MacDon R113 SP Operator's Manual
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MacDon R113 SP Operator's Manual

MacDon R113 SP Operator's Manual

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R113 SP
Rotary Disc Header
Operator's Manual
215009 Revision A
Original Instruction
The harvesting specialists.

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Summary of Contents for MacDon R113 SP

  • Page 1 R113 SP Rotary Disc Header Operator’s Manual 215009 Revision A Original Instruction The harvesting specialists.
  • Page 2 © 2019 MacDon Industries, Ltd. The information in this publication is based on the information available and in effect at the time of printing. MacDon Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the information in this publication.
  • Page 3 Declaration of Conformity Figure 1: EC Declaration of Conformity 215009 Revision A...
  • Page 4 Figure 2: EC Declaration of Conformity 215009 Revision A...
  • Page 5 Use this manual as your first source of information about the machine. If you follow the instructions provided in this manual, and use MacDon parts, the rotary disc header will work well for many years. If you require more detailed service information, contact your Dealer.

  • Page 6: Summary Of Changes

    Windrowers, page 45 3.5 Detaching Header from M1240 Updated illustrations to show MY2020 safety props. ECN 58047 Windrower, page 52 Updated ground speed chart to only show R113 SP 3.8.4 Ground Speed, page 70 Tech Pubs headers. 3.9 Reconfiguring Cutterbar Crop Stream, Updated cutterbar configuration illustration.
  • Page 7 Internal Use Section Summary of Change Only 4.5.4 Maintaining Discblades, page 118 Updated disc rotation illustrations. Tech Pubs Inspecting Accelerators, page 125 Updated accelerators illustration. Tech Pubs Installing Accelerators, page 127 Updated cutterbar door illustration. Tech Pubs Inspecting Rock Guards, page 129 Updated rock guard illustration.

  • Page 8: Model And Serial Number

    Model and Serial Number Record the model number, serial number, and model year of the header on the lines below. R113 SP Header Model: Serial Number: Year: The serial number plate (A) is located near the base of the right side hazard/signal light on the right edge of the header.

  • Page 9: Table Of Contents

    3.4 Attaching Header to Windrower......................27 3.4.1 Attaching R113 SP Rotary Disc Header to M1 Series Windrowers............27 3.4.2 Attaching R113 SP to M155 or M155E4 SP Windrowers – Hydraulic Center-Link with Optional Self-Alignment........................32 3.4.3 Attaching R113 SP to M155 or M155E4 SP Windrower – Hydraulic Center-Link without Optional Self-Alignment........................
  • Page 10 3.8.2 Adjusting Cutterbar Angle......................69 3.8.3 Header Float ..........................69 3.8.4 Ground Speed ..........................70 3.9 Reconfiguring Cutterbar Crop Stream....................... 71 3.9.1 Changing R113 SP Cutterbar Crop Stream Configuration ..............72 3.10 Conditioner ............................73 3.10.1 Roll Gap............................ 73 Checking Roll Gap ........................74 Adjusting Roll Gap –...
  • Page 11 TABLE OF CONTENTS 4.4 Lubrication ............................97 4.4.1 Greasing Procedure ........................97 Every 25 Hours........................... 98 4.5 Cutterbar System..........................99 4.5.1 Lubricating Cutterbar........................99 Checking and Adding Cutterbar Lubricant ..................99 Draining the Cutterbar....................... 102 Filling Lubricant into a Repaired Cutterbar ..................103 4.5.2 Maintaining Cutterbar Discs ......................
  • Page 12 TABLE OF CONTENTS 4.9.5 Installing Cutterbar Inboard Curtain ....................167 4.9.6 Removing Outboard Curtains ....................... 168 4.9.7 Installing Outboard Curtains ......................169 4.10 Conditioner System ........................... 170 4.10.1 Inspecting Roll Conditioner ......................170 4.10.2 Conditioner Drive Belt....................... 172 Inspecting Conditioner Drive Belt ....................172 Removing Conditioner Drive Belt ....................
  • Page 13 TABLE OF CONTENTS 7.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ..............211 7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable ..................212 7.1.4 O-Ring Boss Hydraulic Fittings – Non-Adjustable................214 7.1.5 O-Ring Face Seal Hydraulic Fittings....................215 7.1.6 Tapered Pipe Thread Fittings......................216 7.2 Conversion Chart..........................

  • Page 15: Chapter 1: Safety

    Chapter 1: Safety 1.1 Safety Alert Symbols This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read and follow the safety message accompanying this symbol.

  • Page 16: Signal Words

    SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words, IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if 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.

  • Page 17: General Safety

    SAFETY 1.3 General Safety 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.
  • Page 18 SAFETY • 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. •...

  • Page 19: Maintenance Safety

    SAFETY 1.4 Maintenance Safety To ensure your safety while maintaining machine: • Review operator’s manual and all safety items before operation and/or maintenance of 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.

  • Page 20: Hydraulic Safety

    SAFETY 1.5 Hydraulic Safety • Always place all hydraulic controls in Neutral before dismounting. • Make sure that all components in hydraulic system are kept clean and in good condition. • Replace any worn, cut, abraded, flattened, or crimped hoses and steel lines.

  • Page 21: Welding Precaution

    If an Operator needs to do any welding on the header, it should first be disconnected and removed from the windrower. If it is unfeasible to disconnect the header from the windrower before attempting welding, contact your MacDon Dealer for welding precautions detailing all electrical components that must be disconnected first for safe welding.

  • Page 22: Safety Signs

    • If original part on which a safety sign was installed is replaced, be sure the repair part displays the current safety sign. • Replacement safety signs are available from your MacDon Dealer Parts Department. Figure 1.14: Operator’s Manual Decal 1.7.1 Installing Safety Decals...

  • Page 23: Locating Safety Decals

    SAFETY 1.8 Locating Safety Decals Figure 1.15: Safety Sign Decal Locations Top View A - MD #194466 B - MD #247167 C - MD #194465 D - MD #166466 E - MD #113482 F - MD #190546 Figure 1.16: Safety Sign Decals 215009 Revision A...
  • Page 24 SAFETY Figure 1.17: Safety Sign Decal Locations Roll Conditioner A - MD #190546 B - MD #184385 C - MD #184371 D - MD #246959 E - MD #246956 F - NO STEP Symbol (Imprinted on Shield) 215009 Revision A...

  • Page 25: Understanding Safety Signs

    SAFETY 1.9 Understanding Safety Signs NOTE: This is a general list of safety sign definitions and the decals listed may not necessarily be applicable to your machine. MD #113482 General hazard pertaining to machine operation and servicing. CAUTION • Read the operator’s manual, and follow all safety instructions.
  • Page 26 SAFETY MD #184371 Open drive hazard WARNING • Guard missing. Do NOT operate. • Keep all shields in place. Figure 1.20: MD #184371 MD #184385 Entanglement hazard CAUTION • To avoid injury from entanglement with rotating auger, stand clear of header while machine is running. Figure 1.21: MD #184385 MD #190546 Slippery surface...
  • Page 27 SAFETY MD #194465 Rotating cutters WARNING—STAND CLEAR • Contact with blades or thrown objects can result in serious injury or death. • Do NOT stand on or near machine when in operation. • Do NOT operate with covers or curtains open or removed. •...
  • Page 28 SAFETY MD #246959 Pinch hazard WARNING—KEEP AWAY • Failure to comply could result in death or serious injury. Figure 1.26: MD #246959 MD #247167 Rotating blades WARNING • Disengage power take-off, shut off tractor, and remove key before opening covers. •...

  • Page 29: Chapter 2: Product Overview

    Weight: base machine, adapter frame, and steel conditioner 1850 kg (4079 lb.) Weight: base machine, adapter frame, and polyurethane 1868 kg (4118 lb.) conditioner MacDon M155, M155E4, M1170, Compatible windrower or M1240 Windrower Lighting Left and right turn signals Manual storage...
  • Page 30 PRODUCT OVERVIEW R113 SP Hay Conditioner Options Steel rolls Optional Roll type Steel on steel chevron conditioner rolls Roll length 3275 mm (129 in.) Roll diameter 229 mm (9.0 in.) / 179 mm (7.0 in.) OD tube Roll speed 1009 rpm...

  • Page 31: Component Identification

    PRODUCT OVERVIEW 2.2 Component Identification Figure 2.1: R113 SP A - Front Curtains B - Cutterbar Doors C - Drive Shield (Left) D - Hose Support 2 E - Hydraulic Motor 3 F - Hose Support G - Center-Link Tube...
  • Page 32 PRODUCT OVERVIEW Figure 2.2: R113 SP A - Header Supports B - Side Deflectors C - Side Deflector Adjuster Handles D - Rear Crop Baffle E - Adapter Frame F - Drive Shield 215009 Revision A...

