Page 1 R216 Rotary Disc Header Operator’s Manual 215403 Revision A Original Instruction The Harvesting Specialists.
Page 2 © 2020 MacDon Industries, Ltd. The information in this publication is based on the information available and in effect at the time of printing. MacDon Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the...
Page 3 Benedikt von Riedesel Benedikt von Riedesel Benedikt von Riedesel Benedikt von Riedesel Directeur général, MacDon Europe GmbH Gerente general - MacDon Europe GmbH Peadirektor, MacDon Europe GmbH General Manager, MacDon Europe GmbH Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59...
Page 4 Benedikt von Riedesel Benedikt von Riedesel Benedikt von Riedesel Benedikt von Riedesel Generalni direktor, MacDon Europe GmbH Administra v chef, MacDon Europe GmbH Generálny riadite MacDon Europe GmbH Generalni direktor, MacDon Europe GmbH Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59 Hagenauer Straße 59...
Page 5 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 6 (A) located inside driveshields (B). Manual Storage Case – Grass Seed (GSS) Option NOTE: Keep your MacDon publications up-to-date. The most current version can be downloaded from our website www.macdon.com or from our Dealer-only site (https://portal.macdon.com) (login required).
Page 7: Summary Of Changes
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 Internal Use Only Summary of Change Throughout...
Page 8 GSS version. ECN 60771 Serial Number, page xiii Added information about the grass seed (GSS) ECN 60742 version of the R216 Rotary Disc Header to the ECN 60743 illustration caption. 1.8 Locating Safety Decals – Standard Added decal MD #184372.
Page 9 Section Summary of Change Internal Use Only ECN 58180 3.2.2 Engaging and Disengaging Header Added topic because R216 is now compatible Safety Props – M205 SP Windrower, page with M205 Windrowers. 3.3.2 Attaching R216 Rotary Disc Header to Added step.
Page 10 Summary of Change Internal Use Only ECN 58180 3.6.1 Detaching R216 Rotary Disc Header Added topic because R216 is now compatible from M205 SP Windrower, page 73 with M205 Windrowers. 3.6.2 Removing the Forming Shield , page Added topic because R216 is now compatible ECN 58180 with M205 Windrowers.
Page 11 Section Summary of Change Internal Use Only ECN 60771 Added grass seed operation topics. • 3.11 Grass Seed Version Operation, page ECN 60742 ECN 60743 • 3.11.1 Activating the Grass Seed Option, page 108 • 3.11.2 Operating in the Field, page 110 •...
Page 12 Changing R216 Rotary Disc Header Tech Pubs Cutterbar Crop Stream Configuration, page Crop Stream” because all the information is now in “Changing R216 Rotary Disc Header Cutterbar Crop Stream Configuration” 4.7.1 Checking and Changing Conditioner Revised the following WARNING with the...
Page 13 240 ECN 60771 6.3 Grass Seed Problems, page 252 Added topic for grass seed (GSS) version of the ECN 60742 R216 Rotary Disc Header. ECN 60743 Conditioner roll timing gearbox oil is now ECN 60418 Inside back cover 80W-140, was 85W-140.
Page 14: Noise Levels
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- propelled vehicle used to power the R216 Rotary Disc Header.
Page 15: 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 17: Table Of Contents
3.3.1 Attaching Forming Shield....................... 29 3.3.2 Attaching R216 Rotary Disc Header to M1240 Windrower..............31 3.3.3 Connecting R216 Rotary Disc Header Hydraulics and Electrical to an M1240 Windrower ......36 3.4 Detaching Header from M1240 Windrower....................45 3.4.1 Detaching R216 Rotary Disc Header from an M1240 Windrower ............45 3.4.2 Removing Forming Shield ......................
Page 18 3.5.3 Attaching R216 Rotary Disc Header to M205 SP Windrower – Hydraulic Center-Link without Optional Self-Alignment..........................61 3.5.4 Connecting R216 Rotary Disc Header Hydraulics and Electrical to an M205 SP Windrower ......67 3.6 Detaching Header from M205 SP Windrower .................... 73 3.6.1 Detaching R216 Rotary Disc Header from M205 SP Windrower ............
Page 19 TABLE OF CONTENTS Chapter 4: Maintenance and Servicing....................119 4.1 Daily Start-Up Check ........................... 119 4.2 Preparing Machine for Servicing......................121 4.3 Recommended Safety Procedures ......................122 4.4 Maintenance Requirements ......................... 124 4.4.1 Maintenance Schedule/Record ..................... 124 4.4.2 Break-In Inspections ........................126 4.4.3 Preseason Servicing........................
Page 20 4.6.9 Reconfiguring Cutterbar Crop Stream .................... 207 Changing R216 Rotary Disc Header Cutterbar Crop Stream Configuration ........... 208 Changing R216 Rotary Disc Header Cutterbar Crop Stream Configuration for Grass Seed Option .... 211 4.7 Conditioner Roll Timing Gearbox ......................212 4.7.1 Checking and Changing Conditioner Roll Timing Gearbox Oil..............
Page 21 TABLE OF CONTENTS 6.3 Grass Seed Problems........................... 252 Chapter 7: Reference ..........................253 7.1 Torque Specifications .......................... 253 7.1.1 Metric Bolt Specifications ......................253 7.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ..............255 7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable ..................256 7.1.4 O-Ring Boss Hydraulic Fittings –...
Page 23: Chapter 1: Safety
Chapter 1: Safety 1.1 Safety Alert Symbols The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read and follow the safety message accompanying this symbol.
Page 24: 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 25: General Safety
SAFETY 1.3 General Safety Protect yourself when assembling, operating, and servicing machinery. CAUTION The following general farm safety precautions should be part of your operating procedure for all types of machinery. Wear all protective clothing and personal safety devices that could be necessary for the job at hand.
Page 26 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 27: 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 28: 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 29: Welding Precaution
It is very important that welding on the header is not attempted while the header is connected to the windrower. If it is unfeasible to disconnect the rotary disc header from the windrower before welding, contact your MacDon Dealer for welding precautions detailing all electrical components that must be disconnected first for safe welding.
Page 30: Safety Signs
SAFETY 1.7 Safety Signs Safety signs (decals) are usually yellow, and are placed on the machine where there is a risk of personal injury, or where the operator has to take extra precaution before operating controls. Operator manuals and technical manuals identify the location and meaning of all safety signs placed on the machine.
Page 31: Locating Safety Decals - Standard Header
SAFETY 1.8 Locating Safety Decals – Standard Header Figure 1.15: Safety Sign Decal Locations – Top View A - MD #307746 B - MD #325706 Figure 1.16: Safety Sign Decals A - MD #307746 B - MD #325706 215403 Revision A...
Page 32 SAFETY Figure 1.17: Safety Sign Decal Locations – Rear View A - MD #190546 B - MD #325070 C - Reflector D - MD #184372 215403 Revision A...
Page 33: Locating Safety Decals - Grass Seed Header
SAFETY 1.9 Locating Safety Decals – Grass Seed Header Replace missing or damaged decals. Figure 1.18: Safety Sign Decal Locations – Top View A - MD #307746 B - MD #325706 Figure 1.19: Safety Sign Decals A - MD #307746 B - MD #325706 215403 Revision A...
Page 34 SAFETY F F D Figure 1.20: Safety Sign Decal Locations – Rear View A - MD #246959 B- Reflector C - MD #184372 D- MD #325070 215403 Revision A...
Page 35: Understanding Safety Signs
SAFETY 1.10 Understanding Safety Signs MD #190546 Slipping hazard WARNING To prevent injury: • Do NOT use this area as a step or platform. • Failure to comply could result in serious injury or death. Figure 1.21: MD #190546 MD #246959 Pinch point hazard CAUTION To prevent injury:...
