MacDon R1 SERIES Unloading & Assembly Instruction

Type
Unloading & Assembly Instruction
R113 and R116
Rotary Disc Header
Unloading and Assembly Instructions
215368 Revision A
Original Instruction
The Harvesting Specialists.
R113 Rotary Disc Header
1021763
Published July 2020.
© 2020 MacDon Industries, Ltd.
The information in this publication is based on the information available and in effect at the time of printing. MacDon
Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the
information in this publication. MacDon Industries, Ltd. reserves the right to make changes at any time without notice.
Introduction
This instruction describes the unloading, setup, and predelivery requirements for the MacDon R113 Rotary Disc Header and
R116 Rotary Disc Header.
To ensure your customers receive all of the performance and safety benefits from this product, carefully follow the
unloading and assembly procedure from the beginning through to completion.
Retain this instruction for future reference.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Conventions
The following conventions are followed in this document:
• Right and left are determined from the operator’s position, facing the direction of travel.
• Unless otherwise noted, use the standard torque values provided in this manual.
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).
This instruction is available in English only.
215368 i Revision A
Summary of Changes
This list covers changes made since the last revision.
Section Summary of Change
Internal Use Only
Throughout manual Added R116 Rotary Disc Header content. Tech Pubs
2 Unloading the Header, page 7 Added image of tipping hooks and new decal.
ECN 58772
—
Removed topics for unpacking hydraulic hoses on headers and
installing hose support for M155E4 because the hydraulics bundle
is shipped separately with separate instructions.
ECN 59076
3.4 Installing Hydraulic Header
Drive, page 15
Added topic directing the user to the hydraulic drive installation
instructions.
ECN 59076
4 Changing the Conditioner,
page 17
Moved this chapter and its topics before attaching header to
windrower.
Tech Pubs
5 Attaching Rotary Disc Header
to Windrower, page 31
Added links to specific windrower instructions. Tech Pubs
6.2 Connecting R1 Series Rotary
Disc Header Hydraulics and
Electrical to M1170 Windrowers,
page 52
Removed steps to assemble the pressure hose because it’s
covered in the hydraulic drive kit instruction.
Product Support
6.4 Connecting R113 Rotary Disc
Header Hydraulic and Electrical
to M205 Windrower, page 64
Added topic to advise of kit MD #257188 for connecting R113 SP
to M205 Windrower.
ECN 59549
215368 ii Revision A
215368 iii Revision A
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Chapter 1: Safety .................................................................... .................................................................... 1
1.1 Signal Words ......................................................................................................................................... 1
1.2 General Safety ....................................................................................................................................... 2
1.3 Welding Precaution ................................................................................................................................ 4
1.4 Safety Signs ...........................................................................................................................................5
Chapter 2: Unloading the Header .......................................... .................................................................... 7
Chapter 3: Assembling the Header ............................................................................................................ 9
3.1 Removing Lower Shipping Support ............................................................................................................ 9
3.2 Lowering the Header............................................................................................................................. 12
3.3 Removing Shipping Stands ..................................................................................................................... 14
3.4 Installing Hydraulic Header Drive............................................................................................................. 15
3.5 Assembling Hazard Lights....................................................................................................................... 16
Chapter 4: Changing the Conditioner ...................................................................................................... 17
4.1 Removing the Conditioner ..................................................................................................................... 17
4.2 Installing the Conditioner....................................................................................................................... 21
4.2.1 Installing Conditioner Drive............................................................................................................ 25
4.3 Conditioner Drive Belt ........................................................................................................................... 27
4.3.1 Removing Conditioner Drive Belt .................................................................................................... 27
4.3.2 Installing Conditioner Drive Belt ..................................................................................................... 27
4.4 Discharge Shield – No Conditioner........................................................................................................... 29
4.4.1 Removing Discharge Shield – No Conditioner .................................................................................... 29
4.4.2 Installing Discharge Shield – No Conditioner ..................................................................................... 30
Chapter 5: Attaching Rotary Disc Header to Windrower ....................................................................... 31
5.1 Attaching R1 Series Rotary Disc Header to M1 Series Windrower .................................................................. 31
5.2 Attaching R1 Series Rotary Disc Header to M155, M155E4 , M205 Windrower – Hydraulic Center-Link with
Optional Self-Alignment......................................................................................................................... 37
5.3 Attaching R1 Series Rotary Disc Header to M155, M155E4 , M205 Windrower – Hydraulic Center-Link without
Optional Self-Alignment......................................................................................................................... 42
Chapter 6: Attaching Hydraulic and Electrical Components................................................................... 47
6.1 Connecting R113 Rotary Disc Header Hydraulics and Electrical to M1240 Windrower ....................................... 47
6.2 Connecting R1 Series Rotary Disc Header Hydraulics and Electrical to M1170 Windrowers ................................ 52
6.2.1 Calibrating M1 Series Windrower Knife Drive and Header on the Harvest Performance Tracker
Display ....................................................................................................................................... 55
