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MAINTENANCE AND SERVICING

2. Loosen bolts (A) and slide cover (B) off opening.

Figure 5.63: Gearbox

3. Check gap (E) between sensor (A) and pulley.

If

required, adjust gap by loosening bolts (B) and moving
bracket (C) to achieve 2 mm (0.08 in.) gap (E). When
correct gap is achieved, tighten bolts (B).

4. Check position of sensor. If required, adjust position

by loosening bolt (D) and moving sensor to align it with
rim of pulley.

NOTE:

Top panel removed for clarity.

Figure 5.64: Gearbox Speed Sensor

Replacing the Gearbox Speed Sensor

1. Loosen bolts (A) and remove the cover (B).

Figure 5.65: Gearbox Cover

147757

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Revision B

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Summary of Contents for R85

Page 1: ...The harvesting specialists R85 Rotary Disc 13 Foot Header for Self Propelled Windrower Operator s Manual 147757 Revision B Model Year 2016 Original Instruction ...

Page 2: ...R85 Rotary Disc 13 Foot Header for Self Propelled Windrower Published June 2016 ...

Page 3: ...Declaration of Conformity Figure 1 EC Declaration of Conformity Page 1 147757 i Revision B ...

Page 4: ...Figure 2 EC Declaration of Conformity Page 2 147757 ii Revision B ...

Page 5: ...hicle e g M205 when operated in conjunction with this R85 rotary disc header is 79 dBA This measurement was taken in accordance with ISO 5131 The sound pressure level depends upon the rotary disc speed crop conditions as well the exact type of self propelled vehicle used to power the R85 147757 iii Revision B ...

Page 6: ...review and follow the recommended machine settings in all relevant MacDon publications Failure to do so may compromise machine function and machine life and may result in a hazardous situation 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...

Page 7: ...serial number of the header in the space provided Header Serial No ____________ Serial Number Plate A is located on the top cover at the right side of the header Figure 4 Serial Number Location Self Propelled 147757 v Revision B ...

Page 8: ...page iii Added a statement about following the recommended machine settings in all MacDon publications Introduction page iv Removed decal 166833 Not used on this machine 1 7 Safety Decal Locations page 8 Revised topic title and replaced one of the illustrations 3 3 Engaging Disengaging the Header Safety Props page 26 Inspecting Cutterblades page 119 Inserted CAUTION statement regarding damage or l...

Page 9: ...ng the Driveshield Export Headers 29 3 5 Cutterbar Doors 30 3 5 1 Opening the Cutterbar Doors North America 31 3 5 2 Closing the Cutterbar Doors North American Header 32 3 5 3 Opening the Cutterbar Doors Export Header 33 3 5 4 Closing the Cutterbar Doors Export Header 34 3 6 Daily Start Up Check 36 3 7 Attaching the Header 37 3 7 1 Attaching the Forming Shield 37 3 7 2 Attaching the Header M205 Wi...

Page 10: ... 5 Driving on Windrow 95 4 13 6 Raking and Tedding 95 4 13 7 Using Chemical Drying Agents 95 4 14 Levelling the Header 96 4 15 Unplugging the Header 97 5 Maintenance and Servicing 99 5 1 Preparation for Servicing 99 5 2 Recommended Fluids and Lubricants 100 5 3 Maintenance Requirements 101 5 3 1 Maintenance Schedule Record 101 5 3 2 Preseason Annual Service 103 5 3 3 End of Season Service 104 5 3 ...

Page 11: ...e Belt 138 Replacing the Conditioner Drive Belt 140 5 5 3 Conditioner Gearbox 142 5 5 4 Gearbox Speed Sensor 142 Adjusting the Gearbox Speed Sensor 142 Replacing the Gearbox Speed Sensor 143 5 6 Hydraulics 145 5 6 1 Hydraulic Motor 145 Removing the Hydraulic Motor 145 Installing the Hydraulic Motor 146 5 6 2 Hydraulic Hoses and Lines 147 6 Options and Attachments 149 6 1 Options and Attachments Ki...

Page 12: ...TABLE OF CONTENTS 8 1 7 O Ring Face Seal ORFS Hydraulic Fittings 167 8 1 8 Tapered Pipe Thread Fittings 169 8 2 Conversion Chart 170 Index 171 147757 x Revision B ...

Page 13: ...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 Figure 1 1 Safety Symbol 147757 1 Revision B ...

Page 14: ...mminently hazardous situation that if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury It may also be used to alert against unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may be used to alert against un...

Page 15: ...lter mask 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 ear muffs or ear plugs to help protect against objectionable or loud noises Figure 1 3 Safety Equipment Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the fire extinguisher is proper...

Page 16: ...shorten the machine s life To avoid bodily injury or death from unexpected startup of machine ALWAYS stop the engine and remove the key from ignition before leaving operator s seat for any reason Figure 1 6 Safety around Equipment Keep the service area 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 ...

Page 17: ... that steel lines hoses and couplings are in good condition before applying pressure to hydraulic systems Keep hands feet clothing and hair away from all moving and or rotating parts Clear the area of bystanders especially children when carrying out any maintenance repairs or adjustments Install transport lock or place safety stands under the frame before working under the machine If more than one...

Page 18: ...d create hazardous and unsafe conditions Figure 1 11 Testing for Hydraulic Leaks Wear proper hand and eye protection when searching for high pressure hydraulic leaks Use a piece of cardboard as a backstop instead of hands to isolate and identify a leak If injured by a concentrated high pressure stream of hydraulic fluid seek medical attention immediately Serious infection or toxic reaction can dev...

Page 19: ...fety sign Safety signs are available from your Dealer Parts Department Figure 1 14 Operator s Manual Decal 1 6 1 Installing Safety Decals 1 Clean and dry installation area 2 Decide on exact location before you remove decal backing paper 3 Remove smaller portion of split backing paper 4 Place sign in position and slowly peel back remaining paper smoothing sign as it is applied 5 Prick small air poc...

Page 20: ... Safety Decal Locations Figure 1 15 Safety Decal Locations A MD 194465 B MD 194463 C MD 194466 D MD 194464 E MD 113482 F MD 174436 G MD 184385 H MD 184371 J MD 247166 Figure 1 16 Safety Decals 147757 8 Revision B ...

Page 21: ...SAFETY Figure 1 17 Safety Decal Locations A MD 184385 147757 9 Revision B ...

Page 22: ...rive put transmission in Neutral and wait for all movement to stop before leaving operator s position Stop the engine and remove the key before servicing adjusting lubricating cleaning or unplugging machine Engage safety props to prevent lowering of header or reel before servicing in the raised position refer to the header operator s manual Use slow moving vehicle emblem and flashing warning light...

Page 23: ...ch reel support arm before working on or under reel Refer to operator s manual Figure 1 20 MD 174432 MD 174434 Header hazard DANGER Rest header on ground or engage mechanical locks before going under unit Figure 1 21 MD 174434 MD 184371 Open drive hazard WARNING Guard missing Do not operate Keep all shields in place Figure 1 22 MD 184371 147757 11 Revision B ...

Page 24: ...0546 Slippery surface WARNING Do not use this area as a step or platform Failure to comply could result in serious injury or death Figure 1 24 MD 190546 MD 194463 Rotating blades WARNING Stop engine and remove the key before opening the header covers Listen and look for evidence of rotation before lifting cover Rotating cutters may continue to rotate after power is shut off Figure 1 25 MD 194463 1...

