MacDon R113 User manual

R113
Rotary Disc Header
M205 Compatibility Kit (MD #257188)
Installation Instructions
215276 Revision A
Original Instruction
The Harvesting Specialists.

R113 Rotary Disc Header
1021763
Published April 2020
© 2020 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
This kit configures an R113 rotary disc header for an M205 windrower.
IMPORTANT:
The R113 rotary disc header must be configured for an M1170 windrower BEFORE installing this kit.
•If the header does not have a hydraulic motor, install M1170 compatibility kit MD #B6621 before proceeding.
•If the header is configured for M155E4 windrowers, remove the hydraulic motor from the rotary disc header, and install
M1170 compatibility kit MD #B6621 before proceeding. However, do NOT reposition the conditioner drive speed
sensor on the rotary disc header as described in the M1170 kit instructions.
This document explains how to install the kit. A list of parts included in the kit is provided in 2 Parts List, page 4.
Installation time
This kit takes approximately 1 hour to install.
Conventions
The following conventions are used in this document:
•Right and left are determined from the operator’s position. The front of the header is the side that faces the crop; the
back of the header is the side that connects to the windrower.
•Unless otherwise noted, use the standard torque values provided in the 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.
215276 iRevision A

215276 iii Revision A
Introduction ................................................................................................................................................i
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Signal Words .........................................................................................................................................1
1.2 General Safety .......................................................................................................................................2
Chapter 2: Parts List.................................................................................................................................... 4
Chapter 3: Installation Instructions ........................................................................................................... 5
3.1 Installing Hydraulic Components ...............................................................................................................5
3.1.1 Installing Hydraulic Components –M205 With Quick Couplers...............................................................9
3.1.2 Installing Hydraulic Components –M205 Without Quick Couplers ........................................................ 11
3.2 Checking Speed Sensor.......................................................................................................................... 12
3.2.1 Repositioning Conditioner Drive Speed Sensor –Model Year 2018 and Later .......................................... 13
3.2.2 Repositioning Conditioner Drive Speed Sensor –Model Year 2017........................................................ 15
3.3 Installing Electrical Components.............................................................................................................. 16
Chapter 4: Appendix................................................................................................................................. 19
4.1 Theory of Operation ............................................................................................................................. 19
4.2 Troubleshooting and Harness Schematics ................................................................................................. 21
TABLE OF CONTENTS

215276 1Revision A
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.

215276 2Revision A
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
In addition, take the following precautions:
•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

215276 3Revision A
1000007
Figure 1.4: Safety around Equipment
•Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as scarves or bracelets.
•Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate
independently of shaft and can telescope freely.
•Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.
1000008
Figure 1.5: Safety around Equipment
•Keep hands, feet, clothing, and hair away from moving parts.
NEVER attempt to clear obstructions or objects from a
machine while 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

215276 4Revision A
Chapter 2: Parts List
The following parts are included in this kit:
1032938
1
2
3
4
5
6
7
Ref Part Number Description Quantity
1 21763 FASTENER –CABLE TIE, BLACK 8
2 138344 COUPLER –HYDRAULIC 1
3138345 COUPLER –HYDRAULIC 1
4159635 VALVE –RELIEF, 75 PSI 1
5252232 FITTING –UNION HYD 2
6 256650 HARNESS - R113 TO M205 1
7 256651 ASSY –PWM MODULE AND POWER 1

215276 5Revision A
Chapter 3: Installation Instructions
To install the M205 Compatibility Kit (MD #257188), follow these procedures in the order presented:
3.1 Installing Hydraulic Components
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.
IMPORTANT:
Ensure the R113 SP header is lowered from shipping position. For instructions, refer to the unloading and assembly
instructions shipped with the header.
1. If a header is connected to a windrower:
a. Lower the header fully.
b. Shut down the engine, and remove the key from the ignition.
c. Headers other than the R113 SP: Disconnect the header hydraulic hoses and any electrical connections to the
windrower.

