Page 1 R113 Rotary Disc Header Operator s Manual 262705 Revision A Original Instruction The Harvesting Specialists.
Page 2 The A-weighted sound pressure level inside the Operator s station (e.g., a MacDon M1170 Windrower), when operated in conjunction with this R113 Rotary Disc Header, is 70 dBA. This measurement was taken in accordance with ISO 5131. The sound pressure level depends on the rotary disc speed, crop conditions, and the exact type of self-propelled vehicle used to...
Page 3 Declaration of Conformity 262705 Revision A...
Page 4 262705 Revision A...
Page 5 262705 Revision A...
Page 6 Your machine The rotary disc header, when attached to a MacDon windrower, is designed to cut, condition, and lay a wide variety of grasses and hay crops in windrows. The following is a list of windrowers which are compatible with the rotary disc header:...
Page 7 Store the operator s manual and the parts catalog in plastic manual case (A) at the right side of the rotary disc header. NOTE: Keep your MacDon publications up-to-date. The most current version can be downloaded from our website www.macdon.com or from our Dealer-only site (https://portal.macdon.com) (login required).
Page 8: Summary Of Changes
Summary of Changes At MacDon, we re continuously making improvements. Occasionally, these improvements impact product documentation. The following list provides an account of major changes from the previous version of this document. Summary of Change Internal Use Only Section Updated for M2 Series Windrowers.
Page 9: Model And Serial Number
Model and Serial Number The serial number identifies the header and it is required if you request technical assistance. Record the serial number and model year of the header in the spaces below. Serial number: Model year: Serial number plate (A) is located near the base of the right hazard/signal light on the right side of the rotary disc header.
Page 11: Table Of Contents
TABLE OF CONTENTS Declaration of Conformity ..........................i Introduction .............................. iv Summary of Changes........................... vi Model and Serial Number ........................... vii Chapter 1: Safety ............................1 1.1 Safety Alert Symbols ..........................1 1.2 Signal Words ............................2 1.3 General Safety ............................3 1.4 Maintenance Safety ..........................5 1.5 Hydraulic Safety .............................7 1.6 Welding Precautions ..........................8 1.7 Decommissioning and Disposing of Agricultural Equipment................9...
Page 12 TABLE OF CONTENTS 3.5 Detaching Header from Windrower ......................90 3.5.1 Detaching Header from M2 Series Windrower .................. 90 3.5.2 Detaching Header from M1 Series Windrower .................. 97 3.5.3 Detaching Header from M155 or M155E4 Self-Propelled Windrower ..........103 3.5.4 Detaching Header from M205 Self-Propelled Windrower ..............106 Disconnecting Header Hydraulics M205 Self-Propelled Windrower with Quick Couplers .....
Page 13 TABLE OF CONTENTS 3.13 Transporting Header ......................... 139 Chapter 4: Maintenance and Servicing....................141 4.1 Preparing Machine for Servicing......................141 4.2 Recommended Safety Procedures ......................142 4.3 Maintenance Requirements ......................... 144 4.3.1 Maintenance Schedule/Record ..................... 144 4.3.2 Break-in Inspections ........................146 4.3.3 Preseason Servicing........................
Page 14 TABLE OF CONTENTS 4.5.8 Replacing Cutterbar Spindle Shear Pin ................... 200 Removing Cutterbar Spindle Shear Pin..................201 Installing Cutterbar Spindle Shear Pin ................... 204 4.6 Conditioner Roll Timing Gearbox ......................207 4.6.1 Checking and Changing Lubricant in Conditioner Roll Timing Gearbox ..........207 4.7 Servicing Header Drive Gearbox ......................
Page 15 5.1.4 Steel Roll Conditioner Kit......................245 5.1.5 Updated Blades Kit........................246 5.2 Hydraulic Drive Conversion Kits......................247 5.2.1 R113 SP to M1/M2/M205 Hydraulic Drive Kit.................. 247 5.2.2 M1240/M2260 Case Drain Kit ...................... 247 5.2.3 M155 and M155E4 Hydraulic Drive Conversion Kit................248 5.2.4 M205 Compatibility Kit .......................
Page 17: 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 18: 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 19: 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 20 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 21: Maintenance Safety
SAFETY 1.4 Maintenance Safety Maintaining your equipment safely requires that you follow the relevant safety procedures and wear the appropriate personal protective equipment for the task. To ensure your safety while maintaining the machine: Review the operator s manual and all safety items before operating or performing maintenance on the machine.
Page 22 SAFETY Wear protective gear when working on the machine. Wear heavy gloves when working on knife components. Figure 1.10: Personal Protective Equipment 262705 Revision A...
Page 23: Hydraulic Safety
SAFETY 1.5 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 24: Welding Precautions
SAFETY 1.6 Welding Precautions To prevent damage to sensitive electronics, NEVER attempt welding on the header while it is connected to a windrower. WARNING NEVER attempt welding on the header while it is connected to a windrower. Severe damage to sensitive, expensive electronics can result from welding on the header while it is connected to a windrower.
Page 25: Decommissioning And Disposing Of Agricultural Equipment
SAFETY 1.7 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 26 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 27: Safety Signs
SAFETY 1.8 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 28: Safety Sign Locations
SAFETY 1.9 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 1.17: Safety Sign Decal Locations A - MD #194466 B - MD #247167 C - MD #194465 D - MD #166466 E - MD #113482...
Page 29 SAFETY Figure 1.19: 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) 262705 Revision A...
Page 30: Understanding Safety Signs
SAFETY 1.10 Understanding Safety Signs Safety sign decals use illustrations to convey important safety or equipment maintenance information. MD #113482 General hazard pertaining to machine operation and servicing DANGER To prevent injury or death from improper or unsafe machine operation: Read the operator s manual and follow all safety instructions.
Page 31 SAFETY MD #166832 High-pressure hydraulic fluid hazard WARNING To prevent serious injury, gangrene, or death: Hydraulic fluid from a leak can easily puncture skin and can cause serious injury, gangrene, or death. Do NOT go near hydraulic leaks. Do NOT use your body to check for hydraulic leaks. Before loosening any hydraulic fittings, relieve the pressure in the hydraulic system.
Page 32 SAFETY MD #190546 Slipping hazard WARNING To prevent injury or death: Do NOT use this area as a step or platform. Figure 1.25: MD #190546 MD #194465 Blade cutting hazard WARNING To prevent injury from sharp cutting blades: Do NOT operate the machine without the shields in place. Stand clear of the header while the machine is running.
Page 33 SAFETY MD #246956 Driveline entanglement hazard DANGER To prevent injury: Shut down the engine, and remove the key from the ignition before opening the shield. Do NOT operate the machine without the shields in place. Figure 1.28: MD #246956 MD #246959 Pinch point hazard CAUTION To prevent injury:...
Page 34 SAFETY MD #304865 Header crushing hazard WARNING To prevent injury or death from the fall of a raised header: Do NOT lift the header at the marked locations. Only use locations marked for lifting to lower the header from the vertical to the horizontal position. Figure 1.31: MD #304865 262705 Revision A...
Page 35: Chapter 2: Product Overview
Weight: base machine, adapter frame, and steel roll 1850 kg (4079 lb.) conditioner Weight: base machine, adapter frame, and polyurethane roll 1868 kg (4118 lb.) conditioner MacDon M155, M155E4, M205, M1170, Compatible windrowers M1240, M2170, and M2260 Lighting Left and right turn signals Manual storage...
Page 36 PRODUCT OVERVIEW Hay Conditioner Options Optional Steel rolls Roll type Steel on steel chevron conditioner rolls Roll length 3275 mm (129 in.) 229 mm (9.0 in.) / 179 mm (7.0 in.) OD Roll diameter tube 1009 rpm Roll speed Polyurethane rolls Optional Polyurethane intermeshing conditioner Roll type...
Page 37: Component Identification
PRODUCT OVERVIEW 2.2 Component Identification Operating and maintaining the header requires understanding the names of its parts and their locations. Figure 2.1: R113 Rotary Disc Header A - Front Curtains B - Cutterbar Doors C - Drive Shield (Left) D - Hose Support 2...
Page 38 PRODUCT OVERVIEW Figure 2.2: R113 Rotary Disc Header A - Header Supports B - Side Deflectors C - Side Deflector Adjuster Handles D - Rear Crop Baffle E - Adapter Frame F - Drive Shield 262705 Revision A...
Page 39: Definitions
A tool of hexagonal cross-section used to drive bolts and screws that have a hexagonal Hex key socket in the head (internal-wrenching hexagon drive); also known as an Allen key MacDon M100, M105, M150, M155, M155E4, M200, and M205 Windrowers M Series Windrowers MacDon M1170, M1170 NT, M1170 NT5, and M1240 Windrowers...
Page 40 PRODUCT OVERVIEW Table 2.1 Definitions (continued) Term Definition The relationship between the assembly torque applied to a piece of hardware and the Torque-tension axial load it induces in a bolt or screw A thin cylinder with a hole or a slot located in the center, used as a spacer, a load Washer distribution element, or a locking mechanism The power unit for a header...
Page 41: Chapter 3: Operation
Chapter 3: Operation Safely operating your machine requires familiarizing yourself with its capabilities. 3.1 Break-In Period A brand-new machine must be operated gently when it is run for the first time. After attaching the header to the windrower for the first time, operate the machine slowly for five minutes, watching and listening from the operator s seat for binding or interfering parts.
Page 42: Daily Start-Up Check
OPERATION 3.2 Daily Start-Up Check Perform this procedure before operating the machine. CAUTION • Ensure that the windrower and the header are properly attached, that all controls are in neutral, and that the windrower brakes are engaged. • Clear the area of bystanders. Walk around the header to confirm that no one is nearby. •...
