MacDon R116 User manual

R113/R116
Pull-Type Disc Mower
Unloading and Assembly Instruction: North America
214713 Revision A
Original Instruction
The harvesting specialists.

R113/R116 Pull-Type Disc Mower
1010571
Published: June, 2018

Introduction
This instruction manual describes the unloading, setup, and predelivery requirements for the MacDon R113 and
R116 Pull-Type Disc Mower.
To ensure your customers receive the best performance and safety from this product, carefully follow the unload
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.
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).
This instruction is available in English and French and can be ordered from MacDon, downloaded from our Dealer
Portal, or from our International website (http://www.macdon.com/world).
214713 iRevision A

List of Revisions
At MacDon, we’re continuously making improvements; 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
Updated images with slow moving vehicle signs Various
Updated images to remove old jack stand and mount Various
Added new jack stand information
•3.3.1 Installing Drawbar Hitch, page 16
•5.3.1 Attaching with Drawbar Hitch, page 93
•4.3.1 Installing Drawbar Hitch, page 65
Added image for transport pin installation Installing Transport Assembly, page 34
Updated topic with new slow moving vehicle sign Installing Slow Moving Vehicle (SMV) Sign, page 55
214713 ii Revision A

214713 iii Revision A
Introduction................................................................................................................................................i
Chapter 1: Safety .................................................................................................................................... 1
1.1 Signal Words .......................................................................................................................................1
1.2 General Safety.....................................................................................................................................2
1.3 Tire Safety...........................................................................................................................................4
1.4 Safety Signs ........................................................................................................................................5
Chapter 2: Unloading Truck Shipment .............................................................................................. 7
Chapter 3: Assembling the Disc Mower (With or Without the Dealer-Installed
Transport) ................................................................................................................................. 9
3.1 Repositioning Center-Link Top Anchor...................................................................................................9
3.2 Attaching Hitch to Carrier....................................................................................................................12
3.3 Installing Tractor Mating Hitch to Carrier Hitch ......................................................................................16
3.3.1 Installing Drawbar Hitch .............................................................................................................16
3.3.2 Installing Two-Point Hitch (Cat. II) Adapter ..................................................................................20
3.4 Installing Hitch Swing Cylinder ............................................................................................................24
3.5 Attaching Clutch Driveline...................................................................................................................26
3.6 Attaching Steering Arm.......................................................................................................................28
3.7 Connecting Transport Lighting Module.................................................................................................30
3.8 Installing Options ...............................................................................................................................31
3.8.1 Installing Road Friendly Transport™System ................................................................................31
Installing Components ..............................................................................................................31
Installing Hydraulics..................................................................................................................44
Installing Electrical Components ................................................................................................50
Installing Cover ........................................................................................................................56
3.8.2 Installing Hydraulic Center-Link (Optional) ..................................................................................56
3.8.3 Installing Tall Crop Divider (Optional) ..........................................................................................56
Chapter 4: Assembling the Disc Mower (Factory-Installed Transport) .................................. 57
4.1 Repositioning Center-Link Top Anchor.................................................................................................57
4.2 Attaching Hitch to Carrier....................................................................................................................61
4.3 Installing Tractor Mating Hitch to Carrier Hitch ......................................................................................65
4.3.1 Installing Drawbar Hitch .............................................................................................................65
4.3.2 Installing Two-Point Hitch (Cat. II) Adapter ..................................................................................69
4.4 Installing Hitch Swing Cylinder ............................................................................................................73
4.5 Attaching Clutch Driveline...................................................................................................................74
4.6 Attaching Steering Arm.......................................................................................................................76
4.7 Removing Slow Moving Vehicle Sign (SMV) Covering...........................................................................78
4.8 Completing Road Friendly Transport™System Installation ....................................................................79
4.8.1 Removing Cover .......................................................................................................................79
4.8.2 Installing Transport Alignment Control.........................................................................................79
TABLE OF CONTENTS