  • Page 33: Definitions

    PRODUCT OVERVIEW 2.3 Definitions The following terms and acronyms may be used in this manual: Term Definition American Petroleum Institute ASTM American Society of Testing and Materials Bolt A headed and externally threaded fastener that is designed to be paired with a nut Cab-forward Windrower operation with Operator and cab facing in direction of travel Center-link...
  • Page 34 PRODUCT OVERVIEW Term Definition Tension Axial load placed on a bolt or screw, usually measured in Newtons (N) or pounds (lb.) TFFT Turns from finger tight The product of a force X lever arm length, usually measured in Newton-meters (Nm) or Torque foot-pounds (lbf∙ft) A tightening procedure where fitting is assembled to a precondition (finger tight) and then...

  • Page 35: Chapter 3: Operation

    Chapter 3: Operation 3.1 Break-In Period After attaching the header to the windrower for the first time, operate the machine slowly for five minutes, watching and listening from the operator’s seat for binding or interfering parts. NOTE: Until you become familiar with the sound and feel of your new header, be extra alert and attentive. CAUTION Before investigating an unusual sound or attempting to correct a problem, stop the engine, engage parking brake, and remove the key.

  • Page 36: Daily Start-Up Check

    OPERATION 3.2 Daily Start-Up Check Perform the following checks each day before startup: CAUTION • Ensure the windrower and the header are properly attached, all controls are in neutral, and the windrower brakes are engaged. • Clear the area of other persons, pets etc. Keep children away from machinery. Walk around the header to make sure no one is under, on, or close to it.
  • Page 37 OPERATION 1. Check the machine for leaks or any parts that are missing, broken, or not working correctly. NOTE: Use proper procedure when searching for pressurized fluid leaks. Refer to 4.12.1 Checking Hydraulic Hoses and Lines, page 195. 2. Clean all lights and reflective surfaces on the machine, and check lights for proper operation.

  • Page 38: Engaging And Disengaging Header Safety Props

    OPERATION 3.3 Engaging and Disengaging Header Safety Props Safety props are located on both header lift cylinders on the windrower. Refer to relevant procedure for your windrower: • For M1 Series Windrowers, refer to 3.3.1 Engaging and Disengaging Header Safety Props – M1240 Windrower, page 24 •...

  • Page 39: Engaging And Disengaging Header Safety Props - M Series Self-Propelled Windrower

    OPERATION 4. Disengage safety props on both lift cylinders as follows: NOTE: If safety prop will not disengage, raise header to release the prop. Turn lever (A) away from header to raise safety prop until lever locks into vertical position. b.
  • Page 40 OPERATION 3. Pull lever (A) and rotate toward header to lower safety prop (B) onto cylinder. Repeat for opposite cylinder. Figure 3.8: Safety Prop Disengage safety props as follows: WARNING To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.

  • Page 41: Attaching Header To Windrower

    OPERATION 3.4 Attaching Header to Windrower 3.4.1 Attaching R113 SP Rotary Disc Header to M1 Series Windrowers The windrower may have an optional self-aligning hydraulic center-link that allows vertical position control of the center- link from the cab. WARNING To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
  • Page 42 OPERATION CAUTION When lowering header lift legs without a header or weight box attached to the windrower, ensure the float springs tension is fully released to prevent damage to the header lift linkages. NOTE: If not prompted by the Harvest Performance Tracker (HPT) display to remove float, remove float manually.
  • Page 43 OPERATION 7. Press HEADER DOWN switch (E) on the ground speed lever (GSL) to fully retract header lift cylinders. 8. Self-Aligning Hydraulic Center-Link: Press REEL UP switch (B) on the GSL to raise the center-link until the hook is above the attachment pin on the header. IMPORTANT: If the center-link is too low, it may contact the header as the windrower approaches the header for hookup.
  • Page 44 OPERATION 12. Hydraulic Center-Link without Self-Alignment: Press HEADER TILT UP or HEADER TILT DOWN cylinder switches on the GSL to extend or retract center-link cylinder until the hook is aligned with the header attachment pin. b. Stop the engine and remove the key. Push down on rod end of link cylinder (B) until hook engages and locks onto header pin.
  • Page 45 OPERATION 16. Install clevis pin (A) through support and windrower lift arm and secure with hairpin (B). Repeat for the opposite side of the header. IMPORTANT: Ensure clevis pin (A) is fully inserted, and hairpin is installed behind bracket. Figure 3.21: Header Support 17.

  • Page 46: Attaching R113 Sp To M155 Or M155E4 Sp Windrowers - Hydraulic Center-Link With Optional

    OPERATION 3.4.2 Attaching R113 SP to M155 or M155E4 SP Windrowers – Hydraulic Center-Link with Optional Self-Alignment WARNING To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
  • Page 47 OPERATION 5. Press REEL UP switch (A) on the GSL to raise the center-link until the hook is above the attachment pin on the header. IMPORTANT: If the center-link is too low, it may contact the header as the windrower approaches the header for hookup. Figure 3.27: Ground Speed Lever 6.
  • Page 48 OPERATION 8. Adjust center-link cylinder (A) position with the REEL UP and REEL DOWN switches on the GSL until the hook is positioned above the header attachment pin. IMPORTANT: Hook release (B) must be down to enable the self-locking mechanism. If the release is open (up), manually push it down after hook engages header pin.
  • Page 49 OPERATION 13. Engage the safety props on both lift cylinders as follows: Shut down the engine, and remove the key from the ignition. b. Pull lever (A) and rotate towards the header to release and lower safety prop (B) onto the lift cylinder. Repeat for opposite lift cylinder.
  • Page 50 OPERATION 15. Remove the clevis pin from storage position (B) in linkage and insert into hole (A) to engage the float springs. Secure with hairpin. Figure 3.34: Header Float Linkage 16. Disengage the safety prop by turning lever (A) downwards until lever locks into vertical position.

  • Page 51: Attaching R113 Sp To M155 Or M155E4 Sp Windrower - Hydraulic Center-Link Without Optional

    OPERATION 3.4.3 Attaching R113 SP to M155 or M155E4 SP Windrower – Hydraulic Center-Link without Optional Self-Alignment WARNING To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
  • Page 52 OPERATION CAUTION Check to be sure all bystanders have cleared the area. 4. Start the engine and activate HEADER DOWN button (A) on the ground speed lever (GSL) to fully retract header lift cylinders. Figure 3.39: Ground Speed Lever 5. Remove pin (A) from frame linkage and raise center-link (B) until hook is above the attachment pin on header.
  • Page 53 OPERATION 7. Use the following GSL functions to position the center-link hook above the header attachment pin: • HEADER TILT UP (A) to retract the center-link • HEADER TILT DOWN (B) to extend the center-link 8. Stop engine, and remove key from ignition. Figure 3.42: Ground Speed Lever 9.
  • Page 54 OPERATION 14. Engage the safety props on both lift cylinders as follows: Shut down the engine, and remove the key from the ignition. b. Pull lever (A) and rotate towards the header to release and lower safety prop (B) onto the lift cylinder. Repeat for opposite lift cylinder.
  • Page 55 OPERATION 16. Remove the clevis pin from storage position (B) in linkage and insert into hole (A) to engage the float springs. Secure with hairpin. Figure 3.47: Header Float Linkage 17. Disengage the safety prop by turning lever (A) downwards until lever locks into vertical position.

  • Page 56: Attaching Hydraulic And Electrical Components

    Connecting Header Hydraulics and Electrical – M1 Series Windrowers NOTE: Hydraulic drive kit (A) (MD #B6621) is required for an R113 SP Disc Header that is originally configures for use with an M155 or M155E4 to operate correctly on an M1 Series Windrower. To order this kit, contact your MacDon Dealer.
  • Page 57 OPERATION 3. Attach hose support (A) to windrower frame near left cab- forward leg, and route hose bundle under frame. NOTE: Route hoses as straight as possible and avoid rub/wear points that could damage hydraulic hoses. Figure 3.52: Hose Support Attachment 4.
  • Page 58 Connect case drain hose non-flat face coupler to receptacle (C). NOTE: The R113 SP when attached to M1240 requires a different set of low pressure case drain couplers with a different hose connection to the hydraulic tank. d. Connect the electrical harness to receptacle (D).

  • Page 59: Connecting Header Hydraulics And Electrical - M155 And M155E4 Sp Windrowers

    NOTE: Hydraulic drive kit (A) (MD #B6272) is required for an R113 SP Disc Header to operate correctly on M155 and M155E4 Self- Propelled Windrowers. To order this kit, contact your MacDon Dealer.
  • Page 60 OPERATION 3. Move hose bundle (A) from the windrower and rest the bundle on the header. Figure 3.59: Hose Bundle 4. Position the hose support with lower bolt (A) in the forward hole as shown in the illustration at right. Loosen both bolts and adjust as required.
  • Page 61 OPERATION 6. Move the windrower’s left (cab-forward) platform (A) to the OPEN position. Refer to your windrower operator’s manual for instructions. Figure 3.62: Windrower Left Platform in Open Position 7. Route the windrower hose bundle (A) through hose support (B) on the header. NOTE: Route hoses as straight as possible and avoid rub/wear points that could damage hydraulic hoses.
  • Page 62 OPERATION 9. Connect pressure hose (A) routed from the header to the hydraulic coupler at port M2 (B) on the windrower’s auxiliary disc drive manifold (middle valve block). Figure 3.64: Hydraulic Connections 10. Remove caps and plugs from hoses on windrower and lines on header.
  • Page 63 OPERATION 12. Connect return hose (A) from port R1 (C) on the windrower’s drive manifold to the coupler on steel line (B) attached to the aft port on the header motor. Figure 3.66: Hydraulic Connections NOTE: If the windrower is equipped with a reverser manifold (A) for an auger header, route the return hose (B) from port R1 (D) on the windrower’s reverser manifold to the steel line (C) attached to the aft port on the header motor.
  • Page 64 OPERATION 13. Connect case drain hose (A) from the lift manifold port T3 (C) to the 1/2 in. female coupler at the bulkhead, which is attached to motor port (B). Figure 3.68: Hydraulic Connections 14. Connect electrical harness (A) from windrower to electrical connector (B) on the header.
  • Page 65 OPERATION 15. Lower and lock lever (A). 16. Secure hose (B) with three adjustable straps (C). Figure 3.70: Hose Bundle 17. Move platform (A) to the CLOSED position. Figure 3.71: Top View of Windrower 215009 Revision A...

