MacDon FlexDraper FD1, FM100, FlexDraper FD145, FlexDraper FD130, FlexDraper FD135 Operator's Manual

FD1 Series

FlexDraper

®®

Combine Header

Operator ’s Manual

214683 Revision A

2019 Model Year

Original Instruction

Featuring MacDon FLEX-FLOAT Technology™

The harvesting specialists.

FD1 Series FlexDraper®Header

1016679

Published: June 2018

Declaration of Conformity

1026043

214683 i Revision A

1026044

214683 ii Revision A

1026045

214683 iii Revision A

1026044

214683 iv Revision A

Introduction

This instructional manual contains information on the FD1 Series FlexDraper®and the FM100 Combine Float
Module. It must be used in conjunction with your combine operator's manual.

®

The FD1 Series FlexDraper
above the ground, using a three-piece flexible frame to closely follow ground contours. The FM100 Combine Float
Module is used to attach an FD1 Series FlexDraper

Carefully read all the material provided before attempting to use the machine.

Use this manual as your first source of information about the machine. If you follow the instructions provided, your
header will work well for many years. If you require more detailed service information, a technical manual is
available from your MacDon Dealer.

MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual.
A copy of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided
to you by your Dealer. Damage resulting from any of the following conditions will void the warranty:

• Accident

• Misuse

• Abuse

• Improper maintenance or neglect

• Abnormal or extraordinary use of the machine

is specially designed to work well in all straight cut conditions, whether cutting on or

®

to most makes and models of combines.

• Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions

The following conventions are used in this document:

• Right and left are determined from the operator’s position. The front of the header faces the crop; the back of
the header attaches to the combine.

• Unless otherwise noted, use the standard torque values provided in Chapter 8.1 Torque Specifications, page

577.

When setting up the machine or making adjustments, review and follow the recommended machine settings in all
relevant MacDon publications. Failure to do so may compromise machine function and machine life and may result
in a hazardous situation.

The Table of Contents and Index will guide you to specific areas of this manual. Study the Table of Contents to
familiarize yourself with how the information is organized.

214683 v Revision A

1024245

A

Keep this manual handy for frequent reference and to pass
on to new Operators or Owners. A manual storage case (A)
is located inside the header left endshield.

Call your MacDon Dealer if you need assistance,
information, or additional copies of this manual.

NOTE:

Keep your MacDon publications up-to-date. The most
current version can be downloaded from our website
(www.macdon.com) or from our Dealer-only site
(https://portal.macdon.com) (login required).

This document is available in English, Czech, German,
French, Portuguese, Russian, and Ukrainian.

Figure 1. Manual Storage Location

214683 vi Revision A

List of Revisions

Summary of Change Refer To

Updated Declaration of Conformity for model
year 2019.

Added Ukrainian to the list of languages available.

Added FM100 safety decal locations. 1.7 Safety Decal Locations, page 8

Added safety decal MD #252996. 1.8 Understanding Safety Signs, page 13

Updated illustrations of endshield hinge plate. Added
note to ensure hinge arm is installed in outboard hole
on the hinge bracket.

Updated illustrations to show transport lights.

Revised the high voltage limit adjustment instructions.

Added topic.

Added step and image showing the header
control switch.

Added settings for HEIGHT/TILT RESPONSE and
AUTO HEIGHT OVERRIDE.

Declaration of Conformity, page i

Introduction, page v

• Removing Endshields, page 36

• Installing Endshields, page 37

Repositioning Fore-Aft Cylinders on Non-European­Configured Headers with Multi-Crop Rapid Reel
Conversion Option, page 108

Adjusting Voltage Limits: One-Sensor System, page
131

Replacing Float Indicator Cable, page 135

Calibrating Auto Header Height Control (Case IH 5130/
6130/7130, 5140/6140/7140), page 146

Calibrating the Auto Header Height Control (Case
Combines with Version 28.00 or Higher Software),
page 160

Added settings specific to the two-sensor system.

Added steps to set center link to D, unlock float, and
lock wings.

Added steps for calibrating feeder house speed.

Removed unnecessary steps involving header float;
these steps are not applicable to reel height sensor
calibration.

Deleted note with link to height sensor adjustment; the
note isn’t relevant to feeder house speed calibration.

Added step to lock wings before calibration.

• Setting up the Header on the Combine Display

(Case IH 5130/6130/7130; 5140/6140/7140), page
142

• Calibrating the Auto Header Height Control

(Case IH 7010/8010, 7120/8120/9120,
7230/8230/9230, 7240/8240/9240), page 156

• Calibrating the Auto Header Height Control (Case

Combines with Version 28.00 or Higher Software),
page 160

Calibrating the Auto Header Height Control (Case
Combines with Version 28.00 or Higher Software),
page 160

Calibrating the Auto Header Height Control (John
Deere S and T Series), page 215

Calibrating Reel Height Sensor (John Deere S and T
Series), page 227

Calibrating Feeder House (John Deere S7 Series),
page 236

Calibrating the Auto Header Height Control (CLAAS
600 and 700 Series), page 251

214683 vii Revision A

Added topics.

• Calibrating Reel Height Sensor (CLAAS 600 and

700 Series), page 258

• Adjusting Auto Reel Height (CLAAS 600 and 700

Series), page 260

Revised caution statement about reduced header
stability when cornering.

• Removed mentions of discontinued flighting
bundles B6215 and B6216.

• Updated feed auger illustrations.

Updated feed auger illustrations.

• Added changing oil in header drive gearbox (first 50
hours only).

• Added lubricating center draper roller bearings
(every 50 hours).

• Added checking draper roller bearings for heat
(every 200 hours)

Towing the Header, page 291

4.1 Float Module Feed Auger Configurations, page 307

• 5.7.2 Checking Auger Drive Chain Tension, page

421

• 5.7.3 Adjusting Auger Drive Chain Tension, page

423

• 5.7.4 Removing Auger Drive Chain, page 424

• 5.7.5 Installing Auger Drive Chain, page 426

5.3.1 Maintenance Schedule/Record, page 385

Added checking and adjusting finger timing
instructions.

Revised topic—No adjustment is required if spring
retainers are within +6 to –3 of flush and feed draper is
tracking properly.

Updated torque value for center reel arm brace bolts.
Updated illustration to show new bolt orientation.

Updated reel speed sensor illustrations.

Updated load range D tire pressure to 75 psi.

Added topics.

• Checking Auger Finger Timing, page 434

• Adjusting Auger Finger Timing, page 435

5.10.2 Adjusting Feed Draper Tension, page 468

5.15.3 Centering Double Reel, page 507

• Replacing AGCO (Challenger, Gleaner, and

Massey Ferguson) Sensor, page 538

• Replacing John Deere Reel Speed Sensor, page

540

5.17.3 Checking Tire Pressure, page 544

• 6.4.6 Center Skid Shoes Kit, page 554

• 6.5.9 European Combine Upper Cross Auger

(UCA), page 559

214683 viii Revision A

Model and Serial Number

1020884

A

1020665

A

Record the model number, serial number, and model year of the header, combine float module, and
transport / stabilizer wheel option (if installed) in the spaces provided.

NOTE:

Right and left designations are determined from the operator’s position, facing forward.

®®

FlexDraper

Header Model:

Serial Number:

Year:

The serial number plate (A) is located in the upper corner
on the left endsheet.

Header

Figure 2. Header, Left Side Endshield

Combine Float Module

Float Module
Model:

Serial Number:

Year:

The serial number plate (A) is located at the top left side
of the float module.

Figure 3. Float Module

214683 ix Revision A

1005072

A

Slow Speed Transport / Stabilizer Wheel Option

Serial Number:

Year:

The serial number plate (A) is located on the right axle
assembly.

Figure 4. Transport/Stabilizer Option

214683 x Revision A

TABLE OF CONTENTS

Declaration of Conformity............................................................................................................................ i

Introduction...............................................................................................................................................v

List of Revisions ...................................................................................................................................... vii

Model and Serial Number.......................................................................................................................... ix

Chapter 1: Safety .................................................................................................................................... 1

1.1 Safety Alert Symbols ............................................................................................................................1

1.2 Signal Words .......................................................................................................................................2

1.3 General Safety.....................................................................................................................................3

1.4 Maintenance Safety .............................................................................................................................5

1.5 Hydraulic Safety...................................................................................................................................6

1.6 Safety Signs ........................................................................................................................................7

1.6.1 Installing Safety Decals ...............................................................................................................7

1.7 Safety Decal Locations.........................................................................................................................8

1.8 Understanding Safety Signs................................................................................................................ 13

Chapter 2: Product Overview ............................................................................ ................................ 19

2.1 Definitions .........................................................................................................................................19

2.2 Specifications ....................................................................................................................................21

2.3 Component Identification ....................................................................................................................25

®

2.3.1 FD1 Series FlexDraper

2.3.2 FM100 Float Module..................................................................................................................26

............................................................................................................25

Chapter 3: Operation ...........................................................................................................................29

3.1 Owner/Operator Responsibilities.........................................................................................................29

3.2 Operational Safety .............................................................................................................................30

3.2.1 Header Safety Props .................................................................................................................30

3.2.2 Reel Safety Props .....................................................................................................................31

Engaging Reel Safety Props......................................................................................................31

Disengaging Reel Safety Props .................................................................................................32

3.2.3 Endshields................................................................................................................................33

Opening Endshields..................................................................................................................33

Closing Endshields ...................................................................................................................34

Checking and Adjusting Endshields ...........................................................................................35

Removing Endshields ...............................................................................................................36

Installing Endshields .................................................................................................................37

3.2.4 Linkage Covers.........................................................................................................................37

Removing Linkage Covers ........................................................................................................37

Installing Linkage Covers ..........................................................................................................38

3.2.5 Daily Start-Up Check .................................................................................................................39

3.3 Break-in Period..................................................................................................................................40

3.4 Shutting down the Combine ................................................................................................................41

3.5 Cab Controls .....................................................................................................................................42

214683 xi Revision A

TABLE OF CONTENTS

3.6 Header Setup ....................................................................................................................................43

3.6.1 Header Attachments..................................................................................................................43

3.6.2 Header Settings ........................................................................................................................ 43

3.6.3 Optimizing Header for Straight Combining Canola .......................................................................54

Checking and Adjusting Feed Auger Springs .............................................................................. 54

3.6.4 Reel Settings ............................................................................................................................56

3.7 Header Operating Variables................................................................................................................58

3.7.1 Cutting off the Ground ...............................................................................................................58

Adjusting Stabilizer / Slow Speed Transport Wheels ....................................................................59

Adjusting Stabilizer Wheels .......................................................................................................60

3.7.2 Cutting on the Ground ............................................................................................................... 62

Adjusting Inner Skid Shoes .......................................................................................................62

Adjusting Outer Skid Shoes.......................................................................................................63

3.7.3 Header Float............................................................................................................................. 64

Checking and Adjusting Header Float ........................................................................................64

Locking/Unlocking Header Float ................................................................................................ 69

Locking/Unlocking Header Wings .............................................................................................. 70

Operating in Flex Mode.............................................................................................................70

Operating in Rigid Mode............................................................................................................ 71

3.7.4 Checking and Adjusting Header Wing Balance ............................................................................ 73

Checking Wing Balance ............................................................................................................73

Adjusting Wing Balance ............................................................................................................79

3.7.5 Header Angle............................................................................................................................81

Adjusting Header Angle from Combine.......................................................................................83

3.7.6 Reel Speed............................................................................................................................... 89

Optional Reel Drive Sprockets...................................................................................................89

3.7.7 Ground Speed ..........................................................................................................................90

3.7.8 Draper Speed ...........................................................................................................................91

Adjusting Header Draper Speed ................................................................................................92

Feed Draper Speed ..................................................................................................................93

3.7.9 Knife Speed Data ...................................................................................................................... 94

Checking Knife Speed ..............................................................................................................95

3.7.10 Reel Height............................................................................................................................. 95

Checking and Adjusting Reel Height Sensor..... ..........................................................................96

Replacing Reel Height Sensor...................................................................................................98

3.7.11 Reel Fore-Aft Position .............................................................................................................. 99

Adjusting Reel Fore-Aft Position .............................................................................................. 100

Repositioning Fore-Aft Cylinders on Non-European-Configured Headers....................................101

Repositioning Fore-Aft Cylinders on European-Configured Headers........................................... 104

Repositioning Fore-Aft Cylinders on Non-European-Configured Headers with Multi-Crop Rapid

Reel Conversion Option..............................................................................................108

3.7.12 Reel Tine Pitch ...................................................................................................................... 111

Reel Cam Settings.................................................................................................................. 111

Adjusting Reel Cam ................................................................................................................ 113

3.7.13 Crop Dividers ........................................................................................................................ 115

Removing Crop Dividers with Latch Option from Header............................................................ 115

Removing Crop Dividers without Latch Option from Header ....................................................... 116

Installing Crop Dividers with Latch Option onto Header.............................................................. 116

Installing Crop Dividers without Latch Option onto Header ......................................................... 118

214683 xii Revision A

TABLE OF CONTENTS

3.7.14 Crop Divider Rods ................................................................................................................. 119

Removing Crop Divider Rods .................................................................................................. 120

Installing Crop Divider Rods .................................................................................................... 120

Rice Divider Rods...................................................................................................................121

3.7.15 Setting Auger Position ...........................................................................................................121

3.8 Auto Header Height Control (AHHC)..................................................................................................124

3.8.1 Sensor Operation....................................................................................................................125

