D50 and D60 Harvest Headers® For Self-Propelled Windrowers OPERATOR’S MANUAL Revision B Part #169441 $15
This Manual contains instructions for “SAFETY”, “OPERATION”, and “MAINTENANCE/SERVICE” information for your new MacDon Models D50 and D60 Harvest Header® for self-propelled windrowers.
1 INTRODUCTION This instructional manual contains operating and maintenance information on the MacDon D50/D60 Harvest Headers. They are 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, the D50 and D60 Harvest Headers will cut and lay crop into uniform fluffy windrows.
2 MODEL AND SERIAL NUMBER NOTE: Right hand (RH) and Left-hand (LH) designations are determined from the Operator’s position, facing forward. 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: HEADER MODEL___________SERIAL NUMBER________________YEAR______ Serial Number Plate is located on the left hand endsheet, near the knife drive motor.
TABLE OF CONTENTS 1 2 3 4 5 6 7 INTRODUCTION ............................................................................................................................................ 1 MODEL AND SERIAL NUMBER................................................................................................................... 2 SAFETY ......................................................................................................................................................... 6 3.
TABLE OF CONTENTS 7.17.2 Deflector Rework ......................................................................................................................... 60 7.18 HEADER LEVELLING ......................................................................................................................... 61 7.19 UNPLUGGING CUTTERBAR ............................................................................................................. 61 7.20 UPPER CROSS AUGER ....................................
TABLE OF CONTENTS 8.9.11 Reel Speed Sensor ................................................................................................................... 131 8.9.12 Reel Tines ................................................................................................................................. 132 8.9.13 Tine Tube Bushings .................................................................................................................. 134 8.10 TRANSPORT SYSTEM ..............................
SECTION 3. SAFETY 3 SAFETY 3.2 3.1 Note the use of the signal words DANGER, WARNING, and CAUTION with safety messages. The appropriate signal word for each message has been selected using the following guidelines: SAFETY ALERT SYMBOL SIGNAL WORDS DANGER Indicates an imminently hazardous situation that if not avoided, will result in death or serious injury. WARNING This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine.
SECTION 3. SAFETY 3.3.2 SAFETY SIGN LOCATIONS 3.3.2.
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SECTION 3. SAFETY 3.3.2.
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SECTION 3. SAFETY 3.3.2.
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SECTION 3. SAFETY 3.4 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: • • • • • • a hard hat. protective shoes with slip resistant soles. protective glasses or goggles. heavy gloves.
SECTION 3. SAFETY • 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. • 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.
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SECTION 6. SPECIFICATIONS 6 SPECIFICATIONS HEADER MODEL HEADER SIZE D60 15 FT. D50/D60 20 FT. 25 FT. D60 30 FT. 35 FT. 40 FT. 375.1 (9527) 435.1 (11051) 495.1 (12575) 505.7 (12845) 547.5 (13907) 601.5 (15278) 4700 (2134) Not Applicable OVERALL Transport (Reel Full Aft) With CA20 Adapter Width (Inches (mm)) Length (Inches (mm)) 96 (2438) 255.1 (6479) Field Transport (with Tow Pole) 315.1 (8003) Not Applicable Height - Transport 97 in.
SECTION 6. SPECIFICATIONS HEADER MODEL HEADER SIZE D60 15 FT. D50/D60 20 FT. 25 FT. D60 30 FT. 35 FT. 40 FT. CONVEYOR AND DECKS Draper Drive Hydraulic Draper Width 41.6 in. (1057 mm) Draper Speed 0 - 742 ft/min (225 m/min) D50 D60 Delivery Opening 67.3 - 75.6 in. (1710 - 1920 mm) Not Applicable 60.61 - 69.7 in. (1540 - 1770 mm) 67.1 - 76.7 in. (1720 - 1950 mm) 37.2 - 41.7 in. (945 - 1058 mm) Height Draper Angle (Cutterbar on Ground) Not Applicable D50 & D60 13.0° - 18.
SECTION 7. OPERATION • Never attempt to start the engine or operate the machine except from the windrower seat. • Check the operation of all controls in a safe clear area before starting work. • Do not allow riders on windrower. • Never start or move the machine until you are sure all bystanders have cleared the area. • Avoid travelling over loose fill, rocks, ditches or holes. • Drive slowly through gates and doorways. • When working on inclines, travel uphill or downhill when possible.
SECTION 7. OPERATION 7.3 4. Move hose bundle (A) from tractor around hose support on header. HEADER ATTACHMENT/DETACHMENT 7.3.1 ATTACHMENT ELECTRICAL Refer to the M150/M200 or M205 Self-Propelled Windrower Operator’s Manual for procedures to mechanically attach the header to the selfpropelled windrower. Refer to the following procedures for electrical and hydraulic connections. The header drive hydraulic hoses and electrical harness are located on the left cab-forward side of the tractor.
SECTION 7. OPERATION 7.3.2 DETACHMENT a. Fully lower the reel. b. Disconnect the reel hydraulics as follows: E G E H 1. Push in lock button (G), and pull handle (H) to disengage multi-coupler (E) from header receptacle. b. Connect reel hydraulics (E) as follows: 1. Check connectors, and clean if required. F H G E c. 2. Open cover (F) on header receptacle. 3. Push in lock button (G), and pull handle (H) to “half open” position. 4.
SECTION 7. OPERATION c. Disconnect the header drive hydraulics as follows: C 1. Disengage and rotate lever (C) counter clockwise to fully up position. 2. Disconnect electrical connector from header. 3. Disconnect hoses from header as follows: K J i. Line up slot (J) in collar with pin (K) on connector. ii. Push collar toward pin, and pull connector to disengage. iii. Install caps on connectors and hose ends (if equipped). A D C 4. Route hose bundle (A) back onto hose support on windrower. 5.
SECTION 7. OPERATION 7.4 7.5 BREAK-IN PERIOD a. After attaching header to windrower for the first time, operate the machine with reel drapers and sickle running slowly for 5 minutes, watching and listening FROM THE OPERATOR'S SEAT for binding or interfering parts. NOTE Reel and side drapers will not operate until oil flow fills the lines. CAUTION Before investigating an unusual sound or attempting to correct a problem, shut off engine, and remove key. b. Perform the items specified in 8.11.
SECTION 7. OPERATION 7.6 7.7 DAILY START-UP CHECK SHUTDOWN PROCEDURE Do the following each day before start-up: CAUTION Before leaving the windrower seat for any reason: CAUTION • • Clear the area of other persons, pets etc. Keep children away from machinery. Walk around the machine to be sure no one is under, on or close to it. Wear close fitting clothing and protective shoes with slip resistant soles. • Remove foreign objects from the machine and surrounding area.
SECTION 7. OPERATION 7.8 HEADER CONTROLS CAUTION Be sure all bystanders are clear of machine before starting engine or engaging any header drives. See your Windrower Operator's Manual for identification of in-cab controls for: • • • • • • • 7.
SECTION 7. OPERATION 7.10 REEL PROPS WARNING C To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. IMPORTANT: To prevent damage to reel support arms, do not transport header with reel props engaged. Reel props are located at each reel support arm. To engage reel props, proceed as follows: D60 Header: D a. Raise reel to maximum height. D60 HARVEST HEADER c.
SECTION 7. OPERATION 7.11 HEADER SET-UP The following table is included as a guideline for setting the pick-up reel and the header. Settings other than those suggested can be made to suit various crops and conditions not covered in the table. . Example shown below: Canola, leave long stubble, heavy crop. Select set-up B. In Reel Settings Chart (next page) - Set cam at 2, position reel at 3 or 4, and cut with varying header angles to suit varying crop conditions. To use the table, proceed as follows: 1.
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SECTION 7. OPERATION 7.12 HEADER OPERATING VARIABLES Satisfactory function of the header in all situations requires making proper adjustments to suit various crops and conditions. Correct operation reduces crop loss, and allows cutting of more acres. As well, proper adjustments and timely maintenance will increase the length of service you receive from the machine. The variables listed below and detailed on the following pages will affect the performance of the machine.