214713 iv Revision A
4.8.3 Installing Hydraulic Lines and Hoses...........................................................................................81
4.8.4 Installing Electrical Components.................................................................................................84
Connecting Selector Valve and Transport Lighting Module...........................................................84
Installing Light Assembly...........................................................................................................85
Connecting Transport Lighting Module .......................................................................................85
Installing Remote Control ..........................................................................................................85
4.8.5 Installing Cover .........................................................................................................................87
4.9 Installing Options ...............................................................................................................................88
4.9.1 Installing Hydraulic Center-Link (Optional) ..................................................................................88
4.9.2 Installing Tall Crop Divider (Optional) ..........................................................................................88
4.10 Installing Road Friendly Transport™Wheels .......................................................................................89
Chapter 5: Setting up the Tractor ..................................................................................................... 91
5.1 Adjusting the Drawbar ........................................................................................................................91
5.2 Installing Drawbar Hitch Adapter .........................................................................................................92
5.3 Attaching Disc Mower to the Tractor ....................................................................................................93
5.3.1 Attaching with Drawbar Hitch .....................................................................................................93
5.3.2 Attaching with Two-Point Hitch ...................................................................................................95
5.3.3 Connecting Hydraulics...............................................................................................................98
5.3.4 Connecting Electrical Wiring Harness .........................................................................................99
5.4 Installing Field Wheels......................................................................................................................100
5.5 Priming the Hitch Swing Cylinder.......................................................................................................102
5.6 Setting up Forming Shields ...............................................................................................................104
5.6.1 Setting up Forming Shields for Finger Conditioner .....................................................................104
5.6.2 Setting up Forming Shields for Roll Conditioner .........................................................................109
5.7 Unpacking Curtains.......................................................................................................................... 110
5.8 Discharge Shield (No Conditioner) .................................................................................................... 112
5.8.1 Removing Discharge Shield (No Conditioner)............................................................................ 112
5.8.2 Installing Discharge Shield (No Conditioner).............................................................................. 114
5.9 Removing Disc Mower from Shipping Pallet (No Transport Installed).................................................... 116
5.10 Removing Disc Mower from Shipping Pallet (Transport Installed)....................................................... 117
Chapter 6: Lubricating the Disc Mower ........................................................................................ 119
6.1 Opening Driveshields ....................................................................................................................... 119
6.2 Lubrication Points ............................................................................................................................121
6.3 Closing Driveshields.........................................................................................................................126
Chapter 7: Performing Predelivery Checks .................................................................................127
7.1 Checking Wheel Bolts ......................................................................................................................127
7.2 Checking Tire Pressure ....................................................................................................................128
7.3 Checking Conditioner Drive Belt........................................................................................................129
7.3.1 Adjusting Conditioner Drive Belt ...............................................................................................129
7.4 Checking Cutting Angle ....................................................................................................................130
TABLE OF CONTENTS

