MacDon R85 Assembly Instructions Manual Download Page 14

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214367

Revision A

1009204

Figure 2.3: Moving Header with Forklift

Back up until the unit clears trailer, and slowly lower to
150 mm (6 in.) from the ground.

Take to storage or setup area.

Set machine down on secure, level ground.

If hydraulic motor and hoses are shipped separately on
pallet, unload pallet.

Check for shipping damage and missing parts.

UNLOADING THE HEADER

Summary of Contents for R85

Page 1: ...R85 Rotary Disc 4 9 Meter 16 Foot Self Propelled Windrower Header Unload and Assembly Instructions 214367 Revision A 2018 Model Year Original Instruction The harvesting specialists ...

Page 2: ...R85 Rotary Disc 4 9 Meter 16 Foot Self Propelled Windrower Header 1005291 Published August 2017 ...

Page 3: ...s Failure to do so may compromise machine function and machine life and may result in a hazardous situation Conventions The following conventions are used in this document Right and left are determined from the operator s position facing forward with the windrower in cab forward position Unless otherwise noted use the standard torque values provided in Chapter 5 Reference page 97 of this document ...

Page 4: ...ic description 3 12 Attaching Header to an M1 Series Windrower page 45 Updated procedure steps and illustrations 3 12 1 Attaching Header to an M1240 Windrower Hydraulic Center Link with Optional Self Alignment page 45 Updated illustration 3 12 2 Attaching Header to an M1240 Windrower Hydraulic Center Link without Optional Self Alignment page 50 Added steps for connecting header to M205 windrower u...

Page 5: ... M1240 Windrower page 84 Updated procedure illustrations 4 4 Checking Header Level page 86 Added note and steps to procedure Updated figure title description 4 5 1 Checking Conditioner Roll Gap page 88 Added hazard statement and steps 4 5 2 Checking Conditioner Roll Timing page 89 Reordered procedure steps 4 8 Preparing the Conditioner Roll Timing Gearbox page 93 Updated illustration to show new l...

Page 6: ......

Page 7: ...er to an M200 or M205 Windrower Hydraulic Center Link without Optional Self Alignment 36 3 11 3 Attaching Header to an M200 Windrower Mechanical Center Link 41 3 12 Attaching Header to an M1 Series Windrower 45 3 12 1 Attaching Header to an M1240 Windrower Hydraulic Center Link with Optional Self Alignment 45 3 12 2 Attaching Header to an M1240 Windrower Hydraulic Center Link without Optional Self...

Page 8: ...Conditioner Rolls 88 4 5 1 Checking Conditioner Roll Gap 88 4 5 2 Checking Conditioner Roll Timing 89 4 6 Checking Gauge Rollers or Skid Shoes 91 4 7 Preparing the Bevel Gearbox 92 4 8 Preparing the Conditioner Roll Timing Gearbox 93 4 9 Checking Lights 94 4 10 Checking Manuals 95 4 11 Running up the Header 96 Chapter 5 Reference 97 5 1 Torque Specifications 97 5 1 1 SAE Bolt Torque Specifications...

Page 9: ...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 use...

Page 10: ...goggles Heavy gloves Wet weather gear Respirator or filter mask 1000005 Figure 1 2 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable hearing protection devices such as earmuffs or earplugs to help protect against loud noises 1010391 Figure 1 3 Safety Equipment Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on ...

Page 11: ...machine function and or safety It may also shorten machine s life To avoid bodily injury or death from unexpected startup of machine ALWAYS stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000009 Figure 1 6 Safety around Equipment Keep service area clean and dry Wet or oily floors are slippery Wet spots can be dangerous when working with elect...

Page 12: ...eep 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 repair part also bears current safety sign Safety signs are available from your MacDon Dealer SAFETY ...

Page 13: ...1 mm 78 in IMPORTANT Forklifts are normally rated for a load located 610 mm 24 in ahead of the back end of the forks To obtain the forklift capacity at 1220 mm 48 in check with your forklift distributor Table 2 1 Lifting Vehicle Minimum Capacity 3630 kg 8000 lb Minimum Fork Length 198 cm 78 in 1009203 Figure 2 2 Lifting Header off Trailer 1 Remove hauler s tie down straps and chains WARNING Be sur...

Page 14: ... unit clears trailer and slowly lower to 150 mm 6 in from the ground 5 Take to storage or setup area 6 Set machine down on secure level ground 7 If hydraulic motor and hoses are shipped separately on pallet unload pallet 8 Check for shipping damage and missing parts UNLOADING THE HEADER ...

Page 15: ...A B Figure 3 1 Shipping Support 1 Use a forklift to support stand 2 Remove two bolts A on each end of support and remove shipping support B Lay support on ground 1009206 A B Figure 3 2 Auger Pan Attached to Shipping Support 3 Cut banding A and remove auger pan B and hardware from stand Discard stand 4 Locate the hardware bag strapped between auger pan B and the stand ...

Page 16: ...heck and make sure that center pan is position evenly before tightening Tighten enough so nut is locked and pan can still pivot 8 Retrieve plates C from hardware bag and install as shown at each end of pan with four 1 2 x 1 0 in bolts D Tighten hardware NOTE There may be a gap between the cutterbar lugs and the auger pan when tightening the hardware The hardware does not need to pull the auger pan...

Page 17: ...ily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Lower header to the ground shut off engine and remove key from ignition 2 Unpack kit 1009207 Figure 3 4 Skid Shoe Right Side Shown Left Side Similar 3 Install skid shoes Refer to instruction supplied with kit ASSEMBLING THE HEADE...