SECTION 7. OPERATION 4. Lower header to desired cutting height using windrower controls, and check spring length as shown. Re-adjust wheels as required to achieve range. 2. Adjust left wheels as follows: H Release IMPORTANT G Lock Continuous operation with excessive spring compression (i.e. spring length shorter than 11.6 in. (295 mm) can result in damage to the suspension system. 12.6 in +/- 1.0 (320 mm +/- 25) i. d.
SECTION 7. OPERATION Inner Skid Shoes 7.12.1.2 Cutting On The Ground Cutting on the ground is controlled with a combination of skid shoes, header angle, and float adjustment, and not with the header lift cylinders. Having the header "ride" on the skid shoes allows the float linkage to float header over obstacles and follow ground contours, rather than supporting the header with the cylinder. Lowering the skid shoes or decreasing header angle increases the cutting height.
SECTION 7. OPERATION 7.12.3 The following table summarizes the adjustment range: HEADER ANGLE Header angle is the angle between the drapers and the ground, and is adjustable to accommodate crop conditions and/or soil type. HEADER WIDTH DRAPER ANGLE GUARD ANGLE Guard angle is the similar to header angle which is the angle between the guard upper surface and the ground. 15 FT. N/A N/A 20 FT. 13.0° - 18.4° 7.0° - 12.4° Refer to illustration. 25 FT. 13.0° - 18.4° 7.0° - 12.4° 30 FT. 13.
SECTION 7. OPERATION 7.12.4 REEL SPEED Reel speed affects feeding of crop into the sickle and onto the drapers, as well as the smoothness and evenness of the delivered crop. Operating the reel too fast or too slow relative to ground speed will cause bunching. At the proper speed, the reel discs should appear to be being driven by the ground. • If they look like they are skidding relative to ground, the reel is turning too slow.
SECTION 7. OPERATION 7.12.5 GROUND SPEED Ground speed should be such that the sickle can cut crop smoothly and cleanly, while giving the desired delivery of material to the opening. Excessive ground speed results in "ragged" cutting. Refer to Section 7.15 WINDROW TYPES for effects of ground speed on windrow formation. Higher ground speeds require heavier float settings to prevent excessive bouncing. This will result in increased cutting component damage.
SECTION 7. OPERATION 7.12.6 7.12.7.1 Knife Speed Guidelines DRAPER SPEED a. The draper speed is controlled with the windrower CDM (Cab Display Module). Refer to your SelfPropelled Windrower Operator’s Manual. b. Adjust draper speed to achieve good feeding of crop onto adapter draper. Excessive draper speed will reduce draper life. Recommended Knife Speed Range (RPM) Header Size SK DK (Single Knife Header on SP Windrower) (Double Knife Header on SP Windrower) 15 FT. --- 750 - 950 20 and 25 FT.
SECTION 7. OPERATION 20 and 25 Foot Single and Double Knife GROUND SPEED (km/hr) 3.2 4.8 6.4 8.0 9.7 11.3 12.9 14.5 1750 850 1700 825 1650 800 1600 775 1550 750 1500 725 1450 700 1400 675 1350 650 1300 625 1250 600 KNIFE SPEED SPEED (spm) (spm KNIFE KNIFE SPEED SPEED (rpm) (rpm 1.
SECTION 7. OPERATION 35 Foot Single and Double Knife GROUND SPEED (km/hr) 3.2 4.8 6.4 8.0 9.7 11.3 12.9 14.5 1550 750 1500 725 1450 700 1400 675 1350 650 1300 625 1250 600 1200 575 1150 550 1100 525 1050 500 35 FT DRAPER KNIFE SPEED (spm KNIFE KNIFESPEED SPEED (rpm (rpm)) 1.6 775 DK FLAX MAX DK CEREALS MAX/FLAX MIN DK CEREALS MIN SK FLAX MAX SK CEREAL MAX/FLAX MIN SK CEREAL MIN 1000 1 2 3 4 5 6 7 8 9 GROUND SPEED (miles/hr) Example: Cutting Flax at 5.0 mph (8.
SECTION 7. OPERATION 7.12.8 REEL HEIGHT Depending on crop height, adjust reel height to carry material through the sickle onto the drapers. Operate windrower hydraulics as required. Refer also to Section 7.12.9 Reel Fore-Aft Position. REEL HEIGHT CHART CROP CONDITION REEL POSITION Laying Down / Lodged Down (Also Increase Reel Speed and/or Cam Setting) Bushy or Heavy Standing Up • For straight standing crop, center the reel over the cutterbar (4 - 5 on gauge).
SECTION 7. OPERATION 7.12.9.1 Mechanical Adjustment - Fore-Aft 7.12.9.3 Fore-Aft Cylinder Position WARNING Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. a. Lower or raise reel so support arms are horizontal, stop engine, and remove key. The reel can be moved approximately nine inches further aft by re-positioning the cylinders on the reel arms. a. Position reel so support arms are horizontal, stop engine, and remove key.
SECTION 7. OPERATION c. G Re-position right arm cylinder (Double Reel) as follows: M J K L H RIGHT ARM - DOUBLE REEL 1. Remove bolts (L) that secure aft plate (M), and remove the plate. 5. Lift the aft end of the cylinder out of support assembly, and retract the cylinder so that cylinder center port fitting (K) engages the support assembly. O NOTE Loosen a hose fitting to allow movement of cylinder rod. Be sure to re-tighten fitting after cylinder installation. 6.
SECTION 7. OPERATION NOTE U Loosen a hose fitting to allow movement of cylinder rod. Be sure to re-tighten fitting after cylinder installation. W 4. Re-install plates (M) and (O) with bolts (L) and (N) respectively. d. Re-position right arm cylinder (Single Reel) as follows: X R Q S 5. Lift the aft end of the cylinder out of support assembly, and retract the cylinder so that cylinder center port fitting (X) engages the support assembly. U T RIGHT ARM - SINGLE REEL NOTE 1.
SECTION 7. OPERATION e. Re-position left arm cylinder (Double and Single Reel) as follows: C B A D LEFT ARM - SINGLE and DOUBLE REEL 1. Loosen fitting (A) to allow it to rotate when cylinder is re-positioned. 2. Remove the bolt (B), nut, and spacer (C) that secures the cylinder to the reel arm. 3. Extend cylinder so that mounting hole lines up with new location (D) as shown. NOTE Loosen a hose fitting to allow movement of cylinder rod. Be sure to re-tighten fitting after cylinder installation. 4.
SECTION 7. OPERATION • Cam Positions 3 and 4 - Mainly used to leave long stubble. Allows the reel to reach forward and lift the crop across the knife and onto the drapers. The further forward the reel, the higher the cam angle should be. 7.12.10 REEL TINE PITCH IMPORTANT The following describes the concept and operational guidelines of the pick-up reel. Please read carefully before operating the machine. 7.12.10.1 Concept The pick-up reel is designed to pick up flattened and severely lodged crops.
SECTION 7. OPERATION D50 7.12.10.3 Cam Adjustment WARNING Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. D60 D A G D50 C a. Loosen bolt (D) on clamp securing cam disc to reel arm. B E D60 a. Using a ¾ in. wrench, turn the cam latch pin (A) counter clockwise to release the cam disc. IMPORTANT Turning the pin to the end of the ramp will lock the pin in the disengaged position.
SECTION 7. OPERATION 7.12.11.2 Crop Dividers 7.12.11 CROP DIVIDERS AND RODS The crop dividers are removable to suit installation of a vertical knife at each end of the header, and to decrease the transport width. 7.12.11.1 Divider Rods The divider rods are removable. The rods are suitable when crop is running “down”, while the crop dividers without the rods are better in standing crops.
