAL SAFETY Follow these safety precautions CAUTION x Follow all safety and operational instructions given in your windrower Operator s Manual If you do not have a windrower ma...

Page 15: ...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 gr...

Page 16: ...ition 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 ho...

Page 17: ...three hose bundle to forward and aft valve blocks as shown m Move windrower platform to closed position 6 3 1 2 HEADER CONNECTIONS a Remove caps and plugs from hoses and lines b Connect the three hose...

Page 18: ...d 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 an...

Page 19: ...s and plugs from hoses and lines k Connect the three hoses from windrower to the fittings on the header as shown l Connect harness from windrower to electrical connector m Move windrower platform to c...

Page 20: ...ower shut off engine engage parking brake and remove key 6 4 1 M200 13 FT 16 FT a Move LH cab forward platform to rear of windrower b Disconnect the two hydraulic couplers from windrower valve c If gr...

Page 21: ...ndrower platform back to closed position m Detach header from windrower Refer to the M150 M200 Self Propelled Windrower Operator s Manual for procedures for mechanically detaching the header from the...

Page 22: ...ack to closed position l Detach header from windrower Refer to the M150 M200 Self Propelled Windrower Operator s Manual for procedures for mechanically detaching the header from the self propelled win...

Page 23: ...n drive belt Refer to Section 7 9 3 b Lubricate machine completely Refer to Section 7 7 Lubrication c Perform all annual maintenance See Section 7 12 Maintenance Schedule 6 9 DAILY START UP CHECK CAUT...

Page 24: ...tion Wait for all movement to stop 6 11 UNPLUGGING THE HEADER DANGER Stop windrower engine and remove key before removing plugged material from header A child or even a pet could engage the drive a St...

Page 25: ...ow CROP CONDITION DISC RPM Heavy 2300 2500 Alfalfa Light 1600 2000 Sudan Sorghum Haygrazer Timothy Tall Stemmy 2300 2500 Dense 2500 Short Grass Thin 1800 2000 Disc speeds are set and adjusted from the...

Page 26: ...site end of header 6 12 3 Header Angle Header or cutterbar angle can be varied from 0 8 below horizontal Choose an angle that maximizes performance for your crop and field conditions A flatter angle p...

Page 27: ...Grass type crops may require less gap for proper feeding and conditioning 6 12 5 1 Roll Gap Adjustment To adjust the roll gap refer to following illustration and proceed as follows DANGER Stop engine...

Page 28: ...ditions 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 Check roll timing distance X at each end of...

Page 29: ...frame g Store gauge B inside RH panel with bolt A and nut 6 12 6 Roll Tension The roll tension the force holding the rolls together is factory set to maximum and is adjustable DANGER Stop engine and r...

Page 30: ...the weather allows only a few days to cut and bale Refer to Section 6 13 Haying Tips for more information Where weather conditions permit or when drying is not critical for example when cutting for si...

Page 31: ...aise the deflector by pulling up on one side and then on the other side NOTE For even windrow formation be sure the deflector is not twisted c Tighten handles D to secure deflector position 6 12 7 3 B...

Page 32: ...asses the disc speed will need to be increased c In light crops the header speed can be reduced while maintaining ground speed NOTE Operating the header at the minimum disc speed will extend the wear...

Page 33: ...10 Windrow Forming Rods Grass seed headers are equipped with windrow forming rods which assist in forming the narrow windrows preferred for this application A rod assembly is installed on the windrow...

Page 34: ...when operating the header with the tall crop transition shield in grass seed 6 12 13 Tall Crop Transition Shield Grass Seed The tall crop transition shield deflects the grass seed heads down and into...

Page 35: ...or tedding will expose the hay to fresher less saturated air e Cutting hay perpendicular to the direction of the prevailing winds is also recommended 6 13 4 Windrow Characteristics It is recommended...

Page 36: ...eight off tires e Repaint all worn or chipped painted surfaces to prevent rust f Loosen drive belts g Lubricate the header thoroughly leaving excess grease on fittings to keep moisture out of bearings...

Page 37: ...ng clothing and cover long hair Never wear dangling items such as scarves or bracelets x Wear protective shoes with slip resistant soles a hard hat protective glasses or goggles and heavy gloves x If...

Page 38: ...5 7 3 1 1 SAE Bolts NC BOLT TORQUE SAE 5 SAE 8 BOLT DIA A in lbf ft N m lbf 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...

Page 39: ...pe Hydraulic Fittings a Inspect O ring and seat for dirt or obvious defects b On angle fittings back off the lock nut until washer A bottoms out at top of groove B in fitting c Hand tighten fitting un...

