Page 1 R216 Rotary Disc Header Operator’s Manual 215972 Revision A Original Instruction The Harvesting Specialists.
Page 2 © 2022 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 Use this manual as your first source of information about the machine. If you follow the instructions provided in this manual, and use MacDon parts, the rotary disc header will work well for many years. If you require more detailed service information, contact your Dealer.
Page 4 (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 5 Summary of Changes At MacDon, we’re continuously making improvements, and occasionally these improvements affect product documentation. The following list provides an account of major changes from the previous version of this document. Section Summary of Change Internal Use Only Removed “Header Model” field.
Page 6 Section Summary of Change Internal Use Only 3.12.5 Forming Shields – Roll Conditioner, Removed WARNING: Keep everyone at a safe Technical Publications page 137 distance from your operation. Ensure bystanders are never in line with the front or rear of the machine. Stones or other foreign objects can be ejected from either end with force.
Page 7 Section Summary of Change Internal Use Only Configuring Cutterbar Crop Streams – Revised the NOTE to clarify the procedure does Product Management Standard Header, page 260 not apply to grass seed headers. Added the Technical Publications three-crop stream configuration. — Deleted topic titled “Configuring Cutterbar Crop Technical Publications Streams –...
Page 8: 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 9: Serial Number
Serial Number The serial number identifies the header and is required if you request technical assistance. Record the serial number and model year of the header in the spaces provided below. Serial number: Model year: Serial number plate (A) is located on the left side of the header, on the top of the end panel.
Page 11: Table Of Contents
TABLE OF CONTENTS Introduction ..............................i Summary of Changes........................... iii Noise Levels............................... vi Serial Number............................vii Chapter 1: Safety ............................1 1.1 Safety Alert Symbols ..........................1 1.2 Signal Words ............................2 1.3 General Safety ............................3 1.4 Maintenance Safety ..........................5 1.5 Hydraulic Safety .............................6 1.6 Welding Precaution ..........................7 1.7 Safety Signs ............................8 1.7.1 Installing Safety Decals........................8...
Page 12 TABLE OF CONTENTS 3.5.2 Attaching R2 Series Rotary Disc Header to M205 SP Windrower – Hydraulic Center-Link with Optional Self-Alignment..........................67 3.5.3 Attaching R2 Series Rotary Disc Header to M205 SP Windrower – Hydraulic Center-Link without Optional Self-Alignment ........................ 74 3.5.4 Connecting R2 Series Rotary Disc Header Hydraulics and Electrical to an M205 SP Windrower ....
Page 13 TABLE OF CONTENTS 3.15 Grass Seed Version Operation ......................151 3.15.1 Activating Grass Seed Option...................... 152 3.15.2 Operating with Grass Seed Option....................154 3.15.3 Preparing Header with Grass Seed Option for Transport ..............157 3.15.4 Performance Improvement Tips for Grass Seed Headers ..............158 3.16 Haying Tips ............................
Page 14 TABLE OF CONTENTS 4.6.5 Accelerators..........................207 Inspecting Accelerators......................207 Removing Accelerators ......................209 Installing Accelerators ....................... 211 4.6.6 Rock Guards..........................213 Inspecting Rock Guards......................213 Rotating Rock Guards ........................ 214 Removing Rock Guards ......................215 Installing Rock Guards ....................... 216 4.6.7 Drums............................
Page 15 TABLE OF CONTENTS Chapter 5: Options and Attachments ....................291 5.1 Tall Crop Kit (Cutterbar Deflectors and Tall Crop Feed Plates) – MD #B6967, Standard Headers Only....291 5.2 Double Windrow Attachment ....................... 292 5.3 Grass Seed Configuration – MD #C2081....................293 5.4 Remote Baffle Control Kit –...
Page 17: Chapter 1: Safety
Chapter 1: Safety Understanding and consistently following these safety procedures will help to ensure the safety of those operating the machine and of bystanders. 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: •...
Page 18: 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 19: 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 20 SAFETY • Wear close-fitting clothing and cover long hair. NEVER wear dangling items such as hoodies, scarves or bracelets. • Keep all shields in place. NEVER alter or remove safety equipment. Ensure that the driveline guards can rotate independently of their shaft, and that they can telescope freely.
Page 21: Maintenance Safety
SAFETY 1.4 Maintenance Safety Protect yourself when maintaining machinery. To ensure your safety while maintaining the machine: • Review the operator’s manual and all safety items before operating or performing maintenance on the machine. • Place all controls in Neutral, stop the engine, set the parking brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, or repairing the machine.
Page 22: Hydraulic Safety
SAFETY 1.5 Hydraulic Safety Protect yourself when assembling, operating, and servicing hydraulic components. • Always place all hydraulic controls in Neutral before leaving the operator’s seat. • Ensure that all the components in the hydraulic system are kept clean and in good condition. •...
Page 23: 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 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 24: Safety Signs
SAFETY 1.7 Safety Signs Safety signs are decals placed on the machine where there is a risk of personal injury, or where the Operator should take extra precautions before operating the controls. They are usually yellow. • Keep safety signs clean and legible at all times. •...
Page 25: Safety Decal Locations - Standard Header
SAFETY 1.8 Safety Decal Locations – Standard Header Refer to the diagram below to locate the safety decals on the standard version of the R2 Series Rotary Disc 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...
Page 26 SAFETY Figure 1.17: Safety Sign Decal Locations – Rear View A - MD #190546 B - MD #325070 C - Reflector D - MD #184372 215972 Revision A...
Page 27: Safety Decal Locations - Grass Seed Header
SAFETY 1.9 Safety Decal Locations – Grass Seed Header Refer to the diagram below to locate the safety decals on the grass seed version of the R2 Series Rotary Disc Header. Figure 1.18: Safety Sign Decal Locations – Top View A - MD #307746 B - MD #325706 Figure 1.19: Safety Sign Decals...
Page 28 SAFETY F F D Figure 1.20: Safety Sign Decal Locations – Rear View A - MD #246959 B - Reflector C - MD #184372 D - MD #325070 215972 Revision A...
Page 29: Understanding Safety Signs
SAFETY 1.10 Understanding Safety Signs Refer to this topic to learn the hazards that each type of safety decal denotes. MD #190546 Slipping hazard WARNING To prevent injury or death: • Do NOT use this area as a step or platform. Figure 1.21: MD #190546 MD #246959 Pinch point hazard...
Page 30 SAFETY MD #307746 Thrown objects hazard WARNING To prevent injury or death from thrown objects: • Stand clear of the header while it is operating. • Stop the machine, and wait for all movement to cease before approaching the indicated area. Blade cutting hazard WARNING To prevent injury from sharp blades:...
Page 31 SAFETY MD #325706 Thrown and sharp object/hydraulic oil pressure hazard WARNING • Crop materials exiting at high speed. • Stop the machine and wait for all movement to cease before approaching the indicated area. • Where applicable, disengage the power take-off, shut off the engine, and remove the key before opening any shields.
Page 33: Chapter 2: Product Overview
2154 kg (4740 lb.) conditioner Weight: base machine with hydraulic motor, grass seed 2298 kg (5055 lb.) module, and shield Standard Header: MacDon M1 Series Windrowers, and M205 and M155E4 SP Windrowers Compatible windrower Grass Seed Header: MacDon M1 Series Windrowers...
Page 34 PRODUCT OVERVIEW Optional Grass seed module and anti-shatter shield Grass seed module adds four drums, for a total of Converging drums eight drums on the header Drum speed range Off, or 235–660 rpm Drives Hydraulic motor Piston type into 90° gearbox Direct drive through 90°...
Page 35: Component Identification - Standard Header
Being able to identify the parts and systems of the standard version of the R2 Series Rotary Disc will make looking up content in its reference manuals much easier. Figure 2.1: R216 Rotary Disc Header – Standard Header A - Front Curtain...
Page 36 PRODUCT OVERVIEW Figure 2.2: R216 Rotary Disc Header – Standard Header A - Header Supports B - Deflectors C - Rear Crop Baffle D - Drive Shield 215972 Revision A...
Page 37: Component Identification - Grass Seed Header
Being able to identify the parts and systems of the grass seed version of the R2 Series Rotary Disc will make looking up content in its reference manuals much easier. Figure 2.3: R216 Rotary Disc Header – Grass Seed Header A - Front Curtain...
Page 38 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 39: 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 MacDon M100, M105, M150, M155, M155E4, M200, and M205 Windrowers M Series Windrowers MacDon M1170, M1170NT5, and M1240 Windrowers...
Page 40 PRODUCT OVERVIEW Term Definition An axial load placed on a bolt or screw, usually measured in Newtons (N) or pounds (lb.). Tension This term can also be used to describe the force a belt exerts on a pulley or sprocket Turns from finger tight TFFT The product of a force * the length of a lever arm, usually measured in Newton-meters...
Page 41: Chapter 3: Operation
Chapter 3: Operation Safely operating your machine requires familiarizing yourself with its capabilities. 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.
Page 42: 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 M1170 or M1240 Windrower, refer to 3.2.1 Engaging and Disengaging Header Safety Props – M1 Series Windrower, page •...
Page 43: Engaging And Disengaging Header Safety Props - M Series Self-Propelled Windrower
OPERATION 4. Engage the safety props on both lift cylinders as follows: Pull lever (A) toward you to release it, and then rotate it toward the header to lower the safety prop onto the cylinder. b. Repeat the previous step for the opposite lift cylinder. IMPORTANT: Ensure that the safety props engage over the cylinder piston rods.
Page 44 OPERATION 1. Start the engine and press HEADER UP switch (A) to raise the header to its maximum height. 2. Rephase the cylinders if one end of the header does not rise fully: Press and hold HEADER UP switch (A) until both cylinders stop moving.
Page 45 OPERATION 4. To disengage the safety prop, turn lever (A) away from the header to raise the safety prop until the lever locks into the vertical position. Repeat this step to disengage the safety prop on the opposite side of the windrower. 5.
Page 46: Attaching R2 Series Rotary Disc Header To M1 Series Windrower
OPERATION 3.3 Attaching R2 Series Rotary Disc Header to M1 Series 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 determines the width and the placement of the windrow.
Page 47 OPERATION 5. Secure forming shield (C) to bolt and spacer (D) using clevis pin (B) and lynch pin (A). 6. Repeat Steps 3, page 30 5, page 31 on the opposite side of the forming shield. Figure 3.8: Forming Shield Secured to Front of Windrower Legs 7.
Page 48: Attaching R2 Series Rotary Disc Header To M1 Series Windrower
IMPORTANT: To attach an R216 SP Rotary Disc Header to an M1 Series Windrower previously configured for a D1X Series Draper Header, ensure that two shield mount plates (A) (MD #307045) are attached to the windrower and the forming shield.