Page 25: ...gine and remove the key Disengage PTO and shut off tractor Listen and look for evidence of rotation before lifting cover Rotating cutters may continue to rotate after power is shut off Failure to comply could result in serious injury or death Figure 1 27 MD 194465 MD 194466 Rotating parts under hood WARNING Stand clear Crop materials exiting at high speed Stop machine look listen and wait for all ...

Page 26: ...efore starting engine and during operation Keep riders off the machine Keep all shields in place and stay clear of moving parts Disengage header drive put transmission in Neutral and wait for all movement to stop before leaving operator s position Stop the engine and remove the key from ignition before servicing adjusting lubricating cleaning or unplugging machine Engage locks to prevent lowering ...

Page 27: ...ge power take off stop engine and remove key before opening covers Listen and look for evidence of rotation before lifting cover Rotating cutters may continue to rotate after power is shut off due to inertia Figure 1 31 MD 247167 147757 15 Revision B ...

Page 28: ......

Page 29: ...ight is a reference position where sealing surfaces or components are making contact with each other and fitting has been tightened to a point where fitting is no longer loose FFFT Flats from finger tight GSL Ground speed lever GSS Grass Seed Special GVW Gross vehicle weight Hard joint A joint made with the use of a fastener where joining materials are highly incompressible Header A machine that c...

Page 30: ...ormed threads or forms its own thread in one of mating parts 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 Tension Axial load placed on a bolt or screw usually measured in Newtons N or pounds lb TFFT Turns from finger t...

Page 31: ...n M205 A Doors B Driveshield C Swath Baffle Control D Swath Baffle E Header Boot Figure 2 2 Component Identification M205 A Hydraulic Hoses to SP Windrower B Hose Supports C Drive Motor D Rotary Deflector E 8 Disc Cutterbar F Conditioner Rolls G Front Curtains 147757 19 Revision B ...

Page 32: ...800 2600 rpm Knife tip speed range 59 2 85 5 mps 131 189 mph Cutterbar spindle anti wrap ring S Austempered rock guards S Hourglass converging impellers S Heat treated crop lifters S Cutting angle range 0 8 below horizontal Cutting angle range minimum cut height 19 mm 3 4 in Adjustable shoes O Hay Conditioner S Drive Bevel gearbox to 3 HB belt drive to enclosed timing gearbox and driveline S Roll ...

Page 33: ...4 Windrower tractor to 75 CC 4 6 cu in Eaton heavy duty hydraulic motor S M205 Windrower tractor to 106 cc 6 4 cu in Eaton heavy duty hydraulic motor S M150 M155 maximum hydraulic power developed 97 kW 130 Hp M205 maximum hydraulic power developed 174 kW 231 Hp Hydraulic Header Connection Hydraulic couplers for quick attachment OD Attachments and Accessories Double Windrow Attachment OD Tall Crop ...

Page 34: ......

Page 35: ...ew 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 re...

Page 36: ...use extreme caution If the header hits an obstruction the front of the windrower will usually swerve toward the ditch When working on inclines travel uphill or downhill when possible Be sure to keep the windrower transmission in gear when travelling downhill Never attempt to get on or off a moving machine Do NOT get off the windrower while the header is in operation To avoid bodily injury or death...

Page 37: ...e must be exercised to avoid injury from thrown objects Do NOT under any circumstances operate the header 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 the cutterbar curtains down when operating the header Replace the curtain...

Page 38: ... follows 1 Start engine and press header up A switch to raise header to maximum height 2 Rephase cylinders if one end of the header does not raise fully If rephasing is required proceed as follows a Press and hold the header up A switch until both cylinders stop moving b Continue to hold the switch for 3 4 seconds Cylinders are now phased Figure 3 2 Ground Speed Lever GSL 3 Pull lever A and rotate...

Page 39: ... A away from header to raise safety prop until lever locks into vertical position Repeat for opposite cylinder 2 Start engine choose a level area and lower header to the ground 3 Stop the engine and remove the key Figure 3 4 Safety Prop 147757 27 Revision B ...

Page 40: ...guration is specified in the title when necessary 3 4 1 Opening the Driveshield North American Headers Follow these steps to open the driveshield A on North American headers 1 Disengage rubber latch B from hook C 2 Lift driveshield A to the open position Figure 3 5 Driveshield 3 4 2 Closing the Driveshield North American Headers Follow these steps to close the driveshield on North American headers...

Page 41: ...riveshield and into the notch in latch C and disengage latch 3 Open driveshield D Figure 3 7 Driveshield 3 4 4 Closing the Driveshield Export Headers Follow these steps to close the driveshield on export headers 1 Lower driveshield A so that at lower end of driveshield engage holes in the lower panel and latch B re engages shield 2 Engage rubber latch C Figure 3 8 Driveshield 147757 29 Revision B ...

Page 42: ...led and in good condition Two doors provide access to the cutterbar area Rubber curtains are attached to each door at the front corners and center fixed cover Latches at the lower corners of each curtain keep the curtains together to minimize the risk of thrown objects The cutterbar curtains reduce the potential for thrown objects Always keep curtains down when operating the header Replace the wor...

Page 43: ...ors North America Follow these steps to open the cutterbar doors on a North American header 1 Unhook the curtain latches A Figure 3 10 Curtain Latches 2 Lift front of door to the open position Figure 3 11 Cutterbar Doors 147757 31 Revision B ...

Page 44: ...der CAUTION To avoid injury keep hands and fingers away from corners of doors when closing 1 Pull at top of the cutterbar door and move to the closed position Figure 3 12 Cutterbar Doors 2 Hook curtain latches A NOTE Ensure that curtains hang properly and completely enclose cutterbar area Figure 3 13 Curtain Latches 147757 32 Revision B ...

Page 45: ...OPERATION 3 5 3 Opening the Cutterbar Doors Export Header Follow these steps to open the cutterbar doors on an export header 1 Unhook curtain latches A Figure 3 14 Curtain Latches 147757 33 Revision B ...

Page 46: ...tch to disengage 3 Lift at front of door to open Figure 3 15 Cutterbar Door Latch 3 5 4 Closing the Cutterbar Doors Export Header To close the cutterbar doors on an export header follow these steps CAUTION To avoid injury keep hands and fingers away from corners of doors when closing 147757 34 Revision B ...

Page 47: ...OPERATION 1 Pull at top and move to closed position Ensure latch A has engaged the door Figure 3 16 Cutterbar Door Latch 2 Hook curtain latches A Figure 3 17 Curtain Latches 147757 35 Revision B ...

Page 48: ...d the following A hard hat Protective footwear with slip resistant soles Protective glasses or goggles Heavy gloves A respirator or filter mask Wet weather gear Figure 3 18 Safety Equipment Be aware that exposure to loud noise can cause impairment or loss of hearing Wear suitable hearing protection devices such as ear muffs or ear plugs to help protect against objectionable or loud noises Figure 3...

Page 49: ...ys stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Stop the engine and remove the key 2 Remove the two clevis pins A from forming shield forward end Figure 3 20 Forming Shield 3 Position the forming shield A under the windrower frame Figure 3 21 Forming Shield under Windrower 147757 37 Revision B ...

Page 50: ...and lynch pin Figure 3 22 Forming Shield under Windrower 5 Lift the aft end of the forming shield and attach straps B to pins A on windrower frame 6 Install washer and hairpin to secure strap Use the middle hole and adjust height to suit the crop Figure 3 23 Forming Shield Strap 147757 38 Revision B ...

