Page 1 R1 FR Series Front Mount Rotary Disc Operator s Manual 262391 Revision A Original Instruction The Harvesting Specialists.
Page 2 © 2024 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 This instructional manual contains safety, operating, and maintenance procedures for the MacDon R1 FR Series Rotary Disc. Your machine The MacDon R113 and R116 Front Mounted Rotary Disc Headers, when mounted to the front of a suitable agricultural tractor, are designed to cut, condition, and lay a wide variety of grasses and hay crops in windrows.
Page 4 Store the operator s manual and the parts catalog in the plastic manual case (A) at the right side of the rotary disc header. This document is currently available in English. Manual Storage Case 262391 Revision A...
Page 5 Serial Numbers Record the serial number of the header, the carrier frame, in the spaces provided below., the hitch, and the transport option (if equipped) provided below. Rotary disc header serial number (A): Model year: Rotary Disc Header Serial Number Location 262391 Revision A...
Page 7: Table Of Contents
TABLE OF CONTENTS Introduction ..............................i Serial Numbers............................iii Chapter 1: Safety ............................1 1.1 Safety Alert Symbols ..........................1 1.2 Signal Words ............................2 1.3 General Safety ............................3 1.4 Hydraulic Safety .............................5 1.5 Decommissioning and Disposing of Agricultural Equipment................6 1.6 Safety Signs ............................8 1.6.1 Installing Safety Decals........................8 1.7 Safety Sign Locations..........................9 Chapter 2: Product Overview........................
Page 8 TABLE OF CONTENTS 3.13 Operating Rotary Disc Header ....................... 41 3.13.1 Raising and Lowering Rotary Disc Header ..................41 Header Raise / Lower Auxiliary Lift System ................... 41 3.13.2 Float ............................43 Adjusting Float ........................... 43 3.13.3 Cutting Height ........................... 46 Adjusting Cutting Height ......................
Page 9 TABLE OF CONTENTS Greasing Procedure........................77 Service Intervals ......................... 77 4.4 Cutterbar System..........................83 4.4.1 Cutterbar Doors........................... 83 Inspecting Cutterbar Doors......................83 4.4.2 Maintaining Curtains ........................84 Inspecting Curtains ........................84 Removing Cutterbar Door Curtains ....................85 Installing Cutterbar Door Curtains....................86 Removing Cutterbar Inboard Curtain....................
Page 10 TABLE OF CONTENTS 4.4.12 Maintaining Large Drums......................151 Inspecting Large Drums ......................151 Removing Large Driven Drums and Driveline ................. 153 Installing Large Driven Drums and Driveline................... 156 Removing Large Non-Driven Drums ..................... 160 Installing Large Non-Driven Drums....................162 4.4.13 Replacing Cutterbar Spindle Shear Pin..................164 Removing Cutterbar Spindle Shear Pin..................
Page 11 TABLE OF CONTENTS 5.1.2 Hydraulic Center-Link Kit ......................203 5.1.3 Quick Change Blade Kit ....................... 204 5.2 Replacement Conditioners ........................205 5.2.1 Steel Intermeshing Roller ......................205 Chapter 6: Troubleshooting........................207 6.1 Troubleshooting Rotary Disc Header Performance..................207 6.2 Troubleshooting Mechanical Issues......................209 Chapter 7: Reference ..........................
Page 13: Chapter 1: Safety
Chapter 1: Safety Understanding and consistently following these safety procedures will help to ensure the safety of those operating the machine and of bystanders. 1.1 Safety Alert Symbols The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: ATTENTION! BECOME ALERT!
Page 14: 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 it is not prevented, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if it is not prevented, could result in death or serious injury.
Page 15: General Safety
SAFETY 1.3 General Safety Operating, servicing, and assembling machinery presents several safety risks. These risks can be reduced or eliminated by following the relevant safety procedures and wearing the appropriate personal protective equipment. CAUTION The following general farm safety precautions should be part of your operating procedure for all types of machinery.
Page 16 SAFETY Wear close-fitting clothing and cover long hair. NEVER wear dangling items such as hoodies, scarves, or bracelets. Keep all shields in place. NEVER alter or remove safety equipment. Ensure that the driveline guards can rotate independently of their shaft, and that they can telescope freely.
Page 17: Hydraulic Safety
SAFETY 1.4 Hydraulic Safety Because hydraulic fluid is under extreme pressure, hydraulic fluid leaks can be very dangerous. Follow the proper safety procedures when inspecting hydraulic fluid leaks and servicing hydraulic equipment. Always place all hydraulic controls in NEUTRAL before leaving the operator s seat.
Page 18: Decommissioning And Disposing Of Agricultural Equipment
SAFETY 1.5 Decommissioning and Disposing of Agricultural Equipment When agricultural equipment is no longer serviceable and needs to be decommissioned and disposed of, recyclable materials including ferrous and non-ferrous metals, rubber, and plastics; fluids such as lubricants, refrigerants, and fuels; and hazardous materials found in batteries, some light bulbs, and electronic equipment must be handled safely and not introduced into the environment.
Page 19 SAFETY Use appropriate personal protective equipment when removing and handling objects and materials. Use appropriate personal protective equipment when handling objects with residue from pesticides, fertilizers, or other agricultural chemicals. Follow local regulations when handling and disposing of these objects. Safely release stored energy from suspension components, springs, hydraulic, and electrical systems.
Page 20: Safety Signs
SAFETY 1.6 Safety Signs Safety signs are decals placed on the machine where there is a risk of personal injury, or where the Operator should take extra precautions before operating the controls. They are usually yellow. Keep safety signs clean and legible at all times. Replace safety signs that are missing or illegible.
Page 21: Safety Sign Locations
SAFETY 1.7 Safety Sign Locations Safety signs are installed in several locations on the header. Replace any missing or damaged decals on the machine with identical parts. Figure 1.14: Safety Sign Decal Locations – Top A - MD #194465 B - MD #247167 C - MD #194466 D - MD #190546 E - MD #166466...
Page 22 SAFETY Figure 1.16: Safety Sign Decal Locations – Back and Sides A - MD #113482 B - MD #167502 C - MD #174436 D - MD #171287 E - MD #247166 F - MD #184372 Figure 1.17: Safety Sign Decals – Back and Sides 262391 Revision A...
Page 23 SAFETY Figure 1.18: 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) NOTE: The roller conditioner for R1 FR Front Mount Disc has a split baffle for the driveline. The safety decal locations are correct. 262391 Revision A...
Page 25: Chapter 2: Product Overview
ORS, which stands for O-Ring Seal R113 and R116 Rotary Disc Front Mount for Agricultural Tractors R1 FR Series Society of Automotive Engineers A headed and externally threaded fastener that threads into preformed threads or forms...
Page 26: Component Identification
PRODUCT OVERVIEW 2.2 Component Identification Being able to identify the parts and systems of your front mount rotary disc header will help to find content in reference manuals. Figure 2.1: R116 FR with Conditioner A - Cutterbar B - Curtains C - Cutterbar Door D - Clearance Lights E - Roll Conditioner...
Page 27 PRODUCT OVERVIEW Figure 2.2: R116 FR with Conditioner A - Auxiliary Lift Cylinder Lock-Out Valve B - Manual Case C - Conditioner Gearbox (Guard Removed) D - Skid Shoe E - Side Deflector F - Side Deflector Adjuster G - Baffle Fin Adjuster H - Crop Shield Adjuster J - Hitch Point K - PTO Shaft (Half Shown)
Page 28: Product Specifications
2.3 Product Specifications Consult this section to learn about dimensions, weight, and equipment specifications. NOTE: Specifications and design are subject to change without notice or obligation to revise previously sold units. Table 2.2 R1 FR Series Specifications Components R113 FR R116 FR...
Page 29 PRODUCT OVERVIEW Table 2.2 R1 FR Series Specifications (continued) Components R113 FR R116 FR Forming shields Conditioner mounted assembly with adjustable side deflectors Ground Speed Recommended cutting 8 15 km/h (5 10 mph) Tractor Requirements Power Take-Off (PTO) power minimum...
Page 31: Chapter 3: Operation
Chapter 3: Operation Safely operating your machine requires familiarizing yourself with its capabilities. 3.1 Auxiliary Lift Lock Pins Auxiliary lift linkage lock pins ensure the carrier frame does not move when the header is disconnected from the tractor. 3.1.1 lnstalling Auxiliary Lift Lock Pins Auxiliary lift linkage lock pins are used to lock the auxiliary lift linkage to prevent the carrier frame from moving when the header is not attached to a tractor.
Page 32: Removing Auxiliary Lift Locking Pins
OPERATION 4. Retrieve the auxiliary lift lock straight pins, washers, and Lynch pins from storage location (B) on the left side of the carrier frame, and install the straight pins into the holes (A) in auxiliary lift linkage on both sides of the header. Figure 3.1: Auxiliary Lift Lock Pins –...
