Page 1 Draper Header for Self-Propelled Windrowers IMPORTANT: PAGE 35 HAS BEEN UPDATED SINCE THIS MANUAL WAS PUBLISHED. Operator’s Manual 169594 Rev. C Original Instruction The harvesting specialists worldwide.
Page 2 D65 Draper Header for Windrowers Published: September, 2013...
Page 3 Declaration of Conformity 169594 Rev. C...
Page 4 D65 Draper Headers will cut and lay crop into uniform, ﬂuffy windrows. The D65 Draper Header is specially designed as a “straight cut” header and is equipped to work well in all straight cut conditions, whether cutting on or above the ground.
Page 5 Model and Serial Number Record the model number, serial number, and model year of the header and Slow Speed Transport/Stabilizer Wheel option (if installed) on the lines below. NOTE: Right Hand (RH) and Left Hand (LH) designations are determined from the Operator’s position, facing forward.
Page 7: Table Of Contents
40 Foot .......................... 18 Interpreting Safety Signs ........................ 19 Reference ............................27 Deﬁnitions ............................. 27 Component Identiﬁcation........................ 28 2.2.1 D65 Windrower Header ......................28 Speciﬁcations ............................. 29 Operation ............................33 Owner/Operator Responsibilities..................... 33 Operational Safety ......................... 34 4.2.1 Header Safety Props ......................34 4.2.2...
Page 8 TABLE OF CONTENTS 4.7.2 Header Float .......................... 56 4.7.3 Header Angle......................... 56 Angle Adjustment......................57 4.7.4 Reel Speed..........................57 Optional Reel Drive Sprockets ..................58 4.7.5 Ground Speed ........................58 4.7.6 Draper Speed ........................59 4.7.7 Knife Speed ........................... 59 4.7.8 Reel Height..........................
Page 9 TABLE OF CONTENTS 4.15.4 Converting from Field to Transport Position................97 Moving Left (Front) Wheels into Transport Position ............97 Moving Right (Rear) Wheels into Transport Position............100 4.16 Storage ............................103 Header Attachment/Detachment ......................105 Attaching Header to Windrower .....................105 Detaching Header from Windrower ....................108 Maintenance and Servicing ........................
Page 10 TABLE OF CONTENTS Removing Knife Drive Box....................169 Removing Knife Drive Box Pulley..................175 Installing Knife Drive Box Pulley..................176 Installing Knife Drive Box....................176 Changing Oil in Knife Drive Box ..................179 6.6.10 Knifehead Shield ........................179 Installing Knifehead Shield .....................180 Header Drapers ..........................181 6.7.1 Removing Side Draper ......................181 6.7.2 Installing Side Draper ......................182...
Page 11 TABLE OF CONTENTS Torquing Transport System Wheel Bolts ................235 Axle Bolts........................236 Tire Inﬂation ........................238 Troubleshooting ..........................239 Crop Loss at Cutterbar ........................239 Cutting Action and Knife Components ....................241 Reel Delivery..........................244 Header and Drapers ........................246 Cutting Edible Beans ........................248 Windrow Formation........................252 Options and Attachments ........................253 Options and Attachments ......................253 8.1.1 Cutterbar Plastic Wear Strips ....................253...
Page 13: Safety
1 Safety 1.1 Safety Alert Symbols This safety alert symbol indicates important safety messages in this manual and on safety signs on the header. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read follow safety message accompanying this symbol.
Page 14: Signal Words
SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The appropriate signal word for each situation has been 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.
Page 15: General Safety
SAFETY 1.3 General Safety CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself • When assembling, operating and servicing machinery, wear all the protective clothing and personal safety devices that COULD be necessary for the job at hand.
Page 16 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 the shaft and can telescope freely. •...
Page 17: Maintenance Safety
SAFETY 1.4 Maintenance Safety To ensure your safety while maintaining the machine • Review the operator’s manual and all safety items before operation and/or maintenance of the machine. • Place all controls in Neutral, stop the engine, set the park brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing.
Page 18: Hydraulic Safety
SAFETY 1.5 Hydraulic Safety • Always place all combine/tractor/windrower hydraulic controls in Neutral before dismounting. • Make sure that all components in the hydraulic system are kept in good condition and clean. • Replace any worn, cut, abraded, ﬂattened, or crimped hoses and steel lines.
Page 19: Tire Safety
SAFETY 1.6 Tire Safety • Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion that may result in serious injury or death. Figure 1.14: Lower all safety stops • Do NOT attempt to mount a tire unless you have the proper training and equipment.
Page 20: Safety Signs
SAFETY 1.7 Safety Signs • Keep safety signs clean and legible at all times. • Replace safety signs that missing become illegible. • If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the current safety sign.
Page 21: Safety Decal Locations
SAFETY 1.8 Safety Decal Locations 1.8.1 Upper Cross Auger (UCA) Figure 1.18: Safety sign locations A - Auger bracket MD #174682 169594 Rev. C...
Page 22: Slow Speed Transport
SAFETY 1.8.2 Slow Speed Transport Figure 1.19: Safety sign locations (Header) A - Front transport leg MD #220799 Figure 1.20: Safety sign locations (Hitch) A - MD #220797 B - MD #220798 169594 Rev. C...
Page 23: Vertical Knife
SAFETY 1.8.3 Vertical Knife Figure 1.21: Safety sign locations A - MD #174684 169594 Rev. C...
Page 24: All Headers
SAFETY 1.8.4 All Headers Figure 1.22: All headers A - MD #184422 1 (A1 - double knife [DK]) B - MD #131393 2 C - MD #174632 D - MD #131391 E - MD #131392 F - MD #174436 (F1 - DK) A*- not used at this location for 15 ft.
Page 25: Foot
SAFETY 15 Foot Figure 1.23 A - MD #184422 B - MD #184372 C - MD #131391 Figure 1.24 169594 Rev. C...
Page 26: Foot
SAFETY 20 Foot Figure 1.25 A - MD #184372 B - MD #166466 C - MD #131391 Figure 1.26 169594 Rev. C...
Page 27: Foot
SAFETY 25 Foot Figure 1.27 A - MD #184372 B - MD #166466 C - MD #131391 Figure 1.28 169594 Rev. C...
Page 28: Foot
SAFETY 30 Foot Figure 1.29 A - MD #184372 B - MD #131391 C - MD #166466 D - MD #131392 (DR only) Figure 1.30 169594 Rev. C...
Page 29: Foot
SAFETY 35 Foot Figure 1.31 A - MD #184372 B - MD #131391 C - MD #166466 D - MD #131392 (DR only) Figure 1.32 169594 Rev. C...
Page 30: Foot
SAFETY 40 Foot Figure 1.33 A - MD #184372 (A*- Split Frame Location) B - MD #131391 C - MD #166466 D - MD #131392 Figure 1.34 169594 Rev. C...
Page 31: Interpreting Safety Signs
SAFETY 1.9 Interpreting Safety Signs In the safety sign explanations below, (a) refers to the top or left position panel, (b) refers to the bottom or right position of the safety decal depending on decal orientation. NOTE: If there are more than two panels in a decal, the lettering will continue downward or to the right, depending on decal orientation.
Page 32 SAFETY 3. MD #131393 a. Reel hazard b. WARNING • To avoid injury from fall of raised reel; fully raise reel, stop engine, remove key, and engage mechanical lock on each reel support arm before working on or under reel. •...
Page 33 SAFETY 4. MD #166466 a. High pressure oil hazard b. WARNING Do not go near leaks. • High pressure oil easily punctures skin causing serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. •...
Page 34 SAFETY 6. MD #174632 a. Reel entanglement hazard b. CAUTION • To avoid injury from entanglement with rotating reel, stand clear of header while machine is running. Figure 1.40: MD #174632 7. MD #174682 a. Auger entanglement hazard b. CAUTION •...
Page 35 SAFETY 9. MD #184372 a. General hazard pertaining to machine operation and servicing b. CAUTION To avoid injury or death from improper or unsafe machine operation: • Read the operator’s manual and follow all safety instructions. If you do not have a manual, obtain one from your Dealer.
Page 36 SAFETY 10. MD #184422 a. Keep shields in place hazard b. WARNING • To avoid injury, stop engine before opening power drive system shield. • Keep all shields in place. Figure 1.44: MD #184422 11. MD #220797 a. Tipping hazard in transport mode b.
Page 37 SAFETY 12. MD #220798 a. Loss of control hazard in transport b. CAUTION • Do not tow the header with a dented or otherwise damaged tow pole (the circle with the red X shows a dent in the pole). • Consult operator’s manual more information.
Page 39: Reference
2 Reference 2.1 Deﬁnitions Term Deﬁnition American Petroleum Institute ASTM American Society of Testing and Materials Cab-forward Windrower operation with the Operator and cab facing in the direction of travel Cab Display Module Center-link A hydraulic cylinder or turnbuckle-type link between the header and the windrower Double draper drive Double knife Double knife drive...
Page 40: Component Identification
REFERENCE 2.2 Component Identiﬁcation 2.2.1 D65 Windrower Header Figure 2.1: D65 Windrower Header Components A - Reel cam B - Pick-up reel tines C - Drapers D - Center reel arm prop handle E - Hydraulic connections F - Transport light...
Page 41: Specifications
3 Speciﬁcations Engineering Speciﬁcations Engineering Product Sheet Only, information provided by Product Design Manager. S: standard / O : optional (factory installed) / O : optional (dealer installed) / -: not available CUTTERBAR Effective cutting width (distance between crop divider points) 15 ft.
Page 42 SPECIFICATIONS Guard: Stub / Forged bottom / Forged top / adjustment plate Guard: Stub / Forged bottom / Sheet Metal top / adjustment bolt Guard: 4 Point / no-choke design (2 long points with tangs / 2 short points without tangs) Knife Sections Over-serrated / solid / bolted / 9 serrations per inch Over-serrated / solid / bolted / 14 serrations per inch...
Page 43 SPECIFICATIONS Reel Drive Hydraulic Reel Speed SP Windrower (auto-adjust from cab using ground speed index) 0–85 rpm export conﬁgured FRAME and STRUCTURE Header Width (Field Position) cut width + 15.1 in. (384 mm) Header Width (Transport Position) - reel fore-aft fully retracted Header Only (SP Conﬁguration without external attachments) (Long Dividers Installed) 104 in.
Page 44 SPECIFICATIONS ATTACHMENTS HC10 Hay Conditioner Roll Length 72 in. (1830 mm) Outside Roll Diameter (O.D.) 9.13 in. (232 mm) 6.61 in. (168 mm) Roll Tube Diameter(O.D.) Roll Speed 847–915 rpm Upper Cross Auger Outside (Flighting) Diameter (O.D.) 12 in. (305 mm) Tube Diameter (O.D.): All sizes except 25 ft.
