Page 1 D50 and D60 Draper Headers for Self-Propelled Windrowers Operator’s Manual 169441 Revision D Original Instruction The Harvesting Specialists.
Page 2 © 2022 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 Your header The D50 and D60 are designed to serve a dual function in your grain, hay, and specialty crop harvesting operation. Teamed with your self-propelled windrower and optional hay conditioner, D50 and D60 Draper Headers will cut and lay crop into uniform fluffy windrows.
Page 4: Hydraulic Safety
Summary of Changes The following list provides an account of major changes from the previous version of this document. Section Summary of Change Internal Use Only Changed “Harvest Header ” to “Draper Header”. The term ® Technical Throughout “Harvest Header ”...
Page 5 Section Summary of Change Internal Use Only 4.12.4 Checking Hydraulic Hoses Moved to Maintenance Requirements section. Technical and Lines, page 244 Publications 5 Options and Attachments, page Organized kits by type and added kit part numbers. Technical Publications ECN 61273 Added note explaining that newer upper cross auger kits use bolt- 5.4.8 Upper Cross Auger, page on flighting instead of beater bars.
Page 6: Model And Serial Number
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. Draper Header Header Model: Serial Number: Year: Serial number plate (A) is located on the left endsheet, near the knife drive motor.
Page 7: Table Of Contents
TABLE OF CONTENTS Introduction ..............................i Summary of Changes............................ ii Model and Serial Number ..........................iv Chapter 1: Safety ............................1 1.1 Safety Alert Symbols ..........................1 1.2 Signal Words ............................2 1.3 General Safety ............................3 1.4 Maintenance Safety ..........................5 1.5 Hydraulic Safety .............................7 1.6 Safety Signs ............................8 1.6.1 Installing Safety Decals........................8 1.7 Safety Decal Locations..........................9...
Page 8 3.13 Delivery Opening ..........................75 3.13.1 Adjusting Size of Delivery Opening on Header with Manual Deck Shift – D60 ........75 3.13.2 Adjusting Size of Delivery Opening on Header with Manual Deck Shift – D50 ........76 3.13.3 Double Windrowing........................76 Shifting Decks Hydraulically ......................
Page 9 4.4.2 Service Intervals ........................129 4.5 Hydraulic Schematics .......................... 135 4.5.1 D50 or D60 Single-Reel Header..................... 135 4.5.2 D50 Single-Knife Header with Manual Deck Shift ................136 4.5.3 D60 Double-Reel Header ......................137 4.5.4 D60 Double-Knife Header with Hydraulic Deck Shift ................. 138 4.6 Electrical System ..........................
Page 10 TABLE OF CONTENTS 4.7.3 Removing Knifehead Bearing......................142 4.7.4 Installing Knifehead Bearing......................143 4.7.5 Installing Knife........................... 143 4.7.6 Spare Knife ..........................144 4.7.7 Knife Guards ..........................145 Adjusting Knife Guards ......................145 Replacing Pointed Guards ......................146 Replacing Stub Guards....................... 148 Checking and Adjusting Knife Hold-Downs ..................
Page 11 TABLE OF CONTENTS Reel Speed Sensor ........................224 4.10.5 Reel Tines and Fingers....................... 225 Removing Steel Tines ........................ 225 Installing Steel Tines........................226 Removing Plastic Fingers......................227 Installing Plastic Fingers ......................228 4.10.6 Tine Tube Bushings........................229 Removing Bushings from Five-Bat Reels..................229 Installing Bushings on Five-Bat Reels ....................
Page 12 TABLE OF CONTENTS Chapter 6: Troubleshooting........................255 6.1 Crop Loss at Cutterbar......................... 255 6.2 Cutting Action and Knife Components ....................257 6.3 Reel Delivery ............................. 259 6.4 Header and Drapers..........................261 6.5 Cutting Edible Beans ........................... 263 6.6 Windrow Formation..........................266 Chapter 7: Reference ..........................
Page 13: Chapter 1: Safety
Chapter 1: Safety Understanding and consistently following these safety procedures will help to ensure the safety of those operating the machine and of bystanders. 1.1 Safety Alert Symbols The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: •...
Page 14: Signal Words
SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words, IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if it is not prevented, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if it is not prevented, could result in death or serious injury.
Page 15: General Safety
SAFETY 1.3 General Safety Operating, servicing, and assembling machinery presents several safety risks. These risks can be reduced or eliminated by following the relevant safety procedures and wearing the appropriate personal protective equipment. CAUTION The following general farm safety precautions should be part of your operating procedure for all types of machinery.
Page 16 SAFETY • Wear close-fitting clothing and cover long hair. NEVER wear dangling items such as hoodies, scarves, or bracelets. • Keep all shields in place. NEVER alter or remove safety equipment. Ensure that the driveline guards can rotate independently of their shaft, and that they can telescope freely.
Page 17: Maintenance Safety
SAFETY 1.4 Maintenance Safety Maintaining your equipment safely requires that you follow the relevant safety procedures and wear the appropriate personal protective equipment for the task. To ensure your safety while maintaining the machine: • Review the operator’s manual and all safety items before operating or performing maintenance on the machine.
Page 18 SAFETY • Wear protective gear when working on the machine. • Wear heavy gloves when working on knife components. Figure 1.10: Personal Protective Equipment 169441 Revision D...
Page 19: Hydraulic Safety
SAFETY 1.5 Hydraulic Safety Because hydraulic fluid is under extreme pressure, hydraulic fluid leaks can be very dangerous. The proper safety procedures must be followed when inspecting for hydraulic fluid leaks and servicing hydraulic equipment. • Always place all hydraulic controls in Neutral before leaving the operator’s seat.
Page 20: Safety Signs
SAFETY 1.6 Safety Signs Safety signs are decals placed on the machine where there is a risk of personal injury, or where the Operator should take extra precautions before operating the controls. They are usually yellow. • Keep safety signs clean and legible at all times. •...
Page 21: Safety Decal Locations
SAFETY 1.7 Safety Decal Locations Safety signs are usually yellow decals, and are placed on the machine where there is a risk of personal injury, or where the operator has to take extra precaution before operating controls. Figure 1.15: Upper Cross Auger – Older Version A - MD #174682 NOTE: The Upper Cross Auger (UCA) kits have changed over the years, and the safety decals installed on the augers have changed...
Page 22 SAFETY Figure 1.16: Upper Cross Auger – Newer Version A - MD #279085 Figure 1.17: Slow Speed Transport A - MD #193147 169441 Revision D...
Page 23 SAFETY Figure 1.18: Slow Speed Transport Tow-Bar A - MD #193113 B - MD #129261 NOTE: Decal MD #129261 has two different appearances in this illustration as the decal has changed over the years. The version shown attached to the tow-bar is an older version; the version at the bottom of the illustration is the current version. Figure 1.19: Vertical Knife A - MD #174684 169441...
Page 24 SAFETY Figure 1.20: Endsheets, Reel Arms, Backsheet – North American Headers 1 - D60 Headers Only 2 - D50 Headers Only A - MD #42122 (Both Reel Arms) B - MD #174633 (Both Reel Arms) C - MD #142909 (Both Reel Arms)
Page 25 SAFETY Figure 1.21: Endsheets, Reel Arms, Backsheet – Export Headers 1 - D60 Headers Only 2 - D50 Headers Only A - MD #174332 (Both Reel Arms) B - MD #174632 (Both Reel Arms) C - MD #184371 (Double Knife 4 Places; Single Knife 3 Places)
Page 26 SAFETY Figure 1.22: Decks A - MD #172147 (North American Headers) B - MD #174434 (Export Headers) 169441 Revision D...
Page 27 SAFETY Figure 1.23: Backtube – 4.5 and 6.1 m (15 and 20 ft.) North American Headers 1 - 4.5 m (15 ft.) North American Header 2 - 6.1 m (20 ft.) North American Header A - MD #109843 B - MD #134070 C - MD 3172147 169441 Revision D...
Page 28 SAFETY Figure 1.24: Backtube – 4.5 and 6.1 m (15 and 20 ft.) Export Headers 1 - 4.5 m (15 ft.) Export Header 2 - 6.1 m (20 ft.) Export Header A - MD #113482 B - MD #174474 C - MD #174434 169441 Revision D...
Page 29 SAFETY Figure 1.25: Backtube – 7.6–12.1 m (25–40 ft.) North American Headers A - MD #42122 (Double-Reel Headers Only) B - MD #172147 (Both Ends) C - MD #134070 D - MD #109843 (Both Ends) 169441 Revision D...
Page 30 SAFETY Figure 1.26: Backtube – 7.6–12.1 m (25–40 ft.) Export Headers 1 - 9.1–12.2 m (30–40 ft.) D50 and D60 Export Headers 2 - 7.6 m (25 ft.) D60 Export Header 3 - 7.6–12.2 m (25–40 ft.) D50 and D60 Export Headers...
Page 31: Chapter 2: Product Overview
Intermediate Speed Control Joint Industrial Council: A standards body that developed standard sizing and shape for original 37° flared fitting MacDon M100, M105, M150, M155, M155E4, M200, and M205 Windrowers M Series Windrowers Not applicable The slot opposite the NEUTRAL position on the operator’s console of M Series SP...
Page 32 PRODUCT OVERVIEW Term Definition A tightening procedure in which a fitting is assembled to a specified tightness (usually Torque angle finger tight) and then the nut is turned farther by a specified number of degrees until it achieves its final position The relationship between the assembly torque applied to a piece of hardware and the Torque-tension axial load it induces in a bolt or screw...
Page 33: Specifications
Reel Reel drive Hydraulic from windrower hydraulic oil supply 0–62 rpm Reel speed 6 or 9 D50: 5 or 6; D60: 9 5 or 6 Quantity of tine tubes 1650 mm (65 in.) Effective reel diameter Finger tip radius range 766–800 mm (30.2–31.5 in.)
Page 34: Component Identification
PRODUCT OVERVIEW 2.3 Component Identification Operating and maintaining the header requires understanding the names of its main components and their locations. Figure 2.1: Header Components A - Reel Cam B - Pick-Up Reel Tines C - Drapers D - Center Reel Arm Prop Handle E - Hydraulic Connections F - Reel Safety Prop G - Transport Light...
Page 35: Chapter 3: 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 36: Operational Safety
OPERATION 3.2 Operational Safety Follow all the safety and operational instructions given in this manual. CAUTION Adhere to the following safety precautions: • Follow all safety and operational instructions provided in your operator’s manuals. If you do not have a windrower manual, get one from your Dealer and read it thoroughly.
Page 37: Header Attachment/Detachment
OPERATION 3.3 Header Attachment/Detachment This chapter includes instructions for attaching a header to, and detaching a header from a windrower. 3.3.1 Attaching Header to Windrower Refer to your windrower operator’s manual for instructions for mechanically attaching the header to the windrower. Refer to the following procedures for electrical and hydraulic connections.
Page 38 OPERATION 5. Push the hose connectors onto the mating receptacle until the collar on the receptacle snaps into locked position. 6. Remove the cover from electrical receptacle (A). 7. Push the electrical connector onto the receptacle and turn the collar on the connector to lock it in. 8.
Page 39: Detaching Header From Windrower
OPERATION 11. Open the cover on header receptacle (A). 12. Push in lock button (B) and pull handle (C) to the half-open position. Figure 3.8: Reel Hydraulics Receptacle 13. Remove the hose bundle with multicoupler (C) from the windrower, place the multicoupler onto the header receptacle, and push handle (B) to engage the connector pins.
