MacDon D1 Series Unloading And Assembly Instructions
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MacDon D1 Series Unloading And Assembly Instructions

Draper header for m series windrowers
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D1 Series
Draper Header for M Series Windrowers
Unloading and Assembly Instructions (North America)
215419 Revision A
Original Instruction
The Harvesting Specialists.

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  • Page 1 D1 Series Draper Header for M Series Windrowers Unloading and Assembly Instructions (North America) 215419 Revision A Original Instruction The Harvesting Specialists.
  • Page 2 © 2020 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...
  • Page 3 Introduction This instruction manual describes the unloading, setup, and predelivery requirements for the MacDon D1 Series Draper Header for M Series Self-Propelled Windrowers. To ensure the best performance of this product and the safety of your customers, carefully follow the unload and assembly procedure from the beginning through to completion.
  • Page 4 Summary of Changes At MacDon, we’re continuously making improvements: occasionally these improvements affect product documentation. The following list provides an account of major changes from the previous version of this document. Internal Use Section Summary of Change Only Throughout Removed references to D145 headers.
  • Page 5 Internal Use Section Summary of Change Only 3.1 Attaching Reel Lift Cylinders, page 19 Revised illustrations in step to correctly show North Tech Pubs American single and double reel brackets. • Step NA, page 19 ECN 58360 3.1 Attaching Reel Lift Cylinders, page 19 Revised illustrations to show change in hardware for the center reel shipping bracket.
  • Page 6 Internal Use Section Summary of Change Only 5.4.2 Checking and Tensioning Timed Replaced the WARNING with the following DANGER: Tech Pubs Double-Knife Drive Belts, page 58 • DANGER: To avoid bodily injury or death from unexpected startup of machine, always stop the engine and remove the key before making adjustments to the machine.
  • Page 7 Internal Use Section Summary of Change Only 5.11.1 Measuring Reel Clearance, page 72 Removed the step that showed four locations to measure Tech Pubs the reel clearance (previously intended for double reel), because there are only two locations at which to measure the reel clearance for single and double reels on rigid headers.

  • Page 9: Table Of Contents

    TABLE OF CONTENTS 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 ......................7 2.1 Unloading Header from Trailer........................7 2.2 Lowering Header ............................9 2.2.1 Lowering Single-Reel Header......................9 2.2.2 Lowering Double-Reel Header ......................
  • Page 10 TABLE OF CONTENTS 5.5 Centering the Reel ..........................61 5.5.1 Centering Double Reel ........................61 5.5.2 Centering Single Reel ........................63 5.6 Checking and Adjusting Draper Tension ....................64 5.7 Checking and Adjusting Draper Seal ......................66 5.8 Checking and Adjusting Skid Shoe Settings ....................69 5.9 Leveling the Header ..........................

  • Page 11: Chapter 1: Safety

    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.

  • Page 12: General Safety

    SAFETY 1.2 General Safety Protect yourself when assembling, operating, and servicing machinery. 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.
  • Page 13 SAFETY • 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. •...

  • Page 14: Welding Precaution

    SAFETY 1.3 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.

  • Page 15: Safety Signs

    SAFETY 1.4 Safety Signs Safety signs (decals) are usually yellow, 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.

  • Page 17: Chapter 2: Unloading The Header

    Chapter 2: Unloading the Header Perform all procedures in this chapter in the order they are listed. 2.1 Unloading Header from Trailer The following procedure assumes that two headers were shipped on the trailer. DANGER To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area. WARNING Equipment used for loading and unloading must meet or exceed the minimum specified requirements.
  • Page 18 UNLOADING THE HEADER 3. Approach one of the headers and slide forks (A) through four forklift brackets (B) underneath the shipping support, as far as possible without contacting the shipping support of second header (C). IMPORTANT: Avoid lifting the second header and ensure the forks do not interfere with the shipping frame.

