MacDon R216 SP Operator's Manual
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MacDon R216 SP Operator's Manual

Rotary disc header
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R216 SP
Rotary Disc Header
Operator's Manual
214880 Revision A
Original Instruction
The harvesting specialists.

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Summary of Contents for MacDon R216 SP

  • Page 1 R216 SP Rotary Disc Header Operator’s Manual 214880 Revision A Original Instruction The harvesting specialists.
  • Page 2 The A-weighted sound pressure level inside the operator’s station of a typical self-propelled vehicle (e.g., M1240), when operated in conjunction with this R216 SP Rotary Disc Header, is 70 dBA. This measurement was taken in accordance with ISO 5131. The sound pressure level depends upon the rotary disc speed, crop conditions, as well the exact type of self-...
  • Page 3 Use this manual as your first source of information about the machine. If you follow the instructions provided in this manual, and use MacDon parts, the rotary disc header will work well for many years. If you require more detailed service information, contact your Dealer.
  • Page 4 Serial Number Record the serial number and model year of the header in the spaces provided below. R216 SP Disc Mower Header model: Serial number: Model year: The serial number plate (A) is located on the left side of the header, on top of the end panel.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ..............................i Serial Number............................. ii 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 .............................6 1.6 Welding Precaution ..........................7 1.7 Safety Signs ............................8 1.7.1 Installing Safety Decals........................8 1.8 Locating Safety Decals ..........................9 1.9 Understanding Safety Signs ........................
  • Page 6 TABLE OF CONTENTS 3.9 Reconfiguring Cutterbar Crop Stream....................... 47 3.9.1 Changing R216 SP Cutterbar Crop Stream Configuration ..............48 3.10 Conditioner ............................49 3.10.1 Roll Gap............................ 49 Adjusting Roll Gap ........................49 3.10.2 Roll Tension ..........................50 Adjusting Roll Tension ......................... 50 3.10.3 Roll Timing ..........................
  • Page 7 TABLE OF CONTENTS Inspecting Discblades ........................87 Inspecting Discblade Hardware ..................... 89 Removing Discblades........................90 Installing Discblades ........................92 4.5.5 Maintaining Accelerators....................... 93 Inspecting Accelerators........................ 93 Removing Accelerators ........................ 94 Installing Accelerators ......................... 96 4.5.6 Maintaining Rock Guards....................... 97 Inspecting Rock Guards........................ 97 Removing Rock Guards ........................
  • Page 8 TABLE OF CONTENTS Chapter 5: Options and Attachments ....................153 5.1 Performance Kits ..........................153 5.1.1 Tall Crop Divider Kit........................153 5.1.2 Adjustable Gauge Roller Kit......................153 5.1.3 Adjustable Skid Shoes Kit......................154 5.1.4 Electric Remote Baffle Kit ......................154 Chapter 6: Troubleshooting........................

  • Page 9: Chapter 1: Safety

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

  • Page 10: Signal Words

    SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words, IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

  • Page 11: General Safety

    SAFETY 1.3 General Safety CAUTION The following general farm safety precautions should be part of your operating procedure for all types of machinery. Protect yourself. • When assembling, operating, and servicing machinery, wear all protective clothing and personal safety devices that could be necessary for job at hand.
  • Page 12 SAFETY • Wear close-fitting clothing and cover long hair. NEVER wear dangling items such as scarves or bracelets. • Keep all shields in place. NEVER alter or remove safety equipment. Make sure driveline guards can rotate independently of shaft and can telescope freely. •...

  • Page 13: Maintenance Safety

    SAFETY 1.4 Maintenance Safety To ensure your safety while maintaining machine: • Review operator’s manual and all safety items before operation and/or maintenance of machine. • Place all controls in Neutral, stop the engine, set the park brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing.

  • Page 14: Hydraulic Safety

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

  • Page 15: Welding Precaution

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

  • Page 16: Safety Signs

    SAFETY 1.7 Safety Signs • Keep safety signs clean and legible at all times. • Replace safety signs that are missing or illegible. • If original part on which a safety sign was installed is replaced, be sure the repair part displays the current safety sign.

  • Page 17: Locating Safety Decals

    SAFETY 1.8 Locating Safety Decals Figure 1.15: Safety Sign Decal Locations – Top View A - MD #307746 B - MD #113482 C - MD #166832 D - MD #190546 Figure 1.16: Safety Sign Decals 214880 Revision A...
  • Page 18 SAFETY Figure 1.17: Safety Sign Decal Locations – Rear View A - MD #190546 B - MD #325070 C - Reflector 214880 Revision A...

  • Page 19: Understanding Safety Signs

    SAFETY 1.9 Understanding Safety Signs NOTE: This is a general list of safety sign definitions and the decals listed may not necessarily be applicable to your machine. MD #113482 General hazard pertaining to machine operation and servicing. CAUTION • Read the operator’s manual, and follow all safety instructions.
  • Page 20 SAFETY MD #190546 Slippery surface WARNING—DO NOT STEP ON SURFACE • Do NOT use this area as a step or platform. • Failure to comply could result in serious injury or death. Figure 1.20: MD #190546 MD #307746 Thrown/sharp object hazard WARNING •...

  • Page 21: Chapter 2: Product Overview

    Frame and Structure Width (transport) 5027 mm (198 in.) Weight: base machine with steel conditioner 2156 kg (4750 lb.) Compatible windrower MacDon M1240 Lighting Left and right turn signals Plastic case on header — Left header support Manual storage deflector...
  • Page 22 PRODUCT OVERVIEW Hay Conditioner Options Steel rolls Standard Roll type Steel on steel chevron conditioner rolls Roll length 3275 mm (129 in.) 229 mm (9 in.) roll diameter (outer) on Roll diameter 179 mm (7 in.) OD tube 1009 rpm Roll speed Swath width 915–2438 mm (36–96 in.)

  • Page 23: Component Identification

    PRODUCT OVERVIEW 2.2 Component Identification Figure 2.1: R216 SP Series rotary Rotary Disc Header A - Front Curtain B - Disc Drum (Right) C - 10-Disc Cutterbar D - Conditioner Rolls E - Drive Shield (Left) F - Hydraulic Motor...
  • Page 24 PRODUCT OVERVIEW Figure 2.2: R216 SP Series Rotary Disc Header A - Header Supports B - Deflectors C - Rear Crop Baffle D - Drive Shield 214880 Revision A...

  • Page 25: Definitions

    PARK The slot opposite the NEUTRAL position on operator’s console of M1 Series windrowers R2 SP Series MacDon R216 Rotary Disc Headers for windrowers Revolutions per minute Society of Automotive Engineers A headed and externally threaded fastener that threads into preformed threads or forms...
  • Page 26 PRODUCT OVERVIEW Term Definition A joint made with use of a fastener where joining materials are compressible or Soft joint experience relaxation over a period of time SP rotary disc header Rotary disc header that connects to a self-propelled machine (windrower, etc.) Tension Axial load placed on a bolt or screw, usually measured in Newtons (N) or pounds (lb.) TFFT...

