MacDon R216 User manual

R216
Rotary Disc Header for Windrowers
Unloading and Assembly Instructions
262271 Revision A
Original Instruction
The Harvesting Specialists.

R216 Rotary Disc Header
1031305
Published September 2023
© 2023 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 the Customer receives all of the performance and safety benefits of this product, carefully follow the unloading
and assembly procedure from the beginning through to the end.
Read all of the material provided before attempting to unload, assemble, or use the machine.
Retain this instruction for future reference.
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).
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.
NOTE:
This manual is currently available in English only.
262271 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
—Removed topics concerning the
Feed Roll Drive. ECN 63932
4.1.4 Unpacking Hydraulic Hoses and Electrical Harness,
page 19
Updated procedure to include
instructions for M2260
Windrowers.
Product Support
5 Attaching Rotary Disc Header to Windrower, page 37 Added procedures for M2 Series
and M Series Windrowers.
Technical
Publications
5.1 Attaching R2 Series Rotary Disc Header to M2 Series
Windrower, page 37 Added topic. Technical
Publications
5.1.1 Connecting R2 Series Rotary Disc Header Hydraulic
and Electrical Components –M2170 Windrower, page 44 Added topic. Technical
Publications
5.1.2 Connecting R2 Series Rotary Disc Header Hydraulic
and Electrical Systems –M2260 Windrower, page 50 Added topic and subtopics. Technical
Publications
5.2 Calibrating M2 Series Windrower and Header on
HarvestTouch™Display, page 66 Added topic. Technical
Publications
5.3 Calibrating Knife Drive on HarvestTouch™Display –M2
Series Windrowers, page 67 Added topic. Technical
Publications
5.4 Calibrating Header Position Sensors on HarvestTouch™
Display –M2 Series Windrowers, page 71 Added topic. Technical
Publications
5.7 Calibrating Header Position Sensors on Harvest
Performance Tracker Display –M1 Series Windrowers,
page 100
Added topic. Technical
Publications
5.9 Attaching R2 Series Rotary Disc Header to M155 SP
Windrower, page 121 Added topic and subtopics. Technical
Publications
5.10 Attaching R2 Series Rotary Disc Header to M155E4 SP
Windrower, page 135 Added topic and subtopics. Technical
Publications
6 Unpacking the Curtain, page 151
Updated step to include
instructions for M2 Series
Windrowers.
Technical
Publications
7.1 Installing Skid Shoes or Gauge Rollers, page 153 Updated table. ECN 63963
7.2 Installing Hydraulic Drive Kit –For Headers Shipped
without Hydraulic Drive Only, page 154 Updated table. Product Support
7.3 Installing Grass Seed Anti-Shatter Shield Kit –Grass
Seed Ready Headers Only, page 155 Removed table. Technical
Publications
8.1 Lubrication Locations –Standard Headers, page 158 Updated lubrication locations. ECN 63963
9.2.1 Checking Float –M1 Series and M2 Series
Windrowers, page 164
Updated topic for M2 Series
Windrowers.
Technical
Publications
9.2.2 Setting Float –M2 Series Windrowers, page 164 Added topic. Technical
Publications
9.3 Activating Grass Seed Option –M2 Series Windrowers,
page 171 Added topic. Technical
Publications
9.6 Checking and Adding Oil in Conditioner Timing Gearbox
–Standard Header, page 178 Updated illustration. ECN 63963
262271 ii Revision A

Section Summary of Change Internal Use Only
10.1 Starting Engine –M1 Series and M2 Series
Windrowers, page 187
Updated topic for M2 Series
Windrowers.
Technical
Publications
10.3 Engaging and Disengaging Header Safety Props –M1
Series and M2 Series Windrowers, page 196
Updated topic for M2 Series
Windrowers.
Technical
Publications
10.5 Leveling Header –M2 Series Windrower, page 200 Added topic. Technical
Publications
10.8 Removing and Restoring Float for M2 Series
Windrowers, page 207 Added topic. Technical
Publications
10.9 Removing and Restoring Float for M1 Series
Windrowers, page 209 Moved topic to current location. Technical
Publications
10.14.3 O-Ring Boss Hydraulic Fittings –Adjustable, page
221 Updated table. ECN 64539
10.14.4 O-Ring Boss Hydraulic Fittings –Non-Adjustable,
page 222 Updated table. ECN 64539
10.14.5 O-Ring Face Seal Hydraulic Fittings, page 223 Corrected table. Technical
Publications
Predelivery Checklist, page 229 Updated predelivery checklist. Technical
Publications
262271 iii Revision A

