MacDon R216 Unloading And Assembly Instructions
R216
Rotary Disc Header
Unloading and Assembly Instructions
214882 Revision C
Original Instruction
The harvesting specialists.
R216 SP Rotary Disc Header
1028977
Published May 2019.
© 2019 MacDon Industries, Ltd.
The information in this publication is based on the information available and in effect at the time of printing. MacDon
Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the
information in this publication. MacDon Industries, Ltd. reserves the right to make changes at any time without notice.
Introduction
This document describes the unloading, setup, and predelivery requirements for the MacDon R216 Rotary Disc Header.
To ensure your customers receive all of the performance and safety benefits from this product, carefully follow the
unloading and assembly procedure from the beginning through to completion.
Retain this instruction for future reference.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
This instruction is currently available in English only.
214882 i Revision C
Summary of Changes
At MacDon, we’re continuously making improvements, and occasionally these improvements affect product
documentation. The following list provides an account of major changes from the previous version of this document.
Internal Use
Section Summary of Change
—
• 3.1 Removing Shipping
Supports, page 9
• 3.4 Removing Shipping
Stands, page 21
Revision B was never published. Previous publication is revision A.
Edited steps and rearranged between the two topics. Audit
Only
—
3.2 Lowering the Header, page
18
3.5 Adjusting Rear Baffle
Deflectors, page 23
4.1 Assembling and Installing
Forming Shield, page 27
4.2 Routing Electrical Harness,
page 35
4.3 Attaching Disc Header, page
38
• 4.4 Connecting Rotary Disc
Header Hydraulics Using
Quick Couplers, page 45
• 4.5 Connecting Disc Header
Hydraulics Using Hard
Plumbing, page 47
5.2 Crop Dividers Kit, page 56
Added note alerting readers to the potential for contact between
the lowering chains and hazard light brackets on the header.
Updated illustrations.
Edited details about hardware installation during forming shield
installation. Updated illustrations.
Edited procedure to include additional detail about installing cable
ties securing the electrical harness on the windrower.
Edited attaching procedure to include steps for positioning header
supports for connection, and adjusting forming shield height
according to whether a Double Windrow Attachment (DWA) option
is included on the machine. Added step to secure header harness.
Edited steps to clarify relief valve orientation on the windrower.
Edited procedure to include additional detail for removing/installing
hardware during crop divider installation.
Audit
Audit
Audit
Audit
Audit
Audit
Audit
214882 ii Revision C
TABLE OF CONTENTS
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Signal Words .........................................................................................................................................1
1.2 General Safety .......................................................................................................................................2
1.3 Welding Precaution ................................................................................................................................4
1.4 Safety Signs ...........................................................................................................................................5
Chapter 2: Unloading the Header .............................................................................................................. 7
Chapter 3: Assembling the Header ............................................................................................................ 9
3.1 Removing Shipping Supports ....................................................................................................................9
3.1.1 Installing Adjustable Gauge Roller Kit..... .......................................................................................... 12
3.1.2 Installing Adjustable Skid Shoes Kit. ................................................................................................. 15
3.2 Lowering the Header............................................................................................................................. 18
3.3 Unpacking Hydraulic Hoses and Electrical Harness...................................................................................... 20
3.4 Removing Shipping Stands ..................................................................................................................... 21
3.5 Adjusting Rear Baffle Deflectors .............................................................................................................. 23
3.6 Unpacking Curtain ................................................................................................................................ 25
Chapter 4: Attaching Header to M1240 Windrower............................................................................... 27
4.1 Assembling and Installing Forming Shield.................................................................................................. 27
4.2 Routing Electrical Harness ...................................................................................................................... 35
4.3 Attaching Disc Header ........................................................................................................................... 38
4.4 Connecting Rotary Disc Header Hydraulics Using Quick Couplers .................................................................. 45
4.5 Connecting Disc Header Hydraulics Using Hard Plumbing ............................................................................ 47
4.6 Restoring Float for Disc Header ............................................................................................................... 50
4.7 Calibrating Windrower Knife Drive on the Harvest Performance Tracker Display .............................................. 52
Chapter 5: Installing Options.................................................................................................................... 55
5.1 Electric Remote Baffle Kit....................................................................................................................... 55
5.2 Crop Dividers Kit................................................................................................................................... 56
5.3 Adjustable Gauge Roller Kit .................................................................................................................... 58
