MacDon R216 Unloading And Assembly Instructions Download Page 15

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215028

Revision A

Chapter 3:

Assembling the Header

Follow each procedure in this chapter in order.

3.1

Removing Shipping Supports

To remove the shipping supports from the cutterbar side of the header, follow these steps:

1030605

Figure 3.1: Shipping Supports

Remove four bolts and nuts (A) from each yellow shipping
support (B).

Remove two supports (B)

Summary of Contents for R216

Page 1: ...R216 Rotary Disc Header for Windrowers Unloading and Assembly Instructions 215028 Revision A Original Instruction The harvesting specialists ...

Page 2: ...ation is based on the information available and in effect at the time of printing MacDon Industries Ltd makes no representation or warranty of any kind whether expressed or implied with respect to the information in this publication MacDon Industries Ltd reserves the right to make changes at any time without notice ...

Page 3: ...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 Carefully read all the material provided before attempting to unload assemble or use the machine NOTE Keep your MacDon publications up to date The most current version can be...

Page 4: ...oduct Support 4 1 5 Connecting Rotary Disc Header Hydraulics Using Hard Plumbing page 36 Added note Product Support 4 1 4 Connecting Rotary Disc Header Hydraulics Using Quick Couplers M1240 Windrowers page 34 Updated the procedure ECN 58681 4 1 8 Unpacking the Curtain page 41 Update images and procedure E58886 6 1 Lubrication Locations page 46 Updated driveline positions ECN 58852 7 3 1 Checking S...

Page 5: ...ess 26 4 1 3 Attaching Rotary Disc Header 29 4 1 4 Connecting Rotary Disc Header Hydraulics Using Quick Couplers M1240 Windrowers 34 4 1 5 Connecting Rotary Disc Header Hydraulics Using Hard Plumbing 36 4 1 6 Restoring Float for Rotary Disc Header 38 4 1 7 Calibrating Windrower Knife Drive on the Harvest Performance Tracker Display 40 4 1 8 Unpacking the Curtain 41 Chapter 5 Installing Options 43 ...

Page 6: ... Props 69 8 3 Leveling the Header 71 8 4 Closing Driveshields 74 8 5 Opening Driveshields 75 8 6 Closing Cutterbar Curtain 77 8 7 Opening Cutterbar Curtain 78 8 8 Recommended Lubricants 79 8 9 Torque Specifications 80 8 9 1 Metric Bolt Specifications 80 8 9 2 Metric Bolt Specifications Bolting into Cast Aluminum 82 8 9 3 O Ring Boss Hydraulic Fittings Adjustable 83 8 9 4 O Ring Boss Hydraulic Fitt...

Page 7: ...t 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 Indicate...

Page 8: ...ve glasses or goggles Heavy gloves Wet weather gear Respirator or filter mask 1000005 Figure 1 2 Safety Equipment 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 1010391 Figure 1 3 Safety Equipment Provide a first aid kit in case of emergencies Keep a properly mainta...

Page 9: ... machine function and or safety It may also shorten the machine s life To avoid 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 1000009 Figure 1 6 Safety around Equipment Keep service area clean and dry Wet and or oily floors are slippery Wet spots can be dangerous when working with...

Page 10: ...ave with regard to future malfunctions or shorter lifespan It is very important that welding on the header is not attempted while the header is connected to the windrower If you need to do any welding on the header it should first be disconnected and removed from the windrower If it is unfeasible to disconnect the header from the windrower before attempting welding refer to the windrower s technic...

Page 11: ...Operator s Manual Decal Keep safety signs clean and legible at all times Replace safety signs that are missing or illegible If the original part on which a safety sign was installed is replaced be sure the repair part displays the current safety sign SAFETY ...

Page 12: ......

Page 13: ...ipping NOTE Forklifts are normally rated for a load located 610 mm 24 in ahead of the back end of the forks To obtain the forklift capacity at 1220 mm 48 in check with your forklift distributor Table 2 1 Lifting Vehicle Minimum Capacity 3630 kg 8000 lb Minimum Fork Length 198 cm 78 in 1028160 Figure 2 2 Lifting Rotary Disc Header off Trailer 1 Remove the hauler s tie down straps and chains WARNING...