Page 45: Operation
• It is your responsibility to read and understand this manual completely before operating the header. Contact your MacDon Dealer if an instruction is not clear to you. • Follow all safety messages in the manual and on safety decals on the machine.
Page 46: Operational Safety
OPERATION 4.2 Operational Safety CAUTION Follow these safety precautions: • Follow all safety and operational instructions given in your operator’s manuals. If you do not have a windrower manual, get one from your Dealer and read it thoroughly. • Never attempt to start the engine or operate the machine except from the windrower seat.
Page 47: Reel Safety Props
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. See your windrower operator’s manual for instructions for use and storage of header safety props. 4.2.2 Reel Safety Props WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised...
Page 48: Disengaging Reel Safety Props
OPERATION 3. At the center reel arm on double reel headers, use handle (A) to move lock rod to inboard position (B), engaging pin (C) under prop. 4. Lower reel until safety props contact cylinder mounts on outer reel arms and pin at center arm. Figure 4.4 A - Handle B -Inboard position...
Page 49: Endshields
OPERATION 3. For double reel headers, move lock (A) to outboard position. Figure 4.6 4.2.3 Endshields A hinged, polyethylene endshield is ﬁtted on each end of the header. Opening Endshields To open an endshield, follow these steps. 1. Remove lynch pin (A) and tool (B) from pin (C) at top rear of endshield.
Page 50: Closing Endshields
OPERATION 2. Use tool (B) to unlock latch (A) at lower rear corner of endshield. 3. Lift shield at aft end to clear pin at top rear of endshield. 4. Swing shield out and away from header while maintaining forward pressure to prevent shield from slipping out of tab (C) at front of endsheet.
Page 51: Removing Endshields
OPERATION 3. Push in shield to engage lower latch (A). 4. Use tool (B) to lock lower latch (A). Figure 4.11 5. Replace tool (B) and lynch pin (A) on top pin (C). Figure 4.12 Removing Endshields To remove an endshield, follow these steps: 1.
Page 52: Installing Endshields
OPERATION Installing Endshields To install an endshield, follow these steps. 1. Position endshield on support (A) and align the hole in the endshield with stud (B) on the support. Figure 4.14 2. Secure endshield to the support with acorn nut (A). 3.
Page 53: Adjusting Endshields
OPERATION Adjusting Endshields To adjust an endshield, follow these steps. 1. Check gap ‘X’ between the front end of shield and header frame and compare to chart. Temperature Gap ‘X’ °F (°C) in. (mm) 25 (-4) 1-1/8 (28) 45 (7) 1 (2.4) 65 (18) 13/16 (20)
Page 54: Daily Start-Up Check
OPERATION 4.2.4 Daily Start-Up Check CAUTION • Clear the area of other persons, pets, etc. Keep children away from machinery. Walk around the machine to be sure no one is under, on, or close to it. • Wear close-ﬁtting clothing and protective shoes with slip-resistant soles.
Page 55: Break-In Period
OPERATION 4.3 Break-in Period NOTE: Until you become familiar with the sound and feel of your new header, be extra alert and attentive. After attaching the header to the windrower for the ﬁrst time, follow these steps: 1. Operate the machine with reel drapers and knife running slowly for ﬁve minutes, watching and listening FROM THE OPERATOR’S SEAT for binding or interfering parts.
Page 56: Shutdown Procedure
OPERATION 4.4 Shutdown Procedure CAUTION To shut down and before leaving the windrower seat for any reason, follow these steps: • Park on level ground if possible. • Lower the header fully. • Place all controls in NEUTRAL or PARK. •...
Page 57: Cab Controls
OPERATION 4.5 Cab Controls CAUTION Be sure all bystanders are clear of machine before starting engine or engaging any header drives. See your windrower operator’s manual for identiﬁcation of in-cab controls for: • Header engage control • Header height • Header angle •...
Page 58: Header Setup
4.6 Header Setup 4.6.1 Header Settings This table is a guideline for setting up the D65 Draper Header. Settings other than those suggested can be made to suit various crops and conditions not covered here. Table 4.1 Recommended Header Settings...
Page 59: Reel Settings
OPERATION Reel Skid Upper Crop Stubble Crop Divider Header Knife Reel Reel Stabilizer tine cross Float shoe type height condition rods angle speed speed position wheels pitch position augers Light Medium 5%–10% Variable 6 or 7 Required 4–8 in. Normal 2 or 3 70–100 (102–203...
Page 60 OPERATION Table 4.2 D65 Reel Settings Chart Cam setting number Reel position Reel ﬁnger pattern (ﬁnger speed gain) number 1 (0) 6 or 7 2 (20%) 3 or 4 169594 Rev. C...
Page 61 OPERATION Cam setting number Reel position Reel ﬁnger pattern (ﬁnger speed gain) number 3 (30%) 6 or 7 4 (35%) 2 or 3 NOTE: • Adjust reel forward to get closer to ground when tilting header back. Fingers/tines will dig into ground at extreme reel forward positions, so adjust skid shoes or header angle to compensate.
Page 62: Header Operating Variables
OPERATION 4.7 Header Operating Variables Satisfactory function of the header in all situations requires making proper adjustments to suit various crops and conditions. Correct operation reduces crop loss and allows cutting of more acres. As well, proper adjustments and timely maintenance will increase the length of service you receive from the machine.
Page 63 OPERATION Adjusting Stabilizer/Slow Speed Transport Wheels The proper setting requires balancing the amount of header weight carried by the ﬂoat and the stabilizer/slow speed transport wheels. 1. Raise the header so that the stabilizer wheels are off the ground. Shut down engine and remove the key. 2.
Page 64 OPERATION 13. Lower header to desired cutting height using combine controls and check load indicator. As an example the image shows that the wheels are set to a range between ‘2’ and ‘3’ on load indicator. Figure 4.21: Load indicator between 2 and 3 IMPORTANT Continuous operation with excessive spring compression (i.e., load Indicator reading greater...
Page 65 OPERATION CAUTION Handle may be under tension, especially when the wheels are on the ground. Raise header so that wheels are off the ground before making adjustments. 3. Support wheel weight by lifting slightly with one hand on handle (B). Pull up on handle (A) to release lock. 4.
Page 66: Cutting On The Ground
OPERATION Cutting On the Ground Cutting on the ground is controlled with a combination of skid shoes, header angle, and ﬂoat adjustment and NOT with the header lift cylinders. Having the header ride on the skid shoes allows the ﬂoat linkage to ﬂoat the header over obstacles and follow ground contours, rather than supporting the header with the cylinders.
Page 67 OPERATION 6. Reinsert pin (B), engage in frame, and secure with lynch pin (A). 7. Check that all of the skid shoes are adjusted to the same position. 8. Adjust header angle to desired working position using the machine’s header angle controls. If angle is not critical, set it to mid-position.
Page 68: Header Float
OPERATION 3. Remove lynch pin (A) at each skid shoe (B). 4. Hold shoe and remove pin (C) by disengaging frame and then pulling away from shoe. 5. Raise or lower skid shoe to desired position using holes in support as a guide. 6.
Page 69: Angle Adjustment
Generally, a 9-bat reels can effectively operate at lower reel speed, while minimizing crop loss in shatter prone crops. NOTE: 9-bat reels are available on D65 15, 20, 25 ft. from the factory. If you have a D65 15, 20, 25, 30, or 35 ft.
Page 70: Optional Reel Drive Sprockets
The chart indicates the relationship between ground speed and area cut for the various header sizes. Figure 4.31: D65 ground speed Example shown above: At a ground speed of 6 miles per hour (9.7 km/h) with a 25 ft. header, the area cut in one hour would be approximately 18 acres (7.3 hectares).
Page 71: Draper Speed
OPERATION 4.7.6 Draper Speed The draper speed is controlled with the windrower Cab Display Module (CDM). Refer to your windrower operator’s manual for instructions. Adjust the draper speed to achieve good feeding of crop for a good windrow. Excessive draper speed will reduce draper life.
Page 72: Reel Fore-Aft Position
OPERATION 4.7.9 Reel Fore-Aft Position Reel position has been found to be a critical factor in achieving good results in adverse conditions. The reel position is factory-set for average straight standing crop and can be adjusted forward and backward for different crop conditions.
Page 73 OPERATION Reposition right arm cylinder as follows: NOTE: Reel components are not shown for clarity. 1. Position reel fully aft with support arms horizontal. 2. Stop engine and remove key. 3. Remove four bolts (A) securing cylinder bracket (B) to reel arm.
Page 74 OPERATION Reposition left arm cylinder as follows: NOTE: Reel components are not shown for clarity. 6. Remove pin (A) securing cylinder (B) to bracket/light assembly (C). 7. Remove bolts (D) securing bracket (C) to reel arm and remove bracket/light assembly. 8.
Page 75: Repositioning Fore-Aft Cylinder On Double Reel
OPERATION Repositioning Fore-Aft Cylinder on Double Reel The reel can be moved approximately 9 in (227 mm) further aft by repositioning the cylinders on the reel arms. This may be desirable when straight-combining canola. To reposition the cylinders on a double reel, follow these steps. WARNING Stop windrower engine and remove key before making adjustments to machine.
Page 76 OPERATION Reposition right arm cylinder as follows: NOTE: Reel components are not shown for clarity. 6. Remove four bolts (A) securing cylinder bracket (B) to reel arm. 7. Push reel back until bracket (B) lines up with the aft set of holes (C).
Page 77 OPERATION Reposition left arm cylinder as follows: NOTE: Reel components are not shown for clarity. 9. Remove pin (A) securing cylinder (B) to bracket/light assembly (C). 10. Remove bolts (D) securing bracket (C) to reel arm and remove bracket/light assembly. 11.
Page 78: Reel Tine Pitch
OPERATION 4.7.10 Reel Tine Pitch IMPORTANT The following describes the concept and operational guidelines of the pickup reel. Please read carefully before operating the machine. The pickup reel is designed to pick up ﬂattened and severely lodged crops. It is not always necessary to increase the tine pitch (higher cam setting) to pick up crops that are lodged, but rather, the cam settings are mainly used to determine how the crop will get delivered to the drapers.
Page 79 OPERATION Cam Position 2, Reel Position 3 or 4 is the recommended starting position for most crops and conditions. • This setting gives a ﬁngertip speed approximately 20% faster than the reel speed. • If crops tend to stall on the cutterbar with the reel in a forward position, the cam setting should be increased to push the crop past the rear edge of the cutterbar.
