MacDon D65 User manual

The harvesting specialists worldwide.
D65
Draper Header for Self-Propelled
Windrowers
Operator’s Manual
169594Rev.C
Original Instruction
IMPORTANT: PAGE 35 HAS BEEN
UPDATED SINCE THIS MANUAL WAS
PUBLISHED.

D65 Draper Header for Windrowers
Published: September, 2013

Declaration ofConformity
169594 iRev. C

Introduction
This instructional manual contains information on the D65 Draper Header. It is designed to serve a dual function in
your grain, hay, and specialty crop harvesting operation. Teamed with your self-propelled windrower power unit and
optional hay conditioner, D65 Draper Headers will cut and lay crop into uniform, fluffy windrows.
The D65 Draper Header is specially designed as a “straight cut” header and is equipped to work well in all straight
cut conditions, whether cutting on or above the ground.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR USE
THE MACHINE.
Use this manual as your first source of information about the machine. If you follow the instructions given here,
your header will work well for many years. If you require more detailed service information, a technical manual is
available from your MacDon Dealer.
The Table of Contents and Index will guide you to specific areas of this manual. Study the Table of Contents to
familiarize yourself with how the information is organized.
Keep this manual handy for frequent reference and to pass
on to new Operators or Owners. A storage case for this
manual is located inside the header left endshield.
Call your MacDon Dealer if you need assistance,
information, or additional copies of this manual.
Figure 1: Manual storage location
169594 iiRev. C

Model and Serial Number
Record the model number, serial number, and model year of the header and Slow Speed Transport/Stabilizer Wheel
option (if installed) on the lines below.
NOTE: Right Hand (RH) and Left Hand (LH) designations are determined from the Operator’s position,
facing forward.
Draper Header
Header Model:
Serial Number:
Year:
In shipping configuration, the serial number plate
is located beside the knife drive motor on the left
hand endsheet.
Figure 2: Header serial number location
Slow Speed Transport/Stabilizer Wheel Option
Serial Number:
Year:
The serial number plate is located on the right hand
axle assembly.
Figure 3: Slow Speed Transport/Stabilizer
Wheel Option serial number location
169594 iii Rev. C

TABLE OF CONTENTS
Declaration of Conformity.................................................................................................................. i
Introduction......................................................................................................................................ii
Model and Serial Number.................................................................................................................iii
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 .............................................................................................................................. 6
1.6 Tire Safety....................................................................................................................................... 7
1.7 Safety Signs.................................................................................................................................... 8
1.7.1 Installing Safety Decals ............................................................................................................ 8
1.8 Safety Decal Locations .................................................................................................................... 9
1.8.1 Upper Cross Auger (UCA) ........................................................................................................ 9
1.8.2 Slow Speed Transport............................................................................................................ 10
1.8.3 Vertical Knife...........................................................................................................................11
1.8.4 All Headers............................................................................................................................ 12
15 Foot ..........................................................................................................................13
20 Foot ..........................................................................................................................14
25 Foot ..........................................................................................................................15
30 Foot ..........................................................................................................................16
35 Foot ..........................................................................................................................17
40 Foot ..........................................................................................................................18
1.9 Interpreting Safety Signs................................................................................................................ 19
2 Reference............................................................................................................................................ 27
2.1 Definitions..................................................................................................................................... 27
2.2 Component Identification................................................................................................................ 28
2.2.1 D65 Windrower Header.......................................................................................................... 28
3 Specifications ..................................................................................................................................... 29
4 Operation ............................................................................................................................................ 33
4.1 Owner/Operator Responsibilities..................................................................................................... 33
4.2 Operational Safety......................................................................................................................... 34
4.2.1 Header Safety Props.............................................................................................................. 34
4.2.2 Reel Safety Props.................................................................................................................. 35
Engaging Reel Safety Props............................................................................................ 35
Disengaging Reel Safety Props ....................................................................................... 36
4.2.3 Endshields............................................................................................................................. 37
Opening Endshields........................................................................................................ 37
Closing Endshields ......................................................................................................... 38
Removing Endshields ..................................................................................................... 39
Installing Endshields ....................................................................................................... 40
Adjusting Endshields....................................................................................................... 41
4.2.4 Daily Start-Up Check.............................................................................................................. 42
4.3 Break-in Period.............................................................................................................................. 43
4.4 Shutdown Procedure ..................................................................................................................... 44
4.5 Cab Controls................................................................................................................................. 45
4.6 Header Setup................................................................................................................................ 46
4.6.1 Header Settings..................................................................................................................... 46
4.6.2 Reel Settings ......................................................................................................................... 47
4.7 Header Operating Variables ........................................................................................................... 50
4.7.1 Cutting Height........................................................................................................................ 50
Cutting Off The Ground................................................................................................... 50
Cutting On the Ground.................................................................................................... 54
169594 vRev. C