Page 36 SAFETY • Listen and look for evidence of rotation before. MD #325070 Driveline entanglement hazard DANGER To prevent injury: • Stop engine and remove key before opening shield. • Do NOT operate without shields in place. Hand and arm entanglement hazard WARNING To prevent injury: 1028591...
Page 37 SAFETY • Shut off engine and remove key from ignition before servicing, adjusting, lubricating, cleaning, or unplugging machine. • Engage locks to prevent lowering of self-propelled rotary disc header before servicing in the raised position. • Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law. •...
Page 39: Chapter 2: Product Overview
Weight: base machine with steel conditioner 2156 kg (4750 lb.) Weight: base machine with grass seed module and shield 2298 kg (5055 lb.) Standard Header: MacDon M1240 and M205 Compatible windrower Grass Seed Header: MacDon M1240 Lighting Left and right turn signals Plastic case on header –...
Page 40 PRODUCT OVERVIEW Tall crop kit (cutterbar deflectors and tall crop feed plates) Optional Drives Hydraulic motor Piston type into 90° gearbox Direct drive through 90° gearbox and Cutterbar universal shaft Conditioner drive Belt drive (4HB) from 90° gearbox to conditioner Conditioner roll timing Timing gearbox Hay Conditioner Options...
Page 41: Component Identification - Standard Header
PRODUCT OVERVIEW 2.2 Component Identification – Standard Header Figure 2.1: R216 Rotary Disc Header – Standard Header A - Front Curtain B - Disc Drum (Right Shown) C - 10-Disc Cutterbar D - Conditioner Rolls E - Drive Shield (Left Shown)
Page 42: Component Identification - Grass Seed Header
PRODUCT OVERVIEW 2.3 Component Identification – Grass Seed Header Figure 2.3: R216 Rotary Disc Header – Grass Seed Header A - Front Curtain B - Disc Drum (Right) C - Suspended Drum (Right) D - Grass Seed Module Drums x 2 (Right)
Page 43 PRODUCT OVERVIEW Figure 2.4: R216 Rotary Disc Header – Grass Seed Header A - Anti-Shatter Shield B Actuator for Anti-Shatter Shield C - Hazard/Brake Lights D - Hydraulic Motor E - Left Drive Shield F - Hose Guide G - Header Supports...
Page 44: Definitions
Harvest Performance Tracker display module on an M1 Series Windrower Joint Industrial Council: A standards body that developed standard sizing and shape for original 37° flared fitting M1 Series MacDon M1170 and M1240 Windrowers Not applicable North American header Header configuration typical in North America National Pipe Thread: A style of fitting used for low-pressure port openings.
Page 45 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 47: 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. M1240 Windrowers: DANGER Before investigating an unusual sound or attempting to correct a problem, stop the engine, put the ground speed lever...
Page 48: 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. Proceed according to the model of windrower: • If using an M1240 Windrower, refer to 3.2.1 Engaging and Disengaging Header Safety Props – M1240 Windrower, page •...
Page 49: Engaging And Disengaging Header Safety Props - M205 Sp Windrower
OPERATION 5. Disengage the safety props on both lift cylinders as follows: Turn lever (A) away from the header to raise the safety prop until the lever locks into the vertical position. b. Repeat for the opposite cylinder. NOTE: If the safety prop will NOT disengage, raise the header to release the prop.
Page 50 OPERATION 3. Pull lever (A) and rotate it toward the header to lower safety prop (B) onto the cylinder. Repeat for the opposite cylinder. Figure 3.5: Safety Prop Disengage safety props as follows: 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 51: Attaching Rotary Disc Header To M1240 Windrower
OPERATION 3.3 Attaching Rotary Disc Header to M1240 Windrower Attaching the header to the windrower will allow you to cut, condition, and lay a wide variety of grasses and hay crops in windrows. 3.3.1 Attaching Forming Shield The forming shield controls the width and placement of the windrow. 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 52 OPERATION 5. Secure forming shield (C) to bolt and spacer (D) using clevis pin (B) and lynch pin (A). 6. Repeat Steps 3, page 29 5, page 30 at the opposite side. Figure 3.8: Forming Shield Secured to Front of Windrower Legs 7.
Page 53: Attaching R216 Rotary Disc Header To M1240 Windrower
Figure 3.10: Rubber Strap Securing Forming Shield onto Windrower Leg 3.3.2 Attaching R216 Rotary Disc 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.
Page 54 OPERATION 3. Remove hairpin (A) from clevis pin (B), and remove pin from header support (C) on both sides of the header. Figure 3.12: Header Support 4. Lift header support (A) and place 2 x 4 in. blocks (B) under the header support.
Page 55 OPERATION 8. Press rotary scroll knob (A) on to highlight the QuickMenu options. 9. Rotate scroll knob (A) to highlight HEADER FLOAT symbol (B), and press the scroll knob to select. The Float Adjust page displays. Figure 3.15: HPT Display 10.
Page 56 OPERATION 13. Drive the windrower slowly forward until feet (A) enter supports (B). Continue to drive slowly forward until the feet engage the supports and the header nudges forward. 14. Ensure feet (A) are properly engaged in supports (B). Figure 3.18: Header Support 15.
Page 57 OPERATION DANGER Check to be sure all bystanders have cleared the area. Start the engine. 17. Press HEADER UP switch (A) to raise the header to maximum height. NOTE: If one end of the header does NOT fully raise, rephase the lift cylinders as follows: Press and hold HEADER UP switch (A) until both cylinders stop moving.
Page 58: Connecting R216 Rotary Disc Header 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. One additional set of quick couplers (MD #B6277) is required. • Rotary disc header ready windrowers include hard plumbed hydraulics connections.
Page 59 OPERATION 3. Retrieve hydraulic hoses (A) from the header and route the hose bundle under the windrower frame. NOTE: Adding anti-seize to the hose holder pin will make future removal easier. 4. Insert pin (B) into hole (C) in windrower frame. IMPORTANT: Route hydraulic hoses as straight as possible, and avoid rub/wear points that could damage the hoses.
Page 60 OPERATION Proceed with the steps that are relevant to the following windrower configurations: Steps for Connecting Windrower Configuration Hydraulics and Electrical Step 6, page 38 to Step Rotary disc/draper ready page 40 configuration (A) Step Step 11, page 40 to Step Rotary disc only hard 13, page 41 plumbed configuration (B)
Page 61 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 3.30: Hydraulic Fittings 8.
Page 62 Connect disc return hose (D) to hard plumb fitting (E) and torque to 205–226 Nm (151–167 lbf·ft). Connect case drain hose (F) to fitting (G). Figure 3.33: Hard Plumbed Connections on R216 Rotary Disc Header Ready Windrower 215403 Revision A...
Page 63 OPERATION 12. Grass seed and rotary disc configuration: Connect the additional four hoses supplied with the grass seed version of the header as follows: Remove plug (not shown) from drive manifold port R1. Install 45° fitting (A) in port R1. Connect hose (C) (blue cable tie) to fitting (A).
Page 64 OPERATION 15. Remove the extension fittings and elbows (A) from the rotary disc header hydraulic pressure and return connections. Figure 3.36: Hard Plumbed Connections – Rotary Disc Ready Windrower 16. Install the male quick coupler at windrower pressure receptacle (A). 17.
Page 65 OPERATION 18. 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 66 OPERATION To connect electrical harness, follow these steps: 21. Free electrical harness (A) from adjustable strap (B). Figure 3.40: Electrical Harness Secured to Center-Link 22. Connect main header harness (A) to adapter harness (B). 23. Standard headers equipped with optional electric baffle control kit: Connect electric baffle control harness (C) to adapter harness (D).
Page 67: Detaching Header From M1240 Windrower
Detach the header when replacing the header with a different one or when storing the header. 3.4.1 Detaching R216 Rotary Disc Header from an M1240 Windrower Detach the header when replacing the header with a different one or when storing the header.