Page 49 OPERATION 2. Windrowers equipped with a hydraulic center-link without self-alignment: Remove pin (A) and raise center-link (B) until the hook is above the attachment pin on the header. Replace pin (A) to hold the center-link in place. IMPORTANT: Ensure that the center-link is positioned high enough that it does not contact the header as the windrower approaches the header.
Page 50 OPERATION 7. If the header lift legs will be lowered WITH a header or weight box attached, proceed to Step 11, page If the header lift legs will be lowered WITHOUT a header or weight box attached to the windrower, fully release the tension in header float springs (A): •...
Page 51 OPERATION 11. Press HEADER DOWN switch (E) on the ground speed lever (GSL) to fully retract the header lift cylinders. 12. Windrowers equipped with a self-aligning hydraulic center-link: Press REEL UP switch (B) on the GSL to raise the center-link until the hook is above the attachment pin on the header.
Page 52 OPERATION 16. Windrowers without the self-aligning center-link kit: Press the HEADER TILT UP or HEADER TILT DOWN cylinder switches on the GSL to extend or retract the center-link cylinder until the hook is aligned with the header attachment pin. b. Shut down the engine, and remove the key from the ignition.
Page 53 OPERATION 19. Engage the safety props on both lift cylinders as follows: Pull lever (A) toward you to release it, and then rotate it toward the header to lower the safety prop onto the cylinder. b. Repeat the previous step for the opposite lift cylinder. IMPORTANT: Ensure that the safety props engage over the cylinder piston rods.
Page 54: Connecting R2 Series Rotary Disc Header Electrical And Hydraulics - M1240 Windrower
OPERATION 22. Start the engine and press HEADER DOWN switch (A) on the GSL to fully lower the header. NOTE: If HPT display does not display a message saying that the float must be restored, then restore the float manually. 23.
Page 55 OPERATION Proceed to the relevant procedure: Auger/rotary disc/draper-ready configuration (A): For instructions, refer to Auger/Rotary Disc/Draper-Ready Configuration – Quick Coupler Connections, page 1036608 Figure 3.28: Header Hydraulics Configurations – Auger/Rotary Disc/Draper-Ready Rotary disc-only hard-plumbed configuration (A): For Rotary Disc-Only Configuration – Hard- instructions, refer to Plumbed Connections, page Figure 3.29: Header Hydraulics Configuration –...
Page 56: Auger/Rotary Disc/Draper-Ready Configuration - Quick Coupler Connections
OPERATION Auger/Rotary Disc/Draper-Ready Configuration – Quick Coupler Connections Windrowers with the auger/rotary disc/draper-ready configuration are equipped with the hydraulic connections needed to pair with an auger, rotary disc, or draper header. IMPORTANT: To prevent contamination of the hydraulic system, use a clean rag to remove dirt and moisture from all (fixed and movable) hydraulic couplers.
Page 57 OPERATION 4. Connect the hydraulic fittings to the hydraulic hoses as follows: NOTE: The two quick couplers and two elbow fittings are supplied in the Quick Coupler kit (MD #B6277). Attach 90° elbow fitting (A) and 1 in. female coupler fitting (B) to disc pressure hose (C).
Page 58 OPERATION 6. Grass seed header (GSS): Connect the additional four hoses supplied with the grass seed version of the header as follows: Connect the hose with the green cable tie with female quick coupler (A) to coupler (B) on the windrower frame.
Page 59 OPERATION 8. Connect main header harness (A) to adapter harness (B). 9. Headers equipped with the electric baffle control kit: Connect electric baffle control harness (C) to adapter harness (D). 10. Grass seed headers (GSS): Connect actuator harness (C) to adapter harness (D).
Page 60: Rotary Disc-Only Configuration - Hard-Plumbed Connections
OPERATION 13. If necessary, calibrate the knife drive. Calibrate the knife drive whenever you are: • Attaching the header to the windrower for the first time • Changing the speed sensor or hydraulic drive motor on the header • Changing the header drive pump associated with the knife drive, Harvest Performance Tracker (HPT), or the master controller on the windrower For instructions on calibrating the knife drive, refer to the windrower operator’s manual.
Page 61 Connect disc return hose (D) to hard plumb fitting (E) and torque the connection to 215 Nm (159 lbf·ft). Connect case drain hose (F) to fitting (G). Figure 3.41: Hard-Plumbed Connections on R216 Rotary Disc Header Ready Windrower 4. Grass seed header (GSS): Connect the additional four hoses...
Page 62 OPERATION 5. Free electrical harness (A) from adjustable strap (B). Figure 3.43: Electrical Harness Secured to Center-Link 6. Connect main header harness (A) to adapter harness (B). 7. Headers equipped with the electric baffle control kit: Connect electric baffle control harness (C) to adapter harness (D).
Page 63: Rotary Disc-Only Configuration - Quick Coupler Connections
OPERATION 10. Pull platform (A) towards the cab until it stops and the latch is engaged. Figure 3.46: Left Cab-Forward Platform 11. If necessary, calibrate the knife drive. Calibrate the knife drive whenever you are: • Attaching the header to the windrower for the first time •...
Page 64 OPERATION 3. Connect the hydraulic fittings to the hydraulic hoses as follows: NOTE: Two quick couplers and two elbow fittings are supplied in the Quick Coupler kit (MD #B6277). Attach 90° elbow fitting (A) and 1 in. female coupler fitting (B) to disc pressure hose (C). b.
Page 65 OPERATION 5. Grass seed header (GSS): Connect the additional four hoses supplied with the grass seed version of the header as follows: Remove the 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 66: Connecting R2 Series Rotary Disc Header Hydraulics And Electrical Systems - M1170 Windrower
OPERATION 7. Pull platform (A) towards the cab until it stops and the latch is engaged. Figure 3.52: Left Cab-Forward Platform 8. If necessary, calibrate the knife drive. Calibrate the knife drive whenever you are: • Attaching the header to the windrower for the first time •...
Page 67 OPERATION 3. Retrieve hydraulic hoses (A) from the header and route the hose bundle under the windrower frame. NOTE: Adding anti-seize compound to the hose holder pin will make future removal easier. 4. Insert pin (B) into hole (C) in the windrower frame. IMPORTANT: Route the hydraulic hoses as straight as possible, avoiding wear points that could damage the hoses.
Page 68 OPERATION 6. Hard-plumbed fittings: Connect the hydraulic hoses to the windrower as follows: Connect disc pressure hose (A) (fitted with red cable tie [B]) to hard plumb fitting (C) (fitted with a red cable tie) and torque the connection to 215 Nm (159 lbf·ft). b.
Page 69 OPERATION 8. Quick couplers: Connect the hydraulic hoses to a windrower with quick coupler fittings as follows: Connect disc pressure hose (A) with coupler (B). Torque the connection to 216 Nm (159 lbf·ft). b. Connect disc return hose (C) with coupler (D). Torque the connection to 216 Nm (159 lbf·ft).
Page 70 OPERATION 10. Free electrical harness (A) from adjustable strap (B). Figure 3.60: Electrical Harness Secured to Center-Link 11. Connect main header harness (A) to adapter harness (B). 12. Headers equipped with the electric baffle control kit: Connect electric baffle control harness (C) to adapter harness (D).
Page 71 OPERATION 15. Pull platform (A) towards the cab until it stops and the latch is engaged. Figure 3.63: Left Cab-Forward Platform 16. If necessary, calibrate the knife drive. Calibrate the knife drive whenever you are: • Attaching the header to the windrower for the first time •...
Page 72: Detaching R2 Series Rotary Disc Header From M1 Series Windrower
OPERATION 3.4 Detaching R2 Series Rotary Disc Header from M1 Series Windrower Detach the header when replacing the header with a different one or when storing the header. 3.4.1 Detaching R2 Series Rotary Disc Header from an M1 Series Windrower Detach the header when replacing the header with a different one or when storing the header.
Page 73 OPERATION 5. Disconnect hydraulic hoses (A), (B), and (C) from the windrower. Figure 3.66: Header Drive Hydraulics – Quick Couplers Figure 3.67: Header Drive Hydraulics – Hard-Plumbed Fittings 215972 Revision A...
Page 74 OPERATION 6. Grass seed header: Disconnect additional four hoses (A), (B), (C), and (D). Figure 3.68: Grass Seed Hydraulic Connections – M1240 Draper/Disc Ready Configuration, M1170 Configuration Figure 3.69: Grass Seed Hydraulic Connections – M1240 Rotary Disc Configuration 215972 Revision A...
Page 75 OPERATION 7. Push latch (A) to unlock platform (B). 1015478 Figure 3.70: Left Cab-Forward Platform 8. Pull platform (A) towards the cab until it stops and the latch is engaged. Figure 3.71: Left Cab-Forward Platform 9. Remove hose support (A) and the hose bundle from the windrower frame.
Page 76 OPERATION 10. Rest hydraulic hose bundle (A) on the header for storage as shown. Figure 3.73: Hose Bundle Storage Position 11. Disconnect main header harness (A) from adapter harness (B). 12. Standard headers equipped with optional electric baffle control kit: Disconnect electric baffle control harness (C) from adapter harness (D).
Page 77 OPERATION 15. Remove hairpin (B) from clevis pin (A). Remove the clevis pin from header support (C) on both sides of the header. Figure 3.76: Header Supports 16. Windrowers WITH center-link self-alignment kit: Release center-link latch (A) before returning to the cab. Figure 3.77: Center-Link DANGER Ensure that all bystanders have cleared the area.
Page 78 OPERATION 19. Use HEADER TILT cylinder switches (A) on the GSL to release the load on center-link cylinder. 20. Windrowers WITH center-link self-alignment kit: Operate the link lift cylinder with REEL UP switch (B) to disengage the center-link from the header. Proceed to Step 24, page Figure 3.78: GSL 21.
Page 79: Removing Forming Shield
OPERATION IMPORTANT: When detaching an R216 SP Rotary Disc Header from an M1 Series Windrower that will be configured for a D1X Series Draper Header, ensure two shield mount plates (A) (MD #307045) are removed from the windrower and forming shield.
Page 80 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 3.83: Forming Shield Secured to Front of Windrower Legs 8. Dismount forming shield (A) from bolts and spacers (B). 9.
Page 81: Attaching R2 Series Rotary Disc Header To M205 Sp Windrower
OPERATION 3.5 Attaching R2 Series 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 82 OPERATION 5. Secure forming shield (C) to bolt and spacer (D) using clevis pin (B) and lynch pin (A). 6. Repeat Step 3, page 65 to Step 5, page 66 at the opposite side. Figure 3.86: Forming Shield Secured to Front of Windrower Legs 7.
Page 83: 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 84 OPERATION 2. Remove hairpin (A) from clevis pin (B), and remove the pin from header support (C) on both sides of the header. Figure 3.89: Header Support 3. Lift header support (A) and place 2 x 4 in. blocks (B) under the header support.