Page 40 OPERATION Disconnecting reel hydraulics: 4. Push in lock button (A) and pull handle (B) to disengage multicoupler (C) from the header receptacle. 5. Route the hose bundle back onto the windrower and store multicoupler (C) on the hose support. Figure 3.10: Reel Hydraulics 6.
Page 41 OPERATION 9. To disconnect the hoses from the header, line up slot (A) in collar with pin (B) on the connector. 10. Push the collar toward the pin and pull the connector to disengage. 11. Install caps on the connectors and the hose ends (if equipped).
Page 42: Break-In Period
OPERATION 3.4 Break-in Period Until you become familiar with the sound and feel of your new header, be extra attentive. CAUTION Before investigating an unusual sound or attempting to correct a problem, shut off engine and remove key. After attaching the header to the windrower for the first time, follow these steps: 1.
Page 43: Preseason Check
OPERATION 3.5 Preseason Check Equipment should be inspected and serviced at the beginning of each operating season. Perform the following procedures at the beginning of each operating season: CAUTION • Review this manual to refresh your memory on the safety and operating recommendations. •...
Page 44: Daily Start-Up Check
OPERATION 3.6 Daily Start-Up Check Complete the following tasks each day before starting the machine. 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. •...
Page 45: Shutting Down Header
OPERATION 3.7 Shutting down Header To prevent injuries and equipment damage, always perform the procedures for shutting down the header. DANGER To prevent bodily 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 46: Cab Controls
OPERATION 3.8 Cab Controls The primary header functions are controlled inside the windrower cab. CAUTION Be sure all bystanders are clear of machine before starting engine or engaging any header drives. Refer to your windrower operator’s manual to identify the following in-cab controls: •...
Page 47: Header Safety Props
OPERATION 3.9 Header Safety Props When engaged, the header safety props located on the header lift cylinders prevent the header from falling unexpectedly. For instructions on operating the safety props, refer to your windrower operator’s manual. 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 48: Reel Safety Props
OPERATION 3.10 Reel Safety Props The reel safety props are located on the reel arms. When engaged, the reel safety props prevent the reel from falling unexpectedly. IMPORTANT: To prevent damage to the reel support arms, do NOT transport the header with the reel safety props engaged. 3.10.1 Engaging Reel Safety Props Engage the reel safety props whenever you intend to work on or around a raised reel.
Page 49: Disengaging Reel Safety Props
OPERATION 5. Double-reel header, center arm: 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 pin. NOTE: The center arm only applies to double-reel headers.
Page 50 OPERATION 5. Double-reel headers, center reel arm: Use handle (B) to move lock rod (A) to the outboard position. Figure 3.19: Reel Safety Prop – Center Arm 169441 Revision D...
Page 51: Header Setup
OPERATION 3.11 Header Setup The combination of reel positions and reel cam settings allow the operator to adjust to various crops and conditions. 1. In Table 3.1, page 39, find the row for the type of crop to be cut. 2.
Page 52 OPERATION Table 3.2 Recommended Reel Settings (continued) Cam Setting Reel Setting Reel Position Number (Finger Header Angle Reel Finger Pattern Reference Number Speed Gain) 3 (30%) 6 or 7 Middle 3 (30%) 3 or 4 Variable 4 (35%) 6 or 7 Middle 4 (35%) 2 or 3...
Page 53 OPERATION Table 3.2 Recommended Reel Settings (continued) Cam Setting Reel Setting Reel Position Number (Finger Header Angle Reel Finger Pattern Reference Number Speed Gain) 4 (35%) Maximum 4 (35%) Variable 1 (0%) 6 or 7 Middle 169441 Revision D...
Page 54 OPERATION NOTE: • Adjust the reel forward to position the fingers closer to the ground, while tilting the header back. Fingers/tines will dig into the ground at extreme reel-forward positions, so adjust skid shoes or header angle to compensate. • Adjust the reel aft in thinner crops to prevent plugging on the cutterbar. •...
Page 55: Header Operating Variables
OPERATION 3.12 Header Operating Variables Satisfactory header function requires making adjustments to suit various crops and conditions, reduce crop loss, and increases productivity. The variables listed in Table 3.3, page 43 allow the operator to affect the header performance. You will quickly become adept at adjusting the machine to achieve the results you desire. Most of the adjustments have been preset at the factory, but the settings can be changed to suit crop conditions.
Page 56 OPERATION 4. Remove hairpin (A) from the latch on the right wheel assembly. 5. Disengage latch (B), lift the wheel out of the hook, and place the wheel on the ground as shown. NOTE: This reduces the weight of the assembly and makes adjusting the wheel position easier.
Page 57 OPERATION IMPORTANT: Continuous operation with excessive spring compression (that is, the load indicator reading greater than 4 or compressed length [A] less than 295 mm [11 5/8 in.]) can result in damage to the suspension system. 15. Adjust the header angle to the desired working angle with the machine’s header angle controls.
Page 58: Cutting On Ground
OPERATION 7. Lower the header to the desired cutting height and check load indicator (A). Figure 3.25: Load Indicator IMPORTANT: Continuous operation with excessive spring compression (that is, load indicator reading greater than 4 or a compressed length (A) less than 295 mm [11 5/8 in.]) can result in damage to the suspension system.
Page 59 OPERATION Adjusting Inner Skid Shoes Skid shoes are used to determine stubble height when cutting on the ground. 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. 1.
Page 60: Header Float
OPERATION 6. Hold shoe (B) and remove adjustment pin (C) by disengaging it from the frame and pulling it away from the shoe. 7. Raise or lower skid shoe (B) to achieve the desired position; use the holes in the support as a guide. 8.
Page 61: Controlling Header Angle
OPERATION Header angle also affects the type of windrow that is laid. Refer 3.14 Windrow Types, page 80. Choose an angle that maximizes performance for your crop and field conditions. Figure 3.30: Longest Center-Link Table 3.4 Header Angle Adjustment Range This table summarizes the adjustment range.
Page 62: Optional Reel Drive Sprockets - D60
OPERATION The reel speed is adjustable with the controls in the windrower cab. Refer to your windrower operator’s manual for adjustment details. Optional Reel Drive Sprockets – D60 Optional reel drive sprockets for use in special crop conditions are available as an alternative to the factory-installed sprocket.
Page 63: Draper Speed
OPERATION 3.12.6 Draper Speed Correct draper speed is important for achieving a good flow of cut crop away from the cutterbar. The draper speed is controlled with the windrower cab display module (CDM). Refer to your windrower operator’s manual for instructions. Adjust draper speed to optimize crop feeding for a well formed windrow.
Page 64 OPERATION Figure 3.33: 6.1 and 7.6 m (20 and 25 ft.) Single- and Double-Knife Headers Group A - Forage, alfalfa, and flax Group B - Canola, cereals, and edible beans Example: Cutting Group A crops at 8.0 km/hr (5.0 mph) with a single-knife header, use a knife speed between 710 and 735 rpm (1420 and 1470 spm).
Page 65 OPERATION Figure 3.35: 10.7 m (35 ft.) Single- and Double-Knife Headers Example: Cutting flax at 8.0 km/hr (5.0 mph) with a single-knife header, use a knife speed between 600 and 650 rpm (1200 and 1300 spm). Figure 3.36: 12.2 m (40 ft.) Single- and Double-Knife Headers Example: Cutting flax at 13.7 km/hr (8.5 mph) with a single-knife header, use a knife speed between 595 and 645 rpm (1190 and 1290 spm).
Page 66: Reel Height
OPERATION 3.12.8 Reel Height The crop type and condition determines the operating height of the reel. Set the reel height to carry material past the knife and onto the drapers with minimal disturbance and damage to the cut crop. For instructions, refer to 3.12.9 Reel Fore-Aft Position, page The reel height is controlled using switches in the windrower cab.
Page 67: Reel Fore-Aft Position
OPERATION 3.12.9 Reel Fore-Aft Position Reel fore-aft position is a critical factor for achieving the best results in adverse conditions. The reel position is factory-set for an average, straight standing crop, but it can be adjusted forwards or backwards as required using the controls inside the cab.
Page 68: Adjusting Reel Fore-Aft Position - Hydraulic Method
OPERATION 3. Remove pin (A) from each reel support arm. 4. Using a 15/16 in. wrench on bolt (B), turn the sprocket inside the reel arm to slide the reel to the desired position. If the reel binds on the arms from misalignment, move in smaller increments (two holes at a time).
Page 69 OPERATION NOTE: The reel components are not shown in the illustrations in this procedure for the sake of clarity. 1. Position reel fully aft with support arms horizontal. 2. Shut down the engine, and remove the key from the ignition. Repositioning the right reel arm cylinder 3.
Page 70 OPERATION 7. Lift the aft end of the cylinder out of the support assembly, and retract the cylinder so that cylinder center port fitting (A) engages the support assembly. NOTE: Loosen a hose fitting to allow movement of the cylinder rod.
Page 71: Repositioning Fore-Aft Cylinders On Double Reel
OPERATION Repositioning the left reel arm cylinder 11. Loosen fitting (A) to allow it to rotate when the cylinder is repositioned. 12. Remove bolt (B), nut, and spacer (C) that secure the cylinder to the left reel arm. 13. Extend the cylinder so that the mounting hole lines up with new location (D) as shown.
Page 72 OPERATION 6. Remove bolts (A) so that front support (B) is free to move up. Figure 3.46: Center Reel Arm Cylinder 7. Lift the aft end of the cylinder out of the support assembly, and retract the cylinder so that cylinder center port fitting (A) engages the support assembly.
Page 73 OPERATION 9. Reposition the hoses and reinstall hose shield (C) with bolts (B). 10. Position the hoses inside hose shield (C), and reinstall bolt and nut (A). 11. Reinstall aft support plate (D) with bolts (E). Figure 3.48: Center Reel Arm Cylinder Repositioning the right arm cylinder 12.
Page 74 OPERATION 14. Lift the aft end of the cylinder out of the support assembly, and retract the cylinder so that cylinder center port fitting (A) engages the support assembly. NOTE: Loosen a hose fitting to allow movement of the cylinder rod.
Page 75: Reel Tine Pitch
OPERATION 3.12.10 Reel Tine Pitch The reel is designed to pick up flattened and severely lodged crops. It is not always necessary to increase the tine pitch (select a higher cam setting) to pick up lodged crops, because the cam setting is mainly used to determine how the crop is delivered onto the drapers.
Page 76 OPERATION Cam Position 3, Reel Position 6 or 7 is mainly used to leave long stubble. • This position allows the reel to reach forward and lift the crop across the knife and onto the drapers. • This setting generates a fingertip speed that is approximately 30% faster than the reel speed.
Page 77: Adjusting Reel Cam - D50
2. Lower the header fully. 3. Shut down the engine, and remove the key from the ignition. 4. Loosen bolt (A) on the clamp securing the cam disc to the reel arm. Figure 3.58: Reel Arm – D50 169441 Revision D...
Page 78 (B). 6. Remove bolt (A) from the cam disc. Figure 3.59: Reel Cam – D50 7. Rotate the cam disc to the desired position. Use a wrench on bolt head (A) if necessary.