Page 18: ...stalled later in the assembly sequence but installation may be easier prior to laying the header down 1009208 Figure 3 5 Gauge Roller Right Side Shown Left Side Similar 1 Unpack gauge roller bundle and install gauge rollers Refer to instruction supplied with kit ASSEMBLING THE HEADER ...

Page 19: ...ks IMPORTANT Length of spreader bar must be approximately 4 6 m 15 ft CAUTION Ensure spreader bar is secured to the forks so that it cannot slide off the forks or towards the mast as the header is lowered to the ground 2 Drive lifting vehicle to approach header from its underside 3 Attach chains to hooks B on both sides of header IMPORTANT Chain length must be sufficient to provide a minimum 1 2 m...

Page 20: ...11633 1 2 3 Figure 3 7 Lowering Header to the Ground CAUTION Stand clear when lowering the header 5 Back up SLOWLY while simultaneously lowering header until cutterbar rests on ground 6 Remove chains from header ASSEMBLING THE HEADER ...

Page 21: ...9 A Figure 3 8 Banding on Baffle 1 Cut and remove banding A from baffle 1009218 A B Figure 3 9 Shipping Stand Left Side Shown Right Side Opposite 2 Remove plate A from left shipping stand B and set aside with hardware for reinstallation ASSEMBLING THE HEADER ...

Page 22: ...n Right Side Opposite 4 Remove bolt A securing shipping stand to header lifting arm 5 Remove hairpin from pin B 6 Hold shipping stand and remove pin B 7 Remove stand C and discard Reinsert pin B in header lifting arm and secure with lynch pin 8 Repeat Step 3 page 14 to Step 7 page 14 for other stand 1009215 A Figure 3 12 Shipping Stands 9 Raise baffle A with handle and temporarily secure in raised...

Page 23: ...in hardware 1009216 A B Figure 3 14 Shipping Stand Left Side Shown Right Side Opposite 11 Remove the two bolts A attaching shipping channel B to frame Retain hardware 12 Remove wire and lower baffle so that channel can be removed 13 Remove and discard channel B 1009211 A Figure 3 15 Frame with Shipping Stand Removed 14 Reinstall two bolts A through frame and tighten ASSEMBLING THE HEADER ...

Page 24: ... and lock nuts into cover support and tighten 1009253 A Figure 3 17 Shipping Hook 16 Remove hooks A at front corners Reinstall hardware NOTE If tall crop divider option will be installed do not reinstall hardware 1009349 A Figure 3 18 Swath Baffle 17 Remove wire and lower baffle A ASSEMBLING THE HEADER ...

Page 25: ...uts Do NOT tighten 3 Remove bolt B 4 Remove lynch pin from clevis pin D and remove clevis pin from lever C 1009353 D C A G E F B Figure 3 20 Adjuster Plate and Swath Baffle Lever 5 Move swath baffle lever C to middle hole in bracket A and reinstall clevis pin D through lever and bracket 6 Secure with lynch pin 7 Tighten bolts G NOTE Baffle position may need to be adjusted for proper pin engagement...

Page 26: ...from around curtains 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 1006052 A B Figure 3 22 Export Headers Latch on Cutterbar Doors 3 For export headers insert a screwdriver or equivalent through hole A in door into notch in latch B and push latch to ...

Page 27: ...area for debris and foreign objects Ensure all material is removed 1009313 Figure 3 24 Curtain Unacceptable 6 Close cutterbar doors Ensure that curtains hang properly and completely enclose cutterbar area Minor creases in curtains will eventually straighten out 1009314 Figure 3 25 Curtain Acceptable ASSEMBLING THE HEADER ...

Page 28: ...vision A 1006055 A Figure 3 26 Cutterbar Door Latch 7 For export headers ensure latches A engage cutterbar doors 1006051 A Figure 3 27 Curtain Latches 8 Fasten latches A at corners of curtains ASSEMBLING THE HEADER ...

Page 29: ... 9 Remove shipping edge trim A 10 Close the shields B over the two shipping tie down holes and tighten nuts C 1009311 A A Figure 3 29 Shipping Material around Hoses 11 Remove shipping wire banding and protective packing A from hydraulic hoses ASSEMBLING THE HEADER ...

Page 30: ...4 A B Figure 3 30 Cover in Shipping Configuration 1 Remove bolts A and remove cover B from shipping position 2 Replace bolts A into existing holes 1009255 A Figure 3 31 Hardware on Edge of Hood 3 Remove six carriage bolts A along aft edge ASSEMBLING THE HEADER ...

Page 31: ...214367 23 Revision A 1009355 A B B B Figure 3 32 Cover Installed 4 Position cover A on hood as shown and secure with six carriage bolts B and lock nuts ASSEMBLING THE HEADER ...

Page 32: ...D E Figure 3 34 Forming Shield Cover Right Side Up 4 Install rubber strap A to the side bracket B using bolt C washer D and nut E 5 Repeat for the other side 1018394 A B C Figure 3 35 Forming Shield Cover Upside Down 6 Lay cover A upside down on a flat surface 7 Install the center deflectors B using three bolts and nuts C on each side NOTE The narrow end of deflector B faces the front and the deep...