  • Page 66: Detaching Header From M1240 Windrower

    OPERATION 3.5 Detaching Header from M1240 Windrower 3.5.1 Detaching – M1 Series Windrower WARNING To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. CAUTION Check to be sure all bystanders have cleared the area.
  • Page 67 OPERATION 5. Disconnect electrical harness (A) and hydraulic hoses (B), (C), and (D) from the windrower: Figure 3.74: Header Drive Hydraulics 6. Remove hose support (A) and hose bundle from windrower frame. Figure 3.75: Hoses on Windrower 7. Slide support (A) into center-link support (B) and secure with hardware (C).
  • Page 68 OPERATION 8. Store hoses (A) and electrical harness (B) disconnected from the windrower in Step 5, page 53 into storage plate (C). NOTE: Install caps and plugs on open lines to prevent buildup of dirt and debris while in storage. NOTE: Some parts removed from the illustration for clarity.
  • Page 69 OPERATION Windrowers with center-link self-alignment kit only: 10. Release the center-link latch (A) before returning to the cab. Figure 3.79: Center-Link 11. Disengage safety props on both lift cylinders as follows: NOTE: If safety prop will not disengage, raise header to release the prop.
  • Page 70 OPERATION Self-aligning center-link (if installed): 15. Use HEADER TILT cylinder switches (A) on GSL to release load on center-link cylinder. 16. Operate the link lift cylinder with the REEL UP switch (B) to disengage the center-link from the header. Figure 3.81: GSL Non-self-aligning center-link: 17.

  • Page 71: Detaching R1 Sp Series Header - M155 And M155E4 Windrowers

    OPERATION 3.5.2 Detaching R1 SP Series Header – M155 and M155E4 Windrowers WARNING To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
  • Page 72 OPERATION 5. Raise lever (A) and undo the three cinch straps (C). 6. Move hose (B) to store on header. Figure 3.86: Hose Bundle 7. Disconnect the following hoses from the hydraulic motor: • Pressure hose (A) • Return hose (B) •...
  • Page 73 OPERATION 9. Disconnect the electrical connector (A) by turning the collar counterclockwise and pulling connector to disengage. NOTE: Hydraulic lines and hoses hidden on illustration to show the electrical connection. Figure 3.88: Electrical Connection 10. Move the hose bundle from header to the left-side (cab-forward) hose support (B).
  • Page 74 OPERATION 13. Move the windrower platform (A) to the CLOSED position. 14. Refer to the windrower operator’s manual to mechanically detach the header from the windrower. Figure 3.90: M155 Windrower 215009 Revision A...

  • Page 75: Driveshields

    OPERATION 3.6 Driveshields 3.6.1 Opening Driveshields CAUTION To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown in this procedure are for the left driveshield—the right driveshield is similar. Figure 3.91: Left Driveshield 1.

  • Page 76: Closing Driveshields

    OPERATION 3. Pull top of driveshield (A) away from the header to open. NOTE: For improved access, lift driveshield off the pins at the base of the shield, and lay the shield on the header. Figure 3.94: Left Driveshield 3.6.2 Closing Driveshields CAUTION To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured.
  • Page 77 OPERATION 4. Replace tool (B) and lynch pin (A) on pin (C). Figure 3.96: Left Driveshield 215009 Revision A...

  • Page 78: Cutterbar Doors

    1. Shut down the engine, and remove the key from the ignition. 2. Lift up on doors (A) at the front of header to open. Figure 3.98: R113 SP Cutterbar Doors 215009 Revision A...

  • Page 79: Opening Cutterbar Doors - Export Latches

    OPERATION 3.7.2 Opening Cutterbar Doors – Export Latches Headers 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 the engine and remove the key from the ignition before leaving the operator’s seat for any reason.

  • Page 80: Closing Cutterbar Doors

    OPERATION 4. Lift up on doors (A) while pressing down on the latch. Figure 3.101: R113 SP Cutterbar Doors 3.7.3 Closing Cutterbar Doors CAUTION To avoid injury, keep hands and fingers away from corners of doors when closing. 1. Pull down on door (A) from the top to close.

  • Page 81: Header Settings

    OPERATION 3.8 Header Settings Satisfactory operation of the disc header in all situations requires making proper adjustments to suit various crops and conditions. Correct operation reduces crop loss and increases productivity. Proper adjustments and timely maintenance increases the length of service of the machine. The variables listed in the following table and detailed in this manual, affect the performance of the disc header.

  • Page 82: Adjusting Cutting Height

    OPERATION Adjusting Cutting Height DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. NOTE: There are two skid shoes on the R113. 1.

  • Page 83: Adjusting Cutterbar Angle

    OPERATION 3.8.2 Adjusting Cutterbar Angle The header angle (A) adjustment ranges from 0 to 8 degrees below horizontal. Choose an angle that maximizes performance for your crop and field conditions. A flatter angle provides better clearance in stony conditions, while a steeper angle is required in downed crops for better lifting action.

  • Page 84: Ground Speed

    The chart demonstrates that a ground speed of 21 km/h (13 mph) would produce a cut area of approximately 8 hectares (20 acres) per hour. Figure 3.105: Ground Speed for R113 SP Disc Header A - Acres/Hour B - Hectares/Hour...

  • Page 85: Reconfiguring Cutterbar Crop Stream

    OPERATION 3.9 Reconfiguring Cutterbar Crop Stream Discs are factory-installed to produce three crop streams, but disc rotation pattern can be changed by substitution of spindle and corresponding disc to suit crop conditions. Each spindle and disc pair is designed to rotate in one direction and must be changed as sets when altering crop flows.

  • Page 86: Changing R113 Sp Cutterbar Crop Stream Configuration

    Installing Cutterbar Spindles, page 114. To change R113 SP (8 disc) spindle rotation from three crop streams (B) to one crop stream (A): • Swap disc/spindle (3) with disc/spindle (6) To change R113 SP (8 disc) spindle rotation from one crop stream (A) to three crop streams (B): •...

  • Page 87: Conditioner

    OPERATION 3.10 Conditioner Rolls condition the crop by crimping and crushing the stem in several places, which allows the release of moisture resulting in faster drying times. Both steel and polyurethane conditioner rolls are available. Refer to 5 Options and Attachments, page 197 for ordering information.

  • Page 88: Checking Roll Gap

    OPERATION Checking Roll Gap DANGER 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. Lower the header fully. 2. Shut down the engine, and remove the key from the ignition. 3.

  • Page 89: Adjusting Roll Gap - Polyurethane Rolls

    OPERATION Adjusting Roll Gap – Polyurethane Rolls Because polyurethane rolls operate at smaller gaps and the conditioning is less aggressive, the roll gap setting is more sensitive than on steel rolls. To return roll gap to the factory setting, follow the procedure below: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.

  • Page 90: Adjusting Roll Gap - Steel Rolls

    OPERATION Adjusting Roll Gap – Steel Rolls The length of thread extending above the jam nut on the adjustment rods can be used as an approximation of roll gap but does NOT provide consistent roll gap measurements. To ensure the roll gap is at the factory setting, follow the procedure below: DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key...

  • Page 91: Roll Tension

    OPERATION 3.10.2 Roll Tension Roll tension (the pressure holding the rolls together) is factory-set to maximum and should rarely require adjustment. Heavy crops or tough forage can cause the rolls to separate; therefore, maximum roll tension is required to ensure that materials are sufficiently crimped.

  • Page 92: Roll Timing

    OPERATION 3.10.3 Roll Timing For proper conditioning, the rolls must be properly timed with the bar on one roll centered between two bars on the other roll. The factory setting should be suitable for most crop conditions. IMPORTANT: Roll timing is critical when the roll gap is decreased because conditioning is affected and the bars may contact each other.
  • Page 93 OPERATION 3. Secure bottom roll (A). 4. Manually rotate upper roll (B) in a counterclockwise direction until it stops. 5. Make a mark (C) across yoke (D) and gearbox flange (E). Figure 3.116: Conditioner Drive 6. Manually rotate upper roll (A) in a clockwise direction until it stops.
  • Page 94 OPERATION 7. Determine center point (A) between the two marks on the yoke plate, and place a third mark. 8. Rotate upper roll (B) counterclockwise until the bolt lines up with the third (center) mark. Figure 3.118: Conditioner Drive 9. Ensure the threads on four bolts (A) are clean and free of lubricant.

