MacDon R113 User manual

R113
Rotary Disc Header
Unloading and Assembly Instructions
262300 Revision A
Original Instruction
The Harvesting Specialists.

R113 Rotary Disc Header
1021763
Published August 2023.
© 2023 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 instruction describes the unloading, setup, and predelivery requirements for the MacDon R113 Rotary Disc Header.
To ensure your customers receive all of the performance and safety benefits from this product, carefully follow the
unloading and assembly procedure from the beginning through to completion.
Retain this instruction for future reference.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
If the shipment is damaged or is missing parts, contact [email protected].
Conventions
The following conventions are followed in this document:
•Right and left are determined from the operator’s position, facing the direction of travel.
•Unless otherwise noted, use the standard torque values provided in this manual.
NOTE:
Keep your MacDon publications up-to-date. The most current version can be downloaded from our website
(www.macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login required).
If the shipment is damaged or is missing parts, contact [email protected].
This instruction is available in English only.
262300 iRevision A

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
Throughout manual Removed discontinued R116 Rotary Disc Header content. ECN 63134
Introduction, page i Added contact information for damaged or missing parts in the
shipment.
Tech Pubs
1.1 Safety Alert Symbols, page 1 Added topic. Tech Pubs
1.4 Hydraulic Safety, page 5 Added topic. Tech Pubs
3.4 Installing Hydraulic Header
Drive, page 18
Added the hydraulic drive kit for M205 Windrowers and included
M2 Series Windrowers.
Tech Pubs
4 Changing Conditioner, page 21 Added links to skip some sections if not needed. Tech Pubs
4.1 Removing Conditioner, page
21
Included M2 Series and M205 Windrowers. Tech Pubs
Added steps for removing the conditioner drive belt. Tech Pubs
4.2 Installing Conditioner, page
26
Included M2 Series and M205 Windrowers. Tech Pubs
Added steps for installing the conditioner drive belt. Tech Pubs
5.1 Attaching Header to M2
Series Windrower, page 35
Added topic. Tech Pubs
5.2 Attaching Header to M1
Series Windrower, page 43
Added a note. Tech Pubs
6.1 Connecting Header Hydraulic
and Electrical Systems –M2170
Windrower, page 63
Added topic. Tech Pubs
6 Attaching Hydraulic and
Electrical Components, page 63
Added a footnote. Tech Pubs
6.2 Connecting Header Hydraulic
and Electrical Systems –M2260
Windrower, page 67
Added topic. Tech Pubs
6.2.1 Auger/Rotary Disc/Draper-
Ready Configuration –Quick
Coupler Connections, page 68
Added topic. Tech Pubs
6.2.2 Rotary Disc-Only
Configuration –Hard-Plumbed
Fittings, page 71
Added topic. Tech Pubs
6.2.3 Rotary Disc-Only
Configuration –Quick Coupler
Connections, page 73
Added topic. Tech Pubs
6.2.4 Calibrating M2 Series
Windrower and Header on
HarvestTouch™Display, page 76
Added topic. Tech Pubs
Calibrating Knife Drive on
HarvestTouch™Display, page 76
Added topic. Tech Pubs
262300 ii Revision A

Section Summary of Change
Internal Use
Only
Calibrating Header Position
Sensors on HarvestTouch™
Display, page 80
Added topic. Tech Pubs
10.3.2 Setting Float –M2 Series
Windrowers, page 114
Added topic. Tech Pubs
10.4 Checking Float –M Series
Windrower, page 116
Changed to M Series Windrower to include M205 Windrower. Tech Pubs
10.15 Checking Disc Timing Tool
and Spindle Nut Wrench, page
133
Added topic. ECN 63134
10.16 Running up Header, page
134
Removed a step. Tech Pubs
Predelivery Checklist, page 152 Added checks for timing tool and spindle nut wrench. ECN 63134
Recommended Lubricants,
page
Added topic. Tech Pubs
262300 iii Revision A