  • Page 27: Chapter 3: Operation

    Chapter 3: Operation 3.1 Break-In Period After attaching the header to the windrower for the first time, operate the machine slowly for 5 minutes, watching and listening from the operator’s seat for binding or interfering parts. NOTE: Until you become familiar with the sound and feel of your new header, be extra alert and attentive. CAUTION Before investigating an unusual sound or attempting to correct a problem, stop the engine, put the ground speed lever (GSL) in PARK, and remove the key.

  • Page 28: Daily Start-Up Check

    OPERATION 3.2 Daily Start-Up Check Perform the following checks each day before startup: CAUTION • Ensure the windrower and the header are properly attached, all controls are in neutral, and the windrower brakes are engaged. • Clear the area of other persons, pets etc. Keep children away from machinery. Walk around to make sure no one is under, on, or close to it.
  • Page 29 OPERATION 1. Check the machine for leaks or any parts that are missing, broken, or not working correctly. NOTE: Use proper procedure when searching for pressurized fluid leaks. Refer to 4.12.1 Checking Hydraulic Hoses and Lines, page 151. 2. Clean all lights and reflective surfaces on the machine, and check lights for proper operation.

  • Page 30: Engaging And Disengaging Header Safety Props

    OPERATION 3.3 Engaging and Disengaging Header Safety Props Safety props are located on both header lift cylinders on the windrower. 3.3.1 Engaging and Disengaging Header Safety Props – M1240 Windrower Safety props are located on both header lift cylinders on the windrower. Follow these steps to engage or disengage the header safety props: DANGER To avoid bodily injury from fall of raised header, always engage safety props when working on or around raised header,...
  • Page 31 OPERATION 4. Disengage safety props on both lift cylinders as follows: NOTE: If safety prop will not disengage, raise header to release the prop. Turn lever (A) away from header to raise safety prop until lever locks into vertical position. b.

  • Page 32: Attaching Header To M1240 Windrower

    OPERATION 3.4 Attaching Header to M1240 Windrower 3.4.1 Attaching Rotary Disc Header The M1240 windrower may have an optional self-aligning hydraulic center-link that allows vertical position control of the center-link from the cab. WARNING To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
  • Page 33 OPERATION CAUTION When lowering header lift legs without a header or weight box attached to the windrower, ensure the float springs tension is fully released to prevent damage to the header lift linkages. Figure 3.9: Header Float Spring 4. Press rotary scroll knob (A) on the display to highlight QuickMenu options.
  • Page 34 OPERATION 7. Press HEADER DOWN switch (E) on the ground speed lever (GSL) to fully retract header lift cylinders. 8. Self-Aligning Hydraulic Center-Link: Press the REEL UP switch (B) on the GSL to raise the center-link until the hook is above the attachment pin on the header. IMPORTANT: If the center-link is too low, it may contact the header as the windrower approaches the header for hookup.
  • Page 35 OPERATION 11. Self-Aligning Hydraulic Center-Link: Connect header electrical harness (A) to windrower. Figure 3.15: Header Electrical Harness 12. Self-Aligning Hydraulic Center-Link: Lower center-link (A) onto the header with REEL DOWN switch on the GSL until the center-link locks into position and the hook release (B) is down. b.
  • Page 36 OPERATION 14. Hydraulic Center-Link without Self-Alignment: Connect header electrical harness (A) to windrower. Figure 3.18: Header Electrical Harness 15. Install clevis pin (A) through support and windrower lift arm and secure with hairpin (B). Repeat for opposite side. IMPORTANT: Ensure clevis pin (A) is fully inserted, and hairpin is installed behind bracket.

  • Page 37: Connecting Rotary Disc Header Hydraulics And Electrical - M1240 Windrowers

    OPERATION Connecting Rotary Disc Header Hydraulics and Electrical – M1240 Windrowers 1. Move windrower left (cab forward) platform (A) to the OPEN position. For instructions, refer to the windrower operator’s manual. Figure 3.20: Windrower with Left Platform in Open Position 2.
  • Page 38 OPERATION 4. Remove protective plugs (A) from ends of hydraulic hoses. Figure 3.22: Protective Shipping Plugs on R216 Hydraulic Hoses 5. Use a clean rag to remove dirt and moisture from the couplers on the windrower and remove protective plugs (A) from hoses (B).
  • Page 39 OPERATION 6. Make the following hydraulic connections to the windrower: Connect disc pressure hose (A) marked with a red cable tie (B) to hard plumb fitting marked with a red cable tie (C) and torque to 205–226 Nm (151–167 lbf·ft) b.

  • Page 40: Connecting Rotary Disc Header Hydraulics Using Quick Couplers

    OPERATION 8. Close the windrower’s left side platform (A). Refer to windrower operator’s manual for procedure. Figure 3.26: M1240 Windrower with Left Platform in Closed Position Connecting Rotary Disc Header Hydraulics Using Quick Couplers To connect the R216 Rotary Rotary Disc Header hydraulic hoses to the M1240 Windrower using quick couplers, follow these steps: If your windrower is equipped with hard plumb connections, refer to for connection instructions.
  • Page 41 OPERATION 2. Remove protective plugs (A) from the ends of the hydraulic hoses. Figure 3.28: Protective Shipping Plugs on R216 Hydraulic Hoses 3. Use a clean rag to remove dirt and moisture from the couplers on the left side of the windrower frame. 4.
  • Page 42 OPERATION 5. Move left windrower platform (A) to the CLOSED position. For instructions, refer to the windrower operator’s manual. Figure 3.30: Windrower with Left Platform in Closed Position 214880 Revision A...

  • Page 43: Detaching Header From M1240 Windrower

    OPERATION 3.5 Detaching Header from M1240 Windrower 3.5.1 Detaching Rotary Disc Header from M1240 Windrower WARNING To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. CAUTION Check to be sure all bystanders have cleared the area.
  • Page 44 OPERATION 5. Disconnect electrical harness (A) and hydraulic hoses (B), (C), and (D) from the windrower. Figure 3.33: Header Electrical Connection Figure 3.34: Header Drive Hydraulics 6. Remove hose support (A) and hose bundle from windrower frame. Figure 3.35: Hoses on Windrower 214880 Revision A...
  • Page 45 OPERATION 7. Remove hairpin (B) from clevis pin (A). Remove clevis pin from header support (C) on both sides of header. Figure 3.36: Header Supports Windrowers with self-aligning center-link kit only: 8. Release the center-link latch (A) before returning to the cab.
  • Page 46 OPERATION Self-aligning hydraulic center-link (if installed): 13. Use HEADER TILT cylinder switches (A) on GSL to release load on center-link cylinder. 14. Operate the link lift cylinder with the REEL UP switch (B) to disengage the center-link from the header. Figure 3.39: GSL Hydraulic center-link without self-alignment: 15.

