MacDon D1 Series User manual

D1 Series
Draper Header for M Series
Windrowers
Unloading and Assembly Instructions (North America)
214464 Revision A
2018 Model Year
Original Instruction
The harvesting specialists.

D1 Series Draper Header for M Series Self-Propelled Windrowers
1025150
Published: March 2018

Introduction
This instruction manual describes the unloading, setup, and predelivery requirements for the MacDon D1 Series
Draper Header for M Series Self-Propelled Windrowers.
To ensure the best performance of this product and the safety of your customers, carefully follow the unload and
assembly procedure from the beginning through to completion.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Retain this instruction for future reference.
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 available in English.
214464 iRevision A

214464 iii Revision A
Introduction................................................................................................................................................i
Chapter 1: Safety .................................................................................................................................... 1
1.1 Signal Words .......................................................................................................................................1
1.2 General Safety.....................................................................................................................................2
1.3 Safety Signs ........................................................................................................................................4
Chapter 2: Unloading............................................................................................................................. 5
2.1 Unloading Header from Trailer ..............................................................................................................5
2.2 Lowering Header .................................................................................................................................7
2.2.1 Lowering Single-Reel Header.......................................................................................................7
2.2.2 Lowering Double-Reel Header .....................................................................................................9
2.3 Removing Shipping Supports..............................................................................................................13
Chapter 3: Assembling the Header .................................................................................................. 17
3.1 Attaching Reel Lift Cylinders ...............................................................................................................17
3.2 Attaching Cam Arms ..........................................................................................................................25
3.3 Opening Endshields ...........................................................................................................................26
3.4 Installing Crop Dividers.......................................................................................................................27
3.5 Closing Endshields ............................................................................................................................29
3.6 Positioning Transport Lights................................................................................................................30
3.7 Installing Disc Segments of Outboard Reel Endshields .........................................................................31
3.8 Installing Options ...............................................................................................................................32
Chapter 4: Attaching Header to Windrower ................................................................................... 33
4.1 Connecting Center-Link......................................................................................................................35
4.1.1 Mechanical Link ........................................................................................................................35
4.1.2 Hydraulic Link without Self-Alignment Kit ....................................................................................37
4.1.3 Hydraulic Link with Optional Self-Alignment Kit ............................................................................40
4.2 Connecting Hydraulics .......................................................................................................................42
4.3 Adding Tire Ballast .............................................................................................................................46
Chapter 5: Performing Predelivery Checks ................................................................................... 47
5.1 Checking Tire Pressure: Transport and Stabilizer Wheels .....................................................................47
5.2 Checking Wheel Bolt Torque ...............................................................................................................48
5.3 Checking Knife Drive Box ...................................................................................................................49
5.4 Checking and Adjusting Knife Drive Belt Tension..................................................................................51
5.4.1 Checking and Tensioning Non-Timed Knife Drive Belts ................................................................51
5.4.2 Checking and Tensioning Timed Knife Drive Belts........................................................................52
5.4.3 Tensioning Timed Knife Drive V-Belts..........................................................................................53
5.5 Centering the Reel .............................................................................................................................54
5.5.1 Centering Double Reels.............................................................................................................54
TABLE OF CONTENTS

214464 iv Revision A
5.5.2 Centering Single Reel................................................................................................................55
5.6 Adjusting Draper Tension....................................................................................................................56
5.7 Checking and Adjusting Draper Seal ...................................................................................................58
5.8 Checking and Adjusting Skid Shoe Settings .........................................................................................59
5.9 Leveling the Header ...........................................................................................................................60
5.10 Measuring and Adjusting Reel Clearance to Cutterbar ........................................................................61
5.10.1 Measuring Reel Clearance.......................................................................................................61
5.10.2 Adjusting Reel Clearance.........................................................................................................63
5.11 Checking and Adjusting Endshields ...................................................................................................64
5.12 Lubricating the Header .....................................................................................................................68
5.12.1 Greasing Procedure ................................................................................................................68
5.12.2 Lubrication Points....................................................................................................................69
5.13 Checking Manuals............................................................................................................................70
Chapter 6: Running up the Header................................................................................................... 71
6.1 Performing Post Run-Up Adjustments .................................................................................................71
6.1.1 Adjusting Knife..........................................................................................................................71
Chapter 7: Reference ........................................................................................................................... 73
7.1 Torque Specifications .........................................................................................................................73
7.1.1 Metric Bolt Specifications ...........................................................................................................73
7.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ..................................................................75
7.1.3 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) ......................................................................76
7.1.4 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable)...............................................................78
7.1.5 O-Ring Face Seal (ORFS) Hydraulic Fittings ...............................................................................79
7.1.6 Tapered Pipe Thread Fittings .....................................................................................................80
7.2 Lifting Equipment Requirements .........................................................................................................81
7.3 Conversion Chart...............................................................................................................................82
7.4 Definitions .........................................................................................................................................83
Predelivery Checklist........................................................................................................................... 85
TABLE OF CONTENTS

