MacDon R113 SP User Manual Download

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R113 SP

Rotary Disc Header

Operator

’

s Manual

215009 Revision A

Original Instruction

The harvesting specialists.

Summary of Contents for R113 SP

Page 1: ...R113 SP Rotary Disc Header Operator s Manual 215009 Revision A Original Instruction The harvesting specialists...

Page 2: ...in this publication MacDon Industries Ltd reserves the right to make changes at any time without notice Noise Levels The A weighted sound pressure level inside the operator s station of a typical self...

Page 3: ...Declaration of Conformity Figure 1 EC Declaration of Conformity 1029750 215009 i Revision A...

Page 4: ...Figure 2 EC Declaration of Conformity 1029751 215009 ii Revision A...

Page 5: ...settings in all relevant MacDon publications Failure to do so may compromise machine function and machine life and may result in a hazardous situation MacDon provides warranty for Customers who opera...

Page 6: ...lignment page 32 3 4 3 Attaching R113 SP to M155 or M155E4 SP Windrower Hydraulic Center Link without Optional Self Alignment page 37 Updated float linkage and safety prop illustrations ECN 58047 Conn...

Page 7: ...27 Updated cutterbar door illustration Tech Pubs Inspecting Rock Guards page 129 Updated rock guard illustration Tech Pubs Inspecting Large Drums page 135 Updated cutterbar drum illustration Tech Pubs...

Page 8: ...model year of the header on the lines below 1021877 A Figure 3 Right Side of Header R113 SP Header Model Serial Number Year The serial number plate A is located near the base of the right side hazard...

Page 9: ...indrower 24 3 3 2 Engaging and Disengaging Header Safety Props M Series Self Propelled Windrower 25 3 4 Attaching Header to Windrower 27 3 4 1 Attaching R113 SP Rotary Disc Header to M1 Series Windrow...

Page 10: ...cking Roll Timing 78 Adjusting Roll Timing 78 3 10 4 Adjusting Forming Shields Roll Conditioner 81 Positioning Forming Shield Side Deflectors Roll Conditioner 81 Positioning Rear Baffle Roll Condition...

Page 11: ...Inspecting Rock Guards 129 Removing Inboard Rock Guards 130 Installing Inboard Rock Guards 131 Removing Outboard Rock Guards 132 Installing Outboard Rock Guards 133 4 5 7 Maintaining Large Drums 134 I...

Page 12: ...hields 190 Replacing Driveshield Latch 191 4 11 Electrical System 192 4 11 1 Maintaining Electrical System 192 4 11 2 Replacing Amber Hazard Signal Light Fixture 193 4 11 3 Replacing Amber Hazard Sign...

Page 13: ...m 211 7 1 3 O Ring Boss Hydraulic Fittings Adjustable 212 7 1 4 O Ring Boss Hydraulic Fittings Non Adjustable 214 7 1 5 O Ring Face Seal Hydraulic Fittings 215 7 1 6 Tapered Pipe Thread Fittings 216 7...

Page 14: ......

Page 15: ...indicates important safety messages in this manual and on safety signs on the machine This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Carefully read and follow the safety message acc...

Page 16: ...ded 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 p...

Page 17: ...glasses or goggles Heavy gloves Wet weather gear Respirator or filter mask 1000005 Figure 1 3 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable...

Page 18: ...r machine function and or safety It may also shorten machine s life To avoid injury or death from unexpected startup of machine ALWAYS stop the engine and remove the key from the ignition before leavi...

Page 19: ...ting machine Make sure all components are tight and that steel lines hoses and couplings are in good condition before applying pressure to hydraulic systems Keep hands feet clothing and hair away from...

Page 20: ...sure Makeshift repairs will fail suddenly and create hazardous and unsafe conditions 1001207 Figure 1 12 Hydraulic Pressure Hazard Wear proper hand and eye protection when searching for high pressure...

Page 21: ...have with regard to future malfunctions or shorter lifespan It is very important that welding on the header is not attempted while the header is connected to the windrower If an Operator needs to do...

Page 22: ...repair part displays the current safety sign Replacement safety signs are available from your MacDon Dealer Parts Department 1 7 1 Installing Safety Decals 1 Clean and dry installation area 2 Decide...

Page 23: ...Locating Safety Decals Figure 1 15 Safety Sign Decal Locations Top View 1021067 A B C E F D A MD 194466 B MD 247167 C MD 194465 D MD 166466 E MD 113482 F MD 190546 Figure 1 16 Safety Sign Decals 1023...

Page 24: ...10 Revision A Figure 1 17 Safety Sign Decal Locations Roll Conditioner 1024756 D E A D E C B F F B C A MD 190546 B MD 184385 C MD 184371 D MD 246959 E MD 246956 F NO STEP Symbol Imprinted on Shield S...

Page 25: ...f the machine Keep all shields in place and stay clear of moving parts Disengage self propelled rotary disc header drive put transmission in Neutral and wait for all movement to stop before leaving op...

Page 26: ...ure 1 21 MD 184385 MD 184385 Entanglement hazard CAUTION To avoid injury from entanglement with rotating auger stand clear of header while machine is running 1004138 Figure 1 22 MD 190546 MD 190546 Sl...

Page 27: ...tractor and remove key before opening covers 1004141 Figure 1 24 MD 194466 MD 194466 Rotating fingers under hood WARNING STAND CLEAR Crop materials exiting at high speed Stop machine look listen and...

Page 28: ...result in death or serious injury 1010589 Figure 1 27 MD 247167 MD 247167 Rotating blades WARNING Disengage power take off shut off tractor and remove key before opening covers Listen and look for evi...

Page 29: ...Lighting Left and right turn signals Manual storage Plastic case on header right driveshield Cutterbar Number of cutting discs Eight Blades per disc Two 18 degrees bevel down Disc speed full engine s...

Page 30: ...nal Roll type Polyurethane intermeshing conditioner rolls Roll length 3275 mm 129 in Roll diameter 254 mm 10 0 in 203 mm 8 0 in OD tube Roll speed 1009 rpm Swath width1 915 2540 mm 36 102 in Forming s...

