MacDon R2 Series User manual

R2 Series Clinic Handout

2 R2 Series Clinic Handout
Table of Contents
Break-In Inspections..................................................................3
Checking Conditioner Drive Belt Tensioner ...........................................3
Checking Conditioner Drive Gearbox Lubricant .......................................3
Changing Conditioner Drive Gearbox Lubricant.......................................4
Changing Header Drive Gearbox Lubricant ...........................................4
Lubrication Locations ................................................................5
Left Side Every 25 hours .............................................................5
Right Side Every 25 hours............................................................6
Lubrication Locations (Gauge Rollers) ...............................................7
Recommended Lubricants ..........................................................7
Cutterbar Components ...............................................................8
Disc Blades..........................................................................8
Disc Blade Hardware ................................................................8
Removing / Installing Disc Blades....................................................9
Settings .............................................................................10
Conditioner Roll Gap ...............................................................10
Forming Shields ....................................................................10
Manual Rear Bae..................................................................11
Positioning Rear Bae Deflector Fins ................................................11
In-Cab Electric Remote Bae ......................................................12
Recommended Starting Settings with a DWA .......................................12
Setting Header Float ...............................................................13
Performance Options................................................................14
Tall Crop Divider Kit ................................................................14
Adjustable Gauge Roller Kit.........................................................14
Adjustable Skid Shoes Kit ..........................................................15
In-Cab Electric Remote Bae Kit ...................................................15
R2 Maintenance Schedule...........................................................16
M1240 Windrower ................................................................... 17
Break-in Inspection................................................................. 17
M1240 Maintenance Chart...........................................................18

R2 Series Clinic Handout 3
Break-In Inspections
Checking Conditioner Drive Belt Tensioner
Checking Conditioner Drive Gearbox Lubricant
Measure the length of the belt tensioner spring (A)
and ensure spring length (B) is 53 mm (2 3/32 in)
Open the 2 drive shields on RH side of header.
Oil should be level with the top of the sight glass (A).
Fill as required through breather (B).
Inspection Interval Item
1 Hour Check for loose hardware and tighten to required torque
5 Hours Check for loose hardware and tighten to required torque
5 Hours Check conditioner drive belt tension
50 Hours Check conditioner drive belt tension
50 Hours Change conditioner drive gearbox lubricant
50 Hours Change header drive gearbox lubricant

4 R2 Series Clinic Handout
Break-In Inspections
Changing Conditioner Drive Gearbox Lubricant
Changing Header Drive Gearbox Lubricant
Place a 1 liter (1 Qt.) container underneath the gearbox at plug (A).
Remove plug to drain.
Fill through breather until oil is level with top of sight glass (B).
Locate gearbox on LH side of header.
Place a 4 liter container under drain (A) and remove plug at (A).
Allow oil to drain out of gearbox.
Fill oil at (C) until oil level is at check plug (B).

R2 Series Clinic Handout 5
Lubrication Locations
Left Side Every 25 hours
A - Idler/Tensioner Pivot B- Bearing, Roller Conditioner (2 Places) C- U-Joint, Conditioner Driveline (2 Places)
D- Slip Joint, Conditioner Driveline ** E- Idler/Tensioner Pivot F- Bearing, Feed Roll
G- Tensioner Arm
** Note: Use high-temperature, extreme-pressure (EP2) performance grease with 10% max molybdenum disulphide (NLGI grade 2) lithium base.

6 R2 Series Clinic Handout
Lubrication Locations
Right Side Every 25 hours
A- Bearing, Roller Conditioner (2 Places) B- U-Joint, Upper Driveline (2 Places) C- Slip Joints, Conditioner Drivelines**
D- U-Joint, Lower Driveline (2 Places) E- Idler Pivot
** Note: Use high-temperature, extreme-pressure (EP2) performance grease with 10% max molybdenum disulphide (NLGI grade 2) lithium base.

R2 Series Clinic Handout 7
Lubrication Locations (Gauge Rollers)
Recommended Lubricants
If installed, grease gauge rollers every 25 hrs (A)
2 locations per roller.
Specifications Description Use Capacities
Lubricant: Grease
SAE Multipurpose
High temperature extreme pressure (EP) perfor-
mance with 1% max. Molybdenum Disulphide (NLGI
Grade 2) lithium base
As required unless
otherwise specified.
SAE Multipurpose
High temperature extreme pressure (EP) perfor-
mance 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
service class GL-5 4.9 m (16 ft.) cutterbar 10 liters (10.5 qts [US])
SAE 85W-140 Gear lubricant API service class GL-5 Conditioner drive
gearbox
0.7 liters (0.75 qts
[US])
SAE 80W-140 Fully Synthetic Oil API GL-5 Minimum,
SAE J2360 Preferred
Header drive
90 degree gearbox
1.65 liters (1.74 qts
[US])
Important:
Do NOT overfill the cutterbar when adding lubricant. Overfilling could result in overheating and failure of cutterbar components.

8 R2 Series Clinic Handout
Cutterbar Components
Check daily to ensure that disc blades are securely attached to the disc.
Change disc blades when they show cracks, signs of wear (A) and/or an
elongated hole (B) beyond safe operating limits (C). Max elongation is
21mm (13/16 in)
Disc Blades
Disc Blade Hardware
Check and replace bolt if:
Bolt has been removed and installed five times
Head (A) is worn flush with bearing surface of blade
Diameter of bolt neck is worn (B) 3mm (1/8 in)
Bolt is cracked (C)
Bolt is visibly distorted (D)
Bolt shows evidence of interference (E) with adjacent parts
Check and replace nut if:
Nut has been previously installed – nuts are one-time use only
Nut shows signs of wear (A below)
that is more than half the original
height (B below)
Nut is cracked

R2 Series Clinic Handout 9
Removing / Installing Disc Blades
Rotate disc (A) so blade (B) lines up with the hole (C) in the rock guard.
Place a pin or equivalent in the front hole of the neighboring rock guard
to prevent disc rotation while loosening blade bolts.
Install new or flipped/reversed blade (A) with shoulder bolt (B)
onto disc (C)
Install new nut (D) and torque to 125 Nm (92lbf-ft)
Remove nut (A) and discard
Important:
Nuts are one-time use only. When flipping or changing a blade, replace
using a NEW nut,
Remove shoulder bolt (B) and blade (C)
Important:
Blades should be replaced in pairs or the disc may become unbalanced and cause damage to the cutterbar.
The disc blades have cutting edges on both sides so the blades can be turned over and re-used.

10 R2 Series Clinic Handout
Settings
1. Loosen jam nut (A) on both sides of the conditioner. Turn lower
bolt (B) counterclockwise until the upper roll rests on the lower roll.
Ensure the rolls inter-mesh.
2. Turn lower nut (B) two and a half turns counterclockwise to raise
the upper roll and achieve a 6 mm (1/4 in) roll gap.
3. Hold nut (B) and tighten jam nut (A) on both sides of the conditioner.
4. If further adjustment to roll gap is required:
Turn lower nut (B) clockwise to increase roll gap.
Turn lower nut (B) counterclockwise to decrease roll gap.
Set forming shield side deflectors (A) to the desired width by repositioning
adjuster handle (B). To ensure windrow placement is centered, adjust both
side deflectors to the same position.
Conditioner Roll Gap
Forming Shields
Important:
Make sure the roll gap adjustment nuts are adjusted equally on both sides of the disc header to achieve a consistent gap
across the rolls.