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

MacDon R216 Operator's Manual

Rotary disc header
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R216
Rotary Disc Header
Operator's Manual
215026 Revision A
Original Instruction
The harvesting specialists.

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Summary of Contents for MacDon R216

  • Page 1 R216 Rotary Disc Header Operator’s Manual 215026 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 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 as 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 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. Section Summary of Change Internal Use Only Inside front cover Added copyright statement.
  • Page 5 Section Summary of Change Internal Use Only Positioning Forming Shield Side Deflectors – Removed Step 2. Engineering Roll Conditioner, page 61 3.9 Cutterbar Deflectors, page 65 Added topic. Tech Pubs 3.9.1 Removing Cutterbar Deflectors, page Added topic. Tech Pubs 3.9.2 Installing Cutterbar Deflectors, page 66 Added topic.
  • Page 6 Summary of Change Internal Use Only Installing Cutterbar Spindle Shear Pin, page Revised procedure. Service Dept Changing R216 SP Cutterbar Crop Stream Service Dept • Revised note re disc timing tool—it is Configuration, page 147 included with the header. • Added location of tool on the header.

  • Page 7: Serial Number

    Serial Number Record the serial number and model year of the header in the spaces provided below. R216 Rotary Disc Header 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 9: Table Of Contents

    3.3.1 Installing Forming Shield ....................... 22 3.3.2 Attaching Header to M1240 Windrower................... 24 3.3.3 Connecting R216 SP Hydraulics and Electrical to an M1240 Windrower ..........29 3.4 Detaching Header from Windrower ......................36 3.4.1 Detaching R216 Rotary Disc Header from M1240 Windrower .............. 36 3.4.2 Removing Forming Shield ......................
  • Page 10 TABLE OF CONTENTS 3.7.3 Header Float ..........................52 3.7.4 Ground Speed ..........................53 3.8 Conditioner ............................54 3.8.1 Roll Gap ............................. 54 Adjusting Roll Gap – Steel Rolls ..................... 54 Adjusting Roll Gap – Polyurethane Rolls..................55 3.8.2 Roll Tension ..........................56 Adjusting Roll Tension .........................
  • Page 11 Installing Cutterbar Spindle Shear Pin ................... 143 4.6.9 Reconfiguring Cutterbar Crop Stream .................... 146 Changing R216 SP Cutterbar Crop Stream Configuration ..............147 4.7 Conditioner Roll Timing Gearbox ......................149 4.7.1 Checking and Changing Conditioner Roll Timing Gearbox Oil.............. 149 4.8 Header Drive Gearbox .........................
  • Page 12 TABLE OF CONTENTS 4.12 Electrical System..........................168 4.12.1 Maintaining Electrical System ..................... 168 4.12.2 Replacing Amber Hazard/Signal Light ................... 168 4.12.3 Replacing Header Disc Speed Sensor.................... 169 4.13 Hydraulics ............................170 4.13.1 Checking Hydraulic Hoses and Lines..................... 170 Chapter 5: Options and Attachments ....................171 5.1 Cutterbar Deflectors –...

  • Page 13: 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 14: Signal Words

    SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words, IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if 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 15: 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 the job at hand. Do NOT take chances.
  • Page 16 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 17: Maintenance Safety

    SAFETY 1.4 Maintenance Safety To ensure your safety while maintaining machine: • Review the operator’s manual and all safety items before operation and/or maintenance of the 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 18: Hydraulic Safety

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

  • Page 19: 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 20: 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 the original part on which a safety sign was installed is replaced, be sure the repair part displays the current safety sign.

  • Page 21: Locating Safety Decals

    SAFETY 1.8 Locating Safety Decals Figure 1.15: Safety Sign Decal Locations – Top View A - MD #307746 B - MD #325706 Figure 1.16: Safety Sign Decals 215026 Revision A...
  • Page 22 SAFETY Figure 1.17: Safety Sign Decal Locations – Rear View A - MD #190546 B - MD #325070 C - Reflector 215026 Revision A...

  • Page 23: 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 #190546 Slippery surface WARNING—DO NOT STEP ON SURFACE • Do NOT use this area as a step or platform. •...
  • Page 24 SAFETY MD #325706 Thrown and sharp object/hydraulic oil pressure hazard WARNING • Crop materials exiting at high speed. • Stop machine, look, listen, and wait for all movement to stop before approaching. • Failure to comply could result in death or serious injury. •...

  • Page 25: Chapter 2: Product Overview

    Frame and Structure Width 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 Cutterbar...
  • Page 26 PRODUCT OVERVIEW Hay Conditioner Options Steel rolls Optional 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 Roll speed 1040 rpm (at disc speed of 2600 rpm) Polyurethane rolls Optional...

  • Page 27: Component Identification

    PRODUCT OVERVIEW 2.2 Component Identification Figure 2.1: R216 Rotary Disc Header A - Front Curtain B - Disc Drum (Right) C - 10-Disc Cutterbar D - Conditioner Rolls E - Drive Shield (Left) F - Hydraulic Motor G - Center-Link Tube (Welded to Frame)

  • Page 28: 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 29 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 31: 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 32: Engaging And Disengaging Header Safety Props

    OPERATION 3.2 Engaging and Disengaging Header Safety Props Safety props are located on both header lift cylinders on the windrower. 3.2.1 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 33 OPERATION 5. Disengage the safety props on both lift cylinders as follows: NOTE: If the safety prop will not disengage, raise the header to release the prop. Turn lever (A) away from the header to raise the safety prop until the lever locks into the vertical position. b.

  • Page 34: Attaching Rotary Disc Header To M1240 Windrower

    OPERATION 3.3 Attaching Rotary Disc Header to M1240 Windrower 3.3.1 Installing Forming Shield 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 35 OPERATION 6. Remove lynch pin (A) and washer (B) from straight pin (C). Figure 3.6: Lynch Pin and Washer at Rear of Windrower Leg 7. Attach rubber strap (D) to straight pin (C) at the rear of windrower leg. Secure with washer (B) and lynch pin (A). Figure 3.7: Rubber Strap Securing Forming Shield onto Windrower Leg 215026...

