MacDon D1 Series User manual

D1 Series
Draper Header for M Series Windrowers
Unloading and Assembly Instructions (North America)
215649 Revision A
Original Instruction
The Harvesting Specialists.

D1 Series Draper Header for M Series Windrowers
Published September 2021.
© 2021 MacDon Industries, Ltd.
The information in this publication is based on the information available and in effect at the time of printing. MacDon
Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the
information in this publication. MacDon Industries, Ltd. reserves the right to make changes at any time without notice.

Introduction
This manual contains unloading, assembly, and predelivery information for the MacDon D1 Series Draper Header for
M Series Self-Propelled Windrowers.
To ensure the best performance of this product and the safety of your customers, carefully follow this unloading and
assembly procedure.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Retain this instruction for future reference.
Conventions
The following conventions are used in this document:
•Right and left are determined from the operator’s position. The front of the header faces the crop.
•Unless otherwise noted, use the standard torque values provided in this manual.
NOTE:
Keep your MacDon publications up-to-date. The latest version can be downloaded from our website (www.macdon.com)or
from our Dealer portal (https://portal.macdon.com) (login required).
This document is currently available in English only.
215649 iRevision A

Summary of Changes
At MacDon, we’re continuously making improvements: occasionally these improvements affect product documentation.
The following list provides an account of major changes from the previous version of this document.
Section Summary of Change Internal Use
Only
Introduction, page i Added damaged/missing parts statement. Technical
Publications
4.3 Adding Tire
Ballast, page 49
Clarified considerations to take into account when adding ballast fluid to the
windrower’s caster tires.
Technical
Publications
5.1 Checking Tire
Pressure –Transport
and Stabilizer
Wheels, page 51
Revised pressure recommendations, added safety note, revised hazard
statement.
Product
Engineering
5.5.1 Checking and
Tensioning Single
and Untimed
Double-Knife Drive
Belts, page 58
Added endshield opening and closing steps. Technical
Publications
5.5.2 Checking and
Tensioning Timed
Double-Knife Drive
Belts, page 60
Added endshield opening and closing steps. Technical
Publications
5.8 Checking and
Adjusting Draper
Seal, page 70
Procedure now instructs the reader to repeat the height adjustment steps for
each deck support. Added reel safety prop engage and disengage steps.
Technical
Publications
5.12.2 Adjusting Reel
Clearance, page 80
Added distinct procedures for single reel and double reel headers. Added
steps for engaging and disengaging the reel safety props.
Technical
Publications
5.14 Checking
Manuals, page 86
Added endshield opening and closing steps. Technical
Publications
5.13 Checking
Grease Points, page
83
Replaced greasing procedure. Technical
Publications
6.1.1 Adjusting
Knife, page 89
Added specification for the gap between the knifehead and the pitman arm. Technical
Publications
Predelivery Checklist,
page 103
Added instruction to check for quick cards. Clarified procedure. Technical
Publications
215649 ii Revision A