Page 33 OPERATION 2. Remove auxiliary lift lock straight pins (A) from holes in auxiliary lift linkage on both sides of the header. Store the auxiliary lift lock straight pins, washers, and Lynch pins in storage location (B) on the left side of the carrier frame. Figure 3.2: Auxiliary Lift Lock Pins –...
Page 34: Auxiliary Lift Cylinder Lock-Out Valves
OPERATION 3.2 Auxiliary Lift Cylinder Lock-Out Valves To prevent unintended header movement, engage the auxiliary lift cylinder lock-out valves before disconnecting, servicing, or transporting your machine. The lock-out valves are located on the auxiliary lift cylinders at the back of the header. 3.2.1 Locking and Unlocking Auxiliary Lift Cylinders The auxiliary lift cylinders provide additional lift range when raising the 3-point hitch.
Page 35: Driveshields
OPERATION 3.3 Driveshields Driveshields offer protection from the rotating belts and drives. The header has two driveshields: one on the left side, and one on the right side. 3.3.1 Opening Driveshields The driveshields offer protection for its sensitive components. Open them only when you intend to service the header. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 36: Closing Driveshields
OPERATION 3. Insert the flat end of tool (A) into latch (B) and turn it counterclockwise to unlock the driveshield. Figure 3.7: Driveshield Latch 4. Pull the top of driveshield (A) away from the header to open it. NOTE: For improved access, lift the driveshield off the pins at the base of the shield, and lay the shield on the header.
Page 37 OPERATION 1. Position the driveshield onto the pins, if necessary. 2. Push driveshield (A) to engage latch (B). 3. Ensure that the driveshield is properly secured. Figure 3.9: Left Driveshield 4. Replace tool (B) and lynch pin (A) onto pin (C). Figure 3.10: Left Driveshield 262391 Revision A...
Page 38: Cutterbar Doors
OPERATION 3.4 Cutterbar Doors Two doors with rubber curtains provide access to the cutterbar area. WARNING To reduce the risk of personal injury and machine damage, do NOT operate the machine installed and in good condition. Objects in the path of the blades can be ejected with considerable force when the machine is started. Curtains are attached to cutterbar doors (A), each front corner (B), and at center (C).
Page 39: Closing Cutterbar Doors
OPERATION 3.4.2 Closing Cutterbar Doors Do NOT operate the machine without closing the 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.
Page 40: Daily Start-Up Check
OPERATION 3.5 Daily Start-Up Check Perform this procedure before operating the machine. CAUTION • Ensure that the tractor and the header are properly attached, all controls are in neutral, and the tractor brakes are engaged. • Clear the area of bystanders, pets, etc. Keep children away from the machinery. Walk around the header confirm that no one is under, on, or close to it.
Page 41: Preparing Tractor For Rotary Disc Header
OPERATION 3.6 Preparing Tractor for Rotary Disc Header To attach the rotary disc header to a tractor, the tractor must meet the power and hydraulic requirements. 3.6.1 Tractor Requirements The tractor used to run the rotary disc header must meet the requirements outlined in the table. Table 3.1 Tractor Requirements Minimum Electrical...
Page 42: Attaching Rotary Disc Header To Tractor
The rotary disc header can be attached to the tractor with a 3-point hitch. 3.7.1 Connecting the Tractor to the Rotary Disc Header Connecting the header to the tractor involves connecting the hydraulic and electrical systems. The R1 FR Series can attach to 3-point hitch categories 2, 3, and 3N.
Page 43 OPERATION 6. Remove auxiliary lift lock straight pins (A) from holes in lift linkage on both sides of the header. Store the auxiliary lift lock straight pins, washers, and Lynch pins in storage location (B) on the left side of the carrier frame. Figure 3.16: Auxiliary Lift Lock Pins –...
Page 44 OPERATION Figure 3.17: Alignment with Header Carrier Frame 7. Adjust lower link arms (A) on the 3-point hitch until dimension (B) between the bottom of the carrier frame and the ground is 184 mm (7.25 in). NOTE: The lift assist cylinders must be lowered onto downstops (F) before aligning the carrier frame. 8.
Page 45 OPERATION 11. Locate pressure and return hoses (A): Pressure (yellow tie) Return (green tie) Figure 3.19: Hydraulic Control Hoses 12. Connect pressure hose (A) (yellow tie) and return hose (B) (green tie) to the tractor s front selective control valve. NOTE: Ensure the hoses are connected to the same remote set.
Page 46: Detaching Rotary Disc Header From Tractor
OPERATION 3.8 Detaching Rotary Disc Header from Tractor Detach the rotary disc header from the tractor for servicing or storing. 3.8.1 Disconnecting the Tractor from Rotary Disc Header The following procedure explains how to disconnect the tractor from the rotary disc header. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, stop the engine, remove the key and engage the lift cylinder stops before going under the machine for any reason.
Page 47 OPERATION 10. Disconnect pressure hose (A) (yellow tie) and return hose (B) (green tie) from the tractor s front selective control valve and store hoses on the header. IMPORTANT: Install caps and plugs on open hydraulic hoses and lines to prevent buildup of dirt and debris while in storage.
Page 48 OPERATION 15. Disconnect 3-point hitch (A) from carrier frame linkage (B). Ensure all clevis and hair pins are stored securely on the header frame. Figure 3.26: Tractor Alignment with Header Carrier Frame 262391 Revision A...
Page 49: Breaking In Rotary Disc Header
OPERATION 3.9 Breaking in Rotary Disc Header After attaching the rotary disc header to the tractor for the first time, operate the machine at low speed for 5 minutes while watching and listening FROM THE OPERATOR’S SEAT for binding or interfering parts. DANGER Before investigating an unusual sound or attempting to correct a problem, shut off the engine, engage the parking brake, and remove the key.
Page 50: Engaging Power Take-Off
OPERATION 3.10 Engaging Power Take-Off The power take-off transfers power from the tractor to the rotary disc header. DANGER Ensure that all bystanders are clear of the machine before engaging the power take-off (PTO). Never leave tractor seat with the PTO engaged. 1.
Page 51: Shutdown Procedure
OPERATION 3.11 Shutdown Procedure Follow all the safety procedure and operational instructions given in this manual and in your tractor operator s manual. DANGER Before leaving the tractor seat for any reason: • Disengage the power take-off. • Park on level ground if possible. •...
Page 52: Transporting Rotary Disc Header
OPERATION 3.12 Transporting Rotary Disc Header You can transport the rotary disc header using a tractor. CAUTION • Obey all highway traffic regulations in your area when transporting on public roads. Use flashing amber lights unless prohibited by law. • Be aware of roadside obstructions, oncoming traffic, and bridges. •...
Page 53: Operating Rotary Disc Header
OPERATION 3.13 Operating Rotary Disc Header Operating the rotary disc header properly, results in less crop lost and increased productivity during harvest. This includes making proper adjustments while operating the machine to suit various crops and harvest conditions. Regular maintenance and operating the machine safely and properly increases the machine s length of service.
Page 54 OPERATION Figure 3.27: R1 FR – Fully Raised Position When the 3-point hitch is fully raised, top link (A) moves to within 1 3 mm (1/32 1/8 in.) of upper proximity sensor (B) (inset); the hydraulic system extends auxiliary lift cylinders (C) to lift linkage (D). The header will raise to clear obstacles and windrows during field operation, and provide positioning options for maintenance, storage, or transport.
Page 55: Float
OPERATION 3.13.2 Float Float springs are normally set so a weight of approximately 43 47 kg (95 105 lb.) is required to lift either end of the rotary disc header. From the tractor s operator position, pointer (A) provides a visible indicator of the ground pressure communicated through rod (B).
Page 56 OPERATION 1. Raise the header fully. 2. Shut down the engine, and remove the key from the ignition. 3. Close the rotary disc header s auxiliary lift cylinder lock-out valve (A) on each lift cylinder by turning the handle to the horizontal position (90°...
Page 57 OPERATION Table 3.3 Float Setting Starting Point Conditioner Length of Exposed Thread Model Type R113 FR 120 130 mm (4 3/4 5 1/8 in.) Roll R116 FR 70 80 mm (2 3/4 3 1/8 in.) Roll 7. Reposition cover plate (A) over the float spring adjuster bolt as shown.
Page 58: Cutting Height
OPERATION 11. With the header on level ground in cutting position, calibrate float indicator (A) by loosening jam nut (B), and turning the adjustable rod until the needle is centered on the number 2 . Figure 3.36: Float Indicator – Left Side 3.13.3 Cutting Height The cutting height is determined by a combination of the cutterbar angle and the skid shoe settings.
Page 59 OPERATION 3. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition. d.
Page 60: Cutterbar Angle
OPERATION 3.13.4 Cutterbar Angle The cutterbar angle (sometimes called header angle) is the angle at which the cutterbar approaches the crop relative to the ground. It is one of the variables that impact the cutting height and quality. Cutterbar angle (A) adjustment ranges from 0° to 7° below the horizontal plane.