Page 40: ...t 16 Ft High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base As Required Unless Otherwise Specified SAE Multi Purpose High Temp Extreme Pressure EP Per...

Page 41: ...ascals kPa Pressure pounds per square inch psi x 00689 megapascals MPa pound feet or foot pounds lbf ft or ft lbf x 1 3558 newton meters N m Torque pound inches or inch pounds lbf in or in lbf x 0 112...

Page 42: ...ion b To close lower shield and engage pin C in frame c Place rubber latch A in hook 7 6 CUTTERBAR DOORS WARNING x Do not operate the machine without all the cutterbar doors down curtains installed an...

Page 43: ...n before leaving operator s seat for any reason A child or even a pet could engage an idling machine a Use the recommended lubricants specified in this manual See 7 3 2 Recommended Lubricants b Wipe g...

Page 44: ...Year 2010 I 13 FT HEADER DRIVELINE UNIVERSALS 2 PLCS ROLL SHAFT BEARINGS 3 PLCS BELT TENSIONER PIVOT 1 PLC DRIVELINE UNIVERSALS 2 PLCS DRIVELINE SHAFT 2 PLCS 10 MOLY GREASE IS RECOMMENDED FOR DRIVELIN...

Page 45: ...d DRIVELINE UNIVERSALS SHAFT 3 PLCS ONE SIDE LIFTING ROLL SHAFT BEARING ROLL SHAFT BEARINGS 2 PLCS 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINT ONLY High Temp Extreme Pressure EP2 Per...

Page 46: ...NSIONER PIVOT 1 PLC High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base CHECK PLUG Oil should slightly run out when removed DRIVELINE UNIVERSALS 2 PLC...

Page 47: ...reme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base ROLL SHAFT BEARINGS 3 PLCS OPTIONAL GAUGE ROLL BEARINGS 2 PLCS BOTH SIDES DRIVELINE UNIVERSALS 2 PLCS DRIVESHAF...

Page 48: ...EADER GEARBOX OIL LEVEL CHECK PLUG Oil should slightly run out when removed OPTIONAL GAUGE ROLL BEARINGS 2 PLCS BOTH SIDES CONVERGING DRUMS 2 PLCS BOTH SIDES DRIVELINE UNIVERSALS 2 PLCS DRIVESHAFT 1 P...

Page 49: ...is only on one side of the bearing c Install but do not tighten the flangette bolts E d When the shaft is correctly located lock the lock collar with a punch NOTE The collar should be locked in the sa...

Page 50: ...before going under machine for any reason CAUTION Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades 7 8 1 1 Removal a Rais...

Page 51: ...r machine for any reason CAUTION Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades a Locate forward end of rock guard D ont...

Page 52: ...e and remove key DANGER To avoid bodily injury or death from unexpected start up or fall of raised machine stop engine remove key and engage header lift cylinder stops before going under machine for a...

Page 53: ...til you are sure all bystanders have cleared the area d Start engine and lower header onto blocks Stop engine and remove key DANGER Stop engine and remove key from ignition before leaving operator s s...

Page 54: ...R 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 Open cutterbar door s CAUTION Exercise caution when work...

Page 55: ...ution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades a Position new disc C on spindle ensuring it is 90 degrees to the adjacent discs b I...

Page 56: ...two bolts G e If driveline disc is being installed 1 Lift deflector N and driveline and slide disc O onto spindle 2 Locate deflector N and driveline onto disc O 3 Install bolts P and torque to 92 ft...

Page 57: ...ld engage an idling machine a Check daily that the cutter blades are securely attached to the disc b Check blades for cracks or wear beyond safe operating limits and distortion c Replace blades immedi...

Page 58: ...y b Engage lift cylinder lock out valves c Open cutterbar door s d Rotate disc A so that blade B faces forward and lines up with hole C in rock guard e Place a block of wood between two discs to preve...

Page 59: ...or wear or damage and replace bolt if 1 Bolt has been removed and installed five times 2 Head is worn flush with bearing surface of blade 3 Diameter of bolt neck is worn out of specification 4 Bolt is...

Page 60: ...from disc D Do not remove cutterblade bolt unless it or the blade are being replaced Repeat for other accelerator 7 8 5 2 Installation a Locate accelerator on disc onto existing cutterblade bolt and...

Page 61: ...ve key b Engage header lift cylinder lock outs c Open door s 7 8 6 1 Driveline Deflector NOTE Procedure is the same for both 13 and 16 ft headers 16 ft is shown CAUTION Cutter blades have two cutting...

