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

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D1 Series
Draper Header for M Series Windrowers
Unloading and Assembly Instructions (North America)
215649 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) 215649 Revision A Original Instruction The Harvesting Specialists.
  • Page 2 © 2021 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 manual contains unloading, assembly, and predelivery information 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 this unloading and assembly procedure.
  • 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. Section Internal Use Summary of Change Only Introduction, page i Technical Added damaged/missing parts statement.

  • Page 5: 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 Header........................7 2.1 Unloading Header from Trailer........................7 2.2 Lowering Header to Field Position ......................9 2.2.1 Lowering Single-Reel Header......................9 2.2.2 Lowering Double-Reel Header ......................
  • Page 6 TABLE OF CONTENTS 5.6.2 Centering Single Reel ........................66 5.7 Checking and Adjusting Draper Tension ....................68 5.8 Checking and Adjusting Draper Seal ......................70 5.9 Checking and Adjusting Skid Shoe Settings ....................75 5.10 Leveling Header..........................76 5.11 Checking and Adjusting Float ........................ 77 5.12 Reel to Cutterbar Clearance .........................

  • Page 7: Chapter 1: Safety

    Chapter 1: Safety Understanding and following safety procedures consistently will help to ensure the safety of machine operators and bystanders. 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.

  • Page 8: 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 9 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. Ensure that the driveline guards can rotate independently of their shaft, and that they can telescope freely.

  • Page 10: 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 11: Safety Signs

    SAFETY 1.4 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. • Keep safety signs clean and legible at all times. •...

  • Page 13: Chapter 2: Unloading Header

    Chapter 2: Unloading Header Unload all header parts before beginning assembly. Carefully follow these procedures in the order in which they are presented. 2.1 Unloading Header from Trailer Ensure that you use a forklift which meets the minimum length and capacity requirements when unloading the header. DANGER To prevent injury to bystanders caused by being struck by machinery, do NOT allow people to stand in the unloading area.
  • Page 14 UNLOADING HEADER 6. Unload the second header. Refer to Steps 2, page 7 5, page 7 for instructions. 7. Check the unloaded headers for damage and missing parts. 215649 Revision A...

  • Page 15: Lowering Header To Field Position

    UNLOADING HEADER 2.2 Lowering Header to Field Position The procedure for lowering the header differs depending on whether the header has a single or double reel. To lower the header, follow the relevant procedure: • Single-reel headers: refer to 2.2.1 Lowering Single-Reel Header, page •...
  • Page 16 UNLOADING HEADER CAUTION Stand clear when lowering the header; the machine may sway from side to side. 3. Back the forklift up SLOWLY while lowering the forks until the header is just above the ground, as shown in the numbered steps in the illustration. Figure 2.3: Lowering the Header 215649 Revision A...
  • Page 17 UNLOADING HEADER 4. Place 150 mm (6 in.) blocks (A) under each end and at the center of the cutterbar, then lower the header onto the blocks. 5. Remove the chain and move the lifting vehicle to the rear of the header. Figure 2.4: Block under Cutterbar 6.

  • Page 18: Lowering Double-Reel Header

    UNLOADING HEADER 7. To lower the header stand: pull pin (A), gently lower stand (B) to the desired height, and then release pin (A) again to lock the stand at that height. NOTE: If the ground is soft, place a block under the stand. 8.
  • Page 19 UNLOADING HEADER CAUTION Stand clear when lowering the header; the machine may sway from side to side. 3. Back the forklift up SLOWLY while lowering the forks until the header is just above the ground, as shown in the numbered steps in the illustration. Figure 2.9: Lowering the Header 215649 Revision A...
  • Page 20 UNLOADING HEADER 4. Place 150 mm (6 in.) blocks (A) under each end of the header, and one block at the center of the cutterbar. Lower the header onto the blocks. 5. Remove the chain and move the forklift to the rear of the header.
  • Page 21 UNLOADING HEADER 7. To lower the header stand: pull pin (A), gently lower stand (B) to the desired height, and then release pin (A) again to lock the stand at that height. NOTE: If the ground is soft, place a block under the stand. 8.