  • Page 19: Lowering Header

    UNLOADING THE HEADER 2.2 Lowering Header The procedure for lowering the header varies depending on whether the header has a single or double reel. To lower the header, refer to the procedure according to the type of header: • Single-reel headers: refer to 2.2.1 Lowering Single-Reel Header, page •...
  • Page 20 UNLOADING THE HEADER CAUTION Stand clear when lowering, as machine may swing. 4. Back up SLOWLY while lowering forks until header is just above the ground. Refer to the four positions in the illustration. Figure 2.4: Lowering the Header 215419 Revision A...
  • Page 21 UNLOADING THE HEADER 5. Place 150 mm (6 in.) blocks (A) under the center and each end of the cutterbar, and then lower the header onto blocks. 6. Remove the chain and move the lifting vehicle to the rear of the header. Figure 2.5: Block under Cutterbar 7.

  • Page 22: Lowering Double-Reel Header

    UNLOADING THE HEADER 8. Lower the header stand by pulling pin (A), lowering stand (B), and releasing pin (A) to secure the stand in place. 9. If the ground is soft, place a block under the stand. 10. Lower the header onto the stand. Figure 2.7: Header Stand 2.2.2 Lowering Double-Reel Header Lower the header to prepare it for assembly and setup.
  • Page 23 UNLOADING THE HEADER CAUTION Stand clear when lowering, as machine may swing. 4. Back up SLOWLY while lowering forks until header is just above the ground. Refer to the four positions in the illustration. Figure 2.10: Lowering the Header 215419 Revision A...
  • Page 24 UNLOADING THE HEADER 5. Place 150 mm (6 in.) blocks (A) under the center and under each end of the cutterbar, and then lower the header onto blocks. 6. Remove the chain and move the lifting vehicle to the rear of the header.
  • Page 25 UNLOADING THE HEADER 8. Lower the header stand: pull pin (A), lower stand (B), and release pin (A) to secure the stand in place. 9. If the ground is soft, place a block under the stand. 10. Lower the header onto the stand. 11.

  • Page 26: Removing Shipping Supports

    UNLOADING THE HEADER 2.3 Removing Shipping Supports To prepare for header assembly, remove the large shipping supports that were used to lower the header. NOTE: Unless otherwise specified, discard all shipping materials and hardware. 1. Cut straps and remove draper header supports (A) from the shipping support.
  • Page 27 UNLOADING THE HEADER 4. Remove bolts from locations (A) securing lower support (B) to the header legs. Remove support (B). Figure 2.17: Lower Support 5. Remove four bolts (A) from the shipping stands at both outboard header legs and remove the shipping stands. Figure 2.18: Outer Leg Shipping Support for D130, D135, and D140 Figure 2.19: Outer Leg Shipping Support for D115,...
  • Page 28 UNLOADING THE HEADER 6. Remove reel anti-rotation brace (A) from between the reel and endsheet. Figure 2.20: Anti-Rotation Brace 7. At the left side of the header, cut and remove wire (A) securing the endshield to the panel. Repeat at the opposite side.

  • Page 29: Chapter 3: Assembling The Header

    Chapter 3: Assembling the Header Perform all the procedures in this chapter in the order in which they are listed. 3.1 Attaching Reel Lift Cylinders You must set up the reel lift arms before assembling the header any further. CAUTION Tagged bolts (A) on the reel arms keep the reel from sliding forward.
  • Page 30 ASSEMBLING THE HEADER NOTE: Some parts have been removed from the illustration for clarity. 1. Position sling (A) around reel tube (B) close to the outboard end of the reel and attach a sling to a forklift or an equivalent lifting device. 2.
  • Page 31 ASSEMBLING THE HEADER 5. Lift the reel and remove pins from the endsheet and the reel arm. 6. Align the reel lift cylinder mounting holes until they line up with the lug on the endsheet and the hole in the reel arm. 7.
  • Page 32 ASSEMBLING THE HEADER 9. For double reel only: Position sling (A) around the reel tube near the reel center support arm. b. Lift the reel to gain access to the center lift cylinder. Remove shipping wire and banding from the center reel lift cylinder.
  • Page 33 ASSEMBLING THE HEADER 13. Lift the reel and remove the pins from endsheet (B) and reel arm (A). 14. Align the reel lift cylinder mounting holes until they line up with the lug on the endsheet and the hole in the reel arm. 15.
  • Page 34 ASSEMBLING THE HEADER 17. Double reel only: Remove remaining bolt (A), disengage center reel arm shipping support (B) from the cutterbar, and remove the shipping support. Figure 3.14: Center Reel Arm Shipping Support 18. Remove bolts (A) from reel arm support (B) at the endsheet and remove the support.
  • Page 35 ASSEMBLING THE HEADER 19. Remove brace bolts and tags (A) locking the reel fore-aft position on the outer reel arms. IMPORTANT: Do NOT use hydraulic pressure to move the fore-aft cylinder to aid brace bolts removal. The cylinder could be damaged.
  • Page 36 ASSEMBLING THE HEADER 20. Double reel only: Remove remaining three bolts (A) locking the reel fore-aft position at the center reel arm and remove shipping channel (B). Figure 3.18: Center Reel Arm Shipping Channel – Double-Reel Only 215419 Revision A...

