MacDon D50 User manual

Form # 169007 Model Year - 2009
Model D50 & D60 Harvest Header
®
for Self-Propelled Windrowers
UNLOADING &
ASSEMBLY INSTRUCTIONS
for
NORTH AMERICAN SHIPMENTS

Form # 169007 Model Year - 2009
D60 HARVEST HEADER®
D50 HARVEST HEADER®

Form # 169007 Model Year - 2009
1
INTRODUCTION
This instruction describes the unloading, set-up and pre-delivery requirements for the MacDon D50 and D60
Harvest Headers for MacDon M Series Self-Propelled Windrowers. Use the table of contents to guide you to
specific areas. Retain this instruction for future reference.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE,
OR USE THE MACHINE.
TABLE OF CONTENTS
INTRODUCTION........................................................................................................................................................ 1
GENERAL SAFETY ................................................................................................................................................... 2
RECOMMENDED TORQUES ................................................................................................................................... 4
A. GENERAL.................................................................................................................................................. 4
B. SAE BOLTS ............................................................................................................................................... 4
C. METRIC BOLTS ........................................................................................................................................ 4
D. HYDRAULIC FITTINGS............................................................................................................................. 5
ENGLISH/METRIC EQUIVALENTS .......................................................................................................................... 6
STEP 1. UNLOAD HEADER .............................................................................................................................. 7
STEP 2. LOWER HEADER ................................................................................................................................ 8
A. SINGLE REEL HEADERS ......................................................................................................................... 8
B. DOUBLE REEL HEADERS – D60 ONLY.................................................................................................. 9
STEP 3. REMOVE SHIPPING SUPPORTS..................................................................................................... 10
STEP 4. ATTACH REEL LIFT CYLINDERS..................................................................................................... 11
STEP 5. ATTACH TO TRACTOR..................................................................................................................... 13
STEP 6. CONNECT REEL TO FORE/AFT CYL – D60 ONLY......................................................................... 16
STEP 7. ATTACH CAM ARMS......................................................................................................................... 17
STEP 8. INSTALL ENDSHIELDS..................................................................................................................... 17
STEP 9. RE-INSTALL GUARDS ...................................................................................................................... 18
STEP 10. ADJUST TRANSPORT LIGHTS ........................................................................................................ 19
STEP 11. PRE-DELIVERY INSPECTION .......................................................................................................... 20
A. TIRE PRESSURE (Transport & Stabilizer Wheel Options) ..................................................................... 20
B. WHEEL BOLT TORQUE (Transport & Stabilizer Wheel Options) .......................................................... 20
C. WOBBLE BOX ......................................................................................................................................... 20
D. SICKLE DRIVE BELT TENSION ............................................................................................................. 21
E. REEL CENTERING ................................................................................................................................. 22
F. DRAPER TENSION ................................................................................................................................. 23
G. SKID SHOE SETTINGS .......................................................................................................................... 24
H. REEL TINE TO CUTTERBAR CLEARANCE .......................................................................................... 25
I. LUBRICATE HEADER............................................................................................................................. 26
J. END SHIELDS ......................................................................................................................................... 29
K. OPERATOR’S MANUAL AND PARTS CATALOG ................................................................................. 29
STEP 12. RUN-UP THE HEADER ..................................................................................................................... 30
STEP 13. POST RUN-UP ADJUSTMENTS ....................................................................................................... 30
A. KNIFE ...................................................................................................................................................... 30