  • Page 22: Removing Shipping Supports

    UNLOADING HEADER 2.3 Removing Shipping Supports Once the header has been lowered, the shipping supports must be removed to prepare the header for assembly. NOTE: Unless directed otherwise, discard all shipping materials and hardware. 1. Cut the straps securing draper header supports (A) to the shipping support.
  • Page 23 UNLOADING HEADER 5. Locate lower support (B). 6. Remove bolts (A). Remove lower support (B). Figure 2.16: Lower Support 7. Remove bolts (A) from the left shipping stand. Remove the shipping stand. 8. Repeat the previous step to remove the right shipping stand.
  • Page 24 UNLOADING HEADER 9. Remove reel anti-rotation brace (A) from between the reel and the endsheet. Figure 2.19: Anti-Rotation Brace 10. On the left side of the header, cut and remove wire (A) securing the endshield to the panel. 11. Repeat the previous step to remove the wire from the endshield on the right side.

  • Page 25: Chapter 3: Assembling Header

    Chapter 3: Assembling Header Once the header has been unloaded and the shipping supports have been removed, the header is ready for assembly. 3.1 Attaching Reel-Lift Cylinders Several shipping supports must be removed before the reel-lift cylinders can be attached to the reel arms. CAUTION Tagged bolts (A) on the reel arms keep the reel from sliding forward.
  • Page 26 ASSEMBLING HEADER NOTE: Some parts have been removed from the illustration for the sake of clarity. 1. Position sling (A) around reel tube (B) close to the outboard end of the reel. Attach the sling to a forklift or an equivalent lifting device.
  • Page 27 ASSEMBLING HEADER 6. Support the reel with a lifting device, and remove the pins from the endsheet and the reel arm. 7. Align the reel-lift cylinder mounting holes with the lug on the endsheet and the hole in the reel arm. 8.
  • Page 28 ASSEMBLING HEADER 10. Double reel headers 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 any shipping wire or banding from the center reel-lift cylinder.
  • Page 29 ASSEMBLING HEADER 14. Lift the reel and remove the pins from endsheet (B) and reel arm (A). 15. Align the reel-lift cylinder mounting holes with the lug on the endsheet and the hole in the reel arm. 16. Secure the cylinder to the endsheet and to the reel arm with pins as follows: •...
  • Page 30 ASSEMBLING HEADER 18. Double reel headers only: Remove 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 19. Remove bolts (A) from left reel arm support (B) at the endsheet.
  • Page 31 ASSEMBLING HEADER 21. Remove brace bolts and tags (A). IMPORTANT: Do NOT use hydraulic pressure to move the fore-aft cylinder to aid the removal of the brace bolts. The cylinder could be damaged. Figure 3.16: Right Reel Arm 1 - Single Reel 2 - Double Reel Figure 3.17: Left Reel Arm 215649...
  • Page 32 ASSEMBLING HEADER 22. Double reel headers only: Remove three bolts (A). Remove shipping channel (B). Figure 3.18: Center Reel Arm Shipping Channel – Double-Reel Only 215649 Revision A...

  • Page 33: Positioning Transport Lights

    ASSEMBLING HEADER 3.2 Positioning Transport Lights Transport lights are located on each outboard reel arm. The header is shipped with the transport lights in an inverted position on the inboard sides of the reel arms. 1. Locate right light assembly (A). 2.
  • Page 34 ASSEMBLING HEADER 8. Position left light assembly (B) perpendicular to the left reel arm as shown and attach it using retained lock nuts (A). NOTE: The light assembly should be able to rotate when hand force is applied, yet maintain its position when no force is being applied.

