MacDon R1 Series User manual

R1 Series
Rotary Disc Pull-Types and Headers
Eight- and Ten-Disc Cutterbar Kits (MD #259517 and 259518)
Installation Instructions
214497 Revision D
Original Instruction
The Harvesting Specialists.

R1 Series Rotary Disc Pull-Type
1010571
R1 Series Rotary Disc Header
1027022
Published October 2019
© 2019 MacDon Industries, Ltd.
The information in this publication is based on the information available and in effect at the time of printing. MacDon
Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the
information in this publication. MacDon Industries, Ltd. reserves the right to make changes at any time without notice.

Introduction
The Ten-Disc Cutterbar kit (MD #259517) can be used to replace the cutterbar on a MacDon R116 Rotary Disc Header or
Rotary Disc Pull-Type; the Eight-Disc Cutterbar kit (MD #259518) can be used to replace the cutterbar on a MacDon R113
Rotary Disc Header or Rotary Disc Pull-Type.
This document explains how to install the kits. A list of parts included in the kits is provided in Chapter 2 Parts List, page 5.
Installation time
Installation of this kit will take approximately 6 hours.
Conventions
The following conventions are used in this document:
•Right and left are determined from the operator’s position. The front of the disc mower or header is the side that faces
the crop.
•Unless otherwise noted, use the standard torque values provided in the mower or header operator’s manual and
technical manual.
NOTE:
Keep your MacDon publications up-to-date. The most current version of this instruction can be downloaded from our
Dealer-only site (https://portal.macdon.com) (login required).
NOTE:
This document is currently available in English only.
214497 iRevision D

Summary of Changes
At MacDon, we’re continuously making improvements, and occasionally these improvements affect product
documentation. The following list provides an account of major changes from the previous version of this document.
Section Summary of Change Internal Use
Only
Front cover Changed kit part numbers from MD #259415 and 259416 to
259517 and 259518.
ECN 58773
Inside front cover Inserted copyright and disclaimer statements. Tech Pubs
Introduction, page i Changed kit part numbers from MD #259415 and 259416 to
259517 and 259518.
ECN 58773
2 Parts List, page 5 Replaced tool assembly MD #307769 with 325683. ECN 58773
3.2 Opening Cutterbar Doors –
Export Latches, page 8
Added topic. Tech Pubs
3.3 Removing Drivelines, page 10 Replaced illustration of header safety prop. The decal has
changed.
ECN 58047
3.9 Installing the R113 Cutterbar,
page 22
Replaced tool assembly MD #307769 with 325683. ECN 58773
3.10 Installing the R116
Cutterbar, page 26
Replaced tool assembly MD #307769 with 325683. ECN 58773
214497 ii Revision D

214497 iii Revision D
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Signal Words .........................................................................................................................................1
1.2 General Safety .......................................................................................................................................2
Chapter 2: Parts List.................................................................................................................................... 5
Chapter 3: Installation Instructions ........................................................................................................... 7
3.1 Opening Cutterbar Doors –North America..................................................................................................7
3.2 Opening Cutterbar Doors –Export Latches..................................................................................................8
3.3 Removing Drivelines ............................................................................................................................. 10
3.3.1 Removing Driveline on an R113 –Large Driven Drums ........................................................................ 11
3.3.2 Removing Driveline on an R116 –Small Driven Drums ........................................................................ 14
3.4 Removing Cutterbar Deflectors ............................................................................................................... 17
3.5 Removing the R113 Cutterbar................................................................................................................. 18
3.6 Removing the R116 Cutterbar................................................................................................................. 19
3.7 Checking Cutterbar Lubricant Level.......................................................................................................... 20
3.8 Removing Outboard Rock Guards ............................................................................................................ 21
3.9 Installing the R113 Cutterbar .................................................................................................................. 22
3.10 Installing the R116 Cutterbar ................................................................................................................ 26
3.11 Installing Driveline and Shielding ........................................................................................................... 30
3.11.1 Installing Driveline and Shielding on an R113 –Large Driven Drums .................................................... 30
3.11.2 Installing Driveline and Shielding on an R116 –Small Driven Drums .................................................... 33
3.12 Installing Outboard Rock Guards............................................................................................................ 36
3.13 Installing Cutterbar Deflectors............................................................................................................... 38
3.14 Closing Cutterbar Doors ....................................................................................................................... 39
TABLE OF CONTENTS

214497 1Revision D
Chapter 1: Safety
1.1 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words,
IMPORTANT and NOTE, identify non-safety related information. Signal words are 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.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.