5.4 Adjustable Skid Shoes Kit ....................................................................................................................... 59
Chapter 6: Lubricating the Disc Header ................................................................................................... 61
6.1 Lubrication Locations ............................................................................................................................ 62
Chapter 7: Performing Predelivery Checks.............................................................................................. 65
7.1 Conditioner Drive Belt ........................................................................................................................... 65
7.1.1 Inspecting Conditioner Drive Belt.................................................................................................... 65
7.1.2 Adjusting Conditioner Drive Belt ..................................................................................................... 66
214882 iii Revision C
TABLE OF CONTENTS
7.2 Header Float .. ...................................................................................................................................... 68
7.2.1 Checking Float............................................................................................................................. 68
7.2.2 Setting the Float .......................................................................................................................... 69
7.3 Roll Timing .......................................................................................................................................... 70
7.3.1 Adjusting Roll Timing .................................................................................................................... 70
7.4 Roll Gap .............................................................................................................................................. 74
7.4.1 Adjusting Roll Gap ........................................................................................................................ 74
7.5 Roll Tension......................................................................................................................................... 75
7.5.1 Checking Roll Tension ................................................................................................................... 75
7.5.2 Adjusting Roll Tension................................................................................................................... 76
7.6 Hanging Drums .................................................................................................................................... 77
7.6.1 Checking and Adjusting Hanging Drum Drive..................................................................................... 77
7.7 Feed Roll Drive..................................................................................................................................... 78
7.7.1 Checking and Adjusting Feed Roll Drive............................................................................................ 78
7.8 Checking and Adding Conditioner Roll Timing Gearbox Oil ........................................................................... 79
7.9 Checking and Adding Oil in Header Drive Gearbox ...................................................................................... 80
7.10 Checking and Adding Lubricant in Cutterbar ............................................................................................ 82
7.11 Checking Lights................................................................................................................................... 85
7.12 Checking Manuals ............................................................................................................................... 86
7.13 Running up the Header ........................................................................................................................ 87
Chapter 8: Reference................................................................................................................................ 89
8.1 Recommended Lubricants ... ................................................................................................................... 89
8.2 Torque Specifications ............................................................................................................................ 90
8.2.1 Metric Bolt Specifications.. ............................................................................................................ 90
8.2.2 Metric Bolt Specifications Bolting into Cast Aluminum ........................................................................ 92
8.2.3 O-Ring Boss Hydraulic Fittings – Adjustable ...................................................................................... 93
8.2.4 O-Ring Boss Hydraulic Fittings – Non-Adjustable ................................................................................ 95
8.2.5 O-Ring Face Seal Hydraulic Fittings .................................................................................................. 96
8.2.6 Tapered Pipe Thread Fittings.......................................................................................................... 97
8.3 Conversion Chart .................................................................................................................................. 98
8.4 Definitions .......................................................................................................................................... 99
Predelivery Checklist .............................................................................................................................. 101
214882 iv Revision C
Chapter 1: Safety
1.1 Signal Words
Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words,
IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be
used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may be used
to alert against unsafe practices.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.
214882 1 Revision C
SAFETY
1.2 General Safety
CAUTION
The following general farm safety precautions should be part of
your operating procedure for all types of machinery.
Protect yourself.
• When assembling, operating, and servicing machinery, wear
all protective clothing and personal safety devices that could
be necessary for job at hand. Do NOT take chances. You may
need the following:
• Hard hat
• Protective footwear with slip-resistant soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• Respirator or filter mask
• Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection devices
such as earmuffs or earplugs to help protect against loud
noises.