  • Page 35: Attaching Cam Arms

    ASSEMBLING HEADER 3.3 Attaching Cam Arms The header’s cam arms must be installed before the reel can be operated. NOTE: On nine-bat reel headers, one cam arm assembly will have been removed and secured to the tine tube for shipping purposes.
  • Page 36 ASSEMBLING HEADER 5. Remove bag of hardware (A) from the tine bar. NOTE: The bag of hardware contains the hardware for the cam links and the endshields. Figure 3.26: Hardware Bag attached to Right Reel 6. Rotate tine bar crank (A) and position link (B) so that the attachment holes in the tine bar’s crank are aligned with the hole in the link.

  • Page 37: Installing Crop Dividers

    ASSEMBLING HEADER 3.4 Installing Crop Dividers The crop dividers must be installed before the header can be operated. One crop divider and two divider rods are stored on the right inboard side of the endsheet, while the other crop divider is stored on the left inboard side of the endsheet. 1.
  • Page 38 ASSEMBLING HEADER 7. Lift the forward end of the divider up to the endsheet and install washer (A) and bolt (B). Figure 3.31: Crop Divider Installed 8. Position divider rod (B) on the tip of the crop divider as shown and tighten bolt (A). Figure 3.32: Divider Rod on Crop Divider 9.

  • Page 39: Installing Disc Segments Of Outboard Reel Endshields

    ASSEMBLING HEADER 3.5 Installing Disc Segments of Outboard Reel Endshields Two disc segments of the reel endshields may have been removed from the right reel (tail end) and left reel (cam end) for shipping purposes. They will need to be installed before the header can be operated. 1.

  • Page 40: Installing Options

    ASSEMBLING HEADER 3.6 Installing Options The header you are assembling may have shipped with optional kits. Install those kits now. Retrieve the kits supplied as options with the header, and install them according to the instructions supplied with each kit. 215649 Revision A...

  • Page 41: Chapter 4: Attaching Header To Windrower

    Chapter 4: Attaching Header to Windrower Once the header has been assembled and any optional kits installed, it can be attached to the windrower. Depending on the configuration of the header, there may be further setup procedures to complete. DANGER To prevent bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key before adjusting the machine.
  • Page 42 ATTACHING HEADER TO WINDROWER 3. Position support (B) on lift linkage (A) and reinstall clevis pin (C). NOTE: Clevis pin (C) may be installed from either side of the support. 4. Secure clevis pin (C) with hairpin (D). 5. Repeat Steps 2, page 35 4, page 36 to install the...

  • Page 43: Connecting Center-Link

    ATTACHING HEADER TO WINDROWER 9. Drive the windrower forward slowly so that supports (A) enter header legs (B). Continue to drive forward slowly until the linkages contact support plates (C) in the lower header legs and the header is nudged forward. 10.
  • Page 44 ATTACHING HEADER TO WINDROWER 2. Locate the center-link on the windrower. 3. Loosen nut (A) and rotate barrel (B) to adjust the length of the center-link so that the link lines up with the header bracket. 4. Install pin (C) and secure it with a cotter pin. 5.

  • Page 45: Hydraulic Link Without Self-Alignment Kit

    ATTACHING HEADER TO WINDROWER 13. Remove the pin from storage position (B) in the linkage. Insert the pin into hole (A) to engage the float spring. Secure the pin with a hairpin. 14. Repeat the previous step to install the pin in the other float spring.
  • Page 46 ATTACHING HEADER TO WINDROWER 2. Relocate pin (A) as needed so that hook (B) can be positioned over the header pin (not shown). Figure 4.12: Center-Link WARNING Check to be sure all bystanders have cleared the area. 3. Start the engine. 4.
  • Page 47 ATTACHING HEADER TO WINDROWER 6. 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 to function. If the release is open (up), manually push it down after the hook engages the header attachment pin.