215276 6Revision A
1033015
A
B
C
D
Figure 3.1: Hose Routing from Header to Windrower
2. Route header hose bundle (A) from the header over support (B) and under the windrower frame. Insert pin on hose
support (C) into hole (D) in windrower frame near left cab-forward leg.
IMPORTANT:
Route hoses as straight as possible and avoid rub/wear points that could damage hydraulic hoses.
NOTE:
The pressure hose crosses on top of the return hose once routed past support (B).
INSTALLATION INSTRUCTIONS

215276 7Revision A
1032952
A
Figure 3.2: Pressure Relief Valve
3. Replace pressure relief valve (A), installed in the header
hydraulic motor, with new 517 kPa (75 psi) relief valve
(MD #159635).
B
A
1032973
CD
EF
Figure 3.3: Pressure and Return Hoses
4. Label case drain hose (A).
5. Find narrow fitting (B) to identify RETURN hose. Remove
couplers and elbow fitting (C) from return hose (D).
Label hose.
6. Remove couplers and elbow fitting (E) from PRESSURE
hose (F). Label hose.
INSTALLATION INSTRUCTIONS

215276 8Revision A
7. Proceed according to the type of hydraulic couplers or fittings used on the M205:
1033014
A
A
Figure 3.4: Pressure and Return Steel Lines with Quick
Couplers
•If the M205 is equipped with quick couplers (A) to connect to
the header, proceed to 3.1.1 Installing Hydraulic Components
–M205 With Quick Couplers, page 9.
1033011
A
A
Figure 3.5: Pressure and Return Steel Lines with Union
Fittings
•If the M205 uses union fittings (A) instead of quick couplers
to connect to the header, remove union fittings (A) from the
steel lines, and proceed to 3.1.2 Installing Hydraulic
Components –M205 Without Quick Couplers, page 11.
1033012
A
Figure 3.6: Pressure and Return Steel Lines with Plugs
•If the M205 has plugs (A) installed in the steel lines and
proceed to 3.1.2 Installing Hydraulic Components –M205
Without Quick Couplers, page 11.
INSTALLATION INSTRUCTIONS

215276 9Revision A
3.1.1 Installing Hydraulic Components –M205 With Quick Couplers
NOTE:
Union fittings (MD #252232) supplied in the kit are NOT used on M205 Windrowers equipped with quick couplers.
1033005
A
BC
D
Figure 3.7: M205 equipped with Quick Couplers
1. Install female coupler (A) (MD #138345) onto header
PRESSURE hose (B).
2. Install male coupler (C) (MD #138344) onto header RETURN
hose (D).
A
B
D
E
H
G
C
F
1033016
Figure 3.8: Header Pressure and Return Connections
3. Connect PRESSURE coupler (A) to inboard steel line
coupler (B).
NOTE:
For reference, the other end of the pressure hose is
connected to split flange clamp (C) on the hydraulic motor.
4. Connect RETURN coupler (D) to outboard steel line
coupler (E).
NOTE:
For reference, the other end of the return hose is
connected to fitting (F) on the hydraulic motor.
5. Close coupler lock assembly (G) over couplers and secure
with pin (H).
INSTALLATION INSTRUCTIONS

215276 10 Revision A
1023477
A
B
C
Figure 3.9: Quick Couplers –View from Top
6. Confirm quick couplers are connected properly. Couplers
will restrict oil flow if they are not fully mated (O-ring [A]
will be visible). This will generate excessive heat, damaging
the drive components and the couplers themselves.
Couplers (B) at right are fully mated, and couplers (C) at
right are not fully mated.
1023554
A
B
C
Figure 3.10: Case Drain Connection
7. Connect case drain hose (A) to 1/2 in. male flat face
fitting (B).
8. Secure case drain hose to coupler lock assembly with two
clamps (C).
9. Proceed to 3.2 Checking Speed Sensor, page 12.
INSTALLATION INSTRUCTIONS