262300 vRevision A
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Safety Alert Symbols ...............................................................................................................................1
1.2 Signal Words .........................................................................................................................................2
1.3 General Safety .......................................................................................................................................3
1.4 Hydraulic Safety .....................................................................................................................................5
1.5 Welding Precaution ................................................................................................................................6
1.6 Safety Signs ...........................................................................................................................................7
Chapter 2: Unloading Header..................................................................................................................... 9
Chapter 3: Assembling Header................................................................................................................. 11
3.1 Removing Lower Shipping Support .......................................................................................................... 11
3.2 Lowering Header .................................................................................................................................. 15
3.3 Removing Shipping Stands ..................................................................................................................... 17
3.4 Installing Hydraulic Header Drive............................................................................................................. 18
3.5 Assembling Hazard Lights....................................................................................................................... 19
Chapter 4: Changing Conditioner............................................................................................................. 21
4.1 Removing Conditioner........................................................................................................................... 21
4.2 Installing Conditioner ............................................................................................................................ 26
4.2.1 Installing Conditioner Drive............................................................................................................ 31
4.3 Discharge Shield –No Conditioner........................................................................................................... 33
4.3.1 Removing Discharge Shield –No Conditioner .................................................................................... 33
4.3.2 Installing Discharge Shield –No Conditioner ..................................................................................... 34
Chapter 5: Attaching Rotary Disc Header to Windrower ....................................................................... 35
5.1 Attaching Header to M2 Series Windrower ............................................................................................... 35
5.2 Attaching Header to M1 Series Windrower ............................................................................................... 43
5.3 Attaching Header to M155, M155E4, or M205 Windrower –Hydraulic Center-Link with Self-Alignment............... 50
5.4 Attaching Header –Hydraulic Center-Link without Self-Alignment................................................................. 56
Chapter 6: Attaching Hydraulic and Electrical Components................................................................... 63
6.1 Connecting Header Hydraulic and Electrical Systems –M2170 Windrower...................................................... 63
6.2 Connecting Header Hydraulic and Electrical Systems –M2260 Windrower...................................................... 67
6.2.1 Auger/Rotary Disc/Draper-Ready Configuration –Quick Coupler Connections......................................... 68
6.2.2 Rotary Disc-Only Configuration –Hard-Plumbed Fittings ..................................................................... 71
6.2.3 Rotary Disc-Only Configuration –Quick Coupler Connections............................................................... 73
6.2.4 Calibrating M2 Series Windrower and Header on HarvestTouch™Display ............................................... 76
Calibrating Knife Drive on HarvestTouch™Display ............................................................................. 76
Calibrating Header Position Sensors on HarvestTouch™Display ........................................................... 80
TABLE OF CONTENTS

262300 vi Revision A
6.3 Connecting Header Hydraulic and Electrical Systems –M1240 Windrower...................................................... 83
6.4 Connecting Header Hydraulic and Electrical Systems –M1170 Windrower...................................................... 89
6.4.1 Calibrating M1 Series Windrower Knife Drive and Header on Harvest Performance Tracker Display............ 92
6.5 Connecting Header Hydraulic and Electrical Systems –M155 or M155E4 Windrowers ...................................... 94
6.6 Connecting Header Hydraulic and Electrical Systems –M205 Windrower ..................................................... 101
Chapter 7: Unpacking Curtains .............................................................................................................. 103
Chapter 8: Installing Options.................................................................................................................. 105
8.1 Installing Tall Crop Dividers .................................................................................................................. 105
Chapter 9: Lubricating Rotary Disc Header ........................................................................................... 107
9.1 Lubrication Locations .......................................................................................................................... 108
Chapter 10: Performing Predelivery Checks.......................................................................................... 109
10.1 Checking Conditioner Drive Belt .......................................................................................................... 109
10.1.1 Adjusting Conditioner Drive Belt ................................................................................................. 110
10.2 Checking Skid Shoes .......................................................................................................................... 111
10.3 Checking Float –M1 and M2 Series Windrowers .................................................................................... 112
10.3.1 Setting Float –M1 Series Windrowers.......................................................................................... 113
10.3.2 Setting Float –M2 Series Windrowers.......................................................................................... 114
10.4 Checking Float –M Series Windrower .................................................................................................. 116
10.4.1 Adjusting Float Using Drawbolts –M Series Windrowers ................................................................. 117
10.5 Checking Roll Timing ......................................................................................................................... 118
10.5.1 Adjusting Roll Timing ................................................................................................................ 118
10.6 Checking and Adding Lubricant –Conditioner Roll Timing Gearbox ............................................................ 121
10.7 Checking Header Drive Gearbox Lubricant............................................................................................. 123
10.8 Checking and Adding Lubricant –Cutterbar ........................................................................................... 124
10.9 Checking Roll Gap ............................................................................................................................. 126
10.9.1 Adjusting Roll Gap –Steel Rolls................................................................................................... 126
10.9.2 Adjusting Roll Gap –Polyurethane Rolls ....................................................................................... 127
10.10 Checking Roll Tension ...................................................................................................................... 128
10.10.1 Adjusting Roll Tension ............................................................................................................. 128
10.11 Adjusting Conditioner Baffle Position.................................................................................................. 129
10.12 Checking and Adjusting Forming Shield Deflector Position...................................................................... 130
10.13 Checking Lights............................................................................................................................... 131
10.14 Checking Manuals ........................................................................................................................... 132
10.15 Checking Disc Timing Tool and Spindle Nut Wrench .............................................................................. 133
10.16 Running up Header.......................................................................................................................... 134
Chapter 11: Reference............................................................................................................................ 135
11.1 Opening Driveshields......................................................................................................................... 135
11.2 Closing Driveshields........................................................................................................................... 137
TABLE OF CONTENTS

