MacDon R113 User manual

R113
SP Disc Header
Operator’s Manual
214077 Revision A
2017 Model Year
Original Instruction
The harvesting specialists.

R113 SP Disc Header
1021763
Published: April 2017
Noise Levels
The A-weighted sound pressure level inside the operator’s station of a typical self-propelled vehicle (e.g., M1170),
when operated in conjunction with this R113 SP Disc Header, is 70 dBA. This measurement was taken in
accordance with ISO 5131. The sound pressure level depends upon the rotary disc speed, crop conditions, as well
the exact type of self-propelled vehicle used to power the R113.

Declaration of Conformity
Figure 1. EC Declaration of Conformity
1018494
214077 iRevision A

Figure 2. EC Declaration of Conformity
1018495
214077 ii Revision A

Introduction
This manual contains safety, maintenance, and service procedures for the MacDon R113 SP Disc Header.
Carefully read all the material provided before attempting to maintain or service the machine.
Use this manual as your first source of information about 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.
1019438
Figure 3. Manual Storage Location
The operator’s manual and the parts catalog are stored in
the plastic manual case at the right side of the header.
214077 iii Revision A

Model and Serial Number
Record the model number, serial number, and model year of the header on the lines below.
1021877
A
Figure 4. Header, Right Side
R113 SP Disc Header
Header
Model:
Serial
Number:
Year:
The serial number plate (A) is located near the base
of the right side hazard/signal light on the right edge
of the header.
214077 iv Revision A

214077 vRevision A
Declaration of Conformity............................................................................................................................i
Introduction.............................................................................................................................................. iii
Model and Serial Number.......................................................................................................................... iv
Chapter 1: Safety .................................................................................................................................... 1
1.1 Safety Alert Symbols ............................................................................................................................1
1.2 Signal Words .......................................................................................................................................2
1.3 General Safety.....................................................................................................................................3
1.4 Maintenance Safety .............................................................................................................................5
1.5 Hydraulic Safety...................................................................................................................................6
1.6 Welding Precaution ..............................................................................................................................7
1.7 Safety Signs ........................................................................................................................................8
1.7.1 Installing Safety Decals ...............................................................................................................8
1.8 Locating Safety Decals.........................................................................................................................9
1.9 Understanding Safety Signs................................................................................................................ 11
Chapter 2: Product Overview ............................................................................................................ 15
2.1 Product Specifications........................................................................................................................15
2.2 Component Identification ....................................................................................................................17
2.3 Definitions .........................................................................................................................................19
Chapter 3: Operation ........................................................................................................................... 21
3.1 Break-In Period..................................................................................................................................21
3.2 Daily Start-Up Check..........................................................................................................................22
3.3 Engaging and Disengaging Header Safety Props .................................................................................24
3.3.1 Engaging and Disengaging Header Safety Props: M1170 Windrower ............................................24
3.3.2 Engaging and Disengaging Header Safety Props: M155E4 Windrower..........................................25
3.4 Header Float......................................................................................................................................27
3.5 Attaching Header to Windrower...........................................................................................................28
3.5.1 Attaching R1 SP Disc Header to M1170 Windrower .....................................................................28
3.5.2 Attaching R1 Series SP Disc Header to M155E4 Windrower: Self-Aligning Hydraulic
Center-Link ........................................................................................................................32
3.5.3 Attaching R1 Series SP Disc Header to M155E4 Windrower: Hydraulic Center-Link without
Self-Alignment....................................................................................................................37
3.5.4 Attaching Hydraulics and Electrical Connections..........................................................................42
Connecting R1 Series Hydraulics and Electrical: M1170 Windrowers............................................42
Connecting R1 Series Hydraulics and Electrical: M155E4 Windrowers .........................................44
3.6 Detaching the Header ........................................................................................................................53
3.6.1 Detaching R1 Series Header: M1170 Windrower .........................................................................53
3.6.2 Detaching R1 Series Header: M155E4 Windrower.......................................................................58
3.7 Driveshields.......................................................................................................................................62
3.7.1 Opening Driveshields ................................................................................................................62
TABLE OF CONTENTS

