MacDon R113 User manual

The harvesting specialists.
R113/R116
Pull-Type Rotary Disc Mower
Conditioner
Unloading and Assembly Instruction (North America)
169821 Revision D
Original Instruction

R113 Pull-Type Rotary Disc Mower Conditioner
Published April 2015

Introduction
This instructional manual describes the unloading, setup, and predelivery requirements for the MacDon R113/R116
Pull-Type Rotary Disc Mower Conditioner.
Use the “Table of Contents” to guide you to specific areas.
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).
169821 iRevision D

List of Revisions
Summary of Change Location
Added instruction to apply anti-sieze lubricant to wheel
spindle bore in leg casting before spindle installation.. 5.8 Installing Wheels, page 41
General revisions to Installing Transport Assembly
installation procedure. Installing Components, page 48
Revised fittings callouts. Installing Fittings, page 54
Revised Figure titles. Installing Electrical, page 61
Revised Tall Crop Divider installation. 5.12.3 Installing Tall Crop Divider, page 66
General revisions to Endwise Transport conversion
procedures to improve readability. 8.16.1 Converting from Field to Transport Mode, page 118
8.16.2 Converting from Transport to Field Mode, page
120
Added instruction to remove top shield when
repositioning center-link top anchor. 5.3 Repositioning Center-Link Top Anchor, page 28
Added instructions to “Performing Predelivery Checks”
chapter for checking conditioner gear box, mower
conditioner drive gearbox, forward and rear swivel
gearboxes, and cutterbar lubricant levels.
8.7 Checking Conditioner Drive Gearbox Lubricant,
page 105,
8.8 Checking Mower Conditioner Drive Gearbox
Lubricant, page 106,
8.9 Checking Forward and Rear Swivel Gearbox
Lubricant, page 107,and
8.10 Checking Cutterbar Lubricant, page 109.
Added instructions to “Predelivery Checklist” topic for
checking conditioner gear box, mower conditioner
drive gearbox, forward and rear swivel gearboxes, and
cutterbar lubricant levels.
Predelivery Checklist, page 127
Added instructions for unbolting cutterbar doors from
centre channel frame and removing shipping wire from
cutterbar curtains.
5.11 Unpacking Curtains, page 46
169821 iiRevision D

TABLE OF CONTENTS
Introduction...................................................................................................................................... i
List of Revisions ...............................................................................................................................ii
1 Safety.................................................................................................................................................... 1
1.1 Signal Words................................................................................................................................... 1
1.2 General Safety ................................................................................................................................ 2
1.3 Safety Signs.................................................................................................................................... 4
2 Recommended Torques ........................................................................................................................ 5
2.1 Torque Specifications....................................................................................................................... 5
2.1.1 SAE Bolt Torque Specifications................................................................................................. 5
2.1.2 Metric Bolt Specifications.......................................................................................................... 7
2.1.3 Metric Bolt Specifications Bolting into Cast Aluminum............................................................... 10
2.1.4 Flare-Type Hydraulic Fittings................................................................................................... 10
2.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)................................................................... 12
2.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ........................................................... 14
2.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings............................................................................ 15
3 Conversion Chart................................................................................................................................ 17
4Definitions........................................................................................................................................... 19
5 Unloading and Assembling the Mower Conditioner............................................................................ 21
5.1 Unloading Shipment....................................................................................................................... 21
5.2 Setting Up Forming Shields............................................................................................................ 23
5.2.1 Setting Up Forming Shield for Finger Conditioner..................................................................... 23
5.2.2 Setting Up Forming Shield for Roll Conditioner......................................................................... 27
5.3 Repositioning Center-Link Top Anchor ............................................................................................28
5.4 Attaching Hitch to Carrier ............................................................................................................... 31
5.5 Installing Steering Cylinder............................................................................................................. 34
5.6 Attaching Aft Driveline.................................................................................................................... 36
5.7 Attaching Steering Arm.................................................................................................................. 38
5.8 Installing Wheels ........................................................................................................................... 41
5.9 Installing Drawbar Hitch ................................................................................................................. 42
5.10 Installing 2-Point Hitch (Cat. II) Adapter .......................................................................................... 44
5.11 Unpacking Curtains ....................................................................................................................... 46
5.12 Installing Options........................................................................................................................... 48
5.12.1 Installing Endwise Transport System ....................................................................................... 48
Installing Components..................................................................................................... 48
Installing Hydraulics........................................................................................................ 54
Installing Electrical.......................................................................................................... 61
5.12.2 Installing Hydraulic Center-Link............................................................................................... 65
5.12.3 Installing Tall Crop Divider....................................................................................................... 66
5.13 Setting Up The Tractor................................................................................................................... 67
5.13.1 Adjusting the Drawbar ............................................................................................................ 67
5.13.2 Installing Drawbar Hitch Adapter ............................................................................................. 68
5.14 Attaching Mower Conditioner to the Tractor..................................................................................... 69
5.14.1 Attaching with Drawbar Hitch.................................................................................................. 69
5.14.2 Attaching with Two-Point Hitch................................................................................................ 71
5.14.3 Connecting Hydraulics............................................................................................................ 73
5.14.4 Connecting Electrical Wiring Harness...................................................................................... 74
5.15 Removing Mower Conditioner from Shipping Pallet.......................................................................... 75
6 Changing the Conditioner................................................................................................................... 77
6.1 Separating Header from Carrier...................................................................................................... 77
6.2 Removing the Conditioner.............................................................................................................. 81
6.3 Installing the Conditioner................................................................................................................ 83
6.3.1 Installing Conditioner Drive ..................................................................................................... 84
169821 iii Revision D

