MacDon R216 SP Operator'S Manual Download

Page: 163 / 184

214880

155

Revision A

Chapter 6:

Troubleshooting

6.1

Performance Problems

Problem

Solution

Refer to

Symptom: Cutterbar plugging

Dull, bent, or badly worn discblades

Replace discblades.

•

Removing Discblades, page 90

•

Installing Discblades, page 92

Build-up of dirt between rock guards

Decrease header angle and increase
float. In some conditions, it may be
necessary to carry header slightly with
header lift cylinders.

•

3.8.1 Cutting Height, page 44

•

Refer to windrower
operator

’

s manual

Conditioner drive belt slipping

Adjust conditioner drive belt tension.

Conditioner Drive Belt, page 134

Symptom: Ragged or uneven cutting of crop

Header angle too flat for guards to
pick up downed crop

Increase header angle.

3.8.1 Cutting Height, page 44

Downed crop

Adjust header angle to cut closer to
ground.

3.8.1 Cutting Height, page 44

Header float too light, causing
bouncing

Adjust to heavier float setting.

Refer to windrower operator

’

s manual

Excessive ground speed

Reduce ground speed.

—

Symptom: Strips of uncut crop left on field

Dull, bent, or badly worn discblades

Replace discblades.

•

Removing Discblades, page 90

•

Installing Discblades, page 92

Build-up of dirt between rock guards

Decrease header angle and increase
float. In some conditions, it may be
necessary to carry header slightly with
header lift cylinders.

•

3.8.1 Cutting Height, page 44

•

Refer to windrower
operator

’

s manual

Excessive header speed

Reduce header disc speed.

—

Foreign object on cutterbar

Disengage header and stop engine.
When all moving parts are completely
stopped, remove foreign object.

4.5 Cutterbar System, page 71

Disc not turning

Replace spindle shear pin.

—

Ground speed too slow

Increase ground speed.

—

Symptom: Conditioner rolls plugging

Ground speed too fast

Reduce ground speed.

—

Roll gap too large for proper feeding

Decrease roll gap.

•

Adjusting Roll Gap, page 49

Roll gap too small in thick-stemmed
cane-type crops

Increase roll gap.

•

Adjusting Roll Gap, page 49

Swath baffle set too low

Raise swath baffle.

3.10.4 Adjusting Forming Shields

–

Roll

Conditioner, page 54

Summary of Contents for R216 SP

Page 1: ...R216 SP Rotary Disc Header Operator s Manual 214880 Revision A Original Instruction The harvesting specialists...

Page 2: ...ypical 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 depe...

Page 3: ...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 w...

Page 4: ...year of the header in the spaces provided below Figure 1 Serial Number Location Header model R216 SP Disc Mower Serial number Model year The serial number plate A is located on the left side of the he...

Page 5: ...ader 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 Heade...

Page 6: ...rying 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...

Page 7: ...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 He...

Page 8: ...e 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...

Page 9: ...icates 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 accompa...

Page 10: ...ded 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 p...

Page 11: ...ive glasses or goggles Heavy gloves Wet weather gear Respirator or filter mask Figure 1 3 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable hear...

Page 12: ...chine function and or safety It may also shorten machine s life To avoid injury or death from unexpected startup of machine ALWAYS stop the engine and remove the key from the ignition before leaving t...

Page 13: ...machine Make sure all components are tight and that steel lines hoses and couplings are in good condition before applying pressure to hydraulic systems Keep hands feet clothing and hair away from all...

Page 14: ...pressure Makeshift repairs will fail suddenly and create hazardous and unsafe conditions Figure 1 12 Hydraulic Pressure Hazard Wear proper hand and eye protection when searching for high pressure hydr...

Page 15: ...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...

Page 16: ...he 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 2 Decide on exact l...