  • Page 48: Hydraulic Link With Self-Alignment Kit

    ATTACHING HEADER TO WINDROWER 15. Remove the pin from storage position (B) in the linkage. Insert the pin into hole (A) to engage the float spring. Secure the pin with a hairpin. 16. Repeat the previous step to install the pin in the other float spring.
  • Page 49 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 windrower’s 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 to function.
  • Page 50 ATTACHING HEADER TO WINDROWER 8. Install pin (A) through the header leg, ensuring that the U-bracket in the header leg is engaged by the pin. 9. Repeat the previous step to install the pin in the other header leg. 10. Raise header stand (B) to its storage position by pulling pin (C) and lifting the stand into its uppermost position.

  • Page 51: Connecting Hydraulics

    Figure 4.24: M Series Hydraulics A - Header-Drive Hydraulics B - Reel-Drive Hydraulics 1. If the windrower is not already properly equipped to operate with a D1 Series header, install the optional drive or lift kits specified in Table 4.1, page 45.
  • Page 52 ATTACHING HEADER TO WINDROWER Connect the windrower’s header-drive hydraulics and its electrical harness to the header as follows: 2. Ensure that all electrical and hydraulic connectors are free of contamination. Clean the connectors as needed. 3. Disengage lever (C) and rotate it counterclockwise to the vertical position.
  • Page 53 ATTACHING HEADER TO WINDROWER 11. Ensure that the hose support is positioned so that top bolt (A) is midway in the slot as shown and lower bolt (B) is in the forward hole as shown. Adjust the position of the bolts as needed.
  • Page 54 ATTACHING HEADER TO WINDROWER 14. Open cover (A) on the header receptacle. 15. Push in lock button (B) and pull handle (C) to the half-open position. Figure 4.30: Header Receptacle 16. Remove multicoupler (A) from the windrower and position it onto the header’s receptacle. 17.

  • Page 55: Adding Tire Ballast

    ATTACHING HEADER TO WINDROWER 4.3 Adding Tire Ballast Adding fluid ballast to the windrower’s caster tires will improve the windrower's stability when it is paired with a large header. With respect to ballast capacity, a tire is considered to be “full” of ballast fluid when 75% of the inner volume of the tire is occupied by ballast fluid, or else when the ballast fluid is level with the wheel’s valve stem when the stem is positioned at the 12 o’clock position and the windrower is on level ground.

  • Page 57: Chapter 5: Performing Predelivery Checks

    Chapter 5: Performing Predelivery Checks After completing the setup process, the machine and its features should be inspected. If any adjustments are necessary, follow the procedures detailed in this chapter. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.

  • Page 58: Checking Wheel Bolt Torque - Transport And Stabilizer Wheels

    PERFORMING PREDELIVERY CHECKS 5.2 Checking Wheel Bolt Torque – Transport and Stabilizer Wheels The wheel bolts securing the transport wheels must be torqued correctly before the header can be safely transported. 1. Measure the torque value of each wheel bolt. A correctly torqued wheel bolt torque will show a reading of 115 Nm (85 lbf·ft).

  • Page 59: Checking And Adjusting Endshields

    PERFORMING PREDELIVERY CHECKS 5.3 Checking and Adjusting Endshields The header’s endshields are made from molded plastic and are therefore subject to expansion or contraction caused by variations in the ambient temperature. The position of the top pin and that of the lower latch can be adjusted to compensate for dimensional changes in the endshield.
  • Page 60 PERFORMING PREDELIVERY CHECKS 5. Pull the endshield at handle depression (A). The endshield is retained by hinge tab (B) and will open in direction (C). Figure 5.4: Left Endshield 6. If additional clearance is required, pull the endshield free of hinge tab (A), and swing the shield toward the rear of the header.
  • Page 61 PERFORMING PREDELIVERY CHECKS 9. Loosen three bolts (A) on latch assembly (B). 10. Adjust latch assembly (B) to achieve the desired gap between the front end of the endshield and the header frame. Refer to Table 5.2, page 53 for the recommended endshield gap at various ambient temperatures.
  • Page 62 PERFORMING PREDELIVERY CHECKS 15. Swing the endshield in direction (A) into the closed position. Engage the lock with a firm push. 16. Verify the dimensions of the other endshield. Figure 5.10: Left Endshield 17. Repeat Steps 1, page 53 16, page 56 to adjust the right endshield.