Page 14: ...clears the trailer and slowly lower it to 150 mm 6 in from the ground 5 Take the rotary disc header to the storage or setup area 6 Set the rotary disc header down on secure level ground Do NOT lower the header into working position 7 Check for shipping damage and missing parts UNLOADING THE HEADER FROM A TRAILER ...

Page 15: ...this chapter in order 3 1 Removing Shipping Supports To remove the shipping supports from the cutterbar side of the header follow these steps 1030605 A B B B A Figure 3 1 Shipping Supports 1 Remove four bolts and nuts A from each yellow shipping support B 2 Remove two supports B ...

Page 16: ...Side Opposite 3 Remove nuts and bolts A from the yellow channel and header supports 4 Remove yellow braces B from the header 1030604 A A B B Figure 3 3 Plates 5 Remove three bolts and washers A holding support channel B onto the header supports 6 Remove channel B from the header ASSEMBLING THE HEADER ...

Page 17: ...rks so that it cannot slide off the forks or towards the mast as the header is lowered to the ground Table 3 1 Lifting Vehicle Chain Type Overhead lifting quality 1 2 in Minimum Working Load 2270 kg 5000 lb 1028066 A A B B C C Figure 3 4 Block Placement 1 Place wood blocks A at a distance of 42 cm 16 1 2 in B on the outboard side of each shipping stand C NOTE Wood blocks should be 2 x 4 in and 1 1...

Page 18: ...cient to provide a minimum clearance C of 1219 mm 48 in between the rotary disc header and the spreader bar IMPORTANT Do NOT attach chain hooks to the hazard light standards 5 Raise forks until lift chains are fully tensioned 1028609 A B B Figure 3 6 Lowering Rotary Disc Header to the Ground 6 Back up the forklift SLOWLY and lower the rotary disc header A into working position on the wooden blocks...

Page 19: ...028227 A B C D E Figure 3 8 Hydraulic Hose Bundle in Shipping Position 3 Remove shipping wire cross ties A securing hoses B to center link C near shipping stands D and pull the hoses out from under the center link NOTE Shipping wire cross ties not shown in illustration at right 4 Remove shipping wire E from center link C and move hoses B away from the center link Rest hoses B on top of the header ...

Page 20: ...es of the header 1030248 A A Figure 3 10 Shipping Stand Center link 1 Remove two nuts A and bolts and discard Repeat on the opposite side 1030247 A B A B Figure 3 11 Shipping Stand Right Side Shown Left Side Opposite 2 Remove two bolts A and nuts from the top of the header and discard Repeat on the opposite side of the header 3 Remove nut B and bolt and discard ASSEMBLING THE HEADER ...

Page 21: ...de of the right header boot and bolt B from the inboard side of the right shipping stand C Repeat on the opposite side of the header 1028176 A A B B A A B B C C A A B B A B A B Figure 3 13 Shipping Stand 5 Remove four nuts A and bolts B from top of shipping stands C and remove the shipping stands from the header ASSEMBLING THE HEADER ...

Page 22: ...etain bolts A and remove shipping plate B Discard plate B and repeat for the other side of the header 7 Apply medium strength threadlocker Loctite 243 or equivalent to bolt threads A and reinstall them onto the header Torque hardware to 91 Nm 67 lbf ft Repeat for the other side of the header ASSEMBLING THE HEADER ...

Page 23: ... B to rear baffle C Remove and retain deflector B from the header Repeat on the opposite side of the header NOTE There are three sets of hardware A on the baffle but only two sets hold deflector B in place in shipping position Ensure all three sets of hardware A are removed and retained 1028619 A B C Figure 3 16 Baffle Handle and Baffle Bracket 2 Remove pin A from baffle handle B and adjust the re...

Page 24: ... three locations Do NOT tighten hardware Repeat on the opposite side of the header 6 Adjust the placement of deflector A as far inboard as possible so that it contacts fixed deflector plate C welded in place on the header Tighten hardware E once deflector is properly placed Repeat on the opposite side of the header 7 Check that the baffle is adjustable across all working positions without binding ...