Page 85 OPERATION DANGER Ensure that 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 3.92: Ground Speed Lever 6. Press REEL UP switch (A) on the GSL to raise the center-link until the hook is above the attachment pin on the header.
Page 86 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 3.94: Header Support 8. Use the following GSL functions to position the center-link hook above the header attachment pin: •...
Page 87 OPERATION 9. Adjust the position of center-link cylinder (A) 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.
Page 88 OPERATION 14. Pull lever (A) outward and rotate it toward the header to lower safety prop (B) onto the cylinder. Repeat this step 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 89 OPERATION 16. Remove the clevis pin from storage position (B) in the linkage and insert it into hole (A) to engage the float springs. Secure it with the hairpin. Repeat this step on the opposite float linkage. Figure 3.100: Header Float Linkage 17.
Page 90: Attaching R2 Series Rotary Disc Header To M205 Sp Windrower - Hydraulic Center-Link Without Optional Self-Alignment
OPERATION 3.5.3 Attaching R2 Series 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 (which allows the operator to control the vertical position of the center-link from the cab). DANGER To prevent bodily injury or death from the 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 91 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 this step for the opposite linkage. IMPORTANT: To avoid damaging the lift system when lowering the header lift linkages without a header or weight box...
Page 92 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 3.108: Header Support 8. Use the following GSL functions to position the center-link hook above the header attachment pin: •...
Page 93 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 94 OPERATION 15. Pull lever (A) outward and rotate it toward the header to lower safety prop (B) onto the cylinder. Repeat this step 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 95 OPERATION 17. Remove the clevis pin from storage position (B) in the linkage and insert it into hole (A) to engage the float springs. Secure it with the hairpin. Repeat this step on the opposite float linkage. Figure 3.114: Header Float Linkage 18.
Page 96: Connecting R2 Series Rotary Disc Header Hydraulics And Electrical To An M205 Sp Windrower
NOTE: M205 compatibility kit MD #B7220 is required to connect an 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 97 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 98 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 3.121: Pressure and Return Steel Lines with Plugs 5.
Page 99 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 100 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 101 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 3.127: Case Drain Connection 16.
Page 102: Detaching R2 Series Rotary Disc Header From M205 Sp Windrower
OPERATION 3.6 Detaching R2 Series Rotary Disc 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 R2 Series Rotary Disc Header from M205 SP Windrower Detach the header when replacing the header with a different one or when storing the header. DANGER To prevent bodily injury or death from the 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 103 OPERATION 5. Pull lever (A) outward and rotate it toward the header to lower safety prop (B) onto the cylinder. Repeat for the opposite cylinder. Figure 3.130: Safety Props 6. Remove hairpin (B) from clevis pin (A) and remove the clevis pin from header boot (C) on both sides of the header.
Page 104 OPERATION 7. Remove the hairpin and clevis pin from location (A) to disengage the float springs, and insert the hairpin and clevis pin into storage hole (B). Secure with the hairpin. IMPORTANT: To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to the windrower, ensure the float engagement pin is installed in storage position (B) and NOT in engaged position (A).
Page 105 OPERATION 11. Shut down the engine, and remove the key from the ignition. 12. Lift hook release (C) and lift hook (B) off the header pin. NOTE: If the optional center-link lift cylinder is installed, lift release (C) and then operate the link lift cylinder from the cab to disengage center-link (A) from the header.
Page 106 OPERATION 14. Quick coupler connections: Disconnect case drain hose (A) from fitting (B). 15. Quick coupler connections: Remove two clamps (C) and hose (A). Reinstall clamps (C). Figure 3.137: Case Drain Connection 16. Quick coupler connections: Remove pin (A). Open coupler lock assembly (B).
Page 107 OPERATION 19. Hard-plumbed connections: Disconnect case drain hose (A) from fitting (B). Figure 3.139: Case Drain Connection 20. Hard-plumbed connections: Disconnect the hose with fitting (A) from steel line (B). Disconnect the hose with fitting (C) from steel line (D). 21.
Page 108 OPERATION 22. Remove header hose support (A) from hole (B) in the windrower frame near the left cab-forward leg. Figure 3.141: Hose Support Installed 23. Rest hydraulic hose bundle (A) on the header for storage as shown. Figure 3.142: Hose Bundle Storage Position 215972 Revision A...
Page 109: Removing The Forming Shield
OPERATION 24. Disconnect M205 SP Windrower adapter harness (A) from header connector (C). Install electrical caps on the connectors. 25. Store harness (A) on center-link (B) using straps (not shown). 26. Back the windrower slowly away from the header. Figure 3.143: M205 SP Windrower Adapter Harness 27.
Page 110 OPERATION 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 the rear end of the forming shield. Figure 3.145: Rubber Strap Securing Forming Shield onto Windrower Leg 5.
Page 111 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 3.147: Forming Shield Secured to Front of Windrower Legs 8. Dismount forming shield (A) from bolts and spacers (B). Repeat at the opposite side.
Page 112: Attaching R2 Series Rotary Disc Header To M155E4 Sp Windrower
NOTE: To use an R216 Rotary Disc Header with an M155E4 Self-Propelled Windrower, the following kits must be installed first: • Disc drive kit (MD #B4657) • M155E4 hydraulic drive kit (MD #B7310) Proceed to the relevant topic: •...
Page 113 OPERATION 4. Lift header support (A) and place 2 x 4 in. blocks (B) under the header support. A total of four 2 x 4 in. blocks (B) will be necessary to raise the boot up into field position. Ensure the boot’s bottom edge (C) is parallel with the ground.
Page 114 OPERATION 8. Press REEL UP switch (A) on the GSL to raise the center-link until the hook is above the attachment pin on the header. IMPORTANT: If the center-link is too low, it may contact the header as the windrower approaches the header for hookup. Figure 3.153: Ground Speed Lever 9.
Page 115 OPERATION 10. Use the following GSL functions to position the center-link hook above the header attachment pin: • REEL UP (A) to raise the center-link • REEL DOWN (B) to lower the center-link • HEADER TILT UP (C) to retract the center-link •...
Page 116 OPERATION 16. To lower the safety props: Pull lever (A) outward and rotate it toward the header to lower safety prop (B) onto the cylinder. b. Repeat the previous step for the other safety prop. Shut down the engine, and remove the key from the ignition.
Page 117 OPERATION 19. Remove the clevis pin from storage position (B) in the linkage and insert it into hole (A) to engage the float springs. Secure it with the hairpin. Repeat this step on the opposite float linkage. 20. Repeat the previous step for the other float engagement pin.
Page 118: Attaching R2 Series Rotary Disc Header To M155E4 Sp Windrower - Hydraulic Center-Link Without Self-Alignment
Center-Link without Self-Alignment If the M155E4 Self-Propelled Windrower is equipped with a hydraulic center-link that lacks self-alignment capability, the Operator will have to manually attach the hydraulic center-link’s hook to the R216 Rotary Disc Header’s center pin. DANGER To prevent bodily injury or death from the 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 119 OPERATION 5. Remove the float engagement pin from hole (A) to disengage the float springs. Insert the float engagement pin into storage hole (B). Secure the engagement pin with the lynch pin. IMPORTANT: To prevent damage to the lift system when lowering the header lift linkages without a header or a weight box attached to the windrower, ensure that the float engagement pin is installed in storage hole (B) and NOT in...
Page 120 OPERATION 9. 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 is nudged forward. Figure 3.168: Header Support 10. Use the following GSL functions to position the center-link hook above the header attachment pin: •...
Page 121 OPERATION 12. 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 122 OPERATION 17. To lower the safety props: Pull lever (A) outward and rotate it toward the header to lower safety prop (B) onto the cylinder. b. Repeat the previous step for the other safety prop. Shut down the engine, and remove the key from the ignition.
Page 123 OPERATION 20. Remove the clevis pin from storage position (B) in the linkage and insert it into hole (A) to engage the float springs. Secure it with the hairpin. Repeat this step on the opposite float linkage. 21. Repeat the previous step for the other float engagement pin.
Page 124: Connecting R2 Series Rotary Disc Header Hydraulics And Electrical To M155E4 Sp Windrower
3.7.3 Connecting R2 Series Rotary Disc Header Hydraulics and Electrical to M155E4 SP Windrower Once the R216 Rotary Disc Header is attached to the M155E4 Self-Propelled Windrower, the hydraulic and electrical connections must be completed. 1. Connect the windrower’s hydraulic hoses to the header’s.
Page 125 OPERATION 2. Locate windrower adapter harness (A) on the windrower’s center-link. Remove windrower adapter harness (A) from its storage location on center-link (B). 3. Connect harness (A) to header harness (C). Figure 3.179: Windrower Adapter Harness NOTE: When the harness is not in use, secure harness (A) to the center- link tilt cylinder using strap (B).
Page 126: Detaching R2 Series Rotary Disc Header From M155E4 Sp Windrower
OPERATION 3.8 Detaching R2 Series Rotary Disc Header from M155E4 SP Windrower Detaching a header from the windrower involves removing the header’s mechanical connection to the windrower and disconnecting the hydraulic and electrical connections. The procedure differs slightly depending on whether or not the windrower is equipped with a self-adjusting hydraulic center-link.
Page 127 OPERATION 5. Remove the hairpin from the float spring clevis pin. Remove the clevis pin from hole (B) and insert it into storage hole (A) to disengage the float springs. Secure the clevis pin with the hairpin. 6. Repeat the previous step for the other float engagement pin.
Page 128 OPERATION 9. 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. 10. Start the engine, choose a level area, and lower the header to the ground.
Page 129 OPERATION 14. Disconnect upper pressure hose (A), lower pressure hose (B), return hose (C), and case drain hose (D) from the header. Figure 3.188: Windrower Hydraulic Hoses Connected to Header — View from Rear of Header 15. Pull hydraulic hose bundle (A) and the upper hydraulic pressure hose through the hose guide.
Page 130 OPERATION 18. Disconnect windrower harness (A) from header harness (C). Install the protective caps on each connector. 19. Store harness (A) on center-link (B) with the attached straps (not shown). 20. Slowly back the windrower away from the header. Figure 3.190: Windrower Harness 21.
Page 131: Driveshields
OPERATION 3.9 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. 3.9.1 Opening Driveshields Open the driveshields to gain access to the drive components. WARNING To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured.
Page 132 OPERATION 2. Lift outboard driveshield panel (A) as shown. Figure 3.194: Opening Driveshield – Outboard Panel 3. Pull handle (A) and lift inboard driveshield panel (B) toward the middle of the header. 4. Repeat this procedure to open the right driveshield. Figure 3.195: Driveshield –...
Page 133: Closing Driveshields
OPERATION 3.9.2 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: The illustrations provided in this procedure show the left driveshield; the right driveshield is similar. 1.