Page 17: ...214880 9 Revision A 1 8 Locating Safety Decals Figure 1 15 Safety Sign Decal Locations Top View A MD 307746 B MD 113482 C MD 166832 D MD 190546 Figure 1 16 Safety Sign Decals SAFETY...

Page 18: ...214880 10 Revision A Figure 1 17 Safety Sign Decal Locations Rear View A MD 190546 B MD 325070 C Reflector SAFETY...

Page 19: ...on Keep riders off the machine 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...

Page 20: ...top 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...

Page 21: ...ctor Cutterbar Number of cutting discs Ten Blades per disc Two 18 degrees bevel down Disc speed full engine speed 2500 rpm Blade max tip speed 80 5 m s 180 mph Effective cutting width 4942 mm 16 ft 2...

Page 22: ...29 in Roll diameter 229 mm 9 in roll diameter outer on 179 mm 7 in OD tube Roll speed 1009 rpm Swath width1 915 2438 mm 36 96 in Forming shields Full width adjustable baffle on conditioner with adjust...

Page 23: ...dentification 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 H...

Page 24: ...214880 16 Revision A Figure 2 2 R216 SP Series Rotary Disc Header A Header Supports B Deflectors C Rear Crop Baffle D Drive Shield PRODUCT OVERVIEW...

Page 25: ...nal socket in head internal wrenching hexagon drive also known as an Allen key and various other synonyms hp Horsepower HPT display Harvest Performance Tracker display module on a windrower JIC Joint...

Page 26: ...t of a force X lever arm length usually measured in Newton meters Nm or foot pounds lbf ft Torque angle A tightening procedure where fitting is assembled to a precondition finger tight and then nut is...

Page 27: ...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 unusua...

Page 28: ...arry 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 Figure 3 1...

Page 29: ...king 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 machin...

Page 30: ...art 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 sw...

Page 31: ...ader 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 clear...

Page 32: ...s seat for any reason Figure 3 7 Hydraulic Center Link 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 Replac...

Page 33: ...HPT Display 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 a...

Page 34: ...kup Figure 3 13 Header Support 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 NOTE...

Page 35: ...tch on the GSL Figure 3 17 Hydraulic Center Link 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 lin...

Page 36: ...is 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 CAUTION Check...

Page 37: ...ward platform A to the OPEN position For instructions refer to the windrower operator s manual Figure 3 21 Hydraulic Hoses 2 Route hose bundle A from the header under the windrower frame then insert p...

Page 38: ...ing Plugs on R216 Hydraulic Hoses 4 Remove protective plugs A from ends of hydraulic hoses Figure 3 23 Hose Support 5 Use a clean rag to remove dirt and moisture from the couplers on the windrower and...

Page 39: ...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...

Page 40: ...es to the M1240 Windrower using quick couplers follow these steps If your windrower is equipped with hard plumb connections refer to for connection instructions Figure 3 27 Hydraulic Hoses 1 Route hos...

Page 41: ...d moisture from the couplers on the left side of the windrower frame 4 Make the following hydraulic and electrical connections to the windrower a Connect disc pressure hose A with coupler B and torque...

Page 42: ...4880 34 Revision A Figure 3 30 Windrower with Left Platform in Closed Position 5 Move left windrower platform A to the CLOSED position For instructions refer to the windrower operator s manual OPERATI...

Page 43: ...seat for any reason CAUTION Check to be sure all bystanders have cleared the area Figure 3 31 GSL 1 Start the engine and press switch A to raise the header to the maximum height 2 Stop the engine and...

Page 44: ...lectrical Connection Figure 3 34 Header Drive Hydraulics 5 Disconnect electrical harness A and hydraulic hoses B C and D from the windrower Figure 3 35 Hoses on Windrower 6 Remove hose support A and h...

Page 45: ...tch A before returning to the cab Figure 3 38 Safety Props 9 Disengage safety prop by turning lever A downwards until lever locks into the vertical position 10 Repeat for the opposite side CAUTION Che...