214464 1Revision A
1 Safety
1.1 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. 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.

214464 2Revision A
1.2 General Safety
1000004
Figure 1.1: Safety Equipment
CAUTION
The following are general farm safety precautions that
should be part of your operating procedure for all types
of machinery.
Protect yourself.
•When assembling, operating, and servicing machinery,
wear all protective clothing and personal safety devices
that could be necessary for 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
1000005
Figure 1.2: Safety Equipment
•Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection
devices such as earmuffs or earplugs to help protect
against loud noises.
1010391
Figure 1.3: Safety Equipment
•Provide a first aid kit for use in case of emergencies.
•Keep a fire extinguisher on the machine. Be sure fire
extinguisher is properly maintained. Be familiar with its
proper use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when Operator is
tired or in a hurry. Take time to consider safest way.
Never ignore warning signs of fatigue.
SAFETY

214464 3Revision A
1000007
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. Make sure driveline guards can rotate
independently of shaft and can telescope freely.
•Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.
1000008
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 engine is running.
•Do NOT modify machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten machine’s life.
•To avoid bodily injury or death from unexpected startup of
machine, ALWAYS stop the engine and remove the key
from the ignition before leaving the operator’s seat for
any reason.
1000009
Figure 1.6: Safety around Equipment
•Keep service area clean and dry. Wet or oily floors are
slippery. Wet spots can be dangerous when working with
electrical equipment. Be sure all electrical outlets and
tools are properly grounded.
•Keep work area well lit.
•Keep machinery clean. Straw and chaff on a hot engine is
a fire hazard. Do NOT allow oil or grease to accumulate
on service platforms, ladders, or controls. Clean
machines before storage.
•NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
•When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
SAFETY

214464 4Revision A
1.3 Safety Signs
1000694
Figure 1.7: Operator’s Manual Decal
•Keep safety signs clean and legible at all times.
•Replace safety signs that are missing or become illegible.
•If original part on which a safety sign was installed is
replaced, be sure repair part also bears current
safety sign.
•Safety signs are available from your MacDon Dealer.
SAFETY

214464 5Revision A
2 Unloading
Perform all procedures in this chapter in the order they are listed.
2.1 Unloading Header from Trailer
The following procedure assumes that two headers were shipped on the trailer.
CAUTION
To avoid injury to bystanders from being struck by machinery, do not allow people to stand in
unloading area.
CAUTION
Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate
equipment may result in chain breakage, vehicle tipping, or machine damage.
IMPORTANT:
Forklifts are normally rated with the load centered 610 mm (24 in.) from the back end of forks. To obtain forklift
capacity for a load centered at 1220 mm (48 in.), check with your forklift distributor.
1013855
A
B
C
Figure 2.1: Minimum Lifting Capacity
A - Load Center of Gravity
B - Load Center 1220 mm (48 in.) from Back of Forks
C - Minimum Fork Length 1981 mm (78 in.)
Table 2.1 Lifting Vehicle
Minimum Lifting
Capacity
3178 kg (7000 lb.) load
center (A) at 1220 mm
(48 in.) (B) from back of forks
Minimum Fork
Length (C) 1981 mm (78 in.)
To unload headers from a trailer, follow these steps:
1. Move trailer into position and block trailer wheels.
2. Lower trailer storage stands.