  • Page 37: Positioning Transport Lights

    ASSEMBLING THE HEADER 3.2 Positioning Transport Lights Transport lights are located on each outboard reel arm. They are shipped in an inverted position on the inboard sides of the reel arms. 1. Remove lock nuts (B) holding right light assembly (A) to the reel arm and remove the light assembly.
  • Page 38 ASSEMBLING THE HEADER 4. Position left light assembly (B) perpendicular to the left reel arm and attach it using retained lock nuts (A). NOTE: The light assembly should rotate with normal hand force yet maintain its position. Figure 3.22: Left Transport Light 215419 Revision A...

  • Page 39: Attaching Cam Arms

    ASSEMBLING THE HEADER 3.3 Attaching Cam Arms Cam arms must be installed before operating the reel. To attach the reel cam arms, follow these steps: NOTE: On nine-bat reel headers, one cam arm assembly was removed and secured to the tine tube for shipping purposes. 1.
  • Page 40 ASSEMBLING THE HEADER 3. Rotate the reel manually until the tine bars with disconnected cam links are accessible. 4. Remove shipping wire (A) (if not already removed). Figure 3.25: Disconnected Cam Links and Shipping Wire 5. Remove bag of hardware (A) from tine bar. It contains hardware for cam links and endshields.

  • Page 41: Opening Endshields

    ASSEMBLING THE HEADER 3.4 Opening Endshields Open the endshield at both ends of the header to access serviceable components and stored items. 1. Push release lever (A) located on the backside of the endshield to unlock the shield. 2. Pull the endshield open using handle depression (B). Figure 3.28: Left Endshield 3.

  • Page 42: Installing Crop Dividers

    ASSEMBLING THE HEADER 3.5 Installing Crop Dividers One crop divider and two divider rods are stored on the right inboard side of the endsheet; the other crop divider is stored on the left inboard side of the endsheet. 1. Loosen the bolt at location (A) on the lock tab securing divider rods (B) to storage bracket (C).
  • Page 43 ASSEMBLING THE HEADER 7. Lift the forward end of the divider up to the endsheet and install washer (A) and bolt (B). Figure 3.34: Installing Divider 8. Position divider rod (B) on the tip of the crop divider as shown and tighten bolt (A). Figure 3.35: Divider Rod on Crop Divider 9.

  • Page 44: Closing Endshields

    ASSEMBLING THE HEADER 3.6 Closing Endshields Close and lock the endshields before moving the header. 1. Disengage lock (B) to allow the endshield to move. 2. Insert the front of the endshield behind hinge tab (A) and into the divider cone. Figure 3.37: Left Endshield 3.

  • Page 45: Installing Disc Segments Of Outboard Reel Endshields

    ASSEMBLING THE HEADER 3.7 Installing Disc Segments of Outboard Reel Endshields To meet the trucking load regulations for the maximum load width and height, two disc segments of reel endshields (A) may have been removed from the right reel (tail end) and left reel (cam end).

  • Page 46: Installing Options

    ASSEMBLING THE HEADER 3.8 Installing Options Retrieve the kits supplied as options with the header, and install them according to the instructions supplied with each kit. 215419 Revision A...