Page 80: Adjusting Reel Cam
OPERATION Cam Position 4, Header Angle At Maximum, and Reel Fully Forward provides the maximum amount of reel reach below the cutterbar to pick up lodged crops and gives a ﬁnger tip speed approximately 35% faster than the reel speed. •...
Page 81: Crop Dividers
OPERATION 4.7.11 Crop Dividers Crop dividers are used to help divide the crop when harvesting. They are removable to allow installation of vertical knives and to decrease transport width. Removing Crop Dividers from Header with Latch Option To remove crop dividers from a header with the latch option, follow these steps. 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 82: Removing Crop Dividers From Header Without Latch Option
OPERATION Removing Crop Dividers from Header without Latch Option To remove crop dividers from a header without the latch option, follow these steps. 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 83 OPERATION 3. At divider storage location, lift divider to disengage lugs (A) at lower end and then lower it slightly to disengage pin (B) from endsheet. Figure 4.52 4. Position crop divider as shown by locating lugs (A) in holes in endsheet. 5.
Page 84: Installing Crop Dividers On Header Without Latch Option
OPERATION 7. Check that divider does NOT move laterally. Adjust bolts (A) as required to tighten divider and remove lateral play when pulling at divider tip. 8. Close endshield. Figure 4.54 Installing Crop Dividers on Header without Latch Option To install crop dividers on a header without the latch option, follow these steps. 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: Crop Divider Rods
OPERATION 5. Lift forward end of divider and install bolt (A) and special stepped washer (B) (step towards divider). Tighten bolt. 6. Check that divider does NOT move laterally. Adjust bolts (C) as required to tighten divider and remove lateral play when pulling at divider tip. 7.
Page 86: Removing Crop Divider Rods
OPERATION Removing Crop Divider Rods To remove divider rods, follow these steps: 1. Loosen bolt (B) and remove rod (A). Figure 4.57 2. Store both rods on the inboard side of the right endsheet. Figure 4.58 Rice Dividers Optional special rice dividers can be installed and used when required.
Page 87: Delivery Opening
OPERATION 4.8 Delivery Opening The width and location of the delivery opening affects the width and conﬁguration of the windrow. The decision to widen or narrow the center delivery opening, or to double windrow, should be based on the following factors: •...
Page 88: Adjusting Delivery Opening On Header With Hydraulic Deck Shift
OPERATION 4.8.2 Adjusting Delivery Opening on Header with Hydraulic Deck Shift The delivery opening can be changed by moving the inboard deck shift stops. 1. Remove bolts (A). 2. Slide stop (B) outboard to decrease the maximum opening size, inboard increase maximum opening.
Page 89: Double Windrowing
4.9 Double Windrowing Figure 4.62: DWA attachment The 25 to 40 ft. D65 Draper Header can lay double windrows by shifting the decks for delivery to either the right or left side of the header when equipped with hydraulic deck shift.
Page 90: Shifting Deck Hydraulically
OPERATION 4.9.1 Shifting Deck Hydraulically The hydraulic deck shift feature allows the Operator to select center, left, or right delivery from the windrower cab. It is only available on the 25, 30, 35, and 40 ft. headers. Refer to your windrower operator’s manual for identiﬁcation and operation of the deck shift control. 4.9.2 Shifting Deck Manually To manually shift the deck, follow these steps: Both decks can be moved manually to deliver the crop from...
Page 91: Windrow Types
OPERATION 4.10 Windrow Types There are three basic criteria by which the quality of a windrow is measured: • Weight Distribution: Heads and stalks distributed evenly across full width of windrow • Good Curing: A loose, open windrow for better drying •...
Page 92 OPERATION Machine Weight Windrow type Description Curing Weatherability setting distribution guidelines 45° Diagonal The stalks are Poor Fair Poor • Low reel lined along one speed edge and heads are along opposite • Less edge, 45° to windrow aggressive perpendicular. This tine pitch windrow can be •...
Page 93: Haying Tips
OPERATION 4.11 Haying Tips The following information may be useful when using the D65 Draper Header in hay crops. 4.11.1 Curing A quick cure will maintain top quality because • 5% of the protein is lost for each day hay lies on the ground.
Page 94: Driving On Windrow
OPERATION Conﬁguration Advantage High and ﬂuffy Movement of air through the windrow is more important to the curing process than is direct sunlight. Consistent formation, not bunchy Permits an even ﬂow of material into the baler, chopper, etc. and allows for more even drying. Even distribution of material across windrow Results in even and consistent bales to minimize handling and stacking problems.
Page 95: Levelling The Header
OPERATION 4.12 Levelling the Header Windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. The ﬂoat springs are NOT used to level the header. If the header is not level, check the tire pressures on the windrower to ensure that the tires are properly inﬂated. For instructions, see the windrower operator’s manual.
Page 96: Unplugging Cutterbar
OPERATION 4.13 Unplugging Cutterbar To remove plugged material from the cutterbar, follow these steps. 1. Stop forward movement of machine and disengage header drives. 2. Raise header to prevent it from ﬁlling with dirt, and engage header drive clutch. CAUTION Lowering rotating reel on a plugged cutterbar will damage the reel components.
Page 97: Upper Cross Auger (Uca)
OPERATION 4.14 Upper Cross Auger (UCA) The UCA helps deliver very bulky crops across the header onto the windrow. Removable beater bars assist in delivering material through the header opening, but if wrapping occurs, the beater bars can be removed. Figure 4.66: Upper cross auger 4.14.1 Removing Beater Bars To remove beater bars, follow these steps.
Page 98 OPERATION 2. Remove bolts (A) securing bars (B) and clamps (C) to auger tubes, and remove bars and clamps. Figure 4.67: Single-reel headers Figure 4.68: Double-reel headers 169594 Rev. C...
Page 99: Installing Beater Bars
OPERATION 4.14.2 Installing Beater Bars To install beater bars, follow these steps. 1. Locate one beater bar (B) with one clamp set (C) on auger tube and loosely secure with carriage bolt (A) and nut. Bolt head MUST face direction of auger rotation.
Page 100: Transporting Header
• Travel speed should be such that complete control and machine stability are maintained at all times. 4.15.2 Towing Headers with the Slow Speed Transport/Stabilizer Wheel option can be towed behind a properly conﬁgured MacDon windrower or an agricultural tractor. Refer to the windrower operator’s manual for instructions.
Page 101: Attaching Header To Towing Vehicle
• Connect header wiring harness 7-pole plug to mating receptacle on towing vehicle. (The 7-pole receptacle is available from your MacDon Dealer parts department). • Ensure lights are functioning properly and clean the slow moving vehicle emblem and other reﬂectors.
Page 102: Converting From Transport To Field Position
OPERATION 4.15.3 Converting from Transport to Field Position To convert the header from Transport to Field position, follow these steps. Removing Tow-Bar Remove tow-bar as follows: 1. Block the tires to prevent header rolling and unhook from towing vehicle. 2. Disconnect wiring connector (A) on tow-bar. 3.
Page 103: Storing Tow-Bar
OPERATION 5. Remove clevis aside later installation. 6. Push latch (B) and lift tow-bar (C) from hook. Release latch. Figure 4.73 A - Clevis pin B - Latch C - Tow-bar Storing Tow-Bar Store tow-bar as follows: 1. On the LH side of the header, place the inner end of the outer half of the tow-bar in cradle (A) on header backtube.
Page 104 OPERATION 4. On the RH side of the 25 ft. and 35–40 ft. header, do the following: a. Place the inner end of the inner half of the tow-bar in cradle (A) on header backtube. b. Secure tube end in support (B) with clevis pin (C). Secure with hairpin.
Page 105: Moving Front (Left) Wheels Into Field Position
OPERATION 6. Attach header to windrower. Refer to windrower operator’s manual for instructions. IMPORTANT Carrying the tow-bar on the header will affect the main header ﬂoat. Refer to Section 4.7.2 Header Float, page 56 for adjustment procedures. 7. Put front and rear transport wheels into Field position. Refer to •...
Page 106 OPERATION 2. Swivel front wheel assembly (A), so wheels are aligned with lower frame. 3. Remove pin (B) and pull wheel assembly towards rear of header. Store pin (B) in hole (C) at top of leg. 4. Pull handle (D) up to release and lower the linkage in the vertical support.
Page 107: Moving Rear (Right) Wheels Into Field Position
OPERATION 7. Lift wheel assembly to desired height and slide linkage (A) into appropriate slot in vertical support. 8. Push down on handle (B) to lock. Figure 4.79 Moving Rear (Right) Wheels into Field Position To move the rear (right) transport wheels into Field position, follow these steps.
Page 108 OPERATION 6. Pull pin (A) on brace (B) on the left hand wheel in front of the cutterbar. Disengage brace from cutterbar and lower the brace against axle (C). 7. Remove pin (D), lower the support (E) onto axle, and reinsert pin into support.
Page 109: Converting From Field To Transport Position
OPERATION 9. Pull right wheel, swivel wheel counterclockwise to position shown and lock with pin (A). 10. Remove hairpin (B) from latch (C). 11. Lift wheel, lift latch (C), and engage lug (D) onto left axle. Ensure latch closes. 12. Secure latch with hairpin (B), with open end of pin facing rear of combine.
Page 110 OPERATION CAUTION Stand clear of wheels and release linkage carefully as wheels will drop once the mechanism is released. 1. Pull handle (A) up to release and raise the linkage fully upward in the vertical support. 2. Raise header fully. Engage header safety props. Figure 4.85 3.
Page 111 OPERATION 6. Remove pin from storage at top of leg. 7. Move and swivel wheels clockwise so that lug (A) is turned towards the end of the header. Figure 4.88 8. Insert pin (A) and turn pin to lock. Figure 4.89 9.
Page 112: Moving Right (Rear) Wheels Into Transport Position
OPERATION 12. Connect plug (A) for lights. Figure 4.91: Field to Transport - LH side Moving Right (Rear) Wheels into Transport Position To move the right-hand transport wheels into Transport position, follow these steps. 1. At wheels at the right end of header, remove hairpin (A) from latch.
Page 113 OPERATION 8. Left wheel is now in Transport position as shown. Figure 4.94 9. Pull pin (A), swivel wheel clockwise as shown and lock with pin (A). Figure 4.95 10. Swivel the right axle (A) to front of header. Figure 4.96 169594 Rev.
Page 114 OPERATION 11. Remove pin (A), raise support (B) to position shown, and reinsert pin (A). IMPORTANT Ensure pin (A) engages the tube on the axle. 12. Swing brace (C) into position as shown and insert brace into slot (D) behind cutterbar. Position brace so that pin (A) engages hole in bracket (F).
Page 115: Storage
Oil knife components to prevent rust. 8. Check for worn or broken components, and repair or order replacements from your MacDon Dealer. Attention to these items right away will save time and effort at beginning of next season.