Page 31: ...K L A Front Curtains B Cutterbar Doors C Drive Shield Left D Hose Support2 E Hydraulic Motor3 F Hose Support G Center Link Tube H Hazard Brake Lights J Disc Drum Right K Conditioner Rolls L 8 Disc Cut...

Page 32: ...215009 18 Revision A Figure 2 2 R113 SP 1023134 A B D C F E A Header Supports B Side Deflectors C Side Deflector Adjuster Handles D Rear Crop Baffle E Adapter Frame F Drive Shield PRODUCT OVERVIEW...

Page 33: ...at have a hexagonal socket in head internal wrenching hexagon drive also known as an Allen key and various other synonyms hp Horsepower JIC Joint Industrial Council A standards body that developed sta...

Page 34: ...htening procedure where fitting is assembled to a precondition finger tight and then nut is turned farther a number of degrees to achieve its final position Torque tension The relationship between ass...

Page 35: ...listening from the operator s 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...

Page 36: ...y with you any protective clothing and personal safety devices that could be necessary throughout the day Don t take chances Remove foreign objects from the machine and surrounding area 1001351 Figure...

Page 37: ...working correctly NOTE Use proper procedure when searching for pressurized fluid leaks Refer to 4 12 1 Checking Hydraulic Hoses and Lines page 195 2 Clean all lights and reflective surfaces on the ma...

Page 38: ...ngage safety props when working on or around raised header and before going under header for any reason 1014786 A Figure 3 4 Ground Speed Lever 1 Start the engine Press the HEADER UP A switch to raise...

Page 39: ...eries Self Propelled Windrower Safety props are located on both header lift cylinders on the windrower Follow these steps to engage or disengage the header safety props DANGER To avoid bodily injury f...

Page 40: ...nexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1029697 A Figure 3 9 Safety Prop 1 Turn lever A away from...

Page 41: ...g the operator s seat for any reason 1016889 A B Figure 3 10 Hydraulic Center Link 1 Hydraulic Center Link without Self Alignment Remove pin A and raise center link B until hook is above the attachmen...

Page 42: ...manually Refer to windrower operator s manual for instructions 1015851 A B Figure 3 13 HPT Display 4 Press rotary scroll knob A on the display to highlight QuickMenu options 5 Rotate scroll knob A to...

Page 43: ...rts B Continue to drive slowly forward until feet engage the supports and header nudges forward 10 Ensure that feet A are properly engaged in supports B 1016903 A B C Figure 3 17 Hydraulic Center Link...

Page 44: ...cylinder CAUTION Check to be sure all bystanders have cleared the area e Start engine 1014786 A Figure 3 19 GSL 13 Press HEADER UP switch A to raise the header to maximum height NOTE If one end of th...

Page 45: ...Safety Prop 17 Disengage safety props on both lift cylinders as follows NOTE If safety prop will not disengage raise header to release the prop a Turn lever A away from header to raise safety prop unt...

Page 46: ...oth sides of the header 1029714 A B Figure 3 25 Float Linkage IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to the windrower...

Page 47: ...8 Header Support 6 Slowly drive the windrower forward until the windrower feet A enter header supports B Continue driving slowly forward until the feet engage the supports and the header nudges forwar...

Page 48: ...the center link locks into position and hook release B is down 10 Check that center link is locked onto header by pressing the REEL UP switch on the GSL CAUTION Check to be sure all bystanders have c...

Page 49: ...d rotate towards the header to release and lower safety prop B onto the lift cylinder c Repeat for opposite lift cylinder 1021447 A B Figure 3 33 Header Support 14 Install clevis pin A through support...

Page 50: ...ure 3 35 Safety Prop Lever 16 Disengage the safety prop by turning lever A downwards until lever locks into vertical position 17 Repeat for opposite safety prop 1008947 A Figure 3 36 Ground Speed Leve...

Page 51: ...ader Support 2 Remove hairpin B from clevis pin A and then remove clevis pin from header support C on both sides of the header 1029714 A B Figure 3 38 Header Float Linkage IMPORTANT To prevent damage...

Page 52: ...move pin A from frame linkage and raise center link B until hook is above the attachment pin on header Replace pin A to hold center link in place IMPORTANT If the center link is too low it may contact...

Page 53: ...g mechanism If the release is open up manually push it down after hook engages header pin 10 Check that center link A is locked onto the header by pulling upward on rod end B of cylinder 1008946 A Fig...

Page 54: ...rotate towards the header to release and lower safety prop B onto the lift cylinder c Repeat for opposite lift cylinder 1021447 A B Figure 3 46 Header Support 15 Install clevis pin A through the suppo...

Page 55: ...ure 3 48 Safety Prop Lever 17 Disengage the safety prop by turning lever A downwards until lever locks into vertical position 18 Repeat for opposite safety prop 1008947 A Figure 3 49 Ground Speed Leve...

Page 56: ...aulics and Electrical M155 and M155E4 SP Windrowers page 45 Connecting Header Hydraulics and Electrical M1 Series Windrowers 1027018 Figure 3 50 Hydraulic Drive Kit MD B6621 NOTE Hydraulic drive kit A...

Page 57: ...53 Hose Support 4 Rest hose bundle routed from windrower on header s hose support A 5 If necessary use a clean rag to remove dirt and moisture from the couplers 1027021 A B C D Figure 3 54 Header Driv...

Page 58: ...c and Electrical Connections Draper Ready Configuration 8 For M1240 Connect hydraulic hoses and electrical harness to receptacles on windrower as follows a Connect pressure hose to receptacle A b Conn...

Page 59: ...the operator s seat for any reason 1027204 A Figure 3 57 Hydraulic Drive Kit MD B6272 NOTE Hydraulic drive kit A MD B6272 is required for an R113 SP Disc Header to operate correctly on M155 and M155E4...

Page 60: ...on the header 1005197 A Figure 3 60 Hose Support 4 Position the hose support with lower bolt A in the forward hole as shown in the illustration at right Loosen both bolts and adjust as required 10215...