Page 62: ...isc H b Align cut outs in base of deflector with cutter blades c Install four bolts F and torque to 92 ft lbf 125 N m d Position guard E and tighten bolts D e Position guard C and attach with two bolt...

Page 63: ...moval a Place a block of wood between two discs to prevent deflector from turning b Remove four bolts A and remove deflector B Installation a Position deflector B on disc C and install bolts A and tor...

Page 64: ...deflector from turning b Remove bolts A and remove cover B c Remove four bolts C and remove drum D Installation a Install drum D and secure with four bolts C Ensure plate E is correctly positioned b T...

Page 65: ...ry installed on grass seed headers 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 7 8 7 1 Installati...

Page 66: ...quired trimming to properly locate on disc Locate feed plate D on disc and scribe a trim line on feed plate to clear the accelerators E Trim feed plate to suit h Re position deflector C and align hole...

Page 67: ...ase drain hose C from fitting and install caps on tube end and motor fitting e Remove four bolts D and remove motor E f Cover gearbox opening F with a rag or plastic 7 9 1 2 Installation a Remove cove...

Page 68: ...oner 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 7 9 3 1 Tension Adjustment Conditioner Drive Bel...

Page 69: ...Model Year 2010 e Adjust belt tension by adjusting the length of the spring to the values in the following table NUMBER OF VISIBLE COILS MEASUREMENT X 23 7 75 8 15 inches 197 207 mm 24 8 11 8 5 inches...

Page 70: ...off pulley E and drive pulley F d Remove nut and bolt G and pull U joint off shaft e Slip belt off driveline H 7 9 3 3 Conditioner Drive Belt Installation 16 FT a Slip belt C over driveshaft H at inb...

Page 71: ...D between pulley G and driveline f Slip belt off drive pulley to remove it 7 9 3 5 Conditioner Drive Belt Installation 13 FT a Slip belt D between pulley G and driveline F b Locate belt onto drive pul...

Page 72: ...er header to ground turn off engine and remove key b Open LH drive shield A c Loosen jam nut B d Turn adjuster bolt C counter clockwise to release tension on spring until idler D and belt E are loose...

Page 73: ...idling machine a Lower header to ground turn off engine and remove key b Open RH drive shield B c Remove five bolts C and nuts and remove rear shield D d Insert the end of a inch drive socket wrench i...

Page 74: ...Install new idler C with bolt and nut B f Tighten nut to 150 ft lbf 203 N m g Reinstall belts See previous section h Re install rear shield See previous section i Close drive shield 7 9 7 Lifting Roll...

Page 75: ...elt should be 0 12 in 3 mm IMPORTANT To prolong belt and drive life do not over tighten belts d If necessary adjust as follows 1 Loosen nuts A 2 Loosen jam nut B on adjuster bolt C 3 Turn adjuster bol...

Page 76: ...quired g Tighten nuts B and jam nut C h Re install hourglass deflector Refer to Section 7 8 6 1 Driveline Deflector Driven Side RH a Loosen hourglass deflector drive belts F as follows 1 Loosen nuts G...

Page 77: ...1 Checking Oil The bevel gearbox oil level should be checked every 100 hours or once per year DANGER Stop engine and remove key from ignition before leaving operator s seat for any reason A child or...

Page 78: ...er lift cylinder locks Stop engine and remove key c Open LH drive shield A d Place a suitable container under drain plug C e Remove plugs B and C f Allow sufficient time for oil to drain g Replace plu...

Page 79: ...Move motor and hoses clear of work area e Remove three bolts A1 and lift off panel A2 f Remove bolts D securing sensor bracket E to gearbox and move sensor clear of work area g Loosen jam nut F and lo...

Page 80: ...e guard S k Rotate drum T so that wider space between bars face forward l Remove four bolts U m Pull driveline V through cage and slide U joint W off drive shaft n Remove four bolts X Support gearbox...

Page 81: ...rbox Y into position through top opening NOTE On 16 ft header ensure hourglass deflector drive belts are engaged onto gearbox shaft b Install four bolts X Torque to 106 ft lbf 144 N m c Position drive...

Page 82: ...ward pulley J k Route belt over idler F ensuring it is properly located on pulley H NOTE Check alignment of pulleys H and J l Tension drive belt G Refer to Section 7 9 3 1 Tension Adjustment m Positio...

Page 83: ...10 1 Conditioner Gearbox Removal 13 Foot 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 Lower head...

Page 84: ...arbox onto driveline g Remove bolts N and swivel driveline so that pulley and driveshaft O can be slipped off driveline h Loosen bolt P on lower U joint and slide yoke Q off gearbox i Remove eight bol...