Page 117: Header Attachment/Detachment
5 Header Attachment/Detachment This chapter includes instructions on setting up, attaching, and detaching the header. 5.1 Attaching Header to Windrower Refer your windrower operator’s manual procedures to mechanically attach the header to the self-propelled windrower. Refer to the following procedures for electrical and hydraulic connections.
Page 118 HEADER ATTACHMENT/DETACHMENT 5. Push hose connectors onto mating receptacle until collar on receptacle snaps into lock position. 6. Remove cover on electrical receptacle (A). 7. Push electrical connector onto receptacle and turn collar on connector to lock it in. 8. Attach cover to mating cover on tractor wiring. Figure 5.3 A - Electrical connector B - Knife drive...
Page 119 HEADER ATTACHMENT/DETACHMENT 11. Open cover on header receptacle (A). 12. Push in lock button (B) and pull handle (C) to half open position. Figure 5.6 13. Remove hose bundle with multi-coupler (C) from windrower, locate onto header receptacle and push handle (B) to engage pins on connector.
Page 120: Detaching Header From Windrower
HEADER ATTACHMENT/DETACHMENT 5.2 Detaching Header from Windrower To detach the header from the windrower, follow these steps: 1. Fully lower the reel. 2. To disconnect the reel hydraulics, push in lock button (A) and pull handle (B) to disengage multi-coupler (C) from header receptacle. 3.
Page 121 HEADER ATTACHMENT/DETACHMENT 7. To disconnect hoses from header, line up slot (A) in collar with pin (B) on connector. 8. Push collar toward pin and pull connector to disengage. 9. Install caps on connectors and hose ends (if equipped). Figure 5.11: Disconnect hoses 10.
Page 123: Maintenance And Servicing
The following instructions are provided to assist Operator in the use of header. Detailed maintenance, service, and parts information are contained in the technical manual and parts catalog which are available from your MacDon Dealer. CAUTION To avoid personal injury, before servicing header or opening drive covers: 1.
Page 124: Recommended Safety Procedures
MAINTENANCE AND SERVICING 6.2 Recommended Safety Procedures Follow these general safety procedures: • Park on a level surface whenever possible. Block wheels securely if combine is parked on an incline. Follow all recommendations in your windrower operator's manual. • Wear close-ﬁtting clothing, and cover long hair. Never wear dangling items such as scarves or bracelets.
Page 125: Maintenance Specifications
MAINTENANCE AND SERVICING 6.3 Maintenance Speciﬁcations 6.3.1 Conversion Chart Inch-Pound units SI units (metric) Quantity Factor Unit name Abbreviation Unit name Abbreviation Area acres acres x 0.4047 = hectares US gallons per Flow x 3.7854 = liters per minute L/min minute Force pounds force...
Page 126: Torque Specifications
MAINTENANCE AND SERVICING Lubricant Speciﬁcation Description Capacities High Temperature Extreme Pressure (EP2) Performance As Required Unless With 1% Max. Molybdenum Grease — Multi-Purpose Otherwise Speciﬁed. Disulphide (NLGI Grade 2) Lithium Base Knife Drive Box 2.3 quarts (2.2 liters) Gear API Service Class GL-5 SAE 85W-140 Lubricant Main Drive Gearbox...
Page 127 MAINTENANCE AND SERVICING Table 6.2 SAE Grade 5 Bolt and Grade 5 Distorted Thread Nut Nominal Torque (ft·lbf) Torque (N·m) size (A) (*in·lbf) Min. Min. Max. Min. Max. 1/4-20 5/16-18 *149 *164 16.7 18.5 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 Table 6.3 SAE Grade 8 Bolt and Grade 8 Distorted Thread Nut...
Page 128: Metric Bolt Specifications
MAINTENANCE AND SERVICING Table 6.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Nominal Torque (ft·lbf) Torque (N·m) size (A) (*in·lbf) Min. Min. Max. Min. Max. 1/4-20 *150 *165 16.8 18.6 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1165 1288...
Page 129 MAINTENANCE AND SERVICING Table 6.6 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) size Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 *167 *185 18.8 20.8 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5 24-3.0 Table 6.7 Metric Class 10.9 Bolts and Class 10 Free...
Page 130 MAINTENANCE AND SERVICING Table 6.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque Torque (N·m) Nominal (ft·lbf)(*in·lbf) size Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 *105 10.7 11.8 8-1.25 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5 24-3.0 169594 Rev.
Page 131: Metric Bolt Specifications Bolting Into Cast Aluminum
MAINTENANCE AND SERVICING Metric Bolt Speciﬁcations Bolting into Cast Aluminum Table 6.9 Metric Bolt Bolting into Cast Aluminum Bolt torque Nominal 10.9 size (cast aluminum) (cast aluminum) ft·lbf N·m ft·lbf N·m Figure 6.6 A - Nominal size Flare Type Hydraulic Fittings 1.
Page 132: O-Ring Boss (Orb) Hydraulic Fittings
MAINTENANCE AND SERVICING Table 6.10 Flare-type Hydraulic Tube Fittings Flats from ﬁnger Nutsize Torque value Tube size Threadsize tight (FFFT) SAE NO. across ﬂats O.D. (in.) (in.) (in.) ft·lbf Flats Turns 3/16 7/16 7/16 9/16 5/16 9/16 11/16 1–1/16 1–1/4 1–3/8 1–3/8 1–5/16...
Page 133: O-Ring Face Seal (Orfs) Hydraulic Fittings
MAINTENANCE AND SERVICING Table 6.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque value Flats from ﬁnger tight (FFFT) Thread Nut size across SAE NO. size (in.) ﬂats (in.) ft·lbf Flats Turns 7/16 9/16 9/16 11/16 1–1/2 1–1/16 1–1/4 1–5/16 1–1/2 1–5/8 1–7/8 1–7/8...
Page 134 MAINTENANCE AND SERVICING 2. Apply hydraulic system oil to the O-ring. 3. Align the tube or hose assembly. Ensure that ﬂat face of the mating ﬂange comes in full contact with O-ring. 4. Thread tube or hose nut until hand-tight. The nut should turn freely until it is bottomed out.
Page 135: Installing A Roller Chain
MAINTENANCE AND SERVICING 6.3.4 Installing a Roller Chain To install a roller chain, follow these steps. CAUTION Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. 1.
Page 136: Installing A Sealed Bearing
MAINTENANCE AND SERVICING 6.3.5 Installing a Sealed Bearing To install a sealed bearing, follow these steps. 1. Clean shaft and coat with rust preventative. 2. Install ﬂangette (A), bearing (B), second ﬂangette (C), and lock collar (D). NOTE: The locking cam is only on one side of the bearing.
Page 137: Maintenance Requirements
MAINTENANCE AND SERVICING 6.4 Maintenance Requirements The following maintenance schedule is a listing of periodic maintenance procedures, organized by service intervals. Regular maintenance is the best insurance against early wear and untimely breakdowns. Following this schedule will increase machine life. For detailed instructions, refer to the speciﬁc headings in this section.
Page 138 MAINTENANCE AND SERVICING Maintenance ▲ - Change  - Check  - Lubricate Action: Record Hydraulic Oil Level at Reservoir Knifehead(s) 50 HOURS  Draper Roller Bearings Driveline and Driveline  Universals Knife Drive Box Oil - First  50 Hours Only 100 HOURS OR ANNUALLY Auger to Pan and Feed ...
Page 139: Break-In Inspections
MAINTENANCE AND SERVICING Maintenance ▲ - Change  - Check  - Lubricate Action: Record ▲ Hydraulic Oil Filter 500 HOURS OR ANNUALLY  Draper Seal  Reel Shaft Bearings Stabilizer/Slow Speed  Transport Wheel Bearings  Gearbox Chain Tension 1000 HOURS OR 3 YEARS ▲...
Page 140: End Of Season Service
Oil knife components to prevent rust. 9. Check for worn or broken components and repair or order replacement from your MacDon Dealer. Attention to these items right away will save time and effort at beginning of next season.
Page 141: Hydraulic Hoses And Lines
MAINTENANCE AND SERVICING 6.4.5 Hydraulic Hoses and Lines Check hydraulic hoses and lines daily for signs of leaks. WARNING • Avoid high-pressure ﬂuids. Escaping ﬂuid penetrate skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure.
Page 142: Service Intervals
MAINTENANCE AND SERVICING Service Intervals Refer to the illustrations on the following pages to identify the various locations that require lubrication and servicing. Illustrations are organized by the frequency of service that is required. Refer to Section 6.3.2 Recommended Fluids and Lubricants, page 113 for speciﬁcations.
Page 143 MAINTENANCE AND SERVICING Every 100 Hours Figure 6.17 A - Knife drive box (check oil level with top of knife drive box horizontal B - Between lower hole and end of dipstick C - Upper Cross Auger (UCA) bearing (1 plc) D - Reel drive chain (1 plc) (DR shown - SR similar) E - Lubricate with WD40®...
Page 144 MAINTENANCE AND SERVICING Every 250 Hours Figure 6.18 A - Upper Cross Auger (UCA) U-joint 19 B - UCA bearing C - Reel U-joint (1 plc) — double reel and bearing 19. U-joint has an extended lubrication cross and bearing kit. Stop greasing when greasing becomes difﬁcult or if u-joint stops taking grease.
Page 145 MAINTENANCE AND SERVICING Every 250 Hours (cont’d) Figure 6.19 A - Frame/wheel pivot (1 plc) both sides B - Left side — wheel pivot (1 plc) C - Right side — wheel axle (2 plcs) 169594 Rev. C...
Page 146 MAINTENANCE AND SERVICING Every 500 Hours Figure 6.20 A - Reel shaft bearing (1 plc) B - Reel center bearing (1 plc) C - Wheel bearings (4 plcs) D - Reel shaft LH bearing (1 plc) 169594 Rev. C...
Page 147: Greasing Procedure
MAINTENANCE AND SERVICING Greasing Procedure Greasing points are marked on the machine by decals showing a grease gun and grease interval in hours of operation. Master grease point location decals as shown below are provided on the header. Use the recommended lubricants speciﬁed in this manual. See Section 6.3.2 Recommended Fluids and Lubricants, page...
Page 148: Electrical
MAINTENANCE AND SERVICING 6.5 Electrical Use electrical tape and wire clips as required to prevent wires from dragging or rubbing. Keep lights clean and replace defective bulbs. 6.5.1 Replacing Light Bulbs To replace a light bulb, follow these steps: 1. Using a Phillips screwdriver, remove screws (A) from ﬁxture and remove plastic lens.