Page 51: ...ge 44 Figure 3 24 Forming Shield Adjuster Bar 3 7 2 Attaching the Header M205 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 Refer to your windrower operator s manual for procedures to mechanically attach the header to the windrower Refer to the fo...

Page 52: ... bundle A from the header under 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 4 If optional couplers and lock are installed on hoses and lines proceed as follows Otherwise proceed to Step 13 page 43 Figure 3 27 Hydraulic Hoses 147757 40 Revision B ...

Page 53: ...emove lock from coupler Figure 3 28 Hydraulic Couplers with Coupler Lock 6 Connect the rear pump hose A to outboard line D on windrower using coupler C 7 Connect the front pump hose B to the inboard line E on windrower using coupler C Figure 3 29 Hose Routing and Connections 147757 41 Revision B ...

Page 54: ...ydraulic Couplers with Coupler Lock 9 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 Figure 3 31 Hydraulic Couplers with Coupler Lock 10 Insert lynch pin A to secure the lock 11 Attach case drain hose coupler at B 12 Proceed to Step 17 page 43 Figure 3 32 Hydraulic Couplers with Case Drain ...

Page 55: ...ng fitting D 15 Torque fittings to 183 N m 135 ft lbf 16 Attach case drain hose and coupler C to E Figure 3 33 Hose Routing and Connections 17 Connect the electrical harness to connector HC 2A A located beside the forward valve block on the windrower NOTE Valve block hidden to show the electrical connector Figure 3 34 Electrical Connection 147757 43 Revision B ...

Page 56: ...efore leaving the operator s seat for any reason Refer to 3 7 Attaching the Header page 37 for procedure to mechanically attach the header to the windrower Refer to the following procedures for electrical and hydraulic connections To operate the 13 foot header on an M200 windrower installation of a motor hose kit MD B5511 is required If required obtain the kit through your MacDon Dealer Install ki...

Page 57: ...ounterclockwise to the UP position 2 Remove the cap B securing the electrical connector to the frame Figure 3 37 Hose Bundle 3 Move hose bundle A from the windrower and rest the bundle on the header Figure 3 38 Hose Bundle 147757 45 Revision B ...

Page 58: ... as required Figure 3 39 Hose Support 5 Route hose bundle A from the windrower through the support B on header 6 Route header return and pressure hose bundle C through support B on header to the windrower Figure 3 40 Hose Bundle 7 Secure hose bundles with three cinch straps B 8 Lower and lock lever A Figure 3 41 Hose Bundle 147757 46 Revision B ...

Page 59: ...from port A on the header motor to port M2 on the header drive valve block 11 Connect the return hose D coming from port B on the header motor to port R2 on the header drive valve block NOTE If the windrower is equipped with a reverser valve for an auger header replace the 90 fitting on hose D with a 45 fitting Refer to Figure 3 46 M200 Windrower Hose Connections with Reverser page 49 Figure 3 43 ...

Page 60: ...lve block port R1 to the steel line attached to motor port B Figure 3 44 Windrower Connections 13 Connect the pressure hose B from the header drive valve block port M1 to the steel line attached to motor port A Figure 3 45 Windrower Connections 147757 48 Revision B ...

Page 61: ...er valve Figure 3 46 M200 Windrower Hose Connections with Reverser 14 Connect the case drain hose A from the header lift valve block port T3 to the hose attached to motor port D NOTE Hydraulic pressure lines and hoses hidden to show the case drain hose Figure 3 47 Windrower Connections 147757 49 Revision B ...

Page 62: ...indrowers 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 Refer to your windrower operator s manual for procedures to mechanically attach the header to the windrower Refer to the following procedures for electrical and hydraulic connections NOTE The M150 M155 ...

Page 63: ...indrower If required obtain the kit through your MacDon Dealer Install kit in accordance with the supplied instructions Figure 3 50 Hydraulic Drive Kit MD B5510 1 Disengage and rotate lever A counterclockwise to FULLY UP position 2 Remove the cap B securing the electrical connector to the frame Figure 3 51 Hose Bundle 147757 51 Revision B ...

Page 64: ...ower and rest the bundle on the header Figure 3 52 Hose Bundle 4 Position the hose support with lower bolt A in the forward hole and support positioned as shown Loosen both bolts and adjust as required Figure 3 53 Hose Support 147757 52 Revision B ...

Page 65: ...m A to the OPEN position Figure 3 54 Windrower LH Platform in Open Position 6 Route the windrower hose bundle A through hose support B on the header 7 Route the hose C from the header through support B to the windrower Figure 3 55 Hose Bundle 147757 53 Revision B ...

Page 66: ...r to port M2 on the disc drive valve middle block Figure 3 56 Hydraulic Connections 9 Remove caps and plugs on hoses from windrower and lines on header 10 Connect the pressure hose B from the drive manifold port M1 to the steel line attached to motor port A Figure 3 57 Hydraulic Connections 147757 54 Revision B ...

Page 67: ... motor port B Figure 3 58 Hydraulic Connections NOTE If the windrower is equipped with a reverser valve A for an auger header route the return hose B from port R1 on the reverser valve to the steel line attached to motor port C Figure 3 59 Windrower Hose Connections with Reverser 147757 55 Revision B ...

Page 68: ...itting attached to motor port D Figure 3 60 Hydraulic Connections 13 Connect the electrical harness A from windrower to the electrical connector on the header NOTE Hydraulic hoses removed from the illustration to improve clarity Figure 3 61 Electrical Connection 147757 56 Revision B ...

Page 69: ...OPERATION 14 Lower and lock lever A Secure hose B with three cinch straps C Figure 3 62 Hose Bundle 15 Move platform A to the CLOSED position Figure 3 63 Top View of Windrower 147757 57 Revision B ...

Page 70: ...ical and hydraulic systems 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 1 Lower header to ground If ground is soft place blocks under header 2 Stop the engine and remove the key 3 Move the left side cab forward platform A to the open position Figure 3 64 Wi...

Page 71: ...r lock are installed on lines proceed as follows Otherwise proceed to Step 13 page 60 Figure 3 65 Hydraulic Connections 6 Disconnect 12 7 mm 1 2 in hose B from windrower coupler and remove lynch pin A Figure 3 66 Hydraulic Connections 7 Open up coupler lock A 8 Remove lock from couplers B Figure 3 67 Hydraulic Connections 147757 59 Revision B ...

Page 72: ...Figure 3 68 Hydraulic Connections 11 Attach coupler lock B to hoses and secure with lynch pin A 12 Proceed to Step 14 page 61 Figure 3 69 Hydraulic Connections 13 Disconnect hoses from lines A B and C on windrower Install caps and plugs on open lines Figure 3 70 Hydraulic Connections 147757 60 Revision B ...

Page 73: ...es B and electrical harness onto the header Figure 3 71 Hose Bundle 16 Move maintenance platform A to the CLOSED position 17 Refer to the windrower operator s manual to mechanically detach the header from the windrower Figure 3 72 Windrower LH Platform 147757 61 Revision B ...

Page 74: ... key from the ignition before leaving the operator s seat for any reason 1 Lower the header to ground If ground is soft place blocks under header 2 Stop the engine and remove the key 3 Move the left side cab forward platform A to the open position Figure 3 73 Windrower LH Platform 4 Disconnect the pressure hose A from port M2 on the header drive valve block 5 Disconnect the return hose B from port...

