MacDon R216 SP User manual

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

R216 SP Series Rotary Disc Header
Published April 2019.
Noise Levels
The A-weighted sound pressure level inside the operator’s station of a typical self-propelled vehicle (e.g., M1240), when
operated in conjunction with this R216 SP Rotary Disc Header, is 70 dBA. This measurement was taken in accordance with
ISO 5131. The sound pressure level depends upon the rotary disc speed, crop conditions, as well the exact type of self-
propelled vehicle used to power the R216 SP Rotary Disc Header.

Introduction
This instructional manual contains safety, operating, and maintenance procedures for the MacDon R216 SP Rotary Disc
Header. The rotary disc header when attached to a MacDon M1240 Windrower, is designed to cut, condition, and lay a
wide variety of grasses and hay crops in windrows.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Use this manual as your first source of information about the machine. If you follow the instructions provided in this
manual, and use MacDon parts, the rotary disc header will work well for many years. If you require more detailed service
information, contact your Dealer.
Use the Table of Contents and the Index to guide you to specific topics. Study the Table of Contents to familiarize yourself
with how the material is organized. Keep this manual handy for frequent reference and to pass on to new Operators or
Owners. Call your Dealer if you need assistance, information, or additional copies of this manual.
When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant
MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous
situation.
MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual. A copy
of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided to you by your
Dealer. Damage resulting from any of the following conditions will void the warranty:
•Accident
•Misuse
•Abuse
•Improper maintenance or neglect
•Abnormal or extraordinary use of the machine
•Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions
Conventions
The following conventions are used in this document:
•Right and left are determined from the operator’s position. The front of the rotary disc header faces the crop.
•Unless otherwise noted, use the standard torque values provided in this manual.
Manual Storage Case
Store the operator’s manual and the parts catalog in the plastic
manual case (A) on the left fixed deflector.
NOTE: Keep your MacDon publications up-to-date. The most
current version can be downloaded from our website www.
macdon.com or from our Dealer-only site
(https://portal.macdon.com) (login required).
214880 iRevision A

Serial Number
Record the serial number and model 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
header, on top of the end panel.
214880 ii Revision A

214880 iii Revision A
Introduction ................................................................................................................................................i
Serial Number.............................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Safety Alert Symbols ...............................................................................................................................1
1.2 Signal Words .........................................................................................................................................2
1.3 General Safety .......................................................................................................................................3
1.4 Maintenance Safety ................................................................................................................................5
1.5 Hydraulic Safety .....................................................................................................................................6
1.6 Welding Precaution ................................................................................................................................7
1.7 Safety Signs ...........................................................................................................................................8
1.7.1 Installing Safety Decals....................................................................................................................8
1.8 Locating Safety Decals .............................................................................................................................9
1.9 Understanding Safety Signs .................................................................................................................... 11
Chapter 2: Product Overview................................................................................................................... 13
2.1 Specifications....................................................................................................................................... 13
2.2 Component Identification ...................................................................................................................... 15
2.3 Definitions .......................................................................................................................................... 17
Chapter 3: Operation................................................................................................................................ 19
3.1 Break-In Period .................................................................................................................................... 19
3.2 Daily Start-Up Check ............................................................................................................................. 20
3.3 Engaging and Disengaging Header Safety Props ......................................................................................... 22
3.3.1 Engaging and Disengaging Header Safety Props –M1240 Windrower.................................................... 22
3.4 Attaching Header to M1240 Windrower ................................................................................................... 24
3.4.1 Attaching Rotary Disc Header......................................................................................................... 24
Connecting Rotary Disc Header Hydraulics and Electrical –M1240 Windrowers..................................... 29
Connecting Rotary Disc Header Hydraulics Using Quick Couplers......................................................... 32
3.5 Detaching Header from M1240 Windrower............................................................................................... 35
3.5.1 Detaching Rotary Disc Header from M1240 Windrower ...................................................................... 35
3.6 Driveshields......................................................................................................................................... 39
3.6.1 Opening Driveshields .................................................................................................................... 39
3.6.2 Closing Driveshields...................................................................................................................... 41
3.7 Cutterbar Curtain ................................................................................................................................. 42
3.7.1 Opening Cutterbar Curtain............................................................................................................. 42
3.7.2 Closing Cutterbar Curtain .............................................................................................................. 43
3.8 Header Settings.................................................................................................................................... 44
3.8.1 Cutting Height ............................................................................................................................. 44
3.8.2 Adjusting Cutterbar Angle.............................................................................................................. 45
3.8.3 Header Float ............................................................................................................................... 45
3.8.4 Ground Speed ............................................................................................................................. 46
TABLE OF CONTENTS

