MacDon R113 User manual

The harvesting specialists.
R113/R116
Pull-Type Rotary Disc Mower
Conditioner
Operator’s Manual
169820 Revision A
Original Instruction

R113 13-Foot Rotary Disc Pull-Type Mower Conditioner
Published November, 2014

Introduction
This instructional manual contains operating and maintenance procedures for the MacDon R113 13-Foot And R116
16-Foot Rotary Disc Pull-Type Mower Conditioners. Your new mower conditioner is designed to cut, condition, and
lay a wide variety of grasses and hay crops in windrows.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Use this manual as your first source of information about the machine. If you follow the instructions provided in this
manual, your mower conditioner will work well for many years. A parts catalog also is supplied with your new mower
conditioner. If you require more detailed service information, a technical manual is available from your Dealer.
Use the “Table of Contents” and “Index” to guide you to specific topics. Study the “Table of Contents” to familiarize
yourself with how the material is organized. Keep this manual handy for frequent reference and to pass on to new
Operators or Owners. Call your Dealer if you need assistance, information, or additional copies of this manual.
Store the operator’s manual and the parts catalog
in the plastic manual case at the right side of the
mower conditioner.
Figure 1: Manual Storage Case
169820 iRevision A

Serial Numbers
Record the serial number of the mower conditioner in the space provided below.
Mower Conditioner
Serial Number
Year of Manufacture
Figure 2: Mower Conditioner Serial
Number Location
Swivel Hitch Year
of Manufacture
Figure 3: Swivel Hitch Identification
Plate Location
169820 iiRevision A

