MacDon R216 User manual

R216
Rotary Disc Header for Windrowers
Unloading and Assembly Instructions
215974 Revision A
Original Instruction
The Harvesting Specialists.

R216 Rotary Disc Header
1031305
Published August 2022.
© 2022 MacDon Industries, Ltd.
The information in this publication 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.

Introduction
This document describes the unloading, setup, and predelivery requirements for the MacDon R216 Rotary Disc Header,
including a Grass Seed (GSS) version.
To ensure your customers receive all of the performance and safety benefits from this product, carefully follow the
unloading and assembly procedure from the beginning through to completion.
Retain this instruction for future reference.
If the shipment is damaged or is missing parts, contact the following according to your region:
•North America: [email protected]
•Australia: [email protected]
•Brazil: [email protected]
•Europe (except Russia): [email protected]
•Russia: [email protected]
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.
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 downloaded from our website
(www.macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login required).
This instruction is currently available in English only.
215974 iRevision A

Summary of Changes
At MacDon, we’re continuously making improvements, and occasionally these improvements affect product
documentation. The following list provides an account of major changes from the previous version of this document.
Section Summary of Change
Internal Use
Only
3 Unloading the Header from a Container
–Export, page 11
Removed note that said the GSS option is not available for
export. Engineering
4.1.1 Removing Shipping Wire from the
Bottom of the Header –Standard
Headers Only, page 15
Added note that the shipping wire may be tied to the
cutterbar instead of the lower conditioner roll. Removed
step and illustration for removing the light assemblies from
the shipping locations under the header; the light
assemblies are now shipped in the forming shield crate and
can be removed after the crate is pulled out. Revised the
title based on the changes to the procedure.
ECN 62812
4.1.3 Removing Forming Shield Crate –
Standard Headers Only, page 18 Updated the illustration of the metal shipping straps. ECN 62812
4.1.4 Unpacking Hydraulic Hoses and
Electrical Harness, page 19 Changed the shipping position of the M1 adapter harness. ECN 62815
4.1.5 Removing Shipping Stand, page 21
For Grass Seed headers, the two hydraulic fittings are now
shipped in a bag tied to the outside of the manual case
instead of inside the manual case.
UECN 31481
4.2 Installing Hazard/Brake Light
Assembly –Standard Headers Only, page
26
Added steps and illustration for the new shipping location. ECN 62812
—Removed instructions for configuring GSS headers to one
crop stream. This is now done at the factory. Support
5.1.3 Connecting R2 Series Rotary Disc
Header Electrical and Hydraulics –
M1240 Windrower, page 50
Moved hydraulic connection instructions into subtopics for
different header configurations. Publications
Removed references to calibrating the header position
sensors, which aren’t present on R2 headers. Support
Auger/Rotary Disc/Draper-Ready
Configuration –Quick Coupler
Connections, page 52
Corrected reference to the outboard bulkhead fitting,
which was referenced as the inboard fitting.
Audit
#2022-38
9.3 Activating Grass Seed Option, page
104
Corrected step to read “the system is now active”instead
of “the sensor is now active”.Engineering
Added information on how to control drum position, drum
speed, and anti-shatter shield. Support
Changed operating drum speed to 235–660 rpm. Engineering
9.11 Checking Parts in Storage Location,
page 118 Added topic. Support
Predelivery Checklist, page 157
Updated GSS header pre-delivery checks: removed crop
stream configuration check; added drum operation checks
to the run-up procedure.
Support
Added checks for parts in storage location: timing tool and
spindle nut wrench (all headers); two feed plates and four
support angles (GSS-only header).
Support
Removed reference to a GSS sensor. Support
215974 ii Revision A