3.8.2 Sensor Output Voltage Range – Combine Requirements ...........................................................126

10 Volt Adapter (MD #B6421) – New Holland Combines Only .................................................... 126

Manually Checking Voltage Range: One-Sensor System ........................................................... 127

Manually Checking Voltage Range: Two-Sensor System ........................................................... 129

Adjusting Voltage Limits: One-Sensor System ..........................................................................131

Adjusting Voltage Limits: Two-Sensor System.... .......................................................................131

Replacing the Auto Header Height Control (AHHC) Sensor (One-Sensor System)....................... 133

Replacing Float Indicator Cable ............................................................................................... 135

3.8.3 Case IH 5088/6088/7088 Combines ......................................................................................... 139

Calibrating the Auto Header Height Control (Case IH 5088/6088/7088) ...................................... 139

Setting the Sensitivity of the Auto Header Height (Case IH 5088/6088/7088)...............................140

3.8.4 Case IH 5130/6130/7130 and 5140/6140/7140 Mid-Range Combines......................................... 142

Setting up the Header on the Combine Display (Case IH 5130/6130/7130;

5140/6140/7140)........................................................................................................142

Checking Voltage Range from Combine Cab (Case IH 5130/6130/7130;

5140/6140/7140)........................................................................................................144

Calibrating Auto Header Height Control (Case IH 5130/6130/7130, 5140/6140/7140) .................. 146

Setting Preset Cutting Height (Case 5130/6130/7130, 5140/6140/7140) ..................................... 147

3.8.5 Case IH 7010/8010, 7120/8120/9120, 7230/8230/9230 and 7240/8240/9240 Combines .............. 150

Checking Voltage Range from the Combine Cab (Case 8010)....................................................150

Setting Header Controls (Case 8010).......................................................................................153

Checking Voltage Range from the Combine Cab (Case IH 7010/8010, 7120/8120/9120,

7230/8230/9230, 7240/8240/9240).............................................................................. 153

Calibrating the Auto Header Height Control (Case IH 7010/8010, 7120/8120/9120,

7230/8230/9230, 7240/8240/9240).............................................................................. 156

Calibrating the Auto Header Height Control (Case Combines with Version 28.00 or Higher

Software)................................................................................................................... 160

Checking Reel Height Sensor Voltages (Case IH) .....................................................................164

Setting Preset Cutting Height (Case 7010/8010, 7120/8120/9120, 7230/8230/9230,

7240/8240/9240)........................................................................................................165

3.8.6 Challenger and Massey Ferguson 6 and 7 Series Combines ......................................................166

Checking Voltage Range from the Combine Cab (Challenger and Massey Ferguson) .................. 166

Engaging the Auto Header Height Control (Challenger and Massey Ferguson) ........................... 168

Calibrating the Auto Header Height Control (Challenger and Massey Ferguson).......................... 169

Adjusting the Header Height (Challenger and Massey Ferguson) ............................................... 171

Adjusting the Header Raise/Lower Rate (Challenger and Massey Ferguson) .............................. 171

Setting the Sensitivity of the Auto Header Height Control (Challenger and Massey

Ferguson).................................................................................................................. 172

3.8.7 Gleaner R65/R66/R75/R76 and S Series Combines .. ................................................................ 173

Checking Voltage Range from the Combine Cab (Gleaner R65/R66/R75/R76 and Pre-2016

S Series) ................................................................................................................... 173

Engaging the Auto Header Height Control (Gleaner R65/R66/R75/R76 and Pre-2016

S Series) ................................................................................................................... 175

214683 xiii Revision A

TABLE OF CONTENTS

Calibrating the Auto Header Height Control (Gleaner R65/R66/R75/R76 and Pre-2016

S Series) ................................................................................................................... 177

Turning off the Accumulator (Gleaner R65/R66/R75/R76 and Pre-2016 S Series) ....................... 178

Adjusting the Header Raise/Lower Rate (Gleaner R65/R66/R75/R76 and Pre-2016

S Series) ................................................................................................................... 179

Adjusting Ground Pressure (Gleaner R65/R66/R75/R76 and Pre-2016 S Series) .. ...................... 179

Adjusting the Sensitivity of the Auto Header Height Control (AHHC) (Gleaner

R65/R66/R75/R76 and Pre-2016 S Series) ..................................................................180

Troubleshooting Alarms and Diagnostic Faults (Gleaner R65/R66/R75/R76 and Pre-2016

S Series) ................................................................................................................... 181

3.8.8 Gleaner S9 Series Combines ................................................................................................... 183

Setting up the Header (Gleaner S9 Series) ...............................................................................183

Setting up Reel Settings (Gleaner S9 Series)............................................................................ 188

Setting up Automatic Header Controls (Gleaner S9 Series).. ...................................................... 189

Calibrating the Header (Gleaner S9 Series) ..............................................................................192

Operating Header (Gleaner S9 Series).....................................................................................195

Header In-Field Settings .........................................................................................................196

3.8.9 John Deere 60 Series Combines .............................................................................................. 197

Checking Voltage Range from the Combine Cab (John Deere 60 Series)....................................197

Calibrating the Auto Header Height Control (John Deere 60 Series) ...........................................200

Turning the Accumulator Off (John Deere 60 Series) .................................................................201

Setting the Sensing Grain Header Height to 50 (John Deere 60 Series) ......................................202

Setting the Sensitivity of the Auto Header Height Control (John Deere 60 Series) ........................ 203

Adjusting the Threshold for the Drop Rate Valve (John Deere 60 Series) .................................... 204

3.8.10 John Deere 70 Series Combines ............................................................................................ 205

Checking Voltage Range from the Combine Cab (John Deere 70 Series)....................................205

Calibrating Feeder House Speed (John Deere 70 Series) ..........................................................208

Calibrating the Auto Header Height Control (John Deere 70 Series) ...........................................208

Setting the Sensitivity of the Auto Header Height Control (John Deere 70 Series) ........................ 210

Adjusting the Manual Header Raise/Lower Rate (John Deere 70 Series) .................................... 211

3.8.11 John Deere S and T Series Combines.....................................................................................212

Checking Voltage Range from the Combine Cab (John Deere S and T Series)............................212

Calibrating the Auto Header Height Control (John Deere S and T Series).................................... 215

Setting the Sensitivity of the Auto Header Height Control (John Deere S and T Series) ................ 218

Adjusting the Manual Header Raise/Lower Rate (John Deere S and T Series)............................. 219

Setting Preset Cutting Height (John Deere S and T Series)........................................................ 220

Calibrating Feeder House Fore-Aft Tilt Range (John Deere S and T Series) ................................ 222

Checking Reel Height Sensor Voltages (John Deere S and T Series) .........................................225

Calibrating Reel Height Sensor (John Deere S and T Series) .....................................................227

3.8.12 John Deere S7 Series Combines............................................................................................ 230

Setting up Header (John Deere S7 Series) ...............................................................................230

Checking Voltage Range from the Combine Cab (John Deere S7 Series) ................................... 234

Calibrating Feeder House (John Deere S7 Series) ....................................................................236

Calibrating Header (John Deere S7 Series) .............................................................................. 239

3.8.13 CLAAS 500 Series Combines.................................................................................................242

Calibrating the Auto Header Height Control (CLAAS 500 Series)................................................242

Setting Cutting Height (CLAAS 500 Series) .............................................................................. 244

Setting the Sensitivity of the Auto Header Height Control (CLAAS 500 Series) ............................246

Adjusting Auto Reel Speed (CLAAS 500 Series) .......................................................................248

3.8.14 CLAAS 600 and 700 Series Combines.. .................................................................................. 251

Calibrating the Auto Header Height Control (CLAAS 600 and 700 Series)...................................251

Setting Cutting Height (CLAAS 600 and 700 Series).................................................................. 254

214683 xiv Revision A

TABLE OF CONTENTS

Setting the Sensitivity of the Auto Header Height Control (CLAAS 600 and 700 Series)................ 255

Adjusting Auto Reel Speed (CLAAS 600 and 700 Series) . .........................................................256

Calibrating Reel Height Sensor (CLAAS 600 and 700 Series) .................................................... 258

Adjusting Auto Reel Height (CLAAS 600 and 700 Series) ..........................................................260

3.8.15 New Holland Combines (CR/CX Series—Pre-2015 Model Year) ............................................... 261

Checking Voltage Range from the Combine Cab (New Holland).................................................261

Setting up Auto Header Height Control (New Holland CR/CX Series) . ........................................264

Calibrating the Auto Header Height Control (New Holland CR/CX Series) ...................................265

Adjusting Header Raise Rate (New Holland CR/CX Series) .......................................................268

Setting the Header Lower Rate (New Holland CR/CX Series).....................................................268

Setting the Sensitivity of the Auto Header Height Control (New Holland CR/CX Series)................269

Setting Preset Cutting Height (New Holland CR/CX Series) .......................................................270

3.8.16 New Holland Combines (CR Series—Model Year 2015 and Later) ............................................271

Checking Voltage Range from the Combine Cab (New Holland CR Series) ................................. 271

Setting up Auto Header Height Control (New Holland CR Series) ...............................................274

Calibrating the Auto Header Height Control (New Holland CR Series).........................................277

Checking Reel Height Sensor Voltages (New Holland) .............................................................. 280

Setting Preset Cutting Height (New Holland CR Series – 2015 and Later) ................................... 281

Setting Maximum Work Height (New Holland CR Series) ........................................................... 283

Configuring Reel Fore-Aft, Header Tilt, and Header Type (New Holland CR Series) .....................284

3.9 Leveling the Header ......................................................................................................................... 286

3.10 Unplugging the Cutterbar................................................................................................................ 288

3.11 Unplugging the Float Module...........................................................................................................289

3.12 Transporting the Header . ...............................................................................................................290

3.12.1 Transporting Header on Combine ...........................................................................................290

3.12.2 Towing..................................................................................................................................290

Attaching Header to Towing Vehicle ......................................................................................... 291

Towing the Header..................................................................................................................291

3.12.3 Converting from Transport to Field Position .............................................................................292

Removing Tow-Bar ................................................................................................................. 292

Storing the Tow-Bar ................................................................................................................293

Moving Front (Left) Wheels into Field Position .......................................................................... 295

Moving Rear (Right) Wheels into Field Position.........................................................................296

3.12.4 Converting from Field to Transport Position .............................................................................298

Moving Front (Left) Wheels into Transport Position ...................................................................298

Moving Rear (Right) Wheels into Transport Position ..................................................................300

Attaching Tow-Bar ..................................................................................................................303

3.13 Storing the Header ......................................................................................................................... 306

Chapter 4: Header Attachment/Detachment................................................................................ 307

4.1 Float Module Feed Auger Configurations ........................................................................................... 307

4.1.1 Converting from Ultra Narrow Configuration or Narrow Configuration to Medium

Configuration....................................................................................................................310

4.1.2 Converting from Wide Configuration to Medium Configuration .................................................... 313

4.1.3 Converting from Medium Configuration or Wide Configuration to Narrow Configuration ................315

4.1.4 Converting from Ultra Narrow Configuration to Narrow Configuration ..........................................317

4.1.5 Converting from Medium Configuration to Wide Configuration .................................................... 318

4.1.6 Converting from Ultra Narrow or Narrow Configuration to Wide Configuration .............................. 320

214683 xv Revision A

TABLE OF CONTENTS

4.1.7 Optional Modification to Wide Configuration ..............................................................................322

4.1.8 Converting from Medium Configuration or Wide Configuration to Ultra Narrow

Configuration....................................................................................................................323

4.1.9 Converting from Narrow Configuration to Ultra Narrow Configuration ..........................................327

4.2 Float Module Setup .......................................................................................................................... 331

4.2.1 Using Auger Flighting ..............................................................................................................331

4.2.2 Using Stripper Bars .................................................................................................................331

4.3 Case IH Combines ...........................................................................................................................332

4.3.1 Attaching Header to Case IH Combine......................................................................................332

4.3.2 Detaching Header from Case IH Combine.................................................................................337

4.4 AGCO (Challenger, Gleaner, and Massey Ferguson) Combines ..........................................................340

4.4.1 Attaching Header to a Challenger, Gleaner, or Massey Ferguson Combine.................................. 340

4.4.2 Detaching Header from a Challenger, Gleaner, or Massey Ferguson Combine............................. 345

4.5 John Deere Combines ......................................................................................................................348

4.5.1 Attaching Header to John Deere Combine ................................................................................ 348

4.5.2 Detaching Header from John Deere Combine ...........................................................................352

4.6 CLAAS Combines ............................................................................................................................355

4.6.1 Attaching Header to CLAAS Combine....................................................................................... 355

4.6.2 Detaching Header from CLAAS Combine.................................................................................. 360

4.7 New Holland Combines ....................................................................................................................363

4.7.1 Attaching Header to New Holland CR/CX Combine....................................................................363

4.7.2 Detaching Header from New Holland CR/CX Combine...............................................................367

4.7.3 CR Feeder Deflectors..............................................................................................................371

4.8 Attaching and Detaching Header from Float Module ........................................................................... 372

4.8.1 Detaching Header from Float Module........................................................................................ 372

4.8.2 Attaching Header to Float Module.............................................................................................377

Chapter 5: Maintenance and Servicing .........................................................................................383

5.1 Preparing Machine for Servicing........................................................................................................ 383

5.2 Maintenance Specifications ..............................................................................................................384

5.2.1 Installing a Sealed Bearing.......................................................................................................384