262300 vii Revision A
11.3 Cutterbar Doors................................................................................................................................ 138
11.3.1 Opening Cutterbar Doors........................................................................................................... 138
11.3.2 Opening Cutterbar Doors –Export............................................................................................... 139
11.3.3 Closing Cutterbar Doors............................................................................................................. 140
11.4 Torque Specifications ........................................................................................................................ 141
11.4.1 Metric Bolt Specifications .......................................................................................................... 141
11.4.2 Metric Bolt Specifications –Cast Aluminum .................................................................................. 143
11.4.3 O-Ring Boss Hydraulic Fittings –Adjustable................................................................................... 144
11.4.4 O-Ring Boss Hydraulic Fittings –Non-Adjustable ............................................................................ 145
11.4.5 O-Ring Face Seal Hydraulic Fittings .............................................................................................. 146
11.4.6 Tapered Pipe Thread Fittings ...................................................................................................... 147
11.5 Conversion Chart .............................................................................................................................. 149
11.6 Definitions....................................................................................................................................... 150
Predelivery Checklist .............................................................................................................................. 152
Recommended Lubricants...................................................................................................................... 155
TABLE OF CONTENTS

262300 1Revision A
Chapter 1: Safety
Understanding and consistently following these safety procedures will help to ensure the safety of those operating the
machine and of bystanders.
1.1 Safety Alert Symbols
The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine.
1000915
Figure 1.1: Safety Symbol
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

262300 2Revision A
1.2 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 it is not prevented, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if it is not prevented, could result in death or serious injury. It may also
be used to alert you to unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if it is not prevented, may result in minor or moderate injury. It may
also be used to alert you to unsafe practices.
IMPORTANT:
Indicates a situation that, if not prevented, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.
SAFETY

262300 3Revision A
1.3 General Safety
Operating, servicing, and assembling machinery presents several safety risks. These risks can be reduced or eliminated by
following the relevant safety procedures and wearing the appropriate personal protective equipment.
1000004
Figure 1.2: Safety Equipment
CAUTION
The following general farm safety precautions should be part of
your operating procedure for all types of 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 1.3: Safety Equipment
In addition, take the following precautions:
•Be aware that exposure to loud noises can cause hearing
impairment. Wear suitable hearing protection devices such
as earmuffs or earplugs to help protect against loud noises.
1010391
Figure 1.4: Safety Equipment
•Provide a first aid kit in case of emergencies.
•Keep a properly maintained fire extinguisher on the
machine. Familiarize yourself with its use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when Operators are
fatigued or in a hurry. Take time to consider the safest way
to accomplish a task. NEVER ignore the signs of fatigue.
SAFETY