  • Page 47: Chapter 4: Attaching Header To Windrower

    Chapter 4: Attaching Header to Windrower Attach the header to the windrower to be able to perform pre-delivery maintenance checks. WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before adjusting machine. IMPORTANT: To avoid damaging the lift system when lowering the header lift linkages without a header or weight box attached to the...
  • Page 48 ATTACHING HEADER TO WINDROWER 3. Position support (B) on lift linkage (A) and reinstall clevis pin (C). Pin (C) may be installed from either side of the support. 4. Secure clevis pin (C) with hairpin (D). 5. Repeat for the opposite lift linkage. Figure 4.3: Header Support 6.

  • Page 49: Connecting Center-Link

    ATTACHING HEADER TO WINDROWER 8. Drive the windrower forward slowly so that supports (A) enter header legs (B). Continue to slowly drive forward until the linkages contact support plates (C) in the lower header legs and the header nudges forward. 9.
  • Page 50 ATTACHING HEADER TO WINDROWER 2. Loosen nut (A) and rotate barrel (B) to adjust length so that link lines up with header bracket. 3. Install pin (C) and secure with cotter pin. 4. Adjust link to required length for proper header angle by rotating barrel (B).

  • Page 51: Hydraulic Link Without Optional Self-Alignment Kit

    ATTACHING HEADER TO WINDROWER 11. Remove pin from storage position (B) in linkage and insert into hole (A) to engage float springs. Secure with hairpin and repeat for opposite side of windrower. 12. Disengage safety props. Figure 4.10: Float Springs Engaged WARNING Check to be sure all bystanders have cleared the area.
  • Page 52 ATTACHING HEADER TO WINDROWER 2. Relocate pin (A) at the frame linkage as required to position hook (B) over header pin (not shown). Figure 4.12: Center-Link WARNING Check to be sure all bystanders have cleared the area. 3. Start the engine and activate the HEADER TILT switches on the ground speed lever (GSL) to extend or retract the center-link cylinder so that hook lines up with the header attachment pin.
  • Page 53 ATTACHING HEADER TO WINDROWER 5. Push down on rod end (B) of center-link (A) until the hook engages the pin on the header and is locked. IMPORTANT: The hook release must be down to enable the self-locking mechanism. If the release is up (open), manually push it down after the hook engages the header pin.

  • Page 54: Hydraulic Link With Optional Self-Alignment Kit

    ATTACHING HEADER TO WINDROWER 13. Remove the pin from storage position (B) in the linkage and insert it into hole (A) to engage the float springs. Secure with its hairpin and repeat for the opposite side of the windrower. 14. Disengage the safety props. Figure 4.17: Float Springs Engaged WARNING Check to be sure all bystanders have cleared the area.
  • Page 55 ATTACHING HEADER TO WINDROWER 1. Adjust the position of center-link hook (A) with reel position switches (B), and header tilt switches (C) on the Ground Speed Lever (GSL) until hook (A) is above the header attachment pin. IMPORTANT: Hook release (D) must be down to enable the self-locking mechanism.
  • Page 56 ATTACHING HEADER TO WINDROWER 8. Install pin (A) through the header leg (engaging U-bracket in the header leg) and secure it using the retaining ring. Repeat for the opposite side of the header. 9. Raise header stand (B) to storage position by pulling pin (C) and lifting the stand into its uppermost position.

  • Page 57: Connecting Hydraulics

    ATTACHING HEADER TO WINDROWER 4.2 Connecting Hydraulics Confirm the windrower is configured to operate D1 Series Headers, and then connect the header drive and reel drive hoses to the header. NOTE: Windrowers equipped with D1 Series hydraulics have four header-drive hoses on the left side and up to five reel-drive hoses on the right.
  • Page 58 ATTACHING HEADER TO WINDROWER Connect header-drive hydraulics and electrical harness to header as follows: 2. Check connectors and clean if required. 3. Disengage and rotate lever (C) counterclockwise to fully-up position. 4. Remove cap securing electrical connector (B) to frame. 5.
  • Page 59 ATTACHING HEADER TO WINDROWER 11. Check that hose support is positioned so that top bolt (A) is midway in slot, and lower bolt (B) is in forward hole. Loosen bolts and adjust as required. Figure 4.28: Hose Support Connect reel-drive hydraulics (A) as follows: 12.
  • Page 60 ATTACHING HEADER TO WINDROWER 13. Open cover (A) on header receptacle. 14. Push in lock button (B) and pull handle (C) to half-open position. Figure 4.30: Header Receptacle 15. Remove hose bundle with multicoupler (A) from windrower and position onto header receptacle. 16.