Page 68 OPERATION 5. Grass seed: Disconnect additional four hoses (A), (B), (C), and (D). 6. Install caps and plugs on open lines to prevent buildup of dirt and debris while in storage. Figure 3.45: Grass Seed Hydraulic Connections – Draper/Disc Ready Figure 3.46: Grass Seed Hydraulic Connections –...
Page 69 OPERATION 7. Remove hose support (A) and hose bundle from windrower frame. Figure 3.47: Hoses on Windrower 8. Rest hydraulic hose bundle (A) on header for storage as shown. Figure 3.48: Hose Bundle Storage Position 9. Disconnect main header harness (A) from adapter harness (B).
Page 70 OPERATION 12. Secure adapter harness (A) on the center link with an adjustable strap (B). Figure 3.50: Adapter Harness 13. Remove hairpin (B) from clevis pin (A). Remove clevis pin from header support (C) on both sides of header. Figure 3.51: Header Supports 14.
Page 71 OPERATION DANGER Check to be sure all bystanders have cleared the area. 15. Start the engine. 16. Remove header float when prompted by the Harvest Performance Tracker (HPT). NOTE: If not prompted by the HPT to remove float, remove float manually. 17.
Page 72: Removing Forming Shield
OPERATION 22. Back the windrower slowly away from header. 23. Reinstall clevis pin (A) through support (C) and secure with hairpin (B). Repeat for opposite side. Figure 3.55: Header Support 3.4.2 Removing Forming Shield The forming shield controls the width and placement of the windrow. 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 73 OPERATION 7. Remove lynch pin (A) and clevis pin (B) securing forming shield (C) to bolt and spacer (D). Repeat at the opposite side. Figure 3.57: Forming Shield Secured to Front of Windrower Legs 8. Dismount forming shield (A) from bolts and spacers (B). 9.
Page 74: Attaching Rotary Disc Header To M205 Sp Windrower
OPERATION 3.5 Attaching Rotary Disc Header to M205 SP Windrower Attaching the header to the windrower will allow you to cut, condition, and lay a wide variety of grasses and hay crops in windrows. 3.5.1 Attaching Forming Shield to M205 SP Windrower The forming shield controls the width and placement of the windrow.
Page 75 OPERATION 5. Secure forming shield (C) to bolt and spacer (D) using clevis pin (B) and lynch pin (A). 6. Repeat Step 3, page 52 to Step 5, page 53 at the opposite side. Figure 3.60: Forming Shield Secured to Front of Windrower Legs 7.
Page 76: Self-Alignment
NOTE: The R216 Rotary Disc Header requires conversion kit (MD #B7220) if being used with an M205 SP Windrower. Once configured for an M205 SP Windrower, the R216 Rotary Disc Header is incompatible with the optional Remote Baffle Control kit (MD #B6664).
Page 77 OPERATION 2. Remove hairpin (A) from clevis pin (B), and remove the pin from header support (C) on both sides of the header. Figure 3.63: Header Support 3. Lift header support (A) and place 2 x 4 in. blocks (B) under the header support.
Page 78 OPERATION DANGER Check to be sure all bystanders have cleared the area. 5. Start the engine and activate HEADER DOWN button (A) on the ground speed lever (GSL) to fully retract the header lift cylinders. Figure 3.66: Ground Speed Lever 6.
Page 79 OPERATION 7. Slowly drive the windrower forward until the windrower feet (A) enter header supports (B). Continue driving slowly forward until the feet engage the supports and the header nudges forward. Figure 3.68: Header Support 8. Use the following GSL functions to position the center-link hook above the header attachment pin: •...
Page 80 OPERATION 9. Adjust center-link cylinder (A) position with the REEL UP and REEL DOWN switches on the GSL until the hook is positioned above the header attachment pin. IMPORTANT: Hook release (B) must be down to enable the self-locking mechanism. If the release is open (up), manually push it down after hook engages header pin.
Page 81 OPERATION 14. Pull lever (A) outward and rotate it toward the header to lower safety prop (B) onto the cylinder. Repeat for the opposite cylinder. Shut down the engine, and remove the key from the ignition. b. Pull lever (A) outward and rotate it towards the header to release and lower safety prop (B) onto the lift cylinder.
Page 82 GSL to fully lower the header. 20. Shut down the engine, and remove the key from the ignition. 21. Proceed to 3.5.4 Connecting R216 Rotary Disc Header Hydraulics and Electrical to an M205 SP Windrower, page Figure 3.76: Ground Speed Lever 215403...
Page 83: Attaching R216 Rotary Disc Header To M205 Sp Windrower - Hydraulic Center-Link Without Optional Self-Alignment
OPERATION 3.5.3 Attaching R216 Rotary Disc Header to M205 SP Windrower – Hydraulic Center-Link without Optional Self-Alignment Attach the header to an M205 SP Windrower that is equipped without an optional self-aligning hydraulic center-link (allows the operator to control the vertical position of the center-link from the cab).
Page 84 OPERATION 4. To disengage the float springs, move the float engagement pin from engaged position (A) and insert the pin into storage hole (B). Secure the float engagement pin with a lynch pin. Repeat for opposite linkage. IMPORTANT: To avoid damaging the lift system when lowering the header lift linkages without a header or weight box attached, ensure the float engagement pin is installed in storage position (B) and NOT in engaged position (A).
Page 85 OPERATION 7. Slowly drive the windrower forward until windrower feet (A) enter header supports (B). Continue driving slowly forward until the feet engage the supports and the header nudges forward. Figure 3.82: Header Support 8. Use the following GSL functions to position the center-link hook above the header attachment pin: •...
Page 86 OPERATION 10. Push down on the rod end of link cylinder (A) until hook (B) engages and locks onto the header pin. IMPORTANT: The hook release must be down to enable the self-locking mechanism. If the release is open (up), manually push it down after the hook engages the header pin.
Page 87 OPERATION 15. Pull lever (A) outward and rotate it toward the header to lower safety prop (B) onto the cylinder. Repeat for the opposite cylinder. Shut down the engine, and remove the key from the ignition. b. Pull lever (A) outward and rotate it towards the header to release and lower safety prop (B) onto the lift cylinder.
Page 88 GSL to fully lower the header. 21. Shut down the engine, and remove the key from the ignition. 22. Proceed to 3.5.4 Connecting R216 Rotary Disc Header Hydraulics and Electrical to an M205 SP Windrower, page Figure 3.90: Ground Speed Lever 215403...
Page 89: Connecting R216 Rotary Disc Header Hydraulics And Electrical To An M205 Sp Windrower
NOTE: M205 compatibility kit MD #B7220 is required to connect a R216 Rotary Disc Header to an M205 SP Windrower. This kit supplies the hydraulic fittings used for hard-plumbed connections. If the M205 SP Windrower uses quick coupler connections, install quick coupler kit (MD #B5497) onto the R216 Rotary Disc Header pressure and return hoses.
Page 90 OPERATION NOTE: When connecting the header hoses to the windrower in the following steps, you can adjust the length of the hoses as follows: • Loosen nut (A) and clamp (B) to adjust the length of the case drain hose. •...
Page 91 OPERATION • If the M205 SP Windrower has plugs (A) installed in the steel lines, remove the plugs from the steel lines and install the hard-plumbed connections provided in the M205 compatibility kit. For instructions, proceed to Step 13, page Figure 3.95: Pressure and Return Steel Lines with Plugs 5.
Page 92 OPERATION 6. Quick coupler connections: Connect pressure coupler (A) to inboard steel line coupler (B). NOTE: For reference, the other end (C) of the pressure hose is connected to the front of the hydraulic motor. 7. Quick coupler connections: Connect return coupler (D) to outboard steel line coupler (E).
Page 93 OPERATION 10. Quick coupler connections: Connect case drain hose (A) to 1/2 in. male flat face fitting (B). NOTE: For reference, the other end of the case drain hose is connected to hydraulic motor port (D). 11. Quick coupler connections: Secure case drain hose to coupler lock assembly with two clamps (C).