Page 75: ...eader Figure 3 75 Hose Bundle 9 Disconnect the electrical connector A at the header by turning the collar counterclockwise and pulling the connector to disengage NOTE Hydraulic lines and hoses hidden on illustration to show the electrical connection Figure 3 76 Electrical Connection 147757 63 Revision B ...

Page 76: ...E Hydraulic hoses from the header hidden on illustration for clarity Figure 3 77 Hydraulic Connections 12 Move the hose bundle from header to the left side cab forward hose support B 13 Rotate lever A clockwise and push to engage bracket 14 Route the electrical harness through the hose support B and attach cap to electrical connector C Figure 3 78 Hose Bundle 147757 64 Revision B ...

Page 77: ... s manual for the procedure to mechanically detach the header from a windrower Refer to the following procedure to disconnect electrical and hydraulic systems 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 1 Lower the header to the ground If the ground is sof...

Page 78: ... 3 Move the left side cab forward platform A to the open position Figure 3 80 Windrower LH Platform 4 Disconnect hose A from port M2 on the disc drive valve Figure 3 81 Hydraulic Connections 147757 66 Revision B ...

Page 79: ...Move hose B to store on header Figure 3 82 Hose Bundle 7 Disconnect the following hoses from the hydraulic motor Pressure hose A Return hose B Case drain hose C 8 Install caps on the connectors and hose ends if equipped Figure 3 83 Hose Bundle 147757 67 Revision B ...

Page 80: ...on illustration to show the electrical connection Figure 3 84 Electrical Connection 10 Move the hose bundle from header to the left side cab forward hose support B 11 Rotate lever A clockwise and push to engage bracket 12 Route the electrical harness through the hose support B and attach cap to electrical connector C Figure 3 85 Hose Bundle 147757 68 Revision B ...

Page 81: ...N 13 Move the windrower platform A to the CLOSED position 14 Refer to the windrower operator s manual to mechanically detach the header from the windrower Figure 3 86 Windrower LH Platform 147757 69 Revision B ...

Page 82: ...r seat for binding or interfering parts NOTE Until you become familiar with the sound and feel of your new header be extra alert and attentive CAUTION Before investigating an unusual sound or attempting to correct a problem stop the engine engage parking brake and remove the key NOTE Perform the items specified in 5 3 1 Maintenance Schedule Record page 101 147757 70 Revision B ...

Page 83: ...AUTION Before leaving the windrower seat for any reason 1 Park on level ground if possible 2 Lower the header fully 3 Place ground speed control in N DETENT 4 Stop the engine and remove the key 5 Wait for all movement to stop 147757 71 Revision B ...

Page 84: ...information on transporting the header when attached to the windrower refer to your windrower operator s manual IMPORTANT For cab forward road travel the windrower must have the lighting and marking bundle installed MD B5412 147757 72 Revision B ...

Page 85: ...rowing 4 10 Double Windrowing page 89 4 1 Header Float Header float springs are normally set so 422 467 N 95 105 lbf of force is required to lift the header at either end In rough or stony conditions it may be desirable to maintain a lighter setting to protect cutting components When float setting is light it may be necessary to use a slower ground speed to avoid excessive bouncing resulting in a ...

Page 86: ... cab refer to your windrower operator s manual Check the float by grasping the front corner of the header and lifting The force to lift should be 426 471 N 95 105 lbf and should be approximately the same at both ends If adjustment is required follow these steps 1 Raise the header fully 2 Stop the engine and remove the key 3 Turn drawbolt A a Clockwise to INCREASE float makes header lighter b Count...

Page 87: ...in thick stemmed cane type crops However too large a gap may cause feeding problems Grass type crops may require less gap for proper feeding and conditioning IMPORTANT If settings below the factory setting are used it is recommended that the actual gap be visually checked 4 2 1 Checking Roll Gap DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine an...

Page 88: ...oll Timing page 79 Figure 4 3 Conditioner Roll Gap Roll Spacing Not to Scale A Direction of Crop Flow B Center Roll Bars C Roll Gap 9 Reinstall the conditioner shield A and secure with bolts B 10 Close the driveshield Refer to 3 4 Driveshields page 28 Figure 4 4 Conditioner Shield 4 2 2 Adjusting Roll Gap DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the...

Page 89: ...jam nut A to 102 N m 75 ft lbf NOTE When adjusting roll gap be sure that the thread protruding at the adjustment is the same on both ends of the conditioner rolls This will achieve consistent intermesh across the rolls 9 Check the roll gap Refer to 4 2 1 Checking Roll Gap page 75 IMPORTANT Roll timing is critical when the roll gap is decreased because the bars may contact each other if the timing ...

Page 90: ...e key from the ignition before leaving the operator s seat for any reason 1 Lower the header fully 2 Stop the engine and remove the key 3 Open the driveshield Refer to 3 4 Driveshields page 28 4 To decrease the roll tension turn the spring drawbolts counterclockwise to loosen the springs 5 To increase the roll tension loosen jam nut A and turn the spring drawbolt B clockwise to tighten the spring ...

Page 91: ...before leaving the operator s seat for any reason 1 Lower the header fully 2 Stop the engine and remove the key 3 Open the driveshield Refer to 3 4 Driveshields page 28 4 Loosen nuts B and slide conditioner shield A up to remove Figure 4 7 Conditioner Shield 5 Measure the roll timing distance B at each end of the rolls Each steel bar on one roll should be centered between two bars of the other rol...

Page 92: ...lt heads A 6 Manually rotate upper roll in opposite direction until it stops Make a second mark on yoke flange to align with the bolt 7 Determine the center between the two marks and mark a third line on the yoke flange 8 Rotate the upper roll until the bolt lines up with the third line 9 Tighten bolts A to secure the position Torque to 95 N m 70 ft lbf NOTE For additional conditioning action in l...

Page 93: ...rying is especially important in areas where the weather allows only a few days to cut and bale For more information refer to 4 13 Haying page 94 A narrower windrow may be preferred for ease of pickup and when drying is not critical for example when cutting for silage or green feed 4 5 1 Adjusting the Side Deflectors The position of the side deflectors controls the width and placement of the windr...

Page 94: ...OPERATING THE HEADER 2 If side deflector attachment is too tight or too loose tighten or loosen nut A as required Figure 4 11 Forming Shield 147757 82 Revision B ...

Page 95: ...f the deflector and then on the other side NOTE Locking handles B are located at both ends of the deflector and may be loosened slightly 2 For heavier crops raise the deflector by pulling up on one side and then on the other side NOTE For even windrow formation be sure the deflector A is not twisted 3 Tighten handles B to secure deflector position Figure 4 12 Forming Shield 4 5 3 Adjusting the Swa...

Page 96: ...nward to form a wide swath 1 Remove lynch pin from pin B and remove pin from lever C 2 Move lever to middle hole in bracket and reinstall pin B through lever and bracket 3 Secure with lynch pin Figure 4 13 Swath Baffle Lever NOTE Swath baffle position may need to be adjusted for proper pin engagement Loosen bolts A and adjust bracket B and baffle as required Tighten bolts A Figure 4 14 Swath Baffl...

Page 97: ...ions A flatter angle provides better clearance in stony conditions while a steeper angle provides better lifting action in down crops The header angle may be hydraulically adjusted from the windrower cab using the hydraulic cylinder A if equipped without shutting down the windrower Refer to your windrower operator s manual Figure 4 15 Hydraulic Center Link 147757 85 Revision B ...

