MacDon R216 Unloading And Assembly Instructions
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MacDon R216 Unloading And Assembly Instructions

MacDon R216 Unloading And Assembly Instructions

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R216
Rotary Disc Header
Unloading and Assembly Instructions
214882 Revision C
Original Instruction
The harvesting specialists.

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  • Page 1 R216 Rotary Disc Header Unloading and Assembly Instructions 214882 Revision C Original Instruction The harvesting specialists.
  • Page 2 © 2019 MacDon Industries, Ltd. The information in this publication is based on the information available and in effect at the time of printing. MacDon Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the...
  • Page 3 Introduction This document describes the unloading, setup, and predelivery requirements for the MacDon R216 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.
  • Page 4 Summary of Changes At MacDon, we’re continuously making improvements, and occasionally these improvements affect product documentation. The following list provides an account of major changes from the previous version of this document. Internal Use Section Summary of Change Only —...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ..............................i Summary of Changes............................ ii Chapter 1: Safety ............................1 1.1 Signal Words ............................1 1.2 General Safety ............................2 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 Shipping Supports ........................9 3.1.1 Installing Adjustable Gauge Roller Kit....................
  • Page 6 TABLE OF CONTENTS 7.2 Header Float............................68 7.2.1 Checking Float ..........................68 7.2.2 Setting the Float .......................... 69 7.3 Roll Timing ............................70 7.3.1 Adjusting Roll Timing ........................70 7.4 Roll Gap.............................. 74 7.4.1 Adjusting Roll Gap........................74 7.5 Roll Tension............................75 7.5.1 Checking Roll Tension ........................

  • Page 7: Chapter 1: Safety

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

  • Page 8: General Safety

    SAFETY 1.2 General Safety CAUTION The following general farm safety precautions should be part of your operating procedure for all types of machinery. Protect yourself. • When assembling, operating, and servicing machinery, wear all protective clothing and personal safety devices that could be necessary for job at hand.
  • Page 9 SAFETY • Wear close-fitting clothing and cover long hair. NEVER wear dangling items such as scarves or bracelets. • Keep all shields in place. NEVER alter or remove safety equipment. Make sure driveline guards can rotate independently of shaft and can telescope freely. •...

  • Page 10: Welding Precaution

    SAFETY 1.3 Welding Precaution Welding should never be attempted on the 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.

  • Page 11: Safety Signs

    SAFETY 1.4 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 13: Chapter 2: Unloading The Header

    Chapter 2: Unloading the Header WARNING To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area. IMPORTANT: Equipment used for unloading the header must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, machine damage, or the vehicle tipping.
  • Page 14 UNLOADING THE HEADER 4. Back up until the rotary disc header clears the trailer, and slowly lower it to 150 mm (6 in.) from the ground. 5. Take the rotary disc header to the storage or setup area. 6. Set the rotary disc header down on secure, level ground. Do NOT lower the header into working position.

  • Page 15: Chapter 3: Assembling The Header

    Chapter 3: Assembling the Header Follow each procedure in this chapter in order. 3.1 Removing Shipping Supports To remove the shipping supports from the cutterbar side of the header, follow these steps: 1. Remove four bolts and nuts (A) from each yellow shipping support (B) and remove the four supports from the disc header.
  • Page 16 ASSEMBLING THE HEADER 2. Remove nuts and bolts (A) from the yellow channel and header supports. 3. Remove yellow braces (B) from the header. Figure 3.2: Shipping Stand Brace – Right Side Shown, Left Side Opposite 4. Remove four nuts and bolts (A) holding yellow channel (B) in place against the plates on both sides of the header.
  • Page 17 ASSEMBLING THE HEADER 6. Remove three bolts and washers (A) holding each yellow plate (B) onto the header supports. 7. Remove plates (B) from the header. 8. Each header is shipped with either gauge rollers or skid shoes (but not both). Refer to the relevant installation procedure listed below: •...