Page 149: Knife And Knife Drive
MAINTENANCE AND SERVICING 6.6 Knife and Knife Drive CAUTION To avoid personal injury, before servicing machine or opening drive covers, follow procedures in Section 6.1 Preparation for Servicing, page 111. WARNING Keep hands clear of the area between guards and knife at all times.
Page 150: Removing Knife
MAINTENANCE AND SERVICING 6.6.2 Removing Knife WARNING Stand to rear of knife during removal to reduce risk of injury from cutting edges. Wear heavy gloves when handling knife. 1. Clean area around the knifehead. Stroke knife to its outer limit and remove bolt (A). 2.
Page 151: Installing Knifehead Bearing
MAINTENANCE AND SERVICING 6. Using a ﬂat-ended tool with approximately the same diameter as pin (A). From the underside of the knifehead, tap the seal (B), bearing (C), plug (D), and O-ring (E) from the knifehead. NOTE: Seal (B) can be replaced without removing the bearing.
Page 152: Installing Knife
MAINTENANCE AND SERVICING 6.6.5 Installing Knife WARNING Stand to rear of knife during installation to reduce risk of injury from cutting edges. Wear heavy gloves when handling knife. To install a knife, follow these steps: 1. Slide knife into place and align knifehead with the output arm.
Page 153: Spare Knife
Adjusting Knife Guards To adjust knife guards, follow these steps. The guard straightening tool (MD #140135) is available from your MacDon Dealer. 1. To adjust guard tips upward, position tool as shown, and pull up. Figure 6.34: Upward adjustment 169594 Rev.
Page 154 3. If material is tough to cut, install stub guards with top guard and adjuster plate. A kit is available from your MacDon Dealer. Refer to Section 8.1.21 Stub Guard Conversion Kit, page 261.
Page 155: Replacing Pointed Guards On A Single-Knife Header
MAINTENANCE AND SERVICING Replacing Pointed Guards on a Single-Knife Header To replace pointed knife guards on a single-knife header, follow these steps: WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. 1.
Page 156: Replacing Pointed Guards On A Double-Knife Header
MAINTENANCE AND SERVICING Replacing Pointed Guards on a Double-Knife Header WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. Refer to Replacing Pointed Guards on a Single-Knife Header, page 143 for typical guard replacement.
Page 157: Replacing Stub Guards On A Single-Knife Header
MAINTENANCE AND SERVICING Replacing Stub Guards on a Single-Knife Header WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. Stub guards, complete with top guides and adjuster plates, are designed to cut tough crops. Only 15, 20, 25, 30, and 35 ft.
Page 158: Replacing Stub Guards On A Double-Knife Header
MAINTENANCE AND SERVICING IMPORTANT The ﬁrst four outboard guards on drive side(s) of the header do NOT have a ledger plate. Ensure that the proper replacement is installed. 4. Check and adjust clearance between top guide and knife. Refer to Knife Hold-Downs, page 147.
Page 159: Knife Hold-Downs
MAINTENANCE AND SERVICING 1. Remove the two nuts (A) and bolts that attach guard (B) and top guide (C) and adjuster bar (D) to cutterbar. 2. Remove guard, poly wear plate (if installed), top guide (C), and adjuster bar (D). 3.
Page 160 MAINTENANCE AND SERVICING Adjusting Hold-Downs on Headers with Pointed Guards To adjust hold-downs on header with pointed guards, follow these steps: 1. To adjust the clearance between hold-down and knife for typical pointed guards, turn the adjuster bolts (A). Using a feeler gauge, clearance from hold-down to knife section (C) should be 0.004–0.024 in.
Page 161: Knife Drive Belt
MAINTENANCE AND SERVICING Adjusting Hold-Downs on Headers with Stub Guards To adjust the clearance between the hold-down and knife for all stub guards, follow these steps: 1. Torque nuts (A) to 35 ft·lbf (46 N·m). 2. Turn the adjuster bolts (B) as required. Using a feeler gauge, clearance from hold-down to knife section should be: •...
Page 162 MAINTENANCE AND SERVICING 4. Once the belt is loose, open the access panel (A) inside the draper opening, just behind cutterbar. 5. Remove the knife drive belt. Figure 6.47 Installing Knife Drive Belt On Single Knife Headers And Double Knife Headers with Non-Timed Drives This procedure explains how to install the knife drive belt on single knife headers and double knife headers with non-timed drives.
Page 163: Double Knife Timed
8. Re-adjust tension of a new belt after a short run-in period (about 5 hours). Figure 6.51 Double Knife Timed This section applies to 35 ft. and smaller double knife model D65 Draper Headers with timed drives. 169594 Rev. C...
Page 164 MAINTENANCE AND SERVICING Removing Knife Drive Belt (Timed) (DK) (Left Hand) 1. Open LH endshield. See Opening Endshields, page 2. Loosen two nuts (A) on belt idler bracket to relieve tension on belt. 3. Loosen nut (B) on idler pulley and slide idler down to loosen belt.
Page 165 MAINTENANCE AND SERVICING Installing Knife Drive Belt (Timed) (DK) (Left Hand) If there are problems with belt alignment. See Aligning Knife Drive Belt Pulley (DK) (Left Hand), page 155. 1. Route knife drive belt around knife drive box pulley and knife drive pulley.
Page 166 MAINTENANCE AND SERVICING 5. Rotate the idler pulley bracket (A) down. Loosen nut (B) and slide the idler pulley up by hand to remove most of the belt slack. Tighten nut (B). Figure 6.57 6. Rotate the bracket up using a long punch in slot (B) behind the pulley to obtain the proper belt tension.
Page 167 MAINTENANCE AND SERVICING 3. Insert a long punch (or equivalent) into hole (B) in idler bracket and pry downward until a force of 6 ft·lbf (27 N·m) deﬂects timing belt 1/2 in. (13 mm) at mid-span. 4. Tighten nuts (A) on idler mounting bracket. Figure 6.60 5.
Page 168 MAINTENANCE AND SERVICING 2. Open endshield. See Opening Endshields, page 3. Release tension on the cogged drive belt by loosening nuts (A) to loosen the idler pulley. Figure 6.63 4. Check the ‘toe in’ the knife drive pulley. Use a straight edge (A) across the face of the double pulley bolted to the knife drive pulley.
Page 169 MAINTENANCE AND SERVICING NOTE: The following is important to belt alignment. Follow instructions carefully. 6. This adjustment will toe in the knife drive pulley. This will allow the pulley to be aligned after the belts are tensioned. Use a straight edge (A) across the face of the double pulley bolted to the knife drive pulley.
Page 170 MAINTENANCE AND SERVICING 9. Tighten bolt (B) to tension double V-belts (C). Tension is checked at mid span of the belts. The belts should deﬂect 0.12 in. (3 mm) with 12 ft·lbf (53 N·m) of force. 10. Tighten bolts (A) to lock in the double V-belt setting. Figure 6.69 11.
Page 171 MAINTENANCE AND SERVICING 14. After the double V-belts and timing belts are tensioned, recheck drive pulley alignment with a straight edge. Dimension at point ‘C’ should be 0.16 in. (4 mm) less than point ‘B’. If not go back to step 6., Aligning Knife Drive Belt Pulley (DK) (Left Hand), page 157 readjust the fore-aft position of the drive pulley.
Page 172 MAINTENANCE AND SERVICING 4. Open the access panel (A) inside the draper opening, just behind cutterbar. This will give you access to the knife drive pulley. Figure 6.75 5. Remove the knife drive belt (A). Figure 6.76 169594 Rev. C...
Page 173 MAINTENANCE AND SERVICING Installing Knife Drive Belt (Timed) (DK) (RH) If there are problems with belt alignment. See Aligning Knife Drive Belt Pulley (DK) (Right Hand), page 163. 1. Route knife drive belt around knife drive box pulley and knife drive pulley. NOTE: When installing new belt, never pry belt over pulley.
Page 174 MAINTENANCE AND SERVICING 4. Rotate the bracket up using a long punch in slot (B) behind the pulley to obtain the proper belt tension. Tension is checked at mid span of the belt and should deﬂect 0.51 in. (13 mm) at 6 ft·lbf (24 N·m). 5.
Page 175 MAINTENANCE AND SERVICING 5. Loosen bolts (B) and adjust guide (A). The measurement should be 0.02–0.04 in. (0.5–1.0 mm). 6. Re-adjust tension of a new belt after a short run-in period (about 5 hours). Figure 6.82 Aligning Knife Drive Belt Pulley (DK) (Right Hand) 1.
Page 176 MAINTENANCE AND SERVICING 4. Check the ‘toe in’ the knife drive pulley. Use a straight edge (A) across the face of the double pulley bolted to the knife drive pulley. Measure from the straight edge to the end panel in two places (B, C). Measurements ‘B’ and ‘C’...
Page 177 MAINTENANCE AND SERVICING 7. If more adjustment is required, adjust bolt (A). Check pulley alignment again. Figure 6.88 8. Tighten nuts (A) to retain the pulley setting. Figure 6.89 9. Rotate the bracket up using a long punch in slot (B) behind the pulley to obtain the proper belt tension.
Page 178 MAINTENANCE AND SERVICING 11. Check idler pulley alignment. Place a 12 in. (300 mm) straight edge on the idler pulley horizontally and vertically (B). Measure from the straight edge to the frame. Pulley should be parallel to the frame in both directions within 0.08 in.
Page 179: Adjusting Double Knife Timing
MAINTENANCE AND SERVICING Adjusting Double Knife Timing Double knife D65 Draper Headers, 40 ft. and smaller, require that knives are properly timed to move in opposite directions. 1. Open both endshields. See Opening Endshields, page 2. Remove the belt on the right hand side. See...
Page 180 MAINTENANCE AND SERVICING 5. Install right-hand belt (A). IMPORTANT To maintain timing, knife drive box driver and driven pulleys must NOT rotate as the belt is tightened. Figure 6.96 6. Rotate the idler pulley bracket (A) down. Loosen nut (B) and slide the idler pulley up by hand to remove most of the belt slack.
Page 181: Knife Drive Box
MAINTENANCE AND SERVICING 6.6.9 Knife Drive Box The knife drive box drives the knife. It is belt driven. The knife drive box converts rotational motion into oscillating motion to drive the knife. CAUTION To avoid personal injury, before servicing machine or opening drive covers, follow procedures in Section 6.1 Preparation for Servicing, page 111.
Page 182 MAINTENANCE AND SERVICING 4. Open the access panel (A) inside the draper opening, just behind cutterbar. 5. Remove the knife drive belt. Figure 6.101 6. Clean area around the knifehead. Stroke knife to its outer limit and remove bolt (A). 7.