SECTION 7. OPERATION D50 7.12.11.2.2 Installation a. Raise header, stop engine, remove key, and engage lift cylinder lockouts. Refer to Windrower Operator’s Manual. b. Open/remove header endshields. Refer to Section 8.4 ENDSHIELDS. D60 a. Open/remove header endshield. F B E A b. At divider storage location, lift divider to disengage lugs (E) at lower end, and then lower it slightly to disengage pin (F) from endsheet. c. Remove bolt (A), lock-washer, and flat washer, and lower divider (B). d.
SECTION 7. OPERATION B J f. Check that divider does not move laterally. Adjust bolts (J) as required to tighten divider, and remove lateral play when pulling at divider tip. g. Replace endshields. e. Position crop divider as shown by locating lugs (B) in holes in endsheet. D50 b. Open endshield. A f. A c. Lift forward end of divider and re-install bolt (A), lock-washer, and flat washer. Tighten bolt. Remove bolt (A), lock-washer, and flat washer from inside of end sheet. C B d.
SECTION 7. OPERATION 7.13.1 7.13 DELIVERY OPENING/DECK SHIFT The width and position of the delivery opening affects the width and configuration of the windrow. The decision to widen or narrow the center delivery opening; or whether or not to double windrow should be based on the following factors: • combine pick-up capability, • type and yield of crop, • weather conditions (rain, humidity, wind), and, • drying time available.
SECTION 7. OPERATION 7.13.2 DELIVERY OPENING - D50 Both decks can be shifted manually ,and can be positioned to set the delivery opening at three widths; • • • WIDE MEDIUM NARROW 76 in. (1925 mm) 74 in. (1875 mm) 67.5 in. (1715 mm) The decks are factory set at the “MEDIUM” width position. Change opening as follows: WIDE NARROW MEDIUM A A A LH DECK SHOWN - RH OPPOSITE WIDE MEDIUM NARROW a. Remove six bolts (A) from backsheet, and move deck so that holes at desired opening width line up. b.
SECTION 7. OPERATION 7.14.2 7.14 DOUBLE WINDROWING MANUAL DECK SHIFT Both decks can be shifted manually, and can be positioned to deliver the crop from the right or left end, and the center. WARNING Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. A B The 25 FT. to 40 FT.
SECTION 7. OPERATION C RIGHT DECK MOTOR NOTE If right deck is moved, loosen clamp on plastic sleeve at right deck drive motor so that hoses (C) can be reversed. Re-tighten clamp.
SECTION 7. OPERATION 7.15 WINDROW TYPES There are three basic criteria by which the quality of a windrow is measured: • Weight Distribution - heads and stalks distributed evenly across full width of windrow. WINDROW TYPE • • Good Curing - a loose, open windrow for better drying. Good Weatherability - a well-formed windrow that supports heads off the ground and holds together in extreme weather conditions.
SECTION 7. OPERATION 7.16 HAYING TIPS The following information may be useful when using the D50 and D60 Harvest Headers in hay crops: 7.16.1 7.16.4 CURING a. A quick cure will maintain top quality because: • 5% of the protein is lost for each day hay lies on the ground, • The sooner the cut hay is off, the earlier the start for next growth. b. Leaving the windrow as wide and thin as possible makes for the quickest curing c. The cured hay should be baled as soon as possible. 7.16.2 d.
SECTION 7. OPERATION 7.16.7 CHEMICAL DRYING AGENTS Hay drying agents work by removing wax from legume surfaces, enabling water to escape and evaporate faster. However, treated hay lying on wet ground will also absorb ground moisture faster. Before deciding to use a drying agent, costs and benefits relative to your area should be carefully compared.
SECTION 7. OPERATION 7.17 DRAPER DEFLECTORS D60 single knife headers are equipped with rubber deflectors that are attached to the inboard side of the endsheets to prevent material from falling through the gap between the endsheet and the draper. In some cases material hesitates on the deflectors, and will not flow onto the draper. Replace the existing deflector with a narrower one, or rework the existing deflector. 7.17.1 Deflector Replacement a. Raise reel fully, and lower header to ground. b.
SECTION 7. OPERATION 7.18 HEADER LEVELLING 7.19 UNPLUGGING CUTTERBAR The windrower linkages are factory set to provide the proper level for the header, and should not normally require adjustment. The float springs are not used to level the header. a. Stop forward movement of the machine, and disengage header drives. b. With header on ground, back up several feet, and engage header drive clutch. If the header is not level, check the tire pressures on the windrower ensuring they are properly inflated.
SECTION 7. OPERATION a. Lower header to ground, stop engine, and remove key. 7.20 UPPER CROSS AUGER WARNING Stop engine, and remove key before removing plugged material from header. A child or even a pet could engage the drive. C The cross auger helps deliver very bulky crops across the header onto the windrow. Removable beater bars assist in delivering material through the header opening. A B DOUBLE REEL HEADERS If wrapping occurs, the beater bars can be removed as shown in the next column.
SECTION 7. OPERATION 7.21.2 7.21 TRANSPORTING HEADER WARNING Do not drive windrower with header attached on a road or highway at night, or in conditions which reduce visibility, such as fog or rain. The width of the header may not be apparent under these conditions. 7.21.1 To avoid bodily injury and/or machine damage caused by loss of control: Check local laws for width regulations and lighting or marking requirements before transporting on roads.
SECTION 7. OPERATION 7.21.2.2 Towing The Header 7.21.3 CAUTION THIS IS INTENDED TRANSPORT. AS SLOW SPEED CONVERTING FROM TRANSPORT TO FIELD POSITION a. Block the tires to prevent header rolling, and unhook from towing vehicle. b. Remove tow-bar as follows: CAUTION A To avoid bodily injury and or machine damage caused by loss of control: • Do not exceed 25 mph (40 km/h). Reduce transport speed for slippery or rough conditions. • Turn corners only at very low speeds (5 mph (8 km/h) or less).
SECTION 7. OPERATION G 1. Locate larger end of one section of tow-bar in cradle (K) on header back-tube. 2. For clevis end of tow-bar, secure in support (L) on endsheet with hitch pin (M). Secure with lynch pin. 3. Install rubber strap (N) on cradle. 4. Similarly locate other section of tow-bar in cradle at other end of header. 5. Secure tube end in support (O) with clevis pin (P). Secure with hairpin. 6. Install rubber strap (N) on cradle. d. Attach header to power unit.
SECTION 7. OPERATION 7.21.3.1 Front Wheels To Field DANGER Release To avoid bodily injury or death from unexpected start-up or fall of raised header, stop engine, remove key and engage header lift cylinder stops before going under header for any reason. a. Raise header fully. b. Swivel the wheel assembly so that wheels are aligned with lower frame. C Lock TRANSPORT TO FIELD - FRONT WHEELS d. Pull handle (C) to release and lower the linkage. A D E B A F TRANSPORT TO FIELD - FRONT WHEELS e.
SECTION 7. OPERATION 7.21.3.2 Rear Wheels To Field N G S P Q TRANSPORT TO FIELD - LH WHEEL R a. Pull pin (G) at left wheel, swivel wheel clockwise, and lock with pin (G). TRANSPORT TO FIELD - RH WHEEL L Release f. At right cutterbar wheel, pull pin (N) on brace (P), disengage brace from cutterbar, and lower the brace against axle (Q). g. Remove pin (R), lower the support (S) onto axle, and re-insert pin into support. h. Swing axle clockwise to rear of header.
SECTION 7. OPERATION IMPORTANT Check that wheels are locked, and that handle is in “locked” position. FIELD POSITION - LH SIDE FIELD POSITION - RH SIDE m. The conversion is complete when the wheels are as shown.
SECTION 7. OPERATION 7.21.4 c. CONVERTING FROM FIELD TO TRANSPORT POSITION Place suspension assembly in “full upward” location (E) in leg, and lower handle (F) to lock. Raise header fully, and proceed as follows: DANGER To avoid bodily injury or death from unexpected start-up or fall of raised header, stop engine, remove key, and engage header lift cylinder stops before going under header for any reason. D FIELD TO TRANSPORT - LH SIDE 7.21.4.
