MacDon R1 Series Installation Instructions Manual
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MacDon R1 Series Installation Instructions Manual

Rotary disc pull-types and headers, eight- and ten-disc cutterbar kits installation
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R1 Series
Rotary Disc Pull-Types and Headers
Eight- and Ten-Disc Cutterbar Kits (MD #259517 and 259518)
Installation Instructions
214497 Revision D
Original Instruction
The Harvesting Specialists.

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Summary of Contents for MacDon R1 Series

  • Page 1 R1 Series Rotary Disc Pull-Types and Headers Eight- and Ten-Disc Cutterbar Kits (MD #259517 and 259518) Installation Instructions 214497 Revision D 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...
  • Page 3 Introduction The Ten-Disc Cutterbar kit (MD #259517) can be used to replace the cutterbar on a MacDon R116 Rotary Disc Header or Rotary Disc Pull-Type; the Eight-Disc Cutterbar kit (MD #259518) can be used to replace the cutterbar on a MacDon R113 Rotary Disc Header or Rotary Disc Pull-Type.
  • Page 4 Summary of Changes At MacDon, we’re continuously making improvements, and occasionally these improvements affect product documentation. The following list provides an account of major changes from the previous version of this document. Section Internal Use Summary of Change Only Front cover...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ..............................i Summary of Changes............................ ii Chapter 1: Safety ............................1 1.1 Signal Words ............................1 1.2 General Safety ............................2 Chapter 2: Parts List............................ 5 Chapter 3: Installation Instructions ......................7 3.1 Opening Cutterbar Doors – North America....................7 3.2 Opening Cutterbar Doors –...

  • Page 7: Chapter 1: Safety

    Chapter 1: Safety 1.1 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words, IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

  • Page 8: General Safety

    SAFETY 1.2 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 the job at hand. Do NOT take chances.
  • Page 9 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 11: Chapter 2: Parts List

    Chapter 2: Parts List The following parts are included in this kit: Figure 2.1: Parts Included in the Cutterbar Kits Quantity Part Number Description R113 R116 CUTTERBAR – 8 DISC, QCB READY CUTTERBAR – 10 DISC, QCB READY TOOL ASSEMBLY – DRIVE ALIGNMENT 325683 214497 Revision D...

  • Page 13: Chapter 3: Installation Instructions

    Chapter 3: Installation Instructions To install the cutterbar kits, follow these steps and procedures in the order given. NOTE: Some steps and procedures only apply to some machines. These are clearly labelled. 3.1 Opening Cutterbar Doors – North America 3.2 Opening Cutterbar Doors – Export If the machine was sold outside of North America, it will have export latches.

  • Page 14: Opening Cutterbar Doors - Export Latches

    INSTALLATION INSTRUCTIONS 3.2 Opening Cutterbar Doors – Export Latches Machines 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 the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
  • Page 15 INSTALLATION INSTRUCTIONS 5. Lift up on doors (A) while pressing down on the latch. Figure 3.5: Cutterbar Doors and Curtains – Pull-Type Figure 3.6: Cutterbar Doors and Curtains – Windrower Header 214497 Revision D...

  • Page 16: Removing Drivelines

    INSTALLATION INSTRUCTIONS 3.3 Removing Drivelines 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 (headers) or lift cylinder lock-out valves (pull-types) before going under machine for any reason.

  • Page 17: Removing Driveline On An R113 - Large Driven Drums

    INSTALLATION INSTRUCTIONS Before removing the existing cutterbar, you must remove the drivelines from the machine. The procedure varies slightly depending on the type of driven drums installed on the machine. Some machines have large driven drums (A) and some have small driven drums (B). Refer to the procedure appropriate for your machine: •...
  • Page 18 INSTALLATION INSTRUCTIONS 2. Remove two M10 hex flange head bolts (A) and remove cover plate (B). Figure 3.11: Cover Plate 3. Remove four M10 hex flange head bolts (A), and remove top plate (B) and drum top (C). Figure 3.12: Top Plate and Drum Top 4.
  • Page 19 INSTALLATION INSTRUCTIONS 5. Remove eight M8 hex flange head bolts (A), and remove two drum shields (B). Figure 3.14: Drum Shields 6. Remove four M12 hex flange head bolts (A) and spacers securing driveline assembly (B) to hub drive (C). Figure 3.15: Hub Drive and Driveline Assembly 7.

  • Page 20: Removing Driveline On An R116 - Small Driven Drums

    INSTALLATION INSTRUCTIONS 3.3.2 Removing Driveline on an R116 – Small Driven Drums To remove the vertical driveline from an R116 with small driven drums, follow these steps: 3.3.1 Removing Driveline on an R113 – Large If you are working on an R113 or an R116 with large driven drums, refer to Driven Drums, page NOTE: Retain all parts for reassembly unless otherwise stated.
  • Page 21 INSTALLATION INSTRUCTIONS 4. Remove one 20 mm M10 hex flange head bolt (B), two 16 mm M10 hex flange head bolts (C), and vertical shield (A). Figure 3.20: Driveline Shield 5. Remove eight M8 hex flange head bolts (A) and two drum shields (B).
  • Page 22 INSTALLATION INSTRUCTIONS 7. Slide driveline (A) downwards, tilt it to the side, and pull driveline up and out of drum. NOTE: For clarity, illustration shows a cutaway view of drum and tube shield. Figure 3.23: Driveline 214497 Revision D...

  • Page 23: Removing Cutterbar Deflectors

    INSTALLATION INSTRUCTIONS 3.4 Removing Cutterbar Deflectors The cutterbar deflectors are used with roll conditioners only. 1. Locate deflector (A) on the back of the cutterbar. 2. Clean debris from deflectors and deflector area. 3. Remove bolt (C) shared with the rock guard from the cutterbar on the outboard end of deflector.

  • Page 24: Removing The R113 Cutterbar

    INSTALLATION INSTRUCTIONS 3.5 Removing the R113 Cutterbar WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. CAUTION The cutterbar weighs approximately 560 kg (1300 lb.). Use a suitable lifting device to support and move the cutterbar into place.

  • Page 25: Removing The R116 Cutterbar

    INSTALLATION INSTRUCTIONS 3.6 Removing the R116 Cutterbar WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. CAUTION The cutterbar weighs approximately 560 kg (1300 lb.). Use a suitable lifting device to support and move the cutterbar into place.

  • Page 26: Checking Cutterbar Lubricant Level

    INSTALLATION INSTRUCTIONS 3.7 Checking Cutterbar Lubricant Level The new cutterbar comes from the factory pre-filled with lubricant. Before installing the cutterbar, you should check to make sure the lubricant level is correct, and adjust if needed. Follow these steps: 1. Position the cutterbar on a flat surface. Use a spirit (bubble) level (A) to ensure the cutterbar is level in both directions (front to back and end to end).

  • Page 27: Removing Outboard Rock Guards

    INSTALLATION INSTRUCTIONS 3.8 Removing Outboard Rock Guards WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. Before installing the cutterbar, remove the outboard rock guards as follows to simplify installation. 1.

  • Page 28: Installing The R113 Cutterbar

    INSTALLATION INSTRUCTIONS 3.9 Installing the R113 Cutterbar WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. IMPORTANT: Vertical drive alignment is crucial for proper cutterbar operation. Always use the drive alignment tool (MD #325683) when installing a cutterbar.
  • Page 29 INSTALLATION INSTRUCTIONS 6. Attach drive alignment tool (A) to the drive hub (B), and torque to 95 Nm (70 lbf·ft). Slide the bottom tube down over the cutterbar driveshaft. IMPORTANT: If the alignment tool is not secured to the gearbox using all four bolts, the drive hub will be misaligned.
  • Page 30 INSTALLATION INSTRUCTIONS 13. If shims (A) were removed during disassembly, install them at this time. NOTE: The same number of shims must be installed on both sides of the cutterbar. A maximum gap of 2 mm (0.08 in.) is allowed. 14.
  • Page 31 INSTALLATION INSTRUCTIONS 17. Position skid shoe (B) as shown. Install bolt, washer, and nut (A). Do NOT overtighten; skid shoe must be able to rotate freely. 18. Repeat Steps 13, page 24 17, page 25 on the opposite side. Figure 3.41: Skid Shoe – Rear Side View 214497 Revision D...

  • Page 32: Installing The R116 Cutterbar

    INSTALLATION INSTRUCTIONS 3.10 Installing the R116 Cutterbar WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. IMPORTANT: Vertical drive alignment is crucial for proper cutterbar operation. Always use the drive alignment tool (MD #325683) when installing a cutterbar.
  • Page 33 INSTALLATION INSTRUCTIONS 7. Attach drive alignment tool (A) to drive hub (B), and torque to 95 Nm (70 lbf·ft). Slide the bottom tube down over the cutterbar driveshaft. IMPORTANT: If the alignment tool is not secured to the gearbox using all four bolts, the drive hub will be misaligned.
  • Page 34 INSTALLATION INSTRUCTIONS 15. If shims (A) were removed during disassembly, install them at this time. NOTE: The same number of shims must be installed on both sides of the cutterbar. A maximum gap of 2 mm (0.08 in.) is allowed. 16.
  • Page 35 INSTALLATION INSTRUCTIONS 19. Position outer skid shoe (B) as shown. Install bolt, washer, and nut (A). Do NOT overtighten; skid shoe must be able to rotate freely. Repeat for inner skid shoe. 20. Repeat Steps 15, page 28 19, page 29 on opposite side.

  • Page 36: Installing Driveline And Shielding

    INSTALLATION INSTRUCTIONS 3.11 Installing Driveline and Shielding After installing the new cutterbar, you must reinstall the driveline and shielding. Refer to the procedure appropriate for your machine: • R113 – 3.11.1 Installing Driveline and Shielding on an R113 – Large Driven Drums, page 30 •...
  • Page 37 INSTALLATION INSTRUCTIONS 5. Position two drum shields (B) as shown. Apply a bead of ® medium-strength threadlocker (Loctite 243 or equivalent) around the threads of eight M8 hex flange head bolts (A). Use the bolts to secure the drum shields in place. Torque to 27 Nm (20 lbf·ft).
  • Page 38 INSTALLATION INSTRUCTIONS 8. 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 39: Installing Driveline And Shielding On An R116 - Small Driven Drums

    INSTALLATION INSTRUCTIONS 3.11.2 Installing Driveline and Shielding on an R116 – Small Driven Drums To reinstall the vertical driveline and shielding on an R116, follow these steps: 3.11.1 Installing Driveline and Shielding on an R113 – Large Driven Drums, page If you are working on an R113, refer to NOTE: 3.3.2 Removing Driveline on an R116 –...
  • Page 40 INSTALLATION INSTRUCTIONS 6. Position vertical shield (A) as shown. Apply a bead of ® medium-strength threadlocker (Loctite 243 or equivalent) around the threads of one M10 x 20 mm hex flange head bolt (B) and two M10 x 16 mm hex flange head bolts (C). Use bolts (B) and (C) to secure the vertical shield in place.
  • Page 41 INSTALLATION INSTRUCTIONS 8. 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 42: Installing Outboard Rock Guards

    INSTALLATION INSTRUCTIONS 3.12 Installing Outboard Rock Guards ® 1. Apply medium-strength threadlocker (Loctite 242 or equivalent) to bolt (B). NOTE: Some parts removed for clarity. 2. Install bolt (B) with washer onto the cutterbar. 3. Angle rock guard (A) outward as shown. Align the slot in the side plate between the washer and the cutterbar on rear M16 bolt (B).
  • Page 43 INSTALLATION INSTRUCTIONS ® 7. Apply medium-strength threadlocker (Loctite 242 or equivalent) on two hex head screws (C). Loosely install with lock nuts. 8. Install the M16 x 60 bolt (A) and one washer (B) as shown. Torque bolts (A) and (D) to 251 Nm (185 lbf·ft). 9.

  • Page 44: Installing Cutterbar Deflectors

    INSTALLATION INSTRUCTIONS 3.13 Installing Cutterbar Deflectors The cutterbar deflectors are used with roll conditioners only. IMPORTANT: Pull-Type only: To avoid damage, cutterbar deflectors must NOT be used with the finger conditioner option. 1. Position left deflector (A) on the aft edge of the cutterbar, and align slots in deflector (A) with the existing fasteners and cutterbar plug.

  • Page 45: Closing Cutterbar Doors

    INSTALLATION INSTRUCTIONS 3.14 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. 2. Ensure that curtains hang properly and completely enclose the cutterbar area.
  • Page 48 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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R113R116

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