MacDon R216 Unloading & Assembly Instruction

R216

Rotary Disc Header for Windrowers

Unloading and Assembly Instructions

215405 Revision A

Original Instruction

The Harvesting Specialists.

R216 Rotary Disc Header



Published November 2020.

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.

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.

215405 i Revision 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 without

Conditioner from a Trailer – North

America, page 9

Added topic.

ECN 60771

4 Unloading the Header from a Container

– Export, page 11

Added topic

ECN 59799

5 Assembling the Header, page 15 Added links. Tech Pubs

5.1 Assembling the Header with

Conditioner – Standard Header, page 15

Added topic. Tech Pubs

5.1.1 Removing Shipping Supports, page

15

Added step to remove hazard/brake light assembly from

shipping location (Export only).

Engineering

5.1.3 Unpacking Hydraulic Hoses and

Electrical Harness, page 19

Added step for M205 SP Windrower.

ECN 58180

5.1.4 Removing Shipping Stands, page 20 Added instruction to discard hardware in steps. Tech Pubs

5.1.4 Removing Shipping Stands, page 20 Added step about shipping wire on driveshield handle.

ECN 58792

5.1.4 Removing Shipping Stands, page 20

Added step about protective film on aluminum bumper at

the front.

UECN 31146

5.1.4 Removing Shipping Stands, page 20

Added note about right hazard/light assembly on Export

machines.

Engineering

5.1.5 Installing Hazard/Brake Light

Assembly – Export Only, page 23

Added topic.

Engineering

5.2 Assembling the Header without

Conditioner – Grass Seed Ready, page 27

Added topic.

ECN 60771

5.2.1 Removing Shipping Panel, page 27 Added topic.

ECN 60771

5.2.2 Changing R216 Rotary Disc Header

Cutterbar Crop Stream Configuration for

Grass Seed Option, page 28

Added topic.

ECN 60771

Removing Cutterbar Spindles, page 29

Added topic.

ECN 60771

Installing Cutterbar Spindles, page 31

Added topic.

ECN 60771

5.2.3 Unpacking Hydraulic Hoses and

Electrical Harness, page 36

Added topic.

ECN 60771

6 Assembling and Installing Forming

Shield, page 37

Moved topic before attaching header and windrower as

this topic is applicable to both windrowers.

Tech Pubs

6 Assembling and Installing Forming

Shield, page 37

Revised image.

Engineering

7.1.1 Routing Electrical Harness, page 45

• Removed steps about checking slack in harness.

Product

Support

7.1.2 Attaching Rotary Disc Header, page

47

Added steps about checking slack in harness.

Product

Support

215405 ii Revision A

Section Summary of Change

Internal Use

Only

7.1.3 Connecting R216 Rotary Disc

Header Hydraulics and Electrical to an

M1240 Windrower, page 52

Merged the following topics:

• Connecting Rotary Disc Header Hydraulics Using Quick

Couplers – M1240 Windrowers

• Connecting Rotary Disc Header Hydraulics Using Hard

Plumbing

Tech Pubs

7.1.3 Connecting R216 Rotary Disc

Header Hydraulics and Electrical to an

M1240 Windrower, page 52

Added steps for grass seed.

ECN 60771

7.1.3 Connecting R216 Rotary Disc

Header Hydraulics and Electrical to an

M1240 Windrower, page 52

Added steps for connecting electrical and checking slack in

electrical harness.

Tech Pubs

7.1.5 Calibrating Windrower Knife Drive

on the Harvest Performance Tracker

Display, page 61

Added note about error message. Tech Pubs

7.2 Attaching Rotary Disc Header to

M205 SP Windrower, page 63

Added topic.

ECN 58180

7.2.1 Attaching R216 Rotary Disc Header

to M205 SP Windrower – Hydraulic

Center-Link with Optional Self-Alignment,

page 63

Added topic.

ECN 58180

7.2.2 Attaching R216 Rotary Disc Header

to M205 SP Windrower – Hydraulic

Center-Link without Optional

Self-Alignment, page 69

Added topic.

ECN 58180

7.2.3 Connecting R216 Rotary Disc

Header Hydraulics and Electrical to an

M205 SP Windrower, page 75

Added topic.