Page 33: ...t A 9 Tighten flange nut A enough to hold deflectors C in position but still allow deflectors to move 10 Tighten jam nut E against cover while holding bolt B 1018396 A B C Figure 3 37 Positioning Adjuster Rod 11 Remove lynch pin A from adjuster rod B and position rod in hole in side deflector C Secure with lynch pin A 12 Repeat for other deflector ASSEMBLING THE HEADER ...

Page 34: ...rs Install hose support A to the left side of the top shield B and channel C using two bolts and nuts D 1023052 A B C C D D Figure 3 40 Hose Support 15 For M200 Self Propelled Windrowers Install hose support A to the left forming shield B using two bolts C and flange nuts D NOTE To operate the 4 9 meter 16 foot header on an M200 windrower installation of a motor hose kit MD B5455 is required ASSEM...

Page 35: ...op View A Two 11 mm 7 16 in Holes B Top Shield C Channel D Header Forward E 320 mm 12 6 in F 144 8 mm 5 7 in G 19 5 mm 0 77 in NOTE If there are no mounting slots for the hose support drill two 11 mm 7 16 in holes A through top shield B and channel C ASSEMBLING THE HEADER ...

Page 36: ...ld bundle NOTE Hardware is supplied with forming shield bundle 3 Attach plate A to windrower leg with two 1 2 x 5 1 4 in hex bolts B and nuts Repeat for opposite leg IMPORTANT Plate A is shown in standard position If installing double windrow attachment DWA install plate in inverted position 4 Install a 1 2 x 4 in hex bolt C with spacer D and nut on each plate Hardware is supplied with forming shi...

Page 37: ...Windrower Frame 6 Position the forming shield A under the windrower frame 1005182 A B Figure 3 45 Attaching Forming Shield to Windrower Legs 7 Position the forming shield onto spacers B on windrower legs Secure with clevis pins A and lynch pin ASSEMBLING THE HEADER ...

Page 38: ...all washer and hairpin to secure strap Use the middle hole and adjust height to suit the crop 1018398 A B C Figure 3 47 Adjusting Forming Shield 9 Set the forming shield side deflectors to the desired width by repositioning adjuster bars A Use the same hole location on both sides 10 Adjust rear fluffer deflector C to middle position Loosen handles B if required ASSEMBLING THE HEADER ...

Page 39: ...11 2 Attaching Header to an M200 or M205 Windrower Hydraulic Center Link without Optional Self Alignment page 36 3 11 3 Attaching Header to an M200 Windrower Mechanical Center Link page 41 NOTE Refer to your windrower operator s manual for windrower operating instructions 3 11 1 Attaching Header to an M200 or M205 Windrower Hydraulic Center Link with Optional Self Alignment 1021748 A B C Figure 3 ...

Page 40: ...it may contact the header as the windrower approaches the header for hookup 1008942 A Figure 3 51 Ground Speed Lever 3 Activate the REEL UP switch A on the GSL to raise the center link until the hook is above the attachment pin on the header 1000780 B A Figure 3 52 Header Support 4 Drive the windrower slowly forward until the windrower feet A enter the header supports B Continue driving slowly for...

Page 41: ...ing mechanism If the release is open up manually push it down after hook engages header pin 7 Lower center link A onto the header with REEL DOWN switch until it locks into position hook release B is down 8 Check that center link is locked onto header by pressing the REEL UP switch on the GSL CAUTION Check to be sure all bystanders have cleared the area 1008946 A Figure 3 55 Ground Speed Lever 9 Pr...

Page 42: ...te towards the header to release and lower safety prop B onto the lift cylinder c Repeat for opposite lift cylinder 1021447 A B Figure 3 57 Header Support 12 Install clevis pin A through support and windrower lift member and secure with hairpin B Repeat for opposite side IMPORTANT Ensure clevis pin A is fully inserted and hairpin is installed behind bracket ASSEMBLING THE HEADER ...

Page 43: ...Lever 14 Disengage safety prop by turning lever A downwards to release and lower stop until lever locks into vertical position 15 Repeat for opposite safety prop 1008947 A Figure 3 60 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 16 Start the engine and activate the HEADER DOWN switch A on the GSL to fully lower the header 17 Stop engine and remove key from ignit...

Page 44: ...operator s seat for any reason 1021748 A B C Figure 3 61 Header Support 1 Remove hairpin B from clevis pin A and remove clevis pin from the header supports C on both sides of the header 1008712 A B Figure 3 62 Header Float Linkage CAUTION To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to the windrower ensure the float engagement pin ...

Page 45: ... Relocate pin A in frame linkage as required to raise the center link B until the hook is above the attachment pin on the header IMPORTANT If the center link is too low it may contact the header as the windrower approaches the header for hookup 1000780 B A Figure 3 65 Header Support 4 Drive the windrower slowly forward until the windrower feet A enter the header supports B Continue driving slowly ...

Page 46: ...nism If the release is open up manually push it down after hook engages header pin 8 Check that center link A is locked onto header by pulling upward on rod end B of cylinder 1008946 A Figure 3 68 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 9 Start the engine 10 Press the HEADER UP switch A to raise header to maximum height 11 If one end of the header does NOT ...

Page 47: ...te towards the header to release and lower safety prop B onto the lift cylinder c Repeat for opposite lift cylinder 1021447 A B Figure 3 70 Header Support 13 Install clevis pin A through support and windrower lift member and secure with hairpin B Repeat for opposite side IMPORTANT Ensure clevis pin A is fully inserted and hairpin is installed behind bracket ASSEMBLING THE HEADER ...