TABLE OF CONTENTS
Introduction ...................................................................................................................................... i
Serial Numbers.................................................................................................................................ii
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 Tire Safety....................................................................................................................................... 7
1.7 Safety Signs.................................................................................................................................... 8
1.7.1 Installing Safety Decals ............................................................................................................ 8
1.8 Locating Safety Sign Decals............................................................................................................. 9
1.9 Understanding Safety Signs ............................................................................................................11
2 Reference............................................................................................................................................ 19
2.1 Owner/Operator Responsibilities..................................................................................................... 19
2.2 Operational Safety ......................................................................................................................... 20
2.3 Definitions ..................................................................................................................................... 21
2.4 Component Identification................................................................................................................ 23
2.5 Product Specifications.................................................................................................................... 28
3 Operation ............................................................................................................................................ 31
3.1 Lift Cylinder Lock-Out Valves ......................................................................................................... 31
3.1.1 Engaging Locks ..................................................................................................................... 31
3.1.2 Disengaging Locks................................................................................................................. 32
3.2 Driveshields .................................................................................................................................. 33
3.2.1 Opening Driveshields ............................................................................................................. 33
3.2.2 Closing Driveshields............................................................................................................... 34
3.3 Driveline Shield Cone..................................................................................................................... 36
3.3.1 Removing Driveline Shield Cone ............................................................................................. 36
3.3.2 Installing Driveline Shield Cone ............................................................................................... 36
3.4 Cutterbar Doors............................................................................................................................. 38
3.4.1 Opening Cutterbar Doors........................................................................................................ 38
3.4.2 Closing Cutterbar Doors ......................................................................................................... 38
3.5 Daily Startup Check ....................................................................................................................... 40
3.6 Preparing Tractor for Mower Conditioner ......................................................................................... 42
3.6.1 Tractor Requirements ............................................................................................................. 42
3.6.2 Adjusting the Drawbar ............................................................................................................ 42
3.7 Setting Up the Mower Conditioner Hitch .......................................................................................... 43
3.7.1 Installing Drawbar Hitch Adapter ............................................................................................. 43
3.8 Attaching Mower Conditioner to the Tractor ..................................................................................... 44
3.8.1 Attaching with Drawbar Hitch ..................................................................................................44
3.8.2 Attaching with Two-Point Hitch ................................................................................................45
3.8.3 Connecting Hydraulics............................................................................................................ 49
3.8.4 Connecting Electrical Wiring Harness ...................................................................................... 50
3.9 Detaching Mower Conditioner from Tractor...................................................................................... 51
3.9.1 Detaching from Drawbar ......................................................................................................... 51
3.9.2 Detaching from Two-Point Hitch .............................................................................................. 53
3.10 Breaking-In the Mower Conditioner ................................................................................................. 56
3.11 Engaging the Power Take-Off (PTO) ...............................................................................................57
3.12 Raising and Lowering Mower Conditioner........................................................................................ 58
3.12.1 Lift Cylinders.......................................................................................................................... 58
3.12.2 Lift Control ............................................................................................................................. 58
3.13 Shutdown Procedure ..................................................................................................................... 59
3.14 Maneuvering/Steering the Mower Conditioner.................................................................................. 60
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TABLE OF CONTENTS
3.14.1 Right-Side Operation .............................................................................................................. 61
3.14.2 Left-Side Operation ................................................................................................................ 61
3.14.3 Avoiding Obstacles................................................................................................................. 62
3.14.4 Square Corners...................................................................................................................... 63
3.14.5 180-Degree Turn.................................................................................................................... 63
3.15 Transporting the Mower Conditioner................................................................................................ 65
3.15.1 Preparing Mower Conditioner for Transport.............................................................................. 65
3.15.2 Transporting with a Tractor...................................................................................................... 66
3.15.3 Transporting with a Truck........................................................................................................ 67
3.15.4 Transport Lighting .................................................................................................................. 69
Without Endwise Transport System Option ....................................................................... 69
With Endwise Transport System Option............................................................................ 70
3.15.5 Converting from Transport to Field Mode (without Optional Endwise Transport System).............. 70
3.15.6 Endwise Transport System Option........................................................................................... 71
Converting from Field to Transport Mode.......................................................................... 71
Converting from Transport to Field Mode.......................................................................... 73
3.16 Operating the Mower Conditioner ................................................................................................... 75
3.16.1 Mower Conditioner Float......................................................................................................... 75
Adjusting Float................................................................................................................ 75
3.16.2 Mower Conditioner Angle........................................................................................................ 77
Adjusting Mower Conditioner Angle: Mechanical............................................................... 77
Adjusting Mower Conditioner Angle: Hydraulic.................................................................. 77
3.16.3 Cutting Height ........................................................................................................................ 78
Adjusting Cutting Height.................................................................................................. 78
3.16.4 Ground Speed ....................................................................................................................... 80
3.16.5 Conditioning: Roll Type........................................................................................................... 80
Roll Gap.........................................................................................................................81
Roll Tension ................................................................................................................... 83
Roll Timing ..................................................................................................................... 84
Forming Shields: Roll Conditioner.................................................................................... 86
3.16.6 Conditioning: Finger Type....................................................................................................... 87
Internal Intensity Baffle.................................................................................................... 88
Finger Rotor Speed......................................................................................................... 88
Forming Shields: Finger Conditioner ................................................................................ 92
3.16.7 Cutterbar Deflector ................................................................................................................. 94
Removing Cutterbar Deflectors........................................................................................ 94
Installing Cutterbar Deflectors.......................................................................................... 94
3.16.8 Tall Crop Divider Option.......................................................................................................... 95
Removing Tall Crop Divider ............................................................................................. 95
Installing Tall Crop Divider ............................................................................................... 97
3.17 Haying Tips ................................................................................................................................... 98
3.17.1 Curing ................................................................................................................................... 98
3.17.2 Topsoil Moisture ..................................................................................................................... 98
3.17.3 Weather and Topography........................................................................................................ 98
3.17.4 Windrow Characteristics ......................................................................................................... 98
3.17.5 Driving on Windrow ................................................................................................................ 99
3.17.6 Raking and Tedding................................................................................................................ 99
3.17.7 Using Chemical Drying Agents................................................................................................ 99
3.18 Leveling the Mower Conditioner.....................................................................................................100
3.19 Unplugging the Mower Conditioner ................................................................................................101
4 Maintenance and Servicing................................................................................................................103
4.1 Preparing Machine for Servicing ....................................................................................................103
4.2 Recommended Safety Procedures.................................................................................................104
4.3 Maintenance Specifications ...........................................................................................................106
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TABLE OF CONTENTS
4.3.1 Recommended Lubricants .....................................................................................................106
4.3.2 Torque Specifications ............................................................................................................106
SAE Bolt Torque Specifications.......................................................................................107
Metric Bolt Specifications ...............................................................................................109
Metric Bolt Specifications Bolting into Cast Aluminum ......................................................112
Flare-Type Hydraulic Fittings ..........................................................................................112
O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) ..........................................................114
O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable)...................................................116
O-Ring Face Seal (ORFS) Hydraulic Fittings ...................................................................117
4.3.3 Conversion Chart ..................................................................................................................119
4.4 Maintenance Requirements...........................................................................................................120
4.4.1 Maintenance Schedule/Record...............................................................................................121
4.4.2 Break-In Inspections..............................................................................................................123
4.4.3 Preseason Servicing..............................................................................................................123
4.4.4 End-of-Season Servicing .......................................................................................................124
4.4.5 Lubricating the Mower Conditioner .........................................................................................125
Greasing Procedure.......................................................................................................126
Service Intervals ............................................................................................................127
4.5 Cutterbar......................................................................................................................................136
4.5.1 Cutterbar Lubrication .............................................................................................................136
Checking Lubricant Level ...............................................................................................136
Draining Cutterbar .........................................................................................................138
Filling Cutterbar .............................................................................................................139
4.5.2 Cutterbar Disc Maintenance...................................................................................................139
Inspecting Cutterbar Discs..............................................................................................139
Removing Cutterbar Discs..............................................................................................140
Installing Cutterbar Discs................................................................................................141
4.5.3 Cutterbar Spindles ................................................................................................................143
Removing Cutterbar Spindles .........................................................................................146
Installing Cutterbar Spindles ...........................................................................................148
4.5.4 Cutter Blades ........................................................................................................................153
Inspecting Cutter Blades ................................................................................................153
Inspecting Cutter Blade Hardware...................................................................................155
Removing Cutter Blades.................................................................................................156
Installing Cutter Blades ..................................................................................................157
4.5.5 Cutterbar Doors ....................................................................................................................158
Inspecting Cutterbar Doors.............................................................................................159
Opening Cutterbar Doors ...............................................................................................159
Closing Cutterbar Doors.................................................................................................159
4.5.6 Curtains................................................................................................................................160
Inspecting Curtains ........................................................................................................161
Removing Cutterbar Door Curtains .................................................................................161
Installing Cutterbar Door Curtains ...................................................................................162
Removing Cutterbar Inboard Curtain...............................................................................163
Installing Cutterbar Inboard Curtain.................................................................................164
Removing Outboard Curtains .........................................................................................165
Installing Outboard Curtains ...........................................................................................166
4.5.7 Accelerators..........................................................................................................................168
Inspecting Accelerators ..................................................................................................168
Removing Accelerators ..................................................................................................169
Installing Accelerators ....................................................................................................170
4.5.8 Rock Guards.........................................................................................................................171
Inspecting Rock Guards .................................................................................................171
Removing Rock Guards .................................................................................................171
169820 vRevision A