215649 iii Revision A
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Signal Words .........................................................................................................................................1
1.2 General Safety .......................................................................................................................................2
1.3 Welding Precaution ................................................................................................................................4
1.4 Safety Signs ...........................................................................................................................................5
Chapter 2: Unloading Header..................................................................................................................... 7
2.1 Unloading Header from Trailer..................................................................................................................7
2.2 Lowering Header to Field Position .............................................................................................................9
2.2.1 Lowering Single-Reel Header............................................................................................................9
2.2.2 Lowering Double-Reel Header ........................................................................................................ 12
2.3 Removing Shipping Supports .................................................................................................................. 16
Chapter 3: Assembling Header................................................................................................................. 19
3.1 Attaching Reel-Lift Cylinders ................................................................................................................... 19
3.2 Positioning Transport Lights ................................................................................................................... 27
3.3 Attaching Cam Arms ............................................................................................................................. 29
3.4 Installing Crop Dividers .......................................................................................................................... 31
3.5 Installing Disc Segments of Outboard Reel Endshields ................................................................................. 33
3.6 Installing Options ................................................................................................................................. 34
Chapter 4: Attaching Header to Windrower ........................................................................................... 35
4.1 Connecting Center-Link.......................................................................................................................... 37
4.1.1 Mechanical Link........................................................................................................................... 37
4.1.2 Hydraulic Link without Self-Alignment Kit ......................................................................................... 39
4.1.3 Hydraulic Link with Self-Alignment Kit.............................................................................................. 42
4.2 Connecting Hydraulics ........................................................................................................................... 45
4.3 Adding Tire Ballast................................................................................................................................ 49
Chapter 5: Performing Predelivery Checks.............................................................................................. 51
5.1 Checking Tire Pressure –Transport and Stabilizer Wheels............................................................................ 51
5.2 Checking Wheel Bolt Torque –Transport and Stabilizer Wheels .................................................................... 52
5.3 Checking and Adjusting Endshields .......................................................................................................... 53
5.4 Checking Knife Drive Box ....................................................................................................................... 57
5.5 Checking and Adjusting Knife Drive Belt Tension ........................................................................................ 58
5.5.1 Checking and Tensioning Single and Untimed Double-Knife Drive Belts.................................................. 58
5.5.2 Checking and Tensioning Timed Double-Knife Drive Belts.................................................................... 60
5.5.3 Tensioning Timed Knife Drive V-Belts............................................................................................... 64
5.6 Centering Reel ..................................................................................................................................... 65
5.6.1 Centering Double Reel .................................................................................................................. 65
TABLE OF CONTENTS

215649 iv Revision A
5.6.2 Centering Single Reel.................................................................................................................... 66
5.7 Checking and Adjusting Draper Tension.................................................................................................... 68
5.8 Checking and Adjusting Draper Seal ......................................................................................................... 70
5.9 Checking and Adjusting Skid Shoe Settings ................................................................................................ 75
5.10 Leveling Header.................................................................................................................................. 76
5.11 Checking and Adjusting Float ................................................................................................................ 77
5.12 Reel to Cutterbar Clearance ................................................................................................................. 78
5.12.1 Measuring Reel Clearance............................................................................................................ 78
5.12.2 Adjusting Reel Clearance ............................................................................................................. 80
5.13 Checking Grease Points........................................................................................................................ 83
5.14 Checking Manuals............................................................................................................................... 86
Chapter 6: Running up Header................................................................................................................. 89
6.1 Performing Post Run-Up Adjustments ...................................................................................................... 89
6.1.1 Adjusting Knife ............................................................................................................................ 89
Chapter 7: Reference ................................................................................................................................ 91
7.1 Torque Specifications ............................................................................................................................ 91
7.1.1 Metric Bolt Specifications .............................................................................................................. 91
7.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ........................................................................ 93
7.1.3 O-Ring Boss Hydraulic Fittings –Adjustable ...................................................................................... 94
7.1.4 O-Ring Boss Hydraulic Fittings –Non-Adjustable................................................................................ 96
7.1.5 O-Ring Face Seal Hydraulic Fittings.................................................................................................. 96
7.1.6 Tapered Pipe Thread Fittings.......................................................................................................... 98
7.2 Header Specifications for Unloading and Assembly..................................................................................... 99
7.3 Conversion Chart................................................................................................................................ 100
7.4 Definitions ........................................................................................................................................ 101
Predelivery Checklist .............................................................................................................................. 103
TABLE OF CONTENTS

215649 1Revision A
Chapter 1: Safety
Understanding and following safety procedures consistently will help to ensure the safety of machine operators and
bystanders.
1.1 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words,
IMPORTANT and NOTE, identify non-safety related information.
Signal words are selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be
used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may be used
to alert against unsafe practices.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.