Page 48: ...Lever 15 Disengage safety prop by turning lever A downwards to release and lower stop until lever locks into vertical position 16 Repeat for opposite safety prop 1008947 A Figure 3 73 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 17 Start the engine and activate the HEADER DOWN switch A on the GSL to fully lower the header 18 Stop engine and remove key from ignit...

Page 49: ...rom the header supports C on both sides of the header 1008712 A B Figure 3 75 Header Float Linkage CAUTION To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to the windrower ensure the float engagement pin is installed in storage position B and NOT in engaged position A 1008925 A Figure 3 76 Ground Speed Lever CAUTION Check to be sure a...

Page 50: ...with cotter pin D 7 Adjust length of link to achieve proper header angle by rotating barrel B Tighten nut A against barrel a slight tap with a hammer is sufficient 1008946 A Figure 3 79 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 8 Start the engine 9 Press the HEADER UP switch A to raise header to maximum height 10 If one end of the header does NOT fully raise ...

Page 51: ...te towards the header to release and lower safety prop B onto the lift cylinder c Repeat for opposite lift cylinder 1021447 A B Figure 3 81 Header Support 12 Install clevis pin A through support and windrower lift member and secure with hairpin B Repeat for opposite side IMPORTANT Ensure clevis pin A is fully inserted and hairpin is installed behind bracket ASSEMBLING THE HEADER ...

Page 52: ...Lever 14 Disengage safety prop by turning lever A downwards to release and lower stop until lever locks into vertical position 15 Repeat for opposite safety prop 1008947 A Figure 3 84 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 16 Start the engine and activate the HEADER DOWN switch A on the GSL to fully lower the header 17 Stop engine and remove key from ignit...

Page 53: ...enter Link with Optional Self Alignment DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000812 A B C Figure 3 85 Header Support 1 Remove hairpin B from clevis pin A and remove pin from header support C on both sides of header IMPORTANT Remove protective cover...

Page 54: ...move the header float NOTE If the header float is active the icon at soft key 3 will say REMOVE FLOAT if header float has been removed the icon will say RESUME FLOAT 1018911 A B C D E F Figure 3 89 GSL A Reel Down B Reel Up C Header Tilt Down D Header Tilt Up E Header Down F Header Up 6 Press HEADER DOWN switch E on the ground speed lever GSL to fully retract header lift cylinders 7 Press REEL UP ...

Page 55: ...fter the hook engages the header pin 11 Lower center link A onto the header with REEL DOWN switch on GSL until it locks into position hook release C is down Refer to Figure 3 89 page 46 for GSL controls 12 Check that the center link is locked onto header by pressing the REEL UP switch on the GSL Refer to Figure 3 89 page 46 for GSL controls CAUTION Check to be sure all bystanders have cleared the ...

Page 56: ...its over the rod 1000814 A B Figure 3 94 Header Support 18 Install clevis pin A through support and foot and secure with hairpin B Repeat for opposite side IMPORTANT Ensure clevis pin A is fully inserted and hairpin is installed behind bracket 1014791 A Figure 3 95 Cylinder Safety Prop 19 Disengage safety prop by turning lever A downward to raise safety prop until lever locks into vertical positio...

Page 57: ... HPT Display 24 Turn scroll knob A to highlight left or right float setting and press knob A to activate selection 25 Rotate scroll knob A to adjust float setting and press knob when finished IMPORTANT Float adjustments of 1 0 out of 10 change the header weight at the cutterbar by approximately 91 kg 200 lb Adjust float in increments of 0 05 to optimize field performance 26 Stop the engine and rem...

Page 58: ...lignment Kit 1 Relocate pin A in frame linkage as required to raise the center link B until the hook is above the attachment pin on the header IMPORTANT If the center link is too low it may contact the header as the windrower approaches the header for hookup 1000812 A B C Figure 3 100 Header Boot 2 Remove hairpin B from clevis pin A and remove pin from header boots C on both sides of header IMPORT...

Page 59: ...ay to remove header float remove header float manually by doing the following 4 Press rotary scroll knob A on Harvest Performance Tracker HPT to highlight QUICK MENU options 5 Rotate scroll knob A to highlight the HEADER FLOAT symbol B and press scroll knob to select Screen changes 1015852 A Figure 3 103 HPT Display 6 Press soft key 3 A to remove the header float NOTE If the header float is active...

Page 60: ...r the header supports B Continue driving slowly forward until the feet engage the supports and the header nudges forward 9 Ensure that lift linkages are properly engaged in header legs 1014803 A B Figure 3 106 Ground Speed Lever 10 Press HEADER TILT UP A and HEADER TILT DOWN B cylinder switches on the GSL to extend or retract center link cylinder until the hook is aligned with the header attachmen...

Page 61: ...the HEADER UP switch A to raise header to maximum height NOTE If one end of the header does NOT raise fully rephase the cylinders as follows 1 Press and hold the HEADER UP switch A until both cylinders stop moving 2 Continue to hold the switch for 3 4 seconds Cylinders are now phased 15 Stop engine and remove the key from the ignition 1016103 A Figure 3 109 Cylinder Safety Prop 16 Engage safety pr...

Page 62: ...1014791 A Figure 3 111 Cylinder Safety Prop 18 Disengage safety prop by turning lever A downward to raise safety prop until lever locks into vertical position NOTE If safety prop will not disengage raise header slightly 19 Repeat for opposite side 1014802 A Figure 3 112 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 20 Start the engine and activate the HEADER DOWN...