214077 vi Revision A
3.7.2 Closing Driveshields..................................................................................................................63
3.8 Cutterbar Doors .................................................................................................................................65
3.8.1 Inspecting Cutterbar Doors ........................................................................................................65
3.8.2 Opening Cutterbar Doors...........................................................................................................65
3.8.3 Opening Cutterbar Doors: Export Latches ...................................................................................66
3.8.4 Closing Cutterbar Doors ............................................................................................................68
3.9 Cutterbar Deflectors ...........................................................................................................................69
3.9.1 Removing Cutterbar Deflectors ..................................................................................................69
3.9.2 Installing Cutterbar Deflectors ....................................................................................................69
3.10 Cutting Height..................................................................................................................................71
3.10.1 Adjusting Cutting Height ..........................................................................................................71
3.11 Cutterbar Angle................................................................................................................................72
3.12 Cutterbar Lubrication........................................................................................................................73
3.12.1 Checking and Adding Cutterbar Lubricant .................................................................................73
3.12.2 Draining Cutterbar ...................................................................................................................75
3.12.3 Filling Cutterbar.......................................................................................................................76
3.13 Curtains ..........................................................................................................................................77
3.13.1 Inspecting Curtains..................................................................................................................77
3.13.2 Removing Cutterbar Door Curtains ...........................................................................................78
3.13.3 Installing Cutterbar Door Curtains .............................................................................................79
3.13.4 Removing Cutterbar Inboard Curtain.........................................................................................79
3.13.5 Installing Cutterbar Inboard Curtain ..........................................................................................80
3.13.6 Removing Outboard Curtains ...................................................................................................81
3.13.7 Installing Outboard Curtains .....................................................................................................82
3.14 Roll Gap ..........................................................................................................................................84
3.14.1 Checking Roll Gap ..................................................................................................................84
3.14.2 Adjusting Roll Gap: Polyurethane Rolls .....................................................................................85
3.14.3 Adjusting Roll Gap: Steel Rolls .................................................................................................86
3.15 Roll Tension.....................................................................................................................................87
3.15.1 Adjusting Roll Tension .............................................................................................................87
3.16 Roll Timing ......................................................................................................................................88
3.16.1 Checking Roll Timing...............................................................................................................88
3.16.2 Adjusting Roll Timing ...............................................................................................................88
3.17 Roll Conditioner ...............................................................................................................................91
3.17.1 Positioning Forming Shield Side Deflectors: Roll Conditioner ......................................................91
3.17.2 Positioning Forming Shield Rear Baffle: Roll Conditioner............................................................92
3.18 Haying Tips .....................................................................................................................................93
3.18.1 Curing ....................................................................................................................................93
3.18.2 Topsoil Moisture ......................................................................................................................93
3.18.3 Weather and Topography.........................................................................................................93
3.18.4 Windrow Characteristics ..........................................................................................................94
3.18.5 Driving on Windrow .................................................................................................................94
TABLE OF CONTENTS

214077 vii Revision A
3.18.6 Using Chemical Drying Agents .................................................................................................94
3.19 Transporting the Header ...................................................................................................................95
Chapter 4: Maintenance and Servicing ........................................................................................... 97
4.1 Preparing Machine for Servicing..........................................................................................................97
4.2 Recommended Safety Procedures ......................................................................................................98
4.3 Maintenance Requirements ..............................................................................................................100
4.3.1 Maintenance Schedule/Record ................................................................................................101
4.3.2 Break-In Inspections................................................................................................................103
4.3.3 Preseason Servicing ...............................................................................................................104
4.3.4 End-of-Season Servicing .........................................................................................................104
4.4 Lubrication ...................................................................................................................................... 105
4.4.1 Greasing Procedure ................................................................................................................105
4.4.2 Service Intervals .....................................................................................................................106
First 25 Hours ........................................................................................................................106
Every 25 Hours ......................................................................................................................107
First 50 Hours ........................................................................................................................108
Every 100 Hours or Annually ...................................................................................................109
First 150 Hours....................................................................................................................... 110
Every 250 Hours..................................................................................................................... 111
4.5 Cutterbar......................................................................................................................................... 112
4.5.1 Cutterbar Discs ....................................................................................................................... 112
Inspecting Cutterbar Discs ...................................................................................................... 112
Removing Cutterbar Discs....................................................................................................... 113
Installing Cutterbar Discs ........................................................................................................ 114
4.5.2 Cutterbar Spindles .................................................................................................................. 116
Removing Cutterbar Spindles .................................................................................................. 116
Installing Cutterbar Spindles.................................................................................................... 119
4.5.3 Cutterbar Crop Stream Configuration........................................................................................124
Changing 13-Foot Cutterbar Crop Stream Configuration............................................................125
4.5.4 Discblades..............................................................................................................................125
Inspecting Discblades .............................................................................................................126
Inspecting Discblade Hardware ...............................................................................................127
Removing Discblades .............................................................................................................129
Installing Discblades ...............................................................................................................130
4.5.5 Accelerators ...........................................................................................................................131
Inspecting Accelerators...........................................................................................................132
Removing Accelerators ...........................................................................................................132
Installing Accelerators.............................................................................................................133
4.5.6 Rock Guards...........................................................................................................................134
Inspecting Rock Guards..........................................................................................................134
Removing Rock Guards ..........................................................................................................135
Installing Rock Guards ............................................................................................................136
4.5.7 Drums .................................................................................................................................... 136
Inspecting Drums ...................................................................................................................136
Removing Driven Drums and Driveline .....................................................................................138
Installing Driven Drums and Driveline.......................................................................................141
Removing Non-Driven Drums ..................................................................................................145
TABLE OF CONTENTS