  • Page 95: Adjusting Forming Shields - Roll Conditioner

    OPERATION 3.10.4 Adjusting Forming Shields – Roll Conditioner WARNING Keep everyone several hundred feet away from your operation. Ensure bystanders are never in line with the front or rear of the machine. Stones or other foreign objects can be ejected from either end with force. The forming shield position controls the width and placement of the windrow.

  • Page 96: Positioning Rear Baffle - Roll Conditioner

    OPERATION Positioning Rear Baffle – Roll Conditioner The rear baffle is used in conjunction with the forming shields to determine the height and width the windrow. It is located immediately behind and above the conditioning rolls and can be positioned to do the following: •...
  • Page 97 OPERATION Positioning Rear Baffle Deflector Fins The additional rear baffle deflector fins are stored on top of the baffle, but can be moved under the baffle when a narrower windrow is desired. To install fins, follow these steps: DANGER 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.

  • Page 98: Cutterbar Deflectors

    OPERATION 3.11 Cutterbar Deflectors A two-piece cutterbar deflector is attached to the cutterbar just below the header’s conditioner rolls. Deflectors provide improved feeding into the conditioner rolls and prevent heavy crop with long stems from feeding under the rolls. Cutterbar deflectors may not be well-suited for some crop and field conditions. Refer to the following table: Table 3.2 Conditions for Using Cutterbar Deflectors Use Deflector Crop/Field Condition...

  • Page 99: Installing Cutterbar Deflectors

    OPERATION 3.11.2 Installing Cutterbar Deflectors The cutterbar deflectors are used with roll conditioners only. DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. 1.

  • Page 100: Haying Tips

    OPERATION 3.12 Haying Tips 3.12.1 Curing Curing crops quickly helps maintain the highest quality of crop material as 5% of protein is lost from hay for each day that it lays on the ground after cutting. Leaving the windrow as wide and fluffy as possible results in the quickest curing. Cured hay should be baled as soon as possible.

  • Page 101: Windrow Characteristics

    OPERATION 3.12.4 Windrow Characteristics Producing windrows with the recommended characteristics will achieve the best results. Refer to 3 Operation, page 21 instructions on adjusting the header. Table 3.4 Recommended Windrow Characteristics Characteristic Advantage Enables airflow through windrow, which is more important to the curing High and fluffy process than direct sunlight Consistent formation (not bunching)

  • Page 102: Transporting The Header

    OPERATION 3.13 Transporting the Header For information on transporting the header when attached to the windrower, refer to your windrower operator’s manual. IMPORTANT: For cab-forward road travel, the M155 and M155E4 windrower must have the lighting and marking bundle installed (MD #B5412).

  • Page 103: Chapter 4: Maintenance And Servicing

    Chapter 4: Maintenance and Servicing The following instructions provide information about routine servicing for the header. A parts catalog is located in a plastic case at the right end of the header. Log hours of operation and use the maintenance record provided (refer to 4.3.1 Maintenance Schedule/Record, page 93) to keep track of your scheduled maintenance.

  • Page 104: Recommended Safety Procedures

    MAINTENANCE AND SERVICING 4.2 Recommended Safety Procedures • Park on level surface when possible. Follow all recommendations in your tractor operator's manual. • Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets. Figure 4.1: Safety Around Equipment •...
  • Page 105 MAINTENANCE AND SERVICING • Be prepared if an accident should occur. Know where the first aid kits and fire extinguishers are located, and know how to use them. Figure 4.4: Safety Equipment • Keep the service area clean and dry. Wet or oily floors are slippery.

  • Page 106: Maintenance Requirements

    MAINTENANCE AND SERVICING 4.3 Maintenance Requirements IMPORTANT: Recommended intervals are for average conditions. Service the machine more often if operating under adverse conditions (severe dust, extra heavy loads, etc.). Regular maintenance is the best insurance against early wear and untimely breakdowns. Following the maintenance schedule will increase your machine’s life.

  • Page 107: Maintenance Schedule/Record

    MAINTENANCE AND SERVICING 4.3.1 Maintenance Schedule/Record Keep a record of maintenance as evidence of a properly maintained machine. Daily maintenance records are not required to meet normal warranty conditions. Hour meter reading Service date Serviced by First use Refer to 4.3.2 Break-In Inspections, page End of season Refer to...
  • Page 108 MAINTENANCE AND SERVICING At First 50 Hours Change roll timing gearbox lubricant. Refer to 4.6.1 Checking and Changing Oil ▲ in Conditioner Roll Timing Gearbox (MD #221748 or MD #307211), page 158. Change header drive gearbox. Refer ▲ 4.7.1 Changing Header Drive Gearbox Oil, page 161 Check cutterbar lubricant.

  • Page 109: Break-In Inspections

    MAINTENANCE AND SERVICING 4.3.2 Break-In Inspections Table 4.1 Break-In Inspection Schedule Inspection Item Refer to Interval Check for loose hardware and tighten 7.1 Torque Specifications, page 209 Hour to required torque Check for loose hardware and tighten 7.1 Torque Specifications, page 209 Hours to required torque Check conditioner drive belt tension...

  • Page 110: End-Of-Season Servicing

    MAINTENANCE AND SERVICING 4.3.4 End-of-Season Servicing CAUTION Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable. CAUTION Cover cutterbar to prevent injury from accidental contact. Perform the following procedures at the end of each operating season: 1.

  • Page 111: Lubrication

    MAINTENANCE AND SERVICING 4.4 Lubrication WARNING To avoid personal injury, before servicing header or opening drive covers, refer to 4.1 Preparing Machine for Servicing, page Greasing points are marked on the machine by decals showing a grease gun and the grease interval in hours of operation. Log hours of operation and use the maintenance schedule provided to keep a record of scheduled maintenance.

  • Page 112: Every 25 Hours

    MAINTENANCE AND SERVICING Every 25 Hours Use high temperature extreme pressure (EP2) performance grease with 1% max molybdenum disulphide (NLGI grade 2) lithium base unless otherwise specified. Figure 4.7: Every 25 Hours A - Idler/Tensioner Pivot B - Bearing, Roller Conditioner (4 Places) C - U-Joint, Upper Driveline (2 Places) D - Slip Joints, Conditioner Drivelines 6 E - U-Joint, Lower Driveline (2 Places)

  • Page 113: Cutterbar System

    MAINTENANCE AND SERVICING 4.5 Cutterbar System Figure 4.8: Cutterbar The 3978 mm (13 ft.) cutterbar (A) holds eight discs that rotate to a maximum of 2500 rpm at full engine speed. Each disc carries two cutting blades. 4.5.1 Lubricating Cutterbar Checking and Adding Cutterbar Lubricant WARNING To avoid bodily injury or death from unexpected startup of machine, always stop the engine and remove the key from...
  • Page 114 MAINTENANCE AND SERVICING 5. Open cutterbar doors (A). For instructions, refer to 3.7.1 Opening Cutterbar Doors – North America, page Figure 4.9: Cutterbars 6. Use a spirit (bubble) level (A) to ensure the cutterbar is level in both directions. Adjust the header accordingly. Figure 4.10: Spirit Level on Cutterbar 7.
  • Page 115 MAINTENANCE AND SERVICING CAUTION Never start or move the machine until you are sure all bystanders have cleared the area. 10. Start the engine, and raise the header slightly. 11. Lower the header onto blocks, so the left end is slightly higher than the right end. 12.

  • Page 116: Draining The Cutterbar

    MAINTENANCE AND SERVICING Draining the Cutterbar DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

  • Page 117: Filling Lubricant Into A Repaired Cutterbar

    MAINTENANCE AND SERVICING Filling Lubricant into a Repaired Cutterbar This procedure should be used when the cutterbar has been completely drained of oil. If you are checking oil level or toping it up, refer to Checking and Adding Cutterbar Lubricant, page DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.

  • Page 118: Maintaining Cutterbar Discs

    MAINTENANCE AND SERVICING 4.5.2 Maintaining Cutterbar Discs Perform daily inspections to ensure that cutterbar discs have not suffered damage from rocks, or experienced excessive wear from abrasive working conditions. Cutterbar discs are interchangeable and can be moved to a spindle that rotates in the opposite direction as long as the disc is in usable condition and the blades are oriented to cut in the correct direction.
  • Page 119 MAINTENANCE AND SERVICING 2. Inspect for abrasion (A) on the disc at the cutting blade sides. Replace disc if the material thickness is less than 3 mm (1/8 in.) Figure 4.17: Cutterbar Disc 3. Inspect the cutterbar disc surface (D) for cracks, excessive wear, and disc distortion.