215649 2Revision A
1.2 General Safety
Protect yourself when assembling, operating, and servicing machinery.
Figure 1.1: Safety Equipment
CAUTION
The following general farm safety precautions should be part of
your operating procedure for all types of machinery.
Wear all protective clothing and personal safety devices that
could be necessary for the job at hand. Do NOT take chances.
You may need the following:
•Hard hat
•Protective footwear with slip-resistant soles
•Protective glasses or goggles
•Heavy gloves
•Wet weather gear
•Respirator or filter mask
Figure 1.2: Safety Equipment
In addition, take the following precautions:
•Be aware that exposure to loud noises can cause hearing
impairment. Wear suitable hearing protection devices such as
earmuffs or earplugs to help protect against loud noises.
Figure 1.3: Safety Equipment
•Provide a first aid kit in case of emergencies.
•Keep a properly maintained fire extinguisher on the
machine. Familiarize yourself with its use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when Operators are
fatigued or in a hurry. Take time to consider the safest way
to accomplish a task. NEVER ignore the signs of fatigue.
SAFETY

215649 3Revision A
Figure 1.4: Safety around Equipment
•Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as scarves or bracelets.
•Keep all shields in place. NEVER alter or remove safety
equipment. Ensure that the driveline guards can rotate
independently of their shaft, and that they can telescope
freely.
•Use only service and repair parts made or approved by the
equipment manufacturer. Parts from other manufacturers
may not meet the correct strength, design, or safety
requirements.
Figure 1.5: Safety around Equipment
•Keep hands, feet, clothing, and hair away from moving
parts. NEVER attempt to clear obstructions or objects from a
machine while the engine is running.
•Do NOT modify the machine. Unauthorized modifications
may impair the functionality and/or safety of the machine. It
may also shorten the machine’s service life.
•To avoid injury or death from the unexpected startup of the
machine, ALWAYS stop the engine and remove the key from
the ignition before leaving the operator’s seat for any
reason.
Figure 1.6: Safety around Equipment
•Keep the machine service area clean and dry. Wet and/or
oily floors are slippery. Wet spots can be dangerous when
working with electrical equipment. Ensure that all electrical
outlets and tools are properly grounded.
•Keep the work area well-lit.
•Keep machinery clean. Straw and chaff on a hot engine are
fire hazards. Do NOT allow oil or grease to accumulate on
service platforms, ladders, or controls. Clean machines
before they are stored.
•NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
•When storing machinery, cover any sharp or extending
components to prevent injury from accidental contact.
SAFETY

215649 4Revision A
1.3 Welding Precaution
To prevent damage to sensitive electronics, welding should never be attempted on the header while it is connected to a
windrower.
WARNING
Severe damage to sensitive, expensive electronics can result from welding on the header while it is connected to the
windrower. It can be impossible to know what effect high current could have with regard to future malfunctions or
shorter lifespan. It is very important that welding on the header is not attempted while the header is connected to the
windrower.
If it is unfeasible to disconnect the header from the windrower before welding, refer to the windrower’s technical manual
for welding precautions detailing all electrical components that must be disconnected first for safe welding.
SAFETY

215649 5Revision A
1.4 Safety Signs
Safety signs are decals placed on the machine where there is a risk of personal injury, or where the Operator should take
extra precautions before operating the controls. They are usually yellow.
Figure 1.7: Operator’s Manual Decal
•Keep safety signs clean and legible at all times.
•Replace safety signs that are missing or illegible.
•If the original part on which a safety sign was installed is
replaced, ensure that the repair part displays the current
safety sign.
SAFETY


215649 7Revision A
Chapter 2: Unloading Header
Unload all header parts before beginning assembly. Carefully follow these procedures in the order in which they are
presented.
2.1 Unloading Header from Trailer
Ensure that you use a forklift which meets the minimum length and capacity requirements when unloading the header.
DANGER
To prevent injury to bystanders caused by being struck by machinery, do NOT allow people to stand in the
unloading area.
DANGER
The equipment used for loading or unloading a header must meet or exceed the requirements specified in this
document. Using inadequate equipment may result in chain breakage, vehicle tipping, machine damage or bodily harm
to operators or bystanders.
IMPORTANT:
For lifting equipment requirements, refer to 7.2 Header Specifications for Unloading and Assembly, page 99.
1. Move the trailer into position and block the trailer wheels.
2. Lower the trailer storage stands.
$%
&
%
$
$
%
Figure 2.1: Header Shipping Supports
3. Approach the header and slide forks (A) through four
forklift brackets (B) underneath the shipping support. Insert
the forks as far as possible without contacting the shipping
support of second header (C).
IMPORTANT:
Avoid lifting the second header. Ensure that the forks do
not interfere with the shipping frame.
4. Take the header to the storage or setup area. Ensure that the ground is flat and free of rocks or debris that could
damage the header.
5. Lower the header to the ground.