  • Page 36: Attaching Header To M1240 Windrower

    OPERATION 3.3.2 Attaching Header to M1240 Windrower The 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 37 OPERATION 5. Start the windrower engine. For instructions, refer to the windrower operator’s manual. 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. NOTE: If not prompted by the Harvest Performance Tracker (HPT) display to remove float, remove float manually.
  • Page 38 OPERATION 9. Press HEADER DOWN switch (E) on ground speed lever (GSL) to fully retract header lift cylinders. 10. Self-Aligning Hydraulic Center-Link: Press 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 39 OPERATION 14. Hydraulic Center-Link without Self-Alignment: Press HEADER TILT UP or HEADER TILT DOWN cylinder switches on the GSL to extend or retract center-link cylinder until the hook is aligned with the header attachment pin. b. Shut down the engine, and remove the key from the ignition.
  • Page 40 OPERATION 18. Install clevis pin (A) through support and windrower lift arm and secure with hairpin (B). Repeat for the opposite side of the header. IMPORTANT: Ensure clevis pin (A) is fully inserted, and hairpin is installed behind bracket. Figure 3.20: Header Support 19.

  • Page 41: Connecting R216 Sp Hydraulics And Electrical To An M1240 Windrower

    • Draper header ready windrowers include one set of hydraulic quick couplers which are compatible with the header drive hoses on the R216 SP. One additional set of quick couplers (MD #B6277) is required. • Rotary disc header ready windrowers include hard plumbed hydraulics connections.
  • Page 42 OPERATION Proceed with the steps that are relevant to the following windrower configurations: Windrower Configuration Steps for Connecting Hydraulics and Electrical Steps 6, page 30 9, page Rotary disc/draper ready configuration (A) Step 10, page 32 11, page Rotary disc only hard plumbed configuration (B) Steps 12, page 32...
  • Page 43 OPERATION 7. Connect hydraulic fittings to the hydraulic hoses as follows: Attach 90° elbow fitting (A) and 1 in. female coupler fitting (B) to disc pressure hose (C). b. Attach 90° elbow fitting (A) and 1 in. male coupler fitting (D) to disc return hose (E). Figure 3.27: Hydraulic Fittings 8.
  • Page 44 11. To connect electrical harness, refer to Steps 18, page 34 21, page Figure 3.29: Hard Plumbed Connections on R216 SP Ready Windrower Quick coupler fittings – rotary disc ready configuration: 12. Connect hydraulic fittings to the hydraulic hoses as follows: Attach 90°...
  • Page 45 OPERATION 13. Remove the extension fittings and elbows (A) from the rotary disc header hydraulic pressure and return connections. Figure 3.31: Hard Plumbed Connections – Rotary Disc Ready Windrower 14. Install the male quick coupler at windrower pressure receptacle (A). 15.
  • Page 46 OPERATION 16. Connect the hydraulic hoses to the windrower with quick coupler fittings as follows: Connect disc pressure hose (A) with coupler (B) and torque to 205–226 Nm (151–167 lbf·ft). b. Connect disc return hose (C) with coupler (D) and torque to 205–226 Nm (151–167 lbf·ft).
  • Page 47 OPERATION 19. Connect main header harness (A) to adapter harness (B). 20. Connect electric baffle control harness (C) to adapter harness (D) if installed. Figure 3.35: Electrical Harness Connection at Center-Link 21. Check electrical connection (A) at the windrower. Figure 3.36: Electrical Connection at Windrower 22.

  • Page 48: Detaching Header From Windrower

    OPERATION 3.4 Detaching Header from Windrower 3.4.1 Detaching R216 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.
  • Page 49 OPERATION 6. Remove hose support (A) and hose bundle from windrower frame. Figure 3.39: Hoses on Windrower 7. Rest hydraulic hose bundle (A) on header for storage as shown. Figure 3.40: Hose Bundle Storage Position 8. Disconnect main header harness (A) from adapter harness (B).
  • Page 50 OPERATION 10. Secure adapter harness (A) on the center link with an adjustable strap (B). Figure 3.42: Adapter Harness 11. Remove hairpin (B) from clevis pin (A). Remove clevis pin from header support (C) on both sides of header. Figure 3.43: Header Supports Windrowers with center-link self-alignment kit only: 12.
  • Page 51 OPERATION CAUTION Check to be sure all bystanders have cleared the area. 13. Start the engine. 14. Remove header float when prompted by the Harvest Performance Tracker (HPT). NOTE: If not prompted by the HPT to remove float, remove float manually. Self-aligning center-link (if installed): 15.

  • Page 52: Removing Forming Shield

    OPERATION 20. Back the windrower slowly away from header. 21. Reinstall clevis pin (A) through support (C) and secure with hairpin (B). Repeat for opposite side. Figure 3.47: Header Support 3.4.2 Removing Forming Shield 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 53 OPERATION 7. Remove lynch pin (A) and clevis pin (B) securing forming shield (C) to bolts and spacers (D). Repeat at the opposite side. Figure 3.49: Forming Shield Secured to Front of Windrower Legs 8. Dismount forming shield (A) from bolts and spacers (B). 9.

  • Page 54: Driveshields

    OPERATION 3.5 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. 3.5.1 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 55 OPERATION 2. Lift the outboard driveshield panel toward the outboard end of the header. Figure 3.53: Opening Driveshield – Outboard Side 3. Grab handle (A) and lift the other half of endshield (B) to the inboard side of the header. Figure 3.54: Driveshield –...

  • Page 56: Closing Driveshields

    OPERATION 3.5.2 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 3.55: Driveshield Lock Latch 2.

  • Page 57: Cutterbar Curtain

    OPERATION 3.6 Cutterbar Curtain WARNING To reduce the risk of personal injury and 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 58: Closing Cutterbar Curtain

    OPERATION 2. Secure curtain in place at locations (A) using three clips provided. Figure 3.60: Cutterbar Curtains — View from Below NOTE: Cutterbar curtain (A) is held in place between the tines of retaining clips (B). Figure 3.61: Cutterbar Curtain and Retaining Clips 3.6.2 Closing Cutterbar Curtain CAUTION To avoid injury, keep hands and fingers away from corners of doors when closing.

  • Page 59: Header Settings

    OPERATION 3.7 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 60: Adjusting Skid Shoe Height

    OPERATION Adjusting Skid Shoe Height Adjustable skid shoes are available to provide different cutting heights. The adjustable skid shoes have three position settings: lowest working position (A), intermediate working position (B), and storage position (C). Figure 3.63: Skid Shoe Position Settings To adjust skid shoe height, follow these steps: DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and...