  • Page 61: Adding Tire Ballast

    ATTACHING HEADER TO WINDROWER 4.3 Adding Tire Ballast When using large headers on the windrower, adding fluid ballast to the rear caster tires will improve machine stability. Machine stability is also affected by different attachments, windrower options, terrains, and driving techniques. Ballast capability per tire is at a maximum fill of 75% or when the fluid is level with the valve stem when the stem is positioned at the 12 o’clock position.

  • Page 63: Chapter 5: Performing Predelivery Checks

    Chapter 5: Performing Predelivery Checks This machine has been set at the factory and should not require further adjustments; however, the following checks will ensure your machine provides maximum performance. If adjustments are necessary, follow the procedures in this chapter. WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before adjusting machine.

  • Page 64: Checking Wheel Bolt Torque - Transport And Stabilizer Wheels

    PERFORMING PREDELIVERY CHECKS 5.2 Checking Wheel Bolt Torque – Transport and Stabilizer Wheels Check the torque on all transport and stabilizer wheel bolts to make sure the wheels are installed properly. Follow these steps to check the torque: 1. Check that wheel bolt torque is 115 Nm (85 lbf·ft). 2.

  • Page 65: Checking Knife Drive Box

    PERFORMING PREDELIVERY CHECKS 5.3 Checking Knife Drive Box Single-knife headers have one knife drive box and double-knife headers have two knife drive boxes. To access the knife drive box(es), the endshield(s) must be fully opened. DANGER To avoid bodily injury or death from unexpected startup of machine, always stop the engine and remove the key before making adjustments to the machine.
  • Page 66 PERFORMING PREDELIVERY CHECKS IMPORTANT: The knife drive box breather is shipped in position (A) (forward) to prevent oil loss during transport. The breather MUST be repositioned to location (B) to prevent oil loss during normal operation. Failure to do so can result in damage to the knife drive box.

  • Page 67: Checking And Adjusting Knife Drive Belt Tension

    PERFORMING PREDELIVERY CHECKS 5.4 Checking and Adjusting Knife Drive Belt Tension Correct knife drive belt tension is necessary for the knife sections to stroke properly. Proceed to the section that applies to the header’s knife drive configuration: • 5.4.1 Checking and Tensioning Single and Untimed Double-Knife Drive Belts, page 57 •...

  • Page 68: Checking And Tensioning Timed Double-Knife Drive Belts

    PERFORMING PREDELIVERY CHECKS 6. Ensure clearance between belt (A) and belt guide (B) is 1 mm (1/16 in.). 7. Loosen three bolts (C), and adjust the position of guide (B) as required. 8. Tighten three bolts (C). 9. Close the endshield. 10.
  • Page 69 PERFORMING PREDELIVERY CHECKS 4. If the belt needs to be tensioned, loosen two nuts (A) on knife drive belt idler bracket (B). 5. Position pry bar (C) under the idler bracket, and push the bracket upwards until a force of 27 N (6 lbf) deflects the belt 13 mm (1/2 in.) at the midpoint of the upper span.

  • Page 70: Tensioning Timed Knife Drive V-Belts

    PERFORMING PREDELIVERY CHECKS 5.4.3 Tensioning Timed Knife Drive V-Belts Correct knife drive belt tension is necessary for the knife sections to stroke properly. Double-knife timed headers have a third knife drive belt, which is a v-belt located on the left side of the header. Check the v-belt tension whenever checking the tension on the other two knife drive belts.

  • Page 71: Centering The Reel

    PERFORMING PREDELIVERY CHECKS 5.5 Centering the Reel A centered reel picks up crop evenly and prevents debris from accumulating at the ends of the reel. Refer to the topic for header type: • Double reel: 5.5.1 Centering Double Reel, page 61 •...
  • Page 72 PERFORMING PREDELIVERY CHECKS 3. Loosen bolts (A) on each brace (B) located on both sides of reel center support arm (C). 4. Move the forward end of reel center support arm (C) laterally as required to center both reels. 5. Tighten bolts (A) and torque to 382 Nm (282 lbf∙ft). Figure 5.13: Reel Center Support Arm 215419 Revision A...