Page 134 OPERATION 3. Move the outboard half of driveshield (A) back to the closed position. 4. Repeat this procedure to close the right driveshield. Figure 3.198: Left Driveshield 215972 Revision A...
Page 135: Cutterbar Curtain
OPERATION 3.10 Cutterbar Curtain The curtain is installed at the front of the header. It reduces 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 136: Closing Cutterbar Curtain
OPERATION 3. Secure the curtain in place at locations (A) using the three clips provided. Figure 3.201: Cutterbar Curtain — Standard Header Shown, View from Below NOTE: Cutterbar curtain (A) is held in place between the tines of retaining clips (B). Figure 3.202: Cutterbar Curtain and Retaining Clips 3.10.2 Closing Cutterbar Curtain Once your maintenance tasks are complete, the cutterbar curtain must be closed before the header is operated.
Page 137 OPERATION 1. Pull the curtain outward from the retaining clips and lower the curtain. Figure 3.203: Cutterbar Curtain – Standard Header Shown 215972 Revision A...
Page 138: Header Settings
OPERATION 3.11 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 139: Adjusting Skid Shoe Height
OPERATION Adjusting Skid Shoe Height Adjustable skid shoes can be installed on the header. These allow the skid shoes to be adjusted so that an increased range of cutting height options are available. The adjustable skid shoes have multiple position settings: lowest working position (A), intermediate working positions (B), and storage position (C).
Page 140: Adjusting Gauge Roller Height
OPERATION 5. Position the skid shoe in the preferred working position by aligning skid shoe holes (A) with the mounting holes in bracket (B). Refer to the table below for information on the effect that each skid shoe setting has on the height of the disc blades.
Page 141 OPERATION 1. Raise the header fully. 2. Shut down the engine, and remove the key from the ignition. 3. Engage the lift cylinder safety props. For instructions, refer to the relevant procedure: • M1 Series Windrower: 3.2.1 Engaging and Disengaging Header Safety Props – M1 Series Windrower, page 26 •...
Page 142 OPERATION • To set the gauge wheels to the lowest working position, proceed to Step 6, page 126 • To set the gauge wheels to the intermediate working position, proceed to Step 9, page 126 • To set the gauge wheels to the storage position, proceed to Step 13, page 127 Lowest working position To adjust the gauge rollers to the lowest working position, follow these steps:...
Page 143 OPERATION 11. Reinstall scraper plate (A) in the slot as shown. Secure the scraper plate by inserting hairpin (B) as shown. IMPORTANT: Ensure that the tab on the scraper plate is positioned as shown. 12. Repeat this procedure to adjust the height of the other gauge wheel.
Page 144: Cutterbar Angle
OPERATION 3.11.2 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 145: 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 3.215: Ground Speed for R216 Rotary Disc Headers A - Acres/Hour...
Page 146: Conditioner - Standard Header
OPERATION 3.12 Conditioner – Standard Header 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. 3.12.1 Roll Gap Roll gap refers to the spacing between the conditioner rolls.
Page 147: Adjusting Roll Gap - Polyurethane Rolls
OPERATION Adjusting Roll Gap – Polyurethane Rolls The roll gap controls the degree to which crop is conditioned as it passes through the rolls. The roll gap can be adjusted using the set of nuts on both sides of the header. 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 148: Roll Tension
OPERATION 3.12.2 Roll Tension Roll tension describes the degree of pressure holding the conditioner rolls together. Roll tension 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 the crop materials are conditioned sufficiently.
Page 149: Adjusting Feed Roll Drive Belt Tension
OPERATION 3.12.3 Adjusting Feed Roll Drive Belt Tension There are two tension settings for the feed roll drive belt. One setting suits most crop conditions. The other setting improves belt performance in heavy crop conditions. Figure 3.220: Tensioner Spring 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 150: Roll Timing
OPERATION 3.12.4 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 151 OPERATION 2. On the right side of the header, engage lift release latch (A) and pull handle (B) to open outboard driveshield (C). 3. Lift at handle (D) to open inboard driveshield (E). Figure 3.222: Right Driveshields 4. On the upper roll, loosen four bolts (A) securing yoke plate (B).
Page 152 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 3.225: Conditioner Drive 10.
Page 153: Forming Shields - Roll Conditioner
OPERATION 3.12.5 Forming Shields – Roll Conditioner The forming shield controls the width and placement of the windrow. Consider the following factors when setting the forming shield position: • Weather conditions (rain, sun, humidity, and wind) • Type and yield of crop •...
Page 154: Positioning Rear Baffle
The rear baffle is used in conjunction with the forming shields to control the width of the windrow. NOTE: An optional Remote Baffle Control kit (MD #B6664) is available for R216 Rotary Disc Headers configured for M1 Series Windrowers ONLY. The Remote Baffle Control kit is NOT compatible with M205 or M155E4 Self-Propelled Windowers. For 5.4 Remote Baffle Control Kit –...
Page 155 OPERATION Positioning Rear Baffle Deflector Fins Four rear baffle deflector fins are located under the baffle. The rear baffle deflector fins help spread the crop in the windrow. The fins are set at the factory to an angle of approximately 60°. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 156 OPERATION NOTE: Deflector fins (A) can be put in the storage position by removing the already installed nut and bolt and then reattaching the fins on top of the baffle. Figure 3.232: Left Deflector Fins in Storage Position 215972 Revision A...
Page 157: Cutterbar Deflectors - Standard Headers Only
OPERATION 3.13 Cutterbar Deflectors – Standard Headers Only 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 158: Installing Cutterbar Deflectors
OPERATION 11. If the cutterbar is being replaced, install the deflectors on the new cutterbar. For instructions, refer to 3.13.2 Installing Cutterbar Deflectors, page 142. 3.13.2 Installing Cutterbar Deflectors The cutterbar deflectors are used with roll conditioners only. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 159 OPERATION 8. Position right deflector (A) on the right aft edge of the cutterbar, and loosely secure in place with three M10 carriage bolts and lock nuts (C) . Insert the bolts into the cutterbar from the bottom. NOTE: Some parts removed from illustration for clarity. ®...
Page 160: Cutterbar Disc Feed Plates - Standard And Grass Seed Headers, Installing, Removing, And Storing Plates
OPERATION 3.14 Cutterbar Disc Feed Plates – Standard and Grass Seed Headers, Installing, Removing, and Storing Plates The disc feed plates assist with the feeding of tall crops into the conditioner by encouraging material flow from behind the drums. Overview Figure 3.236: Standard Header and Grass Seed Header Feed Plate Configurations Feed plate configurations include the following: •...
Page 161 OPERATION Safety Steps DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 162 OPERATION Retrieving Feed Plates from Storage Figure 3.239: Standard-Sized Feed Plates and Support Angles in Storage Position 5. Open the right driveshield. For instructions, refer to 3.9.1 Opening Driveshields, page 115. 6. Remove bolt (A), Safecut Spindle-Nut Wrench (B), and standard-sized plates (C). Reinstall bolt (A) and wrench (B). 7.
Page 163 OPERATION Installing Feed Plates A A B Figure 3.240: Cutterbar Disc Cap Hardware Removal – Disc 9 Shown NOTE: All illustrations show disc 2. The drum hanging above disc 2 has been removed for clarity. 10. Open the cutterbar curtain. For instructions, refer to 3.10.1 Opening Cutterbar Curtain, page 119.
Page 164 OPERATION Figure 3.241: Support Angles and Cap 14. Position two support angles (A) across the narrow length of the disc, with cap (B) on top of them. Align the holes in the cap and angles with the disc. NOTE: If installing feed plates on disc 2 or 9: You must position the cap and the support angles on the disc at the same time. There is not enough room to pass the cap between the hanging drums and the support angles once the support angles are installed.
Page 165 OPERATION Figure 3.242: Hardware Installation 15. Secure the cap and angles using four M12 x 30 mm hex bolts (A) and washers (B). 16. Torque bolts (A) to 85 Nm (63 lbf∙ft). 215972 Revision A...
Page 166 OPERATION Figure 3.243: Standard Feed Plate Installed on Disc 17. Position feed plate (A) on top of the support angles and secure with two M12 carriage bolts (B) and M12 lock nuts (C). 18. Remove the pin (or equivalent) from the front hole of the rock guard. 19.
Page 167: Grass Seed Version Operation
OPERATION 3.15 Grass Seed Version Operation The optional grass seed (GSS) version of the header is intended for cutting delicate grass seed crops, and laying them in a windrow prior to a combine picking them up. Anti-shatter shield (A) prevents the shattering of the grass seed heads as the header cuts.
Page 168: Activating Grass Seed Option
OPERATION 3.15.1 Activating Grass Seed Option The grass seed (GSS) option must be activated in the windrower’s control system the first time it is attached to the windrower. NOTE: The windrower requires the software versions (or newer) listed in Table 3.5, page 152 to operate the grass seed header.
Page 169 OPERATION 6. Select R2 DISC (A). 1035830 Figure 3.248: Header Setup 7. Select ATTACHMENTS (A). 1035832 Figure 3.249: Header Setup 8. Select GRASS SEED (A). The system is now active, and the HPT, the GSL, and the operator console can be used to control the grass seed attachment.
Page 170: Operating With Grass Seed Option
OPERATION 9. Once the grass seed option is activated, Run Screen 2 on the HPT will display speed (A) and pressure (B) of the grass seed drums. 1034170 Figure 3.251: Run Screen 2 – Grass Seed Active 3.15.2 Operating with Grass Seed Option The anti-shatter shield on the R2 Series Rotary Disc Header’s grass seed option can be extended or retracted using the controls on the windrower’s operator console.
Page 171 OPERATION 4. FULLY extend (A) or retract (C) the anti-shatter shield as follows: • Fully extend (A) the shield by pressing and holding F6 (D) on the operator console. • Fully retract (C) the shield by pressing and holding F5 (B) on the operator console. IMPORTANT: Do NOT operate the header in the field with the shield partially extended.
Page 172 OPERATION 5. Adjust the drum speed and windrow width (drum spacing) as desired using the 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 173: Preparing Header With Grass Seed Option For Transport
OPERATION 3.15.3 Preparing Header with Grass Seed Option for Transport Before an R2 Series Rotary Disc Header equipped with the grass seed option (GSS) can be transported, several preliminary steps must be completed. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
Page 174: Performance Improvement Tips For Grass Seed Headers
OPERATION 3.15.4 Performance Improvement Tips for Grass Seed Headers You can improve the performance of the grass seed header by changing windrower settings or configurations. Disable Eco Engine Control (EEC) (A) to maximize engine horsepower. 1014733 Figure 3.259: Eco Engine Control Button Use hard-plumbed fittings (A) instead of quick couplers (B) to connect to the header.