Page 79: Adjusting Reel Cam - D60
(B). 9. Tighten the bolts. Figure 3.61: Reel Cam – D50 Adjusting Reel Cam – D60 The reel is designed to pick up flattened and severely lodged crops. Adjustment may be required as crop conditions change.
Page 80: Crop Dividers
OPERATION 6. Turn latch pin (A) clockwise to engage and lock the cam disc. 7. Repeat Steps 4, page 67 6, page 68 for the opposite reel. IMPORTANT: Ensure the cam is secured into position before operating the machine. 3.12.11 Crop Dividers Crop dividers are used to help divide the crop when harvesting.
Page 81: Removing Crop Dividers Without Latch Option From Header - D50
Endshields, page 116. Figure 3.64: Stored Crop Divider Removing Crop Dividers without Latch Option from Header – D50 To correctly remove crop dividers without the latch option, follow the recommended removal procedure provided here. 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 82: Installing Crop Dividers With Latch Option Onto Header - D60
OPERATION Installing Crop Dividers with Latch Option onto Header – D60 To correctly install crop dividers with the latch option, follow the recommended installation procedure provided here. 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 83: Installing Crop Dividers Without Latch Option Onto Header - D50
Endshields, page 116. Figure 3.68: Crop Divider Installing Crop Dividers without Latch Option onto Header – D50 To correctly install crop dividers without the latch option, follow the recommended installation procedure provided here. 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 84 OPERATION 4. Engage the header safety props. For instructions, refer to your windrower operator’s manual. 5. Open or remove the endshields. For instructions, refer to 4.3 Endshields, page 116. 6. Remove bolt (A), lock washer, and flat washer from the inside of the endsheet.
Page 85: Crop Divider Rods
OPERATION 9. Lift the forward end of the crop divider and install bolt (A) and special stepped washer (B) (step towards the divider). Tighten the bolt. 10. Pull at the tip of the crop divider and ensure there is no lateral movement.
Page 86 OPERATION 2. Store both crop divider rods (A) inboard on the right endsheet. Figure 3.74: Right Endsheet 169441 Revision D...
Page 87: Delivery Opening
OPERATION 3.13 Delivery Opening The width and location of the delivery opening can be changed. This 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 Size Of Delivery Opening On Header With Manual Deck Shift - D50
OPERATION 3.13.2 Adjusting Size of Delivery Opening on Header with Manual Deck Shift – D50 Both draper decks can be moved manually to adjust the size of the delivery opening. Both decks can be positioned to set the delivery opening at three widths: •...
Page 89: Shifting Decks Hydraulically
OPERATION Shifting Decks Hydraulically The hydraulic deck shift feature allows you to select center, left, or right delivery from the windrower cab. It is only available on 7.6–12.2 m (25–40 ft.) D60 Draper Headers. Refer to your windrower operator’s manual for identification and operation of the deck shift control. To lay a double windrow, do the following: 1.
Page 90 OPERATION To deliver crop from the right end, move the decks to the left end of the header as follows: 1. Loosen bolt (A) on the right deck. 2. Slide the deck to close off the center opening. Tighten bolt (A). Figure 3.78: Right Deck Shown 3.
Page 91 OPERATION To lay a double windrow, do the following: 4. Position decks at the left end of header to deliver crop from right end (A). 5. Complete one round or one length of the field. 6. Complete the second round or length in the opposite direction to lay a double windrow.
Page 92: Windrow Types
OPERATION 3.14 Windrow Types Review the qualities that make up a good windrow to better understand how the crop delivery method affects your windrow. 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 •...
Page 93 OPERATION Table 3.8 Windrow Descriptions (continued) Windrow Type Windrow Descriptions Description: The stalks are lined along outside edges of windrow and heads are crossed in Dovetail center. This windrow can be formed by center delivery only. Weight Distribution: Poor Curing: Fair Weatherability: Poor Machine Setting Guidelines: •...
Page 94 OPERATION Table 3.8 Windrow Descriptions (continued) Windrow Type Windrow Descriptions Description: The stalks are lined along one edge and heads are along opposite edge, 45° to 45° Diagonal windrow perpendicular. This windrow can be formed by end delivery or by center delivery, if the crop is leaning to one side.
Page 95: Haying Tips
OPERATION 3.15 Haying Tips These tips may be useful when using the header in hay crops 3.15.1 Curing Curing crops quickly helps maintain the highest quality because for each day that hay lies on the ground, 5% of the protein is lost.
Page 96: Windrow Characteristics
OPERATION 3.15.4 Windrow Characteristics Adjust speed and header variables to achieve the ideal windrow characteristics. Table 3.9 Windrow Characteristics Configuration Advantage Movement of air through the windrow is more important to the curing High and fluffy process than is direct sunlight. Permits an even flow of material into the baler, chopper, etc.
Page 97: Draper Deflectors
OPERATION 3.16 Draper Deflectors D60 single-knife headers are equipped with rubber 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. If this happens, replace the existing deflector with a narrower one or rework the existing deflector.
Page 98: Reworking Draper Deflectors
OPERATION 6. Drill out seven pop-rivets (A) along the endsheet and remove deflector (B). 7. Locate new deflector (B) onto the endsheet bracket and attach with seven pop-rivets (MD #18768) (A). Figure 3.82: Wide Deflector 8. Position new deflector (MD #172381) (A) onto the endsheet bracket and attach with seven pop-rivets (MD #18768) (B).
Page 99 OPERATION 5. Mark a straight line (A) on the deflector 100 mm (4 in.) from and parallel to the back edge of the deflector. 6. Mark another line (B) on the deflector 100 mm (4 in.) from and parallel to the endsheet. 7.
Page 100: Knifehead Shield
5.2.2 Knifehead Shield, page 247. The shields and mounting hardware are available from your MacDon Dealer. 3.17.1 Installing Knifehead Shield DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 101 OPERATION 10. Tighten bolts (B). 169441 Revision D...
Page 102: Leveling Header
OPERATION 3.18 Leveling Header The windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. NOTE: The float springs are NOT used to level the header. 1. If the header is not level, check the pressure of the windrower’s tires to ensure they are properly inflated. For instructions, refer to the windrower operator’s manual.
Page 103: Unplugging Cutterbar
OPERATION 3.19 Unplugging Cutterbar Follow safety procedures when clearing a plugged cutterbar, and refer to troubleshooting recommendations of plugging persists. 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 machine for any reason.
Page 104: Upper Cross Auger (Option)
OPERATION 3.20 Upper Cross Auger (Option) The upper cross auger (UCA) (A) improves delivery of very bulky crops across the header and onto the windrow. Beater bars assist in delivering material through the header opening, but the beater bars are removable if wrapping occurs. Figure 3.87: Upper Cross Auger with Beater Bars NOTE: Newer UCA kits do not include or use beater bars;...
Page 105: Installing Beater Bars
OPERATION 3. Remove bolts (A) securing beater bars (B) and clamps (C) to the auger tubes, and remove the beater bars and clamps. Figure 3.89: Beater Bars Figure 3.90: Beater Bars 3.20.2 Installing Beater Bars Beater bars can improve the delivery of material through the header opening. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 106 OPERATION 3. Position one beater bar (B) and one clamp set (C) onto the auger tube and loosely secure with carriage bolt (A) and nut. Bolt head MUST face the direction of auger rotation. 4. Position the remaining clamp sets (C) onto the auger tube and loosely attach to beater bar (B) with carriage bolts (A) and nuts.
Page 107: Transporting Header
• Travel speed should be such that complete control and machine stability are maintained at all times. 3.21.2 Towing Header Headers with the optional Slow Speed Transport can be towed behind a properly configured MacDon windrower, a properly configured combine, or an agricultural tractor.
Page 108: Attaching Header To Towing Vehicle
OPERATION Attaching Header to Towing Vehicle Review this list of cautions before attaching a header behind a MacDon windrower, a properly configured combine, or an agricultural tractor. CAUTION Adhere to the following slow speed transport instructions to prevent loss of control leading to bodily injury and/or machine damage: •...
Page 109: Converting From Transport To Field Position
OPERATION 3.21.3 Converting from Transport to Field Position The header needs to be converted back to field position if it was towed to a new location. Removing Tow-Bar The transport tow-bar can easily be disassembled and stored on the header. 1.
Page 110: Storing The Tow-Bar
OPERATION Storing the Tow-Bar The tow-bar consists of two sections: inner half (A) and outer half (B). Figure 3.96: Tow-Bar Assembly 1. On the left side of the header’s backtube, place the inner end of the outer half of the tow-bar into cradle (A). NOTE: The exact appearance of the tow-bar storage cradle varies according to the model of header.
Page 111: Moving Front Wheels Into Field Position
OPERATION 4. On the right side of the header’s backtube, place the inner end of the inner half of the tow-bar into cradle (A). NOTE: The exact appearance of the tow-bar storage cradle varies according to the model of header. 5.
Page 112 OPERATION 4. Swivel front wheel assembly (A) so the wheels are aligned with the lower frame. 5. Remove pin (B) and pull the wheel assembly toward the rear of the header. Store the pin in hole (C) at the top of the leg.
Page 113: Moving Rear Wheels Into Field Position
OPERATION 9. Lift the wheel assembly to the desired height and slide linkage (A) into the appropriate slot in the vertical support. 10. Push handle (B) down to lock it. Figure 3.101: Front Wheels – Left Moving Rear Wheels into Field Position The rear (right) wheels are located farthest from the towing vehicle.
Page 114 OPERATION 6. Pull pin (A) on brace (B) on the left wheel in front of the cutterbar. Disengage the brace from the cutterbar, and lower the brace against axle (C). 7. Remove pin (D), lower support (E) onto the axle, and reinsert the pin into the support.
Page 115: Converting From Field To Transport Position
OPERATION 13. Complete the conversion by ensuring left (A) and right (B) wheels are in the positions shown. Figure 3.106: Field Position 3.21.4 Converting from Field to Transport Position The header needs to be converted to the transport when being towed to a new location. Moving Front Wheels into Transport Position The front (left) wheels are located closest to the towing vehicle.
Page 116 OPERATION 5. Remove the hairpin and clevis pin (A). 6. Pull latch handle (B) to release suspension linkage (C), and pull the suspension linkage away from spindle (D). 7. Lower the wheels slowly. Figure 3.108: Left Front Wheels 8. Lower handle (B) to lock the linkage. Figure 3.109: Locking Linkage 169441 Revision D...
Page 117: Moving Rear (Right) Wheels Into Transport Position
OPERATION 9. Remove pin (A) from storage at the top of leg (B). 10. Swivel the wheels clockwise until connector (C) is turned towards the left end of the header. 11. Insert pin (A) and turn to lock. 12. Lower the header until the left wheels are just touching the ground.
Page 118 OPERATION 6. Remove pin (A) and install at location (B) to secure the linkage. Turn the pin to lock. 7. Pull pin (D), swivel wheel (C) counterclockwise 90°, and release the pin to lock. Figure 3.112: Wheel Position 8. Ensure the left wheel is in the transport position as shown. Figure 3.113: Left Wheel in Transport Position 9.
Page 119 OPERATION 10. Lock wheel (A) with pin (B). Move right axle (C) to the front of the header. Figure 3.115: Right Rear Wheel 11. Remove pin (A), raise support (B) to the position shown, and reinsert pin. IMPORTANT: Ensure pin (A) engages the tube on the axle. 12.