215649 9Revision A
2.2 Lowering Header to Field Position
The procedure for lowering the header differs depending on whether the header has a single or double reel.
To lower the header, follow the relevant procedure:
•Single-reel headers: refer to 2.2.1 Lowering Single-Reel Header, page 9.
•Double-reel headers: refer to 2.2.2 Lowering Double-Reel Header, page 12.
2.2.1 Lowering Single-Reel Header
Lower the header to the field position to prepare it for assembly and setup.
IMPORTANT:
For information on lifting equipment requirements, refer to 7.2 Header Specifications for Unloading and Assembly, page
99.
$
%
Figure 2.2: Shipping Frame
1. Approach the header from its underside and place the
forklift forks under the top bar of shipping frame (A).
2. Attach chain (B) at each end of the shipping frame and
secure the other end of the chain to the lifting vehicle.
UNLOADING HEADER

215649 10 Revision A
Figure 2.3: Lowering the Header
CAUTION
Stand clear when lowering the header; the machine may sway
from side to side.
3. Back the forklift up SLOWLY while lowering the forks until
the header is just above the ground, as shown in the
numbered steps in the illustration.
UNLOADING HEADER

215649 11 Revision A
$
Figure 2.4: Block under Cutterbar
4. Place 150 mm (6 in.) blocks (A) under each end and at the
center of the cutterbar, then lower the header onto
the blocks.
5. Remove the chain and move the lifting vehicle to the rear
of the header.
$
Figure 2.5: Center-link Anchor –Single-Reel
6. Attach the chain to center-link anchor (A) on the frame
tube and raise the rear of the header so that the stand can
be lowered.
UNLOADING HEADER

215649 12 Revision A
$
%
Figure 2.6: Header Stand
7. To lower the header stand: pull pin (A), gently lower
stand (B) to the desired height, and then release pin (A)
again to lock the stand at that height.
NOTE:
If the ground is soft, place a block under the stand.
8. Lower the forklift forks so that the weight of the header is
supported by the stand.
9. Remove the chain.
2.2.2 Lowering Double-Reel Header
Lower the header to the field position to prepare it for assembly and setup.
IMPORTANT:
For information on the lifting equipment requirements, refer to 7.2 Header Specifications for Unloading and Assembly,
page 99.
Figure 2.7: Underside of Header
1. Orient the forklift so that you are approaching the header
from its underside.
$
Figure 2.8: Shipping Support
2. Attach a chain to shipping support (A) at the center
reel arm.
IMPORTANT:
Do NOT lift the header at this location. The purpose of this
procedure is to lay the header into its working position.
NOTE:
The right reel has been removed for the sake of clarity.
UNLOADING HEADER

215649 13 Revision A
Figure 2.9: Lowering the Header
CAUTION
Stand clear when lowering the header; the machine may sway
from side to side.
3. Back the forklift up SLOWLY while lowering the forks until
the header is just above the ground, as shown in the
numbered steps in the illustration.
UNLOADING HEADER

215649 14 Revision A
$
Figure 2.10: Block under Cutterbar
4. Place 150 mm (6 in.) blocks (A) under each end of the
header, and one block at the center of the cutterbar. Lower
the header onto the blocks.
5. Remove the chain and move the forklift to the rear of the
header.
$
Figure 2.11: Center-Link Anchor –Double-Reel
6. Attach the chain to center-link anchor (A) on the frame
tube and raise the rear of the header so that the stand can
be lowered.
UNLOADING HEADER
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