Page 175: Haying Tips
OPERATION 3.16 Haying Tips Follow the recommendations in this section to ensure the highest quality hay production. 3.16.1 Curing Curing crops quickly helps maintain the highest quality of crop material. Approximately 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.
Page 176: Windrow Characteristics
OPERATION 3.16.4 Windrow Characteristics The shape and density of the windrow is an important factor with respect to how rapidly the hay cures. For instructions, refer to 3 Operation, page 25 for instructions on adjusting the header. Table 3.7 Recommended Windrow Characteristics Advantage Characteristic Enables airflow through windrow, which is more important to the curing...
Page 177: Transporting The Header
OPERATION 3.17 Transporting the Header For information on transporting the header when attached to the windrower, refer to your windrower operator’s manual. 215972 Revision A...
Page 179: 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. 4.4.1 Maintenance Schedule/Record –...
Page 180: Preparing Machine For Servicing
MAINTENANCE AND SERVICING 4.2 Preparing Machine for Servicing A few preliminary tasks will need to be performed before the header can be serviced safely. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 181: 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 4.1: Safety Around Equipment •...
Page 182 MAINTENANCE AND SERVICING • Be prepared if an accident should occur. Know where the first aid kits and fire extinguishers are located, and know how to use them. Figure 4.4: Safety Equipment • Keep the service area clean and dry. Wet or oily floors are slippery.
Page 183: 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 184 MAINTENANCE AND SERVICING Every 25 Hours Lubricate idler pivot. Refer to Lubrication, page 172. Lubricate upper and lower driveline universal joints. Refer to 4.5 Lubrication, page 172. Lubricate roller conditioner and feed roller bearings. Refer to 4.5 Lubrication, page 172. Lubricate conditioner driveline.
Page 185: Maintenance Schedule/Record - Grass Seed Headers
MAINTENANCE AND SERVICING 4.4.2 Maintenance Schedule/Record – Grass Seed Headers Keep a record of maintenance as evidence of a properly maintained machine. Daily maintenance records are not required to meet normal warranty conditions. Hour meter reading Service date Serviced by Refer to 4.4.3 Break-In Inspections, page 170.
Page 186: Break-In Inspections
MAINTENANCE AND SERVICING 4.4.3 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 Standard Item Grass Seed...
Page 187: End-Of-Season Servicing
MAINTENANCE AND SERVICING 4.4.5 End-of-Season Servicing DANGER To prevent injury or death from the unexpected start-up of the 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 188: Lubrication
MAINTENANCE AND SERVICING 4.5 Lubrication Greasing points are marked on the machine by decals on the left and right outboard shielding. WARNING To avoid personal injury, before servicing header or opening drive covers, refer to 4.2 Preparing Machine for Servicing, page 164.
Page 189: Lubrication Locations - Standard Headers
MAINTENANCE AND SERVICING 4.5.2 Lubrication Locations – Standard Headers This topic identifies lubrication locations according to the maintenance schedule for standard headers. Figure 4.6: Left Lubrication Locations A - Idler/Tensioner Pivot B - Bearing, Roller Conditioner (Two Places) C - U-Joint, Conditioner Driveline (Two Places) D - Slip Joint, Conditioner Driveline 5 E - Idler/Tensioner Pivot F - Bearing, Feed Roll...
Page 190 MAINTENANCE AND SERVICING Figure 4.7: Right Lubrication Locations C - Slip Joints, Conditioner Drivelines 6 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 191 MAINTENANCE AND SERVICING Figure 4.8: Vertical Drivelines Lubrication Locations A - Right Driveline U-Joints (Two Places) 7 B - Right Driveline Shaft (One Place) 8 C - Left Driveline U-Joints (Two Places) 9 D - Left Driveline Shaft (One Places) 8 For fittings (A) and (C), use high-temperature, extreme-pressure (EP2) performance grease with 10% max molybdenum disulphide (NLGI grade 2) lithium base.
Page 192: Lubrication Locations - Grass Seed Headers
MAINTENANCE AND SERVICING 4.5.3 Lubrication Locations – Grass Seed Headers This topic identifies lubrication locations according to the maintenance schedule for grass seed headers. Lubricate idler/tensioner locations (A) and (D) every 25 hours. Lubricate grass seed drum locations (B), (C), (E), and (F) every 50 hours.
Page 193 MAINTENANCE AND SERVICING Figure 4.10: Vertical Drivelines Lubrication Locations A - Right Driveline U-Joints (Two Places) 10 B - Right Driveline Shaft (One Place) 11 C - Left Driveline U-Joints (Two Places) 12 D - Left Driveline Shaft (One Places) 11 10.
Page 194: 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 4.11: Gauge Rollers Lubrication Locations 215972 Revision A...
Page 195: Cutterbar System
4.6 Cutterbar System The R216 cutterbar contains 10 rotating discs. Each disc has two blades on it. Each cutting disc is equipped with a rock guard to protect the cutterbar and discs from stones and debris, and to prevent the cutterbar from digging into the ground.
Page 196 MAINTENANCE AND SERVICING 4. Open cutterbar curtain (A). For instructions, refer to 3.10.1 Opening Cutterbar Curtain, page 119. Figure 4.13: Cutterbar Curtain – Header with Conditioner Shown 5. Use spirit level (A) to ensure that the cutterbar is level in both directions.
Page 197 MAINTENANCE AND SERVICING 11. Shut down the engine, and remove the key from the ignition. 12. Remove plug (A) at the right end of the header. IMPORTANT: Do NOT remove bolts (B). 13. Add lubricant as needed. IMPORTANT: Do NOT overfill the cutterbar. Overfilling can cause the cutterbar to overheat, resulting in equipment damage..
Page 198: Draining The Cutterbar
MAINTENANCE AND SERVICING 24. Close cutterbar curtain (A). For instructions, refer to 3.10.2 Closing Cutterbar Curtain, page 120. Figure 4.18: Cutterbar Curtain – Header with Conditioner Shown Draining the Cutterbar Drain the cutterbar if the oil level is too high, or drain the cutterbar completely if the oil will be changed. DANGER To prevent injury or death from the 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 199: Filling Cutterbar With Lubricant
MAINTENANCE AND SERVICING 7. Place a 10 liter (10.5 US qts) container under the right end of the cutterbar. Clean the area around plug (A), and remove the plug. IMPORTANT: Do NOT remove hex head bolts (B) securing the cutterbar end plate to the cutterbar;...
Page 200 MAINTENANCE AND SERVICING 5. Remove access plug (A) from the raised end of the cutterbar and add the EXACT amount of lubricant specified. Refer to the inside back cover of this manual for a list of recommended fluids, lubricants, and quantities for the machine.
Page 201: Cutterbar Discs
MAINTENANCE AND SERVICING 4.6.2 Cutterbar Discs The cutterbar discs provide rotary cutting action. They may need to be replaced from time to time. Figure 4.21: Interchangeable Cutterbar Discs Cutterbar discs (A) are interchangeable and can be moved to a spindle that rotates in the opposite direction, so long as the disc is in usable condition and the blades are oriented to cut in the correct direction.
Page 202 MAINTENANCE AND SERVICING WARNING Damaged or loose disc blades or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage. IMPORTANT: Damaged blades may damage the cutterbar, which could result in poor cutting performance. Replace damaged blades immediately.
Page 203: Removing Cutterbar Discs
MAINTENANCE AND SERVICING 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 the discs as needed. NOTE: Dimension (A) refers to the space between the cutterbar and the edge of the cutterbar disc.
Page 204 MAINTENANCE AND SERVICING 3. Engage the windrower lift cylinder safety props. For instructions, refer to the procedure according to the type of windrower: • M1 Series Windrowers: 3.2.1 Engaging and Disengaging Header Safety Props – M1 Series Windrower, page 26 •...
Page 205: Installing Cutterbar Discs
MAINTENANCE AND SERVICING 9. To remove the outboard cutterbar discs, refer to Removing Left Driven Drum and Driveline, page 230 Removing Right Driven Drum and Driveline, page 236. Installing Cutterbar Discs This procedure applies to the cutterbar discs that are not attached to a driveline. Install the disc so that it is rotated 90° in relation to adjacent discs.
Page 206: Cutterbar Spindles
MAINTENANCE AND SERVICING 8. Close the cutterbar curtain. For instructions, refer to 3.10.2 Closing Cutterbar Curtain, page 120. Figure 4.29: Cutterbar Curtain 9. To install the outboard cutterbar discs, refer to Installing Left Driven Drum and Driveline, page 233 Installing Right Driven Drum and Driveline, page 239.
Page 207: Removing Cutterbar Spindles
MAINTENANCE AND SERVICING IMPORTANT: • Spindles that rotate clockwise have right-leading threading and can be identified by the smooth top on spindle gear shaft (A). • Spindles that rotate counterclockwise have left-leading threading and can be identified by the machined grooves on spindle gear shaft (B) and nut (C).
Page 208 MAINTENANCE AND SERVICING 5. Open cutterbar curtain (A). For instructions, refer to 3.10.1 Opening Cutterbar Curtain, page 119. Figure 4.32: Cutterbar Curtain 6. Place a pin (or equivalent) in front hole (B) of the rock guard to prevent the disc from rotating while the hardware is removed.
Page 209 MAINTENANCE AND SERVICING 10. Remove spacer plate (A). NOTE: The area around the spindle must be cleaned thoroughly to prevent debris from entering into the cutterbar gearbox. Figure 4.35: Spacer Plate 11. Rotate spindle hub (A) to access nuts (B), and remove eleven M12 lock nuts and washers (B).
Page 210: Installing Cutterbar Spindles
MAINTENANCE AND SERVICING Installing Cutterbar Spindles Spindles must be installed correctly with respect to their direction of rotation (clockwise or counterclockwise) and their position relative to neighboring discs. Figure 4.38: Underside of Cutterbar Spindles NOTE: Right discs (A) and left discs (B) are slightly offset, depending on which idler gear the spindle is turning. •...
Page 211 MAINTENANCE AND SERVICING NOTE: The disc timing tool (A) (MD #307954) is stored under the right driveshield. Figure 4.39: Disc Timing Tool A - Disc Timing Tool (MD #307954) B -Safecut Spindle-Nut Wrench Figure 4.40: Checking Timing with Disc Timing Tool – View from Above A - Disc Timing Tool (MD #307954) B - Cutter Disc Cap C - Right Disc, Correct Timing...
Page 212 MAINTENANCE AND SERVICING IMPORTANT: Inspect the disc timing using the disc timing tool (MD #307954) before securing the spindle to the cutterbar. The disc is correctly timed if the spindle hub is aligned with the disc timing tool as shown. Turn the disc by hand to ensure that the disc blades do NOT contact each other or those of adjacent discs.