215276 11 Revision A
3.1.2 Installing Hydraulic Components –M205 Without Quick Couplers
NOTE:
Quick couplers (MD #138344) and (MD #138345) supplied in the kit are
NOT used on M205 Windrowers not equipped with quick couplers.
1033009
A
B
C
D
Figure 3.11: Header Hoses and Union Fittings
1. Install union fitting (A) (MD #252232) onto header pressure
hose (B).
2. Install union fitting (C) (MD #252232) onto header return
hose (D).
G
A
D
BE
H
C
F
1033018
Figure 3.12: Header Hydraulic Connections
3. Connect PRESSURE hose with union fitting (A) to inboard
steel line (B).
NOTE:
For reference, the other end of the pressure hose is
connected to split flange clamp (C) on the hydraulic motor.
4. Connect RETURN hose with union fitting (D) to outboard
steel line (E).
NOTE:
For reference, the other end of the return hose is
connected to fitting (F) on the hydraulic motor.
5. Connect case drain hose (G) to 1/2 in. male flat face
fitting (H).
6. Proceed to 3.2 Checking Speed Sensor, page 12.
INSTALLATION INSTRUCTIONS

215276 12 Revision A
3.2 Checking Speed Sensor
Make sure the speed sensor configured as follows:
A
1032984
Figure 3.13: Left Driveshield
1. Remove left driveshield (A). For instructions, refer to the
header operator’s manual or technical manual.
2. Check the speed sensor as follows:
1027949
A
B
C
Figure 3.14: Speed Sensor –Model Year 2018
and Later
A - Speed Sensor B - Correct Sensor Location
C - Incorrect Sensor Location
•Figure 3.14, page 12 shows a speed sensor assembly from
model year 2018 and later.
–If sensor (A) is installed in top hole (B), the sensor is
positioned correctly. Proceed to 3.3 Installing Electrical
Components, page 16.
–If sensor (A) is installed in bottom hole (C) as shown,
reposition the sensor according to the instructions in
3.2.1 Repositioning Conditioner Drive Speed Sensor –
Model Year 2018 and Later, page 13.
1032982
A
BC
Figure 3.15: Speed Sensor –Model Year 2017
A - Speed Sensor B - Correct Alignment Position
C - Incorrect Alignment Position
•Figure 3.15, page 12 shows a speed sensor assembly from
model year 2017 (if the sensor was NOT updated to the
sensor assembly used on model year 2018 and later).
–If sensor (A) is aligned with the top inside edge (B) of a
long hole, the sensor is positioned correctly. Proceed to
3.3 Installing Electrical Components, page 16.
–If sensor (A) is aligned with a small hole (C), reposition
the sensor according to instructions in 3.2.2 Repositioning
Conditioner Drive Speed Sensor –Model Year 2017, page
15.
INSTALLATION INSTRUCTIONS

215276 13 Revision A
3.2.1 Repositioning Conditioner Drive Speed Sensor –Model Year 2018 and Later
Reposition the speed sensor as follows:
NOTE:
This procedure also applies to model year 2017 headers that have an updated steel speed sensor and mounting bracket as
shown in Figure 3.16, page 13.
1032990
A
C
B
Figure 3.16: Speed Sensor –Model Year 2018
and Later
1. Remove nut (A) from sensor (B).
2. Reinstall sensor (B) into hole (C).
1032992
A
C
B
AD
E
Figure 3.17: Gap between Sensor and Pulley
3. Make sure there is a 2–3 mm (1/16–1/8 in.) gap (A)
between pulley (B) and sensor (C). Adjust gap as required
using nuts (D). Make sure the sensor is parallel with the
pulley.
NOTE:
Additional vertical alignment of the sensor may be achieved
by moving the bracket up or down retaining nut (E). Loosen
nut (E), adjust bracket, and tighten nut (E) to 58 Nm
(43 lbf·ft).
4. Tighten sensor nuts (D) to 12 Nm (9 lbf·ft).
INSTALLATION INSTRUCTIONS

215276 14 Revision A
A
1032984
Figure 3.18: Left Driveshield
5. Close left driveshield (A). For instructions, refer to the
header operator’s manual or technical manual.
6. Proceed to 3.3 Installing Electrical Components, page 16.
INSTALLATION INSTRUCTIONS