SECTION 7. OPERATION 7.21.4.2 Right Side Wheels To Transport A Release C B Lock D FIELD TO TRANSPORT - LH WHEEL h. Left wheel is now in transport position as shown in illustration. FIELD TO TRANSPORT - RH SIDE a. At wheels at the right end of header, remove hairpin (A) from latch. b. Lift latch (B), disengage right axle, and lower to ground. CAUTION J Stand clear of wheels and release linkage carefully as wheels will drop once the mechanism is released. c.
SECTION 7. OPERATION 7.22 STORAGE Do the following at the end of each operating season: Q a. Clean the header thoroughly. O P CAUTION Never use gasoline, naphtha or any volatile material for cleaning purposes. These materials may be toxic and/or flammable. M N CAUTION Cover cutterbar and sickle guards to prevent injury from accidental contact. L b. Store the machine in a dry, protected place if possible. If stored outside, always cover with a waterproof canvas or other protective material. c.
SECTION 8. MAINTENANCE AND SERVICING 8 MAINTENANCE AND SERVICING 8.2 The following instructions are provided to assist the Operator in the use of the header. Detailed maintenance, service, and parts information are contained in the Service Instruction Manual, and the Parts Catalog that are available from your MacDon Dealer. 8.1 RECOMMENDED SAFETY PROCEDURES • Park on level surface when possible. Block wheels securely if windrower is parked on an incline.
SECTION 8. MAINTENANCE AND SERVICING 8.3 MAINTENANCE SPECIFICATIONS 8.3.1 8.3.1.2 Metric Bolts RECOMMENDED TORQUES • 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.
SECTION 8. MAINTENANCE AND SERVICING 8.3.1.3 8.3.1.4 Flare Type Hydraulic Fittings FITTING NUT FLARE O-ring Type Hydraulic Fittings LOCKNUT WASHER O-RING GROOVE BODY FLARESEAT SEAT 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.
SECTION 8. MAINTENANCE AND SERVICING 8.3.2 8.3.3 ROLLER CHAIN INSTALLATION SEALED BEARING INSTALLATION a. Clean shaft, and coat with rust preventative. CAUTION 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. C A B a. Locate ends of chain on sprocket. E D B b. Install flangette (A), bearing (B), second flangette (C), and lock collar (D). A NOTE E The locking cam is only on one side of the bearing. c.
SECTION 8. MAINTENANCE AND SERVICING 8.3.4 RECOMMENDED FLUIDS AND LUBRICANTS Your machine can operate at top efficiency only if clean lubricants are used. • • Use clean containers to handle all lubricants. Store in an area protected from dust, moisture, and other contaminants. LUBRICANT SPEC. DESCRIPTION USE CAPACITIES Grease SAE MultiPurpose High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base As Required Unless Otherwise Specified.
SECTION 8. MAINTENANCE AND SERVICING 8.4 ENDSHIELDS Single knife headers are fitted with a hinged endshield on the LH end of the header for easy access to the header drive. The RH end is not hinged, but is still removable. Double knife headers are fitted with hinged endshields on both ends of the header. 8.4.1 HINGED d. Push in shield where shown (opposite latch) and shield will self-latch. a. To open the hinged endshield, press against latch in opening at (A) on inboard side of endsheet. 8.4.1.
SECTION 8. MAINTENANCE AND SERVICING f. To achieve a snug fit between the aft end of the shield and header frame, loosen bolts (G), and adjust the latch (H) to re-position the shield. J X d. Adjust the endshield to achieve the gap ‘X’ between the front end of the shield and the header frame, in accordance with this chart. TEMPERATURE Degrees ˚F (˚C) GAP ‘X’ Inches (mm) 25 (- 4) 1.1 (28) 45 (7) 1.0 (24) 65 (18) 0.79 (20) 85 (29) 0.64 (16) 105 (41) 0.5 (12) 125 (52) 0.32 (8) 145 (63) 0.
SECTION 8. MAINTENANCE AND SERVICING 8.4.2 8.4.2.1 NON-HINGED Adjustments NOTE a. To remove the endshield, press against latch in opening at (A) on inboard side of endsheet. Plastic endshields are subject to expansion or contraction depending on large temperature variations. Latch pin can be adjusted to compensate for dimensional changes. A a. Remove endshield. b. Lift up on shield, pull out and back to remove shield. E B C D b. Loosen bolts (D). c.
SECTION 8. MAINTENANCE AND SERVICING 8.5 LUBRICATION CAUTION To avoid personal injury, before servicing header or opening drive covers, follow procedures in Section 8.1 PREPARATION FOR SERVICING. Refer to Section 8.3.4 Recommended Fluids and Lubricants for recommended greases. F G SAMPLE GREASE DECAL e. To achieve a snug fit between the aft end of the shield and header frame, loosen bolts (F), and adjust the latch (G) to re-position the shield. f. Tighten bolts (F).
SECTION 8. MAINTENANCE AND SERVICING 8.5.2 LUBRICATION POINTS (Cont’d) NOTE: REEL BEARING LUBE INTERVALS - 500 HOURS OR ONCE PER SEASON - WHICHEVER OCCURS FIRST. REEL CENTER BEARING (1 PLC) DOUBLE REEL ONLY REEL DRIVE CHAIN (1 PLC) DOUBLE REEL SHOWN SINGLE REEL SIMILAR REEL SHAFT RH BEARING (1 PLC) D60 REEL UNIVERSAL (1 PLC) NOTE U-JOINT HAS AN EXTENDED LUBRICATION CROSS AND BEARING KIT. STOP GREASING WHEN GREASING BECOMES DIFFICULT OR IF U-JOINT STOPS TAKING GREASE.
SECTION 8. MAINTENANCE AND SERVICING 8.5.2 LUBRICATION POINTS (Cont’d) D50 High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).
SECTION 8. MAINTENANCE AND SERVICING 8.5.2 LUBRICATION POINTS (Cont’d) NOTE: LUBE INTERVALS - 250 HOURS OR ONCE PER SEASON - WHICHEVER OCCURS FIRST. High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).
SECTION 8. MAINTENANCE AND SERVICING 8.5.2 LUBRICATION POINTS (Cont’d) High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2). Lithium Base FRAME/WHEEL PIVOT (1 PLC) BOTH SIDES NOTE To prevent binding and/or excessive wear caused by sickle pressing on guards, do not over- grease. If more than 6 to 8 pumps of the grease gun are required to fill the cavity, replace the seal in the sickle head.
SECTION 8. MAINTENANCE AND SERVICING 8.5.2 LUBRICATION POINTS (Cont’d) High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).
SECTION 8. MAINTENANCE AND SERVICING 8.5.3 OILING REQUIREMENTS Refer to the following illustration to identify the various locations that require lubrication. See Section 8.3.4 Recommended Fluids and Lubricants for proper oil.
SECTION 8. MAINTENANCE AND SERVICING 8.5.4 HOSES AND LINES Check hydraulic hoses and lines daily for signs of leaks. WARNING • Avoid high-pressure fluids. Escaping fluid can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.
SECTION 8. MAINTENANCE AND SERVICING 8.5.5 HYDRAULIC SCHEMATICS Refer to the appropriate schematic that suits your machine. 8.5.5.
SECTION 8. MAINTENANCE AND SERVICING 8.5.5.
SECTION 8. MAINTENANCE AND SERVICING 8.5.5.
SECTION 8. MAINTENANCE AND SERVICING 8.5.5.
SECTION 8. MAINTENANCE AND SERVICING 8.6 ELECTRICAL a. Use electrical tape and wire clips as required to prevent wires from dragging or rubbing. b. Keep lights clean, and replace defective bulbs. c. To replace light bulbs: 1. Using a Phillips screwdriver, remove screws from fixture, and remove plastic lens. 2. Replace bulb, and re-install plastic lens and screws. NOTE Bulb Part Number - Trade #1156.