Page 61: ...Refer to your windrower operator s manual for instructions 1010938 A B C Figure 3 63 Hose Bundle 7 Route the windrower hose bundle A through hose support B on the header NOTE Route hoses as straight a...

Page 62: ...ort M2 B on the windrower s auxiliary disc drive manifold middle valve block 1029753 A B B C Figure 3 65 Hydraulic Connections 10 Remove caps and plugs from hoses on windrower and lines on header 11 C...

Page 63: ...steel line B attached to the aft port on the header motor 1029755 B C A B D Figure 3 67 Windrower Hose Connections with Reverser NOTE If the windrower is equipped with a reverser manifold A for an au...

Page 64: ...nect case drain hose A from the lift manifold port T3 C to the 1 2 in female coupler at the bulkhead which is attached to motor port B 1021530 B A Figure 3 69 Electrical Connection 14 Connect electric...

Page 65: ...sion A 1005204 A B C Figure 3 70 Hose Bundle 15 Lower and lock lever A 16 Secure hose B with three adjustable straps C 1005193 A Figure 3 71 Top View of Windrower 17 Move platform A to the CLOSED posi...

Page 66: ...ed the area 1014786 A Figure 3 72 GSL 1 Start the engine and press switch A to raise the header to the maximum height 2 Stop the engine and remove the key 1029799 A Figure 3 73 Safety Prop 3 Disengage...

Page 67: ...al harness A and hydraulic hoses B C and D from the windrower 1019603 A Figure 3 75 Hoses on Windrower 6 Remove hose support A and hose bundle from windrower frame 1021553 B C A Figure 3 76 Hose Stora...

Page 68: ...er in Step 5 page 53 into storage plate C NOTE Install caps and plugs on open lines to prevent buildup of dirt and debris while in storage NOTE Some parts removed from the illustration for clarity 100...

Page 69: ...op will not disengage raise header to release the prop a Turn lever A away from header to raise safety prop until lever locks into vertical position b Repeat for opposite cylinder 12 Repeat for the op...

Page 70: ...from the header Non self aligning center link 1021572 B A Figure 3 82 Hydraulic Center Link 17 Shut off the engine and remove the key 18 Lift hook release A and lift hook B off header pin CAUTION Che...

Page 71: ...on before leaving the operator s seat for any reason 1 Lower the header to the ground If the ground is soft place blocks under the header 2 Stop the engine and remove the key 1005185 A Figure 3 84 Win...

Page 72: ...straps C 6 Move hose B to store on header D A D 1010953 A B C Figure 3 87 Hose Bundle 7 Disconnect the following hoses from the hydraulic motor Pressure hose A Return hose B Case drain hose C 8 Insta...

Page 73: ...engage NOTE Hydraulic lines and hoses hidden on illustration to show the electrical connection 1005217 A B C Figure 3 89 Hose Bundle 10 Move the hose bundle from header to the left side cab forward ho...

Page 74: ...Revision A 1005193 A Figure 3 90 M155 Windrower 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...

Page 75: ...ace and secured 1018506 Figure 3 91 Left Driveshield NOTE Images shown in this procedure are for the left driveshield the right driveshield is similar 1010707 A B C Figure 3 92 Left Driveshield 1 Remo...

Page 76: ...osing Driveshields CAUTION To reduce the risk of personal injury do NOT operate the machine without the driveshields in place and secured NOTE Images shown in this procedure are for the left driveshie...

Page 77: ...215009 63 Revision A 1010707 A B C Figure 3 96 Left Driveshield 4 Replace tool B and lynch pin A on pin C OPERATION...

Page 78: ...ered when operating the disc header Rotary disc headers sold outside of North America have latches on the cutterbar door IMPORTANT Replace curtains if they become worn or damaged Refer to 4 9 Maintain...

Page 79: ...unexpected startup of machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and remove the key from the ignition...

Page 80: ...the latch 3 7 3 Closing Cutterbar Doors CAUTION To avoid injury keep hands and fingers away from corners of doors when closing 1020932 A Figure 3 102 Cutterbar Doors and Curtains 1 Pull down on door...

Page 81: ...ectors 3 11 Cutterbar Deflectors page 84 3 8 1 Cutting Height Cutting height is determined by a combination of the cutterbar angle and skid shoe settings Adjust cutting height for optimum cutting perf...

Page 82: ...nition 3 Engage the header safety props For instructions refer to 3 3 Engaging and Disengaging Header Safety Props page 24 4 Loosen bolts C 5 Remove bolts nuts and washers D 6 Raise or lower the skid...

Page 83: ...olt and fine adjustment done through the Cab Display Module CDM in the windrower cab The header float feature allows the header to closely follow ground contours and respond quickly to sudden changes...

Page 84: ...tive grasses set the disc speed to MAXIMUM In light crops reduce the disc header s disc speed while maintaining ground speed NOTE Operating the disc header at the minimum disc speed will extend the we...

Page 85: ...he number of crop streams will also increase the number of diverging disc pairs which may negatively affect cut quality in certain conditions 1019153 A B C Figure 3 107 Cutterbar Spindles IMPORTANT Sp...

Page 86: ...Stream B Three Crop Streams NOTE Refer to Removing Cutterbar Spindles page 111 and Installing Cutterbar Spindles page 114 To change R113 SP 8 disc spindle rotation from three crop streams B to one cro...

Page 87: ...ethane rolls are better suited for crushing stems while providing reduced crimping and are recommended for alfalfa clover legumes and similar crops Correct crop conditioning is achieved when 90 of the...

Page 88: ...ert a feeler gauge through the inspection hole in the conditioner endsheet to check roll gap on polyurethane roll conditioners Factory setting is 3 mm 1 8 in If adjustments are required refer to Adjus...

Page 89: ...he engine and remove the key from the ignition 1018573 A B Figure 3 111 Roll Gap Adjustment 3 Loosen upper jam nut A on both sides of the conditioner 4 Turn lower nut B counterclockwise until the uppe...