Page 63: ...22 Rotate scroll knob A to highlight the HEADER FLOAT symbol B and press to select Screen changes 1015852 A Figure 3 114 HPT Display 23 Press soft key 3 A to restore the header float NOTE If the header float is active the icon at soft key 3 will say REMOVE FLOAT if header float has been removed the icon will say RESUME FLOAT 24 Stop engine and remove key 25 Proceed to 3 13 3 Attaching Hydraulics a...

Page 64: ... the ignition before leaving the operator s seat for any reason NOTE Factory installed hard plumb connections are ideal for attaching an R85 disc header s hydraulics on an M205 windrower If an auger header or draper header will also be used on a disc header ready M205 windrower quick couplers can be ordered and installed to make switching between these headers easier1 Routing hydraulic hose bundle...

Page 65: ...nder the windrower frame and insert pin B into hole in windrower frame 3 Place hoses on support C and on the hose support on the forming shield not shown 1018909 A Figure 3 117 Protective Shipping Plugs on R85 Hydraulic Hoses 4 Remove protective plugs A from ends of hydraulic hoses ASSEMBLING THE HEADER ...

Page 66: ...emove coupler lock as follows a Remove lynch pin A and open up coupler lock B b Remove lock from coupler 1014315 A A B B E D C Figure 3 119 Hose Routing and Connections 2 Connect rear pump hose A to outboard line D on windrower using coupler C 3 Connect front pump hose B to inboard line E on windrower using coupler C ASSEMBLING THE HEADER ...

Page 67: ...ten bolts after adjusting 1005190 A B C Figure 3 121 Hydraulic Couplers with Coupler Lock 5 Lower holder A onto sleeves B so that the flats are positioned on the holder NOTE Holder can be adjusted by loosening bolts C Tighten bolts after adjusting 1005191 A B Figure 3 122 Hydraulic Couplers with Case Drain Hose 6 Insert lynch pin A to secure the lock 7 Attach case drain hose coupler at B 8 Proceed...

Page 68: ...rque fittings to 183 Nm 135 lbf ft 4 Attach case drain hose and coupler C to E 1010748 A Figure 3 124 Electrical Connection Valve Block Removed for Clarity 5 Connect the electrical harness to connector HC 2A A located beside the forward valve block on the windrower NOTE The R85 disc header ships with a factory installed electrical harness extension for compatibility with M1240 windrowers Remove th...

Page 69: ...ts M200 Windrowers DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1006058 Figure 3 126 MD B5455 Hydraulic Drive Kit IMPORTANT To operate the 4 9 meter 16 foot header on an M200 windrower a hydraulic drive kit MD B5455 is required Install kit in accordance wit...

Page 70: ...1 Disengage and rotate lever A counterclockwise to the UP position 2 Remove cap B securing the electrical connector to the frame 1005196 A Figure 3 128 Hose Bundle 3 Move hose bundle A from the windrower and rest the bundle on the header ASSEMBLING THE HEADER ...

Page 71: ...d adjust as required 1005198 A B C Figure 3 130 Hose Bundle 5 Route hose bundle A from the windrower through support B on header 6 Route header return and pressure hose bundle C through support B on header to the windrower 1005199 A B Figure 3 131 Hose Bundle 7 Secure hose bundles with three cinch straps B 8 Lower and lock lever A ASSEMBLING THE HEADER ...

Page 72: ...forward platform A to the OPEN position to access the valve blocks 1023085 M2 M2 R2 A Figure 3 133 Hydraulic Connections 10 Remove caps from pressure M2 and return R2 ports on the header drive manifold A and discard IMPORTANT Keep open lines and ports clean 11 Remove fitting at pressure port A and discard ASSEMBLING THE HEADER ...

Page 73: ...ng from cap A and install over JIC threads on fitting at return port R2 on header drive manifold 14 Install female coupler B from hose in return port R2 on header drive manifold 15 Install male 45 fitting C and male coupler D from hose in pressure port M2 on header drive manifold NOTE Male fitting and coupler may need to be disassembled prior to installing on valve block ASSEMBLING THE HEADER ...

Page 74: ...fold NOTE If the windrower is equipped with a reverser valve for an auger header replace the 90 fitting on return hose B with a 45 fitting 1006066 A B C D Figure 3 137 Header Connections 18 Remove caps and plugs from hoses and lines 19 Connect the pressure A return B and case drain C hoses from windrower to fittings on header as shown 20 Connect electrical harness D from windrower to connector on ...

Page 75: ...e used on a disc header ready M1240 windrower quick couplers can be ordered and installed to make switching between these headers easier2 1015479 A B Figure 3 139 Left Cab Forward Platform 1 Approach platform stair unit A on left cab forward side of windrower and ensure cab door is closed 2 Push latch B and pull platform A toward walking beam until it stops and latch engages ASSEMBLING THE HEADER ...

Page 76: ...1 Protective Shipping Plugs on R85 Hydraulic Hoses 5 Remove protective plugs A from ends of hydraulic hoses 6 Use a clean rag to remove dirt and moisture from the couplers 1020155 A B C Figure 3 142 Knife Drive Hose 7 Disconnect hose A from windrower receptacle B and place in storage cup C on multicoupler NOTE R85 hoses can be connected with either quick disconnect or hard plumbed fittings Refer t...