215974 iii Revision A
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Safety Alert Symbols ...............................................................................................................................1
1.2 Signal Words .........................................................................................................................................2
1.3 General Safety .......................................................................................................................................3
1.4 Hydraulic Safety .....................................................................................................................................5
1.5 Welding Precaution ................................................................................................................................6
1.6 Safety Signs ...........................................................................................................................................7
Chapter 2: Unloading the Header from a Trailer –North America.......................................................... 9
Chapter 3: Unloading the Header from a Container –Export................................................................ 11
Chapter 4: Assembling the Header .......................................................................................................... 15
4.1 Preparing the Header for Assembly ......................................................................................................... 15
4.1.1 Removing Shipping Wire from the Bottom of the Header –Standard Headers Only ................................. 15
4.1.2 Lowering the Header .................................................................................................................... 15
4.1.3 Removing Forming Shield Crate –Standard Headers Only ................................................................... 18
4.1.4 Unpacking Hydraulic Hoses and Electrical Harness ............................................................................. 19
4.1.5 Removing Shipping Stand .............................................................................................................. 21
4.2 Installing Hazard/Brake Light Assembly –Standard Headers Only.................................................................. 26
4.3 Installing Manual Rear Deflectors –Standard Headers Only ......................................................................... 28
4.4 Assembling and Installing Forming Shield.................................................................................................. 30
4.5 Installing Skid Shoes or Gauge Rollers ...................................................................................................... 37
4.6 Installing Hydraulic Drive Kit –For Headers Shipped without Hydraulic Drive Only ........................................... 38
4.7 Installing Grass Seed Anti-Shatter Shield Kit –Grass Seed Ready Headers Only ................................................ 39
Chapter 5: Attaching Rotary Disc Header to Windrower ....................................................................... 41
5.1 Attaching R2 Series Rotary Disc Header to M1240 Windrower...................................................................... 41
5.1.1 Routing Electrical Harness ............................................................................................................. 41
5.1.2 Attaching R2 Series Rotary Disc Header to M1 Series Windrower ......................................................... 43
5.1.3 Connecting R2 Series Rotary Disc Header Electrical and Hydraulics –M1240 Windrower .......................... 50
Auger/Rotary Disc/Draper-Ready Configuration –Quick Coupler Connections ....................................... 52
Rotary Disc-Only Configuration –Hard-Plumbed Connections............................................................. 56
Rotary Disc-Only Configuration –Quick Coupler Connections ............................................................. 59
5.1.4 Restoring Float for Rotary Disc Header............................................................................................. 63
5.1.5 Calibrating Knife Drive on Harvest Performance Tracker Display........................................................... 64
5.2 Attaching R2 Series Rotary Disc Header to M205 SP Windrower ................................................................... 68
5.2.1 Attaching R2 Series Rotary Disc Header to M205 SP Windrower –Hydraulic Center-Link with Optional
Self-Alignment............................................................................................................................. 68
5.2.2 Attaching R2 Series Rotary Disc Header to M205 SP Windrower –Hydraulic Center-Link without
Optional Self-Alignment ................................................................................................................ 74
5.2.3 Connecting R2 Series Rotary Disc Header Hydraulics and Electrical to an M205 SP Windrower .................. 80
TABLE OF CONTENTS

215974 iv Revision A
5.2.4 Setting the Header Cut Width ........................................................................................................ 86
Chapter 6: Unpacking the Curtain............................................................................................................ 87
Chapter 7: Installing Other Options......................................................................................................... 89
Chapter 8: Lubricating the Rotary Disc Header....................................................................................... 91
8.1 Lubrication Locations –Standard Headers................................................................................................. 92
8.2 Lubrication Locations –Grass Seed Headers .............................................................................................. 94
Chapter 9: Performing Predelivery Checks.............................................................................................. 95
9.1 Conditioner Drive Belt –Standard Header................................................................................................. 95
9.1.1 Inspecting Conditioner Drive Belt.................................................................................................... 95
9.1.2 Adjusting Conditioner Drive Belt ..................................................................................................... 96
9.2 Header Float........................................................................................................................................ 98
9.2.1 Checking Float –M1 Series Windrowers........................................................................................... 98
9.2.2 Setting Float –M1 Series Windrowers ............................................................................................. 99
9.2.3 Checking Float –M Series Windrower............................................................................................ 100
9.2.4 Setting Float –M Series Windrower .............................................................................................. 100
Adjusting Float Using Drawbolts .................................................................................................. 103
9.3 Activating Grass Seed Option................................................................................................................ 104
9.4 Suspended Drum Drive........................................................................................................................ 108
9.4.1 Checking Suspended Drum Drive .................................................................................................. 108
9.5 Feed Roll Drive –Standard Header ........................................................................................................ 109
9.5.1 Checking Feed Roll Drive ............................................................................................................. 109
9.6 Checking and Adding Conditioner Roll Timing Gearbox Oil –Standard Header............................................... 110
9.7 Checking and Adding Oil in Header Drive Gearbox.................................................................................... 111
9.8 Checking and Adding Lubricant in Cutterbar ............................................................................................ 113
9.9 Checking Lights .................................................................................................................................. 116
9.10 Checking Manuals............................................................................................................................. 117
9.11 Checking Parts in Storage Location....................................................................................................... 118
9.12 Running up the Header ...................................................................................................................... 119
Chapter 10: Reference............................................................................................................................ 121
10.1 Starting Engine –M1 Series Windrower ................................................................................................ 121
10.2 Starting Engine –M Series Windrower.................................................................................................. 125
10.3 Engaging and Disengaging Header Safety Props –M1 Series Windrower..................................................... 128
10.4 Engaging and Disengaging Header Safety Props –M Series Self-Propelled Windrower................................... 130
10.5 Leveling the Header –M1 Series Windrower ......................................................................................... 132
10.6 Leveling Header –M Series Windrower ................................................................................................ 134
10.7 Opening Driveshields......................................................................................................................... 138
10.8 Closing Driveshields........................................................................................................................... 140
10.9 Opening Cutterbar Curtain ................................................................................................................. 142
TABLE OF CONTENTS