Page 213 MAINTENANCE AND SERVICING 6. Ensure that spindle O-ring (A) is properly seated, clean, and undamaged. Figure 4.41: Left Spindle O-ring 7. Insert spindle (A) into the cutterbar. Figure 4.42: Left Spindle 8. Insert studs (A) into the spindle as shown. NOTE: The plugs are factory-installed as shown in position (B), but may loosen over time.
Page 214 MAINTENANCE AND SERVICING 9. Check and adjust the disc timing as follows: NOTE: There are an odd number of teeth on the cutterbar gears; this can make aligning the spindle hub challenging. Place one end of disc timing tool (A) on adjacent disc (B) and the other end on the left spindle as shown.
Page 215 MAINTENANCE AND SERVICING 13. Install spacer plate (A). Figure 4.47: Spacer Plate 14. Place a pin (or equivalent) in front hole (D) of the rock guard to prevent the disc from rotating while the hardware is tightened. IMPORTANT: Each blade is designed for either clockwise or counterclockwise rotation.
Page 216: Disc Blades
MAINTENANCE AND SERVICING 18. Close cutterbar curtain (A). For instructions, refer to 3.10.2 Closing Cutterbar Curtain, page 120. Figure 4.49: Cutterbar Curtain 4.6.4 Disc Blades Disc blades are attached to the rotating cutting discs on the rotary disc header, and are responsible for cutting the crop. Each disc has two blades (A) attached at opposite ends of the disc.
Page 217 MAINTENANCE AND SERVICING WARNING Damaged or loose disc blades or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage. IMPORTANT: Damaged blades cut poorly and may damage the cutterbar. Replace damaged blades immediately. 1.
Page 218: Inspecting Disc Blade Hardware
MAINTENANCE AND SERVICING Figure 4.53: Clockwise Disc Rotation Inspecting Disc Blade Hardware Whenever the blades on the rotary disc header’s discs are inspected, the hardware securing the blades should also be inspected and replaced as needed. WARNING Damaged or loose disc blades or blade attachment hardware can be ejected during machine operation and may cause personal injury or machine damage.
Page 219 MAINTENANCE AND SERVICING 1. Inspect the bolt securing the disc blade. Replace the bolt if: • The bolt has been removed and installed five times • Head (A) is worn flush with the bearing surface of the blade • The diameter of the bolt’s neck has worn to (B) 3 mm (1/8 in.) NOTE: Excessive wear can occur when the header’s disc speed...
Page 220: Removing Disc Blades
MAINTENANCE AND SERVICING 2. Inspect the nut securing the disc blade. Replace the nut if: • The nut has been previously removed; nuts are intended for one-time use only • The nut shows signs of wear (A) that is more than half of original height (B) •...
Page 221 MAINTENANCE AND SERVICING 4. Open cutterbar curtain (A). For instructions, refer to 3.10.1 Opening Cutterbar Curtain, page 119. Figure 4.56: Cutterbar Curtain 5. Rotate disc (A) so that blade (B) faces forward and lines up with hole (C) in the rock guard. Figure 4.57: Disc Blade Aligned with Hole in Rock Guard 6.
Page 222: Installing Disc Blades
MAINTENANCE AND SERVICING Installing Disc Blades Each disc has two blades. Blades in good condition can be flipped over and reinstalled so that they wear evenly. The disc blades are NOT repairable and must be replaced if they are severely worn or damaged. The blade mounting nuts must always be replaced whenever the blades are replaced.
Page 223: Accelerators
4.6.5 Accelerators Accelerators are designed to quickly move cut material off of the disc and into the conditioner. R216 Rotary Disc Headers have one pairs of accelerators (A) on each pair of outboard discs. Inspect the accelerators periodically for damage and for loose or missing fasteners.
Page 224 MAINTENANCE AND SERVICING To inspect the 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 the safety props. If the header is off the ground and not fully raised, place blocks under the header.
Page 225: Removing Accelerators
MAINTENANCE AND SERVICING Removing Accelerators Accelerators should be removed from the cutterbar discs when they are damaged or so worn that they can no longer effectively move crop from the discs to the conditioner. DANGER To prevent injury or death from the 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 226 MAINTENANCE AND SERVICING 5. Place a pin (or equivalent) in the front hole of the rock guard to prevent the disc from rotating while the hardware is removed. 6. Line up the hole in the rock guard with the bolt to be removed.
Page 227: Installing Accelerators
MAINTENANCE AND SERVICING Installing Accelerators Once the old accelerators have been removed from the outboard discs on the rotary disc header’s cutterbar, the new ones will need to be installed. DANGER To prevent injury or death from the 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 228 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) (the one closest to the blade) to 125 Nm (92 lbf·ft).
Page 229: 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 into contact with stones and other debris. Periodically inspect the rock guards for damage.
Page 230: Rotating Rock Guards
Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when handling blades. 1. Mark the order of the rock guards as shown. 9 10 Figure 4.72: R216 Rotary Disc Header Rock Guard Order 215972 Revision A...
Page 231: Removing Rock Guards
MAINTENANCE AND SERVICING Figure 4.73: R216 Rotary Disc Header Rock Guard Swap Order by Operating Hours 2. Using the illustrations provided above as a guide, note how the rock guards will need to be removed and installed. 3. Remove the rock guards. For instructions, refer to Removing Rock Guards, page 215.
Page 232: Installing Rock Guards
MAINTENANCE AND SERVICING 4. Remove two hex head screws, washers, and lock nuts (A). Figure 4.74: Rock Guards 5. Slide rock guard (A) forward (in the direction of arrow [B]) and remove it. Figure 4.75: Rock Guards Installing Rock Guards The rock guards will need to be secured to the underside of the rotary disc header using two screws and nuts.
Page 233: Drums
MAINTENANCE AND SERVICING 4. Guide the rock guard onto the cutterbar until tabs (A) sit on top of the cutterbar and the bolt holes in the rock guard line up with the holes in the frame. Figure 4.76: Rock Guards 5.
Page 234: Inspecting Drums
MAINTENANCE AND SERVICING Inspecting Drums The drums on the rotary disc header should be inspected daily for signs of damage or wear, and replaced as needed. DANGER To prevent injury or death from the 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 235 MAINTENANCE AND SERVICING 5. Inspect drums (A), (B), and (C) for damage and wear. Replace a drum if it is worn at the center to 50% or more of its original thickness. Do NOT attempt to repair worn drums. 6. Examine the drums for large dents. Replace dented drums. IMPORTANT: Dented drums can cause the cutterbar to become unbalanced.
Page 236: Removing Suspended Drums
MAINTENANCE AND SERVICING WARNING Ensure that the cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the machine is started, which can result in serious injury or cause damage to the machine. 10. Close cutterbar curtain (A). For instructions, refer to 3.10.2 Closing Cutterbar Curtain, page 120.
Page 237 MAINTENANCE AND SERVICING 4. Open cutterbar curtain (A). For instructions, refer to 3.10.1 Opening Cutterbar Curtain, page 119. Figure 4.84: Cutterbar Curtain 5. Loosen two M10 hex flange head bolts (A). Remove driveline shield (B). Figure 4.85: Driveline Shield 6. Remove four M12 hex flange head bolts (A) securing suspended drum (B) to shaft (C), and remove suspended drum (B).
Page 238: Installing Suspended Drums
MAINTENANCE AND SERVICING 7. Remove two M10 hex flange head bolts (A). Remove driveline shield (B). 8. Repeat Step 5, page 221 to Step 7, page 222 to remove the opposite suspended drum. Figure 4.87: Driveline Shield Installing Suspended Drums The rotary disc header’s suspended drum will need to be reinstalled onto its shaft and the driveline shield reinstalled.
Page 239 MAINTENANCE AND SERVICING 5. Position suspended drum (B) to shaft (C) as shown. 6. Apply a bead of medium-strength threadlocker (Loctite ® 243 or equivalent) around the threads of four M12 hex flange head bolts (A). Use the bolts to secure suspended drum to the shaft.
Page 240: Replacing Left Suspended Drum Drive Belt
MAINTENANCE AND SERVICING Replacing Left Suspended Drum Drive Belt DANGER To prevent injury or death from the 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 241 MAINTENANCE AND SERVICING Removing left suspended drive belt 5. On the left side of the header, remove two M10 hex flange bolts (A). Remove driveline shield (B). Figure 4.92: Left Driveline 6. Open left driveshield (A). For instructions, refer to 3.9.1 Opening Driveshields, page 115.
Page 242 MAINTENANCE AND SERVICING NOTE: Removing the four bolts dismounts spindle spline (A) from the gearbox hub. Figure 4.95: Left Driven Drum – Spindle Spline Dismounted 10. Using a ratchet, remove belt tension by rotating tensioner (A) clockwise. 11. Remove belt (B) from the pulley, and slide the belt through opening (C).
Page 243 MAINTENANCE AND SERVICING 17. Hold spindle spline (A) up and secure on gear hub (B) with four bolts (C). NOTE: Frame panel made transparent to show connection between spindle spline (A) and gear hub (B). Figure 4.98: Left Driven Drum – Spindle Spline Dismounted 18.
Page 244: Replacing Right Suspended Drum Drive Belt
MAINTENANCE AND SERVICING 21. Install driveline shield (B) using two bolts (A). Figure 4.101: Left Driveline 22. Close cutterbar curtain (A). For instructions, refer to 3.10.2 Closing Cutterbar Curtain, page 120. 23. Disengage the windrower safety props. For instructions, refer to the procedure according to the type of windrower: •...
Page 245 MAINTENANCE AND SERVICING 3. If the header is fully raised, engage the 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 relevant procedure: •...
Page 246: 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 4.105: Right Drum Belts 10.
Page 247 MAINTENANCE AND SERVICING 3. If the header is fully raised, engage the 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 relevant procedure: •...
Page 248 MAINTENANCE AND SERVICING 7. Remove two M10 hex flange head bolts (A). Remove driveline shield (B). Figure 4.110: Driveline Shield 8. Remove four M12 hex flange head bolts (A) securing driveline assembly (B) to hub drive (C). Figure 4.111: Driveline 9.
Page 249: Installing Left Driven Drum And Driveline
MAINTENANCE AND SERVICING 10. Use an 18 mm deep socket and an extension to remove four M12 bolts (A) and washers securing drum disc assembly (B) in place. 11. Remove drum disc assembly (B). 1028507 Figure 4.113: Driven Drum – View from Above Installing Left Driven Drum and Driveline The rotary disc header’s left driven drum will need to be reinstalled onto the drive spindle and the driveline shield reinstalled.
Page 250 MAINTENANCE AND SERVICING 4. Ensure that spacer (A) is present on the spindle. 5. Apply anti-seize compound to spindle splines (B). Figure 4.114: Driven Spindle 6. Position drum disc assembly (B) over the spindle, ensuring that the disc is rotated 90° from the neighboring disc. 7.
