MacDon R216 SP Operator's Manual

R216 SP

Rotary Disc Header

Operator’s Manual

214880 Revision A

Original Instruction

The harvesting specialists.

R216 SP Series Rotary Disc Header

Published April 2019.

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 SP 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 the exact type of self­propelled vehicle used to power the R216 SP Rotary Disc Header.

Introduction

This instructional manual contains safety, operating, and maintenance procedures for the MacDon R216 SP Rotary Disc
Header. The rotary disc header when attached to a MacDon M1240 Windrower, is designed to cut, condition, and lay a
wide variety of grasses and hay crops in windrows.

Carefully read all the material provided before attempting to unload, assemble, or use the machine.

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.

Use the Table of Contents and the Index to guide you to specific topics. Study the Table of Contents to familiarize yourself
with how the material is organized. Keep this manual handy for frequent reference and to pass on to new Operators or
Owners. Call your Dealer if you need assistance, information, or additional copies of this manual.

When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant
MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous
situation.

MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual. A copy
of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided to you by your
Dealer. Damage resulting from any of the following conditions will void the warranty:

• Accident

• Misuse

• Abuse

• Improper maintenance or neglect

• Abnormal or extraordinary use of the machine

• Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions

Conventions

The following conventions are used in this document:

• Right and left are determined from the operator’s position. The front of the rotary disc header faces the crop.

• Unless otherwise noted, use the standard torque values provided in this manual.

Store the operator’s manual and the parts catalog in the plastic
manual case (A) on the left fixed deflector.

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).

Manual Storage Case

214880 i Revision A

Serial Number

Record the serial number and model year of the header in the spaces provided below.

Header model:

Serial number:

Model year:

The serial number plate (A) is located on the left side of the
header, on top of the end panel.

R216 SP Disc Mower

Figure 1: Serial Number Location

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TABLE OF CONTENTS

Introduction ................................................................................................................................................i

Serial Number............................................................................................................................................. ii

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

1.8 Locating Safety Decals ............................................................................................................................. 9

1.9 Understanding Safety Signs .................................................................................................................... 11

Chapter 2: Product Overview................................................................................................................... 13

2.1 Specifications. . ..................................................................................................................................... 13

2.2 Component Identification ...................................................................................................................... 15

2.3 Definitions .......................................................................................................................................... 17

Chapter 3: Operation................................................................................................................................ 19

3.1 Break-In Period .................................................................................................................................... 19

3.2 Daily Start-Up Check ............................................................................................................................. 20

3.3 Engaging and Disengaging Header Safety Props ......................................................................................... 22

3.3.1 Engaging and Disengaging Header Safety Props – M1240 Windrower .................................................... 22

3.4 Attaching Header to M1240 Windrower ................................................................................................... 24

3.4.1 Attaching Rotary Disc Header ......................................................................................................... 24

Connecting Rotary Disc Header Hydraulics and Electrical – M1240 Windrowers ..................................... 29

Connecting Rotary Disc Header Hydraulics Using Quick Couplers......................................................... 32

3.5 Detaching Header from M1240 Windrower ............................................................................................... 35

3.5.1 Detaching Rotary Disc Header from M1240 Windrower ...................................................................... 35

3.6 Driveshields. .. ...................................................................................................................................... 39

3.6.1 Opening Driveshields .................................................................................................................... 39

3.6.2 Closing Driveshields...................................................................................................................... 41

3.7 Cutterbar Curtain ................................................................................................................................. 42

3.7.1 Opening Cutterbar Curtain............................................................................................................. 42

3.7.2 Closing Cutterbar Curtain .............................................................................................................. 43

3.8 Header Settings.................................................................................................................................... 44

3.8.1 Cutting Height ............................................................................................................................. 44

3.8.2 Adjusting Cutterbar Angle.............................................................................................................. 45

3.8.3 Header Float ............................................................................................................................... 45

3.8.4 Ground Speed ............................................................................................................................. 46

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TABLE OF CONTENTS

3.9 Reconfiguring Cutterbar Crop Stream ....................................................................................................... 47

3.9.1 Changing R216 SP Cutterbar Crop Stream Configuration ..................................................................... 48

3.10 Conditioner ....................................................................................................................................... 49

3.10.1 Roll Gap.................................................................................................................................... 49

Adjusting Roll Gap ...................................................................................................................... 49

3.10.2 Roll Tension . ............................................................................................................................. 50

Adjusting Roll Tension ................................................................................................................. 50

3.10.3 Roll Timing ................................................................................................................................ 51

Checking Roll Timing ................................................................................................................... 51

Adjusting Roll Timing ................................................................................................................... 51

3.10.4 Adjusting Forming Shields – Roll Conditioner................................................................................... 54

Positioning Forming Shield Side Deflectors – Roll Conditioner ............................................................. 54

Positioning Rear Baffle – Roll Conditioner ....................................................................................... 55

3.11 Haying Tips ........................................................................................................................................ 58

3.11.1 Curing ...................................................................................................................................... 58

3.11.2 Topsoil Moisture ........................................................................................................................ 58

3.11.3 Weather and Topography ............................................................................................................ 58

3.11.4 Windrow Characteristics .............................................................................................................. 59

3.11.5 Driving on Windrow .................................................................................................................... 59

3.11.6 Using Chemical Drying Agents ...................................................................................................... 59

3.12 Transporting the Header ...................................................................................................................... 60

Chapter 4: Maintenance and Servicing.................................................................................................... 61

4.1 Preparing Machine for Servicing .............................................................................................................. 61

4.2 Recommended Safety Procedures ........................................................................................................... 62

4.3 Maintenance Requirements ................................................................................................................... 64

4.3.1 Maintenance Schedule/Record ....................................................................................................... 64

4.3.2 Break-In Inspections ..................................................................................................................... 66

4.3.3 Preseason Servicing...................................................................................................................... 66

4.3.4 End-of-Season Servicing ... . ............................................................................................................ 67

4.4 Lubrication .......................................................................................................................................... 68

4.4.1 Greasing Procedure ...................................................................................................................... 68

4.4.2 Lubrication Locations.................................................................................................................... 69

4.5 Cutterbar System.................................................................................................................................. 71

4.5.1 Lubricating Cutterbar.................................................................................................................... 71

Checking and Adding Cutterbar Lubricant ....................................................................................... 71

Draining the Cutterbar................................................................................................................. 74

Filling Lubricant into a Repaired Cutterbar ...................................................................................... 74

4.5.2 Maintaining Cutterbar Discs ........................................................................................................... 75

Inspecting Cutterbar Discs ............................................................................................................ 76

Removing Cutterbar Discs ............................................................................................................ 77

Installing Cutterbar Discs.............................................................................................................. 78

4.5.3 Replacing Cutterbar Spindles.......................................................................................................... 80

Removing Cutterbar Spindles ........................................................................................................ 81

Installing Cutterbar Spindles . ... ..................................................................................................... 83

4.5.4 Maintaining Discblades ................................................................................................................. 87

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TABLE OF CONTENTS

Inspecting Discblades .................................................................................................................. 87

Inspecting Discblade Hardware ..................................................................................................... 89

Removing Discblades................................................................................................................... 90

Installing Discblades .................................................................................................................... 92

4.5.5 Maintaining Accelerators............................................................................................................... 93

Inspecting Accelerators................................................................................................................ 93

Removing Accelerators ................................................................................................................ 94

Installing Accelerators ................................................................................................................. 96

4.5.6 Maintaining Rock Guards............................................................................................................... 97

Inspecting Rock Guards................................................................................................................ 97

Removing Rock Guards . .. . ............................................................................................................ 98

Installing Rock Guards ................................................................................................................. 99

4.5.7 Maintaining Drums..................................................................................................................... 100

Inspecting Drums...................................................................................................................... 100

Removing Suspended Drums ...................................................................................................... 102

Installing Suspended Drums........................................................................................................ 104

Removing Left Driven Drum and Driveline ..................................................................................... 105

Installing Left Driven Drum and Driveline ...................................................................................... 107

Removing Right Driven Drum and Driveline ................................................................................... 110

Installing Right Driven Drum and Driveline .................................................................................... 113

4.5.8 Replacing Cutterbar Spindle Shear Pin ........................................................................................... 116

Removing Cutterbar Spindle Shear Pin.......................................................................................... 117

Installing Cutterbar Spindle Shear Pin ........................................................................................... 121

4.6 Servicing Conditioner Roll Timing Gearbox ............................................................................................. 124

4.6.1 Checking and Changing Conditioner Roll Timing Gearbox Oil.............................................................. 124

4.7 Servicing Header Drive Gearbox ............................................................................................................ 127

4.7.1 Checking Header Drive Gearbox Oil ............................................................................................... 127

4.7.2 Changing Header Drive Gearbox Oil............................................................................................... 129

4.8 Cutterbar Curtain ............................................................................................................................... 130

4.8.1 Inspecting Cutterbar Curtain ..... ................................................................................................... 130

4.8.2 Removing Cutterbar Curtain......................................................................................................... 131

4.8.3 Installing Cutterbar Curtain .......................................................................................................... 132

4.9 Conditioner ....................................................................................................................................... 133

4.9.1 Inspecting Conditioner ................................................................................................................ 133

Conditioner Drive Belt .. ............................................................................................................. 134

Changing the Conditioner........................................................................................................... 138

4.10 Replacing Driveshields ....................................................................................................................... 146

4.10.1 Removing Driveshields .............................................................................................................. 146

4.10.2 Installing Driveshields. ............................................................................................................... 147

4.11 Electrical System............................................................................................................................... 149

4.11.1 Maintaining Electrical System ..................................................................................................... 149

4.11.2 Replacing Amber Hazard/Signal Light........................................................................................... 149

4.11.3 Replacing Header Disc Speed Sensor............................................................................................ 149

4.12 Hydraulics ....................................................................................................................................... 151

4.12.1 Checking Hydraulic Hoses and Lines............................................................................................. 151

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TABLE OF CONTENTS

Chapter 5: Options and Attachments.................................................................................................... 153

5.1 Performance Kits ................................................................................................................................ 153

5.1.1 Tall Crop Divider Kit .................................................................................................................... 153

5.1.2 Adjustable Gauge Roller Kit.......................................................................................................... 153

5.1.3 Adjustable Skid Shoes Kit............................................................................................................. 154

5.1.4 Electric Remote Baffle Kit . ........................................................................................................... 154

Chapter 6: Troubleshooting.................................................................................................................... 155

6.1 Performance Problems ........................................................................................................................ 155

6.2 Mechanical Problems .......................................................................................................................... 158

Chapter 7: Reference.............................................................................................................................. 161

7.1 Torque Specifications .......................................................................................................................... 161

7.1.1 Metric Bolt Specifications ............................................................................................................ 161

7.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ...................................................................... 163

7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable .................................................................................... 164

7.1.4 O-Ring Boss Hydraulic Fittings – Non-Adjustable .............................................................................. 166

7.1.5 O-Ring Face Seal Hydraulic Fittings ................................................................................................ 167

7.1.6 Tapered Pipe Thread Fittings........................................................................................................ 168

7.2 Conversion Chart ................................................................................................................................ 169

Index........................................................................................................................................................ 171

Recommended Lubricants ...................................................................................................................... 175

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Chapter 1: Safety

1.1 Safety Alert Symbols

This safety alert symbol indicates important safety messages in
this manual and on safety signs on the machine.