Page 120: Attaching Tow-Bar
OPERATION Attaching Tow-Bar The tow-bar consists of two sections, which make storage and handling easier. 1. Unhook rubber strap (D) from cradle (A) on the right side of the header. 2. Remove clevis pin (C) and detach the tube end from support (B).
Page 121 OPERATION 8. Connect outer half (B) of the tow-bar to inner half (A). Figure 3.119: Tow-Bar Assembly 9. Lift outer half (B) and insert it into inner half (A). Figure 3.120: Tow-Bar Assembly 10. Secure the two halves together with L-pin (A) and then turn to lock.
Page 122 OPERATION 12. Position tow-bar (A) onto the axle, and push against latch (B) until the tow-bar pins drop into hooks (C). 13. Check that latch (B) has engaged the tow-bar. 14. Install clevis pin (D) and secure with hairpin. Figure 3.122: Attaching Tow-Bar 15.
Page 123: Storing The Header
OPERATION 3.22 Storing the Header Ensure the header is ready for the next harvest by taking steps to prevent corrosion, reduce unnecessary wear, and replace worn components. CAUTION Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable.
Page 125: Chapter 4: Maintenance And Servicing
Chapter 4: Maintenance and Servicing This chapter contains the information necessary to perform routine maintenance and occasional servicing tasks on your machine. The word “maintenance” refers to scheduled tasks that help your machine operate safely and effectively; “service” refers to tasks that must be performed when a part needs to be repaired or replaced. For advanced service procedures, contact your Dealer.
Page 126: General Procedures
MAINTENANCE AND SERVICING 4.2 General Procedures Refer to this chapter for information on procedures which are repeated throughout this manual. 4.2.1 Installing a Roller Chain When working on chain driven systems, you may need to install a new roller chain. This topic explains how to install a chain with a clip and pin connector link.
Page 127: Installing A Sealed Bearing
MAINTENANCE AND SERVICING 4.2.2 Installing a Sealed Bearing This installation procedure applies to all typical sealed bearings. 1. Clean the shaft and apply a rust preventive coating. 2. Install flangette (A), bearing (B), second flangette (C), and lock collar (D). NOTE: The locking cam is on only one side of the bearing.
Page 128: Endshields
MAINTENANCE AND SERVICING 4.3 Endshields Single-knife headers are fitted with a hinged endshield on the left end of the header for easy access to the header drive. The right end is not hinged, but is still removable. Double-knife headers are fitted with hinged endshields on both ends of the header.
Page 129: Closing Hinged Endshields
MAINTENANCE AND SERVICING 4.3.2 Closing Hinged Endshields The header endshields cover components. After accessing the components you will need to close the endshield. 1. Lift latch (A) to allow the endshield to move. Figure 4.5: Open Endshield 2. Swing the endshield forward until the front engages crop divider (A).
Page 130: Adjusting Hinged Endshield
MAINTENANCE AND SERVICING 4.3.3 Adjusting Hinged Endshield Polyethylene endshields expand or contract when subjected to large temperature changes. The position of the latch pin can be adjusted to compensate for dimensional changes. 1. Measure gap (X) between the front end of the endshield and the header frame and compare the measurement to the values provided in this table.
Page 131 MAINTENANCE AND SERVICING 3. Loosen bolts (A) on the support. Figure 4.10: Endshield Support 4. Loosen bolts (A) on latch assembly (B). Figure 4.11: Latch Assembly 169441 Revision D...
Page 132 MAINTENANCE AND SERVICING 5. Close the endshield and adjust its position to achieve the desired gap between the front end of the endshield and the header frame. Figure 4.12: Left Endshield 6. Re-open the endshield and tighten bolts (A). Figure 4.13: Latch Assembly 169441 Revision D...
Page 133 MAINTENANCE AND SERVICING 7. Tighten bolts (A). 8. Loosen bolts (B). Figure 4.14: Endshield Support 9. Loosen bolts (A) on latch (B), and adjust the latch as required to achieve a snug fit between the aft end of the endshield and the header frame. 10.
Page 134: Removing Hinged Endshield
MAINTENANCE AND SERVICING 4.3.4 Removing Hinged Endshield 1. Open the endshield. For instructions, refer to 4.3.1 Opening Hinged Endshield, page 116. Figure 4.16: Left Endshield 2. Remove screw (A) from the top of the endshield support tube. 3. Lift the endshield off the support tube. Figure 4.17: Endshield Support 169441 Revision D...
Page 135: Installing Hinged Endshield
MAINTENANCE AND SERVICING 4.3.5 Installing Hinged Endshield 1. Position the endshield on the support tube. 2. Secure in place with screw (A). Figure 4.18: Endshield Support 3. Close the endshield. For instructions, refer to 4.3.2 Closing Hinged Endshields, page 117. Figure 4.19: Left Endshield 169441 Revision D...
Page 136: Removing Non-Hinged Endshields
MAINTENANCE AND SERVICING 4.3.6 Removing Non-Hinged Endshields The non-hinged header endshields cover components. To access the components, you will need to remove the endshields. 1. To open the endshield, press against the latch in the opening at location (A) on the inboard side of the endsheet. Figure 4.20: Inboard Side of Endsheet 2.
Page 137: Adjusting Non-Hinged Endshields
MAINTENANCE AND SERVICING 2. Push the endshield in at location (A), opposite the latch. The endshield will self-latch. Figure 4.23: Right Endshield 4.3.8 Adjusting Non-Hinged Endshields Polyethylene endshields expand or contract when subjected to large temperature changes. The position of the latch pin can be adjusted to compensate for dimensional changes.
Page 138 MAINTENANCE AND SERVICING If adjustments are required, proceed as follows: 2. Remove the endshield. For instructions, refer to 4.3.6 Removing Non-Hinged Endshields, page 124. Figure 4.25: Right Endshield 3. Loosen bolts (A) on latch assembly (B). Figure 4.26: Latch Assembly 4.
Page 139 MAINTENANCE AND SERVICING 5. Re-open the endshield and tighten bolts (A). Figure 4.28: Latch Assembly 6. Loosen bolts (A) on latch (B), and adjust the latch as required to achieve a snug fit between the aft end of the endshield and the header frame. 7.
Page 140: Lubrication
MAINTENANCE AND SERVICING 4.4 Lubrication Some header components need to be lubricated periodically. CAUTION To avoid personal injury, before servicing header or opening drive covers, follow the procedures in 4.1 Preparing Machine for Servicing, page 113. Refer to the inside back cover for recommended lubricants. Log hours of operation and use the Maintenance Record provided to keep a record of scheduled maintenance.
Page 141: Service Intervals
MAINTENANCE AND SERVICING 4.4.2 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. IMPORTANT: Unless otherwise specified, use high temperature extreme pressure (EP2) performance with 1% maximum molybdenum disulphide (NLGI grade 2) lithium base.
Page 142 MAINTENANCE AND SERVICING Figure 4.33: Every 50 Hours – Upper Cross Auger, New Assembly A- Right End Bearing B - Two-Piece Auger Only: Upper Cross Auger U-joints [Two places, accessible by opening cover (D)] C - Two-Piece Auger Only: Upper Cross Auger Sliding Hubs [Two places, accessible by opening cover (D)] E - Two-Piece Auger Only: Upper Cross Auger Center Bearings (Two Places) 169441 Revision D...
Page 143 MAINTENANCE AND SERVICING Figure 4.34: Every 50 Hours – Upper Cross Auger, Old Assembly A - Upper Cross Auger U-joint 1 B - Upper Cross Auger Bearing (2 Places) C - Right End Bearing The U-joint has a cross and bearing kit with an extended lubrication interval. Stop greasing when greasing becomes difficult or if the U-joint stops taking grease.
Page 144 MAINTENANCE AND SERVICING Figure 4.35: Every 100 Hours C - Reel Drive Chain (1 Place) (Double Reel Shown – Single Reel Similar) A - Knife Drive Box (Check Oil Level Between Lower Hole and End of Dipstick [B]) ® D - Hydraulic Couplers (Use WD40 or Equivalent) 169441 Revision D...
Page 145 MAINTENANCE AND SERVICING Figure 4.36: Every 250 Hours (Continued) B - Double Reel U-Joint (1 Place) 2 A - Front Wheel Pivot (1 Place) C - Frame/Wheel Pivot (1 Place) - Both Sides The U-joint has a cross and bearing kit with an extended lubrication interval. Stop greasing when greasing becomes difficult or if the U-joint stops taking grease.
Page 146 MAINTENANCE AND SERVICING Figure 4.37: Every 500 Hours A - Reel Right Bearing (1 Place) B - Reel Center Bearing (1 Place) C - Wheel Bearings (4 Places) D - Reel Left Bearing (1 Place) 169441 Revision D...
Page 147: Hydraulic Schematics
Refer to the schematics that applies to your machine. 4.5.1 D50 or D60 Single-Reel Header This schematic can be used to troubleshoot hydraulic problems on your D50 or D60 single-reel header. Figure 4.38: Hydraulic Schematic for a D50 or D60 Single-Reel Header...
Page 148: D50 Single-Knife Header With Manual Deck Shift
MAINTENANCE AND SERVICING 4.5.2 D50 Single-Knife Header with Manual Deck Shift This schematic can be used to troubleshoot hydraulic problems on your D50 single-reel header with manual deck shift, with or without an upper cross auger. Figure 4.39: Hydraulic Schematic for a D50 Single-Knife Header with Manual Deck Shift...
Page 149: D60 Double-Reel Header
MAINTENANCE AND SERVICING 4.5.3 D60 Double-Reel Header This schematic can be used to troubleshoot hydraulic problems on your D60 double-reel header. Figure 4.40: Hydraulic Schematic for a D60 Double-Reel Header A - Right Fore-Aft Cylinder B - Right Lift Cylinder C - Reel Motor D - Center Fore-Aft Cylinder E - Center Lift Cylinder...
Page 150: D60 Double-Knife Header With Hydraulic Deck Shift
MAINTENANCE AND SERVICING 4.5.4 D60 Double-Knife Header with Hydraulic Deck Shift This schematic can be used to troubleshoot hydraulic problems on your D60 double-knife header with hydraulic deck shift, and with or without an upper cross auger. Figure 4.41: Hydraulic Schematic for a D60 Double-Knife Header with Hydraulic Deck Shift A - Case Drain B - Draper Pressure C - Return...
Page 151: Electrical System
MAINTENANCE AND SERVICING 4.6 Electrical System The electrical wires and connectors that connect the header lights should be secured to avoid damage. Use electrical tape and wire clips as required to prevent wires from dragging or rubbing. Keep lights clean and replace defective bulbs.
Page 152: Cutterbar
MAINTENANCE AND SERVICING 4.7 Cutterbar The cutterbar is located on the front of the header. It supports the knife and guards which are used to cut the crop. WARNING Keep hands clear of the area between guards and knife at all times.
Page 153: Removing Knife
MAINTENANCE AND SERVICING 7. Reposition bars (C) and/or (D) on knife (A) and install lock nuts (B). NOTE: If replacing screws, ensure they are fully inserted. Do NOT use nuts to draw screws into the knife bar. 8. Torque the nuts to 9.5 Nm (84 lbf∙in). Figure 4.45: Knife Bar 4.7.2 Removing Knife The cutterbar knife is designed to easily be replaced if worn or damaged.