Page 43: Engaging And Disengaging Header Safety Props
OPERATION 3.3 Engaging and Disengaging Header Safety Props The safety props are located on both header lift cylinders on the windrower. Refer to the relevant procedure for your windrower: 3.3.1 Engaging and Disengaging Header Safety Props – M1 Series For M1 Series and M2 Series Windrowers, refer to and M2 Series Windrower, page 3.3.2 Engaging and Disengaging Header Safety Props –...
Page 44 OPERATION 4. Engage the safety props on both lift cylinders as follows: Pull lever (A) toward you to release it, then rotate it toward the header to lower the safety prop onto the cylinder. b. Repeat the previous step for the opposite lift cylinder. IMPORTANT: Ensure that the safety props engage over the cylinder piston rods.
Page 45 OPERATION 1. Start the engine. 2. Press HEADER UP switch (A) to raise the header to its maximum height. 3. Rephase the cylinders if one end of the header does not rise fully: Press and hold HEADER UP switch (A) until both cylinders stop moving.
Page 46 OPERATION 5. To disengage the safety props on the lift cylinders: Turn lever (A) away from the header to raise the safety prop until the lever locks into the vertical position. b. Repeat the previous step for the opposite cylinder. 6.
Page 47: Attaching Header To Windrower
The windrower s lift linkage and center-link will need to be connected to the header. IMPORTANT: The R113 Rotary Disc Header is compatible with an M2170 or M2260 Windrower, but NOT an M2170 NT Windrower. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the...
Page 48 OPERATION Figure 3.8: Float Removal 4. Remove the float as follows: ™ If the HarvestTouch Display shows the message Resume Float? , then select NO (A). ™ If the HarvestTouch Display does NOT show the message, then select FLOAT ADJUST (B), select switch (C), and confirm the switch and float settings (D) are grayed out.
Page 49 OPERATION 5. Prepare the center-link as follows: If not equipped with the Center-Link Alignment kit: Relocate pin (A) in the frame linkage as needed to raise center-link (B) until the hook is above the attachment pin on the header. If equipped with the Center-Link Alignment kit: Press REEL UP switch (D) on the ground speed lever (GSL) to raise the center-link until the hook is above the attachment pin on the header.
Page 50 OPERATION 9. Windrowers equipped with the Center-Link Alignment kit: Press HEADER TILT UP (A) or HEADER TILT DOWN (B) switches on the GSL to extend or retract the center-link cylinder until hook (C) is aligned with the header attachment pin. b.
Page 51 OPERATION 11. Press HEADER UP switch (A) to raise the header to its maximum height. NOTE: If one end of the header does NOT fully rise, rephase the lift cylinders as follows: Press and hold HEADER UP switch (A) until both cylinders stop moving.
Page 52 OPERATION 15. Disengage the safety props on both lift cylinders as follows: Turn lever (A) away from the header to raise the safety prop until the lever locks into the vertical position. b. Repeat the previous step for the opposite cylinder. NOTE: If the safety prop will NOT disengage, raise the header to release the prop.
Page 53 OPERATION Figure 3.19: Float Adjustment 18. Select switch (A), so that it turns green, to activate the float. 19. If the float is not already set up, set the float as follows: The float preset, which is selected using the operator s console, is displayed at location (B). Confirm if the desired preset is selected.
Page 54: Attaching Header To M1 Series Windrower
The procedure for attaching the header to an M1 Series Windrower varies depending on whether or not the self-aligning center-link is installed. IMPORTANT: The R113 Rotary Disc Header is compatible with the M1170 and M1240 Windrowers, but NOT the M1170 NT and M1170 NT5 Windrowers. 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 for any reason.
Page 55 OPERATION 4. Remove hairpin (A) from clevis pin (B) from header support (C) on both sides of the header. Figure 3.22: Header Support 5. If you are lowering the header lift legs with a header or weight box attached, proceed to Step 9, page If you are lowering the header lift legs without a header or weight box attached, fully release the tension in float...
Page 56 OPERATION 8. Press soft key 3 (A) to remove the header float. NOTE: If the header float is active, the icon at soft key 3 will display REMOVE FLOAT; if the header float has been removed, then the icon will display RESUME FLOAT. Figure 3.25: HPT Display 9.
Page 57 OPERATION 13. Windrowers equipped with the Center-Link Alignment kit: Adjust the position of center-link cylinder (A) with the switches on the GSL until hook (B) is above the header attachment pin. IMPORTANT: Hook release (C) must be down to enable the self- locking mechanism to function.
Page 58 OPERATION 15. Press HEADER UP switch (A) to fully raise the header. NOTE: If one end of the header does NOT fully raise, rephase the lift cylinders as follows: Press and hold HEADER UP switch (A) until both cylinders stop moving. b.
Page 59 OPERATION 19. Disengage the safety props on both lift cylinders as follows: Turn lever (A) away from the header to raise the safety prop until the lever locks into the vertical position. b. Repeat the previous step for the opposite cylinder. NOTE: If the safety prop will NOT disengage, raise the header to release the prop.
Page 60 OPERATION 3.4.3 Attaching Header to M155, M155E4, or M205 Self-Propelled Windrower – Hydraulic Center-Link with Self-Alignment The header will need to be physically attached to the windrower, and the hydraulic and electrical connections completed. The windrower may be equipped with an optional self-aligning hydraulic center-link, which allows the Operator to control the vertical position of the center-link from the cab.
Page 61 OPERATION 4. Remove the float engagement pin from hole (A) to disengage the float springs, and insert the float engagement pin into storage hole (B). Secure the pin with the lynch pin. Repeat this step for the opposite linkage. IMPORTANT: To prevent damage to the lift system when lowering the header lift linkages without a header or a weight box attached to the windrower, ensure that the float...
Page 62 OPERATION 7. Slowly drive the windrower forward until windrower feet (A) enter header supports (B). Continue driving slowly forward until the feet engage the supports and the header is nudged forward. Figure 3.40: Header Support 8. Use the following GSL functions to position the center-link hook above the header attachment pin: REEL UP (A) to raise the center-link REEL DOWN (B) to lower the center-link...
Page 63 OPERATION 12. Press HEADER UP switch (A) to raise the header to its maximum height. 13. If one end of the header does NOT fully rise, rephase the lift cylinders as follows: Press and hold the HEADER UP switch until both cylinders stop moving.
Page 64 OPERATION 15. Install clevis pin (A) through the support and the windrower lift member, and secure it with hairpin (B). Repeat this step for the opposite side of the machine. IMPORTANT: Ensure that clevis pin (A) is fully inserted and that the hairpin is installed behind the bracket.
Page 65: Attaching Header To M155, M155E4, Or M205 Self-Propelled Windrower Hydraulic Center-Link
OPERATION 19. Press HEADER DOWN switch (A) on the GSL to fully lower the header. 20. Shut down the engine, and remove the key from the ignition. Figure 3.48: Ground Speed Lever 3.4.4 Attaching Header to M155, M155E4, or M205 Self-Propelled Windrower – Hydraulic Center-Link without Self-Alignment The header will need to be physically attached to the windrower, and the hydraulic and electrical connections completed.
Page 66 OPERATION 3. Remove hairpin (B) and clevis pin (A) from header support (C) on both sides of the header. Figure 3.50: Header Support 4. To disengage the float springs, move the float engagement pin from engaged position (A) and insert the pin into storage hole (B).
Page 67 OPERATION 6. Remove pin (A) from the frame linkage and raise center- link (B) until the hook is above the attachment pin on the header. Replace pin (A) to hold the center-link in place. IMPORTANT: If the center-link is too low, it may contact the header as the windrower approaches the header for hookup.
Page 68 OPERATION 10. Push down on the rod end of link cylinder (A) until hook (B) engages and locks onto the header pin. IMPORTANT: The hook release must be down to enable the self-locking mechanism. If the release is open (up), manually push it down after the hook engages the header pin.
Page 69 OPERATION 14. Engage the safety props on both lift cylinders: Shut down the engine, and remove the key from the ignition. b. Pull lever (A) and rotate it towards the header to release and lower safety prop (B) onto the lift cylinder. Repeat the previous steps for the opposite lift cylinder.
Page 70 OPERATION 16. Remove the clevis pin from storage position (B) in the linkage and insert it into hole (A) to engage the float springs. Secure it with the hairpin. Repeat this step on the opposite float linkage. Figure 3.60: Header Float Linkage 17.
Page 71: Attaching Hydraulic And Electrical Components
M1 and M2-configured headers have a bent-axis motor, while M-configured headers are fitted with an in-line motor. NOTE: Hydraulic conversion kits are needed to configure headers for different windrowers. Contact your MacDon Dealer for more information. Refer to the relevant hydraulic and electrical attachment procedure: Connecting Header Hydraulic and Electrical Systems –...
Page 72 OPERATION 4. Pull platform (A) toward the cab until it stops and the latch is engaged. Figure 3.64: Left Platform 5. Attach hose support (A) to the frame near the windrower left cab-forward leg. Route the hoses under the frame. NOTE: Ensure that the hoses remain as straight as possible and that they are not subject to damage from abrasion.
Page 73 OPERATION 6. If you are replacing an auger header: Disconnect hose (A) from knife pressure receptacle (C) on the frame. 7. Move the hose to storage location (B). Figure 3.66: Knife Pressure Hose Positions 1 - Knife Pressure Hose in Storage Position – Rotary Configuration 2 - Hose to Knife Pressure Receptacle –...
Page 74: Connecting Header Hydraulic And Electrical Systems M2260 Windrower
IMPORTANT: The Low Pressure Case Drain kit (B6698) must be installed on the M2260 Windrower before an R113 Rotary Disc Header can be connected.
Page 75 OPERATION Proceed to the relevant procedure: For auger/rotary disc/draper-ready configuration (A), refer to Auger/Rotary Disc/Draper-Ready Configuration – Quick Coupler Connections, page 60 for instructions. 1036608 Figure 3.70: Header Hydraulics Configurations – Auger/Rotary Disc/Draper-Ready For rotary disc-only hard-plumbed configuration (A), refer to Rotary Disc-Only Configuration –...
