MacDon R116 User manual

R116 (Model Years 2015–2017)
Rotary Disc Pull-Type
Small Drum Kit (MD #259140) Installation Instructions
214913 Revision B
Original Instruction
The harvesting specialists.

R116 Rotary Disc Pull-Type
1010571
Published April 2019

Introduction
The Small Drum kit (MD #259140) can be installed on a MacDon R116 Rotary Disc Pull-Type (model years 2015–2017) to
improve cutting performance in certain conditions. The kit contains two drums and associated parts to replace the factory-
installed inner drums on the pull-type.
This document explains how to install the kit. A list of parts included in the kit is provided in Chapter 2 Parts List, page 5.
Installation time
Installation time for this kit is approximately 2.5 hours.
Conventions
The following conventions are used in this document:
•Right and left are determined from the operator’s position. The front of the pull-type is the side that faces the crop.
•Unless otherwise noted, use the standard torque values provided in the pull-type 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.
214913 iRevision B

List of Revisions
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.
Summary of Change Location
Removed reference to R113 Rotary Disc Pull-Type. Kit
MD #259140 only applies to R116 Rotary Disc Pull-Type
(model years 2015–2017).
Throughout.
Corrected captions. Throughout.
Revised description of NOTE. 1.1 Signal Words, page 1
Added a WARNING to the procedures for opening
cutterbar doors. •3.1 Opening Cutterbar Doors –North America, page 9
•3.2 Opening Cutterbar Doors –Export Latches, page 10
Added a step to the procedures for opening cutterbar
doors. •Step 2, page 9
•Step 2, page 10
Added a DANGER and CAUTION to the procedure for
removing discblades.
3.3 Removing Discblades and Attachment Hardware, page
12
Added two steps to the procedure for removing discblades. •Step 1, page 12
•Step 2, page 12
Added an IMPORTANT to the procedures for removing and
installing discblades. •Step 5, page 12
•Step 3, page 22
Regarding the four bolts that secure the driveline assembly
to the hub drive:
•Corrected the type of threadlocker required. The bolts
require Loctite®243 or equivalent, NOT Loctite®242 or
equivalent.
•Changed the torque value from 95 Nm (70 lbf·ft) to
102 Nm (75 lbf·ft).
•Step 9, page 19
•Step 10, page 19
Regarding the eight bolts used to secure the drum shields:
•Changed the torque value from 29 Nm (21 lbf·ft) to
27 Nm (20 lbf·ft)
Step 12, page 19
Added a CAUTION to the procedure after the kit
installation.
4 After Installation, page 25
214913 ii Revision B

214913 iii Revision B
Introduction ................................................................................................................................................i
List of Revisions...........................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Signal Words .........................................................................................................................................1
1.2 General Safety .......................................................................................................................................2
Chapter 2: Parts List.................................................................................................................................... 5
Chapter 3: Installation Instructions ........................................................................................................... 9
3.1 Opening Cutterbar Doors –North America..................................................................................................9
3.2 Opening Cutterbar Doors –Export Latches................................................................................................ 10
3.3 Removing Discblades and Attachment Hardware ....................................................................................... 12
3.4 Removing Right Inboard Drum and Disc.................................................................................................... 13
3.5 Installing New Right Drum Assembly ........................................................................................................ 14
3.6 Removing Left Inboard Drum, Disc, and Driveline ....................................................................................... 15
3.7 Installing New Left Drum Assembly, Shields, and Driveline ........................................................................... 18
3.8 Installing Discblades on New Discs........................................................................................................... 22
3.9 Closing Cutterbar Doors......................................................................................................................... 23
Chapter 4: After Installation..................................................................................................................... 25
TABLE OF CONTENTS

214913 1Revision B
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.

214913 2Revision B
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 job at hand. Do NOT take chances. You may
need the following:
•Hard hat
•Protective footwear with slip-resistant soles
•Protective glasses or goggles
•Heavy gloves
•Wet weather gear
•Respirator or filter mask
1000005
Figure 1.2: Safety Equipment
•Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection devices
such as earmuffs or earplugs to help protect against loud
noises.
1010391
Figure 1.3: Safety Equipment
•Provide a first aid kit in case of emergencies.
•Keep a properly maintained fire extinguisher on the machine.
Be familiar with its proper use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when the operator is
tired or in a hurry. Take time to consider safest way. NEVER
ignore warning signs of fatigue.
SAFETY

214913 3Revision B
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 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 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 1.6: 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

214913 5Revision B
Chapter 2: Parts List
The following parts are included in this kit:

214913 6Revision B
Figure 2.1: Parts Included in Small Drum Kit
1028930
1
2
3
4
5
6
6
7
8
A
B
B
B
B
B
C
C
D
D
9
PARTS LIST

214913 7Revision B
Ref
Part
Number Description Quantity
1 257085 ASSEMBLY –CW DRUM, 425 MM DRIVE 1
2 257086 ASSEMBLY –CCW DRUM, 425 MM 1
3281981 SHIELD –VERTICAL 2
4281489 DRUM –TOP 1
5 281493 PLATE –BACK 1
6281497 SHIELD –DRUM 2
7 281500 PLATE –COVER 1
8 281501 PLATE –SHIELD 1
9 259139 ASSEMBLY –DRIVELINE 1
A 136485 BOLT –HEX FLG HD TFL M8 X 1.25 X 16 8.8 A3L 8
B 152655 BOLT –HEX FLG HD M10 X 1.5 X 20 8.8 A3L 13
C 246952 WASHER –M12 LOCKING DISC 8
D 281697 BOLT –M12 DISC COVER 8
PARTS LIST