Page 154: Removing Knifehead Bearing
MAINTENANCE AND SERVICING 12. Wrap a chain around the knifehead and pull out the knife. 4.7.3 Removing Knifehead Bearing The knifehead bearing, seals, and greasing interval protect the knifehead from the forces of the knife drive output arm. The seals and bearing require inspection and, when worn—replacement to prevent damage. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the...
Page 155: Installing Knifehead Bearing
MAINTENANCE AND SERVICING 4.7.4 Installing Knifehead Bearing The knifehead bearing, seals, and greasing interval protect the knifehead from the forces of the knife drive output arm. The seals and bearing require inspection and, when worn—replacement to prevent damage. 1. Place O-ring (E) and plug (D) into the knifehead. IMPORTANT: Install the bearing with the stamped end (the end with the identification markings) facing up.
Page 156: Spare Knife
MAINTENANCE AND SERVICING 5. Install knifehead pin (A) through the output arm and into the knifehead. Tap knifehead pin (A) down, and make sure the pin is seated at the bottom of the knifehead. 6. Set groove (B) in the knifehead pin 1.5 mm (1/16 in.) above output arm (C).
Page 157: Knife Guards
NOTE: Use guard straightening tool (MD #140135) available from your MacDon Dealer. 1. Shut down the engine, and remove the key from the ignition. 2. Position the tool as shown, and pull up to adjust the guard tips upwards.
Page 158: Replacing Pointed Guards
MAINTENANCE AND SERVICING Replacing Pointed Guards To replaced pointed guards, perform the recommended replacement procedure provided here. Replacing normal, drive side, and end guards DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 159 MAINTENANCE AND SERVICING 5. Position new guard (A), hold-down (C) (if applicable), and plastic wearplate (if applicable) onto the cutterbar. Secure with two nuts (B) and bolts, but do NOT tighten. 6. Check and adjust the clearance between the hold-downs and the knife.
Page 160: Replacing Stub Guards
MAINTENANCE AND SERVICING 10. Position the plastic wearplate (if applicable), replacement center guard (A), adjuster bar, and hold-down (B) onto the cutterbar. Install bolts, but do NOT tighten. IMPORTANT: Ensure center guard (A) (right of the cutterbar split) has offset cutting surfaces. IMPORTANT: Hold-down (B) must accommodate the two overlapping knives at the center guard location.
Page 161 MAINTENANCE AND SERVICING 2. Stroke the knife manually until the knife sections are spaced midway between the guards. 3. Remove two nuts (A) and bolts attaching guard (B) and hold-down (C) to the cutterbar. 4. Remove guard (B), plastic wearplate (if installed), hold- down (C), and adjuster bar (D).
Page 162 MAINTENANCE AND SERVICING 5. Position the plastic wearplate (if applicable), replacement guard (B), adjuster bar (D), hold-down (C), and install bolts and nuts (A). Do NOT tighten. 6. Check and adjust the clearance between the hold-downs and the knife. For instructions, refer to Checking and Adjusting Knife Hold-Downs, page 151.
Page 163: Checking And Adjusting Knife Hold-Downs
MAINTENANCE AND SERVICING 8. Remove two nuts (A) and bolts attaching guard (B), hold- down (C), and adjuster bar (D) to the cutterbar. 9. Remove guard (B), plastic wearplate (if installed), hold- down (C), and adjuster bar (D). 10. Position the plastic wearplate (if applicable), replacement guard (B), adjuster bar (D), and hold-down (C) onto the cutterbar.
Page 164 MAINTENANCE AND SERVICING 3. Manually stroke the knife to align section (A) under hold-down (B). 4. At standard guard locations, push knife section (A) down against guard (C) and measure the clearance between hold- down (B) and knife section (A) with a feeler gauge. The clearance should be 0.1–0.6 mm (0.004–0.024 in.).
Page 165 MAINTENANCE AND SERVICING 2. Manually stroke knife to locate section under hold-down (A). 3. Standard guard: At standard guard locations, push knife section (B) down against guard (C) and measure clearance between hold-down clip (A) and knife section (B) with a feeler gauge.
Page 166 MAINTENANCE AND SERVICING 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. 1. Shut down the engine, and remove the key from the ignition. 2.
Page 167 MAINTENANCE AND SERVICING Adjusting Stub Guard Hold-Downs Follow the instructions outlined in this section to properly adjust the hold-downs. 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 168 MAINTENANCE AND SERVICING Sheet metal hold-down 9. Stroke knife to center section (A) under hold-down (B). 10. Decrease clearance by turning bolt (C) clockwise to lower front of hold-down. Clearance should be 0.1–0.6 mm (0.004–0.024 in.). 11. Increase clearance by turning bolt (C) counterclockwise to raise front of hold-down.
Page 169: Knife Drive
MAINTENANCE AND SERVICING 4.8 Knife Drive The knife drive system transforms pumped hydraulic pressure into a mechanical motion that strokes a series of serrated knife blades at the front of the header back and forth to cut a variety of crops. 4.8.1 Knife Drive Belts Untimed Knife Drive Belts This section applies to single-knife headers and to 12.2 m (40 ft.) double-knife headers with untimed knife drives.
Page 170 MAINTENANCE AND SERVICING 6. Ensure the clearance between belt (A) and belt guide (B) is 1 mm (1/32 in.). 7. Loosen three bolts (C), and adjust the position of guide (B) as required. 8. Tighten three bolts (C). 9. Close the endshield. For instructions, refer to 4.3.2 Closing Hinged Endshields, page 117.
Page 171 MAINTENANCE AND SERVICING 5. Open access cover (A) on the endsheet behind the cutterbar to provide clearance between the knife drive box pulley and the endsheet. Figure 4.76: Access Cover 6. Remove belt (A) from drive pulley (B). 7. Slip belt (A) over and behind knife drive box pulley (C). Use the notch in the pulley to assist with the belt removal.
Page 172: Timed Double-Knife Drive Belts
MAINTENANCE AND SERVICING 3. Route knife drive belt (A) around knife drive box pulley (C) and knife drive pulley (B). Use the notch in the pulley to assist with the belt installation. NOTE: Ensure the drive motor is fully forward, do NOT pry the belt over the pulley.
Page 173 MAINTENANCE AND SERVICING 3. Loosen two nuts (A) on the knife drive belt idler bracket. Figure 4.80: Left Knife Drive 4. Insert a long punch (or equivalent) into hole (B) in the idler bracket, and pry downward until a force of 27 N (6 lbf) deflects the timing belt 12 mm (1/2 in.) at mid-span.
Page 174 MAINTENANCE AND SERVICING 1. Shut down the engine, and remove the key from the ignition. 2. Open the endshield. For instructions, refer to 4.3.1 Opening Hinged Endshield, page 116. 3. Loosen two nuts (A) on the belt idler bracket to relieve the belt tension.
Page 175 MAINTENANCE AND SERVICING 8. Open access cover (A) on the endsheet behind the cutterbar to provide clearance between the knife drive box pulley and the endsheet. 9. Remove the knife drive belt. Figure 4.86: Access Cover Installing Timed Knife Drive Belts The procedure for installing timed knife drive belts is the same for both sides of the header.
Page 176 MAINTENANCE AND SERVICING 4. Position V-belts (C) on the pulleys. 5. Turn adjuster bolt (B) to move the drive motor until a force of 53 N (12 lbf) applied at mid-span deflects V-belts (C) 3 mm (1/8 in.). 6. Tighten bolts (A) on the drive mounting brackets. Figure 4.88: Knife Drive V-Belts 7.
Page 177 MAINTENANCE AND SERVICING 11. Tension the knife drive belt. For instructions, refer to Tensioning Timed Knife Drive Belts, page 160. 12. Install access cover (A) and secure it with a bolt. 13. Close the endshield. For instructions, refer to 4.3.2 Closing Hinged Endshields, page 117.
Page 178 MAINTENANCE AND SERVICING 4. Loosen two bolts (A) on the knife drive mounting bracket. 5. Turn adjuster bolt (B) to move the drive motor until a force of 53 N (12 lbf) applied at mid-span deflects V-belts (C) 3 mm (1/8 in.). 6.
Page 179 MAINTENANCE AND SERVICING 4. Loosen two bolts (A) on the knife drive mounting bracket. 5. Turn adjuster bolt (B) to loosen the two V-belts (C), then remove the V-belts. Figure 4.95: Knife Drive V-Belts Installing Timed Drive V-Belts DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 180 MAINTENANCE AND SERVICING 6. Tighten two bolts (A) on the endsheet. 7. Close the endshield. For instructions, refer to 4.3.2 Closing Hinged Endshields, page 117. 8. Check the tension of the new V-belts after a short run-in period (about five hours). Figure 4.97: Inboard Side of Endsheet Removing Timed Knife Drive Belt –...
Page 181 MAINTENANCE AND SERVICING 5. Open access cover (A) on the right endsheet behind the cutterbar to provide clearance between the knife drive box pulley and the endsheet. 6. Remove the knife drive belt. Figure 4.99: Access Cover on Right Endsheet Installing Timed Knife Drive Belts –...
Page 182 MAINTENANCE AND SERVICING 4. Route knife drive belt (A) around drive pulley (B). 5. Tension the knife drive belt. For instructions, refer to Tensioning Timed Knife Drive Belts, page 160. Figure 4.101: Right Knife Drive Pulley 6. Reinstall access cover (A) and secure it with a bolt. 7.
Page 183 MAINTENANCE AND SERVICING 4. Rotate the left knife drive box driven pulley clockwise until the left knife (A) is at the center of the inboard stroke (B) (moving towards center of header). NOTE: Center stroke is when the knife sections (C) are centered between guard points.
Page 184: Knife Drive Box
MAINTENANCE AND SERVICING 7. Rotate the idler pulley bracket (A) down and slide the idler pulley up by hand to remove most of the belt slack. Tighten nut (B). 8. Check that the timing belts are properly seated in the grooves on both the driver and driven pulleys.
Page 185: Checking Mounting Bolts
MAINTENANCE AND SERVICING Checking Mounting Bolts Check the torque on the four knife drive box mounting bolts after the first 10 hours of operation and every 100 hours thereafter. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason.
Page 186 MAINTENANCE AND SERVICING Timed double-knife headers: NOTE: The procedure is the same for both ends of a timed double-knife header. Images shown are for the left end—the right end is opposite. 3. Loosen two nuts (A) on the belt idler bracket to relieve the belt tension.
Page 187 MAINTENANCE AND SERVICING 9. Remove belt (A) from drive pulley (B). 10. Slip belt (A) over and behind knife drive box pulley (C). Use the notch in the pulley to assist with the belt removal. 11. Stroke the knife manually to its outer limit. Figure 4.112: Knife Drive 12.
Page 188: Removing Knife Drive Box Pulley
MAINTENANCE AND SERVICING 18. Remove bolt (A) that clamps knife drive arm (B) to the knife drive box output shaft. 19. Remove knife drive arm (B) from the knife drive box output shaft. 20. Remove four knife drive box mounting bolts (C) and (D). NOTE: Bolt (E) is factory set;...
Page 189: Installing Knife Drive Box Pulley
MAINTENANCE AND SERVICING Installing Knife Drive Box Pulley The knife drive box pulley is driven by the knife drive motor and the knife drive belt. To install the knife drive box pulley, follow the recommended installation procedure provided here. 1. Ensure the splines and bores in the pulley and drive arm are free of paint, oil, and solvents.