SECTION 8. MAINTENANCE AND SERVICING 8.7 8.7.1 SICKLE AND SICKLE DRIVE SICKLE SECTIONS Check daily that sections are firmly bolted to the sickle back, and are not worn or broken. Damaged or worn sections leave behind uncut plants. CAUTION To avoid personal injury, before servicing machine or opening drive covers, follow procedures in Section 8.1 PREPARATION FOR SERVICING. Coarse serrated sections last longer than fine serrated sections in dirty or sandy conditions.
SECTION 8. MAINTENANCE AND SERVICING 8.7.2 SICKLE REMOVAL D WARNING G Stand to rear of sickle during removal to reduce risk of injury from cutting edges. Wear heavy gloves when handling sickle. E a. Stroke sickle to its outer limit, and clean area around sickle head. C F H A REMOVAL 8.7.3.2 Bearing Installation a. Place O-ring (C) and plug (E) in sickle head. B IMPORTANT b. Remove zerk from pin (A). c. Remove nut and bolt (B). d.
SECTION 8. MAINTENANCE AND SERVICING 8.7.4 8.7.5 SICKLE INSTALLATION SPARE SICKLE (SINGLE KNIFE HEADERS) WARNING Stand to rear of sickle during installation to reduce risk of injury from cutting edges. Wear heavy gloves when handling sickle. IMPORTANT Align guards, and re-set sickle holddowns while replacing sickle. A F D A spare sickle may be stored in the header frame tube at the left end as shown above. C Ensure sickle is secured in place. E B a.
SECTION 8. MAINTENANCE AND SERVICING 8.7.6 8.7.6.2 SICKLE GUARDS Check daily that guards are aligned to obtain proper shear cut between sickle section and guard. Sickle sections should contact shear surface of each guard. 8.7.6.1 Guard Replacement CAUTION Always engage reel props before working under reel. Guard Adjustment To align guards, proceed as follows: The guard straightening tool (MacDon part #140135) is available from your MacDon Dealer: 8.7.6.2.
SECTION 8. MAINTENANCE AND SERVICING 8.7.6.2.2 Pointed Guards - Double Knife Refer to previous section for typical guard replacement. The guard near the center of the double knife header, where the two sickles overlap, requires a slightly different replacement procedure. Replace the center guard or center top guide as follows: d. Check and adjust clearance between hold-down and sickle. Refer to Section 8.7.7 Sickle HoldDowns. 8.7.6.2.
SECTION 8. MAINTENANCE AND SERVICING 8.7.6.2.4 Stub Guards – Double Knife Refer to previous section for typical guard replacement. The guard at the center of the double knife header, where the two sickles overlap, requires a slightly different replacement procedure. To replace the center guard or center top guide, proceed as follows: A C NORMAL D B CENTER a. Remove the two nuts (A) and bolts that attach guard (B) and top guide (C) and adjuster bar (D) to cutterbar. b.
SECTION 8. MAINTENANCE AND SERVICING c. 8.7.7 SICKLE HOLD-DOWNS Check daily that sickle hold-downs are set to prevent sickle sections from lifting off guards, but still permit sickle to slide without binding. NOTE After adjusting all hold-downs, run header at a low engine speed, and listen for noise due to insufficient clearance. Insufficient clearance will also result in overheating of the sickle and guards. Re-adjust as necessary. 8.7.7.2 Stub Guards a.
SECTION 8. MAINTENANCE AND SERVICING 8.7.8 SICKLE DRIVE BELTS - NONTIMED DRIVE This section applies to single knife headers, and 40 FT. double knife headers with non-timed drives. For double knife headers with timed drives, refer to Section 8.7.9 Sickle Drive Belts - Timed Drive. 8.7.8.1 8.7.8.2 Removal a. Loosen sickle drive belt using procedure in previous section so that belt (C) can be slipped off drive pulley. b. Remove bolt in plate (D) in endsheet at wobble box, and D remove the plate.
SECTION 8. MAINTENANCE AND SERVICING c. 8.7.9 Tighten nuts (A) on idler mounting bracket. SICKLE DRIVE BELTS - TIMED DRIVE This section applies to 35 FT. and smaller double knife Model D60 Harvest Headers with timed drives. For single knife headers and non-timed double knife headers, refer to Section 8.7.8 Sickle Drive Belts - Non-Timed Drive. 8.7.9.1 E 0.02 - 0.04 in. (0.5 - 1.0 mm) GAP D Left End Drive Remove endshield at left end of header. Refer to Section 8.4 ENDSHIELDS.
SECTION 8. MAINTENANCE AND SERVICING 8.7.9.1.3 K Installation - Left End Timing Belt N H J M d. Loosen two bolts (H) on sickle drive mounting bracket. e. Turn adjuster bolt (J) to loosen the two V-belts (K), and remove belts. f. Remove bolt in plate (L) in left endsheet at wobble box, and L remove the plate. This provides clearance between the pulley and endsheet for the belt when it is removed. g.
SECTION 8. MAINTENANCE AND SERVICING f. Tighten the two bolts (G) on the endsheet. g. Slide idler (P) up until most of the belt slack is taken up. Tighten idler nut (F). h. Adjust the timing belt tension, and check belt clearance to belt guide. See 8.7.9.1.1 Tension Adjustment - Timing Belt. i. Re-install plate (L) in endsheet. L j. Re-install left endshield. k. Re-adjust tension of a new belt after a short run-in period, (about 5 hours). 8.7.9.1.4 Tension Adjustment - Left End Double V-Belts 8.7.9.1.
SECTION 8. MAINTENANCE AND SERVICING 8.7.9.2 8.7.9.2.3 Right End Drive Installation - Right End Timing Belt CAUTION D E To avoid personal injury, before servicing machine or opening drive covers, follow procedures in Section 8.1 PREPARATION FOR SERVICING. F 8.7.9.2.1 Tension Adjustment - Timing Belt IMPORTANT To prolong belt and drive life, do not over-tighten belt. Refer to 8.7.9.1.1 Tension Adjustment - Timing Belt. 8.7.9.2.2 Removal - Right End Timing Belt a. Open right endshield. a.
SECTION 8. MAINTENANCE AND SERVICING 8.7.9.3 Sickle Drive Timing Double knife D60 Harvest Headers 35 FT. and smaller require that the sickles are properly timed to move in opposite directions. To adjust the sickle timing, proceed as follows: a. Remove the right sickle drive belt. Refer to Section 8.7.9.2.2 Removal - Right End Timing Belt. C LEFT SICKLE B A DIRECTION OF MOVEMENT RIGHT SICKLE SECTIONS CENTERED BETWEEN GUARDS D c.
SECTION 8. MAINTENANCE AND SERVICING 8.7.10 WOBBLE BOX 8.7.10.3 Pulley Removal CAUTION To avoid personal injury, before servicing machine or opening drive covers, follow procedures in Section 8.1 PREPARATION FOR SERVICING. 8.7.10.1 Mounting Bolts Check four wobble box mounting bolts (B) torque after the first 10 hours operation, and every 100 hours thereafter. Torque should be 200 ft·lbf (270 N·m). When tightening, start with the side mounting bolts. 8.7.10.2 Wobble Box Removal a.
SECTION 8. MAINTENANCE AND SERVICING 8.7.10.5 Wobble Box Installation C A E B D a. Position wobble box with locating tab (C) at original position, and install four bolts (B). Torque side bolts, and then bottom bolts to 200 ft·lbf (270 N·m). d. Slide pitman arm (D) onto output shaft. e. Slide arm up or down on shaft until it “just” contacts knifehead [0.010 in. (0.25 mm) gap] (E). f. Rotate pulley to ensure drive arm just clears frame to ensure proper placement on splines.