214077 viii Revision A
Installing Non-Driven Drums....................................................................................................146
4.5.8 Cutterbar Spindle Shear Pin.....................................................................................................149
Removing Cutterbar Spindle Shear Pin ....................................................................................149
Installing Cutterbar Spindle Shear Pin ......................................................................................152
4.6 Header Drive 90-Degree Gearbox .....................................................................................................156
4.6.1 Checking and Adding Lubricant ................................................................................................156
4.7 Conditioners .................................................................................................................................... 157
4.7.1 Conditioner Drive Belt..............................................................................................................157
Inspecting Conditioner Drive Belt .............................................................................................157
Removing Conditioner Drive Belt .............................................................................................158
Installing Conditioner Drive Belt ...............................................................................................159
4.7.2 Roll Timing Gearbox (MD #221748)..........................................................................................161
Checking and Changing Roll Timing Gearbox Oil ......................................................................161
4.7.3 Hydraulics ..............................................................................................................................163
Hydraulic Hoses and Lines......................................................................................................163
4.7.4 Electrical System ....................................................................................................................163
Maintaining Electrical System ..................................................................................................163
Servicing Amber Hazard/Signal Lights .....................................................................................164
4.7.5 Driveshields............................................................................................................................165
Removing Driveshields ...........................................................................................................165
Installing Driveshields .............................................................................................................166
Replacing Driveshield Latch ....................................................................................................167
4.7.6 Conditioners ...........................................................................................................................169
Roll Conditioner......................................................................................................................169
4.7.7 Changing the Conditioner ........................................................................................................170
Removing the Conditioner .......................................................................................................170
Installing the Conditioner.........................................................................................................173
Installing Conditioner Drive......................................................................................................176
4.7.8 Shield (No Conditioner) ...........................................................................................................178
Removing Shield (No Conditioner) ...........................................................................................178
Installing Shield (No Conditioner).............................................................................................179
Chapter 5: Optional Kits....................................................................................................................181
5.1 Options and Attachments .................................................................................................................181
5.1.1 Tall Crop Divider Kit .................................................................................................................181
5.1.2 No Roll Conditioner Kit ............................................................................................................181
5.1.3 Polyurethane Roll Conditioner Kit .............................................................................................181
5.1.4 Steel Roll Conditioner Kit .........................................................................................................181
Chapter 6: Troubleshooting .............................................................................................................183
6.1 Performance Problems.....................................................................................................................183
6.2 Mechanical Problems .......................................................................................................................187
Chapter 7: Reference .........................................................................................................................191
7.1 Torque Specifications .......................................................................................................................191
7.1.1 Metric Bolt Specifications .........................................................................................................191
7.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ................................................................194
TABLE OF CONTENTS

214077 ix Revision A
7.1.3 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) ....................................................................195
7.1.4 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable).............................................................197
7.1.5 O-Ring Face Seal (ORFS) Hydraulic Fittings .............................................................................198
7.1.6 Tapered Pipe Thread Fittings ...................................................................................................199
7.2 Conversion Chart.............................................................................................................................200
Index.......................................................................................................................................................201
Recommended Lubricants .................................................................................. Inside Back Cover
TABLE OF CONTENTS