  • Page 47: Driveshields

    OPERATION 3.6 Driveshields Driveshields protect drive components from damage and provide access to drive components for maintenance and servicing. Driveshields are located on the left and right ends of the header. 3.6.1 Opening Driveshields CAUTION To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown in this procedure are for the left driveshield—the right driveshield is similar.
  • Page 48 OPERATION 2. Lift outboard driveshield panel toward outboard end of header. Figure 3.44: Opening Driveshield – Outboard Side 3. Grab handle (A) and lift the other half of the endshield (B) to the inboard side of the header. Figure 3.45: Driveshield – Inboard Side 214880 Revision A...

  • Page 49: Closing Driveshields

    OPERATION 3.6.2 Closing Driveshields CAUTION To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown in this procedure are for the left driveshield—the right driveshield is similar. 1. Lift lock latch (A) to disengage driveshield lock. Figure 3.46: Driveshield Lock Latch 2.

  • Page 50: Cutterbar Curtain

    OPERATION 3.7 Cutterbar Curtain WARNING To reduce the risk of personal injury or machine damage, do NOT operate the machine without curtain installed and in good condition. Foreign objects can be ejected with considerable force when the machine is started. NOTE: Cutterbar curtain is attached at the front and the sides of the header.

  • Page 51: Closing Cutterbar Curtain

    OPERATION 2. Securing curtain in place at locations (A) using 3 clips provided. Figure 3.51: Cutterbar Curtains — View from Below NOTE: Cutterbar curtain (A) is held in place between the tines of retaining clips (B). Figure 3.52: Cutterbar Curtain and Retaining Clips 3.7.2 Closing Cutterbar Curtain CAUTION To avoid injury, keep hands and fingers away from corners of doors when closing.

  • Page 52: Header Settings

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

  • Page 53: Adjusting Cutterbar Angle

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

  • Page 54: Ground Speed

    Operating the disc header at the minimum disc speed will extend the wear life of cutting components. The chart below indicates the relationship between ground speed and area cut. Figure 3.55: Ground Speed for R216 SP Rotary Disc Headers A - Acres/Hour...

  • Page 55: Reconfiguring Cutterbar Crop Stream

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

  • Page 56: Changing R216 Sp Cutterbar Crop Stream Configuration

    Refer to Removing Cutterbar Spindles, page 81 Installing Cutterbar Spindles, page To change R216 SP (10 disc) spindle rotation from four crop streams (A) to two crop stream (B): • Swap disc/spindle (3) with disc/spindle (8). NOTE: A disc timing tool (MD #307954) is available through MacDon parts to change disc/spindle configuration.

  • Page 57: Conditioner

    3.10 Conditioner Rolls condition the crop by crimping and crushing the stem in several places, which allows the release of moisture resulting in faster drying times. R216 SP headers are equipped with steel conditioner rolls. 3.10.1 Roll Gap The roll gap controls the degree to which crop is conditioned as it passes through the rolls. Roll gap is factory-set at approximately 6 mm (1/4 in.) for steel rolls.

  • Page 58: Roll Tension

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

  • Page 59: Roll Timing

    OPERATION 3.10.3 Roll Timing For proper conditioning, the rolls must be properly timed with the bar on one roll centered between two bars on the other roll. The factory setting should be suitable for most crop conditions. IMPORTANT: Roll timing is critical when the roll gap is decreased because conditioning is affected and the bars may contact each other.
  • Page 60 OPERATION 3. Secure bottom roll (A). 4. Manually rotate upper roll (B) counterclockwise direction until it stops rotating. 5. Make a mark (C) across yoke (D) and gearbox flange (E). Figure 3.64: Conditioner Drive 6. Manually rotate upper roll (A) clockwise it stops rotating. Make a second mark (B) on the yoke flange, and align it with the mark on the gearbox flange.
  • Page 61 OPERATION 7. Determine center point (A) between the two marks on the yoke plate, and place a third mark. 8. Rotate upper roll (B) counterclockwise, until the bolt lines up with the third (center) mark. Figure 3.66: Conditioner Drive 9. Ensure the threads on four bolts (A) are clean and free of lubricant.

  • Page 62: Adjusting Forming Shields - Roll Conditioner

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

  • Page 63: Positioning Rear Baffle - Roll Conditioner

    OPERATION 2. If side deflector attachment is too tight or too loose, tighten or loosen nut (A) as required. Figure 3.69: Side Deflector Adjustment Positioning Rear Baffle – Roll Conditioner The rear baffle is used in conjunction with the forming shields to affect the windrow width. It is located immediately behind and above the conditioning rolls and can be positioned to do the following: •...
  • Page 64 OPERATION Positioning Rear Baffle Deflector Fins Four rear baffle deflector fins are located under the baffle. Fins are factory-configured to approximately 60°. They can be adjusted when a narrower windrow is desired. To adjust fins, follow these steps: DANGER To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator's seat for any reason.
  • Page 65 OPERATION NOTE: Deflector fins (A) can be put in storage position by removing existing nut and bolt and reattaching fins on top of the baffle. Figure 3.73: Left Deflector Fins in Storage Position 214880 Revision A...

  • Page 66: Haying Tips

    OPERATION 3.11 Haying Tips 3.11.1 Curing Curing crops quickly helps maintain the highest quality of crop material as 5% of protein is lost from hay for each day that it lays on the ground after cutting. Leaving the windrow as wide and fluffy as possible results in the quickest curing. Cured hay should be baled as soon as possible.

  • Page 67: Windrow Characteristics

    OPERATION 3.11.4 Windrow Characteristics Producing windrows with the recommended characteristics will achieve the best results. Refer to 3 Operation, page 19 instructions on adjusting the header. Table 3.3 Recommended Windrow Characteristics Characteristic Advantage Enables airflow through windrow, which is more important to the curing High and fluffy process than direct sunlight Consistent formation (not bunching)

  • Page 68: Transporting The Header

    OPERATION 3.12 Transporting the Header For information on transporting the header when attached to the windrower, refer to your windrower operator’s manual. 214880 Revision A...

  • Page 69: Chapter 4: Maintenance And Servicing

    Chapter 4: Maintenance and Servicing The following instructions provide information about routine servicing for the header. A parts catalog is located in a plastic case on the fixed deflector on the left side of the header. Log hours of operation and use the maintenance record provided (refer to 4.3.1 Maintenance Schedule/Record, page 64) to keep track of your scheduled maintenance.