  • Page 73: Centering Single Reel

    PERFORMING PREDELIVERY CHECKS 5.5.2 Centering Single Reel A centered reel picks up crop evenly and prevents debris from accumulating at the ends of the reel. Adjust the reel support arms at both ends of the header to center the reel. DANGER To avoid bodily injury or death from unexpected startup of machine, always stop the engine and remove the key before making adjustments to the machine.

  • Page 74: Checking And Adjusting Draper Tension

    PERFORMING PREDELIVERY CHECKS 5.6 Checking and Adjusting Draper Tension The drapers are tensioned at the factory and rarely need adjustment. If adjustment is required, tension the drapers just enough to prevent slipping and to keep the draper from sagging below the cutterbar. Adjust drapers on both sides of the header.
  • Page 75 PERFORMING PREDELIVERY CHECKS 6. Ensure idler roller (A) is between draper guides (B). Figure 5.18: Idler Roller IMPORTANT: Do NOT adjust nut (C). This nut is used for draper alignment only. 7. To loosen draper tension: • Turn adjuster bolt (A) counterclockwise. White indicator bar (B) will move outboard in the direction of arrow (D) to indicate that the draper is loosening.

  • Page 76: Checking And Adjusting Draper Seal

    PERFORMING PREDELIVERY CHECKS 5.7 Checking and Adjusting Draper Seal Maintain the deck height such that the draper runs just below the cutterbar. WARNING To avoid injury or death from unexpected start-up of machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
  • Page 77 PERFORMING PREDELIVERY CHECKS 6. Take measurement at deck supports (A) with the header in working position. For instructions, refer to Step 5, page 7. Loosen the draper tension. For instructions, refer to Checking and Adjusting Draper Tension, page Figure 5.21: Draper Deck Supports 8.
  • Page 78 PERFORMING PREDELIVERY CHECKS 12. Locate a gauge that is the same thickness as the draper belt, plus 1 mm (0.04 in.). Slide the thickness gauge along deck (A) under the cutterbar in order to properly set the gap. 13. To create a seal, adjust deck (A) so that clearance (B) between cutterbar (C) and deck is the same thickness as the draper belt plus 1 mm (0.04 in.).

  • Page 79: Checking And Adjusting Skid Shoe Settings

    PERFORMING PREDELIVERY CHECKS 5.8 Checking and Adjusting Skid Shoe Settings In addition to protecting the bottom of the header from damage during operation, skid shoes affect the cutting height. Raise or lower the skid shoes as required to optimize the cutterbar performance. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under machine for any reason.

  • Page 80: Leveling The Header

    PERFORMING PREDELIVERY CHECKS 5.9 Leveling the Header The windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. 1. If the header is not level, check the pressure of the windrower’s tires to ensure they are properly inflated (refer to your windrower operator’s manual).

  • Page 81: Checking And Adjusting The Float

    PERFORMING PREDELIVERY CHECKS 5.10 Checking and Adjusting the Float Check the header float and adjust if necessary. Refer to the appropriate section of the windrower operator’s manual for instructions. 215419 Revision A...

  • Page 82: Reel Clearance To Cutterbar

    PERFORMING PREDELIVERY CHECKS 5.11 Reel Clearance to Cutterbar The minimum clearance between the reel fingers and the cutterbar ensures that the reel fingers do not contact the cutterbar during operation. The clearance is set at the factory, but some adjustment may be necessary before operation. The finger to guard/cutterbar clearances with reels fully lowered are shown in the table below.
  • Page 83 PERFORMING PREDELIVERY CHECKS 3. Set the fore-aft position to the middle position (5) on fore- aft position decal (A). 4. Lower the reel fully. 5. Shut down the engine, and remove the key from the ignition. Figure 5.29: Fore-Aft Position 6.

  • Page 84: Adjusting Reel Clearance

    PERFORMING PREDELIVERY CHECKS 5.11.2 Adjusting Reel Clearance Adjust the reel until there is enough clearance to prevent the reel fingers from contacting the cutterbar during operation. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason.