Page 61: Adjusting Cutterbar Angle Optional Hydraulic Center-Link
OPERATION Adjusting Cutterbar Angle – Optional Hydraulic Center-Link Cutterbar angle is one of the settings that affects cutting height. On machines equipped with the optional hydraulic center- link, you can adjust the cutterbar angle from the tractor cab. To adjust the cutterbar angle on a machine equipped with a hydraulic center-link, follow these steps: NOTE: The cutterbar angle can be adjusted from the tractor without shutting down the header.
Page 62: Cutterbar Deflectors
OPERATION Figure 3.41: Ground Speed for R113 and R116 Rotary Disc Headers A - Acres/Hour B - Hectares/Hour C - Kilometers/Hour D - Miles/Hour E - R116 FR F - R113 FR 3.13.6 Cutterbar Deflectors A two-piece cutterbar deflector is attached to the cutterbar just below the conditioner rolls. Deflectors provide improved feeding into the conditioner rolls and prevent long-stemmed crop from feeding under the rolls.
Page 63: Removing Cutterbar Deflectors
OPERATION Removing Cutterbar Deflectors When cutting a short-stemmed crop in normal field conditions, the cutterbar deflectors may not be necessary and can be removed. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 64: Installing Cutterbar Deflectors
OPERATION Installing Cutterbar Deflectors When cutting long-stemmed crops in certain field conditions, installing cutterbar deflectors is recommended. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. If the rotary disc header is raised, always close the lock-out valves, and place blocks under the header.
Page 65: Tall Crop Divider Option
OPERATION 3.13.7 Tall Crop Divider Option Tall crop dividers (one on each end of the header) help divide tall crops cleanly, and improve crop flow to the cutterbar. Tall crop dividers are not adjustable, but they are removable. Installing Tall Crop Divider Tall crop dividers can provide a cleaner cut in some crop conditions.
Page 66 OPERATION 3. Remove three bolts (A), and remove deflector (B). 4. Reinstall three bolts (A). 5. Repeat for opposite side. 6. Close cutterbar doors. For instructions, refer to 3.4.2 Closing Cutterbar Doors, page Figure 3.45: Deflector and Hardware 262391 Revision A...
Page 67: Roll Conditioner
OPERATION 3.14 Roll Conditioner Rolls condition the crop by crimping and crushing the stem in several places, allowing the release of moisture resulting in faster drying times. 3.14.1 Conditioner Roll Gap The roll gap is the distance between the two conditioner rolls. The roll gap controls the degree to which crop is conditioned as it passes through the rolls.
Page 68: 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. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 69: Roll Tension
OPERATION 3.14.2 Roll Tension Roll tension refers to the tension holding the rolls together. It is factory-set to maximum and should rarely require adjustment. Heavy crops or tough forage can, however, cause the rolls to separate. In such conditions, maximum roll tension is required to ensure that the cut crop is crimped sufficiently.
Page 70: Roll Timing
OPERATION 3.14.3 Roll Timing For proper conditioning, the rolls must be properly timed so that the bar on one roll is 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 71 OPERATION 3. Secure bottom roll (A). 4. Rotate upper roll (B) in a counterclockwise direction until it stops. 5. Make a mark (C) across yoke (D) and gearbox flange (E). Figure 3.51: Conditioner Drive 6. Secure bottom roll (A). 7. Rotate upper roll (B) in a clockwise direction until it stops. 8.
Page 72: Forming Shields Roll Conditioner
OPERATION 9. Determine center point (A) between the two marks on the yoke plate, and place a third mark. 10. Rotate upper roll (B) counterclockwise until the mark on the gearbox flange lines up with the third (center) mark. Figure 3.53: Conditioner Drive 11.
Page 73: Positioning Forming Shield Side Deflectors Roll Conditioner
OPERATION A wider windrow will generally dry faster and more evenly, resulting in less protein loss. Fast drying is especially important in areas where the weather allows only a few days to cut and bale. A narrower windrow may be preferable for ease of pick-up and when drying is not critical (for example, when cutting for silage or green feed).
Page 74 OPERATION 2. Remove lynch pin (A) securing rear baffle adjustment lever (B) to bracket (C). 3. Pull rear baffle adjustment lever (B) inboard to disengage it from bracket (C). 4. Position rear baffle adjustment lever (B) as follows: Move the lever forward to raise the baffle Move the lever backward to lower the baffle 5.
Page 75: Haying Tips
OPERATION 3.15 Haying Tips Follow the recommendations in this section to ensure the highest quality hay production. 3.15.1 Curing Curing crops quickly helps maintain the highest quality of crop material. Approximately 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.
Page 76: Driving On Windrow
OPERATION Table 3.6 Recommended Windrow Characteristics Advantage Characteristic Enables airflow through the windrow, which is more important to the curing High and fluffy process than direct sunlight Consistent formation (not bunching) Permits an even flow of material into the baler, chopper, etc. Results in even and consistent bales to minimize handling and Even distribution of material stacking problems...
Page 77: Unplugging Rotary Disc Header
OPERATION 3.16 Unplugging Rotary Disc Header The cutterbar and conditioner can get plugged with crop and may require unplugging. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 79: Chapter 4: Maintenance And Servicing
Chapter 4: Maintenance and Servicing This section provides information about routine servicing for the header. A parts catalog is located in a plastic case at the right end of the header. Log the machine s hours of operation and use the maintenance record provided (refer to 4.3.1 Maintenance Schedule/ Record, page 72) to keep track of maintenance procedures as they are performed.
Page 80 MAINTENANCE AND SERVICING Be aware that if more than one person is servicing the machine at the same time, rotating a driveline or other mechanically driven component by hand (for example, to access a lubrication fitting) will cause drive components in other areas (belts, pulleys, and discs) to move.
Page 81 MAINTENANCE AND SERVICING Use adequate light for the job at hand. Replace all shields removed or opened for service. Use only service and repair parts made or approved by the equipment manufacturer. Substituted parts may not meet strength, design, or safety requirements. Keep machinery clean.
Page 82: Preparing Machine For Servicing
MAINTENANCE AND SERVICING 4.2 Preparing Machine for Servicing Follow these steps to safely prepare your equipment for maintenance or repair. DANGER To avoid personal injury, perform the following procedures before servicing the header or opening the drive covers: 1. Disengage power take-off (PTO). 2.
Page 83: Maintenance Requirements
MAINTENANCE AND SERVICING 4.3 Maintenance Requirements Regular maintenance is the best insurance against early wear and untimely breakdowns. Following the maintenance schedule will increase your machine s service life. Periodic maintenance requirements are organized according to service intervals. IMPORTANT: The recommended intervals are based on typical operating conditions. Service the machine more often if the machine is operated regularly under adverse conditions, for example.
Page 84: 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 Refer to 4.3.2 Break-in Inspections, page First use Refer to 4.3.4 End-of-Season Servicing, page...
Page 85 MAINTENANCE AND SERVICING Every 25 Hours Check conditioner drive belt tension. ü Refer to Inspecting Conditioner Drive Belt, page 182. Lubricate idler pivot. Refer to 4.3.5 Lubrication, page Lubricate upper and lower driveline universal joints. Refer to 4.3.5 Lubrication, page Lubricate roller conditioner bearings.
Page 86: Break-In Inspections
MAINTENANCE AND SERVICING Check roll timing gearbox lubricant. Refer Checking and Changing Lubricant in ü Conditioner Roll Timing Gearbox, page 188. Check header drive gearbox lubricant. Checking and Adding Lubricant – ü Refer to Header Drive Gearbox , page 191. Every 250 Hours or Annually Change cutterbar lubricant.
Page 87: Preseason Servicing
MAINTENANCE AND SERVICING Table 4.1 Break-In Inspection Schedule (continued) Inspection Item Refer to Interval Change header drive gearbox Draining Lubricant – Header Drive Gearbox , page 192 Hours lubricant 4.4.3 Lubricating Cutterbar, page 92 Check cutterbar lubricant Hours Check and change conditioner roll Checking and Changing Lubricant in Conditioner Roll Timing timing gearbox lubricant Gearbox, page 188...
Page 88: Lubrication
MAINTENANCE AND SERVICING WARNING Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable. CAUTION Cover the cutterbar to prevent injury from accidental contact with the blades. 1. Position the rotary disc header at an appropriate height for the task. 2.
Page 89: Greasing Procedure
MAINTENANCE AND SERVICING Greasing points are marked on the machine by decals showing a grease gun and the grease interval, which is specified in hours of operation. Log the hours of machine operation. Use the maintenance schedule provided in this manual to keep a record of scheduled maintenance.
Page 90 MAINTENANCE AND SERVICING Every 25 Hours Regular maintenance is required to keep your machine operating at peak performance. 3x25 3x25 Figure 4.7: Grease Locations (Every 25 Hours) NOTE: Use high temperature extreme pressure (EP2) performance with 1% max. molybdenum disulphide (NLGI Grade 2) lithium base unless otherwise specified.