Page 94 OPERATION 15. Hard-plumbed connections: Connect case drain hose (A) to 1/2 in. male flat face fitting (B). NOTE: For reference, the other end of the case drain hose is connected to hydraulic motor port (C). Figure 3.101: Case Drain Connection 16.
Page 95: Detaching Header From M205 Sp Windrower
Detach the header when replacing the header with a different one or when storing the header. 3.6.1 Detaching R216 Rotary Disc Header from M205 SP Windrower Detach the header when replacing the header with a different one or when storing the header.
Page 96 OPERATION 6. Remove hairpin (B) from clevis pin (A) and remove the clevis pin from header boot (C) on both sides of the header. Figure 3.105: Header Boots 7. Remove the hairpin and clevis pin from location (A) to disengage float springs, and insert into storage hole (B). Secure with the hairpin.
Page 97 OPERATION 8. Disengage the safety props by turning lever (A) away from the header to raise the safety prop until the lever locks into vertical position. Repeat for the opposite cylinder. 9. Start the engine, choose a level area, and lower the header to the ground.
Page 98 OPERATION 13. Proceed as follows: • If equipped with quick couplers (A), proceed to Step page • If equipped with hard-plumbed couplers (B), proceed to Step 19, page Figure 3.110: Quick Couplers and Hard-Plumbed Couplers 14. Quick coupler connections: Disconnect case drain hose (A) from fitting (B).
Page 99 OPERATION 16. Quick coupler connections: Remove pin (A). Open coupler lock assembly (B). 17. Quick coupler connections: Disconnect coupler (C) from steel line coupler (D). Disconnect coupler (E) from steel line coupler (F). 18. Quick coupler connections: Proceed to Step 21, page Figure 3.112: Header Pressure and Return Connections...
Page 100 OPERATION 22. Remove header hose support (A) from hole (B) in windrower frame near left cab-forward leg. Figure 3.115: Hose Support Installed 23. Rest hydraulic hose bundle (A) on header for storage as shown. Figure 3.116: Hose Bundle Storage Position 215403 Revision A...
Page 101: Removing The Forming Shield
OPERATION 24. Disconnect M205 SP Windrower adapter harness (A) from header connector (C). Install electrical caps on connectors. 25. Store harness (A) on center-link (B) using straps (not shown). 26. Back the windrower slowly away from the header. Figure 3.117: M205 SP Windrower Adapter Harness 27.
Page 102 OPERATION 1. Shut down the engine, and remove the key from the ignition. 2. Remove and retain hairpin (A) and washer (B) from straight pin (C). 3. Pull rubber strap (D) away from straight pin (C). 4. Lower rear end of forming shield. Figure 3.119: Rubber Strap Securing Forming Shield onto Windrower Leg 5.
Page 103 OPERATION 7. Remove lynch pin (A) and clevis pin (B) securing forming shield (C) to bolt and spacer (D). Repeat at the opposite side. Figure 3.121: Forming Shield Secured to Front of Windrower Legs 8. Dismount forming shield (A) from bolts and spacers (B). Repeat at the opposite side.
Page 104: Driveshields
OPERATION 3.7 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. 3.7.1 Opening Driveshields The driveshields provide access to drive components for maintenance and servicing. WARNING To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured.
Page 105 OPERATION 2. Lift outboard driveshield panel (A) in an outboard direction toward the end of the header. Figure 3.125: Opening Driveshield – Outboard Panel 3. Pull handle (A) and lift inboard driveshield panel (B) toward the middle of the header. 4.
Page 106: Closing Driveshields
OPERATION 3.7.2 Closing Driveshields Closing the driveshields before operating the machine will protect drive components from damage. WARNING 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.
Page 107 OPERATION 3. Move outboard-half of driveshield (A) back to closed position. Figure 3.129: Left Driveshield 215403 Revision A...
Page 108: Cutterbar Curtain
OPERATION 3.8 Cutterbar Curtain The curtain is installed at the front of the header. It minimizes the risk of thrown objects being ejected at high speed from the cutterbar area. WARNING To reduce the risk of personal injury and machine damage, do NOT operate the machine without curtain installed and in good condition.
Page 109: Closing Cutterbar Curtain
OPERATION 2. Secure curtain in place at locations (A) using three clips provided. Figure 3.132: Cutterbar Curtain — View from Below NOTE: Cutterbar curtain (A) is held in place between the tines of retaining clips (B). Figure 3.133: Cutterbar Curtain and Retaining Clips 3.8.2 Closing Cutterbar Curtain The curtain is installed at the front of the header.
Page 110 OPERATION 1. Pull curtain outward from retaining clips and lower curtain. Figure 3.134: Cutterbar Curtain 215403 Revision A...
Page 111: Header Settings
OPERATION 3.9 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 112: 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 3.135: 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 the engine, remove the key,...
Page 113: Adjusting Gauge Roller Height
OPERATION 6. 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. 7. Repeat the procedure on the second skid shoe. Ensure both skid shoes are set to the same position.
Page 114 OPERATION 6. Swing the gauge roller forward and align the holes in the gauge roller plate to the bottom hole of the mounting plates. 7. 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 115 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 hair pin (D) and scraper plate (C). Figure 3.142: Gauge Roller Secured in Intermediate Working Position 3.
Page 116: Cutterbar Angle
OPERATION 3.9.2 Cutterbar Angle Cutterbar angle (sometimes called header angle) is the angle at which the cutterbar approaches the crop and the ground. It is one of the settings that affects cutting height and quality. Cutterbar angle (A) adjustment ranges from 0 to 8° below horizontal.
Page 117: 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 3.145: Ground Speed for R216 Rotary Disc Headers A - Acres/Hour...
Page 118: Conditioner
OPERATION 3.10 Conditioner Rolls condition the crop by crimping and crushing the stem in several places, which allows the release of moisture resulting in faster drying times. There are two roll conditioner options—steel conditioner rolls and polyurethane rolls. 3.10.1 Roll Gap The roll gap controls the degree to which crop is conditioned as it passes through the rolls.
Page 119: Adjusting Roll Gap - Polyurethane Rolls
OPERATION Adjusting Roll Gap – Polyurethane Rolls To adjust the roll gap, follow the procedure below: 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. 1.
Page 120: Roll Tension
OPERATION 3.10.2 Roll Tension Roll tension (the pressure holding the conditioner rolls together) is factory-set to maximum and should rarely require adjustment. Heavy crops or tough forage can cause the rolls to separate; therefore, maximum roll tension is required to ensure that materials are sufficiently crimped.
Page 121: Roll Timing
OPERATION 3.10.3 Roll Timing For proper conditioning, the rolls must be properly timed with the bar on one roll centered between two bars on the other roll. The factory setting should be suitable for most crop conditions. IMPORTANT: Roll timing is critical when the roll gap is decreased because conditioning is affected and the bars may contact each other.
Page 122 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 3.152: Conditioner Drive 5. Secure bottom roll (A). 6. Manually rotate upper roll (B) counterclockwise as shown until it stops rotating.
Page 123 OPERATION 8. Manually rotate upper roll (A) clockwise as shown until it stops rotating. 9. Make a second mark (B) on yoke flange (C), and align it with the mark previously made on gearbox flange (D). Figure 3.154: Conditioner Drive 10.
Page 124 OPERATION 12. Remove one of four bolts (A) from yoke plate (B). Ensure the bolt’s threads are clean and free of lubricant. NOTE: Only three of the four bolts are shown in the illustration. ® 13. Apply medium-strength threadlocker (Loctite 242 or equivalent) to the removed bolt.
Page 125: Forming Shields - Roll Conditioner
OPERATION 3.10.4 Forming Shields – Roll Conditioner The forming shield controls the width and placement of the windrow. WARNING Keep everyone at a safe distance from your operation. Ensure bystanders are never in line with the front or rear of the machine.