TABLE OF CONTENTS
6.4 Removing Shield: No Conditioner................................................................................................... 86
6.5 Installing Shield: No Conditioner..................................................................................................... 87
6.6 Assembling Header and Carrier...................................................................................................... 88
7 Lubricating the Mower Conditioner..................................................................................................... 91
7.1 Opening Driveshields..................................................................................................................... 91
7.2 Closing Driveshields ...................................................................................................................... 93
7.3 Lubrication Procedure.................................................................................................................... 94
8PerformingP
redelivery Checks........................................................................................................... 99
8.1 Checking Wheel Bolts.................................................................................................................... 99
8.2 Checking Drive Belt ......................................................................................................................100
8.3 Checking Header Float .................................................................................................................101
8.4 Checking Header Angle ................................................................................................................102
8.5 Checking Skid Shoes....................................................................................................................103
8.6 Checking Roll Timing....................................................................................................................104
8.7 Checking Conditioner Drive Gearbox Lubricant...............................................................................105
8.8 Checking Mower Conditioner Drive Gearbox Lubricant....................................................................106
8.9 Checking Forward and Rear Swivel Gearbox Lubricant...................................................................107
8.10 Checking Cutterbar Lubricant........................................................................................................109
8.11 Checking Roll Gap and Roll Tension..............................................................................................111
8.12 Checking Conditioner Baffle Settings .............................................................................................112
8.13 Checking Lights............................................................................................................................113
8.14 Checking Manuals........................................................................................................................114
8.15 Running Up the Mower Conditioner................................................................................................115
8.16 Checking Endwise Transport System.............................................................................................116
8.16.1 Converting from Field to Transport Mode................................................................................118
8.16.2 Converting from Transport to Field Mode................................................................................120
9 Transporting with a Truck ..................................................................................................................123
10 Preparing Mower Conditioner for Transport.......................................................................................125
Predelivery Checklist ....................................................................................................................127
169821 ivRevision D

1Safety
1.1 Signal Words
Three signal words, DANGER,WARNING,andCAUTION, 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
Indicatesapo
tentially hazardous situation that, if not avoided, could result in death or serious injury. It
mayalsobeuse
d 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.
169821 1Revision D

SAFETY
1.2 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:
• Hard hat
• Protective footwear with slip resistant soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• Respirator or filter mask
Figure 1.1: Safety Equipment
• Be aware that exposure to loud noises can cause
hearing impairment or loss. Wear suitable hearing
protection devices such as ear muffs or ear plugs to
help protect against objectionable or loud noises.
Figure 1.2: Safety Equipment
•Provideafirst aid kit for use in case of emergencies.
•Keepafire 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. Take the time to
consider the safest way. Never ignore the warning
signs of fatigue.
Figure 1.3: Safety Equipment
169821 2Revision D

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 1.4: 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.
• 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.
Figure 1.5: 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 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. Figure 1.6: Safety Around Equipment
169821 3Revision D

SAFETY
1.3 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 MacDon Parts.
Figure 1.7: Operator’s Manual Decal
169821 4Revision D

2 Recommended Torques
2.1 Torque Specifications
The following tables provide the correct torque values for various bolts, cap screws, and hydraulic fittings.
• Tighten all bolts to the torque values specified in the charts (unless otherwise noted throughout this manual).
• Replace hardware with the same strength and grade of bolt.
• Use the torque value tables as a guide and periodically check tightness of bolts.
• Understand torque categories for bolts and cap screws by using their identifying head markings.
2.1.1 SAE Bolt Torque Specifications
Torque values shown in the following tables are valid for non-greased, or non-oiled threads and heads; therefore,
do NOT grease or oil bolts or cap screws unless otherwise specified in this manual.
Table 2.1 SAE Grade 5 Bolt and Grade 5 Free
Spinning Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *106 *117 11.9 13.2
5/16-18*218 *241 24.6 27.1
3/8-16 32 36 44 48
7/16-14 52 57 70 77
1/2-13 79 87 106 118
9/16-12 114 126 153 170
5/8-11 157 173 212 234
3/4-10 281 311 380 420
7/8-9 449 496 606 669
1-8611676825912
Figure 2.1: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
169821 5Revision D