214497 2Revision D
1.2 General Safety
1000004
Figure 1.1: Safety Equipment
CAUTION
The following general farm safety precautions 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 the 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 in case of emergencies.
•Keep a properly maintained fire extinguisher on the machine.
Be familiar with its proper use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when the Operator is
tired or in a hurry. Take time to consider safest way. NEVER
ignore warning signs of fatigue.
SAFETY

214497 3Revision D
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 the engine is running.
•Do NOT modify the machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten the machine’s life.
•To avoid 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.
1000009
Figure 1.6: Safety around Equipment
•Keep service area clean and dry. Wet and/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 are
fire hazards. 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

214497 5Revision D
Chapter 2: Parts List
The following parts are included in this kit:
1027397
12
3
Figure 2.1: Parts Included in the Cutterbar Kits
Ref
Part
Number Description
Quantity
R113 R116
1 NSS CUTTERBAR –8 DISC, QCB READY 1
2NSS CUTTERBAR –10 DISC, QCB READY 1
3325683 TOOL ASSEMBLY –DRIVE ALIGNMENT 1 1

214497 7Revision D
Chapter 3: Installation Instructions
To install the cutterbar kits, follow these steps and procedures in the order given.
NOTE:
Some steps and procedures only apply to some machines. These are clearly labelled.
3.1 Opening Cutterbar Doors –North America
If the machine was sold outside of North America, it will have export latches. Refer to 3.2 Opening Cutterbar Doors –Export
Latches, page 8.
WARNING
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. Pull-types only: If both doors need to be opened, center the pull-type beneath the hitch.
2. Shut down the engine, and remove the key from the ignition.
1027711
A
Figure 3.1: Cutterbar Doors and Curtains –Pull-Type
1029785
A
A
Figure 3.2: Cutterbar Doors and Curtains –
Windrower Header
3. Lift up on doors (A) at the front of the machine.

214497 8Revision D
3.2 Opening Cutterbar Doors –Export Latches
Machines sold outside North America require a tool-operated latch on the cutterbar doors. Follow these steps to open
cutterbar doors with export latches:
WARNING
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. Pull-types only: Center the pull-type beneath the hitch, if both doors need to be opened.
2. Shut down the engine, and remove the key from the ignition.
1015145
A
Figure 3.3: Cutterbar Door Latch Access Hole –
Export Only
3. Locate latch access holes (A) for each door.
1015146
A
Figure 3.4: Cutterbar Door Latch –Cutaway View
4. Use a rod or screwdriver to press down on latch (A) and
release the cutterbar door.
INSTALLATION INSTRUCTIONS

214497 9Revision D
1023524
A
Figure 3.5: Cutterbar Doors and Curtains –Pull-Type
1029785
A
A
Figure 3.6: Cutterbar Doors and Curtains –
Windrower Header
5. Lift up on doors (A) while pressing down on the latch.
INSTALLATION INSTRUCTIONS