Page 25: ... headers without the DWA installed 1030688 A A B B C C B B C C D D Figure 4 1 Setting Forming Shield for Header without DWA Option 2 Install shield mount plates C on the inside of the windrower legs 3 Install two hex head M12 X 1 75 X 140 8 8 bolts A washers D and nuts C in the rear holes on the shield mounting plates This ensures the forming shield is set at its lowest setting The lowest setting ...

Page 26: ...shield mounting plates This ensures the forming shield is set at its highest setting 1030492 A B C Figure 4 3 Forming Shield in Shipping Configuration 5 Unpack and remove shipping material from deflectors A and B 6 Remove right deflector A and left deflector B from shipping position and place them on an even work surface 7 Remove cover C from shipping position and place the cover on an even work s...

Page 27: ...ming shield cover 13 Install three 25 mm long short neck M10 bolts B and three Nyloc nuts C 14 Install support plate D on the top of the cover 15 Install two 35 mm long short neck M10 bolts E and two nuts F 1030527 A A B B C D C D Figure 4 6 Plate and Forming Shield Angle 16 Install one 25 mm long short neck M10 bolt A and nut B through plate C and forming shield angle D Repeat this step on the le...

Page 28: ...ide of the windrower legs Repeat on other side of the windrower and forming shield 1028726 A A B C Figure 4 8 Clevis Pin 20 Install clevis pin A to hold forming shield in place Repeat on the other side of the forming shield NOTE Clevis pin A should pass under hex head bolt B and spacer installed in the previous step with its lynch pin C set towards the interior of the header ATTACHING ROTARY DISC ...

Page 29: ...ce with washer C and hair pin D 23 Repeat Step 21 page 23 to Step 22 page 23 for the left side of the forming shield 1030512 A B C D Figure 4 10 Right Side Bracket and Baffle 24 Retrieve baffle A from shipping position 25 Secure baffle A to side bracket D with one 25 mm M12 bolt B and nut C Snug nut C to allow baffle A to rotate freely Repeat on the other side of the forming shield ATTACHING ROTAR...

Page 30: ...hten any loosened hardware to hold the deflector adjustment covers A in place on the forming shield 1030506 A B C D E F G H J Figure 4 13 Right Side Bracket 28 Install side deflector A on the right side of the forming shield 29 Install pin B to secure the side deflector 30 Install one 40 mm long M10 bolt C and nut D 31 Install one 35 mm long short neck M10 bolt H near the front of the forming shie...

Page 31: ...8 page 24 to Step 33 page 25 on the other side of the forming shield 1030502 A B C D E Figure 4 15 Forming Shield 35 Remove existing bolts and nuts E Retain the bolts and discard the nuts 36 Install right deflector A on the right side of the forming shield using two 25 mm short neck M10 bolt C and nuts D Repeat on the other side of the forming shield NOTE The narrower deflector end faces the front...

Page 32: ...re harness has been routed on the header NOTE Cable ties are located in the manual storage box NOTE Windrower chassis harness is not shown in the illustration at right To route the R216 Rotary Disc Header electrical harness on the M1240 Windrower follow these steps 1015479 A B Figure 4 17 Left Cab Forward Platform 1 Approach platform stair unit A on the left cab forward side of the windrower and e...

Page 33: ...cylinder 1028745 A B C C C Figure 4 19 Forward Cross Member and Cable Ties 5 Route header adapter harness A over the windrower forward cross member and loosely secure it to windrower chassis harness B with three cable ties C NOTE Do NOT tighten cable ties C on harness at this point NOTE The windrower chassis harness is only partially illustrated 1028751 A B C D Figure 4 20 Electrical Harness Routi...

Page 34: ...d avoid contact with multicoupler base C 1030573 A B Figure 4 22 Electrical Connection 10 Extend center link A fully Check that there is some slack in the harness B 11 Retract center link A fully Check that there is not excessive amount of harness B hanging down 12 Adjust harness B positioning as required 13 Tighten all the cables along the harness 1030514 A B Figure 4 23 Electrical Connection 14 ...