SECTION 8. MAINTENANCE AND SERVICING 8.7.10.6 Changing Oil NOTE Change wobble box lubricant after the first 50 hours operation and every 1000 hours (or 3 years) thereafter. a. Raise header to allow a suitable container to be placed under wobble box drain to collect oil. b. Open endshield(s). c. Remove breather/dipstick, and drain plug. d. Re-install drain plug, and add 2.3 U.S. quarts (2.2 litres) SAE 85W-140 oil to required level. e. Close endshield(s).
SECTION 8. MAINTENANCE AND SERVICING b. If required, set draper tension as follows: 8.8 DRAPERS CAUTION LOOSEN To avoid personal injury, before servicing machine or opening drive covers, follow procedures in Section 8.1 PREPARATION FOR SERVICING. 8.8.1 DRAPER TENSION ADJUSTMENT A TIGHTEN Draper tension should be just enough to prevent slipping and keep draper from sagging below cutterbar. Set draper tension as follows: B 1.
SECTION 8. MAINTENANCE AND SERVICING 8.8.2 REPLACING SPLIT DRAPER 8.8.2.2 Draper Installation The draper should be replaced or repaired if it is torn, missing slats, or cracked. CAUTION To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key and engage lift cylinder locks before going under machine for any reason. 8.8.2.
SECTION 8. MAINTENANCE AND SERVICING 8.8.3 REPLACING ENDLESS DRAPER The draper should be replaced or repaired if it is torn, missing slats, or cracked. CAUTION D To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. C DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key and engage lift cylinder locks before going under machine for any reason. 8.8.3.
SECTION 8. MAINTENANCE AND SERVICING 8.8.3.2 Endless Draper Installation g. Install nuts (D), and tighten. h. Adjust draper tension. Refer to Section 8.8.1 Draper Tension Adjustment. E F a. Insert a pry bar (E) through draper, and locate bar in hole in deck located at approximately the deck “mid-point”. NOTE Pry bar should be of sufficient length to accommodate width of draper. b. Lift deck clear of cutter-bar, and support bar on a stand (F) of suitable height. E F c. Slide draper onto deck. d.
SECTION 8. MAINTENANCE AND SERVICING 8.8.4 DRAPER ALIGNMENT Each draper deck has one fixed roller and one spring-loaded roller. The spring-loaded roller is located at the same end of the deck as the draper tensioner. Both rollers can be aligned by adjuster rods so that the draper tracks properly on the rollers. A B C CAUTION To avoid personal injury, before servicing machine or opening drive covers, follow procedures in Section 8.1 PREPARATION FOR SERVICING.
SECTION 8. MAINTENANCE AND SERVICING 8.8.5.2 8.8.5 DRAPER ROLLER MAINTENANCE The draper rollers have non-greaseable bearings. The external seal should be checked every 200 hours (or more frequently in sandy conditions), to obtain the maximum bearing life. Drive Roller Installation DANGER Engage header lift cylinder stops and reel props before working under header or reel. Refer to illustrations opposite. DANGER Engage header lift cylinder stops and reel props before working under header or reel. 8.8.
SECTION 8. MAINTENANCE AND SERVICING 8.8.5.3 8.8.5.4 Idler Roller Removal Idler Roller Installation See illustration opposite. DANGER Engage header lift cylinder stops and reel props before working under header or reel. a. Raise header and reel, and engage cylinder and reel stops. b. On deck shift headers, position deck so idler roller is easily accessible. c. Loosen and uncouple draper. Refer to Section 8.8.2.1 Draper Removal. A a. Position stub shaft in idler roller in forward arm (B) on deck. b.
SECTION 8. MAINTENANCE AND SERVICING d. Install bearing and seal as follows: 1. Install bearing assembly (E) into roller by pushing on outer race of bearing. The bearing is fully positioned when the 0.55 inch (14 mm) dimension is achieved. See illustration below. 0.55 - 0.59 in. (14 - 15 mm) E 0.12 - 0.16 in. (3 - 4 mm) D 2. Apply grease in front of bearing. Refer to Section 8.3.4 Recommended Fluids and Lubricants. e. Install seal (D) as follows: 1.
SECTION 8. MAINTENANCE AND SERVICING Adjust as follows: 8.8.6 DECK HEIGHT DANGER To prevent material from entering drapers and cutterbar, maintain deck height so that draper runs just below cutterbar with maximum 1/32 in. (1 mm) gap, or with draper deflected down slightly (up to 1/16 in. (1.5 mm)) to creat e a seal. Engage header lift cylinder stops and reel props before working under header or reel. DANGER The illustration shows the adjustment without the draper.
SECTION 8. MAINTENANCE AND SERVICING 8.9 REEL AND REEL DRIVE 8.9.1.1 CAUTION DANGER To avoid personal injury, before servicing header or opening drive covers, follow procedures in Section 8.1 PREPARATION FOR SERVICING. 8.9.1 Clearance Measurement REEL CLEARANCE TO CUTTERBAR The finger to guard/cutterbar clearances with reel fully lowered varies with header width, and are as follows. See illustration opposite.
SECTION 8. MAINTENANCE AND SERVICING 8.9.2 8.9.1.2 Reel Clearance Adjustment DANGER Engage header lift cylinder stops before working under header. a. Raise header, engage header lift cylinder stops, and lower header onto stops. b. Lower the reel fully. REEL FROWN ADJUSTMENT The reel has been adjusted at the factory to provide more clearance at the center of the reel than at the ends (frown) to compensate for reel flexing. The frown adjustment compensates for reel flexing.
SECTION 8. MAINTENANCE AND SERVICING 8.9.3 REEL CENTERING 8.9.3.1 Double Reel Headers 8.9.3.2 Single Reel Headers The reel should be centered between the endsheets. The reels should be centered between the endsheets. B J C E D A D60 D60 a. Loosen bolt (A) on each brace (B). b. Move forward end of reel center support arm (C) laterally as required to center both reels. c. Tighten bolts (A), and torque to 265 ft·lbf (359 N·m). F E D D50 a. Loosen bolt (D) on brace (E) at both ends of reel. b.
SECTION 8. MAINTENANCE AND SERVICING 8.9.4 REEL DRIVE CHAIN - D60 8.9.4.1 Tension Adjustment DANGER E To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. a. Lower header, raise reel, and engage reel props . D A C SINGLE REEL - D60 ONLY c. B On 60 single reel headers, the drive is located on the right outside arm. Remove the one piece cover (D) by removing four screws (E). A H F J DOUBLE REEL G b.
SECTION 8. MAINTENANCE AND SERVICING 8.9.4.2 Replacing Drive Chain - D60 Single Reel 8.9.4.3 Drive Chain - D60 Double Reel a. Remove reel drive cover. Refer to previous section. DANGER To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. H Removal a. Remove reel drive cover. section. E Refer to previous B D b. Loosen six bolts (E). C F A A G b. Loosen bolts (A), and slide motor (B) and motor mount (C) down towards reel shaft. c.
SECTION 8. MAINTENANCE AND SERVICING 8.9.4.3.1 c. Loosen the RH reel arm brace by loosening bolt (L) on back-tube. d. Move RH reel “sideways” to separate the reel tube and the U-Joint (K). e. Remove the chain. Disconnecting the Reel Drive (Method 1): H E a. Support inboard end of right reel with a front end loader and nylon slings (or equivalent set-up). IMPORTANT f. To avoid damaging or denting center tube, support reel as close as possible to the end disc.
SECTION 8. MAINTENANCE AND SERVICING 8.9.4.3.2 Breaking the Chain (Method 2): a. Grind off the head from one of the link rivets, and punch out the rivet to separate the chain. b. Locate ends of chain on sprocket. DIRECTION OF ROTATION B A C D C c. d. e. f. g. h. Install pin connector (A) (not available as a MacDon part) into chain, preferably from the sprocket backside. Install connector (B) onto pins. Install spring clip (C) onto front pin (D) with closed end of clip in direction of sprocket rotation.