Form # 169007 Model Year - 2009
2
GENERAL SAFETY
CAUTION
•The following are general farm safety
precautions that should be part of your
operating procedure for all types of
machinery.
•Protect yourself.
•When assembling, operating and servicing
machinery, wear all the protective clothing
and personal safety devices that COULD be
necessary for the job at hand. Don't take
chances.
•You may need:
oa hard hat.
oprotective shoes with slip resistant
soles.
oprotective glasses or goggles.
oheavy gloves.
owet weather gear.
orespirator or filter mask.
ohearing protection. Be aware that
prolonged exposure to loud noise
can cause impairment or loss of
hearing. Wearing a suitable hearing
protective device such as ear muffs
(A) or ear plugs (B) protects against
objectionable or loud noises.
•Be aware that accidents often happen when
the operator is tired or in a hurry to get
finished. Take the time to consider the
safest way. Never ignore warning signs of
fatigue.
•Provide a first-aid kit for use in case of
emergencies.
•Keep a fire extinguisher on the machine. Be
sure the extinguisher is properly maintained
and be familiar with its proper use.
•Wear close-fitting
clothing and cover
long hair. Never wear
dangling items such
as scarves or
bracelets.
•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.
•Keep all shields in place. Never alter or
remove safety equipment. Make sure
driveline guards can rotate independently of
the shaft and can telescope freely.
•Use only service and repair parts made or
approved by the equipment manufacturer.
Substituted parts may not meet strength,
design, or safety requirements.
•Do not modify the machine. Unauthorized
modifications may impair the function
and/or safety and affect machine life.
A
B

Form # 169007 Model Year - 2009
3
•Stop engine and remove key from ignition
before leaving operator's seat for any
reason. A child or even a pet could engage
an idling machine.
•Keep the area used for servicing machinery
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.
•Use adequate light for the job at hand.
•Keep machinery clean. 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.

Form # 169007 Model Year - 2009
4
RECOMMENDED TORQUES
A. GENERAL
The tables shown below give correct torque
values for various bolts and capscrews.
•Tighten all bolts to the torques specified in
chart unless otherwise noted throughout
this manual.
•Check tightness of bolts periodically, using
bolt torque chart as a guide.
•Replace hardware with the same strength
bolt.
•Torque figures are valid for non-greased or
non-oiled threads and heads unless
otherwise specified. Do not grease or oil
bolts or capscrews unless specified in this
manual. When using locking elements,
increase torque values by 5%.
B. SAE BOLTS
BOLT
DIA.
"A"
NC BOLT TORQUE*
SAE 5 SAE 8
ft-lbf N·m ft-lbf N·m
1/4"
9
12
11
15
5/16"
18
24
25
34
3/8"
32
43
41
56
7/16"
50
68
70
95
1/2"
75
102
105
142
9/16"
110
149
149
202
5/8"
150
203
200
271
3/4"
265
359
365
495
7/8"
420
569
600
813
1"
640
867
890
1205
* Torque categories for bolts and capscrews are
identified by their head markings.
C. METRIC BOLTS
BOLT
DIA.
"A"
NC BOLT TORQUE*
8.8 10.9
ft-lbf
N·m
ft-lbf
N·m
M3
0.4
0.5
1.3
1.8
M4 2.2 3 3.3 4.5
M5
4
6
7
9
M6
7
10
11
15
M8 18 25 26 35
M10
37
50
52
70
M12 66 90 92 125
M14
103
140
148
200
M16
166
225
229
310
M20 321 435 450 610
M24
553
750
774
1050
M30 1103 1495 1550 2100
M36
1917
2600
2710
3675
* Torque categories for bolts and capscrews are
identified by their head markings.
SAE-5
SAE-8
8.8
10.9