6.3 Connecting R1 Series Rotary Disc Hydraulic and Electrical to M155 or M155E4 Windrowers .............................. 57
6.4 Connecting R113 Rotary Disc Header Hydraulic and Electrical to M205 Windrower .......................................... 64
TABLE OF CONTENTS
215368 iv Revision A
Chapter 7: Unpacking Curtains ................................................................................................................ 65
Chapter 8: Installing Options .................................................................................................................... 69
8.1 Installing Tall Crop Dividers .................................................................................................................... 69
Chapter 9: Lubricating the Rotary Disc Header....................................................................................... 71
9.1 Lubrication Locations ............................................................................................................................ 72
Chapter 10: Performing Predelivery Checks............................................................................................ 73
10.1 Checking Conditioner Drive Belt ............................................................................................................ 73
10.1.1 Adjusting Conditioner Drive Belt ................................................................................................... 73
10.2 Checking Skid Shoes ............................................................................................................................ 75
10.3 Checking Float – M1 Series Windrowers ................................................................................................. 76
10.3.1 Setting the Float – M1 Series Windrowers ...................................................................................... 76
10.4 Checking Float – M155 or M155E4......................................................................................................... 78
10.4.1 Adjusting Float Using Drawbolts – M155, and M155E4...................................................................... 79
10.5 Checking Roll Timing ........................................................................................................................... 80
10.5.1 Adjusting Roll Timing .................................................................................................................. 80
10.6 Checking and Adding Lubricant – Conditioner Roll Timing Gearbox .............................................................. 83
10.7 Checking Header Drive Gearbox Lubricant............................................................................................... 85
10.8 Checking and Adding Lubricant – Cutterbar ............................................................................................. 86
10.9 Checking Roll Gap ............................................................................................................................... 88
10.9.1 Adjusting Roll Gap – Steel Rolls..................................................................................................... 88
10.9.2 Adjusting Roll Gap – Polyurethane Rolls ......................................................................................... 89
10.10 Checking Roll Tension ........................................................................................................................ 90
10.10.1 Adjusting Roll Tension ............................................................................................................... 90
10.11 Adjusting Conditioner Baffle Position.................................................................................................... 91
10.12 Checking and Adjusting Forming Shield Deflector Position........................................................................92
10.13 Checking Lights ................................................................................................................................. 93
10.14 Checking Manuals ............................................................................................................................. 94
10.15 Running up the Header ...................................................................................................................... 95
Chapter 11: Reference............................................................................................ .................................. 97
11.1 Recommended Lubricants .................................................................................................................... 97
11.2 Opening Driveshields........................................................................................................................... 98
11.3 Closing Driveshields........................................................................................................................... 100
11.4 Cutterbar Doors................................................................................................................................ 101
11.4.1 Opening Cutterbar Doors........................................................................................................... 101
11.4.2 Opening Cutterbar Doors – Export Latches.................................................................................... 102
11.4.3 Closing Cutterbar Doors............................................................................................................. 103
11.5 Torque Specifications ........................................................................................................................ 104
11.5.1 Metric Bolt Specifications .......................................................................................................... 104
TABLE OF CONTENTS
215368 v Revision A
11.5.2 Metric Bolt Specifications Bolting into Cast Aluminum .................................................................... 106
11.5.3 O-Ring Boss Hydraulic Fittings – Adjustable................................................................................... 106
11.5.4 O-Ring Boss Hydraulic Fittings – Non-Adjustable ............................................................................ 108
11.5.5 O-Ring Face Seal Hydraulic Fittings .............................................................................................. 109
11.5.6 Tapered Pipe Thread Fittings ...................................................................................................... 110
11.6 Conversion Chart .............................................................................................................................. 111
11.7 Definitions....................................................................................................................................... 112
Predelivery Checklist .............................................................................................................................. 114
TABLE OF CONTENTS
215368 1 Revision A
Chapter 1: Safety
1.1 Signal Words
Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words,
IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be
used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may be used
to alert against unsafe practices.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.