SECTION 8. MAINTENANCE AND SERVICING 8.9.5 REEL DRIVE CHAIN - D50 8.9.5.1 Tension Adjustment 8.9.5.2 Removal - Drive Chain DANGER DANGER To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. a. Lower header, raise reel, and engage reel props. To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. a. Remove reel drive cover. Refer to previous section. b.
SECTION 8. MAINTENANCE AND SERVICING 8.9.6 IMPORTANT REEL DRIVE SPROCKET - D60 Do not use pry bars and/or hammer to remove sprocket. This will damage the motor. Use a puller if sprocket does not come off by hand. CAUTION To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. 8.9.6.2 Installation - Drive Sprocket Refer to illustrations opposite. 8.9.6.1 Removal - Drive Sprocket a. Remove reel drive cover(s). Refer to Section 8.9.
SECTION 8. MAINTENANCE AND SERVICING 8.9.7 REEL DRIVE SPROCKET - D50 CAUTION C To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. G 8.9.7.1 Removal - Drive Sprocket a. Lower header, raise reel, and engage reel props. F d. Slip chain (C) off drive sprocket (F). e. Remove bolt (G), lock-washer, and flat washer. f. Remove sprocket (F). A IMPORTANT Do not use pry bars and/or hammer to remove sprocket. This will damage the motor.
SECTION 8. MAINTENANCE AND SERVICING 8.9.8 REEL DRIVE U-JOINT - D60 D CAUTION To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. C 8.9.8.1 Removal - U-Joint a. Lower header, raise reel, and engage reel props. b. Remove reel drive cover. Refer to Section 8.9.4 Reel Drive Chain - D60. c. Support inboard end of right reel with a front end loader and nylon slings (or equivalent set-up).
SECTION 8. MAINTENANCE AND SERVICING 8.9.9 8.9.9.2 REEL DRIVE MOTOR - D60 Installation - Drive Motor Refer to illustrations opposite. DANGER To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. 8.9.9.1 Removal - Drive Motor a. Lower header, raise reel, and engage reel props. b. Remove reel drive cover. Refer to Section 8.9.4 Reel Drive Chain - D60. a.
SECTION 8. MAINTENANCE AND SERVICING 8.9.10 8.9.10.2 Installation - Drive Motor REEL DRIVE MOTOR - D50 Refer to illustrations opposite. DANGER To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. 8.9.10.1 Removal - Drive Motor a. Lower header, raise reel, and engage reel props. b. Remove reel drive cover. Refer to Section 8.9.5 Reel Drive Chain - D50. a. Position hydraulic motor on motor mount, and install four countersunk bolts (D).
SECTION 8. MAINTENANCE AND SERVICING 8.9.11 REEL SPEED SENSOR To adjust and replace the self-propelled windrower reel speed sensor, proceed as follows: CAUTION To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. A WARNING B Stop engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. C C D 0.080 - 0.160 in (2 - 4 mm) a. Removal 1. Disconnect sender wire (A). 2.
SECTION 8. MAINTENANCE AND SERVICING 8.9.12 8.9.12.2 Installation - Steel Tines REEL TINES IMPORTANT IMPORTANT Keep reel tines in good condition. Straighten or replace as required. Ensure tine tube is supported at all times to prevent damage to the tube or other components. 8.9.12.1 Removal - Steel Tines CAUTION A To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. a. Lower header, raise reel, and engage reel props. b.
SECTION 8. MAINTENANCE AND SERVICING 8.9.12.4 Installation - Plastic Fingers 8.9.12.3 Removal - Plastic Fingers A INSTALLATION a. Remove screw (A) with TORX-Plus 27 IP socket wrench. a. Position finger on rear of finger tube, and engage lug at bottom of finger in lower hole in finger tube. b. Gently lift top flange, and rotate finger until lug in top flange engages upper hole in finger tube. IMPORTANT Do not apply force to finger prior to tightening mounting screw.
SECTION 8. MAINTENANCE AND SERVICING 8.9.13 TINE TUBE BUSHINGS CAUTION B To avoid bodily injury from fall of raised reel, always engage reel props before going under raised reel for any reason. D Lower header, raise reel fully, and engage reel stops. 8.9.13.1 Bushing Removal - 6 and 9 Bat PickUp Reels a. Remove bushings at center disc, and left end disc as follows: 3. Rotate arm (B) clear of disc, and slide arm inboard off bushing, and remove bushing halves (D).
SECTION 8. MAINTENANCE AND SERVICING g. Install bushing clamps as follows: D J H 3. Slide tine tube to expose bushing. Remove bushing halves (H). 8.9.13.2 Bushing Installation - 6 and 9 Bat PickUp Reels C 1. Spread clamp (C), and slip over tine tube adjacent to flangeless end (J) of bushing. 2. Locate clamp on bushings (D) so that edges of clamp and bushing are flush when clamp fits into groove on bushing, and lock tabs are engaged.
SECTION 8. MAINTENANCE AND SERVICING 2. Remove bolt (D) at on cam linkage so that tine tube (E) is free to rotate. 8.9.13.3 Bushing Removal - 5 Bat Pick-Up Reels a. Remove bushings at cam end disc as follows: G A B F C 3. Slide tine tube outboard to expose bushings. Remove bolt (F) from tine (or remove plastic finger) next to arm if required so that tube can slide through arm. 4. Remove bushing halves (G). 1. Remove bolts (A) securing arm (B) to disc.
SECTION 8. MAINTENANCE AND SERVICING 8.9.13.4 Bushing Installation - 5 Bat Pick-Up Reels G a. At center disc and left end disc, position bushing halves (G) on tine tube so that lug in each bushing half locates in hole in tine tube. b. Slide tine tube inboard (towards cam end) to locate bushing in reel arm. A B D C c. d. e. f. g. h. At the cam end disc, position bushing halves (C) on tine tube so that lug in each bushing “half locates” in hole in tine tube.
SECTION 8. MAINTENANCE AND SERVICING 8.10.3 8.10 TRANSPORT SYSTEM Check tire pressure daily. Maintain pressures recommended in following table: Optional equipment on 30, 35, and 40 FT. headers. 8.10.1 TIRE INFLATION YEAR TIRE SIZE PRESSURE IMPORTANT 2006 and EARLIER 205-75 R15 40 psi (276 kPa) Whenever a wheel is removed and reinstalled, check torque after one hour of operation. Maintain 80 - 90 ft·lbf (110 - 120 N·m) torque.
SECTION 8. MAINTENANCE AND SERVICING 8.11 MAINTENANCE SCHEDULE The following maintenance schedule is a listing of periodic maintenance procedures, organized by service intervals. Regular maintenance is the best insurance against early wear and untimely breakdowns. Following this schedule will increase machine life. For detailed instructions, refer to the specific headings in Section 8 MAINTENANCE AND SERVICING. Use the fluids and lubricants specified in Section 8.3.4 Recommended Fluids and Lubricants.
SECTION 8. MAINTENANCE AND SERVICING 8.11.2 INTERVAL MAINTENANCE INTERVAL SERVICE FIRST USE Refer To Section 8.11.1 BREAK-IN INSPECTIONS (previous page). 100 HOURS OR ANNUALLY * 1. 2. 3. 4. Check Wobble Box Mounting Bolts. Check Wobble Box Lubricant Level. Check Sickle Drive Belt Tension. Check Transport Wheel Bolt Torque (Option). 5. Check Reel Tine To Cutterbar Clearance. END OF SEASON 10 HOURS OR DAILY 6. Check Reel Drive Chain Tension. 7. Grease Reel Drive Chain. 8.
SECTION 8. MAINTENANCE AND SERVICING 8.11.3 MAINTENANCE RECORD 9 - Check MAINTENANCE RECORD ACTION: 6 - Lubricate S - Change Hour Meter Reading Date Serviced By Refer To Section 8.11.1 Break-In Inspections.