TABLE OF CONTENTS
Installing Rock Guards ...................................................................................................172
4.5.9 Rotary Deflectors ..................................................................................................................173
Inspecting Rotary Deflectors...........................................................................................173
Removing Driven Rotary Deflectors and Driveline ............................................................174
Installing Driven Rotary Deflectors and Driveline..............................................................177
Removing Non-Driven Rotary Deflectors .........................................................................181
Installing Non-Driven Rotary Deflectors ...........................................................................182
4.5.10 Cutterbar Spindle Shear Pin...................................................................................................184
Removing Cutterbar Spindle Shear Pin ...........................................................................185
Installing Cutterbar Spindle Shear Pin .............................................................................186
4.6 Drive Systems ..............................................................................................................................190
4.6.1 Primary Driveline...................................................................................................................190
Removing Primary Driveline ...........................................................................................190
Installing Primary Driveline .............................................................................................191
4.6.2 Hitch Driveline.......................................................................................................................192
Removing Hitch Driveline ...............................................................................................192
Installing Hitch Driveline .................................................................................................195
4.6.3 Clutch Driveline.....................................................................................................................199
Removing Clutch Driveline .............................................................................................199
Installing Clutch Driveline ...............................................................................................201
4.6.4 Driveline Guard.....................................................................................................................204
Removing Driveline Guard..............................................................................................204
Installing Driveline Guard ...............................................................................................205
4.6.5 Conditioner Drive Belt............................................................................................................207
Inspecting Conditioner Drive Belt ....................................................................................207
Removing Conditioner Drive Belt ....................................................................................208
Installing Conditioner Drive Belt ......................................................................................209
4.6.6 Conditioner Drive Gearbox.....................................................................................................211
Checking and Changing Conditioner Gearbox Oil ............................................................211
4.6.7 Mower Conditioner Drive Gearbox..........................................................................................213
Lubricating Mower Conditioner Drive Gearbox .................................................................214
4.6.8 Forward and Rear Swivel Gearboxes .....................................................................................219
Checking Lubricant: Forward and Rear Swivel Gearboxes ...............................................219
Draining Lubricant: Forward and Rear Swivel Gearboxes.................................................220
Adding Lubricant: Forward and Rear Swivel Gearboxes...................................................220
4.6.9 Wheels and Tires ..................................................................................................................220
Checking Wheel Bolts ....................................................................................................220
Removing Wheels..........................................................................................................221
Installing Wheels ...........................................................................................................222
Inflating Tires.................................................................................................................222
4.7 Hydraulics ....................................................................................................................................224
4.7.1 Hydraulic Hoses and Lines ....................................................................................................224
4.7.2 Hydraulic Cylinders ...............................................................................................................224
4.8 Electrical ......................................................................................................................................225
4.8.1 Maintaining Electrical System.................................................................................................225
4.8.2 Servicing Amber Hazard/Signal Lights ....................................................................................225
Replacing Amber Hazard/Signal Bulb..............................................................................225
Replacing Amber Hazard/Signal Light Fixture..................................................................225
4.8.3 Servicing Red Brake/Tail Lights..............................................................................................226
Replacing Red Brake/Tail Light Bulb ...............................................................................226
Replacing Red Brake/Tail Light Fixture ............................................................................226
4.9 Driveshields .................................................................................................................................227
4.9.1 Removing Driveshields ..........................................................................................................227
4.9.2 Installing Driveshields ............................................................................................................228
169820 viRevision A