262271 vRevision 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 Header from Trailer –North America ................................................................... 9
Chapter 3: Unloading Header from Shipping Container –Export .......................................................... 11
Chapter 4: Assembling Header................................................................................................................. 15
4.1 Preparing Header for Assembly............................................................................................................... 15
4.1.1 Removing Shipping Wire from Bottom of 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
Chapter 5: Attaching Rotary Disc Header to Windrower ....................................................................... 37
5.1 Attaching R2 Series Rotary Disc Header to M2 Series Windrower .................................................................. 37
5.1.1 Connecting R2 Series Rotary Disc Header Hydraulic and Electrical Components –M2170
Windrower ................................................................................................................................. 44
5.1.2 Connecting R2 Series Rotary Disc Header Hydraulic and Electrical Systems –M2260 Windrower................ 50
Auger/Rotary Disc/Draper-Ready Configuration –Quick Coupler Connections ....................................... 51
Rotary Disc-Only Configuration –Hard-Plumbed Connections............................................................. 56
Rotary Disc-Only Configuration –Quick Coupler Connections ............................................................. 61
5.2 Calibrating M2 Series Windrower and Header on HarvestTouch™Display ....................................................... 66
5.3 Calibrating Knife Drive on HarvestTouch™Display –M2 Series Windrowers..................................................... 67
5.4 Calibrating Header Position Sensors on HarvestTouch™Display –M2 Series Windrowers................................... 71
5.5 Attaching R2 Series Rotary Disc Header to M1 Series Windrower .................................................................. 75
5.5.1 Attaching R2 Series Rotary Disc Header to M1240 Windrower ............................................................. 82
Routing Electrical Harness –M1240 Windrower ............................................................................... 82
Connecting R2 Series Rotary Disc Header Hydraulic and Electrical Systems –M1240 Windrower .............. 84
5.6 Calibrating Knife Drive on Harvest Performance Tracker Display –M1 Series Windrowers ................................. 97
5.7 Calibrating Header Position Sensors on Harvest Performance Tracker Display –M1 Series Windrowers ............. 100
5.8 Attaching R2 Series Rotary Disc Header to M205 SP Windrower ................................................................. 103
TABLE OF CONTENTS