  • Page 18: Installing Adjustable Gauge Roller Kit

    ASSEMBLING THE HEADER 3.1.1 Installing Adjustable Gauge Roller Kit Follow these steps and install the Adjustable Gauge Roller kit (MD #B6666) while the header is still set on the ground on its shipping stands: NOTE: If you are installing the Adjustable Skid Shoe kit (MD #B6667), refer to 3.1.2 Installing Adjustable Skid Shoes Kit, page 1.
  • Page 19 ASSEMBLING THE HEADER 2. Remove and retain clevis pins (A) and lynch pins (B) from holes (C) on both ends of gauge roller (D). 3. Align holes (C) with holes (E) in the header’s support bracket (F). Figure 3.6: Gauge Roller Assembly 4.
  • Page 20 ASSEMBLING THE HEADER 5. Fully insert retained bar (A) into slot (B) from the inboard side of the gauge roller. Figure 3.8: Bar and Support Bracket 6. Secure bar (A) with retained lynch pin (B). 7. Repeat the installation on the opposite side of the disc header.

  • Page 21: Installing Adjustable Skid Shoes Kit

    ASSEMBLING THE HEADER 3.1.2 Installing Adjustable Skid Shoes Kit Follow these steps and install the Adjustable Skid Shoes kit (MD #B6667) while the disc header is still set on the ground on its shipping stands: NOTE: If you are installing the Adjustable Gauge Roller kit (MD #B6666), refer to 3.1.1 Installing Adjustable Gauge Roller Kit, page 1.
  • Page 22 ASSEMBLING THE HEADER 2. Secure the back of skid shoe (A) to bracket (B) in two locations with retained bolts (C), washers (D), spacers (E), and nuts (F). NOTE: Bolt heads should be set outside the skid shoes. Figure 3.11: Skid Shoe 3.
  • Page 23 ASSEMBLING THE HEADER 4. Insert clevis pins (A) from outside the skid shoe (B). Figure 3.13: Clevis Pins 5. Secure each clevis pin (A) with a lynch pin (B). NOTE: Lynch pins should be inserted in the clevis pin from inside the skid shoe.

  • Page 24: Lowering The Header

    ASSEMBLING THE HEADER 3.2 Lowering the Header Complete the following steps to lower the header into working position after it has been lifted off its shipping trailer and set down on the ground. 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.
  • Page 25 ASSEMBLING THE HEADER 2. Attach spreader bar (A) to forks. IMPORTANT: Length of spreader bar must be approximately 457 cm (15 ft.). 3. Approach the header from its underside with the forklift. 4. Attach chains with hooks to the spreader bar (A) and hook into shipping brackets (B) on both sides of the disc header.

  • Page 26: Unpacking Hydraulic Hoses And Electrical Harness

    ASSEMBLING THE HEADER 3.3 Unpacking Hydraulic Hoses and Electrical Harness Follow these steps to unpack the hydraulic hoses and electrical harness. 1. Remove shipping wire securing hose ends (A) to secured hoses (B) and remove all packing foam from the hose ends. NOTE: Packing foam not shown in illustration at right.

  • Page 27: Removing Shipping Stands

    ASSEMBLING THE HEADER 3.4 Removing Shipping Stands Complete the following steps to remove the remaining shipping stands from the header. NOTE: This procedure must be completed on both sides of the header near the forming shields. 1. Remove nut (A) from the outboard side of the right header boot and bolt (B) from the inboard side of the right shipping stand (C).
  • Page 28 ASSEMBLING THE HEADER 3. Remove and retain bolts (A) and remove shipping plate (B). Discard plate (B) and reinstall bolts (A) on the header. Repeat for the other side of the header. Figure 3.23: Shipping Plate – Right Side Shown, Left Side Opposite 214882 Revision C...