TABLE OF CONTENTS
4.9.3 Replacing Driveshield Latch...................................................................................................229
4.10 Roll Conditioner............................................................................................................................231
4.10.1 Inspecting Roll Conditioner ....................................................................................................231
4.11 Finger Conditioner ........................................................................................................................233
4.11.1 Inspecting Finger Conditioner.................................................................................................233
4.12 Changing the Conditioner..............................................................................................................235
4.12.1 Separating Header from Carrier .............................................................................................235
4.12.2 Removing the Conditioner......................................................................................................239
4.12.3 Installing the Conditioner .......................................................................................................240
4.12.4 Assembling Header and Carrier .............................................................................................241
4.13 Shield (No Conditioner).................................................................................................................245
4.13.1 Removing Shield (No Conditioner)..........................................................................................245
4.13.2 Installing Shield (No Conditioner) ...........................................................................................246
5 Troubleshooting.................................................................................................................................249
5.1 Troubleshooting Mower Performance.............................................................................................249
5.2 Troubleshooting Mechanical Issues ...............................................................................................252
6 Options and Attachments ..................................................................................................................255
6.1 Tall Crop Divider Kit ......................................................................................................................255
6.2 Hydraulic Center-Link Kit...............................................................................................................256
6.3 Truck Transport Hitch....................................................................................................................257
6.4 Endwise Transport System............................................................................................................258
Index ..................................................................................................................................................259
169820 vii Revision A

1Safety
1.1 Safety Alert Symbols
This safety alert symbol indicates important safety
messages in this manual and on safety signs on the .
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
Figure 1.1: Safety Symbol
169820 1Revision A

SAFETY
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
mayalsobeusedto 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.
169820 2Revision A

SAFETY
1.3 General Safety
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 the protective clothing and personal safety
devices that COULD be necessary for the job at hand.
Don’t take chances. You may need the following:
• A hard hat
• Protective footwear with slip resistant soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• A respirator or filter mask
Figure 1.2: Safety Equipment
• Be aware that exposure to loud noise can cause
impairment or loss of hearing. Wear suitable hearing
protection devices such as ear muffs or ear plugs to
help protect against objectionable or loud noises.
Figure 1.3: Safety Equipment
•Provideafirst aid kit for use in case of emergencies.
• Keep a fire extinguisher on the machine. Be sure the
fire extinguisher is properly maintained. Be familiar with
its proper use.
• Keep young children away from the machinery at
all times.
• Be aware that accidents often happen when the
Operator is tired or in a hurry to get finished. Take the
time to consider the safest way. Never ignore warning
signs of fatigue.
Figure 1.4: Safety Equipment
169820 3Revision A