214713 vRevision A
7.5 Checking Skid Shoes .......................................................................................................................131
7.6 Checking Disc Mower Float ..............................................................................................................132
7.6.1 Adjusting Disc Mower Float......................................................................................................132
7.7 Checking and Adding Conditioner Roll Timing Gearbox Lubricant........................................................134
7.8 Checking and Adding Disc Mower Drive Gearbox Lubricant ................................................................135
7.9 Checking and Lubricating Forward and Rear Swivel Gearboxes ..........................................................136
7.10 Checking and Adding Cutterbar Lubricant ........................................................................................138
7.11 Checking Roll Gap .........................................................................................................................140
7.11.1 Adjusting Roll Gap (Steel Rolls) ..............................................................................................140
7.11.2 Adjusting Roll Gap (Polyurethane Rolls) ..................................................................................141
7.12 Checking Roll Timing......................................................................................................................142
7.13 Checking Roll Tension ....................................................................................................................143
7.13.1 Adjusting Roll Tension ...........................................................................................................143
7.14 Adjusting Conditioner Baffle Position ...............................................................................................144
7.15 Checking Lights .............................................................................................................................145
7.16 Checking Manuals..........................................................................................................................146
7.17 Checking Clutch Operation .............................................................................................................147
7.17.1 Adjusting Clutch ....................................................................................................................148
7.18 Running up the Header...................................................................................................................151
7.19 Checking and Adjusting the Cam on the Transport Deploy/Swing Mechanism.....................................152
Chapter 8: Transporting the Disc Mower......................................................................................153
8.1 Preparing Disc Mower for Transport ..................................................................................................153
8.2 Transporting with a Tractor ...............................................................................................................156
8.3 Transport Lighting ............................................................................................................................157
8.3.1 Lighting (With Road Friendly Transport™Option) .......................................................................157
8.3.2 Lighting (Without Road Friendly Transport™Option) ..................................................................157
8.4 Converting from Transport to Field Mode (Without Road Friendly Transport™) ......................................158
8.5 Converting from Field Mode to Transport (Without Road Friendly Transport™) ......................................159
8.6 Road Friendly Transport™Option ......................................................................................................160
8.6.1 Converting from Field to Transport Mode (With Road Friendly Transport™)..................................160
8.6.2 Converting from Transport to Field Mode (With Road Friendly Transport™)..................................166
Chapter 9: Changing the Conditioner ...........................................................................................171
9.1 Separating Header from Carrier ........................................................................................................171
9.2 Removing the Conditioner ................................................................................................................174
9.2.1 Removing Cutterbar Deflectors ................................................................................................177
9.3 Installing the Conditioner ..................................................................................................................178
9.3.1 Installing Cutterbar Deflectors ..................................................................................................180
9.3.2 Installing Conditioner Drive ......................................................................................................181
9.4 Assembling Header and Carrier ........................................................................................................183
TABLE OF CONTENTS

214713 vi Revision A
Chapter 10: Hydraulic Schematics.................................................................................................187
Chapter 11: Reference .......................................................................................................................203
11.1 Opening Cutterbar Doors ................................................................................................................203
11.2 Engaging Locks .............................................................................................................................204
11.3 Disengaging Locks .........................................................................................................................205
11.4 Closing Cutterbar Doors .................................................................................................................206
11.5 Recommended Lubricants ..............................................................................................................207
11.6 Torque Specifications .....................................................................................................................208
11.6.1 SAE Bolt Torque Specifications...............................................................................................208
11.6.2 Metric Bolt Specifications .......................................................................................................210
11.6.3 Metric Bolt Specifications Bolting into Cast Aluminum...............................................................212
11.6.4 Flare-Type Hydraulic Fittings ..................................................................................................213
11.6.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) ..................................................................214
11.6.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ...........................................................216
11.6.7 O-Ring Face Seal (ORFS) Hydraulic Fittings ...........................................................................217
11.6.8 Tapered Pipe Thread Fittings..................................................................................................218
11.7 Conversion Chart ...........................................................................................................................219
11.8 Definitions ..................................................................................................................................... 220
11.9 Converting Road Friendly Transport™Decal.....................................................................................222
Predelivery Checklist.........................................................................................................................223
TABLE OF CONTENTS

214713 1Revision A
Chapter 1: Safety
1.1 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. 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.

214713 2Revision A
1.2 General Safety
1000004
Figure 1.1: Safety Equipment
CAUTION
The following are general farm safety precautions that
should be part of your operating procedure for all types
of machinery.
Protect yourself.
•When assembling, operating, and servicing machinery,
wear all protective clothing and personal safety devices
that could be necessary for job at hand. Do NOT take
chances. You may need the following:
•Hard hat
•Protective footwear with slip-resistant soles
•Protective glasses or goggles
•Heavy gloves
•Wet weather gear
•Respirator or filter mask
1000005
Figure 1.2: 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 for use in case of emergencies.
•Keep a fire extinguisher on the machine. Be sure fire
extinguisher is properly maintained. Be familiar with its
proper use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when Operator is
tired or in a hurry. Take time to consider safest way.
Never ignore warning signs of fatigue.
SAFETY