214464 6Revision A
1008902
A
B
C
Figure 2.2: Header Shipping Supports
3. Approach one of the headers and slide forks (A)
underneath the shipping support (B) as far as possible
without contacting the shipping support of second
header (C).
IMPORTANT:
Avoid lifting the second header and ensure the forks do
not interfere with the shipping frame. If the forks contact
the second header, the header could be damaged.
4. Remove hauler’s tie-down straps, chains, and wooden
blocks.
5. Slowly raise header off trailer deck.
WARNING
Be sure forks are secure before moving away from load.
Stand clear when lifting.
6. Back up until header clears trailer and slowly lower to
150 mm (6 in.) from ground.
7. Take header to the storage or setup area. Ensure
ground is flat and free of rocks or debris that could
damage the header.
8. Repeat above steps for second header.
9. Check for shipping damage and missing parts.
UNLOADING

214464 7Revision A
2.2 Lowering Header
The procedure for lowering the header varies depending on whether the header has a single or double reel. Refer
to the following:
•2.2.1 Lowering Single-Reel Header, page 7
•2.2.2 Lowering Double-Reel Header, page 9
2.2.1 Lowering Single-Reel Header
Reposition header in preparation for assembly and setup as follows:
1008905
A
B
Figure 2.3: Shipping Frame
1. Choose an area with level ground.
2. Approach header from its underside and place forks
under top of shipping frame (A).
3. Attach a chain (B) at each end of the shipping frame
and secure other end to lifting vehicle.
UNLOADING

214464 8Revision A
1008906
1
2
3
4
Figure 2.4: Lowering the Header
CAUTION
Stand clear when lowering, as machine may swing.
4. Back up SLOWLY while lowering forks until header is
just above the ground. Refer to the four positions in the
illustration.
UNLOADING

214464 9Revision A
1006363
A
Figure 2.5: Block under Cutterbar
5. Place 150 mm (6 in.) blocks (A) under each end and
center of cutterbar, and then lower header onto blocks.
6. Remove chain and move lifting vehicle to rear of
header.
7. Attach chain to center-link anchor on frame tube and
raise rear of header so that stand can be lowered.
1008297
A
B
Figure 2.6: Header Stand
8. Lower header stand by pulling pin (A), lowering
stand (B), and releasing pin (A) to secure stand
in place.
9. If ground is soft, place a block under the stand.
10. Lower header onto stand.
2.2.2 Lowering Double-Reel Header
Reposition header in preparation for assembly and setup as follows:
1016592
Figure 2.7: Underside of Header
1. Choose an area with level ground.
2. Drive lifting vehicle to approach header from its
underside.
UNLOADING

214464 10 Revision A
1016590
A
Figure 2.8: Shipping Support
3. Attach a chain to shipping support (A) at center
reel arm.
IMPORTANT:
Do NOT lift header at this location. This procedure is
only for laying the machine over into working position.
CAUTION
Stand clear when lowering, as machine may swing.
UNLOADING

214464 11 Revision A
1008121
1
2
3
4
Figure 2.9: Lowering the Header
4. Back up SLOWLY while lowering forks until header is
just above the ground. Refer to the four positions in the
illustration.
UNLOADING

214464 12 Revision A
1006363
A
Figure 2.10: Block under Cutterbar
5. Place 150 mm (6 in.) blocks (A) under each end and
center of cutterbar, and then lower header onto blocks.
6. Remove chain and move lifting vehicle to rear of
header.
7. Attach chain to center-link anchor on frame tube and
raise rear of header so that stand can be lowered.
1008297
A
B
Figure 2.11: Header Stand
8. Lower the header stand: pull pin (A), lower stand (B),
and release pin (A) to secure stand in place.
9. If ground is soft, place a block under the stand.
10. Lower header onto stand.
11. Remove chain.
UNLOADING

214464 13 Revision A
2.3 Removing Shipping Supports
NOTE:
Unless otherwise specified, discard all shipping materials and hardware.
1016847
A
Figure 2.12: Draper Header Supports, and
Shipping Supports
1. Cut straps and remove draper header supports (A) from
shipping support. Set draper header supports aside for
installation.
1008913
A
Figure 2.13: Single Reel
2. Single reel only: Cut banding (A) securing reel to
cutterbar and backtube.
1016591
A
B
Figure 2.14: Upper Support
3. Remove four bolts (A) securing upper support (B) to
header legs and remove support.
UNLOADING

214464 14 Revision A
1016855
AB
A
Figure 2.15: Lower Support
4. Remove six bolts (A) securing lower support (B) to
header legs and remove support.
1016583
A
Figure 2.16: Outer Leg Shipping Supports
5. Remove the four bolts (A) from the shipping stands at
both outboard header legs and remove the shipping
stands.
1008914
A
Figure 2.17: Anti-Rotation Brace
6. Remove reel anti-rotation brace (A) from between reel
and endsheet.
UNLOADING