  • Page 120: Removing Cutterbar Discs

    3. Engage windrower lift cylinder safety props. For instructions, refer to 3.3 Engaging and Disengaging Header Safety Props, page 4. Open cutterbar doors (A). For instructions, refer to 3.7.1 Opening Cutterbar Doors – North America, page Figure 4.19: Cutterbar Doors – R113 SP 215009 Revision A...
  • Page 121 MAINTENANCE AND SERVICING 5. Place a pin (or equivalent) in the front hole of the rock guard (B) to prevent disc rotation while loosening bolts. 6. Remove four M12 bolts (A) and washers. Figure 4.20: Cutterbar Disc Bolts 7. Remove cutterbar disc cap (A). 8.

  • Page 122: Installing Cutterbar Discs

    MAINTENANCE AND SERVICING Installing Cutterbar Discs DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. WARNING Exercise caution when working around the blades.

  • Page 123: Replacing Cutterbar Spindles

    MAINTENANCE AND SERVICING 5. Remove pin (or equivalent) from front hole of rock guard. 6. Close cutterbar doors (A). For instructions, refer to 3.7.3 Closing Cutterbar Doors, page Figure 4.24: Cutterbar Doors 4.5.3 Replacing Cutterbar Spindles To prevent damage to the cutterbar and drive systems, each disc is attached to a spindle containing a shear pin (A).
  • Page 124 MAINTENANCE AND SERVICING IMPORTANT: • Spindles that rotate clockwise have right-leading threading and are identified by a smooth top on the spindle gear shaft (A). • Spindles that rotate counterclockwise have left-leading threading and are identified by machined grooves on the spindle gear shaft (B) and nut (C).

  • Page 125: Removing Cutterbar Spindles

    3. Shut off the engine, and remove the key from the ignition. 4. Open cutterbar doors (A). For instructions, refer to 3.7.1 Opening Cutterbar Doors – North America, page Figure 4.27: Cutterbar Doors – R113 SP Shown 215009 Revision A...
  • Page 126 MAINTENANCE AND SERVICING 5. Place a pin (or equivalent) in the front hole of the rock guard (B) to prevent disc rotation while loosening bolts. 6. Remove four M12 bolts (A) and washers. Figure 4.28: Cutterbar Disc Bolts 7. Remove cutterbar disc cap (A). 8.
  • Page 127 MAINTENANCE AND SERVICING 10. Rotate spindle hub (A) to access nuts, and remove eleven M12 lock nuts (B) and washers. Figure 4.31: Left Spindle Hub and Hardware 11. Remove spindle (A) from cutterbar. Figure 4.32: Left Spindle 215009 Revision A...

  • Page 128: Installing Cutterbar Spindles

    MAINTENANCE AND SERVICING Installing Cutterbar Spindles Figure 4.33: Underside of Cutterbar Spindles IMPORTANT: Right discs (A) and left discs (B) are timed and must be at a 90 degree angle from adjacent discs when reinstalled. Misaligned discs could result in the following: •...
  • Page 129 MAINTENANCE AND SERVICING 1. Park on a flat, level surface. 2. Lower the disc header fully, shut off engine, and remove key. NOTE: To prevent oil from spilling from the cutterbar while installing disc spindles, ensure the disc header is on a flat, level surface and is tilted all the way back.
  • Page 130 MAINTENANCE AND SERVICING 6. Insert studs (A) into spindle as shown. NOTE: Plugs are factory-installed as shown in position (B), but may come loose over time. Ensure studs are inserted into proper location. IMPORTANT: Ensure clockwise spindles rotate clockwise and counterclockwise spindles (with machined grooves) rotate counterclockwise.
  • Page 131 MAINTENANCE AND SERVICING 10. Install spacer plate (A). Figure 4.39: Spacer Plate 11. Place a pin (or equivalent) in the front hole of the rock guard (D) to prevent disc rotation while tightening bolts. IMPORTANT: Blades are rotation specific. It is necessary to switch entire disc when swapping spindles.

  • Page 132: Maintaining Discblades

    MAINTENANCE AND SERVICING 4.5.4 Maintaining Discblades Each disc has two blades (A) attached at opposite ends that are free to rotate horizontally on a specially designed shoulder bolt. The blade (A) has two cutting edges and can be flipped over so that the blade does not need replacing as often.

  • Page 133: Inspecting Discblades

    MAINTENANCE AND SERVICING Inspecting Discblades WARNING 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. CAUTION Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades.
  • Page 134 The twist in each blade determines the cutting direction. If you are unsure which direction the spindles rotate, refer to 3.9.1 Changing R113 SP Cutterbar Crop Stream Configuration, page 72 instructions. Figure 4.44: Counterclockwise Disc Rotation Figure 4.45: Clockwise Disc Rotation...

  • Page 135: Inspecting Discblade Hardware

    MAINTENANCE AND SERVICING Inspecting Discblade Hardware CAUTION Damaged or loose discblades or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage. Inspect blade attachment hardware each time blades are changed. For instructions, refer to Removing Discblades, page Installing Discblades, page 124 for hardware replacement procedure.

  • Page 136: Removing Discblades

    MAINTENANCE AND SERVICING 2. Check and replace nuts under the following conditions: • Nut has been previously installed—nuts are one-time use only • Nut shows signs of wear (A) that is more than half the original height (B) • Nut is cracked Figure 4.47: Discblade Nut Removing Discblades DANGER...
  • Page 137 MAINTENANCE AND SERVICING 4. Rotate disc (A) so blade (B) faces forward and lines up with hole (C) in rock guard. Figure 4.49: Discblade Aligned with Hole in Rock Guard 5. Place a pin (or equivalent) in the front hole of the rock guard to prevent disc rotation while loosening blade bolts.

  • Page 138: Installing Discblades

    MAINTENANCE AND SERVICING Installing Discblades CAUTION Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades. IMPORTANT: If you are unsure which direction the spindles rotate, refer to 3.9 Reconfiguring Cutterbar Crop Stream, page 1.

  • Page 139: Maintaining Accelerators

    IMPORTANT: Always replace accelerators in pairs to ensure proper disc balance. Figure 4.53: R113 SP Cutterbar Accelerators Inspecting Accelerators WARNING 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.

  • Page 140: Removing Accelerators

    MAINTENANCE AND SERVICING Removing Accelerators IMPORTANT: Always replace accelerators in pairs to ensure proper disc balance. 1. Raise the header fully. 2. Shut off the engine, and remove the key from the ignition. 3. Engage windrower lift cylinder safety props. For instructions, refer to 3.3 Engaging and Disengaging Header Safety Props, page 4.

  • Page 141: Installing Accelerators

    MAINTENANCE AND SERVICING 6. Remove lock nut (A), accelerator (B), blade holder (C), and hex-socket bolt (D). 7. Repeat the removal procedure for the second accelerator. Figure 4.57: Accelerator Removal Installing Accelerators CAUTION Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades.
  • Page 142 MAINTENANCE AND SERVICING 3. Install new nut (A), flange bolt (B), and discblade (C) onto disc. Figure 4.59: Accelerator Install 4. Torque the inside nut (A) to 58 Nm (43 lbf·ft). 5. Torque the outside nut (B) (closest to the blade) to 125 Nm (92 lbf·ft).

  • Page 143: Maintaining Rock Guards

    MAINTENANCE AND SERVICING 4.5.6 Maintaining Rock Guards The machine is equipped with rock guards at each cutting disc location. Rock guards prevent the cutterbar from digging into the ground and protect the disc from coming in contact with stones and other debris. Periodically inspect rock guards for damage and replace as necessary.

  • Page 144: Removing Inboard Rock Guards

    MAINTENANCE AND SERVICING Removing Inboard Rock Guards 1. Remove two hex head screws, washers, and lock nuts (A). Figure 4.63: Inboard Rock Guards 2. Slide inboard rock guard (A) forward (in the direction of arrow [B]) and remove. Figure 4.64: Inboard Rock Guards 215009 Revision A...

  • Page 145: Installing Inboard Rock Guards

    MAINTENANCE AND SERVICING Installing Inboard Rock Guards 1. Guide inboard rock guard onto cutterbar until tabs (A) sit on top of the cutterbar and bottom back bolt holes line up. Figure 4.65: Inboard Rock Guards 2. Install two hex head screws, washers, and lock nuts (A). Torque hardware to 68 Nm (50 lbf·ft).

  • Page 146: Removing Outboard Rock Guards

    MAINTENANCE AND SERVICING Removing Outboard Rock Guards DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. WARNING Exercise caution when working around the blades.

  • Page 147: Installing Outboard Rock Guards

    MAINTENANCE AND SERVICING Installing Outboard Rock Guards DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. 1.

  • Page 148: Maintaining Large Drums

    4.5.7 Maintaining Large Drums Drums deliver cut material from the ends of the cutterbar and help maintain an even crop flow into the conditioner. Large drums are attached to the two outboard discs on R113 SP headers. Figure 4.73: Cutterbars...

  • Page 149: Inspecting Large Drums

    MAINTENANCE AND SERVICING Inspecting Large Drums Inspect drums daily for signs of damage or wear. DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. CAUTION Discblades have two sharp cutting edges that can cause serious injury.