214713 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 engine is running.
•Do NOT modify machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten machine’s life.
•To avoid bodily injury or death from unexpected startup of
machine, ALWAYS stop the engine and remove the key
from the ignition before leaving the operator’s seat for
any reason.
1000009
Figure 1.6: 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

214713 4Revision A
1.3 Tire Safety
1000020
Figure 1.7: Overinflated Tire
WARNING
•Service tires safely.
•A tire can explode during inflation which could cause
serious injury or death.
•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.
1000019
Figure 1.8: Safely Inflating Tire
WARNING
•Do NOT stand over tire. Use a clip-on chuck and
extension hose.
•Do NOT exceed maximum inflation pressure indicated
on tire label.
•Replace tires that have defects.
•Replace wheel rims that are cracked, worn, or
severely rusted.
•Never weld a wheel rim.
•Never use force on an inflated or partially inflated tire.
•Make sure tire is correctly seated before inflating to
operating pressure.
•If tire is not correctly positioned on rim or is overinflated, tire bead can loosen on one side causing air
to escape at high speed and with great force. An air leak of this nature can thrust tire in any direction
endangering anyone in area.
•Make sure all air is removed from tire before removing tire from rim.
•Do NOT remove, install, or repair a tire on a rim unless you have proper equipment and experience to
perform job.
•Take tire and rim to a qualified tire repair shop.
SAFETY

214713 5Revision A
1.4 Safety Signs
1000694
Figure 1.9: Operator’s Manual Decal
•Keep safety signs clean and legible at all times.
•Replace safety signs that are missing or illegible.
•If original part on which a safety sign was installed is
replaced, be sure repair part also bears current
safety sign.
•Safety signs are available from your MacDon Dealer.
SAFETY

214713 7Revision A
Chapter 2: Unloading Truck Shipment
CAUTION
To avoid injury to bystanders from being struck by machinery, do NOT allow persons 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.
Lifting Vehicle
Minimum capacity 3630 kg (8000 lb.)
Minimum height 4.5 m (15 ft.)
Chain
Overhead lifting quality 12.7 mm (1/2 inch) 2270 kg (5000 lb.) minimum working load
Figure 2.1: Unloading Hitch
1010549
A
B
A
B
1. Remove hauler's tie-down straps and chains.
2. Attach chain (A) to two brackets (B) on top of hitch as shown.
3. Adjust chain lengths so hitch is lifted evenly.
4. Raise hitch off deck, back up until unit clears trailer, and slowly lower to 150 mm (6 in.) from ground.
IMPORTANT:
Take care not to contact the other machine if load is two headers wide.

214713 8Revision A
5. Take to storage or assembly area, and set hitch down securely on level ground.
6. Repeat for second hitch (if required).
7. Check for shipping damage and missing parts.
1015097
A
B
Figure 2.2: Unloading Disc Mower
8. Approach disc mower (A) from back with forklift (B) as
shown, and slide forks as far as possible into pallet.
NOTE:
Pallet is designed to be lifted from the backside only.
9. Raise disc mower off deck.
IMPORTANT:
Take care not to contact the other machine if load is
two-wide.
10. Back up until unit clears trailer, and slowly lower to
150 mm (6 in.) from ground.
11. Take to storage or set-up area, and set machine down
securely on level ground.
NOTE:
When possible, approach from the backside to
minimize potential for contacting the unit.
12. Repeat for second disc mower (if required).
13. Check for shipping damage and missing parts.
IMPORTANT:
Do NOT remove disc mower from pallet until instructed.
14. Unload remaining pallets and boxes, and take to assembly area.
UNLOADING TRUCK SHIPMENT

