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214880

159

Revision A

Problem

Solution

Refer to

Header angle too steep

Reduce header angle.

3.8.1 Cutting Height, page 44

Crop residue and dirt deposits on
cutterbar

Clean cutterbar.

—

Mud on cutterbar

Remove mud from cutterbar. Do

NOT

allow mud to dry on cutterbar.

—

Symptom: Machine pulling to one side

Header dragging on one end and
pulling to that side

Adjust header float on both ends.

Refer to windrower operator

’

s manual

Symptom: Breakage of conditioner roll timing belt

Belt not in proper groove in pulley

Move belt to proper groove.

Inspecting Conditioner Drive Belt, page
134

Foreign object between rolls

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

4.9.1 Inspecting Conditioner, page 133

Belt pulleys and idlers misaligned

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 when engaging header

Hoses not connected

Connect hoses.

3.4 Attaching Header to M1240
Windrower, page 24

Poor electrical connection at pump
solenoid

Check connection at windrower.

Refer to windrower operator

’

s manual

Symptom: Header slows when going uphill

Hydraulic oil level in windrower is low

Add oil to windrower reservoir.

Refer to windrower operator

’

s manual

Symptom: Header runs while unloaded, but slows or stops when starting to cut

Defective hydraulic motor

Repair/replace hydraulic motor.

See MacDon Dealer

Defective hydraulic pump in
windrower

Repair/replace pump.

See MacDon Dealer

Defective relief valve in windrower

Repair/replace relief valve.

See MacDon Dealer

Cold oil in hydraulic drive system

Reduce ground speed until oil reaches
operating temperature.

—

TROUBLESHOOTING

Содержание R216 SP

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 160: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 168: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 178: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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