Page 183 MAINTENANCE AND SERVICING 11. Remove bolt (A) that clamps the knife drive arm to the knife drive box output shaft. 12. Remove the knife drive arm from the knife drive box output shaft. 13. Remove the four knife drive box mounting bolts (B, D). NOTE: Do NOT remove bolt (C), this is factory set.
Page 184 MAINTENANCE AND SERVICING 4. Open the access panel (A) inside the draper opening, just behind cutterbar. 5. Remove the knife drive belt. Figure 6.105 6. Clean area around the knifehead. Stroke knife to its outer limit and remove bolt (A). 7.
Page 185 MAINTENANCE AND SERVICING 11. Remove bolt (A) that clamps the knife drive arm to the knife drive box output shaft. 12. Remove the knife drive arm from the knife drive box output shaft. 13. Remove the four knife drive box mounting bolts (B, D). NOTE: Do NOT remove bolt (C), this is factory set.
Page 186 MAINTENANCE AND SERVICING 18. Open the access panel (A) inside the draper opening, just behind cutterbar. 19. Remove the knife drive belt. Figure 6.109 20. Clean area around the knifehead. Stroke knife to its outer limit and remove bolt (A). 21.
Page 187: Removing Knife Drive Box Pulley
MAINTENANCE AND SERVICING 25. Remove bolt (A) that clamps the knife drive arm to the knife drive box output shaft. 26. Remove the knife drive arm from the knife drive box output shaft. 27. Remove the four knife drive box mounting bolts (B, D). NOTE: Do NOT remove bolt (C), this is factory set.
Page 188: Installing Knife Drive Box Pulley
MAINTENANCE AND SERVICING Installing Knife Drive Box Pulley To install the knife drive box pulley, follow these steps: 1. Ensure splines and bores in pulley or drive arm are free of paint oil and solvents. ® 2. Apply Loctite #243 adhesive (or equivalent) to spline. Apply in two bands (A) around shaft as shown, with one band at end of spline and one band approximately mid-way.
Page 189 MAINTENANCE AND SERVICING ® 4. Apply Loctite #243 to the output shaft in two bands as shown at (A). 5. Slide output arm (B) onto output shaft. Rotate pulley to ensure drive arm just clears frame on inboard stroke to ensure proper placement on splines.
Page 190 Figure 6.119 11. Align the knife drive box pulley with drive pulley. If adjustment is required, contact your MacDon Dealer. 12. Tighten knife drive box side bolts (A1) ﬁrst, then the bottom bolts (A2). Torque to 200 ft·lbf (271 N·m).
Page 191: Changing Oil In Knife Drive Box
It is recommended that the shield(s) be installed when harvesting severely lodged crop or any crop condition where plugging occurs at the knifehead cutout. The shield(s) and mounting hardware are available from your MacDon Dealer. IMPORTANT Shields should be removed when cutting with the cutterbar on the ground in muddy conditions. Mud may pack into the cavity behind the shield and cause knife drive box failures.
Page 192: Installing Knifehead Shield
MAINTENANCE AND SERVICING Installing Knifehead Shield The knifehead shield is supplied in ﬂattened form and can be bent to suit installation on pointed or stub guard cutterbars and on double-knife headers. Shields are slightly different depending on header size and guard conﬁguration.
Page 193: Header Drapers
MAINTENANCE AND SERVICING 6.7 Header Drapers The draper should be replaced or repaired if it is torn, missing slats, or cracked. 6.7.1 Removing Side Draper To remove a side draper, follow these steps. WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason.
Page 194: Installing Side Draper
MAINTENANCE AND SERVICING 6.7.2 Installing Side Draper To install a header draper, follow these steps: WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. 1. Insert draper into deck at outboard end, under the rollers.
Page 195: Removing Endless Draper
MAINTENANCE AND SERVICING 2. To tighten, turn bolt (A) clockwise. The white indicator bar (B) will move inboard, indicating that draper is tightening. Tighten until bar is about halfway in window. 3. To loosen, turn bolt (A) counterclockwise. The white indicator bar (B) will move outboard, indicating that draper is loosening.
Page 196 MAINTENANCE AND SERVICING 3. Turn bolt (A) counterclockwise to fully loosen draper. White indicator bar (B) will move outboard in direction of arrow to indicate that draper is loosening. Figure 6.127 4. Push draper away from cutterbar (as shown) to expose deck support (A).
Page 197 MAINTENANCE AND SERVICING 7. Insert a pry bar (A) in hole in deck located at approximately the deck mid-point, and lift deck clear of cutterbar. NOTE: Pry bar should be of sufﬁcient length to accommodate width of draper. Figure 6.129 A - Pry bar B - Stand 8.
Page 198: Installing Endless Draper
MAINTENANCE AND SERVICING 6.7.5 Installing Endless Draper To install an endless draper, follow these steps: 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. See your windrower operator’s manual for instructions for use and storage of header safety props.
Page 199: Adjusting Header Draper Tracking
MAINTENANCE AND SERVICING 5. Line-up deck supports (A) with bolts in deck. 6. Move deck towards cutterbar to engage deck supports. 7. Install nuts (B) and tighten. 8. Adjust draper tension. Refer to Section 6.7.3 Adjusting Side Draper Tension, page 182 Figure 6.133 6.7.6 Adjusting Header Draper Tracking Each draper deck has one ﬁxed roller and one spring-loaded roller.
Page 200 MAINTENANCE AND SERVICING 1. Adjust the drive roller ‘X’ (shown in Figure 6.134: Adjustment location, page 187) by loosening nuts (A), jam nut (B) on adjuster rod and turning the adjusting nut (C). Figure 6.135: Adjust LH drive roller ‘X’ A - Nuts B - Jam nut C - Adjusting nut...
Page 201: Adjusting Deck Height
MAINTENANCE AND SERVICING 6.7.7 Adjusting Deck Height To prevent material from entering drapers and cutterbar, maintain deck height so that draper runs just below cutterbar with maximum 1/32 in. (1 mm) gap, or with draper deﬂected down slightly (up to 1/16 in. [1.5 mm]) to create a seal.
Page 202: Draper Roller Maintenance
MAINTENANCE AND SERVICING 5. Tighten deck support hardware (B). 6. Check dimension (A) again it should be set to 5/16–3/8 in. (8–9 mm). 7. Tension draper. See Section 6.7.3 Adjusting Side Draper Tension, page 182. Figure 6.139: Draper removed for clarity Dimension: A - 5/16-3/8 in.
Page 203 MAINTENANCE AND SERVICING 4. Slide idler roller assembly (A) out of the draper deck (B) channels. Figure 6.141 5. Remove the two end bolts (A) that hold the roller to the idler arms. 6. Remove the seal (B). 7. Use a slide hammer to remove bearing (C) from the roller.
Page 204: Side Draper Deck Drive Roller
MAINTENANCE AND SERVICING 3. Tension the draper, locate bolt (A) and follow the directions on the decal for proper draper tensioning. 4. Disengage the reel safety props and header safety props. Lower header to the ground and verify that the draper tracks correctly.
Page 205 MAINTENANCE AND SERVICING 5. Line up the setscrews with the hole (A) in the guard. Remove the two setscrews that hold the motor onto the drive roller. NOTE: The setscrews are a 1/4 turn apart. 6. Remove the four bolts (B) that hold motor to the drive roller arm.
Page 206: Draper Deflectors
Figure 6.150 6.7.9 Draper Deﬂectors D65 single knife headers are equipped with steel deﬂectors that are attached to the inboard side of the endsheets to prevent material from falling through the gap between the endsheet and the draper. In some cases, material hesitates on the deﬂectors and will not ﬂow onto the draper. Replace the existing deﬂector with a narrower one, or rework the existing deﬂector.
Page 207 MAINTENANCE AND SERVICING 3. Remove three carriage bolts (A) securing the aft end of existing deﬂector (B) to frame behind backsheet. Figure 6.151: Remove carriage bolts 4. Drill out seven pop-rivets (A) along endsheet and remove deﬂector. Figure 6.152: Remove deﬂector 5.
Page 208: Reel And Reel Drive
MAINTENANCE AND SERVICING 6.8 Reel and Reel Drive CAUTION To avoid personal injury, before servicing machine or opening drive covers, follow procedures in Section 6.1 Preparation for Servicing, page 111. 6.8.1 Reel Clearance to Cutterbar The ﬁnger to guard/cutterbar clearances with reel fully lowered varies with header width and are as follows: ‘X’...
Page 209 MAINTENANCE AND SERVICING 2. Raise header, engage header safety props, and lower header onto stops or onto blocks (A) as shown. 3. Lower the reel fully. Figure 6.155: Block locations for single reel header Figure 6.156: Block locations for double reel header 4.
Page 210 MAINTENANCE AND SERVICING 7. On SINGLE REEL header, measure clearance in two places (A), at the end of each reel. NOTE: The reel has been adjusted at the factory to provide more clearance at the center of the reel than at the ends (‘frown’) to compensate for reel ﬂexing.
Page 211: Adjusting Reel Clearance
MAINTENANCE AND SERVICING Adjusting Reel Clearance To adjust reel clearance, follow these steps. 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. See your windrower operator’s manual for instructions for use and storage of header safety props.
Page 212: Adjusting Reel Frown
MAINTENANCE AND SERVICING Adjusting Reel Frown To adjust the reel frown, follow these steps: IMPORTANT The frown proﬁle should be measured prior to reel disassembly for servicing so that the proﬁle can be maintained after reassembly. 1. Position the reel over the cutterbar (between ‘4’ and ‘5’...
Page 213: Reel Centering
MAINTENANCE AND SERVICING 6.8.3 Reel Centering The reel(s) should be centered between the endsheets. Centering Double Reels To center the reels, follow these steps: 1. Loosen bolt (A) on each brace (B). 2. Move forward end of reel center support arm (C) laterally as required to center both reels.
Page 214: Reel Drive Chain
MAINTENANCE AND SERVICING 6.8.4 Reel Drive Chain Adjusting Chain Tension To adjust the chain tension on a high torque single and double reel header follow these steps: 1. Lower header and reel, shut down windrower, and remove key from ignition. 2.
Page 215 MAINTENANCE AND SERVICING 4. To adjust tension, loosen six nuts (A). Slide motor (B) and motor mount (C) down towards reel shaft. Figure 6.170 5. When right tension is achieved, tighten nuts (A) to 75 ft·lbf (102 N·m) on motor mount. Figure 6.171 169594 Rev.
Page 216: Removing Chain From Single Reel Drive
MAINTENANCE AND SERVICING 6. Install reel drive cover (A) as follows: a. For SINGLE REEL DRIVE, position reel drive cover (A) to the reel drive and secure with four bolts (B). Figure 6.172: Single reel drive cover b. For DOUBLE REEL DRIVE, position the lower cover (C) ﬁrst (if removed) and secure with three bolts (D).