Page 126: Positioning Rear Baffle
The rear baffle is used in conjunction with the forming shields to affect the windrow width. NOTE: An optional Remote Baffle Control kit (MD #B6664) is available for R216 Rotary Disc Headers configured for M1240 Windrowers ONLY. The Remote Baffle Control kit is incompatible with M205 Windowers. For more information, refer to Remote Baffle Control Kit –...
Page 127 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: DANGER 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 128 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 3.161: Left Deflector Fins in Storage Position 215403 Revision A...
Page 129: Grass Seed Version Operation
The one-crop stream is the recommended cutterbar configuration for grass seed headers. As the operator, you should not have to modify the crop stream configuration. For more information, refer to Changing R216 Rotary Disc Header Cutterbar Crop Stream Configuration for Grass Seed Option, page 211.
Page 130: Activating The Grass Seed Option
OPERATION 3.11.1 Activating the Grass Seed Option The grass seed (GSS) option must be activated in the windrower’s control system the first time it is attached to a windrower. To activate the grass seed option with the Harvest Performance Tracker (HPT), follow these steps: NOTE: If necessary, refer to the windrower operator’s manual to review navigating the HPT display.
Page 131 OPERATION 6. Select the correct header size and type from the HEADER list. Not available at time of printing Figure 3.166: Header Setup Screen 7. Select ATTACHMENTS from the HEADER SETUP screen. Not available at time of printing Figure 3.167: Header Setup Screen 8.
Page 132: Operating In The Field
OPERATION 9. Once the grass seed is activated, Run Screen 2 on the HPT will display speed (A) and pressure (B) of the grass seed drums. 1034170 Figure 3.169: Run Screen 2 – Grass Seed Active 3.11.2 Operating in the Field Operate the anti-shatter shield and set the drum position and speed to lay the desired windrow.
Page 133 OPERATION 4. FULLY extend (A) or retract (C) the anti-shatter shield according to the type of crop as follows: • Fully extend (A) the shield by pressing F5 (B) on the operator console until the baffle position [appears as a pop-up on the Harvest Performance Tracker (HPT)] is “10”.
Page 134 OPERATION 5. Adjust the drum speed and height as desired using the ground speed lever (GSL) or the operator’s console: • To widen the windrow, press REEL UP (A) switch the on the GSL, or button (A) on the operator’s console. •...
Page 135: Preparing For Transport
OPERATION 3.11.3 Preparing for Transport Retract the anti-shatter shield and extend the hazard/brake lights. DANGER 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. 1.
Page 136: Cutterbar Deflectors
OPERATION 3.12 Cutterbar Deflectors A Tall Crop kit (MD #B6967) 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 137: Haying Tips
OPERATION 3.13 Haying Tips 3.13.1 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 138: Windrow Characteristics
OPERATION 3.13.4 Windrow Characteristics Producing windrows with the recommended characteristics will achieve the best results. For instructions, refer to 3 Operation, page 25 for 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 Permits an even flow of material into the baler, chopper, etc.
Page 139: Transporting The Header
OPERATION 3.14 Transporting the Header For information on transporting the header when attached to the windrower, refer to your windrower operator’s manual. 215403 Revision A...
Page 141: Chapter 4: Maintenance And Servicing
Chapter 4: Maintenance and Servicing Proper maintenance and servicing of your machine will ensure great performance and excellent crop yield. 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 124)
Page 142 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. For instructions, refer to 4.13.1 Checking Hydraulic Hoses and Lines, page 235.
Page 143: Preparing Machine For Servicing
MAINTENANCE AND SERVICING 4.2 Preparing Machine for Servicing Prepare the machine to service it safely. 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 144: 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 145 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 146: Maintenance Requirements
MAINTENANCE AND SERVICING 4.4 Maintenance Requirements Regular maintenance is the best insurance against early wear and untimely breakdowns. Following the maintenance schedule will increase your machine’s life. Periodic maintenance requirements are organized according to service intervals. IMPORTANT: Recommended intervals are for average conditions. Service the machine more often if operating under adverse conditions (severe dust, extra heavy loads, etc.).
Page 147 MAINTENANCE AND SERVICING Every 25 Hours Lubricate idler pivot. Refer to Lubrication, page 128. Standard headers: Lubricate upper and lower driveline universal joints. Refer to 4.5 Lubrication, page 128. Standard headers: Lubricate roller conditioner and feed roller bearings. Refer to 4.5 Lubrication, page 128.
Page 148: Break-In Inspections
MAINTENANCE AND SERVICING 4.4.2 Break-In Inspections From the factory the header is ready for normal operation. However, there are several things to check and change or adjust during the first 100 hours of use. Table 4.1 Break-In Inspection Schedule Inspection Item Refer to Interval...
Page 149: End-Of-Season Servicing
MAINTENANCE AND SERVICING 4.4.4 End-of-Season Servicing DANGER 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 Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable.
Page 150: 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 121. 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 151: Lubrication Locations - Standard Headers
MAINTENANCE AND SERVICING 4.5.2 Lubrication Locations – Standard Headers Standard headers are equipped with conditioners. 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...
Page 152 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 153: Lubrication Locations - Grass Seed (Option)
MAINTENANCE AND SERVICING 4.5.3 Lubrication Locations – Grass Seed (Option) The grass seed (GSS) configuration is an option (MD #C2081). Lubricate idler/tensioner locations (A) and (D) every 25 hours. Lubricate grass seed drum locations (B), (C), (E), and (F) every 50 hours. Use high-temperature, extreme-pressure performance grease with 1% max molybdenum disulphide (NLGI grade 2) lithium base for all locations.
Page 154: Lubrication Locations - Gauge Rollers (Option)
MAINTENANCE AND SERVICING 4.5.4 Lubrication Locations – Gauge Rollers (Option) Gauge rollers (MD #B6855) are optional. Grease two grease fittings (A) on both gauge rollers every 25 hours using high-temperature, extreme-pressure performance grease with 1% max molybdenum disulphide (NLGI grade 2) lithium base. Figure 4.12: Gauge Rollers Lubrication Locations 215403 Revision A...
Page 155: Cutterbar System
124. IMPORTANT: Warm cold lubricant by idling the machine for 10 minutes prior to checking level. Figure 4.13: R216 SP Cutterbar 4.6.1 Lubricating Cutterbar Checking and Adding Lubricant in Cutterbar DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 156 MAINTENANCE AND SERVICING 5. Use a spirit (bubble) level (A) to ensure the cutterbar is level in both directions. Adjust the header accordingly. Figure 4.15: 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 157 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 158: Draining The Cutterbar
MAINTENANCE AND SERVICING 24. Close cutterbar curtain (A). For instructions, refer to 3.8.2 Closing Cutterbar Curtain, page Figure 4.19: Cutterbar Curtain Draining the Cutterbar DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 159: Filling Cutterbar With Lubricant
MAINTENANCE AND SERVICING NOTE: Do NOT flush the cutterbar. 8. Fill the cutterbar with lubricant before operating the disc header. For instructions, refer to Filling Cutterbar with Lubricant, page 137. IMPORTANT: Dispose of used lubricant responsibly. Filling Cutterbar with Lubricant Fill the cutterbar with lubricant after completely draining the cutterbar of oil.
Page 160: Cutterbar Discs
MAINTENANCE AND SERVICING 7. Install access plug (A). Torque to 30 Nm (22 lbf·ft). 8. Start the engine, and raise the header fully. 9. Shut down the engine, and remove the key from the ignition. Engage the windrower lift cylinder safety props. For instructions, refer to the procedure according to the type of windrower: •...
Page 161: Inspecting Cutterbar Discs
MAINTENANCE AND SERVICING IMPORTANT: If holes appear in a cutterbar disc, replace the disc immediately. Do NOT attempt to repair the cutterbar discs. Always use factory replacement parts. Inspecting Cutterbar Discs DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine.