Page 35: ...016889 A B Figure 4 24 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 rotary disc header Replace pin A to hold center link in place IMPORTANT If the center link is too low it may contact the rotary disc header as the windrower approaches the rotary disc header for hookup 1030516 A B C Figure 4 25 R...

Page 36: ...stration at right does not show the two 2 x 4 blocks placed in Step 1 page 11 4 Repeat Step 3 page 30 on opposite side CAUTION Check to be sure all bystanders have cleared the area 5 Start the windrower engine 1015853 Figure 4 27 Header Float Spring 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 ...

Page 37: ...ders 10 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 1021743 A B Figure 4 31 Header Support 11 Lift the tractor lift linkage A to align with header supports B 12 Drive the w...

Page 38: ...down after the hook engages the header pin 1028766 A B Figure 4 33 Hydraulic Center Link 15 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 the center link is locked onto the header by pressing the REEL UP switch on the GSL c Turn off the windrower engine...

Page 39: ...o the header by pulling upward on rod end B of the cylinder 1028763 A Figure 4 36 Header Electrical Harness 18 Hydraulic Center Link without Self Alignment Connect header electrical harness A to the header 1023024 A B Figure 4 37 Header Support 19 Install clevis pin A through the support and windrower lift arm and secure with hairpin B Repeat for opposite side IMPORTANT Ensure clevis pin A is full...

Page 40: ...f your windrower is equipped with hard plumb connections refer to 4 1 5 Connecting Rotary Disc Header Hydraulics Using Hard Plumbing page 36 for connection instructions 1028852 A B C Figure 4 38 Hydraulic Hoses 1 Route hose bundle A from the rotary disc header under the windrower frame then insert pin B into hole C in the windrower frame NOTE Adding anti seize to the hose holder pin will make futu...

Page 41: ...nting straight down as shown 1030536 A B C D E F G Figure 4 41 Hydraulic Hoses 5 Position the front plate on hose support G approximately 140 mm 5 5 in away from the windrower frame 6 Route hoses A B and C as straight as possible and avoid rub wear points that could damage the hydraulic hoses 7 Route case drain hose A through clip D and leave it loose 8 Slide hoses B and C back and forth until the...

Page 42: ...Figure 4 42 Protective Shipping Plugs on M1240 Hard Plumb Fittings 1 Use a clean rag to remove dirt and moisture from fittings B on the left side of the windrower frame and remove protective caps A NOTE Fittings should be factory set to 30 to allow hoses to pass by the multicoupler NOTE Parts removed from illustration for clarity 1028852 A B C Figure 4 43 Hydraulic Hoses 2 Route hose bundle A from...

Page 43: ...cal 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 with relief valve pointing towards the ground NOTE If required loosen fitting G ...

Page 44: ...cted startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1029799 A Figure 4 47 Safety Prop 1 Disengage the safety props on both lift cylinders as follows NOTE If the safety prop will not disengage raise the header to release the prop a Turn lever A away from the header to raise the safety prop until the lever locks in...

Page 45: ...by doing the following a Press rotary scroll knob A on HPT to highlight the QuickMenu options b Rotate scroll knob A to highlight HEADER FLOAT symbol B and press the scroll knob to select The screen changes 1019607 A Figure 4 50 HPT Display 4 Press soft key 3 A to restore 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 r...

Page 46: ...ed when calibration is selected the message ENGAGE HEADER will appear on the screen 1016140 A B C Figure 4 51 Opening the Main Menu 1 Start the engine and engage the header 2 Press soft key 5 A to open the HPT main menu 3 Use HPT scroll knob B or the ground speed lever GSL scroll wheel to scroll to settings icon C 4 Press HPT scroll knob B or the GSL SELECT button not shown to activate the setting...

Page 47: ... disc header WARNING To avoid injury or death from unexpected start up of machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Raise the header fully 2 Engage the header safety props For instructions refer to 8 2 Engaging and Disengaging Header Safety Props page 69 1030486 A A A A A A C C C C C C C C B Figure 4 54 Cutterbar Curtain...