Page 91 MAINTENANCE AND SERVICING Every 50 Hours Regular maintenance is required to keep your machine operating at peak performance. NOTE: Use high temperature extreme pressure (EP2) performance with 1% max. molybdenum disulphide (NLGI grade 2) lithium base unless otherwise specified. Figure 4.8: Grease Locations (Every 50 Hours) 262391 Revision A...
Page 92 MAINTENANCE AND SERVICING Every 100 Hours Regular maintenance is required to keep your machine operating at peak performance. NOTE: Ensure the top of the header is horizontal, and verify oil levels. Figure 4.9: Lubrication Check (Every 100 Hours) A - Check Plug - Header Drive Gearbox B - Breather/Dipstick - Cutterbar/Conditioner Drive Gearbox 262391 Revision A...
Page 93 MAINTENANCE AND SERVICING Figure 4.10: Lubrication Check (Every 100 Hours) B - Breather - Conditioner Roll Timing Gearbox 8 A - Sight Glass - Conditioner Roll Timing Gearbox Refer to the inside back cover for lubricant specifications. 262391 Revision A...
Page 94 MAINTENANCE AND SERVICING Every 250 Hours Regular maintenance is required to keep your machine operating at peak performance. 1. Change lubricant in locations (A), (B), (C), and (D). Refer to the following sections for more information: 4.4.3 Lubricating Cutterbar, page Checking and Adding Lubricant –...
Page 95: Cutterbar System
MAINTENANCE AND SERVICING 4.4 Cutterbar System The cutterbar (A) comes in two cutting widths: 3.9 m (13 ft.) and 4.9 m (16 ft.). The 3.9 m (13 ft.) holds eight discs and the 4.9 m (16 ft.) holds ten discs that rotate to a maximum of 2500 rpm at full speed. Each disc carries two cutting blades. Figure 4.12: Cutterbar –...
Page 96: Maintaining Curtains
MAINTENANCE AND SERVICING 3. Inspect hinge pin bolts (A) and tighten them to 69 Nm (51 lbf·ft) if they are loose. 4. Check the door for cracks. Repair the door if any cracks are found. 5. Check the door for exposed metal and surface rust. Repair and repaint the door if necessary.
Page 97: Removing Cutterbar Door Curtains
MAINTENANCE AND SERVICING 1. Shut down the engine, and remove the key from the ignition. 2. Check cutterbar curtains (A) for the following conditions: Rips and tears. If any are found, replace the curtain. Cracking. While the curtain may look whole, this is an indicator that failure is imminent, and so the curtain should be replaced.
Page 98: Installing Cutterbar Door Curtains
MAINTENANCE AND SERVICING 5. Remove seven nuts (A) from the bolt studs. 6. Remove aluminum liner (B). 7. Remove curtain (C). Figure 4.16: Cutterbar Door Installing Cutterbar Door Curtains Be sure not to overtighten the nuts when installing the cutterbar door curtains. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 99: Removing Cutterbar Inboard Curtain
MAINTENANCE AND SERVICING 4. Insert seven cutterbar door stud bolts (B) into the precut holes on curtain (A). NOTE: R1 SP for windrowers shown in the illustration; R1 FR similar. 5. Install seven large washers (C). 6. Install liner panel (D) against the washers. 7.
Page 100: Installing Cutterbar Inboard Curtain
MAINTENANCE AND SERVICING 5. Remove two M10 carriage head bolts (A) and nuts securing curtain assembly (B) to the rotary disc header, and remove the curtain assembly. NOTE: R1 SP for windrowers shown in the illustration; R1 FR similar. Figure 4.18: Inboard Curtain 6.
Page 101: Removing Outboard Curtains
MAINTENANCE AND SERVICING 3. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition. d.
Page 102 MAINTENANCE AND SERVICING DANGER Ensure that all bystanders have cleared the area. WARNING Disc blades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with, or near, blades. 1. Position the rotary disc header at an appropriate height for the task. 2.
Page 103: Installing Outboard Curtains
MAINTENANCE AND SERVICING Installing Outboard Curtains The procedure for installing outboard curtains is the same for both sides of the machine. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 104: Lubricating Cutterbar
MAINTENANCE AND SERVICING 9. Install four bolts, large washers, and nuts (A) to secure outboard curtain (B) to the endsheet. Torque the bolts to 39 Nm (29 lbf·ft). NOTE: R1 SP for windrowers shown in the illustration; R1 FR similar. Figure 4.25: Left Endsheet 4.4.3 Lubricating Cutterbar Correct lubricant and levels are essential to the performance and longevity of the cutterbar.
Page 105 MAINTENANCE AND SERVICING 7. Use spirit level (A) to ensure that the cutterbar is level in both directions. Adjust the cutterbar position accordingly. Figure 4.26: Spirit Level on Cutterbar 8. Clean the area around plug (A). Place a 5 liter (5.2 US qts) capacity container under the plug.
Page 106: Draining Cutterbar
MAINTENANCE AND SERVICING 15. Recheck the oil level. 16. Check O-ring (B) for breaks or cracks, and replace it if necessary. 17. Install plug (A) and O-ring (B). 18. Close the cutterbar doors. For instructions, refer to 3.4.2 Closing Cutterbar Doors, page Figure 4.28: Cutterbar Oil Inspection Plug Draining Cutterbar In order to change the cutterbar lubricant, the cutterbar will first need to be drained.
Page 107: Filling Cutterbar With Lubricant
MAINTENANCE AND SERVICING 7. Place a 10 liter (10.5 US qts) capacity container under the lower end of the cutterbar. Clean the area around plug (A) and remove the plug. IMPORTANT: Do NOT remove hex head bolts (B) securing the cutterbar end plate to the cutterbar, or lubricant leaks may result.
Page 108 MAINTENANCE AND SERVICING IMPORTANT: The cutterbar should be completely empty of oil before filling it. For instructions, refer to Draining Cutterbar, page 1. Start the engine. 2. Raise the header fully. 3. Shut down the engine, and remove the key from the ignition. 4.
Page 109: Cutterbar Discs
MAINTENANCE AND SERVICING 4.4.4 Cutterbar Discs The cutterbar discs provide rotary cutting action. They may need to be replaced from time to time. Figure 4.31: Interchangeable Cutterbar Discs Cutterbar discs (A) are interchangeable and can be moved to a spindle that rotates in the opposite direction, so long as the disc is in usable condition and the blades are oriented to cut in the correct direction.
Page 110 MAINTENANCE AND SERVICING 3. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition. d.
Page 111: Removing Cutterbar Discs
MAINTENANCE AND SERVICING 6. Inspect cutterbar disc surface (D) for cracks, excessive wear, and check if the disc is distorted. Replace any damaged discs immediately. 7. Inspect cutterbar disc edges (E) for cracks, excessive wear, and check if the edge is distorted. Replace any damaged components immediately.
Page 112: Installing Cutterbar Discs
MAINTENANCE AND SERVICING 5. Place a pin (or equivalent) in front hole (B) of the rock guard to prevent the discs from rotating while you are loosening the bolts. 6. Remove four M12 bolts and washers (A). Figure 4.35: Cutterbar Disc Bolts 7.
Page 113 MAINTENANCE AND SERVICING 3. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition. d.
Page 114: Replacing Cutterbar Spindles
MAINTENANCE AND SERVICING 4.4.5 Replacing Cutterbar Spindles Cutterbar spindles allow for the rotation of the cutterbar discs. They have either right or left-handed threads, and are equipped with a shear pin. A shear pin (A) is installed on each disc in order to prevent damage to the cutterbar if the disc collides with an obstacle.
Page 115 MAINTENANCE AND SERVICING WARNING Disc blades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with, or near, blades. 1. Park the machine on a flat, level surface. 2. Open the cutterbar doors. For instructions, refer to 3.4.1 Opening Cutterbar Doors, page 3.
Page 116 MAINTENANCE AND SERVICING 7. Remove spacer plate (A). Figure 4.43: Spacer Plate 8. Rotate spindle hub (A) to access the nuts, and remove 11 M12 lock nuts and washers (B). Figure 4.44: Left Spindle Hub and Hardware 9. Remove spindle (A) from the cutterbar. Figure 4.45: Left Spindle 262391 Revision A...
Page 117: Installing Cutterbar Spindles
MAINTENANCE AND SERVICING Installing Cutterbar Spindles Ensure that the discs are timed correctly when installing the cutterbar spindles, or damage to the cutterbar may result. Figure 4.46: Underside of Cutterbar Spindles NOTE: Right discs (A) and left discs (B) are slightly offset as shown, depending on which idler gear the spindle is turning: Spindles that rotate clockwise have left-leading threading Spindles that rotate counterclockwise have right-leading threading IMPORTANT:...