215974 vRevision A
10.10 Closing Cutterbar Curtain ................................................................................................................. 144
10.11 Recommended Lubricants ................................................................................................................ 145
10.12 Torque Specifications....................................................................................................................... 146
10.12.1 Metric Bolt Specifications......................................................................................................... 146
10.12.2 Metric Bolt Specifications –Cast Aluminum................................................................................. 148
10.12.3 O-Ring Boss Hydraulic Fittings –Adjustable ................................................................................. 149
10.12.4 O-Ring Boss Hydraulic Fittings –Non-Adjustable .......................................................................... 150
10.12.5 O-Ring Face Seal Hydraulic Fittings ............................................................................................ 151
10.12.6 Tapered Pipe Thread Fittings .................................................................................................... 152
10.13 Conversion Chart ............................................................................................................................ 154
10.14 Definitions ..................................................................................................................................... 155
Predelivery Checklist .............................................................................................................................. 157
TABLE OF CONTENTS

215974 1Revision A
Chapter 1: Safety
Understanding and consistently following these safety procedures will help to ensure the safety of those operating the
machine and of bystanders.
1.1 Safety Alert Symbols
The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine.
1000915
Figure 1.1: Safety Symbol
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

215974 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

215974 3Revision A
1.3 General Safety
Protect yourself when assembling, operating, and servicing machinery.
1000004
Figure 1.2: Safety Equipment
CAUTION
The following general farm safety precautions should be part of
your operating procedure for all types of machinery.
Wear all protective clothing and personal safety devices that
could be necessary for the 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
1000005
Figure 1.3: Safety Equipment
In addition, take the following precautions:
•Be aware that exposure to loud noises can cause hearing
impairment. Wear suitable hearing protection devices such
as earmuffs or earplugs to help protect against loud noises.
1010391
Figure 1.4: Safety Equipment
•Provide a first aid kit in case of emergencies.
•Keep a properly maintained fire extinguisher on the
machine. Familiarize yourself with its use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when Operators are
fatigued or in a hurry. Take time to consider the safest way
to accomplish a task. NEVER ignore the signs of fatigue.
SAFETY

215974 4Revision A
1000007
Figure 1.5: Safety around Equipment
•Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as hoodies, scarves or bracelets.
•Keep all shields in place. NEVER alter or remove safety
equipment. Ensure that the driveline guards can rotate
independently of their shaft, and that they can telescope
freely.
•Use only service and repair parts made or approved by the
equipment manufacturer. Parts from other manufacturers
may not meet the correct strength, design, or safety
requirements.
1000008
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 the engine is running.
•Do NOT modify the machine. Unauthorized modifications
may impair the functionality and/or safety of the machine. It
may also shorten the machine’s service life.
•To avoid injury or death from the 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 1.7: Safety around Equipment
•Keep the machine service area clean and dry. Wet and/or
oily floors are slippery. Wet spots can be dangerous when
working with electrical equipment. Ensure that all electrical
outlets and tools are properly grounded.
•Keep the work area well-lit.
•Keep machinery clean. Straw and chaff on a hot engine are
fire hazards. Do NOT allow oil or grease to accumulate on
service platforms, ladders, or controls. Clean machines
before they are stored.
•NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
•When storing machinery, cover any sharp or extending
components to prevent injury from accidental contact.
SAFETY

215974 5Revision A
1.4 Hydraulic Safety
Protect yourself when assembling, operating, and servicing hydraulic components.
1001205
Figure 1.8: Testing for Hydraulic Leaks
•Always place all hydraulic controls in Neutral before leaving
the operator’s seat.
•Ensure that all the components in the 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 can fail suddenly and create
hazardous conditions.
1001207
Figure 1.9: Hydraulic Pressure Hazard
•Wear proper hand and eye protection when searching for
high-pressure hydraulic fluid leaks. Use a piece of cardboard
as a backstop instead of your 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.
1000013
Figure 1.10: Safety around Equipment
•Ensure that all components are tight and that steel lines,
hoses, and couplings are in good condition before applying
pressure to a hydraulic system.
SAFETY