Page 90: ...n 1018573 A B Figure 3 112 Roll Gap Adjustment 3 Loosen jam nut A on both sides of the conditioner 4 Turn lower nut B counterclockwise until the upper roll rests on the lower roll Ensure the rolls int...

Page 91: ...s seat for any reason 1 Lower the header to the ground 2 Shut down the engine and remove the key from the ignition A B C D 1008077 Figure 3 113 Adjusting Roll Tension 3 Loosen jam nut A on both sides...

Page 92: ...m the conditioner rolls 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...

Page 93: ...roll B in a counterclockwise direction until it stops 5 Make a mark C across yoke D and gearbox flange E 1018513 A B Figure 3 117 Conditioner Drive 6 Manually rotate upper roll A in a clockwise direct...

Page 94: ...roll B counterclockwise until the bolt lines up with the third center mark 1018518 A Figure 3 119 Conditioner Drive 9 Ensure the threads on four bolts A are clean and free of lubricant NOTE Only three...

Page 95: ...allows only a few days to cut and bale A narrower windrow may be preferable for ease of pick up and when drying is not critical for example when cutting for silage or green feed Positioning Forming S...

Page 96: ...ns refer to Positioning Rear Baffle Deflector Fins page 83 To position the rear baffle follow these steps DANGER To avoid bodily injury or death from unexpected startup of machine always stop engine a...

Page 97: ...aving operator s seat for any reason 1023132 A B Figure 3 122 Deflector Fins in Storage Position 1 Remove the two deflector fins A from rear baffle B 1023133 A B Figure 3 123 Left Deflector Fins in Fi...

Page 98: ...ove key and engage windrower lift cylinder safety props before going under machine for any reason 1 Raise the header fully 2 Shut down the engine and remove the key from the ignition 3 Engage the head...

Page 99: ...from Underside of Cutterbar 5 Position left deflector A on the aft edge of the cutterbar and align slots in deflector A with the existing fasteners and cutterbar plug 6 Install bolt C shared with rock...

Page 100: ...Use a moisture tester or estimate level If ground is wet due to irrigation wait until soil moisture drops below 45 If ground is wet due to frequent rains cut hay when weather allows and let the forage...

Page 101: ...ales to minimize handling and stacking problems Properly conditioned Prevents excessive leaf damage 3 12 5 Driving on Windrow Driving on previously cut windrows that will not be raked can lengthen dry...

Page 102: ...r information on transporting the header when attached to the windrower refer to your windrower operator s manual IMPORTANT For cab forward road travel the M155 and M155E4 windrower must have the ligh...

Page 103: ...age 93 to keep track of your scheduled maintenance 4 1 Preparing Machine for Servicing CAUTION To avoid personal injury perform the following procedures before servicing self propelled disc header or...

Page 104: ...igure 4 2 Safety Equipment Wear protective shoes with slip resistant soles a hard hat protective glasses or goggles and heavy gloves 1003660 Figure 4 3 Safety Around Equipment Be aware that if more th...

Page 105: ...ngerous when working with electrical equipment Be sure all electrical outlets and tools are properly grounded Use adequate light for the job at hand Replace all shields removed or opened for service U...

Page 106: ...ized according to service intervals If more than one interval is specified for a service item e g 100 hours or annually service the machine at whichever interval is reached first When servicing the ma...

Page 107: ...page 125 Inspect rock guards Refer to Inspecting Rock Guards page 129 Inspect drums Refer to Inspecting Large Drums page 135 Check hydraulic hoses and lines Refer to 4 12 1 Checking Hydraulic Hoses a...

Page 108: ...Check roll timing gearbox lubricant Refer to 4 6 1 Checking and Changing Oil in Conditioner Roll Timing Gearbox MD 221748 or MD 307211 page 158 Check header drive gearbox lubricant Refer to 4 7 1 Cha...

Page 109: ...ant 4 7 1 Changing Header Drive Gearbox Oil page 161 150 Hours Check conditioner drive belt tension Inspecting Conditioner Drive Belt page 172 4 3 3 Preseason Servicing CAUTION Review the operator s m...

Page 110: ...ate repair of these items will save time and effort at beginning of next season 5 Replace or tighten any missing or loose hardware Refer to 7 1 Torque Specifications page 209 6 Lubricate the header th...

Page 111: ...ack cover for a list of recommended fluids and lubricants WARNING To avoid bodily injury or death from unexpected startup of machine always stop the engine and remove the key from the ignition before...

Page 112: ...ified Figure 4 7 Every 25 Hours 1024789 B B A B B C D E D A Idler Tensioner Pivot B Bearing Roller Conditioner 4 Places C U Joint Upper Driveline 2 Places D Slip Joints Conditioner Drivelines 6 E U Jo...

Page 113: ...and remove the key from the ignition before leaving the operator s seat for any reason WARNING Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear glove...

Page 114: ...Cutterbar Oil Inspection Plug 7 Clean the area around plug A Place a 5 liter 5 2 US qts capacity container under plug A 8 Use a 17 mm socket to remove plug A and O ring B from cutterbar Oil level must...

Page 115: ...d to check the oil level IMPORTANT Do NOT overfill the cutterbar Overfilling can cause overheating damage or failure of cutterbar components NOTE Refer to the inside back cover of this manual for lubr...

Page 116: ...right end of the disc header Draining lubricant from the left end of the disc header may lead to breather contamination or failure 4 Lower the disc header onto the blocks 5 Shut down the engine and r...

Page 117: ...eft end 3 Lower the header onto the blocks 4 Shut down the engine and remove the key from the ignition 5 Remove access plug A from the raised end of the cutterbar and add the EXACT amount of lubricant...

Page 118: ...o repair the cutterbar discs Always use factory replacement parts Inspecting Cutterbar Discs WARNING To avoid bodily injury or death from unexpected startup of machine always stop the engine and remov...

Page 119: ...wear and disc distortion Replace as required 4 Inspect the cutterbar disc edges E for cracks excessive wear and edge distortion Replace as required NOTE Cutterbar discs are NOT repairable and must be...