  • Page 85: Checking And Adjusting Endshields

    PERFORMING PREDELIVERY CHECKS 5.12 Checking and Adjusting Endshields Endshields are subject to expansion or contraction caused by large temperature variations. The position of the top pin and lower latch can be adjusted to compensate for dimensional changes. Checking the endshield: 1.
  • Page 86 PERFORMING PREDELIVERY CHECKS 3. Pull endshield at handle depression (A). Endshield is retained by hinge tab (B) and will open in direction (C). Figure 5.36: Left Endshield 4. Pull the endshield free of hinge tab (A) if additional clearance is required, and swing shield towards the rear of the header.
  • Page 87 PERFORMING PREDELIVERY CHECKS 2. Loosen three bolts (A) on latch assembly (B). 3. Adjust latch assembly (B) to achieve the desired gap between the front end of the shield and the header frame. Refer to Table 5.3, page 75 for the recommended endshield gap at various temperatures.
  • Page 88 PERFORMING PREDELIVERY CHECKS 3. Swing endshield in direction (A) into closed position. Engage lock with a firm push. 4. Verify that endshield is locked. Figure 5.42: Left Endshield 215419 Revision A...

  • Page 89: Lubricating Header

    PERFORMING PREDELIVERY CHECKS 5.13 Lubricating Header Two types of lubricant are used on the header. Table 5.4 Recommended Lubricant Specification Description High temperature, extreme pressure (EP2) performance with As required unless SAE multipurpose 1% max molybdenum disulphide (NLGI Grade 2) lithium base otherwise specified High temperature, extreme pressure (EP) performance with SAE multipurpose...

  • Page 90: Lubrication Points

    PERFORMING PREDELIVERY CHECKS 5.13.2 Lubrication Points Some components require additional lubrication instructions. Knifehead IMPORTANT: Overgreasing can cause the knife to bend and make contact with the guards closest to the knifehead. Check for signs of excessive heating on first few guards after greasing. If required, relieve some pressure by removing the grease fitting.

  • Page 91: Checking Manuals

    1. Open the left endshield. Remove the cable tie on manual case (A). 2. Confirm that the case contains the following manuals: • D1 Series Draper Header for Self-Propelled Windrowers Operator’s Manual • D1 Series Draper Header for Self-Propelled Windrowers Quick Card •...

  • Page 93: Chapter 6: Running Up The Header

    Chapter 6: Running up the Header Operate the header and check for any problems. To run up the header, follow these steps: DANGER To avoid bodily injury or death from unexpected startup of machine, always stop the engine and remove the key before making adjustments to the machine.
  • Page 94 RUNNING UP THE HEADER 2. Check guards for signs of heating during run-up due to insufficient clearance between guard and knife. 3. If heating is evident, check gap between knifehead (A) and pitman arm (B). A business card should slide easily through the gap.

  • Page 95: Chapter 7: Reference

    Chapter 7: Reference 7.1 Torque Specifications The following tables provide correct torque values for various bolts, cap screws, and hydraulic fittings. • Tighten all bolts to torque values specified in charts (unless otherwise noted throughout this manual). • Replace hardware with same strength and grade of bolt. •...
  • Page 96 REFERENCE Table 7.2 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (lbf·ft) (*lbf·in) Torque (Nm) Nominal Size (A) Max. Max. Min. Min. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 18.8 20.8 *167 *185 Figure 7.2: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...

  • Page 97: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE Table 7.4 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (lbf·ft) (*lbf·in) Torque (Nm) Nominal Size (A) Max. Max. Min. Min. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 10.7 11.8 *105 8-1.25 Figure 7.4: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...

  • Page 98: O-Ring Boss Hydraulic Fittings - Adjustable

    REFERENCE 7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off lock nut (C) as far as possible. Ensure that washer (D) is loose and is pushed toward lock nut (C) as far as possible.
  • Page 99 REFERENCE Table 7.6 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable (continued) Torque Value SAE Dash Size Thread Size (in.) lbf·ft (*lbf·in) 7/16–20 19–21 14–15 1/2–20 21–33 15–24 9/16–18 26–29 19–21 3/4–16 46–50 34–37 7/8–14 75–82 55–60 1 1/16–12 120–132 88–97 1 3/8–12 153–168 113–124...