  • Page 61: Adjusting Gauge Roller Height

    OPERATION 5. Replace the clevis pins and lynch pins (A) to secure the skid shoe in place. IMPORTANT: Install lynch pins (A) at the inboard side of the skid shoe. 6. Repeat the procedure on the second skid shoe. Ensure both skid shoes are set to the same position.
  • Page 62 OPERATION 5. Swing the gauge roller forward and align the holes in the gauge roller plate to the bottom hole of the mounting plates. 6. Secure with clevis pins (A) and lynch pins (B). IMPORTANT: Lynch pins (B) should be installed at the inboard side of the gauge roller.
  • Page 63 OPERATION Storage position To adjust the gauge roller to the storage position, follow these steps: 1. Remove lynch pins (B) and clevis pins (A). 2. Remove lynch pin (C) and scraper plate (D). Figure 3.70: Gauge Roller Secured in Intermediate Working Position 3.

  • Page 64: Adjusting Cutterbar Angle

    OPERATION 3.7.2 Adjusting Cutterbar Angle Header angle (A) adjustment ranges from 0 to 8° 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 65: 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 3.74: Ground Speed for R216 Rotary Disc Headers A - Acres/Hour...

  • Page 66: Conditioner

    OPERATION 3.8 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. There are two roll conditioner options—steel conditioner rolls and polyurethane rolls. 3.8.1 Roll Gap The roll gap controls the degree to which crop is conditioned as it passes through the rolls.

  • Page 67: Adjusting Roll Gap - Polyurethane Rolls

    OPERATION Adjusting Roll Gap – Polyurethane Rolls To adjust the roll gap, follow the procedure 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. 1.

  • Page 68: Roll Tension

    OPERATION 3.8.2 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 69: Roll Timing

    OPERATION 3.8.3 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 70 OPERATION 4. On the upper roll, loosen four bolts (A) securing yoke plate (B). NOTE: Only three of the four bolts are shown in the illustration. Figure 3.81: Conditioner Drive 5. Secure bottom roll (A). 6. Manually rotate upper roll (B) counterclockwise as shown until it stops rotating.
  • Page 71 OPERATION 8. Manually rotate upper roll (A) clockwise until it stops rotating. Make a second mark (B) on the yoke flange, and align it with the mark on the gearbox flange. Figure 3.83: Conditioner Drive 9. Determine center point (A) between the two marks on the yoke plate, and place a third mark.
  • Page 72 OPERATION 11. Remove one of the four bolts (A), ensure threads 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 bolt (A). Torque to 95 Nm (70 lbf·ft).

  • Page 73: Forming Shields - Roll Conditioner

    OPERATION 3.8.4 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 74: Positioning Rear Baffle - Roll Conditioner

    5. Secure baffle adjustment lever (B) with lynch pin (A). Figure 3.87: Left Side of Conditioner NOTE: An optional remote baffle adjustment kit (MD #B6664) is available for R216 SP. For more information, refer to Electric Remote Baffle Kit – MD #B6664, page 174. 215026...
  • Page 75 OPERATION Positioning Rear Baffle Deflector Fins Four rear baffle deflector fins are located under the baffle. Fins are factory-configured to approximately 60°. The rear baffle deflector fins help spread the crop in the windrow. To adjust fins, follow these steps: WARNING To avoid injury or death from unexpected start-up of machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
  • Page 76 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 3.90: Left Deflector Fins in Storage Position 215026 Revision A...

  • Page 77: Cutterbar Deflectors

    OPERATION 3.9 Cutterbar Deflectors A two-piece cutterbar deflector kit (MD #B6847) is available for attaching to the cutterbar just below the header’s conditioner rolls. Deflectors provide improved feeding into the conditioner rolls and prevent heavy crop with long stems from feeding under the rolls. Cutterbar deflectors may not be well-suited for some crop and field conditions.

  • Page 78: Installing Cutterbar Deflectors

    OPERATION 3.9.2 Installing Cutterbar Deflectors The cutterbar deflectors are used with roll conditioners only. DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop engine and remove key before leaving the operator’s seat, and always engage safety props before going under the machine for any reason. 1.

  • Page 79: Haying Tips

    OPERATION 3.10 Haying Tips 3.10.1 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 80: Windrow Characteristics

    OPERATION 3.10.4 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 3.4 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 81: Transporting The Header

    OPERATION 3.11 Transporting the Header For information on transporting the header when attached to the windrower, refer to your windrower operator’s manual. 215026 Revision A...

  • Page 83: 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 4.4.1 Maintenance Schedule/Record, page 76) to keep track of your scheduled maintenance.
  • Page 84 MAINTENANCE AND SERVICING Perform the following checks each day before startup: 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 4.13.1 Checking Hydraulic Hoses and Lines, page 170.

  • Page 85: Preparing Machine For Servicing

    MAINTENANCE AND SERVICING 4.2 Preparing Machine for Servicing DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop engine and remove key before leaving the operator’s seat, and always engage safety props before going under the machine for any reason. CAUTION To avoid personal injury, perform the following procedures before servicing disc header or opening drive covers: 1.

  • Page 86: Recommended Safety Procedures

    MAINTENANCE AND SERVICING 4.3 Recommended Safety Procedures • Park on level surface when possible. Follow all recommendations in your windrower operator's manual. • Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets. Figure 4.4: Safety Around Equipment •...
  • Page 87 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 4.7: Safety Equipment • Keep the service area clean and dry. Wet or oily floors are slippery.

  • Page 88: Maintenance Requirements

    MAINTENANCE AND SERVICING 4.4 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 89 MAINTENANCE AND SERVICING Every 25 Hours Lubricate idler pivot. Refer to Lubrication, page Lubricate upper and lower driveline universal joints. Refer to 4.5 Lubrication, page Lubricate roller conditioner and feed roller bearings. Refer to 4.5 Lubrication, page Lubricate conditioner driveline. Refer to 4.5 Lubrication, page Every 100 Hours or Annually Check conditioner drive belt tension.

  • Page 90: Break-In Inspections

    MAINTENANCE AND SERVICING 4.4.2 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 187 Hour to required torque Check for loose hardware and tighten 7.1 Torque Specifications, page 187 Hours to required torque Check conditioner drive belt tension...

  • Page 91: End-Of-Season Servicing

    MAINTENANCE AND SERVICING 4.4.4 End-of-Season Servicing WARNING To avoid injury or death from unexpected start-up of machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. CAUTION Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable.