  • Page 70: Recommended Safety Procedures

    MAINTENANCE AND SERVICING 4.2 Recommended Safety Procedures • Park on level surface when possible. Follow all recommendations in your tractor operator's manual. • Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets. Figure 4.1: Safety Around Equipment •...
  • Page 71 MAINTENANCE AND SERVICING • Be prepared if an accident should occur. Know where the first aid kits and fire extinguishers are located, and know how to use them. Figure 4.4: Safety Equipment • Keep the service area clean and dry. Wet or oily floors are slippery.

  • Page 72: Maintenance Requirements

    MAINTENANCE AND SERVICING 4.3 Maintenance Requirements IMPORTANT: Recommended intervals are for average conditions. Service the machine more often if operating under adverse conditions (severe dust, extra heavy loads, etc.). Regular maintenance is the best insurance against early wear and untimely breakdowns. Following the maintenance schedule will increase your machine’s life.
  • Page 73 MAINTENANCE AND SERVICING Every 25 Hours Check conditioner drive belt tension. ü Refer to Inspecting Conditioner Drive Belt, page 134. Lubricate idler pivot. Refer to Lubrication, page Lubricate upper and lower driveline universal joints. Refer to 4.4 Lubrication, page Lubricate roller conditioner and feed roller bearings.

  • Page 74: Break-In Inspections

    MAINTENANCE AND SERVICING 4.3.2 Break-In Inspections Table 4.1 Break-In Inspection Schedule Inspection Item Refer to Interval Check for loose hardware and tighten 7.1 Torque Specifications, page 161 Hour to required torque Check for loose hardware and tighten 7.1 Torque Specifications, page 161 Hours to required torque Check conditioner drive belt drive...

  • Page 75: End-Of-Season Servicing

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

  • Page 76: Lubrication

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

  • Page 77: Lubrication Locations

    MAINTENANCE AND SERVICING 4.4.2 Lubrication Locations Figure 4.6: Left Side Lubrication Locations A - Idler/Tensioner Pivot B - Bearing, Roller Conditioner (2 Places) C - U-Joint, Conditioner Driveline (2 Places) D - Slip Joint, Conditioner Driveline 4 E - Idler/Tensioner Pivot F - Bearing, Feed Roll G - Tensioner Arm 4.
  • Page 78 MAINTENANCE AND SERVICING Figure 4.7: Right Side Lubrication Locations C - Slip Joints, Conditioner Drivelines 5 A - Bearing, Roller Conditioner (2 Places) B - U-Joint, Upper Driveline (2 Places) D - U-Joint, Lower Driveline (2 Places) E - Idler Pivot 5.

  • Page 79: Cutterbar System

    Maintenance Requirements, page IMPORTANT: Warm cold lubricant by idling the machine for 10 minutes prior to checking level. Figure 4.8: R216 SP Cutterbar 4.5.1 Lubricating Cutterbar Checking and Adding Cutterbar Lubricant WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
  • Page 80 MAINTENANCE AND SERVICING 5. Use a spirit (bubble) level (A) to ensure the cutterbar is level in both directions. Adjust the header accordingly. Figure 4.10: Spirit Level on Cutterbar 6. Clean the area around plug (A). Place a 5 liter (5.2 US qts) capacity container under plug (A).
  • Page 81 MAINTENANCE AND SERVICING CAUTION Before starting the machine, check to be sure all bystanders have cleared the area. 15. Start the engine and raise the header fully. 16. Shut down the engine, and remove the key from the ignition. Engage the windrower lift cylinder safety props. 17.

  • Page 82: Draining The Cutterbar

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

  • Page 83: Maintaining Cutterbar Discs

    MAINTENANCE AND SERVICING WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. IMPORTANT: The cutterbar should be completely empty of oil before filling it. Refer to Draining the Cutterbar, page 1.

  • Page 84: Inspecting Cutterbar Discs

    MAINTENANCE AND SERVICING IMPORTANT: If holes appear in a cutterbar disc, replace the disc immediately. Do NOT attempt to repair the cutterbar discs. Always use factory replacement parts. Inspecting Cutterbar Discs WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.

  • Page 85: Removing Cutterbar Discs

    MAINTENANCE AND SERVICING 6. Inspect the cutterbar disc for abrasion (A). The wear limit for abrasion is reached when the material thickness of the cutterbar discs is less than 3 mm (1/8 in.). Replace as required. Figure 4.19: Cutterbar Disc – View from Above Removing Cutterbar Discs DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and...

  • Page 86: Installing Cutterbar Discs

    MAINTENANCE AND SERVICING 5. Place a pin (or equivalent) in the front hole of the rock guard (B) to prevent disc rotation while loosening bolts. 6. Remove four M12 bolts (A) and washers. Figure 4.21: Cutterbar Disc Bolts 7. Remove cutterbar disc cap (A). 8.
  • Page 87 MAINTENANCE AND SERVICING 2. Place a pin (or equivalent) in the front hole of the rock guard (D) to prevent disc rotation while tightening bolts. 3. Position new disc (A) on spindle ensuring that it is positioned at a 90 degree angle in relation to the adjacent discs.

  • Page 88: Replacing Cutterbar Spindles

    MAINTENANCE AND SERVICING 4.5.3 Replacing Cutterbar Spindles To prevent damage to the cutterbar and drive systems, each disc is attached to a spindle containing a shear pin (A). If the disc contacts a large object such as a stone or stump, the pin will shear and the disc will stop rotating and move upwards while remaining attached to the spindle with a snap ring (B).

  • Page 89: Removing Cutterbar Spindles

    MAINTENANCE AND SERVICING Removing Cutterbar Spindles DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. CAUTION Discblades have two sharp cutting edges that can cause serious injury.
  • Page 90 MAINTENANCE AND SERVICING 8. Remove cutterbar disc cap (A). 9. Remove cutterbar disc (B). IMPORTANT: Blades are rotation specific. Switch entire disc when swapping spindles. Figure 4.30: Cutterbar Disc and Cap 10. Remove spacer plate (A). NOTE: The area around the spacer plate must be cleaned thoroughly to prevent debris from entering into the cutterbar gearbox.

  • Page 91: Installing Cutterbar Spindles

    MAINTENANCE AND SERVICING 12. Remove spindle (A) from cutterbar. Figure 4.33: Left Spindle Installing Cutterbar Spindles Figure 4.34: Underside of Cutterbar Spindles IMPORTANT: Right discs (A) and left discs (B) are timed and must be at a 90 degree angle from adjacent discs when reinstalled. Misaligned discs could result in the following: •...
  • Page 92 MAINTENANCE AND SERVICING NOTE: Right discs (A) and left discs (B) are slightly offset as shown, depending on which idler gear the spindle is turning. • Spindles that rotate clockwise have left-leading threading • Spindles that rotate counterclockwise have right-leading threading DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason.
  • Page 93 MAINTENANCE AND SERVICING 6. Insert studs (A) into spindle as shown. NOTE: Plugs are factory-installed as shown in position (B), but may come loose over time. Ensure studs are inserted into proper location. IMPORTANT: Ensure clockwise spindles rotate clockwise and counterclockwise spindles (with machined grooves) rotate counterclockwise.
  • Page 94 MAINTENANCE AND SERVICING 10. Install spacer plate (A). Figure 4.40: Spacer Plate 11. Place a pin (or equivalent) in the front hole of the rock guard (D) to prevent disc rotation while tightening bolts. IMPORTANT: Blades are rotation specific. It is necessary to switch entire disc when swapping spindles.