Page 251 MAINTENANCE AND SERVICING 10. Place a bead of high-strength threadlocker (Loctite ® 262 or equivalent) around the threads of four M12 hex flange head bolts (A). Use the bolts to secure driveline assembly (B) to hub drive (C). Torque the bolts to 100 Nm (74 lbf·ft).
Page 252: Removing Right Driven Drum And Driveline
MAINTENANCE AND SERVICING 13. Position driveline shield (C) as shown. Apply a bead of ® medium-strength threadlocker (Loctite 243 or equivalent) around the threads of four M10 hex flange head bolts (A) and two M10 hex flange head bolts (B). Use bolts (A) and (B) to secure driveline shield (C).
Page 253 MAINTENANCE AND SERVICING 3. If the header is fully raised, engage the 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 relevant procedure: •...
Page 254 MAINTENANCE AND SERVICING 7. Remove two M10 hex flange head bolts (A). Remove driveline shield (B). Figure 4.125: Driveline Shield 8. Remove four M10 hex flange head bolts (A) securing driveline assembly (B) to hub drive (C). Figure 4.126: Driveline 9.
Page 255: Installing Right Driven Drum And Driveline
MAINTENANCE AND SERVICING 10. Use an 18 mm deep socket and an extension to remove four M12 bolts and washers (A) securing drum disc assembly (B). 11. Remove drum disc assembly (B). 1028520 Figure 4.128: Right Driven Drum – View from Above Installing Right Driven Drum and Driveline The rotary disc header’s right driven drum will need to be reinstalled onto the drive spindle and the driveline shield reinstalled.
Page 256 MAINTENANCE AND SERVICING 4. Ensure that spacer (A) is present on the spindle. 5. Apply anti-seize compound to spindle splines (B). Figure 4.129: Right Driven Spindle 6. Position drum disc assembly (B) so that it is oriented 90° relative to the neighboring disc. 7.
Page 257 MAINTENANCE AND SERVICING 10. Place a bead of high-strength threadlocker (Loctite ® 262 or equivalent) around the threads of four M10 hex flange head bolts (A). Use the bolts to secure driveline assembly (B) to hub drive (C). Torque the bolts to 57.5 Nm (42 lbf·ft).
Page 258: Lubricating Vertical Drivelines
MAINTENANCE AND SERVICING 13. Position driveline shield (C) as shown. Apply a bead of ® medium-strength threadlocker (Loctite 243 or equivalent) around the threads of four M10 hex flange head bolts (A) and two M10 hex flange head bolts (B). Use bolts (A) and (B) to secure driveline shield (C).
Page 259 MAINTENANCE AND SERVICING 3. If the header is fully raised, engage the 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 relevant procedure: •...
Page 260 MAINTENANCE AND SERVICING 6. Remove eight M8 hex flange head bolts (A) and two drum shields (B). Figure 4.139: Driveline Shields – Left Drum 7. Remove two M10 hex flange head bolts (A) and remove driveline shield (B). Figure 4.140: Driveline Shield – Left Drum 8.
Page 261 MAINTENANCE AND SERVICING 9. Remove eight M8 hex flange head bolts (A) and two drum shields (B). Figure 4.142: Driveline Shields – Right Drum 10. Remove two M10 hex flange head bolts (A) and remove driveline shield (B). Figure 4.143: Driveline Shield – Right Drum 215972 Revision A...
Page 262 MAINTENANCE AND SERVICING Figure 4.144: 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 263 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 264 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 265: 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 a shear pin. If the disc contacts a large object such as a stone or stump, pin (A) will shear and the disc will stop rotating and move upwards while remaining attached to the spindle with snap ring (B).
Page 266: Removing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING Removing Cutterbar Spindle Shear Pin Once a shear pin in the rotary disc header’s spindle has broken, it will need to be removed before it can be replaced. DANGER To prevent injury or death from the 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 267 MAINTENANCE AND SERVICING 6. Refer to the relevant disc removal procedure: • To remove cutterbar disc (A), refer to Removing Cutterbar Discs, page 187. • To remove left driven drum (B), refer to Removing Left Driven Drum and Driveline, page 230.
Page 268 MAINTENANCE AND SERVICING 8. Locate the storage location for the safecut spindle-nut wrench. Remove the M12 bolt and remove safecut spindle- nut wrench (A) from its storage location. Figure 4.156: Safecut Spindle-Nut Wrench IMPORTANT: • Spindles that rotate clockwise have right-leading threading and a smooth top on spindle gear shaft (A).
Page 269 MAINTENANCE AND SERVICING 9. Remove two M10 bolts and washers (A). 10. Inspect the threads of two M10 bolts (A). Replace any damaged bolts. Figure 4.158: Cutterbar Spindle 11. Use the safecut spindle-nut wrench to remove nut (A). 12. Remove hub (B). Inspect the hub for damage. Replace the hub if necessary.
Page 270: Installing Cutterbar Spindle Shear Pin
MAINTENANCE AND SERVICING 13. Remove damaged shear pins (A) using pin punch (B). Figure 4.160: Removing Shear Pin 14. Remove and clean Belleville washer (A). Figure 4.161: Belleville Washer Installing Cutterbar Spindle Shear Pin The rotary disc header’s spindle will need to have two shear pins connecting the hub to the spindle. DANGER To prevent injury or death from the 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 271 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. 1. Place the header in a position where you can access the component that will be serviced. 2.
Page 272 MAINTENANCE AND SERVICING 8. Install new shear pin (A) using a pin punch and hammer. Repeat this step 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 4.164: Cutterbar Spindle 9.
Page 273 MAINTENANCE AND SERVICING 12. Install two M10 bolts and washers (A). Torque the hardware to 55 Nm (40 lbf·ft). Figure 4.167: Cutterbar Spindle 13. Install retaining ring (A). Figure 4.168: Cutterbar Spindle 14. Proceed to the relevant procedure: • Install cutterbar disc (A). For instructions, refer to Installing Cutterbar Discs, page 189.
Page 274 MAINTENANCE AND SERVICING 15. Close cutterbar curtain (A). For instructions, refer to 3.10.2 Closing Cutterbar Curtain, page 120. 16. Return the safecut spindle-nut wrench to its storage location. For the storage location of wrench (B), refer to Figure . Figure 4.170: Cutterbar Curtain 215972 Revision A...
Page 275: Cutterbar Crop Stream
MAINTENANCE AND SERVICING 4.6.9 Cutterbar Crop Stream The number of crop streams fed into the header affects the shape of the windrow and, in some cases, the quality of the cut. Figure 4.171: Cutterbar Crop Stream Configurations Standard header: You can configure the cutterbar to produce four (A) (factory configuration), three (B), or two (C) crop Configuring Cutterbar Crop Streams –...
Page 276: Configuring Cutterbar Crop Streams - Standard Header
MAINTENANCE AND SERVICING Configuring Cutterbar Crop Streams – Standard Header The cutterbar on the standard header can be configured to produce two, three, or four crop streams. NOTE: This procedure does NOT apply to grass seed headers. Do NOT change the crop stream configuration on a grass seed header.
Page 277 MAINTENANCE AND SERVICING Figure 4.173: Cutterbar Crop Stream Configurations • Four crop streams (A) (factory configuration) are recommended for most crops and conditions. • Three crop streams (B) are recommended if using the double windrower attachment (DWA) in heavy conditions. •...
Page 278 MAINTENANCE AND SERVICING Figure 4.174: Cutterbar Crop Stream Conversion • To change from four streams (A) to three streams (B), swap disc/spindles (8) with (7), (6) with (5), and (4) with (3), and vice versa. • To change from four streams (A) to two streams (C), swap disc/spindle (8) with (3), and vice versa. •...
Page 279: 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. It transfers power from the gearbox-driven lower conditioner roll to the upper roll. Gearbox (A) does not require routine maintenance or service other than checking and changing oil.
Page 280 MAINTENANCE AND SERVICING 5. Remove right driveshield (A). For instructions, refer to 4.11.1 Removing Driveshields, page 282. Figure 4.177: Right Driveshield Checking the oil level: 6. Clean around oil level sight glass (A) and breather (B) on the inboard side of the gearbox. 7.
Page 281 MAINTENANCE AND SERVICING Changing the oil: DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, stop the engine, remove the key from the ignition, and engage the windrower’s lift cylinder safety props before going under the machine. 8.
Page 282: 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 283 MAINTENANCE AND SERVICING 6. Locate gearbox (A) on the left side of the header. Figure 4.181: Header Drive Gearbox Location – Header with Conditioner Shown 7. Clean the area around check plug (A). 8. Remove check plug (A) with a 13 mm (1/2 in.) socket. 9.
Page 284: 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 prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 285: 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 286: Removing Cutterbar Curtain
MAINTENANCE AND SERVICING 4.9.2 Removing Cutterbar Curtain In order to replace the cutterbar curtain, it must first be removed from the header. DANGER To prevent injury or death from the 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 287: Installing Cutterbar Curtain
MAINTENANCE AND SERVICING 4.9.3 Installing Cutterbar Curtain The cutterbar curtain protects bystanders from objects thrown by the cutterbar. It must be installed before the header can be operated. DANGER To prevent injury or death from the 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 288 MAINTENANCE AND SERVICING 10. Disengage the windrower’s safety props. For instructions, refer to the relevant procedure: • M1 Series Windrowers: 3.2.1 Engaging and Disengaging Header Safety Props – M1 Series Windrower, page 26 • M155E4 or M205 SP Windrowers: 3.2.2 Engaging and Disengaging Header Safety Props –...
Page 289: Conditioner - Standard Header
MAINTENANCE AND SERVICING 4.10 Conditioner – Standard Header 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 If there is a problem with the performance of the conditioner, the conditioner roll bearings, feed roll bearings, and driveline U-joints may need to be inspected for signs of wear or damage.
Page 290 MAINTENANCE AND SERVICING 6. Inspect feed roll right bearing (A) for signs of wear, damage, grease, axial play, or radial play. The presence of grease indicates that the bearing seal has failed. Radial or axial play indicates that the bearing is worn out. If the bearing is suffering any form of diminished performance, replace the bearing.
Page 291: Feed Roll Drive Belt
MAINTENANCE AND SERVICING 11. Inspect roll timing gearbox bearings (A) for signs of wear, damage, grease, axial play, or radial play. The presence of grease indicates that the bearing seal has failed. Radial or axial play indicates that the bearing is worn out. If the bearing is suffering any form of diminished performance, replace the bearing.
Page 292 MAINTENANCE AND SERVICING 5. Release spring-lock quick-coupling yoke (B) on conditioner driveline (A). 6. Compress driveline (A) enough to remove the belt. Figure 4.197: Conditioner Driveline Installing Feed Roll Belt The feed roll belt will need to be installed on the drive and driven pulleys on the feed roll drive system. 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 293: Conditioner Drive Belt
MAINTENANCE AND SERVICING 6. Release the spring tension using a 1/2 in. ratchet or breaker bar at location (B). 7. Seat belt (A) in the grooves in the pulleys. 8. Slowly increase the spring tension on the belts. 9. Remove the ratchet or breaker bar. 10.