TABLE OF CONTENTS
4.7.2 Header Float.......................................................................................................................... 56
4.7.3 Header Angle......................................................................................................................... 56
Angle Adjustment............................................................................................................ 57
4.7.4 Reel Speed............................................................................................................................ 57
Optional Reel Drive Sprockets......................................................................................... 58
4.7.5 Ground Speed ....................................................................................................................... 58
4.7.6 Draper Speed ........................................................................................................................ 59
4.7.7 Knife Speed........................................................................................................................... 59
4.7.8 Reel Height............................................................................................................................ 59
4.7.9 Reel Fore-Aft Position ............................................................................................................ 60
Adjusting Reel Fore-Aft Position ...................................................................................... 60
Repositioning Fore-Aft Cylinder on Single Reel................................................................. 60
Repositioning Fore-Aft Cylinder on Double Reel ............................................................... 63
4.7.10 Reel Tine Pitch....................................................................................................................... 66
Pickup Reel Settings....................................................................................................... 66
Adjusting Reel Cam........................................................................................................ 68
4.7.11 Crop Dividers......................................................................................................................... 69
Removing Crop Dividers from Header with Latch Option ................................................... 69
Removing Crop Dividers from Header without Latch Option............................................... 70
Installing Crop Dividers on Header with Latch Option ........................................................ 70
Installing Crop Dividers on Header without Latch Option.................................................... 72
4.7.12 Crop Divider Rods.................................................................................................................. 73
Removing Crop Divider Rods .......................................................................................... 74
Rice Dividers.................................................................................................................. 74
4.8 Delivery Opening........................................................................................................................... 75
4.8.1 Adjusting Delivery Opening on Header with Manual Deck Shift.................................................. 75
4.8.2 Adjusting Delivery Opening on Header with Hydraulic Deck Shift............................................... 76
4.9 Double Windrowing........................................................................................................................ 77
4.9.1 Shifting Deck Hydraulically...................................................................................................... 78
4.9.2 Shifting Deck Manually........................................................................................................... 78
4.10 Windrow Types.............................................................................................................................. 79
4.11 Haying Tips................................................................................................................................... 81
4.11.1 Curing ................................................................................................................................... 81
4.11.2 Topsoil Moisture..................................................................................................................... 81
4.11.3 Weather and Topography........................................................................................................ 81
4.11.4 Windrow Configuration ........................................................................................................... 81
4.11.5 Driving on Windrow................................................................................................................ 82
4.11.6 Raking and Tedding................................................................................................................ 82
4.11.7 Chemical Drying Agents ......................................................................................................... 82
4.12 Levelling the Header...................................................................................................................... 83
4.13 Unplugging Cutterbar..................................................................................................................... 84
4.14 Upper Cross Auger (UCA).............................................................................................................. 85
4.14.1 Removing Beater Bars............................................................................................................ 85
4.14.2 Installing Beater Bars ............................................................................................................. 87
4.15 Transporting Header ..................................................................................................................... 88
4.15.1 Transporting Header on Windrower......................................................................................... 88
4.15.2 Towing................................................................................................................................... 88
Attaching Header to Towing Vehicle................................................................................. 89
Towing the Header.......................................................................................................... 89
4.15.3 Converting from Transport to Field Position.............................................................................. 90
Removing Tow-Bar ......................................................................................................... 90
Storing Tow-Bar.............................................................................................................. 91
Moving Front (Left) Wheels into Field Position.................................................................. 93
Moving Rear (Right) Wheels into Field Position................................................................. 95
169594 viRev. C