5.3 Maintenance Requirements .............................................................................................................. 385

5.3.1 Maintenance Schedule/Record ................................................................................................ 385

5.3.2 Break-In Inspection ................................................................................................................. 388

5.3.3 Preseason Servicing ............................................................................................................... 388

5.3.4 End-of-Season Service............................................................................................................389

5.3.5 Checking Hydraulic Hoses and Lines........................................................................................390

5.3.6 Lubrication and Servicing.........................................................................................................390

Service Intervals.....................................................................................................................390

Greasing Procedure................................................................................................................ 399

Lubricating Reel Drive Chain ...................................................................................................400

Lubricating Auger Drive Chain .................................................................................................402

Lubricating Header Drive Gearbox ........................................................................................... 404

214683 xvi Revision A

TABLE OF CONTENTS

5.4 Hydraulics ....................................................................................................................................... 407

5.4.1 Checking Oil Level in Hydraulic Reservoir .................................................................................407

5.4.2 Adding Oil to Hydraulic Reservoir .............................................................................................408

5.4.3 Changing Oil in Hydraulic Reservoir .........................................................................................409

5.4.4 Changing Oil Filter ..................................................................................................................410

5.5 Electrical System ............................................................................................................................. 411

5.5.1 Replacing Light Bulbs.............................................................................................................. 411

5.6 Header Drive ...................................................................................................................................412

5.6.1 Removing Driveline .................................................................................................................412

5.6.2 Installing Driveline ...................................................................................................................413

5.6.3 Removing Driveline Guard ....................................................................................................... 414

5.6.4 Installing Driveline Guard.........................................................................................................416

5.6.5 Adjusting Gearbox Drive Chain Tension ....................................................................................418

5.7 Auger..............................................................................................................................................419

5.7.1 Adjusting Auger to Pan Clearance ............................................................................................419

5.7.2 Checking Auger Drive Chain Tension........................................................................................421

5.7.3 Adjusting Auger Drive Chain Tension ........................................................................................423

5.7.4 Removing Auger Drive Chain ................................................................................................... 424

5.7.5 Installing Auger Drive Chain..................................................................................................... 426

5.7.6 Using Auger Flighting ..............................................................................................................428

5.7.7 Auger Fingers ......................................................................................................................... 428

Removing Feed Auger Fingers ................................................................................................429

Installing Feed Auger Fingers ..................................................................................................431

Checking Auger Finger Timing.................................................................................................434

Adjusting Auger Finger Timing.................................................................................................435

5.8 Knife ............................................................................................................................................... 437

5.8.1 Replacing Knife Section ...........................................................................................................437

5.8.2 Removing Knife ...................................................................................................................... 438

5.8.3 Removing Knifehead Bearing...................................................................................................439

5.8.4 Installing Knifehead Bearing.....................................................................................................440

5.8.5 Installing Knife ........................................................................................................................ 440

5.8.6 Spare Knife.............................................................................................................................441

5.8.7 Knife Guards...........................................................................................................................441

Adjusting Knife Guards ...........................................................................................................441

Replacing Pointed Guards.......................................................................................................443

Replacing Stub Guards ...........................................................................................................446

Checking Pointed Guard Hold-Downs ...................................................................................... 447

Adjusting Hold-Downs with Pointed Guards..............................................................................448

Adjusting Hold-Down at Double-Knife Center Pointed Guard .....................................................449

Checking and Adjusting Stub Guard Hold-Downs......................................................................450

Adjusting Hold-Downs with Stub Guards .................................................................................. 451

5.8.8 Knifehead Shield.....................................................................................................................452

Installing Knifehead Shield ......................................................................................................453

5.9 Knife Drive System...........................................................................................................................454

5.9.1 Knife Drive Box .......................................................................................................................454

214683 xvii Revision A

TABLE OF CONTENTS

Checking Knife Drive Box........................................................................................................454

Checking Mounting Bolts.........................................................................................................455

Removing Knife Drive Box.......................................................................................................456

Removing Knife Drive Box Pulley.............................................................................................458

Installing Knife Drive Box Pulley.. .............................................................................................458

Installing Knife Drive Box ........................................................................................................459

Changing Oil in Knife Drive Box .... ........................................................................................... 461

5.9.2 Knife Drive Belts .....................................................................................................................462

Knife Drive Belts.....................................................................................................................462

5.10 Feed Draper ..................................................................................................................................466

5.10.1 Replacing Feed Draper..........................................................................................................466

5.10.2 Adjusting Feed Draper Tension...............................................................................................468

5.10.3 Feed Draper Drive Roller ....................................................................................................... 469

Removing Feed Draper Drive Roller......................................................................................... 469

Installing Feed Draper Drive Roller .......................................................................................... 472

Replacing Feed Draper Drive Roller Bearing ............................................................................ 473

5.10.4 Feed Draper Idler Roller.........................................................................................................475

Removing Feed Draper Idler Roller ..........................................................................................475

Installing Feed Draper Idler Roller............................................................................................476

Replacing Feed Draper Idler Roller Bearing.............................................................................. 477

5.11 Lowering Float Module Feed Deck Pan ............................................................................................479

5.12 Raising Float Module Feed Deck Pan .............................................................................................. 481

5.13 Float Module Stripper Bars and Feed Deflectors...............................................................................482

5.13.1 Removing Stripper Bars.........................................................................................................482

5.13.2 Installing Stripper Bars........................................................................................................... 483

5.13.3 Replacing Feed Deflectors on New Holland CR Combines .......................................................483

5.14 Header Drapers .............................................................................................................................485

5.14.1 Removing Side Drapers.........................................................................................................485

5.14.2 Installing Side Drapers ...........................................................................................................486

5.14.3 Adjusting Draper Tension ....................................................................................................... 488

5.14.4 Adjusting Header Draper Tracking ..........................................................................................490

5.14.5 Adjusting Deck Height ........................................................................................................... 492

5.14.6 Header Draper Roller Maintenance.........................................................................................494

Inspecting Draper Roller Bearing .. ........................................................................................... 494

Draper Deck Idler Roller..........................................................................................................494

Draper Deck Drive Roller ........................................................................................................ 497

5.15 Reel ..............................................................................................................................................502

5.15.1 Reel Clearance to Cutterbar...................................................................................................502

Measuring Reel Clearance ...................................................................................................... 502

Adjusting Reel Clearance........................................................................................................ 505

5.15.2 Reel Frown ...........................................................................................................................506

Adjusting Reel Frown..............................................................................................................506

5.15.3 Centering Double Reel...........................................................................................................507

5.15.4 Reel Fingers .........................................................................................................................507

Removing Steel Fingers..........................................................................................................507

Installing Steel Fingers............................................................................................................508

Removing Plastic Fingers.

.......................................................................................................509

214683 xviii Revision A

TABLE OF CONTENTS

Installing Plastic Fingers .........................................................................................................510

5.15.5 Tine Tube Bushings............................................................................................................... 511

Removing Bushings from Five-, Six-, or Nine-Bat Reels............................................................. 511

Installing Bushings on Five-, Six-, or Nine-Bat Reels .................................................................516

5.15.6 Reel Endshields ....................................................................................................................523

Replacing Reel Endshields......................................................................................................523

Replacing Reel Endshield Supports .........................................................................................525

5.16 Reel System .................................................................................................................................. 526

5.16.1 Reel Drive Cover...................................................................................................................526

Removing Reel Drive Cover .................................................................................................... 526

Installing Reel Drive Cover ...................................................................................................... 527

5.16.2 Reel Drive Chain Tension....................................................................................................... 528

Loosening Reel Drive Chain ....................................................................................................528

Tightening Reel Drive Chain ....................................................................................................528

5.16.3 Reel Drive Sprocket............................................................................................................... 530

Removing Reel Drive Sprocket ................................................................................................530

Installing Reel Drive Sprocket..................................................................................................531

5.16.4 Double-Reel U-Joint .............................................................................................................. 532

Removing Double-Reel U-Joint . .............................................................................................. 532

Installing Double-Reel U-Joint .................................................................................................533

5.16.5 Reel Drive Motor ................................................................................................................... 534

Removing Reel Drive Motor.. ...................................................................................................534

Installing Reel Drive Motor ..... .................................................................................................534

5.16.6 Replacing Drive Chain on Double Reel ..... ..............................................................................535

5.16.7 Replacing Drive Chain on Single Reel.....................................................................................537

5.16.8 Replacing Reel Speed Sensor................................................................................................538

Replacing AGCO (Challenger, Gleaner, and Massey Ferguson) Sensor ..................................... 538

Replacing John Deere Reel Speed Sensor...............................................................................540

Replacing CLAAS 400 Series Reel Speed Sensor ....................................................................540

Replacing CLAAS 500/700 Series Reel Speed Sensor .............................................................. 541

5.17 Transport System (Optional) ........................................................................................................... 542

5.17.1 Checking Wheel Bolt Torque .................................................................................................. 542

5.17.2 Checking Axle Bolt Torque .....................................................................................................543

5.17.3 Checking Tire Pressure.......................................................................................................... 544

Chapter 6: Options and Attachments............................................................................................545

6.1 Float Module.................................................................................................................................... 545

6.1.1 Hillside Extension Kit ............................................................................................................... 545

6.2 Reel................................................................................................................................................ 546

6.2.1 Multi-Crop Rapid Reel Conversion Kit ....................................................................................... 546

6.2.2 Reel Arm Extension Kit (European-configured Headers Only).....................................................546

6.2.3 Lodged Crop Reel Finger Kit .................................................................................................... 547

6.2.4 PR15 Tine Tube Reel Conversion Kit ........................................................................................547

6.2.5 Reel Endshield Kit................................................................................................................... 547

6.2.6 Tine Tube Reinforcing Kit.........................................................................................................548

6.3 Cutterbar.........................................................................................................................................549

214683 xix Revision A

TABLE OF CONTENTS

6.3.1 Cutterbar Wearplate ................................................................................................................ 549

6.3.2 Knifehead Shield.....................................................................................................................549

6.3.3 Extended Center Filler ............................................................................................................. 550

6.3.4 Rock Retarder.........................................................................................................................550

6.3.5 Stub Guard Conversion Kit.......................................................................................................550

6.3.6 FD1 Series Vertical Knife Mounts and Double Vertical Knife Hose Kits ........................................551

6.3.7 Vertical Knife Plumbing Kits .....................................................................................................551

6.3.8 Roto-Shear Completion Package ............................................................................................. 551

6.4 Header............................................................................................................................................ 552

6.4.1 Divider Latch Kit.. ....................................................................................................................552

6.4.2 Stabilizer Wheels ....................................................................................................................552

6.4.3 Secondary Stabilizer Wheel .....................................................................................................553

6.4.4 Stabilizer Wheels and Slow Speed Transport Package...............................................................553

6.4.5 Backsheet Extension Kit ..........................................................................................................554

6.4.6 Center Skid Shoes Kit..............................................................................................................554

6.5 Crop Delivery................................................................................................................................... 555

6.5.1 FM100 Dual Auto Header Height Control (AHHC) Sensor Kit......................................................555

6.5.2 FM100 Feed Auger Flighting .................................................................................................... 555

6.5.3 In-Cab Draper Speed Control (ICDSC) Kit................................................................................. 556

6.5.4 Draper Deflector (Narrow)........................................................................................................556

6.5.5 Draper Deflector (Wide) ........................................................................................................... 557

6.5.6 Stripper Bars...........................................................................................................................557

6.5.7 Auger Dent Repair Kit..............................................................................................................558

6.5.8 Upper Cross Auger (UCA) ....................................................................................................... 558

6.5.9 European Combine Upper Cross Auger (UCA) ..........................................................................559

6.5.10 Rice Divider Rods..................................................................................................................559

Chapter 7: Troubleshooting.............................................................................................................561

7.1 Crop Loss at Cutterbar .....................................................................................................................561

7.2 Cutting Action and Knife Components ............................................................................................... 564

7.3 Reel Delivery ...................................................................................................................................567

7.4 Header and Drapers.........................................................................................................................570

7.5 Cutting Edible Beans........................................................................................................................ 572

Chapter 8: Reference .........................................................................................................................577

8.1 Torque Specifications .......................................................................................................................577

8.1.1 Metric Bolt Specifications......................................................................................................... 577

8.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ................................................................ 579

8.1.3 Flare-Type Hydraulic Fittings... .................................................................................................580

8.1.4 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) .................................................................... 581

8.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable).............................................................583

8.1.6 O-Ring Face Seal (ORFS) Hydraulic Fittings .............................................................................584

8.1.7 Tapered Pipe Thread Fittings ...................................................................................................585

214683 xx Revision A

TABLE OF CONTENTS

8.2 Conversion Chart.............................................................................................................................586

8.3 Unloading and Assembly .................................................................................................................. 587

Index.......................................................................................................................................................589

Recommended Fluids and Lubricants ............................................................. Inside Back Cover

214683 xxi Revision A

1 Safety

1000915

1.1 Safety Alert Symbols

This safety alert symbol indicates important safety
messages in this manual and on safety signs on
the machine.

This symbol means:

• ATTENTION!

• BECOME ALERT!

• YOUR SAFETY IS INVOLVED!

Carefully read and follow the safety message
accompanying this symbol.

Why is safety important to you?

• Accidents disable and kill

• Accidents cost

• Accidents can be avoided

Figure 1.1: Safety Symbol

214683 1 Revision A

SAFETY

1.2 Signal Words

Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Signal
words are selected using the following guidelines:

DANGER

Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It
may also be used to alert against unsafe practices.