Page 77: ...with it If necessary increase slack in the hoses by loosening the hose holder at the windrower frame and moving the hoses as required 1018759 A B C D E Figure 3 144 Hard Plumbed Hydraulic and Electrical Connections Parts Removed for Clarity 9 Refer to the following to directly connect the hydraulic hoses with hard plumbed fittings to the windrower a Use a clean rag to remove dirt and moisture from...

Page 78: ...14367 70 Revision A 1015479 A B Figure 3 145 Left Cab Forward Platform 10 Push latch B to unlock the platform A 11 Pull platform A towards the cab until it stops and latch B engages ASSEMBLING THE HEADER ...

Page 79: ...from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1009278 Figure 3 146 Cutterbar Doors 1 Lower header fully 2 Stop the engine and remove the key 3 Unpack kit 4 Open cutterbar doors 1009277 A B Figure 3 147 Tall Crop Divider Kit Left Shown Right Side Opposite 5 Remove four bolts A from divider B NOTE ...

Page 80: ...ivider B on header left front corner and install with four bolts A and nuts in existing holes Tighten hardware 7 Repeat for right side 8 Lower cutterbar doors 3 14 2 Installing Double Windrow Attachment DWA 1000744 Figure 3 149 DWA Refer to instructions supplied with kit ASSEMBLING THE HEADER ...

Page 81: ...09207 Figure 3 150 Skid Shoe Right Side Shown Left Side Similar 3 Install skid shoes Refer to instruction supplied with kit 3 14 4 Installing Gauge Rollers Optional DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1009208 Figure 3 151 Gauge Roller Right Side Sh...

Page 82: ...s are included in the operator s manual 3 14 6 Installing Nut Protectors for Blade Hardware on Discs 1009362 A Figure 3 153 Nut Protector Storage Location Twelve nut protector caps A are supplied as standard equipment with each header These are shipped bolted to the tall crop feed plates The nut protectors can be used in place of the crop accelerators factory installed on each disc when cutting in...

Page 83: ...r drive systems requires opening the driveshield at the left end of the header When a procedure only applies to one configuration the configuration is specified in the procedure title Opening the Driveshield North American Headers Follow these steps to open the driveshield on North American headers 1006043 A B Figure 3 154 Driveshield 1 Release rubber latches A 2 Lift shield B Closing the Driveshi...

Page 84: ...quivalent through hole in shield B and into the notch in latch C and disengage latch 3 Open driveshield D Closing the Driveshield Export Headers Follow these steps to close the driveshield on export headers 1004395 C B A Figure 3 157 Driveshield 1 Lower shield C so that pins at lower end of shield engage holes in the lower panel and latch B re engages the driveshield 2 Engage rubber latches A ASSE...

Page 85: ...h to avoid injecting dirt and grit 2 Inject grease through fitting with grease gun until grease overflows fitting except where noted 3 Leave excess grease on fitting to keep out dirt 4 Replace any loose or broken fittings immediately 5 If fitting will not take grease remove and clean thoroughly Also clean lubricant passageway Replace fitting if necessary 3 15 3 Lubrication Points To identify the v...

Page 86: ... Driveline Universals Two Places B Roll Shaft Bearings Two Places C Driveline Universals Two Places D Driveline Shaft3 Two Places E Driveline Universals3 Two Places F Driveshaft One Place ASSEMBLING THE HEADER 3 10 moly grease is recommended for driveline shaft slip joint only ...

Page 87: ...n A Figure 3 160 Lubrication Points 1013946 A B D C A Roll Shaft Bearings Two Places B Optional Gauge Roll Bearings Two Places Both Sides C Belt Tensioner Pivot One Place D Auger Bearing One Place ASSEMBLING THE HEADER ...

Page 88: ......

Page 89: ...form final checks and adjustments as listed on the yellow sheet attached to back of this instruction to ensure the machine is field ready Refer to the referenced pages as indicated on the checklist for detailed instructions 2 The completed checklist should be retained either by the Operator or the Dealer 4 1 Checking Drive Belts Drive belt tensions have been properly set at the factory and should ...

Page 90: ...end of slots C are aligned with plate D CAUTION Check to be sure all bystanders have cleared the area 1006495 A Figure 4 3 Auger Belt Tension 4 Start engine 5 Raise header fully turn off engine and remove key Engage header safety props 6 To check auger belt tension spring length A should measure 262 mm 10 3 in 7 Lower header and close driveshield PERFORMING PREDELIVERY CHECKS ...

Page 91: ...ER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 4 Stop engine and remove key from ignition 5 Check float by grasping the front corner of header and lifting The force to lift should be 426 471 N 95 105 lbf and should be approximately the same at both ends 1009367 A...

Page 92: ...e same at both ends 6 Restart the engine and adjust float as required Refer to 4 3 1 Setting the Float M1240 Windrower page 84 NOTE Increasing the float value on the HPT makes the header feel lighter 4 3 1 Setting the Float M1240 Windrower The float can be set for windrowing with the cutterbar on the ground or with the cutterbar off the ground normally used with the draper header Cutterbar on Grou...

Page 93: ...knob A to highlight left B or right C float and press knob A to activate selection 6 Rotate scroll knob A to adjust float setting and press knob when finished Float is now set IMPORTANT Float adjustments of 1 0 out of 10 change the header weight at the cutterbar by approximately 91 kg 200 lb Adjust float in increments 0 05 to optimize field performance 7 Use soft key 3 D to remove resume float and...