  • Page 92: Lubrication

    MAINTENANCE AND SERVICING 4.5 Lubrication WARNING To avoid personal injury, before servicing header or opening drive covers, refer to 4.2 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 93: Lubrication Locations

    MAINTENANCE AND SERVICING 4.5.2 Lubrication Locations Figure 4.9: Left Side Lubrication Locations A - Idler/Tensioner Pivot B - Bearing, Roller Conditioner (Two Places) C - U-Joint, Conditioner Driveline (Two Places) D - Slip Joint, Conditioner Driveline 3 E - Idler/Tensioner Pivot F - Bearing, Feed Roll G - Tensioner Arm Use high-temperature, extreme-pressure (EP2) performance grease with 10% max molybdenum disulphide (NLGI...
  • Page 94 MAINTENANCE AND SERVICING Figure 4.10: Right Side Lubrication Locations C - Slip Joints, Conditioner Drivelines 4 A - Bearing, Roller Conditioner (Two Places) B - U-Joint, Upper Driveline (Two Places) D - U-Joint, Lower Driveline (Two Places) E - Idler Pivot Use high-temperature, extreme-pressure (EP2) performance grease with 10% max molybdenum disulphide (NLGI grade 2) lithium base.

  • Page 95: Cutterbar System

    4.4 Maintenance Requirements, page IMPORTANT: Warm cold lubricant by idling the machine for 10 minutes prior to checking level. Figure 4.11: R216 SP Cutterbar 4.6.1 Lubricating Cutterbar Checking and Adding Lubricant in Cutterbar 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 96 MAINTENANCE AND SERVICING 5. Use a spirit (bubble) level (A) to ensure the cutterbar is level in both directions. Adjust the header accordingly. Figure 4.13: 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 97 MAINTENANCE AND SERVICING 12. Remove plug (A) at the right end of the header. IMPORTANT: Do NOT remove bolts (B). 13. Add lubricant to the required level. IMPORTANT: Do NOT overfill the cutterbar. Overfilling can cause overheating, damage, or cutterbar component failure. NOTE: Refer to the inside back cover of this manual for lubrication specifications.

  • Page 98: Draining The Cutterbar

    MAINTENANCE AND SERVICING 24. Close cutterbar curtain (A). For instructions, refer to 3.6.2 Closing Cutterbar Curtain, page Figure 4.17: Cutterbar Curtain 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.

  • Page 99: Filling Cutterbar With Lubricant

    MAINTENANCE AND SERVICING 7. Fill the cutterbar with lubricant before operating the disc header. For instructions, refer to Filling Cutterbar with Lubricant, page IMPORTANT: Dispose of used lubricant responsibly. Filling Cutterbar with Lubricant This procedure should be used when the cutterbar has been completely drained of oil. If you are checking oil level or topping it up, refer to Checking and Adding Lubricant in Cutterbar, page DANGER...

  • Page 100: Cutterbar Discs

    MAINTENANCE AND SERVICING 9. Remove the blocks from under the cutterbar. 10. Lower the header. 11. Shut down the engine, and remove the key from the ignition. Disengage the windrower lift cylinder safety props. For 3.2.1 Engaging and Disengaging Header Safety Props – M1240 Windrower, page instructions, refer to 12.

  • Page 101: Inspecting Cutterbar Discs

    MAINTENANCE AND SERVICING Inspecting Cutterbar Discs 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 Disc blades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades.

  • Page 102: 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 4.23: Cutterbar Disc – View from Above Removing Cutterbar Discs WARNING To avoid injury or death from unexpected start-up of machine, always stop the engine and remove the key from the...
  • Page 103 MAINTENANCE AND SERVICING 5. Place a pin (or equivalent) in the front hole of rock guard (B) to prevent disc rotation while loosening bolts. 6. Remove four M12 bolts (A) and washers. Figure 4.25: Cutterbar Disc Bolts 7. Remove cutterbar disc cap (A). 8.

  • Page 104: Installing Cutterbar Discs

    MAINTENANCE AND SERVICING Installing Cutterbar Discs WARNING To avoid injury or death from unexpected start-up 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. Blades are sharp and can cause serious injury. Wear gloves when handling blades.

  • Page 105: Cutterbar Spindles

    MAINTENANCE AND SERVICING 4.6.3 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 106: 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 Disc blades have two sharp cutting edges that can cause serious injury.
  • Page 107 MAINTENANCE AND SERVICING 8. Remove cutterbar disc cap (A). 9. Remove cutterbar disc (B). IMPORTANT: Blades are rotation specific. Switch the entire disc when swapping spindles. Figure 4.33: Cutterbar Disc and Cap 10. Remove spacer plate (A). NOTE: The area around the spindle must be cleaned thoroughly to prevent debris from entering into the cutterbar gearbox.

  • Page 108: Installing Cutterbar Spindles

    MAINTENANCE AND SERVICING 12. Remove spindle (A) from the cutterbar. Figure 4.36: Left Spindle Installing Cutterbar Spindles Figure 4.37: Underside of Cutterbar Spindles NOTE: Right discs (A) and left discs (B) are slightly offset as shown, depending on which idler gear the spindle is turning. •...
  • Page 109 MAINTENANCE AND SERVICING IMPORTANT: Right discs (A) and left discs (B) are timed and must be at a 90° angle from adjacent discs when reinstalled. Misaligned discs could result in the following: • Disc blades of co-rotating discs hitting each other •...
  • Page 110 MAINTENANCE AND SERVICING 1. Park on a flat, level surface. 2. Lower the disc header fully, shut off the engine, and remove the key. NOTE: To prevent oil from spilling from the cutterbar while installing disc spindles, ensure the disc header is on a flat, level surface, and is tilted all the way back.
  • Page 111 MAINTENANCE AND SERVICING 6. Insert studs (A) into the spindle as shown. NOTE: Plugs are factory-installed as shown in position (B), but may come loose over time. Ensure the studs are inserted into the proper locations. IMPORTANT: Ensure clockwise spindles rotate clockwise and counterclockwise spindles (with machined grooves) rotate counterclockwise.
  • Page 112 MAINTENANCE AND SERVICING 10. Torque bolts to 50 Nm (37 lbf·ft) following the tightening pattern shown at right. NOTE: Hub is removed from the illustration for clarity. IMPORTANT: Do NOT use an impact wrench when tightening as it will damage the weld studs. Figure 4.44: Tightening Pattern 11.