Page 48: ...e the cutterbar is completely clear of foreign objects These objects can be ejected with considerable force when the machine is started and may result in serious injury or machine damage 7 Check the cutterbar area for debris and foreign objects Ensure all shipping material is removed 8 Ensure that the curtain hangs properly and completely encloses the cutterbar area Minor creases in the curtain wi...

Page 49: ...215028 43 Revision A Chapter 5 Installing Options Install options if supplied with shipment according to the instructions supplied with each kit ...

Page 50: ......

Page 51: ...he operator s seat for any reason The rotary disc header has been lubricated at the factory However you should lubricate the rotary disc header prior to delivery to offset the effects of weather during outside storage and transport and to familiarize yourself with the machine Unless otherwise specified use high temperature extreme pressure EP2 performance grease with 1 max molybdenum disulphide NL...

Page 52: ...t B Bearing Roller Conditioner Two Places C U Joint Conditioner Driveline Two Places D Slip Joint Conditioner Driveline1 E Idler Tensioner Pivot F Bearing Feed Roll G Tensioner Arm LUBRICATING THE ROTARY DISC HEADER 1 Use high temperature extreme pressure EP2 performance grease with 10 max molybdenum disulphide NLGI grade 2 lithium base ...

Page 53: ...Conditioner Two Places B U Joint Upper Driveline Two Places C Slip Joints Conditioner Drivelines2 D U Joint Lower Driveline Two Places E Idler Pivot LUBRICATING THE ROTARY DISC HEADER 2 Use high temperature extreme pressure EP2 performance grease with 10 max molybdenum disulphide NLGI grade 2 lithium base ...

Page 54: ......

Page 55: ...pring tensioner 7 1 1 Inspecting Conditioner Drive Belt The conditioner drive belt tension is set at factory and should not require adjustment To inspect the conditioner drive belt 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...

Page 56: ...t page 50 otherwise close the drive shield and proceed to 7 2 Header Float page 52 7 1 2 Adjusting Conditioner Drive Belt 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 fully 2 Shut down the engine and remove the key from the ignition 1028...

Page 57: ...gure 7 7 Conditioner Drive 7 With hardware fully loosened slide threaded rod E up and backward into the disc speed sensor bracket then snug hardware to engage the rod pivot point with the bracket 8 Measure the length of tensioner spring C For proper belt tension dimension D should be set to 17 mm 11 16 in 9 To adjust spring tension loosen jam nut A by turning it counterclockwise 10 Turn adjuster n...

Page 58: ... cylinders fully retracted NOTE Ensure the header is level with the ground with zero tilt 4 Turn the engine off and remove the ignition key 5 Grasp one end of the header and lift Lifting force should be 426 471 N 95 105 lbf and should be the same at both ends 6 Restart the engine and adjust float as required For instructions refer to 7 2 2 Setting the Float page 52 NOTE Increasing the float value ...

Page 59: ...roll knob A to adjust float setting and press knob when finished Float is now set NOTE Float adjustments of 1 0 out of 10 change the header weight at the cutterbar by approximately 91 kg 200 lb Adjust float in increments of 0 05 to optimize field performance 5 Use soft key 3 D to remove resume float and deck position to previous setting for the attached header PERFORMING PREDELIVERY CHECKS ...

Page 60: ...n the left side of the header For instructions refer to 8 5 Opening Driveshields page 75 1030518 A C D B B Figure 7 11 Tensioner Spring 2 Inspect tensioner spring A and ensure it is seated properly in notches B on bracket C and applies tension to both belts D NOTE Belts D are transparent in the illustration at right to better show spring A in bracket C 1030814 B A C A Figure 7 12 Suspended Drum Be...

Page 61: ...ve and ensure belts A are properly seated on pulleys B and idler pulley C NOTE Driveline is not shown in illustration to better show pulleys and belts 3 If necessary adjust belt alignment as follows a Insert 1 2 in ratchet or breaker bar into hole D on bracket E and rotate bracket E and pulley C out of the way b Adjust belt placement on pulleys B and idler pulley C c Rotate bracket E back into its...