Page 94: ...hat clearances A between header and ground at each end of the header are approximately the same 3 If header does NOT need levelling skip remaining steps If header DOES need levelling proceed as follows IMPORTANT The header float springs are NOT used to level the header 4 Observe which side of header is the high side and which is the low side CAUTION Check to be sure all bystanders have cleared the...

Page 95: ...age A lifts at windrower leg and off of shims 11 Shut down engine and remove key 1013914 A B C Figure 4 14 Header Lift Linkage Top View 12 On the high side linkage A remove nut washer and bolt C that attach shims B to link 13 Remove one or both shims B and reinstall the hardware C 14 Raise header approximately 150 mm 6 in off ground and check level of header 15 If additional levelling is required ...

Page 96: ...to Opening the Driveshield North American Headers page 75 or Opening the Driveshield Export Headers page 76 1005156 A B Figure 4 15 Roll Gap A Crop B Roll Gap 3 Check the size of the gap B between the conditioner rolls 1009339 A Figure 4 16 Conditioner Roll Gap Adjuster 4 Check the amount of thread A protruding from jam nut Length of protrusion should be 30 mm 1 3 16 in equal to 25 mm 1 in of roll...

Page 97: ...header fully to the ground 2 Shut down the engine and remove the key 1006111 A B Figure 4 17 Roll Timing A Timing Gap B Crop 3 Header should be on the ground and windrower should be shut down Ensure key is removed from ignition 4 Open driveshield For instructions refer to 3 15 1 Driveshields page 75 1009337 A B Figure 4 18 Roll Timing Gauge in Storage Position 5 Remove bolt A and nut and remove ga...

Page 98: ...ect 7 Manually turn rolls to release gauge WARNING Remove gauge from rolls and return it to storage location before starting machine 1009337 A B Figure 4 20 Roll Timing Gauge in Storage Position 8 Replace gauge B in header with bolt A and nut 1009338 A Figure 4 21 Conditioner Gearbox 9 Check timing flange bolts A are tight NOTE If rolls are out of time refer to the header operator s manual for pro...

Page 99: ...he windrower always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1009207 Figure 4 22 Skid Shoe 1 Raise header and engage header safety props 2 Both gauge rollers or skid shoes should be set at the same position 1009208 Figure 4 23 Gauge Roller PERFORMING PREDELIVERY CHECKS ...

Page 100: ...and remove bags A and B from the breather pipe elbows 1013945 A B Figure 4 26 Bevel Gearbox 4 Remove plug from breather pipe A and replace with breather cap in bag Discard bag and plug 5 Remove check plug B to check oil level Oil should slightly run out when removed NOTE If the oil level is low top up with a 75W90 synthetic gear lubricant with high thermal stability conforming to API GL 5 minimum ...

Page 101: ...r Gearbox 3 Cut cable ties and remove bags A and B from the breather pipe elbows 1009296 A B Figure 4 29 Conditioner Gearbox 4 Remove the plug from breather pipe A and replace it with the breather cap in bag Discard bag and plug 5 Remove check plug B to check oil level Oil should slightly run out when removed NOTE If the oil does not run out top up with a 75W90 synthetic gear lubricant with high t...

Page 102: ...s are mounted on both ends of the header and activated by a switch in the windrower cab 1023025 A B Figure 4 30 Hazard Light 1 Check for operation during run up 2 Ensure light mountings A are secure and check lights B for damage PERFORMING PREDELIVERY CHECKS ...

Page 103: ... A Figure 4 31 Manual Storage Case The following manuals should be stored in the manual storage case A on the right side of the header R85 Rotary Disc 4 9 Meter 16 Foot Header for Self Propelled Windrower Operator s Manual PERFORMING PREDELIVERY CHECKS ...

Page 104: ...e worn or damaged DANGER Before investigating an unusual sound or attempting to correct a problem shut off engine engage parking brake and remove key CAUTION Never start or move the machine until you are sure all bystanders have cleared the area Refer to the windrower operator s manual for windrower operating instructions NOTE Higher engine rpm may be required to engage the header Do NOT exceed 18...

Page 105: ...ular nuts by f 0 65 Self tapping screws Standard torque is to be used not to be used on critical or structurally important joints 5 1 1 SAE Bolt Torque Specifications Torque values shown in following tables are valid for non greased or non oiled threads and heads therefore do NOT grease or oil bolts or cap screws unless otherwise specified in this manual A 1004958 B C D Figure 5 1 Bolt Grades A No...

Page 106: ...12 105 116 77 86 5 8 11 144 160 107 118 3 4 10 259 286 192 212 7 8 9 413 456 306 338 1 8 619 684 459 507 A 1004958 B C D Figure 5 3 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Table 5 3 SAE Grade 8 Bolt and Grade G Distorted Thread Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 1 4 20 16 8 18 6 150 165 5 16 18 24 26 18 19 3 8 16 42 46 31 34 7 16 14 67 74 50 55 1 2 13 102 ...

Page 107: ...8 11 299 330 221 345 3 4 10 531 587 393 435 7 8 9 855 945 633 700 1 8 1165 1288 863 954 5 1 2 Metric Bolt Specifications 1001370 1001370 A Figure 5 5 Bolt Grades Table 5 5 Metric Class 8 8 Bolts and Class 9 Free Spinning Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 3 0 5 1 4 1 6 13 14 3 5 0 6 2 2 2 5 20 22 4 0 7 3 3 3 7 29 32 5 0 8 6 7 7 4 59 66 6 1 0 11 4 12 6 101 112 8 1 25 ...