1000004
Figure 1.1: Safety Equipment
Figure 1.2: Safety Equipment
• Provide a first aid kit in case of emergencies.
• Keep a properly maintained fire extinguisher on the machine.
Be familiar with its proper use.
• Keep young children away from machinery at all times.
• Be aware that accidents often happen when the operator is
tired or in a hurry. Take time to consider safest way. NEVER
ignore warning signs of fatigue.
Figure 1.3: Safety Equipment
214882 2 Revision C
1000005
1010391
1000007
1000008
1000009
SAFETY
• Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as scarves or bracelets.
• Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate
independently of shaft and can telescope freely.
• Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.
• Keep hands, feet, clothing, and hair away from moving parts.
NEVER attempt to clear obstructions or objects from a
machine while engine is running.
• Do NOT modify machine. Unauthorized modifications may
impair machine function and/or safety. It may also shorten
machine’s life.
Figure 1.4: Safety around Equipment
• To avoid injury or death from unexpected startup of machine,
ALWAYS stop the engine and remove the key from the
ignition before leaving the operator’s seat for any reason.
• Keep service area clean and dry. Wet or oily floors are
slippery. Wet spots can be dangerous when working with
electrical equipment. Be sure all electrical outlets and tools
are properly grounded.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff on a hot engine is a
fire hazard. Do NOT allow oil or grease to accumulate on
service platforms, ladders, or controls. Clean machines before
storage.
• NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
• When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
Figure 1.5: Safety around Equipment
Figure 1.6: Safety around Equipment
214882 3 Revision C
SAFETY
1.3 Welding Precaution
Welding should never be attempted on the header while it is connected to a windrower.
WARNING
Severe damage to sensitive, expensive electronics can result from welding on the header while it is connected to the
windrower. It can be impossible to know what effect high current could have with regard to future malfunctions or
shorter lifespan. It is very important that welding on the header is not attempted while the header is connected to the
windrower.
If you need to do any welding on the header, it should first be disconnected and removed from the windrower.
If it is unfeasible to disconnect the header from the windrower before attempting welding,for welding precautions detailing
all electrical components that must be disconnected first for safe welding.
214882 4 Revision C
1.4 Safety Signs
1000694
• Keep safety signs clean and legible at all times.
• Replace safety signs that are missing or illegible.
• If original part on which a safety sign was installed is
replaced, be sure the repair part displays the current
safety sign.
SAFETY
Figure 1.7: Operator’s Manual Decal
214882 5 Revision C
Chapter 2: Unloading the Header
1013855
A
B
C
1028160
WARNING
To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area.
IMPORTANT:
Equipment used for unloading the header must meet or exceed
the requirements specified below. Using inadequate equipment
may result in chain breakage, machine damage, or the vehicle
tipping.
NOTE:
Forklifts are normally rated for a load located 610 mm (24 in.)
ahead of the back end of the forks. To obtain the forklift
capacity at 1220 mm (48 in.), check with your forklift distributor.
Figure 2.1: Minimum Lifting Capacity
A - Load Center of Gravity
B - Load Center 1220 mm (48 in.) from Back of Forks
C - Minimum Fork Length 1981 mm (78 in.)
Table 2.1 Lifting Vehicle
Minimum Capacity
Minimum Fork Length
1. Remove the hauler’s tie-down straps and chains.
WARNING
Be sure forks are secure before moving away from load. Stand
clear when lifting.
2. Approach the rotary disc header from its underside and
slide the forks under the lifting framework as far as
possible.
IMPORTANT:
If the load is two units wide, take care to avoid contacting
the other machine.
3. Raise the rotary disc header off the deck.
3630 kg (8000 lb.)
198 cm (78 in.)
Figure 2.2: Lifting Rotary Disc Header off Trailer
214882 7 Revision C
UNLOADING THE HEADER
4. Back up until the rotary disc header clears the trailer, and
slowly lower it to 150 mm (6 in.) from the ground.