Form # 169007 Model Year - 2009
5
D. HYDRAULIC FITTINGS
FLARE TYPE
a. Check flare and flare seat for defects that might
cause leakage.
b. Align tube with fitting before tightening.
c. Lubricate connection and hand tighten swivel
nut until snug.
d. To prevent twisting the tube(s), use two
wrenches. Place one wrench on the connector
body and with the second tighten the swivel nut
to the torque shown.
TUBE
SIZE
O.D.
(in.)
NUT SIZE
ACROSS
FLATS
(in.)
TORQUE
VALUE*
RECOMMENDED
TURNS TO
TIGHTEN (AFTER
FINGER
TIGHTENING)
lbf-ft N·m Flats Turns
3/16 7/16 6 8 1 1/6
1/4
9/16
9
12
1
1/6
5/16
5/8
12
16
1
1/6
3/8 11/16 18 24 1 1/6
1/2
7/8
34
46
1
1/6
5/8 1 46 62 1 1/6
3/4
1-1/4
75
102
3/4
1/8
7/8
1-3/8
90
122
3/4
1/8
* The torque values shown are based on lubricated
connections as in reassembly.
O-RING TYPE
a. Inspect O-ring and seat for dirt or obvious
defects.
b. On angle fittings, back off the lock nut until
washer (A) bottoms out at top of groove (B) in
fitting.
c. Hand tighten fitting until back up washer (A) or
washer face (if straight fitting) bottoms on part
face (C) and O-ring is seated.
d. Position angle fittings by unscrewing no more
than one turn.
e. Tighten straight fittings to torque shown.
f. Tighten angle fittings to torque shown in the
following table while holding body of fitting with
a wrench.
THD
SIZE
(in.)
NUT SIZE
ACROSS
FLATS
(in.)
TORQUE
VALUE*
RECOMMENDED
TURNS TO
TIGHTEN (AFTER
FINGER
TIGHTENING)
lbf-ft N·m Flats Turns
3/8 1/2 6 8 2 1/3
7/16
9/16
9
12
2
1/3
1/2 5/8 12 16 2 1/3
9/16 11/16 18 24 2 1/3
3/4
7/8
34
46
2
1/3
7/8 1 46 62 1-1/2 1/4
1-1/16
1-1/4
75
102
1
1/6
1-3/16 1-3/8 90 122 1 1/6
1-5/16 1-1/2 105 142 3/4 1/8
1-5/8
1-7/8
140
190
3/4
1/8
1-7/8 2-1/8 160 217 1/2 1/12
* The torque values shown are based on lubricated
connections as in reassembly.
FLARE
FLARESEAT
BODY
NUT
LOCKNUT
SEAT
WASHER
O-RING
GROOVE
FITTING
A
B
C

Form # 169007 Model Year - 2009
6
ENGLISH/METRIC
EQUIVALENTS
ENGLISH FACTOR SI UNITS (METRIC)
acres x 0.4047 = hectares (ha)
ft/min x 0.3048 = meters/min (m/min)
ft/s x 0.3048 = meters/sec (m/s)
gal
(US) x 3.7854 = liters (L)
US
gal/min
(gpm)
x 3.7854 = liters/min (L/min)
hp x 0.7457 = kilowatts (kW)
in.3x 16.3871
= cubic centimeters (cm
3
or cc)
lbf x 4.4482 = Newtons (N)
lbf-ft or
ft-lb x 1.3558 = Newton meters (N·m)
lbf-in.
or in-lbf x 0.1129 = Newton meters (N·m)
mph x 1.6063 = kilometers/hour (km/h)
oz. x 29.5735 = milliliters (ml)
pint
(US) x 0.4732 = liters (L)
psi x 6.8948 = kilopascals (kPa)
psi x 0.00689 = megapascals (MPa).
qt. (US) x 0.9464 = liters (L)

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
7
STEP 1. UNLOAD HEADER
CAUTION
To avoid injury to bystanders from being
struck by machinery, do not allow persons 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.
LIFTING VEHICLE
HDR SIZE
15-25
30-45
Min. Lifting Capacity *
5000 lb
(2270 kg)
7000 lb
(3178 kg)
Min. Fork Length
78 in. (1981 mm)
* At 48 in. (1220 mm) from back end of forks.
IMPORTANT
Forklifts are normally rated for a load
located 24 in. (610 mm) ahead of
back end of the forks. To obtain the
forklift capacity at 48 in. (1220 mm),
check with your forklift distributor.
a. Move trailer into position and block trailer
wheels.
b. Lower trailer storage stands.
CAUTION
Ensure that forks extend beyond the inner
support prior to lifting the header. If the
forks do not lift at the supports, damage to
the header may occur.
c. Approach the header and slide forks in
underneath lower structure as far as possible.
d. Remove hauler's tie down straps and chains.
WARNING
Be sure forks are secure before moving away
from load. Stand clear when lifting.
e. Raise windrower off deck.
f. Back up until unit clears trailer and slowly lower
to 6 in. (150 mm) from ground.
g. Take machine to storage or set-up area.
h. Repeat above steps for second header.
i. Check for shipping damage and missing parts.
TOPSIDE
UNDERSIDE