  • Page 95: Maintaining Discblades

    Always use factory replacement parts. NOTE: Discs are equipped with 18-degree bevel-down blades; 11-degree bevel-down blades are offered as a non-standard option. Refer to R216 SP Series Rotary Disc Header Parts Catalog. Figure 4.43: Discblades Inspecting Discblades WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.
  • Page 96 MAINTENANCE AND SERVICING 1. Check daily that the discblades are securely attached to the disc. 2. Inspect blades for cracks, blade wear (A), and/or elongated hole (B) beyond safe operating limits (C). 3. Replace blades immediately when problems are noticed. IMPORTANT: Blades should be replaced in pairs or the disc may become unbalanced and cause damage to the cutterbar.

  • Page 97: Inspecting Discblade Hardware

    MAINTENANCE AND SERVICING Inspecting Discblade Hardware CAUTION Damaged or loose discblades or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage. Inspect blade attachment hardware each time blades are changed. Refer to Removing Discblades, page 90 Installing Discblades, page 92...

  • Page 98: Removing Discblades

    1. Raise disc header fully, shut off engine, and remove key. 3.3.1 Engaging and Disengaging Header Safety Props – M1240 2. Engage windrower lift cylinder safety props. Refer to Windrower, page 3. Open cutterbar curtain (A). Refer to 3.7.1 Opening Cutterbar Curtain, page Figure 4.49: R216 SP 214880 Revision A...
  • Page 99 MAINTENANCE AND SERVICING 4. Rotate disc (A) so blade (B) faces forward and lines up with hole (C) in rock guard. Figure 4.50: Discblade Aligned with Hole in Rock Guard 5. Place a pin (or equivalent) in the front hole of the neighboring rock guard to prevent disc rotation while loosening blade bolts.

  • Page 100: Installing Discblades

    Figure 4.52: Discblade machine is started and may result in serious injury or machine damage. 4. Close the cutterbar curtain (A). Refer to 3.7.2 Closing Cutterbar Curtain, page Figure 4.53: R216 SP 214880 Revision A...

  • Page 101: Maintaining Accelerators

    IMPORTANT: Always replace accelerators in pairs to ensure proper disc balance. Figure 4.54: R216 SP Cutterbar Accelerators Inspecting Accelerators CAUTION Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades.

  • Page 102: Removing Accelerators

    2. Shut off the engine, and remove the key from the ignition. 3.3.1 Engaging and Disengaging Header Safety Props – M1240 3. Engage windrower lift cylinder safety props. Refer to Windrower, page 4. Open cutterbar curtain (A). Refer to 3.7.1 Opening Cutterbar Curtain, page Figure 4.57: R216 SP 214880 Revision A...
  • Page 103 MAINTENANCE AND SERVICING 5. Place a pin (or equivalent) in the front hole of the rock guard to prevent disc rotation while loosening bolts. 6. Line up rock guard hole and bolt to be removed. 7. Remove nut (A), flange bolt (B), and discblade (C) from disc. Discard nut.

  • Page 104: Installing Accelerators

    MAINTENANCE AND SERVICING Installing Accelerators CAUTION Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades. IMPORTANT: Always replace accelerators in pairs to ensure proper disc balance. 1. Place a pin (or equivalent) in the front hole of the neighboring rock guard to prevent disc rotation while tightening blade bolts.

  • Page 105: Maintaining Rock Guards

    8. Close cutterbar curtain (A). Refer to 3.7.2 Closing Cutterbar Curtain, page Figure 4.63: R216 SP 4.5.6 Maintaining Rock Guards The machine is equipped with rock guards at each cutting disc location. Rock guards prevent the cutterbar from digging into the ground and protect the disc from coming in contact with stones and other debris.

  • Page 106: Removing Rock Guards

    MAINTENANCE AND SERVICING 4. Inspect rock guards for wear, cracks, damage, or distortion. Replace if worn to 75% or more of their original thickness. 5. Check for loose or missing fasteners; tighten or replace fasteners as needed. Figure 4.64: Rock Guards Removing Rock Guards 1.

  • Page 107: Installing Rock Guards

    MAINTENANCE AND SERVICING Installing Rock Guards 1. Guide rock guard onto cutterbar until tabs (A) sit on top of the cutterbar and bottom back bolt holes line up. Figure 4.67: Rock Guards 2. Install two hex head screws, washers, and lock nuts (A). Torque hardware to 68 Nm (50 lbf·ft).

  • Page 108: Maintaining Drums

    Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades. 1. Lower the header fully. 2. Shut off the engine, and remove the key from the ignition. 3. Open cutterbar curtain (A). Refer to 3.7.1 Opening Cutterbar Curtain, page Figure 4.70: R216 SP 214880 Revision A...
  • Page 109 5. Examine drums for large dents. Replace dented drums to prevent an imbalance in the cutterbar. 6. Tighten or replace loose or missing fasteners. Figure 4.71: R216 SP Cutterbar A - Suspended Drums B - Left Driven Drum C - Right Driven Drum 7.

  • Page 110: Removing Suspended Drums

    9. Close cutterbar curtain (A). Refer to 3.7.2 Closing Cutterbar Curtain, page Figure 4.74: R216 SP Removing Suspended Drums DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason.
  • Page 111 MAINTENANCE AND SERVICING 5. Loosen two M10 hex flange head bolts (A). Pull back driveshield (B). Figure 4.76: Driveshield 6. Remove four M12 hex flange head bolts (A) securing suspended drum (B) to shaft (C), and remove suspended drum (B). Figure 4.77: Suspended Drum 7.

  • Page 112: Installing Suspended Drums

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

  • Page 113: Removing Left Driven Drum And Driveline

    MAINTENANCE AND SERVICING 3. Position driveshield (B) as shown. Use two M10 hex flange head bolts (A) to secure driveshield (B) in place. 4. Repeat Step 1, page 104 to Step 3, page 105 to install the opposite suspended drum. 5.
  • Page 114 MAINTENANCE AND SERVICING 5. Remove two M10 hex flange head bolts (A) and loosen two M10 hex flange head bolts (B). Pull back driveshield (C). Figure 4.83: Driveshield 6. Remove two M10 hex flange head bolts (A) and remove driveshield (B). Figure 4.84: Driveshield 7.