  • Page 63: Checking Knife Drive Box

    PERFORMING PREDELIVERY CHECKS 5.4 Checking Knife Drive Box Single-knife headers have one knife drive box, while double-knife headers have two knife drive boxes. The knife drive box(es) can be accessed by opening the endshield(s). Each knife drive’s breather and oil level will need to be inspected. 1.

  • Page 64: Checking And Adjusting Knife Drive Belt Tension

    PERFORMING PREDELIVERY CHECKS 5.5 Checking and Adjusting Knife Drive Belt Tension The belt tension of the knife drive(s) must be set correctly in order for the cutterbar’s knife sections to stroke properly. Single-knife headers have one knife-drive belt and double-knife headers have two knife-drive belts. Refer to the relevant procedure: •...
  • Page 65 PERFORMING PREDELIVERY CHECKS 6. If additional clearance is required, pull the endshield free of hinge tab (A) and swing the endshield toward the rear of the header. 7. Engage safety latch (B) on the hinge arm to secure the endshield in the fully open position. Figure 5.16: Left Endshield 8.

  • Page 66: Checking And Tensioning Timed Double-Knife Drive Belts

    PERFORMING PREDELIVERY CHECKS 14. Disengage latch (B) to allow the endshield to move. 15. Insert the front of the endshield behind hinge tab (A) and into the divider cone. Figure 5.19: Left Endshield 16. Swing the endshield into the closed position (direction [A]). Engage the latch by pushing firmly on the endshield in the direction shown.
  • Page 67 PERFORMING PREDELIVERY CHECKS 2. Locate the endshield. 3. From the back of the header, push release lever (A) to unlock the endshield. 4. Pull the endshield open using handle depression (B). Figure 5.21: Left Endshield 5. Pull the endshield at handle depression (A). NOTE: The endshield is retained by hinge tab (B) and will open in direction (C).
  • Page 68 PERFORMING PREDELIVERY CHECKS 8. Check the tension on drive belt (A). A properly tensioned belt should deflect 13 mm (1/2 in.) at the midpoint of the upper span when a force of 27 N (6 lbf) is applied to it. Figure 5.24: Knife Drive –...
  • Page 69 PERFORMING PREDELIVERY CHECKS 14. Ensure that clearance (A) between belt (B) and guide (C) is 0.5–1.5 mm (1/32–1/16 in.). 15. Loosen bolts (D) and adjust the guide if necessary. 16. Tighten bolts (D). Figure 5.27: Belt Guide – Left Side 17.

  • Page 70: Tensioning Timed Knife Drive V-Belts

    PERFORMING PREDELIVERY CHECKS 5.5.3 Tensioning Timed Knife Drive V-Belts Double-knife timed headers have a third knife drive v-belt located on the left side of the header. Check the tension on the v-belt whenever you check the tension on the other two knife drive belts. 1.

  • Page 71: Centering Reel

    PERFORMING PREDELIVERY CHECKS 5.6 Centering Reel A properly centered reel picks up crop evenly and does not accumulate debris at the ends of the reel. Refer to the relevant topic: • Double-reel headers: 5.6.1 Centering Double Reel, page 65 • Single-reel headers: 5.6.2 Centering Single Reel, page 66 5.6.1 Centering Double Reel Centering a double reel requires measuring the current reel-endsheet clearance on each side of the header and adjusting...