  • Page 29: Adjusting Rear Baffle Deflectors

    ASSEMBLING THE HEADER 3.5 Adjusting Rear Baffle Deflectors Four rear baffle deflector fins are located under the baffle. The baffle and its deflectors require adjustment from shipping configuration to field position. To adjust the rear baffle and deflector fins, follow these steps: 1.
  • Page 30 ASSEMBLING THE HEADER 4. Turn over deflector (A) and place on rear baffle (B) and between fixed deflector plate (C) and outer plate (D). 5. Loosely secure deflector (A) in place with retained hardware (E) in three locations. Do NOT tighten hardware. Repeat on the opposite side of the header.

  • Page 31: Unpacking Curtain

    ASSEMBLING THE HEADER 3.6 Unpacking Curtain Follow these steps to unpack the cutterbar curtain on the rotary disc header: 1. Loosen 12 nuts (A) under the disc header top shield 2–3 turns to loosen bumper (B). IMPORTANT: Do NOT remove nuts (A) from the disc header; the hardware should be loosened only enough so cable ties (C) can be removed.
  • Page 32 ASSEMBLING THE HEADER WARNING Ensure the cutterbar is completely clear of foreign objects. These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage. 4. Check the cutterbar area for debris and foreign objects. Ensure all shipping material is removed. 5.

  • Page 33: Chapter 4: Attaching Header To M1240 Windrower

    Chapter 4: Attaching Header to M1240 Windrower 4.1 Assembling and Installing Forming Shield Unpack and assemble the forming shield as follows: 1. Unpack and remove shipping material from deflectors (A) and remove deflectors from cover (B). 2. Locate and open the included hardware bag. Figure 4.1: Forming Shield in Shipping Configuration 3.
  • Page 34 ATTACHING HEADER TO M1240 WINDROWER 4. Lay the cover upside down on an even work surface and Install right side bracket (A) on the right side of the forming shield with five 25 mm-long short neck M10 bolts (B) and five nuts (C).
  • Page 35 ATTACHING HEADER TO M1240 WINDROWER 6. Install bolt (A) and nut (B) through plate (C) and forming shield angle (D). Repeat this step on the left side of the forming shield. Figure 4.5: Plate and Forming Shield Angle 7. Flip the forming shield over so the forming shield is right side up and set on an even work surface.
  • Page 36 ATTACHING HEADER TO M1240 WINDROWER 9. Flip the forming shield upside down and set on an even work surface. 10. Install side deflector (A) on the right side of the forming shield with one 30 mm-long short neck M10 bolt (B). 11.
  • Page 37 ATTACHING HEADER TO M1240 WINDROWER 16. Install handle (A) with two flat washers (B) and one rubber washer (C) using bolt (D) installed through baffle (E) and right side bracket (F). Repeat installation at the left side of the forming shield. Figure 4.9: Baffle Handle 17.
  • Page 38 ATTACHING HEADER TO M1240 WINDROWER 20. Install shield mount plates (A) on the inside of the windrower legs with two hex head bolts (B) and nuts (C) each. NOTE: Make sure the top bolt (B) is installed in the foremost setting hole on the shield mounting plate (A).
  • Page 39 ATTACHING HEADER TO M1240 WINDROWER 23. Using spacer (A), hex head bolt (B), and nut (C), attach forming shield (D) to shield mount plate (E) installed on the inside of the windrower legs. Repeat on other side of the windrower and forming shield. Figure 4.14: Shield Mount Plate and Attaching Hardware 24.
  • Page 40 ATTACHING HEADER TO M1240 WINDROWER 25. Install rubber strap (A) on side bracket (B) using bolt (C), washer (D), and nut (E). Repeat on the left side of the forming shield. 26. Pull rubber strap (A) up towards windrower frame and place onto straight pin (F).