215368 2 Revision A
1.2 General Safety
1000004
Figure 1.1: Safety Equipment
CAUTION
The following general farm safety precautions should be part of
your operating procedure for all types of machinery.
Protect yourself when assembling, operating, and servicing
machinery, wear all protective clothing and personal safety
devices that could be necessary for the job at hand. Do NOT
take chances. You may need the following:
• Hard hat
• Protective footwear with slip-resistant soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• Respirator or filter mask
1000005
Figure 1.2: Safety Equipment
In addition, take the following precautions:
• Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection devices
such as earmuffs or earplugs to help protect against loud
noises.
1010391
Figure 1.3: Safety Equipment
• Provide a first aid kit in case of emergencies.
• Keep a properly maintained fire extinguisher on the machine.
Be familiar with its proper use.
• Keep young children away from machinery at all times.
• Be aware that accidents often happen when the Operator is
tired or in a hurry. Take time to consider the safest way.
NEVER ignore warning signs of fatigue.
SAFETY
215368 3 Revision A
1000007
Figure 1.4: Safety around Equipment
• Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as scarves or bracelets.
• Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate
independently of shaft and can telescope freely.
• Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.
1000008
Figure 1.5: Safety around Equipment
• Keep hands, feet, clothing, and hair away from moving parts.
NEVER attempt to clear obstructions or objects from a
machine while the engine is running.
• Do NOT modify the machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten the machine’s life.
• To avoid 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.
1000009
Figure 1.6: Safety around Equipment
• Keep service area clean and dry. Wet and/or oily floors are
slippery. Wet spots can be dangerous when working with
electrical equipment. Be sure all electrical outlets and tools
are properly grounded.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff on a hot engine are
fire hazards. Do NOT allow oil or grease to accumulate on
service platforms, ladders, or controls. Clean machines before
storage.
• NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
• When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
SAFETY
215368 4 Revision A
1.3 Welding Precaution
To prevent damage to sensitive electronics, welding should never be attempted on the rotary disc header while it is
connected to a windrower.
WARNING
Severe damage to sensitive, expensive electronics can result from welding on the header while it is connected to the
windrower. It can be impossible to know what effect high current could have with regard to future malfunctions or
shorter lifespan. It is very important that welding on the header is not attempted while the header is connected to the
windrower.
If it is unfeasible to disconnect the rotary disc header from the windrower before welding, refer to the windrower’s
technical manual for welding precautions detailing all electrical components that must be disconnected first for safe
welding.
SAFETY
215368 5 Revision A
1.4 Safety Signs
1000694
Figure 1.7: Operator’s Manual Decal
• Keep safety signs clean and legible at all times.
• Replace safety signs that are missing or illegible.
• If the original part on which a safety sign was installed is
replaced, be sure the repair part displays the current
safety sign.
SAFETY
215368 7 Revision A
Chapter 2: Unloading the Header
CAUTION
To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area.
CAUTION
Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment
may result in chain breakage, vehicle tipping, or machine damage.
Table 2.1 Lifting Vehicle
Minimum Capacity
1
3630 kg (8000 lb.)
Minimum Fork Length
198 cm (78 in.)
IMPORTANT:
Forklifts are normally rated for a load located 610 mm (24 in.) ahead of the back end of the forks. To obtain the forklift
capacity at 1220 mm (48 in.), check with your forklift distributor.
1033533
A
Figure 2.1: Lifting Header off Trailer
IMPORTANT:
Do NOT lift at hooks (A) when unloading from trailer. Hooks (A)
are ONLY for tipping the machine over to working position.
WARNING
Be sure forks are secure before moving away from load. Stand clear when lifting.
1. At 1220 mm (48 in.) from back end of forks.
215368 8 Revision A
1021175
Figure 2.2: Lifting Header off Trailer
1. Remove hauler’s tie-down straps and chains.
2. Approach the header from its underside and slide the forks
under the lifting framework as far as possible.
IMPORTANT:
Do NOT damage the hydraulic hoses hanging below the
header.
3. Raise the header off the deck.
IMPORTANT:
If unloading a header from a two-unit load, avoid damage
to the other header.