Page 98: ...ing header angle allows the crop to be cut lower To minimize damage to cutterbar components scooping soil or soil build up at the cutterbar in damp conditions set header float as light as possible without excessive bouncing A light float setting may require reduced ground speeds to avoid excess bouncing and a ragged cut 4 7 1 Adjusting the Skid Shoe Height DANGER To avoid bodily injury or death fr...

Page 99: ...tion Refer to table below Table 4 2 Disc Speed Recommendations Crop Condition Disc rpm Heavy 2300 2500 Alfalfa Light 1600 2000 Sudan Sorghum Haygrazer Timothy Tall and stemmy 2300 2500 Dense 2500 Short grass Thin 1800 2000 Disc speeds are set and adjusted from the cab using system controls without shutting down the windrower Refer to your windrower operator s manual 147757 87 Revision B ...

Page 100: ...gh cutting conditions such as native grasses the disc speed will need to be increased 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 life of cutting components The chart below indicates the relationship between ground speed and area cut for a 13 foot header Figure 4 17 Ground Speed Chart A Kilom...

Page 101: ...e Windrowing If your windrower is equipped with the Double Windrow Attachment DWA A refer to the MacDon DWA Manual for operating and maintenance instructions The manual is shipped with the DWA Kit Figure 4 18 DWA 147757 89 Revision B ...

Page 102: ...o 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 1 Lower header fully 2 Stop the engine and remove the key 3 Unpack kit 4 Open cutterbar doors Refer to 3 5 Cutterbar Doors page 30 Figure 4 19 Cutterbar Doors 5 Remove the four bolts A from the divider B NOTE Mounting ho...

Page 103: ...void 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 1 Lower the header fully 2 Stop the engine and remove the key 3 Open the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 4 Remove the four bolts A and remove deflector B 5 Reinstall the four bolts A 6 Close the cutterb...

Page 104: ...he conditioner 4 12 1 Removing Header Pan 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 1 Raise the header fully 2 Stop the engine and remove the key 3 Engage header safety props Refer to 3 3 Engaging Disengaging the Header Safety Props page 26 4 Open the cu...

Page 105: ...pan follow these steps 1 Locate pan B under header frame and hold in place 2 Install six 1 2 x 1 in carriage bolts A and flanged lock nuts Tighten hardware 3 Close the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 Figure 4 24 Underside of Header 147757 93 Revision B ...

Page 106: ...d is wet due to frequent rains cut when weather allows and let the forage lie on wet ground until it dries to the moisture level of the ground Cut hay will dry only to the moisture level of the ground beneath it so consider moving the windrow to drier ground 4 13 3 Weather and Topography Cut as much hay as possible by midday when drying conditions are best Fields sloping south get up to 100 more e...

Page 107: ...chine can straddle NOTE Driving on the windrow in high yield crops may be unavoidable if a full width windrow is necessary 4 13 6 Raking and Tedding Raking or tedding speeds up drying however the resulting leaf loss may outweigh the benefits There is little or no advantage to raking or tedding if the ground beneath the windrow is dry Large windrows on damp or wet ground should be turned over when ...

Page 108: ...e float springs are NOT used to level the header If the header is not level check the tire pressures on the windrower ensuring they are properly inflated Refer to your windrower operator s manual If the header is still not level then adjustment to the windrower linkages is required Refer to the appropriate section in the windrower operator s manual 147757 96 Revision B ...

Page 109: ...ard movement of the windrower and disengage the header 2 Raise the header fully 3 Stop the engine and remove the key 4 Engage header safety props Refer to 3 3 Engaging Disengaging the Header Safety Props page 26 WARNING Wear heavy gloves when working around cutterbar 5 Open the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 6 Clean off the cutterbar or rolls by hand NOTE Header reversing fea...

Page 110: ......

Page 111: ...ontact your Dealer Log the hours of operation and use the Maintenance Schedule Record provided to keep a record of scheduled maintenance Refer to 5 3 1 Maintenance Schedule Record page 101 5 1 Preparation for Servicing CAUTION To avoid personal injury before servicing the header or opening drive covers perform the following 1 Lower the header fully 2 Stop the engine and remove the key 3 Engage par...

Page 112: ...I Grade 2 Lithium complex base Grease Driveline slip joints High temperature extreme pressure EP performance with 10 max Molybdenum Disulphide NLGI Grade 2 Lithium base Cutterbar 80W 90 gear lubricant with high thermal and oxidation stability conforming to API gear lubricant service GL 5 minimum SAE J2360 preferred specifications such as Traxon 80W 90 gear oil 3 25 l 3 43 US quarts Conditioner gea...

Page 113: ... is reached first IMPORTANT Recommended intervals are for average conditions Service the machine more often if operated under adverse conditions severe dust extra heavy loads etc CAUTION Carefully follow safety messages given in 1 Safety page 1 5 3 1 Maintenance Schedule Record Action Check Lubricate Change Hour meter reading Service date Serviced by Preseason or Annual Refer to 5 3 2 Preseason An...

Page 114: ... to 5 3 7 Lubricating the Cutterbar page 1111 Change bevel gearbox lubricant Refer to 5 5 1 Bevel Gearbox page 137 Change conditioner gearbox lubricant Refer to 5 5 1 Bevel Gearbox page 137 Every 50 hours Lube drive belt tensioner Refer to 5 3 4 Lubrication and Servicing page 104 Lube roll shaft bearings Refer to 5 3 4 Lubrication and Servicing page 104 Lube gauge roller bearings 2 Every 100 hours...

Page 115: ...2 Preseason Annual Service 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 th...

Page 116: ...ut of bearings Apply grease to exposed threads cylinder rods and sliding surfaces of components Oil cutterbar components to prevent rust Check for worn components and repair as necessary Check for broken components and order replacements from your Dealer Attention to these items right away will save time and effort at beginning of next season Replace or tighten any missing or loose hardware Refer ...

Page 117: ...cals showing a grease gun and grease interval in hours of operation Use the recommended lubricants specified in this manual Refer to 5 2 Recommended Fluids and Lubricants page 100 1 Wipe grease fitting with a clean cloth before greasing 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...

Page 118: ...5 3 6 Lubrication and Servicing Intervals To identify the various locations that require lubrication and servicing refer to the following illustrations organized by the frequency of service that is required 147757 106 Revision B ...

Page 119: ...iveshaft4 C Conditioner Driveline Universals 4 Places D Driveline Shaft4 NOTE Use high temperature extreme pressure EP2 performance with 1 max molybdenum disulphide NLGI grade 2 lithium base except where noted 4 10 moly grease is recommended for driveline shaft slip joint only 147757 107 Revision B ...

Page 120: ...4 A Roll Shaft Bearing 2 Places B Belt Tensioner Pivot 1 Place C Roll Shaft Bearing 2 Places NOTE Use high temperature extreme pressure EP2 performance with 1 max molybdenum disulphide NLGI grade 2 lithium base except where noted 147757 108 Revision B ...

Page 121: ...MAINTENANCE AND SERVICING Every 100 Hours or Annually Figure 5 5 A Conditioner Drive Belt Tension B Gearbox Lubricant Level Check with Top of Header Horizontal 147757 109 Revision B ...

Page 122: ...MAINTENANCE AND SERVICING Every 250 Hours Figure 5 6 A Change Bevel Gearbox Oil B Change Cutterbar Lube 147757 110 Revision B ...