  • Page 115: Installing Left Driven Drum And Driveline

    MAINTENANCE AND SERVICING 8. Remove four M12 hex flange head bolts (A) securing driveline assembly (B) to hub drive (C). Figure 4.86: Driveline 9. Slide driveline (A) downwards, tilt it to the side, and pull driveline up and out of drum. Figure 4.87: Drum and Tube Shield –...
  • Page 116 MAINTENANCE AND SERVICING WARNING Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 1. Ensure spacer (A) is on spindle. Figure 4.89: Driven Spindle 2. Position the drum disc assembly (B) as shown. 3.
  • Page 117 MAINTENANCE AND SERVICING 7. Place a bead of high-strength threadlocker ® (Loctite 262 or equivalent) around the threads of four M12 hex flange head bolts (A). Use the bolts to secure driveline assembly (B) to hub drive (C). Torque bolts to 100 Nm (74 lbf·ft).

  • Page 118: Removing Right Driven Drum And Driveline

    MAINTENANCE AND SERVICING 10. Position driveshield (C) as shown. Apply a bead of medium- ® strength threadlocker (Loctite 243 or equivalent) around the threads of two M10 hex flange head bolts (A) and two M10 hex flange head bolts (B). Use bolts (A) and (B) to secure driveshield (C) in place.
  • Page 119 MAINTENANCE AND SERVICING 5. Remove two M10 hex flange head bolts (A) and loosen two M10 hex flange head bolts (B). Pull back driveshield (C). Figure 4.97: Driveshield 6. Remove two M10 hex flange head bolts (A) and remove driveshield (B). Figure 4.98: Driveshield 7.
  • Page 120 MAINTENANCE AND SERVICING 8. Remove four M10 hex flange head bolts (A) securing driveline assembly (B) to hub drive (C). Figure 4.100: Driveline 9. Slide driveline (A) downwards, tilt it to the side, and pull driveline up and out of drum. Figure 4.101: Drum and Tube Shield –...

  • Page 121: Installing Right Driven Drum And Driveline

    MAINTENANCE AND SERVICING Installing Right Driven Drum and Driveline DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason. WARNING Exercise caution when working around the blades.
  • Page 122 MAINTENANCE AND SERVICING 4. Lightly lubricate spindle splines (A). For specifications, refer to the inside back cover of this manual. 5. Insert driveline (B) at an angle and guide it past hub drive (C) and drum (D). 6. Insert splined spindle end (A) into splined bore of driveline (B).
  • Page 123 MAINTENANCE AND SERVICING 9. Position driveshield (B) as shown. Apply a bead of medium- ® strength threadlocker (Loctite 243 or equivalent) around the threads of two M10 hex flange head bolts (A). Use M10 hex flange head bolts (A) to secure driveshield (B) in place. Figure 4.108: Driveshield 10.

  • Page 124: Replacing Cutterbar Spindle Shear Pin

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

  • Page 125: Removing Cutterbar Spindle Shear Pin

    • To remove left driven drum (B), refer to Removing Left Driven Drum and Driveline, page 105. • To remove right driven drum (C), refer to Removing Right Driven Drum and Driveline, page 110. Figure 4.113: R216 SP Cutterbar 214880 Revision A...
  • Page 126 MAINTENANCE AND SERVICING 7. Remove retaining ring (A). Figure 4.114: Cutterbar Spindle 8. Remove M12 bolt and remove safecut spindle-nut wrench (A) from storage location. Figure 4.115: Safecut Spindle-Nut Wrench Location 214880 Revision A...
  • Page 127 MAINTENANCE AND SERVICING IMPORTANT: • Spindles that rotate clockwise have right-leading threading and a smooth top on the spindle gear shaft (A). • Spindles that rotate counterclockwise have left-leading threading and machined grooves on the spindle gear shaft (B) and nut (C). •...
  • Page 128 MAINTENANCE AND SERVICING 11. Remove shear pins (B). Do NOT damage the pin bore on the pinion. 12. Remove the hub (A). 13. Check the nut and hub for damage. Replace if necessary. Figure 4.119: Cutterbar Spindle 214880 Revision A...

  • Page 129: Installing Cutterbar Spindle Shear Pin

    MAINTENANCE AND SERVICING Installing Cutterbar Spindle Shear Pin WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. CAUTION Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades.
  • Page 130 MAINTENANCE AND SERVICING 5. Install nut (A). Figure 4.122: Cutterbar Spindle 6. Attach the safecut spindle-nut wrench (B) 90 degrees (D) to the torque wrench (A). IMPORTANT: If this is not done, the proper torque will NOT be applied to the nut.
  • Page 131 WARNING Ensure cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the Figure 4.126: R216 SP Cutterbar machine is started and may result in serious injury or machine damage. 13. Close cutterbar curtain (A). Refer to 3.7.2 Closing Cutterbar...

  • Page 132: Servicing Conditioner Roll Timing Gearbox

    MAINTENANCE AND SERVICING 4.6 Servicing Conditioner Roll Timing Gearbox The conditioner roll timing gearbox (A), located inside the drive compartment at the right of the header, transfers power from the gearbox-driven lower roll to the upper roll. The gearbox (A) does not require routine maintenance or service other than checking and changing oil.
  • Page 133 MAINTENANCE AND SERVICING 5. Remove the right driveshield (A). Refer to 4.10.1 Removing Driveshields, page 146. Figure 4.130: Right Driveshield Checking conditioner roll timing gearbox oil level: 6. Clean around oil level sight glass (A) and breather (B) on the inboard side of the gearbox.
  • Page 134 MAINTENANCE AND SERVICING 8. Raise the header to provide sufficient access to oil drain plug (A). 9. Shut down the engine, and remove the key from the ignition. 10. Engage the windrower lift cylinder safety props. Refer to 3.3.1 Engaging and Disengaging Header Safety Props – M1240 Windrower, page 11.

  • Page 135: Servicing Header Drive Gearbox

    MAINTENANCE AND SERVICING 4.7 Servicing Header Drive Gearbox The header drive gearbox (A), transfers power from the hydraulic motor to the cutterbar and conditioner. It is located inside the drive compartment at the left end of the header. The only regular servicing required is maintaining the lubricant level and changing the lubricant according to the intervals specified in this manual.
  • Page 136 MAINTENANCE AND SERVICING 4. Locate gearbox (A) on the left side of the header. Figure 4.134: Header Drive Gearbox Location 5. Clean area around check plug (A). 6. Remove check plug (A) with a 13 mm (1/2 in.) socket. 7. Ensure lubricant is even with bottom of check hole (A) or slightly runs out of hole (A).