RECOMMENDED TORQUES
Table 2.2 SAE Grade 5 Bolt and Grade F Distorted
Thread Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *72 *80 8.1 9
5/16-18 *149 *164 16.7 18.5
3/8-16 22 24 30 33
7/16-14 35 39 48 53
1/2-13 54 59 73 80
9/16-12 77 86 105 116
5/8-11 107 118 144 160
3/4-10 192 212 259 286
7/8-9 306 338 413 456
1-8 459 507 619 684
Figure 2.2: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
Table 2.3 SAE Grade 8 Bolt and Grade G Distorted
Thread Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *150 *165 16.8 18.6
5/16-18 18 19 24 26
3/8-16 31 34 42 46
7/16-14 50 55 67 74
1/2-13 76 84 102 113
9/16-12 109 121 148 163
5/8-11 151 167 204 225
3/4-10 268 296 362 400
7/8-9 432 477 583 644
1-8 647 716 874 966
Figure 2.3: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
169821 6Revision D

RECOMMENDED TORQUES
Table 2.4 SAE Grade 8 Bolt and Grade 8 Free
Spinning Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *150 *165 16.8 18.6
5/16-18 26 28 35 38
3/8-16 46 50 61 68
7/16-14 73 81 98 109
1/2-13 111 123 150 166
9/16-12 160 177 217 239
5/8-11 221 345 299 330
3/4-10 393 435 531 587
7/8-9 633 700 855 945
1-8 863 954 1165 1288
Figure 2.4: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
2.1.2 Metric Bolt Specifications
Table2.5MetricClass8.8BoltsandClass9Free
Spinning Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
3-0.5 *13 *14 1.4 1.6
3.5-0.6 *20 *22 2.2 2.5
4-0.7 *29 *32 3.3 3.7
5-0.8 *59 *66 6.7 7.4
6-1.0 *101 *112 11.4 12.6
8-1.25 20 23 28 30
10-1.5 40 45 55 60
12-1.75 70 78 95 105
14-2.0 113 124 152 168
16-2.0175 193 236 261
20-2.5 341 377 460 509
24-3.0 589 651 796 879
Figure 2.5: Bolt Grades
169821 7Revision D

RECOMMENDED TORQUES
Table2.6MetricClass8.8BoltsandClass9Distorted
Thread Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
3-0.5 *9 *10 11.1
3.5-0.6 *14 *15 1.5 1.7
4-0.7 *20 *22 2.3 2.5
5-0.8 *40 *45 4.5 5
6-1.0 *69 *76 7.7 8.6
8-1.25 *167 *185 18.8 20.8
10-1.5 28 30 37 41
12-1.7548536572
14-2.0 77 85 104 115
16-2.0 119 132 161 178
20-2.5 233 257 314 347
24-3.0 402 444 543 600
Figure 2.6: Bolt Grades
Table 2.7 Metric Class 10.9 Bolts and Class 10 Free
Spinning Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
3-0.5 *18 *19 1.8 2
3.5-0.6 *27 *30 2.8 3.1
4-0.7 *41 *45 4.2 4.6
5-0.8 *82 *91 8.4 9.3
6-1.0 *140 *154 14.3 15.8
8-1.25 28 31 38 42
10-1.5 56 62 75 83
12-1.75 97 108 132 145
14-2.0 156 172 210 232
16-2.0 242 267 326 360
20-2.5 472 521 637 704
24-3.0815 901 1101 1217
Figure 2.7: Bolt Grades
169821 8Revision D

RECOMMENDED TORQUES
Table 2.8 Metric Class 10.9 Bolts and Class 10
Distorted Thread Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
3-0.5 *12 *13 1.3 1.5
3.5-0.6 *19 *21 2.1 2.3
4-0.7 *28 *31 3.1 3.4
5-0.8 *56 *62 6.3 7
6-1.0 *95 *105 10.7 11.8
8-1.25 19 21 26 29
10-1.5 38 42 51 57
12-1.7566739099
14-2.0 106 117 143 158
16-2.0 165 182 222 246
20-2.5 322 356 434 480
24-3.0 556 614 750 829
Figure 2.8: Bolt Grades
169821 9Revision D