This symbol means:

• ATTENTION!

• BECOME ALERT!

• YOUR SAFETY IS INVOLVED!

Carefully read and follow the safety message accompanying this
symbol.

Why is safety important to you?

• Accidents disable and kill

• Accidents cost

• Accidents can be avoided

Figure 1.1: Safety Symbol

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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. 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.

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SAFETY

1.3 General Safety

CAUTION

The following general farm safety precautions should be part of
your operating procedure for all types of machinery.

Protect yourself.

• When assembling, operating, and servicing machinery, wear
all protective clothing and personal safety devices that could
be necessary for 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.

• Provide a first aid kit in case of emergencies.

• Keep a properly maintained fire extinguisher on the machine.

Be familiar with its proper use.

Figure 1.2: Safety Equipment

Figure 1.3: Safety Equipment

• 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 1.4: Safety Equipment

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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 1.5: 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 1.6: Safety around Equipment

Figure 1.7: Safety around Equipment

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SAFETY

1.4 Maintenance Safety

To ensure your safety while maintaining machine:

• Review operator’s manual and all safety items before
operation and/or maintenance of machine.

• Place all controls in Neutral, stop the engine, set the park
brake, remove the ignition key, and wait for all moving parts
to stop before servicing, adjusting, and/or repairing.

• Follow good shop practices:

– Keep service areas clean and dry

– Be sure electrical outlets and tools are properly grounded

– Keep work area well lit

• Relieve pressure from hydraulic circuits before servicing

and/or disconnecting machine.

• Make sure all components are tight and that steel lines,
hoses, and couplings are in good condition before applying
pressure to hydraulic systems.

Figure 1.8: Safety around Equipment

• Keep hands, feet, clothing, and hair away from all moving
and/or rotating parts.

• Clear area of bystanders, especially children, when carrying
out any maintenance, repairs, or adjustments.

• Install transport lock or place safety stands under frame
before working under machine.

• If more than one person is servicing machine at same time,
be aware that rotating a driveline or other mechanically­driven component by hand (for example, accessing a
lubricant fitting) will cause drive components in other areas
(belts, pulleys, and knives) to move. Stay clear of driven
components at all times.

• Wear protective gear when working on machine.

• Wear heavy gloves when working on knife components.

Figure 1.9: Equipment NOT Safe for Children

Figure 1.10: Safety Equipment

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SAFETY

1.5 Hydraulic Safety

• Always place all hydraulic controls in Neutral before
dismounting.

• Make sure that all components in hydraulic system are kept
clean and in good condition.

• Replace any worn, cut, abraded, flattened, or crimped hoses
and steel lines.

• Do NOT attempt any makeshift repairs to hydraulic lines,
fittings, or hoses by using tapes, clamps, cements, or welding.
The hydraulic system operates under extremely high­pressure. Makeshift repairs will fail suddenly and create
hazardous and unsafe conditions.

• Wear proper hand and eye protection when searching for
high-pressure hydraulic leaks. Use a piece of cardboard as a
backstop instead of hands to isolate and identify a leak.

• If injured by a concentrated high-pressure stream of
hydraulic fluid, seek medical attention immediately. Serious
infection or toxic reaction can develop from hydraulic fluid
piercing the skin.

Figure 1.11: Testing for Hydraulic Leaks

• Make sure all components are tight and steel lines, hoses,
and couplings are in good condition before applying pressure
to a hydraulic system.

Figure 1.12: Hydraulic Pressure Hazard

Figure 1.13: Safety around Equipment

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SAFETY

1.6 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 an Operator needs to do any welding on the header, it should first be disconnected and removed from the windrower.

If it is unfeasible to disconnect the header from the windrower before attempting welding, contact your MacDon Dealer for
welding precautions detailing all electrical components that must be disconnected first for safe welding.

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SAFETY

1.7 Safety Signs

• Keep safety signs clean and legible at all times.

• Replace safety signs that are missing or illegible.

• If original part on which a safety sign was installed is

replaced, be sure the repair part displays the current
safety sign.

• Replacement safety signs are available from Dealer Parts
Department.

1.7.1 Installing Safety Decals

1. Clean and dry installation area.

Figure 1.14: Operator’s Manual Decal

2. Decide on exact location before you remove decal backing paper.

3. Remove smaller portion of split backing paper.

4. Place decal in position and slowly peel back remaining paper, smoothing decal as it is applied.

5. Prick small air pockets with a pin and smooth out.

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1.8 Locating Safety Decals

Figure 1.15: Safety Sign Decal Locations – Top View

SAFETY

A - MD #307746 B - MD #113482
C - MD #166832 D - MD #190546

Figure 1.16: Safety Sign Decals

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Figure 1.17: Safety Sign Decal Locations – Rear View

SAFETY

A - MD #190546 B - MD #325070 C - Reflector

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SAFETY

1.9 Understanding Safety Signs

NOTE:

This is a general list of safety sign definitions and the decals listed may not necessarily be applicable to your machine.

MD #113482

General hazard pertaining to machine operation and servicing.

CAUTION

• Read the operator’s manual, and follow all safety
instructions. If you do not have a manual, obtain one from
your Dealer.

• Do NOT allow untrained persons to operate the machine.

• Review safety instructions with all Operators annually.

• Ensure that all safety signs are installed and legible.

• Make certain everyone is clear of machine before starting

engine, and during operation.

• Keep riders off the machine.

Figure 1.18: MD #113482

• Keep all shields in place and stay clear of moving parts.

• Disengage drive, put transmission in Neutral, and wait for all
movement to stop before leaving operator’s position.

• Shut off engine and remove key from ignition before

servicing, adjusting, lubricating, cleaning, or unplugging
machine.

• Engage locks to prevent lowering of self-propelled rotary
disc header before servicing in the raised position.

• Use slow moving vehicle emblem and flashing warning lights
when operating on roadways unless prohibited by law.

MD #166832

Hydraulic pressure oil hazard

WARNING

• High pressure oil easily punctures skin causing serious injury,
gangrene, or death.

• If injured, seek emergency medical help.

• Do NOT use finger or skin to check for leaks.

• Lower load or relieve hydraulic pressure before loosening

fittings.

Figure 1.19: MD #166832

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MD #190546

Slippery surface

WARNING—DO NOT STEP ON SURFACE

• Do NOT use this area as a step or platform.

• Failure to comply could result in serious injury or death.

MD #307746

Thrown/sharp object hazard

WARNING

• Crop materials exiting at high speed.

SAFETY

Figure 1.20: MD #190546

• Stop machine, look, listen, and wait for all movement to stop
before approaching.

• Failure to comply could result in death or serious injury.

• Disengage power take-off, shut off tractor, and remove key

before opening covers.

• Listen and look for evidence of rotation before lifting cover.

• Cutters may continue to rotate after power is shut off due to

inertia.

MD #325070

Pinch/tangle hazard

WARNING

• Guard missing. Do NOT operate.

• Keep all shields in place.

• To avoid entanglement with rotating auger, stand clear of

header while machine is running.

• Failure to comply could result in serious injury or death.

Figure 1.21: MD #307746

Figure 1.22: MD #325070

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Chapter 2: Product Overview

2.1 Specifications

NOTE:

Specifications and design are subject to change without notice or obligation to revise previously sold units.

Frame and Structure

Width (transport) 5027 mm (198 in.)

Weight: base machine with steel conditioner

Compatible windrower

Lighting Left and right turn signals

Manual storage

Cutterbar

Number of cutting discs

Blades per disc Two 18 degrees bevel down

Disc speed (full engine speed)

Blade max tip speed

Effective cutting width

Minimum Cutting height

Cutting angle range 0–8 degrees below horizontal

Adjustable shoes Standard

Gear train protection

Converging Drums

Drives

Hydraulic motor Piston type into 90-degree gearbox

Cutterbar

Conditioner drive

Conditioner roll timing Timing gearbox

Plastic case on header — Left header support

Direct drive through 90-degree gearbox and

Belt drive (4HB) from 90-degree gearbox to

2156 kg (4750 lb.)

MacDon M1240

deflector

Ten

2500 rpm

80.5 m/s (180 mph)

4942 mm (16 ft. 2 in.)

27 mm (1 1/16 in.)

Shearpin (safecut)

Four-drum type

universal shaft

conditioner

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PRODUCT OVERVIEW

Hay Conditioner Options

Steel rolls Standard

Roll type Steel on steel chevron conditioner rolls

Roll length

Roll diameter

Roll speed

Swath width

1

Forming shields

3275 mm (129 in.)

229 mm (9 in.) roll diameter (outer) on

179 mm (7 in.) OD tube

1009 rpm

915–2438 mm (36–96 in.)

Full width adjustable baffle on conditioner with

adjustable windrower mounted forming shield

1. Actual swath width may vary based upon conditioner type, crop type, and crop volume.

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PRODUCT OVERVIEW

2.2 Component Identification

Figure 2.1: R216 SP Series rotary Rotary Disc Header

A - Front Curtain B - Disc Drum (Right) C - 10-Disc Cutterbar
D - Conditioner Rolls E - Drive Shield (Left) F - Hydraulic Motor
G - Center-Link Tube H - Hazard/Brake Lights

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Figure 2.2: R216 SP Series Rotary Disc Header

PRODUCT OVERVIEW

A - Header Supports B - Deflectors
C - Rear Crop Baffle D - Drive Shield

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PRODUCT OVERVIEW

2.3 Definitions

The following terms and acronyms may be used in this manual:

Term

API

ASTM

Bolt A headed and externally threaded fastener that is designed to be paired with a nut

Cab-forward Windrower operation with Operator and cab facing in direction of travel

Center-link A hydraulic cylinder link between header and machine used to change header angle

CGVW

Export header

FFFT

Finger tight

GVW

Hard joint A joint made with use of a fastener where joining materials are highly incompressible

Header A machine that cuts and lays crop into a windrow and is attached to a windrower

Hex key

Definition

American Petroleum Institute

American Society of Testing and Materials

Combined gross vehicle weight

Header configuration typical outside North America

Flats from finger tight

Finger tight is a reference position where sealing surfaces or components are making
contact with each other, and fitting has been tightened to a point where fitting is no
longer loose

Gross vehicle weight

A tool of hexagonal cross-section used to drive bolts and screws that have a hexagonal
socket in head (internal-wrenching hexagon drive); also known as an Allen key and various
other synonyms

hp

HPT display Harvest Performance Tracker display module on a windrower

JIC

M1 Series

n/a

North American header Header configuration typical in North America

NPT

Nut

ORB

ORFS

PARK

R2 SP Series

rpm

SAE

Horsepower

Joint Industrial Council: A standards body that developed standard sizing and shape for
original 37° flared fitting

MacDon M1170 and M1240 Windrowers

Not applicable

National Pipe Thread: A style of fitting used for low-pressure port openings. Threads on
NPT fittings are uniquely tapered for an interference fit

An internally threaded fastener that is designed to be paired with a bolt

O-ring boss: A style of fitting commonly used in port openings on manifolds, pumps,
and motors

O-ring face seal: A style of fitting commonly used for connecting hoses and tubes. This
style of fitting is also commonly called ORS, which stands for O-ring seal

The slot opposite the NEUTRAL position on operator’s console of M1 Series windrowers

MacDon R216 Rotary Disc Headers for windrowers

Revolutions per minute

Society of Automotive Engineers

Screw

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A headed and externally threaded fastener that threads into preformed threads or forms
its own thread into a mating part

PRODUCT OVERVIEW

Term

Soft joint

SP rotary disc header

Tension

TFFT

Torque

Torque angle

Torque-tension

Washer

Definition

A joint made with use of a fastener where joining materials are compressible or
experience relaxation over a period of time

Rotary disc header that connects to a self-propelled machine (windrower, etc.)