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
8
STEP 2. LOWER HEADER
Reposition header as follows in preparation for
assembly and set-up:
A. SINGLE REEL HEADERS
a. Choose an area with level ground.
b. Approach header from its “underside” and place
forks under top of shipping frame.
c. Attach a chain at each end of frame and secure
other end to lifting vehicle.
CAUTION
Stand clear when lowering, as machine may
swing.
d. Back up SLOWLY while lowering forks until
header rests just above the ground. See
illustration.
e. Place 6 in. (150 mm) blocks under each end and
center of cutterbar and lower header onto
blocks.
f. Remove chain and move lifting vehicle to rear of
header.
g. Attach chain to center link anchor on frame tube
and raise rear of header so that stand can be
lowered.
h. Lower header stand by pulling pin, lowering
stand, and releasing pin to secure stand.
i. Lower header onto stand.
NOTE
If ground is soft, place a block under
stand.
1
2
3
4

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
9
B. DOUBLE REEL HEADERS – D60
ONLY
Reposition header as follows in preparation for
assembly and set-up:
a. Choose an area with level ground.
b. Drive lifting vehicle to approach header from its
"underside".
IMPORTANT
Do not lift header at this location. This
procedure is only for laying the
machine over into working position.
c. Attach chain to shipping support at center reel
arm.
CAUTION
Stand clear when lowering, as machine may
swing.
d. Back up SLOWLY while lowering forks until
header rests on the ground. See illustration.
e. Place 6 in. (150 mm) blocks under each end and
center of cutterbar and lower header onto
blocks.
f. Remove chain and move lifting vehicle to rear of
header.
g. Attach chain to center link anchor on frame tube
and raise rear of header so that stand can be
lowered.
h. Lower header stand by pulling pin, lowering
stand, and releasing pin to secure stand.
i. Lower header onto stand.
NOTE
If ground is soft, place a block under
stand.
1
2
3
4

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
10
STEP 3. REMOVE SHIPPING
SUPPORTS
The removable supports are painted yellow.
NOTE
Unless otherwise specified, discard
supports, and all shipping material and
hardware.
a. Remove six bolts securing lower support to
header legs and remove support.
b. Remove four bolts securing upper support to
header legs and remove support.
c. Remove the two shipping stands from each
header leg.
d. Cut banding securing reel to cutterbar and
backtube.
NOTE
Double reel headers may have banding
on each reel.
e. Remove reel anti-rotation brace between reel
and endsheet.

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
11
STEP 4. ATTACH REEL LIFT
CYLINDERS
a. Remove top bolt on outboard reel arm supports.
b. Remove two top bolts on center reel arm
support. (DOUBLE REEL ONLY).
c. Remove LH and RH header drive shields.
d. Position sling around the reel tube close to
outboard end of reel and attach sling to a forklift
(or equivalent).
e. Lift reel so that reel lift cylinder mounting holes
line up with lug on end sheet.
f. Remove shipping wire/banding from cylinder
and remove pin from cylinder. Secure cylinder
to end sheet with pin as shown. Secure with
cotter pin.
g. Remove sling and reposition around reel tube
near reel center support arm. (DOUBLE REEL
ONLY).
(continued next page)
DOUBLE REEL SUPPORT
D60 REEL SUPPORT
D50 REEL SUPPORT
D60 REEL SHOWN