Page 118 MAINTENANCE AND SERVICING NOTE: Remove the shield and retrieve disc timing tools (A) from the left rear side of the header. Figure 4.47: R1 Series Disc Timing Tool Location – Left Rear Side NOTE: Align disc timing tools (A) and (B) and secure them with M8 carriage head bolt (C), washer (D), and M8 flange hex nut (E).
Page 119 MAINTENANCE AND SERVICING Figure 4.49: Checking Timing with Disc Timing Tool – View from Above A - Disc Timing Tool B - Cutter Disc Cap C - Right Disc, Correct Timing D - Left Disc, Correct Timing DANGER Ensure that all bystanders have cleared the area. WARNING Disc blades have two sharp cutting edges that can cause serious injury.
Page 120 MAINTENANCE AND SERVICING 5. Choose a suitable spindle rotation pattern. For more information, refer to 4.4.5 Replacing Cutterbar Spindles, page 102. Figure 4.50: Cutterbars 6. Ensure that spindle O-ring (A) is properly seated, cleaned, and undamaged. Figure 4.51: Left Spindle O-Ring 7.
Page 121 MAINTENANCE AND SERVICING 8. Insert studs (A) into the spindle as shown. NOTE: The plugs are factory-installed as shown in position (B), but may loosen over time. Ensure that the studs are inserted into the proper location. IMPORTANT: Ensure that the clockwise spindles rotate clockwise and that the counterclockwise spindles (with machined grooves) rotate counterclockwise.
Page 122 MAINTENANCE AND SERVICING 10. Ensure that hub (A) is fully seated into the cutterbar before tightening nuts (B). 11. Rotate spindle hub (A) to access the studs, and install 11 M12 lock nuts (B) and washers. Figure 4.55: Left Spindle Hub 12.
Page 123: Reconfiguring Cutterbar Crop Stream
MAINTENANCE AND SERVICING 14. Place a pin (or equivalent) in front hole (D) of the rock guard to prevent the disc from rotating while you are tightening the bolts. IMPORTANT: The blades are oriented to cut in one direction or the other. Therefore, swap the entire disc when swapping spindles.
Page 124: Changing Eight Disc Cutterbar Crop Stream Configuration
MAINTENANCE AND SERVICING IMPORTANT: Spindles that rotate clockwise have right-leading threading and are identified by a smooth top on spindle gear shaft (A). Spindles that rotate counterclockwise have left-leading threading and are identified by machined grooves on spindle gear shaft (B) and nut (C). If the spindle position in the cutterbar has changed, the rotational direction of that spindle MUST remain the same (that is, a clockwise spindle must maintain its clockwise...
Page 125: Changing Ten Disc Cutterbar Crop Stream Configuration
MAINTENANCE AND SERVICING Changing Ten Disc Cutterbar Crop Stream Configuration Multiple crop stream settings are possible. Figure 4.62: Spindle Rotation Pattern and Crop Streams (10 Disc) A - One Crop Stream B - Three Crop Streams To change (10 disc) spindle rotation from one crop stream (A) to three crop streams (B), Swap disc/spindle (7) with disc/spindle (4) To change (10 disc) spindle rotation from three crop streams (B) to one crop stream (A), Swap disc/spindle (4) with disc/spindle (7)
Page 126: Maintaining Disc Blades
MAINTENANCE AND SERVICING 4.4.7 Maintaining Disc Blades Each disc has two blades attached at opposite ends that are free to rotate horizontally on a specially designed shoulder bolt. Each blade (A) has two cutting edges and can be flipped over so that the blade does not need replacing as often.
Page 127 MAINTENANCE AND SERVICING 1. Position the rotary disc header at an appropriate height for the task. 2. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition.
Page 128: Inspecting Disc Blade Hardware
MAINTENANCE AND SERVICING Figure 4.66: Clockwise Disc Rotation Inspecting Disc Blade Hardware Inspect the blade attachment hardware each time the blades are changed. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 129 MAINTENANCE AND SERVICING 2. When inspecting the blades, check each blade-attachment bolt and replace it if: The bolt has been removed and installed five times Head (A) is worn flush with the bearing surface of the blade Diameter (B) of the bolt neck is 3 mm (1/8 in.) or less The bolt is cracked (C) The bolt is visibly distorted (D) The bolt shows evidence of interference (E) with...
Page 130: Removing Disc Blades
MAINTENANCE AND SERVICING 3. Check the nuts holding the disc blades. Replace the nuts if: The nut has been previously installed; nuts are one-time-use items only. The nut shows signs of wear (A) such that the nut has lost more than half the original height (B) in one or more areas.
Page 131: Installing Disc Blades
MAINTENANCE AND SERVICING 4. Rotate disc (A) so blade (B) faces forward and lines up with hole (C) in the rock guard. Figure 4.69: Disc Blade Aligned with Hole in Rock Guard 5. Place a pin (or equivalent) in the front hole of the rock guard to prevent the disc from rotating while loosening blade bolts.
Page 132: Maintaining Quick Change Blade System Option
MAINTENANCE AND SERVICING IMPORTANT: If you are unsure in which direction the spindles rotate, refer to 4.4.6 Reconfiguring Cutterbar Crop Stream, page 111. 1. Position the rotary disc header at an appropriate height for the task. 2. Shut down the engine, and remove the key from the ignition. 3.
Page 133 MAINTENANCE AND SERVICING WARNING Disc blades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with, or near, blades. DANGER To avoid serious injuries or death due to insufficient thickness of material on the retaining bolts, check the thickness (A) of the retaining bolts every time a blade is changed.
Page 134 MAINTENANCE AND SERVICING 4. Remove hairpin clip (A). 5. Remove pin (B). 6. Remove change tool (C). Figure 4.73: Installing Quick Change Blade 7. Remove gauge (A) on change tool (B). NOTE: Section (C) of the gauge is used to check the material thickness of the retaining bolts;...
Page 135: Inspecting Quick Change Plates
MAINTENANCE AND SERVICING Inspecting Quick Change Plates Check the thickness of the retaining bolts and the quick change plate using the supplied gauge. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 136 MAINTENANCE AND SERVICING 7. Remove gauge (A) from change tool (B). NOTE: Section (C) of the gauge is used to check the material thickness of the retaining bolts; section (D) of the gauge is used to check the outer radius of the quick change plate. Figure 4.77: Change Tool and Gauge 8.
Page 137: Replacing Quick Change Blades
MAINTENANCE AND SERVICING Figure 4.80: Gauge and Change Plate Unaligned Replacing Quick Change Blades If the optional quick change blade kit is installed, replace blades as required. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 138 MAINTENANCE AND SERVICING 4. Remove hairpin clip (A). 5. Remove pin (B). 6. Remove blade change tool (C) from the storage location. 7. Open the cutterbar doors. For instructions, refer to 3.4.1 Opening Cutterbar Doors, page Figure 4.81: Blade Change Tool Storage Location 8.
Page 139 MAINTENANCE AND SERVICING 9. Pull down on blade change tool (A), separate disc (B) from quick change plate (C), and remove old blade (D) from blade bolt (E). Push blade change tool (A) upward to return quick change plate (C) to the closed position. 10.
Page 140: Accelerators
MAINTENANCE AND SERVICING 4.4.9 Accelerators Accelerators are mounted on each outboard disc and are designed to quickly move cut material off the disc and into the conditioner. A pair of accelerators (A) is installed on each disc which is topped with a drum: Two pairs of accelerators are installed on an 8 disc cutterbar (one pair on the outboard disc at each end of the cutterbar) Four pairs of accelerators are installed on a ten disc...
Page 141 MAINTENANCE AND SERVICING WARNING Disc blades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with, or near, blades. 1. Position the rotary disc header at an appropriate height for the task. 2.
Page 142: Removing Accelerators
MAINTENANCE AND SERVICING Removing Accelerators Accelerators need to be removed from cutterbar discs when they are damaged, or when they become worn out and can t effectively move crop from the discs to the conditioner. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 143: Installing Accelerators
MAINTENANCE AND SERVICING 6. Remove lock nut (A), accelerator (B), blade holder (C), and hex-socket bolt (D). 7. Repeat Steps 5, page 130 6, page 131 to remove the second accelerator. Figure 4.90: Accelerator Removal Installing Accelerators A new pair of accelerators should be installed on a cutterbar disc whenever the old ones are damaged or worn to the extent that they can no longer effectively move crop off the disc and into the conditioner.
Page 144 MAINTENANCE AND SERVICING 4. Place a wooden block between two cutterbar discs to prevent the discs from rotating while you are tightening the blade bolts. IMPORTANT: Accelerators are unidirectional: both clockwise and counterclockwise accelerators are used on the cutterbar. Verify the direction of the disc before installing any accelerators.
Page 145: Rock Guards
MAINTENANCE AND SERVICING 4.4.10 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 into contact with stones and other debris. Periodically inspect the rock guards for damage.