  • Page 72: Centering Single Reel

    PERFORMING PREDELIVERY CHECKS 3. Locate braces (B) on reel center support arm (C). 4. Loosen bolts (A). 5. Move the forward end of reel center support arm (C) laterally as required to center both reels. 6. Tighten bolts (A). Torque the bolts to 382 Nm (282 lbf∙ft). Figure 5.32: Reel Center Support Arm 5.6.2 Centering Single Reel Centering a single reel requires measuring the current reel-to-endsheet clearance on each side of the header.
  • Page 73 PERFORMING PREDELIVERY CHECKS 3. Loosen bolt (A) on brace (B) at each end of the reel. 4. Move the forward end of reel support arm (C) laterally as needed to center the reel. 5. Tighten bolt (A). Torque the bolt to 359 Nm (265 lbf∙ft). 6.

  • Page 74: Checking And Adjusting Draper Tension

    PERFORMING PREDELIVERY CHECKS 5.7 Checking and Adjusting Draper Tension The header’s drapers are tensioned at the factory and rarely need adjustment. If adjustment is required, tension the drapers just enough so that the drapers do not slip when in operation, and so that the draper does not sag below the cutterbar.
  • Page 75 PERFORMING PREDELIVERY CHECKS 8. Ensure that idler roller (A) sits between draper guides (B). Figure 5.37: Idler Roller IMPORTANT: Do NOT adjust nut (C). This nut is used for draper alignment only. 9. To reduce the tension on the draper, turn adjuster bolt (A) counterclockwise.

  • Page 76: Checking And Adjusting Draper Seal

    PERFORMING PREDELIVERY CHECKS 5.8 Checking and Adjusting Draper Seal The gap between the draper and cutterbar is also known as the draper seal. It should be inspected before the draper is operated, to prevent potential damage to the draper system. DANGER To prevent injury or death from the unexpected start-up of the 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 5. Use handle (A) to move the lock rod to inboard position (B), which engages pin (C) under the prop. 6. Lower the reel until the safety props contact the outer arm cylinder mounts and the center arm pins. 7.
  • Page 78 PERFORMING PREDELIVERY CHECKS 9. Measure the clearance between the draper and the cutterbar at deck supports (A). For instructions, refer to Step 8, page 10. Reduce the tension on the draper. For instructions, refer to 5.7 Checking and Adjusting Draper Tension, page Figure 5.42: Draper Deck Supports 11.
  • Page 79 PERFORMING PREDELIVERY CHECKS 15. Locate a feeler gauge of the same thickness as the draper belt plus 1 mm (0.04 in.). 16. Slide the feeler gauge along deck (A) under the cutterbar in order to properly set the gap. 17. To create a seal, adjust deck (A) so that clearance (B) between cutterbar (C) and the deck is the same thickness as the draper belt plus 1 mm (0.04 in.).
  • Page 80 PERFORMING PREDELIVERY CHECKS 27. Use handle (B) to move lock rod (A) to the outboard position. 28. Lower the reel fully. 29. Shut down the engine, and remove the key from the ignition. Figure 5.48: Reel Safety Prop – Center Arm 215649 Revision A...

  • Page 81: Checking And Adjusting Skid Shoe Settings

    PERFORMING PREDELIVERY CHECKS 5.9 Checking and Adjusting Skid Shoe Settings Skid shoes protect the bottom of the header from damage during operation, and affect the header’s cutting height. Raise or lower the skid shoes as required to optimize the performance of the cutterbar. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the vehicle’s safety props before going under the machine for any reason.

  • Page 82: Leveling Header

    PERFORMING PREDELIVERY CHECKS 5.10 Leveling Header The windrower linkages are factory-set to provide the proper level for the header. Unless you are unable to level the header through normal means, they should not 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 the windrower operator’s manual for instructions.

  • Page 83: Checking And Adjusting Float

    PERFORMING PREDELIVERY CHECKS 5.11 Checking and Adjusting Float Check the header’s float setting and adjust it if necessary. Refer to the windrower operator’s manual for instructions on adjusting the float. 215649 Revision A...