  • Page 100: O-Ring Boss Hydraulic Fittings - Non-Adjustable

    REFERENCE 7.1.4 O-Ring Boss Hydraulic Fittings – Non-Adjustable 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Check that O-ring (A) is NOT on threads and adjust if necessary. 3. Apply hydraulic system oil to O-ring. 4.

  • Page 101: O-Ring Face Seal Hydraulic Fittings

    REFERENCE 7.1.5 O-Ring Face Seal Hydraulic Fittings 1. Check components to ensure that sealing surfaces and fitting threads are free of burrs, nicks, scratches, or any foreign material. Figure 7.9: Hydraulic Fitting 2. Apply hydraulic system oil to O-ring (B). 3.

  • Page 102: Tapered Pipe Thread Fittings

    REFERENCE Table 7.8 O-Ring Face Seal (ORFS) Hydraulic Fittings (continued) Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) lbf·ft – – Note 150–165 111–122 1 7/16 205–226 151–167 1 11/16 1 1/4 1–2 315–347 232–256 1 1/2 510–561 376–414 2 1/2...
  • Page 103 REFERENCE Table 7.9 Hydraulic Fitting Pipe Thread (continued) Tapered Pipe Thread Size Recommended TFFT Recommended FFFT 1.5–2.5 9–15 1 1/2–11 1/2 1.5–2.5 9–15 2–11 1/2 215419 Revision A...

  • Page 104: Lifting Equipment Requirements

    REFERENCE 7.2 Lifting Equipment Requirements The following topic describes the minimum equipment requirements for lifting headers. DANGER To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area. WARNING Equipment used for loading and unloading must meet or exceed the minimum specified requirements. Using inadequate equipment may result in vehicle tipping, machine damage, or chain breakage.

  • Page 105: Conversion Chart

    REFERENCE 7.3 Conversion Chart Table 7.12 Conversion Chart Quantity Factor SI Units (Metric) US Customary Units (Standard) Unit Name Abbreviation Unit Name Abbreviation acre acres Area hectare x 2.4710 = Flow liters per minute L/min x 0.2642 = US gallons per minute Force Newton x 0.2248 =...

  • Page 106: Definitions

    A hydraulic cylinder link between the header and machine used to change header angle CGVW Combined gross vehicle weight D1 SP Series Header MacDon D115, D120, D125, D130, D135, and D140 rigid draper headers for windrowers Double-draper drive Double knife Double-knife drive...
  • Page 107 REFERENCE Term Definition Mechanical deck shift Not applicable North American header Header configuration typical in North America National Pipe Thread: A style of fitting used for low-pressure port openings. Threads on NPT fittings are uniquely tapered for an interference fit An internally threaded fastener that is designed to be paired with a bolt O-ring boss: A style of fitting commonly used in port openings on manifolds, pumps, and motors...
  • Page 108 REFERENCE Term Definition A thin cylinder with a hole or slot located in the center that is to be used as a spacer, load Washer distribution element, or locking mechanism Windrower Power unit for a header 215419 Revision A...

  • Page 109: Predelivery Checklist

    CAUTION Carefully follow the instructions given. Be alert for safety related messages that bring your attention to hazards and unsafe practices. Header Serial Number: Predelivery Checklist for D1 Series Draper Headers – North America ü ü Item Reference Check for shipping damage or missing parts. Be sure all —...
  • Page 110 REFERENCE ü ü Item Reference — Check if lights are functional. — Check if reel lift cylinders extend fully. — Check if reel moves fully fore and aft. 6.1 Performing Post Run-Up Adjustments, page 83 Post run-up check. Stop engine. 5.4 Checking and Adjusting Knife Drive Belt Tension, Check belt drives for heated bearings.
  • Page 112 MacDon Industries Ltd. MacDon Brasil Agribusiness Ltda. 680 Moray Street Rua Grã Nicco, 113, sala 404, B. 04 Winnipeg, Manitoba Mossunguê, Curitiba, Paraná Canada R3J 3S3 CEP 81200-200 Brasil t. (204) 885-5590 f. (204) 832-7749 t. +55 (41) 2101-1713 f. +55 (41) 2101-1699 MacDon, Inc.

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