TABLE OF CONTENTS
4.15.4 Converting from Field to Transport Position.............................................................................. 97
Moving Left (Front) Wheels into Transport Position ........................................................... 97
Moving Right (Rear) Wheels into Transport Position.........................................................100
4.16 Storage........................................................................................................................................103
5 Header Attachment/Detachment ........................................................................................................105
5.1 Attaching Header to Windrower.....................................................................................................105
5.2 Detaching Header from Windrower................................................................................................108
6 Maintenance and Servicing................................................................................................................111
6.1 Preparation for Servicing...............................................................................................................111
6.2 Recommended Safety Procedures.................................................................................................112
6.3 Maintenance Specifications...........................................................................................................113
6.3.1 Conversion Chart..................................................................................................................113
6.3.2 Recommended Fluids and Lubricants.....................................................................................113
6.3.3 Torque Specifications ............................................................................................................114
SAE Bolt Torque Specifications.......................................................................................114
Metric BoltSpecifications ...............................................................................................116
Metric BoltSpecifications Bolting into Cast Aluminum ......................................................119
Flare Type Hydraulic Fittings ..........................................................................................119
O-Ring Boss (ORB) Hydraulic Fittings.............................................................................120
O-Ring Face Seal (ORFS) Hydraulic Fittings...................................................................121
6.3.4 Installing a Roller Chain.........................................................................................................123
6.3.5 Installing a Sealed Bearing ....................................................................................................124
6.4 Maintenance Requirements...........................................................................................................125
6.4.1 Maintenance Schedule/Record...............................................................................................125
6.4.2 Break-In Inspections..............................................................................................................127
6.4.3 Preseason/Annual Service.....................................................................................................127
6.4.4 End of Season Service..........................................................................................................128
6.4.5 Hydraulic Hoses and Lines ....................................................................................................129
6.4.6 Lubrication and Servicing.......................................................................................................129
Service Intervals............................................................................................................130
Greasing Procedure.......................................................................................................135
6.5 Electrical......................................................................................................................................136
6.5.1 Replacing Light Bulbs............................................................................................................136
6.6 Knife and Knife Drive....................................................................................................................137
6.6.1 Replacing Knife Section.........................................................................................................137
6.6.2 Removing Knife.....................................................................................................................138
6.6.3 Removing Knifehead Bearing.................................................................................................138
6.6.4 Installing Knifehead Bearing...................................................................................................139
6.6.5Installing Knife ......................................................................................................................140
6.6.6Spare Knife...........................................................................................................................141
6.6.7Knife Guards.........................................................................................................................141
Adjusting Knife Guards...................................................................................................141
Replacing Pointed Guards on a Single-Knife Header........................................................143
Replacing Pointed Guards on a Double-Knife Header......................................................144
Replacing Stub Guards on a Single-Knife Header............................................................145
Replacing Stub Guards on a Double-Knife Header...........................................................146
Knife Hold-Downs..........................................................................................................147
6.6.8 Knife Drive Belt.....................................................................................................................149
Single Knife and Double Knife Untimed...........................................................................149
Double Knife Timed .......................................................................................................151
Adjusting Double Knife Timing........................................................................................167
6.6.9 Knife Drive Box.....................................................................................................................169
Mounting Bolts...............................................................................................................169
169594 vii Rev. C

