MacDon R85 Unloading & Assembly Instruction

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.

R85 Rotary Disc 4.9-Meter (16-Foot) Self-Propelled Windrower Header

1005291

Published: August 2017

Introduction

This instructional manual describes the unloading, setup, and predelivery requirements for MacDon Model R85

Rotary Disc 4.9-Meter (16-Foot) Self-Propelled Windrower Headers.

Carefully read all the material provided before attempting to use or service the machine.

When setting up the machine or making adjustments, 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.

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.

NOTE: Keep your MacDon publications up-to-date. The most current version can be downloaded from our website

(www.macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login required).

214367 i Revision A

List of Revisions

The following list provides an account of major changes from the previous version of this document.

Summary of Changes

Location

Changed measurement format so that metric values

appear first followed by imperial in parentheses.

Throughout the book

Added conventions to Introduction. Introduction, page i

Added illustration, reorganized topic contents. 2 Unloading the Header, page 5

Updated illustration and adjusted callouts in steps. 3.4 Lowering Header, page 11

Updated illustration and figure title. 3.7 Unpacking Curtains, page 18

Added step, note, and illustration for installing M200

hose support on header.

3.9 Assembling Forming Shield, page 24

Added note to procedure.

3.10 Installing Forming Shield, page 28

Updated illustrations.

3.11.1 Attaching Header to an M200 or M205

Windrower: Hydraulic Center-Link with Optional

Self-Alignment, page 31

Updated illustrations.

3.11.2 Attaching Header to an M200 or M205

Windrower: Hydraulic Center-Link without Optional

Self-Alignment, page 36

Updated illustrations.

3.11.3 Attaching Header to an M200 Windrower:

Mechanical Center-Link, page 41

Updated topic 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

using hard plumb connections.

3.13.1 Attaching Hydraulic and Electrical Components:

M205 Windrowers, page 56

Added note for removing electrical harness extension

from header before connecting to M205 windrower.

3.13.1 Attaching Hydraulic and Electrical Components:

M205 Windrowers, page 56

Updated steps and illustrations, clarified manifold port

IDs for hydraulic connections.

3.13.2 Attaching Hydraulic and Electrical Components:

M200 Windrowers, page 61

Updated procedure to include steps for connecting

header to M1240 windrower using quick-connect and

hard plumb fittings.

3.13.3 Attaching Hydraulics and Electrical: M1240

Windrowers, page 67

Added note at beginning of topic and added footnote

referring users to quick coupler kits available for M1240

windrowers configured for disc headers, and auger and

draper headers.

3.13.3 Attaching Hydraulics and Electrical: M1240

Windrowers, page 67

214367 ii Revision A

Summary of Changes

Location

Updated figure title/description. 3.14.5 Installing Tall Crop Feed Plates, page 74

Updated topic title.

4.2 Checking Header Float: M200 and M205

Windrowers, page 83

Added topic to manual.

4.3 Checking Header Float: M1240 Windrowers, page

84

Added topic to manual.

4.3.1 Setting the Float: 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 light brackets and

added identifying callouts to procedure.

4.9 Checking Lights, page 94

214367 iii Revision A

214367 v Revision A

Introduction................................................................................................................................................i

List of Revisions ........................................................................................................................................ ii

Chapter 1: Safety .................................................................................................................................... 1

1.1 Signal Words .......................................................................................................................................1

1.2 General Safety.....................................................................................................................................2

1.3 Safety Signs ........................................................................................................................................4

Chapter 2: Unloading the Header ....................................................................................................... 5

Chapter 3: Assembling the Header .................................................................................................... 7

3.1 Removing Underside Shipping Support and Installing Auger Pan ............................................................ 7

3.2 Installing Skid Shoes (Optional) ............................................................................................................9

3.3 Installing Gauge Rollers (Optional) ......................................................................................................10

3.4 Lowering Header ............................................................................................................................... 11

3.5 Removing Shipping Stands.................................................................................................................13

3.6 Installing Swath Baffle Lever ..... ..........................................................................................................17

3.7 Unpacking Curtains............................................................................................................................18