Axial load placed on a bolt or screw, usually measured in Newtons (N) or pounds (lb.)

Turns from finger tight

The product of a force X lever arm length, usually measured in Newton-meters (Nm) or
foot-pounds (lbf∙ft)

A tightening procedure where fitting is assembled to a precondition (finger tight) and then
nut is turned farther a number of degrees to achieve its final position

The relationship between assembly torque applied to a piece of hardware and axial load it
induces in bolt or screw

A thin cylinder with a hole or slot located in the center that is to be used as a spacer, load
distribution element, or locking mechanism

Windrower Power unit of a self-propelled header

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Chapter 3: Operation

3.1 Break-In Period

After attaching the header to the windrower for the first time, operate the machine slowly for 5 minutes, watching and
listening from the operator’s seat for binding or interfering parts.

NOTE:

Until you become familiar with the sound and feel of your new header, be extra alert and attentive.

CAUTION

Before investigating an unusual sound or attempting to correct a problem, stop the engine, put the ground speed lever
(GSL) in PARK, and remove the key.

NOTE:

Perform the items specified in 4.3.2 Break-In Inspections, page 66.

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OPERATION

3.2 Daily Start-Up Check

Perform the following checks each day before startup:

CAUTION

• Ensure the windrower and the header are properly attached, all controls are in neutral, and the windrower brakes
are engaged.

• Clear the area of other persons, pets etc. Keep children away from machinery. Walk around to make sure no one is
under, on, or close to it.

• Wear close-fitting clothing and protective shoes with slip resistant soles. As well, carry with you any protective
clothing and personal safety devices that could be necessary throughout the day. Don't take chances.

• Remove foreign objects from the machine and surrounding area.

Protect yourself. You may need the following:

• A hard hat

• Protective footwear with slip-resistant soles

• Protective glasses or goggles

• Heavy gloves

• Wet weather gear

• A respirator or filter mask

Use proper hearing protection:

Be aware that exposure to loud noise can cause impairment or
loss of hearing. Wear suitable hearing protection such as
earmuffs or earplugs to help protect against loud noises.

Figure 3.1: Safety Equipment

Figure 3.2: Safety Equipment

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OPERATION

1. Check the machine for leaks or any parts that are missing,
broken, or not working correctly.

NOTE:

Use proper procedure when searching for pressurized fluid
leaks. Refer to 4.12.1 Checking Hydraulic Hoses and Lines,

page 151.

2. Clean all lights and reflective surfaces on the machine, and
check lights for proper operation.

3. Perform all daily maintenance. Refer to 4.3.1 Maintenance

Schedule/Record, page 64.

Figure 3.3: Safety around Equipment

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OPERATION

3.3 Engaging and Disengaging Header Safety Props

Safety props are located on both header lift cylinders on the windrower.

3.3.1 Engaging and Disengaging Header Safety Props – M1240 Windrower

Safety props are located on both header lift cylinders on the windrower. Follow these steps to engage or disengage the
header safety props:

DANGER

To avoid bodily injury from fall of raised header, always engage safety props when working on or around raised header,
and before going under header for any reason.

1. Start the engine. Press the HEADER UP (A) switch to raise
header to maximum height.

NOTE:

If one end of the header does NOT fully raise, rephase the
lift cylinders as follows:

a. Press and hold the HEADER UP switch (A) until both

cylinders stop moving.

b. Continue to hold the switch for 3–4 seconds. Cylinders

are now phased.

2. Shut down the engine, and remove the key from the
ignition.

3. Engage safety props on both lift cylinders as follows:

a. Pull lever (A), rotate toward header to release, and

lower the safety prop onto the cylinder.

b. Repeat for opposite lift cylinder.

IMPORTANT:

Ensure the safety props engage over cylinder piston
rods. If safety prop does not engage properly, raise the
header until the safety prop fits over the rod.

Figure 3.4: Ground Speed Lever

Figure 3.5: Safety Prop

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OPERATION

4. Disengage safety props on both lift cylinders as follows:

NOTE:

If safety prop will not disengage, raise header to release
the prop.

a. Turn lever (A) away from header to raise safety prop

until lever locks into vertical position.

b. Repeat for opposite cylinder.

CAUTION

Check to be sure all bystanders have cleared the area.

5. Start the engine, choose a level area, and lower header to
the ground. Shut down the engine and remove the key
from the ignition.

Figure 3.6: Safety Prop

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OPERATION

3.4 Attaching Header to M1240 Windrower

3.4.1 Attaching Rotary Disc Header

The M1240 windrower may have an optional self-aligning hydraulic center-link that allows vertical position control of the
center-link from the cab.

WARNING

To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key
from the ignition before leaving the operator’s seat for any reason.

1. Hydraulic Center-Link without Self-Alignment: Remove

pin (A) and raise center-link (B) until hook is above the
attachment pin on disc header. Replace pin (A) to hold
center-link in place.

IMPORTANT:

If the center-link is too low, it may contact the disc header
as the windrower approaches the disc header for hookup.

2. Remove hairpin (A) from clevis pin (B), and remove pin
from disc header support (C) on both sides of disc header.

CAUTION

Check to be sure all bystanders have cleared the area.

3. Start the windrower engine.

Figure 3.7: Hydraulic Center-Link

Figure 3.8: Rotary Disc Header Support

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OPERATION

CAUTION

When lowering header lift legs without a header or weight box
attached to the windrower, ensure the float springs tension is
fully released to prevent damage to the header lift linkages.

4. Press rotary scroll knob (A) on the display to highlight
QuickMenu options.

5. Rotate scroll knob (A) to highlight the HEADER FLOAT
symbol (B), and press scroll knob to select. The header float
adjust screen displays.

Figure 3.9: Header Float Spring

6. Press soft key 3 (A) to remove the header float.

NOTE:

If the header float is active, the icon at soft key 3 will
display REMOVE FLOAT; if header float has been removed,
the icon will display RESUME FLOAT.

Figure 3.10: HPT Display

Figure 3.11: HPT Display

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OPERATION

7. Press HEADER DOWN switch (E) on the ground speed
lever (GSL) to fully retract header lift cylinders.

8. Self-Aligning Hydraulic Center-Link: Press the REEL UP
switch (B) on the GSL to raise the center-link until the hook
is above the attachment pin on the header.

IMPORTANT:

If the center-link is too low, it may contact the header as
the windrower approaches the header for hookup.

9. Drive the windrower slowly forward until the feet (A) enter
the supports (B). Continue to drive slowly forward until feet
engage the supports and header nudges forward.

Figure 3.12: GSL

A - Reel Down B - Reel Up
C - Header Tilt Down D - Header Tilt Up
E - Header Down F - Header Up

NOTE:

Ensure that feet (A) are properly engaged in supports (B).

10. Self-Aligning Hydraulic Center-Link:

a. Adjust position of the center-link cylinder (A) with the

switches on the GSL until hook (B) is above the header
attachment pin.

IMPORTANT:

Hook release (C) must be down to enable self-locking
mechanism.

b. If the hook release (C) is open (up), stop the engine

and remove the ignition key. Manually push the hook
release (C) down after the hook engages the
header pin.

Figure 3.13: Header Support

Figure 3.14: Hydraulic Center-Link

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11. Self-Aligning Hydraulic Center-Link: Connect header

electrical harness (A) to windrower.

12. Self-Aligning Hydraulic Center-Link:

a. Lower center-link (A) onto the header with REEL DOWN

switch on the GSL until the center-link locks into
position and the hook release (B) is down.

b. Check that center-link is locked onto header by

pressing the REEL UP switch on the GSL.

OPERATION

Figure 3.15: Header Electrical Harness

13. Hydraulic Center-Link without Self-Alignment:

a. Press HEADER TILT UP or HEADER TILT DOWN cylinder

switches on the GSL to extend or retract center-link
cylinder until the hook is aligned with the header
attachment pin.

b. Stop the engine and remove the key.

c. Push down on rod end of link cylinder (B) until hook

engages and locks onto header pin.

IMPORTANT:

Hook release must be down to enable self-locking
mechanism. If the hook release is open (up), manually
push it down after hook engages pin.

d. Check that center-link (A) is locked onto header by

pulling upward on rod end (B) of cylinder.

Figure 3.16: Hydraulic Center-Link

Figure 3.17: Hydraulic Center-Link

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OPERATION

14. Hydraulic Center-Link without Self-Alignment: Connect
header electrical harness (A) to windrower.

15. Install clevis pin (A) through support and windrower lift arm
and secure with hairpin (B). Repeat for opposite side.

IMPORTANT:

Ensure clevis pin (A) is fully inserted, and hairpin is installed
behind bracket.

Figure 3.18: Header Electrical Harness

CAUTION

Check to be sure all bystanders have cleared the area.

16. Start the windrower engine.

17. Lower the header fully to the ground.

18. Turn off the windrower engine and remove the key from
the ignition.

Figure 3.19: Header Support

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OPERATION

Connecting Rotary Disc Header Hydraulics and Electrical – M1240 Windrowers

1. Move windrower left (cab forward) platform (A) to the
OPEN position. For instructions, refer to the windrower
operator’s manual.

2. Route hose bundle (A) from the header, under the
windrower frame, then insert pin (B) into the hole (C) in the
windrower frame.

NOTE:

Route hoses as straight as possible to avoid rub/wear
points that could damage the hydraulic hoses.

3. Rest hoses on header.

Figure 3.20: Windrower with Left Platform in Open
Position

Figure 3.21: Hydraulic Hoses

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OPERATION

4. Remove protective plugs (A) from ends of hydraulic hoses.

5. Use a clean rag to remove dirt and moisture from the
couplers on the windrower and remove protective plugs (A)
from hoses (B).

Figure 3.22: Protective Shipping Plugs on R216
Hydraulic Hoses

Figure 3.23: Hose Support

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6. Make the following hydraulic connections to the
windrower:

a. Connect disc pressure hose (A) marked with a red cable

tie (B) to hard plumb fitting marked with a red cable
tie (C) and torque to 205–226 Nm (151–167 lbf·ft)

b. Connect disc return hose (D) to hard plumb fitting (E)

and torque to 205–226 Nm (151–167 lbf·ft)

c. Connect case drain hose (F) to fitting (G)

OPERATION

7. Connect header adapter harness (A) and main header
harness (B).

Figure 3.24: Hydraulic Connections on Header and
M1240 Windrower

Figure 3.25: Electrical Connections

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8. Close the windrower’s left side platform (A). Refer to
windrower operator’s manual for procedure.