ECN 58180

7.2.4 Setting the Header Cut Width, page

80

Added topic.

ECN 58180

8 Unpacking the Curtain, page 83

• Moved topic after attaching header to M1240 or M205.

• Changed Warning to Danger.

• Added step to turn off engine

Tech Pubs

9 Installing Other Options, page 85 Changed topic title from Installing Options. Tech Pubs

10.2 Lubrication Locations – Grass Seed

(Option), page 90

Added topic.

ECN 60771

11.2.3 Checking Float – M205 SP

Windrower, page 95

Added topic.

ECN 58180

11.2.4 Setting Float – M205 SP

Windrower, page 97

Added topic.

ECN 58180

Adjusting Float Using Drawbolts, page 99 Added topic.

ECN 58180

11.3 Activating the Grass Seed (Option),

page 100

Added topic.

ECN 60771

215405 iii Revision A

Section Summary of Change

Internal Use

Only

12.2 Starting the Engine – M205 SP

Windrower, page 119

Added topic.

ECN 58180

11.9 Checking Lights, page 111

Added image of header with grass seed option to show

lights location.

ECN 60771

11.10 Checking Manuals, page 112

Added image of header with grass seed optionto show

manual case location.

ECN 60771

12.4 Engaging and Disengaging Header

Safety Props – M205 SP Windrower, page

123

Added topic.

ECN 58180

12.3 Engaging and Disengaging Header

Safety Props – M1240 Windrower, page

121

Added M1240 Windrower to topic title. Tech Pubs

12.6 Leveling the Header – M205 SP

Windrower, page 127

Added topic.

ECN 58180

11.11 Running up the Header, page 113 Changed Caution to Warning. Tech Pubs

12.11 Recommended Lubricants, page

137

Changed lubricant specification of conditioner roll timing

gearbox.

ECN 60418

12.14 Definitions, page 148

Added cab display module (CDM) to the list.

Tech Pubs

Predelivery Checklist, page 151 Added links to M205 SP Windrower topics. Tech Pubs

Predelivery Checklist, page 151

• Added M205 SP Windrower topic links to predelivery

checklist.

• Added grass seed specific items.

Tech Pubs

215405 iv Revision A

215405 v Revision A

Introduction ................................................................................................................................................ i

Summary of Changes....................................................................................................................................ii

Chapter 1: Safety ........................................................................................................................................ 1

1.1 Signal Words ......................................................................................................................................... 1

1.2 General Safety ....................................................................................................................................... 2

1.3 Welding Precaution ................................................................................................................................ 4

1.4 Safety Signs ........................................................................................................................................... 5

Chapter 2: Unloading the Header with Conditioner from a Trailer – North America............................. 7

Chapter 3: Unloading the Header without Conditioner from a Trailer – North America ....................... 9

Chapter 4: Unloading the Header from a Container – Export................... ............................................. 11

Chapter 5: Assembling the Header .......................................................................................................... 15

5.1 Assembling the Header with Conditioner – Standard Header........................................................................ 15

5.1.1 Removing Shipping Supports.......................................................................................................... 15

5.1.2 Lowering the Header .................................................................................................................... 17

5.1.3 Unpacking Hydraulic Hoses and Electrical Harness ............................................................................. 19

5.1.4 Removing Shipping Stands ............................................................................................................. 20

5.1.5 Installing Hazard/Brake Light Assembly – Export Only......................................................................... 23

5.1.6 Installing Manual Rear Deflectors.................................................................................................... 24

5.2 Assembling the Header without Conditioner – Grass Seed Ready .................................................................. 27

5.2.1 Removing Shipping Panel .............................................................................................................. 27

5.2.2 Changing R216 Rotary Disc Header Cutterbar Crop Stream Configuration for Grass Seed Option ................ 28

Removing Cutterbar Spindles ........................................................................................................ 29

Installing Cutterbar Spindles ......................................................................................................... 31

5.2.3 Unpacking Hydraulic Hoses and Electrical Harness ............................................................................. 36

5.2.4 Installing Grass Seed Completion Package ........................................................................................ 36

Chapter 6: Assembling and Installing Forming Shield ............................................................................ 37