RECOMMENDED TORQUES
2.1.3 Metric Bolt Specifications Bolting into Cast Aluminum
Table 2.9 Metric Bolt Bolting into Cast Aluminum
Bolt Torque
8.8
(Cast Aluminum) 10.9
(Cast Aluminum)
Nominal
Size (A)
ft·lbf N·m ft·lbf N·m
M3 ––1–
M4 –– 2.6 4
M5 ––
5.5 8
M6 6 9 9 12
M8 14 20 20 28
M10 28 40 40 55
M12 52 70 73 100
M14 ––––
M16 ––––
Figure 2.9: Bolt Grades
2.1.4 Flare-Type Hydraulic Fittings
1. Check flare (A) and flare seat (B) for defects that might
cause leakage.
2. Aligntube(C)withfitting (D) and thread nut (E) onto
fitting without lubrication until contact has been made
between the flared surfaces.
3. Torque the fitting nut (E) to the specified number of
flats from finger tight (FFFT) or to a given torque
value shown in Table 2.10 Flare-Type Hydraulic Tube
Fittings, page 11.
4. Use two wrenches to prevent fitting (D) from rotating.
Place one wrench on the fitting body (D) and tighten
nut (E) with the other wrench to the torque shown.
5. Assess the final condition of the connection. Figure 2.10: Hydraulic Fitting
169821 10 Revision D

RECOMMENDED TORQUES
Table 2.10 Flare-Type Hydraulic Tube Fittings
Torque Value1Flats from Finger
Tight (FFFT)
SAE No. Tube Size
O.D.(in.) Thread
Size (in.)
Nut Size
Across Flats
(in.) ft·lbf N·m Flats Turns
33/16 3/8 7/16 681
1/6
41/4 7/16 9/16 91211/6
55/16 1/2 5/8 12 16 1 1/6
63/8 9/16 11/16 18 24 1 1/6
81/2 3/4 7/8 34 46 1 1/6
10 5/8 7/8 146621
1/6
12 3/41-1/161-1/4 75 102 3/4 1/8
14 7/8 1-3/8 1-3/8 90 122 3/4 1/8
16 1 1-5/16 1-1/2 105 142 3/4 1/8
1. Torque values shown are based on lubricated connections as in reassembly.
169821 11Revision D

RECOMMENDED TORQUES
2.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)
1. Inspect O-ring (A) and seat (B) for dirt or
obvious defects.
2. Back off the lock nut (C) as far as possible. Ensure
that washer (D) is loose and is pushed toward the lock
nut (C) as far as possible.
3. Check that O-ring (A) is NOT on the threads and adjust
if necessary.
4. Apply hydraulic system oil to the O-ring (A).
Figure 2.11: Hydraulic Fitting
5. Install fitting (B) into port until back up washer (D) and
O-ring (A) contact the part face (E).
6. Position angle fittings by unscrewing no more than
one turn.
7. Turn lock nut (C) down to washer (D) and tighten to
torque shown. Use two wrenches, one on fitting (B)
and the other on lock nut (C).
8. Check the final condition of the fitting.
Figure 2.12: Hydraulic Fitting
169821 12Revision D

RECOMMENDED TORQUES
Table 2.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)
Torque Value2
SAE Dash Size Thread Size (in.) ft·lbf (*in·lbf) N·m
-3 3/8–24 *106–115 12–13
-4 7/16–20 14–15 19–21
-5 1/2–20 15–24 21–33
-6 9/16–18 19–21 26–29
-8 3/4–16 34–37 46–50
-10 7/8–14 55–60 75–82
-12 1-1/16–12 88–97 120–132
-14 1-3/8–12 113–124 153–168
-16 1-5/16–12 130–142 176–193
-20 1-5/8–12 163–179221–243
-24 1-7/8–12 199–220 270–298
2. Torque values shown are based on lubricated connections as in reassembly.
169821 13 Revision D

RECOMMENDED TORQUES
2.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable)
1. Inspect O-ring (A) and seat (B) for dirt or
obvious defects.
2. Check that O-ring (A) is NOT on the threads and adjust
if necessary.
3. Apply hydraulic system oil to the O-ring.
4. Install fitting (C) into port until fittingishandtight.
5. Torque fitting (C) according to the values in
Table 2.12 O-Ring Boss (ORB) Hydraulic Fittings
(Non-Adjustable), page 14.
6. Check the final condition of the fitting.
Figure 2.13: Hydraulic Fitting
Table 2.12 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable)
Torque Value3
SAE Dash Size Thread Size (in.) ft·lbf (*in·lbf) N·m
-3 3/8–24 *106–11512–13
-4 7/16–20 14–15 19–21
-5 1/2–20 15–24 21–33
-6 9/16–1819–21 26–29
-8 3/4–16 34–37 46–50
-10 7/8–14 55–60 75–82
-12 1-1/16–12 88–97120–132
-14 1-3/8–12 113–124 153–168
-16 1-5/16–12 130–142 176–193
-201-5/8–12 163–179 221–243
-24 1-7/8–12 199–220 270–298
3. Torque values shown are based on lubricated connections as in reassembly.
169821 14Revision D