262300 4Revision A
1000007
Figure 1.5: Safety around Equipment
•Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as hoodies, scarves, or bracelets.
•Keep all shields in place. NEVER alter or remove safety
equipment. Ensure that the driveline guards can rotate
independently of their shaft, and that they can telescope
freely.
•Use only service and repair parts made or approved by the
equipment manufacturer. Parts from other manufacturers
may not meet the correct 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 the engine is running.
•Do NOT modify the machine. Unauthorized modifications
may impair the functionality and/or safety of the machine. It
may also shorten the machine’s service life.
•To avoid injury or death from the 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 1.7: Safety around Equipment
•Keep the machine service area clean and dry. Wet and/or
oily floors are slippery. Wet spots can be dangerous when
working with electrical equipment. Ensure that all electrical
outlets and tools are properly grounded.
•Keep the 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 they are stored.
•NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
•When storing machinery, cover any sharp or extending
components to prevent injury from accidental contact.
SAFETY

262300 5Revision A
1.4 Hydraulic Safety
Because hydraulic fluid is under extreme pressure, hydraulic fluid leaks can be very dangerous. Follow the proper safety
procedures when inspecting hydraulic fluid leaks and servicing hydraulic equipment.
1001205
Figure 1.8: Testing for Hydraulic Leaks
•Always place all hydraulic controls in NEUTRAL before
leaving the operator’s seat.
•Ensure that all of the components in the 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 can fail suddenly and create
hazardous conditions.
1001207
Figure 1.9: Hydraulic Pressure Hazard
•Wear proper hand and eye protection when searching for
high-pressure hydraulic fluid leaks. Use a piece of cardboard
as a backstop instead of your hands to isolate and identify
a leak.
•If you are injured by a concentrated, high-pressure stream
of hydraulic fluid, seek medical attention immediately.
Serious infection or a toxic reaction can develop from
hydraulic fluid piercing the skin.
1000013
Figure 1.10: Safety around Equipment
•Ensure that all components are tight and that steel lines,
hoses, and couplings are in good condition before applying
pressure to a hydraulic system.
SAFETY

262300 6Revision A
1.5 Welding Precaution
To prevent damage to sensitive electronics, welding should never be attempted on the 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.
For further welding precautions, consult the windrower operators manual.
If it is unfeasible to disconnect the header from the windrower before welding, refer to the windrower’s technical manual
for welding precautions detailing all electrical components that must be disconnected first for safe welding.
SAFETY

262300 7Revision A
1.6 Safety Signs
Safety signs are decals placed on the machine where there is a risk of personal injury, or where the Operator should take
extra precautions before operating the controls. They are usually yellow.
1000694
Figure 1.11: Operator’s Manual Decal
•Keep safety signs clean and legible at all times.
•Replace safety signs that are missing or illegible.
•If the original part on which a safety sign was installed is
replaced, ensure that the repair part displays the current
safety sign.
SAFETY

262300 9Revision A
Chapter 2: Unloading Header
To unload the header from the trailer safely and without damage, understand the weights and lifting requirements and
familiarize yourself with the procedure.
CAUTION
To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area.
CAUTION
Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment
may result in chain breakage, vehicle tipping, or machine damage.
Table 2.1 Lifting Vehicle
Minimum Capacity13630 kg (8000 lb.)
Minimum Fork Length 198 cm (78 in.)
IMPORTANT:
Forklifts are normally rated for a load located 610 mm (24 in.) ahead of the back end of the forks. To obtain the forklift
capacity at 1220 mm (48 in.), check with your forklift distributor.
1033533
A
Figure 2.1: Lifting Header off Trailer
IMPORTANT:
Do NOT lift at hooks (A) when unloading from the trailer.
Hooks (A) are ONLY for tipping the machine over to working
position.
WARNING
Be sure forks are secure before moving away from load. Stand clear when lifting.
1. At 1220 mm (48 in.) from back end of forks.

262300 10 Revision A
1021175
Figure 2.2: Lifting Header off Trailer
1. Remove the hauler’s tie-down straps and chains.
2. Approach the header from its underside and slide the forks
under the lifting framework as far as possible.
IMPORTANT:
Do NOT damage the hydraulic hoses hanging below the
header.
3. Raise the header off the deck.
IMPORTANT:
Headers are often shipped two per trailer. If unloading a
header from a two-unit load, avoid damaging the
other header.
1018583
Figure 2.3: Moving Header with Forklift
4. Back up until the header clears the trailer, and then slowly
lower the header to 150 mm (6 in.) from the ground.
5. Take the header to the storage or setup area.
6. Set the header down on secure, level ground.
7. Check for shipping damage and missing parts.
UNLOADING HEADER