OPERATION

Figure 3.26: M1240 Windrower with Left Platform in
Closed Position

Connecting Rotary Disc Header Hydraulics Using Quick Couplers

To connect the R216 Rotary Rotary Disc Header hydraulic hoses to the M1240 Windrower using quick couplers, follow
these steps:

If your windrower is equipped with hard plumb connections, refer to for connection instructions.

1. Route hose bundle (A) from the disc header, under the
windrower frame, then insert pin (B) into hole (C) in the
windrower frame.

NOTE:

Route hoses as straight as possible and avoid rub/wear
points that could damage the hydraulic hoses.

NOTE:

Adding anti-seize to the hose holder pin will make future
removal easier.

Figure 3.27: Hydraulic Hoses

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OPERATION

2. Remove protective plugs (A) from the ends of the
hydraulic hoses.

3. Use a clean rag to remove dirt and moisture from the
couplers on the left side of the windrower frame.

4. Make the following hydraulic and electrical connections to
the windrower:

Figure 3.28: Protective Shipping Plugs on R216
Hydraulic Hoses

a. Connect disc pressure hose (A) with coupler (B) and

torque to 205–226 Nm (151–167 lbf·ft)

b. Connect disc return hose (C) with coupler (D) and

torque to 205–226 Nm (151–167 lbf·ft)

c. Connect case drain hose (E) to fitting (F), with relief

valve pointing towards the ground

NOTE:

Parts removed from illustration for clarity.

Figure 3.29: Hydraulic Connections on Rotary Disc
Header and M1240 Windrower

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OPERATION

5. Move left windrower platform (A) to the CLOSED position.
For instructions, refer to the windrower operator’s manual.

Figure 3.30: Windrower with Left Platform in Closed
Position

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OPERATION

3.5 Detaching Header from M1240 Windrower

3.5.1 Detaching Rotary Disc Header from M1240 Windrower

WARNING

To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key
from the ignition before leaving the operator’s seat for any reason.

CAUTION

Check to be sure all bystanders have cleared the area.

1. Start the engine, and press switch (A) to raise the header to
the maximum height.

2. Stop the engine, and remove the key.

Figure 3.31: GSL

3. Disengage safety props by turning lever (A) away from
header to raise safety prop until lever locks into vertical
position. Repeat for opposite cylinder.

Figure 3.32: Safety Props

4. Open left side platform. For instructions, refer to the windrower operator’s manual.

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OPERATION

5. Disconnect electrical harness (A) and hydraulic hoses (B),
(C), and (D) from the windrower.

Figure 3.33: Header Electrical Connection

6. Remove hose support (A) and hose bundle from
windrower frame.

Figure 3.34: Header Drive Hydraulics

Figure 3.35: Hoses on Windrower

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OPERATION

7. Remove hairpin (B) from clevis pin (A). Remove clevis pin
from header support (C) on both sides of header.

Windrowers with self-aligning center-link kit only:

8. Release the center-link latch (A) before returning to
the cab.

Figure 3.36: Header Supports

Figure 3.37: Center-Link

9. Disengage safety prop by turning lever (A) downwards until
lever locks into the vertical position.

10. Repeat for the opposite side.

CAUTION

Check to be sure all bystanders have cleared the area.

Figure 3.38: Safety Props

11. Start engine and remove header float when prompted by the Harvest Performance Tracker (HPT).

NOTE:

If not prompted by the HPT to remove float, remove float manually.

12. Lower header to the ground.

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OPERATION

Self-aligning hydraulic center-link (if installed):

13. Use HEADER TILT cylinder switches (A) on GSL to release
load on center-link cylinder.

14. Operate the link lift cylinder with the REEL UP switch (B) to
disengage the center-link from the header.

Hydraulic center-link without self-alignment:

15. Shut off the engine and remove the key.

Figure 3.39: GSL

16. Lift hook release (A) and lift hook (B) off header pin.

17. Disconnect header harness and remote baffle connector
(if equipped).

CAUTION

Check to be sure all bystanders have cleared the area.

18. Start the engine.

19. Back the windrower slowly away from header.

20. Turn off engine and remove key from ignition.

21. Reinstall clevis pin (A) through support (C) and secure with
hairpin (B). Repeat for opposite side.

Figure 3.40: Hydraulic Center-Link

Figure 3.41: Header Support

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OPERATION

3.6 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.

3.6.1 Opening Driveshields

CAUTION

To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured.

NOTE:

Images shown in this procedure are for the left driveshield—the
right driveshield is similar.

1. Engage the release latch and lift release lever (A) and pull
handle (B).

Figure 3.42: Left Driveshield

Figure 3.43: Driveshield Latch and Handle

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OPERATION

2. Lift outboard driveshield panel toward outboard end of
header.

3. Grab handle (A) and lift the other half of the endshield (B)
to the inboard side of the header.

Figure 3.44: Opening Driveshield – Outboard Side

Figure 3.45: Driveshield – Inboard Side

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OPERATION

3.6.2 Closing Driveshields

CAUTION

To reduce the risk of personal injury, do NOT operate the machine without the driveshields in place and secured.

NOTE:

Images shown in this procedure are for the left driveshield—the right driveshield is similar.

1. Lift lock latch (A) to disengage driveshield lock.

2. Move inboard half of driveshield (A) back to closed
position.

3. Move ourboard half of driveshield (A) back to closed
position.

Figure 3.46: Driveshield Lock Latch

Figure 3.47: Left Driveshield

Figure 3.48: Left Driveshield

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OPERATION

3.7 Cutterbar Curtain

WARNING

To reduce the risk of personal injury or machine damage, do NOT operate the machine without curtain installed and in
good condition. Foreign objects can be ejected with considerable force when the machine is started.

NOTE:

Cutterbar curtain is attached at the front and the sides of the
header. Always keep curtain lowered when operating the disc
header.

IMPORTANT:

Replace curtain (A) if it becomes worn or damaged. Refer to

4.8.1 Inspecting Cutterbar Curtain, page 130.

Figure 3.49: Cutterbar Curtains

3.7.1 Opening Cutterbar Curtain

WARNING

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator’s seat for any reason.

1. Push curtain (A) inward and up.

Figure 3.50: Cutterbar Curtain

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2. Securing curtain in place at locations (A) using 3 clips
provided.

NOTE:

Cutterbar curtain (A) is held in place
between the tines of retaining clips (B).

OPERATION

Figure 3.51: Cutterbar Curtains — View from Below

Figure 3.52: Cutterbar Curtain and Retaining Clips

3.7.2 Closing Cutterbar Curtain

CAUTION

To avoid injury, keep hands and fingers away from corners of doors when closing.

1. Pull curtain outward from retaining clips and lower curtain.

Figure 3.53: Cutterbar Curtain

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OPERATION

3.8 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. Most of
the adjustments have been set at the factory, but settings can be changed to suit your crop conditions.

Table 3.1 Header Operating Variables

Variable Refer to

Float 3.8.3 Header Float, page 45

Header angle 3.8.2 Adjusting Cutterbar Angle, page 45

Cutting height 3.8.1 Cutting Height, page 44

Ground speed 3.8.4 Ground Speed, page 46

Conditioner Settings 3.10 Conditioner, page 49

Crop Stream Configuration 3.9 Reconfiguring Cutterbar Crop Stream, page 47

3.8.1 Cutting Height

Cutting height is determined by a combination of the cutterbar angle and the optional gauge roller or skid shoe settings if
installed. Adjust cutting height for optimum cutting performance while preventing excessive build-up of mud and soil inside
the disc header, which can lead to poor crop flow and increased wear on cutting components.

Optional adjustable gauge rollers and skid shoes are available to provide different cutting heights. Refer to:

• 5.1.2 Adjustable Gauge Roller Kit, page 153

• 5.1.3 Adjustable Skid Shoes Kit, page 154

Lowering the skid shoes (or gauge rollers) and decreasing the cutterbar angle increases the cutting height, resulting in
higher stubble that helps material dry faster. This may be desirable in stony conditions to help reduce damage to cutting
components.

Raising the skid shoes (or gauge rollers) and increasing the cutterbar angle decreases the cutting height, resulting in a
shorter stubble.

To choose a header angle that maximizes performance for your crop and field conditions, refer to 3.8.2 Adjusting Cutterbar

Angle, page 45.

To minimize cutterbar damage, scooping soil, and soil build-up at the cutterbar in damp conditions, the float should be set
as light as possible without causing excessive bouncing. Refer to 3.8.3 Header Float, page 45.

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OPERATION

3.8.2 Adjusting Cutterbar Angle

The header angle (A) adjustment ranges from 0 to 8 degrees
below horizontal. Choose an angle that maximizes performance
for your crop and field conditions. A flatter angle provides
better clearance in stony conditions, while a steeper angle is
required in downed crops for better lifting action.

Check the float after significantly adjusting the header angle
because the adjustments affect the header float due to shifting
the header center of gravity. Refer to your windrower
operator’s manual for instructions.

NOTE:

In most cases, cut quality is improved by keeping the cutterbar
angle as close to 0 degrees as possible.

Figure 3.54: Cutterbar Angle

3.8.3 Header Float

The M1240 float is completely adjustable from the cab through the Harvest Performance Tracker (HPT).

The header float feature allows the header to closely follow ground contours and respond quickly to sudden changes or
obstacles. The float setting is ideal when the cutterbar is on the ground with minimal bouncing, scooping, or pushing soil.

IMPORTANT:

• Set header float as light as possible—without excessive bouncing—to avoid frequent breakage of knife components,

scooping soil, or soil build-up at the cutterbar in wet conditions.

• Avoid excessive bouncing (resulting in a ragged cut) by operating at a slower ground speed when the float setting

is light.

• Install applicable header options (crop dividers, etc.) before setting header float.

• Adjust the float when adding or removing optional attachments that affect the weight of the header.

• Changing header angle affects the float. Check the float after making appropriate changes to header angle for crop type

and conditions, field conditions, and speed settings.

For instructions on setting and adjusting the header float, refer to your windrower operator’s manual.

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OPERATION

3.8.4 Ground Speed

Choose a ground speed that allows the cutterbar to cut the crop smoothly and evenly. Try different combinations of disc
speed and ground speed to suit your specific crop. Refer to your windrower operator’s manual for instructions on changing
ground speed.

CAUTION

Reduce speed when turning, crossing slopes, or traveling over rough ground.

In tough cutting conditions (such as native grasses), set the disc speed to MAXIMUM.

In light crops, reduce the disc header’s disc speed while maintaining ground speed.

NOTE:

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 3.55: Ground Speed for R216 SP Rotary Disc Headers

A - Acres/Hour B - Hectares/Hour C - Kilometers/Hour D - Miles/Hour

Example: At ground speed of 21 km/h (13 mph) the area cut would be approximately 25 acres (12 hectares) per hour.

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OPERATION

3.9 Reconfiguring Cutterbar Crop Stream

Discs are factory-installed to produce four crop streams, but disc rotation pattern can be changed by substitution of spindle
and corresponding disc to suit crop conditions. Each spindle and disc pair is designed to rotate in one direction and must be
changed as sets when altering crop flows.