Page 162: Removing Cutterbar Discs
MAINTENANCE AND SERVICING 7. Check that cutterbar disc bolts (C) are securely attached to the spindles. Tighten as required. 8. Inspect the cutterbar disc for severe deformation. If the disc is deformed, dimension (A) must NOT exceed 48 mm (1 7/8 in.). Replace as required. NOTE: Dimension (A) shows space between the cutterbar and the edge of the cutterbar disc.
Page 163 MAINTENANCE AND SERVICING • M205 SP Windrowers: 3.2.2 Engaging and Disengaging Header Safety Props – M205 SP Windrower, page 27 4. Open cutterbar curtain (A). For instructions, refer to 3.8.1 Opening Cutterbar Curtain, page Figure 4.26: Cutterbar Curtain 5. Place a pin (or equivalent) in the front hole of rock guard (B) to prevent disc rotation while loosening bolts.
Page 164: Installing Cutterbar Discs
MAINTENANCE AND SERVICING Installing Cutterbar Discs DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 165: Cutterbar Spindles
MAINTENANCE AND SERVICING 8. Close the cutterbar curtain. For instructions, refer to 3.8.2 Closing Cutterbar Curtain, page Figure 4.30: Cutterbar Curtain 9. To install the outboard cutterbar discs, refer to Installing Left Driven Drum and Driveline, page 184 Installing Right Driven Drum and Driveline, page 190.
Page 166 MAINTENANCE AND SERVICING IMPORTANT: • Spindles that rotate clockwise have right-leading threading and are identified by a smooth top on the spindle gear shaft (A). • Spindles that rotate counterclockwise have left-leading threading and are identified by machined grooves on the spindle gear shaft (B) and nut (C).
Page 167: 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, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 168 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 4.35: 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 169: Installing Cutterbar Spindles
MAINTENANCE AND SERVICING 12. Remove spindle (A) from the cutterbar. Figure 4.38: Left Spindle Installing Cutterbar Spindles Figure 4.39: 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 170 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 171 MAINTENANCE AND SERVICING 1. Park on a flat, level surface. 2. Place the header in a position where you can access the component that will be serviced. 3. Shut down the engine, and remove the key from the ignition. 4. If the header is fully raised, engage safety props. If the header is off the ground and not fully raised, place blocks under the header.
Page 172 MAINTENANCE AND SERVICING 8. 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 173 MAINTENANCE AND SERVICING 12. 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 4.46: Tightening Pattern 13.
Page 174: Disc Blades
MAINTENANCE AND SERVICING 18. Close cutterbar curtain (A). For instructions, refer to 3.8.2 Closing Cutterbar Curtain, page Figure 4.49: 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 175: Inspecting Disc Blades
MAINTENANCE AND SERVICING Inspecting Disc Blades DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 176: Inspecting Disc Blade Hardware
MAINTENANCE AND SERVICING IMPORTANT: The disc blades have cutting edges on both sides so the blades can be turned over and reused. The twist in each blade determines the cutting direction. If you are unsure which direction the spindles rotate, refer to: 4.6.9 Reconfiguring Cutterbar Crop Stream, page 207 instructions.
Page 177 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 178: 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 4.55: Disc Blade Nut Removing Disc Blades DANGER...
Page 179 MAINTENANCE AND SERVICING 5. Rotate disc (A) so blade (B) faces forward and lines up with hole (C) in rock guard. Figure 4.57: 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 180: Installing Disc Blades
MAINTENANCE AND SERVICING Installing Disc Blades DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 181: Accelerators
Accelerators are mounted on each outboard disc and are designed to quickly move cut material off the disc and into the conditioner. R216 Rotary Disc Headers have two pairs of accelerators (A) on the two pairs of outboard discs. Periodically inspect accelerators for damage and loose or missing fasteners, and replace as necessary.
Page 182: Removing Accelerators
MAINTENANCE AND SERVICING To inspect accelerators, follow these steps: 1. Place the header in a position where you can access the component that will be serviced. 2. Shut down the engine, and remove the key from the ignition. 3. If the header is fully raised, engage safety props. If the header is off the ground and not fully raised, place blocks under the header.
Page 183 MAINTENANCE AND SERVICING WARNING Disc blades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working with blades. IMPORTANT: Always replace accelerators in pairs to ensure proper disc balance. To remove accelerators, follow these steps: 1.
Page 184 MAINTENANCE AND SERVICING 8. Remove lock nut (A), accelerator (B), blade holder (C), and hex-socket bolt (D). 9. Repeat Step 5, page 161 to Step 8, page 162 for the second accelerator. 10. Remove the pin. Figure 4.66: Accelerator Removal 215403 Revision A...
Page 185: Installing Accelerators
MAINTENANCE AND SERVICING Installing Accelerators A new pair of accelerators should be installed on a cutterbar disc whenever the old ones are damaged or so worn that they can no longer effectively move crop off the disc and into the conditioner. To install accelerators, follow these steps: DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and...
Page 186 MAINTENANCE AND SERVICING 7. Install new nut (A), flange bolt (B), and disc blade (C) onto the disc. Figure 4.68: Accelerator Installation 8. Torque interior nut (A) to 58 Nm (43 lbf·ft). 9. Torque exterior nut (B) (closest to the blade) to 125 Nm (92 lbf·ft).
Page 187: Rock Guards
MAINTENANCE AND SERVICING 4.6.6 Rock Guards The machine is equipped with rock guards at each cutting disc location. Rock guards prevent the cutterbar from digging into the ground and protect the disc from coming in contact with stones and other debris. Periodically inspect rock guards for damage and replace as necessary.
Page 188: Installing Rock Guards
MAINTENANCE AND SERVICING 3. If the header is fully raised, engage safety props. If the header is off the ground and not fully raised, place blocks under the header. Never work on or beneath an unsupported header. For instructions on engaging the safety props, refer to the procedure according to the type of windrower: •...
Page 189: Drums
MAINTENANCE AND SERVICING • M205 SP Windrowers: 3.2.2 Engaging and Disengaging Header Safety Props – M205 SP Windrower, page 27 4. 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 4.74: Rock Guards 5.
Page 190: 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, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 191 MAINTENANCE AND SERVICING 5. Inspect drums (A), (B), and (C) for damage and wear, and replace if the drums are worn at the center to 50% or more of their original thickness. Do NOT repair drums. 6. Examine the drums for large dents. Replace dented drums to prevent an imbalance in the cutterbar.
Page 192 MAINTENANCE AND SERVICING 10. Close cutterbar curtain (A). For instructions, refer to 3.8.2 Closing Cutterbar Curtain, page Figure 4.81: Cutterbar Curtain 215403 Revision A...
Page 193: 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, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 194 MAINTENANCE AND SERVICING 5. Loosen two M10 hex flange head bolts (A). Remove driveline shield (B). Figure 4.83: Driveline Shield 6. Remove four M12 hex flange head bolts (A) securing suspended drum (B) to shaft (C), and remove suspended drum (B). Figure 4.84: Suspended Drum 7.
Page 195: 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, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 196: Replacing Left Suspended Drum Drive Belt
MAINTENANCE AND SERVICING 7. Position driveline shield (B) as shown. Use two M10 hex flange head bolts (A) to secure driveline shield (B) in place. 8. Repeat Step 5, page 173 to Step 7, page 174 to install the opposite suspended drum. Figure 4.87: Driveline Shield 9.
Page 197 MAINTENANCE AND SERVICING 4. Open cutterbar curtain (A). For instructions, refer to 3.8.1 Opening Cutterbar Curtain, page Figure 4.89: Cutterbar Curtain 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 4.90: Left Driveline 6.
Page 198 MAINTENANCE AND SERVICING 7. Loosen two bolts (A) at front. 8. Remove two bolts (B) and shield plate (C). 9. Remove four bolts (D) securing spindle spline to the gearbox hub. Figure 4.92: Gear Hub and Shield Plate NOTE: Removing the four bolts dismounts spindle spline (A) from the gearbox hub.