Page 46: ...ignment Figure 3 40 Hydraulic Center Link 15 Shut off the engine and remove the key 16 Lift hook release A and lift hook B off header pin 17 Disconnect header harness and remote baffle connector if eq...

Page 47: ...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 Figure 3 42 Left Driveshield NOTE Image...

Page 48: ...ening Driveshield Outboard Side 2 Lift outboard driveshield panel toward outboard end of header Figure 3 45 Driveshield Inboard Side 3 Grab handle A and lift the other half of the endshield B to the i...

Page 49: ...E Images shown in this procedure are for the left driveshield the right driveshield is similar Figure 3 46 Driveshield Lock Latch 1 Lift lock latch A to disengage driveshield lock Figure 3 47 Left Dri...

Page 50: ...bar 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 Ins...

Page 51: ...52 Cutterbar Curtain and Retaining Clips NOTE Cutterbar curtain A is held in place between the tines of retaining clips B 3 7 2 Closing Cutterbar Curtain CAUTION To avoid injury keep hands and fingers...

Page 52: ...tional 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 t...

Page 53: ...T 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 mi...

Page 54: ...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 mi...

Page 55: ...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 57 Cutterbar Spindles IMPORTANT Spin...

Page 56: ...ge 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...

Page 57: ...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 leav...

Page 58: ...y reason 1 Lower the header to the ground 2 Shut down the engine and remove the key from the ignition Figure 3 60 Roll Tension Adjuster 3 Loosen jam nut A on both sides of the conditioner 4 Adjust spr...

Page 59: ...up 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...

Page 60: ...roll B counterclockwise direction until it stops rotating 5 Make a mark C across yoke D and gearbox flange E Figure 3 65 Conditioner Drive 6 Manually rotate upper roll A clockwise it stops rotating M...

Page 61: ...oll B counterclockwise until the bolt lines up with the third center mark Figure 3 67 Conditioner Drive 9 Ensure the threads on four bolts A are clean and free of lubricant NOTE Only three of the four...

Page 62: ...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 fee...

Page 63: ...age 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...

Page 64: ...or any reason Figure 3 71 Deflector Fins Under Baffle 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 Fig...

Page 65: ...57 Revision A Figure 3 73 Left Deflector Fins in Storage Position NOTE Deflector fins A can be put in storage position by removing existing nut and bolt and reattaching fins on top of the baffle OPER...

Page 66: ...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...

Page 67: ...ales to minimize handling and stacking problems Properly conditioned Prevents excessive leaf damage 3 11 5 Driving on Windrow Driving on previously cut windrows that will not be raked can lengthen dry...

Page 68: ...214880 60 Revision A 3 12 Transporting the Header For information on transporting the header when attached to the windrower refer to your windrower operator s manual OPERATION...

Page 69: ...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...

Page 70: ...e 4 2 Safety Equipment Wear protective shoes with slip resistant soles a hard hat protective glasses or goggles and heavy gloves Figure 4 3 Safety Around Equipment Be aware that if more than one perso...

Page 71: ...hen working with electrical equipment Be sure all electrical outlets and tools are properly grounded Use adequate light for the job at hand Reinstall all shields removed or opened for service Use only...

Page 72: ...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 Mainte...

Page 73: ...1 Checking and Changing Conditioner Roll Timing Gearbox Oil page 124 Check header drive gearbox lubricant Refer to 4 7 1 Checking Header Drive Gearbox Oil page 127 Every 250 Hours3 Change roll timing...

Page 74: ...4 50 Hours Change header drive gearbox lubricant 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 op...

Page 75: ...ate 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 th...

Page 76: ...commended 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...

Page 77: ...aring Roller Conditioner 2 Places C U Joint Conditioner Driveline 2 Places D Slip Joint Conditioner Driveline4 E Idler Tensioner Pivot F Bearing Feed Roll G Tensioner Arm MAINTENANCE AND SERVICING 4 U...