214880 iv Revision A
3.9 Reconfiguring Cutterbar Crop Stream....................................................................................................... 47
3.9.1 Changing R216 SP Cutterbar Crop Stream Configuration ..................................................................... 48
3.10 Conditioner ....................................................................................................................................... 49
3.10.1 Roll Gap.................................................................................................................................... 49
Adjusting Roll Gap ...................................................................................................................... 49
3.10.2 Roll Tension .............................................................................................................................. 50
Adjusting Roll Tension ................................................................................................................. 50
3.10.3 Roll Timing ................................................................................................................................ 51
Checking Roll Timing ................................................................................................................... 51
Adjusting Roll Timing................................................................................................................... 51
3.10.4 Adjusting Forming Shields –Roll Conditioner................................................................................... 54
Positioning Forming Shield Side Deflectors –Roll Conditioner............................................................. 54
Positioning Rear Baffle –Roll Conditioner ....................................................................................... 55
3.11 Haying Tips ........................................................................................................................................ 58
3.11.1 Curing ...................................................................................................................................... 58
3.11.2 Topsoil Moisture ........................................................................................................................ 58
3.11.3 Weather and Topography ............................................................................................................ 58
3.11.4 Windrow Characteristics.............................................................................................................. 59
3.11.5 Driving on Windrow.................................................................................................................... 59
3.11.6 Using Chemical Drying Agents ...................................................................................................... 59
3.12 Transporting the Header ...................................................................................................................... 60
Chapter 4: Maintenance and Servicing.................................................................................................... 61
4.1 Preparing Machine for Servicing.............................................................................................................. 61
4.2 Recommended Safety Procedures ........................................................................................................... 62
4.3 Maintenance Requirements ................................................................................................................... 64
4.3.1 Maintenance Schedule/Record....................................................................................................... 64
4.3.2 Break-In Inspections ..................................................................................................................... 66
4.3.3 Preseason Servicing...................................................................................................................... 66
4.3.4 End-of-Season Servicing ................................................................................................................ 67
4.4 Lubrication .......................................................................................................................................... 68
4.4.1 Greasing Procedure ...................................................................................................................... 68
4.4.2 Lubrication Locations.................................................................................................................... 69
4.5 Cutterbar System.................................................................................................................................. 71
4.5.1 Lubricating Cutterbar.................................................................................................................... 71
Checking and Adding Cutterbar Lubricant ....................................................................................... 71
Draining the Cutterbar................................................................................................................. 74
Filling Lubricant into a Repaired Cutterbar ...................................................................................... 74
4.5.2 Maintaining Cutterbar Discs........................................................................................................... 75
Inspecting Cutterbar Discs ............................................................................................................ 76
Removing Cutterbar Discs ............................................................................................................ 77
Installing Cutterbar Discs.............................................................................................................. 78
4.5.3 Replacing Cutterbar Spindles.......................................................................................................... 80
Removing Cutterbar Spindles ........................................................................................................ 81
Installing Cutterbar Spindles ......................................................................................................... 83
4.5.4 Maintaining Discblades ................................................................................................................. 87
TABLE OF CONTENTS