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
12
h. Lift reel so that reel center lift cylinder mounting
holes line up with bracket on frame. (DOUBLE
REEL ONLY).
i. Remove shipping wire/banding from cylinder
and remove pin from frame. Secure cylinder to
frame with pin as shown. Secure with cotter pin.
(DOUBLE REEL ONLY).
j. Remove sling and reposition around reel tube
near opposite outboard reel arm.
k. Lift reel so that reel lift cylinder mounting holes
line up with lug on end sheet.
l. Remove shipping wire/banding from cylinder
and remove pin from cylinder. Secure cylinder
to end sheet with pin as shown. Secure with
cotter pin.
m. Remove shipping wire from center arm hose
bundle and remove bolt and nut from hose clip.
(DOUBLE REEL ONLY).
n. Re-install bolt with hose clip through upper hole
in reel prop. (DOUBLE REEL ONLY).
o. Hold support and remove two bolts at base of
center reel arm shipping support so that plate
drops free. (DOUBLE REEL).
p. Slide lower support off cutterbar.
CAUTION
Brace On Double Reel Center Arm Keeps
Reel From Sliding Forward. Do Not Remove.
(continued next page)
CENTER CYLINDER – DOUBLE REEL
CENTER CYLINDER – DOUBLE REEL
DO NOT REMOVE

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
13
q. Remove the two reel arm supports from end
sheets.
CAUTION
Braces On D60 Reel Arms Keep Reel From
Sliding Forward. Do Not Remove.
STEP 5. ATTACH TO TRACTOR
a. If not installed, attach draper header boots
(supplied with header) to tractor lift linkage as
follows:
1. Remove pin (A) from boot (B).
2. Locate boot (B) on lift linkage (C) and
reinstall pin (A). Pin may be installed from
either side of boot.
3. Secure pin (A) with hairpin.
4. Repeat for opposite side.
b. Remove hairpin on pins (D) and remove pins
from header legs.
(continued next page)
D60 REEL SUPPORT
D50 REEL SUPPORT
B
C
A
A
B
D
DO NOT REMOVE

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
14
CAUTION
Check to be sure all bystanders have cleared
the area.
c. Start the engine and fully retract header lift
cylinders.
d. Slowly drive tractor forward so that boots (B)
enter header legs (E). Continue to drive slowly
forward until linkages contact support plates in
the lower header legs, and header nudges
forward.
e. Check that linkages are properly engaged in
header legs, contacting support plates.
f. Position center link cylinder (F) with tractor
hydraulics so that it can connect to header.
g. Push down on rod end of link cylinder until hook
engages pin on header and is locked.
NOTE
If optional auto-connect system is
installed, activate link lift cylinder from in
the cab to lower center link onto header.
h. Raise the header fully with the tractor hydraulics.
Stop engine and remove key.
DANGER
To avoid bodily injury from fall of raised
header, always engage header lift cylinder
stops when working on or around raised
header.
i. Engage lift cylinder stops on both lift cylinders.
j. Install pin (D) through header leg, (engaging U-
bracket in lift linkage) on both sides.
k. Raise header stand (G) to storage position by
pulling pin (H) and lifting stand into uppermost
position. Release pin (H).
l. Remove pin (J) from storage position in linkage
and insert in hole (K) to engage float springs.
Secure with hairpin.
m. Disengage lift cylinder stops.
n. Start engine and lower header fully.
o. Stop engine and remove key.
(continued next page)
B
E
G
H
D
K
J
F

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
15
p. Connect header drive hydraulics (L) and
electrical harness (M) to header as follows:
1. Check connectors and clean if required.
2. Push hose connector onto mating receptacle
until collar on receptacle snaps into lock
position.
3. Remove cover on electrical receptacle.
4. Push electrical connector onto receptacle
and turn collar on connector to lock it in
place.
5. Attach cover to mating cover on tractor
wiring harness
q. Connect reel hydraulics (N) as follows:
1. Open cover (O).
2. Check connectors and clean if required.
3. Push in lock button (P) and pull handle (Q)
to full open position.
4. Position connector from tractor onto
receptacle and push handle (Q) to engage
pins on connector.
5. Push handle to closed position until lock
button (P) snaps out.
6. Raise and lower header and reel a few times
to allow trapped air to pass back to the
reservoir.
NOTE
It is not necessary to bleed the system by
loosening fittings.
KNIFE DRIVE
DRAPER DRIVE
RETURN
CASE DRAIN
(DOUBLE KNIFE)
ELECTRICAL
M
L
HEADER DRIVE HOSES
N
O
P
Q
REEL HYDRAULICS