262271 vi Revision A
5.8.1 Attaching R2 Series Rotary Disc Header to M205 SP Windrower –Hydraulic Center-Link with Optional
Self-Alignment........................................................................................................................... 103
5.8.2 Attaching R2 Series Rotary Disc Header to M205 SP Windrower –Hydraulic Center-Link without
Optional Self-Alignment .............................................................................................................. 109
5.8.3 Connecting R2 Series Rotary Disc Header Hydraulics and Electrical Components –M205 SP
Windrower ............................................................................................................................... 115
5.9 Attaching R2 Series Rotary Disc Header to M155 SP Windrower ................................................................. 121
5.9.1 Attaching R2 Series Rotary Disc Header to M155 SP Windrower –Hydraulic Center-Link with Self-
Alignment................................................................................................................................. 121
5.9.2 Attaching R2 Series Rotary Disc Header to M155 SP Windrower –Hydraulic Center-Link without Self-
Alignment................................................................................................................................. 127
5.9.3 Connecting R2 Series Rotary Disc Header Hydraulics and Electrical to M155 SP Windrower..................... 133
5.10 Attaching R2 Series Rotary Disc Header to M155E4 SP Windrower ............................................................ 135
5.10.1 Attaching R2 Series Rotary Disc Header to M155E4 SP Windrower –Hydraulic Center-Link with Self-
Alignment................................................................................................................................. 135
5.10.2 Attaching R2 Series Rotary Disc Header to M155E4 SP Windrower –Hydraulic Center-Link without
Self-Alignment........................................................................................................................... 141
5.10.3 Connecting R2 Series Rotary Disc Header Hydraulics and Electrical –M155E4 SP Windrower................. 147
5.11 Setting the Header Cut Width ............................................................................................................. 149
Chapter 6: Unpacking the Curtain.......................................................................................................... 151
Chapter 7: Installing Other Options....................................................................................................... 153
7.1 Installing Skid Shoes or Gauge Rollers .................................................................................................... 153
7.2 Installing Hydraulic Drive Kit –For Headers Shipped without Hydraulic Drive Only ......................................... 154
7.3 Installing Grass Seed Anti-Shatter Shield Kit –Grass Seed Ready Headers Only .............................................. 155
Chapter 8: Lubricating Rotary Disc Header ........................................................................................... 157
8.1 Lubrication Locations –Standard Headers............................................................................................... 158
8.2 Lubrication Locations –Grass Seed Headers ............................................................................................ 160
Chapter 9: Performing Predelivery Checks............................................................................................ 161
9.1 Conditioner Drive Belt –Standard Header............................................................................................... 161
9.1.1 Inspecting Conditioner Drive Belt.................................................................................................. 161
9.1.2 Adjusting Conditioner Drive Belt ................................................................................................... 162
9.2 Header Float...................................................................................................................................... 164
9.2.1 Checking Float –M1 Series and M2 Series Windrowers .................................................................... 164
9.2.2 Setting Float –M2 Series Windrowers ........................................................................................... 164
9.2.3 Setting Float –M1 Series Windrowers ........................................................................................... 166
9.2.4 Checking Float –M Series Windrowers .......................................................................................... 167
9.2.5 Setting Float –M Series Windrowers ............................................................................................. 168
Adjusting Float Using Drawbolts .................................................................................................. 170
9.3 Activating Grass Seed Option –M2 Series Windrowers.............................................................................. 171
9.4 Activating Grass Seed Option –M1 Series Windrowers.............................................................................. 173
9.5 Suspended Drum Drive........................................................................................................................ 177
TABLE OF CONTENTS

262271 vii Revision A
9.5.1 Checking Suspended Drum Drive .................................................................................................. 177
9.6 Checking and Adding Oil in Conditioner Timing Gearbox –Standard Header ................................................. 178
9.7 Checking and Adding Oil in Header Drive Gearbox.................................................................................... 179
9.8 Checking and Adding Lubricant in Cutterbar ............................................................................................ 180
9.9 Checking Lights .................................................................................................................................. 183
9.10 Checking Manual Storage Case............................................................................................................ 184
9.11 Checking Parts in Storage Location....................................................................................................... 185
9.12 Running up Header ........................................................................................................................... 186
Chapter 10: Reference............................................................................................................................ 187
10.1 Starting Engine –M1 Series and M2 Series Windrowers .......................................................................... 187
10.2 Starting Engine –M Series Windrower.................................................................................................. 193
10.3 Engaging and Disengaging Header Safety Props –M1 Series and M2 Series Windrowers ............................... 196
10.4 Engaging and Disengaging Header Safety Props –M Series Self-Propelled Windrower................................... 198
10.5 Leveling Header –M2 Series Windrower............................................................................................... 200
10.6 Leveling Header –M1 Series Windrower............................................................................................... 202
10.7 Leveling Header –M Series Windrower ................................................................................................ 204
10.8 Removing and Restoring Float for M2 Series Windrowers ........................................................................ 207
10.9 Removing and Restoring Float for M1 Series Windrowers ........................................................................ 209
10.10 Opening Driveshields ....................................................................................................................... 211
10.11 Closing Driveshields......................................................................................................................... 213
10.12 Opening Cutterbar Curtain................................................................................................................ 215
10.13 Closing Cutterbar Curtain ................................................................................................................. 217
10.14 Torque Specifications....................................................................................................................... 218
10.14.1 Metric Bolt Specifications......................................................................................................... 218
10.14.2 Metric Bolt Specifications –Cast Aluminum................................................................................. 220
10.14.3 O-Ring Boss Hydraulic Fittings –Adjustable ................................................................................. 221
10.14.4 O-Ring Boss Hydraulic Fittings –Non-Adjustable .......................................................................... 222
10.14.5 O-Ring Face Seal Hydraulic Fittings ............................................................................................ 223
10.14.6 Tapered Pipe Thread Fittings .................................................................................................... 224
10.15 Conversion Chart ............................................................................................................................ 226
10.16 Definitions ..................................................................................................................................... 227
Predelivery Checklist .............................................................................................................................. 229
TABLE OF CONTENTS