Page 76 OPERATION Auger/Rotary Disc/Draper-Ready Configuration – Quick Coupler Connections Windrowers with the auger/rotary disc/draper-ready configuration are equipped with the hydraulic connections needed to pair with an auger, rotary disc, or a draper 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 77 OPERATION 5. Ensure that hose (A) is disconnected from windrower receptacle (B) and placed in storage cup (C) on the multicoupler. Figure 3.75: Couplers – Auger/Rotary/Draper Header- Ready Configuration with Case Drain Kit Installed 6. Remove the extra hydraulic quick couplers from pressure hose (A) and return hose (B).
Page 78 OPERATION 8. Push latch (A) to unlock platform (B). 1015478 Figure 3.78: Left Platform 9. Pull platform (A) toward the cab until it stops and the latch is engaged. 10. Calibrate the header on the windrower. For instructions, refer to the windrower operator s manual. Figure 3.79: Left Platform Rotary Disc-Only Configuration –...
Page 79 OPERATION 2. Approach platform (A) on the left side of the windrower. Ensure that the cab door is closed. 3. Push latch (B) and pull platform (A) toward the walking beam until it stops and the latch engages. 1015479 Figure 3.80: Left Platform 4.
Page 80 OPERATION 6. Connect the hydraulic hoses to the windrower as follows: Connect rotary disc pressure hose (A) as shown and torque it to 215 Nm (159 lbf·ft). b. Connect rotary disc return hose (B) as shown and torque it to 215 Nm (159 lbf·ft). Connect case drain hose (C) to the mating 1/2 in.
Page 81 OPERATION Rotary Disc-Only Configuration – Quick Coupler Connections The rotary disc-only configuration allows the windrower to operate with compatible rotary disc headers. Attaching the header s hydraulic connections to the windrower s ports using quick couplers does not require any additional tools or hardware.
Page 82 OPERATION 5. Remove extension fittings and elbows (A) from the rotary disc header s hydraulic pressure and return connections. Figure 3.88: Hard Plumbed Connections – Rotary Disc- Ready Windrower 6. Remove and retain the extra hydraulic quick couplers from pressure hose (A) and return hose (B). Figure 3.89: Hydraulic Quick Couplers 7.
Page 83 OPERATION 9. Connect the hydraulic hoses to the windrower as follows: Connect pressure hose female coupler (A) as shown. b. Connect return hose male coupler (B) as shown. Connect case drain hose (C) as shown. NOTE: The case drain hose coupler will be present only if the Low Pressure Case Drain kit (B6698) has been installed.
Page 84: Connecting Header Hydraulics And Electrical Systems M1 Series Windrower
NOTE: To connect the header to an M1 Series Windrower, hydraulic drive kit (B6845) is required. To order this kit, contact your MacDon Dealer. Figure 3.94: Hydraulic Drive Kit (B6845) NOTE: To connect the header to an M1240 Windrower, Low Pressure Case Drain kit (A) (B6698) is required.
Page 85 OPERATION 1. Move the windrower s left platform to the OPEN position. Refer to your windrower operator s manual for instructions. 2. Retrieve the hydraulic hoses from the header. Figure 3.96: Windrower Left Platform Open – M1240 3. Attach hose support (A) to the windrower frame near the left leg, and route the hose bundle under the frame.
Page 86 OPERATION 4. Rest the hose bundle from the windrower on header hose support (A). 5. If necessary, use a clean rag to remove any dirt and moisture from the couplers. Figure 3.98: Hose Support 6. Connect the header hydraulic hoses and electrical harness as follows: Connect the pressure hose to receptacle (A).
Page 87 OPERATION 7. M1170 Windrowers: Connect the hydraulic hoses and the electrical harness to the receptacles on the windrower as follows: Connect the pressure hose to receptacle (A). b. Connect the return hose to receptacle (B). Connect the case drain hose to receptacle (C). d.
Page 88: Connecting Header Hydraulics And Electrical Systems M155 Or M155E4 Self-Propelled Windrower
Connect the case drain hose non-flat face coupler to receptacle (C). NOTE: The R113 SP, when attached to an M1240 Windrower, requires Low Pressure Case Drain kit (B6698); this kit has a different hose connection to the hydraulic fluid Figure 3.101: M1240 Hydraulic and Electrical reservoir.
Page 89 OPERATION 1. Disengage and rotate lever (A) counterclockwise to the FULLY UP position. 2. Remove cap (B) securing the electrical connector to the frame. Figure 3.104: Hose Bundle 3. Move hose bundle (A) from the windrower and rest the bundle on the header. Figure 3.105: Hose Bundle 262705 Revision A...
Page 90 OPERATION 4. Position the hose support so that lower bolt (A) is in the forward hole as shown. Loosen both bolts and adjust them as required. Figure 3.106: Hose Support 5. Move the windrower s left platform (A) to the OPEN position.
Page 91 OPERATION 6. Route windrower hose bundle (A) through hose support (B) on the header. NOTE: Keep the hoses as straight as possible. Do not allow the hoses to rub against other parts. 7. Route pressure hose (C) from the header through support (B) to the windrower.
Page 92 OPERATION 9. Connect pressure hose (B) from port M1 (C) on the windrower s drive manifold to the female coupler at the steel line attached to port (A) on the header motor. Figure 3.110: Hydraulic Connections 10. Connect return hose (A) from port R1 (C) on the windrower s drive manifold to the coupler on steel line (B) attached to the aft port on the header motor.
Page 93 OPERATION NOTE: If the windrower is equipped with reverser manifold (A) for an auger header, route return hose (B) from port R1 (D) on the windrower s reverser manifold to steel line (C) attached to the aft port on the header motor. Figure 3.112: Windrower Hose Connections with Reverser 11.
Page 94 OPERATION 12. Connect electrical harness (A) from the windrower to electrical connector (B) on the header. Figure 3.114: Electrical Connection 13. Lower and lock lever (A). 14. Secure hose (B) with three adjustable straps (C). 1005204 Figure 3.115: Hose Bundle 262705 Revision A...
Page 95 OPERATION 15. Move platform (A) to the CLOSED position. Figure 3.116: Top View of Windrower 262705 Revision A...
Page 96: Connecting Header Hydraulics And Electrical Systems M205 Self-Propelled Windrower
IMPORTANT: The M205 Self-Propelled Windrower requires a compatibility kit (MD #257188) to connect to the R113 Rotary Disc Header. If the header does not have a hydraulic motor, install the Hydraulic Drive kit (B6845) before proceeding.
Page 97 OPERATION Figure 3.118: Hose Routing from Header to Windrower 1. Route header hose bundle (A) from the header over support (B) and under the windrower frame. Insert the pin on hose support (C) into hole (D) in the windrower frame near the left leg. IMPORTANT: Route the hydraulic hoses as straight as possible while avoiding wear points that could damage the hoses.
Page 98 Plugs – Left Side of Windrower Connecting Header Hydraulics – M205 Self-Propelled Windrower with Quick Couplers Ensure that the couplers are fully mated when connecting the R113 Rotary Disc Header to an M205 Self-Propelled Windrower with hydraulic quick couplers.
Page 99 OPERATION 2. Install female coupler (A) onto header pressure hose (B). NOTE: Some portions of the hoses have been removed from the illustration for clarity. 3. Install male coupler (C) onto header return hose (D). Figure 3.123: M205 Equipped with Quick Couplers 4.
Page 100 OPERATION 7. Confirm that the quick couplers are connected properly. Couplers (B) are fully mated while couplers (C) are not fully mated. You should NOT be able to see O-ring (A). IMPORTANT: If the couplers are not fully mated, the couplers will restrict the flow of oil.
Page 101 OPERATION Connecting Header Hydraulics – M205 Self-Propelled Windrower without Quick Couplers The hydraulic hoses on the header will need union fittings installed before they can be connected to an M205 Self- Propelled Windrower. 1. Locate pressure and return hoses (A) on the left side of the header.
Page 102 OPERATION 4. Connect the pressure hose with union fitting (A) to inboard steel line (B) on the left side of the windrower. NOTE: The other end of the pressure hose is connected to split flange clamp (C) on the hydraulic motor. 5.
Page 103 OPERATION Connecting Header Electrical Components – M205 Self-Propelled Windrower The adapter harness and the power limiter harness on the R113 must be connected to the M205 s electrical system. 1. If your windrower is equipped with a draper/auger header drive, disconnect the hose bundle connectors (not shown) from the chassis harness connectors labeled HC-2 (A) and HC-1 (B).
Page 104 OPERATION Figure 3.134: Installation of PWM Module and Power Assembly 4. Connect the PWM module and power assembly (MD #256651) as follows: Connect 4-pin male connector (A) to piston pump (B). Connect 4-pin female connector (C) to header pump relay harness (D). Route the power wire with terminal (F) through frame channel hole (E) and connect it to bus bar stud (G) beside the battery.
Page 105 The polarity of the 4-pin connections to the header pump relay harness or to the piston pump might be reversed. 6. Confirm that the R113 to M205 harness is functional: In the cab, check the cab display module (CDM). Depending on the software version, the header ID might...
Page 106: Detaching Header From Windrower
OPERATION 3.5 Detaching Header from Windrower Detach the header when replacing the header with a different one or when storing the header. 3.5.1 Detaching Header from M2 Series Windrower Detaching the header from the windrower requires removing the electrical and hydraulic connections, detaching the header supports, and releasing the center-link.