  • Page 137: Changing Header Drive Gearbox Oil

    MAINTENANCE AND SERVICING 4.7.2 Changing Header Drive Gearbox Oil Change oil after the first 50 hours of operation. Perform subsequent oil changes every 250 hours or annually (preferably before the start of the cutting season). WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason.

  • Page 138: Cutterbar Curtain

    MAINTENANCE AND SERVICING 4.8 Cutterbar Curtain A rubber curtain (A) is installed at the front of the header. The curtain forms a barrier that minimizes the risk of thrown objects being ejected from the cutterbar area. Always keep curtains down during operation. Replace the curtains if they become worn or damaged.

  • Page 139: Removing Cutterbar Curtain

    MAINTENANCE AND SERVICING 4.8.2 Removing Cutterbar Curtain 1. Open cutterbar curtain (A). Refer to 3.7.1 Opening Cutterbar Curtain, page Figure 4.139: Cutterbar Curtain NOTE: Cutterbar removed from illustration for clarity. 2. Remove hex flange head bolt and washer (A) securing curtain (B) to the inboard side of the end panel.

  • Page 140: Installing Cutterbar Curtain

    MAINTENANCE AND SERVICING 4.8.3 Installing Cutterbar Curtain NOTE: Top shield removed from illustration for clarity. 1. Position curtain (E) on the front of the header frame. 2. Secure curtain with bumper mount (D), six M10 bolts (B), and six lock nuts (C). Do NOT tighten nuts at this time. 3.

  • Page 141: Conditioner

    MAINTENANCE AND SERVICING 4.9 Conditioner Rolls condition the crop by crimping and crushing the stem in several places, which allows the release of moisture resulting in faster drying times. R216 SP headers are equipped with steel conditioner rolls. 4.9.1 Inspecting Conditioner DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and engage windrower lift cylinder safety props before going under machine for any reason.

  • Page 142: Conditioner Drive Belt

    MAINTENANCE AND SERVICING 5. Inspect conditioner drive U-joints (A) for signs of wear or damage. If the U-joints need replacing, contact your Dealer. Figure 4.146: Conditioner Drive U-Joints 6. Inspect roll timing gearbox bearings (A) for signs of wear or damage.
  • Page 143 MAINTENANCE AND SERVICING 3. Open left driveshield (A). Refer to 3.6.1 Opening Driveshields, page Figure 4.148: Left Driveshield 4. Inspect drive belt (A) and replace if damaged or cracked. 5. Check that jam nut (B) and adjuster nut (C) are tight. Figure 4.149: Conditioner Drive 6.
  • Page 144 MAINTENANCE AND SERVICING Removing Conditioner Drive Belt WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. 1. Lower the header fully. 2. Shut down the engine, and remove key from the ignition. 3.
  • Page 145 MAINTENANCE AND SERVICING Installing Conditioner Drive Belt WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. 1. Lower the header fully. 2. Shut down the engine, and remove the key from the ignition. 3.

  • Page 146: Changing The Conditioner

    Changing the Conditioner R216 SP Series Rotary Disc Headers are equipped with a steel roll conditioner. Rolls condition the crop by crimping and crushing the stem in several places, which allows the release of moisture resulting in faster drying times.
  • Page 147 MAINTENANCE AND SERVICING 2. Move hose bundle (A) clear of the frame and lay it on the header. Figure 4.157: M1 Series Hose Bundle 3. If remote baffle kit is installed, disconnect linear actuator harness (A) from main harness and remove clevis pin (B) and lynch pin from clevis support (C), otherwise proceed to Step 4, page...
  • Page 148 MAINTENANCE AND SERVICING 5. Remove three M10 short square neck carriage head bolts (A) securing the header support deflector (B) to the header support, and remove the deflector. 6. Repeat Steps 4, page 139 5, page 140 at the opposite side of the header.
  • Page 149 MAINTENANCE AND SERVICING 10. Loosen two M16 hex head bolts (A) at each side of the conditioner that secure it to the header. Figure 4.163: Left Side of Conditioner – Right Side Similar 11. Loosen two M12 hex head bolts (A) securing conditioner gearbox (B) to the header.
  • Page 150 MAINTENANCE AND SERVICING Installing the Conditioner This procedure is applicable when the header is not attached to the windrower. If necessary, detach the header from the windrower before proceeding. WARNING Ensure spreader bar is secured to the forks so that it cannot slide off the forks or towards the header while attaching the conditioner to the header.
  • Page 151 MAINTENANCE AND SERVICING 5. Loosen bolts (A) and (B) on gearbox support (C). Do NOT remove hardware. Figure 4.169: Conditioner Gearbox Support 6. Align the holes in the conditioner gearbox (A) with the mounting holes in the header frame (B). Apply high- strength threadlocker (Loctite®...
  • Page 152 MAINTENANCE AND SERVICING 9. Torque nuts (A) to 170 Nm (126 lbf∙ft) on both sides of the conditioner. Figure 4.172: Left Side of Conditioner – Right Side Similar NOTE: Ensure feed roll rotates freely and that there is sufficient clearance between the feed roll pulley (C) and frame for belt removal before installing driveline.
  • Page 153 MAINTENANCE AND SERVICING 15. Position the fixed deflector support (C) onto the header support deflector as shown, and install two M10 short square neck carriage head bolts (B). Bolt heads face inboard. 16. Apply medium-strength threadlocker (Loctite® 243 or equivalent) to the threads of two M10 hex flange bolts (A), and install M10 bolts (A) as shown to secure the fixed deflector support to the header support.

  • Page 154: Replacing Driveshields

    MAINTENANCE AND SERVICING 4.10 Replacing Driveshields If driveshields are missing, severely damaged, or are not securely installed due to damage, they must be replaced. 4.10.1 Removing Driveshields CAUTION To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown in this procedure are for the left driveshield—the right driveshield is similar.

  • Page 155: Installing Driveshields

    MAINTENANCE AND SERVICING 3. Pull the outboard side (A) and inboard side (B) of driveshield away from the header to remove. Figure 4.180: Inboard and Outboard Half of Driveshield 4.10.2 Installing Driveshields CAUTION Do NOT operate the machine without the driveshields in place and secured. NOTE: Images shown in this procedure are for the left driveshield—the right driveshield is similar.
  • Page 156 MAINTENANCE AND SERVICING 2. Secure top and bottom of inboard and outboard driveshields with washer (A), retaining pin (B), and bolt (C). Figure 4.182: Retaining Pins and Hardware on Driveshield 3. Close driveshields. Refer to 3.6.2 Closing Driveshields, page Figure 4.183: Left Driveshield 214880 Revision A...