Page 146: Removing Inboard Rock Guards
MAINTENANCE AND SERVICING Removing Inboard Rock Guards Remove any damaged or worn rock guards to maximize the life of the cutting blades. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 147: Installing Inboard Rock Guards
MAINTENANCE AND SERVICING 5. Slide inboard rock guard (A) forward (in the direction of arrow [B]) and remove it. Figure 4.96: Inboard Rock Guards Installing Inboard Rock Guards Ensure that the nuts securing the rock guards are installed on top of the cutterbar when installing an inboard rock guard. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 148: Removing Outboard Rock Guards
MAINTENANCE AND SERVICING 4. Guide the inboard rock guard onto the cutterbar until tabs (A) sit on top of the cutterbar, and the bottom back bolt holes in the rock guard line up with the holes in the cutterbar. Figure 4.97: Inboard Rock Guards 5.
Page 149: Installing Outboard Rock Guards
MAINTENANCE AND SERVICING 3. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition. d.
Page 150 MAINTENANCE AND SERVICING WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 1. Position the rotary disc header at an appropriate height for the task. 2. Shut down the engine, and remove the key from the ignition. 3.
Page 151: Maintaining Small Drums Ten Disc Cutterbar
MAINTENANCE AND SERVICING 10. Ensure that rock guards (B) and (C) are parallel to one another. NOTE: A parallel gap (for example, gap [A]) of 5 7 mm (3/16 1/4 in.) between outboard (B) and inboard (C) rock guards is acceptable. You may need to loosen the next one or two rock guards to change the gap.
Page 152: Inspecting Small Drums Ten Disc Cutterbar
MAINTENANCE AND SERVICING Inspecting Small Drums – Ten Disc Cutterbar Inspect the drums daily for signs of damage or wear. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 153: Removing Small Driven Drum And Driveline Ten Disc Cutterbar
MAINTENANCE AND SERVICING 4. Open the cutterbar doors. For instructions, refer to 3.4.1 Opening Cutterbar Doors, page 5. Inspect small drums (B) and (C) for damage and wear. Replace the drums if they are worn at the center to 50% or less of their original thickness.
Page 154 MAINTENANCE AND SERVICING WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 1. Position the rotary disc header at an appropriate height for the task. 2. Shut down the engine, and remove the key from the ignition. 3.
Page 155 MAINTENANCE AND SERVICING 7. Remove four M10 hex flange head bolts (A), top plate (B), and drum top (C). Figure 4.110: Driveline Shield 8. Remove one 20 mm M10 hex flange head bolt (B), two 16 mm M10 hex flange head bolts (C), and vertical shield (A).
Page 156 MAINTENANCE AND SERVICING 10. Remove four M12 hex flange head bolts and spacers (A) securing driveline assembly (B) to hub drive (C). Figure 4.113: Hub Drive to Driveline Connection 11. Slide driveline (A) downwards, tilt it to the side, and pull the driveline up and out of drum.
Page 157: Installing Small Driven Drum And Driveline Ten Disc Cutterbar
MAINTENANCE AND SERVICING Installing Small Driven Drum and Driveline – Ten Disc Cutterbar The small driven drum is the second drum from the end on the left side of the cutterbar. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 158 MAINTENANCE AND SERVICING 6. Lubricate spindle splines (A). For specifications, refer to the inside back cover of this manual. NOTE: For clarity, the illustration shows a cutaway view of the drum and tube shield. 7. Insert driveline (B) at an angle and guide it past hub drive (C) and drum (D).
Page 159 MAINTENANCE AND SERVICING 11. 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.
Page 160: Removing Small Non-Driven Drum Ten Disc Cutterbar
MAINTENANCE AND SERVICING 13. Apply a bead of medium-strength threadlocker ® (Loctite 243 or equivalent) around the threads of M10 hex flange head bolt (B). Install bolt (B) through cover plate (A) and top plate (C). Torque the hardware to 61 Nm (45 lbf·ft). 14.
Page 161: Installing Small Non-Driven Drum Ten Disc Cutterbar
MAINTENANCE AND SERVICING DANGER Ensure that all bystanders have cleared the area. WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 1. Position the rotary disc header at an appropriate height for the task. 2.
Page 162 MAINTENANCE AND SERVICING WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 1. Position the rotary disc header at an appropriate height for the task. 2. Shut down the engine, and remove the key from the ignition. 3.
Page 163: Maintaining Large Drums
MAINTENANCE AND SERVICING 4.4.12 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 8 and 10 disc cutterbars. Figure 4.127: Cutterbars A - Eight Disc Cutterbar B - Ten Disc Cutterbar...
Page 164 MAINTENANCE AND SERVICING 3. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition. d.
Page 165: Removing Large Driven Drums And Driveline
MAINTENANCE AND SERVICING 11. Close the cutterbar doors. For instructions, refer to 3.4.2 Closing Cutterbar Doors, page Removing Large Driven Drums and Driveline The large driven drum is on the left end of the cutterbar. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 166 MAINTENANCE AND SERVICING 6. Remove two M10 hex flange head bolts (A) and remove cover plate (B). Figure 4.131: Cover Plate 7. Remove four M10 hex flange head bolts (A), and remove top plate (B) and drum top (C). Figure 4.132: Top Plate and Drum Top 8.
Page 167 MAINTENANCE AND SERVICING 9. Remove eight M8 hex flange head bolts (A), and remove two drum shields (B). Figure 4.134: Drum Shields 10. Remove four M12 hex flange head bolts and spacers (A) securing driveline assembly (B) to hub drive (C). Figure 4.135: Hub Drive to Driveline Connection 11.
Page 168: Installing Large Driven Drums And Driveline
MAINTENANCE AND SERVICING 12. Inside the drum, remove four M12 bolts and washers (A) holding the drum disc in place. 13. Remove the drum disc assembly. Figure 4.137: Driven Drum – 8 Disc 1026214 Figure 4.138: Driven Drum – 10 Disc Installing Large Driven Drums and Driveline The large driven drum is on the left end of the cutterbar.
Page 169 MAINTENANCE AND SERVICING 3. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition. d.
Page 170 MAINTENANCE AND SERVICING 7. 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 171 MAINTENANCE AND SERVICING 12. 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.
Page 172: Removing Large Non-Driven Drums
MAINTENANCE AND SERVICING 14. Apply a bead of medium-strength threadlocker ® (Loctite 243 or equivalent) around the threads of M10 hex flange head bolt (B). Install bolt (B) through cover plate (A) and top plate (C). Torque the hardware to 61 Nm (45 lbf·ft). 15.
Page 173 MAINTENANCE AND SERVICING DANGER Ensure that all bystanders have cleared the area. WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 1. Position the rotary disc header at an appropriate height for the task. 2.
Page 174: Installing Large Non-Driven Drums
MAINTENANCE AND SERVICING Installing Large Non-Driven Drums Ensure that the spacer is in place before installing the large non-driven drum. DANGER To prevent injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 175 MAINTENANCE AND SERVICING 5. Position non-driven drum/disc (B) onto the spindle as shown. 6. Install four M12 bolts and washers (A) to secure the drum and disc assembly to the spindle. Torque the hardware to 85 Nm (63 lbf·ft). Figure 4.151: Non-Driven Drum 7.
Page 176: Replacing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING 4.4.13 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. If the disc contacts a large object such as a stone or stump, pin (A) will shear and the disc will stop rotating and move upwards.
Page 177 MAINTENANCE AND SERVICING 3. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition. d.
Page 178 MAINTENANCE AND SERVICING 9. Remove the M12 bolt securing Safecut spindle-nut wrench (A) to its storage location. Remove the Safecut spindle-nut wrench. Figure 4.156: Safecut Spindle-Nut Wrench Location IMPORTANT: Spindles that rotate clockwise have right-leading threading and a smooth top on the spindle gear shaft (A). Spindles that rotate counterclockwise have left-leading threading and machined grooves on the spindle gear shaft (B) and nut (C).
Page 179: Installing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING 11. Use the Safecut spindle-nut wrench to remove nut (A). Figure 4.159: Cutterbar Spindle 12. Remove shear pins (B). IMPORTANT: Do NOT damage the pin bore on the pinion. 13. Remove hub (A). 14. Check the nut and the hub for damage. Replace them if necessary.
Page 180 MAINTENANCE AND SERVICING 3. If the rotary disc header is raised: Place blocks under each end, or just inside each end, of the cutterbar. b. Lower the rotary disc header onto the blocks. Shut down the engine, and remove the key from the ignition. d.
Page 181 MAINTENANCE AND SERVICING 8. Install nut (A). 9. Retrieve the Safecut spindle-nut wrench from the left shield plate. Figure 4.163: Cutterbar Spindle 10. Attach Safecut spindle-nut wrench (B) 90° (D) to torque wrench (A). IMPORTANT: The Safecut spindle-nut wrench MUST be used with a torque wrench.