  • Page 113: Disc Blades

    MAINTENANCE AND SERVICING 16. Close cutterbar curtain (A). For instructions, refer to 3.6.2 Closing Cutterbar Curtain, page Figure 4.47: Cutterbar Curtain 4.6.4 Disc Blades Each disc has two blades (A) attached at opposite ends that are free to rotate horizontally on a specially designed shoulder bolt. Blade (A) has two cutting edges and can be flipped over so that the blade does not need replacing as often.

  • Page 114: Inspecting Disc Blades

    MAINTENANCE AND SERVICING Inspecting Disc Blades 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 Disc blades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades.

  • Page 115: Inspecting Disc Blade Hardware

    MAINTENANCE AND SERVICING Figure 4.51: Clockwise Disc Rotation Inspecting Disc Blade Hardware CAUTION Damaged or loose disc blades or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage. Inspect the blade attachment hardware each time the blades are changed. Refer to Removing Disc Blades, page 105 Installing Disc Blades, page 107 for the hardware replacement procedure.
  • Page 116 MAINTENANCE AND SERVICING 1. Check and replace the bolt if: • Bolt has been removed and installed five times • Head (A) is worn flush with the bearing surface of the blade • Diameter of the bolt neck is worn (B) 3 mm (1/8 in.) NOTE: This can occur when disc speed is set too low in cane- type crops.

  • Page 117: Removing Disc Blades

    MAINTENANCE AND SERVICING 2. Check and replace nuts under the following conditions: • Nut has been previously installed—nuts are one-time use only • Nut shows signs of wear (A) that is more than half the original height (B) • Nut is cracked Figure 4.53: Disc Blade Nut Removing Disc Blades DANGER...
  • Page 118 MAINTENANCE AND SERVICING 5. Rotate disc (A) so blade (B) faces forward and lines up with hole (C) in rock guard. Figure 4.55: Disc Blade Aligned with Hole in Rock Guard 6. Place a pin (or equivalent) in the front hole of the neighboring rock guard to prevent disc rotation while loosening blade bolts.

  • Page 119: Installing Disc Blades

    MAINTENANCE AND SERVICING Installing Disc Blades WARNING To avoid injury or death from unexpected start-up of machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. CAUTION Disc blades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades.

  • Page 120: Accelerators

    Accelerators (A) are mounted on each outboard disc and are designed to quickly move cut material off the disc and into the conditioner. R216 SP headers have two pairs of accelerators on the two pairs of outboard discs. Periodically inspect accelerators for damage and loose or missing fasteners, and replace as necessary.

  • Page 121: Removing Accelerators

    MAINTENANCE AND SERVICING 5. Inspect accelerators (A) for damage and wear, and replace if worn to 50% or more of their original height or if they are no longer effectively moving crop. 6. Tighten or replace any loose or missing fasteners. Figure 4.61: Accelerators –...
  • Page 122 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 the hole in the rock guard with the bolt to be removed. 7. Remove nut (A), flange bolt (B), and disc blade (C) from the disc.

  • Page 123: Installing Accelerators

    MAINTENANCE AND SERVICING Installing Accelerators WARNING To avoid injury or death from unexpected start-up of machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. CAUTION Disc blades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades.

  • Page 124: Rock Guards

    MAINTENANCE AND SERVICING 4. Torque interior nut (A) to 58 Nm (43 lbf·ft). 5. Torque exterior nut (B) (closest to the blade) to 125 Nm (92 lbf·ft). 6. Repeat the installation procedure for the second accelerator. WARNING Ensure the cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage.

  • Page 125: 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 4.69: Rock Guards Removing Rock Guards 1.

  • Page 126: Installing Rock Guards

    MAINTENANCE AND SERVICING Installing Rock Guards 1. Guide the rock guard onto the cutterbar until tabs (A) sit on top of the cutterbar and the bottom back bolt holes line up. Figure 4.72: Rock Guards 2. Center the rock guard if there are gaps on either side, and install two hex head screws, washers, and lock nuts (A).

  • Page 127: Inspecting Drums

    MAINTENANCE AND SERVICING Inspecting Drums Inspect drums daily for signs of damage or wear. 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 Disc blades have two sharp cutting edges that can cause serious injury.
  • Page 128 MAINTENANCE AND SERVICING 7. Inspect the left and right driven drums for severe deformation. If the drum is deformed, dimension (A) must NOT exceed 48 mm (1 7/8 in.). Replace as required. Figure 4.77: Driven Drum – Cutaway View 8. Inspect the left and right driven drums for abrasion (A). The wear limit for abrasion is reached when the material thickness of the drums is less than 3 mm (1/8 in.).

  • Page 129: Removing Suspended Drums

    MAINTENANCE AND SERVICING 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. WARNING Exercise caution when working around the blades.
  • Page 130 MAINTENANCE AND SERVICING 6. Remove four M12 hex flange head bolts (A) securing suspended drum (B) to shaft (C), and remove suspended drum (B). Figure 4.82: Suspended Drum 7. Remove two M10 hex flange head bolts (A) and remove driveline shield (B). 8.

  • Page 131: 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 132: Replacing Left Suspended Drum Drive Belt

    MAINTENANCE AND SERVICING 5. Close cutterbar curtain (A). For instructions, refer to 3.6.2 Closing Cutterbar Curtain, page Figure 4.86: Cutterbar Curtain Replacing Left Suspended Drum Drive Belt 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 133 MAINTENANCE AND SERVICING Removing left suspended drive belt 5. On the left side of the header, remove two M10 hex flange bolts (A). Remove driveline shield (B). Figure 4.88: Left Driveline 6. Open left driveshield (A). For instructions, refer to 3.5.1 Opening Driveshields, page Figure 4.89: Left Driveshield...
  • Page 134 MAINTENANCE AND SERVICING NOTE: Removing the four bolts dismounts spindle spline (A) from the gearbox hub. Figure 4.91: Left Driven Drum – Spindle Spline Dismounted 10. Using a ratchet, remove belt tension by rotating tensioner (A) clockwise. 11. Remove belt (B) from the pulley, and slide the belt through opening (C).
  • Page 135 MAINTENANCE AND SERVICING 17. Hold spindle spline (A) up and secure on gear hub (B) with four bolts (C). NOTE: Frame panel made transparent to show connection between spindle spline (A) and gear hub (B). Figure 4.94: Left Driven Drum – Spindle Spline Dismounted 18.