  • Page 41: Routing Electrical Harness

    NOTE: Windrower main harness is not shown in the illustration at right. To route the R216 Rotary Disc Header electrical harness on the M1240 Windrower, follow these steps: Figure 4.17: Cable Ties Securing Header Electrical Harness 1.
  • Page 42 ATTACHING HEADER TO M1240 WINDROWER 2. Retrieve electrical harness (A) and loosely attach it to center-link (B) with two cable ties (C). NOTE: Cable ties (C) should bundle electrical harness (A) with other hydraulic hoses from the windrower. The other hydraulic hoses are not shown in the illustration at right.
  • Page 43 ATTACHING HEADER TO M1240 WINDROWER 4. Route electrical harness (A) over windrower frame (B) towards the multicoupler base. 5. Loosely secure electrical harness (A) to the windrower main harness (C) with one cable tie (D) near the windrower frame. NOTE: Do NOT tighten cable tie (D) on harness at this point.

  • Page 44: Attaching Disc Header

    ATTACHING HEADER TO M1240 WINDROWER 4.3 Attaching 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 45 ATTACHING HEADER TO M1240 WINDROWER 3. Lift header support (A) and place 2 x 4 in. blocks (B) under the header support. A total of four 2 x 4 in. blocks (B) will be necessary to raise the boot up and into field position. Ensure the boot’s bottom edge (C) is parallel with the ground.
  • Page 46 ATTACHING HEADER TO M1240 WINDROWER 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 header float has been removed, the icon will display RESUME FLOAT. Figure 4.28: HPT Display 9.
  • Page 47 ATTACHING HEADER TO M1240 WINDROWER 14. Self-Aligning Hydraulic Center-Link: Adjust position of the 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 self-locking mechanism.
  • Page 48 ATTACHING HEADER TO M1240 WINDROWER 17. Hydraulic Center-Link without Self-Alignment: Press the HEADER TILT UP or HEADER TILT DOWN cylinder switches on the GSL to extend or retract the center-link cylinder until the hook is aligned with the header attachment pin. b.
  • Page 49 (A) and nuts (B) through the forming shield frame and the cutout on shield mounting plate (C). Tighten bolts (D). This ensures the forming shield is set at its lowest setting. Figure 4.38: Setting for R216 SP Disc Header without DWA Option 214882...
  • Page 50 ATTACHING HEADER TO M1240 WINDROWER CAUTION Check to be sure all bystanders have cleared the area. 25. Start the windrower engine and raise the header slightly. 26. Turn off the windrower engine and remove the key from the ignition. DANGER To avoid bodily injury from fall of raised header, always engage safety props when working on or around raised header, and before going under header for any reason.

  • Page 51: Connecting Rotary Disc Header Hydraulics Using Quick Couplers

    ATTACHING HEADER TO M1240 WINDROWER 4.4 Connecting Rotary Disc Header Hydraulics Using Quick Couplers To connect the R216 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 4.5 Connecting Disc Header Hydraulics Using Hard...
  • Page 52 ATTACHING HEADER TO M1240 WINDROWER 3. Use a clean rag to remove dirt and moisture from the couplers on the left side of the windrower frame. 4. Make the following hydraulic and electrical connections to the windrower: Connect disc pressure hose (A) with coupler (B) and torque to 205–226 Nm (151–167 lbf·ft).

  • Page 53: Connecting Disc Header Hydraulics Using Hard Plumbing

    Hard plumbing helps reduce the potential for leaks at the hydraulic connection sites and helps the header drive run more efficiently. To connect the R216 Rotary Disc Header to the M1240 Windrower with hard plumb fittings, follow these steps: If your windrower is equipped with quick coupler connections, refer to 4.4 Connecting Rotary Disc Header Hydraulics Using...
  • Page 54 ATTACHING HEADER TO M1240 WINDROWER 3. Remove protective plugs (A) from ends of hydraulic hoses. Figure 4.45: Protective Shipping Plugs on R216 Hydraulic Hoses 4. Make the following hydraulic and electrical 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 (151–157 lbf·ft)
  • Page 55 ATTACHING HEADER TO M1240 WINDROWER 5. Move windrower platform (A) to the CLOSED position. For instructions, refer to the windrower operator’s manual. Figure 4.47: Windrower with Left Platform in Closed Position 214882 Revision C...