SAFETY
•Wearclose-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 the shaft and can telescope freely.
• Use only service and repair parts made or approved by
the equipment manufacturer. Substituted parts may not
meet strength, design, or safety requirements.
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.
•DoNOT modify the machine. Non-authorized
modifications may impair machine function and/or
safety. It may also shorten the machine’s life.
• Stop the engine and remove the key from ignition before
leaving operator’s seat for any reason. A child or even
a pet could engage an idling machine.
Figure 1.6: Safety Around Equipment
• Keep the 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, are 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.
Figure 1.7: Safety Around Equipment
169820 4Revision A

SAFETY
1.4 Maintenance Safety
To ensure your safety while maintaining the machine:
• Review the operator’s manual and all safety items
before operation and/or maintenance of the 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 the job at hand Figure 1.8: Safety Around Equipment
• Relieve pressure from hydraulic circuits before servicing
and/or disconnecting the machine.
• Make sure all components are tight and that steel lines,
hoses, and couplings are in good condition before
applying pressure to a hydraulic system.
• Keep hands, feet, clothing, and hair away from all
moving and/or rotating parts.
• Clear the area of bystanders, especially children, when
carrying out any maintenance and repairs or when
making any adjustments.
• Install transport lock or place safety stands under the
frame before working under the .
• If more than one person is servicing the machine at the
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 knife) to move. Stay
clear of driven components at all times.
Figure 1.9: Equipment NOT Safe for Children
• Wear protective gear when working on the machine.
• Wear heavy gloves when working on knife components.
Figure 1.10: Safety Equipment
169820 5Revision A

SAFETY
1.5 Hydraulic Safety
• Always place all hydraulic controls in Neutral
before dismounting.
• Make sure that all components in the hydraulic system
are kept clean and in good condition.
• Replace any worn, cut, abraded, flattened, or crimped
hoses and steel lines.
•DoNOT attempt any makeshift repairs to the 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 a hazardous and unsafe condition.
Figure 1.11: Testing for Hydraulic Leaks
•Wearprope
r hand and eye protection when searching
for a high-pressure hydraulic leak. Use a piece of
cardboard as a backstop instead of hands to isolate
and identify a leak.
•Ifinjure
d by a concentrated high-pressure stream of
hydraulicfluid, seek medical attention immediately.
Serious infection or toxic reaction can develop from
hydraulic fluid piercing the skin.
Figure 1.12: Hydraulic Pressure Hazard
• Make sure all components are tight and that steel lines,
hoses, and couplings are in good condition before
applying pressure to a hydraulic system.
Figure 1.13: Safety Around Equipment
169820 6Revision A

SAFETY
1.6 Tire Safety
• Follow proper procedures when mounting a tire on a
wheel or rim. Failure to do so can produce an explosion
that may result in serious injury or death.
Figure 1.14: Overinflated Tire
•DoNOT attempt to mount a tire unless you have the
proper training and equipment.
• Haveaqua
lified tire dealer or repair service perform
required tire maintenance.
Figure 1.15: Safely Filling a Tire with Air
169820 7Revision A

SAFETY
1.7 Safety Signs
• 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 the repair part also bears the current
safety sign.
• Safety signs are available from your Dealer
Parts Department.
Figure 1.16: Operator’s Manual Decal
1.7.1 Installing Safety Decals
1. Clean and dry the installation area.
2. Decide on the exact location before you remove the decal backing paper.
3. Remove the smaller portion of the split backing paper.
4. Place the sign in position and slowly peel back the remaining paper, smoothing the sign as it is applied.
5. Prick small air pockets with a pin and smooth out.
169820 8Revision A

SAFETY
1.8 Locating Safety Sign Decals
Figure 1.17: Safety Sign Decal Locations
A - MD #194466 B - MD #247167 C - MD #194465 D - MD #190546
E - MD #247166 F - MD #113482 G - MD #174474
Figure 1.18: Safety Sign Decals
169820 9Revision A

SAFETY
Figure 1.19: Safety Sign Decal Location
A - MD #171287
Figure 1.20: Safety Sign Decal Locations
A - MD #113482 B - MD #171287 C - MD #174436
169820 10 Revision A