  • Page 157: Electrical System

    MAINTENANCE AND SERVICING 4.11 Electrical System 4.11.1 Maintaining Electrical System • Use electrical tape and cable ties as required to prevent the wiring harness from dragging or rubbing. • Keep lights clean. • Replace damaged lights. 4.11.2 Replacing Amber Hazard/Signal Light 1.
  • Page 158 MAINTENANCE AND SERVICING 4. Disconnect wire harness (A) from speed sensor connector (B). 5. Remove fir tree clip and cable tie (E). Retain clip for reinstallation. 6. Remove nut (C) from end of sensor and remove sensor from bracket (D). 7.

  • Page 159: Hydraulics

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

  • Page 161: Chapter 5: Options And Attachments

    Chapter 5: Options and Attachments 5.1 Performance Kits 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 self-propelled disc header for clean crop dividing and cutterbar entry in tall crops.

  • Page 162: Adjustable Skid Shoes Kit

    OPTIONS AND ATTACHMENTS 5.1.3 Adjustable Skid Shoes Kit The Adjustable Skid Shoes kit (MD #B6667) allows the R216 Rotary Rotary Disc Header to achieve the desired cutting height for optimum cutting performance. Figure 5.3: Adjustable Skid Shoe 5.1.4 Electric Remote Baffle Kit The Electric Remote Baffle kit (MD #B6664), allows the operator to adjust the disc header baffle electronically from inside the windrower.

  • Page 163: Chapter 6: Troubleshooting

    Chapter 6: Troubleshooting 6.1 Performance Problems Problem Solution Refer to Symptom: Cutterbar plugging • Removing Discblades, page 90 Dull, bent, or badly worn discblades Replace discblades. • Installing Discblades, page 92 Decrease header angle and increase • 3.8.1 Cutting Height, page 44 float.
  • Page 164 TROUBLESHOOTING Problem Solution Refer to — Roll speed too low Increase disc speed. Disengage header and stop engine. 4.5.2 Maintaining Cutterbar Discs, Foreign object between rolls When all moving parts are completely page 75 stopped, remove foreign object. Decrease header angle to raise cutting Cutting height too low 3.8.1 Cutting Height, page 44 height.
  • Page 165 TROUBLESHOOTING Problem Solution Refer to Symptom: Slow crop drying • Positioning Forming Shield Side Deflectors – Roll Conditioner, page Crop is bunched in windrow Adjust forming shields/baffle. • Positioning Rear Baffle Deflector Fins, page 56 Rolls not crimping crop sufficiently Decrease roll gap.

  • Page 166: Mechanical Problems

    TROUBLESHOOTING 6.2 Mechanical Problems Problem Solution Refer to Symptom: Excessive noise • Removing Discblades, page 90 Bent discblade Replace blade. • Installing Discblades, page 92 • Check roll timing and adjust if Checking Roll Timing, page 51 Conditioner roll timing off necessary.
  • Page 167 When all moving parts are completely 4.9.1 Inspecting Conditioner, page 133 stopped, remove foreign object. Belt pulleys and idlers misaligned Align pulleys and idler. See MacDon Dealer Symptom: Conditioner roll does not rotate Inspecting Conditioner Drive Belt, page Faulty drive belt Check drive belt pulleys.

  • Page 169: Chapter 7: Reference

    Chapter 7: Reference 7.1 Torque Specifications The following tables provide correct torque values for various bolts, cap screws, and hydraulic fittings. • Tighten all bolts to torque values specified in charts (unless otherwise noted throughout this manual). • Replace hardware with same strength and grade of bolt. •...
  • Page 170 REFERENCE Table 7.2 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (lbf·ft) (*lbf·in) Torque (Nm) Nominal Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 18.8 20.8 *167 *185 10-1.5 Figure 7.2: Bolt Grades 12-1.75 14-2.0 16-2.0...

  • Page 171: Metric Bolt Specifications Bolting Into Cast Aluminum

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

  • Page 172: O-Ring Boss Hydraulic Fittings - Adjustable

    REFERENCE 7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off lock nut (C) as far as possible. Ensure that washer (D) is loose and is pushed toward lock nut (C) as far as possible.
  • Page 173 REFERENCE Table 7.6 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable Torque Value SAE Dash Size Thread Size (in.) lbf·ft (*lbf·in) 5/16–24 6–7 *53–62 3/8–24 12–13 *106–115 7/16–20 19–21 14–15 1/2–20 21–33 15–24 9/16–18 26–29 19–21 3/4–16 46–50 34–37 7/8–14 75–82 55–60 1 1/16–12 120–132...

  • Page 174: O-Ring Boss Hydraulic Fittings - Non-Adjustable

    REFERENCE 7.1.4 O-Ring Boss Hydraulic Fittings – Non-Adjustable 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Check that O-ring (A) is NOT on threads and adjust if necessary. 3. Apply hydraulic system oil to O-ring. 4.

  • Page 175: O-Ring Face Seal Hydraulic Fittings

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

  • Page 176: Tapered Pipe Thread Fittings

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

  • Page 177: Conversion Chart

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

  • Page 179: Index

    Index See also accelerators See also spindle shear pins accelerators crop streams ............47 inspecting ............93 changing R216 SP configuration......48 installing............96 discblades............87 maintaining............93 inspecting cutterbar discs removing ............94 inspecting discs ..........76 adjustable skid shoes kit ........154 lubricating ............
  • Page 180 INDEX left driven drums installing left driven drums ......107 haying tips ............58 removing left driven drums ......105 chemical drying agents......... 59 right driven drums curing ............... 58 installing right driven drums ......113 driving on windrows ..........59 removing right driven drums......
  • Page 181 INDEX locations............69 rear baffles positioning on roll conditioner....... 55 recommended settings header .............. 44 reference maintenance and servicing maintenance requirements ........64 break-in inspections ..........66 rock guards break-in period ........... 19 inspecting ............97 end-of-season servicing........67 installing............99 maintenance records ...........
  • Page 182 INDEX maintenance and servicing ........61 preparing for servicing ......... 61 soft joint definition............17 specifications header .............. 13 torque specifications ......... 161 spindle shear pins..........116 installing............121 removing ............117 spindles changing............80 installing............83 removing ............81 rotating .............

  • Page 183: Recommended Lubricants

    Recommended Lubricants Keep your machine operating at top efficiency by using only clean lubricants and by ensuring the following: • Use clean containers to handle all lubricants. • Store lubricants in an area protected from dust, moisture, and other contaminants. IMPORTANT: Do NOT overfill the cutterbar when adding lubricant.
  • Page 184 MacDon Industries Ltd. MacDon Brasil Agribusiness Ltda. 680 Moray Street Rua Grã Nicco, 113, sala 404, B. 04 Winnipeg, Manitoba Mossunguê, Curitiba, Paraná Canada R3J 3S3 CEP 81200-200 Brasil t. (204) 885-5590 f. (204) 832-7749 t. +55 (41) 2101-1713 f. +55 (41) 2101-1699 MacDon, Inc.

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