214913 9Revision B
Chapter 3: Installation Instructions
To install the Small Drum kit (MD #259140), follow these procedures in order:
3.1 Opening Cutterbar Doors –North America
If the pull-type was sold outside of North America, it will have export latches. Refer to 3.2 Opening Cutterbar Doors –
Export Latches, page 10.
WARNING
To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator’s seat for any reason.
1. Center the pull-type beneath the hitch, if both doors need
to be opened.
2. Shut down the engine, and remove the key from the
ignition.
1027711
A
Figure 3.1: Cutterbar Doors and Curtains –Pull-Type
3. Lift up on door (A) at the front to open.

214913 10 Revision B
3.2 Opening Cutterbar Doors –Export Latches
Pull-types sold outside North America require a tool-operated latch on the cutterbar doors. Follow these steps to open
cutterbar doors with export latches:
WARNING
To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator’s seat for any reason.
1. Center the pull-type beneath the hitch, if both doors need
to be opened.
2. Shut down the engine, and remove the key from the
ignition.
1015145
A
Figure 3.2: Cutterbar Door Latch Access Hole –
Export Only
3. Locate latch access holes (A) for each door.
1015146
A
Figure 3.3: Cutterbar Door Latch –Cutaway View
4. Use a rod or screwdriver to press down on latch (A) and
release the cutterbar door.
INSTALLATION INSTRUCTIONS

214913 11 Revision B
1023524
A
Figure 3.4: Cutterbar Doors and Curtains –Pull-Type
5. Lift up on door (A) while pressing down on the latch.
INSTALLATION INSTRUCTIONS

214913 12 Revision B
3.3 Removing Discblades and Attachment Hardware
The kit includes two new disc/drum assemblies, but no discblades or attachment hardware. You will need to remove the
discblades and hardware from the discs under the two inboard rotary deflectors, and install them on the new discs. To
remove the discblades and hardware, follow these steps:
DANGER
To avoid bodily injury or death from unexpected startup or fall of a raised machine, stop engine, remove key, and
engage lift cylinder lock-out valves before going under machine for any reason.
WARNING
Wear heavy gloves when working around or handling knives. Blades are sharp and can cause serious injury.
CAUTION
Check to be sure all bystanders have cleared the area.
1. Raise the pull-type fully, shut off engine, and remove key.
2. Engage lift cylinder lock-out valves. Refer to the pull-type
operator’s manual or technical manual for instructions.
1004027
A
B
C
Figure 3.5: Discblade Aligned with Hole in Rock Guard
3. Rotate disc (A) so blade (B) faces forward and lines up with
hole (C) in rock guard.
4. Place a pin (or equivalent) in the front hole of the rock
guard to prevent disc rotation while loosening blade bolts.
1021892
A
B
C
Figure 3.6: Discblade Hardware
5. Remove nut (A), shoulder bolt (B), and blade (C). Retain for
installation on one of the new cutterbar discs.
IMPORTANT:
Nuts are one-time use only. When flipping or changing a
blade, replace using a NEW nut only.
INSTALLATION INSTRUCTIONS

214913 13 Revision B
3.4 Removing Right Inboard Drum and Disc
To remove the inboard drum on the right side of the cutterbar, follow these steps:
WARNING
Wear heavy gloves when working around or handling knives. Blades are sharp and can cause serious injury.
NOTE:
Arrows in the following illustrations point to the front of the machine.
1027251
A
B
Figure 3.7: Cover of Inboard Right Drum –View
from Above
1. Place a wooden block between two cutterbar discs to
prevent disc rotation while loosening blade bolts.
2. Remove eight M8 bolts (A) and washers securing the
cover (B) to the non-driven drum, and remove cover.
1021920
A
B
C
Figure 3.8: Inboard Right Drum with Cover Removed –
View from Above
3. Remove four M12 bolts (A) inside the drum using a 305 mm
(12 in.) extension and 18 mm socket.
4. Remove wooden block.
5. Remove drum (B) and disc (C) assembly.
6. Discard all parts removed.
INSTALLATION INSTRUCTIONS

214913 14 Revision B
3.5 Installing New Right Drum Assembly
To install the new counterclockwise drum assembly (MD #257086) provided in the kit, follow these steps:
WARNING
Wear heavy gloves when working around or handling knives. Blades are sharp and can cause serious injury.
NOTE:
Unless otherwise specified, all parts are provided in the kit.
1017492
A
Figure 3.9: Non-Driven Spindle
1. Ensure spacer (A) is on spindle.
1026164
A
A
A
A
B
Figure 3.10: Counterclockwise Drum Assembly
Installed
2. Position new counterclockwise drum assembly (B)
(MD #257086) onto the spindle as shown. The disc must be
positioned at a 90-degree angle relative to
neighboring discs.
3. Use an 18 mm deep socket to install four M12 bolts (A)
(MD #281697) and washers (MD #246952), securing drum
assembly (B) to the spindle.
4. Torque to 85 Nm (63 lbf·ft).
INSTALLATION INSTRUCTIONS