3.8 Attaching Conditioner Cover ...............................................................................................................22

3.9 Assembling Forming Shield ................................................................................................................24

3.10 Installing Forming Shield...................................................................................................................28

3.11 Attaching Header to an M Series Windrower.......................................................................................31

3.11.1 Attaching Header to an M200 or M205 Windrower: Hydraulic Center-Link with Optional

Self-Alignment.................................................................................................................... 31

3.11.2 Attaching Header 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-Alignment.................................................................................................................... 50

3.13 Attaching Hydraulics and Electrical Connections ................................................................................56

3.13.1 Attaching Hydraulic and Electrical Components: M205 Windrowers ............................................56

3.13.2 Attaching Hydraulic and Electrical Components: M200 Windrowers ............................................61

3.13.3 Attaching Hydraulics and Electrical: M1240 Windrowers.............................................................67

3.14 Installing Other Options ....................................................................................................................71

3.14.1 Installing Tall Crop Divider........................................................................................................71

3.14.2 Installing Double Windrow Attachment (DWA) ........................................................................... 72

3.14.3 Installing Skid Shoes (Optional)................................................................................................73

3.14.4 Installing Gauge Rollers (Optional) ........................................................................................... 73

3.14.5 Installing Tall Crop Feed Plates ................................................................................................74

TABLE OF CONTENTS

214367 vi Revision A

3.14.6 Installing Nut Protectors (for Blade Hardware on Discs)..............................................................74

3.15 Lubricating the Header .....................................................................................................................75

3.15.1 Driveshields ............................................................................................................................75

Opening the Driveshield: North American Headers...................................................................... 75

Closing the Driveshield: North American Headers .......................................................................75

Opening the Driveshield: Export Headers ...................................................................................76

Closing the Driveshield: Export Headers..................................................................................... 76

3.15.2 Greasing Procedure ................................................................................................................77

3.15.3 Lubrication Points....................................................................................................................77

Chapter 4: Performing Predelivery Checks ............................................ ....................................... 81

4.1 Checking Drive Belts ..........................................................................................................................81

4.2 Checking Header Float: M200 and M205 Windrowers...........................................................................83

4.3 Checking Header Float: M1240 Windrowers ........................................................................................84

4.3.1 Setting the Float: M1240 Windrower ...........................................................................................84

4.4 Checking Header Level ......................................................................................................................86

4.5 Checking 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 ..................................................................................................97

5.1.2 Metric Bolt Specifications...........................................................................................................99

5.1.3 Metric Bolt Specifications Bolting into Cast Aluminum ................................................................101

5.1.4 Flare-Type Hydraulic Fittings.................................................................................................... 102

5.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) .... ................................................................103

5.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable)............................................................. 105

5.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings .............................................................................106

5.1.8 Tapered Pipe Thread Fittings ...................................................................................................107

5.2 Conversion Chart. ............................................................................................................................ 108

5.3 Definitions ....................................................................................................................................... 109

Predelivery Checklist......................................................................................................................... 1 1 1

TABLE OF CONTENTS

214367 1 Revision A

1 Safety

1.1 Signal Words

Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations.

The appropriate signal word for each situation has been selected using the following guidelines:

DANGER

Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

It 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 unsafe practices.

214367 2 Revision A

1.2 General Safety

1000004

Figure 1.1: Safety Equipment

CAUTION

The following are general farm safety precautions that

should be part of your operating procedure for all types

of machinery.

Protect yourself.

• When assembling, operating, and servicing machinery,

wear all protective clothing and personal safety devices

that could be necessary for job at hand. Do NOT take

chances. You may need the following:

• Hard hat

• Protective footwear with slip resistant soles

• Protective glasses or 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 the machine. Be sure fire

extinguisher is properly maintained. Be familiar with its

proper use.

• Keep young children away from machinery at all times.

• Be aware that accidents often happen when Operator is

tired or in a hurry. Take time to consider safest way.

Never ignore warning signs of fatigue.

SAFETY

214367 3 Revision A

1000007

Figure 1.4: Safety around Equipment

• Wear close-fitting clothing and cover long hair. Never

wear dangling items such as scarves or bracelets.