Page 190 MAINTENANCE AND SERVICING 4. Apply two bands (A) of medium-strength threadlocker ® (Loctite 243 or equivalent) to the output shaft as shown. Apply one band at the end of the output shaft and the second band at the approximate midpoint location. 5.
Page 191: Changing Oil In Knife Drive Box
If the knife drive box requires adjustment, contact your MacDon Dealer. Figure 4.122: Knifehead 16. Install and tension the knife drive belts. Refer to the following topics depending on your header: •...
Page 192 MAINTENANCE AND SERVICING 4. Remove breather/dipstick (A) and drain plug (B). 5. Allow the oil to drain. 6. Reinstall drain plug (B). 7. Add oil to the knife drive box. Refer to the inside back cover for specifications. 8. Reinstall breather/dipstick (A). 9.
Page 193: Drapers
MAINTENANCE AND SERVICING 4.9 Drapers Two side drapers (A) convey cut crop to the center opening. Replace the side drapers if they are torn, cracked, or missing slats. 4.9.1 Adjusting Draper Tension The drapers are tensioned at the factory and should not require adjustment. If adjustment is required, draper tension should be just enough to prevent slipping and to keep the draper from sagging below the cutterbar.
Page 194: Removing Split Drapers
MAINTENANCE AND SERVICING 7. Ensure idler roller (A) is between draper guides (B). Figure 4.126: Idler Roller IMPORTANT: Do NOT adjust nut (C). This nut is used for draper alignment only. 8. Turn adjuster bolt (A) counterclockwise to loosen the draper.
Page 195: Installing Split Drapers
MAINTENANCE AND SERVICING WARNING To prevent bodily injury from the fall of a raised reel, always engage the reel safety props before going under the raised reel for any reason. 1. Start the engine. 2. Raise the reel fully. 3. Raise the header fully. 4.
Page 196: Removing Endless Draper
MAINTENANCE AND SERVICING 1. Raise the reel fully. 2. Raise the header fully. 3. Shut down the engine, and remove the key from the ignition. 4. Engage the header safety props. 5. Engage the reel safety props. For instructions, refer to 3.10.1 Engaging Reel Safety Props, page 6.
Page 197 MAINTENANCE AND SERVICING 1. Raise the reel fully. 2. Raise the header fully. 3. Shut down the engine, and remove the key from the ignition. 4. Engage the header safety props. 5. Engage the reel safety props. For instructions, refer to 3.10.1 Engaging Reel Safety Props, page 6.
Page 198: Installing Endless Draper
MAINTENANCE AND SERVICING 10. Insert a pry bar (A) into the hole located in the deck at the approximate deck mid-point location, and lift the deck clear of the cutterbar. NOTE: Ensure the pry bar is long enough to accommodate the width of the draper.
Page 199 MAINTENANCE AND SERVICING 6. Insert pry bar (A) through draper, and place the bar into the hole located in the deck at the approximate deck mid-point location. NOTE: Ensure the pry bar is long enough to accommodate the width of the draper. 7.
Page 200: Adjusting Draper Tracking
MAINTENANCE AND SERVICING 4.9.6 Adjusting Draper Tracking Draper tracking is adjusted by aligning the drive and idler draper rollers. CAUTION To avoid personal injury, before servicing machine or opening drive covers, refer to 4.1 Preparing Machine for Servicing, page 113. Each draper deck has fixed drive roller (A) and spring-loaded idler roller (B) that can be aligned using the adjuster rods so the draper tracks properly on the rollers.
Page 201: Draper Roller Maintenance
MAINTENANCE AND SERVICING 3. Adjust the idler roller distance (Y) as follows: Loosen nut (A) and jam nut (B). b. Turn adjuster nut (C). NOTE: If the draper does not track at the idler roller end after the idler roller adjustment, the drive roller is likely not square to the deck.
Page 202: Installing Draper Drive Roller
MAINTENANCE AND SERVICING 8. Loosen the two set screws in access hole (A) in the drive roller hub at the motor end. 9. Remove two bolts (B) that secure the hydraulic motor to the arm, and then pull the motor off the roller. Figure 4.141: Motor End of Drive Roller 10.
Page 203: Removing Draper Idler Roller
MAINTENANCE AND SERVICING 3. Secure the motor with shoulder bolts (B), and tighten. The shoulder bolts allow clearance between the motor and arm. The motor is not secured tightly to the arm. 4. Push the roller against the shoulder on the motor shaft, and hand-tighten the two set screws (A).
Page 204 MAINTENANCE AND SERVICING 4. Shut down the engine, and remove the key from the ignition. 5. Engage the header safety props. 6. Engage the reel safety props. For instructions, refer to 3.10.1 Engaging Reel Safety Props, page 7. Loosen the draper by turning adjuster bolt (A) counterclockwise.
Page 205: Installing Draper Idler Roller
MAINTENANCE AND SERVICING Installing Draper Idler Roller The roller needs to be installed after it has been repaired or replaced 1. Position the stub shaft into the idler roller in forward arm (B) on the deck. 2. Push on the roller to slightly deflect the forward arm so the stub shaft at the rear of the roller can be slipped into rear arm (C).
Page 206 7. Remove bearing assembly (A) and seal (B) from roller tube (C) as follows: NOTE: Seal (B) is not used on the D50 Draper Header. Attach slide hammer (D) to threaded shaft (E) in the bearing assembly. b. Tap out bearing assembly (A) and seal (B).
Page 207: Adjusting Deck Height
Figure 4.152: Deck Height Measurements A - Lock Nut B - Deck Support C - Draper Deck D - D50 Gap: 3–4 mm (0.12–0.16 in.); D60 Gap: 7–8 mm (0.27–0.31 in.) To adjust the deck height, follow these steps: 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 208 MAINTENANCE AND SERVICING 5. Lift the front edge of draper (A) past cutterbar (B) to expose the deck support. Figure 4.153: Deck Adjustment 6. Loosen two lock nuts (A) on deck support (B) by one half-turn ONLY. NOTE: The deck is shown with the draper removed in the illustration at right.
Page 209: Reel
MAINTENANCE AND SERVICING 4.10 Reel The reel features a uniquely shaped cam, which allows the fingers to get underneath lodged crop and pick it up before it is cut. CAUTION To avoid personal injury, before servicing machine or opening drive covers, refer to 4.1 Preparing Machine for Servicing, page 113.
Page 210: Fore-Aft Position
MAINTENANCE AND SERVICING 4. Adjust the fore-aft reel position so that the back end of the cam disc is between the 4 and 5 on fore-aft position indication decal (A). 5. Lower the reel fully. 6. Shut down the engine, and remove the key from the ignition.
Page 211: Adjusting Reel Clearance
MAINTENANCE AND SERVICING 8. Check finger clearance (X) when positioned between locations (A) and (B). Depending on the reel fore-aft position, the minimum clearance can result at the guard tine, hold-down, or cutterbar. For finger clearance measurements, refer to Table 4.4, page 197.
Page 212: Reel Frown
MAINTENANCE AND SERVICING 6. Double reel: Adjust center arm lift cylinder link (A) to set the clearance at the center of the reel as follows: NOTE: This adjustment is most easily performed from the underside of the arm. Loosen nut (B). b.
Page 213: Centering Reel
MAINTENANCE AND SERVICING 3. Start with the reel disc closest to the center of the header and proceed outward toward the ends, adjusting the header profile as follows: Remove bolts (A). b. Loosen bolt (B) and adjust arm (C) until the desired measurement is obtained between the reel tine tube and the cutterbar.
Page 214: Reel Drive
MAINTENANCE AND SERVICING Single-reel headers 6. Loosen bolt (A) on brace (B) at both ends of the reel. 7. Move the forward end of reel support arm (C) side to side as required to center the reel. 8. Tighten bolts (A) and torque to 359 Nm (265 lbf·ft). Figure 4.165: Reel Outboard Support Arm Double-reel headers 9.
Page 215 2. D60: Remove four bolts (A) securing cover (B) to the reel drive. Figure 4.167: Drive Cover – D60 Single Reel 3. D50: Remove six screws (A) securing cover (B) to the reel drive. NOTE: Only three screws (A) are visible in the illustration. The other three are on the other side of the cover.
Page 216 MAINTENANCE AND SERVICING Double-Reel Drive 4. Remove six bolts (A) securing upper cover (B) to the reel drive and lower cover (C). Figure 4.169: Drive Cover – Double Reel 5. If necessary, remove three bolts (A) and remove lower cover (B). Figure 4.170: Drive Cover –...
Page 217 MAINTENANCE AND SERVICING 2. D50: Position drive cover (B) onto the reel drive and secure it with six screws (A). NOTE: Only three screws (A) are visible in the illustration. The other three are on the other side of the cover.
Page 218: Adjusting Reel Drive Chain Tension
MAINTENANCE AND SERVICING 4. Position upper drive cover (B) onto the reel drive and lower cover (C), and secure it with six bolts (A). Figure 4.174: Drive Cover – Double Reel Adjusting Reel Drive Chain Tension The reel drive chain transfers power from the hydraulically driven reel motor to the sprockets that rotate the reels. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 219: Replacing Drive Chain On Single Reel
MAINTENANCE AND SERVICING 4. D50: Tension on chain (A) should be such that hand force deflects chain 3 mm (1/8 in.) at mid-span. Adjust as follows: Loosen four bolts (B) on motor mount (C). b. Slide the motor and motor mount (C) until the required tension is achieved.
Page 220 NOTE: There are four of bolt (A) on the D50 and six on the D60. 3. Lift chain (C) off drive sprocket (D). 4. Lower the chain until free of lower sprocket (E) and remove the chain from the drive.
Page 221: Replacing Drive Chain On Double Reel
MAINTENANCE AND SERVICING Replacing Drive Chain on Double Reel The drive chain allows the hydraulic reel drive motor to turn the reel. It can be replaced if damaged or worn. There are two methods for replacing the reel drive chain. Proceed to the procedure that is most appropriate for your circumstances: •...
Page 222 MAINTENANCE AND SERVICING 4. Support the inboard end of the right reel with a front end loader and nylon slings (or equivalent setup). NOTE: To avoid damaging or denting center tube, support reel as close as possible to the cam end disc. Figure 4.180: Supporting Reel 5.
Page 223 MAINTENANCE AND SERVICING 6. Loosen the right reel arm brace by loosening bolt (A) on the backtube. Figure 4.182: Right Reel Arm Brace 7. Move the right reel sideways to separate the reel tube (A) and U-joint (B). 8. Remove chain (C). 9.
Page 224 MAINTENANCE AND SERVICING 10. Slide the motor and motor mount (B) up until the tension on chain (C) is such that hand force deflects the chain 3 mm (1/8 in.) at mid-span. 11. Tighten nuts (A), and then recheck the chain tension. Figure 4.184: Reel Drive 12.
Page 225: Reel Drive Cover Installing
MAINTENANCE AND SERVICING 16. Remove the temporary reel support. Figure 4.186: Supporting Reel 17. Retighten reel arm brace bolt (A), and torque to 366 Nm (270 lbf∙ft). 18. Reinstall the drive cover. For instructions, refer to Installing Reel Drive Cover, page 204.
Page 226 5. Position the ends of the new chain onto sprocket (B). Figure 4.188: Reel Drive 6. Install pin connector (A) (not available as a MacDon part) into the chain, preferably from the backside of the sprocket.