Page 78: ...tioner 2 Places B U Joint Upper Driveline 2 Places C Slip Joints Conditioner Drivelines5 D U Joint Lower Driveline 2 Places E Idler Pivot MAINTENANCE AND SERVICING 5 Use high temperature extreme press...

Page 79: ...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 sha...

Page 80: ...oceed to Step 22 page 73 8 Reinstall the inspection plug CAUTION Before starting the machine check to be sure all bystanders have cleared the area 9 Start the engine and raise the header slightly 10 L...

Page 81: ...afety 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...

Page 82: ...ey 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 e...

Page 83: ...terbar end plate to the cutterbar or lubricant leaks could result 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 clear...

Page 84: ...ce Replace damaged blades immediately Figure 4 17 Cutterbar Disc 1 Inspect the cutterbar disc surface D for cracks excessive wear and disc distortion Replace as required 2 Inspect the cutterbar disc e...

Page 85: ...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...

Page 86: ...ove four M12 bolts A and washers Figure 4 22 Cutterbar Disc and Cap 7 Remove cutterbar disc cap A 8 Remove cutterbar disc B Installing Cutterbar Discs WARNING Exercise caution when working around the...

Page 87: ...ll 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 ejecte...

Page 88: ...g damaged shear pins Refer to 4 5 8 Replacing Cutterbar Spindle Shear Pin page 116 to replace shear pin Figure 4 27 Cutterbar Spindles IMPORTANT Spindles that rotate clockwise have right leading threa...

Page 89: ...rking 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...

Page 90: ...tire disc when swapping spindles Figure 4 31 Spacer Plate 10 Remove spacer plate A NOTE The area around the spacer plate must be cleaned thoroughly to prevent debris from entering into the cutterbar g...

Page 91: ...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...

Page 92: ...des 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 an...

Page 93: ...nstall spindles that rotate in the wrong direction This will prevent discs from spinning up after impact resulting in cutterbar component damage Figure 4 38 Left Spindle Hub 7 Ensure that hub A is ful...

Page 94: ...ngle 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 instructio...

Page 95: ...ee 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 Inspecting Discblades WARNING To avoid bodily injury or d...

Page 96: ...blems are noticed IMPORTANT Blades should be replaced in pairs or the disc may become unbalanced and cause damage to the cutterbar Figure 4 45 Counterclockwise Disc Rotation Direction IMPORTANT The di...

Page 97: ...ades are changed Refer to Removing Discblades page 90 and Installing Discblades page 92 for hardware replacement procedure Figure 4 47 Discblade Bolts 1 Check and replace bolt if Bolt has been removed...

Page 98: ...e 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 Exercis...

Page 99: ...scblade 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 7 Remove nut A and di...

Page 100: ...event 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...

Page 101: ...Inspecting Accelerators CAUTION Discblades have two sharp cutting edges that can cause serious injury Exercise caution and wear gloves when working with blades WARNING To avoid bodily injury or death...

Page 102: ...ng edges that can cause serious injury Exercise caution and wear gloves when working with blades IMPORTANT Always replace accelerators in pairs to ensure proper disc balance 1 Raise the header fully 2...

Page 103: ...n while loosening bolts 6 Line up rock guard hole and bolt to be removed 7 Remove nut A flange bolt B and discblade C from disc Discard nut Figure 4 59 Accelerator Removal 8 Remove lock nut A accelera...

Page 104: ...uivalent in the front hole of the neighboring rock guard to prevent disc rotation while tightening blade bolts IMPORTANT Accelerators are unidirectional both clockwise and counterclockwise accelerator...

Page 105: ...machine is equipped with rock guards at each cutting disc location Rock guards prevent the cutterbar from digging into the ground and protect the disc from coming in contact with stones and other deb...

Page 106: ...more of their original thickness 5 Check for loose or missing fasteners tighten or replace fasteners as needed Removing Rock Guards Figure 4 65 Rock Guards 1 Remove two hex head screws washers and lo...