SECTION 9. TROUBLESHOOTING 9 TROUBLESHOOTING 9.1 CROP LOSS AT CUTTERBAR SYMPTOM Does Not Pick-Up Down Crop. PROBLEM SOLUTION Cutterbar too high. Lower cutterbar. 7.12.1 Header angle too flat. Steepen header angle. 7.12.3 Reel too high. Lower reel. 7.12.8 Reel too far back. Move reel forward. 7.12.9 Ground speed too fast for reel speed. Reduce ground speed or increase reel speed. 7.12.5 7.12.4 Increase finger pitch aggressiveness. 7.12.10 Reel fingers not lifting crop sufficiently.
SECTION 9. TROUBLESHOOTING SYMPTOM Crop Not Being Cut At Ends. Crop Getting Stuffed In Gap Between Cutout in Endsheet and Knife Head. 9.2 PROBLEM SOLUTION SECTION Reel not "frowning" or not centered in header. Adjust reel "frown" or reel horizontal position. Sickle hold-downs not adjusted properly. Adjust hold-downs so sickle works freely, but still keep sections from lifting off guards. 8.7.7 Sickle sections or guards are worn or broken. Replace all worn and broken cutting parts. 8.
SECTION 9. TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Ragged Or Uneven Cutting Of Crop (Continued). Loose sickle drive belt. Adjust drive belt tension. 8.7.8 & 8.7.9 Reel too high or too far forward. Lower reel or move reel rearward. 7.12.8 & 7.12.9 Ground speed too slow. Increase ground speed. 7.12.5 Loose sickle drive belt. Adjust drive belt tension. 8.7.8 & 8.7.9 Improper sickle hold-down adjustment. Adjust hold-down. 8.7.7 Dull or broken sickle sections. Replace sickle section. 8.7.
SECTION 9. TROUBLESHOOTING SYMPTOM Excessive Breakage Of Sickle Sections Or Guards. 9.3 PROBLEM SOLUTION SECTION Sickle hold-downs not adjusted properly. Adjust hold-downs. Cutterbar operating too low in stony conditions. Raise cutterbar, using skid shoes. Float is set too heavy. Adjust float springs for lighter float. 7.12.2 Bent or broken guard. Straighten or replace. 8.7.6 Header angle too steep. Flatten header angle. 7.12.3 8.7.7 7.12.1.
SECTION 9. TROUBLESHOOTING SYMPTOM Reel Motion Is Uneven Or Stalls In Heavy Crop. PROBLEM SOLUTION Reel speed too fast. Reduce reel speed. 7.12.4 Reel fingers not aggressive enough. Move to a more aggressive finger pitch notch. 7.12.10 Reel too low. Raise reel. 7.12.8 Relief valve on windrower has low relief pressure setting. Increase relief pressure to manufacturer’s recommendations. Low oil reservoir level on windrower. (NOTE: Sometimes more than one reservoir.) Fill to proper level.
SECTION 9. TROUBLESHOOTING 9.4 HEADER AND DRAPERS SYMPTOM PROBLEM SOLUTION Header Lift Insufficient. Low relief pressure. Increase relief pressure. ** Speed control set too low. Increase control setting. 7.12.6 Relief pressure too low. Increase relief pressure to recommended setting. *** Windrower header drive too slow. Adjust to correct speed for windrower model. ** Worn out gear pump. Replace pump. *** Pressure compensator (V7) set too low. Adjust to increase setting.
SECTION 9. TROUBLESHOOTING SYMPTOM Material Accumulating On End Deflectors And Releasing In Bunches. 9.5 PROBLEM SOLUTION End deflectors too wide. For headers with manual deck shift only, trim deflector or replace with narrow deflector (172381). SECTION 7.17 CUTTING EDIBLE BEANS SYMPTOM Plants Being Stripped, and Complete Or Partial Plants Left Behind. PROBLEM SOLUTION Header being carried off ground. Lower header to ground and run on skid shoes and/or cutterbar. SECTION 7.12.1.
SECTION 9. TROUBLESHOOTING SYMPTOM Plants Being Stripped, and Complete Or Partial Plants Left Behind (Continued). PROBLEM SOLUTION Plastic wear strip for cutterbar has been installed over top of steel wear plates. Remove steel cutterbar wear plates when installing the plastic wear strips for cutterbar. Header not level. Level header. Worn/damaged knife sections. Replace sections or complete knife. 8.7.1, 8.7.2 & 8.7.4 Parts of vines get caught in pointed guard tip.
SECTION 9. TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Float insufficient. Increase float. SECTION 7.12.2 Consider installing optional stub guards. Cutterbar Guards Breaking. Excessive amount of rocks in field. Header too heavy. Cutterbar Pushing Too Much Trash And Dirt. Cutterbar Pushing Too Much Dirt In Certain Locations For Length Of Field. Cutterbar Fills Up With Dirt. Header angle too steep. * & 8.7.6 & 10.3 Re-adjust float to make header lighter. 7.12.
SECTION 9. TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Reel fingers (steel) bent and hook plants out of the crop flow on drapers. Straighten fingers (steel). Dirt accumulation on end of fingers do not let plants slide off fingers over drapers. Raise reel. Adjust reel fore and aft location to move fingers out of the ground. 7.12.8 Excessive accumulation of crop on drapers (up to height of reel center tube). Increase draper speed. 7.12.6 Finger pitch too retarded. Increase finger pitch. 7.12.
SECTION 10. OPTIONS AND ATTACHMENTS 10 OPTIONS AND ATTACHMENTS 10.4 STABILIZER WHEELS See your MacDon Dealer for availability and ordering information. 10.1 CUTTERBAR POLY Available as an attachment for use with selected sizes of D50 and D60 Harvest Headers. Available as an attachment for use with D50 and D60 Harvest Headers. They are recommended for cutting on the ground where the soil adheres to steel. 10.
SECTION 10. OPTIONS AND ATTACHMENTS 10.6 LODGED CROP REEL FINGER KIT 10.8 UPPER CROSS AUGER KIT Available as an attachment for use with D50 and D60 Harvest Headers. The steel fingers attach to ends of “every other” tine bar and help in clearing material in heavy hard to cut crops. Two kits are required for modifying each bar of a 6-bat reel. Available as an attachment for use with D50 and D60 Harvest Headers. The cross auger helps deliver very bulky crops across the header onto the windrow.
SECTION 10. OPTIONS AND ATTACHMENTS 10.11 DRAPER EXTENSION KIT 10.14 SWATH FORMING RODS This kit increases the length of each deck up to 10 inches (250 mm) into the header opening which decreases the swath width when cutting light/thin crops. It includes roller support extensions a draper repair kit and necessary hardware. Installation instructions are included. 10.12 RICE DIVIDER KIT Available as an attachment for D50 and D60 Harvest Headers, and are mainly used for grass seed cutting applications.
SECTION 10. OPTIONS AND ATTACHMENTS 10.17 HAY CONDITIONER 10.19 HYDRAULIC REEL FORE-AFT POSITIONER Available for mounting on D Series Draper Headers. The hay conditioner will lay uniform fluffy windrows. Conditioning or crimping the cut hay allows moisture release for quicker drying and earlier processing. Installation instructions, Operator’s manual, and parts list are included. Available for headers that were not factory equipped with the hydraulic reel fore-aft option.
SECTION 11.
INDEX Abbreviations ................................................................ 18 Attachments ................................................................ 152 Bearing, sealed installation ................................................................. 75 Bolt Torques .................................................................. 73 Break-In Inspections ................................................... 139 Break-In Period .............................................................
INDEX Rice Divider Kit ............................................................ 154 Rock Retarder Kit ........................................................ 155 Roller Chain ................................................................... 75 Safety 2-Panel Decals .......................................................... 10 3-Panel Decals ............................................................ 7 decal locations ............................................................. 7 decals ............