Page 123: ...r s seat for any reason CAUTION Be careful when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades DANGER To avoid bodily injury or death from unexpected start up or fall of raised machine stop engine remove key and engage header safety props before going under machine for any reason 1 Place a block under each end of the header A NOTE The block...

Page 124: ... an 8 mm hex key NOTE Rotate disc to expose filler plug if necessary 8 Place a suitably sized container under the cutterbar drain hole A 9 Remove plug A with an 8 mm hex key and allow sufficient time for lubricant to drain IMPORTANT Do NOT flush the cutterbar 10 Replace drain plug A and tighten 11 Safely dispose of lubricant 12 Add lubricant Refer to Filling the Cutterbar Lubricant page 113 Figure...

Page 125: ...rops page 26 5 Move higher block to right end of header NOTE Having the fill end higher allows for quicker filling of cutterbar 6 Disengage header safety props Refer to 3 3 Engaging Disengaging the Header Safety Props page 26 CAUTION Never start or move the machine until you are sure all bystanders have cleared the area 7 Start windrower and lower header onto blocks A Figure 5 10 Header Raised Rig...

Page 126: ...ants page 100 IMPORTANT DO NOT overfill the cutterbar Overfilling can cause overheating and damage to or failure of the cutterbar 14 Install the filler plug that was removed 15 Close the cutterbar door s Refer to 3 5 Cutterbar Doors page 30 16 Start engine and raise header off blocks 17 Engage header safety props Refer to 3 3 Engaging Disengaging the Header Safety Props page 26 18 Remove blocks an...

Page 127: ... props 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 1 Raise the header fully 2 Stop the engine and remove the key 3 Engage header safety props 4 Engage header safety props Refer to 3 3 Engaging Disengaging the Header Safety Props page 26 5 Inspect rock guards A for se...

Page 128: ...OT repairable and must be replaced if severely damaged or worn IMPORTANT If holes appear in a cutterbar disc replace the disc immediately Do NOT attempt to repair the cutterbar discs Always use factory replacement parts 5 4 1 Direction of Spindle Rotation When installing cutter blades or disc accelerators the direction of rotation determines proper crop positioning Refer to Figure 5 14 Spindle Rot...

Page 129: ... page 117 5 4 4 Installing a Cutterbar Disc page 118 6 Replace damaged fasteners Tighten loose fasteners 7 Close the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 Figure 5 15 Cutterbar Disc 5 4 3 Removing a Cutterbar Disc CAUTION Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades 1 Open cutterbar door s Refer to 3 5...

Page 130: ...se caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades 1 Install the new disc on spindle positioned at a 90 angle to the adjacent discs Figure 5 17 Cutterbar Discs 2 Install cover B and secure with four bolts A Tighten bolts 3 Reinstall previously removed rotary deflector if applicable Refer to Installing the Driveline Deflector pag...

Page 131: ...ANGER To avoid bodily injury or death from unexpected startup of machine always stop engine and remove key from ignition before leaving operator s seat for any reason CAUTION Cutter blades have two cutting edges Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades CAUTION Damaged blades may damage the cutterbar and result in...

Page 132: ...amage to the cutterbar Figure 5 20 Cutterblades A Blade Wear to Center Line B Elongated Hole C Maximum Elongation 21 mm 13 16 in IMPORTANT The cutterblades have cutting edges on both sides so the blades can be turned over and reused The twist in each blade determines the cutting direction If you are unsure which direction the spindles rotate refer to 5 4 1 Direction of Spindle Rotation page 116 Fi...

Page 133: ...SERVICING Inspecting Cutterblade Hardware CAUTION Damaged or loose cutterblades or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage 147757 121 Revision B ...

Page 134: ...eplacement procedure Check bolts and replace bolt if Bolt has been removed and installed five times Head A is worn flush with bearing surface of blade Diameter of bolt neck is worn B 3 mm 1 8 in Bolt is cracked C Bolt is visibly distorted D There is evidence of interference E with adjacent parts Figure 5 23 Cutterblade Bolt 147757 122 Revision B ...

Page 135: ... CAUTION Cutterblades have two cutting edges Be careful when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades 1 Raise the header fully 2 Stop the engine and remove the key 3 Engage header safety props Refer to 3 3 Engaging Disengaging the Header Safety Props page 26 4 Open the cutterbar door s Refer to 3 5 Cutterbar Doors page 30 5 Rotate dis...

Page 136: ...ation page 116 11 Install nut A Tighten nut to 135 N m 100 ft lbf 12 Remove block of wood if used 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 13 Close the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 Figure 5 26 Cutterblades 5 4 6 Accelerat...

Page 137: ...header safety props Refer to 3 3 Engaging Disengaging the Header Safety Props page 26 4 Open the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 CAUTION Cutter blades have two cutting edges Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades Figure 5 28 Cutterbar Doors 5 Inspect accelerators A and replace if severely d...

Page 138: ...o existing cutter blade bolt Install nut B NOTE Accelerators are handed for clockwise or counterclockwise operation Verify the direction of disc before installing accelerators 8 Install hex bolt A and nut at inboard hole Bolt head faces up 9 Tighten both nuts to 135 N m 100 ft lbf 10 Repeat for other accelerator 11 Reinstall disc D on spindle Refer to 5 4 4 Installing a Cutterbar Disc page 118 Fig...

Page 139: ...ise the header fully 2 Stop the engine and remove the key 3 Engage header safety props Refer to 3 3 Engaging Disengaging the Header Safety Props page 26 4 Open the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 5 Inspect nut shields A and replace if severely damaged or worn 6 Check for loose or missing fasteners and tighten or replace fastener if missing If replacement is required refer to R...

Page 140: ...c D on spindle Refer to 5 4 4 Installing a Cutterbar Disc page 118 Figure 5 33 Disc Accelerator 10 Remove block of wood if used 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 11 Close the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 5 4 8 Rota...

Page 141: ...bjects These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage 7 Close the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 Figure 5 34 Rotary Deflector Removing the Driven Deflector Follow these steps to replace the driven rotary deflector DANGER To avoid bodily injury or death from unexpected startup of the machine a...

Page 142: ...r Follow these steps to replace the driveline deflector 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 1 Lower the header fully 2 Stop the engine and remove the key 3 Open the cutterbar doors Refer to 3 5 Cutterbar Doors page 30 4 Locate the deflector C with ...

Page 143: ...hield onto spindle 2 Raise the upper driveline shield C into position and slide plates B into slots in shield Do not tighten bolts Figure 5 39 Driveline Deflector 3 insert spacer D onto disc 4 Insert driveline B into deflector C and install onto shaft Ensure that driveline B grease zerks will be accessible through large opening in deflector 5 Align mounting holes in deflector C spindle and driveli...

Page 144: ...tacts a large stone a stump or other large object In the event of a sheared key the disc stops rotating but remains attached to the spindle Replacing a Spindle Key Follow these steps to replace a spindle key 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 1 Lo...

Page 145: ... M12 mm x 60 mm long bolts A into holes in plate B 7 Use bolts A as jacking screws to remove plate B from gear Remove bolts from plate Figure 5 44 Cutterbar Spindle 8 Pry out failed key A from gear B and plate 9 Thoroughly clean metal debris from disassembled components and cutterbar Figure 5 45 Cutterbar Spindle Gear 147757 133 Revision B ...

Page 146: ...utterbar Spindle 5 4 10 Cutterbar Doors Inspecting Curtains Replace the curtains if they should become worn or damaged Contact your Dealer for replacement instructions Inspecting Door Latches Export Header The cutterbar door latches should operate smoothly and remain engaged when the doors are down Tighten latch hardware if loose If the rubber bushing is damaged or does not allow the latch to oper...