  • Page 150: Removing Large Driven Drums And Driveline

    MAINTENANCE AND SERVICING 7. Close cutterbar doors (A). Figure 4.76: Cutterbars Removing Large Driven Drums and Driveline DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. WARNING Exercise caution when working around the blades.
  • Page 151 MAINTENANCE AND SERVICING 2. Remove four M10 hex flange head bolts (A) and remove vertical driveshield (B). Figure 4.78: Vertical Drive Shield 3. Remove two M10 hex flange head bolts (A) and remove cover plate (B). Figure 4.79: Cover Plate 4.
  • Page 152 MAINTENANCE AND SERVICING 5. Remove one M10 x 20 hex flange head bolt (A), two M10 x 16 hex flange head bolts (B), and vertical shield (C). Figure 4.81: Vertical Shield 6. Remove eight M8 hex flange head bolts (A), and remove two drum shields (B).
  • Page 153 MAINTENANCE AND SERVICING 8. Slide driveline (A) downwards, and tilt it to the side. Pull the driveline up and out of the drum. NOTE: For clarity, the illustration shows a cutaway view of drum and tube shield. Figure 4.84: Driveline 9.

  • Page 154: Installing Large Driven Drums And Driveline

    MAINTENANCE AND SERVICING Installing Large Driven Drums and Driveline DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. WARNING Exercise caution when working around the blades.
  • Page 155 MAINTENANCE AND SERVICING 4. Lubricate spindle splines (A). For specifications, refer to the inside back cover of this manual. NOTE: The driveline U-joints were greased at the factory and are considered to be lubricated for life. No further lubrication is required.
  • Page 156 MAINTENANCE AND SERVICING 9. Position vertical shield (A) as shown. Apply a bead of ® medium-strength threadlocker (Loctite 243 or equivalent) around the threads of one M10 hex flange head bolt (B) and two M10 hex flange head bolts (C). Use bolts (B) and (C) to secure the vertical shield in place.
  • Page 157 MAINTENANCE AND SERVICING 11. Apply a bead of medium-strength threadlocker ® (Loctite 243 or equivalent) around the threads of an M10 hex flange head bolt (B). Install bolt (B) through cover plate (A) and top plate (C). Torque hardware to 61 Nm (45 lbf·ft).
  • Page 158 MAINTENANCE AND SERVICING 15. Close cutterbar doors (A). For instructions, refer to 3.7.3 Closing Cutterbar Doors, page Figure 4.95: Cutterbar Doors and Curtains – Header 215009 Revision A...

  • Page 159: Removing Large Non-Driven Drums

    MAINTENANCE AND SERVICING Removing Large Non-Driven Drums DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. WARNING Exercise caution when working around the blades.
  • Page 160 MAINTENANCE AND SERVICING 4. Remove the four M10 bolts (A) inside the drum using a 305 mm (12 in.) extension and 16 mm socket. 5. Remove wooden block. 6. Remove drum/disc (B). Figure 4.98: Non-Driven Drum 215009 Revision A...

  • Page 161: Installing Large Non-Driven Drums

    MAINTENANCE AND SERVICING Installing Large Non-Driven Drums DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. WARNING Exercise caution when working around the blades.
  • Page 162 MAINTENANCE AND SERVICING 4. Install eight M8 bolts (A) and washers to secure cover (B) to non-driven drum, and torque to 28 Nm (20 lbf·ft). WARNING Ensure the cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage.

  • Page 163: Replacing Cutterbar Spindle Shear Pin

    MAINTENANCE AND SERVICING 4.5.8 Replacing Cutterbar Spindle Shear Pin To prevent damage to the cutterbar and drive systems, each disc is attached to a spindle containing a shear pin (A). If the disc contacts a large object such as a stone or stump, the pin will shear and the disc will stop rotating and move upwards while remaining attached to the spindle with a snap ring (B).

  • Page 164: Removing Cutterbar Spindle Shear Pin

    MAINTENANCE AND SERVICING Removing Cutterbar Spindle Shear Pin WARNING 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. CAUTION Discblades have two sharp cutting edges that can cause serious injury.
  • Page 165 MAINTENANCE AND SERVICING 7. Depending on the type of disc with a broken shear pin, refer to the applicable disc removal procedure: • To remove cutterbar disc (A), refer to Removing Cutterbar Discs, page 106. • To remove driven drum (B), refer to Removing Large Driven Drums and Driveline, page 136.
  • Page 166 MAINTENANCE AND SERVICING 9. Remove the M12 bolt and remove safecut spindle-nut wrench (A) from its storage location. Figure 4.107: Safecut Spindle-Nut Wrench Location IMPORTANT: • Spindles that rotate clockwise have right-leading threading and a smooth top on the spindle gear shaft (A).
  • Page 167 MAINTENANCE AND SERVICING 11. Use the safecut spindle-nut wrench and remove nut (A). Figure 4.110: Cutterbar Spindle 12. Remove shear pins (B). Do NOT damage the pin bore on the pinion. 13. Remove hub (A). 14. Check the nut and hub for damage, and replace if necessary.

  • Page 168: Installing Cutterbar Spindle Shear Pin

    MAINTENANCE AND SERVICING Installing Cutterbar Spindle Shear Pin WARNING 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. CAUTION Discblades have two sharp cutting edges that can cause serious injury.
  • Page 169 MAINTENANCE AND SERVICING 5. Install nut (A). Figure 4.114: Cutterbar Spindle 6. Attach safecut spindle-nut wrench (B) 90 degrees (D) to the torque wrench (A). IMPORTANT: If this is not done, the proper torque will NOT be applied to the nut. 7.
  • Page 170 WARNING Ensure the cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage. Figure 4.118: R113 SP Cutterbar 215009 Revision A...
  • Page 171 MAINTENANCE AND SERVICING 14. Close cutterbar doors (A). For instructions, refer to 3.7.3 Closing Cutterbar Doors, page Figure 4.119: Cutterbar Doors 215009 Revision A...

  • Page 172: Conditioner Roll Timing Gearbox

    MAINTENANCE AND SERVICING 4.6 Conditioner Roll Timing Gearbox The conditioner roll timing gearbox (A), located inside the drive compartment at the right of the header, transfers power from the gearbox-driven lower roll to the upper roll. NOTE: MD #221748 is for model year 2018 and prior; MD #307211 is for model year 2019. Figure 4.120: Conditioner Roll Timing Gearbox 4.6.1 Checking and Changing Oil in Conditioner Roll Timing Gearbox (MD #221748 or MD #307211)
  • Page 173 MAINTENANCE AND SERVICING 3. Remove right driveshield (A). For instructions, refer to Removing Driveshields, page 188. Figure 4.121: Right Driveshield Checking conditioner roll timing gearbox oil level: 4. Clean around oil level sight glass (A) and breather (B) on the inboard side of the gearbox.
  • Page 174 MAINTENANCE AND SERVICING Changing conditioner roll timing gearbox oil: WARNING To avoid bodily injury or death from unexpected start-up or fall of raised machine: stop engine, remove key, and engage lift cylinder lock-out valves before going under machine. 7. Raise the header to provide sufficient access to oil drain plug (A).

  • Page 175: Servicing Header Drive Gearbox

    MAINTENANCE AND SERVICING 4.7 Servicing Header Drive Gearbox The header drive gearbox (A), transfers power from the hydraulic motor to the cutterbar and conditioner. It is located inside the drive compartment at the left end of the header. The only regular servicing required is maintaining the lubricant level and changing the lubricant according to the intervals specified in this manual.
  • Page 176 MAINTENANCE AND SERVICING 4. Clean around oil drain plug (A) on the bottom of the gearbox and around oil level plug (B) on the inboard side of the gearbox. 5. Place a 4 liter (1 gal. [US]) container under drain (A). 6.

  • Page 177: Inspecting Cutterbar Doors

    MAINTENANCE AND SERVICING 4.8 Inspecting Cutterbar Doors 1. Ensure that the door operates smoothly and lies flat when closed. Adjust if necessary. 2. Inspect hinge pin bolts (A) and tighten to 68.5 Nm (50.5 lbf·ft) if loose. 3. Check the door for cracks, and repair if required. 4.

  • Page 178: Maintaining Curtains

    MAINTENANCE AND SERVICING 4.9 Maintaining Curtains Rubber curtains are installed at the following locations: • Inboard curtain (A) attached to the center fixed cover • Door curtains (B) attached to each cutterbar door • Outboard curtains (C) attached to each front corner The curtains form a barrier that minimizes the risk of thrown objects being ejected from the cutterbar area.

  • Page 179: Removing Cutterbar Door Curtains

    The procedure for removing cutterbar door curtains is the same for both doors. 1. Open cutterbar doors (A). For instructions, refer to 3.7.1 Opening Cutterbar Doors – North America, page Figure 4.129: R113 SP 2. Remove seven nuts (A) from the bolt studs. 3. Remove aluminum liner (B). 4. Remove curtain (C).

  • Page 180: Removing Cutterbar Inboard Curtain

    MAINTENANCE AND SERVICING 4.9.4 Removing Cutterbar Inboard Curtain 1. Open cutterbar doors (A). For instructions, refer to 3.7.1 Opening Cutterbar Doors – North America, page Figure 4.132: Cutterbar Doors – R113 Shown 2. Remove two M10 carriage head bolts (A) and nuts securing curtain assembly (B) to the disc header, and remove curtain assembly.