Page 182 MAINTENANCE AND SERVICING 15. Install retaining ring (A). Figure 4.166: Cutterbar Spindle 16. Install the disc or drum. Refer to the relevant procedure: Install cutterbar disc (A). For instructions, refer to Installing Cutterbar Discs, page 100. Install driven drum (B). For instructions, refer to Installing Large Driven Drums and Driveline, page 156.
Page 183: Drive Systems
MAINTENANCE AND SERVICING 4.5 Drive Systems 4.5.1 Driveshields Driveshields protect people from rotating belts and drives. Removing Driveshields No additional tools are needed to remove the driveshields. WARNING To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured. NOTE: The illustrations shown in this procedure depict the left driveshield (A);...
Page 184: Installing Driveshields
MAINTENANCE AND SERVICING 2. Insert the flat end of tool (A) into latch (B) and turn it counterclockwise to unlock the latch. Figure 4.170: Tool to Unlock Driveshield and Latch 3. Pull the top of driveshield (A) away from the header and lift the driveshield off of the pins at the base of the shield.
Page 185: Replacing Driveshield Latch
MAINTENANCE AND SERVICING 1. Position driveshield (A) onto pins (B) at the base of the driveshield. NOTE: R1 SP for windrowers shown in the illustration; R1 FR similar. 2. Push the driveshield so that latch (C) is engaged. 3. Check that driveshield (A) is properly secured. Figure 4.172: Driveshield and Latch 4.
Page 186 MAINTENANCE AND SERVICING 1. Remove driveshield (A). For instructions, refer to Removing Driveshields, page 171. Figure 4.174: Left Driveshield 2. Remove and retain hex nut and flat washer (A) securing the latch to the backside of the driveshield. 3. Remove the latch and replace it with the new part. 4.
Page 187: Driveline Guards
MAINTENANCE AND SERVICING 4.5.2 Driveline Guards Removing Driveline Guards Driveline guards protect components from dirt and debris, and protect operators from moving components. Driveline guards need to be removed before drivelines can be serviced or removed. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 188: Installing Driveline Guards
MAINTENANCE AND SERVICING Installing Driveline Guards Driveline guards protect components from dirt and debris, and protect operators from moving components. Driveline guards must installed before operating the machine. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 189: Removing Primary Driveline
MAINTENANCE AND SERVICING Removing Primary Driveline The primary driveline transfers power from the tractor s power take-off (PTO) to the header drive gearbox. These instructions describe the procedure for removing the driveline. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 190: Installing Primary Driveline
MAINTENANCE AND SERVICING Installing Primary Driveline The primary driveline transfers power from the tractor s power take-off (PTO) to the header drive gearbox. These instructions describe the procedure for installing the driveline. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 191: Cross Driveline
MAINTENANCE AND SERVICING 4.5.4 Cross Driveline The cross driveline transfers power from the tractor s power take-off (PTO) to the cutterbar-conditioner drive gearbox (T-gearbox). Follow the regular lubrication schedule for cross driveline (A). For instructions, refer to 4.3.5 Lubrication, page Figure 4.183: Cross Driveline Removing Cross Driveline The cross driveline transfers power from the tractor s power take-off (PTO) to the cutterbar-conditioner drive gearbox...
Page 192: Installing Cross Driveline
MAINTENANCE AND SERVICING Figure 4.185: Cross Driveline 4. At the inboard end of cross driveline (A), pull back collar (B) while pulling driveline away from the splined shaft of the header drive gearbox. 5. At the outboard end of cross driveline (A), remove nuts (C) and bolts securing the driveline to the splined shaft of the cutterbar/conditioner drive gearbox.
Page 193 MAINTENANCE AND SERVICING Figure 4.186: Cross Driveline 2. At the outboard end of cross driveline (A), install the driveline onto the splined shaft of the cutterbar/conditioner drive gearbox. 3. Secure the driveline to the splined shaft with existing nuts and bolts (C) configured as shown in 4.186, page 181.
Page 194: Conditioner Drive Belt
MAINTENANCE AND SERVICING 4.5.5 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. Inspecting Conditioner Drive Belt The belt tension must be checked and inspected for damage or wear according to the intervals specified. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 195: Removing Conditioner Drive Belt
MAINTENANCE AND SERVICING 6. Measure the length of tensioner spring (A). Spring length (B) should be 366 mm (14 3/8 in.) in accordance with spring tension decal (B). If the spring length requires adjustment, refer to Installing Conditioner Drive Belt, page 184.
Page 196: Installing Conditioner Drive Belt
MAINTENANCE AND SERVICING 4. Turn jam nut (A) counterclockwise to unlock tension adjustment. 5. Turn jam nut (A) and adjuster nut (B) counterclockwise to fully collapse tensioner spring (C) and release the tension from conditioner drive belt (D). 6. Remove drive belt (D). Figure 4.191: Conditioner Drive Installing Conditioner Drive Belt DANGER...
Page 197 MAINTENANCE AND SERVICING 4. Install drive belt (A) onto driven pulley (C), and then onto drive pulley (B). Ensure the belt is in the pulley grooves. NOTE: If it is necessary, loosen the jam nut and adjuster nut (D) to relieve spring tension.
Page 198: Conditioner System
The conditioner system is intended to crimp and crush crop stems, helping the crop to dry faster. The conditioner system is attached to the rear of the header. Figure 4.194: R1 FR Series Rotary Disc A — Roll Conditioner System Inspecting Roll Conditioner The conditioner bearings, U-joints, and roll timing gearbox should be inspected periodically for signs of wear or damage.
Page 199 MAINTENANCE AND SERVICING 4. Inspect conditioner roll left bearing (A) for signs of wear or damage. If the bearing needs replacing, contact your Dealer. Figure 4.195: Conditioner Roll Left Bearing 5. Inspect conditioner drive U-joints (A) for signs of wear or damage.
Page 200: Conditioner Roll Timing Gearbox
MAINTENANCE AND SERVICING 4.5.7 Conditioner Roll Timing Gearbox The conditioner roll timing gearbox transfers power from the gearbox-driven lower roll to the upper roll. Conditioner roll timing gearbox (A) is located inside the drive compartment at the right of the header. Figure 4.198: Conditioner Roll Timing Gearbox Checking and Changing Lubricant in Conditioner Roll Timing Gearbox The lubricant in the conditioner roll timing gearbox must be serviced regularly to ensure performance.
Page 201 MAINTENANCE AND SERVICING 4. Open right driveshield (A). For instructions, refer to 3.3.1 Opening Driveshields, page Figure 4.199: Right Driveshield Checking the conditioner roll timing gearbox lubricant level: 5. Clean any dirt from around lubricant level sight glass (A) and breather (B) on the inboard side of the gearbox. 6.
Page 202: Header Drive Gearbox
The header drive gearbox (A) is located in the center of the machine and receives power from the tractor s PTO via the primary driveline. NOTE: If the gearbox requires repair, contact your MacDon dealer. For service intervals, refer to 4.3.1 Maintenance Schedule/ Record, page Figure 4.202: Header Drive Gearbox...
Page 203: Checking And Adding Lubricant Header Drive Gearbox
MAINTENANCE AND SERVICING Checking and Adding Lubricant – Header Drive Gearbox The header drive gearbox will need lubricant checks according to the Maintenance Schedule. Follow this procedure for checking and added lubricant. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 204: Draining Lubricant Header Drive Gearbox
MAINTENANCE AND SERVICING 9. Clean around breather port (A) on the top facing side of the gearbox. 10. Use a 22 mm socket to remove the breather (A) and add lubricant into the breather port. NOTE: Refer to the inside back cover for lubrication specifications. 11.
Page 205: Cutterbar / Conditioner Drive Gearbox
NOTE: If the gearbox requires repair, contact your MacDon dealer. For service intervals, refer to 4.3.1 Maintenance Schedule/ Record, page Figure 4.206: Left Drive Compartment...
Page 206: Draining Lubricant From Cutterbar Conditioner Drive Gearbox (T-Gearbox)
MAINTENANCE AND SERVICING 2. Shut down the engine, and remove the key from the ignition. 3. Open the left driveshield. For instructions, refer to 3.3.1 Opening Driveshields, page 4. Clean the area around dipstick (A). 5. Remove dipstick using a 22 mm socket. 6.
Page 207 MAINTENANCE AND SERVICING 5. Remove two M10 hex flange head bolts (A) and cover plate (B). Figure 4.209: Cover Plate 6. Remove four M10 hex flange head bolts (A), top plate (B), and drum top (C). Figure 4.210: Top Plate and Drum Top 7.
Page 208 MAINTENANCE AND SERVICING 8. Place a 2 liter (2.11 qts [US]) container under drain plug (A). Remove the plug using a 17 mm socket. 9. Let the lubricant drain, replace drain plug (A), then tighten it. 10. Properly dispose of the used oil. Figure 4.212: Drain Plug 11.