Page 217: Installing Chain On A Single Reel Drive
MAINTENANCE AND SERVICING 3. Loosen nuts (A). Slide motor (B) and motor mount (C) down towards reel shaft. Figure 6.175 A - Nuts B - Reel drive motor C - Motor mount 4. Remove chain (A). Figure 6.176 Installing Chain on a Single Reel Drive To install a chain on a high torque single reel drive follow these steps: 1.
Page 218: Replacing Chain On Double Reel Drive
MAINTENANCE AND SERVICING 2. Slide motor (B) and motor mount (C) upward until tension on chain is such that hand-force deﬂects the chain 1/8 in. (3 mm) at mid-span. 3. Tighten nuts (A) and recheck tension. Figure 6.178 A - Nuts B - Reel drive motor C - Motor mount 4.
Page 219 MAINTENANCE AND SERVICING Disconnecting the Reel Drive Method 1. Lower header and reel, shut down windrower, and remove key from ignition. 2. Remove six screws (A) and then remove upper reel drive cover (B). Figure 6.180 3. Remove three screws (A) and remove lower cover (B). 4.
Page 220 MAINTENANCE AND SERVICING 6. Remove four bolts (A) attaching reel tube to U-joint (B). Figure 6.183 7. Move right-hand reel sideways to separate the reel tube (A) and U-joint (B). 8. Remove the chain (C). 9. Route new chain (C) over U-joint (B) and locate on sprockets.
Page 221 MAINTENANCE AND SERVICING 14. Remove temporary reel support. Figure 6.186 15. Adjust the chain tension (C). Tension on chain should be such that hand-force deﬂects the chain 1/8 in. (3 mm) at midspan. 16. Install lower cover (B) and secure with three screws (A).
Page 222 7. Locate ends of chain on sprocket. Figure 6.190 8. Install pin connector (A) (not available as a MacDon part) into chain, preferably from sprocket backside. 9. Install connector (B) onto pins.
Page 223: Reel Drive Sprocket
MAINTENANCE AND SERVICING 14. Adjust the chain tension. Tension on chain should be such that hand-force deﬂects the chain 1/8 in. (3 mm) at midspan. 15. Install lower cover (B) and secure with three screws (A). Figure 6.192 16. Install upper reel drive cover (B) and secure with six screws (A).
Page 224 MAINTENANCE AND SERVICING 1. Lower header and reel, shut down windrower, and remove key from ignition. NOTE: For DOUBLE REEL DRIVE, this procedure is written with the reel removed from the header and either sitting on the ground or on stands. 2.
Page 225 MAINTENANCE AND SERVICING 5. Remove the cotter pin (A), slotted nut, and ﬂat washer (B) from the motor shaft. 6. Remove the drive sprocket (C). Ensure not to lose the key in the shaft. IMPORTANT Do NOT use pry bar and/or hammer to remove drive sprocket (C).
Page 226: Reel Drive U-Joint
MAINTENANCE AND SERVICING 10. Install reel drive cover (A) as follows: a. For SINGLE REEL DRIVE, position reel drive cover (A) to the reel drive and secure with four bolts (B). Figure 6.200: Single reel drive cover b. For DOUBLE REEL DRIVE, position the lower cover (C) ﬁrst (if removed) and secure with three bolts (D).
Page 227: Removing U-Joint
MAINTENANCE AND SERVICING Removing U-Joint To remove the U-joint, follow these steps. 1. Lower header and reel, shut down windrower, and remove key from ignition. 2. Remove six screws (A) and then remove upper reel drive cover (B). Figure 6.202: Remove upper reel drive cover 3.
Page 228: Installing U-Joint
MAINTENANCE AND SERVICING 5. Remove four bolts (A) attaching reel tube to U-joint ﬂange (B) and move reel sideways to disengage stub shaft from U-joint. Figure 6.205 6. Remove six bolts (A) attaching U-joint ﬂange (B) to driven sprocket (C). 7.
Page 229 MAINTENANCE AND SERVICING 2. Position right-hand reel tube against reel drive and engage stub shaft into U-joint pilot hole. 3. Rotate reel until holes in end of reel tube and U-joint ﬂange (B) line up. 4. Install four bolts (A) and torque to 70–80 ft·lbf (95–108 N·m).
Page 230 MAINTENANCE AND SERVICING 7. Install upper reel drive cover (B) and secure it with six screws (A). Figure 6.211: Remove upper reel drive cover 169594 Rev. C...
Page 231: Reel Drive Motor
6.8.7 Reel Drive Motor The reel drive motor does not require regular maintenance or servicing. If problems develop with the motor, it should be removed and serviced at your MacDon Dealer. Removing Reel Drive Motor To replace a reel drive motor on a single and double reel header, follow these steps: 1.
Page 232 MAINTENANCE AND SERVICING 3. Loosen the six bolts (A) and slide down the hydraulic motor assembly. 4. Remove the drive chain (B). Figure 6.214 5. Remove the cotter pin (A), slotted nut, and ﬂat washer (B) from the motor shaft. 6.
Page 233: Installing Reel Drive Motor
MAINTENANCE AND SERVICING Installing Reel Drive Motor 1. Line up the hydraulic motor’s four mounting holes (A) with the four holes on the reel drive plate (B) and install the four bolts. Figure 6.217 2. Install the drive sprocket (C), ﬂat washer (B), slotted nut, and cotter pin (A) onto the motor shaft.
Page 234: Reel Tines
MAINTENANCE AND SERVICING 4. Install reel drive cover (A) as follows: a. For SINGLE REEL DRIVE, position reel drive cover (A) to the reel drive and secure with four bolts (B). Figure 6.220: Single reel drive cover b. For DOUBLE REEL DRIVE, position the lower cover (C) ﬁrst (if removed) and secure with three bolts (D).
Page 235: Removing Steel Tines
MAINTENANCE AND SERVICING Removing Steel Tines WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. 1. Lower header and raise reel. Engage reel safety props. 2. Shut down engine and remove key from ignition. 3.
Page 236: Removing Plastic Fingers
MAINTENANCE AND SERVICING Removing Plastic Fingers WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. ® 1. Remove screw (A) with a Torx Plus 27 IP socket wrench.
Page 237: Tine Tube Bushings
MAINTENANCE AND SERVICING IMPORTANT Do NOT apply force to ﬁnger prior to tightening mounting screw. Applying force to ﬁnger without screw tightened will break ﬁnger or shear off locating pins. 3. Install screw (A) and torque to 75–80 in·lbf ® (8.5–9.0 N·m) with a Torx -Plus 27 IP socket wrench.
Page 238 MAINTENANCE AND SERVICING IMPORTANT Ensure tine tube is supported at all times to prevent damage to the tube or other components. 2. Remove reel endshields and endshield support (C) from the tail end of the reel at applicable tine tube location. NOTE: There are no endshields on the center disks.
Page 239 MAINTENANCE AND SERVICING Cam end bushings 6. On the cam end, remove endshields and endshield support (A) at applicable tine tube location on the cam end. Figure 6.231 7. On the tail end, remove reel endshields and endshield support (C) from the tail end of the reel at applicable tine tube location.
Page 240 MAINTENANCE AND SERVICING 10. Release bushing clamps (A) using a small screwdriver to separate the serrations. Pull clamp off tine tube. Figure 6.234 11. Slide tine tube (A) outboard to expose the bushing. Remove the bushing halves (B). If required remove the next tine or plastic ﬁnger, so that the arm can slide off the bushing.
Page 241: Installing Bushings On 5, 6, Or 9 Bat Reels
MAINTENANCE AND SERVICING Installing Bushings on 5, 6, or 9 Bat Reels WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. IMPORTANT Ensure tine tube is supported at all times to prevent damage to the tube or other components.
Page 242 MAINTENANCE AND SERVICING 5. Tighten clamp (A) with modiﬁed channel lock pliers (B) so that ﬁnger pressure will NOT move clamp. NOTE: To modify channel lock pliers – secure in a vice and grind out center of arms to accomadate clamps (as shown in image). IMPORTANT Over-tightening clamp may result in breakage.
Page 243 MAINTENANCE AND SERVICING 8. On the tail and center discs, install the bolts (A) securing arm (B) to disc. 9. On the tail end, install reel endshields and endshield support (C) from the tail end of the reel at applicable tine tube location.
Page 244 MAINTENANCE AND SERVICING 15. Install bushing clamps (A) by spreading clamp (A) and slip over tine tube adjacent to ﬂangeless end of bushing. 16. Position clamp on bushings (B) so that edges of clamp and bushing are ﬂush when clamp ﬁts into groove on bushing and lock tabs are engaged.
Page 245: Reel Endshields
MAINTENANCE AND SERVICING 18. On the tail and center discs, install the bolts (A) securing arm (B) to disc. 19. On the tail end, install reel endshields and endshield support (C) from the tail end of the reel at applicable tine tube location.
Page 246: Replacing Support
MAINTENANCE AND SERVICING 4. Lift end of endshield (A) off support (B). Figure 6.247 5. Lift endshield off supports. Figure 6.248 6. Move endshield (A) away from support (B) and place new endshield (C) onto supports. 7. Re-attach end of endshield (A) to support (B). 8.
Page 247: Transport System (Optional)
MAINTENANCE AND SERVICING 2. Manually rotate reel for access to endshield support (A) to be replaced. 3. Remove bolt (B) from support (A). 4. Remove bolts (C) from support (A) and two adjacent supports. Figure 6.250 5. Move endshields (A) away from tine tube and rotate support (B) towards reel to remove it.
Page 248: Axle Bolts
MAINTENANCE AND SERVICING Check and tighten wheel bolts after the ﬁrst hour of operation and every 100 hours thereafter. Maintain 80–90 ft·lbf (110–120 N·m) torque. Figure 6.252: Bolt tightening sequence Axle Bolts If a Transport System is installed, follow procedure for torquing the axle bolts. 169594 Rev.
Page 249 MAINTENANCE AND SERVICING Check and tighten axle bolts DAILY until torque is maintained as follows: • (A): 180 ft·lbf (244 N·m) • (B): 150 ft·lbf (203 N·m) • (C): 180 ft·lbf (244 N·m) Figure 6.253 169594 Rev. C...
Page 250: Tire Inflation
MAINTENANCE AND SERVICING Tire Inﬂation Check tire pressure daily. Maintain pressures recommended in following table: Size Load range Pressure 65 psi (448 kPa) ST205/75 R15 80 psi (552 kPa) WARNING • Service tires safely. • A tire can explode during inﬂation and cause serious injury or death.