Page 199 MAINTENANCE AND SERVICING Installing left suspended drive belt 13. Slide belt (A) through opening (B). 14. Using a ratchet, rotate tensioner (E) clockwise. 15. Position belt (A) on gearbox hub (D) and pulley (C) as shown. 16. Remove the ratchet to release tensioner (E). Figure 4.95: Left Drum Belts 17.
Page 200 MAINTENANCE AND SERVICING 20. Close left driveshield (A). For instructions, refer to 3.7.2 Closing Driveshields, page Figure 4.98: Left Driveshield 21. Install driveline shield (B) using two bolts (A). Figure 4.99: Left Driveline 22. Close cutterbar curtain (A). For instructions, refer to 3.8.2 Closing Cutterbar Curtain, page 23.
Page 201: Replacing Right Suspended Drum Drive Belt
MAINTENANCE AND SERVICING Replacing Right Suspended Drum Drive Belt DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 202: Removing Left Driven Drum And Driveline
MAINTENANCE AND SERVICING Installing right suspended drive belt 7. Using a ratchet, rotate tensioner (A) counterclockwise to move it away from the pulleys. 8. Slide belt (B) on pulleys as shown. 9. Remove ratchet from tensioner to release tensioner. Figure 4.103: Right Drum Belts 10.
Page 203 MAINTENANCE AND SERVICING • M205 SP Windrowers: 3.2.2 Engaging and Disengaging Header Safety Props – M205 SP Windrower, page 27 4. Open cutterbar curtain (A). For instructions, refer to 3.8.1 Opening Cutterbar Curtain, page Figure 4.105: Cutterbar Curtain 5. Remove four M10 hex flange head bolts (A) and loosen two M10 hex flange head bolts (B).
Page 204 MAINTENANCE AND SERVICING 7. Remove two M10 hex flange head bolts (A) and remove driveline shield (B). Figure 4.108: Driveline Shield 8. Remove four M12 hex flange head bolts (A) securing driveline assembly (B) to hub drive (C). Figure 4.109: Driveline 9.
Page 205 MAINTENANCE AND SERVICING 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. 11. Remove drum disc assembly (B). 1028507 Figure 4.111: Driven Drum – View from Above 215403 Revision A...
Page 206: 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, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 207 MAINTENANCE AND SERVICING 8. Insert driveline (B) at an angle and guide it past hub drive (C) and drum (D). 9. Insert splined spindle end (A) into the splined bore of driveline (B). Figure 4.114: Drum and Tube Shield – Cutaway View ®...
Page 208 MAINTENANCE AND SERVICING 12. 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 209: 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, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 210 MAINTENANCE AND SERVICING 6. Remove eight M8 hex flange head bolts (A) and two drum shields (B). Figure 4.122: Driveline Shields 7. Remove two M10 hex flange head bolts (A) and remove driveline shield (B). Figure 4.123: Driveline Shield 8. Remove four M10 hex flange head bolts (A) securing driveline assembly (B) to hub drive (C).
Page 211 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 4.125: 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 212: 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, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 213 MAINTENANCE AND SERVICING 8. Insert driveline (B) at an angle and guide it past hub drive (C) and drum (D). 9. Insert splined spindle end (A) into the splined bore of driveline (B). 1028521 Figure 4.129: Drum and Tube Shield – Cutaway View ®...
Page 214 MAINTENANCE AND SERVICING 12. 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 215: Lubricating Vertical Drivelines
MAINTENANCE AND SERVICING Lubricating Vertical Drivelines DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 216 MAINTENANCE AND SERVICING 6. Remove eight M8 hex flange head bolts (A) and two drum shields (B). Figure 4.137: Driveline Shields – Left Drum 7. Remove two M10 hex flange head bolts (A) and remove driveline shield (B). Figure 4.138: Driveline Shield – Left Drum 8.
Page 217 MAINTENANCE AND SERVICING 9. Remove eight M8 hex flange head bolts (A) and two drum shields (B). Figure 4.140: Driveline Shields – Right Drum 10. Remove two M10 hex flange head bolts (A) and remove driveline shield (B). Figure 4.141: Driveline Shield – Right Drum 215403 Revision A...
Page 218 MAINTENANCE AND SERVICING Figure 4.142: Vertical Drivelines Lubrication Locations 11. Lubricate the left and right vertical drivelines every 250 hours at the following locations: • Two grease fittings (A) on right driveline U-joints • One grease fitting (B) on right driveline shaft •...
Page 219 MAINTENANCE AND SERVICING 12. On the right of the header, position driveline shield (B) as shown. Apply a bead of medium-strength threadlocker ® (Loctite 243 or equivalent) around the threads of two M10 hex flange head bolts (A). Use M10 hex flange head bolts (A) to secure driveline shield (B) in place.
Page 220 MAINTENANCE AND SERVICING 16. On the left of the header, position driveline shield (B) as shown. Apply a bead of medium-strength threadlocker ® (Loctite 243 or equivalent) around the threads of two M10 hex flange head bolts (A). Use bolts (A) to secure driveline shield (B) in place.
Page 221: 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 222: Removing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING Removing Cutterbar Spindle Shear Pin DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 223 MAINTENANCE AND SERVICING 7. Remove spacer plate (A) and retaining ring (B). Figure 4.153: Cutterbar Spindle 8. Remove the M12 bolt and remove safecut spindle-nut wrench (A) from its storage location. Figure 4.154: Safecut Spindle-Nut Wrench 215403 Revision A...
Page 224 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 225 MAINTENANCE AND SERVICING 13. Remove damaged shear pins (A) using pin punch (B). Figure 4.158: Removing Shear Pin 14. Remove and clean Belleville washer (A). Figure 4.159: Belleville Washer 215403 Revision A...
Page 226: Installing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING Installing Cutterbar Spindle Shear Pin DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 227 MAINTENANCE AND SERVICING 8. 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 4.162: Cutterbar Spindle 9.
Page 228 MAINTENANCE AND SERVICING 12. Install two M10 bolts (A) and washers. Torque hardware to 55 Nm (40 lbf·ft). Figure 4.165: Cutterbar Spindle 13. Install retaining ring (A). Figure 4.166: Cutterbar Spindle 14. Depending on the type of disc with the new shear pin, refer to the applicable disc installation procedure: •...
Page 229: Reconfiguring Cutterbar Crop Stream
• One crop steam (C) is intended for the grass seed (GSS) version of the header. During the installation of the grass seed kit, the cutterbar is reconfigured to the one crop stream, and the operator should not have to change it. For more information, refer to Changing R216 Rotary Disc Header Cutterbar Crop Stream Configuration for Grass Seed Option, page 211.
Page 230: Changing R216 Rotary Disc Header Cutterbar Crop Stream Configuration
(GSS) option, it is recommended that the cutterbar use the one-crop stream configuration specifically intended for grass seed. For more information, refer to Changing R216 Rotary Disc Header Cutterbar Crop Stream Configuration for Grass Seed Option, page 211.
Page 231 Removing Cutterbar Spindles, page 145 Installing Cutterbar Spindles, page 147. To change R216 Rotary Disc Header (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 four streams to two streams is a recommended setting when cutting light alfalfa and using the double windrower attachment (DWA).
Page 232 MAINTENANCE AND SERVICING Figure 4.173: 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 147.
Page 233: Changing R216 Rotary Disc Header Cutterbar Crop Stream Configuration For Grass Seed Option
A - Four Crop Stream B - One Crop Stream To change R216 Rotary Disc Header (10 disc) spindle rotation from four crop streams (A) to one crop stream (B): 1. Swap disc/spindle (3) with disc/spindle (8). For instructions, refer to...