Page 107 OPERATION 6. Remove hairpin (B) and clevis pin (A) from header support (C) on each side of the header. Figure 3.138: Header Support 7. Windrowers with self-aligning center-link: Release center- link latch (A). Figure 3.139: Center-Link 8. Disengage the safety props on both lift cylinders as follows: Turn lever (A) away from the header to raise the safety prop until the lever locks into the vertical position.
Page 108 OPERATION Figure 3.141: Float Removal 10. Remove the float as follows: ™ If the HarvestTouch Display shows the message Resume Float? , then select NO (A). ™ If the HarvestTouch Display does NOT show the message, then select FLOAT ADJUST (B), select switch (C), and confirm the switch and float settings (D) are grayed out.
Page 109 OPERATION 11. Lower the header fully using HEADER DOWN switch (A). 12. Press HEADER TILT switches (B) as needed on the GSL to release the load on the center-link. Figure 3.142: GSL 13. Windrowers with self-aligning center-link: Press REEL UP switch (A) to disengage the center-link from the header.
Page 110 OPERATION 15. Approach platform (A) on the left side of the windrower. Ensure that the cab door is closed. 16. Push latch (B) and pull platform (A) toward the walking beam until it stops and the latch engages. 1015479 Figure 3.145: Left Platform 17.
Page 111 OPERATION 18. Push latch (A) to unlock platform (B). 1015478 Figure 3.148: Left Platform 19. Pull platform (A) toward the cab until it stops and the latch is engaged. Figure 3.149: Left Platform 20. Remove hose support (A) and the hose bundle from the windrower frame.
Page 112 OPERATION 21. Slide support (A) into center-link support (B) and secure it with hardware (C). Figure 3.151: Hose Storage Position 22. Place hoses (A) and electrical harness (B) disconnected from the windrower into storage plate (C). NOTE: Install caps and plugs on open lines to prevent contamination while the header is in storage.
Page 113: Detaching Header From M1 Series Windrower
OPERATION 25. Reinstall clevis pin (A) through header support (C) and secure the clevis pin with hairpin (B). Repeat this step on the opposite side of the header. Figure 3.153: Header Support 3.5.2 Detaching Header from M1 Series Windrower Detaching the header from the windrower requires removing the electrical and hydraulic connections, detaching the header supports, and releasing the center-link.
Page 114 OPERATION 4. Engage the safety props on both lift cylinders as follows: Pull lever (A) toward you to release it, then rotate it toward the header to lower the safety prop onto the cylinder. b. Repeat the previous step for the opposite lift cylinder. IMPORTANT: Ensure that the safety props engage over the cylinder piston rods.
Page 115 OPERATION 6. Disconnect electrical harness (A) and hydraulic hoses (B), (C), and (D) from the windrower. Figure 3.157: Header Drive Hydraulics 7. Remove hose support (A) and the hose bundle from the windrower frame. Figure 3.158: Hoses on Windrower 8. Slide support (A) into center-link support (B) and secure it with hardware (C).
Page 116 OPERATION 9. Store hoses (A) and electrical harness (B) disconnected from the windrower in Step 6, page 99 into storage plate (C). NOTE: Install caps and plugs on open lines to prevent contamination while the header is in storage. NOTE: Some parts have been removed from the illustration.
Page 117 OPERATION 11. Windrowers WITH center-link self-alignment kit: Release center-link latch (A). Figure 3.162: Center-Link 12. Disengage the safety props on both lift cylinders as follows: Turn lever (A) away from the header to raise the safety prop until the lever locks into the vertical position. b.
Page 118 OPERATION 17. Use HEADER TILT cylinder switches (A) on the GSL to release the load on the center-link cylinder. 18. Windrowers WITH center-link self-alignment kit: Operate the link lift cylinder with REEL UP switch (B) to disengage the center-link from the header. Proceed to Step 22, page 102.
Page 119: Detaching Header From M155 Or M155E4 Self-Propelled Windrower
OPERATION 3.5.3 Detaching Header from M155 or M155E4 Self-Propelled Windrower Detaching the header from the windrower involves removing the electrical and hydraulic connections and then following the detaching procedure in the windrower operator s manual. DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 120 OPERATION 4. Disconnect hose (A) from port M2 on the disc drive valve. Figure 3.168: Hydraulic Connections 5. Raise lever (A) and undo three cinch straps (C). 6. Move hose (B) so that it can be stored on the header. 1005204 Figure 3.169: Hose Bundle 262705...
Page 121 OPERATION 7. Disconnect the following hoses from the hydraulic motor: Pressure hose (A) Return hose (B) Case drain hose (C) 8. Install caps on the connectors and on the ends of the hoses to prevent contamination. Figure 3.170: Hose Bundle 9.
Page 122: Detaching Header From M205 Self-Propelled Windrower
Figure 3.173: M155 Windrower 3.5.4 Detaching Header from M205 Self-Propelled Windrower The procedure for detaching your R113 Rotary Disc Header from an M205 Self-Propelled Windrower will depend on whether or not the windrower is equipped with hydraulic quick couplers. DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 123: Disconnecting Header Hydraulics M205 Self-Propelled Windrower With Quick Couplers
OPERATION 1. Lower the header to the ground. If the ground is soft, place blocks under the header. 2. Shut down the engine, and remove the key from the ignition. 3. Move left platform (A) to the open position. 4. To disconnect the header from an M205 Windrower equipped with quick couplers, refer to Disconnecting Header Hydraulics –...
Page 124: Disconnecting Header Hydraulics M205 Self-Propelled Windrower Without Quick Couplers
OPERATION 3. Disconnect PRESSURE coupler (A) from inboard steel line coupler (B). NOTE: Some portions of the hoses have been removed from the illustration for clarity. 4. Disconnect RETURN coupler (C) from outboard steel line coupler (D). 5. Remove pin (E) and open coupler lock assembly (F) over the couplers.
Page 125: Disconnecting Header Electrical System M205 Self-Propelled Windrower
OPERATION Disconnecting Header Electrical System – M205 Self-Propelled Windrower The procedure for disconnecting an R113 Rotary Disc Header from an M205 Self-Propelled Windrower differs depending on whether or not you are simply swapping the header or storing it long-term. Disconnect the following when switching headers: 1.
Page 126 OPERATION 3. Disconnect the adapter harness: Disconnect 8-pin female connector (B) from chassis harness connector HC-2 (A). Disconnect 29-pin round male connector (C) from header connector (D). 4. If you are swapping the rotary disc header for another header, proceed to Step 6, page 111.
Page 127 OPERATION Figure 3.182: Detaching Header Hose from Windrower 6. Remove hose support pin (B) from hole (C) in the windrower frame. 7. Place header hose bundle (A) on top of the rotary disc header. 262705 Revision A...
Page 128: Driveshields
OPERATION 3.6 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. 3.6.1 Opening Driveshields The driveshields offer protection from moving components. Open them only when you intend to service the machine. 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 129: Closing Driveshields
OPERATION 3. Insert the flat end of tool (A) into latch (B) and turn it counterclockwise to unlock the driveshield. Figure 3.185: Driveshield Latch 4. Pull the top of driveshield (A) away from the machine 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 machine.
Page 130 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 3.187: Left Driveshield 4. Replace tool (B) and lynch pin (A) onto pin (C). Figure 3.188: Left Driveshield 262705 Revision A...
Page 131: Cutterbar Doors
OPERATION 3.7 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 without all the cutterbar doors down or without curtains installed and in good condition. Objects in the path of the blades can eject with considerable force when the machine is started.
Page 132: Opening Cutterbar Doors Export
OPERATION 3.7.2 Opening Cutterbar Doors – Export Machines sold outside North America have a tool-operated latch on the cutterbar doors. 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 133: Closing Cutterbar Doors
OPERATION 4. Lift up on doors (A) while pressing down on the latch. Figure 3.193: Cutterbar Doors and Curtains 3.7.3 Closing Cutterbar Doors Do NOT operate the machine without closing the cutterbar doors. CAUTION Keep your hands and fingers away from the corners of the doors when you are closing them. 1.
Page 134: Header Settings
OPERATION 3.8 Header Settings Satisfactory operation of the rotary disc header in all situations requires making proper adjustments to suit various crops and conditions. Correct operation of the machine reduces crop loss and increases productivity. Proper adjustments and timely maintenance extend the service life of the machine.
Page 135: Adjusting Cutting Height
DANGER Ensure that all bystanders have cleared the area. NOTE: There are two skid shoes on the R113 SP. 1. Raise the header fully. 2. Shut down the engine, and remove the key from the ignition. 3. Engage the windrower lift cylinder safety props. For instructions, refer to 3.3 Engaging and Disengaging Header Safety...
Page 136: Cutterbar Angle
OPERATION 3.8.2 Cutterbar Angle The cutterbar angle (sometimes called the 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 8° below the horizontal plane.
Page 137 R113 Rotary Disc Headers. The chart demonstrates that a ground speed of 21 km/h (13 mph) would produce a cut area of approximately 8 hectares (20 acres) per hour.
Page 138: Reconfiguring Cutterbar Crop Stream
OPERATION 3.9 Reconfiguring Cutterbar Crop Stream Discs are factory-installed to produce three crop streams; however, the disc rotation pattern can be changed by changing the spindle and its disc to suit crop conditions. Each spindle and disc pair is designed to rotate in one direction, and must be changed as a set when the crop flow is altered.
Page 139: Changing Cutterbar Crop Stream Configuration
OPERATION 3.9.1 Changing Cutterbar Crop Stream Configuration Two crop stream settings are possible: one stream and three streams. Figure 3.200: Spindle Rotation Pattern and Crop Streams A - One Crop Stream B - Three Crop Streams To change the spindle rotation from three crop streams (B) to one crop stream (A): Swap disc/spindle (3) with disc/spindle (6).
Page 140: Conditioner
OPERATION 3.10 Conditioner Conditioner rolls crimp and crush the stem of the crop in several places, allowing the release of moisture and resulting in faster crop drying times. Both steel and polyurethane conditioner rolls are available. Refer to Chapter 5 Options and Attachments, page 245 for information on ordering conditioner rolls.