  • Page 56: Restoring Float For Disc Header

    ATTACHING HEADER TO M1240 WINDROWER 4.6 Restoring Float for Disc Header Follow these steps to restore the float for an R216 Rotary Disc Header used with an 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.
  • Page 57 ATTACHING HEADER TO M1240 WINDROWER 3. If not prompted by the Harvest Performance Tracker (HPT) display to restore the header float, restore the header float manually by doing the following: Press rotary scroll knob (A) on HPT to highlight the QuickMenu options.

  • Page 58: Calibrating Windrower Knife Drive On The Harvest Performance Tracker Display

    4.7 Calibrating Windrower Knife Drive on the Harvest Performance Tracker Display When the R216 Rotary Disc Header is attached to an M1240 Windrower, the Harvest Performance Tracker (HPT) will recognize the header ID and configure the windrower accordingly. The disc header must be calibrated to ensure that the knife drive pump output is accurate.
  • Page 59 ATTACHING HEADER TO M1240 WINDROWER 8. Press the PLAY button to begin the calibration process. NOTE: During the calibration sequence, the engine rpm and header speed will increase and decrease multiple times. NOTE: Press the X button (A) on the screen or use the HEADER DISENGAGE switch at any time during the calibration process to exit calibration without saving.

  • Page 61: Chapter 5: Installing Options

    Chapter 5: Installing Options 5.1 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. This kit includes a linear actuator and support which will need to be installed and adjusted on the disc header.

  • Page 62: Crop Dividers Kit

    INSTALLING OPTIONS 5.2 Crop Dividers Kit To install the Crop Dividers kit (MD #B6665), follow these steps: 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. 1.
  • Page 63 10. Position left crop divider (A) on the front left corner of the disc header. 11. Install using two retained bolts (B) and nuts (C). Figure 5.4: Crop Divider on R216 12. Reinstall hazard light assembly (A) using retained hardware (B) over the installed crop divider (C). Apply ®...

  • Page 64: Adjustable Gauge Roller Kit

    INSTALLING OPTIONS 5.3 Adjustable Gauge Roller Kit The Adjustable Gauge Roller kit (MD #B6666) allows the R216 Rotary Disc Header to achieve the desired cutting height for optimum cutting performance. This kit is installed after removing the header shipping supports. To review installation and adjustment instructions, refer to 3.1.1 Installing Adjustable Gauge Roller Kit, page...

  • Page 65: Adjustable Skid Shoes Kit

    INSTALLING OPTIONS 5.4 Adjustable Skid Shoes Kit The Adjustable Skid Shoes kit (MD #B6667) allows the R216 Rotary Disc Header to achieve the desired cutting height for optimum cutting performance. This kit is installed after removing the header shipping supports. To review installation and adjustment instructions, refer to 3.1.2 Installing Adjustable Skid Shoes Kit, page...

  • Page 67: Chapter 6: Lubricating The Disc Header

    Chapter 6: Lubricating the Disc Header 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. The disc header has been lubricated at the factory. However, you should lubricate the disc header prior to delivery to offset the effects of weather during outside storage and transport, and to familiarize yourself with the machine.

  • Page 68: Lubrication Locations

    LUBRICATING THE DISC HEADER 6.1 Lubrication Locations Figure 6.1: 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 1 E - Idler/Tensioner Pivot F - Bearing, Feed Roll G - Tensioner Arm 1.
  • Page 69 LUBRICATING THE DISC HEADER Figure 6.2: Right Side Lubrication Locations C - Slip Joints, Conditioner Drivelines 2 A - Bearing, Roller Conditioner (2 Places) B - U-Joint, Upper Driveline (2 Places) D - U-Joint, Lower Driveline (2 Places) E - Idler Pivot 2.

  • Page 71: Chapter 7: Performing Predelivery Checks

    Chapter 7: Performing Predelivery Checks 1. Perform final checks and adjustments as listed on the yellow sheet attached at the back of this instruction, to ensure the machine is field-ready. Refer to the referenced pages as indicated on the checklist for detailed instructions. 2.

