MacDon NEW HOLLAND D2 Series User manual

D2 Series
Draper Header for M and M1 Self-
Propelled Windrowers
Unloading and Assembly Instructions (North America)
214510 Revision A
Original Instruction
The Harvesting Specialists.

D2 Series Draper Header For Windrowers
Published: January 2023
© 2023 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 instruction manual describes the unloading, setup, and predelivery requirements for the MacDon D2 Series Draper
Header for windrower.
To ensure the best performance from this product and the safety of your customers, carefully follow the unload and
assembly procedure from the beginning through to completion.
Some sections/steps do not apply to all header configurations and sizes. Refer to the instructions for your specific header.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
If the shipment is damaged or is missing parts, contact [email protected].
Retain this instruction for future reference.
This document is currently available in English only.
214510 iRevision A

214510 iii Revision A
Introduction ................................................................................................................................................i
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Safety Alert Symbols ...............................................................................................................................1
1.2 Signal Words .........................................................................................................................................2
1.3 General Safety .......................................................................................................................................3
1.4 Hydraulic Safety .....................................................................................................................................5
1.5 Welding Precaution ................................................................................................................................6
1.6 Safety Signs ...........................................................................................................................................7
Chapter 2: Unloading Header..................................................................................................................... 9
2.1 Header Specifications for Unloading and Assembly.......................................................................................9
2.2 Unloading Header from Trailer................................................................................................................ 11
2.3 Removing Upper Cross Auger from Shipping Location –Option .................................................................... 13
2.4 Removing Parts from Shipping Location.................................................................................................... 15
2.5 Lowering Header to Field Position ........................................................................................................... 17
2.5.1 Lowering Header to Field Position –Single Reel................................................................................. 17
2.5.2 Lowering Header to Field Position –Double Reel ............................................................................... 19
2.5.3 Removing and Installing Hydraulic Hose Management System ............................................................. 21
2.6 Removing Shipping Stands and Supports .................................................................................................. 23
Chapter 3: Assembling Header................................................................................................................. 27
3.1 Installing Reel Lift Cylinders –Single Reel.................................................................................................. 27
3.2 Installing Reel Lift Cylinders –Double-Reel ................................................................................................ 33
Chapter 4: Attaching Header to M Series Windrower............................................................................ 41
4.1 Adding Tire Ballast................................................................................................................................ 41
4.2 Attaching Draper Header Supports .......................................................................................................... 42
4.3 Attaching Header to an M Series Windrower –Hydraulic Center-Link with Self-Alignment................................. 43
4.4 Attaching Header to an M Series Windrower –Hydraulic Center-Link without Self-Alignment ............................ 48
4.5 Attaching Header to an M Series Windrower –Mechanical Center-Link.......................................................... 52
4.6 Connecting Header Hydraulic and Electrical Systems to an M Series Windrower .............................................. 56
Chapter 5: Attaching Header to M1 Series Windrower.......................................................................... 59
5.1 Adding Rear Ballast Weights ................................................................................................................... 59
5.2 Adding Tire Ballast................................................................................................................................ 60
5.3 Attaching Draper Header Supports .......................................................................................................... 61
5.4 Connecting Center-Link.......................................................................................................................... 62
5.5 Connecting Hydraulics ........................................................................................................................... 68
Chapter 6: Completing Header Assembly................................................................................................ 73
6.1 Installing Clearance Lights ...................................................................................................................... 73
TABLE OF CONTENTS