Page 141: Adjusting Roll Gap Polyurethane Rolls
OPERATION 3. Polyurethane rolls: Insert a feeler gauge through the inspection hole in the conditioner endsheet to check the roll gap on polyurethane roll conditioners. The factory setting is 3 mm (1/8 in.). Figure 3.201: Polyurethane Roll Conditioner 4. Steel rolls: The length of thread (A) extending above the jam nut on the adjustment rods can be used as an approximation of the roll gap;...
Page 142: Adjusting Roll Gap Steel Rolls
OPERATION 1. Lower the header fully. 2. Shut down the engine, and remove the key from the ignition. 3. Loosen upper jam nut (A) on both sides of the conditioner attachment. 4. Turn lower nut (B) counterclockwise until the upper roll rests on the lower roll.
Page 143: Roll Tension
OPERATION 3. Loosen jam nut (A) on both sides of the conditioner. 4. Turn lower nut (B) counterclockwise until the upper roll rests on the lower roll. Ensure the rolls intermesh. 5. Turn lower nut (B) two and a half full turns clockwise to raise the upper roll and achieve a 6 mm (1/4 in.) roll gap.
Page 144: Roll Timing
OPERATION 3. Loosen jam nut (A) on both sides of the conditioner. 4. Turn spring drawbolt (B) clockwise to tighten spring (C) and increase the roll tension. 5. Turn spring drawbolt (B) counterclockwise to loosen spring (C) and decrease the roll tension. 6.
Page 145: Adjusting Roll Timing
OPERATION Adjusting Roll Timing The roll timing is factory-set and should not require adjustment; however, if there is excessive noise coming from the conditioner rolls, the timing will need to be adjusted. 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 146 OPERATION 6. Secure bottom roll (A). 7. Rotate upper roll (B) clockwise until it stops. 8. Make a mark (C) across yoke (D) and gearbox flange (E). Figure 3.209: Conditioner Drive 9. Determine center point (A) between the two marks on the yoke plate, and place a third mark.
Page 147: Forming Shields Roll Conditioner
OPERATION 11. Ensure that the threads on four bolts (A) are clean and free of lubricant. NOTE: Only three of the four bolts are shown in the illustration. 12. Apply medium-strength threadlocker (Loctite ® 242 or equivalent) to bolts (A). 13.
Page 148: Positioning Rear Baffle Roll Conditioner
OPERATION 2. Loosen locking handle (A). 3. Slide adjuster bar (B) along adjuster plate (C) to the desired deflector position. 4. Tighten locking handle (A). 5. Repeat Step 2, page 132 to Step 4, page 132 on the opposite side of the conditioner. Figure 3.212: Forming Shield Side Deflector and Adjuster Bar Positioning Rear Baffle –...
Page 149 OPERATION Positioning Rear Baffle Deflector Fins The additional rear baffle deflector fins are stored on top of the baffle, but can be moved under the baffle when a narrower windrow is desired. To install the fins, follow these steps: WARNING To avoid bodily injury or death from unexpected startup of machine, always stop the engine and remove the key from the ignition before leaving the operator's seat for any reason.
Page 150: Cutterbar Deflectors
OPERATION 3.11 Cutterbar Deflectors A two-piece cutterbar deflector is attached to the cutterbar just below the conditioner rolls. Cutterbar deflectors improve feeding into the conditioner rolls and prevent long-stemmed crop from feeding under the rolls. Refer to the following table for the suitability of cutterbar deflectors in different crops and field conditions: Table 3.2 Conditions for Using Cutterbar Deflectors Use Deflector? Crop/Field Condition...
Page 151: Installing Cutterbar Deflectors
OPERATION 4. Locate deflector (A) behind the cutterbar. 5. Clear any debris from the deflector area. 6. Remove bolt (C) shared with the rock guard on the outboard end of the deflector. Retain the hardware. 7. Remove and retain three bolts and nuts (B) securing deflector (A) to the cutterbar.
Page 152 OPERATION 5. Position left deflector (A) on the back edge of the cutterbar. Align the slots in the deflector with the existing fasteners and the cutterbar plug. 6. At the outboard end of the deflector, install bolt (C) shared with the rock guard. 7.
Page 153: Haying Tips
OPERATION 3.12 Haying Tips Follow the recommendations in this section to ensure the highest quality hay production. 3.12.1 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 154: Windrow Characteristics
OPERATION 3.12.4 Windrow Characteristics The shape and density of the windrow is an important factor with respect to how rapidly the hay cures. Refer to Chapter 3 Operation, page 25 for instructions on adjusting the header. Table 3.4 Recommended Windrow Characteristics Advantage Characteristic Enables airflow through the windrow, which is more important to the curing...
Page 155: Transporting Header
OPERATION 3.13 Transporting Header For information on transporting the header when it is attached to a windrower, refer to your windrower operator s manual. IMPORTANT: For cab-forward road travel, M Series Windrowers must have the lighting and marking bundle installed (B5412). 262705 Revision A...
Page 157: 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 144) to keep track of maintenance procedures as they are performed.
Page 158: Recommended Safety Procedures
MAINTENANCE AND SERVICING 4.2 Recommended Safety Procedures These procedures will minimize the chances of injury when maintaining or repairing the machine. Park on a level surface when possible. Follow all recommendations in your windrower operator's manual. Wear close-fitting clothing and cover any long hair. Never wear dangling items such as scarves or bracelets.
Page 159 MAINTENANCE AND SERVICING Be prepared to deal with an accident should it occur. Know where the first aid kits and fire extinguishers are located, and know how to use them. Figure 4.4: Safety Equipment Keep the service area clean and dry. Wet or oily floors are slippery.
Page 160: 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 operates regularly under adverse conditions (for example, severe dust, extra heavy loads, etc.).
Page 161 MAINTENANCE AND SERVICING At First 25 Hours Check conditioner drive belt tension. For ü instructions, refer to Inspecting Conditioner Drive Belt, page 222. Check roll timing gearbox lubricant level. For instructions, refer to 4.6.1 Checking ü and Changing Lubricant in Conditioner Roll Timing Gearbox, page 207.
Page 162: Break-In Inspections
MAINTENANCE AND SERVICING Every 100 Hours or Annually Check conditioner drive belt tension. For ü instructions, refer to Inspecting Conditioner Drive Belt, page 222. Check roll timing gearbox lubricant. For instructions, refer to 4.6.1 Checking and ü Changing Lubricant in Conditioner Roll Timing Gearbox, page 207.
Page 163: Preseason Servicing
MAINTENANCE AND SERVICING Table 4.1 Break-In Inspection Schedule (continued) Inspection Item Refer to Interval 4.5.1 Lubricating Cutterbar, page 155 Check cutterbar lubricant Hours Inspecting Conditioner Drive Belt, page 222 Check conditioner drive belt tension Hours 4.3.3 Preseason Servicing Perform these procedures when taking the machine out of storage. CAUTION •...
Page 164: End-Of-Season Servicing
MAINTENANCE AND SERVICING 4.3.4 End-of-Season Servicing Perform these procedures when storing the machine at the end of the season. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 165: Lubrication
MAINTENANCE AND SERVICING 4.4 Lubrication Proper lubrication is essential to ensuring the service life of the machine. WARNING To avoid personal injury, before servicing the header or opening the drive covers, refer to 4.1 Preparing Machine for Servicing, page 141. Greasing points are marked on the machine by decals showing a grease gun and the grease interval, which is specified in hours of operation.
Page 166: First 25 Hours
MAINTENANCE AND SERVICING First 25 Hours After the first 25 hours of operation, you will need to check the conditioner drive belt tension and inspect the conditioner roll timing gearbox s lubricant level. To check the conditioner roll timing gearbox oil level, refer to 4.6.1 Checking and Changing Lubricant in Conditioner Roll Timing Gearbox, page 207.
Page 167: Every 25 Hours
MAINTENANCE AND SERVICING Every 25 Hours After every 25 hours of machine operation, add grease to the idler/tensioner pivot, the roller conditioner bearing, the driveline U-joints, and the driveline slip joints. When adding grease, use high-temperature extreme-pressure (EP2) performance grease with 1% max molybdenum disulphide (NLGI grade 2) lithium base unless otherwise specified.
Page 168: First 50 Hours
MAINTENANCE AND SERVICING First 50 Hours After the first 50 hours of machine operation, the conditioner roll timing gearbox s lubricant will need to be changed, the header drive gearbox s lubricant will need to be changed, and the cutterbar lubricant level should be inspected. To change the conditioner roll timing gearbox oil level, refer to 4.6.1 Checking and Changing Lubricant in Conditioner Roll Timing Gearbox, page...
Page 169: Every 100 Hours Or Annually
MAINTENANCE AND SERVICING Every 100 Hours or Annually After 100 hours of machine operation, or annually (whichever interval occurs first), the conditioner drive belt tension should be checked, the conditioner roll timing gearbox s lubricant level should be checked, the rotary disc header drive gearbox s lubricant level should be checked, and the forming shield pivot tubes should be lubricated.
Page 170: Every 250 Hours
MAINTENANCE AND SERVICING Every 250 Hours After every 250 hours, or annually (whichever interval occurs first), the conditioner roll gearbox lubricant should be changed, the rotary disc header drive gearbox lubricant should be changed, and the cutterbar lubricant should be changed. Figure 4.11: Every 250 Hours A - Header Drive Gearbox B - Cutterbar...
Page 171: Cutterbar System
MAINTENANCE AND SERVICING 4.5 Cutterbar System Cutterbar (A) is 3.9 m (13 ft.) long. The 3.9 m (13 ft.) cutterbar holds eight discs that rotate to a maximum of 2500 rpm at full engine speed. Figure 4.12: Cutterbar Each cutterbar disc carries two cutting blades. 4.5.1 Lubricating Cutterbar The machine should be on flat, level ground when checking and changing the lubricant in the cutterbar.