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
16
STEP 6. CONNECT REEL TO
FORE/AFT CYL – D60
ONLY
CAUTION
The reel fore-aft hydraulic cylinders must be
connected to the reel prior to removing the
fore-aft supports. Failure to do so may result
in the reel sliding full forward when the
supports are removed.
CAUTION
Reel arms must be level prior to removing
reel shipping braces. Failure to do so may
result in reel moving suddenly.
CAUTION
Be sure all bystanders are clear of machine
before starting engine or engaging any
header drives.
a. Remove shipping wire and pins from fore/aft
cylinders. Pin may be installed in arm. One
cylinder on each reel support arm.
b. Start tractor and level the reel arms with the
tractor hydraulics.
c. Extend and retract fore/aft cylinders to rephase
cylinders.
d. Align cylinders with reel arm mounting holes with
tractor hydraulics. Stop engine and remove key.
e. Attach fore/aft cylinders to reel arms with clevis
pins, washers, and cotter pins.
f. Remove supports on reel arms.
LH ARM
RH ARM
CENTER ARM – DOUBLE REEL
CENTER ARM
LH ARM
RH ARM

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
17
STEP 7. ATTACH CAM ARMS
a. Manually rotate reel until the tine bars with the
disconnected cam links are accessible.
b. Remove shipping wire if not already removed.
c. Remove bag of hardware from tine bar.It
contains hardware for cam links and endshields.
d. Rotate tine bar crank (A), and position link (B)
until attachment holes in bar crank and link are
approximately aligned.
e. Install bolt (C) in link and position shim (D) (5/8”
ID lockwasher on D50) on bolt so that shim is
between link and tine bar crank.
NOTE
Bolts are pre-coated with Loctite so no
further locking method is required.
f. Realign link and tine bar crank and thread in the
bolt (C).
g. Repeat for remaining tine bars and torque bolts
to 120 ft-lbf (165 N∙m).
STEP 8. INSTALL ENDSHIELDS
Up to three endshields on each end of some
reels were removed for shipping purposes. If
necessary, re-install shields as follows.
a. Manually rotate reel until the wired endshields
are accessible. Remove endshields.
b. Manually rotate reel for accessibility to re-install
the shields.
c. Loosen bolts securing endshield supports to disc
and rotate supports approximately as shown.
d. Retrieve hardware from bag removed in
previous step.
(continued next page)
A
B
C
D

UNLOADING AND ASSEMBLY
Form # 169007 Model Year - 2009
18
e. Install endshields with lip in relation to reel
rotation. Use 3/8”x0.5 lg. torx head screws and
torque to 20 ft-lbf (27 N∙m). See photos for
hardware orientation. The jam nuts must be
locking jam nuts. If they aren’t locking nuts, use
Loctite.
f. Re-tighten endshield support bolts if necessary.
STEP 9. RE-INSTALL GUARDS
a. Retrieve parts bag from cutterbar.
b. Position guards and poly wear plates (if
applicable) on cutterbar and install 7/16”x1.5 lg.
carriage bolts.
NOTE
Poly wear plates should
be installed with special
bolts as shown.
c. Locate hold-downs on cutterbar as shown and
secure with nuts. Adjuster bolt should not
require adjusting.
d. Tighten nuts to 50 ft-lbf (68 N∙m).
DIRECTION
OF ROTATION
TAIL END
DIRECTION
OF ROTATION
CAM END