262271 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

262271 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 it is not prevented, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if it is not prevented, could result in death or serious injury. It may also
be used to alert you to unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if it is not prevented, may result in minor or moderate injury. It may
also be used to alert you to unsafe practices.
IMPORTANT:
Indicates a situation that, if not prevented, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.
SAFETY

262271 3Revision A
1.3 General Safety
Operating, servicing, and assembling machinery presents several safety risks. These risks can be reduced or eliminated by
following the relevant safety procedures and wearing the appropriate personal protective equipment.
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

262271 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

262271 5Revision A
1.4 Hydraulic Safety
Because hydraulic fluid is under extreme pressure, hydraulic fluid leaks can be very dangerous. Follow the proper safety
procedures when inspecting hydraulic fluid leaks and servicing hydraulic equipment.
1001205
Figure 1.8: Testing for Hydraulic Leaks
•Always place all hydraulic controls in NEUTRAL before
leaving the operator’s seat.
•Ensure that all of 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 you are injured by a concentrated, high-pressure stream
of hydraulic fluid, seek medical attention immediately.
Serious infection or a 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

262271 6Revision A
1.5 Welding Precaution
To prevent damage to sensitive electronics, NEVER attempt welding on the header while it is connected to a windrower.
WARNING
NEVER attempt welding on the header while it is connected to the windrower. 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 a high current may have regarding future malfunctions or a shorter lifespan.
For further welding precautions, consult the windrower operator’s manual.
If it is not practical 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

262271 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

262271 9Revision A
Chapter 2: Unloading Header from Trailer –North America
The rotary disc header, when shipped anywhere in North America, is secured on a shipping stand. The header and the
stand are unloaded from the transport vehicle using a forklift.
DANGER
Do NOT allow people to stand in the 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 2 m (6.5 ft.)
IMPORTANT:
The equipment used for unloading the header must meet or
exceed the requirements specified below. Using inadequate
equipment may result in chains breaking, damage to the
machine, or the vehicle tipping.
NOTE:
Forklifts are normally rated for a load located 610 mm (24 in.)
from the back end of the forks. To obtain 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 2 m (6.5 ft.)
ϭϬϯϳϯϵϵ
 
Figure 2.2: Lifting Header off Trailer
1. Remove the hauler’s tie-down straps and chains.
WARNING
Ensure the forks are secure before moving away from the load.
Stand clear when lifting the machine.
2. Approach the header with the forklift from the underside of
the header and slide the forks as far as possible through
four fork straps (A).
IMPORTANT:
If the load is two units wide, avoid contacting the other
machine.
3. Raise the header off of the deck.

262271 10 Revision A
ϭϬϯϳϰϬϬ

Figure 2.3: Moving Header with Forklift
4. Back the forklift until the header clears the trailer, the
slowly lower the header until distance (A) between the
ground and the header is 150 mm (6 in.).
5. Take the header to the storage or setup area.
6. Set the header down on secure, level ground.
Do NOT lower the header into working position.
7. Check the header for any shipping damage or missing parts.
8. Proceed to Chapter 4 Assembling Header, page 15.
UNLOADING HEADER FROM TRAILER –NORTH AMERICA