Chapter 7: Attaching Rotary Disc Header to Windrower ....................................................................... 45

7.1 Attaching Rotary Disc Header to M1240 Windrower ................................................................................... 45

7.1.1 Routing Electrical Harness ............................................................................................................. 45

7.1.2 Attaching Rotary Disc Header......................................................................................................... 47

7.1.3 Connecting R216 Rotary Disc Header Hydraulics and Electrical to an M1240 Windrower .......................... 52

7.1.4 Restoring Float for Rotary Disc Header............................................................................................. 59

7.1.5 Calibrating Windrower Knife Drive on the Harvest Performance Tracker Display ..................................... 61

7.2 Attaching Rotary Disc Header to M205 SP Windrower................................................................................. 63

7.2.1 Attaching R216 Rotary Disc Header to M205 SP Windrower – Hydraulic Center-Link with Optional

Self-Alignment............................................................................................................................. 63

7.2.2 Attaching R216 Rotary Disc Header to M205 SP Windrower – Hydraulic Center-Link without Optional

Self-Alignment............................................................................................................................. 69

7.2.3 Connecting R216 Rotary Disc Header Hydraulics and Electrical to an M205 SP Windrower ........................ 75

TABLE OF CONTENTS

215405 vi Revision A

7.2.4 Setting the Header Cut Width ........................................................................................................ 80

Chapter 8: Unpacking the Curtain............................................................................................................ 83

Chapter 9: Installing Other Options......................................................................................... ................ 85

Chapter 10: Lubricating the Rotary Disc Header............................................... ...................................... 87

10.1 Lubrication Locations – Standard Headers ............................................................................................... 88

10.2 Lubrication Locations – Grass Seed (Option) ............................................................................................ 90

Chapter 11: Performing Predelivery Checks............................................................................................ 91

11.1 Conditioner Drive Belt – Standard Header ............................................................................................... 91

11.1.1 Inspecting Conditioner Drive Belt .................................................................................................. 91

11.1.2 Adjusting Conditioner Drive Belt ................................................................................................... 92

11.2 Header Float ...................................................................................................................................... 94

11.2.1 Checking Float – M1240 Windrower .............................................................................................. 94

11.2.2 Setting Float – M1240 Windrower................................................................................................. 95

11.2.3 Checking Float – M205 SP Windrower............................................................................................ 95

11.2.4 Setting Float – M205 SP Windrower .............................................................................................. 97

Adjusting Float Using Drawbolts .................................................................................................... 99

11.3 Activating the Grass Seed (Option)....................................................................................................... 100

11.4 Suspended Drum Drive ...................................................................................................................... 103

11.4.1 Checking Suspended Drum Drive................................................................................................. 103

11.5 Feed Roll Drive – Standard Header....................................................................................................... 104

11.5.1 Checking Feed Roll Drive ........................................................................................................... 104

11.6 Checking and Adding Conditioner Roll Timing Gearbox Oil – Standard Header ............................................. 105

11.7 Checking and Adding Oil in Header Drive Gearbox .................................................................................. 106

11.8 Checking and Adding Lubricant in Cutterbar .......................................................................................... 108

11.9 Checking Lights................................................................................................................................. 111

11.10 Checking Manuals ........................................................................................................................... 112

11.11 Running up the Header .................................................................................................................... 113

Chapter 12: Reference............................................................................................................................ 115

12.1 Starting the Engine – M1240 Windrower .............................................................................................. 115

12.2 Starting the Engine – M205 SP Windrower ............................................................................................ 119

12.3 Engaging and Disengaging Header Safety Props – M1240 Windrower......................................................... 121

12.4 Engaging and Disengaging Header Safety Props – M205 SP Windrower ...................................................... 123

12.5 Leveling the Header – M1240 Windrower ............................................................................................. 125

12.6 Leveling the Header – M205 SP Windrower........................................................................................... 127

12.7 Closing Driveshields........................................................................................................................... 130

12.8 Opening Driveshields......................................................................................................................... 132

12.9 Closing Cutterbar Curtain ................................................................................................................... 134

12.10 Opening Cutterbar Curtain................................................................................................................ 135

TABLE OF CONTENTS

215405 vii Revision A

12.11 Recommended Lubricants ................................................................................................................ 137