214713 9Revision A
Chapter 3: Assembling the Disc Mower (With or Without
the Dealer-Installed Transport)
Perform the following procedures in the order provided to assemble the disc mower without the transport system, or
when the Road Friendly Transport™will be installed by the Dealer.
To assemble a disc mower with the factory-installed transport, refer to 4 Assembling the Disc Mower (Factory-
Installed Transport), page 57.
3.1 Repositioning Center-Link Top Anchor
Perform this procedure to reposition the center-link top anchor into working position.
1011354
A
B
C
Figure 3.1: Carrier
1. Place forklift forks (B) under top beam and lift carrier
frame (A) slightly until pin at base of center-link anchor
is loose. Use a piece of wood (C) to protect paint
on frame.
1011500
A
B
Figure 3.2: Float Spring
2. Loosen jam nut (A) and fully loosen float spring bolt (B).
Repeat on the opposite side.

214713 10 Revision A
1013184
A
B
Figure 3.3: Top Shield (Left of Center-Link)
3. Remove four M10 hex head bolts (A) and flat washers,
and remove top shield (B).
CAUTION
To avoid injury, keep fingers clear of opening at base of
anchor.
1018340
A
B
C
D
Figure 3.4: Center-Link Anchor (Right of
Center-Link)
4. Remove cotter pin (B), washer (C), and shipping
tag (D).
5. Remove pin (A) from center location and lower forks on
forklift.
NOTE:
Pin should slide out freely. Adjust forklift or move carrier
until pin is loose. Do NOT use hammer to remove pin.
1018340
A
B
C
Figure 3.5: Center-Link Anchor (Right of
Center-Link)
6. Install pin (A) and secure with washer (B) and cotter
pin (C). Move the carrier and anchor so the pin can be
installed in working location.
ASSEMBLING THE DISC MOWER (WITH OR WITHOUT THE DEALER-INSTALLED TRANSPORT)

214713 11 Revision A
1013184
A
B
Figure 3.6: Top Shield (Left of Center-Link)
7. Install top shield (B) and secure with four M10 hex head
bolts (A) and flat washers. Torque to 27–30 Nm
(20–22 lbf·ft).
NOTE:
If transport is also being installed, leave bolts (A) loose.
These bolts will be tightened when installing the lighting
harness.
1014709
B
A
C
D
Figure 3.7: Lift Cylinder Lock-Out Valve, Jam
Nut, and Adjuster Bolt
8. Close the disc mower’s lift cylinder lock-out valve (A) on
each lift cylinder by turning the handle to the horizontal
position.
9. Loosen jam nut (B).
10. Turn the adjuster bolt (C) and set dimension (D) to
130 mm (5-1/8 in.).
•Turn bolt clockwise (towards spring) to increase float
•Turn bolt counterclockwise (away from spring) to
decrease float
11. Tighten jam nut (B) against spring.
ASSEMBLING THE DISC MOWER (WITH OR WITHOUT THE DEALER-INSTALLED TRANSPORT)

214713 12 Revision A
3.2 Attaching Hitch to Carrier
1011361
A
Figure 3.8: Carrier
1. Remove M20 bolts (A), washers, and nuts from carrier
at the hitch attachment location. Retain bolts, washers,
and nuts.
1013890
A
B
C
Figure 3.9: Hitch Packing
2. Cut banding (A) securing wood supports, then
remove supports (B).
3. Remove the two bolts securing wood support to hitch
pin (C). Discard bolts.
1012287
A
B
Figure 3.10: Lifting Hitch
4. Place sling (A) around the hitch frame. Adjust sling
position until hitch is balanced when lifting.
•R113: Approximately 2.7 m (106 in.) from the edge
of the tractor end of the hitch (B)
•R116: Approximately 3.5 m (138 in.) from the edge
of the tractor end of the hitch (B)
5. Raise the hitch approximately 610 mm (24 in.) off
the ground.
ASSEMBLING THE DISC MOWER (WITH OR WITHOUT THE DEALER-INSTALLED TRANSPORT)