CAUTION

Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It
may be used to alert against unsafe practices.

214683 2 Revision A

1000004

1000005

1010391

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 protective clothing and personal safety devices
that could be necessary for job at hand. Do NOT take
chances. You may need the following:

• Hard hat

• Protective footwear with slip-resistant soles

• Protective glasses or goggles

• Heavy gloves

• Wet weather gear

• Respirator or filter mask

• Be aware that exposure to loud noises can cause hearing

impairment or loss. Wear suitable hearing protection
devices such as earmuffs or earplugs to help protect
against loud noises.

Figure 1.2: Safety Equipment

Figure 1.3: Safety Equipment

• Provide a first aid kit for use in case of emergencies.

• Keep a fire extinguisher on the machine. Be sure fire

extinguisher is properly maintained. Be familiar with its
proper use.

• Keep young children away from machinery at all times.

• Be aware that accidents often happen when Operator is

tired or in a hurry. Take time to consider safest way.
Never ignore warning signs of fatigue.

Figure 1.4: Safety Equipment

214683 3 Revision A

1000007

1000008

1000009

SAFETY

• Wear close-fitting clothing and cover long hair. Never
wear dangling items such as scarves or bracelets.

• Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate
independently of shaft and can telescope freely.

• Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.

• Keep hands, feet, clothing, and hair away from moving
parts. NEVER attempt to clear obstructions or objects
from a machine while engine is running.

• Do NOT modify machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten machine’s life.

Figure 1.5: Safety around Equipment

• To avoid bodily injury or death from unexpected startup of
machine, ALWAYS stop the engine and remove the key
from the ignition before leaving the operator’s seat for
any reason.

• Keep service area 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 is

a fire hazard. Do NOTallow oil or grease to accumulate
on service platforms, ladders, or controls. Clean
machines before storage.

• NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.

• When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.

Figure 1.6: Safety around Equipment

Figure 1.7: Safety around Equipment

214683 4 Revision A

1000009

1008958

1000004

SAFETY

1.4 Maintenance Safety

To ensure your safety while maintaining machine:

• Review operator’s manual and all safety items before
operation and/or maintenance of 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 outlets and tools are properly

grounded

– Keep work area well lit

• Relieve pressure from hydraulic circuits before servicing

and/or disconnecting machine.

• Make sure all components are tight and that steel lines,

hoses, and couplings are in good condition before
applying pressure to hydraulic systems.

Figure 1.8: Safety around Equipment

• Keep hands, feet, clothing, and hair away from all

moving and/or rotating parts.

• Clear area of bystanders, especially children, when

carrying out any maintenance, repairs, or adjustments.

• Install transport lock or place safety stands under frame

before working under machine.

• If more than one person is servicing machine at same

time, be aware that rotating a driveline or other
mechanically-driven component by hand (for example,
accessing a lubricant fitting) will cause drive components
in other areas (belts, pulleys, and knives) to move. Stay
clear of driven components at all times.

• Wear protective gear when working on machine.

• Wear heavy gloves when working on knife components.

Figure 1.9: Equipment NOT Safe for Children

Figure 1.10: Safety Equipment

214683 5 Revision A

1001205

1001207

1000013

SAFETY

1.5 Hydraulic Safety

• Always place all hydraulic controls in Neutral before
dismounting.

• Make sure that all components in hydraulic system are
kept clean and in good condition.

• Replace any worn, cut, abraded, flattened, or crimped
hoses and steel lines.

• Do NOT attempt any makeshift repairs to hydraulic lines,
fittings, or hoses by using tapes, clamps, cements, or
welding. The hydraulic system operates under extremely
high-pressure. Makeshift repairs will fail suddenly and
create hazardous and unsafe conditions.

• Wear proper hand and eye protection when searching for
high-pressure hydraulic leaks. Use a piece of cardboard
as a backstop instead of hands to isolate and identify
a leak.

Figure 1.11: Testing for Hydraulic Leaks

• If injured by a concentrated high-pressure stream of
hydraulic fluid, seek medical attention immediately.
Serious infection or toxic reaction can develop from
hydraulic fluid piercing the skin.

• Make sure all components are tight and steel lines,
hoses, and couplings are in good condition before
applying pressure to a hydraulic system.

Figure 1.12: Hydraulic Pressure Hazard

Figure 1.13: Safety around Equipment

214683 6 Revision A

1000694

SAFETY

1.6 Safety Signs

• Keep safety signs clean and legible at all times.

• Replace safety signs that are missing or illegible.

• If original part on which a safety sign was installed is

replaced, be sure repair part also bears current
safety sign.

• Replacement safety signs are available from your
MacDon Dealer Parts Department.

1.6.1 Installing Safety Decals

1. Clean and dry installation area.

Figure 1.14: Operator’s Manual Decal

2. Decide on exact location before you remove decal backing paper.

3. Remove smaller portion of split backing paper.

4. Place decal in position and slowly peel back remaining paper, smoothing decal as it is applied.

5. Prick small air pockets with a pin and smooth out.

214683 7 Revision A

1.7 Safety Decal Locations

1003348

A

A

A

1003341

A

A

Figure 1.15: Upper Cross Auger

SAFETY

A - MD #174682

Figure 1.16: Slow Speed Transport

A - MD #220799

214683 8 Revision A

Figure 1.17: Slow Speed Transport Tow-Bar

1003338

A

B

A

B

1003382

A

A

SAFETY

A - MD #220797 B - MD #220798

Figure 1.18: Vertical Knife

A - MD #174684

214683 9 Revision A

Figure 1.19: Endsheets, Reel Arms, and Backsheet

1020695

B

A

A

C

F

F

C

E

D

E

C

A

B

E

B

C

F

D

F

SAFETY

A - MD #174632 B - MD #131393 C - MD #184422
D - MD #131392 (Double Reel Only) E - MD #131391 (Two Places) F - MD #166466 (Three Places)

214683 10 Revision A

Figure 1.20: Backtube

1003403

A

B

C

D

E

1009678

A

BCD

C

A

E

SAFETY

A - MD #184372 B - MD #166466 C - MD #131391
D - MD #131392 E - MD #184372 (Split Frame)

214683 11 Revision A

Figure 1.21: FM100 Float Module

1026294

A

B

A

B

SAFETY

A - MD #252996 B - MD #184372

214683 12 Revision A

1000917

1003356

SAFETY

1.8 Understanding Safety Signs

MD #113482

General hazard pertaining to machine operation and
servicing

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 with all Operators every year.

Figure 1.22: MD #113482

• Ensure that all safety signs are installed and legible.

• Make certain everyone is clear of machine before starting engine and during operation.

• Keep riders off the machine.

• Keep all shields in place and stay clear of moving parts.

• Disengage header drive, put transmission in Neutral, and wait for all movement to stop before leaving
operator’s position.

• Stop the engine and remove the key before servicing, adjusting, lubricating, cleaning, or unplugging machine.

• Engage safety props to prevent lowering of header or reel before servicing in the raised position.

• Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited

by law.

MD #131391

Crushing hazard

DANGER

• Rest header on ground or engage safety props before
going under unit.

Figure 1.23: MD #131391

214683 13 Revision A

1003404

1001649

1000706

SAFETY

MD #131392

Crushing hazard

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.

MD #131393

Reel hazard

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.

Figure 1.24: MD #131392

MD #166466

High-pressure oil hazard

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 1.25: MD #131393

Figure 1.26: MD #166466

214683 14 Revision A

1000920

1003402

SAFETY

MD #174436

High-pressure oil hazard

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.

MD #174632

Reel entanglement hazard

CAUTION

• To avoid injury from entanglement with rotating reel,
stand clear of header while machine is running.

Figure 1.27: MD #174436

Figure 1.28: MD #174632

MD #184372

General hazard pertaining to machine operation and
servicing

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 with all Operators annually.

Figure 1.29: MD #184372

• Ensure that all safety signs are installed and legible.

• Make certain everyone is clear of machine before starting engine and during operation.

• Keep riders off the machine.

• Keep all shields in place and stay clear of moving parts.

214683 15 Revision A

1000923

1003333

SAFETY

• Disengage header drive, put transmission in Neutral, and wait for all movement to stop before leaving
operator’s position.

• Stop the engine and remove the key from the ignition before servicing, adjusting, lubricating, cleaning, or
unplugging machine.

• Engage safety props to prevent lowering of raised unit before servicing in the raised position.

• Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited

by law.

MD #184422

Chain drive hand and arm entanglement hazard

WARNING

• Do NOT open or remove safety shields while engine is
running.

• To avoid injury, stop the engine and remove the key
before opening shield.

MD #220797

Tipping hazard in transport mode

WARNING

• Read the operator’s manual for more information on
potential tipping or rollover of header while transporting.

Figure 1.30: MD #184422

Figure 1.31: MD #220797

214683 16 Revision A

1003337

1003331

1026259

SAFETY

MD #220798

Loss of control hazard in transport

CAUTION

• Do not tow the header with a dented or otherwise
damaged tow pole (the circle with the red X shows a dent
in the pole).

• Consult the operator’s manual for more information.

MD #220799

Transport/roading hazard

WARNING

• Ensure tow-bar lock mechanism is locked.

Figure 1.32: MD #220798

MD #252996

Hot oil spray hazard

WARNING

• Hydraulic oil is under pressure and may be hot.

• Never remove fill cap when machine is hot. Always allow

machine to cool down before removing fill cap.

Figure 1.33: MD #220799

Figure 1.34: MD #252996

214683 17 Revision A

1019658

SAFETY

MD #279085

Auger entanglement hazard

WARNING

• To avoid injury from rotating auger, stand clear of auger
while machine is running.

Figure 1.35: MD #279085

214683 18 Revision A

2 Product Overview

2.1 Definitions

The following terms and acronyms may be used in this manual:

Term

AHHC Automatic Header Height Control

API American Petroleum Institute

ASTM American Society of Testing and Materials

Bolt

Center-link

CGVW Combined gross vehicle weight

D1 Series header

DDD Double-draper drive

DK

DKD

DR Double reel

FD1 Series header

FFFT

Finger tight

Definition

A headed and externally threaded fastener that is designed to be paired with a nut

A hydraulic cylinder link between header and machine used to change header angle

MacDon D120, D125, D130, D135, D140, and D145 combine draper header from
D1 model number series

Double knife

Double-knife drive

MacDon FD130, FD135, FD140, or FD145 combine FlexDraper
FD1 Series model number series

Flats from finger tight

Finger tight is a reference position where sealing surfaces or components are
making contact with each other, and fitting has been tightened to a point where
fitting is no longer loose

®

header from the

GVW Gross vehicle weight

Hard joint

Header

Hex key

HDS Hydraulic deck shift

hp Horsepower

JIC

Knife A cutting device which uses a reciprocating cutter (also called a sickle)

MDS Mechanical deck shift

n/a

214683 19 Revision A

A joint made with use of a fastener where joining materials are highly
incompressible

A machine that cuts crop and feeds it into an attached combine

A tool of hexagonal cross-section used to drive bolts and screws that have a
hexagonal socket in head (internal-wrenching hexagon drive); also known as an
Allen key and various other synonyms

Joint Industrial Council: A standards body that developed standard sizing and shape
for original 37° flared fitting

Not applicable

PRODUCT OVERVIEW

Term

NPT

Nut

ORB

ORFS

RoHS (Reduction of
Hazardous Substances)

rpm

Definition

National Pipe Thread: A style of fitting used for low-pressure port openings. Threads
on NPT fittings are uniquely tapered for an interference fit

An internally threaded fastener that is designed to be paired with a bolt

O-ring boss: A style of fitting commonly used in port openings on manifolds, pumps,
and motors

O-ring face seal: A style of fitting commonly used for connecting hoses and tubes.
This style of fitting is also commonly called ORS, which stands for O-ring seal

A directive by the European Union to restrict use of certain hazardous substances
(such as hexavalent chromium used in some yellow zinc platings)

Revolutions per minute

SAE Society of Automotive Engineers

Screw

A headed and externally threaded fastener that threads into preformed threads or
forms its own thread into a mating part

SDD Single-draper drive

Soft joint

spm

A joint made with use of a fastener where joining materials are compressible or
experience relaxation over a period of time

Strokes per minute

Tension

TFFT

Torque

Torque angle

Torque-tension

Truck

UCA

Untimed knife drive

Washer

Axial load placed on a bolt or screw, usually measured in Newtons (N) or
pounds (lb.)

Turns from finger tight

The product of a force X lever arm length, usually measured in Newton-meters (Nm)
or foot-pounds (lbf∙ft)

A tightening procedure where fitting is assembled to a precondition (finger tight) and
then nut is turned farther a number of degrees to achieve its final position

The relationship between assembly torque applied to a piece of hardware and axial
load it induces in bolt or screw

A four-wheel highway/road vehicle weighing no less than 3400 kg (7500 lb.)

Upper cross auger

Unsynchronized motion applied at cutterbar to two separately driven knives from a
single hydraulic motor or two hydraulic motors

A thin cylinder with a hole or slot located in the center that is to be used as a spacer,
load distribution element, or locking mechanism

214683 20 Revision A

PRODUCT OVERVIEW

2.2 Specifications

The following symbol and letters are used in Table 2.1, page 21 and Table 2.2, page 23:

| FD1 | FM100 | Attachments

S: standard / O

: optional (factory installed) / OD: optional (dealer installed) / –: not available

F

Table 2.1 Header Specifications

Cutterbar

Effective cutting width (distance between crop divider points)

9.1 m (30 ft.) header 914.4 cm (360 in.) S

10.7 m (35 ft.) header 10.668 m (420 in.) S

12.2 m (40 ft.) header 12.192 m (480 in.) S

13.7 m (45 ft.) header 13.716 m (540 in.) S

Cutterbar lift range

Varies with combine model

Knife

Single-knife drive (all sizes): hydraulic motor to C-belt to enclosed heavy-duty (MD) knife drive box.