Page 107: ...ard onto cutterbar until tabs A sit on top of the cutterbar and bottom back bolt holes line up Figure 4 68 Rock Guards 2 Install two hex head screws washers and lock nuts A Torque hardware to 68 Nm 50...

Page 108: ...o 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 CAU...

Page 109: ...Driven Drum Cutaway View 7 Inspect the driven and non driven drums for deformation If the drum is deformed dimension A must NOT exceed 48 mm 1 7 8 in Replace as required Figure 4 73 Driven Drum View f...

Page 110: ...RNING Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades NOTE Illustrations show right suspended drum left suspended drum is...

Page 111: ...7 Suspended Drum 6 Remove four M12 hex flange head bolts A securing suspended drum B to shaft C and remove suspended drum B Figure 4 78 Driveshield 7 Remove two M10 hex flange head bolts A and remove...

Page 112: ...spended drum is opposite Figure 4 79 Driveshield NOTE Ensure driveshield B is installed before suspended drum 1 Position driveshield B as shown Apply a bead of medium strength threadlocker Loctite 243...

Page 113: ...and engage windrower lift cylinder safety props before going under machine for any reason WARNING Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear glo...

Page 114: ...ts A and loosen two M10 hex flange head bolts B Pull back driveshield C Figure 4 84 Driveshield 6 Remove two M10 hex flange head bolts A and remove driveshield B Figure 4 85 Driveline Shields 7 Remove...

Page 115: ...f drum Figure 4 88 Driven Drum View from Above 10 Use a 18 mm deep socket to remove four M12 bolts A and washers holding the drum disc assembly B in place 11 Remove drum disc assembly B Installing Lef...

Page 116: ...m disc assembly B as shown 3 Use a 18 mm deep socket to install four M12 bolts A and washers that hold the drum disc in place Torque hardware to 85 Nm 63 lbf ft Figure 4 91 Drum and Tube Shield Cutawa...

Page 117: ...drum shields B as shown Apply a bead of medium strength threadlocker Loctite 243 or equivalent around the threads of eight M8 hex flange head bolts A Use the bolts to secure the drum shields in place...

Page 118: ...43 Removing Right Driven Drum and Driveline DANGER To avoid bodily injury or death from unexpected start up or fall of a raised machine stop engine remove key and engage windrower lift cylinder safet...

Page 119: ...ts A and loosen two M10 hex flange head bolts B Pull back driveshield C Figure 4 98 Driveshield 6 Remove two M10 hex flange head bolts A and remove driveshield B Figure 4 99 Driveline Shields 7 Remove...

Page 120: ...4 101 Drum and Tube Shield Cutaway View 9 Slide driveline A downwards tilt it to the side and pull driveline up and out of drum Figure 4 102 Right Driven Drum View from Above 10 Use a 18 mm deep socke...

Page 121: ...y reason WARNING Exercise caution when working around the blades Blades are sharp and can cause serious injury Wear gloves when handling blades Figure 4 103 Right Driven Spindle 1 Ensure spacer A is o...

Page 122: ...ine 7 Place a bead of high strength threadlocker Loctite 262 or equivalent around the threads of four M10 hex flange head bolts A Use the bolts to secure driveline assembly B to hub drive C Torque bol...

Page 123: ...ead of medium strength threadlocker Loctite 243 or equivalent around the threads of two M10 hex flange head bolts A and two M10 hex flange head bolts B Use bolts A and B to secure driveshield C in pla...

Page 124: ...nsure correct orientation of the shear pins during replacement Spindles that rotate clockwise have right leading threading Spindles that rotate counterclockwise have left leading threading NOTE Once s...

Page 125: ...Engage windrower lift safety props Refer to 3 3 1 Engaging and Disengaging Header Safety Props M1240 Windrower page 22 Figure 4 112 R216 SP 4 Open cutterbar curtain A Refer to 3 7 1 Opening Cutterbar...