Reducing or increasing the number of crop streams will produce
the following results:

• Reducing the number of crop streams will result in narrower

windrows.

• Increasing the number of crop streams will result in

smoother, wider windrows.

NOTE:

Increasing the number of crop streams will also increase the
number of diverging disc pairs which may negatively affect
cut quality in certain conditions.

Figure 3.56: R216 Cutterbar

IMPORTANT:

• Spindles that rotate clockwise have right-leading threading

and are identified by a smooth top on the spindle gear
shaft (A).

• Spindles that rotate counterclockwise have left-leading

threading and are identified by machined grooves on the
spindle gear shaft (B) and nut (C).

• If spindle position in cutterbar has changed, the rotational

direction of that spindle MUST remain the same (that is, a
clockwise spindle must maintain its clockwise rotation).

• Failure to maintain rotation pattern can result in damage to

spindle and/or cutterbar components.

• Safecut (shear pin) will not work if spindles used in the

wrong orientation.

Figure 3.57: Cutterbar Spindles

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OPERATION

3.9.1 Changing R216 SP Cutterbar Crop Stream Configuration

Figure 3.58: R216 SP (10 Disc) Spindle Rotation Pattern and Crop Streams

A - Four Crop Stream B - Two Crop Streams

NOTE:

Refer to Removing Cutterbar Spindles, page 81 and Installing Cutterbar Spindles, page 83.

To change R216 SP (10 disc) spindle rotation from four crop streams (A) to two crop stream (B):

• Swap disc/spindle (3) with disc/spindle (8).

NOTE:

A disc timing tool (MD #307954) is available through MacDon parts to change disc/spindle configuration.

NOTE:

Switching from 4 streams to 2 streams is a recommended setting when cutting light alfalfa and using the double windrower
attachment (DWA).

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OPERATION

3.10 Conditioner

Rolls condition the crop by crimping and crushing the stem in several places, which allows the release of moisture resulting
in faster drying times. R216 SP headers are equipped with steel conditioner rolls.

3.10.1 Roll Gap

The roll gap controls the degree to which crop is conditioned as it passes through the rolls. Roll gap is factory-set at
approximately 6 mm (1/4 in.) for steel rolls.

Steel rolls can be operated over a large range of roll gap settings (intermesh). Using a roll gap of (up to) 25 mm (1 in.), they
are suited to a wide range of crops (including alfalfa and thicker-stemmed cane-type crops). However operating with too
large of a gap may cause feeding problems.

Grass-type crops may require less gap for proper feeding and conditioning.

IMPORTANT:

If using settings below the factory setting, visually inspect the roll gap.

Adjusting Roll Gap

To adjust the roll gap to factory setting, follow the procedure below:

WARNING

To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key
from the ignition before leaving the operator’s seat for any reason.

1. Lower the disc header fully.

2. Shut down the engine, and remove the key from the ignition.

3. Loosen jam nut (A) on both sides of the conditioner.

4. Turn lower nut (B) counterclockwise until the upper roll
rests on the lower roll. Ensure the rolls intermesh.

5. Turn lower nut (B) two and a half turns clockwise to raise
the upper roll and achieve a 6 mm (1/4 in.) roll gap.

6. Hold nut (B) and tighten jam nut (A) on both sides of the
disc header.

IMPORTANT:

Make sure the roll gap adjustment nuts are adjusted
equally on both sides of the disc header to achieve a
consistent gap across the rolls.

7. If further adjustment to roll gap is required:

• Turn lower nut (B) clockwise to increase roll gap.

• Turn lower nut (B) counterclockwise to decrease

roll gap.

Figure 3.59: Roll Gap Adjustment

NOTE:

Make further adjustments to roll gap based on header
performance and crop conditions.

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OPERATION

3.10.2 Roll Tension

Roll tension (the pressure holding the conditioner rolls together) is factory-set to maximum and should rarely require
adjustment.

Heavy crops or tough forage can cause the rolls to separate; therefore, maximum roll tension is required to ensure that
materials are sufficiently crimped.

Adjusting Roll Tension

To adjust roll tension, follow these steps:

WARNING

To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key
from the ignition before leaving the operator’s seat for any reason.

1. Lower the header to the ground.

2. Shut down the engine, and remove the key from the ignition.

3. Loosen jam nut (A) on both sides of the conditioner.

4. Adjust spring drawbolt as follows:

• Turn spring drawbolt (B) clockwise to tighten spring and

INCREASE the roll tension.

• Turn spring drawbolt (B) counterclockwise to loosen

spring and DECREASE the roll tension.

IMPORTANT:

Turn each bolt equally. Roll tension changes by
approximately 32 N (7.2 lbf) with each turn of the drawbolt.

5. Measure the amount of exposed thread on spring
drawbolt (A) at each end of the conditioner. For steel roll
conditioners, measurement (B) should be 12–15 mm
(1/2–9/16 in.).

6. Tighten jam nut (C) on both sides of the conditioner.

Figure 3.60: Roll Tension Adjuster

Figure 3.61: Roll Tension Adjuster

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OPERATION

3.10.3 Roll Timing

For proper conditioning, the rolls must be properly timed with the bar on one roll centered between two bars on the other
roll. The factory setting should be suitable for most crop conditions.

IMPORTANT:

Roll timing is critical when the roll gap is decreased because
conditioning is affected and the bars may contact each other.

Figure 3.62: Properly Timed Rolls

Checking Roll Timing

Check roll timing if excessive noise is coming from the conditioner rolls.

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.

Roll timing is factory-set and should not require adjustment; however, if there is excessive noise coming from the
conditioner rolls, the timing will need to be adjusted. Refer to Adjusting Roll Timing, page 51.

Adjusting Roll Timing

WARNING

To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key
from the ignition before leaving the operator’s seat for any reason.

1. Shut down the engine and remove the key.

2. On the upper roll, loosen four bolts (A) securing yoke
plate (B).

NOTE:

Only three of the four bolts are shown in the illustration.

Figure 3.63: Conditioner Drive

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OPERATION

3. Secure bottom roll (A).

4. Manually rotate upper roll (B) counterclockwise direction
until it stops rotating.

5. Make a mark (C) across yoke (D) and gearbox flange (E).

6. Manually rotate upper roll (A) clockwise it stops rotating.
Make a second mark (B) on the yoke flange, and align it
with the mark on the gearbox flange.

Figure 3.64: Conditioner Drive

Figure 3.65: Conditioner Drive

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OPERATION

7. Determine center point (A) between the two marks on the
yoke plate, and place a third mark.

8. Rotate upper roll (B) counterclockwise, until the bolt lines
up with the third (center) mark.

9. Ensure the threads on four bolts (A) are clean and free of
lubricant.

NOTE:

Only three of the four bolts are shown in the illustration.

®

10. Apply medium-strength threadlocker (Loctite

242 or
equivalent) and tighten bolts (A). Torque to 95 Nm
(70 lbf·ft).

Figure 3.66: Conditioner Drive

Figure 3.67: Conditioner Drive

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OPERATION

3.10.4 Adjusting Forming Shields – Roll Conditioner

WARNING

Keep everyone at a safe distance from your operation. Ensure bystanders are never in line with the front or rear of the
machine. Stones or other foreign objects can be ejected from either end with force.

The forming shield position controls the width and placement of the windrow. Consider the following factors when setting
the forming shield position:

• Weather conditions (rain, sun, humidity, and wind)

• Type and yield of crop

• Available drying time

• Method of processing (bales, silage, and green-feed)

A wider windrow will generally dry faster and more evenly, resulting in less protein loss. Fast drying is especially important
in areas where the weather allows only a few days to cut and bale. A narrower windrow may be preferable for ease of
pick-up and when drying is not critical (for example, when cutting for silage or green feed).

Positioning Forming Shield Side Deflectors – Roll Conditioner

The position of the side deflectors controls the width and placement of the windrow. To ensure windrow placement is
centered between the carrier wheels, adjust the left and right deflectors to the same position.

WARNING

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator’s seat for any reason.

1. Set forming shield side deflectors (A) to the desired width
by repositioning adjuster handle (B). To ensure windrow
placement is centered, adjust both side deflectors to the
same position.

Figure 3.68: Forming Shield Side Deflector and
Adjuster Handle

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OPERATION

2. If side deflector attachment is too tight or too loose,
tighten or loosen nut (A) as required.

Figure 3.69: Side Deflector Adjustment

Positioning Rear Baffle – Roll Conditioner

The rear baffle is used in conjunction with the forming shields to affect the windrow width. It is located immediately
behind and above the conditioning rolls and can be positioned to do the following:

• Direct crop flow into forming shield for narrow and moderate width windrows.

• Direct crop downward to form a wide swath.

• Provide even material distribution across windrow with adjustable fins under rear baffle. Refer to Positioning Rear

Baffle Deflector Fins, page 56.

To position the rear baffle, follow these steps:

DANGER

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator's seat for any reason.

1. Remove lynch pin (A) securing rear baffle adjustment
lever (B) to bracket (C).

2. Pull rear baffle adjustment lever (B) inboard to disengage
from bracket (C).

3. Position rear baffle adjustment lever (B) as follows:

• Move the lever forward to raise the baffle

• Move the lever backward to lower the baffle

4. Release rear baffle adjustment lever (B) so that the tab
engages the hole in bracket (C).

5. Secure baffle adjustment lever (B) with lynch pin (A).

NOTE:

An optional remote baffle adjustment kit (B6664) is
available for R216 headers. For more information, refer to

5.1.4 Electric Remote Baffle Kit, page 154.

Figure 3.70: Left Side of Conditioner

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OPERATION

Positioning Rear Baffle Deflector Fins

Four rear baffle deflector fins are located under the baffle. Fins are factory-configured to approximately 60°. They can be
adjusted when a narrower windrow is desired.

To adjust fins, follow these steps:

DANGER

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator's seat for any reason.

1. Deflector fins (A) are located on the underside of the rear
baffle.

NOTE:

There are two fins on the left and two fins on the right of
the header.

2. To adjust deflector fins (A), use existing bolt and nut (B).
Once adjusted to the desired angle for windrow width,
torque nut to 69 Nm (51 lbf·ft).

3. Repeat for the opposite deflector fins.

NOTE:

Fins may interfere with crop flow in large-stemmed crops,
or when using the double windrower attachment. It may be
necessary to remove fins in these conditions.

Figure 3.71: Deflector Fins Under Baffle

Figure 3.72: Left Deflector Fins in Field Position
under Baffle

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OPERATION

NOTE:

Deflector fins (A) can be put in storage position by removing
existing nut and bolt and reattaching fins on top of the
baffle.

Figure 3.73: Left Deflector Fins in Storage Position

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OPERATION

3.11 Haying Tips

3.11.1 Curing

Curing crops quickly helps maintain the highest quality of crop material as 5% of protein is lost from hay for each day that it
lays on the ground after cutting.

Leaving the windrow as wide and fluffy as possible results in the quickest curing. Cured hay should be baled as soon as
possible.

3.11.2 Topsoil Moisture

Table 3.2 Topsoil Moisture Levels

Level

Wet

Damp

Dry

• On wet soil, the general rule of wide and thin does not apply. A narrower windrow will dry faster than hay left flat on

wet ground.