  • Page 181: Installing Cutterbar Inboard Curtain

    MAINTENANCE AND SERVICING 4.9.5 Installing Cutterbar Inboard Curtain 1. Open cutterbar doors (A). For instructions, refer to 3.7.1 Opening Cutterbar Doors – North America, page Figure 4.135: Cutterbar Doors – R113 Shown 2. Install curtain onto weld and bolt studs on center shield, install two curtain brackets (B), and secure with four nuts (A).

  • Page 182: Removing Outboard Curtains

    MAINTENANCE AND SERVICING 4.9.6 Removing Outboard Curtains The procedure for removing outboard curtains is the same for both sides. 1. Open cutterbar doors (A). For instructions, refer to 3.7.1 Opening Cutterbar Doors – North America, page Figure 4.138: Cutterbar Doors – R113 Shown 2.

  • Page 183: Installing Outboard Curtains

    MAINTENANCE AND SERVICING 4.9.7 Installing Outboard Curtains The procedure for installing outboard curtains is the same for both sides. 1. Open cutterbar doors (A). For instructions, refer to 3.7.1 Opening Cutterbar Doors – North America, page Figure 4.141: Cutterbar Doors – R113 Shown 2.

  • Page 184: Conditioner System

    The conditioner system (A) is intended to crimp and crush crop stems, helping the crop to dry faster; it is attached to the rear of the header. Figure 4.144: R113 SP Shown, R116 SP Similar 4.10.1 Inspecting Roll Conditioner DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason.
  • Page 185 MAINTENANCE AND SERVICING 4. Remove left and right driveshields (A). Refer to 3.6.1 Opening Driveshields, page Figure 4.145: Driveshields 5. Inspect conditioner roll left bearing (A) for signs of wear or damage. If the bearing needs replacing, contact your Dealer. Figure 4.146: Conditioner Roll Left Bearing 6.

  • Page 186: Conditioner Drive Belt

    MAINTENANCE AND SERVICING 7. Inspect roll timing gearbox bearings (A) for signs of wear or damage. If the bearing needs replacing, contact your Dealer. Figure 4.148: Roll Timing Gearbox Bearings 4.10.2 Conditioner Drive Belt The conditioner drive belt is located inside the left driveshield and is tensioned with a spring tensioner. The tension is factory-set and should not require adjustment.
  • Page 187 MAINTENANCE AND SERVICING 4. Inspect drive belt (A) and replace if damaged or cracked. 5. Check that jam nut (B) and adjuster nut (C) are tight. Figure 4.150: Conditioner Drive 6. Measure the length of belt tensioner spring (A) and ensure spring length (B) is 366 mm (14 3/8 in.) in accordance with spring tension decal (C).

  • Page 188: Removing Conditioner Drive Belt

    MAINTENANCE AND SERVICING Removing Conditioner Drive Belt WARNING 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. 1. Lower the header fully. 2.

  • Page 189: Installing Conditioner Drive Belt

    MAINTENANCE AND SERVICING Installing Conditioner Drive Belt WARNING 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. 1. Lower the header fully. 2.
  • Page 190 MAINTENANCE AND SERVICING 8. Reconnect speed sensor (B) to wiring harness (A). NOTE: Ensure the speed sensor is installed correctly for the windrower: use the bottom hole for M1 Series; use the top hole for M155E4 SP Windrower. 9. Close the left driveshield. For instructions, refer to 3.6.2 Closing Driveshields, page Figure 4.156: Speed Sensor...

  • Page 191: Changing The Conditioner

    4.10.3 Changing the Conditioner The R113 SP Rotary Disc Header can be operated either with no conditioner, with a polyurethane roll conditioner, or with a steel roll conditioner. If the disc header is not conditioner-equipped, a shield must be installed.
  • Page 192 MAINTENANCE AND SERVICING WARNING To prevent frame from slipping off forks, ensure frame is secured to forks. Failure to do so could result in death or serious injury. 5. Support and secure the adapter frame for lifting using one of the two methods below: Method 1: Attach straps (A) to adapter frame (B) and the forklift forks.
  • Page 193 MAINTENANCE AND SERVICING 7. Remove nut (A) securing bolt (B), washer (C), and washer shims (D) from the center-link support. If necessary, adjust the height of the forks lifting the frame. Retain the hardware for reinstallation. Figure 4.162: Center-Link Support 8.
  • Page 194 MAINTENANCE AND SERVICING 12. Loosen two M16 hex head bolts (A) at each side of the conditioner that secure it to the header. Figure 4.165: Left Side of Conditioner – Right Side Similar 13. Loosen two carriage bolts (A) securing conditioner gearbox support (B) to the header.

  • Page 195: Installing The Conditioner

    MAINTENANCE AND SERVICING Installing the Conditioner This procedure is applicable when the header is not attached to the windrower. If necessary, detach the header from the windrower before proceeding. Refer to header operator’s manual for instructions. 1. Attach spreader bar (A) to the forklift (or an equivalent lifting device) and attach chains to lugs (B) on the conditioner.
  • Page 196 MAINTENANCE AND SERVICING 5. Align the holes in support (B) with the mounting holes in the header frame and install two carriage bolts (A) to secure conditioner gearbox support (B) to the header. Bolt heads face inboard. Torque nuts to 69 Nm (51 lbf·ft). Figure 4.171: Conditioner Gearbox 6.
  • Page 197 MAINTENANCE AND SERVICING Method 2: To protect the finish on the frame, wrap packing foam (A) (or equivalent) around the approximate frame locations shown. b. Position forks (B) under the packing foam on the frame as shown at right. Raise the forks and lift the frame slightly.
  • Page 198 MAINTENANCE AND SERVICING 14. Install washer (A) onto bolt (B) and apply an anti-seize compound to the bolt shank only. Do NOT apply anti-seize to the threads. 15. Install bolt (B) with washers (C) as determined in Step page 183. 16.

  • Page 199: Installing Conditioner Drive

    This procedure describes the installation of conditioner drive components on a machine that was originally supplied with no conditioner. The procedure is similar for machines that will have a conditioner installed. If a conditioner is to be installed on the R113 SP, refer to Installing the Conditioner, page 181...

  • Page 200: Replacing Shield - No Conditioner

    MAINTENANCE AND SERVICING 2. Position tensioner assembly (A) as shown, and secure with M16 x 120 bolt (B) and nut (C). Torque nut (C) to 47–54 Nm (35–40 lbf∙ft). Figure 4.183: Tensioner 3. Install spring (A) into forward hole (B) in the frame. 4.

  • Page 201: Installing Discharge Shield (No Conditioner)

    MAINTENANCE AND SERVICING 3. Lift the shield (A) until pins (B) disengage from slots in support (C). Figure 4.186: Left Side of Header – Right Opposite Installing Discharge Shield (No Conditioner) Follow these steps to install the shielding on a disc header configured without a conditioner: 1.

  • Page 202: Replacing Driveshields

    MAINTENANCE AND SERVICING 4.10.5 Replacing Driveshields If driveshields are missing, severely damaged, or are not securely installed due to damage, they must be replaced. Removing Driveshields CAUTION To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown in this procedure are for the left driveshield—the right driveshield is similar.
  • Page 203 MAINTENANCE AND SERVICING 2. Insert the flat end of tool (A) into latch (B) and turn it counterclockwise to unlock. Figure 4.191: Tool to Unlock Driveshield and Latch 3. Pull the top of driveshield (A) away from the header and lift off the pins at the base of the shield to remove.

  • Page 204: Installing Driveshields

    MAINTENANCE AND SERVICING Installing Driveshields CAUTION Do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown in this procedure are for the left driveshield—the right driveshield is similar. 1. Position driveshield (A) onto pins (B) at the base of driveshield.

  • Page 205: Replacing Driveshield Latch

    MAINTENANCE AND SERVICING Replacing Driveshield Latch CAUTION Do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown are for left side driveshield—right side driveshield is similar. 1. Remove driveshield (A). Refer to Removing Driveshields, page 188.

  • Page 206: Electrical System

    MAINTENANCE AND SERVICING 4.11 Electrical System The header’s electrical system is powered by the windrower. The electrical harness (A) from the header connects to the windrower, and supplies power to hazard/signal lights and speed sensor that is on the header. Figure 4.198: Electrical Harness 4.11.1 Maintaining Electrical System •...

  • Page 207: Replacing Amber Hazard/Signal Light Fixture

    MAINTENANCE AND SERVICING 4.11.2 Replacing Amber Hazard/Signal Light Fixture WARNING 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. 1.

  • Page 208: Replacing Header Rpm Sensor

    MAINTENANCE AND SERVICING 4.11.4 Replacing Header RPM Sensor If the header rpm sensor malfunctions or is damaged, use this procedure to replace it. 1. Lower the header fully. 2. Shut down the engine, and remove the key from the ignition. 3.

  • Page 209: Hydraulics

    MAINTENANCE AND SERVICING 4.12 Hydraulics 4.12.1 Checking Hydraulic Hoses and Lines Check hydraulic hoses and lines daily for signs of leaks. WARNING • Avoid high-pressure fluids. Escaping fluid can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure.