5. Take the rotary disc header to the storage or setup area.
6. Set the rotary disc header down on secure, level ground. Do
NOT lower the header into working position.
7. Check for shipping damage and missing parts.
1028097
Figure 2.3: Moving Disc Header with Forklift
214882 8 Revision C
Chapter 3: Assembling the Header
1027916
A
A
A
A
B
B
B
Follow each procedure in this chapter in order.
3.1 Removing Shipping Supports
To remove the shipping supports from the cutterbar side of the header, follow these steps:
1. Remove four bolts and nuts (A) from each yellow shipping
support (B) and remove the four supports from the
disc header.
Figure 3.1: Shipping Supports
214882 9 Revision C
ASSEMBLING THE HEADER
2. Remove nuts and bolts (A) from the yellow channel and
header supports.
3. Remove yellow braces (B) from the header.
4. Remove four nuts and bolts (A) holding yellow channel (B)
in place against the plates on both sides of the header.
5. Remove channel (B) from the header.
A
A
A
B
A
B
A
A
Figure 3.2: Shipping Stand Brace – Right Side Shown,
Left Side Opposite
1029718
B
A
A
A
B
B
A
A
Figure 3.3: Shipping Channel – Right Side Shown, Left
Side Opposite
214882 10 Revision C
1029724
1029728
A
A
A
A
A
B
B
ASSEMBLING THE HEADER
6. Remove three bolts and washers (A) holding each yellow
plate (B) onto the header supports.
7. Remove plates (B) from the header.
8. Each header is shipped with either gauge rollers or skid
shoes (but not both). Refer to the relevant installation
procedure listed below:
• 3.1.1 Installing Adjustable Gauge Roller Kit, page 12
• 3.1.2 Installing Adjustable Skid Shoes Kit, page 15
Figure 3.4: Plates
214882 11 Revision C
ASSEMBLING THE HEADER
3.1.1 Installing Adjustable Gauge Roller Kit
Follow these steps and install the Adjustable Gauge Roller kit (MD #B6666) while the header is still set on the ground on its
shipping stands:
NOTE:
If you are installing the Adjustable Skid Shoe kit (MD #B6667), refer to 3.1.2 Installing Adjustable Skid Shoes Kit, page 15.
1. Remove the gauge rollers from the shipping crate and
remove lynch pin (A) and bar (B) from each gauge roller (C).
Retain the bars and lynch pins.
B
C
A
C
B
Figure 3.5: Gauge Rollers
1028056
214882 12 Revision C
1028810
A
A
B
B
C
F
D
E
E
F
C
1028035
A
B
C
C
D
ASSEMBLING THE HEADER
2. Remove and retain clevis pins (A) and lynch pins (B) from
holes (C) on both ends of gauge roller (D).
3. Align holes (C) with holes (E) in the header’s support
bracket (F).
4. Secure gauge roller (A) to support bracket (B) using
retained clevis pins (C) and lynch pins (D).
NOTE:
Insert clevis pins (C) from outside gauge roller (A) and
secure with lynch pins (D) from inside gauge roller (A).
Figure 3.6: Gauge Roller Assembly
Figure 3.7: Clevis Pins and Lynch Pins
214882 13 Revision C
ASSEMBLING THE HEADER
5. Fully insert retained bar (A) into slot (B) from the inboard
side of the gauge roller.
B
6. Secure bar (A) with retained lynch pin (B).
7. Repeat the installation on the opposite side of the
disc header.
8. Continue to 3.2 Lowering the Header, page 18.
A
1028033
Figure 3.8: Bar and Support Bracket
A
B
1028030
Figure 3.9: Bar and Lynch Pin
214882 14 Revision C
1028048
A
B
C
D
A
B
D
C
ASSEMBLING THE HEADER
3.1.2 Installing Adjustable Skid Shoes Kit
Follow these steps and install the Adjustable Skid Shoes kit (MD #B6667) while the disc header is still set on the ground on
its shipping stands:
NOTE:
If you are installing the Adjustable Gauge Roller kit (MD #B6666), refer to 3.1.1 Installing Adjustable Gauge Roller Kit, page
12.