Page 120: ...cutting edges that can cause serious injury Exercise caution and wear gloves when working with blades 1 Raise the header fully 2 Shut off the engine and remove key from the ignition 3 Engage windrower...

Page 121: ...ce a pin or equivalent in the front hole of the rock guard B to prevent disc rotation while loosening bolts 6 Remove four M12 bolts A and washers 1004039 A B Figure 4 21 Cutterbar Disc and Cap 7 Remov...

Page 122: ...ate A on spindle 1011305 B A C D Figure 4 23 Cutterbar Disc and Cap 2 Place a pin or equivalent in the front hole of the rock guard D to prevent disc rotation while tightening bolts 3 Position new dis...

Page 123: ...ched to a spindle containing a shear pin A If the disc contacts a large object such as a stone or stump the pin will shear and the disc will stop rotating and move upwards while remaining attached to...

Page 124: ...g and are identified by machined grooves on the spindle gear shaft B and nut C If the spindle position in the cutterbar has changed the rotational direction of that spindle MUST remain the same that i...

Page 125: ...ous injury Exercise caution and wear gloves when working with blades 1 Park on a flat level surface 2 Lower the header fully NOTE To prevent oil from spilling from the cutterbar when removing disc spi...

Page 126: ...t disc rotation while loosening bolts 6 Remove four M12 bolts A and washers 1004039 A B Figure 4 29 Cutterbar Disc and Cap 7 Remove cutterbar disc cap A 8 Remove cutterbar disc B IMPORTANT Blades are...

Page 127: ...5 A B Figure 4 31 Left Spindle Hub and Hardware 10 Rotate spindle hub A to access nuts and remove eleven M12 lock nuts B and washers 1011379 A Figure 4 32 Left Spindle 11 Remove spindle A from cutterb...

Page 128: ...dle to clear mounting bolts rotate spindle 180 degrees ensuring that base does not turn and reinstall Recheck timing before bolting hub down and tightening all of the nuts NOTE Right discs A and left...

Page 129: ...c header is on a flat level surface and is tilted all the way back 3 Determine suitable spindle rotation pattern for crop conditions For instructions refer to 4 5 3 Replacing Cutterbar Spindles page 1...

Page 130: ...esign makes it possible to install spindles that rotate in the wrong direction This will prevent discs from spinning up after impact resulting in cutterbar component damage 1011375 A B Figure 4 37 Lef...

Page 131: ...to the adjacent discs NOTE Turn disc A by hand to ensure discblades do not contact each other or adjacent discs 13 Install cutter disc cap B and secure assembly with four M12 bolts and washers C Torq...

Page 132: ...two cutting edges and can be flipped over so that the blade does not need replacing as often The blades are NOT repairable and must be replaced if severely worn or damaged IMPORTANT Always use factor...

Page 133: ...e damaged blades immediately CAUTION Damaged or loose discblades or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage A B C 1003888 Figu...

Page 134: ...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 3 9 1 Changing R113 SP Cutter...

Page 135: ...instructions refer to Removing Discblades page 122 and Installing Discblades page 124 for hardware replacement procedure 1008430 A B C D D E E Figure 4 46 Discblade Bolts 1 Check and replace bolt if...

Page 136: ...emove key and engage windrower lift cylinder safety props before going under machine for any reason CAUTION Discblades have two sharp cutting edges that can cause serious injury Exercise caution and w...

Page 137: ...B C A Figure 4 50 Discblade 5 Place a pin or equivalent in the front hole of the rock guard to prevent disc rotation while loosening blade bolts 6 Clean debris from blade attachment area 7 Remove nut...

Page 138: ...isc rotation while tightening blade bolts 2 Install new or reversed blade A with shoulder bolt B onto disc C IMPORTANT Nuts are one time use only When flipping or changing a blade replace using a NEW...

Page 139: ...remove the key from the ignition before leaving the operator s seat for any reason 1 Raise the header fully 2 Shut down the engine and remove the key from the ignition 3 Engage the windrower lift cyl...

Page 140: ...o 3 3 Engaging and Disengaging Header Safety Props page 24 1021476 A Figure 4 55 Cutterbar Doors 4 Open cutterbar doors A For instructions refer to 3 7 1 Opening Cutterbar Doors North America page 64...

Page 141: ...ith blades IMPORTANT Always replace accelerators in pairs to ensure proper disc balance 1018993 A B C D Figure 4 58 Accelerator Install 1 Place a wooden block between two cutterbar discs to prevent di...

Page 142: ...to 125 Nm 92 lbf ft 6 Repeat the installation procedure for the second accelerator WARNING Ensure the cutterbar is completely clear of foreign objects Foreign objects can be ejected with considerable...

Page 143: ...when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades 1 Raise the header fully 2 Shut down the engine and remove the key from the ignition 3 Eng...

Page 144: ...ards 1003622 A Figure 4 63 Inboard Rock Guards 1 Remove two hex head screws washers and lock nuts A 1003630 A B Figure 4 64 Inboard Rock Guards 2 Slide inboard rock guard A forward in the direction of...

Page 145: ...nboard rock guard onto cutterbar until tabs A sit on top of the cutterbar and bottom back bolt holes line up 1003622 A Figure 4 66 Inboard Rock Guards 2 Install two hex head screws washers and lock nu...

Page 146: ...e ignition 3 Engage the header safety props For instructions refer to 3 3 Engaging and Disengaging Header Safety Props page 24 1027053 A B C Figure 4 67 Left Outboard Rock Guard View from Rear 4 Locat...

Page 147: ...fer to 3 3 Engaging and Disengaging Header Safety Props page 24 1027045 A B Figure 4 69 Left Outboard Rock Guard Angled 5 Apply medium strength threadlocker Loctite 242 or equivalent to bolt B NOTE So...

Page 148: ...trength threadlocker Loctite 242 or equivalent on two hex head screws C Loosely install with lock nuts 12 Install the M16 x 60 bolt A MD 136141 and one washer B as shown Torque bolts A and D to 251 Nm...