• When the ground is wetter than the hay, moisture from the soil is absorbed by the hay above it. Determine topsoil

moisture level before cutting. Use a moisture tester or estimate level.

• If ground is wet due to irrigation, wait until soil moisture drops below 45%.

• If ground is wet due to frequent rains, cut hay when weather allows and let the forage lie on wet ground until it dries to

the moisture level of the ground.

• Cut hay will dry only to the moisture level of the ground beneath it, so consider moving the windrow to drier ground.

% Moisture

Over 45%

25–45%

Under 25% Surface is dusty

Condition

Soil is muddy

Shows footprints

3.11.3 Weather and Topography

• Cut as much hay as possible by midday when drying conditions are best.

• Slopes that face the sun receive up to 100% more exposure to the sun’s heat than slopes that do not face the sun. If

hay is baled and chopped, consider baling sun-facing slopes and chopping slopes that do not.

• When relative humidity is high, the evaporation rate is low and hay dries slowly.

• Humid air is trapped around the windrow in calm conditions. Raking or tedding will expose the hay to fresher and

drier air.

• Cut hay perpendicular to the direction of the prevailing winds if possible.

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OPERATION

3.11.4 Windrow Characteristics

Producing windrows with the recommended characteristics will achieve the best results. Refer to 3 Operation, page 19 for
instructions on adjusting the header.

Table 3.3 Recommended Windrow Characteristics

Characteristic Advantage

High and fluffy

Consistent formation (not bunching) Permits an even flow of material into the baler, chopper, etc.

Even distribution of material
across windrow

Properly conditioned Prevents excessive leaf damage

Enables airflow through windrow, which is more important to the curing
process than direct sunlight

Results in even and consistent bales to minimize handling and
stacking problems

3.11.5 Driving on Windrow

Driving on previously cut windrows that will not be raked can lengthen drying time by a full day. If practical, set forming
shields to produce a narrower windrow that the machine can straddle.

NOTE:

Driving on the windrow in high-yield crops may be unavoidable if a full width windrow is necessary.

3.11.6 Using Chemical Drying Agents

Hay drying agents work by removing wax from legume surfaces and allowing moisture to escape cut crop and evaporate
faster; however, treated hay lying on wet ground will absorb ground moisture faster.

Before deciding to use a drying agent, carefully compare the relative costs and benefits for your area.

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OPERATION

3.12 Transporting the Header

For information on transporting the header when attached to the windrower, refer to your windrower operator’s manual.

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Chapter 4: Maintenance and Servicing

The following instructions provide information about routine servicing for the header. A parts catalog is located in a plastic
case on the fixed deflector on the left side of the header.

Log hours of operation and use the maintenance record provided (refer to 4.3.1 Maintenance Schedule/Record, page 64)to
keep track of your scheduled maintenance.

4.1 Preparing Machine for Servicing

CAUTION

To avoid personal injury, perform the following procedures before servicing disc header or opening drive covers:

1. Lower the header fully. If you need to perform service in the raised position, always engage safety props. For
instructions, refer to 3.3.1 Engaging and Disengaging Header Safety Props – M1240 Windrower, page 22.

2. Put the ground speed lever (GSL) in PARK.

3. Stop the engine and remove the key from the ignition.

4. Wait for all moving parts to stop.

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MAINTENANCE AND SERVICING

4.2 Recommended Safety Procedures

• Park on level surface when possible. Follow all recommendations in your tractor 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

• Wear protective shoes with slip-resistant soles, a hard hat,
protective glasses or goggles, and heavy gloves.

• Be aware that if more than one person is servicing the
machine at the same time, rotating a driveline or other
mechanically driven component by hand (for example, to
access a lube fitting) will cause drive components in other
areas (belts, pulleys, and discs) to move. Stay clear of driven
components at all times.

Figure 4.2: Safety Equipment

Figure 4.3: Safety Around Equipment

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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.

• Keep the 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.

Figure 4.4: Safety Equipment

Figure 4.5: Safety Around Equipment

• Use adequate light for the job at hand.

• Reinstall all shields removed or opened for service.

• Use only service and repair parts made or approved by the equipment manufacturer. Substituted parts may not meet

strength, design, or safety requirements.

• Keep machinery clean. Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may
be toxic and/or flammable.

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MAINTENANCE AND SERVICING

4.3 Maintenance Requirements

IMPORTANT:

Recommended intervals are for average conditions. Service the machine more often if operating under adverse conditions
(severe dust, extra heavy loads, etc.).

Regular maintenance is the best insurance against early wear and untimely breakdowns. Following the maintenance
schedule will increase your machine’s life. Periodic maintenance requirements are organized according to service intervals.

If more than one interval is specified for a service item (e.g., 100 hours or annually), service the machine at whichever
interval is reached first.

When servicing the machine, refer to the specific headings in this section. Refer to this manual’s inside back cover and use
only the specified fluids and lubricants.

Log hours of operation, use the maintenance record, and keep copies of your maintenance records. Refer to 4.3.1

Maintenance Schedule/Record, page 64.

CAUTION

Carefully follow all safety messages. Refer to 4.2 Recommended Safety Procedures, page 62.

4.3.1 Maintenance Schedule/Record

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

First use Refer to 4.3.2 Break-In Inspections, page 66.

End of season Refer to 4.3.4 End-of-Season Servicing, page 67.

Action ü Check S Lubricate ▲ Change

First 10 hours then Daily

Inspect cutterbar discs. Refer to

ü

Inspecting Cutterbar Discs, page 76.

Inspect discblades. Refer to Inspecting

ü

Discblades, page 87.

Inspect accelerators. Refer to Inspecting

ü

Accelerators, page 93.

Inspect rock guards. Refer to Inspecting

ü

Rock Guards, page 97.

Inspect drums. Refer to Inspecting Drums,

ü

page 100.

Check hydraulic hoses and lines. Refer to

ü

4.12.1 Checking Hydraulic Hoses and
Lines, page 151.

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MAINTENANCE AND SERVICING

Every 25 Hours

2

Check conditioner drive belt tension.

ü

Refer to Inspecting Conditioner Drive Belt,

page 134.

Lubricate idler pivot. Refer to 4.4

S

Lubrication, page 68.

Lubricate upper and lower driveline

S

universal joints. Refer to 4.4 Lubrication,

page 68.

Lubricate roller conditioner and feed

S

roller bearings. Refer to 4.4 Lubrication,

page 68.

Lubricate conditioner driveline .Refer to

S

4.4 Lubrication, page 68.

Every 100 Hours or Annually

Check conditioner drive belt tension.

ü

Refer to Inspecting Conditioner Drive Belt,

page 134.

Check roll timing gearbox lubricant. Refer
to 4.6.1 Checking and Changing

ü

Conditioner Roll Timing Gearbox Oil, page

124.

Check header drive gearbox lubricant.

ü

Refer to 4.7.1 Checking Header Drive

Gearbox Oil, page 127

Every 250 Hours

3

Change roll timing gearbox lubricant.
Refer to 4.6.1 Checking and Changing

▲

Conditioner Roll Timing Gearbox Oil, page

124.

Change header drive gearbox lubricant.

▲

Refer to 4.7.2 Changing Header Drive

Gearbox Oil, page 129

Change cutterbar lubricant. Refer to 4.5.1

▲

Lubricating Cutterbar, page 71.

Lubricate left and right driven drums.
Refer to Removing Left Driven Drum and

▲

Driveline, page 105 and Removing Right
Driven Drum and Driveline, page 110

2. The driveline inside the driven drum is lubricated for life and does not require any routine lubrication.

3. Begins after the first 150 hour service.

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4.3.2 Break-In Inspections

Table 4.1 Break-In Inspection Schedule

MAINTENANCE AND SERVICING

Inspection

Interval

1

Hour

5

Hours

5

Hours

25

Hours

50

Hours

50

Hours

50

Hours

Check for loose hardware and tighten
to required torque

Check for loose hardware and tighten
to required torque

Check conditioner drive belt drive
tension

Check converging drum and feed
roller belt drive tension

Check conditioner drive belt tension Inspecting Conditioner Drive Belt, page 134

Change conditioner roll timing
gearbox lubricant

Change header drive gearbox
lubricant

Item

Refer to

7.1 Torque Specifications, page 161

7.1 Torque Specifications, page 161

Inspecting Conditioner Drive Belt, page 134

Inspecting Conditioner Drive Belt, page 134

4.6.1 Checking and Changing Conditioner Roll Timing Gearbox Oil,
page 124

4.7.2 Changing Header Drive Gearbox Oil, page 129

4.3.3 Preseason Servicing

CAUTION

• Review the operator's manual to refresh your memory on safety and operating recommendations.

• Review all safety signs and other decals on the self-propelled disc header and note hazard areas.

• Ensure all shields and guards are properly installed and secured. Never alter or remove safety equipment.

• Make certain you understand and have practiced safe use of all controls. Know the capacity and the operating

characteristics of the machine.

• Check the first aid kit and fire extinguisher. Know where they are and how to use them.

Perform the following procedures at the beginning of each operating season:

1. Lubricate machine completely. Refer to 4.4 Lubrication, page 68 and 4.5.1 Lubricating Cutterbar, page 71 .

2. Perform all annual maintenance. Refer to 4.3.1 Maintenance Schedule/Record, page 64.

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MAINTENANCE AND SERVICING

4.3.4 End-of-Season Servicing

CAUTION

Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or
flammable.

CAUTION

Cover cutterbar to prevent injury from accidental contact.

Perform the following procedures at the end of each operating season:

1. Raise the header and engage lift cylinder safety props.

2. Clean the header thoroughly.

3. Check for worn components and repair as necessary.

4. Check for broken components and order replacements from your Dealer. Immediate repair of these items will save

time and effort at beginning of next season.

5. Replace or tighten any missing or loose hardware. Refer to 7.1 Torque Specifications, page 161.

6. Lubricate the header thoroughly leaving excess grease on fittings to keep moisture out of bearings.

7. Apply grease to exposed threads, cylinder rods, and sliding surfaces of components.

8. Oil cutterbar components to prevent rust.

9. Loosen drive belt.

10. Remove divider rods (if equipped) to reduce space required for inside storage.

11. Repaint all worn or chipped painted surfaces to prevent rust.

12. Store in a dry, protected place if possible. If stored outside, always cover header with a waterproof canvas or other

protective material.

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MAINTENANCE AND SERVICING

4.4 Lubrication

WARNING

To avoid personal injury, before servicing header or opening drive covers, refer to 4.1 Preparing Machine for Servicing,

page 61.

Greasing points are marked on the machine by decals on the left and right outboard shielding.

Log hours of operation and use the maintenance schedule provided to keep a record of scheduled maintenance. Refer to

4.3.1 Maintenance Schedule/Record, page 64.

4.4.1 Greasing Procedure

Only use clean, high temperature, extreme pressure grease. Refer to this manual’s inside back cover for a list of
recommended fluids and lubricants.

WARNING

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator’s seat for any reason.

1. Open driveshields at the ends of the header to access greasing points. Refer to 3.6.1 Opening Driveshields, page 39.

2. Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit.