1. Remove the skid shoes from the shipping crate and remove
bolts (A), washers (B), spacers (C), and nuts (D). Retain the
hardware.
Figure 3.10: Skid Shoe
214882 15 Revision C
A
B
C
D
E
F
F
E
D
C
ASSEMBLING THE HEADER
2. Secure the back of skid shoe (A) to bracket (B) in two
locations with retained bolts (C), washers (D), spacers (E),
and nuts (F).
NOTE:
Bolt heads should be set outside the skid shoes.
3. Position skid shoe (A) on bracket (B) in fully raised position
(as shown) by aligning skid shoe mounting holes (C) with
bracket mounting holes (D).
Figure 3.11: Skid Shoe
D
B
C
D
A
C
Figure 3.12: Fully Raised Alignment Position
1028834
1027935
214882 16 Revision C
1027927
A
A
B
1027925
A
B
A
ASSEMBLING THE HEADER
4. Insert clevis pins (A) from outside the skid shoe (B).
5. Secure each clevis pin (A) with a lynch pin (B).
NOTE:
Lynch pins should be inserted in the clevis pin from inside
the skid shoe.
6. Repeat the installation on the opposite side of the
disc header.
Figure 3.13: Clevis Pins
7. Continue to 3.2 Lowering the Header, page 18.
Figure 3.14: Clevis Pin and Lynch Pin
214882 17 Revision C
ASSEMBLING THE HEADER
3.2 Lowering the Header
Complete the following steps to lower the header into working position after it has been lifted off its shipping trailer and
set down on the ground.
CAUTION
Ensure spreader bar is secured to the forks so that it cannot slide off the forks or towards the mast as the header is
lowered to the ground.
Table 3.1 Lifting Vehicle
Chain Type
Minimum Working Load
1. Place wood blocks (A) at a distance of 42 cm (16 1/2 in.) (B)
on the outboard side of each shipping stand (C).
NOTE:
Wood blocks should be 2 x 4 in. and 1–1.5 m (3–5 ft.) in
length.
Overhead lifting quality (1/2 in.)
2270 kg (5000 lb.)
A
B
C
Figure 3.15: Block Placement
A
B
C
1028066
214882 18 Revision C
1028261
A
B
B
C
1028609
A
B
B
ASSEMBLING THE HEADER
2. Attach spreader bar (A) to forks.
IMPORTANT:
Length of spreader bar must be approximately 457 cm
(15 ft.).
3. Approach the header from its underside with the forklift.
4. Attach chains with hooks to the spreader bar (A) and hook
into shipping brackets (B) on both sides of the disc header.
CAUTION
Stand clear when lowering the disc header.
IMPORTANT:
Chain length must be sufficient to provide a minimum
clearance (C) of 1219 mm (48 in.) between the disc header
and the spreader bar.
IMPORTANT:
Do NOT attach chain hooks to the hazard light standards.
5. Raise forks until lift chains are fully tensioned.
Figure 3.16: Spreader Bar Attached to Disc Header
6. Back up the forklift SLOWLY, and lower the disc header (A)
into working position on the wooden blocks (B) placed in
Step 1, page 18.
NOTE:
Watch out for contact between hazard light brackets and
the lowering chains while the header is being lowered. Take
care to avoid damaging the lights and brackets.
7. Remove chains from the header.
Figure 3.17: Lowering Disc Header to the Ground
214882 19 Revision C
ASSEMBLING THE HEADER
3.3 Unpacking Hydraulic Hoses and Electrical Harness
Follow these steps to unpack the hydraulic hoses and electrical harness.
1. Remove shipping wire securing hose ends (A) to secured
hoses (B) and remove all packing foam from the hose ends.