Page 149: ...Figure 4 74 Cutterbar Doors 3 Open cutterbar doors A For instructions refer to 3 7 1 Opening Cutterbar Doors North America page 64 1029730 A B Figure 4 75 Cutterbars A Large Drums B Large Driven Drum...

Page 150: ...engage windrower lift cylinder safety props before going under machine for any reason WARNING Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves...

Page 151: ...d bolts A and remove vertical driveshield B 1011077 A B Figure 4 79 Cover Plate 3 Remove two M10 hex flange head bolts A and remove cover plate B 1011327 A B C Figure 4 80 Top Plate and Drum Top 4 Rem...

Page 152: ...ge head bolts B and vertical shield C 1011136 A B Figure 4 82 Drum Shields 6 Remove eight M8 hex flange head bolts A and remove two drum shields B 1011137 A A B C Figure 4 83 Hub Drive and Driveline A...

Page 153: ...p and out of the drum NOTE For clarity the illustration shows a cutaway view of drum and tube shield 1024792 A Figure 4 85 Driven Drum 9 Inside the drum use a 305 mm 12 in extension and 18 mm socket t...

Page 154: ...p and can cause serious injury Wear gloves when handling blades NOTE Illustrations show left the drum and driveline 1017492 A Figure 4 86 Spacer Plate 1 Ensure spacer plate A is on the spindle 1024792...

Page 155: ...D 6 Insert splined spindle end A into the splined bore on driveline B 1011137 A A B C Figure 4 89 Driveline 7 Place a bead of medium strength threadlocker Loctite 243 or equivalent around the threads...

Page 156: ...e head bolts C Use bolts B and C to secure the vertical shield in place Torque to 61 Nm 45 lbf ft 1011327 A B C Figure 4 92 Driveline Shield 10 Position top plate B and drum top C onto the drum as sho...

Page 157: ...ough cover plate A and vertical shield E Torque hardware to 61 Nm 45 lbf ft 13 Tighten bolts B and D 1011078 A B Figure 4 94 Driveline Shield 14 Position vertical driveshield B as shown at right Apply...

Page 158: ...215009 144 Revision A 1026996 A Figure 4 95 Cutterbar Doors and Curtains Header 15 Close cutterbar doors A For instructions refer to 3 7 3 Closing Cutterbar Doors page 66 MAINTENANCE AND SERVICING...

Page 159: ...d the blades Blades are sharp and can cause serious injury Wear gloves when handling blades 1021476 A Figure 4 96 Cutterbar Doors 1 Open cutterbar doors A For instructions refer to 3 7 1 Opening Cutte...

Page 160: ...evision A 1024794 B A Figure 4 98 Non Driven Drum 4 Remove the four M10 bolts A inside the drum using a 305 mm 12 in extension and 16 mm socket 5 Remove wooden block 6 Remove drum disc B MAINTENANCE A...

Page 161: ...aution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades 1017492 A Figure 4 99 Non Driven Spindle 1 Ensure spacer A is on spindle 1024794 B...

Page 162: ...bf ft WARNING Ensure the cutterbar is completely clear of foreign objects Foreign objects can be ejected with considerable force when the machine is started and may result in serious injury or machine...

Page 163: ...rotating and move upwards while remaining attached to the spindle with a snap ring B IMPORTANT Ensure correct orientation of the shear pins during replacement Spindles that rotate clockwise have right...

Page 164: ...ar gloves when working with blades 1 Raise the header fully 2 Shut off the engine and remove the key from the ignition 3 Engage windrower lift safety props For instructions refer to 3 3 Engaging and D...

Page 165: ...removal procedure To remove cutterbar disc A refer to Removing Cutterbar Discs page 106 To remove driven drum B refer to Removing Large Driven Drums and Driveline page 136 To remove non driven drum C...

Page 166: ...ear shaft A Spindles that rotate counterclockwise have left leading threading and machined grooves on the spindle gear shaft B and nut C If the spindle position in the cutterbar has changed the rotati...

Page 167: ...1 Use the safecut spindle nut wrench and remove nut A 1016456 A B Figure 4 111 Cutterbar Spindle 12 Remove shear pins B Do NOT damage the pin bore on the pinion 13 Remove hub A 14 Check the nut and hu...

Page 168: ...ng with blades 1016458 A B C Figure 4 112 Cutterbar Spindle 1 Fill the space above the bearing with grease 2 Place hub A on spindle C 3 Install shear pins B NOTE Ensure that the ends of shear pins B d...

Page 169: ...not done the proper torque will NOT be applied to the nut 7 Position safecut spindle nut wrench B on spindle nut C Torque nut to 300 Nm 221 lbf ft 8 Return safecut spindle nut wrench B to the left shi...

Page 170: ...ructions refer to Installing Cutterbar Discs page 108 Install driven drum B For instructions refer to Installing Large Driven Drums and Driveline page 140 Install non driven drum C For instructions re...

Page 171: ...215009 157 Revision A 1021489 A Figure 4 119 Cutterbar Doors 14 Close cutterbar doors A For instructions refer to 3 7 3 Closing Cutterbar Doors page 66 MAINTENANCE AND SERVICING...

Page 172: ...equent oil changes every 250 hours or annually preferably before the start of the cutting season Refer to the inside back cover for a list of recommended fluids lubricants and capacity DANGER To avoid...

Page 173: ...B Figure 4 122 Roll Timing Gearbox 4 Clean around oil level sight glass A and breather B on the inboard side of the gearbox 5 Ensure that the lubricant is level at the top of the sight glass If neces...

Page 174: ...indrower lift cylinder safety props For instructions refer to 3 3 Engaging and Disengaging Header Safety Props page 24 10 Clean around oil drain plug A on the bottom of the gearbox and around oil leve...

Page 175: ...Maintenance Schedule Record page 93 4 7 1 Changing Header Drive Gearbox Oil Change oil after the first 50 hours of operation Perform subsequent oil changes every 250 hours or annually preferably befo...

Page 176: ...nd tighten 8 Remove the oil level plug from bore hole B 9 Remove the plug from fill hole C 10 Add lubricant through fill hole C until the oil level is even with bore hole B For a list of recommended f...