  • Page 84: Reel To Cutterbar Clearance

    PERFORMING PREDELIVERY CHECKS 5.12 Reel to Cutterbar Clearance Correctly setting the clearance between the reel fingers and the cutterbar ensures that the reel fingers do not contact the cutterbar when the header is operating. The clearance is set at the factory, but some adjustment may be necessary before the header can be operated.
  • Page 85 PERFORMING PREDELIVERY CHECKS 4. Set the fore-aft position to the middle position (5), as shown on fore-aft position decal (A). 5. Lower the reel fully. 6. Shut down the engine, and remove the key from the ignition. Figure 5.52: Fore-Aft Position 7.

  • Page 86: Adjusting Reel Clearance

    PERFORMING PREDELIVERY CHECKS 5.12.2 Adjusting Reel Clearance Adjust the reel until there is enough clearance to prevent the reel fingers from contacting the cutterbar during operation. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason.
  • Page 87 PERFORMING PREDELIVERY CHECKS 7. Single-reel headers: Adjust the outboard reel arm lift cylinders to set the clearance at the outboard ends of the reel as follows: Loosen bolt (A). b. Turn cylinder rod (B) out of the clevis to raise the reel and thereby increase the reel-to-cutterbar clearance, or else turn cylinder rod into the clevis to lower the reel and thereby decrease the reel-to-cutterbar...
  • Page 88 PERFORMING PREDELIVERY CHECKS 13. Raise the reel to its maximum height. 14. Move reel safety props (A) back inside the reel arms. 15. Repeat the previous step on the opposite end of the reel. Figure 5.59: Left Reel Safety Prop 16.

  • Page 89: Checking Grease Points

    PERFORMING PREDELIVERY CHECKS 5.13 Checking Grease Points The grease zerks on the header will need to be checked to ensure that they can accept grease. IMPORTANT: All grease points on the header should have received grease from the factory. Do not add more than one pump of grease from a grease gun before consulting the greasing procedures in the header operator’s manual, as some components have special greasing requirements and can be damaged if the wrong procedure is followed.
  • Page 90 PERFORMING PREDELIVERY CHECKS 7. If additional clearance is required, pull the endshield free of hinge tab (A) and swing the endshield toward the rear of the header. 8. Engage safety latch (B) on the hinge arm to secure the endshield in the fully open position. Figure 5.63: Left Endshield 9.
  • Page 91 PERFORMING PREDELIVERY CHECKS 11. Close both endshields. To close an endshield: 12. Disengage latch (B) to allow the endshield to move. 13. Insert the front of the endshield behind hinge tab (A) and into the divider cone. Figure 5.66: Left Endshield 14.

  • Page 92: Checking Manuals

    PERFORMING PREDELIVERY CHECKS 5.14 Checking Manuals The header’s manual case is located inside the left endshield. 1. Locate the endshield. 2. From the back of the header, push release lever (A) to unlock the endshield. 3. Pull the endshield open using handle depression (B). Figure 5.68: Left Endshield 4.
  • Page 93 PERFORMING PREDELIVERY CHECKS 7. Remove the cable tie on manual case (A). 8. 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 95: Chapter 6: Running Up Header

    Chapter 6: Running up Header The header must be run up before it is delivered to the customer, to ensure that all its features are functional. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key before making adjustments to the machine.
  • Page 96 RUNNING UP HEADER 2. Check the guards for signs of overheating occurring during the initial run-up procedure. NOTE: Overheating can be caused by insufficient clearance between the guard and the knife. 3. Check the gap between knifehead (A) and pitman arm (B). A feeler gauge set to 0.4 mm (0.016 in.) should slide easily through the gap.

  • Page 97: Chapter 7: Reference

    Chapter 7: Reference The reference section provides additional, non-procedural information on topics such as torque specifications, the requirements for lifting equipment, unit measurement conversions, and terminology definitions. Consult this section as needed. 7.1 Torque Specifications The following tables provide torque values for various bolts, cap screws, and hydraulic fittings. Use these values only when no other torque value has been specified in a given procedure.
  • Page 98 REFERENCE Table 7.2 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) 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 10-1.5 12-1.75 Figure 7.2: Bolt Grades 14-2.0 16-2.0 20-2.5...