  • Page 72: Adjusting Conditioner Drive Belt

    PERFORMING PREDELIVERY CHECKS 6. Measure the length of belt tensioner spring (A) and ensure spring length (B) is 17 mm (11/16 in.) in accordance with spring tension decal (C). If the spring length requires adjustment, refer to 7.1.2 Adjusting Conditioner Drive Belt, page 66, otherwise close the drive shield and proceed 7.2 Header Float, page...
  • Page 73 PERFORMING PREDELIVERY CHECKS 4. Ensure drive belt (A) is in the grooves on drive pulley (B) and driven pulley (C). NOTE: If necessary, loosen the jam nut and adjuster nut to relieve belt tension while checking. Figure 7.5: Conditioner Drive 5.

  • Page 74: Header Float

    PERFORMING PREDELIVERY CHECKS 7.2 Header Float 7.2.1 Checking Float 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 Before starting the machine, check to be sure all bystanders have cleared the area.

  • Page 75: Setting The Float

    PERFORMING PREDELIVERY CHECKS 7.2.2 Setting the Float The optimum float setting lets the disc header follow the contour of the terrain. Proceed as follows: 1. Press rotary scroll knob (A) on the Harvest Performance Tracker (HPT) to display the QuickMenu system. 2.

  • Page 76: Roll Timing

    PERFORMING PREDELIVERY CHECKS 7.3 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 77 PERFORMING PREDELIVERY CHECKS 2. On the right side of the header, engage lift release latch (A) and pull handle (B) to open outboard driveshield (C). 3. Lift at handle (D) and open inboard driveshield (E). 4. On the upper roll, loosen four bolts (A) securing yoke plate (B).
  • Page 78 PERFORMING PREDELIVERY CHECKS 8. 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. Figure 7.15: Conditioner Drive 9. Determine center point (A) between the two marks on the yoke plate, and place a third mark.
  • Page 79 PERFORMING PREDELIVERY CHECKS 11. Ensure 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) and tighten bolts (A). Torque to 95 Nm (70 lbf·ft).

  • Page 80: Roll Gap

    PERFORMING PREDELIVERY CHECKS 7.4 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. Steel rolls can be operated over a large range of roll gap settings (intermesh). Using a roll gap of (up to) 25 mm (1 in.), they are suited to a wide range of crops (including alfalfa and thicker-stemmed cane-type crops).

  • Page 81: Roll Tension

    PERFORMING PREDELIVERY CHECKS 7.5 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 82: Adjusting Roll Tension

    PERFORMING PREDELIVERY CHECKS 7.5.2 Adjusting Roll Tension To adjust roll tension, follow these steps: 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. 1.

  • Page 83: Hanging Drums

    PERFORMING PREDELIVERY CHECKS 7.6 Hanging Drums Hanging drums aid in feeding crop from the ends of the header into the conditioner. 7.6.1 Checking and Adjusting Hanging Drum Drive The hanging drum drive is set up and tensioned at factory. Ensure the drive belt is properly set and tensioned by following the steps below: WARNING To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key...

  • Page 84: Feed Roll Drive

    PERFORMING PREDELIVERY CHECKS 7.7 Feed Roll Drive 7.7.1 Checking and Adjusting Feed Roll Drive The feed roll drive is set up and tensioned at factory. Ensure the drive belt is properly set and tensioned by following the steps below: 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 85: Checking And Adding Conditioner Roll Timing Gearbox Oil

    PERFORMING PREDELIVERY CHECKS 7.8 Checking and Adding Conditioner Roll Timing Gearbox Oil 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. IMPORTANT: Check the gearbox oil level when the oil is warm.

  • Page 86: Checking And Adding Oil In Header Drive Gearbox

    PERFORMING PREDELIVERY CHECKS 7.9 Checking and Adding Oil in Header Drive Gearbox IMPORTANT: Check the gearbox oil level when the oil is warm. If the oil is cold, idle the machine for approximately 10 minutes prior to checking. 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 87 PERFORMING PREDELIVERY CHECKS 4. Clean area around check plug (A). 5. Remove check plug (A) with a 13 mm (1/2 in.) socket. 6. Ensure lubricant is even with bottom of check hole (with check plug [A] removed) or slightly runs out of the check hole.