214880 vRevision A
Inspecting Discblades .................................................................................................................. 87
Inspecting Discblade Hardware ..................................................................................................... 89
Removing Discblades................................................................................................................... 90
Installing Discblades .................................................................................................................... 92
4.5.5 Maintaining Accelerators............................................................................................................... 93
Inspecting Accelerators................................................................................................................ 93
Removing Accelerators ................................................................................................................ 94
Installing Accelerators ................................................................................................................. 96
4.5.6 Maintaining Rock Guards............................................................................................................... 97
Inspecting Rock Guards................................................................................................................ 97
Removing Rock Guards ................................................................................................................ 98
Installing Rock Guards ................................................................................................................. 99
4.5.7 Maintaining Drums..................................................................................................................... 100
Inspecting Drums...................................................................................................................... 100
Removing Suspended Drums ...................................................................................................... 102
Installing Suspended Drums........................................................................................................ 104
Removing Left Driven Drum and Driveline..................................................................................... 105
Installing Left Driven Drum and Driveline ...................................................................................... 107
Removing Right Driven Drum and Driveline ................................................................................... 110
Installing Right Driven Drum and Driveline .................................................................................... 113
4.5.8 Replacing Cutterbar Spindle Shear Pin ........................................................................................... 116
Removing Cutterbar Spindle Shear Pin.......................................................................................... 117
Installing Cutterbar Spindle Shear Pin ........................................................................................... 121
4.6 Servicing Conditioner Roll Timing Gearbox ............................................................................................. 124
4.6.1 Checking and Changing Conditioner Roll Timing Gearbox Oil.............................................................. 124
4.7 Servicing Header Drive Gearbox ............................................................................................................ 127
4.7.1 Checking Header Drive Gearbox Oil ............................................................................................... 127
4.7.2 Changing Header Drive Gearbox Oil............................................................................................... 129
4.8 Cutterbar Curtain ............................................................................................................................... 130
4.8.1 Inspecting Cutterbar Curtain ........................................................................................................ 130
4.8.2 Removing Cutterbar Curtain......................................................................................................... 131
4.8.3 Installing Cutterbar Curtain.......................................................................................................... 132
4.9 Conditioner ....................................................................................................................................... 133
4.9.1 Inspecting Conditioner ................................................................................................................ 133
Conditioner Drive Belt ............................................................................................................... 134
Changing the Conditioner........................................................................................................... 138
4.10 Replacing Driveshields ....................................................................................................................... 146
4.10.1 Removing Driveshields .............................................................................................................. 146
4.10.2 Installing Driveshields................................................................................................................ 147
4.11 Electrical System............................................................................................................................... 149
4.11.1 Maintaining Electrical System ..................................................................................................... 149
4.11.2 Replacing Amber Hazard/Signal Light ........................................................................................... 149
4.11.3 Replacing Header Disc Speed Sensor............................................................................................ 149
4.12 Hydraulics ....................................................................................................................................... 151
4.12.1 Checking Hydraulic Hoses and Lines............................................................................................. 151
TABLE OF CONTENTS

214880 vi Revision A
Chapter 5: Options and Attachments .................................................................................................... 153
5.1 Performance Kits................................................................................................................................ 153
5.1.1 Tall Crop Divider Kit.................................................................................................................... 153
5.1.2 Adjustable Gauge Roller Kit.......................................................................................................... 153
5.1.3 Adjustable Skid Shoes Kit............................................................................................................. 154
5.1.4 Electric Remote Baffle Kit ............................................................................................................ 154
Chapter 6: Troubleshooting.................................................................................................................... 155
6.1 Performance Problems ........................................................................................................................ 155
6.2 Mechanical Problems .......................................................................................................................... 158
Chapter 7: Reference .............................................................................................................................. 161
7.1 Torque Specifications .......................................................................................................................... 161
7.1.1 Metric Bolt Specifications ............................................................................................................ 161
7.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ...................................................................... 163
7.1.3 O-Ring Boss Hydraulic Fittings –Adjustable .................................................................................... 164
7.1.4 O-Ring Boss Hydraulic Fittings –Non-Adjustable.............................................................................. 166
7.1.5 O-Ring Face Seal Hydraulic Fittings................................................................................................ 167
7.1.6 Tapered Pipe Thread Fittings........................................................................................................ 168
7.2 Conversion Chart................................................................................................................................ 169
Index........................................................................................................................................................ 171
Recommended Lubricants...................................................................................................................... 175
TABLE OF CONTENTS

214880 1Revision A
Chapter 1: Safety
1.1 Safety Alert Symbols
Figure 1.1: Safety Symbol
This safety alert symbol indicates important safety messages in
this manual and on safety signs on the machine.
This symbol means:
•ATTENTION!
•BECOME ALERT!
•YOUR SAFETY IS INVOLVED!
Carefully read and follow the safety message accompanying this
symbol.
Why is safety important to you?
•Accidents disable and kill
•Accidents cost
•Accidents can be avoided