Page 126: ...on A Figure 4 114 Cutterbar Spindle 7 Remove retaining ring A Figure 4 115 Safecut Spindle Nut Wrench Location 8 Remove M12 bolt and remove safecut spindle nut wrench A from storage location MAINTENAN...

Page 127: ...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 Failu...

Page 128: ...Revision A Figure 4 119 Cutterbar Spindle 11 Remove shear pins B Do NOT damage the pin bore on the pinion 12 Remove the hub A 13 Check the nut and hub for damage Replace if necessary MAINTENANCE AND...

Page 129: ...igure 4 120 Cutterbar Spindle 1 Fill the space above the bearing with grease Refer to the inside back cover of this manual 2 Place the hub A on the spindle C 3 Install shear pins B NOTE Ensure that th...

Page 130: ...ne the proper torque will NOT be applied to the nut 7 Locate the safecut spindle nut wrench B on spindle nut C Torque nut to 300 Nm 221 lbf ft 8 Return safecut spindle nut wrench to left shield plate...

Page 131: ...ll left driven drum B Refer to Installing Left Driven Drum and Driveline page 107 Install right driven drum C Refer to Installing Right Driven Drum and Driveline page 113 WARNING Ensure cutterbar is c...

Page 132: ...l s inside back cover for a list of recommended fluids lubricants and capacity WARNING To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key...

Page 133: ...ide of the gearbox 7 Ensure that the lubricant is level with the top of the sight glass If necessary add lubricant through breather B Refer to this manual s inside back cover for a list of recommended...

Page 134: ...f the gearbox and around oil level plug B on the inboard side of the gearbox 12 Place a 1 liter 1 05 qts US container underneath the conditioner gearbox 13 Remove oil drain plug A using a hex key 14 A...

Page 135: ...Oil Change oil after the first 50 hours of operation Perform subsequent oil changes every 250 hours or annually preferably before the start of the cutting season IMPORTANT Check the gearbox oil level...

Page 136: ...A with a 13 mm 1 2 in socket 7 Ensure lubricant is even with bottom of check hole A or slightly runs out of hole A 8 If necessary remove fill plug B and add lubricant to gearbox through hole B until...

Page 137: ...bottom of the gearbox and around oil level plug B on the inboard side of the gearbox 2 Place a 4 liter 1 gal US container under drain A 3 Remove hex plug A 4 Allow sufficient time for oil to drain re...

Page 138: ...s Always keep the curtain down when operating the header WARNING To reduce the risk of personal injury or machine damage do NOT operate the machine without curtain installed and in good condition Fore...

Page 139: ...r A securing curtain B to the inboard side of the end panel 3 Loosen six lock nuts C securing curtain B to the front of the header frame Do NOT remove nuts at this time NOTE Curtain seam is on the ins...

Page 140: ...Do NOT tighten nuts at this time 3 Slide bumper A onto bumper mount D from outboard end Figure 4 143 Cutterbar Curtain View from Below NOTE Cutterbar removed from illustration for clarity 4 Tighten si...

Page 141: ...der safety props before going under machine 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 Lowe...

Page 142: ...elt The conditioner drive belt is located inside the left driveshield and is tensioned with a spring tensioner Inspecting Conditioner Drive Belt Check the belt tension and inspect for damage or wear e...

Page 143: ...d 5 Check that jam nut B and adjuster nut C are tight Figure 4 150 Belt Tension Spring 6 Measure the length of belt tensioner spring A and ensure spring length B is 17 mm 11 16 in in accordance with s...

Page 144: ...remove key from the ignition 3 Remove the left driveshield Refer to 3 6 1 Opening Driveshields page 39 Figure 4 151 Speed Sensor Assembly 4 Disconnect wire harness A from speed sensor B Figure 4 152 C...