Double knife drive (12.2 and 13.7 m [40 and 45 ft.]): two hydraulic motors to C-belts, untimed, to enclosed
heavy-duty (MD) knife drive boxes.

Knife stroke 76 mm (3 in.) S

Single-knife speed (strokes per minute)

Single-knife speed (strokes per minute)

Single-knife speed (strokes per minute)

1

1

1

9.1 m (30 ft.)

10.7 m (35 ft.)

12.2 m (40 ft.)

1200–1400 spm

1100–1300 spm

1050–1200 spm

S

O

F

O

F

S

S

S

Double-knife speed (strokes per minute)

1

12.2, 13.7 m (40, 45 ft.)

1100–1400 spm

Knife Sections

Over-serrated / solid / bolted / 3.5 serrations per cm (9 serrations per inch) S

Knife overlap at center (double-knife headers) 3 mm (1/8 in.) S

Guards and Hold-Downs

Guard: pointed / forged / double heat treated (DHT)
Hold-down: sheet metal / adjustment bolt

Guard Angle (Cutterbar on Ground)

Center-link retracted

Center-link extended

2.0 degrees

7.4 degrees

Draper (Conveyor) and Decks

Draper width

1.057 m (41-19/32 in.) S

Draper drive Hydraulic

1. Under normal cutting conditions, knife speed taken at the knife drive pulley should be set at 600 rpm
(1200 spm). If set to low end of the speed range, you could experience knife stalling.

S

S

S

S

S

214683 21 Revision A

PRODUCT OVERVIEW

Table 2.1 Header Specifications (continued)

Draper speed: FM100 Float Module controlled

0–193 m/min. (635 fpm) S

PR15 Pick-Up Reel

Quantity of tine tubes

5-, 6-, or 9-tine tubes

Center tube diameter 203 mm (8 in.) S

Finger tip radius Factory-set

Finger tip radius Adjustment range

800 mm (31-1/2 in.) S

766–800 mm

(30-3/16–31-1/2 in.)

Effective reel diameter (via cam profile) 1.650 m (65 in.) S

Finger length

290 mm (11 in.) S

Finger spacing (staggered on alternate bats) 150 mm (6 in.) S

Reel drive Hydraulic

Reel speed (adjustable from cab, varies with combine model)

0–67 rpm

Frame and Structure

Header
width

Header
width

Field mode

Transport position - reel
fore-aft fully retracted
(shortest center-link)

(A) Long dividers installed
(refer to Figure 2.1, page 23)

Cut width +

384 mm (15-1/8 in.)

2.684 m (106 in.)

—

S

S

S

S

Header
width

Transport position - reel
fore-aft fully retracted
(shortest center-link)

(B) Long dividers removed
(refer to Figure 2.1, page 23)

2.500 m (98 in.)

—

214683 22 Revision A

Figure 2.1: Header Dimensions

1025198

A

B

C

PRODUCT OVERVIEW

Table 2.2 Header Attachments

FM100 Float Module

Feed draper Width

Feed draper

Speed

Feed auger Width

Feed auger

Outside diameter 559 mm (22 in.) S

Feed auger Tube diameter

Feed auger

Speed (varies with combine model)

Oil reservoir capacity

Oil type

Driveline overall length

Driveline overall length

2

2

Case, New Holland

Case, New Holland

Maximum
(extended)

Minimum
(compressed)

2.000 m

(78-11/16 in.)

107–122 m/min

(350–400 fpm)

1.660 m

(65-5/16 in.)

356 mm (14 in.) S

190 rpm

75 liters

(20 US gallons)

DURATRAN

™

1.230 m (48-7/16 in.) O

603 mm

(23-3/4 in.)

O

S

S

S

S

S

—

F

F

2. Subtract 265 mm (10-7/16 in.) for length between yoke pins.

214683 23 Revision A

Table 2.2 Header Attachments (continued)

PRODUCT OVERVIEW

Driveline overall length

2

John Deere, CLAAS,
Massey Ferguson

Challenger, Gleaner,

Challenger, Gleaner,

Driveline overall length

2

John Deere, CLAAS,
Massey Ferguson

Driveline overall length

Driveline overall length

2

2

John Deere 9650/9660

John Deere 9650/9660

Upper Cross Auger O

Outside diameter 305 mm (12 in.)

Tube diameter

Stabilizer Wheel / Slow Speed Transport O

Wheels 15 in.

Tires

Maximum
(extended)

Minimum
(compressed)

Maximum
(extended)

Minimum
(compressed)

1.262 m

(49-11/16 in.)

916 mm

(36-1/16 in.)

775 mm (30-1/2 in.) O

880 mm (34-5/8 in.) O

152 mm (6 in.)

P205/75 R-15

O

O

F

F

F

F

D

—

—

D

—

—

Weight

Estimated weight range – base header, no float module – variances are due to different package configurations.

9.1 m (30 ft.) header

10.7 m (35 ft.) header

12.2 m (40 ft.) header

North America frame

12.2 m (40 ft.) header Export frame

13.7 m (45 ft.) header

North America frame

13.7 m (45 ft.) header Export frame

2218–2317 kg (4890–5240 lb.)

2409–2558 kg (5310–5640 lb.)

2644–2708 kg (5830–5970 lb.)

2685–2706 kg (5920–5965 lb.)

2903 kg (6400 lb.)

2892–2912 kg (6375–6420 lb.)

214683 24 Revision A

1017159

A

B

C

D

E

F

G

H

K

L

J

M

PRODUCT OVERVIEW

2.3 Component Identification

2.3.1 FD1 Series FlexDraper

®®

Figure 2.2: FD1 Series FlexDraper®®Components

A - Wing Float Linkage B - Center Reel Arm C - Reel Fore-Aft Cylinder
D - Endshield E - Reel Lift Cylinder F - Knife Drive Box (inside endshield)
G - Side Draper H - Center Reel Drive J - Pick-up Reel
K - Reel Endshield L - Crop Divider M - Header Light (except Europe)

214683 25 Revision A

1012484

A

B

C

D

E

F

F

B

G

H

PRODUCT OVERVIEW

2.3.2 FM100 Float Module

Figure 2.3: Header Side of FM100 Float Module

A - Feed Auger B - Header Float Springs C - Center-Link
D - Hydraulic Reservoir E - Gearbox F - Header Support Arms
G - Feed Draper H - Hydraulic Filter

214683 26 Revision A

1016972

A

B

C

D

E

F

G

H

H

J

G

PRODUCT OVERVIEW

Figure 2.4: Combine Side of FM100 Float Module

A - Float Module Gearbox B - Hydraulic Compartment Cover C - Reservoir Oil Level Sight Glass
D - Center-Link E - Header Height Control Indicator F - Torque Wrench
G - Drain Tube (x2) H - Float Lock Handle (x2) J - Auto Header Height Control (AHHC) Sensor

214683 27 Revision A

3 Operation

3.1 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.

• Before allowing anyone to operate the header, for however short a time or distance, make sure they

have been instructed in its safe and proper use.

• Review the manual and all safety related items with all Operators annually.

• Be alert for other Operators not using recommended procedures or not following safety precautions.

Correct these mistakes immediately, before an accident occurs.

• Do NOT modify the machine. Unauthorized modifications may impair the function and/or safety of the

machine and may reduce the length of service you receive from your machine.

• The safety information given in this manual does not replace safety codes, insurance needs, or laws

governing your area. Be sure your machine meets the standards set by these regulations.

214683 29 Revision A

1001602

1001683

OPERATION

3.2 Operational Safety

CAUTION

Adhere to the following safety precautions:

• Follow all safety and operational instructions
provided in your operator’s manuals. If you do not
have a combine manual, get one from your Dealer and
read it thoroughly.

• Never attempt to start the engine or operate the
machine except from the combine seat.

• Check the operation of all controls in a safe, clear
area before starting work.

• Do NOT allow riders on the combine.

CAUTION

• Never start or move the machine until you are sure all
bystanders have cleared the area.

Figure 3.1: No Riders

• Avoid travelling over loose fill, rocks, ditches,
or holes.

• Drive slowly through gates and doorways.

• When working on inclines, travel uphill or downhill

whenever possible. Be sure to keep transmission in
gear when travelling downhill.

• Never attempt to get on or off a moving machine.

• Do NOT leave operator’s station while the engine is

running.

• To avoid bodily injury or death from unexpected startup of a machine, always stop the engine and
remove the key before adjusting or removing plugged material from the machine.

• Check for excessive vibration and unusual noises. If there is any indication of trouble, shut down and
inspect the machine. Follow proper shutdown procedure. Refer to 3.4 Shutting down the Combine,

page 41.

• Operate only in daylight or good artificial light.

Figure 3.2: Bystander Safety

3.2.1 Header Safety Props

The header safety props, located on the header lift cylinders, prevent the lift cylinders from unexpectedly retracting
and lowering the header. Refer to your combine operator’s manual for instructions.

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.

214683 30 Revision A

1001694

A

B

OPERATION

3.2.2 Reel Safety Props

The reel safety props, located on the reel support arms, prevent the reel from unexpectedly lowering.

WARNING

To avoid bodily injury from fall of raised reel, always engage reel safety props before going under raised
reel for any reason.

IMPORTANT:

To prevent damage to the reel support arms, do NOT transport the header with the reel safety props engaged.

Engaging Reel Safety Props

1. Raise reel to maximum height.

2. Move reel safety props (A) to engaged position
(as shown).

NOTE:

Keep pivot bolt (B) sufficiently tight so prop remains in
stored position when not in use, but can be engaged
using hand force.

3. Repeat on right reel arm.

Figure 3.3: Reel Safety Prop – Left Side

214683 31 Revision A

1001695

A

C

B

1004154

A

OPERATION

4. Use handle (A) to move lock rod to inboard position (B),
which engages pin (C) under prop.

5. Lower reel until safety props contact the outer arm
cylinder mounts and the center arm pins.

Disengaging Reel Safety Props

1. Raise the reel to maximum height.

2. Move the reel safety props (A) back inside the
reel arms.

Figure 3.4: Reel Safety Prop – Center Arm

Figure 3.5: Reel Safety Prop – Left Side Shown
(Right Opposite)

214683 32 Revision A

1001697

B

A

1024277

A

B

1024681

A

B

C

OPERATION

3. Use handle (B) to move lock rod (A) to the
outboard position.

Figure 3.6: Reel Safety Prop – Center Arm

3.2.3 Endshields

A hinged, polyethylene endshield is fitted on each end of the header.

Opening Endshields

1. Push release lever (A) located on the backside of the
endshield to unlock the shield.

2. Pull endshield open using handle depression (B).

3. Pull endshield at handle depression (A). Endshield is
retained by a hinge tab (B) and will open in
direction (C).

Figure 3.7: Left Endshield

214683 33 Revision A

Figure 3.8: Left Endshield

1012300

A

B

1012300

A

B

1024683

A

OPERATION

4. If additional clearance is required, pull the endshield
free of hinge tab (A) and swing shield towards the rear
of the header.

5. Engage safety latch (B) on hinge arm to secure the
shield in fully open position.

Closing Endshields

1. Disengage lock (B) to allow endshield to move.

2. Insert front of endshield behind hinge tab (A) and into
divider cone.

Figure 3.9: Left Endshield

3. Swing endshield in direction (A) into closed position.
Engage lock with a firm push.

4. Check that endshield is locked.

Figure 3.10: Left Endshield

Figure 3.11: Left Endshield

214683 34 Revision A

1001672

X

1025332

A
B

A

A

A

OPERATION

Checking and Adjusting Endshields

Endshields are subject to expansion or contraction caused by large temperature variations. The position of the top
pin and lower latch can be adjusted to compensate for dimensional changes.

Checking the endshield:

1. Check gap (X) between front end of shields and header
frame and compare to the values in Table 3.1, page 35.

Table 3.1 Endshield Gap at Various Temperatures

Temperature in °C (°F)

Gap (X)

mm (in.)

7 (45) 13–18 (1/2–23/32)

18 (65) 10–15 (3/8–19/32)

29 (85) 7–12 (9/32–15/32)

41 (105) 4–9 (5/32–11/32)

Adjusting the endshield gap:

1. Loosen the four bolts (A) on support tube bracket (B).

Figure 3.12: Gap between Endshield and
Header Frame

Figure 3.13: Left Endshield Support Tube

214683 35 Revision A

1024666

A

B

1025332

A
B

A

A

A

1025329

C

A

B

C

OPERATION

2. Loosen the three bolts (A) on latch assembly (B).

3. Adjust latch assembly (B) to achieve the desired gap
between the front end of the shield and the header
frame. Refer to Table 3.1, page 35 for the
recommended endshield gap at various temperatures.

4. Tighten the three bolts (A) on the latch assembly.

5. Tighten the four bolts (A) on support tube bracket (B).

6. Close endshield.

Figure 3.14: Left Endshield Latch Assembly

Removing Endshields

1. Fully open the endshield. For instructions, refer to

Opening Endshields, page 33.