Page 177: ...ure 4 126 Right Cutterbar Door in Open Position 2 Inspect hinge pin bolts A and tighten to 68 5 Nm 50 5 lbf ft if loose 3 Check the door for cracks and repair if required 4 Check for exposed metal sur...

Page 178: ...features that reduce the potential for thrown objects Always keep these curtains down when operating the header WARNING To reduce the risk of personal injury or machine damage do NOT operate the mach...

Page 179: ...emove curtain C 4 9 3 Installing Cutterbar Door Curtains The procedure for installing cutterbar door curtains is the same for both doors 1020948 A B C D E Figure 4 131 Cutterbar Curtain 1 Insert seven...

Page 180: ...tterbar Doors North America page 64 1020979 A B Figure 4 133 Inboard Curtain 2 Remove two M10 carriage head bolts A and nuts securing curtain assembly B to the disc header and remove curtain assembly...

Page 181: ...136 Inboard Curtain 2 Install curtain onto weld and bolt studs on center shield install two curtain brackets B and secure with four nuts A 3 Torque hardware to 28 Nm 21 lbf ft IMPORTANT To avoid dama...

Page 182: ...s A For instructions refer to 3 7 1 Opening Cutterbar Doors North America page 64 1020992 A B Figure 4 139 Left Endsheet 2 Remove four bolts large washers and nuts A securing outboard curtain B to end...

Page 183: ...rs North America page 64 1021000 D B A C Figure 4 142 Outboard Curtain 2 Install curtain A into bracket B 3 Install two nuts D and tighten 4 Slide bracket B into position and install the square neck c...

Page 184: ...xpected start up or fall of a raised machine stop engine remove key and engage windrower lift cylinder safety props before going under machine for any reason WARNING Exercise caution when working arou...

Page 185: ...gure 4 146 Conditioner Roll Left Bearing 5 Inspect conditioner roll left bearing A for signs of wear or damage If the bearing needs replacing contact your Dealer 1010987 A Figure 4 147 Conditioner Dri...

Page 186: ...t Inspecting Conditioner Drive Belt Check the belt tension and inspect for damage or wear every 100 hours or annually preferably before the start of the cutting season WARNING To avoid bodily injury o...

Page 187: ...054 B A C Figure 4 151 Belt Tension Spring 6 Measure the length of belt tensioner spring A and ensure spring length B is 366 mm 14 3 8 in in accordance with spring tension decal C If spring length req...

Page 188: ...m the ignition 3 Open the left driveshield For instructions refer to 3 6 1 Opening Driveshields page 61 1023177 A B Figure 4 152 Speed Sensor Assembly 4 Disconnect wire harness A from speed sensor B 1...

Page 189: ...n onto drive pulley B ensuring that the belt is in the pulley grooves NOTE If necessary loosen the jam nut and adjuster nut to relieve the spring tension 1023361 A B C D Figure 4 155 Conditioner Drive...

Page 190: ...B to wiring harness A NOTE Ensure the speed sensor is installed correctly for the windrower use the bottom hole for M1 Series use the top hole for M155E4 SP Windrower 9 Close the left driveshield For...

Page 191: ...eader from the windrower before proceeding 1 Remove the driveshields For instructions refer to Removing Driveshields page 188 For instructions refer to header operator s manual or technical manual 2 R...

Page 192: ...4 160 Supporting Frame Using Chain Method 2 a To protect the finish on the frame wrap packing foam A or equivalent around the frame at approximately the locations shown b Position forks B under the p...

Page 193: ...aching frame as frame may shift when bolts are removed 9 Remove bolt A from frame C If necessary adjust the height of the forks to improve access to bolt A Repeat at the opposite side of the frame Ret...

Page 194: ...n detaching frame as frame may shift when bolts are removed 14 Adjust the height of the forks to raise the conditioner slightly Remove the loosened bolts and retain hardware for reinstallation 1024879...

Page 195: ...s so that it cannot slide off the forks or towards the header while attaching the conditioner to the header Failure to do so could result in death or serious injury 2 Lift conditioner C and align it w...

Page 196: ...evice clear of the work area 8 If necessary install conditioner drive components For instructions refer to Installing Conditioner Drive page 185 WARNING To prevent frame from slipping off forks ensure...

Page 197: ...in C around the end of the forks and attach it to the forklift d Pick up the frame and position it against the header A B C Figure 4 175 Frame Left Side Shown 10 Slowly move forward until lift arm C i...

Page 198: ...nter Link Support 18 With flat washer shim A on both sides of the center link support install securing bolt B and washer C through the conditioner center link support bracket and center link support 1...

Page 199: ...ons refer to Installing Driveshields page 190 Installing Conditioner Drive This procedure describes the installation of conditioner drive components on a machine that was originally supplied with no c...

Page 200: ...s F and straight pin G NOTE Install the conditioner drive belt after reattaching the header to the adapter 4 10 4 Replacing Shield No Conditioner Removing Discharge Shield No Conditioner Follow these...

Page 201: ...ured without a conditioner 1024824 A B C D D Figure 4 187 Left Side of Header Right Opposite 1 Position shield A until pins B engage the slots in support C and bolt holes in shield align with holes D...

Page 202: ...ds CAUTION To reduce the risk of personal injury do NOT operate the machine without the driveshields in place and secured 1021830 A Figure 4 189 Left Driveshield NOTE Images shown in this procedure ar...

Page 203: ...eld and Latch 2 Insert the flat end of tool A into latch B and turn it counterclockwise to unlock 1010709 A Figure 4 192 Driveshield 3 Pull the top of driveshield A away from the header and lift off t...

Page 204: ...left driveshield the right driveshield is similar 1021884 B B A C Figure 4 193 Driveshield and Latch 1 Position driveshield A onto pins B at the base of driveshield 2 Push the driveshield to engage la...

Page 205: ...Removing Driveshields page 188 1010701 A Figure 4 196 Backside of Driveshield 2 Remove hex nut A and flat washer securing latch to the backside of the driveshield replace latch if worn or damaged and...