Page 294 MAINTENANCE AND SERVICING 4. Inspect drive belt (A). If the belt is cracked or otherwise damaged, replace it. 5. Ensure that jam nut (B) and adjuster nut (C) are tight. Figure 4.201: Conditioner Drive 6. Measure the length of belt tensioner spring (A). Ensure that spring length (B) is 17.5 mm (11/16 in.) in accordance with spring tension decal (C).
Page 295 MAINTENANCE AND SERVICING Removing Conditioner Drive Belt The conditioner drive belt is located inside the left driveshield and is tensioned with a spring tensioner. The tension on the belt will need to be relieved in order for the belt to be removed. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 296 MAINTENANCE AND SERVICING Installing Conditioner Drive Belt In order for the conditioner drive rolls to turn when the header is operating, the conditioner drive belt will need to be installed and its tension set. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 297 MAINTENANCE AND SERVICING 5. Check the position of bracket (B). Center-to- center distance (C) between drive pulley (D) and driven pulley (E) should be 723 mm (28 7/16 in.). If bracket (B) is not set correctly, loosen M16 hex head bolt and lock nuts (A) on pulley mount bracket (B), and adjust the position of bracket (B).
Page 298: 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 Remove the left or right driveshields as needed to service the header. WARNING To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured.
Page 299: Installing Driveshields
MAINTENANCE AND SERVICING 4. Pull outboard side (A) and inboard side (B) of the driveshield away from the rotary disc header. 1028564 Figure 4.211: Inboard and Outboard Half of Driveshield 4.11.2 Installing Driveshields Install and close the left and right driveshields before operating the header. CAUTION Do NOT operate the machine without the driveshields in place and secured.
Page 300 MAINTENANCE AND SERVICING 2. Secure the top of the outboard half of the driveshield using two washers (A), retaining pin (B), bolt (C), and the hex flange center lock nut. 3. Secure the front and rear of the inboard half of the driveshield using retaining pin (B), bolt (C), and the hex flange center lock nut.
Page 301: Electrical System
MAINTENANCE AND SERVICING 4.12 Electrical System The header’s electrical system is powered by the windrower. The electrical harness from the header connects to the windrower, supplying power to the hazard and signal lights. It also receives signals from the header speed sensor. 4.12.1 Maintaining Electrical System Proper maintenance of the electrical system helps prevent future problems.
Page 302 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 303: Replacing Header Disc Speed Sensor
MAINTENANCE AND SERVICING 4.12.3 Replacing Header Disc Speed Sensor If the rotary disc header’s disc speed sensor malfunctions or is damaged, it will need to be removed from the header drive system and replaced. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat.
Page 304 MAINTENANCE AND SERVICING 10. Adjust nuts (A) as needed to achieve 2–3 mm (1/16–1/8 in.) gap (B) between sensor (C) and the high end of pulley (D) (M1 Series Windrowers) or encoder (D) (M155E4 or M205 SP Windrowers). Ensure that the faces of the sensor and of the pulley are parallel.
Page 305: Hydraulics
MAINTENANCE AND SERVICING 4.13 Hydraulics Consult this section for general information on the hydraulic system. Detailed procedures for maintaining and repairing the hydraulic system are beyond the scope of the operator’s manual. 4.13.1 Checking Hydraulic Hoses and Lines Check hydraulic hoses and lines daily for signs of damage or leaks. Replace any damaged or leaking hoses immediately. Follow all applicable safety procedures while inspecting and maintaining the hydraulic system.
Page 307: Chapter 5: Options And Attachments
Chapter 5: Options and Attachments Consult this section to learn about additional hardware and configuration options for your machine. Contact your Dealer for more information. 5.1 Tall Crop Kit (Cutterbar Deflectors and Tall Crop Feed Plates) – MD #B6967, Standard Headers Only 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 308: Double Windrow Attachment
When paired with a R216 Rotary Disc Header, the double windrow attachment (DWA) is compatible with standard headers, but incompatible with grass seed headers. If using the DWA in heavy conditions, it is recommended that the R216 Rotary Disc Header cutterbar be configured to produce three crop streams. If using the DWA in light conditions, it is recommended that the R216 Rotary Disc Header cutterbar be configured to produce two crop streams.
Page 309: 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 310: 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 NOT compatible with M155E4 or M205 SP Windrowers.
Page 311: Adjustable Gauge Roller Kit - Md #B7334
OPTIONS AND ATTACHMENTS 5.5 Adjustable Gauge Roller Kit – MD #B7334 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 215972 Revision A...
Page 312: 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 313: 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 314: Adjustable Skid Shoes Kit - Md #B7333
OPTIONS AND ATTACHMENTS 5.8 Adjustable Skid Shoes Kit – MD #B7333 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 315: 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 317: Chapter 6: Troubleshooting
Chapter 6: Troubleshooting Refer to this table if you encounter problems while operating your machine. 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. 3.11.1 Cutting Height, page 122 pick up downed crop Header float too light, causing Refer to windrower operator’s...
Page 318 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 130 Roll gap too small in thick-stemmed •...
Page 319 TROUBLESHOOTING Problem Solution Refer to • Positioning Forming Shield Side Deflectors, page 137 Crop is bunched in windrow Adjust forming shields/baffle. • Positioning Rear Baffle Deflector Fins, page 139 • Adjusting Roll Gap – Steel Rolls, Rolls not crimping crop sufficiently Decrease roll gap.
Page 320: Mechanical Problems
TROUBLESHOOTING 6.2 Mechanical Problems Problem Solution Refer to Symptom: Excessive noise • Removing Disc Blades, page 204 Replace blade. Bent disc blade • Installing Disc Blades, page 206 • Check roll timing and adjust if Checking Roll Timing, page 134 Conditioner roll timing off necessary.
Page 321 Components, page 273 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. Symptom: Disc does not turn when engaging header Hoses not connected Connect hoses.
Page 322: 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 323: Chapter 7: Reference
Chapter 7: Reference The reference chapter provides additional information such as torque specifications and a unit conversion chart. 7.1 Torque Specifications The following tables provide torque values for various bolts, cap screws, and hydraulic fittings. Refer to these values only when no other torque value has been specified in a given procedure.
Page 324 REFERENCE Table 7.2 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) 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 10-1.5 12-1.75 Figure 7.2: Bolt Grades 14-2.0 16-2.0 20-2.5...
Page 325: Metric Bolt Specifications - Cast Aluminum
REFERENCE Table 7.4 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) 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 10-1.5 12-1.75 14-2.0 Figure 7.4: Bolt Grades 16-2.0 20-2.5 24-3.0...
Page 326: O-Ring Boss Hydraulic Fittings - Adjustable
REFERENCE 7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable The standard torque values are provided for adjustable hydraulic fittings. If a procedure specifies a different torque value for the same type and size of fitting found in this topic, refer to the value specified in the procedure instead. 1.
Page 327: O-Ring Boss Hydraulic Fittings - Non-Adjustable
REFERENCE Table 7.6 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable (continued) Torque Value Thread Size (in.) SAE Dash Size 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 328: O-Ring Face Seal Hydraulic Fittings
REFERENCE Table 7.7 O-Ring Boss (ORB) Hydraulic Fittings – Non-Adjustable (continued) Torque Value Thread Size (in.) SAE Dash Size lbf·ft (*lbf·in) 7/8–14 75–82 55–60 1 1/16–12 120–132 88–97 1 3/8–12 153–168 113–124 1 5/16–12 176–193 130–142 1 5/8–12 221–243 163–179 1 7/8–12 270–298 199–220...
Page 329: Tapered Pipe Thread Fittings
REFERENCE 6. Use three wrenches when assembling unions or joining two hoses together. 7. Verify the final condition of the fitting. Table 7.8 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value Thread Size (in.) Tube O.D. (in.) SAE Dash Size lbf·ft –...
Page 330 REFERENCE Table 7.9 Hydraulic Fitting Pipe Thread Tapered Pipe Thread Size Recommended TFFT Recommended FFFT 2–3 12–18 1/8–27 2–3 12–18 1/4–18 2–3 12–18 3/8–18 2–3 12–18 1/2–14 1.5–2.5 12–18 3/4–14 1.5–2.5 9–15 1–11 1/2 1.5–2.5 9–15 1 1/4–11 1/2 1.5–2.5 9–15 1 1/2–11 1/2 1.5–2.5...
Page 331: Conversion Chart
REFERENCE 7.2 Conversion Chart Both SI units (including metric) and US customary units (sometimes referred to as standard units) of measurement are used in this manual. A list of those units along with their abbreviations and conversion factors is provided here for your reference.
Page 333: Index
Index inspecting drive belt .......... 277 installing drive belt ..........280 accelerators............207 installing feed roll belt ........276 inspecting ............207 polyurethane rolls ..........131 installing............211 removing drive belt ........... 279 removing ............209 removing feed roll belt........275 adjustable skid shoes kit ........
Page 334 INDEX deflectors replacing header disc speed sensor ...... 287 cutterbar deflectors........... 141 replacing light fixture ......... 285 installing ............142 engine-forward removing............141 definition............23 side deflectors positioning on roll conditioner ......137 disc blades ............200 See also cutterbars feed roll drive belt tension inspecting ............
Page 335 ............287 headers float..............128 grass seed............151 knife maintenance and servicing ......... 163 definition............23 R216 Series Rotary Disc Header attaching ............96 recommended settings........122 transporting ............. 161 hex keys lights definition............23 replacing amber hazard/signal lights..... 285...
Page 336 INDEX attaching header – M205 SP Windrowers metric bolts torque specifications ......... 307 self-aligning hydraulic center-link......67 moisture ............. 159 without self-aligning hydraulic center-link .... 74 connecting hydraulics .......... 38 connecting hydraulics – M1170 Windrowers .... 50 connecting hydraulics – M155E4 SP Windrowers............
Page 337 INDEX hydraulic safety ............6 definition............23 maintenance safety ..........5 torque angles noise levels ............vi definition............23 procedures ............165 torque specifications..........307 safety alert symbols..........1 metric bolt specifications........307 safety sign decals ..........8 cast aluminum..........309 O-ring boss (ORB) hydraulic fittings – adjustable ..310 installing decals ..........8 O-ring boss (ORB) hydraulic fittings –...
Page 339: 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 340 CUSTOMERS M M a a c c D D o o n n . . c c o o m m DEALERS P P o o r r t t a a l l . . M M a a c c D D o o n n . . c c o o m m Trademarks of products are the marks of their respective manufacturers and/or distributors.

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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