12.12 Torque Specifications....................................................................................................................... 138

12.12.1 Metric Bolt Specifications......................................................................................................... 138

12.12.2 Metric Bolt Specifications Bolting into Cast Aluminum................................................................... 140

12.12.3 O-Ring Boss Hydraulic Fittings – Adjustable ................................................................................. 141

12.12.4 O-Ring Boss Hydraulic Fittings – Non-Adjustable .......................................................................... 143

12.12.5 O-Ring Face Seal Hydraulic Fittings ............................................................................................ 144

12.12.6 Tapered Pipe Thread Fittings .................................................................................................... 145

12.13 Conversion Chart ............................................................................................................................ 147

12.14 Definitions ..................................................................................................................................... 148

Predelivery Checklist .............................................................................................................................. 151

TABLE OF CONTENTS

215405 1 Revision A

Chapter 1: Safety

1.1 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.

215405 2 Revision A

1.2 General Safety

Protect yourself when assembling, operating, and servicing machinery.



Figure 1.1: 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



Figure 1.2: Safety Equipment

In addition, take the following precautions:

• 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 1.3: 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 the safest way.

NEVER ignore warning signs of fatigue.

SAFETY

215405 3 Revision A



Figure 1.4: 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 1.5: 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 machine function and/or safety. It may also

shorten the machine’s life.

• To avoid injury or death from 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.



Figure 1.6: Safety around Equipment

• Keep service area clean and dry. Wet and/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 are

fire hazards. 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

215405 4 Revision A

1.3 Welding Precaution

To prevent damage to sensitive electronics, welding should never be attempted on the rotary disc 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 rotary disc 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

215405 5 Revision A

1.4 Safety Signs

Safety signs are usually yellow decals, and are placed on the machine where there is a risk of personal injury, or where the

operator has to take extra precaution before operating controls. Operator manuals and technical manuals identify the

location and meaning of all safety signs placed on the machine.



Figure 1.7: 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, be sure the repair part displays the current

safety sign.

SAFETY

215405 7 Revision A

Chapter 2: Unloading the Header with Conditioner from a Trailer

– North America

The rotary disc header when shipped with a conditioner to anywhere in North America is secured on a shipping stand.

WARNING

To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area.



$

%

&

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.)



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 from its underside and

slide the forks under the lifting framework 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.

215405 8 Revision A



Figure 2.3: Moving Disc Header with Forklift

4. Back up until the rotary disc header clears the trailer, and

slowly lower it to 150 mm (6 in.) from the ground.

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 WITH CONDITIONER FROM A TRAILER – NORTH AMERICA

215405 9 Revision A

Chapter 3: Unloading the Header without Conditioner from a

Trailer – North America

The rotary disc header when shipped without a conditioner to anywhere in North America is secured on a pallet. It is grass

seed (GSS) ready, and it is shipped with a GSS.

CAUTION

To avoid injury to bystanders from being struck by machinery, do NOT allow persons to stand in unloading area.

CAUTION

Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment

may result in chain breakage, vehicle tipping or machine damage.

Lifting Vehicle

Minimum capacity

3630 kg (8000 lb.)

Minimum height

4.5 m (15 ft.)



$

%

Figure 3.1: Unloading Rotary Disc Header

1. Remove hauler’s tie-down straps (A).

2. Approach rotary disc header (B) from back with forklift, and

slide forks as far as possible into pallet.

NOTE:

Pallet is designed to be lifted from the backside only.

3. Raise rotary disc header off deck.

IMPORTANT:

Take care not to contact the other machine if load is

two-headers wide.

4. Back up until unit clears trailer, and slowly lower to 150 mm

(6 in.) from ground.

5. Take the machine to a storage or set-up area, and set

machine down securely on level ground.

NOTE:

When possible, approach from the backside to minimize

potential for contacting the unit.

6. Repeat for second rotary disc header (if required).

7. Check for shipping damage and missing parts.

IMPORTANT:

Do NOT remove header from pallet until instructed.

8. Unload remaining pallets and boxes, and take to assembly area.

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MacDon R216 Unloading & Assembly Instruction

MacDon R216 Unloading & Assembly Instruction

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