214077 1Revision A
1 Safety
1.1 Safety Alert Symbols
1000915
Figure 1.1: Safety Symbol
This safety alert symbol 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
accompanying this symbol.
Why is safety important to you?
•Accidents disable and kill
•Accidents cost
•Accidents can be avoided

214077 2Revision A
1.2 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.
SAFETY

214077 3Revision A
1.3 General Safety
1000004
Figure 1.2: 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 1.3: Safety Equipment
•Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection
devices such as ear muffs or ear plugs to help protect
against loud noises.
1010391
Figure 1.4: 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

214077 4Revision A
1000007
Figure 1.5: 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 1.6: 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 1.7: 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

214077 5Revision A
1.4 Maintenance Safety
1000009
Figure 1.8: Safety around Equipment
To ensure your safety while maintaining machine:
•Review operator’s manual and all safety items before
operation and/or maintenance of machine.
•Place all controls in Neutral, stop the engine, set the park
brake, remove the ignition key, and wait for all moving
parts to stop before servicing, adjusting, and/or repairing.
•Follow good shop practices:
–Keep service areas clean and dry
–Be sure electrical outlets and tools are properly
grounded
–Use adequate lighting for job at hand
1008958
Figure 1.9: Equipment NOT Safe for Children
•Relieve pressure from hydraulic circuits before servicing
and/or disconnecting 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 all moving
and/or rotating parts.
•Clear area of bystanders, especially children, when
carrying out any maintenance, repairs or, adjustments.
•Install transport lock or place safety stands under frame
before working under machine.
•If more than one person is servicing machine at same
time, be aware that rotating a driveline or other
mechanically-driven component by hand (for example,
accessing a lube fitting) will cause drive components in other areas (belts, pulleys, and knives) to move. Stay
clear of driven components at all times.
1000004
Figure 1.10: Safety Equipment
•Wear protective gear when working on machine.
•Wear heavy gloves when working on knife components.
SAFETY

214077 6Revision A
1.5 Hydraulic Safety
1001205
Figure 1.11: Testing for Hydraulic Leaks
•Always place all hydraulic controls in Neutral before
dismounting.
•Make sure that all components in hydraulic system are
kept clean and in good condition.
•Replace any worn, cut, abraded, flattened, or crimped
hoses and steel lines.
•Do NOT attempt any makeshift repairs to hydraulic lines,
fittings, or hoses by using tapes, clamps, cements, or
welding. The hydraulic system operates under extremely
high pressure. 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 hydraulic leaks. Use a piece of cardboard
as a backstop instead of hands to isolate and identify
a leak.
•If injured by a concentrated high-pressure stream of
hydraulic fluid, seek medical attention immediately.
Serious infection or toxic reaction can develop from
hydraulic fluid piercing the skin.
1000013
Figure 1.13: Safety around Equipment
•Make sure all components are tight and steel lines,
hoses, and couplings are in good condition before
applying pressure to a hydraulic system.
SAFETY

214077 7Revision A
1.6 Welding Precaution
Welding should never be attempted on the R113 SP Disc Header while it is connected to a windrower.
WARNING
Severe damage to sensitive, expensive electronics can result from welding on the header while it is
connected to the windrower. It can be impossible to know what effect high current could 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 any welding on the R113 SP Disc Header, the header should first be disconnected and
removed from the windrower.
If it is unfeasible to disconnect the header from the windrower before attempting welding, refer to the windrower’s
technical manual (available from your Dealer) for welding precautions detailing all electrical components that must
be disconnected first for safe welding.
SAFETY

214077 8Revision A
1.7 Safety Signs
1000694
Figure 1.14: 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.
•Replacement safety signs are available from your Dealer
Parts Department.
1.7.1 Installing Safety Decals
1. Clean and dry installation area.
2. Decide on exact location before you remove decal backing paper.
3. Remove smaller portion of split backing paper.
4. Place sign in position and slowly peel back remaining paper, smoothing sign as it is applied.
5. Prick small air pockets with a pin and smooth out.
SAFETY