Page 85: ...in drive compartment and secure with eight bolts S Torque to 92 ft lbf 125 N m b Ensure woodruff key is in shaft keyway and slide yoke Q onto gearbox shaft Tighten bolt P on U joint a Slide upper driv...

Page 86: ...en jam nut H e Re install panel G with five bolts and nuts F Install bolts from inside f Position LH drive shield on header and locate on existing pin S g Position pin E in shield and attach to frame...

Page 87: ...9 11 1 Conditioner Gearbox Removal 16 Foot 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 Lower h...

Page 88: ...nge yoke onto driveshaft N g Remove bolts O and swivel driveshaft N so that pulley can be slipped off driveline h Position driveline clear of work area i Loosen bolt Q on lower U joint and slide yoke...

Page 89: ...n conditioner gearbox T in drive compartment and secure with eight bolts S Torque to 92 ft lbf 125 N m b Ensure woodruff key is in shaft keyway and slide yoke R onto gearbox shaft Tighten bolt Q on U...

Page 90: ...n jam nut H g Re install panel G with five bolts F and nuts Install bolts from inside h Position LH drive shield on header and locate on existing pin U i Position pin E in shield and attach to frame w...

Page 91: ...nd pulley should be 0 08 in 2 mm d To adjust gap loosen bolts C and move bracket D to achieve gap Tighten bolts e To replace speed sensor 1 Remove bolts C and remove bracket D and sensor from gearbox...

Page 92: ...this type of injury or gangrene may result Use a piece of cardboard or paper to search for leaks IMPORTANT Keep hydraulic coupler tips and connectors clean Dust dirt water and foreign material are the...

Page 93: ...00 hours or Annually service the machine at whichever interval is reached first IMPORTANT Recommended intervals are for average conditions Service the machine more often if operated under adverse cond...

Page 94: ...aks 2 Check Cutter Blades For Security And Condition 3 Check Hourglass Deflectors For Security And Condition 25 HOURS 1 Grease Cutterbar Driveline Bearings 2 Grease Roll Universal Shafts Except Grass...

Page 95: ...on 6 14 STORAGE 10 HOURS OR DAILY 9 Hydraulic Hoses Lines 9 Cutter Blades Deflectors Discs 25 HOURS 6 Roll Universal Shafts 6 Cutterbar Driveline Bearings NOTE A RECORD OF DAILY MAINTENANCE IS NOT NOR...

Page 96: ...peed Reduce ground speed 6 12 8 Downed crop Adjust header angle to cut closer to ground 6 12 3 Strips Of Uncut Crop Left On Field Bent cutter blades Replace blades 7 8 4 3 Build up of dirt between roc...

Page 97: ...l blades Replace blades or turn blades over 7 8 4 3 Ground speed too fast Reduce ground speed 6 12 8 Not Cutting Short Enough In Down Crop Cutting height too high Adjust header angle to lower cutting...

Page 98: ...n cutterbar 6 11 Spindle bearing failure Replace spindle bearing See MacDon Dealer Material wrapped around spindle Remove disc and remove material 7 8 3 1 Cutting too low in rocky field conditions Dec...

Page 99: ...Mud on cutterbar Remove mud from cutterbar Do not allow mud to dry on cutterbar 6 11 Hoses not connected Connect hoses 6 3 Poor connection at valve Check connection at windrower See windrower manual H...

Page 100: ...te lift kit consists of spacer assemblies that attach to the existing skid plates to increase the ground clearance by approximately 2 inches 51 mm The kit includes four assemblies and attachment hardw...

Page 101: ...tion instructions 9 8 11 DEGREE BEVEL UP CUTTERBLADES 11 bevel up cutter blades provide good cutting performance for general cutting conditions where the occurrence of hitting a stone and bending the...

Page 102: ...LY Form 169089 100 Model Year 2010 10 UNLOADING AND ASSEMBLY Refer to R80 Rotary Disc Self Propelled Windrower Header Unloading Assembly Instructions 169079 and Pre Delivery Checklist that is included...

Page 103: ...ce 52 removal 52 Disc Speed 23 Double Windrowing 31 Driving on Windrow 33 Drying Agents 33 Electrical lights and wiring 90 Feed Plates 63 Float 24 Forming Shields 28 rear deflector 29 side deflectors...

Page 104: ...40 Shut Down 22 Skid Plate Lift Kit 98 Skid Shoes 24 48 Specifications 11 maintenance 36 Speed Sensor 89 Storage 34 Tall Crop Divider Kit 98 Tall Crop Feed Plates 63 Tall Crop Transition Shield 32 99...

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