TABLE OF CONTENTS
Removing Knife Drive Box..............................................................................................169
Removing Knife Drive Box Pulley....................................................................................175
Installing Knife Drive Box Pulley......................................................................................176
Installing Knife Drive Box................................................................................................176
Changing Oil in Knife Drive Box......................................................................................179
6.6.10 Knifehead Shield...................................................................................................................179
Installing Knifehead Shield .............................................................................................180
6.7 Header Drapers............................................................................................................................181
6.7.1 Removing Side Draper ..........................................................................................................181
6.7.2 Installing Side Draper ............................................................................................................182
6.7.3 Adjusting Side Draper Tension...............................................................................................182
6.7.4 Removing Endless Draper.....................................................................................................183
6.7.5 Installing Endless Draper.......................................................................................................186
6.7.6 Adjusting Header Draper Tracking..........................................................................................187
6.7.7 Adjusting Deck Height ...........................................................................................................189
6.7.8 Draper Roller Maintenance ....................................................................................................190
Side Draper Deck Idler Roller.........................................................................................190
Side Draper Deck Drive Roller........................................................................................192
6.7.9 Draper Deflectors..................................................................................................................194
Replacing Draper Deflectors...........................................................................................194
6.8 Reel and Reel Drive......................................................................................................................196
6.8.1 Reel Clearance to Cutterbar...................................................................................................196
Measuring Reel Clearance ............................................................................................196
Adjusting Reel Clearance...............................................................................................199
6.8.2 Reel Frown...........................................................................................................................199
Adjusting Reel Frown.....................................................................................................200
6.8.3 Reel Centering......................................................................................................................201
Centering Double Reels.................................................................................................201
Centering Single Reel....................................................................................................201
6.8.4 Reel Drive Chain...................................................................................................................202
Adjusting Chain Tension.................................................................................................202
Removing Chain from Single Reel Drive..........................................................................204
Installing Chain on a Single Reel Drive............................................................................205
Replacing Chain on Double Reel Drive............................................................................206
6.8.5 Reel Drive Sprocket ..............................................................................................................211
Replacing Reel Drive Sprocket .......................................................................................211
6.8.6 Reel Drive U-Joint.................................................................................................................214
Removing U-Joint..........................................................................................................215
Installing U-Joint............................................................................................................216
6.8.7 Reel Drive Motor...................................................................................................................219
Removing Reel Drive Motor............................................................................................219
Installing Reel Drive Motor..............................................................................................221
6.8.8 Reel Tines ............................................................................................................................222
Removing Steel Tines....................................................................................................223
Installing Steel Tines......................................................................................................223
Removing Plastic Fingers...............................................................................................224
Installing Plastic Fingers.................................................................................................224
6.8.9 Tine Tube Bushings...............................................................................................................225
Removing Bushings from 5, 6 or 9 Bat Reels...................................................................225
Installing Bushings on 5, 6, or 9 Bat Reels.......................................................................229
6.8.10 Reel Endshields....................................................................................................................233
Replacing Endshield......................................................................................................233
Replacing Support.........................................................................................................234
6.8.11 Transport System (Optional) ..................................................................................................235
169594 viii Rev. C