  • Page 211: Chapter 5: Options And Attachments

    MD #B5800 Figure 5.1: Left Side Tall Crop Divider 5.1.2 No Conditioner Kit The R113 SP Rotary Disc Header can be operated without a conditioner. Kit includes required rear windrow shielding and curtain. MD #B5818 5.1.3 Polyurethane Roll Conditioner Kit Rolls condition the crop by crimping and crushing the stem in several places, which allows the release of moisture resulting in faster drying times.

  • Page 212: Hydraulic Drive Conversion Kits

    OPTIONS AND ATTACHMENTS 5.2 Hydraulic Drive Conversion Kits Headers are factory-configured for use with either M155 and M155E4 SP Windrowers, or M1 Series Windrowers. Headers can be reconfigured for use on the alternative windrower options by using hydraulic conversion kits. 5.2.1 M1 Series Hydraulic Drive Conversion Kit Hydraulic Drive kit is required for an R113 Rotary Disc Header that is originally configured for use with an M155 or M155E4 SP...

  • Page 213: M155 And M155E4 Hydraulic Drive Conversion Kit

    OPTIONS AND ATTACHMENTS 5.2.3 M155 and M155E4 Hydraulic Drive Conversion Kit Hydraulic Drive kit (A) is required for an R1 Series Rotary Disc Header that is originally configured for use with an M1 Series to operate correctly on M155 or M155E4 Self-Propelled Windrower.

  • Page 215: Chapter 6: Troubleshooting

    Chapter 6: Troubleshooting 6.1 Performance Problems Problem Solution Refer to Symptom: Cutterbar plugging • Removing Discblades, page 122 Dull, bent, or badly worn discblades Replace discblades. • Installing Discblades, page 124 Decrease header angle and increase • 3.8.1 Cutting Height, page 67 float.
  • Page 216 TROUBLESHOOTING Problem Solution Refer to • Adjusting Roll Gap – Polyurethane Rolls, page 75 Roll gap too small in thick-stemmed Increase roll gap. cane-type crops • Adjusting Roll Gap – Steel Rolls, page 76 3.10.4 Adjusting Forming Shields – Roll Swath baffle set too low Raise swath baffle.
  • Page 217 TROUBLESHOOTING Problem Solution Refer to Symptom: Material being pulled out by roots when cutting, and tall crop leaning into machine • Adjusting Roll Gap – Polyurethane Crop in conditioner rolls before Rolls, page 75 Increase roll gap. crop is cut •...
  • Page 218 TROUBLESHOOTING Problem Solution Refer to Symptom: Poorly formed or bunchy windrows • Positioning Forming Shield Side Deflectors – Roll Conditioner, page Forming shields not properly Adjust forming shields. positioned • Positioning Rear Baffle – Roll Conditioner, page 82 215009 Revision A...

  • Page 219: Mechanical Problems

    TROUBLESHOOTING 6.2 Mechanical Problems Problem Solution Refer to Symptom: Excessive noise • Removing Discblades, page 122 Bent discblade Replace blade. • Installing Discblades, page 124 • Check roll timing and adjust if Checking Roll Timing, page 78 Conditioner roll timing off necessary.
  • Page 220 When all moving parts are completely stopped, remove foreign object. Belt pulleys and idlers misaligned Align pulleys and idler. See MacDon Dealer Symptom: Conditioner roll does not rotate Inspecting Conditioner Drive Belt, page Faulty drive belt Check drive belt pulleys.
  • Page 221 Solution Refer to Symptom: Header runs while unloaded, but slows or stops when starting to cut Defective hydraulic motor Repair/replace hydraulic motor. See MacDon Dealer Defective hydraulic pump in Repair/replace pump. See MacDon Dealer windrower Defective relief valve in windrower Repair/replace relief valve.

  • Page 223: Chapter 7: Reference

    Chapter 7: Reference 7.1 Torque Specifications The following tables provide correct torque values for various bolts, cap screws, and hydraulic fittings. • Tighten all bolts to torque values specified in charts (unless otherwise noted throughout this manual). • Replace hardware with same strength and grade of bolt. •...
  • Page 224 REFERENCE Table 7.2 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (lbf·ft) (*lbf·in) Torque (Nm) Nominal Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 18.8 20.8 *167 *185 10-1.5 Figure 7.2: Bolt Grades 12-1.75 14-2.0 16-2.0...

  • Page 225: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE Table 7.4 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (lbf·ft) (*lbf·in) Torque (Nm) Nominal Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 10.7 11.8 *105 8-1.25 10-1.5 Figure 7.4: Bolt Grades 12-1.75 14-2.0 16-2.0 20-2.5...

  • Page 226: O-Ring Boss Hydraulic Fittings - Adjustable

    REFERENCE 7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off lock nut (C) as far as possible. Ensure that washer (D) is loose and is pushed toward lock nut (C) as far as possible.
  • Page 227 REFERENCE Table 7.6 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable Torque Value SAE Dash Size Thread Size (in.) lbf·ft (*lbf·in) 5/16–24 6–7 *53–62 3/8–24 12–13 *106–115 7/16–20 19–21 14–15 1/2–20 21–33 15–24 9/16–18 26–29 19–21 3/4–16 46–50 34–37 7/8–14 75–82 55–60 1 1/16–12 120–132...

  • Page 228: O-Ring Boss Hydraulic Fittings - Non-Adjustable

    REFERENCE 7.1.4 O-Ring Boss 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 threads and adjust if necessary. 3. Apply hydraulic system oil to O-ring. 4.

  • Page 229: O-Ring Face Seal Hydraulic Fittings

    REFERENCE 7.1.5 O-Ring Face Seal Hydraulic Fittings 1. Check components to ensure that sealing surfaces and fitting threads are free of burrs, nicks, scratches, or any foreign material. Figure 7.9: Hydraulic Fitting 2. Apply hydraulic system oil to O-ring (B). 3.

  • Page 230: Tapered Pipe Thread Fittings

    REFERENCE Table 7.8 O-Ring Face Seal (ORFS) Hydraulic Fittings (continued) Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) lbf·ft 1 7/16 150–165 111–122 205–226 151–167 1 11/16 1 1/4 1–2 315–347 232–256 1 1/2 510–561 376–414 2 1/2 7.1.6 Tapered Pipe Thread Fittings Assemble pipe fittings as follows: 1.

  • Page 231: Conversion Chart

    REFERENCE 7.2 Conversion Chart Table 7.10 Conversion Chart Quantity SI Units (Metric) Factor US Customary Units (Standard) Unit Name Abbreviation Unit Name Abbreviation acre acres Area x 2.4710 = hectare Flow liters per minute x 0.2642 = US gallons per minute L/min Force Newton...

  • Page 233: Index

    Index polyurethane rolls ........75 steel rolls ............ 76 accelerators checking roll gap inspecting ............125 polyurethane rolls ........74 installing............127 roll tension............77 maintaining............125 adjusting ............77 removing ............126 roll timing ............78 adjusting ............78 definition............
  • Page 234 INDEX definition of terms..........19 deflectors FFFT cutterbar deflectors..........84 definition............19 installing ............85 finger tight removing............84 definition............19 side deflectors fixtures, See lights positioning on roll conditioner ......81 fluids, See lubricants disc maintenance forming shields accelerators on roll conditioner..........
  • Page 235 INDEX operation............21 recommended settings......... 67 maintenance and servicing transporting ............88 break-in inspections ..........95 hex keys break-in period ........... 21 definition............19 end-of-season servicing........96 hydraulics maintenance requirements ........92 connecting header hydraulics maintenance schedule/records......93 M1 Series windrower ........42 preparing for servicing .........
  • Page 236 INDEX signal words ............2 understanding safety signs........11 preseason servicing ..........95 screws definition............19 definition............19 rear baffles serial numbers positioning on roll conditioner....... 82 locations............. vi recommended settings records............... vi header .............. 67 servicing reference maintenance and servicing ........89 conversion chart ..........
  • Page 237 INDEX washers definition............19 weather ..............86 windrowers definition............19 M1 Series attaching to header.......... 27 detaching from header ........52 M155, M155E4 detaching from header ........57 M155, M155E4 SP Windrowers attaching to header hydraulic center-link with optional self-alignment kit ............

  • Page 239: Recommended Lubricants

    Recommended Lubricants Keep your machine operating at top efficiency by using only clean lubricants and by ensuring the following: • Use clean containers to handle all lubricants. • Store lubricants in an area protected from dust, moisture, and other contaminants. IMPORTANT: Do NOT overfill the cutterbar when adding lubricant.
  • Page 240 MacDon Industries Ltd. MacDon Brasil Agribusiness Ltda. 680 Moray Street Rua Grã Nicco, 113, sala 404, B. 04 Winnipeg, Manitoba Mossunguê, Curitiba, Paraná Canada R3J 3S3 CEP 81200-200 Brasil t. (204) 885-5590 f. (204) 832-7749 t. +55 (41) 2101-1713 f. +55 (41) 2101-1699 MacDon, Inc.

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