Page 147: ...to position as shown 5 Tighten nut C Figure 5 48 Cutterbar Door Latch Replacing Latches To replace cutterbar door latches follow these steps 1 Unlatch and lift curtain 2 Remove bolts A and remove latch assembly from frame 3 Locate new latch assembly on frame and reinstall bolts A 4 Adjust to position shown and tighten bolts A Figure 5 49 Cutterbar Door Latch 147757 135 Revision B ...

Page 148: ...move bolts A washers and nuts and remove latch bracket B from door 3 Locate new latch bracket B on door and reinstall bolts A washers and nuts Use three washers on aft bolt as spacers between bracket B and door 4 Close door and check alignment with latch Adjust as necessary and tighten bolts A Figure 5 50 Latch Bracket 147757 136 Revision B ...

Page 149: ...cord page 101 Figure 5 51 Bevel Gearbox Changing the Bevel Gearbox Lubricant Follow these steps to change the bevel gearbox lubricant 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 1 Drain the gearbox when the lubricant is warm If the lubricant is cold idle t...

Page 150: ...ants page 100 for quantity and specification 15 Install plug C bushing and breather B and tighten 16 Properly dispose of used lubricant and clean up any spilled lubricant 17 Close the driveshield Refer to 3 4 Driveshields page 28 Figure 5 52 Bevel Gearbox 5 5 2 Conditioner Drive Belt Inspecting the Conditioner Drive Belt Check the belt tension and inspect for damage or wear every 100 hours or annu...

Page 151: ... to 5 15 16 in in length Figure 5 54 Drive Belt Tensioner Spring 6 If necessary adjust tension as follows a Loosen jam nut B b Turn nut A clockwise to increase spring length increase tension c Turn nut A counterclockwise to decrease spring length decrease tension 7 Tighten jam nut B 8 Close the driveshield Refer to 3 4 Driveshields page 28 Figure 5 55 Conditioner Drive Belt Adjuster 147757 139 Rev...

Page 152: ...for any reason IMPORTANT Change all three belts when replacing as they are a matched set 1 Lower the header fully 2 Stop the engine and remove the key 3 Open the driveshield Refer to 3 4 Driveshields page 28 4 Remove three bolts A then remove lower shield B Figure 5 56 Driveshield 5 Release tension on conditioner drive belt A 6 Remove conditioner drive belt A from drive pulley B Tensioner C can be...

Page 153: ...Install new belts A onto driven pulley B first and then onto drive pulley D ensure belts are in the pulley grooves 10 Tension belt A Figure 5 59 Conditioner Drive Belt 11 Reattach upper driveline to driven pulley B with bolts and washers A Check roll timing before fully tightening bolts Refer to 4 4 1 Checking Roll Timing page 79 12 Torque bolts to 102 N m 75 ft lbf Figure 5 60 Conditioner Drive B...

Page 154: ...If repairs are required the conditioner gearbox should be removed and serviced at your MacDon Dealer Figure 5 62 Conditioner Gearbox 5 5 4 Gearbox Speed Sensor The gearbox speed sensor monitors the rotational speed of the gearbox output shaft and sends a signal to the system monitor in the operator s station that is displayed as disc speed The sensor does not require regular maintenance if it malf...

Page 155: ...ket C to achieve 2 mm 0 08 in gap E When correct gap is achieved tighten bolts B 4 Check position of sensor If required adjust position by loosening bolt D and moving sensor to align it with rim of pulley NOTE Top panel removed for clarity Figure 5 64 Gearbox Speed Sensor Replacing the Gearbox Speed Sensor 1 Loosen bolts A and remove the cover B Figure 5 65 Gearbox Cover 147757 143 Revision B ...

Page 156: ...ve the sensor 6 Install the new sensor D onto the bracket with bolt and nut C Ensure sensor is aligned with the pulley rim 7 Check that gap between sensor and pulley is 2 mm 0 08 in Adjust as required 8 Route connector and harness through hole in the frame and through grommet in cover 9 Connect sensor wiring to existing connector A Figure 5 66 Gearbox Speed Sensor 10 Reinstall cover B and secure w...

Page 157: ...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 If the machine is connected to the windrower lower header to ground 2 Stop the engine and remove the key 3 Disconnect case drain hose A from motor B 4 Disconnect pressure and return hoses at fittings C IMPORTANT To protect the motor from contaminati...

Page 158: ...osite end to a lifting device NOTE Do not lift the motor with hydraulic lines Figure 5 71 Hydraulic Motor Removed 3 Lower the motor B on gearbox opening 4 Install four bolts D Torque to 140 N m 103 ft lbf 5 Remove caps from motor ports and hoses and reconnect hoses A and C to motor NOTE Hydraulic connections vary depending on the windrower Refer to the specific instructions supplied with your hydr...

Page 159: ... If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Figure 5 73 Hydraulic Pressure Hazard Use a piece of cardboard or paper to search for leaks IMPORTANT Keep hydraulic coupler tips and connectors clean Allowing dust dirt water or foreign material to enter the system is the major cause of hydr...

Page 160: ......

Page 161: ...ls required to replace the cutterbar idler gears MD B4905 Figure 6 1 MD B4905 6 1 2 Double Windrow Attachment DWA Allows auger and draper headers without deck shift to lay a double windrow when installed on a self propelled windrower The kit includes a draper deck linkage assembly hydraulics and installation instructions MD C1987 consists of MD B5973 Deck MD B5974 Linkage assembly MD B5301 Hydraul...

Page 162: ... MD B5457 6 1 4 Tall Crop Divider Kit The tall crop dividers attach to the ends of the header for clean crop dividing and reel entry in tall crops The kit includes left and right dividers and attachment hardware MD B5509 Instruction Part Number MD 169485 Figure 6 3 MD B5509 147757 150 Revision B ...

Page 163: ...der Angle page 85 Header flotation too light causing bouncing Adjust to heavier float setting 4 1 Header Float page 73 Ragged or uneven cutting of crop Excessive ground speed Reduce ground speed 4 9 Ground Speed page 88 Bent cutterblades Replace blades Replacing the Cutterblades page 123 Build up of dirt between rock guards Decrease header angle and increase flotation 4 6 Header Angle page 85 and ...

Page 164: ...roll timing 4 4 2 Adjusting Roll Timing page 80 Rear deflector bypassing or dragging crop Adjust rear deflector for proper crop control 4 5 2 Adjusting the Rear Deflector Fluffer Shield page 83 Forming shields improperly adjusted Adjust forming shields 4 5 Forming Shields page 81 Roll gap too large Adjust roll gap 4 2 2 Adjusting Roll Gap page 76 Uneven formation and bunching of windrow Conditione...

Page 165: ...oll Timing page 80 Crop is bunched in windrow Adjust forming shields baffle 4 5 Forming Shields page 81 Slow crop drying Rolls not crimping crop sufficiently Decrease roll gap Excessive crimping Increase roll gap 4 2 2 Adjusting Roll Gap page 76 Excessive drying or bleaching of crop Crop is spread too wide in windrow Poorly formed or bunchy windrows Forming shields not properly adjusted Adjust for...