  • Page 136: Replacing Right Suspended Drum Drive Belt

    MAINTENANCE AND SERVICING 21. Install driveline shield (B) using two bolts (A). Figure 4.97: Left Driveline 22. Close cutterbar curtain (A). For instructions, refer to 3.6.2 Closing Cutterbar Curtain, page 23. Disengage the windrower safety props. For instructions, refer to 3.2.1 Engaging and Disengaging Header Safety Props –...
  • Page 137 MAINTENANCE AND SERVICING Removing right suspended drive belt 4. Open right driveshield (A). For instructions, refer to 3.5.1 Opening Driveshields, page Figure 4.99: Right Driveshield 5. Using a ratchet, release belt tension by rotating counterclockwise on tensioner (A). 6. Remove belt (B) from the pulleys. Figure 4.100: Right Drum Belts Installing right suspended drive belt 7.

  • Page 138: Removing Left Driven Drum And Driveline

    MAINTENANCE AND SERVICING 10. Close right driveshield (A). For instructions, refer to 3.5.2 Closing Driveshields, page 11. Disengage the windrower safety props. For instructions, refer to 3.2.1 Engaging and Disengaging Header Safety Props – M1240 Windrower, page Figure 4.102: Right Driveshield Removing Left 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...
  • Page 139 MAINTENANCE AND SERVICING 5. Remove two M10 hex flange head bolts (A) and loosen two M10 hex flange head bolts (B). Remove driveline shield (C). Figure 4.104: Driveline Shield 6. Remove two M10 hex flange head bolts (A) and remove driveline shield (B).
  • Page 140 MAINTENANCE AND SERVICING 8. Remove four M12 hex flange head bolts (A) securing driveline assembly (B) to hub drive (C). Figure 4.107: Driveline 9. Slide driveline (A) downwards, tilt it to the side, and pull the driveline up and out of the drum. Figure 4.108: Drum and Tube Shield –...

  • Page 141: Installing Left Driven Drum And Driveline

    MAINTENANCE AND SERVICING Installing Left 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 142 MAINTENANCE AND SERVICING 5. Insert driveline (B) at an angle and guide it past hub drive (C) and drum (D). 6. Insert splined spindle end (A) into the splined bore of driveline (B). Figure 4.112: Drum and Tube Shield – Cutaway View ®...
  • Page 143 MAINTENANCE AND SERVICING 9. Position two drum shields (B) as shown. Apply a bead of ® medium-strength threadlocker (Loctite 243 or equivalent) around the threads of eight M8 hex flange head bolts (A). Use the bolts to secure the drum shields in place. Torque hardware to 27 Nm (20 lbf·ft).

  • Page 144: Removing Right Driven Drum And Driveline

    MAINTENANCE AND SERVICING Removing 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 145 MAINTENANCE AND SERVICING 6. Remove eight M8 hex flange head bolts (A) and two drum shields (B). Figure 4.120: Driveline Shields 7. Remove two M10 hex flange head bolts (A) and remove driveline shield (B). Figure 4.121: Driveline Shield 8. Remove four M10 hex flange head bolts (A) securing driveline assembly (B) to hub drive (C).
  • Page 146 MAINTENANCE AND SERVICING 9. Slide driveline (A) downwards, tilt it to the side, and pull the driveline up and out of the drum. 1028519 Figure 4.123: Drum and Tube Shield – Cutaway View 10. Use an 18 mm deep socket and an extension to remove four M12 bolts (A) and washers holding drum disc assembly (B) in place.

  • Page 147: 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 148 MAINTENANCE AND SERVICING 5. Insert driveline (B) at an angle and guide it past hub drive (C) and drum (D). 6. Insert splined spindle end (A) into the splined bore of driveline (B). 1028521 Figure 4.127: Drum and Tube Shield – Cutaway View ®...
  • Page 149 MAINTENANCE AND SERVICING 9. Position two drum shields (B) as shown. Apply a bead of ® medium-strength threadlocker (Loctite 243 or equivalent) around the threads of eight M8 hex flange head bolts (A). Use the bolts to secure the drum shields in place. Torque hardware to 27 Nm (20 lbf·ft).

  • Page 150: Cutterbar Spindle Shear Pin

    MAINTENANCE AND SERVICING 4.6.8 Cutterbar Spindle Shear Pin To prevent damage to the cutterbar and drive systems, each disc is attached to a spindle containing 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 snap ring (B).

  • Page 151: Removing Cutterbar Spindle Shear Pin

    MAINTENANCE AND SERVICING Removing Cutterbar Spindle Shear Pin 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 Disc blades have two sharp cutting edges that can cause serious injury.
  • Page 152 MAINTENANCE AND SERVICING 7. Remove spacer plate (A) and retaining ring (B). Figure 4.137: Cutterbar Spindle 8. Remove the M12 bolt and remove safecut spindle-nut wrench (A) from its storage location. Figure 4.138: Safecut Spindle-Nut Wrench 215026 Revision A...
  • Page 153 MAINTENANCE AND SERVICING IMPORTANT: • Spindles that rotate clockwise have right-leading threading and a smooth top on spindle gear shaft (A). • Spindles that rotate counterclockwise have left-leading threading and machined grooves on spindle gear shaft (B) and nut (C). •...
  • Page 154 MAINTENANCE AND SERVICING 13. Remove damaged shear pins (A) using pin punch (B). Figure 4.142: Removing Shear Pin 14. Remove and clean Belleville washer (A). Figure 4.143: Belleville Washer 215026 Revision A...

  • Page 155: Installing Cutterbar Spindle Shear Pin

    MAINTENANCE AND SERVICING Installing Cutterbar Spindle Shear Pin 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 Disc blades have two sharp cutting edges that can cause serious injury.
  • Page 156 MAINTENANCE AND SERVICING 5. Install new shear pin (A) with a pin punch and hammer. Repeat on the other side of spindle. NOTE: Ensure that the ends of the shear pins do NOT protrude past the step in the hub. Figure 4.146: Cutterbar Spindle 6.
  • Page 157 MAINTENANCE AND SERVICING 9. Install two M10 bolts (A) and washers. Torque hardware to 55 Nm (40 lbf·ft). Figure 4.149: Cutterbar Spindle 10. Install retaining ring (A). Figure 4.150: Cutterbar Spindle 11. Depending on the type of disc with the new shear pin, refer to the applicable disc installation procedure: •...

  • Page 158: Reconfiguring Cutterbar Crop Stream

    NOTE: Increasing the number of crop streams will also increase the number of diverging disc pairs which may negatively affect cut quality in certain conditions. 1028073 Figure 4.153: R216 Cutterbar Figure 4.154: Cutterbar Spindles 215026 Revision A...