• Keep all shields in place. NEVER alter or remove safety

equipment. Make sure driveline guards can rotate

independently of shaft and can telescope freely.

• Use only service and repair parts made or approved by

equipment manufacturer. Substituted parts may not meet

strength, design, or safety requirements.

1000008

Figure 1.5: Safety around Equipment

• Keep hands, feet, clothing, and hair away from moving

parts. NEVER attempt to clear obstructions or objects

from a machine while engine is running.

• Do NOT modify machine. Unauthorized modifications

may impair 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

electrical equipment. Be sure all electrical outlets and

tools are properly grounded.

• Keep work area well lit.

• Keep machinery clean. Straw and chaff on a hot engine is

a fire hazard. Do NOT allow oil or grease to accumulate

on service platforms, ladders, or controls. Clean

machines before storage.

• NEVER use gasoline, naphtha, or any volatile material for

cleaning purposes. These materials may be toxic and/or

flammable.

• When storing machinery, cover sharp or extending

components to prevent injury from accidental contact.

SAFETY

214367 4 Revision A

1.3 Safety Signs

1000694

Figure 1.7: Operator’s Manual Decal

• Keep safety signs clean and legible at all times.

• Replace safety signs that are missing or become illegible.

• If original parts on which a safety sign was installed are

replaced, be sure repair part also bears current

safety sign.

• Safety signs are available from your MacDon Dealer.

SAFETY

214367 5 Revision A

2 Unloading the Header

CAUTION

To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in

unloading area.

CAUTION

Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate

equipment may result in chain breakage, vehicle tipping, or machine damage.

1013855

A

B

C

Figure 2.1: Minimum Lifting Capacity

A - Load Center of Gravity

B - Load Center 1220 mm (48 in.) from Back of Forks

C - Minimum Fork Length 1981 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 sure forks are secure before moving away from load.

Stand clear when lifting.

2. Approach header from its underside and slide forks in

under the lifting framework as far as possible.

IMPORTANT:

If load is two units wide, take care to avoid contacting

the other machine.

3. Raise header off the deck.

214367 6 Revision A

1009204

Figure 2.3: Moving Header with Forklift

4. Back up until the 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

214367 7 Revision A

3 Assembling the Header

3.1 Removing Underside Shipping Support and Installing

Auger Pan

CAUTION

Keep feet clear when removing final bolts.

1009307

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.

214367 8 Revision A

1009346

A

B

C

D

Figure 3.3: Auger Pan Installed

5. Position auger pan (A) against cutterbar lugs and install

four 1/2 x 3.5 in. long bolts (B) and lock nuts. Do NOT

fully tighten.

6. Check and make sure that auger pan is oriented

as shown.

7. Check 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 flush against the

cutterbar lugs.

ASSEMBLING THE HEADER

214367 9 Revision A

3.2 Installing Skid Shoes (Optional)

NOTE:

This kit may be installed later in the assembly sequence, but installation may be easier prior to laying the header

down.

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 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 HEADER

214367 10 Revision A

3.3 Installing Gauge Rollers (Optional)

NOTE:

This kit may be installed 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

214367 11 Revision A

3.4 Lowering Header

CAUTION

Equipment used for lowering the header must meet or exceed the requirements specified below. Using

inadequate equipment may result in chain breakage, vehicle tipping, or machine damage.

Table 3.1 Lifting Vehicle

Chain Type Overhead lifting quality 12.7 mm (1/2 in.)

Minimum Working Load

2270 kg (5000 lb.)

1023058

B

A

Figure 3.6: Spreader Bar Attached to Header

1. Attach spreader bar (A) to forks.

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 (4 ft.) vertical chain height.

IMPORTANT:

Do NOT lift at hooks when unloading from trailer. This

procedure is only for laying the machine over into

working position.

4. Raise forks until lift chains are fully tensioned.

ASSEMBLING THE HEADER

214367 12 Revision A

10093791011633

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

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MacDon R85 Unloading & Assembly Instruction

MacDon R85 Unloading & Assembly Instruction

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