Page 166: ...t in cutterbar Drain lubricant and refill with specified amount Draining the Cutterbar Lubricant page 111 Mud on cutterbar Remove mud from cutterbar do NOT allow mud to dry on cutterbar Spindle bearing failure Replace spindle bearing See MacDon Dealer Material wrapped around spindle Remove disc and remove material 5 4 3 Removing a Cutterbar Disc page 117 Cutting too low in rocky field conditions D...

Page 167: ...saligned Align pulleys and idler See MacDon Dealer Mud on cutterbar Remove mud from cutterbar do NOT allow mud to dry on cutterbar Hoses not connected Connect hoses 3 7 Attaching the Header page 37 Faulty drive belt Check drive belt pulleys Inspecting the Conditioner Drive Belt page 138 Disc does not turn when engaging header Poor electrical connection at pump solenoid Check connection at windrowe...

Page 168: ......

Page 169: ...arkings 8 1 1 SAE Bolt Torque Specifications Torque values shown in the 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 Table 8 1 SAE Grade 5 Bolt and Grade 5 Free Spinning Nut Torque N m Torque ft lbf in lbf Nominal Size A Min Max Min Max 1 4 20 11 9 13 2 106 117 5 16 18 24 6 27 ...

Page 170: ...56 306 338 1 8 619 684 459 507 Figure 8 2 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Table 8 3 SAE Grade 8 Bolt and Grade G Distorted Thread Nut Torque N m Torque ft lbf in lbf Nominal Size A 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 13 102 113 76 84 9 16 12 148 163 109 121 5 8 11 204 225 151 167 3 4 10 362 400 268 296 7 8 9 583...

Page 171: ...65 1288 863 954 Figure 8 4 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 8 1 2 Metric Bolt Specifications Table 8 5 Metric Class 8 8 Bolts and Class 9 Free Spinning Nut Torque N m Torque ft lbf in lbf Nominal Size A 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 28 30 20 23 10 1 5 55 60 40 45 12 1 75 95 105 70 7...

Page 172: ...16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 Figure 8 6 Bolt Grades Table 8 7 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Torque N m Torque ft lbf in lbf Nominal Size A 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 5 75 83 56 62 12 1 75 132 145 97 108 14 2 0 210 232 ...

Page 173: ...Size A Min Max Min Max 3 0 5 1 3 1 5 12 13 3 5 0 6 2 1 2 3 19 21 4 0 7 3 1 3 4 28 31 5 0 8 6 3 7 56 62 6 1 0 10 7 11 8 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 Figure 8 8 Bolt Grades 147757 161 Revision B ...

Page 174: ...d flare seat B for defects that might cause leakage 2 Align tube C with fitting D and thread nut E onto fitting without lubrication until contact has been made between flared surfaces 3 Torque fitting nut E to specified number of flats from finger tight FFFT or to a given torque value in Table 8 10 Flare Type Hydraulic Tube Fittings page 163 4 Use two wrenches to prevent fitting D from rotating Pl...

Page 175: ... 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 89 60 66 1 1 2 1 1 2 12 1 1 16 12 113 124 83 91 1 1 2 1 1 4 14 1 3 16 12 136 149 100 110 1 1 2 1 1 4 16 1 5 16 12 160 176 118 130 1 1 2 1 20 1 5 8 12 228 250 168 184 1 1 24 1 7 8 12 264 291 195 215 1 1 32 2 1 2 12 359 395 265 291 1 1 40 3 12 1 1 7 Torque values shown are based on lubricated connections as i...

Page 176: ...s NOT on threads and adjust if necessary 4 Apply hydraulic system oil to O ring A Figure 8 11 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 one on fitting B and other on lock nut C 8 Check final condi...

Page 177: ...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 8 Torque values shown are based on lubricated connections as in reassembly 147757 165 Revision B ...

Page 178: ...Check final condition of fitting Figure 8 13 Hydraulic Fitting Table 8 12 O Ring Boss ORB Hydraulic Fittings Non Adjustable Torque Value9 SAE Dash Size Thread Size in N m ft lbf in lbf 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...

Page 179: ...r C comes in full contact with O ring B 4 Thread tube or hose nut D until hand tight The nut should turn freely until it is bottomed out 5 Torque fittings according to values in Table 8 13 O Ring Face Seal ORFS Hydraulic Fittings page 168 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 uni...

Page 180: ... 3 8 40 44 29 32 8 13 16 1 2 55 61 41 45 10 1 5 8 80 88 59 65 12 1 3 16 3 4 115 127 85 94 14 Note11 7 8 16 1 7 16 1 150 165 111 122 20 1 11 16 1 1 4 205 226 151 167 24 1 2 1 1 2 315 347 232 256 32 2 1 2 2 510 561 376 414 10 Torque values and angles shown are based on lubricated connection as in reassembly 11 O ring face seal type end not defined for this tube size 147757 168 Revision B ...

Page 181: ...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 position of fitting If a fitting leaks disassemble fitting and check for damage NOTE Over...

Page 182: ...egapascals MPa x 00689 Pressure bar Non SI bar 14 5038 pounds per square inch psi Newton meters N m x 1 3558 pound feet or foot pounds ft lbf Torque Newton meters N m x 0 1129 pound inches or inch pounds in lbf Temperature Celsius C F 32 x 0 56 degrees Fahrenheit F meters per minute m min x 0 3048 feet per minute ft min meters per second m s x 0 3048 feet per second ft s Velocity kilometers per ho...

Page 183: ...ing draining lubricant 111 filling cutterbar with lubricant 113 repair tool kit 149 spindles direction of rotation 116 cutterbar doors 30 134 adjusting 134 closing export headers 34 North American headers 32 inspecting latches export headers 134 latch brackets replacing 136 latches 134 replacing 135 opening export headers 33 North American headers 31 cutterbars cutterblades inspecting 119 discs nu...

Page 184: ...ing 37 M150 155 155E4 windrowers 50 M200 windrowers 44 M205 windrowers 39 definitions 17 detaching 58 M150 M155 or M155E4 windrowers 65 M200 windrowers 62 M205 windrowers 58 float adjusting 74 float checking 73 operating 73 transporting 72 unplugging 97 hydraulic motors See motors hydraulics fittings flare type 162 O ring boss ORB adjustable 164 O ring boss ORB non adjustable 166 O ring face seal ...

Page 185: ...sibilities 23 P preseason service 103 R raking 95 recommended fluids and lubricants See lubrication revisions list vi rock guards inspecting 115 roll gap adjusting 76 checking 75 roll tension 78 adjusting 78 roll timing 79 adjusting 80 checking 79 rotary deflectors 128 driveline deflectors installing 131 removing 130 driven deflectors installing 130 removing 129 inspecting deflectors 128 rpm defin...

Page 186: ...are type hydraulic fittings 162 metric bolt specifications 159 bolting into cast aluminum 162 O ring boss ORB fittings non adjustable 166 O ring boss ORB hydraulic fittings adjustable 164 O ring face seal ORFS fittings 167 169 SAE bolt torque specifications 157 troubleshooting mechanical 154 mower performance 151 trucks definitions 17 W weather 94 windrows driving on windrows 95 windrow characteri...

Page 187: ......

Page 188: ...204 885 5590 f 204 832 7749 MacDon Inc 10708 N Pomona Avenue Kansas City Missouri United States 64153 1924 t 816 891 7313 f 816 891 7323 MacDon Australia Pty Ltd A C N 079 393 721 P O Box 243 Suite 3 143 Main Street Greensborough Victoria Australia 3088 t 03 9432 9982 f 03 9432 9972 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t...

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