Page 206: ...to the windrower and supplies power to hazard signal lights and speed sensor that is on the header Figure 4 198 Electrical Harness 1029895 A B 4 11 1 Maintaining Electrical System Use electrical tape...

Page 207: ...ctrical harness 4 Connect the new light to the electrical harness 5 Position the new light on bracket with bolts B and install and tighten four nuts A 6 Check operation of the new light 4 11 3 Replaci...

Page 208: ...om hole for M1 Series Windrowers use the top hole for M155E4 SP Windrowers 8 Connect sensor wire D to harness C 9 Install plastic fastener B in the small hole in bracket A Secure the sensor wire to fa...

Page 209: ...nozzles which eject fluids under high pressure 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 res...

Page 210: ......

Page 211: ...hane Roll Conditioner Kit Rolls condition the crop by crimping and crushing the stem in several places which allows the release of moisture resulting in faster drying times A polyurethane roll conditi...

Page 212: ...B6621 Hydraulic Drive kit is required for an R113 Rotary Disc Header that is originally configured for use with an M155 or M155E4 SP Windrower to operate correctly on an M1 Series SP Windrower MD B66...

Page 213: ...1021508 A Figure 5 4 Hydraulic Drive Kit MD B6272 Hydraulic Drive kit A is required for an R1 Series Rotary Disc Header that is originally configured for use with an M1 Series to operate correctly on...

Page 214: ......

Page 215: ...avier float setting Refer to windrower operator s manual Excessive ground speed Reduce ground speed Symptom Strips of uncut crop left on field Dull bent or badly worn discblades Replace discblades Rem...

Page 216: ...er page 82 Forming shields improperly adjusted Adjust roll conditioner forming shields Positioning Forming Shield Side Deflectors Roll Conditioner page 81 Positioning Rear Baffle Roll Conditioner page...

Page 217: ...one side to the other Float not properly balanced Adjust header float Refer to windrower operator s manual Symptom Slow crop drying Crop is bunched in windrow Adjust forming shields baffle Positioning...

Page 218: ...er to Symptom Poorly formed or bunchy windrows Forming shields not properly positioned Adjust forming shields Positioning Forming Shield Side Deflectors Roll Conditioner page 81 Positioning Rear Baffl...

Page 219: ...urethane Rolls page 75 Adjusting Roll Gap Steel Rolls page 76 Conditioner rolls contacting each other Check roll timing Checking Roll Timing page 78 Symptom Excessive heat in cutterbar Incorrect level...

Page 220: ...proper groove in pulley Move belt to proper groove 4 10 2 Conditioner Drive Belt page 172 Foreign object between rolls Disengage header and stop the engine When all moving parts are completely stopped...

Page 221: ...hydraulic motor Repair replace hydraulic motor See MacDon Dealer Defective hydraulic pump in windrower Repair replace pump See MacDon Dealer Defective relief valve in windrower Repair replace relief v...

Page 222: ......

Page 223: ...head markings Jam nuts When applying torque to finished jam nuts multiply the torque applied to regular nuts by f 0 65 Self tapping screws Standard torque is to be used NOT to be used on critical or s...

Page 224: ...65 72 48 53 14 2 0 104 115 77 85 16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 1001370 1001370 A Figure 7 3 Bolt Grades Table 7 3 Metric Class 10 9 Bolts and Class 10 Free Spin...

Page 225: ...5 105 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 7 1 2 Metric Bolt Specifications Bolting int...

Page 226: ...ar as possible 3 Check that O ring A is NOT on threads and adjust if necessary 4 Apply hydraulic system oil to O ring A 1003432 D A E B C Figure 7 7 Hydraulic Fitting 5 Install fitting B into port unt...

Page 227: ...3 106 115 4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16 12 176 193 130 14...

Page 228: ...Table 7 7 page 214 6 Check final condition of fitting Table 7 7 O Ring Boss ORB Hydraulic Fittings Non Adjustable SAE Dash Size Thread Size in Torque Value8 Nm lbf ft lbf in 2 5 16 24 6 7 53 62 3 3 8...

Page 229: ...orque fittings according to values in Table 7 8 page 215 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 w...

Page 230: ...ector typically 45 degree or 90 degree is aligned to receive incoming tube or hose assembly Always finish alignment of fitting in tightening direction Never back off loosen pipe threaded connectors to...

Page 231: ...ressure megapascal MPa x 145 038 pounds per square inch psi Pressure bar Non SI bar x 14 5038 pounds per square inch psi Torque Newton meter Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton...

Page 232: ......

Page 233: ...73 roll gaps 73 adjusting roll gap polyurethane rolls 75 steel rolls 76 checking roll gap polyurethane rolls 74 roll tension 77 adjusting 77 roll timing 78 adjusting 78 checking 78 conversion chart 21...

Page 234: ...55 M155E4 SP Windrowers 45 electrical system 192 maintaining 192 engine forward definition 19 F FFFT definition 19 finger tight definition 19 fixtures See lights fluids See lubricants forming shields...

Page 235: ...ing 97 See also greasing cutterbars 99 lubricating the disc header conditioner roll timing gearbox MD 221748 or MD 307211 checking gearbox oil 158 M maintenance and servicing break in inspections 95 b...

Page 236: ...ures 90 safety alert symbols 1 safety sign decals 8 installing decals 8 locations 9 signal words 2 understanding safety signs 11 screws definition 19 SDD definition 19 serial numbers locations vi reco...

Page 237: ...detaching from header 52 M155 M155E4 detaching from header 57 M155 M155E4 SP Windrowers attaching to header hydraulic center link with optional self alignment kit 32 hydraulic center link without opt...

Page 238: ......

Page 239: ...ase SAE Multipurpose High temperature extreme pressure EP performance with 1 max Molybdenum Disulphide NLGI Grade 2 lithium base As required unless otherwise specified SAE Multipurpose High temperatur...

Page 240: ...16 891 7313 f 816 891 7323 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 f 7 495 967 7600 MacDon Australia Pty Ltd...

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MacDon R113 SP, Operator'S Manual

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