Page 234: Conditioner Roll Timing Gearbox
MAINTENANCE AND SERVICING 4.7 Conditioner Roll Timing Gearbox The 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 235 MAINTENANCE AND SERVICING 5. Remove right driveshield (A). For instructions, refer to 4.11.1 Removing Driveshields, page 228. Figure 4.177: 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 236 MAINTENANCE AND SERVICING Changing conditioner roll timing gearbox oil: DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop the engine, remove the key, and engage the windrower lift cylinder safety props before going under the machine for any reason. 8.
Page 237: 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 238 MAINTENANCE AND SERVICING 6. Locate gearbox (A) on the left side of the header. Figure 4.181: 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 239: 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). 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 240: 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 241: Removing Cutterbar Curtain
MAINTENANCE AND SERVICING 4.9.2 Removing Cutterbar Curtain DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 242: Installing Cutterbar Curtain
MAINTENANCE AND SERVICING 4.9.3 Installing Cutterbar Curtain DANGER To avoid bodily injury or death from unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat or making adjustments to the machine. Never work on or beneath an unsupported header.
Page 243: 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 Components Inspect conditioner roll bearings, feed roll bearings, and driveline U-joints for signs of wear or damage.
Page 244 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 4.192: Feed Roll Right Bearing – View from Below 6. Inspect conditioner roll left bearings (A) for signs of wear or damage.
Page 245: 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 4.195: 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 246 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 4.197: 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 247 MAINTENANCE AND SERVICING Removing Conditioner Drive Belt 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. 1. Lower the header fully. 2.
Page 248 MAINTENANCE AND SERVICING Installing Conditioner Drive Belt 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. 1. Lower the header fully. 2.
Page 249 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 250: 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 WARNING 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 251: Installing Driveshields
MAINTENANCE AND SERVICING 4. Pull outboard side (A) and inboard side (B) of driveshield away from the disc header to remove. 1028564 Figure 4.207: 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 252 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 253: 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 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 254 MAINTENANCE AND SERVICING 2. Detach harness (A) on light (B) from main header harness (C). 3. Loosen nut (D), and then remove light (B) from light bracket (E). Discard the light. 4. Loosen nut (D) on new light fixture (B), then insert the light into light bracket (E).
Page 255: 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. 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 256 MAINTENANCE AND SERVICING 10. Adjust nuts (A) as required to achieve a 2–3 mm (1/16–1/8 in.) gap (B) between sensor (C) and the high end of pulley (D) (M1240 Windrowers) or encoder (D) (M205 SP Windrowers). Ensure the sensor face and pulley face are parallel.
Page 257: 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 259: Chapter 5: Options And Attachments
Chapter 5: Options and Attachments 5.1 Tall Crop Kit (Cutterbar Deflectors and Tall Crop Feed Plates) – MD #B6967 The tall crop kit supplies cutterbar deflectors and tall crop feed plates to improve crop feeding from the cutterbar into the conditioner in thick stemmed crops such as sorghum.
Page 260: Double Windrow Attachment
OPTIONS AND ATTACHMENTS 5.2 Double Windrow Attachment 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. M1240 Windrowers MD #C2070 consists of: •...
Page 261: Grass Seed Configuration - Md #C2081
5.3 Grass Seed Configuration – MD #C2081 The optional grass seed (GSS) version of the R216 Rotary Disc Header is intended for cutting delicate grass seed crops, and laying them in a windrow prior to a combine picking it up. At the time of printing, it is only available for (and required for) North American headers that are not equipped with conditioners.
Page 262: Remote Baffle Control Kit - Md #B6664
OPTIONS AND ATTACHMENTS 5.4 Remote Baffle Control Kit – MD #B6664 The Remote Baffle Control kit (MD #B6664), allows the operator to electronically adjust the disc header baffle from inside the windrower. The Remote Baffle Control kit is incompatible with M205 SP Windrowers.
Page 263: 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 5.6: Adjustable Gauge Roller 215403 Revision A...
Page 264: 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 265: 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 266: 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 5.9: Adjustable Skid Shoe –...
Page 267: 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 5.10: Tall Crop Divider –...
Page 269: 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. 3.9.1 Cutting Height, page 89 pick up downed crop Header float too light, causing Adjust to heavier float setting.
Page 270 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 96 Roll gap too small in thick-stemmed •...
Page 271 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, page 103 Crop is bunched in windrow Adjust forming shields/baffle.
Page 272: Mechanical Problems
TROUBLESHOOTING 6.2 Mechanical Problems Problem Solution Refer to Symptom: Excessive noise • Removing Disc Blades, page 156 Bent disc blade Replace blade. • Installing Disc Blades, page 158 • Checking Roll Timing, page 99 Check roll timing and adjust if Conditioner roll timing off necessary.
Page 273 When all moving parts are completely Components, page 221 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 274: Grass Seed Problems
TROUBLESHOOTING 6.3 Grass Seed Problems Grass seed problems are specific to headers configured with the grass seed (GSS) option (MD #C2081). Problem Solution Refer to Symptom: Rear drum not turning • Check for debris buildup around drums and remove as necessary. This will most likely occur on the front set of drums.
Page 275: 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 276 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) Max. Max. Min. Min. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 18.8 20.8 *167 *185 Figure 7.2: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...
Page 277: 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) Max. Max. Min. Min. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 10.7 11.8 *105 8-1.25 Figure 7.4: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...
Page 278: 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 279 REFERENCE Table 7.6 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable (continued) Torque Value SAE Dash Size Thread Size (in.) lbf·ft (*lbf·in) 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 88–97 1 3/8–12 153–168 113–124...
Page 280: 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 281: 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 282: 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 – – Note 150–165 111–122 1 7/16 205–226 151–167 1 11/16 1 1/4 1–2 315–347 232–256 1 1/2 510–561 376–414 2 1/2...
Page 283 REFERENCE Table 7.9 Hydraulic Fitting Pipe Thread (continued) Tapered Pipe Thread Size Recommended TFFT Recommended FFFT 1.5–2.5 9–15 1 1/2–11 1/2 1.5–2.5 9–15 2–11 1/2 215403 Revision A...
Page 284: Conversion Chart
REFERENCE 7.2 Conversion Chart Table 7.10 Conversion Chart Quantity Factor SI Units (Metric) US Customary Units (Standard) Unit Name Abbreviation Unit Name Abbreviation acre acres Area hectare x 2.4710 = Flow liters per minute L/min x 0.2642 = US gallons per minute Force Newton x 0.2248 =...
Page 285: Index
Index closing .............. 87 inspecting ............218 accelerators............159 installing............220 inspecting ............159 opening............. 86 installing............163 removing ............219 removing ............160 cutterbar angles adjustable skid shoes kit ........244 adjusting angle ........... 94 cutterbar discs ............. 138 definition............
Page 286 ............. 117 hex keys definition............22 FFFT hydraulics definition............22 connecting R216 Rotary Disc Headers – M1 Series finger tight definition............22 Windrowers ..........36 R216 Rotary Disc Headers – M205 SP fluids, See lubricants forming shields Windrowers ..........67 attaching –...
Page 287 – gauge rollers........132 R2 SP Series locations – grass seed ........131 definition............22 R216 Rotary Disc Headers attaching header – M1 Series ........ 31 attaching header – M205 SP Windrowers self-aligning hydraulic center-link......54 maintenance and servicing without self-aligning hydraulic center-link ....
Page 288 INDEX roll conditioners ..........96, 221 torque specifications ......... 253 deflectors ............103 spindle shear pins..........199 forming shields ..........103 installing............204 roll gaps ............96 removing ............200 roll tension............98 spindles roll timing ............99 changing............143 roll gaps..............
Page 289: 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 290 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.

MacDon R216 Operator's Manual

Chapter 1: Safety

Chapter 2: Product Overview

Chapter 3: Operation

Chapter 4: Maintenance and Servicing

Chapter 5: Options and Attachments

Chapter 6: Troubleshooting

Chapter 7: Reference

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Summary of Contents for MacDon R216

Table of Contents