3. Replace any loose or broken fittings immediately.

4. Inject grease through fitting with grease gun until grease overflows fitting (except where noted).

5. Leave excess grease on fitting to keep out dirt.

6. Remove and thoroughly clean any fitting that will not take grease and clean lubricant passageway. Replace fitting if
necessary.

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4.4.2 Lubrication Locations

Figure 4.6: Left Side Lubrication Locations

MAINTENANCE AND SERVICING

A - Idler/Tensioner Pivot B - Bearing, Roller Conditioner (2 Places) C - U-Joint, Conditioner Driveline (2 Places)
D - Slip Joint, Conditioner Driveline
G - Tensioner Arm

4

E - Idler/Tensioner Pivot F - Bearing, Feed Roll

4. Use high-temperature, extreme-pressure (EP2) performance grease with 10% max molybdenum disulphide (NLGI
grade 2) lithium base.

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Figure 4.7: Right Side Lubrication Locations

MAINTENANCE AND SERVICING

A - Bearing, Roller Conditioner (2 Places) B - U-Joint, Upper Driveline (2 Places) C - Slip Joints, Conditioner Drivelines
D - U-Joint, Lower Driveline (2 Places) E - Idler Pivot

5

5. Use high-temperature, extreme-pressure (EP2) performance grease with 10% max molybdenum disulphide (NLGI
grade 2) lithium base.

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MAINTENANCE AND SERVICING

4.5 Cutterbar System

Check and change the lubricant at regular intervals. Refer to 4.3

Maintenance Requirements, page 64.

IMPORTANT:

Warm cold lubricant by idling the machine for 10 minutes prior
to checking level.

4.5.1 Lubricating Cutterbar

Checking and Adding Cutterbar Lubricant

Figure 4.8: R216 SP Cutterbar

WARNING

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator’s seat for any reason.

WARNING

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when
handling blades.

1. Park the machine on level ground.

2. Lower the header onto 25 cm (10 in.) blocks under both ends of the cutterbar.

3. Shut down the engine, and remove the key from the ignition.

4. Open cutterbar curtain (A). Refer to 3.7.1 Opening

Cutterbar Curtain, page 42.

Figure 4.9: Cutterbar Curtain

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MAINTENANCE AND SERVICING

5. Use a spirit (bubble) level (A) to ensure the cutterbar is
level in both directions. Adjust the header accordingly.

6. Clean the area around plug (A). Place a 5 liter (5.2 US qts)
capacity container under plug (A).

7. Use a 17 mm socket to remove plug (A) and O-ring (B) from
cutterbar. Oil level must be up to the inspection plug hole.
If additional lubricant is required, continue following this
procedure and refer to the next step. If additional lubricant
is NOT required, proceed to Step 22, page 73.

Figure 4.10: Spirit Level on Cutterbar

8. Reinstall the inspection plug.

CAUTION

Before starting the machine, check to be sure all bystanders
have cleared the area.

Figure 4.11: Cutterbar Oil Inspection Plug

9. Start the engine, and raise the header slightly.

10. Lower the header onto blocks, so the right end is slightly higher than left end.

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 to the required level.

IMPORTANT:

Do NOT overfill the cutterbar. Overfilling can cause
overheating, damage, or cutterbar component failure.

NOTE:

Refer to the inside back cover of this manual for lubrication
specifications.

14. Replace plug (A) and torque to 30 Nm (22 lbf·ft).

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Figure 4.12: Cutterbar Oil Plug

MAINTENANCE AND SERVICING

CAUTION

Before starting the machine, check to be sure all bystanders have cleared the area.

15. Start the engine and raise the header fully.

16. Shut down the engine, and remove the key from the ignition. Engage the windrower lift cylinder safety props.

17. Remove the block from under the header.

18. Disengage the windrower lift cylinder safety props.

CAUTION

Before starting the machine, check to be sure all bystanders have cleared the area.

19. Start the engine and lower the header to a level position on the ground.

20. Shut down the engine, and remove the key from the ignition.

21. Recheck the oil level.

22. Check O-ring (B) for breaks or cracks, and replace if
necessary.

23. Install plug (A) and O-ring (B). Tighten securely.

24. Close cutterbar curtain (A). Refer to 3.7.2 Closing Cutterbar

Curtain, page 43.

Figure 4.13: Cutterbar Oil Inspection Plug

Figure 4.14: Cutterbar Curtain

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MAINTENANCE AND SERVICING

Draining the Cutterbar

DANGER

To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key
from the ignition before leaving the operator’s seat for any reason.

WARNING

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when
handling blades.

1. Start the engine and raise the disc header.

2. Place a block under each end of the disc header so the right
end is lower than the left end.

IMPORTANT:

Always drain lubricant from the right end of the disc
header. Draining lubricant from the left end of the disc
header may lead to breather contamination or failure.

3. Lower the disc header onto the blocks.

4. Shut down the engine, and remove the key from the
ignition.

5. Place a 10 liter (10.5 US qts) capacity container under lower
end of cutterbar, clean area around plug (A), and
remove plug.

IMPORTANT:

Do NOT remove hex head bolts securing cutterbar end
plate to cutterbar or lubricant leaks could result.

6. Allow sufficient time for lubricant to drain, then reinstall
cutterbar plug (A).

NOTE:

Do NOT flush the cutterbar.

7. Fill the cutterbar with lubricant before operating the disc
header. Refer to Filling Lubricant into a Repaired Cutterbar,

page 74.

IMPORTANT:

Dispose of used lubricant responsibly.

Figure 4.15: Draining Cutterbar

Filling Lubricant into a Repaired Cutterbar

This procedure should be used when the cutterbar has been completely drained of oil. If you are checking oil level or
topping it up, refer to Checking and Adding Cutterbar Lubricant, page 71.

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.

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MAINTENANCE AND SERVICING

WARNING

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when
handling blades.

IMPORTANT:

The cutterbar should be completely empty of oil before filling it. Refer to Draining the Cutterbar, page 74.

1. Start the engine, and raise the header fully.

2. Place a block under each end of the disc header, so the
right end is higher than the left end.

3. Lower the header onto the blocks.

4. Shut down the engine, and remove the key from the
ignition.

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 list of
recommended fluids and lubricants.

IMPORTANT:

Do NOT overfill the cutterbar. Overfilling can cause
overheating, damage, or failure of cutterbar components.

NOTE:

Do NOT remove the hex bolts (B) securing the cutterbar
end plate to the cutterbar or lubricant leaks could result.

Figure 4.16: Filling Cutterbar

6. Install access plug (A). Torque to 30 Nm (22 lbf·ft).

CAUTION

Never start or move the machine until you are sure all bystanders have cleared the area.

7. Start the engine, and raise the header fully.

8. Shut down the engine, and remove the key from the
ignition. Engage the windrower lift cylinder safety props.
Refer to 3.3.1 Engaging and Disengaging Header Safety

Props – M1240 Windrower, page 22.

9. Remove the block from under the cutterbar.

10. Lower the header.

11. Check the lubricant level. Refer to Checking and Adding

Cutterbar Lubricant, page 71.

4.5.2 Maintaining Cutterbar Discs

Perform daily inspections to ensure that cutterbar discs have not suffered damage from rocks, or experienced excessive
wear from abrasive working conditions.

Cutterbar discs are interchangeable and can be moved to a spindle that rotates in the opposite direction as long as it is in
usable condition and the blades are oriented to cut in the correct direction.

The cutterbar discs are NOT repairable and must be replaced if severely damaged or worn.

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MAINTENANCE AND SERVICING

IMPORTANT:

If holes appear in a cutterbar disc, replace the disc immediately. Do NOT attempt to repair the cutterbar discs. Always use
factory replacement parts.

Inspecting Cutterbar Discs

WARNING

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator’s seat for any reason.

CAUTION

Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working
with blades.

CAUTION

Damaged blades may damage the cutterbar and result in poor cutting performance. Replace damaged blades
immediately.

1. Inspect the cutterbar disc surface (D) for cracks, excessive
wear, and disc distortion. Replace as required.

2. Inspect the cutterbar disc edges (E) for cracks, excessive
wear, and edge distortion. Replace as required.

NOTE:

Cutterbar discs are NOT repairable and must be replaced if
damaged.

3. Ensure that the discblade fasteners (A) are securely
attached to the cutterbar disc and that nut shields (B) are
present and undamaged. Replace as required.

4. Check that the cutterbar disc bolts (C) are securely attached
to the spindles. Tighten as required.

5. Inspect the cutterbar disc for deformation. If the disc is
deformed, dimension (A) must NOT exceed 48 mm
(1 7/8 in.). Replace as required.

Figure 4.17: Cutterbar Disc

Figure 4.18: Cutterbar Disc – Cutaway View

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6. Inspect the cutterbar disc for abrasion (A). The wear limit
for abrasion is reached when the material thickness of the
cutterbar discs is less than 3 mm (1/8 in.). Replace as
required.

Figure 4.19: Cutterbar Disc – View from Above

Removing Cutterbar Discs

DANGER

To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and
engage windrower lift cylinder safety props before going under machine for any reason.

CAUTION

Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working
with blades.

1. Raise the header.

2. Shut off the engine, and remove key from the ignition.

3. Engage windrower lift cylinder safety props. Refer to 3.3.1 Engaging and Disengaging Header Safety Props – M1240

Windrower, page 22.

4. Open cutterbar curtain (A). Refer to 3.7.1 Opening

Cutterbar Curtain, page 42.

Figure 4.20: Cutterbar Curtain

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5. Place a pin (or equivalent) in the front hole of the rock
guard (B) to prevent disc rotation while loosening bolts.

6. Remove four M12 bolts (A) and washers.

7. Remove cutterbar disc cap (A).

8. Remove cutterbar disc (B).

Figure 4.21: Cutterbar Disc Bolts

Figure 4.22: Cutterbar Disc and Cap

Installing Cutterbar Discs

WARNING

Exercise caution when working around the blades. Blades are sharp and can cause serious injury. Wear gloves when
handling blades.

1. Install spacer plate (A) on spindle.

Figure 4.23: Disc Spindle

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2. Place a pin (or equivalent) in the front hole of the rock
guard (D) to prevent disc rotation while tightening bolts.

3. Position new disc (A) on spindle ensuring that it is
positioned at a 90 degree angle in relation to the
adjacent discs.

4. Install cutter disc cap (B), and secure assembly with four
M12 bolts and washers (C). Torque bolts to 85 Nm
(63 lbf·ft).

WARNING

Ensure cutterbar is completely clear of foreign objects. Foreign
objects can be ejected with considerable force when the
machine is started and may result in serious injury or machine
damage.

5. Remove pin (or equivalent) from front hole of rock guard.

6. Close the cutterbar curtain. Refer to 3.7.2 Closing Cutterbar

Curtain, page 43.

Figure 4.24: Cutterbar Disc and Cap

Figure 4.25: Cutterbar Curtain

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4.5.3 Replacing Cutterbar Spindles

To prevent damage to the cutterbar and drive systems, each
disc is attached to a spindle containing a shear pin (A).

If the disc contacts a large object such as a stone or stump, the
pin will shear and the disc will stop rotating and move upwards
while remaining attached to the spindle with a snap ring (B).