214510 iv Revision A
6.2 Installing Fore-Aft Indicator and Sensor Spring (Parts Bag MD #368002)......................................................... 75
6.3 Connecting Reel to Fore-Aft Cylinders –Single-Reel .................................................................................... 78
6.4 Connecting Reel to Fore-Aft Cylinders –Double-Reel (Parts Bags MD #347593, MD #347580)............................ 83
6.5 Attaching Reel Height Sensor.................................................................................................................. 89
6.6 Installing Reel Fore-Aft Hose Clamps –Double-Reel Headers ........................................................................ 91
6.7 Attaching Cam Arms ............................................................................................................................. 92
6.8 Retrieving Single-Reel Endshields ............................................................................................................ 93
6.8.1 Installing Single-Reel Endshields at Cam End ................................................................................... 100
6.8.2 Installing Single-Reel Endshields at Tail End .................................................................................... 104
6.9 Installing Double-Reel Endshields –Parts Bags MD #340985 (Five-Bat Reels) or MD #340986 (Six-Bat
Reels) ............................................................................................................................................... 109
6.9.1 Installing Double-Reel Endshields at Outboard Cam End ................................................................... 114
6.9.2 Installing Double-Reel Endshields at Inboard Tail End ....................................................................... 120
6.9.3 Installing Double-Reel Endshields at Inboard Cam End ...................................................................... 126
6.9.4 Installing Double-Reel Endshields at Outboard Tail End..................................................................... 132
6.10 Installing Single-Reel Endshields –Parts Bag MD #311363 (Nine-Bat Reel) .................................................. 138
6.10.1 Installing Single-Reel Endshields at Cam End ................................................................................. 139
6.10.2 Installing Single-Reel Endshields at Tail End................................................................................... 146
6.11 Removing and Installing Cutterbar Seal –D215, D220, D225, D230, D235 ................................................... 153
6.12 Removing and Installing Deck Cutterbar Seals –D241.............................................................................. 155
6.13 Crop Dividers ................................................................................................................................... 157
6.13.1 Installing Crop Dividers.............................................................................................................. 157
6.13.2 Installing Crop Divider Rods........................................................................................................ 159
6.14 Setting up Reel Position Sensors –M1 Series Only .................................................................................. 160
6.14.1 Checking and Adjusting Reel Height Sensor................................................................................... 160
6.14.2 Checking and Adjusting Fore-Aft Position Sensor............................................................................ 162
6.15 Installing Options.............................................................................................................................. 165
Chapter 7: Performing Predelivery Checks............................................................................................ 167
7.1 Checking Tire Pressure –Option............................................................................................................ 167
7.2 Checking Wheel Bolt Torque................................................................................................................. 168
7.3 Checking Oil Level in Knife Drive Box ..................................................................................................... 169
7.4 Checking and Adjusting Reel Clearance................................................................................................... 170
7.5 Lubricating Header ............................................................................................................................. 173
7.5.1 Greasing Procedure .................................................................................................................... 173
7.6 Checking and Adjusting Header Float ..................................................................................................... 175
7.7 Checking and Adjusting Draper Tension.................................................................................................. 176
7.8 Checking Draper Seal .......................................................................................................................... 178
7.9 Reel-to-Cutterbar Clearance ................................................................................................................. 181
7.9.1 Measuring Reel Clearance ........................................................................................................... 181
7.9.2 Adjusting Reel-to-Cutterbar Clearance ........................................................................................... 183
7.10 Guard Identification .......................................................................................................................... 186
TABLE OF CONTENTS

214510 vRevision A
7.10.1 Checking Hold-Down –Pointed Knife Guards................................................................................. 187
7.10.2 Adjusting Hold-Down –Pointed Knife Guards ................................................................................ 188
7.10.3 Checking Center Hold-Down –Pointed Knife Guards....................................................................... 189
7.10.4 Adjusting Center Hold-Down –Pointed Knife Guards ...................................................................... 190
7.10.5 Checking Hold-Down –Short Knife Guards.................................................................................... 191
7.10.6 Adjusting Hold-Down –Short Knife Guards ................................................................................... 192
7.10.7 Checking Center Hold-Down –Short Knife Guards.......................................................................... 193
7.10.8 Adjusting Center Hold-Down –Short Knife Guards ......................................................................... 193
7.11 Checking and Adjusting Header Endshields............................................................................................ 195
7.12 Checking Manuals............................................................................................................................. 199
Chapter 8: Running up Header............................................................................................................... 201
8.1 Post Run-Up Adjustments .................................................................................................................... 201
8.1.1 Adjusting Draper Tracking............................................................................................................ 202
8.1.2 Checking Knife Position ............................................................................................................... 203
Chapter 9: Reference .............................................................................................................................. 205
9.1 Reel Safety Props................................................................................................................................ 205
9.1.1 Engaging Reel Safety Props .......................................................................................................... 205
9.1.2 Disengaging Reel Safety Props...................................................................................................... 206
9.2 Header Endshields .............................................................................................................................. 208
9.2.1 Opening Header Endshields ......................................................................................................... 208
9.2.2 Closing Header Endshields ........................................................................................................... 209
9.3 Torque Specifications .......................................................................................................................... 211
9.3.1 Metric Bolt Specifications ............................................................................................................ 211
9.3.2 Metric Bolt Specifications –Cast Aluminum .................................................................................... 213
9.3.3 O-Ring Boss Hydraulic Fittings –Adjustable .................................................................................... 214
9.3.4 O-Ring Boss Hydraulic Fittings –Non-Adjustable.............................................................................. 215
9.3.5 O-Ring Face Seal Hydraulic Fittings................................................................................................ 216
9.3.6 Tapered Pipe Thread Fittings........................................................................................................ 217
9.4 Conversion Chart................................................................................................................................ 219
9.5 Definitions ........................................................................................................................................ 220
Predelivery Checklist .............................................................................................................................. 223
TABLE OF CONTENTS

214510 1Revision A
Chapter 1: Safety
Understanding and consistently following these safety procedures will help to ensure the safety of those operating the
machine and of bystanders.
1.1 Safety Alert Symbols
The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine.
Figure 1.1: Safety Symbol
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

214510 2Revision A
1.2 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words,
IMPORTANT and NOTE, identify non-safety related information.
Signal words are selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if it is not prevented, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if it is not prevented, could result in death or serious injury. It may also
be used to alert you to unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if it is not prevented, may result in minor or moderate injury. It may
also be used to alert you to unsafe practices.
IMPORTANT:
Indicates a situation that, if not prevented, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.
SAFETY

214510 3Revision A
1.3 General Safety
Operating, servicing, and assembling machinery presents several safety risks. These risks can be reduced or eliminated by
following the relevant safety procedures and wearing the appropriate personal protective equipment.
Figure 1.2: 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 1.3: 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 1.4: 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