  • Page 88: Checking And Adding Lubricant In Cutterbar

    PERFORMING PREDELIVERY CHECKS 7.10 Checking and Adding Lubricant in Cutterbar 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. WARNING Exercise caution when working around the blades.
  • Page 89 PERFORMING PREDELIVERY CHECKS 6. Clean the area around plug (A). Place a 5 liter (5.2 US qts) capacity container under plug (A). 7. Use a 17 mm socket to remove plug (A) and gasket (B) from cutterbar. Oil level must be up to the inspection plug hole. If additional lubricant is required, continue following this procedure and refer to the next step.
  • Page 90 PERFORMING PREDELIVERY CHECKS CAUTION Before starting the machine, check to be sure all bystanders have cleared the area. 19. Start the engine and lower the header to a level position on the ground. 20. Shut down the engine, and remove the key from the ignition. 21.

  • Page 91: Checking Lights

    PERFORMING PREDELIVERY CHECKS 7.11 Checking Lights 1. Check light brackets (A) and make sure they’re securely installed and undamaged. 2. Check operation of hazard lights (B) during machine run-up. Figure 7.36: Lights 214882 Revision C...

  • Page 92: Checking Manuals

    PERFORMING PREDELIVERY CHECKS 7.12 Checking Manuals The following manuals should be stored in the manual storage case (A) on the left fixed deflector: • R216 Rotary Disc Header Operator’s Manual • R216 Rotary Disc Header Parts Catalog Figure 7.37: Manual Case 214882...

  • Page 93: Running Up The Header

    PERFORMING PREDELIVERY CHECKS 7.13 Running up the Header WARNING • Keep everyone several hundred feet away from your operation. Ensure bystanders are never in line with the front or rear of the machine. Stones and other foreign objects can be ejected from either end with force. •...

  • Page 95: Chapter 8: Reference

    Chapter 8: Reference 8.1 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 96: Torque Specifications

    REFERENCE 8.2 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 97 REFERENCE Table 8.3 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 8.2: Bolt Grades 12-1.75 14-2.0 16-2.0...

  • Page 98: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE Table 8.5 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 8.4: Bolt Grades 12-1.75 14-2.0 16-2.0 20-2.5...

  • Page 99: O-Ring Boss Hydraulic Fittings - Adjustable

    REFERENCE 8.2.3 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 100 REFERENCE Table 8.7 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 101: O-Ring Boss Hydraulic Fittings - Non-Adjustable

    REFERENCE 8.2.4 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 102: O-Ring Face Seal Hydraulic Fittings

    REFERENCE 8.2.5 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 8.9: Hydraulic Fitting 2. Apply hydraulic system oil to O-ring (B). 3.

  • Page 103: Tapered Pipe Thread Fittings

    REFERENCE Table 8.9 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 8.2.6 Tapered Pipe Thread Fittings Assemble pipe fittings as follows: 1.

  • Page 104: Conversion Chart

    REFERENCE 8.3 Conversion Chart Table 8.11 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 105: 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 106 REFERENCE 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 107: Predelivery Checklist

    Predelivery Checklist Perform these checks and adjustments before delivering the machine to your Customer. If adjustments are required, refer to the appropriate page number in this manual. The completed Checklist should be retained by either the Operator or the Dealer. WARNING Do NOT operate the machine with the driveshields open.
  • Page 108 REFERENCE ü ü Item Reference Check cutterbar area carefully for loose parts and hardware on the cutterbar. WARNING — These objects can be ejected with considerable force when the machine is started, and may result in serious injury or machine damage. Run-Up Procedure 7.13 Running up the Header, page 87 Check hydraulic hose and wiring harness routing to ensure...
  • Page 110 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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