Page 62: ...t the cutterbar is level parallel with the ground 2 Shut down the engine and remove the key from the ignition 1028277 A B C D E Figure 7 15 Right Driveshields 3 On the right side of the header engage lift release latch A and pull handle B to open outboard driveshield C 4 Lift at handle D and open inboard driveshield E 1028655 A B Figure 7 16 Roll Timing Gearbox 5 Clean around oil level sight glass...

Page 63: ...pected 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 Park the windrower on a level surface 2 Start the engine 3 Adjust the header height until the cutterbar is parallel with the ground 4 Shut down the engine and remove the key from the ignition 1028481 A Figure 7 17 Header Drive Gearbox Location 5 Locate gearb...

Page 64: ...tly runs out of the check hole 9 If necessary remove fill plug B and add lubricant to gearbox through the fill hole until lubricant runs out of check hole with check plug A removed Refer to 8 8 Recommended Lubricants page 79 for a list of recommended fluids lubricants and capacity for the machine 10 Reinstall the plug s and torque to 23 Nm 17 lbf ft 11 Close the left driveshield 12 Lower the heade...

Page 65: ...es 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 1028638 A Figure 7 19 Cutterbar Curtain 4 Open cutterbar curtain A 1030742 A A Figure 7 20 Spirit Level on Cutterbar 5 Use a spirit bubble level A ...

Page 66: ...he engine and remove the key from the ignition 1028587 A B B Figure 7 22 Cutterbar Oil Plug 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 For lubrication specifications refer to 8 8 Recommended Lubricants page ...

Page 67: ...d remove the key from the ignition 21 Recheck the oil level 1028526 A B Figure 7 23 Cutterbar Oil Inspection Plug 22 Check gasket B for breaks or cracks and replace if necessary 23 Install plug A and gasket B Tighten securely 1028638 A Figure 7 24 Cutterbar Curtain 24 Close cutterbar curtain A PERFORMING PREDELIVERY CHECKS ...

Page 68: ...7 8 Checking Lights 1027821 A B B A Figure 7 25 Lights 1 Check light brackets A and make sure they re securely installed and undamaged 2 Check operation of hazard lights B during machine run up PERFORMING PREDELIVERY CHECKS ...

Page 69: ...e 7 26 Manual Case The following manuals should be stored in the manual storage case A on the left fixed deflector R216 Rotary Disc Header Operator s Manual R216 Rotary Disc Header Parts Catalog R216 Rotary Disc Header Quick Card PERFORMING PREDELIVERY CHECKS ...

Page 70: ...ual sound or attempting to correct a problem shut off engine engage parking brake and remove key CAUTION Never start or move the machine until you are sure all bystanders have cleared the area NOTE Higher engine rpm may be required to engage the rotary disc header Do NOT exceed 1800 rpm 1 Clear all bystanders from the area 2 Start the windrower 3 Set the rotary disc header 152 305 mm 6 12 in above...

Page 71: ...ore starting the engine be sure there is plenty of ventilation to avoid asphyxiation IMPORTANT Before starting the windrower check fluid level of the following and add fluid if necessary Engine oil Refer to the operator s manual Hydraulic oil Refer to the operator s manual Gearbox oil Refer to the operator s manual IMPORTANT Do NOT tow the machine to start the engine Damage to hydrostatic drives w...

Page 72: ... A is engaged at the base of the steering column 1015952 A B C Figure 8 3 Operator Controls 3 Move GSL A into PARK C 4 Turn the steering wheel until it locks It may be possible to move the steering wheel slightly in the locked position IMPORTANT Do NOT attempt to force the wheel out of the locked position or damage to the steering system may occur 5 Fasten seat belt 6 Push HEADER ENGAGE switch B t...

Page 73: ...HPT Header Disengaged Screen 10 Turn the IGNITION switch to crank A NOTE When the engine starts and the header is not engaged the HPT will display the header disengaged page B IMPORTANT Do NOT operate the starter for longer than 15 seconds at a time If the engine does not start wait at least 2 minutes before trying again If you crank the engine for more than 30 seconds within a 2 minute period the...