2. Engage lock (A) to prevent endshield movement.

3. Remove self-tapping screw (B).

4. Slide endshield upwards and remove from hinge
arm (C).

5. Place endshield away from work area.

Figure 3.15: Left Endshield Support Tube

Figure 3.16: Left Endshield

214683 36 Revision A

1025329

C

A

B

C

1004527

A

B

OPERATION

Installing Endshields

1. Guide endshield onto hinge arm (C) and slowly slide it
downwards.

NOTE:

Ensure hinge arm (C) is installed in the outboard hole
on the hinge bracket, as shown in illustration at right.

2. Install self-tapping screw (B).

3. Disengage lock (A) to allow endshield movement.

4. Close endshield. Refer to Closing Endshields, page 34.

NOTE:

Endshields may expand or contract when subjected to
large temperature changes. Top pin and lower latch
bracket positions can be adjusted to compensate for
dimensional changes. Refer to Checking and Adjusting

Endshields, page 35.

3.2.4 Linkage Covers

Figure 3.17: Left Endshield

Plastic covers are attached to the header frame to protect the header wing balance mechanism from debris and
weather.

Removing Linkage Covers

1. Remove screw (A) and lift outboard end of cover (B).

Figure 3.18: Linkage Cover

214683 37 Revision A

1004528

A

1004530

A

B

1004527

A

B

OPERATION

2. Rotate cover (A) upward until inboard end can be
lifted off.

Installing Linkage Covers

1. Position inboard end of cover (A) over linkage and
behind indicator bar (B).

2. Lower cover until secure and against header tube.

Figure 3.19: Linkage Cover

3. Install screw (A) to hold cover (B) in place.

Figure 3.20: Linkage Cover

Figure 3.21: Linkage Cover

214683 38 Revision A

1001351

OPERATION

3.2.5 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.

• Carry with you any protective clothing and personal
safety devices that could be necessary through the
day. Do NOT take chances. You may need a hard hat,
protective glasses or goggles, heavy gloves, a
respirator or filter mask, or wet weather gear.

• Protect against noise. Wear a suitable hearing protective device such as ear muffs or ear plugs to
protect against objectionable or uncomfortably loud noises.

Complete the following tasks each day before start-up:

Figure 3.22: Safety Devices

1. Check the machine for leaks and any parts that are missing, broken, or not working correctly.

NOTE:

Use proper procedure when searching for pressurized fluid leaks. Refer to 5.3.5 Checking Hydraulic Hoses and

Lines, page 390.

2. Clean all lights and reflective surfaces on the machine.

3. Perform all daily maintenance. Refer to 5.3.1 Maintenance Schedule/Record, page 385.

214683 39 Revision A

OPERATION

3.3 Break-in Period

CAUTION

Before investigating an unusual sound or attempting to correct a problem, shut off engine and
remove key.

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 combine for the first time, follow these steps:

1. Operate the machine with the reels, drapers, and knives running slowly for five minutes. Watch and listen

FROM THE OPERATOR’S SEAT for binding or interfering parts.

NOTE:

Reels and side drapers will not operate until oil flow fills the lines.

2. Refer to 5.3.2 Break-In Inspection, page 388 and perform all the specified tasks.

214683 40 Revision A

OPERATION

3.4 Shutting down the Combine

DANGER

To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key
from ignition before leaving operator’s seat for any reason.

To shut down the combine and before leaving the operator’s seat for any reason, follow these steps:

1. Park on level ground whenever possible.

2. Lower the header fully.

3. Place all controls in NEUTRAL or PARK.

4. Disengage the header drive.

5. Lower and fully retract the reel.

6. Stop the engine and remove the key from the ignition.

7. Wait for all movement to stop.

214683 41 Revision A

OPERATION

3.5 Cab Controls

CAUTION

Be sure all bystanders are clear of machine before starting engine or engaging any header drives.

Refer to your combine operator’s manual for identification of the following in-cab controls:

• Header engage/disengage control

• Header height

• Header angle

• Ground speed

• Reel speed

• Reel height

• Reel fore-aft position

214683 42 Revision A

OPERATION

3.6 Header Setup

3.6.1 Header Attachments

Several attachments to improve the performance of your header are available as options that can be installed by
your MacDon Dealer. Refer to 6 Options and Attachments, page 545 for descriptions of available items.

3.6.2 Header Settings

The following tables provide a guideline for setting up the FD1 FlexDraper®Header; however, the suggested
settings can be changed to suit various crops and conditions not covered in the tables.

Refer also to 3.6.4 Reel Settings, page 56.

For FM100 auger configurations, refer to 4.1 Float Module Feed Auger Configurations, page 307.

214683 43 Revision A

Auger

Upper Cross

Recommended

Auger

Upper Cross

Not required

Reel Position

7

Reel

Speed %

Reel Cam

56

Header

Angle

4

2 10 6 or 7 Not required

310–15 6 or 7 Not required

B – C

B – C

3or4 5–10 4 or 5 Not required

B – C

B – C2 106or7

Reel Position

7

Reel

Speed %

Reel Cam

56

Header

Angle

4

10–15 6 or 7

4

A 2 10 6 or 7 Not required

A 2 10 6 or 7 Recommended

D3or45–10 4 or 5 Not required

8

Setting

Draper Speed

Off

On

Up or middle

Crop

Position

Divider Rods

Light

Condition

Normal

Storage

3

Stubble Height 102 (<4)

Stabilizer

Wheels

Table 3.2 Recommended FD1 Series / FM100 Combine Header Settings for Cereals

214683 44 Revision A

Skid Shoe

Off

On

Heavy

Lodged

Stubble Height 102–203 (4–8)

Stabilizer

As required

Wheels

Skid Shoe

Down for lodged crop conditions, middle or down for other crop conditions

Position

Setting

Draper Speed

Divider Rods

Crop

Condition

8B– C

Off

Light

7

7

On

On

Heavy

Normal

7

Off

Lodged

Stubble Height 203+ (8+)

As required

Stabilizer

Wheels

3. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing.

4. Setting on FM100 draper control.

5. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height.

6. Cutting height is controlled with a combination of skid shoes and header angle.

7

7

7

7. Percentage above ground speed.

Auger

Upper Cross

Reel Position

7

Not required

OPERATION

Not required

Reel

Speed %

Reel Cam

56

Header

Angle

4

Setting

Draper Speed

10–15 6 or 7

3or4 5–10 4 or 5 Not required

A4

8

A 2 10 6 or 7 Not required

7

B – C

B – C2 106or7

7

7

Off

On

Divider Rods

Not applicable

Crop

Skid Shoe

Table 3.2 Recommended FD1 Series / FM100 Combine Header Settings for Cereals (continued)

214683 45 Revision A

Position

Light

Condition

Normal

Off

On

Heavy

Lodged

Auger

Upper Cross

Reel Position

12

Reel

Speed %

Reel Cam

2 10 6 or 7 Not required

25–10 6 or 7 Not required

2 10 6 or 7 Not required

Stubble Height On ground

Table 3.3 Recommended FD1 Series / FM100 Combine Header Settings for Lentils

Storage

Up or middle

8

Stabilizer

Wheels

Skid Shoe

10 11

Header

Angle

9

Setting

Draper Speed

Divider Rods

Crop

Condition

Position

B – C

8

On

Light

B – C

B – C

7

7

On

On

Heavy

Normal

D25–10 6 or 7 Not required

7

On

Lodged

8. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing.

9. Setting on FM100 draper control.

10. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height.

11. Cutting height is controlled with a combination of skid shoes and header angle.

12. Percentage above ground speed.

214683 46 Revision A

Auger

Upper Cross

Reel Position

17

Reel

Speed %

Reel Cam

4 or 5 Recommended

2 10 4 or 5 Recommended

2 10 6 or 7 Recommended

25–10 6 or 7 Recommended

25–10

Table 3.4 Recommended FD1 Series / FM100 Combine Header Settings for Peas

Stubble Height On ground

Stabilizer

Storage

13

Wheels

Skid Shoe

Header

Draper Speed

Up or middle

Crop

Position

15 16

B – C

Angle

14

7

Setting

On

Divider Rods

Light

Condition

B – C

B – C

7

7

On

On

Heavy

Normal

7D

On

Lodged

13. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing.

14. Setting on FM100 draper control.

15. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height.

16. Cutting height is controlled with a combination of skid shoes and header angle.

17. Percentage above ground speed.

214683 47 Revision A

Auger

Upper Cross

Recommended

Auger

Upper Cross

Reel Position

22

Reel

Speed %

Reel Cam

20 21

Header

Angle

19

1 10 3 or 4 Recommended

1 10 6 or 7 Recommended

A25–10 6 or 7 Recommended

B – C

7

7

25–10 3 or 4

D

B – C

8

7

Reel Position

Reel

Speed %

Reel Cam

20 21

Header

Angle

19

2 10 6 or 7 Recommended

1 or 2 10 3 or 4 Recommended

A25–10 6 or 7 Recommended

B – C

7

7

D2or35–10 3 or 4 Recommended

B – C

8

7

Setting

Draper Speed

On

On

On

As required

18

Stubble Height 102–203 (4–8)

Stabilizer

Wheels

Table 3.5 Recommended FD1 Series / FM100 Combine Header Settings for Canola

214683 48 Revision A

Skid Shoe

Divider Rods

Down for light or heavy crop conditions, middle or down for normal or lodged crop conditions

Crop

Condition

Position

Light

Normal

On

Heavy

Lodged

Stubble Height 203+ (8+)

Stabilizer

As required

Not applicable

Wheels

Skid Shoe

Setting

Draper Speed

Divider Rods

Crop

Condition

Position

On

Light

On

On

Heavy

Normal

On

Lodged

18. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing.

19. Setting on FM100 draper control.

20. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height.

21. Cutting height is controlled with a combination of skid shoes and header angle.

22. Percentage above ground speed.

Auger

Upper Cross

4 or 5 Not required

Auger

Upper Cross

Not required

Reel Position

28

Reel

Speed %

Reel Cam

26 27

Header

Angle

25

2 10 4 or 5 Not required

B – C2 10

B – C

Reel Position

28

Reel

Speed %

Reel Cam

26 27

Header

Angle

25

310–15 6 or 7

3 10 6 or 7 Not required

3 10 6 or 7 Not required

B – C

B – C

Setting

Draper Speed

24

Up or middle

Crop

Position

Divider Rods

Light Rice divider rod 4 D 2 10–15 6 or 7 Not required

Condition

As required

Middle or down

23

Heavy Rice divider rod 4

Normal Rice divider rod 4

Lodged Rice divider rod 4 D 2 5–10 4 or 5 Not required

Stubble Height 102–203 (4–8)

Stabilizer

Wheels

Skid Shoe

Storage

23

Stubble Height 102 (<4)

Stabilizer

Wheels

Table 3.6 Recommended FD1 Series / FM100 Combine Header Settings for California Rice

214683 49 Revision A

Skid Shoe

Setting

Draper Speed

24

Divider Rods

Crop

Condition

Position

Light Rice divider rod 4 D

Heavy Rice divider rod 4

Normal Rice divider rod 4

Lodged Rice divider rod 4 D 4 5–10 6 or 7 Not required

23. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing.

24. The rice divider rod is available. Rice divider rod not required on both ends of header.

25. Setting on FM100 draper control.

26. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height.

27. Cutting height is controlled with a combination of skid shoes and header angle.

28. Percentage above ground speed.

Auger

Upper Cross

Reel Position

28

Reel

Speed %

OPERATION

Not required

As required

Reel Cam

26 27

Header

Angle

25

Setting

Draper Speed

24

Divider Rods

Not applicable

3 10 6 or 7 Not required

B – C3 106or7

B – C

23

Crop

Stubble Height 203+ (8+)

Stabilizer

Wheels

Skid Shoe

Table 3.6 Recommended FD1 Series / FM100 Combine Header Settings for California Rice (continued)

214683 50 Revision A

Position

Light Rice divider rod 4 A 3 10–15 6 or 7 Not required

Condition

Normal Rice divider rod 4

Heavy Rice divider rod 4

Lodged Rice divider rod 4 D 4 5–10 6 or 7 Not required

Auger

Upper Cross

Not required

Auger

Upper Cross

Not required

Reel Position

33

Reel

Speed %

Reel Cam

31 32

Header

Angle

30

2 or 3 10 6 or 7 Not required

B – C

6

6D2or310–15 6 or 7 Not required

6B– C 2 or 3 10 6 or 7

6D3or45–10 4 or 5 Not required

Reel Position

33

Reel

Speed %

Reel Cam

31 32

Header

Angle

30

2or3 10–15 6 or 7

A

6

2 or 3 10 6 or 7 Not required

2 or 3 10 6 or 7 Not required

B – C

B – C

6

6

6D3or45–10 4 or 5 Not required

Setting

Draper Speed

Off

Off

Off

Middle or down

Crop

Position

Divider Rods

Light

Condition

Normal

As required

29

Stabilizer

Wheels

Stubble Height 51–152 (2–6)

Table 3.7 Recommended FD1 Series / FM100 Combine Header Settings for Delta Rice

214683 51 Revision A

Skid Shoe

Off

Heavy

Lodged

Stubble Height 152+ (6+)

Stabilizer

As required

Not applicable

Wheels

Skid Shoe

Setting

Draper Speed

Divider Rods

Crop

Condition

Position

Off

Light

Off

Off

Heavy

Normal

Off

Lodged

29. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing.

30. Setting on FM100 draper control.

31. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height.

32. Cutting height is controlled with a combination of skid shoes and header angle.

33. Percentage above ground speed.

Auger

Upper Cross

Reel Position

38

Reel

Speed %

Reel Cam

2 10 6 or 7 Not required

2 10 6 or 7 Not required

Stubble Height On ground

Table 3.8 Recommended FD1 Series / FM100 Combine Header Settings for Edible Beans

Storage

Up or middle

34

Stabilizer

Wheels

Skid Shoe

36 37

Header

Angle

35

Setting

Draper Speed

Divider Rods

Crop

Condition

Position

B – C

8D25–10 6 or 7 Not required

7

On

On

Light

Normal

D25–10 6 or 7 Not required

B – C

7

7

On

On

Heavy

Lodged

34. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing.

35. Setting on FM100 draper control.

36. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height.

37. Cutting height is controlled with a combination of skid shoes and header angle.

38. Percentage above ground speed.

214683 52 Revision A

Auger

Upper Cross

Reel Position

43

Reel

Speed %

Reel Cam

Not required

25–10 6 or 7 Not required

Table 3.9 Recommended FD1 Series / FM100 Combine Header Settings for Flax

Stabilizer

Stubble Height 51–153 (2–6)

As required

39

Wheels

Skid Shoe

41 42

Header

Angle

40

Setting

Draper Speed

Divider Rods

Down for lodged crop conditions, middle or down for other crop conditions

Crop

Condition

Position

B – C

8

On

Light

A 2 10 6 or 7 Not required

D25–10 6 or 7 Not required

B – C2 106or7

7

7

7

On

On

On

Heavy

Normal

Lodged

39. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing.

40. Setting on FM100 draper control.

41. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height.

42. Cutting height is controlled with a combination of skid shoes and header angle.

43. Percentage above ground speed.

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OPERATION

3.6.3 Optimizing Header for Straight Combining Canola

Ripe canola can be straight combined, but most varieties are very susceptible to shelling and subsequent seed
loss. This section provides recommended attachments, settings, and adjustments to optimize FD1 Series
FlexDraper

Recommended attachments

The optimization includes the following modifications to the header:

• Installing a full-length upper cross auger

• Installing vertical knives

• Installing short center reel braces

NOTE:

Each kit includes installation instructions and the necessary hardware. Refer to 6 Options and Attachments, page

545.

Recommended settings

Optimizing the header requires adjustments to the following settings:

• Moving the reel fore-aft cylinders to the alternative aft location. Refer to Repositioning Fore-Aft Cylinders on

Non-European-Configured Headers, page 101.

®

Headers for straight combining canola.

• Adjusting reel fore-aft position. Refer to Adjusting Reel Fore-Aft Position, page 100.

• Adjusting reel height so that fingers just engage the crop. Refer to 3.7.10 Reel Height, page 95.

• Setting reel cam to position 1. Refer to Adjusting Reel Cam, page 113.

• Setting reel speed equal to ground speed and increase as required. Refer to 3.7.6 Reel Speed, page 89.

• Set the side draper speed to position nine on FM100 control valve. Refer to 3.7.8 Draper Speed, page 91.

• Set auger to floating position. Refer to 3.7.15 Setting Auger Position, page 121.

• Loosen auger spring tension. Refer to Checking and Adjusting Feed Auger Springs, page 54.

Checking and Adjusting Feed Auger Springs

The feed auger has an adjustable spring tensioning system that allows the auger to float on top of the crop instead
of crushing and damaging it. The factory-set tension is adequate for most crop conditions.

DANGER

To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key
from ignition before leaving operator’s seat for any reason.

1. Raise header to full height.

2. Shut down the combine, and remove the key from the ignition.

3. Engage header lift cylinder safety props.

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B

C

1009147

A

B

C

OPERATION

4. Check the thread length protruding past the nut (B).

Length should be 22–26 mm (7/8–1 in.).

If adjustment is required, follow these steps:

1. Loosen upper jam nut (A) on spring tensioner.

2. Turn lower nut (B) until the thread (C) protrudes

22–26 mm (7/8–1 in.).

Figure 3.23: Spring Tensioner

3. Tighten jam nut (A).

4. Repeat Steps 1, page 55 to 3, page 55 on

opposite side.

Figure 3.24: Spring Tensioner

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1001819

1001820

OPERATION

3.6.4 Reel Settings

Table 3.10 FD1 Series Recommended Reel Settings

Cam Setting Number

(Finger Speed Gain)

1 (0)

2 (20%)

Reel Position

Number

6or7

6or7

Reel Finger Pattern

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OPERATION

Table 3.10 FD1 Series Recommended Reel Settings (continued)

Cam Setting Number

(Finger Speed Gain)

3 (30%)

4 (35%)

Reel Position

Number

3or4

2or3

Reel Finger Pattern

NOTE:

• Adjust the reel forward to get closer to the ground while tilting the header back. Fingers/tines will dig into the

ground at extreme reel-forward positions, so adjust skid shoes or header angle to compensate. Adjust the reel
rearwards to position the reel farther away from the ground when tilting the header forward.

• Header tilt can be increased to position the reel closer to the ground, or decreased to position the reel farther

from the ground, while keeping material flowing onto drapers.

• To leave the maximum amount of stubble behind in lodged crop, raise the header and increase the header tilt to

keep the reel close to the ground. Position the reel fully forward.

• The reel may have to be moved back to prevent lumps or plugging on the cutterbar in thinner crops.

• Minimum crop carrying capacity (minimum area of exposed draper between the reel and the header backsheet)

occurs with the reel in the furthest aft position.

• Maximum crop carrying capacity (maximum area of exposed draper between the reel and the header

backsheet) occurs with the reel in the furthest forward position.

• Due to the nature of the cam action, the tip speed of the fingers/tines at the cutterbar becomes higher than that

of the reel speed at higher cam settings. Refer to Table 3.10, page 56.

214683 57 Revision A

OPERATION

3.7 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 increases productivity. As well, proper adjustments and timely
maintenance will increase the length of service you receive from your machine.

The variables listed in Table 3.11, page 58 and detailed on the following pages will affect the performance of your
header.

You will quickly become adept at adjusting the machine to achieve the results you desire. Most of the adjustments
have been preset at the factory, but the settings can be changed to suit crop conditions.

Table 3.11 Operating Variables

Variable

Cutting height 3.7.1 Cutting off the Ground, page 58; 3.7.2 Cutting on the Ground, page 62

Header float

Header angle

Reel speed

Ground speed 3.7.7 Ground Speed, page 90

Reel height 3.7.10 Reel Height, page 95

Reel fore-aft position

Reel tine pitch

Crop divider rods 3.7.13 Crop Dividers, page 115

Feed auger configurations 4.1 Float Module Feed Auger Configurations, page 307

3.7.3 Header Float, page 64

3.7.5 Header Angle, page 81

3.7.6 Reel Speed, page 89

3.7.11 Reel Fore-Aft Position, page 99

3.7.12 Reel Tine Pitch, page 111

Refer to

3.7.1 Cutting off the Ground

The header’s design allows operators to cut crop above the ground in relation to desired stubble height. The cutting
height will vary depending on factors including crop type, crop conditions, etc.

The stabilizer wheel system is designed to minimize bouncing at the header ends and may be used to float the
header to achieve an even cutting height when cutting above ground level in cereal grains. The system produces
even stubble height and greatly reduces operator fatigue.

Cutting height is controlled using a combination of the combine header height control and a stabilizer wheel system
(or stabilizer / slow speed transport wheel system).

If stabilizer wheels are installed, refer to Adjusting Stabilizer Wheels, page 60 to change the wheel position.

If stabilizer / slow speed transport wheels are installed, refer to Adjusting Stabilizer / Slow Speed Transport Wheels,

page 59 to change the wheel position.

214683 58 Revision A

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D

B

A

1001702

B

A

OPERATION

Adjusting Stabilizer / Slow Speed Transport Wheels

A properly adjusted header will achieve a balance between the amount of header weight carried by the float and
the amount carried by the stabilizer / slow speed transport wheels.

DANGER

To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key
from ignition before leaving operator’s seat for any reason.

1. Raise the header so the stabilizer wheels are off the ground. Shut down engine and remove the key.

2. Remove the hairpin (A) from the latch on the right wheel

assembly.

3. Disengage the latch (B), lift the wheel out of the hook,

and place on the ground as shown. (This reduces
weight of assembly and makes adjusting the wheel
position easier.)

4. Lift the left wheel slightly to support the weight, and the

pull handle (C) upwards to release the lock.

5. Lift the left wheel to the desired height and engage the

support channel into the slot (D) in the upper support.

6. Push down on the handle (C) to lock.

7. Lift the right wheel back into the field position and

ensure the latch (B) is engaged.

8. Secure the latch with hairpin (A).

9. Support the wheel weight by lifting slightly with one

hand, and pull up on handle (A) to release the lock.

10. Lift the wheels to the desired height, and engage the

support channel into the slot (B) in the upper support.

11. Push down on the handle (A) to lock.

Figure 3.25: Right Wheel

Figure 3.26: Left Wheel

214683 59 Revision A

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A

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OPERATION

12. Lower the header to the desired cutting height using the
combine controls and check the load indicator (A).

13. Adjust the header angle to the desired working angle
with the machine’s header angle controls. If header
angle is not critical, set it to mid-position.

IMPORTANT:

Continuous operation with excessive spring
compression (i.e., load indicator reading greater than 4
or a compressed length [A] less than 295 mm
[11-5/8 in.]) can result in damage to the suspension
system.

Figure 3.27: Load Indicator

14. Use the combine’s auto header height control (AHHC)
to automatically maintain cutting height. Refer to 3.8

Auto Header Height Control (AHHC), page 124 and

your combine operator’s manual for details.

Figure 3.28: Spring Compression

NOTE:

The height sensor on the FM100 Float Module must be
connected to the combine header control module in
the cab.

Adjusting Stabilizer Wheels

A properly adjusted header will achieve a balance between the amount of header weight carried by the float and
the amount carried by the stabilizer wheels.

Refer to 3.6.2 Header Settings, page 43 for recommended use in specific crops and crop conditions.

DANGER

To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key
from ignition before leaving operator’s seat for any reason.

1. Raise the header until the stabilizer wheels are off the ground. Shut down engine and remove the key.

214683 60 Revision A

1001654

A

B

C

1013795

A

1001655

A

OPERATION

2. Support the wheel weight by lifting slightly with one
hand on handle (B), and pull up on the handle (A) to
release the lock.

3. Lift the wheel using handle (B), and engage the support
channel into the center slot (C) in the upper support.

4. Push down on the handle (A) to lock.

5. Lower the header to the desired cutting height using the
combine controls and check the load indicator (A).

Figure 3.29: Stabilizer Wheel

6. Adjust the header angle to the desired working angle
with the machine’s header angle controls. If header
angle is not critical, set it to mid-position.

IMPORTANT:

Continuous operation with excessive spring
compression (i.e., load indicator reading greater than 4
or a compressed length less than 295 mm
[11-5/8 in.]) (A) can result in damage to the suspension
system.

7. Use the combine’s Auto Header Height Control (AHHC)
to automatically maintain cutting height. Refer to 3.8

Auto Header Height Control (AHHC), page 124 and

your combine operator’s manual for details.

NOTE:

The height sensor on the FM100 Float Module must be
connected to the combine height control system in
the cab.

Figure 3.30: Load Indicator

Figure 3.31: Spring Compression

214683 61 Revision A

1001659

D

C

B

A

OPERATION

3.7.2 Cutting on the Ground

Header design allows you to cut crop at ground level with the header on the ground. Cutting height will vary
depending on what kind of crop, crop conditions, etc.

Cutting on the ground is performed with the header fully lowered and the cutterbar on the ground. The orientation of
the knife and knife guards relative to the ground (header angle) is controlled by the skid shoes and the center-link—
it is NOT controlled by the header lift cylinders. The skid shoes and center-link allow you to adjust to field conditions
and maximize the amount of material cut while reducing damage to the knife caused by stones and debris.

The header float system floats the header over the surface to compensate for ridges, trenches, and other variations
in ground contour to prevent the cutterbar from pushing into the ground or leaving uncut crop.

Refer to the following for additional information:

• Adjusting Inner Skid Shoes, page 62

• Adjusting Outer Skid Shoes, page 63

• 3.7.5 Header Angle, page 81

• 3.7.3 Header Float, page 64

Also refer to 3.6.2 Header Settings, page 43.

Adjusting Inner Skid Shoes

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.

1. Raise header to full height, engage safety props.

2. Shut off the engine, and remove key.

3. Raise the stabilizer wheels or slow speed transport wheels fully (if installed). Refer to the following:

• Adjusting Stabilizer Wheels, page 60

• Adjusting Stabilizer / Slow Speed Transport Wheels, page 59

4. Remove the lynch pin (A) from each skid shoe.

5. Hold the shoe (B) and remove the pin (C) by
disengaging from the frame and pulling away from
the shoe.

6. Raise or lower the skid shoe (B) to achieve the desired
position using the holes in the support (D) as a guide.

7. Install the pin (C), engage in frame, and secure with
lynch pin (A).

8. Check that all of the skid shoes are adjusted to the
same position.

214683 62 Revision A

Figure 3.32: Inner Skid Shoe

1001658

A

B

C

OPERATION

9. Adjust the header angle to the desired working position using the machine’s header angle controls. If the
header angle is not critical, set it to the mid-position.