Page 209 MAINTENANCE AND SERVICING 13. Install top M10 hex flange head bolt (B) through cover plate (A) and top plate (C). 14. Install lower M10 hex flange head bolt (D) through cover plate (A) and vertical shield (E). 15. Tighten bolts (B) and (D). Figure 4.215: Cover Plate and Vertical Drive Shield 16.
Page 210: Hydraulics
4.6.2 Hydraulic Cylinders The hydraulic cylinders do not require routine maintenance or service. Occasionally visually inspect cylinders for signs of leaks or damage. If repairs are required, remove them and have them serviced by your MacDon Dealer. 262391 Revision A...
Page 211: Electrical System
MAINTENANCE AND SERVICING 4.7 Electrical System The R1 FR's electrical system is powered by the tractor. The electrical harness from the header connects to the tractor and supplies power to the position lights and the header lift assist system. 4.7.1 Maintaining Electrical System Proper maintenance of the electrical system helps prevent future problems.
Page 212 MAINTENANCE AND SERVICING DANGER Ensure that all bystanders have cleared the area. 1. Remove auxiliary lift lock straight pins (A) from holes in lift linkage on both sides of the header. Store the auxiliary lift lock straight pins, washers, and Lynch pins in storage location (B) on the left side of the carrier frame.
Page 213: Setting Relay Logic Switch
MAINTENANCE AND SERVICING 5. Ensure that upper proximity sensor (B) (inset) is within 1 3 mm (1/32 1/8 in.) of top link (A) when the 3-point hitch is fully raised. NOTE: Auxiliary lift cylinders (C) should be fully extended and to assist the 3 point hitch by lifting the header with lift linkage (D).
Page 215: Chapter 5: Options And Attachments
5.1 Performance Kits Performance kits allow your machine to cut different types of crop in different conditions. The following kits are available through your MacDon Dealer. The Dealer will require the bundle number for pricing and availability. 5.1.1 Tall Crop Divider Kit Tall crop dividers attach to the ends of the machine for clean crop dividing and cutterbar entry in tall crops.
Page 216: Quick Change Blade Kit
OPTIONS AND ATTACHMENTS 5.1.3 Quick Change Blade Kit The Quick Change Blade kit allows you to change blades quickly using a blade change tool that separates the disc assembly. Kits include all hardware and installation instructions. Available for factory-configured machines with quick-change-ready discs. 10 Disc Kit B6699 8 Disc Kit B6700 Figure 5.3: Quick Change Blade Kit...
Page 217: Replacement Conditioners
OPTIONS AND ATTACHMENTS 5.2 Replacement Conditioners The following kits are available through your MacDon Dealer. The Dealer will require the bundle number for pricing and availability. 5.2.1 Steel Intermeshing Roller Steel conditioner rolls are suited to a wide range of crops (including alfalfa and thicker-stemmed cane-type crops).
Page 219: Chapter 6: Troubleshooting
Chapter 6: Troubleshooting Refer to this table if problems are encountered while operating the machine. 6.1 Troubleshooting Rotary Disc Header Performance A list of solutions are presented here on how to troubleshoot your rotary header performance. Problem Solution Refer to Symptom: Cutterbar plugging Dull, bent, or badly Replace blades.
Page 220 TROUBLESHOOTING Problem Solution Refer to Decrease rotary disc header angle to raise Cutting height too low 3.13.4 Cutterbar Angle, page 48 cutting height. 3.13.1 Raising and Lowering Rotary Disc Backing into windrow Raise rotary disc header before backing up. Header, page 41 Rolls improperly timed Adjust roll timing.
Page 221: Troubleshooting Mechanical Issues
TROUBLESHOOTING 6.2 Troubleshooting Mechanical Issues A list of solutions are presented here on how to troubleshoot your rotary disc header mechanical issues. Problem Solution Refer to Symptom: Excessive noise 4.4.7 Maintaining Disc Blades, page Replace blade. Bent disc blade Check roll timing, and adjust if Conditioner roll timing off 3.14.3 Roll Timing, page 58 necessary.
Page 222 Adjust the header position sensors. Sensors, page 199 Header position sensor(s) damaged Replace damaged sensors. Contact your MacDon dealer. Relay logic switch is set to OFF or 4.7.4 Setting Relay Logic Switch, page Set relay logic switch to AUTO. MANUAL.
Page 223: Chapter 7: Reference
Chapter 7: Reference The reference chapter provides additional information such as torque specifications and a unit conversion chart. 7.1 Torque Specifications The following tables provide torque values for various bolts, cap screws, and hydraulic fittings. Refer to these values only when no other torque value has been specified in a given procedure.
Page 224 REFERENCE Table 7.2 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) Nominal Size (A) Max. Max. Min. Min. 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 12-1.75 Figure 7.2: Bolt Grades 14-2.0 16-2.0 20-2.5...
Page 225: Metric Bolt Specifications Cast Aluminum
REFERENCE Table 7.4 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) Nominal Size (A) Max. Max. Min. Min. 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 12-1.75 14-2.0 Figure 7.4: Bolt Grades 16-2.0 20-2.5 24-3.0...
Page 226: O-Ring Boss Hydraulic Fittings Adjustable
REFERENCE 7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable The standard torque values are provided for adjustable hydraulic fittings. If a procedure specifies a different torque value for the same type and size of fitting found in this topic, refer to the value specified in the procedure instead. 1.
Page 227: O-Ring Boss Hydraulic Fittings Non-Adjustable
REFERENCE Table 7.6 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable and Non-Adjustable Torque Value Thread Size (in.) SAE Dash Size lbf·ft (*lbf·in) 5/16 24 10 11 *89 97 3/8 24 18 20 *159 177 7/16 20 29 32 21 24 1/2 20 32 35 24 26...
Page 228: O-Ring Face Seal Hydraulic Fittings
REFERENCE Table 7.7 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable and Non-Adjustable (continued) Torque Value Thread Size (in.) SAE Dash Size lbf·ft (*lbf·in) 9/16 18 40 44 30 32 3/4 16 70 77 52 57 7/8 14 115 127 85 94 1 1/16 12 183 201 135 148...
Page 229: Tapered Pipe Thread Fittings
REFERENCE 2. Apply hydraulic system oil to O-ring (B). 3. Align the tube or hose assembly so that the flat face of sleeve (A) or (C) comes into full contact with O-ring (B). 4. Thread tube or hose nut (D) until it is hand-tight. The nut should turn freely until it bottoms out.
Page 230 REFERENCE 4. Torque the connector to the appropriate torque angle. The turns from finger tight (TFFT) and flats from finger tight (FFFT) values are shown in Table 7.9, page 218. Ensure that the tube end of a shaped connector (typically a 45° or 90° elbow) is aligned to receive the incoming tube or hose assembly.
Page 231: Conversion Chart
REFERENCE 7.2 Conversion Chart This manual uses both SI units (including metric) and US customary units (sometimes referred to as standard units) of measurement. A list of those units along with their abbreviations and conversion factors is provided here for your reference.
Page 233: Index
Index removing door curtains ........85 removing inboard curtains ........87 accelerators removing outboard curtains........89 inspecting ............128 cutterbar installing............131 unplugging............65 maintaining............128 cutterbar discs ............97 removing ............130 cutterbars ........83, 97, 128, 133, 164 attachments, See options and attachments See also accelerators auxiliary lift cylinders...
Page 234 INDEX decals..............9 installing non-driven drums ......149 definitions............. 13 maintaining ..........139 deflectors removing driven drum and driveline....141 cutterbar deflectors..........50 removing non-driven drum......148 installing ............52 drying agents............64 removing............51 side deflectors positioning on roll conditioner ......61 disc blades ............
Page 235 INDEX hydraulic cylinders..........198 end-of-season servicing........75 hydraulics maintenance records ........... 72 fittings maintenance requirements ........71 O-ring boss adjustable........214 preparing for servicing ......... 70 O-ring boss non-adjustable ......215 preseason/annual servicing........75 O-ring face seal ..........216 recommended lubricants........225 tapered pipe thread fittings ......
Page 236 INDEX steel rolls............56 detaching rotary disc header ......... 34 roll tension ............57 setting up tractor adjusting ............57 tractor requirements ........29 roll timing ............. 58 setup ..............29 adjusting ............58 transporting ............40 roll-type conditioning, See conditioners lighting..............
Page 237: 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. Overfilling could result in overheating and failure of cutterbar components.
Page 238 CUSTOMERS M M a a c c D D o o n n . . c c o o m m DEALERS P P o o r r t t a a l l . . M M a a c c D D o o n n . . c c o o m m Trademarks of products are the marks of their respective manufacturers and/or distributors.

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MacDon R1 FR Series Operator's Manual

Chapter 1: Safety

Chapter 2: Product Overview

Chapter 3: Operation

Chapter 4: Maintenance and Servicing

Chapter 5: Options and Attachments

Chapter 6: Troubleshooting

Chapter 7: Reference

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Troubleshooting

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Summary of Contents for MacDon R1 FR Series

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