Page 172 MAINTENANCE AND SERVICING IMPORTANT: Check the cutterbar lubricant level when the lubricant is warm. If the lubricant is cold, idle the machine for approximately 10 minutes prior to checking. 1. Park the machine on a flat, level surface. 2. Shut down the engine, and remove the key from the ignition. 3.
Page 173: Draining Cutterbar
MAINTENANCE AND SERVICING 14. Add lubricant through the inspection hole that is used to check the oil level. IMPORTANT: Do NOT overfill the cutterbar. Overfilling can cause overheating, damage, and failure of cutterbar components. NOTE: Refer to the inside back cover of this manual for lubricant specifications. 15.
Page 174: Filling Cutterbar With Lubricant
MAINTENANCE AND SERVICING 6. Shut down the engine, and remove the key from the ignition. 7. Place a 10 liter (10.5 US qts) container under the right end of the cutterbar. 8. Clean the area around plug (A) and remove it. IMPORTANT: Do NOT remove hex head bolts (B) securing the cutterbar end plate to the cutterbar or lubricant may leak.
Page 175 MAINTENANCE AND SERVICING 4. Place blocks under the right end of the header so that the right end is higher than the left end. 5. Lower the header onto the blocks. 6. Shut down the engine, and remove the key from the ignition.
Page 176: Cutterbar Discs
MAINTENANCE AND SERVICING 4.5.2 Cutterbar Discs The cutterbar discs provide rotary cutting action. They may need to be replaced from time to time. Figure 4.18: 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 177 MAINTENANCE AND SERVICING 2. Inspect the cutterbar disc for any deformity on the side of the disc blades. Dimension (A) must not exceed 48 mm (1 7/8 in.). Replace any damaged discs immediately. IMPORTANT: Cutterbar discs are NOT repairable and must be replaced if damaged.
Page 178: Removing Cutterbar Discs
MAINTENANCE AND SERVICING Removing Cutterbar Discs Cutterbar discs may need to be removed for replacement or so they can be swapped to change the type of crop stream. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, stop the engine, remove the key from the ignition, and engage the windrower’s lift cylinder safety props before going under the machine.
Page 179: Installing Cutterbar Discs
MAINTENANCE AND SERVICING Installing Cutterbar Discs Ensure that the blades of the installed disc are perpendicular to those on the adjacent discs. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, stop the engine, remove the key from the ignition, and engage the windrower’s lift cylinder safety props before going under the machine.
Page 180: Replacing Cutterbar Spindles
MAINTENANCE AND SERVICING 4.5.3 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 181 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. Park the machine on a flat, level surface. 2.
Page 182 MAINTENANCE AND SERVICING 9. Remove spacer plate (A). Figure 4.30: Spacer Plate 10. Rotate spindle hub (A) to access the nuts, and remove 11 M12 lock nuts and washers (B). Figure 4.31: Left Spindle Hub and Hardware 11. Remove spindle (A) from the cutterbar. Figure 4.32: Left Spindle 262705 Revision A...
Page 183: Installing Cutterbar Spindles
MAINTENANCE AND SERVICING Installing Cutterbar Spindles Ensure that the discs are timed correctly when installing the cutterbar spindles or the cutterbar may become damaged. Figure 4.33: 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.
Page 184 MAINTENANCE AND SERVICING NOTE: Remove the driveshield and retrieve disc timing tools (A) from the left rear side of the header. Figure 4.34: Disc Timing Tool Location – Left Rear Side NOTE: Assemble disc timing tools (A) and (B) and secure them with M8 carriage head bolt (C), washer (D), and M8 flange hex nut (E).
Page 185 MAINTENANCE AND SERVICING Figure 4.36: 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 To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, stop the engine, remove the key from the ignition, and engage the windrower’s lift cylinder safety props before going under the machine.
Page 186 MAINTENANCE AND SERVICING 5. Choose a suitable spindle rotation pattern. For more information, refer to 4.5.3 Replacing Cutterbar Spindles, page 164. Figure 4.37: Cutterbars 6. Ensure that spindle O-ring (A) is properly seated, cleaned, and undamaged. Figure 4.38: Left Spindle O-Ring 7.
Page 187 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: The design of the cutterbar makes it possible to install spindles that rotate in the wrong direction.
Page 188 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 4.42: Left Spindle Hub 12.
Page 189: Maintaining Disc Blades
MAINTENANCE AND SERVICING 14. To prevent the disc from rotating while you are tightening the bolts, place a pin (or equivalent) in front hole (D) of the rock guard. IMPORTANT: The blades are oriented to cut in one direction or the other. Swap the entire disc when you are swapping spindles.
Page 190: Inspecting Disc Blades
MAINTENANCE AND SERVICING Inspecting Disc Blades Inspect the disc blades daily and flip or replace them as needed. 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 191: Inspecting Disc Blade Hardware
MAINTENANCE AND SERVICING IMPORTANT: The disc blades have cutting edges on both sides so that the blades can be turned over and reused. The twist in each blade determines the cutting direction. If you are unsure which direction the spindles rotate, refer to 3.9.1 Changing Cutterbar Crop Stream Configuration, page 123 instructions.
Page 192 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 has been worn down to 3 mm (1/8 in.) or less The bolt is cracked (C) The bolt is visibly distorted (D)
Page 193: 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 194: Installing Disc Blades
MAINTENANCE AND SERVICING 5. Rotate disc (A) so blade (B) faces forward and lines up with hole (C) in the rock guard. Figure 4.52: Disc Blade Aligned with Hole in Rock Guard 6. To prevent the disc from rotating while loosening the blade bolts, place a pin (or equivalent) in the front hole of the rock guard.
Page 195: Accelerators
MAINTENANCE AND SERVICING 2. To prevent the disc from rotating while you are tightening the blade bolts, place a pin (or equivalent) in the front hole of the rock guard. 3. Install new or reversed blade (A) with shoulder bolt (B) onto disc (C).
Page 196: Removing Accelerators
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. Raise the header fully. 2.
Page 197: Installing Accelerators
MAINTENANCE AND SERVICING 1. Raise the header fully. 2. Shut down the engine, and remove the key from the ignition. 3. Engage the windrower lift cylinder safety props. For instructions, refer to 3.3 Engaging and Disengaging Header Safety Props, page 3.7.1 Opening Cutterbar Doors –...
Page 198 MAINTENANCE AND SERVICING 1. To prevent the cutterbar discs from rotating while you are tightening the blade bolts, place a wooden block between the two discs. 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 199: Rock Guards
MAINTENANCE AND SERVICING WARNING Ensure that the cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the machine is started, which can result in serious injury or cause damage to the machine. 7. Remove the wooden block from between the cutterbar discs. 8.
Page 200: 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 bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 201: Installing Inboard Rock Guards
MAINTENANCE AND SERVICING Installing Inboard Rock Guards When installing an inboard rock guard, ensure that the nuts securing the rock guards are installed on top of the cutterbar. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 202: Removing Outboard Rock Guards
MAINTENANCE AND SERVICING Removing Outboard Rock Guards The outboard rock guards are secured to the cutterbar with more hardware than the inboard rock guards. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, stop the engine, remove the key from the ignition, and engage the windrower’s lift cylinder safety props before going under the machine.
Page 203: Installing Outboard Rock Guards
MAINTENANCE AND SERVICING Installing Outboard Rock Guards Use a rubber mallet to properly install the outboard rock guard. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 204 MAINTENANCE AND SERVICING 10. Ensure that rock guards (B) and (C) are parallel. Gap (A) should be 5 7 mm (3/16 1/4 in.). NOTE: You may need to loosen the next one or two rock guards to adjust gap (A). Figure 4.71: Outboard Rock Guard Installed 11.
Page 205: Maintaining Large Drums
MAINTENANCE AND SERVICING 4.5.7 Maintaining Large Drums Drums deliver cut material from the ends of the cutterbar and help maintain an even crop flow into the conditioner. Large drums are attached to the two outboard discs on 8 disc cutterbars. NOTE: Large drums measure 250 mm (9 7/8 in.) in diameter.
Page 206: Removing Large Driven Drums And Driveline
MAINTENANCE AND SERVICING 4. Inspect large drums (B) and (C) for signs of damage or wear. Replace the large drums if the drum feed bars are 50% or less of their original thickness. Do NOT repair the drums. 5. Examine the drums for large dents. Replace dented drums to prevent an imbalance in the cutterbar.
Page 207 MAINTENANCE AND SERVICING 3. Remove four M10 hex flange head bolts (A) and remove vertical driveshield (B). Figure 4.75: Vertical Drive Shield 4. Remove two M10 hex flange head bolts (A) and remove cover plate (B). Figure 4.76: Cover Plate 5.
Page 208 MAINTENANCE AND SERVICING 6. Remove one M10 x 20 hex flange head bolt (A), two M10 x 16 hex flange head bolts (B), and vertical shield (C). Figure 4.78: Vertical Shield 7. Remove eight M8 hex flange head bolts (A), and remove two drum shields (B).
Page 209: Installing Large Driven Drums And Driveline
MAINTENANCE AND SERVICING 9. Slide driveline (A) downwards, and tilt it to the side. Pull the driveline up and out of the drum. NOTE: The illustration shows a cutaway view of the drum and the tube shield. Figure 4.81: Hub Drive to Driveline Connection 10.
Page 210 MAINTENANCE AND SERVICING 2. Ensure that spacer plate (A) is on the spindle. Figure 4.83: Spacer Plate 3. Position the drum disc assembly as shown. NOTE: Orient the disc so that the blades are perpendicular to those on the adjacent disc. 4.