Page 74: ... Screen NOTE When the engine temperature is below 5 C 40 F the engine will cycle through a period where it appears to labor until it warms up Do NOT operate the engine above 1500 rpm until the HPT engine temperature gauge is above the blue range A REFERENCE ...

Page 75: ...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 1029808 A Figure 8 8 Safety Prop 3 Engage the safety props on both lift cylinders as follows a Pull lever A toward ...

Page 76: ...y props on both lift cylinders as follows NOTE If the safety prop will not disengage raise the header to release the prop a Turn lever A away from the header to raise the safety prop until the lever locks into the vertical position b Repeat for the opposite cylinder REFERENCE ...

Page 77: ...tartup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1015851 A B Figure 8 10 HPT Display 1 Press rotary scroll knob A on Harvest Performance Tracker HPT to display the QuickMenu system 2 Rotate scroll knob A to highlight the header float symbol B and press scroll knob to select The SET UP FLOAT page displays 1019607 A F...

Page 78: ...ly 150 mm 6 in off the ground 7 Ensure that channel A is against link B 8 Shut down the engine and remove the key from the ignition 9 Measure the distance to the ground at both ends of the header to determine if the header is level 1015881 A B Figure 8 14 Lift Linkage CAUTION Check to be sure all bystanders have cleared the area 10 If adjustment is necessary start engine and resume float Lower the...

Page 79: ...l the hardware A CAUTION Check to be sure all bystanders have cleared the area 14 Repeat Step 5 page 72 to Step 9 page 72 to rephase the cylinders and check the header level 15 If additional adjustment is required repeat Step 10 page 72 to Step 13 page 73 and install one of the removed shims on the opposite linkage 16 Reset the header float For instructions refer to 7 2 2 Setting the Float page 52...

Page 80: ...in this procedure are for the left driveshield the right driveshield is similar 1028453 A Figure 8 16 Driveshield Lock Latch 1 Lift lock latch A to disengage driveshield lock 1028455 A Figure 8 17 Left Driveshield 2 Move inboard half of driveshield A back to closed position 1028456 A Figure 8 18 Left Driveshield 3 Move outboard half of driveshield A back to closed position REFERENCE ...

Page 81: ...Left Driveshield NOTE Images shown in this procedure are for the left driveshield the right driveshield is similar 1028433 A B Figure 8 20 Driveshield Latch and Handle 1 Push down on release lever A to disengage the release latch and pull handle B 1028439 Figure 8 21 Opening Driveshield Outboard Side 2 Lift the outboard driveshield panel toward the outboard end of the header REFERENCE ...

Page 82: ...215028 76 Revision A 1028446 A B Figure 8 22 Driveshield Inboard Side 3 Grab handle A and lift the other half of endshield B to the inboard side of the header REFERENCE ...

Page 83: ...6 Closing Cutterbar Curtain CAUTION To avoid injury keep hands and fingers away from corners of doors when closing 1028783 Figure 8 23 Cutterbar Curtain 1 Pull curtain outward from retaining clips and lower curtain REFERENCE ...

Page 84: ...ore leaving the operator s seat for any reason 1028779 A Figure 8 24 Cutterbar Curtain 1 Push curtain A inward and up 1028782 A Figure 8 25 Cutterbar Curtains View from Below 2 Secure curtain in place at locations A using three clips provided 1028807 A B Figure 8 26 Cutterbar Curtain and Retaining Clips NOTE Cutterbar curtain A is held in place between the tines of retaining clips B REFERENCE ...

Page 85: ...cant Grease 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 extreme pressure EP performance with 10 max Molybdenum Disulphide NLGI Grade 2 lithium base Driveline slip joints Lubricant Gear Lubricant SAE 80W 90 High thermal and oxidation stability API...

Page 86: ...am 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 critical or structurally important joints 8 9 1 Metric Bolt Specifications 1001370 1001370 A Figure 8 27 Bolt Grades Table 8 2 Metric Class 8 8 Bolts and Class 9 Free Spinning Nut Nominal Size A Torque Nm Torque lbf ft lbf in Mi...