214497 10 Revision D
3.3 Removing Drivelines
DANGER
To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and
engage windrower lift cylinder safety props (headers) or lift cylinder lock-out valves (pull-types) before going under
machine for any reason.
1. Raise the header/pull-type fully and then engage the safety
props (headers) or the lift cylinder lock-out valves (pull-
types) to prevent an unexpected fall before going under the
machine.
1029808
A
Figure 3.7: Safety Props –Right Shown, Left Similar
2. Headers: Pull lever (A) rotate toward header to release, and
lower the safety prop onto the cylinder. Repeat on
opposite side.
IMPORTANT:
Ensure the safety props engage over cylinder piston rods. If
safety prop does not engage properly, raise the header until
the safety prop fits over the rod.
10237341023734
A
Figure 3.8: Lift Cylinder Lock-out Valve
3. Pull-type: Close the lock-out valve (A) on each lift cylinder
by turning the handle to the closed position (90° angle to
the hose).
INSTALLATION INSTRUCTIONS

214497 11 Revision D
1027443
A
B
Figure 3.9: Large and Small Driven Drums
Before removing the existing cutterbar, you must remove the
drivelines from the machine. The procedure varies slightly
depending on the type of driven drums installed on the
machine. Some machines have large driven drums (A) and some
have small driven drums (B). Refer to the procedure appropriate
for your machine:
•R113: 3.3.1 Removing Driveline on an R113 –Large
Driven Drums, page 11
•R116: 3.3.2 Removing Driveline on an R116 –Small
Driven Drums, page 14
NOTE:
Drums vary slightly depending on the year of manufacture, so
there may be some small differences between the drums in the
illustration and the drums installed on your machine.
3.3.1 Removing Driveline on an R113 –Large Driven Drums
To remove the vertical driveline from a machine with large driven drums, follow these steps:
WARNING
Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when
handling blades.
If you are working on an R116 with small driven drums, refer to 3.3.2 Removing Driveline on an R116 –Small Driven Drums,
page 14.
NOTE:
Retain all parts for reassembly unless otherwise stated.
1011078
A
B
Figure 3.10: Driven Drum
1. On the left side of the cutterbar, remove four M10 hex
flange head bolts (A) and remove vertical driveshield (B).
INSTALLATION INSTRUCTIONS

214497 12 Revision D
1011077
A
B
Figure 3.11: Cover Plate
2. Remove two M10 hex flange head bolts (A) and remove
cover plate (B).
1011327
A
B
C
Figure 3.12: Top Plate and Drum Top
3. Remove four M10 hex flange head bolts (A), and remove
top plate (B) and drum top (C).
1021850
A
B
B
C
Figure 3.13: Vertical Shield
4. Remove one M10 x 20 hex flange head bolt (A), two
M10 x 16 hex flange head bolts (B), and vertical shield (C).
INSTALLATION INSTRUCTIONS

214497 13 Revision D
1011136
A
B
Figure 3.14: Drum Shields
5. Remove eight M8 hex flange head bolts (A), and remove
two drum shields (B).
1011137
AA
B
C
Figure 3.15: Hub Drive and Driveline Assembly
6. Remove four M12 hex flange head bolts (A) and spacers
securing driveline assembly (B) to hub drive (C).
1011143
A
Figure 3.16: Driveline
7. Slide driveline (A) downwards, and tilt it to the side. Pull
the driveline up and out of the drum.
NOTE:
For clarity, the illustration shows a cutaway view of drum
and tube shield.
INSTALLATION INSTRUCTIONS

214497 14 Revision D
3.3.2 Removing Driveline on an R116 –Small Driven Drums
To remove the vertical driveline from an R116 with small driven drums, follow these steps:
If you are working on an R113 or an R116 with large driven drums, refer to 3.3.1 Removing Driveline on an R113 –Large
Driven Drums, page 11.
NOTE:
Retain all parts for reassembly unless otherwise stated.
1024929
A
B
A
A
A
Figure 3.17: Driven Drum
1. On the left side of the cutterbar, remove four M10 hex
flange head bolts (A) and remove vertical driveshield (B).
1024659
A
B
B
Figure 3.18: Driveline Shield
2. Remove two M10 hex flange head bolts (B) and cover
plate (A).
1024925
A
B
C
Figure 3.19: Driveline Shield
3. Remove four M10 hex flange head bolts (A), top plate (B),
and drum top (C).
INSTALLATION INSTRUCTIONS