Page 211 MAINTENANCE AND SERVICING 8. Place a bead of medium-strength threadlocker (Loctite ® or equivalent) around the threads of four M12 hex flange head bolts (A). 9. Use the bolts and spacers to secure driveline assembly (B) to hub drive (C). Torque the bolts to 102 Nm (75 lbf·ft). Figure 4.86: Hub Drive to Driveline Connection 10.
Page 212 MAINTENANCE AND SERVICING 16. Position top plate (B) and drum top (C) onto the drum as shown. 17. Apply a bead of medium-strength threadlocker ® (Loctite 243 or equivalent) around the threads of four M10 hex flange head bolts (A). 18.
Page 213: Removing Large Non-Driven Drums
MAINTENANCE AND SERVICING 23. Position vertical driveshield (B) as shown. 24. Apply a bead of medium-strength threadlocker (Loctite ® 243 or equivalent) around the threads of four M10 hex flange head bolts (A). 25. Use bolts (A) to secure the vertical driveshield. 26.
Page 214: Installing Large Non-Driven Drums
MAINTENANCE AND SERVICING 3. To prevent the disc from rotating while you are loosening the blade bolts, place a wooden block between the two cutterbar discs. 4. Remove eight M8 bolts and washers (A) securing cover (B) to the non-driven drum. 5.
Page 215 MAINTENANCE AND SERVICING 2. Ensure that spacer (A) is on the spindle. Figure 4.94: Non-Driven Spindle 3. Position non-driven drum/disc (B) onto the spindle as shown. 4. Install four M12 bolts and washers (A) to secure the drum and disc assembly to the spindle. 5.
Page 216: Replacing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING 4.5.8 Replacing Cutterbar Spindle Shear Pin To prevent damage to the cutterbar and drive systems, each disc is attached to a spindle containing a shear pin. 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 217: Removing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING Removing Cutterbar Spindle Shear Pin Once the shear pin on a cutterbar spindle has broken, it will need to be 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 218 MAINTENANCE AND SERVICING 8. Remove retaining ring (A). Figure 4.99: Cutterbar Spindle 9. Remove the M12 bolt securing Safecut spindle-nut wrench (A) to its storage location. 10. Remove the Safecut spindle-nut wrench and reinstall the M12 bolt for safekeeping. Figure 4.100: Safecut Spindle-Nut Wrench Location IMPORTANT: Spindles that rotate clockwise have right-leading threading and a smooth top on spindle gear shaft (A).
Page 219 MAINTENANCE AND SERVICING 11. Remove two M10 bolts and washers (A). Figure 4.102: Cutterbar Spindle 12. Use the Safecut spindle-nut wrench to remove nut (A). Figure 4.103: Cutterbar Spindle 13. Remove shear pins (B). IMPORTANT: Do NOT damage the pin bore on the pinion. 14.
Page 220: Installing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING Installing Cutterbar Spindle Shear Pin Ensure that the grooves in the shear pin are parallel to the cutterbar when it is installed into the spindle. 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 221 MAINTENANCE AND SERVICING 6. Install nut (A). 7. Retrieve the Safecut spindle-nut wrench from the left shield plate. Figure 4.107: Cutterbar Spindle 8. Attach Safecut spindle-nut wrench (B) by 90° (D) to torque wrench (A). IMPORTANT: The Safecut spindle-nut wrench MUST be used with a torque wrench.
Page 222 MAINTENANCE AND SERVICING 14. Install retaining ring (A). Figure 4.110: Cutterbar Spindle 15. Install the disc or drum. Refer to the relevant procedure: Install cutterbar disc (A). For instructions, refer to Installing Cutterbar Discs, page 163. Install driven drum (B). For instructions, refer to Installing Large Driven Drums and Driveline, page 193.
Page 223: Conditioner Roll Timing Gearbox
MAINTENANCE AND SERVICING 4.6 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 4.112: Conditioner Roll Timing Gearbox 4.6.1 Checking and Changing Lubricant in Conditioner Roll Timing Gearbox The conditioner roll timing gearbox will need its lubricant changed from time to time.
Page 224 MAINTENANCE AND SERVICING 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. Ensure that the lubricant is level at the top of the sight glass.
Page 225 MAINTENANCE AND SERVICING Changing the conditioner roll timing gearbox lubricant: 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. 7.
Page 226: Servicing Header Drive Gearbox
MAINTENANCE AND SERVICING 4.7 Servicing Header Drive Gearbox The header drive gearbox transfers power from the hydraulic motor to the cutterbar and to the conditioner. It is located inside the drive compartment at the left end of the header. The only regular servicing that header drive gearbox (A) requires is maintaining the lubricant level and changing the lubricant according to the intervals specified in this manual.
Page 227 MAINTENANCE AND SERVICING 4. Clean around lubricant drain plug (A) on the bottom of the gearbox and around lubricant level plug (B) on the inboard side of the gearbox. 5. Place a 4 liter (1 gal. [US]) container under drain (A). 6.
Page 228: Inspecting Cutterbar Doors
MAINTENANCE AND SERVICING 4.8 Inspecting Cutterbar Doors The cutterbar doors protect bystanders from flung objects and protect the blades from obstacles. They should be inspected periodically. 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 229: Maintaining Curtains
MAINTENANCE AND SERVICING 4.9 Maintaining Curtains The curtains prevent objects from being ejected from the cutterbar area. Always lower the curtains down when operating the header. Rubber curtains are installed at the following locations: Inboard curtain (A) is attached to the center fixed cover Door curtains (B) is attached to each cutterbar door Outboard curtains (C) is attached to each front corner Replace the curtains if they become worn or damaged.
Page 230: Removing Cutterbar Door Curtains
MAINTENANCE AND SERVICING 4.9.2 Removing Cutterbar Door Curtains The procedure for removing the cutterbar door curtains is the same for both doors. 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 231: Removing Cutterbar Inboard Curtain
MAINTENANCE AND SERVICING 2. Insert seven cutterbar door stud bolts (B) into the precut holes on curtain (A). 3. Install seven large washers (C). 4. Install liner panel (D) against the washers. 5. Install seven nuts (E) onto the bolt studs. Torque the nuts to 28 Nm (21 lbf·ft [248 lbf·in]).
Page 232: Installing Cutterbar Inboard Curtain
MAINTENANCE AND SERVICING 4. Remove four nuts (A) from the studs on the center shield. 5. Remove two curtain brackets (B). 6. Remove the curtain. Figure 4.123: Inboard Curtain 4.9.5 Installing Cutterbar Inboard Curtain Do NOT overtighten the nuts when installing the inboard curtain. 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 233: Removing Outboard Curtains
MAINTENANCE AND SERVICING 5. Secure two curtain brackets (A) to the center shield using two M10 carriage head bolts and nuts (B). 6. Torque bolts (B) to 39 Nm (29 lbf·ft). Figure 4.125: Inboard Curtain 4.9.6 Removing Outboard Curtains Remove the outboard curtains if they are damaged or cracked. 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 234: Installing Outboard Curtains
MAINTENANCE AND SERVICING 4. Remove two nuts (A) from the bolt studs. 5. Remove nut (B) from the carriage head bolt, remove bracket (C), and remove curtain (D). Figure 4.127: Outboard Curtain 4.9.7 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 of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 235 MAINTENANCE AND SERVICING 7. 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). Figure 4.129: Left Endsheet 262705 Revision A...
Page 236: Conditioner System
MAINTENANCE AND SERVICING 4.10 Conditioner System The conditioner system crimps and crushes crop stems, helping crop dry faster. Figure 4.130: Conditioner System Conditioner system (A) is attached to the rear of the header. 4.10.1 Inspecting Roll Conditioner The conditioner bearings, U-joints, and roll timing gearbox should be inspected periodically for signs of wear or damage. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, stop the engine, remove the key from the ignition, and engage the windrower’s lift cylinder safety props before going under the machine.
Page 237 MAINTENANCE AND SERVICING 4. Inspect conditioner roll left bearing (A) for signs of wear or damage. If the bearing needs replacing, contact your MacDon Dealer. Figure 4.131: Conditioner Roll Left Bearing 5. Inspect conditioner drive U-joints (A) for signs of wear or damage.
Page 238: Conditioner Drive Belt
MAINTENANCE AND SERVICING 4.10.2 Conditioner Drive Belt The conditioner drive belt is located inside the left driveshield and is tensioned with a spring tensioner. The tension is factory-set and should not require adjustment. 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 239: Removing Conditioner Drive Belt
MAINTENANCE AND SERVICING Removing Conditioner Drive Belt Remove the conditioner drive belt if it is torn or cracked. 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. 1.
Page 240 MAINTENANCE AND SERVICING 1. Lower the header fully. 2. Shut down the engine, and remove the key from the ignition. 3. Install drive belt (A) onto driven pulley (C) first, and then onto drive pulley (B), ensuring that the belt is in the pulley grooves.
Page 241: Changing Conditioner
There are several ways that the conditioner can be configured, depending on your particular machine. The R113 Rotary Disc Header can be operated either with no conditioner, with a polyurethane roll conditioner, or with a steel roll conditioner. If the rotary disc header is not conditioner-equipped, a shield must be installed.
Page 242 MAINTENANCE AND SERVICING WARNING To prevent the frame from slipping off of the forks, ensure that the frame is secured to the forks. Failing to secure the frame to the forks could result in death or serious injury. 7. Support and secure the adapter frame for lifting. Use one of the two methods below: Method 1: Attach straps (A) to adapter frame (B) and to the forklift forks.
Page 243 MAINTENANCE AND SERVICING 9. Remove nut (A) securing bolt (B), washer (C), and washer shims (D) from the center-link support. If necessary, adjust the height of the forks lifting the frame. Retain the hardware for reinstallation. NOTE: Some sections are made hidden in the illustration to help clarify the position of shims (D).