Page 87: ... 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 1001370 1001370 A Figure 8 29 Bolt Grades Table 8 4 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 3 0 5 1 8 2 18 19 3 5 0 6 2 8 3 1 27 30 4 0 7 4 2 4 6 41 45 5 0 8 8 4 9 3 82 91 6 1 0 14 3 15 8 140 154 8 1 25 38 42 28 31 10 1 ...

Page 88: ...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 8 9 2 Metric Bolt Specifications Bolting into Cast Aluminum 1001370 1001370 A Figure 8 31 Bolt Grades Table 8 6 Metric Bolt Bolting into Cast Aluminum Nominal Size A Bolt Torque 8 8 Cast Aluminum 10 9 Cast Aluminum Nm lbf ft Nm lbf ft M3 1 M4 4...

Page 89: ...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 1003432 D A E B C Figure 8 33 Hydraulic Fitting 5 Install fitting B into port until backup washer D and O ring A contact part face E 6 Position angle fittings by unscrewing no more than one turn 7 Turn lock nut C down to washer D and tighten to torque shown Use two wrenches one ...

Page 90: ...13 106 115 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 12 176 193 130 142 20 1 5 8 12 221 243 163 179 24 1 7 8 12 270 298 199 220 32 2 1 2 12 332 365 245 269 REFERENCE 3 Torque values shown are based on lubricated connections as in reassembly ...

Page 91: ...n Table 8 8 page 85 6 Check final condition of fitting Table 8 8 O Ring Boss ORB Hydraulic Fittings Non Adjustable SAE Dash Size Thread Size in Torque Value4 Nm lbf ft lbf in 2 5 16 24 6 7 53 62 3 3 8 24 12 13 106 115 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 19...

Page 92: ...t is bottomed out 5 Torque fittings according to values in Table 8 9 page 86 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 assembling unions or joining two hoses together 7 Check final condition of fitting Table 8 9 O Ring Face Seal ORFS Hydraulic Fittings SAE Dash Size Thread Size in Tube O D in T...

Page 93: ...ypically 45 or 90 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 achieve alignment 5 Clean all residue and any excess thread conditioner with appropriate cleaner 6 Assess final condition of fitting Pay special attention to possibility of cracks to port opening 7 Mark final position of...

Page 94: ...Pressure 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 meter Nm x 8 8507 pound inches or inch pounds lbf in Temperature degrees Celsius C C x 1 8 32 degrees Fahrenheit F Velocity meters per minute m min x 3 2808 feet per minute ft min Velocity meters per...

Page 95: ...a hexagonal 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 Industrial Council A standards body that developed standard sizing and shape for original 37 flared fitting M1 Series MacDon M1170 and M1240 Windrowers n a Not applicable North American header...

Page 96: ... The product 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 turned farther a number of degrees to achieve its final position Torque tension The relationship between assembly torque applied to a piece of hardware and axial load it induces in bolt or...

Page 97: ...ck that side forming shields are evenly set 4 1 1 Assembling and Installing Forming Shield page 19 Check that baffle deflectors are set in field position and the rear baffle is in the correct position fully up for headers with the Double Windrow Attachment DWA option and down for headers without the DWA option 3 5 Installing Manual Rear Deflectors page 17 Grease all bearings and drivelines 6 Lubri...

Page 98: ...raulic hose and wiring harness routing to ensure adequate clearance when raising or lowering header Ensure the hazard lights are functional 7 8 Checking Lights page 62 Post Run Up Check Stop Engine Check for hydraulic leaks Check belt drive for proper idler alignment and overheated bearings 7 1 Conditioner Drive Belt page 49 Ensure the header manuals are in storage compartment 7 9 Checking Manuals...

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Page 100: ...t 816 891 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 A C N 079 393 721 P O Box 103 Somerton Victoria Australia Australia 3061 t 61 3 8301 1911 f 61 3 8301 1912 MacDon Europe GmbH Hagenauer Strasse 59 65203 Wiesbaden Germany CUSTOMERS MacDon com DEAL...

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MacDon R216, Unloading And Assembly Instructions

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