Page 145: ...ader fully 2 Shut down the engine and remove the key from the ignition Figure 4 153 Left Driveshield 3 Open left driveshield A Refer to 3 6 1 Opening Driveshields page 39 Figure 4 154 Conditioner Driv...

Page 146: ...clockwise Figure 4 156 Speed Sensor 9 Reconnect speed sensor B to wiring harness A 10 Close the left driveshield Refer to 3 6 2 Closing Driveshields page 41 Changing the Conditioner R216 SP Series Rot...

Page 147: ...n harness and remove clevis pin B and lynch pin from clevis support C otherwise proceed to Step 4 page 139 Figure 4 159 Fixed Deflector Support Left Side of Header 4 Remove two M10 hex flange bolts A...

Page 148: ...spreader bar A to a forklift or equivalent lifting device and attach chains to lugs B on conditioner C Use a chain rated for overhead lifting with a minimum working load of 1135 kg 2500 lb NOTE Heade...

Page 149: ...shift when bolts are removed 12 Adjust the height of the forks to raise the conditioner slightly Remove the loosened bolts and retain hardware for reinstallation Figure 4 165 Conditioner Lift WARNING...

Page 150: ...in rated for overhead lifting with a minimum working load of 1135 kg 2500 lb 2 Lift conditioner C and align it with the header opening Avoid contact between the top of the conditioner and the center l...

Page 151: ...the conditioner gearbox A with the mounting holes in the header frame B Apply high strength threadlocker Loctite 262 or equivalent on two M12 hex head bolts C and install bolts and washers to secure...

Page 152: ...own NOTE Anti seize compound is applied to splined shaft of driveline before leaving the factory 11 If conditioner driveline B was removed from conditioner secure driveline to the conditioner with a M...

Page 153: ...er support deflector in Figure 4 174 page 144 is flush with inboard side of header support once fixed deflector support is installed 17 Torque bolts A and B to 53 Nm 39 lbf ft 18 Repeat Steps 13 page...

Page 154: ...erate 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 Figure 4 178 Left Driveshield 1 Open d...

Page 155: ...ove 4 10 2 Installing Driveshields CAUTION Do NOT operate the machine without the driveshields in place and secured NOTE Images shown in this procedure are for the left driveshield the right driveshie...

Page 156: ...and Hardware on Driveshield 2 Secure top and bottom of inboard and outboard driveshields with washer A retaining pin B and bolt C Figure 4 183 Left Driveshield 3 Close driveshields Refer to 3 6 2 Clos...

Page 157: ...nd then remove light B from light bracket E Discard light 3 Loosen nut D on new light fixture B then insert light into light bracket E 4 Tighten nut D to secure light in place Torque to 16 Nm 12 lbf f...

Page 158: ...ires are clear of belt and pulley 9 Secure with fir tree clip E and new cable tie Figure 4 186 Header rpm Sensor 10 Adjust nuts A as required to achieve a 2 3 mm 1 16 1 8 in gap B between the sensor C...

Page 159: ...nozzles which eject fluids under high pressure If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may res...

Page 160: ......

Page 161: ...t Side Tall Crop Divider Tall crop dividers attach to the ends of the self propelled disc header for clean crop dividing and cutterbar entry in tall crops The kit MD B6665 includes left and right divi...

Page 162: ...r to achieve the desired cutting height for optimum cutting performance Figure 5 3 Adjustable Skid Shoe 5 1 4 Electric Remote Baffle Kit The Electric Remote Baffle kit MD B6664 allows the operator to...

Page 163: ...perator s manual Excessive ground speed Reduce ground speed Symptom Strips of uncut crop left on field Dull bent or badly worn discblades Replace discblades Removing Discblades page 90 Installing Disc...

Page 164: ...rated header speed Refer to windrower operator s manual Symptom Uneven windrow formation in light crop Uneven feeding Reduce header speed Refer to windrower operator s manual Symptom Plugging behind...