NOTE:
Packing foam not shown in illustration at right.
2. Remove packing foam from hose support (C).
NOTE:
Packing foam not shown in illustration at right.
Figure 3.18: Hydraulic Hose Bundle in Shipping
Position
3. Remove shipping wire cross ties (A) securing hoses (B) to
center-link (C) near shipping stands (D), and pull the hoses
out from under the center-link.
NOTE:
Shipping wire cross ties not shown in illustration at right.
A
C
B
C
1028196
B
E
4. Remove shipping wire (E) from center-link (C) and move
hoses (B) away from the center-link. Rest hoses (B) on top
of the header.
5. Remove shipping wire and remove coiled electrical
harness (A) from the center-link (B). Place the harness in a
safe and clean spot until it’s time to install on an M1240
Windrower.
A
D
1028227
Figure 3.19: Hydraulic Hose Bundle in Shipping
Position
B
A
1028228
Figure 3.20: Center-Link
214882 20 Revision C
1028173
A
B
C
1028176
A
A
B
B
A
A
B
B
C
C
A
A
B
B
A
B
A
B
ASSEMBLING THE HEADER
3.4 Removing Shipping Stands
Complete the following steps to remove the remaining shipping stands from the header.
NOTE:
This procedure must be completed on both sides of the header near the forming shields.
1. Remove nut (A) from the outboard side of the right header
boot and bolt (B) from the inboard side of the right
shipping stand (C). Repeat on the opposite side of the
header.
Figure 3.21: Shipping Stand – Right Side Shown, Left
Side Opposite
2. Remove four nuts (A) and bolts (B) from top of shipping
stands (C) and remove the shipping stands from the header.
Figure 3.22: Shipping Stand
214882 21 Revision C
ASSEMBLING THE HEADER
3. Remove and retain bolts (A) and remove shipping plate (B).
Discard plate (B) and reinstall bolts (A) on the header.
Repeat for the other side of the header.
B
A
A
1028182
Figure 3.23: Shipping Plate – Right Side Shown, Left
Side Opposite
214882 22 Revision C
1028618
A
B
A
A
A
A
A
C
1028619
A
B
C
1029740
A
B
C
ASSEMBLING THE HEADER
3.5 Adjusting Rear Baffle Deflectors
Four rear baffle deflector fins are located under the baffle. The baffle and its deflectors require adjustment from shipping
configuration to field position.
To adjust the rear baffle and deflector fins, follow these steps:
1. Remove and retain hardware (A) securing deflector (B) to
rear baffle (C). Remove and retain deflector (B) from the
header. Repeat on the opposite side of the header.
NOTE:
There are three sets of hardware (A) on the baffle, but only
two sets hold deflector (B) in place in shipping position.
Ensure all three sets of hardware (A) are removed and
retained.
Figure 3.24: Deflector and Rear Baffle — View of
Deflector Underside, Right Side of the Header
2. Remove pin (A) from baffle handle (B), and adjust the rear
baffle by placing handle (B) in center position on baffle
bracket (C).
3. Replace pin (A) in baffle handle (B) to secure the handle in
fully raised position on baffle bracket (C).
Figure 3.25: Baffle Handle and Baffle Bracket
Figure 3.26: Baffle Handle
214882 23 Revision C
ASSEMBLING THE HEADER
4. Turn over deflector (A) and place on rear baffle (B) and
between fixed deflector plate (C) and outer plate (D).
5. Loosely secure deflector (A) in place with retained
hardware (E) in three locations. Do NOT tighten hardware.
Repeat on the opposite side of the header.
6. Adjust the placement of deflector (A) as far inboard as
possible so that it contacts fixed deflector plate (C) welded
in place on the header. Tighten hardware (E) once deflector
is properly placed. Repeat on the opposite side of the
header.
E
D
E
E
A
B
C
1028813
Figure 3.27: Deflector and Rear Baffle
214882 24 Revision C
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