Page 251: Troubleshooting
4.7.10 Reel Tine Pitch, Reel ﬁngers not lifting crop aggressiveness page 66 sufﬁciently Install lifter guards See your MacDon Dealer Reduce reel speed Reel speed too fast 4.7.4 Reel Speed, page 57 Reel too low Raise reel 4.7.8 Reel Height, page 59 Heads shattering or 4.7.5 Ground Speed, page...
Page 252 Adjust reel position/ﬁnger Position, page 60 properly ahead of knife pitch 4.7.10 Reel Tine Pitch, page 66 See your MacDon Dealer, Divider runs down thick 6.6.7 Knife Guards, page crop at ends, preventing Replace 3 or 4 end guards 141,...
Page 253: Cutting Action And Knife Components
6.6.7 Knife Guards, page 141, 8.1.21 Stub Guard Tangled / tough to cut crop. Install stub guards. Conversion Kit, page 261, and see your MacDon Dealer 4.7.9 Reel Fore-Aft Reel too far back. Move reel forward. Position, page 60 Tensioning Single and...
Page 254 Raise cutterbar by lowering Cutting On the Ground, skid shoes. page 54 Mud or dirt build-up on Install cut-out sections. See your MacDon Dealer cutterbar. 4.7.3 Header Angle, page Flatten header angle. Knife is not operating at Check engine speed of Refer to your windrower’s...
Page 255 138, and Tighten or replace parts. pin or drive arm. 6.6.9 Knife Drive Box, page Bent cutterbar. Straighten cutterbar. See your MacDon Dealer 6.6.7 Knife Guards, page Bent or broken guard. Straighten or replace. 6.6.3 Removing Knifehead Worn knifehead pin.
Page 256: Reel Delivery
Raise reel. Wrapping on reel end 4.7.4 Reel Speed, page Reel speed too fast. Reduce reel speed. Crop conditions. Install optional endshields. See your MacDon Dealer Reel not centered in 6.8.3 Reel Centering, Center reel in header. header. page 201 Reel tines not aggressive 4.7.10 Reel Tine Pitch,...
Page 257 TROUBLESHOOTING Symptom Problem Solution Section 4.7.4 Reel Speed, page Reel speed too fast. Reduce reel speed. Move to a more Reel ﬁngers not 4.7.10 Reel Tine Pitch, aggressive ﬁnger pitch page 66 aggressive enough. notch. 4.7.8 Reel Height, page Reel too low. Raise reel.
Page 258: Header And Drapers
Problem Solution Section Header lift insufﬁcient. Low relief pressure. Increase relief pressure. See your MacDon Dealer 4.7.6 Draper Speed, page Speed control set too low. Increase control setting. Increase relief pressure to Relief pressure too low. See your MacDon Dealer recommended setting.
Page 259 TROUBLESHOOTING Symptom Problem Solution Section Material accumulates 6.7.7 Adjusting Deck Deck height improperly inside or under front Adjust deck height. Height, page 189 adjusted. edge of draper. Adjusting Deck Height Material wrapping at Crop conditions do not 4.14.1 Removing Beater upper cross auger Remove beater bars.
Page 260: Cutting Edible Beans
54 Dirt packs on bottom Install plastic wear strips of cutterbar and raises on bottom of cutterbar and See your MacDon Dealer cutterbar off the ground. skid shoes. Ground too wet. Allow soil Dirt packing on bottom of to dry.
Page 261 TROUBLESHOOTING Symptom Problem Solution Section Plastic wear strip for Remove steel cutterbar cutterbar has been wear plates when — installed over top of installing the plastic wear strips for cutterbar. steel wear plates. 4.12 Levelling the Header, Header not level. Level header.
Page 262 TROUBLESHOOTING Symptom Problem Solution Section 4.7.2 Header Float, page Float insufﬁcient. Increase ﬂoat. Consider installing optional stub guards. Cutterbar guards 6.6.7 Knife Guards, page Tip: Experiment with a breaking Excessive amount of 141, and 8.1.21 Stub few guards on a section of rocks in ﬁeld.
Page 263 TROUBLESHOOTING Symptom Problem Solution Section Excessive accumulation 4.7.6 Draper Speed, page of crop on drapers (up to Increase draper speed. Reel carries over height of reel center tube). excessive amounts of plants or wads 4.7.10 Reel Tine Pitch, Finger pitch too retarded. Increase ﬁnger pitch.
Page 264: Windrow Formation
TROUBLESHOOTING 7.6 Windrow Formation Symptom Problem Solution Section 4.7.6 Draper Speed, page Draper speed too slow. Increase draper speed. 4.7.3 Header Angle, page Draper angle too ﬂat. Increase header angle. Heads on ground (ﬂowered out) 4.7.5 Ground Speed, page Ground speed too slow. Increase ground speed.
Page 265: Options And Attachments
8.1 Options and Attachments The following options and attachments are available for use with your header. Most come with installation instructions. See your MacDon Dealer for availability and ordering information. 8.1.1 Cutterbar Plastic Wear Strips Available as an attachment, they are recommended for cutting on the ground where soil adheres to steel.
Page 266: Double Draper Drive (Ddd) Kit
This is ideal for today’s large forage harvesters and can translate into signiﬁcant time and fuel savings for producers who employ this feature. When mounting to D65 double knife headers an HC10 Conditioner is required.
Page 267: Draper Deflector (Wide)
MD #B5407 8.1.8 Draper Header Supports (Boots for M Series) The boots allow you to pick up a D65 Draper Header with an M Series Windrower. Figure 8.6: MD #B5427 23. Not for use with Double Draper Drive (DDD).
Page 268: End Swath Deflector Rods (End Delivery)
OPTIONS AND ATTACHMENTS 8.1.9 End Swath Deﬂector Rods (End Delivery) Available as an attachment, the rods are used for double swathing – end delivery only, but can be kept on for center delivery. Rods prevent crop coming off drapers from getting thrown up to standing crop under wide deﬂector (see Section 8.1.6 Draper Deﬂector (Wide), page...
Page 269: Knifehead Shield
OPTIONS AND ATTACHMENTS 8.1.12 Knifehead Shield The shields attach to the endsheets and reduce the knifehead opening to prevent cut crop, particularly severely lodged crop, from accumulating over the knifehead, which could damage the knife drive box and the endsheet. Order kit according to header size and guard type.
Page 270: Compression Molded Skid Shoes
OPTIONS AND ATTACHMENTS 8.1.15 Compression Molded Skid Shoes Inner skid shoes are recommended for cutting on the ground. Reduces wear on the cutterbar and may enhance the in-ﬁeld performance of the header in some harvesting conditions. Inner skid shoes are standard on D Series draper headers.
Page 271: Pr15 Tine Tube Reel Conversion Kit
OPTIONS AND ATTACHMENTS 8.1.17 PR15 Tine Tube Reel Conversion Kit This kit allows conversion of a 6-bat reel to a 9-bat reel. Bundles by header size • 15 ft. – Steel Fingers MD #B5654 • 20 ft. – Steel Fingers MD #B5655 •...
Page 272: Stabilizer Wheels
OPTIONS AND ATTACHMENTS 8.1.19 Stabilizer Wheels The stabilizer wheels help stabilize the header in ﬁeld conditions that would otherwise cause the header to bounce and result in uneven cutting height. Installation and adjustment instructions are included with the kit. Available as an attachment for use with 30, 35, and 40 ft.
Page 273: Stub Guard Conversion Kit
OPTIONS AND ATTACHMENTS 8.1.21 Stub Guard Conversion Kit Stub guards, complete with top guides and adjuster shoes, are designed to cut tough crops. Installation and adjustment instructions are included in the kit. Order Kit according to header length. • 15 ft. - MD #B5009 •...
Page 274: Vertical Knife Mounts
OPTIONS AND ATTACHMENTS 8.1.24 Vertical Knife Mounts The vertical knife mounts allow installation of vertically oriented knives onto both ends of the header. Installation and adjustment instructions are included with the bundle. Order Bundles • LH - MD #B5757 • RH - MD #B5758 NOTE: If mounting on multiple headers, you will also require the auxiliary vertical knife plumbing kit MD #B5406.
Page 275: Unloading And Assembly
Refer to the header speciﬁc instructions for unloading, assembly, and setup procedures that are included with your shipment. The instruction part numbers are shown in the table below: MacDon instruction Shipping destination Header description part number D65 Draper Header for Self-Propelled North America MD #169603 Windrowers Export (that is, anywhere except D65 Draper Header for Self-Propelled...
Page 277: Index
.............. 59 draper deﬂectors ..........194 adjusting ............68 narrow ............254 center-link replacing............194 deﬁnition ............27 wide .............. 255 component identiﬁcation........28 draper extension kit ........... 255 D65 windrower header........28 conversion chart ..........113 deﬁnition ............27...
Page 278 INDEX adjustment range ..........56 header draper electrical adjusting deck height ........189 maintenance ..........136 adjusting draper tension........182 replacing light bulbs........136 adjusting tracking ........... 187 end of season service ........128 installing endless draper ......... 186 endless draper installing side draper........
Page 279 INDEX installing single and double knife untimed..176 mounting bolts mounting bolts ..........169 knife drive box..........169 removing left-hand and double knife timed..171 removing pulley ..........175 removing right-hand and double knife timed ............173 operating variables ..........50 removing single and double knife untimed..
Page 280 .......... 42 replacing sprockets ........211 decal location installing U-joint..........216 all headers............ 12 removing U-joint ..........215 D65 15 ft............13 single reel D65 20 ft............14 replacing sprockets ........211 D65 25 ft............15 sprockets ..........58, 211 D65 30 ft.
Page 281 INDEX attaching tow-bar..........90 deﬁnition ............27 converting from ﬁeld to transport position ... 97 skid shoe converting from transport to ﬁeld position ... 90 adjusting inner skid shoe ........54 header............. 89 adjusting outer skid shoe ........55 moving front (left) wheels to ﬁeld position... 93 outboard skid shoes with poly ......
Page 282 INDEX safety ..............7 chemical drying agents ........82 wheel bolt torque ..........235 conﬁguration ............ 81 wheels and tires curing .............. 81 tire inﬂation ............ 238 delivery opening ..........75 wheel bolt torque..........235 double ............. 77 windrower driving on............82 haying tips ............
Page 284 10708 N. Pomona Avenue Kansas City, Missouri United States 64153-1924 t. (816) 891-7313 f. (816) 891-7323 MacDon Australia Pty. Ltd. A.C.N. 079 393 721 P.O. Box 243, Suite 3, 143 Main Street Greensborough, Victoria, Australia 3088 t. 03 9432 9982 f.

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