1018583
Figure 2.3: Moving Header with Forklift
4. Back up until the header clears the trailer, and then slowly
lower to 150 mm (6 in.) from the ground.
5. Take header to the storage or setup area.
6. Set header down on secure, level ground.
7. Check for shipping damage and missing parts.
UNLOADING THE HEADER
215368 9 Revision A
Chapter 3: Assembling the Header
Follow each procedure in this chapter in order.
3.1 Removing Lower Shipping Support
1018484
A
B
Figure 3.1: Shipping Support
1. Support wood brace (B), cut three shipping straps (A), and
then remove the wood brace.
1018423
A
B
A
Figure 3.2: Vertical Fork Channels
2. Remove four bolts (A) on both vertical fork channels (B),
and then remove vertical fork channels.
1021435
B
A
Figure 3.3: R113 SP Left Skid Shoe Shown
NOTE:
R113 SP headers have one skid shoe per side; R116 SP
headers have two.
3. Remove bolt (A) at skid shoe (B) (inner skid shoe on
R116 SP). Retain bolt for reinstallation.
215368 10 Revision A
1019587
A
B
Figure 3.4: R113 Left Skid Shoe Shown
4. Lift skid shoe (B) out of the way and support it with
wire (A). Repeat for opposite skid shoe.
1020942
A
B
Figure 3.5: Base Shipping Support – Right Side Shown
5. Remove three bolts (A) per side on base support (B).
Repeat at opposite end of base support.
ASSEMBLING THE HEADER
215368 11 Revision A
1018427
A
Figure 3.6: Base Shipping Support
6. Remove base support (A).
1019587
A
B
Figure 3.7: R113 SP Left Skid Shoe Shown
7. Remove wire (A) holding skid shoe (B).
1018481
A
B
C
Figure 3.8: R113 SP Left Skid Shoe Shown
8. Tilt skid shoe (B) inward, and align link (A) with the
mounting hole in the skid shoe.
9. Install bolt, washer, and nut (C).
10. Push the skid shoe towards the header, and tighten nut (C).
11. Repeat Steps 7, page 11 to 10, page 11 for the
opposite side.
ASSEMBLING THE HEADER
215368 12 Revision A
3.2 Lowering the Header
CAUTION
Ensure spreader bar is secured to the forks so that it cannot slide off the forks or towards the mast as the header is
lowered to the ground.
Table 3.1 Lifting Vehicle
Chain Type
Overhead lifting quality, 13 mm (1/2 in.)
Minimum Working Load
2270 kg (5000 lb.)
1021185
A
B
B
C
Figure 3.9: Spreader Bar Attached to Header
1. Attach spreader bar (A) to forks.
IMPORTANT:
Length of spreader bar must be approximately
4600 mm (180 in.).
2. Drive lifting vehicle to approach the header from
its underside.
3. Attach chains to hooks (B) on either side of the header.
IMPORTANT:
Do NOT lift at hooks when unloading from trailer. This
procedure is only for laying the machine over into working
position.
IMPORTANT:
Chain length must be sufficient to provide a minimum
1220 mm (48 in.) (C) between spreader bar and header.
4. Raise forks until lift chains are fully tensioned.
CAUTION
Stand clear when lowering the disc header.
ASSEMBLING THE HEADER
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80
  • Page 81 81
  • Page 82 82
  • Page 83 83
  • Page 84 84
  • Page 85 85
  • Page 86 86
  • Page 87 87
  • Page 88 88
  • Page 89 89
  • Page 90 90
  • Page 91 91
  • Page 92 92
  • Page 93 93
  • Page 94 94
  • Page 95 95
  • Page 96 96
  • Page 97 97
  • Page 98 98
  • Page 99 99
  • Page 100 100
  • Page 101 101
  • Page 102 102
  • Page 103 103
  • Page 104 104
  • Page 105 105
  • Page 106 106
  • Page 107 107
  • Page 108 108
  • Page 109 109
  • Page 110 110
  • Page 111 111
  • Page 112 112
  • Page 113 113
  • Page 114 114
  • Page 115 115
  • Page 116 116
  • Page 117 117
  • Page 118 118
  • Page 119 119
  • Page 120 120
  • Page 121 121
  • Page 122 122
  • Page 123 123
  • Page 124 124
  • Page 125 125
  • Page 126 126

MacDon R1 SERIES Unloading & Assembly Instruction

Type
Unloading & Assembly Instruction

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI