D65 Draper Header for Self-Propelled Windrowers Operator’s Manual 169899 Revision A Original Instruction The harvesting specialists.
D65 Draper Header for Self-Propelled Windrowers Published: August, 2014
Declaration of Conformity 169899 i Revision A
Introduction This instructional manual contains information on the D65 Draper Header. It is designed to serve a dual function in your grain, hay, and specialty crop harvesting operation. Teamed with your self-propelled windrower power unit and optional hay conditioner, D65 Draper Headers will cut and lay crop into uniform, fluffy windrows. CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR USE THE MACHINE. Use this manual as your first source of information about the machine.
List of Revisions The following lists the changes from the previous version (169594 Revision C) of this document. Summary of Change Refer To Document Number revised. List of Revisions added. Timed Knife Drive Tensioning revised. Tensioning Timed Knife Drive Belts, page 168 Knife Drive Belt Tracking added. Adjusting Belt Tracking, page 172 Reel reinforcement bushing replacement added.
Model and Serial Number Record the model number, serial number, and model year of the header and Slow Speed Transport/Stabilizer Wheel option (if installed) on the lines below. NOTE: Right Hand (RH) and Left Hand (LH) designations are determined from the operator’s position, facing forward. Draper Header Header Model: Serial Number: Year: The serial number plate (A) is located beside the knife drive motor on the left hand endsheet.
TABLE OF CONTENTS Declaration of Conformity .................................................................................................................. i Introduction ......................................................................................................................................ii List of Revisions .............................................................................................................................. iii Model and Serial Number............................
TABLE OF CONTENTS 4.7.9 Reel Fore-Aft Position ............................................................................................................ 58 Adjusting Reel Fore-Aft Position ...................................................................................... 59 Repositioning Fore-Aft Cylinders on Single Reel ............................................................... 59 Repositioning Fore-Aft Cylinders on Double Reel..............................................................
TABLE OF CONTENTS 6 Maintenance and Servicing ................................................................................................................113 6.1 Preparation for Servicing ............................................................................................................... 113 6.2 Maintenance Specifications ........................................................................................................... 114 6.2.1 Conversion Chart ....................................
TABLE OF CONTENTS 6.7.1 6.7.2 6.7.3 6.7.4 6.7.5 6.7.6 6.7.7 6.7.8 Removing Drapers ................................................................................................................176 Installing Drapers ..................................................................................................................176 Adjusting Draper Tension .......................................................................................................178 Removing Endless Draper ..................
TABLE OF CONTENTS Installing Reel Drive Motor..............................................................................................231 Installing Drive Sprocket.................................................................................................232 Tightening Drive Chain ...................................................................................................232 Installing Drive Cover .............................................................................................
TABLE OF CONTENTS 8.4.6 8.4.7 8.4.8 8.4.9 8.4.10 8.4.11 8.4.12 8.4.13 9 End Swath Deflector Rods (End Delivery) ...............................................................................266 HC10 Hay Conditioner...........................................................................................................267 Hydraulic Deck Shift Package ................................................................................................267 Swath Forming Rods (Center Delivery) ..................
1 1.1 Safety Safety Alert Symbols This safety alert symbol indicates important safety messages in this manual and on safety signs on the header. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read and follow accompanying this symbol. the safety message Why is safety important to you? • Accidents disable and kill Figure 1.
SAFETY 1.2 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The appropriate signal word for each situation has been selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be used to alert against unsafe practices.
SAFETY 1.3 General Safety CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself • When assembling, operating, and servicing machinery, wear all the protective clothing and personal safety devices that COULD be necessary for the job at hand. Don’t take chances. • You may need: – A hard hat Figure 1.
SAFETY • Provide a first aid kit for use in case of emergencies. • Keep a fire extinguisher on the machine. Be sure the fire extinguisher is properly maintained. Be familiar with its proper use. • Keep young children away from the machinery at all times. • Be aware that accidents often happen when the Operator is tired or in a hurry to get finished. Take the time to consider the safest way. Never ignore warning signs of fatigue. Figure 1.
SAFETY • Keep the area used for servicing machinery clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment. Be sure all electrical outlets and tools are properly grounded. • Keep work area well lit. • Keep machinery clean. Straw and chaff, on a hot engine, are a fire hazard. Do NOT allow oil or grease to accumulate on service platforms, ladders, or controls. Clean machines before storage.
SAFETY 1.4 Maintenance Safety To ensure your safety while maintaining the machine: • Review the operator’s manual and all safety items before operation and/or maintenance of the machine. • Place all controls in Neutral, stop the engine, set the park brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing. • Follow good shop practices: – Keep service areas clean and dry – Be sure electrical properly grounded outlets and tools are Figure 1.
SAFETY 1.5 Hydraulic Safety • Always place all hydraulic before dismounting. controls in Neutral • Make sure that all 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 the hydraulic lines, fittings, or hoses by using tapes, clamps, cements, or welding. The hydraulic system operates under extremely high pressure.
SAFETY 1.6 Tire Safety • Follow proper procedures when mounting a tire on a wheel or rim. Failure to do so can produce an explosion that may result in serious injury or death. Figure 1.14: Over-Inflated Tire • Do NOT attempt to mount a tire unless you have the proper training and equipment. • Have a qualified tire dealer or repair service perform required tire maintenance. Figure 1.
SAFETY 1.7 Safety Signs • Keep safety signs clean and legible at all times. • Replace safety become illegible. signs that are missing or • If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the current safety sign. • Safety signs are Parts Department. available from your Dealer Figure 1.16: Operator’s Manual Decal 1.7.1 Installing Safety Decals To install a safety decal, follow these steps: 1. Clean and dry the installation area. 2.
SAFETY 1.8 Safety Decal Locations Figure 1.17: Upper Cross Auger A - MD #174682 Figure 1.
SAFETY Figure 1.19: Slow Speed Transport Tow-Bar A - MD #220797 B - MD #220798 Figure 1.
SAFETY Figure 1.
SAFETY Figure 1.
SAFETY Figure 1.
SAFETY Figure 1.
SAFETY Figure 1.25: Back Tube: 30-, 35-, 40-Foot Header A - MD #184372 D - MD #131392 (30 & 35 Ft.
SAFETY 1.9 Interpreting Safety Signs In the safety sign explanations below, (a) refers to the top or left position panel, (b) refers to the bottom or right position of the safety decal depending on decal orientation. NOTE: If there are more than two panels in a decal, the lettering will continue downward or to the right, depending on decal orientation. 1. MD #113482 a. General hazard pertaining to machine operation and servicing b.
SAFETY 2. MD #131391 a. Crushing hazard b. DANGER • Rest header on ground or engage safety props before going under unit Figure 1.27: MD #131391 3. MD #131392 a. Crushing hazard b. WARNING • To avoid injury from fall of raised reel; fully raise reel, stop the engine, remove the key, and engage safety prop on each reel support arm before working on or under reel. • Refer to header operator’s manual. Figure 1.28: MD #131392 4. MD #131393 a. Reel hazard b.
SAFETY 5. MD #166466 a. High pressure oil hazard b. WARNING Do not go near leaks. • High pressure oil easily punctures skin causing serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. • Do not use finger or skin to check for leaks. • Lower load or relieve hydraulic pressure before loosening fittings. Figure 1.30: MD #166466 6. MD #174436 a. High pressure oil hazard b.
SAFETY 8. MD #174682 a. Auger entanglement hazard b. CAUTION • To avoid injury from entanglement with rotating auger, stand clear of header while machine is running. Figure 1.33: MD #174682 9. MD #174684 a. Sharp component hazard b. CAUTION • Wear heavy canvas or leather gloves when working with knife. • Be sure no one is near the vertical knife when removing or rotating knife. Figure 1.
SAFETY 10. MD #184372 a. General hazard pertaining to machine operation and servicing b. CAUTION To avoid injury or death from improper or unsafe machine operation: • Read the operator’s manual and follow all safety instructions. If you do not have a manual, obtain one from your Dealer. • Do not allow untrained persons to operate the machine. • Review safety instructions Operators annually. with all Figure 1.35: MD #184372 • Ensure that all safety signs are installed and legible.
SAFETY 12. MD #193147 a. Transport/roading hazard b. WARNING • Ensure tow-bar lock mechanism is locked Figure 1.37: MD #193147 13. MD #220797 a. Tipping hazard in transport mode b. WARNING • Read the operator’s manual for more information on potential tipping or roll-over of header while transporting. Figure 1.38: MD #220797 14. MD #220798 a. Loss of control hazard in transport b.
SAFETY 15. MD #220799 a. Transport/roading hazard b. WARNING • Ensure tow-bar lock mechanism is locked Figure 1.
2 Reference 2.1 Definitions The following terms and acronyms may be used in this manual.
REFERENCE Term Definition NPT National Pipe Thread: a style of fitting used for low pressure port openings. Threads on NPT fittings are uniquely tapered for an interference fit ORB O-ring boss: a style of fitting commonly used in port opening on manifolds, pumps and motors ORFS O-ring face seal: a style of fitting commonly used for connecting hoses and tubes.
REFERENCE 2.2 Component Identification Figure 2.
3 Specifications | D65 | Attachments S: standard / OF: optional (factory installed) / OD: optional (dealer installed) / -: not available D65 CUTTERBAR Effective cutting width (distance between crop divider points) 15 ft. header 15.00 ft. (180 in. [4572 mm]) S 20 ft. header 20.00 ft. (240 in. [6096 mm]) S 25 ft. header 25.00 ft. (300 in. [7620 mm]) S 30 ft. header 30.00 ft. (360 in. [9144 mm]) S 35 ft. header 35.00 ft. (420 in. [10,668 mm]) S 40 ft. header 40.00 ft. (480 in.
SPECIFICATIONS D65 Guard: Pointed / Forged / Double Heat Treated (DHT) Hold-Down: Sheet Metal / Adjustment bolt OF Guard: Pointed / Forged / Case Hardened (CH) Hold-Down: Sheet Metal / Adjustment Bolt OF Guard: Stub / Forged Bottom / Forged Top / Adjustment Plate OF Guard: Stub / Forged Bottom / Sheet Metal Top / Adjustment Bolt OF Guard: 4 Point / No-choke Design (2 Long Points with Tangs / 2 Short Points without Tangs) OF Guard Angle (cutterbar on ground) Center-Link Retracted 15–25 ft. 7.
SPECIFICATIONS D65 Header Width (Field Mode) Cut Width + 15-1/8 in. (384 mm) Header Only Header Width (Transport Mode—Reel Fore-Aft Fully Retracted) With HC10 Hay Conditioner Installed (B)1 (Long Dividers Installed) 104 in. (2636 mm) (A)1 (Long Dividers Removed) 97 in. (2452 mm) (B)1 (Long Dividers Installed) 112 in. (2834 mm) (A)1 (Long Dividers Removed) 104 in. (2650 mm) S - Figure 3.1: Header Width 1. Refer to Figure 3.1: Header Width, page 31.
SPECIFICATIONS D65 ATTACHMENTS HC10 Hay Conditioner OD Roll Length 72 in. (1830 mm) Outside Diameter 9-1/8 in. (232 mm) Roll Tube Diameter 6-5/8 in. (168 mm) 847–915 rpm Roll Speed Upper Cross Auger OD Outside Diameter Tube Diameter 12 in. (305 mm) All sizes except 25 ft. 6 in. (152 mm) 25 ft. 7 in. (178 mm) Stabilizer Wheel / Slow Speed Transport OD Wheels 15 in.
4 4.1 Operation Owner/Operator Responsibilities CAUTION • It is your responsibility to read and understand this manual completely before operating the header. Contact your MacDon Dealer if an instruction is not clear to you. • Follow all safety messages in the manual and on safety decals on the machine. • Remember that YOU are the key to safety. Good safety practices protect you and the people around you.
OPERATION 4.2 Operational Safety CAUTION Follow these safety precautions: • Follow all safety and operational instructions given in your operator’s manuals. If you do not have a windrower manual, get one from your Dealer and read it thoroughly. • 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 the windrower. Figure 4.
OPERATION DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. Refer to the windrower operator’s manual for instructions regarding the proper use and storage of header safety props. 4.2.2 Reel Safety Props WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason.
OPERATION 3. At the center reel arm on double reel headers, use handle (A) to move lock rod to inboard position (B), engaging pin (C) under prop. 4. Lower reel until safety props contact cylinder mounts on outer reel arms and pin at center arm. Figure 4.4: Center Arm Reel Prop Disengaging Reel Safety Props 1. Raise reel to maximum height. 2. At outer reel arms, move props (A) back inside reel arms. Figure 4.
OPERATION 3. Use handle (B) to move lock rod (A) to outboard position. Figure 4.6: Center Arm Safety Prop 4.2.3 Endshields A hinged, polyethylene endshield is fitted on each end of the header. Opening Endshields To open an endshield, follow these steps. 1. Remove lynch pin (A) and tool (B) from pin (C) at top rear of endshield. Figure 4.
OPERATION 2. Use tool (B) to unlock latch (A) at lower rear corner of endshield. 3. Lift shield at aft end to clear pin at top rear of endshield. 4. Swing shield out and away from header while maintaining forward pressure to prevent shield from slipping out of tab (C) at front of endsheet. IMPORTANT: Do NOT force shield once it has reached its end of travel, as damage to the shield structure can occur. Shield is designed to open sufficiently for normal access to the drive system and manual case as shown.
OPERATION 3. Push in shield to engage lower latch (A). 4. Use tool (B) to lock lower latch (A). Figure 4.11: Endshield 5. Replace tool (B) and lynch pin (A) on top pin (C). Figure 4.12: Endshield Pin Removing Endshields To remove an endshield, follow these steps: 1. Open endshield. Refer to Opening Endshields, page 37. 2. Remove acorn nut (A) that secures the endshield to support (B). 3. Lift endshield off support (B). Figure 4.
OPERATION Installing Endshields To install an endshield, follow these steps. 1. Position endshield on support (A) and align the hole in the endshield with stud (B) on the support. Figure 4.14: Endshield 2. Secure endshield to the support with acorn nut (A). 3. Close endshield. Refer to Closing Endshields, page 38. NOTE: Plastic endshields are subject to expansion, or contraction depending on large temperature variations.
OPERATION Adjusting Endshields Plastic endshields are subject to expansion or contraction from large temperature variations. The position of the top pin and lower catch can be adjusted to compensate for dimensional changes. To adjust the endshield, perform the following: 1. Check gap ‘X’ between the front end of shield and header frame and compare to chart. Temperature °F (°C) Gap ‘X’ in.
OPERATION 4.2.4 Daily Start-Up Check 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. • As well, carry with you any protective clothing and personal safety devices that could be necessary through the day. Do NOT take chances.
OPERATION 4.3 Break-in Period NOTE: Until you become familiar with the sound and feel of your new header, be extra alert and attentive. After attaching the header to the windrower for the first time, follow these steps: 1. Operate the machine with reel drapers and knife running slowly for five 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. 2. Perform the items specified. Refer to 6.3.
OPERATION 4.4 Shutdown Procedure CAUTION To shut down and before leaving the windrower seat for any reason, follow these steps: • Park on level ground if possible. • Lower the header fully. • Place all controls in NEUTRAL or PARK. • Disengage the header drive. • Lower and retract Reel fully. • Stop engine and remove key from ignition. • Wait for all movement to stop.
OPERATION 4.5 Cab Controls CAUTION Be sure all bystanders are clear of machine before starting engine or engaging any header drives.
OPERATION 4.6 4.6.1 Header Setup Header Attachments Several attachments to improve performance of your D65header are available as options that can be installed at your MacDon dealer. Refer to 8 Options and Attachments, page 259 in this manual for a description of each item. 4.6.2 Header Settings This table is a guideline for setting up the D65 Draper Header. Settings other than those suggested can be made to suit various crops and conditions not covered here. Table 4.
OPERATION Crop Type Stubble Height in. (mm) Divider Crop Condition Rods Header Angle2 Light Knife Speed3 Reel Cam4 Reel Speed %5 Medium 2 5–10 Reel Position6 Normal On 1 8–10 10 Low Heavy 2 5–10 3 5–10 Canola Light Medium Middle or Down Down 3 or 4 Lodged 10+ (254+) 2 On 8–10 As Required Recommended Middle or Down 3 Flax 3 or 4 5–10 Lodged 2–6.
OPERATION 4.6.3 Reel Settings The following chart illustrates the profile of the reel at each cam or finger pitch setting as well as the reel position relative to the ground at different positions on the reel arm. Refer to 4.6.2 Header Settings, page 46 for applicability of each finger pattern and reel position. Table 4.
OPERATION Cam Setting Number (Finger Speed Gain) Reel Position Number 3 (30%) 6 or 7 4 (35%) 2 or 3 Reel Finger Pattern NOTE: • Adjust reel forward to get closer to ground when tilting header back. Fingers/tines will dig into ground at extreme reel forward positions, so adjust skid shoes or header angle to compensate. Adjust reel rearward to get reel further away from ground when tilting header forward.
OPERATION 4.7 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.
OPERATION 3. On the right wheel assembly, remove hairpin (A) from latch. 4. Disengage latch (B) and lift right wheel out of hook and place on ground as shown. This reduces weight of assembly and makes adjusting wheel position easier. 5. Support left wheel weight by lifting slightly with one hand. Pull up on handle (C) to release lock. 6. Lift left wheel to desired height and engage support channel into slot (D) in upper support. 7. Push down on handle (C) to lock. 8.
OPERATION IMPORTANT: Continuous operation with excessive spring compression (i.e., load Indicator reading greater than ‘4’ or a compressed length (A) less than 11–5/8 in. [295 mm]) can result in damage to suspension system. 14. Adjust header angle to desired working angle with the machine’s header angle controls. If angle is not critical, set it to mid-position. NOTE: The height sensor on the CA25 adapter must be connected to the combine header control module in the cab. 15.
OPERATION 6. Lower header to desired cutting height using combine controls and check load indicator. As an example the image shows that the wheels are set to a range between ‘2’ and ‘3’ on load indicator. Figure 4.24: Load Indicator IMPORTANT: Continuous operation with excessive spring compression (i.e., load Indicator reading greater than ‘4’ or a compressed length less than 11-5/8 in. [295 mm]) (A) can result in damage to suspension system. 7.
OPERATION Adjusting Inner Skid Shoe 1. Fully raise the stabilizer wheels or slow speed transport wheels (if installed). Refer to: • Adjusting Stabilizer Wheels, page 52, or • Adjusting Stabilizer/Slow Speed Transport Wheels, page 50 DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason.
OPERATION DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. Refer to the windrower operator’s manual for instructions regarding the proper use and storage of header safety props. 2. Fully raise header, engage safety props, shut off engine, and remove key. 3. Remove lynch pin (A) at each skid shoe (B). 4.
OPERATION Controlling Header Angle Header angle is varied by adjusting the length of the top center-link (mechanical or hydraulic) between the windrower and the header. Refer to your windrower operator’s manual for adjustment details. 4.7.4 Reel Speed Reel speed is one of the factors that determines the manner in which the crop is moved from the cutterbar onto the drapers. The reel performs best when it appears to be driven by the ground.
OPERATION 4.7.5 Ground Speed Using the proper ground speed will result in cleanly cut crop and even delivery of material for a good windrow. Refer to 4.10 Windrow Types, page 79 for effects of ground speed on windrow formation. Reduce ground speed in difficult cutting conditions to reduce loads on cutting components and drives. Use lower ground speeds in very light crops (for example, short soybeans), to allow the reel to pull in short plants. Start at 3.0–3.5 mph (4.8–5.8 km/h) and adjust as required.
OPERATION 4.7.7 Knife Speed The header knife drive is driven by the windrower hydraulic pump and is controlled with the windrower Cab Display Module (CDM). The default speed is 1200 strokes per minute (spm). Refer to your windrower operator’s manual. Table 4.3 Knife Speed Guidelines Header Size (ft.) 4.7.8 Recommended Knife Speed Range (spm) Single Knife Double Knife 15 ft. — 1500–1900 20, 25 ft. 1200–1400 1400–1700 30 ft. 1200–1400 1200–1600 35 ft. 1100–1300 1200–1400 40 ft.
OPERATION A decal (A) is provided on the reel right support arm for identifying reel position. The cam disc aft edge (B) is the gauge indicator. For straight standing crop, center the reel over the cutterbar (4–5 on decal). For crops that are down, tangled, or leaning, it may be necessary to move the reel ahead of the cutterbar (lower number on decal). IMPORTANT: When difficulty is encountered picking up flattened crop, adjust header angle to a steeper position.
OPERATION Reposition right arm cylinder as follows: NOTE: Reel components are not shown for clarity. 1. Position reel fully aft with support arms horizontal. 2. Stop engine and remove key. 3. Remove four bolts (A) securing cylinder bracket (B) to reel arm. 4. Push reel back until bracket (B) lines up with the aft set of holes (C). 5. Reinstall the four bolts (A) to secure bracket to reel arm at new position. Figure 4.32: Right Arm Cylinder - Forward Position Figure 4.
OPERATION Reposition left arm cylinder as follows: NOTE: Reel components are not shown for clarity. 6. Remove pin (A) securing cylinder (B) to bracket/light assembly (C). 7. Remove bolts (D) securing bracket (C) to reel arm and remove bracket/light assembly. 8. If necessary, remove cable tie securing harness to bracket or reel arm. 9. Swivel light to working position as shown. Figure 4.34: Forward Position 10.
OPERATION Repositioning Fore-Aft Cylinders on Double Reel The reel can be moved approximately 9 in (227 mm) further aft by repositioning the fore-aft cylinders on the reel arms. To reposition the cylinders on a double reel, follow these steps: WARNING Stop windrower engine and remove key before making adjustments to machine. A child or even a pet could engage the drive. 1. Position reel fully aft with support arms horizontal. 2. Stop engine and remove key.
OPERATION Reposition right arm cylinder as follows: NOTE: Reel components are not shown for clarity. 6. Remove four bolts (A) securing cylinder bracket (B) to reel arm. 7. Push reel back until bracket (B) lines up with the aft set of holes (C). 8. Reinstall the four bolts (A) to secure bracket to reel arm at new position. Figure 4.38: Forward Position Figure 4.
OPERATION Reposition left arm cylinder as follows: NOTE: Reel components are not shown for clarity. 9. Remove pin (A) securing cylinder (B) to bracket/light assembly (C). 10. Remove bolts (D) securing bracket (C) to reel arm and remove bracket/light assembly. 11. If necessary, remove cable tie securing harness to bracket or reel arm. 12. Swivel light to working position as shown. Figure 4.40: Forward Position 13.
OPERATION 4.7.10 Reel Tine Pitch IMPORTANT: The following describes the concept and operational guidelines of the pick-up reel. Please read carefully before operating the machine. The pick-up reel is designed to pick up flattened and severely lodged crops. It is not always necessary to increase the tine pitch (higher cam setting) to pick up crops that are lodged, but rather, the cam settings are mainly used to determine how the crop will get delivered to the drapers.
OPERATION Cam Position 2, Reel Position 3 or 4 is the recommended starting position for most crops and conditions. • This setting gives a fingertip speed approximately 20% faster than the reel speed. • If crops tend to stall on the cutterbar with the reel in a forward position, the cam setting should be increased to push the crop past the rear edge of the cutterbar. • If the crop getting fluffed, or the flow across the drapers is disrupted, the cam setting should be decreased. Figure 4.
OPERATION Cam Position 4, Header Angle At Maximum, and Reel Fully Forward provides the maximum amount of reel reach below the cutterbar to pick up lodged crops and gives a finger tip speed approximately 35% faster than the reel speed. • Cutting height is set to approximately 8 in. (203 mm) to leave a significant amount of stubble. In damp materials such as rice, it is possible to double ground speed because the amount of material that is being cut is less.
OPERATION 4.7.11 Crop Dividers Crop dividers are used to help divide the crop when harvesting. They are removable to allow installation of vertical knives and to decrease transport width. Removing Crop Dividers from Header with Latch Option To remove crop dividers from a header with the latch option, follow these steps.
OPERATION Removing Crop Dividers from Header without Latch Option To remove crop dividers from a header without the latch option, follow these steps. DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. Refer to the windrower operator’s manual for instructions regarding the proper use and storage of header safety props. 1.
OPERATION 3. At divider storage location, lift divider to disengage lugs (A) at lower end and then lower it slightly to disengage pin (B) from endsheet. Figure 4.51: Stored Crop Divider 4. Position crop divider as shown by locating lugs (A) in holes in endsheet. 5. Lift forward end of divider until pin (B) at top of divider engages and closes latch (C). 6. Push safety lever (D) down to lock pin in latch. Figure 4.
OPERATION 7. Check that divider does NOT move laterally. Adjust bolts (A) as required to tighten divider and remove lateral play when pulling at divider tip. 8. Close/install endshields. Figure 4.53: Crop Divider Installing Crop Dividers on Header without Latch Option To install crop dividers on a header without the latch option, follow these steps.
OPERATION 5. Lift forward end of divider and install bolt (A) and special stepped washer (B) (step towards divider). Tighten bolt. 6. Check that divider does not move laterally. Adjust bolts (C) as required to tighten divider and remove lateral play when pulling at divider tip. 7. Close endshield. Refer to 4.2.3 Endshields, page 37. Figure 4.55: Crop Divider 4.7.12 Crop Divider Rods Crop divider rods are used with the crop dividers.
OPERATION Removing Crop Divider Rods To remove divider rods, follow these steps: 1. Loosen bolt (B) and remove rod (A). Figure 4.56: Crop Divider Rod 2. Store both rods on the inboard side of the right endsheet. Figure 4.57: Stored Divider Rod Using Rice Dividers Optional special rice dividers can be installed and used when required. Refer to 8.4.13 Rice Divider Rods, page 269. The installation and removal procedures are the same as for the standard crop dividers. Figure 4.
OPERATION 4.8 Delivery Opening The width and location of the delivery opening affects the width and configuration of the windrow. The decision to widen or narrow the center delivery opening, or to double windrow, should be based on the following factors: • Windrower pick-up capability • Type and yield of crop • Weather conditions (rain, humidity, wind) • Drying time available Refer to 4.
OPERATION 4.8.2 Adjusting Delivery Opening on Header with Hydraulic Deck Shift The delivery opening can be changed by moving the inboard deck shift stops. 1. Remove bolts (A). 2. Slide stop (B) outboard to decrease the maximum opening size, or inboard to increase the maximum opening. CAUTION Adjust the outboard stops to prevent the decks from contacting each other. 3. Reinstall bolts (A) and tighten. Figure 4.
OPERATION 4.9 Double Windrowing Double windrowing is laying two swaths side-by-side. Larger capacity combines or forage harvesters can then pick up twice as much material in a single pass, saving time and fuel. Double windrowing is performed with the D65 Draper Headers by two methods; deck shifting, or using the Double Windrow Attachment (DWA). Deck shifting is used for crops that don’t require conditioning, such as grains, canola, and beans for example. Refer to • 4.9.
OPERATION 4.9.2 Shifting Decks Manually Both decks can be moved manually to deliver the crop from the center or right/left end on 25 to 40 ft. headers. To deliver crop from the right end, move the decks to the left end of the header: 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. 1. Loosen bolt (A) on the right deck. 2. Slide deck to close off the center opening. Retighten bolt (A). Figure 4.
OPERATION Laying a Double Windrow NOTE: 30 ft. headers equipped with transport or stabilizer system, require that the wheels be in the raised position to avoid interfering with the windrow. 4. Position decks at the left end of header to deliver crop from right end (A). 5. Complete one round or one length of the field. 6. Complete the second round or length in the opposite direction to lay a double windrow. 7. Repeat above steps to lay the second double windrow. Figure 4.64: Double Windrowing 4.9.
OPERATION 4.
OPERATION Windrow Type 45° Diagonal 75° Diagonal 169899 Weight Distribution Curing Weatherability The stalks are lined along one edge and heads are along opposite edge, 45° to windrow perpendicular. This windrow can be formed by end deliver or by center delivery if the crop is leaning to one side. Poor Fair Poor The stalks are closer to parallel than the 45° windrow. Stalk tips are lined along one edge with heads opposite, 75° to windrow perpendicular.
OPERATION 4.11 Haying Tips The following information may be useful when using the D65 Draper Header in hay crops. 4.11.1 Curing 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 new growth. Leaving the windrow as wide and thin as possible makes for the quickest curing. The cured hay should be baled as soon as possible. 4.11.
OPERATION Configuration Advantage High and fluffy Movement of air through the windrow is more important to the curing process than is direct sunlight. Consistent formation, not bunchy Permits an even flow of material into the baler, chopper, etc. and allows for more even drying. Even distribution of material across windrow Results in even and consistent bales to minimize handling and stacking problems. Properly conditioned Prevents excessive leaf damage. 4.11.
OPERATION 4.12 Levelling the Header The windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. NOTE: The float springs are NOT used to level the header. If the header is not level, check the pressure of the windrower’s tires to ensure they are properly inflated (refer to your windrower’s operator’s manual).
OPERATION 4.13 Unplugging Cutterbar To remove plugged material from the cutterbar, follow these steps. 1. Stop forward movement of machine and disengage header drives. 2. Raise header to prevent it from filling with dirt, and engage header drive clutch. CAUTION Lowering rotating reel on a plugged cutterbar will damage the reel components. 3. If plug does NOT clear, disengage header drive clutch and raise header fully. WARNING Stop engine and remove key before removing plugged material from header.
OPERATION 4.14 Upper Cross Auger (UCA) The UCA helps deliver very bulky crops across the header onto the windrow. Removable beater bars assist in delivering material through the header opening, but if wrapping occurs, the beater bars can be removed. IMPORTANT: The upper cross auger drive motor must be equipped with a case drain kit when used on single draper drive headers. See your MacDon Dealer for details. Figure 4.66: Upper Cross Auger 4.14.
OPERATION 2. Remove bolts (A) securing bars (B) and clamps (C) to auger tubes, and remove bars and clamps. Figure 4.67: Single Reel Headers Figure 4.
OPERATION 4.14.2 Installing Beater Bars To install beater bars, follow these steps. 1. Locate one beater bar (B) with one clamp set (C) on auger tube and loosely secure with carriage bolt (A) and nut. Bolt head MUST face direction of auger rotation. 2. Locate remaining clamp sets on tube and loosely attach to beater bar with carriage bolts and nuts. Bolt heads MUST face direction of auger rotation. 3. Position second beater bar in clamps and secure with carriage bolts and nuts. 4. Tighten bolts.
OPERATION 4.15 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. 4.15.1 Transporting Header on Windrower CAUTION • Check local laws for width regulations and lighting or marking requirements before transporting on roads.
OPERATION Attaching Header to Towing Vehicle CAUTION To avoid bodily injury and/or machine damage caused by loss of control: • Weight of towing vehicle must exceed header weight to ensure adequate braking performance and control. • Do NOT tow with any highway-capable vehicle. Use only an agricultural tractor, agricultural combine, or properly configured MacDon windrower. • Ensure that reel is down and fully back on support arms to increase header stability in transport.
OPERATION 4.15.3 Converting from Transport to Field Position To convert the header from Transport to Field position, follow these steps. Removing Tow-Bar Remove tow-bar as follows: 1. Block the tires to prevent header rolling, and unhook from towing vehicle. 2. Disconnect wiring connector (A) on tow-bar. 3. Remove pin (B) from tow-bar and disassemble outer section (C) from inner section (D). Figure 4.71: Tow-Bar Assembly A - Wiring Connector C - Outer Section B - Pin D - Inner Section 4.
OPERATION 5. Remove clevis later installation. pin (A) and set aside for 6. Push latch (B) and lift tow-bar (C) from hook. Release latch. 7. Reinstall clevis pin. Figure 4.73: Tow-Bar Latch Storing Tow-Bar Store tow-bar as follows: 1. At the left end of the header, place the inner end of the outer half of the tow-bar in cradle (A) on header backtube. 2. For clevis or pintle end of tow-bar, secure in support (B) on endsheet with hitch pin (C). Secure with lynch pin. 3.
OPERATION 4. At the right end of the 25, 35, and 40 ft. header: a. Place the inner end of the inner half of the tow-bar in cradle (A) on header backtube. b. Secure tube end in support (B) with clevis pin (C). Secure with hairpin. c. Install rubber strap (D) on cradle (A). Figure 4.75: 25, 35, and 40 ft. Header 5. At the right end of the 30 ft. header: a. Place the inner end of the inner half of the tow-bar in cradle (A) on header backtube. b. Secure tube end in support (B) with pin (C). c.
OPERATION 6. Attach header to windrower. Refer to windrower operator’s manual for instructions. IMPORTANT: Carrying the tow-bar on the header will affect the main header float. Refer to your windrower operator’s manual for adjustment procedures. 7. Place transport wheels into field position.
OPERATION 5. Align lift hook (A) with lug (B) and lift wheel assembly to engage pin in hook (A). Ensure latch (C) is engaged. 6. Install clevis pin (D) and secure with hairpin to center of axle. Figure 4.78: Front (Left) Wheels 7. Lift wheel assembly to desired height and slide linkage (A) into appropriate slot in vertical support. 8. Push down on handle (B) to lock. Figure 4.
OPERATION 2. Remove pin (A) and store at (B). 3. Pull handle (C) up to release. 4. Lift wheel to desired height and engage support channel into slot (D) in vertical support. 5. Push down on handle (C) to lock. Figure 4.81: Left Rear Wheel 6. Pull pin (A) on brace (B) on the left hand wheel in front of the cutterbar. Disengage brace from cutterbar and lower the brace against axle (C). 7. Remove pin (D), lower the support (E) onto axle, and reinsert pin into support. 8.
OPERATION 9. Pull pin (A) at right wheel, swivel wheel counterclockwise to position shown and lock with pin (A). 10. Remove hairpin (B) from latch (C). 11. Lift wheel, lift latch (C), and engage lug (D) onto left axle. Ensure latch closes. 12. Secure latch with hairpin (B), with open end of pin facing rear of combine. NOTE: Installing hairpin with the open end facing the cutterbar will cause it to be dislodged by crop during operation. Figure 4.
OPERATION CAUTION Stand clear of wheels and release linkage carefully as wheels will drop once the mechanism is released. 1. Pull handle (B) up to release and raise the linkage (A) fully upward in the vertical support. 2. Raise header fully, stop engine, and remove key from ignition. Engage header safety props. Figure 4.85: Raising Linkage 3. Remove hair pin and clevis pin (A). 4. Pull latch handle (B) to release suspension linkage (C) and pull suspension linkage (C) away from spindle (D). 5.
OPERATION 7. Remove pin (A) from storage at top of leg (B). 8. Move and swivel wheels clockwise so that connector (C) is turned towards the front end of the header. 9. Insert pin (A) and turn to lock. 10. Lower header so that left wheels are just touching the ground. Figure 4.
OPERATION 1. Remove hairpin (A) from latch (B). 2. Lift latch (B), disengage right axle (C), and lower to ground. CAUTION Stand clear of wheels and release linkage carefully as wheels will drop once the mechanism is released. 3. Carefully pull handle (D) to release the spring and let the wheel drop to the ground. 4. Lift wheel and linkage with handle (E) and position linkage in second slot from bottom. 5. Lower handle (C) to lock. Figure 4.89: Separating Axles 6.
OPERATION 8. Left wheel is now in Transport position as shown. Figure 4.91: Transport Position 9. Pull pin (A), and swivel wheel (B) clockwise 90 degrees. Figure 4.92: Right Rear Wheel 10. Lock wheel (A) with pin (B). Move the right axle (C) to front of header. Figure 4.
OPERATION 11. Remove pin (A), raise support (B) to position shown, and reinsert pin (A). IMPORTANT: Ensure pin (A) engages the tube on the axle. 12. Swing brace (C) into position as shown and insert brace into slot (D) behind cutterbar. Position brace so that pin (E) engages hole in bracket (F). Right hand wheel is now in Transport position. 13. Disengage the header cylinder lift stops. 14. Detach the header from the windrower. Refer to your windrower operator’s manual for procedure. 15.
OPERATION 5. At left side of the header, unhook rubber strap (D) on cradle (A). 6. Remove hitch pin (C) from support (B), and remove tow-bar. 7. Install rubber strap (D) on cradle (A). Figure 4.96: Removing Tow-Bar 8. Connect the outer half (B) of the tow-bar to the inner half (A). Figure 4.
OPERATION 9. Lift the outer half (B) and insert it into the inner half (A) Figure 4.98: Assembling Tow-Bar 10. Secure the two halves together with L-pin (A), then turn to lock. Secure pin with ring (B). 11. Connect electrical harness to connector (C). Figure 4.99: Assembling Tow-Bar 12. Position tow-bar (A) onto axle, and push against latch (B) until tow-bar pins drop into hooks (C). 13. Check that latch (B) has engaged tow-bar. 14. Install clevis pin (D), and secure with hairpin. Figure 4.
OPERATION 15. Make the electrical connection (A) at the front wheel. Figure 4.
OPERATION 4.16 Storage The following should be done at the end of each operating season: CAUTION Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic or flammable. CAUTION Cover cutterbar and knife guards to prevent injury from accidental contact. 1. Clean header thoroughly. 2. Store machine in a dry, protected place if possible. If stored outside, always cover with a waterproof canvas or other protective material.
5 Header Attachment/Detachment This chapter includes instructions on setting up, attaching, and detaching the header. 5.1 Attaching Header to Windrower Refer to your windrower operator’s manual for procedures to mechanically attach the header to the self-propelled windrower. Refer to the following procedures for electrical and hydraulic connections. Header drive hydraulic hoses and electrical harness are located on the left cab-forward side of the tractor.
HEADER ATTACHMENT/DETACHMENT 5. Push hose connectors onto mating receptacle until collar on receptacle snaps into lock position. 6. Remove cover on electrical receptacle (A). 7. Push electrical connector onto receptacle and turn collar on connector to lock it in. 8. Attach cover to mating cover on tractor wiring. Figure 5.3: Header Receptacles A - Electrical Connector C - Case Drain (Double Knife) E - Return B - Knife Drive D - Draper Drive 9. Lower lever (A) and engage in down position. Figure 5.
HEADER ATTACHMENT/DETACHMENT 11. Open cover on header receptacle (A). 12. Push in lock button (B) and pull handle (C) to half open position. Figure 5.6: Reel Hydraulics Receptacle 13. Remove hose bundle with multi-coupler (C) from windrower, locate onto header receptacle and push handle (B) to engage pins on connector. 14. Push handle away from hoses until lock button (A) snaps out. 15. Raise and lower header and reel a few times to allow trapped air to pass back to the reservoir. Figure 5.
HEADER ATTACHMENT/DETACHMENT 5.2 Detaching Header from Windrower To detach the header from the windrower, these steps: follow 1. Fully lower the reel. 2. To disconnect the reel hydraulics, push in lock button (A) and pull handle (B) to disengage multi-coupler (C) from header receptacle. 3. Route hose bundle back onto windrower and store multi-coupler (C) on hose support. Figure 5.8: Reel Hydraulics 4. Close cover on header receptacle (A). Figure 5.9: Close Cover 5.
HEADER ATTACHMENT/DETACHMENT 7. To disconnect hoses from header, line up slot (A) in collar with pin (B) on connector. 8. Push collar toward pin and pull connector to disengage. 9. Install caps on connectors and hose ends (if equipped). Figure 5.11: Quick Disconnect 10. Route hose bundle (A) back onto hose support on windrower. 11. Rotate lever (B) and lock in down position. 12. Install cap (C) on electrical connector. 13. Detach header from windrower. Refer to the windrower operator’s manual. Figure 5.
6 6.1 Maintenance and Servicing Preparation for Servicing The following instructions are provided to assist Operator in the use of header. Detailed maintenance, service, and parts information are contained in the technical manual and parts catalog which are available from your MacDon Dealer. CAUTION To avoid personal injury, before servicing header or opening drive covers: 1. Fully lower the header. If necessary to service in the raised position, always engage safety props. 2. Stop engine and remove key.
MAINTENANCE AND SERVICING 6.2 Maintenance Specifications 6.2.1 Conversion Chart Quantity Inch-Pound Units Unit Name Factor Abbreviation SI Units (Metric) Unit Name Abbreviation Area Acres acres x 0.4047 = Hectares ha Flow US Gallons per Minute gpm x 3.7854 = Liters per Minute L/min Force Pounds Force lbf x 4.4482 = Newtons N Inch in. x 25.4 = Millimeters mm Foot ft. x 0.305 = Meters m Power Horsepower hp x 0.7457 = Kilowatts kW x 6.
MAINTENANCE AND SERVICING 6.2.2 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 Grease Specification Description Use Capacities SAE Multi-Purpose High Temperature Extreme Pressure (EP2) Performance With 1% Max. Molybdenum Disulphide (NLGI Grade 2) As Required Unless Otherwise Specified.
MAINTENANCE AND SERVICING Table 6.2 SAE Grade 5 Bolt and Grade 5 Distorted Thread Nut Nominal Size (A) Torque (ft·lbf) (*in·lbf) Torque (N·m) Min. Max. Min. Max. 1/4-20 *72 *80 8.1 9 5/16-18 *149 *164 16.7 18.5 3/8-16 22 24 30 33 7/16-14 35 39 48 53 1/2-13 54 59 73 80 9/16-12 77 86 105 116 5/8-11 107 118 144 160 3/4-10 192 212 259 286 7/8-9 306 338 413 456 1-8 459 507 619 684 Figure 6.
MAINTENANCE AND SERVICING Table 6.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Nominal Size (A) Torque (ft·lbf) (*in·lbf) Torque (N·m) Min. Max. Min. Max. 1/4-20 *150 *165 16.8 18.6 5/16-18 26 28 35 38 3/8-16 46 50 61 68 7/16-14 73 81 98 109 1/2-13 111 123 150 166 9/16-12 160 177 217 239 5/8-11 221 345 299 330 3/4-10 393 435 531 587 7/8-9 633 700 855 945 1-8 863 954 1165 1288 Figure 6.
MAINTENANCE AND SERVICING Table 6.6 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Nominal Size (A) Torque (ft·lbf) (*in·lbf) Torque (N·m) Min. Max. Min. Max. 3-0.5 *9 *10 1 1.1 3.5-0.6 *14 *15 1.5 1.7 4-0.7 *20 *22 2.3 2.5 5-0.8 *40 *45 4.5 5 6-1.0 *69 *76 7.7 8.6 8-1.25 *167 *185 18.8 20.8 10-1.5 28 30 37 41 12-1.75 48 53 65 72 14-2.0 77 85 104 115 16-2.0 119 132 161 178 20-2.5 233 257 314 347 24-3.0 402 444 543 600 Figure 6.
MAINTENANCE AND SERVICING Table 6.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Nominal Size (A) Torque (ft·lbf) (*in·lbf) Torque (N·m) Min. Max. Min. Max. 3-0.5 *12 *13 1.3 1.5 3.5-0.6 *19 *21 2.1 2.3 4-0.7 *28 *31 3.1 3.4 5-0.8 *56 *62 6.3 7 6-1.0 *95 *105 10.7 11.8 8-1.25 19 21 26 29 10-1.5 38 42 51 57 12-1.75 66 73 90 99 14-2.0 106 117 143 158 16-2.0 165 182 222 246 20-2.5 322 356 434 480 24-3.
MAINTENANCE AND SERVICING Metric Bolt Specifications Bolting into Cast Aluminum Table 6.9 Metric Bolt Bolting into Cast Aluminum Bolt Torque Nominal Size (A) 8.8 (Cast Aluminum) 10.9 (Cast Aluminum) ft·lbf N·m ft·lbf N·m M3 – – 1 – M4 – – 2.6 4 M5 – – 5.5 8 M6 6 9 9 12 M8 14 20 20 28 M10 28 40 40 55 M12 52 70 73 100 M14 – – – – M16 – – – – Figure 6.9: Bolt Grades Flare-Type Hydraulic Fittings 1.
MAINTENANCE AND SERVICING Table 6.10 Flare-Type Hydraulic Tube Fittings Flats from Finger Tight (FFFT) Tube Size O.D. (in.) Thread Size (in.) Nut Size across Flats (in.
MAINTENANCE AND SERVICING O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) 1. Inspect O-ring (A) obvious defects. and seat (B) for dirt or 2. Back off the lock nut (C) as far as possible. Ensure that washer (D) is not loose and is pushed toward the lock nut (C) as far as possible. 3. Check that O-ring (A) is NOT on the threads, and adjust if necessary. 4. Apply hydraulic system oil to the O-ring (A). Figure 6.11: Hydraulic Fitting 5.
MAINTENANCE AND SERVICING Table 6.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) SAE Dash Size Thread Size (in.) -3 Torque Value11 ft·lbf (*in·lbf) N·m 3/8-24 *106–115 12–13 -4 7/16–20 14–15 19–21 -5 1/2–20 15–24 21–33 -6 9/16–18 19–21 26–29 -8 3/4–16 34–37 46–50 -10 7/8–14 55–60 75–82 -12 1-1/16-12 88–97 120–132 -14 1-3/8-12 113–124 153–168 -16 1-5/16-12 130–142 176–193 -20 1-5/8-12 163–179 221–243 -24 1-7/8-12 199–220 270–298 11.
MAINTENANCE AND SERVICING O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) 1. Inspect O-ring (A) obvious defects. and seat (B) for dirt or 2. Check that O-ring (A) is NOT on the threads, and adjust if necessary. 3. Apply hydraulic system oil to the O-ring. 4. Install fitting (C) into port until fitting is hand tight. 5. Torque fitting (C) according to the values in Table 6.12 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable), page 124. 6. Check the final condition of the fitting. Figure 6.
MAINTENANCE AND SERVICING O-Ring Face Seal (ORFS) Hydraulic Fittings To tighten O-ring face seal (ORFS) hydraulic fittings, follow these steps: 1. Check components to ensure that the sealing surfaces and fitting threads are free of burrs, nicks, and scratches or any foreign material. Figure 6.14: Hydraulic Fitting 2. Apply hydraulic system oil to the O-ring (B). 3. Align the tube or hose assembly so that the flat face of the sleeve (A) or (C) comes in full contact with O-ring (B). 4.
MAINTENANCE AND SERVICING Table 6.13 O-Ring Face Seal (ORFS) Hydraulic Fittings SAE Dash Size Thread Size (in.) -3 Torque Value13 ft·lbf (*in·lbf) N·m Note14 – – -4 9/16–18 18–21 25–28 -5 Note14 – – -6 11/16-16 29–32 40–44 -8 13/16-16 41–45 55–61 -10 1–14 59–65 80–88 -12 1-3/16-12 85–94 115–127 -14 Note14 – – -16 1-7/16-12 111–122 150–165 -20 1-11/16-12 151–167 205–226 -24 2–12 232–256 315–347 -32 2-1/2-12 376–414 510–561 6.2.
MAINTENANCE AND SERVICING 1. Locate ends of chain on sprocket. 2. Install pin connector (A) into chain, preferably from the sprocket backside. 3. Install connector (B) onto pins. 4. Install spring clip (C) onto front pin (D) with closed end of clip in direction of sprocket rotation. 5. Locate one leg of clip in groove of aft pin (E). 6. Press other leg of spring clip over face of aft pin (E) until it slips into groove. Do NOT press clip lengthwise from closed end. 7.
MAINTENANCE AND SERVICING 6.3 Maintenance Requirements 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 this section. Use the fluids and lubricants specified, Refer to 6.2.2 Recommended Fluids and Lubricants, page 115.
MAINTENANCE AND SERVICING 6.3.1 Maintenance Schedule/Record Copy this page to continue record. Maintenance Record Action: - Lubricate - Check ▲ - Change Hour Meter Reading Date Serviced By FIRST USE, Refer to 6.3.2 Break-In Inspection, page 130 END OF SEASON, Refer to 6.3.
MAINTENANCE AND SERVICING Maintenance Record Action: - Lubricate - Check ▲ - Change Upper Cross Auger RH Bearing 250 HOURS OR ANNUALLY15 Draper Seal Upper Cross Auger Center Support and U-Joint Reel Drive U-joint Transport Axle Pivot Bushings 500 HOURS OR ANNUALLY15 Draper Seal Reel Shaft Bearings Stabilizer/Slow Speed Transport Wheel Bearings 1000 HOURS OR 3 YEARS15 ▲ Knife Drive Box Lubricant 6.3.
MAINTENANCE AND SERVICING 6.3.3 Preseason/Annual Service Perform the following the beginning of each operating season CAUTION • Review this manual to refresh your memory on safety and operating recommendations. • Review all safety decals and other decals on the header and note hazard areas. • Be sure all shields and guards are properly installed and secured. equipment. Never alter or remove safety • Be sure you understand and have practiced safe use of all controls.
MAINTENANCE AND SERVICING 6.3.5 Checking Hydraulic 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 pin holes and nozzles which eject fluids under high pressure.
MAINTENANCE AND SERVICING Service Intervals Refer to the illustrations on the following pages to identify the various locations that require lubrication and servicing. Illustrations are organized by the frequency of service that is required. IMPORTANT: Unless otherwise specified, use High Temperature Extreme Pressure (EP2) Performance with 1% Maximum Molybdenum Disulphide (NLGI Grade 2) Lithium Base. Knife: Except in sandy conditions. Figure 6.
MAINTENANCE AND SERVICING Figure 6.
MAINTENANCE AND SERVICING Figure 6.23: Every 250 Hours A - Upper Cross Auger U-joint17 B - Upper Cross Auger Bearing (2 PLCS)18 17. U-joint has an extended lubrication cross and bearing kit. Stop greasing when greasing becomes difficult or if U-joint stops taking grease. Overgreasing will damage U-joint. six to eight pumps are sufficient at first grease (factory). Decrease grease interval as U-joint wears and requires more than six pumps. 18.
MAINTENANCE AND SERVICING Figure 6.24: Every 250 Hours (Continued) A - Rear Axle Pivots C -Frame/Wheel Pivot (1 PLC) - Both Sides B - Front Wheel Pivot (1 PLC) D - Double Reel U-Joint (1 PLC)19 19. U-joint has an extended lubrication cross and bearing kit. Stop greasing when greasing becomes difficult or if U-joint stops taking grease. Overgreasing will damage U-joint. six to eight pumps are sufficient at first grease (factory). Decrease grease interval as U-joint wears and requires more than six pumps.
MAINTENANCE AND SERVICING Figure 6.
MAINTENANCE AND SERVICING Greasing Procedure Greasing points are marked on the machine by decals showing a grease gun and grease interval in hours of operation. Master grease point location decals as shown below are provided on the header. Use the recommended lubricants specified in this manual. Refer to 6.2.2 Recommended Fluids and Lubricants, page 115. 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.
MAINTENANCE AND SERVICING 6.4 Electrical Use electrical tape and wire clips as required to prevent wires from dragging or rubbing. Keep lights clean and replace defective bulbs. 6.4.1 Replacing Light Bulbs To replace a light bulb, follow these steps: 1. Using a Phillips screwdriver, remove screws (A) from fixture and remove plastic lens. 2. Replace bulb and reinstall plastic lens and screws.
MAINTENANCE AND SERVICING 6.5 Knife WARNING Keep hands clear of the area between guards and knife at all times. CAUTION To avoid personal injury, before servicing machine or opening drive covers, refer to 6.1 Preparation for Servicing, page 113. CAUTION Wear heavy gloves when working around or handling knives. Figure 6.28: Cutterbar Hazard 6.5.1 Replacing Knife Section Check daily that knife sections are firmly bolted to the knife back and are not worn or broken.
MAINTENANCE AND SERVICING To replace a section, follow these steps: 1. Stroke knife as required to center the section (A) between guards. 2. Remove nuts (B). 3. Remove bars (C) and lift section off the knife bar. 4. If section is under a splice bar (D), remove the bar. 5. Clean any dirt off of knife back and position new section on knife. IMPORTANT: Do NOT mix fine or coarse sections on same knife. 6. Reposition bars (C) and/or (D) and install lock nuts (A).
MAINTENANCE AND SERVICING 6.5.2 Removing Knife WARNING Stand to rear of knife during removal to reduce risk of injury from cutting edges. Wear heavy gloves when handling knife. 1. Manually stroke knife to its outer limit and clean area around the knifehead. 2. Remove bolt (A). 3. Remove the grease zerk (B) from the pin. 4. Use a screwdriver or a chisel in slot (C) to release load on knifehead pin. 5. Pry pin upward with a screwdriver in pin groove until pin is clear of knifehead. 6.
MAINTENANCE AND SERVICING 2. Using a flat-ended tool with approximately the same diameter as pin (A). Tap the seal (B), bearing (C), plug (D), and O-ring (E) from the underside of the knifehead. NOTE: Seal (B) can be replaced without removing the bearing. When changing seal, check pin and needle bearing for wear. Replace if necessary. Figure 6.31: Removing Bearing A - Flat-ended tool D - Plug 6.5.
MAINTENANCE AND SERVICING NOTE: For ease of removing or installing knifehead pin, remove grease zerk from pin. 2. Install knifehead pin (A) through the output arm and into the knifehead. 3. Set groove (B) in knifehead pin 0.06 in. (1.5 mm) above (C). Install the 5/8 in. x 3 hex head bolt and nut (D) and torque to 160 ft·lbf (217 N·m). Figure 6.33: Knifehead 4. Install grease zerk (A) into the knifehead pin, turn the grease zerk for easy access. Figure 6.34: Knifehead 6.5.
MAINTENANCE AND SERVICING Adjusting Knife Guards To adjust knife guards, follow these steps. The guard straightening tool (MD #140135) is available from your MacDon Dealer. 1. To adjust guard tips upward, position tool as shown, and pull up. Figure 6.36: Upward Adjustment 2. To adjust tips downward, position tool as shown and push down. TIP: If trouble is encountered cutting tangled or fine-stemmed material, install a knife hold-down on every guard and then replace lower guards with stub guards. 3.
MAINTENANCE AND SERVICING IMPORTANT: The first four outboard guards (B) on drive side(s) of header do not have a ledger plate. Ensure that proper replacement is installed. 5. Install hold-down, and secure with nuts. Tighten nuts to 50 ft·lbf (68 N·m). 6. Check and adjust clearance between hold-down and knife. Refer to Checking Knife Hold-Downs, page 149. Figure 6.
MAINTENANCE AND SERVICING 3. Position poly wear plate (if applicable), replacement guard (A), adjuster bar, and top guide (B). Install bolts, but do NOT tighten. IMPORTANT: Ensure center guard (A) (right of cutterbar split) has offset cutting surfaces. NOTE: Top guide (B) must accommodate the two overlapping knives at center guard location on double knife header. Ensure replacement is correct part. 4. Check and adjust clearance between hold-down and knife. Refer to Checking Knife Hold-Downs, page 149.
MAINTENANCE AND SERVICING To replace stub guards, follow these steps: 1. Remove the two nuts (A) and bolts that attach guard (B) and top guide (C) to cutterbar. 2. Remove guard, poly wear plate (if installed), top guide, and adjuster bar (D). 3. Position poly wear plate (if applicable), replacement guard (B), adjuster bar (D), top guide (C), and install bolts and nuts (A). Do NOT tighten. IMPORTANT: Note position of mitre on adjuster bar (D). Bar should be reinstalled in same position.
MAINTENANCE AND SERVICING 1. Remove the two nuts (A) and bolts that attach guard (B) and top guide (C) and adjuster bar (D) to cutterbar. 2. Remove guard, poly wear plate (if installed), top guide (C), and adjuster bar (D). 3. Locate poly wear plate (if applicable), replacement guard (B), adjuster bar (D), top guide (C), and install bolts, but do NOT tighten. IMPORTANT: Ensure center guard (B) has offset cutting surfaces.
MAINTENANCE AND SERVICING Adjusting Hold-Downs with Pointed Guards To adjust the clearance between hold-downs and knife on header with pointed guards, follow these steps: 1. Check the clearance (A) between the normal hold-down and knife section with a feeler gauge. The clearance should be 0.004–0.024 in. (0.1–0.6 mm). 2. Adjust as required by turning bolt (B). NOTE: For larger adjustments, it may be necessary to loosen nuts (C), turn adjuster bolt (B), then retighten nuts (C). Figure 6.
MAINTENANCE AND SERVICING Adjusting Hold-Downs with Stub Guards To adjust the clearance between hold-downs and knife for all stub guards, follow these steps: 1. Check the clearances between the center guard hold-down (A) and knife section with a feeler gauge. The clearances should be: • 0.004–0.016 in. (0.1–0.4 mm) at guide tip (B) • 0.004–0.040 in. (0.1–1.0 mm) at rear of guide (C) 2. If required, adjust clearances as follows: a. Torque nuts (D) to 35 ft·lbf (46 N·m). b.
MAINTENANCE AND SERVICING CAUTION Wear heavy gloves when working around or handling knives. 3. Place knifehead shield (A) against endsheet as shown. Orient the shield so that cutout matches profile of knifehead and/or hold-downs. 4. Bend shield along slit to conform to endsheet. 5. Align mounting holes and then install two 3/8 in. x 1/2 Torx® head bolts (B). 6. Snug up bolts just enough so that shield can be adjusted as close as possible to the knifehead. 7.
MAINTENANCE AND SERVICING 6.6 Knife Drive 6.6.1 Knife Drive Box The knife drive box converts rotational motion into reciprocating motion to the knife. It is belt driven from a hydraulic motor that is powered by the adapter hydraulic pump. CAUTION To avoid personal injury, before servicing machine or opening drive covers, refer to 6.1 Preparation for Servicing, page 113.
MAINTENANCE AND SERVICING 4. Open the access cover (A) on the endsheet behind cutterbar to provide clearance between the knife drive box pulley and the endsheet. Figure 6.51: Access Cover 5. Remove belt (A) from drive pulley (B). 6. Slip belt (A) over and behind the knife drive box pulley (C). Use notch in pulley to assist in removing belt. Figure 6.52: Knife Drive 7. Manually stroke knife to its outer limit and clean area around the knifehead. 8. Remove bolt (A). 9.
MAINTENANCE AND SERVICING 14. Remove bolt (A) that clamps the knife drive arm to the knife drive box output shaft. 15. Remove the knife drive arm (B) from the knife drive box output shaft. 16. Remove the four knife drive box mounting bolts (C, D). NOTE: Do NOT remove bolt (E), this is factory set. It is used to position the knife drive box in the proper fore-aft position. 17. Remove knife drive box and place on a bench for disassembly. CAUTION Knife drive box with pulley weighs over 65 lb (35 kg).
MAINTENANCE AND SERVICING 4. Open the access cover (A) on the endsheet behind cutterbar to provide clearance between the knife drive box pulley and the endsheet. Figure 6.56: Access Cover 5. Manually stroke knife to its outer limit and clean area around the knifehead. 6. Remove bolt (A). 7. Remove the grease zerk (B) from the pin. 8. Use a screwdriver or a chisel in slot (C) to release load on knifehead pin. 9. Pry pin upward with a screwdriver in pin groove until pin is clear of knifehead. 10.
MAINTENANCE AND SERVICING 12. Remove bolt (A) that clamps the knife drive arm to the knife drive box output shaft. 13. Remove the knife drive arm (B) from the knife drive box output shaft. 14. Remove the four knife drive box mounting bolts (C, D). NOTE: Do NOT remove bolt (E), this is factory set. It is used to position the knife drive box in the proper fore-aft position. 15. Remove knife drive box and place on a bench for disassembly. CAUTION Knife drive box with pulley weighs over 65 lb (35 kg).
MAINTENANCE AND SERVICING Installing Knife Drive Box Pulley To install the knife drive box pulley, follow these steps: 1. Ensure splines and bores in pulley or drive arm are free of paint oil and solvents. 2. Apply Loctite® #243 adhesive (or equivalent) to spline. Apply in two bands (A) around shaft as shown, with one band at end of spline and one band approximately mid-way. 3. Install pulley (B) until flush with end of shaft. 4. Secure pulley with 5/8 in.
MAINTENANCE AND SERVICING 4. Apply Loctite® #243 to the output shaft in two bands as shown at (A). 5. Slide output arm (B) onto output shaft. Rotate pulley to ensure drive arm just clears frame on inboard stroke to ensure proper placement on splines. Figure 6.62: Knife Drive Box 6. Position output arm (A) to farthest outboard position. Move output arm (A) up or down on splined shaft until it almost contacts knifehead (B). Exact clearance (C) will be set when installing knifehead pin. Figure 6.
MAINTENANCE AND SERVICING NOTE: For ease of removing or installing knifehead pin, remove grease zerk from pin. 8. Install knifehead pin (A) through the output arm and into the knifehead. 9. Set groove (B) in knifehead pin 0.06 in. (1.5 mm) above (C). Install the 5/8 in. x 3 hex head bolt and nut (D) and torque to 160 ft·lbf (217 N·m). Figure 6.65: Knifehead 10. Install grease zerk (A) into the knifehead pin, turn the grease zerk for easy access.
MAINTENANCE AND SERVICING Changing Oil in Knife Drive Box Change knife drive box lubricant after the first 50 hours of operation and every 1,000 hours (or 3 years) thereafter. To change the oil in the knife drive box, follow these steps: 1. Raise header to allow a suitable container to be placed under the knife box drain to collect oil. 2. Open endshield(s). page 37. Refer to Opening Endshields, 3. Remove breather/dipstick (A) and drain plug (B). 4. Allow oil to drain. 5. Reinstall drain plug (B).
MAINTENANCE AND SERVICING 1. Open endshield. Refer to Opening Endshields, page 37. 2. Loosen the two bolts (A) that secure the motor assembly to header endsheet. 3. Loosen the belt by turning the tensioning bolt (B) counterclockwise. Figure 6.69: Knife Drive 4. Open the access cover (A) on the endsheet behind cutterbar to provide clearance between the knife drive box pulley and the endsheet. Figure 6.70: Access Cover 5. Remove belt (A) from drive pulley (B). 6.
MAINTENANCE AND SERVICING 1. Route knife drive belt (A) around knife drive box pulley (C) and knife drive pulley (B). Use notch in pulley (C) to assist in installing belt. NOTE: When installing new belt, never pry belt over pulley. Be sure drive motor is fully forward. 2. Tension knife drive belt. Refer to Tensioning Non-Timed Knife Drive Belts, page 163. Figure 6.72: Knife Drive 3. Reinstall the access cover (A) and secure it with bolt. 4. Close endshield. Refer to Closing Endshields, page 38. Figure 6.
MAINTENANCE AND SERVICING 4. Ensure that clearance between belt (A) and belt guide (B) is 1/32 in. (1 mm). 5. Loosen three bolts (C), and adjust position of guide (B) as required. 6. Tighten bolts (C). 7. Close endshield. Refer to Closing Endshields, page 38. NOTE: Readjust tension of a new belt after a short run-in period (about five hours). Figure 6.75: Knife Drive Timed Double Knife Drive Belts This section applies to 35-foot and smaller double knife model D65 Draper Headers with timed drives.
MAINTENANCE AND SERVICING Installing Timed Drive V-Belts NOTE: New belts must be installed as a matched pair. Never pry belt over pulley. Be sure drive motor is fully forward. 1. Install V-belts (C) onto pulleys. IMPORTANT: To prolong belt and drive life, do NOT overtighten belt. 2. Turn adjuster bolt (B) to tighten belts. The belts should deflect 5/32 in. (4 mm) with 12–17 lbf (52–77 N) of force applied to each belt at mid-span when properly tensioned. 3. Tighten the two bolts (A). 4. Close endshield.
MAINTENANCE AND SERVICING NOTE: The following two steps are not applicable to the right side drive. 4. Loosen two bolts (A) on endsheet. 5. Turn adjuster bolt (B) to loosen the two V-belts (C) and remove them. Figure 6.79: Knife Drive V-Belts 6. Open the access panel (A) inside the draper opening, just behind cutterbar. This will give you access to the knife drive pulley. 7. Remove the knife drive belt. Figure 6.
MAINTENANCE AND SERVICING NOTE: The following two steps do not apply to the right site drive. 2. Install the two V-belts (C) and turn adjuster bolt (B) to tension them. Tension is checked at mid span of the belts. The belts should deflect 5/32 in. (4 mm) with 12–17 lbf (52–77 N) of force applied to each belt. NOTE: Ensure drive motor is fully forward to allow V-belt’s installation. 3. Tighten the two bolts (A) on endsheet. Figure 6.82: Knife Drive V-Belts 4.
MAINTENANCE AND SERVICING Tensioning Timed Knife Drive Belts This describes the tensioning procedure for the timed left and right knife drive belts. The illustrations for the right side are opposite to what is shown. IMPORTANT: To prolong belt and drive life, do NOT over-tighten belt. IMPORTANT: Do NOT use the adjuster bolt at the drive pulley to adjust timing belt tension. 1. Open left endshield. Refer to Opening Endshields, page 37. 2. Loosen two nuts (A) on knife drive belt idler bracket. Figure 6.
MAINTENANCE AND SERVICING 4. Tighten nuts (C) to 54–59 ft·lbf (73–80 N·m) when proper belt tension is achieved. 5. Remove pry bar (A) and wood (B). NOTE: Readjust tension of a new belt after a short run-in period (about five hours). Figure 6.87: Knife Drive 6. Check that clearance (A) between belt (B) and guide (C) is 1/32–1/16 in. (0.5–1.5 mm). 7. If necessary, loosen bolts (D) and adjust guide as required. Tighten bolts. 8. Repeat procedure for opposite side of header. 9. Close endshields. Figure 6.
MAINTENANCE AND SERVICING 3. Rotate the left knife drive box driven pulley clockwise until the left knife (A) is at the center of the inboard stroke (B) (moving towards center of header). NOTE: Center stroke is when the knife sections (C) are centered between guard points. Figure 6.89: Timing: Left Side 4. Rotate the right knife drive box pulley counterclockwise until the right knife (A) is at the center of the inboard stroke (B) (moving towards center of header).
MAINTENANCE AND SERVICING 6. Rotate the idler pulley bracket (A) down and slide the idler pulley up by hand to remove most of the belt slack. Tighten nut (B). Figure 6.92: Knife Drive: Right Side 7. Position pry bar (A) under the idler bracket (C), and push the bracket up until a force of 6 lb (27 N) deflects the belt 1/2 in. (13 mm) at mid-point of the upper span. NOTE: Place a piece of wood (B) under pry bar (A) to protect paint. Figure 6.93: Left Side Shown-Right Side Opposite 8.
MAINTENANCE AND SERVICING 12. Re-tension the right side drive belt as per above, ensuring that the drive pulleys do not rotate. IMPORTANT: Do NOT use the adjuster bolt at the drive pulley to adjust timing belt tension. 13. Recheck the timing. 14. Close both endshields. Refer to Closing Endshields, page 38. Adjusting Belt Tracking The following procedure is applicable to the left side knife drive and the right side knife drive on timed drive headers.
MAINTENANCE AND SERVICING 5. If the belt (A) is tracking to one side of the knife drive box pulley (B), the likely cause is an out of position idler pulley (C). Proceed to Step 7., Adjusting Belt Tracking, page 174 to correct the problem. Figure 6.96: Knife Drive Belt 6. To correct the tracking problem on the drive pulley, adjust the position of the cross shaft support tube as follows: a. Loosen nut (A) on support assembly (B). b.
MAINTENANCE AND SERVICING 7. To correct the tracking problem on the knife drive box pulley, adjust the position of the idler as follows: a. Loosen nuts (A) and (B) and move bracket and idler until belt is loose. b. Remove nut (B) securing idler to bracket, and remove lock washer, idler pulley, and flat washer. c. Install the idler pulley (C), ensuring it lines up with the knife drive box pulley, using flat washer(s) (D) as required. d. Reinstall lock washer (E) and nut (B). e. Tension the belt.
MAINTENANCE AND SERVICING 8. If further adjustment to correct the drive pulley tracking, proceed as follows: a. Loosen nut (A) on idler and nuts (B) on idler bracket. b. Loosen nuts (C) at drive pulley location. c. Turn adjuster bolt (D) clockwise to correct a toe-in problem, which will allow the belt to track inboard. d. Turn adjuster bolt (D) counterclockwise to correct a toe-out problem, which will allow the belt to track outboard. e. Tighten nuts (C) at drive pulley location. f. Tension the belt.
MAINTENANCE AND SERVICING 6.7 Header Drapers The draper should be replaced or repaired if it is torn, missing slats, or cracked. 6.7.1 Removing Drapers To remove a draper, follow these steps: WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. 1. Raise reel and engage reel safety props. 2. Raise header and engage safety props. 3. Move draper until draper joint is in work area.
MAINTENANCE AND SERVICING 1. Apply talc (baby powder) or talc/graphite lubricant mix to the draper surface that forms the seal with the cutter bar and to the underside draper guides. 2. Insert draper into deck at outboard end, under the rollers. Pull draper into deck while feeding it at the end. 3. Feed in the draper until it can be wrapped around the drive roller. 4. Similarly, insert the other end into the deck over the rollers. Pull draper fully into the deck. Figure 6.102: Installing Draper 5.
MAINTENANCE AND SERVICING 8. Check for seal between the drapers and the cutter bar. There should be a 0.04–0.08 in. (1–2 mm) gap (A) between the cutterbar (C) and the draper (B). 9. To achieve the proper gap, refer to 6.7.7 Adjusting Deck Height, page 186. Figure 6.105: Draper Seal 10. If required, adjust backsheet deflector (A) by loosening nut (D) and moving deflector (A) until there is a 1/32–5/16 in. (1–7 mm) gap (C) between the draper (B) and the deflector (A). 11.
MAINTENANCE AND SERVICING 1. Ensure white bar (A) is about halfway in the window. CAUTION Check to be sure all bystanders have cleared the area. 2. Start engine and raise header. 3. Stop engine, remove key, and engage header safety props. Figure 6.107: Tension Adjuster: Left-Hand Shown – Right-Hand Opposite 4. Check that draper guide (rubber track on underside of draper) is properly engaged in groove of drive roller. Figure 6.108: Drive Roller 5. Check that idler roller is between the guides. Figure 6.
MAINTENANCE AND SERVICING IMPORTANT: Do NOT adjust nut (C). This nut is used for draper alignment only. 6. Turn adjuster bolt (A) counterclockwise to loosen, and white indicator bar (B) will move outboard in direction of arrow (D) to indicate that draper is loosening. Loosen until bar is about halfway in window. 7. Turn adjuster bolt (A) clockwise to tighten, and white indicator bar (B) will move inboard in direction of arrow (E) to indicate that draper is tightening.
MAINTENANCE AND SERVICING 3. Turn bolt (A) counterclockwise to fully loosen draper. White indicator bar (B) will move outboard in direction of arrow to indicate that draper is loosening. Figure 6.111: Draper Tensioner 4. Push draper away from cutterbar (as shown) to expose deck support (A). NOTE: There are two or three supports, depending on header size. 5. Remove two center nuts (B) at each support. 6. Move deck away from cutterbar to disengage deck supports. Figure 6.
MAINTENANCE AND SERVICING 7. Insert a pry bar (A) in hole in deck located at approximately the deck mid-point, and lift deck clear of cutterbar. NOTE: Pry bar should be of sufficient length to accommodate width of draper. 8. Support pry bar (A) on a stand (B) of suitable height. Figure 6.113: Lifting the Deck 9. Pull draper off deck onto pry bar. 10. Remove stand (B), draper, and pry bar (A). Figure 6.
MAINTENANCE AND SERVICING 6.7.5 Installing Endless Draper To install an endless draper, follow these steps: DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. Refer to the windrower operator’s manual for instructions regarding the proper use and storage of header safety props. 1.
MAINTENANCE AND SERVICING 5. Line-up deck supports (A) with bolts in deck. 6. Move deck towards cutterbar to engage deck supports. 7. Install nuts (B) and tighten. 8. Adjust draper tension. Refer to Section 6.7.3 Adjusting Draper Tension, page 178. Figure 6.117: Deck Support 6.7.6 Adjusting Header Draper Tracking Each draper deck has a fixed drive roller (A) and a spring-loaded idler roller (B) that can be aligned by adjuster rods so that the draper tracks properly on the rollers.
MAINTENANCE AND SERVICING 3. Adjust the drive roller at ‘X’ as follows: a. Loosen nuts (A) and jam nut (B). b. Turn adjuster nut (C). Figure 6.119: Drive Roller 4. Adjust the idler roller ‘Y’ as follows: a. Loosen nut (A) and jam nut (B). b. Turn adjuster nut (C). 5. If the draper does not track at the idler roller end after adjusting the idler roller, the drive roller is likely not square to the deck. Adjust the drive roller, and then readjust the idler roller. Figure 6.
MAINTENANCE AND SERVICING 6.7.7 Adjusting Deck Height 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 (A), or with draper deflected down slightly (up to 1/16 in. [1.5 mm]) to create a seal. NOTE: Measurement is at supports with header in working position and decks slid fully ahead.
MAINTENANCE AND SERVICING 5. Set deck (A) to 5/16–3/8 in. cutterbar (C) to create a seal. (8–9 mm) below the 6. Tighten deck support hardware (D). 7. Check dimension (B) again it should be set to 5/16–3/8 in. (8–9 mm). 8. Tension draper. Refer to 6.7.3 Adjusting Draper Tension, page 178. Figure 6.123: Deck Support 9. Adjust the backsheet deflector (A). Loosen nut (D) and adjust deflector (A) until there is a 0.04–0.3 in. (1–7 mm) gap (C) between the draper (B) and the deflector (A). Figure 6.
MAINTENANCE AND SERVICING 6.7.8 Draper Roller Maintenance The draper rollers have non-greaseable bearings. The external seal should be checked every 200 hours (and more frequently in sandy conditions) to obtain the maximum bearing life. Inspecting Draper Roller Bearing Procedure to inspect draper roller bearings. 1. If a bad bearing is suspected in one of the draper rollers, a quick way to check is using a infrared thermometer. 2. Engage header and run for approximately 3 minutes. 3.
MAINTENANCE AND SERVICING 5. Remove fasteners (A) and tube connectors (B) at the draper joint to uncouple the draper. 6. Pull the draper off the idler roller. Figure 6.127: Draper Connector 7. Remove bolts (A) and washer at ends of idler roller. 8. Spread roller arms (B) and (C), and remove idler roller. Figure 6.128: Idler Roller Replacing Draper Idler Roller Bearing 1. Remove draper idler roller assembly. Removing Draper Idler Roller, page 188.
MAINTENANCE AND SERVICING 2. Remove bearing assembly (A) and seal (B) from roller tube (C) as follows: a. Attach a slide hammer (D) to threaded shaft (E) in bearing assembly. b. Tap out the bearing assembly (A) and seal (B). 3. Clean inside of roller tube (C). Check tube for wear or damage and replace if necessary. Figure 6.129: Idler Roller Bearing 4. Install new bearing assembly (A) into roller by pushing on outer race of bearing. The bearing is fully positioned when the 9/16 in.
MAINTENANCE AND SERVICING Installing Draper Idler Roller 1. Position stub shaft in idler roller in forward arm (B) on deck. 2. Push on roller to deflect forward arm slightly so that stub shaft at rear of roller can be slipped into rear arm (C). 3. Install bolts (A) with washers, and torque to 70 lb-ft (93 N·m). 4. Wrap the draper over the idler roller, re-connect it and set the tension. See 6.7.2 Installing Drapers, page 176. 5. Run machine to verify that draper tracks correctly.
MAINTENANCE AND SERVICING 5. Remove fasteners (A) and tube connectors (B) at the draper joint to uncouple the draper. 6. Pull the draper off the drive roller. Figure 6.133: Draper Connector 7. Line up the setscrews with the hole (A) in the guard. Remove the two setscrews that hold the motor onto the drive roller. NOTE: The setscrews are a 1/4 turn apart. 8. Remove the four bolts (B) that hold motor to the drive roller arm. NOTE: Plastic shield (C) may require removal to gain access to the top bolt.
MAINTENANCE AND SERVICING 2. Remove bearing assembly (A) and seal (B) from roller tube (C) as follows: a. Attach a slide hammer (D) to threaded shaft (E) in bearing assembly. b. Tap out the bearing assembly (A) and seal (B). 3. Clean inside of roller tube (C). Check tube for wear or damage and replace if necessary. Figure 6.136: Drive Roller Bearing 4. Install new bearing assembly (A) into roller by pushing on outer race of bearing. The bearing is fully positioned when the 9/16 in.
MAINTENANCE AND SERVICING Installing Draper Drive Roller 1. Locate the drive roller (B) between the roller support arms. 2. Install bolt (A) that holds the drive roller to the arm closest to the cutterbar. Torque bolt to 70 ft·lbf (95 N·m). 3. Grease motor shaft and insert into the end of the drive roller. Figure 6.138: Drive Roller 4. Secure motor to the roller support with four bolts (A). Torque to 20 ft·lbf (27 N·m). NOTE: Tighten any loosened bolt and reinstall plastic shield (B), if removed. 5.
MAINTENANCE AND SERVICING 7. Tension the draper, with tensioner bolt (A) and follow the directions on the decal for proper draper tensioning. 8. Disengage the reel and header safety props. 9. Start the engine and lower header and reel. 10. Run machine to verify that draper tracks correctly. 11. If adjustment is required, refer to 6.7.6 Adjusting Header Draper Tracking, page 184. Figure 6.141: Draper Tensioner 6.7.
MAINTENANCE AND SERVICING 6. Remove fasteners securing deflector to endsheet. Nuts (A) are accessible from endshield side. Nuts (B) on uppermost fasteners are accessible from behind the deflector (C). 7. Remove the deflector (C). Figure 6.143: Wide Deflector 8. Remove bolts (A) and remove deflector support (B). 9. If support (B) will not be re-installed, replace lower bolt (B) that holds belt guide (C) on opposite side of endsheet. 10. Repeat above steps for opposite end. Figure 6.
MAINTENANCE AND SERVICING 4. Open endshield. 5. Loosen bolts (A) on cutterbar until retainer (B) is loose. 6. Remove existing bolt that secures belt guide (C) on opposite side of endsheet. 7. Locate support (D) as shown and re-install bolt (E), with nut on far side. 8. Install a second 3/8 in. x 3/4 carriage bolt (F) and lock nut. Do not tighten bolts. Figure 6.145: Deflector Support 9. Position deflector (A) as shown and adjust forward edge for best fit on cutterbar. Slide deflector under retainer (B).
MAINTENANCE AND SERVICING Removing Narrow Draper Deflectors To remove narrrow draper deflectors, follow these steps: Left end removal is illustrated. 1. Raise reel fully and lower header to ground. 2. Shift decks to allow work space at one end of header if hydraulic deck shift installed, otherwise move decks manually after shutting down windrower. 3. Stop engine, remove key, and engage reel safety props. 4. Open endshield. 5. Remove the two Torx® head screws (A) and lock nuts. 6.
MAINTENANCE AND SERVICING 4. Open endshield. 5. Position forward deflector (B) onto endsheet and temporarily install forward and aft 3/8 in. x 5/8 self tapping screws (A). 6. Check fit of forward end of deflector onto cutterbar. There should be no gap between deflector and cutterbar. Remove and bend deflector as required to obtain best fit. 7. Install the four 3/8 in. x 5/8 self-tapping screws (A) and tighten. Figure 6.150: Forward Deflector 8. Position aft deflector (C) as shown and install three 3/8 in.
MAINTENANCE AND SERVICING 6.8 Reel CAUTION To avoid personal injury, before servicing machine or opening drive covers, refer to 6.1 Preparation for Servicing, page 113. 6.8.1 Reel Clearance to Cutterbar The minimum clearance between the reel fingers and the cutterbar ensures that the reel fingers do not contact the cutterbar during operation. The clearance is adjusted at the factory, but adjustments may be necessary before the header is put into operation.
MAINTENANCE AND SERVICING 2. Set the fore-aft position to mid–position (‘5’ on the reel arm indicator decal). 3. Fully lower the reel. 4. Shut down engine. Remove key from ignition. Figure 6.153: Fore-Aft Position 5. Measure clearance ‘X’ between points ‘Y’ and ‘Z’ at ends of each reel (A). NOTE: 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. 6.
MAINTENANCE AND SERVICING Figure 6.156: Double Reel Measurement Locations (Four Places) 7. If necessary, refer to Adjusting Reel Clearance, page 202 for adjustment procedure. Adjusting Reel Clearance DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. Refer to the windrower operator’s manual for instructions regarding the proper use and storage of header safety props.
MAINTENANCE AND SERVICING 2. For Double Reel Only: Adjust center arm lift cylinder stop (A) to change clearance at inboard ends of reels as follows: NOTE: Instructions apply to double-reel headers only and are performed from the underside of the arm. a. Loosen nut (B). b. Turn nut (C) counterclockwise to raise reel and increase clearance to cutterbar, or clockwise to lower reel and decrease clearance. c. 6.8.2 Tighten nut (B). Figure 6.
MAINTENANCE AND SERVICING 3. Adjust the profile as follows: Start with the reel disc set closest to center of header and proceed to the ends. a. Remove bolts (A). b. Loosen bolt (B) and adjust arm (C) until desired measurement is obtained between reel tube and cutterbar. NOTE: Allow the reel tubes to find a natural curve and position the hardware appropriately. c. Reinstall bolts (A) in aligned holes and tighten. Figure 6.160: Reel Arm 6.8.
MAINTENANCE AND SERVICING Centering Single Reel To center the reel, follow these steps: 1. Loosen bolt (A) on brace (B) at both ends of reel. 2. Move forward end of reel support arm (C) laterally as required to center reel. 3. Tighten bolts (A) and torque to 265 ft·lbf (359 N·m). Figure 6.162: Centering Reel 6.8.4 Reel Tines IMPORTANT: Keep reel tines in good condition. Straighten or replace as required.
MAINTENANCE AND SERVICING IMPORTANT: Ensure tine tube is supported at all times to prevent damage to the tube or other components. 1. Slide new tines and reel arm (A) onto end of tube. 2. Install tine tube bushings. Refer to 6.8.5 Tine Tube Bushings, page 207. 3. Attach tines to tine bar with bolts and nuts (B). Figure 6.164: Tine Tube Removing Plastic Fingers WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. 1.
MAINTENANCE AND SERVICING Installing Plastic Fingers WARNING To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised reel for any reason. 1. Position finger on rear of finger tube and engage lug at bottom of finger in lower hole in finger tube. 2. Gently lift top flange and rotate finger until lug in top flange engages upper hole in finger tube. Figure 6.167: Installing Finger IMPORTANT: Do NOT apply force to finger prior to tightening mounting screw.
MAINTENANCE AND SERVICING 2. Remove reel endshields and endshield support (C) from the tail end of the reel at applicable tine tube location. NOTE: There are no endshields on the center disc. 3. Remove bolts (A) securing arm (B) to disc. IMPORTANT: Note the hole locations in arm and disc and ensure bolts are reinstalled at original locations. Figure 6.169: Tail End 4. Release bushing clamps (A) using a small screwdriver to separate the serrations. Pull clamp off tine tube. Figure 6.170: Bushing Clamp 5.
MAINTENANCE AND SERVICING Cam End Bushings NOTE: Removing cam end bushings requires that the tine tube be moved through the disc arms to expose the bushing. 6. At the cam end, remove endshields and endshield support (A) at applicable tine tube location on the cam end. Figure 6.172: Cam End 7. At the tail end, remove reel endshields and endshield support (C) at applicable tine tube location. NOTE: There are no endshields on the center discs. 8.
MAINTENANCE AND SERVICING 10. Remove bolt (A) at on cam linkage so that tine tube (B) is free to rotate. Figure 6.175: Cam End 11. Release bushing clamps (A) at the cam discwith a small screwdriver to separate the serrations. Move clamps off bushings. Figure 6.176: Bushing Clamp 12. Slide tine tube (A) outboard to expose the bushing. Remove the bushing halves (B). If required remove the next tine or plastic finger, so that the arm can slide off the bushing.
MAINTENANCE AND SERVICING Tine Tube Support Bushings (If installed) If the tine tube reinforcing kit is installed: 13. Locate the support (A) that requires a new bushing. 14. Remove four bolts (B) securing channels (C) to support (A). 15. If finger (D) is too close to support to allow access to bushing, remove screw (E) and remove finger (D). Refer to Removing Plastic Fingers, page 206. Figure 6.178: Tine Tube Support 16. Release bushing clamp (A) using a small screwdriver to separate the serrations.
MAINTENANCE AND SERVICING 17. Slide support (A) off of the bushing halves (B). NOTE: Two tine tubes have supports that are assembled opposite to what is shown. Those supports (A) can be rotated for the flange to clear the channels before they can be moved off the bushing. The tine tube can also be moved outward slightly. 18. Remove the bushing halves (B). Figure 6.181: Support Figure 6.
MAINTENANCE AND SERVICING NOTE: A pair of modified channel lock pliers is recommended to install the bushing clamps. Secure pliers (A) in vice and grind in a notch (B) at the end of each arm that fits the clamp (C). Figure 6.183 Cam End Bushings 1. Position bushing halves (B) on tine tube with flangeless end adjacent to reel arm, and locate lug in each bushing half in hole in tine tube. 2. Slide tine tube (A) toward tail end of reel to insert the bushing (B) into the reel arm.
MAINTENANCE AND SERVICING 6. Tighten clamp (A) with modified channel lock pliers (B) so that finger pressure will NOT move clamp. IMPORTANT: Over-tightening clamp may result in breakage. Figure 6.186: Clamp Tool 7. Line up tine bar (B) with cam arm and install bolt (A). Torque bolt to 120 ft·lbf (165 N·m). Figure 6.187: Cam End 8. At the center disc, install the bolts (A) securing arm (B) to disc. 9.
MAINTENANCE AND SERVICING 10. At the cam end, install endshield support (A) at applicable tine tube location on the cam end. 11. Re-install reel endshields. Endshields, page 218. Refer to 6.8.6 Reel Figure 6.189: Cam End Center Disc and Tail End Bushings 12. Position bushing halves (B) on tine tube with flangeless end adjacent to reel arm, and locate lug in each bushing half in hole in tine tube. 13. Slide reel arm (A) onto bushing (B) and position against disc at original location. 14.
MAINTENANCE AND SERVICING 17. Tighten clamp (A) with modified channel lock pliers (B) so that finger pressure will NOT move clamp. IMPORTANT: Over-tightening clamp may result in breakage. Figure 6.192: Clamp Tool 18. At the center disc, install the bolts (A) securing arm (B) to disc. 19. At the tail end, install reel arm (B) and endshield support (C) at applicable tine tube location with bolts (A). Re-install endshields. NOTE: There are no endshields on the center discs. Figure 6.
MAINTENANCE AND SERVICING Tine Tube Support (If installed) Bushings 20. Position bushing halves (B) on tine tube with flangeless end adjacent to reel arm, and locate lug in each bushing half in hole in tine tube. 21. Slide support (C) onto bushing (B). For the opposite tine tube, rotate support (C), or slightly move tine tube, so that it clears channels (D). Figure 6.194: Support Figure 6.195: Opposite Support 22. Install bushing clamp (A) onto tine tube adjacent to flangeless end of bushing (B). 23.
MAINTENANCE AND SERVICING 24. Tighten clamp (A) with modified channel lock pliers (B) so that finger pressure will NOT move clamp. IMPORTANT: Over-tightening clamp may result in breakage. Figure 6.197: Installing Clamp 25. Re-attach channels (C) to support (A) with screws (B) and nuts. Torque screws to 32 lbf·ft (43 N·m). 26. Reinstall any fingers (D) that were removed with screws (E). Refer to Installing Plastic Fingers, page 207. Figure 6.198: Support Figure 6.199: Opposite Support 6.8.
MAINTENANCE AND SERVICING Replacing Endshield 1. Lower header and reel, and shutdown engine. Remove key from ignition. 2. Manually rotate reel for access to endshield (A) to be replaced. 3. Remove three bolts (B). Figure 6.200: Endshields 4. Lift end of endshield (A) off support (B). Figure 6.201: Endshields 5. Lift endshield off supports. Figure 6.
MAINTENANCE AND SERVICING 6. Move endshield (A) away from support (B), and place new endshield (C) onto supports. 7. Reattach end of endshield (A) to support (B). 8. Reinstall bolts (D). 9. Tighten all hardware. Figure 6.203: Endshields Replacing Support 1. Lower header and reel, and shut down engine. Remove key from ignition. 2. Manually rotate reel for access to endshield support (A) to be replaced. 3. Remove bolt (B) from support (A). 4. Remove bolts (C) from support (A) and two adjacent supports.
MAINTENANCE AND SERVICING 6.9 Reel Drive The reel is hydraulically driven through a chain case that is attached to the right end on a single reel header, and between the reels on a double reel header. 6.9.1 Replacing Reel Drive Sprocket Removing Drive Cover 1. Remove the reel drive cover (A) as follows: a. For SINGLE REEL DRIVE, remove the four bolts (B) that secure the cover (A) to the reel drive. Figure 6.206: Single Reel b.
MAINTENANCE AND SERVICING Loosening Drive Chain 1. Loosen nuts (A). Slide motor (B) and motor mount (C) down towards reel shaft. Figure 6.208: Reel Drive Removing Drive Sprocket 1. Remove the drive chain (A) from the drive sprocket (B). Figure 6.209: Reel Drive 2. Remove the cotter pin (A), slotted nut (B), and flat washer (C) from the motor shaft. 3. Remove the drive sprocket (D). Ensure key remains in the shaft. IMPORTANT: Do NOT use pry bar and/or hammer to remove drive sprocket (D).
MAINTENANCE AND SERVICING Installing Drive Sprocket 1. Install the new drive sprocket (D), flat washer (C), and slotted nut (B), onto the motor shaft. 2. Torque nut to 40 lbf·ft (54 N·m). Tighten to next slot if necessary to install cotter pin (A). Figure 6.211: Reel Drive Sprocket 3. Install the chain (A) onto drive sprocket (B). Figure 6.212: Reel Drive Tightening Drive Chain 1. Ensure the six bolts (B) securing motor mount to chain case are loose. 2.
MAINTENANCE AND SERVICING Installing Drive Cover Install reel drive cover as follows: 1. For SINGLE REEL DRIVE, position reel drive cover (A) to the reel drive and secure with four bolts (B). Figure 6.214: Single Reel Drive Cover 2. For DOUBLE REEL DRIVE, position the lower cover (C) first (if removed) and secure with three bolts (D). Install upper cover (A) using the six bolts (B). Figure 6.215: Double Reel Drive Cover 6.9.
MAINTENANCE AND SERVICING Removing Drive Cover 1. Remove the six bolts (B) that secure the upper cover (A) to the reel drive and to the lower cover (C). NOTE: The lower cover (C) may also be removed by taking off the three bolts (D). Figure 6.216: Double Reel Removing Double Reel U-Joint To remove the U-joint, follow these steps. 1. Support inboard end of right reel with a front end loader and nylon slings (or equivalent setup).
MAINTENANCE AND SERVICING 3. Remove six bolts (A) attaching U-joint flange (B) to driven sprocket (C). 4. Remove U-joint. NOTE: Right hand reel may need to be moved sideways for U-joint to clear reel tube. Figure 6.219: U-Joint Installing Double Reel U-Joint To install the U-joint, follow these steps. NOTE: Right hand reel may need to be moved sideways for U-joint to clear reel tube. 1. Position U-joint flange (B) onto driven sprocket (C) as shown. Install six bolts (A) and hand-tighten.
MAINTENANCE AND SERVICING 5. Remove temporary reel support. Figure 6.222: Supporting Reel Installing Drive Cover 1. Position the lower cover (C) first (if removed) and secure with three bolts (D). 2. Install upper cover (A) using the six bolts (B). Figure 6.
MAINTENANCE AND SERVICING 6.9.3 Replacing Reel Drive Motor The reel drive motor does not require regular maintenance or servicing. If problems develop with the motor, it should be removed and serviced at your MacDon Dealer. Removing Drive Cover 1. Remove the reel drive cover (A) as follows: a. For SINGLE REEL DRIVE, remove the four bolts (B) that secure the cover (A) to the reel drive. Figure 6.224: Single Reel b.
MAINTENANCE AND SERVICING Loosening Drive Chain 1. Loosen nuts (A). Slide motor (B) and motor mount (C) down towards reel shaft. Figure 6.226: Reel Drive Removing Drive Sprocket 1. Remove the drive chain (A) from the drive sprocket (B). Figure 6.227: Reel Drive 2. Remove the cotter pin (A), slotted nut (B), and flat washer (C) from the motor shaft. 3. Remove the drive sprocket (D). Ensure key remains in the shaft. IMPORTANT: Do NOT use pry bar and/or hammer to remove drive sprocket (D).
MAINTENANCE AND SERVICING Removing Reel Drive Motor To remove the reel drive motor from a single or double reel header, follow these steps: 1. Disconnect hydraulic lines (A) at motor (B). Cap or plug open ports and lines. 2. Slide motor (B) and motor mount (C) up or down so that attachment bolts (D) are exposed in holes and slots in back plate. Figure 6.229: Reel Drive Motor 3. Remove four nuts (A) and attachment bolts and remove motor (B) from motor mount (C).
MAINTENANCE AND SERVICING Installing Reel Drive Motor To install the reel drive hydraulic motor, follow these steps: 1. Slide motor mount (A) up or down so that mounting holes are accessible through openings in chain case. 2. Attach motor (B) and spacer (C) to motor mount with four 1/2 in.x 1.75 countersunk bolts (D). 3. Secure motor with lock nuts (E). 4. Torque nuts to 54 lbf·ft (73 N·m). 5. If installing new motor, install fittings (F) from old motor onto new motor. Figure 6.
MAINTENANCE AND SERVICING Installing Drive Sprocket 1. Install the new drive sprocket (D), flat washer (C), and slotted nut (B), onto the motor shaft. 2. Torque nut to 40 lbf·ft (54 N·m). Tighten to next slot if necessary to install cotter pin (A). Figure 6.233: Reel Drive Sprocket 3. Install the chain (A) onto drive sprocket (B). Figure 6.234: Reel Drive Tightening Drive Chain 1. Ensure the six bolts (B) securing motor mount to chain case are loose. 2.
MAINTENANCE AND SERVICING Installing Drive Cover Install reel drive cover as follows: 1. For SINGLE REEL DRIVE, position reel drive cover (A) to the reel drive and secure with four bolts (B). Figure 6.236: Single Reel Drive Cover 2. For DOUBLE REEL DRIVE, position the lower cover (C) first (if removed) and secure with three bolts (D). Install upper cover (A) using the six bolts (B). Figure 6.237: Double Reel Drive Cover 6.9.
MAINTENANCE AND SERVICING Removing Drive Cover 1. Remove the six bolts (B) that secure the upper cover (A) to the reel drive and to the lower cover (C). NOTE: The lower cover (C) may also be removed by taking off the three bolts (D). Figure 6.238: Double Reel Loosening Drive Chain 1. Loosen nuts (A). Slide motor (B) and motor mount (C) down towards reel shaft. Figure 6.239: Reel Drive Disconnecting the Reel Drive Method 1.
MAINTENANCE AND SERVICING 2. Remove four bolts (A) attaching reel tube to U-joint (B). Figure 6.241: U-Joint 3. Move right-hand reel sideways to separate the reel tube (A) and U-joint (B). 4. Remove the chain (C). 5. Route new chain (C) over U-joint (B) and locate on sprockets. Figure 6.242: Replacing Chain 6. Position right-hand reel tube (A) against reel drive and engage stub shaft into U-joint (B) pilot hole. 7. Rotate reel until holes in end of reel tube and U-joint line up. 8.
MAINTENANCE AND SERVICING 10. Remove temporary reel support. 11. Proceed to Tightening Drive Chain. Figure 6.244: Supporting Reel Breaking the Chain Method 1. Grind off head of a link rivet on chain (A), punch out the rivet, and remove chain. 2. Grind off the head from one of the link rivets on the new chain and punch out rivet to separate the chain. 3. Locate ends of chain on sprocket (B). Figure 6.245: Reel Drive 4.
MAINTENANCE AND SERVICING Tightening Drive Chain 1. Ensure the six bolts (B) securing motor mount to chain case are loose. 2. Slide motor and motor mount upwards until chain (A) is tight, and tighten bolts (nuts on backside). 3. There should be 1/8 in. (3 mm) of slack in the chain. Adjust if necessary. 4. Torque bolts (B) to 54 lbf·ft (73 N·m). Figure 6.247: Reel Drive Installing Drive Cover 1. Position the lower cover (C) first (if removed) and secure with three bolts (D). 2.
MAINTENANCE AND SERVICING 6.9.5 Replacing Drive Chain on Single Reel Removing Drive Cover 1. Remove the reel drive cover (A) as follows: a. For SINGLE REEL DRIVE, remove the four bolts (B) that secure the cover (A) to the reel drive. Figure 6.249: Single Reel b. For DOUBLE REEL DRIVE, remove the six bolts (B) that secure the upper cover (A) to the reel drive and to the lower cover (C). NOTE: The lower cover (C) may also be removed by taking off the three bolts (D). Figure 6.
MAINTENANCE AND SERVICING Replacing Chain on Single Reel 1. Lift chain (A) off drive sprocket (B). 2. Lower chain until free of lower sprocket (C) and remove chain from drive. 3. Locate new chain (A) around bottom teeth on lower sprocket (C). 4. Lift chain onto drive sprocket (B) ensuring all links are properly engaged in teeth. Figure 6.252: Reel Drive Tightening Drive Chain 1. Ensure the six bolts (B) securing motor mount to chain case are loose. 2.
MAINTENANCE AND SERVICING 2. For DOUBLE REEL DRIVE, position the lower cover (C) first (if removed) and secure with three bolts (D). Install upper cover (A) using the six bolts (B). Figure 6.255: Double Reel Drive Cover 6.9.6 Adjusting Reel Drive Chain Tension Removing Drive Cover 1. Remove the reel drive cover (A) as follows: a. For SINGLE REEL DRIVE, remove the four bolts (B) that secure the cover (A) to the reel drive. Figure 6.256: Single Reel b.
MAINTENANCE AND SERVICING Tightening Drive Chain 1. Ensure the six bolts (B) securing motor mount to chain case are loose. 2. Slide motor and motor mount upwards until chain (A) is tight, and tighten bolts (nuts on backside). 3. There should be 1/8 in. (3 mm) of slack in the chain. Adjust if necessary. 4. Torque bolts (B) to 54 lbf·ft (73 N·m). Figure 6.258: Reel Drive Installing Drive Cover Install reel drive cover as follows: 1.
MAINTENANCE AND SERVICING 6.10 Transport System (Optional) Refer to 8.3.3 Stabilizer/Slow Speed Transport Wheels, page 264 for more information. 6.10.1 Checking Wheel Bolt Torque If a Transport System is installed, follow procedure for torquing the wheel bolts. IMPORTANT: Whenever a wheel is removed and reinstalled, check torque after one hour of operation and every 100 hours thereafter. Maintain 80–90 ft·lbf (110–120 N·m) torque. Follow bolt tightening sequence shown below. Figure 6.
MAINTENANCE AND SERVICING 6.10.2 Checking Axle Bolt Torque If a transport system is installed, follow this procedure for torquing the axle bolts. Figure 6.262: Axle Bolts 1.
MAINTENANCE AND SERVICING 6.10.3 Checking Tire Pressure Check tire pressure daily. recommended in following table: Size Maintain pressure Load Range Pressure D 65 psi (448 kPa) E 80 psi (552 kPa) ST205/75 R15 WARNING • Service tires safely. • A tire can explode during inflation and cause serious injury or death. • Do NOT stand over tire. Use a clip-on chuck and extension hose. • NEVER increase air pressure beyond pressure specified on tire sidewall to seat the bead on the rim.
7 7.1 Troubleshooting Crop Loss at Cutterbar Symptom Does not pick up down crop Problem Solution Section Cutterbar too high Lower cutterbar. 4.7.1 Cutting Height, page 50 Header angle too low Increase header angle. Controlling Header Angle, page 56 Reel too high Lower reel. 4.7.8 Reel Height, page 58 Reel too far back Move reel forward. 4.7.9 Reel Fore-Aft Position, page 58 Ground speed too fast for reel speed Reduce ground speed or increase reel speed. 4.7.4 Reel Speed, page 56 4.7.
TROUBLESHOOTING Symptom Problem Solution Section Excessive bouncing at normal field speed Float set too light Adjust header float. 4.7.2 Header Float, page 55 Divider rod running down standing crop Divider rods too long Remove divider rod. 4.7.12 Crop Divider Rods, page 72 Bushy or tangled crop flows over divider rod, builds up on endsheets Divider rods providing insufficient separation Install long divider rods. 4.7.
TROUBLESHOOTING 7.2 Cutting Action and Knife Components Symptom Ragged or uneven cutting of crop Problem Solution Section Knife hold-downs not adjusted properly. Adjust hold-downs. Checking Knife Hold-Downs, page 149 Knife sections or guards are worn or broken. Replace all worn and broken cutting parts. 6.5 Knife, page 140 Knife is not operating at recommended speed. Check engine speed of windrower. Refer to your windrower operator’s manual Ground speed too fast for reel speed.
TROUBLESHOOTING Symptom Knife plugging Problem Solution Section Reel too high or too far forward. Lower reel or move reel rearward. 4.7.8 Reel Height, page 58 4.7.9 Reel Fore-Aft Position, page 58 Ground speed too slow. Increase ground speed. 4.7.5 Ground Speed, page 57 Loose knife drive belt. Adjust drive belt tension. Tensioning Non-Timed Knife Drive Belts, page 163 or Tensioning Timed Knife Drive Belts, page 168 Improper knife hold-down adjustment. Adjust hold-down.
TROUBLESHOOTING Symptom Excessive header vibration Problem Solution Section Knife hold-downs not adjusted properly. Adjust hold-downs. Checking Knife Hold-Downs, page 149 Knives on double-knife drive not timed. Adjust knife timing. Adjusting Double Knife Timing, page 169 Knife not operating at recommended speed. Check engine speed of windrower. Refer to your windrower’s operator’s manual Replace knife. 6.5.2 Removing Knife, page 142 6.5.
TROUBLESHOOTING 7.3 Reel Delivery Symptom Reel not releasing material in normal standing crop Reel not releasing material in lodged and standing crop (reel fully lowered) Wrapping on reel end Reel releases crop too quickly Reel will not lift Reel will not turn Reel motion uneven under no load 169899 Problem Solution Section Reel speed too fast Reduce reel speed. 4.7.4 Reel Speed, page 56 Reel too low Raise reel. 4.7.8 Reel Height, page 58 Reel tines too aggressive Reduce cam setting.
TROUBLESHOOTING Symptom Reel motion is uneven or stalls in heavy crops Plastic fingers cut at tip Plastic fingers bent rearward at tip Plastic fingers bent forward at tip (opposite of above) Plastic fingers bent close to tine tube. 169899 Problem Solution Section Reel speed too fast Reduce reel speed. 4.7.4 Reel Speed, page 56 Reel fingers not aggressive enough Move to a more aggressive finger pitch notch. 4.7.10 Reel Tine Pitch, page 65 Reel too low Raise reel. 4.7.
TROUBLESHOOTING 7.4 Header and Drapers Symptom Problem Solution Section Header lift insufficient Low relief pressure Increase relief pressure. See your MacDon Dealer Speed control set too low Increase control setting. 4.7.6 Draper Speed, page 57 Relief pressure too low Increase relief pressure to recommended setting. See your MacDon Dealer Windrower header drive too slow Adjust to correct speed for windrower model.
TROUBLESHOOTING Symptom Problem Solution Drapers back-feed Drapers running too slow in heavy crop Increase draper speed. Crop is thrown across opening and under opposite side draper Drapers running too fast in light crop Reduce draper speed. Material accumulates inside or under front edge of draper Deck height improperly adjusted Adjust deck height. 6.7.
TROUBLESHOOTING 7.5 Cutting Edible Beans Symptom Plants being stripped and complete or partial plants left behind. Problem Solution Section Header off ground. Lower header to ground and run on skid shoes and/or cutterbar. Cutting On the Ground, page 53 Float set too light—rides on high spots and does not lower soon enough. Set float for: - Dry ground: 100–150 lbf - Wet ground: 50–100 lbf 4.7.2 Header Float, page 55 Reel too high. Fully retract reel cylinders. 4.7.
TROUBLESHOOTING Symptom Plants being stripped and complete or partial plants left behind (cont’d) Excessive losses at dividers Plant vines pinched between top of draper and cutterbar Crop accumulating at guards and not moving rearward onto drapers Problem Solution Section 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. 4.
TROUBLESHOOTING Symptom Cutterbar guards breaking Problem Solution Section Float insufficient. Increase float. 4.7.2 Header Float, page 55 Consider installing optional stub guards. Tip: Experiment with a few guards on a section of cutterbar to compare the performance of the two different styles of guards. Excessive number of rocks in field. Re-adjust float to make header lighter. Header too heavy. Decrease header angle with lift cylinders. Header angle too steep.
TROUBLESHOOTING Problem Solution Section Excessive accumulation of crop on drapers (up to height of reel center tube). Increase draper speed. 4.7.6 Draper Speed, page 57 Finger pitch too retarded. Increase finger pitch. 4.7.10 Reel Tine Pitch, page 65 Reel wraps up with crop Reel too low. Raise reel. 4.7.8 Reel Height, page 58 Reel ends wrap up with crop Uncut crop interfering on reel ends. Add reel endshields. Refer to the header parts catalog MD #169902.
TROUBLESHOOTING 7.6 Windrow Formation Symptom Heads on ground and scattered Problem Solution Section Draper speed too slow Increase draper speed. 4.7.6 Draper Speed, page 57 Draper angle too flat Increase header angle. Controlling Header Angle, page 56 Ground speed too slow Increase ground speed. 4.7.5 Ground Speed, page 57 Crop too ripe Cut material before too mature. — Draper speed too slow Increase draper speed. 4.7.
8 Options and Attachments The following options and attachments are available for use with your header. Most come with installation instructions. See your MacDon Dealer for availability and ordering information. 8.1 8.1.1 Reel Lodged Crop Reel Finger Kit The steel fingers attach to ends of every other tine bar and help in clearing material in heavy, hard-to-cut crops such as lodged rice. Each kit contains three fingers for the cam end and three fingers for the tail end of the reel.
OPTIONS AND ATTACHMENTS 8.1.3 Reel Endshield Kit The steel shields attach to ends of the reel(s) and help in clearing material in heavy, hard-to-cut crops. They are standard equipment on all, except 9-bat, headers. See your MacDon Dealer for more information. Installation and adjustment instructions are included with the kit. Figure 8.2: Reel Endshields 8.1.
OPTIONS AND ATTACHMENTS 8.2 8.2.1 Cutterbar Cutterbar Plastic Wear Strips Available as an attachment, they are recommended for cutting on the ground where soil adheres to steel. Bundles by header size: • 15 ft. – MD #B4864 • 20 ft. – MD #B4865 • 25 ft. – MD #B4838 • 30 ft. – MD #B4839 • 35 ft. – MD #B4840 • 40 ft. – MD #B4841 Figure 8.4: Wear Strips 8.2.
OPTIONS AND ATTACHMENTS 8.2.3 Stub Guard Conversion Kit Stub guards, complete with top guides and adjuster shoes, are designed to cut tough crops. Installation and adjustment instructions are included in the kit. Order bundle according to the length of your header: • 15 ft. – MD #B5009 • 20 ft. – MD #B5010 • 25 ft. – MD #B5011 • 30 ft. – MD #B5012 • 35 ft. – MD #B5013 Figure 8.6: Stub Guards 8.2.
OPTIONS AND ATTACHMENTS 8.3 8.3.1 Header Divider Latch Kit The latches attach to the endsheets. They allow for quick removal of endsheet divider cones to accommodate storage and if required, to reduce the transport width of the header. Installation instructions are included with the kit. MD #B5607 Figure 8.8: Divider Latch 8.3.2 Stabilizer Wheels The stabilizer wheels help stabilize the header in field conditions that would otherwise cause the header to bounce and result in uneven cutting height.
OPTIONS AND ATTACHMENTS 8.3.3 Stabilizer/Slow Speed Transport Wheels The Stabilizer/Slow Speed Transport Wheels help stabilize the header in field conditions that would otherwise cause the header to bounce, and result in uneven cutting height. This system is similar to the Stabilizer Wheel option. The Stabilizer/Slow Speed Transport Wheels convert to transport mode to allow the header to be towed behind a properly configured MacDon windrower (or agricultural tractor) at slow speed.
OPTIONS AND ATTACHMENTS 8.4 8.4.1 Crop Delivery Double Draper Drive (DDD) Kit This option minimizes draper slipping in heavy forage crops when using the side delivery feature, by having four draper rollers powered instead of the normal two. Installation instructions are included with the kit. Available for 30 to 40 ft. headers. MD #B565322 8.4.2 Double Windrow Attachment (DWA) The DWA23 lays up to 48 ft. (14.6 m) of crop in a single windrow which is ideal for today’s large forage harvesters.
OPTIONS AND ATTACHMENTS 8.4.4 Draper Deflector (Wide) Wide metal deflectors attach to the inboard side of the endsheets, to prevent material from falling through the gap between the endsheet and draper. Refer to the D65 Draper Header Parts Catalog (MD #169902) for required parts. Figure 8.13: Draper Deflector 8.4.5 Draper Extension Kit This kit increases the length of each deck up to 10 in. (250 mm) into the header opening which decreases the swath width when cutting light/thin crops.
OPTIONS AND ATTACHMENTS 8.4.7 HC10 Hay Conditioner 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, operating instructions, and parts list are included. MD #C1982 NOTE: Not for use on M205 Windrower. Figure 8.15: Hay Conditioner 8.4.8 Hydraulic Deck Shift Package This system allows shifting of the decks from the operator’s console when double-swathing.
OPTIONS AND ATTACHMENTS 8.4.10 Upper Cross Auger (UCA) Attaches in front of the backtube, the UCA improves feeding of crop to the center of the header in heavy crop conditions. Ideal for high volume harvesting of forages, oats, canola, mustard and other tall, bushy, hard to feed crops. Order bundle 26according to the length of your header: • 15 ft. – MD #B4844 • 25 ft. – MD #B4846 • 30 ft. – MD #B4847 • 35 ft. – MD #B4848 • 40 ft. – MD #B4849 Figure 8.17: Upper Cross Auger 8.4.
OPTIONS AND ATTACHMENTS 8.4.13 Rice Divider Rods The rice divider rods attach to the left hand and right hand endsheet cones and perform the same function in tall and tangled rice crops as standard equipment crop dividers. Installation instructions are included with the kit. MD #B5609 Figure 8.
9 Unloading and Assembly Refer to the header-specific instructions for unloading, assembly, and setup procedures that are included with your shipment.
Index A AHHC definition .......................................................... 25 API definition .......................................................... 25 ASTM definition .......................................................... 25 axle bolt ............................................................ 243 B beater bar installing .......................................................... 87 removing ......................................................... 85 belt knife drive adjusting (35 ft.
INDEX E electrical maintenance .................................................. 139 replacing light bulbs........................................ 139 end of season service ........................................ 131 endless draper removing ................................................ 180, 183 endshield ............................................................ 37 adjusting .......................................................... 41 closing.........................................................
INDEX knife drive box ................................................... 153 changing oil ................................................... 161 installing pulley............................................... 158 installing single and double knife untimed......... 158 mounting bolts ............................................... 153 removing double knife timed ........................... 155 removing pulley .............................................. 157 removing single and double knife untimed.....
INDEX R recommended fluids and lubricant .......................115 recommended setting .......................................... 46 reel ................................................................... 200 adjusting cam.............................................................. 67 fore-aft position ............................................. 59 frown.......................................................... 203 reel clearance .............................................
INDEX ground............................................................. 57 knife ................................................................ 58 reel.................................................................. 56 spm definition .......................................................... 25 sprocket ............................................................ 221 optional reel drive sprockets.............................. 56 SR definition ..........................................................
INDEX W wheel and tire.................................................... 244 safety ................................................................ 8 wheel bolt torque............................................ 242 windrow chemical drying agents ..................................... 82 configuration .................................................... 81 curing .............................................................. 81 delivery opening ............................................... 74 double ..
MacDon Industries Ltd. 680 Moray Street Winnipeg, Manitoba Canada R3J 3S3 t. (204) 885-5590 f. (204) 832-7749 MacDon, Inc. 10708 N. Pomona Avenue Kansas City, Missouri United States 64153-1924 t. (816) 891-7313 f. (816) 891-7323 MacDon Australia Pty. Ltd. A.C.N. 079 393 721 P.O. Box 243, Suite 3, 143 Main Street Greensborough, Victoria, Australia 3088 t. 03 9432 9982 f. 03 9432 9972 LLC MacDon Russia Ltd. 123317 Moscow, Russia 10 Presnenskaya nab, Block C Floor 5, Office No. 534, Regus Business Centre t.