  • Page 159: Changing R216 Sp Cutterbar Crop Stream Configuration

    For instructions, refer to Removing Cutterbar Spindles, page 94 Installing Cutterbar Spindles, page To change R216 SP (10 disc) spindle rotation from four crop streams (A) to two crop streams (B): • Swap disc/spindle (3) with disc/spindle (8). NOTE: Switching from 4 streams to 2 streams is a recommended setting when cutting light alfalfa and using the double windrower attachment (DWA).
  • Page 160 MAINTENANCE AND SERVICING Figure 4.156: Disc Timing Tool Location on Header A - Disc Timing Tool (MD #307954) B - Safecut Spindle-Nut Wrench (MD #246314) NOTE: A disc timing tool (A) (MD #307954) is provided with the header and is located on the panel on the right side of the header. For instructions on using the disc timing tool, refer to Installing Cutterbar Spindles, page 215026...

  • Page 161: Conditioner Roll Timing Gearbox

    MAINTENANCE AND SERVICING 4.7 Conditioner Roll Timing Gearbox Conditioner roll timing gearbox is located inside the drive compartment at the right of the header and transfers power from the gearbox-driven lower roll to the upper roll. Gearbox (A) does not require routine maintenance or service other than checking and changing oil.
  • Page 162 MAINTENANCE AND SERVICING 5. Remove right driveshield (A). For instructions, refer to 4.11.1 Removing Driveshields, page 165. Figure 4.159: 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 163 MAINTENANCE AND SERVICING Changing conditioner roll timing gearbox oil: WARNING To avoid bodily injury or death from unexpected start-up or fall of raised machine: stop engine, remove key, and engage lift cylinder lock-out valves before going under machine. 8. Raise the header to provide sufficient access to oil drain plug (A).

  • Page 164: Header Drive Gearbox

    MAINTENANCE AND SERVICING 4.8 Header Drive Gearbox 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 165 MAINTENANCE AND SERVICING 6. Locate gearbox (A) on the left side of the header. Figure 4.163: Header Drive Gearbox Location 7. Clean the area around check plug (A). 8. Remove check plug (A) with an 13 mm (1/2 in.) socket. 9.

  • Page 166: Changing Oil In Header Drive Gearbox

    MAINTENANCE AND SERVICING 4.8.2 Changing Oil in Header Drive Gearbox 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 the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.

  • Page 167: Cutterbar Curtain

    MAINTENANCE AND SERVICING 4.9 Cutterbar Curtain 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 168: Removing Cutterbar Curtain

    MAINTENANCE AND SERVICING 4.9.2 Removing Cutterbar Curtain 1. Raise header fully and engage safety props. For instructions, refer to 3.2.1 Engaging and Disengaging Header Safety Props – M1240 Windrower, page 2. Remove hex flange head bolt and washer (A) securing curtain (B) to the inboard side of the end panel.

  • Page 169: Installing Cutterbar Curtain

    MAINTENANCE AND SERVICING 4.9.3 Installing Cutterbar Curtain 1. Position curtain (E) on the front of the header frame. NOTE: Top shield removed from illustration for clarity. 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 170: Conditioner

    MAINTENANCE AND SERVICING 4.10 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. There are two roll conditioner options—steel conditioner rolls and polyurethane rolls. 4.10.1 Inspecting Conditioner Inspect conditioner roll bearings, feed roll bearings, and driveline U-joints for signs of wear or damage.
  • Page 171 MAINTENANCE AND SERVICING 5. Inspect feed roll right bearing (A) for signs of wear or damage. If the bearing needs replacing, contact your Dealer. Figure 4.174: Feed Roll Right Bearing – View from Below 6. Inspect conditioner roll left bearings (A) for signs of wear or damage.

  • Page 172: Conditioner Drive Belt

    MAINTENANCE AND SERVICING 10. Inspect roll timing gearbox bearings (A) for signs of wear or damage. If the bearings need replacing, contact your Dealer. Figure 4.177: Roll Timing Gearbox Bearings Conditioner Drive Belt The conditioner drive belt is located inside the left driveshield and is tensioned with a spring tensioner. Inspecting Conditioner Drive Belt Check the belt tension after the first 25 hours, and then check and inspect for damage or wear every 100 hours.
  • Page 173 MAINTENANCE AND SERVICING 4. Inspect drive belt (A) and replace if damaged or cracked. 5. Check that jam nut (B) and adjuster nut (C) are tight. Figure 4.179: Conditioner Drive 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).
  • Page 174 MAINTENANCE AND SERVICING Removing Conditioner Drive Belt 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. Lower the header fully. 2.
  • Page 175 MAINTENANCE AND SERVICING Installing Conditioner Drive Belt 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. Lower the header fully. 2.
  • Page 176 MAINTENANCE AND SERVICING 5. Check position of the bracket, center-to-center distance (C) between drive pulley (D) and driven pulley (E) should be 723 mm (28 7/16 in.). If not, loosen M16 hex head bolt and lock nuts (A) on pulley mount bracket (B), and adjust the position of the bracket.

  • Page 177: Replacing Driveshields

    MAINTENANCE AND SERVICING 4.11 Replacing Driveshields If driveshields are missing, severely damaged, or are not securely installed due to damage, they must be replaced. 4.11.1 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 178: Installing Driveshields

    MAINTENANCE AND SERVICING 4. Pull outboard side (A) and inboard side (B) of driveshield away from the disc header to remove. Figure 4.189: Inboard and Outboard Half of Driveshield 4.11.2 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 179 MAINTENANCE AND SERVICING 2. Secure the top of the outboard half of the driveshield with two washers (A), retaining pin (B), bolt (C), and a hex flange center lock nut. 3. Secure the front and rear of the inboard half of the driveshield with retaining pin (B), bolt (C), and a hex flange center lock nut.

  • Page 180: Electrical System

    MAINTENANCE AND SERVICING 4.12 Electrical System 4.12.1 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. 4.12.2 Replacing Amber Hazard/Signal Light 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 181: Replacing Header Disc Speed Sensor

    MAINTENANCE AND SERVICING 4.12.3 Replacing Header Disc Speed Sensor If the header disc sensor malfunctions or is damaged, use this procedure to replace it. 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 182: Hydraulics

    MAINTENANCE AND SERVICING 4.13 Hydraulics 4.13.1 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 183: Chapter 5: Options And Attachments

    Chapter 5: Options and Attachments 5.1 Cutterbar Deflectors – MD #B6847 A two-piece cutterbar deflector is attached to the cutterbar just below the header’s conditioner rolls. Deflectors provide improved feeding into the conditioner rolls and prevent heavy crop with long stems from feeding under the rolls. Cutterbar deflectors may not be well-suited for some crop and field conditions.