Page 108: ...5 65 72 48 53 14 2 0 104 115 77 85 16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 1001370 1001370 A Figure 5 7 Bolt Grades Table 5 7 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 3 0 5 1 8 2 18 19 3 5 0 6 2 8 3 1 27 30 4 0 7 4 2 4 6 41 45 5 0 8 8 4 9 3 82 91 6 1 0 14 3 15 8 140 154 8 1 25 38 42 28 31 10 1 ...

Page 109: ...95 105 8 1 25 26 29 19 21 10 1 5 51 57 38 42 12 1 75 90 99 66 73 14 2 0 143 158 106 117 16 2 0 222 246 165 182 20 2 5 434 480 322 356 24 3 0 750 829 556 614 5 1 3 Metric Bolt Specifications Bolting into Cast Aluminum 1001370 1001370 A Figure 5 9 Bolt Grades Table 5 9 Metric Bolt Bolting into Cast Aluminum Nominal Size A Bolt Torque 8 8 Cast Aluminum 10 9 Cast Aluminum Nm lbf ft Nm lbf ft M3 1 M4 4...

Page 110: ...ghten nut E with other wrench to torque shown 5 Assess final condition of connection Table 5 10 Flare Type Hydraulic Tube Fittings SAE Dash Size Thread Size in Torque Value4 Flats from Finger Tight FFFT Nm lbf ft Tube Swivel Nut or Hose 2 5 16 24 4 5 3 4 3 3 8 24 7 8 5 6 4 7 16 20 18 19 13 14 2 1 2 2 5 1 2 20 19 21 14 15 2 2 6 9 16 18 30 33 22 24 2 1 1 2 8 3 4 16 57 63 42 46 2 1 1 2 10 7 8 14 81 8...

Page 111: ...s far as possible 3 Check that O ring A is NOT on threads and adjust if necessary 4 Apply hydraulic system oil to O ring A 1003432 D A E B C Figure 5 12 Hydraulic Fitting 5 Install fitting B into port until back up washer D and O ring A contact part face E 6 Position angle fittings by unscrewing no more than one turn 7 Turn lock nut C down to washer D and tighten to torque shown Use two wrenches o...

Page 112: ... 13 106 115 4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16 12 176 193 130 142 20 1 5 8 12 221 243 163 179 24 1 7 8 12 270 298 199 220 32 2 1 2 12 332 365 245 269 REFERENCE 5 Torque values shown are based on lubricated connections as in reassembly ...

Page 113: ...in Table 5 12 page 105 6 Check final condition of fitting Table 5 12 O Ring Boss ORB Hydraulic Fittings Non Adjustable SAE Dash Size Thread Size in Torque Value6 Nm lbf ft lbf in 2 5 16 24 6 7 53 62 3 3 8 24 12 13 106 115 4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16 12 17...

Page 114: ...omed out 5 Torque fittings according to values in Table 5 13 page 106 NOTE If applicable hold hex on fitting body E to prevent rotation of fitting body and hose when tightening fitting nut D 6 Use three wrenches when assembling unions or joining two hoses together 7 Check final condition of fitting Table 5 13 O Ring Face Seal ORFS Hydraulic Fittings SAE Dash Size Thread Size in Tube O D in Torque ...

Page 115: ...tor typically 45º or 90º is aligned to receive incoming tube or hose assembly Always finish alignment of fitting in tightening direction Never back off loosen pipe threaded connectors to achieve alignment 5 Clean all residue and any excess thread conditioner with appropriate cleaner 6 Assess final condition of fitting Pay special attention to possibility of cracks to port opening 7 Mark final posi...

Page 116: ...ure megapascals MPa x 145 038 pounds per square inch psi Pressure bar Non SI bar x 14 5038 pounds per square inch psi Torque Newton meters Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton meters Nm x 8 8507 pound inches or inch pounds lbf in Temperature degrees Celsius ºC ºC x 1 8 32 degrees Fahrenheit ºF Velocity meters per minute m min x 3 2808 feet per minute ft min Velocity meters pe...

Page 117: ...re making contact with each other and fitting has been tightened to a point where fitting is no longer loose FFFT Flats from finger tight GSS Grass Seed Special GVW Gross vehicle weight Hard joint A joint made with use of a fastener where joining materials are highly incompressible Header A machine that cuts and lays crop into a windrow and is attached to a self propelled windrower Hex key A tool ...

Page 118: ...s its own thread into a mating part Self Propelled SP Windrower Self propelled machine consisting of a power unit with a header Soft joint A joint made with use of a fastener where joining materials are compressible or experience relaxation over a period of time Truck A four wheel highway road vehicle weighing no less than 3400 kg 7500 lb Tension Axial load placed on a bolt or screw usually measur...

Page 119: ...heck auger drive belt tension 4 1 Checking Drive Belts page 81 Check header angle Set center link to middle of adjustment range 3 11 Attaching Header to an M Series Windrower page 31 Check header float 426 471 N 95 105 lbf 4 2 Checking Header Float M200 and M205 Windrowers page 83 Check if header is level 4 4 Checking Header Level page 86 Check if side forming shields are evenly set to desired pos...

Page 120: ...loose parts and hardware on the cutterbar WARNING These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage Run Up Procedure 4 11 Running up the Header page 96 Check hydraulic hose and wiring harness routing for clearance when raising or lowering header Check that hazard lights are functional 4 9 Checking Lights page 94 Post...

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