NOTE:

Once spindle has risen due to shear pin failure, the spindle’s
bearing will become unloaded. Do NOT replace the spindle due
to excessive play. Check play after torquing spindle nut and
replacing damaged shear pins.

Refer to 4.5.8 Replacing Cutterbar Spindle Shear Pin, page 116
to replace shear pin.

IMPORTANT:

• Spindles that rotate clockwise have right-leading threading
and are identified by a smooth top on the spindle gear
shaft (A).

• Spindles that rotate counterclockwise have left-leading
threading and are identified by machined grooves on the
spindle gear shaft (B) and nut (C).

• If spindle position in cutterbar has changed, the rotational
direction of that spindle MUST remain the same (that is, a
clockwise spindle must maintain its clockwise rotation).

• Failure to maintain rotation pattern can result in damage to
spindle and/or cutterbar components.

• Safecut (shear pin) will not work if spindles are used in the
wrong orientation.

Figure 4.26: Cutterbar Spindles

Figure 4.27: Cutterbar Spindles

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Removing Cutterbar Spindles

DANGER

To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and
engage windrower lift cylinder safety props before going under machine for any reason.

CAUTION

Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working
with blades.

1. Park on a flat, level surface.

2. Raise the header.

3. Shut off the engine, and remove the key from the ignition.

4. Engage windrower lift cylinder safety props. Refer to 3.3.1 Engaging and Disengaging Header Safety Props – M1240

Windrower, page 22.

5. Open cutterbar curtain (A). Refer to 3.7.1 Opening

Cutterbar Curtain, page 42.

6. Place a pin (or equivalent) in the front hole of the rock
guard (B) to prevent disc rotation while loosening bolts.

7. Remove four M12 bolts (A) and washers.

Figure 4.28: Cutterbar Curtain

Figure 4.29: Cutterbar Disc Bolts

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8. Remove cutterbar disc cap (A).

9. Remove cutterbar disc (B).

IMPORTANT:

Blades are rotation specific. Switch entire disc when
swapping spindles.

10. Remove spacer plate (A).

NOTE:

The area around the spacer plate must be cleaned
thoroughly to prevent debris from entering into the
cutterbar gearbox.

Figure 4.30: Cutterbar Disc and Cap

11. Rotate spindle hub (A) to access nuts, and remove eleven
M12 lock nuts (B) and washers.

Figure 4.31: Spacer Plate

Figure 4.32: Left Spindle Hub and Hardware

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12. Remove spindle (A) from cutterbar.

Installing Cutterbar Spindles

Figure 4.34: Underside of Cutterbar Spindles

MAINTENANCE AND SERVICING

Figure 4.33: Left Spindle

IMPORTANT:

Right discs (A) and left discs (B) are timed and must be at a 90 degree angle from adjacent discs when reinstalled.
Misaligned discs could result in the following:

• Discblades of co-rotating discs hitting each other

• Discblades of diverging discs hitting adjacent discs

Check clearance (timing) before tightening spindle to the cutterbar. Turn disc by hand to ensure discblades do not contact
each other or adjacent discs. If contact occurs or alignment is incorrect, lift spindle to clear mounting bolts, rotate spindle
180 degrees (ensuring that base does not turn), and reinstall. Recheck timing before bolting hub down and tightening all of
the nuts.

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NOTE:

Right discs (A) and left discs (B) are slightly offset as shown, depending on which idler gear the spindle is turning.

• Spindles that rotate clockwise have left-leading threading

• Spindles that rotate counterclockwise have right-leading threading

DANGER

To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and
engage windrower lift cylinder safety props before going under machine for any reason.

CAUTION

Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working
with blades.

1. Park on a flat, level surface.

2. Lower the disc header fully, shut off engine, and remove key.

NOTE:

To prevent oil from spilling from the cutterbar while installing disc spindles, ensure the disc header is on a flat, level
surface, and is tilted all the way back.

3. Determine suitable spindle rotation pattern for crop conditions. Refer to 4.5.3 Replacing Cutterbar Spindles, page 80.

4. Ensure that spindle O-ring (A) is properly seated, cleaned,
and undamaged.

Figure 4.35: Left Spindle O-Ring

5. Insert spindle (A) into cutterbar.

Figure 4.36: Left Spindle

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6. Insert studs (A) into spindle as shown.

NOTE:

Plugs are factory-installed as shown in position (B), but may
come loose over time. Ensure studs are inserted into
proper location.

IMPORTANT:

Ensure clockwise spindles rotate clockwise and
counterclockwise spindles (with machined grooves) rotate
counterclockwise.

IMPORTANT:

The offset gear design makes it possible to install spindles
that rotate in the wrong direction. This will prevent discs
from spinning up after impact, resulting in cutterbar
component damage.

7. Ensure that hub (A) is fully seated into cutterbar before
tightening nuts (B).

8. Rotate spindle hub (A) to access studs, and install eleven
M12 lock nuts (B) and washers.

Figure 4.37: Spindle Orientation

9. Torque bolts to 50 Nm (37 lbf·ft) following the tightening
pattern shown at right.

NOTE:

Hub removed from illustration for clarity.

IMPORTANT:

Do NOT use an impact wrench when tightening as it will
damage the weld studs.

Figure 4.38: Left Spindle Hub

Figure 4.39: Tightening Pattern

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10. Install spacer plate (A).

11. Place a pin (or equivalent) in the front hole of the rock
guard (D) to prevent disc rotation while tightening bolts.

IMPORTANT:

Blades are rotation specific. It is necessary to switch entire
disc when swapping spindles.

Figure 4.40: Spacer Plate

12. Position disc (A) on spindle ensuring that it is positioned at
a 90 degree angle in relation to the adjacent discs.

NOTE:

Turn disc (A) by hand to ensure discblades do not contact
each other or adjacent discs.

NOTE:

Each header comes with a disc timing tool (MD #307954)
and instructions.

13. Install cutter disc cap (B) and secure assembly with four
M12 bolts and washers (C). Torque bolts to 85 Nm
(63 lbf·ft).

Figure 4.41: Cutterbar Disc and Cap

WARNING

Ensure cutterbar is completely clear of foreign objects. Foreign objects can be ejected with considerable force when the
machine is started and may result in serious injury or machine damage.

14. Remove pin (or equivalent) from front hole of rock guard.

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15. Close cutterbar curtain (A). Refer to 3.7.2 Closing Cutterbar

Curtain, page 43.

4.5.4 Maintaining Discblades

Each disc has two blades (A) attached at opposite ends that are
free to rotate horizontally on a specially designed shoulder bolt.

Figure 4.42: R216 SP

The blade (A) has two cutting edges and can be flipped over so
that the blade does not need replacing as often.

The blades are NOT repairable and must be replaced if severely
worn or damaged.

IMPORTANT:

Always use factory replacement parts.

NOTE:

Discs are equipped with 18-degree bevel-down blades; 11-degree
bevel-down blades are offered as a non-standard option. Refer
to R216 SP Series Rotary Disc Header Parts Catalog.

Figure 4.43: Discblades

Inspecting Discblades

WARNING

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition
before leaving operator’s seat for any reason.

CAUTION

Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working
with blades.

CAUTION

Damaged blades may damage the cutterbar and result in poor cutting performance. Replace damaged blades
immediately.

CAUTION

Damaged or loose discblades or blade attachment hardware can be ejected during machine operation and may cause
personal injury or machine damage.

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1. Check daily that the discblades are securely attached to
the disc.

2. Inspect blades for cracks, blade wear (A), and/or elongated
hole (B) beyond safe operating limits (C).

3. Replace blades immediately when problems are noticed.

IMPORTANT:

Blades should be replaced in pairs or the disc may become
unbalanced and cause damage to the cutterbar.

IMPORTANT:

The discblades have cutting edges on both sides so the
blades can be turned over and reused. The twist in each
blade determines the cutting direction. If you are unsure
which direction the spindles rotate, refer to 3.9

Reconfiguring Cutterbar Crop Stream, page 47.

Figure 4.44: Discblades

A - Blade Wear to Center Line
B - Elongated Hole
C - Maximum Elongation 21 mm (13/16 in.)

Figure 4.45: Counterclockwise Disc Rotation Direction

Figure 4.46: Clockwise Disc Rotation Direction

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Inspecting Discblade Hardware

CAUTION

Damaged or loose discblades or blade attachment hardware can be ejected during machine operation and may cause
personal injury or machine damage.

Inspect blade attachment hardware each time blades are changed. Refer to Removing Discblades, page 90 and Installing

Discblades, page 92 for hardware replacement procedure.

1. Check and replace bolt if:

• Bolt has been removed and installed five times

• Head (A) is worn flush with bearing surface of blade

• Diameter of bolt neck is worn (B) 3 mm (1/8 in.)

• Bolt is cracked (C)

• Bolt is visibly distorted (D)

• Bolt shows evidence of interference (E) with

adjacent parts

Figure 4.47: Discblade Bolts

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2. Check and replace nuts under the following conditions:

• Nut has been previously installed—nuts are one-time

use only

• Nut shows signs of wear (A) that is more than half the

original height (B)

• Nut is cracked

Figure 4.48: Discblade Nut

Removing Discblades

DANGER

To avoid bodily injury or death from unexpected start-up or fall of a raised machine, stop engine, remove key, and
engage windrower lift cylinder safety props before going under machine for any reason.

CAUTION

Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working
with blades.

1. Raise disc header fully, shut off engine, and remove key.

2. Engage windrower lift cylinder safety props. Refer to 3.3.1 Engaging and Disengaging Header Safety Props – M1240

Windrower, page 22.

3. Open cutterbar curtain (A). Refer to 3.7.1 Opening

Cutterbar Curtain, page 42.

Figure 4.49: R216 SP

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4. Rotate disc (A) so blade (B) faces forward and lines up with
hole (C) in rock guard.

5. Place a pin (or equivalent) in the front hole of the
neighboring rock guard to prevent disc rotation while
loosening blade bolts.

6. Clean debris from blade attachment area.

Figure 4.50: Discblade Aligned with Hole in
Rock Guard

7. Remove nut (A) and discard.

IMPORTANT:

Nuts are one-time-use only. When flipping or changing a
blade, replace using a NEW nut only.

8. Remove shoulder bolt (B) and blade (C).

Figure 4.51: Discblade

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Installing Discblades

CAUTION

Discblades have two sharp cutting edges that can cause serious injury. Exercise caution and wear gloves when working
with blades.

IMPORTANT:

If you are unsure which direction the spindles rotate, refer to 3.9 Reconfiguring Cutterbar Crop Stream, page 47.

1. Place a pin (or equivalent) in the front hole of the rock
guard to prevent disc rotation while tightening blade bolts.

2. Install new or reversed blade (A) with shoulder bolt (B)
onto disc (C).

IMPORTANT:

Nuts are one-time-use only. When flipping or changing a
blade, replace using a NEW nut only.

3. Install new nut (D) and torque to 125 Nm (92 lbf·ft).

WARNING

Ensure cutterbar is completely clear of foreign objects. Foreign
objects can be ejected with considerable force when the
machine is started and may result in serious injury or machine
damage.

4. Close the cutterbar curtain (A). Refer to 3.7.2 Closing

Cutterbar Curtain, page 43.

Figure 4.52: Discblade

Figure 4.53: R216 SP

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