  • Page 184: Double Windrow Attachment - Md #C2070

    OPTIONS AND ATTACHMENTS 5.2 Double Windrow Attachment – MD #C2070 This kit allows disc headers to lay a double windrow when installed on a windrower. The kit includes a draper deck, linkage assembly, hydraulics, and installation instructions. MD #C2070 consists of: •...

  • Page 185: Disc Feed Plate Kit - Md #B6669

    OPTIONS AND ATTACHMENTS 5.3 Disc Feed Plate Kit – MD #B6669 The tall crop feed plates assist the feeding of tall crops into the conditioner by encouraging material flow from behind the cage deflectors. Do not use this kit in medium to light alfalfa as it will degrade the cutterbar’s cutting performance.

  • Page 186: Electric Remote Baffle Kit - Md #B6664

    OPTIONS AND ATTACHMENTS 5.4 Electric Remote Baffle Kit – MD #B6664 The Electric Remote Baffle kit (MD #B6664), allows the operator to electronically adjust the disc header baffle from inside the windrower. Figure 5.3: Electric Remote Baffle Kit 215026 Revision A...

  • Page 187: Adjustable Gauge Roller Kit - Md #B6855

    OPTIONS AND ATTACHMENTS 5.5 Adjustable Gauge Roller Kit – MD #B6855 The adjustable gauge roller kit allows the header to achieve the desired cutting height for optimum cutting performance. Adjustable gauge rollers are recommended only for dry and hard packed terrain. Figure 5.4: Adjustable Gauge Roller 215026 Revision A...

  • Page 188: Polyurethane Intermeshing Roller - Md #B6661

    OPTIONS AND ATTACHMENTS 5.6 Polyurethane Intermeshing Roller – MD #B6661 Rolls condition the crop by crimping and crushing the stem in several places, which allows the release of moisture resulting in faster drying times. A polyurethane roll conditioner is better suited for crushing stems while providing reduced crimping and is recommended for alfalfa, clover, legumes, and similar crops.

  • Page 189: Steel Intermeshing Roller - Md #B6662

    OPTIONS AND ATTACHMENTS 5.7 Steel Intermeshing Roller – MD #B6662 Rolls condition the crop by crimping and crushing the stem in several places, which allows the release of moisture resulting in faster drying times. Steel rolls with a larger gap (up to 25 mm [1 in.]) may be desirable for thick-stemmed cane-type crops;...

  • Page 190: Adjustable Skid Shoes Kit - Md #B6848

    OPTIONS AND ATTACHMENTS 5.8 Adjustable Skid Shoes Kit – MD #B6848 The adjustable skid shoes kit allows the header to achieve the desired cutting height for optimum cutting performance. Skid shoes are recommended for most conditions including wet or muddy terrain. Figure 5.7: Adjustable Skid Shoe –...

  • Page 191: Tall Crop Divider Kit - Md #B6808

    OPTIONS AND ATTACHMENTS 5.9 Tall Crop Divider Kit – MD #B6808 Tall crop dividers attach to the ends of the disc header for clean crop division and cutterbar entry in tall crops. The kit includes left and right dividers and attachment hardware. Figure 5.8: Tall Crop Divider –...

  • Page 193: Chapter 6: Troubleshooting

    Chapter 6: Troubleshooting 6.1 Performance Problems Problem Solution Refer to Symptom: Ragged or uneven cutting of crop Header angle too flat for blades to Increase header angle. 3.7.1 Cutting Height, page 47 pick up downed crop Header float too light, causing Adjust to heavier float setting.
  • Page 194 TROUBLESHOOTING Problem Solution Refer to Symptom: Conditioner rolls plugging — Ground speed too fast Reduce ground speed. • Adjusting Roll Gap – Steel Rolls, Roll gap too large for proper feeding Decrease roll gap. page 54 Roll gap too small in thick-stemmed •...
  • Page 195 TROUBLESHOOTING Problem Solution Refer to Symptom: Cutting height varies from one side to the other Float not properly balanced Adjust header float. Refer to windrower operator’s manual Symptom: Slow crop drying • Positioning Forming Shield Side Deflectors – Roll Conditioner, page Crop is bunched in windrow Adjust forming shields/baffle.

  • Page 196: Mechanical Problems

    TROUBLESHOOTING 6.2 Mechanical Problems Problem Solution Refer to Symptom: Excessive noise • Removing Disc Blades, page 105 Bent disc blade Replace blade. • Installing Disc Blades, page 107 • Check roll timing and adjust if Checking Roll Timing, page 57 Conditioner roll timing off necessary.
  • Page 197 When all moving parts are completely 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 199: 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 200 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 201: 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 202: 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 203 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 204: 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 205: 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 206: 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 207: 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 209: Index

    Index closing .............. 46 inspecting ............155 accelerators............108 installing............157 inspecting ............108 opening............. 45 installing............111 removing ............156 removing ............109 cutterbar angles adjustable skid shoes kit ........178 adjusting angle ........... 52 cutterbar discs ............88 definition............
  • Page 210 INDEX removing............109 cutterbar discs gearboxes ............149 inspecting............89 conditioner roll timing gearbox installing ............92 checking and changing gearbox oil ....149 removing............90 checking gearbox oil ........149 drive systems header drive conditioner drive belts ........160 changing oil ..........
  • Page 211 80 See also greasing cutterbars ............83 lubrication R2 SP Series locations............81 definition............16 R216 SP attaching header..........24 connecting hydraulics .......... 29 maintenance and servicing detaching header ..........36 break-in inspections ..........78 rear baffle deflector fins break-in period ...........
  • Page 212 INDEX safety ..............1 tapered pipe thread fittings ........ 194 daily start-up checks ..........71 torque-tension general safety............3 definition............16 hydraulic safety ............6 transporting the header........... 69 maintenance safety ..........5 troubleshooting noise levels ............2 mechanical ............184 procedures ............74 performance ............ 181 safety alert symbols..........1 safety sign decals ..........8 installing decals ..........8...

  • Page 213: 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 214 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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