  • Page 99: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE Table 7.4 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) 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 10-1.5 12-1.75 Figure 7.4: Bolt Grades 14-2.0 16-2.0 20-2.5...

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

    REFERENCE 7.1.3 O-Ring Boss Hydraulic Fittings – Adjustable The standard torque values are provided for adjustable hydraulic fittings. If a procedure specifies a different torque value for the same type and size of fitting found in this topic, use the value specified in the procedure instead. 1.
  • Page 101 REFERENCE Table 7.6 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable (continued) Torque Value Thread Size (in.) SAE Dash Size 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 102: O-Ring Boss Hydraulic Fittings - Non-Adjustable

    REFERENCE 7.1.4 O-Ring Boss Hydraulic Fittings – Non-Adjustable The standard torque values are provided for non-adjustable hydraulic fittings. If a procedure specifies a different torque value for the same type and size of fitting found in this topic, use the value specified in the procedure instead. Torque values are shown in following table below.
  • Page 103 REFERENCE 1. Check the components to ensure that the sealing surfaces and the fitting threads are free of burrs, nicks, scratches, and any foreign material. Figure 7.9: Hydraulic Fitting 2. Apply hydraulic system oil to O-ring (B). 3. Align the tube or hose assembly so that the flat face of sleeve (A) or (C) comes into full contact with O-ring (B).

  • Page 104: Tapered Pipe Thread Fittings

    REFERENCE Table 7.8 O-Ring Face Seal (ORFS) Hydraulic Fittings (continued) Torque Value Thread Size (in.) Tube O.D. (in.) SAE Dash Size lbf·ft 1–2 1 1/2 315–347 232–256 2 1/2 510–561 376–414 7.1.6 Tapered Pipe Thread Fittings The standard torque values are provided for tapered pipe thread fittings. If a procedure specifies a different torque value for the same type and size of fitting found in this topic, use the value specified in the procedure instead.

  • Page 105: Header Specifications For Unloading And Assembly

    REFERENCE 7.2 Header Specifications for Unloading and Assembly Header dimensions and weight specifications are provided so that you can choose the correct equipment to lift or transport the header safely. DANGER To prevent injury to bystanders caused by being struck by machinery, do NOT allow people to stand in the unloading area.

  • Page 106: Conversion Chart

    REFERENCE 7.3 Conversion Chart Both SI units (including metric) and US customary units (sometimes referred to as standard units) of measurement are used in this manual. A list of those units along with their abbreviations and conversion factors is provided here for your reference.

  • Page 107: Definitions

    A hydraulic cylinder connection between the header and the vehicle, which is used to Center-link change the angle of the header relative to the vehicle Combined gross vehicle weight CGVW MacDon D115, D120, D125, D130, D135, and D140 rigid draper headers for windrowers D1 SP Series Header Double-draper drive Double knife Double-knife drive...
  • Page 108 REFERENCE Term Definition O-ring face seal: A style of fitting commonly used for connecting hoses and tubes. This ORFS style of fitting is also commonly called ORS, which stands for O-Ring Seal Revolutions per minute Society of Automotive Engineers A headed and externally threaded fastener that threads into preformed threads or forms Screw its own thread when inserted into a mating part Single-draper drive...

  • Page 109: Predelivery Checklist

    CAUTION Carefully follow the instructions provided herein. 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. Ensure that all —...
  • Page 110 REFERENCE ü ü Item Reference — Ensure that the reel moves fully fore and aft. Post run-up check. Stop the engine. 6.1 Performing Post Run-Up Adjustments, page 89 Inspect the belt drives. Ensure that the bearings are not 5.5 Checking and Adjusting Knife Drive Belt Tension, overheating.
  • Page 112 CUSTOMERS MacDon.com DEALERS Portal.MacDon.com Trademarks of products are the marks of their respective manufacturers and/or distributors. Printed in Canada...

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