Page 244 MAINTENANCE AND SERVICING 14. Loosen two M16 hex head bolts (A) on each side of the conditioner. Figure 4.149: Left Side of Conditioner – Right Side Similar 15. Loosen two carriage bolts (A) securing conditioner gearbox support (B) to the header. 16.
Page 245: Installing Conditioner
MAINTENANCE AND SERVICING Installing Conditioner The conditioner is very heavy. Installing it will require a forklift or an equivalent lifting device. 1. Attach spreader bar (A) to the forklift (or an equivalent lifting device) and attach chains to lugs (B) on the conditioner.
Page 246 MAINTENANCE AND SERVICING 7. Align the holes in support (B) with the mounting holes in the header frame. 8. Install two carriage bolts (A) to secure conditioner gearbox support (B) to the header. NOTE: The bolt heads must face inboard. 9.
Page 247 MAINTENANCE AND SERVICING WARNING To prevent the frame from slipping off of the forks, ensure that the frame is secured to the forks. Failure to do so could result in death or serious injury. 13. Support and secure the adapter frame for lifting. Use one of the two methods below: Method 1: Attach straps (A) to adapter frame (B) and the forks of the forklift.
Page 248 MAINTENANCE AND SERVICING 15. Install bolt (A) through frame (B) and bushing (D) in the lift arm. Repeat this step for the opposite side of the machine. 16. Check gaps (C) between bushing inner steel sleeve (D) and frame (B). NOTE: If there is a gap, install 1.2 mm thick flat washers to minimize the gap on both sides of the bushing.
Page 249 MAINTENANCE AND SERVICING WARNING To prevent the frame from slipping off of the forks, ensure that the frame is secured to the forks. Failure to do so could result in death or serious injury. 26. Lift the header and remove wooden blocks (A) under the skid shoes.
Page 250: Installing Conditioner Drive
This procedure describes the installation of conditioner drive components on a machine that was originally supplied with no conditioner. The procedure is similar for machines which have a conditioner installed. If a conditioner is to be installed on the R113 SP, refer to Installing Conditioner, page 229...
Page 251: Replacing Discharge Shield No Conditioner
MAINTENANCE AND SERVICING 4.10.4 Replacing Discharge Shield – No Conditioner If the discharge shield on a header not equipped with a conditioner is damaged, it will need to be replaced. Removing Discharge Shield – No Conditioner The discharge shields on a rotary disc header may occasionally need to be removed for machine service. IMPORTANT: The discharge shield must be installed if operating the machine without a conditioner.
Page 252 MAINTENANCE AND SERVICING DANGER Ensure that all bystanders have cleared the area. 1. Position shield (A) until pins (B) (one on each side) engage the slots in support (C) and the bolt holes in shield (A) align with holes (D) in the header. Figure 4.171: Left Side of Header –...
Page 253: Replacing Driveshields
MAINTENANCE AND SERVICING 4.10.5 Replacing Driveshields If driveshields are missing, severely damaged, or are not securely installed due to damage, they must be replaced. Removing Driveshields 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;...
Page 254 MAINTENANCE AND SERVICING 2. Insert the flat end of tool (A) into latch (B) and turn it counterclockwise to unlock the latch. Figure 4.175: 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 255: Installing Driveshields
MAINTENANCE AND SERVICING Installing Driveshields No additional tools are needed to install 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; the right driveshield is similar. 1.
Page 256 MAINTENANCE AND SERVICING 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. Reinstall retained hex nut and flat washer (A). Figure 4.179: Backside of Driveshield 5.
Page 257: Electrical System
MAINTENANCE AND SERVICING 4.11 Electrical System The electrical system is powered by the windrower. Figure 4.181: Electrical Harness Electrical harness (A) connects the header to the windrower, supplying power to the hazard and signal lights. The system also receives signals from speed sensor (B). 4.11.1 Maintaining Electrical System Proper maintenance of the electrical system helps prevent future problems.
Page 258: Replacing Amber Hazard/Signal Bulb
MAINTENANCE AND SERVICING 3. Remove four nuts (A) and bolts (B) securing the light to the bracket. NOTE: Only three bolts are shown in the illustration. 4. Remove the light and disconnect it from the electrical harness. 5. Connect the new light to the electrical harness. 6.
Page 259: Replacing Header Speed Sensor
MAINTENANCE AND SERVICING 4.11.4 Replacing Header Speed Sensor If the header speed sensor malfunctions or is damaged, it will need to be replaced. 1. Lower the header fully. 2. Shut down the engine, and remove the key from the ignition. 3.
Page 260: Hydraulics
MAINTENANCE AND SERVICING 4.12 Hydraulics Consult this section for general information on the hydraulic system. Detailed procedures for maintaining and repairing the hydraulic system are beyond the scope of the operator s manual. 4.12.1 Checking Hydraulic Hoses and Lines Check the hydraulic hoses and lines daily for signs of damage or leaks. Replace any damaged or leaking hoses immediately. Follow all applicable safety procedures while inspecting and maintaining the hydraulic system.
Page 261: 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 262: Updated Blades Kit
OPTIONS AND ATTACHMENTS 5.1.5 Updated Blades Kit The blades included in this kit have a larger cut length, providing a cleaner cut in lighter crops. MD #359122 Figure 5.2: Updated Blades Kit 262705 Revision A...
Page 263: Hydraulic Drive Conversion Kits
5.2.1 R113 SP to M1/M2/M205 Hydraulic Drive Kit The Hydraulic Drive kit is required to configure an R113 SP Rotary Disc Header for use with an M155 or M155E4 SP Windrower to an M205 SP, M1 Series, or an M2 Series Windrower.
Page 264: M155 And M155E4 Hydraulic Drive Conversion Kit
OPTIONS AND ATTACHMENTS 5.2.3 M155 and M155E4 Hydraulic Drive Conversion Kit The Hydraulic Drive kit is required for an R113 Rotary Disc Header to operate correctly with M155 or M155E4 Self- Propelled Windrowers. The hydraulic motor supplied in the kit will need to be installed on the header gearbox and hydraulic lines (A) will need to be attached to the motor.
Page 265: Chapter 6: Troubleshooting
Chapter 6: Troubleshooting Refer to this table if you encounter problems while operating your machine. 6.1 Performance Problems If your machine is in good mechanical condition but is not performing to your satisfaction, consult this table. Problem Solution Refer to Symptom: Cutterbar plugging Removing Disc Blades, page 177 Dull, bent, or badly worn disc blades...
Page 266 TROUBLESHOOTING Problem Solution Refer to Symptom: Conditioner rolls plugging Ground speed is too fast Reduce the ground speed. Adjusting Roll Gap – Polyurethane Roll gap too large for the proper Rolls, page 125 Decrease the roll gap. feeding of crop Adjusting Roll Gap –...
Page 267 TROUBLESHOOTING Problem Solution Refer to Symptom: Not cutting short enough in down crop Ground speed is too fast Reduce the ground speed. Replace the blades or turn the Removing Disc Blades, page 177 Broken, bent, or dull blades blades over. Installing Disc Blades, page 178 If field conditions allow, adjust the Cutting height is too high...
Page 268 TROUBLESHOOTING Problem Solution Refer to Positioning Forming Shield Side Deflectors – Roll Conditioner, page Crop is spread too wide in the Adjust the forming shields. windrow Positioning Rear Baffle – Roll Conditioner, page 132 Symptom: Poorly formed or bunchy windrows Positioning Forming Shield Side Deflectors –...
Page 269: Mechanical Problems
TROUBLESHOOTING 6.2 Mechanical Problems If your machine develops mechanical problems, consult this table for guidance. Problem Solution Refer to Symptom: Excessive noise Removing Disc Blades, page 177 Replace the blade. Bent disc blade Installing Disc Blades, page 178 Check the roll timing and adjust it, if Checking Roll Timing, page 128 Conditioner roll timing is off necessary.
Page 270 Belt pulleys and idlers misaligned Align the pulleys and the idler. Contact your MacDon Dealer Symptom: Conditioner roll does not rotate Inspecting Conditioner Drive Belt, page Faulty drive belt Check the drive belt pulleys.
Page 271 TROUBLESHOOTING Problem Solution Refer to Defective relief valve in the windrower Repair or replace the relief valve. Contact your MacDon Dealer Reduce ground speed until the oil Cold oil in the hydraulic drive system reaches operating temperature. 262705 Revision A...
Page 273: 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 274 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 275: 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 276: 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 277: 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 278: 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 279: 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 280 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 264. 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 281: 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 283: Index
Index roll tension............127 adjusting ............127 accelerators roll timing ............128 inspecting ............179 adjusting ............129 installing............181 checking............128 maintaining............179 conversion chart ..........265 removing ............180 curtains attaching windrowers inspecting curtains ..........213 M Series Windrowers installing door curtains........
Page 284 INDEX decals..............12 M155, M155E4 Windrowers ......103 definitions............. 23 M2 Series Windrowers........90 deflectors M205 Windrowers ......... 109 cutterbar deflectors........... 134 electrical systems ..........241 installing ............135 maintaining............241 removing............134 side deflectors positioning on roll conditioner ......131 disc blades ............
Page 285 INDEX M1 Series Windrowers........97 M155, M155E4 Windrowers ......103 operations............. 25 M2 Series Windrowers........90 cutting height ........... 118 M205 Windrowers daily start-up check ..........26 with quick couplers........107 driveshields............112 without quick couplers ........ 108 haying tips ............137 fittings header angle ............
Page 286 INDEX polyurethane rolls.......... 125 transporting the header......... 139 steel rolls............126 troubleshooting roll tension ............127 mechanical ............253 adjusting ............127 performance ............ 249 roll timing ............128 adjusting ............129 checking ............128 roll-type conditioning, See roll conditioners weather and topography ........
Page 287: 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 288 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.

MacDon R113 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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