Page 227: Replacing Reel Drive Sprocket
Figure 4.190: Reel Drive Replacing Reel Drive Sprocket The reel drive sprocket is attached to the reel drive motor. Removing Reel Drive Sprocket – D50 The reel drive sprocket is attached to the reel drive motor. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 228 3. Loosen four bolts (A) and slide the motor and motor mount (B) down towards the reel shaft. 4. Lift chain (C) off drive sprocket (D). Figure 4.191: D50 Reel Drive 5. Remove bolt (A), lock washer (B), and flat washer (C) from the motor shaft.
Page 229 MAINTENANCE AND SERVICING 3. Loosen six bolts (A) and slide the motor and motor mount (B) down towards the reel shaft. 4. Lift chain (C) off drive sprocket (D). Figure 4.193: D60 Reel Drive 5. Remove cotter pin (A) and slotted nut (B) from the motor shaft.
Page 230 MAINTENANCE AND SERVICING Installing Reel Drive Sprocket – D50 The reel drive sprocket is attached to the reel drive motor. 1. Align the keyway in sprocket (D) with the key on the motor shaft, and slide the sprocket onto the shaft.
Page 231: Replacing Double-Reel U-Joint
MAINTENANCE AND SERVICING Installing Reel Drive Sprocket – D60 The reel drive sprocket is attached to the reel drive motor. 1. Align the keyway in sprocket (C) with the key on the motor shaft, and slide the sprocket onto the shaft. 2.
Page 232 MAINTENANCE AND SERVICING Removing Double-Reel U-Joint If the double-reel U-joint is worn or damaged, it will need to be replaced. DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 233 MAINTENANCE AND SERVICING 8. Remove six bolts (A) attaching U-joint flange (B) to driven sprocket (C). 9. Remove the U-joint. NOTE: It may be necessary to move the right reel sideways for the U-joint to clear the tube. Figure 4.201: U-Joint Installing Double-Reel U-Joint Once the old U-joint has been removed, a new one can be installed.
Page 234: Replacing Reel Drive Motor
Replacing Reel Drive Motor The reel drive motor does not require regular maintenance or servicing. If problems occur with the motor, remove it and have it serviced at your MacDon Dealer. Removing Reel Drive Motor The reel drive motor does not require regular maintenance or servicing. If problems occur with the motor, remove it and have it serviced at your MacDon Dealer.
Page 235 Installing Reel Drive Motor The reel drive motor does not require regular maintenance or servicing. If problems occur with the motor, remove it and have it serviced at your MacDon Dealer. 1. Attach motor (A) to motor mount (B) with four countersunk bolts and nuts (C).
Page 236: Reel Speed Sensor
MAINTENANCE AND SERVICING Reel Speed Sensor The reel speed sensor system is located inside the reel drive cover. Removing Reel Speed Sensor DANGER To prevent bodily injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before making adjustments to the machine.
Page 237: Reel Tines And Fingers
MAINTENANCE AND SERVICING 4. Adjust the clearance between sensor (A) and driven sprocket (B) to 2–4 mm (0.08–0.16 in.) by bending the support. Figure 4.210: Reel Speed Sensor 4.10.5 Reel Tines and Fingers If a steel tine or plastic finger is damaged or worn, it will need to be removed so it can be replaced. IMPORTANT: Keep the reel tines and fingers in good condition.
Page 238: Installing Steel Tines
MAINTENANCE AND SERVICING 6. Attach reel arms (B) (temporarily) to the reel disc at the original attachment locations (A). 7. Cut the damaged tine so it can be removed from the tine tube. 8. Remove the bolts from the existing tines and slide the tines over to replace the tine that was cut off in Step 7, page 226 (remove reel arms [B] from the tine tubes as necessary).
Page 239: Removing Plastic Fingers
MAINTENANCE AND SERVICING Removing Plastic Fingers ® Plastic reel fingers are secured to the tine tube with a single Torx screw. 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 240: Installing Plastic Fingers
MAINTENANCE AND SERVICING Installing Plastic Fingers Once the old plastic reel finger has been removed, a new one can be installed. 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 241: Tine Tube Bushings
MAINTENANCE AND SERVICING 4.10.6 Tine Tube Bushings The reel tine tube rests in a tine tube bushing, which is secured to the reel disc. If a tine tube bushing is damaged or worn, it will need to be replaced. Removing Bushings from Five-Bat Reels The bushing clamps securing the tine tube to the bushing will need to be released so that the bushing halves can be removed.
Page 242 MAINTENANCE AND SERVICING 7. Remove bolt (A) on the cam linkage so that tine tube (B) is free to rotate. Figure 4.218: Tail End 8. Slide the tine tube outboard to expose the bushings. Remove bolt (A) from the tine next to the arm (or remove the plastic finger) if required so that the tube can slide through the arm.
Page 243: Installing Bushings On Five-Bat Reels
MAINTENANCE AND SERVICING 11. Release bushing clamp (A) at the cam disc using a small screwdriver to separate the serrations. Move the clamp off the bushings. Figure 4.221: Bushing Clamp 12. Rotate arm (A) clear of the disc, and then slide the arm off the bushing.
Page 244 MAINTENANCE AND SERVICING NOTE: Use a pair of modified channel lock pliers (A) to install bushing clamps (C). Secure the pliers in a vise and grind a notch (B) into the end of each arm to fit the clamp as shown. Figure 4.223: Modified Pliers Installing cam end bushings: 1.
Page 245: Removing Bushings From Six- Or Nine-Bat Reels
MAINTENANCE AND SERVICING 7. Tighten clamp (A) using modified channel lock pliers (B) until finger pressure will NOT move the clamp. IMPORTANT: Overtightening the clamp might break the clamp. Figure 4.226: Clamp on Bushing Installing center disc and tail-end bushings: 8.
Page 246 MAINTENANCE AND SERVICING 3. Shut down the engine, and remove the key from the ignition. 4. Engage the reel safety props. For instructions, refer to 3.10.1 Engaging Reel Safety Props, page 5. If replacing only the cam end bushing, proceed to Step 10, page 235.
Page 247: Installing Bushings On Six- Or Nine-Bat Reels
MAINTENANCE AND SERVICING Removing cam end bushings 10. Remove bolt (A) from the cam linkage so that tine tube (B) is free to rotate. Figure 4.231: Cam Linkage 11. Slide the tine tube outboard to expose bushing (A). 12. Remove bushing halves (A). If required, remove the next tine or plastic finger so the arm can slide off the bushing.
Page 248 MAINTENANCE AND SERVICING NOTE: Use a pair of modified channel lock pliers (A) to install bushing clamps (C). Secure the pliers in a vise and grind a notch (B) into the end of each arm to fit the clamp as shown. Figure 4.233: Modified Pliers Installing cam end bushings 1.
Page 249 MAINTENANCE AND SERVICING 8. Spread bushing clamp (A) and slip it over the tine tube adjacent to the flangeless end of bushing (B). Position the clamp such that the edges of the clamp and bushing are flush when the clamp is fit into the groove on the bushing and the lock tabs are engaged.
Page 250: Transport System (Optional)
MAINTENANCE AND SERVICING 4.11 Transport System (Optional) The header can be equipped with a set of transport wheels so that the header can be towed by a windrower, combine, or tractor. This option is available for use with 9.1, 10.7, and 12.2 m (30, 35, and 40 ft.) headers. Refer to 5.3.2 Stabilizer / Slow Speed Transport Wheels, page 250 for more information.
Page 251: Checking Axle Bolt Torque
MAINTENANCE AND SERVICING 4.11.2 Checking Axle Bolt Torque The hardware that secures the optional transport system components to the header must be checked daily to ensure safe operation. 1001276 Figure 4.239: Axle Bolts 1. Check and tighten axle bolts DAILY until the torque is maintained as follows: •...
Page 252: Checking Tire Pressure
MAINTENANCE AND SERVICING 4.11.3 Checking Tire Pressure Proper tire pressure ensures tires perform properly and wear evenly. WARNING • Service tires safely. • A tire can explode during inflation which could cause serious injury or death. • Do NOT stand over the tire. Use a clip-on chuck and extension hose.
Page 253: Maintenance Requirements
MAINTENANCE AND SERVICING 4.12 Maintenance Requirements Regular maintenance is the best insurance against early wear and untimely breakdowns. Periodic maintenance requirements are organized according to service intervals. When servicing the machine, refer to the appropriate section in this chapter and use only the fluids and lubricants specified in Recommended Fluids and Lubricants on the inside back cover.
Page 254 MAINTENANCE AND SERVICING Interval Service 4.12.1 Break-in Inspection, page 241 First use • Check the wobble box mounting bolts • Check the wobble box lubricant level • Check the knife drive belt tension • Check the torque on the stabilizer/transport wheels (if installed) •...
Page 255: Maintenance Record
MAINTENANCE AND SERVICING 4.12.3 Maintenance Record Log hours of operation, use the maintenance record, and keep copies of your maintenance records. Maintenance ▲ ▲ - Change ü ü - Check S S - Lubricate Action: Record Hour Meter Reading Date Serviced by First Use, refer to 4.12.1 Break-in Inspection, page 241...
Page 256: Checking Hydraulic Hoses And Lines
MAINTENANCE AND SERVICING Maintenance ▲ ▲ - Change ü ü - Check S S - Lubricate Record Action: 500 Hours or Annually S Reel shaft bearings Stabilizer/slow speed transport wheel bearings 1000 Hours or 3 Years ▲ Knife drive box lubricant 4.12.4 Checking Hydraulic Hoses and Lines Check hydraulic hoses and lines daily for signs of leaks.
Page 257: Chapter 5: Options And Attachments
Chapter 5: Options and Attachments The following options and attachments are available for use with your header. See your MacDon Dealer for availability and ordering information. 5.1 Reel Kits 5.1.1 Lodged Crop Reel Finger Kit The steel fingers provided in the Lodged Crop Reel Finger kit attach to the ends of every other tine tube and help to clear material in heavy, hard-to-cut crops such as lodged rice.
Page 258: Hydraulic Reel Fore-Aft Positioner
OPTIONS AND ATTACHMENTS 5.1.3 Hydraulic Reel Fore-Aft Positioner The Hydraulic Reel Fore-Aft Positioner allows the Operator to control the reel fore-aft position from the windrower cab. This option is available only for headers that were not factory-equipped with the hydraulic reel fore-aft option. Installation and adjustment instructions are included with the kit.
Page 259: Cutterbar Kits
OPTIONS AND ATTACHMENTS 5.2 Cutterbar Kits The cutterbar is located on the front of the header. It supports the knife and guards which is used to cut the crop. 5.2.1 Cutterbar Wearplate Cutterbar wearplates are recommended for cutting on the ground when the soil is adhering to the steel. Installation instructions are included in the kit.
Page 260: Stub Guard Conversion Kit
5.2.4 Vertical Knife Mounts The vertical knife mounts allow the installation of vertically oriented knives onto both ends of the header. The vertical knives themselves are not sold by MacDon and must be purchased from a separate supplier. Installation and adjustment instructions are included in the bundle.
Page 261: Adjustable Skid Shoes With Poly Covers
OPTIONS AND ATTACHMENTS 5.2.5 Adjustable Skid Shoes with Poly Covers Adjustable skid shoes with poly covers are recommended for cutting on the ground. Installation and adjustment instructions are included in the kits. • Outboard skid shoes, model years 2006 and older – MD #B4836 •...