TABLE OF CONTENTS
Torquing Transport System Wheel Bolts..........................................................................235
Axle Bolts......................................................................................................................236
Tire Inflation ..................................................................................................................238
7 Troubleshooting.................................................................................................................................239
7.1 Crop Loss at Cutterbar..................................................................................................................239
7.2 Cutting Action and Knife Components............................................................................................241
7.3 Reel Delivery................................................................................................................................244
7.4 Header and Drapers .....................................................................................................................246
7.5 Cutting Edible Beans ....................................................................................................................248
7.6 Windrow Formation.......................................................................................................................252
8 Options and Attachments ..................................................................................................................253
8.1 Options and Attachments..............................................................................................................253
8.1.1 Cutterbar Plastic Wear Strips.................................................................................................253
8.1.2 Divider Latches.....................................................................................................................253
8.1.3 Double Draper Drive (DDD) Kit...............................................................................................254
8.1.4 Double Windrow Attachment (DWA).......................................................................................254
8.1.5 Draper Deflector (Narrow)......................................................................................................254
8.1.6 Draper Deflector (Wide).........................................................................................................255
8.1.7 Draper Extension Kit..............................................................................................................255
8.1.8 Draper Header Supports (Boots for M Series).........................................................................255
8.1.9 End Swath Deflector Rods (End Delivery)...............................................................................256
8.1.10 HC10 Hay Conditioner...........................................................................................................256
8.1.11 Hydraulic Deck Shift Package................................................................................................256
8.1.12 Knifehead Shield...................................................................................................................257
8.1.13 Lodged Crop Reel Finger Kit..................................................................................................257
8.1.14 Outboard Skid Shoes with Poly..............................................................................................257
8.1.15 Compression Molded Skid Shoes...........................................................................................258
8.1.16 Reel Endshield Kit.................................................................................................................258
8.1.17 PR15 Tine Tube Reel Conversion Kit......................................................................................259
8.1.18 Rice Divider Rods .................................................................................................................259
8.1.19 Stabilizer Wheels ..................................................................................................................260
8.1.20 Stabilizer/Slow Speed Transport Wheels.................................................................................260
8.1.21 Stub Guard Conversion Kit ....................................................................................................261
8.1.22Swath Forming Rods (Center Delivery)...................................................................................261
8.1.23Upper Cross Auger (UCA) .....................................................................................................261
8.1.24Vertical Knife Mounts.............................................................................................................262
9 Unloading and Assembly...................................................................................................................263
Index ..................................................................................................................................................265
169594 ixRev. C

1 Safety
1.1 Safety Alert Symbols
This safety alert symbol indicates important safety
messagesinthismanualandonsafetysignsontheheader.
This symbol means:
•ATTENTION!
•BECOME ALERT!
•YOUR SAFETY IS INVOLVED!
Carefully read and follow the safety message
accompanying this symbol.
Why is safety important to you?
• Accidents disable and kill.
• Accidents cost.
• Accidents can be avoided.
Figure 1.1: Read operator’s manual before
operating
169594 1Rev. C

SAFETY
1.2 Signal Words
Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The
appropriate signal word for each situation has been selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death, or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death, or serious injury.
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.
169594 2Rev. C

SAFETY
1.3 General Safety
CAUTION
The following are general farm safety precautions
that should be part of your operating procedure
for all types of machinery.
Protect yourself
• When assembling, operating and servicing machinery,
wear all the protective clothing and personal safety
devices that COULD be necessary for the job at hand.
Don’t take chances.
Figure 1.2
• You may need:
– A hard hat
– Protective footwear with slip resistant soles
– Protective glasses or goggles
– Heavy gloves
– Wet weather gear
– A respirator or filter mask
– Hearing protection
Be aware that exposure to loud noise can cause
impairment, or loss of hearing. Wearing suitable
hearing protection devices such as ear muffs, or ear
plugs. These will help protect against objectionable,
or loud noises.
Figure 1.3
•Provideafirst aid kit for use in case of emergencies.
•Keepafire extinguisher on the machine. Be sure the fire
extinguisher is properly maintained. Be familiar with its
proper use.
• Keep young children away from the machinery at
all times.
• BeawarethataccidentsoftenhappenwhentheOperator
istiredorinahurrytogetfinished. Takethetimeto
consider the safest way. Never ignore warning signs
of fatigue.
Figure 1.4
169594 3Rev. C

SAFETY
•Wearclosefitting clothing and cover long hair. Never
wear dangling items such as scarves or bracelets.
• Keep all shields in place. Never alter or remove safety
equipment. Make sure driveline guards can rotate
independently of the shaft and can telescope freely.
• Use only service and repair parts, made, or approved by
the equipment manufacturer. Substituted parts may not
meet strength, design, or safety requirements.
Figure 1.5
• 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. Non-authorized
modifications mayimpairmachinefunctionand/orsafety.
It may also shorten the machine’s life.
• 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
Figure 1.6
• 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.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff, on a hot
engine, are 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.
Figure 1.7
169594 4Rev. C

SAFETY
1.4 Maintenance Safety
To ensure your safety while maintaining the machine
• Review the operator’s manual and all safety items before
operation and/or maintenance of the machine.
•Placeallcon
trols in Neutral, stop the engine, set the park
brake, remove the ignition key, and wait for all moving
partstostopbeforeservicing, adjusting,and/orrepairing.
• Follow good shop practices:
– Keep service area clean and dry.
–Be sure ele
ctrical outlets and tools are
properly grounded.
– Use adequate light for the job at hand. Figure 1.8: Slip on Puddle
• Relieve pressure from hydraulic circuits before servicing
and/or disconnecting the machine.
• Before applying pressure to a hydraulic system, make
sure all components are tight and that steel lines, hoses,
and couplings are in good condition.
• Keephands, feet, clothing, andhairawayfromallmoving
and/or rotating parts.
•Clearth
e area of bystanders especially children when
carrying out any maintenance and repairs or when
making any adjustments.
•Instal
l transport lock or place safety stands under the
frame before working under the header.
•Ifmore
than one person is servicing the machine at the
same time,beawarethatrotatingadrivelineorother
mechanically driven component by hand (for example,
accessing a lube fitting) will cause drive components in
otherareas(belts, pulleys, andknife)to move. Stayclear
of driven components at all times.
Figure 1.9: Keep Away
• Wear protective gear when working on the machine.
• Wear heavy gloves when working on knife components.
Figure 1.10: Safety Gear
169594 5Rev. C

SAFETY
1.5 Hydraulic Safety
• Always place all combine/tractor/windrower hydraulic
controls in Neutral before dismounting.
• Makesurethatall components in the hydraulic system
are kept in good condition and clean.
•Replaceanyw
orn, cut, abraded, flattened, or crimped
hoses and steel lines.
• Do not attempt any makeshift repairs to the hydraulic
lines, fittings, or hoses by using tapes, clamps, cements,
or welding. The hydraulic system operates under
extremely high pressure. Such makeshift repairs will fail
suddenly and create a hazardous and unsafe condition.
Figure 1.11: Checking hydraulic leaks
• Wearproperhand andeyeprotectionwhensearchingfor
a high-pressure hydraulic leak. Use a pieceof cardboard
as a backstop instead of hands to isolate and identify
aleak.
• If injured by a concentrated high-pressure stream of
hydraulicfluid, seek medical attention immediately.
Serious infection or toxic reaction can develop from
hydraulic fluid piercing the skin.
Figure 1.12: Hydraulic pressure hazard
• Before applying pressure to a hydraulic system, make
sure all components are tight and that steel lines, hoses,
and couplings are in good condition.
Figure 1.13: Wear safety glasses
169594 6Rev. C

SAFETY
1.6 Tire Safety
• Failure to follow proper procedures when mounting a tire
on a wheel or rim can produce an explosion that may
result in serious injury or death.
Figure 1.14: Lower all safety stops
•DoNOT attempt to mount a tire unless you have the
proper training and equipment.
Figure 1.15: Safely filling a tire with air
•Haveaq
ualified tire dealer or repair service perform
required tire maintenance.
Figure 1.16: Over-inflation of tire
169594 7Rev. C

SAFETY
1.7 Safety Signs
• Keep safety signs clean and legible at all times.
•Replace safet
y signs that are missing or
become illegible.
• If original parts on which a safety sign was installed are
replaced, be sure the repair part also bears the current
safety sign.
• Safety signs are available from your Dealer Parts
Department.
Figure 1.17: Read operator’s manual before
operating
1.7.1 Installing Safety Decals
To install a safety decal, follow these steps:
1. Be sure the installation area is clean and dry.
2. Decide on the exact location before you remove the decal backing paper.
3. Remove the smaller portion of the split backing paper.
4. Place the sign in position and slowly peel back the remaining paper, smoothing the sign as it is applied.
5. Small air pockets can be smoothed out or pricked with a pin.
169594 8Rev. C