10. Check the header float. Refer to 3.7.3 Header Float, page 64.

Adjusting Outer Skid Shoes

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.

1. Raise the header to its full height, engage the safety props.

2. Shut off the engine, and remove the key from the ignition.

3. Raise the stabilizer wheels or slow speed transport wheels fully (if installed). Refer to the following:

• Adjusting Stabilizer Wheels, page 60

• Adjusting Stabilizer / Slow Speed Transport Wheels, page 59

4. Remove the lynch pin (A) from each skid shoe (B).

5. Hold the shoe (B) and remove the pin (C) by
disengaging from the frame and pulling away from
the shoe.

6. Raise or lower the skid shoe (B) to achieve the desired
position using the holes in the support (D) as a guide.

7. Reinstall pin (C), engage in frame, and secure with
lynch pin (A).

8. Check that all of the skid shoes are adjusted to the
same position.

9. Check the header float. Refer to 3.7.3 Header Float,

page 64.

Figure 3.33: Outer Skid Shoe

214683 63 Revision A

1009193

A

1009194

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OPERATION

3.7.3 Header Float

The header float system reduces the ground pressure at the cutterbar allowing the header to more easily follow the
ground and quickly respond to sudden ground contour changes or obstacles.

Header float is indicated on the float indicator (A). Values 0
to 4 represent the force of the cutterbar on the ground with 0
being the minimum and 4 being the maximum.

The maximum force is determined by the tension on the
float module’s adjustable float springs. Float can be
changed to suit field and crop conditions and is dependent
on what options have been installed on the header. Refer to

Checking and Adjusting Header Float, page 64.

The FD1 Series combine header performs best with
minimum ground pressure under normal conditions.
Readjust the float if adding optional attachments to the
header that affect header weight.

Figure 3.34: Float Indicator

1. Set the float for cutting on the ground as follows:

a. Ensure the header float locks are disengaged.

Refer to Locking/Unlocking Header Float, page 69.

b. Lower feeder house using the combine header

controls until the float indicator (A) reaches the
desired float value (cutterbar ground force). Set the
float indicator initially to float value 2 and adjust as
necessary.

2. Set the float for cutting off the ground as follows:

a. Set up the stabilizer wheels. Refer to 3.7.1 Cutting

off the Ground, page 58.

b. Note the float value on the float indicator and

maintain this value during operation (disregard
minor fluctuations on the indicator).

Figure 3.35: Cutting on the Ground

Checking and Adjusting Header Float

The header is equipped with a suspension system that floats the header over the ground to compensate for ridges,
trenches, and other variations in ground contour. If the header float is not set properly, it may cause the cutterbar to
push into the ground or leave uncut crop. This procedure describes how to check header float and adjust to the
factory-recommended settings.

DANGER

To avoid bodily injury or death from unexpected start-up of machine, always stop engine and remove key
from ignition before leaving operator’s seat for any reason.

Use the following guidelines when adjusting float:

• Turn each adjustment bolt pair equally. Refer to Step 12, page 67, and repeat torque wrench reading procedure
on both sides of header.

214683 64 Revision A

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A

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A

OPERATION

• Set header float as light as possible without causing excessive bouncing to prevent knife component breakage,
soil scooping, or soil build-up at the cutterbar in wet conditions.

• To avoid excessive bouncing and leaving a ragged cut, use a slower ground speed with a light float setting, if
necessary.

• When cutting off the ground, use the stabilizer wheels in conjunction with header float to minimize bouncing at
the header ends and to control cut height. Refer to Adjusting Stabilizer Wheels, page 60.

NOTE:

If adequate header float cannot be achieved using all of the available adjustments, an optional heavy-duty spring is
available. See your MacDon Dealer or refer to the parts catalog for ordering information.

To check and adjust header float, follow these steps:

1. Level the header and float module. If the header and

float module are not level, perform the following checks
before adjusting the float:

IMPORTANT:

Do NOT use the float module springs to level the
header.

• Park the combine on a level surface.

• Check that the combine feeder house is level. Refer
to your combine operator’s manual for instructions.

• Check that the top of the float module is level with

the combine axle.

• Ensure the combine tires are inflated equally.

2. Adjust header so that the cutterbar is 150–254 mm
(6–10 in.) off the ground.

3. Extend the header angle hydraulic cylinder to between
B and C on indicator (A).

4. Adjust the reel fore-aft position to between 5 and 6 on
the position indicator decal (A) located on the reel
right arm.

5. Lower the reel fully.

6. Shut down the combine, and remove the key from the
ignition.

Figure 3.36: Center-Link

Figure 3.37: Fore-Aft Position

214683 65 Revision A

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A

1024737

A

B

OPERATION

7. Place wing lock spring handles (A) in the LOCKED
(upper) position.

8. Disengage both header float locks by pulling the float
lock handle (A) away from the float module and pushing
the float lock handle down and into position (B)
(UNLOCK).

Figure 3.38: Wing Lock Spring Handle in Lock
Position

Figure 3.39: Header Float Lock (in Locked
Position)

214683 66 Revision A

1001702

B

A

1019186

A

1019188

A

B

C

OPERATION

9. Place stabilizer wheels and slow speed transport
wheels (if equipped) in storage position as follows:

a. Support the wheel weight by lifting slightly with one

hand, and pull up on handle (A) to release the lock.

b. Lift the wheels to the desired height, and engage

the support channel into the slot (B) in the upper
support.

c. Push down on the handle (A) to lock.

10. Remove the supplied torque wrench (A) from its storage
position at the right side of the float module frame. Pull
in the direction shown to disengage the wrench from
the hook.

Figure 3.40: Left Wheel

11. Place the torque wrench (A) onto the float lock (B). Note
the position of the wrench for checking left or right side.

12. Push down on wrench to rotate bell crank (C) forward.

Figure 3.41: Torque Wrench Storage Location

Figure 3.42: Float Module – Left Side

214683 67 Revision A

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C

B

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A

OPERATION

13. Push down on the wrench until indicator (A) reaches a
maximum reading and then begins to decrease. Note
the maximum reading. Repeat at opposite side.

14. Use the following table as a guide for float settings:

Figure 3.43: Float Module – Right Side

• If reading on the wrench is high, the header is heavy

• If reading on the wrench is low, the header is light

Table 3.12 Float Settings

Header Size

Cutting on the Ground Cutting off the Ground

9.1 m and 10.7 m
(30 ft. and 35 ft.)

12.2 m and 13.7 m
(40 ft. and 45 ft.)

Figure 3.44: Torque Wrench

Indicator Reading

1-1/2 to 2 2 to 2-1/2

2 to 2-1/2 2-1/2 to 3

214683 68 Revision A

1020309

C

A

B

B

A

C

OPERATION

15. Before adjusting the float spring adjustment bolts (A),
rotate the spring locks (B) by loosening bolts (C).

16. To increase float (decrease header weight), turn both
adjustment bolts (A) on the left side clockwise. Repeat
adjustment at opposite side.

NOTE:

Turn each bolt pair equally.

17. To decrease float (increase header weight), turn left
side adjustment bolts (A) counterclockwise. Repeat at
opposite side.

NOTE:

Turn each bolt pair equally.

18. Adjust the float so the wrench readings are equal on
both sides of the header.

NOTE:

For 12.2 and 13.7 m (40 and 45 ft.) double-knife
headers: adjust the float so the wrench readings are

equal at both sides, and then loosen both right side
spring bolts two turns.

19. Lock adjustment bolts (A) with spring locks (B). Ensure
bolt heads (A) are engaged in the spring lock cutouts.
Tighten bolts (C) to secure spring locks in place.

Figure 3.45: Float Adjustment (Left Side Shown)

20. Proceed to Adjusting Wing Balance, page 79.

Locking/Unlocking Header Float

Two header float locks—one on each side of the float module—lock and unlock the header float system.

IMPORTANT:

The float locks must be engaged when the header is being transported with the float module attached so there is no
relative movement between the float module and the header. The float locks also must be locked when detaching
from the combine to enable the feeder house to release the float module.

214683 69 Revision A

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C

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OPERATION

To disengage (unlock) float locks, pull the float lock
handle (A) into position (B) (UNLOCK). In this position, the
header is unlocked, and can float with respect to the float
module.

To engage (lock) float locks, push the float lock handle (A)
into position (C) (LOCK). In this position, the header cannot
move with respect to the float module.

Figure 3.46: Float Lock (in Locked Position)

Locking/Unlocking Header Wings

The header is designed to operate with the cutterbar on the ground. The three sections move independently to
follow the ground contours. In this mode, each wing is unlocked and is free to move up and down.

The header can also be operated as a rigid header with the cutterbar straight. A typical application is in cereals
when cutting above the ground. In this mode, the wing is locked.

Operating in Flex Mode

In flex mode, the three sections will be unlocked and will move independently to follow the ground contours.

Unlock the wings as follows:

1. Move spring handle (A) in the lower slot to unlock the
wing. The unlocking should be audible.

2. If the lock link does not disengage, move the wing by
raising and lowering the header, changing the header
angle, or driving the combine until it disengages.

Figure 3.47: Wing Lock

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NOTE:

The following steps are only required if the above has not worked.

3. Remove the linkage cover. Refer to Removing Linkage

Covers, page 37.

4. Retrieve the supplied torque wrench (A) that is stored
on the float module frame on the right side.

5. Place the torque wrench (A) on bolt (B) and use it to
move the wing until the lock disengages.

6. Replace the torque wrench (A) and reinstall the
linkage cover.

Figure 3.48: Torque Wrench

7. If necessary, balance the wing. Refer to 3.7.4 Checking

and Adjusting Header Wing Balance, page 73.

Figure 3.49: Torque Wrench on Wing Nut

Operating in Rigid Mode

The three sections will be locked and operate as a rigid cutterbar.

Lock the wings as follows:

1. If the lock link does not engage, move the wing by raising and lowering the header, changing the header angle,
or driving the combine until it engages.

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2. Move spring handle (A) in the upper slot to lock the
wing. The locking should be audible.

3. If the lock link does not engage, move the wing by
raising and lowering the header, changing the header
angle, or driving the combine until it engages.

Figure 3.50: Wing Lock

NOTE:

The following steps are only required if the above has not worked.

4. Remove the linkage cover. Refer to Removing Linkage

Covers, page 37.

5. Retrieve the supplied torque wrench (A) that is stored
on the float module frame on the right side.

6. Place the torque wrench (A) on bolt (B) and use it to
move the wing until the lock engages.

7. Replace the torque wrench (A) and reinstall the
linkage cover. The wings will not move relative to the
header.

Figure 3.51: Torque Wrench

Figure 3.52: Header Wing

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3.7.4 Checking and Adjusting Header Wing Balance

IMPORTANT:

Before proceeding, the header float must be set properly. Refer to Checking and Adjusting Header Float, page 64.

The header wing balance allows the wings to react to changing ground conditions. If set too light, the wings will
bounce or not follow ground contours, leaving uncut crop. If set too heavy, the end of the header will dig into the
ground. After the header float has been set, the wings must be balanced for the header to follow the ground
contours properly.

Checking Wing Balance

This procedure describes how to check the balance of each wing.

IMPORTANT:

To ensure correct wing balance readings, make sure the header float is set properly before proceeding. Refer to

Checking and Adjusting Header Float, page 64.

WARNING

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key
before making adjustments to machine.

If a header wing has a tendency to be in a smile (A) or a
frown (B) position, wing balance may require adjusting.
Perform the following steps to check if the wings are not
balanced, and how much adjustment is required.

The header wings are balanced when it takes an equal
amount of force to move a wing up or down.

1. Adjust the reel fore-aft position to between 5 and 6 on
the position indicator decal (A) located on the reel
right arm.

2. Lower the reel fully.

Figure 3.53: Wing Imbalance

Figure 3.54: Fore-Aft Position

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3. Adjust the center-link (A) so that indicator (B) is
between B and C on gauge (C).

4. Park combine on level ground and raise header until
cutterbar is 152–254 mm (6–10 in.) off the ground.

5. Shut down the engine, and remove the key from the
ignition.

6. If installed, move stabilizer/transport wheels so that
they are supported by header. Refer to Adjusting

Stabilizer / Slow Speed Transport Wheels, page 59.

7. Remove linkage cover (A) by removing bolt (B) and
rotating cover upward until inboard end can be lifted off.

Figure 3.55: Center-Link

NOTE:

Refer to the decal (A) inside each linkage cover.

Figure 3.56: Linkage Cover

Figure 3.57: Linkage Cover

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8. Unlock the wings by moving spring handles (A) to lower
(UNLOCK) position.

NOTE:

If lock link does not engage lower slot, move wing with
the torque wrench until lock link moves into slot.

9. Retrieve wrench (A) from float module right leg.

Figure 3.58: Wing Lock in UNLOCK Position

Figure 3.59: Torque Wrench

10. Place torque wrench (A) onto bolt (B).

Figure 3.60: Balance Linkage

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OPERATION

11. Check that pointer (D) is properly positioned as follows:

a. Use wrench (A) to move bell crank (B) so that lower

edge of bell crank is parallel to top-link (C).

b. Check that pointer (D) is lined up with the

top-link (C). Bend pointer if necessary.

12. Move wing upward with torque wrench (A) until the
pointer’s lower alignment tab (C) lines up with the upper
edge of the top-link (B). Observe the indicator
reading (D) on wrench and record it.

Figure 3.61: Balance Linkage

Figure 3.62: Balance Linkage

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