215974 6Revision A
1.5 Welding Precaution
To prevent damage to sensitive electronics, 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 it is unfeasible to disconnect the header from the windrower before welding, refer to the windrower’s technical manual
for welding precautions detailing all electrical components that must be disconnected first for safe welding.
SAFETY

215974 7Revision A
1.6 Safety Signs
Safety signs are decals placed on the machine where there is a risk of personal injury, or where the Operator should take
extra precautions before operating the controls. They are usually yellow.
1000694
Figure 1.11: 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, ensure that the repair part displays the current
safety sign.
SAFETY

215974 9Revision A
Chapter 2: Unloading the Header from a Trailer –North America
The rotary disc header, when shipped anywhere in North America, is secured on a shipping stand. The header and stand
are unloaded from the transport vehicle using a forklift.
DANGER
To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area.
1013855
A
B
C
Figure 2.1: Minimum Lifting Capacity
A - Load Center of Gravity
B - Load Center 1220 mm (48 in.) from Back of Forks
C - Minimum Fork Length 1981 mm (78 in.)
IMPORTANT:
Equipment used for unloading the header must meet or exceed
the requirements specified below. Using inadequate equipment
may result in chain breakage, machine damage, or the vehicle
tipping.
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.)
ϭϬϯϳϯϵϵ
 
Figure 2.2: Lifting Rotary Disc Header off Trailer
1. Remove the hauler’s tie-down straps and chains.
WARNING
Be sure forks are secure before moving away from load. Stand
clear when lifting.
2. Approach the rotary disc header with the forklift from the
underside of the header and slide the forks through four
fork straps (A), and as far as possible.
IMPORTANT:
If the load is two units wide, take care to avoid contacting
the other machine.
3. Raise the rotary disc header off the deck.

215974 10 Revision A
ϭϬϯϳϰϬϬ

Figure 2.3: Moving Disc Header with Forklift
4. Back the forklift up until the rotary disc header clears the
trailer, and slowly lower the header until distance (A) from
the ground is 150 mm (6 in.).
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 –NORTH AMERICA

215974 11 Revision A
Chapter 3: Unloading the Header from a Container –Export
The rotary disc headers, when shipped anywhere outside of North America, are shipped in a shipping container. The
shipping container contains up to four R216 Rotary Disc Headers (complete with conditioner) placed side by side. Unload
the headers one at a time, using a forklift and other unloading equipment.
DANGER
To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area.
ϭϬϯϳϱϯϮ



Figure 3.1: R216 Header Shipping Specifications
NOTE:
In its shipping configuration, the R216 header has the following
specifications:
•Width (A): 5.01 m (16 ft. 5 in.)
•Height (B): 2.56 m (8 ft. 5 in.)
•Depth (C): 1.43 m (4 ft. 8 in.)
•Weight: 2427 kg (5351 lbs.)
1013855
A
B
C
Figure 3.2: Minimum Lifting Capacity
A - Load Center of Gravity
B - Load Center 1220 mm (48 in.) from Back of Forks
C - Minimum Fork Length 1981 mm (78 in.)
IMPORTANT:
Equipment used for unloading the header must meet or exceed
the requirements specified below. Using inadequate equipment
may result in chain breakage, machine damage, or the vehicle
tipping.
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.

215974 12 Revision A
Table 3.1 Lifting Vehicle
Minimum Capacity 3630 kg (8000 lb.)
Minimum Fork Length 198 cm (78 in.)
1034090
A
B
C
D
Figure 3.3: Headers in Container —View from Above
The headers are positioned inside the container as shown.
Unload headers one at a time. Start with header (A) then
unload headers (B), (C), and (D).
1. Move the trailer into position, and block the trailer wheels.
2. Lower the trailer storage stands.
3. Open the container doors, and remove the wood blockings and strapping from one header at a time. This is to prevent
the unit from shifting which can cause damage.
4. Check the container floors for nails or other obstructions, and remove these obstructions if necessary.
ϭϬϯϳϰϯϴ


Figure 3.4: Rotary Disc Header in Shipping Container
—View from Left
5. Connect chain or equivalent device (A) to the middle of
shipping stand crossmember (B).
UNLOADING THE HEADER FROM A CONTAINER –EXPORT