214880 2Revision A
1.2 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words,
IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be
used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may be used
to alert against unsafe practices.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.
SAFETY

214880 3Revision A
1.3 General Safety
Figure 1.2: Safety Equipment
CAUTION
The following general farm safety precautions should be part of
your operating procedure for all types of machinery.
Protect yourself.
•When assembling, operating, and servicing machinery, wear
all protective clothing and personal safety devices that could
be necessary for job at hand. Do NOT take chances. You may
need the following:
•Hard hat
•Protective footwear with slip-resistant soles
•Protective glasses or goggles
•Heavy gloves
•Wet weather gear
•Respirator or filter mask
Figure 1.3: 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.
Figure 1.4: Safety Equipment
•Provide a first aid kit in case of emergencies.
•Keep a properly maintained fire extinguisher on the machine.
Be familiar with its proper use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when the operator is
tired or in a hurry. Take time to consider safest way. NEVER
ignore warning signs of fatigue.
SAFETY

214880 4Revision A
Figure 1.5: Safety around Equipment
•Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as scarves or bracelets.
•Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate
independently of shaft and can telescope freely.
•Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.
Figure 1.6: Safety around Equipment
•Keep hands, feet, clothing, and hair away from moving parts.
NEVER attempt to clear obstructions or objects from a
machine while engine is running.
•Do NOT modify machine. Unauthorized modifications may
impair machine function and/or safety. It may also shorten
machine’s life.
•To avoid injury or death from unexpected startup of machine,
ALWAYS stop the engine and remove the key from the
ignition before leaving the operator’s seat for any reason.
Figure 1.7: Safety around Equipment
•Keep service area clean and dry. Wet or oily floors are
slippery. Wet spots can be dangerous when working with
electrical equipment. Be sure all electrical outlets and tools
are properly grounded.
•Keep work area well lit.
•Keep machinery clean. Straw and chaff on a hot engine is a
fire hazard. Do NOT allow oil or grease to accumulate on
service platforms, ladders, or controls. Clean machines before
storage.
•NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
•When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
SAFETY

214880 5Revision A
1.4 Maintenance Safety
Figure 1.8: Safety around Equipment
To ensure your safety while maintaining machine:
•Review operator’s manual and all safety items before
operation and/or maintenance of machine.
•Place all controls in Neutral, stop the engine, set the park
brake, remove the ignition key, and wait for all moving parts
to stop before servicing, adjusting, and/or repairing.
•Follow good shop practices:
–Keep service areas clean and dry
–Be sure electrical outlets and tools are properly grounded
–Keep work area well lit
Figure 1.9: Equipment NOT Safe for Children
•Relieve pressure from hydraulic circuits before servicing
and/or disconnecting machine.
•Make sure all components are tight and that steel lines,
hoses, and couplings are in good condition before applying
pressure to hydraulic systems.
•Keep hands, feet, clothing, and hair away from all moving
and/or rotating parts.
•Clear area of bystanders, especially children, when carrying
out any maintenance, repairs, or adjustments.
•Install transport lock or place safety stands under frame
before working under machine.
•If more than one person is servicing machine at same time,
be aware that rotating a driveline or other mechanically-
driven component by hand (for example, accessing a
lubricant fitting) will cause drive components in other areas
(belts, pulleys, and knives) to move. Stay clear of driven
components at all times.
Figure 1.10: Safety Equipment
•Wear protective gear when working on machine.
•Wear heavy gloves when working on knife components.
SAFETY

214880 6Revision A
1.5 Hydraulic Safety
Figure 1.11: Testing for Hydraulic Leaks
•Always place all hydraulic controls in Neutral before
dismounting.
•Make sure that all components in hydraulic system are kept
clean and in good condition.
•Replace any worn, cut, abraded, flattened, or crimped hoses
and steel lines.
•Do NOT attempt any makeshift repairs to hydraulic lines,
fittings, or hoses by using tapes, clamps, cements, or welding.
The hydraulic system operates under extremely high-
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 hydraulic leaks. Use a piece of cardboard as a
backstop instead of hands to isolate and identify a leak.
•If injured by a concentrated high-pressure stream of
hydraulic fluid, seek medical attention immediately. Serious
infection or toxic reaction can develop from hydraulic fluid
piercing the skin.
Figure 1.13: Safety around Equipment
•Make sure all components are tight and steel lines, hoses,
and couplings are in good condition before applying pressure
to a hydraulic system.
SAFETY