Page 262: Header Kits
OPTIONS AND ATTACHMENTS 5.3 Header Kits Header options add features or enhancements to the header frame rather than a specific system or function. 5.3.1 Stabilizer Wheels Stabilizer wheels help to stabilize the header in field conditions that would otherwise cause the header to bounce, resulting in uneven cutting heights.
Page 263: Crop Delivery Kits
OPTIONS AND ATTACHMENTS 5.4 Crop Delivery Kits Optional crop delivery kits can optimize header performance for specific crops or conditions. 5.4.1 Rice Divider Rods Rice divider rods attach to the left and right crop dividers and divide tall and tangled rice crops in a similar manner to standard crop divider rods performing in standing crops.
Page 264: Double Windrow Attachment
OPTIONS AND ATTACHMENTS 5.4.3 Double Windrow Attachment The Double Windrow Attachment (DWA) can be attached to an M Series Self-Propelled Windrower to enable double- windrowing with a hay conditioner. The DWA lays up to 18.3 m (60 ft.) of crop in a single windrow which is ideal for large forage harvesters.
Page 265: Hc10 Hay Conditioner
MD #C1982 NOTE: Not for use on D50 Draper Headers or M205 SP Windrowers. Figure 5.14: Hay Conditioner 5.4.7 Hydraulic Deck Shift Package This system allows shifting of the decks from the operator’s console when double-windrowing.
Page 266 OPTIONS AND ATTACHMENTS NOTE: Newer UCA kits do not include or use beater bars; they use bolt- on flighting instead. Figure 5.16: Upper Cross Auger with Bolt-On Flighting 169441 Revision D...
Page 267: Chapter 6: Troubleshooting
Replace with standard torque page 215 (6 mph) with high torque (10-tooth) (19-tooth) reel drive sprocket reel drive sprocket • See your MacDon Dealer Worn or broken knife components Replace knife components 4.7 Cutterbar, page 140 Symptom: Strips of Uncut Material Allow enough room for crop to be fed —...
Page 268 Replace three or four end guards with preventing proper feeding due to stub guards • See your MacDon Dealer material bridging the knife guards Symptom: Material Accumulating in Gap between Cutout in Endsheet and Knifehead Crop heads leaning away from Add knifehead shield(s), except in 3.17 Knifehead Shield, page 88...
Page 269: Cutting Action And Knife Components
• 4.7.7 Knife Guards, page 145 Tangled / tough to cut crop Install stub guards • See your MacDon Dealer 3.12.9 Reel Fore-Aft Position, page 55 Reel too far back Move reel forward •...
Page 270: Adjusting
Mud or dirt build up on cutterbar Raise cutterbar by lowering skid shoes Cutting on Ground, page 46 Mud or dirt build up on cutterbar See your MacDon Dealer Install cut-out sections Mud or dirt build up on cutterbar Flatten header angle...
Page 271: Reel Delivery
Reel speed too fast Reduce reel speed 3.12.4 Reel Speed, page 49 Crop conditions Install optional endshields See your MacDon Dealer 4.10.3 Centering Reel, page 201 Reel not centered in header Center reel in header Symptom: Reel Releases Crop too Quickly...
Page 272 TROUBLESHOOTING Problem Solution Refer to Optional Reel Drive Sprockets – D60, Cutting tough crops with standard Replace with high torque (10-tooth) or torque (19-tooth) reel drive sprocket page 50 14-tooth reel drive sprocket Symptom: Plastic Fingers Cut at Tip 4.10.1 Reel Clearance to Cutterbar, Insufficient reel to cutterbar clearance Increase clearance page 197...
Page 273: Header And Drapers
248 Material not feeding evenly off knife Install stub guards • 4.7.7 Knife Guards, page 145 • See your MacDon Dealer Symptom: Hesitation in Flow of Bulky Crop Header angle too low Increase header angle Controlling Header Angle, page 49...
Page 274 TROUBLESHOOTING Problem Solution Refer to Symptom: Material Wrapping at Upper Cross Auger Beater Bars NOTE: Some newer upper cross augers do not have beater bars. Crop conditions do not require 3.20.1 Removing Beater Bars, page 92 Remove beater bars beater bars Symptom: Material Accumulating on End Deflectors and Releasing in Bunches For headers with manual deck shift 3.19 Unplugging Cutterbar, page 91...
Page 275: Cutting Edible Beans
Cutting on Ground, page 46 Skid shoes too low Dirt packs on bottom of cutterbar and Install plastic wear strips on bottom of See your MacDon Dealer raises cutterbar off the ground cutterbar and skid shoes Dirt packing on bottom of cutterbar —...
Page 276 TROUBLESHOOTING Problem Solution Refer to Symptom: Excessive Losses at Dividers Divider rod running down crop and 3.12.12 Crop Divider Rods, page 73 Remove divider rods shattering pods Vines and plants build up on endsheet 3.12.12 Crop Divider Rods, page 73 Install divider rods Plant Vines Pinched between Top of Draper and Cutterbar Cutterbar has filled up with trash with...
Page 277 TROUBLESHOOTING Problem Solution Refer to Raise header fully at each end of field Excessive gap between top of front of — or as required and shift decks back draper and cutterbar and forth to help clean out cutterbar Symptom: Reel Carries Over Odd Plants in Same Location Reel steel fingers bent and hook —...
Page 278: Windrow Formation
TROUBLESHOOTING 6.6 Windrow Formation Use the following tables to determine the cause of any windrow formation problems and the recommended solutions. Problem Solution Refer to Symptom: Heads on Ground and Scattered Draper speed too slow Increase draper speed 3.12.6 Draper Speed, page 51 Draper angle too flat Increase header angle Controlling Header Angle, page 49...
Page 279: Chapter 7: Reference
Chapter 7: Reference This chapter provides quick access to frequently needed information or numbers (for example, units of measurement or torque values). 7.1 Conversion Chart Both SI units (including metric) and US customary units (sometimes referred to as standard units) of measurement are used in this manual.
Page 280: Torque Specifications
REFERENCE 7.2 Torque Specifications The following tables provide torque values for various bolts, cap screws, and hydraulic fittings. Refer to these values only when no other torque value has been specified in a given procedure. • Tighten all bolts to the torque values specified in the charts below, unless you are directed otherwise in this manual. •...
Page 281 REFERENCE Table 7.3 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 282: Metric Bolt Specifications - Cast Aluminum
REFERENCE Table 7.5 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 14-2.0 Figure 7.4: Bolt Grades 16-2.0 20-2.5 24-3.0...
Page 283: O-Ring Boss Hydraulic Fittings - Adjustable
REFERENCE 7.2.3 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, refer to the value specified in the procedure instead. 1.
Page 284: O-Ring Boss Hydraulic Fittings - Non-Adjustable
REFERENCE Table 7.7 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 285: O-Ring Face Seal Hydraulic Fittings
REFERENCE Table 7.8 O-Ring Boss (ORB) Hydraulic Fittings – Non-Adjustable (continued) Torque Value Thread Size (in.) SAE Dash Size lbf·ft (*lbf·in) 7/8–14 75–82 55–60 1 1/16–12 120–132 88–97 1 3/8–12 153–168 113–124 1 5/16–12 176–193 130–142 1 5/8–12 221–243 163–179 1 7/8–12 270–298 199–220...
Page 286: Tapered Pipe Thread Fittings
REFERENCE 6. Use three wrenches when assembling unions or joining two hoses together. 7. Verify the final condition of the fitting. Table 7.9 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value Thread Size (in.) Tube O.D. (in.) SAE Dash Size lbf·ft –...
Page 287 REFERENCE Table 7.10 Hydraulic Fitting Pipe Thread Tapered Pipe Thread Size Recommended TFFT Recommended FFFT 2–3 12–18 1/8–27 2–3 12–18 1/4–18 2–3 12–18 3/8–18 2–3 12–18 1/2–14 1.5–2.5 12–18 3/4–14 1.5–2.5 9–15 1–11 1/2 1.5–2.5 9–15 1 1/4–11 1/2 1.5–2.5 9–15 1 1/2–11 1/2 1.5–2.5...
Page 288: Unloading And Assembly
The instruction part numbers are shown in the following table: MacDon Instruction Shipping Destination Header Description Part Number D50 and D60 Draper Header for North America MD #169007 Self-Propelled Windrowers Export (anywhere other than D50 and D60 Draper Header for...
Page 289: Index
Index crop dividers............68 installing on header with latch option ..... 70 adjustable skid shoes with poly covers ..... 249 installing on header without latch option ....71 removing from header with latch option ....68 definition............19 removing from header without latch option..... 69 ASTM cutterbars definition............
Page 290 INDEX installing ............193 See also lubrication and servicing removing............191 greasing procedure..........128 installing endless drapers ........186 ground speeds ............50 removing endless draper guards removing............184 knife guards ............. 145 removing split drapers ........182 replacing pointed guards......... 146 side draper rollers replacing stub guards ........
Page 291 INDEX checking hold-downs ........151 stub guard idler rollers adjusting hold-downs ........155 drapers stub knife guard installing ............193 checking hold-downs ........152 removing............191 installing knife ..........143 inspections knife sections break-in............241 replacing ............140 knifehead bearings definition............
Page 292 INDEX reel safety props ..........36 disengaging ............ 37 N-DETENT engaging ............36 definition............19 PR15 pick-up reel centering ............201 definition............19 PR15 pick-up reels drive chains definition............19 replacing chain double-reel drive........213 definition............19 fore-aft position repositioning cylinder double reel..........
Page 293 INDEX fore-aft position..........55 general safety............3 adjusting ........... 55–56 header safety props..........35 frown.............. 200 hydraulic safety ............7 adjusting ............200 maintenance safety ..........5 height ............... 54 operational ............24 plastic fingers reel safety props ..........36 installing ............228 safety alert symbols..........1 removing............
Page 294 INDEX stabilizer/slow speed transport wheels axle bolt torque ..........239 adjusting ............43 tire inflation/pressures........240 start-up tow-bars daily checks............32 attaching ............108 steel tines storing ............98 installing............226 wheel bolt torque ..........238 removing ............225 transporting on windrower ........95 stubble height troubleshooting ...........
Page 295 INDEX topsoil moisture..........83 types ..............80 weather and topography ........83 definition............19...
Page 297: Recommended Fluids And Lubricants
Recommended Fluids and Lubricants Ensure your machine operates at top efficiency by using clean fluids and lubricants only. • Use clean containers to handle all fluids and lubricants. • Store fluids and lubricants in an area protected from dust, moisture, and other contaminants. Lubricant Specification Description...
Page 298 CUSTOMERS M M a a c c D D o o n n . . c c o o m m DEALERS P P o o r r t t a a l l . . M M a a c c D D o o n n . . c c o o m m Trademarks of products are the marks of their respective manufacturers and/or distributors.

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D60

MacDon D50 Operator's Manual

Section 1

Chapter 1: Safety

Chapter 2: Product Overview

Chapter 3: Operation

Chapter 4: Maintenance and Servicing

Chapter 5: Options and Attachments

Chapter 6: Troubleshooting

Chapter 7: Reference

Section 2

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Summary of Contents for MacDon D50