Page 165: ...e 49 Symptom Excessive drying or bleaching of crop Excessive crimping Increase roll gap Adjusting Roll Gap page 49 Crop is spread too wide in windrow Adjust forming shields Positioning Forming Shield...

Page 166: ...le or too much Drain lubricant and refill with specified amount Draining the Cutterbar page 74 Symptom Frequent blade damage Mud on cutterbar Remove mud from cutterbar Do NOT allow mud to dry on cutte...

Page 167: ...d Align pulleys and idler See MacDon Dealer Symptom Conditioner roll does not rotate Faulty drive belt Check drive belt pulleys Inspecting Conditioner Drive Belt page 134 Symptom Disc does not turn wh...

Page 168: ......

Page 169: ...ntifying head markings Jam nuts When applying torque to finished jam nuts multiply the torque applied to regular nuts by f 0 65 Self tapping screws Standard torque is to be used NOT to be used on crit...

Page 170: ...65 72 48 53 14 2 0 104 115 77 85 16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 Figure 7 3 Bolt Grades Table 7 3 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Nominal S...

Page 171: ...5 105 8 1 25 26 29 19 21 10 1 5 51 57 38 42 12 1 75 90 99 66 73 14 2 0 143 158 106 117 16 2 0 222 246 165 182 20 2 5 434 480 322 356 24 3 0 750 829 556 614 7 1 2 Metric Bolt Specifications Bolting int...

Page 172: ...far as possible 3 Check that O ring A is NOT on threads and adjust if necessary 4 Apply hydraulic system oil to O ring A Figure 7 7 Hydraulic Fitting 5 Install fitting B into port until backup washer...

Page 173: ...3 106 115 4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16 12 176 193 130 14...

Page 174: ...7 page 166 6 Check final condition of fitting Table 7 7 O Ring Boss ORB Hydraulic Fittings Non Adjustable SAE Dash Size Thread Size in Torque Value7 Nm lbf ft lbf in 2 5 16 24 6 7 53 62 3 3 8 24 12 1...

Page 175: ...ngs according to values in Table 7 8 page 167 NOTE If applicable hold hex on fitting body E to prevent rotation of fitting body and hose when tightening fitting nut D 6 Use three wrenches when assembl...

Page 176: ...ector typically 45 degree or 90 degree is aligned to receive incoming tube or hose assembly Always finish alignment of fitting in tightening direction Never back off loosen pipe threaded connectors to...

Page 177: ...ressure megapascal MPa x 145 038 pounds per square inch psi Pressure bar Non SI bar x 14 5038 pounds per square inch psi Torque Newton meter Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton...

Page 178: ......

Page 179: ...131 cutterbar angles adjusting angle 45 cutterbars 71 93 116 See also accelerators See also spindle shear pins crop streams 47 changing R216 SP configuration 48 discblades 87 inspecting cutterbar dis...

Page 180: ...ce schedule records 64 ground speed 46 GVW definition 17 H haying tips 58 chemical drying agents 59 curing 58 driving on windrows 59 topsoil moisture 58 weather and topography 58 windrow characteristi...

Page 181: ...17 P preseason servicing 66 R R2 SP Series definition 17 rear baffles positioning on roll conditioner 55 recommended settings header 44 reference maintenance requirements 64 rock guards inspecting 97...

Page 182: ...rque angles definition 17 torque specifications 161 metric bolt specifications 161 bolting into cast aluminum 163 O ring boss ORB hydraulic fittings adjustable 164 O ring boss ORB hydraulic fittings n...

Page 183: ...e SAE Multipurpose High temperature extreme pressure EP performance with 1 max Molybdenum Disulphide NLGI Grade 2 lithium base As required unless otherwise specified SAE Multipurpose High temperature...

Page 184: ...16 891 7313 f 816 891 7323 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 f 7 495 967 7600 MacDon Australia Pty Ltd...

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MacDon R216 SP, Operator'S Manual

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