214880 7Revision A
1.6 Welding Precaution
Welding should never be attempted on the header while it is connected to a windrower.
WARNING
Severe damage to sensitive, expensive electronics can result from welding on the header while it is connected to the
windrower. It can be impossible to know what effect high current could have with regard to future malfunctions or
shorter lifespan. It is very important that welding on the header is not attempted while the header is connected to the
windrower.
If an Operator needs to do any welding on the header, it should first be disconnected and removed from the windrower.
If it is unfeasible to disconnect the header from the windrower before attempting welding, contact your MacDon Dealer for
welding precautions detailing all electrical components that must be disconnected first for safe welding.
SAFETY

214880 8Revision A
1.7 Safety Signs
Figure 1.14: Operator’s Manual Decal
•Keep safety signs clean and legible at all times.
•Replace safety signs that are missing or illegible.
•If original part on which a safety sign was installed is
replaced, be sure the repair part displays the current
safety sign.
•Replacement safety signs are available from Dealer Parts
Department.
1.7.1 Installing Safety Decals
1. Clean and dry installation area.
2. Decide on exact location before you remove decal backing paper.
3. Remove smaller portion of split backing paper.
4. Place decal in position and slowly peel back remaining paper, smoothing decal as it is applied.
5. Prick small air pockets with a pin and smooth out.
SAFETY

214880 9Revision 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

214880 10 Revision A
Figure 1.17: Safety Sign Decal Locations –Rear View
A - MD #190546 B - MD #325070 C - Reflector
SAFETY

214880 11 Revision A
1.9 Understanding Safety Signs
NOTE:
This is a general list of safety sign definitions and the decals listed may not necessarily be applicable to your machine.
Figure 1.18: MD #113482
MD #113482
General hazard pertaining to machine operation and servicing.
CAUTION
•Read the operator’s manual, and follow all safety
instructions. If you do not have a manual, obtain one from
your Dealer.
•Do NOT allow untrained persons to operate the machine.
•Review safety instructions with all Operators annually.
•Ensure that all safety signs are installed and legible.
•Make certain everyone is clear of machine before starting
engine, and during operation.
•Keep riders off the machine.
•Keep all shields in place and stay clear of moving parts.
•Disengage drive, put transmission in Neutral, and wait for all
movement to stop before leaving operator’s position.
•Shut off engine and remove key from ignition before
servicing, adjusting, lubricating, cleaning, or unplugging
machine.
•Engage locks to prevent lowering of self-propelled rotary
disc header before servicing in the raised position.
•Use slow moving vehicle emblem and flashing warning lights
when operating on roadways unless prohibited by law.
Figure 1.19: MD #166832
MD #166832
Hydraulic pressure oil hazard
WARNING
•High pressure oil easily punctures skin causing serious injury,
gangrene, or death.
•If injured, seek emergency medical help.
•Do NOT use finger or skin to check for leaks.
•Lower load or relieve hydraulic pressure before loosening
fittings.
SAFETY

214880 12 Revision A
Figure 1.20: MD #190546
MD #190546
Slippery surface
WARNING—DO NOT STEP ON SURFACE
•Do NOT use this area as a step or platform.
•Failure to comply could result in serious injury or death.
Figure 1.21: MD #307746
MD #307746
Thrown/sharp object hazard
WARNING
•Crop materials exiting at high speed.
•Stop machine, look, listen, and wait for all movement to stop
before approaching.
•Failure to comply could result in death or serious injury.
•Disengage power take-off, shut off tractor, and remove key
before opening covers.
•Listen and look for evidence of rotation before lifting cover.
•Cutters may continue to rotate after power is shut off due to
inertia.
Figure 1.22: MD #325070
MD #325070
Pinch/tangle hazard
WARNING
•Guard missing. Do NOT operate.
•Keep all shields in place.
•To avoid entanglement with rotating auger, stand clear of
header while machine is running.
•Failure to comply could result in serious injury or death.
SAFETY