214510 4Revision A
Figure 1.5: Safety around Equipment
•Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as hoodies, scarves, or bracelets.
•Keep all shields in place. NEVER alter or remove safety
equipment. Ensure that the driveline guards can rotate
independently of their shaft, and that they can telescope
freely.
•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 1.6: 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 1.7: 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

214510 5Revision A
1.4 Hydraulic Safety
Because hydraulic fluid is under extreme pressure, hydraulic fluid leaks can be very dangerous. The proper safety
procedures must be followed when inspecting for hydraulic fluid leaks and servicing hydraulic equipment.
Figure 1.8: Testing for Hydraulic Leaks
•Always place all hydraulic controls in Neutral before leaving
the operator’s seat.
•Ensure that all the components in the hydraulic system are
kept clean and in good condition.
•Replace any worn, cut, abraded, flattened, or crimped hoses
and steel lines.
•Do NOT attempt any makeshift repairs to hydraulic lines,
fittings, or hoses by using tapes, clamps, cements, or
welding. The hydraulic system operates under extremely
high pressure. Makeshift repairs can fail suddenly and create
hazardous conditions.
Figure 1.9: Hydraulic Pressure Hazard
•Wear proper hand and eye protection when searching for
high-pressure hydraulic fluid leaks. Use a piece of cardboard
as a backstop instead of your hands to isolate and identify
a leak.
•If injured by a concentrated, high-pressure stream of
hydraulic fluid, seek medical attention immediately. Serious
infection or toxic reaction can develop from hydraulic fluid
piercing the skin.
Figure 1.10: Safety around Equipment
•Ensure that all components are tight and that steel lines,
hoses, and couplings are in good condition before applying
pressure to a hydraulic system.
SAFETY

214510 6Revision A
1.5 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.
For further welding precautions, consult the windrower operators manual.
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

214510 7Revision A
1.6 Safety Signs
Safety signs are decals placed on the machine where there is a risk of personal injury, or where the Operator should take
extra precautions before operating the controls. They are usually yellow.
Figure 1.11: 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

214510 9Revision 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 Header Specifications for Unloading and Assembly
Header dimensions, weight, and spreader bar specifications are provided so that you can choose the correct equipment to
lift, tip, or transport the header safely.
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.
Refer to the following specifications:
•For header weight, refer to Table 2.1, page 9.
•For header dimensions (fully assembled header attached to shipping stands), refer to Table 2.2, page 10.
Table 2.1 Header Weight
IMPORTANT:
These are approximate weights for a SINGLE HEADER that include the bare header and shipping stands. When additional
optional kits are installed, the weight will increase.
Header Model Weight
D215 1689 kg. (3723 lb.)
D220 1852 kg. (4081 lb.)
D225 2163 kg. (4768 lb.)
D230 2622 kg. (5779 lb.)
D235 2843 kg. (6266 lb.)
D241 2946 kg. (6493 lb.)
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.)
IMPORTANT:
Forklifts are normally rated for a load center 610 mm (24 in.)
ahead of back end of the forks. To obtain the forklift capacity for
a load center (A) at 1220 mm (48 in.) (B), check with your forklift
distributor. The minimum fork length (C) is 1981 mm (78 in.).

214510 10 Revision A
Table 2.2 Header Dimensions –Fully Assembled and Attached to Shipping Stands
IMPORTANT:
These approximate dimensions are provided to help you choose the correct size of vehicle to lift or transport the header.
These dimensions assume the header is assembled and attached to the shipping stands.
Header Model Dimensions
ABC
D215 5.1 m (16 ft. 7 in.)
D220 6.6 m (21 ft. 7 in.)
D225 8.1 m (26 ft. 7 in.)
D230 9.6 m (31 ft. 7 in.) 2.6 m (8.4 ft.) 1.5 m (4.9 ft.)
D235 11.2 m (36 ft. 7 in.)
D241 13.0 m (42 ft. 7 in.)
UNLOADING HEADER

214510 11 Revision A
2.2 Unloading Header from Trailer
To ensure that the header is unloaded safely and without damage, follow the recommended unloading procedure provided
here.
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 minimum lifting equipment requirements, refer to 2.1 Header Specifications for Unloading and Assembly, page 9.
1. Move the trailer into position and block the trailer wheels.
2. Lower the trailer storage stands.
Figure 2.2: Header Shipping Supports
3. Approach one of the headers with a forklift, and slide forks
(A) through shipping support (B) as far as possible without
contacting the shipping support of the second header.
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 the hauler’s tie-down straps, chains, and wooden
blocks.
5. Slowly raise the header off the trailer deck.
NOTE:
Raise the header just enough to clear the trailer deck.
UNLOADING HEADER

214510 12 Revision A
Figure 2.3: Header on Level Ground
6. Back up until the header clears the trailer and slowly lower
it to 254 mm (10 in.) from the ground.
7. Take the header to the storage area, and set it down
securely on level ground. Ensure the ground is flat and free
of rocks or debris that could damage the header.
8. Check for shipping damage and missing parts.
UNLOADING HEADER